Dmax PDF

WORKSHOP MANUAL
TFR / TFS SERIES
PubNo.TF04-01-E
TFR/S Series Workshop Manual

Sec.
Applicable Component
'04
Publication No.
Remarks
Sec.0
General Information
TFGEN-WE-0431
G.Export
Sec.1
Heating and Airconditioning
TFHAC-WE-0431
G.Export
Sec.2
Frame and Cab
TFFRM-WE-0431
G.Export
Sec.3
Steering Suspension,Whells and Tires
TFSTG-WE-0431
G.Export
Sec.4
Axle
TFPRO-WE-0431
G.Export
Sec.5
Brakes
TFBRK-WE-0431
G.Export
Sec.6
Engine 4JA1/4JH1-TC
TF4JE-WE-0431
G.Export
Sec.6
Engine 6VE1
TF6VE-WE-0431
G.Export
Sec.6
Engine C24SE
TFHEO-WE-0431
G.Export
Sec.7A
Transmission AW30-40LE Model
TFAW3-WE-0431
G.Export
Sec.7A
Transmission JR405E Model
TFJR4-WE-0431
G.Export
Sec.7B
Manual Transmission (MSG Models)
TFMSG-WE-0431
G.Export
Sec.7B1 Manual Transmission (MUA Models)
TFMUA-WE-0431
G.Export
Sec.7C
Clutch
TFCLU-WE-0431
G.Export
Sec.7D
Transfer
TFT150-WE-0431
G.Export
Sec.8
Electrical-Body and Chassis
TFCEL-WE-0431
G.Export
Sec.9
Accessories & Restraints
TFRET-WE-0431
G.Export
Sec.10
Cab
TFCAB-WE-0431
G.Export
Sec.11
Security
TFSCR-WE-0431
G.Export
WORKSHOP MANUAL
TF SERIES
GENERAL INFORMATION
SECTION 0
GENERAL INFORMATION 0A-1
SECTION 0A
GENERAL INFORMATION
TABLE OF CONTENTS
PAGE
General Repair Instructions............................................................................................ 0A- 2
Notes on The Format of this Manual.............................................................................. 0A- 3
Identification .................................................................................................................... 0A- 6
Lifting Instructions .......................................................................................................... 0A- 7
Conversion Table............................................................................................................. 0A- 9
0A-2 GENERAL INFORMATION
GENERAL REPAIR INSTRUCTIONS

1.Park the vehicle on level ground and chock the front or rear wheels before lifting the vehicle.
2.Raise the vehicle with a jack set against the axle or the frame.
3.Support the vehicle on chassis stands.
4.Use covers on the vehicle body, seats, and floor to prevent damage and/or contamination.
5.Disconnect the grounding cable from the battery before performing service operations.
This will prevent cable damage or burning due to short circuiting.
6.Handle brake fluid and antifreeze solution with great care.
Spilling these liquids on painted surfaces will damage the paint.
7.The use of the proper tool(s) and special tool(s) where specified is essential to efficient, reliable, and safe
service operations.
8.Always use genuine ISUZU replacement parts.
9.Discard used cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts at disassembly.
Normal function of these parts cannot be guaranteed if they are reused.
10. Prepare new cotter pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts for installation.
11. Keep the disassembled parts neatly in groups.
This will facilitate smooth and correct reassembly.
12. Keep fixing nuts and bolts separate.
Fixing nuts and bolts vary in hardness and design according to installation position.
13. Clean all parts before inspection or reassembly.
14. Clean the oil ports and other openings with compressed air to make certain that they are free from dirt and
obstructions.
15. Lubricate the rotating and sliding faces of all moving parts with oil or grease before installation.
16. Use the recommended liquid gasket to prevent leakage.
17. Carefully observe all nut and bolt torque specifications.
18. When removing or replacing parts that require refrigerant to the discharged from the Air conditioning system, be
sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle R134a,
to promote the movement for the protection of the ozone layer covering the earth.
19. Check and recheck your work. No service operation is complete until you have done this.
NOTES ON THE FORMAT OF THIS MANUAL

1. Find the applicable Section by referring to the index at the front of the Workshop Manual binder.
2. The following technical service information is included in this Section:
Identification
Maintenance schedules
Recommended Iubricants
Recommended fuels
Oil viscosity charts
3. Individual Sections of this Workshop Manual are divided into the following categories:
Main data and specifications
Torque specifications
Recommended liquid gasket
Loctite application procedure
Servicing
Removal and installation
Disassembly
Inspection and repair
Reassembly
Troubleshooting
4. Each "Major Components" page of this Workshop Manual has an exploded view of the applicable area.
A brief explanation of the notation used follows:

5. Below is a sample of the Workshop Manual text following the " Major Components " page.
A brief explanation of the notation used follows:
6. The following symbols appear throughout the Workshop Manual.

They tell you at a glance the type of service operation to perform.
........ Removal
........ Adjustment
........ Installation
........ Cleaning
........ Disassembly
........ Important operation requiring extra care
........ Reassembly
........ Specified torque
........ Alignment
........ ISUZU special tool(s) required or recommended
........ Directional indication
........ Other special tool(s) required or recommended
........ Inspection
........ Lubrication (Oil)
........ Measurement
........ Lubrication (Grease)
........ Torque Angle Method
........ Liquid gasket application

7. Measurement criteria are defined by the terms "standard" and "limit".
A measurement falling within the "standard" range indicates that the applicable part or parts are serviceable.
"Limit" is an absolute value.
A measurement falling outside the "limit" indicates that the applicable part or parts must be repaired or replaced.
8. Components are parts are listed in the singular form throughout the Workshop Manual.
9. The following directional criteria are used throughout the Workshop Manual:
Front:
The cooling fan side of the engine.
Right:
The right-hand side of the engine viewed from the flywheel.
Left:
The left-hand side of the engine viewed from the flywheel.
Rear:
The flywheel side of the engine.
Cylinder numbers are counted from the front of the engine towards the rear.
The engine's rotation is clockwise viewed from the front of the engine.
IDENTIFICATION
CHASSIS NUMBER
The chassis number is stamped on the right-hand side of the
chassis side member under the right door.
VEHICLE IDENTIFICATION PLATE

The vehicle identification plate is attached to the upper face of
the radiator sill in the engine compartment.
BODY AND OPTION IDENTIFICATION

PLATE
The body and option plate shows body style, body serial
number, paint and trim colour combination, paint number,
engine transmissions, axle ratio options and built date. The
built date is defined as 'the date of manufacture' by the
calendar month and year in which the body shell and power
train sub-assemblies are co-joined or moved from the
production line.
LIFTING INSTRUCTIONS
If a lifting device other than the original jack is used, it is most important that the device be applied only to the
correct lifting points. (See the illustration.) Raising the vehicle from any other point may result in serious damage.
Lifting Points and Supportable Point-Locations
RTW30AXF000101
LIFTING POINT; FRONT

4
2 model
When using floor jack, lift the center of 1st cross member.
4
4 model
When using floor jack, lift the under surface of skid plate (1)
(set the circle depression shape, shown on left picture) or
lift the center of front axle case (2).
RTW30ASH000301
SUPPORTABLE POINT; FRONT

Position the chassis stands at the bottom of the frame side
member, backward of front wheel.
RTU4Z0SH007901
LIFTING POINT; REAR

When using floor jack, lift the center of rear axle case.
RTW30ASH000101
SUPPORTABLE POINT; REAR

Position the chassis stands at the bottom of the frame side
member, forward of the rear wheel.
RTW30ASH000201
CONVERSION TABLE
TABLE OF CONTENTS
PAGE
Length............................................................................................................................... 0A- 9
Area................................................................................................................................... 0A-11
Volume.............................................................................................................................. 0A-11
Mass.................................................................................................................................. 0A-13
Pressure ........................................................................................................................... 0A-14
Torque............................................................................................................................... 0A-15
Temperature ..................................................................................................................... 0A-16
LENGTH
MILLIMETERS TO INCHES
INCHES TO MILLIMETERS
mm
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
in.
0.0394
0.0787
0.1181
0.1575
0.1969
0.2362
0.2756
0.3150
0.3543
0.3937
0.4331
0.4724
0.5118
0.5512
0.5906
0.6299
0.6693
0.7087
0.7480
0.7874
0.8268
0.8661
0.9055
0.9449
0.9843
mm
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
in.
1.0236
1.0630
1.1024
1.1417
1.1811
1.2205
1.2598
1.2992
1.3386
1.3780
1.4173
1.4567
1.4961
1.5354
1.5748
1.6142
1.6535
1.6929
1.7323
1.7717
1.8110
1.8504
1.8898
1.9291
1.9685
mm
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
in.
2.0079
2.0472
2.0866
2.1260
2.1654
2.2047
2.2441
2.2835
2.3228
2.3622
2.4016
2.4409
2.4803
2.5197
2.5591
2.5984
2.6378
2.6772
2.7165
2.7559
2.7953
2.8346
2.8740
2.9134
2.9528
mm
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
in.
2.9921
3.0315
3.0709
3.1102
3.1496
3.1890
3.2283
3.2677
3.3071
3.3465
3.3858
3.4252
3.4646
3.5039
3.5433
3.5827
3.6220
3.6614
3.7008
3.7402
3.7795
3.8189
3.8583
3.8976
3.9370
101
102
103
104
105
106
107
108
109
3.9764
4.0157
4.0551
4.0945
4.1339
4.1732
4.2126
4.2520
4.2913
111
112
113
114
115
116
117
118
119
4.3701
4.4094
4.4488
4.4882
4.5276
4.5669
4.6063
4.6457
4.6850
121
122
123
124
125
126
127
128
129
4.7638
4.8031
4.8425
4.8819
4.9213
4.9606
5.0000
5.0394
5.0787
131
132
133
134
135
136
137
138
139
5.1575
5.1968
5.2362
5.2756
5.3150
5.3543
5.3937
5.4331
5.4724
in.
1/32
1/16
3/32
1/8
5/32
3/16
7/32
1/4
9/32
5/16
11/32
3/8
13/32
7/16
15/32
1/2
1/64
3/64
5/64
7/64
9/64
11/64
13/64
15/64
17/64
19/64
21/64
23/64
25/64
27/64
29/64
31/64
mm
0.3969
0.7938
1.1906
1.5875
1.9844
2.3813
2.7781
3.1750
3.5719
3.9688
4.3656
4.7625
5.1594
5.5563
5.9531
6.3500
6.7469
7.1438
7.5406
7.9375
8.3344
8.7313
9.1281
9.5250
9.9219
10.3188
10.7156
11.1125
11.5094
11.9063
12.3031
12.7000
in.
17/32
9/16
19/32
5/8
21/32
11/16
23/32
3/4
25/32
13/16
27/32
7/8
29/32
15/16
31/32
1
33/64
35/64
37/64
39/64
41/64
43/64
45/64
47/64
49/64
51/64
53/64
55/64
57/64
59/64
61/64
63/64
mm
13.0969
13.4938
13.8906
14.2875
14.6844
15.0813
15.4781
15.8750
16.2719
16.6688
17.0656
17.4625
17.8594
18.2563
18.6531
19.0500
19.4469
19.8438
20.2406
20.6375
21.0344
21.4313
21.8281
22.2250
22.6219
23.0188
23.4156
23.8125
24.2094
24.6063
25.0031
25.4000
LENGTH
FEET TO METERS
ft.
10
20
30
40
50
60
70
80
90
100
0
m
3.048
6.096
9.144
12.192
15.240
18.288
21.336
24.384
27.432
30.480
1
m
0.305
3.353
6.401
9.449
12.497
15.545
18.593
21.641
24.689
27.737
30.785
2
m
0.610
3.658
6.706
9.754
12.802
15.850
18.898
21.946
24.994
28.042
31.090
3
m
0.914
3.962
7.010
10.058
13.106
16.154
19.202
22.250
25.298
28.346
31.394
1
ft.
3.2808
36.0892
68.8976
101.7060
134.5144
167.3228
200.1312
232.9396
265.7480
298.5564
331.3648
2
ft.
6.5617
39.3701
72.1785
104.9869
137.7953
170.6037
203.4121
236.2205
269.0289
301.8373
334.6457
3
ft.
9.8425
42.6509
75.4593
108.2677
141.0761
173.8845
206.6929
239.5013
272.3097
305.1181
337.9265
4
m
1.219
4.267
7.315
10.363
13.411
16.459
19.507
22.555
25.603
28.651
31.699
5
m
1.524
4.572
7.620
10.668
13.716
16.764
19.812
22.860
25.908
28.956
32.004
6
m
1.829
4.877
7.925
10.973
14.021
17.069
20.117
23.165
26.213
29.261
32.309
7
m
2.134
5.182
8.230
11.278
14.326
17.374
20.422
23.470
26.518
29.566
32.614
8
m
2.438
5.486
8.534
11.582
14.630
17.678
20.726
23.774
26.822
29.870
32.918
9
m
2.743
5.791
8.839
11.887
14.935
17.983
21.031
24.079
27.127
30.175
33.223
ft.
6
ft.
19.6850
52.4934
85.3018
118.1102
150.9186
183.7270
216.5354
249.3438
282.1522
314.9606
347.7690
7
ft.
22.9659
55.7743
88.5827
121.3911
154.1995
187.0079
219.8163
252.6247
285.4331
318.2415
351.0499
8
ft.
26.2467
59.0551
91.8635
124.6719
175.4803
190.2887
223.0971
255.9055
288.7139
321.5223
354.3307
9
ft.
29.5276
62.3360
95.1444
127.9528
160.7612
193.5696
226.3780
259.1864
291.9948
324.8032
357.6116
7
km
11.265
27.359
43.452
59.546
75.639
91.733
107.826
123.919
140.013
156.106
172.200
8
km
12.875
28.968
45.062
61.155
77.249
93.342
109.435
125.529
141.622
157.716
173.809
9
km
14.484
30.578
46.671
62.764
78.858
94.951
111.045
127.138
143.232
159.325
175.418
miles
7
miles
4.350
10.563
16.777
22.990
29.204
35.418
41.632
47.845
54.059
60.273
66.487
8
miles
4.971
11.185
17.398
23.612
29.826
36.039
42.253
48.467
54.681
60.894
67.108
9
miles
5.592
11.806
18.020
24.233
30.447
36.661
42.875
49.088
55.302
61.516
67.729
km
10
20
30
40
50
60
70
80
90
100
METERS TO FEET
m
10
20
30
40
50
60
70
80
90
100
0
ft.
32.8084
65.6168
98.4252
131.2336
164.0420
196.8504
229.6588
262.4672
295.2756
328.0840
4
ft.
13.1234
45.9318
78.7402
111.5486
144.3570
177.1654
209.9738
242.7822
275.5906
308.3990
341.2074
5
ft.
16.4042
49.2126
82.0210
114.8294
147.6378
180.4462
213.2546
246.0630
278.8714
311.6798
344.4882
10
20
30
40
50
60
70
80
90
100
MILES TO KILOMETERS
miles
10
20
30
40
50
60
70
80
90
100
0
km
16.093
32.187
48.280
64.374
80.467
96.561
112.654
128.748
144.841
160.934
1
km
1.609
17.703
33.796
49.890
65.983
82.077
98.170
114.263
130.357
146.450
162.544
2
km
3.219
19.312
35.406
51.499
67.592
83.686
99.779
115.873
131.966
148.060
164.153
3
km
4.828
20.921
37.015
53.108
69.202
85.295
101.389
117.482
133.576
149.669
165.762
4
km
6.437
22.531
38.624
54.718
70.811
86.905
103.000
119.091
135.185
151.278
167.372
5
km
8.047
24.140
40.234
56.327
72.420
88.514
104.607
120.700
136.794
152.888
168.981
6
km
9.656
25.750
41.843
57.936
74.030
90.123
106.217
122.310
138.404
154.497
170.590
10
20
30
40
50
60
70
80
90
100
KILOMETERS TO MILES
km
10
20
30
40
50
60
70
80
90
100
0
miles
6.214
12.427
18.641
24.855
31.065
37.282
43.496
49.711
55.923
62.137
1
miles
0.621
6.835
13.049
19.262
25.476
31.690
37.904
44.117
50.331
56.545
62.758
2
miles
1.243
7.456
13.670
19.884
26.098
32.311
38.525
44.739
50.952
57.166
63.390
3
miles
1.864
8.078
14.292
20.505
26.719
32.933
39.146
45.360
51.574
57.187
64.001
4
miles
2.485
8.699
14.913
21.127
27.340
33.554
39.768
45.981
52.195
58.409
64.622
5
miles
3.107
9.321
15.534
21.748
27.962
34.175
40.389
46.603
52.816
59.030
65.244
6
miles
3.728
9.942
16.156
22.370
28.583
34.797
41.010
47.224
53.438
59.652
65.865
10
20
30
40
50
60
70
80
90
100
AREA
SQUARE INCHES TO SQUARE CENTIMETERS
in2
10
20
30
40
50
60
70
80
90
100
0
cm2
64.516
129.032
193.548
258.064
322.580
387.096
451.612
516.128
580.644
645.160
1
cm2
6.452
70.968
135.484
200.000
264.516
329.032
393.548
458.064
522.580
587.096
651.612
2
cm2
12.903
77.419
141.935
206.451
270.967
335.483
399.999
464.515
529.031
593.547
658.063
3
cm2
19.355
83.871
148.387
212.903
277.419
341.935
406.451
470.967
535.483
599.999
664.515
4
cm2
25.806
90.322
154.838
219.354
283.870
348.386
412.902
477.418
541.934
606.450
670.966
5
cm2
32.258
96.774
161.290
225.806
290.322
354.838
419.354
483.870
548.386
612.902
677.418
6
cm2
38.710
103.226
167.742
232.258
296.774
361.290
425.806
490.322
554.838
619.354
683.870
7
cm2
45.161
109.677
174.193
238.709
303.225
367.741
432.257
496.773
561.289
625.805
690.312
in2
8
cm2
51.613
116.129
180.645
245.161
309.677
374.193
438.709
503.225
567.741
632.257
696.773
9
cm2
58.064
122.580
187.096
251.612
316.128
380.644
445.160
509.676
574.192
638.708
703.224
8
in2
1.240
2.790
4.340
5.890
7.440
8.990
10.540
12.090
13.640
15.190
16.740
9
in2
1.395
2.945
4.495
6.045
7.595
9.145
10.695
12.245
13.795
15.345
16.895
cm2
8
cm (cc)
131.097
294.967
458.838
622.708
786.579
950.450
1114.320
1278.191
1442.062
1605.932
1769.803
9
cm (cc)
147.484
311.354
475.225
639.095
802.966
966.837
1130.707
1294.578
1458.449
1622.319
1786.190
in3
10
20
30
40
50
60
70
80
90
100
SQUARE CENTIMETERS TO SQUARE INCHES

cm2
10
20
30
40
50
60
70
80
90
100
0
in2
1.550
3.100
4.650
6.200
7.750
9.300
10.850
12.400
13.950
15.500
1
in2
0.155
1.705
3.255
4.805
6.355
7.905
9.455
11.005
12.555
14.105
15.655
2
in2
0.310
1.860
3.410
4.960
6.510
8.060
9.610
11.160
12.710
14.260
15.810
3
in2
0.465
2.015
3.565
5.115
6.665
8.215
9.765
11.315
12.865
14.415
15.965
4
in2
0.620
2.170
3.720
5.270
6.820
8.370
9.920
11.470
13.020
14.570
16.120
5
in2
0.775
2.325
3.875
5.425
6.975
8.525
10.075
11.625
13.175
14.725
16.275
6
in2
0.930
2.480
4.030
5.580
7.130
8.680
10.230
11.780
13.330
14.880
16.430
7
in2
1.085
2.635
4.185
5.735
7.285
8.835
10.385
11.935
13.485
15.035
16.583
10
20
30
40
50
60
70
80
90
100
VOLUME
CUBIC INCHES TO CUBIC CENTIMETERS
in3
10
20
30
40
50
60
70
80
90
100
0
cm3(cc)
163.871
327.741
491.612
655.483
819.353
983.224
1147.094
1310.965
1474.836
1638.706
1
cm3(cc)
16.387
180.258
344.128
507.999
671.870
835.740
999.611
1163.482
1327.352
1491.223
1655.093
2
cm (cc)
32.774
196.645
360.515
524.386
688.257
852.127
1015.998
1179.869
1343.739
1507.610
1671.481
3
3
cm (cc)
49.161
213.032
376.902
540.773
704.644
868.514
1032.385
1196.256
1360.126
1523.997
1687.868
3
4
cm (cc)
65.548
229.419
393.290
557.160
721.031
884.901
1048.772
1212.643
1376.513
1540.384
1704.255
3
5
cm (cc)
81.935
245.806
209.677
573.547
737.418
901.289
1065.159
1229.030
1392.900
1156.771
1720.642
3
6
cm (cc)
98.322
262.193
426.064
589.934
753.805
917.676
1081.546
1245.417
1409.288
1573.158
1737.029
3
7
cm (cc)
114.709
278.580
442.451
606.321
770.192
934.063
1097.933
1261.804
1425.675
1589.545
1753.416
3
10
20
30
40
50
60
70
80
90
100
CUBIC CENTIMETERS TO CUBIC INCHES

3
cm (cc)
10
20
30
40
50
60
70
80
90
100
0
in3
0.6102
1.2205
1.8307
2.4409
3.0512
3.6614
4.2716
4.8818
5.4921
6.1023
1
in3
0.0610
0.6713
1.2815
1.8917
2.5020
3.1122
3.7224
4.3326
4.9429
5.5531
6.1633
2
in3
0.1220
0.7323
1.3425
1.9527
2.5630
3.1732
3.7834
4.3937
5.0039
5.6141
6.2243
3
in3
0.1831
0.7933
1.4035
2.0138
2.6240
3.2342
3.8444
4.4547
5.0649
5.6751
6.2854
4
in3
0.2441
0.8543
1.4646
2.0748
2.6850
3.2952
3.9055
4.5157
5.1259
5.7362
6.3464
5
in3
0.3051
0.9153
1.5256
2.1358
2.7460
3.3563
3.9665
4.5767
5.1870
5.7972
6.4074
6
in3
0.3661
0.9764
1.5866
2.1968
2.8071
3.4173
4.0275
4.6377
5.2480
5.8582
6.4684
7
in3
0.4272
1.0374
1.6476
2.2579
2.8681
3.4783
4.0885
4.6988
5.3090
5.9192
6.5295
8
in3
0.4882
1.0984
1.7086
2.1389
2.9291
3.5393
4.1496
4.7598
5.3700
5.9803
6.5905
9
in3
0.5492
1.1594
1.7697
2.3799
2.9901
3.6004
4.2106
4.8208
5.4310
6.0413
6.6515
cm3(cc)
10
20
30
40
50
60
70
80
90
100
VOLUME
GALLONS (U.S.) TO LITERS
U.S. gal.
0
liters
10
20
30
40
50
60
70
80
90
100
37.8543
75.7085
113.5629
141.4171
189.2713
227.1256
264.9799
302.8342
340.6884
378.5427
1
liters
3.7854
41.6397
79.4940
117.3482
155.2025
193.0568
230.9110
268.7653
306.6196
344.4738
382.3281
2
liters
7.5709
45.4251
83.2794
121.1337
158.9879
196.8422
234.6965
272.5507
310.4050
348.2593
386.1135
3
liters
11.3563
49.2105
87.0648
124.9191
162.7734
200.6276
238.4819
276.3362
314.1904
352.0447
389.8990
4
liters
15.1417
52.9960
90.8502
128.7045
166.5588
204.4131
242.2673
280.1216
317.9759
355.8301
393.6844
5
liters
18.9271
56.7814
94.6357
132.4901
170.3442
208.1985
246.0527
283.9070
321.7613
359.6156
397.4698
6
liters
22.7126
60.5668
98.4211
136.2754
174.1296
211.9839
249.8382
287.6924
325.5467
363.4010
401.2553
7
liters
26.4980
64.3523
102.2065
140.0608
177.9151
215.7693
253.6236
291.4779
329.3321
367.1864
405.0407
8
liters
30.2834
68.1377
105.9920
143.8462
181.7005
219.5548
257.4090
295.2633
333.1176
370.9718
408.8261
9
liters
34.0633
71.9231
109.7774
147.6316
185.4859
223.3402
261.1945
299.0487
336.9030
374.7573
412.6115
U.S. gal.
7
gal.
1.8492
4.4909
7.1326
9.7743
12.4161
15.0578
17.6995
20.3412
22.9830
25.6247
28.2664
8
gal.
2.1134
4.7551
7.3968
10.0385
12.6803
15.3220
17.9637
20.6054
23.2471
25.8889
28.5306
9
gal.
2.3775
5.0193
7.6610
10.3027
12.9444
15.5861
18.2279
20.8696
23.5113
26.1530
28.7947
liters
7
liters
31.8213
77.2803
122.7393
168.1983
213.6573
259.1163
304.5753
350.0343
395.4933
440.9523
486.4113
8
liters
36.3672
81.8262
127.2852
172.7442
218.2032
263.6622
309.1212
354.5802
400.0392
445.4982
490.9572
9
liters
40.9131
86.3721
131.8311
177.2901
222.7491
268.2081
313.6671
359.1261
404.5851
450.0441
495.5031
Imp gal.
7
gal.
1.5399
3.7397
5.9395
8.1393
10.3391
12.5389
14.7387
16.9385
19.1383
21.3381
23.5379
8
gal.
1.7598
3.9596
6.1594
8.3592
10.5590
12.7588
14.9586
17.1584
19.3582
21.5580
23.7578
9
gal.
1.9798
4.1796
6.3794
8.5792
10.7790
12.9788
15.1786
17.3784
19.5782
21.7780
23.9778
liters
10
20
30
40
50
60
70
80
90
100
LITERS TO GALLONS (U.S.)

liters
0
gal.
-
10
20
30
40
50
60
70
80
90
100
2.6417
5.2834
7.9252
10.5669
13.2086
15.8503
18.4920
21.1338
23.7755
26.4172
1
gal.
0.2642
2.9059
5.5476
8.1893
10.8311
13.4728
16.1145
18.7562
21.3979
24.0397
26.6814
2
gal.
0.5283
3.1701
5.8118
8.4535
11.0952
13.7369
16.3787
19.0204
21.6621
24.3038
26.9455
3
gal.
0.7925
3.4342
6.0760
8.7117
11.3594
14.0011
16.6428
19.2846
21.9263
24.5680
27.2097
4
gal.
1.0567
3.6984
6.3401
8.9818
11.6236
14.2653
16.9070
19.5487
22.1904
24.8322
27.4739
5
gal.
1.3209
3.9626
6.6043
9.2460
11.8877
14.5295
17.1711
19.8129
22.4546
25.0963
27.7381
6
gal.
1.5850
4.2268
6.8685
9.5102
12.1519
14.7936
17.4354
20.0771
22.7188
25.3605
28.0022
10
20
30
40
50
60
70
80
90
100
GALLONS (IMP.) TO LITERS

Imp gal.
10
20
30
40
50
60
70
80
90
100
0
liters
45.4590
90.9180
136.3770
181.8360
227.2950
272.7540
318.2130
363.6720
409.1310
454.5900
1
liters
4.5459
50.0049
95.4639
140.9229
186.3819
231.8409
277.2999
322.7589
368.2179
413.6769
459.1359
2
liters
9.0918
54.5508
100.0098
145.4688
190.9278
236.3868
281.8458
327.3048
372.7638
418.2228
463.6818
1
gal.
0.2200
2.4198
4.6196
6.8194
9.0192
11.2190
13.4188
15.6186
17.8184
20.0182
22.2180
2
gal.
0.4400
2.6398
4.8396
7.0394
9.2392
11.4390
13.6388
15.8386
18.0384
20.2382
22.4380
3
liters
13.6377
59.0967
104.5557
150.0147
195.4737
240.9327
286.3917
331.8507
377.3097
422.7687
468.2277
4
liters
18.1836
63.6426
109.1016
154.5606
200.0196
245.4786
290.9376
336.8966
381.8556
427.3146
472.7736
5
liters
22.7295
68.1885
113.6475
159.1065
204.5655
250.0245
295.4835
340.9425
386.4015
431.8605
477.3195
6
liters
27.2754
72.7344
118.1934
163.6524
209.1114
254.5704
300.0294
345.4884
390.9474
436.4064
481.8654
10
20
30
40
50
60
70
80
90
100
LITERS TO GALLONS (IMP.)

liters
10
20
30
40
50
60
70
80
90
100
0
gal.
2.1998
4.3996
6.5994
8.7992
10.9990
13.1988
15.3986
17.5984
19.7982
21.9980
3
gal.
0.6599
2.8597
5.0595
7.2593
9.4591
11.6590
13.8587
16.0585
18.2583
20.4581
22.6579
4
gal.
0.8799
3.0797
5.2795
7.4793
9.6791
11.8789
14.0787
16.2785
18.4783
20.6781
22.8779
5
gal.
1.0999
3.2997
5.4995
7.6993
9.8991
12.0989
14.2987
16.4985
18.6983
20.8981
23.0979
6
gal.
1.3199
3.5197
5.7195
7.9193
10.1191
12.3189
14.5187
16.7185
18.9183
21.1181
23.3179
10
20
30
40
50
60
70
80
90
100
MASS
POUNDS TO KILOGRAMS
lbs.
10
20
30
40
50
60
70
80
90
100
0
kg
4.536
9.072
13.608
18.144
22.680
27.216
31.751
36.287
40.823
45.359
1
kg
0.454
4.990
9.525
14.061
18.597
23.133
27.669
32.205
36.741
41.277
45.813
2
kg
0.907
5.443
9.979
14.515
19.051
23.587
28.123
32.659
37.195
41.731
46.266
1
lbs.
2.205
24.251
46.297
68.343
90.390
112.436
134.482
156.528
178.574
200.621
222.667
2
lbs.
4.409
26.455
48.502
70.548
92.594
114.640
136.687
158.732
180.780
202.825
224.871
3
kg
1.361
5.897
10.433
14.969
19.504
24.040
28.576
33.112
37.648
42.184
46.720
4
kg
1.814
6.350
10.886
15.422
19.958
24.494
29.030
33.566
38.102
42.638
47.174
5
kg
2.268
6.804
11.340
15.876
20.412
24.948
29.484
34.019
38.555
43.091
47.627
6
kg
2.722
7.257
11.793
16.329
20.865
25.401
29.937
34.473
39.009
43.545
47.081
7
kg
3.175
7.711
12.247
16.783
21.319
25.855
30.391
34.927
39.463
43.998
48.534
8
kg
3.629
8.165
12.701
17.237
21.772
26.308
30.844
35.380
39.916
44.452
48.988
9
kg
4.082
8.618
13.154
17.690
22.226
26.762
31.298
35.834
40.370
44.906
49.442
7
lbs.
15.432
37.479
59.525
81.571
103.617
125.633
147.710
169.756
191.802
213.848
235.895
8
lbs.
17.637
39.683
61.729
83.776
105.822
127.868
149.914
171.961
194.007
216.053
238.099
9
lbs.
19.842
41.888
63.934
85.980
108.026
130.073
152.119
174.165
196.211
218.258
240.304
lbs.
10
20
30
40
50
60
70
80
90
100
KILOGRAMS TO POUNDS
kg
10
20
30
40
50
60
70
80
90
100
0
lbs.
22.046
44.092
66.139
88.185
110.231
132.277
154.324
176.370
198.416
220.462
3
lbs.
6.614
28.660
50.706
72.753
94.799
16.845
138.891
160.937
182.984
205.030
227.076
4
lbs.
8.818
30.865
52.911
74.957
97.003
119.050
141.096
163.142
185.188
207.234
229.281
5
lbs.
11.023
33.069
55.116
77.162
99.208
121.254
143.300
165.347
187.393
209.439
231.485
6
lbs.
13.228
35.274
57.320
79.366
101.413
123.459
145.505
167.551
189.597
211.644
233.690
kg
10
20
30
40
50
60
70
80
90
100
KILOGRAMS TO NEWTON
kg
10
20
30
40
50
60
70
80
90
100
0
N
98.07
196.13
294.20
392.27
490.33
558.40
686.47
784.53
882.60
980.67
1
N
9.81
107.87
205.94
304.01
402.07
500.14
598.21
696.27
794.34
892.41
990.47
0
kg
10.197
20.394
30.592
40.789
50.986
61.183
71.380
81.578
91.775
101.972
10
kg
1.020
11.217
21.414
31.611
41.809
52.006
62.203
72.400
82.597
92.795
102.992
2
N
19.61
117.68
215.75
313.81
411.88
509.95
608.01
706.08
804.15
902.21
1000.28
3
N
29.42
127.49
225.55
323.62
421.69
519.75
617.82
715.89
813.95
912.02
1010.08
4
N
39.23
137.29
235.36
333.43
431.49
529.56
627.63
725.69
823.76
921.83
1019.89
5
N
49.03
147.10
245.17
343.23
441.30
539.37
637.43
735.50
833.57
931.63
1029.70
6
N
58.84
156.91
254.97
353.04
451.11
549.17
647.24
745.31
843.37
941.44
1039.50
7
N
68.65
166.71
264.78
362.85
460.91
558.98
657.05
755.11
853.18
951.25
1049.31
8
N
78.45
176.52
274.59
372.65
470.72
568.79
666.85
764.92
862.99
961.05
1059.12
9
N
88.26
186.33
284.39
382.46
480.53
578.59
676.66
774.73
872.79
970.86
1068.92
kg
10
20
30
40
50
60
70
80
90
100
NEWTON TO KILOGRAMS
N
10
20
30
40
50
60
70
80
90
100
20
kg
2.039
12.237
22.434
32.631
42.828
53.025
63.223
73.420
83.617
93.814
104.011
30
kg
3.059
13.256
23.453
33.651
43.848
54.045
64.242
74.440
84.637
94.834
105.031
40
kg
4.079
14.276
24.473
34.670
44.868
55.065
65.262
75.459
85.656
95.854
106.051
50
kg
5.099
15.296
25.493
35.690
45.887
56.085
66.282
76.479
86.676
96.873
107.071
60
kg
6.118
16.316
26.513
36.710
46.907
57.104
67.302
77.499
87.696
97.893
108.090
70
kg
7.138
17.335
27.532
37.730
47.927
58.124
68.321
78.518
88.716
98.913
109.110
80
kg
8.158
18.355
28.552
38.749
48.947
59.144
69.341
79.538
89.735
99.933
110.130
90
kg
9.177
19.375
29.572
39.769
49.966
60.163
70.361
80.558
90.755
100.952
111.149
kg
N
10
20
30
40
50
60
70
80
90
100
PRESSURE
POUNDS PER SQUARE INCHES TO KILOGRAMS PER SQUARE CENTIMETERS
lb/in2
(psi)
10
20
30
40
50
60
70
80
90
100
0
kg/cm2
0.7031
1.4061
2.1092
2.8123
3.5154
4.2184
4.9215
5.6246
6.3276
7.0307
1
kg/cm2
0.0703
0.7734
1.4764
2.1795
2.8826
3.5857
4.2887
4.9918
5.6947
6.3979
7.1010
2
kg/cm2
0.1406
0.8437
1.5468
2.2498
2.9529
3.6560
4.3590
5.0621
5.7652
6.4682
7.1713
3
kg/cm2
0.2109
0.9140
1.6171
2.3201
3.0232
3.7263
4.4293
5.1324
5.8355
6.5386
7.2416
4
kg/cm2
0.2812
0.9843
1.6874
2.3904
3.0935
3.7966
4.4996
5.2027
5.9058
6.6089
7.3119
5
kg/cm2
0.3515
1.0546
1.7577
2.4607
3.1638
3.8669
4.5700
5.2730
5.9761
6.6792
7.3822
6
kg/cm2
0.4218
1.1249
1.8280
2.5311
3.2341
3.9372
4.6403
5.3433
6.0464
6.7495
7.4525
7
kg/cm2
0.4921
1.1952
1.8983
2.6014
3.3044
4.0075
4.7106
5.4136
6.1167
6.8198
7.5228
8
kg/cm2
0.5625
1.2655
1.9686
2.6717
3.3747
4.0778
4.7809
5.4839
6.1870
6.8901
7.5932
lb/in2
(psi)
10
20
30
40
50
60
70
80
90
100
9
kg/cm2
0.6328
1.3358
2.0389
2.7420
3.4450
4.1481
4.8512
5.5543
6.2573
6.9604
7.6635
KILOGRAMS PER SQUARE CENTIMETERS TO POUNDS PER SQUARE INCHES

kg/cm2
10
20
30
40
50
60
70
80
90
100
0
lb/in2(psi)
142.23
284.46
426.69
568.92
711.16
853.38
995.61
1137.84
1280.07
1422.30
1
lb/in2(psi)
14.22
156.45
298.6
440.91
583.14
725.37
867.60
1009.83
1152.06
1294.20
1436.52
2
lb/in2(psi)
28.45
170.68
312.91
455.14
597.37
739.60
881.83
102406
1166.27
1308.52
1450.75
3
lb/in2(psi)
42.67
184.90
327.13
469.36
611.59
753.82
896.05
1038.28
1180.51
1322.74
1464.97
4
lb/in2(psi)
56.89
199.12
341.35
483.58
625.81
768.04
910.27
1052.50
1194.73
1336.96
1479.19
5
lb/in2(psi)
71.12
213.35
355.58
497.81
640.04
782.27
924.50
1066.73
1208.96
1351.19
1493.42
6
lb/in2(psi)
85.34
227.57
369.80
512.03
654.26
795.49
938.72
1080.95
1223.18
1365.41
1507.64
7
lb/in2(psi)
99.56
241.79
384.02
526.25
668.48
810.71
952.94
1095.17
1237.40
1379.63
1521.86
8
lb/in2(psi)
113.78
256.01
398.24
540.47
682.70
824.93
967.16
1109.39
1251.62
1393.85
1536.08
9
lb/in2(psi)
128.01
270.24
412.47
554.70
696.93
839.16
981.39
1123.62
1265.85
1408.08
1550.31
kg/cm2
10
20
30
40
50
60
70
80
90
100
KILOGRAMS PER SQUARE CENTIMETERS TO KILO PASCAL

kg/cm
10
20
30
40
50
60
70
80
90
100
0
KPa
980.7
1961.3
2942.0
3922.7
4903.3
5584.0
6864.7
7845.3
8826.0
9806.7
1
KPa
98.1
1078.7
2059.4
3040.1
4020.7
5001.4
5982.1
6962.7
7943.4
8924.1
9904.7
2
KPa
196.1
1176.8
2157.5
3138.1
4118.8
5099.5
6080.1
7060.8
8041.5
9022.1
10002.8
3
KPa
294.2
1274.9
2255.5
3236.2
4216.9
5197.5
6178.2
7158.9
8139.5
9120.2
10100.8
4
KPa
392.3
1372.9
2353.6
3334.3
4314.9
5295.6
6276.3
7256.9
8237.6
9218.3
10198.9
5
KPa
490.3
1471.0
2451.7
3432.3
4413.0
5393.7
6374.3
7355.0
8335.7
9316.3
10297.0
6
KPa
588.4
1569.1
2549.7
3530.4
4511.1
5491.7
6472.4
7453.1
8433.7
9414.4
10395.0
7
KPa
686.5
1667.1
2647.8
3628.5
4609.1
5589.8
6570.5
7551.1
8531.8
9512.5
10493.1
8
KPa
784.5
1765.2
2745.9
3726.5
4707.2
5687.9
6668.5
7649.2
8629.9
9610.5
10591.2
9
KPa
882.6
1863.3
2843.9
3824.6
4805.3
5785.9
6766.6
7747.3
8727.9
9708.6
10689.2
kg/cm2
10
20
30
40
50
60
70
80
90
100
KILO PASCAL TO KILOGRAMS PER SQUARE CENTIMETERS

KPa
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
0
kg/cm2
10.197
20.394
30.592
40.789
50.986
61.183
71.380
81.578
91.775
101.972
100
kg/cm2
1.020
11.217
21.414
31.611
41.809
52.006
62.203
72.400
82.597
92.794
102.992
200
kg/cm2
2.039
12.237
22.434
32.631
42.828
53.025
63.223
73.420
83.617
93.814
104.011
300
kg/cm2
3.059
13.256
23.453
33.651
743.848
54.045
64.242
74.440
84.637
94.834
105.031
400
kg/cm2
4.079
14.276
24.473
34.670
44.868
55.065
65.262
75.459
85.656
95.854
106.051
500
kg/cm2
5.099
15.296
25.493
35.690
45.887
56.085
66.282
76.479
86.676
96.873
107.071
600
kg/cm2
6.118
16.316
26.513
36.710
46.907
57.104
67.302
77.499
87.696
97.893
108.090
700
kg/cm2
7.138
17.335
27.532
37.730
47.927
58.124
68.321
78.518
88.716
98.913
109.110
800
kg/cm2
8.158
18.355
28.552
38.749
48.947
59.144
69.341
79.538
89.735
99.933
110.130
900
kg/cm2
9.177
19.375
29.572
39.769
49.966
60.163
70.361
80.558
90.755
100.952
111.149
KPa
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
TORQUE
FOOT POUNDS TO KILOGRAMMETERS
ft. lbs.
10
20
30
40
50
60
70
80
90
100
0
kg-m
1.383
2.765
4.148
5.530
6.913
8.295
9.678
11.060
12.442
13.826
1
kg-m
0.138
1.521
2.903
4.286
5.668
7.051
8.434
9.816
11.199
12.581
13.964
2
kg-m
0.277
1.659
3.042
4.424
5.807
7.189
8.572
9.954
11.337
12.719
14.102
3
kg-m
0.415
1.797
3.180
4.562
5.945
7.328
8.710
10.093
11.475
12.858
14.240
4
kg-m
0.553
1.936
3.318
4.700
6.083
7.466
8.848
10.231
11.613
12.996
14.379
5
kg-m
0.691
2.074
3.456
4.839
6.221
7.604
8.987
10.369
11.752
13.134
14.517
6
kg-m
0.830
2.212
3.595
4.977
6.360
7.742
9.125
10.507
11.890
13.272
14.655
7
kg-m
0.968
2.350
3.733
5.115
6.498
7.881
9.263
10.646
12.028
13.410
14.793
8
kg-m
1.106
2.489
3.871
5.253
6.636
8.019
9.401
10.784
12.166
13.549
14.932
9
kg-m
1.244
2.627
4.009
5.392
6.774
8.157
9.540
10.922
12.305
13.687
15.070
ft. lbs.
10
20
30
40
50
60
70
80
90
100
KILOGRAMMETERS TO FOOT POUNDS

kg-m
10
20
30
40
50
60
70
80
90
100
0
ft. lbs.
72.33
144.66
217.00
289.32
361.65
433.98
506.31
578.64
650.97
723.30
1
ft. lbs.
7.23
79.56
151.89
224.22
296.55
368.88
441.21
513.54
585.87
658.20
730.53
2
ft. lbs.
14.47
86.80
159.13
231.46
303.79
376.12
448.45
520.78
593.11
665.44
737.77
3
ft. lbs.
21.70
94.03
166.36
238.69
311.02
383.35
455.68
528.01
600.34
672.67
745.00
4
ft. lbs.
28.93
101.26
173.59
245.92
318.25
390.58
462.91
535.24
607.57
679.90
752.23
5
ft. lbs.
36.17
108.50
180.83
253.16
325.49
397.82
470.15
542.48
614.81
687.14
759.47
6
ft. lbs.
43.40
115.73
188.06
260.39
332.72
405.05
477.38
549.71
622.04
694.37
766.70
7
ft. lbs.
50.63
122.96
195.29
267.62
339.95
412.28
484.61
556.94
629.27
701.60
773.93
8
ft. lbs.
57.86
130.19
202.52
274.85
347.18
419.51
491.84
564.17
636.50
708.83
781.16
9
ft. lbs.
65.10
137.43
209.76
282.09
354.42
426.75
499.08
571.41
643.74
716.07
788.40
kg-m
8
N-m
78.45
176.52
274.59
372.65
470.72
568.79
666.85
764.92
862.99
961.05
1059.12
9
N-m
88.26
186.33
284.39
382.46
480.53
578.59
676.66
774.73
872.79
970.86
1068.92
kg-m
10
20
30
40
50
60
70
80
90
100
KILOGRAMMETERS TO NEWTONMETERS
kg-m
10
20
30
40
50
60
70
80
90
100
0
N-m
98.07
196.13
294.20
392.27
490.33
588.40
686.47
784.53
882.60
980.67
1
N-m
9.81
107.87
205.94
304.01
402.07
500.14
589.21
696.27
794.34
892.41
990.47
0
kg-m
10.197
20.394
30.591
40.789
50.986
61.183
71.380
81.577
91.774
101.972
10
kg-m
1.020
11.217
21.414
31.611
41.808
52.005
62.202
72.399
82.596
92.793
102.990
2
N-m
19.61
117.68
215.75
313.81
411.88
509.95
608.01
706.08
804.15
902.21
1000.28
3
N-m
29.42
127.49
225.55
323.62
421.69
519.75
617.82
715.89
813.95
912.02
1010.08
4
N-m
39.23
137.29
235.36
333.43
431.49
529.56
627.63
725.69
823.76
921.83
1019.89
5
N-m
49.03
147.10
245.17
343.23
441.30
539.37
637.43
735.50
833.57
931.63
1029.70
6
N-m
58.84
156.91
254.97
353.04
451.11
549.17
647.24
745.31
843.37
941.44
1039.50
7
N-m
68.65
166.71
264.78
362.85
460.91
558.98
657.05
755.11
853.18
951.25
1049.31
10
20
30
40
50
60
70
80
90
100
NEWTONMETERS TO KILOGRAMMETERS
N-m
100
200
300
400
500
600
700
800
900
1000
20
kg-m
2.039
12.236
22.433
32.630
42.827
53.024
63.221
73.418
83.615
93.812
104.009
30
kg-m
3.059
13.256
23.453
33.650
43.847
54.044
64.241
74.438
84.635
94.832
105.029
40
kg-m
4.079
14.276
24.473
34.670
44.867
55.064
65.261
75.485
85.655
95.852
106.049
50
kg-m
5.099
15.296
25.493
35.690
45.887
56.084
66.281
76.478
86.675
96.872
107.069
60
kg-m
6.118
16.315
26.512
36.710
46.906
57.103
67.300
77.497
87.694
97.891
108.088
70
kg-m
7.138
17.335
27.532
37.729
47.926
58.123
68.320
78.517
88.714
98.911
109.108
80
kg-m
8.158
18.355
28.552
38.749
48.946
59.143
69.340
79.537
89.734
99.931
110.128
90
kg-m
9.177
19.374
29.571
39.768
49.965
60.162
70.359
80.556
90.753
100.950
111.147
N-m
100
200
300
400
500
600
700
800
900
1000
TEMPERATURE
FAHRENHEIT TO CENTIGRADE
F
-60
-58
-56
-54
-52
-50
-48
-46
-44
-42
-40
-38
-36
-34
-32
-30
-28
-26
-24
-22
-20
-18
-16
-14
-12
-10
-8
-6
-4
C
-51.1
-50
-48.9
-47.8
-46.7
-45.6
-44.4
-43.3
-42.2
-41.1
-40.0
-38.9
37.8
36.7
-35.6
-34.4
-33.3
-32.2
-31.1
-30.0
-28.9
-27.8
-26.7
-25.6
-24.4
-23.3
-22.2
-21.1
-20.0
F
-2
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
C
-18.9
-17.8
-16.7
-15.6
-14.4
-13.3
-12.2
-11.1
-10.0
-8.9
-7.8
-3.7
-5.6
-4.4
-3.3
-2.2
-1.1
-0
1.1
2.2
3.3
4.4
5.6
6.7
7.8
8.9
10.0
11.1
12.2
F
56
58
60
62
64
66
68
70
72
74
76
78
80
82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
112
C
13.3
14.4
15.6
16.7
17.8
18.9
20.0
21.1
22.2
23.3
24.9
25.6
26.7
27.8
28.9
30.0
31.1
32.2
33.3
34.4
35.6
36.7
37.8
38.9
40.0
41.1
42.2
43.3
44.4
F
114
116
118
120
122
124
126
128
130
132
134
136
138
140
142
144
146
148
150
152
154
156
158
160
162
164
166
168
170
C
45.6
46.7
47.8
48.9
50.0
51.1
52.2
53.3
54.4
55.6
56.7
57.8
58.9
60.0
61.1
62.2
63.3
64.4
65.6
66.7
67.8
68.9
70.0
71.1
72.2
73.3
74.4
75.6
76.7
F
172
147
176
178
180
182
184
186
188
190
192
194
196
198
200
202
204
206
208
210
212
214
216
218
220
222
224
226
228
C
77.8
78.9
80.0
81.1
82.2
83.3
84.4
85.6
86.7
87.8
88.9
90.0
91.1
92.2
93.3
94.4
95.6
96.7
97.8
98.9
100.0
101.1
102.2
103.3
104.4
105.6
106.7
107.8
108.9
F
230
232
234
236
238
240
242
244
246
248
250
252
254
256
258
260
262
264
266
268
270
272
274
276
278
280
282
284
286
C
110.0
111.1
112.2
113.3
114.4
115.6
116.7
117.8
118.9
120.0
121.1
122.2
123.3
124.4
125.6
126.7
127.8
128.9
130.0
131.1
132.2
133.3
134.4
135.6
136.7
137.8
138.9
140.0
141.1
F
288
290
292
294
296
298
300
302
304
306
308
310
312
314
316
318
320
322
324
326
328
330
332
334
336
338
340
342
344
C
142.2
143.3
144.4
145.6
146.7
147.8
148.9
150.0
151.1
152.2
153.3
154.4
155.6
156.7
157.8
158.9
160.0
161.1
162.2
163.3
164.4
165.6
166.7
167.8
168.9
170.0
171.1
172.2
173.3
F
346
348
350
352
354
356
358
360
362
364
366
368
370
372
374
376
378
380
382
384
386
388
390
382
400
410
420
430
440
C
174.4
175.6
176.7
177.8
178.9
180.0
181.1
182.2
183.3
184.4
185.6
186.7
187.8
188.9
190.0
191.1
192.2
193.3
194.4
195.6
196.7
197.8
198.9
200.0
204.4
210.0
215.6
221.1
226.7
F
230.0
231.8
233.6
235.4
237.2
239.0
240.8
242.6
244.4
246.2
248.0
249.8
251.6
253.4
255.2
257.0
258.8
260.6
262.4
264.2
266.0
267.8
269.6
271.4
273.2
275.0
276.8
278.6
280.4
282.2
284.0
285.8
C
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
F
287.6
289.4
291.2
293.0
294.8
296.6
298.4
300.2
302.0
303.8
305.6
307.4
309.2
311.0
312.8
314.6
316.4
318.2
320.0
321.8
323.6
325.4
327.2
329.0
330.8
332.6
334.4
336.4
338.0
339.8
341.6
343.4
C
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
210
220
230
240
250
F
345.2
347.0
348.8
350.6
352.4
354.2
356.0
357.8
359.6
361.4
363.2
365.0
366.8
368.6
370.4
372.2
374.0
375.8
377.6
379.4
381.2
383.0
384.8
386.6
388.4
390.2
392.0
410.0
428.0
446.0
464.0
482.0
CENTIGRADE TO FAHRENHEIT
C
-50
-49
-48
-47
-46
-45
-44
-43
-42
-41
-40
-39
-38
-37
-36
-35
-34
-33
-32
-31
-30
-29
-28
-27
-26
-25
-24
-23
-22
-21
-20
-19
F
-58.0
-56.2
-54.4
-52.6
-50.8
-49.0
-47.2
-45.4
-43.6
-41.8
-40.0
-38.2
-36.4
-34.6
-32.8
-31.0
-29.2
-27.4
-25.6
-23.8
-22.0
-20.2
-18.4
-16.6
-14.8
-13.0
-1.2
-9.4
-7.6
-5.8
-4.4
-2.2
C
-18
-17
-16
-15
-14
-13
-12
-11
-10
-9
-8
-7
-6
-5
-4
-3
-2
-1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
F
-0.4
1.4
3.2
5.0
6.8
8.6
10.4
12.2
14.0
15.8
17.6
19.4
21.2
23.0
24.8
26.6
28.4
30.2
32.0
33.8
35.6
37.4
39.2
41.0
42.8
44.6
46.4
48.2
50.0
51.8
53.6
55.4
C
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
F
57.2
59.0
60.8
62.6
64.4
66.2
68.0
69.8
71.6
73.4
75.2
77.0
78.8
80.6
82.4
84.2
86.0
87.8
89.6
91.4
93.2
95.0
96.8
98.6
100.4
102.2
104.0
105.8
107.6
109.4
111.2
113.0
C
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
F
114.8
116.6
118.4
120.2
122.0
123.8
125.6
127.4
129.2
131.0
132.8
134.6
136.4
138.2
140.0
141.8
143.6
145.4
147.2
149.0
150.8
152.6
154.4
156.2
158.0
159.8
161.6
163.4
165.2
167.0
168.8
170.6
C
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
F
172.4
174.2
176.0
177.8
179.6
181.4
183.2
185.0
186.8
188.6
190.4
192.2
194.0
195.8
197.6
199.4
201.2
203.0
204.8
206.6
208.4
210.2
212.0
213.8
215.6
217.4
219.2
221.0
222.8
224.6
226.4
228.2
C
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
MAINTENANCE AND LUBRICATION 0B-1
SECTION 0B
MAINTENANCE AND LUBRICATION

TABLE OF CONTENTS
PAGE
Maintenance Schedule (For GENERAL EXPORT)......................................................... 0B- 2
Maintenance Schedule (For EUROPE)........................................................................... 0B- 5
Severe Conditions Maintenance Schedule (For GENERAL EXPORT) ........................ 0B-11
Severe Conditions Maintenance Schedule (For EUROPE) .......................................... 0B-12
Recommended Fluids and Lubricants (For GENERAL EXPORT)................................ 0B-13
Recommended Fluids and Lubricants (For EUROPE).................................................. 0B-15
Oil Viscosity Chart ........................................................................................................... 0B-16
0B-2 MAINTENANCE AND LUBRICATION
MAINTENANCE SCHEDULE (For GENERAL EXPORT)

Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."
I : Inspect and correct or replace as necessary A : Adjust
R : Replace or change T : Tighten to specified torque L : Lubricate
SERVICE INTERVAL:
1,000 km
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
(Use odometer reading
1,000 miles
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
57
60
12
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
114
120
or months whichever
comes first)
ENGINE
100
or months
Idling speed and acceleration

(GASOLINE)
(DIESEL)
* Air cleaner element
(GASOLINE)
(DIESEL)
* D Engine oil (4JH1-TC)
* D Engine oil (4JA1-TC)
* D Engine oil (4JA1-T)
* P Engine oil filter (6VE1)
* P Engine oil (6VE1)

* P Engine oil (C24SE)
Replace every 12,000km
* P Engine oil filter (C24SE)
* D Engine oil filter (4JH1-TC, 4JA1-T)
* D Engine oil filter (4JA1-TC)
Oil leakage and contamination

(GASOLINE)
(DIESEL)
Fuel leakage
Fuel tank
P O2 Sensor
P Valve clearances (6VE1)
Check and adjust if noisy
D Valve clearances
P Spark plugs (C24SE) (for leaded
fuel use)
P Spark plugs (C24SE) (for unleaded
fuel use)
P Spark plugs (6VE1)
Spark plug wire

|
Fuel filter
(GASOLINE)
Fuel filter
(DIESEL)
Engine / Accessory drive belt

(GASOLINE)
Fan belt tension and damage
(DIESEL)
* Exhaust system
Engine coolant concentration (6VE1)
(C24SE)
Engine coolant level concentration

(DESEL)
Cooling system for water leakage
All hoses and pipes in engine

compartment for clogs or damage
P Timing belt (C24SE)
(Replace every 120,000km)

P Timing belt (6VE1)
CLUTCH
Clutch fluid
Clutch pedal travel and free play

SERVICE INTERVAL:
1,000 km
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
1,000 miles
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
57
60
or months whichever
comes first)
or months
TRANSMISSION OR TRANSMISSION
WITH TRANSFER CASE
12
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
114
120
AT
100
* AT Transfer case oil

* Manual transmission fluid
* Transfer case oil
Oil leakage
Gear control mechanism for

looseness
Automatic transmission fluid
PROPELLER SHAFT
Loose connections
* Universal joints and splines for wear
4WD Universal joints and splines
FRONT AND REAR AXLE

* Differential gear oil (Front and rear)
Oil leakage
Shift on the fly system gear oil
Front axle shaft rubber boot for

damage
Axle shafts for distortion or damage
Axle case for distortion or damage
STEERING
Power steering fluid
Oil leakage
Steering wheel play
Steering function
Right and left turning radius
Wheel alignment
Joint ball for oil leakage or damage
Joint ball rubber boot for damage
* Steering system for looseness or

damage
Power steering hose

SERVICE INTERVAL:
1,000 km
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
1,000 miles
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
57
60
12
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
114
120
Brake fluid
Brake system for fluid leakage
Brake function
* Rear brake lining and drum wear
* Front disc brake pads and discs
Brake pedal travel and free play
Pipes and hoses loose connections

or damage
or months whichever
comes first)
SERVICE BRAKES
100
or months
PARKING BRAKE
Parking brake function
Parking brake lever travel
Cables for looseness or damage

and guide for damage
Ratchet for wear or damage
Leaf / Coil / Torsion bar springs for

damage
Mount for looseness or damage
Shock absorbers for oil leakage
Shock absorbers mount for

looseness
Rubber bushes of suspension wear
or damage
Spring action for loss of balance
due to weakening
Wheel nuts
Wheel disc for damage
Hub bearing grease
Front and rear hub bearing for

looseness
Tire pressure and damage
SUSPENSION
WHEELS
Tire rotation
(Rotate as required)
OTHERS
Bolts and nuts on chassis and body
Lube front free wheding hubs
MAINTENANCE SCHEDULE (For EUROPE)

Items followed by an asterisk (*) require more frequent maintenance if the vehicle is driven under severe conditions.
Refer to "SEVERE CONDITIONS MAINTENANCE SCHEDULE."
Diesel Engine model (ACEA B2 specification engine oil)

1,000 km
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
1,000 miles
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
57
60
12
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
114
120
* Engine oil (4JH1-TC)
* Engine oil (4JA1-TC)
* Engine oil filter(4JH1-TC)
* Engine oil filter (4JA1-TC)
SERVICE INTERVAL:
(Use odometer reading or
months whichever comes
first)
DIESEL ENGINE
100
or months
Exhaust system

compartment for clog of damage
Valve clearance (4JH1-TC)
A
-
Valve clearance (4JA1-TC)
* Air cleaner element (4JH1-TC)
* Air clearance element (4JA1-TC)
Fuel filter (4JH1-TC)
Fuel filter (4JA1-TC)
Engine coolant concentration
(4JH1-TC)

(4JA1-TC)

(4JH1-TC)
Cooing system for water leakage

(4JA1-TC)
CLUTCH
Clutch fluid (4JH1-TC)
Clutch fluid (4JA1-TC)
Clutch pedal travel and play (4JH1-TC)
Clutch pedal travel and play (4JA1-TC)
I
-
WITH TRANSFER CASE
* Manual transmission with fluid
(4JH1-TC)
* Transfer case oil (4JH1-TC)
* Transfer case oil (4JA1-TC)
(4JA1-TC)
Oil leakage (4JH1-TC)
Oil leakage (4JA1-TC)

looseness (4JH1-TC)
looseness (4JA1-TC)
* AT Automatic transmission fluid
(4JH1-TC)
(4JA1-TC)
* AT Transfer case oil (4JH1-TC)
AT
Transfer case oil (4JA1-TC)

SERVICE INTERVAL:
first)
1,000 km
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
1,000 miles
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
57
60
12
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
114
120
100
or months
PROPELLER SHAFT
Loose connections (4JH1-TC)
Loose connections (4JA1-TC)
I
-

(4JH1-TC)

(4JA1-TC)
4WD Universal joints and sliding
sleeve (4JH1-TC)
FRONT AND REAR AXLE

(4JH1-TC)
(4JA1-TC)
Shift on the fly system

Gear oil (4JH1-TC)
Gear oil (4JA1-TC)

damage (4JH1-TC)
damage (4JA1-TC)
(4JH1-TC)

(4JA1-TC)

(4JH1-TC)

(4JA1-TC)
STEERING
Power steering fluid (4JH1-TC)
Power steering fluid (4JA1-TC)

damage (4JH1-TC)
damage (4JA1-TC)
Power steering hose (4JH1-TC)
Power steering hose (4JA1-TC)
Steering wheel play (4JH1-TC)
Steering wheel play (4JA1-TC)
Steering function (4JH1-TC)
Steering function (4JA1-TC)
Right and left turning radius (4JH1-TC)
Right and left turning radius (4JA1-TC)
Wheel alignment (4JH1-TC)
Wheel alignment (4JA1-TC)
(4JH1-TC)

(4JA1-TC)

(4JH1-TC)

(4JA1-TC)

SERVICE INTERVAL:
first)
1,000 km
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
1,000 miles
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
57
60
12
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
114
120
100
or months
SERVICE BRAKES
Brake fluid (4JH1-TC)
Brake fluid (4JA1-TC)
I
-
(4JH1-TC)
Brake function (4JH1-TC)
Brake function (4JA1-TC)
(4JA1-TC)
* Front Disc brake pads and discs wear

(4JH1-TC)

(4JA1-TC)

(4JH1-TC)

(4JA1-TC)
Brake pedal travel and play (4JH1-TC)
Brake pedal travel and play (4JA1-TC)
Pipes and hoses for loose

connections or damage (4JH1-TC)
connections or damage (4JA1-TC)
PARKING BRAKE
Parking brake function (4JH1-TC)
Parking brake function (4JA1-TC)
Parking brake lever travel (4JH1-TC)
Parking brake lever travel (4JA1-TC)
Cables for looseness or damage and

guide for damage (4JH1-TC)
guide for damage (4JA1-TC)
Ratchet for wear or damage (4JH1-TC)
Ratchet for wear or damage (4JA1-TC)

SUSPENSION
Leaf/Coil/Torsion bar springs for
damage (4JH1-TC)
damage (4JA1-TC)
(4JH1-TC)

(4JA1-TC)

(4JH1-TC)

(4JA1-TC)

looseness (4JH1-TC)
looseness (4JA1-TC)
or damage (4JH1-TC)
or damage (4JA1-TC)
Spring action for loss of balance due
to weakening (4JH1-TC)
to weakening (4JA1-TC)
(4JH1-TC)

(4JA1-TC)

1,000 km
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
1,000 miles
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
57
60
12
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
114
120
Wheel nuts (4JH1-TC)
Wheel nuts (4JA1-TC)
Wheel disc for damage (4JH1-TC)
Wheel disc for damage (4JA1-TC)
Hub bearing grease (4JH1-TC)
Hub bearing grease (4JA1-TC)
Front and rear hub bearings for

looseness (4JH1-TC)
looseness (4JA1-TC)
Tire pressure and damage (4JH1-TC)
Tire pressure and damage (4JA1-TC)
SERVICE INTERVAL:
first)
100
or months
WHEELS
OTHERS
(4JH1-TC)

(4JA1-TC)
Lube front free - wheeling hubs


Diesel Engine model (Engine oil that meet or exceeds ACEA B3 specification)

1,000 km
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
1,000 miles
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
57
60
12
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
114
120
* Engine oil
* Engine oil filter
Exhaust system

compartment for clog of damage
Valve clearance
I
A
I
A
I
A
I
A
I
A
SERVICE INTERVAL:
first)
100
or months
DIESEL ENGINE
Fuel filter
Clutch fluid
Clutch pedal travel and play
* Air cleaner element
CLUTCH
WITH TRANSFER CASE
* Transfer case oil
Oil leakage
looseness
*
AT
Transfer case oil
PROPELLER SHAFT
Loose connections
4WD Universal joints and sliding
sleeve
FRONT AND REAR AXLE
Oil leakage

Gear oil

damage
STEERING
Power steering fluid
Oil leakage
Steering wheel play
Steering function
Right and left turning radius
Wheel alignment

damage
Power steering hose

1,000 km
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
1,000 miles
12
15
18
21
24
27
30
33
36
39
42
45
48
51
54
57
60
12
18
24
30
36
42
48
54
60
66
72
78
84
90
96
102
108
114
120
Brake fluid
Brake function
SERVICE INTERVAL:
first)
100
or months
SERVICE BRAKES
Brake pedal travel and play

connections or damage
PARKING BRAKE
Parking brake function
Parking brake lever travel

guide for damage
Ratchet for wear or damage
I
I
I
I
I
I
I
I

damage

looseness
or damage
to weakening
Wheel nuts
Wheel disc for damage
Hub bearing grease

looseness
Tire pressure and damage
SUSPENSION
WHEELS
Tire rotation
(Rotate as required)
OTHERS
Lube front free - wheeling hubs
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For GENERAL EXPORT)

Severe driving conditions
A : Repeated short trips
B : Driving on rough roads
C : Driving on dusty roads
D : Driving in extremely cold weather and/or on salted roads
E : Towing trailer or climbing mountain frequently
4JA1-T
4JA1-TC
4JH
D
MT
AT
4WD

Item
Engine oil
Interval
G
Exhaust system
Air cleaner element
Steering system for looseness
or damage
Universal joints and sleeves
Transmission or transfer case
oil
Differential oil
Front brake pads and discs
Rear brake lining and drum
wear
Condition
C
D
A+D
4JH
: Change every 5,000 km (3,000 miles) or 3 month

: Change every 2,500 km (1,500 miles)
Replace every 5,000 km (3,000 miles) or 3 month
Replace every 5,000 km (3,000 miles)
4JA1-T
4JA1-TC
Engine oil filter
: Gasoline engine
: 4JA1-T Diesel engine
: 4JA1-TC Diesel engine
: 4JH1-TC Diesel engine
: Diesel engine
: Manual transmission
: Automatic transmission
Four wheel drive
Inspect every 5,000 km (3,000 miles)

D
: Inspect every 2,500 km (1,500 miles)
Inspect for wear and lubricate every 5,000 km (3,000
miles)
Change every 20,000 km (12,000 miles)
MT
after changing at initial 10,000 km (6,000 miles)
Transmission:
AT
Transfer:
4WD
l
l
l
l
l
l
l
l
l
SEVERE CONDITIONS MAINTENANCE SCHEDULE (For EUROPE)

Severe driving conditions
A: Repeated short trips
B: Driving on rough roads
C: Driving on dusty roads
D: Driving in extremely cold weather and/or on salted roads
E: Towing trailer or climbing mountein frequently

Item
Engine oil
4JA1-TC
4JH
D
MT
AT
4WD
: 4JA1-TC Diesel engine

: 4JH1-TC Diesel engine
: Diesel engine
: Manual transmission
: Automatic transmission
: Four wheel drive
Interval
4JH
: Replace every 5,000 km (3,000 miles)
4JA1-TC : Replace every 7,5000 km (4,500 miles)
Condition
B
C D A+D
4JH
4JA1-TC
Engine oil filter

Exhaust pipes and mounting
Air cleaner element
Steering system for looseness or
damage
Universal joints and sleeves
Transmission or transmission
with transfer case oil
Transfer:
After changing at initial 10,000 km (6,000 miles)
Front brake pads and discs

Rear brake lining and drum wear

l
l
l
l
4WD
Differential oil

Inspect for wear and lubricate every 10,000 km (6,000 miles)
MT
Transmission:
AT
Inspection every 20,000 km (12,000 miles)
l
l
l
l
l
l
l
Recommended Fluids and Lubricants (For GENERAL EXPORT)

In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very important to
select and use correctly best lubricants and diesel fuels.
When lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below, according to
the maintenance schedule for each vehicle model.
The lubrication intervals in the maintenance schedule and coverage and period of new vehicle warranty are based
on the use of ISUZU genuine lubricants or recommended lubricants as given in the chart which will serve as a guide
for selecting lubricants of proper brand name.

LUBRICATION
Petrol engine crankcase
MAKE
ISUZU GENUINE
ISUZU GENUINE
ISUZU GENUINE
EXXON / ESSO
EXXON / ESSO
MOBIL
CALTEX / TEXACO
Diesel engine crankcase
SHELL
ELF
TOTAL
CASTROL
ISUZU GENUINE
ISUZU GENUINE
ISUZU GENUINE
ISUZU GENUINE
EXXON / ESSO
EXXON / ESSO
MOBIL
CALTEX/CHEVRON
SHELL
ELF
TOTAL
CASTROL
ISUZU GENUINE
EXXON / ESSO
EXXON / ESSO
MOBIL
Manual transmission Transfer
case
Differential
(GL-5 only)
Differential
(Limited Slip Differential)
BRAND / TYPE
BESCO RACING - ACE SJ (5W-30)
BESCO MULTI - Z SUV (5W-30)
BESCO MULTI - ACE (7.5W-30)
ESOO SUPERFLO (15W-40, 15W-50, 20W-50)
ESOO UNIFLO (15W-40, 15W-50, 20W-50)
MOBIL SUPER XHP (15W-40, 15W-50, 20W-50)
HAVOLINE FORMULA-3 (15W-40, 20W-50)
HELIX SUPER (10W-30)
SUPER SPORTI S (15W-40)
QUARTZ 5000 (15W-40, 20W-50)
GTX-2 (15W-40)
BESCO MULTI - Z TYPE CE (10W-30)
BESCO MULTI - Z (10W-30)
BESCO MULTI - Z SUV (5W-30)
BESCO S-3 (10W, 20W, 30, 40)
ESSOLUBE XD-3+ (15W-40)
ESSOLUBE XT 331 (15W-40)
DELVAC HP (15W-40, 30, 40)
DELO CXJ (15W-40, 30, 40)
RIMULA D (15W-40, 30, 40)
PERFORMANCE TROPHY (15W-40)
RUBIA XT (15W-40)
RX SUPER PLUS (15W-40)
SHELL
ELF
TOTAL
CASTROL
BESCO GEAR OIL TRANSAXLE (5W-30)

ESSOLUBE XD-3+ (15W-40)
ESSOLUBE XT 331 (15W-40)
MOBIL SUPER (10W-30)
HAVOLINE FORMULA-3 (15W-40, 20W-50)
RIMULA D (15W-40)
SUPER SPORTI S (15W-40)
QUARTZ 5000 (15W-40, 20W-50)
RX SUPER PLUS (15W-40)
ISUZU GENUINE
ISUZU GENUINE
EXXON / ESSO
MOBIL
CALTEX
SHELL
ELF
TOTAL
CASTROL
CASTROL
ISUZU GENUINE
EXXON / ESSO
MOBIL
CALTEX
ELF
TOTAL
CASTROL
BESCO GEAR OIL SH (80W-90, 90, 140)

BESCO SHIFT ON THE FLY (75W-90)
GEAR OIL GX (85W-90)
MOBILUBE HD (80W-90, 85W-140)
THURBAN GL-5 EP (80W-90, 85W-140)
SPIRAX HD (90, 140)
TRANSELF TYPE B (80W-90, 85W-140)
TRANSMISSION TM (80W-90, 85W-140)
EPX 90 (90)
DYNA DRIVE (80W-90)
BESCO GEAR OIL LSD (140)
GEAR OIL LSA (90)
MOBILUBE HD LS (80W-90)
GEAR OIL LSD (90)
TRANSELF TYPE BLS (90)
TRANSMISSION DA (85W-90)
HYPOY LS (90)
CALTEX / TEXACO
GRADE
API
SJ
SH/CF
SG
SJ
SJ
SJ
SJ
SJ
SG
SJ
SG/SH
CE
CD
SH/CF
CD
CG-4/CF
CG-4/CF
CF/CE
CF
CD/CF
CE
CF-4
CC/CD
CG-4/CH-4
SG
CG-4/CF
CG-4/CF
SH
SH
CD/CF
SG/CD
SJ/CF
CC/CD
CG-4/CH-4
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
GL-5
ACEA
A2
A2
A3
A2
E2/B2
E2/B2
E3
E2
E3/B3
E2/B2
E2/B2
A2/B2
E3/B3

LUBRICATION
Automatic transmission
Power steering
Grease fitting
(Multi purpose grease)
Propeller shaft sliding yoke

Universal joint
Multi purpose grease
containing molybdenum
disulfide
MAKE
ISUZU GENUINE
EXXON / ESSO
MOBIL
CALTEX
SHELL
ELF
TOTAL
CASTROL
CASTROL
ISUZU GENUINE
EXXON / ESSO
MOBIL
CALTEX / TEXACO
SHELL
TOTAL
CASTROL
ISUZU GENUINE
EXXON / ESSO
EXXON / ESSO
CALTEX
TOTAL
ISUZU GENUINE
TEXACO
Engine cooling system
CALTEX
GM GENUINE
GRADE
BRAND / TYPE
API
BESCO ATF III, ATF II

ESSO ATF D (DEXRON II-D)
MOBIL ATF (DEXRON III)
ATF HD (DEXRON II)
SHELL DONAX TA (DEXRON II-D)
ELFMATIC G3 (DEXRON III)
TOTAL FLUID IID (DEXRON II-D)
TQ-D (DEXRON II)
TQ DEXRON III (DEXRON III)
BESCO L-2 GREASE (No.2), L-3 GREASE (No.3)
RONEX MP (No.2)
MOBILGREASE HP 222 (No.2)
STARPLEX-2 (No.2)
RETINAX A (No.2)
MULTIS EP2, EP3 (No.2, No.3)
LM GREASE (No.2, No.3)
ONE LUBER MO GREASE
BEACON Q2 (No.2)
MULTIPURPOSE GREASE (Moly) (No.2)
MOLYTEX GREASE EP2 (No.2)
TOTAL MULTIS MS2 (No.2)
BESCO LLC SUPER TYPE E
HAVOLINE EXTENDED LIFE ANTIFREEZE
COOLANT
HAVOLIN XLC
EXTENDED LIFE COOLANT 6280
XLC
GOODWRENCH DEX-COOL (TM) ANTIFREEZE
EXTENDED LIFE COOLANT

FLUID
TYPE
Besco brake fluid (For light duty)
Hydraulic brake fluid SAE J1703
FMVSS 116 DOT.3 grade
Clutch and brake fluid reservoir

DIESEL FUEL/APPLICABLE STANDARD
JIS (JAPANESE INDUSTRIAL STANDARD)
DIN (DEUTSCHE INDUSTRIE NORMEN)
SAE (SOCIETY OF AUTOMOTIVE ENGINEERS)
BS (BRITISH STANDARD)

NOTE:
Use the applicable standard or equivalent for diesel fuels.
Based on K2204 GAS OIL

Based on EN590 : 1997
Based on SAE J-313C
Based on BS EN590 : 1997
ACEA
RECOMMENDED FLUIDS AND LUBRICANTS (For EUROPE)

In order to obtain maximum performance and longest service life from your ISUZU vehicles, it is very important to
select and use correctly best lubricants and diesel fuels.
When lubricating, be sure to use ISUZU genuine lubricants or recommended lubricants listed below, according to
the maintenance schedule for each vehicle model.
LUBRICATION/FLUID
GRADE
API
Diesel engine crankcase

Manual transmission
Transfer case
Differential
(GL-5 only)
Differential
(Limited Slip Differential)
ACEA
OTHER
B2/B3
E2/E3
B2/B3
E2/E3
GL-5
GL-5
* Limited
Slip
Differential
Gear
Lubricant
Power steering
Propeller shaft sliding yoke
Universal joint
(General purpose grease in
Molybdenum)
Engine cooling system
BESCO GEAR OIL SH (80W-90, 90, 140) (ISUZU GENUINE)

BESCO SHIFT ON THE FLY (75W-90) (ISUZU GENUINE)
GEAR OIL GX (85W-90) (EXXON / ESSO)
MOBILUBE HD (80W-90, 85W-140) (MOBIL)
THURBAN GL-5 EP (80W-90, 85W-140) (CALTEX)
SPIRAX HD (90, 140) (SHELL)
TRANSELF TYPE B (80W-90, 85W-140) (ELF)
TRANSMISSION TM (80W-90, 85W-140) (TOTAL)
BESCO GEAR OIL LSD (140) (ISUZU GENUINE)
GEAR OIL LSA (90) (EXXON/ESSO)
MOBILUBE HD LS (80W-90) (MOBIL)
GEAR OIL LSD (90) (CALTEX)
TRANSELF TYPE BLS (90) (SHELL)
TRANSMISSION DA (85W-90) (ELF)
HYPOY LS (90) (TOTAL)
DEXRON II, III
NLGI #2 or #3
multi purpose type grease
containing molybdenum disulfide
Good quality ethylene glycol antifreeze or GM spec.
6033-M or equivalent
* If GL-5 Limited Slip Differential Lubricant is not available, use GL-5 Lubricant together with Limited Slip Differential Lubricant additive (Parts No. 8-01052-358-0) or
equivalent.
FLUID
Clutch and brake fluid reservoir
TYPE
Besco brake fluid (For light duty)
Hydraulic brake fluid SAE J1703
FMVSS 116 DOT.3 grade
DIESEL FUEL/APPLICABLE STANDARD

JIS (JAPANESE INDUSTRIAL STANDARD)
Based on K2204 GAS OIL
DIN (DEUTSCHE INDUSTRIE NORMEN)
Based on EN590: 1997L
SAE (SOCIETY OF AUTOMOTIVE ENGINEERS) Based on SAE J-313C
BS (BRITISH STANDARD)
Based on BS EN590: 1997
NOTE:
Use the applicable standard or equivalent for diesel fuels.

OIL VISCOSITY CHART

Lubricants should be carefully selected according to the lubrication chart. It is also important to select viscosity of
lubricants according to the ambient temperature by referring to the following table.
OIL VISCOSITY CHART FOR DIESEL ENGINE

APPLY DIESEL ENGINE OIL
(Single grade)
VISCOSITY GRADE - AMBIENT TEMPERATURE
SAE 40, 50
SAE 30
SAE 20, 20W
SAE 10W
-25 C
-13 F
(Multi grade)
-15 C
-10 C
0C
15 C
25 C
30 C
5F
14 F
32 F
60 F
77 F
86 F
SAE 10W-30
SAE 15W-40, 20W-40, 20W-50
*
SAE 5W-30
*Not recomended for sustained high speed driving.
ED-03

OIL VISCOSITY CHART FOR GASOLINE ENGINE

APPLY GASOLINE ENGINE OIL
(Malti grade)
OIL VISCOSITY CHART FOR TRANSMISSION CASE
OIL VISCOSITY CHART FOR FRONT AXLE AND REAR AXLE

No. TFGEN-WE-0431
WORKSHOP MANUAL
TF SERIES
HEATING AND AIR CONDITIONING
SECTION 1
HEATER AND AIR CONDITIONING 1-1
SECTION 1
HEATER AND AIR CONDITIONING

TABLE OF CONTENTS
PAGE
General Description......................................................................................................... 1- 3
Parts Location ................................................................................................................. 1- 5
Main Data and Specifications ......................................................................................... 1- 15
Special Parts Fixing Nuts and Bolts .............................................................................. 1- 17
ON-Vehicle Service.......................................................................................................... 1- 26
Precautions For Replacement or repair of air conditioning parts .......................... 1- 26
Condenser ........................................................................................................................ 1- 36
Removal and Installation (4JA1-TC, 4JH1-TC).......................................................... 1- 36
Removal and Installation (Except 4JA1-TC, 4JH1-TC) ............................................. 1- 37
Condenser Fan Motor...................................................................................................... 1- 38
Removal and Installation ............................................................................................ 1- 38
Receiver/drier................................................................................................................... 1- 39
Compressor...................................................................................................................... 1- 40
Removal and Installation (4J ENGINE)...................................................................... 1- 40
Removal and Installation (6VE1)................................................................................ 1- 42
Removal and Installation (C24SE) ............................................................................. 1- 44
Disassembly ................................................................................................................ 1- 50
Reassembly ................................................................................................................. 1- 52
Heater Unit........................................................................................................................ 1- 54
Disassembly and Reassembly ................................................................................... 1- 56
Vent Unit (Without Heater) ............................................................................................. 1- 57
Evaporator (With A/C)...................................................................................................... 1- 60
1-2 HEATER AND AIR CONDITIONING
PAGE
Duct (Without A/C) ........................................................................................................... 1- 63
Blower Unit Assembly ..................................................................................................... 1- 65
Defroster Nozzle and Vent Duct ..................................................................................... 1- 68
Rear Heater Duct.............................................................................................................. 1- 69
Control Lever Assembly.................................................................................................. 1- 70
Control Panel Illumination Bulb ..................................................................................... 1- 74
Inspection and Repair................................................................................................. 1- 76
Troubleshooting .............................................................................................................. 1- 79
Special Service Tool........................................................................................................ 1-104
GENERAL DESCRIPTION
SYSTEM COOLING LINE
1.
2.
3.
4.
5.
6.
7.
Compressor
Magnetic clutch
Receiver/Drier
Dual pressure switch or Trinary
pressure switch (4J*-TC, 6VE1,
C24SE)
Condenser
Evaporator assembly
Expansion valve
8.
9.
10.
11.
12.
13.
14.
Evaporator core
Blower motor
Heater unit
Mode (DEF/FOOT) control door
Mode (VENT) control door
Electronic thermostat
Heater core
RTW310LF001001
UNIT (only indoor parts)
This illustration is based on RHD model

RTW410LF000801
PARTS LOCATION
RHD
RTW48AXF018801&RTW48AXF018901
LHD
WIRING DIAGRAM (4JA1-T(L) WITH A/C)
RTW48AXF003601
(4JA1-T(L) WITH COOLER)
RTW48AXF005601
(4JA1-TC / 4JH1-TC WITH A/C)
RTW48AXF003501
(4JA1-TC / 4JH1-TC WITH COOLER)
RTW48AXF005801
(6VE1)
RTW48AXF029401
(C24SE WITH A/C)
RTW48AXF029401
(C24SE WITH COOLER)
RTW48AXF005701
VENTILATION

840R300008 & RTW410MF000301
MAIN DATA AND SPECIFICATIONS

AIR COMPRESSOR
Model
Type
Displacement
Oil type
Oil capacity
Magnetic clutch
cm (lmp fl oz)
3
cm (lmp fl oz)
HEATING UNIT (VENT UNIT)

Type
Core dimension
Capacity
mm (in.)
(kcal./hr.)
BLOWER UNIT
Type
COOLING UNIT
Type
Evaporator element dimensions
Evaporator capacity
* Expansion Valve type
* Thermo Switch type (Cooler)
Maximum Cool position
mm (in.)
(kcal./hr.)
(C)
(C)
* Thermo Switch type (A/C)
(C)
* Trinary Pressure Switch
ELECTRIC FAN
Fan Dia
Motor Power
Rehead air mix

(LHW) 180 (7.06) 182.3 (7.18) 27 (1.06)
4200
Sirocco fan type
Minimum Cool position
CONDENSER
Type
Capacity
CR-14
5 Vane rotary type
144 (4.03)
DH-PR
180 (5.04)
Type: Dry single disc dia. 109 mm (4.3 in.)
(kcal./hr.)
Fin and tube evaporator

(LHW) 230 (9.06) 212 (8.35) 74 (2.91)
3
2960/4420 kcal./hr. (300/500 m /hr.)
External pressure equalizer type
Variable electronic thermostat
OFF 3 0.5
DIFF 1.5 0.5
OFF 11.6 2
DIFF 2.9 2
Fixed electronic thermostat
OFF 3 0.5
DIFF 1.5 0.5
Low pressure control and High pressure control are same
as Dual pressure switch
* Medium pressure control
2
OFF 1128 118 kpa (11.5 1.2 kg/cm G)
2
ON 1521 88 kpa (15.5 0.92 kg/cm G)
Aluminum louvered fins
12300 kcal./hr.
250
(w)
90

RECEIVER/DRIER
Capacity
REFRIGERANT
IDLE SPEED-UP CONTROL
cc (cu in)
250 (15.3 cu in)

Assembly includes sight glass
and pressure sensitive device
(Dual pressure switch)
*Low pressure control
2
OFF: 183 (1.80.25kg/cm G)
2
ON: 193 (1.90.3kg/cm G)
*High pressure control
2
OFF: 27520Nm (280.2kg/cm G)
2
ON: 5920Nm (62kg/cm G)
Type: HFC-134a Capacity: 0.65 kg (1.43 lbs.)
Idle speed controlled by solenoid switch
SPECIAL PARTS FIXING NUTS AND BOLTS

COMPRESSOR ASSEMBLY
Nm (kgfm/lbin)
E06R300002
REFRIGERATION SYSTEM
(4J*
* RHD MODEL)
RTW410LF001101
(6VED1, C24SE RHD MODEL)
RTW410LF000301
(4J*
* LHD MODEL)
RTW410LF000101
(6VE1, C24SE LHD MODEL)
RTW410LF000201
FIXING TORQUE
(4J*
* RHD MODEL)
Nm (kgfm/lbft)
RTW410LF001201
(6VE1, C24SE RHD MODEL)
Nm (kgfm/lbft)
RTW410LF000401
(4J*
*, LHD MODEL)
Nm (kgfm/lbft)
RTW410LF001001
(6VE1, C24SE LHD MODEL)
Nm (kgfm/lbft)
RTW410LF000901
ON-VEHICLE SERVICE
PRECAUTIONS FOR REPLACEMENT OR
REPAIR OF AIR CONDITIONING PARTS
There are certain procedures, practices and precautions that
should be followed when servicing air conditioning systems:
Keep your work area clean.
Always wear safety goggle and protective gloves when
working on refrigerant systems.
Beware of the danger of carbon monoxide fumes caused by
running the engine.
Beware of discharged refrigerant in enclosed or improperly
ventilated garages.
Always disconnect the negative battery cable and discharge
and recover the refrigerant whenever repairing the air
conditioning system.
When discharging and recovering the refrigerant, do not
allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.
Keep moisture and contaminants out of the system. When
disconnecting or removing any lines or parts, use plugs or
caps to close the fittings immediately.
Never remove the caps or plugs until the lines or parts are
reconnected or installed.
When disconnecting or reconnecting the lines, use two
wrenches to support the line fitting, to prevent from twisting
or other damage.
Always install new O-rings whenever a connection is
disassembled.
Before connecting any hoses or lines, apply new specified
compressor oil to the O-rings.
When removing and replacing any parts which require
discharging the refrigerant circuit, the operations described
in this section must be performed in the following sequence:
4
1) Using the ACR (HFC-134a Refrigerant Recovery/

Recycling/Recharging/System) or equivalent to
thoroughly discharge and recover the refrigerant.
4
ACR (115V 60Hz) : 5-8840-0629-0 (J-39500-A)
4
ACR (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
4
ACR (220-240V 50/60Hz Australian model)
: 5-8840-0631-0 (J-39500-220ANZ)
2) Remove and replace the defective part.
3) After evacuation, charge the air conditioning system and
check for leaks.
REPAIR OF REFRIGERANT LEAKS

Refrigerant Line Connections
Install new O-ring, if required. When disconnecting or
connecting lines, use two wrenches to prevent the connecting
portion from twisting or becoming damaged.
RTW410SH000101
When connecting the refrigerant line at the block joint, securely

insert the projecting portion of the joint portion into the
connecting hole on the unit side and secure with a bolt.
Apply specified compressor oil to the O-rings prior to

connecting.
CAUTION:
Compressor (PAG) oil to be used varies according to
compressor model. Be sure to apply oil specified for the
model of compressor.
O-rings must be closely aligned with raised portion of

refrigerant line.

Insert nut into union. First tighten nut by hand as much as
possible. Then, tighten nut to specified torque.
(Refer to "Special Parts Fixing Nuts and Bolts" in this section)
LEAK AT REFRIGERANT LINE

CONNECTIONS
1) Check the torque on the refrigerant line fitting and, if too
loose, tighten to the specified torque.
Use two wrenches to prevent twisting and damage to the
Line.
Do not over tighten.
2) Perform a leak test on the refrigerant line fitting.
3) If the leak is still present, discharge and recover the
refrigerant from the system.
4) Replace the O-rings.
O-rings cannot be reused. Always replace with new
ones.
Be sure to apply specified compressor oil to the new Orings.
5) Retighten the refrigerant line fitting to the specified torque.
Use two wrenches to prevent twisting and damage to the
line.
6) Evacuate, charge and retest the system.
LEAK IN THE HOSE

If the compressor inlet or outlet hose is leaking, the entire hose
must be replaced. Refrigerant hose must not be cut or spliced
for repair.
1) Locate the leak.
2) Discharge and recover the refrigerant.
3) Remove the hose assembly.
Cap the open connections at once.
4) Connect the new hose assembly.
Use two wrenches to prevent twisting or damage to the
hose fitting.
Tighten the hose fitting to the specified torque.
5) Evacuate, charge and test the system.
COMPRESSOR LEAKS
If leaks are located around the compressor shaft seal or shell,
replace or repair the compressor.
RECOVERY, RECYCLING, EVACUATION

AND CHARGING
Handling Refrigerant-134a (HFC-134a)
Air conditioning systems contain HFC-134a.
This is a chemical mixture which requires special handling
procedures to avoid personal injury.
Always wear safety goggles and protective gloves.
Always work in a well-ventilated area. Do not weld or steam
clean on or near any vehicle-installed air conditioning lines
or components.
If HFC-134a should come in contact with any part of the
body, flush the exposed area with cold water and
immediately seek medical help.
If it is necessary to transport or carry any container of HFC134a in a vehicle, do not carry it in the passenger
compartment.
If it is necessary to fill a small HFC-134a container from a
large one, never fill the container completely. Space should
always be allowed above the liquid for expansion.
Keep HFC-134a containers stored below 40C (104F).
WARNING
SHOULD HFC-134a CONTACT YOUR EYE(S), CONSULT
A DOCTOR IMMEDIATELY.
DO NOT RUB THE AFFECTED EYE(S). INSTEAD,
SPLASH QUANTITIES OF FRESH COLD WATER OVER
THE AFFECTED AREA TO GRADUALLY RAISE THE
TEMPERATURE OF THE REFRIGERANT ABOVE THE
FREEZING POINT.
OBTAIN PROPER MEDICAL TREATMENT AS SOON AS
POSSIBLE. SHOULD THE HFC-134a TOUCH THE SKIN,
THE INJURY MUST BE TREATED THE SAME AS SKIN
WHICH HAS BEEN FROSTBITTEN OR FROZEN.
REFRIGERANT RECOVERY
F06R300012
The refrigerant must be discharged and recovered by using

4
ACR (HFC-134a Refrigerant Recovery/Recycling/Recharging/
System) or equivalent before removing or installing air
conditioning parts.
4
ACR (115V 60Hz) :5-8840-0629-0 (J-39500-A)
4
ACR (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
4
: 5-8840-0631-0 (J-39500-220ANZ)
4
1) Connect the high and low charging hoses of the ACR (or
equivalent) as shown.
4
2) Recover the refrigerant by following the ACR
Manufacturer's Instructions.
3) When a part is removed, put a cap or a plug on the
connecting portion so that dust, dirt or moisture cannot get
into it.
REFRIGERANT RECYCLING
4
Recycle the refrigerant recovered by ACR or equivalent.

For the details of the actual operation, follow the steps in the
4
ACR Manufacturer's Instructions.
4
ACR (115V 60Hz) :5-8840-0629-0 (J-39500-A)
4
ACR (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
4
: 5-8840-0631-0 (J-39500-220ANZ)
EVACUATION OF THE REFRIGERANT

SYSTEM
NOTE:
Explained below is a method using a vacuum pump. Refer
to the ACR4 (or equivalent) Manufacturer's Instructions
4
when evacuating the system with ACR (or equivalent).
F06R300014
Air and moisture in the refrigerant will cause problems in the air
Therefore, before charging the refrigerant, be sure to evacuate
air and moisture thoroughly from the system.
1) Connect the gauge manifold.
High-pressure valve (HI) - Discharge-side
Low-pressure valve (LOW) - Suction-side
2) Discharge and recover the refrigerant.
3) Connect the center hose of the gauge manifold set to the
vacuum pump inlet.
4) Operate the vacuum pump, open shutoff valve and then
open both hand valves.
5) When the low-pressure gauge indicates approx. 100kPa
(750 mmHg/30 inHg), continue the evacuation for 5 minutes
or more.
6) Close both hand valves and stop the vacuum pump.
7) Check to ensure that the pressure does not change after 10
minutes or more.
If the pressure changes, check the system for leaks.
If leaks occur, retighten the refrigerant line connections
and repeat the evacuation steps.
8) If no leaks are found, again operate the vacuum pump for
20 minutes or more. After confirming that the gauge
manifold pressure is at 100 kPa (750 mmHg/30 inHg), close
both hand valves.
9) Close positive shutoff valve.
Stop the vacuum pump and disconnect the center hose
from the vacuum pump.
CHARGING THE REFRIGERANT SYSTEM

There are various methods of charging refrigerant into the air
4
These include using the ACR (HFC-134a Refrigerant
Recovery/ Recycling/Recharging/System) or equivalent and
direct charging with a manifold gauge charging station.
4
ACR (115V 60Hz) : 5-8840-0629-0 (J-39500-A)
4
ACR (220-240V 50/60Hz)
: 5-8840-0630-0 (J-39500-220A)
4
: 5-8840-0631-0 (J-39500-220ANZ)
Charging procedure
4
ACR (or equivalent) method

4
For the charging of refrigerant recovered by ACR , follow the
Manufacturer's Instruction.
F06R300012
F06R300013
Direct charging with a manifold gauge charging

station method.
Handling the charging valve handle when installing refrigerant
container.
1) Before attaching the charge valve to the refrigerant
container, turn the charge valve handle counterclockwise
until the needle is fully retracted.
2) Turn the plate nut counterclockwise until it reaches its
highest position relative to the charge valve.
3) Install the charge valve onto the refrigerant container.
4) Turn the plate nut clockwise and connect the center hose of
the manifold gauge to the charge valve.
5) Tighten the plate nut sufficiently by hand. Then turn the
charge valve handle clockwise to lower the needle and bore
a hole in the refrigerant container.
6) Turn the charge valve handle counterclockwise to raise the
needle. The refrigerant in the refrigerant container is
charged into the air conditioning system by the operation of
the manifold gauge.
Be absolutely sure not to reuse the emptied

refrigerant container.
1) Make sure the evacuation process is correctly completed.
2) Connect the center-hose of the manifold gauge to the
Turn the charge valve handle counterclockwise to purge
to the charging line and purge any air exiting in the
center-hose of the manifold gauge.
3) Open the low-pressure hand valve and charge the
refrigerant about 200 g (0.44 lbs.).
Make sure the high-pressure hand valve is closed.
Avoid charging the refrigerant by turning the refrigerant
container upside down.
4) Close the low-pressure hand valve of the manifold gauge.
Check to ensure that the degree of pressure does not
change.
5) Check the refrigerant leaks by using a HFC-134a leak
detector.
If a leak occurs, repair the leak connection, and start all
over again from the first step of evacuation.
6) If no leaks are found, open the low-pressure hand valve of
the manifold gauge. Then continue charging refrigerant to
the system.
When charging the system becomes difficult:
(1) Run the engine at Idling and close the all vehicle
doors.
(2) A/C switch is "ON".
(3) Set the fan control knob (fan switch) to its highest
position.
(4) Set air soure selector lever to RECIRC
WARNING
BE ABSOLUTELY SURE NOT TO OPEN THE HIGHPRESSURE HAND VALVE. SHOULD THE HIGHPRESSURE HAND VALVE BE OPENED, THE HIGHPRESSURE REFRIGERANT GAS WOULD FLOW
BACKWARD, AND THIS MAY CAUSE THE REFRIGERANT
CONTAINER TO BURST.
7) When the refrigerant container is emptied, use the following
procedure to replace it with a new refrigerant container.
(1) Close the low-pressure hand valve.
(2) Raise the needle upward and remove the charge valve.
(3) Reinstall the charge valve to the new refrigerant
container.
(4) Purge any air existing in the center hose of the manifold
gauge.
8) Charge the system to the specified amount and then close
the low-pressure hand valve.
Refrigerant Amount
g(lbs.)
720 (1.59)

9) Check for refrigerant leaks by using a HFC-134a leak
detector.
A fully charged system is indicated by the sight glass on
the receiver/drier being free of any bubbles (Refer to
"Reading Sight Glass").
Check the high and low pressure value of the manifold
gauge. (Refer to CHECKING REFRIGERANT SYSTEM
WITH MAINFOLD GAUGE in SERVICE
INFORMATION.)
Immediately after charging refrigerant, both high and low
pressures are slightly high and to the left of the gauge, but they
settle down to the guide pressure valves as shown below:
Ambient temperature; 30~35C (86~95F)
Guide pressure
High-pressure side;
2
Approx. 1373~1670 kPa (14~17 kg/cm / 199~242 PSI)
Low-pressure side;
2
Approx. 127~245 kPa (1.3~2.5 kg/cm / 18~36 PSI)
10) Close the low pressure hand valve and charge valve of the
11) Stop the air conditioning and the engine.
12) Disconnect the high and low pressure hoses from the
manifold gauge fittings.

Reading Sight Glass
High and low
pressure pipe
temperature
The high pressure

pipe is hot and the
low pressure pipe
is cold. There is a
distinct difference
in temperature
between them.
Sight glass
condition
Almost transparent.
A flow of bubbles
can be seen, but
they disappear
when the throttle is
opened.
Air conditioning
cycle condition
OK
The high pressure

pipe is warm and
the low pressure
pipe is cool. There
is no great
difference in
temperature
between them.
A flow of bubbles
always can be
seen. It appears
sometimes
transparent, and
sometimes frothy.
NG
(Not enough
refrigerant)
There is little
difference in
temperature
between the high
pressure pipe and
the low pressure
pipe.
Something like fog
faintly can be seen.
NG
(Almost no
refrigerant)
The high pressure

pipe is hot and the
low pressure pipe
is slightly warm.
There is a
difference in
temperature
between them.
Evan at idle with
the fan at "HI" (with
the window fully
open), the bubbles
cannot be seen.
NG
(Too much
refrigerant)
The sight glass provides accurate diagnosis only under the following conditions.
If the vehicle can be tested under these conditions, check the sight glass appearance and compare to the chart.
* Engine speed Idling
* A/C switch "ON"
* Blower fan operating at highest speed
* Air source selector lever at "RECIRC"
* Temperature control knob at coldest position
* Ambient temperature below 35C (95F) and humidity below 70% (See NOTE 1)
2
* High side pressure less than 1470 kPa (15 kg/cm / 213 PSI) (See NOTE 2)
NOTE 1
If the vehicle cannot be moved to a testing location that meets these specifications, then the sight glass cannot be
used for diagnosis. You must discharge and recover the refrigerant, then recharge the system with the specified
amount of refrigerant. Then continue checking the system performance.
NOTE 2
If the high side pressure is greater than stated, the sight glass cannot be used for diagnosis. You must discharge
and recover the refrigerant, then recharge the system with the specified amount of refrigerant. Then continue
checking system performance.
CONDENSER
REMOVAL AND INSTALLATION (4JA1-TC, 4JH1-TC)

RTW410LF000501
Removal Steps
1. Radiator grille
2. Front bumper fascia
Refer to SECTION 2A FRONT
BUMPER
3. Front bumper inpact support assembly
BUMPER
4. Air cleaner assembly
5. Inter cooler
Refer to SECTION 6A INTER COOLER
6. Engine hood lock
7. Engine hood front end stay
8. Pressure switch connector
9. Condenser fan connector
10. Refrigerant line
12. Receiver/drier bracket
13. Receiver/drier
14. Condenser assembly
Installation Steps
13. Receiver/drier
6. Engine hood lock
5. Inter cooler
Refer to SECTION 6A INTER COOLER
4. Air cleaner assembly
BUMPER
BUMPER
1. Radiator grille
REMOVAL AND INSTALLATION (EXCEPT 4JA1-TC, 4JH1-TC)
RTW410LF000701
Removal Steps
1. Radiator grille
2. Engine hood lock
6. Refrigerant line
7. Refrigerant line
9. Receiver/drier
Installation Steps
9. Receiver/drier
7. Refrigerant line
6. Refrigerant line
2. Engine hood lock
1. Radiator grille
CONDENSER FAN MOTOR

REMOVAL AND INSTALLATION
RTW410MF000101
Removal Steps
1. Radiator grille
2. Fan connector
3. Condenser fan motor
Installation Steps
3. Condenser fan motor
2. Fan connector
1. Radiator grille
RECEIVER / DRIER
RTW410LF000601
Removal Steps
1. Radiator grille
2. Trinary pressure switch connector
3. Refrigerant line
4. Bracket bolt
5. Receiver/drier
Installation Steps
5. Receiver/drier
4. Bracket bolt
3. Refrigerant line
2. Trinary pressure switch connector
1. Radiator grille
COMPRESSOR
REMOVAL AND INSTALLATION (4J ENGINE)
Removal Steps
1. Air duct
2. Magnetic clutch harness connector
3. Lock nut
4. Tension adjustment bolt
5. Drive belt
6. Refrigerant line
7. Bolt; compressor to bracket
8. Compressor assembly
Installation Steps
6. Refrigerant line
5. Drive belt
4. Tension adjustment bolt
3. Lock nut
1. Air duct
852R300006
Important Operations - Installation

7. Bolt; Compressor to Bracket
Torque
Nm (kgfm/lbft)
44 (4.5/33)
6. Refrigerant Line
Torque
Nm (kgfm/lbft)
11~19 (1.1/9.5~1.9/14)
Compressor Belt
Check the drive belt tension.
Depress the drive belt mid-portion with a 98N (10kg/22Ib)
force.
mm(in.)
Standard deflection
14~17 (0.55~0.67)
REMOVAL AND INSTALLATION (6VE1)
RTW310MF000301
Removal Steps
2. Compressor belt
3. Refrigerant line
Installation Steps
3. Refrigerant line
2. Compressor belt

Torque
Nm (kgfm/lbft)
19 (1.9/14)
3. Refrigerant Line
Torque
Nm (kgfm/lbft)
11~19 (1.1/9.5~1.9/14)
2. Compressor Belt
Move compressor belt tensioner to loose side using
wrench, then install serpentine belt to normal position.
RTW310MH000101
REMOVAL AND INSTALLATION (C24SE)
RTW310MF000401
Removal Steps
2. Compressor belt
3. Refrigerant line
Installation Steps
3. Refrigerant line
2. Compressor belt

Torque
Nm (kgfm/lbft)
19 (1.9/14)
3. Refrigerant Line
Torque
Nm (kgfm/lbft)
11~19 (1.1/9.5~1.9/14)
2. Compressor Belt
Move compressor belt tensioner to loose side using
wrench, then install serpentine belt to normal position.
GENERAL REPAIR PROCEDURE

OIL SPECIFICATION
The HFC-134a system requires a synthetic (PAG)
compressor oil.
Compressor (PAG) oil varies according to compressor
model. Be sure to use oil specified for the model of
compressor.
Specified Compressor Oil
DH-PR
HANDLING OF OIL
The oil should be free from moisture, dust, metal powder,
etc.
Do not mix with other oil.
The water content in the oil increases when exposed to the
air. After use, seal oil from air immediately.
The compressor oil must be stored in steel containers, not
in plastic containers.
COMPRESSOR OIL CHECK

The Oil used to lubricate the compressor is circulating with the
refrigerant.
Whenever replacing any component of the system or a large
amount of gas leakage occurs, add oil to maintain the original
amount of. oil.
Oil Capacity
Capacity total in
system
Compressor
(Service parts)
charging amount
CR-14
180 cm (5.0 fl.oz.)
CR-14
180 cm (5.0 fl.oz.)
Checking and Adjusting for Used Compressor

(1) Perform Oil return operation.
(Refer to "Oil Return Operation" in this section.)
(2) Discharge refrigerant and remove the compressor.
(3) Drain the compressor oil and measure the extracted oil with
a measuring cylinder.
(4) Check the compressor oil for contamination.
(Refer to "Contamination of Compressor Oil" in this
section.)
(5) Adjust oil level following the procedure below.
Type
Collected Amount
Charging Amount
more than 90 cm
CR-14
(3.0 fl.oz.)
less than 90 cm
same as collected
amount
3
90 cm (3.0 fl.oz.)
(3.0 fl.oz.)
(6) Install the compressor, then evacuate, charge and perform
oil return operation.
(7) Check system operation.
When it is impossible to perform oil return operation, the
compressor oil should be checked in the following order:
(1) Discharge refrigerant and remove the compressor.
(2) Drain the compressor oil and measure the extracted oil with
a measuring cylinder.
(3) Check the oil for contamination.
3
(4) If more than 90 cm (3.0 fl.oz.) for CR-14 type is extracted
from the compressor, supply same amount of oil to the
compressor to be installed.
3
If the amount of oil extracted is less than 90 cm (3.0 fl.oz.)
for CR-14 type recheck the compressor oil in the following
order:
3
(5) Supply 90 cm (3.0 fl.oz.) for CR-14 type oil to the
compressor and install it onto the vehicle.
(6) Perform oil return operation.
(7) Remove the compressor and recheck the amount of oil.
(8) Adjust the compressor oil.
Checking and Adjusting for Compressor

Replacement
3
180 cm (5.0 lmp fl oz) of oil is charged in compressor (service

parts). So it is necessary to drain the proper amount of oil from
the new compressor.
1) Perform oil return operation.
2) Discharge refrigerant and remove the compressor.
3) Drain the compressor oil and measure the extracted oil.
4) Check the compressor oil for contamination.
5) Adjust oil level as required.
Amount of oil drained
Draining amount of oil
From used compressor
From new compressor
less than
Some as drained
90 cm (2.5 lmp fl oz)
amount
more than

6) Evacuate, charge and perform oil return operation.
7) Check system operation.
CONTAMINATION OF COMPRESSOR OIL

Unlike engine oil, no cleaning agent is added to the
compressor oil. Even is the compressor runs for a long period
of time (approximately 1 season), the oil never becomes
contaminated as long as there is nothing wrong with the
compressor or its method of use.
Inspect the extracted oil for any of the following
conditions:
The capacity of the oil has increased.
The oil has changed color to red.
Foreign substances, metal powder, etc., are present in the
oil.
If any of these conditions exists, compressor oil is
contaminated. Whenever contaminated compressor oil is
discovered, the receiver/drier must be replaced.
OIL RETURN OPERATION

There is close affinity between the oil and the refrigerant.
During normal operation, part of the oil recirculates with the
refrigerant in the system.
When checking the amount of oil in the system, or replacing
any component of the system, the compressor must be run in
advance for oil return operation. The procedure is as follows:
1) Open the all doors and engine hood.
2) Start the engine and A/C switch is "ON" and Set the fan
control knob at its highest position.
3) Run the compressor for more than 20 minutes between
800 and 1,000 rpm in order to operate the system.
4) Stop the engine.
REPLACEMENT OF COMPONENT PARTS

When replacing system component parts, supply the following
amount of oil to the component parts to be installed.
Component parts to be installed
Amount of oil
3
Evaporator
50 cm (1.7 fl.oz.)
Condenser
30 cm (1.0 fl.oz.)
Receiver/drier
30 cm (1.0 fl.oz.)
Refrigerant line (One piece)
10 cm (0.3 fl.oz.)
3
3
3
Refrigeration oil must be replenished if more than two parts

are removed at the same time. After installing these
components, check compressor oil.
DISASSEMBLY
This illustration is based on the 4J engine model

871R300002
Disassembly Steps
1. Drive plate bolt
2. Plain washer
3. Drive plate
4. Snap ring
5. Pulley assembly
6. Snap ring
7. Thermo sensor and lead wire connector
8. Field coil
9. Compressor
Important Operations - Dissassembly

1. Drive Plate Bolt
Using drive plate holder to prevent the drive plate from
rotating, then remove the bolt.
Drive Plate Holder: 5-8840-4056-0 (J-37872)

3. Drive Plate
Remove the drive plate.
If the frictional surface shows signs of damage due to
excessive heat, the drive plate and pulley should be
replaced.
5. Pulley Assembly
Using pulley puller pilot and pulley puller to remove the
pulley assembly.
Pulley Puller Pilot: 5-8840-0121-0 (J-33943)
Pulley Puller:
5-8840-0111-0 (J-8433)
Check the appearance of the pulley assembly. If the
frictional surface of the pulley shows signs of excessive
grooving due to slippage, both the pulley and drive plate
should be replaced. The frictional surfaces of the pulley
assembly should be cleaned with a suitable solvent before
reinstallation.
6. Snap ring
Using snap ring pliers to remove the snap ring.
REASSEMBLY
This illustration is based on the 4J engine model

871R30003
Reassembly Steps
1. Compressor
2. Field coil
3. Thermo sensor and lead wire connector
4. Snap ring
5. Pulley assembly
6. Snap ring
7. Drive plate
8. Plain washer
9. Drive prate bolt
Important Operation - Resassembly

2. Field Coil
Installation field coil.
Align the located portion (1) of the clutch coil and
compressor.
5. Pulley Asssembly
Using pulley installer and drive handle to install the pulley
assembly.
Pulley Installer: 5-8840-0118-0 (J-33940)
Drive Handle: 5-8840-0007-0 (J-8092)
9. Drive Plate Bolt

Using drive plate holder to prevent the drive plate from
rotating.
Drive Plate Holder: 5-8840-4056-0 (J-37872)
Tighten the bolt to the specified torque.
Nm (kgfm/Ibin)
Torque
13 (1.3/113)
After tightening the bolt, check to be sure the pulley rotates
smoothly.
HEATER UNIT

RTW310LF000501-X
Removal Steps
Installation steps
1. Control cable
2. Instrument panel assembly and cross
beam
3. Electronic thermostat connector
4. Evaporator or duct
5. Heater unit
5. Heater unit
beam
1. Control cable
Important Operations Removal

2. Instrument Panel Assembly and Cross Beam.
Refer to INSTRUMENT PANEL in CAB section.
4. Evaporator or Duct
Refer to EVAPORATOR or DUCT in this section.
Important Operation - Installation

2. Instrument Panel Assembly and Cross Beam
Adjust the heater control cables.
Refer to "CONTROL LEVER ASSEMBLY" in this section.
DISASSEMBLY AND REASSEMBLY
Disassembly Steps
Reassembly Steps
1. Attaching screw
2. Main link-side
3. Sub link-side
4. Mode rod
5. Holder rod
6. Mode lever
7. DEF/FOOT-spring
8. VENT-spring
9. Heater box clip
10. Attaching screws
11. Foot duct
12. Fod H/Pipes seal
13. Heater core clamp
14. Heater core
15. Mix lever (2)
16. Mix lever (1)
17. Control cable clamp
19. Upper case
20. Lower case
21. DEF/FOOT door
22. VENT door
23. Mix door

23. Mix door
22. VENT door
21. DEF/FOOT door
20. Lower case
19. Upper case
18 Attaching screws
16. Mix lever (1)
15. Mix lever (2)
14. Heater core
12. Fod H/Pipes seal
11. Foot duct
9. Heater box clip
8. VENT-spring
7. DEF/FOOT-spring
6. Mode lever
5. Holder rod
4. Mode rod
3. Sub link-side
2. Main link-side
1. Attaching screw
RTW310LF001401
VENT UNIT (WITHOUT HEATER)


860R300001-X
Removal Steps
Installation steps
1. Control cable
beam
5. Vent unit
5. Vent unit
beam
1. Control cable
Important Operations - Removal

2. Instrument Panel Assembly and Cross Beam.

Refer to "CONTROL LEVER ASSEMBLY" in this section.
Disassembly Steps
Reassembly Steps
1. Attaching screw
2. Main link-side
3. Sub link-side
4. Mode rod
5. Holder rod
6. Mode lever
7. DEF/FOOT-spring
8. VENT-spring
9. FOD H/pipes seal
10. Heater box clip
12. Foot duct
14. Upper case
15. Lower case
16. DEF/FOOT door
17. VENT door

17. VENT door
16. DEF/FOOT door
15. Lower case
14. Upper case
12. Foot duct
10. Heater box clip
9. FOD H/pipes seal
8. VENT-spring
7. DEF/FOOT-spring
6. Mode lever
5. Holder rod
4. Mode rod
3. Sub link-side
2. Main link-side
1. Attaching screw
EVAPORATOR (WITH A/C)

Removal Steps
1. Glove box
2. Passenger lower bracket
4. Drain hose
5. Refrigerant line
6. Evaporator assembly
Installation Steps
5. Refrigerant line
4. Drain hose
1. Glove box

RTW410MF000501
Disassembly Steps
1. Packing cooler outlet
2. Packing cooler inlet
3. Seal fod cooler
4. Filter cover assembly
5. Air filter
6. Electronic thermostat
7. Clip heater
8. Attaching screws
9. Case : cooler upper
10. Case : cooler lower
11. Insulator : case lower
12. Drain hose
13. Packing drain
14. Evaporator assembly W/Expansion valve
15. Grommet : A/C pipe
Reassembly Steps
14. Evaporator assembly W/Expansion valve
13. Packing drain
12. Drain hose
11. Insulator : case lower
8. Attaching screws
7. Clip heater
6. Electronic thermostat
5. Air filter
3. Seal fod cooler
Important Operation -Reassembly

6. Electronic Thermostat
1) Install the electronic thermostat to the evaporator core
specified position with the clip.
2) Sensor part must not interfere with the evaporator core.
DUCT (WITHOUT A/C)


RTW310LF001601
Removal Steps
1. Glove box
Installation Steps
1. Glove box

RTW310LF001501
Disassembly Steps
3. Seal fod cooler
5. Clip heater
6. Attaching screws
9. Packing drain
Reassembly Steps
10. Grommet
9. Packing drain
6. Attaching screws
5. Clip heater
3. Seal fod cooler
BLOWER UNIT ASSEMBLY


873R300002-X
Removal Steps
Installation Steps
1. Control cable
beam
5. Resistor connector
6. Blower motor connector
7. Blower unit assembly
7. Blower unit assembly

6. Blower motor connector
5. Resistor connector
beam
1. Control cable


Refer to CONTOROL LEVER ASSEMBLY in this section.
Disassembly Steps
1. Attaching screw
2. Intake link
3. Intake lever
4. Intake packing
5. Attaching screws
6. Blower motor assembly
7. Attaching screw
8. Flat resistor
9. Upper case
10. Lower case
11. Mode door
12. Bell mouth
Reassembly Steps
12. Bell mouth
11. Mode door
10. Lower case
9. Upper case
8. Flat resistor
7. Attaching screw
6. Blower motor assembly
5. Attaching screws
4. Intake packing
3. Intake lever
2. Intake link
1. Attaching screw
DEFROSTER NOZZLE AND VENT DUCT

Removal Steps
beam
2. Side def hose R/LH
3. Defroster nozzle
4. Vent duct driver side and assist side
5. Center vent duct
Installation Steps
5. Center vent duct
4. Vent duct driver side and assist side
3. Defroster nozzle
2. Side def hose R/LH
1. Instrument panel assembly and cross beam
Important Operation - Removal

REAR HEATER DUCT


RTW410LF001301
Disassembly Steps
1. Front seat assembly (RH/LH)
Refer to SECTION 10 FRONT SEAT
2. Rear floor console
Refer to SECTION 10 FLOOR
CONSOLE
3. Front floor console (A/T, M/T Model)
CONSOLE
4. Sill plate (RH/LH)
Refer to SECTION 10 INTERIOR
TRIM PANELS
5. Dash side trim cover (RH/LH)
6. Carpet
7. Clip
8. Rear Heater duct (RH/LH)
9. Rear Heater duct center
Reassembly Steps
9. Rear heater duct center
8. Rear heater duct (RH/LH)
7. Clip
6. Carpet
5. Dash side trim cover (RH/LH)
4. Sill plate (RH/LH)
Refer to SECTION 10 INTERIOR
TRIM PANELS
3. Front floor console (A/T, M/T Model)
CONSOLE
2. Rear floor console
CONSOLE
1. Front seat assembly (RH/LH)
Refer to SECTION 10 FRONT SEAT
CONTROL LEVER ASSEMBLY


RTW310MF000601
Removal Steps
Installation Steps
1. Glove box
2. Instrument panel driver lower cover
3. Ash tray
4. Control cables
5. Center cluster
6. Attaching screw
7. A/C switch connector
8. Fan switch connector
9. Control lever assembly

8. Fan switch connector
7. A/C switch connector
6. Attaching screw
5. Center cluster
4. Control cables
3. Ash tray
1. Glove box

2. Instrument Panel Driver Lower Cover
4. Control Cables
Disconnect control cables at each unit side.
RTW310SH000101
5. Center Cluster

9. Control Lever Assembly
Air source control cable
RHD
1) Slide the control lever to the left (CIRC position).
2) Connect the control cable at the "CIRC" position of the link
unit of blower assembly and fix it with the clip.
LHD
1) Slide the control lever to the right (FRESH position).
2) Connect the control cable at the "FRESH" position of the
link unit of blower assembly and fix it with the clip.
Temperature control cable
RHD
1) Turn the control knob to the right (FULL HOT position).
2) Connect the control cable at the FULL HOT position of the
mix lever of the heater unit and fix it with the clip.
LHD
1) Turn the control knob to the left (FULL COLD position).
2) Connect the control cable at the FULL COLD position of
the mix lever of the heater unit and fix it with the clip.
Air select control cable
RHD
1) Turn the control knob to the left (VENT position).
2) Connect the control cable at the VENT position of the
mode control link of the heater unit and fix it with the clip.
LHD
1) Turn the control knob to the right (DEF position).
2) Connect the control cable at the DEF position of the mode
control link of the heater unit and fix it with the clip.
4. Control Cables
Check control cable operation
RTW410MF000201
CONTROL PANEL ILLUMINATION BULB


RTW410MF000601
Removal Steps
2. Illumination bulb
Installation Steps
2. Illumination bulb

Refer to CONTROL LEVER ASSEMBLY in this section.
2. Illumination Bulb
To remove the illumination bulb, insert an ordinary screwdriver
into the slot (B) at the back of the bulb. Turn the bulb
counterclockwise and pull it free.
INSPECTION AND REPAIR

Resistor
As for air-conditioning model, fixed on left (RHD) / right (LHD)
side of the evaporator unit.
As for heater only model, fixed on left (RHD) / right (LHD) side
of the duct placed between blower unit and heater unit.
Replace the resistor with a new on if the coil is found to be
open or if the resistance value deviates from the specified
range.
840R300005-X
Terminal
Resistance
32
1.99 9
34
0.9 9
31
0.17 9
Blower motor
Check blower motor for smooth rotation.
Connect the battery positive terminal to the No.1 terminal of the
blower motor and negative to the No.2.
Be sure to check to see if the blower motor operates correctly.
Fan switch and Circuit board

Check for continuity between fan switch and A/C switch side
connector terminals.
B-13
Terminal
No.
SW.
position
B-57
5
10
OFF
1
(FAN SW.)
2
3
D08R300070
4
CIRCUIT
BOARD
(A/C SW.)
OFF
ON
Electronic Thermostat
Check for continuity between electronic thermostat side
connector terminals.
(Cooler)
(A/C)
RTW410SH000201
11
Pressure switch
Disconnect pressure switch connector and check for continuity
between pressure switch side connector terminal.
RTW4A0SH000201
Heater and thermo switch relay.

Check for continuity between the relay terminals.
1 - 5
No continuity
(When battery voltage is applied between 2 - 4 )

1 - 5
Continuity
825r300045
Check for continuity between the relay terminals.

1 - 2
No continuity
(When battery voltage is applied between 3 - 4 )

1 - 2
825r300023
Continuity
TROUBLESHOOTING
FAN CONTROL KNOB (FAN SWITCH)
Current flows to the blower motor through the Heater & A/C relay (X-11) to activate the rotation of the blower motor
by turning ON the fan control knob (fan switch). Blower motor speed is controlled in stages by the resistor, by
operating the switch from LOW to HIGH.
D08R300046-X2
BLOWER MOTOR DOES NOT RUN

Is heater & A/C relay (X-11) OK?
YES
NO
Is No.SBF-8 (30A) slow blow fuse OK?
Replace
YES
NO
Is resistor OK?
Replace
YES
NO
Is fan control knob (Fan switch) OK?
Replace
YES
NO
Is blower motor OK?
Replace control lever

assembly
YES
NO
Turn the ignition switch "ON" (Engine is running)

Fan control knob (Fan switch) "ON"
Replace
Check to see if battery voltage is present at

chassis side connector terminal No.C105-1 is there a
battery voltage?
YES
Poor ground or open circuit either between chassis
side connector terminal No.C105-2 and No.C104-3
or No.B13-1 and body ground No.C-109.
NO
Open circuit between
No.SBF-8 (30A) slow blow
fuse and No.C105-1.
BLOWER MOTOR DOES NOT RUN IN CERTAIN POSITION

A
1: (Low)
Blower motor does not B 2: (Medium Low) Position
C 3: (Medium Hi)
run at
D 4: (High)
* Checking is performed only when in the malfunction
mode.
Is resist or OK?
YES
NO
Replace
YES
NO
Replace
assembly
Condition:
Open circuit between chassis side connector
terminal No. C104-2 and No. B13-3
B
Condition :
Condition:
Condition:
terminal No. C105-2 a nd No. B13-4
control
lever
BLOWER MOTOR DOES NOT STOP AT OFF POSITION
YES
NO
Short circuit between chassis side connector terminal

No. C105-2 and No. C104-3
(or)
No. C105-2 and No. B13-4
(or)
No. C104-1 and No. B13-5
(or)
No. C104-4 and No. B13-6
(or)
No. C104-2 and No. B13-3
Replace control lever assembly
AIR CONDITIONING CYCLE TROUBLESHOOTING

TROUBLE
No cooling or
insufficient
cooling
POSSIBLE CAUSE
1. Magnetic clutch does not run
2. Compressor is not rotating properly
Drive belt loosened or broken
Magnetic clutch face is not clean and

slips
Incorrect clearance between magnetic

drive plate and pulley
Compressor oil leaks from shaft seal or

shell
Compressor seized
3. Insufficient or excessive charge of
refrigerant
4. Leaks in the refrigerant system
5. Condenser clogged or insufficient radiation
CORRECTION
Refer to MAGNETIC CLUTCH
troubleshooting in this section
Adjust the drive belt to the specified

tension or replace the drive belt
Clean the magnetic clutch face or replace
Adjust the clearance (Refer to
COMPRESSOR OVERHAUL
Replace the compressor
Replace the compressor

Discharge and recover refrigerant.
Recharge to specified amount.
Check refrigerant system for leaks and
repair as necessary
Discharge and recover refrigerant.
Recharge to specified amount.
Clean the condenser or replace as
necessary
Check radiator or condenser fan function
Repair the link unit
Replace the expansion valve
Check electronic thermostat and replace

as necessary
1. Evaporator clogged or frosted
Check evaporator core and replace or

clean the core
2. Air leaking from cooling unit or air duct
3. Blower motor does not rotate prop-erly
Check evaporator and duct connection,

then repair as necessary
Refer to FAN CONTROL KNOB (FAN
SWITCH) troubleshooting in this section
6. Temperature control link unit of the heater

unit defective
7. Unsteady operation due to foreign
substance in expansion valve
8. Poor operation of electronic thermostat
Insufficient
velocity
of cooling air
* For the execution of the charging and discharging operation in the table above, refer to the RECOVERY,
RECYCLING, EVACUATING AND CHARGING in this section.
CHECKING REFRIGERANT SYSTEM

WITH MANIFOLD GAUGE
Conditions;
Ambient temperature at approx. 30~35C (86~95F)
Run the engine at Idling
A/C switch is ON
Run the blower motor at 4 (high) position
Temperature control knob sets at MAX COLD
Air source selector lever at CIRC
Close the all doors

2
Normal pressures kPa (kg/cm / PSI);
Low-pressure side:
Approx. 127 245 (1.3 2.5 / 18 36)
High-pressure side:
Approx. 1373 1670 (14 17 / 199 242)
Connect the manifold gauge
Low-pressure hose (LOW) ~ Suction side
High-pressure hose (HI) ~ Discharge side
f06r300014
RESULT
Discharge
(High)
pressure
gauge
abnormally
high
SYMPTOM
TROUBLE CAUSE
Condenser clogged or dirty

Radiator (condenser) fan
does not operate properly
Clean
Check cooling fan
operation
No bubbles in sight glass when

condenser is cooled by water
(Insufficient cooling)
Excessive refrigerant in
system
Check sight glass.

(See Reading Sight
Glass)
Discharge and
recover refrigerant.
Recharge to specified
amount
Evacuate and charge
refrigerant system
Discharge
(High)
pressure
gauge
abnormally
low
Suction
(Low)
pressure
gauge
abnormally
high
CORRECTION
Reduced or no air flow through

the condenser
After stopping air conditioning,

pressure drops approx. 196 kPa
2
(2.0kg/cm / 28 PSI) quickly
Insufficient cooling and excessive
bubbles in the sight glass
Air in system
Insufficient refrigerant in
system
Low pressure gauge indicates

vacuum
Frost or dew on refrigerant line
before and after receiver/ drier or
expansion valve, and low pressure gauge indicates vacuum
After turning off air conditioning,
high and low pressure gauge
balanced quickly
Low pressure gauge is lowered

after condenser is cooled by
water
Low pressure hose temperature

around the compressor refrigerant
line connector is lower than
around evaporator
After turning off air conditioning,

high and low pressure gauge is
balanced quickly
Air conditioning turns off before
passenger compartment is
sufficiently
cool
Clogged or defective
expansion valve
Restriction caused by debris
or moisture in receiver/drier
Check sight glass.

(See Reading Sight
Glass)
Check for leaks
Discharge and
amount
Replace the
expansion valve
Check system for
restriction and
replace receiver/drier
Compressor seal defective

Poor compression due to
defective compressor
gasket
system
Replace or repair
compressor
Discharge and
recover refrigerant
amount
Unsatisfactory valve
operation due to defective
temperature sensor of
expansion valve
Expansion valve opens too
long
Compressor gasket is
defective
Replace the
expansion valve
Replace
Electronic thermostat
defective
Check the electronic

thermostat and
replace as necessary
* For the charging and discharging operations in the table above, refer to RECOVERY, RECYCLING,
EVACUATION AND CHARGING in this section.
RESULT
Suction
(Low)
pres-sure
abnormally
low
Suction
(Low) and
Discharge
(High)
pressure
abnormally
high
Suction
(Low) and
Discharge
(High)
pres-sure
abnormally
low
SYMPTOM
Condenser is not hot and
excessive bubble in sight glass
TROUBLE CAUSE
Insufficient refrigerant
CORRECTION
Check sight
glass.(See Reading
Sight Glass)
Check for leaks
Discharge and
amount
Replace the
expansion valve
Replace the receiver/
drier
Frost on the expansion valve inlet

line
A distinct difference in
temperature between the inlet and
outlet refrigerant lines of the
receiver/drier
Expansion valve outlet refrigerant
line is not cold and low-pressure
gauge indicates vacuum
Expansion valve clogged
Receiver/drier clogged
Replace the
expansion valve
Discharge temperature is low and

air flow from vents is restricted
The temperature sensor of

the expansion valve is
defective, and the valve
cannot regulate the correct
flow of the refrigerant
Frozen evaporator core fins
Low-pressure gauge reading is

low, or a vacuum reading may be
shown
No bubbles in sight glass after
condenser is cooled by water
(Insufficient cooling)
Clogged or blocked
refrigerant line
Check electronic
thermostat and
replace as necessary
Replace refrigerant
line
system
Reduce air flow through condenser
Suction (Low) pressure hose is

not cold
Insufficient cooling and excessive

bubbles in the sight glass
Condenser clogged
Radiator (condenser) fan
does not rotate properly
Air in system
Insufficient refrigerant in
system
Check sight
glass.(See Reading
Sight Glass)
Discharge and
amount
Clean
Check cooling fan
operation
Evacuate and charge
refrigerant
Check sight glass.
(See Reading Sight
Glass)
Check for leaks
Discharge and
amount
MAGNETIC CLUTCH
When the A/C switch and the fan control knob (fan switch) are turned on with the engine running, current flows
through the thermostat and the compressor relay to activate the magnetic clutch.
The air conditioning can be stopped by turning off the A/C switch or the fan control knob (fan switch).
However, even when the air conditioning is in operation, the electronic thermostat, the pressure switch or the ECM
is used to stop the air conditioning temporarily by turning off the magnetic clutch in the prearranged conditions to
reduce the engine load which is being caused by the rise in the engine coolant temperature, and the acceleration of
the vehicle, etc.
4JA1 L
RTW410LF000401
4JH1 TC
RTW410LF000101
MAGNETIC CLUTCH DOES NOT RUN (4JA1L/4JH1-TC)

Are the No. SBF-8 fuse (30A) and the No. EB-13
(10A) fuses OK
YES
NO
Are the A/C thermo (X-15) and heater & A/C (X-11)
and A/C compressor (X-14) relay OK?
Replace
YES
NO
Is the pressure switch (C-24) OK?
Replace
YES
NO
Are the A/C switch (B-57) and the fan switch (B-13)
OK?
Defective switch or insufficient

refrigerant
YES
NO

A/C switch and fan control knob (fan switch "ON")
Replace
Disconnect the magnetic clutch connector.

Is there battery voltage between the engine room harness
connector terminal No.1 (E-3) and ground?
NO
YES
Disconnect the A/C compressor relay.
Does the magnetic clutch

operate?
Is there continuity between the engine harness

connector terminal No.1 (E-3) and engine room harness
connector terminal No.2 (X-14)?
YES
Defective compressor
Defective magnetic clutch
NO
YES
NO
Is there battery voltage between the engine room

harness connector terminal No.1 (X-14) and
ground?
Open circuit between the engine

harness connector terminal No.1 (E-3)
and engine room harness connector
terminal No.2 (X-14).
YES
NO
Disconnect the A/C thermo relay.
Open circuit between the No. EB-13

fuse and engine room harness
connector terminal No.1 (X-14).
Is there continuity between the engine room

harness connector terminal No.3 (X-14) and No.1
(X-15)?
YES
Disconnect the ECM harness connector.
Is there continuity between the ECM harness
connector terminal No.38 (C-56) and engine
room harness connector terminal No.4 (X-14)?
NO
Open circuit between the engine room
harness connector terminal No.1 (X15) and engine room harness
connector terminal No. 3 (X-14).
YES
NO

connector terminal No.30 (C-56) and engine

harness connector terminal No.1 (X15) and engine room harness
YES
NO

ground?
Open circuit between the ECM

harness connector No. 38 (C-56) and
engine room harness connector
terminal No. 4 (X-14).
YES
NO
Disconnect the pressure switch?

harness connector terminal No. 3 (X-15) and the
engine room harness connector terminal No. 1 (C24).

YES
Disconnect the condenser fan relay connector
condenser fan.
Is there continuity between the relay terminal
4JH1TC No. 4 (X-6) 4JA1L No.3 (X-13)and
engine room harness connector terminal No.4
(C-24)?
YES
NO
Is there battery voltage between the engine

room harness connector terminal NO.3 (C24) and ground?
Open circuit between the condenser

fan relay 4JH1TC No.4 (X-6) 4JA1L
No. 3 (X-13) and engine room harness
NO
connector terminal No. 3 (C-24).
YES
connect the A/C thermo relay connector.
Disconnect the electronic themostat.
NO
Open circuit between and engine room
harness connector terminal No. 3 (X15) and the engine room harness
connector terminal No. 1(C-24).

harness connector terminal No. 2 (C-55) and the
engine room harness connector terminal No. 2
(C-24).
YES
NO

room harness connector terminal No.3 (C-55)
d
d?

harness connector terminal No. 2 (C55) and the engine room harness
YES
NO

harness connector terminal No.1 (C-55) and
ground (C-109) ? or (cooler only) the short
connector terminal No.3 (B-79) and ground (C109)?

YES
NO
Is there continuity between the engine room harness

connector (cooler only) terminal No. 4 (C-55) and the
chassis side harness connector terminal No. 11 (B-57).

harness connector terminal No. 1 (C-55) or
(cooler only) the short connector No. 3 (B79) and ground (C-109).
YES
NO
Is there battery voltage between the chassis side

harness connector terminal No. 10 (B-57) and ground?

harness connector (cooler only) terminal
No. 4 (C-55) and the chassis side harness
connector terminal No. 11 (B-57).
YES
NO
Disconnect the A/C switch.
Open circuit between the chassis side

harness connector No. 1 (B-79) and
chassis side harness connector terminal
No. 10 (B-57).

harness connector terminal No. 6 (B-57) and ground (C109)?
YES
NO
Is the electronic themostat OK?
Open circuit between the No. EB-13 fuse

and the chassis side harness connector
No. 6 (B-57).
YES
NO
Defective ECM
Replace electronic thermostat
6VE1
RTW410XF000201
MAGNETIC CLUTCH DOES NOT RUN

Are the No. SBF 8 fuse (30A) and the No. EB-13
(10A) fuses OK
YES
NO
Are the A/C thermo (X-15), heater & A/C (X-11)

Replace
YES
NO
Replace
YES
NO
OK?

refrigerant
YES
NO

Replace

harness connector terminal No.1 (E-2) and ground?
NO
YES

operate?

connector terminal No.1 (E-2) and engine room
harness connector terminal No.2 (X-14)?
YES
NO
YES
NO

ground?

harness connector terminal No.1 (E13) and engine room harness
YES
NO

Is there battery voltage the engine room harness

connector terminal No.3 (X-14) and ground?
YES
connector terminal No. 11 (E-61) and engine
NO
Open circuit between the No.EB-13
YES
NO

connector terminal No.31 (E-61) and engine

harness connector No. 11 (E-61) and
YES
NO

ground?
YES
Disconnect the pressure switch.
connector terminal No. 4 (X-15) and the engine room
harness connector terminal No. 1 (C-24)?

NO
YES
Disconnect the condenser fan relay connector
condenser fan.
Is there continuity between the relay terminal
No. 4 (X-6) and engine room harness connector
terminal No.4 (C-24)?
YES
room harness connector terminal NO. 3 (C24) and ground?
NO
Open circuit between the condenser
fan relay No.4 (X-6) 4JAH No. 3 (X13) and engine room harness
NO
YES
connect the A/C thermo relay connector.
Disconnect the electronic themostat.
harness connector terminal No. 2 (C-55) and the
engine room harness connector terminal No. 2
(C-24)?
NO
room harness connector terminal
No. 4 (X-15) and the engine room
harness connector terminal No. 1(C24).
YES
NO

room harness connector terminal No.3 (C-55)
d
d?

harness connector terminal No. 2 (C24) and the engine room harness
YES
NO

harness connector terminal No.1 (C-55) and
ground (C-109) ?

YES
NO
Open circuit between the chassis side

harness connector No. 1 (B-79) and
chassis side harness connector terminal
No. 10 (B-57).

harness connector terminal No. 6 (B-57) and ground (C109)?
YES
NO

No. 6 (B-57).
YES
NO
Defective ECM
RTW410XF000301
Are the No. SBF 8 fuse (30A) and the No. EB-13
(10A) fuses OK?
YES
NO
Are the A/C thermo (X-15), heater & A/C (X-11)

Replace
YES
NO
Replace
YES
NO
OK?

refrigerant
YES
NO

Replace

harness connector terminal No.1 (E-2) and ground?
NO
YES

operate?

connector terminal No.1 (E-2) and engine room
harness connector terminal No.2 (X-14)?
YES
NO
YES
NO

ground?
Open circuit between the engine harness

connector terminal No.1 (E-3) and engine
room harness connector terminal No.2 (X14).
YES
NO

Is there battery voltage the engine room harness

connector terminal No.3 (X-14) and ground?
YES
connector terminal No. 14 (C-56) and engine
NO
YES
NO

connector terminal No. 26 (C-56) and engine
room harness connector terminal No. 1 (X-15)?

harness connector No.14 (C-56) and
YES
NO

harness connector terminal No. 2 (X-15) and
ground?

harness connector No. 26 (C-56) and
the engine room harness connector
YES
NO
Disconnect the pressure switch?

harness connector terminal No. 3 (X-15) and the
engine room harness connector terminal No. 1 (C24).

YES
Disconnect the condenser fan relay connector condenser
fan.
Is there continuity between the relay terminal No. 3 (X-7)
and engine room harness connector terminal No.4 (C24)?
YES
NO

harness connector terminal NO. 3 (C-24) and ground?
Open circuit between the condenser fan

relay No.3 (X-7) and engine room harness
NO
terminal No. 4 (C-24).
YES
Disconnect the pressure switch.
connector terminal No. 4 (X-15) and the engine room
harness connector terminal No. 1 (C-24).
YES
Connect the A/C thermo relay connector.
Disconnect the electronic thermostat.
connector terminal No. 2 (C-55) and the engine room
harness connector terminal No. 2 (C-24)?
NO
NO
harness connector terminal No. 4 (CX-15)
and the engine room harness connector
YES
NO

harness connector terminal No. 3 (C-55) and ground?

harness connector terminal No. 2 (C-24)
and the engine room harness connector
YES
NO

connector terminal No. 1 (C-55) and ground (C-109)?

YES
NO

harness connector No. 1 (C-55) and ground
(C-109).

harness connector terminal No. 6 (B-57) and ground?
YES
NO

No. 4 (C-55).
YES
NO
Defective ECM
SPECIAL SERVICE TOOL

ITEM NO.
ILLUSTRATION
PART NO.
PART NAME
5-8840-0629-0
(J-39500-A)
5-8840-0630-0
(J-39500-220A)
5-8840-0631-0
(J-39500-220ANZ)
ACL-2
5-8840-4056-0
(J-37872)
Drive plate holder
ACL-4
5-8840-0121-0
(J-33943)
Clutch pulley puller pilot
ACL-5
5-8840-0111-0
(J-8433)
Clutch pulley puller
CDL-10
5-8840-0118-0
(J-33940)
Clutch pulley installer
OTL-1
5-8840-0007-0
(J-8092)
Driver handle
No. TFHAC-WE-0431
WORKSHOP MANUAL
TF SERIES
FRAME AND CAB
SECTION 2
FRAME AND BUMPER 2A-1
SECTION 2A
FRAME AND BUMPER

TABLE OF CONTENTS
PAGE
Front Bumper .....................................................................................................................2A- 2
Rear Step Bumper .............................................................................................................2A- 4
Rear Bumper And Rear Guard ASM .................................................................................2A- 7
Frame Dimensions.............................................................................................................2A- 9
2A-2 FRAME AND BUMPER
FRONT BUMPER
RTW42ALF000101
Removal Steps
Installation Steps
I 1. Radiator grille
I 2. Front bumper fascia
3. Bezel (W/O Fog light)
4. Fog light
5. Front bumper flare assembly (W/ Front
wheel extention)
7. Front bumper inpact bar assembly
(Except Europe equipment)
8. Front bumper inpact bar assembly (For
Europe equipment)
9. Fascia support side bracket
10. Fascia support lower bracket
10. Fascia support lower bracket

9. Fascia support side bracket
I 8. Front bumper inpact bar assembly (For
Europe equipment)
I 7. Front bumper inpact bar assembly
(Except Europe equipment)
I 5. Front bumper flare assembly (W/ Front
wheel extention)
I 4. Fog light
3. Bezel (W/O Fog light)
1. Radiator grille

1. Radiator Grille
Refer to the Radiator Grille in this section.
2. Front Bumper Fascia

Remove the nine clips and four screws.
Disconnect the fog light harness connectors.

8. Front Bumper Inpact Bar Assembly (For Europe
equipment)
7. Front Bumper Inpact Bar Assembly (Except Europe
equipment)
Tighten the fixing bolts to the specified torque.
Torque
Nm(kgfm/lbft)
62 (6.3 / 46)
This illustration is except Europe equipment model.
5. Front Bumper Flare Assembly
Tighten the fixing nuts to the specified torque.
Torque
Nm(kgfm/lbin)
7 (0.7 / 61)
4. Fog Light
Tighten the fixing nuts to the specified torque.
Torque
Nm(kgfm/lbin)
7 (0.7 / 61)
REAR STEP BUMPER

RTW32AMF000301
Removal Steps
Installation Steps
1. Rear step bumper assembly

2. Side step pad
3. License light
4. Rear bumper center pad
5. Extension harness
6. Back bar / Conner brace
7. Rear bumper
8. Reinforce assembly
8. Reinforce assembly
7. Rear bumper
6. Back bar / Conner brace
5. Extension harness
4. Rear bumper center pad
3. License light
2. Side step pad
1. Rear step bumper assembly

1. Rear Step Bumper Assembly
Remove the 3 bolts from each side.
Disconnect the extension harness connector.

2. Side Step Pad
Push out the 4 fixing portions of side step pad from the
back face of the rear step bumper.
RTW32ASH000101
4. Rear Bumper Center Pad

Remove the 2 clips from both end of the center pad.
Push out the 7 fixing portions of center pad from the
back face of the rear step bumper.
RTW32ASH000201

7. Rear bumper
A: Bolt
Torque
Nm(kgfm/lbft)
40 (4.1 / 30)
6. Back Bar / Conner Brace

1) B: Bolt
Torque
Nm(kgfm/lbft)
40 (4.1 / 30)
2) C: Bolt
Torque
Nm(kgfm/lbin)
9 (0.9 / 78)
3) D: Bolt
Torque
Nm(kgfm/lbft)
85 (8.7 / 63)
RTW32AMH000101

1. Rear Step Bumper Assembly
1) Align the back bar to the frame as follows:
Face A should be contacted with the upper face of the
frame
Face B should be contacted with the rear end of the
frame.
2) Tighten the 3 fixing bolts on the each side of back bar.
Torque
Nm(kgfm/lbft)
150 (15.3 / 111)
RTW32AMH000201
REAR BUMPER AND REAR GUARD ASM

RTW42AMF000201
Removal Steps
Installation Steps
I 1. Rear guard assembly

I 2. Rear bumper assembly
3. Nut
4. Bolt
5. Bumper bracket
6. Screw
7. Cap
8. Rear bumper
8. Rear bumper
7. Cap
6. Screw
5. Bumper bracket
4. Bolt
I 3. Nut
I 2. Rear bumper assembly
I 1. Rear guard assembly

1. Rear Guard Assembly
2. Rear bumper assembly

3. Nut
Torque
Nm (kgfm/lbft)
116 (11.8 / 85)
2. Rear Bumper Assembly
frame
frame.
Torque
Nm (kgfm/lbft)
150 (15.3 / 111)
1. Rear Guard Assembly

frame
frame.
RTW42AMH000101
Torque
Nm (kgfm/lbft)
150 (15.3 / 111)
FRAME DIMENSIONS
4
2, LWB, REGULAR CAB MODEL
RTW32AXF002601
4
2, LWB, EXTEND CAB MODEL
RTW32AXF000201
4
2, LWB, CREW CAB MODEL
This illustration is based on the RHD model.
RTW32AXF000301
4
RTW32AXF002701
4
RTW32AXF000501
4
RTW32AXF000601
4
2, EXTRA LWB, REGULAR CAB MODEL
RTW32AXF000701
4
2, EXTRA LWB, EXTEND CAB MODEL
RTW32AXF000801
4
RTW32AXF002801
4
RTW32AXF001001
4
4, EXTRA LWB, CREW CAB MODEL
RTW32AXF002901
4
RTW42AXF000101
4
RTW42AXF000201
4
RTW42AXF000901
HI / RIDE, LWB, REGULAR CAB MODEL
RTW42AXF000401
HI / RIDE, LWB, CREW CAB MODEL
RTW42AXF000501
4
RTW42AXF000601
4
RTW32AXF003001
4
RTW32AXF003101
4
RTW32AXF003201
HI/RIDE, LWB, CREW CAB MODEL
RTW32AXF003301
4
RTW32AXF001601
4
RTW32AXF003401
4
RTW32AXF003501
4
RTW32AXF003601
4
RTW32AXF002001
4
RTW32AXF002101
4
4, EXTRA LWB, CREW CAB MODEL
RTW32AXF003701
4
4, EXTRA, LWB, CREW CAB MODEL
RTW42AXF000301
HI / RIDE, LWB, REGULAR CAB MODEL
RTW42AXF000701
HI / RIDE, LWB, EXTEND CAB MODEL
This illustration on the RHD model.
RTW42AXF000801
MEMO
SHEET METAL 2B-1
SECTION 2B
SHEET METAL
This section includes items of front end sheet metal that are attached by bolts, screws or clips and related
accessory components.
Anticorrosion materials have been applied to the interior surfaces of some metal panels to provide rust resistance.
When servicing these panes, areas on which this material has been disturbed, should be properly recoated with
service-type anticorrosion material.
TABLE OF CONTENTS
PAGE
Engine Hood Assembly .....................................................................................................2B- 2
Engine Hood Lock .............................................................................................................2B- 5
Front Fender Panel ............................................................................................................2B- 7
Radiator Grille ....................................................................................................................2B- 10
Rear Body...........................................................................................................................2B- 11
Body Mounting...................................................................................................................2B- 13
Body Dimension................................................................................................................. 2B- 19
2B-2 SHEET METAL
ENGINE HOOD ASSEMBLY

RTW42BLF000101
Removal Steps
1. Washer nozzle tube

2. Hood hinge bolts
3. Engine hood
4. Washer nozzle
5. Hood insulator (Die. Eng. Only)
6. Hood seal
Installation Steps
6. Hood seal
5. Hood insulator (Die. Eng. Only)
4. Washer nozzle
3. Engine hood
2. Hood hinge bolts
1. Washer nozzle tube
SHEET METAL 2B-3

1. Washer Nozzle Tube
1) Open the hood.
2) Support the hood.
3) Remove the windshield washer nozzle tube.
2. Hood Hinge Bolts

Before removing the hinges from the engine hood, scribe a
mark showing location of the hinges to facilitate installation in
the original position.

3. Engine Hood
Check the engine hood and fender. (1)
RTW32BSH000101
Clearance : 4.0 mm (0.16 in)

Height (step) : Flushness
Adjust clearance with the hinges on the engine hood.
Adjust height (step) with the hood rests (1).
Engine Hood Striker

Apply a light coat of grease to the striker.
2B-4 SHEET METAL

2. Hood Hinge Bolts
Tighten the engine hood hinge fixing bolts to the specified
torque.
Torque
Nm(kgfm/lbin)
10 (1.0 / 87)
SHEET METAL 2B-5
ENGINE HOOD LOCK


RTW42BMF000101
Removal Steps
Installation Steps
1. Radiator grille
2. Engine food lock assembly
3. Hood lock control lever
4. Control cable
4. Control cable
3. Hood lock control lever
2. Engine food lock assembly
1. Radiator grille

1. Radiator Grille
2. Engine Hood Lock Assembly
Apply setting marks (1) to the hood lock assembly and the
body prior to removal.
4. Control Cable
Pull out the control cable toward the passenger compartment.
2B-6 SHEET METAL

4. Control Cable
Reroute the control cable to its original position, and check and
see if the lock assembly and control lever work normally.
2. Engine Hood Lock Assembly
Adjustment
1) Install the engine hood lock assembly (4) and temporarily
tighten the bolts securing it.
2) Close the hood.
3) Position the hood so that the stepped portion between the
hood (1) and the fender (2) is precisely 1.5 mm (0.06 in)
high.
4) Final tighten the bolts securing the engine hood lock
assembly.
5) Turn the buffers (3) counterclockwise until the stepped
portion between the hood and the fender disappears.
6) Tighten the hood lock assembly fixing bolts to the specified
torque.
Torque
Nm(kgfm/lbin)
10 (1.0 / 87)
SHEET METAL 2B-7
FRONT FENDER PANEL

RTW42BLF000201
Removal Steps
Installation Steps
1. Radiator grille
2. Mud guard (W/O Front wheel extention)
3. Front wheel extention (W/ Front wheel
extention)
4. Inner liner
5. Front bumper facia
6. Side turn signal light

7. Front fender panel

6. Side turn signal light
4. Inner liner
3. Front wheel extention (W/ Front wheel
extention)
2. Mud guard (W/O Front wheel extention)
1. Radiator grille
2B-8 SHEET METAL

1. Radiator Grille
4. Inner liner
Remove the inner liner fixing screws.

Refer to the Front Bumper in this section.

Remove the eight fixing bolts.

7. Front Fender Panel
1) Tighten the front fender panel fixing bolts to the
specified torque.
Torque
Nm(kgfm/lbin)
10 (1.0 / 87)
SHEET METAL 2B-9

2) Check the fender and front door (1).
Clearance : 5.0 mm (0.2 in)
Height (step) : Flushness
RTW32BSH000201
RTW32BSH000301
2B-10 SHEET METAL
RADIATOR GRILLE
RTW42AMF000101
Removal Steps
1. Screw
2. Clip
3. Radiator grille
Installation Steps
3. Radiator grille
2. Clip
1. Screw

2. Clip
Use a screwdriver to release the 4 clips at the top of the
radiator grille.
Pull the grille together with the 2 bottom clips from the
vehicle.
SHEET METAL 2B-11
REAR BODY
RTW32MF000301
Removal Steps
Installation Steps
1. Battery ground cable

2. Rear combination lamp & license lamp
harness connector
3. Rear wheel house extension panel
4. Fuel filler door release cable assembly
5. Fuel filler pipe and evaporator hose
6. Bolt; frame to rear body
7. Rear body assembly
7. Rear body assembly

6. Bolt; frame to rear body
5. Fuel filler pipe and evaporator hose
4. Fuel filler door release cable assembly
3. Rear wheel house extension panel
2. Rear combination lamp & license lamp
connector
1. Battery ground cable
NOTE:
The rear body must be empty before removal.
2B-12 SHEET METAL

4. Fuel Filler Pipe and Evaporator Hose
7. Rear Body Assembly

Attach lifting wires to the rear body hooks and raise the rear
body.
Note:
In lifting up rear body, take care not to dash it against cab
body.
Important Operation Installation

6. Bolt; Frame to Body
Torque
Nm(kgfm/lbft)
54 (5.5 / 40)
SHEET METAL 2B-13
BODY MOUNTING
REGULAR CAB Model
RTW32BXF000101-X
2B-14 SHEET METAL
Important Operations Installation

Bolt : A
Torque
Nm(kgfm/lbft)
50 (5.1 / 37)
Bolt : B,C
Torque
Nm(kgfm/lbft)
72 (7.3 / 53)
Bolt : D,E,H,I
Torque
Nm(kgfm/lbft)
54 (5.5 / 40)
NOTE :
Discard used the mounting bolts D,E,H,I shown in the
figure and install new one.
SHEET METAL 2B-15

EXTEND CAB Model
RTW32BXF000201-X
2B-16 SHEET METAL

Bolt : A
Torque
Nm(kgfm/lbft)
50 (5.1 / 37)
Bolt : B,C
Torque
Nm(kgfm/lbft)
72 (7.3 / 53)
Bolt : D,G,H
Torque
Nm(kgfm/lbft)
54 (5.5 / 40)
NOTE :
Discard used the mounting bolts D,G,H shown in the
figure and install new one.
SHEET METAL 2B-17

CREW CAB Model
RTW32BXF000301-X
2B-18 SHEET METAL

Bolt : A
Torque
Nm(kgfm/lbft)
50 (5.1 / 37)
Bolt : B,C/D
Torque
Nm(kgfm/lbft)
72 (7.3 / 53)
Bolt : E-1
Torque
Nm(kgfm/lbft)
116 (11.8 / 85)
Bolt : E-2
Torque
Nm(kgfm/lbft)
168 (17.1 / 124)
RTW32BSH000401
Bolt : F,H,I
Torque
Nm(kgfm/lbft)
54 (5.5 / 40)
NOTE :
Discard used the mounting bolts G,H shown in the figure
and install new one.
SHEET METAL 2B-19
BODY DIMENSION
FRONT SECTION
2B-20 SHEET METAL
10
11
12
SHEET METAL 2B-21
13
14
15
16
17
18
2B-22 SHEET METAL

ROOM SECTION (REGULAR CAB)
19
20
21
22
SHEET METAL 2B-23
23
24
25
26
27
28
2B-24 SHEET METAL

ROOM SECTION (EXTEND CAB)
19
20
21
22
SHEET METAL 2B-25
29
30
31
32
33
34
35
36
2B-26 SHEET METAL
37
38
39
40
SHEET METAL 2B-27

ROOM SECTION (CREW CAB)
19
20
21
22
2B-28 SHEET METAL
48
49
50
51
52
53
54
55
SHEET METAL 2B-29
56
57
58
59
2B-30 SHEET METAL

SIDE BODY SECTION (REGULAR CAB)
41
42
43
44
SHEET METAL 2B-31
45
23
25
46
2B-32 SHEET METAL

SIDE BODY SECTION (EXTEND CAB)
41
42
43
44
SHEET METAL 2B-33
45
29
31
47
2B-34 SHEET METAL

SIDE BODY SECTION; FRONT SIDE (CREW CAB)
41
42
43
44
SHEET METAL 2B-35
45
48
50
60
2B-36 SHEET METAL

SIDE BODY SECTION; REAR SIDE (CREW CAB)
48
54
61
62
No. TFFRM-WE-0431
WORKSHOP MANUAL
TF SERIES
STEERING SUSPENSION,
WHELLS AND TIRES
SECTION 3
FRONT ALIGNMENT 3A-1
SECTION 3A
FRONT ALIGNMENT
TABLE OF CONTENTS
PAGE
Front End Alignment Inspection and Adjustment ..........................................................3A- 2
General Description .....................................................................................................3A- 2
Inspection .....................................................................................................................3A- 3
Alignment for 4
2 (Except High Ride Suspension) .......................................................3A- 4
Alignment for 4
2 (High Ride Suspension) and 4
4 ......................................................3A- 10
3A-2 FRONT ALIGNMENT
Front End Alignment Inspection and

Adjustment
General Description
Front End Alignment refers to the angular
relationshipbetween the front wheels, the front suspension
attachingparts and the ground.
Proper front end alignment must be maintained in order
toinsure efficient steering, good directional stability and
toprevent abnormal tire wear.
The most important factors of front end alignment arewheel
toe-in, wheel camber and axle caster.
Camber:
This illustration shows view from the front of the vehicle.
Camber is the vertical tilting inward or outward of the front
wheels. When the wheels tilt outward at the top, the camber is
positive (+). When the wheels tilt inward at the top, the camber
is negative (-). The amount of tilt measured in degrees from
the vertical is called the camber angle (1). If camber is extreme
or unequal between the wheels, improper steering and
excessive tire wear will result. Negative camber causes wear
on the inside of the tire, while positive camber causes wear to
the outside.
Caster:
This illustration shows view from the side of the vehicle.
Caster (1) is the vertical tilting of the wheel axis either
forward or backward (when viewed from the side of the
vehicle). A backward tilt is positive (+) and a forward tilt is
negative (-). On the short and long arm type suspension
you cannot see a caster angle without a special instrument, but
if you look straight down from the top of the upper control arm
to the ground, the ball joints do not line up (fore and aft) when
a caster angle other than 0 degree is present. With a positive
angle, the lower ball joint would be slightly ahead (toward the
front of the vehicle) of the upper ball joint center line.
Toe-in:
This illustration shows view from the top of the vehicle.
Toe-in is the measured amount the front wheels are turned in.
The actual amount of toe-in is normally a fraction of a degree.
Toe-in is measured from the center of the tire treads or from
the inside of the tires. The purpose of toe-in is to insure parallel
rolling of the front wheels and to offset any small deflections of
the wheel support system which occurs when the vehicle is
rolling forward. Incorrect toe-in results in excessive toe-in and
unstable steering. Toe-in is the last alignment to be set in
the front end alignment procedure.
Inspection
Before making any adjustments affecting caster, camber or
toe-in, the following front end inspection should be made.
1. Inspect the tires for proper inflation pressure. Refer to
Main Data and Specifications in Wheel and Tire System
section.
2. Make sure that the vehicle is unlade condition (Withno
passenger or loading).
3. Make sure that the spare tire is installed at the normal
position.
4. Inspect the front wheel bearings for proper adjustment.
Refer to Front Hub and Disc Overhaul in Suspension
section.
5. Inspect the ball joints and tie rod ends. If excessive
looseness is noted, correct before adjusting. Refer to
Steering Linkage in this section.
6. Inspect the wheel and tires for run-out. Refer to Wheel
Replacement in Wheel and Tire System section.
7. Inspect the trim height. If not within specifications, the
correction must be made before adjusting caster.
8. Inspect the steering unit for looseness at the frame.
9. Inspect shock absorbers for leaks or any noticeable noise.
Refer to Shock Absorber in Suspension section.
10.Inspect the control arms or stabilizer bar attachment for
looseness. Refer to Suspension section.
11.Inspect the front end alignment using alignment equipment.
Follow the manufacturers instructions.
12.Park the vehicle on a level surface.
2 (Except High Ride Suspension)

Alignment for 4
Caster and camber Adjustment
The lower links of the 4 X2 vehicle front suspension have an adjusting cam at either end (front and rear). This
permits simultaneous adjustment of camber and caster angle.
Front
Front
RTW340LF000301
Legend
1. Lower link ASM RH
2. Adjust cam RR
3. Adjust cam FRT
4. -direction The lower link ASM protrudes
toward the inside
5. +direction The lower link ASM protrudes
toward the outside
6. Lower link ASM LH

7. Adjust cam RR
8. Adjust cam FRT
9. -direction The lower link ASM protrudes
toward the inside
10. +direction The lower link ASM protrudes
toward the outside

The follow illustration shows the alignment procedure.
RTW340LF000401

Example
Measured value
Camber angle
Standard value
Camber angle
110'
Caster angle
310'
030'
Caster angle
335'45'
1. Mark an A at the intersection point of the measured

camber angle value (solid line) and the measured caster
angle value (dotted line).
RTW340SH001001
2. Mark a B at the intersection point of the standard camber

angle value (solid line) and the standard caster angle value
(dotted line).
RTW340SH001101
3. The vertical distance between points A and B represents

the adjustment required at the front cam. The horizontal
distance between points A and B represents the
adjustment required at the rear cam.
In this example, the front cam would be moved 5 integers to
the positive and the rear cam would be moved 8 integers to
the positive.
RTW340SH001201
CAUTION:
Maximum possible adjustment from the center point of the
cams is 9 integers to either side.
CASTER
335'45'
Note:
Left and right side to be equal within 30'
CAMBER
030'
Note:
Left and right side to be equal within 30'
KING PIN INCLINATION
1230'30'
Toe-in Adjustment
Measurement should be taken with the vehicle on a surface
plate.
If a surface plate is not available, toe-in should be checked
with the vehicle parked on a level floor.
1. Set front wheels to straight ahead position.
2. Align the toe-in gauge with center height of each wheel at
front end.
3. Apply center marks to each wheel, then take measurement
of distance A between the center marks on each wheel.
4. Slowly move the vehicle rearward until the center marks
reach the rear end position.
5. Take measurement of distance B between the center
marks at rear end.
The toe-in can be calculated with next formula.
Toe-in = B - A
Toe-in
mm (in)
42
02 (00.08)
(Except high ride suspension)
To adjust the toe-in angle, loosen the lock nuts (2) on the tie
rod (1) and turn the tie rod. Turn both rods the same amount,
to keep the steering wheel centered.
Lock Nut Torque
Nm (kgfm/lbft)
986.0 (10.00.6 / 72.34.3)
Trim Height
Trim Height : at Curb Weight (Reference Data)
Trim height (Z) = A - B
Front
Z
105(4.13)
RTW330SH000101
mm (in)

FRT Buffer clearance (Reference Data)
42 (Except high ride suspension)
25.9(1.02)
RTW340SH001301-X
RR Buffer clearance (Reference Data)

mm(in)
82.1 (3.23)
RTW340SH000101-X
MAXIMUM STEERING ANGLE

Outside wheel
33.5
Inside wheel
37.1

4
Alignment for 4
Caster and camber Adjustment
The camber angle and caster angle can be adjusted by means of the camber shims and caster shims installed in
position between the chassis frame and fulcrum pins.
RTW340LF001901
Legend
1. Camber shim
2. Caster shim
3. Upper link ASM RH
4. Lower link ASM LH
5. Adjust cam
Adjust Method
addition / subtraction of shim
front side
rear side
caster
adjustment
camber
adjustment
move direction
of upper b/j
caster angle
alteration
addition
subtraction
decrease
subtraction
addition
increase
no change
no change
subtraction
addition
c
d
decrease
increase
addition
no alteration
subtraction
no alteration
camber angle alteration

de crease (to negative
direction)
in crease (to positive
direction)
no alteration
no alteration
de crease (to negative
direction)
in crease (to positive
direction)
Note:
1. Adjust cam is set initial position (the hole & projection
are upward as shown in a illustration) before a shim
adjustment.
2. Difference of caster shim front/rear thickness shall be
3.6mm(0.142in) or less.
Overall thickness of caster shim and camber shim be
10.8mm(0.426in) or less.
3. Make a combination in a such a way that number of
shims becomes minimum.
Fulcrum Pin Bolt Torque
Nm (kgfm/lbft)
152.015 (15.51.5 / 112.110.8)
CASTER
31045
Note:
Left and right side to be equal within 30.
CAMBER
030
Note:
Left and right side to be equal within 30.
KING PIN INCLINATION
123030
Toe-in Adjustment
Measurement should be taken with the vehicle on a surface
plate.
If a surface plate is not available, toe-in should be checked
with the vehicle parked on a level floor.
1. Set front wheels to straight ahead position.
2. Align the toe-in gauge with center height of each wheel at
front end.
3. Apply center marks to each wheel, then take measurement
of distance A between the center marks on each wheel.
4. Slowly move the vehicle rearward until the center marks
reach the rear end position.
5. Take measurement of distance B between the center
marks at rear end.
The toe-in can be calculated with next formula.
Toe-in = B - A
Toe-in
mm (in)
42 (High ride suspension)
02 (00.08)
44
To adjust the toe-in angle, loosen the lock nuts (2) on the tie
rod (1) and turn the tie rod. Turn both rods the same amount,
to keep the steering wheel centered.
Lock Nut Torque
Nm (kgfm/lbft)
986.0 (10.00.6 / 72.34.3)
Trim Height
Trim Height : at Curb Weight
Trim height (Z) = A - B
mm (in)
Z
1405 (5.51)
RTW330SH000201

FRT Buffer clearance (Reference Data)
42 (High ride suspension), 44
29.7(1.17)
450R100002-X
Adjustment
Adjust the trim height by means of the adjusting bolt on the
height control arms.
1. Check and adjust the tire inflation pressures.
2. Park the vehicle on a level ground and move the front of the
vehicle up and down several times to settle the suspension.
3. Make necessary adjustment with the adjusting bolt on the
height control arms.
410RS001
RR Buffer clearance (Reference Data)
42 (High ride suspension), 44

80.0 (3.15)
RTW340SH000201-X
mm(in)
MEMO
POWER-ASSISTED STEERING SYSTEM 3B-1
STEERING
POWER-ASSISTED STEERING SYSTEM
TABLE OF CONTENTS
PAGE
General Description......................................................................................................... 3B
Power Steering System Test........................................................................................... 3B
Maintenance ..................................................................................................................... 3B
Fluid Level ........................................................................................................................ 3B
Bleeding The Power Steering System............................................................................ 3B
Bleeding Procedure ......................................................................................................... 3B
Flushing The Power Steering System ............................................................................ 3B
Steering Wheel Free Play Inspection ............................................................................. 3B
Front End Alignment Inspection and Adjustment ......................................................... 3B
Special Tools.................................................................................................................... 3B 10
Power Steering Unit......................................................................................................... 3B 11
Power Steering Unit and Associated Parts............................................................... 3B 11
Removal ....................................................................................................................... 3B 11
Installation ................................................................................................................... 3B 12
Power Steering Unit Disassembled View.................................................................. 3B 13
Disassembly ................................................................................................................ 3B 13
Inspection and Repair................................................................................................. 3B 13
Reassembly ................................................................................................................. 3B 14
Main Data and Specifications..................................................................................... 3B 14
Special Tools ............................................................................................................... 3B 15
Power Steering Pump and Associated Parts (4JH1-TC, 4JA1-TC, 4JA1-L)............ 3B 16
Removal ....................................................................................................................... 3B 16
Installation ................................................................................................................... 3B 16
Power Steering Pump Disassembled View .............................................................. 3B 17
Disassembly ................................................................................................................ 3B 18
Reassembly ................................................................................................................. 3B 19
3B-2 POWER-ASSISTED STEERING SYSTEM
PAGE
Power Steering Pump and Associated Parts (C24SE) ............................................. 3B 21
Removal ....................................................................................................................... 3B 21
Installation ................................................................................................................... 3B 21
Power Steering Pump Disassembled View............................................................... 3B 22
Disassembly ................................................................................................................ 3B 23
Reassembly ................................................................................................................. 3B 24
Power Steering Pump and Associated Parts (6VE1)................................................ 3B 26
Removal ....................................................................................................................... 3B 26
Installation ................................................................................................................... 3B 26
Power Steering Pump Disassembled View............................................................... 3B 27
Disassembly ................................................................................................................ 3B 27
Reassembly ................................................................................................................. 3B 28
Supplemental Restraint System Steering Wheel & Column......................................... 3B 31
Service Precaution ...................................................................................................... 3B 31
SRS Connectors .......................................................................................................... 3B 31
Inflator Module ................................................................................................................. 3B 32
Inflator Module and Associated Parts ....................................................................... 3B 32
Removal ....................................................................................................................... 3B 33
Inspection and Repair (with SRS air bag) ................................................................. 3B 35
Installation ................................................................................................................... 3B 35
Steering Wheel ................................................................................................................. 3B 37
Steering Wheel and Associated Parts ....................................................................... 3B 37
Removal ....................................................................................................................... 3B 37
Installation ................................................................................................................... 3B 40
The adjustment method in case a mark is not attached............................................... 3B 42
PAGE
Combination Switch ........................................................................................................ 3B 43
Combination Switch and Associated Parts .............................................................. 3B 43
Removal ....................................................................................................................... 3B 43
Installation ................................................................................................................... 3B 46
Lock Cylinder ................................................................................................................... 3B 49
Lock Cylinder and Associated Parts ......................................................................... 3B 49
Removal ....................................................................................................................... 3B 49
Installation ................................................................................................................... 3B 52
System Inspection (with SRS air bag) ....................................................................... 3B 54
Steering Column .............................................................................................................. 3B 55
Steering Column and Associated Parts .................................................................... 3B 55
Removal ....................................................................................................................... 3B 55
Inspection .................................................................................................................... 3B 58
Installation ................................................................................................................... 3B 59
System Inspection (with SRS air bag) ....................................................................... 3B 61
Supplemental Restraint System Steering Wheel & Column and Associated Parts ... 3B 62
Special Tools ............................................................................................................... 3B 62
General Description
The hydraulic power steering system consists of a
pump, an oil reservoir, a steering unit, a pressure hose
and a return hose.
Power Steering Unit

440R300001
The power steering unit is rack and pinion type.

The toe-in angle can be adjusted by turning the rod on
each side.
The steering housing cannot be disassembled.
Hydraulic Pump
442R300004
The hydraulic pump is vane-type design. The

submerged pump has housing and internal parts that
are inside the reservoir and operate submerged in oil.
There are two bore openings at the rear of the pump
housing. The larger opening contains the cam ring,
pressure plate, thrust plate, rotor and vane assembly,
and end plate. The smaller opening contains the
pressure line union, flow control valve and spring.
The flow control orifice is part of the pressure line union.

The pressure relief valve inside the flow control valve
limits the pump pressure.
Steering Column

RTW43BLF000101
WARNING: TO AVOID DEPLOYMENT WHEN

TROUBLE-SHOOTING THE SRS SYSTEM, DO NOT
USE ELECTRICAL TEST EQUIPMENT, SUCH AS
BATTERY-POWERED OR A/C-POWERED VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN SPECIFIED
IN THIS MANUAL. DO NOT USE A NON-POWERED
PROBE-TYPE TESTER.
INSTRUCTION IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
When servicing a vehicle equipped with Supplemental
Restraint System, pay close attention to all WARNINGS
and CAUTIONS.
For detailed explanation about SRS, refer to Restraints
section.
The steering column has three important features in
addition to the steering function:
1. The column is energy absorbing, designed to

compress in a front-end collision to minimize the
possibility of injury to the driver of the vehicle.
2. The ignition switch and lock are mounted
conveniently on the column.
3. With the column mounted lock, the ignition and
steering operation can be locked to prevent theft of
the vehicle.
The column can be disassembled and reassembled.
However, to insure the energy absorbing action, use
only the specified screws, bolts and nuts as designated,
and tighten them to the specified torque.
Handle the column with care when it is removed from
the vehicle. A sharp blow on the end of steering shaft or
shift lever, or dropping the assembly could shear or
loosen the fastenens that maintain column rigidity.
Power Steering System Test

Test Procedure
F02RX002
Legend
(1) Bolt
(2) Hose
Test of fluid pressure in the power steering system is

performed to determine whether or not the oil pump and
power steering unit are functioning normally.
The power steering system test is used to identify and
isolate hydraulic circuit difficulties. Prior to performing
this test, the following inspections and corrections, if
necessary, must be made.
Inspect pump reservoir for proper fluid level.
Inspect pump belt for proper tension.
Inspect pump driver pulley condition.
1. Place a container under the pump to catch the fluid
when disconnecting or connecting the hoses.
2. With the engine NOT running, disconnect the
pressure hose at the power steering pump and
install power steering tester 5-8840-0135-0 as
shown in the illustration. The gage must be between
the shutoff valve and pump. Open the shutoff valve.
(3) Power Steering Unit

(4) Power Steering Pump
3. Check the fluid level. Fill the reservoir with power

steering fluid, to the "Full" mark. Start the engine,
then turn the steering wheel and momentarily hold it
against a stop (right or left). Turn the engine off and
check the connections at tester for leakage.
4. Bleed the system. Refer to Bleeding the Power
Steering System in this section.
5. Start the engine and check the fluid level. Add
power steering fluid if required. When the engine is
at normal operating temperature, increase engine
speed to 1500 rpm.
CAUTION: Do not leave shutoff valve fully closed
for more than 5 seconds, as the pump could
become damaged internally.

6. Fully close the shutoff valve. Record the highest
pressures.
If the pressure recorded is within 9300-9800 kPa
2
(95-100 kg/cm /1350-1420 psi), the pump is
functioning within its specifications.
If the pressure recorded is higher than 9800 kPa
2
(100 kg/cm /1420 psi), the valve in the pump is
defective.
If the pressure recorded is lower than 9300 kPa (95
2
kg/cm /1350 psi), the valve or the rotating group in
the pump is defective.
7. If the pump pressures are within specifications,
leave the valve open and turn (or have someone
else turn) the steering wheel fully in both directions.
Record the highest pressures and compare with the
maximum pump pressure recorded in step 6. If this
pressure cannot be built in either side of the power
steering unit, the power steering unit is leaking
internally and must be replaced.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level
and make the needed repairs.
10. If the problem still exists, the steering and front
suspension must be thoroughly examined.
Maintenance
The hydraulic system should be kept clean and fluid
level in the reservoir should be checked at regular
intervals and fluid added when required. Refer to
Recommended Fluids and Lubricants in General
Information section for the type of fluid to be used and
the intervals for filling.
If the system contains some dirt, flush it as described in
this section. If it is exceptionally dirty, the pump must be
completely disassembled before further usage. (The
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
kinked or tightly bent. Air in the system will cause
spongy action and noisy operation. When a hose is
disconnected or when fluid is lost, for any reason, the
system must be bled after refilling. Refer to Bleeding the
Power Steering System in this section.
Inspect belt for tightness.
Inspect pulley for looseness or damage. The pulley
should not wobble with the engine running.
Inspect hoses so they are not touching any other
parts of the vehicle.
Inspect fluid level and fill to the proper level.
Fluid Level
1. Run the engine until the power steering fluid
reaches normal operating temperature, about 55
C (130F), then shut the engine off.
2. Check the level of fluid in the reservoir.
3. If the fluid level is low, add power steering fluid as

specified in General Information to the proper level
and install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from
the system. Refer to Bleeding the Power Steering
System in this section.
Bleeding The Power Steering System

When a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
entered the system must be bled out before the vehicle
is operated. If air is allowed to remain in the power
steering fluid system, noisy and unsatisfactory operation
of the system may result.
Bleeding Procedure
When bleeding the system, and any time fluid is added
to the power steering system, be sure to use only power
steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and
let the fluid settle for at least two minutes.
2. Start the engine and let it run for a few seconds. Do
not turn the steering wheel. Then turn the engine
off.
3. Add fluid if necessary.
4. Repeat the above procedure until the fluid level
remains constant after running the engine.
5. Raise and support the front end of the vehicle so
that the wheels are off the ground.
6. Start the engine. Slowly turn the steering wheel right
and left, lightly contacting the wheel stops.
7. Add power steering fluid if necessary.
8. Lower the vehicle, set the steering wheel at the
straight forward position after turning it to its full
steer positions 2 or 3 times, and stop the engine.
9. Check the fluid level and refill as required.
10. If the fluid is extremely foamy, allow the vehicle to
set a few minutes, then repeat the above procedure.
Flushing The Power Steering System

1. Raise and support the front end of the vehicle off
the ground until the wheels are free to turn.
2. Remove the fluid return line at the pump inlet
connector and plug the connector port on the pump.
Position the line toward a large container to catch
the draining fluid.
3. While running the engine at idle, fill the reservoir
with new power steering fluid. Turn the steering
wheel in both directions. Do not contact or hold the
steering wheel to the wheel stops. This will cause
the pump to go to pressure relief mode, which may
cause a sudden fluid overflow at the reservoir.

4. Install all the lines and hoses. Fill the system with
new power steering fluid and bleed the system as
described in Bleeding The Power Steering System.
Operate the engine for about 15 minutes.
Remove the pump return line at the pump inlet and
plug the connection on the pump. While refilling the
reservoir, check the draining fluid for contamination.
If foreign material is still evident, replace all lines,
disassemble and clean or replace the power
steering system components. Do not re-use any
drained power steering fluid.
Front End Alignment Inspection and

Adjustment
Toe-in Adjustment
Toe-in: Refer to Section 3A FRONT ALIGNMENT
1. To adjust the toe-in angle, loosen the lock nuts (2)
on the tie rod (1) and turn the tie rod. Turn both rods
the same amount, to keep the steering wheel
centered .
Steering Wheel Free Play Inspection

431R30006
2. Tighten the lock nut to the specified torque.

Torque:
92 - 104 N
m (9.4 - 10.6 kg
m/68 - 77 lb ft)
060R300016
1. With the tires in the straight-ahead position, check

the amount of steering wheel play by turning the
wheel in both directions until the tires begin to move.
NOTE: The wheel free play should be checked with the
engine running.
Free play: 0 - 30 mm (0 - 1.18 in)
2. Also check the steering wheel for play and
looseness in the mount by moving it back and forth
and sideways. When test driving, check for hard
steering, steering shimmy and tendency to pull to
one side.
Torque Specification
Nm (kgm/Ibft)

RTW33BLF000101
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-0135-0
Tester;
Power steering
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-2297-0
Adapter;
Power steering tester
Power Steering Unit

Power Steering Unit and Associated Parts

431R300016
Legend
(1) Crossmember
(2) Power Steering Unit Assembly
(3) Bracket
(4) Universal joint (Steering shaft)
Removal
1. Remove the universal joint assembly.
Make a setting mark across the coupling flange and
steering unit to ensure reassembly of the parts in
the original position.
2. Drain power steering fluid.
3. Remove the tie rod end assembly from knuckle.

Use tie rod end remover 5-8840-2005-0.
Installation
901RW270
4. Disconnect the feed line and return line from

steering unit.
Remove the clips on the crossmember and frame.
Wire the power steering line to frame.
NOTE: Take care to prevent foreign matter from entry
when disconnect the power steering line.
5. Remove the power steering unit from the
crossmember.
1. Install power steering unit to crossmember.

Tighten fixing bolt and nut to specified torque.
Torque:
106 126 N
m (10.8 12.8 kg
m/78 - 93 lb ft)
Torque:
198 - 242 N
m (20.2 24.7 kg
m/146 - 178 lb ft)
2. Connect the feed line and return line.
Torque:
m (2.0 3.0 kg
m/14 - 22 lb ft)
20 - 29 N
3. Install tie-rod end assembly to knuckle.
Torque:
88 127 N
m (9.0 13.0 kg
m/65 - 94 lb ft)
4. Align the setting marks on the universal joint
(applied at disassembly) with the setting marks on
the power steering unit. Connect the universal joint
assembly to the power steering unit. Temporarily
tighten the universal joint bolts on the universal joint
assembly side.
5. Tighten the universal joint bolts (bolts at either end
of the joint temporarily tightened in Step 1 and 2) to
the specified torque.
6. Install the stone guard.
7. Bleed the system.
Refer to Bleeding the Power Steering System in this
section.
Power Steering Unit Disassembled View

440R300003
Legend
(1) Tie-rod End
(2) Lock Nut
(3) Clip
(4) Bellows
(5) Band
(6) Tie-rod Assembly
(7) Oil Line

(8) Inner Ball Joint Assembly
(9) Tab Washer
(10)Mounting Rubber
(11)Housing Assembly
Disassembly
4. Remove oil line, mounting rubber and dust cover.
NOTE: The valve housing is made of aluminum and

care should be exercised when clamping in a vise, etc.
to prevent distortion or damage.
1. Loosen lock nut and remove tie-rod end.
2. Remove clip and band, then remove bellows.
3. Remove tie-rod assembly.
To remove, move the boot toward the tie-rod end,
then remove tab washer.
Inspection and Repair

Inspect the following parts for wear, damage or any
abnormal conditions.
Tie-rod End
Reassembly
If looseness or play is found when checked by moving

the end of ball joint at tie-rod end, replace tie-rod end.
1. Install mounting rubber and dust cover (If removed).

2. Install oil line.
Torque: 10 - 15 N
m (1.0 1.5 kg
m/87 - 130 lb in)
3. Install tie-rod assembly with tab washer.
Apply grease to ball joint, install tie-rod and tab
washer, then tighten to specified torque.
Torque: 69 - 98 N
m (7.0 10.0 kg
m/51 - 72 lb ft)
After tightening, bend tab washer against width
across flat of inner ball joint.
4. Apply a thin coat of grease to the shaft for smooth
installation. Then install bellows.
5. Install band and clip.
6. Install tie-rod end and tighten lock nut.
Torque:
92 - 104 N
m (9.4 10.6 kg
m/68 - 77 lb ft)
Tie-rod Assembly
If the resistance is insufficient or play is felt when
checked by moving the ball on the tie-rod, replace the
tie-rod assembly.
Rubber Parts
If wear or damage is found through inspection, replace
with new ones.
Main Data and Specifications

General Specifications
2WD
Steering unit
Power steering
Type
Rack stroke mm (in)
Lock to lock
4WD
Without
138 (5.43)
4.84
With
Rack and pinion
138 (5.43)
3.38
152 (5.98)
3.26
Torque Specifications
Nm (kgm/Ibft)

RTW33LF000201
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-2005-0
(J-29107)
Tie rod end remover
Power Steering Pump

Power Steering Pump and Associated Parts (4JH1-TC, 4JA1-TC, 4JA1-L)
442R300002
Legend
(1) Pump Assembly
(2) Hose, Suction
Removal
1.
2.
3.
4.
5.
6.
Remove the drive belt.

Remove the pulley
Place a drain pan below the pump.
Disconnect the suction hose.
Disconnect the flexible hose.
Remove the power steering fixing bolt and remove
the pump assembly.
Installation
1. Install the pump assembly to the pump braket,
tighten the fixing bolt to the specified torque.
Torque: 34 - 46 Nm (3.5 4.7 kgm/25 - 34 lb ft)
(3) Hose, Flexible

(4) Bolt
2. Install the flexible hose.

Tighten the eye bolt to specified torque.
3. Install the pulley and tighten the bolt to the specified
torque.
4. Install the drive belt.
5. Connect the suction hose, then fill and bleed system.
section.
Power Steering Pump Disassembled View
442R300001-X
Legend
(1) Bolt
(2) Suction Pipe
(3) O-ring
(4) Shaft Assembly
(5) Oil Seal
(6) Front Housing
(7) O-ring
(8) O-ring
(9) Side Plate
(10) Rotor and Vane
(11) Pin
(12) Cam
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Pump Cartridge Assembly

O-ring
Snap Ring
Rear Housing
Bolt
Spring
Relief Valve
O-ring
Connector
Bush
Plley
Disassembly
Vane
1. Clean the oil pump with solvent (plug the discharge

and suction ports to prevent the entry of solvent).
Be careful not to expose the oil seal of shaft
assembly to solvent.
2. Remove the bolt, suction pipe and O-ring.
3. Remove the connector, O-ring, relief valve and
spring.
4. Remove the bolt, rear housing and O-ring.
5. Remove the snap ring.
6. Remove the shaft assembly.
7. Remove the oil seal.
CAUTION: When removing the oil seal, be careful
not to damage the housing.
8. Remove the pump cartridge assembly from the front
housing.
9. Remove two O-rings.

Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection.
Rotor
442RS003
Sliding faces of the vane should be free from wear.

(Particularly the curved face at the tip that contact with
the cam should be free from wear and distortion). When
part replacement becomes necessary, the pump
cartridge should be replaced as a subassembly.
Cam
The inner face of the arm should have a uniform contact
pattern without a sign of step wear. When part
replacement becomes necessary, the pump cartridge
should be replaced as a subassembly.
Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finger
nail.
The parts with minor scores may be reused after lapping
the face.
Relief Valve
442RS002
Check that the groove in the vane is free from excessive

wear and that the vane slides smoothly. When part
The sliding face of the valve must be free from burrs

and damage. The parts with minor scores may be
reused after smoothing with emery cloth (#800 or finer).
Shaft
Oil seal sliding faces must be free from a step wear
which can be felt by the finger nail. Bushing fitting face
must be free from damage and wear.
O-ring, Oil Seal, Snap Ring

Be sure to discard used parts, and always use new
parts for installation. Prior to installation, lubricate all
seals and rings with power steering fluid.
Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts for
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
housing.
2. Install shaft assembly.
3. Install the vanes to roter with curved face in contact
with the inner wall of cam.
4. Install roter and vanes to cam.

5. Install pin to front housing.
6. Install two new O-rings to front housing. Be sure to
discard used O-ring.
7. Install side plate.
CAUTION: When installing side plate, be careful not
to damage its inner surface. Damaged side plate
may cause poor pump performance, pump seizure
or oil leakage.
8. Install pump cartridge assembly to front housing.
9. Install snap ring to shaft end.
10. Install rear housing with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it
to specified torque.
Torque: 22-26 N
m (2.2-2.7kg
m/16-20 lb ft)
11. Install suction pipe with a new O-ring. Be sure to
Torque: 7.8-12 N
m (0.8-1.2kg
m/69-104 lb in)
12. Install relief valve and spring.
13. Install connector with a new O-ring. Be sure to
discard used O-ring. Tighten the connector to
specified torque.
Torque: 49-69 N
m (5.0-7.0kg
m/36-51 lb ft)
442RS005

Oil pump
Type
Operating fluid
Vane
ATF DEXRONIII
4JH1-TC, 4JA1-TC, 4JA1-L
Nm (kgm/Ib ft)
RTW43BLF000501
Power Steering Pump and Associated Parts (C24SE)
RTW33BLF000801
Legend
(1) Pump Assembly
(2) Hose, Suction
(3) Hose, Flexible
Removal
1.
2.
3.
4.
5.
6.
7.

Remove the pulley
Disconnect the oil pressure switch connector.
the pump assembly.
Installation
Torque: 34-46 Nm (3.5-4.7 kgm/25-34 lb ft)
(4) Bolt
(5) Connector, Pressure switch
2. Connector the oil pressure switch connector.

4. Install the pulley and tighten the bolt to the specified
torque.
6. Connect the suction hose, then fill and bleed
system.
section.
RTW43BMF000101
Legend
(1) Bolt
(2) Suction Pipe
(3) O-ring
(4) Shaft
(5) O-ring
(6) Front Housing
(7) O-ring
(8) O-ring
(9) Side plate
(10) Roter and vane
(11) Pin
(12) Cam
(13) Pump Cartridge
(14) O-ring
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Snap Ring
Rear Housing
Bolt
Spring
Relief Valve
O-ring
Connector
Bush
Pressure Switch Assembly
Disassembly
Rotor

and suction ports to prevent the entry of solvent). Be
careful not to expose the oil seal of shaft assembly
to solvent.
Remove the O-ring.
spring.
4. Remove the pressure switch assembly.
housing.

442RS002

Vane
442RS003

Cam
Side Plate
nail. The parts with minor scores may be reused after
lapping the face.

Valve
Shaft
which can be felt by the finger nail. Needle bearing fitting
face must be free from damage and wear.
O-ring, Oil Seal, Retaining Ring

Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. If
system fails to function properly, disconnect connector
at the pressure switch and repeat system check while
testing continuity across disconnected SW connector.
Reassembly
installation.
housing.
442RS005
4. Install rotor and vanes to cam.

or oil leakage.
Torque: 7.8-12 Nm (0.8-1.2 kgm/6-9 lb ft)
specified torque.
14. Install pressure switch assembly and tighten it to
specified torque.

Oil pump
Type
Operating fluid
Vane
ATF DEXRONIII
C24SE
Nm (kgm/Ib ft)
RTW43BLF000401
Power Steering Pump and Associated Parts (6VE1)
RTW33BLF000701
Legend
(1) Pump Assembly
(2) Hose, Suction
(3) Hose, Flexible
Removal
1.
2.
3.
4.
5.
6.

Disconnect the oil pressure switch connector.
the pump assembly.
Installation
(4) Bolt
(5) Connector, Pressure switch
2. Connector the oil pressure switch connector.

5. Connect the suction hose, then fill and bleed
system.
section.
RTW43BMF000301
Legend
(1) Bolt
(2) Suction Pipe
(3) O-ring
(4) Shaft Assembly
(5) Oil Seal
(6) Front Housing
(7) O-ring
(8) O-ring
(9) Side Plate
(10) Rotor and Vane
(11) Pin
(12) Cam
Disassembly
and suction ports to prevent the entry of solvent). Be
careful not to expose the oil seal of shaft assembly
to solvent.
Remove the O-ring.
spring.
4. Remove the pressure switch assembly.
(13)
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
Pump Cartridge Assembly

O-ring
Snap Ring
Rear Housing
Bolt
Spring
Relief Valve
O-ring
Connector
Bush
Pressure Switch Assembly

housing.
Cam


Rotor
Side Plate
nail.
The parts with minor scores may be reused after lapping
the face.
Relief Valve
Shaft
which can be felt by the finger nail. Bushing fitting face
must be free from damage and wear.
442RS002

O-ring, Oil Seal, Snap Ring

Pressure Switch
Vane
Check the switch operation as follows:

With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. If
system fails to function properly, disconnect connector
at the pressure switch and repeat system check while
testing continuity across disconnected SW connector.
Reassembly
installation.
housing.
442RS003


442RS005
4. Install rotor and vanes to cam.

or oil leakage.
Torque: 7.8-12 Nm (0.8-1.2 kgm/6-9 lb ft)
specified torque.
14. Install pressure switch assembly and tighten it to
specified torque.

Oil pump
Type
Operating fluid
Vane
ATF DEXRONIII
6VE1
Nm (kgm/Ib ft)
RTW43BMF000401
Supplemental Restraint System Steering Wheel & Column

Service Precaution
This steering wheel and column repair section covers
the Supplemental Restraint System (SRS) steering
column. The following repair procedures are specific to
SRS components. When servicing a vehicle equipped
with Supplemental Restraint System, pay close attention
to all WARNINGS and CAUTIONS.
For detailed explanation about SRS, refer to Restraints
section.
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE
SRS COMPONENTS OR THE SRS WIRING, REFER
TO THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
SAFE HANDLING OF INFLATOR MODULES
REQUIRES
FOLLOWING
THE
PROCEDURES
DESCRIBED BELOW FOR BOTH LIVE AND
DEPLOYED MODULES.
SAFETY PRECAUTIONS MUST BE FOLLOWED
WHEN HANDLING A DEPLOYED AIR BAG
ASSEMBLY (AIR BAG). AFTER DEPLOYMENT, THE
AIR BAG ASSEMBLY (AIR BAG) SURFACE MAY
CONTAIN A SMALL AMOUNT OF SODIUM
HYDROXIDE,
A
BY-PRODUCT
OF
THE
DEPLOYMENT REACTION, THAT IS IRRITATING TO
THE SKIN AND EYES. MOST OF THE POWDER ON
THE AIR BAG ASSEMBLY (AIR BAG) IS HARMLESS.
AS A PRECAUTION, WEAR GLOVES AND SAFETY
GLASSES WHEN HANDLING A DEPLOYED AIR BAG
ASSEMBLY, AND WASH YOUR HANDS WITH MILD
SOAP AND WATER AFTERWARDS.
WHEN CARRYING A LIVE AIR BAG ASSEMBLY,

MAKE SURE THE BAG AND TRIM COVER ARE
POINTED AWAY FROM YOU. NEVER CARRY AN AIR
BAG ASSEMBLY BY THE WIRES OR CONNECTOR
ON THE UNDERSIDE OF MODULE. IN THE CASE OF
AN ACCIDENTAL DEPLOYMENT, THE BAG WILL
THEN DEPLOY WITH MINIMAL CHANCE OF INJURY.
WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A
BENCH OR OTHER SURFACE, ALWAYS FACE THE
BAG AND TRIM COVER UP, AWAY FROM THE
SURFACE.
NEVER REST A STEERING COLUMN ASSEMBLY
ON THE STEERING WHEEL WITH THE AIR BAG
ASSEMBLY FACE DOWN AND COLUMN VERTICAL.
THIS IS NECESSARY SO THAT A FREE SPACE IS
PROVIDED TO ALLOW THE AIR BAG ASSEMBLY
TO EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL
DEPLOYMENT.
OTHERWISE,
PERSONAL INJURY COULD RESULT.
TO
AVOID
DEPLOYMENT
WHEN
TROUBLESHOOTING THE SRS SYSTEM, DO NOT
USE ELECTRICAL TEST EQUIPMENT, SUCH AS
BATTERY-POWERED OR A/C-POWERED VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN SPECIFIED
IN THIS MANUAL. DO NOT USE A NON-POWERED
PROBE-TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
INJURY MAY RESULT.
SRS Connectors
CAUTION: The special yellow color connectors are
used for supplemental restraint system-air bag
circuit.
When removing the cable harness, do not pull the
cables. Otherwise, cable disconnection may occur.
When connect the SRS connector, insert the
connector completely. Imperfect locking may cause
malfunction of SRS circuit.
Inflator Module
Inflator Module and Associated Parts
430R300013
Legend
(1) Horn Lead
(2) SRS Connector
(3) Steering Wheel
(4) Steering Wheel Fixing Nut

(5) Inflator Module or Horn Pad
Removal
1. Turn the steering wheel so that the vehicle's wheels
are pointing straight ahead.
2. Turn the ignition switch to "LOCK".
3. Disconnect the battery "-" terminal cable, and wait at
least 5 minutes. (with SRS air bag)
4. Disconnect the yellow 2-way SRS connector located
under the steering column. (with SRS air bag)
CAUTION: The wheels of the vehicle must be
straight ahead and the steering column in the
"LOCK" position before disconnecting the steering
wheel. Failure to do so will cause the coil assembly
to become uncentered which will cause damage to
the coil assembly. (with SRS air bag)
7. Check the position of the pins in a hole. Push the

pin in the direction of an arrow. (with SRS air bag)
5. Disable the SRS (Refer to "Disabling the SRS" in

this section). (with SRS air bag)
6. Check the both side hole of the steering cover. (with
SRS air bag)
060R300032
8. Push the four pins at 56 mm bar. (with SRS air

bag)
060R300025
060R300031
9. Cancel the lock four pins. (with SRS air bag)

10. Loosen the horn pad fixing screw at the rear of the
steering wheel (without SRS air bag).
12. Remove the horn pad and the horn leads at the
center of the wheel (without SRS air bag).
NOTE: It removes previosly from the spoke bottom.
430R300009
11. Disconnect the SRS air bag connector and horn

lead connector located behind the air bag assembly
and remove the air bag assembly. (with SRS air
bag)
RTW43BSH000201
WARNING: THE INFLATOR MODULE SHOULD

ALWAYS BE CARRIED WITH THE COVER AWAY
FROM YOUR BODY AND SHOULD ALWAYS BE
LAID ON A FLAT SURFACE WITH THE COVER SIDE
UP. THIS IS NECESSARY BECAUSE A FREE SPACE
IS PROVIDED TO ALLOW THE AIR CUSHION TO
EXPAND
IN
THE
UNLIKELY
EVENT
OF
ACCIDENTAL
DEPLOYMENT.
OTHERWISE,
PERSONAL INJURY MAY RESULT. (with SRS air
bag)
060R300041
430R300007
Inspection and Repair (with SRS air

bag)
The inflator module consists of a cover, air bag, inflator,
and retainer. Inspect the inflator module mainly for the
following:
Check for holes, cracks, severe blemishes and
deformation on the cover.
Check that the retainer is not deformed.
Check for defects such as damage and breakage in
the lead wire for the igniter.
If an abnormality is found as the result of the inspection,
replace the inflator module with a new one.
2. Connect the horn leads at center of wheel. (without

SRS air bag)
NOTE: Horn leads is letting a bracket top pass.
(Plastic type steering wheel only)
Installation
1. Support the inflator module and carefully connect the
SRS connector and horn lead. (with SRS air bag)
RTW43BSH000301
3. Push the born pad area 1-4.

Tighten the born pad fixing screw to the specifed
torque (without SRS air bag)
m (0.2 0.4 kg
m/17 - 35 lb ft)
Torque: 2 - 4 N
NOTE: A horn pad is not struck at the time of
attachment.
060R300041
RTW43BSH000401

3. Align the each snap stud of driver air bag to the hole
of steering wheel. (with SRS air bag)
060R300030
4. Push the SRS air bag area1 and area2. At that time
confirm the audible noise of each stud.
060R300036
5. Enable the SRS (Refer to "Enabling the SRS" in this

section). (with SRS air bag)
6. Connect the SRS connector. (with SRS air bag)
7. Connect the battery "-" terminal cable. (with SRS air
bag)
8. Turn the ignition switch to "ON" while watching
warning light and check the light should flash 7 times
and then go off. If lamp does not operate correctly,
refer to Restraints section.
060R300020
Steering Wheel
Steering Wheel and Associated Parts
430R300013
Legend
(1) Horn Lead
(2) SRS Connector
(3) Steering Wheel
Removal
(4) Steering Wheel Fixing Nut



SRS air bag)

bag)
060R300025
060R300031


060R300032
430R300009

bag)
430R300007
060R300041
NOTE: It removes previously from the spoke bottom.
13. Apply a setting mark (1) across the steering wheel

and shaft so parts can be reassembled in their
original position. Move the front wheels to the
straight ahead position, then use steering wheel
remover 5-8521-0016-0 to remove the steering
wheel.
430R300008
RTW33BSH000401

EXPAND
IN
THE
UNLIKELY
EVENT
OF
ACCIDENTAL
DEPLOYMENT.
OTHERWISE,
bag)
CAUTION: Never apply force to the steering wheel in

direction of the shaft by using a hammer or other
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.

2. Tighten the steering wheel fixing nut to the specified
torque.
m (3.2 4.0 kg
m/23 - 29 lb ft)
Torque: 31 - 39 N
3. Support the inflator module and carefully connect the
SRS connector and horn lead. (with SRS air bag)
430RX005-X
14. Remove steering column cover.

15. Disconnect the wiring harness connectors located
under the steering column then remove combination
switch and SRS coil assembly.
Installation
060R300041
1. Align the setting marks made when removing then

install steering wheel.
Refer to the adjustment method in case a mark is
not attached in this section.
NOTE: Confirm SRS and Horn harness connector is
fixed by the steering wheel.

SRS air bag)
RTW43BSH000301
RTW33BSH000601

absorbing unit.

Torque: 2 - 4 N
m (0.2 0.4 kg
m/17 - 35 lb ft)
attachment.
060R300020
confirm the audible noise of each stud. (with SRS air
bag)
RTW43BSH000401
060R300036
060R300030

bag)
The adjustment method in case a mark is not attached

with SRS air bag
430R300011
without SRS air bag
430R300010
Combination Switch
Combination Switch and Associated Parts

RTW43BLF000601
Legend
(1) Steering Column Cover
(2) Steering Wheel
Removal
(4) Combination Switch and SRS Coil Assembly

(5) Instrument Panel Lower Cover
(6) Driver Knee Bolster (reinforcement)

5. Remove the engine hood opening lever, then
remove instrument panel lower cover.
6. Remove the driver knee bolster (reinforcement).

8. Check the both side hole of the steering cover.
bag)
060R300025

060R300032
430R300009
060R300031

bag)
430R300007
060R300041

wheel.
430R300008
RTW43BSH00201

EXPAND
IN
THE
UNLIKELY
EVENT
OF
ACCIDENTAL
DEPLOYMENT.
OTHERWISE,
bag)

absorbing unit.
When
turning
the
SRS
coil
CAUTION:
counterclockwise to full, stop turning if resistance
is felt. Forced further turning may damage the cable
in the SRS coil. (with SRS air bag)
430RX005-X

under the steering column then remove combination
switch and SRS coil assembly. (with SRS air bag)
NOTE: The SRS coil is a part of the combination switch
assembly, which can not be replaced separately.
Therefore, be sure not to remove the SRS coil from the
combination switch assembly. (with SRS air bag)
826RW014
Legend
(1) Neutral mark
3. Connect the wiring harness connectors located at

the base of steering column.
4. Install the air conditioning lower duct.
5. Install the steering column cover.
CAUTION: When installing the steering column
cover, be sure to wire (through each harness) as
illustrated so that the harness starter switch,
combination switch and SRS coil may not catch
wiring. (with SRS air bag)
430R300014
Installation
1. Install the combination switch assembly with SRS
coil. (with SRS air bag)
2. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark. (with SRS
air bag)
825RS048

6. Install the driver knee bolster assembly.
7. Install the steering lower cover and engine hood
opening lever.
8. Install the steering wheel and align the setting
marks.

SRS air bag)
RTW43BSH000301
RTW33BSH000601

absorbing unit.

m (0.2 0.4 kg
m/17 - 35 lb ft)
Torque: 2 - 4 N
attachment.

torque.
Torque: 31 - 39 N
m (3.2 4.0 kg
m/23 - 29 lb ft)
10. Support the inflator module and carefully connect
the SRS connector and horn lead. (with SRS air
bag)
RTW43BSH00040
060R300010

bag)
060R300030
060R300036

16. Install driver knee bolster (reinforcement).
17. Install instrument panel lower cover then Install the
engine hood opening lever.
bag)
060R300020
Lock Cylinder
Lock Cylinder and Associated Parts

RTW43BLF000701
Legend
(2) Steering Wheel
(3) Inflator Module or Horn pad
Removal
(5)
(6)
(7)
(8)
Steering Column Assembly

Lock Cylinder Assembly
Instrument Panel Lower Cover
Driver Knee Bolster (reinforcement)


bag)
5. Remove the engine hood opening lever and

steering lower cover.
6. Remove driver knee bolster (reinforcement).
SRS air bag)
060R300031
060R300025

430R300009
060R300032

bag)
430R300008
060R300041
16. Move the front wheels to the straight ahead position,

then use steering wheel remover 5-8521-0016-0 to
remove the steering wheel.
absorbing unit.
RTW43BSH00201

original position.
430RX005-X

EXPAND
IN
THE
UNLIKELY
EVENT
OF
ACCIDENTAL
DEPLOYMENT.
OTHERWISE,
bag)

21. Insert a pin (1) into the hole and push on it. Pull the
key cylinder free.
430R300007

under the steering column.
19. Remove the combination switch assembly with SRS
coil.
combination switch assembly. (with SRS air bag)
P1010003
Installation
1. Install lock cylinder assembly.
coil. (with SRS air bag)
air bag)
When
turning
the
SRS
coil
CAUTION:
is felt. Forced further turning may damage the cable
in the SRS coil. (with SRS air bag)
430R300014
20. Turn the ignition switch to the ACC position.
826RW014
Legend
(1) Neutral mark

8. Support inflator module and carefully connect the
SRS connector and horn lead, then install inflator
module. (with SRS air bag)
825RS048

opening lever.
6. Install the steering wheel and align the setting marks.
Refer to the adjustment method in case a mark is not
attached in this section.
060R300010

SRS air bag)
NOTE: Horn leads is letting a bracket type pass.
RTW43BSH000301
RTW33BSH000601

absorbing unit.
torque.
m (3.2 4.0 kg
m/23 - 29 lb ft)
Torque: 31 - 39 N

Torque: 2 - 4 N
m (0.2 0.4 kg
m/17 - 35 lb ft)
attachment.
060R300020
bag)
RTW43BSH000401
060R300036
060R300030

15. Install instrument panel lower cover, then install the
engine hood opening lever.
16. Connect the yellow 2-way SRS connector located
bag)
System Inspection (with SRS air bag)

Turn the ignition switch to "ON" while watching warning
light.
The light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints section.
Steering Column
Steering Column and Associated Parts

RTW43BLF000201
Legend
(2) Steering Wheel
(5) Steering Column Assembly
Removal
(6)
(7)
(8)
(9)
Second Steering Shaft

Lower Second Steering Shaft
Instrument Panel Lower Cover
Driver Knee Bolster (reinforcement)


CAUTION: The wheel of the vehicle must be straight
ahead and the steering column in the "LOCK"
position before disconnecting the steering column
from the steering gear. Failure to do so will cause
the SRS coil assembly to become uncentered which
will cause damage to the SRS coil assembly. (with
SRS air bag)
bag)
5. Remove the engine hood opening lever and

steering lower cover.
6. Remove the driver knee bolster (reinforcement).
SRS air bag)
060R300031
060R300025

430R300009
060R300032

bag)

wheel.
060R300041
430R300008
430RX005-X
RTW33BSH000401

18. Remove the combination switch assembly with SRS
coil.
combination switch assembly.
23. Apply a setting mark (1) across the universal joint

and transfer gear to reassemble the parts in their
original position, then remove steering column
assembly and second shaft.
NOTE: A setting mark can be easily made if the shaft is
withdrawn a little by loosening the steering shaft
universal joint.
RTW33BSH000501
430R300014
19.
20.
21.
22.
Remove snap ring.

Remove cushion rubber.
Remove shift lock cable (For A/T).
Disconnect the starter switch harness connector
located under the steering column, then remove
lock cylinder assembly.
Inspection
If the abnormal conditions are found through inspection,
replace the steering column assembly.
Column Capsule
Check capsules on steering column bracket assembly;
all must be securely seated in bracket slots and
checked for any loose conditions when pushed or pulled
by hand.
431RW030

Check clearance between capsule and bracket. If must
be within 1mm (0.039 in).
431RW031
Column Universal Joint (between the

power steering unit and the steering shaft)
If the resistance is felt when checked by rotate the joint,
replace the lower second steering shaft.
Shaft Universal Joint (between the lower

second steering shaft and the second
steering shaft)
If the resistance is felt when checked by rotate the joint,
replace the second steering shaft assembly.
Tilt Mechanism
Tilt mechanism should moves smoothly.
While locked the tilt mechanism, be sure the steering
column latch securely by pushing the steering wheel
upward and downward.
Installation
1. Align the setting marks on the second steering shaft
and the steering column assembly (applied at
disassembly).
2. Connect the steering column assembly to the second
steering shaft. Tighten the bolts to the specified
torque.
Torque: 26 - 36 N
m (2.7 3.7 kg
m/20 - 27 lb ft)
3. Thread the steering column assembly through the
hole in the dashpanel. Temporarily tighten the
steering column and the second steering shaft fixing
bolt.
4. Connect the lower second steering shaft and the
second steering shaft. Tighten the universal joint
bolts to the specified torque.
Torque: 26 - 36 N
m (2.7 3.7 kg
m/20 - 27 lb ft)
5. Tighten the steering column fixing bolt (pedal brkt
side) to the specified torque (This bolt was
temporarily tighten in Step 3).
Torque: 18 -23 N
m (1.8 2.3 kg
m/13 - 17 lb ft)
6. Tighten the second steering shaft fixing bolt to the
specified torque (This bolt was temporarily tightened
in Step 3)
Torque: 18 -23 N
m (1.8 2.3 kg
m/13 - 17 lb ft)
7. Tighten the steering column fixing bolt (dashpanel
side) to the specified torque (This bolt was
temporarily tighten in Step 3).
Torque: 18 -23 N
m (1.8 2.3 kg
m/13 - 17 lb ft)
8. Install combination switch and SRS coil assembly.
After installation of combination switch assembly,
connect the combination switch wiring harness
connector and the SRS 2-way connector located

9. Turn the SRS coil counter clockwise to full, return
air bag)
CAUTION: When turning the SRS coil counter
clockwise to full, stop turning if resistance is felt.
Forced further turning may damage to the cable in
the SRS coil.
11. Install steering wheel and align the setting marks

made when removing.
RTW33BSH000601
826RW014
10. When installing the steering column cover, be sure to

route each wire harness as illustrated so that the
harnesses do not catch any moving parts.
825RW017
Legend
(2) Starter Switch Harness
(3) Combination Switch Harness
(4) Inflator Module Harness

absorbing unit.
torque.
Torque: 31 - 39 N
m (3.2 4.0 kg
m/23 - 29 lb ft)
13. Support the module and carefully connect the
module connector and horn lead, then install inflator
module.
NOTE: Pass the lead wire through the tabs on the
plastic cover (wire protector) of inflator to prevent lead
wire from being pinched.
14. Tighten bolts to specified torque.
Torque: 2 - 4 N
m (0.2 0.4 kg
m/17 - 35 lb in)
16. Install instrument panel lower cover.
17. Install the engine hood opening lever.
18. Connect the yellow 2-way SRS connector and horn
lead located under the steering column.
bag)
System Inspection (with SRS air bag)

Turn the ignition switch to "ON" while watching warning
light.
The light should flash 7 times and then go off. If lamp
does not operate correctly, refer to Restraints section.
Supplemental Restraint System Steering Wheel & Column and

Associated Parts
Nm (kgm/lb ft)

RTW43BLF000301
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8521-0016-0
(J-29752)
Steering wheel remover
FRONT SUSPENSION 3C-1
SECTION 3C
FRONT SUSPENSION
TABLE OF CONTENTS
PAGE
Main Data and Specifications ...........................................................................................3C- 2
Torque Specifications .......................................................................................................3C- 3
Special Parts Fixing Nuts and Bolts............................................................................3C- 3
Front Suspension ..............................................................................................................3C- 6
General Description ......................................................................................................3C- 6
Front Suspension (4
2 Except High Ride Suspension).............................................3C- 8
Front Suspension (4
2 High Ride Suspension, 4
4) .................................................3C- 30
Troubleshooting............................................................................................................3C- 54
3C-2 FRONT SUSPENSION

4
2 (EXCEPT HIGH RIDE SUSPENSION) MODEL
Front suspension
Type
Coil spring
Spring Rate
Front shock absorber
Type
Stroke
Compressed length
Extended length
Diameter
Stabilizer bar
Independent wishbone arms, coil spring

with stabilizer bar.
4JH1-TC / 4JA1-TC / 4JA1-L (ENGINE); 9.62 kg/mm
(94.3 N/mm)
C24SE (ENGINE); 7.94 kg/mm (77.9 N/mm)
Gas-sealed. Hydraulic, double acting
116.5 mm (4.59 in)
284.0 mm (11.18 in)
400.5 mm (15.77 in)
25.0 mm (0.98 in)
4
2 (HIGH RIDE SUSPENSION) MODEL
Front suspension
Type
Torsion bar spring
Length
Diameter
Type
Stroke
Compressed length
Extended length
Diameter
Stabilizer bar
Independent wishbone arms, torsion bar spring

1142 mm (44.96 in)
29.0 mm (1.14 in)
121.0 mm (4.76 in)
257.0 mm (10.12 in)
378.0 mm (14.88 in)
26.0 mm (1.02 in)
4
4 MODEL
Front suspension
Type
Torsion bar spring
Length
Diameter
Type
Stroke
Compressed length
Extended length
Diameter
Stabilizer bar
Independent wishbone arms, torsion bar spring

1142 mm (44.96 in)
29.0 mm (1.14 in)
121.0 mm (4.76 in)
257.0 mm (10.12 in)
378.0 mm (14.88 in)
26.0 mm (1.02 in)
TORQUE SPECIFICATIONS
4
2 (Except High Ride Suspension) Model
Nm (kgfm/lbft)
RTW440LF001001
4
Nm (kgfm/lbft)
RTW440MF000201
4
4 Model
Nm (kgfm/lbft)
RTW440LF001101
FRONT SUSPENSION
GENERAL DESCRIPTION
4
4
4 Model
RTW340LF000801
The links attach to the vehicle with bolts and bushings at their inner pivot points and to the steering knuckle, which
is part of the front wheel spindle, at their outer points.
The knuckle is mounted to the upper and lower links each of which has a ball joint to permit pivoting of the knuckle
for steering operations. The hub is supported in position on the knuckle spindle by means of the two bearings and
the rotor is mounted to the hub.
The front suspension is an independent type utilizing torsion bar springs (44, 42 (High ride suspension)) and coil
springs (42 (Except High ride suspension)). The torsion bar spring has splines on each end. Height control is
provided on the third crossmember. Both the upper and lower links are pressed steel and the torsion bar is
supported at the ends by lower link in front and by height control arm in rear.
FRONT SUSPENSION
(4
2 Except High Ride Suspension)
CONTENTS
Service Precaution.............................................
Shock Absorber .................................................
Shock Absorber and Associated Parts...........
Removal .........................................................
Installation.......................................................
Shock Absorber with Coil Spring ....................
Stabilizer Bar .....................................................
Stabilizer Bar and Associated Parts ...............
Removal .........................................................
Inspection and Repair.....................................
Installation.......................................................
Knuckle ..............................................................
Knuckle and Associated Parts........................
Removal .........................................................
Installation.......................................................
Upper Control Arm.............................................
Upper Control Arm and Associated Parts ......
Removal .........................................................
Installation.......................................................
3C-8
3C-9
3C-9
3C-9
3C-10
3C-12
3C-15
3C-15
3C-15
3C-15
3C-16
3C-17
3C-17
3C-17
3C-18
3C-18
3C-19
3C-19
3C-19
3C-20
3C-20
Lower Control Arm.............................................

Lower Control Arm and Associated Parts ......
Removal .........................................................
Installation ......................................................
Upper Ball Joint .................................................
Upper Ball Joint and Associated Parts ...........
Removal .........................................................
Installation ......................................................
Lower Ball Joint .................................................
Lower Ball Joint and Associated Parts ...........
Removal .........................................................
Installation ......................................................
Bump Rubber ....................................................
Bump Rubber Joint and Associated Parts......
Removal .........................................................
Installation ......................................................
Special Tools ..................................................
3C-21
3C-21
3C-21
3C-22
3C-22
3C-23
3C-23
3C-23
3C-24
3C-24
3C-25
3C-25
3C-25
3C-26
3C-26
3C-27
3C-27
3C-27
3C-27
3C-27
3C-28
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM
REPAIRS.
CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (Paints, greases, or
other corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener.
When you install fasteners, use the correct
tightening sequence and specifications. Following
these instructions can help you avoid damage to
parts and systems.
Shock Absorber
Shock Absorber and Associated Parts
RTW440LF001201
Legend
(1) Shock Absorber ASM with coil
(2) Nut
(3) Nut
(4) Nut
Removal
1. Raise the vehicle and support it with suitable
safety stands.
(5) Lower ball joint Nut and cot ter pin

(6) Nut
(7) Bolt
(8) Cam bolt
2. Remove wheel and tire assembly. Refer to Wheel

Replacement in this section.
3. Remove nut (6).
CAUTION: Be careful not o break the ball joint boot.

4. Support lower control arm with a jack.
5. Remove the bolt (7) and nut (4).
6. Remove lower ball joint nut and cotter pin(5), then
use remover 5-8840-2017-0 to remove the lower
ball joint from the knuckle.
7. Apply the setting marks to the front and rear cam

bolt and cross member, then loosen nut, and cam
bolt.
8. Remove the nut (2).
9. Remove to Shock Absorber ASM.
P1010003
Installation
1. Install shock absorber.
RTW340MF000801

NOTE: Paint mark to be outer side of after assembly to
vehicle.
2. Install nut (2), then tighten it to the specified
torque.
Torque: 55Nm (5.6kgm/41lb ft)
3. Install bolt (7) and nut (4), then tighten to the
specified torque.
Buffer clearance: 25.9 mm (1.02 in)
Torque: 137Nm (14.0kgm/101 lb ft)
7. Nut (3) tighten it to the specified torque.

NOTE: Apply oil to the thread.
NOTE: Tighten the bolt and nut with the parts in the
position shown in the illustration below.

NOTE: Tighten the bolt and nut with the parts in the
RTW340SH001301-X
8. Install wheel and tire assembly. Refer to wheel in

this section.
RTW340SH001301-X
4. Install nut (6), then tighten it to the specified

torque.
5. Tighten the cam bolt (8) and nut (3), it to the
interim torque, then turn the cam bolt to the setting
mark applied during disassembly.
6. Install ball joint nut, then tighten it to the specified
torque with just enough additional torque to align
cotter pin holes. Install new cotter pin (5).
NOTE: Check the trim height. Refer to Front Alignment
Inspection and Adjustment.
Shock Absorber with Coil Spring
RTW340LF002101
Legend
1. Nut
2. Washer
3. Bushing ; Rubber
4. Mounting Bracket
5. Coil Spring
6. Bushing ; Rubber
7. Washer
8. Shock Absorber ASM
Disassembly
1. Install the support fixture (5-8840-0595-0) to the base (58840-003-0).
2. Install the upper adapter (5-8840-0597-0) and the lower
adapter (5-8840-0596-0) to the base and support fixture
assembly.
3. Install the shock absorber assembly to the support fixture.
4. Remove the nut with spring in place.
CAUTION:
Take care not to apply excessive force to the nut during
removal.
CAUTION :
The shock absorbers have been charged with gas at the
factory. Exposure to high temperatures or an open flame
can result in a dangerous explosion.
Keep the shock absorbers away from high temperatures
and open flames.

Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspections.
Visual Check
Inspect the following parts for wear, damage or other abnormal
conditions.
Shock absorber
Rubber bushing
Coil spring
Reassembly
1. Reassemble the parts inside the support fixture.
2. When tightening the bolt, compress the spring so that it
does not apply pressure to the spring seat.
3. Install the nut (1), then tighten to the specified torque.
Torque : 25 Nm (2.5 kgm/19 lb ft)
Stabilizer Bar
Stabilizer Bar and Associated Parts
RTW340LF000901
Legend
(1) Stabilizer Bar
(2) Link
(3) Nut
Removal
1. Raise the vehicle and support the frame with
suitable safety stands.
(4) Nut
(5) Bracket and Bolt
(6) Rubber Bushing
3. Remove nut (3) and (4).

CAUTION: Be careful not to break the ball joint
boot.
4.
5.
6.
7.
Remove link.
Remove bracket and bolt.
Remove stabilizer bar.
Remove rubber bushing.

Make necessary correction or parts replacement if
wear, damage, corrosion or any other abnormal
condition are found through inspection.
Check the following parts :
Stabilizer bar
Rubber bushing
Link ball joint
Installation
1. Install rubber bushing.
2. Install stabilizer bar.
3. Install bracket and bolt (5), then tighten it to the
specified torque.
Torque: 25 Nm (2.5kgm/18 lb ft)
4. Install link.
5. Install nut (3), (4), then tighten it to the specified
torque.
Knuckle
Knuckle and Associated Parts
450R300037
Legend
(1) Nut and Cotter Pin
(2) Back Plate
Removal
in this section.

(5) Knuckle
(6) Bolt
3. Remove the brake caliper. Refer to Disc Brakes in

Brake section.
4. Remove the hub assembly. Refer to Front Hub
and Disk in this section.
5. Remove tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.

6.
7.
8.
9.
Remove the stabilizer link nut. Right and left.

Remove the wheel speed sensor from the knuckle.
Remove back plate.
Remove lower ball joint by using remover 5-88402017-0.
CAUTION: Be careful not to damage the ball joint

boot.

Check the following parts:
Knuckle
Knuckle arm
Installation
1. Install knuckle assembly.
2. Install upper ball joint and tighten the nut to the
specified torque, with just enough additional torque
to align cotter pin holes. Install new cotter pin (1).
3. Install lower ball joint and tighten the nut to the
4. Install back plate.
5. Install wheel speed sensor.
6. Install stabilizer link nut. Right and left.
P1010009
10. Remove upper ball joint by using remover 5-88402017-0.

boot.
P1010011
11. Remove knuckle.
Upper Control Arm

Upper Control Arm and Associated Parts
450R300038
Legend
(1) Bolt
(2) Bushing
(3) Nut
(4) Upper Control Arm Assembly
(5) Upper Ball Joint
Removal
(7) Knuckle
(8) Nut
(9) Nut
(10) Bolt
(11) Nut
(12) Nut

in this section.
3. Remove nut (11).
4. Remove nut (12).

5. Remove nut (8).
boot.
P1010062
P1010005
7. Remove nut (3).

8. Remove bolt(1).
9. Remove bolt (10) and nut (9).
10. Remove upper ball joint.
11. Remove upper control arm assembly.
12. Remove bushing.

Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
2. Install upper ball joint and tighten it to the specified

torque (9).
3. Install nut (6) and cotter pin then tighten the nut to
the specified torque, with just enough additional
torque to align cotter pin holes. Install new cotter
pin.
4. Install upper control arm assembly.
5. Install bolt (1) and nut (3).
NOTE: Tighten the bolt (1) with the parts in the position
shown in the illustration below.
Upper control arm

Bushing
Installation
1. Install bushing by using installer 5-8840-0257-0
and 5-8840-2327-0.
RTW340SH001301-X
6. Install nut (12).

7. Install nut (11).
Lower Control Arm

Lower Control Arm and Associated Parts
RTW340LF002301
Legend
(1) Cam bolt
(2) Bush
(3) Cam plate
(4) Nut
(5) Nut
Removal
(6) Bolt
(7) Lower Ball Joint
(8) Nut and cotter pin
(9) Nut
(10) Nut
(11) Bolt

in this section.
3. Remove the tie-rod end from the knuckle. Refer to

4.
5.
6.
7.
Support lower control arm with a jack.

Remove the nut (10).
Remove the nut (8).
Remove the shock absorber lower end from the
lower control arm.
8. Remove the lower ball joint from the lower control
arm.
9. Remove nut (4) and cam plate.
10. Remove cam bolt.
11. Remove lower control arm.
12. Remove bushing.

NOTE: Tighten the nut (4) with the parts in the position

Lower control arm
Bushing
Installation
RTW340SH001301-X
1. Install rear bushing by using installer 5-88400257-0 and 5-8840-2327-0.
6. Install stabilizer link and tighten it to the specified

torque (10).
7. Install nut (4) and cam plate and tighten lower link
nut finger-tight.
NOTE: Tighten the nut (4) with the parts in the position
P1010063
2. Install lower control arm.

3. Install cam bolt.
4. Install lower ball joint and tighten it to the specified
torque (9).
5. Install shock absorber and tighten it to the
specified torque (5).
RTW340SH001301-X
8. Install nut (8) and cotter pin then tighten the nut to
the specified torque, with just enough additional
torque to align cotter pin holes. Install new cotter

pin.
Upper Ball Joint

Upper Ball Joint and Associated Parts
RTW340LF001101
Legend
(1) Bolt
Removal
2. Remove wheel and tire assembly. Refer to wheel
in this section.
3. Remove nut (5).
(3) Nut
(5) Nut
4. Remove upper ball joint nut and cotter pin, then

use remover 5-8840-2017-0 to remove the upper
boot and brake hose.
P1010005
450RS024
If the above limits specified are exceeded, replace the

ball joint assembly.

Installation

through inspection.
Inspect the lower end boot for damage or grease
leak. Move the ball joint as shown in the figure to
confirm its normal movement.
Inspect screw/taper area of ball for damage.
If any defects are found by the above inspections,
replace the ball joint assembly with new one.
450R300030
After moving the ball joint 4 or 5 times, attach nut

then measure the preload.
Starting torque: 1.3-3.2 Nm (0.13-0.33kgm/0.92.4 lb ft)
1. Install upper ball joint.

2. Install bolt (1) and nut (3), then tighten them to the
specified torque.
3. Install nut and cotter pin, then tighten the nut to the
specified torque with just enough additional torque
4. Install nut (5), then tighten to the specified torque.
Lower Ball Joint

Lower Ball Joint and Associated Parts
RTW340LF002201
Legend
Removal
in this section.
3. Remove the nut (4).
(3) Nut
(4) Nut
(5) Bolt
5. Remove lower ball joint nut and cotter pin, then


boot.

P1010003
6. Remove nut (3).

7. Remove bolt (5).
8. Remove lower ball joint.
450RS024
If the above limits specified are exceeded, replace

the ball joint assembly.

corrosion or any other abnormal condition are found
through inspection.
confirm its normal movement .
450RS026
Installation
1. Install lower ball joint.
2. Install bolt (5).
3. Install nut (3) and tighten it to the specified torque.
5. Install nut (4), then tighten to the specified torque.
Bump Rubber
Bump Rubber and Associated Parts
RTW340LF002601
Legend
(2) Bump Rubber
(1) Bolt
Removal
2. Remove bolt.
3. Remove bump rubber.

Bump Rubber
Installation
1. Install bump rubber.
2. Install bolt (1), then tighten it to the specified
torque.
2 Except High Ride Suspension)

Special Tools (4
ILLUSTRATION
PART NO.
PART NAME
5-8840-0595-0
Support; fixture
5-8840-0596-0
Adapter; lower
5-8840-0597-0
Adapter; Upper
5-8840-0003-0
Base
5-8840-2017-0
Ball joint remover
5-8840-0257-0
Installer; Upper and
lower arm bushing
ILLUSTRATION
PART NO.
PART NAME
5-8840-2327-0
Installer; Upper and
lower arm bushing
FRONT SUSPENSION
(4
4)
CONTENTS
Shock Absorber .................................................
Shock Absorber and Associated Parts...........
Removal .........................................................
Installation.......................................................
Stabilizer Bar .....................................................
Stabilizer Bar and Associated Parts ...............
Removal .........................................................
Installation.......................................................
Torsion Bar ........................................................
Torsion Bar and Associated Parts ..................
Removal .........................................................
Installation.......................................................
Knuckle ..............................................................
Knuckle and Associated Parts........................
Removal .........................................................
Installation.......................................................
Upper Control Arm.............................................
Upper Control Arm and Associated Parts ......
Removal .........................................................
3C - 29
3C - 30
3C - 30
3C - 30
3C - 30
3C - 30
3C - 31
3C - 31
3C - 31
3C - 31
3C - 32
3C - 33
3C - 33
3C - 33
3C - 34
3C - 34
3C - 36
3C - 36
3C - 36
3C - 38
3C - 38
3C - 39
3C - 39
3C - 39

Installation ......................................................
Lower Control Arm.............................................
Lower Control Arm and Associated Parts ......
Removal .........................................................
Installation ......................................................
Upper Ball Joint .................................................
Upper Ball Joint and Associated Parts ...........
Removal .........................................................
Installation ......................................................
Lower Ball Joint .................................................
Lower Ball Joint and Associated Parts ...........
Removal .........................................................
Installation ......................................................
Bump Rubber ....................................................
Bump Rubber and Associated Parts ..............
Removal .........................................................
Installation ......................................................
Special Tools ....................................................
3C - 40
3C - 41
3C - 43
3C - 43
3C - 44
3C - 45
3C - 45
3C - 47
3C - 47
3C - 47
3C - 48
3C - 48
3C - 49
3C - 49
3C - 49
3C - 50
3C - 50
3C - 51
3C - 51
3C - 51
3C - 51
3C - 51
3C - 52
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.

parts and systems.
Shock Absorber
Shock Absorber and Associated Parts
RTW340MF000901
Legend
(1) Nut
(2) Rubber Bushing and Washer
Removal
1. Raise the vehicle and support it with suitable
safety stands.
3. Remove bolt and nut.
4. Remove nut.
5. Remove rubber bushing and washer.
6. Remove shock absorber.
7. Remove rubber bushing and washer.

(3) Bolt and Nut

(4) Shock Absorber
(5) Rubber Bushing and Washer

Shock absorber
Rubber bushing
Installation
1.
2.
3.
4.
Install rubber bushing and washer.

Install shock absorber.
Install rubber bushing and washer.
Install nut (1), then tighten it to the specified
torque.
5. Install bolt and nut (3), then tighten to the specified
torque.
Stabilizer Bar
Stabilizer Bar and Associated Parts
RTW340MF000401
Legend
(1) Rubber Bushing
(2) Bracket and Bolt
(3) Link
Removal
2. Remove the stone guard.
4. Remove nut (4) and (6).
CAUTION: Be careful not to break the ball joint
boot.
5.
6.
7.
8.
Remove link.
Remove bracket.
Remove stabilizer bar.
Remove rubber bushing.
(4) Nut
(5) Stabilizer Bar
(6) Nut

Stabilizer bar
Rubber bushing
Link ball joint
Installation
1. Install rubber bushing.
2. Install stabilizer bar.
3. Install bracket and bolt (2), then tighten it to the
specified torque.
4. Install link.
5. Install nut (4), (6), then tighten it to the specified
torque.
Torsion Bar
Torsion Bar and Associated Parts
RTW340MF000501
Legend
(1) Adjust Bolt, End Piece and Seat
(2) Height Control Arm
(3) Torsion Bar
Removal
2. Apply the setting marks (1) to the adjust bolt and
end piece, then remove adjust bolt, end piece and
seat.
410RS004

3. Apply the setting marks(2) to the height control
arm and torsion bar, then remove height control
arm.
NOTE: Besco chassis grease shall be applied on
contact area of height control arm with frame.
(RH & LH Both side)
Installation
1. Apply grease to the serrated portions, then install
torsion bar. Make sure the bars are on their correct
respective sides and align the setting marks (3).
410RS007
410RS005
4. Apply the setting marks (3) to the torsion bar and

lower control arm, then remove torsion bar.
RTW340SH000301
RTW340SH000301

Torsion bar
Height control arm
Adjust bolt

Rubber seat
2. Apply grease to the portion that fits into the bracket

then install height control arm and align the setting
marks (2).
4. Apply grease to the serrated portions.

5. Install adjust bolt and seat, then turn the adjust bolt
to the setting mark (1) applied during disassembly.
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering
section.
410RS005
3. Apply grease to the bolt portion of the end piece

(4). Apply grease to the portion of the seat (5) that
fits into the bracket.
410RS008
410RS004
Knuckle
Knuckle and Associated Parts
RTW340LF001301
Legend
(1) Torsion Bar
(2 )Lower Ball Joint, Nut and Cotter Pin
(3) Back Plate
(4) Knuckle Assembly
(5) Knuckle
Removal
(6) Needle Bearing (44 Model Only)

(7) Thrust Washer (44 Model Only)
(8) Oil Seal (44 Model Only)
(9) Upper Ball Joint, Nut and Cotter Pin
(10) Speed Sensor harness

in this section.
3. Remove the brake caliper. Refer to Disc Brakes in
Brake section.

4. Remove the hub assembly. Refer to Front Hub
and Disk in this section.
5. Remove tie-rod end from the knuckle. Refer to
6. Remove the speed sensor from the knuckle.
7. Loosen torsion bar by height control arm adjust
bolt, then remove torsion bar. Refer to Torsion Bar
in this section.
8. Remove speed sensor harness.
9. Remove back plate.
10. Remove lower ball joint by using remover 5-88402005-0.

boot.

boot.
901RW272
12. Remove knuckle assembly.

13. Remove oil seal. If replacement required.
(44 Model Only)
14. Remove washer. If replacement required.
(44 Model Only)
15. Remove needle bearing by using remover 5-88402000-0 and sliding hammer 5-8840-0019-0.
If replacement required. (44 Model Only)
901RW271
(44 Model Only)

RTW340SH00401

Knuckle
Knuckle arm
Thrust washer (44 Model Only)
3. Use a new oil seal, and apply multipurpose type

grease to the area surrounded by the lip (approx. 2
g). Then use installer 5-8840-2127-0 and grip 58840-0007-0 to install oil seal. After fitting the oil
seal to the installer, drive it to the knuckle using a
hammer or bench press until the tool front face
contacts with the thrust washer. (44 Model Only)
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g) and
install needle bearing by using installer 5-88402128-0 and grip 5-8840-0007-0. (44 Model Only)
(44 Model Only)

901RW274
(44 Model Only)

901RW275
2. Apply multipurpose type grease to the thrust

washer, and install washer with chamfered side
facing knuckle. (44 Model Only)
4. Install knuckle assembly.

5. Install upper ball joint and tighten the nut to the
6. Install lower ball joint and tighten the nut to the
7. Install back plate.
8. Install speed sensor harness.
9. Install torsion bar, refer to Torsion Bar in this
section.
Alignment Inspection and Adjustment in Steering.
Upper Control Arm

Upper Control Arm and Associated Parts
RTW440LF001301
Legend
(1)Bolt and Plate
(2)Camber Shims
(3)Caster Shims
(4)Nut Assembly
(5)Upper Control Arm Assembly
(6)Fulcrum Pin
Removal
(7)Bushing
(8)Plate
(9)Nut
(10)Speed Sensor harness
(11)Nut and Cotter Pin
(12)Upper Ball Joint, Bolt and Nut

in this section.
3. Remove the brake caliper and disconnect brake
pipe. Refer to Disc Brakes in Brake section.

4. Support lower control arm with a harness.
5. Remove speed sensor harness.
6. Remove nut and cotter pin then remove knuckle
using remover 5-8840-2121-0.
15. Remove bushing (7) by using remover 5-88400256-0.

boot.
RTW340SH000501
RTW340SH000401

8. Remove bolt and plate.
9. Remove nut assembly.
10. Remove camber shims and note the positions and
number of shims.
11. Remove caster shims and note the positions and
number of shims.
12. Remove upper control arm assembly.
13. Remove nut (9).
14. Remove plate (8).
RTW340SH000601
16. Remove fulcrum pin (6).

through inspection.
Upper control arm
Bushing
Fulcrum pin
Installation
1. Install fulcrum pin.
2. Install bushing by using installer 5-8840-0256-0
and 5-8840-2307-0.
6. Install nut (9) and tighten fulcrum pin nut fingertight.

NOTE: Tighten the nut with the parts in the position
RTW340SH000701
450R100002
7. Install upper control arm assembly with the fulcrum

pin projections turned inward.
RTW340SH000801
3. Install upper ball joint and tighten it to the specified

torque (12).
4. Install nut and cotter pin then tighten the nut to the
5. Install plate (8).
8. Install the caster shims (2) between the chassis
RTW340SH000901
Legend
(1) Projection
(2) Outward

frame and fulcrum pin.
9. Install the camber shims (1) between the chassis
frame and fulcrum pin.
450R100004
10. Install nut assembly.

11. Install bolt and plate (1), then tighten the bolt to the
specified torque.
12. Install speed sensor harness.
Lower Control Arm

Lower Control Arm and Associated Parts
RTW33CLF000201
Legend
(1) Cam Bolt
(2)Bush, Front
(3) Cam Plate and Nut
(4) Nut, Rear
(5) Bush, Rear
(6) Bolt, Rear
(7) Bolt, Lower Ball Joint
(8) Bolt, Torsion Bar Arm

(9) Torsion Bar Arm Bracket and Nut
(10) Torsion Bar
(11) Lower Control Arm
(12) Lower Ball Joint and Nut
(13) Shock Absorber, Bolt and Nut
(14) Stabilizer Link and Nut

Front
Removal
in this section.
4. Remove the retaining ring from the front axle
driving shaft to release the shaft from hub. Refer to
Front Hub and Disc in Driveline/Axle section.
6. Remove cam plate and nut.
7. Remove rear nut.
8. Remove torsion bar, refer to Torsion Bar in this
section.
9. Remove torsion bar arm bracket.
10. Disconnect the stabilizer link at the lower control
arm.
11. Remove the shock absorber lower end from the
lower control arm.
12. Remove the lower ball joint from the lower control
arm.
13. Remove cam bolt.
14. Remove rear bolt.
15. Remove lower control arm.
16. Remove torsion bar arm bolt.
17. Remove lower ball joint bolt.
18. Remove front bushing by using remover 5-88402123-0.
901RW155
19. Remove rear bushing by using remover 5-88402124-0.

Front
Front
901RW051
901RW154
Front
901RW052

Lower control arm
Bushing
Installation
1. Install rear bushing by using installer 5-8840-21240.
Front
3.
4.
5.
6.
7.
Install lower ball joint bolt.

Install torsion bar arm bolt.
Install lower control arm.
Install rear bolt.
Install cam bolt the hole and projection are
upward.
8. Install lower ball joint and tighten it to the specified
torque (12).
9. Install shock absorber and tighten it to the
specified torque (13).
10. Install stabilizer link and tighten it to the specified
torque (14).
11. Install torsion bar arm bracket and tighten it to the
specified torque.
12. Install Torsion bar, refer to Torsion Bar in this
section.
13. Install rear nut and tighten lower link nut fingertight (4).
NOTE: Tighten the nut or bolt with the parts in the
901RW053
2. Install front bushing by using installer 5-88402123-0.

Front
450R100002
901RW156

14. Install cam plate and nut then tighten lower link nut
finger-tight.
NOTE: Tighten the nut (3) or bolt with the parts in the
Alignment Inspection and Adjustment in Steering
section.
450R100002
Upper Ball Joint

Upper Ball Joint and Associated Parts
RTW440LF001401
Legend
(1) Bolt and Nut
Removal
2. Remove the speed sensor from the knuckle.
3. Remove upper ball joint nut and cotter pin, then
use remover 5-8840-2121-0 to remove the upper

boot.

Starting torque: 1.33.2 Nm (0.13-0.33kgm/0.92.4 lb ft)
RTW340SH000401
4. Remove bolt and nut.

450RS024
If the above limits specified are exceeded, replace the

ball joint assembly.

through inspection.
confirm its normal movement.
450RS023
Installation
1. Install upper ball joint.
2. Install bolt and nut (1), then tighten them to the
specified torque.
3. Install nut and cotter pin, then tighten the nut to the
specified torque with just enough additional torque
Lower Ball Joint

Lower Ball Joint and Associated Parts
RTW340LF001601
Legend
(1) Bolt
Removal
in this section.
(3) Nut
4. Remove the retaining ring from the front axle

driving shaft to release the shaft from hub. Refer to
Front Hub and Disc in Driveline/Axle section.
6. Remove lower ball joint nut and cotter pin, then

boot.

901RW271
7. Remove nut.
8. Remove bolt.
9. Remove lower ball joint.
450RS024
If the above limits specified are exceeded, replace

the ball joint assembly.

corrosion or any other abnormal condition are found
through inspection.
confirm its normal movement .
450RS026
Installation
1. Install lower ball joint.
2. Install bolt.
Bump Rubber
Bump Rubber and Associated Parts
RTW340MF001001
Legend
(1) Bolt
(2) Bump Rubber
Removal
2. Remove bolt.
3. Remove bump rubber.

Bump Rubber
Installation
1. Install bump rubber.
NOTE: Arrow points to be vehicle outer side of after
assembly to vehicle.
2. Install bolt (1), then tighten it to the specified
torque.

2)
Special Tools (4
ILLUSTRATION
PART NO.
PART NAME
5-8840-2000-0
(J-23907)
Remover; Needle bearing
5-8840-0019-0
Sliding hammer
ILLUSTRATION
PART NO.
PART NAME
5-8840-2123-0
(J-36833)
Remover and Installer kit;
Lower arm front bushing
5-8840-2128-0
(J-36838)
Installer; Needle bearing
5-8840-2124-0
(J-36834)
Remover and Installer kit;
Lower arm rear bushing
5-8840-0007-0
(J-8092)
Grip
5-8840-2121-0
(J-36831)
Ball joint remover
5-8840-2127-0
(J-36837)
Installer; Oil seal
5-8840-2005-0
5-8840-2307-0
(J-39376)
Installer; Upper arm
bushing
5-8840-0256-0
(J-29775)
Remover and Installer
Upper arm bushing
(J-29107)
Tie-rod end remover
TROUBLESHOOTING
1. VIBRATION, SHOCK, AND SHIMMY OF STEERING WHEEL
Checkpoint
Check vehicle trim height
Trouble Cause
NG
Countermeasure
Incorrect
Adjust
Malfunction or loose
Replace or retighten
Worn
Replace
Worn
Replace
Faulty
Adjust
Check steering unit and

linkage
Replace
OK
Check shock absorber or

attaching nut and bolt
NG
OK
Check upper and lower link

bushings
NG
OK
Check suspension ball joint
NG
OK
Check wheel alignment
NG
OK
Check front axle
NG
Improperly adjusted or worn front

wheel bearing.
Worn or incorrectly adjusted wheel
bearing.
Replace; refer to Section 4C "Front
Wheel Drive"
Insufficiently tightened steering

gear housing.
Wear of steering linkage.
Excessive
backlash
due
to
improper adjustment of the steering
gear box.
Worn column bearing weakened
column bearing spring, or loose
clamp.
Replace; refer to Section 3B
"Steering"
Improper tire pressure.

Imbalance and deformation of frond
wheel.
Unevenly worn tire or insufficient
tightening of wheel nuts.
Replace; refer to Section 3E "Wheel
and Tires"
2. VEHICLE PULLS TO RIGHT OR LEFT

Checkpoint
Coil spring (42 Except high

ride suspension)
Torsion bar (44, 42 High
ride suspension)
Trouble Cause
NG
Countermeasure
Collapsed or break (42

Except high ride suspension)
Collapsed or twisted (44, 42
High ride suspension)
Replace
Incorrect
Adjust
Incorrect
Adjust
Incorrect
Adjust
Worn
Replace
Deformed
Replace
Incorrect adjustment or
abrasion
Adjust or replace
OK
Vehicle trim height
NG
OK
Brake adjustment (binding)
NG
OK
Wheel alignment
NG
OK
Rubber bushing for upper and

lower link
NG
OK
Steering linkage, and upper

and lower link
NG
OK
Front wheel bearing
Continued on the next page
NG

Checkpoint
Trouble Cause
Countermeasure
Continued from the previous page
Tire pressure or wheel nuts
NG
Improper or instufficient
tightening
Adjust or tighten
NG
Difference in wear and tear
Replace (tire)
OK
Tire tread (right and left)
3. INSTABILITY OF VEHICLE
Checkpoint
Vehicle trim height
Trouble Cause
NG
Countermeasure
Incorrect
Adjust
Worn
Replace
Worn or deformed
Replace
Incorrect
Adjust
Incorrect
Adjust
Deformed or unbalanced
Adjust
OK
Rubber bushings for upper
and lower links. (4 2 Except
high ride suspension)
NG
OK
Steering linkage and upper

and lower links
NG
OK
Wheel alignment
NG
OK
Tire pressure
NG
OK
Road wheel
NG
4. STIFF STEERING WHEEL

Checkpoint
Upper and ball joint
Trouble Cause
Countermeasure
NG
Stiff or damaged or lack of

grease
Replace
NG
Incorrect
Adjust
Worn or damaged
Replace
Deformed
Replace
Insufficient lubricants or
impurities present; or
excessively worn
Replace the part
Interference abrasion
Replace
Improper
Adjust
OK
Wheel alignment
OK
Steering gear
NG
OK
Steering linkage
NG
OK
Steering gear box or steering

linkage
NG
OK
Steering column with turn

signal switch
NG
OK
Tire pressure
NG
5. NOISES
Checkpoint
Upper and lower links

bushings
Trouble Cause
NG
Countermeasure
Worn
Replace
Loose
Retighten
Loose
Retighten
Faulty
Replace
Insufficient
Replace
Damaged
Replace
OK
Shock absorber fixing nut and

bolt
NG
OK
Stabilizer fixing nuts and bolts
NG
OK
Shock absorber
NG
OK
Lubricating oil and grease for

upper and lower ball joint
NG
OK
Upper and lower ball joint
NG

Checkpoint
Trouble Cause
Countermeasure

OK
Tire pressure
NG
Improper
Adjust
NG
Worn
Replace
NG
abrasion
Adjust or replace
NG
Loose
Retighten
NG
Insufficient
Replace
OK
Steering linkage and steering

gear
OK
Front wheel bearing
OK
Steering unit fixing bolts and

linkage
OK
Lubricating oil and grease to

steering linkage
6. EXCESSIVE STEERING WHEEL PLAY

Checkpoint
Upper, and lower links,

bushing (4 2 Except high
ride suspension)
Trouble Cause
NG
Countermeasure
Worn
Replace
NG
Worn
Replace
NG
abrasion
Adjust or replace
OK
Steering linkage
OK
Front wheel bearing
7. GRATING TIRE NOISE

Checkpoint
Wheel alignment
Trouble Cause
NG
Countermeasure
Incorrect
Adjust
Deformed
Replace
Loose
Replace
Improper
Adjust
OK
Knuckle spindle and steering
linkage
NG
OK
Suspension fixing bolt
NG
OK
Tire pressure
NG
8. EXCESSIVELY OR PARTIALLY WORN TIRE

Checkpoint
Tire pressure
Trouble Cause
NG
Countermeasure
Improper
Adjust
Incorrect
Adjust
Faulty
Replace
Incorrect
Adjust
Not rotated
Rotate tires at recomended

intervals
OK
Wheel alignment
NG
OK
Front wheel bearing
NG
OK
Brake adjustment
NG
OK
Tire rotation
NG
MEMO
REAR SUSPENSION 3D-1
SECTION 3D
REAR SUSPENSION
TABLE OF CONTENTS
PAGE
Main Data and Specifications ...........................................................................................3D- 2
Torque Specifications........................................................................................................3D- 3
Rear Suspension................................................................................................................3D- 4
General Description ......................................................................................................3D- 4
Leaf Spring and Shock Absorber .....................................................................................3D- 5
Leaf Spring and Associated Parts ...............................................................................3D- 5
Removal .........................................................................................................................3D- 6
Inspection and Repair...................................................................................................3D- 7
Installation .....................................................................................................................3D- 8
Leaf Spring Assembly .......................................................................................................3D- 9
Disassembly ..................................................................................................................3D- 9
Inspection and Repair...................................................................................................3D- 9
Reassembly ...................................................................................................................3D- 10
Troubleshooting.................................................................................................................3D- 11
3D-2 REAR SUSPENSION

Models
Items
Standard
Heavy-duty Suspension
42
42
42
42
(High Ride Sus)
(High Ride Sus)
(Except High Ride Sus)

44
44
Semi-elliptic, rubber bushed, leaf type springs and direct double acting shock
absorbers.
(Except High Ride Sus)
Type
Leaf spring
No. of leaves
Spring eye type
Berlin eye type
Up turned eye type
Bushing outside dia
mm(in)
Front; 40 (1.57), Rear; 30 (1.18)
Length
mm(in)
1200 (47.24)
Width
mm(in)
60 (2.36)
Rear shock absorbers

Type
Gas-sealed Hydraulic, double acting telescopic
Mean stroke
mm(in)
198 (7.80)
199 (7.83)
198 (7.80)
199 (7.83)
Compressed length
mm(in)
323 (12.7)
349 (13.8)
323 (12.7)
349 (13.7)
Extended length
mm(in)
521 (20.5)
549 (21.6)
521 (20.5)
549 (21.9)
Nm(kgm/lbft)
RTW430LF000101
REAR SUSPENSION
GENERAL DESCRIPTION
Rear suspension absorbs vibration from the road surface thus preventing vehicle damage, as well as providing a
good ride.
Components parts
Spring between the body and the axle case

Spring shackle connecting the spring to the body
Clamp and U-bolt fixing the axle case to the spring
Shock absorber as a countermeasure for vibration
LEAF SPRING AND SHOCK ABSORBER

LEAF SPRING AND ASSOCIATED PARTS
460R300001
Legend
1. Parking Brake Cable Bracket
2. Nut and Washer
3. Nut and Washer
4. Shock Absorber
5. Nut
6. U Bolt and Seat
7. Lower Clamp
8. Nut
9. Shackle Plate
10. Shackle Pin

11. Rubber Bushing
12. Nut and Plain Washer
13. Spring Pin
14. Leaf Spring
15. Bump Rubber
Removal
Jack up the rear axle and place chassis stands under the
frame near the front end of the rear spring brackets.
Note:
F03L100003
Be careful not to stretch the flexible brake hose or

parking brake cable.
Support the vehicle on the specified jack point.
1. Remove the parking brake cable (1) from the leaf spring.
2. Loosen the shock absorber fixing nut and remove the nut
and special washer (2) from the lower clamp.
3. Remove the shock absorber fixing nut and washer (3) at
frame side.
4. Lifting the rear axle by a jack, remove the shock absorber
(4) and lower the jack.
5. Remove the U bolt fixing nut (5).
6. Take out the U bolt (6), seat and lower clamp (7).
7. Support the leaf spring by a jack and remove the shackle
pin fixing nuts (8).
8. Drive out the shackle pin (10), using a brass bar and
hammer.
9. Remove the shackle plate (9) and rubber bushings (11).
10.Remove the nut (12) and drive out the shackle with a
hammer using a brass bar.
11.Remove the leaf spring (14).
12.Remove the bump rubber (15).

Make correction or parts replacement if wear, damage or their abnormal conditions are found through inspection.
Visual Check
Inspect the following parts for wear, damage, nuts or other
Leaf spring assembly
Clip
Center bolt
U-bolt
Spring pin
Shackle pin
Shock absorber
Rubber bumper
Rubber bushing
Bump rubber seat
Shackle Pin
Shackle Pin diameter
mm (in)
17.93 - 18.00 (0.706 - 0.709)
Spring Pin
Spring Pin Diameter
mm (in)
13.8 - 14.0 (0.543 - 0.551)
Shock Absorber
Inspection operation of shock absorber
If no resistance is felt while expanding the shock absorber, that
indicates the absorber is faulty.
Installation
1. Install the bump rubber (15) and bolt and tighten it to the
specified torque.
Torque
Nm (kgm/lbft)
42 (4.3/31)
2. Install the leaf spring (14).
The leaf spring assembly should be installed so that the
built-in rubber bush is toward the front.
Align the holes of the spring eye and frame bracket.
Insert the spring pin (13) toward vehicle inner side
through the frame bracket holes and the spring bush
hole.
Tighten the nut (12) a little and after the vehicle is
lowered, tighten it to the specified torque.
Torque
Nm (kgm/lbft)
152 (15.5/112)
Apply rubber grease to inside and outside of the rubber
bushing.
Install the rubber bushings (11) into the hole of the
frame side bracket and the spring rear eye.
Install the shackle pin (10) and shackle plate (9).
Tighten the nuts (8) a little and after vehicle is lowered,
tighten it to the specified torque.
Torque
Nm (kgm/lbft)
98 (10/72)
RTW340LF000101
3. Support the lower clamp (7) under the leaf spring.

4. Apply oil to the thread portion of U bolt (6).
Install the U bolt and seat on the rear axle and insert the U
bolt in the lower clamp holes.
5. Tighten the nut (5) to the specified torque.
Torque
Nm (kgm/lbft)
78 (8.0/58)
6. Install the shock absorber (4) and inner washer on the
lower clamp pin and frame side pin.
7. Install the washer and nut (3) on the frame side pin and
tighten the nut to the specified torque.
Torque
Nm (kgm/lbft)
39 (4.0/29)
8. Install the washer and nut (2) on the lower clamp pin and
tighten the nut to the specified torque.
Torque
Nm (kgm/lbft)
39 (4.0/29)
9. Install the parking brake cable (1) on the leaf spring and
tighten the nut at its bracket.
Torque
Nm (kgm/lbft)
7 (0.7/5)
LEAF SPRING ASSEMBLY

Disassembly
1. Remove the bushing using a bench press and a suitable
metal fitting.
F03L100004
2. Apply a setting mark across the

disassembling the leaf spring assembly.
springs
before
RTW430SH000101
3. Use a bench press and remove the center bolt.

Discard center bolt and install a new one.
F03L100006
4. Disassemble the leaf spring assembly.
465R300001

Inspect leaf spring, bush, clips, liners and center spacer for
wear, damage, rust or other abnormal conditions and if
necessary, repair or replace it.
Reassembly
1. Apply grease to both faces of each leaf spring at
reassembly.
2. Set the leaf springs aligning the setting mark before
disassemble.
3. Assemble the leaf springs using a bench press.
4. Apply grease to the outside of the bushing.
Install a new center bolt and tighten it to the specified
torque.
Torque
Nm (kgm/lbft)
29 (3.0/22)
5. Install the bushing using a bench press and a suitable
metal fitting.
F03L100006
TROUBLESHOOTING
1. BODY INCLINATION
Checkpoint
Trouble Cause
NG
Spring
Countermeasure
Weak or broken
Replace
Worn or disintegrated
Replace
Poorly lubricated
Regrease
Bolt loosened
Retighten
Cracked
Replace
Bushings worn or
disintegrated
Replace
Defective
Replace
OK
Shackle pins and bushings
NG
NG
OK
Spring brackets and U-bolts
NG
NG
OK
Shock absorbers
NG
OK
Mounting brackets
NG
2. REDUCTION GROUND CLEARANCE

Checkpoint
Trouble Cause
Countermeasure
Condition of load
OK
Leaf springs
NG
Broken
Replace
Worn or broken
Replace
Loosened
Retighten
Deteriorated or disintegrated
Replace
Poorly lubricated
Regrease
Over lubricated
Wipe off excess grease
OK
Springs clip bands
NG
NG
OK
Bushings
NG
NG
NG

Checkpoint
Trouble Cause
Countermeasure

OK
Parts for looseness
NG
NG
Loose
Retighten
Cracked or damaged
Replace
3. SPRING BREAKAGE
Checkpoint
Trouble Cause
Countermeasure
Condition of loading
OK
Shackle pins and pivot pins
NG
NG
Bolts and nuts for loosening
Retighten
Worn or damaged
Replace
Bolts and nuts for loosening
Retighten
Damaged
Replace
Oil leakage
Replace
Bushing worn
Replace
OK
NG
U-bolts
NG
OK
Shock absorber
NG
NG

Checkpoint
Trouble Cause
Countermeasure
NG
NG
Brackets cracked
Replace
Defective
Replace
Worn or disintegrated
Replace
Loosened
Retighten
Damaged
Replace
OK
Spring bushing
NG
OK
Center bolts
NG
NG
4. HARSHNESS
Checkpoint
Road test vehicle(Noise has a

certain pattern)
Trouble Cause
Countermeasure
NG
Noise does not have any

specific pattern
Replace tires
NG
Incorrect
Adjust
Incorrect
Adjust or replace
Defective
Replace
Loosen or broken
Retighten or replace
OK
Tire inflation pressure
OK
Tires for out of balance
NG
OK
Bushings in suspension
System
NG
NG
WHEELS AND TIRES 3E-1
SECTION 3E
WHEELS AND TIRES

TABLE OF CONTENTS
PAGE
Main Data and Specifications ...........................................................................................3E- 2
Torque Specifications .......................................................................................................3E- 3
Special Parts Fixing Nuts and Bolts............................................................................3E- 3
Wheels and Tires ............................................................................................................... 3E- 4
General Description ......................................................................................................3E- 4
Servicing ........................................................................................................................3E- 6
Disassembly and Reassembly .....................................................................................3E- 7
Inspection and Repair...................................................................................................3E- 8
Troubleshooting ................................................................................................................ 3E- 10
3E-2 WHEELS AND TIRES

Tire Size and Pressure
Model
Tire Size
Wheel Size
Tire Pressure
2
Front kg/cm (psi/kPa)
2
Rear kg/cm (psi/kPa)
4
2 Except HIGH RIDE SUS
4
2 HIGH RIDE SUS, 4
4
195R14C
8PR 106/104Q
215/70R15C
106/104S
225/75R15C
110/108S
245/70R16
111S
14 x 5.5J
15 x 6.5JJ
15 x 6.5JJ
16 x 7JJ
2.5 (36/250)
4.5 (65/450)
2.25 (33/225)
3.75 (54/375)
2.25 (33/225)
3.25 (47/325)
2.0 (29/200)
2.8 (41/280)
WHEELS AND TIRES
kgfm (lbft/Nm)
WHEELS AND TIRES

GENERAL DESCRIPTION
TIRE DESIGNATION
TIRE PRESSURE LABEL (LOCATION : DRIVERS DOOR OR FRAME OF DRIVERS DOOR)

4
2 HIGH RIDE SUS, 4
4
SEE OWNERS AND
DRIVERS MANUAL FOR
ADDITIONAL INFORMATION
4
2 Except HIGH RIDE SUS
SEE OWNERS AND
DRIVERS MANUAL FOR
ADDITIONAL INFORMATION
TIRE PRESSURE : kg/cm2 (PSI)
TIRE PRESSURE : kg/cm2 (PSI)
TIRE
FRONT
REAR
TIRE
FRONT
REAR
195R14C8PR
2.5 (36)
4.5 (65)
225/75R15C
2.25 (33)
3.25 (47)
215/70R15C
2.25 (33)
3.75 (54)
245/70R16 111S
2.0 (29)
2.8 (41)
Note :
The air pressure of the tire should be maintained as indicated in the label instruction on the driver's
door or frame of driver's door.
Lower pressure can cause burst and adverse vehicle handling.
On the other hand, higher pressure can cause shock-burst and reduce gripping effect.
SERVICING
Servicing refers to general maintenance procedures to be performed by qualified service personnel.
WHEEL NUT TORQUES

Wheel Nut Torque
kgfm(lbft/Nm)
12.0 1.0 (86.8 7.2 / 117.7 9.8)
TIRE ROTATION
For of radial tires, interchange the front and the rear wheels on
the same side as shown in the figure.
If one-sided tire wear appears on radial tires, rotate the wheels

as shown in the figure.
Note:
After rotation, adjust the front and rear tire pressure and be sure to check wheel nut tightness.
DISASSEMBLY and REASSEMBLY
Disassembly Steps
Reassembly Steps
(for Alumi models)
(for Alumi models)
1. Wheel cap
2. Wheel nut
3. Wheel and tire assembly
4. Tire assembly
(for Steel models)

1. Wheel nut
2. Wheel cap
4. Tire assembly
4. Tire assembly
2. Wheel nut
1. Wheel cap
(for Steel models)

4 Tire assembly
2. Wheel cap
1. Wheel nut

Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found
through inspection.
Visual Check
Inspect all disassembled parts for wear, damage or other
Measure Wheel Runout

mm
Wheel Type
14 inch Steel
15 inch Steel
Radial
Lateral
Less than 1.0
Less than 1.0
Less than 0.4
Less than 0.55
16 inch Steel
15 inch Alumi
16 inch Alumi
If the measured value exceed the specified limit, the wheel

must be replaced.
Balancing Wheel and Tire

On-vehicle Balancing
On-Vehicle balancing methods very with equipment and tool
manufacturers. Be sure to follow each manufacturers
instructions during balancing operation.
Off- vehicle Balancing
Most electronic off-vehicle balancers are more accurate than
the on-vehicle spin balancers. They are easy to use and give a
dynamic balance. Although they do not correct for drum or
disc unbalance (as on-vehicle spin balancing does), they are
very accurate.
Important Operations
1. Tire Assembly
Align the match mark (approx. 10mm diameter paint mark) of
wheel with match mark (approx. 8mm diameter red paint mark)
of tire to assemble. If the match mark at wheel has
disappeared, align with air valve to assemble.
2. Wheel and Tire Assembly
3. Wheel Nut
Tighten wheel nuts in numerical order.
Wheel Nut Torque
kgfm (lbft/Nm)
12.0 1.0 (86.8 7.2 / 117.7 9.8)
TROUBLESHOOTING
Typical examples of abnormal tire tread wear and major causes :
CAUTION:
Similar wear patterns can be caused by worn suspension parts, misalignment of wheels and tires, and
other suspension related problems.
Spotty wear - wear localized

on shoulder section. In
extreme cases, the tire
becomes polygonal in shape.
Tire or wheel out of

round or distorted.
Hub or knuckle out

of round or distorted.
Play in hub bearings

or ball joints.
Rotating parts out of

balance.
Tread wear one-sided.
Rotating parts out of

balance.

round.
Hub or knuckle out

of round or distorted.
Localized tread wear.
Once spotty wear develops in

tread due to hard braking or
abrupt starting, localized wear
tends to be accelerated.
Shoulder wear (generally

wear develops on outer
shoulder).
Camber or toe-in
incorrect.
Shoulder wear
caused by repeated
hard-cornering.
Wear on shoulders at points

opposed to each other.

round or distorted.
Play in bearings or
ball joint.
Premature wear on
shoulders.
Flexing of tire excessive due

to under-inflation.
One-sided feather edging.
Wear caused by
repeated hardcornering.
Camber or toe-in
incorrect.
MEMO
No. TFSTG-WE-0431
WORKSHOP MANUAL
TF SERIES
AXLE
SECTION 4
PROPELLER SHAFT 4A-1
SECTION 4A
PROPELLER SHAFT
TABLE OF CONTENTS
PAGE
Main Data and Specifications ...........................................................................................4A- 3
Rear Propeller Shaft......................................................................................................4A- 3
Torque Specifications .......................................................................................................4A- 5
Front Propeller Shaft ...................................................................................................4A- 6
Torque Specifications .......................................................................................................4A- 7
Rear Propeller Shaft ..........................................................................................................4A- 8
General Description ......................................................................................................4A- 8
Removal and Installation ..............................................................................................4A-11
Universal Joint Disassembly........................................................................................4A-12
Inspection and Repair ..................................................................................................4A-14
Universal Joint Reassembly ........................................................................................4A-16
Rear Propeller Shaft Assembly ........................................................................................4A-17
Disassembly and Reassembly ....................................................................................4A-18
Front Propeller Shaft ........................................................................................................4A-19
Removal and Installation ..............................................................................................4A-19
Disassembly .................................................................................................................4A-21
Universal Joint Disassembly and Reassembly .........................................................4A-23
Reassembly ..................................................................................................................4A-27
4A-2 PROPELLER SHAFT
Service Precaution
WARNING:
THIS
VEHICLE
HAS
A
SUPPLEMENTAL RESTRAINT SYSTEM (SRS).
REFER TO THE SRS COMPONENT AND WIRING
LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON
OR NEAR THE SRS COMPONENTS OR THE SRS
WIRING. WHEN YOU ARE PEREFORMING
SERVICE ON OR NEAR THE SRS COMPONENTS
OR THE SRS WIRING, REFER TO THE SRS
SERVICE INFORMATION. FAILURE TO FOLLOW
WARNING COULD RESULT IN POSSIBLE AIR
BAG DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE
UNNEEDED
SRS
SYSTEM
REPAIRS.
CAUTION : Always use the correct fastener in the

proper location. When you replace a fastener,
use ONLY the exact part number for that
application. ISUZU will call out those fasteners
that require a replacement after removal. ISUZU
will also call out the fasteners that require thread
lockers or thread sealant. UNLESS OTHERWISE
SPECIFIED, do not use supplemental coatings
(Paints, greases, or other corrosion inhibitors)
on threaded fasteners or fastener joint
interfaces. Generally, such coatings adversely
affect the fastener torque and the joint clamping
force, and may damage the fastener. When you
install fasteners, use the correct tightening
sequence and specifications. Following these
instructions can help you avoid damage to parts
and systems.

REAR PROPELLER SHAFT
mm(in)
4b2 Model
Engine Model
Transmission Type
Wheel Base
Front Suspension
4JA1-T(L) 4JA1-TC
5 M/T (MUA)
Long
mm
75
(in)
(2.95)
Inside Diameter
mm
71.8
(in)
(2.89)
Length
1st(L1) mm
799.5
(in)
(31.48)
2nd(L2) mm
796
(in)
(31.34)
Spline Major
mm
29.89
Diameter
(in)
(1.18)
Fix Bolt Size
M10
* OBS - Outboard Slip (Spline Engagement To T/M)
Rear Axle
Type
Outside Diameter
4JH1-TC
5M/T (MUA)
Long
Extra Long
High Ride Except High
Suspension
Ride
Suspension
220mm
OBS
68.9
68.9
68.9
(2.71)
(2.71)
(2.71)
64.9
64.9
64.9
(2.63)
(2.63)
(2.63)
798.5
801.5
946.5
(31.44)
(31.56)
(37.26)
801
796
801
(31.54)
(31.34)
(31.54)
29.89
29.89
29.89
(1.18)
(1.18)
(1.18)
M10
M10
M10
4A/T
Long
63.5
(2.50)
60.3
(2.44)
720.5
(28.37)
801
(31.54)
29.89
(1.18)
M10
mm(in)
4b2 Model
C24SE
5M/T (MUA)
Transmission Type
Wheel Base
Long
Extra Long
Except High
High Ride
Front Suspension
Ride
Suspension
Suspension
Rear Axle
Type
Outside Diameter mm
75
75
75
(in)
(2.95)
(2.95)
(2.95)
Inside Diameter
mm
71.8
71.8
71.8
(in)
(2.89)
(2.89)
(2.89)
Length
1st(L1) mm
823.5
820.5
970.5
(in)
(32.42)
(32.30)
(38.21)
2nd(L2) mm
801
796
796
(in)
(31.54)
(31.34)
(31.34)
Spline Major
mm
29.89
29.89
29.89
Diameter
(in)
(1.18)
(1.18)
(1.18)
Fix Bolt Size
M10
M10
M10
Engine Model
6VE1
5M/T (MUA)
Long
Extra Long
Long
4A/T
Extra Long
220mm
OBS
68.9
(2.71)
64.9
(2.63)
823.5
(32.42)
801
(31.54)
29.89
(1.18)
M10
68.9
(2.71)
64.9
(2.63)
971.5
(38.25)
801
(31.54)
29.89
(1.18)
M10
75
(2.95)
71.8
(2.89)
778.5
(30.65)
801
(31.54)
30.48
(1.20)
M10
75
(2.95)
71.8
(2.89)
928.5
(36.56)
801
(31.54)
30.48
(1.20)
M10
mm(in)
4b4 Model
Engine Model
4JA1-T(L)
4JA1-TC
Transmission Type
5M/T (MUA)
Wheel Base
Long
Front Suspension
Rear Axle
220mm
Type
OBS
Outside Diameter mm
75
(in)
(2.95)
Inside Diameter
mm
71.8
(in)
(2.89)
Length
1st(L1) mm
469.5
(in)
(18.48)
2nd(L2) mm
801
(in)
(31.54)
Spline Major
mm
29.89
Diameter
(in)
(1.18)
Fix Bolt Size
M10
4JH1-TC
5M/T (MUA)
Long
Extra Long
220mm
OBS
68.9
68.9
(2.71)
(2.71)
64.9
64.9
(2.63)
(2.63)
468.5
616.5
(18.44)
(24.27)
801
801
(31.54)
(31.54)
29.89
29.89
(1.18)
(1.18)
M10
M10
mm(in)
4b4 Model
C24SE
6VE1
5M/T
Transmission Type
5M/T (MUA)
(MUA)
Wheel Base
Long
Long
Extra Long
Front Suspension
Rear Axle
Type
Outside Diameter mm
63.5
68.9
68.9
(in)
(2.50)
(2.71)
(2.71)
Inside Diameter
mm
60.3
64.9
64.9
(in)
(2.44)
(2.63)
(2.63)
Length
1st(L1) mm
495.5
492.5
641.5
(in)
(19.51)
(19.39)
(25.26)
2nd(L2) mm
801
801
801
(in)
(31.54)
(31.54)
(31.54)
Spline Major
mm
29.89
29.89
29.89
Diameter
(in)
(1.18)
(1.18)
(1.18)
Fix Bolt Size
M10
M10
M10
Engine Model
4A/T
Long
75
(2.95)
71.8
(2.89)
484.5
(19.07)
801
(31.54)
29.89
(1.18)
M10
4A/T
Long
63.5
(2.50)
60.3
(2.44)
402.5
(15.85)
801
(31.65)
29.89
(1.18)
M10
401R300006
Nm (kgfm/lbft)
RTW34ASF000301
Front Propeller Shaft

mm(in)
Engine Model
4JA1-T(L)
Transmission Type
Wheel Base
Outside Diameter
Inside Diameter
Length (L)
Fix Bolt Size
4JA1-TC
5M/T (MUA)
mm
(in)
mm
(in)
mm
(in)
T/F
Axle
Long
40
(1.57)
32
(1.26)
607
(25.90)
M10
M10
4b4 Model
4JH1-TC
5M/T
4A/T
(MUA)
Long
Long
40
40
(1.57)
(1.57)
32
32
(1.26)
(1.26)
607
676
(25.90)
(26.61)
M10
M10
M10
M10
C24SE
5M/T
(MUA)
Long
40
(1.57)
32
(1.26)
586
(23.07)
M10
M10
6VE1
5M/T
4A/T
(MUA)
Long
Long
40
40
(1.57)
(1.57)
32
32
(1.26)
(1.26)
586
607
(23.07)
(23.90)
M10
M10
M10
M10
RTW34ASF000101
RTW34ASF000201
Rear Propeller Shaft

General Description
4b
b2 (Except High Ride Suspension) Model
F04R300001
4b
b2 (High Ride Suspension), 4b
b4 Model
401R300007
Torque is transmitted from the transmission to the

axle through propeller shaft and universal joint
assembles. All propeller shafts are the balanced
tubular type. A splined slip joint is provided in some
drivelines.
Since the propeller shaft is total balanced carefully,
welding or any other modification are not permitted.
Alignment marks should be applied to each

propeller shaft before removal.
Be sure vehicle is stopped, engine is not running,
brake is secured and vehicle is secured to prevent
injury.
Be careful not to grip the propeller shaft tube too
tightly in the bise as this will be cause deformation.
Phasing
The propeller shaft is designer and built with the yoke lugs
(ears) in line with each other. This design produces the
smoothest running shaft possible, called phasing. Vibration can
be caused by an out-of-phase propeller shaft. The propeller
shaft down each time the universal joint goes around. This
vibration would be the same as a person snapping rope and
watching the wave reaction flow to the end. A propeller shaft
working in phase would be similar to two persons snapping a
rope at the same time, and watching the waves meet and
cancel each other out. In comparison, this would be the same
as the universal joints on a propeller shaft. A total cancellation
of vibration produces a smooth flow of power in the driveline. It
is very important to apply a reference mark to the propeller
shaft before removal, to assure installation alignment.
Universal Joint
401RW015
A universal joint consists of two Y-shaped yokes

connected by a crossmember called a spider.
The spider is shaped like a cross. Universal joints are
designed to handle the effects of various loadings and
front or rear axle windup during acceleration. Within the
designed angle variations, the universal joint will operate
efficiently and safely. When the design angle is changed
or exceeded the operational life of the joint may decrease.
The bearings used in universal joints are of the needle
roller type. The needle rollers are held in place on the
trunnions by round bearing cups. The bearing cups are
held inside the yokes by snap rings.
Diagnosis of Propeller Shaft and

Universal Joint
Condition
Leak at the Front Slip Yoke (An
Occasional Drop of Lubricant
Leaking from the Splined Yoke is
Normal)
Possible cause
Rough surface on splined yoke;
burred nicked or worn.
Defective transmission rear oil seal.
Universal Joint Noise.
Ping, Snap, or Click in Drive Line

(Usually Heard on Initial Load after
the Transmission is in Forward or
Reverse Gear)
Worn universal joint bearings.

Improper lubrication.
Loose flange bolts.
Loose bushing bolts on the rear
springs or upper and lower control
arms.
Loose or out-of-phase end yoke.
Squeak
Lack of lubricant.
Shudder on Acceleration (Low

Speed)
Loose or missing bolts at the

flanges.
Incorrectly set front joint angle.
Vibration
Worn universal joint.

Incorrect shaft runout.
Shaft out of balance.
Transmission rear housing bushing,
transfer case housing bushing worn.
Yoke spline jammed.
Correction
Replace the seal. Minor burrs can
be Smoothed by careful use of
crocus cloth or fine stone honing.
Replace the yoke if badly burred.
Replace the transmission rear oil
seal and replenish the transmission
oil.
Replace.
Lubricate as directed.
Tighten to specifications.
Tighten the bolts to specified
torque.
Remove end yoke, turn 180
degrees from its original position,
lubricate the splines and reinstall.
Tighten the bolts and pinion nut to
specified torque.
Lubricate joints and splines. Also
check for worn or brinelled parts.
Replace or tighten bolts to specified
torque.
Install shim under the transmission
support mount to change the front
joint angle.
Replace.
Replace.
Adjust.
Replace.
Replace.
Removal and Installation

Removal
1. Raise the vehicle on a hoist.
NOTE:
Apply alignment marks on the flange at the rear
propeller shaft both front and rear side.
401RS023
2. Remove center bearing fixing bolt.

3. Remove rear axle side bolt, nut and washer.
4. Remove rear propeller shaft.
NOTE:
Plug the hole of the transmission rear end to prevent oil
leakage.
Installation
NOTE:
Cover the slip yoke with cloth to avoid damage to the oil seal
contact surface, when removing propeller shaft from
transmission. Do not damage the oil seal contact surface of
slip yoke with other parts at removal and installation.
Completely remove the dust or foreign matter from the
connecting surface of flange coupling on each end of the
propeller shaft.
401L100007
1. Align the mark which is applied at removal and insert the

propeller shaft in the transmission.
2. Install rear propeller shaft and tighten the bolts to the
specified torque.
Torque: 63 Nm(6.4kgm/46 lbft)
3. Install center bearing and tighten the bolts to the specified
torque.
Torque: 69 Nm(7.0kgm/51 lbft)
Universal Joint Disassembly
401R300002
Legend
(1). Snap Ring
(2). Needle Roller Bearing
(3). Spider
(4). Propeller Shaft
1. Remove the snaprings.

Apply alignment marks on the yokes of the universal
joint.
401R300003
2. Remove the needle roller bearings.

Tap out the bearing by gently striking the shoulder of the
yoke, using a mallet or a copper hammer.
3. Remove the spider.
Make sure of proper position for reinstallation by
applying setting marks.
4. Remove the propeller shaft.
401R300004

Make all necessary adjustment, repairs, and part replacements if wear, damage, or other problems are discovered
during inspection.
Visual Check
Inspect following parts for wear, damage, or other abnormal
conditions.
Spider
Needle roller bearing
Yoke
Flange
Center bearing
Cushioning rubber
Bracket
Outside Diameter of Spider Pins

mm(in)
401RS007
Standard
Limit
17 (0.67)
16.99 (0.669)
Propeller Shaft Run-Out
401R300005
Support 1 of splined yoke, 2 of center bearing and 3 of flange

yoke and check for static run-out by holding the probe of a dial
indicator in contact with the center part of the shaft and turning
the propeller shaft.
If the amount of run-out is beyond the limit value, correct with a
bench press or replace the shaft with a new one.
mm(in)
Limit
1.0 (0.04)
Play in Spider Bearing

(1) Check the spider bearings for wear or damage.
(2) Check the amount of axial and radial play in spider bearing
by moving the yoke back and forth on the spider axes and
shaft axis.
mm(in)
Limit
0.1(0.004)
If the limit is exceeded, replace the shaft assembly.
401R300008
Universal Joint Reassembly
401RS011
1. Set the propeller shafts.

Be sure to set the propeller shaft yoke by aligning the
setting marks made during dissassembly.
2. Spider
Be sure to install the spider by aligning the setting marks
made during disassembly.
3. Needle Roller Bearing
1) Apply a molybdenum-disulfide grease or a multi-purpose.
type grease NLGI No.2 to inside of the bearing cap.
Grease Amount
g(oz)
Approx. 1.2 (0.042)
2) Using either a mallet (or copper hammer) or a press, install
the needle roller bearing into the yoke so that snap ring can
be installed in its groove.
CAUTION:
The needle roller bearing cannot be installed smoothly
if it is set at an incorrect angle with the flange.
Excessive hammering will damage the needle roller
bearing.
401RS012
3) Align setting marks and join the yokes.

NOTE:
Assemble the spider and spline yoke so that their grease
fittings are arranged on the same side.(4b4)
4. Snap ring
NOTE:
Discard used snap rings and install new ones.
401R300003
When the bearing cap is in position, select and attach a snap

ring of suitable thickness so that the end play of the spider pin
is held within 0.1mm (0.004in).
mm(in)
Snap ring thickness
Identification color
1.50
(0.059)
Light Blue
1.53
(0.060)
White
1.56
(0.061)
Pink
1.59
(0.063)
Yellow
1.62
(0.064)
Green
1.65
(0.065)
Brown
1.68
(0.066)
Not colored
NOTE:
Be sure to use snap rings of the same thickness on both sides.
Rear Propeller Shaft Assembly
401R300009
Legend
(1). Splined Yoke
(2). Journal Assembly
(3). 1st Tube Assembly
(4). Center Bearing
(5). Plain Washer
(6). Center Yoke

(7). Lock Nut
(8). 2nd Tube Assembly
(9). Flange Yoke
(10). Snap Ring
Disassembly
1. Disassembly the three portions of the journal assemblies.
2. Remove the splined yoke, the 1st tube assembly with center
bearing, the 2nd tube assembly and the flange yoke.
3. Remove the lock nut.
4. Remove the center yoke, the plain washer the center
bearing and the 1st tube assembly.
Reassembly
1. Install the center bearing on the 1st tube assembly.
Clean the bearing fitting face.
Repack the grease.
Amount of grease
required
g(oz)
Approx. 12 (0.42)
2. Install the plain washer and the center yoke.

3. Install the lock nut and tighten it to the specified torque.
Lock nut Torque : 118 Nm (12.0kgm/87lbft)
(1) Discard the flange nut and install a new one.
(2) Stake the outer face of the flange nut against the slot in the
shaft.
4. Install the splined yoke, the 1st tube assembly with center
bearing, the 2nd tube assembly and the flange yoke by
assembling the universal joint.
Front Propeller Shaft

RTW34AMF000301
Legend
(1) Bolt, Nut and Washer (Front Axle Side)
(2) Front Propeller Shaft
(3) Nut and Washer (Transfer Side)
Removal
1. Jack up the vehicle and support it on the chassis stands.
2. Gear shift lever should be placed in neutral position and
parking brake released.
3. Remove the exhaust and transfer protectors.
NOTE:
Apply alignment marks on the flange at the front propeller shaft
both front and rear side.
401RS020
4. Remove bolt, nut and washer (Front axle side).

5. Remove bolt, nut and washer (Transfer side).
6. Remove front propeller shaft.
Installation
NOTE:
Never install the shaft assembly backwards. Completely
remove the black paint from the connecting surface of flange
coupling on each end of propeller shaft. Clean so that no
foreign matter will be caught in between.
1. Align the mark which was applied at removal. Install front
propeller shaft and tighten the bolts and nuts to the
specified torque.
Torque: 59 Nm (6.0 kgm/43 lb ft)
2. Install the exhaust and transfer protectors.
3. After installing the propeller shaft, be sure to apply black
paint (1) to exposed area (other than connecting surface) of
the entire surface of flange coupling.
401RS019
Disassembly
401RW057
Legend
(1) Sleeve Yoke
(2) Seal
(3) Tube Assembly

1. Apply alignment marks (1) on the sleeve yoke and tube
assembly then remove sleeve yoke.
401RW056
2. Remove seal.
3. Remove tube assembly.
Universal
Joint
Reassembly
Disassembly
and
401RW055
Legend
(1) Flange Yoke
(2) Spider
(3) Snap Ring
(4) Needle Roller Bearing

(5) Grease Fitting

1. Apply alignment marks (1) on the yokes of the universal
joint, then remove snap ring.
401RS028
2. Tap out the needle roller bearing by gently striking the

shoulder of the yoke, using a mallet or a copper hammer.
3. Make sure of proper position for reinstallation by applying
setting marks, then remove spider.
401RS006

Make necessary correction or parts replacement if wear,
damage, corrosion or any other abnormal condition is found
through inspection.
NOTE:
When any part of the journal assembly (spider, needle roller
bearing) requires replacement, be sure to replace the entire
assembly.
Check the following parts for wear, damage, noise or any other
abnormal conditions:
1. Spider
2. Needle roller bearing
3. Yoke
4. Flange
5. Constant velocity joint
Outside Diameter of Spider Pin

Standard: 17.00 mm (0.669 in)
Limit: 16.90 mm (0.665 in)
401RS007
Propeller Shaft Run

out
Support the ends of the propeller shaft on V-blocks (2) and
check for runout by holding the probe of a dial indicator (1) in
contact with the center part of the shaft. If the amount of run
out is beyond the standard value for assembly, correct with a
bench press or replace the shaft with a new propeller shaft
assembly.
Limit: 0.5 mm (0.02 in)
401RS027
Play in Splines in Normal Direction of Rotation

Check the amount of play between the sleeve yoke (1) and the
propeller shaft spline (2) in the direction of rotation, using a
pointed feeler gauge.
Standard: 0.073 0.156 mm (0.003 0.006 in)
Limit: 0.3 mm (0.012 in)
401RS009
Play in Universal Joint

Limit: Less than 0.1 mm (0.004 in)
401RS010
Reassembly
1. Install spider to flange yoke. Be sure to install the spider by
aligning the setting marks made during disassembly.
2. Apply a molybdenumdisulfide grease or a multipurpose
type grease NLGI No. 2 to inside of the bearing cap.
Grease Amount: Approx. 1.2 g (0.042 oz)
401RS011

3. Using either a mallet (or copper hammer) or a press, install
the needle roller bearing into the yoke so that the snap ring
can be installed in its groove.
CAUTION:
The needle roller bearing cannot be installed smoothly if it
is set at an incorrect angle with the flange and excessive
hammering will damage the needle roller bearing.
401RS012
401RS028
4. Align setting marks (1) and join the yokes.

5. Install snap ring.
NOTE:
Discard used snap rings and install new ones.
When the bearing cap is in position, select and attach a snap
ring of suitable thickness so that the end play of the spider pin
is held within 0.1 mm (0.004 in).
Snap ring thickness and Identification color
1.50 mm (0.059 in); Light Blue
1.56 mm (0.061 in); Prink
1.53 mm (0.060 in); White
1.59 mm (0.063 in); Yellow
1.62 mm (0.064 in); Green
1.65 mm (0.065 in); Brown
1.68 mm (0.066 in); Not colored
NOTE:
Be sure to use snap rings of the same thickness
on both sides.
Reassembly
401RW057
Legend
(1) Sleeve Yoke
(2) Seal
(3) Tube Assembly
1. Discard used seal and install new one.

2. Align the alignment marks and install tube assembly to
sleeve yoke.
MEMO
REAR AXLE 4B-1
SECTION 4B
REAR AXLE
TABLE OF CONTENTS
PAGE
Main Data and Specifications ...........................................................................................4B- 3
Torque Specifications ....................................................................................................................4B- 4
Recommended Liquid Gasket ..........................................................................................4B- 6
Recommended Thread Locking Agents ..........................................................................4B- 6
Rear Axle Assembly ..........................................................................................................4B- 7
General Description ......................................................................................................4B- 7
Servicing.............................................................................................................................4B- 8
Rear Axle ............................................................................................................................4B- 9
Disassembly ..................................................................................................................4B- 10
Inspection and Repair...................................................................................................4B- 13
Reassembly ...................................................................................................................4B- 14
Differential Assembly .....................................................................................................................4B- 19
Disassembly ..................................................................................................................4B- 20
Reassembly ...................................................................................................................4B- 22
Differential Cage Assembly ..........................................................................................................4B- 32
Disassembly ..................................................................................................................4B- 33
Inspection and Repair...............................................................................................................4B- 33
Reassembly .................................................................................................................................4B- 35
Limited Slip Differential (LSD) ..........................................................................................4B- 36
Disassembly ................................................................................................................................4B- 37
Inspection and Repair...................................................................................................4B- 38
Reassembly ...................................................................................................................4B- 40
Troubleshooting............................................................................................................4B- 43
Special Service Tool..................................................................................................................4B- 54
4B-2 REAR AXLE
Service Precaution
WARNING:
THIS
VEHICLE
HAS
A
SUPPLEMENTAL
ARE REFORMING SERVICE ON OR NEAR THE
TO THE SRS SERVICE INFORMATION. FAILURE
TO FOLLOW WARNINGS COULD RESULT IN
INJURY, OR OTHERWISE UNNEEDED SRS
SYSTEM REPAIRS.
CAUTION:
Always use the correct fastener in the proper
location. When you replace a fastener, use ONLY
the exact part number for that application. ISUZU
will call out those fasteners that require a
the fasteners that require thread lockers or
thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (Paints,
greases, or other corrosion inhibitors) on threaded
fasteners or fastener joint interfaces. Generally,
such coatings adversely affect the fastener torque
and the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specification.
Following these instructions can help you avoid
damage to parts and systems.
REAR AXLE 4B-3

REAR AXLE
Ring gear size
mm(in)
Rear axle type

Rear axle capacity
220 (8.66)
Banjo, semi-floating
N (kg/lb)
Rear axle case
16475 (1680/3700)
16965 (1730/3815) (EC)
Axle tube section

Outside diameter
mm(in)
80 (3.15)
Thickness
mm(in)
4.5 (0.118)
Final drive type
Single speed
Final gear type
Hypoid
Drive pinion bearing preload
kg-cm(lb.in)
Starting torque (At drive pinion flange nut)
7-13 (6.1-11.3)
Preload adjusting method

Final gear backlash
Collapsible
mm(in)
0.15-0.20 (0.006-0.008)
Differential carrier assembly

Weight (Dry)
kg/lb
29.0/63.9
Lubrication
Specified gear oil (APL grade)
Oil capacity
GL5 (STD), GL5LSD (LSD)

lit (US/UK gal)
2.4 (0.63/0.53)
4B-4 REAR AXLE
Rear Axle
Nm (kgfm/lbft)
RTW34BLF000501
REAR AXLE 4B-5
Differential
Nm (kgfm/lbft)
RTW34BLF000201
4B-6 REAR AXLE
RECOMMENDED LIQUID GASKET

Type
RTV*
Silicon Base
Brand Name
Manufacture
ThreeBond 1207B
Three Bond
ThreeBond 1207C
Three Bond
ThreeBond 1215
Three Bond
Remarks
For Engine Repairs
For Axle Case

Repairs, T/M
Water Base
Solvent
Anaerobic
ThreeBond 1141E
Three Bond
ThreeBond 1104
Three bond
BelcoBond 4
Isuzu
BelcoBond 401
Isuzu
BelcoBond 402
Isuzu
LOCTITE 515
Loctite
LOCTITE 518
Loctite
For Engine Repairs
For Engine Repairs
All
* RTV : Room Temperature Vulcanizer

Note :
1. It is very important that the liquid gaskets listed
above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid
gasket.
Follow the manufacture's instructions at all
times.
3. Be absolutely sure to remove all lubricants and

moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. LOCTITE 515 and LOCTITE 518 harden upon
contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518
between two metal surfaces having a clearance
of greater than 0.25 mm (0.01 in). Poor
adhesion will result.
RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type
LOCTITE Color
LOCTITE 242
Blue
LOCTITE 262
Red
LOCTITE 270
Green
LOCTITE 271
Red
Application Steps
1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.
3. Tighten the bolts to the specified torque.

4. Wait at least one hour before continuing the installation procedure.
REAR AXLE 4B-7
REAR AXLE ASSEMBLY

General Description
A03R300001
The rear axle assembly is of the semifloating type in

which the vehicle weight is carried on the axle
housing .
The center line of the pinion gear is below the center
line of the ring gear (hypoid drive).
All parts necessary to transmit power from the
propeller shaft to the rear wheels are enclosed in a
banjo type axle housing.
The 220 mm (8.6 in) ring gear rear axle uses a
conventional ring and pinion gear set to transmit the
driving force of the engine to the rear wheels. This
gear set transfers this driving force at a 90 degree
angle from the propeller shaft to the drive shafts.
The axle shafts are supported at the wheel end of the
shaft by a double tapered roller bearing.
The pinion gear is supported by two tapered roller
bearings. The pinion depth is set by a shim pack
located between the gear end of the pinion and the
roller bearing that is pressed onto the pinion. The
pinion bearing preload is set by crushing a collapsible
spacer between the bearings in the axle housing.
The ring gear is bolted onto the differential cage with

12 bolts.
The differential cage is supported in the axle housing
by two tapered roller bearings. The differential and ring
gear are located in relationship to the pinion by using
selective shims and spacers between the bearing and
the differential cage. To move the ring gear, shims are
deleted from one side and an equal amount are added
to the other side. These shims are also used to
preload the bearings which are pressed onto the
differential cage. Two bearing caps are used to hold
the differential into the rear axle housing.
The differential is used to allow the wheels to turn at
different rates of speed while the rear axle continues
to transmit the driving force. This prevents tire
scuffing when going around corners and prevents
premature wear on internal axle parts.
The rear axle is sealed with a pinion seal, a seal at
each axle shaft end, and by a liquid gasket between
the differential carrier and the axle housing
4B-8 REAR AXLE
SERVICING
Rear Axle Oil Replacement
Oil Capacity
liters (US/UK gal.)
2.4 (0.63/0.53)
Specified gear oil
GL5 (API grade)(STD)

GL5LSD (LSD)
Filler Plug and Drain Plug Torque
Nm (kgfm/lbft)
78 (8.0/58)
Axle Shaft Roller Bearing Endplay

Inspection
1. Raise and suitably support vehicle.
2. Remove the wheel and brake drum.
3. Inspect the axle shaft roller bearing endplay using
dial gauge.
Endplay
Standard
mm (in)
0 ~ 0.2 (0 ~ 0.008)
If the endplay exceeds 0.2mm (0.008 in), replace the

axle shaft roller bearings.
Refer to Rear Axle Reassembly.
RTW34BSH000101
REAR AXLE 4B-9
REAR AXLE
1.
2.
Refer to Section 3E "WHEEL and TIRE" for road

wheel Disassembly procedure.
Refer to Section 5 "BRAKE" for rear brake
removal procedure.
RTW34BLF000401
Legend
1.
2.
3.
4.
5.
6.
7.
Brake Drum
Bolt and Nut
Axle Shaft Assembly with Brake
Shim
Snap Ring
Axle Shaft
Sensor Rotor (with ABS)
Spacer (without ABS)
8. Double Taper Roller Bearing
9.
10.
11.
12.
13.
14.
15.
16.
17.
Oil Seal
Bearing Holder
Rear Brake
Bolt and Nut
Differential Assembly
Rear Axle Case Assembly
Wheel Pin
Axle Case Oil Seal
Front
4B-10 REAR AXLE
Disassembly
Raise vehicle to the working level.

Support the axle assembly with the proper jack
and chassis stands.
Remove wheel and tire.
Drain differential oil.
Remove propeller shaft. (Refer to the section
Rear Propeller Shaft.)
1. Remove brake drum.

2. Remove ABS sensor. (Refer to the section ABS.)
3. Remove brake pipe from wheel cylinder.
420R300003
REAR AXLE 4B-11
305R30000
Legend
1.
2.
3.
4.
5.
6.
7.
4.
5.
6.
7.
8.
9.
Tension Pin
Shoe Clamp Spring
Return Spring
Shoe Assembly with Parking Brake Lever
Shoe Assembly with Adjuster Lever
Spring
Parking Brake Cable
8.
9.
10.
11.
12.
13.
Adjuster
Parking Brake Lever
Adjuster Spring
Adjuster Lever
Wheel Cylinder
Back plate
Remove tension pin and shoe clamp spring.

Remove return spring.
Remove shoe assembly with parking brake lever.
Remove shoe assembly with adjuster lever and
spring.
Remove parking brake inner cable from parking
brake lever.
Use offset box wrench to compress locking lugs
on the cable, then remove parking brake outer
cable from back plate.
311RS012
4B-12 REAR AXLE

Legend
Legend
1. Offset Box Wrench
10. Remove wheel cylinder.
11. Remove bearing holder fixing nuts.
12. Take out axle shaft assembly with back plate and
set it on a bench press as following illustration.
Put bolt head on thick steel plate.
When axle shaft is extracted, since axle case oil
seal is damaged, axle case oil seal.
13. Remove snap ring. Use snap ring pliers to
remove. Snap ring is prohibition of reuse.
14. Remove shim (If so equipped)
15. Remove sensor rotor (or spacer), double taper
roller bearing, oil seal, bearing holder, and back
plate from axle shaft by means of a press.
Discard used oil seal, double taper roller
bearing, snap ring, ABS sensor rotor and
spacer.
1. Bench Press Fitting

2. Steel Plate (25-30 mm thickness)
3. Axle Shaft
16. Remove differential assembly fixing bolts and
nuts and take out differential assembly.
17. Remove wheel pin from axle shaft, using the
remover 5-8840-0079-0.
420L100009
18. Remove axle case oil seal.

Discard used oil seal.
A03R300002
REAR AXLE 4B-13

discovered during inspections.
Visual Check
Inspect the following parts for wear, damage or other
Axle Shaft
Axle Shaft
When checking the axle shaft, pay special attention to
the splined portions and replace the shaft if distortion
or step wear is noticeable. Correct slight step wear
with a pencil grinder.
420RY00019
Axle Shaft Flange Run-Out

Check the axle shaft flange for run-out. Hold the
probe of a dial indicator in contact with the flange.
Rotate the shaft slowly and observe the dial.
Limit
mm(in)
0.08 (0.003)
420RS008
Axle Shaft Run-Out

Check the shafts for bending with the use of a dial
indicator in contact with the shaft. Rotate the shaft
slowly and observe the dial indicator.
Limit
mm(in)
1.0 (0.039)
Note :
Never use heat to correct bending.
420RY00018
4B-14 REAR AXLE
Reassembly
1.
Using the oil seal installer 5-8840-2202-0, install

new axle case oil seal.
F04R300002
Legend
1. Oil Seal
2. Bearing Holder
420R300004
Note :
Confirm that the dimention : A should be 34.5
36.1 mm (1.36 1.42 in)
3.
4.
Drive wheel pin into axle shaft flange, using a

hammer.
Differential assembly
a. Clean the mating surface of axle case and
differential carrier.
b. Apply Three Bond 1215 (TB1215) or
equivalent on the surface of differential
assembly as flowing illustration.
A03R300004
2.
Install new oil seal in bearing holder, using the oil

seal installer 9-8522-1269-0.
425RS006
c.
Tighten bolts and nuts to the specified torque.

Torque : Bolt
64 Nm (6.5 kgm/47 lbft)
Nut
44 Nm (4.5 kgm/33 lbft)
REAR AXLE 4B-15

5. Axle Shaft Assembly
a. Insert new double taper roller bearing in the
bearing holder with oil seal.
b. Set special tool (support stand : 9-8522-12710) on a bench press.
c.
6.
7.
Put new sensor rotor (or spacer) on the special

tool 9-8522-1271-0.
Press fit axle shaft with the bearing into sensor
rotor and make axle shaft assembly.
Put bearing holder with bearing and oil seal

and back plate on the support stand as
following illustration.
d. Insert bolts and axle shaft, aligning center of

holes.
e. Press fit axle shaft into double taper roller
bearing.
420R300011
Legend
1.
2.
3.
4.
Axle shaft
Oil Seal
Bolt
Back Plate
5. Sensor Rotor (or Spacer)

420R300010
Legend
1.
2.
3.
4.
5.
Axle shaft
Oil Seal
Bolt
Back Plate
Double Taper Roller Bearing
4B-16 REAR AXLE

8. Certainly install new snap ring, use snap ring pliers.
When transform or damage, replace new one.
9. Insert a shim of sufficient thickness between snap

ring and end of sensor rotor (or spacer).
Standard
0 - 0.2 mm (0 - 0.008 in)
Crevice is measured using thickness gauge, and

when crevice exceeds 0.2 (mm), it adjusts so that
is may become 0.2 (mm) or less using shim.
Shim Pats No.
1 9-41519110-*
2 8-97130387-*
RTW34BMH000101
Legend
1. Snap ring
2. Crevice
3. Sensor rotor (with ABS)
Spacer (without ABS)
Thickness
0.18 mm (0.0071 in)
0.50 mm (0.0197 in)
Crevice
Mm (in)
No. of shim
1
1.0(0.0394)
0.9(0.0354)
0.8(0.0315)
0.7(0.0276)
0.6(0.0236)
0.5(0.0197)
0.4(0.0158)
0.3(0.0118)
0.2(0.0079)
2
1
1
2
1
1
2
1
1
1
1
1
Total
mm (in)
1.00(0.0394)
0.86(0.0339)
0.68(0.0268)
0.68(0.0268)
0.50(0.0197)
0.50(0.0197)
0.36(0.0142)
0.18(0.0071)
0.18(0.0071)
10. Install axle shaft assembly in rear axle case

assembly.
Note:
When inserting an axle shaft, it inserts so that an
oil seal may not be damaged.
11. Install and tighten bearing holder fixing nut to the
specified torque.
Torque : 84 Nm (8.6 kgm/62 lbft)
12. Install wheel cylinder and tighten the bolt to the
specified torque.
13. Install parking brake outer cable in back plate and
inner cable in parking brake lever.
REAR AXLE 4B-17

14. Install shoe assembly with adjuster lever, shoe
assembly with parking brake lever and spring.
15. Install return spring.
16. Install shoe clamp spring and tension pin.
305R300001
Legend
1.
2.
3.
4.
5.
6.
7.
Tension Pin
Shoe Clamp Spring
Return Spring
Shoe Assembly with Parking Brake Lever
Shoe Assembly with Adjuster Lever
Spring
Parking Brake Cable
8.
9.
10.
11.
12.
13.
Adjuster
Parking Brake Lever
Adjuster Spring
Adjuster Lever
Wheel Cylinder
Back plate
4B-18 REAR AXLE

17. Install brake pipe and ABS sensor and tighten it to
Torque :
ABS Sensor 8 Nm (0.8 kgm/69 lbft)
Brake Pipe
16 Nm (1.6 kgm/12 lbft)
420R30003
18. Bleed brake pipe at the wheel cylinder. (Refer to

the section Power-assisted Brake System)
19. Install brake drum.
Install propeller shaft. (Refer to Section Rear
Propeller Shaft.)
Refill differential oil.
Install wheel and tire.
Lower vehicle.
REAR AXLE 4B-19
Differential Assembly
Disassemble View
415RY00005
Legend
1.
2.
3.
4.
5.
6.
7.
8.
9.
Bolt
Bearing Cap
Differential Cage Assembly
Side Bearing Outer Race
Side Bearing
Adjust Shim
Flange Nut
Flange Assembly
Drive Pinion Shaft Assembly
10.
11.
12.
13.
14.
15.
16.
17.
Collapsible Spacer
Inner Bearing
Adjust Shim
Oil Seal
Outer Bearing
Inner Bearing Outer Race
Outer Bearing Outer Race
Differential Carrier
4B-20 REAR AXLE
Disassembly
1. Using holding fixture 5-8840-0275-0 and holding
fixture base 5-8840-0003-0, fix the differential
assembly to the bench.
415L100001
425L100007
2.
Apply a setting mark to the side bearing cap and

the differential carrier then remove bearing cap.
6. Note the thickness and position of the shims then

remove adjust shim.
7. Remove the flange nut by using pinion flange
holder 5-8840-0133-0 after raising up its staked
parts completely.
415RW040
425RS009
3.
4.
5.
Remove differential cage assembly.

Remove side bearing outer race. After removal,
keep the right and left hand side bearing
assemblies separate to maintain inner and outer
race combinations.
Remove side bearing by using remover 5-88400013-0, 5-8840-0014-0 and adapter 5-8840-21960.
REAR AXLE 4B-21

8. Removed flange assembly.
9. Remove the drive pinion assembly using a soft
metal rod and a hammer.
12.
13.
14.
15.
Remove adjust shim.

Remove oil seal.
Remove outer bearing.
Remove the inner bearing outer race (1) and the
outer bearing outer race (2) by using a brass bar
and a hammer.
425RY005
10. Remove collapsible spacer.

11. Remove the inner bearing by using separator 58840-2197-0
425RS014
425RS015
415L100002
4B-22 REAR AXLE
Reassembly
1. Install outer bearing outer race by using installer 58840-2164-0 and grip 5-8840-0007-0.
3. Adjust the drive pinion mounting distance as

follows:
a. Apply gear oil to the inner and outer drive
pinion bearing. Clean the pinion setting
gauge set. Then install the gauge set
together with the inner and outer bearings.
Install gauge plate 5-8840-2166-0 (3), inner
pilot 5-8840-0129-0 (2), stud and nut 5-88400127-0 (4) and outer pilot 5-8840-2085-0 (1)
through inner and outer bearings.
b. Tighten the nut to the specified torque.
Torque: 2.3 Nm (0.23 kgm/20 lb in)
425L100002
2. Install inner bearing outer race by using installer 58840-2163-0 and grip 5-8840-0007-0.
425RW030
425L100003
REAR AXLE 4B-23

c.
Clean the side bearing bores. Place discs and

dial indicator on to arbor, and place tool into
position in side bearing bores. Install and
tighten the bearing caps to the specified
torque.
Torque :
108 Nm (11 kgm/80 lb in)
425RS020
Legend
1.
2.
3.
4.
425RW031
Legend
1.
2.
3.
4.
Dial Indicator : 5-8840-0126-0

Gauge Plate : 5-8840-2166-0
Disc (2 pcs.) : 5-8840-2167-0
Arbor : 5-8840-0128-0
Dial Indicator
Gauging Arbor
Plunger
Gauge Plate
e. Position the plunger on the gauge plate. Move

the gauging arbor slowly back and forth and
locate the position at which the dial indicator
shows the greatest deflection. At this point,
once again set the dial indicator to 0".
Repeat the procedure to verify the 0"
setting.
Note :
The scale on the dial indicator (5-8840-0126-0) is
inch unit.
d. Set the dial indicator 5-8840-0126-0 to 0".
Place it on the mounting post of the gauging
arbor with the contact button touching the
indicator pad. Force the dial indicator
downward until the needle has made a half
turn clockwise. Tighten down the dial
indicator in this position.
425RS021
f.
After the ZERO setting is obtained, rotate the

gauging arbor until the dial indicator rod does
not touch the gauging plate. Record the
number the dial indicator needle points to.
4B-24 REAR AXLE
425RS022
Legend
1. Example=Dial indicator reading od 0.085
g. Record the pinion depth code on the head of
the drive pinion. The number indicates a
necessary change in the pinion mounting
distance. A plus number indicates the need
for a greater mounting distance (which can be
achieved by decreasing the shim thickness).
A minus number indicates the need for a
smaller mounting distance (which can be
achieved by increasing the shim thickness).
If examination reveals pinion depth code 0",
the pinion is nominal".
425RS023
REAR AXLE 4B-25

h. Select the shim using table below.
mm (in)
Pinion
marking
+10
+8
+6
+4
+2
-2
-4
-6
-8
-10
1.94 (0.0764)
1.96 (0.0772)
2.00 (0.0787)
2.02 (0.0787)
2.04 (0.0803)
2.06 (0.0811)
2.10 (0.0827)
2.12 (0.0835)
2.14 (0.0842)
2.16 (0.0850)
2.20 (0.0866)
2.22 (0.0874)
2.24 (0.0882)
2.28 (0.0898)
2.30 (0.0906)
2.32 (0.0913)
2.34 (0.0921)
1.94 (0.0764)
1.96 (0.0772)
1.98 (0.0779)
2.02 (0.0795)
2.04 (0.0803)
2.06 (0.0811)
2.08 (0.0819)
2.12 (0.0835)
2.14 (0.0842)
2.16 (0.0850)
2.18 (0.0858)
2.22 (0.0874)
2.24 (0.0882)
2.26 (0.0890)
2.30 (0.0906)
2.32 (0.0913)
2.34 (0.0921)
2.36 (0.0929)
1.96 (0.0772)
1.98 (0.0779)
2.00 (0.0787)
2.04 (0.0803)
2.06 (0.0811)
2.08 (0.0819)
2.10 (0.0827)
2.14 (0.0842)
2.16 (0.0850)
2.18 (0.0858)
2.20 (0.0866)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.32 (0.0913)
2.34 (0.0921)
2.36 (0.0929)
Dial indicator
reading (inches)
0.073
0.074
0.075
0.076
0.077
0.078
0.079
0.080
0.081
0.082
0.083
0.084
0.085
0.086
0.087
0.088
0.089
0.090
0.091
0.092
0.093
0.094
0.095
0.096
0.097
1.94 (0.0764)
1.96 (0.0772)
1.98 (0.0779)
2.00 (0.0787)
2.04 (0.0803)
2.06 (0.0811)
2.08 (0.0819)
2.12 (0.0835)
2.14 (0.0842)
2.16 (0.0850)
2.18 (0.0858)
2.22 (0.0874)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.32 (0.0913)
2.34 (0.0921)
2.36 (0.0929)
1.96 (0.0772)
1.98 (0.0779)
2.00 (0.0787)
2.02 (0.0787)
2.06 (0.0811)
2.08 (0.0819)
2.10 (0.0827)
2.14 (0.0842)
2.16 (0.0850)
2.18 (0.0858)
2.20 (0.0866)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.30 (0.0906)
2.34 (0.0921)
2.36 (0.0929)
1.94 (0.0764)
1.98 (0.0779)
2.00 (0.0787)
2.02 (0.0787)
2.04 (0.0803)
2.08 (0.0819)
2.10 (0.0827)
2.12 (0.0835)
2.16 (0.0850)
2.18 (0.0858)
2.20 (0.0866)
2.22 (0.0874)
2.26 (0.0890)
2.28 (0.0898)
2.30 (0.0906)
2.32 (0.0913)
2.36 (0.0929)
1.94 (0.0764)
1.96 (0.0772)
2.00 (0.0787)
2.02 (0.0787)
2.04 (0.0803)
2.06 (0.0811)
2.10 (0.0827)
2.12 (0.0835)
2.14 (0.0842)
2.18 (0.0858)
2.20 (0.0866)
2.22 (0.0874)
2.24 (0.0882)
2.28 (0.0898)
2.30 (0.0906)
2.32 (0.0913)
2.34 (0.0921)
1.96 (0.0772)
1.98 (0.0779)
2.02 (0.0787)
2.04 (0.0803)
2.06 (0.0811)
2.08 (0.0819)
2.12 (0.0835)
2.14 (0.0842)
2.16 (0.0850)
2.20 (0.0866)
2.22 (0.0874)
2.24 (0.0882)
2.26 (0.0890)
2.30 (0.0906)
2.32 (0.0913)
2.34 (0.0921)
2.36 (0.0929)
Note :
When ordering shims, find the part number in the
Parts Catalog by using the thickness of the shims
listed in the above table.
1.94 (0.0764)
1.96 (0.0772)
1.98 (0.0779)
2.00 (0.0787)
2.04 (0.0803)
2.06 (0.0811)
2.08 (0.0819)
2.10 (0.0827)
2.14 (0.0842)
2.16 (0.0850)
2.18 (0.0858)
2.22 (0.0874)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.32 (0.0913)
2.34 (0.0921)
2.36 (0.0929)
1.96 (0.0772)
1.98 (0.0779)
2.00 (0.0787)
2.02 (0.0787)
2.06 (0.0811)
2.08 (0.0819)
2.10 (0.0827)
2.12 (0.0835)
2.16 (0.0850)
2.18 (0.0858)
2.20 (0.0866)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.30 (0.0906)
2.34 (0.0921)
2.36 (0.0929)
1.94 (0.0764)
1.98 (0.0779)
2.00 (0.0787)
2.02 (0.0787)
2.04 (0.0803)
2.08 (0.0819)
2.10 (0.0827)
2.12 (0.0835)
2.14 (0.0842)
2.18 (0.0858)
2.20 (0.0866)
2.22 (0.0874)
2.26 (0.0890)
2.28 (0.0898)
2.30 (0.0906)
2.32 (0.0913)
2.36 (0.0929)
4B-26 REAR AXLE

4.
Place the shim on the drive pinion, then install the

inner bearing onto the pinion by using installer 98522-1165-0 and a press.
Note:
Do not apply pressure to the roller cage. Apply
NOTE: pressure only to the inner race.
9. Install flange assembly.

10.Install flange nut.
a. Apply lubricant to the pinion threads.
b. Using the pinion flange holder 5-8840-0133-0,
tighten the nut only enough to remove the shaft
end play.
Note :
Discard used flange nut and install new one.
425L100008
5. Install collapsible spacer. Discard the used

collapsible spacer and install a new one.
415RW040
6. Install drive pinion shaft assembly.
c. Adjust pinion bearing preload.
7. Install outer bearing and oil seal.
Measure the bearing preload by using a torque

meter and note the scale reading required to
rotate the flange.
8. Use oil seal installer 5-8840-2165-0 to install a

new oil seal that has grease on seal lip.
Continue tightening flange nut until the specified

starting torque is obtained.
Starting torque :
0.7-1.3 Nm (0.07-0.13 kgm/6-11 lbft)
415RW029
REAR AXLE 4B-27

Note :
Do not overtighten or loosen and then
retighten the nut.
Pinion nut torque will be in the range of 245294 Nm (25-30 kgm/181-217 lbft).
11.Adjust ring gear backlash.

a. Attach the side bearing to the differential
assembly without shims by using installer 58840-2162-0 and grip 5-8840-0007-0.
425L100010
425RW018
d. Using punch 5-8840-2293-0, stake the flange

nut at two points.
Note :
When staking, be sure to turn the nut to ensure
that there is no change in bearing preload. Make
sure NOTE: of preload again as instructed in c.
RTW34BSH000201
b. Insert the differential cage assembly with

bearing outer races into the side bearing bores
of the carrier.
4B-28 REAR AXLE
425RS030
425RS032
c. Using two sets of feeler gauges, insert a feeler

stock of sufficient thickness between each
bearing outer race and the carrier to remove all
end play. Make certain the feeler stock is
pushed to the bottom of the bearing bores.
With zero end play and correct backlash

established, remove the feeler gauge packs,
determine the thickness of the shims required
and add 0.05 mm (0.002 in) to each shim pack
to provide side bearing preload. Always use
new shims.
Mount the dial indicator 5-8840-0126-0 on the

carrier so that the indicator stem is at right
angles to a tooth on the ring gear.
e. Remove side bearing by using remover 58840-0013-0 and 5-8840-0014-0 and adapter
5-8840-2196-0.
425RW049
415L100001
d. Adjust feeler gauge thickness from side to side

until ring gear backlash is in the specified range.
Backlash :
0.150.20 mm (0.0060.008 in)
REAR AXLE 4B-29

12. Install the side bearings together with the selected
shims by using installer 5-8840-2162-0, drive
handle 5-8840-0007-0.
425L100010
13. Install side bearing outer race.

14. Install differential cage assembly.
15. Align the setting marks (1) applied at disassembly
then install the bearing cap.
425RS035
16. Tighten the bolt to the specified torque.

Torque :
108 Nm (11 kgm/80 lbft)
4B-30 REAR AXLE

Gear Tooth Contact Pattern Check and Adjustment
1.
Apply a thin coat of Prussian blue or equivalent to

the faces of the 78 teeth of the ring gear. Check
the impression of contact on the ring gear teeth
and make necessary adjustment as described in
illustration if the contact is abnormal.
425RS038
Legend
1.
2.
3.
4.
Heel
Toe
Concave Side(Coast)
Convex Side(Drive)
REAR AXLE 4B-31
425RS039
4B-32 REAR AXLE
Differential Cage Assembly

Disassembled View
425R300005
Legend
1.
2.
3.
4.
Bolt
Ring Gear
Lock Pin
Cross Pin
5.
6.
7.
8.
Pinion Gear
Side Gear
Thrust Washer (for Side Gear)
Differential Cage
REAR AXLE 4B-33
Disassembly
1.
2.
3.

conditions are found through inspection.
Ring gear, pinion gear
Bearing
Side gear, pinion gear, cross pin
Differential cage, carrier
Thrust washer
Oil seal
Clearance between pinion gear and cross pin:
mm(in)
Remove bolt.
Remove ring gear.
Drive out lock pin using a long drift Punch.
Standard
Limit
0.06 - 0.12
(0.002 - 0.005)
0.2 (0.008)
425RS042
4.
Check the amount of backlash between pinion

gear on side gear before removal of cross pin.
Backlash :
0.13-0.18 mm (0.0050.007 in)
5.
Remove the cross pin by using a brass drift

punch and hammer.
425L100012
Clearance between side gear and differential cage.

mm(in)
425RS043
6.
Take out pinion gear, side gear and thrust

washer.
Standard
Limit
0.05 - 0.11
(0.002 - 0.004)
0.15 (0.006)
4B-34 REAR AXLE
Differential cage
Check the ring gear the side gear fitting faces and the
cross pin hole for scores or roughness. Correct as
necessary. Slight scores or roughness may be
corrected with an oil stone or fine sand paper.
425R300010
Play in splines between the side gear and axle shafts.

mm(in)
Standard
Limit
0.08 - 0.38
(0.003 - 0.015)
0.5 (0.02)
425R300006
Ring gear replacement:

1. The ring gear should always be replaced with the
drive pinion as a set.
2. Discard use bolts and install new ones.
3. Apply LOCTITE 271 on bolt from the end of thread
to the middle of straight portion.
4. Tighten the fixing bolts in a diagonal sequence as
illustrated.
Torque : 108 Nm (11 kgm/80 lbft)
425L100014
425RW033
REAR AXLE 4B-35

mm (in)
Reassembly
1. Install side gear with thrust washer in differential
cage.
2. Install the pinion gear by engaging it with the side
gears while turning both pinion gears
simultaneously in the same direction.
0.13-0.18 (0.005-0.007)
If the backlash is beyond the limits, adjust with a thrust
washer of selected thickness.
Thicknesses of thrust washers available.
Backlash
mm (in)
0.80
0.90
1.00
1.10
1.20
1.30
(0.031) (0.035) (0.039) (0.043) (0.047) (0.051)
425RS048
3.
Install cross pin.

Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the
differential cage.
425RS049
4.
Check the amount of backlash.

Backlash between the side gear and the pinion
gear.
425RY00008
5.
Install lock pin.

After lock pin installation, stake the case to
secure the lock pin.
6.
Install ring gear.

Refer to Ring gear replacement on this section.
4B-36 REAR AXLE
LIMITED SLIP DIFFERENTIAL (LSD)

Disassembled View
425R300007
Legend
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Screw
Differential Cage B
Thrust Washer
Spring Plate
Spring Plate
Friction plate
Friction disc
Friction plate
Friction disc
Pressure Ring
Side Gear
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Pinion and Pinion Shaft

Side Gear
Pressure Ring
Friction Disc
Friction Plate
Friction Disc
Friction Plate
Spring Plate
Spring Plate
Thrust Washer
Differential Cage A
REAR AXLE 4B-37
Disassembly
Prepare a side gear holder : 5-8840-2682-0 as

shown in the left figure, clamp it with a stock vice,
and set a differential.
425R300008
1.
Screw
Apply a setting mark to the differential cage

A and differential cage B remove the bolt
using the press.
Loosen four screws fixing differential cage A

to cage B equally and remove them.
425RS055
2.
3.
4.
5.
6.
7.
8.
Remove differential cage A and B.

Remove thrust washer and two spring plates.
Remove friction plate and friction disc.
Remove friction plate and friction disc.
Remove pressure ring and side gear.
Remove pinion and pinion shaft.
Remove side gear and pressure ring.
9. Remove friction disc and friction plate.

10.Remove friction disc and friction plate.
11.Remove two spring plates and thrust washer.
4B-38 REAR AXLE

replacements if wear, damage, rust or other problems
are discovered during inspection.
Visual Check
Inspect the following parts for wear, damage or other
Friction disc
Friction plate
Spring plate
1
Sliding surface
2
Protrusion
425RY00022
10
11
Thrust Washer
Groove on side gear circumference small burrs of
dens should be repaired, using oil stone.
Sliding surface between side gear and thrust
washer.
425RS056
Pressure ring
Check the parts for damage or other abnormal
conditions.
3
Sliding surface for friction disc
If dents or damages are discovered, grind them
with oil stone, and repair them with compound on
surface plate.
4
Sliding surface of pressure ring inner surface and
pinion gear.
5
Slinding surface of pressure ring bore and side
gear.
6
sliding surface of pressure ring and side gear.
7
Sliding surface of pressure ring and pinion shaft.
8
Mating surface to differential cage A.
9
Burrs or dents on sliding surface of pressure ring
and rear differential cage should be repaired,
using oil stone.
425RY00024
12
13
Differential cage A and B

Contact surface to spring plate
Differential cage A and B contact surfaces to
thrust washers Small burrs or dents should be
repair, using oil stone.
REAR AXLE 4B-39
425RS061
425RY00025
Check friction plate and friction disc for wear.

Limit : (A-B)
0.1 mm
A : Protrusion Portion
B : Sliding Portion
425RY00023
Friction Desc and Friction Plate
Check friction disc and friction plate for distorsion.

Limit : 0.08 mm
425RS062
Check thrust washer for wear.

Limit : 1.3 mm
4B-40 REAR AXLE
425RS065
425RS063
3.
After A, B, C and D dimensions are measured,

perform adjustment with the following procedure.
Measure spring plate :

1.75 mm (0.69 in) 4 pcs (E)
Measure thickness of plate spring

Standard dimension :
1.75 mm (0.069 in) 2 pcs (F)
4.
Select a friction disc or plate so that ((A-B+C) (D+E) = 0.06 to 0.20 mm (0.002 to 0.008 in.) and
also the difference in total dimension of friction
disc and plate and spring plate (left/right side)
does not exceed 0.05 mm (0.002 in.).
Thickness : 1.65, 1.75, 1.85 mm (0.065, 0.069,
0.073 in)
Reassembly
Adjustment of Clearance between
Friction Disc and Plate
1.
Measuring depth of differential case

mm(in)
Standard (A-B)
80.58 (3.17)
(C)
10.58 (0.42)
Adjusting Backlash of Side Gear in

Axial Direction
1.
Measuring depth of differential case

mm(in)
425RS064
2.
Measuring overall length of pressure ring, friction

disc and plate assembly
Assemble pinion shaft with pressure ring,

then friction disc and plate.
Measure length between plates at both ends

over V-shape groove. (D)
Standard (F-B)
82.03 (3.23)
(G)
12.03 (0.47)
REAR AXLE 4B-41

(left/right side) does not exceed 0.05 mm (0.002
in).
Thickness : 1.5, 1.6, 1.7 mm (0.059, 0.063,
0.067 in)
Note :
When reassembling, sufficiently apply gear oil on
every part, especially on sliding surface.
1. Install thrust washer in differential cage A and
B.
2. Assemble spring plate, friction plate and
friction disc as following illustration.
Install spring plate with dished side turned
to the differential cage side.
425RS066
2.
Measuring dimension between thrust washers at

both ends.
Assemble side gear, pinion, pinion shaft pressure
ring and thrust washer.
Eliminate clearance by pushing pressure ring
against the pinion shaft in axial direction.
Eliminate backlash by connecting side gear to
the pinion.
Measure dimension between thrust washers at
both ends. (H)
425R300009
Legend
1. Friction Plate
2. Spring Plate
3. Friction Disc
4.
425RS067
3.
After each dimension is measured, perform

adjustment with the following procedure.
Adjust so that ((F-B) + G-H) = 0.05 to 0.2 mm
(0.002 to 0.008 in). Also, select a proper thrust
washer so that the dimension difference from
back face of the pressure ring to thrust washer
5.
6.
7.
Install pressure ring and side gear.

Fit two side gears in two pressure rings, one
from under a ring and the other from above a
ring.
Fit two pairs of a friction disc and a friction
plate under it on and under these two pressure
rings.
Set pinion and pinion shaft on differential cage A
assembly.
Assemble differential cage A and B.
Align the setting marks on differential cage A and
B and tighten screws in diagonal order evenly.
4B-42 REAR AXLE
Confirmation of Operation
Using the side gear holder : 5-8840-2682-0,

measure the starting torque of the side gear.
Starting torque : 29-45 Nm (3.0-4.6 kgm/22-33 lb
ft)
425RW065
Legend
1. Side Gear Holder : 5-8840-2682-0
REAR AXLE 4B-43
TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair
rear axle problems.
Each troubleshooting chart has three headings
arranged from left to right.
(1) Checkpoint
(2) Trouble Cause
(3) Countermeasure
This Section is divided into five sub-sections:
1. Abnormal Rear Axle Noise
1) Noise when the engine is driving the vehicle
2) Noise when the vehicle is coasting
3) Intermittent noise
4) Noise when the vehicle is turning
5) Constant noise
2. Vibration
3. Oil Leakage
1) Differential carrier leakage
2) Axle case leakage
3) Axle case to inside hub leakage
4) Axle case to inside brake drum leakage
4. Power Not Being Transmitted to the Wheels
(Propeller Shaft Operation is Normal)
4B-44 REAR AXLE
1. ABNORMAL REAR AXLE NOISE

1) Noise when the Engine is Driving the Vehicle
Checkpoint
Rear axle gear oil
Trouble Cause
Countermeasure
NG
Insufficient gear oil
Replenish the gear oil
NG
Wrong or poor grade gear oil
Replace the gear oil
Too much or too little backlash
Adjust the backlash
Loose drive pinion bearings
Adjust the drive pinion bearing

preload
Worn drive pinion bearings
Replace the drive pinion

bearings
Loose differential side

bearings
Adjust the differential side

bearing preload
Worn differential side bearings
Replace the differential side

bearings
OK
Drive pinion to ring gear

backlash
NG
OK
Drive pinion end play
NG
NG
OK
Differential side bearing
NG
NG
OK
REAR AXLE 4B-45

Checkpoint
Trouble Cause
Countermeasure
Drive pinion and ring gear
NG
Drive pinion and/or ring gear

damage
Replace the drive pinion and

the ring gear as a set
NG
Excessive ring gear run-out

NG
Worn drive pinion and ring

gear

2) Noise when the Vehicle is Coasting

Checkpoint

backlash
Trouble Cause
NG
Countermeasure
Insufficient backlash
Adjust the backlash
Ring gear damaged
Replace the ring gear and the

pinion as a set
OK
Ring gear
NG
4B-46 REAR AXLE

3) Intermittent Noise
Checkpoint
Trouble Cause
NO
Axle shaft
Countermeasure
Too much spline play
Replace the shaft
Warped ring gear

Loose differential cage bolts
Tighten the differential cage

bolts
Foreign material in the axle

case
Remove the foreign material
OK
NG
Ring gear
OK
NG
Differential cage
OK
Axle case inside
NG
REAR AXLE 4B-47

4) Noise when the Vehicle is Turning
Checkpoint
Trouble Cause
NO
Rear axle shaft
Countermeasure
Worn rear axle shaft splines
Replace the rear axle shaft
Worn side gear
Replace the side gear
Worn differential pinion
Replace the differential pinion
Worn differential cross pin
Replace the differential cross

pin
OK
NG
Side gear
OK
NG
Differential pinion
OK
Differential cross pin
NG
4B-48 REAR AXLE

5) Constant Noise
Checkpoint
Rear axle shaft
Trouble Cause
Countermeasure
NG
Bent rear axle shaft
NG
Flat spot on the drive pinion

gear teeth

Worn pinion splines oil seal

Flat spot on the gear teeth

pilot bearing wear

Flat spot on the drive pinion
Replace the drive pinion

bearing
Flat spot on the side bearing

oil seal
Replace the side bearing
OK
Drive pinion
NG
OK
NG
Ring gear
OK
Bearing
NG
NG
REAR AXLE 4B-49
2. VIBRATION
Checkpoint
Rear hub bearing
Trouble Cause
NG
Countermeasure
Worn rear hub bearing
Replace the rear hub bearing
Bent rear axle shaft
OK
Rear axle shaft
NG
4B-50 REAR AXLE
3. OIL LEAKAGE
1) Differential Carrier Leakage
Checkpoint
Gear oil level
Trouble Cause
Countermeasure
NG
Too much gear oil
Correct the oil level
NG
Worn or defective oil seal
Replace the oil seal
Clogged air breather
Clean the air breather
Loose bolts
Tighten the bolts to the

specified torque
Liquid gasket seal bed
Reapply the liquid gasket
Loose lock nut and/or liquid

and/or tighten the lock nut to
the specified torque
OK
Oil seal
OK
NG
Air breather
OK
Differential carrier
NG
NG
OK
Ring gear thrust bolt
NG
REAR AXLE 4B-51

2) Axle Case Leakage
Checkpoint
Oil filler and drain plug
Trouble Cause
Countermeasure
NG
Loose drain plug and/or

defective gasket(s)
Tighten the drain plug and/or

replace the gasket(s)
NG
Clogged air breather
Clean the air breather
Cracked axle case
Replace the axle case
Loose bolts
Tighten the bolts to the

specified torque
Liquid gasket seal bad
OK
Air breather
OK
NG
Axle case
OK
Differential carrier
NG
NG
4B-52 REAR AXLE

3) Axle Case to Inside Brake Drum Leakage
Checkpoint
Oil seal
Trouble Cause
NG
Countermeasure
REAR AXLE 4B-53
4. POWER NOT BEING TRANSMITTED TO THE WHEELS

(PROPELLER SHAFT OPERATION IS NORMAL)
Checkpoint
Rear axle shaft
Trouble Cause
Countermeasure
NG
Broken rear axle shaft
NG
Broken drive pinion and/or ring

gear

NG
Broken differential cage gears

and/or spider
Replace the differential gears

and/or the spider
OK
OK
Differential cage gears
4B-54 REAR AXLE

ITEM NO.
ILLUSTRATION
PART NO.
PART NAME
5-8840-0079-0
Wheel Pin Remover
9-8522-1269-0
Oil Seal Installer
5-8840-2202-0
Oil Seal Installer
9-8522-1271-0
Support Stand
5-8840-0275-0
Holding Fixture
5-8840-0003-0
Holding Fixture Base
5-8840-0013-0
Remover
5-8840-0014-0
Remover
5-8840-2196-0
Adapter
REAR AXLE 4B-55
ITEM NO.
ILLUSTRATION
PART NO.
PART NAME
5-8840-0133-0
Flange Holder
5-8840-2197-0
Separator
5-8840-2164-0
Installer
5-8840-0007-0
Grip
5-8840-2163-0
Installer
5-8840-2166-0
Gauge Plate
5-8840-0129-0
Inner Pilot
5-8840-0127-0
Stud and Nut
5-8840-2085-0
Outer Pilot
4B-56 REAR AXLE
ITEM NO.
ILLUSTRATION
PART NO.
PART NAME
5-8840-0126-0
Dial Indicator
5-8840-2167-0
Disc
5-8840-0128-0
Arbor
9-8522-1165-0
Installer
5-8840-2165-0
Installer
5-8840-2293-0
Punch
5-8840-2162-0
Installer
5-8840-2682-0
Sid Gear Holder
FRONT WHEEL DRIVE 4C1-1
SECTION 4C1
FRONT WHEEL DRIVE

TABLE OF CONTENTS
PAGE
Main Data and Specifications ...........................................................................................4C1- 3
Special Parts Fixing Nuts and Bolts ................................................................................4C1- 4
Recommended Liquid Gasket ..........................................................................................4C1- 6
Recommended Thread Locking Agents ..........................................................................4C1- 6
Servicing.............................................................................................................................4C1- 7
General Description...........................................................................................................4C1- 8
Front Drive Axle Assembly ............................................................................................. 4C1- 14
Front Drive Axle Assembly and Associated Parts ................................................... 4C1- 14
Removal ....................................................................................................................... 4C1- 15
Installation ................................................................................................................... 4C1- 16
Front Axle Drive Shaft ..................................................................................................... 4C1- 18
Front Axle Drive Shaft and Associated Parts ........................................................... 4C1- 18
Disassembly ................................................................................................................ 4C1- 19
Inspection and Repair................................................................................................. 4C1- 20
Bushing Replacement ............................................................................................... 4C1- 21
Reassembly ................................................................................................................. 4C1- 21
Standard caulk Measure ............................................................................................ 4C1- 22
Differential ................................................................................................................... 4C1- 24
Disassembly ................................................................................................................ 4C1- 24
Major Components................................................................................................ 4C1- 24
Minor Components................................................................................................ 4C1- 27
Reassembly ................................................................................................................ 4C1- 31
Minor Components................................................................................................. 4C1- 31
Major Components ................................................................................................. 4C1- 33
4C1-2 FRONT WHEEL DRIVE
PAGE
Front Hub and Disc (4
2 Except High Ride Suspension Model) ................................. 4C1- 42
Disassembly ................................................................................................................ 4C1- 42
Reassembly ................................................................................................................. 4C1- 46
4, 4
4 Rigid Hub,
4
4 Shift On The Fly Model)........................................................................................... 4C1- 50
Disassembly ................................................................................................................ 4C1- 50
Reassembly ................................................................................................................. 4C1- 53
4 Manual Locking Hub Model) ................................................. 4C1- 57
Disassembly ................................................................................................................ 4C1- 57
Reassembly ................................................................................................................. 4C1- 61
Troubleshooting .............................................................................................................. 4C1-67
Special Service Tool ................................................................................................... 4C1-75

FRONT AXLE AND DIFFERENTIAL
Ring gear size mm (in)
194 (7.6)
Axle tube
Type
It consists of the duce, a cast iron housing and the Axle tube.
Gear type
Hypoid
Gear ratio
(to 1)
4.100, 4.300, 4.555, 4.777, 5125
Differential type
Two pinion
Specified gear oil (APL grade)

Oil capacity
GL-5
liter
1.4
(US/UK gal.)
(0.4/0.33)
Axle shaft type
Constant velocity joint (Birfield joint type and double offset joint).
FRONT PROPELLER SHAFT

Engine Model
4JA1-T(L)
Transmission Type
Front Axle
Outside Diameter
Inside Diameter
Length (L)
Fix Bolt Size
mm(in)
4JA1-TC
5M/T (MUA)
mm
(in)
mm
(in)
mm
(in)
T/F
Axle
194 mm
40
(1.57)
32
(1.26)
607
(23.90)
M10
M10
4b4 Model
4JH1-TC
5M/T
4A/T
(MUA)
40
40
(1.57)
(1.57)
32
32
(1.26)
(1.26)
607
676
(23.90)
(26.61)
M10
M10
M10
M10
C24SE
5M/T
(MUA)
40
(1.57)
32
(1.26)
586
(23.07)
M10
M10
6VE1
5M/T
4A/T
(MUA)
40
40
(1.57)
(1.57)
32
32
(1.26)
(1.26)
586
607
(23.07)
(23.90)
M10
M10
M10
M10

FRONT DRIVE AXLE AND PROPELLER SHAFT
Nm (kgfm/lbft)
RTW440LF000101
FRONT DIFFERENTIAL
Nm (kgfm/lbft)
RTW440LF000901

Type
RTV*
Silicon Base
Brand Name
Manufacture
ThreeBond 1207B
Three Bond
ThreeBond 1207C
Three Bond
ThreeBond 1215
Three Bond
Remarks
For Engine Repairs
For Axle Case

Repairs, T/M
Water Base
Solvent
Anerobic
ThreeBond 1141E
Three Bond
ThreeBond 1104
Three bond
BelcoBond 4
Isuzu
BelcoBond 401
Isuzu
BelcoBond 402
Isuzu
LOCTITE 515
Loctite
LOCTITE 518
Loctite
For Engine Repairs
For Engine Repairs
All

Note :
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacture's instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying
the liquid gasket.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of greater
than 0.25 mm (0.01 in). Poor adhesion will result.
RECOMMENDED THREAD LOCKING AGENTS

LOCTITE Type
LOCTITE Color
LOCTITE 242
Blue
LOCTITE 262
Red
LOCTITE 270
Green
LOCTITE 271
Red
Application Steps
1. Completely remove all lubricant and moisture from the bolts and
the female threaded surfaces of the parts to be joined.
2. Apply LOCTITE to the bolts.

4. Wait at least on hour before continuing the installation procedure.
SERVICING
Hub Bearing Preload at the Wheel Pin
44, 42 (High Ride Suspension) Model
N (lb)
New bearing and New oil seal
20 - 25 (4.4 - 5.5)
Reuse bearing and New oil seal
12 - 18 (2.6 - 4.0)

N (lb)
8 - 12 (1.8 - 2.2)
8 - 12 (1.8 - 2.2)
GENERAL DESCRIPTION
FRONT DRIVE AXLE (With Shift On The Fly)
412R300015
(Without Shift On The Fly)
RTW440MF000101
FRONT HUB AND DISC (4

2 Except High Ride Suspension Model)
412R300010
(4
2 High Ride Suspension Model)
RTW34CLF000701
FRONT HUB AND DISC (4

4 Rigid Hub, 4
4 Shift On the Fly)
RTW440LF000601
(4
4 Manual Locking Hub Model)
RTW440LF000201
FRONT PROPELLER SHAFT
RTW34ASF000101
FRONT DRIVE AXLE ASSEMBLY

Front Drive Axle Assembly and Associated Parts
RTW440LF000501
Legend
1. Propeller Shaft
2. Front Axle Case Assembly and Front Drive
Shaft Assembly
3. Washer
4. Mounting Bolt
5. Tie-rod End ; Steering Unit
6. Knuckle and Back Plate
7. Hub and Disc Assembly
8. Suspension Crossmember
Removal
1.
2.
3.
4.
Jack up the vehicle and support it using jack stand.

Remove the tire and wheel.
Remove the stone guard.
Remove the brake caliper fixing bolt and hang the caliper.
Refer to Disc Brakes in Brake section.
5. Remove the antilock brake system speed sensor.
Refer to Front Wheel Speed Sensor in Brake section.
6. Remove the hub and disc assembly.
Refer to Front Hub and Disc in this section.
7. Remove the propeller shaft, refer to Front Propeller Shaft in
this section.
8. Loosen the height control arm of the torsion bar, then
remove the torsion bar from lower control arm.
Refer to Torsion Bar in Suspension section.
9. Remove the suspension crossmember.
10. Remove the lower nut (1) of the stabilizer link.
11. Remove the lower bolt and nut (2) of the shock absorber.
12. Remove the tie-rod end from the knuckle.

Refer to Power Steering Unit in Steering Section.
13. Disconnect the breather hose of the front axle.
14. Disconnect the actuator connector. (With shift on the fly)
15. Remove the bolts and nuts of the lower control arm (Frame
side), then disconnect the lower control arm from frame.
16. Disconnect between the right side upper control arm and
the knuckle, then remove the knuckle with lower control
arm.
CAUTION :
When removing the knuckle, be careful not to damage the
oil seal inside of the knuckle.

17. Support the differential case by the jack.
18. Remove the front axle mounting bolts and nuts, lower the
jack slowly. Remove the left side drive shaft end from the
knuckle, then lower the axle assembly from the vehicle.
CAUTION :
1. During the work, be sure that the axle assembly is
supported securly.
2. Be careful not to damage the bellows of the power
steering unit by interference.
3. Be careful not to damage the breater pipe and breater
pip bracket of the shift on the fly by interference.
Installation
1. Support the differential case by the jack.
2. Jack up the front drive axle assembly, install the left side
drive shaft to the knuckle, then install the mount bolts and
nuts.
CAUTION :
1. Be careful not to damage the bellows of the power
steering unit by interference.
2. Be careful not to damage the breater pipe and breater
pip bracket of the shift on the fly by interference.
3. When installing the drive shaft to the knuckle, be
careful not to damage the oil seal inside of the knuckle.
3. Tighten the mounting bolts and nuts to the specified torque.
Torque : 169 Nm (17.2kgm/124 lb ft)
RTW34CSH000101
4. Install the right side knuckle with lower control arm to the
upper control arm.
Refer to Knuckle in Suspension section.
CAUTION :
When insert the drive shaft to the knuckle, be careful not
to damage the oil seal inside of the knuckle.
5. Align the bolt hole of the lower control arm, install the bolts
and nuts.

NOTE :
Adjust the buffer clearance before tighten the bolts and nuts of
the lower control arm.
6. Install the breather hose of the front axle.
7. Install the actuator connector of the shift on the fly. (With
shift on the fly)
8. Install the tie-rod end of the power steering unit to the
knuckle, tighten the nut to the specified torque.
9. Install lower bolts and nuts of the shock absorber, tighten it
to the specified torque.
10. Install lower nuts of the stabilizer link, tighten it to the
specified torque.
11. Install the suspension crossmember.
12. Install the torsion bar.
Refer to Torsion Bar in Suspension section.
13. Install the front propeller shaft.
Refer to Front Propeller Shaft in this section.
14. Install the hub and disc assembly and adjust the bearing
preload.
Refer to Front Hub and Disc in this section.
15. Install the wheel speed sensor of the antilock brake
system.
16. Install the brake caliper. Tighten the bolt of the caliper
bracket to the specified torque.
17. Install the stone guard.
18. Install the tire and wheel.
19. Lower the vehicle, adjust the trim height.
Refer to Trim Height Adjustment in Steering section.
20. Tighten the bolts and nuts of the lower control arm to the
specified torque.
Refer to Lower Control Arm in Suspension section.
FRONT AXLE DRIVE SHAFT

Front Axle Drive Shaft and Associated Parts
RTW34CLF000401
Legend
1. Axle Case and Differential
2. Snap Ring
3. Bearing
4. Snap Ring
5. Oil Seal
6. Bracket
7. DOJ Case
8. Circlip
9. Bolt
10. Drive shaft Joint Assembly
11. Ball
12. Snap Ring

13. Ball Retainer
14. Ball Guide
15. Band
16. Bellows
17. Band
18. Band
19. Bellows
20. Band
21. UJ Shaft
22. Dust Seal
Disassembly
NOTE :
For the left side, follow the same steps as right side.
1. Use a hammer and chisel to remove the 3 pawls (above
the large and small boot bands on the DOJ side).
COUTION :
Take care not to damage the bellows during band removal.
2. Remove band (1).
3. Pry off circlip (1) with a screwdriver or equivalent.
4. Remove drive shaft joint assembly.

5. Remove the six balls (1) with a screwdriver or equivalent.

6. Using snap ring pliers, remove the snap ring (1) fastening
the ball retainer to the center shaft.
7. Remove ball retainer, ball guide and bellows.
8. Use a hammer and chisel to remove the 3 pawls (above

the large and small boot bands on the UJ side).
CAUTION :
Take care not to damage the bellows during band removal.
9. Remove band (1).

10. Remove bellows.
11. Remove dust seal from UJ.
12. Remove UJ shaft assembly.
13. Remove the mounting bracket fixing bolts, and then
remove DOJ case assembly from the axle case.
14. Remove snap ring and bearing.
15. Remove snap ring and oil seal.
16. Remove bracket.
Inspection And Repair

damage, corrosion or any other abnormal condition are found
through inspection.
Check the following parts.
1. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal
Bushing Replacement
Remove the bushings using a remover 5-8840-2309-0 and

hammer.
By using installer and base 5-8840-2309-0, press fit the

bushings into the bracket.
Reassembly
1. Install DOJ case to bracket.
2. Install oil seal and fix snap ring.
Discard the used oil seal, snap ring and install a new one.
3. Install bearing and fix snap ring.
Discard the used snap ring and install a new one.
4. Install bracket to axle case. Tighten the bracket bolt to the
specified torque.
5. Apply 135g of the specified grease in UJ.
6. Install dust seal for UJ.
Discard the used dust seal and install a new one.
7. Apply a thin coat of grease to the shaft for smooth
installation then install bellows.
CAUTION :
During bellows assembly, be sure to insert both ends of
the bellows into the case and shaft grooves.
Legend
1. Bellows
2. Shaft
Legend
1. UJ Case
2. Bellows
8. Install band. Note the setting direction. After installation,
check Standard Caulk Measure.
Discard the used band and install a new one.
Use the special tool pliers 5-8840-2745-0 to caulk the band
to the specified value.
For both sides on UJ bellows.
Standard Caulk Measure

1.2mm (0.05in) <= (1), (2) <= 4.0mm (0.16in)
(1) - (2) or (2) - (1) <= 0.4mm (0.016in)
9. Install another bellows and fix band.
10.Install the ball guide with the smaller diameter side ahead
onto the shaft.
11.Install ball retainer.
12.Using snap ring pliers, install the snap ring (1) securing the
ball retainer to the shaft.
Discard the used snap ring and install a new one.

13. Align the track on the ball (1) retainer with the window in
the cage, and install the six balls into position.
14. Pack 150g of the specified grease in DOJ case, then install
drive shaft joint assembly. After reassembly, move the DOJ
longitudinally several times to get to fit.
15. Install the circlip (1) so that open ends are positioned away
from the ball groove.
Discard the used circlip and install a new one.
Legend
1. Outer Case
2. Circlip
3. Open Ends
16. Install band. After installation, check that the bellows is free
from distortion.
Use the special tool pliers 5-8840-2745-0 to caulk the band
to the specified valve.
For both sides on UJ bellows.
DIFFERENTIAL
DISASSEMBLY
MAJOR COMPONENTS
RTW34CLF000501
Disassembly Steps
1. Bolt
2. Differential assembly
3. Axle case
4. Bolt
5. Bearing cap
6. Diff. cage assembly
7. Side bearing outer race
8. Side bearing
9. Adjust shims
10. Flange nut
11. Flange
12. Dust cover

13. Pinion gear
14. Inner bearing
15. Adjust shim
16. Collapsible spacer
17. Inner bearing outer race
18. Oil seal
19. Outer bearing
20. Outer bearing outer race
21. Diff. carrier
5. Bearing Cap
Apply a setting mark to the side bearing cap and the differential
carrier.
7. Side Bearing Outer Race

After removal, keep the right and left hand side bearing
assemblies separate to maintain inner and outer race
combinations.
8. Side Bearing
Remover : 5-8840-0013-0
(J-22888)
Adapter : 9-8521-1743-0
(J-8107-2)
9. Adjust Shims
Note the thickness and position of the shims removed.
10.Flange Nut
Holding wrench : 5-8840-0133-0
(J-8614-01)

13.Pinion Gear
Remove the drive pinion assembly using a soft metal rod and a
hammer.
Spindle : 9-8521-5032-0
14.Inner Bearing
Remove the inner bearing using a separator and a press.
Separator : 5-8840-0015-0
(J-22912-01)
17.Inner Bearing Outer Race

20.Outer Bearing Outer Race
Remove the inner bearing outer race and the outer bearing
outer race by using a brass bar and a hammer.
MINOR COMPONENTS
Disassembly Steps
1. Bolt
2. Ring gear
3. Lock pin
4. Cross pin
5. Pinion gear
6. Side gear
7. Thrust washer
8. Differential cage
3. Lock Pin
Break staking on the lock pin using a 5 mm (0.20 in.) diameter
drill.
4. Cross Pin
Remove the cross pin using a soft metal rod and a hammer.

Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered
during inspection.
Visual Check
Ring gear, pinion gear
Bearing
Side gear, pinion gear, cross pin
Differential cage, carrier
Thrust washer
Oil seal
Inspect the following parts for wear, damage, or other

Ring Gear Replacement

(1) The ring gear should always be replaced with the drive
pinion as a set.
(2) When installing the ring gear, apply LOCTITE 271 or
equivalent to the threaded hole and bolt.
(3) Tighten the fixing bolts in a diagonal sequence as
illustrated.
(4) Discard used bolts and install new ones.
Bolt Torque
Nm (kgfm/lbft)
107.9 9.8 (11 1/79.6 7.2)
Clearance Between the Differential Pinion

and the Cross Pin
mm(in)
Standard
Limit
0.05 - 0.10 (0.002 - 0.004)
0.2 (0.008)
Clearance Between the Side Gear and the

Differential Box
mm(in)
Standard
Limit
0.03 - 0.10 (0.001 - 0.004)
0.15 (0.006)
Play in Splines Between the Side Gear

and the Axle Shaft
mm(in)
Standard
Limit
0.07 - 0.36 (0.003 - 0.014)
0.25 (0.010)
REASSEMBLY
MINOR COMPONENTS
Reassembly Steps
1. Differential cage
2. Thrust washer
3. Side gear
4. Pinion gear
5. Cross pin
6. Lock pin
7. Ring gear
8. Bolt
4. Pinion Gear
Install the pinion gear by engaging it with the side gears while
turning both pinion gears simultaneously in the same direction.

5. Cross Pin
(1) Be sure to install the cross pin so that it is in alignment with
the lock pin hole in the differential cage.
(2) Adjust the backlash between the side gear and the pinion
gear.
mm(in)
Backlash
0.10 - 0.20 (0.004 - 0.008)
Thickness of thrust washers available
mm(in)
1.00, 1.05, 1.10 (0.039, 0.041, 0.043)
6. Lock Pin
After lock pin installation, stake the cage to prevent discharge
of the lock pin.
7. Ring Gear
When installing the ring gear, apply LOCTITE 271 or
equivalent to the threaded hole and bolt.
8. Bolt
Tighten the bolts in diagonal sequence as illustrated.
Bolt Torque
Nm (kgfm/lbft)
107.9 9.8 (11 1/79.6 7.2)
Note :
Discard used bolts and install new ones.
Note that all bolts have a left hand thread.
MAJOR COMPONENTS
Reassembly Steps
1. Diff. carrier
2. Outer bearing outer race
3. Inner bearing outer race
4. Adjust shim
5. Inner bearing
6. Collapsible spacer
7. Pinion gear
8. Outer bearing
9. Oil seal
10. Dust cover
11. Flange
12. Flange nut and washer
13. Adjust shim
14. Side bearing
15. Bearing outer race
16. Diff. cage assembly
17. Bearing cap
18. Bolt
19. Axle case
20. Differential assembly
21. Bolt
2. Outer Bearing Outer Race
Installer : 9-8522-1141-0
(J-24256)
Grip
: 5-8840-0007-0
(J-8092)
3. Inner Bearing Outer Race

Installer : 9-8522-1274-0
Grip
: 5-8840-0007-0
(J-8092)
4. Adjust Shim
Adjustment of drive pinion mounting distance
(1) Apply gear oil to the inner and outer drive pinion bearing.
Clean the pinion setting gage set.
Then install the gage set together with the inner and outer
bearings.
1. Pilot
: 5-8840-2085-0
(J-21777-42)
2. Nut and bolt : 5-8840-2089-0

(J-23597-9)
3. Gage plate : 5-8840-2087-0
(J-23597-7)

Tighten the nut to the specified torque.
New bearing
Used bearing
Nm (kgfm/lbft)
2.26 (23/20)
0.98 - 1.18
(10 - 12/8.7 - 10.4)
(2) Clean the side bearing bores. Install the dial indicator with
the discs and Arbor. Install and tighten the bearing caps to
Torque
Nm (kgfm/lbft)
98.1 9.8 (10.0 1.0/72.3 7.2)
Dial indicator : 5-8840-0126-0

(J-8001)
Disc (2 pcs.) : 5-8840-2088-0

(J-23597-8)
Arbor
: 5-8840-0128-0
(J-23597-1)
Gage plate
: 5-8840-2087-0
(J-23597-7)
(3) Set the dial indicator to 0. Place it on the mounting post of

the gaging arbor with the contact button touching the
indicator pad. Force the dial indicator downward until the
needle has made a half turn clockwise. Tighten down the
dial indicator in this position.
(4) Position the plunger on the gage plate. Move the gaging
arbor slowly back and forth and locate the position at which
the dial indicator shows the greatest deflection. At this
point, once again set the dial indicator to 0.
Repeat the procedure to verify the 0 setting.

(5) After the ZERO setting is obtained, rotate the gaging arbor
until the dial indicator rod does not touch the gaging plate.
Record the number the dial indicator needle points to.
(6) Record the pinion depth code on the head of the drive
pinion.
The number indicates a necessary change in the pinion
mounting distance. A plus number indicates the need for a
greater mounting distance (which can be achieved by
decreasing the shim thickness). A minus number indicates
the need for a smaller mounting distance (which can be
achieved by increasing the shim thickness). If examination
reveals pinion depth code 0, the pinion is nominal.

(7) Select the shim using the chart;
mm(in)
Pinion
marking
+10
+8
+6
+4
+2
-2
-4
-6
-8
-10
Dial indicator
reading (inches)
0.081
2.18 (0.0858)
0.082
2.18 (0.0858)
2.20 (0.0866)
2.18 (0.0858)
2.20 (0.0866)
2.24 (0.0882)
2.18 (0.0858)
2.20 (0.0866)
2.24 (0.0882)
2.26 (0.0890)
2.18 (0.0858)
2.20 (0.0866)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.18 (0.0858)
2.20 (0.0866)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.32 (0.0914)
2.18 (0.0858)
2.20 (0.0866)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.32 (0.0914)
2.34 (0.0921)
2.18 (0.0858)
2.20 (0.0866)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.32 (0.0914)
2.34 (0.0921)
2.36 (0.0929)
2.18 (0.0858)
2.20 (0.0866)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.32 (0.0914)
2.34 (0.0921)
2.36 (0.0929)
2.38 (0.0937)
2.18 (0.0858)
2.20 (0.0866)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.32 (0.0914)
2.34 (0.0921)
2.36 (0.0929)
2.38 (0.0937)
2.42 (0.0953)
0.083
0.084
0.085
0.086
0.087
0.088
0.089
0.090
0.091
2.18 (0.0858)
2.20 (0.0866)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.32 (0.0914)
2.34 (0.0921)
2.36 (0.0929)
2.38 (0.0937)
2.42 (0.0953)
2.44 (0.0961)
0.092
2.20 (0.0866)
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.32 (0.0914)
2.34 (0.0921)
2.36 (0.0929)
2.38 (0.0937)
2.42 (0.0953)
2.44 (0.0961)
2.46 (0.0969)
0.093
2.24 (0.0882)
2.26 (0.0890)
2.28 (0.0898)
2.32 (0.0914)
2.34 (0.0921)
2.36 (0.0929)
2.38 (0.0937)
2.42 (0.0953)
2.44 (0.0961)
2.46 (0.0969)
2.48 (0.0977)
0.094
2.26 (0.0890)
2.28 (0.0898)
2.32 (0.0914)
2.34 (0.0921)
2.36 (0.0929)
2.38 (0.0937)
2.42 (0.0953)
2.44 (0.0961)
2.46 (0.0969)
2.48 (0.0977)
2.52 (0.0992)
0.095
2.28 (0.0898)
2.32 (0.0914)
2.34 (0.0921)
2.36 (0.0929)
2.38 (0.0937)
2.42 (0.0953)
2.44 (0.0961)
2.46 (0.0969)
2.48 (0.0977)
2.52 (0.0992)
2.54 (0.1000)
0.096
2.32 (0.0914)
2.34 (0.0921)
2.36 (0.0929)
2.38 (0.0937)
2.42 (0.0953)
2.44 (0.0961)
2.46 (0.0969)
2.48 (0.0977)
2.52 (0.0992)
2.54 (0.1000)
2.56 (0.1008)
0.097
2.34 (0.0921)
2.36 (0.0929)
2.38 (0.0937)
2.42 (0.0953)
2.44 (0.0961)
2.46 (0.0969)
2.48 (0.0977)
2.52 (0.0992)
2.54 (0.1000)
2.56 (0.1008)
0.098
2.36 (0.0929)
2.38 (0.0937)
2.42 (0.0953)
2.44 (0.0961)
2.46 (0.0969)
2.48 (0.0977)
2.52 (0.0992)
2.54 (0.1000)
2.56 (0.1008)
0.099
2.38 (0.0937)
2.42 (0.0953)
2.44 (0.0961)
2.46 (0.0969)
2.48 (0.0977)
2.52 (0.0992)
2.54 (0.1000)
2.56 (0.1008)
2.56 (0.1008)
2.42 (0.0953)
2.44 (0.0961)
2.46 (0.0969)
2.48 (0.0977)
2.52 (0.0992)
2.54 (0.1000)
0.001
2.44 (0.0961)
2.46 (0.0969)
2.48 (0.0977)
2.52 (0.0992)
2.54 (0.1000)
2.56 (0.1008)
0.002
2.46 (0.0969)
2.48 (0.0977)
2.52 (0.0992)
2.54 (0.1000)
2.56 (0.1008)
0.003
2.48 (0.0977)
2.52 (0.0992)
2.54 (0.1000)
2.56 (0.1008)
0.004
2.52 (0.0992)
2.54 (0.1000)
2.56 (0.1008)
0.005
2.54 (0.1000)
2.56 (0.1008)
0.006
2.56 (0.1008)
Note :
When ordering shims, find the part number in the Parts Catalog by using the thickness of the shims listed
in the above table.
5. Inner Bearing
Place the shim on the drive pinion, with the chamfered side
turned towards the pinion head then install the inner bearing on
to the pinion using an installer and a press.
Installer : 9-8522-1165-0 (J-6133-01)
Note:
Do not apply pressure to the roller cage.
Apply pressure only to the inner race.
6. Collapsible Spacer
Discard the used collapsible spacer and install a new one.
9. Oil Seal
Use oil seal installer to install a new oil seal that has been
soaked in rear axle lubricant.
Installer : 9-8522-1275-0 (J-24250)
Note :
Take care not to use a rear differential oil seal instead of
the front differential oil seal.

12.Flange Nut and Washer
(1) Apply lubricant to the pinion threads.
(2) Tighten the nut to the specified torque using the pinion
flange holder.
Pinion flange holder : 5-8840-0133-0
(J-8614-01)
Torque
Nm (kgfm/lbft)
176.6 - 274.7 (18 - 28/130 - 202)
Discard used flange nut and install new one.

(3) Pinion bearing preload
(a) Measure the bearing preload by using a torque meter. Note
the scale reading required to rotate the flange.
(b) continue tightening until the specified starting torque is
obtained.
Starting Torque
Nm (kgfcm/lbin)
0.63 - 1.13 (6.5 - 11.5/5.7 - 9.9)
13.Adjust Shim
(1) Attach the side bearing to the differential assembly without
shims. Support the opposite side using a pilot to prevent
bearing damage.
1
Installer
Drive handle : 5-8840-0007-0

(J-8092)
Pilot
: 9-8522-1164-0
(J-24244)
: 9-8521-1743-0
(J-8107-2)
(2) Insert the differential cage assembly with bearing outer

races into the side bearing bores of the carrier.

(3) Using two sets of feeler gauges, insert a feeler stock of
sufficient thickness between each bearing outer race and
the carrier to remove all end plat. Make certain the feeler
stock is pushed to the bottom of the bearing bores.
Mount the dial indicator on the carrier so that the indicator
stem is at right angles to a tooth on the ring gear.
Dial indicator : 5884-0126-0
(J-8001)
(4) Adjust feeler gauge thickness from side to side until ring
gear backlash is in the specified range.
Backlash
mm(in)
0.13 - 0.18 (0.005 - 0.007)
With zero end play and correct backlash established,
remove the feeler gauge packs, determine the thickness of
the shims required and add 0.05 mm (0.002 in) to each
shim pack to provide side bearing preload. Always use new
shims.
(5) Remove side bearing
Remover : 5-8840-0013-0
(J-22888)
Pilot
: 9-8521-1743-0
(J-8107-2)
14.Side Bearing
Install the side bearings together with the selected shims.
1
Installer
: 9-8522-1164-0 (J-24244)
Drive handle : 5-8840-0007-0 (J-8092)
3 Pilot
: 9-8521-1743-0 (J-8107-2)
2
17.Bearing Cap
Align the setting marks applied at disassembly.
18.Bolt
Bolt Torque
Nm (kgfm/lbft)
98.1 9.8 (10.0 1.0/72.3 7.2)
Measure the amount of run-out of the ring gear at its rear face.
mm(in)
Standard
Limit
0.02 (0.001)
0.05 (0.002)
Gear Tooth Contact Pattern Check and Adjustment

Apply a thin coat of prussian blue or equivalent to the faces of
the 7 - 8 teeth of the ring gear. Check the impression of
contact on the ring gear teeth and make necessary adjustment
as described below if the contact is abnormal.
20.Differential Assembly
(1) Clean the faces of the front axle case and differential
carrier.
Apply the recommended liquid gasket or its equivalent to
the sealing side of the axle case and the carrier.
(2) Attach the differential case and the carrier assembly to the
front axle case and tighten the nuts and bolts. The axle
case bolt is used for drainage.
Torque
Nm (kgfm/lbft)
26 5 (2.6 0.5/18.8 3.6)
(3) Install the axle shaft assemblies as instructed earlier in this
section under Axle Shaft Replacement.
(4) Fill the axle case with hypoid gear lubricant, to just below
the filler hole.
Lubricant capacity
liter (US/UK gal)
1.4 (0.37/0.31)
FRONT HUB AND DISC

(4
2 Except High Ride Suspension Model)
DISASSEMBLY
Refer to SECTION 3E WHEEL AND TIRE for wheel removal procedure.
RTW34CLF000801
Disassembly Steps
1. Bolt
2. Brake caliper
3. Hub cap
4. Split pin
5. Nut retainer
6. Hub nut
7. Lock washer
8. Outer bearing
9. Hub and disc assembly
10. Oil seal
11. Inner bearing and outer race
12. ABS sensor rotor
13. Bolt
14. Wheel pin
Before removal, jack up the front of vehicle and support frame
with jack stands.
2. Brake Caliper
(1) Remove the two bolts from the rear side of the knuckle arm,
then remove the brake caliper, with the brake hose
attached.
(2) Use a wire etc., for attaching the brake caliper to the upper
link.
Refer to the section Brake.
3. Hub Cap
When removing hub cap, exercise care so as not to scratch or
distort hub fitting face.

Using a brass bar to remove the outer bearing outer race (1),
oil seal, inner bearing and inner bearing outer race (2) from the
hug.
If necessary, replace the wheel pin in the following manner.

13.Bolt
14.Wheel Pin ; Front Hub
(1) Scribe mark on hub to disc before disassembly to insure
proper assembly.
(2) Drive out the ABS sensor rotor using a metal bar and
hammer through the two bolt holes.
Discard the used ABS sensor rotor

(3) Clamp hub and disc assembly in vise using protective pads
and remove six (6) disc to hub retaining bolts.
(4) Place hub on a suitable work surface and remove wheel

studs, as required, using a hammer.

through inspection.
For inspection and servicing of disc caliper, and relative parts, and ABS parts, refer to section 5 Brakes.
Hub
Hub bearing
Bearing outer race
Disc
Oil seal
Knuckle spindle
ABS sensor rotor
Caliper
Visual Check
Check the following parts for wear, damage or other abnormal
conditions.
REASSEMBLY
RTW34CLF000901
Reassembly Steps
1. Wheel pin
2. Bolt
3. ABS sensor rotor
4. Inner bearing and outer race
5. Oil seal
7. Outer bearing
8. Lock washer
9. Hub nut
10. Nut retainer
11. Split pin
12. Hub cap
13. Brake caliper
14. Bolt
1. Wheel Pin
(1) Place hub on a wood workbench or a block of wood,
approx. 6 by 6 to protect the wheel stud ends and threads.
(2) Install wheel stud using a hammer.
Be sure wheel stud is started squarely and seats
completely.
(3) Align index marks and install hub to disc.
2. Bolt
Torque
Nm (kgfm/lbft)
103 10 (10.5 1/75.9 7.2)
3. ABS sensor rotor

(1) Set a new ABS sensor rotor, if replacement is required.
(2) Install the ABS sensor rotor in the hub, using special tools.
Installer : 5-8840-2789-0
Grip :
5-8840-0007-0
4. Inner Bearing and Outer Race
5. Oil Seal
Outer Bearing Outer Race
(1) Install the bearing outer race by driving into the hub.
Installer (Outer) : 5-8822-0053-0 (J-29016)
Installer (Inner) : 5-8822-0054-0 (J-29015)
Drive handle
: 5-8840-0007-0 (J-8092)

(2) Install the outer and inner bearing into the hub with fingers.
(3) Install oil seal using special tools.

Discard the used oil seal and install a new one.
Installer : 5-8522-0051-0
(J-33161)
Grip
: 5-8840-0007-0
(J-8092)

12. Hub Cap
Apply grease in the hub and hub cap.
Description
Hub cap
Hub
Amount g(oz)
Hub
50 (1.76)
Hub cap
20 (0.70)
Outer bearing
6.5 (0.23)
Inner bearing
12 (0.42)
9. Hub nut
Adjustment of front wheel hub bearing preload
1. Tighten spindle nut to 3.0 kgm (21.7 lb.ft/29.4 Nm) torque.
2. Turn the hub 2-3 turns and loosen the nut just enough so
that it can be turned with the fingers.
3. Turn the nut all the way in with the fingers and check to be
sure the hub has no free play.
4. Measure the bearing preload by pulling one of the wheel
hub studs with a spring scale.
5. Tighten the spindle nut until specified bearing preload Is
obtained.
6. Install the split pin in the nut retainer.
Discard the used split pin and install a new one.
After reassembling, install the disc brake caliper assembly.
Bearing Preload
Nm (kgfm/lbft)
8-12 (0.8-1.2 / 69-104)
8-12 (0.8-1.2 / 69-104)

14.Bolt
Torque
Nm (kgfm/lbft)
215.7 19.6 (22 2/159.2 14.5)
FRONT HUB AND DISC

(4
4, 4
2 High Ride Suspension,
4 Rigid Hub, 4
4 Shift On the Fly Model)
4
DISASSEMBLY
Refer to SECTION 3E WHEEL AND TIRE for wheel removal procedure
411R300011
Disassembly Steps
1. Bolt
2. Hub cap
3. Snap ring and shim (44 model only)
4. Flange (44 model only)
5. Lock washer
6. Hub nut
8. Outer bearing
9. Oil seal
10. Inner bearing
12. Bolt
13. Wheel pin
6. Hub nut
Wrench : 5-8840-2117-0
(J-36827)

Before disassembly, remove the disc brake caliper assembly
and hang it on the frame with wires.
Refer to Section Brake for disc brake caliper removal
procedure.
12.Bolt
proper assembly.


through inspection.
For inspection and servicing of disc caliper, and relative parts, and ABS parts, refer to Section Brakes.
Hub
Hub bearing, oil seal
Knuckle spindle
Disc
Caliper
ABS sensor rotor
Cap, Hub flange, Shim, Snap ring
Visual Check
conditions.
REASSEMBLY
Reassembly Steps
1. Wheel pin
2. Bolt
3. ABS sensor rotor
4. Inner bearing
5. Oil seal
6. Outer bearing
8. Hub nut
9. Lock washer
10. Flange (44 model only)
11. Snap ring and shim (44 model only)
12. Hub cap
13. Bolt
1. Wheel Pin
completely.
2. Bolt
Torque
Nm (kgfm/lbft)
103 10 (10.5 1/75.9 7.2)
3. ABS sensor rotor

Installer : 5-8840-2789-0
Grip :
5-8840-0007-0
4. Inner Bearing
Outer race ; outer bearing
Install the outer race by driving it into the hub.
Installer : 5-8840-2119-0
(J-36829)
Grip
: 5-8840-0007-0
(J-8092)

5. Oil Seal
Installer : 5-8840-2120-0
(J-36830)
Grip
: 5-8840-0007-0
(J-8092)
Apply grease (Besco L-2 or equivalent) to the lip portion.
6. Outer bearing
Installer : 5-8522-0054-0
(J-29015)
Grip
: 5-8840-0007-0
(J-8092)
RTW44CSH000101

(1) Apply grease in the hub.
(2) Apply grease (Besco L-2 or equivalent) to the outer and
inner bearing.
g(oz)
Hub
35 (1.23)
Outer bearing
10 (0.35)
Inner bearing
15 (0.53)
8. Hub Nut
(1) Turn the place where there is a chamfer in the tapped hole
to the outer side, and attach the nut.
Wrench : 5-8840-2117-0
(J-36827)
Preload Adjustment
Tighten the hub nut at 29.4 Nm (3 kgfm / 21.716 lb.ft), then
loosen the nut to the full.
Tighten the hub nut at the value given below, using a spring
scale on the wheel pin.
Bearing Preload
N(lb)
20 - 25 (4.4 - 5.5)
Used bearing and New oil seal
12 - 18 (2.68 - 4.0)
If the measured bearing preload is outside the specifications,

adjust it by loosening or tightening the bearing nut.
9. Lock Washer
Turn the side with larger diameter of the tapered bore to the
vehicle outer side, and attach the washer.
If the bolt holes in the lock plate are not aligned with the
corresponding holes in the nut, reverse the lock plate.
If the bolt holes are still out of alignment, turn in the nut just
enough to obtain alignment,. Screw is to be fastened tightly so
its head may come lower than the surface of the washer.
11.Snap ring, shims (4

4 model only)
Adjust the clearance between the flange and the snap ring.
Clearance
mm(in)
0 - 0.2 (0 - 0.08)
Adjust shims available

mm(in)
0.2, 0.3, 0.5, 1.0
(0.008, 0.011, 0.020, 0.039)
13.Bolt
Torque
Nm (kgfm/lbft)
59 (6.0 / 43)
RTW440SH000901
FRONT HUB AND DISC

(4
4 Manual Locking Hub Model)
DISASSEMBLY
Refer to SECTION 3E WHEEL AND TIRE for wheel removal procedure
RTW440LF000301
Disassembly Steps
1. Bolt
2. Cover assembly
3. Snap ring and shim
4. Body assembly
5. Lock washer
6. Hub nut
8. Outer bearing
9. Oil seal
10. Inner bearing
12. Bolt
13. Wheel pin
14. Clutch assembly

15. Snap ring
16. Knob
17. Compression spring
18. Follower
19. Retaining spring
20. X-ring
21. Snap ring
22. Inner assembly
23. Snap ring
24. Ring
25. Spacer
1. Bolt
Before removal, shift transfer lever into 2H position and set
free wheeling hub knob into FREE position.
6. Hub nut
Wrench : 5-8840-2117-0
(J-36827)

Before disassembly, remove the disc brake caliper assembly
and hang it on the frame with wires.
Refer to Section Brake for disc brake caliper removal
procedure.
14.Clutch Assembly
While pushing follower knob, turn clutch assembly clockwise
and then remove clutch assembly from knob.
19.Retaining Spring
Remove retaining spring from clutch assembly by turning it
counterclockwise.

12.Bolt
proper assembly.


through inspection.
For inspection and servicing of disc caliper, and relative parts, and ABS parts, refer to Section Brakes.
Hub
Hub bearing, oil seal
Knuckle spindle
Disc
Caliper
ABS sensor rotor
Cap, Hub flange, Shim, Snap ring
Free wheeling hub parts (Option)
Clutch, Knob, follower, inner, ring and
spring
Visual Check
conditions.
REASSEMBLY
RTW440LF000401
Reassembly Steps
1. Spacer
2. Ring
3. Snap ring
4. Inner assembly
5. Snap ring
6. X-ring
7. Knob
8. Snap ring
9. Retaining spring
10. Follower
11. Compression spring
12. Clutch assembly
13. Wheel pin

14. Bolt
16. Inner bearing
17. Oil seal
18. Outer bearing
20. Hub nut
21. Lock washer
22. Body assembly
23. Snap ring and shim
24. Cover assembly
25. Bolt
1. Spacer
Apply grease to both faces of spacer.
4. Inner Assembly
Apply grease wheel bearing to inside face of ring.
g(oz)
Amount of grease
6 (0.21)
7. Knob
(1) Apply grease Wheel bearing to outer circumference of knob
and inner circumference of cover.
(2) Align detent ball to either groove of cover.
8. Snap Ring
Turn the smoother face to knob side.
9. Retaining Spring
Align the end of spring to the end of cut portion of clutch spring
groove.
10.Follower
Install follower to clutch so that follower nail will come closer to
the bent portion of retaining spring by aligning follower stopper
nail to outer teeth of clutch. Then, hook retaining spring onto
upper portion of hanger nails of follower.
11.Compression Spring
Turn the smaller diameter side to follower.
12.Clutch Assembly
Align follower nail to handle groove, and then assemble clutch
with knob by pushing and turning clutch counterclockwise to
knob.

13.Wheel Pin
completely.
14.Bolt
Torque
Nm (kgfm/lbft)
103 10 (10.5 1/75.9 7.2)
15.ABS sensor rotor

Installer : 5-8840-2789-0
Grip :
5-8840-0007-0
16.Inner Bearing
Installer : 5-8840-2119-0
(J-36829)
Grip
: 5-8840-0007-0
(J-8092)

17.Oil Seal
Installer : 5-8840-2120-0
(J-36830)
Grip
: 5-8840-0007-0
(J-8092)
Apply grease (Besco L-2 or equivalent) to the lip portion.
18.Outer bearing
Installer : 5-8522-0054-0
(J-29015)
Grip
: 5-8840-0007-0
(J-8092)
RTW44CSH000201
19.Hub and Disc Assembly

(1) Apply grease in the hub.
(2) Apply grease (Besco L-2 or equivalent) to the outer and
inner bearing.
g(oz)
Hub
35 (1.23)
Outer bearing
10 (0.35)
Inner bearing
15 (0.53)
20.Hub Nut
(1) Turn the place where there is a chamfer in the tapped hole
to the outer side, and attach the nut.
Wrench : 5-8840-2117-0
(J-36827)
Preload Adjustment
Tighten the hub nut at 29.4 Nm (3 kgfm / 21.716 lb.ft), then
loosen the nut to the full.
Tighten the hub nut at the value given below, using a spring
scale on the wheel pin.
Bearing Preload
N(lb)
20 - 25 (4.4 - 5.5)
Used bearing and New oil seal
12 - 18 (2.68 - 4.0)
If the measured bearing preload is outside the specifications,

adjust it by loosening or tightening the bearing nut.
21.Lock Washer
Turn the side with larger diameter of the tapered bore to the
vehicle outer side, and attach the washer.
If the bolt holes in the lock plate are not aligned with the
corresponding holes in the nut, reverse the lock plate.
If the bolt holes are still out of alignment, turn in the nut just
enough to obtain alignment,. Screw is to be fastened tightly so
its head may come lower than the surface of the washer.
22.Body Assembly
Apply adhesive (Loctite 15 or equivalent) to the both joining
faces.
23.Snap Ring and Shims

Adjust the clearance between the free wheeling hub body and
the snap ring.
Clearance
mm(in)
0 - 0.2 (0 - 0.08)
Adjust Shims Available

0.2, 0.3, 0.5, 1.0
(0.008, 0.011, 0.020, 0.039)
24.Cover Assembly
Align stopper nails to grooves of body.
mm(in)

25.Bolt
Torque
Nm (kgfm/lbft)
12.0 2.0 (1.2 0.2 / 8.7 1.4)
TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair front axle problems. Each troubleshooting chart has three
headings arranged from left to right.
(1) Checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into ten sub-sections:
4
2 Model
1. Wanders and pulls
2. Front wheel shimmy
4
4 Model
1.
2.
3.
4.
5.
6.
Oil leak at front axle

Oil leak at pinion shaft
Noises in front axle drive shaft joint
Noises in front axle
Wanders and pulls
Front wheel shimmy
Propeller shaft
1. Noise
2. Vibration
2 Model
4
1. WANDERS AND PULLS
Checkpoint
Wheel bearing preload
Trouble Cause
Countermeasure
NG
Too tight
Adjust the wheel bearing

preload
NG
Incorrect
Adjust the front alignment
Loose or worn
Tighten or replace
Worn or improperly inflated
Replace or adjust the inflation
Front or rear suspension parts

loose or broken
Tighten or replace
OK
Front alignment
OK
Steering unit
NG
OK
NG
Tire
OK
NG
Suspension
2. FRONT WHEEL SHIMMY

Checkpoint
Wheel bearing
Trouble Cause
NG
Countermeasure
Worn or improperly adjusted
Adjust or replace
Incorrect
Worn
Replace the ball joint or bush
Loose or worn
Tighten or replace
Worn
Replace the shock absorber
OK
Front alignment
NG
OK
Ball joint or bush
NG
OK
NO
Steering unit
OK
NG
Tire
OK
Shock absorber
NG
4 MODEL
4
1. OIL LEAK AT FRONT AXLE
Checkpoint
Trouble Cause
NG
Oil seal
Countermeasure
Cracked
Repair or replace
OK
NG
Front axle housing
2. OIL LEAK AT PINION SHAFT

NG
Gear oil level
Too much gear oil
Correct the oil level
NG
Worn or defective
NG
Loose or damaged
Tighten or replace
OK
Oil seal
OK
Pinion flange
3. NOISES IN FRONT AXLE DRIVE SHAFT JOINT

Drive shaft joints and bellows
(UJ and DOJ)
NG
Broken or worn
Replace the drive shaft joints

and bellows
4. NOISES IN FRONT AXLE

Checkpoint
Oil level
Trouble Cause
Countermeasure
NG
Insufficient gear oil
Replenish the gear oil
NG
Wrong or poor grade gear oil
Too much or too little backlash
Adjust the backlash
Worn or chipped
Replace the ring gear pinion

gear or side gear
Worn
Replace the pinion shaft

bearing
Worn
Replace the wheel bearing
Loose or worn
Tighten or replace
OK
Drive pinion to ring gear

backlash
NG
OK
Ring gear, pinion gear or side

gear
NG
OK
Pinion shaft bearing
NG
OK
Wheel bearing
NG
OK
Differential bearing
NG
5. WANDERS AND PULLS

Checkpoint
Wheel bearing preload
Trouble Cause
Countermeasure
NG
Too tight
Adjust the wheel bearing

preload
NG
Incorrect
Loose or worn
Tighten or replace
Front or rear suspension parts

loose or broken
Tighten or replace
OK
Front alignment
OK
Steering unit
NG
OK
NG
Tab
OK
Suspension
NG
6. FRONT WHEEL SHIMMY

Checkpoint
Wheel bearing
Trouble Cause
NG
Countermeasure
Worn or improperly adjusted
Adjust or replace
Incorrect
Worn
Replace the ball joint or bush
Loose or worn
Tighten or replace
OK
Front alignment
NG
OK
Ball joint or bush
NG
OK
Steering unit
NO
OK
NG
Tire
OK
Shock absorber
NG
Worn
Replace the shock absorber
PROPELLER SHAFT
1. NOISE
Checkpoint
Yoke spline
Trouble Cause
NG
Countermeasure
Damaged or worn
Replace
Worn or jammed
Replace
OK
Spider bearing
NG
2. VIBRATION
Shaft runout
NG
Incorrect
Replace
NG
Unbalance
Adjust
NG
Worn
Replace
NG
Jammed
Replace
OK
Shaft balance
OK
Transmission rear housing
bushing, transfer case
housing bushing
OK
Yoke spline

ITEM NO.
ILLUSTRATION
PART NO.
PART NAME
FAL-1
5-8840-0013-0
(J-22888)
Side bearing puller
FAL-14
9-8521-1743-0
(J-8107-2)
Side bearing plug adapter
FAL-3
5-8840-0133-0
(J-8614-01)
Pinion flange holder
FAL-8
9-8521-5032-0
Final pinion spindle
FAL-10
5-8840-0015-0
(J-22912-01)
Separator
FAL12
9-8522-1141-0
(J-24256)
Outer bearing outer race

installer
OTL-1
5-8840-0007-0
(J-8092)
Driver handle
FAL-16
9-8522-1274-0
(J-24252)
Inner bearing outer race

installer
FAL-34
5-8840-2085-0
(J-21777-42)
Pilot
ITEM NO.
ILLUSTRATION
PART NO.
PART NAME
FAL-41
5-8840-2089-0
(J-23597-9)
Nut & bolt
FAL-36
5-8840-2087-0
(J-23597-7)
Gauge plate
FAL-42
5-8840-0126-0
(J-8001)
Dial indicator
FAL-43
5-8840-0128-0
(J-23597-1)
Arbor
FAL-38
5-8840-2088-0
(J-23597-8)
Disc (2 pcs. required)
FAL-59
9-8522-1165-0
(J-6133-01)
Pinion bearing installer

(for 4WD)
FAL-52
9-8522-1275-0
(J-24250)
Pinion oil seal installer
FAL-56
9-8522-1164-0
(J-24244)
Side bearing installer
FAL-57
5-8522-0053-0
(J-29016)
Outer bearing installer

(for 2WD)
ITEM NO.
ILLUSTRATION
PART NO.
PART NAME
FAL-58
5-8522-0054-0
(J-29015)
Inner bearing installer

(for 2WD)
FAL-54
5-8522-0051-0
(J-33161)
Hub oil seal installer

(for 2WD)
FAL-62
5-8840-2117-0
(J-36827)
Hub nut wrench
FAL-17
5-8840-2119-0
(J-36829)
Outer bearing inner race

installer (for 4WD)
FAL-19
5-8840-2120-0
(J-36830)
Oil seal installer (for 4WD)
FAL-18
5-8522-0054-0
(J-29015)
Outer bearing outer race

installer (for 4WD)
FAL-61
5-8840-2137-0
(J-38194)
Inner cam installer
5-8840-2126-0
Auto locking shim gauge

(for 4WD)
5-8840-2125-0
Snap ring installer

(for 4WD)
FAL-39
FAL-60
ITEM NO.
ILLUSTRATION
PART NO.
PART NAME
5-8840-2789-0
ABS sensor rotor installer
SHIFT ON THE FLY SYSTEM 4C2-1
DRIVELINE/AXLE
SHIFT ON THE FLY SYSTEM
CONTENTS
Shift On The Fly System....................................
Outline of Shift on The Fly System .................
Shift On The Fly Electrical Equipment...............
Axle Shaft Connection and Disconnection .....
Actuator Assembly..........................................
4C2-1
4C2-2
4C2-2
4C2-3
4C2-3
4C2-3
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.
Shift On The Fly System and Association

Parts ................................................................. 4C2-4
Disassembly ................................................... 4C2-5
Inspection and Repair..................................... 4C2-6
Reassembly.................................................... 4C2-9
Torque Specifications..................................... 4C2-12
Special Service Tool....................................... 4C2-13

parts and systems.
4C2-2 SHIFT ON THE FLY SYSTEM
Shift On The Fly System

Outline of Shift on The Fly System
The shift on the fly system switches between 2 wheel
drive (2WD) and 4 wheel drive (4WD) electrically by
driver's pressing the 4WD switch (push button type) on
instrument panel.
This system controls below operations.
2. Retrial of shifting the transfer front output gear.

3. Connecting front wheels to, and disconnecting them
from, the front axles by axle motor actuator.
4. Indicator on instrument panel.
5. 4WD out signal to other Electronic Hydraulic Control
Unit.
1. Shifting the transfer front output gear (Connecting to,

and disconnecting from, front propeller shaft by
motor actuator).
System Diagrams
RUW34BLF000201
Shift On The Fly Electrical Equipment

Axle Shaft Connection and Disconnection
RUW34BMF000101
Actuator Assembly
412RY00004
Shift On The Fly System and Association Parts
RTW440LF000701
Disassembly steps
1. Filler plug
2. Bolt
3. Front axle drive shaft (LH side)
4. Bolt
5. Actuator assembly
6. Bolt
7. Housing
8. Sleeve
9. Clutch gear
10. Snap ring
11. Inner shaft
12. Snap ring
13. Inner shaft bearing
14. Needing bearing
15. Oil seal
Reassembly steps
To reassemble, follow the disassembly steps in
the reverse order.
DISASSEMBLY
1. Filler Plug
Remove filler plug and packing and drain oil.
2. Bolt
Loosen mounting bracket fitting bolts and remove front axle
drive shaft from front axle case.
3. Front Axle Drive Shaft (LH side)
4. Bolt
Loosen actuator ASM fitting bolts.
5. Actuator Assembly
Draw out actuator ASM.
6. Bolt
Remove hosing fitting bolts.
7. Housing
8. Sleeve
9. Clutch Gear
10.Snap Ring
Remove snap ring from front axle case by using a snap ring
pliers.
412RW017
11.Inner Shaft
Take out inner shaft from front axle case.
12.Snap Ring
Remove snap ring from inner shaft by using a snap ring
pliers.
412RW016
13.Inner Shaft Bearing

Remove inner shaft bearing by using a special tool and
press.
Remove : 5-8840-2197-0 (J-37452)
NOTE:
Be careful not to damage the shaft.
412RW015

14.Needle Bearing
Remove needle bearing from inner shaft by using a special
tool.
Remover
: 5-8840-0027-0 (J-26941)
Sliding hammer
: 5-8840-0084-0 (J-2619-01)
NOTE:
Be careful not to damage the shaft.
412RS045
15.Oil Seal
Remove oil seal from front axle case.
NOTE:
Be careful not to damage the front axle case.

Inspect the removed parts. If there are abnormalities such as
wear and damage, take corrective action or replace.
Visual Check
412RW014
412RS008
Check and see if the inner shaft has such

abnormalities as wear and damage.
When inspecting the inner shaft, be sure to check and

see if its splined part is twisted, worn, or cracked. If so,
replace with a new shaft. In case such an abnormality
in its gear part (a slide with sleeve), replace the shaft.
Inner Shaft Run-Out

With both end centers supported, rotate the shaft slowly
and measure deflection with a dial gauge.
Inner Shaft Run-Out (Limit)
0.5 (0.02)
NOTE:
Do not heat the shaft to correct its bend.
412RS026
mm (in)
Inner Shaft Bearing

Inspect the state of inner shaft bearing. If any abnormality
such as smoothlessness is found, replace with a new inner
shaft bearing.
Insert a clutch gear and check the state of needle bearing.
If there is an abnormality such as smoothlessness, replace
the needle bearing.
RTW440SH000101
Sleeve
Visual Check
Check and see that there is not wear, damage, or crecking
in the sleeve.
NOTE:
Close inspection of the groove and inner gear are required
because those are important parts.
Functional Check
Operate the sleeve with the inner shaft combined with the
clutch gear.
If smoothlessness is felt, replace the sleeve.
NOTE:
Gear oil should be applied to the contact surface of gear.
412RW011
Dimensional Check
Check the width of sleeve center groove.
Sleeve Center Groove (Limit)
7.1 (0.28)
412RW022
mm (in)
Clutch Gear
Visual Check
Check and see the there is not wear, damage, crack, or
any other abnormality in the clutch gear.
Functional Check
If there is an abnormality such as soothlessness when
operated in combination with sleeve, replace the clutch
gear.
RTW440SH000201
NOTE:
When inspection, gear oil should be applied to the contact
surface of gear.
Dimensional Check
Make sure of the size illustrated.
Clutch Gear Out Side Diameter (Limit)
mm (in)
36.98 (1.46)
RTW440SH000301
Actuator
Visual Check
Check and see that there is no damage, cracking, or other
abnormality.
Functional Check
Make sure of function with voltage (12V) applied to
terminal 3 , 4 and set the tester to terminal 1 , 2 in
accordance with the table below.
RTW440SH000501
State
Port 3
Port 4
Port 1 , 2
Conducting
Function
C
If there is an abnormality, replace the actuator as an

assembly.
NOTE:
Be careful not to permit the entry of water or dust into the ports
of the actuator.
Do not open the actuator cover, if the actuator will be reused.
RTW440SH000401
RTW440SH000601
Dimension Check
Measure illustration sized A, B, and C
Limit
mm (in)
A
64.3 (2.53)
6.7 (0.26)
6.7 (0.26)
RTW440SH000801
REASSEMBLY
15. Oil seal
Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer.
Installer
5-8840-2407-0 (J-41693)
Grip
5-8840-0007-0 (J-8092)
RTW440SH000701
14. Needle Bearing

Force a new needle bearing into inner shaft by using a
special tool.
412RS051
Installer
: 5-8840-2408-0 (J-41694)
Grip
: 5-8840-0007-0 (J-8092)

13. Inner Shaft Bearing
Place a new snap ring in inner shaft.
Force a new inner shaft bearing into the inner shaft.
Installer
: 5-8840-2197-0 (J-37452)
412RS044
12.Snap Ring
NOTE;
Be careful not to damage the inner shaft.
11.inner Shaft
Clean the housing contact surface of the front axle
case.
Insert inner shaft assembly into the front axle case.
NOTE:
Be careful not to damage oil seal.
10.Snap Ring
Install snap ring in the groove of front axle case.
NOTE:
Be sure to install the snap ring properly.
412RW017
9. Clutch Gear
Apply differential gear oil to clutch oil.
8. Sleeve
Apply differential gear oil to sleeve.
7. Housing
Clean contact surface with the front axle and sctuator
mounting surface.
Apply liquid gasket to the contact surface on the front
axle case and install in the housing.
412RW023
6. Bolt
Tighten bolts to specified tightening torque.
Housing Bolt Torque
N m (kg m/lb ft)
75 (7.6/55)

5. Actuator
Clean the actuator contact surface with the housing.
Apply liquid gasket to the contact surface on the
actuator side.
Align shift arm with the groove of sleeve and install the
actuator.
4. Bolt
Tighten bolts to specified torque.
Actuator Bolt Torque
9 (0.95/78)
N m (kg m/lb ft)
3. Front Axle Drive Shaft (LH side)

2. Bolt
Install front axle drive shaft and mounting bracket.
Tighten fitting bolts to specified tightening torque.
Bolt Torque
N m (kg m/lb ft)
116 (11.8/85)
1. Filler Plug
Pour specified amount of differential gear oil.
Front Differential Oil Capacity
liter (US/UK gal)
1.4 (0.37/0.31)
Actuator Housing Oil Capacity
liter (US/UK gal)
0.12 (0.03/0.03)
Install filler plug through packing and tighten to

specified torque.
Filler Plug Torque
Nm (kgm/lbft)
78 (8.0/58)
Nm (kgfm / lb ft)
RTW440LF000801

ILLUSTRATION
PART NO.
PART NAME
5-8840-0007-0
(J-8092)
Grip
5-8840-2407-0
(J-41693)
Installer: Oil seal
5-8840-2408-0
(J-41694)
Installer: Bearing needle
5-8840-0027-0
(J-26941)
Remover: Bearing needle
5-8840-0084-0
(J-2619-01)
Hammer: Sliding
5-8840-2197-0
(J-37452)
Remover: Bearing inner shaft
MEMO
No. TFPRO-WE-0431
WORKSHOP MANUAL
TF SERIES
BRAKES
SECTION 5
BRAKE CONTROL SYSTEM 5A-1
SECTION 5A
BRAKE CONTROL SYSTEM

CONTENTS
Service Precaution............................................................................................................. 5A-4
General Description........................................................................................................... 5A-5
EHCU, Brake Pipe Diagram .......................................................................................... 5A-6
Hydraulic Unit (H/U)....................................................................................................... 5A-7
Normal Braking ......................................................................................................... 5A-8
Pressure Isolation (Pressure Maintain) .................................................................. 5A-9
Pressure Reduction.................................................................................................. 5A-10
Brake Release ........................................................................................................... 5A-11
Circuit Diagram.............................................................................................................. 5A-12
Connector List ............................................................................................................... 5A-13
Part Location ................................................................................................................. 5A-15
EHCU Pin-outs............................................................................................................... 5A-17
System Components..................................................................................................... 5A-19
Electronic Hydraulic Control Unit (EHCU) .............................................................. 5A-19
ABS Warning Lamp .................................................................................................. 5A-19
Wheel Speed Sensor (WSS)..................................................................................... 5A-19
G-Sensor ................................................................................................................... 5A-19
Normal and Anti-lock Braking ................................................................................. 5A-19
Electronic Brake-force Distribution (EBD) System................................................ 5A-20
Brake Pedal Travel.................................................................................................... 5A-20
Acronyms and Abbreviations ....................................................................................... 5A-20
General Diagnosis ............................................................................................................. 5A-20
General Information ...................................................................................................... 5A-20
ABS Service Precautions.............................................................................................. 5A-20
Computer System Service Precautions....................................................................... 5A-21
General Service Precautions........................................................................................ 5A-21
Note on Intermittents .................................................................................................... 5A-21
Test Driving ABS Complaint Vehicles ......................................................................... 5A-21
"ABS and Brake" Warning Lamp ................................................................................. 5A-22
Normal Operation .......................................................................................................... 5A-22
5A-2 BRAKE CONTROL SYSTEM
Brake (EBD) Warning Lamp.......................................................................................... 5A-22

Tech 2 Scan Tool........................................................................................................... 5A-23
DATA LIST (Tech 2) ....................................................................................................... 5A-26
Actuator Test (Tech 2)................................................................................................... 5A-27
Diagnostic Trouble Codes................................................................................................. 5A-30
Diagnosis By "ABS" Warning Lamp Illumination Pattern .............................................. 5A-32
Basic Diagnostic Flow Chart ............................................................................................ 5A-35
Basic Inspection Procedure.............................................................................................. 5A-37
1. Basic Inspection of Service Brake........................................................................... 5A-37
2. Ground Inspection .................................................................................................... 5A-37
Wheel Speed Sensor Inspection Procedure.................................................................... 5A-38
Symptom Diagnosis........................................................................................................... 5A-39
ABS Works Frequently But Vehicle Does Not Decelerate ......................................... 5A-39
Uneven Braking Occurs While ABS Works................................................................. 5A-40
The Wheels Are Locked ................................................................................................ 5A-40
Brake Pedal Feed Is Abnormal..................................................................................... 5A-41
Braking Sound (From EHCU) Is Heard
While Not Braking ....................................................................................................... 5A-42
No ABS Warning Lamp ................................................................................................. 5A-43
DTC C0221 (Flash Code 21) Front Right Wheel Speed Sensor
Short Circuit or Circuit Open ......................................................................................... 5A-44
DTC C0222 (Flash Code 22) Front Right Wheel Speed Sensor Incorrect Signal.......... 5A-46
DTC C0223 (Flash Code 23) Front Right Wheel Speed Sensor
Signal - Tooth Chipping................................................................................................... 5A-48
DTC C0225 (Flash Code 25) Front Left Wheel Speed Sensor Short Circuit or
Circuit Open .................................................................................................................... 5A-50
DTC C0226 (Flash Code 26) Front Left Wheel Speed Sensor Incorrect Signal ............ 5A-52
DTC C0227 (Flash Code 27) Front Left Wheel Speed Sensor Signal - Tooth
Chipping ........................................................................................................................... 5A-54
DTC C0231 (Flash Code 31) Rear Right Wheel Speed Sensor Short Circuit or
Circuit Open .................................................................................................................... 5A-56
DTC C0232 (Flash Code 32) Rear Right Wheel Speed Sensor Incorrect Signal........... 5A-58
DTC C0233 (Flash Code 33) Rear Right Wheel Speed Sensor Signal - Tooth
Chipping ........................................................................................................................... 5A-60
DTC C0235 (Flash Code 35) Rear Left Wheel Speed Sensor Short Circuit or
Circuit Open .................................................................................................................... 5A-62
DTC C0236 (Flash Code 36) Rear Left Wheel Speed Sensor Incorrect Signal ............. 5A-64
DTC C0237 (Flash Code 37) Rear Left Wheel Speed Sensor Signal - Tooth
Chipping ........................................................................................................................... 5A-66
DTC C0238 (Flash Code 38) Tire Diameter Error............................................................. 5A-68
DTC C0241 (Flash Code 41) Front Right Isolation Solenoid Circuit Open or
Shorted to Ground ........................................................................................................... 5A-69
DTC C0242 (Flash Code 42) Front Right Dump Solenoid Circuit Open or Shorted
to Ground.......................................................................................................................... 5A-69
DTC C0243 (Flash Code 43) Front Right Isolation Solenoid Circuit Shorted to
Battery............................................................................................................................... 5A-69
DTC C0244 (Flash Code 44) Front Right Dump Solenoid Circuit Shorted to
Battery............................................................................................................................... 5A-69
DTC C0245 (Flash Code 45) Front Left Isolation Solenoid Circuit Open or
Shorted to Ground ........................................................................................................... 5A-71
DTC C0246 (Flash Code 46) Front Left Dump Solenoid Circuit Open or Shorted
to Ground.......................................................................................................................... 5A-71
DTC C0247 (Flash Code 47) Front Left Isolation Solenoid Circuit Shorted to
Battery............................................................................................................................... 5A-71
DTC C0248 (Flash Code 48) Front Left Dump Solenoid Circuit Shorted to
Battery............................................................................................................................... 5A-71
DTC C0251 (Flash Code 51) Rear Isolation Solenoid Circuit Open or Shorted to
Ground .............................................................................................................................. 5A-73
DTC C0252 (Flash Code 52) Rear Dump Solenoid Circuit Open or Shorted to
Ground .............................................................................................................................. 5A-73
DTC C0253 (Flash Code 53) Rear Isolation Solenoid Circuit Shorted to Battery ......... 5A-73
DTC C0254 (Flash Code 54) Rear Dump Solenoid Circuit Shorted to Battery.............. 5A-73
DTC C0265 (Flash Code 65) Fail Safe Relay (FSR) Shorted to Ground ......................... 5A-75
DTC C0266 (Flash Code 66) Fail Safe Relay (FSR) Shorted to Battery.......................... 5A-75
DTC C0267 (Flash Code 67) ABS Motor Shorted to Ground .......................................... 5A-77
DTC C0268 (Flash Code 68) ABS Motor Shorted to Battery ........................................... 5A-77
DTC C0271 (Flash Code 71) ECU Failure or Valve +B Circuit Open .............................. 5A-79
DTC C0274 (Flash Code 74) ABS Operation Long Time ................................................. 5A-80
DTC C0276 (Flash Code 76) G-Sensor Malfunction ........................................................ 5A-82
DTC C0277 (Flash Code 77) Power Supply Low Input.................................................... 5A-84
DTC C0278 (Flash Code 78) Power Supply High Input ................................................... 5A-84
DTC C0282 (Flash Code 82) 4 Wheel Drive State Input Signal Failure .......................... 5A-86
DTC C0285 (Flash Code 85) Assembly Error (G-sensor)................................................ 5A-88
Special Tools...................................................................................................................... 5A-90
Service Precaution
FOLLOW WARNINGS COULD RESULT IN
REPAIRS.

parts and systems.
General Description
EHCU has controlled ABS (Anti-lock Brake System)
and EBD (Electronic Brake-force Distribution System).
ABS works on all four wheels. EBD system works on
rear 2 wheels. A combination of wheel speed sensor
and Electronic Hydraulic Control Unit (EHCU) can
determine when a wheel is about to stop turning and
adjust brake pressure to maintain best braking.
This system helps the driver maintain greater control of

the vehicle under heavy braking conditions.
Note: The Electronic Hydraulic Control Unit (EHCU)
comprises the Hydraulic Unit (H/U) and Control Unit.

C05L300010
Legend
(1) Electronic
(6) Front Left Wheel Speed Sensor
(2) Hydraulic
(7) Rear Right Wheel Speed Sensor
(3) Hydraulic Unit (H/U)
(8) Rear Left Wheel Speed Sensor
(4) Control Unit
(9) G-sensor (4WD only)
(5) Front Right Wheel Speed Sensor
(10) 2-4WD Control Unit (4WD only)
EHCU, Brake Pipe Diagram

C05L300011
Legend
(1) Front Right Brake Port (out)
(2) Front Left Brake Port (out)
(3) Rear Brake Port (out)
(4) Front Brake Port (in)

(5) Rear Brake Port (in)
Hydraulic Unit (H/U)
C05L300004
Legend
(1) Brake Pedal
(5) Dump Valve
(2) Master Cylinder
(6) Buffer Chamber
(3) Motor and Pump
(7) Brake
(4) Isolation Valve
Normal Braking
During normal (non anti-lock) braking, the solenoid
valve has current flow. The dump valve is closed and
the isolation valve is opened due to spring force.
Brake fluid travels through the center of the isolation

valve (normally open) around the dump valve (normally
closed) then to the brake pistons.
C05L300012
Pressure Isolation (Pressure Maintain)

The electronic-hydraulic control unit is activated when
the brakes are applied.
If the information from the wheel speed sensors
indicates excessive wheel deceleration (imminent
lockup), the first step in the anti-lock sequence is to
isolate the brake pressure being applied by the brake
pedal.
The microprocessor in the Control Unit sends a voltage

to the coil to energize and close the isolation valve.
This prevents any additional fluid pressure applied by
the brake pedal from reaching the wheel. With the
isolation valves closed, unnecessary increase in the
brake pressure is prevented.
C05L300013
Pressure Reduction
Once the brake pressure is isolated, it must be reduced
to allow the wheels to unlock. This is accomplished by
dumping a portion of the brake fluid pressure into a
buffer chamber.
The microprocessor activates the normally closed dump
valve to open, allowing fluid from the wheels to be
dumped into the buffer chamber. This is done with very
short activation pulses opening and closing the dump
valve passageway. Brake pressure is reduced at the

wheel and allows the wheel to begin rotating again. The
fluid from the brake piston is stored in the buffer
chamber against spring pressure and a portion of this
fluid also primes the pump.
The dump valves are operated independently to control
the deceleration of the wheel.
C05L300014
Brake Release
At the end of the anti-lock stop, when the brake pedal is
released, the pump will remain running for a short time
to help drain any fluid from the buffer chamber. As this
fluid returns into the system, the spring forces
the piston back to its original position.

The isolation valve opens and fluid may return to the
master cylinder. Conventional braking is then resumed.
C05L300015
Circuit Diagram
RTW45AXF000101
Connector List
No.
Connector face
B-23
Green
Meter-A
Meter-B
G-sensor
I2
J/B I4
Data Link Connector
Ignition Switch (IGSUB : G1)
Ignition Switch (IGSUB : G2)
EHCU
White
J/B E2
White
J/B E1
Silver
Body-LH ; Ground
Gray
ABS Sensor Rear
H-6
Engine Room-RH ; ground
C-36
Silver
Black
F-4
C-2
Silver
ABS Sensor Front-LH
C-109
B-63
White
Orange
C-108
B-62
White
ABS Sensor Front-RH
C-107
B-58
Black
Orange
C-67
B-56
White
Stop Light Switch
C-54
B-54
White
White
C-53
B-48
Black
Connector face
C-44
B-24
Green
No.
White
Engine Room ~ INST
H-7
Engine Room-LH ; Ground
White
Engine Room ~ INST
No.
Connector face
H-15
White
Engine Room ~ Chassis
H-18
White
Engine Room ~ INST
P-2
Silver
Relay & Fuse Box
P-6
Silver
Body Earth (Ground)
P-10
Silver
Engine Ground
R-15
Black
2-4WD Control Unit
No.
Connector face
Part Location (RHD)
RTW48AXF022101 & RTW48AXF022201
Part Location (LHD)
RTW48AXF022301 & RTW48AXF022401
EHCU Pin-outs
C05L300005
EHCU Side
Pin No.
(Harness
side
Pin No.)
1
(C67-11)
2
(C67-10)
3
(C67-28)
4
(C67-27)
5
(C67-9)
6
(C67-8)
7
(C67-7)
8
(C67-6)
9
(C67-5)
10
(C67-4)
11
(C67-3)
12
(C67-2)
13
(C67-1)
Wire
Color
Typical Value
WHT/GRN
Battery Voltage
Solenoid
Ground 1
BLK
Solenoid, Control Unit
Ground 2
BLK
0V
(Less than 0.1V)
0V
(Less than 0.1V)
Battery Voltage
Pin Function
Power Supply
Power Supply
WHT/RED
Stop Light Switch

Serial
Serial
Not Used
Not Used
Note
Motor
Motor
RED
Open : 0V
Close Condition :
Close : Battery Voltage Step on the Brake Pedal
ORN/WHT
J1850 Class 2
Communication
GRN
J1850 Class 2
Communication
-
G-Sensor Ground
BLK
Front Right Wheel Speed Sensor (-)
GRY
Front Right Wheel Speed Sensor (+)
GRY/RED
0V
(Less than 0.1V)
High Level: 1.28~2.2V
Low Level: 0.5~0.86V
12H1.5V
Rear Right Wheel Speed Sensor (-)
BLK
4WD Only
DTC C0276, C0285
DTC C0221,C0222,
C0223
DTC C0221,C0222,
C0223
High Level: 1.28~2.28V DTC C0231,C0232,

Low Level: 0.5~0.86V C0233

EHCU Side
Pin No.
Pin Function
(Harness
side
Pin No.)
14
ABS Warning Lamp
(C67-17)
15
Not Used
(C67-16)
16
Not Used
(C67-15)
17
G-Sensor Signal
(C67-14)
18
(C67-13)
19
(C67-12)
20
(C67-26)
21
(C67-25)
22
(C67-22)
23
(C67-23)
24
(C67-22)
25
(C67-21)
26
(C67-20)
27
(C67-19)
28
(C67-18)
Wire
Color
Typical Value
YEL
More than 10V
YEL/BLK
2.0~3.0V
(MAX4.0V,MIN1.0V)
Front Left Wheel Speed Sensor (+)
RED
12H1.5V
Rear Right Wheel Speed Sensor (+)
ORN
12H1.5V
LT BLU
More than 10V
BLU/WHT
Battery Voltage
Not Used
Not Used
Transfer (2-4WD Control Unit)
GRY
Front Left Wheel Speed Sensor (-)
WHT
Rear Left Wheel Speed Sensor (+)
GRY/BLU
Pulse Signal
(High 4.5V, Low 1.5V)
High Level: 1.28~2.2V
Low Level: 0.5~0.86V
12H1.5V
Rear Left Wheel Speed Sensor (-)
WHT/BLU
EBD (Brake) Warning Lamp

Starter Switch ON
(Power Supply and Switch Position)
Not Used
Note
4WD Only
It checks in a flat place
(0G:2.5V)
DTC C0276, C0285
DTC C0225, C0226,
C0227
DTC C0231,C0232,
C0233
Control Unit
DTC C0277,C0278
4WD Only
DTC C0282
DTC C0225, C0226,
C0227
DTC C0235, C0236,
C0237
High Level: 1.28~2.2V DTC C0235, C0236,

Low Level: 0.5~0.86V C0237
System Components
Electronic Hydraulic Control Unit (EHCU), four Wheel
Speed Sensors, two Warning Lamps, and G-sensor.
Electronic Hydraulic Control Unit (EHCU)
The EHCU consists of ABS control circuits, fault
detector, and a fail-safe. It drives the EHCU according
to the signal from each sensor, cancelling ABS to return
to normal braking when a malfunction has occurred in
the ABS.
The EHCU has a self-diagnosing function which can
indicate faulty circuits during diagnosis.
The EHCU is mounted on the engine compartment rear
left side. It consists of a motor, solenoid valves fail safe
relay.
Solenoid Valves: Reduces or holds the caliper fluid
pressure for each front brake or both rear brakes
according to the signal sent from the EHCU.
Buffer chamber: Temporarily holds the brake fluid that
returns from the front and rear brake so that pressure
of front brake can be reduced smoothly.
Motor: Drives the pump according to the signal from
EHCU.
Fail safe Relay: When failure occurs in ABS.
The power supply to solenoid Valve is cut.
ABS Warning Lamp
The ABS warning lamp will turn ON for

approximately three seconds after the ignition switch is
to the ON position.
If the ABS warning lamp stays ON after the ignition
switch is the ON position, or comes ON and stays
ON while driving, the Anti-lock Brake System should
be inspected for a malfunction according to the
diagnosis procedure.
Wheel Speed Sensor (WSS)
It consists of a sensor and a rotor. The sensor is
attached to the knuckle on the front wheels and to the
rear wheels.
The rotor is press-fit in the axle shaft.
G-Sensor
The G-sensor detects the vehicle deceleration speed
and sends a signal to the EHCU. In 4WD operation, all
four wheels may be decelerated in almost the same
phase, since all wheels are connected mechanically.
This tendency is noticeable particularly on roads with
low friction coefficient, and the ABS control is adversely
affected.
The G-sensor judges whether the friction coefficient of
road surface is low or high, and changes the EHCU's
operating system to ensure ABS and EBD control.
Normal and Anti-lock Braking
Under normal driving conditions, the Anti-lock Brake
System functions the same as a standard power
assisted brake system. However, with the detection of
wheel lock-up, a slight bump or kick-back will be felt in
the brake pedal. This pedal bump will be followed by a
series of short pedal pulsations which occurs in rapid
succession. The brake pedal pulsation will continue
until there is no longer a need for the anti-lock function
or until the vehicle is stopped. A slight ticking or
popping noise may be heard during brake applications
when the anti-lock features is being used.
When the anti-lock feature is being used, the brake
pedal may rise even as the brakes are being applied.
This is also normal. Maintaining a constant force on
the pedal will provide the shortest stopping distance.
825L300001
Vehicles equipped with the Anti-lock Brake System

have an amber ABS warning lamp in the instrument
panel. The ABS warning lamp will illuminate if a
malfunction in the Anti-lock Brake System is detected
by the Electronic Hydraulic Control Unit (EHCU). In
case of an electronic malfunction, the EHCU will turn
ON the ABS warning lamp and disable the anti-lock
braking function.

Electronic Brake-force Distribution (EBD) System
ABS has the EBD function. EBD is a function which
controls braking force distribution of a front wheel and a
rear wheel, and makes brake fluid pressure of a rear
wheel the optimal. If the rate of a slip of a rear wheel
becomes large more than fixed compared with a front
wheel about the rate of a slip in order to perform
braking force distribution of a front wheel and a rear
wheel, the brake fluid pressure of a rear wheel will be
controlled. EBD enables it to always utilize the braking
power of a rear wheel for the maximum according to
the load change concerning the back axis by vehicles
loading states (No luggage, loading, etc.), deceleration,
etc. Brake fluid pressure control to a rear wheel is
performed by the EBD function which used the ABS
function without the mechanical proportioning valve.
EHCU
Electronic Hydraulic Control Unit
FL
Front Left
FR
Front Right
GEN
Generator
H/U
Hydraulic Unit
MV
Millivolts
RR
Rear
RPS
Revolution per Second
VDC
DC Volts
VAC
AC Volts
W/L
Warning Lamp
WSS
Wheel Speed Sensor
General Diagnosis
General Information
C05L300016
Brake Pedal Travel

Vehicles equipped with the Anti-lock Brake System may
be stopped by applying normal force to the brake pedal.
Although there is no need to push the pedal beyond the
point where it stops or holds the vehicle, by applying
more force the pedal will continue to travel toward the
floor.
This extra brake pedal travel is normal.
ABS troubles can be classified into two types, those

which can be detected by the ABS warning lamp and
those which can be detected as a vehicle abnormality
by the driver.
In either case, locate the fault in accordance with the
BASIC DIAGNOSTIC FLOWCHART and repair.
Please refer to Section 5C for the diagnosis of
mechanical troubles such as brake noise, brake judder
(brake pedal or vehicle vibration felt when braking),
uneven braking, and parking brake trouble.
ABS Service Precautions

Acronyms and Abbreviations
Required Tools and Items:
Several acronyms and abbreviations are commonly

used throughout this section:
ABS
Anti-lock Brake System
CKT
Circuit
DLC
Data Link Connector
EBD
Electronic Brake-force Distribution
Box Wrench
Brake Fluid
Special Tool
Some diagnosis procedures in this section require the
installation of a special tool.
5-8840-0366-0 High Impedance Multimeter
When circuit measurements are requested, use a
circuit tester with high impedance.
Computer System Service Precautions
Note on Intermittents
The Anti-lock Brake System and Electronic Brake-force

Distribution interfaces directly with the Electronic
Hydraulic Control Unit (EHCU) which is a control
computer that is similar in some regards to the Engine
Control Module. These modules are designed to
withstand normal current draws associated with vehicle
operation. However, care must be taken to avoid
overloading any of the EHCU circuits. In testing for
opens or shorts, do not ground or apply voltage to any
of the circuits unless instructed to do so by the
appropriate diagnostic procedure. These circuits should
only be tested with a high impedance multimeter
5-8840-0366-0 or special tools as described in this
section. Power should never be removed or applied to
any control module with the ignition in the ON
position.
Before removing or connecting battery cables, fuses or
connectors, always turn the ignition switch to the OFF
position.
As with virtually any electronic system, it is difficult to

identify an intermittent failure. In such a case
duplicating the system malfunction during a test drive or
a good description of vehicle behavior from the
customer may be helpful in locating a most likely
failed component or circuit. The symptom diagnosis
chart may also be useful in isolating the failure. Most
intermittent problems are caused by faulty electrical
connections or wiring. When an intermittent failure is
encountered, check suspect circuits for:
Suspected harness damage.
Poor mating of connector halves or terminals not
fully seated in the connector body (backed out).
Improperly formed or damaged terminals.
General Service Precautions

The following are general precautions which should be
observed when servicing and diagnosing the Anti-lock
Brake System and/or other vehicle systems. Failure to
observe these precautions may result in Anti-lock Brake
System and Electronic Brake-force Distribution
damage.
If welding work is to be performed on the vehicle
using an electric arc welder, the EHCU and valve
block connectors should be disconnected before
the welding operation begins.
The EHCU and valve block connectors should
never be connected or disconnected with the
ignition ON.
Note:
If only rear wheels are rotated using jacks or drum
tester, the system will diagnose a speed sensor
malfunction and the ABS and Brake warning lamp
will illuminate. But actually no trouble exists. When
the DTC is not detected and the ABS and BRAKE
warning lamp is on, How to erase code is
performed and a ABS and BRAKE warning lamp
are off.
If the battery has been discharged
The engine may stall if the battery has been completely
discharged and the engine is started via jumper cables.
This is because the Anti-lock Brake System (ABS) and
Electronic Brake-force Distribution (EBD) System
requires a large quantity of electricity. In this case, wait
until the battery is recharged, or set the ABS and EBD
to a non-operative state by removing the fuse for the
ABS. After the battery has been recharged, stop the
engine and install the ABS fuse. Start the engine again,
and confirm that the ABS warning Lamp does not light.
Test Driving ABS Complaint Vehicles

In case that there has been an abnormality in the
lighting pattern of ABS warning lamp, the fault can be
located in accordance with the DIAGNOSIS BY ABS
WARNING LAMP ILLUMINATION PATTERN. In case
of such trouble as can be detected by the driver as a
vehicle symptom, however, it is necessary to give a test
drive following the test procedure mentioned below,
thereby reproducing the symptom for trouble diagnosis
on a symptom basis:
1. Start the engine and make sure that the ABS W/L
goes OFF. If the W/L remains ON, it means that
the Diagnostic Trouble Code (DTC) is stored.
Therefore, read the code and locate the fault.
Note: The DTC cannot be cleared if the vehicle speed
does not exceed about 6km/h (4mph) at DTC, even
though the repair operation is completed.
2. Start the vehicle and accelerate to about 30 km/h
(19 mph) or more.
3. Slowly brake and stop the vehicle completely.
4. Then restart the vehicle and accelerate to about 40
km/h (25 mph) or more.
5. Brake at a time so as to actuate the ABS and stop
the vehicle.
6. Be cautious of abnormality during the test. If the
W/L is actuated while driving, read the DTC and
locate the fault.
7. If the abnormality is not reproduced by the test,
make best efforts to reproduce the situation
reported by the customer.
8. If the abnormality has been detected, repair in
accordance with the SYMPTOM DIAGNOSIS .
Note:
Be sure to give a test drive on a wide, even road
with a small traffic.
If an abnormality is detected, be sure to suspend
the test and start trouble diagnosis at once.
ABS Warning Lamp

When ABS and trouble occurs to actuate ABS
warning lamp, the trouble code corresponding to the
trouble is stored in the EHCU. Only ordinary brake is
available with ABS being unactuated. Even when
ABS warning lamp is actuated, if the starter switch is
set ON after setting it OFF once, the EHCU checks up
on the entire system and, if there is no abnormality,
judges ABS to work currently and the warning lamp is lit
normally even though the trouble code is stored.
NOTE: Illumination of the ABS warning lamp indicates
that anti-lock braking is no longer available. Power
assisted braking without anti-lock control is still
available.
Normal Operation
ABS Warning Lamp
When the ignition is first moved from OFF to RUN,
the amber ABS warning lamp will turn ON. The
ABS warning lamp will turn ON during engine
starting and will usually stay ON for approximately
three seconds after the ignition switch is returned to the
ON position. The warning lamp should remain OFF
at all other times.
Brake (EBD) Warning Lamp
825L300001
Vehicles equipped with the EBD (Electronic Brake-force

Distribution) System have an have Brake warning
lamp in the instrument panel.
If ABS warning lamp and Brake warning lamp are turn
"ON", then EBD is failed. ( Parking brake switch is
"OFF")
In the following conditions, EBD warning lamp is "ON".

Starter switch is "ON", engine "OFF".
( Parking brake switch is "OFF")
If engine is started, then EBD warning lamp is "OFF".
( Parking brake switch is "OFF")
Tech 2 Scan Tool
scan tool user guide.
From 98 MY, Isuzu dealer service departments are

recommended to use Tech 2. Please refer to Tech 2
901RW257
Legend
(1) PCMCIA Card
(2) SAE 16/19 Adaptor
(3) DLC Cable
(4) Tech2

Getting Started
Before operating the Isuzu PCMCIA card with the
Tech 2, the following steps must be performed:
1. The Isuzu System PCMCIA card inserts into the
Tech 2.
2. Connect the SAE 16/19 adapter to the DLC cable.
3. Connect the DLC cable to the Tech 2.
4. Mark sure the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the
vehicle DLC.
060R300015
6. The vehicle ignition turns on.

7. Power up the Tech 2.
8. Verify the Tech 2 power up display.
060R100102
060RW0009
Operating Procedure
The power up screen is displayed when you power
up the tester with the Isuzu systems PCMCIA card.
Follow the operating procedure below.
DATA LIST (Tech 2)

The data displayed by DATA LIST are as follows:
Strings
Front Left Wheel Speed
Units
km/h (MPH)
Description
Start the vehicle and make sure of linear
change in each wheel speed
Front Right Wheel Speed
km/h (MPH)
Rear Left Wheel Speed
km/h (MPH)
Rear Right Wheel Speed
km/h (MPH)
Brake Switch
Open/Closed Brake switch is closed when brake pedal is

stepped on.
ABS Warning Lamp
On/Off
To be Off usually
EBD Warning Lamp
On/Off
To be Off usually
ABS Stop State
On/Off
To be Off usually
ABS Relay
Active/Inactive To be Active usually
Return Pump
Active/Inactive To be Inactive usually
DTC Status
No DTC
To be No DTC usually
4 Wheel Drive Status
Yes/No
To be Yes usually
FL Dump Valve Commanded

(Front Left)
FL Isolation Valve Commanded
(Front Left)
FR Dump Valve Commanded
(Front Right)
FR Isolation Valve Commanded
(Front Right)
Rear Dump Valve Commanded
Active/Inactive Each valve is Active when each valve is

opereted.
Rear Isolation Valve Commanded
Active/Inactive
FL Dump Valve Feedback

(Front Left)
FL Isolation Valve Feedback
(Front Left)
FR Dump Valve Feedback
(Front Right)
FR Isolation Valve Feedback
(Front Right)
Rear Dump Valve Feedback
Active/Inactive
Active/Inactive
Rear Isolation Valve Feedback
Active/Inactive
Active/Inactive
Active/Inactive
Active/Inactive
Active/Inactive
Active/Inactive
Active/Inactive
Active/Inactive
G-Sensor Output
Battery Voltage
Diagnostics Connector
2WD
2.0~3.0V when vehicle speed is 0 km/h (flat

place)
The voltage value currently supplied to EHCU
Open/Closed Diagnostics connector is Open when

diagnostics connector is connected.
4WD
Actuator Test (Tech 2)

There are 5 different menus available for this test. The
state of each circuit can be tested by using these
menus. Especially when DTC cannot be detected, a
faulty circuit can be diagnosed by testing each circuit by
means of these menus.
Even when DTC has been detected, the circuit tests
using these menus could help discriminate between a
mechanical trouble and an electrical trouble.
In all cases test condition; Engine stops with the key
turned to the ON position. To be more specific, the
test is conducted with the brake pedal stepped on after
stepping once and releasing.
Engine: Stop
Ignition SW: ON
060L300002
Return Pump Test

Test condition: Engine stops with the key turned to the
ON position. To be more specific, the test is
conducted with the brake pedal stepped on after
Make sure of the working sound of the return pump
relay and return pump.
The circuit is normal if the working sound of the return
pump relay and return pump are made in accordance
with Tech2s instruction.
060L300002
ABS Check Light Test

Test condition: Engine stops with the key turned to the
ON position. To be more specific, the test is
conducted with the brake pedal stepped on after
The circuit is normal if the warning light (lamp) in
the meter panel comes on and goes out in
accordance with Tech2s instruction.
060L300002

Isolation Valve Test
Purpose: The purpose of this test is to detect brake
pipe and valve line harness wire for wrong connections
and valve trouble.
This test will help you confirm the result of your repair
service including the removal/reinstallation of brake
pipe, valve line harness and valve.
Test conditions: The ignition key is in the ON position
with the four wheels lifted up. The brake pedal is
stepped on, released and stepped on again with the
Test procedure:
1. Connect Tech 2 with the vehicle, and select
Actuaor Test from the menus.
2. Select a Solenoid Valve Test Menu from the
Actuaor Test Menus.
060L300002
CAUTION: When conducting this test, please

observe the following cautions.
1. Do not start the engine.
2. Lift up the vehicle at a level floor.
Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
3. Maintain the lift up.
4. Wipe the floor surface to remove water and oil
so that the surface may become unslippery.
5. Do not load the vehicle.
When lifting up the vehicle, be sure to
observe the lifting up points. Refer to
vehicle lifting points in 0A section.
060L300002
3. Select Isolation Valve from the Valve Select Menus.

4. Step on the brake pedal.
5. Release the brake pedal.
6. Make sure that the Isolation Valve ON aimed at by
Tech 2 and the wheel locked position are the same.
If different, check brake pipe, valve line harness
wiring and H/UNIT. Repair is needed if abnormality
is found.
7. Conduct Step 2 through Step 5 above on all the
four wheels.

Dump Valve Test
Purpose: The purpose of this test is to detect brake
pipe and valve line harness wire for wrong connections
and valve trouble.
This test will help you confirm the result of your repair
service including the removal/reinstallation of brake
pipe, valve line harness and valve.
Test conditions: The ignition key is in the ON position
with the four wheels lifted up. The brake pedal is
stepped on, released and stepped on again with the
Test procedure:
1. Connect Tech 2 with the vehicle, and select
Actuator Test Function from the menus.
2. Select a Solenoid Valve Test Menu from the
Actuator Test Menus.
060L300002
CAUTION: When conducting this test, please

observe the following cautions.
1. Do not start the engine.
2. Lift up the vehicle at a level floor.
Secure a clearance from the floor surface
enough to allow the lifted tire to rotate.
3. Maintain the lift up.
4. Wipe the floor surface to remove water and oil
so that the surface may become unslippery.
5. Do not load the vehicle.
When lifting up the vehicle, be sure to
observe the lifting up points. Refer to
vehicle lifting points in 0A section.
060L300002
3. Select Dump Valve from the Valve Select Meuns.

4. Step on the brake pedal.
5. Make sure that the Dump Valve ON aimed at by
Tech 2 and the wheel released position are the
same. If different, check brake pipe, valve line
harness wiring and H/UNIT. Repair is needed if
abnormality is found.
6. Conduct Step 2 through Step 5 above on all the
four wheels.

Note:
DTC cannot be erased when the DTC is a present.
Diagnostic Trouble Codes

Choose and trace an appropriate flowchart by the
numbers listed below to find fault and repair.
DTC
(Flash
Code)
(12)
C0221
(21)
C0222
(22)
C0223
(23)
C0225
(25)
C0226
(26)
C0227
(27)
C0231
(31)
C0232
(32)
C0233
(33)
C0235
(35)
C0236
(36)
C0237
(37)
C0238
(38)
C0241
(41)
C0242
(42)
C0243
(43)
C0244
(44)
C0245
(45)
C0246
(46)
C0247
(47)
Warning Lamp
Description
Normal Condition
ABS
Brake
(EBD)
System Control
ABS
Main Items
EBD
-
*A
Sensor or Wiring
A
Sensor or install condition
Front Right Wheel Speed Sensor Signal

- Tooth Chipping
*A
Sensor Rotor or install

condition
Front Left Wheel Speed Sensor Short

Circuit or Circuit Open
*A
Sensor or Wiring
*A
Front Left Wheel Speed Sensor Signal Tooth Chipping
*A

condition
Rear Right Wheel Speed Sensor Short

*A
Sensor or Wiring
*A
Rear Right Wheel Speed Sensor Signal

- Tooth Chipping
*A

condition
Rear Left Wheel Speed Sensor Short

*A
Sensor or Wiring
*A
*A

condition
Front Right Wheel Speed Sensor Short

Front Right Wheel Speed Sensor
Incorrect Signal
Front Left Wheel Speed Sensor

Incorrect Signal
Rear Right Wheel Speed Sensor

Incorrect Signal
Rear Left Wheel Speed Sensor

Incorrect Signal
Rear Left Wheel Speed Sensor Signal Tooth Chipping
*B
*B
*B
*B
Tire Diameter Error
Vehicle , Sensor or Tire
Front Right Isolation Solenoid Circuit

Open or Shorted to Ground
Solenoid (EHCU)
Front Right Dump Solenoid Circuit

Open or Shorted to Ground
Solenoid (EHCU)
Front Right Isolation Solenoid Circuit

Shorted to Battery
Solenoid (EHCU)
Front Right Dump Solenoid Circuit

Shorted to Battery
Solenoid (EHCU)
Front Left Isolation Solenoid Open Or

Shorted to Ground
Solenoid (EHCU)
Front Left Dump Solenoid Circuit Open

Or Shorted to Ground
Solenoid (EHCU)
Front Left Isolation Solenoid Circuit

Shorted to Battery
Solenoid (EHCU)

DTC
(Flash
Code)
C0248
(48)
C0251
(51)
C0252
(52)
C0253
(53)
C0254
(54)
C0265
(65)
C0266
(66)
C0267
(67)
C0268
(68)
C0271
(71)
C0274
(74)
C0276
(76)
C0277
(77)
Warning Lamp
Description
ABS
Brake
(EBD)
System Control
Main Items
ABS
EBD
Front Left Dump Solenoid Circuit

Shorted to Battery
Solenoid (EHCU)
Rear Isolation Solenoid Circuit Open or

Shorted to Ground
Solenoid (EHCU)
Rear Dump Solenoid Circuit Open or

Shorted to Ground
Solenoid (EHCU)
Rear Isolation Solenoid Circuit Shorted

to Battery
Solenoid (EHCU)
Rear Dump Solenoid Circuit Shorted to

Battery
Solenoid (EHCU)
Fail Safe Relay (FSR) Shorted to

Ground
Fail Safe Relay (FSR) Shorted to

Battery
Motor (EHCU)

Relay (EHCU)
ABS Motor Shorted to Ground
Motor (EHCU)
ABS Motor Shorted to Battery
Motor (EHCU)
ECU Failure or Valve +B Circuit Open
EHCU
ABS Operation Long Time
EHCU
G-Sensor Malfunction
Power Supply Low Input

C0278 Power Supply High Input

(78)
C0282 4 Wheel Drive State Input Signal Failure
(82)
C0285 Assembly Error (G-sensor)
(85)
*A : When three or more failure are detected, or when
failure containing both front wheels and each rear
wheels are detected, EBD warning lamp is "ON"
and control is canceled.
*B : ABS lamp is OFF when the ABS lamp is ON
after a repair until vehicles speed becomes more
than 6km/h (4mph) in the following ignition cycle
and failure is not detected.
Sensor or Wiring

Battery, Wiring or EHCU

(less than 9V)
Battery or Wiring
(less than 10V)
Battery or Wiring EHCU
Wiring
Vehicle (Sensor or EHCU)
Diagnosis By ABS Warning Lamp

Illumination Pattern
In the event that there is abnormality in the ABS
No.
Condition
warning Lamp illumination pattern while the key is in the

ON position or if the warning Lamp is actuated during
driving, trouble should be diagnosed on a illumination
pattern basis as follows:
ABS Warning Lamp Illumination Pattern
Diagnostic
Warning Lamp is
actuated normally
Normal
Warning Lamp is not

lit
Warning Lamp lighting circuit

trouble. Go to No ABS
Warning Lamp.
Warning Lamp
remains ON
Diagnostic trouble codes are

stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to
the flow charts.
Warning Lamp is
actuated while driving
Diagnostic trouble codes are

stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to
the flow charts.
Diagnostic Trouble Codes (DTCs)

When the warning lamp in the meter remains ON, the
EHCU stores the fault identification and disables the
ABS.

How to display and erase DTCs:
Note:
DTCs can be displayed also by TECH 2 use
Diagnostic Trouble Codes mode.
1. How to start DTC display:
Confirm that the vehicle has come to a
complete stop (with the wheels standing still)
and that the brake pedal is not depressed.
(Unless these two condition are satisfied, DTC
display cannot be started.)
With IGN OFF, connect #12 terminal with #4
terminal or # 5 terminal (GND) . Then turn IGN
ON.
The DLC is located behind the driver side kick panel

350L300005
Keep #12 terminal connected with #4 terminal

or # 5 terminal (GND) during DTC display. (If
#12 terminal is separated from #4 terminal or #
5 terminal (GND) during display, display will
stop.)
2. DTC display:
DTC is displayed by blinking warning lamp.
Double-digit display.
First, normal DTC 12 is displayed three times
and then any other DTCs are displayed three
times. (If no other DTCs have been stored, the
display of DTC 12 will be repeated.)
3. How to erase code:

Conduct brake switch ON/OFF operation 6 or
more times within 3 seconds of self-diagnosis
startup.
The code cannot be erased if more than 3
seconds have passed since self-diagnosis
startup, or if self-diagnosis has started with
brake switched on (brake pedaled).
B05RW0005

4. Notes
If the following should occur during Diagnostic
Trouble Code (DTC) display, the display will be
discontinued. After initial check, the status that
is under the control of ABS will be returned :
The vehicle starts (The wheels turn) or the
brake pedal is depressed.
Up to 3 different codes can be stored.
If the ABS should turn OFF due to an

intermittent defect, the system will be restored
at the next key cycle, if the initial check finds no
abnormality (when IGN is switched from OFF to
ON).
5. An example of DTC display
Display of DTC 23
B05R100001
After displaying DTC 12 three times, one DTC after

another is displayed. DTC is displayed on small
order.
C05L300017
The DTC 12 is displayed repeatedly.
Basic Diagnostic Flow Chart
RTW45AMF000101
Step
1
Action
Value(s)
Yes
No
1. Ignition ON,engine OFF.

2. Observe the ABS warning lamp.
Note: If a starter switch is turned ON, ABS warning
lamp will turn on and a ABS warning lamp will be
turned off after 3 seconds.
Is the ABS warning lamp ON?
Go to Step 2
Go to No
ABS warning
lamp
1. Ignition OFF.
2. Install Tech2.
3. Ignition ON.
4. Attempt to display ABS data with the Tech 2.
Does the Tech 2 display ABS data?
Go to Step 5
Go to Step 3
1. Ignition OFF, disconnect the EHCU.

2. Check the DLC (Data Link Connector) circuit for an
open, short to ground, or short to voltage.
Also, check the DLC ignition feed circuit for an
open or short to ground and the DLC ground circuit
for an open.
3. If a problem is found, repair as necessary.
Was a problem found?
Go to Step 2
Go to Step 4

Step
Action
Value(s)
Yes
No
1. Check the EHCU circuit for an open, short to

ground, or short to voltage. Also, check the EHCU
ignition feed circuit for an open or short to ground
and the EHCU ground circuit for an open.
Go to Step 2
Go to Step 11
Go to Step 6
Go to Step 10
Go to Step 7
Go to
applicable
DTC table
after Go to
step 8
Go to Step 8
Go to Step 9
5
6
Select Display DTCs with the Tech 2.

Are any DTCs stored?
Review and record for Tech 2 Failure Records data
and DTCs.
Is the action complete?
Following the DTC is stored.
Is this DTC C0271 stored?
Clear the DTCs by Clear the Information with Tech

2.
Did the DTCs cleared?
Go to
applicable
DTC table
Go to
Symptom
Diagnosis and
Go to Basic
Inspection
Procedure
Verify repair
10
11
Review and record for Tech 2 data.

Replace the EHCU.

Note: Check the EHCU type for specification, when
the EHCU is replaced.
(Specification; 2WD Model or 4WD Model)
Go to Step 10
Basic Inspection Procedure

1. Basic Inspection of Service Brake
Step
1
2
3
4
5
Action
Value(s)
Yes
Go to Step 2
Repair
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 3
Repair
Go to Step 4
Repair
Go to Step 5
Finished
Go to Step 5
Value(s)
Yes
Go to Step 2
No
Repair
Go to Step 2
Finished
Go to Step 2
Is the fluid level normal?
Does fluid leak?

Is the booster function normal?
Is the pad and rotor normal?
Reconnect all components. Ensure all component
are properly mounted.
Was this step finished?
No
Replenish with
fluid
Go to Step 2
2. Ground Inspection
Step
1
2
Action
Does ABS related ground points normally?
Reconnect all components. Ensure all component
Wheel Speed Sensor Inspection Procedure

Procedure
1.Ignition "OFF".
2.Disconnect the each wheel speed sensors.
3.Check the voltage at sensor harness connector.
Note : Voltage measurement is performed in the phase
where the wheel speed sensor is installed in vehicles.
C05L300019
Connector Pin-outs
Front Wheel Speed Sensor
1
(+) (+12V)
2
(-) (signal)
Rear Wheel Speed Sensor
1
LH (+) (+12V)
2
LH (-) (signal)
3
RH (+)(+12V)
4
RH (-) (signal)
Output Value
High State
Low State
High-Low
Difference
1.28~2.2V
0.5~0.86V
more than 0.8V
Symptom Diagnosis
The symptoms that cannot be indicated by warning
lamp can be divided in the following five categories:
1. ABS works frequently but vehicle does not
decelerate.
2. Uneven braking occurs while ABS works.
3. The wheels are locked.
4. Brake pedal feel is abnormal.

5. Braking sound (from EHCU) is heard while not
braking.
6. No ABS warning lamp
These are all attributable to problems which cannot be
detected by EHCU self-diagnosis. Use the customer
complaint and a test to determine which symptom is
present.
ABS Works Frequently But Vehicle Does Not Decelerate

Step
1
Action
Value(s)
Yes
Go to Step 2
Go to Step 3
Repair wheel
speed sensor.
Go to Step 7
Replace
wheel speed
sensor or
sensor rotor.
Go to Step 8
Go to Step 6
2-4WD Repair
or Go to Step
7
Go to Step 5
Replace
wheel speed
sensor or
repair
harness.
Go to Step 7
Repair or
replace 24WD control
System.
Go to Step 7
Repeat the
Basic
diagnostic
flow chart
Go to Step 7
Is braking force distribution normal between front

and rear of vehicle?
Are axle parts installed normally?
Is there play in each or any wheel speed sensor?
Is there damage, or powered iron sticking to each or

any wheel speed sensor/sensor rotor?
Is the each wheel speed sensor output normal?
Is the 4WD control system function normal?
Reconnect all components, ensure all components

No
Repair brake
parts.
Go to Step 7
Repair axle
parts.
Go to Step 7
Go to Step 4
Uneven Braking Occurs While ABS Works

Step
1
Action
Value(s)
Is there play in each or any sensor?

-
Damage or powdered iron sticking to each or any

sensor/sensor rotor?
Is the each sensor output normal?
Is brake pipe connecting order correct?

Yes
No
Repair.
Go to Step 5
Repair.
Go to Step 5
Go to Step 4
Go to Step 2
Replace
EHCU.
Go to Step 5
-
Go to Step 3
Replace
sensor or
repair
harness.
Go to Step 5
Reconnect
brake pipe
correctly.
Go to Step 5
Go to Step 5
Repeat the
Basic
diagnostic
flow chart
Value(s)
Yes
No
The Wheels Are Locked

Step
Action
Is ABS working?
Go to Step 2
Go to Step 4
Is vehicle speed under 5 km/h?
Go to Step 3
Is the each sensor output normal?
Go to Step 4
Normal.
Replace
sensor or
repair
harness.
Go to Step 6
Go to Step 5
Replace 24WD controll

unit or repair
harness.
Go to Step 6
Replace
EHCU.
Go to Step 6
Repair.
Go to Step 6
Repeat the
Basic
diagnostic
flow chart
Go to Step 6
Is 2-4WD system function normal?
Is EHCU grounded properly?

Brake Pedal Feed Is Abnormal

Step
1
Action
Is the stop light actuated when the brake pedal is
depressed?
1. Turn the ignition switch off.

2. Disconnected EHCU connector.
Is the check voltage for EHCU connector terminals
when brake pedal is depressed than battery voltage?
Is stop light fuse normal?
Is the check continuity between EHCU connector to

body grounded?
Value(s)
Yes
No
Go to Step 2
Go to Step 4
Go to Step 5
Go to Step 6
Repair stop
light harness.
Go to Step 6
Go to Step 3
Harness NG
between stop
light SW and
EHCU.
Go to Step 6
Replace stop
light fuse.
Go to Step 6
Repair body
grounded
harness.
Go to Step 6
Replace stop
light switch.
Go to Step 6
Repeat the
Basic
diagnostic
flow chart
Go to Step 6
Is stop light switch operation normal?

Braking Sound (From EHCU) Is Heard While Not Braking

Step
Action
Value(s)
Yes
Is this the first vehicle start after engine start?
Is vehicle speed under 10 km/h?
Check for the following condition:

At the time of shift down or clutch operation.
At the time of low road friction drive (ice or snow
road) or rough road drive.
At the time of high-speed turn.
At the time of passing curb.
At the time of operating electrical equipment
switches.
At the time of racing the engine.
Did it occur under any one condition above?
Is there play in each or any sensor/wheel speed

sensor rotor?
Damage or powdered iron sticking to each or any

sensor/wheel speed sensor rotor?
ABS may
sometimes be
actuated even
when brake
pedal is not
applied.
Repair.
Go to Step 7
Repair.
Go to Step 7
Check
harness/
connector for
suspected
disconnection
If no
disconnection
is found,
replace EHCU
Go to Step 7
Repair.
Go to Step 7
Repeat the
Basic
diagnostic
flow chart
Go to Step 7
4
5
6
Is each sensor normal?

Note : Check the EHCU type for specification, the
EHCU is replaced.
(Specification; 2WD or 4WD Model)

It is self
checking
sound
Normal.
It is self
checking
sound
Normal.
No
Go to Step 2
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
No ABS Warning Lamp

Step
1
2
3
4
5
Action
Check the meter fuse for the instrument cluster
ignition feed circuit.
Is the fuse OK?
Replace the fuse.
1. Ignition OFF, disconnect the EHCU.
Value(s)
Yes
No
Go to Step 2
Go to Step 3
Verify repair
Go to Step 3
Go to Step 5
Go to Step 4
Repair or replace the meter circuit or meter.

and the EHCU ground circuit for an open.
Verify repair
Verify repair
Go to Step 6
1. Ignition OFF, reconnect the EHCU.

Verify repair
Go to Step 7
Replace EHCU.
Note : Check the EHCU type for specification, the
EHCU is replaced.
(Specification; 2WD or 4WD Model)
Verify repair
DTC C0221 (Flash Code 21) Front Right Wheel Speed Sensor Short Circuit or
Circuit Open
LTW35AMF000101
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
1. Check for a poor connection at the front right wheel

speed sensor harness connector.
2. Check installation condition for front right wheel
speed sensor.
Verify repair
Go to Step 3
1. Ignition OFF, disconnect the EHCU and front right

wheel speed sensor.
2. Check the circuit between EHCU and front right
wheel speed sensor. (Circuit for an open, short to
ground,or short to voltage.)
Verify repair
Go to Step 4
Was the Basic Diagnostic Flow Chart performed?

Step
Action
Value(s)
Yes
No
1. Replace front right wheel speed sensor.

2. Select Display DTCs with the Tech 2.
Note : Perform the various tests (actuator test, test
run, brake test, etc.) then observe the DTC with a
Tech2.
Replace EHCU.
Note : Check the EHCU type for specification, when
(Specification ; 2WD model or 4WD model)
Was the action complete?
Go to Step 5
Verify repair
Verify repair
DTC C0222 (Flash Code 22) Front Right Wheel Speed Sensor Incorrect Signal
LTW35AMF000101
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart

speed sensor.
Verify repair
Go to Step 3

wheel speed sensor.
wheel speed sensor. (short to ground, or short to
voltage.)
Verify repair
Go to Step 4

Tech2.
Go to Step 5
Verify repair

Step
5
Action
Repair or replace the front right sensor rotor at front
hub.
Tech2.
Replace EHCU.
Value(s)
Yes
No
Verify repair
Go to Step 6
Go to Step 7
Verify repair
Verify repair
DTC C0223 (Flash Code 23) Front Right Wheel Speed Sensor Signal - Tooth
Chipping
LTW35AMF000101
Step
Action
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart

speed sensor.
Verify repair
Go to Step 3
1. Check condition for sensor rotor at front hub.

Verify repair
Go to Step 4

wheel speed sensor.
voltage.)
Verify repair
Go to Step 5
Value(s)

Step
Action
Value(s)
Yes
No

Tech2.
Replace EHCU.
Go to Step 6
Verify repair
Verify repair
DTC C0225 (Flash Code 25) Front Left Wheel Speed Sensor Short Circuit or
Circuit Open
LTW35AMF000101
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
1. Check for a poor connection at the front left wheel

2. Check installation condition for front left wheel
speed sensor.
Verify repair
Go to Step 3
1. Ignition OFF, disconnect the EHCU and front left

wheel speed sensor.
2. Check the circuit between EHCU and front left
ground, or short to voltage.)
Verify repair
Go to Step 4

Step
Action
Value(s)
Yes
No
1. Replace front left wheel speed sensor.

Tech2.
Replace EHCU.
Go to Step 5
Verify repair
Verify repair
DTC C0226 (Flash Code 26) Front Left Wheel Speed Sensor Incorrect Signal
LTW35AMF000101
Step
Action
Value(s)
Yes
No

-
Go to Step 2
Go to Basic
Diagnostic
Flow Chart

speed sensor.
Verify repair
Go to Step 3

wheel speed sensor.
voltage.)
Verify repair
Go to Step 4

Go to Step 5
Verify repair
Repair or replace the front left sensor rotor at front

hub.
Verify repair
Go to Step 6

Step
Action

Tech2.
Replace EHCU.
Value(s)
Yes
No
Go to Step 7
Verify repair
Verify repair
DTC C0227 (Flash Code 27) Front Left Wheel Speed Sensor Signal - Tooth
Chipping
LTW35AMF000101
Step
Action
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart

speed sensor.
Verify repair
Go to Step 3
1. Check condition for sensor rotor at front hub.

Verify repair
Go to Step 4

wheel speed sensor.
voltage.)
Verify repair
Go to Step 5
Value(s)

Step
Action
Value(s)
Yes
No

Tech2.
Replace EHCU.
Go to Step 6
Verify repair
Verify repair
DTC C0231 (Flash Code 31) Rear Right Wheel Speed Sensor Short Circuit or
Circuit Open
LTW35AMF000101
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
1. Check for a poor connection at the rear right wheel

2. Check installation condition for rear right wheel
speed sensor.
Verify repair
Go to Step 3
1. Ignition OFF, disconnect the EHCU and rear right

wheel speed sensor.
2. Check the circuit between EHCU and rear right
ground,or short to voltage.)
Verify repair
Go to Step 4

Step
Action
Value(s)
Yes
No
1. Replace rear right wheel speed sensor.

Tech2.
Replace EHCU.
Go to Step 5
Verify repair
Verify repair
DTC C0232 (Flash Code 32) Rear Right Wheel Speed Sensor Incorrect Signal
LTW35AMF000101
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart

speed sensor.
Verify repair
Go to Step 3

wheel speed sensor.
voltage.)
Verify repair
Go to Step 4

Tech2.
Go to Step 5
Verify repair

Step
Action
Repair or replace the rear right sensor rotor at rear

axle.
Tech2.
Replace EHCU.
Value(s)
Yes
No
Verify repair
Go to Step 6
Go to Step 7
Verify repair
Verify repair
DTC C0233 (Flash Code 33) Rear Right Wheel Speed Sensor Signal - Tooth
Chipping
LTW35AMF000101
Step
Action

speed sensor.
1. Check condition for sensor rotor at rear axle.

wheel speed sensor.
voltage.)
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
Verify repair
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5

Step
Action
Value(s)
Yes
No

Tech2.
Replace EHCU.
Go to Step 6
Verify repair
Verify repair
DTC C0235 (Flash Code 35) Rear Left Wheel Speed Sensor Short Circuit or
Circuit Open
LTW35AMF000101
Step
Action
1. Check for a poor connection at the rear left wheel

2. Check installation condition for rear left wheel
speed sensor.
1. Ignition OFF, disconnect the EHCU and rear left

wheel speed sensor.
2. Check the circuit between EHCU and rear left
ground, or short to voltage.)
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
Verify repair
Go to Step 3
Verify repair
Go to Step 4

Step
Action
Value(s)
Yes
No
1. Replace rear left wheel speed sensor.

Tech2.
Replace EHCU.
Go to Step 5
Verify repair
Verify repair
DTC C0236 (Flash Code 36) Rear Left Wheel Speed Sensor Incorrect Signal
LTW35AMF000101
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart

speed sensor.
Verify repair
Go to Step 3

wheel speed sensor.
voltage.)
Verify repair
Go to Step 4

Tech2.
Go to Step 5
Verify repair

Step
Action
Repair or replace the rear left sensor rotor at rear

axle.
Tech2.
Replace EHCU.
Value(s)
Yes
No
Verify repair
Go to Step 6
Go to Step 7
Verify repair
Verify repair
DTC C0237 (Flash Code 37) Rear Left Wheel Speed Sensor Signal - Tooth
Chipping
LTW35AMF000101
Step
Action

speed sensor.
1. Check condition for sensor rotor at rear axle.

wheel speed sensor.
voltage.)
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
Verify repair
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5

Step
Action
Value(s)
Yes
No

Tech2.
Replace EHCU.
Go to Step 6
Verify repair
Verify repair
DTC C0238 (Flash Code 38) Tire Diameter Error

Step
Action
1. Check for the tire size of each wheels.

2. If the tire size is different, replace the tire.
1. Check for the gear ratio of a front axle differential

gear and a rear axle differential gear.
2. If the gear ratio is different, repair the gear ratio.

Tech2.
Replace EHCU.
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
Verify repair
Go to Step 3
Verify repair
Go to Step 4
Go to Step 5
Verify repair
Verify repair
DTC C0241 (Flash Code 41) Front Right Isolation Solenoid Circuit Open or
Shorted to Ground
DTC C0242 (Flash Code 42) Front Right Dump Solenoid Circuit Open or
Shorted to Ground
DTC C0243 (Flash Code 43) Front Right Isolation Solenoid Circuit Shorted to
Battery
DTC C0244 (Flash Code 44) Front Right Dump Solenoid Circuit Shorted to
Battery
RTW45AMF000201
Step
Action
1. Ignition OFF.
and the EHCU ground circuit for an open or short to
voltage.
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
Verify repair
Go to Step 3

Step
Action
Value(s)
Yes
No
1. Ignition ON, engine OFF.

Note: Perform the various tests (actuator test, test
Tech2.
Replace EHCU.
Go to Step 4
Verify repair
Verify repair
DTC C0245 (Flash Code 45) Front Left Isolation Solenoid Circuit Open or
Shorted to Ground
DTC C0246 (Flash Code 46) Front Left Dump Solenoid Circuit Open or
Shorted to Ground
DTC C0247 (Flash Code 47) Front Left Isolation Solenoid Circuit Shorted to
Battery
DTC C0248 (Flash Code 48) Front Left Dump Solenoid Circuit Shorted to
Battery
RTW45AMF000201
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
Verify repair
Go to Step 3
1. Ignition OFF.
voltage.

Step
Action
Value(s)
Yes
No

Tech2.
Replace EHCU.
Go to Step 4
Verify repair
Verify repair
DTC C0251 (Flash Code 51) Rear Isolation Solenoid Circuit Open or Shorted
to Ground
DTC C0252 (Flash Code 52) Rear Dump Solenoid Circuit Open or Shorted to
Ground
DTC C0253 (Flash Code 53) Rear Isolation Solenoid Circuit Shorted to Battery
DTC C0254 (Flash Code 54) Rear Dump Solenoid Circuit Shorted to Battery
RTW45AMF000201
Step
Action
1. Ignition OFF.
voltage.
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
Verify repair
Go to Step 3

Step
Action
Value(s)
Yes
No

Tech2.
Replace EHCU.
Go to Step 4
Verify repair
Verify repair
DTC C0265 (Flash Code 65) Fail Safe Relay (FSR) Shorted to Ground
DTC C0266 (Flash Code 66) Fail Safe Relay (FSR) Shorted to Battery
RTW45AMF000201
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
1. Ignition OFF.
voltage.
Verify repair
Go to Step 3

Tech2.
Go to Step 4
Verify repair

Step
Action
Value(s)
Yes
No
Replace EHCU.
Verify repair
DTC C0267 (Flash Code 67) ABS Motor Shorted to Ground

DTC C0268 (Flash Code 68) ABS Motor Shorted to Battery
RTW45AMF000201
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
1. Ignition OFF.
voltage.
Verify repair
Go to Step 3

Tech2.
Go to Step 4
Verify repair

Step
Action
Value(s)
Yes
No
Replace EHCU.
Verify repair
DTC C0271 (Flash Code 71) ECU Failure or Valve +B Circuit Open
RTW45AMF000201
Step
Action
1. Ignition OFF.
voltage.

Tech2.
Replace EHCU.
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
Verify repair
Go to Step 3
Go to Step 4
Verify repair
Verify repair
DTC C0274 (Flash Code 74) ABS Operation Long Time
RTW45AMF000201
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
Go to Step 3
Go to Basic
Inspection
Procedure
Verify repair
Go to Step 4
Verify repair
Go to Step 5
Verify repair
Go to Step 6

-
Was the Basic Inspection Procedure performed?
1. Check for a poor connection at the wheel speed

sensor harness connector.
2. Check installation condition for wheel speed
sensor.
1. Check condition for sensor rotor.
1. Ignition OFF, disconnect the EHCU and wheel
speed sensor.
2. Check the circuit between EHCU and wheel speed
sensor.(short ground, or short to voltage.)

Step
Action
Value(s)
Yes
No
1. Ignition OFF.
voltage.
Verify repair
Go to Step 7

Tech2.
Replace EHCU.
Go to Step 8
Verify repair
Verify repair
DTC C0276 (Flash Code 76) G-Sensor Malfunction
RTW35AMF000301
Step
Action
1. Check for a poor connection at the G-sensor

harness connector.
1. Ignition OFF, disconnect the G-sensor and
EHCU.
3. Check the supply voltage to G-sensor.
Was the value normal?
4
5
Repair or replace the power supply circuit.

1. Check the circuit between EHCU and G-sensor.
(Circuit for an open, short to ground, or short to
voltage.)
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
Verify repair
Go to Step 3
Battery
Voltage
Go to Step 5
Go to Step 4
Verify repair
Verify repair
Go to Step 6

Step
Action
1. Remove the G-sensor.

2. Reconnect G-sensor and EHCU
3. Install the Tech 2.
4. Ignition "ON", engine "OFF".
5. Observe the G-sensor reading on Tech 2.
If G-sensor inclines, reading voltage will change.
Is the reading voltage between specified value?
1. Ignition "OFF".
2. Install the G-sensor.
5. Select "Display DTCs" with the Tech 2.
1. Replace G-sensor.
Tech2.
Replace EHCU.
Value(s)
Yes
No
1.0 - 4.0V
Go to Step 7
Go to Step 8
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Verify repair
DTC C0277 (Flash Code 77) Power Supply Low Input

DTC C0278 (Flash Code 78) Power Supply High Input
RTW45AMF000201
Step
1
Action
1. Check for a poor connection at EHCU

1. Ignition OFF, disconnect EHCU.

3. Check the supply voltage to EHCU.
4
5
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
Verify repair
Go to Step 3
Battery
Voltage
Go to Step 5
Go to Step 4
Verify repair
Verify repair
Go to Step 6
Repair or replace the power supply circuit.

1. Check the power supply circuit.
(Circuit for an open, short to ground, or short to
voltage.)

Step
Action
Value(s)
Yes
No

Tech2.
Replace EHCU.
Go to Step 7
Verify repair
Verify repair
DTC C0282 (Flash Code 82) 4 Wheel Drive State Input Signal Failure
RTW35AMF000301
Step
Action
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
Verify repair
Go to Step 3
1. Ignition OFF, disconnect the EHCU and 2-4WD

control unit.
2. Check the circuit between EHCU and 2-4WD
control unit. (Circuit for an open, short to ground, or
short to voltage.)
Verify repair
Go to Step 4
1. Check the 2-4WD Control system.

Verify repair
Go to Step 5
1. Check for a poor connection at EHCU and 2-4WD

control unit.
Value(s)

Step
5
Action
1. Ignition "OFF".
2. Connect 2-4WD control unit.
3. Disconnect EHCU.
4. Ignition "ON," engine "OFF."
5. Install the high impedance digital multimeter.
6. Check the transfer (2-4WD control unit) signal
value.
Replace 2-4WD control unit.
Tech2.
Replace EHCU.
Value(s)
Yes
No
Transfer 2WD
Mode: 8.3Hz
(15%)
Transfer 4WD
Mode: 4.2Hz
(15%)
Go to Step 7
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair
Verify repair
DTC C0285 (Flash Code 85) Assembly error (G-sensor)
RTW35AMF000301
Step
1
Action
1. Ignition OFF.
2. Check for vehicle type and EHCU type.
(Vehicle type : 2WD or 4WD)
3. Checks the EHCU type is the same as a vehicles
type.
If the EHCU type differs from the vehicles type,
EHCU is replaced.
Note: Check the EHCU type for specification, when the
EHCU is replaced.
1. Check for vehicle type. (Vehicle type : 2WD or
4WD)
Was vehicle type 2WD?
Value(s)
Yes
No
Go to Step 2
Go to Basic
Diagnostic
Flow Chart
Go to Step 3
Go to Step 4
Go to Step 6

Step
4
Action
1. Ignition "OFF".
2. Check for a poor condition at the EHCU harness
connector.
and the EHCU ground circuit for an open or short
to voltage.
1. Ignition "OFF," disconnect the EHCU and Gsensor.
2. Check the circuit between EHCU and G-sensor.
(short to ground, or short to voltage.)
1. Remove the G-sensor.
2. Reconnect G-sensor and EHCU
5. Observe the G-sensor reading on Tech 2.
If G-sensor inclines, reading voltage will change.
Is the reading voltage between specified value?
1. Ignition "OFF".
2. Install the G-sensor.
1. Replace G-sensor.
Tech2.
Replace EHCU.
Value(s)
Yes
No
Verify repair
Go to Step 9
Verify repair
Go to Step 6
Go to Step 6
1.0 4.0 V
Go to Step 7
Go to Step 8
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Verify repair
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
5884003850
(J35616)
Connector test adapter
kit
5884003660
(J39200)
High impedance
multimeter
Tech 2 Set
(1) PCMCIA Card
(2) SAE 16/19 Adapter
(3) DLC Cable
(4) Tech 2
ANTI-LOCK BRAKE SYSTEM 5B-1
SECTION 5B
BRAKES
ANTI-LOCK BRAKE SYSTEM
TABLE OF CONTENTS
PAGE
Service Precaution ...................................................................................................................... 5B
Torque Specifications ................................................................................................................ 5B
Electronic Hydraulic Control Unit ........................................................................................... 5B
Electronic Hydraulic Control Unit and Associated Parts ............................................ 5B
Removal .................................................................................................................................... 5B
Installation ................................................................................................................................ 5B
Front Wheel Speed Sensor ....................................................................................................... 5B
Front Wheel Speed Sensor and Associated Parts ........................................................ 5B
Removal .................................................................................................................................... 5B
Inspection and Repair ........................................................................................................... 5B
Installation ................................................................................................................................ 5B 10
Rear Wheel Speed Sensor ........................................................................................................ 5B 11
Rear Wheel Sensor and Associated Parts ....................................................................... 5B 11
Removal .................................................................................................................................... 5B 11
Inspection and Repair ........................................................................................................... 5B 11
Installation ................................................................................................................................ 5B 12
Front Speed Sensor Rotor ........................................................................................................ 5B 13
Front Sensor Rotor and Associated Parts ....................................................................... 5B 13
Removal .................................................................................................................................... 5B 13
Installation ................................................................................................................................ 5B 14
Rear Speed Sensor Rotor .......................................................................................................... 5B 16
Rear Sensor Rotor and Associated Parts ........................................................................ 5B 16
Removal .................................................................................................................................... 5B 16
Installation ................................................................................................................................ 5B 17
G-Sensor ........................................................................................................................................ 5B 19
G-Sensor and Associated Parts ......................................................................................... 5B 19
5B -2 ANTI-LOCK BRAKE SYSTEM
Removal .................................................................................................................................... 5B 19
Installation ................................................................................................................................ 5B 19
Special Tools ........................................................................................................................... 5B 20
Service Precaution

parts and systems.
This illustration is based

on RHD model
E05R300007

4
2 Front Speed Sensor
E05R300002

Front Speed Sensor (4
4, 4
2 High Ride)
E05R300003

Rear Speed Sensor
E05R300008

Electronic Hydraulic Control Unit and Associated Parts
RHD model
LHD model
350R300001-X
Legend
1.
2.
3.
4.
Flare Nut from master cylinder front

Flare Nut to front right wheel cylinder
Flare Nut to front left wheel cylinder
Flare Nut to rear wheel cylinder
Removal
1. Disconnect the harness connector.
2. Loosen five flare nuts and remove brake pipes.
After disconnecting brake pipe, cap or tape the
openings of the brake pipe to prevent the entry of
foreign matter.
3. Remove three bracket fixing bolts.
Installation
1. Install EHCU and tighten the bolt to the specified
torque.
Torque : 8 Nm (0.8 kgm /69 lb in)
2. Tighten the flare nuts to the specified torque.
Torque : 16 Nm (1.6 kgm /12 lb ft)
5.
6.
7.
8.
Electronic Hydraulic Control Unit (EHCU)

Flare Nut from master cylinder rear
Bolt
Front
3. Connect the harness connector.
Front Wheel Speed Sensor

Front Wheel Speed Sensor and Associated Parts
4
2
350R300005

4
4, 4
2 High Ride
350R300006
Legend
1. Connector Portion
2. Front Speed Sensor Assembly
3. Bolt : cable to knuckle
4. Bolt : sensor to knuckle

5. Nut: cable to upper link (42)
Bolt: cable to upper link (44)
Removal
1. Remove speed sensor connector at connector

portion.
2. Remove sensor fixing bolt (4).
3. Remove cable fixing bolts and nut (42).
4. Disconnect the arrow mark locks of the cable clips.
5. Remove the speed sensor assembly.
1. Check the speed sensor head for presence of

foreign materials; remove any dirt, etc.
2. Check the head for damage; replace speed sensor if
necessary.
3. Check the speed sensor cable for short or open
circuit, and replace with a new one if necessary.
To check for cable short or open, bend or stretch the
cable while checking for continuity.
Installation
1. Install the speed sensor in the knuckle and take care
not to hit the speed sensor head during installation.
2. Install speed sensor fixing bolt and tighten the fixing
bolt to the specified torque.
Torque: 8 Nm (0.8 kgm /69 lb in)
3. Connect the cable clips at the arrow mark places.
4. Install the cable fixing bolt and nut (42) and tighten
the fixing bolt and nut to the specified torque.
Torque :
Bolt 8 Nm (0.8 kgm /69 lb in)
Nut 20 Nm (2.0 kgm /14 lb ft)
NOTE: Confirm that the cable is not twisted when
connecting the speed sensor cable.
5. Connect the speed sensor connector.
Rear Wheel Speed Sensor

Rear Wheel Sensor and Associated Parts
420R300008
Legend
1.
2.
3.
4.
Rear Speed Sensor Assembly

Bolt : cable to frame
Connector
Bolt : sensor to rear axle
5.
6.
7.
8.
Speed Sensor
Bolt : cable to axle
Bolt : sensor to rear axle
Speed Sensor
Removal
1.
2.
3.
4.
1. Check speed sensor head for presence of foreign

materials; remove any dirt, etc.
2. Check the head for damage, and replace speed
sensor if necessary.
Disconnect the harness connector (3).

Remove the cable fixing bolt (2)(6).
Disconnect the cable fixing clips (arrow marked).
Remove the speed sensor fixing bolts (4)(7) and
speed sensor (5)(8).

3. Check speed sensor cable for short or open, and
replace with a new one if necessary. To check for
cable short or open, bend or stretch the cable while
checking for continuity.
Installation
1. Install the speed sensor (5)(8).
2. Tighten the sensor fixing bolts (4)(7) to the specified
torque.
3. Connect the cable fixing clips (arrow marked).
4. Install the cable fixing bolts (2)(6) and tighten it to
5. Connect the harness connector (3).
Front Speed Sensor Rotor

Front Sensor Rotor and Associated Parts
411R300010
Legend
1. Sensor Rotor
2. Hub and Disc
Removal
1. Remove the hub and disc assembly (4). (Refer to
the section Front wheel Drive).
2. Remove two disc rotor fixing bolts (3) on a diagonal.
3. Drive out the sensor rotor using a metal bar and
Discard the used sensor rotor.
4. Install disc rotot fixing bolts and tighten them to the
specified torque.
Torque : 103 Nm (10.5 kgm /76 lb ft)
3. Disc Rotor fixing Bolt

411R300007
Legend
1. Metal Bar

Make all necessary adjustments, repairs or part
replacement.
Check damage or powdered iron sticking to the
sensor rotor.
Check play in the sensor rotor.
Check a broken tooth or indentation in the sensor
rotor.
Installation
1. Set a new sensor rotor.
2. Install the new sensor rotor in the hub, using installer
5-8840-2789-0 and grip 5-8840-0007-0.
NOTE: Sensor rotor is surely using a new article.
2. Sensor Rotor
411R300006
Legend
1. Hub and Disc
2. Sensor Rotor
3. Press
3. Measure the gap A at 4 points at intervals of 90

(degrees).
Confirm that the gap A should be within the
specified range.
Range
Type
A
42
7.0 - 7.4 mm (0.276 - 0.291 in)
4 4,
7.2 - 7.6 mm (0.283 - 0.299 in)
4 2 High Ride
411R300016
4. Install the hub and disc assembly. (Refer to the

section Front wheel Drive).
Rear Speed Sensor Rotor

Rear Sensor Rotor and Associated Parts
420R300007
Legend
1. Axle Shaft Assembly with Brake
2. Sensor Rotor
Removal
1. Remove the axle shaft assembly with brake (1).
(Refer to the section Rear Axle)
3. Front
A03R300003
Legend
1. Bench Press Fitting
2. Steel Plate (25-30 mm thickness)

Make all necessary adjustments, repairs or part
replacement.
Check damage or powdered iron sticking to the
sensor rotor.
Check play in the sensor rotor.
Check a broken tooth or indentation in the sensor
rotor.
NOTE: If replacement is required remove the sensor
rotor from the axle shaft assembly with brake. (Refer to
the section Rear Axle).
Discard the used sensor rotor.
(Snapring, Oil seal and Bearing)
Installation
1. Install the sensor rotor and assemble it into the axle
shaft assembly with back plate. (Refer to the section
Rear Axle)
3. Axle Shaft
4. Sensor Rotor
420R300005
Legend
1. Axle Shaft
2. Oil Seal
3. Bolt
2. Install the axle shaft assembly with brake in the rear
axle. (Refer to the section Rear Axle).
4. Back Plate
5. Sensor Rotor
G-Sensor
G-Sensor and Associated Parts
RTW45BLF000101
Legend
1. G-Sensor
2. Nut
Removal
Installation
1. Remove the front floor console. (Refer to the section

Floor Console)
2. Disconnect the connector.
3. Remove the nuts.
4. Take out the G-sensor.
1. Set the G-sensor.

2. Install the nut and tighten it to specified torque.
Torque : 8.0 Nm (0.8 kgm /69 lb in)
3. Connect the connector.
4.
Install the front floor console. (Refer to the
section Floor Console)
Special Tools
ILLUSTRATION
PART NO.
PART NAME
5884027890
Installer ; Sensor rotor,
front hub
5-8840-0007-0
Grip
ILLUSTRATION
PART NO.
PART NAME
9-8522-1271-0
Setting Tool
BRAKES 5C-1
SECTION 5C
BRAKES
TABLE OF CONTENTS
PAGE
General Description......................................................................................................... 5C- 2
Main Data and Specifications ......................................................................................... 5C- 9
Torque Specifications ..................................................................................................... 5C-10
Servicing........................................................................................................................... 5C-19
Front Brake Assembly..................................................................................................... 5C-33
Removal and Installation ............................................................................................ 5C-33
Removal and installation of Disc Pad ....................................................................... 5C-37
Disassembly ................................................................................................................ 5C-39
Inspection and Repair................................................................................................. 5C-40
Reassembly ................................................................................................................. 5C-42
Rear Drum Brake Assembly............................................................................................ 5C-44
Disassembly ................................................................................................................ 5C-44
Reassembly ................................................................................................................. 5C-47
Brake Control ................................................................................................................... 5C-51
Master Cylinder ................................................................................................................ 5C-52
Disassembly ................................................................................................................ 5C-53
Reassembly ................................................................................................................. 5C-56
Vacuum Booster .............................................................................................................. 5C-58
5C-2 BRAKES
GENERAL DESCRIPTION
FRONT DISC BRAKE
REAR DRUM BRAKE
BRAKES 5C-3
REAR WHEEL CYLINDER
LOAD SENSING PROPORTIONING VALVE (LSPV)
RTW35CMF000101
5C-4 BRAKES
BLEND PROPORTIONING VALVE
RTW45CMF000301
BRAKES 5C-5
PIPING DIAGRAM (MODEL WITH BLEND PROPORTIONING VALVE)
5C-6 BRAKES
HYDRAULIC LINES (MODEL WITH LOAD SENSING PROPORTIONING VALVE)
05007-2
BRAKES 5C-7
HYDRAULIC LINES (MODEL WITH ABS)
5C-8 BRAKES
VACUUM SERVO WITH MASTER CYLINDER (RHD)
VACUUM SERVO WITH MASTER CYLINDER (LHD)
RTW45CMF000101
BRAKES 5C-9

FRONT DISC BRAKE
mm(in.)
42
4 4, 4 2 HIGH RIDE
Caliper type
Pin slide
Disc outside diameter
256(10.079)
280 (11.023)
Disc thickness
26(1.024)
27 (1.063)
Piston diameter
42.8 (1.685) 2
Adjustment method
REAR DRUM BRAKE
45.5 (1.79)
Self-adjusting
mm(in.)
Type
42
44
Leading and Trailing
Drum inside diameter
254(10.008)
295 (11.614)
Brake lining dimension
244 50 5
283 45 5
(9.57 1.97 0.20)
(11.14 1.77 0.20)
(Length Width Thickness)

Adjustment method
WHEEL CYLINDER
Self-adjusting
mm(in.)
Inside diameter : rear

MASTER CYLINDER
25.4 (1.000)
23.8 (0.937)
mm(in.)
Type
Split
Bore diameter
25.4 (1.000)
Piston stroke (Primary + Secondary)

VACUUM SERVO
Diaphragm diameter
21.8 + 12 (0.86 + 0.47)

mm(in.)
6VE1/C24NE
4JA1-T/4JA1-TC/4JH1-TC
205(8.077) + 230(9.055)
180(7.087) + 205(8.077)
4JA1-T
Power cylinder stroke
PEDAL RATIO
BALANCE
Type
35 (1.378)
3.7
EBD (with ABS)
Load sensing proportioning valve (without ABS)
Blend valve (without ABS)
5C-10 BRAKES
FRONT WHEEL BRAKE
Nm(kgfm/lbft)
E05R300016
BRAKES 5C-11
REAR WHEEL DRUM BRAKE
Nm(kgfm/lbin)
E05R300014-1
5C-12 BRAKES
VACUUM SERVO WITH MASTER CYLINDER AND BRAKE PEDAL

Nm(kgfm/lbft)
This illustration is based on RHD model.
BRAKES 5C-13
BLEND PROPORTIONING VALVE
Nm(kgfm/lbft)
13-19 (1.3-1.9/9.4-14)
14-25 (1.4-2.5/10-18)
03260002-1B
5C-14 BRAKES
LOAD SENSING PROPORTIONING VALVE (LSPV)
Nm(kgfm/lbft)
RTW5CLF000101
BRAKES 5C-15
BRAKE PEDAL ASSEMBLY

LHD model is opposite.
E05R300011-1
5C-16 BRAKES
BRAKE LINES (HOSES AND PIPES)

(MODEL WITH BLEND PROPORTIONING VALVE)
RTW45CMF000401
BRAKES 5C-17

(MODEL WITH LOAD SENSING PROPORTIONING VALVE)
Nm(kgfm/lbft)
13-19 (1.3-1.9/9.4-14)
7.8-18 (0.8-1.8/5.8-13)
13-19 (1.3-1.9/9.4-14)
11-20 (1.1-2.0/8-14)
13-19 (1.3-1.9/9.4-14)
Eye Bolt Tightening

29-39 (3.0-4.0/22-29)
05020
5C-18 BRAKES

(MODEL WITH ABS)
Nm(kgfm/lbft)

RTW35CLF0002
BRAKES 5C-19
SERVICING
BLEND PROPORTIONING VALVE (IF SO EQUIPPED)
Structure and Operation

Structure
Side a shows P-valve ; side b shows bypass valve.
Bypass valve seals the routes 4 and 5 using the seal 2 at
the piston 1 end.
In addition, spring 3 presses against the piston 1 , and in
order to seal out the route 4 and route 5 sufficiently, spring
3 presses seal 2 against cylinder end surface.
The left figure is a characteristic curve diagram.
5C-20 BRAKES
Operation
The operation of the P-valve by the master cylinder
pressure is unchanged up to the brake points A and B .
If master cylinder fluid pressure penetrates into the second
break point B , the fluid pressure pressing against the seal
2 , (which isolated route 4 and route 5 ), passing the route
4 of the master cylinder side, overcomes the operating
force of the spring 3 + fluid pressure affecting the seal 2 of
the wheel cylinder, and presses the piston 1 to the right
side, resulting in the opening of the routes 4 and 5 , and
canceling of the P-valve operation.
Then, because the master cylinder fluid pressure and the
wheel cylinder fluid pressure, up to the point C , operate on
the identical surface of the seal 2 , both have identical
ascending ratio.
However, because of the operation of spring 3 in the wheel
cylinder side, wheel cylinder fluid pressure operate to
preserve the balance against the master cylinder fluid
pressure on the lower level with the difference in pressure
resulting from this spring.
Valve Maintenance
In the case of fluid leak or other abnormalities, faulty valve
should be replaced.
The valve is set up at the engine room.
Note:
The blend proportioning valve is not repairable and must
be replaced as a complete assembly.
03260002-2
BRAKES 5C-21
LAOD SENSING PROPORTIONING VALVE (LSPV)
RTW35CMF000101
Structure and Operation

The following is an explanation of the structure and operation
of the spring type load sensing device.
This device controls the fluid pressure to the rear brakes in
accordance with changes in rear axle load (vertical
displacements of the rear axle springs).
Structure
This device consists of a load sensing spring and a valve.
The valve is mounted through a bracket to the frame.
One end of the load sensing spring is fixed to the valve at
the frame and the other end to the rear axle housing
through a bracket.
5C-22 BRAKES
Operation
1) Outline
When the LSPV (Load Sensing Proportioning Valve)
detects a change in load weight, the load sensing spring
stretches.
Its reaction force is transmitted to the bottom of the load
sensing valve to secure an optimum rear wheel cylinder
fluid pressure break point in proportion to the actual load
weight.
Besides, if the front brake system should fail, the device is
designed to prevent the master cylinder fluid pressure from
decreasing and to apply it directly to the rear wheel cylinder
to obtain a sufficient braking performance.
RTW35CSH001001
2) Bellow cutting point.

The Force (F) keeps the main piston (1) the rest position.
The inlet pressure (A) and outlet pressure (B) are the same
as well as the inlet pressure (C) from front master cylinder.
The bypass piston (2) is kept on rest position by equilibrium
of the pressures (A) and (C) and the bypass spring load (3).
RTW35CSH001101
3) Cutting point.
The cutting point is given by relation between force (F), that
is the load applied by suspension of the vehicle and the
main piston area (1). The cutting point is achieved when the
force generated by hydraulic pressure is upper than the
force (F) given by the load suspension. The main piston (1)
moves from the rest position closing the valve. In this
moment the inlet pressure (A) is upper than the outlet
pressure (B). The bypass piston (2) continues on the rest
position by equilibrium of (A) and (C) pressure.
RTW35CSH001201
BRAKES 5C-23
4) Failure on front master cylinder.
In case of failure on front master cylinder the pressure on
the inlet port (C) drop to zero. The pressure from inlet port
(A) acts on the bypass piston (2) and move it by comprising
of bypass spring (3). It makes possible the communication
between the inlet port (A) to outlet port (B) through the
bypass system. The outlet pressure (B) reaches the inlet
pressure (A) and the LSPV is bypassed.
RTW35CSH001301
Valve Maintenance
In the case to fluid lead or other a abnormalities, faulty valve
should be replaced.
Note:
The load sensing proportioning valve is not repairable and
must be replaced as a completed assembly.
LOAD SENSING PROPORTIONING

VALVE (LSPV) ADJUSTMENT
1. Fluid Pressure Measurement
1) Rear axle weight adjustment
With an axle eight meter, adjust the rear axle weight with
a person sitting in the drivers seat and a weight loaded
in the rear body.
N (kg/lb)
MODEL
Adjustment value
RTW35CSH000301
42
4 2 HIGH RIDE
44
7845 (800/1764)
9316 (950/2095)
2) Installation of a fluid pressure gauge

Remove the air bleeder of the left hand wheel front and
rear brakes. Bleed air out of the fluid pressure gauge
with the measurement hose of the fluid pressure gauge
installed.
Pressure Tester: Brake oil (Fluid pressure gauge)
5-8840-2190-0
RTW35CSH000101
5C-24 BRAKES
RTW35CSH000201
3) Rear wheel cylinder fluid pressure measurement

Step on the brake pedal until the fluid pressure of the
2
front wheel cylinder gets to 9.8Mpa (100kg/cm ), and
check the rear wheel cylinder fluid pressure. (Read the
value of the front wheel cylinder fluid pressure 2
seconds after the measurement. When measuring the
L.S.V fluid pressure, keep the brake pedal pressed
down without stepping it down twice or releasing it.)
2
Rear Wheel Cylinder Fluid Pressure
MPa (kg/cm )
2WD
6.770.83 (69.08.5)
2WD (With High Ride
Suspension), 4WD
6.770.83 (69.08.5)
2. Oil Pressure Adjustment

1) LSPV spring length adjustment
Loosen the adjust nut of the LSPV spring joint, and
adjust the length of the LSPV spring.
When the oil pressure is insufficient, turn the adjust nut
clockwise to extend the span A. When the oil pressure
is too high, turn the adjust nut counterclockwise to
reduce the span A.
RTW35CSH000401
2) After adjustment, tighten the lock nut securely.

Lock Nut Torque
Nm (kgm/lb in)
11-20 (1.1-2.0/95-174)
BRAKES 5C-25
Filling Master Cylinder Reservoir

CAUTION :
Use only specified brake fluid. Do not use any fluid which
contains a petroleum base. Do not use a container which
has been used for petroleum based fluids or a container
which is wet with water. Petroleum based fluid will cause
swelling and distortion of rubber parts in the hydraulic
brake system. Water mixed with brake fluid lowers the
fluid boiling point. Keep all fluid containers capped to
prevent contamination.
Always fill the master cylinder reservoir when the engine
is cold.
Never allow the brake fluid to come in contact with the
painted surfaces.
The master cylinder reservoir must be kept properly filled
to ensure adequate reserve and to prevent air and
moisture from entering the hydraulic system. However,
because of expansion due to heat absorbed from the
brakes and the engine, the reservoir must not be
overfilled. Thoroughly clean reservoir cap before removal
to avoid getting dirt into reservoir. Add fluid as required to
bring level to the MAX mark on the reservoir tank. Use
DOT 3 Hydraulic Brake Fluid.
Leakage of Brake Fluid

With engine idling, set shift lever in the neutral position and
continue to depress brake pedal at a constant pedal
application force.
Should the pedal stroke become deeper gradually, leakage
from the hydraulic pressure system is possible.
Make sure by visual check that there is no leak.
BLEEDING OF THE BRAKE HYDRAULIC

CIRCUIT
If air enters the bake lines, it will cause poor brake action.
Therefore, bleeding should be performed if the brakes have
been used with the level of brake fluid in the reservoir
excessively low or if brake pipes have been disconnected in
the course of brake servicing.
Bleeding operation calls for co-operative action of 2 persons.
Set the parking brake firmly while bleeding.
Perform bleeding operation with ENGINE RUNNING, to
prevent damage to push rod seal.
Make sure exhaust is suitably ventilated.
Bleed the hydraulic system with the fluid reservoir filled to
the specified level.
Bleed the system starting with the rear wheel cylinder
farthest from the master cylinder.
5C-26 BRAKES
A bleeding operation is necessary to remove air from the
hydraulic brake system whenever air is introduced into the
hydraulic system. It may be necessary to bleed the hydraulic
system at all four brakes if air has been introduced through a
low fluid level or by disconnecting brake pipes at the master
cylinder. If a brake pipe is disconnected at one wheel, only that
wheel cylinder/caliper needs to be bled. If the pipes are
disconnected at any fitting located between the master cylinder
and brakes, then the brake system served by the disconnected
pipe must be bled.
1. Set the parking brake completely, then start the engine.
NOTE :
The vacuum booster will be damaged if the bleeding operation
is performed with the engine off.
2. Remove the master cylinder reservoir cap.
3. Fill the master cylinder reservoir with brake fluid. Keep the
reservoir at least half full during the air bleeding operation
4. Always use new brake fluid for replenishment.
5. In replenishing rake fluid, take care that air bubbles do not
enter the brake fluid.
When the master cylinder is replaced or overhauled, first

bleed the air from the master cylinder, then from each
wheel cylinder and caliper following the procedures
described below.
Bleeding the Master Cylinder

6. Disconnect the rear wheel brake pipe (1) from the master
cylinder.
Check the fluid level and replenish as necessary. If
replenished, leave the system for at least one minute.
7. Depress the brake pedal slowly once and hold it depressed.
8. Completely seal the delivery port of the master cylinder with
your finger, where the pipe was disconnected then release
the brake pedal slowly.
9. Release your finger from the delivery port when the brake
pedal returns completely.
10.Repeat steps 7 through 9 until the brake fluid comes out of
the delivery port during step 7.
NOTE : Do not allow the fluid level in the reservoir to go below
the half-way mark.
11.Reconnect the brake pipe (1) to the master cylinder and
tighten the pipe.
12.Depress the brake pedal slowly once and hold it depressed.
13.Loosen the rear wheel brake pipe (1) at the master cylinder.
14.Retighten the brake pipe, then release the brake pedal
slowly.
BRAKES 5C-27
15.Repeat steps 12 through 14 until no air comes out of the
port when the brake pipe is loosened
NOTE : Be very careful not to allow the brake fluid to come in
contact with painted surfaces.
16.Bleed the air from the front wheel brake pipe connection (2)
by repeating steps 6 through 15.
Bleeding the Caliper

17.Bleed the air from each wheel in the order listed below:
Right rear wheel cylinder
Left rear wheel cylinder
Left front caliper
Right front caliper
Conduct air bleeding from the wheels in the above order. If
no brake fluid comes out, it suggests that air is mixed in the
master cylinder. In this case, bleed air from the master
cylinder. In this case, bleed air from the master cylinder in
accordance with steps 6 through 16, and then bleed air
from the caliper or wheel cylinder.
18.Place the proper size box end wrench over the bleeder
screw.
19.Cover the bleeder screw with a transparent tube, and
submerge the free end of the transparent tube in a
transparent container containing brake fluid.
RTW35CSH000501
5042
20.Pump the brake pedal slowly three (3) times (once/sec),

then hold it depressed.
21.Loosen the bleeder screw until fluid flows through the tube.
22.Retighten the bleeder screw.
23.Release the brake pedal slowly.
24.Repeat steps 21 through 24 until the air is completely
removed.
It may be necessary to repeat the bleeding procedure 10 or
more times for front wheels and 15 or more times for rear
wheels.
25.Go to the next wheel in the sequence after each wheel is
bled.
Be sure to monitor reservoir fluid level.
26.Depress the brake pedal to check if you feel sponginess"
after the air has been removed from all wheel cylinders and
calipers.
If the pedal feels spongy", the entire bleeding procedure
must be repeated.
5C-28 BRAKES
27.After the bleeding operation is completed on the each
individual wheel, check the level of the brake fluid in the
reservoir and replenish up to the MAX" level as necessary.
28.Attach the reservoir cap.
29.Stop the engine.
BRAKE LINE (HOSES AND PIPES)

Inspect all hoses and pipes for wear, bending, chafing,
cracks, dents, or any other damage.
Make necessary correction or parts replacement if these
abnormal conditions are found through inspection.
All hoses, pipes and joints can be damaged easily.
Do not allow the hose to become excessively twisted and
bent when working with then, and pay special attention to all
the brake lines not to damage them when repairing or
replacing other parts (axle, suspension, etc).
Inspection for leakage should be performed by depressing
the brake pedal fully.
If leakage is apparent at the circumference of joints,
retighten or replace these parts.
This procedure must be performed whenever brake lines
are installed.
After disconnecting the hoses and pipes, cap or tape the
openings to prevent entry of foreign material.
05007-1
BRAKES 5C-29
ADJUSTMENT PROCEDURE OF SERVICE AND PARKING BRAKE

Stem type
All brakes are self-adjusting.
Brakes are adjusted by repeated stepping on the brake pedal.
(After stepping on the pedal and releasing it, the rear autoadjuster, in the rear brake, produces a clicking sound.
the same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake lever to its fully released position.
2. Parking cable must be loosened sufficiently.
(Loosen the adjust nut and the lock nut.)
3. Repeat stepping on the brake pedal firmly, and releasing it
until the clicking sound can no longer be heard.
If the difference between the brake drum inside diameter of
the brake shoes is adjusted to be 0.5 mm, the number of
times for depressing the brake pedal can be reduced.
4. Remove the drum.
Measure the brake drum inside diameter and diameter of
the brake shoes.
Shoe Clearance
mm(in)
0.25 - 0.40 (0.0098 - 0.0157)
If incorrect, check the brake auto-adjusting system.
5. Turn the adjuster nut so that the parking brake lever travels
8 to 14 notches when pulled up with a force 30 kg (66 lbs.).
6. Make sure there is not brake dragging.
311R300007
Floor mount type

All brakes are self-adjusting.
Brakes are adjusted by repeated stepping on the brake pedal.
(After stepping on the pedal and releasing it, the rear autoadjuster, in the rear brake, produces a clicking sound.
the same operation should be repeated until the sound
disappears.)
Take the following steps after overhauling the rear brake
assembly.
1. Move the parking brake lever to its fully released position.
2. Parking cable must be loosened sufficiently.
(Loosen the adjust nut and the lock nut.)
3. Repeat stepping on the brake pedal firmly, and releasing it
until the clicking sound can no longer be heard.
If the difference between the brake drum inside diameter of
the brake shoes is adjusted to be 0.5 mm, the number of
times for depressing the brake pedal can be reduced.
4. Remove the drum.
Measure the brake drum inside diameter and diameter of
the brake shoes.
5C-30 BRAKES
Shoe Clearance
mm(in)
0.25 - 0.40 (0.0098 - 0.0157)
If incorrect, check the brake auto-adjusting system.

5. Turn the adjuster nut so that the parking brake lever travels
6 to 8 notches when pulled up with a force 30 kg (66 lbs.).
6. Make sure there is not brake dragging.
BRAKES 5C-31
ADJUSTMENT PROCEDURE OF BRAKE PEDAL

The push rod serves as the brake pedal stopper when the
pedal is fully released.
Brake pedal height adjustment should be performed as follows.
Brake Pedal - Height

Measure the brake pedal height after making sure the pedal is
fully returned by the pedal return spring.
Note:
Pedal height (L2) must be measured after starting the
engine and increasing the revolution several times by
stepping on the accelerator pedal.
mm(in)
Pedal free play (L1)
6-10 (0.23 - 0.39)
Height (L2)
RTW35CSH000601
RHD
M/T
174-186 (6.85-7.32)
LHD
A/T
176-188 (6.93-7.40)
Note:
Pedal free play must be measured after turning off the
engine and stepping on the brake pedal firmly five times
or more.
If the measured value deviates from the above range, adjust
the brake pedal as follows:
a) Disconnect the stop lamp switch.
b) Loosen the lock nut on the push rod.
c) Adjust the brake pedal to the specified height by rotating the
push rod in the appropriate direction.
Nm(kgfm/lbft)
Lock Nut Torque

12 - 18 (1.2 1.8 / 9 - 13)
d) Install the stop lamp switch.
Note:
Pedal height (L2) must be 80 mm (3.14 in.) or more when
applying about 50 kg (110.25 lbs.) of stepping force.
331R300005
How to connect the CLEVICE of BOOSTER ROD with PEDAL

ARM. and how to adjust the PEDAL SW.
After connecting the CLEVIS of BOOSTER ROD with PEDAL
ARM, adjust the PEDAL SW mounted (PDA) to PEDAL
BRACKET by the procedure explained still more bellow.
1. Set the hole of the CLEVIS of BOOSTER&M/CYL ROD
with the hole of the PEDAL ARM.
2. Enter the PIN; PUSH ROD to PEDAL to these holes
from left side of the PEDAL.
3. Enter and fix the PIN; SANP PIN FIX to the DITCH of
the PIN; PUSH ROD to PEDAL from right side of the
PEDAL.
4. Release the LOCK by turning the SWITCH counterclock-wise.
5C-32 BRAKES
5. After doing so, pull PEDAL ARM to yourself a little so
that PEDAL ARM is not pushed in.
6. Making PEDAL ARM not movable with one hand, push
in the whole SWITCH with the other hand until the
PLUNGER of SWTCH is pushed in and SWITCH itself
hits the RUBBER of PEDAL ARM.
In the condition, turn SWITCH clock-wise until click
sound is made and lock it.
By doing this the SWITCH is adjusted at 0.70.5mm
clearance.
BRAKES 5C-33
FRONT BRAKE ASSEMBLY

Removal Steps
Installation Steps
1. Brake flexible hose

2. Lock bolt
3. Pad assembly
4. Clip; pad
5. Caliper assembly
6. Support bracket
7. Front hub and disc assembly
7. Front hub and disc assembly

6. Support bracket
5. Caliper assembly
4. Clip; pad
3. Pad assembly with shim
2. Lock bolt
1. Brake flexible hose
5C-34 BRAKES

1. Brake Flexible hose
Remove the bolt and gasket and disconnect the brake flexible
hose from the caliper.
After disconnecting the flexible hose, cap or tape the openings
to prevent entry of foreign material.
2. Lock Bolt
Remove the lock bolt from the caliper.
3. Pad Assembly with Shim

Rotate the caliper upward.
Mark the lining locations if they are to be reinstalled.
BRAKES 5C-35
6. Support Bracket
Take care not to damage the flexible brake hose when
removing the support bracket.
7. Front Hub and Disc Assembly

For the removal procedure, refer to Section 4C "FRONT
WHEEL DRIVE".

7. Front Hub and Disc Assembly
For the installation procedure, refer to the front hub and disc
reassembly procedure in Section 4C "FRONT WHEEL
DRIVE".
5C-36 BRAKES
6. Support Bracket
Torque
Nm(kgfm/lbft)
196 - 235 (20.0 24.0 / 145 - 174)
Set up the clip and pad before installation of the support
racket.
4. Clip ; Pad
Install new parts if necessary.
2. Lock Bolt
Torque
Nm(kgfm/lbft)
32 - 40 (3.3 4.1 / 24 - 30)
1. Brake Flexible Hose

Attach the bolt and new gasket
Torque
29 -39 (3.0 - 4.0 / 22 - 29)
Nm(kgfm/lbft)
After installation, bleeding and replenishing procedure must be

performed.
Wipe the circumference of the hose clean.
Note:
Always use new gaskets.
Be sure to put the hooked edge of the flexible hose end into
the anti-rotation cavity.
BRAKES 5C-37
REMOVAL AND INSTALLATION OF DISC PAD

Removal Steps
1. Lock Bolt
Remove the lock bolt from the caliper.
Note:
Don't remove the brake hose from caliper when replacing
pads.
2. Rotate the Caliper Upward

Remove the caliper from the support bracket and the caliper to
the upper link or the frame.
Note:
While caliper is removed from support bracket, never step
on the brake pedal or the piston will protrude rapidly.

Remove the pad assembly with the shim.
Mark the pad locations if they are to be reinstalled.
4. Clip ; Pad
Discard the used clip and install a new one.
Installation Steps
1. Clip ; Pad
After attaching the pad assembly with the shim to the support
bracket, position the wear indicator to the lower side of the
inner pad and position the wear indicator to the upper side of
the outer pad.
5C-38 BRAKES
3. Caliper Assembly
Lower the caliper into its original position.
Do not damage the flexible hose by twisting or pulling it.
4. Lock Bolt
Attach the lock bolt to the caliper.
Torque
32 - 40 (3.3 4.1 / 24 - 30)
Nm(kgfm/lbft)
BRAKES 5C-39
DISASSEMBLY
CALIPER ASSEMBLY
Disassembly Steps
1. Bleeder with cap
2. Piston
3. Dust seal; piston
4. Ring seal
5. Body; caliper
2. Piston (with Ring Seal)
Insert a block of wood into the caliper and force out the piston
by blowing compressed air into the caliper at the flexible hose
attachment.
This procedure must be done prior to removal of dust seal.
CAUTION:
Do not place your fingers in front of the piston in an
attempt to catch or protect it when applying compressed
air.
5C-40 BRAKES

Make necessary correction or parts replacement if wear damage or any other abnormal conditions are found
through inspection.
Visual Check
Rotor
Caliper body
Cylinder bore
Piston
Support bracket
Lock bolt
Guide pin
Inspect the following parts for wear, bending, distortion,

cracking, corrosion, or other abnormal conditions.
Rotor
Thickness (t)
Standard
42
42 HIGH RIDE
44
26.0 (1.024)
27.0 (1.063)
Run out
Limit
mm(in)
Replacement
thickness (Discard)
24.6 (0.969)
25.6 (1.008)
mm(in)
0.075 (0.0029)
Before inspection, adjust the wheel bearing correctly.

Using a dial gauge, measure the run out at the 10mm inside
position from rotor out side edge of disc pad contact surface.
Parallelism (Total circumferential thickness variation)

Limit
mm(in)
0.023 (0.0009)
Contact surface must be within 0.023mm at the 10mm inside
position from rotor out side edge.
(Measurement; shall be measure more than 8 position at
circumferential direction.)
BRAKES 5C-41
Thickness of Disc Pad

Thickness (t)
Standard
10.0 (0.394)
mm(in)
Limit
1.8 (0.071)
Replace the front disc pad whenever the pad wear indicator
makes a squeaking noise or when the pad is worn to within 1.8
mm of the shoe table.
All four brake pads should be replaced together.
Seal and Boot

The dust seal, dust boot and ring seal are to be replaced each
time the caliper is overhauled.
Discard thee used rubber parts.
302R300019
5C-42 BRAKES
REASSEMBLY
CALIPER ASSEMBLY
Disassembly Steps
1. Body ; caliper
2. Ring seal
3. Dust seal ; piston
4. Piston
5. Bleeder
6. Cap
1. Body ; Caliper
2. Ring Seal
Apply clean brake fluid to the ring seal and cylinder wall, then
insert the ring seal into the cylinder.
Ensure that the piston ring seal are not twisted in the caliper
bore grooves.
BRAKES 5C-43
3. Dust seal ; Piston
Install the dust seal on the pistons.
4. Piston
Apply clean brake fluid to the piston, the dust seal is certainly
put into the slot on the piston and attach the caliper.
When inserting the piston into the cylinder, use finger pressure
only. Do not use a mallet or other impact tools, since damage
to the cylinder wall or ring seal can result.
The movement of a caliper piston into a caliper bore should be
smooth and even. If a caliper piston is frozen or difficult to
bottom, the caliper requires overhaul or replacement.
When not entering with a finger, insert a discarded inner brake
pad (2) or block of wood in front of the pistons. Using 2 large
C-clamps (1) installed over the body of the caliper (3) and
against the brake pad or block of wood, slowly bottom the
pistons evenly into the bores.
Insert the dust seal ring into the dust seal.
CAUTION:
Piston made by plastic material.
Dont must be hit on the piston by hammer etc. and dont
grasp to face of piston by pliers.
RTW35CSH000701
5. Bleeder
Torque
Nm(kgfm/Ibin)
9 16 (0.9 1.6 / 78 - 139)
6. Cap
5C-44 BRAKES
REAR DRUM BRAKE ASSEMBLY

DISASSEMBLY
First, disassemble the brake drum. Then disassemble the rear brake assembly.
Refer to the REAR AXLE section for the brake drum disassembly procedure.
RTW35CMF000201
MAJOR COMPONENTS
Disassembly Steps
1. Spring ; adjuster
2. Ring ; Adjuster lever
3. Lever ; adjuster
4. Spring ; Shoe hold
5. Pin ; Shoe hold
6. Spring ; Shoe to shoe, lower
7. Adjuster assembly
8. Spring ; shoe to shoe, upper
9. Shoe ; leading
10. Shoe ; trailing

11. Spring ; lever return
12. Retainer
13. Washer ; lever
14. Lever ; parking
15. Bolt ; wheel cylinder
16. Wheel cylinder assembly
17. Cover
18. Back plate
MINOR COMPONENTS
Disassembly Steps
Wheel Cylinder Assembly (14)
19. Piston
20. Cup
21. Boot ; piston
22. Return spring

23. Bleeder
24. Cap ; bleeder
BRAKES 5C-45
4. Spring ; shoe hold
Push the shoe hold spring toward the brake shoe and hold it.
Rotate the spring to remove it from the shoe hold pin.
P1010008
6. Spring ; shoe to shoe, lower

Slide the brake shoes and lower spring toward the ground.
Remove the lower spring.

through inspection.
Visual check
Brake drum
Back plate
Brake lining
Wheel cylinder body
Piston
Piston cup
Return spring
Inspect the following parts for wear scuffs, scratches,

corrosion, stains, deterioration, or other abnormal conditions.
Thickness of the Brake Lining

Thickness
standard (T)
mm(in)
Limit (t)
42
5.0 (0.197)
1.0 (0.039)
42 HIGH RIDE
44
5.0 (0.197)
1.0 (0.039)
5C-46 BRAKES
Clean wheel Cylinder Parts

Always use clean brake fluid to clean wheel cylinder parts.
Note:
Do not use mineral-vase cleaning solvents such as
gasoline, kerosene, acetone, paint thinner, or carbon
tetrachloride.
Piston Cups
Inspect the piston cups for wear, distortion, fatigue, fatigue or
other abnormal conditions.
Measuring the Brake Drum

Standard
mm(in)
Limit
Inside diameter
254 (10.000)
255.5 (10.059)
Run out
0.08 (0.003)
0.15 (0.006)
TFR
Inside diameter
295 (11.614)
296.5 (11.673)
TFS
Run out
0.08 (0.003)
0.15(0.006)
TFR
(HIGH RIDE)
BRAKES 5C-47
REASSEMBLY
RTW35CMF000301
MINOR COMPONENTS
Reassembly Steps
Wheel cylinder Assembly (7)
1. Piston assembly
2. Cup ; piston
3. Return spring
4. Boot ; piston
5. Bleeder
6. Cap ; bleeder
MAJOR COMPONENTS
Reassembly Steps
7. Back plate
8. Cover
9. Wheel cylinder assembly
10. Bolt ; wheel cylinder
11. Shoe ; leading
12. Lever ; parking
13. Washer ; lever
14. Retainer
15. Spring ; lever return
16. Shoe ; trailing

17. Spring ; shoe to shoe, upper
18. Adjust assembly
19. Spring ; shoe to shoe ; lower
20. Lever ; adjuster
21. Ring ; Adjuster lever
22. Spring ; shoe hold
23. Pin ; shoe hold
24. spring ; adjuster
5C-48 BRAKES
Note :
Wash the disassembled parts in clean brake fluid.
Use compressed air to clean the ports.
Protect the disassembled part surfaces from dust and other
foreign material contamination.
Before reassembly, check the part surfaces for dust and
other foreign material contamination.
Be sure to replace the designated parts with new ones.
4. Piston Assembly
Install new piston cups on each piston so that the flared end of
the cups are turned to the inboard side of the pistons.
Attach the return spring and the boot to the piston.
Be sure to use new piston cup and boot.
Apply brake fluid to the piston and the inner face of the
boots.
Note the direction of piston cup.
5. Bleeder ; Wheel Cylinder

Torque
6 - 8 (0.6 0.8 / 52 - 69)
9. Wheel Cylinder Assembly

10.Bolt ; Wheel cylinder
Torque
7 - 11 (0.7 1.1 / 61 - 95)
Nm(kgfm/Ibin)
Nm(kgfm/Ibft)
BRAKES 5C-49
308R300008
11.Shoe ; leading
Be sure to use new spring; shoe hold.
12.Lever ; parking
13.Washer ; lever
14.Retainer
Install the lever, the washer and the retainer to the leading
brake shoe.
Apply grease to the sliding surfaces of the lever and
brake shoe.
Be sure to use new retainer and washer.
16.Shoe ; trailing
Be sure to use new spring; shoe hold.
17.Spring ; shoe to shoe, upper
18.Adjuster assembly
1. Apply grease to each of the parts shown in the
illustration before installing the brake shoe.
Lever; adjuster-shoe
Adjuster-shoe
305R300009
2. Clean the adjuster bolt (5) and the adjuster rods (1) (4).
Apply grease to the threaded portion of the adjuster bolt.
3. Install the adjuster rod to the adjuster bolt.
4. Apply grease to the adjuster asm ends (2) (3). Set the
spring ; upper to the adjuster asm, then install them to
the brake shoe.
5. Before setting the brake shoes, apply grease to the back

plate portions (1) contacting the brake shoe edge as
shown in the illustration.
6. Apply grease to the wheel cylinder parts contacting the
brake shoe (2).
7. Install the brake shoe.
Note :
Be careful not to damage the wheel cylinder dust cover.
Do not allow the wheel cylinder piston to fly free.
305R300010
5C-50 BRAKES
20.Lever ; adjuster
21.Ring ; Adjuster lever
Apply grease to the lever ; adjuster sliding surface.
Install the lever ; adjuster and the ring to the shoe ;
trailing.
Be sure to use new ring.
23.Pin ; shoe hold
24.Spring ; shoe hold
Install the brake drum.
Install the rear wheel.
If the wheel cylinder has been removed, the brake
system must be bled.
Pump the brake pedal 10 times. Check that there is little
or no stroke length variation as the pedal is pumped.
Adjust the lining clearance.
P1010008B
Brake Line
Torque
Nm(kgfm/Ibft)
13 - 19 (1.3 - 1.9 / 9 - 14)
BRAKES 5C-51
BRAKE CONTROL
BRAKE PEDAL ASSEMBLY
This illustration shows RHD model

310R300001
Removal Steps
1. Nut ; fulcrum pin
2. Pin ; fulcrum, pedal to bracket
3. Pedal arm
4. Return spring
5. Pedal pad
Installation steps
To install, follow the removal procedure in
reverse order.
Before installation, apply grease to the entire
circumference of the fulcrum pin (2).
Refer to "SERVICING" in this section for
adjustment procedure of brake pedal.
5C-52 BRAKES
MASTER CYLINDER
MASTER CYLINDER ASSEMBLY

330R300008
Removal Steps
Installation Steps
1. Brake line
2. Nut ; master cylinder to vacuum booster
3. Master cylinder assembly

2. Nut ; master cylinder to vacuum booster
1. Brake line

1. Brake Line
Be very careful not to spill brake fluid on the painted surface.
Damage to the painted surface will result.

2. Nut ; Master Cylinder to Vacuum Booster
Torque
Nm (kgfm/lbft)
12 18 (1.2 1.8 / 9 13)
1. Brake Line
Torque
Nm (kgfm/lbft)
13 19 (1.3 1.9 / 9 14)
BRAKES 5C-53
DISASSEMBLY
RTW35CMF000401
Disassembly Steps
1. Cap
2. Diaphragm
3. Bolt
4. Resever tank
5. Grommet
6. Snap ring
7. Stop pin
8. Primary piston
9. Secondary piston
10. Cylinder body
Note :
Be sure to replace the designated with new ones.
Wash the disassembled parts in clean brake fluid.
Use compressed air to clean the ports.
Do not allow dirt and dust to contaminate the disassembled
parts.
5C-54 BRAKES
When disassembling, inspecting or reassembling the master
cylinder assembly, take care not to bring the parts into contact
with mineral oil or dust. Wash the piston cups only with brake
fluid. Do not use gasoline or other mineral-base cleaning
solvents.
6. Ring ; Snap
Remove the snap ring from the cylinder body with pushing in
the primary and secondary pistons.
7. Stop Pin
Remove the stop pin from the cylinder body with pushing in the
primary and secondary pistons.
8. Piston Assembly ; Primary and Spring

9. Piston Assembly ; Secondary and Spring
Dont remove the spring from the piston.
BRAKES 5C-55

through inspection.
Visual Check
Cylinder inside face
Piston
Piston cap
Piston cap spacer
Return port
Return spring
Inspect the following parts for wear, distortion, cuts, nicks,

corrosion, or other abnormal conditions.
Return Port
Check the return port for obstructions and if necessary, clean
with a tag wire.
Blow away foreign matter with compressed air.
Primary Piston
After reassembly, push in the primary piston to see that returns
smoothly.
Repeat the test two or three times to see that brake fluid is
forced out from the front and rear outlets.
5C-56 BRAKES
REASSEMBLY
Reassembly Steps
1. Secondary piston
2. Primary piston
3. Cylinder body
4. Grommet
5. Reservoir tank
6. Stop pin
7. Bolt
8. Snap ring
9. Diaphragm
10. Cap
1. Secondary piston
Lubricate the piston cups on the secondary piston assemblies
with brake fluid.
Note :
Be sure to use a new piston.
2. Primary piston
Lubricate the piston cups on the primary piston assemblies
with brake fluid (1) and the rubber grease (2).
Note :
Be sure to use a new piston.
BRAKES 5C-57
3. Cylinder body
Install the secondary piston and the primary piston to the
cylinder body.
Note :
The secondary piston long hole and the cylinder body stop pin
hole must be aligned at installation.
4.
5.
6.
7.
Grommet
Reservoir tank
Stop pin
Bolt
1. Install the grommets to the reservoir tank.
Note :
Be sure to use are new grommets.
2. Press down on the primary piston and install the stop pin
to the cylinder body (the piston long hole must be
aligned with the cylinder body installation hole).
3. Install the reservoir tank to the cylinder body.
Torque
Nm (kgfm/lbin)
2 - 3 (0.2 - 0.3 / 17 - 26)
330R300018
8. Snap pin
Press down on the primary piston and install the snap ring to
the cylinder body groove.
Note :
Be sure to use new snap ring.
9. Diaphragm
10.Cap
5C-58 BRAKES
VACUUM BOOSTER

RTW35CMF000501
Removal Steps
Installation Steps
1. Brake pipe
2. Master cylinder fixing nut
3. Bracket (only RHD model)
5. Vacuum hose
6. Snap pin
7. Vacuum booster fixing nut
8. Vacuum booster assembly
8. Vacuum booster assembly

7. Vacuum booster fixing nut
6. Snap pin
5. Vacuum hose
2. Master cylinder fixing nut
1. Brake pipe
BRAKES 5C-59
Important Operation-Removal
330R300002
1. Brake pipe
When hurdling, be careful not to spill brake fluid over the
painted surfaces, as damage to the paint finish will result.
2. Master Cylinder Fixing Nut
4. Master Cylinder Assembly
NOTE:
When removing the master cylinder from the vacuum booster,
be sure to get rid of the internal negative pressure of the
vacuum booster (by, for instance, disconnecting the vacuum
hose) in advance.
If any negative pressure remains in the vacuum booster, the
piston may possibly come out when the master cylinder is
being removed, letting the brake fluid run out.
While removing the master cylinder, further, do not hold the
piston as it can be easily pulled out.
5C-60 BRAKES

Vacuum Hose (The built in check valve)
1) Inspect the check valve (2), which is installed inside the
vacuum hose.
2) Blow air into the hose from the booster side as shown in
the illustration. The air should pass freely through the
hose.
3) Blow air into the hose from the engine side. The check
valve should close to block the passage of air.
The vacuum hose and built-in check valve must be
replaced as a set if either is found to be defective.
360R300002
Important Operation-Installation
8. Vacuum Booster Assembly
7. Vacuum Booster Fixing Nut
6. Snap Pin
1) Perform vacuum booster and vacuum booster push rod
adjustment.
Note :
When replacing either the master cylinder or vacuum booster,
be sure to measure push rod, and adjust if required.
2) Measure the dimension (B) of master cylinder.
RTW35CSH000901
3) Apply negative pressure by means of vacuum pump so

that the pressure in the vacuum booster becomes
GASOLINE ENGINE: 66.7 kPa (500 mm Hg) or DIESEL
ENGINE 93.3 kPa (700 mm Hg).
Note :
Be sure to apply NEGATIVE pressure after installing a push
rod gauge on the vacuum booster.
BRAKES 5C-61
4) Measure dimension (A)
5) Calculate the gap (B-A) when assembling the master

cylinder and vacuum booster.
GAP
mm (in)
0 - 0.4 (0 - 0.0157)
RTW35CSH000801
6) If dimension (A) is out of the standard range, adjust the

push rod.
Loosen the push rod lock nut (1) on the vacuum
booster.
Set the clevis (2).
Use the adjuster (3) to adjust the length of the
protruding portion of the push rod.
Vacuum (negative) pressure should be GASOLINE
ENGINE: 66.7 kPa (500mm Hg) or DIESEL
ENGINE: 93.3 kPa (700mm Hg) after adjustment.
Tighten the push rod lock nut to the specified torque.
Torque
Nm(kgfm/lbft)
18 25 (1.8 2.5 / 13 18)
7) Install the vacuum booster assembly to the dash panel
and pedal mounting bracket.
Torque
Nm(kgfm/lbft)
18 24 (1.8 2.4 / 13 17)
5C-62 BRAKES
5. Vacuum Hose
The check valve (2) is built-in to the vacuum hose.
When installing the vacuum hose make sure that the arrow on
the hose is facing the engine (1).
Note :
Do not apply oil to the vacuum hose.
360r300003
Installation direction is very important. The booster will not

operate if the vacuum hose is installed in the wrong
direction.
4JA1-T/4JA1-TC/4JH1-TC LHD model (with 2nd Battery)
RTW45CLF000101
BRAKES 5C-63
4JA1-T/4JA1-TC/4JH1-TC LHD Model (without 2nd Battery)
RTW45CMF0002
4JA1-T/4JA1-TC/4JH1-TC RHD Model
331R300008
5C-64 BRAKES
MEMO
PARKING BRAKE SYSTEM 5D-1
SECTION 5D
BRAKES
PARKING BRAKE SYSTEM
CONTENTS
Service Precaution ..........................................
Service Precaution .......................................
General Description ......................................
Parking Brake Lever ........................................
Parking Brake Lever Assembly and
Associated Parts (Bench Seat)..................
Removal.......................................................
Installation............................................................
Front Parking Brake Cable....................................
Front Parking Brake Cable and Associated
Parts (Bench Seat) .........................................
Removal ...............................................................
Installation............................................................
5D-1
5D-1
5D-1
5D-2
5D-2
5D-3
5D-3
5D-5
5D-5
5D-6
5D-6
Parking Brake Lever............................................... 5D-8

Parking Brake Lever Assembly and Associated
Parts (Buckle Seat)....................................... 5D-8
Removal ....................................................... 5D-8
Installation .................................................... 5D-8
Parking Brake Rear Cable ............................... 5D-9
Parking Brake Rear Cable and Associated
Parts ............................................................ 5D-9
Removal ....................................................... 5D-10
Installation .................................................... 5D-10
Inspection and Repair................................... 5D-11
Parking Brake Adjustment ............................ 5D-11
Main Data and Specifications........................... 5D-12
Troubleshooting............................................ 5D-13
Service Precaution
General Description

FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.
Pulling up the parking brake lever by hand will set the

parking brake. By means of a ratchet type lock, the
lever can be held in that position until it is released. The
position of the lever is transmitted through cable/lever
systems to the rear wheels. These parts are designed
to obtain sufficient braking force even when parking on
slopes. When the parking brake is set, or when the
ignition SW is in the "ON" position, the brake warning
light illuminates. The rear wheel parking brake is a
leading-trailing brake (mechanical inside expansion
type) built in the rear drum brake. Parking brake
adjustment is made through the adjusting hole (bored
through back plate). Parking brake lever stroke should
be adjusted to 8-14 notches with 30kg (bench seat) or
6-8 notches with 30kg (bucket seat). Refer to Parking
Brake Adjustment" in this section.

parts and systems.
5D-2 PARKING BRAKE SYSTEM
Parking Brake Lever

Parking Brake Lever Assembly and Associated Parts (Bench Seat)

740R300010
Legend
(1) Front Console Assembly
(2) Glove Box
(3) Instrument Panel Driver Lower Cover Assembly
(4) Driver Knee Bolster Assembly
(5) Driver Air Bag
(6) Steering Wheel/Steering Cowl

(7) Meter Cluster Assembly
(8) Dash Side Trim Cover
(9) Front Piller Trim Cover
(10) Instrument Panel Assembly & Cross Beam
This illustration shows RHD model

RTW35DLH000101
Legend
(1) Nut
(2) Bolt and Washer
(3) Adjust Nut
(4) Bolt
Removal
1. Remove instrument panel assembly & cross beam
in legend numbers order.
Refer to section 10.
2. Bolts (2)(8) are already removed in step 1.
3. Remove adjust nut (3).
4. Pull out clip (6) and take out front parking brake
cable (5) from parking lever assembly (9).
5. Remove bolts (4) and nut (1) and take out parking
lever assembly (9).
6. Remove switch (7).
(5) Front Parking Brake Cable

(6) Clip
(7) Switch
(8) Bolt
(9) Parking Lever Assembly
Installation
1. Install switch (7).
Torque: 1.5 Nm (0.15 kgm/13 lb in)
2. Set parking lever assembly (9).
3. Install bolts (4) and nut (1) and tighten them to the
specified torque.
4. Set front parking brake cable (5) in parking lever
assembly (9).
5. Drive clip (6) into the outer cable groove of front
parking brake cable (5) at the outside of parking
lever assembly (9).

6. Drive adjust nut (3) on the front end of front
parking brake cable (5) so that front ends of rear
parking brake fit into the rear end (equalizer) of
front cable (5).
7. Install instrument panel assembly & cross beam.
8. Install bolts (2) (8) and tighten them to the
specified torque.
9. Install all parts removed when removal steps.
10. When a parking cable is replaced, pull parking
brake lever with a force equivalent to operating
force: 490N (50 kg/110 lb), 10 times for
conditioning.
11. Adjust nut (3) so that lever (9) goes through 8-14
notches, when pulled with a operation force of
294N (30 kg/66 lb) and check brake for no drag.
Front Parking Brake Cable

Front Parking Brake Cable and Associated Parts (Bench Seat)
750R300003
Legend
(1) Shift Knob (manual transmission)
(2) Front Floor Console
(3) Rear Cover
(4) Bolt
(5) Seat Assembly

(6) Buckle: side seat and Center Seat Belt
(7) Seat Adjuster

RTW35DMF000101
Legend
(1) Adjust Nut
(2) Clip
(3) Bolt
Removal
1. Remove seat assembly and seat adjuster.
2. Turn over the carpet so that front parking brake
cable (6) appears.
3. Remove adjust nut (1).
4. Pull out clip (2) and take out front parking brake
cable (6).
5. Remove bolt (3) (4).
6. Disconect parking brake cable T-ends (5) from
front parking brake cable (6).
7. Take out front parking brake cable through the
floor hole.
(4) Bolt
(5) Parking Brake Cable T-end
(6) Front Parking Brake Cable
Installation
1. Apply grease (multipurpose type grease) to the
connecting portion of parking brake cable T-end
(5) and front parking brake equalizer. (arrow mark)
2. Let rear end (equalizer) of front parking brake
cable (6) enter the floor hole and connect it with
parking brake rear cable T-end (5).
3. Set front parking brake cable (6) in the parking
lever assembly.
4. Drive clip (2) into the outer cable groove of front
parking brake cable (6) at the outside of the
parking lever assembly.
5. Install bolt (3)(4) on the floor and tighten them to

6. Drive adjust nut (1) on the front end of front
parking brake cable (6) so that parking brake
cable T-end fits into the rear end (equalizer) of
front cable (6).
7. Fit the carpet on the floor.
8. Install seat adjuster and seat assembly.
9. Pull parking brake lever with a force equivalent to
operating force: 490N (50 kg/110 lb), 10 times for
conditioning.
10. Adjust nut (1) so that parking brake lever goes
through 8-14 notches, when pulled with a
operation force of 294N (30 kg/66 lb).
11. Check brake for no drag.
Parking Brake Lever

Parking Brake Lever Assembly and Associated Parts (Bucket Seat)
RTW35DSF000101
Legend
(1) Rear Floor Console
(2) Parking Brake Cable T-end
(3) Adjust Nut
Removal
1. Remove rear floor console (1).
2. Loosen adjust nut (3).
3. Remove bolt (6).
4. Remove switch (4).
5. Disconnect parking brake cable T-end (2) from
parking brake lever assembly (5).
6. Take out parking brake lever assembly (5).
Installation
connecting portion of parking brake rear cable Tend (2) and parking brake lever equalizer (7).
(arrow mark)
2. Connect parking brake rear cable T-end (2) to
equalizer (7).
3. Install switch (4).
(4) Switch
(5) Parking Brake Lever Assembly
(6) Bolt
(7) Equalizer
4. Tighten the parking brake lever fixing bolt (6) to

5. Drive adjust nut (3) on parking brake assembly so
that parking brake cable T-end fits into equalizer
(7).
6. Install rear floor console (1).
operating force: 490 N (50 kg/110 lb), 10 times for
conditioning.
8. Adjust nut (3) so that parking brake lever goes
through 6-8 notches, when pulled with a operation
force of 294 N (30 kg/66 lb).
Parking Brake Rear Cable

Parking Brake Rear Cable and Associated Parts
RTW35DLF000101
Legend
(1) Tension Pin
(2) Shoe Clamp Spring
(3) Return Spring
(4) Shoe Assembly with Parking Brake Lever
(5) Shoe Assembly with Adjuster Lever
(6) Spring
(7) Parking Brake Rear Cable
(8) Nut
(9) Bolt
(10) Nut
(11) T-end
(12) Outer Cable Retainer
(13) Equalizer
(14) Adjuster Lever Clip
Removal
Installation
1.
2.
3.
4.
5.
Remove wheel and tire.

Remove brake drum.
Remove tension pin (1) and shoe clamp spring (2).
Remove return spring (3).
Remove shoe assemblly with parking brake lever
(4).
6. Remove shoe assembly with adjuster lever (5) and
spring (6).
7. Remove parking brake inner cable from parking
brake lever (4).
8. Use offset box wrench (12mm hex.) to compress
locking lugs on the cable, then remove parking
brake outer cable from back plate.
NOTE: Do not twist or bend the cable too much.
A damaged cable will cause poor operation or a cable
break down.
311RS012
Legend
(1) Offset Box Wrench (12mm hex)
9. Remove nut (8) to fix the cable (7) on the leaf
spring.
10. Take out parking brake rear cable (7) from the
back plate.
12. Disconnect T-end (11) from the equalizer of front
cable.
NOTE: Be sure to use the new shoe clamp spring (2)

and the new adjuster lever clip (14).
connecting portion of the rear cable (11) and
equalizer (13). (aroow mark).
2. Install parking brake outer cable in back plate and
inner cable in parking brake lever (4).
3. Install return spring (3).
4. Install shoe clamp spring (2) and tension pin (1)
5. Install shoe assembly with adjuster lever, shoe
assembly with parking brake lever (4) and spring
(6). ---- snap action
Torque: 7Nm (0.7 kgm/61 lb in)
7. Connect T-end (11) with equalizer (13) through
outer cable retainer (12).
8. Install nut (10) and tighten it to the specifed
torque.
9. Install bolt (9) and tighten it to the specified
torque.
Torque: 7 Nm (0.7 kgm/61 lb in)
10. Install brake drum.
11. Install wheel and tire.
poerating force: 490 N (50 kg/110 lb), 10 times for
conditioning.
13. Adjust parking brake lever adjusting nut so that
parking brake lever goes through 8-14 (bench
seat) or 6-8 (bucket seat) notches, when pulled
with a operation force of 294N (30 kg/66 lb).

Brake Lining Inspection
Check the shoe assemblies for wear by removing the
brake drum.
Replace the shoe assemblies if the lining thickness is
less than 1.0 mm (0.039 in).
Minimum limit: 1.0 m (0.039 in)
308RS004
4. Remove the drum. Measure the brake drum inside

diameter and diameter of the brake shoes.
Total shoe clearance: 0.4 mm
If incorrect, readjust the brake shoe clearance.
5. Rotate the adjust nut of hand brake lever until all
slack disappears from the cable. Set the adjust
nut.
6. After the rear brake shoe/drum gap has been
adjusted, perform parking brake cable adjustment.
7. Turn the adjusting nut so that the parking brake
lever travels 6-8 (bucket seat) or 8-14 (bench
seat) notches when pulled up with a force of 294
N (30 kg/66 lb).
8. Make sure there is no brake dragging.

Type
Drum inside diameter
Parking brake lever stroke
Model
Leading-Trailing
254 mm (10 in) or 295 mm (11.6 in)
6-8 notches (bucket seat) or 8-14 notches (bench seat)
When pulled with a force of 294 N (30 kg/66 lb)
Nm (kgm/lb ft)

RTW35DSF000201
Nm (kgm/lb ft)
E05R300006
MEMO
No. TFBRK-WE-0431
WORKSHOP MANUAL
TF SERIES
ENGINE
4JA1/4JH1-TC
SECTION 6
TROUBLESHOOTING 6 1
SECTION 6
TROUBLESHOOTING
TABLE OF CONTENTS
PAGE
BASIC INSPECTION PROCEDURE ... 6 2
1. HARD STARTING ........................... 6 3
1-1.Starter Motor Inoperative ......... 6 3
1-2. Starter Motor Operates But
Engine Does Not Turn Over .......... 6 3
1-3. Engine Turns Over But Does
Not Start Engine ............................. 6 4
PAGE
11. ROTATING PART WEAR OF
TURBOCHARGER ............................. 6 14
12. OIL LEAKAGE FROM
TURBOCHRGER ............................... 6 15
13. INSUFFICIENT ACCELERATION
AND/OR LACK OF POWER DUE
TO TURBOCHARGER ....................... 6 15
2. UNSTABLE IDLING ........................ 6 5
14. BATTERY CHARGING AND

NOISE PROBLEM.............................. 6 16
3. INSUFFICIENT POWER ................. 6 6
14-1. Battery No Charging .............. 6 16
4. EXCESSIVE FUEL
CONSUMPTION................................. 6 7
14-2. Battery Overcharging ............ 6 16
5. EXCESSIVE OIL CONSUMPTION.. 6 8
14-3. Battery Under Charging......... 6 17
6. OVERHEATING............................... 6 9
14-4. Battery Unstable Charging

Current ............................................ 6 17
7. WHITE EXHAUST SMOKE ............. 6 9
14-5. Charging System Noise......... 6 18
8. DARK EXHAUST SMOKE .............. 6 10
15. STARTER MOTOR PROBLEM..... 6 19
9. OIL PRESSURE DOES NOT RISE . 6 11
15-1. Starter Motor Pinion Engages

to Ring Gear But Engine Does
Not Turn Over ................................. 6 19
10. ABNORMAL ENGINE NOISE ....... 6 12

10-1. Engine Knocking.................... 6 12
10-2. Gas Leakage Noise ................ 6 12
10-3. Continuous Noise .................. 6 13
10-4. Slapping Noise ....................... 6 13
10-5. Excessive Turbocharger
Noise ............................................... 6 14
15-2. Incorrect Pinion And Ring

Gear Engagement .......................... 6 19
15-3. Starter Motor Continues To
Run After The Starter Switch Is
Turned Off....................................... 6 20
15-4. Excessive Commutator
Sparking.......................................... 6 20
6 2 TROUBLESHOOTING
Basic Inspection Procedure

Follow the under inspection procedure, when the problem vehicle comes workshop.
Step
1
Inspection point
Check the check engine lamp
Inspection result
YES
NO
Is the check engine lamp turn

ON ?
Go to section
6E On Board
Diagnostic
(OBD) System
Check"
Go to Step 2
Re-charge the
battery or
replace the
battery
Go to Step 3
The battery fluid level and the Was the problem found?
gravity
The engine coolant capacity
Was the problem found?
Replenish the
engine coolant
Go to Step 4
The engine oil level
Replenish the
engine oil
Go to Step 5
The air cleaner element
Clean or
replace
Go to Step 6
The piping fixing condition (oil, Was the problem found?

vacuum and fuel piping)
Return normal
condition
Go to Step 7
The drive belt tension and break
Re-adjust the
tension or
replace
Go to Step 8
Go to section 6E On Board Was the problem found?

Diagnostic
(OBD)
System
Check
Verify repair
Go to Step 9
Go
to
mechanical Was the problem found?
troubleshooting chart
Verify repair
TROUBLESHOOTING 6 3
1. Hard Starting
Inspect the following items before diagnosis.
1. The battery conditions.
The terminal connection condition.
The battery charge condition or battery power weakness.
2. The fan belt loosen or broken.
3. The main fuse condition (open or not).
4. Fuel quantity level.
11 Starter motor inoperative
Step
1
Action
Value(s)
Check the starter switch.

Does the starter switch work?
Check the starter relay.

Does the starter relay work?
Check the magnetic switch.

Does the magnetic switch work?
Check the pinion gear condition on the starter motor.

Was the condition normal?
Check the brush wear or brush spring weakness.

Was the condition normal?
Yes
No
Go to Step 2
Repair or
replace the
starter switch
Go to Step 3
Repair or
replace the
starter relay
Go to Step 4
Repair or
replace the
magnetic
switch
Go to Step 5
Replace the
pinion gear
Replace the
starter motor
assembly
Repair or
replace the
brush or brush
spring
Yes
No
Repair or
replace seized
parts
Check other
DTC by Tech
2 and go to
indicated DTC
1-2 Starter motor operates but engine does not turn over
Step
1
Action
Check the engine internal seizure.
Was the engine seized?
Value(s)
6 4 TROUBLESHOOTING
1-3 Engine turn over but does not start engine

Incase of the fuel not being delivered to the injection pump
Step
Action
Value(s)
Check clogged, damaged the fuel piping or the

connector loosen.
Was any problem found?
Was the over flow valve on the fuel filter closed?
Was the fuel filter element clogged?
Yes
No
Repair replace
problem parts.
Go to Step 2
Repair replace
the over flow
valve
Go to Step 3
Replace the
fuel filter
element
Go to Step 4
Was the fuel line air bled?
Go to Step 5
Bleed the air
Are any DTC stored?
Go to indicated
DTC
Solved
Value(s)
Yes
No
Incase of the fuel is being delivered to the injection pump

Step
Action
Was the water contain in the fuel?
Replace the
fuel
Go to Step 2
Was the fuel line air bled?
Go to Step 5
Bleed the air
Was the injection spray condition complete?
Go to Step 4
Replace the
injection nozzle
Go to Step 5
Replace the
injection nozzle
Was the injection nozzle injection starting pressure

OK?
(See below)
Was the injection nozzle sticking?
Replace the
injection nozzle
Go to Step 6
Are any DTC stored?
Go to indicated
DTC
Solved
Injection nozzle opening pressure

2
1st = 19.5 MPa (199 kg/cm , 2828 psi)
TROUBLESHOOTING 6 5
2. Unstable Idling
Step
Action
Value(s)
Yes
No
Was the fuel line air bled completely?
Go to Step 3
Bleed the air
Was the fuel line leakage or blockage found?
Repair or
replace relation
parts.
Go to Step 4
Was the water contained in the fuel?
Replace the
fuel
Go to Step 5
Was the fuel filter element clogged?
Replace the
fuel filter
element
Go to Step 6
Go to Step 7
Replace the
injection nozzle
Was the injection starting pressure or the injection

spray condition OK?
(See below)
Was the injection nozzle sticking?
See Step 6
Replace the
injection nozzle
Go to Step 8
Check the throttle valve condition.

Was the idling port clogged in the throttle valve?
Repair or
replace the
throttle valve
Go to Step 9
Adjust the
valve clearance
Go to Step 10
Go to Step 11
Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
Go to indicated
DTC
Solved
10
Was the valve clearance improper adjusted?
Was the compression pressure OK?
Are any DTC stored?

2
1st = 19.5 MPa (199 kg/cm , 2828 psi)
0.4 mm
(0.016 in)
both intake
and exhaust
valves
3,040 kPa
2
(31 kg/cm ,
441 psi) at
200rpm
6 6 TROUBLESHOOTING
3. Insufficient Power
Step
Action
Value(s)
Was the air cleaner element condition OK? (Clogged

or not)
Was the intake air leakage found from intake

system?
Was the fuel filter element condition OK? (Clogged

or not)
Check the fuel injection pipes.

Does the injection pipes have obstruction or any
damage?
Was the water contained in the fuel?
Was the injection nozzle pressure or spray pattern

normal?
Was the exhaust pipe clogged?
Was the exhaust gas leakage found from exhaust

system?
Was the waste gate control actuator hose broken or

cracked?
11
Was the waste gate working completely?
13
Was turbocharger working completely?
Are any DTC stored?
No
Go to Step 2
Clean or
replace the air
cleaner
element.
Repair or
replace the
intake air
system.
Go to Step 3
Go to Step 4
Clean or
replace the fuel
filter element.
Repair or
replace the fuel
injection pipes.
Go to Step 5
Replace the
fuel
Go to Step 6
Go to Step 7
Readjust the
injection nozzle
pressure or
replace the
nozzle.
Go to Step 8
Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
Repair or
replace the
exhaust pipe.
Go to Step 9
Repair or
replace the
exhaust
system.
Go to Step 10
Replace the
hose.
Go to Step 11
Go to Step 12
Replace the
turbocharger
assembly.
Go to Step 13
Replace the
turbocharger
assembly.
Go to indicated
DTC
Solved
3.0 MPa
2
(31.0 kg/cm ,
441 psi) at
200 rpm
10
12
Yes
TROUBLESHOOTING 6 7
4. Excessive Fuel Consumption

Step
1
Action
Was the air cleaner element clogged?
Was the air leakage found from the air intake side of
the turbocharger?
Value(s)
Yes
No
Clean or
replace the air
cleaner
element.
Go to Step 2
Repair or
replace the air
intake side of
the
turbocharger.
Go to Step 3
Go to Step 4
Replace the
turbocharger
Repair or
replace the fuel
leakage part.
Go to Step 5
Go to Step 6
Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and valve seat
Go to Step 7
Replace the
injection nozzle
Go to indicated
DTC
Solved
Was the turbocharger working completely?
Was there the fuel leakage?
Was the injection nozzle pressure or spray pattern

normal?
Are any DTC stored?
3.0 MPa
2
(31.0 kg/cm ,
441 psi) at
200 rpm
6 8 TROUBLESHOOTING
5. Excessive Oil Consumption

Step
Action
Value(s)
Does the air cleaner element conditon OK? (Clogged

or not)
Does PCV (Positive Crankcase Ventilation) Valve

has problem?
Was the oil pressure value more than normal value?
Less than
588 kPa (6.0
2
kg/cm , 85
psi)
Inspect the front and rear crankshaft oil seal.
Was the oil leakage found?
Yes
No
Go to Step 2
Clean or
replace the air
cleaner
element
Repair or
replace the
relation parts.
Go to Step 3
Repair or
replace the oil
relief valve
Go to Step 4
Replace the
failure part.
Go to Step 5
Replace the
wrong gasket
Go to Step 6
Replace the
worn part.
Go to Step 7
Was the oil leakage found from any gasket?
Inspect the valve stem seal, the valve stem and the
valve guide for worn.
Were any worn found?
Was the oil leakage found from the turbocharger oil

seal?
Replace the oil

seal.
Go to Step 8
Was the oil drain pipe of the turbocharger restricted?
Repair or
replace the oil
drain pipe.
Go to Step 9
Was the oil drain passage in the turbocharger center

housing restricted?
Clean the
center housing
Go to Step 10
10
Does turbine wheel has any impact damage?
Replace the
turbocharger
Go to Step 11
11
Are any DTC stored?
Go to indicated
DTC
Solved
TROUBLESHOOTING 6 9
6. Overheating
Step
Action
Value(s)
Yes
No
Go to Step 2
Replenish the
coolant
Repair or
replace the
leakage part.
Go to Step 3
Tension or
replace the fan
belt.
Go to Step 4
Go to Step 5
Replace the
fan clutch
assembly.
Replace the
fan clutch
assembly
Go to Step 6
Go to Step 7
Replace the
thermostat.
Go to Step 8
Replace the
water pump
assembly.
Clean or
replace the
clog part.
Go to Step 9
Replace the
sealing cap or
replace the
cylinder body.
Go to Step 10
Go to indicated
DTC.
Solved
Value(s)
Yes
No
Go to Step 2
Readjust the
valve clearance
or replace the
cylinder head
gasket or
cylinder liner or
piston or piston
ring or valve
and relation
parts.
Go to Step 3
Repair or
replace the
PCV valve.
Go to Step 4
Replace the
turbocharger.
Go to indicated
DTC
Solved
Was the engine coolant level OK?
Was the water leakage or the radiator restriction

found? (Include radiator cap)
Was the fan belt slippage found?
Was the fan clutch working completely?
Was the oil leakage found from fan clutch?
Was the thermostat working normally?
Was the water pump working OK?
10
Was the restriction by the foreign materials in the

cooling system found? For example, clog the water
hose between the cylinder body and radiator etc..
Was the water leakage found from the sealing cap

on the cylinder body?
Are any DTC stored?
7. White Exhaust Smoke

Step
1
Action
3.0 MPa
2
(31.0 kg/cm ,
441 psi) at
200 rpm
Was the PCV (Positive Crankcase Ventilation) valve

working completely?
Was the turbocharger working completely?
Are any DTC stored?
6 10 TROUBLESHOOTING
8. Dark Exhaust Smoke

Step
1
Action
Was the air cleaner element normal condition?
Value(s)
Yes
No
Go to Step 2
Clean or
replace the air
cleaner
element
Replace the
EGR valve
Go to Step 3
Go to Step 4
Replace the
injection nozzle
Was the EGR valve sticking?
Was the injection nozzle pressure or the injection

spray pattern OK?
Was the oil leakage found from the turbocharger oil

seal?
Replace the oil

seal
Go to Step 5
Was the oil drain pipe of the turbocharger restricted?
Repair or
replace the oil
drain pipe
Go to Step 6
Was restricted the oil drain passage in the

turbocharger center housing restricted?
Clean the
center housing
Go to Step 7
Does turbine wheel has any impact damage?
Replace the
turbocharger
Go to Step 8
Does PCV (Positive Crankcase Ventilation) Valve

has problem?
Repair or
replace the
relation parts
Go to Step 9
Are any DTC stored?
Go to indicated
DTC
Solved
TROUBLESHOOTING 6 11
9. Oil Pressure Does Not Rise

Step
1
Action
Value(s)
Was the oil pressure warning lamp working OK?
Yes
No
Go to Step 2
Replace the oil

pressure
warning lamp
Does the oil filter element clog?
Replace the oil

filter element
Go to Step 3
Does the relief valve open?
Repair or
replace the
relief valve
Go to Step 4
Clean or
replace the oil
strainer
Go to Step 5
Go to Step 6
Repair or
replace the oil
pump.
Replace the
rocker arm
and/or relation
parts
Go to Step 7
Replace the
camshaft
and/or relation
parts
Go to Step 8
Replace the
crankshaft
and/or relation
parts
Go to Step 9
Go to indicated
DTC
Solved
Does the oil strainer clog?
Was the oil pump working OK? (The pump related

parts worn etc.)
Was the rocker arm and/or relation parts worn?
Was the camshaft and/or relation parts worn?
Was the crankshaft and/or relation parts worn?
Are any DTC stored?
Resistance
Electric current
Table of pressure unit

Pressure
kPa (kg/cm )
ohm
A
100
(1.0)
980
(10.0)
81
30
63.5
106.7
10. Abnormal Engine Noise

101 Engine knocking
Step
Action
Value(s)
Was the injection nozzle pressure or injection spray

pattern OK?
Are any DTC stored?
Yes
No
Go to Step 2
Replace the
injection nozzle
Go to Step 3
Replace the
cylinder head
gasket or
piston ring
Go to indicated
DTC
Solved
Value(s)
Yes
No
Retighten or
replace the
exhaust pipe
Go to Step 2
Retighten or
replace the
exhaust
manifold. Or
replace the
exhaust
manifold
gasket
Go to Step 3
Retighten or
replace the
injection nozzle
fixing bolt
Go to Step 4
Replace the
cylinder head
gasket
Go to Step 5
Go to indicated
DTC
Solved
3.0 MPa
2
(31.0 kg/cm ,
441 psi) at
200 rpm
102 Gas leakage noise

Step
1
Action
Was the exhaust pipe loose or broken?
Was the exhaust manifold loose?
Was the injection nozzle loose?
Was the cylinder head gasket broken?
Are any DTC stored?
103 Continuous noise
Step
1
Action
Was the fan belt tension OK?
Value(s)
Yes
No
Go to Step 2
Adjust the fan

belt tension.
9 13 mm
(0.35 0.51
in)
Was the cooling fan loose?
Tighten the
cooling fan
Go to Step 3
Was noise coming from the generator?
Repair or
replace the
generator
and/or the
vacuum pump
Go to Step 4
Was noise coming from the water pump?
Replace the
water pump
Go to Step 5
Was noise coming from the cylinder head cover?
Readjust the
valve
clearance.
Go to Step 6
Go to indicated
DTC
Solved
Value(s)
Yes
No
Go to Step 2
Go to Step 4
0.4 mm
(0.016 in)
both intake
and exhaust
Adjust the
valve
clearances
Go to Step 3
Are any DTC stored?
10-4 Slapping noise

Step
Action
Was noise coming from the cylinder head cover?
Were valve clearances correct?
Were the rocker arms damaged?
Replace the
rocker arms
Go to Step 4
Was the flywheel fixing bolt loose?
Tighten the
fixing bolt.
Go to Step 5
Was noise coming from the cylinder body?
Go to Step 6
Go to Step 10
Inspect the crankshaft bearing and/or crankshaft.

Was the crankshaft bearing and/or crankshaft worn?
Replace the
worn parts
Go to Step 7
Inspect the connecting rod bearing and/or crankpin.

Was the connecting rod bearing and/or crankpin
worn?
Replace the
worn parts
Go to Step 8
Inspect the connecting rod small end bushing and/or

piston pin.
Was the connecting rod small end bushing and/or
piston pin worn?
Replace the
worn parts
Go to Step 9
Inspect the piston and/or cylinder liner.

Was the piston and/or cylinder liner worn or
damaged?
Replace the
worn or
damaged parts
Go to Step 10
Are any DTC stored?
Go to indicated
DTC
Solved
10
10-5 Excessive turbocharger noise
The vibration noise (the air aspiration noise) occurred when turbocharger rotates, it is normal condition of the
turbocharger, no necessary any actions.
Step
Action
noise
Value(s)
coming
from
the
Yes
No
Go to Step 2
Go to Step 10
Was the excessive

turbocharger?
Inspect the fixing bolts and bands.

Was any problem found?
Tighten the
loose parts
Go to Step 3
Was the intake or exhaust system gasket damaged?
Replace the
damaged
gasket.
Go to Step 4
Inspect rotation parts condition.

Was the turbine wheel rotation rough?
Replace the
turbocharger.
Go to Step 5
Inspect the turbine wheel.

Was the turbine wheel rubbing against housing?
Replace the
turbocharger.
Go to Step 6
Was the turbine wheel damaged?
Replace the
turbocharger.
Go to Step 7
Were there carbon deposits in the turbine or

compressor housing?
Clean or
replace the
turbocharger.
Go to Step 8
Inspect the oil supply condition.

Was the oil feed pipe clogged?
Repair or
replace the oil
feed pipe.
Go to Step 9
Was the turbine shaft bearing worn?
Replace the
turbocharger.
Go to Step 10
10
Are any DTC stored?
Go to indicated
DTC
Solved
Value(s)
Yes
No
Replace the
engine oil
Go to Step 2
Go to Step 3
Replace the
engine oil
Clean or
replace the oil
feed pipe
Go to Step 4
11. Rotating Part Wear of Turbocharger

Step
Action
Inspect engine oil.

Was it contaminated with foreign materials?
Was the recommended engine oil grade/viscosity

being used?
Was the oil feed pipe restricted?
API CD or
ISUZU
genuine/
10W30
Was the oil seal of turbocharger defective?
Replace the oil

seal
Go to Step 5
Was the center housing oil drain passage clogged?
Clean center
housing or
replace the
turbocharger
Go to Step 6
Was there oil sludge and/or coking on the turbine

shaft?
Replace the
turbocharger
Go to Step 7
Are any DTC stored?
Go to indicated
DTC
Solved
12. Oil Leakage from Turbocharger

Step
Action
Value(s)
Yes
No
Inspect the oil leakage area.

Was the oil feed pipe eye bolt loose or the gasket
broken?
Tighten the eye

bolt or replace
the gasket.
Go to Step 2
Were the V band fixing faces tight?
Tighten band
or replace the
turbocharger
Go to Step 3
Was there oil leakage from the flange of the turbine

housing?
Replace the
turbocharger
Go to Step 4
Was there oil leakage from the flange of compressor

housing?
Tighten the bolt

and/or hose
clamp.
Go to Step 5
Are any DTC stored?
Go to indicated
DTC
Solved
13. Insufficient Acceleration and/or Lack of Power due to turbocharger

Step
1
Action
Value(s)
Yes
No
Inspect the air or exhaust route.

Was the air and/or exhaust gas piping loose?
Tighten flange
bolts or hose
clamp.
Go to Step 2
Inspect the work of waste gate valve control.

Was there rust on the linkage rod or pin of the waste
gate valve?
Replace the
turbocharger
Go to Step 3
Was air leakage found from the actuator piping?
Repair or
replace the
actuator pipe or
hose/
Go to Step 4
Inspect the inside of the turbocharger.

Was the turbine shaft end nut loose?
Replace the
turbocharger
Go to Step 5
Were the turbine blades bent?
Replace the
turbocharger
Go to Step 6
Was the turbine wheel rubbing against housing?
Replace the
turbocharger
Go to Step 7
Are any DTC stored?
Go to indicated
DTC
Solved
14. Battery Charging and Noise Problem

Visual/physical check the following items before diagnosis.
The drive belt tension.
The battery terminals connection condition.
The ground connection condition.
The generator and the battery fastener condition.
The battery fluid level and specific gravity.
14-1 Battery No Charging
Step
1
Action
Was Visual/Physical Check" performed.
Value(s)
Yes
No
Go to Step 2
Go to
visual/physical
check
Repair or
replace the
brush and/or
the slip ring.
Go to Step 3
Replace the
stator coil.
Go to Step 4
Replace the
rotor coil.
Go to Step 5
Inspect the brush contact condition on the generator.

Was there poor contact between the brush and the
slip ring?
Inspect the stator coil on the generator.

Was there an open circuit or the scorching on the
stator coil?
Inspect the rotor coil on the generator.

Was there an open circuit or the scorching on the
rotor coil?
Inspect the rectifier on the generator.

Was the rectifier defective?
Replace the
rectifier
Go to Step 6
Inspect the IC regulator.

Was the IC regulator defective?
Replace the IC
regulator.
Go to Step 7
Are any DTC stored?
Go to indicated
DTC.
Solved
Value(s)
Yes
No
Go to Step 2
Go to
visual/physical
check
14-2 Battery Overcharging

Step
1
Action
Inspect the terminal circuit.

Were the B and F terminals shorted?
Repair the
short circuit.
Go to Step 3
Check the regulating voltage.

Was the IC regulator voltage excessive?
Replace the IC
regulator.
Go to Step 4
Are any DTC stored?
Go to indicated
DTC.
Solved
14-3 Battery Under Charging
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to
visual/physical
check
Repair or
replace the
brush holder
assembly.
Go to Step 3
Repair or
replace the
rotor coil.
Go to Step 4
Repair or
replace the
stator coil.
Go to Step 5

Was there intermittent contact between the brush
and the slip ring?

Was there a short circuit in the rotor coil?

Was there an open circuit or the short circuit on the
stator coil?
Inspect the rectifier on the generator.

Was the rectifier defective?
Replace the
rectifier
Go to Step 6
Inspect the IC regulator on the generator.

Replace the IC
regulator.
Go to Step 7
Was the electrical load excessive?
Replace more
higher capacity
generator.
Go to Step 8
Go to indicated
DTC.
Solved
Value(s)
Yes
No
Go to Step 2
Go to
visual/physical
check
Repair or
replace the
brush and/or
the slip ring.
Go to Step 3
Repair or
replace the
rotor coil.
Go to Step 4
Repair or
replace the
stator coil.
Go to Step 5
Repair the
loose
connection.
Go to Step 6
Are any DTC stored?
14-4 Battery Unstable Charging Current

Step
1
Action

Was there poor contact between the brush and the
slip ring?

Was there the short circuit or an open circuit in the
rotor coil?

Was there an open circuit or the short circuit in the
stator coil?
Inspect the connection between the rectifier and

stator coil on the generator.
Was there a loose connection between the rectifier
and stator coil ?
Inspect the IC regulator on the generator.

Replace the IC
regulator.
Go to Step 7
Are any DTC stored?
Go to indicated
DTC.
Solved
14-5 Charging System Noise
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to
visual/physical
check
Replace the
bearing.
Go to Step 3
Was there intermittent noise or continuous noise and

that could be identified clearly by increasing and
decreasing engine speed?
Was there a growling sound and does this sound

stop when the connector was disconnected?
Replace the
stator coil.
Go to Step 4
Was intermittent sound heard when the generator

was running?
Replace the
brush and/or
slip ring.
Go to Step 5
Was frictional sound heard when generator was

running?
Clean the slip

ring or replace
the brush.
Go to Step 6
Are any DTC stored?
Go to indicated
DTC.
Solved
15. Starter Motor Problem

Visual/physical check the following items before diagnosis.
The battery terminals connection condition.
The ground connection condition.
The starter motor or the battery fastener condition.
The battery fluid level and specific gravity.
15-1 Starter motor pinion engages to ring gear but engine does not turn over
Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to
visual/physical
check
Replace the
brush or repair
the
commutator.
Go to Step 3
Clean contact
face
Go to Step 4
Check the contact condition between the brush and

the commutator.
Was the brush and the commutator contact
intermittent?
Were the brush and the commutator contact faces

dirty?
Was the pinion clutch slipped?
Replace the
pinion clutch
Go to Step 5
Inspect the armature field coil.

Was there an open circuit or a short circuit in the
armature field coil?
Repair or
replace the
armature field
coil.
Go to Step 6
Are any DTC stored?
Go to indicated
DTC.
Solved
Value(s)
Yes
No
Go to Step 2
Go to
visual/physical
check
Replace the
wron parts.
Go to Step 3
Adjust or
replace the
movement
parts.
Go to Step 4
Go to indicated
DTC.
Solved
15-2 Incorrect pinion and ring gear engagement

Step
1
Action
Inspect the pinion and the ring gear teeth.

Were the pinion and/or the ring gear teeth worn or
broken?
Inspect the pinion gear return movement.

Was the pinion gear return movement incorrect?
Are any DTC stored?
15-3 Starter motor continues to run after the starter switch is turned off
Step
1
Action
Inspect the magnetic switch contact point.

Was the contact point seized?
Value(s)
Yes
No
Go to Step 2
Go to
visual/physical
check
Repair or
replace the
magnetic
switch.
Go to Step 3
Inspect the starter switch.

Was the starter switch defective?
Replace the
starter switch.
Go to Step 4
Are any DTC stored?
Go to indicated
DTC.
Solved
Value(s)
Yes
No
Go to Step 2
Go to
visual/physical
check
Replace the
brush or repair
the
commutator.
Go to Step 3
Clean the
contact face or
replace the
brush.
Go to Step 4
15-4 Excessive commutator sparking

Step
1
Action
Inspect the contact condition between the brush and

the commutator.
Was the brush and the commutator contact
intermittent?
Was there the slag accumulation on the contact

face?
Was the brush holder loose?
Repair the
brush holder
Go to Step 5
Inspect the commutator.

Was there excessive wear or pitting?
Repair or
replace the
commutator.
Go to Step 6
Was there loose the solder on the commutator?
Clean and
repair
Go to Step 7
Inspect the armature shaft.

Was the run-out of armature shaft outside the
standard value due to worn bearing ?
Replace the
bearing
Go to Step 8
Are any DTC stored?
Go to indicated
DTC.
Solved
ENGINE MECHANICAL 6A 1
SECTION 6A
ENGINE MECHANICAL
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6A -
Torque Specifications ................................................................................................... 6A -
Standard Bolts ........................................................................................................... 6A -
Special Parts Fixing Nuts and Bolts ........................................................................ 6A -
Recommended Liquid Gasket ...................................................................................... 6A - 22

LOCTITE Application Procedure .................................................................................. 6A - 23
Servicing......................................................................................................................... 6A - 24
Model Identification ................................................................................................... 6A - 24
Air Cleaner .................................................................................................................. 6A - 24
Lubricating System .................................................................................................... 6A - 24
Fuel System ................................................................................................................ 6A - 25
Cooling System .......................................................................................................... 6A - 27
Valve Clearance Adjustment ..................................................................................... 6A - 31
Compression Pressure Measurement...................................................................... 6A - 32
General Description....................................................................................................... 6A- 36
Removal and Installation............................................................................................... 6A- 37
Removal ...................................................................................................................... 6A- 37
Installation .................................................................................................................. 6A- 40
Coolant Replenishment.......................................................................................... 6A- 41
Engine Warm-Up..................................................................................................... 6A- 41
Engine Repair Kit........................................................................................................... 6A- 42
Engine Overhaul ............................................................................................................ 6A- 43
Removal ...................................................................................................................... 6A- 43
External Parts ......................................................................................................... 6A- 43
6A 2 ENGINE MECHANICAL
Disassembly ............................................................................................................... 6A- 47

Internal Parts........................................................................................................... 6A- 47
Major Components.............................................................................................. 6A- 47
Minor Components ............................................................................................. 6A- 56
Rocker Arm Shaft and Rocker Arm................................................................ 6A- 56
Cylinder Head .................................................................................................. 6A- 57
Piston and Connecting Rod ........................................................................... 6A- 59
Inspection and Repair................................................................................................ 6A- 61
Cylinder Head ......................................................................................................... 6A- 61
Rocker Arm Shaft and Rocker Arm....................................................................... 6A- 68
Cylinder Body ......................................................................................................... 6A- 69
Camshaft ................................................................................................................. 6A- 77
Crankshaft and Bearing ......................................................................................... 6A- 79
Crankshaft Bearing Selection................................................................................ 6A- 83
Crankshaft Pilot Bearing........................................................................................ 6A- 85
Flywheel and Ring Gear......................................................................................... 6A- 85
Piston....................................................................................................................... 6A- 86
Cylinder Head Gasket Selection............................................................................ 6A- 88
Connecting Rod ...................................................................................................... 6A- 90
Idler Gear Shaft and Idler Gear.............................................................................. 6A- 91
Timing Gear Case Cover ........................................................................................ 6A- 91
Reassembly ................................................................................................................ 6A- 93
Internal Parts........................................................................................................... 6A- 93
Minor Component ............................................................................................... 6A- 93
Rocker Arm Shaft and Rocker Arm................................................................ 6A- 93
Cylinder Head .................................................................................................. 6A- 94
Piston and Connecting Rod ........................................................................... 6A- 96
Positive Crankcase Ventilation (PCV) Valve ................................................. 6A- 99
Major Component................................................................................................ 6A- 101
Installation .................................................................................................................. 6A- 118
External Parts ......................................................................................................... 6A- 118
Lubrication System........................................................................................................ 6A- 126
Lubricating Flow ........................................................................................................ 6A- 126

Oil Pump and Oil Filter .............................................................................................. 6A- 127
Oil Pump ..................................................................................................................... 6A- 128
Disassembly............................................................................................................ 6A- 128
Inspection and Repair ............................................................................................ 6A- 129
Reassembly............................................................................................................. 6A- 130
Oil Filter and Oil Cooler ............................................................................................. 6A- 131
Disassembly............................................................................................................ 6A- 131
Inspection and Repair ............................................................................................ 6A- 132
Reassembly............................................................................................................. 6A- 133
Inter Cooler .................................................................................................................... 6A- 135
Removal .................................................................................................................. 6A- 136
Installation .............................................................................................................. 6A- 136
Special Tools.................................................................................................................. 6A- 137

Engine model
Item
Engine type
4JA1T (L)
4JA1TC
Four-cycle, overhead valve, water cooled
Combustion chamber type
Direct injection
Cylinder liner type
Dry type, chrome plated
Timing gear train system
Gear drive
No. of cylinders-bore stroke
4 93 92 (3.66 3.62)
mm (in)
No. of piston rings
Compression ring: 2 / Oil ring: 1

3
Total piston displacement
cm (in )
2,499(152.4)
Compression ratio (to 1)

Compression pressure
18.5
2
Mpa(kg/cm /psi)
3.0 (31.0/441) 200 rpm
kg (lb)
Approximately 239 (527)
Engine weight (dry)

Fuel injection order
134-2
Fuel injection timing BTDC
deg
Specified fuel type
JIS No. 2, DIN/EN590, GB252-1944 Diesel fuel
Idling speed
rpm
730 25 (A/C Off)

850 25 (A/C ON)
Valve clearances (At cold): Intake

Exhaust
Intake valves
Exhaust valves
mm (in)
0.4 (0.016)
mm (in)
0.4 (0.016)
Open at (BTDC)
deg
24.5
Close at (ABDC)
deg
55.5
Open at (BBDC)
deg
54.0
Close at (ATDC)
deg
26.0
Fuel system
Injection pump type
BOSCH distributor VE type
BOSCH distributor VP44 type
Governor type
Mechanical (Half all speed

type)
Electronically controled
Injection nozzle type
Hole with 5 orifices

2
Mpa(kg/cm /psi)
Main fuel filter type
1st 19.1 (195 / 2,773)
1st 19.0 (194 / 2,755)
2nd (Reference)
25.5~27.0
(260~275 / 3,702~3,920)
2nd (Reference)
34.0~35.5
(347~362 / 4,936~5,154)
Cartridge paper element and water separator
Lubricating system
Lubricating method
Specified engine oil (API grade)
Pressure circulation
ISUZU genuine 10W 30 (API CD of ACEA B2/B3)
Engine model
Item
4JA1T (L)
4JA1TC
Gear
Oil pump type
Cartridge paper element
Oil filter type

Oil capacity
lit (US/UK gal)
6.2 (1.64/1.36)
Water cooled
Oil cooler type

Cooling system
Water pump type
Centrifugal
Thermostat type
Wax pellet with jiggle valve
Air cleaner type
Dry paper element
Battery type/voltage No. of units
Viscous paper element

80D26L 1
95D31L 1 (OPT)
Generator capacity
V-A
12 60
12 80
Starter motor output
V-Kw
Turbocharger model
Turbine type
Compressor type
*IHI : Ishikawajima-Harima Heavy Industries., Ltd.
12 2.3
*IHI RHF 4H
Mixed flow type
Backward & rake

Engine model
Item
Engine type
4JH1TC
Four-cycle, overhead valve, water cooled
Combustion chamber type
Direct injection
Cylinder liner type
Dry type, chrome plated
Timing gear train system
Gear drive
No. of cylinders-bore stroke
mm (in)
No. of piston rings
4 95.4 104.9 (3.76 4.13)

Compression ring: 2 / Oil ring: 1
liter
Compression ratio (to 1)

Compression pressure
2,999
18.3
MPa(kg/cm /psi)
Engine weight (dry)
kg (lb)
3.0 (31.0/441) 200 rpm

MT : Approximately 249 (549)
AT : Approximately 236 (520)
Fuel injection order
134-2
Specified fuel type
JIS No.2, DIN/EN590, GB252-1944 Diesel fuel
Idling speed
rpm
700 H 25 (A/C OFF)

800 H 25 (A/C ON)
Valve clearances (At cold): Intake

Exhaust
Intake valves
Exhaust valves
mm (in)
0.4 (0.016)
mm (in)
0.4 (0.016)
Open at (BTDC)
deg
24.5
Close at (ABDC)
deg
55.5
Open at (BBDC)
deg
54.0
Close at (ATDC)
deg
26.0
Fuel system
Injection pump type
BOSCH distributor VP44 type
Hole with 5 orifices

2
MPa(kg/cm /psi)
1st 19.5 (199/2,828)

2nd (Reference) 34.3~35.8 (350~365/4,980~5,197)
Cartridge paper element and water separator
Lubricating system
Lubricating method
Pressure circulation
Specified engine oil (API grade)
ISUZU genuine 10W 30 (API CD of ACEA B2/B3)
Oil pump type
Gear
Oil filter type

Oil capacity

lit (US/UK gal)
6.2 (1.64/1.36) (For 4 2)

7.0 (1.85/1.54) (For 4 4)
Oil cooler type
Water cooled
Engine model
Item
4JH1TC
Cooling system
Water pump type
Centrifugal
Thermostat type

Dry paper element (except for Euro3 spec)
Viscous paper element (for Euro3 spec)
Air cleaner type
80D26L 1
Battery type/voltage No. of units
95D31L 1 (OPT)
75D26R 2 (OPT for EC, MT)
80D26R 2 (OPT for EC, AT)
Generator capacity
Starter motor output
V-A
V-Kw
Turbocharger model
Turbine type
Compressor type
*IHI: Ishikawajima-Harima Heavy Industries., Ltd.
12 60/12 80
12 2.3
*IHI RHF5
Mixed flow type Radial-inflow
Backward & rake type Radial-outflow
TORQUE SPECIFICATION
STANDARD BOLTS
The torque values given in the following table should be applied whenever a particular torque is not specified.
Nm (kgm/lbft)
Strength
Class
4.8 (4T)
8.8
(7T)
Refined
9.8 (9T)
Non-Refined
Bolt
Identification
Bolt
Diameter
Pitch (mm)
M 6 1.0
5.88 1.96
(0.60 0.20/4.33 1.44)
7.35 2.45
(0.75 0.25/5.43 1.80)
M 8 1.25
12.74 4.90
(1.30 0.50/9.40 3.62)
17.15 5.39
(1.75 0.55/12.66 4.00)
23.52 6.86
(2.40 0.70/17.36 5.06)
M 10 1.25
27.44 6.86
(2.80 0.70/20.25 5.06)
36.75 9.31
(3.75 0.95/27.12 6.87)
49.98 12.74
(5.10 1.30/36.89 9.40)
M 12 1.25
61.25 12.25
(6.25 1.25/45.21 9.04)
75.95 15.19
(7.75 1.55/56.06 11.21)
94.57 19.11
(9.65 1.95/69.80 14.10)
M 14 1.5
95.55 19.11
(9.75 1.95/70.52 14.10)
116.13 23.03
(11.85 2.35/85.71 17.00)
142.10 28.42
(14.50 2.90/104.88 21.00)
M 16 1.5
130.34 26.46
(13.30 2.70/96.20 19.53)
169.54 34.30
(17.30 3.50/125.13 25.32)
199.92 40.18
(20.40 4.10/147.55 29.66)
M 18 1.5
188.16 37.24
(19.20 3.80/138.87 27.49)
244.02 49.00
(24.90 5.00/180.10 36.17)
287.14 57.82
(29.30 5.90/211.93 42.67)
M 20 1.5
257.74 51.94
(26.30 5.30/190.23 38.33)
337.12 67.62
(34.40 6.90/248.82 49.41)
395.92 79.38
(40.40 8.10/292.21 58.59)
M 22 1.5
332.22 81.34
(33.90 8.30/245.20 60.03)
453.25 90.65
(46.25 9.25/334.53 66.91)
530.18 105.84
(54.10 10.80/391.30 78.12)
M 24 2.0
448.84 90.16
(45.80 9.20/331.27 66.54)
570.36 140.14
(58.20 14.30/420.96 103.43)
691.88 138.18
(70.60 14.10/510.65 101.99)
* M 10 1.5
26.46 6.86
(2.70 0.70/19.53 5.06)
36.26 8.82
(3.70 0.90/26.76 6.50)
48.02 11.76
(4.90 1.20/35.44 8.68)
* M 12 1.5
56.84 11.76
(5.80 1.20/41.95 8.68)
70.56 13.72
(7.20 1.40/52.08 10.13)
89.18 17.64
(9.10 1.80/65.82 13.02)
* M 14 2.0
89.18 17.64
(9.10 1.80/65.82 13.02)
109.76 21.56
(11.20 2.20/81.01 15.91)
133.28 26.46
(13.60 2.70/98.37 19.53)
* M 16 2.0
124.46 24.50
(12.70 2.50/91.86 18.08)
161.70 32.34
(16.50 3.30/119.34 23.87)
191.10 38.22
(19.50 3.90/141.04 28.21)
An asterisk (*) indicates that the bolts are used for female threaded parts that are made of soft materials
such as casting. Those shown in parentheses in the strength class indicate the classification by the old
standard.
FLARE NUTS
Nm (kgm/lbft)
Pipe diameter mm
(in)
Torque
Pipe diameter mm
(in)
Torque
4.76 (0.187)
15.2 2.45(1.55 0.25/11.2 1.8)
10.00 (0.394)
53.95 4.90(5.50 0.5 /39.7 3.6)
6.35 (0.250)
26.48 2.94(2.70 0.30/19.5 2.1)
12.00 (0.472)
88.29 9.80(9.00 1.0/65.0 7.2)
8.00 (0.315)
44.14 4.90(4.50 0.50/32.5 3.6)
15.00 (0.591)
105.45 12.26(10.75 1.25/77.7 9.0)

Cylinder Head Cover, Cylinder Head, and Rocker Arm Shaft Bracket
Nm (kgm/lbft)
RTW46AXF000501
Crankshaft Bearing Cap, Connecting Rod Bearing Cap, Crankshaft Damper Pulley,
Flywheel, and Oil Pan
Nm (kgm/lbft)
RTW36AXF000101
Timing Gear Case, Pulley Housing, Timing Gear, and Camshaft

Nm (kgm/lbft)
RTW46AXF000601
Cooling and Lubricating System

Nm (kgm/lbft)
RTW46AXF000701
Intake Manifold (4JA1TC / 4JH1TC)

Nm (kgm/lbft)
RTW36AXF000201
EGR Valve, EGR Pipe, EGR Cooler
RTW46AXF000801
Exhaust Manifold, and Turbocharger (4JA1L)
RTW46AXF000901
Exhaust Manifold, and Turbocharger (4JA1TC/4JH1TC)

Nm (kgm/lbft)
RTW46AXF001001
Engine Electricals
Nm (kgm/lbft)
RTW36AXF000501
Fuel Injection System (4JA1L)

Nm (kgm/lbft)
RTW46AXF001101
Fuel Injection System (4JA1TC)

Nm (kgm/lbft)
RTW46AXF001201
Fuel Injection System (4JH1TC)

Nm (kgm/lbft)
RTW46AXF001301
Engine Mounting Bracket

Nm (kgm/lbft)
022R300001

Type
Brand Name
Manufacturer
RTV*
Silicon Base
ThreeBond 1207B
ThreeBond 1207C
Three Bond
Three Bond
Water Base
ThreeBond 1141E
ThreeBond 1215
Three Bond
Three Bond
Solvent
ThreeBond 1104
Belco Bond 4
Belco Bond 401
Belco Bond 402
Three Bond
Isuzu
Isuzu
Isuzu
Anaerobic
LOCTITE 515
LOCTITE 518
LOCTITE 262
Loctite
Loctite
Loctite
Remarks
Recommended for
transaxle repairs

Note:
1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the
vehicle.
2. Be careful to use the specified amount of liquid gasket.
Follow the manufacturers instructions at all times.
3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before
applying the liquid gasket.
4. LOCTITE 515 and LOCTITE 518 harden upon contact with a metal surface.
Do not apply LOCTITE 515 or LOCTITE 518 between two metal surfaces having a clearance of
greater than 0.25 mm (0.01 in). Poor adhesion will result.
LOCTITE APPLICATION PROCEDURE

LOCTITE Type
LOCTITE 242
LOCTITE Color
Red
LOCTITE 270
Green
LOCTITE 515
1.
Completely remove all lubricant and moisture from the bolts and the
female threaded surfaces of the parts to be joined.
2.
Apply LOCTITE to the bolts.
3.
Tighten the bolts to the specified torque.
4.
Wait at least one hour before continuing the installation procedure.
1.
Completely remove lubricant and moisture from the connecting

surfaces.
2.
Apply a 2.0 2.5 mm bead of LOCTITE to one of the connecting

surfaces.
There must be no gaps in the bead.
3.
4.
Let the joined parts set for at least thirty minutes.
Blue
LOCTITE 262
LOCTITE 271
Application Steps
Red
Violet
SERVICING
MODEL IDENTIFICATION
Engine Serial Number
The engine number is stamped on the rear left hand side
of the cylinder body.
The engine number is stamped in the plate in front of the
engine room as well.
RTW36ASH000401
AIR CLEANER
Element cleaning procedures will vary according to the
condition of the element.
Dust Fouled Element
130RY00003
Rotate the element with your hand while applying

compressed air to the inside of the element. This will blow
the dust free.
2
Compressed air pressure
kPa (kg/cm /psi)
392 490 (4 5/57 71)
LUBRICATING SYSTEM
Main Oil Filter (Cartridge Type Paper Element)
Replacement Procedure
1. Drain the engine oil.
2. Retighten the drain plug.
3. Loosen the used oil filter by turning it counterclockwise
with a filter wrench.
Filter Wrench: 5-8840-0200-0
6A-6
4. Clean the oil cooler fitting face. This will allow the new
oil filter to seat properly.
5. Apply a light coat of engine oil to the filter O-ring.
6. Turn in the new oil filter until the filter O-ring is fitted
against the sealing face.
7. Use the filter wrench to turn in the filter an additional
2/3 turns.
8. Check the engine oil level and replenish to the
specified level if required.
RTW36ASH000101
Replenished Engine Oil
MAX lit (US/UK gal)
Condition
Engine Dry
With oil filter

replacement
Without oil
filter
replacement
42
44
(4JA1L/TC)
42
(4JH1TC)
6.2 (1.64/1.36)
5.2 ~ 4.2
(1.37 ~ 1.11
/ 1.14 ~ 0.92)
4.5 ~ 3.5
(1.19 ~ 0.93
/ 0.99 ~ 0.77)
6.2 (1.64/1.36)
44
(4JH1TC)
7.0 (1.85/1.54)
5.2 ~ 4.2
(1.37 ~ 1.11
/ 1.14 ~ 0.92)
6.2 ~ 5.2
(1.64 ~ 1.37
/ 1.36 ~ 1.14)
4.5 ~ 3.5
(1.19 ~ 0.93
/ 0.99 ~ 0.77)
5.3 ~ 4.3
(1.72 ~ 1.14
/ 1.17 ~ 0.95)
Model
9. Start the engine and check for oil leakage from the
main oil filter.
FUEL SYSTEM
Fuel Filter Replacement Procedure
1. Remove the fuel filter by turning it counterclockwise
with a filter wrench.
Filter Wrench: 5-8840-0253-0 (J-22700)
Note:
Be careful not to spill the fuel in the filter cartridge.
6A-7
RTW46ASH000501
2. Clean the fuel filter cartridge fitting faces.

This will allow the new fuel filter to seat properly
3. Apply a light coat of engine oil to the O-ring.
4. Turn in the fuel filter until the sealing face comes in
contact with the O-ring.
5. Turn in the fuel filter an additional 2/3 of a turn with a
filter wrench.
Filter Wrench : 5-8840-0253-0 (J-22700)
041RY00009
6. Operate the priming pump until the air discharged

completely from fuel system.
7. Start the engine and check for fuel leakage.
Note:
The use of an ISUZU genuine fuel filter is strongly
recommended.
Draining Procedure
The indicator light will come on when the water level in the
water separator exceeds the specified level.
Drain the water and foreign material from the water
separator (inside chassis frame) with the following
procedure.
041RY00011
1.
2.
3.
4.
Place the drain pan under the drain plug.

Loosen the drain plug and drain water.
After draining the water, tighten the drain plug.
Operate the priming pump on the fuel filter several
times and check for fuel leakage.
5. Check the water separator indicator light. It should be
off.
Air Bleeding
Except EURO III model

RTW46ASH002901
For EURO III model
RTW46ASH000501
1. Operate the priming pump until strong resistance is

felt.
2. Wait 1 minute, and operate the priming pump until
strong resistance is felt.
3. Once more wait, and operate the priming pump until
4. Turn the ignition switch to the "ON" position. Wait until
the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position and
crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air
completely form the fuel system and check for fuel
leakage.
Note:
Insufficient air bleeding may cause the Diagnostic
Trouble Code (DTC) store or improper engine
performance.
COOLING SYSTEM
Coolant Level
Check the coolant level and replenish the radiator reserve
tank as necessary.
If the coolant level falls below the MIN line, carefully
check the cooling system for leakage. Then add enough
coolant to bring the level up to the MAX line.
111R300001
Engine coolant Filling up procedure

1. Make sure that the engine is cool.
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
2. Open rediator cap pour coolant up to filler neck
3. Pour coolant into reservoir tank up to MAX line
4. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
5. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
6. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
7. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
8. Pour coolant into the reservoir tank up to MAX line.
Engine Coolant Total Capacity
Lit (U.S / UK gal)
4JA1 / TC
4JH1TC
9.4 (2.5 / 2.1)

M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)
Mixing Ratio (Anti-Freeze Solution/Water)

50 %
Cooling System Inspection

Install a radiator filler cap tester to the radiator. Apply
testing pressure to the cooling system to check for
leakage. The testing pressure must not exceed the
specified pressure.
2
Testing Pressure
kPa(kg/cm /psi)
150 (1.5/21)
030LX003
Radiator Cap Inspection

The radiator filler cap is designed to maintain coolant
2
pressure in the cooling system at 103 kPa(1.05 kg/cm ,
15psi).
Check the radiator filler cap with a radiator filler cap tester.
The radiator filler cap must be replaced if it fails to hold the
specified pressure during the test procedure.
Radiator Cap Valve Opening Pressure
2
kPa(kg/cm /psi)
030LX002
90 120 (0.9 1.2/13 17)

Negative Valve (Reference)
kPa(kg/cm /psi)
1.9 4.9 (0.02 0.05/0.28 0.71)
Thermostat Operating Test

1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature
C (F)
82 (180)
030LX014
C (F)
Oil Cooler Thermo Valve

76.5 (170)
EGR Cooler Thermo Valve
C (F)
40 (104)
4. Check the thermostat full opening temperature.
Thermostat Full Opening Temperature
C (F)
95 (203)
C (F)

90 (194)
C (F)
55 (131)
Valve Lift at Fully Open position
mm (in)
9.5 (0.37)
mm (in)
4.5 (0.18)
mm in)
3.5 (0.14)
Drive Belt Adjustment
033RY00002
Check drive belts for wear or damage, and replace with

new ones as necessary. Check belts for tension, and
adjust as necessary.
1 Crankshaft damper pulley
2 Generator pulley
3 Cooling fan pulley
4 Oil pump pulley or idler pulley
5 Compressor pulley or idler pulley
Cooling Fan Pulley Drive Belt

Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98N (10 kg/22 lb)
force.
Cooling Fan Drive Belt Deflection
mm (in)
New belt
4 - 7 (0.16 - 0.28)
Reuse belt 6 - 9 (0.24 - 0.35)
033RY00003

2 Generator pulley
3 Cooling fan pulley
A/C Compressor Drive Belt

Compressor belt tension is adjusted by moving the P/S
pumppulley.
Depress the drive belt mid-portion with a 98N (10 kg/22 Ib)
force.
A/C Compressor Drive Belt Deflection
mm (in)
New belt
9 - 10 (0.35 - 0.39)
Reuse belt 12 - 13 (0.47 - 0.51)
033RY00004

2 P/S pump pulley
2 A/C Compressor pulley
VALVE CLEARANCE ADJUSTMENT

1. Bring the piston in either the No. 1 cylinder or the No. 4
cylinder to TDC on the compression stroke by turning
the crankshaft until the crankshaft damper pulley TDC
line is aligned with the timing pointer.
2. Check the rocker arm shaft bracket nuts for
looseness.
Tighten any loose rocker arm shaft bracket nuts
before adjusting the valve clearance.
Rocker Arm Shaft Bracket Nut Torque
Nm (kgm /lbft)
54 (5.5/40)
014RY00014
8. Check for play in the No. 1 intake and exhaust valve

push rods.
If the No. 1 cylinder intake and exhaust valve push
rods have play, the No. 1 piston is at TDC on the
compression stroke.
rods are depressed, the No. 4 piston is at TDC on the
compression stroke.
014RY00015
Adjust the No.1 or the No. 4 cylinder valve clearances

while their respective cylinders are at TDC on the
compression stroke.
Valve Clearance (At Cold)
mm (in)
0.4 (0.016)
014RY00016
9. Loosen each valve clearance adjusting screw as

10. Insert a feeler gauge of the appropriate thickness
between the rocker arm and the valve stem end.
11. Turn the valve clearance adjusting screw until a slight
drag can be felt on the feeler gauge.
12. Tighten the lock nut securely.
13. Rotate the crankshaft 360.
14. Realign the crankshaft damper pulley TDC notched
line with the timing pointer.
15. Adjust the clearances for the remaining valves as
014RY00017
COMPRESSION PRESSURE
MEASUREMENT
F06XL056
1. Start the engine and allow it to idle until the coolant

temperature reaches 70 80 C (158 176 F).
2. Remove the following parts.
Leak off pipe
Injection nozzle holder bracket
Injection nozzle holder
3. Install the following parts.
Set the adapter and compression gauge (SST) to
the No.1 cylinder injection nozzle hole.
Injection nozzle holder bracket
Injection nozzle holder bracket Bolt Torque
Nm (kgm /lbft)
37 (3.8/27)
Compression Gauge: 5-8840-2675-0
Adapter; Compression Gauge: 5-8531-7001-0
4. Turn the engine over with the starter motor and take
the compression gauge reading.
Compression Pressure
901R100003
MPa (kg/cm /psi) at 200 rpm
Standard
Limit
3.0 (31.0/441)
2.1 (21.7/309)
5. Repeat the procedure (Steps 3 and 4) for the

remaining cylinders.
If the measured value is less than the specified limit,
refer to Troubleshooting in this Manual.
INJECTION TIMING ADJUSTMENT

(4JA1T(L) only)
1. Check that the notched line on the injection pump
flange is aligned with the front plate or the timing gear
case notched line.
2. Bring the piston in the No. 1 cylinder to TDC on the

compression stroke by turning the crankshaft until the
crankshaft pulley TDC line is aligned with the timing
mark.
Note:
Check for play in the No. 1 intake and exhaust valve
push rods.
rods have play, the No. 1 piston is at TDC on the
compression stroke.
RTW46ASH000601
3. Disconnect the injection pipe from the injection pump

4. Remove one bolt from the distributor head.
5. Install the static timing gauge.
The probe of the gauge should be depressed inward
approximately 2 mm (0.079 in).
Static Timing Gauge: 5-8840-0145-0 (J-28827)
6. Rotate the crankshaft to bring the piston in the No. 1

cylinder to a point 30 - 40 BTDC.
7. Set the timing gauge needle to zero.
8. Move the crankshaft pulley slightly in both directions to
check that the gauge indication is stable.
9. Turn the crankshaft clockwise and read the gauge
indication when the crankshaft pulley timing mark (8)
is aligned with the pointer.
Injection Timing : BTDC 8 2
Standard Reading
mm (in)
0.5 (0.02)
RTW46ASH000701
If the injection timing is outside the specified range,

continue with the following steps.
10. Loosen the injection pump fixing nuts and bracket
bolts.
11. Adjust the injection pump setting angle.
When large than standard
value
When smaller than standard

value
A: Move the injection pump toward the engine.

R: Move the injection pump away from the engine.
ENGINE CONTROL (4JA1T(L) only)

Idling Speed Adjustment
1. Set the vehicle parking brake and chock the drive
wheels.
2. Place the transmission in neutral.
3. Start the engine and allow it to idle until the coolant
temperature reaches 70 - 80C (158 - 176F).
4. Disconnect the engine control cable from the control

lever.
5. Set a tachometer to the engine.
6. Check the engine idling speed.
If the engine idling speed is outside the specified
range, it must be adjusted.
Engine Idling Speed : 730 25 rpm
Idling Speed Adjustment

1. Loosen the idling set screw lock nut Q on the injection
pump idling set bolt.
2. Adjust the idling speed to the specified range by
turning the idling set bolt R.
3. Lock the engine set nut Q with the idling set bolt lock
nut.
4. Check that the idling control cable is tight (free of
slack). If required, remove the slack from the cable.
Fast Idling Speed Inspection

1. Set tachometer to the engine.
2. Disconnect the vacuum hose Q from the fast idle
actuator U on the injection pump.
3. Disconnect the other vacuum hose R from the

vacuum switching valve S and connect it to the fast
idle actuator U.
The vacuum line will now be connected directly from
the vacuum pump T to the fast idle actuator.
4. Check the engine fast idling speed.
If the engine idling speed is outside the specified
range, it must be adjusted.
Fast Idling Speed
rpm
850 25
Fast Idling Speed Adjustment

1. Loosen the fast idle actuator bracket bolts.
2. Adjust the fast idling speed by moving the actuator

bracket, so that the clearance S can be 1 ~ 2 mm
(0.04 ~ 0.08 in.).
3. Tighten the bracket bolts.
Accelerator Control Cable Adjustment

Refer to Sec. 6H-6 (Accelerator Control)
GENERAL DESCRIPTION
RTW46AMF000401
The 4J series automotive diesel engine has special designed combustion chambers in the piston. This design
provides superior fuel economy over a wide range of driving conditions.
Auto-thermatic pistons with cast steel struts are used to reduce thermal expansion and resulting engine noise when
the engine is cold.
Chrome plated dry type cylinder liners provide the highest durability.
The laminated steel sheet cylinder head gasket is very durable and, to increase the head gasket reliability.
The crankshaft has been tufftrided to provide a longer service life. Because the crankshaft is tufftrided, it cannot be
reground.
The 4JA1T(L) engine is equipped with the BOSCH VE-Type distributor injection pump.
The 4JH1TC and 4JA1TC engine is equipped with the BOSCH VP44-Type distributor injection pump.
The engine is turbocharger equipped.

Read this section carefully before performing any removal and installation procedure. This section gives
you important points as well as the order of operation. Be sure that you understand everything in this section before
you begin.
Removal
1. Battery
1) Disconnect the battery cable and the grounding cable
from the battery terminals.
2) Remove the battery clamp. Take care not to
accidentally short the battery with the wrench or some
other tool.
3) Remove the battery.
4) Disconnect the battery cable at the starter motor and
the ground cable at the cylinder body.
P1010011
2. Engine Hood
Apply setting marks to the engine hood and the engine
hood hinges before removing the engine hood. This will
facilitate reinstallation of the engine hood to its original
position.
P1010002
3. Supporting the Vehicle

1) Jack up the vehicle.
2) Place chassis stands at the front and the rear of the
vehicle.
F06R300006
4. Under cover (for 4x4 model)

5. Rear propeller shaft
1) Remove the propeller shaft flange yoke at the rear
differential.
2) Remove the center bearing retainer bolts.
3) Remove the propeller shaft together with the center
bearing from the transmission mainshaft spline.
6. Front propeller shaft (for 4x4 model)
Remove the spline yoke flange bolt at the transfer output
shaft.
Do not allow the spline yoke to fall away from the front
propeller shaft.
If the spline yoke should fall away from the front propeller
shaft, align the setting marks on the spline yoke and the
propeller shaft to reassemble the two marks. The setting
marks are punched circles approx. 3mm (0.12 in) in
diameter.
7. Clutch slave cylinder (for M/T model)
8. ATF pipe (for A/T model)
9 Shift control cable (for A/T model)
10. Transmission sensor harness
Remove the vehicle speed sensor connector, inhibitor
switch connector (A/T), ATF temperature sensor
connector, back up light switch connector (M/T) from
transmission.
11. Breather hose (for A/T model)
12. Transmission shift lever (for M/T model)
Remove the shift lever from the floor.
13. Transfer shift lever (for 4x4 model)
Remove the shift lever from the floor.
14. Transmission member
1) Support the transmission with the transmission jack.
2) Remove the transmission member mounting bolts
fixing the transmission member to the chassis frame.
P1010025
15. Torque converter bolt (for A/T model)

1) Remove the under cover under the torque converter
housing.
2) Rotate the flywheel by using tire lever or some other
tool, and then remove the torque converter bolts.
16. Transmission coupling bolt
1) Support the engine with the garage jack.
2) Use the jack to slightly lower the transmission.
3) Remove the transmission coupling bolts.
17. Transmission (and transfer)
Separate the transmission (and transfer) from the
engine.Take care not to damage the transmission, the
engine, and their related parts..
F06R300007
18. Radiator
1) Drain the engine coolant.
2) Remove the reservoir hose.
3) Remove the upper and lower hose.
4) Remove the fan guide.
5) Remove the radiator.
P1010009
19. Fan
20. Air cleaner
1) Remove the MAF sensor connector (4JA1TC/4JH1TC)
from air cleaner duct.
2) Remove the air cleaner duct and the air cleaner box
from engine room.
3) Remove the two air ducts from inter cooler
(4JA1TC/4JH1TC).
P1010034
21. Power Steering Pump

Loosen the power steering pump adjust plate bolt, then
remove the power steering pump assembly. Place the
power steering pump assembly along with piping on the
body side.
22. Air conditioner compressor
1) Remove air compressor magnet connector.
2) Remove the air conditioner compressor. Place the air
conditioner compressor along with piping on the body
side.
23. Engine Control Cable
Remove the engine control cable from its bracket
(4JA1TC/4JH1TC) or the injection pump (4JA1T(L)).
24. Vacuum Piping
Remove the vacuum pipe from the vacuum pump, the
EGR valve, injection pump FICD (4JA1T(L)).
25. Engine Harness
1) Remove following connectors from engine.
TPS connector
Oil pressure switch connector
Thermo switch connector
Injection pump connector
Engine earth
Thermometer unit connector
TDC sensor
2) Remove the clips fixing engine harness.
26. Fuel Hose
Remove the fuel hose from the fuel filter (Except EURO
III).
140R300001
Remove the fuel hose from injection pump (EURO III

only).
RTW46ASH000501
27. Exhaust Pipe

Remove the front exhaust pipe bolts and separate the
exhaust manifold and the front exhaust pipe.
28. Engine Assembly
1) Remove two right side engine foot bolts.
2) Remove two left side engine mount bolts.
3) Use the hoist to lift the engine from the engine
compartment.
022R300002
F06R300008
Installation
To reassemble, follow the removal steps in the reverse
order.
Coolant Replenishment
Warning:
When the coolant is heated to a high temperature, be
sure not to loosen or remove the rediator cap.
Otherwise you might get scalded by hot vapor or
boiling water.
To open the radiator cap, put a piece of thick cloth on
the cap and loosen the cap slowly to reduce the
pressure when the coolant has become cooler.
1. Open rediator cap pour coolant up to filler neck
2. Pour coolant into reservoir tank up to "MAX" line
3. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
4. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and let
the coolant circulate also into heater water system.
5. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
6. When the engine has been cooled, check filler neck for
water level and replenish if required. Should extreme
shortage of coolant is found, check the coolant system
and reservoir tank hose for leakage.
7. Pour coolant into the reservoir tank up to "MAX" line.
Coolant Capacity
4JA1 / TC
4JH1TC
lit (US/UK gal)

9.4 (2.5 / 2.1)
M/T: 10.1 (2.7 / 2.2)
A/T: 10.0 (2.6 / 2.2)
9.5 (2.5/2.1)
Engine Warm-Up
After completing the required maintenance procedures,
start the engine and allow it to idle until it is warm.
Check the following:
1. Engine idling speed.
2. Engine noise level.
3. Engine lubricating system and cooling system.
Carefully check for oil and coolant leakage.
4. Clutch engagement.
5. Transmission operation.
6. Indicator warning light operation.
ENGINE REPAIR KIT
RTW36ALF000601
Removal Steps
1. Cylinder head gasket
2. Head cover gasket
3. Head cover cap nut gasket
4. Drain cock gasket
5. Crankshaft rear oil seal
6. Gear case gasket
7. Oil pan drain plug gasket
8. Oil pan gasket
9. Oil filter gasket
10. Joint bolt gasket
11. Vacuum pump gasket

12. Water pump O-ring
13. Water outlet pipe gasket
14. Intake pipe gasket
15. Thermostat housing gasket
16. Intake manifold gasket
17. Exhaust manifold gasket
18. Nozzle holder O-ring
19. Nozzle holder gasket
20. Crankshaft front oil seal
NOTE
Discard all O-rings, gaskets, and seals removed at disassembly and replace them with new ones. Reuse of
these parts will result in oil, water, and gas leakage.
ENGINE OVERHAUL
REMOVAL
EXTERNAL PARTS
RTW36AMF000401
Removal Steps
1. Clutch Assembly or Flex Plate
2. Intake Pipe and Throttle Body
3-1. EGR Pipe
3-2. EGR cooler (EURO III model only)
4. EGR Valve
5. Oil Level Gauge
6. Fuel Filter Assembly (Except EURO III)
7. Fuel Filter Bracket (Except EURO III)
8. Fuel Injection Pipe with Clip
9. Power Steering Oil Pump Bracket
10. Intake Manifold
11. Engine Mounting Bracket and Foot
12. Injection Pump Cover
13. Injection Pump
14. Starter Motor
15. Oil Pressure Warning Switch

16. Fuel Leak Off Pipe
17. Oil Cooler Water Pipe
18. Cooling Fan Pulley
19. Heat Protector
20. Catalytic Converter
21. Turbocharger
22. Compressor Bracket
23. Vacuum Pump Oil Return Hose
24. Generator and Adjusting Plate
25. Water Inlet Pipe
26. Generator Bracket
27. Oil Cooler with Oil Filter
28. Exhaust Manifold
Removal
Remove the clutch assembly or the flex plate.
2. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only)
1) Loosen hose clamp between turbocharger and intake
duct.
2) Remove the rubber hose.
3) Remove the intake pipe and the throttle body.
(4JA1TC/4JH1TC only)
4JA1L
RTW46ASH000801
4JA1TC/4JH1TC
RTW36ASH000201
3-1. EGR Pipe

1) Remove two bolts from the exhaust manifold.
2) Remove two nuts from the EGR valve adapter.
3) Remove the EGR pipe with gaskets.
4JA1L
025R100008
4JH1TC
RTW36ASH000301
3-2. EGR Cooler (EURO III model only)
4. EGR Valve
1) Remove four nuts and remove the EGR valve
assembly from the intake manifold.
2) Remove four bolts and remove the adapter from the
EGR valve assembly.
4JA1*L
RTW46ASH001001
5. Oil Level Gauge

1) Disconnect PCV hose.
2) Remove two bolts and remove the engine oil level
gauge.
4JA1*TC
RTW46ASH000901
6. Fuel Filter Assembly (Except EURO III model)

1) Disconnect fuel hose.
2) Remove two bolts and remove the fuel filter.
7. Fuel Filter Bracket (Except EURO III model)
Remove three bolts and remove the fuel filter bracket with
leak pipe.
1) Loosen the injection pipe sleeve nuts at pump side
and nozzle side.
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clips.
3) Remove the injection pipe.
NOTE:
Plug the delivery holder ports with the caps to prevent the
entry of foreign material.
4JH1*TC
RTW36ASH001201

10. Intake Manifold
1) Disconnect the PCV hose from the cylinder head
cover.
2) Remove the intake manifold with gasket.
RTW36ASH000701
11. Engine Mounting Bracket and Foot

12. Injection Pump Cover
13. Injection Pump
14.
15.
16.
17.
18.
19.
Rrefer to secton 6C-19 (Injection Iump)

Starter Motor
Oil Pressure Warning Switch
Fuel Leak Off Pipe
Oil Cooler Water Pipe
Cooling Fan Pulley
Heat Protector
027R100007
037RY00001
21. Turbocharger
1) Disconnect the water hose between thermostat
housing cover and turbocharger.
2) Disconnect the water hose between water inlet pipe
and turbocharger.
3) Remove the oil feed pipe.
4) Remove the oil return pipe.
5) Remove the turbocharger and the gasket.
NOTE:
Plug the turbocharger body oil ports and water ports after
removing the turbocharger assembly to prevent the entry
of foreign material.
22.
23.
24.
25.
26.
27.
28.
Compressor Bracket
Vacuum Pump Oil Return Hose
Generator and Adjusting Plate
Water Inlet Pipe
Generator Bracket
Oil Cooler with Oil Filter
Exhaust Manifold
1
DISASSEMBLY
INTERNAL PARTS
MAJOR COMPONENTS
011R300001
Disassembly Steps-1
1.
2.
3.
4.
Water bypass hose

Thermostat housing with thermo
switch
Cylinder head cover
Injection nozzle and bracket
5.
6.
7.
8.
Rocker arm shaft and rocker

arm
Push rod
Cylinder head
Cylinder head gasket
RTW46ALF000101
Disassembly Steps-2
9.
10.
11.
12.
13.
14.
15.
16.
Crankshaft damper pulley

Timing gear case cove
Water pump
Idle gear "B" and shaft
Idle gear "A"
Idle gear shaft
Crankshaft timing gear
Injection pump
014R300005
Disassembly Steps-3
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Flywheel
Crank case
Oil pump with oil pipe
Camshaft timing gear
Camshaft thrust plate
Camshaft
Timing gear case
Cylinder body rear plate
Piston cooling oil jet
Connecting rod bearing cap with
lower bearing
27.
28.
29.
30.
31.
32.
33.
34.
Piston and connecting rod with

upper bearing
Crankshaft bearing cap with
lower bearing
Crankshaft thrust bearing
Crankshaft
Crankshaft upper bearing
Tappet
Crankshaft rear oil seal
Cylinder body
Disassembly
1.
2.
3.
4.
Water Bypass Hose

Thermostat Housing with Thermo Switch
Cylinder Head Cover
Injection Nozzle and Bracket
1. Remove the injection nozzle bracket bolts.
011R100002
2. Use the injection nozzle remover and the sliding

hammer to remove the injection nozzle together.
Injection Nozzle Remover: 5-8840-2723-0
Sliding Hammer:
5-8840-0019-0
011RY00005
5. Rocker Arm Shaft and Rocker Arm

Loosen the rocker arm shaft bracket bolts in numerical
order a little at a time.
Note:
Failure to loosen the rocker arm shaft bracket bolts in
numerical order a little at a time will adversely affect the
rocker arm shaft.
6. Push Rod
011RY00006
7. Cylinder Head
Loosen the cylinder head bolts in numerical order a little at
a time.
Note:
Failure to loosen the cylinder head bolts in numerical
order a little at a time will adversely affect the cylinder
head lower surface.
011RY00007
8. Cylinder Head Gasket

9. Crankshaft Damper Pulley
10. Timing Gear Case Cover
The timing gear case is tightened together with the
injection pump at the 6 points indicated by the arrows in
the illustration.
11. Water Pump
020L200006
12. Idle Gear B and shaft

Before removing the idle gear B, install bolt (M6,L=30) to
the hole marked with an arrow in the illustration to hold the
scissor gear in place.
020L200020
13. Idler Gear "A"

1. Measure the camshaft timing gear backlash and the
crankshaft timing gear backlash before removing the
idler gear.
2. Measure the idler gear end play before removing the
idler gear.
020RY00019
NOTE:
Refer to the following items for details on the backlash
and end play measurement procedures.
Timing Gear Backlash Measurement

1. Set a dial indicator to the timing gear to measured.
Hold both the gear to be checked and the adjusting
gear stationary.
2. Move the gear to be checked as far as possible to
both the right and the left.
Take the dial indicator reading.
If the measured value exceeds the specified limit, the
timing gear must be replaced.
020RY00020
Timing Gear Backlash

Standard
0.10 - 0.17 (0.0039 - 0.0067)
mm (in)
Limit
0.30 (0.012)
Idler Gear "A" End Play Measurement

Insert a feeler gauge between the idler gear and the thrust
collar to measure the gap and determine the idler gear
end play.
thrust collar must be replaced.
RTW36ASH000801
4JA1T(L)
Idler Gear End Play

Standard
0.07 (0.0028)
mm (in)
Limit
0.2 (0.0079)
14. Idle Gear Shaft

15. Crankshaft Timing Gear
040R300009
4JA1TC/4JH1TC
RTW36ASH001301
16. Injection Pump

1. Remove the injection pump cover (4JA1TC/4JH1TC
only).
2. Remove the injection pump bracket.
3. Pull the injection pump along with the injection pump
timing gear free toward the rear of the engine.
NOTE:
Plug the injection pump delivery ports with the caps to
prevent the entry of foreign material.
17. Flywheel
Loosen the flywheel bolts in numerical order a little at a
time.
Use the gear stoper to stop the flywheel gear.
Gear stoper: 5-8840-0214-0
18. Crank Case
19. Oil Pump With Oil Pipe
015RY00001
20. Camshaft Timing Gear
1. Use a dial indicator to measure the camshaft end play.
This must be done before removing the camshaft
gear.
If the camshaft end play exceeds the specified limit,
the thrust plate must be replaced.
014RT0001
901R100008
Camshaft End Play

Standard
0.050 - 0.114
(0.002 - 0.0044)
mm (in)
Limit
0.20
(0.008)
2. Remove the camshaft timing gear bolt from the

camshaft.
Note:
Hold the camshaft stationary to prevent the camshaft
from turning.
3. Remove the sensor rotor plate.
4. Use the universal puller to pull out the camshaft
timing gear.
Universal Puller: 5-8521-0002-0
5. Remove the thrust plate.
21. Camshaft Thrust Plate
22. Camshaft
Jiggle the camshaft with your hand as you pull it free from
the front of the engine.
23. Timing Gear Case

24. Cylinder Body Rear Plate
014RY00019
25. Piston Cooling Oil Jet

The oiling jet uses thin steel tubing which is easily bent.
Accidental contact between the oiling jet and the cylinder
body, piston, or a tool will damage the oiling jet.
Never attempt to repair a damaged oiling jet. Replace it
with a new one.
052RY00001
26. Connecting Rod Bearing Cap with Lower Bearing
If the connecting rod lower bearings are to be reinstalled,
mark their fitting positions by tagging each bearing with the
cylinder number from which it was removed.
014LX056
27. Piston and Connecting Rod with Upper Bearing

1. Remove carbon deposits from the upper portion of the
cylinder wall with a scraper before removing the piston
and connecting rod.
2. Move the piston to the top of the cylinder and tap it
with a hammer grip or a similar object from the
connecting rod lower side to drive it out.
015LX018
If the connecting rod upper bearings are to be reinstalled,

mark their fitting positions by tagging each bearing with the
RTW36ASH001501
28. Crankshaft Bearing Cap with Lower Bearing

1. Measure the crankshaft end play at the center journal
of the crankshaft.
Do this before removing the crankshaft bearing caps.
crankshaft thrust bearing must be replaced.
015RY00002
Crankshaft End Play

Standard
0.10 (0.004)
mm (in)
Limit
0.30 (0.012)
2. Loosen the crankshaft bearing cap bolts in numerical
order a little at a time.
If the crankshaft bearings are to be reinstalled, mark
their fitting positions by tagging each bearing with the
29. Crankshaft Thrust Bearing
30.Crankshaft
015RY00003
31. Crankshaft Upper Bearing

If the crankshaft upper bearings are to be reinstalled, mark
015RY00004
32. Tappet
If the tappets are to be reinstalled, mark their fitting
positions by tagging each tappet with the cylinder number
from which it was removed.
015RY00005
33. Crankshaft Rear Oil Seal

With the oil seal pushed in deep, install the special
tool as shown in the illustration and remove the oil
seal.
Oil Seal Remover: 5-8840-2360-0
34. Cylinder Body

015LV002
MINOR COMPONENTS
ROCKER ARM SHAFT AND ROCKER ARM
011RY00009
Disassembly Steps
1.
2.
3.
4.
Rocker arm shaft snap ring

Rocker arm
Rocker arm shaft bracket
Rocker arm
5.
6.
7.
Rocker arm shaft spring

Rocker arm shaft
Disassembly
011RY00010
1. Rocker Arm Shaft Snap Ring

2. Rocker Arm
3. Rocker Arm Shaft Bracket
1. Use a pair of pliers to remove the snap rings.
2. Remove the rocker arms.
3. Remove the rocker arm shaft brackets.
If the rocker arms and rocker arm shaft brackets are to
be reinstalled, mark their installation positions by
tagging each rocker arm and rocker arm shaft bracket
with the cylinder number from which it was removed.
4. Rocker Arm
5. Rocker Arm Shaft Spring
7. Rocker Arm Shaft
CYLINDER HEAD
RTW46ALF001201
Disassembly Steps
1.
2.
3.
4.
5.
Intake manifold
Intake manifold gasket
Split collar
Valve spring upper seat
Valve spring
6.
7.
8.
9.
Intake and exhaust valve

Valve stem oil seal
Valve spring lower seat
Cylinder head
Disassembly
1. Intake Manifold
2. Intake Manifold Gasket
3. Split Collar
011RY00011
1. Place the cylinder head on a flat wooden surface.

2. Use the spring compressor to remove the split collars.
Do not allow the valve to fall from the cylinder head.
Spring Compressor: 9-8523-1423-0
4. Valve Spring Upper Seat
5. Valve Spring
6. Intake and Exhaust Valve
If the intake and exhaust valves are to be reinstalled, mark
their installation positions by tagging each valve with the
If the intake and exhaust valves are to be replaced, the
valve guides must also be replaced.
7. Valve Stem Oil Seal
8. Valve Spring Lower Seat
9. Cylinder Head
011LX022
PISTON AND CONNECTING ROD
RTW46ALF000301
Disassembly Steps
1.
2.
3.
Connecting rod bearing

Piston ring
Piston pin snap ring
4.
5.
6.
Piston pin
Connecting rod
Piston
Disassembly
1. Connecting Rod Bearing
If the connecting rod bearings are to be reinstalled, mark
RTW36ASH001501
2. Piston Ring
1. Clamp the connecting rod in a vise.
Take care not to damage the connecting rod.
2. Use a piston ring replacer to remove the piston rings.
Piston Ring Replacer
Do not attempt to use some other tool to remove the
piston rings. Piston ring stretching will result in
reduced piston ring tension.
015RW041
3. Piston Pin Snap Ring

Use a pair of pliers to remove the piston pin snap rings.
F06MV015
4. Piston Pin
5. Connecting Rod
6. Piston
Tap the piston pin out with a hammer and a brass bar.
If the pistons and piston pins are to be reinstalled, mark
their installation positions by tagging each piston and piston
pin with the cylinder number from which it was removed.
RTW36ASH001601

Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during
inspection.
CYLINDER HEAD
Cylinder Head Lower Face Warpage
1. Use a straight edge and a feeler gauge to measure the
four sides and the two diagonals of the cylinder head lower
face.
2. The cylinder head lower surface warpage is more than the
limit, it should be replaced.
011RY00012
Cylinder Head Lower Face Warpage
mm (in)
Standard
Limit
0.05
(0.002) or less
0.20
(0.0079)
NOTE:
The cylinder head lower face cannot be reground.
011RY00013
Cylinder Head Height (H) (Reference)
mm (in)
Standard
91.95 92.05
(3.620 3.624)
011RY00014
Positive Crankcase Ventilation (PCV) Valve

1.
2.
3.
4.
Remove PCV valve assembly from cylinder head cover.

Inspect the diaphragm for broken.
Inspect the spring for broken or weaken.
If find any abnormal condition, replace the PCV valve
assembly.
Manifold Fitting Face Warpage

Use a straight edge and a feeler gauge to measure the
manifold cylinder head fitting face warpage.
Regrind the manifold cylinder head fitting surfaces if the
measured values are greater than the specified limit but less
than the maximum grinding allowance.
If the measured values exceed the maximum grinding
allowance, the cylinder head must be replaced.
Manifold Fitting Face Warpage
027RY00001
mm (in)
Standard
Limit
Maximum Grinding
Allowance
0.05
(0.002) or less
0.20
(0.008)
0.40
(0.016)
Exhaust Manifold Warpage

manifold cylinder head fitting face warpage.
If the measured values exceed the specified limit, the manifold
must be replaced.
Exhaust Manifold Warpage
mm (in)
Standard
Limit
0.05 (0.002) or less
0.20 (0.008)
027RY00002
Valve Stem and Valve Guide Clearance

Measuring Method-I
1. With the valve stem inserted in the valve guide, set the dial
indicator needle to "0".
2. Move the valve head from side to side.
Read the dial indicator.
Note the highest dial indication.
If the measured values exceed the specified limit, the valve
and the valve guide must be replaced as a set.
011RY00022
Valve Stem Clearance

Standard
mm (in)
Limit
Intake Valve
0.039 - 0.071
(0.0015 - 0.0028)
0.200
(0.008)
Exhaust Valve
0.064 - 0.096
(0.0025 - 0.0038)
0.250
(0.0098)
Measuring Method-II
1. Measure the valve stem outside diameter.
Refer to the Item "Valve Stem Outside Diameter".
2. Use a caliper calibrator or a telescoping gauge to measure
the valve guide inside diameter.
011RY00023
Valve Guide Replacement

Valve Guide Removal
Use a hammer and the valve guide replacer to drive out the
valve guide from the cylinder head lower face.
Valve Guide Replacer: 9-8523-1212-0
011LX029
Valve Guide Installation

1. Apply engine oil to the valve guide outer circumference.
2. Attach the valve guide installer to the valve guide.
3. Use a hammer to drive the valve guide into position from
the cylinder head upper face.
Valve Guide Replacer: 9-8523-1212-0
011RY00024
4. Measure the height of the valve guide upper end from the
upper face of the cylinder head.
Valve Guide Upper End Height (H) (Reference)
12.8-13.2 (0.50-0.52)
mm (in)
NOTE:
If the valve guide has been removed, both the valve
011RY000025
Valve Stem Outside Diameter

Measure the valve stem diameter at three points.
If the measured value is less than the specified limit, the valve
Valve Stem Outside Diameter
Standard
mm (in)
Limit
Intake Valve
7.946 - 7.961
(0.3128 - 0.3134)
7.880
(0.3102)
Exhaust Valve
7.921 - 7.936
(0.3119 - 0.3124)
7.850
(0.3090)
011LX027
Valve Thickness
Measure the valve thickness.
Intake and Exhaust Valve Thickness
Standard
014RY00020
4JA1T (L)
1.8 (0.07)
Inlet
4JA1TC,
4JH1TC Exhaust
1.34 (0.054)
1.36 (0.055)
mm (in)
Limit
1.5 (0.06)
1.1 (0.045)
Valve Depression
1. Install the valve (1) to the cylinder head (2).
2. Use a depth gauge or a straight edge with steel rule to
measure the valve depression from the cylinder head lower
surface.
If the measured value exceeds the specified limit, the valve
seat insert must be replaced.
Valve Depression
Standard
014RY00021
mm (in)
Limit
4JA1T(L)
0.72 (0.029)
1.28 (0.050)
4JA1TC, 4JH1TC
1.17 (0.048)
1.67 (0.068)
Valve Contact Width

1. Check the valve contact faces for roughness and
unevenness. Make smooth the valve contact surfaces.
2. Measure the valve contact width.
seat insert must be replaced.
Valve Contact Width
Standard
014RY00027
mm (in)
Limit
Intake
1.7 (0.067)
2.2 (0.087)
Exhaust
2.0 (0.079)
2.5 (0.078)
Valve Seat Insert Replacement
011LX039
Valve Seat Insert Removal

1. Arc weld the entire inside circumference (1) of the valve
seat insert (2).
2. Allow the valve seat insert to cool for a few minutes.
This will invite contraction and make removal of the valve
seat insert easier.
3. Use a screwdriver (3) to pry the valve seat insert free.
Take care not to damage the cylinder head (4).
4. Carefully remove carbon and other foreign material from
the cylinder head insert bore.
Valve Seat Insert Installation
1. Carefully place the attachment (1) (having a smaller
outside diameter than the valve seat insert) on the valve
seat insert (2).
NOTE:
The smooth side of the attachment must contact the
valve seat insert.
014RY00026
2. Use a bench press (3) to gradually apply pressure to the

attachment and press the valve seat insert into place.
NOTE:
Do not apply an excessive amount of pressure with
the bench press. Damage to the valve seat insert will
result.
Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert surface.
2. Use a valve cutter (15, 45, and 75 blades) to minimize
scratches and other rough areas. This will bring the
contact width back to the standard value.
Remove only the scratches and rough areas. Do not cut
away too much. Take care not to cut away unblemished
areas of the valve seat surface.
011LX063
Valve Seat Angle
Degree
45
NOTE:
Use an adjustable valve cutter pilot.
Do not allow the valve cutter pilot to wobble inside the
valve guide.
011LX037
3.
4.
5.
6.
7.
011LX038
Apply abrasive compound to the valve seat insert surface.

Insert the valve into the valve guide.
Turn the valve while tapping it to fit the valve seat insert.
Check that the valve contact width is correct.
Check that the valve seat insert surface is in contact with
the entire circumference of the valve.
Valve Spring Free Height

Use a vernier caliper to measure the valve spring free height.
spring must be replaced.
Spring Free Height
011LX024
4JA1T (L)
4JA1TC,
4JH1TC
mm (in)
Single spring
Standard
Limit
48.0 (1.89)
47.1 (1.85)
Valve Spring Squareness

Use a surface plate and a square to measure the valve spring
squareness.
Spring Squareness
mm (in)
Limit
014RY00025
4JA1T (L)
4JA1TC,
4JH1TC
Single spring
1.7 (0.070)
Valve Spring Tension

Use a spring tester to measure the valve spring tension.
011LX026
4JA1T (L)
4JA1TC,
4JH1TC
Single
spring
N (kg/lb)
Compressed
Height
Standard
Limit
38.9mm
(1.53in)
296.0
(30.2/66.4)
257.7
(26.3/57.9)

Rocker Arm Shaft Run-Out
015LX008
1. Place the rocker arm shaft on a V-block.

2. Use a dial indicator to measure the rocker arm shaft
central portion run-out.
If the run-out is very slight, correct the rocker arm shaft
run-out with a bench press. The rocker arm must be at cold
condition.
If the measured rocker arm shaft run-out exceeds the
specified limit, the rocker arm shaft must be replaced.
Rocker Arm Shaft Run-Out
mm (in)
Limit
0.3 (0.012)
Rocker Arm Shaft Outside Diameter

Use a micrometer to measure the rocker arm fitting portion
outside diameter.
If the measured value is less than the specified limit, the rocker
arm shaft must be replaced.
Rocker Arm Shaft Outside Diameter
015LX009
mm (in)
Standard
Limit
18.9819.00 (0.7470.748)
18.90 (0.744)
Rocker Arm Shaft and Rocker Arm Clearance

1. Use either a vernier caliper or a dial indicator to measure
the rocker arm inside diameter.
Rocker Arm Inside Diameter
mm (in)
Standard
Limit
19.01019.030
(0.7480.749)
19.100 (0.752)
014RY00024
2. Measure the rocker arm shaft outside diameter.

If the measured value exceeds the specified limit, replace
either the rocker arm or the rocker arm shaft.
Rocker Arm Shaft and Rocker Arm Clearance
Standard
Limit
0.010.05
(0.00040.0020)
0.20 (0.008)
mm (in)
3. Check that the rocker arm oil port is free of obstructions.
If necessary, use compressed air to clean the rocker arm
oil port.
014RY00024
Rocker Arm Correction

Inspect the rocker arm valve stem contact surfaces for step
wear (1) and scoring (2).
If the contact surfaces have light step wear or scoring, they
may be honed with an oil stone.
If the step wear or scoring is severe, the rocker arm must be
replaced.
014RY00023
CYLINDER BODY
Cylinder Body Upper Face Warpage
1. Remove the cylinder body dowel.
2. Remove the cylinder liner.
Refer to "Cylinder Liner Replacement".
3. Use a straight edge (1) and a feeler gauge (2) to measure
the four sides and the two diagonals of the cylinder body
upper face.
If the measured values exceeds the limit, the cylinder body
must be replaced.
Cylinder Body Upper Face Warpage
mm (in)
Standard
Limit
0.05 (0.002) or less
0.20 (0.008)
012R100001
Cylinder Body Height (H) (Reference)
mm (in)
Standard
4JA1T(L), 4JA1TC : 244.945-245.055 (9.6435-9.6478)
4JH1TC : 269.945-270.055 (10.6277-10.6320)
4. Reinstall the cylinder liner.
Refer to "Cylinder Liner Replacement".
5. Reinstall the cylinder body dowel.
012RY00009
Cylinder Liner Bore Measurement

Use a cylinder indicator to measure the cylinder bore at
measuring point (1) in the thrust (2-2) and axial (3-3) directions
of the crankshaft.
Measuring Point (1): 20 mm (0.79 in)
If the measured value exceeds the specified limit, the cylinder
liner must be replaced.
Cylinder Liner Bore
mm (in)
012RY00010
Standard
Limit
4JA1T(L), 4JA1TC
93.00 (3.6614)
93.08 (3.6646)
4JH1TC
95.40 (3.7559)
95.48 (3.7590)
NOTE:
The inside of the dry type cylinder liner is chrome
plated. It cannot be rebored or honed.
If the inside of the cylinder liner is scored or
scorched, the cylinder liner must be replaced.
Cylinder Liner Projection Inspection

1. Hold a straight edge along the top edge of the cylinder liner
to be measured.
2. Use a feeler gauge to measure each cylinder liner
projection.
Cylinder Liner Projection
mm (in)
Standard
0-0.1 (0-0.004)
012LX016
The difference in the cylinder liner projection height

between any two adjacent cylinders must not exceed 0.03
mm (0.0012 in).
Cylinder Liner Replacement

Cylinder Liner Removal
1. Insert the cylinder liner remover (1) into the cylinder body
(from the lower side of the cylinder body) until it makes firm
contact with the cylinder liner.
Cylinder Liner Remover : 5-8840-2039-0 (4JA1L/TC)
: 5-8840-2304-0 (4JH1TC)
2. Use a bench press (2) to slowly force the cylinder liner
from the cylinder body.
012RY00012
NOTE:
Take care not to damage the cylinder body upper face
during the cylinder liner removal procedure.
3. Measure the cylinder body upper face warpage.
Refer to "Cylinder Body Upper Face Warpage".
Cylinder Liner Grade Selection

Subtract the average cylinder body bore from the average
cylinder liner outside diameter to obtain the fitting interference.
Fitting Interference
mm (in)
Standard
-0.0010*-0.019 (-0.00004*-0.0007)
012RY00013
* A minus (-) value indicates that the cylinder body bore is

smaller than the liner outside diameter.
Cylinder Body Bore Measurement

1. Take measurements at measuring point (1) across
positions 1-1 and 2-2.
Measuring Point (1):
4JA1T(L), 4JA1TC : 13,48,83,118,153 mm
(0.51,1.89,3.27,4.65,6.02 in)
4JH1TC : 18,53,88,123,158 mm (0.71,2.09,3.46,4.84,6.22
in)
012RY00014
012R300001
Cylinder Liner Grade Selection and Standard

Fitting Interference
Accurately measured fitting interference and proper cylinder
liner grade selection are extremely important.
If the cylinder liner fitting interference is too small, engine
cooling efficiency will be adversely affected.
If the cylinder liner fitting interference is too large, it will be
difficult to insert the cylinder liner into the cylinder body.
A mark was stamped on the upper side of the cylinder block
during production to indicate the correct liner.
The liner grade (i.e.1.2.3.4) is indicated in metal stamp.
012RY00022
Cylinder Liner Grade

4JA1T (L), 4JA1TC
Liner
Cylinder Body
Outside
Bore Diameter
Grade
mm (in)
Liner Outside
Diameter
Liner Bore
Grade
Service Liner Bore Measurement
AX
93.035-93.050 (3.6628-3.6634)
CX
93.051-93.066 (3.6634-3.6640)
AX
93.035-93.050 (3.6628-3.6634)
CX
93.051-93.066 (3.6634-3.6640)
AX
95.035-93.050 (3.6628-3.6634)
CX
93.051-93.066 (3.6634-3.6640)
AX
93.035-93.050 (3.6628-3.6634)
CX
93.051-93.066 (3.6634-3.6640)
95.001-95.010
(3.7402-3.7405)
95.011-95.020
(3.7406-3.7409)
95.011-95.020
(3.7406-3.7409)
95.021-95.030
(3.7410-3.7413)
95.021-95.030
(3.7410-3.7413)
95.031-95.040
(3.7414-3.7417)
95.031-95.040
(3.7414-3.7417)
95.041-95.050
(3.7418-3.7421)
4JH1TC
Liner
Outside
Grade
mm (in)
Cylinder Body
Bore Diameter
Liner Outside
Diameter
Liner Bore
Grade
Service Liner Bore Measurement
97.001-97.010
(3.8189-3.8193)
97.011-97.020
(3.8193-3.8197)
AX
95.435-95.450 (3.7573-3.7579)
CX
95.451-95.466 (3.7579-3.7585)
97.011-97.020
(3.8193-3.8197)
97.021-97.030
(3.8197-3.8200)
AX
95.435-95.450 (3.7573-3.7579)
CX
95.451-95.466 (3.7579-3.7585)
97.021-97.030
(3.8197-3.8200)
97.031-97.040
(3.8200-3.8205)
AX
95.435-95.450 (3.7573-3.7579)
CX
95.451-95.466 (3.7579-3.7585)
97.031-97.040
(3.8200-3.8205)
97.041-97.050
(3.8205-3.8209)
AX
95.435-95.450 (3.7573-3.7579)
CX
95.451-95.466 (3.7579-3.7585)
Cylinder Liner Installation

1. Cylinder Liner Installation Using The Special Tool
1. Use new kerosene or diesel oil to thoroughly clean the
cylinder liners and bores.
2. Use compressed air to blow-dry the cylinder liner and
bore surfaces.
NOTE:
012RY00017
All foreign material must be carefully removed from

the cylinder liner and the cylinder bore before
installation.
3. Insert the cylinder liner (1) into the cylinder body (2)
from the top of the cylinder body.
4. Set the cylinder liner installer (3) to the top of the
cylinder liner.
Cylinder Liner Installer : 5-8840-2040-0 (4JA1L/TC)
: 5-8840-2313-0 (4JH1TC)
5. (3) is directly beneath the bench press shaft center (4).
NOTE:
Check that the cylinder liner is set perpendicular to
the bench press and that there is no wobble.
012RY00018
6. Use the bench press to apply a seating force of 4,900

N (500 kg/1,100 Ib) to the cylinder liner.
7. Apply a force of 24,500 N (2,500 kg/5,500 Ib) to fully
seat the cylinder liner.
8. After installing the cylinder liner, measure the cylinder
liner projection.
Refer to "Cylinder Liner Projection Inspection".
Piston Grade Selection

Measure the cylinder liner bore after installing the cylinder liner.
Then select the appropriate piston grade for the installed
cylinder liner.
1. Measure the cylinder liner bore.
Refer to "Cylinder Liner Bore Measurement"
Cylinder Liner Bore (Service Part) Grade
4JA1T(L)
4JA1TC
mm (in)
Grade
Bore measurement
AX
93.035-95.050
(3.6628-3.6634)
CX
93.051-95.066
(3.6634-3.6640)
AX
95.435-95.450
(3.7573-3.7579)
CX
95.451-95.466
(3.7579-3.7585)
4JH1TC
NOTE:
It is most important that the correct piston grade be
used. Failure to select the correct piston grade will
result in engine failure. Always measure the cylinder
bore and select the correct piston grade.
2. Measure the piston diameter.
Piston Measuring Point
4JA1T(L)
4JA1TC
4JH1TC
mm (in)
78 (3.07)
70 (2.76)
Piston Grade (Service Part)

015LX021
4JA1T(L)
4JA1TC
mm (in)
AX
92.949 - 92.964
(3.6549 - 3.6600)
CX
92.965 - 92.980
(3.6600 - 3.6606)
AX
95.359 - 95.374
(3.7542 - 3.7548)
CX
95.375 - 95.390
(3.7548 - 3.7555)
4JH1TC
Cylinder Liner and Piston Clearance

mm (in)
4JA1T(L)
0.041-0.071 (0.0016-0.0027)
4JA1TC
4JH1TC
0.047-0.065 (0.0019-0.0026)
NOTE:
Cylinder liner kit clearances are preset. However, the
cylinder liner installation procedure may result in
slight decreases in cylinder liner clearances. Always
measure the cylinder liner clearance after installation
to be sure that it is correct.
TAPPET AND PUSH ROD
014RY00028
Visually inspect the tappet contact surfaces for pitting,

cracking, and other abnormal conditions. The tappet must be
replaced if any of these conditions are present.
Refer to the illustration at the left.
1. Normal contact
2. Cracking
3. Pitting
4. Irregular contact Uneven contact
5. Irregular contact One-sided contact
NOTE:
The tappet surfaces are spherical. Do not attempt to
grind them with an oil stone or similar tool in an effort
to repair the tappet. If the tappet is damaged, it must
be replaced.
Tappet Outside Diameter

Measure the tappet outside diameter with a micrometer.
If the measured value is less than the specified limit, the tappet
must be replaced.
Tappet Outside Diameter
014RY00029
mm (in)
Standard
Limit
12.97 - 12.99
(0.510 - 0.511)
12.95 (0.510)
Tappet and Cylinder Body Clearance
mm (in)
Standard
Limit
0.01 - 0.046
(0.0004 - 0.0018)
0.10 (0.004)
012LX014
Push Rod Curvature

1. Lay the push rod on a surface plate.
2. Roll the push rod along the surface plate and measure the
push rod curvature with a thickness gauge.
If the measured value exceeds the specified limit, the push
rod must be replaced.
Pushrod Curvature
014RY00031
mm (in)
Limit
0.3 (0.012)
3. Visually inspect both ends of the push rod for excessive

wear and damage. The push rod must be replaced if these
conditions are discovered during inspection.
CAMSHAFT
Visually inspect the journals, the cams, the oil pump drive gear,
and the camshaft bearings for excessive wear and damage.
The camshaft and the camshaft bearings must be replaced if
these conditions are discovered during inspection.
Camshaft Journal Diameter

Use a micrometer to measure each camshaft journal diameter
in two directions (1 and 2). If the measured value is less than
the specified limit, the camshaft must be replaced.
Camshaft Journal Diameter
014RY00032
mm (in)
Standard
Limit
49.945 - 49.975
(1.9663 - 1.9675)
49.60 (1.953)
Cam Height
Measure the cam height (H) with a micrometer. If the
measured value is less than the specified limit, the camshaft
must be replaced.
Cam Height (H)
mm (in)
Standard
Limit
42.016 (1.6542)
41.65 (1.640)
014RY00033
Camshaft Run-Out
1. Mount the camshaft on V-blocks.
2. Measure the run-out with a dial indicator.
camshaft must be replaced.
Camshaft Run-Out
014LX092
mm (in)
Standard
Limit
0.02 (0.0008)
0.10 (0.004)
Camshaft and Camshaft Bearing Clearance

Use an inside dial indicator to measure the camshaft bearing
inside diameter.
Crankshaft Bearing Inside Diameter
014RY00034
mm (in)
Standard
Limit
50.00 - 50.03
(1.968 - 1.970)
50.08 (1.972)
If the clearance between the camshaft bearing inside diameter

and the journal exceeds the specified limit, the camshaft
bearing must be replaced.
Camshaft Bearing Clearance
mm (in)
Standard
Limit
0.055 (0.0022)
0.12 (0.005)
Camshaft Bearing Replacement

Camshaft Bearing Removal
1. Remove the cylinder body plug plate.
2. Use the bearing replacer to remove the camshaft bearing.
Bearing Replacer: 5-8840-2038-0
014RY00035
Camshaft Bearing Installation

1. Align the bearing oil holes with the cylinder body oil holes.
2. Use the replacer to install the camshaft bearing.
Bearing Replacer: 5-8840-2038-0
014RY00036
CRANKSHAFT AND BEARING

Inspect the surface of the crankshaft journals and crankpins for
excessive wear and damage.
Inspect the oil seal fitting surfaces for excessive wear and
damage.
Inspect the oil ports for obstructions.
NOTE:
To increase crankshaft strength, tufftriding (Nitrizing
Treatment) has been applied. Because of this, it is not
possible to regrind the crankshaft surfaces.
Therefore, under size bearing are not available.
Crankshaft Run-Out
1. Set a dial indicator to the center of the crankshaft journal.
2. Gently turn the crankshaft in the normal direction of
rotation.
Read the dial indicator as you turn the crankshaft.
crankshaft must be replaced.
015LX061
Crankshaft Run-Out
mm (in)
Standard
Limit
0.05 (0.002) or less
0.08 (0.003)
Bearing Spread
Use a vernier caliper to measure the bearing spread.
If the measured value is less than the specified limit, the
Bearing Spread
Creankshaft Bearing
015RY00007
Connecting Rod Bearing
mm (in)
Limit
4JA1T (L),
4JA1TC
4JH1TC
64.5 (2.54)
74.5 (2.93)
56.5 (2.22)
Crankshaft Journal and Crankpin Diameter

1. Use a micrometer to measure the crankshaft journal
diameter across points 1 - 1 and 2 - 2.
2. Use the micrometer to measure the crankshaft journal
diameter at the two points (3 and 4).
3. Repeat Steps 1 and 2 to measure the crankpin diameter.
If the measured values are less than the specified limit, the
crankshaft must be replaced.
015RY00008
Crankshaft Journal and Diameter
mm (in)
Standard
Limit
4JA1T (L),
4JA1TC
59.921-59.928
(2.3591-2.3594)
59.91 (2.3586)
4JH1TC
69.917-69.932
(2.7526-2.7532)
69.91(2.7524)
Crankpin Diameter
mm (in)
Standard
Limit
52.915 - 52.930
(2.0833 - 2.0839)
52.90 (2.083)
Crankshaft Journal and Crankpin Uneven Wear
mm (in)
Standard
Limit
0.05 (0.002) or less
0.08 (0.003)
Crankshaft Journal and Crankpin Diameter

If the clearance between the measured bearing inside diameter
and the crankshaft journal diameter exceeds the specified limit,
the bearing and/or the crankshaft must be replaced.
Crankshaft Journal and Bearing Clearance
015RY00009
mm (in)
Standard
Limit
0.032 - 0.077
(0.0013 - 0.0030)
0.110 (0.0043)
Connecting Rod Bearing Inside Diameter

1. Install the bearing to the connecting rod big end.
2. Tighten the bearing cap to the two step of anglar tightening
method.
015RY00011
Connecting Rod Bearing Cap Bolt Torque

Nm (kgm/Ib ft)
4JA1T (L),
78-88 (8.0/57 9.0/65)
4JA1TC
1st step ; 29.029.2 (3.00/22.03.01/22.2)
4JH1TC
2nd step ; 45-60
3. Use an inside dial indicator to measure the connecting rod
bearing inside diameter.
Crankpin and Bearing Clearance

If the clearance between the measured bearing inside diameter
and the crankpin exceeds the specified limit, the bearing
and/or the crankshaft must be replaced.
mm (in)
Standard
Limit
4JA1T (L),
4JA1TC
0.029-0.066
(0.0011-0.0026)
0.100(0.0039)
4JH1TC
0.029-0.083
(0.0011-0.033)
0.100 (0.0039)
Clearance Measurements (With Plastigage)
015RY00012

1. Clean the cylinder body, the journal bearing fitting surface,
the bearing caps, and the bearings.
2. Install the bearings to the cylinder body.
3. Carefully place the crankshaft on the bearings.
4. Rotate the crankshaft approximately 30 to seat the
bearing.
5. Place the Plastigage (arrow) over the crankshaft journal
across the full width of the bearing.
6. Install the bearing caps with the bearing.
7. Tighten the bearing caps to the specified torque.
Crankshaft Bearing Cap Bolt Torque
mm (in)
167 (17/123)
Do not allow the crankshaft to turn during bearing cap
installation and tightening.
8. Remove the bearing cap.
015RY00013
015LX129
015LX060
9. Compare the width of the Plastigage attached to either the

crankshaft or the bearing against the scale printed on the
Plastigage container.
If the measured value exceeds the limit, perform the
following additional steps.
1. Use a micrometer to measure the crankshaft outside
diameter.
2. Use an inside dial indicator to measure the bearing
inside diameter.
If the crankshaft journal and bearing clearance
exceeds the limit, the crankshaft and/or the bearing
must be replaced.
mm (in)
Standard
Limit
0.032 - 0.077
(0.0013 - 0.0030)
0.110 (0.0043)

1. Clean the crankshaft, the connecting rod, the bearing cap,
and the bearings.
2. Install the bearing to the connecting rod and the bearing
cap.
Do not allow the crankshaft to move when installing the
bearing cap.
3. Prevent the connecting rod from moving.
4. Attach the Plastigage to the crankpin.
Apply engine oil to the Plastigage to keep it from falling.
5. Install the bearing cap and tighten it to the two step of
anglar tihtening method.
Do not allow the connecting rod to move when installing
and tightening the bearing cap.
Nm (kgm/Ib ft)
4JA1T (L),
78-88 (8.0/57 9.0/65)
4JA1TC
1st step ; 29.029.2 (3.00/22.03.01/22.2)
4JH1TC
2nd step ; 45-60
6. Remove the bearing cap.
7. Compare the width of the Plastigage attached to either the
crankshaft or the bearing against the scale printed on the
Plastigage container.
If the measured value exceeds the specified limit, perform
the following additional steps.
1. Use a micrometer to measure the crankpin outside
diameter.
2. Use an inside dial indicator to measure the bearing
inside diameter.
If the crank pin and bearing clearance exceeds the
specified limit, the crankshaft and/or the bearing must
be replaced.
mm (in)
Standard
Limit
4JA1T (L),
4JA1TC
0.029-0.066
(0.0011-0.0026)
0.100 (0.0039)
4JH1TC
0.029-0.083
(0.0011-0.0033)
0.100 (0.0039)
CRANKSHAFT BEARING SELECTION

Crankshaft bearing selection is based on the measured
diameters of the crankshaft journals and the bearing inserts.
Match the crankshaft bearing housing grade marks and the
crankshaft journal grade marks in the table below to determine
the correct crankshaft bearing size.
Crankshaft Bearing Housing Grade Mark

Position
Crankshaft bearing housing grade marks 1, 2 or 3 are stamped
on the rear right hand side of the cylinder body.
015LX060
Crankshaft Journal Grade Mark Position

The crankshaft journal grade marks (1 or -, 2 or --, 3 or ---) are
stamped on each crankshaft journal web.
The crankshaft journal and bearing clearance must be the
same for each position after installation of the crankshaft and
the crankshaft bearings.
NOTE:
015RY00016
The crankshaft journal mark No. 4 is stamped on

crankshaft No. 4 journal web front side or rear side.
REFERENCE
4JA1T(L), 4JA1TC
Crankshaft
Bearing Housing
Grade
Mark
015RY00017
Diamaeter
63.99264.000
(2.51942.5197)
63.98363.992
(2.51902.5194)
RTW46ASH002501
63.97563.983
(2.51872.5190)
mm (in)
Crankshaft Journal
Grade
Mark
Diamaeter
1 or
-
59.927-59.932
(2.3593-23.595)
2 or
--
59.922-59.927
(2.3591-2.3539)
3 or
---
59.917-59.922
Yellow or 5
(2.3589-2.3591)
1 or
-
59.927-59.932
(2.3593-2.3595)
Black or 2
2 or
--
59.922-59.927
(2.3591-2.3593)
Blue or 3
3 or
---
59.917-59.922
Brown or 4
(2.3589-2.3591)
1 or
-
59.927-59.932
Green or 1
(2.3593-2.3595)
2 or
--
59.922-59.927
(2.3591-2.3593)
3 or
---
59.917-59.922
(2.3598-2.3591)
4JH1TC
Brown or 4
Black or 2
mm (in)
Crankshaft
Bearing Housing
Grade
Mark
Crankshaft
Bearing
Size Code
Diamaeter
73.99274.000
(2.91312.9134)
73.98373.992
(2.91272.9131)
73.97573.983
(2.91242.9127)
Crankshaft Journal
Crankshaft
Bearing
Size Code
Grade
Mark
Diamaeter
1 or
-
69.927-69.932
(2.7530-2.7532)
2 or
--
69.922-69.927
(2.7528-2.7530)
3 or
---
69.917-69.922
(2.7556-2.7528)
1 or
-
69.927-69.932
(2.7530-2.7532)
2 or
--
69.922-69.927
(2.7528-2.7530)
3 or
---
69.917-69.922
(2.7556-2.7528)
1 or
-
69.927-69.932
(2.7530-2.7532)
2 or
--
69.922-69.927
(2.7528-2.7530)
3 or
---
69.917-69.922
(2.7526-2.7528)
CRANKSHAFT PILOT BEARING

Check the crankshaft pilot bearing for excessive wear and
damage and replace it if necessary.
Crankshaft Pilot Bearing Replacement

Crankshaft Pilot Bearing Removal
Use the pilot bearing remover to remove the crankshaft pilot
bearing.
Pilot Bearing Remover: 5-8840-2000-0
Sliding Hammer: 5-8840-0019-0
015RY00018
Crankshaft Pilot Bearing Installation

1. Place the crankshaft pilot bearing right angle across the
crankshaft bearing installation hole.
2. Tap around the edges of the crankshaft pilot bearing outer
races with a brass hammer to drive the bearing into the
crankshaft bearing installation hole.
Pilot Bearing Installer: 5-8522-0024-0
NOTE:
015RY00010
Strike only the crankshaft pilot bearing outer race with

the hammer. Do not strike the bearing inner race.
Bearing damage and reduced bearing service life will
result.
FLYWHEEL AND RING GEAR

Flywheel
015RY00019
1. Inspect the flywheel friction surface for excessive wear and

heat cracks.
2. Measure the flywheel friction surface depth.
If the measured value is within the specified limit, the
flywheel may be reground.
flywheel must be replaced.
Flywheel Friction Surface Depth (1)
4JA1T (L),
4JA1TC
4JH1TC
mm (in)
Standard
Limit
20 (0.7874)
21 (0.8267)
18 (0.7087)
19 (0.7480)
Ring Gear
Inspect the ring gear.
If the ring gear teeth are broken or excessively worn, the ring
gear must be replaced.
Ring Gear Replacement

Ring Gear Removal
Strike around the edges of the ring gear with a hammer and
chisel to remove it.
020LX008
Ring Gear Installation

1. Heat the ring gear evenly with a gas burner to invite
thermal expansion.
Do not allow the temperature of the gas burner to exceed
200C (390F).
2. Install the ring gear when it is sufficiently heated.
The ring gear must be installed with the chamfer facing the
clutch.
020LX009
PISTON
Piston Grade Selection and Cylinder Bore
Measurement
Refer to the Section "Cylinder Body", Item "Cylinder Liner Bore
Measurement" for details on piston grade selection and
cylinder liner bore measurement.
Piston Ring Gap

1. Insert the piston ring horizontally (in the position it would
assume if it were installed to the piston) into the cylinder
liner.
015LX023
2. Push the piston ring into the cylinder bore until it reaches
the measuring point 1 or 2 where the cylinder liner bore is
the smallest.
Do not allow the piston ring to slant to one side or the
other. It must be perfectly horizontal.
Measuring Point 1 10 mm (0.4 in)
or
Measuring Point 2 120 mm (4.7 in)
015RY00020
3. Use a feeler gauge to measure the piston ring gap.
piston ring must be replaced.
Piston Ring Gap
4JA1T (L), 4JA1TC
mm (in)
Standard
1st Compression Ring

015RY00021
2nd Compression Ring

Oil Ring
0.3-0.3
(0.0118-0.0197)
0.250-0.450
(0.0098-0.0177)
Limit
1.5
(0.059)
4JH1TC
Standard
Oil Ring
0.3-0.5
(0.0118-0.0197)
0.250-0.450
(0.0098-0.0177)
Limit
1.5
(0.059)
Piston Ring and Piston Ring Groove Clearance

Use a feeler gauge to measure the clearance between the
piston ring and the piston ring groove at several points around
the piston.
If the clearance between the piston ring and the piston ring
groove exceeds the specified limit, the piston ring must be
replaced.
015LX025
Piston Ring and Piston Ring Groove Clearance

4JA1T (L), 4JA1TC
Standard
0.09-0.125
(0.0035-0.0049)
0.05-0.085
(0.0020-0.0033)
Oil Ring
0.03-0.070
(0.0012-0.0028)
mm (in)
Limit
0.15
(0.0059)
4JH1TC
Standard
0.09-0.130
(0.0035-0.0051)
0.05-0.090
(0.0020-0.0035)
Oil Ring
0.03-0.070
(0.0012-0.0028)
Limit
0.15
(0.0059)
4. Visually inspect the piston rings.
If a piston ring groove is damaged or distorted, the piston
must be replaced.
Piston Pin Diameter

Use a micrometer to measure the piston pin diameter at
several points.
If the measured value is less than the specified limit, the piston
pin must be replaced.
Piston Pin Diameter
015LX026
mm (in)
Standard
Limit
30.995-31.000
(1.2202-1.2204)
30.97
(1.2193)
Piston Pin and Piston Clearance

Use and inside dial indicator to measure the piston pin hole (in
the piston).
Piston Pin Hole
015RW048
mm (in)
4JA1T (L)
31.002-31.010 (1.2206-1.2208)
4JA1TC, 4JH1TC
31.005-31.013 (1.2207-1.2210)
Piston Pin and Piston Pin Hole Clearance
mm (in)
4JA1T (L)
0.002-0.015 (0.00008-0.0006)
4JA1TC, 4JH1TC
0.005-0.018 (0.0002-0.0007)
CYLINDER HEAD GASKET SELECTION
011LX011
Cylinder head gasket is determined by the piston head

projection from the cylinder body upper surface, in order to
improve engine performance.
Three types of gasket are provided by the difference of
thickness. Select the adequet one out of three grades of
gasket, according to the following procedure.
Before measurement, clear off carbon from the piston head
and cylinder body surface and also clean the place where a
gasket was installed.
Piston Head Projection Measuring Point

1. Use a dial indicator to measure the piston projection
amount.
2. Refer to the illustration for the piston head projection
measuring positions.
All measuring positions should be as close as possible to
the cylinder liner.
RTW36ASH001701
3. Measure the points 1, 2, 3, 4 and obtain two differences 12 and 3-4 on each cylinder.
Calculate the average value of the piston head projection
on each cylinder.
4. Obtain the maximum value in the four cylinders.
5. Determine the gasket grade required to the maximum
value described above in accordance with the following
table.
011RY00027
Cylinder Head Gasket Combination

Cylinder Head Gasket Combination
4JA1T (L), 4JA1TC
Gasket Grade Mark Piston Projection
mm (in)
mm (in)
Gasket Thickness
(Reference)
0.718-0.773
(0.0283-0.0304)
1.6
(0.0630)
0.773-0.819
(0.0304-0.0322)
1.65
(0.0650)
0.819-0.874
(0.0322-0.0344)
1.70
(0.0669)
011RY00030
4JH1TC
mm (in)
Gasket Grade Mark Piston Projection
Gasket Thickness
(Reference)
0.215-0.265
(0.0085-0.0104)
1.3
(0.5118)
0.265-0.315
(0.0104-0.0124)
1.35
(0.5315)
0.315-0.365
(0.0124-0.0144)
1.4
(0.5512)
NOTE:
Difference of the each piston projection and must be
equal or within 0.1 mm (0.004 in).
CONNECTING ROD
Connecting Rod Alignment
Use a connecting rod aligner to measure the distortion and the
parallelism between the connecting rod big end hole and the
connecting rod small end hole.
If either the measured distortion or parallelism exceed the
specified limit, the connecting rod must be replaced.
015LX034
Connecting Rod Alignment Per Length of 100 mm (3.94 in)

mm (in)
Standard
Limit
Distortion
0.08 (0.003) or Less
0.20 (0.008)
Parallelism
0.05 (0.002) or Less
0.15 (0.006)
Connecting Rod Side Face Clearance

1. Install the connecting rod to the crankpin.
2. Use a feeler gauge to measure the clearance between the
connecting rod big end side face and the crankpin side
face.
connecting rod must be replaced.
011RY00029
Connecting Rod Big End and Crankpin Side Face Clearance

mm (in)
Standard
Limit
0.23 (0.009)
0.35 (0.014)
Piston Pin and Connecting Rod Small End

Bushing Clearance
Use a caliper calibrator and a dial indicator to measure the
piston pin and connecting rod small end bushing clearance.
If the clearance between the piston pin and the connecting rod
small end bushing exceeds the specified limit, replace the
piston pin and/or the connecting rod.
015LX028
Piston Pin and Connecting Rod Small End

Bushing Clearance
mm (in)
Standard
Limit
4JA1T (L)
0.008-0.020
(0.003-0.0008)
0.050 (0.002)
4JA1TC,
4JH1TC
0.005-0.018
(0.0002-0.0007)
0.050 (0.002)
IDLER GEAR SHAFT AND IDLER GEAR

Idler Gear "A" Shaft Outside Diameter
Use a micrometer to measure the idler gear shaft outside
diameter.
If the measured value is less than the specified limit, the idler
gear shaft must be replaced.
Idler Gear "A" Shaft Outside Diameter
020RY00025
mm (in)
Standard
Limit
44.945-44.975
(1.7695-1.7707)
44.845 (1.755)
Idler Gear "A" Shaft inside Diameter

1. Use an inside dial indicator or an inside micrometer to
measure the idler gear inside diameter.
Idler Gear Inside Diameter
014LX022
mm (in)
Standard
Limit
45.0-45.03
(1.7717-1.7718)
45.10 (1.7756)
If the clearance between the idler gear shaft outside diameter

and the idler gear inside diameter exceeds the limit, the idler
gear must be replaced.
Idler Gear Shaft and Idler Gear Clearance
mm (in)
Standard
Limit
0.025-0.085
(0.0010-0.0033)
0.200 (0.0079)
TIMING GEAR CASE COVER

Replace the crankshaft front oil seal if it is excessively worn or
damaged.
Crankshaft Front Oil Seal Replacement
020R300004
Oil Seal Removal

Use a plastic hammer and a screwdriver to tap around the oil
seal to free it from the gear case cover.
Take care not to damage the oil seal lip surfaces.
020R300005
Oil Seal Installation

Use the special tool to install the front oil seal.
Front Oil Seal Installer: 5-8840-2361-0
1. With the oil seal attached to the sleeve, insert it into the
front end section of the crankshaft.
2. With the oil seal end section attached securely to the
crankshaft, tighten up the center bolt until the sleeve hits
the front end reference plane of the crankshaft securely.
3. Remove the sleeve.
4. With the seal pressed in, check the dimension of the oil
seal section.
Standard Dimension = 1.0 0.03mm
NOTE:
Install the oil seal after assembling the timing pulley
housing. The oil seal lip section is applied with oil.
Take notice of the press-in direction of the oil seal.
REASSEMBLY
INTERNAL PARTS
MINOR COMPONENT
020RY00029
Reassembly Steps
1.
2.
3.
4.
Rocker arm shaft

Rocker arm
Rocker arm shaft bracket
5.
6.
7.
Rocker arm
Rocker arm shaft spring
Reassembly
014RY00037
1. Rocker Arm Shaft

1. Position the rocker arm shaft with the large oil hole (4
) facing the front of the engine.
2. Install the rocker arm shaft together with the rocker
arm, the rocker arm shaft bracket, and the spring.
3. Rocker Arm
4. Rocker Arm Shaft Bracket
5. Rocker Arm
6. Rocker Arm Shaft Spring
CYLINDER HEAD
RTW46ALF001301
Reassembly Steps
1.
2.
3.
4.
5.
Cylinder head
Valve spring lower seat
Valve stem oil seal
Intake and exhaust valve
Valve spring
6.
7.
8.
9.
Valve spring upper seat

Split collar
Intake manifold gasket
Intake manifold
Reassembly
011RW027
1. Cylinder Head
2. Valve Spring Lower Seat
3. Valve Stem Oil Seal
1. Apply a coat of engine oil to the oil seal inner face.
2. Use an oil seal installer to install the oil seal to the
valve guide.
Oil Seal Installer: 5-8840-2033-0
4. Intake and Exhaust Valve
1. Apply a coat of engine oil to each valve stem before
installation.
2. Install the intake and exhaust valves.
3. Turn the cylinder head up to install the valve
springs.Take care not to allow the installed valves to
fall free.
5. Valve Spring
Install the valve spring with their fine pitched end (painted)
facing down.
6. Valve Spring Upper Seat
011LX055
7. Split Collar
1. Use the spring compressor to compress the valve
spring into position.
Spring Compressor: 9-8523-1423-0
2. Install the split collars to the valve stem.
3. Set the split collars by tapping around the head of the
collar with a rubber hammer.
014RY00039
8. Intake manifold gasket

9. Intake manifold
1. Install the manifold gasket with the end having the
sharp corners facing the rear of the engine.
2. Install the intake manifold to the cylinder head.
3. Tighten the manifold bolt/nuts to the specified torque.
Manifold Bolt/Nut Torque
RTW46ASH002301
Nm(kgm/lbft)
Bolt
19 (1.9/14)
Nut
24 (2.4/17)
PISTON AND CONNECTING ROD
RTW46ALF000301
Reassembly Steps
1.
2.
3.
4.
Piston
Connecting rod
Piston pin
5.
6.
7.

Piston ring
Connecting rod bearing
Reassembly
1. Piston
2. Connecting Rod
1. Clamp the connecting rod in a vise.Take care not to
damage the connecting rod.
2. Use a pair of pliers to install the piston pin snap ring to
the piston.
F06MV015
Install the piston to the connecting rod so that the piston

head front mark (1) and the connecting rod mark (2) are
facing in the same direction.
RTW36ASH001801
4. Piston Pin
1. Apply a coat of engine oil to the piston pin and the
piston pin hole.
2. Use your fingers to force the piston pin into the piston
until it makes contact with the snap ring.
RTW36ASH001901

1. Use your fingers to force the piston pin snap ring into
the piston snap ring groove.
2. Check that the connecting rod moves smoothly on the
piston pin.
015R100001
6. Piston Ring
1. Use a piston ring replacer to install the three piston
rings.
Piston Ring Replacer
Install the piston rings in the order shown in the
illustration.
1. Oil ring
2. 2nd compression ring
3. 1st compression ring
RTW36ASH002001
NOTE:
Install the compression rings with the stamped side
facing up.
Insert the expander coil into the oil ring groove so that
there is no gap on either side of the expander coil
before installing the oil ring.
2. Apply engine oil to the piston ring surfaces.
3. Check that the piston rings rotate smoothly in the
piston ring grooves
7. Connecting Rod Bearing
Carefully wipe any oil or other foreign material from the
connecting rod bearing back face and the connecting rod
bearing fitting surface.
015R100006
POSITIVE CRANKCASE VENTILATION (PCV) VALVE
RTW46AMF000101
Reassembly Steps
1.
2.
3.
4.
Positive Crankcase Ventilation

(PCV) Valve
Rubber space
Cylinder head insulator cover
Breather pipe
5.
Fixing bolt
6.
Oil filler cap
Reassembly
1. PCV Valve
Install the PCV valve and tighten the bolts to specified
torque.
PCV Valve Bolts Torque
Nm(kgm/lb in)
2 (0.2/17)
010R100014
2. Rubber Spacer
3. Cylinder Head Insulator Cover
4. Breather Hose
Apply LOCTITE 262 or equivalent to the new breather pipe.
Do not reuse the breather pipe.
5. Fixing Bolt
Fixing Bolt Torque
Nm(kgm/lb in)
19 (1.9/14)
RTW36ASH001401
6. Oil Filler Cap
MAJOR COMPONENT
014R300004
Reassembly Steps-1
1.
Cylinder body
10.
2.
Tappet
11.
3.
Crankshaft upper bearing
12.
4.
5.
Crankshaft
Crankshaft thrust bearing
Crankshaft bearing cap with
lower bearing
Camshaft
Timing gear case
Camshaft thrust plate
13.
14.
Camshaft timing gear

Piston and connecting rod with
upper bearing
Connecting rod bearing cap with
lower bearing
Piston cooling oil pipe
Oil pump with oil pipe
15.
Crankshaft rear oil seal
16.
17.
18.
Crank case
Cylinder body rear plate
Flywheel
6.
7.
8.
9.
RTW46ALF000501
Reassembly Steps-2
19.
20.
21.
22.
Crankshaft timing gear

Idler gear shaft
Idler gear "A"
Idler gear "B" and shaft
23.
24.
25.
26.
Injection pump
Water pump
Timing gear case cover
Crankshaft damper pulley
011R300002
Reassembly Steps-3
27.
Cylinder head gasket
31.
28.
29.
Cylinder head
Push rod
Rocker arm shaft and rocker
arm
32.
33.
Thermostat housing with thermo

switch
Water by-pass hose
Injection nozzle and bracket
34.
Cylinder head cover with gasket
30.
Reassembly
1. Cylinder Body
Use compressed air to thoroughly clean the inside and
outside surfaces of the cylinder body, the oil holes, and the
water jackets.
015R100003
2. Tappet
1. Apply a coat of engine oil to the tappet and the
cylinder body tappet insert holes.
2. Locate the position mark applied at disassembly (if
the tappet is to be reused).
NOTE:
The tappet must be installed before the camshaft
installation.
014LX088
3. Crankshaft Upper Bearing

The crankshaft upper bearings have an oil hole and an oil
groove. The lower bearings do not.
1. Carefully wipe any foreign material from the upper
bearing.
NOTE:
Do not apply engine oil to the bearing back faces and
the cylinder body bearing fitting surfaces.
015LX125
2. Locate the position mark applied at disassembly if the

removed upper bearings are to be reused.
4. Crankshaft
Apply an ample coat of engine oil to the crankshaft journals
and the crankshaft bearing surfaces before installing the
crankshaft.
015R100004

5. Crankshaft Thrust Bearing
Apply an ample coat of engine oil to the thrust bearings
before installation.
Install the thrust bearings to the crankshaft center journal.
The thrust bearing oil grooves must be facing the sliding
faces.
015LX115
6. Crankshaft Bearing Cap With Lower Bearing

Before the crankshaft bearing installation, select the
appropriate bearings in accordance with the description in
CRANK BEARING SELECTION of INSPECTION AND
REPAIR.
1. Apply the recommended liquid gasket or its equivalent
to the No. 5 crankshaft bearing cap cylinder body fitting
surfaces at the points shown in the illustration.
NOTE:
015LX127
Be sure that the bearing cap fitting surface is

completely free of oil before applying the liquid
gasket. Three bond 1207B Do not allow the liquid
gasket to obstruct the cylinder thread holes and
bearings.
ThreeBond 1207B is a fast-drying liquid gasket.
Tighten the bearing caps immediately after applying
the gasket.
2. Install the bearing caps with the bearing cap head
arrow mark facing the front of the engine.The bearing
cap numbers must be facing up.
3. Apply engine oil to the crankshaft bearing cap bolts.
015LX128
4. Tighten the crankshaft bearing cap bolts to the

specified torque a little at time in the sequence shown
in the illustration.
Crankshaft Bearing Cap Torque
Nm(kgm/lbft)
167 (17/123)
5. Check to see the crankshaft turns smoothly by rotating

it manually.
015LX129

7. Camshaft
1. Apply a coat of engine oil to the camshaft and the
camshaft bearings.
2. Install the camshaft to the cylinder body.
Take care not to damage the camshaft bearings.
014RY00019
8. Timing Gear Case

Tighten the timing gear case with timing gear case gasket
Timing Gear Case Bolt Torque
Nm(kgm/lbft)
19 (1.9/14)
020R300003
9. Camshaft Thrust Plate

Install the thrust plate to the cylinder body and tighten the
thrust plate bolts to the specified torque.
Thrust Plate Bolt Torque
Nm(kgm/lbft)
19 (1.9/14)
020RY00032
10. Camshaft Timing Gear

1. Install the camshaft timing gear to the camshaft. The
timing gear mark must be facing outward.
2. Tighten the timing gear to the specified torque.
Timing Gear Bolt Torque
110 (11.2/82)
RTW36ASH000901
Nm(kgm/lbft)

11. Piston and Connecting Rod with Upper Bearing
12. Connecting Rod Bearing Cap with Lower Bearing
1. Apply a coat of engine oil to the circumference of each
piston ring and piston.
2. Position the piston ring gaps as shown in the
illustration.
1. Oil ring
RTW36ASH002001
3. Apply a coat of molybdenum disulfide grease to the two

piston skirts.
This will facilitate smooth break-in when the engine is
first started after reassembly.
4. Apply a coat of engine oil to the upper bearing
surfaces.
5. Apply a coat of engine oil to the cylinder wall.
015R100006
6. Position the piston head front mark so that it is facing

the front of the engine.
7. Use the piston ring compressor to compress the piston
rings.
Piston Ring Compressor: 5-8840-9018-0
8. Use a hammer grip to push the piston in until the
connecting rod makes contact with the crankpin.
At the same time, rotate the crankshaft until the
crankpin is at BDC.
015LX096
9. Align the bearing cap cylinder number marks and the

connecting rod cylinder number marks.
The cylinder number marks must be turned toward the
exhaust manifold.
015R100007

10. Apply a coat of engine oil to the threads and setting
faces of each connecting rod cap bolt.
11. Tighten the connecting rod caps to the two step of
anglar tigthen method.
Nm (kgm/Ib ft)
4JA1T (L),
78-88 (8.0/57 9.0/65)
4JA1TC
1st step ; 29.029.2 (3.00/22.03.01/22.2)
4JH1TC
2nd step ; 45-60
015LX130
13. Piston Cooling Oil Jet

1. Install the piston cooling oil jet to the cylinder body.
2. Tighten the oil jet bolts and relief valve to the specified
torque.
Oil Jet Bolt Torque
Nm(kgm/lbft)
M8 1.25
19 (1.9/14)
M6 1.00
8 (0.8/6)
052LX010
Relief Valve Torque
Nm(kgm/lbft)
29 (3.0/22)
NOTE:
Check that there is no interference between the piston
and the oiling jet by slowly rotating the crankshaft.
14. Oil Pump with Oil Pipe
Install the oil pump with the oil pipe and tighten the bolts to
Oil Pump Bolt Torque
Nm(kgm/lbft)
19 (19/14)
NOTE:
051R100004
Take care not to damage the O-rings when tightening

the oil pipe bolts.
15. Crankshaft Rear Oil Seal
Use a oil seal install to install the crankshaft rear oil seal.
Oil Seal Installer : 5-8840-2359-0
015LX112

16. Crank Case
1. Apply the recommended liquid gasket (Three bond
1207B) or its equivalent to arch gasket fitting surface
as shown in the illustration.
2. Install the crankcase front gasket (1) to the timing gear
case arches.
The gasket projection (2) must be facing forward.
NOTE:
ThreeBond 1207B is a fast-drying liquid gasket.
013RW012
Install the arch packing to the crankcase immediately

aftter applying the gasket.
3. Install the rear arch gasket (2) to the No. 5 bearing
cap. Use your fingers to push the arch gasket into the
bearing cap groove.Take care not to scratch the arch
gasket outer surface.
Also apply the recommended liquid gasket (1207C) or
its equivalent to arch gasket fitting area as indicated in
the illustration.
013RW011

to groove of the crankcase fitting surface as shown in
the illustration.
NOTE:
Be sure that the crank case fitting surface is
completely free of oil and dust before applying the
liquid gasket.
013LV003
5. Install the crank case to the cylinder body.

6. Tighten the crank case bolts to the specified torque a
little at a time in the sequence shown in the illustration.
Crank Case Bolt Torque
Nm(kgm/lbft)
19 (1.9/14)
013R100001

17. Cylinder Body Rear Plate
1. Align the rear plate with the cylinder body knock pins.
2. Tighten the rear plate to the specified torque.
Rear Plate Torque
Nm(kgm/lbft)
82 (8.4/61)
020R100001
18. Flywheel
1. Apply a coat of engine oil to the threads of the flywheel
bolts.
2. Align the flywheel with the crankshaft dowel pin.
3. Tighten the flywheel bolts in the numerical order shown
Gear stoper: 5-8840-0214-0
Flywheel Bolt Torque
015LX113
Nm(kgm/lbft)
118 (12/87)
19. Crankshaft Timing Gear

Use the crankshaft timing gear installer (1) to install the
crankshaft timing gear (2).
The crankshaft timing gear setting mark must be facing
outward.
Crankshaft Timing Gear Installer: 9-8522-0020-0
020RY00034
20. Idler Gear Shaft

21. Idler Gear "A"
1. Turn the crankshaft clockwise to set the DTC of the
No.1 piston.
2. Apply engine oil to the idler gear and the idler gear
shaft.
The idler gear shaft oil hole (A) must be facing up.
3. Position the idler gear setting marks so that they are
facing the front of the engine.
020RY00035

4. Align the idler gear setting mark with the crankshaft
timing gear (1) setting mark.
5. Align the idler gear setting mark with the camshaft
timing gear (2) setting mark.
6. Install the thrust collar and bolts to the cylinder body
through the shaft.
The thrust collar oil hole must be facing up, and the
thrust collar chamfered must be outward.
7. Tighten the idler gear bolt to the specified torque.
020RY00036
Idler Gear "A" Bolt Torque
Nm(kgm/lbft)
30 (3.1/22)
22. Idler Gear "B" and Shaft

1. Apply engine oil to the idler gear and the idler gear shaft.
2. Align the idler gear "B" (3) setting mark with the idler
gear "A" (4) setting mark.
3. Tighten the idler gear bolt to the specified torque.
4. Be sure to remove the lock bolt (5) from idle gear B.
Idler Gear "B" Bolt Torque
Nm(kgm/lbft)
76 (7.7/56)
020R300006
5. If the idle gear "B" is disassembled, reassemble in the

following procedure.
1) Drive pins into the main gear, the front gear, and the
rear gear.
020L200019
2) Install the main gear bearing from the front side of

the main gear (the side with the groove).
3) Place the main gear in a vise with copper plate so
that the rear side of the main gear facing up.
020L200007

4) Set the spring as shown in the illustration.
RTW31BSH000101
5) Position the rear gear so that the pin is aligned with

the receiving end of the spring.
RTW31BSH000201
6) Install the snap ring to the main gear groove.
RTW31BSH000301
7) Install suitable bolts, nuts and washers to special tool

as shown in the illustration to rotate the scissors
gear.
End yoke holder: 5-8840-2447-0
RTW31BSH000501
RTW31BSH000401
8) Insert the bolts of the special tool into the rear gear
setting hole. Rotate the rear gear to mesh the teeth
of main gear and rear gear.
9) Insert a lock bolt (M6 1 L=30) into scissors gear
fixing hole to prevent the scissors gear from turning.
10) Place the main gear in a vise with copper plate so
that the front side of the main gear facing up.
11) Repeat steps 4 to 8 to install the front gear.
12) Lock the front gear, the main gear, and the rear gear
with lock bolt (inserted at Step 8).

23. Injection Pump
1. Install the O-ring (1) to the injection pump flange (2).
2. Attach the noise insulator rubber to the cylinder body .
3. Install the injection pump to the timing gear case.Align
the idler gear "B" (3) mark with the injection pump timing
gear (4) mark.
020RY00039
4JA1TC/4JH1TC:
4. Tighten the injection pump bolts (5) to the specified
torque.
Injection Pump Bolt Torque
Nm(kgm/lbft)
19 (1.9/14)
5. Install the injection pump bracket (6) and the bracket

bolts (7) and (8) to the cylinder body.
Temporarily tighten the bracket bolts.
6. Tighten the bracket bolts (7) to the specified torque.
7. Tighten the bracket bolt (8) to the specified torque.
NOTE:
Tighten the bracket bolt (7) first.
Injection Pump Bracket Bolt Torque

19 (1.9/14)
RTW36AMH000101
Nm(kgm/lbft)

4JA1T(L):
4. Tighten the injection pump bolts to the specified torque.
5. Install the injection pump bracket (4) and the bracket
bolts (5) and (6) to the cylinder body. Temporarily tighten
the bracket bolts.
Injection pump Bracket Bolt Torque (6)
RTW46ASH002201
Nm(kgm/lbft)
19 (1.9/14)
Injection pump Bracket Bolt Torque (5)
Nm(kgm/lbft)
40 (4.1/30)
24. Water Pump

to the water pump at the position shown in the
illustration.
Do not apply an excessive amount of liquid gasket.
2. Tighten the water pump bolts to the specified torque.
Water Pump Bolt Torque
Nm(kgm/lbft)
20 (2.0/14)
030RY00007
25.Timing Gear Case Cover

1. Align the gear case with the timing gear case knock pin
and then install the timing gear case cover.
2. Tighten the gear case cover bolts to the specified
torque.
Gear Case Cover Bolt Torque
Nm(kgm/lbft)
M8
19 (1.9/14)
M12
76 (7.7/56)
020R300004
26. Crankshaft Damper Pulley

Tighten the crankshaft damper pulley bolt to the specified
torque.
Note:
Hold the flywheel ring gear stationary to prevent the
crankshaft from turning when tightening the damper
pulley bolt.
Crankshaft Damper Pulley Bolt Torque
014R100014
Nm(kgm/lbft)
206 (21/152)
Take care not to damage the crankshaft damper pulley
boss.

27. Cylinder Head Gasket
The cylinder head gasket "TOP" mark must be facing up.
NOTE:
Before the gasket installation, measure the piston
head projection and select the appropriate head
gasket.
Refer to "INSPECTION AND REPAIR", "Cylinder Head
Gasket Selection".
28. Cylinder Head
1. Align the cylinder body dowels and the cylinder head
dowel holes.
Carefully place the cylinder head on the cylinder head
gasket.
2. Apply a coat of engine oil to the cylinder head bolt
threads and setting faces.
3. Tighten the cylinder head bolts in three steps of anglar
tightening methed.
Follow the numerical sequence shown in the
illustration.
Cylinder Head Bolt Torque
011LX073
Nm(kgm/lbft)
1st step
49 (5.0/36)
2nd step
60 - 75
3rd step
60 - 75
30. Rocker Arm Shaft and Rocker Arm

Tighten the rocker arm shaft bracket bolts in the numerical
order shown in the illustration.
Rocker Arm Shaft Braket Bolt Torque
Nm(kgm/lbft)
54 (5.5/40)
014LX083
31. Thermostat Housing

1. Install the thermostat housing.
2. Tighten the thermostat housing bolts to the specified
torque.
Thermostat Housing Bolt Torque
19 (1.9/14)
031R300002
Nm(kgm/lbft)

33. Injection Nozzle Holder
1. Install the injection nozzle gasket and the O-ring to the
injection nozzle holder.
Be sure that the O-ring fits snugly in the injection
nozzle groove.
2. Install the nozzle holder toghther with the nozzle holder
bracket to the cylinder head.
RTW46ASH001201
3. Tighten the nozzle holder bracket bolt to the specified

torque.
Injection Nozzle Holder Bracket Bolt
Torque
Nm(kgm/lbft)
37 (3.8/28)
Note on Valve Clearance Adjustment

Valve clearances must be adjusted before the cylinder
head cover is reinstalled.Refer to "Valve Clearance
Adjustment" in the "Servicing" Section of this manual.
Valve Clearance (At Cold)
mm(in)
0.4 (0.0157)
014RY00015
34. Cylinder Head Cover

1. Apply engine oil to the rocker arm and the valve spring.
2. Install the cylinder head cover gasket to the head
cover. Check to see that the head cover gasket has no
loose areas.
3. Tighten the cylinder head cover nuts in the numerical
order shown in the illustration.
Cylinder Head Cover Bolt Torque
RTW46ASH001101
Nm(kgm/lbft)
13 (1.3/9.4)
4. Connect the positive crankcase ventilation (PCV) hose
to the cylinder head cover.
INSTALLATION
EXTERNAL PARTS
RTW36AMF000701
Installation Steps
1.
2.
3.
4.
5.
6.
Exhaust Manifold
Oil Cooler with Oil Filter
Generator Bracket
Water Inlet Pipe
Generator and Adjusting Plate
Vacuum Pump Oil Return Hose
18.
19.
20.
7.
Compressor Bracket
22.
8.
Turbocharger
23.
21.
9.
10.
11.
Catalytic Converter
Heat Protector
Cooling Fan Pulley
24.
25.
26-1.
12.
Oil Cooler Water Pipe
26-2.
13.
Fuel Leak Off Pipe
27.
14.
15.
16.
17.
Oil Pressure Warning Switch

Starter Motor
Injection Pump
Injection Pump Cover
28.
Engine Mounting Bracket and

Foot
Intake Manifold
Power Steering Oil Pump
Bracket
Fuel Injection Pipe with Clip
Fuel Filter Bracket (Except
EURO III)
Fuel Filter Assembly (Except
EURO III)
Oil Level Gauge
EGR Valve
EGR Pipe
EGR Cooler (EURO III model
only)
Intake Pipe and Throttle Body
Clutch Assembly or Flex Plate
Installation
1. Exhaust Manifold
1) Install the exhaust manifold to the cylinder head with
the manifold gasket.
2) Tighten the exhaust manifold bolts and nuts to the
specified torque a little at a time.
Exhaust Manifold Bolt and Nuts
Torque
Nm(kgm/Ib ft)
027R100003
27 (2.7/20)
3) Install the exhaust manifold bracket to the manifold
and the cylinder body.
Manifold Bracket Bolt Torque
Nm(kgm/Ib ft)
19 (1.9/14)
027R100004
2. Oil Cooler with Oil Filter

1) Install the O-ring to the oil filter body flange groove.
2) Install the oil filter body to cylinder block and tighten to
Oil Filter Body Bolt and Nut
Torque
Nm(kgm/Ib ft)
BOLT 19 (1.9/14)
NUT 24 (2.4/17)
RTW46ASH001301
3. Generator Bracket
Install the generator bracket to the cylinder body and
tighten the bracket bolts to the specified torque.
Bracket Bolt Torque
Nm(kgm/Ib ft)
40 (4.1/30)
066RY00001

4. Water Inlet Pipe
1) Tighten the water inlet pipe bolts to the specified
torque.
Suction Pipe Bolt Torque
Nm(kgm/Ib ft)
19 (1.9/14)
032R300001
5. Generator and Adjusting Plate

1) Install the generator to the bracket (1).
2) Temporarily tighten the generator bolt (2) and
adjusting plate bolts (3).
The bolts will be finally tightened after installation of
the cooling fan drive belt.
066RY00002
3) Connect the vacuum pump rubber hose (4) to the

vacuum pump (5), and the oil pan (6).
6. Vacuum Pump Oil Return Hose
Connect the vacuum oil pipe (7) to the vacuum pump, and
the cylinder body
052R300001
7. Compressor Bracket
1) Install the compressor bracket to the cylinder head.
2) Tighten the bracket bolts to the specified torque.
Bracket Bolt Torque
Nm(kgm/Ib ft)
042RY00003
M8b1.25
19 (1.9/14)
M10b1.25
40 (4.1/30)

8. Turbocharger
1) Install the turbocharger and the gasket.
2) Temporarily tighten the turbocharger nuts at this time.
They will be fully tightened after the installation of the
turbocharger oil pipe.
Always install new nuts and new gasket.
027R100002
3) Install the oil return pipe with gasket to the

turbocharger.
4) Tighten the turbocharger oil return pipe to the
specified torque.
Bracket Bolt Torque
Nm(kgm/Ib ft)
8 (0.8/6)
036R100001
5) Before installing the oil feed pipe, supply 10 - 20 cc of

clean engine oil to the turbocharger center housing
through the oil feed opening.
6) Turn the rotating assembly with your hand to
thoroughly lubricate the internal parts.
7) Tighten the oil feed pipe to the specified torque.
Turbocharger Oil Feed Pipe Joint
Bolt Torque
Nm(kgm/Ib ft)
RTW46ASH001501
M10b1.5
22 (2.25/16)
M14b1.5
54 (5.5/40)
8) Tighten the turbocharger nut to the specified torque.

Turbocharger Nut Torque
Nm(kgm/Ib ft)
27 (2.7/20)
027R100005

9) Install the water feed adapter (1) with the gaskets to
turbocharger and tighten to the specified torque.
Adapter Torque
Nm(kgm/Ib ft)
39 (4.0/29)
10) Install the water feed pipe with the gaskets and tighten
Water Return Pipe Torque
Nm(kgm/Ib ft)
39 (4.0/29)
11) Install the water return pipe with the gaskets and
tighten to the specified torque.
Water Return Torque
Nm(kgm/Ib ft)
39 (4.0/29)
12) Clamp the water feed pipe to the oil return pipe of the
turbocharger.
Fixing Bolt (3) Torque
Nm(kgm/Ib ft)
8 (0.8/6)
RTW46ASH001601
13) Install the hoses for the water feed and return.
Install the catalytic converter with gasket and tighten the
nut to the specified torque.
Catalytic converter Nut Torque
Nm(kgm/Ib ft)
27 (2.7/20)
Do not install the catalytic converter, if drop down it.
027R100007
10. Heat Protector

Install the heat protector and tighten the bolt to the
specified torque.
Heat Protector Bolt Torque
Nm(kgm/Ib ft)
9 (0.9/6.5 Ib in)
11. Cooling Fan Pulley
1) Install the cooling fan pulley to the water pump.
2) Tighten the cooling fan pulley nuts to the specified
torque.
Pulley Nut Torque
Nm(kgm/Ib ft)
8 (0.8/6)
033R300002
12. Oil Cooler Water Pipe

13. Fuel Leak Off Pipe
14. Oil Pressure Warning Switch

15. Starter Motor
Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque
Nm(kgm/Ib ft)
85 (8.7/63)
16. Injection Pump
17. Injection Pump Cover (4JA1TC/4JH1TC only)
18. Engine Foot
Install the engine foot to the cylinder body and tighten the
bracket bolts to the specified torque.
Engine Foot Bolt Torque
Nm(kgm/Ib ft)
4JA1L, 4JH1TC
Right Side
Left Side
M10b1.25
40 (4.1/30)
M10b1.25
40 (4.1/30)
M14b1.50
127 (13/93)
022R300003
4JA1TC
RTW46ASH002601
19. Intake Manifold

1) Install the manifold gasket to the intake manifold.
2) Connect the intake rubber hose to the intake duct.
3) Tighten the intake manifold bolts and the flange nuts
Intake Manifold Bolt Torque
Nm(kgm/Ib ft)
19 (1.9/14)
Intake Manifold Flange Nut Torque
RTW36ASH001001
Nm(kgm/Ib ft)
24 (2.4/18)
4) Connect the PCV hose to the cylinder head cover.
5) Install the fan drive belt and adjust the belt tension
referring SERVICING of this section

Oil Pump Braket Nut and Bolt Torque
Nm(kgm/Ib ft)
M10b1.25
37 (3.8/28)
2
3
M8b1.25
18 (1.8/13) (Bolt ID:8)
431RY00013
040R300005

1) Temporarily tighten the injection pipe sleeve nut.
2) Set the clip in the illustrated position.
Note:
Make absolutely sure that the clip is correctly
positioned.
An improperly positioned clip will result in injection
pipe breakage and fuel pulsing noise.
3) Tighten the injection pipe sleeve nut to the specified
torque.
Torque
Injection Pump Side (4JA1TC/4JH1TC) Nm(kgm/Ib ft)
40 (4.1/30)
Injection Pipe Sleeve Nuts
Nm(kgm/Ib ft)
29 (3.0/22)
Injection Pipe Clip Nuts
Nm(kgm/Ib ft)
8 (0.8/6)

Install the fuel filter bracket and tighten fixing bolts to the
specified torque.
Fuel Filter Bracket Bolt Torque
Nm(kgm/Ib ft)
21 (2.1/15)
Install the fuel filter assembly and tighten fixing bolts to the
specified torque.
Fuel Filter Assembly Bolt Torque
Nm(kgm/Ib ft)
21 (2.1/15)
24. Oil Level Gauge
Install the oil level gauge and tighten fixing bolts to the
specified torque.
Oil Level Gauge Bolt Torque
Nm(kgm/Ib ft)
M8
19 (1.9/14)
M6
8 (0.8/6)

25. EGR Valve
Install the EGR valve assembly to the intake minifold with
the two gasket.
Tighten the four nuts to the specified torque.
Nut Tolque
Nm(kgm/Ib ft)
31 (3.1/23)
Connector the vacuum hose.
26-1. EGR Pipe
Install the EGR valve adapter with the gasket to the EGR
valve assembly and install the EGR pipe with the gasket.
Tighten fixing bolts and nuts to the specified torque.
EGR Valve Adapter Bolts
Nm(kgm/Ib ft)
24 (2.4/17)
EGR Pipe Bolts and Nuts
Nm(kgm/Ib ft)
27 (2.7/20)
025R100008
RTW36ASH000301
26-2. EGR Cooler (EURO III model only)
RTW48ASH001801
27. Intake Pipe and Throttle Body (4JA1TC/4JH1TC only)

Install the throttle body with the gasket to the intake
manifold and install the intake duct with the gasket.
Tighten the two bolts and the two nuts to the specified
torque.
Throttle Body and Intake Duct
Nm(kgm/Ib ft)
Bolt
19 (1.9/14)
Nut
24 (2.4/17)
RTW36ASH000201
LUBRICATION SYSTEM
LUBRICATING OIL FLOW
1.
2.
3.
4.
5.
6.
Oil Pump Relief Valve Operating Pressure: 6.2 - 7.8kg/cm 2 (608 - 764Kpa)
Regulating Valve Operating Pressure: 5.7 - 6.3kg/cm 2 (558.6 - 617.4Kpa)
Oil Cooler Relief Valve Opening Pressure: 2.8 - 3.4kg/cm 2 (270 - 330Kpa)
Oil Filter Relief Valve Opening Pressure: 0.8 - 1.2kg/cm 2 (78.4 - 117.6Kpa)
Oil Pressure Switch Operating Pressure: 0.3 - 0.5kg/cm 2 (29.4 - 49.0Kpa)
Regulating Valve: 1.8 - 2.2kg/cm 2 (176 - 216Kpa)
The 4J series engine has a full flow type lubricating system.

Lubricating oil is pumped from the oil pump to the cylinder body oil gallery through the oil cooler and the oil filter. It is
then delivered to the vital parts of the engine from the cylinder body oil gallery.
Oiling jets installed on the cylinder body spray engine oil to the piston backside faces to achieve maximum piston
cooling effect.
OIL PUMP AND OIL FILTER
RTW46ALF001501
The 4J series engine is equipped with a gear type oil pump.

The oil filter and the water cooled oil cooler integrated a single unit to increase the cooling effect.
OIL PUMP
DISASSEMBLY
051R100005
Disassembly Steps
1.
Oil pipe
2.
Strainer
3.
Pump cover
4.
Driven gear with bushing
Disassembly procedure is shown in the illustration above numerical order.
5.
6.
7.
8.
Driven gear
Relief valve assembly
Pinion gear
Oil pump body

inspection.
Gear Teeth and Body Inner Wall Clearance

gear teeth and the body inner wall.
If the clearance between the gear teeth and the body inner
wall exceeds the specified limit, either the gear or the body
must be replaced.
Gear Teeth and Body Inner Wall Clearance
mm (in)
051RY00001
Standard
Limit
0.14 (0.0055)
0.20 (0.0079)
Gear and Body Clearance

body and the gear.
If the clearance between the gear and the body exceeds
the specified limit, the body must be replaced.
Gear and Body Clearance
mm (in)
Standard
Limit
0.06 (0.024)
0.15 (0.0059)
RTW46ASH002701
Drive Shaft and Oil Pump Body Clearance

Use a micrometer to measure the drive shaft outside
diameter.
Use an inside dial indicator to measure the pump body
inside diameter.
If the clearance between the drive shaft and the oil pump
body exceeds the specified limit, the oil pump assembly
must be replaced.
Drive Shaft and Oil Pump Body Clearance
mm (in)
051RY00003
Standard
Limit
0.04 (0.0016)
0.20 (0.0079)
REASSEMBLY
051R100006
Reassembly Steps
1.
Oil pump body
2.
Drive gear
3.
Driven gear
4.
Pump cover
Reassembly procedure is shown in the illustration above numerical order.
Pump cover fixing bolts torque: 16 Nm (1.6 kgm/12 lb ft)
5.
6.
7.
8.
Pinion gear
Strainer
Relief valve assembly
Oil pipe
OIL FILTER AND OIL COOLER

DISASSEMBLY
050R300004
Disassembly Steps
1.
Oil filter cartridge
5.
2.
Bolt
6.
3.
Gasket
7.
4.
Oil cooler
Disassembly procedure is shown in the illustration above numerical order.
Body
Oil cooler relief valve
Regulating valve

inspection.
Oil Cooler
Water Leakage at Water Passage
1. Plug one side of the oil cooler water passage.
2. Submerge the oil cooler in water.
2
3. Apply compressed air (200kPa (2kg/cm / 28psi)) to
the other side of the oil cooler water passage.
If air bubbles rise to the surface, there is water leakage.
Should be replaced oil cooler assembly.
050RY00002
REASSEMBLY
050R300003
Reassembly Steps
1.
Body
5.
2.
Regulating valve
6.
3.
Oil cooler relief valve
7.
4.
Oil cooler
Reassembly procedure is shown in the illustration above numerical order.
Gasket
Bolt
Oil filter cartridge

1. Body
2. Oil Filter Safety Valve
3. Oil Cooler Safety Valve
Tighten the oil filter A and oil cooler B relief valve to the
specified torque.
Regulating Valve
Nm(kgm/lb ft)
A
64 (6.5/48)
RTW46ASH001701
4. Oil Cooler
5. Gasket
6. Bolt
Tighten bolt with gasket and oil cooler to the specified
torque.
Bolt Torque
Nm(kgm/lb ft)
40 (4.1/30)
050R300006
7. Oil Filter Cartridge

1) Apply engine oil to the O-ring.
2) Tighten the oil filter cartridge to the specified torque.
Filter wrench: 5-8840-0201-0
Oil Filter Cartride Torque
Nm(kgm/lb ft)
18 (1.8/13)
050RY00004
INTER COOLER
RTW46ALF001001
Removal Steps
1. Radiator grille
4. Inter cooler
Installation Steps
4. Inter cooler
1. Radiator grille
Removal
1. Radiator Grille
Refer to removal procedure in Sheet Metal section.
RTW36ASH000601

Remove the nine clips and four screws.
Disconnect the fog light harness connectors.
RTW36ASH000501
3. Front Bumper Impact Support Assembly

Remove the nut and two bolts.
RTW46ASH002101
4. Inter Cooler
Remove the nut and two bolts.
Disconnect the air hose.
Installation
4. Inter Cooler
Tighten the nut and two bolts.
3. Front Bumper Impact Support Assembly
Tighten the nut and two bolts.
Install the nine clips and four screws.
Connect the fog light harness connectors.
1. Radiator grille
Refer to installation procedure in Sheet Metal section.
SPECIAL TOOLS
Illustration
Tool Number
Tool Name
5-8840-0201-0
Filter Wrench
5-8840-0253-0
Filter Wrench
5-8840-2675-0
Compression Gauge
5-8531-7001-0
Adapter; Compression Gauge
5-8840-2723-0
Nozzle Holder Remover
5-8840-0019-0
Sliding Hammer
5-8521-0002-0
Universal Puller
5-8840-2360-0
Oil Seal Remover
9-8523-1423-0
Spring Compressor
9-8523-1212-0
Valve Guide Replacer
Illustration
Tool Number
5-8840-2040-0 (4JA1L/TC)
5-8840-2313-0 (4JH1TC)
Tool Name
Cylinder Liner Installer
5-8840-2038-0
Bearing Replacer; Camshaft
5-8840-2000-0
Pilot Bearing Remover
5-8522-0024-0
Pilot Bearing Installer
5-8840-2033-0
Oil Seal Installer
5-8840-9018-0
Piston Ring Compressor
5-8840-2359-0
Oil Seal Installer
9-8522-0020-0
Crankshaft Timing Gear Installer
5-8840-0266-0
Angle Gauge
5-8840-0214-0
Gear Stopper
5-8840-2039-0 (4JA1L/TC)
5-8840-2304-0 (4JH1TC)
Cylinder Liner Remover
Illustration
Tool Number
5-8840-2361-0
Tool Name
Front Oil Seal Installation
MEMO
ENGINE COOLING 6B 1
SECTION 6B
ENGINE COOLING
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6B -
General Description .................................................................................................. 6B -
Coolant Flow .............................................................................................................. 6B -
Water Pump................................................................................................................ 6B -
Thermostat ................................................................................................................. 6B -
Radiator ...................................................................................................................... 6B -
Diagnosis........................................................................................................................ 6B -
Draining and Refilling Cooling System........................................................................ 6B -
Water Pump.................................................................................................................... 6B - 10
Removal and Installation .......................................................................................... 6B - 10
Removal...................................................................................................................... 6B - 10
Inspection and Repair ............................................................................................... 6B - 11
Installation.................................................................................................................. 6B - 11
Thermostat ..................................................................................................................... 6B - 13
Removal...................................................................................................................... 6B - 13
Installation.................................................................................................................. 6B - 14
Radiator .......................................................................................................................... 6B - 15
Radiator and Associated Parts................................................................................. 6B - 15
Removal...................................................................................................................... 6B - 16
Installation.................................................................................................................. 6B - 18
6B 2 ENGINE COOLING
PAGE
Engine coolant change ............................................................................................. 6B - 19
Fan Clutch with Cooling Fan ........................................................................................ 6B - 20
ENGINE COOLING 6B 3

Description
Item
M/T
Engine coolant forced circulation
Cooling system
Centrifugal impeller type
Water pump type

Pump to crankshaft speed ratio
Delivery volume
A/T
1.2
(To 1)
lit (US/UK gal)/min
100 (26.3/22.2)
Pump speed at 3000 rpm

Water temperature at 30C (86F)
Double row shaft
Pump bearing type
Thermostat type
Valve initial opening temperature
C (F)
76.5 (170)
40 (104)
(Oil cooler thermo valve)

(EGR cooler thermo valve)
Valve full opening temperature
82 (180)
C (F)
95 (203)
90 (194)
55 (131)

Valve lift at fully open position
9.5 (0.37)
mm (in)
4.5 (0.18)
3.5 (0.14)

Radiator
Heat radiation capacity
Tube type corrugated

93.0 kw (79,980 kcal/h)
Heat radiation area
11.63 m (1.081ft )
Radiator front area
0.28m (0.026 ft )
Radiator dry weight

Radiator cap valve opening pressure
52 N (5.3 kg/11.7 lb)
53 N (5.4 kg/11.9 lb)
93.3 ~ 122.7kpa (13.5 ~ 17.8psi)
Engine coolant capacity
2.4 lit (5.1 U.S pint)
2.3 lit (4.9 U.S pint)
Engine coolant total capacity
10.1 lit (21.3 U.S pint)
10.0 lit (21.1 U.S pint)
6B 4 ENGINE COOLING
GENERAL DESCRIPTION
COOLANT FLOW
RTW46ALF001101
The engine cooling system consists of the radiator, the water pump, the cooling fan, and the thermostat.
To quickly increase cold engine coolant temperature for smooth engine operation, the coolant is circulated by the
water pump and thermostat through the bypass hose and back to the cylinder body.
The coolant does not circulate through the radiator.
When the coolant temperature reaches specified value, the thermostat will begin to open and a gradually increasing
amount of coolant will circulate through the radiator.
The thermostat will be fully open when the coolant temperature reaches specified value. All of the coolant is now
circulating through the radiator for effective engine cooling.
ENGINE COOLING 6B 5
WATER PUMP
RTW46ASF000101
A centrifugal type water pump forcefully circulates the coolant through the cooling system.
The water pump is not disassembled type.
THERMOSTAT
030RY00005
A wax pellet type thermostat is used.

The jiggle valve accelerates engine warm-up.
6B 6 ENGINE COOLING
RADIATOR
The radiator is a tube type with corrugated fins. In order to
raise the boiling point of the coolant, the radiator is fitted with a
cap in which the valve is operated at 93.3 ~ 122.7 kPa (13.5 ~
17.8 psi) pressure. (No oil cooler provided for M/T)
110RS001
Antifreeze Solution
NOTE: Antifreeze solution + Water = Total cooling system
capacity.
Total Cooling System Capacity Lit (US / UK gal)
9.4 (2.5/21) 4JA1L/TC
M/T 10.1 (2.7/2.2) 4JH1TC
A/T 10.0 (2.6/2.2) 4JH1TC
See section 0B MAINTENACE AND LUBRICATION.
F06RW005
NOITE:
To maintain the corrosion resistance of the aluminum
radiator, water and antifreeze must be combined in a 1:1
solution (50% antifreeze and 50% water)
NOTE
PTW46BSH000201
ENGINE COOLING 6B 7
DIAGNOSIS
Engine Cooling Trouble
Symptom
Engine overheating
Possible Cause
Action
Low Engine Coolant level
Replenish
Thermo meter unit faulty
Replace
Faulty thermostat
Replace
Faulty Engine Coolant temperature Repair or replace

sensor
Clogged radiator
Clean or replace
Faulty radiator cap
Replace
Low engine oil level or use of Replenish or change oil

improper engine oil
Clogged exhaust system
Clean exhaust system or replace

faulty parts
Faulty Throttle Position sensor
Replace throttle valve assembly
Open or shorted Throttle Position Repair or replace

sensor circuit
Damaged cylinder head gasket
Replace
Engine overcooling
Faulty thermostat
Replace
Engine slow to warmup
Faulty thermostat
Replace
Thermo unit faulty
Replace
6B 8 ENGINE COOLING
Draining and Refilling Cooling System

Before draining the cooling system, inspect the system and
perform any necessary service to ensure that it is clean, does
not leak and is in proper working order. The engine coolant
(EC) level should be between the MIN" and MAX" lines of
reserve tank when the engine is cold. If low, check for leakage
and add EC up to the MAX" line.
There should not be any excessive deposit of rust or scales
around the radiator cap or radiator filler hole, and the EC
should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the drain
plug at the bottom of the radiator.
P1010064
2. Remove the radiator cap.

WARNING: To avoid the danger of being burned, do not
remove the cap while the engine and radiator are still hot.
Scalding fluid and steam can be blown out under
pressure.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with soap
and water. Flush it well with clean water, then drain it.
Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution that is
at least 50 percent antifreeze.
Procedure for filling with coolant (in case of full change)
Make sure that the engine is cool.
Open radiator cap pour coolant up to filler neck.
Pour coolant into reservoir tank up to MAX" line.
Tighten radiator cap and start the engine. After idling for 2
to 3 minutes, stop the engine and reopen radiator cap. If the
water level is lower, replenish.
WARNING: When the coolant is heated to a high
temperature, be sure not to loosen or remove the radiator
cap. Otherwise you might get scalded by not vapor or
boiling water. To open the radiator cap, put a piece of
thick cloth on the cap and loosen the cap slowly to reduce
the pressure when the coolant has become cooler.
ENGINE COOLING 6B 9
After tightening radiator cap, warm up the engine at about
2000 rpm. Set heater adjustment to the highest temperature
position, and let the coolant circulate also into heater water
system.
Check to see the thermostat has opened through the
needle position of water thermometer, conduct a 5minute
idling again and stop the engine.
When the engine has been cooled, check filler neck for
water level and replenish if required. Should extreme
shortage of coolant is found, check the cooling system and
reservoir tank hose for leakage.
Pour coolant into the reservoir tank up to MAX" line.
6B 10 ENGINE COOLING
WATER PUMP
Read this Section carefully before performing any removal and installation procedure. This Section gives you
important points as well as the order of operation. Be sure that you understand everything in this Section before you
begin.
Removal
1. Radiator Upper Hose
1) Partially drain the engine coolant.
2) Remove the radiator upper hose.
2. Water Outlet Pipe

1) Disconnect the turbocharger-cooling pipe from outlet
pipe.
2) Loosen the fixing bolt and remove the water outlet
bolt.
3. Thermostat
Remove the thermostat from the thermostat housing.
Take care not to damage the thermostat.
4. Upper Fan Shroud
031R300003
5. Fan and Fan Clutch

1) Loosen the fan clutch nuts.
2) Remove the fan together with the fan clutch. Take
care not to damage the radiator core.
6. Fan Drive Belt and Pulley
1) Loosen the tension adjust bolt on the generator.
2) Remove the fan drive belt with the fan pulley.
030R300001
7. Water Pump
1) Remove the water pump bolts.
2) Remove the water pump.
030R300002
ENGINE COOLING 6B 11

The water pump is not disassembled type.
Make necessary parts replacement if extreme wear or
damage is found during inspection. Should any of the
following problems occur, the entire water pump assembly
must be replaced.
Cracks in the water pump body
Coolant leakage from the seal unit
Excessive radial play or abnormal noise in the fan center
when rotate by hand
Excessive thrust play in the fan center (Standard play: less
than 0.2mm)
Cracks or corrosion in the impeller
Installation
1. Water Pump
1) Install the water pump with new gasket.
2) Tighten bolts and nuts to specified torque.
Water Pump Bolt/Nut Torque
Nm(kgm/lb ft)
20 (2.0/14)
030R300002
2. Fan Drive Belt and Pulley

1) Install the fan drive belt and fan pulley.
2) Apply tension to the fan drive belt by moving the
generator.
3) Apply a force of 98N(10kg/22 lb) to the drive belt midportion to check the drive belt deflection.
Fan Drive Belt Deflection
mm (in)
New belt: 4-7(0.16-0.28)
Reuse belt: 6-9(0.24-0.35)
3. Fan and Fan Clutch
1) Install the fan and fan clutch to pulley.
2) Tighten the nuts to specified torque.
Fan Clutch Nut Torque
Nm(kgm/lb in)
8(0.8/69)
4. Upper Fan Shroud
030R300001
5. Thermostat
Install the thermostat to the thermostat housing.
1) Install the water outlet pipe with new gasket to the
thermostat housing.
2) Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque
Nm(kgm/lb ft)
19(1.9/14)
031R300003
3) Connect the turbocharger-cooling pipe to outlet pipe.

1) Connect the radiator upper hose to the water outlet
pipe.
2) The knob of clamp shall be dircted to holizonal side.
3) Replenish the engine coolant.
THERMOSTAT
begin.
Removal
1) Partially drain the engine coolant.
2) Remove the radiator upper hose.

3) Disconnect the turbocharger-cooling pipe from outlet
pipe.
4) Loosen the fixing bolt and remove the water outlet
bolt.
3. Thermostat
Remove the thermostat from the thermostat housing.
Take care not to damage the thermostat.
031R300003

Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
Operating Test of Thermostat

1. Completely submerge the thermostat in water.
2. Heat the water.
Stir the water constantly to avoid direct heat being
applied to the thermostat.
3. Check the thermostat initial opening temperature.
Thermostat Initial Opening Temperature
C (F)
82 (180)
031RY00005
4. Check the thermostat full opening temperature.

Thermostat Full Opening Temperature
C (F)
95 (203)
Valve Lift At Fully Open Position
9.5 (0.37)
mm (in)
Q Thermometer
R Agitating rod
S Wooden piece
Installation
1. Thermostat
Install the thermostat to the thermostat housing.
3) Install the water outlet pipe with new gasket to the
thermostat housing.
4) Tighten the outlet pipe bolt to specified torque.
Outlet Pipe Bolt Torque
Nm(kgm/lb ft)
031R300003
19(1.9/14)
5) Connect the turbocharger-cooling pipe to outlet pipe.
1) Connect the radiator upper hose to the water outlet
pipe.
2) The knob of clamp shall be directed to holizonal side.
3) Replenish the engine coolant.
RADIATOR
Radiator and Associated Parts
RTW36BLF000101
Legend
1. Radiator Hose
2. Drain Plug
3. Fan Guide, Lower
4. Fan Guide
5. Bracket
6. Reserve Tank Hose

7. Reserve Tank
8. Radiator Cap
9. Radiator Assembly
Removal
1.
2.
3.
4.
Disconnect battery ground cable.

Loosen a drain plug to drain EC.
Disconnect oil cooler hose on automatic transmission (A/T).
Disconnect radiator inlet hose and outlet hose from the
engine.
P1010064
5. Remove fan guide(1), clips(2) on both sides and the bottom

lock, then remove lower fan guide(3) with fan shroud(4).
6. Disconnect the reserve tank hose(6) from radiator.
PTW46BSH000101
7. Remove bracket(5).
RTW36BMH000101
8. Lift up and remove the radiator assembly with hose, taking

care not to damage the radiator core with a fan blade.

replacements if excessive wear or damage is discovered
during inspection.
Radiator Cap
Measure the valve opening pressure of the pressurizing valve
with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside the
standard range.
Valve opening pressure kPa (psi) 93.3
~17.8)
~ 122.7 (13.5
Cap tester: 5884002770

Adapter: 5884026030
Check the condition of the vacuum valve in the center of the
valve seat side of the cap. If considerable rust or dirt is found,
or if the valve seat cannot be moved by hand, clean or replace
the cap.
Valve opening vacuum kPa (psi) 1.96 ~ 4.91 (0.28 ~ 0.71)
110RS006
Radiator Core
1. A bent fin may result in reduced ventilation and overheating
may occur. All bent fins must be straightened. Pay close
attention to the base of the fin when it is being straightened.
2. Remove all dust, bugs and other foreign material.
Flushing the Radiator

Thoroughly wash the inside of the radiator and the engine
coolant passages with cold water and mild detergent. Remove
all signs of scale and rust.
Cooling System Leakage Check

Use a radiator cap tester to force air into the radiator through
the filler neck at the specified pressure of 196 kPa (28.5 psi)
with a cap tester:
Leakage from the radiator
Leakage from the coolant pump
Leakage from the water hoses
Check the rubber hoses for swelling.
110RS005
Installation
1. Install radiator assembly (9) with hose, taking care not to
damage the radiator core with a fan blade.
2. Support the radiator upper tank with the bracket (5) and
secure the radiator.
3. Connect reserve tank hose (6).
4. Install lower fan guide (3).
5. Connect radiator inlet hose and outlet hose (1) to the
engine.
6. Connect oil cooler hose to automatic transmission.
7. Connect battery ground cable.
RTW36BMH000101
8. Pour engine coolant up to filler neck of radiator, and up to
MAX mark of reserve tank.
Important operation (in case of 100% engine coolant
change) procedure for filling with engine coolant.
RTW36BSH000101
Engine coolant change

Refer to 6B-8 (Draining and Refilling Cooling System).
FAN CLUTCH WITH COOLING FAN

Make necessary correction or parts replacement if wear, damage or any other abnormal condition are found through
inspection.
033R300001
Visually inspect for damage, leak (sillicon grease) or other

1. Inspection (on-vehicle)
1) Turn the fan clutch by hand when in a low temperature
condition before starting the engine, and confirm that it
can be turned readily.
2) Start the engine to warm it up until the temperature at
the fan clutch portion gets to around 80C. Then stop
the engine and confirm that the fan clutch can be
turned with considerable effort (clutch torque) when
turned by hand.
If the fan clutch rotates more readily, however, this
indicates that the silicone grease is leaking internally.
Replace the fan clutch with a new one.
2. Inspection (in unit)
Warm up the bimetal of the fan clutch by using the heat
gun until the temperature gets to about 80C when
measured with the thermistor. Then confirm that the fan
clutch can be turned with considerable effort (clutch
torque).
If the fan clutch retates more readily at this time, this
indicates that the silicone grease is leaking internally.
033RY00011
FUEL SYSTEM
6C 1
SECTION 6C
FUEL SYSTEM
TABLE OF CONTENTS
PAGE
Main Data and Specifications ....................................................................................... 6C -
General Description....................................................................................................... 6C -
Fuel Flow.................................................................................................................... 6C -
Fuel Filter and Water Separator ............................................................................... 6C -
Injection Pump........................................................................................................... 6C -
Injection Nozzle ......................................................................................................... 6C -
Fuel Tank ........................................................................................................................ 6C -
Removal ..................................................................................................................... 6C -
Installation ................................................................................................................. 6C - 10
Fuel Pump ...................................................................................................................... 6C - 12
Removal...................................................................................................................... 6C - 13
Installation.................................................................................................................. 6C - 13
Fuel Tube / Quick - Connector Fittings........................................................................ 6C - 14
Filler Neck ...................................................................................................................... 6C - 16
Removal...................................................................................................................... 6C - 16
Installation.................................................................................................................. 6C - 16
Fuel Filler Cap ................................................................................................................ 6C - 17
Injection Pump ............................................................................................................... 6C - 18
Removal and Installation .......................................................................................... 6C - 18
Removal...................................................................................................................... 6C - 18
Installation.................................................................................................................. 6C - 21
6C 2 FUEL SYSTEM
PAGE
Injection Nozzle.............................................................................................................. 6C - 25
Inspection................................................................................................................... 6C - 25
Special Tools.................................................................................................................. 6C - 36
FUEL SYSTEM
6C 3

Description
Item
4JA1T (L)
4JA1TC
4JH1TC
Injection pump type
Bosch distributor
VE type
Bosch distributor VP44 type
Governor type
Mechanical variable
(Half speed oil
pressure)
Electrical controled
Oil pressure
Electrical controled
Timer type
Fuel feed pump type
Vane with input shaft
Hole type
Number of injection nozzle orifices
Injection nozzle orifices

Inside diameter
Injection nozzle designed operating
2
pressure MPa (kg/cm )
mm (in)
0.19 (0.0075)
0.17 (0.0067)
0.21 (0.0083)
19.1 (195)
19.0 (194)
19.5 (199)
25.0 (255)
33.5 (328)
33.8 (331)
1st
2nd
Disposable cartridge paper element
Precautions
When working on the fuel system, there are several things
to keep in mind:
Any time the fuel system is being worked on,

disconnect the negative battery cable except for
those tests where battery voltage is required.
Always keep a dry chemical (Class B) fire
extinguisher near the work area.
Replace all pipes with the same pipe and fittings that
were removed.
Clean and inspect O" rings. Replace if required.
Always relieve the line pressure before servicing any
fuel system components.
Do not attempt repairs on the fuel system until you
have read the instructions and checked the pictures
relating to that repair.
Adhere to all Notices and Cautions.
NOTE:
Injection nozzle adjustment is possible only on the 4JA1L
engine.
6C 4 FUEL SYSTEM
GENERAL DESCRIPTION
FUEL FLOW
RTW46CMF000201
The fuel system consists of the fuel tank, the fuel filter, the water separator, the injection pump, and the injection
nozzle.
The fuel from the fuel tank passes through the water separator and the fuel filter where water particles and other
foreign material are removed from the fuel.
Fuel, fed by the injection pump plunger, is delivered to the injection nozzle in the measured volume at the optimum
timing for efficient engine operation.
NOTE:
1 If it find abnormal condition on the fuel injector, refer to section 6E ENGINE DRIVEABILITY AND
EMISSIONS.
2 Do not contain "Additive for water drain" with fuel.
FUEL SYSTEM
6C 5
FUEL FILTER AND WATER SEPARATOR

As the inside of the injection pump is lubricated by the fuel which it is pumping, the fuel must be perfectly clean. The
fuel filter and the water separator remove water particles and other foreign material from the fuel before it reaches
the injection pump.
The water separator has an internal float. When the float reaches the specified level, a warning light comes on to
remind you to drain the water from the water separator.
A diaphragm type priming pump is installed at the top of the fuel filter. It is used during the air bleeding procedures.
(Except EURO III model)
RTW36CLF000701
6C 6 FUEL SYSTEM
For EURO III model
RTW46AMF000201
FUEL SYSTEM
6C 7
INJECTION PUMP
RTW46CLF000201
4JA1T(L):
A Bosch Distributor Type Injection Pump is used. A single reciprocating/revolving plunger delivers the fuel uniformly
to the injection nozzles, regardless of the number of cylinders.
The governor, the injection timer, and the feed pump are all contained in the injection pump housing. The injection
pump is compact, light weight, and provides reliable high-speed operation.
The vacuum-type fast idle actuator increases the engine idling speed to provide the additional power required to
operate the air conditioner.
Fast idler diaphragm movement is caused by changes in the negative pressure created by the engines vacuum
pump.
The diaphragm motion is transferred to the injection pump control lever to increase or decrease the idling speed.
4JA1TC/4JH1TC:
The Bosch VP44 injection pump is electronically controlled. The pump controller combine to injection pump.
Signals from the pump controller are sent to the engine control module (ECM). In response to these signals, the
ECM selects the optimum fuel injection timing and volume for the existing driving conditions.
6C 8 FUEL SYSTEM
INJECTION NOZZLE (4JA1L)
RTW46CMF000301
NOTE:
Injection nozzle adjustment is possible only on the 4JA1L engine.
A hole (with 5 orifices) type injection nozzle. It consists of the nozzle body and the needle valve assembly.
The injection nozzle assembly sprays pressurized fuel from the injection pump into the combustion chamber through
the nozzle body injection orifice.
FUEL SYSTEM
6C 9
FUEL TANK
Fuel Tank and Associated Parts
RTW46CLF000401
Legend
1. Bolt; Fuel Tank
2. Fuel Tank Band
3. Fuel Tube/Quick Connector
4. Fuel Filler Hose
5. Fuel Tank
6. Under Shield Band
7. Under Shield (only, specified model)
8. Evapo Pipe (only specified model)
6C 10 FUEL SYSTEM
Removal
CAUTION: When repair to the fuel system has been
completed, start engine and check the fuel system for
loose connection or leakage. For the fuel system
diagnosis, see Section Driveability and Emission".
1. Disconnect battery ground cable.
2. Loosen slowly the fuel filler cap.
NOTE: Be careful not to spouting out fuel because of change
the pressure in the fuel tank.
NOTE: Cover opening of the filler neck to prevent any dust
entering.
3.
4.
5.
6.
7.
Jack up the vehicle.

Support underneath of the fuel tank with a lifter.
Remove the inner liner of the wheel house at rear left side.
Remove fixing bolt of the filler neck from the body.
Disconnect the quick connector (3) of the fuel tube from the
fuel pipe.
NOTE: Cover the quick connector to prevent any dust entering

and fuel leakage.
NOTE: Refer to Fuel Tube/Quick Connector Fittings in this
section when performing any repairs.
8. Remove fixing bolt (1) of the tank band and remove the
tank band (2).
9. Disconnect the pump and sender connector on the fuel
pump and remove the harness from weld clip on the fuel
tank.
10.Lower the fuel tank (5).
NOTE: When lower the fuel tank from the vehicle, dont scratch
each hose and tube by around other parts.
Installation
1. Raise the fuel tank.
NOTE: When raise the fuel tank to the vehicle, dont scratch
each hose and tube by around other parts.
2. Connect the pump and sender connector to the fuel pump
and install the harness to weld clip on the tank.
NOTE: The connector must be certainly connected against
stopper.
3. Install the tank band and fasten bolt.
Torque
Nm (kgm / lb ft)
68 (6.9 / 50)
NOTE: The anchor of the tank band must be certainly installed
to guide hole on frame.
4. Connect the quick connector of the fuel tube to the fuel pipe
and the evapo tube from evapo joint connector.
NOTE: Pull off the left checker on the fuel pipe.
FUEL SYSTEM
6C 11
5. Install the filler neck to the body with bolt.

6. Install the inner liner of the wheel house at rear left side.
7. Remove lifter from the fuel tank.
8. Lower the vehicle.
9. Tigten the filler cap until at least three clicks.
10.Connect the battery ground cable.
6C 12 FUEL SYSTEM
FUEL GAUGE UNIT

Fuel Gauge Unit and Associated Parts
RTW46CLF000501
Legend
1. Fuel Feed Port
2. Fuel Return Port
3. Fuel Emission Port
4. Fuel Gauge Unit and Sender Assembly
5. Connector; Fuel Gauge Unit
6. Fuel Tube/Quick Connector

7. Retainer Ring (Fuel Gauge Unit Lock)
8. Seal; Fuel Gauge Unit
9. Fuel Tank Assembly
10. Evapo Tube/Quick Connector
FUEL SYSTEM
6C 13
Removal
loose connection or leakage. For the fuel system
1. Remove fuel tank assembly (9). Refer to Fuel Tank
Removal" in this section.
2. Disconnect the quick connector (6) of the fuel tube from fuel
gauge unit.
3. Disconnect the quick connector (10) of the evapo tube from
fuel gauge unit.
3. Remove the retainer ring (7) from the fuel tank with the
removal tool 5-8840-2602-0.
4. Remove slowly the fuel gauge unit (4) from the fuel tank as
no bend float arm.
NOTE: Cover opening for the fuel gauge unit on fuel tank to
prevent any dust entering.
5. Discard fuel gauge unit seal (8) because it cannot be
reusable.
140R100035
Installation
1. Clean the seal surface of the fuel tank and the fuel gauge
unit.
NOTE: If there is dust on the seal surface, it becomes cause of
fuel leak.
2. Install the new fuel gauge unit seal (8) to opening of the fuel
tank as along the groove.
3. Install slowly the fuel gauge unit (4) into the fuel tank as no
bend float arm.
4. Set flange of the fuel gauge unit on fuel gauge unit seal as
mating convexity of the fuel gauge unit and reentrant of the
fuel tank.
5. Lock slowly the retainer ring (7) to the fuel tank with the
remover tool 5-8840-2602-0.
6. Connect the quick connector (10) of the evapo tube from
fuel gauge unit.
7. Connect the quick connector (6) of the fuel tube to to gauge
unit.
NOTE: Pull off the left ckecker of the fuel pipe.
6C 14 FUEL SYSTEM
8. Check leak.
Methed of leak check.
(1) Plug end of quick connector and breather hose (Pull off
the breather hose from fuel tank) and tighten fuel filler
cap until at least one click are heard.
(2) Apply water soap around the fuel gauge unit seal area.
(3) Pressure air into the fuel tank from end of breather pipe
2
at 5psi (34.3 kPa/2.8kgf/cm ) over 15 seconds.
(4) Verify no bubbles around the fuel gauge unit seal area.
9. Install the fuel tank assembly (9).
NOTE: Refer to Install the fuel tank in this section.
FUEL SYSTEM
6C 15
FUEL TUBE / QUICK CONNECTOR FITTINGS

Precautions
Do not light a match or create a flame.
Keep flames away from your work area to prevent
flammable materials from catching fire.
Disconnect battery ground cable to prevent electrical shorts.
Pre-treat piping system or associated parts from thermal
damage or from spattering when welding or similar
heat-generating work.
Cautions During Work

Do not expose the assembly to battery electrolyte or do not
wipe the assembly with a cloth used to wipe off spilt battery
electrolyte.
Piping that has been splattered with battery electrolyte or
battery electrolyte soaked cloth that was wiped on the piping
cannot be used.
140R100032
Legend
(1) O-ring
(2) Port
(3) Connector
(4) Plastic Tube
Removal
1. Open the fuel cap to relieve the fuel pressure in the tank.
Use compressed air to remove any dirt on the fuel quick
connect fittings prior to disconnecting the fittings.
When disconnecting the fuel pipe, cover the area with a
cloth to prevent fuel from splashing as the
fuel pipe may
still have some pressure in it.
141R100002
6C 16 FUEL SYSTEM
2. For removal of the quick connector, hold the quick
connector in one hand, and pull out the connector with the
other hand while pressing the square relieve button of the
connector, as illustrated.
NOTE: Do not use tools of any kind. Only use bare hands
when disconnecting the connector. Use a lubricant (light oil)
and/or push and pull the connector until the pipe is
disconnected.
140R100037
Cover the connectors that was removed with a plastic bag,

to prevent dust or rain water from entering.
140R100028
Reuse of QuickConnector
Replace the port and connector if scratch, dent or crack is
found.
Remove any dirt build up on the port when installing the
connector. Replace the connector, if there is any forms of
rust, dent, scratch.
After cleaning the port, insert it straight into the connector
until it clicks. After it clicks, try pulling at 49N (5kgf) it out to
make sure that it is not drawn and is securely locked.
140R100036
Assembling Advice
By applying engine oil or light oil to the pipe, port makes pipe
assembly easier. The pipe assembly should take place
immediately after applying oil (to prevent dust from sticking to
the pipe surface which may decrease sealing ability).
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Start the engine and observe the engine idle speed. The
presence of dirt in the fuel system may affect the fuel
injection system.
3. Check for fuel leakage from the connector.
FUEL SYSTEM
6C 17
FILLER NECK
Removal
1. Remove the fuel tank.
NOTE: Refer to "Fuel Tank" in this section.
2. Put a marking the following point as the filler neck assembly
is restored.
Each joint area of the hose (to restore axial direction and
insertion length of the hose)
Each fasten area of the clamp (to restore axial direction
and position of the clamp)
Each bolt in the clamp (to restore fasten length of bolt in
the clamp)
The band clip (to restore position and fasten length of
the band clip)
NOTE: Cover end of each hose and pipe to prevent any dust
entering.
Installation
1. Align each marking and restore the following point.
Each joint area of the hose (Restore axial direction and
insertion length of the hose)
Each fasten area of the clamp (Restore axial direction
and position of the clamp)
Each bolt in the clamp (Restore fasten length of bolt in
the clamp)
Torque
Nm (kgm / lb ft)
2.5 (0.25 / 21.7)
filler neck side except flat deck model.
The band clip (Restore position and fasten length of the
band clip)
2. Install the fuel tank.
6C 18 FUEL SYSTEM
FUEL FILLER CAP

General Description
A vacuum valve and pressure valve are built into the fuel filler
cap which adjusts the fuel pressure in the fuel tank to prevent
fuel tank damage.
RTW36CSH000401
Legend
(1) Pressure Valve
(2) Vacuum Valve
(3) Seal Ring
Inspection
The fuel filler cap must be inspected for seal condition.
The fuel filler cap must be replaced if found defective
CAUTION: A replacement fuel filler cap must be the same
as the original. The fuel filler cap valve was designed
primarily for this application and must be replaced with
the same type or decreased engine performance may
occur.
FUEL SYSTEM
6C 19
INJECTION PUMP
begin.
Removal
1. Battery
Remove the battery from the battery tray.
6C-1
2. Drive Belt
1) Loosen the adjust bolt of the power steering pump
pulley.
2) Remove the drive belt.
3. Power Steering Pump Assembly
4. Accelerator Control Cable
Disconnect the accelerator cable from the intake throttle.
P1010003
5. Vacuum Hose
Disconnect the vacuum hose from the EGR valve and the
intake throttle.
6. Fan
6C 20 FUEL SYSTEM
7. Power Steering Pump Bracket
6C-4
8. Throttle
Position
Sensor
Harness
Connector
Disconnect the harness connector from the throttle
position sensor.
9. Oil Level Gauge
10. Fuel Pipe
1) Disconnect the fuel hoses from the fuel filter or priming
pump.
2) Disconnect the fuel hoses from the injection pump.
6C-5

13. Leak Off Hose
Disconnect the leak off hose at the injection pump.
14. Injection Pipe Clip
15. Injection Pipe
1) Loosen the injection pipe sleeve nuts at the delivery
valve side and the injection nozzle side.
Note:
Do not apply excessive force to the injection pipes.
2) Loosen the injection pipe clip.
3) Remove the injection pipes.
Note:
Plug the delivery holder ports with the caps to prevent
the entry of foreign material.
16. Intake Manifold
1) Remove the EGR valve from the intake manifold and
EGR pipe.
2) Loosen the intake rubber hoses clip.
3) Loosen the intake manifold bolts and nuts.
FUEL SYSTEM
020L200017
6C 21
18. Timing Check Hole Cover

1) Remove the timing check hole cover.
2) For ease in reinstalling the injection pump, align the
timing mark on the timing gear case cover by turning
the crankshaft using wrench.
And bring the piston in the No.1 cylinder to TDC on the
crankshaft pulley TDC line aligned with the timing
mark.
Note:
If the check hole cover is reinstalled with the lock bolt
still in place, the crank pulley will not turn.
RTW46CSH000201
3) Insert the lock bolt (M6 x 30) into the scissors gear idle
gear B fixing hole to prevent the scissors gear from
turning.
6C-7
29. Injection Pump Bracket

20. Injection Pump
6C 22 FUEL SYSTEM
Installation
1. Injection Pump
1) Install the injection pump gear (When gear is
removed).
Injection Pump Gear Nut
Nm (kgm/lb ft)
64 (6.5 / 47)
RTW46CSH000201
2) Bring the piston in the No.1 cylinder to TDC on the

crankshaft pulley TDC line aligned with the timing
mark.
3) Install the injection pump to the timing gear case with
align the timing mark on the pump gear to the arrow
mark on the timing gear case cover.
4) Check that the setting marks of the injection pump
gear and the idler gear B are aligned.
5) Remove the lock bolt (M6 30) from the idle gear B.
020L200017
6) Tighten the injection pump fixing bolts to the specified

torque.
Injection Pump Bolts Torque
Nm (kgm/lb ft)
19 (1.9 / 14)
6C-7
FUEL SYSTEM
6C 23
4JA1T (L)
RTW46CSH000101
4JA1TC/4JH1TC
2. Injection Pump Bracket

1) Install the injection pump bracket (6) and the bracket
bolts (7) and (8) to the cylinder body. Temporarily
tighten the bracket bolts.
2) Tighten the bracket bolts (7) to the specified torque.
3) Tighten the bracket bolts (8) to the specified torque.
Note:
Tighten the bracket bolt (8) first.
Injection Pump Bracket Torque
Nm(kgm / lb ft)
(8) 19 (1.9 / 14)
(7) 40 (4.1 / 30)
RTW36AMH000101
3. Timing Check Hole Cover

Install the timing check hole cover and tighten bolts to the
specified torque.
Timing Check Hole Cover Bolts
Torque
Nm(kgm / lb ft)
8 (0.8 / 69)
5. Intake Manifold
1) Install the intake manifold with gasket.
Intake Manifold Bolts
Torque
Nm(kgm / lb ft)
19 (1.9 / 14)
Intake Manifold Nuts Torque
Nm(kgm / lb ft)
24 (2.4 / 17)
2) Install the EGR valve to the intake manifold and EGR
pipe temporarily.
3) Tighten the nuts and bolts to the specified torque
Torque
Nm (kgm/lb ft)
Nuts
Bolts
24 (2.4/17)
27 (2.8/20)
6C 24 FUEL SYSTEM
6. Injection Pipe
Install the injection pipe.
Injection Pipe Torque
Nm(kgm / lb ft)
29 (3.0 / 22)
Nozzle Side (4JA1TC/4JH1TC)
Nm(kgm / lb ft)
29 (3.0 / 22)
Pump Side (4JA1TC/4JH1TC)
Nm(kgm / lb ft)
40 (4.1 / 30)
7. Injection Pipe Clip
Install the injection pipe clip.
Note:
Make absolutely sure that the clip is correctly
positioned.
Injection Pipe Clip Torque
Nm(kgm / lb in)
8 (0.8 / 69)
8. Leak Off Pipe and Leak Off Hose
Install the leak off pipe to injection nozzle and connect the
leak off hose to the injection pump.
Install the fuel filter bracket and tighten bolts to the
specified torque.
Fuel Filter Bracket Bolts Torque
Nm(kgm / lb ft)
21 (2.1 / 15)
Install the fuel filter assembly to bracket and tighten bolts
Fuel Filter Assembly Bolts
Torque
Nm(kgm / lb ft)
21 (2.1 / 15)
11. Fuel Pipe
1) Connect the fuel hoses to the fuel filter or priming
pump.
2) Connect the fuel hoses to the injection pump.
12. Oil Level Gauge
Install the oil level gauge and tighten bolts to the specified
torque.
Oil Level Gauge Bolts
Torque
Nm(kgm / lb ft)
M8: 19 (1.9 / 14)
M6: 8 (0.8/6 lb in)
FUEL SYSTEM
6C 25
13. Throttle Position Sensor Harness Connector

Reconnect the harness connector to the throttle position
sensor.
14. Power Steering Pump Bracket
15. Fan
16. Vacuum Hose
Connect the vacuum hose to the EGR valve and the
intake throttle.
Euro under
Euro I
Euro II
Euro III
4JA1L
without
with
with
4JA1TC
Not used
Not used
Not used
4JH1TC
without
with
with
Not used
With cooler
(EGR cooler)
With
(EGR cooler)
17. Accelerator Control Cable

1) Connect the accelerator cable to the injection pump
(4JA1T) the intake throttle. (4JA1TC/4JH1TC only)
18. Power Steering Pump Assembly
19. Drive Belt
Install the drive belt and adjust the belt tension.
20. Battery
6C 26 FUEL SYSTEM
INJECTION NOZZLE (4JA1L)

DISASSEMBLY
080L200009
Disassembly Steps
1.
2.
3.
4.
Retaining nut
Nozzle & pin
Spacer & pin
Lift Piece
9.
10.
11.
12.
5.
6.
7.
Spring seat
Push rod
Shim (Second nozzle opening
pressure adjustment)
Second spring
13.
14.
15.
8.
Collar
Spring seat
First spring
Shim (First nozzle
pressure adjustment)
Nozzle holder body
Eye bolt
Gasket
opening
Injection nozzle adjustment is possible only on the 4JA1L
engine.
The two-spring nozzle holder has been developed to
reduce NOx (Nitrogen Oxides) and particulates from direct
injection diesel engine exhaust.
Before disassembly remove carbon deposit from nozzle
and nozzle holder using a wire brush and wash the outside
nozzle holder assembly.
Caution:
Do not touch nozzle holes with the wire brush during
cleaning it.
Disassemble the nozzle holder assembly to numerical
order.
FUEL SYSTEM
6C 27
REASSEMBLY
080L200010
Reassembly Steps
1.
2.
3.
4.
5.
6.
7.
8.
Nozzle holder body

Shim (First opening pressure
adjustment)
First spring
Spring seat
Collar
Second spring
Push rod
Shim (Second opening pressure
adjustment)
9.
10.
Spring seat
Lift Piece
11.
12.
13.
14.
15.
Spacer & pin

Nozzle & pin
Retaining nut
Gasket
Eye bolt
The nozzle holder is adjusted as the components are
reassembled in the sequence above.
As adjustment of the two-spring nozzle holder is made in
hundredths of a millimeter, clean the parts thoroughly in
light oil to completely remove any dirt or foreign matter.
6C 28 FUEL SYSTEM
REASSEMBLY AND ADJUSTMENT PROCEDURE
1
First nozzle opening pressure adjustment
Full needle valve lift confirmation
Pre-lift confirmation
Adjust the first nozzle opening pressure using the shim.
Confirm the full needle valve lift in accordance with the

closed method.
Confirm pre-lift in accordance with the closed method.
CAUTION:
If not as specified, replace the nozzle assembly, lift
piece, pins and spacer using the nozzle service kit.
Second nozzle opening pressure

confirmation
Confirm the second nozzle opening pressure in accordance

with the closed method.
Second nozzle opening pressure

adjustment
Adjust the second nozzle opening pressure using the shim.
6
Final inspection
Confirm the condition of the fuel spray with the nozzle and
nozzle holder assembled.

Nozzle needle valve full-lift
0.25 mm (0.0098 in)
Nozzle needle valve pre-lift
0.04 mm(0.0016 in) at 20,000 kpa (2901 psi, 204 kg/cm )
Nozzle pressure
4JA1T(L)
1st Stage
2nd Stage
19.1 Mpa (2759 psi, 194 kg/cm )

2
25.5-27.0 Mpa (3768-3911 psi, 260-275 kg/cm )
NOTE: Only 4JA1L can perform adjustment of a nozzle.
FUEL SYSTEM
6C 29
Injection Nozzle Adjustment

1.Clamp the nozzle holder in a vise.
040MV015.tif
2. Install the shim, first spring and spring seat in the

nozzle holder.
040MV016.tif
3. Install the collar, second spring, shim, spring seat and

pushrod in the nozzle holder.
040MV017.tif
4. Install the pins, lift piece and spacer in the nozzle

holder.
040MV018.tif
6C 30 FUEL SYSTEM
5. Install the pins in the spacer.
6. Install the nozzle on the spacer.
040MV019.tif
7. Hand-tighten the adjustment retaining nut together

with the gasket to the nozzle holder.
Retaining nut: 157892-3200 (Bosch AS)
Gasket:
157892-5100 (Bosch AS)
(Bosch AS = Bosch Automotive Systems Corporation)
040MV010.tif
8. Tighten the adjustment retaining nut to the specified

torque.
Torque: 5.1 kgm (36.9 Ibft/50 Nm)
040MV014-1.tif
9. Set the nozzle holder to the nozzle tester.

10. Operate the nozzle tester and measure the first nozzle
opening pressure.
11. If the first nozzle opening pressure is not as specified,
disassemble the nozzle holder and replace the shim
until the pressure is as specified.
CAUTION:
Use a micrometer to measure shim thickness.

040MV030.tif
FUEL SYSTEM
040LX010.tif
6C 31
First nozzle opening pressure adjusting shims

Parts No. (ISUZU)
Thickness (mm)
115349-0420
0.40
115349-0430
0.50
115349-0440
0.52
115349-0450
0.54
115349-0460
0.56
115349-0470
0.58
115349-0480
0.60
115349-0490
0.70
Full needle valve lift confirmation

1. Install the gasket and plug on the adjustment retaining
nut.
Gasket:
026508-1140 (Bosch AS)
894227-6020 (ISUZU)
Plug:
157892-1600 (Bosch AS)
040MV013.tif
2. Position the nozzle holder with the nozzle facing down

and install the dial gauge holder on the nozzle holder.
Dial gauge holder: 157892-5000 (Bosch AS)
040MV012.tif
3. Install the nut on the dial gauge holder.

Nut: 157892-1000 (Bosch AS)
040MV011.tif
6C 32 FUEL SYSTEM
4. Install the pin to the dial gauge.
Note:
The lengths of the pins do not include the
threaded portions.
Pin (L=100 mm): 157892-5200 (Bosch AS)
Dial gauge:
157954-3800 (Bosch AS)
185317-0150 (ISUZU)
040MV029.tif
5. Secure the dial gauge to the nozzle holder using the

nut so that the pin contacts the tip of the first spring
seat.
CAUTION:
Secure the dial gauge so that a stroke of 2 mm can
be measured.
Do not over-tighten the nut as the dial gauge shaft
may jam. (Confirm from the dial gauge that the
shaft moves smoothly.)
040MV009.tif
6. Set the nozzle holder to the nozzle tester and put

needle to zero on the dial gauge.
7. Operate the nozzle tester to bleed any air from inside
the retaining nut and to confirm that no fuel leaks.
040MV030.tif
FUEL SYSTEM
6C 33
8. Operate the nozzle tester and increase the in-line

2
pressure to 34.3 - 44.1 MPa (350 - 450 kg/cm ) so that
the nozzles needle valve moves through its full lift.
Record full lift L. (Read dial gauge)
Nozzle Full Lift
mm (in)
0.25 H 0.02 (0.0098 H 0.00008)
040MV008.tif
Note:
The above operation is used to determine whether
the nozzle seat is worn and whether the nozzle
assembly is in good condition.
Pre-lift confirmation
1. With the needle valve at full lift, release the nozzle
tester handle.
Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.
040MV007.tif
040R300008
6C 34 FUEL SYSTEM
2. Read the needle valve pre-lift point from the dial
gauge indication (once the needle valve has
descended when the second spring has stopped
operating).
Pre-lift measuring point:
Read the dial gauge at first nozzle opening pressure +approx
2
1 MPa (10 kg/cm ).
Pre-lift
mm
040H100007
4JA1T(L)
Pressure Mpa
2
(psi/ kg/cm )
Lift mm (in)
20.1 (2,858/205)
0.04 (0.0016)
Note:
This point can be found while the pressure is
decreasing.
3. Confirm that pre-lift is as specified.
040MV005.tif
4. If pre-lift is not as specified, replace the pins, lift piece,

spacer and nozzle assembly as a set with the service
kit.
Service kit
105017-2990 (Bosch AS)
897302-3070 (ISUZU)
040MV031.tif
Second nozzle opening pressure confirmation

1. After pre-lift confirmation, operate the nozzle tester to
increase in-line pressure to 34.3 - 44.1 MPa (350 - 450
2
kg/cm ) so that the nozzles needle valve moves
through its full lift.
040MV030.tif
FUEL SYSTEM
6C 35
2. Release the nozzle tester handle so that in-line

pressure decreases.
Note:
The in-line pressure will decrease and needle
valve lift (as indicated on the dial gauge) will also
decrease a little.
040MV022.tif
3. Then, read the pressure gauge indication (second

nozzle opening pressure) the instant that the dial
gauge indicates the specified needle valve lift (usually
pre-lift + 0.05 mm).
Second Nozzle Opening Pressure
Pressure Mpa
2
(psi/ kg/cm )
4JA1T(L)
040M100006
25.5-27.0
(3768-3911/260-275)
Lift mm (in)
0.09 (0.0035)
6C 36 FUEL SYSTEM
040MV017.tif
Second nozzle opening pressure adjustment

If the second nozzle opening pressure is not as specified,
disassemble the nozzle from the nozzle holder and
replace the shim until the pressure is as specified.
CAUTION:
Because the second opening pressure changes
when the first opening pressure changes, the
second opening pressure must be adjusted when
the first opening pressure changes.
Use a micrometer to measure shim thickness.
Use some combination of 3 adjusting shims to
adjust the pressure.
040LX009.tif
Second nozzle opening pressure adjusting shims

Part No.
(ISUZU)
Thickness
(mm)
Part No.
(ISUZU)
Thickness
(mm)
897116-0290
897116-0320
897116-0330
897116-0340
897116-0350
897116-0360
897116-0370
0.10
0.20
0.30
0.40
0.50
0.51
0.52
897116-0380
897116-0390
897116-0400
897116-0410
897116-0420
897116-0430
897116-0440
0.53
0.54
0.55
0.56
0.57
0.58
0.59
Final inspection
1. Remove the dial gauge, nut and dial gauge holder.
040MV028.tif
2. Remove the adjustment retaining nut and gasket.

3. Install the original retaining nut, confirm that the pins
are inserted fully into the nozzle, and then hand-tighten
the retaining nut. Then, tighten the original retaining
nut to the specified torque.
Torque: 7.0 kgm (50.6 Ibft/69 Nm)
040MV014-1.tif
FUEL SYSTEM
6C 37
4. Set the nozzle holder to the nozzle tester and check

first nozzle opening pressure, spray condition, seat oil
tightness and each part for oil leaks.
5. When replacing the nozzle, replace the nozzle, lift
piece, pins and spacer as a set with the nozzle service
kit.
CAUTION:
Pre-lift will not be as specified if only the nozzle is
replaced.
040MV030.tif
6C 38 FUEL SYSTEM
SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
TOOL NAME
5-8840-2602-0
Remover: fuel pump retainer ring
(J-39765)
ENGINE ELECTRICAL 6D 1
SECTION 6D
ENGINE ELECTRICAL
TABLE OF CONTENTS
PAGE
Main Data and Specifications ......................................................................................... 6D - 2
General Description......................................................................................................... 6D - 3
Torque Specifications ..................................................................................................... 6D - 5
Generator.......................................................................................................................... 6D - 7
Removal and Installation ............................................................................................ 6D - 7
Disassembly................................................................................................................. 6D - 9
Inspection and Repair ................................................................................................. 6D - 12
Reassembly.................................................................................................................. 6D - 18
Starter Motor .................................................................................................................... 6D - 22
Removal and Installation ............................................................................................ 6D - 22
Disassembly................................................................................................................. 6D - 23
Inspection and Repair ................................................................................................. 6D - 26
Reassembly.................................................................................................................. 6D - 29
Pre-heating System ......................................................................................................... 6D -33
Inspection and Repair ................................................................................................. 6D -33
Glow Relay ................................................................................................................... 6D -33
Glow Plug..................................................................................................................... 6D -33
EGR System ................................................................................................................. 6D -33
6D 2 ENGINE ELECTRICAL

Description
Item
60A
Generator
Type
80A
AC generator with IC regulator and vacuum pump

Hitachi LR160-503E
Voltage
Drive and rotation
Ground polarity
Maximum output
Engine speed ratio
Maximum speed
Weight with vacuum pump
Vacuum Pump
Delivery volume
Exhaust Characteristic
A
to 1
rpm
kg(lb)
3
cm /rev
Hitachi LR180-513B
12
V-belt, clockwise viewed from the drive pulley
Negative
60
80
1.788
11,000
5.8(12.8)
6.4(14.1)
50
-66.7 kPa (-500 mmHg) bulid up time 21 seconds or less at 1,000
rpm
7 seconds or less at 5,000 rpm
-90.7 kPa (-680 mmHg) or more
Maximum vacuum
Starter Motor
Type
Solenoid controlled
Hitachi S13-555
Rated voltage
Rated output
Load characteristics
Terminal voltage
Load current
Weight
V
kW
12
2.3
V
A
8.76
300
kg(Ib)
4.7 (10.4)
GENERAL DESCRIPTION
GENERATOR
STARTER MOTOR
066L300004
065L300002
The basic charging system is the IC integral regulator charging system. The internal components are connected
electrically as shown in charging circuit diagram.
The generator features a solid state regulator that is mounted inside the generator. All regulator components are
enclosed into a solid mold, and this unit along with the brush holder assembly is attached to the slip ring end frame.
The generator voltage setting cannot be adjusted.
The starter motor circuit is composed of a 4-pole 4-brush type direct current series motor. The starter motor circuit
utilizes negative ground polarity.
CHARGING CIRCUIT DIAGRAM
RTW46DSH005101
STARTING CIRCUIT DIAGRAM
RTW46DSH005501
GENERATOR
Nm (kgm/Ibft)
RTW46DLF000201
STARTER MOTOR
Nm (kgm/Ibft)
RTW46DLF000301
GENERATOR
begin.
Important Operations-Removal
Cooling Fan Belt
1. Disconnect the battery cables at the battery terminals.
2. Loosen and remove the fan belt adjusting plate bolts.
3. Remove the fan belt from the generator drive pulley.
Generator
P1010002
1. Remove the vacuum pump hose.

2. Remove the generator bolt and the generator from the
bracket.
Important Operations-Installation
Follow the removal procedure in the reverse order to
perform the installation procedure. Pay careful attention to
the important points during the installation procedure.
Generator
1. Install the generator to the bracket.
2. Tighten the generator bolt to the specified torque.
3. Install the vacuum pump hose.
Generator Bolt Torque
Nm (kgm/Ibft)
40 (4.1/30)
Cooling Fan Drive Belt
1. Hold the generator toward the engine.
2. Install the fan belt to the three pulleys.
1 Crankshaft pulley
2 Generator pulley
3 Cooling fan drive pulley
033RY00009
3. Adjust the fan belt tension

Fan belt tension is adjusted by moving the generator.
Depress the drive belt mid-portion with a 98N (10
kg/22 Ib) force.
Cooling Fan Drive Belt Deflection
mm (in)
New belt
4 - 7 (0.16 - 0.28)
Reuse belt 6 - 9 (0.24 - 0.35)
4. Tighten the adjusting plate bolts to the specified

torque.
Adjusting Plate Bolt
Nm (kgm/lbft)
19 (1.9/14)
5. Reconnect the battery cable to the battery.
DISASSEMBLY
RTW46DLF000401
Disassembly Step
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Vacuum pump
O-ring
Through bolt
B Terminal nut
Rear cover
Pulley
Rotor assembly
Front cover assembly
Rear rotor bearing
Rectifier assembly
Stator assembly
Rotor assembly
1.
Vacuum Pump
1. Loosen the vacuum pump fixing screws.
2. Support the vacuum pump O-ring.
3. Carefully remove the O-ring.
2. Cover
RTW46DSH000101
3.
Through Bolt
1. Remove the M5 through bolt.
2. Separate the front and rear sides of the vacuum pump.
3. Insert the tips of 2 ordinary screwdrivers into the space
between the front cover and the stator core. Remove
the front cover and rotor together with the rear cover
and stator.
If removal is difficult, push the rear cover to the side and
lightly tap the end of the shaft with a plastic hammer to
loosen it.
The front cover oil seal must be replaced with a new
one when the front cover is removed.
Take care not to damage the stator core with the
screwdriver tips.
4.
Pulley
1. Carefully clamp the rotor assembly in a vise.
2. Loosen the pulley nut.
3. Remove the pulley and the front cover from the rotor.
RTW46DSH000201
RTW46DSH000601
RTW46DSH002101
7. Rotor Assembly
1. Remove the rotor from front cover assembly.
Remove the front cover stator and rectifier.
RTW46DSH000301
8. Front Cover Assembly

1. Remove the front cover bearing retainer screws.
2. Remove the bearing.
RTW46DSH000701
9. Rear rotor bearing

Re-use improper parts.
10. Rectifier
1. Disconnect the stator coil leads between each rectifier
by melting the solder connection.
Hold the lead wire between the solder and the rectifier
with a pair of long nose pliers.
This will prevent heat transfer and resultant damage to
the rectifier.
RTW46DSH000801
RTW46DSH000401

Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during
inspection.
ROTOR ASSEMBLY
1. Inspect the slip ring faces for dirt and pitting.
Wipe away any dirt with a clean cloth soaked in
alcohol.
2. Measure the slip ring diameter.
Slip Ring Diameter
mm (in)
Standard
Limit
31.6 (1.245)
30.6 (1.183)
RTW06DSH000101
If the slip ring diameter is less than the specified limit, the
slip rings must be replaced.
3. Measure the rotor coil resistance.
Rotor Coil Resistance at 20C (68F)
Standard
ohms
3.8
RTW46DSH001001
4. Check for continuity between the slip rings and the

rotor core or shaft.
If there is continuity, the entire rotor assmbly must be
replaced.
RTW46DSH001101
STATOR COIL ASSEMBLY

1. Check for continuity across the stator coils.
If there is no continuity, the stator coils must be
replaced.
Resistance Between The Terminal N and the Coil Ends
(Reference)
ohms
Standard
0.1
066RY00022
2. Check for continuity between each stator coils and the

stator core.
If there is continuity, the stator coils must be replaced.
066RY00023
BRUSH
Measure the length of the brush. If abrasion has reduced
the brush length to less than 6.5 mm, the brush must be
replaced with a new one.
A wear line is inscribed in the brush. If the line is not
visible, the brush must be replaced.
Brush Length (Reference)
mm (in)
RTW46DSH004801
Standard
Limit
25 (1.0)
6.5 (0.25)
Rectifier
RTW46DSH001201
Tester wire
E
U, V, and WN
BAT
U, V, and WN
-----
Conductivity
-----
No
conductivity
Conductivity
-----
No
----conductivity
Negative side diode check
Positive side diode check
RECTIFIER ASSEMBLY
RTW46DSF000301
1.
2.
3.
4.
5.
6.
7.
8.
9.
Voltmeter
Switch 1
DC regulated power supply
Lamp 2
Lamp 1
Switch 3
Switch 2
Pulse generator
Output signal
Test circuit
Refer to the judgment criteria shown in the Table below.
Carefully check Items 1~5. If all the items are OK, the IC
regulator is normal.
Circuit components
DC regulated power supply
1
Lamps (2)
2
Switches (3)
3
DC voltmeter
4
Pulse generator (Oscillator)
5
0~20 volts variable with output of 1 ampere or more

12 volts, 1.4~3.4 watts
----0~30 volts, 0.5 grade
5~30 volt output at a frequency of 1kHz
Judgment criteria
No.
Switch
1
Switch
2
Switch
3
ON
OFF
OFF
Voltmeter
reading
12V
ON
ON
OFF
ON
ON
OFF
16V
OFF
ON
OFF
12V
ON
ON
ON
18V
Lamp condition
Lamp 1 Lamp 2
On
ON
(dim)
On or
flashing
OFF
Off or
on (dim)
On or
flashing
On
ON
Remarks
Initial excitation check
Full excitation check
Lamp 1 off or dimly lit when the
voltmeter shows less than 12 volts or
16 volts
Stator and brush separation check
Excess voltage check
Oil seal
The oil seal must be replaced with a new one whenever
the alternator is disassembled.
Oil Seal Replacement

1. Push the old oil seal from the rear bracket outside
holes.
2. Use the insertion tool to press the new oil seal into
place. Follow the procedure shown in Figures A, B, C
and D.
Position the oil seal beneath the shaft and the
guide lip.
Position the cradle against the rear cover bosses
(3 points) so that the E1 and E2 surfaces fit into
the cradle. Take care not to damage the E1 and
E2 surfaces.
After completing the procedure, carefully check the
oil seal seating. Be absolutely sure that the seal is
evenly inserted (no warp) and level with the
surrounding surfaces.
Caution
Be sure that no foreign material enters the space
between the oil seal and the rotor shaft surfaces
during the installation procedure.
Take care not to damage the D surface.
Under no circumstances may the original oil seal
be reused.
The oil seal must be perfectly flat after being
pressed into place. If the oil seal is tilted, there will
be oil leakage.
RTW46DSF000101
Vacuum Pump
Vacuum Pump Disassembly
1. Remove the center plate from the vacuum pump
housing.
2. Remove the vacuum pump rotor and the vanes from
the housing.
RTW46DSH000901
Inspection
Vacuum Pump Housing and Center Plate
Inspect the vacuum pump housing and the center plate for
excessive wear, abrasion, and scoring.
If any of these conditions are present, the vacuum pump
housing and center plate must be replaced.
Vane
Inspect the vanes for excessive wear and damage.
Replace all four vanes if either of these conditions are
present.
Never replace only one vane.
Rotor
1. Inspect the rotor for excessive wear, abrasion, and
scoring.
Pay particular attention to the internal spline.
Replace the rotor if any of these conditions are
present.
2. Inspect the generator rotor shaft splines for backlash.
Replace the rotor if backlash is present.
Check Value
1. Carefully force the valve from the B side as shown in
the illustration.
The valve must move smoothly.
If it does not, the check valve must be replaced.
2. Apply compressed air to the A side.
2
Air Pressure
kPa (kg/cm /psi)
98 - 490 (1-5/14 71)
RTW46DSH005201
Check for air leakage from the check valve.

If there is air leakage, the valve must be replaced.
Vacuum Pump Reassembly
1. Install the vanes to the rotor slits.
The rounded side of the vanes must be facing the
rotor housing.
RTW46DSH001801
2. Install the rotor with the concave side facing the center
plate.
RTW46DSH001901
3. Install the center plate to the rotor housing.

Be sure to use a new O-ring.
RTW46DSH002001
REASSEMBLY
RTW46DLF000501
Reassembly Step
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Front cover
Rear rotor bearing
Rotor Assembly
Pulley
Rectifier Assembly
Stator Assembly
Rear cover
B Terminal nuts
Through bolt
O-ring
Vacuum pump
2. Rear rotor bearing
Re-use improper parts.
RTW46DSH000401
5. Rectifier
6. Stator
Use a pair of long-nose plier to connect the stator coil
leads and the rectifier leads.
Finish the work as quickly as possible to prevent the
rectifier from heat transferred by the soldering.
3. Rotor Assembly
4. Pulley Assembly
Clamp the rotor in a vise and install the pulley nut.
Pulley Nut Torque
Nm (kgm/lbft)
83.3 ~ 98.0 (8.5 ~ 10.0 / 61 ~ 72)
RTW46DSH002101
Remove the tape from the splines.
RTW46DSH006001
The rear ball bearing is pressed into the wheel eccentric

groove. The bearing ring projects from the groove.
During installation, rotate the bearing to the point of
minimum bearing ring projection.
Inspect the rear cover bearing box and replace it if it is
damaged.
RTW46DSH004901
NOTE: Be sure to attach a cooler to B terminal.
RTW46DSH002201
Insert the pin from the outside of the rear cover. Press the
brushes into the brush holder. Complete the assembly
procedure.
Remove the pin after completion of the assembly
procedure.
RTW46DSH005301
9. Through Bolt
1. Place a pilot bar into the through bolt hole to align the
front cover and the rear cover.
2. Install the through bolts and tighten them to the
specified torque.
Through Bolt Torque
Nm (kgm/lbft)
3.1 ~ 3.9 (0.32 ~ 0.41 / 2.6 ~ 3.5)
RTW06DSH000201
11. Vaccum Pump

To install the generator 1. Note the direction of the arrow on the vacuum pump.
2. Look forward from the base of the arrow to locate the
3 generator fixing points.
3. Twist the fixing points down and to the left to align
them with the middle of the center plate and the rotor.
Install vanes into slits in rotor.
The vanes should be installed with the chamfered side
facing outward.
RTW46DSH006101
Install the vacuum pump housing.

Make sure that the O-ring is not projecting beyond the
slots of the center plate.
Take care so that no scratching takes place on the vane
resulted by contact with the housing.
RTW46DSH002401
Install the housing in the generator and fix it with the three
bolts.
Supply engine oil (5cc or so) from the oil port and check
that the generator pulley can be turned smoothly with your
hand.
Generator Housing Bolt Torque
Nm (kgm/lbft)
5.9 ~ 6.9 (0.6 ~ 0.7 / 5.2 ~ 6.1)
RTW46DSH002501
STARTER MOTOR
begin.

Starter Motor
1. Disconnect the battery cable and the ground cable at
the battery terminals.
2. Disconnect the magnetic switch cable at the terminal
bolts.
3. Disconnect the battery cable at the starter motor and
4. Remove the starter motor from the engine.

Starter Motor
1. Install the starter motor to the rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Bolt Torque
Nm (kgm/lbft)
85 (8.7/63)
3. Reconnect the battery cable at the starter motor and
4. Reconnect the battery cable and the ground cable at
the battery terminals.
DISASSEMBLY
RTW460LF000201
Disassembly Step
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Lead wire
Bolt
Magnetic switch assembly
Torsion spring
Plunger
Dust cover
Magnetic switch
Screw
Through bolt
Rear cover
Motor assembly
Brush holder
Yoke
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Armature
Bolt
Bearing retainer
Pinion assembly
Pinion stopper clip
Pinion stopper
Return spring
Pinion shaft
Clutch
Dust cover
Shift lever
Gear case
1. Lead Wire
Disconnect the lead wire at the magnetic switch.
RTW46DSH002601
3. Magnetic Switch Assembly

Remove the magnetic switch bolts, then remove the
switch from the shift lever.
RTW46DSH002701
Remove the torsion spring from the magnetic switch.
RTW46DSH002801
8. Through Bolt
9. Screw
10. Rear Cover
Remove the through bolts, then remove the rear cover.
RTW46DSH002901
11. Motor Assembly

Remove the four brushes from the brush holders.
RTW46DSH003001
Remove the yoke along with the armature and the brush
holder from the gear case.
Remove the brushes and commutator carefully so as not
to allow them in contact with the adjacent parts.
RTW46DSH003101
12. Brush Holder

13. Yoke
14. Armature
Remove the brush holder and pull out the armature
assembly free from the yoke.
RTW46DSH003201
16.
17.
23.
24.
25.
Bearing Retainer
Pinion Assembly
Dust Cover
Shift Lever
Gear Case
1. Remove the bearing retainer.
2. Remove the pinion from the gear case.
RTW46DSH003301
3. Use a screwdriver to remove the stopper clip. Then

disassemble the pinion assembly.
RTW46DSH003401

Make the necessary adjustments, repairs, and part replacement if excessive wear or damage is discovered during
inspection.
ARMATURE
1. Measure the commutator run-out.
Replace the commutator if the measured run-out
exceeds the specified limit.
Commutator Run-Out
mm (in)
Standard
Limit
0.05 (0.002)
0.2 (0.008)
RTW46DSH003501
2. Check the commutator mica segments for excessive

wear.
3. Measure the mica segment depth.
Mica Segment Depth
mm (in)
065RY00025
Standard
Limit
0.5 ~ 0.8 (0.020 ~ 0.030)
0.2 (0.008)
If the mica segment depth is less than the standard but

more than the limit, the commutator may be reground.
If the mica segment depth is less than the limit, the
commutator must be replaced.
4. Measure the commutator outside diameter.
Commutator Outside Diameter
Standard
Limit
36.5 (1.44)
35.5 (1.40)
mm (in)
If the measured outside diameter is less than the specified

limit, the commutator must be replaced.
065RY00026
5. Use a circuit tester to check the armature for

grounding.
1 Hold one probe of the circuit tester against the
commutator segment.
2 Hold the other circuit tester probe against the
armature core.
If the circuit tester indicates continuity, the armature is
grounded.
The armature must be replaced.
RTW46DSH003601
6. Use the circuit tester to check the armature for
continuity.
1 Hold the circuit tester probes against two
commutator segments.
2 Repear Step 1 at different segments of the
armature core.
There should be continuity between all segments of
the commutator.
If there is not, the armature must be replaced.
RTW46DSH003701
YOKE
1. Use a circuit tester to check the field winding ground.
1 Hold one circuit tester probe against the field
winding end or brush.
2 Hold the other circuit tester probe against the bare
surface of the yoke body.
There should be no continuity.
If there is continuity, the field coil is grounded.
The yoke must be replaced.
RTW46DSH003801
2. Use the circuit tester to check the field winding

continuity.
1 Hold one circuit tester probe against the M
terminal lead wire.
2 Hold the other circuit tester probe against the field
winding brush.
There should be continuity.
If there is no continuity, the yoke must be replaced.
RTW46DSH003901
BRUSH AND BRUSH HOLDER

1. Use a vernier caliper to measure the brush length (four
brushes).
Replace the brushes as a set if one or more of the
brush lengths is less than the specified limit.
Brush Length
mm (in)
Standard
Limit
15 (0.59)
12 (0.47)
RTW46DSH004001
2. Use a circuit tester to check the brush holder

insulation.
Touch one probe to the holder plate and the other
probe to the positive brush holder.
There should be no continuity.
RTW46DSH004101
3. Inspect the brushes for excessive wear.

If the negative brushes have excessive wear, the
entire brush holder assembly must be replaced.
If the positive brushes have excessive wear, the entire
yoke must be replaced.
OVERRUNNING CLUTCH
1. Inspect the overrunning clutch gear teeth for
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise.
It should turn smoothly.
3. Try to rotate the pinion in the opposite direction.
The pinion should lock.
065RY00035
BEARING
Inspect the bearings for excessive wear and damage.
Replace the bearings if necessary.
RTW46DSH004401
REASSEMBLY
RTW46DLF000601
Reassembly Steps
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Magnetic switch assembly

Magnetic switch
Dust cover
Plunger
Torsion spring
Shift lever
Gear case
Dust cover
Bolt
Pinion assembly
Clutch
Pinion shaft
Rerurn spring
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Pinion stopper
Pinion stopper clip
Bearing retainer
Bolt
Motor assembly
Armature
Yoke
Brush holder
Rear cover
Screw
Through bolt
Lead wire
1. Magnetic Switch Assembly
1. Attach the torsion spring to the hole in the magnetic
switch as illustrated.
2. Insert the shift lever into the plunger hole of the
magnetic switch.
RTW46DSH005601
7. Gear Case
3,8. Dust Cover
1. Install the magnetic switch assembly in the gear case.
2. Install the dust cover.
Dust Cover Bolt Torque
Nm (kgm/lbft)
8 (0.8/5.4)
RTW46DSH005701
10. Pinion Assembly

Apply a coat of grease to the reduction gear and install the
pinion assembly to the armature shaft.
065RY00041
21. Brush Holders

1. Install the brushes into the brush holder with raising
the spring end of the brush spring.
Take care not to damage the commutator face.
2. Install the brush holder with aligning the peripheries of
the yoke and the brush holder.
RTW46DSH004501
24. Through Bolt
Install the through bolts in the rear cover and tighten them
Through Bolt Torque
Nm (kgm/lbft)
8.1 (0.83/6.00)
065RY00044
25. Lead Wire

Connect the lead wire in the magnetic switch and tighten
the terminal nut to the specified torque.
Lead Wire Terminal Nut Torque
Nm (kgm/lbft)
8.6 (0.88/6.40)
RTW46DSH002601
Inspection After Assembly

Use a vernier caliper to measure the pinion shaft thrust
play.
The pinion shaft thrust play is equal to the pinion shaft end
and pinion stopper clearance.
Pinion Shaft Thrust Play
mm (in)
0.1 2.0 (0.004 0.078)
RTW46DSH005801
MAGNETIC SWITCH
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the M
terminal.
To prevent coil burning, complete each test as quickly as
possible (within three to five seconds).
Temporarily connect the solenoid switch between the
clutch and the housing and run the following test.
Complete each test within three to five seconds.
1. Pull-in Test
Connect the battery negative terminal with the solenoid
switch body and the M terminal. When current is applied to
the S terminal from the battery positive terminal, the pinion
should flutter.
RTW46DSH004601
2. Hold-in Maintenance Test

Disconnect the lead at the M terminal. The pinion should
continue to flutter.
RTW46DSH005901
3. Return Test
Disconnect the battery positive lead at the S terminal.
The pinion should return to its home position.
RTW46DSH004701
PRE-HEATING SYSTEM
Make the necessary adjustments, repairs, and part replacement if excessive wear of damage is discovered during
inspection.
VISUAL CHECK
Check the main fuses and glow indicator for damage.
Replace the part(s) if required.
GLOW RELAY
The glow relay is located in the relay box the engine
compartment.
Use an ohmmeter to measure the resistance between
terminals No.2 and No.3.
If the measured value is outside the specified range, the
glow relay must be replaced.
Glow Relay Resistance
Ohms
94 - 114
825R300046
GLOW PLUG
Use a circuit tester to test the glow plugs for continuity.
Glow Plug Resistance (Reference)
Approximately 0.9
LNW21KSH001401
EGR SYSTEM 4JA1T (L)

Refer to 6F-9. (EGR system diagram)
Ohms
MEMO
4JA1/4JH1 ENGINE DRIVEABILITY AND EMISSIONS
6E1
ENGINE
CONTENTS
ABBREVIATION CHARTS ........................
6E-9
4JA1-TC ....................................................
6E-10
4JH1-TC ....................................................
6E-11
ECM CIRCUIT DIAGRAM (4JA1-TC) ........
6E-14
ECM CIRCUIT DIAGRAM (4JA1-TC) ........
6E-15
ECM CIRCUIT DIAGRAM (4JH1-TC) ........
6E-16
ECM CIRCUIT DIAGRAM (4JH1-TC) ........
6E-17
GROUND POINT CHART GENERAL EXPORT
(LHD) (1/4) ...............................................
6E-18
LOCATION ................................................
6E-34
PARTS LOCATION ...................................
6E-39
CONNECTOR LIST ...................................
6E-40
RELAY AND FUSE ....................................
6E-43
RELAY AND FUSE BOX LOCATION
(LHD & RHD) ...........................................
6E-43
(LHD & RHD) ...........................................
6E-44
FUSE AND RELAY LOCATION (LHD & RHD) 6E-45
ECM WIRING DIAGRAM (1/7) ..................
6E-46
6E-47
6E-48
6E-49
6E-50
6E-51
6E-52
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL ....................................
6E-53
GENERAL DESCRIPTION FOR ECM AND
SENSORS ...............................................
6E-64
Engine Control Module (ECM) ...................
6E-64
Pump Control Unit (PSG) & Data Exchange
Between Control Module .........................
6E-64
Mass Air Flow (MAF) Sensor & Intake Air
Temperature (IAT) Sensor .......................
6E-65
Throttle Position Sensor (TPS) ..................
6E-66
Crankshaft Position (CKP) Sensor ............
6E-66
Engine Coolant Temperature (ECT) Sensor
6E-67
Vehicle Speed Sensor (VSS) ....................
6E-67
GENERAL DESCRIPTION FOR EGR
(EXHAUST GAS RE-CIRCULATION) .....
6E-68
GENERAL DESCRIPTION FOR
INJECTION PUMP ..................................
6E-70
Outline .......................................................
6E-70
Cross-section View ....................................
6E-70
Low Pressure Fuel Circuit ..........................
6E-71
High Pressure Fuel Circuit .........................
6E-72
Pump Camshaft Speed Sensor .................
6E-72
High Pressure Solenoid Valve ...................
6E-73
Timing Control Valve (TCV) .......................
6E-74
ISUZU Strategy Based Diagnostics ..............
6E-76
Overview ....................................................
6E-76
STRATEGY BASED DIAGNOSTICS CHART 6E-76
Diagnostic Thought Process ......................
6E-77
1. Verify the Complaint ..............................
6E-77
2. Perform Preliminary Checks ..................
6E-77
3. Check Bulletins and Troubleshooting Hints 6E-78
4. Perform Service Manual Diagnostic Checks 6E-78
5a and 5b. Perform Service Manual Diagnostic
Procedures ..............................................
6E-78
5c. Technician Self Diagnoses ..................
6E-78
5d. Intermittent Diagnosis ..........................
6E-79
5e. Vehicle Operates as Designed ............
6E-80
6. Re-examine the complaint .....................
6E-81
7. Repair and Verify Fix .............................
6E-81
GENERAL SERVICE INFORMATION .......
6E-82
ON-BOARD DIAGNOSTIC (OBD) .............
6E-82
TECH 2 OPERATING FLOW CART
(START UP) .............................................
6E-86
TYPICAL SCAN DATA & DEFINITIONS
(ENGINE DATA) ...................................
6E-88
(ENGINE DATA) ...................................
6E-90
MISCELLANEOUS TEST ..........................
6E-92
Plotting Snapshot Graph ............................
6E-93
Plotting Graph Flow Chart (Plotting graph
after obtaining vehicle information) ..........
6E-94
Flow Chart for Snapshot Replay
(Plotting Graph) .......................................
6E-95
SNAPSHOT DISPLAY WITH TIS2000 ......
6E-96
ON-BOARD DIAGNOSTIC (OBD) SYSTEM
CHECK ....................................................
6E-105
Circuit Description ......................................
6E-105
Diagnostic Aids ..........................................
6E-105
Test Description .........................................
6E-105
6E2
On-Board Diagnostic (OBD) System Check

6E-106
NO CHECK ENGINE LAMP (MIL) .............
6E-109
Circuit Description .....................................
6E-109
Diagnostic Aids ..........................................
6E-109
No Check Engine Lamp (MIL) ...................
6E-110
CHECK ENGINE LAMP (MIL) ON STEADY 6E-112
Circuit description ......................................
6E-112
Diagnostic Aids ..........................................
6E-112
Check Engine Lamp (MIL) On Steady .......
6E-113
ECM Diagnostic Trouble Codes ................
6E-114
DIAGNOSTIC TROUBLE CODE (DTC) P0100
(SYMPTOM CODE 7) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR
VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-128
MASS AIR FLOW (MAF) SENSOR
VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-128
(SYMPTOM CODE B) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR OUTPUT
CIRCUIT LOW INPUT .............................
6E-128
(SYMPTOM CODE C) (FLASH CODE 65)
MASS AIR FLOW (MAF) SENSOR OUTPUT
CIRCUIT HIGH INPUT ............................
6E-128
6E-129
Diagnostic Aids ..........................................
6E-129
Diagnostic Trouble Code (DTC) P0100
(Symptom Code 7) (Flash Code 65) Mass
Air Flow (MAF) Sensor Voltage Supply
Circuit High Input .....................................
6E-129
(Symptom Code 9) (Flash Code 65) Mass
Air Flow (MAF) Sensor Voltage Supply
Circuit Low Input ......................................
6E-132
(Symptom Code B) (Flash Code 65) Mass
Air Flow (MAF) Sensor Output Circuit Low
Input .........................................................
6E-134
Diagnostic Trouble Code (DTC) P0100 (Symptom
Code C) (Flash Code 65) Mass Air Flow (MAF)
Sensor Output Circuit High Input .............
6E-137
VACUUM PRESSURE SENSOR CIRCUIT HIGH
INPUT ......................................................
6E-140
VACUUM PRESSURE SENSOR CIRCUIT
LOW INPUT .............................................
6E-140
VACUUM PRESSURE SENSOR VOLTAGE

SUPPLY CIRCUIT HIGH INPUT .............
6E-140
VACUUM PRESSURE SENSOR VOLTAGE
SUPPLY CIRCUIT LOW INPUT ..............
6E-140
6E-141
Diagnostic Aids ..........................................
6E-141
(Symptom Code 1) (Flash Code 34) Vacuum
Pressure Sensor Circuit High Input .........
6E-142
Pressure Sensor Circuit Low Input ...........
6E-145
Pressure Sensor Voltage Supply Circuit
High Input .................................................
6E-148
Pressure Sensor Voltage Supply Circuit Low
Input..........................................................
6E-150
INTAKE AIR TEMPERATURE (IAT) SENSOR
6E-152
6E-152
6E-152
Diagnostic Aids ..........................................
6E-153
(Symptom Code 1) (Flash Code 23) Intake Air
Temperature (IAT) Sensor Circuit High Input 6E-153
(Symptom Code 2) (Flash Code 23) Intake Air
Temperature (IAT) Sensor Circuit Low Input 6E-157
ENGINE COOLANT TEMPERATURE SENSOR
CIRCUIT HIGHINPUT .............................
6E-160
ENGINE COOLANT TEMPERATURE SENSOR
6E-160
6E-160
Diagnostic Aids ..........................................
6E-161
(Symptom Code 1) (Flash Code 14) Engine
Coolant Temperature Sensor Circuit
HighInput .................................................
6E-161

(Symptom Code 2) (Flash Code 14) Engine
Coolant Temperature Sensor Circuit
LowInput ..................................................
6E-165
FUEL TEMPERATURE SENSOR CIRCUIT
RANGE/PERFORMANCE .......................
6E-168
6E-168
Diagnostic Aids ..........................................
6E-168
(Symptom Code B) (Flash Code 15) Fuel
Temperature Sensor Circuit
Range/Performance ................................
6E-169
(SYMPTOM CODE A) (FLASH CODE 52)
FUEL CUTOFF SOLENOID VALVE
MALFUNCTION .......................................
6E-170
6E-170
FUEL CUTOFF SOLENOID VALVE ALWAYS
ACTIVE ....................................................
6E-170
(SYMPTOM CODE D) (FLASH CODE 52)
MALFUNCTION .......................................
6E-170
6E-171
Diagnostic Aids ..........................................
6E-171
(Symptom Code A) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction ...........
6E-171
Cutoff Solenoid Valve Circuit High Input .
6E-173
(Symptom Code C) (Flash Code 52) Fuel
Cutoff Solenoid Valve Always Active .......
6E-175
(Symptom Code D) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction ...........
6E-177
INJECTION TIMING CONTROL CIRCUIT
MALFUNCTION .......................................
6E-178
INJECTION TIMING CONTROL CIRCUIT
MALFUNCTION .......................................
6E-178
6E-179
Diagnostic Aids ..........................................
6E-179
6E3

(Symptom Code A) (Flash Code 54) Injection
Timing Control Circuit Malfunction ...........
6E-180
(Symptom Code B) (Flash Code 54) Injection
Timing Control Circuit Malfunction ...........
6E-180
TURBOCHARGER WASTEGATE
SOLENOID "A" RANGE/PERFORMANCE 6E-183
SOLENOID"A" LOW ................................
6E-183
SOLENOID "A" LOW ...............................
6E-183
SOLENOID "A" RANGE/PERFORMANCE 6E-183
SOLENOID "A" MALFUNCTION .............
6E-183
SOLENOID"A" HIGH ...............................
6E-183
6E-184
Diagnostic Aids ..........................................
6E-184
(Symptom Code 3) (Flash Ccode 64)
Turbocharger Wastegate Solenoid
"A" Range/Performance ...........................
6E-185
(Symptom Code 4) (Flash Code 64)
Turbocharger Wastegate Solenoid "A" Low 6E-187
Turbocharger Wastegate Solenoid "A"
Range/Performance ................................
6E-190
Turbocharger Wastegate Solenoid "A"
Malfunction ..............................................
6E-192
Turbocharger Wastegate Solenoid "A" High 6E-194
(SYMPTOM CODE 6)
(FLASH CODE 53) INJECTION PUMP
6E4
MALFUNCTION .......................................
6E-196
INJECTION PUMP MALFUNCTION .......
6E-196
6E-196
6E-196
6E-196
6E-196
(SYMPTOM CODE E) (FLASH CODE 53)
6E-196
6E-197
Diagnostic Aids ..........................................
6E-197
Injection Pump Malfunction .....................
6E-197
6E-199
6E-203
(Symptom Code A) (Flash Code 53)
6E-204
(Symptom Code B) (Flash Code 53)
6E-205
(Symptom Code D) (Flash Code 53)
6E-206
(Symptom Code E) (Flash Code 53)
6E-207
CRANKSHAFT POSITION SENSOR
CIRCUIT MALFUNCTION .......................
6E-208
CRANKSHAFT POSITION SENSOR
MALFUNCTION .......................................
6E-208
ENGINE SPEED INPUT CIRCUIT
RANGE/PERFORMANCE .......................
6E-208
6E-209
Diagnostic Aids ..........................................
6E-209
Crankshaft Position Sensor Circuit
Malfunction ..............................................
6E-209
Crankshaft Position Sensor Malfunction ..
6E-209
(Symptom Code E) (Flash Code 43) Engine
Speed Input Circuit Range/Performance .
6E-214
GLOW RELAY CIRCUIT VOLTAGE LOW
6E-217
GLOW RELAY CIRCUIT VOLTAGE HIGH 6E-217
6E-217
Diagnostic Aids ..........................................
6E-217
Glow Relay Circuit Voltage Low ..............
6E-218
(Symptom Code 8) (Flash Code 66) Glow
Relay Circuit Voltage High .......................
6E-221
(SUB CODE 4) (FLASH CODE 67) GLOW PLUG
INDICATOR CIRCUIT VOLTAGE LOW ..
6E-222
(SUB CODE 8) (FLASH CODE 67) GLOW PLUG
INDICATOR CIRCUIT VOLTAGE HIGH .
6E-222
6E-222
Diagnostic Aids ..........................................
6E-222
Plug Indicator Circuit Voltage Low ...........
6E-222
Plug Indicator Circuit Voltage High ..........
6E-226
EXHAUST GAS RECIRCULATION FLOW
EXCESSIVE DETECTED ........................
6E-227
EXHAUST GAS RECIRCULATION CIRCUIT
SHORT TO GROUND OR OPEN CIRCUIT 6E-227
EXHAUST GAS RECIRCULATION FLOW
INSUFFICIENT DETECTED ....................
6E-227

EXHAUST GAS RECIRCULATION CIRCUIT
SHORT TO BATTERY ............................
6E-227
6E-228
Diagnostic Aids ..........................................
6E-228
(Symptom Code 3) (Flash Code 32) Exhaust
Gas Recirculation Flow Excessive Detected 6E-228
Gas Recirculation Circuit Short to Ground or
Open Circuit .............................................
6E-232
Gas Recirculation Flow Insufficient Detected 6E-235
Gas Recirculation Circuit Short to Battery
6E-238
VEHICLE SPEED SENSOR CIRCUIT HIGH
INPUT ......................................................
6E-240
VEHICLE SPEED SENSOR INPUT SIGNAL
FREQUENCY TOO HIGH .......................
6E-240
VEHICLE SPEED SENSOR INCORRECT
SIGNAL ...................................................
6E-240
6E-241
Diagnostic Aids ..........................................
6E-241
(Symptom Code 1) (Flash Code 24) Vehicle
Speed Sensor Circuit High Input .............
6E-241
Vehicle Speed Sensor Input Signal
Frequency Too High ................................
6E-245
VehicleSpeed Sensor Incorrect Signal ....
6E-248
SYSTEM VOLTAGE TOO HIGH .............
6E-253
SYSTEM VOLTAGE TOO LOW ..............
6E-253
SYSTEM VOLTAGE MALFUNCTION .....
6E-253
6E-253
6E5
Diagnostic Aids ..........................................

6E-254
System Voltage Too High ........................
6E-254
System Voltage Too Low .........................
6E-256
System Voltage Malfunction ....................
6E-258
IGNITION SWITCH CIRCUIT
MALFUNCTION .......................................
6E-260
IGNITION SWITCH CIRCUIT
MALFUNCTION .......................................
6E-260
6E-261
Diagnostic Aids ..........................................
6E-261
Ignition Switch Circuit Malfunction ...........
6E-261
Ignition Switch Circuit Malfunction ...........
6E-261
CONTROL MODULE PROGRAMMING
ERROR ....................................................
6E-264
Circuit Description & Diagnostic Aids ........
6E-264
Control Module Programming Error .........
6E-264
ECU MALFUNCTION ..............................
6E-265
ECU MALFUNCTION ..............................
6E-265
6E-265
ECU Malfunction ......................................
6E-265
ECU Malfunction ......................................
6E-267
A/C COMPRESSOR RELAY CIRCUIT
VOLTAGE LOW ......................................
6E-268
A/C COMPRESSOR RELAY CIRCUIT
VOLTAGE HIGH ......................................
6E-268
6E6

6E-268
Diagnostic Aids ..........................................
6E-268
(Symptom Code 4) (Flash Code 46) A/C
Compressor Relay Circuit Voltage Low ...
6E-269
(Symptom Code 8) (Flash Code 46) A/C
Compressor Relay Circuit Voltage High ..
6E-272
BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273
BRAKE SWITCH CIRCUIT MALFUNCTION 6E-273
6E-274
Diagnostic Aids ..........................................
6E-274
(Symptom Code A) (Flash Code 25) Brake
Switch Circuit Malfunction .......................
6E-274
Brake Switch Circuit Malfunction .............
6E-278
CLUTCH SWITCH INPUT CIRCUIT
MALFUNCTION .......................................
6E-281
6E-281
Diagnostic Aids ..........................................
6E-281
Clutch Switch Input Circuit Malfunction ...
6E-282
BAROMETRIC PRESSURE SENSOR
6E-285
BAROMETRIC PRESSURE SENSOR
6E-285
6E-285
Diagnostic Aids ..........................................
6E-285
(Symptom Code 1) (Flash Code 86) Barometric
Pressure Sensor Circuit High Input .........
6E-285
(Symptom Code 2) (Flash Code 86) Barometric
Pressure Sensor Circuit Low Input ..........
6E-285
PEDAL/THROTTLE POSITION SENSOR
6E-287

VOLTAGE SUPPLY CIRCUIT HIGH INPUT 6E-287
VOLTAGE SUPPLY CIRCUIT LOW INPUT 6E-287
BRAKE SWITCH ERROR .......................
6E-287
IDLE POSITION SWITCH ERROR .........
6E-287
6E-288
Diagnostic Aids ..........................................
6E-288
Pedal/Throttle Position Sensor
Circuit High Input .....................................
6E-288
Pedal/Throttle Position Sensor Voltage
Supply Circuit High Input .........................
6E-293
Pedal/Throttle Position Sensor Voltage
Supply Circuit Low Input ..........................
6E-295
Pedal/Throttle Position Sensor Brake
Switch Error .............................................
6E-298
Pedal/Throttle Position Sensor Idle
Position Switch Error ...............................
6E-300
(SYMPTOM CODE 3) (FLASH CODE 22) FUEL
REDUCTION CAUSED BY HIGH COOLANT
TEMPERATURE ......................................
6E-302
(SYMPTOM CODE 7) (FLASH CODE 22) FUEL
REDUCTION CAUSED BY HIGH FUEL
TEMPERATURE ......................................
6E-302
(SYMPTOM CODE A) (FLASH CODE 22) FUEL
REDUCTION CAUSED BY LOW FUEL
TEMPERATURE ......................................
6E-302
6E-302
Diagnostic Aids ..........................................
6E-302
(Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant

Temperature ............................................
6E-302
(Symptom Code 7) (Flash Code 22) Fuel
Reduction Caused By High Fuel
Temperature ............................................
6E-305
Reduction Caused By Low Fuel
Temperature ............................................
6E-305
(SYMPTOM CODE A)
(FLASH CODE 43) ENGINE SPEED OUTPUT
CIRCUIT MALFUNCTION .......................
6E-306
6E-306
Diagnostic Aids ..........................................
6E-306
Engine Speed Output Circuit Malfunction
6E-307
CAMSHAFT SPEED MALFUNCTION .....
6E-311
6E-311
Diagnostic Aids ..........................................
6E-311
Camshaft Speed Malfunction ..................
6E-312
NEUTRAL SWITCH ON ERROR ............
6E-313
NEUTRAL SWITCH OFF ERROR ..........
6E-313
6E-313
Diagnostic Aids ..........................................
6E-313
Neutral Switch ON Error ..........................
6E-314
Neutral Switch OFF Error ........................
6E-314
SEED AND KEY FILE DESTROYED ......
6E-318
EEPROM DEFECT ..................................
6E-318
EEPROM DEFECT ..................................
6E-318
6E-318
(Symptom Code C) (Flash Code 55)
Seed and Key File Destroyed ..................
6E-318
6E7

EEPROM Defect ......................................
6E-318
EEPROM Defect ......................................
6E-318
SECURITY KEY AND SECURITY CODE NOT
PROGRAMMED ......................................
6E-320
6E-320
Diagnostic Aids ..........................................
6E-320
(Symptom Code A) (Flash Code 56) Security
Key and Security Code Not Programmed
6E-320
WRONG SECURITY CODE ENTERED ..
6E-322
6E-322
Diagnostic Aids ..........................................
6E-322
Wrong Security Code Entered .................
6E-323
IMMOBILIZER NO OR WRONG SIGNAL
6E-324
6E-324
Diagnostic Aids ..........................................
6E-324
Immobilizer No or Wrong Signal ..............
6E-325
IMMOBILIZER NO OR WRONG SIGNAL
6E-330
6E-330
Diagnostic Aids ..........................................
6E-330
Immobilizer No or Wrong Signal ..............
6E-331
WRONG TRANSPONDER KEY ..............
6E-335
6E-335
Diagnostic Aids ..........................................
6E-335
Wrong Transponder Key ..........................
6E-336
(SYMPTOM CODE A) (FLASH CODE 76) ECM
MAIN RELAY SWITCHED OFF
TOO EARLY ............................................
6E-337
6E8
(SYMPTOM CODE B) (FLASH CODE 76) ECM

MAIN RELAY SWITCHED OFF TOO LATE 6E-337
6E-337
Diagnostic Aids ..........................................
6E-337
(Symptom Code A) (Flash Code 76) ECM
Main Relay Switched Off Too Early .........
6E-338
(Symptom Code B) (Flash Code 76) ECM
Main Relay Switched Off Too Late ..........
6E-339
FUEL INJECTION QUANTITY CIRCUIT
MALFUNCTION .......................................
6E-340
FUEL INJECTION QUANTITY CIRCUIT
MALFUNCTION .......................................
6E-340
6E-340
Diagnostic Aids ..........................................
6E-341
Injection Quantity Circuit Malfunction ......
6E-341
Injection Quantity Circuit Malfunction ......
6E-341
(SYMPTOM CODE A)
(FLASH CODE 44) CAN DEVICE OFFLINE 6E-342
CAN DEVICE HANG-UP .........................
6E-342
6E-342
Diagnostic Aids ..........................................
6E-342
CAN Device Offline ..................................
6E-343
CAN Device Hang-up ..............................
6E-348
CAN MALFUNCTION ..............................
6E-349
CAN RECEIVES ERROR ........................
6E-349
6E-349
Diagnostic Aids ..........................................
6E-349
CAN Malfunction ......................................
6E-350
CAN Receives Error ................................

6E-351
CHECK ENGINE LAMP (MIL) CIRCUIT
VOLTAGE LOW ......................................
6E-356
CHECK ENGINE LAMP (MIL) CIRCUIT
VOLTAGE HIGH ......................................
6E-356
6E-356
Diagnostic Aids ..........................................
6E-356
(Symptom Code 4) (Flash Code 77) Check
Engine Lamp (MIL) Circuit Voltage Low ..
6E-357
(Symptom Code 8) (Flash Code 77) Check
Engine Lamp (MIL) Circuit Voltage High .
6E-360
SYMPTOM DIAGNOSIS ............................
6E-361
PRELIMINARY CHECKS ..........................
6E-361
VISUAL/PHYSICAL CHECK ......................
6E-361
INTERMITTENT ........................................
6E-361
ENGINE CRANKS BUT WILL NOT RUN ..
6E-362
HARD START SYMPTOM .........................
6E-366
ROUGH, UNSTABLE, OR INCORRECT
IDLE, STALLING SYMPTOM ..................
6E-370
SURGES AND/OR CHUGS SYMPTOM ...
6E-377
HESITATION, SAG, STUMBLE SYMPTOM 6E-383
CUTS OUT, MISSES SYMPTOM ..............
6E-389
LACK OF POWER, SLUGGISH OR
SPONGY SYMPTOM ..............................
6E-396
POOR FUEL ECONOMY SYMPTOM .......
6E-402
EXCESSIVE WHITE SMOKE ....................
6E-407
EXCESSIVE BLACK SMOKE ....................
6E-413
ON-VEHICLE SERVICE PROCEDURE ....
6E-418
ENGINE CONTROL MODULE (ECM) ...
6E-418
CRANKSHAFT POSITION (CKP) SENSOR 6E-419
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR .......................................
6E-419
MASS AIR FLOW (MAF) & INTAKE AIR
TEMPERATURE (IAT) SENSOR ............
6E-420
THROTTLE POSITION SENSOR (TPS) ...
6E-420
EGR EVRV
(Electrical Vacuum Regulating Valve) .....
6E-421
ABBREVIATION CHARTS
Abbreviations
Appellation
A/C
Air conditioner
A/T
ACC
Accessory
BLK
Black
BLU
Blue
BRN
Brown
CAN
Controller Area Network
CEL
Check engine lamp
CKP
Crankshaft position sensor
DLC
Data link connector
DTC
Diagnosis trouble code
DVM
Digital voltage meter
ECM
Engine control module
ECT
Engine coolant temperature
EEPROM
Electrically erasable & programmable read only memory
EGR
Exhaust gas recirculation
EVRV
Electric vacuum regulating valve
GND
Ground
GRY
Gray
IAT
Intake air temperature
IG
Ignition
M/T
Manual transmission
MAB
High pressure solenoid valve cutoff (German abbreviation)
MAF
Mass air flow
MIL
Malfunction indicator lamp
OBD
On-board diagnostic
ORN
Orange
PNK
Pink
RED
Red
PSG
Pump control unit (German abbreviation)
SW
Switch
TCM
Transmission control module
TCV
Timing control valve
TDC
Top dead center
TPS
Throttle position sensor
VCC
Voltage constunt control
VIO
Violet
VSS
Vehicle speed sensor
WHT
White
YEL
Yellow
6E9
6E10
COMPONENT LOCATOR
Engine Component Locator Table
4JA1-TC
(1) Mass Air Flow (MAF) & Intake Air Temperature

(IAT) Sensor Assembly
(2) Throttle Cable
(3) Air Cleaner Case
(4) Battery
(5) Relay & Fuse Box
(6) EGR Cooler
6E11
4JH1-TC
4
3

(2) Throttle Cable
5
4
(4) Battery
(6) EGR Cooler (Euro3) / EGR Pipe (Except Euro3)
6E12
(1) Throttle Position Sensor (TPS)

(2) Pump Control Unit (PSG)

(2) EGR EVRV
(3) Injection Pump Assembly

(4) Fuel Filter (Except Euro 3)
(1) Engine Control Module (ECM)
(1) EGR EVRV

(2) To Vacuum Pump
(3) To EGR Valve
(1) Engine Coolant Temperature (ECT) Sensor

(2) Thermo Unit for Water Temperature Gauge
(1) Crankshaft Position (CKP) Sensor

(2) Clutch Housing
(1) Vehicle Speed Sensor (VSS)
6E13
6E14
ECM CIRCUIT DIAGRAM (4JA1-TC)

ECM CIRCUIT DIAGRAM (4JA1-TC)
6E15
6E16
ECM CIRCUIT DIAGRAM (4JH1-TC)

ECM CIRCUIT DIAGRAM (4JH1-TC)
6E17
6E18
GROUND POINT CHART GENERAL EXPORT (LHD) (1/4)

6E19
6E20

6E21
6E22
GROUND POINT CHART EUROPE (LHD) (1/4)

6E23
6E24

6E25
6E26
GROUND POINT CHART GENERAL EXPORT (RHD) (1/4)

6E27
6E28

6E29
6E30
GROUND POINT CHART EUROPE (RHD) (1/4)

6E31
6E32

6E33
6E34
LOCATION

CABEL HARNESS & CONNECTOR LOCATION
6E35
6E36
4JA1-TC & 4JH1-TC ENGINE (LHD)

4JA1-TC & 4JH1-TC ENGINE (RHD)
6E37
6E38

PARTS LOCATION
6E39
6E40
CONNECTOR LIST
No.
Connector face
B-24
Green
Meter-B
J/B I2
J/B I4
Check connector
Ignition switch (IGSUB : G1)
C-2
TCM
White
J/B E2
White
J/B E1
C-109
Engine room-RH ground
C-36
Silver
Body-LH ; ground
C-115
Engine room-LH ; Ground
C-44
White
White
C-108
Immobilizer
Silver
TCM
C-107
B-68
Silver
White
C-95
B-63
White
Clutch switch
C-94
B-62
White
ECM-B
C-77
B-58
Black
ECM-A
C-57
B-56
White
Connector face
C-56
B-54
White
No.
Brown
C-116
Stop lamp switch
EVRV
No.
Connector face
C-118
No.
E-23
A/C Resister & Neutral switch

C-123
Gray
C-124
E-3
Magnetic clutch AC COMP
Gray
E-9
Inhibiter switch
H-4
White
E-10
Engine room ~ Mission
H-6
Engine ground
White
Engine room ~ INST
H-7
E-11
Neutral switch
White
Engine room ~ INST
H-18
E-12
Neutral switch
E-22
Brown
Glow plug
E-51
Black
Natural
green
E-49
E-6
Natural
green
Coolant temp sensor
E-44
Gray
Silver
Idle SW
E-41
Black
Black
Connector face
White
Engine room ~ INST
H-22
TPS 1 main
White
Engine ~ Engine room C
6E41
6E42
No.
Connector face
H-33
P-1
Battery (+)
Relay & Fuse box
P-5
Silver
Battery (-)
P-6
Silver
Body earth (Ground)
P-10
Silver
Engine ground
X-5
Black
Relay ; Glow
X-13
Black
Relay ; ECM MAIN
X-14
Black
Relay; A/C Compressor
X-15
Black
Black
DIODE
X-17
P-2
Silver
Connector face
X-16
Engine ~ Engine room
Silver
No.
Relay; Thermo
Black
DIODE

RELAY AND FUSE
RELAY AND FUSE BOX LOCATION (LHD & RHD)
LHD
RHD
6E43
6E44

RELAY & FUSE BOX
RELAY
No.
X-1
X-2
X-3
X-4
X-5
X-6
X-7
X-8
X-9
X-10
X-11
X-12
X-13
X-14
X-15
RELAY
(4JA1-TC/4JH1-TC)
RELAY; TAIL LIGHT
RELAY; FRT FOG LIGHT
RELAY; HORN
RELAY; DIMMER
RELAY; GLOW
RELAY; COND, FAN
RELAY; RR FOG
RELAY; STARTER
SHORT CONNECTOR
(with Cooler) (LHD)
RELAY; HAZARD-RH (RHD)
SHORT CONNECTOR
(with Cooler) (LHD)
RELAY; HAZARD-LH (RHD)
RELAY; HEATER
RELAY; HEAD LIGHT
RELAY; ECM MAIN
RELAY; A/C COMP
RELAY; THERMO
FUSE
FUSE
(4JA1-TC/4JH1-TC)
NO.
EB-1
EB-2
EB-3
EB-4
EB-5
EB-6
EB-7
EB-8
EB-9
EB-10
EB-11
EB-12
EB-13
EB-14
EB-15
EB-16
10A ECM
10A RR FOG
15A FRT FOG
10A ILLUMI & TAIL-RH

10A TAIL-LH
10A H/LIGHT RH-LOW
10A H/LIGHT LH-LOW
10A TRA ILER
10A AC G (S)
10A H/LIGHT RH-HIGH
10A H/LIGHT LH-HIGH
10A A/C
10A 4WD
10A HORN
10A HAZARD
SLOW BLOW FUSE

NO.
SBF-1
SBF-2
SBF-3
SBF-4
SBF-5
SBF-6
SBF-7
SBF-8
SBF-9
SLOW BLOW FUSE

4JA1-TC/4JH1-TC
80A MAIN
20A COND, FAN
50A GLOW
30A ECM
40A IG 1
40A ABS-1
30A ABS-2
30A BLOWER
50A IG 2

FUSE AND RELAY LOCATION (LHD & RHD)
FUSE BOX
FUSE
No.
1
2
3
4
5
6
7
8
9
10
11
Capacity
10A
15A
15A
10A
15A
15A
20A
15A
10A
Indication on label
ABS
BACK UP
METER
TURN
ELEC.IG
ENGINE
FRT WIPER
EGR
AUDIO
SLOW BLOW FUSE

No.
Capacity
SBF-10
20A
SBF-11
30A
Indication on label
RR DEF
POWER WINDOW
RELAY
Connector No.
4JA1-TC, 4JH1-TC
B-7
B-8
REAR
POWER
DEFOGGER WINDOW
No.
12
13
14
15
16
17
18
19
20
21
Capacity
15A
15A
20A
10A
10A
10A
15A
15A
10A
10A
B-40
ACC
SOCKET
Indication on label
CIGER
AUDIO (+B)
DOOR LOCK
METER (+B)
ROOM
ANTI THEFT
STOP
ACC SOCKET
STARTER
SRS
6E45
6E46
ECM WIRING DIAGRAM (1/7)

6E47
6E48

6E49
6E50

6E51
6E52
6E53
ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

4JA1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL
View Looking Into ECM Case
Signal or Continuity
Tester Position
Pin
No.
B/Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM
Connection
Range
(+)
(-)
ECM Ground
BLK
Continuity
with
ground
Disconnect
Ohm
GND
ECM Ground
BLK
Continuity
with
ground
Disconnect
Ohm
GND
Battery Power Supply
BLU/
RED
Less than
1V
Connect
DC V
GND
25
25
No Connection
26
26
No Connection
27
27
Engine Speed Output

(To Tacho Meter)
LGN
Approx.
23Hz by
wave form
or approx.
6.3V
Approx.
67Hz by
wave form
or approx.
6.8V
Connect
AC V
27
GND
28
28
No Connection
29
29
No Connection
30
30
Brake Switch 1 Signal
GRN
Less than
1V
31
31
Clutch Switch Signal

(MT Only)
YEL
Less than
1V
32
32
No Connection
33
33
A/C ON Signal Relay
GRN/
YEL
Less than
1V
10-14V
Pedal is not stepped on: Less than 1V

Pedal is stepped on: 10-14V
Pedal is not stepped on: 10-14V
Pedal is stepped on: Less than 1V
-
A/C request switch is turned on: 1014V

A/C request switch is turned off: Less
than 1V
Connect
DC V
30
GND
Connect
DC V
31
GND
Connect
DC V
33
GND
34
34
No Connection
35
35
To Data Link Connector No. 6 & Immobilizer Control Unit (ICU

B8)
YEL
36
36
No Connection
37
37
No Connection
38
38
Throttle Position Sensor (TPS) Output Signal
GRN/
ORG
Less than
1V
39
39
Key Switch Input Signal Via Engine Fuse
WHT
Less than
1V
40
40
No Connection
Less than 1V
Approx.
0.5V
Connect
DC V
38
49
Connect
DC V
39
GND
10-14V
-
6E54

Pin
No.
B/Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
2000rpm
ECM
Connection
Range
(+)
(-)
41
41
A/C Compressor
Relay
WHT/
GRN
Less than
1V
10-14V
A/C comp. is operated:

Less than 1V
A/C comp. is not operated: 10 - 14V
Connect
DC V
41
GND
42
42
Check Engine Lamp
GRN/
YEL
Less than
1V
Lamp is turned on: Less than 1V

Lamp is turned off: 10-14V
Connect
DC V
42
GND
43
43
Glow Lamp
ORG/
BLU
Less than
1V

Connect
DC V
43
GND
44
44
No Connection
45
45
To Data Link Connector No. 6
BLU
Less than
1V
Connect
DC V
45
GND
46
46
No Connection
47
47
No Connection
Engine
Idle
Tester Position
10-14V
48
48
No Connection
49
49
Throttle Position Sensor (TPS) Ground
BLK/
GRN
Idle:
Approx.
0.4K ohm /
WOT:
Approx.
4.0K ohm
Disconnect
Ohm
38
49
50
50
No Connection
51
51
No Connection
52
52
No Connection
53
53
No Connection
54
54
No Connection
55
55
No Connection
56
56
No Connection
57
57
Throttle Position Sensor (TPS) Power Supply
RED/
GRN
Less than
1V
Approx. 5V
Connect
DC V
57
49
58
58
ECM Relay
BLU/
BLK
10-14V
Less than 1V
Connect
DC V
58
GND
59
59
No Connection
60
60
No Connection
61
61
No Connection
DC V
63
GND
Connect
DC V
65
GND
62
62
No Connection
63
63
ECM Power Supply
64
64
No Connection
65
65
WHT/
BLK
Less than
1V
66
66
No Connection
67
67
No Connection
68
68
Vehicle Speed Sensor (VSS)
YEL/
GRN
Approx. 14.5Hz by wave form or

approx. 6.0V at vehicle speed 20km/h
Connect
AC V
68
GND
69
69
Idle Switch
GRN/
BLK
Less than
1V
Pedal is not stepped on: Less than 1V

Pedal is stepped on: Approx. 5V
Connect
DC V
69
GND
70
70
No Connection
71
71
No Connection
72
72
No Connection
73
73
No Connection
74
74
No Connection
Less than
1V
10-14V
-


6E55
Tester Position
Pin
No.
B/Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM
Connection
Range
(+)
(-)
75
75
No Connection
76
76
No Connection
77
77
No Connection
78
78
No Connection
79
79
No Connection
80
80
No Connection
81
81
No Connection
82
82
No Connection
83
83
Mass Air Flow (MAF)

Sensor Power Supply
WHT/
RED
Less than
1V
Approx. 5V
Connect
DC V
83
92
84
84
Intake Air Temperature (IAT) Sensor Signal
BLK/
BLU
Less than
1V
0 deg. C: Approx. 3.6V / 20 deg. C:

Approx. 2.6V / 40 deg. C: Approx.
1.7V / 60 deg. C: 1.1V / 80 deg. C:
0.7V
Connect
DC V
84
92
85
85
No Connection
86
86
No Connection
87
87
Neutral Switch
BLK/
WHT
Less than
1V
88
88
Mass Air Flow (MAF)

Sensor Signal
GRN/
RED
Less than
1V
89
89
Engine Coolant Temperature (ECT) Sensor Signal
GRY
Less than
1V
90
90
CKP Sensor Signal
RED
Approx.
47Hz by
wave form
91
91
CKP Sensor Output

To Pump Control Unit
(PSG) No.8
PNK
92
92
Mass Air Flow (MAF)

Sensor Ground
BLK/
RED
Continuity
with
ground
93
93
Engine Coolant Temperature (ECT) Sensor Ground
BLK/
PNK
Continuity
with
ground
94
94
Glow Relay
BLK/
RED
Less than
1V
95
95
No Connection
96
96
No Connection
97
97
EGR EVRV
BLK/
ORG
98
98
CKP Sensor Ground
WHT
Continuity
with
ground
99
99
CAN (Controller Area

Network) to PSG No.1
BLU
100
100

Network) to PSG No.2
YEL
Connect
DC V
87
GND
Approx.
2.5V
Connect
DC V
88
92

2.9V / 60 deg. C: 2.1V / 80 deg. C:
1.4V
Connect
DC V
89
93
Approx.
134Hz by
wave form
or approx.
1.1V
Connect
AC V
90
98
Approx.
47Hz by
wave form
Approx.
134Hz by
wave form
or approx.
0.7V
Connect
AC V
91
GND
Connect
Ohm
92
GND
Connect
Ohm
93
GND
Connect
DC V
94
GND
Connect
Ohm
98
GND
In neutral: Less than 1V

Other than neutral: 10-14V
Approx. 1V
Approx.
1.8V
Glow system is operated: Less than

1V
Glow system is not operated: 10 - 14V
Approx. 140Hz by wave

form when EVRV is
operated
6E56

Tester Position
Pin
No.
B/Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM
Connection
Range
(+)
(-)
101
101
CKP Sensor Shield

Line
BLK
Continuity
with
ground
Connect
Ohm
101
GND
102
102
No Connection
103
103
No Connection
104
104
No Connection
105
105
Solenoid Valve Shut

Off (MAB) Output Signal to PSG No.5
ORG
6E57
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

View Looking Into PSG Case
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM &
PSG Connection
Rang
e
(+)
(-)
99

Network) to ECM
No.99
RED
Continuity
between
ECM &
PSG
Disconnect
Ohm
99
(EC
M)
100

Network) to ECM
No.100
WHT
Continuity
between
ECM &
PSG
Disconnect
Ohm
100
(EC
M)
No Connection
No Connection
105
Solenoid Valve Shut

Off (MAB) Output
Signal to ECM
No.105
ORG
Continuity
between
ECM &
PSG
Disconnect
Ohm
105
(EC
M)
Ground
BLK
Continuity with
ground
Disconnect
Ohm
GND
BLU/
RED
Less
than 1V
Disconnect
Ohm
GND
91
CKP Sensor Output

ECM No.91 to Pump
Control Unit (PSG)
PNK
Continuity
between
ECM &
PSG
Disconnect
Ohm
91
(EC
M)
No Connection
10-14V
6E58
4JH1-TC ECM CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

View Looking Into ECM Case
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM
Connection
Ran
ge
(+)
(-)
ECM Ground
BLK
Continuity with
ground
Disconnect
Ohm
GND
ECM Ground
BLK
Continuity with
ground
Disconnect
Ohm
GND
BLU/
RED
Less
than 1V
Connect
DC V
GND
25
25
No Connection
26
26
No Connection
27
27
Engine Speed Output

(To Tacho Meter)
LGN
Approx.
23Hz by
wave
form or
approx.
6.3V
Approx.
67Hz by
wave
form or
approx.
6.8V
Connect
AC V
27
GND
28
28
No Connection
29
29
Throttle Position Signal To TCM (A16)

(AT Only)
30
30
31
31
32
10-14V
Approx. 140Hz by wave form (Idle:

Off duty 10% / WOT: Off duty 90%)
GRN
Less
than 1V
Pedal is not stepped on: Less than

1V
Pedal is stepped on: 10-14V
Connect
DC V
30
GND
Clutch Switch Signal

(MT Only)
YEL
Less
than 1V

Connect
DC V
31
GND
32
No Connection
33
33
A/C ON Signal Relay
GRN/
YEL
Less
than 1V
Connect
DC V
33
GND
34
34
No Connection
35
35
To Data Link Connector No. 6 & Immobilizer Control Unit

(ICU B8)
YEL
36
36
No Connection
A/C request switch is turned on: 1014V

A/C request switch is turned off:
Less than 1V

6E59
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
ECM
Connection
Ran
ge
(+)
(-)
37
37
No Connection
38
38
Throttle Position
Sensor (TPS) Output Signal
GRN/
ORG
Less
than 1V
Approx.
0.5V
Connect
DC V
38
49
39
39
Key Switch Input Signal Via Engine Fuse
WHT
Less
than 1V
Connect
DC V
39
GND
40
40
No Connection
41
41
A/C Compressor
Relay
WHT/
GRN
Less
than 1V
10-14V
Connect
DC V
41
GND
42
42
Check Engine Lamp
GRN/
YEL
Less
than 1V

Connect
DC V
42
GND
43
43
Glow Lamp
ORG/
BLU
Less
than 1V

Connect
DC V
43
GND
44
44
No Connection
45
45
To Data Link Connector No. 6
BLU
Less
than 1V
Connect
DC V
45
GND
46
46
No Connection
47
47
No Connection
48
48
No Connection
49
49
Throttle Position
Sensor (TPS)
Ground
BLK/
GRN
Idle:
Approx.
0.4K
ohm /
WOT:
Approx.
4.0K
ohm
Disconnect
Ohm
38
49
50
50
No Connection
51
51
No Connection
52
52
No Connection
53
53
No Connection
54
54
No Connection
55
55
No Connection
56
56
No Connection
57
57
Throttle Position
Sensor (TPS) Power
Supply
RED/
GRN
Less
than 1V
Approx. 5V
Connect
DC V
57
49
58
58
ECM Relay
BLU/
BLK
10-14V
Less than 1V
Connect
DC V
58
GND
59
59
No Connection
60
60
No Connection
61
61
No Connection
62
62
No Connection
Less than 1V
10-14V
A/C comp. is operated: Less than 1V

A/C comp. is not operated: 10 - 14V
10-14V
6E60

Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
63
63
ECM Power Supply
Less
than 1V
10-14V
64
64
No Connection
65
65
WHT/
BLK
Less
than 1V
66
66
No Connection
67
67
No Connection
68
68
YEL/
GRN
69
69
Idle Switch
GRN/
BLK
Less
than 1V
70
70
No Connection
71
71
No Connection
72
72
No Connection
73
73
No Connection
74
74
No Connection
75
75
76
Tester Position
ECM
Connection
Ran
ge
(+)
(-)
DC V
63
GND
Connect
DC V
65
GND
Approx. 14.5Hz by wave form or

approx. 6.0V at vehicle speed
20km/h
Connect
AC V
68
GND
Pedal is not stepped on: Less than

1V
Pedal is stepped on: Approx. 5V
Connect
DC V
69
GND
No Connection
76
No Connection
77
77
No Connection
78
78
No Connection
79
79
No Connection
80
80
No Connection
81
81
No Connection
82
82
Boost Pressure Sensor (High Altitude

Spec. Only)
WHT/
BLU
Less
than 1V
Approx. 5V
Connect
DC V
82
93
83
83
Mass Air Flow (MAF)

Sensor Power Supply
WHT/
RED
Less
than 1V
Approx. 5V
Connect
DC V
83
92
84
84
Intake Air Temperature (IAT) Sensor

Signal
BLK/
BLU
Less
than 1V

1.7V / 60 deg. C: 1.1V / 80 deg. C:
0.7V
Connect
DC V
84
92
85
85
Manifold Pressure
Sensor (High Altitude Spec. Only)
RED/
BLU
Less
than 1V
Connect
DC V
85
93
86
86
No Connection
87
87
Neutral Switch
BLK/
WHT
Less
than 1V
In neutral (A/T: P or N): Less than

1V
Other than neutral (A/T: other than
P or N): 10-14V
Connect
DC V
87
GND
88
88
Mass Air Flow (MAF)

Sensor Signal
GRN/
RED
Less
than 1V
Approx.
1V
Connect
DC V
88
92
Engine
2000rpm

Approx.
1.8V
Approx.
2.5V

Engine
Idle
6E61
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
2000rpm
ECM
Connection
Ran
ge
(+)
(-)
89
89
Engine Coolant Temperature (ECT) Sensor Signal
GRY
Less
than 1V

2.9V / 60 deg. C: 2.1V / 80 deg. C:
1.4V
Connect
DC V
89
93
90
90
CKP Sensor Signal
RED
Approx.
47Hz by
wave
form
Approx.
134Hz by
wave
form or
approx.
1.1V
Connect
AC V
90
98
91
91
CKP Sensor Output

To Pump Control Unit
(PSG) No.8
PNK
Approx.
47Hz by
wave
form
Approx.
134Hz by
wave
form or
approx.
0.7V
Connect
AC V
91
GND
92
92
Mass Air Flow (MAF)

Sensor Ground
BLK/
RED
Continuity with
ground
Connect
Ohm
92
GND
93
93
Engine Coolant Temperature (ECT) Sensor & Manifold

Pressure Sensor
Ground
BLK/
PNK
Continuity with
ground
Connect
Ohm
93
GND
94
94
Glow Relay
BLK/
RED
Less
than 1V
Connect
DC V
94
GND
95
95
No Connection
96
96
Turbocharger Wastegate Control EVRV
BRW/
RED
Wave form
97
97
EGR EVRV
BLK/
ORG
Approx. 140Hz by
wave form when
EVRV is operated
98
98
CKP Sensor Ground
WHT
Continuity with
ground
Connect
Ohm
98
GND
99
99

Network) to PSG
No.1
BLU
100
100

Network) to PSG
No.2
YEL
101
101
CKP Sensor Shield

Line
BLK
Continuity with
ground
Connect
Ohm
101
GND
102
102
No Connection
103
103
No Connection
104
104
No Connection
105
105
Solenoid Valve Shut

Off (MAB) Output
Signal to PSG No.5
ORG
Glow system is operated: Less than

1V
Glow system is not operated: 10 14V
-
6E62
PSG CONNECTOR PIN ASSIGNMENT & OUTPUT SIGNAL

View Looking Into PSG Case
Tester Position
Pin
No.
B/
Box
No.
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rp
m
ECM &
PSG Connection
Rang
e
(+)
(-)
99

Network) to ECM
No.99
RED
Continuity
between
ECM &
PSG
Disconnect
Ohm
99
(ECM
)
100

Network) to ECM
No.100
WHT
Continuity
between
ECM &
PSG
Disconnect
Ohm
100
(ECM
)
No Connection
No Connection
105
Solenoid Valve Shut

Off (MAB) Output
Signal to ECM
No.105
ORG
Continuity
between
ECM &
PSG
Disconnect
Ohm
105
(ECM
)
Ground
BLK
Continuity with
ground
Disconnect
Ohm
GND
BLU/
RED
Less
than 1V
Disconnect
Ohm
GND
91
CKP Sensor Output

ECM No.91 to Pump
Control Unit (PSG)
PNK
Continuity
between
ECM &
PSG
Disconnect
Ohm
91
(ECM
)
No Connection
10-14V

Crankshaft Position (CKP) Sensor Reference Wave Form
6E63
Crankshaft Position (CKP) Sensor & TDC Output Signal

Reference Wave Form
CH1
0V
0V
CH2
0V
Measurement Terminal: 90(+)

98(-)
Measurement Scale: 20V/div
2ms/div
Measurement Condition: Approximately 2000rpm
Measurement Terminal: CH1: 90(+) / CH2: 91(+) GND(-)

Measurement Scale: CH1: 50V/div / CH2: 10V/div
1ms/div
Engine Speed Output Signal Reference Wave Form
Vehicle Speed Sensor (VSS) Reference Wave Form
0V
0V

GND(-)
10ms/div

GND(-)
50ms/div
Measurement Condition: Approximately 20km/h
6E64

SENSORS
management system.
Engine Control Module (ECM)
Pump Control Unit (PSG) = Pumpen Steuer Great

(German)
The engine control module (ECM) is located flower

panel just under the passenger's seat.
The fuel quantity and injection timing related functions
are controlled by the pump control unit (PSG).
The engine control module (ECM) performs the
following functions.
The pump control unit (PSG) receives signals from the

sensors inside the pump to determine the cam ring
rotation angle, the pump speed and the fuel
temperature .
These values are then compared to the desired values
sent by the engine control module (ECM) such as the
desired injection timing and the desired fuel injection
quantity.
The engine control module (ECM) processes all engine
data and data regarding the surrounding environment
received from external sensors to perform any engine
side adjustments.
Maps for both are encoded in both control units. The
control units input circuit process sensor data.
A Microprocessor then determines the operating
conditions and calculates set values for optimum
running.
The interchange of data between the engine control
module (ECM) and the pump control unit (PSG) is
perfumed via a CAN-bus system. The abbreviation CAN
stands for Controller Area Network. By having two
separate control modules, the high pressure solenoid
valve. This prevents the discharge of any disturbing
signals.
Control of the exhaust gas re-circulation (EGR)

Control of the quick on start (QOS) glow control
system
Control of the A/C compressor
Execution of the immobilizer function
Self Diagnosis / Interface / Signal

To High Pressure Solenoid
Accelerator Pedal
Engine
Control
Module
(ECM)
Cam Ring Rotational Angle

Fuel Temperature
Injection Timing
Injection Quantity
Intake Air Temperature
Response Signal
High Pressure
Solenoid Valve
Pump
Control
Unit
(PSG)
Fuel Injection
(Mechanical)
Mass Air Flow

Additional Signal
Timing Device
Others
Additional Operations
Via analogue signal leads

Via the CAN-bus
Pump Control Unit (PSG) & Data Exchange

Between Control Module
Engine Speed
The information exchange between the two control

modules takes place via two means.
To Timing Control Valve (TCV)
The radial plunger distributor type injection pump uses

two control modules to execute full control of the engine
The analogue signal leads are used to exchange the

following information.
Engine speed signal (ECM terminal 91)
Pump Speed (ECM terminal 105)
Fuel Cutoff solenoid valve signal (MAB signal) (ECM
terminal 105)
The engine speed signal is sent from the ECM to PSG
based on the input from the crank shaft position (CKP)
sensor.
The analogue CKP sensor signal is converted by the
ECM into a square wave signal.
The fuel cutoff solenoid valve signal is also referred to
as MAB signal.
MAB in this case, refers to the German abbreviation
Magnet ventil ABschaltung that stands for high pressure
solenoid valve cut off.
The MAB signal wire is used for two purposes.
-As a reference for the engine control module (ECM) for
the pump speed (back up for the CKP sensor).
-To turn Off the engine.
6E65
The following signals are exchanged via the CAN-bus:

From ECM to PSG
Desired injection quantity
Desired injection timing
Characteristic of IAT Sensor -Reference100000
From PSG to ECM

Fuel temperature
Pump speed
Cylinder identifier
Control pulse (actual injection quantity + actual
injection timing)
Resistance (ohm) (Solid Line)
Engine speed
10000
1000
100
10
PSG status
-30
-20
-10
10
20
30
40
50
60
70
80
90
100
110
Intake Air Temp. (deg. C) (Tech2 Reading)

Temperature (IAT) Sensor
The IAT sensor is a thermistor. A temperature changes
the resistance value. And it changes voltage. In other
words it measures a temperature value. Low air
temperature produces a high resistance.
The ECM supplies 5 volts signal to the IAT sensor
through resisters in the ECM and measures the voltage.
The signal voltage will be high when the air temperature
is cold, and it will be low when the air temperature is
hot.

(IAT) Sensor
The mass air flow (MAF) sensor is part of the intake air
system.
It is fitted between the air cleaner and turbocharger and
measure the mass air flowing into the engine.
The mass air flow (MAF) sensor uses a hot film element
to determine the amount of air flowing into the engine.
The mass air flow (MAF) sensor assembly consist of a
mass air flow (MAF) sensor element and an intake air
temperature sensor that are both exposed to the air flow
to be measured.
The mass air flow (MAF) sensor element measures the
partial air mass through a measurement duct on the
sensor housing.
Using calibration, there is an extrapolation to the entire
mass air flow to the engine.
6E66
Throttle Position Sensor (TPS)
Crankshaft Position (CKP) Sensor
Output Voltage (V)

(2) Idle Switch
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
Characteristic of TPS -Reference-
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Pedal Position (%) (Tech2 Reading
The TPS is a potentiometer connected to throttle shaft

on the throttle body. It is installed to the main TPS and
idle switch.
The engine control module (ECM) monitors the voltage
on the signal line and calculates throttle position. As the
throttle valve angle is changed when accelerator pedal
moved. The TPS signal also changed at a moved
throttle valve. As the throttle valve opens, the output
increases so that the output voltage should be high.
The engine control module (ECM) calculates fuel
delivery based on throttle valve angle.

(2) Fly wheel with sensor slot
The CKP sensor is located on top of the flywheel
housing of the flywheel and fixed with a bolt.
The CKP sensor is of the magnet coil type. The
inductive pickup sensors four gaps in the flywheel
exciter ring and is used to determine the engine speed
and engine cylinder top dead center (TDC).

6E67

(2) Thermo Unit for Water Temperature Gauge
M/T & A/T 4WD
Characteristic of ECT Sensor -Reference100000
10000
1000
100
10
-30
-20
-10
10
20
30
40
50
60
70
80
90
100
110
120
130
Engine Coolant Temp (deg. C) (Tech2 Reading)
A/T 2WD
The ECT sensor is a thermistor. A temperature changes
words it measures a temperature value. It is installed on
the coolant stream. Low coolant temperature produces
a high resistance.
The ECM supplies 5 volts signal to the ECT sensor
The signal voltage will be high when the engine
temperature is cold, and it will be low when the engine
temperature is hot.
The VSS is a magnet rotated by the transmission output

shaft. The VSS uses a hall element. It interacts with the
magnetic field treated by the rotating magnet. It outputs
pulse signal. The 12 volts operating supply from the
meter fuse.
The engine control module (ECM) calculates the vehicle
speed by VSS.
The 2WD model fitted with automatic transmission,
vehicle speed sensor signal is transmitted to from the
TCM to the ECM via vehicle speed meter.
6E68
GENERAL DESCRIPTION FOR EGR

(EXHAUST GAS RE-CIRCULATION)
(1) EGR Valve

(2) EGR Cooler (Euro 3) / EGR Pipe (Except Euro
3)
(3) Intercooler
(4) Intake Manifold
(5) Exhaust Manifold
(6) Waste Gate
(7) Fresh Air
(8) Exhaust Gas
(9) Turbocharger
(1)
(2)
(3)
(4)
(5)
(6)
To EGR Valve
From Vacuum Pump
EGR EVRV
EGR Cooler
Thermo Valve
EGR Valve
The 4JA1-TC & 4JH1-TC engine with Euro 3 regulation

is equipped with the EGR cooler. The EGR cooler
reduces the temperature of the air being drawn into the
engine and the combustion temperature. This results in
reducing nitrogen oxide (Nox) emissions. The 4JH1-TC
engine except Euro 3 regulation, it does not have EGR
cooler. It has steel EGR pipe instead of the cooler.
The amount of EGR is controlled by EVRV (electrical
vacuum regulating valve) via the engine control module
(ECM) command signal depends on the following
inputs.
Engine speed
Injection quantity
Mass air flow
Coolant temperature
Barometric pressure
7.1ms
0.7ms
Time
Off duty 10% =EGR Pulse Ratio 10%
7.1ms
6.4ms
Time
Off duty 90% =EGR Pulse Ratio 90%
The EVRV is shaped to control vacuum applied to the

diaphragm chamber of the EGR valve based on duty
signal sent from the ECM. The duty ratio is the time that
the EVRV is opened to one cooperate EVRV operating
cycle. A duty ratio change of 90% to 10 % is EGR
amount control.
6E69
6E70
GENERAL DESCRIPTION FOR INJECTION

PUMP
Cross-section View
Outline
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Drive Shaft
Feed Pump
Pump Camshaft Speed Sensor
Pump Control Unit (PSG)
Distributor Head
Constant Pressure Valve (CPV) Holder
High Pressure Solenoid Valve
Constant Pressure Valve (CPV)
Timing Control Valve (TCV)
Timer
Radial Plunger High Pressure Pump
Instead of the previous face cam type, the radial plunger

distributor type injection pump utilizes a cam ring to
enable fuel injection at high-pressures, marking it
suitable for small, high-speed direct injection diesel
engines. This pump was developed to provide the most
suitable fuel injection quantity and injection timing to
satisfy the demand for engine reliability, driveability, low
smoke, low noise, high output and clear exhaust
emissions.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
Drive Shaft
Feed Pump
Distributor Head
Constant Pressure Valve (CPV) Holder
Timer
6E71
Low Pressure Fuel Circuit
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Rotor Shaft
Radial Plunger
High Pressure Passage
Low Pressure Inlet
Distributor Slit
Valve Needle
Barrel
Annular Passage
Fuel Return
High Pressure Outlet
Diaphram Chamber
Accumulator Diaphram
(1)
(2)
(3)
(4)
(5)
Fuel Suction
Regulating Valve
Overflow Valve
Feed Pump
To Fuel Tank
The low pressure fuel circuit must supply sufficient fuel

to the high pressure fuel circuit. The main components
are the feed pump, the regulating valve and the
overflow valve.
6E72
High Pressure Fuel Circuit
(1)
(2)
(3)
(4)
(5)

Distributor Head
In addition high pressure generating device, the high

pressure circuit also consists of fuel piping, and devices
to set the beginning of injection and fuel injection
quantity.
The main components are as follows.
High pressure generation: Radial Plunger High
Pressure Pump
Fuel distribution: Distributor Head
Beginning of injection timing: Timing Device
Prevention of secondary injection: Constant Pressure
Valve (CPV)
(1)
(2)
(3)
(4)
(5)

Sensor Wheel
Pump Camshaft Speed Sensor Retaining Ring
Flexible Connector Harness
Drive Shaft
When the drive shaft rotates, the pump camshaft speed

sensor receives signal form the sensor wheel, and an
electric pulse is sent through the flexible connecting
harness to the pump control unit (PSG).
From these signals the pump control unit (PSG) can
determine the average pump speed and the momentary
pump speed.
The pump camshaft speed sensor is mounted to the
cam ring. Thus, the relationship between the cam ring
and the pump camshaft speed sensor signal is
constant.

The pump camshaft speed sensor signal is utilized for
the following purposes.
To determine the momentary angular position of the
cam ring.
To calculate the actual speed of the fuel injection pump.
To determine the actual timing plunger position.
Sensor
Wheel
Pump
Pump
Camshaft
Control
Speed
Unit
Sensor
(PSG)
6E73
-Cam Ring Angle

-Pump Speed
-Timer Position
(1)
(2)
(3)
(4)
The pump camshaft sensor signal has a tooth gap, and
the crankshaft position (CKP) sensor on the flywheel
housing is used as a reference signal of engine top
dead center (TDC) for the start timing of fuel delivery or
injection which is to be set.
Valve Needle
Magnet Anchor
Coil
High Pressure Passage
Fuel injection quantity control is performed from the

beginning of pressure delivery at the beginning of cam
lift until the high pressure solenoid valve opens at the
end of pressure delivery.
This interval is called the pressure delivery interval.
Accordingly, the interval that the high pressure solenoid
valve is closed determines the fuel injection quantity
(high pressure fuel supply ends when the high pressure
solenoid valve opens).
6E74
When current from the pump control unit (PSG) flows to

the high pressure solenoid valve coil, the magnet
anchor (a movable iron core) pushes the valve needle,
toward the valve seat.
When the valve seat is completely closed by the valve
needle, the way, of the fuel in the high pressure
passage to the low pressure circuit is closed.
The pressure of the fuel in the high pressure passage is
rapidly increased by radial plunger lift, and the high
pressure fuel is delivered through the constant pressure
valve (CPV) to the nozzle holder assembly and is
injected into the engine cylinder.
(1) Valve Needle

(2) Coil
When the fuel injection quantity demanded by the
engine is reached, the current to the coil is cut and the
valve needle re-opens the valve seat.
As a result of this, a path is opened for the fuel in the
high pressure passage to the low pressure circuit and
the pressure decreases. With a decrease in injection
pressure the nozzle closes and injection ends.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Cam Ring
Servo Valve
Timer Piston
Outlet
Feed Pump
Inlet
Fuel Suction
Ball Pin
Annular Chamber
Hydraulic Stopper
Return Passage
The pressure of the fuel fed from the feed pump is

adjusted in accordance with speed by the regulating
valve. This delivery pressure acts on the hydraulic
stopper's annular chamber as control pressure.
The chamber pressure of the annular chamber is
controlled by the timing control valve (TCV).
The timing plunger is connected to the cam ring by a
ball pin. Axial movement of the timing plunger is
transferred to the cam ring in the form of rotational
movement. Movement to the right of the timing plunger
(to the spring side) advances injection timing.
6E75
Engine Load
Engine Speed
Engine
Pump
Timing
Control
Control
Control
Module
Unit
Valve
(ECM)
(PSG)
(TCV)
Engine Coolant
Temperature
Pump Camshaft
Speed Sensor
(1)
(2)
(3)
(4)
(5)
Coil
From Annular Chamber
To Feed Pump
Orifice
Valve Needle
When control current flows to the timing control valve

(TCV) coil, the valve needle opens and the fuel annular
chamber flows through the orifice to the feed pump inlet.
Consequently, the pressure of the annular chamber
decreases and the hydraulic stopper is moved to the
retard side.
The timing control valve (TCV) acts as a variable
throttle, using the rapid opening and closing (cycling) of
the valve needle in the timing control valve (TCV).
At normal operation, the TCV controls the pressure
acting on the annular chamber so that the hydraulic
stopper cam move to any position, from the retard
position to the advance position. At this time, the duty
ratio is set by the pump control unit (PSG).
Duty ratio is the ratio of the time that the timing control
valve (TCV) is opened to one complete timing control
valve (TCV) operating cycle. A duty ratio change of
100% to 0% is an advance in injection timing. (The
VP44 displays an ON duty ratio.)
The engine control module (ECM) contains

characteristic maps of the start of injection,
corresponding to engine operating conditions (engine
load, engine speed and engine coolant temperature).
The pump control unit (PSG) is constantly comparing
the set start of injection timing and the actual start of
injection timing. If there is a difference, the timing
control valve (TCV) is controlled by the duty ratio. (The
actual start of injection timing is determined from the
pump camshaft speed sensor.)
6E76
ISUZU Strategy Based Diagnostics

Overview
As a retail service technician, you are part of the ISUZU
service team. The team goal is FIX IT RIGHT THE
FIRST TIME for the satisfaction of every customer. You
are a very important member of the team as you
diagnose and repair customer vehicles.
You have maximum efficiency in diagnosis when you

have an effective, organized plan for your work.
Strategy Based Diagnostics (refer to Figure 1) provides
you with guidance as you create and follow a plan of
action for each specific diagnostic situation.
STRATEGY BASED DIAGNOSTICS CHART
Diagnostic Thought Process

As you follow a diagnostic plan, every box on the
Strategy Based Diagnostics chart requires you to use
the diagnostic thought process. This method of thinking
optimizes your diagnosis in the following ways:
Improves your understanding and definition of the
customer complaint
Saves time by avoiding testing and/or replacing good
parts
Allows you to look at the problem from different
perspectives
Guides you to determine what level of understanding
about system operation is needed:
Owners manual level
Service manual level
In-depth (engineering) level
Owners manual level
1. Verify the Complaint

What you should do
To verify the customer complaint, you need to know the
correct (normal) operating behavior of the system and
verify that the customer complaint is a valid failure of the
system.
The following information will help you verify the
complaint:
WHAT the vehicle model/options are
WHAT aftermarket and dealer-installed accessories
exist
WHAT related system(s) operate properly
WHEN the problem occurs
WHERE the problem occurs
HOW the problem occurs
HOW LONG the condition has existed (and if the
system ever worked correctly)
HOW OFTEN the problem occurs
Whether the severity of the problem has increased,
decreased or stayed the same
Circuit testing tools

Vehicle road tests
Complaint check sheet
Contact with the customer
2. Perform Preliminary Checks

NOTE: An estimated 10 percent of successful vehicle
repairs are diagnosed with this step!
What you should do

You perform preliminary checks for several reasons:
To detect if the cause of the complaint is VISUALLY
OBVIOUS
To identify parts of the system that work correctly
To accumulate enough data to correctly and
accurately search for a ISUZU Service Bulletin on
ISUZU Web site.
The initial checks may vary depending on the
complexity of the system and may include the following
actions:
Operate the suspect system
Make a visual inspection of harness routing and
accessible/visible power and ground circuits
Check for blown fuses
Make a visual inspection for separated connectors
Make a visual inspection of connectors (includes
checking terminals for damage and tightness)
Check for any DTCs stored by the on-board
computers
Sense unusual
movements
noises,
smells,
vibrations
What resources you should use

Whenever appropriate, you should use the following
resources for assistance in performing preliminary
checks:
Tech II or other technical equipment for viewing DTCs
Service manual information:
Component locations
Harness routing
Wiring schematics
Whenever possible, you should use the following

resources to assist you in verifying the complaint:
Procedures for viewing DTCs
Owner manual operational description

Technician experience
Identical vehicle for comparison
or
Investigate the vehicle service history (call other

dealerships, if appropriate)
Service manual Theory or Circuit Description

sections
Service manual System Performance Check
6E77
Dealership service history file

Vehicle road test
Identical vehicle or system for comparison
6E78
3. Check Bulletins and

Troubleshooting Hints
to the customer complaint.
NOTE: As estimated 30 percent of successful vehicle

What you should do

You should have enough information gained from
preliminary checks to accurately search for a bulletin
and other related service information. Some service
manual sections provide troubleshooting hints that
match symptoms with specific complaints.

resources to perform service manual diagnostic
procedures:
Service manual
Technical equipment (for analyzing diagnostic data)
Digital multimeter and circuit testing tools
Essential and special tools
5c. Technician Self Diagnoses

You should use the following resources for assistance in
checking for bulletins and troubleshooting hints:
Printed bulletins
Access ISUZU Bulletin Web site.
Videotapes
Service manual
When there is no DTC stored and no matching

symptom for the condition identified in the service
manual, you must begin with a thorough understanding
of how the system(s) operates. Efficient use of the
service manual combined with you experience and a
good process of elimination will result in accurate
diagnosis of the condition.
What you should do
4. Perform Service Manual

Diagnostic Checks
Step 1: Identify and understand the suspect

circuit(s)
What you should do

The System Checks in most service manual sections
and in most cells of section 8A (electrical) provide you
with:
A systematic approach to narrowing down the
possible causes of a system fault
Having completed steps 1 through 4 of the Strategy

Based Diagnostics chart, you should have enough
information to identify the system(s) or sub-system(s)
involved. Using the service manual, you should
determine and investigate the following circuit
characteristics:
Electrical:
Direction to specific diagnostic procedures in the

service manual
How is the circuit powered (power distribution

charts and/or fuse block details)?
Assistance to identify what systems work correctly
How is the circuit grounded (ground distribution

charts)?
How is the circuit controlled or sensed (theory of

operation):
If it is a switched circuit, is it normally open or
normally closed?

resources to perform service manual checks:
Service manual
Technical equipment (for viewing DTCs
analyzing data)
and
Other tools as needed
5a and 5b. Perform Service Manual

Diagnostic Procedures
repairs are diagnosed with these steps!
What you should do

When directed by service manual diagnostic checks,
you must then carefully and accurately perform the
steps of diagnostic procedures to locate the fault related
Is the power switched or is the ground

switched?
Is it a variable resistance circuit (ECT sensor
or TP sensor, for example)?
Is it a signal generating device (MAF sensor of
VSS, for example)?
Does it rely on some mechanical/vacuum
device to operate?
Physical:
Where are the circuit components (component
locators and wire harness routing diagrams):
Are there areas where wires could be chafed
or pinched (brackets or frames)?
Are there areas
temperatures?
subjected
to
extreme

Are there areas subjected to vibration or
movement
(engine,
transmission
or
suspension)?
Are there areas exposed to moisture, road salt
or other corrosives (battery acid, oil or other
fluids)?
Are there common mounting areas with other
systems/components?
Have previous repairs been performed to wiring,
connectors, components or mounting areas
(causing pinched wires between panels and
drivetrain or suspension components without
causing and immediate problem)?
Does the vehicle have aftermarket or dealerinstalled equipment (radios, telephone, etc.)
At this point, you should have a good idea of what could

cause the present condition, as well as could not cause
the condition. Actions to take include the following:
Divide (and separate, where possible) the system or
circuit into smaller sections
Confine the problem to a smaller area of the vehicle
(start with main harness connections while removing
panels and trim as necessary in order to eliminate
large vehicle sections from further investigation)
For two or more circuits that do not share a common
power or ground, concentrate on areas where
harnesses are routed together or connectors are
shared (refer to the following hints)
Hints
Though the symptoms may vary, basic electrical failures
are generally caused by:
Loose connections:
in
terminals,
splices,

resources to assist in the diagnostic process:
Service manual
Technical equipment (for data analysis)
Experience
Technical Assistance
By definition, an intermittent problem is one that does

not occur continuously and will occur when certain
conditions are met. All these conditions, however, may
not be obvious or currently known. Generally,
intermittents are caused by:
Faulty electrical connections and wiring
Malfunctioning components (such as sticking relays,
solenoids, etc.)
EMI/RFI
(Electromagnetic/radio
frequency
interference)
Aftermarket equipment
Intermittent diagnosis requires careful analysis of
suspected systems to help prevent replacing good
parts. This may involve using creativity and ingenuity to
interpret customer complaints and simulating all
external and internal system conditions to duplicate the
problem.
What you should do

Step 1: Acquire information
Incorrect connector/harness routing (usually in new

vehicles or after a repair has been made):
Open/high resistance in
connectors of grounds
Corrosion and wire damage:
Open/high resistance
at the component
If a number of components do no operate, begin tests
at the area of commonality (such as power sources,
ground circuits, switches or major connectors)
5d. Intermittent Diagnosis
Step 2: Isolate the problem
connectors or grounds
6E79
in
terminals,
splices,
terminals,
splices,
Step 2: Analyze the intermittent problem
Component failure:
Opens/short and high resistance
modules, switches or loads
A thorough and comprehensive customer check sheet

is critical to intermittent problem diagnosis. You should
require this, since it will dictate the diagnostic starting
point. The vehicle service history file is another
source for accumulating information about the
complaint.
in
relays,
Aftermarket equipment affecting normal operation of

other systems
You may isolate circuits by:
Unplugging connectors or removing a fuse to
separate one part of the circuit from another part
Operating shared circuits and eliminating those that
function normally from the suspect circuit
If only one component fails to operate, begin testing
Analyze the customer check sheet and service history

file to determine conditions relevant to the suspect
system(s).
Using service manual information, you must identify,
trace and locate all electrical circuits related to the
malfunctioning system(s). If there is more than one
system failure, you should identify, trace and locate
areas of commonality shared by the suspect circuits.
6E80
Step 3: Simulate the symptom and isolate the

problem
Simulate the symptom and isolate the system by
reproducing all possible conditions suggested in Step 1
while monitoring suspected circuits/components/
systems to isolate the problem symptom. Begin with the
most logical circuit/component.
Isolate the circuit by dividing the suspect system into
simpler circuits. Next, confine the problem into a smaller
area of the system. Begin at the most logical point (or
point of easiest access) and thoroughly check the
isolated circuit for the fault, using basic circuit tests.
For parts and sensors, apply slight vibration to the part

with a light tap of the finger while monitoring the system
for a malfunction.
2. Heat
This method is important when the complaint suggests
that the problem occurs in a heated environment. Apply
moderate heat to the component with a hair drier or
similar tool while monitoring the system for a
malfunction.
CAUTION: Care must be take to avoid overheating
the component.
3. Water and Moisture
Hints
You can isolate a circuit by:
separate one part of the circuit from another
If only component fails to operate, begin testing the
component
If a number of components do not operate, begin test
at areas of commonality (such as power sources,
ground circuits, switches, main connectors or major
components)
Substitute a known good part from the parts
department or the vehicle system
Try the suspect part in a known good vehicle
See Symptom Simulation Tests on the next page for
problem simulation procedures. Refer to service manual
sections 6E and 8A for information about intermittent
diagnosis. Follow procedures for basic circuit testing in
service manual section 8A.
This method may be used when the complaint suggests

that the malfunction occurs on a rainy day or under
conditions of high humidity. In this case, apply water in a
light spray on the vehicle to duplicate the problem.
CAUTION: Care must be take to avoid directly
exposing electrical connections to water.
4. Electrical loads
This method involves turning systems ON (such as the
blower, lights or rear window defogger) to create a load
on the vehicle electrical system at the same time you
are monitoring the suspect circuit/component.
5e. Vehicle Operates as Designed

This condition refers to instances where a system
operating as designed is perceived to be unsatisfactory
or undesirable. In general, this is due to:
A lack of understanding by the customer

Service manual
Bulletins
Tech II and Tech II upload function
connector
A system performance that is unacceptable to the

customer
What you should do
Digital multimeter (with a MIN/MAX feature)

Circuit testing tools (including
harnesses and jumper wires)
A conflict between customer expectations and

vehicle design intent
kits/
Experience
Intermittent problem solving simulation methods
Customer complaint check sheet
Symptom Simulation Tests

1. Vibration
This method is useful when the customer complaint
analysis indicates that the problem occurs when the
vehicle/system undergoes some form of vibration.
For connectors and wire harness, slightly shake
vertically and horizontally. Inspect the connector joint
and body for damage. Also, tapping lightly along a
suspected circuit may be helpful.
You can verify that a system is operating as designed

by:
Reviewing
checks
service
manual
functional/diagnostic
Examining bulletins and other service information for

supplementary information
Compare system operation to an identical vehicle
If the condition is due to a customer misunderstanding
or a conflict between customer expectation and system
operation, you should explain the system operation to
the customer.
If the complaint is due to a case of unsatisfactory
system performance, you should contact Technical
Assistance for the latest information.

resources to facilitate the diagnostic process:

Vehicle service information (service manual, etc.)
ISUZU field support
Experience
6. Re-examine the complaint

When you do not successfully find/isolate the problem
after executing a diagnostic path, you should reexamine the complaint.
What you should do

In this case, you will need to backtrack and review
information accumulated from step 1 through 4 of
Strategy Based Diagnostics. You also should repeat any
procedures that require additional attention.
A previous path may be eliminated from consideration
only if you are certain that all steps were executed as
directed. You must then select another diagnostic path
(step 5a, 5b, 5c or 5d). If all possible options have been
explored, you may call or seek ISUZU field support.

Service manual
Accumulated information form a previous diagnostic
path
Service information and publications
ISUZU field support
7. Repair and Verify Fix

What you should do
After you have located the cause of the problem, you
must execute a repair by following recommended
service manual procedures.
When the repair is completed, you should verify the fix
by performing the system checks under the conditions
listed in the customer complaint.
If applicable, you should carry out preventive measures
to avoid a repeat complaint.

resources to facilitate the repair process:
Electrical repair procedures
Service manual information and publications
6E81
6E82
GENERAL SERVICE INFORMATION

Serviceability Issues
Non-OEM Parts
All of the OBD diagnostics have been calibrated to run
with OEM parts.
Accordingly, if commercially sold
sensor or switch is installed, it makes a wrong diagnosis
and turns on the check engine lamp.
Aftermarket electronics, such as cellular phones,
stereos, and anti-theft devices, may radiate EMI into the
control system if they are improperly installed. This may
cause a false sensor reading and turn on the check
engine lamp.
Poor Vehicle Maintenance
The sensitivity of OBD diagnostics will cause the check
engine lamp to turn on if the vehicle is not maintained
properly. Restricted oil filters, fuel filters, and crankcase
deposits due to lack of oil changes or improper oil
viscosity can trigger actual vehicle faults that were not
previously monitored prior to OBD.
Poor vehicle
maintenance can not be classified as a non-vehicle
fault, but with the sensitivity of OBD diagnostics,
vehicle maintenance schedules must be more closely
followed.
Related System Faults
Many of the OBD system diagnostics will not run if the
ECM detects a fault on a related system or component.
Visual/Physical Engine Compartment

Inspection
Perform a careful
visual and physical engine
compartment inspection when performing any
diagnostic procedure or diagnosing the cause of an
emission test failure. This can often lead to repairing a
problem without further steps.
Use the following
guidelines
when
performing
a
visual/physical
inspection:
Inspect all vacuum hoses for punches, cuts,
disconnects, and correct routing.
Inspect hoses that are difficult to see behind other
components.
Inspect all wires in the engine compartment for
proper connections, burned or chafed spots, pinched
wires, contact with sharp edges or contact with hot
exhaust manifolds or pipes.
Basic Knowledge of Tools Required

NOTE: Lack of basic knowledge of this powertrain
when performing diagnostic procedures could result in
an incorrect diagnosis or damage to powertrain
components. Do not attempt to diagnose a powertrain
problem without this basic knowledge.
A basic understanding of hand tools is necessary to
effectively use this section of the Service Manual.
ON-BOARD DIAGNOSTIC (OBD)

On-Board Diagnostic (Self Diagnosis
System) Tests
A diagnostic test is a series of steps, the result of which
is a pass or fail reported to the diagnostic executive.
When a diagnostic test reports a pass result, the
diagnostic executive records the following data:
The diagnostic test has been completed since the
last ignition cycle.
The diagnostic test has passed during the current
ignition cycle.
The fault identified by the diagnostic test is not
currently active.
When a diagnostic test reports a fail result, the
The fault identified by the diagnostic test is currently
active.
The fault has been active during this ignition cycle.
The operating conditions at the time of the failure.
The Diagnostic Executive

The Diagnostic Executive is a unique segment of
software which is designed to coordinate and prioritize
the diagnostic procedures as well as define the protocol
for recording and displaying their results. The main
responsibilities of the Diagnostic Executive are listed as
follows:
Commanding the check engine lamp on and off
DTC logging and clearing
Current status information on each diagnostic
Diagnostic Information
The diagnostic charts and functional checks are
designed to locate a faulty circuit or component through
a process of logical decisions. The charts are prepared
with the requirement that the vehicle functioned
correctly at the time of assembly and that there are not
multiple faults present.
There is a continuous self-diagnosis on certain control
functions. This diagnostic capability is complemented
by the diagnostic procedures contained in this manual.
The language of communicating the source of the
malfunction is a system of diagnostic trouble codes.
When a malfunction is detected by the control module, a
diagnostic trouble code is set and the check engine
lamp is illuminated.
Check Engine Lamp
The check engine lamp looks the same as the check
engine lamp you are already familiar with, the Check
Engine lamp.
Basically, the check engine lamp is turned on when the

ECM detects a DTC that will impact the vehicle
emissions.
When the check engine lamp remains ON while the
engine is running, or when a malfunction is
suspected due to a driveability or emissions problem,
a Powertrain On-Board Diagnostic (OBD) System
Check must be performed. The procedures for these
checks are given in On-Board Diagnostic (OBD)
System Check. These checks will expose faults
which may not be detected if other diagnostics are
performed first.
Data Link Connector (DLC)
The provision for communication with the contorl
module is the Data Link Connector (DLC). It is located
behind the lower front instrument panel. The DLC is
used to connect to a Tech2. Some common uses of the
Tech2 are listed below:
Identifying stored Diagnostic Trouble Codes (DTCs).
Clearing DTCs.
Reading serial data.
6E83
Reading Flash Diagnostic Trouble Codes

The provision for communicating with the Engine
Control Module (ECM) is the Data Link Connector
(DLC). The DLC is located in the front console box. It is
used in the assembly plant to receive information in
checking that the engine is operating properly before it
leaves the plant.
The diagnostic trouble code(s) (DTCs) stored in the
ECMs memory can be read either through a hand-held
diagnostic scanner plugged into the DLC or by counting
the number of flashes of the check engine lamp when
the diagnostic test terminal of the DLC is grounded. The
DLC terminal 6 (diagnostic request) is pulled Low
(grounded) by jumping to DLC terminal 4 or 5, which is
a ground wire.
This will signal the ECM that you want to flash DTC(s),
if any are present. Once terminals 4 or 5 and 6 have
been connected, the ignition switch must be moved to
the ON position, with the engine not running.
The check engine lamp will indicate a DTC three times if
a DTC is present. If more than one DTC has been
stored in the ECMs memory, the DTC(s) will be output
from the lowest to the highest, with each DTC being
displayed three times.
The DTC display will continue as long as the DLC is
shorted.
Reading Diagnostic Trouble Codes Using a

Tech 2
The procedure for reading diagnostic trouble code(s) is
to used a diagnostic Tech2. When reading DTC(s),
follow instructions supplied by Tech2 manufacturer.
For the 1998 model year, Isuzu dealer service
departments will continue to use Tech2.
Clearing Diagnostic Trouble Codes
To clear Diagnostic Trouble Codes (DTCs), use the
Tech2 clear DTCs or clear information function.
When clearing DTCs follow instructions supplied by the
Tech2 manufacturer.
Verifying Vehicle Repair
History DTC
Verification of vehicle repair will be more

comprehensive for vehicles with OBD system
diagnostic. Following a repair, the technician should
perform the following steps:
1. Review and record the Fail Records for the DTC
which has been diagnosed.
History DTC can be candeled after 40 cycle driving with

no defect. Or history code can be deleted by Tech 2
Clear DTCs function.
2. Clear DTC(s).
3. Operate the vehicle within conditions noted in the
Fail Records.
4. Monitor the DTC status information for the specific
DTC which has been diagnosed until the diagnostic
test associated with that DTC runs.
Following these steps is very important in verifying
repairs on OBD systems. Failure to follow these steps
could result in unnecessary repairs.
6E84

DIAGNOSIS WITH Tech 2
If no codes are set:
Refer to F1: Data Display and identify the electrical
faults that are not indicated by trouble code.
Refer to SYMPTOM DIAGNOSIS.
6E85
Connect the SAE 16/19 adapter (3) to the DLC

cable (4).
Connect the DLC cable (4) to the Tech 2 (5).
Connect the SAE 16/19 adapter (3) to the data
link connector of the vehicle.
If codes are set:

1. Record all trouble codes displayed by Tech 2 and
check id the codes are intermittent.
2. Clear the codes.
3. Drive the vehicle for a test to reproduce the faulty
status.
4. Check trouble codes again using the Tech 2.
5. If no codes is displayed by test driving, the fault is
intermittent. In this case, refer to DIAGNOSIS
AIDS.
6. If a code is present, refer to DTC Chart for
diagnosis.
Tech 2 CONNECTION
Turn the key switch of the vehicle ON and press
the PWR key of the Tech 2.
Check the display of the Tech 2.
NOTE: Be sure to check that the power is not supplied
to the Tech 2 when attaching or removing the PCMCIA
card.
Tech 2 scan tool is used to electrically diagnose the

automatic transmission system and to check the
system. The Tech 2 enhances the diagnosis efficiency
though all the troubleshooting can be done without the
Tech 2.
1. Configuration of Tech 2
Tech 2 scan tool kit (No. 7000086), Tech 2 scan
tool (No. 7000057) and DLC cable (No.
3000095).
SAE 16/19 adapter (No. 3000098) (3), RS232
loop back connector (No. 3000112) (2) and
PCMCIA card (No. 3000117) (1).
2. Tech 2 Connection
Check the key switch is turn OFF.
Insert the PCMCIA card (1) into the Tech 2 (5).
6E86
TECH 2 OPERATING FLOW CART (START UP)

Vehicle Identification
(UB) Trooper, Bighorn
(UE) Rodeo,/Amigo, Wizard/Mu
(TF/UC) LUV, Frontier, LAO-Rodeo
(TBR)
(N*) ELF, NPR, NQR
Press (ENTER) to Continue
Press ENTER key.

Main Menu
F0:
F1:
F2:
F3:
F4:
Diagnostic
Service Programming System (SPS)
View Capture Data
Tool Option
Download/ Upload Help
Select F0: Diagnostic.

(3) 2003
(2) 2002
(1) 2001
(Y) 2000
(X) 1999
(W) 1998
Select (3) 2003or later.
Select (TF/UC).
System Selection Menu
F0: Powertrain
F1: Chassis
F3: Body
Select F0: Powertrain.

4JH1-TC Bosch
4JA1-TC Bosch
4JH1-T Denso
3.5L V6 6VE1 Hitachi
AW30-40LE
A/T JR405E
Select 4JA1-TC Bosch or 4JH1-TC Bosch.
Select 4JA1-TC Bosch or 4JH1-TC Bosch in Vehicle Identification menu and the following table is shown in the
Tech 2 screen.

F0: Diagnostic Trouble Codes
F0: Read DTC Infor As Stored By ECU
F1: Clear DTC Information
F1: Data Display
F2: Snapshot
F3: Miscellaneous Test
F0: Lamps
F0: Glow Time Telltale Test
F1: Relays
F0: Glow Time Relay Test
F2: Solenoids
F0: EGR Solenoid Test
F3: Engine Speed (RPM) Control
F4: Programming
F0: Program VIN
F1: Lock ECU
F0: Diagnostic Trouble Code
The purpose of the Diagnostic Trouble Codes mode is
to display stored trouble code in the ECM.
When Clear DTC Information is selected, a Clear
DTC Information, warning screen appears.
This screen informs you that by cleaning DTC's all
stored DTC information in the ECM will be erased.
After clearing codes, confirm system operation by test
driving the vehicle.
Symptom Code:
Read DTC Infor As Stored By ECU
DTC No.
P0100 Present
(7)
Mass Air Flow (MAF) Sensor
Voltage Supply Circuit High Input
Symptom Code
This number or alphabet means identification of the

malfunction. Each DTC includes plural symptoms, such
as DTC P0100 has four kinds of symptom code (7), (9),
(B) and (C). DTC chart (check procedure) is separated
depending on the symptom code.
6E87
F1: Data Display

The purpose of the Data Display mode is to
continuously monitor data parameters.
The current actual values of all important sensors and
signals in the system are display through F1 mode.
See the Typical Scan Data section.
F2: Snapshot
Snapshot allows you to focus on making the condition
occur, rather than trying to view all of the data in
anticipation of the fault.
The snapshot will collect parameter information around
a trigger point that you select.
F3: Miscellaneous Test:
The purpose of Miscellaneous Test mode is to check
for correct operation of electronic system actuators.
F4: Programming (Factory Use Only)
The purpose of Programming is to program VIN in the
ECM and lock the programmed data.
6E88

TYPICAL SCAN DATA & DEFINITIONS (ENGINE DATA)
4JA1-TC ENGINE
Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were
noted, and you have determined that the On-Board Diagnostic are functioning properly.
Tech2 values from a properly running engine may be used for comparison with the engine you are diagnosing.
Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately
80 deg. C)
Tech 2 Parameter
Units
Engine Speed
rpm
Vehicle Speed
km/h / MPH
Pump Speed
rpm
Accelerator Position
Sensor Signal
Idle Switch
Active/
Inactive 0V
Mass
Sensor
Desired
Flow
Barometric Pressure
hpa
Desired
Quantity
10
Air
Idle
1500rpm
2000rpm
Description
730
1475 1525
1975 2025
The engine speed is measured by ECM from the CKP

sensor.
This displays vehicle speed. The vehicle speed is

measured by ECM from the vehicle speed sensor.
345 - 385
725 - 775
975 - 1025
This displays injection pump speed. The injection speed is

measured by ECM from the pump cam sensor.
4-6
6-8
Throttle position operating angle is measured by the ECM

from throttle position output voltage. This should display
0% at idle and 99 - 100% at full throttle.
Active
Active
Inactive 0V
This displays operating status of the idle switch. This

should display "Active" until the accelerator position nearly
4 - 5%.
Flow
mg/strk
380 - 420
360 - 400
380 - 420
This displays calculated intake air volume for one cylinder

stroke. The mass air flow is measured by ECM from the
MAF sensor output voltage.
Air
mg/strk
350
350
350 - 370
This displays desired intake air volume for one cylinder

stroke. The desired mass air flow is calculated by ECM
depending on engine condition.
Depends
on altitude
Depends
on altitude
Depends
on altitude
The barometric pressure is measured by ECM from the

sensor in the ECM. This data is changing by altitude.
mg/stk
8 - 10
6 - 10
7 - 10
This displays desired value from the ECM. The ECM

compensates for fuel rate to basic rate.
Injection Quantity
mg/stk
8 - 10
5 - 10
5-9
This displays calculated actual fuel quantity from the PSG.

The PSG receives desired injection quantity from the ECM.
And, it compensates actual injection depending on timer
position to determine duration of the high pressure
solenoid valve operation.
11
Desired Fuel Injection

Start
deg. CA
2-4
2- 5
3-5
This displays desired injection timing from the ECM. The

ECM compensates for fuel injection timing by throttle
position and various sensor signal.
12
Actual Injection Start
deg. CA
2-4
2-5
3-5
This displays calculated actual injection timing based on

CKP signal and pump cam signal. The PSG controls TCV
duty ratio to meet desired injection timing from the ECM.
13
Coolant Temperature
deg. C / deg.
F
80 - 85
80 - 85
80 - 85
The ECT is measured by ECM from ECT sensor output

voltage. This data is changing by coolant temperature.
When the engine is normally warm upped, this data
displays approximately 80 deg. C.
14
Fuel Temperature
deg. C / deg.
F
Depends
on fuel
temp.
Depends
on fuel
temp.
Depends
on fuel
temp.
The FT is measured by PSG from FT sensor. This data is

changing by fuel temperature.
15
Intake
Temperature
deg. C / deg.
F
Depends
on ambient
temp.
Depends
on ambient
temp.
Depends
on ambient
temp.
The IAT is measured by ECM from IAT sensor output

voltage. This data is changing by intake air temperature.
16
Ignition Status
On12V/
Off0V
On 12V
On 12V
On 12V
This displays the key switch status indicated by the ECM

with key switch signal. This should display "Off 0V" at key
OFF and "On12V" at key ON.
17
Brake Switch 1
Active/
Inactive
Inactive
Inactive
Inactive
This displays operating status of the brake switch. This

should display "Active" when the brake pedal is stepped
on.
Mass
Injection
Air

Tech 2 Parameter
Units
Idle
1500rpm
2000rpm
Description
6E89
18
Brake Switch 2
Active/
Inactive
Inactive
Inactive
Inactive

on.
19
Clutch Switch
Active/
Inactive
Inactive
Inactive
Inactive
This displays operating status of the clutch switch. This

should display "Active" when the clutch pedal is stepped
on.
20
Neutral Switch
On/Off
On
On
On
This displays operating status of the neutral switch. This

should display "On" when the gear position is neutral.
21
A/C
Switch
Active 12V/
Inactive 0V
Inactive 0V
Inactive 0V
Inactive 0V
This displays the air conditioner request signal. This

should display "Active 12V" when the air conditioner switch
is switched on.
22
Diagnostic Request
Active
0V/
Inactive 12V
Inactive
12V
Inactive
12V
Inactive
12V
This displays the diagnostic request signal. This should

display "Inactive 12V" when the Tech 2 is connected.
23
System Voltage
10 - 14
10 - 14
10 - 14
This displays the system voltage measured by the ECM at

ignition feed.
24
Main Relay
Active/
Inactive
Active
Active
Active
This displays operating status for the ECM main relay. This
should display "Active" when the key switch is turned on
and while engine is running.
25
Glow Time Relay
Active
0V/
Inactive12V
Inactive
12V
Inactive
12V
Inactive
12V
This displays operating status for the glow relay. This

should display "Inactive 12V" when the engine is warm
upped.
26
Check Engine Light
On/Off
Off
Off
Off
This displays operating status for the Check Engine Lamp.

This should display "On" when the Check Engine Lamp is
turned on.
27
Glow Time Telltale
On/Off
Off
Off
Off
This displays operating status for the glow indicator lamp.

This should display "On" when the glow lamp is turned on.
28
Desired Engine Idle

Speed
rpm
730
730
730
The desired engine idle speed that the ECM commanding.

The ECM compensates for various engine loads based on
engine coolant temperature.
29
A/C Request
Active
0V/
Inactive 12V
Inactive
12V
Inactive
12V
Inactive
12V
This displays operating status of the A/C compressor. This

should display "Active 0V" when the compressor relay is
operated.
30
Immobilizer
Active/
Inactive
Inactive
Inactive
Inactive
This should display "Inactive" when the immobilizer is

correctly operated.
31
Immobilizer Signal
Received/
Not
Received
Not
Received
Not
Received
Not
Received
This should display "Not Received" when the immobilizer is

not activated.
32
Immobilizer Function
Programmed
Yes/ No
Yes
Yes
Yes
This should display "Yes" when the immobilizer is correctly

programmed.
33
EGR Pulse
(Exhaust
Recirculation)
70
70
70
This displays the duty signal from the ECM to control the
EGR flow amount.
Information
Ratio
Gas
6E90

4JH1-TC ENGINE
Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were
noted, and you have determined that the On-Board Diagnostic are functioning properly.
80 deg. C)
Tech 2 Parameter
Units
Engine Speed
rpm
Vehicle Speed
km/h / MPH
Pump Speed
rpm
Accelerator Position
Sensor Signal
Idle Switch
Active/
Inactive 0V
Mass
Sensor
Desired
Flow
Air
Idle
1500rpm
2000rpm
Definition
675 - 725
1475 1525
1975 2025
The engine speed is measured by ECM from the CKP

sensor.

335 - 375
725 - 775
975 - 1025
This displays injection pump speed. The injection speed is

measured by ECM from the pump cam sensor.
3-5
5-7
Throttle position operating angle is measured by the ECM

from throttle position output voltage. This should display
0% at idle and 99 - 100% at full throttle.
Active
Active/
Inactive 0V
Inactive 0V
This displays operating status of the idle switch. This

should display "Active" until the accelerator position nearly
4 - 5%.
Flow
mg/strk
420 - 490
380 - 460
410 - 480
This displays calculated intake air volume for one cylinder

stroke. The mass air flow is measured by ECM from the
MAF sensor output voltage.
Air
mg/strk
430 - 470
380 - 420
410 - 470
This displays desired intake air volume for one cylinder

stroke. The desired mass air flow is calculated by ECM
depending on engine condition.
Barometric Pressure
hpa
Depends
on altitude
Depends
on altitude
Depends
on altitude

sensor in the ECM. This data is changing by altitude.
Desired
Quantity
mg/stk
6 - 10
6 - 10
7 - 11
This displays desired value from the ECM. The ECM

compensates for fuel rate by throttle position and various
sensor signals.
10
Injection Quantity
mg/stk
6 - 10
6 - 10
7 - 11
This displays calculated actual fuel quantity from the PSG.

The PSG receives desired injection quantity from the ECM.
And, it compensates actual injection depending on timer
position to determine duration of the high pressure
solenoid valve operation.
11
Desired Fuel Injection

Start
deg. CA
1-3
2-4
3-5
This displays desired injection timing from the ECM. The

ECM compensates for fuel injection timing by throttle
position and various sensor signal.
12
Actual Injection Start
deg. CA
1-3
2-4
3-5
This displays calculated actual injection timing based on

CKP signal and pump cam signal. The PSG controls TCV
duty ratio to meet desired injection timing from the ECM.
13
Coolant Temperature
deg. C / deg.
F
80 - 85
80 - 85
80 - 85

voltage. This data is changing by coolant temperature.
When the engine is normally warm upped, this data
displays approximately 80 deg. C.
14
Fuel Temperature
deg. C / deg.
F
Depends
on fuel
temp.
Depends
on fuel
temp.
Depends
on fuel
temp.
The FT is measured by PSG from FT sensor. This data is

changing by fuel temperature.
15
Intake
Temperature
deg. C / deg.
F
Depends
on ambient
temp.
Depends
on ambient
temp.
Depends
on ambient
temp.

16
Ignition Status
On12V/
Off0V
On 12V
On 12V
On 12V
This displays the key switch status indicated by the ECM

with key switch signal. This should display "Off 0V" at key
OFF and "On12V" at key ON.
17
Brake Switch 1
Active/
Inactive
Inactive
Inactive
Inactive

on.
Mass
Injection
Air

Tech 2 Parameter
Units
Idle
1500rpm
2000rpm
Definition
6E91
18
Brake Switch 2
Active/
Inactive
Inactive
Inactive
Inactive

on.
19
Clutch Switch (M/T

Only)
Active/
Inactive
Inactive
Inactive
Inactive
This displays operating status of the clutch switch. This

should display "Active" when the clutch pedal is stepped
on.
20
Neutral Switch
On/Off
On
On
On
This displays operating status of the neutral switch. This

should display "On" when the gear position is neutral (M/T)
or P, N position (A/T).
21
A/C
Switch
Active 12V/
Inactive 0V
Inactive 0V
Inactive 0V
Inactive 0V

should display "Active 12V" when the air conditioner switch
is switched on.
22
Diagnostic Request
Active
0V/
Inactive 12V
Inactive
12V
Inactive
12V
Inactive
12V
This displays the diagnostic request signal. This should

display "Inactive 12V" when the Tech 2 is connected.
23
System Voltage
10 - 15
10 - 15
10 - 15
This displays the system voltage measured by the ECM at

ignition feed.
24
Main Relay
Active/
Inactive
Active
Active
Active
This displays operating status for the ECM main relay. This
should display "Active" when the key switch is turned on
and while engine is running.
25
Glow Time Relay
Active
0V/
Inactive12V
Inactive
12V
Inactive
12V
Inactive
12V
This displays operating status for the glow relay. This

should display "Inactive 12V" when the engine is warm
upped.
26
Check Engine Light
On/Off
Off
Off
Off

This should display "On" when the Check Engine Lamp is
turned on.
27
Glow Time Telltale
On/Off
Off
Off
Off
This displays operating status for the glow indicator lamp.

This should display "On" when the glow lamp is turned on.
28
Desired Engine Idle

Speed
rpm
700
700
700

The ECM compensates for various engine loads based on
engine coolant temperature.
29
A/C Request
Active
0V/
Inactive 12V
Inactive
12V
Inactive
12V
Inactive
12V
This displays operating status of the A/C compressor. This

should display "Active 0V" when the compressor relay is
operated.
30
Immobilizer
Active/
Inactive
Inactive
Inactive
Inactive
This should display "Inactive" when the immobilizer is

correctly operated.
31
Immobilizer Signal
Received/
Not
Received
Not
Received
Not
Received
Not
Received
This should display "Not Received" when the immobilizer is

not activated.
32
Programmed
Yes/ No
Yes
Yes
Yes
This should display "Yes" when the immobilizer is correctly

programmed.
33
EGR Pulse
(Exhaust
Recirculation)
85 - 90
85 - 90
85 - 90
EGR flow amount.
Information
Ratio
Gas
6E92
MISCELLANEOUS TEST
The state of each circuit can be tested by using
miscellaneous test menus. Especially when DTC
cannot be detected, a faulty circuit can be diagnosed by
testing each circuit by means of these menus.
Even DTC has been detected, the circuit tests using
these menus could help discriminate between a
Connect Tech 2 and select "Powertrain", "4JA1-TC
Bosch" or "4JH1-TC Bosch" & "Miscellaneous Test".
F0: Lamps
F0: Glow Time Telltale Test
When the Tech 2 is operated, "Glow Time Indicator
Lamp" is turned on or off.
The circuit is correct if the "Glow Time Indicator Lamp"
in the instrument panel is turned on or off in accordance
with this operation.
F1: Relays
F0: Glow Time Relay Test
When the Tech 2 is operated, glow relay turns ON or
OFF.
The circuit is correct if glow relay is operated in
accordance with this operation.
F2: Solenoids
F0: EGR Solenoid Test
When the Tech 2 is operated, control duty ratio of EGR
EVRV changes to 5% to 95%.
The circuit is correct if glow relay is operated in
EGR Solenoid Test
Desired Mass Air Flow
470 mg/strk
Mass Air Flow
450 mg/strk
Engine Speed
700 rpm
Exhaust Gas Recirculation
95%
Press "Active" key.

Then, EVRV duty ratio increases to 95%
Press "Inactive key".
EVRV duty ratio decreases to 5%
F3: Engine Speed (RPM) Control

When the Tech 2 is operated, "Desired Idle Speed"
increases 50rpm-by-50rpm up to 1200rpm.
The circuit is correct if engine speed is changed in
Engine Speed (RPM) Control
Engine Speed
850 rpm
Desired Idle Speed
850 rpm
Injection Quantity
7.5 mg/ strk
Press "Increase" key.

Then, Desired Idle speed is increases
50rpm-by-50rpm up to 1200rpm. Engine speed is
also
Plotting Snapshot Graph

This test selects several necessary items from the data
list to plot graphs and makes data comparison on a long
term basis. It is an effective test particularly in emission
related evaluations.
For trouble diagnosis, you can collect graphic data

(snap shot) directly from the vehicle.
You can replay the snapshot data as needed. Therefore,
accurate diagnosis is possible, even though the vehicle
is not available.
6E93
6E94
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)

Flow Chart for Snapshot Replay (Plotting Graph)
6E95
6E96
SNAPSHOT DISPLAY WITH TIS2000
Procedures for transferring and displaying Tech2

snapshot data by using TIS2000 [Snapshot Upload]
function is described below.
Snapshot data can be displayed with [Snapshot Upload]
function included in TIS2000.
1. Record the snapshot data, in Tech2.
2. Transfer the snapshot data to PC.
By analyzing these data in various methods, trouble

conditions can be checked.
Snapshot data is displayed by executing the three steps
below shown:

After recording the snapshot in Tech2, transfer the data
from Tech2 to PC by the below procedures.
1. Start TIS2000.
2. Select [Snapshot Upload] on the TIS2000 start
screen.
3. Select [Upload from trouble diagnosis tool (transfer
from diagnosis tester)] or click the corresponding
icon of the tool bar.
4. Select Tech2, and transfer the recorded snapshot
information.
5. Select the transferred snapshot.
6. After ending transfer of the snapshot,
parameter list is displayed on the screen.
data
6E97
3.
Snapshot data is displayed with TIS2000

[Snapshot Upload] function.
Snapshot is stored in the PC hard disk or floppy disk,
and can be displayed any time.
Stored snapshot can be displayed by the below
procedures.
1. Start TIS2000.
screen.
3. Select [Open the existing files] or click the
corresponding icon of the tool bar.
5. Open the snapshot, to display the data parameter
list on the screen.
Graph display Values and graphs (Max. 3 graphs):
1. Click the icon for graph display. [Graph Parameter]

window opens.
2. Click the first graph icon of the window upper part,
and select one parameter from the list of the window
lower part. Selected parameter is displayed nest to
the graph icon. Graph division can be selected in
the field on the parameter right side.
3. Repeat the same procedures with the 2nd and 3rd
icons.
4. After selecting all parameters to be displayed (Max.
3 parameters), click [OK] button.
5. Parameter selected is displayed in graph form on
the right of the data parameter on the screen.
6. Graph display can be moved with the navigation
icon.
7. For displaying another parameter by graph, click the
parameter of the list, drug the mouse to the display
screen while pressing the mouse button and release
the mouse button. New parameter is displayed at
the position of the previous parameter.
For
displaying the graph display screen in full size,
move the cursor upward on the screen. When the
cursor is changed to the magnifying glass form, click

the screen. Graph screen is displayed on the whole
screen.
6E98
Display of graphs on one screen (Max. 6 graphs):
1. Click the 6 graph icon. [Graph Parameter] window

opens.
2. Click the graph icon, select the parameter to be
displayed from the list and change divisions
according to necessity.
3. Repeat the same procedures with the graph icons,
from the 2nd to 6th.
4. Click the [OK] button to display.
5. In this case, parameters are displayed only in graph
form. All parameters are displayed in one graph.
6. The graph display screen can be moved with the
navigation icon.
6E99
SERVICE PROGRAMMING SYSTEM (SPS)

The procedure to program the control unit by using the
Service Programming System (SPS) software contained
in TIS2000 is explained below.
NOTE:
If the Engine Control Module (ECM) was
programmed, the Immobilizer System must be
linked to the ECM: Refer to section 11
Immobilizer System-ECM replacement for the
ECM/Immobilizer linking procedure.
Should Tech2 display "SPS Procedure was not
successful", engine will not start, but no DTCs
are present, low battery voltage or poor electrical
connections should be the primary suspects.
Perform the SPS procedure again after rectifying
the fault/s.
5. On the screen of Diagnostic Tester and Processing

Program Selection, choose the one that will comply
with the following.
Tech-2 in use
New programming by the existing module or new
programming by the replaced/new module.
Fixing position of the control unit.
IMPORTANT:
Perform the following checks before attempting to
program the control unit:
The Tech2 PCMCIA card is programmed with The
latest software release.
The latest release of TIS2000 is loaded on the PC.
The vehicle battery is fully charged.
The control unit to be programmed is connected
to the vehicle.
1. Preparations of TIS 2000
1. Connect Tech 2 to P/C.
2. Check to see if Hardware Key is plugged into Port.
3. Activate TIS 2000 by P/C.
4. On the activating screen of TIS2000, choose
Service Programming System
6. Upon completion of the selection, push the button of

Next.
6E100
2. Demand of Data
1. Connect Tech-2 to the vehicle. When activated by
turning on the power of Tech-2, push the Enter
switch.
2. Turn on the ignition switch (without starting the
engine)
5. Where vehicle data has been already saved in Tech

2, the existing data come on display. In this
instance, as Tech-2 starts asking whether to keep
the data or to continue obtaining anew data from the
control unit, choose either of them
3. In the main menu of Diagnostic Tester, push F1:

Service Programming System (SPS).
4. Push F0: Request Info of Tech-2.
6. If you select continue, you have to select Model

Year, Vehicle Type.
7. After that. then push button and turn Ignition switch
tuned on, off, on following Tech-2 display. Tech-2
will read information from controller after this
procedure.
8. During obtaining information, Tech-2 is receiving
information from the control unit ECM and TCM (A/T
only) at the same time. With VIN not being
programmed into the new control unit at the time of
shipment, "obtaining information" is not complete
(because the vehicle model, engine model and
model year are specified from VIN). For the
procedure get additional information on vehicles,
instruction will be provided in dialog form, when
TIS2000 is in operation.
9. Following instructions by Tech-2, push the Exit
switch of Tech-2, turn off the ignition of the vehicle
and turn off the power of Tech-2, thereby removing
from the vehicle.
3. Data Exchange
1. Connect Tech-2 to P/C, turn on the power and click
the Next button of P/C.
2. Check VIN of the vehicle and choose Next.
3. Select System Type for required control unit.
Engine (Programming for ECM or PCM)
Transmission (Programming for TCM)
4. When a lack of data is asked from among the
following menu, enter accordingly.
Select following Menu
Model Year
Model
Engine type
Transmission type
Destination code (vehicles for general export)*1
Immobilizer
Etc.
* 1: How to read the destination code
Destination code can be read from ID Plate affixed on
vehicles, while on VIN plate the destination code is
described at the right-hand edge of Body Type line. In
the figure, the destination code can be read as "RR3"
(Australia).
5. After choosing the data, click the Next button.

6. When all the necessary information is entered, the
details of software within the database that match
the entered data will appear for confirmation. Click
the Program switch and then download the new
software onto Tech-2.
7. Data Transfer comes on display. The progress of
downloading will be displayed on the screen in the
form of bar graph.
8. Upon finishing the data transfer, turn off the power
of Tech-2, removing from P/C.
6E101
4. Programming of ECM
1. Check to see if batteries are fully charged, while
ABS connectors shall be removed from the vehicle.
2. Connect Tech-2 to Vehicle Diagnostic Connectors.
3. Turn on the power of Tech-2 and the title screen
comes on display.
4. Turn on the ignition (without allowing the engine to
start)
5. On the title screen of Tech-2, push the Enter
button.
6. Choose F1: Service Programming System on the
main screen and then choose Fl: Program ECU.
7. While data is being transferred, Programming in
Progress will be displayed on the Tech-2 screen.
8. Upon finishing the data transfer, Tech-2 will display
Reprogramming Was Successful. Push the Exit
button to bring program to completion
9. Following Procedure 2: Demand of Data, try over
again Information Obtaining and check to confirm
if the data has been correctly re-loaded.
10. Upon finishing confirmation, turn off the ignition of
the vehicle and then turn off the power of Tech-2,
removing from the vehicle.
6E102
HOW TO USE BREAKER BOX

(2) Harness Adapter
The engine control module (ECM) and other connectors
have water proof connector and special terminal. Water
proof terminal does not allow to use back prove. In
addition, the engine control module (ECM) special
terminal can not let regular digital voltage meter prove
to access, because terminal shape is very fin pin type.
In order to prevent damage of female terminal and
connector itself, the breaker box and adapter is the
most suitable special tool.

(3) Breaker Box

Breaker Box Connection Type A

(2) Harness Adapter
(3) Breaker Box
Breaker box connection type A, check for open circuit
and short to ground circuit.
(4) Digital Voltage Meter

(5) ECM - Harness Adapter Disconnection
6E103
6E104
Breaker Box Connection Type B

(2) Harness Adapter
(3) Breaker Box
Breaker box connection type B, check for short to
power supply circuit and power, signal voltage check
between the engine control module (ECM) and
electrical components.

(5) ECM - Harness Adapter Connection
6E105
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK
Circuit Description
connection, and damaged harness.
The on-board diagnostic system check is the starting

point for any driveability complaint diagnosis. Before
using this procedure, perform a careful visual/physical
check of the ECM and engine grounds for cleanliness
and tightness.
The on-board diagnostic system check is an organized
approach to identifying a problem created by an
electronic engine control system malfunction.
Test Description
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbed-through wire insulation or a wire broken inside
the insulation.
Check for poor connections or a
damaged harness. Inspect the ECM harness and
connector for improper mating, broken locks, improperly
formed or damaged terminals, poor terminal-to-wire
Number(s) below refer the step number(s) on the

Diagnostic Chart:
1. The Check Engine Lamp (MIL) should be ON steady
with the ignition On, engine Off. If not, No Check
Engine Lamp (MIL) chart should be used to isolate the
malfunction.
2. Checks the Class 2 data circuit and ensures that the
ECM is able to transmit serial data.
3. This test ensures that the ECM is capable of
controlling the Check Engine Lamp (MIL) and the Check
Engine Lamp (MIL) driver circuit is not shorted to
ground circuit.
4. If the engine will not start, Engine Cranks But Will
Not Run chart should be used to diagnose the fault.
6E106
6. The Tech2 parameters which is not within the typical

range may help to isolate the area which is causing the
problem.
12. This vehicle is equipped with ECM which utilizes an

electrically erasable programmable read only memory
(EEPROM).

Step
1
Action
Value(s)
Go to Step 3
Go to Step 7
Go to Step 4
Go to CHECK
ENGINE LAMP
On Steady
Go to Step 5
Go to Engine
Cranks But Will
Not Run
Go to DTC
Chart
Go to Step 6
Refer to
SYMPTOM
DIAGNOSIS
Refer to
TYPICAL
SCAN DATA
Repair faulty
harness and
verify repair
Go to Step 8
Attempt to start the engine.

Does the engine start and continue to Run?
1. Using the Tech 2, ignition On and engine Off.
2. Select the Read DTC Infor As Stored By ECU in
Diagnostic Trouble Code.
3. Are any DTCs stored?
Go to Step 2

2. Select the Miscellaneous Test and perform the
Check Light in Lamps.
3. Operate the Tech 2 in accordance with the Tech 2
instructions.
Does the CHECK ENGINE lamp turn Off?
Go to No
CHECK
ENGINE Lamp

2. Attempt to display Data Display with the Tech 2.
Does the Tech 2 display engine data?
No
1. Ignition On, engine Off.

2. Check the CHECK ENGINE lamp (MIL).
Does the CHECK ENGINE lamp turn On?
Yes
Compare typical scan data values displayed on the

Tech 2 Data Display.
Are the displayed values within the range?
Using the DVM and check the data link connector
power supply circuit.
1. Ignition Off, engine Off.
2. Check the circuit for open circuit.
B-58

Step
Action

ground circuit.
6E107
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Less than 1V
Go to Step 10
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 11

B-58
4

ground circuit.
2. Check the circuit for short to power supply circuit.
Was the DVM indicated specified value?
B-58
4
V V
10

communication circuit.
Was the DVM indicated fixed battery voltage?
B-58
6
6E108
Step
Action
Value(s)
Yes
No
11

Repair faulty
harness and
verify repair
Go to Step 12
Is the ECM programmed with the latest software

release?
If not, download the latest software to the ECM using
the SPS (Service Programming System).
Was the problem solved?
Verify repair
Go to Step 13
Replace the ECM.

IMPORTANT: The replacement ECM must be
programmed. Refer to section of the Service
Programming System (SPS) in this manual.
Following ECM programming, the immobilizer system
(if equipped) must be linked to the ECM. Refer to
section 11 Immobilizer System-ECM replacement for
the ECM/Immobilizer linking procedure.
Verify repair

2. Disconnect the ECM connector.
3. Check the circuit for open or short to ground
circuit.
C-56
B-58
12
13
6E109
NO CHECK ENGINE LAMP (MIL)
Circuit Description
The check engine lamp should be illuminated and
steady for about five seconds with the ignition ON and
the engine stopped. Ignition feed voltage is supplied to
the check engine lamp bulb through the meter fuse.
The Engine Control Module (ECM) turns the check
engine lamp ON by grounding the check engine lamp
driver circuit.
Diagnostic Aids
An intermittent check engine lamp may be cased by a
poor connection, rubbed-through wire insulation, or a
wire broken inside the insulation.

following items:
Check for the
Inspect the ECM harness and connections for

improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection,
and damaged harness.
If the engine runs OK, check for a faulty light bulb, an
open in the check engine lamp driver circuit, or an
open in the instrument cluster ignition feed.
If the engine cranks but will not run, check for an
open ECM ignition or battery feed, or a poor ECM to
engine ground.
6E110
No Check Engine Lamp (MIL)

Step
1
Action
Check the meter fuse (15A).
If the fuse is burnt out, repair as necessary.
Value(s)
Yes
No
Verify repair
Go to Step 2
10-14.5V
Go to Step 5
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Using the DVM and check the CHECK ENGINE

lamp circuit.
3. Ignition On.
C-56
42
V
3
Check the CHECK ENGINE lamp bulb.

If the bulb is burnt out, repair as necessary.
lamp circuit.
2. Disconnect the meter connector
connector.
and
ECM
C-56
42
B-24
17

release?
6E111
Step
Action
Value(s)
Yes
No
Replace the ECM.

Verify repair
6E112
CHECK ENGINE LAMP (MIL) ON STEADY
Circuit description
Diagnostic Aids
The check engine lamp should always be illuminated

and steady for about five seconds with ignition ON and
the engine stopped. Ignition feed voltage is supplied
directly to the check engine lamp indicator. The Engine
Control Module (ECM) turns the check engine lamp
ON by grounding the check engine lamp driver circuit.
The check engine lamp should not remain ON with the
engine running and no DTC(s) set. A steady check
engine lamp with the engine running and no DTC(s)
suggests a short to ground in the check engine lamp
driver circuit.

rubbed-through wire insulation, or a wire broken inside
the insulation. Check for the following items:
Poor connection or damaged harness Inspect the
ECM harness and connectors for improper mating,
broken locks, improperly formed or damaged
terminals, poor terminal-to-wire connection, and
damaged harness.
6E113
Check Engine Lamp (MIL) On Steady

Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to Step 4
Verify repair
Go to Step 3
Replace the meter assembly.

Verify repair

release?
Verify repair
Go to Step 5
Replace the ECM.

Verify repair

3. Ignition On.
Was the CHECK ENGINE lamp turned on?

lamp circuit.
2. Disconnect
connector.
the
meter connector
and
ECM
3. Check the circuit for short to ground circuit.

C-56
42
B-24
17
3
4
6E114
ECM Diagnostic Trouble Codes

Flash
Code
Code
Symptom
Code
MIL
DTC Name
65
P0100
ON
34
P0105
ON
ON
ON
ON
ON
DTC Setting Condition
Fail-Safe (Back Up)

Voltage Supply Circuit High
Input
MAF sensor power supply

voltage is more than 5.2V.
ECM uses mass air flow

1600mg/strk & EGR 10%
conditions as substitute.

Voltage Supply Circuit Low
Input

voltage is below 4.6V.

Output Circuit Low Input

Output Circuit High Input
Vacuum Pressure Sensor

Circuit High Input

Circuit Low Input
MAF sensor output is more

than -27.4mg/strk.
MAF sensor output is below

1378mg/strk (4JA1-TC) or
1784mg/strk (4JH1-TC).
1. Engine speed is between

600rpmand5000rpm.
2. MAF sensor output is
more than 1378mg/strk
(4JA1-TC) or 1784mg/
strk (4JH1-TC).
Vacuum sensor output




600rpmand5000rpm.
below -33.7mg/strk.

Recovery Condition
1. Fuel injection quantity is

reduced.
2. ECM use 615hpa
conditions for
turbocharger waste gate
control.


Related Failure Parts
Related
ECM Pin
No.
Related
Multiple
DTC
1. Sensor power supply

circuit short to battery
voltage circuit.
2. MAFsensormalfunction.
3. ECM malfunction.
83

circuit short to ground
circuit.
3. ECM malfunction.
83

circuit open circuit.
2. Sensor signal circuit
open or short to ground
circuit.
3. Sensor heater harness
open circuit.
4. Poor connector
connection.
6. ECM malfunction.
83/
88
P0110(1)

shortto voltagecircuit.
2. Sensor ground circuit
open or short to voltage
circuit.
4. ECM malfunction.
88/
92
P0110(1)

shortto voltagecircuit.
circuit.
3. Vacuum sensor
malfunction.
4. ECM malfunction.
85/
93
P0115(1)

circuit open circuit.
circuit.
3. Poor connector
connection.
4. Vacuum sensor
malfunction.
5. ECM malfunction.
82/
85
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)

Flash
Code
Code
Symptom
Code
MIL
34
P0105
ON
23
P0110
14
P0115
15
P0180
ON
ON
ON
ON
ON
ON
DTC Name

Input
Vacuum sensor power

supply voltage is more than
5.2V.

Input
Vacuum sensor power

supply voltage is below 4.5V.
Intake Air Temperature (IAT)

Sensor Circuit High Input
IAT sensor output voltage is

more than 4.7V.

Sensor Circuit Low Input

below 0.3V.
Engine Coolant Temperature

(ECT) Sensor Circuit High
Input
ECT sensor output voltage is

more than 4.7V.

(ECT) Sensor Circuit Low
Input

below 0.3V.
Fuel Temperature Sensor

Circuit Range/Performance
FT sensor output is high

temperature (more than 150
deg. C) or low temperature
(below -40 deg. C).
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)

voltage circuit.
2. Vacuum sensor
malfunction.
3. ECM malfunction.
82
Vacuum sensor power

supply voltage is more than
4.5V.

circuit.
2. Vacuum sensor
malfunction.
3. ECM malfunction.
82

below 4.7V.

circuit.
circuit.
3. Poor connector
connection
4. IATsensormalfunction.
5. ECM malfunction.
84/
92
P0100(B)/
P0100(C)

more than 0.3V.

shortto groundcircuit.
2. IATsensormalfunction.
3. ECM malfunction.
84

below 4.7V.

circuit.
circuit.
3. Poor connector
connection
4. ECTsensormalfunction.
5. ECM malfunction.
89/
93
P0105(1)

more than 0.3V.

shortto groundcircuit.
3. ECM malfunction.
89
FT sensor output is correct

temperature range between
150 deg. C and -40 deg. C.
1. ECM malfunction.
2. PSG (pump control unit)
malfunction.
Fail-Safe (Back Up)
Recovery Condition

reduced.
2. ECM use vacuum sensor
output voltage 5.0V
condition as substitute.
Vacuum sensor power

supply voltage is below 5.2V.
ECM use 0 deg. C conditions

as substitute.
1. ECM uses fuel

temperature as
substitute.
2. ECM uses 60 deg. C
condition for injection
timing control.
3. ECM uses -25 deg. C
condition (4JA1-TC) or 15 deg. C condition
(4JH1-TC) for glow time
control.
The ECM use 75 deg. C

4JH1-TC
(MT)
6E115
4JH1-TC
(AT)
6E116
Flash
Code
Code
Symptom
Code
MIL
52
P0215
ON
54
P0216
ON
ON
ON
ON
ON
DTC Name
Fuel Cutoff Solenoid Valve
Malfunction

Circuit High Input

Always Active
Fail-Safe (Back Up)
Recovery Condition
1. Ignition key switchoff.

2. Engine speed is below
1500rpm.
3. Vehicle speed is below
1.5km/h.
recognizes MAB (fuel
cutoff solenoid valve)
signal from the ECM, but
the MAB could not
operate.
1. MAB (fuel cutoff solenoid

valve) is operated.
2. Desired injection quantity
becomes 0mg/strk.
No recovery until condition

match in the next ignition key
cycle.

malfunction.
valve) malfunction.
ECM does not command

MAB (fuel cutoff solenoid
valve) signal to the PSG
(pump control unit), but PSG
detected MAB signal line
circuit is high level.
1. Ignition key switchoff.
1500rpm.
1.5km/h.
does not recognize MAB
(fuel cutoff solenoid
valve) signal from the
ECM.
Engine does not start.

valve) is operated.
becomes 0mg/strk.

Malfunction
1. Ignition key switch off.

2. CAN controller does not
operate Bus-off.
Injection Timing Control

Circuit Malfunction
Fuel injection quantity is

1. Engine speed is more
reduced.
than 700rpm.
more than 4mg/stk.
3. Deviation of actual
injection timing and
desired injection timing is
more than +3 deg. CA or
-6 deg. CA for 8 seconds.

Circuit Malfunction

than 2014rpm.
2. Fluctuation of actual
injection timing is more
than +-5.2 deg. CA.
No recovery.

cycle.
No fail-safe function.

valve) signal circuit short
to voltage circuit.
malfunction.
valve) signal circuit open
orshorttogroundcircuit.
malfunction.
1. ECM malfunction.
malfunction.
Deviation of actual injection
timing and desired injection
timing is more than +3 deg.
CA or -6 deg. CA for 8
seconds.

than 2014rpm.
than +-5.2 deg. CA.
1. Timing control valve

malfunction.
2. Timer piston sticking.
3. Pump camshaft speed
sensor malfunction.
1. Insufficient air bleeding of

fuel line.
2. Fuel filterclogging.
3. Timing control valve
malfunction.
sensor malfunction.
Related
ECM Pin
No.
Related
Multiple
DTC
105
105
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)

Flash
Code
Code
Symptom
Code
MIL
64
P0243
ON
ON
ON
ON
DTC Name
Turbocharger Wastegate
Solenoid "A" Range/
Performance
Solenoid "A" Low
Solenoid "A" Range/
Performance
Solenoid "A" Malfunction
Fail-Safe (Back Up)
Recovery Condition
1. Intake air temperature is

between -50 deg. C and
200 deg. C.
2. Engine coolant
temperature is between 50 deg. C and 150 deg.
C.
3. Barometric pressure is
between 0hpa and
3500hpa.
4. Low vacuum pressure
condition. (Desired
vacuum pressure - actual
vacuum pressure is more
than 50hpa.)

reduced.
2. EGR EVRV becomes
10% condition.

500rpm and 6000rpm.
2. Correct vacuum pressure
condition. (Desired
vacuum pressure is less
than 50hpa.)
1. Turbocharger wastegate
control EVRV
malfunction.
2. Vacuum line is
obstructed.
3. Vacuum is leaking.
4. Vacuum pump
malfunction.
5. Vacuum sensor
malfunction.
6. Turbocahrger wastegate
valve malfunction.
7. ECM malfunction.
Wastegate control EVRV

circuit open or short to
ground circuit.

200 deg. C.
2. Engine coolant
C.
between 0hpa and
3500hpa.
4. High vacuum pressure
condition. (Desired
vacuum pressure is less
than -50hpa.)
1. Engine coolant
C.
2. EGR control EVRV 0%
condition.
3. No DTC relating to MAF
sensor, vacuum sensor &
IAT sensor.
4. Large amount of mass air
flow. (= Incorrect boost
pressure condition)
(Desired mass air flow actual mass air flow is
less than -56mg/strk.)

reduced.
2. EGR EVRV becomes
10% condition.
3. Wastegate control EVRV
becomes 32% condition.
reduced.
2. EGR EVRV becomes
10% condition.

circuit is correct condition.

500rpm and 6000rpm.
2. Correct vacuum pressure
condition. (Desired
vacuum pressure is more
than -50hpa.)
1. Correct amount of mass

air flow. (= Correct boost
pressure condition)
(Desired mass air flow actual mass air flow is
more than -56mg/strk.)

ground circuit.
malfunction.
3. ECM malfunction.
control EVRV
malfunction.
2. Vacuum regulating valve
malfunction.
3. Vacuum pump
malfunction.
4. Vacuum sensor
malfunction.
5. ECM malfunction.
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)
85/
96
96
85/
96
actuator malfunction.
2. Vacuumlinemalfunction.
3. ECM malfunction.
4JH1-TC
(MT)
6E117
4JH1-TC
(AT)
6E118
Flash
Code
Code
Symptom
Code
MIL
64
P0243
ON
53
P0251
ON
ON
ON
ON
ON
ON
ON
DTC Name
Solenoid "A" High
Injection Pump Malfunction
Fail-Safe (Back Up)

circuit short to voltage circuit.

reduced.
2. EGR EVRV becomes
10% condition.

circuit is correct condition.

valve) is operated.
becomes 0mg/strk.

cycle.
1. No pump camshaft
speed sensor error.
2. High pressure solenoid
valve control pulse width
does not match with
desired fuel injection
quantity.
Recovery Condition
1. No pump camshaft
speed sensor error.
2. No CKP sensor error.
3. Difference of engine
speed and doubled pump
camshaft speed is below
800rpm (4JA1-TC) or
690rpm (4JH1-TC).
No recovery until in the
next ignition key cycle.
1. No pump camshaft
speed sensor error.
3. Difference of engine
speed and doubled pump
camshaft speed is more
than 720rpm (4JA1-TC)
or 690rpm (4JH1-TC).
No pump map programmed

in the PSG (pump control
unit) or PSG malfunction.
EEPROM or A/D converter
malfunction in the PSG
(pump control unit).

reduced.
PSG (pump control unit)

recognized high pressure
solenoid valve drive circuit
error.
Related
ECM Pin
No.
Related
Multiple
DTC
4JA1-TC
(MT)

circuit short to voltage
circuit.
malfunction.
3. ECM malfunction.
96
91
99/
100
P1650(A)/
P1651(B)

malfunction.
sensor malfunction.
1. Missing CKP sensor

pulses.
2. Electrical interference.
3. Magneticinterference.
malfunction.

cycle.

malfunction.

no malfunction in the PSG
(pump control unit).
No recovery until in the next
ignition key cycle.

malfunction.

cycle.

malfunction.

malfunction.

could not measure the high
pressure solenoid valve drive
voltage.
ECM could not accept PSG
(pump control unit) message.

valve) is operated.
becomes 0mg/strk.
ECM accepts PSG (pump

control unit) message.
1. CAN high circuit open,

short to ground or short
to voltage circuit.
2. CAN low circuit open,
to voltage circuit.
3. ECM malfunction.
malfunction.
4JH1-TC
(MT)
4JH1-TC
(AT)

Flash
Code
Code
Symptom
Code
MIL
43
P0335
ON
66
P0380
ON
ON
ON
ON
DTC Name
Crankshaft Position Sensor
Circuit Malfunction

Circuit Malfunction
Engine Speed Input Circuit

Range/Performance
Fail-Safe (Back Up)

than 665rpm.
2. CKP sensor pulse width
error.
When pump camshaft speed

sensor is OK:
ECM uses doubled pump
camshaft speed as substitute
enginespeed.
sensor is not OK:
valve) is operated.
becomes 0mg/strk.
1. No pump camshaft
speed sensor error.
2. "Crankshaft Position
Sensor Circuit
Malfunction (Symptom
CodeB)" isnotstored.
3. Engine speed is 0rpm.
4. Doubled pump camshaft
speed is more than
50rpm.
Engine speed is more than

5700rpm.
Glow Relay Circuit Voltage

Low
Glow relay circuit open or

short to ground circuit.

High
Glow relay circuit short to

voltage circuit.

sensor is OK:
enginespeed.
Other than pump camshaft
speed sensor is OK:
reduced.
Recovery Condition
ECM detects correct CKP
pulse width.

than 0rpm.
speed is below 100rpm.
When intermittent
malfunction:
valve) is operated.
becomes 0mg/strk.
When preliminary
malfunction:
engine speed.
Engine speed is below

5700rpm.
Glow relay circuit is correct

condition.
Related
ECM Pin
No.
Related
Multiple
DTC
1. During engine run:

1. CKP sensor harness
open circuit, short to
ground or short to
voltage circuit.
2. Poor connector
connection.
3. CKPsensormalfunction.
4. Pulse sensing gap
incorrect.
5. Pulser malfunction.
7. Magnetic interference.
8. ECM malfunction.
90/
98/
101
P1335 (A)
During engine crank:

ground or short to
voltage circuit.
2. Poor connector
connection.
incorrect.
8. ECM malfunction.
90/
98/
101
P1135 (A)
90/
98/
101
94
1. Engine over-running.
4. ECM malfunction.
1. Glow relay circuit open or

short to groundcircuit.
2. Glowrelaymalfunction.
3. ECM malfunction.
ECM malfunction.
4JA1-TC
(MT)
4JH1-TC
(MT)
6E119
4JH1-TC
(AT)
6E120
Flash
Code
Code
Symptom
Code
MIL
67
P0381
ON
32
P0400
DTC Name
Glow Plug Indicator Circuit
Voltage Low
ON

Voltage High
ON

Flow Excessive Detected
ON
ON
ON

Circuit Short to Ground or
Open Circuit
Flow Insufficient Detected

Circuit Short to Battery

Glow plug indicator circuit
circuit.
Fail-Safe (Back Up)

Recovery Condition
Related
ECM Pin
No.
Related
Multiple
DTC
Glow plug indicator circuit is

correct condition.
1. Glow plug indicator

ground circuit.
2. Glow plug indicator lamp
malfunction.
3. ECM malfunction.
43
88/
97
97
88/
97
97

short to voltage circuit.
between 15 deg. C and
100 deg. C.
2. Engine coolant
temperature is between
55 deg. C and 100 deg.
C (4JA1-TC) or 35 deg. C
and 100 deg. C (4JH1TC).
between 850hpa and
1100hpa.
4. Small amount of mass air
flow. (Desired mass air
flow - mass air flow is
more than 150mg/strk)
EGR EVRV circuit open or

between 15 deg. C and
100 deg. C.
2. Engine coolant
temperature is between
55 deg. C and 100 deg.
C (4JA1-TC) or 35 deg. C
and 100 deg. C (4JH1TC).
between 850hpa and
1100hpa.
4. Large mount of mass air
below -150 mg/strk)
EGR EVRV circuit short to
voltage circuit.
ECM malfunction.

reduced.

1500rpm and 3100rpm
(4JA1-TC) or 1500rpm
and3200rpm(4JH1-TC).
2. Injection quantity is
below 32mg/strk (4JA1TC) or 40mg/stk (4JH1TC).
air flow.
1. EGR valve is stuck at

open position.
2. EGREVRVmalfunction.
3. Air intake is obstructed.
4. Airintakeisleaking.
6. ECM malfunction.

EGR EVRV circuit is correct
reduced and EGR EVRV
condition.
10% conditions as substitute.
1. EGR EVRV circuit open

orshorttogroundcircuit.
3. ECM malfunction.

reduced.
1. EGR valve is stuck at

close position.
2. EGR valve operating
vacuum hose is clogged
or disconnected.
4. MAF sensor signal circuit
short to voltagecircuit.
6. ECM malfunction.

reduced & EGR EVRV 10%

1500rpm and 3100rpm
(4JA1-TC) or 1500rpm
and3200rpm(4JH1-TC).
2. Injection quantity is
below 32mg/strk (4JA1TC) or 40mg/stk (4JH1TC).
air flow.
EGR EVRV circuit is correct

condition.
1. EGR EVRV circuit short

to voltage circuit.
3. ECM malfunction.
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)

Flash
Code
Code
Symptom
Code
24
P0500
35
P0560
MIL
DTC Name
Fail-Safe (Back Up)
ON Vehicle Speed Sensor Circuit

High Input
at
next
igniti
on
cycle
Vehicle speed is more than

200km/h.
ECM uses vehicle speed

5km/h condition as
substitute.
ON Vehicle Speed Sensor Input

Signal Frequency Too High
at
next
igniti
on
cycle
Input signal frequency is too

high.
ON Vehicle Speed Sensor

Incorrect Signal
at
next
igniti
on
cycle
OFF
OFF
System Voltage Too High
System Voltage Too Low

or3600rpm(4JH1-TC).
more than 30mg/strk
(4JA1-TC) or 41mg/strk
(4JH1-TC).
1.5km/h.
System voltage is more than
20V.
System voltage is below 7V.
ECM uses vehicle speed

5km/h condition as
substitute.

reduced.
ECM uses 9V conditions as

substitute.
Recovery Condition
Vehicle speed is below
200km/h.
Correct vehicle speed signal

frequency.

1.5km/h.

7V.
Related
ECM Pin
No.
Related
Multiple
DTC
1. VSS signal circuit open,

to voltage circuit.
2. VSS malfunction.
3. Speed meter
malfunction.
4. TCM malfunction (AT
2WD).
5. ECM malfunction.
68
1. VSS malfunction.
2. Speed meter
malfunction.
4. Magneticinterference.
5. ECM malfunction.
68
1. VSS open circuit, short

to ground or short to
voltage.
2. Poor connector
connection.
3. VSS malfunction.
4. Speed meter
malfunction.
5. ECM malfunction.
68
1. Charge system
malfunction.
2. Battery jump start cable
misconnect.
3. ECM malfunction.
3/
39
1. Battery power feed

harness open circuit or
2. ECM ground harness
openorpoorconnection.
3. Poor connector
connection.
4. Battery malfunction.
5. Charge system
malfunction.
6. ECM malfunction.
3/
39
4JA1-TC
(MT)
4JH1-TC
(MT)
6E121
4JH1-TC
(AT)
6E122
Flash
Code
Code
Symptom
Code
MIL
35
P0560
OFF
18
P0561
P0602
28
P0606
OFF
OFF
ON
ON
DTC Name
System Voltage Malfunction
Ignition Switch Circuit

Malfunction
Ignition Switch Circuit

Malfunction

System voltage of PSG
(pump control unit) is below
4.5V or more than 27V.
The ECM recognized ignition

switch turn off signal during
ECM is activated.
PSG uses default voltage as

substitute.
ECM stops engine.
Recovery Condition
System voltage of PSG is
between 4.5V and 27V.

cycle.
Ignition switch circuit is

malfunction.
Control Module
Programming Error
ECM memory area error.
ECU Malfunction
Gate Array communication

error.
ECU Malfunction
Fail-Safe (Back Up)
1. Throttle position is below

1%.
is more than 0mg/strk.
than 2000rpm.
Engine control disabled.

valve) is operated.
becomes 0mg/strk.
valve) is operated.
Related
ECM Pin
No.
Related
Multiple
DTC
1. Battery power feed

harness open circuit or
ground harness open or
poor connection.
3. Poor connector
connection.
5. Charge system
malfunction.
6. Battery jump start cable
misconnect.
malfunction.
1. Ignition switch circuit

circuit.
2. Poor connector
connection.
3. Ignition switch
malfunction.
4. ECM malfunction.
39
1. Ignition switch circuit

circuit.
2. Poor connector
connection.
3. Ignition switch
malfunction.
4. ECM malfunction.
39
Memory are is OK.
ECM is not programmed.
No recovery.
ECM malfunction.
Desired injection quantity is

below 0mg/strk.
1. ECM malfunction.
malfunction.
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)

Flash
Code
Code
Symptom
Code
MIL
46
P0645
ON
25
P0703
86
P0704
P1105
A/C Compressor Relay

Circuit Voltage Low
ON

Circuit Voltage High
ON
Brake Switch Circuit

Malfunction
57
DTC Name
ON
ON
ON
ON

Malfunction

A/C compressor relay circuit
circuit.
Fail-Safe (Back Up)


is correct condition.

1. Throttle position is more
than 0%.
or665rpm(4JH1-TC).
3. Vehicle speed is more
than 0km/h.
4. Brake switch 1 signal and
brake switch 2 signal are
differently inputted to the
ECM since the ignition
switch was turned on.

1. A/C compressor relay
ground circuit.
2. Poor connector
connection.
3. A/C compressor relay
malfunction.
4. ECM malfunction.
ECM malfunction.
Brake switch 1 signal and

correctly inputted to the
ECM.
1. Brake switch 1 circuit

open, short to ground or
2. Poor connector
connection.
3. Brake switch 1
malfunction.
4. ECM malfunction.
1. Brake switch 2 circuit

circuit.
2. Poor connector
connection.
3. Brake switch 2
malfunction.
4. ECM malfunction.

than 0%.
or665rpm(4JH1-TC).
than 0km/h.
ECM.
Clutch signal does not
change between vehicle
speed 1.5km/h and 80km/h
since ignition switch was
tuned on.
Barometric Pressure Sensor

Circuit High Input
Barometric pressure sensor

output voltage is more than
4.4V.
ECM uses 1013hpa


Circuit Low Input

output voltage is below 1.5V.
Clutch Switch Input Circuit

Malfunction
Recovery Condition
Clutch signal correctly

changes.
1. Clutch switch circuit

open, short to ground or
shorttovoltage circuit.
2. Poor connector
connection.
3. Clutch switch
malfunction.
4. ECM malfunction.

ECM malfunction.

1.5V.
ECM malfunction.
Related
ECM Pin
No.
Related
Multiple
DTC
41
30
65
31
4JA1-TC
(MT)
4JH1-TC
(MT)
6E123
4JH1-TC
(AT)
6E124
Flash
Code
Code
Symptom
Code
MIL
21
P1120
ON
22
P1173
ON
ON
ON
ON
OFF
OFF
OFF
DTC Name
Pedal/Throttle Position

4.5V.
Fail-Safe (Back Up)
Recovery Condition
Related
ECM Pin
No.
Related
Multiple
DTC
ECM increases idle speed up

to 1400rpm.


circuit short to voltage
circuit.
short to voltagecircuit.
circuit.
4. Poor connector
connection.
5. TPS malfunction.
6. ECM malfunction.
38/
49/
57
Sensor Voltage Supply
Circuit High Input

power supply voltage is more
than 5.2V.

power supply voltage is
below 5.2V.

voltage circuit.
2. TPS malfunction.
3. ECM malfunction.
57
Sensor Voltage Supply
Circuit Low Input

power supply voltage is
below 4.6V.

than 4.6V.

circuit.
2. TPS malfunction.
3. ECM malfunction.
57
Throttle position is more than

20% or brake pedal is
released(switchisinactive).
1. Throttle sticking.
2. TPSincorrectadjusting.
3. TPS malfunction.
4. Brake switch
malfunction.
5. ECM malfunction.
30/
38/
65
38/
69
Sensor Brake Switch Error
Sensor Idle Position Switch
Error

than 1700rpm.
than 1.5km/h.
3. When brake pedal is
depressed during
accelerator pedal is
depressing.
1. When throttle position

sensor is 100%, idle
switch turns off.
2. When throttle position
sensor is 0%, idle switch
turns on.
1. When idle switch is

turned off, throttle
position sensor was
below 0.35%.
or
2. When idle switch is tuned
on, throttle position
sensor was more than
7.8%.
Fuel Reduction Caused By

High Coolant Temperature
Excessive high engine

coolant temperature is
detected.

High Fuel Temperature
Fuel temperature is more

than 100 deg. C.

Low Fuel Temperature
Excessive low fuel

temperature is detected.
4JA1-TC
(MT)
1. TPS malfunction.
2. Idle switch malfunction.
3. ECM malfunction.

is normal range.
1. Engine overheat.
3. ECM malfunction.
89

controls fuel injection
quantity based on engine
speed and fuel temperature.
Fuel temperature is below

100 deg. C.
1. ECM malfunction.
malfunction.
Fuel temperature is normal

range.
1. ECM malfunction.
malfunction.
4JH1-TC
(MT)
4JH1-TC
(AT)

Flash
Code
Code
Symptom
Code
MIL
DTC Name
43
P1335
ON
Engine Speed Output Circuit

Malfunction
The PSG (pump control unit)

is recognized defective
engine speed signal form the
ECM.
45
47
P1345
P1520
55
P1605
ON
ON
ON
Camshaft Speed Malfunction The PSG (pump control unit)

is recognized incorrect
camshaft speed signal.
Neutral Switch ON Error
Neutral Switch OFF Error
Neutral switch signal is

inputted "On" three times
consecutively under driving
conditions.
Fail-Safe (Back Up)

reduced.
Recovery Condition
Related
ECM Pin
No.
Related
Multiple
DTC
Correct engine speed signal.

ground or short to
voltage.
2. CKP sensor output
harness open circuit,
to voltage.
3. Poor connector
connection.
incorrect.
9. ECM malfunction.
malfunction.
90/
91/
98/
101
P0335(B)/
P0335(D)

sensor malfunction.
incorrect.
6. ECM malfunction.
malfunction.
1. Neutral switch circuit

shorttovoltage circuit.
2. Neutral switch
malfunction.
3. ECM malfunction.
87
1. Neutral switch circuit

open, short to ground
circuit.
2. Poor connector
connection.
3. Neutral switch
malfunction.
4. ECM malfunction.
87
Correct camshaft speed.
Correct neutral switch signal

is inputted two times
conditions.
Neutral switch signal is

inputted "Off" three times
conditions.
ON
Seed and Key File Destroyed Seed or key file in EEPROM

is destroyed.
No recovery.
ECM malfunction.
ON
EEPROM Defect
ECM uses default values

from the EPROM.
Write and read from the

EEPROM are correct during
initialization of the ECM.
ECM malfunction.

EEPROM are failed during
4JA1-TC
(MT)
4JH1-TC
(MT)
6E125
4JH1-TC
(AT)
6E126
Flash
Code
Code
Symptom
Code
MIL
55
P1605
ON
DTC Name
EEPROM Defect
Fail-Safe (Back Up)
EEPROM checksum does

not match with the read
check sum during
Recovery Condition
Security Key and Security

Code not Programmed
Immobilizer functions are not

programmed in the ECM.
1. Engine does not start.

2. Check engine lamp flash.
No recovery.
56
P1611
Wrong Security Code

Entered
Received security code is not

correct.

No recovery.
56
56
76
P1613
P1614
P1625
OFF
OFF
Immobilizer No or Wrong
Signal
Immobilizer No or Wrong
Signal
Wrong Transponder Key
Received challenge signal is

not correct or not received.
Received response signal is


not correct from the
transponder key.
ECM Main Relay Switched

Off Too Early
When ignition switch was

turned off, timing of the ECM
main relay turning off is too
early.

Off Too Late

late or does not off.



B****
1. ECM malfunction.
2. Immobilizer control unit
malfunction.
3. Transponder key
malfunction.
B****
1. ECM and immobilizer

control unit
communication circuit
ground circuit or short to
voltage circuit.
2. ECM malfunction.
malfunction.
4. Transponder key
malfunction.
27/
35
B****
1. ECM and immobilizer

control unit
communication circuit
ground circuit or short to
voltage circuit.
2. ECM malfunction.
malfunction.
4. Transponder key
malfunction.
27/
35
B****
1. ECM malfunction.
malfunction.
3. Transponder key
malfunction.
B****
3/
58
3/
58
ECM malfunction.
ECM malfunction.
P1610
P1612
Related
Multiple
DTC
EEPROM checksum match

with the read check sum
during initialization of the
ECM.
56
56
Related
ECM Pin
No.
No recovery.
No recovery.
No recovery.
No recovery.
No recovery.
ECM malfunction.
1. ECM main relay

malfunction.
2. ECM malfunction.
4JA1-TC
(MT)
4JH1-TC
(MT)
4JH1-TC
(AT)

Flash
Code
Code
Symptom
Code
MIL
51
P1630
ON
44
P1650
45
P1651
77
P1690
ON
ON
ON
ON
ON
OFF
OFF
DTC Name
Fuel Injection Quantity
Circuit Malfunction
Fuel Injection Quantity

Circuit Malfunction
CAN Device Offline
CAN Device Hang-up
CAN Malfunction
CAN Malfunction
Check Engine Lamp (MIL)

Circuit Voltage Low


detects high pressure
solenoid valve control circuit
malfunction due to high
current.
detects high pressure
solenoid valve control circuit
malfunction due to
continuous current.
CAN controller detects Busoff or canceling.
Fail-Safe (Back Up)

reduced.

valve) is operated.
becomes 0mg/strk.
valve) is operated.
CAN controller does not

react under engine running.
does not recognize CAN
signal from the CAN
controller.

valve) is operated.
becomes 0mg/strk.
The ECM does not read CAN

signal from the PSG (pump
control unit).
Check engine lamp circuit

circuit.

Related
ECM Pin
No.
Related
Multiple
DTC

to voltage circuit.
to voltage circuit.
3. Poor connector
connection.
4. Electricalinterference.
5. ECM malfunction.
malfunction.
99/
100
P1651(B)
CAN controller reacts

correctly under engine
running.
1. ECM malfunction.
malfunction.

recognizes CAN signal from
the CAN controller.
1. ECM malfunction.
malfunction.
The ECM reads CAN signal

from the PSG (pump control
unit).

to voltage circuit.
to voltage circuit.
3. Poor connector
connection.
5. ECM malfunction.
malfunction.
99/
100
P1650(A)
1. Check engine lamp

ground circuit.
2. Check engine lamp
malfunction
3. ECM malfunction.
42
B****
Recovery Condition
The PSG (pump control unit) PSG (pump control unit)

detects correct high pressure malfunction.
solenoid valve control circuit.
No recovery.
CAN controller detects

correct Bus signal.
Check engine lamp circuit is

correct condition.

malfunction.
ECM malfunction.
4JA1-TC
(MT)
4JH1-TC
(MT)
6E127
4JH1-TC
(AT)
6E128
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE 7)

(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR VOLTAGE SUPPLY
CIRCUIT HIGH INPUT
(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR VOLTAGE SUPPLY
CIRCUIT LOW INPUT
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE B)
(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR OUTPUT CIRCUIT LOW
INPUT
DIAGNOSTIC TROUBLE CODE (DTC) P0100 (SYMPTOM CODE C)
(FLASH CODE 65) MASS AIR FLOW (MAF) SENSOR OUTPUT CIRCUIT HIGH
INPUT
6E129
Condition for setting the DTC and action taken when the DTC sets
Flash
Code
Code
Symptom
Code
MIL
DTC Name
Fail-Safe (Back Up)
65
P0100
ON

Input

ECM uses mass air flow

1600mg/strk & EGR 10% conditions as substitute.
ON

Input

ON

Output Circuit Low Input

600rpm
and
5000rpm.
below -33.7mg/strk.
ON

Output Circuit High Input

600rpm
and
5000rpm.
2. MAF sensor output is more
than 1378mg/strk (4JA1-TC)
or 1784mg/strk (4JH1-TC).
Circuit Description
Diagnostic Aids
The mass air flow (MAF) sensor is part of the intake air
system. It is fitted between the air cleaner and
turbocharger and measure the mass air flowing into the
engine.
The mass air flow (MAF) sensor element measures the
partial air mass through a measurement duct on the
sensor housing.
The ECM monitors the MAF sensor supply voltage and
MAF sensor output voltage. The supply voltage is out of
range, DTC P0100 (Symptom Code 7) or P0100
(Symptom Code 9) will be stored. The output voltage
excessively high or low, DTC P0100 (Symptom Code B)
or P0100 (Symptom Code C) will be stored.
An intermittent may be caused by the following:

Poor connections.
Misrouted harness.
Rubbed through wire insulation.
Broken wire inside the insulation.
Check for the following conditions:
Poor connection at ECM-Inspect harness connectors
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and
poor terminal to wire connection.
Damaged harness-Inspect the wiring harness for
damage. If the harness appears to be OK, observe
the Mass Air Flow display on the Tech2 while
moving connectors and wiring harness related to the
sensor.
Diagnostic Trouble Code (DTC) P0100 (Symptom Code 7) (Flash Code 65)
Mass Air Flow (MAF) Sensor Voltage Supply Circuit High Input
Step
Action
Was the On-Board Diagnostic (OBD) System Check

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
1. Connect the Tech 2.

2. Review and record the failure information.
3. Select F0: Read DTC Infor As Stored By ECU in
F0: Diagnostic Trouble Codes.
Is the DTC P0100 (Symptom Code 7) stored as
Present Failure?
6E130
Step
Action
Value(s)

2. Select F1: Clear DTC Information in F0:
Diagnostic Trouble Codes with the Tech 2 and
clear the DTC information.
3. Operate the vehicle and monitor the F0: Read
DTC Infor As Stored By ECU in the F0:
Diagnostic Trouble Codes.
Was the DTC P0100 (Symptom Code 7) stored in this
ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 11
Go to Step 6
Approximately
5.0V
Go to Step 11
Less than 1V:

Go to Step 7
More than
specified value:
Go to Step 8
Verify repair
Go to Step 8
C-116
92
2 3
83
88
No
Check for poor/faulty connection at the MAF sensor or

ECM connector. If a poor/faulty connection is found,
repair as necessary.
C-57(B)
Yes
Visually check the MAF sensor.

Using the DVM and check the MAF sensor power
supply circuit.
2. Disconnect the MAF & IAT sensor connector.
3. Check the circuit for short to battery voltage
circuit.
C-116
4
V
7
Repair the open circuit between the ECM and MAF

sensor.
C-57(B)
C-116
4
83

Step
Action

supply circuit.
6E131
Value(s)
Yes
No
No continuity
Go to Step 10
Go to Step 9
Verify repair
Verify repair
Go to Step 13
Substitute a known good MAF & IAT sensor assembly

and recheck.
Go to Step 12
Go to Step 13
Replace the MAF & IAT sensor assembly.

Verify repair

release?
Verify repair
Go to Step 14
Replace the ECM.

Verify repair

2. Disconnect the MAF & IAT sensor connector and
ECM connector.
3. Check the circuit for short to MAF sensor +12V
supply circuit.
C-116
10
Repair the circuit for short to MAF sensor +12V supply

circuit.
Repair the short to battery voltage circuit between the
ECM and MAF sensor.
C-57(B)
C-116
4
83
11
12
13
14
6E132
Mass Air Flow (MAF) Sensor Voltage Supply Circuit Low Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 10
Go to Step 6
Approximately
5.0V
Go to Step 10
Go to Step 7

Present Failure?

ignition cycle?

C-57(B)
C-116
92
2 3
88
5
6
83

supply circuit.
C-116
4

Step
Action

supply circuit.
6E133
Value(s)
Yes
No
No continuity
Go to Step 9
Go to Step 8
Verify repair
Verify repair
Go to Step 12

and recheck.
Go to Step 11
Go to Step 12

Verify repair

release?
Verify repair
Go to Step 13
Replace the ECM.

Verify repair

ECM connector.
3. Check the circuit for short to MAF sensor ground
circuit.
C-116
8
9
Repair the circuit for short to MAF sensor ground.

Repair the short to ground circuit between the ECM
and MAF sensor.
C-57(B)
C-116
4
83
10
11
12
13
6E134
Diagnostic Trouble Code (DTC) P0100 (Symptom Code B) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output Circuit Low Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 11
Go to Step 6

Is the DTC P0100 (Symptom Code B) stored as
Present Failure?

Was the DTC P0100 (Symptom Code B) stored in this
ignition cycle?

C-57(B)
C-116
92
2 3
88
83


Step
Action
Using the DVM and check the MAF sensor signal

circuit.
Breaker box is available:
2. Install the breaker box as type A.
disconnected) Ref. Page 6E-103
6E135
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Approximately
5.0V
Go to Step 9
Go to Step 8
(ECM

4. Check the circuit for open, short to sensor ground
or short to ground circuit.
Breaker Box
88
C-116
Breaker box is not available:

ECM connector.
C-57(B)
C-116
88

supply circuit.
C-116
4
6E136
Step
Action
Value(s)
Yes
No
Repair the open circuit between the ECM and MAF

sensor.
Verify repair
Go to Step 13
10-14.5V
Go to Step 11
Go to Step 10
Repair the open circuit between the ECM main relay

and MAF sensor.
Verify repair
Go to Step 11

and recheck.
Go to Step 12
Go to Step 13

Verify repair

release?
Verify repair
Go to Step 14
Replace the ECM.

Verify repair
C-57(B)
C-116
4
83
Using the DVM and check the MAF sensor +12V

supply circuit.
C-116
V
10
11
12
13
14
6E137
Diagnostic Trouble Code (DTC) P0100 (Symptom Code C) (Flash Code 65)
Mass Air Flow (MAF) Sensor Output Circuit High Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 11
Go to Step 6

Is the DTC P0100 (Symptom Code C) stored as
Present Failure?

Was the DTC P0100 (Symptom Code C) stored in this
ignition cycle?

C-57(B)
C-116
92
2 3
88
83

6E138
Step
Action
Using the DVM and check the MAF sensor ground

circuit.
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Go to Step 8
Repair faulty
harness and
verify repair
(ECM
3. Disconnect the MAF sensor connector.

Breaker Box
92
C-116

2. Disconnect the MAF sensor connector and ECM
connector.
C-57
C-116
92

circuit.
2. Disconnect the MAF sensor connector .
C-116
V
Less than 1V

Step
Action

circuit.
Value(s)
6E139
Yes
No
Less than 1V
Go to Step 9
Repair faulty
harness and
verify repair

and recheck.
Go to Step 10
Go to Step 11

Verify repair

release?
Verify repair
Go to Step 12
Replace the ECM.

Verify repair

C-116
V
9
10
11
12
6E140
DIAGNOSTIC TROUBLE CODE (DTC) P0105 (SYMPTOM CODE 1) (FLASH

CODE 34) VACUUM PRESSURE SENSOR CIRCUIT HIGH INPUT
CODE 34) VACUUM PRESSURE SENSOR CIRCUIT LOW INPUT
CODE 34) VACUUM PRESSURE SENSOR VOLTAGE SUPPLY CIRCUIT HIGH
INPUT
CODE 34) VACUUM PRESSURE SENSOR VOLTAGE SUPPLY CIRCUIT LOW
INPUT
6E141
Flash
Code
Code
Symptom
Code
MIL
DTC Name
Fail-Safe (Back Up)
34
P0105
ON

Circuit High Input


reduced.
ON

Circuit Low Input

2. ECM use 615hpa

conditions for
turbocharger waste gate
control.
ON

Input
Vacuum sensor power supply


reduced.
ON

Input
Vacuum sensor power supply

2. ECM use vacuum sensor

output voltage 5.0V
Circuit description
Diagnostic Aids
The ECM monitors altitude from the barometric

pressure sensor. To apply specified vacuum pressure to
the turbocharger wastegate valve, ECM sends control
signal to the wastegate control solenoid depending on
altitude.
Then, apply vacuum pressure to the turbocharger
wastegate valve is monitored by the ECM form the
vacuum pressure sensor output signal. The ECM
controls wastegate control solenoid based on signal
from vacuum pressure sensor output.
The output voltage excessively high or low, DTC P0105
(Symptom Code 1) or P0105 (Symptom Code 2) will be
stored.
The supply voltage is out of range, DTC P0105
stored.

Poor connections.
Misrouted harness.
Broken wire inside insulation.
the DTC P0105 display on the Tech 2 while moving
connectors and wiring harnesses. A change in the
display will indicate the location of the fault.
6E142
Vacuum Pressure Sensor Circuit High Input
Step
Action
Value(s)
Was the "On-Board Diagnostic (OBD) System Check"

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 9
Go to Step 6
1. 1Connect the Tech 2.

3. Select "F0: Read DTC Infor As Stored By ECU" in
"F0: Diagnostic Trouble Codes".
"Present Failure"?
1. Using the Tech 2, ignition "On" and engine "Off".

2. Select "F1: Clear DTC Information" in "F0:
Diagnostic Trouble Codes" with the Tech 2 and
3. Operate the vehicle and monitor the "F0: Read
DTC Infor As Stored By ECU" in the "F0:
Diagnostic Trouble Codes".
ignition cycle?
Check for poor/faulty connection at the vacuum

pressure sensor or ECM connector. If a poor/faulty
connection is found, repair as necessary.
C-57

Visually check the vacuum sensor.

C-124

Step
Action
Using the DVM and check the vacuum pressure

sensor ground circuit.
6E143
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Go to Step 8
Repair faulty
harness and
verify repair

1. Ignition "Off", engine "Off".
3. Disconnect
connector.
the
vacuum
pressure
(ECM
sensor

Breaker Box
93
C-124

2. Disconnect the vacuum pressure
connector and ECM connector.
sensor

C-57
C-124

1. Ignition "On", engine "Off".
2. Disconnect
connector.
the
vacuum
pressure
sensor

C-124
Less than 1V
6E144
Step
Action
Yes
No

sensor signal circuit.
Less than 1V
Go to Step 9
Repair faulty
harness and
verify repair
Substitute a known good vacuum pressure sensor

and recheck.
Go to Step 10
Go to Step 11
Replace
the
vacuum
Verify repair

release?
the "SPS (Service Programming System)".
Verify repair
Go to Step 12
Replace the ECM.

Programming System(SPS) in this manual.
Following ECM programming, the immobiliser system
section 11 "Immobilizer System-ECM replacement" for
Verify repair

2. Disconnect the vacuum
connector.
Value(s)
pressure
sensor

C-124
10
11
12
pressure
sensor.
6E145
Vacuum Pressure Sensor Circuit Low Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 9
Go to Step 6

"Present Failure"?

ignition cycle?

C-57

C-124
Visually check the vacuum pressure sensor.

6E146
6

3. Disconnect
connector.
the
vacuum
pressure
(ECM
sensor

Breaker Box
85
C-124


sensor

C-57
C-124
Repair faulty
harness and
verify repair
Go to Step 7
Approximately
5.0V
Go to Step 9
Go to Step 8

sensor power supply circuit.
2. Disconnect
connector.
the
vacuum
pressure
sensor

C-124

8
6E147
Repair the open circuit between the ECM and vacuum

pressure sensor.
C-57
C-124
10
11
12
Verify repair
Go to Step 11

assembly and recheck.
Go to Step 10
Go to Step 11
Replace the vacuum sensor assembly.

Verify repair

release?
Verify repair
Go to Step 12
Replace the ECM.

Verify repair
6E148
Vacuum Pressure Sensor Voltage Supply Circuit High Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6
Approximately
5.0V
Go to Step 8
Go to Step 7

"Present Failure"?

ignition cycle?

C-57

5
6
C-124

2. Disconnect
connector.
the
vacuum
pressure
sensor

circuit.
C-124

7
6E149

ECM and vacuum pressure sensor.
C-57
C-124
9
10
11
Verify repair
Go to Step 10

Go to Step 9
Go to Step 10
Replace the vacuum pressure sensor assembly.

Verify repair

release?
Verify repair
Go to Step 11
Replace the ECM.

Verify repair
6E150
Vacuum Pressure Sensor Voltage Supply Circuit Low Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 10
Go to Step 6
Approximately
5.0V
Go to Step 10
Go to Step 7

"Present Failure"?

ignition cycle?

C-57

5
6
C-124

2. Disconnect
connector.
the
vacuum
pressure
sensor

C-124

7
6E151

sensor
3. Check the circuit for short to vacuum pessure

C-124
10
11
12
13
No continuity
Go to Step 9
Go to Step 8
Repair the circuit for short to vacuum pressure sensor

ground.
Verify repair
Repair the short to ground circuit between the vacuum

pressure sensor.
Verify repair
Go to Step 12

and recheck.
Go to Step 11
Go to Step 12

Verify repair

release?
Verify repair
Go to Step 13
Replace the ECM.

Verify repair
6E152

(FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH
INPUT
(FLASH CODE 23) INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW
INPUT
Flash
Code
Code
Symptom
Code
MIL
DTC Name
23
P0110
ON


more than 4.7V.
ON


below 0.3V.
Circuit Description
Fail-Safe (Back Up)

ECM use deg.C conditions as
substitute.

6E153

hot.
stored.
Misrouted harness.
Diagnostic Aids

the Intake Air Temperature display on the Tech2
while moving connectors and wiring harness related
to the sensor.

Poor connections.

Intake Air Temperature (IAT) Sensor Circuit High Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6

Present Failure?

ignition cycle?
Check for poor/faulty connection at the IAT sensor or

C-57(B)
C-116
92
84
Visually check the IAT sensor.

6E154
Step
6
Action
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 10
Less than 1V:

Go to Step 8
More than
specified value:
Go to Step 9
Verify repair
Go to Step 14
Using the DVM and check the IAT sensor.

2. Disconnect MAF & IAT sensor connector.
3. Measure the resistance of IAT sensor.
Does the tester indicate standard resistance as shown
in the following table?
Temperature (C)
Resistance (W) (Approximately)
-20
13660
5430
20
2433
40
1153
60
598
80
334
100
204
IAT Sensor
1
1
Using the DVM and check the IAT sensor signal

circuit.
C-116
V
8
Repair the open circuit between the ECM and IAT

sensor.
C-57(B)
84
C-116

Step
Action
Repair the short to voltage circuit between the ECM

and IAT sensor.
C-57(B)
Value(s)
Yes
No
Verify repair
Go to Step 14
Go to Step 11
Repair faulty
harness and
verify repair
C-116
84
10
6E155
Using the DVM and check the IAT sensor ground

circuit.
C-116
V
Less than 1V
6E156
Step
Action
Value(s)
Yes
No
11

circuit.
Repair faulty
harness and
verify repair
Go to Step 14

and recheck.
Go to Step 13
Go to Step 14

Verify repair

release?
Verify repair
Go to Step 15
Replace the ECM.

Verify repair

(ECM

Breaker Box
92
C-116

ECM connector.
C-57(B)
C-116
92
12
13
14
15
6E157
Intake Air Temperature (IAT) Sensor Circuit Low Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6

Present Failure?

ignition cycle?

C-57(B)
C-116
92
84
Remove the MAF & IAT sensor assembly and visually

check.
6E158
Step
6
Action
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 8

2. Disconnect MAF & IAT sensor connector.
Temperature (C)
-20
13660
5430
20
2433
40
1153
60
598
80
334
100
204
IAT Sensor
4
3
1
1

Step
Action

circuit.
6E159
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10

and recheck.
Go to Step 9
Go to Step 10

Verify repair

release?
Verify repair
Go to Step 11
Replace the ECM.

Verify repair

(ECM

4. Check the circuit for short to sensor ground or
ground circuit.
Breaker Box
84
92


ECM connector.
ground circuit.
C-57(B)
92
84
9
10
11
6E160

(FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT
HIGH INPUT
(FLASH CODE 14) ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT LOW
INPUT
Flash
Code
Code
Symptom
Code
MIL
14
P0115
ON
ON
DTC Name
Fail-Safe (Back Up)

(ECT) Sensor Circuit High
Input

more than 4.7V.

(ECT) Sensor Circuit Low
Input

below 0.3V.
1. ECM uses fuel temperature

as substitute.
2. ECM uses 60 deg.C
condition for injection timing
control.
3. ECM uses -25 deg.C
condition (4JA1-TC) or -15
deg.C condition (4JH1-TC)
for glow time control.
Circuit Description


a high resistance.
temperature is hot.
stored.
6E161
Misrouted harness.
the Coolant Temperature display on the Tech2 while
sensor.
Diagnostic Aids
Poor connections.
Engine Coolant Temperature Sensor Circuit High Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6

Present Failure?

ignition cycle?
Check for poor/faulty connection at the ECT sensor or

C-57(B)
93
89
Visually check the ECT sensor.

E-41
6E162
Step
6
Action
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 10
Less than 1V:

Go to Step 8
More than
specified value:
Go to Step 9
Verify repair
Go to Step 14
Using the DVM and check the ECT sensor.

2. Disconnect ECT sensor connector.
3. Measure the resistance of ECT sensor.
Temperature (C)
-20
16100
5760
20
2370
40
1080
60
537
80
290
100
161
120
95
ECT Sensor
2
1
2
Using the DVM and check the ECT sensor signal

circuit.
2. Disconnect the ECT sensor connector.
E-41
V
8
Repair the open circuit between the ECM and ECT

sensor.
C-57(B)
89
E-41

Step
Action

and ECT sensor.
C-57(B)
Value(s)
Yes
No
Verify repair
Go to Step 14
Less than 1V
Go to Step 11
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 14
E-41
89
10
6E163
Using the DVM and check the ECT sensor ground

circuit.
E-41
V
11

circuit.
(ECM

Breaker Box
93
E-41

2. Disconnect the ECT sensor connector ECM
connector.
C-57
E-41
2
93
6E164
Step
Action
Value(s)
Yes
No
12
Substitute a known good ECT sensor assembly and

recheck.
Go to Step 13
Go to Step 14
Replace the ECT sensor.

Verify repair

release?
Verify repair
Go to Step 15
Replace the ECM.

Verify repair
13
14
15
6E165
Engine Coolant Temperature Sensor Circuit Low Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6

Present Failure?

ignition cycle?

C-57(B)
93
89

E-41
6E166
Step
6
Action
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 8

Temperature (C)
-20
16100
5760
20
2370
40
1080
60
537
80
290
100
161
120
95
ECT Sensor
2
1
2

Step
Action

circuit.
6E167
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10

recheck.
Go to Step 9
Go to Step 10

Verify repair

release?
Verify repair
Go to Step 11
Replace the ECM.

Verify repair

(ECM

ground circuit.
Breaker Box
89
93


2. Disconnect the ECT sensor connector and ECM
connector.
ground circuit.
C-57(B)
93
89
9
10
11
6E168

(FLASH CODE 15) FUEL TEMPERATURE SENSOR CIRCUIT RANGE/
PERFORMANCE
Flash
Code
Code
Symptom
Code
MIL
DTC Name
15
P0180
ON
Fuel Temperature Sensor Circuit Range/Performance
FT sensor output is high temperature (more than

150deg.C) or low temperature
(below -40deg.C).
Fail-Safe (Back Up)

The ECM use 75deg.C conditions as substitute.
Circuit Description
Misrouted harness.
The fuel temperature sensor is assembled inside of the

pump control unit (PSG). The signal of fuel temperature
is sent via the CAN-bus from the PSG to ECM.
If the fuel temperature is excessively high or low
condition, DTC P0180 will be stored.
Diagnostic Aids
Poor connections.

Poor connection at ECM and PSG-Inspect harness
connectors for backed out terminals, improper
mating, broken locks, improperly formed or damaged
terminals, and poor terminal to wire connection.
the Fuel Temperature display on the Tech2 while
6E169

sensor.
Diagnostic Trouble Code (DTC) P0180 (Symptom Code B) (Flash Code 15) Fuel
Temperature Sensor Circuit Range/Performance
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5
Substitute a known good ECM and recheck.

Go to Step 6
Go to Step 7
Replace the ECM.

Verify repair
Replace the injection pump assembly.

Verify repair

Present Failure?

6E170
DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE A)

(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION
(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE CIRCUIT HIGH INPUT
(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE ALWAYS ACTIVE
DIAGNOSTIC TROUBLE CODE (DTC) P0215 (SYMPTOM CODE D)
(FLASH CODE 52) FUEL CUTOFF SOLENOID VALVE MALFUNCTION
6E171
Flash
Code
Code
Symptom
Code
MIL
DTC Name
Fail-Safe (Back Up)
52
P0215
ON

Malfunction

1500rpm.
1.5km/h.
recognizes MAB (fuel cutoff
solenoid valve) signal from
the ECM, but the MAB
could not operate.

valve) is operated.
becomes 0mg/strk.
ON

Circuit High Input
ECM does not command

valve) signal to the PSG
(pump control unit), but PSG
detected MAB signal line circuit is high level.
Engine does not start.
ON

Always Active

1500rpm.
1.5km/h.
does not recognize MAB
(fuel cutoff solenoid valve)
signal from the ECM.

valve) is operated.
becomes 0mg/strk.
ON

Malfunction

2. CAN controller does not
operate Bus-off.
Circuit Description
Diagnostic Aids
When the ignition switch is turned Off, the fuel

solenoid valve (MAB) signal is supplied from the ECM to
the PSG. This signal is the command for the PSG to turn
Off the engine.
If the MAB signal circuit is short to voltage circuit or
short to ground circuit, DTC P0215 (Symptom Code B)
or P0215 (Symptom Code C) will be stored.

Poor connections.
Misrouted harness.
Diagnostic Trouble Code (DTC) P0215 (Symptom Code A) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Is the DTC P0215 (Symptom Code A) stored as
Present Failure?
6E172
Step
Action
Value(s)
Yes
No

Was the DTC P0215 (Symptom Code A) stored in this
ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

Verify repair
6E173
Cutoff Solenoid Valve Circuit High Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6

Present Failure?

ignition cycle?
Check for poor/faulty connection at the ECM or PSG

(pump control unit) connector. If a poor/faulty
105
C-57
E-6
Visually check the PSG (pump control unit).

6E174
Step
Action
Using the DVM and check the MAB (fuel cutoff

solenoid valve) circuit.
2. Install the breaker box as type B.
connected) Ref. Page 6E-104
Value(s)
Yes
No
Less than 1V
Go to Step 8
Go to Step 7
Verify repair
Go to Step 8
Verify repair
(ECM
3. Check the circuit for short to voltage circuit.

Breaker Box
105

C-57
105
V
7

and PSG (pump control unit).
C-57
E-6
5
105

6E175
Diagnostic Trouble Code (DTC) P0215 (Symptom Code C) (Flash Code 52) Fuel
Cutoff Solenoid Valve Always Active
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 7
Go to Step 6

Is the DTC P0215 (Symptom Code C) stored as
Present Failure?

Was the DTC P0215 (Symptom Code C) stored in this
ignition cycle?

105
C-57
E-6

6E176
Step
Action
Using the DVM and check the MAB (fuel cutoff

solenoid valve) circuit.
3. Disconnect
connector.
the
PSG
(pump
control
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Verify repair
(ECM
unit)

circuit.
Breaker Box
105
E-6

2. Disconnect the PSG (pump control unit)
connector.
circuit.
C-57
105

E-6
6E177
Diagnostic Trouble Code (DTC) P0215 (Symptom Code D) (Flash Code 52) Fuel
Cutoff Solenoid Valve Malfunction
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Was the DTC P0215 (Symptom Code D) stored in this
ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5

Go to Step 6
Go to Step 7
Replace the ECM.

Verify repair

Verify repair

Is the DTC P0215 (Symptom Code D) stored as
Present Failure?

6E178
DIAGNOSTIC TROUBLE CODE (DTC) P0216 (SYMPTOM CODE A) (FLASH

CODE 54) INJECTION TIMING CONTROL CIRCUIT MALFUNCTION
DIAGNOSTIC TROUBLE CODE (DTC) P0216 (SYMPTOM CODE B) (FLASH
CODE 54) INJECTION TIMING CONTROL CIRCUIT MALFUNCTION
Flash
Code
Code
Symptom
Code
MIL
54
P0216
ON
DTC Name
Circuit Malfunction

than 700rpm.
more than 4mg/stk.
3. Deviation of actual
injection timing and
desired injection timing is
more than +3 deg. CA or
-6 deg. CA for 8
seconds.
ON

Circuit Malfunction

than 2014rpm.
than +-5.2 deg. CA.
Fail-Safe (Back Up)

reduced.
6E179
Circuit Description
Air bleeding procedure:
The ECM is calculates an injection quantity and an

injection timing using the various sensors (crankshaft
position sensor, camshaft position sensor, engine
coolant temperature sensor, etc.). The timing control
valve (TCV) operation performs an injection timing
decision.
The TCV performs as a variable throttle, using the rapid
opening and closing cycle of the valve needle in the
TCV.
The TCV is assembled in the injection pump. The signal
of desired injection timing and actual injection timing are
exchanged via the CAN-bus between the PSG and
ECM.
If the timer position is out of tolerance (deviation or
fluctuation), DTC P0216 will be stored.
1.Operate the priming pump until strong resistance is

felt.
Diagnostic Aids
Poor connections.
Misrouted harness.
Insufficient air bleeding of fuel line.
Low fuel quantity in the fuel tank.
Insufficient air bleeding of fuel line inside, clogged
fuel filter or pinched fuel pipe/hose may cause the
DTC store or improper engine performance.
2.Wait 1 minute, and operate the priming pump until

3.Wait 1 minute, and operate the priming pump until
4.Turn the ignition switch to the "ON" position. Wait
until the glow indicator lamp turns off.
5.Turn the ignition switch to the "START" position and
crank the engine until it starts.
6.If the engine does not start, repeat Step 3 - 5.
7.Allow the engine to idle for 3 minutes to bleed air
leakage.
the "Actual Injection Start" display on the Tech2 while
sensor.
6E180
Diagnostic Trouble Code (DTC) P0216 (Symptom Code A) (Flash Code 54)
Injection Timing Control Circuit Malfunction
Injection Timing Control Circuit Malfunction
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 5
Verify repair

Is the DTC P0216 (Symptom Code A) or P0216
(Symptom Code B) stored as "Present Failure"?
1. 1Using the Tech 2, ignition "On" and engine "Off".

Was the DTC P0216 (Symptom Code A) or P0216
(Symptom Code B) stored in this ignition cycle?
Perform the air bleeding in the fuel line sufficiently.

Air Bleeding Procedure:
1. Operate the priming pump until strong resistance
is felt.
2. Wait 1 minute, and operate the priming pump until
3. Once more wait, and operate the priming pump
until strong resistance is felt.
4. Turn the ignition switch to the "ON" position. Wait
until the glow indicator lamp turns off.
5. Turn the ignition switch to the "START" position
and crank the engine until it starts.
6. If the engine does not start, repeat Step 3 - 5.
7. Allow the engine to idle for 3 minutes to bleed air
leakage.
DTC Re-check:
(Symptom Code B) restored in this ignition cycle?

Step
5
6
7
Action
6E181
Value(s)
Yes
No
Restrict fuel supply system. Check for a pinched

fuel hose/pipe.
Check for a condition that causes fuel waxing or
icing, such as the customer is using an incorrect
fuel type in winter season or water mixed with the
fuel.
If a problem is found, repair as necessary.
Verify repair
Go to Step 6
Replace the fuel filter.

Verify repair
Go to Step 7
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 8

release?
If
not, download the latest software to the ECM using
Verify repair
Go to Step 9

Go to Step 10
Go to Step 11
Visually/physically inspect for the following conditions.
Remove the eye bolt with gauze filter from the

injectionpumpandcheckforthefollowingconditions.
Objects blocking at the gauze filter. Check for a
condition that causes contaminated fuel, such as
the customer is using an aftermarket fuel filter or
extended maintenance interval.
fuel.
6E182
Step
Action
Value(s)
Yes
No
10
Replace the ECM.

Verify repair

Verify repair
11
6E183

CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" RANGE/
PERFORMANCE
CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" LOW
CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" RANGE/
PERFORMANCE
CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" MALFUNCTION
CODE 64) TURBOCHARGER WASTEGATE SOLENOID "A" HIGH
6E184
Flash
Code
Code
Symptom
Code
MIL
64
P0243
ON
DTC Name
Solenoid "A" Range/
Performance
Fail-Safe (Back Up)

200 deg. C.

reduced.
2. Engine coolant
C.
4
ON
Solenoid "A" Low

circuit open or short to ground
circuit.
2. EGR EVRV becomes 10%

condition.

reduced.
condition.
ON
Solenoid "A" Range/
Performance

200 deg. C.
2. Engine coolant
C.
ON
Solenoid "A" Malfunction

reduced.
condition.
1. Engine coolant
C.
2. EGR control EVRV 0%
condition.
ON
Solenoid "A" High

circuit short to voltage circuit.

reduced.
condition.
Circuit description
Diagnostic Aids
The ECM monitors altitude from the barometric

pressure sensor. To apply specified vacuum pressure to
the turbocharger wastegate valve, ECM sends control
signal to the wastegate control solenoid depending on
altitude.
Then, apply vacuum pressure to the turbocharger
wastegate valve is monitored by the ECM form the
vacuum pressure sensor output signal. The ECM
controls wastegate control solenoid based on signal
from vacuum pressure sensor output.
If the vacuum pressure sensor detected vacuum
pressure is excessively low or high due to faulty vacuum
line, vacuum pump or turbocharger wastegate valve,
DTC P0243 (Symptom Code 3), P0243 (Symptom Code
5) or P0243 (Symptom Code 6) will be stored.
If the wastegate control solenoid circuit is open or short
to ground circuit, DTC P0243 (Symptom Code 4) will be
stored.
If the wastegate control solenoid circuit is short to
voltage circuit, DTC P0243 (Symptom Code 8) will be
stored.

Poor connections.
Misrouted harness.
Broken wire inside insulation.
Turbocharger wastegate valve sticking or broken.
Misrouted vacuum hose.
Faulty vacuum pump or regulating valve.
the DTC P0243 display on the Tech 2 while moving
6E185
Diagnostic Trouble Code (DTC) P0243 (Symptom Code 3) (Flash Ccode 64)
Turbocharger Wastegate Solenoid "A" Range/Performance
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Objects blocking at the wastegate solenoidvalve.

Verify repair
Go to Step 5
Remove the vacuum pressure sensor and visually

check.
Go to Step 6
Go to Step 8

and recheck.
Go to Step 7
Go to Step 8
Replace the vacuum pressure sensor.

Verify repair

"Present Failure"?

ignition cycle?
Remove the vacuum hose & vacuum regulating valve

and check for the following conditions.
Objects blocking the vacuum hose.
Objects blocking the vacuumregulating valve.
Vacuum leaking at vacuum hose or vacuum
regulating valve.
6E186
Step
Action
Using the DVM and check the wastegate control

solenoid.
Value(s)
Yes
No
Approximately
14.7 - 16.1 W
at 20C
Go to Step 11
Go to Step 9

2. Disconnect thewastegatesolenoid connector.
3. Measure the resistance of wastegate solenoid
coil.
Does the tester indicate standard resistance?
Wastegate Solenoid

9
Substitute a known good wastegate control solenoid

and recheck.
Go to Step 10
Go to Step 11
10
Replace the wastegate control solenoid.

Verify repair
Using the pressure gauge and check the turbocharger

wastegate valve operation for broken diaphragm.
Go to Step 12
Go to Step 13
12
Replace the turbocharger wastegate valve .

Verify repair
13

release?
Verify repair
Go to Step 14
Replace the ECM.

Verify repair
11
14
6E187
Turbocharger Wastegate Solenoid "A" Low
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Approximately
14.7 - 16.1 W
at 20C
Go to Step 6
Go to Step 9

"Present Failure"?

ignition cycle?
Check for poor/faulty connection at the wastegate

control solenoid or ECM connector. If a poor/faulty
C-57
C-123

solenoid.
coil.
Wastegate Solenoid

6E188
Step
Action
Value(s)
Yes
No

solenoid power supply circuit.
10 - 14.5V
Go to Step 8
Go to Step 7
Verify repair
Repair faulty
harness and
verify repair
Go to Step 11

and recheck.
Go to Step 10
Go to Step 11

Verify repair

2. Remove the wastegate
connector.
control
solenoid

7

and wastegate control solenoid.
solenoid circuit.
(ECM
3. Removethewattagecontrolsolenoid connector.
circuit.
Breaker Box
96
C-123


3. Remove the
connector.
wastegate
control
solenoid

circuit.
C-57
10
C-123
6E189
Step
Action
Value(s)
Yes
No
11

release?
Verify repair
Go to Step 12
Replace the ECM.

Verify repair
12
6E190
Turbocharger Wastegate Solenoid "A" Range/Performance
Step
Action
Value(s)

performed?
-
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

"Present Failure"?

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Visually check the vacuum regulating valve.

Verify repair
Go to Step 5
Approximately
14.7 - 16.1 W
at 20C
Go to Step 8
Go to Step 6

and recheck.
Go to Step 7
Go to Step 8

Verify repair

wastegate valve operation for broken diaphragm.
Go to Step 9
Go to Step 10
Replace the turbocharger

Verify repair

solenoid.
coil.
Wastegate Solenoid

6
wastegate
valve

Step
Action
10

Value(s)
Yes
No
Verify repair
Go to Step 11
Go to Step 13
Go to Step 12
Less than 1V
Go to Step 15
Repair faulty
harness and
verify repair

Go to Step 14
Go to Step 15
Replace the vacuum pressure sensor assembly.

Verify repair

release?
Verify repair
Go to Step 16
Replace the ECM.

Verify repair
11
12
6E191
C-57
C-123

2. Disconnect
connector.
the
vacuum
pressure
sensor

C-124
13
14
15
16
6E192
Turbocharger Wastegate Solenoid "A" Malfunction
Step
Action
Value(s)

performed?
-
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

"Present Failure"?

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Visually check the turbocharger wastegate valve and

hose.
If the hose is clogged or disconnected, repair as
necessary.
Verify repair
Go to Step 5

wastegate valve operation for broken diaphragm or
restrict shaft operation.
Go to Step 6
Go to Step 7
Replace the turbocharger wastegate valve.

Verify repair
Verify repair
Go to Step 8
Go to Step 10
Go to Step 9

C-57
C-116

8


Step
Action
Value(s)

circuit.
6E193
Yes
No
Less than 1V
Go to Step 12
Repair faulty
harness and
verify repair

and recheck.
Go to Step 11
Go to Step 12
Replace the MAF &

Verify repair

release?
Verify repair
Go to Step 13
Replace the ECM.

Verify repair

C-116
10
11
12
13
IAT
sensor
assembly.
6E194
Turbocharger Wastegate Solenoid "A" High
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
Check for poor/faulty connection at the wastegate

control solenoid or ECM connector. If a poor/faulty
Verify repair
Go to Step 5
Approximately
14.7- 16.1 W at
20C
Go to Step 6
Go to Step 8

"Present Failure"?


solenoid.
coil.
Wastegate Solenoid


Step
Action

solenoid circuit.
6E195
Value(s)
Yes
No
No continuity
Go to Step 10
Go to Step 7
Verify repair

and recheck.
Go to Step 9
Go to Step 10

Verify repair

release?
Verify repair
Go to Step 11
Replace the ECM.

Verify repair

2. Remove the wastegate control solenoid connector
and ECM connector.
C-123

7
10
11
Repair
the
short
to
voltage
circuit.
6E196

(FLASH CODE 53) INJECTION PUMP MALFUNCTION
DIAGNOSTIC TROUBLE CODE (DTC) P0251 (SYMPTOM CODE E)
6E197
Flash
Code
Code
Symptom
Code
MIL
DTC Name
Fail-Safe (Back Up)
53
P0251
ON
1. No pump camshaft speed

sensor error.
2. High pressure solenoid
valve control pulse width
does not match with
desired fuel injection quantity.
ON

sensor error.
3. Difference of engine speed
and doubled pump camshaft speed is more than
720rpm (4JA1-TC) or 690
rpm (4JH1-TC).
ON
No pump map programmed in

the PSG (pump control unit)
or PSG malfunction.
ON

malfunction in the PSG (pump
control unit).

reduced.
ON
PSG (pump control unit) recognized high pressure solenoid valve drive circuit error.
ON
PSG (pump control unit) could

not measure the high pressure solenoid valve drive voltage.
ON
ECM could not accept PSG

(pump control unit) message.

valve) is operated.
becomes 0mg/strk.

valve) is operated.
becomes 0mg/strk.
Circuit Description
Diagnostic Aids

injection timing using the various sensors. And the PSG
controls the high pressure solenoid valve depending on
programmed pump map data.
The signal of desired injection quantity and actual injection quantify are exchanged via the CAN-bus between
the PSG and ECM.
If the relation of engine speed signal and doubled pump
camshaft speed signal excessively large, DTC P0251
(Symptom Code 7) will be stored.
If the CAN high or low circuit is defected, DTC P0251
(Symptom Code E) will be stored.

Poor connections.
Misrouted harness.
the Injection Quantity display on the Tech2 while
sensor.
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
6E198
Step
2

Action
Yes
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

Verify repair

Present Failure?
Value(s)

6E199
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to DTC
Chart P0335
(Symptom
Code B)
(Symptom
Code D) or
P1335
(Symptom
Code A)
Go to Step 5
Verify repair
Go to Step 6

Present Failure?

ignition cycle?
Was the DTC P0335 (Symptom Code B), P0335

(Symptom Code D) or P1335 (Symptom Code A)
stored at the same time?

connection is found, repair the faulty terminal.
C-57(B)
E-6
91
6E200
Step
Action
If a oscilloscope is available, monitor the CKP sensor

output signal. Does the oscilloscope indicate correct
wave form?
Value(s)
Yes
No
Go to Step 13
Not available:
Go to Step 7
Fixed at low:
Go to Step 7
Fixed at High:
Go to Step 8

Reference Wave Form
CH1
0V
CH2
0V

Measurement Scale: CH1: 50V/div / CH2: 10V/div 1ms/div

Step
Action
Using the DVM and check the CKP sensor output

circuit.
3. Disconnect
connector.
the
PSG
(pump
control
6E201
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
Go to Step 9
Repair faulty
harness and
verify repair
(ECM
unit)

circuit.
Breaker Box
91
E-6

3. Disconnect
connector.
the
PSG
(pump
control
unit)

circuit.
C-57(B)
E-6
91

circuit.
2. Disconnect
connector.
the
PSG
(pump
control
unit)

E-6
V
Less than 1V
6E202
Step
Action
10
11
12
13
Value(s)
Yes
No
Check any accessory parts which may cause electric

interference or magnetic interference.
Remove the
accessory parts
and verify repair
Go to Step 10

release?
Verify repair
Go to Step 11

Go to Step 12
Go to Step 13
Replace the ECM.

Verify repair

Verify repair
6E203
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

Verify repair

Present Failure?

6E204
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

Verify repair

Present Failure?

6E205
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

Verify repair

Present Failure?

6E206
Diagnostic Trouble Code (DTC) P0251 (Symptom Code D) (Flash Code 53)
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

Verify repair

Present Failure?

6E207
Diagnostic Trouble Code (DTC) P0251 (Symptom Code E) (Flash Code 53)
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Go to DTC
Chart P1650
(Symptom
Code A)
Go to Step 5

release?
Verify repair
Go to Step 6

Go to Step 7
Go to Step 8
Replace the ECM.

Verify repair

Verify repair

Is the DTC P0251 (Symptom Code E) stored as
Present Failure?

Was the DTC P0251 (Symptom Code E) stored in this
ignition cycle?

(Symptom Code B) stored at the same time?
6E208

(FLASH CODE 43)CRANKSHAFT POSITION SENSOR CIRCUIT MALFUNCTION
(FLASH CODE 43) CRANKSHAFT POSITION SENSOR MALFUNCTION
(FLASH CODE 43) ENGINE SPEED INPUT CIRCUIT RANGE/PERFORMANCE
6E209
Flash
Code
Code
Symptom
Code
MIL
43
P0335
ON
DTC Name
Fail-Safe (Back Up)

Circuit Malfunction
1. Engine speed is more than

665rpm.
2. CKP sensor pulse width
error.

sensor is OK:
ECM uses doubled pump camshaft speed as substitute
engine speed.
sensor is not OK:
valve) is operated.
becomes 0mg/strk.
ON

Circuit Malfunction

sensor error.
2. Crankshaft Position Sensor Circuit Malfunction
(Symptom Code B) is not
stored.
3. Engine speed is 0rpm.
speed is more than 50rpm.

sensor is OK:
engine speed.
Other than pump camshaft
speed sensor is OK:
reduced.
ON
Engine Speed Input Circuit

Range/Performance
Engine speed is more than

5700rpm.
When intermittent malfunction:

valve) is operated.
becomes 0mg/strk.
When preliminary malfunction:
engine speed.
Circuit Description
Diagnostic Aids

housing of the flywheel and fixed with a bolt. The CKP
sensor is of the magnet coil type. The inductive pickup
sensors four gaps in the flywheel exciter ring and is
used to determine the engine speed and engine
cylinder top dead center.
If the CKP sensor harness or sensor malfunction is
detected during engine run, DTC P0335 (Symptom
Code B) is stored.
If the CKP sensor harness or sensor malfunction is
detected during engine cranking, DTC P0335
(Symptom Code D) is stored.
If the CKP sensor signal frequency is excessively high
or engine over-running, DTC P0335 (Symptom Code E)
is stored.

Poor connections.
Misrouted harness.
the Engine Speed display on the Tech2 while
sensor.
Crankshaft Position Sensor Circuit Malfunction
Crankshaft Position Sensor Malfunction
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
6E210
Step
2
Action
Value(s)
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Approximately
0.9k9 at 20C
Go to Step 10
Go to Step 7

Is the DTC P0335 (Symptom Code B) or P0335
(Symptom Code D) stored as Present Failure?
Yes

Was the DTC P0335 (Symptom Code B) or P0335
(Symptom Code D) stored in this ignition cycle?
Check for poor/faulty connection at the CKP sensor or

repair the faulty terminal.
C-57(B) 101
E-9
98
90
Visually check the CKP sensor. If a faulty installation

is found, repair as necessary.
Using the DVM and check the CKP sensor circuit.
(ECM
3. Check the resistance of the CKP sensor.

Breaker Box
90
98

C-57(B)
98
90

Step
7
Action
6E211
Value(s)
Yes
No
Approximately
0.9k9 at 20C
Go to Step 8
Go to Step 14
Repair faulty
harness and
verify repair
Go to Step 9

2. Disconnect the CKP sensor connector.
E-9

(ECM

4. Check the circuit for open, short to sensor wire or
Breaker Box
98
90
101


Breaker Box
90
E-9
98

6E212
Step
9
Action
Value(s)
Yes
No
Less than 1V
Verify repair
Go to Step 13
Go to Step 11
Verify repair
Go to Step 12
Repair faulty
harness and
verify repair
Go to Step 13

If the DVM indicated out of specified value, repair
faulty harness and verify repair.
E-9
V
10
Using the DVM and check the CKP sensor signal.

1. Ignition On, engine On.
2. Measure the CKP output voltage at the sensor
and ECM.
Does the tester indicate standard voltage?
Measurement Point
At CKP sensor terminal 2 & 1
At ECM C57 connector 90 & 98
Voltage (V) (AC Range)

Approximately 1.1 V at
2000rpm

signal. Does the oscilloscope indicate correct wave
form?
0V
Measurement Terminal: 90(+) 98(-)

Measurement Scale: 20V/div 2ms/div
11
Remove the CKP sensor from the flywheel housing

and visually check.
Check for the following conditions.
Objects sticking the CKP sensor.
Objects sticking the CKP sensor pulser.
12
Check the CKP sensor shield wire for open or short

circuit.

Step
Action
13
14
15
16
17
6E213
Value(s)
Yes
No

Remove the
accessory parts
and verify repair
Go to Step 14
Substitute a known good CKP sensor and recheck.

Go to Step 15
Go to Step 16
Replace the CKP sensor.

Verify repair
Go to Step 16

release?
Verify repair
Go to Step 17
Replace the ECM.

Verify repair
6E214
Engine Speed Input Circuit Range/Performance
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Explain the
reason of DTC
to the customer
Go to Step 5
Verify repair
Go to Step 6

Present Failure?

ignition cycle?
Ask to the customer whether over-speed condition

such as miss-gear shifting etc. has been experienced
or not.
C-57(B) 101
E-9
98
90

Step
6
Action
Value(s)
6E215
Yes
No
Go to Step 9
Go to Step 7
Verify repair
Go to Step 8
Repair faulty
harness and
verify repair
Go to Step 9

Remove the
accessory parts
and verify repair
Go to Step 10

Go to Step 11
Go to Step 12

Verify repair
Go to Step 12

release?
Verify repair
Go to Step 13

and ECM.
Measurement Point
At ECM C57 connector 90 & 98

2000rpm

form?
0V
Measurement Terminal: 90(+) 98(-)

Measurement Scale: 20V/div 2ms/div

and visually check.
10
11
12

circuit.
6E216
Step
Action
Value(s)
Yes
No
13
Replace the ECM.

Verify repair
6E217

(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE LOW
(FLASH CODE 66) GLOW RELAY CIRCUIT VOLTAGE HIGH
Flash
Code
Code
Symptom
Code
MIL
DTC Name
66
P0380
ON

Low
Glow relay circuit open or

ON

High
Glow relay circuit short to voltage circuit.
Fail-Safe (Back Up)

Circuit Description
Diagnostic Aids
The voltage on the coil of the relay glow plug is supplied

by the relay engine control module (ECM) main. The
ECM switches glow relay to operate glow plug depends
on the coolant temperature.
In the after glow phase the lamp is not illuminated but
the glow plugs remain active for a certain period
depending on engine coolant temperature.

Poor connections.
Misrouted harness.
6E218


the DTC P0380 display on the Tech2 while moving
Glow Relay Circuit Voltage Low
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Replace glow
relay and verify
repair

Present Failure?

ignition cycle?
Check for poor/faulty connection at the glow relay or

C-57
X-5
94
3
4
Using the DVM and check the glow relay.

2. Remove the glow relay from the relay box.
3. Check the relay coil.
Grow Relay
Approximately
1059

Step
Action
Using the DVM and check the glow relay power

supply circuit.
6E219
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
Repair faulty
harness and
verify repair
Go to Step 9

circuit.
X-5
2
V
7
Repair the open or short to ground circuit between the

ECM main relay and glow relay.
Using the DVM and check the glow relay ground
circuit.
(ECM

circuit.
Breaker Box
94
X-5

circuit.
C-57
X-5
3
94
6E220
Step
Action
Value(s)
Yes
No

release?
Verify repair
Go to Step 10
Replace the ECM.

Verify repair
10
6E221
Glow Relay Circuit Voltage High
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5

Go to Step 6
Replace the ECM.

Verify repair

Present Failure?

6E222
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 4) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE LOW
DIAGNOSTIC TROUBLE CODE (DTC) P0381 (SUB CODE 8) (FLASH CODE 67)
GLOW PLUG INDICATOR CIRCUIT VOLTAGE HIGH
Flash
Code
Code
Symptom
Code
MIL
DTC Name
67
P0381
ON

Voltage Low

open or short to ground circuit.
ON

Voltage High

Circuit Description
The function of the glow time indicator lamp is to inform
the driver whether the glow system is activated.
When the lamp turned off, the engine can be started.
This does not imply that the glow plugs are no longer
activated.
In the after glow phase the lamp is not illuminated but
Fail-Safe (Back Up)

the glow plugs remain active for a certain period

depending on engine coolant temperature.
Diagnostic Aids
Poor connections.
Misrouted harness.

6E223

Glow Plug Indicator Circuit Voltage Low
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Present Failure?


ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

2. Check the glow plug indicator lamp.
Does the lamp turn On?
Go to Step 5
Go to Step 6
2. Check the glow plug indicator lamp.

Does the lamp turn Off?
Go to Step 9
Go to Step 7
Check the glow plug indicator lamp bulb.

Verify repair
Go to Step 7
6E224
Step
Action
Check for poor/faulty connection at the meter

connector and ECM connector. If a poor/faulty
C-56
Yes
No
Verify repair
Go to Step 8
Repair faulty
harness and
verify repair
Go to Step 9
43
B-24
30
Value(s)
Using the DVM and check the glow time telltale circuit.
3. Remove the meter connector.
(ECM

circuit.

B-24
Breaker Box
43

circuit.
C-56
43
6
B-24
6E225
Step
Action
Value(s)
Yes
No

release?
Verify repair
Go to Step 10
Replace the ECM.

Verify repair
10
6E226
Glow Plug Indicator Circuit Voltage High
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5

Go to Step 6
Replace the ECM.

Verify repair

Present Failure?

6E227

(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW EXCESSIVE
DETECTED
(FLASH CODE 32) EXHAUST GAS RECIRCULATION CIRCUIT SHORT TO
GROUND OR OPEN CIRCUIT
(FLASH CODE 32) EXHAUST GAS RECIRCULATION FLOW INSUFFICIENT
DETECTED
(FLASH CODE 32) EXHAUST GAS RECIRCULATION CIRCUIT SHORT TO
BATTERY
6E228
Flash
Code
Code
Symptom
Code
MIL
DTC Name
Fail-Safe (Back Up)
32
P0400
ON

Flow Excessive Detected

between 15 deg.C and 100
deg.C.
2. Engine coolant temperature is between 55 deg.C
and 100 deg.C (4JA1-TC)
or 35 deg.C and 100 deg.C
(4JH1-TC).
between 850hpa and
1100hpa.
4. Small amount of mass air
flow. (Desired mass air flow
- mass air flow is more than
150mg/strk)

reduced.
ON

Circuit Short to Ground or
Open Circuit
EGR EVRV circuit open or


reduced and EGR EVRV 10%
ON

Flow Insufficient Detected

between 15deg.C and 100
deg.C.
2. Engine coolant temperature is between 55 deg.C
and 100 deg.C (4JA1-TC)
or 35 deg.C and 100 deg.C
(4JH1-TC).
between 850hpa and
1100hpa.
4. Large mount of mass air
below 150 mg/strk)

reduced.
ON

Circuit Short to Battery
EGR EVRV circuit short to

voltage circuit.

reduced & EGR EVRV 10%
Circuit Description
Diagnostic Aids
The amount of EGR is controlled by EVRV (electrical

vacuum regulating valve) via the engine control module
(ECM) command signal depends on the engine speed,
operating of the accelerator pedal and engine coolant
temperature.
The EVRV is shaped to control vacuum applied to the
diaphragm chamber of the EGR valve based on duty
signal sent from the ECM.
If the EGR valve is stuck at open position or close
position, DTC P0400 (Symptom Code 3) or DTC P0400
(Symptom Code 5) is stored.
If the EGR EVRV circuit is open or short ground circuit,
DTC P0400 (Symptom Code 4) is stored.
If the EGR EVRV circuit is short to voltage circuit, DTC
P0400 (Symptom Code 8) is stored.

Poor connections.
Misrouted harness.
EGR valve sticking.
Faulty intake air duct connection.
6E229
Exhaust Gas Recirculation Flow Excessive Detected
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Objects blocking the turbocharger.

Verify repair
Go to Step 5

check.
Go to Step 6
Go to Step 8

and recheck.
Go to Step 7
Go to Step 8

Verify repair
Approximately
149 at 20C
Go to Step 11
Go to Step 9

Present Failure?

ignition cycle?
Remove the MAF & IAT sensor assembly and check

for the following conditions.
Objects blocking the air cleaner.
Objects blocking the MAF sensor.
Vacuum leaking at intake duct.
7
8
Using the DVM and check the EGR EVRV.

2. Disconnect the EGR EVRV connector.
3. Measure the resistance of EGR EVRV solenoid
coil.
EGR EVRV
2
1
2
6E230
Step
9
10
11
Action
Value(s)
Yes
No
Substitute a known good EGR EVRV and recheck.

Go to Step 10
Go to Step 11
Replace the EGR EVRV.

Verify repair
Verify repair or
Go to Step 13
Go to Step 12
2. Inspect the EGR valve whether pintle valve is

stuck or damaged.
If excessive carbon deposit is found, clean up the
EGR valve and inspect damage of the pintle and seat.
Verify repair or
Go to Step 13
Go to Step 14
Replace the EGR valve.

Verify repair
Using the Tech 2 or the vacuum pump and check the

EGR valve operation for the following condition
through the small window.
ERestrict shaft movement. Check for objects sticking
the shaft, broken diaphragm or excessive carbon
deposit.
Tech 2:
1. Using the Tech 2, ignition "On" and engine "On".
2. Select the "Miscellaneous Test" and perform the
"EGR Solenoid Test" in the "Solenoid".
3. Operate the Tech 2 in accordance with procedure.
Solenoid 95%: EGR Valve Open
Solenoid 5%: EGR Valve Close
Vacuum Pump:
1. Using the vacuum pump. Disconnect the original
vacuum hose and connect the hose to the EGR
valve.
2. Apply vacuum pressure.
Vacuum Apply: EGR Valve Open
Vacuum Release: EGR Valve Close
Vacuum Pump
Small Window

12
13
Inspect the EGR valve.

1. Remove the EGR valve from the engine.
6E231
Step
Action
Value(s)
Yes
No
14

release?
Verify repair
Go to Step 15
Replace the ECM.

Verify repair
15
6E232
Exhaust Gas Recirculation Circuit Short to Ground or Open Circuit
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Approximately
149 at 20C
Go to Step 6
Go to Step 9

Present Failure?

ignition cycle?
Check for poor/faulty connection at the EGR EVRV or

C-57
C-115
97

coil.
EGR EVRV
2
1
2

Step
Action
Using the DVM and check the EGR EVRV power

supply circuit.
6E233
Value(s)
Yes
No
10-14.5 V
Go to Step 8
Go to Step 7
Verify repair
Repair faulty
harness and
verify repair
Go to Step 11
Go to Step 10
Go to Step 11

2. Remove the EGR EVRV connector.
C-115
V
7

and EGR EVRV.
Using the DVM and check the EGR EVRV circuit.
(ECM

circuit.
C-115
Breaker Box
97

circuit.
C-57
C-115
2
97

6E234
Step
10
11
12

Action
Value(s)
Yes
No

Verify repair

release?
Verify repair
Go to Step 12
Replace the ECM.

Verify repair
6E235
Exhaust Gas Recirculation Flow Insufficient Detected
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Present Failure?

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Visually check the EGR control vacuum hose.

If the hose is clogged or disconnected, repair as
necessary.
Verify repair
Go to Step 5
Approximately
149 at 20C
Go to Step 8
Go to Step 6

Go to Step 7
Go to Step 8

Verify repair

coil.
EGR EVRV
2
1
2
6
7
6E236
Step
Action
Value(s)
Yes
No

deposit.
Verify repair or
Go to Step 10
Go to Step 9
2. Inspect the EGR valve whether pintle valve is

stuck or damaged.
Verify repair or
Go to Step 10
Go to Step 11

Verify repair
Tech 2:
Vacuum Pump:
valve.
Vacuum Pump
Small Window

9

10

Step
Action
11

Value(s)
Yes
No
Verify repair
Go to Step 12
Go to Step 14
Go to Step 13
Less than 1V
Go to Step 16
Repair faulty
harness and
verify repair

and recheck.
Go to Step 15
Go to Step 16

Verify repair

release?
Verify repair
Go to Step 17
Replace the ECM.

Verify repair
C-57(B)
C-116
92
2 3
88
12
13
6E237
83

circuit.
C-116
V
14
15
16
17
6E238
Exhaust Gas Recirculation Circuit Short to Battery
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5
Approximately
149 at 20C
Go to Step 6
Go to Step 8

Present Failure?

ignition cycle?
Check for poor/faulty connection at the EGR EVRV or

C-57
C-115
97

coil.
EGR EVRV
2
1
2

Step
6
Action
6E239
Value(s)
Yes
No
No continuity
Go to Step 10
Go to Step 7
Repair the short to voltage circuit.

Verify repair

Go to Step 9
Go to Step 10

Verify repair

release?
Verify repair
Go to Step 11
Replace the ECM.

Verify repair
Using the DVM and check the EGR EVRV circuit.

2. Remove the EGR EVRV connector and ECM
connector.
3. 3. Check the circuit for short to voltage circuit.
C-115
7
8
9
10
11
6E240

(FLASH CODE 24) VEHICLE SPEED SENSOR CIRCUIT HIGH INPUT
(FLASH CODE 24) VEHICLE SPEED SENSOR INPUT SIGNAL FREQUENCY
TOO HIGH
(FLASH CODE 24) VEHICLE SPEED SENSOR INCORRECT SIGNAL
6E241
Flash
Code
Code
Symptom
Code
MIL
DTC Name
Fail-Safe (Back Up)
24
P0500
ON
at next
ignition
cycle
Vehicle Speed Sensor Circuit

High Input

200km/h.
ECM uses vehicle speed 5km/

h condition as substitute.
ON
at next
ignition
cycle
Vehicle Speed Sensor Input

Signal Frequency Too High
Input signal frequency is too

high.
ECM uses vehicle speed 5km/

h condition as substitute.
ON
at next
ignition
cycle
Vehicle Speed Sensor Incorrect Signal

3200rpm (4JA1-TC) or
3600rpm (4JH1-TC).
more than 30mg/strk
(4JA1-TC) or 41mg/strk
(4JH1-TC).
1.5km/h.

reduced.
Circuit Description
Misrouted harness.

meter fuse.
The engine control module (ECM) calculates the vehicle
speed by VSS.
Diagnostic Aids
Poor connections.

Vehicle Speed Sensor Circuit High Input
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Present Failure?

ignition cycle?
6E242
Step
Action
Value(s)
Yes
No
Perform test drive and check the speed meter.

Does the speed meter indicate correct vehicle speed.
Go to Step 5
Go to Step 6
Perform test drive and use the Tech 2.

Monitor the Vehicle Speed in the data display.
Does the Tech 2 indicate correct vehicle speed as
same as the speed meter indication in the instrument
panel?
Go to Step 15
Go to Step 7
Remove the VSS from the housing case and visually

check.
Go to Step 8
Go to Step 7
Refer to
Diagnostic Aids
and Go to Step
15
Refer the table
Using the DVM and check the VSS signal.

1. Ignition On, vehicle Run (lift up).
2. Measure the VSS output voltage at sensor, TCM
(A/T 2WD), meter and ECM.
Does the tester indicate specified value?
Measurement Position
VSS terminal 3 & GND
Voltage (V)
(AC Range)
If No
Good
Approximately 6.0
V at 20km/h
Go to
Step 8
TCM C94 connector 10 &

GND (A/T 2WD)
Go to
Step 9
Meter B24 connector 9 &

GND
Go to
Step 10

GND
Go to
Step 12
ECM C56 connector 68 &

GND
Go to
Step 13
If a oscilloscope is available, monitor the VSS signal

at each connector connection. Does the oscilloscope
indicate correct wave form?
0V

GND(-)
50ms/div
8
9
Replace the VSS.

Verify repair
Replace the TCM.

IMPORTANT: The replacement TCM must be
programmed. SPS (Service Programming System)
is necessary.
Verify repair

Step
10
Action
Value(s)
6E243
Yes
No
Less than 1V
Go to Step 11
Repair faulty
harness and
verify repair
Verify repair
Verify repair
Go to Step 14
Repair faulty
harness and
verify repair
Using the DVM and check the VSS signal circuit.

2. Disconnect the meter connector.
B-24
V
11

2. Disconnect the VSS connector and meter
connector.
circuit.
If a open or short to ground circuit is found, repair the
B-24
E-44
3
12
13
Replace the speed meter.

2. Disconnect the
connector.
3. Ignition On.
meter connector
and
ECM

B-24
10
V
Less than 1V
6E244
Step
14
Action
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 15

release?
Verify repair
Go to Step 16
Replace the ECM.

Verify repair

(ECM

4. Check the circuit for open or shot to ground circuit.
B-24
Breaker Box
68

2. Disconnect
connector.
the
meter connector
and
ECM

circuit.
C-56
68
B-24
15
16
10
6E245
Vehicle Speed Sensor Input Signal Frequency Too High
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Present Failure?
4
5

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Go to Step 5
Go to Step 6

panel?
Go to Step 10
Go to Step 7

check.
Go to Step 8
Go to Step 7
6E246
Step
7
Action
Value(s)
Yes
No
Refer to
Diagnostic Aids
and Go to Step
10
Refer the table

Voltage (V)
(AC Range)
If No
Good
Approximately 6.0
V at 20km/h
Go to
Step 8
TCM terminal A10 & B5

(A/T 2WD)
Go to
Step 9

GND
Go to
Step 10

GND
Go to
Step 11

GND
Go to
Step 10

0V

GND(-)
50ms/div
8
9
10
11
12
Replace the VSS.

Verify repair
Replace the TCM.

is necessary.
Verify repair

Remove the
accessory parts
and verify repair
Go to Step 12

Verify repair

release?
Verify repair
Go to Step 13
6E247
Step
Action
Value(s)
Yes
No
13
Replace the ECM.

Verify repair
6E248
Vehicle Speed Sensor Incorrect Signal
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Present Failure?
4
5

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Go to Step 5
Go to Step 6

panel?
Go to Step 17
Go to Step 7
Verify repair
Go to Step 8
Check for poor/faulty connection at the VSS, TCM (A/

T 2WD) and meter connectors. If a poor/faulty
E-44
1
2
B-24
9 10
C-94(10)
10

Step
Action
Check for poor/faulty connection at the ECM and

other connectors. If a poor/faulty connection is found,
6E249
Value(s)
Yes
No
Verify repair
Go to Step 9
Go to Step 10
Go to Step 9
Refer to
Diagnostic Aids
and Go to Step
17
Refer the table
C-56
68

check.
Voltage (V)
(AC Range)
If No
Good
Approximately 6.0
V at 20km/h
Go to
Step 10
TCM C94 connector 10 &

GND (A/T 2WD)
Go to
Step 11

GND
Go to
Step 12

GND
Go to
Step 14

GND
Go to
Step 15

0V

GND(-)
50ms/div
10
Replace the VSS.

Verify repair
6E250
Step
Action
Value(s)
Yes
No
11
Replace the TCM.

is necessary.
Verify repair
Less than 1V
Go to Step 13
Repair faulty
harness and
verify repair
Verify repair
Verify repair
12

B-24
V
13

2. Disconnect the VSS connector
connector.
and
meter

circuit.
B-24
E-44
3
14


Step
15
Action
Value(s)
6E251
Yes
No
Less than 1V
Go to Step 16
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 17

connector.
and
ECM
3. Ignition On.
B-24
10
V
16

(ECM

B-24
Breaker Box
68

2. Disconnect the meter connector and ECM
connector.
circuit.
C-56
68
B-24
10
6E252
Step
Action
Value(s)
Yes
No
17

release?
Verify repair
Go to Step 18
Replace the ECM.

Verify repair
18
6E253

(FLASH CODE 35) SYSTEM VOLTAGE TOO HIGH
(FLASH CODE 35) SYSTEM VOLTAGE TOO LOW
(FLASH CODE 35) SYSTEM VOLTAGE MALFUNCTION
Flash
Code
Code
Symptom
Code
MIL
DTC Name
35
P0560
OFF

20V.
OFF
OFF
System voltage of PSG

(pump control unit) is below
4.5V or more than 27V.
Circuit Description
The ECM and PSG monitors the system voltage on the
ignition feed terminal to the ECM or PSG. The system
Fail-Safe (Back Up)

ECM uses 9V conditions as
substitute.
PSG uses default voltage as

substitute.
voltage to the ECM excessively high or low, DTC P0560

stored. The system voltage to the PSG excessively high
6E254
or low, DTC P0560 (Symptom Code A) will be stored.
Diagnostic Aids
Poor connections.
Misrouted harness.

the System Voltage display on the Tech2 while
sensor.
Step
Action
Value(s)

performed?
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Present Failure?
Yes

4
5

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Was the battery

connecting?
Verify
procedure
Go to Step 5
jump
start
cable
incorrectly
1. Using the Tech 2, ignition On and engine On.

2. Monitor the System Voltage in the data display.
3. Load the electrical system by turning on the

headlights, etc..
Does the Tech 2 indicate correct ignition voltage?
10 - 14.5V
Go to Step 6
Check the
charging
system

release?
Verify repair
Go to Step 7
6E255
Step
Action
Value(s)
Yes
No
Replace the ECM.

Verify repair
6E256
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
10 - 14.5V
Go to Step 6
Go to Step 5
10 - 14.5V
Go to Step 6
Check the
charging
system, charge
or replace the
battery
Verify repair
Go to Step 7

Present Failure?

ignition cycle?

2. Monitor the System Voltage in the data display.
headlights, etc..
Does the Tech 2 indicate enough ignition voltage?
Using the DVM and check the battery voltage at the

battery terminal.
Does the tester indicate enough battery voltage?
Check for poor/faulty connection at the ECM

connector. If a poor/faulty connection is found, repair
as necessary.
C-56
56

Step
7
Action
Value(s)
6E257
Yes
No
120-1509
Go to Step 8
Replace ECM
main relay and
verify repair
Verify repair
Go to Step 9

release?
Verify repair
Go to Step 10
Replace the ECM.

Verify repair
Using the DVM and check the ECM main relay.

2. Remove the ECM main relay from the relay box.
ECM Main Relay

Check for poor/faulty connection of the ECM ground

at the body. If a poor/faulty connection is found, repair
as necessary.
C-109
10
6E258
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
10 - 14.5V
Go to Step 7
Go to Step 6

Present Failure?

ignition cycle?
Check for poor/faulty connection at the PSG (pump

control unit) connector. If a poor/faulty connection is
found, repair as necessary.
E-6
6
Using the DVM and check the PSG (pump control

unit) power supply circuit.
connector.
3. Check the PSG (pump control unit) power supply
circuit.
6
E-6
V
7

Step
Action
Check for poor/faulty connection of the PSG (pump

control unit) ground at the cylinder body. If a poor/
faulty connection is found, repair as necessary.
6E259
Value(s)
Yes
No
Verify repair
Go to Step 7
Verify repair
E-10

6E260

(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION
(FLASH CODE 18) IGNITION SWITCH CIRCUIT MALFUNCTION
Flash
Code
Code
Symptom
Code
MIL
DTC Name
18
P0561
OFF
Ignition Switch Circuit Malfunction
The ECM recognized ignition

switch turn off signal during
ECM is activated.
OFF
Ignition switch circuit is malfunction.
Fail-Safe (Back Up)

ECM stops engine.

Circuit Description
The ECM monitors the ignition switch signal on the feed

terminal to the ECM. If the ignition switch signal with
malfunction, DTC P0561 (Symptom Code A) or DTC
P0561 (Symptom Code B) will be stored.

Diagnostic Aids
Poor connections.
Misrouted harness.
6E261

the Ignition Status display on the Tech2 while
sensor.
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

(Symptom Code B) stored as Present Failure?


(Symptom Code B)stored in this ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Check the Engine fuse (10A).

Verify repair
Go to Step 5
6E262
Step
Action
Value(s)
Yes
No
Using the DVM and check the ignition power feed

circuit.
Repair faulty
harness and
verify repair
Go to Step 6
Check the ignition switch.

If a poor/faulty connection is found, repair as
necessary.
Verify repair
Go to Step 7

release?
Verify repair
Go to Step 8

2. Install the breaker box
disconnected)
as type A.
(ECM

circuit.
C-107
Breaker Box
39

circuit.
C-56
39
C-107
6E263
Step
Action
Value(s)
Yes
No
Replace the ECM.

Verify repair
6E264
DIAGNOSTIC TROUBLE CODE (DTC) P0602 CONTROL MODULE

PROGRAMMING ERROR
Flash
Code
Code
Symptom
Code
MIL
DTC Name
P0602
Control Module Programming

Error
Circuit Description & Diagnostic Aids

The replacement ECM must be programmed by Service
Programming System (SPS). Because, the service

Fail-Safe (Back Up)

ECM does not programmed.

When the service ECM is used without SPS, DTC
P0602 will appear.
Diagnostic Trouble Code (DTC) P0602 Control Module Programming Error

Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check

Is the DTC P0602 stored as Present Failure?
Go to Step 3
Refer to
Diagnostic Aids
Download the latest software to the ECM using the

SPS (Service Programming System).
Verify repair
6E265

(FLASH CODE 28) ECU MALFUNCTION
(FLASH CODE 28) ECU MALFUNCTION
Flash
Code
Code
Symptom
Code
MIL
DTC Name
Fail-Safe (Back Up)
28
P0606
ON
ECM Malfunction
Gate Array communication

error.

valve) is operated.
becomes 0mg/strk.
ON
ECM Malfunction
1. Throttle position is below

1%.
2. Desired injection quantity is
more than 0mg/strk.
2000rpm.

valve) is operated.

If the ECM inside (IC, circuit, memory, etc,) failed, DTC
P0606 (Symptom Code A) or P0606 (Symptom Code B)
will be stored.
Diagnostic Trouble Code (DTC) P0606 (Symptom Code A) (Flash Code 28) ECU
Malfunction
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5

Present Failure?

6E266
Step
Action
Value(s)
Yes
No
Replace the ECM.

Verify repair
6E267
Diagnostic Trouble Code (DTC) P0606 (Symptom Code B) (Flash Code 28) ECU
Malfunction
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5

Go to Step 6
Go to Step 7
Replace the ECM.

Verify repair

Verify repair

Present Failure?

6E268

(FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE LOW
(FLASH CODE 46) A/C COMPRESSOR RELAY CIRCUIT VOLTAGE HIGH
Flash
Code
Code
Symptom
Code
MIL
DTC Name
46
P0645
ON
A/C Compressor Relay Circuit

Voltage Low

ON
A/C Compressor Relay Circuit

Voltage High

Fail-Safe (Back Up)

Circuit Description
Diagnostic Aids
The voltage on the coil of the A/C compressor is

supplied by the ECM main relay. The ECM switches A/C
compressor relay to operate A/C compressor depends
on the A/C request signal and certain setting conditions.

Poor connections.
Misrouted harness.

6E269

connectors and wiring harnesses.

Diagnostic Trouble Code (DTC) P0645 (Symptom Code 4) (Flash Code 46) A/C
Compressor Relay Circuit Voltage Low
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Replace A/C
compressor
relay and verify
repair

Present Failure?

ignition cycle?
Check for poor/faulty connection at the A/C

compressor relay or ECM connector. If a poor/faulty

C-56
X-14

Using the DVM and check the A/C compressor relay.

2. Remove the A/C compressor relay from the relay
box.

120-1509
6E270
Step
Action
Using the DVM and check the A/C compressor relay

Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair

box.
circuit.
X-14
V
7

ECM main relay and A/C compressor relay.

Step
Action

ground circuit.
6E271
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9

release?
Verify repair
Go to Step 10
Replace the ECM.

Verify repair

disconnected)
as type A.
(ECM

box.
circuit.
X-14
Breaker Box
41

box.
circuit.
X-14
C-56

10
6E272
Diagnostic Trouble Code (DTC) P0645 (Symptom Code 8) (Flash Code 46) A/C
Compressor Relay Circuit Voltage High
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5

Go to Step 6
Replace the ECM.

Verify repair

Present Failure?


(FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION
(FLASH CODE 25) BRAKE SWITCH CIRCUIT MALFUNCTION
6E273
6E274
Flash
Code
Code
Symptom
Code
MIL
DTC Name
Fail-Safe (Back Up)
25
P0703
ON

Malfunction

than 0%.
693rpm (4JA1-TC) or
665rpm (4JH1-TC).
3. Vehicle speed is more than
0km/h.
ECM since the ignition
switch was turned on.
ON

Malfunction

than 0%.
693rpm (4JA1-TC) or 665
rpm (4JH1-TC).
0km/h.
ECM.
Circuit Description
The ECM monitors the brake switch signal on the feed

terminal to the ECM. If brake switch 1 or 2 circuit with
malfunction, DTC P0703 (Symptom Code A) or P0703
(Symptom Code B) will be stored.

Diagnostic Aids
Poor connections.
Misrouted harness.

the Brake Switch 1 and Brake Switch 2 display on
the Tech2 while moving connectors and wiring
harness related to the sensor.
Brake Switch Circuit Malfunction
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Present Failure?

Step
Action
Value(s)
Yes
No

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Check the Stop Lamp fuse (15A).

Verify repair
Go to Step 5
Verify repair
Go to Step 6
Pedal is not
stepped on:
Continuity
Pedal stepped
on: No
continuity
Go to Step 7
Replace pedal
switch and
verify repair
10-14.5V
Go to Step 9
Go to Step 8
Check for poor/faulty connection at the brake switch

or ECM connector. If a poor/faulty connection is found,
C-56
C-44
30
6
6E275
Using the DVM and check the brake switch 1.

2. Remove the brake switch connector at the brake
pedal.
3. Check the brake switch 1.
Brake Switch
Using the DVM and check the brake switch 1 power

supply circuit.
2. Remove the brake switch connector from the
brake switch.
C-44
6E276
Step
Action
Value(s)
Yes
No
Repair the open circuit between the Stop Lamp fuse

(15A) and brake switch 1.
Verify repair
Pedal is not
stepped on:
Less than 1V
Pedal stepped
on: 10-14.5V
Go to Step 12
Fixed at 1014.5V: Go to
Step 10
Fixed at less
than 1V: Go to
Step 11
Verify repair
Verify repair
Using the DVM and check the brake switch 1 circuit.

(ECM

4. Check the circuit for open or short to voltage
circuit.
Breaker Box
105

2. Back probe the DVM to the brake switch 1 and
check the circuit for open or short to voltage
circuit.
C-44
V
10
Repair the short to voltage circuit between the brake

switch 1 connector and ECM.
C-56
30
11
C-44
Repair the open circuit between the brake switch 1

connector and ECM.
C-56
30
C-44
6E277
Step
Action
Value(s)
Yes
No
12

release?
Verify repair
Go to Step 13
Replace the ECM.

Verify repair
13
6E278
Brake Switch Circuit Malfunction
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Replace pedal
switch and
verify repair

Present Failure?

ignition cycle?
Check for poor/faulty connection at the brake switch

C-56
C-44
65
5
Using the DVM and check the brake switch 2.

2. Remove the brake switch connector at the brake
pedal.
3. Check the brake switch 2.
Brake Switch
Pedal is not
stepped on:
No continuity
Pedal stepped
on: Continuity

Step
Action
Using the DVM and check the brake switch 2 power

supply circuit.
6E279
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
Go to Step 11
Step 9
Fixed at less
than 1V: Go to
Step 10

2. Remove the brake switch connector from the
brake switch.
C-44
V
7
Repair the open circuit between the ECM fuse (10A)

and brake switch 2.
Using the DVM and check the brake switch 2 circuit.
connected)
as type B.
(ECM

circuit.
Breaker Box
65

2. Back probe the DVM to the brake switch 2 and
circuit.
C-44
Pedal is not
stepped on:
10-14.5V
Pedal stepped
on: Less than
1V
6E280
Step
Action
Value(s)
Yes
No
Repair the short to voltage circuit between the brake

switch 2 connector and ECM.
Verify repair
Verify repair

release?
Verify repair
Go to Step 12
Replace the ECM.

Verify repair
C-56
65
10
Repair the open circuit between the brake switch 2

connector and ECM.
C-56
65
11
12
C-44
C-44
6E281

(FLASH CODE 57) CLUTCH SWITCH INPUT CIRCUIT MALFUNCTION
Flash
Code
Code
Symptom
Code
MIL
57
P0704
ON
DTC Name
Clutch Switch Input Circuit
Malfunction
Circuit Description
The ECM monitors the clutch switch signal on the feed
terminal to the ECM. If clutch switch circuit with
malfunction, DTC P0704 (Symptom Code 6) will be
stored.
Diagnostic Aids
Poor connections.
Misrouted harness.

Clutch signal does not change
between vehicle speed
1.5km/h and 80km/h since
ignition switch was tuned on.
Fail-Safe (Back Up)


the Clutch Switch display on the Tech2 while
sensor.
6E282
Clutch Switch Input Circuit Malfunction
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 6
Replace pedal
switch and
verify repair

Present Failure?

ignition cycle?
Check for poor/faulty connection at the clutch switch

C-56
31
C-77
1
2
Using the DVM and check the clutch switch.

2. Remove the clutch switch connector at the clutch
pedal.
3. Check the clutch switch.
Clutch Switch

Pedal is not
stepped on:
Continuity
Pedal stepped
on: No
continuity

Step
Action
Using the DVM and check the clutch switch power

supply circuit.
6E283
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
Go to Step 11
Step 9
Fixed at less
than 1V: Go to
Step 10

2. Remove the clutch switch connector from the
clutch switch.
C-77
1
2
V
7

and clutch switch.
Using the DVM and check the clutch switch circuit.
(ECM

circuit.
Breaker Box
31

2. Back probe the DVM to the clutch switch and
circuit.
C-77
Pedal is not
stepped on:
10-14.5V
Pedal stepped
on: Less than
1V
6E284
Step
Action
Value(s)
Yes
No
Repair the short to voltage circuit between the clutch

switch connector and ECM.
Verify repair
Verify repair

release?
Verify repair
Go to Step 12
Replace the ECM.

Verify repair
C-56
31
10
Repair the open circuit between the clutch switch

connector and ECM.
C-56
31
11
12
C-77
C-77
6E285

(FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT HIGH INPUT
(FLASH CODE 86) BAROMETRIC PRESSURE SENSOR CIRCUIT LOW INPUT
Flash
Code
Code
Symptom
Code
MIL
DTC Name
86
P1105
ON

Circuit High Input

4.4V.
ON

Circuit Low Input

Fail-Safe (Back Up)

ECM uses 1013hpa condition
as substitute.
Circuit Description
Diagnostic Aids
The ECM monitors the barometric pressure signal at

inside of the ECM. If the sensor with malfunction, DTC
P1105 (Symptom Code 1) or P1105 (Symptom Code 2)
will be stored.
If the DTC P1105 is stored, sensor or circuit of ECM

inside is failed.
Barometric Pressure Sensor Circuit High Input
Barometric Pressure Sensor Circuit Low Input
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Was the DTC P1105 (Symptom Code 1) or P1105
(Symptom Code 2) stored in this ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5

Is the DTC P1105 (Symptom Code 1) or P1105
(Symptom Code 2) stored as Present Failure?

6E286
Step
Action
Value(s)
Yes
No
Replace the ECM.

Verify repair
6E287

(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR CIRCUIT HIGH
INPUT
(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR VOLTAGE SUPPLY
CIRCUIT HIGH INPUT
(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR VOLTAGE SUPPLY
CIRCUIT LOW INPUT
(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR BRAKE SWITCH
ERROR
(FLASH CODE 21) PEDAL/THROTTLE POSITION SENSOR IDLE POSITION
SWITCH ERROR
6E288
Flash
Code
Code
Symptom
Code
MIL
DTC Name
Fail-Safe (Back Up)
21
P1120
ON
Pedal/Throttle Position Sensor Circuit High Input
Throttle position sensor output voltage is more than 4.5V.
ON
Pedal/Throttle Position Sensor Voltage Supply Circuit

High Input

than 5.2V.
ON
Pedal/Throttle Position Sensor Voltage Supply Circuit

Low Input

power supply voltage is below
4.6V.
ON
Pedal/Throttle Position Sensor Brake Switch Error

1700rpm.
1.5km/h.
3. When brake pedal is
depressed during accelerator pedal is depressing.
ON
Pedal/Throttle Position Sensor Idle Position Switch Error
1. When idle switch is turned

off, throttle position sensor
was below 0.35%.
or
2. When idle switch is tuned
on, throttle position sensor
was more than 7.8%.
ECM increases idle speed up

to 1400rpm.
Circuit Description
Diagnostic Aids

on the throttle body. It is installed to the main TPS and
idle switch.
The ECM monitors the TPS supply voltage and TPS
output voltage. The supply voltage is out of range, DTC
P1120 (Symptom Code 7) or P1120 (Symptom Code 9)
will be stored. The output voltage excessively high, DTC
P1120 (Symptom Code 1) will be stored.
If the brake pedal is depressed during accelerator pedal
is depressing, DTC P1120 (Symptom Code D) will be
stored.
If the relation of idle switch and TPS position are
incorrect, DTC P1120 (Symptom Code E) will be stored.

Poor connections.
Misrouted harness.
the Throttle Position, Idle Switch, Brake Switch 1
and Brake Switch 2 display on the Tech2 while
sensor.
Pedal/Throttle Position Sensor Circuit High Input
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check

Step
2
Action
Value(s)
Yes
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6

Present Failure?
6E289

ignition cycle?
Check for poor/faulty connection at the TPS or ECM

as necessary.
C-56
49
39
57
Visually check the TPS.

E-22
2 3
6E290
Step
6
Action
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 9
Go to Step 8
Verify repair
Go to Step 14
Using the DVM and check the TPS.

2. Disconnect TPS connector.
3. Measure the resistance of TPS.
Measurement
Terminal
1-2
2-3
1-3
Resistance (W)
Approximately 0.4kW at idle position
Approximately 4.0kW at WOT
Approximately 4.6kW at idle position &
WOT
TPS
3
2
2
Using the DVM and check the TPS power supply

circuit.
2. Disconnect the TPS connector.
E-22
V
8

and TPS.
C-56
57
E-22

Step
9
Action
Value(s)
6E291
Yes
No
Go to Step 10
Repair faulty
harness and
verify repair
Go to Step 11
Repair faulty
harness and
verify repair
Using the DVM and check the TPS signal circuit.

E-22
V
Less than 1V
10
Using the DVM and check the TPS ground circuit.

2. Disconnect the TPS connector .
E-22
V
Less than 1V
6E292
Step
11
Action
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 14
Substitute a known good TPS and recheck.

Go to Step 13
Go to Step 14
Replace the TPS.

Verify repair

release?
Verify repair
Go to Step 15
Replace the ECM.

Verify repair

(ECM

Breaker Box
49
E-22

2. Disconnect
connector.
the
TPS
connector
and
ECM

C-56
49
E-22
12
13
14
15
6E293
Pedal/Throttle Position Sensor Voltage Supply Circuit High Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6

Present Failure?

ignition cycle?

as necessary.
C-56
49
39
57

E-22
2 3
6E294
Step
Action
Value(s)
Yes
No

circuit.
Approximately
5.0V
Go to Step 12
Go to Step 7
Verify repair
Go to Step 8

Go to Step 9
Go to Step 10
Replace the TPS.

Verify repair

release?
Verify repair
Go to Step 11
Replace the ECM.

Verify repair

E-22
V
7

ECM and TPS.
C-56
57
E-22
8
9
10
11
6E295
Pedal/Throttle Position Sensor Voltage Supply Circuit Low Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check

Present Failure?
Go to Step 3
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 10
Go to Step 6

ignition cycle?
Refer to
Diagnostic Aids

as necessary.
C-56
49
39
57

E-22
2 3
6E296
Step
Action
Value(s)
Yes
No

circuit.
Approximately
5.0V
Go to Step 10
Go to Step 7
No continuity
Go to Step 9
Go to Step 8
Verify repair
Verify repair
Go to Step 12

Go to Step 11
Go to Step 12
Replace the TPS.

Verify repair

circuit.
E-22
V
7

circuit.
2. Disconnect the TPS connector
connector.
and
ECM
3. Check the circuit for short to TPS ground circuit.

E-22
8
9
Repair the circuit for short to TPS ground circuit.

and TPS.
C-56
57
E-22
10
11
6E297
Step
Action
Value(s)
Yes
No
12

release?
Verify repair
Go to Step 13
Replace the ECM. Is the action complete?

Verify repair
13
6E298
Pedal/Throttle Position Sensor Brake Switch Error
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 7
Go to Step 6
Verify repair
Go to Step 11
2. Monitor the Brake Switch 1 and Brake Switch 2

in the data display.
Does the Tech 2 indicate Inactive when the brake
pedal was not stepped on?
Go to Step 13
Go to Step 8
Adjust the brake switch.

Verify repair
Go to Step 9
Substitute a known good brake switch and recheck.

Go to Step 10
Go to Step 13
Replace the brake switch.

Verify repair

Go to Step 12
Go to Step 13
Replace the TPS.

Verify repair

Present Failure?

ignition cycle?

Accelerator pedal sticking.

2. Monitor the Throttle Position in the data display.
Does the Tech 2 indicate correct Throttle Position
from 0% to 100% depending on accelerator pedal
operation?

3. Adjust the TPS within 0% to 100%.
8
9
10
11
12
6E299
Step
Action
Value(s)
Yes
No
13

release?
Verify repair
Go to Step 14
Replace the ECM.

Verify repair
14
6E300
Pedal/Throttle Position Sensor Idle Position Switch Error
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Present Failure?
4
5

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Go to Step 8
Go to Step 5

Does the Tech 2 indicate correct Throttle Position
operation?
Go to Step 7
Go to Step 6Go
to Step 6
Verify repair
Go to Step 8
2. Monitor the Idle Switch in the data display.

Does the Tech 2 indicate Inactive when the
accelerator pedal was stepped on?
Go to Step 10
Go to Step 8

Go to Step 9
Go to Step 10
Replace the TPS.

Verify repair

release?
Verify repair
Go to Step 11

8
9
10
6E301
Step
Action
Value(s)
Yes
No
11
Replace the ECM.

Verify repair
6E302

(FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH COOLANT
TEMPERATURE
(FLASH CODE 22) FUEL REDUCTION CAUSED BY HIGH FUEL TEMPERATURE
(FLASH CODE 22) FUEL REDUCTION CAUSED BY LOW FUEL TEMPERATURE
Flash
Code
Code
Symptom
Code
22
P1173
MIL
DTC Name
Fail-Safe (Back Up)
OFF

High Coolant Temperature
Excessive high engine coolant temperature is detected.
OFF

High Fuel Temperature
Fuel temperature is more than

100 deg. C.
PSG (pump control unit) controls fuel injection quantity

based on engine speed and
fuel temperature.
OFF

Low Fuel Temperature
Excessive low fuel temperature is detected.
Circuit Description
Diagnostic Aids
The engine coolant temperature (ECT) sensor is

installed on the coolant stream. High coolant
temperature produces a low resistance. The ECM
supplies 5 volts signal to the ECT sensor through
resisters in the ECM and measures the voltage. The
signal voltage will be low when the engine temperature
is hot.
The fuel temperature sensor is assembled inside of the
pump control unit (PSG). The signal of fuel temperature
If the engine coolant temperature is excessively high
condition, DTC P1173 (Symptom Code 3) will be stored.
If the fuel temperature is excessively high or low
condition, DTC P1173 (Symptom Code 7) or P1173
(Symptom Code A) will be stored.

Poor connections.
Misrouted harness.
the Coolant Temperature or Fuel Temperature
display on the Tech2 while moving connectors and
wiring harness related to the sensor.
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 3) (Flash Code 22) Fuel
Reduction Caused By High Coolant Temperature
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Present Failure?

Step
Action
Value(s)
Yes
No
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Repair the
cause of
overheat and
verify repair
Go to Step 5
Go to Step 9
Go to Step 6
Standard
resistance
Go to Step 9
Go to Step 7

recheck.
Go to Step 8
Go to Step 9

Verify repair

release?
Verify repair
Go to Step 10

ignition cycle?
4
Check the engine overheat condition.


2. Monitor the Coolant Temperature in the data
display.
Does the Tech 2 indicate correct Coolant
Temperature depending on warm up time?
6E303

Temperature (C)
-20
16100
5760
20
2370
40
1080
60
537
80
290
100
161
120
95
ECT Sensor
2
1
2
8
9
6E304
Step
Action
Value(s)
Yes
No
10
Replace the ECM.

Verify repair
6E305
Diagnostic Trouble Code (DTC) P1173 (Symptom Code 7) (Flash Code 22) Fuel
Reduction Caused By High Fuel Temperature
Reduction Caused By Low Fuel Temperature
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Was the DTC P1173 (Symptom Code 7) or P1173
(Symptom Code A) stored in this ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5

Go to Step 6
Go to Step 7
Replace the ECM.

Verify repair

Verify repair

Is the DTC P1173 (Symptom Code 7) or P1173
(Symptom Code A) stored as Present Failure?

6E306

(FLASH CODE 43) ENGINE SPEED OUTPUT CIRCUIT MALFUNCTION
Flash
Code
Code
Symptom
Code
MIL
43
P1335
ON
DTC Name
Engine Speed Output Circuit

Malfunction

is recognized defective
engine speed signal form the
ECM.
Fail-Safe (Back Up)

reduced.
Circuit Description
Diagnostic Aids

housing of the flywheel and fixed with a bolt. The CKP
sensor is of the magnet coil type. The inductive pickup
sensors four gaps in the flywheel exciter ring and is
used to determine the engine speed and engine
cylinder top dead center.
The ECM converts sine wave signal to square wave
signal. And this signal is provided from the ECM to
pump control unit (PSG).

Poor connections.
Misrouted harness.

the Engine Speed display on the Tech2 while
6E307

sensor.
Engine Speed Output Circuit Malfunction
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to DTC
Chart P0335
(Symptom
Code B)
(Symptom
Code C)
Go to Step 5
Verify repair
Go to Step 6

Present Failure?

ignition cycle?
Was the DTC P0335 (Symptom Code B) or P0335

(Symptom Code D) stored at the same time?

C-57(B)
E-6
91
6E308
Step
Action

wave form?
Value(s)
Yes
No
Go to Step 13
Not available:
Go to Step 7
Fixed at low:
Go to Step 7
Fixed at High:
Go to Step 8

Reference Wave Form
CH1
0V
CH2
0V

1ms/div

Step
Action

circuit.
3. Disconnect
connector.
the
PSG
(pump
control
6E309
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
Go to Step 9
Repair faulty
harness and
verify repair
(ECM
unit)

circuit.
Breaker Box
91
E-6

3. Disconnect
connector.
the
PSG
(pump
control
unit)

circuit.
C-57(B)
E-6
91

circuit.
connector.
E-6
V
Less than 1V
6E310
Step
Action
10
11
12
13
Value(s)
Yes
No

Remove the
accessory parts
and verify repair
Go to Step 10

release?
Verify repair
Go to Step 11

Go to Step 12
Go to Step 13
Replace the ECM.

Verify repair

Verify repair
6E311

(FLASH CODE 45) CAMSHAFT SPEED MALFUNCTION
Flash
Code
Code
Symptom
Code
MIL
DTC Name
45
P1345
ON
Camshaft Speed Malfunction

is recognized incorrect camshaft speed signal.
Fail-Safe (Back Up)

Circuit Description
The pump camshaft sensor is a magnet with a coil. It

uses to combine with the pulser. The pulser is attached
main shaft in the pump. It likes a gear shape.
The pump camshaft sensor is attached to the pump
control unit (PSG). The signal of pump camshaft speed

Diagnostic Aids
Poor connections.
Misrouted harness.

the Pump Speed display on the Tech2 while moving
6E312
Camshaft Speed Malfunction
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 6
Go to Step 5

Remove the
accessory parts
and verify repair
Go to Step 9

release?
Verify repair
Go to Step 7

Go to Step 8
Go to Step 9
Replace the ECM.

Verify repair

Verify repair

Present Failure?

ignition cycle?

2. Monitor the Pump Speed in the data display.
Does the Tech 2 indicate correct Pump Speed
depending on engine speed?
6E313

(FLASH CODE 47) NEUTRAL SWITCH ON ERROR
(FLASH CODE 47) NEUTRAL SWITCH OFF ERROR
Flash
Code
Code
Symptom
Code
MIL
DTC Name
47
P1520
ON
Neutral switch signal is inputted On three times consecutively under driving

conditions.
ON
Neutral switch signal is inputted Off three times consecutively under driving
conditions.
Fail-Safe (Back Up)

Circuit Description
(Symptom Code B) will be stored.
The ECM monitors the neutral switch (A/T: N or P

position switch in inhibitor switch) signal on the feed
terminal to the ECM. If the neutral switch with
malfunction, DTC P1520 (Symptom Code A) or P1520
Diagnostic Aids
Poor connections.
6E314
Misrouted harness.


the Neutral Switch display on the Tech2 while
sensor.
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

(Symptom Code B) stored as Present Failure?

(Symptom Code B) stored in this ignition cycle?

Step
Action
Check for poor/faulty connection at the neutral switch

(inhibitor switch) or ECM connector. If a poor/faulty
6E315
Value(s)
Yes
No
Verify repair
Go to Step 5
Go to Step 6
Replace neutral
switch (inhibitor
switch) and
verify repair
C-57
87
M/T
E-11
E-12
A/T
E-51
3
Using the DVM and check the neutral switch (inhibitor

switch).
2. Remove the neutral switch connector (inhibitor
switch connector) at the transmission.
3. Check the neutral switch (P range
switch).
N range
M/T
E-11
E-12
A/T
3
6
10 9
7
8
Neutral (P or
N): Continuity
Other than
neutral (P or
N): No
continuity
6E316
Step
Action

switch) power supply circuit.
Value(s)
Yes
No
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
Go to Step 11
Step 9
Fixed at less
than 1V: Go to
Step 10

2. Remove the neutral switch (inhibitor switch)
connector from the switch.
A/T
E-51
M/T
E-12
V
7

and neutral switch (between the Back Up fuse (15A)
and inhibitor switch).
switch) circuit.
(ECM

circuit.
Breaker Box
87
E-6

2. Back probe the DVM to the neutral switch
(inhibitor switch) and check the circuit for open or
M/T
E-11
A/T
E-51
V
V
Neutral (P or
N): 10-14.5V
Other than
neutral (P or
N): Less than
1V

Step
Action
Repair the short to voltage circuit between the neutral

switch connector (inhibitor switch connector) and
ECM.
6E317
Value(s)
Yes
No
Verify repair
Verify repair

release?
Verify repair
Go to Step 12
Replace the ECM.

Verify repair
M/T
C-57
E-11
87
A/T
C-57
E-51
87
10
Repair the open circuit between the neutral switch

connector (inhibitor switch connector) and ECM.
M/T
C-57
E-11
87
A/T
C-57
87
11
12
E-51
6E318

(FLASH CODE 55) SEED AND KEY FILE DESTROYED
(FLASH CODE 55) EEPROM DEFECT
(FLASH CODE 55) EEPROM DEFECT
Flash
Code
Code
Symptom
Code
MIL
DTC Name
55
P1605
ON
Seed and Key File Destroyed
Seed or key file in EEPROM

is destroyed.
ON
EEPROM Defect

EEPROM are failed during initialization of the ECM.
ECM uses default values from

the EPROM.
ON
EEPROM Defect
EEPROM checksum does not

match with the read check
sum during initialization of the
ECM.

The ECM used in this vehicle utilizes an electrically
erasable & programmable read only memory
(EEPROM).
The
EEPROM
contains
program
information and the calibrations required for engine and
Fail-Safe (Back Up)
diagnostics operation.
If the ECM inside (IC, circuit, memory, etc,) failed, DTC
P1605 (Symptom Code C), P1605 (Symptom Code D)
or P1605 (Symptom Code E) will be stored.
Diagnostic Trouble Code (DTC) P1605 (Symptom Code C) (Flash Code 55)
Seed and Key File Destroyed
EEPROM Defect
EEPROM Defect
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Is the DTC P1605 (Symptom Code C), P1605
(Symptom Code D) or P1605 (Symptom Code E)
stored as Present Failure?

Step
Action
6E319
Value(s)
Yes
No

Was the DTC P1605 (Symptom Code C), P1605
(Symptom Code D) or P1605 (Symptom Code E)
stored in this ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5
Replace the ECM.

Verify repair
6E320

(FLASH CODE 56) SECURITY KEY AND SECURITY CODE NOT PROGRAMMED
Flash
Code
Code
Symptom
Code
MIL
56
P1610
DTC Name
Security Key and Security
Code not Programmed

Immobilizer functions are not
Fail-Safe (Back Up)

Circuit Description
Diagnostic Aids
The ECM decides whether that is an abnormality in the

immobilizer control system. DTC P1610 (Symptom
Code A) is recorded when immobilizer function was not

Poor connection at ECM and immobilizer control unitInspect harness connectors for backed out terminals,
damaged terminals, and poor terminal to wire
connection.
6E321
Security Key and Security Code Not Programmed
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
3. Select Read DTC Info Ordered By Priority in the

Was the any DTC's B0002 or B0009 stored in this
ignition cycle?
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B0002 or
B0009
Go to Step 5

release?
Verify repair
Go to Step 6
Replace the ECM.

Verify repair

Present Failure?

ignition cycle?

2. Select Immobilizer in the system selection menu
Body.
6E322

(FLASH CODE 56) WRONG SECURITY CODE ENTERED
Flash
Code
Code
Symptom
Code
MIL
DTC Name
56
P1611
Wrong Security Code Entered
Received security code is not

correct.
Fail-Safe (Back Up)

Circuit Description
Diagnostic Aids

Code A) is recorded when received immobilizer security
code was not correct.

connection.
6E323
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Was the any DTC's B**** stored in this ignition cycle?
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B****
Go to Step 5

release?
Verify repair
Go to Step 6
Replace the ECM.

Verify repair

Present Failure?

ignition cycle?

Body.
6E324

(FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL
Flash
Code
Code
Symptom
Code
MIL
DTC Name
56
P1612
Immobilizer No or Wrong Signal
Received challenge signal is

Fail-Safe (Back Up)

Circuit Description
Diagnostic Aids

Code A) is recorded when received immobilizer
challenge signal was not correct.

connection.
6E325
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B0007
Go to Step 5
Verify repair
Go to Step 6

Present Failure?

ignition cycle?

Body.
Diagnositic Trouble Code.
Was the DTC B0007 stored in this ignition cycle?
Check for poor/faulty connection at the immobilizer

control unit connector or ECM connector. If a poor/
C-56
42
35
B-68
8
7
6E326
Step
Action
Value(s)

lamp circuit.
Yes
No
Go to Step 7
Repair faulty
harness and
verify repair

2. Disconnect the meter connector and immobilizer
control unit connector.
3. Ignition On.
Was DVM indicated specified value?
B-68
V
Less than 1V

Step
Action

lamp circuit.
6E327
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
(ECM
3. Disconnect the immobilizer control unit connector.

circuit.
Breaker Box
42
B-68

2. Disconnect the the immobilizer control unit
circuit.
C-56
42
B-68
6E328
Step
Action
Value(s)
Using the DVM and check the ECM and immobilizer

control unit communication circuit.
Yes
No
Less than 1V
Go to Step 9
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 10

3. Ignition On.
B-68
V
9

(ECM

circuit.
Breaker Box
35
B-68

circuit.
C-56
B-68
35
6E329
Step
Action
Value(s)
Yes
No
10

release?
Verify repair
Go to Step 11
Replace the ECM.

Verify repair
11
6E330

(FLASH CODE 56) IMMOBILIZER NO OR WRONG SIGNAL
Flash
Code
Code
Symptom
Code
MIL
DTC Name
56
P1613

Fail-Safe (Back Up)

Circuit Description
Diagnostic Aids

response signal was not correct.

connection.
6E331
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B****
Go to Step 5
Verify repair
Go to Step 6

Present Failure?

ignition cycle?

Body.

C-56
42
35
B-68
8
7
6E332
Step
Action
Value(s)

lamp circuit.
Yes
No
Go to Step 7
Repair faulty
harness and
verify repair

3. Ignition On.
Was DVM indicated specified value?
B-68
V
Less than 1V

Step
Action

lamp circuit.
6E333
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
Go to Step 9
Repair faulty
harness and
verify repair
(ECM

circuit.
Breaker Box
42
B-68

circuit.
C-56
42
B-68

3. Ignition On.
B-68
V
Less than 1V
6E334
Step
Action
Value(s)
Yes
No

Repair faulty
harness and
verify repair
Go to Step 10

release?
Verify repair
Go to Step 11
Replace the ECM.

Verify repair

(ECM

circuit.
Breaker Box
35
B-68

circuit.
C-56
B-68
35
10
11
6E335

(FLASH CODE 56) WRONG TRANSPONDER KEY
Flash
Code
Code
Symptom
Code
MIL
56
P1614
DTC Name

not correct from the transponder key.
Fail-Safe (Back Up)

Circuit Description
Diagnostic Aids

response signal was not correct from the transponder
key.

connection.
6E336
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B****
Go to Step 5

release?
Verify repair
Go to Step 6
Replace the ECM.

IMPORTANT: The replacement ECM must e
Verify repair

Present Failure?

ignition cycle?

Body.
6E337

(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO EARLY
(FLASH CODE 76) ECM MAIN RELAY SWITCHED OFF TOO LATE
Flash
Code
Code
Symptom
Code
MIL
DTC Name
76
P1625
OFF

Off Too Early

early.
OFF

Off Too Late

late or does not off.
Fail-Safe (Back Up)

Circuit Description
Diagnostic Aids
The ECM switches ECM main relay to operate ECM

and other sensors or controller.

Poor connections.
Misrouted harness.
6E338


the Main Relay display on the Tech2 while moving
ECM Main Relay Switched Off Too Early
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5
Replace the ECM.

Verify repair

Present Failure?

6E339
ECM Main Relay Switched Off Too Late
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
No continuitly
Go to Step 5
Replace ECM
main relay and
verify repair

release?
Verify repair
Go to Step 6
Replace the ECM.

Verify repair

Present Failure?

ignition cycle?
Using the DVM and check the ECM main relay.

2. Remove the ECM main relay from the relay box.
3. Check the relay switch.
ECM Main Relay

6E340

(FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION
(FLASH CODE 51) FUEL INJECTION QUANTITY CIRCUIT MALFUNCTION
Flash
Code
Code
Symptom
Code
MIL
DTC Name
51
P1630
ON
Fuel Injection Quantity Circuit

Malfunction

detects high pressure solenoid valve control circuit malfunction due to high current.

reduced.
ON
Fuel Injection Quantity Circuit

Malfunction

detects high pressure solenoid valve control circuit malfunction due to continuous
current.

valve) is operated.
becomes 0mg/strk.
Circuit Description
injection timing using the various sensors. And the PSG
controls the high pressure solenoid valve depending on
programmed pump map data.
Fail-Safe (Back Up)

Diagnostic Aids
Poor connections.
Misrouted harness.
6E341

Injection Quantity Circuit Malfunction
Injection Quantity Circuit Malfunction
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

(symptom Code B) stored in this ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

Verify repair

(symptom Code B) stored as Present Failure?

6E342

(FLASH CODE 44) CAN DEVICE OFFLINE
(FLASH CODE 44) CAN DEVICE HANG-UP
Flash
Code
Code
Symptom
Code
MIL
DTC Name
44
P1650
ON
CAN Device Offline
CAN controller detects Busoff or canceling.
ON
CAN Device Hang-up
CAN controller does not react

under engine running.
Fail-Safe (Back Up)

valve) is operated.
Circuit Description
Diagnostic Aids

performed via a CAN-bus system. The individual CANbus systems are connected via two interfaces and can
exchange information and data. This allows control
modules that are connected to different CAN-bus
systems to communicate.

Poor connections.
Misrouted harness.

6E343

CAN Device Offline
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 18
Go to Step 6
Go to Step 7
Repair faulty
harness and
verify repair

Present Failure?

ignition cycle?

C-57
E-6
100
5
6
99

Using the DVM and check the CAN high circuit.
2. Disconnect the ECM connector and PSG (pump
control unit) connector.
3. Check the circuit for short to CAN low circuit.
E-6
2
No continuity
6E344
Step
7
Action
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8

3. Disconnect
connector.
the
PSG
(pump
control
(ECM
unit)

circuit.
Breaker Box
100
E-6

2. Disconnect the PSG (pump
connector.
control
unit)

circuit.
C-57
100
E-6

Step
8
Action
6E345
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Go to Step 10
Go to Step 11
Using the DVM and check the CAN low circuit.

3. Disconnect
connector.
the
PSG
(pump
control
(ECM
unit)

circuit.
Breaker Box
99
E-6

connector.
control
unit)

circuit.
C-57
E-6
99

2. Disconnect
connector.
the
PSG
(pump
control
unit)

Was the DVM indicated battery voltage or
approximately 5V?
E-6
6E346
Step
Action
10

C-57
Yes
No
Verify repair
Go to Step 12
Go to Step 13
Verify repair
Repair faulty
harness and
verify repair
Go to Step 14
E-6
100
11
Value(s)

connector.
control
unit)

approximately 5V?
E-6
V
12

C-57
E-6
99
13

unit) ground circuit.
2. Disconnect
connector.
the
PSG
(pump
control
unit)

E-6

Step
Action
14
15
16
17
18
6E347
Value(s)
Yes
No

interference.
Remove the
accessory parts
and verify repair
Go to Step 15

release?
Verify repair
Go to Step 16

Go to Step 17
Go to Step 18
Replace the ECM.

Verify repair

Verify repair
6E348
CAN Device Hang-up
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5

Go to Step 6
Go to Step 7
Replace the ECM.

Verify repair

Verify repair

Present Failure?

6E349

(FLASH CODE 45) CAN MALFUNCTION
(FLASH CODE 45) CAN RECEIVES ERROR
Flash
Code
Code
Symptom
Code
MIL
DTC Name
45
P1651
ON
CAN Malfunction

does not recognize CAN signal from the CAN controller.
ON
CAN Malfunction
The ECM does not read CAN

signal from the PSG (pump
control unit).
Circuit Description

performed via a CAN-bus system. The individual CANbus systems are connected via two interfaces and can
exchange information and data. This allows control
modules that are connected to different CAN-bus
Diagnostic Aids
Fail-Safe (Back Up)

valve) is operated.
becomes 0mg/strk.

Poor connections.
Misrouted harness.
6E350


CAN Malfunction
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5

Go to Step 6
Go to Step 7
Replace the ECM.

Verify repair

Verify repair

Present Failure?

6E351
CAN Receives Error
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to DTC
Chart P1650
(Symptom
Code A)
Go to Step 5
Verify repair
Go to Step 6
Go to Step 19
Go to Step 7
Go to Step 8
Repair faulty
harness and
verify repair

Present Failure?

ignition cycle?
Was the DTC P1650 (Symptom Code A) stored at the

same time?

C-57
E-6
100
6
7
99

2. Disconnect the ECM connector and PSG (pump
control unit) connector.
3. Check the circuit for short to CAN low circuit.
E-6
2
No continuity
6E352
Step
8
Action
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9

3. Disconnect
connector.
the
PSG
(pump
control
(ECM
unit)

circuit.
Breaker Box
100
E-6

connector.
control
unit)

circuit.
C-57
100
E-6

Step
9
Action
6E353
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 11
Go to Step 12

3. Disconnect
connector.
the
PSG
(pump
control
(ECM
unit)

circuit.
Breaker Box
99
E-6

connector.
control
unit)

circuit.
C-57
E-6
99
10

2. Disconnect
connector.
the
PSG
(pump
control
unit)

approximately 5V?
E-6
6E354
Step
Action
11

C-57
Yes
No
Verify repair
Go to Step 13
Go to Step 14
Verify repair
Repair faulty
harness and
verify repair
Go to Step 15
E-6
100
12
Value(s)

2. Disconnect
connector.
the
PSG
(pump
control
unit)

approximately 5V?
E-6
V
13

C-57
E-6
99
14

unit) ground circuit.
2. Disconnect
connector.
the
PSG
(pump
control
unit)

E-6

Step
Action
15
16
17
18
19
6E355
Value(s)
Yes
No

interference.
Remove the
accessory parts
and verify repair
Go to Step 16

release?
Verify repair
Go to Step 17

Go to Step 18
Go to Step 19
Replace the ECM.

Verify repair

Verify repair
6E356

(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE LOW
(FLASH CODE 77) CHECK ENGINE LAMP (MIL) CIRCUIT VOLTAGE HIGH
Flash
Code
Code
Symptom
Code
MIL
DTC Name
77
P1690
OFF

Circuit Voltage Low

OFF


Fail-Safe (Back Up)

Circuit Description
Diagnostic Aids
The Check Engine Lamp (Malfunction Indicator Lamp

=MIL) should always be illuminated and steady with
ignition On. Ignition feed voltage is supplied to the
Check Engine Lamp bulb through the meter fuse. The
ECM turns the Check Engine Lamp On by grounding
the check engine lamp driver circuit for a certain time.

Poor connections.
Misrouted harness.

6E357

the Check Engine Lamp display on the Tech2 while
moving connectors and wiring harnesses. A change
in the display will indicate the location of the fault.
Check Engine Lamp (MIL) Circuit Voltage Low
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 5
Go to Step 6
2. Check the Check Engine lamp.

Go to Step 9
Go to Step 7
Check the Check Engine lamp bulb.

Verify repair
Go to Step 7
Verify repair
Go to Step 8

Present Failure?

ignition cycle?


C-56
17
42
B-24
6E358
Step
Action
Using the DVM and check the Check Engine lamp

circuit.
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Verify repair
Go to Step 10
(ECM

circuit.
Breaker Box
42
B-24

circuit.
C-56
42
B-24
17

release?
6E359
Step
Action
Value(s)
Yes
No
10
Replace the ECM.

Verify repair
6E360
Check Engine Lamp (MIL) Circuit Voltage High
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

ignition cycle?
Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5

Go to Step 6
Replace the ECM.

Verify repair

Present Failure?

6E361
SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS
Before using this section, perform the On-Board
Diagnostic (OBD) System Check and verify all of the
following items:
The engine control module (ECM) and check engine
lamp (MIL=malfunction indicator lamp are operating
correctly.
Road test the vehicle with a Digital Multimeter

connected to a suspected circuit. An abnormal voltage
when the malfunction occurs is a good indication that
there is a fault in the circuit being monitored.
Using Tech 2 to help detect intermittent conditions. The
Tech 2 have several features that can be used to
located an intermittent condition. Use the following
features to find intermittent faults:
There are no Diagnostic Trouble Code(s) stored.

Tech 2 data is within normal operating range. Refer to
Typical Scan Data Values.
Verify the customer complaint and locate the correct
symptom in the table of contents. Perform the
procedure included in the symptom chart.
VISUAL/PHYSICAL CHECK
Several of the symptom procedures call for a careful
visual/physical check. This can lead to correcting a
problem without further checks and can save valuable
time. This check should include the following items:
ECM grounds for cleanliness, tightness and proper
location.
Vacuum hoses for splits, kinks, and proper
connection. Check thoroughly for any type of leak or
restriction.
Air intake ducts for collapsed or damaged areas.
Air leaks at throttle body mounting area, mass air flow
(MAF) sensor and intake manifold sealing surfaces.
Wiring for proper connections, pinches and cuts.
INTERMITTENT
Important: An intermittent problem may or may not turn
on the check engine lamp (MIL=malfunction indicator
lamp) or store a Diagnostic Trouble Code. Do NOT use
the Diagnostic Trouble Code (DTC) charts for
intermittent problems.
The fault must be present to locate the problem.
Most intermittent problems are cased by faulty electrical
connections or wiring. Perform a careful visual/physical
check for the following conditions.
Poor mating of the connector halves or a terminal not
fully seated in the connector (backed out).
Improperly formed or damaged terminal.
All connector terminals in the problem circuit should
be carefully checked for proper contact tension.
Poor terminal-to-wire connection. This requires
removing the terminal form the connector body to
check.
Check engine lamp (MIL=malfunction indicator lamp)
wire to ECM shorted to ground.
Poor ECM grounds. Refer to the ECM wiring
diagrams.
To check for loss of diagnostic code memory,

disconnect the MAF sensor and idle the engine until the
check engine lamp (MIL=malfunction indicator lamp)
comes on. Diagnostic Trouble Code P0100 should be
stored and kept in memory when the ignition is turned
OFF.
If not, the ECM is faulty. When this test is completed,
make sure that you clear the Diagnostic Trouble Code
P0100 from memory.
An intermittent check engine lamp (MIL=malfunction
indicator lamp) with no stored Diagnostic Trouble Code
may be caused by the following:
wire to ECM short to ground.
diagrams.
Check for improper installation of electrical options such
as light, cellular phones, etc. Check all wires from ECM
to the ignition control module for poor connections.
Check for an open diode across the A/C compressor
clutch and check for other open diodes (refer to wiring
diagrams in Electrical Diagnosis).
If problem has not been found, refer to ECM connector
symptom tables.
Check the Broadcast Code of the ECM, and
compare it with the latest Isuzu service bulletins and/
or Isuzu EEPROM reprogramming equipment to
determine if an update to the ECM's reprogrammable
memory has been released.
This identifies the contents of the reprogrammable
software and calibration contained in the ECM.
If the Broadcast Code is not the most current
available, it is advisable to reprogram the ECM's
EEPROM memory, which may either help identify a
hard-to find problem or may fix the problem.
The Service Programming System (SPS) will not allow
incorrect software programming or incorrect calibration
changes.
6E362
ENGINE CRANKS BUT WILL NOT RUN

DEFINITIONS: Engine cranks, but will not run. (The engine never start.)
NOTE: The vehicle with immobilizer system, this system may be activated. Check the immobilizer system diagnosis.
Step
Action

performed?
3
4
5
6
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Go to Step 5
Add fuel to the

tank
Diesel fuel
only
Replace with
diesel fuel
Go to Step 6
Verify repair
Go to Step 7
Restrict air intake system at the turbocharger.

Check for objects blocking the turbocharger
compressor wheel or turbine shaft sticking.
Verify repair
Go to Step 8
Check the ECM & PSG grounds to verify that they are
clean and tight. Refer to the ECM wiring diagrams.
Verify repair
Go to Step 9

2. Monitor the Neutral Switch in the data display.
Does the Tech 2 indicate correct Neutral Switch
status depending on any shift positions?
Verify repair
Go to Step 10
1. Perform a bulletin search.

2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom?
Value(s)
Was a visually/physical check performed?

Is the fuel amount enough?
Is the customer using the incorrect fuel type?

Check the ECM fuse (10A) and Engine fuse (15A).
Restrict air intake system. Check for a restricted air
filter element, or foreign objects blocking the air
intake system
Check for objects blocking or excessive deposits in
the throttle bore and on the throttle plate
Check for a condition that causes a large vacuum
leak, such as an incorrectly installed or faulty
crankcase ventilation hose.

Step
Action
10

Value(s)
Yes
No
Verify repair
Go to Step 11
Check for any accessory parts which may cause

electric interference.
Verify repair
Go to Step 12

Go to Step 13
Go to Step 14

Verify repair
Verify repair
Go to Step 16

fuel.
Verify repair
Go to Step 17

Verify repair
Go to Step 18

11
6E363
Check the CKP sensor harness for the following

conditions.
Check for poor connector connection.
Check for misrouted harness.
12
13
14
Check the exhaust system for a possible restriction.

Damaged or collapsed pipes or catalytic converter.
Internal muffler failure.
15

fuel hose/pipe.
16
6E364
Step
Action
17

injection pump and check for the following conditions.
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 18
More than 2.1

Mpa (21.0 kg/
cm2)
Verify repair
Go to Step 19
Go to Step 20
Repair as
necessary

fuel.
18
19
Check the engine compression pressure for each

cylinders.
If the injection pump was replaced, are the timing

gears or injection pump correctly installed?

Step
Action
20
1. Review all diagnostic procedures within this table.
6E365
Value(s)
Yes
No
All electrical connections within a suspected circuit

and/or system
Verify repair
Go to Step 21

release?
Verify repair
Go to Step 22

Go to Step 23
Go to Step 24
Replace the ECM.

Verify repair

Verify repair
2. If all procedures have been completed and no

malfunctions have been found, review/inspect the
following:
Visual/physical inspection
Tech 2 data
21
22
23
24
6E366
HARD START SYMPTOM

DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, or may start and then
immediately stall.
Step
Action

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Go to Step 6

Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 20
Go to Step 9
Go to Step 20
Go to Step 10

3
4
5
Value(s)

intake system
1. Using the Tech 2, display the ECT sensor and IAT

sensor value.
2. Check the displayed value.
Does the Tech 2 indicate correct temperature
depending on engine condition?
1. Using the Tech 2, display the FT sensor value.

1. Using the Tech 2, ignition On.

2. Monitor the Glow Time Relay in the data display.
Does the Tech 2 indicate correct Glow Time Relay
status depending on the time from ignition switch
On?

Step
10
Action
Value(s)
6E367
Yes
No
Go to Step 11
Repair voltage
supply circuit
and verify repair
Verify repair
Go to Step 12
Verify repair
Go to Step 13

fuel.
Verify repair
Go to Step 14

Verify repair
Go to Step 15
1. Using the Tech 2, ignition On.

2. Monitor the Glow Time Relay in the data display
and then, does the supply voltage correctly supply
to the glow plug?
11
12
Check the glow plugs for continuity.


13
14

fuel hose/pipe.
6E368
Step
Action
15

Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 16
Replace the
injection nozzle
and verify repair
Go to Step 17
More than 2.1

Mpa
Verify repair
Go to Step 18

fuel.
16
Remove the injection nozzles from the engine and

Improper splay condition.
Operating pressure is incorrect.
17
1 st Stage
2nd Stage
4JA1-TC
Approximatly
19.0 Mpa
Approximatly
33.5 Mpa
4JH1-TC
Approximatly
19.5 Mpa
Approximatly
33.8 Mpa

cylinders.

Step
Action
18
Check the inlet/exhaust valve clearance for each

valves.
Are the valve clearances within the specified value?
19
6E369
Value(s)
Yes
No
0.4mm at cold
(In/Ex)
Go to Step 19
Adjust and
verify repair

and/or system
Verify repair
Go to Step 20

release?
Verify repair
Go to Step 21

Go to Step 22
Go to Step 23
Replace the ECM.

Verify repair

Verify repair

following:
Tech 2 data
20
21
22
23
6E370
ROUGH, UNSTABLE, OR INCORRECT IDLE, STALLING SYMPTOM

DEFINITIONS: Engine runs unevenly at idle. If severe,
the engine or vehicle may shake. Engine idle speed
may vary in RPM. Either condition may be severe
enough to stall the engine.
rpm
X
Rough Idle
Stall
time
Step
Action

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Go to Step 5
Desired
Engine Idle
Speed 25
rpm
Go to Step 7
Go to Step 6

Verify repair
Go to Step 7
Verify repair
Go to Step 8

3
4
5

1. Check for incorrect idle speed. Ensure that the
following conditions are present.
Engine fully warm.
Accessories are OFF.
2. Using a Tech 2, monitor Desired Engine Idle
Speed and Engine Speed.
Is the Engine Speed within the specified values?
Value(s)

intake system

Step
Action
Value(s)
Yes
No
Verify repair
Go to Step 9
Verify repair
Go to Step 10
Verify repair
Go to Step 11
Go to Step 16
Go to Step 12
Verify repair
Go to Step 13

Verify repair
Go to Step 14

and recheck.
Go to Step 15
Go to Step 35

Verify repair
Go to Step 21
Go to Step 17

9
1. Using the Tech 2, ignition On and engine Run.

2. Monitor the A/C Information Switch in the data
display.
Does the Tech 2 indicate correct A/C Information
Switch status depending on A/C switch position?
10

sensor value.
11

2. Monitor the Mass Air Flow in the data display.
Does the Tech 2 indicate correct Mass Air Flow
depending on accelerator pedal operation?
12

Objects blocking at the MAF sensor element.
13
6E371
Check the MAF sensor harness for the following

conditions.
14
15
16

2. Monitor the Pedal/Throttle Position and Idle
Switch in the data display.
Does the Tech 2 indicate correct Pedal/Throttle
Position from 0% to 100% and correct Idle Switch
status depending on accelerator pedal operation?
6E372
Step
Action
Value(s)
Yes
No
17
Verify repair
Go to Step 18

Verify repair
Go to Step 19

Go to Step 20
Go to Step 36
Replace the TPS.

Verify repair
Verify repair
Go to Step 22

Verify repair
Go to Step 23
Substitute aknown good CKP sensorand recheck.

Go to Step 24
Go to Step 25

Verify repair

3. Adjust the accelerator cable or TPS within 0% to
100%.
18
Check the TPS harness for the following conditions.

19
20
21

22

conditions.
23
24

Step
Action
25
1. Using the Tech 2 and ignition On and engine

Run.
6E373
Value(s)
Yes
No
Go to Step 29
Go to Step 26
2. Monitor the following parameters in the data

display.
Desired Injection Quantity & Injection Quantity
Desired Injection Start & Actual Injection Start
Are the large gap or unstable parameter displayed
between Desired and Actual?
When idling or part-throttle

Desired
High
Actual
Low
Time
6E374
Step
Action
Value(s)
Yes
No
26

deposit.
Verify repair
Go to Step 27
Verify repair
Go to Step 28

fuel.
Verify repair
Go to Step 29

Verify repair
Go to Step 30
Tech 2:
Vacuum Pump:
valve.
Vacuum Pump
Small Window

27

28
29

fuel hose/pipe.

Step
Action
30

6E375
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 32
Replace the
injection nozzle
and verify repair
Go to Step 32
More than 2.1

Mpa
Verify repair
Go to Step 33

fuel.
31

32
1 st Stage
2nd Stage
4JA1-TC
Approximatly
19.0 Mpa
Approximatly
33.5 Mpa
4JH1-TC
Approximatly
19.5 Mpa
Approximatly
33.8 Mpa

cylinders. Each cylinder must be evenly.
6E376
Step
Action
33

valves.
34
Value(s)
Yes
No
0.4mm at cold
(In/Ex)
Go to Step 34
Adjust and
verify repair
Tech 2 data
and/or system
Verify repair
Go to Step 35

release?
Verify repair
Go to Step 36

Go to Step 37
Go to Step 38
Replace the ECM.

Verify repair

Verify repair

following:
35
36
37
38
6E377
SURGES AND/OR CHUGS SYMPTOM

DEFINITIONS: Engine power variation under steady
throttle or cruise. Feels like the vehicle speeds up and
slows down with no charge in the accelerator pedal.
rpm
Surge
time
Step
Action

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Go to Step 5

Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8

3
4
5
Value(s)

intake system

display.
6E378
Step
8
Action
Value(s)
Yes
No
Verify repair
Go to Step 9
Go to Step 14
Go to Step 10
Verify repair
Go to Step 11

Verify repair
Go to Step 12

and recheck.
Go to Step 13
Go to Step 29

Verify repair
Go to Step 19
Go to Step 15
Verify repair
Go to Step 16

Verify repair
Go to Step 17

Go to Step 18
Go to Step 29
Replace the TPS.

Verify repair

sensor value.

10

11

conditions.
12
13
14

15

100%.
16

17
18

Step
Action
19

Value(s)
Yes
No
Verify repair
Go to Step 20

Verify repair
Go to Step 21

Go to Step 22
Go to Step 23

Verify repair
Go to Step 25
Go to Step 24

20
6E379

conditions.
21
22
23

Run.
display.
When accelerated
Desired
Desired
High
High
Actual
Actual
Low
Low
Time
Time
6E380
Step
Action
Value(s)
Yes
No
24

deposit.
Verify repair
Go to Step 25

fuel.
Verify repair
Go to Step 26

Verify repair
Go to Step 27
Tech 2:
Vacuum Pump:
valve.
Vacuum Pump
Small Window

25

fuel hose/pipe.
26

Step
Action
27

6E381
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 28

and/or system
Verify repair
Go to Step 29

release?
Verify repair
Go to Step 30

Go to Step 31
Go to Step 32
Replace the ECM.

Verify repair

fuel.
28

following:
Tech 2 data
29
30
31
6E382
Step
32

Action
Value(s)
Yes
No
Verify repair
6E383
HESITATION, SAG, STUMBLE SYMPTOM

DEFINITIONS: Momentary lack of response as the
accelerator is pushed down. Can occur at any vehicle
speed. Usually most pronounced when first trying to
make the vehicle move, as from a stop sign. May cause
the engine to stall if severe enough.
Stumble
rpm
Sug
Hesitation
time
Step
Action

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Go to Step 5
Verify repair
Go to Step 6

Verify repair
Go to Step 7
Verify repair
Go to Step 8

3
4
5
Value(s)

Check the torque converter clutch (TCC) for proper
operation (if A/T model). If a problem is found, repair
as necessary.
intake system
6E384
Step
8
Action
Value(s)
Yes
No
Verify repair
Go to Step 9
Go to Step 14
Go to Step 10
Verify repair
Go to Step 11

Verify repair
Go to Step 12

and recheck.
Go to Step 13
Go to Step 31

Verify repair
Go to Step 19
Go to Step 15
Verify repair
Go to Step 16

Verify repair
Go to Step 17

Go to Step 18
Go to Step 31
Replace the TPS.

Verify repair

sensor value.

10

11

conditions.
12
13
14

15

100%.
16

17
18

Step
Action
19

Value(s)
Yes
No
Verify repair
Go to Step 20

Verify repair
Go to Step 21

Go to Step 22
Go to Step 23

Verify repair
Go to Step 27
Go to Step 24

20
6E385

conditions.
21
22
23

Run.
display.
When accelerated
Desired
Desired
High
High
Actual
Actual
Low
Low
Time
Time
6E386
Step
Action
Value(s)
Yes
No
24

deposit.
Verify repair
Go to Step 25
Verify repair
Go to Step 26

fuel.
Verify repair
Go to Step 27

Verify repair
Go to Step 28
Tech 2:
Vacuum Pump:
valve.
Vacuum Pump
Small Window

25

26
27

fuel hose/pipe.

Step
Action
28

6E387
Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 29

and/or system
Verify repair
Go to Step 30

release?
Verify repair
Go to Step 31

Go to Step 32
Go to Step 33
Replace the ECM.

Verify repair

fuel.
29

following:
Tech 2 data
30
31
32
6E388
Step
33

Action
Value(s)
Yes
No
Verify repair
6E389
CUTS OUT, MISSES SYMPTOM

DEFINITIONS: Steady pulsation or jerking that follows
engine speed; usually more pronounced as engine load
increases.
rpm
time
Step
Action

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Go to Step 5

compressor
wheel or turbine shaft sticking.
Verify repair
Go to Step 6
Verify repair
Go to Step 7

3
4
5
Value(s)

intake system
6E390
Step
7
Action
Value(s)
Yes
No
Go to Step 11
Go to Step 8

Verify repair
Go to Step 9
Substitute a known good VSS and recheck.

Go to Step 10
Go to Step 31
Replace the VSS assembly.

Verify repair

Go to Step 16
Go to Step 12
Verify repair
Go to Step 13

Verify repair
Go to Step 14

and recheck.
Go to Step 15
Go to Step 31

Verify repair
1. Using the Tech 2, perform test drive.

2. Monitor the Vehicle Speed in the data display.
Does the Tech 2 indicate correct Vehicle Speed
depending on driving speed?
When constant vehicle speed

Correct Speed
High
Unstable Data
Low
Time
Check the VSS harness for the following conditions.

9
10
11
12

13

conditions.
14
15

Step
Action
16
Value(s)
Yes
No
Go to Step 21
Go to Step 17
Verify repair
Go to Step 18

Verify repair
Go to Step 19

Go to Step 20
Go to Step 31
Replace the TPS.

Verify repair
Verify repair
Go to Step 22

Verify repair
Go to Step 23

Go to Step 24
Go to Step 25

Verify repair

17
6E391

100%.
18

19
20
21

22

conditions.
23
24
6E392
Step
Action
25

Run.
Value(s)
Yes
No
Go to Step 29
Go to Step 26

display.

Desired
High
Actual
Low
Time

Step
Action
26

deposit.
6E393
Value(s)
Yes
No
Verify repair
Go to Step 27

fuel.
Verify repair
Go to Step 28

Verify repair
Go to Step 29
Tech 2:
Vacuum Pump:
valve.
Vacuum Pump
Small Window

27

fuel hose/pipe.
28
6E394
Step
Action
Value(s)
Yes
No
29

Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 30
Tech 2 data
and/or system
Verify repair
Go to Step 31

release?
Verify repair
Go to Step 32

Go to Step 33
Go to Step 34
Replace the ECM.

Verify repair

fuel.
30

following:
31
32
33

Step
34
Action
6E395
Value(s)
Yes
No
Verify repair
6E396
LACK OF POWER, SLUGGISH OR SPONGY SYMPTOM

DEFINITIONS: Engine delivers less than expected power. Attempting part-throttle acceleration results in little or no
increase in vehicle speed.
Step
Action

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Go to Step 5

Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 29
Go to Step 9
Go to Step 14
Go to Step 10

3
4
5
Value(s)

intake system

sensor value.



Step
Action
10

Value(s)
Yes
No
Verify repair
Go to Step 11

Verify repair
Go to Step 12

and recheck.
Go to Step 13
Go to Step 29

Verify repair
Go to Step 19
Go to Step 15
Verify repair
Go to Step 16

Verify repair
Go to Step 17

Go to Step 18
Go to Step 30
Replace the TPS.

Verify repair

11
6E397

conditions.
12
13
14

15

100%.
16

17
18
6E398
Step
Action
19

Run.
Value(s)
Yes
No
Go to Step 22
Go to Step 20
Verify repair
Go to Step 21

display.
When accelerated
Desired
Desired
High
High
Actual
Actual
Low
Low
Time
20
Time

deposit.
Tech 2:
Vacuum Pump:
valve.
Vacuum Pump
Small Window


Step
21
Action
Value(s)
Yes
No
Verify repair
Go to Step 22

fuel.
Verify repair
Go to Step 23

Verify repair
Go to Step 24
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 25

22
6E399

fuel hose/pipe.
23
24

fuel.
6E400
Step
Action
25

Value(s)
Yes
No
Replace the
injection nozzle
and verify repair
Go to Step 26
More than 2.0

Mpa
Verify repair
Go to Step 27
0.4mm at cold
(In/Ex)
Go to Step 28
Adjust and
verify repair
Verify repair
Go to Step 29

26
27
28
1 st Stage
2nd Stage
4JA1-TC
Approximatly
19.0 Mpa
Approximatly
33.5 Mpa
4JH1-TC
Approximatly
19.5 Mpa
Approximatly
33.8 Mpa

cylinders.

valves.

following:
Tech 2 data
and/or system
6E401
Step
Action
Value(s)
Yes
No
29

release?
Verify repair
Go to Step 30

Go to Step 31
Go to Step 32
Replace the ECM.

Verify repair

Verify repair
30
31
32
6E402
POOR FUEL ECONOMY SYMPTOM

DEFINITIONS: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, economy
is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test. (Larger than
standard tires will cause odometer readings to be incorrect, and that may cause fuel economy to appear poor when it
is actually normal.)
Step
Action

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Is acceleration too much, too often?
Go to Step 5
Go to Step 6
Review the items in Step 4 with the customer and

advise as necessary.
System OK
Check for low engine coolant level.

Verify repair
Go to Step 7
Check for incorrect or faulty engine thermostat. Refer

to Engine Cooling.
Verify repair
Go to Step 8
Check for proper calibration of the speedometer.

Does the speed indicated on the speed meter closely
match the vehicle speed displayed on the Tech 2?
Go to Step 10
Go to Step 9
Diagnose and repair the inaccurate speedometer

condition as necessary. Refer to Vehicle Speed
Sensor in Electrical Diagnosis.
Verify repair
10
Check for proper calibration of the fuel gauge.

Verify repair
Go to Step 11
11

as necessary.
Verify repair
Go to Step 12
Verify repair
Go to Step 13

3
4
Value(s)

Check owner's driving habits.
Is the A/C On full time?
Are tires at the correct pressure?
Are excessively heavy loads being carried?
12


Step
Action
13

display.
14
6E403
Value(s)
Yes
No
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Go to Step 31
Go to Step 17
Go to Step 22
Go to Step 18
Verify repair
Go to Step 19
Verify repair
Go to Step 20

intake system
15

sensor value.
16

17

18

19

conditions.
6E404
Step
Action
Value(s)
Yes
No
20

and recheck.
Go to Step 21
Go to Step 31

Verify repair
Go to Step 27
Go to Step 23
Verify repair
Go to Step 24

Verify repair
Go to Step 25

Go to Step 26
Go to Step 31
Replace the TPS.

Verify repair
Replace the
injection nozzle
and verify repair
Go to Step 28
21
22

23

100%.
24

25
26
27

1 st Stage
2nd Stage
4JA1-TC
Approximatly
19.0 Mpa
Approximatly
33.5 Mpa
4JH1-TC
Approximatly
19.5 Mpa
Approximatly
33.8 Mpa

Step
Action
28

cylinders.
29
30
6E405
Value(s)
Yes
No
More than 2.0

Mpa
Verify repair
Go to Step 29
0.4mm at cold
(In/Ex)
Go to Step 30
Adjust and
verify repair

and/or system
Verify repair
Go to Step 31

release?
Verify repair
Go to Step 32

Go to Step 33
Go to Step 34

valves.

following:
Tech 2 data
31
32
6E406
Step
Action
Value(s)
Yes
No
33
Replace the ECM.

Verify repair

Verify repair
34
6E407
EXCESSIVE WHITE SMOKE

Step
Action

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Go to Step 5
Check the engine coolant consumption to verify that it

leaks to combustion chamber or exhaust through the
gasket.
Verify repair
Go to Step 6
Verify repair
Go to Step 7

Verify repair
Go to Step 8

Go to Step 30
Go to Step 9

Go to Step 14
Go to Step 10

Verify repair
Go to Step 11
Verify repair
Go to Step 12

3
4
5
10
11
Value(s)


sensor value.

conditions.
6E408
Step
Action
Value(s)
Yes
No
12

and recheck.
Go to Step 13
Go to Step 30

Verify repair
Go to Step 30
Go to Step 15
Go to Step 16
Repair voltage
supply circuit
and verify repair
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 19
13
14

2. Monitor the Glow Time Relay in the data display.
Does the Tech 2 indicate correct Glow Time Relay
status depending on the time from engine Run?
15
16
17

2. Monitor the Glow Time Relay in the data display
and then, does the supply voltage correctly supply
to the glow plug?
Check the glow plugs for continuity.


18

conditions.

Step
19
20
21
Action
6E409
Value(s)
Yes
No

Go to Step 20
Go to Step 21

Verify repair
Go to Step 23
Go to Step 22
Verify repair
Go to Step 23

fuel.
Verify repair
Go to Step 24

Verify repair
Go to Step 25

Run.
display.
When accelerated
Desired
Desired
High
High
Actual
Actu al
Low
Low
Time
22
Time

23
24

fuel hose/pipe.
6E410
Step
Action
25

Value(s)
Yes
No
Replace the
eye bolt with
gauze filter and
verify repair
Go to Step 26
Replace the
injection nozzle
and verify repair
Go to Step 27

fuel.
26

1 st Stage
2nd Stage
4JA1-TC
Approximatly
19.0 Mpa
Approximatly
33.5 Mpa
4JH1-TC
Approximatly
19.5 Mpa
Approximatly
33.8 Mpa

Step
Action
27

cylinders.
28
29
6E411
Value(s)
Yes
No
More than 20
Mpa
Verify repair
Go to Step 28
0.4mm at cold
(In/Ex)
Go to Step 29
Adjust and
verify repair

and/or system
Verify repair
Go to Step 30

release?
Verify repair
Go to Step 31

Go to Step 32
Go to Step 33

valves.

following:
Tech 2 data
30
31
6E412
Step
Action
Value(s)
Yes
No
32
Replace the ECM.

Verify repair

Verify repair
33
6E413
EXCESSIVE BLACK SMOKE

Step
Action

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check
Diesel fuel
only
Replace with
diesel fuel
Go to Step 5

Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 21
Go to Step 9
Go to Step 14
Go to Step 10

3
4
5
Value(s)

intake system

sensor value.


6E414
Step
Action
Value(s)
Yes
No
10

Verify repair
Go to Step 11

Verify repair
Go to Step 12

and recheck.
Go to Step 13
Go to Step 21

Verify repair
Go to Step 20
Go to Step 15

11

conditions.
12
13
14

Run.
display.
When accelerated
Desired
Desired
High
High
Actual
Actual
Low
Low
Time
Time

Step
Action
15

deposit.
6E415
Value(s)
Yes
No
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Tech 2:
Vacuum Pump:
valve.
Vacuum Pump
Small Window

16

6E416
Step
Action
17

Value(s)
Yes
No
Replace the
injection nozzle
and verify repair
Go to Step 18
More than 20
Mpa
Verify repair
Go to Step 19
0.4mm at cold
(In/Ex)
Go to Step 20
Adjust and
verify repair
Verify repair
Go to Step 21

18
19
20
1 st Stage
2nd Stage
4JA1-TC
Approximatly
19.0 Mpa
Approximatly
33.5 Mpa
4JH1-TC
Approximatly
19.5 Mpa
Approximatly
33.8 Mpa

cylinders.

valves.

following:
Tech 2 data
and/or system
6E417
Step
Action
Value(s)
Yes
No
21

release?
Verify repair
Go to Step 22

Go to Step 24
Go to Step 23
Replace the ECM.

Verify repair

Verify repair
22
23
24
6E418
ON-VEHICLE SERVICE PROCEDURE

ENGINE CONTROL MODULE
(ECM)
Location
Under the left-hand side seat.
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the seat left-hand side.
3. Roll up the floor carpet.
4. Remove four bolts from the ECM cover.
5. Disconnect the two connectors from the ECM.
Installation Procedure
1. Connect the two connectors to the ECM.
2. Put on the ECM to the floor panel.
3. Tighten the ECM cover by four bolts with specified
tightening torque.
Tightening torque
Bolts: 8.0 - 12.0 Nm (0.8 - 1.2 kgfm)
4. Lay the floor carpet exactly.
5. Put on the seat to the floor panel and tighten with
specified tightening torque.
Tightening torque
Bolts: 40.0 Nm (4.1 kgfm)
6. Connect the negative battery cable.
NOTE: The replacement ECM must be programmed.
Refer to section of the Service Programming System
(SPS) in this manual.
Following ECM programming, the immobilizer system (if
equipped) must be linked to the ECM. Refer to section
11 Immobilizer System-ECM replacement for the
CRANKSHAFT POSITION (CKP)

SENSOR
6E419

(ECT) SENSOR
Location
Installed to the clutch housing.
Location
Installed to the thermostat housing.
Removal Procedure
Removal Procedure
2. Disconnect connector from the CKP sensor.
2. Drain enough engine coolant so that the coolant

level will be below the ECT sensor.
3. Loosen a bolt and remove the CKP sensor from the

clutch housing.
3. Disconnect connector from the ECT sensor.

4. Loosen and remove the ECT sensor from the
thermostat housing.
NOTE: Cool down the engine before above procedures
are carried out.
1. Install the CKP sensor to the clutch housing.
2. Tighten CKP sensor by a bolt with specified
tightening torque.
Tightening Torque
Bolts: 8.0 - 12.0 Nm (0.8 - 1.2 kgfm)
3. Connect a CKP sensor connector to the CKP
sensor.
NOTE: Verify any DTCs (diagnosis Trouble Code) are
not stored after replacement.
1. Apply sealer to threads of screw at the ECT sensor.
2. Tighten the ECT sensor with specified tightening
torque.
Tightening Torque
Bolt: 13Nm (1.3kgfm)
3. Connect a ECT sensor connector to the ECT
sensor.
4. Fill the engine coolant.
Verify no engine coolant leaking from the sensor
threads after replacement.
6E420
MASS AIR FLOW (MAF) & INTAKE

AIR TEMPERATURE (IAT) SENSOR
THROTTLE POSITION SENSOR

(TPS)
Location
Installed to the intake duct housing.
Location
Installed on the throttle body.
Removal Procedure
Removal Procedure
2. Disconnect a MAF & IAT sensor connector from the

MAF & IAT sensor assembly.
3. Loosen the clips and remove the MAF & IAT sensor
assembly from the intake duct housing.
3. Loosen two screws and remove TPS from the

throttle body.
1. Install the MAF & IAT sensor assembly into intake
air duct.
2. Tighten the clips.
3. Connect a MAF & IAT sensor connector to the MAF
& IAT sensor assembly.
1. Temporary tighten the TPS by two screws.

2. Connect a TPS connectors to the TPS.
3. Connect the Tech2 to the vehicle.
5. Select Data Display with the Tech2.
6. Check the throttle position data and adjust the TPS
position.
7. Tighten two screws.
EGR EVRV (Electrical Vacuum

Regulating Valve)
Location
Back of the air cleaner case.
Removal Procedure
1. Disconenct the negative battery cable.
2. Disconnect a EVRV connector from the EVRV.
3. Disconnect two hoses from the EVRV.
4. Loosen two bolts and remove the EVRV from the
bracket.
1. Tighten the purge solenoid by tow bolts.
2. Connect a connector to the EVRV.
3. Connect two hoses to the EVRV.
Verify proper connection of two hoses.
6E421
6E422
SPECIAL SERVICE TOOLS

ILLUSTRATION
TOOL NO.
TOLL NAME
5-8840-0285-0
(J 39200)
High Impedance
Multimeter
(Digital Voltmeter -DVM)
(1) PCMCIA Card
(2) RS232 Loop Back
Connector
(4) DLC Cable
(5) TECH 2
5-8840-0385-0
(J 35616-A/BT-8637)
Connector Test Adapter Kit
Breaker Box
5-8840-0279-0
(J 23738-A)
Vacuum Pump with Gauge
EXHAUST SYSTEM 6F 1
SECTION 6F
EXHAUST SYSTEM
TABLE OF CONTENTS
PAGE
Main Data and Specifications ........................................................................................... 6F - 2
General Description........................................................................................................... 6F - 3
Removal and Installation................................................................................................... 6F - 4
Inspection and Repair ....................................................................................................... 6F - 6
General Description........................................................................................................... 6F -7
EGR System Diagram ........................................................................................................ 6F 9
Inspection........................................................................................................................... 6F-11
EGR Cooler (4JA1TC/4JH1TC Euro-III model)................................................................. 6F-12
Turbocharger ..................................................................................................................... 6F -15
Main Data and Specifications....................................................................................... 6F -15
General Description........................................................................................................... 6F -16
Inspection and Repair ....................................................................................................... 6F -17
Special Tools...................................................................................................................... 6F -19
IHI Service Network ........................................................................................................... 6F -20
6F 2 EXHAUST SYSTEM

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EXHAUST SYSTEM 6F 3
GENERAL DESCRIPTION
RTW46FLF000201
The exhaust pipe layout is described in the above illustration.

The catalytic coverter is installed between the turbocharger and the front pipe.
6F 4 EXHAUST SYSTEM
RTW46FLF000101
Removal Steps
1. Rear hanger rubber
2. Silencer front nut
3. Exhaust silencer
4. Silencer hanger rubber
5. Middle pipe nut
6. Front hanger rubber

7. Front pipe nut
8. Exhaust pipe gasket
EXHAUST SYSTEM 6F 5
1. Front Pipe Nut
Connect the exhaust pipe to the catalytic converter.
Torque
Nm (kgm/lbft)
67 (6.8/49)
2. Middle pipe Nut (4
4 only)
Connect the middle pipe to the front pipe.
Torque
Nm (kgm/lbft)
43 (4.4/32)
3. Silencer Front Nut
Connect the silencer to the front or middle pipe.
Torque
Nm (kgm/lbft)
43 (4.4/32)
6F 6 EXHAUST SYSTEM

inspection.
Front Exhaust Pipe

Exhaust Silencer
Check the pipes for corrosion, cracking, damage or
misalignment and repair as required.
Check the rubber rings for deterioration or damage and repair
as required.
Catalytic Converter
1. Inspect outside the catalytic converter for any hitting mark.
2. Visual check inside the catalytic converter for crack or break
converter element.
3. If find any problem during the inspection, replace the
catalytic converter assembly.
EXHAUST SYSTEM 6F 7
GENERAL DESCRIPTION
This system controls the formation of NOx emission by recirculating the exhaust gas into the combustion chamber
through the intake manifold.
4JA1T(L):
The two EGR valves are controlled by two Vacuum Switching Valve (VSV) controlled by EGR controller according to
signals from various sensors.
The amount of EGR depends on the number of engine rotations and the opening of the accelerator.
RTW46ELF001201
6F 8 EXHAUST SYSTEM
4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to Engine driveability and emissions section for detail.
RTW46ELF001101
EXHAUST SYSTEM 6F 9
EGR SYSTEM DIAGRAM 4JA1T (L)
RTW46AMF000301
EGR System Operation

Inspect EGR valve motion visually while changing engine RPM under no load condition after warming-up.
Inspection point (Engine RPM)
RPM
Idling
900 ~ 960
2000
3250
Engine Front Side VSV-1
ON
ON
ON
OFF
Engine Rear Side VSV-2
ON
OFF
ON
OFF
ON means VSV should receive signal to move EGR valve.

OFF means VSV shouldnt receive signal to move EGR valve.
6F 10 EXHAUST SYSTEM
4JA1TC/4JH1TC
The EGR system engine is controlled by ECM. Refer to Engine driveability and
emissions section for detail.
RTW46EMF000701
EXHAUST SYSTEM 6F 11
INSPECTION
4JA1T(L)
Vacuum switch valve (VSV)
Use a circuit tester to measure the V.S.V. resistance.
V.S.V Resistance
W at 20C
37 ~ 44
If the resistance is not within specification, replace it.
EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.
Negative Pressure
Less then 180 mmHg
Not operation
More than 240 mmHg
Operation
4JA1TC/4JH1TC
EVRV
Use a circuit tester to measure the EVRV resistance.
EVRV Resistance
W at 20C
14
If the resistance is not within specification, replace it.
RTW46ESH000301
EGR Valve
Apply vacuum to the EGR valve, check to see the valve
operation.
Negative Pressure 4JH1TC
Less than 250 mmHg
Not operation
More than 300 mmHg
Operation
Negative Pressure 4JA1TC

Less than 100 mmHg
Not operation
More than 170 mmHg
Operation
EGR COOLER (4JA1TC/4JH1TC EURO-III MODEL)

RTW46EMF000201
Removal Steps
1. Bolt
2. Gasket
3. Bolt
4. Gasket
5. Bolt
6. Bolt
7. EGR Pipe Assembly

8. Gasket
9. Bolt
10. EGR Cooler Assembly
11. Gasket
12. EGR Cooler Adapter
Removal
1. Bolt
2. Gasket
3. Bolt
4. Gasket
5. Bolt
6. Bolt
8. Gasket
9. Bolt
11.Gasket
12.EGR Cooler Adapter
RTW46EMF000901
Installation steps
1. EGR Cooler Adapter
2. Gasket
4. Gasket
5. Bolt
7. Bolt
8. Bolt
9. Gasket
10. EGR Valve Assembly
11. Bolt
12. EXH Manifold
13. Gasket
14. Bolt
Installation
1.
2.
3.
4.
EGR Cooler Adapter

Gasket
EGR Cooler Assembly
Bolt
EGR adapter bolt torque
Nm(kgm/lb ft)
27(2.8/20)
5. Gasket
7. Bolt
Tighten bolts temporarily.
8. Bolt
9. Gasket
10. Bolt
11.Gasket
12.Bolt
Finally tighten all bolts to the specified torque.
Confirm that there is no misalignment on the sealing
surface.
Bolt torque (Cooler-pipe) Nm(kgm/lb ft)
27(2.8/20)
Bolt torque (Cooler-bracket) Nm (kgm/lb ft)
24(2.4/17)
Bolt torque (Adapter-EGR valve) Nm (kgm/lb ft)
27(2.8/20)
Bolt torque (Pipe-manifold) Nm (kgm/lb ft)
27(2.8/20)
TURBOCHARGER
Engine
4JA1T(L)
4JA1TC
4JH1TC
Model
IHI RHF4H
IHI RHF4H
IHI RHF5
Turbine type
Mixed type
Compressor type
Maximum permissible speed rpm
IHI : Ishikawajima Harima Heavy Industries., Ltd.
Backword & rake type

190,000
190,000
180,000
GENERAL DESCRIPTION
036LV002
The turbocharger internal mechanism consists of the turbine wheel, the compressor wheel, and the radial bearings.
These parts are supported by the bearing housing.
The turbocharger external mechanism consists of the compressor housing air intake port and the turbine housing
air exhaust port.
The turbocharger increases air intake efficiency. This results in increased engine power, reduced fuel consumption,
and minimal engine noise.
The turbocharger operates at very high speeds and temperatures. Part materials have been carefully selected and
machined to extremely high precision.
Turbocharger servicing requires great care and expertise.
If reduced performance is noted, check the engine for damage or wear. If there is no apparent engine damage or
wear, trouble with the turbocharger is indicated.

inspection.
Turbocharger pressure check

1. Remove the hose between the master gate and the
compressor outlet pipe.
2. Connect the pressure gauge. To compressor outlet
pipe.
3. Start the engine and gradually increase the engine
speed (the vehicle must be stationary with no load
applied to the engine).
4. Check to see that turbocharger pressure rises to
approximately 300 mmHg.
Pressure Gauge : 5-8840-0075-0
150RY00030
Waste gate operation check

1. Remove the hose between the waste gate and the
compressor outlet pipe.
2. Connect the pressure gauge. To waste gate actuator.
3. Check to see that the rod begins to move when a
pressure of approximately 665 mmHg is applied to the
waste gate.
Note:
2
Do not apply a pressure greater than 1 kg/cm to the
wastegate during this check.
150RY00031
Unit Inspection (Remove Turbo. from engine)

Check to see the pressure required to move the control
rod 2 mm is within the limits shown below.
Kpa/mmHg
4JH1TC
134.8/1011
4JA1TC
147.7/1108
150RY00032
Contact the ISUZU MOTORS LIMITED Dealer service

department or IHI SERVICE FACILITY for major repairs
and maintenance.
Important wheel shaft end play and bearing clearance
standards and limits are included below for your reference.
Wheel Shaft End Play
Use a dial indicator to measure the wheel shaft end play.
Apply a force of 1.2 kg (2.6 lb/11.8N) alternately to the
compressor wheel end and the turbine wheel end.
Wheel Shaft End Play
mm (in)
Standard
Limit
0.03 - 0.06
(0.001 - 0.002)
0.09 (0.004)
150RY00034
Wheel Shaft and Bearing Clearance

Use a dial indicator to measure the wheel shaft and
bearing clearance.
Wheel Shaft and Bearing Clearance
mm (in)
150RY00036
Standard
Limit
0.056 - 0.127
(0.0022 - 0.0050)
0.127 (0.0050)
SPECIAL TOOLS
ILLUSTRATION
TOOL NUMBER
5-8840-0075-0
901RX00143
TOOL NAME
Pressure Gauge
IHI SERVICE NETWORK

For inquiries relating to turbochargers, please contact your ISUZU distributor or the nearest IHI Turbocharger
Service Facility.
HEADQUARTERS
ISHIKAWAJIMA HARIMA HEAVY INDUSTRIES CO., LTD.(IHI)
General Machinery Division
Tokyo Chuo Building 1-6-2 Marunouchi Chiyoda-ku
Tokyo 100-0005 JAPAN
TEL:
81-(3)-3286-2405 to 2407 (3 lines)
FAX: 81-(3)-3286-2430
CHINA
IHI BEIJING OFFICE
Room 705, China World Trade Center, No. 1 Jian Guo Men Wai Avenue
Beijing, Peoples Republic of CHINA
TEL:
86-(1)-505-4997, 0408
FAX: 86-(1)-505-4350
TLX:
210343 IHIPK CN
TAIWAN
IHI TAIPEI OFFICE
Room 1202, Chia Hsin Building, No. 96 Chung Shan
North Road, Section 2, Taipei, TAIWAN
TEL:
886-(2)-542-5520, 5521, 5523
FAX: 886-(2)-542-4362
TLX:
11320 IHICO
THAILAND
IHI BANGKOK OFFICE
8th Floor, Thaniya Building, 62 Silom Road, Bangkok, THAILAND
TEL:
66-(2)-236-3490, 7356, 9099
FAX: 66-(2)-236-7340
TLX:
82375 IHICO TH
MALAYSIA
IHI KUALA LUMPUR OFFICE
Letter Box No. 52, 22nd Floor, UBN Tower,
10 Jin. P. Ramlee 50250 Kuala Lumpur, MALAYSIA
TEL:
60-(3)-232-1255, 1271
FAX: 60-(3)-232-1418
TLX:
IHI KLMA 20257
INDONESIA
IHI JAKARTA OFFICE
9th Floor, Skyline Building JI. M. H. Thamrin, No. 9, Jakarta, INDONESIA
TEL:
62-(21)-32-2147, 390-2211
FAX: 62-(21)-32-3273
TLX:
44175 IHIJKT
ACCELERATOR CONTROL
6H 1
SECTION 6H
ACCELERATOR CONTROL
TABLE OF CONTENTS
PAGE
Removal and Installation............................................................................................... 6H -
Removal...................................................................................................................... 6H -
Inspection................................................................................................................... 6H -
Installation.................................................................................................................. 6H -
6H 2 ACCELERATOR CONTROL

4JA1T(L)/RHD
RTW46HLF000301
ACCELERATOR CONTROL
6H 3
4JA1T(L)/LHD
RTW46HLF000601
4JA1TC, 4JH1TC/RHD
RTW46HLF000201
ACCELERATOR CONTROL
6H 5
4JA1TC, 4JH1TC/LHD
PTW46BMF000101
Removal
1. Disconnect the accelerator control cable from the
accelerator pedal and dash panel.
2. Remove the cable clips.
3. Remove the accelerator control cable from accelerator
control cable bracket.
1) Slide the lock in direction A
2) Rotate the ratchet ring in undirection an arrow 90.
4. Remove the accelerator control cable from the throttle.
Inspection
Check the following items and replace the control cable if

any abnormality is found.
The control cable should move smoothly.
The control cable should not be bent or kinked.
The control cable should not be damage or
corrosion.
RTW46HMH000201
Installation
1. Install the accelerator control cable to accelerator
control pedal dash panel.
2. Install the accelerator control cable to throttle.
Attach T-END and inner cable to throttle cam of
engine.
3. Install accelerator control cable to accelerator bracket.
1) Rotate the ratchet ring in direction an arrow 90
until both white marking are aligned.
2) Confirm marking of outer cap must be upper side.
3) Slider the lock in direction B.
4) Confirm ratchet ring is locked.
4. Install the cable clips to accelerator control cable.
NOTE:
Confirm that the throttle (engine side) is at full stroke
when the accelerator pedal is at full stroke.
No. TF4JE-WE-0431
WORKSHOP MANUAL
TF SERIES
ENGINE
6VE1
SECTION 6
ENGINE MECHANICAL (6VE1 3.5L) 6A-1
ENGINE
CONTENTS
Engine Mechanical................................................. 6A
Engine Cooling........................................................ 6B
Engine Fuel ............................................................. 6C
Engine Electrical..................................................... 6D1
Ignition System ....................................................... 6D2
Starting and Changing System............................. 6D3
Driveability and Emissions.....................................6E

Engine Exhaust .......................................................6F
Engine Lubrication ..................................................6G
Engine Speed Control System ..............................6H
Induction...................................................................6J
ENGINE MECHANICAL (6VE1 3.5L)

CONTENTS
Service Precaution .................................................
General Description ...............................................
Engine Diagnosis....................................................
Cylinder Head Cover LH........................................
Removal ...............................................................
Installation ............................................................
Cylinder Head Cover RH .......................................
Removal ...............................................................
Installation ............................................................
Common Chamber.................................................
Removal ...............................................................
Installation ............................................................
Exhaust Manifold LH..............................................
Removal ...............................................................
Installation ............................................................
Exhaust Manifold RH .............................................
Removal ...............................................................
Installation ............................................................
Crankshaft Pulley ...................................................
Removal ...............................................................
Installation ............................................................
Timing Belt ..............................................................
Removal ...............................................................
Installation ............................................................
Camshaft .................................................................
Removal ...............................................................
Installation ............................................................
Cylinder Head .........................................................
Removal ...............................................................
Installation ............................................................
Valve Stem Oil Controller , Valve Spring
and Valve Guide ....................................................
6A-2
6A-3
6A-4
6A-21
6A-21
6A-21
6A-23
6A-23
6A-23
6A-24
6A-24
6A-25
6A-26
6A-26
6A-26
6A-27
6A-27
6A-27
6A-28
6A-28
6A-28
6A-29
6A-29
6A-30
6A-34
6A-34
6A-34
6A-37
6A-37
6A-37
6A-39
Removal................................................................
Installation.............................................................
Piston, Piston Ring and Connecting Rod ............
Removal................................................................
Installation.............................................................
Crankshaft and Main Bearings..............................
Removal................................................................
Installation.............................................................
Rear Oil Seal ...........................................................
Removal................................................................
Installation.............................................................
Engine Assembly ....................................................
Removal................................................................
Installation.............................................................
Cylinder Head..........................................................
Cylinder Head and Associated Parts ................
Disassembly .........................................................
Clean .....................................................................
Inspection and Repair .........................................
Reassembly..........................................................
Valve Spring, Oil Controller, Valve, Valve
Guide .......................................................................
Valve Spring, Oil Controller, Valve, Valve
Guide and Associated Parts .............................
Disassembly .........................................................
Reassembly..........................................................
Camshaft..................................................................
Camshaft and Associated Parts ........................
Disassembly .........................................................
Reassembly..........................................................
6A-39
6A-39
6A-40
6A-40
6A-41
6A-43
6A-43
6A-44
6A-48
6A-48
6A-48
6A-49
6A-49
6A-49
6A-52
6A-52
6A-53
6A-53
6A-53
6A-54
6A-56
6A-56
6A-57
6A-57
6A-61
6A-64
6A-64
6A-64
6A-65
6A-67
6A-2 ENGINE MECHANICAL (6VE1 3.5L)

Crankshaft ...............................................................
Crankshaft and Associated Parts .....................
Disassembly ........................................................
Inspection and Repair ........................................
Reassembly .........................................................
Piston and Connecting Rod ..................................
Piston, Connecting Rod and Associate
Parts ....................................................................
Disassembly ........................................................
Reassembly .........................................................
Cylinder Block .........................................................
Cylinder Block and Associated Parts ...............
Disassembly ........................................................
Reassembly .........................................................
Main Data and Specification .................................
Special Tool .........................................................
6A-71
6A-71
6A-71
6A-73
6A-75
6A-79
6A-79
6A-79
6A-80
6A-84
6A-87
6A-87
6A-88
6A-88
6A-89
6A-93
6A-99
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.

parts and systems.
General Description
Engine Cleanliness And Care
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousandths of a
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and
cleanliness are important. Throughout this section, it
should be understood that proper cleaning and
protection of machined surfaces and friction areas is
part of the repair procedure. This is considered
standard shop practice even if not specifically stated.
A liberal coating of engine oil should be applied to
all friction areas during assembly to protect and
lubricate the surfaces on initial operation.
Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and
crankshaft journal bearings are removed for
service, they should be retained in order.
At the time of installation, they should be installed
in the same locations and with the same mating
surfaces as when removed.
Battery cables should be disconnected before any
major work is performed on the engine. Failure to
disconnect cables may result in damage to wire
harness or other electrical parts.
The six cylinders of this engine are identified by
numbers; Right side cylinders 1, 3 and 5, Left side
cylinders 2, 4 and 6, as counted from crankshaft
pulley side to flywheel side.
Cylinder Block
The cylinder block is made of aluminum die-cast casting
for 75V-type six cylinders. It has a rear plate integrated
structure and employs a deep skirt. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width is different
between No.2, No.3 and No.1, No.4; the width of No.3
bearing on the body side is different in order to support
the thrust bearing. The bearing cap is made of nodular
cast iron and each bearing cap uses four bolts and two
side bolts.
Cylinder Head
The cylinder head, made of aluminum alloy casting
employs a pent-roof type combustion chamber with a
spark plug in the center. The intake and exhaust valves
are placed in V-type design. The ports are cross-flow
type.
Valve Train
Intake and exhaust camshaft on the both side of banks
are driven through an camshaft drive gear by timing
belt. The valves are operated by the camshaft and the
valve clearance is adjusted to select suitable thickness
shim.
Intake Manifold
The intake manifold system is composed of the
aluminum cast common chamber and intake manifold
attached with six fuel injectors.
General Information on Engine Service
Exhaust Manifold
The following information on engine service should be

noted carefully, as it is important in preventing damage
and contributing to reliable engine performance.
When raising or supporting the engine for any
reason, do not use a jack under the oil pan. Due to
the small clearance between the oil pan and the oil
pump strainer, jacking against the oil pan may
cause damage to the oil pick-up unit.
The 12-volt electrical system is capable of
damaging circuits. When performing any work
where electrical terminals could possibly be
grounded, the ground cable of the battery should
be disconnected at the battery.
Any time the intake air duct or air cleaner is
removed, the intake opening should be covered.
This will protect against accidental entrance of
foreign material into the cylinder which could
cause extensive damage when the engine is
started.
The exhaust manifold is made of nodular cast iron.
Pistons and Connecting Rods

Aluminum pistons are used after selecting the grade
that meets the cylinder bore diameter. Each piston has
two compression rings and one oil ring. The piston pin
made of chromium steel is offset 1mm toward the thrust
side, and the thrust pressure of piston to the cylinder
wall varies gradually as the piston travels. The
connecting rods are made of forged steel. The
connecting rod bearings are graded for correct size
selection.
Crankshaft and Bearings

The crankshaft is made of Ductile cast-iron. Pins and
journals are graded for correct size selection for their
bearing.

The ECM location is on the common charmber.
Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Symptom
Possible Cause
Action
Headlights go out or dim considerably Battery run down or under charged
Recharge or replace battery
Terminals poorly connected
Clean battery posts and terminals

and connect properly
Starting motor coil circuit shorted
Overhaul or replace
Starting motor defective
Overhaul or replace
2. Ignition Trouble - Starting Motor Turns Over But

Engine Does Not Start Spark Test
Disconnect an ignition coil from any spark plug.
Connect the spark plug tester 5-8840-0383-0, start the
engine, and check if a spark is generated in the spark
plug tester. Before starting the engine, make sure that
the spark plug tester is properly grounded. To avoid
electrical shock, do not touch the part where insulation
of the ignition coil is broken while the engine is running.
Symptom
Spark jumps across gap
Possible Cause
Action
Spark plug defective
Clean or replace
Ignition timing incorrect
Refer to Ignition System
Fuel not reaching fuel injector(s) or Refer to item 3 (Trouble in fuel

engine
system)
No sparking takes place
Valve timing incorrect
Adjust
Engine lacks compression
Refer to item
compression)
Ignition coil disconnected or broken
Connect properly or replace
Electronic
module
Ignition
System
with Replace
Poor connections in engine harness

Engine
Control
Module
disconnected or defective
Correct
cable Correct or replace
(Engine
lacks

3. Trouble In Fuel System
Symptom
Possible Cause
Starting motor turns over and spark Fuel tank empty

occurs but engine does not start.
Action
Fill
Water in fuel system
Clean
Fuel filter clogged
Replace filter
Fuel pipe clogged
Clean or replace
Fuel pump defective
Replace
Fuel pump circuit open
Correct or replace
Evaporative Emission Control System Correct or replace

circuit clogged
Multiport Fuel Injection System faulty
Refer to Electronic Fuel Injection"

section
Possible Cause
Action
4. Engine Lacks Compression

Symptom
Spark plug loosely fitted
Tighten to specified torque
Adjust
Cylinder head gasket defective
Replace gasket
Valve incorrectly seated
Lap valve
Valve stem seized
Replace valve and valve guide
Valve spring weakened or broken
Replace
Cylinder or piston rings worn
Overhaul engine
Piston ring seized
Overhaul engine.
Engine Compression Test Procedure

1. Start and run the engine until the engine reaches
normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and
fuse box.
6. Engage the starter and check that the cranking
speed is approximately 300 rpm.
7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the
starter engaged until the compression gage needle
reaches the maximum level. Note the reading.
9. Repeat the test with each cylinder.

If the compression pressure obtained falls below
the limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)
Rough Engine Idling or Engine Stalling

Symptom
Trouble in fuel injection system
Possible Cause
Action
Idle air control valve defective
Replace
Throttle shutting off incomplete
Replace
Throttle position sensor circuit open Correct or replace

or shorted
Fuel injector circuits open or shorted
Correct or replace
Fuel injectors damaged
Replace
Fuel pump relay defective
Replace
Mass Airflow Sensor circuit open or Correct or replace

poor connections
Mass Airflow Sensor defective
Replace
Engine Coolant Temperature Sensor Correct or replace

circuit open or poor connections
Engine Coolant Temperature Sensor Replace
defective
Intake Air Temperature sensor circuit Correct or replace
open or poor connections
Intake Air Temperature sensor Replace
defective
Vehicle Speed Sensor circuit open or Correct or replace
shorted
Trouble in emission control system
Vehicle Speed Sensor defective
Replace
EGR valve defective
Replace
EGR valve circuit open or poor Correct or replace

connection
Engine Control Module defective
Replace
Canister purge valve circuit open or Correct or replace

poor connections
Canister purge valve defective
Replace
Evaporative Emission Canister Purge Replace

control valve defective
Others
Trouble in ignition system
Refer to Hard Start"
Refer to Hard Start"
Lap valve
Air Cleaner Filter clogged
Replace filter element
Readjust
Idle air control valve broken
Replace
Fast idle solenoid defective
Replace
Positive Crankcase Ventilation valve Replace

defective or clogged
Rough Engine Running

Symptom
Engine misfires periodically
Engine knocks periodically

Engine lacks power
Possible Cause
Action
Ignition coil layer shorted
Replace
Spark plugs fouling
Clean or install hotter type plug
Spark plug(s) insulator nose leaking
Replace
Fuel injector(s) defective
Replace
Engine control module faulty
Replace
Spark plugs running too hot
Install colder type spark plugs
Replace
Spark plugs fouled
Clean
Fuel injectors defective
Replace
Mass Airflow Sensor or Intake Airflow Correct or replace

Sensor circuit defective
or Engine Coolant Temperature
Sensor circuit defective
Engine Control Module faulty
Replace
Intake Air Temperature Sensor or Correct or replace

Intake Air Temperature Sensor circuit
defective
Throttle Position Sensor or Throttle Correct or replace
Position Sensor circuit defective
Hesitation
Symptom
Hesitation on acceleration
Possible Cause
Action
Throttle Position Sensor adjustment Replace throttle valve assembly

incorrect
Throttle Position Sensor circuit open Correct or replace
or shorted
Excessive play in accelerator linkage
Adjust or replace

poor connections
Replace
Intake Air Temperature (IAT) Sensor Correct or replace

circuit open or poor connections
Hesitation at high speeds
IAT Sensor defective
Replace
Fuel tank strainer clogged
Clean or replace
Fuel pipe clogged
Clean or replace
Fuel filter clogged
Replace
Defective fuel pump system
Check and replace
Fuel Pressure Control Valve leaking
Replace
(Fuel pressure too low)

(Fuel injector not working normally)
Power supply or ground circuit for Check and correct or replace

Multiport Fuel Injection System
shorted or open
Fuel Injector defective
Replace
Cable of Multiport Fuel Injection Correct or replace

System circuit open or poor
connections

Symptom
Possible Cause
Action
Replace
Throttle Position Sensor cable broken Correct or replace

or poor connections
Throttle Position Sensor defective
Replace

circuit open or shorted
defective
poor connections
Replace
IAT Sensor circuit open or poor Correct or replace

connections
Replace
Throttle valve not fully opened
Check and correct or replace
Power supply voltage too low
Engine Lacks Power

Symptom
Trouble in fuel system
Possible Cause
Action
Fuel Pressure Control Valve not Replace

working normally
Fuel injector clogged
Clean or replace
Fuel pipe clogged
Clean
Fuel filter clogged or fouled
Replace
Fuel pump drive circuit not working Correct or replace

normally
Fuel tank not sufficiently breathing Clean or replace
due to clogged Evaporative Emission
Control System circuit
Clean
Inferior quality fuel in fuel system
Use fuel of specified octane rating
Engine Control Module supplied poor Correct circuit

voltage
Throttle Position Sensor cable broken Correct or replace
or poor connections
Replace
Mass Airflow Sensor not working Replace

normally
Manifold Absolute Pressure Sensor Replace
not working normally
Intake Air Temperature Sensor not Replace
working normally
defective
Trouble in intake or exhaust system
Ignition failure
Replace
Air duct kinked or flattened
Correct or replace
Exhaust system clogged
Correct or replace
Refer to Hard Start Troubleshooting

Guide
Heat range of spark plug inadequate
Install spark plugs of adequate heat

range
Ignition coil defective
Replace

Symptom
Engine overheating
Possible Cause
Action
Level of Engine Coolant too low
Replenish
Fan clutch defective
Replace
Thermostat defective
Replace
Engine Coolant pump defective
Correct or replace
Radiator clogged
Clean or replace
Radiator filler cap defective
Replace
Level of oil in engine crankcase too Change or replenish

low or wrong engine oil
Resistance
increased
in
exhaust
system Clean exhaust system or replace

defective parts
Throttle Position Sensor adjustment Replace with Throttle Valve ASM

incorrect
Throttle Position Sensor circuit open Correct or replace
or shorted
Cylinder head gasket damaged
Replace
Engine overcooling
Replace (Use a thermostat set to

open at 82C (180F))
Refer to Hard Start
Others
Tire inflation pressure abnormal
Adjust to recommended pressures
Brake drag
Adjust
Clutch slipping
Adjust or replace
Level of oil in engine crankcase too Correct level of engine oil

high
EGR valve defective
Replace
Engine Noisy
Abnormal engine noise often consists of various noises
originating in rotating parts, sliding parts and other
moving parts of the engine. It is, therefore, advisable to
locate the source of noise systematically.
Symptom
Possible Cause
Action
Noise from crank journals or from Oil clearance increased due to worn Replace
crank
bearings
and
crank bearings
crank journals or crank bearings
crankshaft or regrind crankshaft and
install the undersize bearing
(Faulty crank journals and crank
bearings usually make dull noise that
becomes
more
evident
when
accelerating)
Crankshaft out of round
Replace
crank
bearings
and
crankshaft or regrind crankshaft and
install the undersize bearing
Crank bearing seized
Crank bearing seized Replace crank

bearings and crankshaft or regrind
crankshaft and install the undersize
bearing
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with defective
bearing by listening for abnormal noise that stops when
spark plug is shorted out.
Symptom
Possible Cause
Noise from connecting rods or from Bearing or crankshaft pin worn

connecting rod bearings
(Faulty connecting rods or connecting
rod bearings usually make an
abnormal noise slightly higher than
the crank bearing noise, which
becomes more evident when engine
is accelerated)
Action
Replace connecting rod bearings and
crankshaft or regrind crankshaft pin
and install the undersize bearing
Crankpin out of round

Connecting rod bent
Correct or replace
Connecting rod bearing seized


Abnormal noise stops when the spark plug on the
cylinder with defective part is shorted out.
Symptom
Possible Cause
Action
Piston clearance increased due to Replace piston and cylinder body

(Faulty piston or cylinder usually cylinder wear
makes a combined mechanical
thumping noise which increases
when engine is suddenly accelerated
but diminishes gradually as the
engine warms up)
Piston and cylinder noise
Piston seized
Replace piston and cylinder body
Piston ring broken
Piston defective
Replace pistons and others
Short out each spark plug and listen for change in
engine noise.
Symptom
Piston pin noise
(Piston makes noise each time it
goes up and down)
Possible Cause
Piston pin or piston pin hole worn
Action
Replace piston, piston
connecting rod assembly
pin
and

The slapping sound stops when spark plug on bad
cylinder is shorted out.
Symptom
Timing belt noise
Possible Cause
Action
Timing belt tension is incorrect
Replace pusher or adjust the tension

pulley or replace timing belt
Tensioner bearing defective
Replace
Timing belt defective
Replace
Timing pulley defective
Replace
Timing belt comes in contact with Replace timing belt and timing cover
timing cover
Valve noise
Valve clearance incorrect
Replace adjusting shim
Valve and valve guide seized
Valve spring broken or weakened
Replace
Valve seat offpositioned
Correct
Camshaft worn out
Replace
Crankshaft noise
Crankshaft end play excessive (noise Replace thrust bearing

occurs when clutch is engaged)
Engine knocking
Preignition due to use of spark plugs Install Spark Plugs of adequate heat
of inadequate heat range
range
Carbon deposits
chambers
in
combustion Clean
Fuel too low in octane rating

Wide Open Throttle
system failure
Selection
incorrect
Others
of
Replace fuel
enrichment Refer to Section 6E
transmission
gear Caution operator of incorrect gear

selection
Engine overheating
Refer to Engine Lacks Power"
Water pump defective
Replace
Drive belt slipping
Replace auto tentioner or drive belt
Abnormal Combustion
Symptom
Possible Cause
Action
Fuel pressure control valve defective
Replace
Fuel filter clogged
Replace
Fuel pump clogged
Clean or replace
Fuel tank or fuel pipe clogged
Clean or replace
Clean or replace
Replace
Power supply cable for fuel pump Reconnect, correct or replace

broken or poor connections
Mass Airflow (MAF) Sensor circuit Correct or replace
open or defective
MAF Sensor defective
Replace
Engine Coolant Temperature (ECT) Correct or replace

Sensor circuit open or shorted
ECT Sensor defective
Replace
Throttle Position Sensor adjustment Readjust

incorrect
Replace
Throttle Position Sensor connector Reconnect

poor connections
Vehicle Speed Sensor cable poor Correct or replace
connections or defective
Vehicle Speed Sensor loosely fixed
Fix tightly
Vehicle Speed Sensor in wrong Replace

contact or defective
Engine Control Module cable poor Correct or replace
connections or defective

Symptom
Trouble in emission control system
Possible Cause
Action
Heated Oxygen Sensor circuit open
Correct or replace
Heated Oxygen Sensor defective
Replace
Signal vacuum hose loosely fitted or Correct or replace

defective
EGR Valve circuit open or shorted
Correct or replace
EGR Valve defective
Replace
ECT Sensor circuit open or shorted
Correct or replace
Canister Purge Valve circuit open or Correct or replace

shorted
Canister Purge Valve defective
Replace
Replace
Positive Crankcase Ventilation (PCV) Correct or replace

valve and hose clogged
Evaporator system
Refer to Section 6E
Refer to Engine Lacks Power"
Trouble in cylinder head parts
Carbon deposits
chamber
in
combustion Remove carbon
Carbon deposit on valve, valve seat Remove carbon

and valve guide
Engine Oil Consumption Excessive

Symptom
Oil leaking
Possible Cause
Action
Oil pan drain plug loose
Retighten or replace gasket
Crankcase fixing bolts loosened
Retighten
Oil pan setting bolts loosened
Retighten
Oil pan gasket broken
Replace gasket
Front cover retaining bolts loose or Retighten or replace gasket

gasket broken
Head cover fixing bolts loose or Retighten or replace gasket
gasket broken
Oil filter adapter cracked
Replace
Oil filter attachings bolt loose or Retighten or replace oil filter

rubber gasket broken
Oil cooler broken
Replace
Crankshaft front or rear oil seal Replace oil seal

defective
Oil pressure unit loose or broken
Blowby gas hose broken
Replace hose
Positive Crankcase Ventilation Valve Clean

clogged
Engine/Transmission coupling failed
Oil leaking into combustion chambers Valve stem oil seal defective
due to poor seal in valve system
Replace
Valve stem or valve guide worn

Oil leaking into combustion chambers Cylinders
and
due to poor seal in cylinder parts
excessively
Piston
ring
positioned
Positive
Crankcase
System malfunctioning
Others
pistons
gaps
Replace oil seal

worn Replace cylinder body assembly and
pistons
incorrectly Correct
Piston rings set with wrong side up
Correct
Piston ring sticking
Replace cylinder body assembly and

pistons
Piston ring and ring groove worn
Return ports in oil rings clogged
Clean piston and replace rings
Ventilation Positive Crankcase Ventilation Valve Clean

clogged
Improper oil viscosity
Use oil of recommended S.A.E.

viscosity
Continuous high speed driving and/or Continuous high speed operation

severe usage such as trailer towing
and/or severe usage will normally
cause increased oil consumption
Fuel Consumption Excessive

Symptom
Possible Cause
Action
Mixture too rich or too lean due to Refer to Abnormal Combustion"

trouble in fuel injection system
Fuel cut function does not work
Refer to Abnormal Combustion"
Misfiring or abnormal combustion due Refer to Hard Start" or Abnormal

to trouble in ignition system
Combustion"
Others
Engine idle speed too high

Returning
sluggish
of
accelerator
Reset to Section 6E
control Correct
Fuel system leakage
Correct or replace
Clutch slipping
Correct
Brake drag
Correct
Selection
incorrect
of
transmission
gear Caution operator of incorrect gear

selection
Lubrication Problems
Symptom
Oil pressure too low
Possible Cause
Action
Wrong oil in use
Replace with correct engine oil
Relief valve sticking
Replace
Oil pump not operating properly
Correct or replace
Oil pump strainer clogged
Clean or replace strainer
Oil pump worn
Replace
Oil pressure gauge defective
Correct or replace
Crankshaft bearing or connecting rod Replace

bearing worn
Oil contamination
Oil not reaching valve system
Wrong oil in use
Oil filter clogged
Replace oil filter
Cylinder head gasket damage
Replace gasket
Burned gases leaking
Replace piston and piston rings or

cylinder body assembly
Oil passage in cylinder head or Clean or correct

cylinder body clogged
Engine Oil Pressure Check

1. Check for dirt, Fuel or water in the engine oil.
a. Check the viscosity of the oil.
b. Check the viscosity of the oil.
c. Change the oil if the viscosity is outside the
specified standard.
d. Refer to the Maintenance and Lubrication"
section of this manual.
2. Check the engine oil level.
The level should fall somewhere between the
ADD" and the FULL" marks on the oil level
dipstick.
If the oil level does not reach the ADD" mark on
the oil level dipstick, engine oil must be added.
3. Remove the oil pressure unit.
4. Install an oil pressure gauge.
5. Start the engine and allow the engine to reach
normal operating temperature (About 80C).
6. Measure the oil pressure.
Oil pressure should be:
392-550 kPa (56.9-80.4 psi) at 3000 rpm.
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Install the oil pressure unit.
10. Start the engine and check for leaks.
Malfunction Indicator Lamp

The instrument panel CHECK ENGINE" Malfunction
Indicator Lamp (MIL) illuminates by self diagnostic
system when the system checks the starting of engine,
or senses malfunctions. CHECK ENGINE" MIL does
not illuminate at the starting of engine
Symptom
Possible Cause
Action
CHECK ENGINE" MIL does not Bulb defective

illuminate at the starting of engine
Replace
MIL circuit open
Correct or replace
Command signal circuit to operate Correct or replace

self diagnostic system shorted
Engine Control Module (ECM) cable Correct or replace
loosely connected, disconnected or
defective
ECM defective
CHECK ENGINE" MIL illuminates, Deterioration of heated
and stays on
sensor internal element
Replace
oxygen Replace
Heated oxygen sensor connector Reconnect properly

terminal improper contact
Heated oxygen sensor lead wire Correct
shorted
Heated oxygen sensor circuit open
Correct or replace
Deterioration of engine coolant Replace

temperature sensor internal element
Engine coolant temperature sensor Reconnect properly
connector terminal improper contact
Engine coolant temperature sensor Correct
lead wire shorted
Engine coolant temperature sensor Correct or replace
circuit open
Throttle position sensor open or Correct or replace
shorted circuits
Deterioration of crankshaft position Replace
sensor
Crankshaft position sensor circuit Correct or replace
open or shorted
Vehicle speed sensor circuit open
Correct or replace
Intake air temperature sensor circuit Correct or replace

open or shorted
Fuel injector circuit open or shorted
Correct or replace
ECM driver transistor defective
Replace ECM
Malfunctioning
of
ECM
RAM Replace ECM
(Random Access Memory) or ROM
(Read Only Memory)
Cylinder Head Cover LH

7. Remove eight fixing bolts, then the cylinder head
cover.
Removal
1.
2.
3.
4.

Disconnect positive crankcase ventilation hose.
Remove camshaft angle sensor connector.
Remove ground cable fixing bolt on cylinder head
cover.
5. Ignition coil connector and ignition coil.
Disconnect the three connectors from the
ignition coils.
Remove harness bracket bolt on cylinder head
cover.
Remove fixing bolts on ignition coils.
010RW001
Installation
060RW078
Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assemblies
1. Install cylinder head cover.

Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area
of camshaft bracket on front and rear sides.
The cylinder head cover must be installed with
in 5 minutes after sealant application to prevent
hardening of sealant.
Tighten bolts to the specified torque.
6. Remove fixing bolt for fuel injector harness

bracket.
010RW006

2. Install fuel injection harness bracket and tighten
3. Connect ignition coil connector and ignition coil,
then tighten bolt to the specified torque.
060RW078
Legend
(2) Bolt
(3) Ignition Coil Assembly
4. Connect ground cable and tighten bolts to the
specified torque.
5. Connect camshaft angle sensor connector.
6. Install positive crankcase ventilation hose.
Cylinder Head Cover RH

Removal
2. Remove air cleaner duct assembly.
3. Disconnect ventilation hose from cylinder head
cover.
4. Disconnect three ignition coil connectors from
ignition coils and remove harness bracket bolts on
cylinder head cover then remove ignition coil fixing
bolts on ignition coils and remove ignition coils.
5. Remove heater pipe fixing bolts from the bracket.
6. Disconnect fuel injector harness connector then
remove fuel injector harness bracket bolt.
7. Remove eight fixing bolts then the cylinder head
cover.
014RW019
010RW002
Installation
1. Install cylinder head cover.
Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-1207B or equivalent) of bead
diameter 2&dash;3 mm at eight place of arched
area of camshaft bracket on front and rear
sides.
The cylinder head cover must be installed
within 5 minutes after sealant application to
prevent premature hardening of sealant.
2. Install exhaust gas recirculation pipe and tighten to

specified torque.
Torque :
Exhaust manifold side: 29 Nm (3.0 kgm/21 lb ft)
Flare nut: 44 Nm (4.5 kgm/33 lb ft)
Cylinder head side: 20 Nm (2.0 kgm/14 lb ft)
3. Tighten fuel injector harness bracket bolts to
specified torque then reconnect fuel injector
harness connector.
Torque : 8 Nm (0.8 kgm/5.7 lb ft)
4. Install heater pipe bolt to the specified torque.
5. Connect ignition coil connector and tighten ignition
coil fixing bolts to specified torque.
6. Connect ventilation hose to cylinder head.
7. Install air cleaner duct assembly.
Common Chamber
Legend
Removal
3. Remove the ECM.
Disconnect the two connectors from the ECM.
Remove fixing bolts on the common chamber.
Remove fixing bolts for ground cable.
060RW025
4. Remove the accelerator control cable from

accelerator control cable bracket.
Slide the lock in direction A
Rotate the ratchet ring in indirection an arrow
90
(1) Cable Bracket

(2) Ratchet ring
(3) Outer Cap
(4) Lock
(5) Paint Mark
(6) Arrow Mark
5. Remove the accelerator control cable from the
throttle.
6. Disconnect vacuum booster hose from common
chamber.
7. Disconnect connector from manifold absolute
pressure sensor, idle air control valve, throttle
position sensor, solenoid valve, electric vacuum
sensing valve.
8. Disconnect vacuum hose on canister VSV and
positive crankcase ventilation hose, fuel rail
assembly with pressure control valve bracket.
9. Remove ventilation hose from throttle valve and
intake duct and remove water hose.
10. Remove exhaust gas recirculation valve assembly
fixing bolt and nut on common chamber.
11. Remove two bolts from common chamber rear
side for remove fuel hose bracket.
12. Remove common chamber four bolts and four
nuts then remove the common chamber.
025RW001
Legend
RTW46ASH000201
(1) Common Chamber

(2) Throttle Valve Assembly
(3) Bolt
13. Remove the four throttle body fixing bolts.

Legend
Installation
1. Install throttle body and tighten bolts to the
specified torque.
2. Install common chamber and tighten bolts and
nuts to the specified torque.
Torque :
Bolt : 18 Nm (1.8 kgm/13 lb ft)
Nut : 18 Nm (1.8 kgm/13 lb ft)
3. Install fuel hose bracket and tighten bolts to
specified torque.
Torque : 10 Nm (1.0 kgm/89 lb in)
4. Install ventilating hose to throttle valve and intake
duct.
5. Connect vacuum hoses on canister VSV and
positive crankcase ventilation hose. Tighten bolts
for fuel rail assembly with pressure control valve
bracket.
6. Connect each connector without fail.
7. Connect vacuum booster hose.
8. Install the ECM.
Tighten the four bolts.
Connect the two connectors.
Tighten the two ground cable bolts.
9. Install accelerator control cable to accelerator
cable bracket.
Rotate the ratchet ring in direction an arrow 90
Confirm marking of outer cap must be upper
side.
Slider the lock of outer cap must be upper side.
Confirm ratchet ring is locked.
060RW093
(1) Cable Bracket

(2) Ratchet ring
(3) Outer Cap
(4) Lock
(5) Paint Mark
(6) Arrow Mark
Exhaust Manifold LH
Removal
Installation

2. Disconnect O2 sensor connector.
3. Remove torsion bar. Refer to removal procedure in
Front Suspension section.
4. Remove exhaust front pipe three stud nuts from
exhaust side and two nuts from rear end of
exhaust front pipe.
1. Install exhaust manifold and tighten exhaust

manifold fixing nuts to the specified torque with
new nuts.
2. Install heat protector.
3. Install exhaust front pipe and tighten three stud
nuts and two nuts to the specified torque.
Torque:
Stud nuts: 67 Nm (6.8 kgm/49 lb ft)
Nuts: 43 Nm (4.4 kgm/32 lb ft)
RTW36FSH000201
5. Remove heat protector two fixing bolts then the

heat protector.
6. Remove a bolt on engine LH side for air
conditioner (A/C) compressor bracket and loosen
two bolts for A/C compressor then move A/C
compressor to front side.
7. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.
RTW36FSH000201
4. Install the torsion bar and readjust the vehicle

height. Refer to installation and vehicle height
adjustment procedure for front suspension.
5. Set A/C compressor to normal position and tighten
two bolts and a bolt to the specified torque.
6. Reconnect O2 sensor connector.
Exhaust Manifold RH
Removal
Installation

2. Remove exhaust front pipe three stud nuts and
two nuts then disconnect exhaust front pipe.
RTW36FSH000101
3. Remove steering shaft. Refer to removal

procedure in Steering section.
4. Remove heat protector two fixing bolts then the
heat protector.
5. Remove EGR pipe.
6. Remove exhaust manifold eight fixing nuts then
the exhaust manifold.
1. Install exhaust manifold and tighten bolts to the

specified torque.
2. Install EGR pipe.
3. Install heat protector
4. Install exhaust front pipe and tighten three stud
nuts and two nuts to the specified torque.
Torque:
Stud nuts: 67 Nm (6.8 kgm/49 lb ft)
Nuts: 43 Nm (4.4 kgm/32 lb ft)
5. Install steering shaft. Refer to installation
procedure in Steering section.
Crankshaft Pulley
Removal
1.
2.
3.
4.
Installation

Remove air cleaner assembly.
Remove radiator upper fan shroud from radiator.
Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
850RW001
Legend
(1) Crankshaft Pulley
(2) Cooling Fan Pulley
(3) Tensioner
(4) Generator
(5) Air Conditioner Compressor
(6) Power Steering Oil Pump
(7) Serpentine Belt
5. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.
6. Remove crankshaft pulley assembly using
5-8840-0133-0 crankshaft holder, hold crankshaft
pulley then remove center bolt and pulley.
1. Install crankshaft pulley using 5-8840-0133-0

crankshaft holder, hold the crankshaft pulley and
tighten center bolt to the specified torque.
2. Install cooling fan assembly and tighten bolts/nuts
Torque: 25 Nm (2.5 kgm/18 lb ft) for fan pulley
and fan bracket.
Torque: 10 Nm (1.0 kgm/88.5 lb in) for fan and
clutch assembly.
3. Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.
Timing Belt
13. Remove pusher.
Removal
1.
2.
3.
4.

Remove air cleaner assembly.
Remove radiator upper fan shroud from radiator.
Move drive belt tensioner to loose side using
wrench then remove drive belt.
CAUTION: The pusher prevents air from entering

the oil chamber. Its rod must always be facing
upward.
014RW011
Legend
850RW001
Legend
(3) Tensioner
(4) Generator
(7) Drive Belt
5. Remove cooling fan assembly four nuts, then the
cooling fan assembly.
6. Remove cooling fan drive pulley assembly.
7. Remove idle pulley assembly.
8. Remove serpentine belt tensioner assembly.
9. Remove power steering pump assembly.
10. Remove crankshaft pulley assembly using
5-8840-0133-0 crankshaft holder, hold crankshaft
pulley remove center bolt, then the pulley.
11. Remove right side timing belt cover then left side
timing belt cover.
12. Remove lower timing belt cover
(1) Up Side
(2) Down Side
(3) Direction For Installation
(4) Locking Pin
14. Remove timing belt.
CAUTION:
1. Do not bend or twist the belt, otherwise its
core could be damaged. The belt should not be
bent at a radius less than 30 mm.
2. Do not allow oil or other chemical substances
to come in contact with the belt. They will
shorten the life.
3. Do not attempt to pry or stretch the belt with a
screw driver or any other tool during
installation.
4. Store timing belt in a cool and dark place.
Never expose the belt direct sunlight or heat.
Installation
Legend
For correct belt installation, the letter on the belt must

be able to be read as viewed from the front of the
vehicle.
(7) Alignment Mark on Oil Pump.

(8) Alignment Mark on Timing Belt
(9) Alignment Mark (notch) on Crankshaft Timing
Pulley
(10) Alignment Mark (groove) on Crankshaft Timing
Pulley.
014RY00042
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley
(4) Idle Pulley
(5) LH Bank Camshaft Drive Gear Pulley
(6) Tension Pulley
014RW006
Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
1. Install timing belt.
1. Align the mark (notch) of crankshaft timing
pulley (2) with mark on oil pump (1).
Align the mark (groove) on the crankshaft
timing pulley (3) with alignment mark (white
dots line) on the timing belt (4).
014RY00043

NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear Pulley.
(3) Alignemnt Mark on Cylinder Head Cover RH.
014RW003
Legend
(1) Alignment Mark on Oil Pump
(2) Groove on Crankshaft Timing Pulley
(3) Alignment Mark on Crankshaft Timing Pulley
(4) Alignment Mark on Timing Belt
4. Align the alignment mark on the LH bank

camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover LH (3).
5. Align the alignment mark (white line) on the
timing belt (1) with the alignment mark on the
LH bank camshaft drive gear pulley (2).
When aligning the timing marks, use a wrench
to turn the camshaft drive gear pulley, then set
the timing mark between timing belt and
camshaft drive gear pulley and put the timing
belt on the camshaft drive gear pulley.
Secure the belt with a double clip or equivalent
clip.
NOTE: It is recommended for easy installation that the
belt be secured with a double clip or equivalent clip after
it is installed the timing belt to each pulley.
2. Align the alignment mark on the RH bank

camshaft drive gear pulley (2) to the alignment
mark of the cylinder head cover RH (3).
3. Align the alignment mark (white line) on the
timing belt (1) with alignment mark on the RH
bank camshaft drive gear pulley (2) (on the left
side as viewed from the front of the vehicle)
and put the timing belt on the camshaft drive
gear pulley.
Secure the belt with a double clip or equivalent
clip.
014RW00005
Legend
(1) Alignment Mark on Timing Belt (White line).
(2) Alignment Mark on Camshaft Drive Gear Pulley.
(3) Alignemnt Mark on Cylinder Head Cover LH.
6. Install crankshaft pulley temporarily and tighten
center bolt by hand (do not use a wrench).
Turn the crankshaft pulley clockwise to give
some belt slack between the crankshaft timing
pulley and the RH bank camshaft drive gear
pulley.
014RW00004

2. Install pusher and tighten bolt to the specified
torque.
Torque: 25 Nm (2.5 Kgm/18 lb ft)
1. Install the pusher while pushing the tension
pulley to the belt.
2. Pull out pin from the pusher.
NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).
3. Install timing belt cover.

Remove crankshaft pulley that was installed in
step 1 item 5.
020RW004
Legend
014RW011
Legend
(1) Timing Belt Cover RH

(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower
(1) Up Side
(2) Down Side
(3) Direction for Installation
(4) Locking Pin
3. Remove double clips or equivalent clips, from
timing belt pulleys.
Turn the crankshaft pulley clockwise by two
turns.
020RW003
Legend
(1) Timing Belt Cover
(2) Rubber Bushing
(3) Sealing Rubber
(4) Cylinder Body

4. Install crankshaft pulley using 5-8840-0133-0, hold
the crankshaft pulley and tighten center bolt to the
specified torque.
5. Install fan pulley bracket and tighten fixing bolts to
6. Install power steering pump assembly and tighten
Torque:
M8 bolt: 25 Nm (2.5 kgm/18 lb ft)
and fan bracket.
Torque: 10 Nm (1.0 kgm/7 lb ft) for fan and
clutch assembly.
8. Move drive belt tensioner to loose side using
wrench, then install drive belt to normal position.
850RW001
Legend
(3) Tensioner
(4) Generator
(7) Drive Belt
9. Install radiator upper fan shroud.

Camshaft
Removal
2. Remove crankshaft pulley.
Refer to removal procedure for Crankshaft
Pulley in this manual.
Refer to removal procedure for Timing Belt in
this manual.
4. Remove cylinder head cover LH.
Refer to removal procedure for Cylinder Head
Cover LH in this manual.
5. Remove cylinder head cover RH.
Cover RH in this manual.
6. Remove twenty fixing bolts from inlet and exhaust
camshaft bracket on one side bank, then camshaft
brackets.
014RW026
Legend
(1) Right Bank
(2) Left Bank
(3) Timing Mark on Retainer
Installation
014RW027
7. Remove camshaft assembly.

8. Remove fixing bolt for camshaft drive gear pulley.
9. Remove three fixing bolts from camshaft drive
gear retainer, then camshaft drive gear assembly.
1. Install camshaft drive gear assembly and tighten

three bolts to the specified torque.
2. Tighten bolt for camshaft drive gear assembly
pulley to the specified torque.
3. Tighten sub gear setting bolt.
1. Use 5-8840-2443-0 to turn sub gear to right
direction until it aligns with the M5 bolt hole
between camshaft driven gear and sub gear.
2. Tighten the M5 bolt to a suitable torque to
prevent the sub gear from moving.
014RW041
4. Install camshaft assembly and camshaft brackets,

tighten twenty bolts on one side bank to the
specified torque.
1. Apply engine oil to camshaft journal and
bearing surface of camshaft bracket.
2. Align timing mark on intake camshaft (one dot
for right bank, two dot for left bank) and
exhaust camshaft (one dot for right bank, two
dots for left bank) to timing mark on camshaft
drive gear (one dot).
014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
(LI: Left bank intake, RI: Right bank intake)
(LE: Left bank exhaust, RE: Right bank exhaust)
014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin
014RW024
Legend
(3) Alignment Mark on Camshaft Drive Gear

(4) Alignment Mark on Camshaft
(5) Alignment Mark on Retainer
(1) Right Bank

(2) Left Bank
3. Tighten twenty bolts on numerical order an one

side bank as shown in the illustration.
014RW031
5. Install cylinder head cover RH.

Refer to installation procedure for CYLINDER
HEAD COVER RH in this manual.
6. Install cylinder head cover LH.
Refer to installation procedure for CYLINDER
HEAD COVER LH in this manual.
Refer to installation procedure for TIMING
BELT in this manual.
8. Install crankshaft pulley.

Refer
to
installation
procedure
CRANKSHAFT PULLEY in this manual.
for
Cylinder Head
Removal
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Installation
Remove engine hood.

Drain radiator coolant.
Drain engine oil.
Remove crankshaft pulley.
Remove timing belt.
this manual.
Remove cylinder head cover LH.
Cover LH in this manual.
Remove cylinder head cover RH.
Cover RH in this manual.
Remove common chamber.
Refer to removal procedure for Common
Chamber in this manual.
Remove cylinder head assembly.
1. Loosen eights bolts for tight cylinder head.
2. Remove cylinder head assembly.
1. Install cylinder head assembly to cylinder block.

1. Put cylinder head gasket on the cylinder block.
NOTE: There is discrimination mark “R" for right
bank and “L" for left bank on the cylinder head
gasket as shown in the illustration.
Do not reuse cylinder head gasket.
011RW005
2. Align dowel pin hole to dowel pin on the

cylinder block.
3. Tighten two bolts temporarily by hand to
prevent the cylinder head assembly from
moving.
4. Using 9-8511-4209-0 cylinder head bolt
wrench, tighten bolts in numerical order as
shown in the illustration to the specified torque.
014RW028
Legend
(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft

NOTE: Do not reuse cylinder head bolts.
Do not apply any lubricant to the cylinder head bolts.
Torque:
Temporary: 29 Nm (3.0 kgm/21 lb ft)
Final: 64 Nm (6.5 kgm/47 lb ft)
014RW029
2. Install common chamber.

Refer to installation procedure for Common
Chamber in this manual.
3. Install cylinder head cover RH.
Refer to installation procedure for Cylinder
Head Cover RH in this manual.
4. Install cylinder head cover LH.
Head Cover LH in this manual.
Refer to installation procedure for Timing Belt in
this manual.

Refer to installation procedure for Crankshaft
Valve Stem Oil Controller, Valve Spring and Valve Guide

Removal
Installation

Drain engine oil.
2. Drain engine coolant.
in this manual.
4. Remove camshaft.
Refer to removal procedure for Camshaft in this
manual.
5. Remove tappets with shim.
NOTE: Do not damage shim surface.
6. Remove valve springs using 5-8840-2446-0
valve spring compressor and 5-8840-2547-0
valve spring compressor adapter then remove
upper valve spring seat and lower seat.
1. Install valve guide using 5-8840-2442-0 valve

guide installer.
2. Install oil controller using 5-8840-0624-0 oil
controller installer.
3. Install lower valve spring seat, valve spring and
upper valve spring seat then put split collars on the
upper spring seat, using 5-8840-2442-0 valve
spring compressor and 5-8840-0624-0 valve
spring compressor adapter to install the split
collars.
014RW042
014RW042
7. Remove oil controller using 5-8840-0623-0 oil

controller remover, remove each valve stem oil
controller.
8. Remove valve guide using 5-8840-2549-0 valve
guide replacer.
4. Install tappet with shim.

5. Install camshaft assembly.
Refer to installation procedure for Camshaft in
this manual.
6. Install cylinder head assembly.
Head in this manual.
7. Fill engine oil until full level.
8. Fill engine coolant.
Piston, Piston Ring and Connecting Rod

Removal
F06RW011
Legend
(1) Cylinder Head
(2) Crankcase with Oil Pan
(3) Oil Pipe
in this manual.
2. Remove crankcase with oil pan.
Refer to removal procedure for Oil Pan and
Crankcase in this manual.
(4) Oil Strainer

(5) Oil Gallery
(6) Piston with Connecting Rod Assembly

3. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
015RW003
Legend
050RW002
Legend
(1) Oil Pump
(2) Oil Strainer
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
4. Remove three fixing bolts, oil pipe with O-ring.
5. Remove eight fixing bolts, oil gallery.
6. Remove piston with connecting rod assembly,
before removing the bearing cap, remove carbon
on the top of cylinder bore and push piston with
connecting rod out from the top of cylinder bore.
(1) Piston Front Mark

(2) Piston Grade
(3) Connecting Rod Front Mark
2. Install oil gallery and tighten the bolts in two steps,
in the order shown in illustration.
Torque:
1st step: 29 Nm (3.0 kgm/21 lb ft)
2nd step: 55-65
Installation
1.
Install piston with connecting rod assembly.

Apply engine oil to cylinder bore, connecting
rod bearing and crank pin.
When installing the piston, its front mark must
face the engine front side.
The bearing cap number must be the same as
connecting rod number.
Apply engine oil to the thread and seating
surface of each nut.
Tighten nuts to the specified torque.
After tightening the nuts, make sure that the
crankshaft rotates smoothly.
NOTE: Do not apply engine oil to the bearing back
faces and connecting rod bearing fitting surfaces.
051RS009
3. Install oil pipe with O-ring.

4. Install oil strainer assembly with O-ring.
5. Install crankcase with oil pan.
Refer to installation procedure for Oil Pan and

6. Install cylinder head assembly.
Head in this manual.
Crankshaft and Main Bearings

Removal
F06RW010
Legend
(1) Engine Assembly
(3) Timing Belt Cover
(4) Timing Belt
(6) Oil Pipe
(7) Oil Strainer
(8) Oil Pump Assembly

(9) Cylinder Body Side Bolt
(10) Oil Gallery
(11) Flywheel
(12) Rear Oil Seal Retainer
(13) Connecting Rod Cap
(14) Crankshaft Main Bearing Cap
(15) Crankshaft and Main Bearing

1. Remove engine assembly.
Refer to removal procedure for Engine
Assembly in this manual.
this manual.
3. Remove oil pan and crankcase.
4. Remove oil pipe with O-ring.
5. Remove oil strainer assembly with O-ring.
6. Remove oil pump assembly.
Refer to removal procedure for Oil Pump in this
manual.
7. Remove cylinder body side bolts.
8. Remove oil gallery.
9. Remove flywheel.
10. Remove rear oil seal retainer.
Refer to removal procedure for Rear Oil Seal in
this manual.
11. Remove connecting rod caps.
12. Remove crankshaft main bearing caps.
13. Remove crankshaft and main bearings.
015RS012
Installation
1. Install crankshaft and main bearings.
Install main bearing in the cylinder block and
main bearing cap respectively.
Apply new engine oil to upper and lower main
bearings.
NOTE:
Do not apply engine oil to the bearing back faces.
Make sure that main bearings are in correct
position.
Install crankshaft with care.
Apply engine oil to the thrust washer.
Install thrust washer on No.3 journal.
Oil grooves in thrust washer must face the
crankshaft.
015RS013
2. Install crankshaft main bearing caps.

surface of each bearing cap fixing bolt.
NOTE:
Do not apply engine oil to the bearing back faces.
Install bearing caps in the order of numbers,
starting with cylinder block front side.
Tighten main bearing fixing bolts to the specified
torque.
After tightening the bolts, make sure that the
3. Install connecting rod caps.
The cap number must be same as connecting
rod number.
surface of each nut.

Tighten nuts to the specified torque.
After tightening the nuts, make sure that the
4. Install rear oil seal retainer.
Remove oil on cylinder block and retainer fitting
surface.
Apply sealant (TB1207B or equivalent) to
retainer fitting surface as shown in illustration.
The oil seal retainer must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
Tighten retainer fixing bolts to the specified

torque.
015RW001
015RW002
Legend
5. Install flywheel.
Clean tapped holes in the crankshaft.
Remove oil on crankshaft and flywheel fitting
surface.
NOTE:
Do not reuse the bolts.
Do not apply oil or thread lock to the bolts.
Tighten fixing bolts to the specified torque.
(1) Around Bolt Holes

(2) Around Dowel Pin
Apply engine oil to oil seal lip and align a dowel
pin hole in the cylinder block with that in the
retainer.
015RS018

6. Install oil gallery.
Clean contact surface of oil gallery and main
bearing cap.
Apply engine oil to oil gallery fixing bolts and
tighten the bolts in two steps, in the order
shown.
Torque:
1st step: 29 Nm (3.0 kgm/21 lb ft)
2nd step: 55-65
7. Install cylinder body side bolts and tighten bolts in
order to the specified torque.
NOTE: Do not apply the oil to the bolts.
Install oil pump in the cylinder block and tighten

fixing bolts to the specified torque.
051RW002
Legend
012RS007
8. Install oil pump assembly.

Remove oil on cylinder block and oil pump
mounting surface.
Apply sealant (TB1207B or equivalent) to the oil
pump mounting surface.
The oil pump assembly must be installed within
5 minutes after sealant application to prevent
Apply engine oil to oil seal lip.
051RW001
9. Install oil strainer with O-ring, tighten to the

specified torque.
10. Install oil pipe with O-ring, tighten fixing bolts to the
specified torque.

11. Install crankcase.
Remove oil on crankcase mounting surface
and dry the surface.
Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the
crankcase mounting surface. The bead must
be continuous.
The crankcase must be installed within 5
Properly apply a 4.5 mm (0.7 in) wide bead of

sealant (TB1207C or equivalent) to the oil pan
mounting surface. The bead must be
continuous.
The oil pan must be installed within 5 minutes
after sealant application to prevent premature
013RW003
013RW010
013RW002
013RW004
12. Install oil pan

Remove oil on oil pan mounting surface and
dry the surface.

this manual.
14. Install engine assembly.
Refer to installation procedure for Engine
Assembly in this manual.
Rear Oil Seal

Removal
1. Remove transmission assembly.
See Transmission section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil
seal retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal
using 5-8840-2286-0.
015RS018
3. Install transmission.
See Transmission section in this manual.
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Take care that dowel positions are different
between the manual transmission and the
automatic
transmission.
Otherwise,
the
transmission may be damaged.
015RS017
2. Install flywheel.
Clean tapped holes in the crankshaft.
Remove oil on the crankshaft and flywheel
mounting surface.
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
012RS009
Engine Assembly
Removal
P1010068
1. Disconnect battery ground and positive cable.

2. Remove battery.
3. Make alignment mark on the engine hood and
hinges before removal in order to return the hood
to original position exactly.
4. Remove engine hood.
5. Drain radiator coolant.
6. Disconnect accelerator cable and automatic cruise
control cable from throttle valve on common
chamber.
7. Remove the ECM.
. Remove fixing bolts on the common chamber.
Remove fixing bolts for ground cable.
8. Disconnect air duct with air cleaner cover.
9. Remove air cleaner assembly.
10. Disconnect canister vacuum hose.
11. Disconnect vacuum booster hose.
12. Disconnect three engine harness connectors.
13. Disconnect harness connector to transmission (left
front side of engine compartment), disconnect shift
on the fly harness connector from front side of
front axle and remove transmission harness
bracket from engine left side.
14. Disconnect ground cable between engine and
frame.
15. Disconnect bonding cable connector on the back
of right dash panel.
16. Disconnect bonding cable terminal on the left
bank.
17. Disconnect starter harness connector from starter.

18. Disconnect generator harness connector from
generator.
19. Disconnect coolant reserve tank hose from
radiator.
20. Remove radiator upper and lower hoses.
21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts,
then the cooling fan assembly.
wrench then remove drive belt.
24. Remove power steering pump fixing bolts, then
power steering pump. Place the power steering
pump along with piping on the body side.
25. Remove air conditioning compressor fixing bolts
from bracket and place the compressor along with
piping on the body side.
26. Remove four O2 sensor harness connectors (two
each bank) from exhaust front pipe.
27. Remove three exhaust pipe fixing nuts from each
bank.
28. Remove two exhaust pipe fixing nuts from each
exhaust pipe, then move exhaust pipe to rear side
of vehicle.
29. Remove flywheel dust covers.
30. Disconnect two heater hoses from engine.
31. Disconnect fuel hose from right side of
transmission.
CAUTION: Plug fuel pipe on engine side and fuel
hose from fuel tank.
32. Remove transmission assembly. Refer to
Transmission section in this manual.
33. Support the engine by engine hoist.
34. Remove two left side engine mount fixing bolts
from engine mount on chassis side.
35. Remove two right side engine mount fixing bolts
from engine mount on chassis side.
36. Remove engine assembly.
Installation
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side. Also take care that dowel positions are
different between the manual transmission and the
automatic
transmission.
Otherweise,
the
transmission may be damaged.

and fan bracket.
Torque : 10 Nm (1.0 kgm/7 lb ft) for fan and
clutch assembly.
9. Install air conditioner compressor to engine and
tighten to the specified torque.
10. Install power steering pump, tighten fixing bolt to
Torque :
M8 bolts : 25 Nm (2.5 kgm/18 lb ft)
M10 bolts : 43 Nm (4.4 kgm/32 lb ft)
012RS009
1. Install engine assembly. Tighten engine mount

fixing bolts to frame to the specified torque.
2. Reconnect fuel hose to fuel pipe on engine.
3. Install
transmission
assembly.
Refer
to
Transmission section in this manual.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two
(each bank) rear exhaust flange nuts then tighten
three stud nuts (each bank) between exhaust
manifold and exhaust pipe, finally tighten rear side
stud nuts to the specified torque.
850RW001
Legend
(3) Tensioner
(4) Generator
(7) Drive Belt
LTW36FSH000101
7. Reconnect O2 sensor connector.
12.
13.
14.
15.
16.
17.
18.
Install upper fan shroud.

Reconnect radiator upper and lower hoses.
Reconnect coolant reserve tank hose to radiator.
Reconnect generator harness connector.
Reconnect starter harness connector.
Reconnect bonding cable terminal on left bank
Reconnect bonding cable terminal on the back of
right dash panel.

19. Reconnect ground cable between engine and
chassis.
20. Reconnect harness connector to transmission and
install transmission harness bracket on engine left
side.
21. Reconnect three engine harness connectors.
22. Reconnect vacuum booster hose.
23. Reconnect canister vacuum hose.
25. Reconnect air duct.
26. Reconnect accelerator cable to throttle valve on
common chamber.
27. Install the ECM.
Tighten the four bolts.
Connect the two connectors.
Tighten the two ground cable bolts.
28. Install engine hood to the origine position.
Refer to installation procedure for Body section
in this manual.
Install accelerator control cable to accelerator
cable bracket.
Rotate the ratchet ring in direction an arrow 90
Confirm marking of outer cap must be upper
side.
Slider the lock in direction B.
Confirm ratchet ring is locked.
RTW46ASH000201
Legend
(1) Cable Bracket
(2) Ratchet ring
(3) Outer Cap
(4) Lock
(5) Paint Mark
(6) Arrow Mark
Cylinder Head
Cylinder Head and Associated Parts
011RW008
Legend
(1) Spark Plug
(2) Cylinder Head Bolt
(3) Camshaft Drive Gear Pulley Fixing Bolt
(4) Camshaft Drive Gear Pulley
(5) Camshaft Drive Gear Pulley
(6) Camshaft Bracket
(7) Camshaft Exhaust
(8) Camshaft Intake

(9) Retainer Fixing Bolt
(10) Retainer Assembly
(11) Tappet with Shim
(12) Split Collar
(13) Valve Spring and Spring Upper Seat
(14) Valve
Disassembly
NOTE:
During disassembly, be sure that the valve train
components are kept together and identified so
that they can be reinstalled in their original
locations.
Before removing the cylinder head from the engine
and before disassembling the valve mechanism,
perform a compression test and note the results.
1. Remove camshaft drive gear pulley fixing bolt (3),
then pulley (4).
2. Remove camshaft bracket fixing bolt (5), camshaft
bracket (6), then camshaft exhaust (7), and intake
side (8).
3. Remove tappet with shim (11).
4. Use the 5-8840-2446-0 valve spring compressor
and 5-8840-2547-0 valve spring compressor
adapter to remove the split collar (12), valve spring
with upper seat (13) and valve (14).
1. Cylinder head gasket and mating surfaces for

leaks, corrosion and blow-by. If the gasket has
failed, determine the cause.
-Insufficient torque on head bolts
-Improper installation
-Loose or warped cylinder head
-Missing dowel pins
-Warped case surface
2. Cylinder head for cracks, especially between valve
seats and in the exhaust ports.
3. Cylinder head deck for corrosion, sand particles in
head and porosity.
CAUTION:
Do not attempt to weld the cylinder head.
Replace it.
Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and
exhaust manifold mating surfaces for flatness.
These surfaces may be reconditioned by milling. If
the surfaces are out of flat" by more than
specification, the surface should be ground to
within specifications. Replace the head if it
requires machining beyond the repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362
in)
014RW042
5. Remove spark plug (1).

CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.
011RW019

5. Water jacket sealing plugs seating surfaces.
Reassembly
1. Install spark plug and tighten all the spark plugs to
specified torque.
1. Use 5-8840-2443-0 gear spring lever to turn
sub gear to right direction until the M5 bolt
aligns with the hole between camshaft driven
gear and sub gear.
2. Tighten the M5 bolt to a suitable torque to
prevent the sub gear from moving.
014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust
014RW041

three bolts to the specified torque.
specified torque.
for right bank, two dots for left bank) and
014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(2) Left Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin
014RW024
Legend

(1) Right Bank

(2) Left Bank
3. Tighten twenty bolts in numerical order on each
bank as shown in the illustration.
014RW031

pulley to the specified torque.
Valve Spring, Oil Controller, Valve, Valve Guide

Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts
014RW039
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Camshaft Bracket Fixing Bolts

Camshaft Assembly Inlet
Camshaft Assembly Exhaust
Shim
Tappet
Split Collar
(7)
(8)
(9)
(10)
(11)
(12)
Spring Upper Seat

Valve Spring
Oil Controller
Spring Lower Seat
Valve Guide
Valve
Disassembly
1.
2.
3.
4.
5.
Remove camshaft bracket fixing bolts (1).

Remove camshaft assembly (intake).
Remove camshaft assembly (Exhaust side).
Remove shim (4) and tappet (5).
Use the 5-8840-2446-0 valve spring compressor
and 5-8840-2547-0 valve spring compressor
adapter to remove split collar.
014RS004
2. Measure the valve spring squareness with a steel

square and replace the valve springs if the
measured value exceeds the specified limit.
Limit: 2 mm (0.079 in)
014RW042
6.
7.
8.
9.
Remove valve spring.

Remove valve.
Remove oil controller and spring lower seat.
Remove the valve guide using the 5-8840-2442-0
valve guide replacer.

Valve Spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is
evident.
1. Measure the free height of the springs. The
springs must be replaced if the free height is below
the specified limit.
Limit: 43.6 mm (1.717 in)
014RS005
3. Using a spring tester to compress the springs to

the installed height, measure the compressed
spring tension, and replace the springs if the
measured tension is below the specified limit.
At installed height: 35.0 mm (1.38 in)
Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)
LNW21BSH056701
Valve Guide
CAUTION: Take care not to damage the valve seat
contact surface, when removing carbon adhering to
the valve head. Carefully inspect the valve stem for
scratchs or abnormal wear. If these conditions are
present, the valve and the valve guide must be
replaced as a set.
1. Measure the valve stem diameter with a
micrometer. If the valve stem diameter is less than
the specified limit, the valve and the valve guide
must be replaced as a set.
Diameter of Valve Stem
Intake
Standard: 5.977 mm-5.959 mm
(0.2353 in-0.2346 in)
Limit: 5.90 mm (0.2323 in)
Exhaust
(0.2343 in-0.2350 in)
Limit: 5.90 mm (0.2323 in)
014RS007
2. Measure the inside diameter of the valve guide

with a micrometer. Subtract the measured outer
diameter of the valve stem from the measured
inner diameter of the valve guide. If the value
exceeds the specified limit, the valve and the valve
guide must be replaced as a set.
Inside Diameter of the Vale Guide
Inlet clearance
Standard : 0.023 mm-0.056 mm(0.0009
in-0.0002 in)
Limit : 0.20 mm (0.00787 in)
Exhaust clearance
Standard : 0.030 mm-0.063 mm(0.0012
in-0.0025 in)
Limit : 0.20 mm (0.00787 in)
Valve Guide Replacement
Valve Seat
1. Using Valve guide replacer: 5 ?8840 ?2442 ?0,

drive out the valve guide from the combustion
chamber side.
1. Measure the protrusion of the valve stem when a

new valve is installed in the cylinder head. If the
protrusion of the valve stem exceeds the limit,
replace the valve seat insert or the cylinder head
assembly.
Protrusion of valve stem
Intake
Limit: 39.47 mm (1.5539 in)
Exhaust
Limit: 39.45 mm (1.5531 in)
014RS008
2. Apply engine oil to the outside of the valve guide.

Using valve guide replacer 5 ?8840 ?2442 ?0,
drive in a new valve guide from the camshaft side,
and check the valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)
014RW047
014RW046
3. Check the clearance. If the clearance is less than

the specified value, ream the inside diameter of
valve guide. Using a sharp 6 mm reamer, ream the
valve guide to obtain the specified clearance.

2. Measure the valve seat contact width. Make the
necessary corrections if the seat contact surface is
damaged or rough or if the contact width wear
exceeds the limit.
Valve seat contact width
Limit: 1.7 mm (0.0669 in)
Valve Seat Insert Correction

1. Remove the carbon from the valve seat insert
surface.
2. Use a valve cutter to minimize scratches and other
rough areas. This will bring the contact width back
to the standard value. Remove only the scratches
and rough areas. Do not cut away too much. Take
care not to cut away unblemished areas of the
valve seat surface.
Valve seat angle degree: 90
014RS011
Contact Surface Angle on Valve Seat on

Valve
1. Measure contact surface angle on valve seat.
2. If the measured value exceeds the limit, replace
valve, valve guide and valve seat as a set.
Valve contact surface angle: 45
014RW059
3. Apply abrasive compound to the valve seat insert

surface.
4. Insert the valve into the valve guide.
5. Turn the valve while lapping it to fit the valve seat
insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in
contact with the entire circumference of the valve.
014RS012
014RS014
Reassembly
Valve Seat Insert Replacement

1. Arc weld the rod at several points. Be careful not
to damage the aluminum section.
2. Allow the rod to cool for a few minutes. This will
cause the valve seat to shrink.
3. Strike the rod and pull it out.
1. Install valve guide (1) to cylinder head. Apply

engine oil to the outside of the valve guide. Using
valve guide replacer 5-8840-2442-0, drive in a
new valve guide from the camshaft side.
2. Install oil controller (3) and spring lower seat (2).
Using oil controller replacer 5-8840-0623-0, drive
in a new oil controller.
014RS015
4. Carefully clean the valve seat press-fit section on

the cylinder head side.
5. Heat the press-fit section with steam or some
other means to cause expansion. Cool the valve
seat with dry ice or some other means.
6. Insert the press-fit section into the valve seat
horizontally.
Standard fitting interference: 0.14 mm-0.09 mm
(0.0055 in-0.0035 in)
7. After insertion, use a seat grinder to grind finish
the seating face. Carefully note the seating angle,
the contact width, and the depression.
8. Lap the valve and the seat.
014RW058
3. Install valve to valve guide. Before install valve

guide apply engine oil to the outside of the valve
stem.
4. Install valve spring to cylinder head. Attach the
valve spring to the lower spring seat. The painted
area of the valve spring should be facing
downward.
014RS020

5. Install lower valve spring seat, valve spring and
upper valve spring seat then put split collars on the
upper spring seat, using the 5-8840-2446-0 valve
spring compresor and 5-8840-2547-0 valve
spring compressor adapter to install the split
collars.
014RW081
Legend
(1) Cam
(2) Shim
(3) Tappet
014RW042
6. Install tappet with shim.

7. Install camshaft assembly.
Refer to installation procedure for Camshaft in
this manual.
Valve Clearance Adjustments

NOTE: To adjust valve clearance, apply engine oil to
the cam as well as to the adjusting shim (2) with the
cylinder head built on the cylinder block, give a few
turns to the camshaft by means of timing pulley
tightening bolt, and measure valve clearance when the
nose of cam is just opposite to maximum cam lift (1) as
shown in illustration below.
Valve Clearance Standard Value (cold)

Intake: 0.23 mm-0.33 mm
(0.0091 in-0.0130 in)
Exhaust: 0.25 mm-0.35 mm
(0.0098 in-0.0138 in)
Selection of Adjusting Shim

Shim to be selected = (Thickness of removed
shim) + (Valve clearance measurement - Standard
value) Based on the above formula, the best suited
shim should be selected from 41 sorts of shim
(differently thick at 0.02mm (0.0008 in) intervals from
2.40mm (0.0945 in) through 3.2mm (0.1260 in) thick).
Install the shim and check valve clearance.
Replacement of Shim
Let the cam push down the edge of tappet by using
5-8840-2444-0 valve clearance adjusting tool and
push out the shim with a flat blade screw driver as
shown in illustrations below.
014RW084
014RW082
014RW083
Camshaft
Camshaft and Associated Parts
014RW040
Legend
(1)
(2)
(3)
(4)
(5)
Camshaft Bracket Fixing Bolt

Camshaft Bracket
Camshaft Assembly Intake
Camshaft Assembly Exhaust
Pulley Fixing Bolt
Disassembly
1. Remove fixing bolt (5) for camshaft drive gear
pulley using 5-8840-2447&-ndash;0 universal
holder.
(6)
(7)
(8)
(9)
(10)
Camshaft Drive Gear Pulley

Retainer Fixing Bolt
Retainer
Camshaft Drive Gear
Oil Seal

1. Use a micrometer to measure the cam lobe height
and uneven wear. Replace the camshaft if either
the lobe height or the uneven wear exceeds the
specified limit.
Lobe height: 44.709 mm (1.7602 in)
Uneven wear: 0.05 mm (0.0020 in)
014RW060
2. Remove twenty fixing bolts from inlet and exhaust

camshaft bracket on one side bank, then camshaft
brackets (2).
014RW043
2. Use a micrometer to measure the diameter and

the uneven wear of the camshaft journals.
Replace the camshaft if the diameter or the
uneven wear exceeds the specified limit.
Journal Diameter
Standard: 25.972 mm-25.993 mm (1.0225
in-1.0233 in)
Limit: 25.8 mm (1.0157 in)
Uneven wear: 0.05 mm (0.0020 in)
014RW027
3. Remove camshaft assembly (3), (4).

4. Remove three fixing bolts (7) from camshaft drive
gear retainer (8), then camshaft drive gear
assembly.
014RS023

3. Place the camshaft on V-blocks.
Slowly rotate the camshaft and measure the
runout with a dial indicator.
Replace the camshaft if the runout exceeds the
specified limit.
Run out
Limit: 0.1 mm (0.0039 in)
2. Subtract the camshaft outside diameter from the

camshaft bracket housing inside diameter.
Oil Clearance
Standard : 0.027 mm-0.078 mm(0.0011 in-0.0031
in)
Limit : 0.11 mm (0.0043 in)
014RW037
014RW044
4. Measure the camshaft journal oil clearance.

1. Measure the camshaft bracket housing inside
diameter.
NOTE: Tighten camshaft bracket (2) to specified torque
before measuring the camshaft bracket inside diameter.
5. Replace the cylinder head and/or camshaft if the

measured oil clearance exceeds the specified
limit.
1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
2. Install camshaft assembly and camshaft
brackets (2), tighten twenty bolts (1) on one
side bank to the specified torque.
014RW031
014RW031

3. Measure the camshaft thrust clearance with a dial
indicator. Replace the camshaft and/or the cylinder
head if the camshaft thrust clearance exceeds the
specified limit.
Camshaft thrust Clearance
Standard : 0.03 mm-0.08 mm(0.0012 in -0.0031
in)
Limit : 0.12 mm (0.0047 mm)

specified torque.
for right bank, two dots for left bank) and
014RW035
Reassembly
014RW020

three bolts to specified torque.
1. Use 5-8840-2443-0 to turn sub gear to right
direction until the M5 bolt hole aligns between
camshaft driven gear and sub gear.
2. Tighten M5 bolt suitable torque for prevent
moving the sub gear.
014RW041
Legend
(1)
(2)
(3)
(4)
LI:
RI:
LE:
RE:
Intake Camshaft Timing Gear for Right Bank

Intake Camshaft Timing Gear for Left Bank
Exhaust Camshaft Timing Gear
Discerning Mark
Left Bank Intake
Right Bank Intake
Left Bank Exhaust
Right Bank Exhaust
014RW023
Legend
(1)
(2)
(3)
(4)
Right Bank Camshaft Drive Gear

Left Bank Camshaft Drive Gear
Timing Mark on Drive Gear
Dowel Pin
014RW024
Legend

(1) Right Bank

(2) Left Bank
3. Tighten twenty bolts in numerical order on one
side bank as shown in the illustration.
4. If the oil seal requires replacement, use the

5-8840-2445-0 to install the oil seal.
014RW034
014RW031

pulley to the specified torque using the
5-8840-2447-0 universal holder.
014RW060
Crankshaft
Crankshaft and Associated Parts
013RW009
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Cylinder Head Assembly

Crankcase with Oil Pan
Oil Pipe and O-Ring
Oil Strainer and O-Ring
Oil Pump Assembly
Cylinder Block Side Bolts
Oil Gallery
Disassembly
1. Remove cylinder head assembly (1). Refer to
Head" in this manual.
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Piston and Connecting Rod Assembly

Flywheel
Rear Oil Seal Retainer and Oil Seal
Main Bearing Cap
Crankshaft
Main Bearing Cap Fixing Bolts
Oil Gallery Fixing Bolts
2. Remove crankcase with oil pan (2). Refer to Oil

Pan and Crankcase" in this manual.
CAUTION: Take care not to damage or deform the
sealing flange surface of crankcase.

3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Remove oil pipe and O-ring (3).

Remove oil strainer and O-ring (4).
Remove oil pump assembly (5).
Remove crankcase side bolts (6).
Remove oil gallery (7).
Remove piston and connecting rod assembly (8).
Refer to Piston, Piston Ring and Connecting Rod"
in this manual.
Remove flywheel (9).
Remove rear oil seal retainer (10).
Remove main bearing cap (11).
Remove crankshaft (12).

1. Crankshaft
Set the dial indicator as shown in the illustration
and measure the crankshaft thrust clearance. If
the thrust clearance exceeds the specified limit,
replace the thrust bearings as a set.
Thrust Clearance
Standard : 0.06 mm-0.24 mm
(0.0024 in-0.0094 in)
Limit : 0.30 mm (0.0118 in)
015RS004
3. Remove the crankshaft. Remove the main

bearings.
4. Clean the upper and lower bearings as well as the
crankshaft main journal.
5. Check the bearings for damage or excessive wear.
The bearings must be replaced as a set if damage
or excessive wear is discovered during inspection.
6. Set the upper bearings and the thrust washers to
their original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8. Apply plastigage to the crankshaft journal unit as
NOTE: Do not set the plastigage on the oil hole.
015RS003
Main Bearing Clearance

1. Remove the bearing caps and measure the oil
clearance.
2. Remove the main bearing cap fixing bolts in the
sequence shown in the illustration.
Arrange the removed main bearing caps in the
cylinder number order.
Remove the main bearings.
015RS005
9. Install main bearing caps, oil gallery and crank

case bolts in the order shown, and tighten each
NOTE: Do not apply engine oil to the crank case side

(0.0007 in-0.0017 in)
Limit : 0.08 mm (0.0031 in)
bolts.
Main bearing cap bolts.
Oil gallery fixing bolts.
Torque:
1st step: 29 Nm (3.0 Kgm/21 lb ft)
2nd step 55 ~ 65
Crank case side bolts
Torque : 39 Nm (4.0 Kgm/29 lb ft)
NOTE: Do not allow the crankshaft to rotate.
015RS008
12. Clean the plastigage from the bearings and the

crankshaft.
Remove the crankshaft and the bearings.
Crankshaft (12) Inspection
015RS006
10. Remove the main bearing caps in the sequence

Inspect the surface of the crankshaft journal and crank

pins for excessive wear and damage. Inspect the oil
seal fitting surfaces for excessive wear and damage.
Inspect the oil ports for obstructions.

1. Carefully set the crankshaft on the V-blocks.
Slowly rotate the crankshaft and measure the
runout. If the crankshaft runout exceeds the
specified limit, the crankshaft must be replaced.
Runout : 0.04 mm (0.0016 in)
015RS004
11. Measure the plastigage width and determine the

oil clearance. If the oil clearance exceeds the
specified limit, replace the main bearings as a set
and/or replace the crankshaft.
015RS007

2. Measure the diameter and the uneven wear of
main journal and crank pin. If the crankshaft wear
exceeds the specified limit, crankshaft must be
replaced.
Main journal diameter : 63.918 mm-63.933 mm
(2.5165 in.-2.5170 in.)
Crank pin diameter : 53.922 mm-53.937 mm
(2.1229 in.-2.1235 in.)
Uneven wear limit : 0.005 mm (0.0002 in)
2. The crankshaft journal diameter grade mark (1)

are stamped on the No.1 crankshaft balancer (2)
as shown in the illustration.
015R200005
015RS009
3. Match the cylinder block journal grade marks and

the crankshaft journal grade marks in the table
below to determine the correct crankshaft bearing
size.
The size color code is painted to side of the
crankshaft bearings.
Crankshaft Bearing Selection

Crankshaft bearing selection is based on the measured
diameters of the crankshaft journals and the bearing
inserts.
1. The grade mark (1) for cylinder block journal are
stamped on the lower face of cylinder block as
RTW31BSH000601
RTW31BSH000701
Grade
Mark
1
Cylinder Block
Journal
68.994-69.000
(2.7163-2.7165)
68.987-68.993
(2.7160-2.7163)
68.980-68.986
(2.7157-2.7160)
Grade
Mark
Color Code
Blue
63.926-63.933
(2.5168-2.5170)
Brown
63.918-63.925
(2.5165-2.5167)
63.926-63.933
(2.5168-2.5170)
63.918-63.925
(2.5165-2.5167)
63.926-63.933
(2.5168-2.5170)
Crank Shaft Journal

Diameter
63.918-63.925
(2.5165-2.5167)
Oil Clearance
(Reference)
0.024-0.043
(0.0009-0.0017)
0.022-0.041
(0.0009-0.0016)
0.023-0.042
(0.0009-0.0016)
Green
0.021-0.040
(0.0008-0.0016)
0.022-0.041
(0.0009-0.0016)
Yellow
0.020-0.039
(0.0008-0.0015)
Reassembly
1. Crankshaft (12)
Install the main bearings to the cylinder block
and the main bearing caps.
Be sure that they are positioned correctly.
Apply new engine oil to the upper and lower
main bearing faces.
NOTE: Do not apply engine oil to the main bearing back
faces.
015RS013
2. Rear oil seal (10)

Remove the oil from the cylinder block and the
retainer mounting surface.
Apply sealant (TB-1207B or equivalent) to the
retainer mounting surface, following the pattern
The retainer must be installed within 5 minutes
after sealant application before the sealant
hardens.
015RS012
Legend
(1) Numver 1 and 4 main bearing upper and lower
(2) Numver 2 and 3 main bearing upper
(3) Numver 2 and 3 main bearing lower
Carefully mount the crankshaft.
Assemble the thrust washer to the No.3 bearing
journal. The oil grooves must face the
crankshaft.
015RW002
Legend
Apply engine oil to the oil seal lip.
Align the cylinder block dowel pin holes with the
rear retainer dowel pins.
Tighten the rear retainer fixing bolts. New bolts
should be used when installing rear retainer.
NOTE: Be very careful not to disengage the oil seal
garter spring during installation of the rear retainer.
If the seal was removed from retainer for
replacement, apply engine oil to the oil seal lip
and install the oil seal using 5-8840-2286-0 oil
seal installer.
015RS017
3. Flywheel (9)
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and
flywheel mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
4. Hold the crankshaft to prevent from rotating
then install the bolts in the order shown to the
specified torque.
NOTE: Do not reuse the bolt and do not apply oil or
thread lock to the bolt.
015RS018
015RW001
4. Piston and connecting rod assembly (8)

Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft
pins. Check to see that the piston ring end gaps
are correctly positioned.
015RS019
Legend
(1)
(2)
(3)
(4)
(5)
No.1 Compression Ring

Oil Ring Side Rail Upper
Oil Ring Side Rail Lower
Piston Front Mark
Insert the piston/connecting rod assemblies into

each cylinder with the piston ring compressor.
The front marks must be facing the front of the
engine.
Match the numbered caps with the numbers on
the connecting rods. Align the punched marks
on the connecting rods and caps.
Apply engine oil to the threads and seating
faces of the nuts.
Tighten the nuts.
After tightening the cap nuts, check to see that
the crankshaft rotates smoothly.
faces.
015RS020
5. Install oil gallery (7) and tighten the bolts in 2

steps, in the order shown.
1st step: 29 Nm (3.0 Kgm/22 lb ft)
2nd step: 55 ~ 65
051RS009
6. Cylinder block side bolts (6)

Tighten all the bolts to the specified torque in
the order shown.
NOTE: Do not apply engine oil to the crank case side
bolts.

Legend
(1) Portion Between Bolt Holes
(2) Bolt Hole Portion
11. Install cylinder head assembly, refer to Cylinder
head" in this manual.
012RS001
7. Install oil pump assembly (5), refer to Oil pump" in

this manual.
8. Install oil strainer and O-ring (4).
9. Install oil pipe and O-ring (3) and tighten the bolts.
10. Install crankcase with oil pan (2).
1. Completely remove all residual sealant,
lubricant and moisture from the sealing
surfaces. The surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB
1207C or its equivalent) to the contact surfaces
of the oil pan. There must be no gaps in the
bead.
3. The crankcase assembly must be installed
within 5 minutes after sealant application to
prevent premature hardening of the sealant.
4. Tighten the bolts and nuts to the specified
torque.
Torque : 10 Nm (1.0 Kgm/7 lb ft)
013RW010
Piston and Connecting Rod

Piston, Connecting Rod and Associate Parts
015RW019
Legend
(1)
(2)
(3)
(4)
(5)
(6)

Cylinder Head Gasket
Oil Pipe and O-Ring
Oil Gallery
Disassembly
1. Remove cylinder head assembly (1). Refer to
Cylinder Head Removal" in this manual.
(7)
(8)
(9)
(10)
(11)
(12)

Piston Ring
Piston Pin
Piston
Connecting Rod
Connecting Rod Cap
2. Remove cylinder head gasket (2).

3. Remove crankcase with oil pan (3). Refer to Oil
Pan and Crankcase" in this manual.
4. Remove oil pipe and O-ring (4).

5. Remove oil strainer and O-ring (5).
6. Remove oil gallery (6).
7. Remove connecting rod cap with connecting rod
lower bearing (12).
8. Remove piston and connecting rod assembly (7).
NOTE: Before removing piston and connecting rod
assembly, measure thrust clearance.
NOTE: Keep the parts removed from each cylinder

separate. All parts must be reinstalled in their original
positions. Heating the connecting rod will permit easy
removal of the piston pin.
015RX001
Legend
015RS031
Remove any ridge or carbon build up from the

top end of the cylinder.
9. Remove the piston rings (8) with a piston ring
expander. Arrange the removed piston rings in the
cylinder number order.
(1)
(2)
(3)
(4)
Press Ram
Piston
Connecting Rod
Piston Pin
11. Piston (10)

12. Connecting rod (11)

Pistons (10)
Carefully clean away all the carbon adhering to the
piston head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston for
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must
be replaced.
Piston Diameter
015RS022
10. Remove the piston pin (9) using 5-8840-0551-0

piston pin service set and piston support with a
press.
1. Measure the piston outside diameter with

micrometer at the piston grading position and a
right angle to the piston pin.
Piston grading position (from piston head)
Piston grading position : 43.0 mm (1.6929 in)
015RV014
The size mark (1) for piston outside diameter is

represented as shown in illustration below.
Outside Diameter
Size Mark A : 93.360 mm-93.370 mm
(3.6756 in-3.6760 in)
Size Mark B : 93.371 mm-93.380 mm
(3.6760 in-3.6764 in)
Size Mark C : 93.381 mm-93.390 mm
(3.6764 in-3.6768 in)
015RS025
Measure the cylinder bore inside diameter (refer

to Cylinder Block" in this manual).
012RS002
Piston Rings (8)

Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.
1. Ring end gap measurement
Insert the piston ring into the bore.
Push the ring by the piston, at a right angle to
the wall, into the point at which the cylinder
bore diameter is the smallest.
Measure the ring end gap.
Compression Ring
1st ring
(0.0118 in-0.0157 in)
Limit:
1.0 mm (0.0394 in)
2nd ring
(0.0177 in-0.0236 in)
Limit: 1.2 mm (0.0472 in)
Oil ring
(0.0059 in-0.0177 in)
Limit: 1.05 mm (0.0413 in)
015RS026
The No.1 compression ring must be set with

direction of origin.
No.2 compression ring: Positioning mark (1) is
painted as shown in the illustration.
015RS028
Piston Pin (9)

NOTE: Do not reuse the old piston pin.
1. Use a micrometer to measure the new piston pin
outside diameter in both directions at three
different positions.
2. Measure the inside diameter of the connecting rod
small end. If the fitting interference between the
small end and pin does not conform to the
specified value, the connecting rod must be
replaced.
(0.0009 in-0.0015 in)
015RS027
2. Measure the clearance between the piston ring

groove and the piston ring with a feeler gauge. If
the piston ring groove / piston ring clearance
exceeds the specified limit, the piston must be
replaced.
Compression Ring Clearance
(0.0006 in. -0.0015 in)
Limit : 0.15mm (0.0059 in)
015RS029

3. Insert the new pin into the piston and rotate it. If
the pin rotates smoothly with no backlash, the
clearance is normal. If there is backlash or
roughness, measure the clearance. If the
clearance exceeds the specified limit, the piston
must be replaced.
Clearance
(0.0004 in. -0.0007 in)
Limit : 0.040 mm (0.0016 in)
Connecting Rods (11)

1. Check the connecting rod alignment If either the
bend or the twist exceeds the specified limit, the
connecting rod must be replaced.
Bend per 100 mm (3.937 in)
Limit: 0.15 (0.0059)
Twist per 100 mm (3.937 in)
Limit: 0.20 (0.0078)
015RS031
3. Measure the oil clearance between the connecting

rod and the crankshaft.
1. Remove the connecting rod cap nuts and the
rod caps (12).
Arrange the removed rod caps in the cylinder
number order.
2. Clean the rod bearings and the crankshaft pins.
3. Carefully check the rod bearings. If even one
bearing is found to be damaged or badly worn,
the entire bearing assembly must be replaced
as a set. Reinstall the bearings in their original
positions. Apply plastigage to the crank pin.
015RS030
2. Measure the connecting rod thrust clearance. Use

a feeler gauge to measure the thrust clearance at
the large end of the connecting rod If the clearance
exceeds the specified limit, the connecting rod
must be replaced.
(0.0063 in. -0.0138 in)
Limit : 0.40 mm (0.0157 in)
015RS032
4. Reinstall the rod caps (12) to their original

positions.
Tighten the rod cap nuts.

NOTE: Do not allow the crankshaft to rotate.
5. Remove the rod caps.
6. Measure the width of the plastigage and determine
the oil clearance. If the oil clearance exceeds the
limit, replace the rod bearing as a set.
(0.0007 in-0.0017 in)
Limit : 0.08 mm (0.003 in)
7. Clean the plastigage from the bearings and the

crankshaft pins.
Con-rod Bearing Selection

Select and install the new connecting rod bearings,
paying close attention to the connecting rod big end
diameter size mark (1).
NOTE: Take care not to confuse the alignment mark (2)
and the size mark (1) during the installation procedure.
015RS008
015RS034
1 Size Mark
A
B
C
Big end Bore

Diameter
56.994-57.000
(2.2439-2.2441)
56.988-56.994
(2.2436-2.2439)
56.982-56.988
(2.2434-2.2436)
Crankshaft Pin
Diameter
53.922-53.937
(2.1229-2.1235)
Reassembly
1. Install connecting rod
2. Install piston
3. Install piston pin
Apply a thin coat of engine oil to the piston pin.
Try to insert the piston pin into the piston pin
hole with normal finger pressure.
NOTE: When changing piston / connecting rod
combinations, do not change the piston / piston pin
combination and do not reuse the old piston pin.
Attach the piston to the connecting rod with the
piston front mark and the connecting rod front
mark on the same side.
Connecting Rod
Color of
Bearing Thickness
Size Mark
(Reference)
1.512-1.516
(0.0595-0.0597)
1.508-1.512
(0.0594-0.0595)
1.504-1.508
(0.0592-0.0594)
Yellow
Green
Pink
Oil Clearance
(Reference)
0.025-0.054
(0.0010-0.0021)
0.027-0.056
(0.0011-0.0022)
0.029-0.058
(0.0011-0.0023)
RUW36ASH000501
With 5-8840-0551-0 Piston pin service set

and a press, press fit the piston pin.
NOTE: Heat the connecting rod small end to a suitable
temperature to ensure smooth installation.
015RS027
Install piston rings in the following sequence.

1. Oil ring
1. Expander ring
2. Upper side rail
3. Lower side rail
The 2nd compression ring must be set with the
T2 mark facing up.
The compression ring must be set with
direction of origin.
After installation, apply engine oil to the entire
circumference of the piston rings. Check to see
that all the rings rotate smoothly.
015RX001
Legend
(1)
(2)
(3)
(4)
Press Ram
Piston
Connecting Rod
Piston Pin
4. Install piston ring with the piston ring expander.

The No.2 compression ring must be set with the
T2 mark (1) facing up.
015RS038

5. Install piston and connecting rod assembly.
Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces
and nuts.
Tighten the connecting rod cap nuts
faces.
6. Oil gallery, refer to Crankshaft and main bearing"
in this manual.
7. Oil strainer and O-ring.
8. Oil pipe and O-ring.
9. Install crankcase with oil pan, refer to Oil pan and
Crankcase" in this manual.
10. Install cylinder head gasket.
11. Install Cylinder head assembly.
Refer to Cylinder head" in this manual.
Cylinder Block
Cylinder Block and Associated Parts
012RW010
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)

Oil Pipe and O-Ring
Oil Pump Assembly
Cylinder Block Side Bolts
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Oil Gallery
Flywheel
Rear Oil Seal Retainer Assembly
Main Bearing Cap
Crankshaft
Cylinder Block
Disassembly
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Remove cylinder head assembly.

Remove cylinder head gasket.
Remove crankcase with oil pan.
Remove oil pipe and O-ring.
Remove oil strainer and O-ring.
Remove oil pump assembly.
Remove crankcase side bolts.
Remove oil gallery.
Remove piston and connecting rod assembly.
Remove flywheel.
Remove rear oil seal retainer assembly.
Remove main bearing cap.
Remove crankshaft.
Remove cylinder block.

1. Remove the cylinder head gasket and any other
material adhering to the upper surface of the
cylinder block. Be very careful not to allow any
material to accidentally drop into the cylinder block.
Be very careful not to scratch the cylinder block.
2. Carefully remove the oil pump, rear oil seal
retainer, and crankcase assembly installation
surface seal.
3. Wipe the cylinder block clean.
4. Visually inspect the cylinder block. If necessary,
use a flaw detector to perform a dye penetrate and
hydraulic (or air pressure) test. If cracking or other
damage is discovered, the cylinder block must
either be repaired or replaced.
Flatness
1. Using a straight-edge and feeler gauge, check
that the upper surface of the cylinder block is not
warped.
NOTE: Be very careful not to allow any material to
accidentally drop into the upper surface of the cylinder
block. Be very careful not to scratch the upper surface
of the cylinder block.
2. The cylinder block must be reground or replaced if
the warpage exceeds the limit.
Warpage
Limit : 0.15 mm (0.0059 in)
Maximum repairable limit: 0.15 mm (0.0059 in)
012RS004
Cylinder Bore
Use a cylinder gauge to measure the cylinder bore
diameter in both the axial and thrust directions. Each
measurement should be made at six points.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
Cylinder Bore Inside Diameter
Limit : 93.530 mm (3.6823 in)
If the measurement exceed the specified limit, the
cylinder block must be replaced.
Diameter
Grade A : 93.400 mm-93.410 mm
(3.6772 in-3.6776 in)
Grade B : 93.411 mm-93.420 mm
(3.6776 in-3.6779 in)
Grade C : 93.421 mm-93.430 mm
(3.6780 in-3.6783 in)
012RS005
NOTE: For information on piston diameter, please refer

to the section "Inspection of the Piston and Connecting
Rod Assembly" in this manual.
The "Grade" mark (1) is stamped at the
position illustrated.
015RS012
Legend
(1) Number 1 and 4 main bearing upper and lower.
(2) Number 2 and 3 main bearing upper.
(3) Number 2 and 3 main bearing lower.
Carefully mount the crankshaft.
Assemble the thrust washer to the No. 3
bearing journal. The oil grooves must face the
crankshaft.
012RS006
Reassembly
1. Install cylinder block.
2. Install crankshaft.
Install the main bearings to the cylinder block
and the main bearing caps.
Be sure that they are positioned correctly.
Apply new engine oil to the upper and lower
main bearing faces.
faces.
015RS013
3. Install rear oil seal retainer.

Remove oil on cylinder block and retainer fitting
surface.
Apply sealant (TB1207B or equivalent) to
retainer fitting surface as shown in illustration.
The oil seal retainer must be installed within 5
minutes after sealant application before the
sealant hardens.

NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
015RW002
Legend
015RS018
Apply engine oil to oil seal lip and align a dowel

pin hole in the cylinder block with that in the
retainer.
Tighten retainer fixing bolts to the specified
torque.
Torque: 25 Nm (2.5 kgm/18.4 lb ft)
5. Install piston and connecting rod assembly.

Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft
pins.
faces.
Check to see that the piston ring end gaps are
correctly positioned.
015RW001
4. Install flywheel
1. Thoroughly clean and remove the oil from the
threads of crankshaft.
2. Remove the oil from the crankshaft and
flywheel mounting faces.
3. Mount the flywheel on the crankshaft and then
install the washer.
4. Holding the crankshaft stationary, tighten the
flywheel bolts in the order shown.
015RS019
Legend
(1)
(2)
(3)
(4)
(5)

Oil Ring Side Rail Upper
Oil Ring Side Rail Lower
Piston Front Mark

Insert the piston/connecting rod assemblies into
each cylinder with the piston ring compressor.
The front marks (1) must be facing the front of
the engine.
012RW005
015RS020
6. Install oil gallery and tighten the bolts in 2 steps in

the order shown.
1st step : 29 Nm (3.0 kgm/22 lb ft)
2nd step : 55 ~ 65°
012RS007
7. Install cylinder block side bolts (1) and tighten

crankcase bolts in sequence shown in the
illustration.
8. Install oil pump assembly. Refer to Oil Pump" in

this manual.
9. Install oil strainer and O-ring.
10. Install oil pipe and O-ring.
11. Install crankcase with oil pan.
1. Completely remove all residual sealant,
lubricant and moisture from the sealing
surfaces. The surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB1207C or its equivalent) to the contact surfaces
of the crankcase. There must be no gaps in the
bead.
3. The oil pan must be installed within 5 minutes
after sealant application to prevent premature

4. Tighten the bolts and nuts to the specified
torque.
013RW010
Legend
(1) Portion Between Both Holes
(2) Bolt Hole Portions
12. Install cylinder head gasket.
13. Install cylinder head assembly. Refer to Cylinder
Head" in this manual.
Main Data and Specification

General Specification
Item
Engine type, number of cylinders and arrangement
Form of combustion chamber
Specifications
Water cooled, four cycle V6
Pent-roof type
Valve mechanism
4-Cams, 4-Valves, DOHC Gear & Belt Drive
Cylinder liner type
Casted in cylinder block

Cylinder bore x stroke
3494 cc
93.4mm x 85.0mm
(3.6772 in 3.3465 in)
Compression ratio
Compression pressure at 300rpm
Engine idling speed rpm
Valve clearance
8.6
2
1.37 MPa (14.0 Kg/cm )

Non adjustable (750)
Intake: 0.28 mm (0.11 in)
Exhaust: 0.30mm (0.12 in)
Oil capacity
Ignition timing
Spark plug
Plug gap
5.3 liters
Non adjustable (12 BTDC at idle rpm)
PK16PR11, RC10PYP4, K16PR-P11
1.0 mm 1.1 mm (0.0394 in 0.0433 in)
Ignition coil, Spark plug, Crankshaft angle sensor and Under cover
Nm (kgm/ lb ft)
RTW460LF000101

Cylinder head cover, Cylinder head, Camshaft bracket, Common chamber, ECM
Nm (kgm/ lb ft)
RTW46ALF000601

Crankshaft main bearing, Flywheel, Crankcase, Oil pan, Timing belt tensioner, Timing pulley, timing belt
cover, Oil pump, Oil gallery, Oil strainer and water pump
Nm (kgm/ lb ft)
RTW46ALF000701

Connecting rod and Water pump
Nm (kgm/ lb ft)
E06RW042

Engine mount
Nm (kgm/ lb ft)
RTW36ALF000101
Special Tool
ILLUSTRATION
PART NO.
PART NAME
ILLUSTRATION
PART NO.
PART NAME
5-8840-0011-0
(J-21687-02)
Remover; tie rod end
5-8840-2445-0
(J-42985)
Installer; Camshaft
oil seal
5-8840-0203-0
(J-36390)
Wrench; Oil filter (79f)
5-8840-2545-0
(J-39206)
Installer; Pilot bearing
5-8840-2446-0
(J-8062)
Compressor;
Valve spring (1)
5-8840-2547-0
(J-42898)
Adapter; Compressor,
Valve spring (2)
5-8840-0133-0
(J-8614-01)
Holder; Crankshaft
5-8840-0623-0
(J-37281)
Remover; Oil controller
5-8840-2153-0
(J-37228)
Seal cutter
5-8840-0624-0
(J-38537)
Installer; Oil controller
5-8840-2286-0
(J-39201)
Installer; Real oil seal
5-8840-2005-0
(J-29107)
Universal pitman arm
remover
5-8840-2287-0
(J-39202)
Installer; Oil pump
oil seal
ILLUSTRATION
PART NO.
PART NAME
9-8511-4209-0
(J-24239-1)
Cylinder head bolt wrench
5-8840-2442-0
(J-42899)
Replacer; Valve guide (1,2)
5-8840-2548-0
(J-42687)
Installer; Valve guide (1)
5-8840-2549-0
(J-37985-1)
Remover; Valve guide (2)
5-8840-2444-0
(J-42689)
Adjusting Tool; Valve
clearance
5-8840-2443-0
(J-42686)
Lever; Gear spring
5-8840-2447-1
(J-43041)
Holder; Universal
ENGINE COOLING (6VE1 3.5L) 6B-1
ENGINE
ENGINE COOLING (6VE1 3.5L)
CONTENTS
General Description ...........................................
Diagnosis ...........................................................
Draining and Refilling Cooling System ..............
Water Pump ......................................................
Water Pump and Associated Parts ................
Removal .........................................................
Inspection .......................................................
Installation.......................................................
Thermostat ........................................................
Thermostat and Associated Parts ..................
Removal .........................................................
Inspection .......................................................
6B1
6B2
6B5
6B6
6B7
6B7
6B7
6B7
6B7
6B9
6B9
6B9
6B9
Installation ......................................................
Radiator .............................................................
Radiator and Associated Parts .......................
Removal .........................................................
Inspection .......................................................
Installation ......................................................
Drive Belt and Cooling Fan................................
Drive Belt and Associated Parts .....................
Inspection .......................................................
Installation ......................................................
Main Data and Specifications ............................
Special Tool....................................................
6B9
6B10
6B10
6B11
6B11
6B12
6B15
6B15
6B15
6B15
6B16
6B18
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.

parts and systems.
6B-2 ENGINE COOLING (6VE1 3.5L)
General Description
030RW001
Legend
(7) Cylinder Head
(1) Water Pump
(8) Right Bank
(2) Thermostat
(9) Throttle Body
(3) Radiator
(10) Cylinder Block
(4) Reserve Tank
(11) Cylinder Head
(5) Cooling Fan
(12) Left Bank
(6) Cylinder Block
(13) Heater
The engine cooling system consists of the radiator, the

water pump, the cooling fan, and the thermostat.
To quickly increase cold engine coolant temperature for
smooth engine operation, the coolant is circulated by
the water pump and thermostat through the bypass
hose and back to the cylinder body.
The coolant does not circulate through the radiator.
When the coolant temperature reaches specified value,
the thermostat will begin to open and a gradually
increasing amount of coolant will circulate through the
radiator.
The thermostat will be fully open when the coolant
temperature reaches specified value. All of the coolant
is now circulating through the radiator for effective
engine cooling.
Water Pump
The EC pump is a centrifugal impeller type and is driven
by a timing belt.
110RS001
Antifreeze Solution
Calculating mixing ratio
030RS001
Thermostat
The thermostat is a wax pellet type with a air hole(1)
and is installed in the thermostat housing.
F06RW005
031RW002
Radiator
The radiator is a tube type with corrugated fins. In order
to raise the boiling point of the coolant, the radiator is
fitted with a cap in which the valve is operated at 93.3 ~
122.7 kPa (13.5 ~ 17.8 psi) pressure. (No oil cooler
provided for M/T)

NOTE: Antifreeze solution + Water = Total cooling
system capacity.
Total Cooling System Capacity
M/T 12.3Lit (13.0Us qt)
A/T 12.2Lit (12.9Us qt)
See section 0B MAINTENACE AND LUBRICATION.
Mixing ratio
NOTE: To maintain the corrosion resistance of the
aluminum radiator, water and antifreeze must be
combined in a 1:1 solution (50% antifreeze and 50%
water).
RTW46BSH000201
Diagnosis
Symptom
Engine overheating
Possible Cause
Action
Replenish
Thermo meter unit faulty
Replace
Faulty thermostat
Replace
Faulty Engine Coolant temperature Repair or replace

sensor
Clogged radiator
Clean or replace
Faulty radiator cap
Replace
Low engine oil level or use of Replenish or change oil

improper engine oil

faulty parts
Open or shorted Throttle Position Repair or replace

sensor circuit
Replace
Engine overcooling
Faulty thermostat
Replace
Engine slow to warmup
Faulty thermostat
Replace
Thermo unit faulty
Replace

Tighten radiator cap and start the engine. After
idling for 2 to 3 minutes, stop the engine and reopen
radiator cap. If the water level is lower, replenish.
Draining and Refilling Cooling

System
Before draining the cooling system, inspect the system
and perform any necessary service to ensure that it is
clean, does not leak and is in proper working order.
The engine coolant (EC) level should be between the
MIN" and MAX" lines of reserve tank when the engine
is cold. If low, check for leakage and add EC up to the
MAX" line.
There should not be any excessive deposit of rust or
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
1. Completely drain the cooling system by opening the
drain plug at the bottom of the radiator.

temperature, be sure not to loosen or remove the
radiator cap. Otherwise you might get scalded by
not vapor or boiling water. To open the radiator
cap, put a piece of thick cloth on the cap and
loosen the cap slowly to reduce the pressure when
the coolant has become cooler.
After tightening radiator cap, warm up the engine at
about 2000 rpm. Set heater adjustment to the
highest temperature position, and let the coolant
circulate also into heater water system.
Check to see the thermostat has opened through
the needle position of water thermometer, conduct a
5minute idling again and stop the engine.
When the engine has been cooled, check filler neck
cooling system and reservoir tank hose for leakage.
Pour coolant into the reservoir tank up to MAX"
line.
P1010064

WARNING: To avoid the danger of being burned, do
not remove the cap while the engine and radiator
are still hot. Scalding fluid and steam can be blown
out under pressure.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a
solution that is 50 percent antifreeze.
Procedure for filling with coolant (in case of full change)
Make sure that the engine is cool.
Open radiator cap pour coolant up to filler neck.
Pour coolant into reservoir tank up to MAX" line.
Water Pump
Water Pump and Associated Parts
030RS002
Legend
(1) Timing Belt
(3) Water Pump Assembly
(2) Idle Pulley
(4) Gasket
Removal
2. Drain coolant.
3. Radiator hose (on inlet pipe side).
4. Remove timing belt. Refer to Timing Belt" in this
manual.
5. Remove Idle pulley.
6. Remove water pump assembly.
7. Remove gasket.
Inspection
Make necessary repair and parts replacement if
extreme wear or damage is found during inspection.
Should any of the following problems occur, the entire
water pump assembly must be replaced:
Crack in the water pump body
EC leakage from the seal unit
Play or abnormal noise in the bearing
Cracks or corrosion in the impeller.
Installation
1. Install gasket, clean the mating surface of gasket
before installation.
2. Install water pump assembly and tighten bolts to the
specified torque.
Tightening order
The tightening order are in the illustrate.

NOTE: To prevent the oil leakage, apply the LOCTITE
262 or an equivalent, to the arrow marked fixing bolt
thread.
030RW008
3. Idle pulley
Install idle pulley and tighten bolt to the specified
torque.
4. Timing belt
Install timing belt. Refer to timing belt installation
step in Timing Belt" in this manual.
5. Connect radiator inlet hose and replenish EC.
Thermostat
Thermostat and Associated Parts
031RS003
031RW001
Legend
(1) Thermostat Housing
(2) Thermostat
(3) Outlet Pipe
Confirm the temperature when the valve first begins to

open.
Valve opening temperature 74.5C ~ 78.5C
(166.1F ~ 173.3F)
Confirm the temperature when the valve is fully opened.
Removal
2. Drain engine coolant from the radiator and engine.
3. Disconnect radiator hose from the inlet pipe.
4. Remove thermostat housing.
5. Remove thermostat(2).
Inspection
Suspend the thermostat in a waterfilled container
using thin wire. Place a thermometer next to the
thermostat.
Do not directly heat the thermostat.
Gradually increase the water temperature. Stir the water
so that the entire water is same temperature.
Valve full open temperature and lift More than

8.5mm (0.33 in) at 90C (194F)
Make necessary repair and parts replacement if
extreme wear or damage is found during inspection.
Installation
1. Install thermostat into the outlet pipe(4) making sure
that the air hole is in the up position.
2. Install thermostat housing and tighten bolts to the
specified torque.
3. Installation rubber hose.
4. Replenish engine coolant (EC).
5. Start engine and check for EC leakage.
Radiator
RTW36BLF000101
Legend
(5) Bracket
(1) Radiator Hose
(6) Reserve Tank Hose
(2) Drain Plug
(7) Reserve Tank
(3) Fan Guide, Lower
(8) Radiator Cap
(4) Fan Guide
(9) Radiator Assembly
Removal
2. Loosen a drain plug to drain EC.
3. Disconnect oil cooler hose on automatic
transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose
from the engine.
110RW004
P1010064
5. Remove fan guide(1), clips(2) on both sides and

the bottom lock, then remove lower fan guide(3)
with fan shroud(4).
8. Lift up and remove the radiator assembly with

hose, taking care not to damage the radiator core
with a fan blade.
Inspection
Radiator Cap
Measure the valve opening pressure of the pressurizing
valve with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside
the standard range.
Valve opening pressure kPa (psi) 93.3
(13.5 ~17.8)
~ 122.7

Adapter: 5884026030
Check the condition of the vacuum valve in the center
of the valve seat side of the cap. If considerable rust or
dirt is found, or if the valve seat cannot be moved by
hand, clean or replace the cap.
RTW46BSH000101
6. Disconnect the reserve tank hose(6) from radiator.

7. Remove bracket(5).

Valve opening vacuum kPa (psi) 1.96
~ 0.71)
~ 4.91 (0.28

Adapter: 5884026030
110RS005
110RS006
Radiator Core
1. A bent fin may result in reduced ventilation and
overheating may occur. All bent fins must be
straightened. Pay close attention to the base of the
fin when it is being straightened.
Installation
1. Install radiator assembly (9) with hose, taking care
not to damage the radiator core with a fan blade.
2. Support the radiator upper tank with the bracket (5)
and secure the radiator.
3. Connect reserve tank hose (6).
4. Install lower fan guide (3).

Thoroughly wash the inside of the radiator and the
engine coolant passages with cold water and mild
detergent. Remove all signs of scale and rust.

Use a radiator cap tester to force air into the radiator
through the filler neck at the specified pressure of 196
kPa (28.5 psi) with a cap tester:
5. Connect radiator inlet hose and outlet hose (1) to

the engine.

6. Connect oil cooler hose to automatic transmission.
Engine coolant change

1. To change engine coolant, make sure that the
engine is cool.
hot vapor or boiling water. To open the radiator
2. Open radiator cap and drain the cooling system by
loosening the drain valve on the radiator and on the
cylinder body.
NOTE: For best result it is suggested that the engine
cooling system be flushed at least once a year. It is
advisable to flash the interior of the cooling system
including the radiator before using anti-freeze
(ethylene-glycol based).
Replace damaged rubber hoses as the engine
anti-freeze coolant is liable to leak out even minor
cracks.
Isuzu recommends to use Isuzu genuine anti-freeze
(ethylen-glycol based) or equivalent, for the cooling
system and not add any inhibitors or additives.
RTW36BSH000101

8. Pour engine coolant up to filler neck of radiator, and
up to MAX mark of reserve tank.
CAUTION: A failure to correctly fill the engine

cooling system in changing or topping up coolant
may sometimes cause the coolant to overflow from
the filler neck even before the engine and radiator
are completely full.
If the engine runs under this condition, shortage of
coolant may possibly result in engine overheating.
To avoid such trouble, the following precautions
should be taken in filling the system.
3. To refill engine coolant, pour coolant up to filler neck
using a filling hose which is smaller in outside
diameter of the filler neck. Otherwise air between
the filler neck and the filling hose will block entry,
preventing the system from completely filling up.
4. Keep a filling rate of 9 liter/min. or less. Filling over
this maximum rate may force air inside the engine
and radiator.
And also, the coolant overflow will increase, making
it difficult to determine whether or not the system is
completely full.
RTW36BSH000101
Important operation (in case of 100% engine

coolant change) procedure for filling with engine
coolant.
5. After filling the system to the full, pull out the filling
hose and check to see if air trapped in the system is
disclodged and the coolant level goes down. Should
the coolant level go down, repeat topping-up until
there is no more drop in the coolant level.

6. After directly filling the radiator, fill the reservoir to
the maximum level.
7. Install and tighten radiator cap and start the engine.
After idling for 2 to 3 minutes, stop the engine and
reopen radiator cap. If the water level is lower,
replenish.
hot vapor or boiling water. To open the radiator
8. After tightening radiator cap, warm up the engine at
about 2,000 rpm.
Set heater adjustment to the highest temperature
position, and let the coolant circulate also into
heater water system.
9. Check to see the thermostat has opened through
the needle position of water thermometer, conduct a
5-minute idling again and stop the engine.
10. When the engine has been cooled, check filler neck
coolant system and reservoir tank hose for leakage.
11. Fill the coolant into the reservoir tank up to MAX"
line.
Drive Belt and Cooling Fan

Drive Belt and Associated Parts
015RW005
Legend
(4) Water Pump and Cooling Fan Pulley
(5) Idle Pulley
(2) Generator
(6) Tension Pulley
(3) Power Steering Pump
(7) Drive Belt
The drive belt adjustment is not required as automatic

drive belt tensioner is equipped.
Inspection
Check drive belt for wear or damage, and replace with a
new one as necessary.
Installation
Install cooling fan assembly and tighten bolts/nuts to the
specified torque.
Torque : 25 Nm (2.5 kgm/18 lb ft) for fan pulley
and fan bracket.
Torque : 10 Nm (1.0 kgm/7 lb ft) for fan and
clutch assembly.
NOTE: Fan belts for 6VE1 Gasoline Engine mounted on
98MY (UX) have been brought into one. As a result, the
rotating direction of a fan belt is opposite to the direction
of cooling fan for 92 to 97MY 6VD1 with no
interchangeability.
Therefore, incorrect installation of a fan may cause the
air for cooling to flow in the opposite direction, this
resulting in the poor performance of the air-conditioner
and a rise temperature in engine cooling water.

M/T
Cooling system
Radiator
A/T
Engine coolant forced circulation

Tube type corrugated
81.4 kw (70.004 kcal/h)
Heat radiation area
9.42m (0.875ft )
Radiator front area
0.28m (0.026ft )
Radiator dry weight

Engine coolant pump
Delivery
5.0kg (11.0lb)
5.2kg (11.4lb)
93.3 ~ 122.7kpa (13.5 ~ 17.8psi)

Centrifugal impeller type
300 (317) or more
Pump speed
5000 50 rpm
Thermostat
Wax pellet type with air hole
Valve opening temperature

74.5 ~ 78.5C (166.1 ~ 173.3F)

12.3lit (13.0U.S qt)
12.2lit (12.9U.S qt)
Nm (kgm/ lb ft)
E06RW041
Special Tools
ILLUSTRATION
PART NO.
PART NAME
588402770
(J2446001)
Tester; radiator cap
5-8840-2603-0
(J33984A)
Adapter; radiator cap
ENGINE FUEL (6VE1 3.5L) 6C-1
ENGINE
ENGINE FUEL (6VE1 3.5L)
CONTENTS
Fuel Metering ..........................................................
Fuel Filter.................................................................
Removal ...............................................................
Inspection.............................................................
Installation ............................................................
Inspection.............................................................
In-Tank Fuel Filter...............................................
Fuel Pump Flow Test .........................................
Fuel Pump ...............................................................
Fuel Pump and Associated Parts .....................
Removal ...............................................................
Installation ............................................................
Fuel Tube / Quick - Connector Fittings ...............
Precautions ..........................................................
Cautions During Work........................................
6C-1
6C-2
6C-3
6C-4
6C-4
6C-4
6C-4
6C-4
6C-4
6C-4
6C-6
6C-6
6C-6
6C-7
6C-8
6C-8
6C-8
Removal................................................................
Reuse of Quick-Connector.................................
Assembling Advice ..............................................
Fuel Pump Relay.....................................................
General Description ............................................
Fuel Tank .................................................................
Fuel Tank and Associated Parts .......................
Removal................................................................
Installation.............................................................
Filler Neck ................................................................
Removal................................................................
Installation.............................................................
Fuel Gauge Unit ......................................................
Removal and Installation ....................................
Fuel Filler Cap .........................................................
General Description ............................................
Inspection .............................................................
Main Data and Specifications................................
Special Tool..........................................................
6C-8
6C-9
6C-9
6C-10
6C-10
6C-11
6C-11
6C-11
6C-12
6C-13
6C-13
6C-13
6C-13
6C-13
6C-14
6C-14
6C-14
6C-15
6C-16
Service Precaution
When working on the fuel system, there are several
things to keep in mind:
Any time the fuel system is being worked on,

disconnect the negative battery cable except
for those tests where battery voltage is
required.
Always keep a dry chemical (Class B) fire
extinguisher near the work area.
Replace all pipes with the same pipe and
fittings that were removed.
Clean and inspect O" rings. Replace if
required.
Always relieve the line pressure before
servicing any fuel system components.
Do not attempt repairs on the fuel system until
you have read the instructions and checked
the pictures relating to that repair.
All gasoline engines are designed to use only

unleaded gasoline. Unleaded gasoline must be
used for proper emission control system operation.
Its use will also minimize spark plug fouling and
extend engine oil life. Using leaded gasoline can
damage the emission control system and could
result in loss of emission warranty coverage.
All cars are equipped with an Evaporative Emission
Control System. The purpose of the system is to
minimize the escape of fuel vapors to the
atmosphere.
6C-2 ENGINE FUEL (6VE1 3.5L)
General Description
RTW36CLF000301
Legend
(1) Fuel Filler Cap
(8) Fuel Rail Left

(9) Intake Air Port Left Bank
(2) Fuel Tank
(10) Fuel Pressure Control Valve
(3) Rollover Valve
(11) Common Chamber
(4) Fuel Pump and Sender Assembly
(12) Duty Solenoid Valve
(5) Fuel Filter
(13) Throttle Valve
(6) Fuel Rail Right
(14) Canister
(7) Intake Air Port Right Bank
(15) Evapo Control Valve
Fuel Metering
The Engine Control Module (ECM) is in complete
control of this fuel delivery system during normal driving
conditions.
The intake manifold function, like that of a diesel, is
used only to let air into the engine. The fuel is injected
by separate injectors that are mounted over the intake
manifold.
The Barometric Pressure (BARO) sensor measures the
changes in the barometric pressure which result from
engine load and speed changes, which the BARO
sensor converts to a voltage output.
This sensor generates the voltage to change
corresponding to the flow of the air drawn into the
engine.
The changing voltage is transformed into an electric
signal and provided to the ECM.
With receipt of the signals sent from the BARO sensor,
Intake Air Temperature sensor and others, the ECM
determines an appropriate fuel injection pulse width
feeding such information to the fuel injector valves to
effect an appropriate air/fuel ratio.
The Multiport Fuel Injection system utilizes an injection
system where the injectors turn on at every crankshaft
revolution. The ECM controls the injector on time so
that the correct amount of fuel is metered depending on
driving conditions.
Two interchangeable O" rings are used on the injector
that must be replaced when the injectors are removed.
The fuel rail is attached to the top of the intake manifold
and supplies fuel to all the injectors.
Fuel is recirculated through the rail continually while the
engine is running. This removes air and vapors from the
fuel as well as keeping the fuel cool during hot weather
operation.
The fuel pressure control valve that is mounted on the
fuel rail maintains a pressure differential across the
injectors under all operating conditions. It is
accomplished by controlling the amount of fuel that is
recirculated back to the fuel tank based on engine
demand.
See Section Driveability and Emission" for more
information and diagnosis.
Fuel Filter
Removal
NOTE: Verify to hang holder hook to fuel filter.

completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system
1. Disconnect the battery ground cable.
NOTE: To prevent spouting out fuel to change the
pressure in the fuel tank.
NOTE: Cover opening of the filler neck to prevent any
dust entering.
3. Disconnect the quick connector into the fuel tube
from the fuel filter.
NOTE: Cover the quick connector to prevent any dust
entering and fuel leaking.
NOTE: Refer to Fuel Tube/Quick Connector Fittings in
this section when performing any repairs.
4. Pull off fuel filter from holder to side member side.
RTW36CSH000301
2. Connect the quick connector from the fuel tube to

the fuel filter.
NOTE: Pull of the left checker into the fuel pipe.
Inspection
1. Replace the fuel filter if the fuel leaks from fuel filter
body or if the fuel filter body itself is damaged.
2. Replace the filter if it is clogged with dirt or
sediment.
Installation
1. Install the filter to holder from side member side.
NOTE: Attend direction of fuel filter. (1) to engine side
(2) to fuel tank side.

3. Tighten fuel filler cap until at least one click are
heard.
4. Connect the battery ground cable.
Inspection
After installation, start engine and check for fuel
leakage.
InTank Fuel Filter

The filter is located on the lower end of fuel pickup tube
in the fuel tank. It prevents dirt from entering the fuel
pipe and also stops water unless the filter is completely
submerged in the water. It is a selfcleaning type, not
requiring scheduled maintenance. Excess water and
sediment in the tank restricts fuel supply to the engine,
resulting in engine stoppage. In such a case, the tank
must be cleaned thoroughly.
Fuel Pump Flow Test

If reduction of fuel supply is suspected, perform the
following checks.
1. Make sure that there is fuel in the tank.
2. With the engine running, check the fuel feed pipe
and hose from fuel tank to injector for evidence of
leakage. Retighten, if pipe or hose connection is
loose. Also, check pipes and hoses for squashing
or clogging.
3. Insert the hose from fuel feed pipe into a clean
container, and check for fuel pump flow rate.
4. Connect the pump relay terminals (2) with a
jumper wire (1) as shown and start the fuel pump
to measure delivery.
RTW36CSH000201
CAUTION: Never generate sparks when connecting

a jumper wire.
Delivery
Delivery
15 seconds
0.38 liters minimum
If the measure value is out of standard, conduct the

pressure test.
Pressure test
For the pressure test to the fuel system, see Section 6E
Fuel Control System".
Fuel Pump
Fuel Pump and Associated Parts
RTW46FMF000401
Legend
(6) Fuel Tube/Quick Connector
(1) Fuel Feed Port
(7) Retainer Ring (Fuel Pump Lock)
(2) Fuel Return Port
(8) Seal; Fuel Pump
(3) Fuel Emission Port
(9) Fuel Tank Assembly

(5) Connector; Fuel Feed Pump & Sender
Removal
1. Remove fuel tank assembly (9). Refer to Fuel
Tank Removal" in this section.
2. Disconnect the quick connector (6) into the fuel
tube from fuel pump.
3. Disconnect the quick connector (10) into the evapo
(10) Evapo Tube/Quick Connector

3. Remove the retainer ring (7) from the fuel tank
with the removal tool 5-8840-2602-0.
8. Check leak.
(1) Plug end of quick connector and breather hose
(Pull off the breather hose from fuel tank) and
tighten fuel filler cap until at least one click are
heard.
(2) Apply water soap around the fuel pump seal
area.
(3) Pressure air into the fuel tank from end of
2
breather pipe at 5psi (34.3 kPa/2.8kgf/cm )
over 15 seconds.
(4) Verify no bubbles around the fuel pump seal
area.
140R100035
4. Remove slowly the fuel pump (4) from the fuel

tank as no bend float arm.
NOTE: Cover opening for the fuel pump on fuel tank to
prevent any dust enthering.
5. Discard fuel pump seal (8) because it cannot be
reusable.
Installation
1. Clean the seal surface of the fuel tank and the fuel
pump.
NOTE: If there is dust on the seal surface, it becomes
cause of fuel leak.
2. Install the new fuel pump seal (8) to opening of the
fuel tank as along the groove.
3. Install slowly the fuel pump (4) into the fuel tank as
no bend float arm.
4. Set flange of the fuel pump on fuel pump seal as
mating convexity of the fuel pump and reentrant of
the fuel tank.
5. Lock slowly the retainer ring (7) to the fuel tank
with the remover tool 5-8840-2602-0.
6. Connect the quick connector (10) into the evapo
tube to fuel pump.
7. Connect the quick connector (6) into the fuel tube
to fuel pump.
NOTE: Pull off the left ckecker into the fuel pipe.
Fuel Tube / Quick Connector Fittings

Precautions
Disconnect battery
electrical shorts.
ground
cable
to
prevent
Pre-treat piping system or associated parts from

thermal damage or from spattering when welding
or similar heat-generating work.
141R100002
When disconnecting the fuel pipe, cover the area

with a cloth to prevent fuel from splashing as the
fuel pipe may still have some pressure in it.
connector in one hand, and pull out the connentor
with the other hand while pressing the square
relieve button of the connector, as illustrated.
140R100032
Legend
(1) O-ring
(2) Port
(3) Connector
(4) Plastic Tube
Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spilt
battery electorolyte.
Piping that has been splattered with battery electrolyte
or battery electrolyte soaked cloth that was wiped on the
piping cannot be used.
Removal
1. Open the fuel cap to relieve the fuel pressure in the
tank.
Use compressed air to remove any dirt on the fuel
quick connect fittings prior to disconnecting the
fittings.
140R100037
NOTE: Do not use tools of any kind. Only use bare

hands when disconnecting the connector. Use a
lubricant (light oil) and/or push and pull the connector
until the pipe is disconnected.
Cover the connectors that was removed with a
plastic bag, to prevent dust or rain water from
entering.
Assembling Advice
By applying engine oil or light oil to the pipe, port makes
pipe assembly easier. The pipe assembly should take
place immediately after applying oil (to prevent dust
from sticking to the pipe surface which may
decrease sealing ability).
2. Turn the ignition key to the ON" position and listen
for pump start-up sound. Inspect for leaks, the
fuel pressure will increase as the fuel pump is
actuated.
3. Perform leak inspection (step 2) several times.
140R100028
Replace the port and connector if scratch, dent or
crack is found.
Remove any dirt build up on the port when installing
the connector. Replace the connector, if there is any
forms of rust, dent, scratch.
After cleaning the port, insert it straight into the
connector until it clicks. After it clicks, try pulling at
49N (5kgf) it out to make sure that it is not drawn
and is securely locked.
140R100036
4. Start the engine and observe the engine idle speed.

The presence of dirt in the fuel system may affect
the fuel injection system.
Fuel Pump Relay

General Description
In order to control the fuel pump and sender assembly
(FPAS) operation, the FPAS relay is provided. When
the starter switch is turned to ON" position, the FPAS
relay operates the FPAS for 2 seconds.
When it is turned to START" position, the Engine
Control Module receives the reference pulse from the
Ignition Control Module and it operates the relay, again
causing the FPAS to feed fuel.
Fuel Tank
RTW46FLF000301
Legend
(7) Fuel Filler Hose
(1) Bolt; Fuel Tank
(2) Fuel Tank Band
(9) Evapo Tube / Quick Connector Only Specified

Model
(3) Rear Side Shield

(4) Side Shield
(10) Fuel Filter
(5) Retainer
(11) Band; Under Shield
(6) Fuel Tank
(12) Under Shield
Removal
dust entering.
3. Jack up the vehicle.
4. Support underneath of the fuel tank with a lifter.
5. Remove the inner liner of the wheel house on rear
left side.
6. Remove fasten bolt to the filler neck from the
body.
tube from the fuel pipe and the evapo tube from
evapo joint connector.
8. Remove fasten bolt (1) to the tank band and the
tank band (2).
9. Disconnect the pump and sender connector on the
fuel pump and remove the harness from weld clip
on the fuel tank.
10. Lower the fuel tank (6).
NOTE: When the fuel tank is lowered from the vehicle,
dont scratch each hose and tube by around other pars.
Installation
1. Rise the fuel tank into position.
NOTE: Ensure hoses and tubes do not foul on other
component.
2. Connect the pump and sender connector to the
fuel pump and install harness to into the plastic clip
welded to the top of the fuel tank..
NOTE: The connector must be certainly connected
against stopper.
Ensure tank band anchor mates with guide hole on
frame.
3. Install the tank band to fasten bolt.
NOTE: The anchor of the tank band must be certainly
installed to guide hole on frame.
the fuel pipe and the evapo tube from evapo joint
connector.
NOTE: Pull off the left checker into the fuel pipe.
5. Install the filler neck to the body by bolt.
6. Install the inner liner of the wheel house on rear
side.
7. Remove lifter to support underneath of the fuel
tank.
8. Put back the vehicle.
9. Tigten the filler cap until at least three clicks are
heard.
Filler Neck
Removal
Installation


Each joint area of the hose (Restore axial
direction and insertion length of the hose)
Each fasten area of the clamp (Restore axial
direction and position of the clamp)
Each bolt in the clamp (Restore fasten length of
bolt in the clamp)
Torque: 2.5 N
m (0.25 kg
m / 2 lb ft) filler neck
side except flat deck model.
The band clip (Restore position and fasten
length of the band clip)
2. Put a marking the following point as the filler neck

assembly is restored.
Each joint area of the hose (to restore axial
Each fasten area of the clamp (to restore axial
Each bolt in the clamp (to restore fasten length
of bolt in the clamp)
The band clip (to restore position and fasten
NOTE: Cover end of each hose and pipe to prevent any
dust entering.
Fuel Gauge Unit

As for removal and installation of the Fuel Gauge Unit,
refer to Fuel Tank" of this section 6C as the fuel gauge
unit is combined with the fuel pump and sender
assembly.
Fuel Filler Cap

General Description
A vacuum valve and pressure valve are built into the
fuel filler cap which adjusts the fuel pressure in the fuel
tank to prevent fuel tank damage.
RTW36CSH000401
Legend
(1) Pressure Valve
(2) Vacuum Valve
(3) Seal Ring
Inspection
CAUTION: A replacement fuel filler cap must be the
same as the original. The fuel filler cap valve was
designed primarily for this application and must be
replaced with the same type or decreased engine
performance may occur.

Nm (kgm/ lb ft)
RTW46FMF000601
Special Tools
ILLUSTRATION
PART NO.
PART NAME
5884026020
(J39765)
Remover; fuel pump
retainer
ENGINE ELECTRICAL (6VE1 3.5L) 6D1-1
ENGINE
ENGINE ELECTRICAL (6VE1 3.5L)
CONTENTS
Battery......................................................................
General Description............................................
Diagnosis .............................................................
Battery Charging .................................................
6D1-1
6D1-2
6D1-2
6D1-2
6D1-3
Jump Starting .......................................................

Battery Removal ..................................................
Battery Installation ...............................................
6D1-3
6D1-4
6D1-4
6D1-5
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.

parts and systems.
6D1-2 ENGINE ELECTRICAL (6VE1 3.5L)
Battery
General Description
2. Fluid Level Check
There are six battery fluid caps on the top of the battery.
These are covered by a paper label.
The battery is completely sealed except for the six small
vent holes on the side. These vent holes permit the
escape of small amounts of gas generated by the
battery.
This type of battery has the following advantages over
conventional batteries:
The fluid level should be between the upper level line(1)

and lower level line(2) on side of battery.
a. CORRECT FLUID LEVEL Charge the battery.
b. BELOW LOWER LEVEL Replace battery.
1. There is no need to add water during the entire

service life of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an extensive
charge.
(A conventional battery will accept an excessive
charge, resulting in gassing and loss of battery
fluid.)
3. The battery is much less vulnerable to self
discharge than a conventional type battery.
Diagnosis
1. Visual Inspection
Inspect the battery for obvious physical damage, such
as a cracked or broken case, which would permit
electrolyte loss.
Replace the battery if obvious physical damage is
Check for any other physical damage and correct it as
necessary.
RTW36DSH000101
3. Voltage Check
1. Put voltmeter test leads to battery terminals.
a. VOLTAGE IS 12.4V OR ABOVE Go to Step 5.
b. VOLTAGE IS UNDER 12.4V Go to procedure
(2) below.
2. Determine fast charge amperage from specification.
(See Main Data and Specifications in this section).
Fast charge battery for 30 minutes at amperage
rate no higher than specified value.
Take voltage and amperage readings after charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE Replace battery.
b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE Drop charging voltage to
15V and charge for 10 15 hours. Then go to
Step 5.
c. VOLTAGE IS BETWEEN 12V AND 16V
Continue charging at the same rate for an
additional 31/2 hours. Then go to Step 5.
d. VOLTAGE BELOW 12V Replace Battery.

4. Battery temperature can have a great effect on
battery charging capacity.
4. Load Test
1. Connect a voltmeter and a battery load tester
across the battery terminals.
2. Apply 300 ampere load for 15 seconds to remove
surface charge from the battery. Remove load.
3. Wait 15 seconds to let battery recover. Then apply
specified load from specifications (See Main Data
and Specifications in this section).
Read voltage after 15 seconds, then remove load.
a. VOLTAGE DOES NOT DROP BELOW THE
MINIMUM LISTED IN THE TABLE The
battery is good and should be returned to
service.
b. VOLTAGE IS LESS THAN MINIMUM LISTED
Replace battery.
ESTIMATED TEMPERATURE
MINIMUM
VOLTAGE
70
21
9.6
60
16
9.5
50
10
9.4
40
9.3
30
9.1
20
8.9
10
12
8.7
18
8.5
The battery temperature must be estimated by feel

and by the temperature the battery has been
exposed to for the preceding few hours.
Battery Charging
Observe the following safety precautions when charging
the battery:
1. Never attempt to charge the battery when the fluid
level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Pay close attention to the battery during charging
procedure.
Battery charging should be discontinued or the rate
of charge reduced if the battery feels hot to the
touch.
Battery charging should be discontinued or the rate
of charge reduced if the battery begins to gas or
spew electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue dot
or ring, it may be necessary to jiggle or tilt the
battery.
5. The sealed battery used on this vehicle may be

either quick charged or slow charged in the same
manner as other batteries.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
charge the battery.
Jump Starting
Jump Starting with an Auxiliary (Booster)
Battery
CAUTION: Never push or tow the vehicle in an
attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
Treat both the discharged battery and the booster
battery with great care when using jumper cables.
Carefully follow the jump starting procedure, being
careful at all times to avoid sparking.
WARNING: FAILURE TO CAREFULLY FOLLOW
THE JUMP STARTING PROCEDURE COULD
RESULT IN THE FOLLOWING:
1. Serous personal injury, particularly to your
eyes.
2. Property damage from a battery explosion,
battery acid, or an electrical fire.
3. Damage to the electronic components of one or
both vehicles particularly.
Never expose the battery to an open flame or electrical
spark. Gas generated by the battery may catch fire or
explode.
Remove any rings, watches, or other jewelry before
working around the battery. Protect your eyes by
wearing an approved set of goggles.
Never allow battery fluid to come in contact with your
eyes or skin.
Never allow battery fluid to come in contact with fabrics
or painted surfaces.
Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes,
skin, fabric, or a painted surface, immediately and
thoroughly rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of reach of young children.
Jump Starting Procedure
Battery Removal
1. Set the vehicle parking brake.

If the vehicle is equipped with an automatic
transmission, place the selector level in the PARK"
position.
If the vehicle is equipped with a manual
transmission, place the shift lever in the
NEUTRAL" position.
Turn OFF" the ignition.
Turn OFF" all lights and any other accessory
requiring electrical power.
2. Look at the builtin hydrometer.
If the indication area of the builtin hydrometer is
completely clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive
terminal of the booster battery.
Attach the other end of the same cable to the
positive terminal of the discharged battery.
Do not allow the vehicles to touch each other. This
will cause a ground connection, effectively
neutralizing the charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the
negative terminal of the booster battery.
Attach the other end of the same cable to a solid
engine ground (such as the air conditioning
compressor bracket or the generator mounting
bracket) of the vehicle with the discharged battery.
The ground connection must be at least 450 mm
(18 in.) from the battery of the vehicle whose battery
is being charged.
WARNING: NEVER ATTACH THE END OF THE
JUMPER CABLE DIRECTLY TO THE NEGATIVE
TERMINAL OF THE DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical
accessories have been turned OFF".
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above
directions in reverse order.
Be sure to first disconnect the negative cable from
the vehicle with the discharged battery.
P1010001
1. Remove negative cable.

2. Remove positive cable (2).
3. Remove retainer screw and rods.
4. Remove retainer.
5. Remove battery.
Battery Installation
1. Install battery.
2. Install retainer.
3. Install retainer screw and rods.
NOTE: Make sure that the rod is hooked on the body
side.
4. Install positive cable.
5. Install negative cable.

Model (JIS)
55D23LMF
Voltage (V)
12
MEMO
IGNITION SYSTEM (6VE1 3.5L) 6D2-1
ENGINE
IGNITION SYSTEM (6VE1 3.5L)
CONTENTS
Diagnosis.................................................................
Ignition Coil..............................................................
Removal ...............................................................
Installation ............................................................
Spark Plug...............................................................
6D2-1
6D2-2
6D2-2
6D2-3
6D2-3
6D2-3
6D2-3
6D2-4
Inspection .............................................................
Replacement spark plugs...................................
Crankshaft Position Sensor...................................
Removal................................................................
Installation.............................................................
6D2-4
6D2-4
6D2-5
6D2-5
6D2-5
6D2-6
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.

parts and systems.
6D2-2 IGNITION SYSTEM (6VE1 3.5L)
General Description
Ignition is done by the electronic ignition (El) that directly
fires the spark plugs from ignition coils through spark
plug wires without using a distributor. A pair of ignition
coils for the cylinders having different phases by 360
(No.1 and No.4, No.2 and No.5, No.3 and No.6) are
fired simultaneously.
Since the cylinder on exhaust stroke requires less
energy to fire its ignition plug, energy from the ignition
coils can be utilized to fire the mating cylinder on
compression stroke. After additional 360 rotation,
respective cylinder strokes are reversed.
The EI consists of six ignition coils, crankshaft position
sensor, engine control module (ECM) and other
components.
The ignition coils are connected with the ECM.
The ECM turns on/off the primary circuit of ignition coils,
and also it controls the ignition timing.
A notch in the timing disc on the crankshaft activates
the crankshaft position sensor which then sends
information such as firing order and starting timing of
each ignition coil to the ECM.
Further, the El employs ignition control (IC) to control
similar to a distributor system.
Diagnosis
Refer to Section Drivability and Emissions for the
diagnosis to electronic ignition system (El system).
Ignition Coil
Measure resistance of ignition coil assembly, and
replace the ignition coil assembly if its value exceeds
the standard.
Removal
Disconnect three connector from ignition coil.
cover.
Remove fixing bolts on ignition coil.
060RW006
Installation
1. Install the ignition coil assembly (3).
Connect ignition coil connector (1) and ignition coil
(3), then tighten bolt (2) to the specified torque.
RTW4Z0SH000101
Legend

(2) Bolt

Check the ignition coil assembly for insulation. Check
terminals for corrosion or damage, and replace as
necessary.
Measuring resistance of ignition coil assembly.
Terminal No.
Limit
1 to 2
Without 0 ohm or infinity

maximum ohm.
1 to 3
Same as above
2 to 3
Same as above
RTW4Z0SH000101
Spark Plug
7. Check the spark plug gap. Replace the spark plug
the if gap is not as specified.
Inspection
Poor spark plug condition adversely affects engine
performance.
Carefully inspect each spark plug
following the procedure outlined below.
Standard: 1.01.1 mm (0.040.043 in)

Limit: 1.3 mm (0.05 in)
1. Remove the spark plug.

2. Check the plug for dirt and other foreign material.
If the plug is extremely dirty, the fuel and electrical
systems must be checked.
3. If necessary, clean the spark plugs by placing them
in a spark plug cleaning machine for no more than
20 seconds.
4. Check the electrode and insulator for wear and/or
cracking. If there is significant wear or cracking, the
plug must be replaced.
5. Check the gasket for damage. Replace the gasket if
necessary.
6. Measure the insulation resistance with a 500-volt
megaohm meter. Replace the plug if the resistance
is less than the specified value.
011RS011
Insulation resistance: 50 M9 or more
Do not attempt to adjust the gap of an old spark

plug. Replace the plug and adjust the gap of the
new plug if required.
Take care not to damage the spark plug tip
during handling.
8. Tighten the spark plugs to the specified torque.
Replacement spark plugs

Under normal conditions (no problem with the fuel
and/or electrical systems), use replacement spark
plugs with a low heat value (hot-type plug).
If insulator and electrode scorching is significant,
use replacement spark plugs with a high heat value
(cold-type plug).
011RS010

Removal
1. Disconnect battery ground cable
2. Wiring connector from crankshaft position sensor.
3. Remove crankshaft position sensor from cylinder
block.
012RS008
Installation
1. Install crankshaft position sensor into the cylinder
block.
Before installation, apply small amount of engine
oil to the Oring.
2. Reconnect wiring connector to crankshaft position
sensor.

Ignition System
Ignition Form
Electronic Ignition System (El system) with Crankshaft position sensor
Spark Plug
Type
K16PR-P11
RC10PYP4
RK16PR11
Plug gap
Torque
1.0 mm (0.04 in) 1.1 mm (0.043 in)

18 Nm (13lb ft)
Nm (kgm/lb ft)
RTW460LF000101
MEMO
STARTING AND CHARGING SYSTEM (6VE1 3.5L) 6D3-1
ENGINE
STARTING AND CHARGING SYSTEM (6VE1 3.5L)
CONTENTS
Service Precaution ................................................. 6D3-1
Starting System ...................................................... 6D3-2
General Description ............................................... 6D3-2
Diagnosis................................................................. 6D3-4
Starter ...................................................................... 6D3-5
Removal ............................................................... 6D3-5
Installation ............................................................ 6D3-5
Disassembled View ............................................ 6D3-6
Disassembly ........................................................ 6D3-7
Inspection and Repair ........................................ 6D3-9
Reassembly ......................................................... 6D3-12
Main Data and Specifications............................ 6D3-13
Charging System .................................................... 6D3-15
General Description................................................6D3-15
General On-Vehicle Inspection .............................6D3-15
Generator .................................................................6D3-16
Removal................................................................6D3-16
Inspection .............................................................6D3-16
Installation.............................................................6D3-16
Disassembled View.............................................6D3-17
Disassembly .........................................................6D3-17
Inspection and Repair .........................................6D3-20
Reassembly..........................................................6D3-22
Bench Test ...........................................................6D3-22
Main Data and Specifications................................6D3-23
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.

parts and systems.
6D3-2 STARTING AND CHARGING SYSTEM (6VE1 3.5L)
Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter,
starter switch, starter relay, etc. These main
components are connected.
Starter
The cranking system employs a magnetic type
reduction starter in which the motor shaft is also used
as a pinion shaft. When the starter switch is turned on,
the contacts of magnetic switch are closed, and the
armature rotates. At the same time, the plunger is
attracted, and the pinion is pushed forward by the shift
lever to mesh with the ring gear.
Then, the ring gear runs to start the engine. When the
engine starts and the starter switch is turned off, the
plunger returns, the pinion is disengaged from the ring
gear, and the armature stops rotation. When the engine
speed is higher than the pinion, the pinion idles, so that
the armature is not driven.
RTW46DXF000101
Diagnosis
Symptom
Starter does not run
Possible Cause
Action
Charging failure
Repair charging system
Battery Failure
Replace Battery
Terminal connection failure
Repair or replace terminal connector

and/or wiring harness
Starter switch failure
Repair or replace starter switch
Starter failure
Repair or replace starter
Starter
Removal
Installation
1. Battery ground cable.
1. Install starter assembly.
2. Disconnect left heated O2 sensor connector.
2. Install mounting bolts and tighten bolts to specified

torque.
3. Remove exhaust front left pipe.
4. Remove dust cover.

5. Disconnect starter wiring connector from terminals
30" and 50".
6. Remove starter assembly mounting bolts on inside
and outside.
7. Remove starter assembly toward the bottom of
engine.
065RY00050
Legend
(1) Terminal "30"
(2) Terminal "50"
(3) Fixing Bolts
(4) Starter Assembly
3. Reconnect the connectors to terminals 30" and

50" and tighten Terminals 30" to specified torque.
4. Install dust cover.
065RY00050
Legend
(1) Terminal "30"
(2) Terminal "50"
(3) Fixing Bolts
(4) Starter Assembly
5. Install exhaust front left pipe and tighten bolts and
nuts to specified torque(2).
Stud Nuts
Nuts
6. Connect heated O2 sensor connector.
7. Reconnect the battery ground cable.
Disassembled View
065R100012
Legend
(7) Housing
(1) Lead Wire
(8) Over Running Clutch
(2) Through Bolt
(9) Return Spring
(3) Yoke Assembly
(10) Steel Ball
(4) Yoke Cover
(11) Idle Pinion
(5) Brush and Brush Holder
(12) Retainer
(6) Armature
(13) Magnetic Switch
Disassembly
1. Remove the lead wire (1) from the magnetic switch.
2. Remove the through bolts (2).
065RY00055
Legend
(1) Spring
(2) Brush
065RY00053
Legend
6. Remove the armature.
(1) Lead Wire

(2) Through Bolt
7. Remove the housing.

8. Remove the overrunning clutch from the housing.
3. Remove the yoke from the magnetic.

4. Remove the yoke cover.
5. Use the long nose pliers to remove the brush and
brush holder.
065RY00056
065RY00054

9. Remove the return spring from the magnetic switch.
11.Remove the idle pinion from the magnetic switch.
065R100014
10. Remove the steel ball from the overrunning clutch.
065R100015
12. Remove the retainer from the magnetic switch.
065RY00058
065R100016
13. Remove the magnetic switch.

Repair or replace necessary parts if extreme wear or
damage is found during inspection.
Check for continuity between commutator and shaft.

Also, check for continuity between commutator and
armature core, armature core and shaft. Replace
commutator if there is continuity (i.e., internally
grounded).
Armature
Measure the outer diameter of commutator, and replace
with a new one if it is out of the limit.
Standard: 30 mm (1.1811 in)
Limit: 29 mm (1.1417 in)
065RS016
Measure runout of the commutator with a dial gauge.

Repair or replace, if it exceeds the limit.
Limit: 0.4 mm (0.0157 in)
065RS014
Check for continuity between segment and segment on

the commutator. Replace commutator if there is no
continuity (i.e., disconnected).
065RY00061
065RS015

Polish the commutator surface with sandpaper #500 to
#600 if it is rough.
Brush
Measure the length of brush.
Replace with a new one, if it is below the limit.
Standard: 15 mm (0.5906 in)
Limit: 11 mm (0.43 in)
065RW012
Measure the depth of insulator in commutator. Replace,

if it is below the limit.
Standard: 0.45 mm to 0.75 mm (0.0177 in to
0.0295 in)
065RW014
Limit: 0.2 mm (0.008 in)
Brush Holder
Check for continuity between brush holder (+) (4) and
base (). Replace, if there is continuity (i.e., insulation is
broken).
065RY00070
Legend
(1) Insulator
(2) Depth of Insulator
(3) Commutator Segments
065RW015
Brush Spring
Use spring balancer to measure the spring setting force
when remove the spring from the brush.
Standard: 17.6523.54 N (38.951.9 lb)
Limit: 11.77 N (25.9 lb)
Magnetic Switch
3. Return test
Connect the ground (-) to terminal 50 and magnetic
switch body.
Verify that the pinion pulls out when the battery (+)
pole is connected to terminal C and the pinion
pulls away when the lead wire is disconnected from
terminal 50.
Temporarilly connect the magnetic switch between the

overrunning clutch and housing.
Perform the steps described below in 3 to 5 seconds.
1. Pull in test
Connect the ground (-) to terminal C and magnetic
switch body.
Verify that the pinion pulls out when the battery (+)
pole is connected to terminal 50.
065R100019
Field Coil
1. Check for continuity between the end of the field coil
and yoke body.
Replace the field coil, if there is continuity.
065R100017
2. Hold in test
Observe that the pinion stays when the lead wire is
disconnected from terminal C.
065RY00065
065R100018

2. Check continuity between the lead wire of terminal
C and brush.
Replace the yoke assembly, if there is no continuity.
Bearing
1. Inspect excessive wear or damage.
Replace the bearing if an abnormal noise is heard
under normal operating condition.
065RY00066
Overrunning Clutch
065RY00068
1. Visual check for excessive wear or damage.

2. Test the pinion rotation, it must rotate smoothly
when rotated clockwise and it shouldn't rotate when
turned counterclockwise.
Reassembly
To install, follow the removal steps in the reverse order,
noting the following points:
Grease application places
Bearing in rear cover
Gears in reduction gear
Sliding portion of pinion
065RY00067

Model
ADX4IH
Rating
Voltage
12 V
Output
1.4 Kw
Time
30 sec
Number of teeth of pinion

Rotating direction(as viewed from pinion)
Weight(approx.)
9
Clockwise
3.8kg (8.4lb)
Noload characteristics
Voltage /Current
11.5V/90A or less
Speed
3000rpm or more
Load characteristics
Voltage/current
8.5V/350A or less
Torque
13.2Nm (1.35kgm/9.77lb in.) or more
Speed
1000rpm or more
Locking characteristics
Voltage/current
Torque
2.4V/500A or less
11.8Nm (1.2kgm/8.68lb in) or more
Nm (kgm/lb ft)
RTW46DLF000101
Charging System
General Description
General OnVehicle Inspection
The IC integral regulator charging system and its main

components are connected as shown in illustration.
The regulator is a solid state type and it is mounted
along with the brush holder assembly inside the
generator installed on the rear end cover.
The generator does not require particular maintenance
such as voltage adjustment.
The rectifier connected to the stator coil has eight
diodes to transform AC voltage into DC voltage.
This DC voltage is connected to the output terminal of
generator.
The operating condition of charging system is indicated

by the charge warning lamp. The warning lamp comes
on when the starter switch is turned to ON" position.
The charging system operates normally if the lamp
goes off when the engine starts.
If the warning lamp shows abnormality or if
undercharged or overcharged battery condition is
suspected, perform diagnosis by checking the charging
system as follows:
1. Check visually the belt and wiring connector.
2. With the engine stopped, turn the stator switch to
ON" position and observe the warning lamp.
If lamp does not come on:
Disconnect wiring connector from generator, and
ground the terminal L" on connector side.
If lamp comes on:
Repair or replace the generator.
F06RW009
Generator
Removal
If voltage is not present, the line between battery

and connector is disconnected and so requires
repair.

wrench then remove drive belt (1).
3. Disconnect the wire from
disconnect the connector (4).
terminal
B"
and
3. Reconnect the wiring connector to the generator,

run the engine at middle speed, and turn off all
electrical devices other than engine.
4. Measure battery voltage. If it exceeds 16V, repair or
replace the generator.
4. Remove generator fixing bolt (3).
5. Connect an ammeter to output terminal of

generator, and measure output current under load
by turning on the other electrical devices (eg.,
headlights). At this time, the voltage must not be
less than 13V.
5. Remove generator assembly (2).
Installation
1. Install generator assembly to the position to be
installed.
2. Install generator assembly and tighten the fixing
Torque:
3. Connect wiring harness connector and direct
terminal B".
060RW002
Inspection
1. Disconnect the wiring connector from generator.
2. With the engine stopped, turn starter switch to ON"
and connect a voltmeter between connector
terminal L (2) and ground or between terminal IG (1)
and ground.
066RW001

5. Reconnect battery ground cable.
Disassembled View
066RW007
Legend
(6) Rectifier
(1) Pulley Nut
(7) Terminal Insulator and Nut
(2) Pulley
(8) Regulator Assembly
(3) Front Cover Assembly
(9) Brush Holder Assembly
(4) Rotor Assembly
Disassembly
1. Terminal insulator and nut (2).
(10) Rear Cover

2. Remove three nuts(1) on the rear cover and a nut
on terminal B and insulator, then remove the rear
cover(3).
4. Remove three screws on the IC regulator, then the

IC regulator assembly(6).
060RW003
060RW005
3. Remove two screws that fix the brush holder(5) and

rectifier, then remove the brush holder assembly(4).
5. Remove four screws that fix rectifier(7) and stator

lead wires.
066RW004
060RW004

6. Secure the pulley directly in the vise between two
copper plates, and remove the nut and pulley.
066RS010
7. Remove four nuts(8) that secure the front cover

assembly and rear end cover, and an insulator(9).
066RW005
8. Use the puller to remove the rear end cover.

9. Rotor assembly
066RS012
10. Pull the rotor assembly(10) off the front cover

assembly(12) using a bench press(11).
066RW006

3. Check resistance between slip rings, and replace if
there is no continuity.

Repair or replace necessary parts if extreme wear or
damage is found during inspection.
Rotor Assembly
1. Check the rotor slip ring surfaces for contamination
and roughness. If rough, polish with #500600
sandpaper.
066RS016
4. Check for continuity between slip ring and rotor

core.
In case of continuity, replace the rotor assembly.
066RS014
2. Measure the slip ring diameter, and replace if it

exceeds the limit.
066RS017
066RS015
Stator Coil
Rectifier Assembly
1. Measure resistance between respective phases.

2. Measure insulation resistance between stator coil
and core with a megaohmmeter.
If less than standard, replace the coil.
Check for continuity across P" and E" in the

range of multimeter.
\ 100W
066RW002
066RS018
Brush
Change polarity, and make sure that there is continuity

in one direction, and not in the reverse direction. In case
of continuity in both directions, replace the rectifier
assembly.
IC Regulator Assembly
Measure the brush length.

If more than limit, replace the brush.
Check for continuity across B" and F" in the

range of multimeter.
Standard: 10.mm (0.4134 in)
\ 100W
Limit: 8.4.mm (0.3307 in)
066RS021
066RS019
Change polarity, and make sure that there is continuity

in one direction, and not in the reverse direction. In case
of continuity in both directions, replace the IC regulator
assembly.
Reassembly
Bench Test
To reassemble, follow the disassembly steps in the

reverse order, noting the following points:
Conduct a bench test of the generator.
1. Using a press with a socket wrench attached,

reassemble rotor and rear end cover assembly in
the front cover.
066RS023
Preparation
066RS022
2. Install pulley on the rotor.

Secure the pulley directly in the vise between two
copper plates, and tighten nut to the specified
torque.
Remove generator from the vehicle (see Generator

removal").
1. Secure generator to the bench test equipment and
connect wires.
Terminal IG" for energization
Terminal L" for neutral (warning lamp)
Terminal B" for output
2. Conduct the generator characteristic test.
Characteristics of generator are shown in
illustration.
Repair or replace the generator if its outputs are
abnormal.
066RS010
B06RW001

Parts Number
Model
102211-1740
ACJV74
Rated voltage
12 V
Rated output
90 A
Rotating direction (As viewed from pulled)

Pulley effective diameter
Weight
Clockwise
57.5 mm (2.26 in)
5.1 kg (11 lb)
MEMO
3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E-1
ENGINE
3.5L ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
ABBREVIATION CHARTS ................................
COMPONENT LOCATOR.................................
ENGINE COMPONENT LOCATOR TABLE ..
ECM CIRCUIT DIAGRAM .................................
GROUND POINT CHART G.EXP (LHD)
WITHOUT EUROPE, ISRAEL, TURKEY (1/4).
GROUND POINT CHART G.EXP (LHD) (2/4) ..
GROUND POINT CHART G.EXP (RHD) (1/4) .
LOCATION ........................................................
CABLE HARNESS & CONNECTOR
LOCATION .......................................................
CONNECTOR LIST...........................................
RELAY AND FUSE............................................
(LHD&RHD)...................................................
(LHD&RHD)...................................................
FUSE AND RELAY LOCATION
(LHD&RHD)...................................................
ECM WIRING DIAGRAM (1/10)........................
ECM WIRING DIAGRAM (10/10)......................
ECM CONNECTOR PIN ASSIGNMENT
& OUTPUT SIGNAL .........................................
SENSORS ........................................................
6E-5
6E-6
6E-6
6E-10
6E-13
6E-14
6E-15
6E-16
6E-17
6E-18
6E-19
6E-20
6E-21
6E-22
6E-27
6E-30
6E-30
6E-31
6E-32
6E-33
6E-34
6E-35
6E-36
6E-37
6E-38
6E-39
6E-40
6E-41
6E-42
6E-43
6E-51

Temperature (IAT) Sensor ............................. 6E-52
Throttle Position Sensor (TPS)....................... 6E-52
Idle Air Control (IAC) Valve ............................ 6E-53
Camshaft Position (CMP) Sensor .................. 6E-53
Crankshaft Position (CKP) Sensor ................. 6E-54
Engine Coolant Temperature (ECT) Sensor .. 6E-54
Vehicle Speed Sensor (VSS) ......................... 6E-55
Heated Oxygen (O2) Sensor........................... 6E-55
GENERAL DESCRIPTION FOR FUEL
METERING....................................................... 6E-56
GENERAL DESCRIPTION FOR ELECTRONIC
IGNITION SYSTEM IGNITION
COILS & CONTROL......................................... 6E-58
GENERAL DESCRIPTION FOR EVAPORATIVE
EMISSION SYSTEM ........................................ 6E-61
GENERAL DESCRIPRION FOR EXHAUST
GAS RECIRCULATION (EGR) SYSTEM......... 6E-62
ISUZU STRATEGY BASED DIAGNOSTICS .... 6E-63
Diagnostic Thought Process .......................... 6E-64
1. Verify the Complaint ................................... 6E-64
2. Perform Preliminary Checks....................... 6E-64
3. Check Bulletins and Troubleshooting
Hints ........................................................... 6E-65
4. Perform Service Manual Diagnostic
Checks ....................................................... 6E-65
Diagnostic Procedures ............................... 6E-65
5c. Technician Self Diagnoses ....................... 6E-65
5d. Intermittent Diagnosis............................ 6E-66
Symptom Simulation Tests.......................... 6E-67
5e. Vehicle Operates as Designed ................. 6E-68
6. Re-Examine the Complaint ........................ 6E-68
7. Repair and Verify Fix .................................. 6E-68
GENERAL SERVICE INFORMATION .............. 6E-69
Aftermarket Electrical and Vacuum
Equipment ..................................................... 6E-69
Electrostatic Discharge Damage .................... 6E-69
6E-2 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Inspection ...................................................... 6E-74
Basic Knowledge of Tools Required............... 6E-71
Serial Data Communications .......................... 6E-71
On-Board Diagnostic (OBD) ........................... 6E-71
Comprehensive Component Monitor
Diagnostic Operation ..................................... 6E-71
The Diagnostic Executive ............................... 6E-72
Verifying Vehicle Repair ................................. 6E-73
Reading Flash Diagnostic Trouble Codes ...... 6E-73
Reading Diagnostic Trouble Codes Using
a Tech 2......................................................... 6E-73
On-Board Diagnosis (Self-Diagnosis)............. 6E-74
Diagnosis with Tech 2 .................................... 6E-75
(ENGINE DATA)............................................... 6E-79
(O2 SENSOR DATA)........................................ 6E-81
MISCELLANEOUS TEST.................................. 6E-83
PLOTTING SNAPSHOT GRAPH ...................... 6E-85
Plotting Graph Flow Chart (Plotting graph
after obtaining vehicle information)................ 6E-86
(Plotting Graph) ............................................. 6E-87
SNAPSHOT DISPLAY WITH TIS2000.............. 6E-88
SERVICE PROGRAMMING SYSTEM (SPS).... 6E-91
HOW TO USE BREAKER BOX ........................ 6E-94
CHECK ............................................................. 6E-97
NO CHECK ENGINE LAMP (MIL)..................... 6E-101
CHECK ENGINE LAMP (MIL) "ON" STEADY... 6E-104
FUEL INJECTOR COIL TEST PROCEDURE
AND FUEL INJECTOR BALANCE
TEST PROCEDURE ......................................... 6E-106
FUEL SYSTEM ELECTRICAL TEST ................ 6E-111
FUEL SYSTEM DIAGNOSIS............................. 6E-116
A/C SYSTEM CIRCUIT DIAGNOSIS ................ 6E-122
ECM DIAGNOSTIC TROUBLE CODES (DTC) 6E-130
MULTIPLE DTC SETS TROUBLESHOOTING
AIDS ................................................................. 6E-142
DTC P0101 (FLASH CODE 61) MASS
AIR FLOW SENSOR CIRCUIT
RANGE/PERFORMANCE ................................ 6E-146
AIR FLOW SENSOR CIRCUIT LOW INPUT ... 6E-149
AIR FLOW SENSOR CIRCUIT HIGH INPUT .. 6E-154
DTC P0112 (FLASH CODE 23) INTAKE AIR
TEMPERATURE (IAT) SENSOR LOW
INPUT ............................................................... 6E-158
DTC P0113 (FLASH CODE 23) INTAKE AIR

TEMPERATURE (IAT) SENSOR HIGH
INPUT............................................................... 6E-163
DTC P0117 (FLASH CODE 14) ENGINE
COOLANT TEMPERATURER (ECT)
SENSOR LOW INPUT ..................................... 6E-168
COOLANT TEMPERATURER (ECT)
SENSOR HIGH INPUT..................................... 6E-173
DTC P0121 (FLASH CODE 21) THROTTLE
POSITION SENSOR (TPS) CIRCUIT
RANGE/PERFORMANCE................................ 6E-179
LOW INPUT ..................................................... 6E-183
HIGH INPUT..................................................... 6E-188
DTC P0131 (FLASH CODE 15) O2 SENSOR
CIRCUIT LOW VOLTAGE
(BANK 1 SENSOR 1) ....................................... 6E-193
CIRCUIT LOW VOLTAGE
(BANK 2 SENSOR 1) ....................................... 6E-193
CIRCUIT HIGH VOLTAGE
(BANK 1 SENSOR 1) ....................................... 6E-201
DTC P0152 (FLASH CODE 15) O2
SENSOR CIRCUIT HIGH VOLTAGE
(BANK 2 SENSOR 1) ....................................... 6E-201
CIRCUIT NO ACTIVITY DETECTED
(BANK 1 SENSOR 1) ....................................... 6E-207
CIRCUIT NO ACTIVITY
DETECTED (BANK 2 SENSOR 1)................... 6E-207
SYSTEM TOO LEAN (BANK 1) ....................... 6E-211
SYSTEM TOO LEAN (BANK 2) ....................... 6E-211
SYSTEM TOO RICH (BANK 1) ........................ 6E-216
SYSTEM TOO RICH (BANK 2) ........................ 6E-216
DTC P1171 (FLASH CODE 44) FUEL
SUPPLY SYSTEM LEAN DURING POWER
ENRICHMENT (TYPE A) ................................. 6E-221
DTC P1172 (FLASH CODE 44) FUEL SUPPLY
SYSTEM LEAN DURING POWER
ENRICHMENT (TYPE B) ................................. 6E-221

DTC P0201 (FLASH CODE 31) INJECTOR 1
CONTROL CIRCUIT ........................................ 6E-226
DTC P0336 (FLASH CODE 29) CRANKSHAFT
POSITION SENSOR CIRCUIT
RANGE/PERFORMANCE (58X) ...................... 6E-234
DTC P0337 (FLASH CODE 29) CRANKSHAFT
POSITION SENSOR CIRCUIT NO SIGNAL
(58X) ................................................................. 6E-234
DTC P0341 (FLASH CODE 41) CAMSHAFT
POSITION SENSOR CIRCUIT
RANGE/PERFORMANCE ............................... 6E-243
DTC P0342 (FLASH CODE 41) CAMSHAFT
POSITION SENSOR CIRCUIT NO SIGNAL .... 6E-243
DTC P0351 (FLASH CODE 42) IGNITION 1
DTC P0404 (FLASH CODE 32) EGR CIRCUIT
RANGE/PERFORMANCE (OPEN VALVE)....... 6E-258
DTC P1404 (FLASH CODE 32) EGR CIRCUIT
RANGE/PERFORMANCE (CLOSED VALVE) .. 6E-258
DTC P0405 (FLASH CODE 32) EGR
CIRCUIT LOW.................................................. 6E-263
DTC P0406 (FLASH CODE 32) EGR
CIRCUIT HIGH ................................................. 6E-268
DTC P0444 EVAP PURGE SOLENOID
VALVE CIRCUIT LOW VOLTAGE ................... 6E-274
DTC P0445 EVAP PURGE SOLENOID
VALVE CIRCUIT HIGH VOLTAGE .................. 6E-274
DTC P0500 (FLASH CODE 24) VEHICLE
SPEED SENSOR (VSS) CIRCUIT
RANGE/PERFORMANCE ................................ 6E-279
DTC P0562 (FLASH CODE 66) SYSTEM

VOLTAGE LOW .............................................. 6E-288
DTC P0563 (FLASH CODE 66) SYSTEM
VOLTAGE HIGH .............................................. 6E-321
CONTROL MODULE (ECM) MEMORY
CHECKSUM ..................................................... 6E-293
DTC P0602 PROGRAMMING ERROR............. 6E-295
DTC P1508 (FLASH CODE 22) IDLE AIR
CONTROL SYSTEM LOW/CLOSED ............... 6E-296
DTC P1509 (FLASH CODE 22) IDLE AIR
CONTROL SYSTEM HIGH/OPEN ................... 6E-296
DTC P1601 (FLASH CODE 65) CAN BUS
OFF .................................................................. 6E-304
DTC U2104 (FLASH CODE 67) CAN BUS
RESET COUNTER OVER-RUN ...................... 6E-310
DTC P1626 IMMOBILIZER NO SIGNAL........... 6E-317
DTC P1631 IMMOBILIZER WRONG
SIGNAL ............................................................ 6E-323
DTC P1648 IMMOBILIZER WRONG
SECURITY CODE ENTERED.......................... 6E-325
DTC P1649 IMMOBILIZER FUNCTION NOT
PROGRAMMED ................................................ 6E-327
SYMPTOM DIAGNOSIS ................................... 6E-329
PRELIMINARY CHECKS .............................. 6E-329
VISUAL/PHYSICAL CHECK .......................... 6E-329
INTERMITTENT ............................................. 6E-329
ENGINE CRANKS BUT WILL NOT RUN ......... 6E-331
HARD START SYMPTOM ................................ 6E-334
ROUGH, UNSTABLE, OR INCORRECT
IDLE, STALLING SYMPTOM ........................... 6E-337
SURGES AND/OR CHUGS SYMPTOM ........... 6E-341
HESITATION, SAG, STUMBLE SYMPTOM ..... 6E-345
CUTS OUT, MISSES SYMPTOM ..................... 6E-347
LACK OF POWER, SLUGGISH OR SPONGY
SYMPTOM ....................................................... 6E-352
DETONATION/SPARK KNOCK SYMPTOM..... 6E-356
POOR FUEL ECONOMY SYMPTOM ............... 6E-359
EXCESSIVE EXHAUST EMISSIONS OR
ODORS SYMPTOM ......................................... 6E-362
DIESELING, RUN-ON SYMPTOM.................... 6E-365
BACKFIRE SYMPTOM ..................................... 6E-366
ON-VEHICLE SERVICE PROCEDURE ........... 6E-368
ENGINE CONTROL MODULE (ECM) .............. 6E-368
CRANKSHAFT POSITION (CKP) SENSOR..... 6E-369
CAMSHAFT POSITION (CMP) SENSOR......... 6E-369
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR .......................................................... 6E-370
MASS AIR FLOW (MAF) SENSOR & INTAKE AIR
TEMPERATURE (IAT) SENSOR ...................... 6E-370

THROTTLE POSITION SENSOR (TPS)........... 6E-371
IDLE AIR CONTROL (IAC) VALVE ................... 6E-371
HEATED OXYGEN SENSOR (HO2S) .............. 6E-372
EVAP CANISTER PURGE VALVE
SOLENOID ....................................................... 6E-373
FUEL PRESSURE RELIEF ............................... 6E-374
FUEL RAIL ASSEMBLY .................................... 6E-374
FUEL INJECTORS ............................................ 6E-375
FUEL PRESSURE REGULATOR ..................... 6E-377
IGNITION COIL ................................................. 6E-379
SPARK PLUGS ................................................. 6E-380
SPECIAL TOOLS .............................................. 6E-382
ABBREVIATION CHARTS
Abbreviations
A/C
A/T
ACC
BLK
BLU
BRN
CAN
CEL
CKP
CMP
DLC
DTC
DVM
ECM
ECT
EEPROM
EGR
GND
GRY
HO2S
IAT
IAC
IG
M/T
MAF
MIL
OBD
ORN
PNK
PROM
RED
SW
TPS
TCM
VCC
VIO
VSS
WHT
WOT
YEL
Appellation
Air conditioner
Accessory
Black
Blue
Brown
Controller Area Network
Check engine lamp
Crankshaft position
Camshaft position
Data link connector
Diagnosis trouble code
Digital voltage meter
Electrically erasable & programmable read only memory
Exhaust gas recalculation
Ground
Gray
Heated Oxygen Sensor
Idle air control
Ignition
Manual transmission
Mass air flow
Malfunction indicator lamp
On-board diagnostic
Orange
Pink
Programmable read only memory
Red
Switch
Voltage Constant Control
Violet
White
Wide open throttle
Yellow
COMPONENT LOCATOR
ENGINE COMPONENT LOCATOR TABLE

Legend
(3) Idle Air Control (IAC) Valve
(4) Battery

(6) Auto Cruise Actuator
Legend
(5) Ignition Coil #1 Cylinder

(1) Injector #1 Cylinder

(4) EGR Valve
Legend
(5) Throttle Position Sensor

(9) Canister Purge Solenoid Valve

(1) Bank 1 Heated Oxygen Sensor (RH)
(1) Bank 2 Heated Oxygen Sensor (LH)
1

(1) Canister
(1) Camshaft Position Sensor (CMS)

(2) EGR Valve

(1) Fuel Tank
(2) Fuel Pump


(1) Power Steering Pressure Switch
ECM CIRCUIT DIAGRAM
RTW48AXF001401
RTW48AXF027601
RTW48AXF001601
RTW48AXF026001
RTW48AXF028701
RTW48AXF030101
RTW48AXF030201
RTW48AXF026001
RTW48AXF026301
RTW48AXF030501
RTW48AXF030601
LOCATION
6VE1
P-5
P-6
CABLE HARNESS & CONNECTOR LOCATION
RTW46EXF000101
(General Export - LHD)
RTW46EXF000201&RTW48AXF004001
General Export - RHD
RTW46EXF000301&RTW48AXF004301
6VE1 ENGINE
RTW36ELF000301
CONNECTOR LIST
No.
Connector face
B-24
Green
Meter-B
J/B I4
Silver
Check connector
Magnetic clutch
Fuel injector
E-7
Fuel injector
E-8
B-68
Immobilizer
Fuel injector
E-9
C-2
Silver
Fuel injector
E-51
C-24
Triple pressure switch
TCM-(A)
Fuel injector
E-53
C-107
White
Fuel injector
E-52
C-94
Gray
Body-LH ; ground
E-6
B-63
White
J/B E1
E-2
B-62
White
White
C-109
B-58
Black
Connector face
C-108
B-56
White
No.
J/B E2
Ignition coil
No.
Connector face
No.
Connector face
E-64
E-54
Ignition coil
Oil pressure switch (P/STRG)

E-66
E-55
Ignition coil
Duty solenoid
E-68
E-56
Ignition coil

E-69
E-57
Ignition coil
Temperature sensor
E-70
E-58
Ignition coil
IACV
E-72
E-59
Crank position sensor

E-60
Engine earth-A
E-73
Engine earth-A
ECM-A
E-61
E-74
Engine earth-B
ECM-B
E-76
E-62
Cam position sensor

E-63
EGR valve
E-77
MAF sensor
O2 sensor RH-Front
No.
Connector face
E-78
Neutral start switch
Fuel pump & sensor
Engine room ~ INST
Silver
Battery (-)
White
ACG (L)
Silver
Engine ground
X-2
H-7
Engine room ~ INST
Black
Relay ; Fuel pump
X-13
H-9
Engine room ~ Chassis
Black
Relay ; ECM MAIN
X-14
H-18
White
Relay & Fuse box
P-10
H-6
Blue
Silver
P-8
H-4
White
Battery (+)
P-5
F-2
White
Silver
P-2
E-79
White
Connector face
P-1
O2 sensor LH-Front
White
No.
Engine room ~ INST
Black
Relay ; A/C Compressor
X-15
H-22
White
Relay ; Thermo
X-17
H-23
White
Black
Engine ~ Engine room B
Black
DIODE
RELAY AND FUSE

LHD
RHD
RTW48ALF000201 & 825R300008

RELAY & FUSE BOX
RELAY
NO.
Relay name
X-1 RELAY; TAIL LIGHT
X-2 RELAY; FUEL PUMP
X-3 RELAY; HORN
X-4 RELAY; DIMMER
X-5 RELAY; FOG LIGHT
X-6 RELAY; STARTER
X-7 RELAY; COND, FAN
X-8 RELAY;
X-9 RELAY; HAZARD-RH
X-10 RELAY; HAZARD-LH
X-11 RELAY; HEATER
X-12 RELAY; HEAD LIGHT
X-13 RELAY; ECM MAIN
X-14 RELAY; A/C COMP
X-15 RELAY; THERMO
FUSE

!
"
#
$

!

%%

&
'(
)
)*(
SLOW BLOW FUSE

!
"
#
$
+,-+,-

(.

'

FUSE & RELAY LOCATION (LHD & RHD)

FUSE BOX
RTW46EMF001001
FUSE
/ 0123 410 21,,+ 5+

7%

!

"

#

$

'%

(
/ 0123

!

"

#

$

410 21,,+ 5+

(6
( 7
6

)
%
7

SLOW BLOW FUSE

/ 0123 410 21,,+ 5+

(

%''('
RELAY
Connector No.
6VE1
B-7
REAR DEFOGGER
B-8
POWER WINDOW
B-40
ACC SOCKET
RTW46EMF000401
RUW46EMF000101
RUW46EMF000201
RTW46EMF000301
RTW36EMF000901
RTW46ELF001001
RTW36EMF000201
RTW36ELF000101
RTW36EMF000101
RTW36EMF000801

Connector A Port: View Looking Into ECM Case
Pin B/Box
Wire
Pin Function
No.
No.
Color
Key SW
Off
Key SW
Engine
On
Idle
Engine
2000rpm
Tester Position
ECM
Connection Range
(+)
(-)
A1
A1
No Connection
A2
A2
No Connection
A3
A3
No Connection
A4
A4
Ground (Case)
BLK/
RED
Continuity
with ground
Disconnect
Ohm
A4
GND
A5
A5
EGR Valve
Control Duty
Signal
YEL
Less than 1V
Wave form
Connect
DC V
A5
GND
Connect
DC V
A6
GND
10-14V
A6
A6
ECM Main
Relay
BLU/
YEL
While main
relay is
activated:
10-14V
Main relay is
not activated:
Less than 1V
A7
A7
Ground
BLK/
YEL
Continuity
with ground
Disconnect
Ohm
A7
GND
A8
A8
Ground
BLK/
YEL
Continuity
with ground
Disconnect
Ohm
A8
GND
A9
A9
EGR Valve
Position Signal
YEL/
RED
Less than 1V
Connect
DC V
A9
GND
A10
A10
CAN (Controller
Area Network)
to TCM A17
RED
A11
A11
CAN (Controller
Area Network)
to TCM A7
WHT
A12
A12
No Connection
A13
A13
No Connection
10-14V
0.5-0.8V

Pin B/Box
Wire
Pin Function
No.
No.
Color
Key SW
Off
Key SW
Engine
On
Idle
Engine
2000rpm
Tester Position
ECM
Connection Range
(+)
(-)
A14
A14
No Connection
A15
A15
No Connection
A16
A16
No Connection
A17
A17
No Connection
A18
A18
No Connection
A19
A19
Intake Air
Temperature
(IAT) Sensor
Signal
Connect
DC V
A19
B39
A20
A20
No Connection
A21
A21
Engine Coolant
Temperature
(ECT) Sensor
Signal
BLU/
RED
Connect
DC V
A21
A22
A22
A22
EGR Valve &

ECT Sensor
Ground
YEL/
BLK
Continuity
with ground
Connect
Ohm
A22
GND
A23
A23
Crank Position
(CKP) Sensor
Signal
YEL
Wave form or approx. 1.9V
Connect
AC V
A23
A25
A24
A24
Crank Position
(CKP) Sensor & RED/
EGR Valve +5V BLU
Supply
Approx. 5V
Connect
DC V
A24
A25
A25
A25
Crank Position
(CKP) Sensor
Ground
YEL/
BLK
Continuity
with ground
Connect
Ohm
A25
GND
A26
A26
No Connection
A27
A27
No Connection
BLU/
RED
While main
relay is
activated:
Less than 1V
Main relay is
not activated:
10-14V
Connect
DC V
A28
GND
RED/
YEL
A28
A28
ECM Main
Relay
A29
A29
No Connection
A30
A30
No. 5 Ignition
Coil
YEL/
GRN
0 deg. C: Approx. 3.5V / 20 deg. C: Approx.

Less than 1V 2.5V / 40 deg. C: Approx. 1.6V / 60 deg. C:
0.9V / 80 deg. C: 0.6V
0 deg. C: Approx. 3.6V / 20 deg. C: Approx.

Less than 1V 2.4V / 40 deg. C: Approx. 1.4V / 60 deg. C:
3.4V / 80 deg. C: 2.6V
Less than 1V
Less than 1V
Wave form

Pin B/Box
Wire
Pin Function
No.
No.
Color
Key SW
Off
Key SW
Engine
On
Idle
Engine
2000rpm
Tester Position
ECM
Connection Range
(+)
(-)
A31
A31
No. 3 Ignition
Coil
RED/
BLU
Wave form
A32
A32
No. 1 Ignition
Coil
RED
Wave form
A33
A33
Ground (Power)
BLK/
RED
Continuity
with ground
Disconnect
Ohm
A33
GND
A34
A34
No. 5 Injector
GRN/
BLK
Less than 1V
Wave form or 12-14V
Connect
DC V
A34
GND
A35
A35
No. 3 Injector
BLU
Less than 1V
Wave form or 12-14V
Connect
DC V
A35
GND
A36
A36
No. 1 Injector
GRN/
WHT
Less than 1V
Wave form or 12-14V
Connect
DC V
A36
GND
A37
A37
Ground (Case)
BLK/
RED
Continuity
with ground
Disconnect
Ohm
A37
GND
A38
A38
No Connection
A39
A39
No Connection
A40
A40
No Connection
Connector B Port: View Looking Into ECM Cace
Pin
No.
B/Box
Pin Function
No.
Tester Position
Wire
Color
Key SW Off
Key SW On
Engine Idle
Engine
2000rpm
ECM
Connection
Range
(+)
(-)
B1
B1
No Connection
B2
B2
No Connection
B3
B3
No. 2 Injector
GRN/
ORG
Less than 1V
Wave form or 12-14V
Connect
DC V
B3
GND
B4
B4
No. 4 Injector
GRN/
RED
Less than 1V
Wave form or 12-14V
Connect
DC V
B4
GND
B5
B5
No. 6 Injector
GRN/
YEL
Less than 1V
Wave form or 12-14V
Connect
DC V
B5
GND
B6
B6
Ground
(Power)
BLK
Continuity
with ground
Disconnect
Ohm
B6
GND
B7
B7
No. 2 Ignition
Coil
RED/
BLK
Wave form
B8
B8
No. 4 Ignition
Coil
RED/
WHT
Wave form
B9
B9
No. 6 Ignition
Coil
RED/
GRN
Wave form
B10
B10
No Connection
B11
B11
A/C
Compressor
Relay
GRY/
RED
Less than 1V
Connect
DC V
B11
GND
B12
B12
Tachometer
Output Signal
BLK/
RED
Connect
AC V
B12
GND
B13
B13
Idle Air Control

(IAC) Valve
Coil A High
BLU
Less than 1V
Less than 1V / 10-14V
Connect
DC V
B13
GND
B14
B14
Idle Air Control

(IAC) Valve
Coil B High
BLU/
WHT
Less than 1V
Connect
DC V
B14
GND
B15
B15
Canister Purge
Solenoid Valve
RED/
BLU
Less than 1V
Wave form or 12-14V
Connect
AC V
B15
GND

A/C comp. is not operated: 10-14V
Wave form or Wave form or

6.2V
6.2V
Pin
No.
B/Box
Pin Function
No.
Wire
Color
Key SW Off
Key SW On
Engine Idle
Tester Position
Engine
2000rpm
ECM
Connection
Range
(+)
(-)
B16
B16
Idle Air Control

(IAC) Valve
Coil A Low
BLU/
RED
Less than 1V
Connect
DC V
B16
GND
B17
B17
Idle Air Control

(IAC) Valve
Coil B Low
BLU/
BLK
Less than 1V
Connect
DC V
B17
GND
B18
Check Engine
Lamp
(Immobilizer
Control Unit
Terminal B7)
BRN/
YEL
Less than 1V Less than 1V
Lamp is turned on:

Less than 1V
Connect
DC V
B18
GND
10-14V
Connect
DC V
B19
GND
Connect
DC V
B20
GND
Connect
DC V
B21
B22
Connect
Ohm
B22
GND
Connect
DC V
B23
B24
B18
B19
B19
Fuel Pump
Relay
GRN/
WHT
While relay is
activated:
10-14V
Less than 1V
Relay is not
activated:
Less than 1V
B20
B20
Mass Air Flow

(MAF) Sensor
BLK/
YEL
Less than 1V Approx. 0.47V
B21
B21
Bank 1 Oxygen
Sensor Signal
PNK
B22
B22
Bank 1 Oxygen BLU/

Sensor Ground YEL
B23
B23
Bank 2 Oxygen
Sensor Signal
B24
B24
Bank 2 Oxygen BLU/

Sensor Ground BLK
B25
B25
To Data Link
Connector
No.6
RED
Continuity
with ground
Approx. 1.5V
at 750 rpm
Approx. 2V
0.1 - 0.9V
0.1 - 0.9V
Continuity
with ground
Connect
Ohm
B24
GND
BLK/
GRN
B26
Throttle
Position
Sensor (TPS)
Signal
BLU
Less than 1V
Approx. 0.6V
Connect
DC V
B26
B39
B27
B27
TPS & Cam

Position
Sensor +5V
Supply
GRN
Less than 1V
Connect
DC V
B27
B39
B28
B28
Camshaft
Position (CMP)
Sensor Signal
BLU
B29
B29
Inhibitor Switch
(AT Only)
BLK
Less than 1V
P or N range: Less than 1V

Other than P or N range: 10-14V
Connect
DC V
B29
GND
B30
B30
Power Steering
GRN/
Pressure
YEL
Switch
Less than 1V
Pressure switch is turned on: Less than 1V

Pressure Switch is turned off: 10-14V
Connect
DC V
B30
GND
B31
B31
A/C Thermo
Relay
Less than 1V
A/C request is activated: 10-14V

A/C request is not activated: Less than 1V
Connect
DC V
B31
GND
B26
GRN/
BLK
Approx. 0.5V
Approx. 5V
Wave form
Pin
No.
B/Box
Pin Function
No.
Key SW Off
Key SW On
WHT
Less than 1V
B32
B32
Vehicle Speed
Signal
(Immobilizer
Control Unit
Terminal B8)
B33
B33
Ignition Switch
BLU/
YEL
B34
B34
Back Up
Power Supply
RED/
WHT
B35
B35
No Connection
B36
B36
Wire
Color
Engine Idle
Tester Position
Engine
2000rpm
Wave form or approx. 6.5V at

20km/h
10-14V
10-14V
ECM
Connection
Range
(+)
(-)
Connect
AC V
B32
GND
Connect
DC V
B33
GND
Connect
DC V
B34
GND
ECM Main
Relay
While main
relay is
activated:
RED/
10-14V
BLU
Main relay is
not activated:
Less than 1V
10-14V
Connect
DC V
B36
GND
10-14V
Connect
DC V
B37
GND
B37
B37
ECM Main
Relay
While main
relay is
activated:
RED/
10-14V
BLU
Main relay is
not activated:
Less than 1V
B38
B38
To Data Link
Connect to No.
2
GRN
B39
B39
TPS, MAF, IAT

& CMP Sensor
Ground
RED
Continuity
with ground
Connect
Ohm
B39
GND
B40
B40
No Connection

Camshaft Position (CMP) Sensor Reference Wave Form
0V
0V
Measurement Terminal: B28(+)

B39(-)
10ms/div
Measurement Terminal: A23(+)

A25(-)
Measurement Scale: 2.0V/div
5ms/div
Crankshaft Position (CKP) Sensor & Camshaft Position (CMP)

Sensor Reference Wave Form
Crankshaft Position (CKP) Sensor & Tacho Output Signal

Reference Wave Form
CH1
0V
CH1
0V
CH2
0V
CH2
0V
Measurement Terminal: CH1: A23(+) / CH2: B28(+) GND(-)

Measurement Scale: 2V/div / CH2: 5V/div
10ms/div
Measurement Terminal: CH1: A23(+) / CH2: B12(+) GND(-)

5ms/div
Heated Oxygen Sensor (HO2S) Reference Wave Form
CH1
0V
CH1
0V
CH2
0V
Measurement Terminal: CH1: ECM B32(+) / CH2: VSS 3(+)

GND(-)
50ms/div
Note: The vehicle is without immobilizer system,
CH1 signal is same as CH2.
CH2
0V
Measurement Terminal: CH1: B21(+) / CH2: B23(+)

GND(-)
Measurement Scale: CH1: 500mV/div / CH2: 500mV/div 1s/div
Measurement Condition: Approximately 2000rpm in Closed Loop
Ignition Coil Control Signal Reference Wave Form
Injector Control Signal Reference Wave Form
0V
0V
Measurement Terminal: A36(+) (No.1 Cylinder)

GND(-)
10ms/div
Measurement Terminal: A32(+) (No.1 Cylinder)

GND(-)
10ms/div
Injector & Ignition Coil Control Signal Reference Wave Form

EVAP Canistor Purge Solenoid Reference Wave Form
0V
CH1
0V
CH2
0V
Measurement Terminal: CH1: A36(+) (No.1 Cylinder)

CH2: A32(+) (No.1 Cylinder)
EGR Solenoid Reference Wave Form
0V
Measurement Terminal: CH1: A5(+)

Measurement Scale: CH1: 10V/div
Frequency: Approximately 128Hz
GND(-)
2ms/div
GND(-)
10ms/div
Measurement Terminal: B15(+) GND(-)

20ms/div

SENSORS
Power steering pressure

Air conditioning request on or off
EGR valve position
Outputs (Systems controlled):
(1) A Port
(2) B Port
The engine control module (ECM) is located on the
common chamber. The ECM controls the following.
Fuel metering system
Ignition timing
On-board diagnostics for powertrain functions.
The ECM constantly observes the information from
various sensors. The ECM controls the systems that
affect vehicle performance. And it performs the
diagnostic function of the system.
The function can recognize operational problems, and
warn to the driver through the check engine lamp, and
store diagnostic trouble code (DTC). DTCs identify the
problem areas to aid the technician in marking repairs.
The input / output devices in the ECM include analog to
digital converts, signal buffers, counters and drivers.
The ECM controls most components with electronic
switches which complete a ground circuit when turned
on.
Inputs (Operating condition read):
Battery voltage
Electrical ignition
Exhaust oxygen content
Mass air flow
Crankshaft position
Camshaft position
Throttle position
Vehicle speed
Ignition control
Fuel control
Idle air control
Fuel pump
EVAP canister purge
Air conditioning
Diagnostics functions
The vehicle with automatic transmission, the

interchange of data between the engine control module
(ECM) and the transmission control module (TCM) is
performed via a CAN-bus system.
The following signals are exchanged via the CAN-bus:
ECM to TCM:
ECM CAN signal status

Engine torque
Coolant temperature
Throttle position
Engine speed
A/C status
CAN valid counter
TCM to ECM:
Ignition timing retard request
Garage shift status
CAN valid counter

Mass Air Flow (MAF)
Temperature (IAT) Sensor
Sensor
&
Intake
Air
The MAF sensor is part of the intake air system.

It is fitted between the air cleaner & throttle body and
measure the mass air flowing into the engine.
The MAF sensor uses a hot wire element to determine
the amount of air flowing into the engine. (The wire
temperature reaches to 170 - 300C)
The MAF sensor assembly consist of a MAF sensor
element and an intake air temperature sensor that are
both exposed to the air flow to be measured.
The MAF sensor element measures the partial air mass
through a measurement duct on the sensor housing.
Using calibration, there is an extrapolation to the entire
mass air flow to the engine.
Characteristic of IAT Sensor
100000
Resistance ()
10000
1000
100
10
-30
10
50
Temperature ( )
90
130

hot.

(2) Idle Air Control Valve (IACValve)
on the throttle body.
The throttle body has a throttle plate to control the
amount of air delivered to the engine. Engine coolant is
directed through a coolant cavity in the throttle body to
warm the throttle valve and to prevent icing.

If the IAC valve is disconnected and reconnected with
the engine running, the idle speed will be wrong. In this
case, the IAC must be reset. The IAC resets when the
key is cycled "On" then "Off". When servicing the IAC, it
should only be disconnected or connected with the
ignition "Off".
The position of the IAC pintle valve affects engine startup and the idle characteristic of the vehicle.
If the IAC pintle is fully open, too much air will be
allowed into the manifold. This results in high idle
speed, along with possible hard starting and lean
air/fuel ratio.
Idle Air Control (IAC) Valve
Camshaft Position (CMP) Sensor

Coil
Coil
(ECM
Coil
(ECM
Coil
(ECM
Coil
(ECM
Step
A High
B13)
A
Low
B16)
B High
B14)
B
Low
B17)
On
On
On
On
On
On
On
On
(IAC Valve Close Direction)

(IAC Valve Open Direction)
The idle air control valve (IAC) valve is two directional

and gives 2-way control. It has a stepping motor
capable of 256 steps, and also has 2 coils. With power
supply to the coils controlled steps by the engine control
module (ECM), the IAC valve's pintle is moved to adjust
idle speed, raising it for fast idle when cold or there is
extra load from the air conditioning or power steering.
By moving the pintle in (to decrease air flow) or out (to
increase air flow), a controlled amount of the air can
move around the throttle plate. If the engine speed is
too low, the engine control module (ECM) will retract the
IAC pintle, resulting in more air moving past the throttle
plate to increase the engine speed.
If the engine speed is too high, the engine control
module (ECM) will extend the IAC pintle, allowing less
air to move past the throttle plate, decreasing the
engine speed.
The IAC pintle valve moves in small step called counts.
During idle, the proper position of the IAC pintle is
calculated by the engine control module (ECM) based
on battery voltage, coolant temperature, engine load,
and engine speed.
If the engine speed drops below a specified value, and
the throttle plate is closed, the engine control module
(ECM) senses a near-stall condition. The engine control
module (ECM) will then calculate a new IAC pintle valve
position to prevent stalls.
(1) Camshaft Position (CMP) Sensor

(2) EGR Valve
With the use of sequential multi-point fuel injection, a
hall element type camshaft position (CMP) is adopted to
provide information to be used in making decisions on
injection timing to each cylinder. It is mounted on the
rear of the left-hand cylinder head and sends signals to
the ECM.
One pulse is generated per two rotations of crankshaft.

Characteristic of ECT Sensor
100000
Resistance ()
10000
1000
100
-30
The crankshaft position (CKP) sensor, which sends a

signal necessary for deciding on injection timing to the
ECM, is mounted on the right-hand side of the cylinder
block.
The crankshaft has a 58 teeth press-fit timing disc, from
which the CKP sensor reads the position of the
crankshaft at all the times. It converts this to an
electrical signal, which it sends to the ECM.
Of the 58 teeth, 57 have a base with of 3, and are
evenly spaced, but tooth No. 58 is 15 wide at its based
to serve as a timing mark, allowing the sensor to report
the standard crankshaft position.
Using the 58 X signals per rotation and the timing-mark
signal sent by the CKP sensor, the ECM is able to
accurately calculate engine speed and crank position.
Also, the position of each cylinder is precisely known by
the ECM from signals sent by the camshaft position
(CMP) sensor, so the sequential multi-point fuel
injection can be controlled with accuracy.
The 58 X signals are converted by the ECM into a
retangle wave signal. This converted signal is sent from
the ECM terminal B12 to the tachometer and transfer
case control module (TCCM) terminal 15 (if 4WD
model).
10
10
50
Temperature ( )
90
130
The ECT sensor is a thermistor. A temperature

changes the resistance value. And it changes voltage.
In other words it measures a temperature value. It is
installed on the coolant stream. Low coolant
temperature is hot.


meter fuse.
Heated Oxygen (O2) Sensor
(1) Bank 1 Heated Oxygen Sensor (RH)
1
(1) Bank 2 Heated Oxygen Sensor (LH)
Each oxygen sensor consists of a 4-wire low

temperature activated zirconia oxygen analyzer element
with heater for operating temperature of 315C, and
there is one mounted on each exhaust pipe.
A constant 450millivolt is supplied by the ECM between
the two supply terminals, and oxygen concentration in
the exhaust gas is reported to the ECM as returned
signal voltage.
The oxygen present in the exhaust gas reacts with the
sensor to produce a voltage output. This voltage should
constantly fluctuate from approximately 100mV to
1000mV and the ECM calculates the pulse width
commanded for the injectors to produce the proper
combustion chamber mixture.
Low oxygen sensor output voltage is a lean mixture
which will result in a rich commanded to compensate.
High oxygen sensor output voltage is a rich mixture
which result in a lean commanded to compensate.
When the engine is first started the system is in "Open
Loop" operation. In "Open Loop", the ECM ignores the
signal from the oxygen sensors. When various
conditions (ECT, time from start, engine speed &
oxygen sensor output) are met, the system enters
"Closed Loop" operation. In "Closed Loop", the ECM
calculates the air fuel ratio based on the signal from the
oxygen sensors.
Heated oxygen sensors are used to minimize the
amount of time required for closed loop fuel control to
begin operation and allow accurate catalyst monitoring.
The oxygen sensor heater greatly decreases the
amount of time required for fuel control sensors to
become active.
Oxygen sensor heaters are required by catalyst monitor
and sensors to maintain a sufficiently high temperature
which allows accurate exhaust oxygen content readings
further away from the engine.

METERING
The fuel metering system starts with the fuel in the fuel
tank. An electric fuel pump, located in the fuel tank,
pumps fuel to the fuel rail through an in-line fuel filter.
The pump is designed to provide fuel at a pressure
above the pressure needed by the injectors.
A fuel pressure regulator in the fuel rail keeps fuel
available to the fuel injectors at a constant pressure.
A return line delivers unused fuel back to the fuel tank.
The basic function of the air/fuel metering system is to
control the air/fuel delivery to the engine. Fuel is
delivered to the engine by individual fuel injectors
mounted in the intake manifold.
The main control sensor is the heated oxygen sensor
located in the exhaust system. The heated oxygen
sensor reports to the ECM how much oxygen is in the
exhaust gas. The ECM changes the air/fuel ratio to the
engine by controlling the amount of time that fuel
injector is "On".
The best mixture to minimize exhaust emissions is 14.7
parts of air to 1 part of gasoline by weight, which allows
the catalytic converter to operate most efficiently.
Because of the constant measuring and adjusting of the
air/fuel ratio, the fuel injection system is called a "closed
loop" system.
The ECM monitors signals from several sensors in
order to determine the fuel needs of the engine. Fuel is
delivered under one of several conditions called
"mode". All modes are controlled by the ECM.
Acceleration Mode
The ECM provides extra fuel when it detects a rapid
increase in the throttle position and the air flow.
Battery Voltage Correction Mode
When battery voltage is low, the ECM will compensate
for the weak spark by increasing the following:
The amount of fuel delivered.
The idle RPM.
Ignition dwell time.
Clear Flood Mode

Clear a flooded engine by pushing the accelerator pedal
down all the way. The ECM then de-energizes the fuel
injectors.
The ECM holds the fuel injectors deenergized as long as the throttle remains above 80%
and the engine speed is below 800 RPM. If the throttle
position becomes less than 80%, the ECM again begins
to pulse the injectors "ON" and "OFF," allowing fuel into
the cylinders.
Deceleration Mode
The ECM reduces the amount of fuel injected when it
detects a decrease in the throttle position and the air
flow. When deceleration is very fast, the ECM may cut
off fuel completely for short periods.
Engine Speed/Vehicle Speed/Fuel Disable Mode
The ECM monitors engine speed. It turns off the fuel
injectors when the engine speed increase above 6400
RPM. The fuel injectors are turned back on when
engine speed decreases below 6150 RPM.
Fuel Cutoff Mode
No fuel is delivered by the fuel injectors when the
ignition is "OFF." This prevents engine run-on. In
addition, the ECM suspends fuel delivery if no reference
pulses are detected (engine not running) to prevent
engine flooding.
Run Mode
The run mode has the following two conditions:
Open loop
Closed loop
When the engine is first started the system is in "open
loop" operation. In "open loop," the ECM ignores the
signal from the heated oxygen sensor (HO2S). It
calculates the air/fuel ratio based on inputs from the TP,
ECT, and MAF sensors.
The system remains in "open loop" until the following
conditions are met:
The HO2S has a varying voltage output showing
that it is hot enough to operate properly (this
depends on temperature).
The ECT has reached a specified temperature.
A specific amount of time has elapsed since
starting the engine.
Engine speed has been greater than a specified
RPM since start-up.
The specific values for the above conditions vary with
different engines and are stored in the programmable
read only memory (PROM). When these conditions are
met, the system enters "closed loop" operation. In
"closed loop," the ECM calculates the air/fuel ratio
(injector on-time) based on the signal from the HO2S.
This allows the air/fuel ratio to stay very close to 14.7:1.

Starting Mode
When the ignition is first turned "ON," the ECM
energizes the fuel pump relay for two seconds to allow
the fuel pump to build up pressure. The ECM then
checks the engine coolant temperature (ECT) sensor
and the throttle position sensor to determine the proper
air/fuel ratio for starting.
The ECM controls the amount of fuel delivered in the
starting mode by adjusting how long the fuel injectors
are energized by pulsing the injectors for very short
times.
Fuel Rail
The fuel rail is mounted to the top of the engine and
distributes fuel to the individual injectors. Fuel is
delivered to the fuel inlet tube of the fuel rail by the fuel
lines. The fuel goes through the fuel rail to the fuel
pressure regulator. The fuel pressure regulator
maintains a constant fuel pressure at the injectors.
Remaining fuel is then returned to the fuel tank.
Fuel Metering System Components

The fuel metering system is made up of the following
parts.
Fuel injector
Throttle Body
Fuel Rail
Fuel Pressure regulator
ECM
Crankshaft position (CKP) sensor
Camshaft position (CMP) sensor
Idle air control valve
Fuel pump
055RV009
Fuel Injector
The sequential multi-port fuel injection fuel injector is a
solenoid operated device controlled by the ECM. The
ECM energizes the solenoid, which opens a valve to
allow fuel delivery.
The fuel is injected under pressure in a conical spray
pattern at the opening of the intake valve. Excess fuel
not used by the injectors passes through the fuel
pressure regulator before being returned to the fuel
tank.
Fuel Pressure Regulator
The fuel pressure regulator is a diaphragm-operated
relief valve mounted on the fuel rail with fuel pump
pressure on one side and manifold pressure on the
other side. The fuel pressure regulator maintains the
fuel pressure available to the injector at three times
barometric pressure adjusted for engine load. It may be
serviced separate.
If the pressure is too low, poor performance and a DTC
P0131, P0151, P0171, P0174, P1171 or P1174 will be
the result. If the pressure is too high, excessive odor
and/or a DTC P0132, P0152, P0172 or P0175 will be
the result.
Refer to Fuel System Diagnosis for
information on diagnosing fuel pressure conditions.
Fuel Pump Electrical Circuit

When the key is first turned "ON," the ECM energizes
the fuel pump relay for two seconds to build up the fuel
pressure quickly. If the engine is not started within two
seconds, the ECM shuts the fuel pump off and waits
until the engine is cranked. When the engine is cranked
and the 58 X crankshaft position signal has been
detected by the ECM, the ECM supplies 12 volts to the
fuel pump relay to energize the electric in-tank fuel
pump.
An inoperative fuel pump will cause a "no-start"
condition. A fuel pump which does not provide enough
pressure will result in poor performance.
Camshaft Position (CMP) Sensor Signal
The ECM uses this signal to determine the position of
the number 1 piston during its power stroke, allowing
the ECM to calculate true sequential multiport fuel
injection. Loss of this signal will set a DTC P0341. If the
CMP signal is lost while the engine is running, the fuel
injection system will shift to a calculated sequential fuel
injection based on the last fuel injection pulse, and the
engine will continue to run. The engine can be restarted
and will run in the calculated sequential mode as long
as the fault is present, with a 1-in-6 chance of being
correct.

ELECTRONIC IGNITION SYSTEM IGNITION
COILS & CONTROL
A separate coil-at-plug module is located at each spark
plug.
The coil-at-plug module is attached to the engine with
two screws. It is installed directly to the spark plug by an
electrical contact inside a rubber boot.
A three way connector provides 12 volts primary supply
from the ignition coil fuse, a ground switching trigger
line from the ECM, and ground.
The ignition control spark timing is the ECM's method of
controlling the spark advance and the ignition dwell.
The ignition control spark advance and the ignition dwell
are calculated by the ECM using the following inputs.
Engine speed
Camshaft position (CMP) sensor
Engine coolant temperature (ECT) sensor
Park or neutral position switch
ECM and ignition system supply voltage
Based on these sensor signal and engine load

information, the ECM sends 5V to each ignition coil
requiring ignition. This signal sets in the power
transistor of the ignition coil to establish a grounding
circuit for the primary coil, applying battery voltage to
the primary coil.
At the ignition timing, the ECM stops sending the 5V
signal voltage. Under this condition the power transistor
of the ignition coil is set off to cut the battery voltage to
the primary coil, thereby causing a magnetic field
generated in the primary coil to collapse.
On this moment a line of magnetic force flows to the
secondary coil, and when this magnetic line crosses the
coil, high voltage induced by the secondary ignition
circuit to flow through the spark plug to the ground.
Ignition Control ECM Output

The ECM provides a zero volt (actually about 100 mV to
200 mV) or a 5-volt output signal to the ignition control
(IC) module. Each spark plug has its own primary and
secondary coil module ("coil-at-plug") located at the
spark plug itself. When the ignition coil receives the
5-volt signal from the ECM, it provides a ground path for
the B+ supply to the primary side of the coil-at -plug
module. This energizes the primary coil and creates a
magnetic field in the coil-at-plug module.
When the
ECM shuts off the 5-volt signal to the ignition control
module, the ground path for the primary coil is broken.
The magnetic field collapses and induces a high voltage
secondary impulse which fires the spark plug and
ignites the air/fuel mixture.
The circuit between the ECM and the ignition coil is
monitored for open circuits, shorts to voltage, and
shorts to ground. If the ECM detects one of these
events, it will set one of the following DTCs:
P0351:
P0352:
P0353:
P0354:
P0355:
P0356:
Ignition coil Fault on Cylinder #1

Spark Plug
Although worn or dirty spark plugs may give satisfactory
operation at idling speed, they frequency fail at higher
engine speeds. Faulty spark plugs may cause poor fuel
economy, power loss, loss of speed, hard starting and
generally poor engine performance. Follow the
scheduled maintenance service recommendations to
ensure satisfactory spark plug performance. Refer to
Maintenance and Lubrication.
Normal spark plug operation will result in brown to
grayish-tan deposits appearing on the insulator portion
of the spark plug. A small amount of red-brown, yellow,
and white powdery material may also be present on the
insulator tip around the center electrode. These
deposits are normal combustion by-products of fuels
and lubricating oils with additives. Some electrode wear
will also occur. Engines which are not running properly
are often referred to as misfiring." This means the
ignition spark is not igniting the air/fuel mixture at the
proper time.
Spark plugs may also misfire due to fouling, excessive
gap, or a cracked or broken insulator. If misfiring
occurs before the recommended replacement interval,
locate and correct the cause.

Carbon fouling of the spark plug is indicated by dry,
black carbon (soot) deposits on the portion of the spark
plug in the cylinder. Excessive idling and slow speeds
under light engine loads can keep the spark plug
temperatures so low that these deposits are not burned
off. Very rich fuel mixtures or poor ignition system
output may also be the cause. Refer to DTC P0172.
Oil fouling of the spark plug is indicated by wet oily
deposits on the portion of the spark plug in the cylinder,
usually with little electrode wear. This may be caused by
oil during break-in of new or newly overhauled engines.
Deposit fouling of the spark plug occurs when the
normal red-brown, yellow or white deposits of
combustion by products become sufficient to cause
misfiring. In some cases, these deposits may melt and
form a shiny glaze on the insulator around the center
electrode. If the fouling is found in only one or two
cylinders, valve stem clearances or intake valve seals
may be allowing excess lubricating oil to enter the
cylinder, particularly if the deposits are heavier on the
side of the spark plug facing the intake valve.
Excessive gap means that the air space between the

center and the side electrodes at the bottom of the
spark plug is too wide for consistent firing. This may be
due to excessive wear of the electrode during use. A
check of the gap size and comparison to the gap
specified for the vehicle in Maintenance and Lubrication
will tell if the gap is too wide. A spark plug gap that is
too small may cause an unstable idle condition.
Excessive gap wear can be an indication of continuous
operation at high speeds or with engine loads, causing
the spark to run too hot. Another possible cause is an
excessively lean fuel mixture.
TS23992
TS23995
Low or high spark plug installation torque or improper

seating can result in the spark plug running too hot and
can cause excessive center electrode wear. The plug
and the cylinder head seats must be in good contact for
proper heat transfer and spark plug cooling. Dirty or
damaged threads in the head or on the spark plug can
keep it from seating even though the proper torque is
applied. Once spark plugs are properly seated, tighten
them to the torque shown in the Specifications Table.
Low torque may result in poor contact of the seats due
to a loose spark plug. Over tightening may cause the
spark plug shell to be stretched and will result in poor
contact between the seats. In extreme cases, exhaust
blow-by and damage beyond simple gap wear may
occur.
Cracked or broken insulators may be the result of
improper installation, damage during spark plug heat
shock to the insulator material. Upper insulators can be
broken when a poorly fitting tool is used during
installation or removal, when the spark plug is hit from
the outside, or is dropped on a hard surface. Cracks in
the upper insulator may be inside the shell and not
visible. Also, the breakage may not cause problems
until oil or moisture penetrates the crack later.
TS2394
A broken or cracked lower insulator tip (around the

center electrode) may result from heat shock" (spark
plug suddenly operating too hot).
TS23993
"Heat shock" breakage in the lower insulator tip

generally occurs during several engine operating
conditions (high speeds or heavy loading) and may
be caused by over-advanced timing or low grade
fuels. Heat shock refers to a rapid increase in the
tip temperature that causes the insulator material
to crack.
If there is any doubt about the serviceability of a spark
plug, replace it. Spark plugs with cracked or broken
insulators should always be replaced.

EVAPORATIVE EMISSION SYSTEM
EVAP Control System

The evaporate emission canister purge is controlled by
a duty solenoid valve that allows manifold to purge the
canister when following operating conditions are met.
Purge solenoid valve operating condition at idle
condition:
Engine speed is below 1000rpm.
Vehicle speed is below 3km/h.
Engine coolant temperature is more than 80C.
Intake air temperature is more than 10C.
In closed loop operation.
All above conditions are met for 4 seconds.
Purge solenoid valve operating condition at other than

idle condition:
(1) Purge Solenoid Valve

(2) From Canistor to Purge Solenoid
(3) From Purge Solenoid to Intake
Engine speed is below 6375rpm.

Vehicle speed is more than 14km/h.
All above conditions are met for 4 seconds.
Results of Incorrect Operation

Poor idle, stalling and poor driveability can be caused
by:
Inoperative purge solenoid.
Damaged canister.
Hoses split, cracked and/or not connected to the
proper tubes.
Evidence of fuel loss or fuel vapor odor can be caused
by:
2
(1) Canistor
(2) Air Separator
The basic evaporative emission control system used on
the charcoal canister storage method. The method
transfers fuel vapor from the fuel tank to an activated
carbon (charcoal) storage devise to hold the vapors
when the vehicle is not operating.
The canister is located on the rear axle housing by the
frame cross-member.
When the engine is running, the fuel vapor is purged
from the carbon element by intake air flow and
consumed in the normal combustion process.
Liquid fuel leaking from fuel lines, or fuel pump.

Cracked or damaged canister.
Disconnected, misrouted, kinked, deteriorated or
damaged vapor hoses, or control hoses.
If the solenoid is always open, the canister can purge to
the intake manifold at all times. This can allow extra fuel
at idle or during warm-up, which can cause rough or
unstable idle, or too rich operation.
If the solenoid is always closed, the canister can
become over-loaded, resulting in fuel odor.
GENERAL DESCRIPTION FOR EXHAUST

GAS RECIRCULATION (EGR) SYSTEM
Linear EGR Valve
Linear EGR valve Operation and Results of

Incorrect Operation
The linear EGR valve is designed to accurately supply
EGR to the engine independent of intake manifold
vacuum. The valve controls EGR flow from the exhaust
to the intake manifold through an orifice with a ECM
controlled pintle. During operation, the ECM controls
pintle position by monitoring the pintle position feedback
signal.
The linear EGR valve is activated under the following
conditions:
No DTC relating to the EGR.
Engine speed is between 1200 and 4375rpm.
Engine coolant temperature is between 20 and
100.
Throttle position sensor output voltage is below
3V.
Too mach EGR flow at idle, cruise or cold operation
may cause any of the following conditions to occur:
Engine stalls after a cold start.

Engine stalls at idle after deceleration.
Vehicle surges during cruise.
Rough idle.
Too little or no EGR flow may allow combustion

temperatures to get too high. This could cause:
Spark knock (detonation).
Emission test failure.
Poor fuel economy.
060R200237
Legend
(1) ECM
(2) Linear EGR Valve
(3) Throttle
(4) Exhaust Manifold
The exhaust gas re-circulation (EGR) system is used to
reduce emission levels of oxides of nitrogen (NOx).
NOx emission levels are caused by a high combustion
levels by decreasing the combustion temperature.
The EGR valve feeds small amount of exhaust gas
back into the combustion chamber. The fuel/air mixture
will be diluted and combustion temperatures reduced.
ISUZU STRATEGY BASED DIAGNOSTICS

Overview


customer complaint
Saves time by avoiding testing and/or replacing
good parts
perspectives
Guides you to determine what level of
understanding about system operation is needed:
- Owners manual level
- Service manual level
- In-depth (engineering) level

What you should do
verify that the customer complaint is a valid failure of
the system.
complaint:
WHAT
aftermarket
and
dealer-installed
accessories exist
Whether the severity of the problem has
increased, decreased or stayed the same

sections


Vehicle road tests

NOTE: An estimated 10 percent of successful
vehicle repairs are diagnosed with this step!
What you should do
To detect if the cause of the complaint is
VISUALLY OBVIOUS
accurately search for a ISUZU Service Bulletin.
actions:
computers
Sense unusual noises, smells, vibrations or
movements

checks:
Tech 2 or other technical equipment for viewing
DTCs
- Component locations
- Harness routing
- Wiring schematics
- Procedures for viewing DTCs
Vehicle road test

NOTE: As estimated 30 percent of successful
vehicle repairs are diagnosed with this step!
What you should do

What you should do

You should use the following resources for assistance
in checking for bulletins and troubleshooting hints:
Printed bulletins
Access ISUZU Bulletin Web site
Videotapes
Service manual

Diagnostic Checks
What you should do
with:
service manual

Service manual
Technical equipment (for viewing DTCs and
analyzing data)

NOTE: An estimated 40 percent of successful
vehicle repairs are diagnosed with these steps!

procedures:
Service manual
Technical equipment (for analyzing diagnostic
data)

What you should do

circuit(s)
characteristics:
Electrical:
- How is the circuit powered (power distribution
- How is the circuit grounded (ground distribution
charts)?
- How is the circuit controlled or sensed (theory
of operation):
- If it is a switched circuit, is it normally open or
normally closed?
- Is the power switched or is the ground
switched?
- Is it a variable resistance circuit (ECT sensor
or TPS, for example)?
- Is it a signal generating device (MAF sensor
of VSS, for example)?

- Does it rely on some mechanical/vacuum
device to operate?
Physical:
- Where are the circuit components (component
- Are there areas where wires could be
chafed or pinched (brackets or frames)?
- Are there areas subjected to extreme
temperatures?
- Are there areas subjected to vibration or
movement
(engine,
transmission
or
suspension)?
- Are there areas exposed to moisture, road
salt or other corrosives (battery acid, oil or
other fluids)?
- Are there common mounting areas with
other systems/components?
- Have previous repairs been performed to
wiring, connectors, components or mounting
areas (causing pinched wires between panels
and drivetrain or suspension components
without causing and immediate problem)?
- Does the vehicle have aftermarket or dealerinstalled equipment (radios, telephone, etc.)
Divide (and separate, where possible) the system
or circuit into smaller sections
Confine the problem to a smaller area of the
vehicle (start with main harness connections while
removing panels and trim as necessary in order to
eliminate large vehicle sections from further
investigation)
For two or more circuits that do not share a
common power or ground, concentrate on areas
where harnesses are routed together or
connectors are shared (refer to the following hints)
Hints
Loose connections:
- Open/high resistance in terminals, splices,
Incorrect connector/harness routing (usually in
new vehicles or after a repair has been made):

Component failure:
- Opens/short and high resistance in relays,
Aftermarket equipment affecting normal operation
of other systems You may isolate circuits by:
Operating shared circuits and eliminating those
that function normally from the suspect circuit
If only one component fails to operate, begin
testing at the component
If a number of components do no operate, begin
tests at the area of commonality (such as power
sources, ground circuits, switches or major
connectors)

Service manual
Experience

Malfunctioning components (such as sticking
relays, solenoids, etc.)
EMI/RFI
frequency
interference)
problem.
What you should do

complaint.


system(s).
problem
Hints
If only component fails to operate, begin testing
the component
If a number of components do not operate, begin
test at areas of commonality (such as power
sources, ground circuits, switches, main
connectors or major components)
Try the suspect part in a known good vehicle See
Symptom Simulation Tests on the next page for
problem simulation procedures. Refer to service
manual sections 6E and 8A for information about
intermittent diagnosis. Follow procedures for basic
circuit testing in service manual section 8A.
Service manual
Bulletins
Tech 2 and Tech 2 upload function
Circuit
testing
tools
(including connector
kits/harnesses and jumper wires)
Experience

1. Vibration
for a malfunction.
2. Heat
malfunction.
the component.
conditions of high humidity. In this case, apply water in
a light spray on the vehicle to duplicate the problem.
4. Electrical loads



customer
previous
Service manual
Accumulated information form a
diagnostic path
ISUZU field support
What you should do

by:
Reviewing service manual functional/diagnostic
checks
Examining bulletins and other service information
for supplementary information
the customer.


ISUZU field support
Experience

What you should do

Strategy Based Diagnostics. You also should repeat
any procedures that require additional attention.
What you should do



Equipment
Aftermarket (add-on) electrical and vacuum equipment
is defined as any equipment which connects to the
vehicle's electrical or vacuum systems that is installed
on a vehicle after it leaves the factory. No allowances
have been made in the vehicle design for this type of
equipment.
NOTE: No add-on vacuum equipment should be
added to this vehicle.
NOTE: Add-on electrical equipment must only be
connected to the vehicle's electrical system at the
battery (power and ground).
Add-on electrical equipment, even when installed to
these guidelines, may still cause the powertrain system
to malfunction. This may also include equipment not
connected to the vehicle electrical system such as
portable telephones and radios. Therefore, the first
step in diagnosing any powertrain problem is to
eliminate all aftermarket electrical equipment from the
vehicle. After this is done, if the problem still exists, it
may be diagnosed in the normal manner.
Electrostatic Discharge Damage

Electronic components used in the ECM are often
designed to carry very low voltage.
Electronic
components are susceptible to damage caused by
electrostatic discharge. Less than 100 volts of static
electricity can cause damage to some electronic
components. By comparison, it takes as much as 4000
volts for a person to feel even the zap of a static
discharge.
TS23793
There are several ways for a person to become

statically charged. The most common methods of
charging are by friction and induction.
An example of charging by friction is a person sliding
across a vehicle seat.
Charge by induction occurs when a person with well
insulated shoes stands near a highly charged object
and momentary touches ground. Charges of the
same polarity are drained off leaving the person
highly charged with the opposite polarity. Static
charges can cause damage, therefore it is important
to use care when handling and testing electronic
components.
NOTE: To prevent possible electrostatic discharge
damage, follow these guidelines:
Do not touch the ECM connector pins or soldered
components on the ECM circuit board.
Do not open the replacement part package until
the part is ready to be installed.
Before removing the part from the package,
ground the package to a known good ground on
the vehicle.
If the part has been handled while sliding across
the seat, while sitting down from a standing
position, or while walking a distance, touch a
known good ground before installing the part.
Fuel Quality
Fuel quality is not a new issue for the automotive

industry, but its potential for turning on the MIL (Check
Engine" lamp) with OBD systems is new.
Fuel additives such as dry gas" and octane
enhancers" may affect the performance of the fuel. The
Reed Vapor Pressure of the fuel can also create
problems in the fuel system, especially during the spring
and fall months when severe ambient temperature
swings occur. A high Reed Vapor Pressure could show
up as a Fuel Trim DTC due to excessive canister
loading. High vapor pressures generated in the fuel
tank can also affect the Evaporative Emission
diagnostic as well.
Using fuel with the wrong octane rating for your vehicle
may cause driveability problems. Many of the major
fuel companies advertise that using premium" gasoline
will improve the performance of your vehicle. Most
premium fuels use alcohol to increase the octane rating
of the fuel. Although alcohol-enhanced fuels may raise
the octane rating, the fuel's ability to turn into vapor in
cold temperatures deteriorates. This may affect the
starting ability and cold driveability of the engine.
Low fuel levels can lead to fuel starvation, lean engine
operation, and eventually engine misfire.
The sensitivity of OBD diagnostics will cause the MIL

(Check Engine" lamp) to turn on if the vehicle is not
maintained properly. Restricted air filters, fuel filters,
and crankcase deposits due to lack of oil changes or
improper oil viscosity can trigger actual vehicle faults
that were not previously monitored prior to OBD. Poor
vehicle maintenance can not be classified as a
non-vehicle fault", but with the sensitivity of OBD
diagnostics, vehicle maintenance schedules must be
more closely followed.
Non-OEM Parts
with OEM parts.
cause a false sensor reading and turn on the MIL
(Check Engine" lamp).
Environment
Temporary environmental conditions, such as localized
flooding, will have an effect on the vehicle ignition
system. If the ignition system is rain-soaked, it can
temporarily cause engine misfire and turn on the MIL
(Check Engine" lamp).
Vehicle Marshaling
The transportation of new vehicles from the assembly
plant to the dealership can involve as many as 60 key
cycles within 5Km miles of driving. This type of
operation contributes to the fuel fouling of the spark
plugs and will turn on the MIL (Check Engine" lamp).
Severe Vibration
The Misfire diagnostic measures small changes in the
rotational speed of the crankshaft. Severe driveline
vibrations in the vehicle, such as caused by an
excessive amount of mud on the wheels, can have the
same effect on crankshaft speed as misfire.
One example would be that if the ECM detected a
Misfire fault, the diagnostics on the catalytic converter
would be suspended until Misfire fault was repaired. If
the Misfire fault was severe enough, the catalytic
converter could be damaged due to overheating and
would never set a Catalyst DTC until the Misfire fault
was repaired and the Catalyst diagnostic was allowed to
run to completion. If this happens, the customer may
have to make two trips to the dealership in order to
repair the vehicle.
Maintenance Schedule
Refer to the Maintenance Schedule.
Visual/Physical
Inspection
Engine
Compartment
Perform a careful visual and physical engine

Use the following
guidelines when performing a visual/physical inspection:
Inspect all vacuum hoses for punches, cuts,
components.

Lack of basic knowledge of this powertrain when
performing diagnostic procedures could result in an
incorrect diagnosis or damage to powertrain
Serial Data Communications

active.
Remember, a fuel trim DTC may be triggered by a list of
vehicle faults. Make use of all information available
(other DTCs stored, rich or lean condition, etc.) when
diagnosing a fuel trim fault.
Comprehensive
Component
Diagnostic Operation
Monitor
Class II Serial Data Communications
Input Components:
This vehicle utilizes the Class II" communication

system. Each bit of information can have one of two
lengths: long or short. This allows vehicle wiring to be
reduced by transmitting and receiving multiple signals
over a single wire. The messages carried on Class II
data streams are also prioritized. If two messages
attempt to establish communications on the data line at
the same time, only the message with higher priority will
continue. The device with the lower priority message
must wait. The most significant result of this regulation
is that it provides Tech 2 manufacturers with the
capability to access data from any make or model
vehicle that is sold.
The data displayed on the other Tech 2 will appear the
same, with some exceptions. Some scan tools will only
be able to display certain vehicle parameters as values
that are a coded representation of the true or actual
value. For more information on this system of coding,
refer to Decimal/Binary/Hexadecimal Conversions. On
this vehicle the Tech 2 displays the actual values for
vehicle parameters. It will not be necessary to perform
any conversions from coded values to actual values.
Input components are monitored for circuit continuity

and out-of-range values.
This includes rationality
checking. Rationality checking refers to indicating a
fault when the signal from a sensor does not seem
reasonable, i.e.throttle position sensor that indicates
high throttle position at low engine loads. Input
components may include, but are not limited to the
following sensors:
On-Board Diagnostic (OBD)

On-Board Diagnostic Tests
ignition cycle.
currently active.

Inlet Air Temperature (IAT) Sensor
Camshaft Position (CMP) Sensor
In addition to the circuit continuity and rationality check
the ECT sensor is monitored for its ability to achieve a
steady state temperature to enable closed loop fuel
control.
Output Components:
Output components are diagnosed for proper response
to control module commands. Components where
functional monitoring is not feasible will be monitored for
circuit continuity and out-of-range values if applicable.
Output components to be monitored include, but are not
limited to, the following circuit:
Control module controlled EVAP Canister Purge
Valve
Electronic Transmission controls
A/C relays
VSS output
MIL control
Refer to ECM and Sensors in General Descriptions.
Passive and Active Diagnostic Tests
A passive test is a diagnostic test which simply monitors

a vehicle system or component. Conversely, an active
test, actually takes some sort of action when performing
diagnostic functions, often in response to a failed
passive test.
The Check Engine Lamp (MIL) looks the same as the

MIL you are already familiar with (Check Engine"
lamp).
Basically, the MIL is turned on when the ECM detects a
DTC that will impact the vehicle emissions.
The MIL is under the control of the Diagnostic
Executive.
The MIL will be turned on if an
emissions-related
diagnostic
test
indicates
a
malfunction has occurred. It will stay on until the
system or component passes the same test, for three
consecutive trips, with no emissionsrelated faults.
Intrusive Diagnostic Tests

This is any on-board test run by the Diagnostic
Management System which may have an effect on
vehicle performance or emission levels.
Warm-Up Cycle
A warm-up cycle means that engine at temperature
must reach a minimum of 70C (160F) and rise at
least 22C (40F) over the course of a trip.

follows:
Commanding the MIL (Check Engine" lamp) on and
off
Freeze Frame data for the first emission related DTC
recorded
The Diagnostic Executive records DTCs and turns on
the MIL when emission-related faults occur. It can also
turn off the MIL if the conditions cease which caused
the DTC to set.
When a malfunction is detected by the control module,
a diagnostic trouble code is set and the MIL (Check
Engine" lamp) is illuminated.
Extinguishing the MIL

When the MIL is on, the Diagnostic Executive will turn
off the MIL after three consecutive trips that a test
passed" has been reported for the diagnostic test that
originally caused the MIL to illuminate.
Although the MIL has been turned off, the DTC will
remain in the ECM memory (both Freeze Frame and
Failure Records) until forty(40) warm-up cycles after no
faults have been completed.
If the MIL was set by either a fuel trim or misfire-related
DTC, additional requirements must be met. In addition
to the requirements stated in the previous paragraph,
these requirements are as follows:
The diagnostic tests that are passed must occur with
375 RPM of the RPM data stored at the time the last
test failed.
Plus or minus ten (10) percent of the engine load that
was stored at the time the last failed.
Similar engine temperature conditions (warmed up or
warming up ) as those stored at the time the last test
failed.
Meeting these requirements ensures that the fault which
turned on the MIL has been corrected.
The MIL (Check Engine" lamp) is on the instrument
panel and has the following functions:
It informs the driver that a fault that affects vehicle
emission levels has occurred and that the vehicle
should be taken for service as soon as possible.
As a bulb and system check, the MIL will come ON"
with the key ON" and the engine not running. When
the engine is started, the MIL will turn OFF."
When the MIL remains ON" while the engine is
running, or when a malfunction is suspected due to a
driveability or emissions problem, a Powertrain
On-Board Diagnostic (OBD) System Check must be
performed. The procedures for these checks are
given in On-Board Diagnostic (OBD) System Check.
These checks will expose faults which may not be
detected if other diagnostics are performed first.

Fail Records and/or Freeze Frame data.
Intermittent Check Engine Lamp

In the case of an intermittent" fault, the MIL (Check
Engine" lamp) may illuminate and then (after three trips)
go OFF". However, the corresponding diagnostic
trouble code will be stored in the memory. When
unexpected diagnostic trouble codes appear, check for
an intermittent malfunction.
A diagnostic trouble code may reset. Consult the
Diagnostic Aids" associated with the diagnostic trouble
code. A physical inspection of the applicable sub
system most often will resolve the problem.
The provision for communication with the control
module is the Data Link Connector (DLC). The DLC is
used to connect to a Tech 2. Some common uses of
the Tech 2 are listed below:
Clearing DTCs.
Performing out put control tests.
060RW046

1. Review and record the Fail Records and/or Freeze
Frame data for the DTC which has been diagnosed
(Freeze Frame data will only be stored for an A or B
type diagnostic and only if the MIL has been
requested).
2. Clear DTC(s).

Following these steps are very important in verifying
Reading Flash Diagnostic Trouble Codes

The provision for communicating with the Engine
Control Module (ECM) is the Data Link Connector
(DLC). The DLC is located behind the lower front
instrument panel. It is used in the assembly plant to
receive information in checking that the engine is
operating properly before it leaves the plant.
The diagnostic trouble code(s) (DTCs) stored in the
ECM's memory can be read either through a hand-held
diagnostic scanner plugged into the DLC or by counting
the number of flashes of the Check Engine Lamp (MIL)
when the diagnostic test terminal of the DLC is
grounded. The DLC terminal 6" (diagnostic request) is
pulled Low" (grounded) by jumpering to DLC terminal
4", which is a ground wire.
This will signal the ECM that you want to flash" DTC(s),
if any are present. Once terminals 4" and 6" have
been connected, the ignition switch must be moved to
the ON" position, with the engine not running. At this
point, the Check Engine" MIL should flash DTC12
three times consecutively.
This would be the following flash, sequence: "flash,
pause, flash?flash, long pause, flash, pause,
flash?flash, long pause, flash, pause, flash?flash". DTC
12 indicates that the ECM's diagnostic system is
operating. If DTC 12 is not indicated, a problem is
present within the diagnostic system itself, and should
be addressed by consulting the appropriate diagnostic
chart in DRIVEABILITY AND EMISSIONS.
Following the output of DTC 12, the Check Engine" MIL
will indicate a DTC three times if a DTC is present, or it
will simply continue to output DTC12. If more than one
DTC three has been stored in the ECM's memory, the
DTC(s) will be output from the lowest to the highest,
with each DTC being displayed three times.

TECH 2
to used a diagnostic Tech 2. When reading DTC(s),
follow instructions supplied by Tech 2 manufacturer.
For the 1998 model year, Isuzu dealer service
departments will continue to use Tech 2.

0.4 Sec
0.4 Sec
Normal Code (12)

ON
OFF

3.2 Sec.
1.2 Sec.
0.4 Sec
3.2 Sec.
0.4 Sec
Trouble Code (32)
ON
OFF
3.2 Sec.
1.2 Sec.

3.2 Sec.
Self-diagnosis Start
12
12
12
14
14
14
32
32
32
In case DTC 14 & 32 are stored

Important: Do not clear DTCs unless directed to do so
by the service information provided for each diagnostic
procedure. When DTCs are cleared, the Freeze Frame
and Failure Record data which may help diagnose an
intermittent fault will also be erased from memory.
If the fault that caused the DTC to be stored into
memory has been corrected, the Diagnostic Executive
will begin to count the warm-up" cycles with no further
faults detected, the DTC will automatically be cleared
from the ECM memory.
Tech 2 clear DTCs" or clear information" function.
Tech 2 manufacturer.
When a Tech 2 is not available, DTCs can also be
cleared by disconnecting one of the following sources
for at least thirty (30) seconds.
To prevent system damage, the ignition key must be
OFF" when disconnecting or reconnecting battery
power.
The power source to the control module. Examples:
fuse, pigtail at battery ECM connectors etc.
The negative battery cable. (Disconnecting the
negative battery cable will result in the loss of other
on-board memory data, such as preset radio tuning).
On-Board Diagnosis (Self-Diagnosis)

1. The Engine Control Module (ECM) conducts a
self-test of most of the wiring and components in
the system each time the key is turned to ON, and
can detect faults in the system while the key is ON.
If a fault is detected, the ECM will store a trouble
code in memory and flash the CHECK ENGINE
indicator to alert the driver.
2. The Diagnostic Trouble Codes (DTC) can be
displayed by shorting together terminals and the
Data Link Connector (DLC) located below
Instrument Panel of drivers side.
The CHECK ENGINE indicator will flash DTC 12
three times, followed by any DTC.If several DTC are
stored, each DTC will be displayed three times. The
DTC will be displayed in numerical order. The DTC
display will continue as long as the DLC is shorted.
Some DTC can cause other DTC to be stored, It is
important to diagnose and repair the lowest
numbered DTC first before going on to the higher
numbered DTC.

TECH 2 CONNECTION

Te c h 2 .
Tech 2 scan tool kit (No. 7000086), Tech 2
scan tool (No. 7000057) and DLC cable (No.
3000095).
SAE 16/19 adapter (No. 3000098) (3), RS232

NOTE: Be sure to check that the power is not
supplied to the Tech 2 when attaching or removing
the PCMCIA card.
Diagnosis with TECH 2

If No Codes are Set
Refer to "SYMPTOM DIAGNOSIS".
If Codes are Set
2. Clear the codes.
status.
intermittent. In this case, refer to "DIAGNOSIS
AIDS".
diagnosis.
Select "3.5L V6 6VE1 Hitachi" in Vehicle Identification

menu and the following table is shown in the Tech 2
screen.

F0: Read DTC Infor By Priority
F2: DTC Information
F0: History
F1: MIL SVS or Message Requested
F2: Last Test Failed
F3: Test Failed Since Code Cleared
F4: Not Run Since Code Cleared
F5: Failed This Ignition
F3: Freeze Frame/Failure Record
F1: Data Display
F0: Engine Data
F1: O2 Sensor Data
F2: Snapshot
F0: Lamps
F0: Malfunction Indicator Lamps
F1: Relays
F0: Fuel Pump Relay
F1: A/C Clutch Relay
F2: EVAP
F0: Purge Solenoid
F3: IAC System
F0: RPM Control
F1: IAC Control
F4: Fuel System
F0: Fuel Trim Reset
F4: System Information
F0: MIL/System Status

The purpose of the "Diagnostic Trouble Codes" mode is
to display stored trouble code in the
ECM.
When "Clear DTC Information" is selected, a "Clear
DTC Information", warning screen appears.
This screen informs you that by cleaning DTC's "all
stored DTC information in the ECM will be erased".
Use the "DTC Information" mode to search for a
specific type of stored DTC information.
History
This selection will display only DTCs that are stored in
the ECM's history memory. It will not display Type B
DTCs that have not requested the MIL ("Check Engine
Lamp"). It will display all type A and B DTCs that
requested the MIL and have failed within the last 40
warm-up cycles. In addition, it will display all type C and
D DTCs that have failed within the last 40 warm-up
cycles.
MIL SVC or Message Request
This selection will display only DTCs that are requesting
the MIL. Type C and Type D DTCs cannot be displayed
using the MIL. Type C and D DTCs cannot be displayed
using this option.
This selection will report type B DTCs only after the MIL
has been requested.
Last Test Failed
This selection will display only DTCs that have failed the
last time the test run. The last test may have run during
a previous ignition cycle of a type A or type B DTC is
displayed. For type C and type D DTCs, the last failure
must have occurred during the current ignition cycle to
appear as last test fail.
Test Failed Since Code Cleared
The selection will display all active and history DTCs
that have reported a test failure since the last time
DTCs were cleared. DTCs that last failed more that 40
warm-up cycles before this option is selected will not be
displayed.
Not Run Since Code Cleared
This selection will display up to DTCs that have not run
since the DTCs were last cleared. Since any displayed
DTCs have not run, their condition (passing or failing) is
unknown.
Failed This Ignition
This selection will display all DTCs that have failed
during the present ignition cycle.
Freeze Frame/Failure Record
This selection will display stored various vehicle
information at the moment an emission related fault
when the MIL ("Check Engine Lamp") is commanded
on.
The Freeze Frame data will not be erased unless the
associated history DTC is cleared.

F1: Data Display
The purpose of the "Data Display" mode is to
See the "Typical Scan Data" section.

Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were noted, and you have determined that the On-Board
Diagnostic are functioning properly.
Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately 80C)
Tech 2
Parameter
Ignition Voltage
Units
Idle
2000rpm
Definitions
10.0 - 14.5
10.0 - 14.5
This displays the system voltage measured by the ECM at ignition feed.
Engine Speed
rpm
710 - 860
1950 - 2050
The actual engine speed is measured by ECM from the CKP sensor 58X signal.
Desired Idle
Speed
rpm
750 - 770
750 - 770
Engine Coolant
Temperature
C or F
80 - 90 ()
80 - 90 ()
Start Up ECT
(Engine Coolant
Temperature)
C or F
Intake Air
Temperature
C or F
Throttle Position

The ECM compensates for various engine loads.
The ECT is measured by ECM from ECT sensor output voltage.

When the engine is normally warm upped, this data displays approximately 80 C or
more.
Depends on ECT Depends on ECT Start-up ECT is measured by ECM from ECT sensor output voltage when engine is
started.
at start-up
at start-up
Depends on
ambient temp.
Depends on
ambient temp.
The IAT is measured by ECM from IAT sensor output voltage.

This data is changing by intake air temperature.
4-6
Throttle Position
Sensor
0.4 - 0.7
0.6 - 0.8
Mass Air Flow
g/s
5.0 - 8.0
13.0 - 16.0
10
Air Fuel Ratio
14.7:1
14.7:1
This displays the ECM commanded value.

In closed loop, this should normally be displayed around 14.2:1 - 14.7:1.
11
Idle Air Control
Steps
10 - 20
20 - 30
This displays the ECM commanded position of the idle air control valve pintle.
A larger number means that more air is being commanded through the idle air
passage.
12
EGR Valve
0.00
0.00 - 0.10
The EGR position sensor output voltage is displayed.

This data is changing by EGR valve solenoid operating position.
13
Desired EGR
Opening
0.00
0.05 - 1.10
The ECM commanded EGR position sensor voltage is displayed.

According to the current position, ECM changes EGR valve solenoid operating
position to meet the desired position.
14
EGR Valve On
Duty
32 38
This displays the duty signal from the ECM to control the EGR valve.
15
Engine Load
2-7
8 - 15
This displays is calculated by the ECM form engine speed and MAF sensor reading.
Engine load should increase with an increase in engine speed or air flow amount.
16
B1 Fuel System
Status
Open Loop/ Close

Loop
Close Loop
Close Loop
17
B2 Fuel System
Status
Open Loop/ Close

Loop
Close Loop
Close Loop
When the engine is first started the system is in "Open Loop" operation.
In "Open Loop", the ECM ignores the signal from the oxygen sensors.
When various conditions (ECT, time from start, engine speed & oxygen sensor
output) are met, the system enters "Closed Loop" operation.
In "Closed Loop", the ECM calculates the air fuel ratio based on the signal from the
oxygen sensors.
18
Fuel Trim
Yes/No
Learned (Bank 1)
Yes
Yes
19
Fuel Trim
Yes/No
Learned (Bank 2)
Yes
Yes
20
Injection Pulse
Bank 1
ms
2.0 - 4.0
2.0 - 4.0
21
Injection Pulse
Bank 2
ms
2.0 - 4.0
2.0 - 4.0
This displays the amount of time the ECM is commanding each injector On during
each engine cycle.
A longer injector pulse width will cause more fuel to be delivered. Injector pulse width
should increase with increased engine load.
22
Spark Advance
CA
10 - 15
35 - 42
This displays the amount of spark advance being commanded by the ECM.
Throttle position operating angle is measured by the ECM from throttle position
output voltage.
This should display 0% at idle and 99 - 100% at full throttle.
The TPS output voltage is displayed.
This data is changing by accelerator operating angle.
This displays intake air amount.
The mass air flow is measured by ECM from the MAF sensor output voltage.
When conditions are appropriate for enabling long term fuel trim corrections, fuel trim
learn will display "Yes".
This indicates that the long term fuel trim is responding to the short term fuel trim.
If the fuel trim lean displays "No", then long term fuel trim will not respond to changes
in short term fuel trim.
Units
Idle
2000rpm
Definitions
On/Off
Off
Off
This displays the air conditioner request signal. This should display "On" when the air
conditioner switch is switched on.
Off
Off
This displays whether the ECM has commanded the A/C compressor clutch "On" or
"Off".
50 - 80
This displays the duty signal from the ECM to control the canister purge solenoid
valve.
49 - 52
13 - 17
On
On
This displays operating status for the fuel pump main relay.
This should display "On" when the key switch is turned on and while engine is
running.
Inactive
Inactive
The ECM will command the deceleration fuel mode when it detects a closed throttle
position while the vehicle is traveling.
While in decreasing fuel mode, the ECM will decrease the amount of fuel delivered
by entering open loop and decreasing the injector pulse width.
No
No
The ECM will command power enrichment mode "Yes" when a large increase in
throttle position and load is detected.
While in power enrichment mode, the ECM will increase the amount of fuel delivered
by entering open loop and increasing the injector pulse width.
Present
Present
24
A/C Clutch
On/Off
25
EVAP Purge
Solenoid
(Evaporative
Emission)
26
Fuel Trim Cell
27
Fuel Pump
28
Deceleration Fuel Active/ Inactive

Cutoff
29
Power Enrichment Yes/No
30
Vehicle Speed
km/h or mph
31
Cam Signal
Present/ Missing
32
PSP Switch
(Power Steering
Pressure)
Normal Pressure / Normal Pressure

High Pressure
33
Security Code
Status
34
Security Code
Programmable/
Not
Programmable
Okay/ Not Okay
35
Immobilizer
System
Normal /
Abnormal
36
Malfunction
Indicator Lamp
On/Off
37
Time From Start
On/Off
This displays dependent on engine speed and MAF sensor reading.

A plot of engine speed versus MAF amount is divided into the cells.
Fuel trim cell indicates which cell is currently active.
This displays vehicle speed.

The vehicle speed is measured by ECM from the vehicle speed sensor.
This displays input signal from the camshaft position sensor.
When the correct pulse is generated, signal is received.
Normal Pressure This displays the power steering pressure signal.

This should display "High Pressure" when the steering is steered.
Programmable
Programmable
This should display "Programmable" when the correct security code & secret code
are programmed.
Okay
Okay
This should display "Okay" when the security code is correctly accepted.
Normal
Normal
This should display "Normal" when the immobilizer is correctly operated.
Off
Off

This should display "On" when the Check Engine Lamp is turned on.
This displays the engine time elapsed since the engine was started.
If the engine is stopped, engine run time will be reset to 00:00:00
23
Tech 2
Parameter
A/C Request (Air
Conditioning)
TYPICAL SCAN DATA & DEFINITIONS (O2 SENSOR DATA)

Use the typical values table only after the On-Board Diagnostic System check has been completed, no DTC(s) were noted, and you have determined that the On-Board
Diagnostic are functioning properly.
Condition : Vehicle stopping, engine running, air conditioning off & after warm-up (Coolant temperature approximately 80 C)
Tech 2
Parameter
Ignition Voltage
Units
Idle
2000rpm
Definitions
10.0 - 14.5
10.0 - 14.5
This displays the system voltage measured by the ECM at ignition feed.
Engine Speed
rpm
710 - 860
1950 - 2050
The actual engine speed is measured by ECM from the CKP sensor 58X signal.
Desired Idle
Speed
rpm
750 - 770
750 - 770
Engine Coolant
Temperature
C or F
80 - 90 (C)
80 - 90 (C)
Start Up ECT
(Engine Coolant
Temperature)
C or F
Throttle Position
4-6
Throttle Position
Sensor
0.4 - 0.7
0.6 - 0.8
Mass Air Flow
g/s
5.0 - 8.0
13.0 - 16.0
Air Fuel Ratio
14.7:1
14.7:1
This displays the ECM commanded value. In closed loop, this should normally be
displayed around 14.2:1 - 14.7:1.
10
Engine Load
2-7
8 - 15
This displays is calculated by the ECM form engine speed and MAF sensor reading.
Engine load should increase with an increase in engine speed or air flow amount.
11
B1 Fuel System
Status
Open Loop/ Close

Loop
Close Loop
Close Loop
12
B2 Fuel System
Status
Open Loop/ Close

Loop
Close Loop
Close Loop
When the engine is first started the system is in "Open Loop" operation.
In "Open Loop", the ECM ignores the signal from the oxygen sensors.
When various conditions (ECT, time from start, engine speed & oxygen sensor
output) are met, the system enters "Closed Loop" operation.
In "Closed Loop", the ECM calculates the air fuel ratio based on the signal from the
oxygen sensors.
13
B1S1 O2 Sensor mV
(Bank1 Sensor 1)
50 - 950
50 -950
14
B2S1 O2 Sensor mV
(Bank2 Sensor 1)
50 - 950
50 - 950
15
B1 O2 Sensor
Ready (Bank 1)
Yes/No
Yes
Yes
16
B2 O2 Sensor
Ready (Bank 2)
Yes/No
Yes
Yes
17
B1 Long Term
Fuel Trim (Bank
1)
-10 - 20
-10 - 20
18
B2 Long Term
Fuel Trim (Bank
2)
-10 - 20
-10 - 20

The ECM compensates for various engine loads.
The ECT is measured by ECM from ECT sensor output voltage.

When the engine is normally warm upped, this data displays approximately 80 C or
more.
Depends on ECT Depends on ECT Start-up ECT is measured by ECM from ECT sensor output voltage when engine is
started.
at start-up
at start-up
Throttle position operating angle is measured by the ECM from throttle position
output voltage.
This should display 0% at idle and 99 - 100% at full throttle.
The TPS output voltage is displayed.
This data is changing by accelerator operating angle.
This displays intake air amount.
The mass air flow is measured by ECM from the MAF sensor output voltage.
This displays the exhaust oxygen sensor output voltage.

Should fluctuate constantly within a range between 10mV (lean exhaust) and
1000mV (rich exhaust) while operating in closed loop.
This displays the status of the exhaust oxygen sensor.

This display will indicate "Yes" when the ECM detects a fluctuating oxygen sensor
output voltage sufficient to allow closed loop operation.
This will not occur unless the oxygen sensor is warmed up.
The long term fuel trim is delivered from the short term fuel term values and
represents a long term correction of fuel delivery for bank in question.
A value of 0% indicates that fuel delivery requires no compensation to maintain the
ECM commanded air fuel ratio.
A negative value indicates that the fuel system is rich and fuel delivery is being
reduced (decreased injector pulse width).
A positive value indicates that a lean condition exists and the ECM is compensating
by add fuel (increased injector pulse width).
Because long term fuel trim tends to follow short term fuel trim, a value in the
negative range due to canister purge at idle should not be considered unusual.
Excessive long term fuel trim values may indicate an rich or lean condition.
Units
Idle
2000rpm
Definitions
-10 - 20
-10 - 20
-10 - 20
-10 - 20
The short term fuel trim to a bank represents a short term correction to the bank fuel
delivery by the ECM in response to the amount of time the bank fuel control oxygen
sensor voltage spends above or below the 450mV threshold.
If the oxygen sensor voltage has mainly remained less than 450mV, indicating a lean
air/fuel, short term fuel trim will increase into the positive range above 0% and the
ECM will pass fuel.
If the oxygen sensor voltage stays mainly above the threshold, short term fuel trim
will decrease below 0% into the negative range while the ECM reduces fuel delivery
to compensate for the indicated rich condition.
Under certain conditions such as extended idle and high ambient temperatures,
canister purge may cause short term fuel trim to read in the negative range during
normal operation.
Excessive short term fuel trim values may indicate an rich or lean condition.
49 - 52
13 - 17
20
B2 Short Term
Fuel Trim (Bank
2)
21
Fuel Trim Cell
22
Fuel Trim
Yes/No
Learned (Bank 1)
Yes
Yes
23
Fuel Trim
Yes/No
Learned (Bank 2)
Yes
Yes
24
B1S1 Status
Rich / Lean
(Bank 1 Sensor 1)
Rich / Lean
Rich / Lean
25
B2S1 Status
Rich / Lean
(Bank 2 Sensor 1)
Rich / Lean
Rich / Lean
This displays dependent on engine speed and MAF sensor reading.

A plot of engine speed versus MAF amount is divided into the cells.
Fuel trim cell indicates which cell is currently active.
When conditions are appropriate for enabling long term fuel trim corrections, fuel trim
learn will display "Yes".
This indicates that the long term fuel trim is responding to the short term fuel trim.
If the fuel trim lean displays "No", then long term fuel trim will not respond to changes
This displays dependent on the exhaust oxygen sensor output voltage.

Should fluctuate constantly "Rich" and "Lean" in closed loop.
19
Tech 2
Parameter
B1 Short Term
Fuel Trim (Bank
1)
3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E -83
MISCELLANEOUS TEST
miscellaneous test menus. Especially when DTC cannot
be detected, a faulty circuit can be diagnosed by testing
each circuit by means of these menus.
Connect Tech 2 and select "Powertrain", "3.5L V6 6VE1
Hitachi" & "Miscellaneous Test".
F0: Lamps
F0: Malfunction Indicator Lamp
When the Tech 2 is operated, "Malfunction Indicator
Lamp (Check Engine Lamp)" is turned on or off.
The circuit is normal if the "Malfunction Indicator Lamp
(Check Engine Lamp)" in the instrument panel is turned
on or off in accordance with this operation.
F1: Relays
F0: Fuel Pump Relay
When the Tech 2 is operated, fuel pump relay signal
turns ON or OFF.
The circuit is normal if fuel pump sound is generated in
accordance with this operation when key switch is
turned ON.
"F1: A/C Clutch Relay"
When the Tech 2 is operated, A/C clutch relay signal
turns ON or OFF.
The circuit is normal if A/C compressor clutch is
energized in accordance with this operation when the
engine is running.
F2: EVAP
F0: Purge Solenoid
When the Tech 2 is operated, duty ratio of EVAP purge
solenoid is changed 10%-by-10%.
Purge Solenoid
Engine Speed
Desired Idle Speed
Start Up ECT
Throttle Position
EVAP Purge Solenoid
800 RPM
762 RPM
80 C
50 C
30 C
0%
10 %

Then, EVAP Purge Solenoid increases
10%-by-10%.
Press "Quit" Key.
F3: IAC System
F0: RPM Control
When the Tech 2 is operated, "Desired Idle Speed"
increases 50rpm-by-50rpm up to 1550rpm.
The circuit is normal if engine speed is changed in
RPM Control
Engine Speed
Desired Idle Speed
Start Up ECT
Throttle Position
850 RPM
850 RPM
80 C
50 C
30 C
0%
Desired Idle Speed
850 RPM

Then, Desired Idle speed increases
50rpm-by-50rpm up to 1550rpm. Engine speed is
also changed by this operation.
Press "Quit" Key.
F0: IAC Control
When the Tech 2 is operated, "Idle Air Control"
increases or decreases 10steps-by-10steps up to
160steps.
The circuit is normal if idle engine speed is changed in
IAC Control
Engine Speed
Desired Idle Speed
Start Up ECT
Throttle Position
875 RPM
762 RPM
80
50
30
0%
Idle Air Control
30 Steps

Then, Idle Air Control increases 10steps-by10steps up to 160steps.
Engine speed is also changed by this operation.
Press "Quit" Key.

F4: Fuel System
F0: Fuel Trim Reset
When the Tech 2 is operated, "Long Term Fuel Trim" is
reset to 0%.
Fuel Trim Reset

B1 Long Term Fuel Trim (Bank 1)
B2 Long Term Fuel Trim (Bank 2)
B1 Short Term Fuel Trim (Bank 1)
B2 Short Term Fuel Trim (Bank 2)
Fuel Trim Cell
Fuel Trim Learned (Bank 1)
Fuel Trim Learned (Bank 2)
B1 Long Term Fuel Trim
3%
3%
-1 %
-2 %
53
Yes
Yes
0%
Press "Reset" key.

Then, B1 & B2 Long Term Fuel Trim is reseted to
0%.
Press "Quit" Key.
PLOTTING SNAPSHOT GRAPH

060RX037

You can replay the snapshot data as needed.
Therefore, accurate diagnosis is possible, even though
the vehicle is not available.
D06RY00167
060RX040


below shown:

1. Start TIS2000.
screen.
information.
6. After ending transfer of the snapshot, data
3. Snapshot data is displayed with TIS2000

procedures.
1. Start TIS2000.
screen.
list on the screen.

window opens.
and select one parameter from the list of the
window lower part. Selected parameter is
displayed nest to the graph icon. Graph division
can be selected in the field on the parameter right
side.
icons.
4. After selecting all parameters to be displayed
(Max. 3 parameters), click [OK] button.

icon.
7. For displaying another parameter by graph, click
the parameter of the list, drug the mouse to the
display screen while pressing the mouse button
and release the mouse button. New parameter is
displayed at the position of the previous
parameter. For displaying the graph display screen
in full size, move the cursor upward on the screen.
When the cursor is changed to the magnifying
glass form, click the screen. Graph screen is
displayed on the whole screen.


opens.

5. In this case, parameters are displayed only in
graph form. All parameters are displayed in one
graph.
navigation icon.

Service Programming System (SPS) software
contained in TIS2000 is explained below.
NOTE:
"Immobilizer System-ECM replacement" for the
are present, low battery voltage or poor
electrical connections should be the primary
suspects. Perform the SPS procedure again
after rectifying the fault/s.
5. On the screen of "Diagnostic Tester and

Processing Program Selection", choose the one
that will comply with the following.
Diagnostic Tech 2 in use
IMPORTANT:
The Tech2 PCMCIA card is programmed with
the latest software release.
The latest release of TIS2000 is loaded on the
PC.
The control unit to be programmed is
connected to the vehicle.
1.
2.
3.
4.
Connect Tech 2 to P/C.

Check to see if Hardware Key is plugged into Port.
Activate TIS 2000 by P/C.
On the activating screen of TIS2000, choose
"Service Programming System"

6. Upon completion of the selection, push the button
of "Next".

2.Demand of Data
turning on the power of Tech-2, push the "Enter"
switch.
engine)
3. In the main menu of Tech 2, push "F1: Service
Programming System (SPS)".
4. Push "F0: Request Info" of Tech-2.

Year, Vehicle Type.
procedure.
information from the control unit ECM and TCM
(A/T only) at the same time. With VIN not being
programmed into the new control unit at the time
of shipment, "obtaining information" is not
complete (because the vehicle model, engine
model and model year are specified from VIN). For
the procedure get additional information on
vehicles, instruction will be provided in dialog form,
when TIS2000 is in operation.
9. Following instructions by Tech-2, push the "Exit"
from the vehicle.
5. Where vehicle data has been already saved in

Tech-2, the existing data come on display. In this
the data or to continue obtaining anew data from
the control unit, choose either of them.
3.Data Exchange
1. Connect Tech-2 to P/C, turn on the power and
click the "Next" button of P/C.
2. Check VIN of the vehicle and choose "Next".
Model Year
Model
Engine type
Transmission type
Immobilizer
Etc.
"Destination code can be read from service ID Plate
affixed on vehicles, while on service ID plate the
destination code is described at the right-hand edge of
Body Type line. In the figure, the destination code can
be read as "RR3" (Australia).
5. After choosing the data, click the "Next" button.

"details" of software within the database that
match the entered data will appear for
confirmation. Click the "Program" switch and then
download the new software onto Tech-2.
7. "Data Transfer" comes on display. The progress of
form of bar graph.
ABS connectors shall be removed from the
vehicle.
comes on display.
start)
5. On the title screen of Tech-2, push the "Enter"
button.
6. Choose "F1: Service Programming System" on the
main screen and then choose "F1: Program ECU".
7. While data is being transferred, "Programing in
Progress" will be displayed on the Tech-2 screen.
8. Upon finishing the data transfer, Tech-2 will
display "Reprogramming was Successful". Push
the "Exit" button to bring program to completion.
9. Following "Procedure 2: Demand of Data", try over

again "Information Obtaining" and check to confirm
Legend
(2) Harness Adapter
(3) Breaker Box
addition, the ECM special terminal can not let regular
digital voltage meter prove to access, because terminal
shape is very fin pin type.

2
1
3
5
Legend
(1) Engine Control Module (ECM) (Under the harness
adaptoer)
(2) Harness Adapter
(3) Breaker Box
Breaker box connection type A, check for "open circuit"
and "short to ground circuit".


2
1
5
3
Legend
(1) Engine Control Module (ECM) (Under the harness
adapter)
(2) Harness Adapter
(3) Breaker Box
Breaker box connection type B, check for "short to
power supply circuit" and "power, signal voltage check"

RTW46EMF000401
CIRCUIT DESCRIPTION
TEST DESCRIPTION

and tightness.

Diagnostic Chart:
1. The Check Engine Lamp (MIL) should be ON
steady with the ignition "On", engine "Off". If not,
"No Check Engine Lamp (MIL)" chart should be
used to isolate the malfunction.
2. Checks the Class 2 data circuit and ensures that
the ECM is able to transmit serial data.
controlling the Check Engine Lamp (MIL) and the
Check Engine Lamp (MIL) driver circuit is not
shorted to ground circuit.
4. If the engine will not start, "Engine Cranks But Will
Not Run" chart should be used to diagnose the
fault.
6. The Tech2 parameters which is not within the
typical range may help to isolate the area which is
causing the problem.
12. This vehicle is equipped with ECM which utilizes
an electrically erasable programmable read only
memory (EEPROM).
DIAGNOSTIC AIDS
the insulation. Check for poor connections or a

Step
1
Action
Value (s)
Yes
No
Go to Step 2
Go to No CHECK
ENGINE Lamp
Go to Step 3
Go to Step 7

2. Check the "CHECK ENGINE" lamp (MIL).
Does the "CHECK ENGINE" lamp turn "On"?

2. Attempt to display "Engine Data" with the Tech 2.
Does the Tech 2 display "Engine Data" and "O2
Sensor Data"?

"Malfunction Indicator Lamp" in "Lamps".
instructions.
Does the "CHECK ENGINE" lamp turn "Off"?
Go to Step 4
Attempt to start the engine. Does the engine start and

continue to "Run"?
Go to Step 5
Go to CHECK
ENGINE LAMP
On Steady
Go to Engine
Cranks But Will
Not Run
Go to DTC Chart
Go to Step 6
Refer to
SYMPTOM
DIAGNOSIS
Refer to
TYPICAL SCAN
DATA
Repair faulty
harness and
verify repair
Go to Step 8

2. Select the "Read DTC In for By Priority" in
"Diagnostic Trouble Code".

Tech 2 "Engine Data" and "O2 Sensor Data".

B-58

Step
8
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Less than 1V
Go to Step 10
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 11

ground circuit.
B-58

ground circuit.
10
B-58

Was the DVM indicated battery voltage?
B-58

Step
11
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair

3. Check the circuit for open or short to ground circuit.
E-61(B)

B-58
12

release?
13
Replace the ECM.

Programming System (SPS) in this manual. Following
ECM programming, the Immobilizer system (if
RTW46EMF000401
CIRCUIT DESCRIPTION
The Check Engine" lamp (MIL) should always be
illuminated and steady with the ignition ON" and the
engine stopped. Ignition feed voltage is supplied to the
MIL bulb through the meter fuse. The Engine Control
Module (ECM) turns the MIL ON" by grounding the MIL
driver circuit.
DIAGNOSTIC AIDS
An intermittent MIL may be cased by a poor connection,
open in the MIL driver circuit, or an open in the
instrument cluster ignition feed.
engine ground.

Step
1
Action
Yes
No
Verify repair
Go to Step 2
10 14.5V
Go to Step 5
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Check the meter fuse (15A). If the fuse is burnt out,

Value (s)
Using the DVM and check the "CHECK ENGINE"

lamp circuit.
3. Ignition "On".
E-61(B)
Check the "CHECK ENGINE" lamp bulb. If the bulb is

burnt out, repair as necessary.

lamp circuit.
2. Disconnect
connector.
the
meter
connector
and
ECM

E-61(B)
B-24

release?

Step
6
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.

CHECK ENGINE LAMP (MIL) ON" STEADY
RTW46EMF000401
CIRCUIT DESCRIPTION
The Check Engine" lamp (MIL) should always be
illuminated and steady with ignition ON" and the engine
stopped. Ignition feed voltage is supplied directly to the
MIL indicator. The Engine Control Module (ECM) turns
the MIL ON" by grounding the MIL driver circuit.
The MIL should not remain ON" with the engine
running and no DTC(s) set. A steady MIL with the
engine running and no DTC(s) suggests a short to
ground in the MIL driver circuit.
DIAGNOSTIC AIDS
rubbedthrough wire insulation, or a wire broken inside
damaged harness.
Check Engine Lamp (MIL) ON" Steady

Step
1
Action
Value (s)
Yes
No
Go to Step 2
Go to Step 4
Verify repair
Go to Step 3
Verify repair
Verify repair
Go to Step 5
Verify repair

3. Ignition "On".
Was the "CHECK ENGINE" lamp turned on?

lamp circuit.
2. Disconnect
connector.
the
meter
connector
and
ECM

E-61(B)
B-24


release?
Replace the ECM.

FUEL INJECTOR COIL TEST

PROCEDURE AND FUEL INJECTOR
BALANCE TEST PROCEDURE
3. Record the lowest voltage displayed by the DVM

after the first second of the test. (During the first
second, voltage displayed by the DVM may be
inaccurate due to the initial current surge.)
Injector Specifications:
Resistance Ohms
Voltage Specification at
10C-35C (50F-95F)
11.8 12.6
5.7 6.6
The voltage displayed by the DVM should be within

the specified range.
The voltage displayed by the DVM may increase
throughout the test as the fuel injector windings
warm and the resistance of the fuel injector
windings changes.
An erratic voltage reading (large fluctuations in
voltage that do not stabilize) indicates an
intermittent connection within the fuel injector.
5. Injector Specifications:
Test Description
Number(s) below refer to the step number(s) on the
Diagnostic Chart:
2. Relieve the fuel pressure by connecting the 5
884003780 Fuel Pressure Gauge to the fuel
pressure connection on the fuel rail.
CAUTION: In order to reduce the risk of fire and
personal injury, wrap a shop towel around the fuel
pressure connection. The towel will absorb any fuel
leakage that occurs during the connection of the
fuel pressure gauge. Place the towel in an approved
container when the connection of the fuel pressure
gauge is complete.
Place the fuel pressure gauge bleed hose in an
approved gasoline container.
With the ignition switch OFF," open the valve on
the fuel pressure gauge.
Highest Acceptable
Voltage Reading
Above/Below 35C/10C
(95F/50F)
Acceptable Subtracted
Value
9.5 Volts
0.6 Volts
7. The Fuel Injector Balance Test portion of this chart

(Step 7 through Step 11) checks the mechanical
(fuel delivery) portion of the fuel injector. An engine
cool-down period of 10 minutes is necessary in
order to avoid irregular fuel pressure readings due
to Hot Soak" fuel boiling.
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure
(Steps 7-11)
CYLINDER
1st Reading (1)
296 kPa
(43 psi)
296 kPa
(43 psi)
296 kPa
(43 psi)
296 kPa
(43 psi)
296 kPa
(43 psi)
296 kPa
(43 psi)
2nd Reading (2)
131 kPa
(19 psi)
117 kPa
(17 psi)
124 kPa
(18 psi)
145 kPa
(21 psi)
131 kPa
(19 psi)
130 kPa
(19 psi)
Amount of Drop
(1st Reading2nd Reading)
165 kPa
(24 psi)
179 kPa
(26 psi)
172 kPa
(25 psi)
151 kPa
(22 psi)
165 kPa
(24 psi)
166 kPa
(24 psi)
Av.drop = 166 kPa/24 psi

10 kPa/1.5 psi
= 156- 176 kPa or
22.5- 25.5 psi
OK
Faulty, Rich
(Too Much
Fuel Drop)
OK
Faulty, Lean
( Too Little
Fuel Drop)
OK
OK
NOTE: These figures are examples only.
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure
(Steps 7-11)
Step
1
Action
Value(s)
YES
NO
Go to Step 2
Go to OBD
System Check
Go to Step 3
Go to Step 5
5.7-6.6 V
Go to Step 4
Go to Step 7
Go to Step 7
Was the On-Board Diagnostic (OBD) System Check"

performed?
1. Turn the engine OFF."
In order to prevent flooding of a single cylinder and
possible engine damage, relieve the fuel pressure
before performing the fuel injector coil test procedure.
2. Relieve the fuel pressure.
Description Number 2.
Refer
to
Test
3. Connect the 5884026180 Fuel Injector Tester

to B+ and ground, and to the 5884026350
Injector Switch Box.
4. Connect the injector switch box to the gray fuel
injector harness connector located at the rear of
the air cleaner assembly.
5. Set the amperage supply selector switch on the
fuel injector tester to the Coil Test" 0.5 amp
position.
6. Connect the leads from the Digital Voltmeter
(DVM) to the injector tester. Refer to the
illustrations associated with the test description.
7. Set the DVM to the tenths scale (0.0).
8. Observe the engine coolant temperature.
Is the engine coolant temperature within the specified 10C (50F) to
values?
35C (95F)
3
1. Set injector switch box injector #1.

2. Press the Push to Start Test" button on the fuel
injector tester.
3. Observe the voltage reading on the DVM.
Important: The voltage reading may rise during the
test.
4. Record the lowest voltage observed after the first
second of the test.
5. Set the injector switch box to the next injector and
repeat steps 2, 3, and 4.
Did any fuel injector have an erratic voltage reading
(large fluctuations in voltage that did not stabilize) or a
voltage reading outside of the specified values?
Replace the faulty fuel injector(s). Refer to Fuel

Injector.

Step
5
Action
Value(s)
YES
NO
9.5 V
Go to Step 4
Go to Step 6
0.6 V
Go to Step 4
Go to Step 7
Go to Step 8
Go to Fuel
System
Diagnosis
Go to Step 9
Go to Fuel
System
Diagnosis
1. Set injector switch box injector #1.

2. Press the Push to Start Test" button on the fuel
injector tester.
test.
second of the test.
5. Set the injector switch box to the next injector and
repeat steps 2, 3, and 4.
voltage reading above the specified value?
1. Identify the highest voltage reading recorded (other

than those above 9.5 V).
2. Subtract the voltage reading of each injector from
the highest voltage selected in step 1. Repeat until
you have a subtracted value for each injector.
For any injector, is the subtracted Value in step 2
greater than the specified value?

pressure connection. The towel will absorb any
fuel leakage that occurs during the connection of
the fuel pressure gauge. Place the towel in an
approved container when the connection of the
fuel pressure gauge is complete.
1. Connect the 5884003780 Fuel Pressure Gauge
to the fuel pressure test port.
2. Energize the fuel pump using the Tech 2.
3. Place the bleed hose of the fuel pressure gauge
into an approved gasoline container.
4. Bleed the air out of the fuel pressure gauge.
5. With the fuel pump running, observe the reading
on the fuel pressure gauge.
Is the fuel pressure within the specified values?
296 kPa-376
kPa
(43-55 psi)
Turn the fuel pump OFF."

Does the fuel pressure remain constant?

Step
Action
1. Connect the 5884026180 Fuel Injector Tester

and 5884026350 Injector Switch Box the fuel
injector harness connector.
Value(s)
YES
NO
10 kPa
(1.5 psi)
Go to Step 10
Go to OBD
System Check
10 kPa
(1.5 psi)
Go to Step 11
Go to
Symptoms
Verify repair

fuel injector tester to the Balance Test" 0.5-2.5
amp position.
3. Using the Tech 2 turn the fuel pump ON" then
OFF" in order to pressurize the fuel system.
4. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure stabilizes.
This is the first pressure reading.
5. Energize the fuel injector by depressing the Push
to Start Test" button on the fuel injector tester.
pressure gauge after the fuel pressure gauge
needle has stopped moving. This is the second
pressure reading.
7. Repeat steps 1 through 6 for each fuel injector.
8. Subtract the second pressure reading from the first
pressure reading for one fuel injector. The result
is the pressure drop value.
9. Obtain a pressure drop value for each fuel injector.
10. Add all of the individual pressure drop values.
This is the total pressure drop.
11. Divide the total pressure drop by the number of
fuel injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that
is either higher than the average pressure drop or
lower than the average pressure drop by the specified
value?
10
Re-test any fuel injector that does not meet the

specification. Refer to the procedure in step 11.
Do not repeat any portion of this test before running
the engine in order to prevent the engine from
flooding.
Does any fuel injector still have a pressure drop value
that is either higher than the average pressure drop or
value?
11
Replace the faulty fuel injector(s). Refer to Fuel

Injector.
FUEL SYSTEM ELECTRICAL TEST
RTW36ELF000101
CIRCUIT DESCRIPTION
When the ignition switch is first turned ON," the Engine
Control Module (ECM) energizes the fuel pump relay
which applies power to the in-tank fuel pump. The fuel
pump relay will remain ON" as long as the engine is
running or cranking and the ECM is receiving 58X
crankshaft position pulses. If no 58X crankshaft position
pulses are present, the ECM de-energizes the fuel
pump relay within 2 seconds after the ignition is turned
ON" or the engine is stopped.
The fuel pump delivers fuel to the fuel rail and injectors,
then to the fuel pressure regulator. The fuel pressure
regulator controls fuel pressure by allowing excess fuel
to be returned to the fuel tank. With the engine stopped
and ignition ON," the fuel pump can be turned ON" by
using a command by the Tech 2.
DIAGNOSTIC AIDS
damaged harness.

CAUTION: To reduce the risk of fire and personal
injury:
FUEL PRESSURE RELIEF PROCEDURE
It is necessary to relieve fuel system pressure

before connecting a fuel pressure gauge. Refer to
Fuel Pressure Relief Procedure, below.
1. Remove the fuel cap.
A small amount of fuel may be released when

disconnecting the fuel lines. Cover fuel line
fittings with a shop towel before disconnecting,
to catch any fuel that may leak out. Place the
towel in an approved container when the
disconnect is completed.
3. Start the engine and allow it to stall.
2. Remove the fuel pump relay from the underhood

relay center.
4. Crank the engine for an additional 3 seconds.
FUEL GAUGE INSTALLATION

1. Remove the fuel pressure fitting cap.
2. Install fuel gauge 5-8840-0378-0 to the fuel feed line
located in front of and above the right side valve
cover.
3. Reinstall the fuel pump relay.
Fuel System Electrical Test

Step
1
Action
Value (s)
Yes

performed?
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Test completed
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5

"Fuel Pump Relay" in the "Relays".
Was the fuel pump operated, when the Tech 2 is
operated?
Check the "Fuel Pump" fuse (20A). If the fuse is burnt

out, repair as necessary.
Check for poor/faulty connection at the fuel pump, fuel

pump relay or ECM connector. If a poor/faulty
E-61(B)
F-2
X-2

C-109


Step
5
Action
Value (s)
Yes
No
Approximately
140
Go to Step 6
Replace fuel
pump relay and
verify repair
10 14.5V
Go to Step 8
Go to Step 7
Verify repair
Repair faulty
harness and
verify repair
Go to Step 9
Using the DVM and check the fuel pump relay.

2. Remove the fuel pump relay from the relay box.
X-2
1
2
Using the DVM and check the fuel pump relay power
supply circuit.
X-2


"ECM" fuse (15A) and fuel pump relay.
Using the DVM and check the fuel pump relay ground
circuit.
E-61(B)
X-2


Step
9
Action
Value (s)
Yes
No
10 14.5V
Go to Step 11
Go to Step 10
Verify repair
10 14.5V
Go to Step 13
Go to Step 12
Verify repair
supply circuit.
X-2
10
Repair the open circuit between the fuel pump relay

and battery.
11
Using the DVM and check the fuel pump power supply
circuit.
2. Disconnect the fuel pump connector.
F-2
12

fuel pump relay and fuel pump.
F-2
X-2

Step
13
Action
Value (s)
Yes
No
Continuity
Go to Step 15
Go to Step 14
Verify repair
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Using the DVM and check the fuel pump ground

circuit.
F-2
14
Repair the open circuit between the fuel pump and

body ground.
F-2
15
C-109
Replace the fuel pump.

16

release?
17
Replace the ECM.

ECM programming, the immobilizer system (if
FUEL SYSTEM DIAGNOSIS
RTW36ELF000501
Legend
(1) Fuel Filler Cap
(2) Fuel Tank
(3) Rollover Valve
(4) Fuel Pump Assembly
(5) Fuel Filter
(6) Fuel Rail Right
(7) Intake Air Port Right Bank
(8) Fuel Rail Left
(9) Intake Air Port Left Bank

(10) Fuel Pressure Control Valve
(11) Common Chamber
(12) Duty Solenoid Valve
(13) Throttle Valve
(14) Canister
(15) Check Valve
(16) Air Separator
CIRCUIT DESCRIPTION
When the ignition switch is turned ON," the Engine
Control Module (ECM) will turn ON" the in-tank fuel
pump. The in-tank fuel pump will remain ON" as long
as the engine is cranking or running and the ECM is
receiving 58X crankshaft position pulses. If there are no
58X crankshaft position pulses, the ECM will turn the
in-tank fuel pump OFF" 2 seconds after the ignition
switch is turned ON" or 2 seconds after the engine
stops running.
The in-tank fuel pump is an electric pump within an
integral reservoir. The in-tank fuel pump supplies fuel
through an in-line fuel filter to the fuel rail assembly. The
fuel pump is designed to provide fuel at a pressure
above the pressure needed by the fuel injectors. A fuel
pressure regulator, attached to the fuel rail, keeps the
fuel available to the fuel injectors at a regulated
pressure. Unused fuel is returned to the fuel tank by a
separate fuel return line.
TEST DESCRIPTION
Diagnostic Chart.
2. Connect the fuel pressure gauge to the fuel feed line
as shown in the fuel system illustration. Wrap a shop
towel around the fuel pressure connection in order to
absorb any fuel leakage that may occur when
installing the fuel pressure gauge. With the ignition
switch ON" and the fuel pump running, the fuel
pressure indicated by the fuel pressure gauge
2
should be 333-376 kPa (3.4-3.8 kg/cm / 48-55 psi).
This pressure is controlled by the amount of
pressure the spring inside the fuel pressure regulator
can provide.
3. A fuel system that cannot maintain a constant fuel
pressure has a leak in one or more of the following
areas:
The fuel pump check valve.
The fuel pump flex line.
The valve or valve seat within the fuel pressure
regulator.
The fuel injector(s).
4. Fuel pressure that drops off during acceleration,
cruise, or hard cornering may case a lean condition.
A lean condition can cause a loss of power, surging,
or misfire. A lean condition can be diagnosed using
a Tech 1 Tech 2. If an extremely lean condition
occurs, the oxygen sensor(s) will stop toggling. The
oxygen sensor output voltage(s) will drop below 500
mV. Also, the fuel injector pulse width will increase.
Important: Make sure the fuel system is not operating

in the Fuel Cut-Off Mode."
When the engine is at idle, the manifold pressure is
low (high vacuum). This low pressure (high vacuum)
is applied to the fuel pressure regulator diaphragm.
The low pressure (high vacuum) will offset the
pressure being applied to the fuel pressure regulator
diaphragm by the spring inside the fuel pressure
regulator. When this happens, the result is lower fuel
pressure. The fuel pressure at idle will vary slightly
as the barometric pressure changes, but the fuel
pressure at idle should always be less than the fuel
pressure noted in step 2 with the engine OFF."
16.Check the spark plug associated with a particular
fuel injector for fouling or saturation in order to
determine if that particular fuel injector is leaking. If
checking the spark plug associated with a particular
fuel injector for fouling or saturation does not
determine that a particular fuel injector is leaking,
use the following procedure:
Remove the fuel rail, but leave the fuel lines and
injectors connected to the fuel rail. Refer to Fuel
Rail Assembly in On-Vehicle Service.
Lift the fuel rail just enough to leave the fuel
injector nozzles in the fuel injector ports.
personal injury that may result from fuel spraying
on the engine, verify that the fuel rail is positioned
over the fuel injector ports and verify that the fuel
injector retaining clips are intact.
Pressurize the fuel system by connecting a 10
amp fused jumper between B+ and the fuel pump
relay connector.
Visually and physically inspect the fuel injector
nozzles for leaks.
17. A rich condition may result from the fuel pressure
being above 376 kPa (55 psi). A rich condition may
cause a DTC P0132 or a DTC P0172 to set.
Driveability conditions associated with rich conditions
can include hard starting (followed by black smoke)
and a strong sulfur smell in the exhaust.
20.This test determines if the high fuel pressure is due
to a restricted fuel return line or if the high fuel
pressure is due to a faulty fuel pressure regulator.
21.A lean condition may result from fuel pressure below
333 kPa (48 psi). A lean condition may cause a DTC
P0131 or a DTC P0171 to set. Driveability conditions
associated with lean conditions can include hard
starting (when the engine is cold ), hesitation, poor
driveability, lack of power, surging , and misfiring.

22.Restricting the fuel return line causes the fuel
pressure to rise above the regulated fuel pressure.
Command the fuel pump ON" with the Tech 2. The
fuel pressure should rise above 376 kPa (55 psi) as
the fuel return line becomes partially closed.
NOTE: Do not allow the fuel pressure to exceed 414
kPa (60 psi). Fuel pressure in excess of 414 kPa (60
psi) may damage the fuel pressure regulator.
injury:
before connecting a fuel pressure gauge. Refer to
Fuel Pressure Relief Procedure, below.
fittings with a shop towel before disconnecting,
to catch any fuel that may leak out. Place the
disconnect is completed.
FUEL PRESSURE RELIEF PROCEDURE

relay center.
FUEL GAUGE INSTALLATION

2. Install fuel gauge 5-8840-0378-0 to the fuel supply
line located in front of and above the right side valve
cover.
Fuel System Diagnosis

Step
1
Action
Value(s)
YES
NO

performed?
Go to Step 2
Go to OBD
System Check
290-376 kPa
(42-55 psi)
Go to Step 3
Go to Step 17
Go to Step 4
Go to Step 12
Did the reading drop by the amount specified after the

engine was started?
21-105 kPa
(3-15 psi)
Go to Step 5
Go to Step 9
Is fuel pressure dropping off during acceleration,

cruise, or hard cornering?
Go to Step 6
Check for
improper fuel
Verify repair
Go to Step 7
Verify repair
Go to Step 8
1. Turn the ignition OFF."

2. Turn the air conditioning system OFF."
3. Relieve fuel system pressure and install the fuel
pressure gauge.
Refer to 6E-118 FUEL GAUGE INSTALLATION
4. Turn the ignition ON."
NOTE: The fuel pump will run for approximately 2
seconds. Use the Tech 2 to command the fuel
pump ON".
5. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running.
Is the fuel pressure within the specified limits?
The fuel pressure will drop when the fuel pump stops
running, then it should stabilize and remain constant.
Does the fuel pressure indicated by the fuel pressure
gauge remain constant?
1. When the vehicle is at normal operation

temperature, turn the ignition ON" to build fuel
pressure and observe the measurement on the
gauge.
2. Start the engine and observe the fuel pressure
gauge.
Visually and physically inspect the following items for

a restriction:
The in-line fuel filter.
The fuel feed line.
Was a restriction found?
Remove the fuel tank and visually and physically

inspect the following items:
The fuel pump strainer for a restriction.
The fuel line for a leak.
Verify that the correct fuel pump is in the vehicle.
Was a problem found in any of these areas?

Step
8
Action
YES
NO
Verify repair
21-105 kPa
(3-15 psi)
Go to Step 10
Go to Step 11
Verify repair
Verify repair
Go to Step 13
Go to Step 15
Verify repair
Go to Step 14
Verify repair
Go to Step 8
Go to Step 11
Go to Step 16
Verify repair
376 kPa (55

psi)
Go to Step 18
Go to Step 21

Value(s)
1. Disconnect the vacuum hose from the fuel

pressure regulator.
2. With the engine idling, apply 12-14 inches of
vacuum to the fuel pressure regulator.
gauge drop by the amount specified?
10
Locate and repair the loss of vacuum to the fuel

pressure regulator.
11
Replace the fuel pressure regulator.

12
1. Run the fuel pump with the Tech 2.

2. After pressure has built up, turn off the pump and
clamp the supply hose shut with suitable locking
pliers.
13
Visually inspect the fuel supply line and repair any

leaks.
14
Remove the fuel tank and inspect for leaky hose or

in-tank fuel line.
15
1. If the pliers are still clamped to the fuel supply

hose, remove the locking pliers.
2. With suitable locking pliers, clamp the fuel return
line to prevent fuel from returning to the fuel tank.
4. After pressure has built up, remove power to the
pump.
16
Locate and replace any leaking fuel injector(s).

17
Is the fuel pressure indicated by the fuel pressure

gauge above the specified limit?

Step
Action
Value(s)
YES
NO
18
1. Relieve the fuel pressure. Refer to the Fuel

Pressure Relief.
290-376 kPa
(42-55 psi)
Go to Step 19
Go to Step 20
Verify repair
Verify repair
Go to Step 11
0 kPa (0 psi)
Go to Step 22
Go to Step 23
376 kPa (55

Does the fuel pressure indicated by the fuel pressure psi). 414 kPa
gauge rise above the first specified value?
(60 psi).
Go to Step 11
Go to Step 7
Go to Step 7
Go to Fuel
System
Electrical Test
Chart
2. Disconnect the fuel return line from the fuel rail.

3. Attach a length of flexible hose to the fuel rail
return outlet passage.
4. Place the open end of the flexible hose into an
19
Locate and correct the restriction in the fuel return

line.
20
Visually and physically inspect the fuel rail outlet

passages for a restriction.
21
22

gauge above the specified value?
1. Command the fuel pump ON" with the Tech 2.
2. Using suitable pliers which will not damage the fuel
hose, gradually apply pressure with the pliers to
pinch the flexible fuel return hose closed.
CAUTION: Do not let the fuel pressure exceed the
second specified value.
23
1. Command the fuel pump ON" with the Tech 2.

2. Remove the fuel filler cap and listen for the sound
of the fuel pump running.
3. Turn the pump off.
Was the fuel pump running?
A/C SYSTEM CIRCUIT DIAGNOSIS
RTW36EMF000101
CIRCUIT DESCRIPTION
When air conditioning and blower fan are selected, and
if the system has a sufficient refrigerant charge, a
12-volt signal is supplied to the A/C request input of the
Engine Control Module (ECM). The A/C request signal
may be temporarily canceled during system operation
by the electronic thermostat in the evaporator case. The
electronic thermostat may intermittently remove the
control circuit ground for the A/C thermostat relay to
prevent the evaporator from forming ice. When the A/C
request signal is received by the ECM, the ECM
supplies a ground from the compressor clutch relay if
the engine operating conditions are within acceptable
ranges. With the A/C compressor relay energized,
voltage is supplied to the compressor clutch coil.
The ECM will enable the compressor clutch to engage
whenever A/C has been selected with the engine
running, unless any of the following conditions are
present:
The A/C request switch is "Off".

The engine speed is lower than 550rpm or greater
than 6375rpm.
The engine coolant temperature is greater than
120.
DIAGNOSTIC AIDS
To diagnose an the intermittent fault, check for the
following conditions:
Poor connection at the ECMInspect connections for
backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
Damaged harnessInspect the wiring harness for
damage. If the harness appears to OK, observe the
A/C clutch while moving connectors and wiring
harnesses related to the A/C. A sudden clutch
malfunction will indicate the source of the intermittent
fault.
A/C CLUTCH DIAGNOSIS

This chart should be used for diagnosing the electrical
portion of the A/C compressor clutch circuit. A Tech 2
will be used in diagnosing the system. The Tech 2 has
the ability to read the A/C request input to the ECM. The
Tech 2 can display when the ECM has commanded the
A/C clutch ON." The Tech 2 should have the ability to
override the A/C request signal and energize the A/C
compressor relay.
A/C Clutch Control Circuit Diagnosis

Step
1
3
4
5
Action
Value (s)
Yes

performed?
Go to Step 2
Are the A/C setting conditions met?
Is the A/C compressor worked properly?
Go to Step 3
Diagnosis
completed
Does the blower motor operate?
Go to Step 6
Go to Step 5
Verify repair
Go to Step 15
Go to Step 7
Verify repair
Go to Step 8
Go to Step 4
Repair the blower motor circuit.

No
Go to On Board
Diagnostic (OBD)
System Check
Set the setting
condition and Go
to Step 3

"A/C Clutch Relay" in the "Relays".
Was the A/C compressor magnet clutch engaged,
when the Tech 2 is operated?
Check the "A/C" fuse (10A). If the fuse is burnt out,


Step
8
Action
Value (s)
Yes
No
Verify repair
Go to Step 9
Approximately
140
Go to Step 10
Replace A/C
compressor relay
and verify repair
10 14.5V
Go to Step 12
Go to Step 11
Verify repair
Check for poor/faulty connection at the A/C

compressor, A/C compressor relay or ECM connector.
necessary.
E-61(B)
E-2
X-14

9
Using the DVM and check the A/C compressor relay.

box.
X-14

10

box.
X-14

11

"A/C" fuse (10A) and A/C compressor relay.

Step
12
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 13
10 14.5V
Go to Step 27
Go to Step 14
Verify repair

ground circuit.
box.
E-61(B)
X-14

13
Using the DVM and check the A/C magnet clutch

"A/C Clutch Relay" in the "Relays".
4. Disconnect the A/C clutch connector. Check the
circuit for open or short to ground circuit.
E-2
14

A/C compressor relay and A/C magnet clutch.
X-14
E-2


Step
15
Action
Value (s)
Yes
No
Verify repair
Go to Step 16
Approximately
140
Go to Step 17
Replace thermo
relay and verify
repair
10 14.5V
Go to Step 19
Go to Step 18
Verify repair
Check for poor/faulty connection at the thermo relay,

triple pressure switch, thermostat or ECM connector. If
a poor/faulty connection is found, repair as necessary.
E-61(B)
X-15
C-24
16
C-55

Using the DVM and check the thermo relay.

2. Remove the thermo relay from the relay box.
X-15

17
Using the DVM and check the thermo relay power

supply circuit.
X-15

18

"A/C" fuse (10A) and thermo relay.

Step
19
Action
Value (s)
Yes
No
10 14.5V
Go to Step 21
Go to Step 20
Verify repair
Go to Step 23
Go to Step 22
Verify repair
Using the DVM and check the triple pressure switch

circuit.
2. Turn "On" blower motor.
3. Disconnect the triple pressure switch connector.
C-24
20

thermo relay and triple pressure switch.
X-15
C-24
21
Using the DVM and check the triple pressure switch.

3. Check the switch.
Was the switch closed?
Triple Pressure
SW

22
Replace the triple pressure switch.


Step
23
Action
Value (s)
Yes
No
10 14.5V
Go to Step 25
Go to Step 24
Verify repair
Verify repair
Repair faulty
harness and
verify repair
Go to Step 28
Verify repair
Using the DVM and check the thermostat circuit.

2. Turn "On" blower motor.
C-55

V
24

triple pressure switch and thermostat.
C-24
25
C-55
Replace the thermostat.

26
Using the DVM and check the thermo relay input

circuit.
E-61(B)
X-15
27
Replace the A/C compressor.


Step
28
Action
Yes
No
Verify repair
Go to Step 29
Verify repair

release?
29
Value (s)
Replace the ECM.

ECM DIAGNOSTIC TROUBLE CODES (DTC)

DTC Type A
Emission related.
Requests illumination of the MIL (Malfunction Indicator Lamp = Check Engine Lamp) of the first trip with a fail.
Stores a history DTC on the first trip with a fail.
Stores a freeze frame (If empty).
Stores a fail record.
Updates the fail record each time the diagnostic test fails.
DTC Type B
Emission related.
"Armed" after one trip with fail.
"Disarmed" after one trip with a pass.
Requests illumination of the MIL on the second consecutive trip with a fail.
Store a history DTC on the second consecutive trip with a fail. (The DTC will be armed after the first fail.)
Stores a freeze frame on the second consecutive trip with a fail (If empty).
Stores a fail record when the first test fails (not dependent on consecutive trip).
DTC Type D
Non emission related.

Does not request illumination of any lamp.
Stores a history DTC on the first trip with a fail.
Does not store a freeze frame.
Stores fail record when test fails.
Flash
Code
61
Code Type
P0101
DTC Name
Mass Air Flow Sensor Circuit

Range/Performance
1. No DTC relating to barometer sensor, TPS,

CMP sensor, CKP sensor and MAF sensor
(low input & high input).
Fail-Safe (Back Up)
Recovery Condition
Air flow amount is more than

0.04g/s or below 177g/s.
1. Air intake is obstructed.

2. Sensor signal circuit short to voltage circuit.
Related
ECM Pin
No.
B20/
B39
Related
Multiple
DTC
-
B20
B20/
B39
P0113/
P0123/
P0341/
P0342
A19
A19/
B39
P0103/
P0123/
P0341/
P0342
3. MAF sensor malfunction.
2. Engine speed is between 2800rpm and

4500rpm.
5. ECM malfunction.
3. Throttle position sensor output voltage is

between 1V and 3V.
4. Intake air temperature is between -14C and
70C.
P0102

Low Input
5. Air flow amount below 0.04g/s (small air) or

more than 177g/s (large air). Above
conditions are met for 3 seconds.
MAF sensor output voltage is below 0.3V.
The ECM uses default mass

MAF sensor output voltage is
air flow value based on IAC
more than 0.3V.
valve position, throttle position,
barometer pressure and
engine speed.
1. Sensor power supply circuit open circuit.

2. Sensor signal circuit open or short to ground
circuit.
3. Poor connector connection.
5. ECM malfunction.
P0103

High Input
MAF sensor output voltage is more than 4.9V.
MAF sensor output voltage is

below 4.9V.

2. Sensor ground circuit open or short to voltage
circuit.
4. ECM malfunction.
23
P0112
Intake Air Temperature Sensor IAT sensor output voltage is below 0.08V.
Low Input
The ECM use 40C conditions IAT sensor output voltage is

as substitute.
more than 0.08V.
1. Sensor signal circuit short to ground circuit.

2. IAT sensor malfunction.
3. ECM malfunction.
P0113
Intake Air Temperature Sensor IAT sensor output voltage is more than 4.9V.
High Input

below 4.9V.
1. Sensor signal circuit open or short to voltage

circuit.
circuit.
3. Poor connector connection
5. ECM malfunction.

Flash
Code
14
Code Type
P0117
P0118
DTC Name

Sensor Low Input

Sensor High Input
ECT sensor output voltage is below 0.08V.
Fail-Safe (Back Up)
The ECM uses default engine

coolant temperature value
based on start-up ECT and
time from start.
Recovery Condition

more than 0.08V.
1. Sensor signal circuit short to ground circuit.
Related
ECM Pin
No.
A21
Related
Multiple
DTC
-
A21/
A22
P0406
B27/
B26/
B39
B27/
B26
P0336/
P0337
or
P0342
B27/
B26/
B39
P0103/
P0113/
P0341/
P0342
2. ECT sensor malfunction.

3. ECM malfunction.

below 4.8V.
ECT sensor output voltage is more than 4.8V.
1. Sensor signal circuit open or short to voltage

circuit.
circuit.
5. ECM malfunction.
21
P0121
Throttle Position Sensor

Range/Performance
1. No DTC relating to barometer sensor, ECT

sensor, CMP sensor, CKP sensor, MAF
sensor and TPS (low input & high input).
2. Engine speed is more than 2000rpm.
3. Engine coolant temperature is more than
75C.
TPS output voltage is below

0.24V or more than 0.26V.
OR
4.54V or more than 4.56V.
1. TPS malfunction.
4. ECM malfunction.
4. TPS output voltage is between 0.24V and

0.26V. Above conditions are met for 3
seconds.
OR
1. No DTC relating to barometer sensor, ECT
sensor, CMP sensor, CKP sensor, MAF
sensor and TPS (low input & high input).
2. Engine speed is below 3200rpm.
75C.
P0122
Throttle Position Sensor Low

Input
4. TPS output voltage is between 4.54V and

4.56V. Above conditions are met for 3
seconds.
TPS output voltage is below 0.24V.
The ECM uses default throttle TPS output voltage is more

position value based on mass than 0.24V.
air flow and engine speed.
1. Sensor power supply circuit open or short to

ground circuit.
2. Sensor signal circuit open or short to ground
circuit.
4. TPS malfunction.
5. ECM malfunction.
P0123
Throttle Position Sensor High

Input
TPS output voltage is more than 4.56V.

4.56V.
1. Sensor power supply circuit short to voltage

circuit.
circuit.
5. TPS malfunction.
6. ECM malfunction.

Flash
Code
15
Code Type
P0131
DTC Name
Fail-Safe (Back Up)
O2 Sensor Circuit Low Voltage 1. No DTC relating to ECT sensor, CMP sensor, "Open Loop" fuel control.
(Bank 1 Sensor 1)
CKP sensor, VSS, injector control circuit,
ignition control circuit and O2 sensor circuit no
activity (bank 1 & 2).
Recovery Condition
O2 sensor bank 1 or bank 2

1. Sensor harness open or short to ground
output voltage is below 400mV
circuit.
for 50 seconds.
2. O2 sensor malfunction.
Related
ECM Pin
No.
B21/
B22
Related
Multiple
DTC
P0171/
P1171/
P1172
B23/
B24
P0174/
P1171/
P1172
B21/
B22
P0172
B23/
B24
P0175
B21/
B22
B23/
B24
3. MAF sensor output is incorrect.

4000rpm.
P0151
4. Air intake line malfunction.
3. Engine coolant temperature is between 70C

and 110C.
5. IAC valve malfunction.
4. Vehicle speed is between 0km/h and

120km/h.
7. Injector malfunction.
6. Low fuel pressure.

8. ECM malfunction.
O2 Sensor Circuit Low Voltage 5. Engine load is between 80% and 160%.
(Bank 2 Sensor 1)
6. Throttle position fluctuation is below 0.28V.
7. O2 sensor bank 1 or bank 2 output voltage is
more than 400mV for 50 seconds.
P0132
O2 Sensor Circuit High Voltage 1. No DTC relating to ECT sensor, CMP sensor, "Open Loop" fuel control.
(Bank 1 Sensor 1)
CKP sensor, VSS, injector control circuit,
ignition control circuit and O2 sensor circuit no

and 110C.
5. AC valve malfunction.
4. Vehicle speed is between 0km/h and

120km/h.

8. EVAP purge solenoid valve malfunction.
O2 Sensor Circuit High Voltage 5. Engine load is between 80% and 160%.
(Bank 2 Sensor 1)
O2 Sensor Circuit No Activity

Detected (Bank 1 Sensor 1)
1.No DTC relating to MAF sensor, ECT sensor,

CMP sensor, CKP sensor, VSS, injector
control circuit and ignition control circuit.
70C.
3. Vehicle speed is more than 60km/h.
P0154
O2 Sensor Circuit No Activity

Detected (Bank 2 Sensor 1)
9. Ignition system malfunction.

10. Spark plug malfunction.

below 600mV for 50 seconds.
P0134

circuit.

4000rpm.
P0152

600mV for 50 seconds.

between 350mV and 600mV.
11. ECM malfunction.
"Open Loop" fuel control.

output voltage is below 0.35mV
2. ECM malfunction.
consecutively.
OR
600mV consecutively.

Flash
Code
44
Code Type
P0171
P0174
DTC Name
O2 Sensor System Too Lean

(Bank 1)
O2 Sensor System Too Lean

(Bank 2)
1. No DTC relating to MAF sensor, IAT sensor,

ECT sensor, TPS, CMP sensor, CKP sensor,
VSS, injector control circuit, ignition control
circuit, O2 sensor circuit low voltage & high
voltage (bank 1 & 2) and O2 sensor circuit no
Fail-Safe (Back Up)
Recovery Condition
Air fuel ratio correction volume 1. Sensor harness open or short to ground
is between 50% and 150% for
circuit.
5 seconds.
Related
ECM Pin
No.
-
Related
Multiple
DTC
-

3. Intake air temperature is more than 50C.

and 120C.
8. ECM malfunction.
5. Engine load is more than 20.

6. EVAP purge solenoid valve on-duty is below
100%.
7. Air-fuel ratio correction volume is more than
150% for 20 seconds.
45
P0172
P0175
O2 Sensor System Too Rich

(Bank 1)
O2 Sensor System Too Rich

(Bank 2)

Air fuel ratio correction volume 1. Sensor harness open or short to ground
is between 50% and 150% for
circuit.
5 seconds.
5. AC valve malfunction.

and 120C.
5. Engine load is more than 20.

6. EVAP purge solenoid valve on-duty is below
100%.
7. Air-fuel ratio correction volume is below 50%
for 20 seconds.


Flash
Code
44
Code Type
P1171
DTC Name
Fuel Supply System Lean

During Power Enrichment
(Bank 1)

Fail-Safe (Back Up)
Recovery Condition
O2 sensor output voltage is

more than 520mV for 5
seconds.

circuit.
Related
ECM Pin
No.
B21/
B22/
Related
Multiple
DTC
-
B23/
B24
A36
B3
A35
3. MAF sensor output is incorrect. 4. Air intake
line malfunction.

6000rpm.
3. Intake air temperature is below 70C.

and 120C.
8. ECM malfunction.
5. Engine load is between 150 and 255.

P1172
Fuel Supply System Lean

During Power Enrichment
(Bank 2)
6. Throttle position output is more than 2.22V

and fluctuation is below 0.28V.
7. Except fuel cut operation.
8. O2 sensor output voltage below 250mV for 10
seconds.
31
P0201
P0202
Injector 1 Control Circuit
1. No DTC relating to CMP sensor and CKP

sensor.
30 injection signals are

detected consecutively.
1. Injector harness open circuit, short to ground

or short to voltage.
2. Under sequential injection.
3. Injection pulse is between 2.5ms and 7.5 ms.
3. ECM malfunction.

2000rpm.
6. 30 injection signals are not detected
consecutively.
P0203
P0204
B4
P0205
A34
P0206
B5

Flash
Code
29
Code Type
P0336
DTC Name

(58X)
1. No DTC relating to CMP sensor.
Fail-Safe (Back Up)
Recovery Condition
Correct pulse is detected

consecutively.
1. CKP sensor harness open circuit, short to

ground or short to voltage.
3. Extra or missing pulse is detected

consecutively.
Related
ECM Pin
No.
A23/
A24/
A25
Related
Multiple
DTC
P0122/
P0337
A23/
A24/
A25
P0112/
P0336
B27/
B28/
B39
P0103/
P0113/
P0123/
P0342
B27/
B28/
B39
P0103/
P0113/
P0123/
P0341
or
P0122
3. CKP sensor malfunction.

4. Pulse sensing gap incorrect.
7. ECM malfunction.
P0337

Circuit No Signal (58X)
1. No DTC relating to CKP sensor.

2. CMP sensor signal circuit short to ground

circuit.
3. Incorrect pulse is detected consecutively.
3. TPS & CMP sensor power supply circuit short

to ground.
9. ECM malfunction.
41
P0341
Camshaft Position Sensor

1. Engine speed below 2000rpm.

2. No crankshaft position sensor DTC P0336 or
P0337.
Fuel cut is operated at high

engine speed.
Correct pulse is detected

consecutively.
1. CMP sensor harness open circuit, short to

3. CMP sensor malfunction.
7. ECM malfunction.
P0342
Camshaft Position Sensor

Circuit No Signal
1. CMP sensor harness open circuit, short to

3. No pulse is detected consecutively.
3. CMP sensor malfunction.

7. ECM malfunction.

Flash
Code
42
Code Type
P0351
DTC Name
Ignition 1 Control Circuit
1. No DTC relating to CMP sensor and CKP

sensor.
2. Engine speed is between 250rpm and 850
rpm.
Fail-Safe (Back Up)
Recovery Condition
Fuel cut is operated more than 10 ignition signals are detected 1. Ignition coil harness open circuit, short to
2000rpm.
consecutively.
Related
ECM Pin
No.
A32
Related
Multiple
DTC
-
B7
2. Ignition coil malfunction.

3. ECM malfunction.
P0352
P0353
A31
P0354
B8
P0355
A30
P0356
B9
3. 10 ignition signals are not detected

consecutively.

Flash
Code
32
Code Type
P0404
DTC Name
EGR Circuit
Range/Performance (Open
Valve)
Fail-Safe (Back Up)
Recovery Condition
3. Vehicle speed is below 4km/h.
1. EGR operation is stopped. EGR valve output monitoring

signal low.
2. EGR valve closed position
learning operation is
disabled.

75C.
3. EGR position feedback is

disabled.
1. Engine is stopping.
2. No DTC relating to ECT sensor, CKP sensor
and VSS.
1. EGR solenoid harness short to voltage circuit.
Related
ECM Pin
No.
A5
Related
Multiple
DTC
-
A5
A9/
A24
A9/
A22/
A24
P0118
B15
B15
2. EGR valve sticking.

3. ECM malfunction.
5. EGR solenoid valve on-duty ratio is more than

100%.
6. EGR valve output monitoring signal high.
P1404
EGR Circuit
Range/Performance (Closed
Valve)
EGR valve output monitoring

signal high.
1. Engine is running.
1. EGR solenoid harness open circuit or short to

ground circuit.
2. EGR valve sticking.
4. EGR solenoid valve on-duty ratio is 0%.
3. ECM malfunction.
5. EGR valve output monitoring signal low.

P0405
EGR Circuit Low
1. No DTC relating to EGR circuit

range/performance.
EGR position sensor output

1. EGR position sensor power supply circuit

2. EGR solenoid valve on-duty ratio is more than

40%.
2. EGR position sensor signal circuit open or

3. EGR position sensor output voltage is below

0.3V.

4. EGR valve malfunction.
5. ECM malfunction.
P0406
EGR Circuit High
EGR position sensor output

1. No DTC relating to EGR circuit

range/performance.
1. EGR position sensor power supply circuit

2. EGR solenoid valve on-duty ratio is below

40%.
2. EGR position sensor signal circuit short to

voltage circuit.
3. EGR position sensor output voltage is more

than 4.6V.
3. EGR position sensor ground circuit open or

5. EGR valve malfunction.
6. ECM malfunction.
P0444
EVAP Purge Solenoid Valve

Circuit Low Voltage
1. No DTC relating to CKP sensor and system

voltage.
Purge solenoid valve output

monitoring signal high.
1. Solenoid harness open circuit or short to

ground.
2. Solenoid malfunction.
3. Purge solenoid valve on-duty ratio is below

48%.
3. ECM malfunction.
4. Purge solenoid valve output monitoring signal

low.
P0445
EVAP Purge Solenoid Valve

Circuit High Voltage
1. No DTC relating to CKP sensor and system

voltage.
3. Purge solenoid valve on-duty ratio is more
than 50%.
4. Purge solenoid valve output monitoring signal
high.
Purge solenoid valve output

monitoring signal low.
1. Solenoid harness short to voltage.

3. ECM malfunction.

Flash
Code
24
Code Type
P0500
DTC Name
Vehicle Speed Sensor Circuit

Range/Performance

2. Under fuel cut operation.
Fail-Safe (Back Up)
The ECM use 10km/h

Recovery Condition
Vehicle speed sensor output is 1. Sensor harness open circuit, short to ground
more than 2km/h.
circuit or short to voltage circuit.
Related
ECM Pin
No.
B32
Related
Multiple
DTC
-
3. Vehicle speed sensor output is below 1km/h.

Above conditions are met for 4 seconds.
5. VSS malfunction.
6. ECM malfunction.
66
P0562
System Voltage Low
Battery voltage is below 6V for more than 20

seconds.
Battery voltage is between 6V

and 16V.
1. Battery power feed harness open circuit or

2. ECM ground harness open or poor
connection.
5. Charge system malfunction.
6. ECM malfunction.
P0563
System Voltage High
Battery voltage is above 16V for more than 20

seconds.

2. Battery jump start cable misconnect.
3. ECM malfunction.
51
P0601
Control Module Memory

Checksum
Memory are is OK.
1. ECM malfunction.
P0602
ECU Programming Error
Memory are is OK.
1. ECM is not programmed.

Flash
Code
22
Code Type
P1508
DTC Name
Idle Air Control System

Low/Closed

VSS and system voltage.
6000rpm.
Fail-Safe (Back Up)
Recovery Condition
Fuel cut is operated at high idle Correct amount of air intake

through the idle air control
speed.
valve. (Correct movement of
the idle air control valve.)
1. IAC valve harness open circuit, short to

ground circuit or short to voltage circuit.
Related
ECM Pin
No.
B13/
B14/
B16/
B17
Related
Multiple
DTC
-
B13/
B14/
B16/
B17
A10/
A11
A10/
A11
P1767/
U2104 (AT)

4. IAC valve is sticking at close position.

75C.
5. ECM malfunction.

80C.
5. Vehicle is stopping.
6. Small amount of intake air through the idle air
control valve. (Idle air control valve is sticking
at close position.) Above conditions are met
for 2 seconds.
P1509
Idle Air Control System

High/Open

VSS and system voltage.
1. IAC valve harness open circuit, short to


6000rpm.

4. IAC valve is sticking at open position.
3. Engine coolant temperature more than 75C.
5. ECM malfunction.

80C.
65
P1601
CAN BUS Off
6. Large amount of intake air through the idle air

control valve. (Idle air control valve is sticking
at open position.) Above conditions are met
for 2 seconds.
CAN BUS off condition is detected consecutively.
Torque reduction control is

disable.
CAN BUS on condition is

detected consecutively for 2
seconds.
1. ECM and TCM communication circuit open,

short to ground or short to voltage.
3. ECM malfunction.
4. TCM malfunction.
67
U2104
CAN BUS Reset Counter

Overrun
1. No DTC CAN BUS Off.

2. CAN valid counter does not change for 2
seconds.
CAN valid counter changes

consecutively for 2 seconds.
1. ECM and TCM communication circuit open,

short to ground or short to voltage.
3. ECM malfunction.
4. TCM malfunction.

Flash
Code
67
Code Type
P1626
DTC Name
Immobilizer No Signal
No response from immobilizer control unit.
Fail-Safe (Back Up)

Recovery Condition
No recovery
1. ECM and immobilizer control unit

communication circuit open circuit, short to
Related
ECM Pin
No.
B18/
B32
Related
Multiple
DTC
B****
B****
B****
B****
4. ECM malfunction.
5. Immobilizer control unit malfunction.
6. Transponder key malfunction.
P1631
Immobilizer Wrong Signal
Received response is not correct.
1. ECM malfunction.
P1648
Wrong Security Code Entered Received incorrect security code.
1. ECM malfunction.
P1649
Immobilizer Function Not

Programmed
Immobilizer function is not programmed in the

ECM.
ECM malfunction.
MULTIPLE DTC SETS TROUBLESHOOTING AIDS

An open or short to voltage circuit in the sensor ground circuit between the ECM terminal A22 and splice will cause
one or more of following DTCs to be set:
P0406 (Flash Code 32): EGR Circuit High
P0118 (Flash Code 14): Engine Coolant Temperature Sensor High Input
A short to ground circuit in the sensor power supply circuit between the ECM terminal A24 and splice will cause one
or more of following DTCs to be set:
P0122 (Flash Code 21): Throttle Position Sensor Low Input
P0336 (Flash Code 29): Crankshaft Position Sensor Circuit Range/Performance (58X)
P0337 (Flash Code 29): Crankshaft Position Sensor Circuit No Signal (58X)
RTW46EMF000201

An open or short to voltage circuit in the sensor ground circuit between the ECM terminal B39 and splice will cause
one or more of following DTCs to be set:
P0103 (Flash Code 61): Mass Air Flow Sensor Circuit High Input
P0113 (Flash Code 23): Intake Air Temperature Sensor High Input
P0123 (Flash Code 21): Throttle Position Sensor High Input
P0341(Flash Code 41): Camshaft Position Sensor Circuit Range/Performance
P0342 (Flash Code 41): Camshaft Position Sensor Circuit No Signal
An open circuit in the sensor power supply circuit between the ECM terminal B27 and splice will cause one or more of
following DTCs to be set:
P0342 (Flash Code 41): Camshaft Position Sensor Circuit No Signal
A short to ground circuit in the sensor power supply circuit between the ECM terminal B27 and splice will cause one
or more of following DTCs to be set:
P0336 (Flash Code 29): Crankshaft Position Sensor Circuit Range/Performance (58X)
A short to ground circuit in the sensor signal circuit between the ECM terminal B28 and sensor will cause one of
following DTC to be set:
RUW46EMF000101

Too low fuel pressure (poor fuel) will cause one or more of following DTCs to be set.
P0131 (Flash Code 15): O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
P0151 (Flash Code 15): O2 Sensor Circuit Low Voltage (Bank 2 Sensor 1)
P0171 (Flash Code 44): O2 Sensor System Too Lean (Bank 1)
P0174 (Flash Code 44): O2 Sensor System Too Lean (Bank 2)
P1171 (Flash Code 44): Fuel Supply System Lean During Power Enrichment (Bank 1)
P1172 (Flash Code 44): Fuel Supply System Lean During Power Enrichment (Bank 2)
Too high fuel pressure (excessive fuel) will cause one or more of following DTCs to be set.
P0132 (Flash Code 15): O2 Sensor Circuit High Voltage (Bank1 Sensor 1)
P0152 (Flash Code 15): O2 Sensor Circuit High Voltage (Bank 2 Sensor 1)
P0172 (Flash Code 45): O2 Sensor System Too Rich (Bank 1)
P0175 (Flash Code 45): O2 Sensor System Too Rich (Bank 2)
RTW36ELF000101
DIAGNOSTIC TROUBLE CODE (DTC) P0101 (FLASH CODE 61) MASS AIR
FLOW SENSOR CIRCUIT RANGE/PERFORMANCE
RUW46EMF000101
Condition For Setting The DTC and Action Taken When The DTC Sets
Flash Code Type
Code
61
P0101
DTC Name
Mass Air Flow Sensor
Circuit
Range/Performance
Fail-Safe (Back Up)
1. No DTC relating to barometer sensor, TPS, CMP sensor, No fail-safe function.

CKP sensor and MAF sensor (low input & high input).
2. Engine speed is between 2800rpm and 4500rpm.
3. Throttle position sensor output voltage is between 1V and
3V.
4. Intake air temperature is between -14C and 70C.
5. Air flow amount below 0.04g/s (small air) or more than
177g/s (large air).

Mis-routed harness.
CIRCUIT DESCRIPTION
The mass air flow (MAF) sensor measures the amount
of air which passes through it into the engine during a
given time. The Engine Control Module (ECM) uses the
mass air flow information to monitor engine operating
conditions for fuel delivery calculations. A large quantity
of air entering the engine indicates an acceleration or
high load situation, while a small quantity or air indicates
deceleration or idle.
The MAF sensor produces a frequency signal which
can be monitored using a Tech 2. The frequency will
vary within a range of around 4 to 7 g/s at idle to around
25 to 40 g/s at maximum engine load. DTC P0101 will
be set if the signal from the MAF sensor does not match
a predicted value based on throttle position and engine
RPM.

Refer to Intermittents under service category
Symptoms.
Any un-metered air may cause this DTC to set. Check
for the following:
The duct work at the MAF sensor for leaks.
An engine vacuum leak.
The PCV system for vacuum leaks.
An incorrect PCV valve.
The engine oil dip stick not fully seated.
The engine oil fill cap loose or missing.
DIAGNOSTIC AIDS
Poor connections.
Diagnostic Trouble Code (DTC) P0101 (Flash Code 61)

Mass Air Flow Sensor Circuit Range/Performance
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4

3. Select "F0: Read DTC Infor By Priority" in "F0:
Diagnostic Trouble Code".
Is the DTC P0101 stored as "Present Failure"?
1. Using the Tech2, ignition "On" and engine "Off".

2. Select "Clear DTC Information" with the Tech2 and
3. Operate the vehicle and monitor the "F5: Failed
This Ignition" in "F2: DTC Information"
Was the DTC P0101 stored in this ignition cycle?

Step
4
Action
Value (s)
Yes
No
Go to Step 6
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Go to Step 11
Go to Step 8

2. Monitor the "Mass Air Flow" in the data display.
Does the Tech 2 indicate correct "Mass Air Flow" as
shown in the following graph, when engine speed is
increasing little by little?
Characteristic of MAF Sensor -Ref erence (No Engine Load)50
45
Mass Air Flow (g/s)

(Tech2 Reading)
40
35
30
25
20
15
10
5
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
Engine Speed (rpm) (Tech2 Reading)


Objects blocking the throttle valve.
Vacuum leaking at throttle body.

6

E-61(B)

E-63

7

check.

Step
8
Action
Value (s)
Yes
No

circuit.
3. Ignition "On".
E-63
Go to Step 9
Remove the
accessory parts
and verify repair
Go to Step 10
Verify repair
Go to Step 11
Go to Step 12
Go to Step 13
Verify repair
Verify repair
Go to Step 14
Verify repair
Less than 1V
9
10

interference.
Check the shield wire for open or short circuit.
11

and recheck.
12

13

release?
14
Repair faulty
harness and
verify repair
Replace the ECM.

FLOW SENSOR CIRCUIT LOW INPUT
RUW46EMF000101
Flash Code Type
Code
61
P0102
DTC Name
Circuit Low Input

MAF sensor output voltage is below 0.3V.
Fail-Safe (Back Up)

The ECM uses default mass air flow
value based on IAC valve position,
throttle position, barometer pressure
and engine speed.
CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS

high load situation, while a small quantity of air indicates
vary within a range of around 5 to 8 g/s at idle to around
be set if the signal from the MAF sensor is below the
possible range of a normally operating MAF sensor.
.

Poor connection at ECM Inspect harness
connectors for backed-out terminals, improper
terminals, and poor terminal-to-wire connection.
Misrouted harness Inspect the MAF sensor
harness to ensure that it is not routed too close to
high voltage wires.
Damaged harness Inspect the wiring harness for
the Tech 2 while moving connectors and wiring
harnesses related to the MAF sensor. A change in
the display will indicate the location of the fault.
If DTC P0102 cannot be duplicated, the information
included in the Failure Records data can be useful in
determining vehicle mileage since the DTC was last set
Diagnostic Trouble Code (DTC) P0102 (Flash Code 61) Mass Air Flow Sensor
Circuit Low Input
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4



Step
4
Action
Value (s)
Yes
No
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6

E-61(B)

E-63

5

check.

circuit.
2. Install the breaker
disconnected).
box
as
type
(ECM
Refer to 6E-99 page.

Breaker Box
B20
B39
E-63


Step
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Repair faulty
harness and
verify repair
Go to Step 8
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11

connector.
E-61(B)
E-63

7

supply circuit.
main relay.
E-63
X-13


and recheck.

10

release?

Step
11
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.

FLOW SENSOR CIRCUIT HIGH INPUT
RUW46EMF000101
Flash Code Type
Code
61
P0103
DTC Name
Circuit High Input

MAF sensor output voltage is more than 4.9V.
Fail-Safe (Back Up)

The ECM uses default mass air flow
value based on IAC valve position,
throttle position, barometer pressure
and engine speed.
CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS

high load situation, while a small quantity of air indicates
vary within a range of around 5 ~ 8 g/s at idle to around
be set if the signal from the MAF sensor is above the
possible range of a normally operating MAF sensor.

determining vehicle mileage since the DTC was last set.

Mass Air Flow Sensor Circuit High Input
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Verify repair
Go to Step 5



E-61(B)

E-63

Step
5
Action
Yes
No
Go to Step 9
Go to Step 6
Repair faulty
harness and
verify repair
Go to Step 7

check.
Value (s)

circuit.
disconnected).
box
as
type
(ECM

Breaker Box
B39
E-63

connector.
E-61(B)
E-63


Step
7
Action
circuit.
Value (s)
Yes
No
Go to Step 8
Repair faulty
harness and
verify repair
Less than 1V
Go to Step 11
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 11
Verify repair
Verify repair
Go to Step 12
Verify repair
2. Disconnect the MAF sensor connector .

E-63
Less than 1V
8

circuit.
E-63

and recheck.
10

11

release?
12
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0112 (FLASH CODE 23) INTAKE AIR
TEMPERATURE (IAT) SENSOR LOW INPUT
RUW46EMF000101
Flash Code Type
Code
23
P0112
DTC Name
Intake Air Temperature IAT sensor output voltage is below 0.08V.

Sensor Low Input
CIRCUIT DESCRIPTION
The intake air temperature (IAT) sensor is a thermistor
which measures the temperature of the air entering the
engine. The Engine Control Module (ECM) applies 5
volts through a pull-up resistor to the IAT sensor. When
the intake air is cold, the sensor resistance is high and
the ECM will monitor a high signal voltage on the IAT
signal circuit. If the intake air is warm, the sensor
resistance is lower, causing the ECM to monitor a lower
voltage. DTC P0112 will set when the ECM detects an
excessively low signal voltage on the intake air
temperature sensor signal circuit.
Fail-Safe (Back Up)

The ECM use 40C conditions as
substitute.
DIAGNOSTIC AIDS
the IAT display on the Tech 2 while moving
connectors and wiring harnesses related to the IAT
sensor. A change in the IAT display will indicate the
location of the fault.
Diagnostic Trouble Code (DTC) P0112 (Flash Code 23) Intake Air Temperature
(IAT) Sensor Low Input
Step
1
Action
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6

performed?


E-60(A)
E-61(B)
E-63


check.

Step
6
Action
Value (s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 8

2. Disconnect IAT sensor connector.
MAF & IAT Sensor

-20
0
20
40
60
80
Resistance (W)
(Approximately)
15230
5760
2480
1185
584
332
100
183
120
119
Temperature (C)

Step
7
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 9
Go to Step 10
Verify repair

circuit.
disconnected).
box
as
type
(ECM

3. Disconnect the IAT sensor connector.
ground circuit.
Breaker Box
A19
B39


ground circuit.
E-60(A)
E-61(B)

and recheck.


Step
10
Action
Yes
No
Verify repair
Go to Step 11
Verify repair

release?
11
Value (s)
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0113 (FLASH CODE 23) INTAKE AIR
TEMPERATURE (IAT) SENSOR HIGH INPUT
RUW46EMF000101
Flash Code Type
Code
23
P0113
DTC Name
Intake Air Temperature IAT sensor output voltage is more than 4.9V.
Sensor High Input
Fail-Safe (Back Up)

The ECM use 40C conditions as
substitute.
CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS

engine. The Engine Control Module (ECM) applies 5
resistance is lower causing the ECM to monitor a lower
voltage. DTC P0113 will set when the ECM detects an
excessively high signal voltage on the intake air
temperature sensor signal circuit.

the IAT display on the Tech 2 while moving
Diagnostic Trouble Code (DTC) P0113 (Flash Code 23) Intake Air Temperature
(IAT) Sensor High Input
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6



E-60(A)
E-61(B)
E-63



Step
6
Action
Value (s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 10
Less than 1V:

Go to Step 8
More than
specified value:
Go to Step 9
Verify repair
Go to Step 14

MAF & IAT Sensor

-20
0
20
40
60
80
Resistance (W)
(Approximately)
15230
5760
2480
1185
584
332
100
183
120
119
Temperature (C)

circuit.
E-63

sensor.
E-60(A)
E-63

Step
9
Action
Value (s)
Yes
No
Verify repair
Go to Step 14
Go to Step 11
Repair faulty
harness and
verify repair

and IAT sensor.
E-60(A)
E-63
10

circuit.
E-63
Less than 1V
11

circuit.
disconnected).
box
as
type

Breaker Box
B39
E-63
(ECM

Step
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 14
Go to Step 13
Go to Step 14
Verify repair
Verify repair
Go to Step 15
Verify repair

E-61(B)
E-63
12

and recheck.
13

14

release?
15
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0117 (FLASH CODE 14) ENGINE

COOLANT TEMPERATURE (ECT) SENSOR LOW INPUT
RUW46EMF000201
Flash Code Type
Code
14
P0117
DTC Name
Engine Coolant
Temperature Sensor
Low Input

ECT sensor output voltage is below 0.08V.
Fail-Safe (Back Up)

coolant temperature value based on
start-up ECT and time from start.
Circuit Description
DIAGNOSTIC AIDS
The engine coolant temperature (ECT) sensor is a

thermistor mounted on a coolant crossover pipe at the
rear of the engine. The Engine Control Module (ECM)
applies a voltage (about 5 volts) through a pull-up
resistor to the ECT signal circuit. When the engine
coolant is cold, the sensor (thermistor) resistance is
high, therefore the ECM will measure a high signal
voltage. As the engine coolant warms, the sensor
resistance becomes lower, and the ECT signal voltage
measured at the ECM drops.

the ECT display on the Tech 2 while moving
connectors and wiring harnesses related to the ECT
sensor. A change in the ECT display will indicate the
If it is determined that the DTC occurs intermittently.
Diagnostic Trouble Code (DTC) P0117 (Flash Code 14) Engine Coolant
Temperature (ECT) Sensor Low Input
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6



E-60(A)

E-69


Step
6
Action
Value (s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 8

ECT Sensor

-20
0
20
40
60
100
Resistance (W)
(Approximately)
30300
9850
3650
1540
649
182
120
104
Temperature (C)

Step
7
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 9
Go to Step 10
Verify repair
Verify repair
Go to Step 11

circuit.
disconnected).
box
as
type
(ECM

ground circuit.
Breaker Box
A21
A22

ground circuit.
E-60(A)

recheck.

10

release?

Step
11
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0118 (FLASH CODE 14) ENGINE

COOLANT TEMPERATURE (ECT) SENSOR HIGH INPUT
RUW46EMF000201
Flash Code Type
Code
14
P0118
DTC Name
Engine Coolant
Temperature Sensor
High Input

ECT sensor output voltage is more than 4.8V.
CIRCUIT DESCRIPTION
thermistor mounted in on a coolant crossover pipe at
the rear of the engine. The Engine Control Module
(ECM) applies a voltage (about 5 volts) through a
pull-up resistor to the ECT signal circuit. When the
engine coolant is cold, the sensor (thermistor)
resistance is high, therefore the ECM will measure a
high signal voltage. As the engine coolant warms, the
sensor resistance becomes less, and the ECT signal
voltage measured at the ECM drops.
Fail-Safe (Back Up)

coolant temperature value based on
start-up ECT and time from start.
DIAGNOSTIC AIDS
Diagnostic Trouble Code (DTC) P0118 (Flash Code 14) Engine Coolant
Temperature (ECT) Sensor High Input
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6



E-60(A)

E-69
Visually check the ECT sensor. Was the problem

found?

Step
6
Action
Value (s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 10
Less than 1V:

Go to Step 8
More than
specified value:
Go to Step 9
Verify repair
Go to Step 14

ECT Sensor

-20
0
20
40
60
100
Resistance (W)
(Approximately)
30300
9850
3650
1540
649
182
120
104
Temperature (C)

circuit.
E-69

sensor.
E-60(A)
E-69

Step
9
Action
and ECT sensor.
Value (s)
Yes
No
Verify repair
Go to Step 14
Go to Step 11
Repair faulty
harness and
verify repair
E-60(A)
E-69
10

circuit.
E-69
Less than 1V

Step
11
Action
circuit.
disconnected)
box
as
type
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 14
Go to Step 13
Go to Step 14
Verify repair
Verify repair
Go to Step 15
(ECM

Breaker Box
A22
E-69

E-60(A)
E-69
12

recheck.
13

14

release?

Step
15
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0121 (FLASH CODE 21) THROTTLE

POSITION SENSOR (TPS) CIRCUIT RANGE/PERFORMANCE
RUW46EMF000101
Flash Code Type
Code
21
P0121
DTC Name
Throttle Position
Sensor
Range/Performance

1. No DTC relating to barometer sensor, ECT sensor, CMP
sensor, CKP sensor, MAF sensor and TPS (low input &
high input).
3. Engine coolant temperature is more than 75C.
4. TPS output voltage is between 0.24V and 0.26V.
OR
1. No DTC relating to barometer sensor, ECT sensor, CMP
sensor, CKP sensor, MAF sensor and TPS (low input &
high input).
4. TPS output voltage is between 4.54V and 4.56V.
Fail-Safe (Back Up)

CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS
The TPS circuit provides a voltage signal that changes

relative to throttle blade angle. The signal voltage will
vary from about 0.6 volts at closed throttle to about 4.5
volts at wide open throttle (WOT).
The TPS signal is one of the most important inputs
used by the Engine Control Module (ECM) for fuel
control and many of the ECM-controlled outputs. The
ECM monitors throttle position and compares actual
throttle position from the TPS to a predicted TPS value
calculated from engine speed. If the ECM detects an
out-of-range condition, DTC P0121 will set.

mating, broken locks improperly formed or damaged
connectors and wiring harnesses related to the
sensor. A change in the display will indicate the
Diagnostic Trouble Code (DTC) P0121 (Flash Code 21) Throttle Position
Sensor (TPS) Circuit Range/Performance
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Go to Step 6
Go to Step 5
Verify repair
Go to Step 12



2. Monitor the "Throttle Position" in the data display.
Does the Tech 2 indicate correct "Throttle Position"
operation?
1. Using the Tech 2, ignition "On" and engine "Off


Step
6
Action
Value (s)
Yes
No
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 12
Go to Step 9
Less than 1V
Go to Step 10
Repair faulty
harness and
verify repair
Remove the
accessory parts
and verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 13
Go to Step 14
Verify repair

the faulty terminal.

E-61(B)
E-68


E-68
10

interference.
11

12

13
Replace the TPS.


Step
14
Action
release?
15
Value (s)
Yes
No
Verify repair
Go to Step 15
Verify repair
Replace the ECM.


POSITION SENSOR CIRCUIT LOW INPUT
RUW46EMF000101
Flash Code Type
Code
21
P0122
DTC Name
Throttle Position
Sensor Low Input

CIRCUIT DESCRIPTION
vary from below 0.6 volts at closed throttle to about 4.5
The TPS signal is used by the Engine Control Module
(ECM) for fuel control and many of the ECM-controlled
outputs.
Fail-Safe (Back Up)

The ECM uses default throttle
position value based on mass air
flow and engine speed.
DIAGNOSTIC AIDS
the throttle position display on the Tech 2 while
moving connectors and wiring harnesses related to
the TPS. A change in the display will indicate the
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Verify repair
Go to Step 5
Go to Step 10
Go to Step 6



as necessary.

E-61(B)
E-68


Step
6
Action
Value (s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 10
Approximately
5.0V
Go to Step 9
Go to Step 8
Verify repair
Go to Step 12

TPS

Measurement Terminal
Resistance (9)
1-2
Approximately 4.7k9 at idle position
Approximately 1.0k9 at WOT
23
Approximately 5.0k9 at idle position &
13
WOT

circuit.
E-68

ECM and TPS.
E-61(B)
E-68

Step
9
Action
disconnected).
box
as
type
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 12
Go to Step 11
Go to Step 12
Verify repair
Verify repair
Go to Step 13
(ECM

E-68
Breaker Box
B26
B39


2. Disconnect
connector.
the
TPS
connector
and
ECM

E-61(B)
E-68
10

11
Replace the TPS.

12

release?

Step
13
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.


POSITION SENSOR CIRCUIT HIGH INPUT
RUW46EMF000101
Flash Code Type
Code
21
P0123
DTC Name
Throttle Position
Sensor High Input

CIRCUIT DESCRIPTION
vary from about 0.6 volts at closed throttle to about 4.5
The TPS signal is one of the most important inputs
used by the Engine Control Module (ECM) for fuel
control and many of the ECM-controlled outputs.
DIAGNOSTIC AIDS
Fail-Safe (Back Up)

The ECM uses default throttle
position value based on mass air
flow and engine speed.

the TPS display on the Tech 2 while moving
connectors and wiring harnesses related to the TP
Faulty TPS With the ignition key ON," engine
OFF," observe the TPS display on the Tech 2 while
slowly depressing the accelerator to wide open
throttle. If a voltage over 4.56 volts is seen at any
point in normal accelerator travel, replace the TPS.
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6



as necessary.

E-61(B)
E-68


Step
6
Action
Value (s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 9
Go to Step 8
Verify repair
Go to Step 14

TPS

1-2
Resistance (W)
23
13

Approximately 5.0kW at idle position &
WOT

circuit.
E-68

and TPS.
E-61(B)
E-68

Step
9
Action
Value (s)
Yes
No
Go to Step 10
Repair faulty
harness and
verify repair
Go to Step 11
Repair faulty
harness and
verify repair

E-68
Less than 1V
10

E-68
Less than 1V
11

disconnected).
box
as
type
A.

E-68
Breaker Box
B39
(ECM

Step
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 14
Go to Step 13
Go to Step 14
Verify repair
Verify repair
Go to Step 15
Verify repair
2. Disconnect the TPS connector and ECM connector.

E-61(B)
E-68
12

13
Replace the TPS.

14

release?
15
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0131 (FLASH CODE 15) O2 SENSOR

CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)
CIRCUIT LOW VOLTAGE (BANK 2 SENSOR 1)
RTW36ELF000101
Flash Code Type
Code
15
P0131
P0151
DTC Name
Fail-Safe (Back Up)
O2 Sensor Circuit Low 1. No DTC relating to ECT sensor, CMP sensor, CKP sensor, "Open Loop" fuel control.
VSS, injector control circuit, ignition control circuit and O2
Voltage (Bank 1
sensor circuit no activity (bank 1 & 2).
Sensor 1)
O2 Sensor Circuit Low 2. Engine speed is between 1000rpm and 4000rpm.
Voltage (Bank 2
Sensor 1)
3. Engine coolant temperature is between 70C and 110C.

4. Vehicle speed is between 0km/h and 120km/h.
5. Engine load is between 80% and 160%.
7. O2 sensor bank 1 or bank 2 output voltage is more than
CIRCUIT DESCRIPTION
The Engine Control Module (ECM) supplies a bias
voltage of about 450 mV between the heated oxygen
sensor (HO2S) signal high and signal low circuits. The
ECM constantly monitors the HO2S signal during
closed loop" operation and compensates for a rich or
lean condition by decreasing or increasing injector pulse
width as necessary. If HO2S voltage remains
excessively low for an extended period of time, DTC
P0131 or P0151 will be set.
DIAGNOSTIC AIDS
Heated oxygen sensor wiring The sensor pigtail
may be routed incorrectly and contacting the exhaust
system.
Poor ECM to engine block grounds.
Fuel pressure The system will go lean if pressure is
too low. The ECM can compensate for some
decrease. However, If fuel pressure is too low, a DTC
P0131 or P0151 may be set. Refer to 6E-116 Fuel
System Diagnosis.
Lean injector(s) Perform Injector Balance Test."

Exhaust leaks An exhaust leak may cause outside
air to be pulled into the exhaust gas stream past the
HO2S, causing the system to appear lean. Check for
exhaust leaks that may cause a false lean condition
to be indicated.
MAF sensor The system can go lean if the MAF
sensor signal indicates an engine airflow
measurement that is not correct. Disconnect the MAF
sensor to see if the lean condition is corrected. If so,
replace the MAF sensor.
Fuel contamination Water, even in small amounts,
can be delivered to the fuel injectors. The water can
cause a lean exhaust to be indicated. Excessive
alcohol in the fuel can also cause this condition.
Refer to 6E-116 Fuel System Diagnosis for the
procedure to check for fuel contamination.
If none of the above conditions are present, replace
the affected HO2S.
Diagnostic Trouble Code (DTC) P0131 (Flash Code 15) O2 Sensor Circuit Low
Voltage (Bank 1 Sensor 1)
Diagnostic Trouble Code (DTC) P0151 (Flash Code 15) O2 Sensor Circuit Low
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Verify repair
Go to Step 5

Is the DTC P0131 or P0151 stored as "Present
Failure"?

Was the DTC P0131 or P0151 stored in this ignition
cycle?
Check for poor/faulty connection at the O2 sensor or

E-61(B)

E-77/E-78

Step
5
Action
Using the DVM and check the O2 sensor circuit for the
affected bank.
Value (s)
Yes
No
Approximatly
450mV
Go to Step 7
Go to Step 6

2. Disconnect the O2 sensor connector for the
affected bank.
3. Check the circuit for open, short to heater ground or
ground circuit.
BANK1/BANK2
E-77/E-78

V
affected bank.
disconnected).
box
as
type
(ECM

3. Disconnect the O2 sensor for the affected bank.
BANK1
E-77
Breaker Box
B21
B22

E-77
Breaker Box
B21
B22

Step
Action
BANK2
E-78
Breaker Box
B23
B24
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 15

E-78
Breaker Box
B23
B24


affected bank and ECM connector.
BANK1
E-77
E-61(B)

E-77
E-61(B)


Step
Action
Value (s)
Yes
No
No continuity
Go to Step 9
Go to Step 8
Verify repair
Go to Step 15
BANK2
E-78
E-61(B)

E-78
E-61(B)

affected bank.
affected bank.
3. Check the circuit for short to heater ground circuit.
BANK1/BANK2
O2 Sensor

Repair the short to heater ground circuit.


Step
9
Action
Value (s)
Yes
No
Go to Step 11
Go to Step 10
Verify repair
Refer to DTC
P0101 and Go to
Step 11
Go to Step 13
Go to Step 12
Verify repair
Refer to DTC
P1508/P1509
and Go to Step
13
Go to Step 14
Refer to Injector
Coil Test &
Injecotr Balance
Test Procedure
Go to Step 15
Refer to Fuel
System
Diagnosis
Verify repair
Go to Step 16

45
Mass Air Flow (g/s)

(Tech2 Reading)
40
35
30
25
20
15
10
5
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
10

11

"IAC Control" in the "IAC System".
3. Operate the Tech 2 in accrodance with procedure.
Was the engine speed changed, when the IAC Valve
is operating step by step?
12

Objects blocking the IAC Valve.
13
Check for injector for the affected bank.

Refer to 6E-106 "Injector Coil Test & Injector Balance
Test Procedure"
Was the injector operation correct?
14
Check for fuel pressure.

Refer to 6E-116 "Fuel System Diagnosis".
Was the fuel pressure correct?
15
Replace the O2 sensor for the affected bank.


Step
16
Action
release?
17
Value (s)
Yes
No
Verify repair
Go to Step 17
Verify repair
Replace the ECM.


CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)
CIRCUIT HIGH VOLTAGE (BANK 2 SENSOR 1)
RTW36ELF000101
Flash Code Type
Code
15
P0132
P0152
DTC Name
Fail-Safe (Back Up)
O2 Sensor Circuit High 1. No DTC relating to ECT sensor, CMP sensor, CKP sensor, "Open Loop" fuel control.
Voltage (Bank 1
VSS, injector control circuit, ignition control circuit and O2
Sensor 1)
sensor circuit no activity (bank 1 & 2).
O2 Sensor Circuit High 2. Engine speed is between 1000rpm and 4000rpm.
Voltage (Bank 2
3. Engine coolant temperature is between 70 and 110.
Sensor 1)
4. Vehicle speed is between 0km/h and 120km/h.
5. Engine load is between 80% and 160%.
7. O2 sensor bank 1 or bank 2 output voltage is below
CIRCUIT DESCRIPTION
sensor (HO2S) signal high and signal low circuits. The
ECM constantly monitors the HO2S signal during
closed loop" operation and compensates for a rich or
lean condition by decreasing or increasing injector pulse
width as necessary. If the HO2S voltage remains
excessively high for an extended period of time, DTC
P0132 or P0152 will be set.
DIAGNOSTIC AIDS
Check the following items:
Fuel pressure The system will go rich if pressure is
too high. The ECM can compensate for some
increase. However, if fuel pressure is too high, a DTC
P0132 or P0152 may be set. Refer to 6E-116 Fuel
System Diagnosis.
Perform Injector Balance Test" Refer to 6E-116
Fuel System Diagnosis.
Check the canister for fuel saturation If full of fuel,
check canister control and hoses.
MAF sensor The system can go rich if MAF sensor
signal indicates an engine airflow measurement that
is not correct. Disconnect the MAF sensor to see it
the rich condition is corrected. If so, replace the MAF
sensor.
Check for a leak in the fuel pressure regulator

diaphragm by checking the vacuum line to the
regulator for the presence of fuel. There should be no
fuel in the vacuum line.
An intermittent throttle position sensor output will
cause the system to go rich due to a false indication
of the engine accelerating.
Shorted Heated Oxygen Sensor (HO2S) If the
HO2S is internally shorted, the HO2S voltage
displayed on the Tech 2 will be over 1 volt. Try
disconnecting the affected HO2S with the key ON,"
engine OFF." If the displayed HO2S voltage
changes from over 1000 mV to around 450 mV,
replace the HO2S. Silicon contamination of the
HO2S can also cause a high HO2S voltage to be
indicated. This condition is indicated by a powdery
white deposit on the portion of the HO2S exposed to
the exhaust stream. If contamination is noticed,
replace the affected HO2S.
Open HO2S Signal Circuit or Faulty HO2SA poor
connection or open in the HO2S signal circuit can
cause the DTC to set during deceleration fuel mode.
An HO2S which is faulty and not allowing a full
voltage swing between the rich and lean thresholds
can also cause this condition. Operate the vehicle by
monitoring the HO2S voltage with a Tech 2. If the
HO2S voltage is limited within a range between 300
mV to 600 mV, check the HO2S signal circuit wiring
and associated terminal conditions.
If none of the above conditions are present, replace
the affected HO2S.
Diagnostic Trouble Code (DTC) P0132 (Flash Code 15) O2 Sensor Circuit High
Diagnostic Trouble Code (DTC) P0152 (Flash Code 15) O2 Sensor Circuit High
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Verify repair
Go to Step 5

Failure"?

cycle?

ECM connector.
necessary.
E-61(B)

E-77/E-78

Step
5
Action
affected bank.
Value (s)
Yes
No
Approximatly
450mV
Go to Step 7
Go to Step 6
Go to Step 15
Repair faulty
harness and
verify repair

affected bank.
ground circuit.
BANK1/BANK2
E-77/E-78

V

6
affected bank.
affected cylinder.
Was the DVM indicated specifed value?
BANK1/BANK2
E-77/E-78

V
Less than 1V

Step
7
Action
affected bank.
Value (s)
Yes
No
No continuity
Go to Step 9
Go to Step 8
Verify repair
Go to Step 15
Go to Step 11
Go to Step 10
Verify repair
Refer to DTC
P0101 and Go to
Step 11

affected bank.
3. Check the circuit for short to heater power supply
circuit.
BANK1/BANK2
O2 Sensor

Repair the short to heater power supply circuit.


45
Mass Air Flow (g/s)

(Tech2 Reading)
40
35
30
25
20
15
10
5
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
10

-Objects blocking the air cleaner.

Step
11
Action
Value (s)
Yes
No
Go to Step 13
Go to Step 12
Verify repair
Refer to DTC
P1508/P1509
and Go to Step
13
Go to Step 14
Refer to Injector
Coil Test &
Injector Balance
Test Procedure
Go to Step 15
Refer to Fuel
System
Diagnosis
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair

12

13

Test Procedure".
14

15

16

release?
17
Replace the ECM.


CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)
CIRCUIT NO ACTIVITY DETECTED (BANK 2 SENSOR 1)
RTW36ELF000101
Flash Code Type
Code
15
P0134
P0154
DTC Name
Fail-Safe (Back Up)
1. No DTC relating to MAF sensor, ECT sensor, CMP sensor, "Open Loop" fuel control.
O2 Sensor Circuit No
CKP sensor, VSS, injector control circuit and ignition
Activity Detected (Bank
control circuit.
1 Sensor 1)
2.
O2 Sensor Circuit No
Activity Detected (Bank 3. Vehicle speed is more than 60km/h.
2 Sensor 1)
4. O2 sensor bank 1 or bank 2 output voltage is between
350mV and 600mV.
CIRCUIT DESCRIPTION
sensor (HO2S) high and low circuits. The ECM
constantly monitors the HO2S signal during closed
loop" operation and compensates for a rich or lean
condition by decreasing or increasing injector pulse
width as necessary. If the HO2S voltage remains at
or near the 450 mV bias for an extended period of
time, DTC P0134 or P0154 will be set, indicating an
open sensor signal or sensor low circuit.
Faulty HO2S heater or heater circuit With the

ignition ON," engine OFF," after a cool down period,
the HO2S voltage displayed on the Tech 2 is
normally 455-460 mV. A reading over 1000 mV
indicates a signal line shorted to voltage. A reading
under 5 mV indicates a signal line shorted to ground
or signal lines shorted together.
Intermittent test With the Ignition ON," monitor the
HO2S signal voltage while moving the wiring harness
and related connectors. If the fault is induced, the
HO2S signal voltage will change. This may help
isolate the location of the malfunction.
DIAGNOSTIC AIDS
harness connectors for backed-out terminals,
Diagnostic Trouble Code (DTC) P0134 (Flash Code 15) O2 Sensor Circuit No
Activity Detected (Bank 1 Sensor 1)
Diagnostic Trouble Code (DTC) P0154 (Flash Code 15) O2 Sensor Circuit No
Activity Detected (Bank 2 Sensor 1)
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4

Failure"?

cycle?

Step
4
Action
Value (s)
Yes
No
Verify repair
Go to Step 5
Approximatly
450mV
Go to Step 6
Go to Step 12
10-14.5 V
Go to Step 9
Go to Step 7
E-61(B)

E-77/E-78
affected bank.
affected bank.
3. Check the circuit for open, short to heater ground
or ground circuit.
BANK1/BANK2
E-77/E-78

V

6
Using the DVM and check the O2 sensor heater

power supply circuit for the affected bank.
affected cylinder.
BANK1/BANK2
E-77/E-78

V

Step
7
Action
fuel pump relay and O2 sensor heater for the affected
cylinder.
Yes
No
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Repair the open circuit between the O2 sensor heater

and engine ground for the affected cylinder.
Value (s)
Using the DVM and check the O2 sensor heater circuit

for the affected bank.
affected bank.
3. Check the circuit for short circuit.
Was the tester indicated specified value?
BANK1/BANK2
O2 Sensor

10
Repair the short circuit between the O2 sensor heater

power supply and ground circuit.
11
Verify repair
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair

release?
13

12
Approximatly
16.5W at 20
Approximataly
0W: Go to Step
10
No continuitly: Go
Go to Step 12
to Step 11
Replace the ECM.


SYSTEM TOO LEAN (BANK 1)
SYSTEM TOO LEAN (BANK 2)
RTW36ELF000101
Flash Code Type
Code
44
P0171
P0174
DTC Name
Fail-Safe (Back Up)
O2 Sensor System Too 1. No DTC relating to MAF sensor, IAT sensor, ECT sensor, No fail-safe function.
TPS, CMP sensor, CKP sensor, VSS, injector control
Lean (Bank 1)
circuit, ignition control circuit, O2 sensor circuit low voltage
O2 Sensor System Too
& high voltage (bank 1 & 2) and O2 sensor circuit no
Lean (Bank 2)
5. Engine load is more than 20%.
6. EVAP purge solenoid valve on-duty is below 100%.
7. Air-fuel ratio correction volume is more than 150%
for 20 seconds.
CIRCUIT DESCRIPTION
To provide the best possible combination of driveability,
fuel economy, and emission control, a closed loop"
air/fuel metering system is used. While in closed loop,"
the Engine Control Module (ECM) monitors the HO2S
signals and adjusts fuel delivery based upon the HO2S
signal voltages. A change made to fuel delivery will be
indicated by the long and short term fuel trim values
which can be monitored with a Tech 2. Ideal fuel trim
values are around 0%; if the HO2S signals are
indicating a lean condition the ECM will add fuel,
resulting in fuel trim values above 0%. If a rich condition
is detected, the fuel trim values will be below 0%,
indicating that the ECM is reducing the amount of fuel
delivered. If an excessively lean condition is detected,
the ECM will set DTC P0171 or P0174.
The ECM's maximum authority to control long term fuel
trim allows a range between 15% (automatic
transmission) or 12% (manual transmission) and
+20%. The ECM monitors fuel trim under various
engine speed/load fuel trim cells before determining the
status the fuel trim diagnostic.
DIAGNOSTIC AIDS
the HO2S display on the Tech 2 while moving
engine harness. A change in the display will indicate
the location of the fault.
Diagnostic Trouble Code (DTC) P0171 (Flash Code 44) O2 Sensor System
Too Lean (Bank 1)
Diagnostic Trouble Code (DTC) P0174 (Flash Code 44) O2 Sensor System
Too Lean (Bank 2)
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Go to Step 6
Go to Step 5
Verify repair
Refer to DTC
P0101 and Go to
Step 6

Failure"?

cycle?

45
Mass Air Flow (g/s)

(Tech2 Reading)
40
35
30
25
20
15
10
5
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000


Step
6
Action
Value (s)
Yes
No
Go to Step 8
Go to Step 7
Verify repair
Verify repair
Refer to DTC
P0121 and Go to
Step 9
Go to Step 11
Go to Step 10
Verify repair
Refer to DTC
P1508/P1509
and Go to Step
11
Go to Step 12
Refer to Injector
Coil Test &
Injector Balance
Test Procedure
Go to Step 13
Refer to Fuel
System
Diagnosis
Verify repair
Go to Step 14
Verify repair
Go to Step 15

operation?
7



10

11

Test Procedure".
12

13

14

release?

Step
15
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.


SYSTEM TOO RICH (BANK 1)
SYSTEM TOO RICH (BANK 2)
RTW36ELF000101
Flash Code Type
Code
45
P0172
P0175
DTC Name
Fail-Safe (Back Up)
O2 Sensor System Too 1. No DTC relating to MAF sensor, IAT sensor, ECT sensor, No fail-safe function.
Rich (Bank 1)
O2 Sensor System Too
Rich (Bank 2)
5. Engine load is more than 20%.
6. EVAP purge solenoid valve on-duty is below 100%.
7. Air-fuel ratio correction volume is below 50% for 20
seconds.
CIRCUIT DESCRIPTION
To provide the best possible combination of driveability,
fuel economy, and emission control, a closed loop"
air/fuel metering system is used. While in closed loop,"
the Engine Control Module (ECM) monitors the heated
oxygen sensors (HO2S) signals and adjusts fuel
delivery based upon the HO2S signal voltages. A
change made to fuel delivery will be indicated by the
long and short term fuel trim values which can be
monitored with a Tech 2. Ideal fuel trim values are
around 0%; if the HO2S signals are indicating a lean
condition the ECM will add fuel, resulting in fuel trim
values above 0%. If a rich condition is detected, the fuel
trim values will be below 0%, indicating that the ECM is
reducing the amount of fuel delivered. If an excessively
rich condition is detected on Bank 1, the ECM will set
DTC P0172 or P0175.
The ECM's maximum authority to control long term fuel
trim allows a range between 15% (automatic
transmission) or 12 (manual transmission) and +20%.
The ECM's maximum authority to control short term fuel
trim allows a range between 11% and +20%. The ECM
monitors fuel trim under various engine speed/load fuel
trim cells before determining the status of the fuel trim
diagnostic.
DIAGNOSTIC AIDS
the HO2S display on the Tech 2 while moving
engine harness. A change in the display will indicate
Diagnostic Trouble Code (DTC) P0172 (Flash Code 45) O2 Sensor System Too
Rich (Bank 1)
Diagnostic Trouble Code (DTC) P0175 (Flash Code 44) O2 Sensor System Too
Rich (Bank 2)
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Go to Step 6
Go to Step 5
Verify repair
Refer to DTC
P0101 and Go to
Step 6

Failure"?

cycle?

45
Mass Air Flow (g/s)

(Tech2 Reading)
40
35
30
25
20
15
10
5
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000


Step
6
Action
Value (s)
Yes
No
Go to Step 8
Go to Step 7
Verify repair
Verify repair
Refer to DTC
P0121 and Go to
Step 9
Go to Step 11
Go to Step 10
Verify repair
Refer to DTC
P1508/P1509
and Go to Step
11
Go to Step 12
Refer to Injector
Coil Test &
Injector Balance
Test Procedure
Go to Step 13
Refer to Fuel
System
Diagnosis
Verify repair
Go to Step 14
Verify repair
Go to Step 15

operation?
7



10

11

Test Procedure".
12

13

14

release?

Step
15
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P1171 (FLASH CODE 44) FUEL SUPPLY
SYSTEM LEAN DURING POWER ENRICHMENT (Bank 1)
DIAGNOSTIC TROUBLE CODE (DTC) P1172 (FLASH CODE 44) FUEL SUPPLY
SYSTEM LEAN DURING POWER ENRICHMENT (Bank 2)
RTW36ELF000101
Flash Code Type
Code
44
DTC Name
P1171
Fuel Supply System

Lean During Power
Enrichment (Bank 1)
P1172
Fuel Supply System

Lean During Power
Enrichment (Bank 2)
Fail-Safe (Back Up)
1. No DTC relating to MAF sensor, IAT sensor, ECT sensor, No fail-safe function.
3. Intake air temperature is below 70C.
5. Engine load is between 150 and 255.
6. Throttle position output is more than 2.22V and fluctuation
is below 0.28V.
8. O2 sensor output voltage below 250mV for 10 seconds.
CIRCUIT DESCRIPTION
The engine control module (ECM) internal circuitry can
identify if the vehicle fuel system is capable of supplying
adequate amounts of fuel during heavy acceleration
(power enrichment). The ECM monitors the voltage of
the oxygen sensor during power enrichment. When a
power enrichment mode of operation is requested
during closed loop" operation (by heavy acceleration),
the ECM will provide more fuel to the engine. Under
these conditions the ECM should detect a rich"
condition (high oxygen sensor voltage). If this rich"
exhaust is not detected at this time, a DTC P1171 or
P1172 will set. A plugged fuel filter, restricted fuel line,
restricted in-tank filter or defective fuel pump can
prevent adequate amouts of fuel from being supplied
during power enrichment mode.
DIAGNOSTIC AIDS
A restricted fuel filter or fuel line, restricted in-tank
filter, or a defective fuel pomp may supply adequate
amounts of fuel at idle, but may not be able to supply
enough fuel during heavy acceleration.
Water or alcohol in the fuel may cause low HO2S
voltage during acceleration.
Check for faulty or plugged fuel injector(s).
Check for low fuel.
Diagnostic Trouble Code (DTC) P1171 (Flash Code 44) Fuel Supply System
Lean During Power Enrichment (Bank 1)
Diagnostic Trouble Code (DTC) P1172 (Flash Code 44) Fuel Supply System
Lean During Power Enrichment (Bank 2)
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Go to Step 6
Go to Step 5
Verify repair
Refer to DTC
P0101 and Go to
Step 6

Failure"?

cycle?

45
Mass Air Flow (g/s)

(Tech2 Reading)
40
35
30
25
20
15
10
5
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000


Step
6
Action
Value (s)
Yes
No
Go to Step 8
Go to Step 7
Verify repair
Verify repair
Refer to DTC
P0121 and Go to
Step 9
Go to Step 10
Go to Step 10
Verify repair
Refer to DTC
P1508/P1509
and Go to Step
11
Go to Step 12
Refer to Injector
Coil Test &
Injector Balance
Test Procedure
Go to Step 13
Refer to Fuel
System
Diagnosis
Verify repair
Go to Step 14
Verify repair
Go to Step 15

operation?
7



10

11

Test Procedure".
12

13

14

release?

Step
15
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0201 (FLASH CODE 31) INJECTOR 1

CONTROL CIRCUIT
CONTROL CIRCUIT
CONTROL CIRCUIT
CONTROL CIRCUIT
CONTROL CIRCUIT
CONTROL CIRCUIT
RTW36EMF000901
Flash Code Type
Code
31
DTC Name
P0201
Injector 1 Control
Circuit
1. No DTC relating to CMP sensor and CKP sensor.
P0202
Injector 2 Control
Circuit
3. Injection pulse is between 2.5ms and 7.5 ms.
P0203
Injector 3 Control
Circuit
P0204
Injector 4 Control
Circuit
P0205
Injector 5 Control
Circuit
P0206
Injector 6 Control
Circuit
Fail-Safe (Back Up)

2. Under sequential injection.
6. 30 injection signals are not detected consecutively.
CIRCUIT DESCRIPTION
The Engine Control Module ECM has six individual
injector driver circuits. Each controls an injector. When
a driver circuit is grounded by the (ECM), the injector is
activated. The ECM monitors the current in each driver
circuit. The voltage on each driver is monitored to detect
a fault. If the voltage is not what the ECM expects to
monitor on the circuit, a DTC is set. This DTC is also
set if an injector driver is shorted to voltage or if there is
an open circuit.
DIAGNOSTIC AIDS
An injector driver circuit that is open or shorted to
voltage will cause a DTC P0201, P0202, P0203, P0204,
P0205 or P0206 to set. It will also cause a misfire due
to an inoperative injector.
Long term and short term fuel trims that are excessively
high or low are a good indication that an injector is
faulty.
Diagnostic Trouble Code (DTC) P0201 (Flash Code 31) Injector 1

Control Circuit
Control Circuit
Control Circuit
Control Circuit
Control Circuit
Control Circuit
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4

Is the DTC P0201, P0202, P0203, P0204, P0205 or
P0206 stored as "Present Failure"?

Was the DTC P0201, P0202, P0203, P0204, P0205 or
P0206 stored in this ignition cycle?

Step
4
Action
Check for poor/faulty connection at the injector or
Value (s)
Yes
No
Verify repair
Go to Step 5
Go to Step 11
Go to Step 6
Approximately
15W at 20C
Go to Step 7
Go to Step 11
E-60(A)

E-61(B)

E-6/E-7/E-8/E-9/
E-51/E-52

Visually check the injector for affected cylinder.

Using the DVM and check the injector coil.

2. Disconnect injector connector for the affected
cylinder.
3. Measure the resistance of injector coil.
Injector

Step
7
Action
Using the DVM and check the injector power supply
circuit.
Value (s)
Yes
No
Battery voltage
Go to Step 9
Go to Step 8
Verify repair

2. Disconnect the injector connector for the affected
cylinder.
E-6/E-7/E-8/E-9/
E-51/E-52

ECM main relay and injector for the affected cylinder.
Using the DVM and check the injector signal circuit.

disconnected).
box
as
type
(ECM

cylinder.
E-6
No.1 Cylinder
Breaker Box
A36
E-7
No.2 Cylinder
Breaker Box
B3

Step
Action
Value (s)
E-8
No.3 Cylinder
Breaker Box
A35
E-9
No.4 Cylinder
Breaker Box
B4
E-51
No.5 Cylinder
Breaker Box
A34
E-52
No.6 Cylinder
Breaker Box
B5

cylinder and ECM connector.
No.1 Cylinder
E-60(A)

E-6
Yes
No

Step
Action
No.2 Cylinder
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
E-61(B)
E-7
No.3 Cylinder
E-60(A)
E-8

No.4 Cylinder
E-61(B)
E-9

No.5 Cylinder
E-60(A)
E-51

No.6 Cylinder
E-52
E-61(B)


Step
10
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 12
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair

cylinder.
3. Check the circuit for short to battery voltage circuit.
E-6/E-7/E-8/E-9/
E-51/E-52
11
Replace the injector for the affected cylinder.

12

release?
13
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0336 (FLASH CODE 29) CRANKSHAFT

POSITION SENSOR CIRCUIT RANGE/PERFORMANCE (58X)
DIAGNOSTIC TROUBLE CODE (DTC) P0337 (FLASH CODE 29) CRANKSHAFT
POSITION SENSOR CIRCUIT NO SIGNAL (58X)
RUW46EMF000201
Flash Code Type
Code
29
P0336
P0337
DTC Name
Crankshaft Position
Sensor Circuit
Range/Performance
(58X)
1. No DTC relating to CMP sensor.
Crankshaft Position
Sensor Circuit No
Signal (58X)

3. Extra or missing pulse is detected consecutively.

Fail-Safe (Back Up)

CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS
The CKP reference signal is produced by the crankshaft

position (CKP) sensor. During one crankshaft
revolution, crankshaft pulses will be produced. The
Engine Control Module (ECM) uses the CKP reference
signal to calculate engine RPM and crankshaft position.
The ECM constantly monitors the number of pulses on
the CKP reference circuit and compares them to the
number of camshaft position (CMP) signal pulses being
received. If the ECM receives an incorrect number of
pulses on the CKP reference circuit, DTC P0336 will
set.

rubbedthrough wire insulation or a wire broken inside
the insulation. Check for:
Poor connection Inspect the ECM harness and
connectors for improper mating, broken locks,
damage.
Reviewing the Failure Records vehicle mileage since
the diagnostic test last failed may help determine how
often the condition that caused the DTC to be set
occurs. This may assist in diagnosing the condition.
Diagnostic Trouble Code (DTC) P0336 (Flash Code 29) Crankshaft Position
Sensor Circuit Range/Performance (58X)
Diagnostic Trouble Code (DTC) P0337 (Flash Code 29) Crankshaft Position
Sensor Circuit No Signal (58X)
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Remove the
accessory parts
and verify repair
Go to Step 5
Go to Step 6
Go to Step 7

Failure"?

cycle?


Does the engine start and continue to "Run"?

Step
6
Action
Value (s)
Yes
No
Go to Step 17
Go to Step 7
Verify repair
Go to Step 8
1. Ignition "On", engine "On".

2. Measure the CKP output voltage at the sensor and
ECM.
Measurement Point
At CKP sensor terminal 3 & GND

At ECM E60 connector A23 & GND
2000rpm

signal.
Does the oscilloscope indicate correct wave form?
0V
Measurement Terminal: A23(+)

A25(-)
Measurement Scale: 2.0V/div
5ms/div

E-60(A)

E-59

Step
8
Action
Remove the CKP sensor from the cylinder block and
visually check.
Value (s)
Yes
No
Verify repair
Go to Step 9
Approximately
5.0V
Go to Step 12
Less than 1V:

Go to Step 10
More than
specified value:
Go to Step 11
Verify repair
Go to Step 21

Objects sticking the CKP sensor pluser.
Gear missing the CKP sensor pluser.
9
Using the DVM and check the CKP sensor power

supply circuit.
3. Check the circuit for open, short to ground or short
to battery voltage circuit.
E-59
10

ECM and CKP sensor.
E-60(A)
E-59

Step
11
Action
ECM and CKP sensor.
Value (s)
Yes
No
Verify repair
Go to Step 21
E-60(A)
E-59
12
Using the DVM and check the CKP sensor signal

circuit.
disconnected).
box
as
type
(ECM

E-59
Breaker Box
A23
A25

Step
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 13
Go to Step 14
Repair faulty
harness and
verify repair
2. Disconnect the CKP sensor connector and ECM

connector.
E-60(A)
E-59
13
Using the DVM and check the CKP sensor signal

circuit.
E-59
Less than 1V

Step
14
Action
Using the DVM and check the CKP sensor ground
circuit.
disconnected).
box
as
type
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 15
(ECM

3. Disconnect CKP sensor connector.
Breaker Box
A25
E-59

2. Disconnect the CKP sensor connector and ECM
connector.
E-60(A)
E-59

Step
15
Action
Using the DVM and check the CKP ground circuit.
Value (s)
Yes
No
Less than 1V
Go to Step 21
Repair faulty
harness and
verify repair
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Repair faulty
harness and
verify repair
Go to Step 19

E-59
16

circuit.
17
Check for poor/faulty connection at the TPS, CMP

sensor or ECM connector. If a poor/faulty connection
is found, repair the faulty terminal.
E-61(B)

E-62
E-68

18
Using the DVM and check the CMP sensor signal

circuit.
2. Disconnect the CMP sensor connector and ECM
connector.
3. Check the circuit for short to sensor ground or short
to ground circuit.
E-62

Step
19
Action
Using the DVM and check the TPS or CMP sensor
Value (s)
Yes
No
Approximately
5.0V
Go to Step 23
Go to Step 20
Verify repair
Go to Step 23
Go to Step 21
Go to Step 23
Verify repair
Go to Step 23
Verify repair
Go to Step 24
Verify repair

2. Disconnect the TPS or CMP sensor connector.
E-68
E-62

20

and TPS or CMP sensor.
21

22

23

release?
24
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0341(FLASH CODE 41) CAMSHAFT

POSITION SENSOR CIRCUIT RANGE/PERFORMANCE
DIAGNOSTIC TROUBLE CODE (DTC) P0342 (FLASH CODE 41) CAMSHAFT
POSITION SENSOR CIRCUIT NO SIGNAL
RUW46EMF000101
Flash Code Type
Code
41
P0341
P0342
DTC Name
Camshaft Position
Sensor Circuit
Range/Performance
1. Engine speed below 2000rpm.
Camshaft Position
Sensor Circuit No
Signal
2. No crankshaft position sensor DTC P0336 or P0337.


3. No pulse is detected consecutively.
Fail-Safe (Back Up)

Fuel cut is operated at high engine
speed.
CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS
If the ECM receives an incorrect number of pulses on

the CMP reference circuit, DTC P0341 will set.
If the ECM does not receive pulses on the CMP
reference circuit, DTC P0342 will set.

damage.
Diagnostic Trouble Code (DTC) P0341(Flash Code 41) Camshaft

Position Sensor Circuit Range/Performance
Diagnostic Trouble Code (DTC) P0342 (Flash Code 41) Camshaft
Position Sensor Circuit No Signal
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Remove the
accessory parts
and verify repair
Go to Step 5

Failure"?

cycle?


Step
5
Action
Value (s)
Yes
No
Refer to
Diagnostic Aids
and Go to Step
17
Not available:
Go to Step 6
Fixed at low:
Go to Step 6
Fixed at High:
Go to Step 12
Verify repair
Go to Step 7
Verify repair
Go to Step 8
If a oscilloscope is available, monitor the CMP sensor

form?
Camshaft Position (CMP) Sensor Reference Wave Form
0V
Measurement Terminal: B28(+)

B39(-)
10ms/div
Check for poor/faulty connection at the TPS, CMP

sensor or ECM connector. If a poor/faulty connection is
found, repair the faulty terminal.
E-61(B)
E-62

E-68

Remove the CMP sensor from the cylinder head and

visually check.
Objects sticking the CMP sensor.

Step
8
Action
Value (s)
Yes
No
Approximately
5.0V
Go to Step 11
Less than 1V:

Go to Step 9
More than
specified value:
Go to Step 10
Verify repair
Go to Step 15
Verify repair
Go to Step 15
2. Disconnect the CMP sensor connector.

3. Check the circuit for open, short to ground or short
to battery voltage circuit.
E-62

V
Repair the open, short to sensor gorund or short to

ground circuit between the ECM and CMP sensor.
E-61(B)
E-62
10

ECM and CMP sensor.
E-61(B)
E-62

Step
11
Action
circuit.
disconnected).
box
as
type
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 12
Go to Step 13
Repair faulty
harness and
verify repair
(ECM

Breaker Box
B28
E-62


2. Disconnect the CMP sensor connector and ECM
connector.
E-61(B)
E-62
12

circuit.
E-62
Less than 1V

Step
13
Action
Using the DVM and check the CMP sensor ground
circuit.
Value (s)
Yes
No
Less than 1V
Go to Step 14
Repair faulty
harness and
verify repair
Verify repair
Go to Step 15
Go to Step 16
Go to Step 17
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair

2. Disconnect the CMP sensor connector .
E-62
14

15
Substitute a known good CMP sensor and recheck.

16
Replace the CMP sensor.

17

release?
18
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0351 (FLASH CODE 42) IGNITION 1

CONTROL CIRCUIT
CONTROL CIRCUIT
CONTROL CIRCUIT
CONTROL CIRCUIT
CONTROL CIRCUIT
CONTROL CIRCUIT
RTW46ELF001001
Flash Code Type
Code
42
DTC Name
P0351
Ignition 1 Control
Circuit
1. No DTC relating to CMP sensor and CKP sensor.
P0352
Ignition 2 Control
Circuit
3. 10 ignition signals are not detected consecutively.
P0353
Ignition 3 Control
Circuit
P0354
Ignition 4 Control
Circuit
P0355
Ignition 5 Control
Circuit
P0356
Ignition 6 Control
Circuit
2. Engine speed is between 250rpm and 850 rpm.
CIRCUIT DESCRIPTION
The Engine Control Module's (ECM) control circuit 1
provides a zero-volt or a 5-volt output signal to the
ignition coil. The normal voltage on the circuit is zero
volts. When the ignition coil receives the 5-volt signal
from the ECM, it provides a ground path for the B+
supply to the primary side of the number 1 ignition coil.
When the ECM shuts off the 5 volts to the ignition coil,
the ignition coil turns OFF." This causes the ignition coil
primary magnetic field to collapse, producing a voltage
in the secondary coil which fires the spark plug.
The circuit between the ECM and ignition coil is
monitored for an open circuit, short to voltage, and short
to ground. When the ECM detects a problem on ignition
control circuit, it will set a DTC P0351, P0352, P0353,
P0354, P0355 or P0356.
Fail-Safe (Back Up)

Fuel cut is operated more than
2000rpm.
DIAGNOSTIC AIDS
Poor connection at ECM Inspect the harness
terminals, and poor terminal-to-wire connections.
the Tech 2 display related to DTC P0351 or P0352,
P0353, P0354, P0355 or P0356 while moving the
connector and wiring related to the ignition system. A
change in the display will indicate the location of the
fault.
Diagnostic Trouble Code (DTC) P0351 (Flash Code 42) Ignition 1

Control Circuit
Control Circuit
Control Circuit
Control Circuit
Control Circuit
Control Circuit
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4

Is the DTC P0351, P0352, P0353, P0354, P0355 or
P0356 stored as "Present Failure"?

Was the DTC DTC P0351, P0352, P0353, P0354,
P0355 or P0356 stored in this ignition cycle?

Step
4
Action
Check for poor/faulty connection at the ignition coil or
Value (s)
Yes
No
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6
Repair faulty
harness and
verify repair
Go to Step 7
E-60(A)

E-61(B)
E-53/E-54/E-55/
E-56/E-57/E-58

E-73/E-74
Visually check the ignition coil for the affected cylinder.

Using the DVM and check the ignition coil signal

circuit for the affected cylinder.
2. Disconnect the ignition coil connector for the
affected cylinder.
E-53/E-54/E-55/
E-56/E-57/E-58

Step
7
Action
disconnected).
box
as
type
(ECM

affected cylinder.
No.1 Cylinder
Breaker Box
A32
E-53
No.2 Cylinder
Breaker Box
B7
E-54
No.3 Cylinder
Breaker Box
A31
E-55
No.4 Cylinder
Breaker Box
B8
E-56
No.5 Cylinder
Breaker Box
A30
E-57
Value (s)
Yes
No

Step
Action
Value (s)
No.6 cylinder
Breaker Box
B9
E-58

affected cylinder and ECM connector.
No.1 Cylinder
E-60(A)
E-53
No.2 Cylinder
E-60(A)
E-54
No.3 Cylinder
E-60(A)
E-55
Yes
No

Step
Action
No.4 Cylinder
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
E-60(A)
E-56
No.5 Cylinder
E-60(A)
E-57
No.6 Cylinder
E-60(A)
E-58

Step
8
Action
Using the DVM and check the ignition coil power
supply circuit.
Value (s)
Yes
No
10-14.5V
Go to Step 10
Go to Step 9
Verify repair
Go to Step 11
Repair faulty
harness and
verify repair

affected cylinder.
E-53/E-54/E-55/
E-56/E-57/E-58

"IGN. COIL" (15A) and ignition coil for the affected
cylinder.
10
Using the DVM and check the ignition coil ground

affected cylinder.
E-53/E-54/E-55/
E-56/E-57/E-58
Less than 1V

Step
11
Action
Using the DVM and check the ignition coil ground
circuit.
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair

affected cylinder and ECM connector.
E-53/E-54/E-55/
E-56/E-57/E-58
12
Replace the ignition coil for the affected cylinder.

13

release?
14
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0404 (FLASH CODE 32) EGR CIRCUIT
RANGE/PERFOMANCE (OPEN VALVE)
DIAGNOSTIC TROUBLE CODE (DTC) P1404 (FLASH CODE 32) EGR CIRCUIT
RANGE/PERFOMANCE (CLOSED VALVE)
RUW46EMF000201
Flash Code Type
Code
32
P0404
DTC Name
EGR Circuit
Range/Performance
(Open Valve)

1. Engine is stopping.
1. EGR operation is stopped.
2. No DTC relating to ECT sensor, CKP sensor and VSS.
2. EGR valve closed position

learning operation is disabled.

5. EGR solenoid valve on-duty ratio is more than 100%.
6. EGR valve output monitoring signal high.
P1404
EGR Circuit
Range/Performance
(Closed Valve)
Fail-Safe (Back Up)
4. EGR solenoid valve on-duty ratio is 0%.
5. EGR valve output monitoring signal low.
3. EGR position feedback is

disabled.
CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS
The engine control module (ECM) monitors the EGR

valve pintle position input to ensure that the valve
responds properly to commands from the PCM, and to
detect a fault if pintle position is different
fromcommanded position.

Excessive carbon deposit on EGR valve shaft
maycause EGR stuck open or unsmooth operation.
Those carbon deposit may occur by unusual
portoperation. Clean up carbon may make
smoothfunction of EGR valve.
Poor connection or damaged harness - Inspect
thewiring harness for damage. If the harness
appears to be OK, observe the EGR actual position
display on the Tech 2 while moving connectors and
wiring harnesses related to EGR valve. A change in
the display will indicate the location of the fault.
Diagnostic Trouble Code (DTC) P0404 (Flash Code 32) EGR Circuit
Range/Perfomance (Open Valve)
Diagnostic Trouble Code (DTC) P1404 (Flash Code 32) EGR Circuit
Range/Perfomance (Closed Valve)
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4

Failure"?

cycle?

Step
4
Action
Check for poor/faulty connection at the EGR valve or
Value (s)
Yes
No
Verify repair
Go to Step 5
Apporoximately
8.3W at 20C
Go to Step 6
Go to Step 11
Verify repair or
Go to Step 11
Go to Step 7
10-14.5 V
Go to Step 9
Go to Step 8
E-60(A)
E-76
Using the DVM and check the EGR valve.

2. Disconnect EGR valve connector.
3. Measure the resistance of EGR valve solenoid coil.
EGR Valve

2. Inspect the EGR valve whether there is any carbon
deposit on shaft.
Using the DVM and check the EGR valve solenoid

2. Disconnect the EGR valve connector.
E-76

Step
8
Action
ECM main relay and EGR valve.
Value (s)
Yes
No
Verify repair
Repair faulty
harness and
verify repair
Go to Step 10

signal circuit.
disconnected).
box
as
type
(ECM

A5
Breaker Box
A22
E-76


2. Disconnect the EGR valve connector and ECM
connector.
E-76
E-60(A)


Step
10
Action
signal circuit.
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 11
Go to Step 12
Go to Step 13
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair

E-76
11
Substitute a known good EGR valve and recheck.

12

13

release?
14
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0405 (FLASH CODE 32)

EGR CIRCUIT LOW
RUW46EMF000201
Flash Code Type
Code
32
P0405
DTC Name
EGR Circuit Low

1. No DTC relating to EGR circuit range/performance.
Fail-Safe (Back Up)

2. EGR solenoid valve on-duty ratio is more than 40%.

3. EGR position sensor output voltage is below 0.3V.
CIRCUIT DESCRIPTION
responds properly to command from the ECM. If current
pintle position voltage indicates less than 0.3 V the ECM
will set DTC P0405.
DIAGNOSTIC AIDS
wiring harness for damage. If the harness appears to
be OK, observe the EGR actual position display on
harnesses related to EGR valve. A change in the

EGR Circuit Low
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Verify repair
Go to Step 5
Go to Step 10
Go to Step 6



E-60(A)
E-76

Visually check the EGR valve.


Step
6
Action
Using the DVM and check the EGR valve position
sensor.
Value (s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 10
Approximately
5.0V
Go to Step 9
Go to Step 8
Verify repair
Go to Step 12

3. Measure the resistance of EGR valve position
sensor.
EGR Valve
EGR Valve

Resistance (W)
23
Approximately 1.1kW
34
Approximately 4.5kW
2-4
Approximately 4.7kW

E-76

ECM and EGR valve position sensor circuit.
E-60(A)
E-76

Step
9
Action
disconnected).
box
as
type
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 11
Go to Step 12
Verify repair
(ECM

A9
Breaker Box
A22
E-76


connector.
E-76
E-60(A)
10

11


Step
12
Action
release?
13
Value (s)
Yes
No
Verify repair
Go to Step 13
Verify repair
Replace the ECM.


EGR CIRCUIT HIGH
RUW46EMF000201
Flash Code Type
Code
32
P0406
DTC Name
EGR Circuit High

1. No DTC relating to EGR circuit range/performance.
Fail-Safe (Back Up)

2. EGR solenoid valve on-duty ratio is below 40%.

3. EGR position sensor output voltage is more than 4.6V.
CIRCUIT DESCRIPTION
responds properly to command from the ECM. If current
pintle position voltage indicates more than 4.6 V the
ECM will set DTC P0406.
DIAGNOSTIC AIDS
wiring harness for damage. If the harness appears to
be OK, observe the EGR actual position display on
harnesses related to EGR valve. A change in the

EGR Circuit High
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6



E-60(A)
E-76
Visually check the EGR valve.


Step
6
Action
sensor.
Value (s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 9
Go to Step 8
Verify repair
Go to Step 14

3. Measure the resistance of EGR valve position
sensor.
EGR Valve
EGR Valve

Resistance (W)
23
Approximately 1.1kW
34
Approximately 4.5kW
2-4
Approximately 4.7kW
Using the DVM and check the EGR position sensor

E-76

and EGR valve.
E-60(A)
E-76

Step
9
Action
signal circuit.
Value (s)
Yes
No
Go to Step 10
Repair faulty
harness and
verify repair
Go to Step 11
Repair faulty
harness and
verify repair

E-76
Less than 1V
10

ground circuit.
E-76
Less than 1V

Step
11
Action
ground circuit.
disconnected).
box
as
type
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 12
Go to Step 13
Go to Step 14
Verify repair
Verify repair
Go to Step 15
(ECM

Breaker Box
A22
E-76

connector.
E-60(A)

E-76
12

13

14

release?

Step
15
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0444 EVAP PURGE SOLENOID

VALVE CIRCUIT LOW VOLTAGE
DIAGNOSTIC TROUBLE CODE (DTC) P0445 EVAP PURGE SOLENOID
VALVE CIRCUIT HIGH VOLTAGE
RTW46EMF000301
Flash Code Type
Code
32
P0444
DTC Name
EVAP Purge Solenoid
Valve Circuit Low
Voltage

1. No DTC relating to CKP sensor and system voltage.
Fail-Safe (Back Up)


3. Purge solenoid valve on-duty ratio is below 48%.
4. Purge solenoid valve output monitoring signal low.
P0445
EVAP Purge Solenoid

Valve Circuit High
Voltage
1. No DTC relating to CKP sensor and system voltage.

3. Purge solenoid valve on-duty ratio is more than 50%.
4. Purge solenoid valve output monitoring signal high.
CIRCUIT DESCRIPTION
The canister purge solenoid valve is controlled by the
Engine Train Control Module (ECM).
At an appropriate time, the EVAP canister purge
solenoid is ON," allowing engine vacuum to draw a
small vacuum on the entire evaporative emissions
system.
DIAGNOSTIC AIDS
Poor connections.
Mis routed harness.

the EVAP purge solenoid display on the Tech 2 while
moving connectors and wiring harnesses related to
the sensor.
A change in the display will indicate the location of
the fault. If DTC P0444 or P0445 cannot be
duplicated, the information included in the Failure
Records data can be useful in determined vehicle
mileage since the DTC was last set.
If it is determined that the DTC occurs intermittently,
performing the DTC P0444 or P0445 Diagnostic
Chart may isolate the cause of the fault.
Diagnostic Trouble Code (DTC) P0444 EVAP Purge Solenoid

Valve Circuit Low Voltage
Diagnostic Trouble Code (DTC) P0445 EVAP Purge Solenoid
Valve Circuit High Voltage
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4

Failure"?

cycle?

Step
4
Action
Check for poor/faulty connection at the purge solenoid
valve or ECM connector. If a poor/faulty connection is
Value (s)
Yes
No
Verify repair
Go to Step 5
25 - 30W at
20C
Go to Step 6
Go to Step 9
10-14.5V
Go to Step 8
Go to Step 7
Verify repair
E-61(B)
E-66
Using the DVM and check the purge solenoid valve.

2. Disconnect purge solenoid valve connector.
3. Measure the resistance of purge solenoid valve
coil.
Using the DVM and check the purge solenoid valve

2. Disconnect the purge solenoid valve connector.
E-66

"Engine" fuse (15A) and purge solenoid valve.

Step
8
Action
solenoid signal circuit.
disconnected).
box
as
type
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
(ECM

E-66
Breaker Box
B15

2. Disconnect the purge solenoid valve connector and
ECM connector.
E-61(B)
E-66


Step
9
Action
signal circuit.
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Go to Step 11
Go to Step 12
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair

E-66
10
Substitute a known good purge solenoid valve and

recheck.
11
Replace the purge solenoid valve.

12

release?
13
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0500 (FLASH CODE 24) VEHICLE

SPEED SENSOR (VSS) CIRCUIT RANGE/PERFORMANCE
RTW46EMF000301
Flash Code Type
Code
24
P0500
DTC Name
Vehicle Speed Sensor
Circuit
Range/Performance

2. Under fuel cut operation.
Fail-Safe (Back Up)

The ECM use 10km/h condition as
substitute.
3. Vehicle speed sensor output is below 1km/h.

CIRCUIT DESCRIPTION
The vehicle speed sensor has a magnet rotated by the
transmission output shaft. Attached to the sensor is a
hall effect circuit the interacts with the magnetic field
treated by the rotating magnet. A 12-volt operating
supply for the speed sensor hall circuit is supplied from
the meter fuse. The VSS pulses to ground the 9-volt
signal sent from the Engine Control Module (ECM) on
the reference circuit. The ECM interprets vehicle speed
by the number of pulses to ground per second on the
reference circuit.
DIAGNOSTIC AIDS
damage.
Diagnostic Trouble Code (DTC) P0500 (Flash Code 24) Vehicle Speed Sensor
(VSS) Circuit Range/Performance
Step
1
Action
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Remove the
accessory parts
and verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 25
Go to Step 8
Verify repair
Go to Step 9

performed?

3. Operate the vehicle and monitor the "F5: Failed This
Ignition" in "F2: DTC Information"



Monitor the "Vehicle Speed" in the data display.
panel?
Check for poor/faulty connection at the VSS and meter

connectors. If a poor/faulty connection is found, repair
E-44

B-24


Step
8
Action
control unit (if equipped), ECM and other connectors. If
a poor/faulty connection is found, repair the faulty
terminal.
Value (s)
Yes
No
Verify repair
Go to Step 10
Go to Step 23
Go to Step 10
E-61(B)
B-68

9

check.

Step
10
Action
Value (s)
Yes
No
Refer to
Diagnostic Aids
and Go to Step
25
Refer the table
10-14.5V
Go to Step 13
Go to Step 12
1. Ignition "On", vehicle "Run (lift up)".

2. Measure the VSS output voltage at sensor, meter,
immobilizer control unit (if equipped) and ECM.
Voltage (V)
(AC Range)
Meter B24 connector 9 & GND
Meter B24 connector 10 & GND
Immobilizer control unit B68
connector 6 & GND
connector 8 & GND
ECM E-61 connector 32 & GND
Approximately
6.0 V at 20km/h
Approximately
4.0 V at 20km/h
If No Good
Go to
Step 11
Go to
Step 15
Go to
Step 17
Go to
Step 18
Go to
Step 20
Go to
Step 21
If a oscilloscope is available, monitor the VSS signal.

CH1
0V
CH2
0V
Measurement Terminal: CH1: ECM B32(+) / CH2: VSS 3(+)

GND(-)
50ms/div
Note: The vehicle is without immobilizer system,
11
Using the DVM and check the VSS power supply

circuit.
2. Disconnect the VSS connector.
E-44

Step
12
Action
Repair the open circuit between the VSS and meter
fuse.
13
Value (s)
Yes
No
Verify repair
Less than 1V
Go to Step 14
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 23
Go to Step 16
Repair faulty
harness and
verify repair
Using the DVM and check the VSS ground circuit.

E-44
14

E-44
15

2. Disconnect
connector.
the
VSS
connector
and
meter

E-44
B-24
Less than 1V

Step
16
Action
Value (s)
Yes
No
Verify repair
Verify repair
Go to Step 19
Repair faulty
harness and
verify repair

2. Disconnect
connector.
the
VSS
connector
and
meter

If a open or short to ground circuit is found, repair
the faulty harness and verify repair.
E-44
B-24
17

18

control unit connector (if equipped).
B-24
B-68
Less than 1V

Step
19
Action
Value (s)
Yes
No
Verify repair
Verify repair
Go to Step 22
Repair faulty
harness and
verify repair

B-24
20
B-68
Replace the immobilizer control unit (if equipped).

21

2. Disconnect the immobilizer control unit connector (if
equipped) and ECM connector.
3. Ignition "On".
E-61(B)
B-68
Less than 1V

Step
22
Action
disconnected).
box
as
type
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 25
Go to Step 24
Go to Step 25
Verify repair
Go to Step 25
Verify repair
Go to Step 26
(ECM

equipped).
Breaker Box
B32
B-68

equipped) and ECM connector.
E-61(B)
B-68

23

24
Replace the VSS.

25

release?

Step
26
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0562 (FLASH CODE 66) SYSTEM

VOLTAGE LOW
Flash Code Type
Code
66
P0562
DTC Name
System Voltage Low
Fail-Safe (Back Up)
Battery voltage is below 6V for more than 20 seconds.
CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS
The engine control module (ECM) monitors the system

voltage on the ignition feed terminals to the ECM. A
system voltage DTC will set whenever the voltage is
above a calibrated value.
If the DTC sets when an accessory is operated, check

for a poor connection or defective accessory.

System Voltage Low
Action
Step

performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
10 14.5V
Go to Step 6
10 14.5V
Go to Step 6



2. Monitor the "Ignition Voltage" in the data display.
headlights, etc..

battery terminal.
Go to Step 5
Check the
charging system,
charge or replace
the battery

Step
Action
as necessary.
Value (s)
Yes
No
Verify repair
Go to Step 7
Verify repair
Go to Step 8
E-60(A)

7

E-61(B)

Check for poor/faulty connection of the ECM ground at

the common chamber right and left. If a poor/faulty
E-72/E-73/E-74
Using the DVM and check the ECM ground circuit.

disconnected).
box
as
type
(ECM

A4
A7
Breaker Box
A8
A33
A37
B6

Step
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Verify repair
Go to Step 10
Verify repair

E-60(A)
E-61(B)

release?
10
Replace the ECM.


SYSTEM VOLTAGE HIGH
Flash Code Type
Code
66
P0563
DTC Name
System Voltage High
Fail-Safe (Back Up)
Battery voltage is above 16V for more than 20 seconds.
CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS

system voltage DTC will set whenever the voltage is
above a calibrated value.
If the DTC sets when an accessory is operated, check

for a poor connection or defective accessory.

System Voltage High
Step
1
Action
Value (s)
No
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 2
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
Go to Step 4
4

performed?
Yes


3. Operate the vehicle and monitor the "F5: Failed This
Ignition" in "F2: DTC Information"

2. Monitor the "Ignition Voltage" in the data display.
Check the
charging
system and Go
Go to Step 5
to Step 5
Verify
Go to Step 6
procedure
Verify repair

headlights, etc..
5
6
Is the battery jamp start cable incorrectly connecting?
Less than 16V

release?
If not, download the latest software to the ECM using the
"SPS (Service Programming System)".
Go to Step 7

Step
7
Action
Value (s)
Yes
No

ECM programming, the immobilizer system (if equipped)
must be linked to the ECM. Refer to section 11
Verify repair
Replace the ECM.


CONTROL MODULE MEMORY CHECKSUM
Flash Code Type
Code
51
P0601
DTC Name
Control Module
Memory Checksum
Fail-Safe (Back Up)
CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS
The engine control module (ECM) used in this vehicle

utilizes an electrically erasable programmable read-only
memory (EEPROM). The EEPROM contains program
information and the calibrations required for engine,
transmission, and engine diagnostics operation.
Unlike the PROM used in past applications, the
EEPROM is not replaceable.
DTC P0601 indicates that the contents of the

EEPROM have changed since the ECM was
programmed. The only possible repair is ECM
replacement.

Control Module Memory Checksum
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
Verify repair
Go to Step 5



release?

Step
5
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P0602 ECU PROGRAMMING ERROR

Flash Code Type
Code
51
P0602
DTC Name
ECU Programming
Error
Fail-Safe (Back Up)
CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS

transmission, and engine diagnostics operation.
EEPROM is not replaceable.
Check for following conditions.

When reprogramming operation is stopped under
Service Programming System (SPS), DTC P0602 will
be set.
When non programmed ECM (service ECM) is used
without Service Programming System (SPS), DTC
P0602 will be set.
Diagnostic Trouble Code (DTC) P0602 ECU Programming Error

Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
Verify repair

Download the latest software to the ECM. "SPS

(Service Programming System) is necessary."
DIAGNOSTIC TROUBLE CODE (DTC) P1508 (FLASH CODE 22) IDLE AIR
CONTROL SYSTEM LOW/CLOSED
DIAGNOSTIC TROUBLE CODE (DTC) P1509 (FLASH CODE 22) IDLE AIR
CONTROL SYSTEM HIGH/OPEN
RTW36EMF000201
Flash Code Type
Code
22
P1508
DTC Name
Fail-Safe (Back Up)
Idle Air Control System 1. No DTC relating to MAF sensor, IAT sensor, ECT sensor, Fuel cut is operated at high idle
TPS, CMP sensor, CKP sensor, VSS and system voltage. speed.
Low/Closed
6. Small amount of intake air through the idle air control
valve. (Idle air control valve is sticking at close position.)
P1509
Idle Air Control System 1. No DTC relating to MAF sensor, IAT sensor, ECT sensor,
TPS, CMP sensor, CKP sensor, VSS and system voltage.
High/Open
3. Engine coolant temperature more than 75C.
6. Large amount of intake air through the idle air control
valve. (Idle air control valve is sticking at open position.)
CIRCUIT DESCRIPTION
The engine control module (ECM) controls engine idle
speed by adjusting the position of the idle air control
(IAC) motor pintle. The IAC is a bi-directional stepper
motor driven by two coils. The ECM applies current to
the IAC coils in steps (counts) to extend the IAC pintle
into a passage in the throttle body to decrease air flow.
The ECM reverses the current to retract the pintle,
increasing air flow. This method allows highly accurate
control of idle speed and quick response to changes in
engine load. If the ECM detects a condition where too
low of an idle speed is present and the ECM is unable
to adjust idle speed by increasing the IAC counts, DTC
P1508 or P1509 will set, indicating a problem with the
idle control system.
DIAGNOSTIC AIDS
Poor connection at ECM or IAC motor Inspect
damaged terminals, and poor terminal-to-wire
connection.
Damaged harness Inspect the wiring for damage.
Restricted air intake system Check for a possible
collapsed air intake duct, restricted air filter element,
or foreign objects blocking the air intake system.
Diagnostic Trouble Code (DTC) P1508 (Flash Code 22) Idle Air
Control System Low/Closed
Diagnostic Trouble Code (DTC) P1509 (Flash Code 22) Idle Air
Control System High/Open
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Verify repair
Go to Step 5
Verify repair
Go to Step 6

Failure"?

cycle?

Objects blocking the Idle Air Control (IAC) Valve.
Check for poor/faulty connection at the IAC Valve or

ECM connector.
If a poor/faulty connection is found, repair the faulty
terminal.
E-61(B)

E-70


Step
6
Action
Remove the IAC Valve and visually check.
Value (s)
Yes
No
Go to Step 12
Go to Step 7
Go to Step 8
Go to Step 12
Repair faulty
harness and
verify repair
Go to Step 9
Using the DVM and check the IAC Valve coil at IAC
Valve.
2. Disconnect the IAC Valve connector.
3. Check the coil resistance.
IAC Valve

Resistance (W)
1-2
Approximately 50W
2-3
Approximately 50W
13
Approximately 100W
4-5
Approximately 50W
5-6
Approximately 50W
4-6
Approximately 100W
Using the DVM and check the IAC Valve power supply
circuit.
2. Disconnect the IAC Valve connector and ECM
main relay
X-13
E-70


Step
9
Action
Using the DVM and check the IAC Valve circuit.
2. Install the breaker box as type B. (ECM connection)
Does the DVM indicate correct characteristic as
shown in the following table, when the IAC Valve is
operating step by step?
B13
Breaker Box
B14
B16
B17
Measurement Point
IACV steps at
0, 20, 40, 160
IACV steps at
10, 30, 50, 150
Coil A High (Breaker Box 53 & GND)
Less than 1V
Battery voltage
Coil A Low (Breaker Box 56 & GND)
Battery voltage
Less than 1V
Coil B High (Breaker Box 54 & GND)
Less than 1V
Battery voltage
Coil B Low (Breaker Box 57 & GND)
Battery voltage
Less than 1V
Value (s)
Yes
No

Step
Action
Value (s)
Yes
No

Does the DVM indicate correct characteristic as
shown in the following table, when the IAC Valve is
operating step by step?

E-61(B)

V
Measurement Point
IACV steps at
0, 20, 40, 160
IACV steps at
10, 30, 50, 150
Coil A High (ECM E61 connector 13 & GND)
Less than 1V
10 - 14.5 V
Coil A Low (ECM E61 connector 16 & GND)
10 - 14.5 V
Less than 1V
Coil B High (ECM E61 connector 14 & GND)
Less than 1V
10 - 14.5 V
Coil B Low (ECM E61 connector 17 & GND)
10 - 14.5 V
Less than 1V
Fixed at less than

1V: Go to Step
10
Fixed at battery
voltage: Go to
Go to Step 14
Step 11

Step
10
Action
disconnected).
box
as
type
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 14
(ECM

Breaker Box
B14
B16
B13
B17
E-70

Breaker Box
B14
B16
B13
B17

E-61(B)

E-70

E-61(B)


Step
11
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 14
Go to Step 13
Go to Step 14
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair

Was the DVM indicate voltage?
E-70
12
Substitute a known good IAC Valve and recheck.

13
Replace the IAC Valve.

14

release?
15
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P1601 (FLASH CODE 65) CAN BUS OFF
RTW46EMF000301
Flash Code Type
Code
65
P1601
DTC Name
CAN BUS Off

CAN BUS off condition is detected consecutively.
Fail-Safe (Back Up)

Torque reduction control is disable.
Circuit Description
Diagnostic Aids
The engine control system in 6VE1 uses high speed

CAN bus system. The individual CAN bus systems are
connected via two interfaces and can exchange
information and data. This allows control modules that
are connected to different CAN bus systems to
communicate. Engine control modules (ECM) in the
vehicle that require continuous, rapid communication
are connected to the high speed CAN bus. The engine
is continuously notified of the current engine load
status. Since the ECM has to react immediately to load
status changes, rapid communication is required
between the ECM and the automatic transmission
control module. The high speed CAN bus in the 6VE1 is
designed as a two-wire CAN bus (twisted pair). The
wires are shielded and twisted. The engine rate is 500K
band.
Inspect the wiring for poor electrical connection at the

ECM. Look for possible bent, backed out, deformed
or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
could short to bare metal or other wiring. Inspect for a
broken wire inside the insulation.
When diagnosing for a possible intermittent short or
open condition, move the wiring harness while
observing test equipment for a change.
Inspect the wiring for EMI (Erectro-Magnetic
Interference). Check that all wires are properly routed
away from coil, and generator. Also check for
improperly installed electrical options. When this test
is performed, turn OFF" on electronic autoparts
switches to improperly for a noise preventing.
Diagnostic Trouble Code (DTC) P1601 (Flash Code 65) CAN Bus Off
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Remove the
accessory parts
and verify repair
Go to Step 5
Refer to
"Automatic
Transmission
Workshop
Manual" & Go to
DTC Chart
P1767 or U2104
Go to Step 6
Verify repair
Go to Step 7



interference.

2. Select "AW30-40LE" in the system selection menu
"Powertrain".
3. Select "Read DTC Info Ordered By Priority" in the
"Diagnositic Trouble Code".
Was the any DTC's P1767 or U2104 stored in this
ignition cycle?
Check for poor/faulty connection at the TCM or ECM

as necessary.
E-60(A)


Step
7
Action
Using the DVM and check the CAN BUS high circuit.
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
Repair faulty
harness and
verify repair
Go to Step 9
Go to Step 14
Close to 0W:
Go to Step 10
No resistance:
Go to Step 11

2. Disconnect the TCM connector.
3. Ignition "On".

Using the DVM and check the CAN BUS low circuit.
3. Ignition "On".
Using the DVM and check the ECM CAN BUS circuit.
2. Disconnect TCM connector.
3. Measure the resistance of ECM CAN BUS circuit.

Approximately
120W

Step
10
Action
Repair the open circuit between the ECM CAN BUS
high and low circuit.
Value (s)
Yes
No
Verify repair
Go to Step 15

E-60(A)

11
disconnected).
box
as
type
(ECM

Breaker Box
A10


Step
Action
2. Disconnect
connector.
the
TCM
connector
and
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 12
ECM

E-60(A)

12
disconnected).
box
as
type
(ECM

Breaker Box
A11


Step
Action
2. Disconnect
connector.
the
TCM
connector
and
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair
ECM

E-60(A)

13
Is the ECM or TCM programmed with the latest

software release?
If not, download the latest software to the ECM or
TCM using the "SPS (Service Programming
System)".
14
Replace the TCM.

programmed. "SPS (Service Programming System)
is necessary."
15
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) U2104 (FLASH CODE 67) CAN BUS
RESET COUNTER OVER-RUN
RTW46EMF000301
Flash Code Type
Code
67
U2104
DTC Name
CAN BUS Reset
Counter Overrun

1. No DTC CAN BUS Off.
Fail-Safe (Back Up)

Torque reduction control is disable.
2. CAN valid counter does not change for 2 seconds.
CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS
The engine control system in 6VE1 uses high speed

CAN bus system. The individual CAN bus systems are
connected via two interfaces and can exchange
information and data. This allows control modules that
are connected to different CAN bus systems to
communicate. Engine control modules (ECM) in the
vehicle that require continuous, rapid communication
are connected to the high speed CAN bus. The engine
is continuously notified of the current engine load
status. Since the ECM has to react immediately to load
status changes, rapid communication is required
between the ECM and the automatic transmission
control module. The high speed CAN bus in the 6VE1 is
designed as a two-wire CAN bus (twisted pair). The
wires are shielded and twisted. The engine rate is 500K
band.
Inspect the wiring for poor electrical connection at the

ECM. Look for possible bent, backed out, deformed
or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
could short to bare metal or other wiring. Inspect for a
broken wire inside the insulation.
Interference). Check that all wires are properly routed
away from coil, and generator. Also check for
is performed, turn OFF" on electronic auto parts
Diagnostic Trouble Code (DTC) U2104 (Flash Code 67) CAN Bus Reset
Counter Over-Run
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Refer to
"Automatic
Transmission
Workshop
Manual" & Go to
DTC Chart
P1767 or U2104
Go to Step 5
Remove the
accessory parts
and verify repair
Go to Step 6
Verify repair
Go to Step 7

Is the DTC U2104 stored as "Present Failure"?

Was the DTC U2104 stored in this ignition cycle?

2. Select "AW30-40LE" in the system selection menu
"Powertrain".
Was the any DTC's P1767 or U2104 stored in this
ignition cycle?

interference.
Check for poor/faulty connection at the TCM or ECM

as necessary.
E-60(A)


Step
7
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
Repair faulty
harness and
verify repair
Go to Step 9
Go to Step 14
Close to 0W: Go
to Step 10
No resistance:
Go to Step 11

3. Ignition "On".

3. Ignition "On".
Using the DVM and check the ECM CAN BUS circuit.
2. Disconnect TCM connector.
3. Measure the resistance of ECM CAN BUS circuit.

Approximately
120W

Step
10
Action
Repair the open circuit between the ECM CAN BUS
high and low circuit.
Value (s)
Yes
No
Verify repair
Go to Step 15
E-60(A)


Step
11
Action
disconnected).
box
as
type
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 12
(ECM

Breaker Box
A10


2. Disconnect
connector.
the
TCM
connector
and
ECM

E-60(A)


Step
12
Action
disconnected).
box
as
type
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair
Go to Step 15
(ECM

Breaker Box
A11


2. Disconnect
connector.
the
TCM
connector
and
ECM

E-60(A)

13
Is the ECM or TCM programmed with the latest

software release?
If not, download the latest software to the ECM or
TCM using the "SPS (Service Programming
System)".
14
Replace the TCM.

programmed. "SPS (Service Programming System)
and is necessary."

Step
15
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P1626 IMMOBILIZER NO SIGNAL
RTW46EMF000301
Flash Code Type
Code
67
P1626
DTC Name
Fail-Safe (Back Up)

CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS
The Engine Control Module (ECM) decides whether that

is an abnomality in the immobilizer control system. DTC
P1626 is recorded by the ECM when no response from
immoblizer.

Poor connection at Engine Control Module (ECM)
and immobilizer inspect harness connectors for
backed out terminals, improper mating, broken
Damaged harness-inspect the wiring harness for
damage, if the harness appears to be OK,
disconnect the ECM and immobilizer, turn the
ignition "ON" and observe a voltmeter connected to
the suspect driver circuit at the ECM and immobilizer
harness connector while moving connectors and
wiring harnesses relates to the Check Engine Lamp
(MIL). A change in voltage will indicate the location
of the fault.
Diagnostic Trouble Code (DTC) P1626 Immobilizer No Signal

Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Remove the
accessory parts
and verify repair
Go to Step 5
Refer to
"Immobilizer
Workshop
Manual" & Go to
DTC Chart
B0007
Go to Step 6
Verify repair
Go to Step 7



interference.

2. Select "Immobilizer" in the system selection menu
"Body".

control unit connector or ECM connector. If a
poor/faulty connection is found, repair as necessary.
E-61(B)
B-68

Step
7
Action
lamp circuit.
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8

3. Ignition "On".
B-68

Step
8
Action
lamp circuit.
disconnected).
box
as
type
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
(ECM

Breaker Box
B18
B-68


2. Disconnect the immobilizer control unit connector
and ECM connector.
E-61(B)
B-68

Step
9
Action
Value (s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
Repair faulty
harness and
verify repair
Go to Srtep 11

and ECM connector.
3. Ignition "On".
B-68
10

disconnected).
box
as
type
(ECM

3. Disconnect the immobilizer control unit connector .
Breaker Box
B32
B-68


and ECM connector.
E-61(B)
B-68


Step
11
Action
release?
12
Value (s)
Yes
No
Verify repair
Go to Step 12
Verify repair
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P1631 IMMOBILIZER WRONG SIGNAL
RTW46EMF000301
Flash Code Type
Code
67
P1631
DTC Name
Immobilizer Wrong
Signal

Fail-Safe (Back Up)

CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS

immobilizer control system. DTC P1631 is recorded by
the ECM when received response was not correct.

of the fault.
Diagnostic Trouble Code (DTC) P1631 Immobilizer Wrong Signal

Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Refer to
"Immobilizer
Workshop
Manual" & Go to
DTC Chart
B0005 or B0006
Go to Step 5
Verify repair
Go to Step 6
Verify repair



"Body".
ignition cycle?

release?
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P1648 WRONG SECURITY CODE

ENTERED
RTW46EMF000301
Flash Code Type
Code
67
P1648
DTC Name
Wrong Security Code
Entered

Received incorrect security code.
Fail-Safe (Back Up)

CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS

the ECM when received security code was not correct.

of the fault.
Diagnostic Trouble Code (DTC) P1648 Wrong Security Code Entered

Action
Step

performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Refer to
"Immobilizer
Workshop
Manual" & Go to
DTC Chart
B0002 or B0003
Go to Step 5
Verify repair
Go to Step 6
Verify repair



"Body".
ignition cycle?

release?
Replace the ECM.

DIAGNOSTIC TROUBLE CODE (DTC) P1649 IMMOBILIZER FUNCTION

NOT PROGRAMMED
RTW46EMF000301
Flash Code Type
Code
67
P1649
DTC Name
Not Programmed

Immobilizer function is not programmed in the ECM.
Fail-Safe (Back Up)

CIRCUIT DESCRIPTION
DIAGNOSTIC AIDS

the ECM when immobilizer function was not

of the fault.
Diagnostic Trouble Code (DTC) P1649 Immobilizer Function

Not Programmed
Step
1
Action
performed?
Value (s)
Yes
Go to Step 2
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step 3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step 4
Refer to
"Immobilizer
Workshop
Manual" & Go to
DTC Chart
B0007
Go to Step 5
Verify repair
Go to Step 6
Verify repair



"Body".

release?
Replace the ECM.

SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS
Before using this section, perform the "On-Board
Diagnostic (OBD) System Check" and verify all of the
following items:
The engine control module (ECM) and check engine
lamp (MIL=malfunction indicator lamp) are operating
correctly.
Tech 2 data is within normal operating range. Refer
to Typical Scan Data Values.
location.
connection. Check thoroughly for any type of leak or
restriction.
Air leaks at throttle body mounting area, manifold
absolute pressure (MAP) sensor and intake manifold
sealing surfaces.
Ignition wires for cracking, harness, and carbon
tracking.
INTERMITTENT
on the check engine lamp (MIL=malfunction indicator
lamp) or store a Diagnostic Trouble Code. Do NOT use
the Diagnostic Trouble Code (DTC) charts for
intermittent problems.
Poor mating of the connector halves or a terminal
not fully seated in the connector (backed out).

check.
Ignition coils shorted to ground and arcing at ignition
wires or plugs.
wire to ECM shorted to ground.
diagrams.
Tech 2 have several features that can be used to
located an intermittent condition. Use the following
features to find intermittent faults:
To check for loss of diagnostic code memory,
disconnect the mass air flow (MAF) sensor and idle the
engine until the check engine lamp (MIL=malfunction
indicator lamp) comes on. Diagnostic Trouble Code
P0102 should be stored and kept in memory when the
ignition is turned OFF.
If not, the ECM is faulty. When this test is completed,
make sure that you clear the Diagnostic Trouble Code
P0102 from memory.
An intermittent check engine lamp (MIL=malfunction
indicator lamp) with no stored Diagnostic Trouble Code
may be caused by the following:
Ignition coil shorted to ground and arcing at ignition
wires or plugs.
wire to ECM short to ground.
diagrams.

symptom tables.
Check the "Broadcast Code" of the ECM, and
compare it with the latest Isuzu service bulletins
and/or Isuzu EEPROM reprogramming equipment to
determine
if
an
update
to
the
ECM's
reprogrammable memory has been released.
To check the "Broadcast Code", connect the Tech 2,
then look for "ID info." then select "Broadcast Code".
This should display a 4 character code, such as "8501"
(example only).
If the "Broadcast Code" is not the most current
available, it is advisable to reprogram the ECM's
changes.

DEFINITIONS: Engine cranks, but will not run. (The
engine never start.)
NOTE: The replacement ECM must be programmed.
Refer to section of the Service Programming
System (SPS) in this manual. Following ECM
programming, the immobilizer system (if equipped)
must be linked to the ECM. Refer to section 11
"Immobilizer System-ECM replacement" for the
successful", engine will not start, but no DTCs are
present, low battery voltage or poor electrical
connections should be the primary
suspects.Perform the SPS procedure again after
rectifying the fault/s.
NOTE: The vehicle with immobilizer system, this
system may be activated. Check the immobilizer
system diagnosis.
Step
1
Action
performed?
Value (s)
Yes
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 2
Verify repair
Go to Step 4
Go to Step 3
Go to Visual /
physical Check
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Go to Step 7
Replace fuel
Verify repair
Go to Step 8

3
4

Check the "Meter" fuse (15A), "Engine" fuse (15A),
"IGN Coil" fuse (15A) and "Fuel Pump" fuse (20A). If
the fuse is burnt out, repair as necessary.
Check the ECM grounds to verify that they are clean

and tight. Refer to the ECM wiring diagrams.
Check the fuel quality.

Is the customer using proper fuel?
Visually/physically inspect for the following conditions:

intake system.
Check for objects blocking the IAC passage or
throttle bore, excessive deposits in the throttle bore
and on the throttle plate.
crankcase ventilation hose/brake booster hose.

Step
8
Action
1. Using a Tech 2, display the IAC value.
Value (s)
Yes
No
Verify repair
Go to Step 9
Verify repair
Go to Step 10
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
2. Check for a faulty, plugged, or sticking IAC

operation.
9
Check the CKP sensor signal or installation condition.

Refer to DTC P0336 "Crankshaft Position Sensor
Circuit Range/Performance" and DTC P0337
"Crankshaft Position Sensor Circuit No Signal".
10
Check for proper ignition voltage output with the spark

tester.
11
1. Remove the spark plugs and check for gas or oil

fouling cracks, wear, improper gap, burned
electrodes, heavy deposits, or improper heat
range.
2. If spark plugs are fouled, the cause of fouling must
be determined before replacing the spark plugs.
12
Check the fuel pressure. Refer to Fuel System

Diagnosis.
13
Perform the procedure in Fuel System Pressure Test

to determine if there is a problem with fuel delivery.
14
Visually/physically check the vacuum hose for splits,

kinks and proper connections and routing.
15
Check the exhaust system for a possible restriction:

Damaged or collapsed pipes.
16
Check for the following engine mechanical problems

(refer to Engine Mechanical section):
Low compression.
Leaking cylinder head gaskets.
Worn camshaft.
Camshaft drive belt slipped or stripped.

Step
17
Action
Value (s)
Yes
No
Verify repair
Go to Step 18
Verify repair
Go to Step 19
Verify repair

following:
Visual/physical inspection.
Tech 2 data.
and/or system.
18

release?
19
Replace the ECM.

HARD START SYMPTOM

DEFINITIONS: Engine cranks, but does not start for a
long time. Does eventually start, or may start and then
immediately stall.
Step
1
Action
performed?
Value (s)
Yes
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 2
Verify repair
Go to Step 4
Go to Step 3
Go to Visual /
physical Check
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10

3
4

1. Using a Tech 2, display the ECT sensor and IAT
sensor value.
2. Check the specified value or wire.


intake system.

operation.

Check for proper ignition voltage output with a spark

tester.

Step
10
Action
range.
Value (s)
Yes
No
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17

11
Check for water or alcohol contaminated fuel.

12

13
1. Check the injector connectors.

2. If any of the connectors are connected at an
improper cylinder, connect as necessary.
14

Low compression.
Worn camshaft.
15

following:
Tech 2 data.
and/or system.
16

release?

Step
17
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.


rpm
X
Rough Idle
Stall
time
Step
1
Action
performed?
Value (s)
Yes
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 2
Verify repair
Go to Step 4
Go to Step 3
Go to Visual /
physical Check
10 - 20 Steps
Go to Step 6
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7

3
4

Engine fully warm.
Accessories are OFF. 2. Using a Tech 2, monitor
IAC position.
Is the IAC position within the specified values?

intake system.

sensor value.

Step
7
Action
Value (s)
Yes
No
Go to Step 9
Go to Step 8
Verify repair
Refer to DTC
P0101 and Go to
Step 9
Go to Step 11
Go to Step 10
Verify repair
Verify repair
Go to Step 12

45
Mass Air Flow (g/s)

(Tech2 Reading)
40
35
30
25
20
15
10
5
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000


operation?
10

100%.
11


Step
12
Action
Check the fuel control Heated Oxygen Sensor
(HO2S). When monitored on the Tech 2, the HO2S
should respond quickly to different throttle positions. If
it doesn't check for silicon or other contaminates from
fuel or use of improper sealant. The sensors may have
a white powdery coating. Silicon contamination sends
a rich exhaust signal which causes the ECM to
command and excessively lean air/fuel mixture.
13
Yes
No
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Go to Step 16
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 18
Verify repair
Go to Step 19
Verify repair
Go to Step 20
Verify repair
Go to Step 21
Verify repair
Go to Step 22

Diagnosis.
14
Value (s)

15
Monitor "B1S1 (Bank 1 Sensor 1) Status" and "B2S1

(Bank 2 Sensor 1) Status" on the Tech 2.
Is the "B1S1 (Bank 1 Sensor 1) Status" or "B2S1
(Bank 2 Sensor 1) Status" in the rich condition?
16
Check items that can cause the engine to run rich.

Refer to DTC P0172 "O2 Sensor System Too Rich
(Bank 1)" or DTC P0175 "O2 Sensor System Too Rich
(Bank 2)".
17
Check items that can cause the engine to run lean.

Refer to DTC P0171 "O2 Sensor System Too Lean
(Bank 1)" or DTC P0174 "O2 Sensor System Tool
Lean (Bank 2)".
18

tester.
19
Check the ignition coils for cracks or carbon tracking.

20

electrodes, heavy deposits, or improper heat range.
21


Step
22
Action
23
Value (s)
Yes
No
Verify repair
Go to Step 23
Verify repair
Go to Step 24
Verify repair
Go to Step 25
Verify repair
Go to Step 26
Verify repair
Go to Step 27
Verify repair
1. Check for faulty engine mounts.

24

Low compression.
Worn camshaft.
Sticking or leaking valves. -Valve timing.
Broken valve springs.
25

following:
Tech 2 data.
and/or system.
26

release?
27
Replace the ECM.


DEFINITIONS: Engine power variation under steady
throttle or cruise. Feels like the vehicle speeds up and
slows down with no charge in the accelerator pedal.
rpm
Surge
time
Step
1
Action
performed?
Value (s)
Yes
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 2
Verify repair
Go to Step 4
Go to Step 3
Go to Visual /
physical Check
System OK
Go to Step 5
Go to Step 7
Go to Step 6

Be sure that the driver understands transmission

torque converter clutch and A/C compressor operation
as explained in the owner's manual. Inform the
customer how the torque converter clutch (TCC) (if
A/T model) and the A/C clutch operate.
Is the customer experiencing a normal condition?


45
Mass Air Flow (g/s)

(Tech2 Reading)
40
35
30
25
20
15
10
5
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000

Step
6
Action
Value (s)
Yes
No
Verify repair
Refer to DTC
P0101 and Go to
Step 7
Go to Step 9
Go to Step 8
Verify repair
Verify repair
Go to Step 10
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 13
Go to Step 14

7

operation?

8

100%.

10

11
Check the fuel pressure. Refer to 6E-116 Fuel System

Diagnosis.
12


Step
13
Action
(Bank 2)".
14
Verify repair
Go to Step 15
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 19
Verify repair
Go to Step 20
Verify repair
Go to Step 21
Verify repair
Go to Step 22

17
No

tester.
16
Yes

Lean (Bank 2)".
15
Value (s)

electrodes, heavy deposits, or improper heat range.
18

19

20

21


Step
22
Action
Value (s)
Yes
No
Verify repair
Go to Step 23
Verify repair
Go to Step 24
Verify repair

following:
Tech 2 data.
and/or system.
23

release?
24
Replace the ECM.


Stumble
rpm
Sug
Hesitation
time
Step
1
Action
performed?
Value (s)
Yes
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 2
Verify repair
Go to Step 4
Go to Step 3
Go to Visual /
physical Check.
Replace fuel
Go to Step 5
Go to Step 7
Go to Step 6

3
4

Is the customer using improper fuel or degraded fuel?
45
40
Mass Air Flow (g/s)
(Tech2 Reading)
35
30
25
20
15
10
5
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000

Step
6
Action
Value (s)
Yes
No
Verify repair
Refer to DTC
P0101 and Go to
Step 7
Go to Step 9
Go to Step 8
Verify repair
Verify repair
Go to Step 10
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Go to Step 13
Go to Step 14

7

operation?

8

100%.

10

11

Diagnosis.
Diagnosis. Was a problem found?
12


Step
13
Action
(Bank 2)".
14
Verify repair
Go to Step 15
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 19
Verify repair
Go to Step 20
Verify repair
Go to Step 21
Verify repair
Go to Step 22

17
No

tester.
16
Yes

Lean (Bank 2)".
15
Value (s)

range.
18

19

20

21


Step
22
Action
Value (s)
Yes
No
Verify repair
Go to Step 23
Verify repair
Go to Step 24
Verify repair

following:
Tech 2 data.
and/or system.
23

release?
24
Replace the ECM.


increases.
rpm
time
Step
1
Action
performed?
Value (s)
Yes
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 2
Verify repair
Go to Step 4
Go to Step 3
Go to Visual /
physical Check.
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Go to Step 7
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 9

3
4




(Bank 2)".

Lean (Bank 2)".

Step
9
Action
Value (s)
Yes
No
Go to Step 11
Go to Step 10
Verify repair
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17

operation?
10

100%.
11

12

intake system.
13
Perform the Injector Coil/Balance Test.

Refer to 6E-106 page
Was a problem found.
14
1. Check for fuel in the pressure regulator vacuum

hose.
2. If fuel is present, replace the fuel pressure regulator
assembly.
15

tester.
16

range.

Step
17
Action
(refer to Engine Mechanical Section):
Value (s)
Yes
No
Verify repair
Go to Step 18
Verify repair
Go to Step 19
Verify repair
Go to Step 20
Verify repair
Go to Step 21
Verify repair
Low compression. -Leaking cylinder head gaskets.

Worn camshaft. -Sticking or leaking valves.
Valve timing. -Broken valve springs.
18

19

following:
Tech 2 data.
and/or system.
20

release?
21
Replace the ECM.


DEFINITIONS: Engine delivers less than expected
power. Attempting part-throttle acceleration results in
little or no increase in vehicle speed.
Step
1
Action
Value (s)
No
Go to On
Board
Diagnostic
(OBD) System
Go to Step 2
Check
Verify repair
Go to Step 4
Go to Step 3
Go to Visual /
physical
Check.
Verify repair
Go to Step 5
Replace fuel
Go to Step 6
Go to Step 8
Go to Step 7

performed?
Yes

2. If a bulletin that addresses the symptom is found, correct
the condition as instructed in the bulletin.
1. Remove and check the air filter element for dirt or

restrictions.
2. Replace the air filter element if necessary.
Was a repair required?


Does the Tech 2 indicate correct "Mass Air Flow" as shown in
the following graph, when engine speed is increasing little by
little?

45
Mass Air Flow (g/s)

(Tech2 Reading)
40
35
30
25
20
15
10
5
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000

Step
7
Action
Remove the MAF & IAT sensor assembly and check for the
following conditions.
Value (s)
Yes
No

8
Refer to DTC
P0101 and Go
to Step 8
Verify repair

Does the Tech 2 indicate correct "Throttle Position" from 0%
to 100% depending on accelerator pedal operation?
Go to Step 10 Go to Step 9

3. Adjust the accelerator cable or TPS within 0% to 100%.
10
Verify repair
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Verify repair
Go to Step 13

11
Check the fuel control Heated Oxygen Sensor (HO2S). When

monitored on the Tech 2, the HO2S should respond quickly to
different throttle positions. If it doesn't check for silicon or other
contaminates from fuel or use of improper sealant. The
sensors may have a white powdery coating. Silicon
contamination sends a rich exhaust signal which causes the
ECM to command and excessively lean air/fuel mixture.
12
Check the fuel pressure. Refer to 6E-116 Fuel System

Diagnosis.
13
Monitor "B1S1 (Bank 1 Sensor 1) Status" and "B2S1 (Bank 2

Sensor 1) Status" on the Tech 2.
Is the "B1S1 (Bank 1 Sensor 1) Status" or "B2S1 (Bank 2
Sensor 1) Status" in the rich condition?
14
Go to Step 14 Go to Step 15
Check items that can cause the engine to run rich. Refer to
DTC P0172 "O2 Sensor System Too Rich (Bank 1)" or DTC
P0175 "O2 Sensor System Too Rich (Bank 2)".
Verify repair
Go to Step 16

Step
15
Action
Check items that can cause the engine to run lean. Refer to
DTC P0171 "O2 Sensor System Too Lean (Bank 1)" or DTC
P0174 "O2 Sensor System Tool Lean (Bank 2)".
16
No
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 19
Verify repair
Go to Step 20
Verify repair
Go to Step 21
Verify repair
Go to Step 22
Verify repair
Go to Step 23
Verify repair
Go to Step 24
Check the ignition coils for cracks or carbon tracking. If a

problem is found, repair as necessary.
18
Yes
Check for proper ignition voltage output with the spark tester.
17
Value (s)
1. Remove the spark plugs and check for gas or oil fouling
cracks, wear, improper gap, burned electrodes, heavy
deposits, or improper heat range.
2. If spark plugs are fouled, the cause of fouling must be
determined before replacing the spark plugs.
19
Visually/physically check the vacuum hose for splits, kinks and

proper connections and routing.
20

21
Check the torque converter clutch (TCC) for proper operation

(if A/T model). If a problem is found, repair as necessary.
22
Check for the following engine mechanical problems (refer to

Engine Mechanical Section):
Low compression.
Worn camshaft.
Sticking or leaking valves.
Valve timing.
23

2. If all procedures have been completed and no malfunctions
have been found, review/inspect the following:
Tech 2 data.
All electrical connections within a suspected circuit and/or
system.

Step
24
Action
Is the ECM programmed with the latest software release?
Value (s)
Yes
No
Verify repair
Go to Step 25
Verify repair
If not, download the latest software to the ECM using the

"SPS (Service Programming System)".
25
Replace the ECM.

IMPORTANT: The replacement ECM must be programmed.
Refer to section of the Service Programming System (SPS) in
this manual. Following ECM programming, the immobilizer
system (if equipped) must be linked to the ECM. Refer to
section 11 Immobilizer System-ECM replacement for the
DETONATION/SPARK KNOCK SYMPTOM

DEFINITIONS: A mild to sever ping, usually worse
under acceleration. The engine makes a shape metallic
knocking sound that changes with throttle opening.
Prolonged detonation may lead to complete engine
failure.
Step
1
Action
performed?
Value (s)
Yes
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 2
Verify repair
Go to Step 4
Go to Step 3
Go to Visual /
physical Check.
Go to Step 5
Verify repair
Verify repair
Go to Step 6
Verify repair
Go to Step 7

3
4

1. If Tech 2 readings are normal (refer to Typical Scan
Data Values) and there are no engine mechanical
faults, fill the fuel tank with a known quality
gasoline.
2. Re-evaluate the vehicle performance.
Is detonation present?
Check for obvious overheating problems:

Low engine coolant.
Restricted air flow to radiator.
Incorrect coolant solution.

sensor value.

Step
7
Action
Value (s)
Yes
No
Go to Step 9
Go to Step 8
Verify repair
Refer to DTC
P0101 and Go to
Step 9
Go to Step 11
Go to Step 10
Verify repair
Verify repair
Go to Step 12


45
Mass Air Flow (g/s)

(Tech2 Reading)
40
35
30
25
20
15
10
5
0
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000

8


operation?

10

100%.
11


Step
12
Action
Diagnosis.
13
Verify repair
Go to Step 13
Go to Step 14
Go to Step 15
Verify repair
Go to Step 15
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 19
Verify repair
Go to Step 20
Verify repair
Check spark plugs for proper heat range.

Were incorrect spark plugs installed?
16
No

Lean (Bank 2)".
15
Yes

(Bank 2 Sensor 1) Status" in the lean condition?
14
Value (s)
1. Remove excessive carbon buildup with a top

engine cleaner.
2. Re-evaluate vehicle performance.
Is detonation still present?
17
Check for an engine mechanical problem. Perform a

cylinder compression check. Refer to Engine
Mechanical.
18

following:
Tech 2 data.
and/or system.
19

release?
20
Replace the ECM.


DEFINITIONS: Fuel economy, as measured by an
actual road test, is noticeably lower than expected. Also,
economy is noticeably lower than it was on this vehicle
at one time, as previousl shown by an actual road test.
(Larger than standard tires will cause odometer
readings to be incorrect, and that may cause fuel
economy to appear poor when it is actually normal.)
Step
1
Action
performed?
Value (s)
Yes
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 2
Verify repair
Go to Step 4
Go to Step 3
Go to Visual /
physical Check.
Go to Step 5
Go to Step 6
System OK
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10
Verify repair
Go to Step 11

3
4

Check owner's driving habits.
Is the A/C On full time (defroster mode On)?

Visually/physically check: Vacuum hoses for splits,

kinks, and improper connections.


to Engine Cooling.
Remove and check the air filter element for dirt or for
restrictions.
10

as necessary.

Step
11
Action
sensor value.
Value (s)
Yes
No
Verify repair
Go to Step 12
Verify repair
Go to Step 13

Go to Step 15
Go to Step 14

Verify repair
Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Go to Step 18
Verify repair
Go to Step 19

12

range.
13
14
15

16

(refer to Engine Mechanical):
Low compression.
Worn camshaft.
Valve timing.
17

following:
Tech 2 data.
and/or system.
18

release?

Step
19
Action
Value (s)
Yes
No

Verify repair
Replace the ECM.

EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOM

DEFINITIONS: Vehicle fails an emission test. There is
excessive "rotten egg" smell. (Excessive odors do not
necessarily indicate excessive emissions.)
Step
1
Action
performed?
Value (s)
Yes
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 2
Verify repair
Go to Step 4
System OK
Replace to
Unlead fuel
Verify repair &

Go to Step 17
Go to Step 7
Verify repair &

Go to Step 17
Go to Step 8
Verify repair &

Go to Step 17
Go to Step 9
Verify repair &

Go to Step 17
Go to Step 10
Verify repair &

Go to Step 17
Go to Step 11
Verify repair &

Go to Step 17
Go to Step 12
Verify repair &

Go to Step 17
Go to Step 13
Verify repair &

Go to Step 17
Go to Step 14

3
4
5
6

Is the customer continual accelerated On/Off in cold
condition?
Is the customer used lead fuel?
Go to Step 5
Go to Step 6
Check for vacuum leaks (vacuum lines, intake

manifold, throttle body, etc.)
Were any vacuum leaks found?
Go to Step 3
Go to Visual /
physical Check.
1. Check fuel cap for proper installation.

2. Secure the fuel cap if necessary.
Check the fuel pressure. Refer to 6E-116 page Fuel

System Pressure Test.
1. Check for faulty, plugged or incorrectly installed

PCV valve.
2. Verify that the PCV system is not plugged.
10
Check the injector connectors, if any of the injectors

are connected an incorrect cylinder, correct as
necessary.
11
Perform the Injector Coil/Balance Test.

12
Check for a problem with the engine cooling system.

13
Check EVAP canister for fuel loading. Refer to

Evaporative Emission Control System.

Step
14
Action
Check the EVAP purge solenoid valve operation.
Is the valve operated normally?
15
Value (s)
Yes
No
Verify repair &

Go to Step 17
Verify repair &

Go to Step 15
Verify repair &

Go to Step 17
Go to Step 16
System OK
Go to Step 18
System OK
Go to Step 18
Verify repair
Go to Step 19
Go to Step 20
Go to Step 21
Verify repair
Go to Step 22
Verify repair
Go to Step 22
Verify repair
Go to Step 23

Internal catalytic converter failure.
16

engine cleaner. Refer to the instructions on the top
engine cleaner can.
2. Perform the exhaust emission test.
Does the vehicle pass the test?
17
Perform the exhaust emission test.

18

19

20

(Bank 2)".
21

Lean (Bank 2)".
22

Low compression.
Worn camshaft. -Sticking or leaking valves.
Valve timing. -Broken valve springs.

Step
23
Action
Value (s)
Yes
No
Verify repair
Go to Step 24
Verify repair
Go to Step 25
Verify repair

following:
Tech 2 data.
and/or system.
24

release?
25
Replace the ECM.

DIESELING, RUN-ON SYMPTOM

DEFINITIONS: Engine continues to run after key is
turned OFF, but runs very rough. If engine runs
smoothly, check the ignition switch and adjustment.
Step
1
Action
performed?
Value (s)
Yes
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 2
Verify repair
Go to Step 4
Go to Step 3
Go to Visual /
physical Check.
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair

3
4

Check for a short between voltage circuit and the
Check the fuel leaking from injector. Perform the

Injector Coil/Balance Test.

following:
Tech 2 data.
and/or system.

release?
Replace the ECM.

BACKFIRE SYMPTOM
DEFINITIONS: Fuel ignites in the intake manifold, or in
the exhaust system, making a loud popping noise.
Step
1
Action
performed?
Value (s)
Yes
No
Go to On Board
Diagnostic (OBD)
System Check
Go to Step 2
Verify repair
Go to Step 4
Go to Step 3
Go to Visual /
physical Check.
Verify repair
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Verify repair
Go to Step 10

3
4

tester.


range.

Pressure Test.
Refer to 6E-116 page Fuel System Diagnosis to

determine if there is a problem with fuel delivery.
Check the CKP sensor signal, shield wire, or

installation condition. Refer to DTC P0336 "Crankshaft
Position Sensor Circuit Range/Performance" and DTC
P0337 "Crankshaft Position Sensor Circuit No Signal".

Step
10
Action
Value (s)
Yes
No
Verify repair
Go to Step 11
Verify repair
Go to Step 12
Verify repair
Go to Step 13
Verify repair
Go to Step 14
Verify repair

Low compression.
Worn camshaft.
Valve timing.
11
Check the intake and exhaust manifold for casting

flash. Refer to Engine Mechanical.
12

following:
Tech 2 data.
and/or system.
13

release?
14
Replace the ECM.


ENGINE CONTROL MODULE (ECM)
NOTE:
To prevent possible electrostatic
damage, follow these guidelines:
discharge
Do not touch the control module connector pins

or soldered components on the control module
circuit board.
Do not open the replacement part package until
the par is ready to be installed.
Before removing the part from the package,
ground the package to a known good ground on
the vehicle.
If the part has been handled while sliding across
the seat, or while sitting down from a standing
position, or while walking a distance, touch a
known good ground before installing the part.
NOTE:
To prevent internal ECM damage, the ignition must
be in the "OFF" position in order to disconnect or
reconnect power to the ECM (for example: battery
cable, ECM pigtail, ECM fuse, jumper cables, etc.).
NOTE:
When replacing the production ECM with a service
ECM, it is important to transfer the broadcast code
and production ECM number to the service ECM
label. This will allow positive identification of ECM
parts throughout the service life of the vehicle.
Location
On the common chamber.
Removal Procedure
1.
2.
3.
4.
Disconnect the negative battery cable.

Remove four bolts.
Remove the ECM from common chamber.
1.
2.
3.
4.
Put on the ECM on the common chamber.

Tighten the ECM by four bolts.
Connect the two connectors to the ECM.
Connect the negative battery cable.
NOTE:
The replacement ECM must be programmed.
Service
Programming
System
(SPS)
and
Immobilizer programming (if equipped) is/are
necessary. In case "SPS procedure does not
succeed" or "engine does not run but No DTC after
SPS", low vehicle battery voltage or disconnected
electrical connector (e.g. poor connection of data
link connector) are supposed. Perform the SPS
procedure once again by correct conditions. The
programming ECM will be recovered normally.
CRANKSHAFT POSITION (CKP)

SENSOR
CAMSHAFT POSITION (CMP)

SENSOR
Location
Right-hand side of the cylinder block.
Location
The rear of right bank of the cylinder head.
Removal Procedure
Removal Procedure

3. Loosen a bolt and remove the CKP sensor from
the cylinder block.
NOTE:
Use caution to avoid any hot oil that might drip out.

2. Disconnect connector from the CMP sensor.
3. Loosen a bolt and remove the CMP sensor from
the cylinder head.
1. Install the CKP sensor to the cylinder block.
oil to the O-ring.
tightening torque.
Tightening Torque
Bolt: 10Nm (1.0kgfm).
3. Connect a sensor connector to the CKP sensor.
NOTE:
Verify any DTCs (diagnosis Trouble Code) are not
stored after replacement.
1. Install the CMP sensor to the cylinder head.

oil to the O-ring.
2. Tighten CMP sensor by a bolt with specified
tightening torque.
Tightening Torque
3. Connect a sensor connector to the CMP sensor.
NOTE:

(ECT) SENSOR
MASS AIR FLOW (MAF) SENSOR &

INTAKE AIR TEMPERATURE (IAT)
SENSOR
Location
Location
Removal Procedure
Removal Procedure

thermostat housing.
NOTE:
Cool down the engine before above procedures are
carried out.

2. Disconnect a MAF & IAT sensor connector from
the MAF & IAT sensor.
3. Loosen two screws and remove the MAF & IAT
sensor from the intake duct.
1. Apply sealer to threads of screw at the ECT
sensor.
torque.
Tightening Torque
13Nm (1.3kgfm)
sensor.
NOTE:
1. Install the MAF & IAT sensor into intake air duct.
2. Tighten MAF & IAT sensor by two screws.
Tightening Torque : 1.5 Nm (0.15 kgfm)
3. Connect a sensor connector to the MAF & IAT
sensor.
NOTE:

(TPS)
Location
IDLE AIR CONTROL (IAC) VALVE

Location
Removal Procedure
Removal Procedure
throttle body.

2. Disconnect the IAC valve connector.
3. Loosen two screws and remove IAC valve from
the throttle body.
Cleaning and Inspection

1.
2.
3.
4.
5.
6.
Temporary tighten the TPS by two screws.

Connect a TPS connectors to the TPS.
Connect the Tech2 to the vehicle.
Select "Data Display" with the Tech2.
Check the throttle position data and adjust the TPS
position.
NOTE:
1. Clean the IAC valve O-ring sealing surface, pintle

valve seat and air passage.
2. Use carburetor cleaner and a parts cleaning brush
to remove carbon deposit.
Do not use a cleaner that contain methyl ethyl
ketone. This is an extremely strong solvent and not
necessary for this type of deposit.
3. Shiny spots on the pintle are normal and do not
indicate misalignment or a bent pintle shaft.
4. Inspect the IAC valve O-ring for cuts, cracks or
distortion.
Measurement
In order to install a new IAC valve, messier the distance
between the tip of the pintle and the mounting flange. If
that measurement is 28mm (1.1in.) or less, the valve
need no adjustment. If the measurement is greater than
28mm (1.1in.), apply finger pressure and retract the
valve. The force required to retract the pintle on a new
valve will not damage the valve, shaft, or pintle.
28mm(1.1in.)
or less
HEATED OXYGEN SENSOR (HO2S)

Location
Installed on the exhaust pipe for each bank.
Removal Procedure
2. Disconnect the O2 sensor connector.
3. Loosen and remove the O2 sensor from the
exhaust pipe.
1. Tighten the IAC valve by two screws.
2. Connect a IAC valve connector to the IAC valve.
Bank 1 Heated Oxygen Sensor (Right bank)
NOTE:
Bank 2 Heated Oxygen Sensor (Left bank)
Inspection
Inspect the louvered end of the sensor for grease,

dirt, excessive carbon build up or other
contamination.
A special anti-seize compound is used on the O2
sensor threads. This compound consists of glass
breads suspended in a liquid graphite solution.
The graphite burns away with engine heat, but the
glass breads will remain, marking the sensor
easier to remove.
New or service sensors will already have the
compound applied to the threads. If a sensor is
removed and is to be reinstalled for any reason,
the threads must have anti-seize compound
applied.
EVAP CANISTER PURGE VALVE

SOLENOID
Location
On the intake manifold.
Removal Procedure
2. Disconnect a purge solenoid connector from the
purge solenoid.
3. Disconnect two hoses from the purge solenoid
valve.
4. Loosen a bolt and remove the purge solenoid from
the intake manifold.
1. Install the O2 sensor to the exhaust pipe.
Apply anti-seize compound or the equivalent to the
threads of the oxygen sensor, if necessary.
2. Tighten the O2 sensor with specified tightening
torque.
Tightening Torque
3. Connect a sensor connector to the O2 sensor.
NOTE:
Verify no exhaust gas leaking from the sensor
1.
2.
3.
4.
5.
Put on the purge solenoid on the intake manifold.

Tighten the purge solenoid by a bolt.
Connect a connector to the purge solenoid.
Connect two hoses to the purge solenoid valve.
NOTE:
FUEL PRESSURE RELIEF

Caution:
To reduce the risk of the fire and personal injury, it
is necessary to relive the fuel system pressure
before servicing the fuel system components.
Caution:
After relieving the fuel system pressure, a small
amount of fuel may be released when servicing fuel
lines or connections. Reduce the chance of
personal injury by covering the fuel line fitting with
a short towel before disconnecting the fittings. The
towel will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.
1.
2.
3.
4.
5.
5. Disconnect the connectors from, solenoid valve,

sensing valve.
6. Disconnect the vacuum hose on canister solenoid
and positive crankcase ventilation hose.
7. Remove the common chamber Refer to the
common chamber in Engine Mechanical.
1. Lift up carefully on the fuel injectors. Do not
separate the fuel injectors from the fuel rail.
2. If an injector becomes separated from the fuel
rail, the infector O-ring seals and the retainer
clip must be replaced.
3. Drain residual fuel into an approved container.
Remove the fuel filler cap.

Remove the fuel pump relay.
Start the engine and allow it to stall.
Crank the engine for about 30 seconds.
FUEL RAIL ASSEMBLY

Removal Procedure
NOTE:
Do not attempt to remove the fuel inlet fitting on
the fuel rail. It is staked in place. Removing the
fuel inlet fitting will result in damage to the fuel
rail or the internal O-ring seal.
Use care when removing the fuel rail assembly in
order to prevent damage to the injector electrical
connector terminals and the injector spray tips.
Fittings should be capped and holes plugged
during servicing to prevent dirt and other
contaminants from entering open lines and
passages.
Important: Before removal, the fuel rail assembly may
be cleaned with a spray type engine cleaner. Follow the
spray package instructions. Do not immerse the fuel
rails in liquid cleaning solvent.
1. Depressurize the fuel system. Refer to Fuel
Pressure Relief Procedure in this Section.
3. Remove the engine cover.
4. Disconnect the accelerator pedal cable from throttle
body and cable bracket.
060RW044
8. If removal of the fuel pressure regulator is

necessary, refer to Fuel Pressure Regulator.
9. If removal of the fuel injectors is necessary, refer to
Fuel Injectors.
1. If the fuel injectors were removed, install them.
Refer to Fuel Injectors.
2. If the fuel pressure regulator was removed, install
it. Refer to Fuel Pressure Regulator.

3. Install the common chamber. Refer to common
chamber in engine Mechanical.
FUEL INJECTORS
Removal Procedure
NOTE: If the fuel injectors are leaking, the engine oil
may be contaminated with fuel. Check the oil for
signs of contamination and change the oil and the
filter if necessary.
NOTE: Use care in removing the fuel injectors in
order to prevent damage to the fuel injector
electrical connector pins or the fuel injector
nozzles. The fuel injector is an electrical component
and should not be immersed in any type of cleaner
as this may damage the fuel injector.
Important: Fuel injectors are serviced as a complete
assembly only.
060RW044
4. Connect the vacuum hose on Canister Solenoid

and positive crankcase ventilation hose.
5. Connect the connectors to, solenoid valve.
6. Connect the accelerator pedal cable to throttle
body and cable bracket.
7. Install the engine cover.
9. Crank the engine until it starts. Cranking the
engine may take longer than usual due to trapped
air in the fuel rail and in the injectors.
2. Remove the upper intake manifold. Refer to

Common Chamber in Engine Mechanical..
3. Remove the fuel rail. Refer to Fuel Rail.
060RW044

4. Remove the injector retainer clip.
4. Use new fuel injector retainer clips to retain the fuel

injector to the fuel rail.
5. Coat the end of the fuel injector with engine oil.
6. Install the fuel rail. Refer to Fuel Rail.
F06RW017
5. Remove the fuel injector assembly.

6. Remove the O-ring from the fuel injector.
060RW044
7. Remove the O-ring backup from the fuel injector .
7. Install the upper intake manifold. Refer to Common

Chamber in Engine Mechanical.
Inspection Procedure
1. Inspect the O-rings for cracks or leaks.
8. Install the engine cover.
2. Replace worn or damaged O-rings.
3. Lubricate the new O-rings with engine oil before

installation.
1. Install the O-ring backup on the fuel injector.
2. Install the new O-ring on the fuel injector.
3. Install the fuel injector on the fuel rail.
F06RW017
FUEL PRESSURE REGULATOR
6. Remove the fuel pressure regulator attaching

screw.
Removal Procedure
injury, it is necessary to relieve the fuel system
pressure before servicing the fuel system
components.
CAUTION: After relieving the system pressure, a
small amount of fuel may be released when
servicing fuel lines or connections. Reduce the
chance of personal injury by covering the fuel line
fittings with a shop towel before disconnecting the
fittings. The towels will absorb any fuel that may
leak out. When the disconnect is completed, place
the towel in an approved container.
NOTE: Compressed air must never be used to test
or clean a fuel pressure regulator, as damage to the
fuel pressure regulator may result.
NOTE: To prevent damage to the fuel pressure
regulator, do not immerse the pressure regulator in
solvent.
060RW116
7. Remove the fuel pressure regulator from the fuel

rail.
Disassembly Procedure

Pressure Relief Procedure.
1. Remove the O-ring from the fuel pressure regulator.
2. Remove the fuel return line from the fuel pressure

regulator.
3. Remove the fuel pump relay. Refer to Fuel Pump

Relay.
3. Remove the O-ring from the fuel return line.
4. Remove the pressure regulator hose from the fuel

pressure regulator.
The O-ring may be left inside the fuel pressure

regulator instead of on the fuel return line.
5. Remove the two bolts from the protector that

secures the common chamber.
060RW116
060RW066
Assembly Procedure
3. Install the two bolts to the protector that secures

the common chamber.
1. Install a new O-ring on the fuel return line.

2. Install the fuel return line on the fuel pressure
regulator.
Do not over-tighten the swivel nut on the fuel pressure
regulator. The fuel pressure regulator can be damaged
and fuel may leak if the swivel nut is over-tightened.
3. Tighten the swivel nut.
4. Install a new O-ring on the fuel pressure regulator.
1. Install the fuel pressure regulator attaching screw.
Tighten
Tighten the fuel pressure regulator attaching screw
to 3 Nm (0.3 kgm/26 lb in.).
060RW066
4. Install the pressure regulator hose to the fuel

pressure regulator.
5. Install the fuel pump relay. Refer to Fuel Pump
Relay.
7. Crank the engine until it starts. Cranking the engine
may take longer than usual due to trapped air in the
fuel lines.
060RW116
2. Install the fuel pressure regulator on the fuel rail.

Measure resistance of ignition coil assembly, and
replace the ignition coil assembly if its value exceeds
the standard.
IGNITION COIL
Removal Procedure
Disconnect three connector from ignition coil.
cover.
Remove fixing bolts on ignition coil.
060RW006
1. Install the ignition coil assembly (3).
Connect ignition coil connector (1) and ignition coil
(3), then tighten bolt (2) to the specified torque.
060RW001
Legend
(2) Bolt
Check the ignition coil assembly for insulation. Check
terminals for corrosion or damage, and replace as
necessary.
Measuring resistance of ignition coil assembly.
Terminal No.
Limit
1 to 2
Without 0 ohm or infinity

maximum ohm.
1 to 3
Same as above
2 to 3
Same as above
060RW001
SPARK PLUGS
Measuring Insulation Resistance

Measure insulation resistance using a 500 volt
megaohm meter.
Removal Procedure
1. Remove spark plugs.
Replace spark plugs if measured value is out of

standard.
The spark plug affects entire engine performance and
therefore its inspection is very important.
Insulation resistance: 50 MW
W or more
Check electrode and insulator for presence of

cracks, and replace if any.
Check electrode for wear, and replace if necessary.
Check gasket for damage, and replace if necessary.
Measure insulation resistance with an ohmmeter,
and replace if faulty.
Adjust spark plug gap to 1.0 mm (0.04 in)
(0.043 in).
~ 1.1 mm
Check fuel and electrical systems if spark plug is

extremely dirty.
Use spark plugs having low heat value (hot type
plug) if fuel and electrical systems are normal.
Use spark plugs having high heat value (cold type
plug) if insulator and electrode are extremely
burned.
Sooty Spark Plugs

Much deposit of carbon or oil on the electrode and
insulator of spark plug reduces the engine performance.
Possible causes:
Too rich mixture
011RS010
Cleaning Spark Plugs

Clean spark plugs with a spark plug cleaner.
Raise the ground electrode to an angle of 45 to 60
degrees. If electrode is wet, dry it before cleaning.
Presence of oil in combustion chamber
After spark plug is thoroughly cleaned, check

insulator for presence of cracks.
Incorrectly adjusted spark plug gap
Clean threads and metal body with a wire brush.

File the electrode tip if electrode is extremely worn.
Burning Electrodes
This fault is characterized by scorched or heavily
oxidized electrode or blistered insulator nose.
Possible causes:
Too lean mixture
Improper heat value

Bend the ground electrode to adjust the spark plug
gap.
011RS011
1. Spark plugs
Tighten spark plugs to the specified torque.
Special Tools
ILLUSTRATION
PART NO.
PART NAME
5884002850
(J 39200)
High Impedance
Multimeter (Digital
Voltmeter DVM)
(1) PCMCIA Card

(2) RS232 Loop Back
Connector
(4) DLC Cable
(5) TECH 2
5884003850
(J 35616-A/BT-8637)
Connector Test Adapter
Kit
5884003780
(J 34730-E)
Port Fuel Injection
Diagnostic Kit
5884026350
(J 39021-90)
Injector Switch Box
5884003830
(J 26792/BT-7220-1)
Spark Tester
ILLUSTRATION
PART NO.
PART NAME
Breaker Box
5884026180
Fuel Injector Tester
ENGINE EXHAUST (6VE1 3.5L) 6F-1
ENGINE
ENGINE EXHAUST (6VE1 3.5L)
CONTENTS
Three Way Catalytic Converter and Center
Exhaust Pipe..........................................................
Three Way Catalytic Converter and Center
Exhaust Pipe and Associated Parts ................
Removal ...............................................................
6F-1
6F-2
6F-3
6F-3
6F-3
Installation.............................................................
Exhaust Silencer and Rear Exhaust Pipe ...........
Exhaust Silencer and Rear Exhaust Pipe and
Associated Parts.................................................
Removal................................................................
Installation.............................................................
6F-3
6F-4
6F-4
6F-4
6F-4
6F-5
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.

parts and systems.
6F-2 ENGINE EXHAUST (6VE1 3.5L)
General Description
RTW46FLF000101
Legend
(3) Three Way Catalytic Converter
(1) Front Exhaust Pipe LH
(4) Center Exhaust Pipe
(2) Front Exhaust Pipe RH
(5) Exhaust Silencer & Tail Pipe
When inspecting or replacing exhaust system

components, make sure there is adequate clearance
from all points on the underbody to prevent overheating
the floor pan and possible damage to the passenger
compartment insulation and trim materials.
Check complete exhaust system and nearby body
areas and rear compartment lid for broken, damaged,
missing or mispositioned parts, open seams, holes,
loose connections or other deterioration which could
permit exhaust fumes to seep into the rear
compartment or passenger compartment. Dust or water
in the rear compartment may be an indication of a
problem in one of these areas. Any faulty areas should
be corrected immediately.
Hangers
Various types of hangers are used to support exhaust
system(s). These include conventional rubber straps,
rubber rings, and rubber blocks.
The installation of exhaust system supports is very
important, as improperly installed supports can cause
annoying vibrations which can be difficult to diagnose.
Three Way Catalytic Converter

The three way catalytic converter is an emission control
device added to the exhaust system to reduce
pollutants from the exhaust gas stream.

CAUTION: The catalytic converter requires the use
of unleaded fuel only.
Periodic maintenance of the exhaust system is not
required. If the vehicle is raised for other service, it is
advisable to check the condition of the complete
exhaust system.
A dual bed monolith catalytic converter is used in
combination with three way catalytic converter.
Catalytic Converter Types:
Three way (Reduction/Oxidation) catalyst
The catalyst coating on the three way (reduction)
converter contains platinum and rhodium which lowers
the levels of nitrous oxide (NOx) as well as
hydrocarbons (HC) and carbon monoxide (Co).
Gasket
The gasket must be replaced whenever a new exhaust
pipe, muffler or catalytic converter is installed.
Three Way Catalytic Converter and Center Exhaust Pipe

Three Way Catalytic Converter and Center Exhaust Pipe and Associated Parts
RTW46FMF000201
Legend
(4) Three Way Catalytic Converter LH
(1) Front Exhaust Pipe Fixing Nuts
(5) Mounting Rubber
(2) O2 Sensor
(6) Exhaust Pipe Fixing Nuts
(3) Three Way Catalytic Converter RH
Removal
2. Lift up the vehicle and support with suitable safety
stands.
3. Disconnect O2 sensor harness connectors (2).
4. Remove the center exhaust pipe fixing nuts (6) and
the exhaust silencer fixing bolts, then remove the
center exhaust pipe and the mounting rubber.
5. Remove the front exhaust pipe fixing nuts (1) and
the mounting rubber, then remove the three way
catalytic converter (3) (4).
Installation
1. Install the three way catalytic converter (3) (4) and
the mounting rubber, and tighten the fixing nuts (1)
2. Install the center exhaust pipe and the mounting
rubbler, and tighten the fixing nuts (6) and bolts to
3. Connect the O2 sensor connectors (2).
Exhaust Silencer and Rear Exhaust Pipe

Exhaust Silencer & Tail Pipe and Associated Parts
RTW46FMF000301
Legend
(4) Exhaust Silencer Mounting Rubber
(5) Exhaust Silencer & Tail Pipe
(2) Exhaust Pipe Fixing Bolts
(6) Rear Exhaust Pipe Mounting Rubber
(3) Exhaust Pipe Fixing Nuts
Removal
Installation
2. Lift up the vehicle and support with suitable safety

stands.
1. Install the exhaust silencer and pipe (5), then install

the exhaust silencer and rear exhaust pipe
mounting rubber (4)(6).
3. Remove the exhaust pipe fixing nuts (3) and bolts

(2).
2. Tighten the exhaust pipe fixing nuts (3) and exhaust

pipe fixing bolts (2).
4. Remove the silencer and rear exhaust pipe

mounting rubber (4)(6), then remove the exhaust
silencer (5) and rear exhaust pipe (6).

Nm (kgm/lb ft)
RTW36FLF000301
ENGINE LUBRICATION (6VE1 3.5L) 6G-1
ENGINE
ENGINE LUBRICATION (6VE1 3.5L)
CONTENTS
Oil Pump..................................................................
Oil Pump and Associated Parts ........................
Disassembly ........................................................
Reassembly .........................................................
Oil Pan and Crankcase..........................................
Removal ...............................................................
6G-1
6G-2
6G-3
6G-3
6G-4
6G-4
6G-5
6G-7
6G-7
Installation............................................................. 6G-7
Oil Pump .................................................................. 6G-9
Removal................................................................ 6G-9
Installation............................................................. 6G-9
Oil Pump Oil Seal.................................................... 6G-11
Removal................................................................ 6G-11
Installation............................................................. 6G-11
Main Data and Specification.................................. 6G-12
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.

parts and systems.
6G-2 ENGINE LUBRICATION (6VE1 3.5L)
General Description
C06RW003
Legend
(10) Connecting Rod Bearing
(1) Oil Strainer
(11) Connecting Rod
(2) Oil Pump
(12) Piston
(3) Relief Valve
(13) Oil Gallery; Cylinder Head
(4) Oil Pressure Switch
(14) Camshaft
(5) Oil Filter
(15) Camshaft Journal
(6) Safety Valve
(16) Front Journal; Camshaft Drive Gear
(7) Oil Gallery
(17) Rear Journal; Camshaft Drive Gear
(8) Crankshaft Bearing
(18) Oil Pan
Oil Pump
Oil Pump and Associated Parts
051RW005
Legend
(1) Crankshaft Timing Pulley
(8) Relief Valve

(9) Oil Pump Cover
(10) Driven Gear
(3) Oil Pipe
(11) Drive Gear
(4) Oil Strainer
(12) Oil Seal
(5) Oil Pump Assembly
(13) O-ring
(6) Plug
(14) Oil Pump Body

Badly worn or damaged driven gear (10).
Disassembly
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Badly worn drive gear (11) driving face.
Remove crankshaft timing pulley.

Remove crankcase with oil pan.
Remove oil pipe.
Remove oil strainer.
Remove plug.
Remove spring.
Remove relief valve.
Remove oil pump cover.
Remove driven gear.
Remove drive gear.
Remove oil seal.
Remove O-ring.
Badly scratched or scored body sliding face (14) or

driven gear (10).
Badly worn or damaged gear teeth.
Measure the clearance between the body and the
driven gear with a feeler gauge.
Standard : 0.10 mm0.18 mm
(0.0039 in.0.0070 in)
Limit : 0.20mm (0.0079 in)

CAUTION: Make necessary correction or parts
replacement if wear, damage or any other abnormal
conditions are found during inspection.
Relief Valve (8)

Check to see that the relief valve slides freely.
The oil pump must be replaced if the relief valve
does not slide freely.
Replace the spring and/or the oil pump assembly
(5) if the spring is damaged or badly worn.
051RS004
Measure the clearance between the drive gear and

driven gear with a feeler gauge.
(0.0043 in0.0094 in)
Limit : 0.35mm (0.0138 in)
051RS002
Body (14) and Gears (10, 11)

The pump assembly must be replaced if one or more of
the conditions below is discovered during inspection.
051RS003

Measure the side clearance with a precision straight
edge and a feeler gauge.
Reassembly
1. Install drive gear (11).
Clearance
2. Install driven gear (10).
3. Install oil pump cover (9) and first, loosely tighten all
of the attaching screws. Next, tighten the attaching
screws to the specified torque.
(0.0011 in0.0035 in)

Limit : 0.15mm (0.0059 in)

After installation, check that the gear rotates
smoothly.
4. Install relief valve (8) and apply engine oil to the
relief valve and spring (7).
5. Install spring (7).
6. Install the plug (6).
051RS005
Oil Strainer
Check the oil strainer for cracking and scoring. If
cracking and scoring are found, the oil strainer must be
replaced.
051RS007
7. Install oil pump assembly (5).

Carefully remove any oil from the cylinder body
and the pump. Apply sealant (TB1207B or
equivalent) to the pump fitting face as shown in
illustration. Take care that sealant is not applied
to oil port surfaces. The oil pump assembly
must be installed within 5 minutes after sealant
application to prevent premature hardening of
sealant.
CAUTION: Do not apply an excessive amount of
sealant to the contact surface. Applying too much
sealant will overflow the contact surfaces. This
could cause serious damage to the engine.
051RS006
Attach oil pump assembly to cylinder body.

Tighten the oil pump fixing bolts.
051RW002
015RS001
9. Install oil strainer (4) with O-ring (13).

10. Install oil pipe (3) with O-ring (13).
11. Install crankcase with oil pan (2).
Remove oil on crankcase mounting surface and
dry the surface.
Apply a proper 4.5 mm (0.7 in) wide bead of
sealant (TB1207C or equivalent) to the
crankcase mounting surface. The bead must be
continuous.
051RW001
Legend

8. Install the new oil seal (12). Apply engine oil to the
oil seal lip before installation then use 58840
22870 oil seal Installer, install oil seal.
013RW010
12. Install crankshaft timing pulley.
Oil Pan and Crankcase

NOTE: Do not deform or damage the flange of oil pan
and crankcase.
Replace the oil pan and/or crankcase if deformed or
damaged.
Removal
2. Drain engine oil.
3. Lift vehicle by supporting the frame.
4. Remove front wheels.
5. Remove oil level dipstick from level gauge tube.
6. Remove stone guard.
7. Remove radiator under fan shroud.
NOTE: For 4WD model, remove front axle housing
assembly from chassis (steps 8 to 10).
8. Remove suspension cross member fixing bolts, 2
pcs each per side and remove suspension cross
member.
9. Remove pitman arm and relay lever assembly,
using the 5884020050 remover, remove pitman
arm from the steering unit and remove four fixing
bolts for relay lever assembly.
10. Remove axle housing assembly four fixing bolts
from housing isolator side and mounting bolts from
wheel side. At this time support the axle with a
garage jack and remove axle housing assembly.
11. Remove oil pan fixing bolts.
12. Remove oil pan, using 5884021530 sealer
cutter, remove oil pan.
013RS003
Installation
1. Install crankcase.
1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB-1207C or equivalent) to mounting
surface of crankcase.
Sealant beat must be continuous.
sealant hardens.
013RS003
13. Remove crankcase fixing bolts.

14. Remove crankcase, using 5884021530 sealer
cutter, remove crankcase.
013RW010

3. Install crankcase, tighten crankcase fixing bolts
Torque : 10 Nm (1.0 kgm/89 lb in)
3. Install oil pan, tighten oil pan fixing bolts to the

specified torque.
3. Install axle housing assembly and tighten fixing
bolts to the specified torque (4WD model).
Axle case bolts
Mounting bolts
013RW004
2. Install oil pan

1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (0.17 in) wide bead of
sealant (TB-1207C or equivalent) to mounting
surface of oil pan.
Sealant beat must be continuous.
sealant hardens.
RTW34CSH000101
4. Install relay lever assembly and tighten fixing bolts.

5. Engage teeth of pitman arm and steering unit, and
tighten nut to the specified torque.
6. Install suspension cross member and tighten fixing
7. Install radiator under fan shroud.
8. Install stone guard.
9. Install engine oil level dipstick.
10. Fill engine oil until full level on engine oil gauge
dipstick.
013RW003
Oil Pump
Removal
3. Remove crankcase assembly.


this manual.
6. Remove timing pulley from crankshaft.
7. Remove four fixing bolts from oil filter assembly.
8. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
9. Remove three bolts from oil pipe and O-ring.
10. Remove eight oil pump fixing bolts, then oil pump
assembly.
11. Remove sealant from mounting surface of oil pump
assembly, cylinder block and take care not to
damage mounting surfaces of oil pump and cylinder
block.
051RW002
Use 5884022870 installer when installing

new oil seal.
Apply engine oil to oil seal lip.
Install oil pump assembly to the cylinder block.
NOTE: Do not damage oil seal during installation of oil
pump assembly.
Installation
1. Install oil pump assembly
Apply sealant (TB-1207B or equivalent) to the oil
pump mounting surfaces as shown in the
illustration.
The oil pump assembly must be installed within
5 minutes after sealant application before the
sealant hardens.
NOTE: Do not apply sealant to the oil ports.
015RS001

5. Install timing pulley on crankshaft.

Install timing belt.
this manual.
Refer to install procedure for Crankshaft Pulley
in this manual.
7. Install crankcase assembly.
Refer to installation procedure for Oil Pan and
8. Refill engine oil until full level on engine oil dipstick.
051RW001
2. Install oil pipe with O-ring, tighten fixing bolt to the

specified torque.
3. Install oil strainer with O-ring, tighten fixing bolt to
4. Install oil filter assembly and tighten bolts to the
specified torque.
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
Oil Pump Oil Seal

Removal
Installation
1. Install oil pump oil seal, apply engine oil to oil seal
lip, then install oil seal using 5884022870
installer.

this manual.
5. Remove timing pulley from crankshaft.
6. Remove oil pump oil seal using a sealer puller.
NOTE: Take care not to damage sealing surfaces of oil
pump and crankshaft when removing oil seal.
015RS001
2. Install timing pulley to crankshaft.

this manual.
Refer to installation procedure for Crankshaft
5. Refill engine oil until full level.

Item
Oil capacity
Specifications
5.3 liters
Crankcase, Oil pan, Timing belt tensioner, Timing pulley, timing belt cover, Oil pump, Oil gallery, Oil strainer
Nm (kgm/lb ft)
RTW46GLF000101
ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L) 6H-1
ENGINE
ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L)
CONTENTS
Accelerator Pedal Control Cable..........................
Removal ...............................................................
Inspection.............................................................
Installation ............................................................
6H-1
6H-2
6H-2
6H-2
6H-3
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.

parts and systems.
6H-2 ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L)
Accelerator Pedal Control Cable
RTW46HLF000101
Removal
2) Rotate the ratchet ring in indirection an arrow
90.
ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L) 6H-3

throttle.
RTW46HMH000101
Inspection
Check the following items and replace the control
cable if any abnormality is found.
corrosion.
Installation
control pedal and dash panel.
engine.
bracket.
2) Confirm marking of outer cap must be upper
side.
6H-4 ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L)
MEMO
INDUCTION (6VE1 3.5L) 6J-1
ENGINE
INDUCTION (6VE1 3.5L)
CONTENTS
Air Cleaner Element...............................................
Removal ...............................................................
6J-1
6J-2
6J-2
Inspection .............................................................
Installation.............................................................
6J-2
6J-2
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.

parts and systems.
6J-2 INDUCTION (6VE1 3.5L)
Air Cleaner
Removal
Installation
1. Remove positive ventilation hose connector.
1. Install air cleaner housing.

NOTE: The air cleaner filter is not damaged with the
edge to an air cleaner housing.
2. Remove MAF and IAT sensor.

4. Remove air cleaner housing.
RTW46JSH000101
P1010024
2. Attach the mass air cleaner duct cover to the body

completely, then clamp it with the clip.
Inspection
3. Install MAF and IAT sensor.
Check the air cleaner filter for damage or dust clogging.

Replace if it is damaged, or clean if it is clogged.
4. Install positive
connector.
crankcase
ventilation
hose
Cleaning Method
Tap the air cleaner filter gently so as not to damage the
paper filter, or clean the element by blowing with
compressed air of about 490 kPa (71 psi) from the
clean side if it is extremely dirty.
P1010024
130RW002
No. TF6VE-WE-0431
WORKSHOP MANUAL
TF SERIES
ENGINE
C24SE
SECTION 6
ENGINE DIAGNOSIS (C24SE) 6-1
SECTION 6
ENGINE DIAGNOSIS
CONTENTS
PAGE
Engine Diagnosis............................................................................................................... 6- 2
Hard Starting ................................................................................................................. 6- 2
Engine Compression Test Procedure ......................................................................... 6- 3
Rough Engine Idling or Engine Stalling...................................................................... 6- 4
Rough Engine Running ................................................................................................ 6- 5
Hesitation....................................................................................................................... 6- 6
Engine Lacks Power ..................................................................................................... 6- 7
Engine Noisy ................................................................................................................. 6- 8
Abnormal Noise Due to Hydraulic Lash Adjustor ...................................................... 6- 9
Troubleshooting Procedure ......................................................................................... 6- 9
Abnormal Combustion.................................................................................................. 6-11
Engine Oil Consumption Excessive ............................................................................ 6-12
Fuel Consumption Excessive ...................................................................................... 6-13
Oil Problems.................................................................................................................. 6-13
Engine Oil Pressure Check .......................................................................................... 6-13
Malfunction Indicator Lamp ......................................................................................... 6-14
6-2 ENGINE DIAGNOSIS (C24SE)
Engine Diagnosis
Hard Starting
1.Starting Motor Does Not Turn Over
Trouble Shooting Procedure
Turn on headlights and starter switch.
Condition
Headlights go out or dim
considerably
Possible cause
Battery run down or under
charged
Terminals poorly connected
Starting motor coil circuit shorted
Starting motor defective
Correction
Recharge or replace battery
Clean battery posts and terminals
and connect properly
Overhaul or replace
Overhaul or replace
2.Ignition Trouble - Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect a high tension cable from any spark plug.
Connect the spark plug tester (use commercially
available tool), crank the engine, and check if a spark is
generated in the spark plug tester. Before cranking the
engine, make sure that the spark plug tester is properly
grounded. To avoid electrical shock, do not touch the
high tension cable while the engine is running.
Condition
Spark jumps across gap
Possible cause
Spark plug defective
Spark plug wire in correct
Ignition timing incorrect
Fuel not reaching fuel injector(s)
or engine
No sparking takes place
Ignition coil disconnected or

broken
Electronic Ignition System with
module
Poor connections in engine
harness
Engine Control Module cable
Correction
Clean, adjust spark gap or replace
Refer to Ignition System
Refer to item 3 (Trouble in fuel
system)
Adjust
Refer to item 4 (Engine lacks
compression)
Replace
Correct
Correct or replace

3.Trouble in Fuel System
Condition
Starting motor turns over and
spark occurs but engine does not
start.
Possible cause
Fuel tank empty
Correction
Fill

Fuel filter clogged
Fuel pipe clogged
Fuel pump defective
Fuel pump circuit open
Evaporative Emission Control
system circuit clogged
faulty
Clean
Replace filter
Clean or replace
Replace
Correct or replace
Correct or replace
Possible cause
Spark plug loosely fitted or spark
plug gasket defective
Spark plug wire incorrect
Cylinder head gasket defective
Valve stem seized
Valve spring weakened
Cylinder or piston rings worn
Piston ring seized
Correction
Tighten to specified torque or
replace gasket
Adjust
Replace gasket
Lap valve
Replace
Overhaul engine
Overhaul engine.
Refer to "Electronic Fuel Injection"

section
4.Engine Lacks Compression

Condition
Engine Compression Test Procedure

1.
Start and run the engine until the engine

reaches normal operating temperature.
2.
Turn the engine off.
3.
Remove all the spark plugs.
4.
Remove ignition coil fuse (15A) and disable the

ignition system.
5.
Remove the fuel pump relay from the relay and

fuse box.
6.
Engage the starter and check that the cranking

speed is approximately 300 rpm.
7.
Install cylinder compression gauge into spark

plug hole.
8.
With the throttle valve opened fully, keep the

starter engaged until the compression gauge
needle reaches the maximum level. Note the
reading.
9.
Repeat the test with each cylinder.

The pressure difference between the individual
cylinders should not exceed 100kPa (14.5 psi).
Rough Engine Idling or Engine Stalling

Condition
Trouble in emission control

system
Possible cause
Idle air control valve defective
Throttle shutting off incomplete
Throttle position sensor circuit
open or shorted
Fuel injector circuits open or
shorted
Fuel injectors damaged
Manifold Absolute Pressure
Sensor cable disconnected or
broken
Sensor defective
Sensor cable disconnected or
broken
Sensor defective
Intake Air Temperature sensor
cable disconnected or broken
Intake Air Temperature sensor
defective
Knock Sensor (KS) circuits open
or shorted
KS defective
KS Module circuits open or
ground
KS Module defective
Vehicle Speed Sensor circuit open
or shorted
Vehicle Speed Sensor defective
Canister purge solenoid circuit
open
Canister purge solenoid defective
Evaporative Emission Canister
Purge control valve defective
Others

Idle air control valve broken
Correction
Replace
Correct or replace
Correct or replace
Correct or replace
Replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Replace
Correct
Replace
Replace
Refer to Hard Start
Troubleshooting Guide
Refer to Hard Start
Lap valve
Readjust
Replace
Rough Engine Running

Condition
Engine misfires regularly
Engine knocks regularly

Engine lacks power
Possible cause
Ignition coil layer shorted
Spark plugs fouling
Spark plug(s) insulator nose
leaking
Fuel injector(s) defective
Spark plugs running too hot
Powertrain control module faulty
Spark plugs fouled
Fuel injectors defective
(MAP)
Sensor or Manifold Absolute
Pressure Sensor circuit defective
Sensor or Engine Coolant
Temperature Sensor circuit
defective
Engine Control Module faulty
Intake Air Temperature Sensor or
Intake Air Temperature Sensor
circuit defective
Throttle Position Sensor or
Throttle Position Sensor circuit
defective
Knock Sensor or Knock Sensor
circuits defective
Knock Sensor Module or Knock
Sensor Module circuits defective
Correction
Replace
Clean or install hotter type plug
Replace
Replace
Replace
Install colder type spark plugs
Replace
Clean
Replace
Correct or replace
Correct or replace
Replace
Correct or replace
Correct or replace
Correct or replace
Correct or replace
Hesitation
Condition
Hesitation on acceleration

(Fuel pressure too low)

(Fuel injector not working
normally)
Possible cause
adjustment incorrect
open or shorted
Excessive play in accelerator
linkage
(MAP) Sensor circuit open or
shorted
MAP Sensor defective
Knock Sensor (KS) Circuit open or
shorted
KS defective
KS Module circuits open or
shorted
KS Module defective
Fuel tank strainer clogged
Fuel pipe clogged
Fuel filter clogged
Defective fuel pump system
Fuel Pressure Control Valve
leaking
Power supply or ground circuit for
shorted or open
Cable of Multiport Fuel Injection
System disconnected or defective
open or shorted
Sensor defective
MAP Sensor cable open or
shorted
MAP Sensor defective
IAT Sensor circuit open or shorted
KS Circuit open or shorted
KS defective
KS Module circuit open or shorted
KS Module defective
Throttle valve not wide opened
Power supply voltage too low
Correction
Correct or replace
Adjust or replace
Correct or replace
Replace
Correct or replace
Correct or replace
Replace
Correct or replace
Replace
Replace
Clean or replace
Clean or replace
Replace
Check and replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Correct or replace
Replace
Engine Lacks Power

Condition
Trouble in intake or exhaust

system
Possible cause
Fuel Pressure Control Valve not
working normally
Fuel pipe clogged
Fuel filter clogged or fouled
Fuel pump drive circuit not
working normally
Fuel tank not sufficiently breathing
due to clogged Evaporative
Emission Control System circuit
Inferior quality fuel in fuel system
Engine Control Module supplied
poor voltage
Throttle Position Sensor cable
disconnected or broken
Sensor not working normally
Intake Air Temperature sensor not
working normally
Sensor defective
Air duct kicked or flattened
Ignition failure
Heat range of spark plug

inadequate
Electronic Ignition System with
module
Correction
Replace
Clean or replace
Clean
Replace
Correct or replace
Clean or replace
Clean
Use fuel of specified octane rating
Correct circuit
Correct or replace
Replace
Replace
Replace
Correct or replace
Replace
Replace
Correct or replace
Refer to Hard Start
Install spark plugs of adequate
heat range
Replace

Condition
Engine overheating
Possible cause
Level of Engine Coolant too low
Thermo switch or fan motor
defective
Engine Coolant pump defective
Radiator clogged
Radiator filter cap defective
Level of oil in engine crankcase
too low or wrong oil in engine
Resistance in exhaust system
increased
open or shorted
Cylinder head gasket damaged
Cooling Fan clutch defective
Fan belt slipping
Engine overcooling

Others
Tire inflation pressure abnormal

Brake drag
Clutch slipping
Level of oil in engine crankcase
too high
Correction
Replenish
Replace
Replace
Correct or replace
Clean or replace
Replace
Change or replenish
defective parts
Adjust Wide Open Throttle switch
setting
Correct or replace
Replace
Replace
Adjust tension of V-belt or replace
V-belt
Replace (Use a thermostat set to
open at 92C (197.6F))
Refer to Hard Start
Adjust to recommend pressures
Adjust
Adjust or replace
Correct level of engine oil
Engine Noisy
Abnormal engine noise often consists of various
noises originating in rotating parts, sliding parts and
other moving parts of the engine. It is, therefore,
advisable to locate the source of noise systematically.
Condition
Noise from crank journals or from
crank bearings
(Faulty crank journals and crank
bearings usually make dull noise
that becomes more evident when
accelerating)
Possible cause
Oil clearance increased due to
worn crank journals or crank
bearings
Correction
Replace crank bearings and
crankshaft or regrind crankshaft
and install the over size bearing
Crankshaft out of round

Crank bearing seized
Abnormal Noise Due to Hydraulic Lash Adjuster

Should abnormal noise due to the hydraulic lash
adjuster trouble be heard immediately after the engine
is started, inspect as follows:
Condition
Abnormal noise is heard
HLA is spongy
Valve clearance is not zero
Possible cause
Air contaminated
Check ball valve broken
Safety valve in cylinder head
broken
HLA inside stick
Correction
Bleed
Repair
Replace
Replace HLA assembly
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with
defective bearing by listening for abnormal noise that
stops when spark plug is shorted out.
Condition
Noise from connecting rods or
from connecting rod bearings
(Faulty connecting rods or
connecting rod bearings usually
make an abnormal noise slightly
higher than the crank bearing
noise, which becomes more
evident when engine is
accelerated)
Possible cause
Bearing or crankshaft pin worn
Correction
Replace connecting rod bearings
and crankshaft or regrind
crankshaft and install the under
size bearing
Crankpin out of round

size bearing
Correct or replace
size bearing
Connecting rod bent

Connecting rod bearing seized
Abnormal noise stops when the spark plug on the
cylinder with defective parts is shorted out.
Condition
Piston and cylinder
(Faulty piston or cylinder usually
makes a combined mechanical
thumping noise which increases
when engine is suddenly
accelerated but diminishes
gradually as the engine warms up)
Possible cause
Piston clearance increased due to
cylinder wear
Correction
Piston seized
Piston ring broken
Piston defective

Condition
Piston pin noise
(Piston makes noise each time it
goes up and down)
Possible cause
Piston pin or piston pin hole worn
Correction
Replace piston, piston pin and
connecting rod assy
The slapping sound stops when spark plug on bad
cylinder is shorted out.
Condition
Timing belt noise
Valve noise
Crankshaft noise
Engine knocking
Others
Possible cause
Timing belt tension is incorrect
Tensioner bearing defective

Timing belt defective
Timing wheels defective
Timing belt comes in contact with
timing cover
Valve and valve guide seized
Valve spring broken
Valve seat off-positioned
Crankshaft end play excessive
(noise occurs when clutch is
engaged)
Preignition due to use of spark
plugs of inadequate heat range
Fuel too low in octane rating
Wide Open Throttle enrichment
system failure
Selection of transmission gear
incorrect
Engine overheating
Water pump defective
V-belt slipping
Correction
Replace pusher or adjust the
tension pulley or replace timing
belt
Replace
Replace
Replace
Replace timing belt and timing
cover
Replace
Correct
Replace thrust bearing
Install Spark Plugs of adequate

heat range
Replace fuel
Refer to Section 6E
Caution operator or incorrect gear
selection
Refer to "Engine Lacks Power"
Replace
Adjust tension of V-belt or replace
V-belt
Abnormal Combustion
Condition
Trouble in emission control

system

Trouble in cylinder head parts
Possible cause
Fuel pressure control valve
defective
Fuel filter clogged
Fuel pump clogged
Fuel tank or fuel pipe clogged
Power supply cable for fuel pump
loosely connected or defective
Sensor defective
(ECT) Sensor circuit open or
shorted
connector loosely connected
Vehicle Speed Sensor cable
Vehicle Speed Sensor loosely
fixed
Vehicle Speed Sensor in wrong
contact or defective
Engine Control Module cable
Heated Oxygen Sensor circuit
open (If applicable)
Heated Oxygen Sensor defective
(If applicable)
Signal vacuum hose loosely fitted
or defective
ECT Sensor circuit open or
shorted
Evaporative Emission Control
system (If applicable)
Carbon deposits in combustion
chamber
Carbon deposit on valve, valve
seat and valve guide
Correction
Replace
Replace
Clean or replace
Clean or replace
Clean or replace
Replace
Reconnect, correct or replace
Correct or replace
Replace
Correct or replace
Replace
Reconnect
Replace
Reconnect
Correct or replace
Fix tightly
Replace
Correct or replace
Correct or replace
Replace
Correct or replace
Correct or replace
Replace
Refer to Section 6E
Refer to "Engine Lacks Power"
Remove carbon
Remove carbon
Engine Oil Consumption Excessive

Condition
Oil leaking
Oil leaking into combustion

chambers due to poor seal in
valve system
Oil leaking into combustion
chambers due to poor seal in
cylinder parts
Crank case ventilation, Positive

Crankcase Ventilation System
malfunctioning
Others
Possible cause
Oil pan drain plug loose
Oil pan setting bolds loosened
Oil pan gasket broken
Front cover retaining bolts loose
or gasket broken
Head cover retaining bolts loose
or gasket broken
Oil filter adapter cracked
Oil filter attaching bolt loose or
rubber gasket broken
Crankshaft front or rear oil seal
defective
Oil pressure unit loose or broken
Blow-by gas hose broken
Engine/Transmission coupling
area
Valve stem oil seal defective
Correction
Retighten
Replace gasket
Replace
Retighten or replace oil filter
Replace oil seal
Replace hose
Replace oil seal
Replace
Valve stem or valve guide worn

Cylinders and pistons worn
excessively

Rebore cylinder and replace
pistons and others
Piston ring gaps incorrectly

positioned
Piston rings set with wrong side
up
Piston rings sticking
Correct
Piston ring and ring groove worn

Return ports in oil rings clogged
Positive Crankcase Ventilation
Hose clogged
Improper oil viscosity
Continuous high speed driving
and or severe usage such as
trailer towing
Correct
Rebore cylinder and replace
pistons and others
Clean piston and replace rings
Clean
Use oil of recommended S.A.E.

viscosity
Continuous high speed operation
and or severe usage will normally
cause increased oil consumption
Fuel Consumption Excessive

Condition
Others
Possible cause
Mixture too rich or too lean due to
trouble in fuel injection system
Fuel cut function does not act
Misfiring or abnormal combustion
due to trouble in ignition system
Engine idle speed too high
Returning of accelerator control
sluggish
Fuel system leakage
Clutch slipping
Brake drag
Selection of transmission gear
incorrect
Correction
Refer to "Abnormal Combustion"
Refer to "Abnormal Combustion"
Refer to Hard Start or Abnormal
Combustion Troubleshooting
Guide
Reset Idle Air Control Valve
Correct
Correct or replace
Correct
Correct
Caution operator of incorrect gear
selection
Oil Problems
Condition
Oil pressure too low
Oil contamination
Oil not reaching valve system
Possible cause
Wrong oil in use
Relief valve sticking
Oil pump not operating properly
Oil pump strainer clogged
Oil pump worn
Oil pressure gauge defective
Crankshaft bearing or connecting
rod bearing worn
Wrong oil in use
Oil filter clogged
Cylinder head gasket damage
Burned gases leaking
Oil passage in cylinder head or
cylinder body clogged
Engine Oil Pressure Check

1.
Check for dirt, gasoline or water in the engine

oil.
a. Check the viscosity of the oil.
b. Change the oil if the viscosity is outside the
specified standard.
c. Refer to the "Maintenance and Lubrication"
section of this manual.
2.
Check the engine oil level.

The level should fall somewhere between the
"ADD" and the "FULL" marks on the oil level
dipstick.
If the oil level does not reach the "ADD" mark on
the oil level dipstick, engine oil must be added.
Correction
Replace
Correct or replace
Clean or replace strainer
Replace
Correct or replace
Replace
Replace with new engine oil
Replace oil filter
Replace gasket
Replace piston and piston rings or
rebore cylinders
Clean or correct
3.
Remove the oil pressure unit.
4.
Install an oil pressure gauge.
5.
Start the engine and allow the engine to reach

normal operating temperature (About 80C).
6.
Measure the oil pressure.
7.
Oil pressure should be:

150 kPa(21.8 psi) at idle speed.
Stop the engine.
8.
Remove the oil pressure gauge
9.
Install the oil pressure unit.
10.
Start the engine and check for leaks.

The instrument panel "CHECK ENGINE" Malfunction
Indicator lamp (MIL) illuminates by self diagnostic
system when the system checks the starting of
engine, or senses malfunctions.
Condition
"CHECK ENGINE" MIL does not
illuminate at the starting of engine
CHECK ENGINE MIL

illuminates, and stays on
Possible cause
Bulb defective
MIL circuit open
Command signal circuit to operate
self diagnostic system shorted
cable loosely connected,
ECM defective
Deterioration heated oxygen
sensor of internal element
Heated oxygen sensor connector
terminal improper contact
(If applicable)
Heated oxygen sensor lead wire
shorted (If applicable)
Heated oxygen sensor circuit
open (If applicable)
Deterioration engine coolant
temperature sensor of internal
element
sensor connector terminal
improper contact
sensor lead wire shorted
sensor circuit open
Throttle position sensor open or
shorted circuits
Deterioration of crankshaft
position sensor
Crankshaft position sensor circuit
open or shorted
Vehicle speed sensor circuit open
Manifold absolute pressure sensor
Intake air temperature sensor
Fuel injector circuit open or shorted
ECM driver transistor defective
Malfunctioning of ECM RAM
(Random Access Memory) or
Malfunctioning of ECM PROM
(Programmed Read Only Memory)
Correction
Replace
Correct or replace
Correct or replace
Correct or replace
Replace
Replace
Reconnect properly
Correct
Correct or replace
Replace
Reconnect properly
Correct
Correct or replace
Correct or replace
Replace
Correct or replace
Correct or replace
Correct or replace
Correct or replace
Correct or replace
Replace EPROM or ECM
Replace EPROM or ECM
ENGINE MECHANICAL (C24SE) 6A-1
SECTION 6A
ENGINE MECHANICAL
CONTENTS
PAGE
General Description......................................................................................................... 6A- 4
ENGINE PICTORIAL .................................................................................................... 6A- 6
Main Data and Specification ........................................................................................... 6A-11
CRANKCASE VENTILATION SYSTEM ....................................................................... 6A-16
ENGINE ASSEMBLY & LOOSE PARTS ..................................................................... 6A-17
OPERATIONS ON ENGINE AGGREGATES.................................................................... 6A-18
Engine Damping Blocks(Engine without Transmission)......................................... 6A-18
Toothed Belt and Timing Check ............................................................................... 6A-21
Toothed Belt Tension, Adjust .................................................................................... 6A-23
Toothed Belt, Replace ................................................................................................ 6A-24
OPERATIONS ON INSTALLED ENGINE ......................................................................... 6A-26
Gasket, Exhaust Manifold, Cylinder Head ................................................................ 6A-26
Gasket, Intake Manifold, Cylinder Head .................................................................... 6A-26
Seal Ring, Camshaft Housing, Timing Side.............................................................. 6A-27
Seal Ring, Thermostat Housing, Cylinder Head ....................................................... 6A-27
Seal Ring - Front Camshaft Housing, Replace ......................................................... 6A-28
Toother Belt Rear Cover ............................................................................................. 6A-30
Toother Belt Tension Roller ....................................................................................... 6A-31
COMPONENT PARTS ...................................................................................................... 6A-32
Cylinder Head .............................................................................................................. 6A-32
Hydraulic Valve Lifter.................................................................................................. 6A-33
OPERATIONS ON CYLINDER HEAD AND CAMSHAFT HOUSING ............................... 6A-34
Camshaft...................................................................................................................... 6A-34
Camshaft Housing Removal and Installation ........................................................... 6A-35
Cylinder Head .............................................................................................................. 6A-35
Hydraulic Valve Lifers, Replace ................................................................................. 6A-37
Camshaft Housing, Replace....................................................................................... 6A-37
6A-2 ENGINE MECHANICAL (C24SE)
PAGE
Camshaft Housing, Check for Plance Surface ......................................................... 6A-39
Cylinder Head, Removal and Installation .................................................................. 6A-39
Cylinder Head, Disassemble and Assemble ............................................................. 6A-42
Valve, Grind ................................................................................................................. 6A-44
Valve Guide, Ream ..................................................................................................... 6A-44
Valve Seating, Mill....................................................................................................... 6A-45
Cylinder Head, Overhaul............................................................................................. 6A-45
Flywheel ....................................................................................................................... 6A-46
Starter Ring Gear(Manual Transmission) ................................................................. 6A-47
Seal Ring, Crankshaft ................................................................................................. 6A-48
Seal Ring, Crankshaft Rear ........................................................................................ 6A-48
Oil Pan and Bearing Bridge........................................................................................ 6A-49
OPERATIONS ON CRANK DRIVE ................................................................................... 6A-51
Con-Rod Bearing......................................................................................................... 6A-51
Piston with Con-Rod................................................................................................... 6A-51
Con-Rod ....................................................................................................................... 6A-52
Pistion Rings ............................................................................................................... 6A-53
OPERATIONS ON REMOVED ENGINE ........................................................................... 6A-55
Crankshaft ................................................................................................................... 6A-55
Bearing Free Play Measurement................................................................................ 6A-57
Plastigage Method ...................................................................................................... 6A-57
Micrometer and gauge method .................................................................................. 6A-58
Bypass Valve ............................................................................................................... 6A-59
Oil Filter ....................................................................................................................... 6A-59
Oil Pump ...................................................................................................................... 6A-59
Oil Pump Safety Valve ................................................................................................ 6A-60
Oil Pump(Overhaul) .................................................................................................... 6A-60
OPERATIONS ON OIL CIRCULATION ............................................................................ 6A-61
Cylinder Head Safety Valve ........................................................................................ 6A-61
OPERATIONS ON COOLING SYSYTEM ......................................................................... 6A-63
Cooling System, Check for Leakes ........................................................................... 6A-63
Cooling System, Fill Up and Bleed ............................................................................ 6A-63
Refill Coolant ............................................................................................................... 6A-64
Ignition Timing, Check................................................................................................ 6A-64
PAGE
ENGINE EXTERNAL PARTS............................................................................................ 6A-65
Radiator ....................................................................................................................... 6A-65
Thermostat................................................................................................................... 6A-66
Water Pump ................................................................................................................. 6A-66
Coating sealing surfaces with Silicone Grease ....................................................... 6A-67
Alternator ..................................................................................................................... 6A-67
Starter .......................................................................................................................... 6A-67
V-belt Tension of Alternator ....................................................................................... 6A-68
FUEL INJECTION SYSTEM.............................................................................................. 6A-69
Map Sensor.................................................................................................................. 6A-69
Pressure Regulator ..................................................................................................... 6A-69
ECM (Engine Control Module).................................................................................... 6A-69
ECT............................................................................................................................... 6A-70
Idle Air Control(IAC) Valve.......................................................................................... 6A-70
Ignition Coil ................................................................................................................. 6A-70
Crank Position Sensor................................................................................................ 6A-71
FUEL INJECTOR .............................................................................................................. 6A-72
Knock Sensor .............................................................................................................. 6A-72
Oxygen Sensor............................................................................................................ 6A-73
Throttle Valve Position Sensor .................................................................................. 6A-73
Acclelerator Pedal and Cable..................................................................................... 6A-73
Air Cleaner Filter ......................................................................................................... 6A-74
Spark Plug Thread ...................................................................................................... 6A-75
TECHNICAL DATA ........................................................................................................... 6A-76
Recommended Troque Values................................................................................... 6A-87
SPECIAL SERVICE TOOL................................................................................................ 6A-88
GENERAL DESCRIPTION
Engine Cleanliness And Care

An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances
that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal
engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that
proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is
considered standard shop practice even if not specifically stated.
l A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate
the surfaces on initial operation.
l
Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal
bearings are removed for service, they should be retained in order.
At the time of installation, they should be installed in the same locations and with the same mating surfaced as
when removed.
Battery cables should be disconnected before any major work is performed on the engine. Failure to
disconnect cables may result in damage to wire harness or other electrical parts.
The four cylinders of this engine are identified by numbers; cylinders 1, 2, 3 and 4, as counted from crankshaft
pulley.
General Information on Engine Service

The following information on engine service should be noted carefully, as it is important in preventing damage and

contributing to reliable engine performance:
l When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the
oil pick up unit.
l
The 12-volt electrical system is capable of damaging circuits. When performing any work where electrical
terminals could possible be grounded, the ground cable of the battery should be disconnected at the battery.
Any time the intake air duct or air cleaner is removed, the intake opening should be covered. This will protect
against accidental entrance of foreign material into the cylinder which could cause extensive damage when
the engine is started.
Cylinder Block
The cylinder block is made of cast iron. The crankshaft is supported by five bearings. The bearing cap is made of
nodular cast iron.
Cylinder Head
The cylinder head is made of aluminum alloy casting with a spark plug in the center.
Valve Train
Valve system is a single over head camshaft.
The valves clearance adjustment are hydraulic.
Hydraulic valve lifter adjustment, no adjustment necessary.
Intake Manifold
The intake manifold is made of aluminum alloy.
Exhaust Manifold
The exhaust manifold is made of high Si-Mo nodular iron.
Pistons and Connecting Rods

Aluminum pistons are used after selecting the grade that meets the cylinder bore diameter. Each piston has two
compression rings and one oil ring. The piston pin is made of cast hardened steel. The connecting rod bearings are
made of modular cast iron. The connecting rod bearings are made of steel backed with tri-metal babbitt metal.
Crankshaft and Bearings

The crank shaft is made of modular cast iron. Pins and journal are graded for correct size selection for their bearing.
ENGINE PICTORIAL
Front View
4WD OIL PAN
Inlet Side View
4WD OIL PAN
Rear View
4WD OIL PAN
Exhaust Side View
4WD OIL PAN
Top View

Engine - General
Engine type
Combustion chamber type (Volume)

Timing train system
No. of cylinders-bore stroke mm (in)
Bore Spacing(C/L to C/L)
Firing Order
BoreStroke mm (in)
3
3
Total piston displacement cm (in )
Combustion Chamber Volume
No. of piston ring
2
Compression pressure kg/cm (psi/pa)
Ignition timing (BTDC)
Idling speed: rpm(WO/AC,W/AC) A/C off
Valve clearances (At cold)
Intake mm (in)
Exhaust mm (in)
Open at (BTDC) deg
Close at (ABDC) deg
Exhaust valves
Open at (BBDC) deg
Close at (ATDC) deg
Ignition system
Distributor type
Distributor advance type
Spark plug type
Spark plug gap mm (in)
Lubrication system
Lubricating method
Special engine oil (API grade)
2
Oil pressure kg/cm (psi/Pa) rpm
Oil pump type
Oil filter type
Oil capacity lit. (US/UK gal.)
Cooling system
Radiator type
Coolant capacity lit.
(US/UK gal.)
Water pump type
Thermostat
C24SE
Four-cycle, water cooled cross-flow with single over head
camshaft
Micro-computer control, fuel injection
3
Hemispherical (43.3cm )
Belt drive
4-87.5100.0 (3.443.93)
93.0 mm (3.66 in)
1-3-4-2
87.5100.0 (3.443.93)
2,405(146.80)
3
43.3cm
Compression ring: 2, Oil ring: 1
12.2-16.3 (174-232/1200-1600)
No adjustment
825
0 (0) (Hydraulic valve lash adjustment)
0 (0) (
"
)
1730
7630
5830
3530
Fully transistorized battery ignition
Not applicable, Electronic Spark Timing control
Not applicable, Electronic Spark Timing control
RN9YC4
1.0--1.1 (0.039--0.043)
Fully flow pressure circulation
SE, SF, SG or SH grade
4-4.6 (56.9-65.4/400-450)
Gear
Cartridge full flow
4.25
Corrugated fin with reserve tank
2.3 (0.66/0.55)
Centrifugal
Wax pellet with jiggle hole

Engine - General
Fuel system
Fuel pump type
2
Fuel pressure kg/cm (psi/Pa)
Fuel filter type
Air cleaner type
Battery Type/V-Ax No. of units
Alternator
Capacity V-A(W)
Starter
Output V-kW
Exhaust system CO Adjustment
Compression Ratio (with Tolerance)
Cylinder Head Material
Cylinder Block Material
No. of Mounting Points (including trans.)
Engine Installation Angles
-Longitudinal
-Lateral
Overall Dimensions (L W H):
- TF (2.4Litre/2WD)
- TF (2.4Litre/4WD)
Engine Weight
Engine Weight
- TF (2.4Liter/Man)
Camshaft Type
No. of Valves per Cylinder
- Inlet
- Exhaust
Spark Plug Location
Port Arrangement
Working Principle
C24SE
Electronically controlled Multi Port Fuel Injection System
Electric
3.4 (48.4/334)
Dry paper element
34B19L/50D20L
12-90 (1080), 12-100 (1200)
1.4
(1) Applicable to Open Loop System (Not equipped H2OS)
(2) Not applicable to Closed Loop System (Equipped H2OS)
9.6:10.25
Aluminum Alloy (gravity cast)
Cast Iron
3
4 60'
7 50' (towards exhaust side)
610564708mm
610564746mm
140kg
SOHC
1
1
Side
Cross Flow
Spark Ignition 4-stroke

Valve System
Actuation Type
Valve Clearance Adjustment
Valve Rotor Type
Inlet-Valve Material
-Seat Insert Material
Exhaust-Valve Material
-Seat Insert Material
Valve Spring Material
Valve Guide Material
Valve Seal Type
Water Pump
Type
Drive-Material &Type
Bearing Type
Shaft Seal Type
C24SE
Direct-acting Inverted Bucked Tappet
Hydraulic
None
Chromium Alloyed Steel
Sintered Iron
Head: Cr-Mn-Ni Alloyed Shaft: Cr-Si Alloyed &Cr plated
Sintered Iron
GME 06 100-C1
QS 13 MR 00
Lip
C24SE
Centrifugal
HNBR Toothed-belt
Double Row Ball
Mechanical Ceramic
Thermostat-Coolant
C24SE
Bypass
Oil Pump & Filter
C24SE
Gear Pump
Front of Engine
Direct Crankshaft Driven
Full Flow with Bypass for blocked filter
Oil & Oil Reservoir

Reservoir-Description & Location
Reservoir Material
Replacement Oil Fill Volume
-With Filter change
-Without Filter change
Recommended Oil-Run-in
-Service (above-18C)
-Service (below-18C)
Oil Classification
C24SE
1-piece below Engine
Aluminum Alloy (pressure cast)
Type
Type
Location
Drive
Filter Type
Ignition Components
Spark Plugs
Type
No. of Coils &Type
Coil Location
Ignition Lead Type
4.25liters
4.00liters
10W/30SG
10W/40SG
5W/30SG
API&CCMC
C24SE
Conventional
Electronic Spark Control
2 Solid State
Engine-mounted
Inductive (hi-resistance)

Crankshaft
Material
Bearing subjected to End Thrust
Main Bearing-Material &Type
Front Seal-Diameter &Type
Rear seal-Diameter &Type
Crankshaft Balancing
No. of Counterweights
Camshaft
Location
Material
Bearing Material
No. of Bearings Camshaft Drive-Material
&Type
Pistons
Material
Finish & Type
Piston Rings
Function (top to bottom)
-Ring 1
-Ring 2
-Ring 3
Description
-Ring 1
-Ring 2
-Ring 3
Material
-Ring 1
-Ring 2
-Ring 3
Material
Retention
Bearing
Connecting Rod
Material
Bearing-Material &Type
Inlet Manifold
Material
Exhaust Manifold
Description
Material
C24SE
Nodular Cast Iron
Guide Bearing NO.3
Steel Backed Tri-metal Babbitt
35.0mm Lip Seal
90.0mm Micro-lip Seal
Individually Balanced
8
C24SE
Overhead (Cylinder Head)
Grey Cast Iron
Aluminum
200-250 HB5/750
(Camshaft drive type: toothed belt
Camshaft drive material: rubber composite GD380)
C24SE
Aluminum Alloy
Tin-coated Strutless
Compression Ring
Compression Ring
Oil Ring
Rectangular
Taper Face
3-piece (2 Scrapers&1 Expander)
Molybdenum Inlay Nodular Cast Iron
Cast Iron (individually cast)
Steel
Case Hardened Steel
Locked in Rod
Machined in Piston Pin Boss
C24SE
Nodular Cast Iron
Steel Backed Tri-metal Babbitt
C24SE
Aluminum Alloy
C24SE
Dual Take-down
High Si-Mo Nodular Iron
Engine Specification Matrix for destination

04 HEO FOR TF MODEL:
2.4L
VEHICLE MODEL TFR/S
Major Description
VEHICLE TYPE
VEHICLE IDENT. CODE
ENGINE TYPE
FUEL CONTROL SYSYTEM
COMPRESSION RATIO
FUEL OCTANE(ROD)
FUEL TYPE
AUSTRALIA, CHILE,
GULF, NEW
ZEALAND, SAUDI
ARABIA, SOUTH
AFRICA
42
TX
4x4
TY
COLOMBIA, COSTA
RICA, EQUADOR,
GUATEMALA
42
TX
44
TY
BOLIVIA, GENERAL
EXPORT, PERU,
VENEZUELA
42
TX
C24SE
CLOSE LOOP
CLOSED LOOP
OPEN LOOP
9.6:1
91RON
85RON
80RON
UN-LEADED
UN-LEADED
LEADED
HO2
YES
YES
YES
NO
EVAP CANISTER
PURGE CONTROL
SOLENOID
CHECK & RELIEF VALVE
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
ECM
YES
YES
YES
YES
EXHAUST SYSTEM
FRONT PIPE
SILENCER
TWC
YES
YES
YES
NO
CO ADJUSTMENT
NO
Refer to 6A-77
NO
NO
Refer to 6A-77
YES
Refer to 6A-77
CRANKCASE VENTILATION SYSTEM
The Engine Ventilation System passes crankcase vapours, via the Engine Vent Pipe, to the Cam Support Cover,
where separation of oil and exhaust gases occur. The oil drains into the Cylinder Head, via the Camshaft Support.
The gases pass through the Primary and Secondary Vent Hoses to the intake system, and are consumed during
the combustion process.
ENGINE ASSEMBLY & LOOSE PARTS
Loose Parts
1
2
3
4
5
6
7
8
9
Alternator
P/S Pivot Spacer
P/S Adjusting Screw
P/S Adjusting Plate
P/S Adjusting Nut
Alternator & Fan Drive Belt
A/C Compressor Drive Belt
P/S Pump Drive Belt
Tensioner Bolt
10
11
12
13
14
15
16
Tensioner Pulley
Pulley Dust Shield Cover
Pulley Spacer
A/C Compressor Bracket
Pulley Bolt
Fan Pulley
Cooling Fan
Engine Assembly
20 C24SE
OPERATIONS ON ENGINE AGGREGATES

Engine Damping Blocks (Engine Without
Transmission)
Removal
1.
Remove bonnet.
2.
Remove radiator.
3.
Remove air inlet hose.
4.
Remove power steering pump drive belt and power

steering pump from engine.
5.
Remove all cable connections, hoses and lines from

engine.
6.
Remove accelerator cable from inlet pipe.
7.
Remove exhaust pipe from manifold.
8.
Remove lower nine bolts and transmission from engine

block.
9.
Remove clutch slave cylinder and allow to hang free.
10.
Remove starter from engine block.
11.
Remove upper bolts of left and right engine mounting

from damping blocks.
12.
Raise engine slightly.
13.
Remove lower bolts of left and right damping blocks.
14.
Remove damping blocks.

Attach engine to cable, support transmission with car jack and
remove upper transmission fastening bolt.
Press off engine from transmission and lift out of engine
compartment.
Installation
Lower engine into engine compartment and insert guide
bushings on cylinder block into transmission.
Tighten (Torque)
Transmission to cylinder block (M10)
Transmission to cylinder block (M12)
-45 Nm (4.6 kgfm)

-60 Nm (6.1 kgfm)
Installation
1.
Install engine to vehicle and transmission.
2.
Install clutch slave cylinder.
Tighten (Torque)
Transmission to engine block bolts - 76 Nm (7.6 kgfm)
3.
Install left engine damping block to sidemember.
4.
Install left and right engine damping blocks to engine

brackets.
Tighten (Torque)
Engine damper block to sidememebr - 50 Nm (5.1 kgfm)
Engine damper block to engine bracket - 85 Nm (8.6 kgfm)
RTW46ASH000401
5.
Install exhaust pipe to manifold.

6.
Install power steering pump and V-belt.
Adjust
Adjust power steering pump V-belt tension according to the
corresponding operation.
Installation
7.
Install radiator according to the corresponding operation.
8.
Install air inlet hose.
9.
Install all electrical cable connections, hoses and lines to

engine.
10.
Install accelerator cable from inlet pipe.
11.
Install bonnet.
Inspection
1.
Check engine oil level.
2.
Fill up cooling system and bleed according to the

Toothed Belt and Timing Check

Removal
1.
Remove the belts on the bracket for alternator.
2.
Remove the fan.
3.
Remove the V-belt for power steering.
4.
Remove the V-belt for A/C.
5.
Remove the fan belt.
6.
Remove the fan shroud.
7.
Remove the crankshaft pulley while counterholding on

the fastening bolt of toothed belt drive gear.
8.
Remove the toothed belt from cover.
Inspection
1.
Turn the crankshaft in the engine rotational direction

mark(2) so that the notch (1) on the camshaft gear aligns
with the mark on toothed belt rear cover.
2.
Check the timing belt for worn, cracks or oil adhesion.
3.
Check that the cast on the water pump aligns with the
counterpart on cylinder block (arrowed).
4.
The tension of a toothed belt is correctly adjusted when

the pointer and the center of the notch are aligned(I).
The tension of a run-in toothed belt (regardless of
mileage covered) is correctly adjusted when the pointer
is positioned approx. 4mm (0.16 in.) to the left of the
center of the notch(II).
Check the condition of the run-in toothed belt for
suitability for reuse. Only toothed belts of the toothed
belt tension rollers must be replaced and the source of oil
contamination must be eliminated.
Installation
1.
Install the toothed belt to the cover.
2.
Install the crankshaft pulley while counterholding on the

fastening bolt of toothed belt drive gear.
3.
Install the fan shroud.
Tighten(Torque)
Crankshaft pulley bolts - 20 Nm (2.1 kgfm)
4.
Install the fan belt
5.
Install the V-belt for A/C.
6.
Install the V-belt for power steering.
7.
Install the fan.
8.
Install the belts on the bracket for alternator.
Toothed Belt Tension, Adjust

(Engines with toothed belt tension
roller)
Removal
Refer to 6A-21. Toothed Belt and Timing check and removal
steps.
Adjust
1.
Loosen the fastening bolt of the toothed belt tension

roller.
2.
Turn the toothed belt tension roller at adjustment

eccentric (1) in the direction of arrow (counterclockwise),
until pointer (2) comes to the right stop.
3.
If necessary tighten the fastening bolt of toothed belt

tension roller.
4.
Rotate the crankshaft twice (720) in the engine

rotational direction until marks (2) and (1) align again.
5.
Turn the eccentric in the direction of arrow (clockwise)

until pointer (1) and notch (2) are positioned to suit age of
toothed belt.
6.
Rotate the crankshaft twice (720) in the engine

rotational direction again and correct adjustment if
necessary.
Installation
Refer to 6A-21. Toothed Belt and Timing check and installation
steps.
Toothed Belt, Replace

(Engine with toothed belt tension
roller)
Removal
1.
Remove the belts on the bracket for alternator.
2.
Remove the fan.
3.
Remove the V-belt for power steering.
4.
Remove the V-belt for A/C.
5.
Remove the fan belt.
6.
Remove the fan shroud.
7.
Remove the crankshaft pulley while counterholding on

the fastening bolt of toothed belt drive gear.
8.
Remove the toothed belt from cover.
Adjust
Turn the crankshaft in the engine rotational direction to
mark(2).
Align markings on toothed belt and on toothed belt rear cover.
Simultaneously, notch (1) on camshaft gear must align with the
mark on toothed belt rear cover.
Turn the crankshaft slowly and smoothly.
Adjust
Loosen the fastening bolt of the toothed belt tension roller and
turn the adjustment eccentric in the direction of arrow
(clockwise) until pointer (1) comes to the left stop.
Remove the toothed belt.
Installation
1. Install a new toothed belt while keeping tension side taut.
Adjust
Toothed belt tension - see operation " Toothed Belt Tension".
2.
Install the toothed belt to the cover.
3.
Install the crankshaft pulley while counterholding on the

fastening bolt of toothed belt drive gear.
4.
Install the fan shroud.
5.
Install the fan belt.
6.
Install the V-belt for A/C.
7.
Install the V-belt for power steering.
8.
Install the fan.
9.
Install the belts to the bracket for alternator.
OPERATIONS ON INSTALLED ENGINE

SEALING OPERATIONS
Gasket, Exhaust Manifold, Cylinder Head
Removal
1.
Remove front exhaust pipe from exhaust manifold.
2.
Remove exhaust manifold heat shield.
3.
Remove exhaust manifold retaining nut.
4.
Remove exhaust manifold from cylinder head.
Clean
Sealing surfaces.
Tighten (Torque)
Exhaust manifold to cylinder head - 22 Nm (2.2 kgfm)
Front exhaust pipe to exhaust manifold - 25 Nm (2.6 kgfm)
Gasket, Intake Manifold, Cylinder Head
Removal
1.
Remove air intake hose.
2.
Remove drive belt for alternator.
3.
Remove bolt clamping bracket for alternator from intake

manifold.
4.
Remove intake manifold from cylinder head.
Clean
Sealing surfaces
Tighten (Torque)
Intake manifold to cylinder head - 22 Nm (2.2 kgfm)
Clamping bracket for alternator to intake manifold - 25 Nm (2.5
kgfm)
Installation
1.
Install V-belt according to the corresponding operation.
2.
Install air intake hose.
Seal Ring, Camshaft Housing, Timing Side
Removal
1.
Remove front toothed belt cover toothed belt from

camshaft timing gear according to the corresponding
operation.
2.
Remove camshaft housing cover and camshaft timing

gear.
3.
Remove sealing ring by making hole in middle of ring,

turning in self-tapping screw and edging out.
Installation
1.
Install sealing ring by using 5-8840-0451-0 with camshaft

sprocket bolt and washer.
2.
Install coat seal lips of shaft seal ring slightly.
Seal Ring, Thermostat Housing, Cylinder Head
Removal
1.
Open radiator drain tap and collect coolant.
2.
Remove toothed belt rear cover and toothed belt

according to the corresponding operation.
3.
Remove camshaft housing cover.
4.
Remove camshaft timing gear by counterholding

camshaft with a flat spanner.
5.
Remove cable from temperature sensor.
6.
Remove upper inner hex bolts of rear toothed belt cover.
7.
Turn rear toothed belt cover to one side.
8.
Remove thermostat housing.
9.
Remove sealing ring from cylinder head.
Clean
Sealing surfaces in cylinder head and thermostat housing.
Installation
1.
Install sealing ring in recess of cylinder head.

2.
Install cable to temperature sensor.
3.
Install upper bolts of rear toothed belt rear cover.
4.
Install camshaft timing gear then check timing according

to the corresponding operation.
5.
Install camshaft housing cover.
6.
Install toothed belt and front cover.
7.
Fill up and bleed cooling system according to the

Tighten (Torque)
Thermostat housing to cylinder head - 15 Nm/1.5 kgfm.
Seal Ring - Front Camshaft Housing, Replace
Removal
Mark running direction of toothed belt.
Remove toothed belt-see operation Toothed Belt, Replace.
Camshaft housing cover, camshaft pulley-counterhold on hex
of camshaft.
Removal
Screw self-tapping screw into seal ring.
Edge out seal ring.
Installation
Lightly coat sealing lip of seal ring with protective grease.
Install seal ring with 5-8840-0451-0 into camshaft housing-use
screw and washer of camshaft pulley.
Installation
Camshaft pulley-counterhold at hex head of camshaft,
camshaft housing cover.
Toothed belt-see operation Toothed Belt, Replace.
Note operating erection of toothed belt.
Tighten (Torque)
Camshaft pulley to cammshaft-45 Nm (3.7 kgfm)
Tighten (Torque)
Camshaft housing cover to cover to housing-8 Nm (0.8 kgfm)
Toothed Belt Rear Cover

(Engine with toothed belt tension
roller)
Removal
1.
Mark operating direction of toothed belt.
2.
Remove toothed belt according to the operation "Toothed

Belt".
3.
Remove toothed belt tension roller according to the

operation "Toothed Belt Tension Roller ".
4.
Remove fastening bolt while counterholding with 5-88402598-0 (Holding wrench).
5.
Remove toothed belt drive gear while counterholding with

5-8840-2598-0 (Holding wrench).
6.
7.
Remove camshaft pulley while counterholding at hex

head of camshaft.
8.
Remove toothed belt rear cover (arrows) from oil pump

and camshaft housing.
Installation
1.
Install toothed belt rear cover.
2.
Install camshaft pulley while counterholding at camshaft

hex head.
3.
Install camshaft housing cover.
Tighten (Torque)
Toothed belt rear cover to oil pump and camshaft housing - 6
Nm/4 lbf ft.
Camshaft housing cover to housing - 6 Nm (0.6 kgfm).
Camshaft pulley to camshaft - 45 Nm (4.6 kgfm).
4.
Install toothed belt drive gear to crankshaft - 130 Nm

(13.3 kgfm).
5.
Install toothed belt according to the operation "Toothed

Belt".
Toothed Belt Tension Roller
Removal
1.
Mark operating direction of toothed belt.
2.
Remove toothed belt according to the operation "Toothed

Belt.
3.
Remove toothed belt tension roller (1) from oil pump.
Installation
1.
Install toothed belt tension roller and make sure that the
locking lever (1) engages in the guide lugs (arrowed) on
the oil pump housing.
2.
Install toothed belt according to the operation "Toothed

Belt" with paying attention to the operating direction of
toothed belt.
Tighten (Torque)
Toothed belt tension roller to oil pump - 25 Nm (2.5 kgfm)
COMPONENT PARTS
CYLINDER HEAD
(A)
1.
Camshaft Housing Cover
2.
Camshaft Housing
3.
Camshaft
4.
Cylinder Head
(A)
Valve Drive
HYDRAULIC VALVE LIFTER
1.
Hydraulic Valve Lifter
1.
Oil reservoir
2.
Piston with ball head (moving)
3.
Pressure cylinder (fixed)
4.
Check ball
5.
Pressure chamber
6.
Oil feed
OPERATIONS ON CYLINDER HEAD AND CAMSHAFT

HOUSING
Camshaft
Removal
1.
Remove cylinder head according to the corresponding

operation.
2.
Remove camshaft housing from cylinder head and lay

housing on base provided
3.
Remove rear sealing gasket and plate camshaft housing

with taking care not to damage housing.
4.
Remove thrust plate.
5.
Remove camshaft.
6.
Remove front sealing gasket and plate from camshaft

housing with taking care not to damage housing.
Inspection
All parts.
Installation
1.
Install camshaft.
2.
Coat sliding surfaces with molybdenum disulphate paste.
Tighten (Torque)
Thrust plate for camshaft housing - 8 Nm (0.8 kgfm)
Camshaft Housing, Removal and

Installation
Cylinder Head
Important!
Remove cylinder head only from cold engine (room
temperature).
Removal
1.
Remove ground cable from battery.
2.
Open radiator drain tap and collect coolant.
3.
Remove air intake hose.
4.
Remove all cable connections, hoses and lines to the

cylinder head.
5.
Remove accelerator cable on the throttle valve.
6.
Remove V-belt for alternator.
7.
Remove front toothed belt cover according to the

8.
Bring piston of 1st cylinder to TDC and mark the position.
9.
10.
Remove camshaft timing gear after releasing tension on

toothed belt.
11.
Remove upper bolts of rear toothed belt cover.
12.
Remove exhaust pipe from exhaust manifold.
13.
Remove cylinder head after loosening bolts from outside

inwards (at first quarter turn then half turn) in a spiral
pattern.
14.
Remove camshaft housing from cylinder head.
15.
Remove rocker arm, pressure parts and hydraulic valve

lifter adjuster.
Clean
All sealing surfaces, drill holes in cylinder head bolts.
Check cylinder block and cylinder head for plane surface
according to the corresponding operations.
Installation
1.
Install cylinder head sealing with marking "OBEN/TOP"

facing upwards and to right side of engine.
2.
Install cylinder head on cylinder block.
3.
Install hydraulic valve lash adjuster, pressure parts and

rocker arm - molybdenum disulphate paste.
4.
Install camshaft housing-Sealing Compound TB-1207C

or equivalent.
Important!
Use new cylinder head bolts.
Screw in bolts until they rest on cover.
Torque - Angle Method

Cylinder head to cylinder block - 25 Nm (2.5 kgfm)
Further turn angle 90+90+ 90.
Tighten cylinder head bolts from inside outwards. In four
stages in a spiral pattern.
5.
Install rear toothed belt cover onto camshaft housing.
6.
Install toothed belt and apply tension according to the

Tighten (Torque)
Camshaft timing gear to camshaft - 45 Nm (4.6 kgfm)
7.
Install camshaft housing cover and front toothed belt

cover.
8.
Install cable connections, all hoses and lines onto

cylinder head.
9.
Adjust accelerator cable for free of play.
10.
Install V-belt according to the corresponding operation.
11.
12.
Install front exhaust pipe.
13.
Install ground cable onto battery.
14.
Fill up cooling system and bleed according to the

Hydraulic Valve Lifters, Replace
Removal
1.
Remove the spark plug connectors and spark plugs.
2.
Remove the camshaft housing cover.
Removal
3.
Turn the crankshaft at fastening bolt of toothed belt drive

gear in the direction of the engine rotation until the cam
of hydraulic valve lifter being replaced stands vertically.
Removal
4.
Apply 5-8840-0457-0 to the camshaft housing, valve

spring cap and tension valve spring.
Removal
5.
Remove the cam follower from camshaft housing.

Note thrust pieces.
6.
Remove hydraulic valve lifter from camshaft housing.
Camshaft Housing, Replace
Removal
Cylinder head-see operation Cylinder Head. Remove and
Install.
Inspection
All parts, if necessary replace.
When replacing camshaft, always replace all cam followers.
Installation
Insert hydraulic valve lifter (1) in camshaft housing.
Coat sliding surfaces of rocker arm with Mcs, Paste and insert
in camshaft housing.
Adjust
Adjustment of the hydraulic valve liters is not required.
Pretension is provided by the design.
Installation
1.
Remove 5-8840-0457-0 and install the camshaft housing

cover.
2.
Insert the spark plug connectors.
Tighten (Torque)
Guide plate to camshaft housing.
Insert camshaft with MoS2 paste.
Installation
1.
Install the front seal ring in camshaft housing with

5-8840-0451-0.
2.
Install the camshaft housing rear cover.
3.
Install the cylinder head.
Camshaft Housing, Check for Plane Surface
Clean
Sealing surfaces.
Inspection
Check length and width of sealing surface for deformation and
diagnosis for warpage and use straight edge feeler gauge.
Measure
Height of camshaft housing (sealing surface to sealing
surface).
Dimension I: (74.0 mm)
Cylinder Head, Removal and Installation
Important
Only remove cylinder head with engine cold (room
temperature).
Removal
1.
Remove the alternator, power steering and V-belts.
Removal
2.
Loosen the fastening bolts from alternator.
3.
Loosen the lower alternator fastening bolt by swinging

the alternator to the rear.
Removal
4.
Remove the front toothed belt cover.
5.
Remove the toothed belt from camshaft pulley.

See operation "Timing Check and Adjust".
Removal
6.
Remove the camshaft housing cover and camshaft

pulley by counter-holding at the hex head of camshaft.
Removal
7.
Remove the fastening bolts from camshaft housing.
Removal
8.
Remove the exhaust pipe from exhaust manifold.
9.
Loosen the cylinder head bolts spirally from the outside

inwards (first 1/4, then 1/2 revolution).
Removal
1.
Remove the camshaft housing from cylinder head.
2.
Remove the cam followers, thrust pieces and hydraulic

valve lifters.
Note the allocation.
3.
Remove the cylinder head.
Clean
Sealing surfaces, bores and threads of cylinder head bolts.
Inspection
Check cylinder head and cylinder block for plane surfface-see
operations Cylinder Head, Check for Plane Surface and
Cylinder Block, Check for Plane Surface.
Installation
1.
Install the cylinder head gasket.

Mark "OBEN/TOP" on top and turn it towards timing side
of engine.
2.
1
2
3
Place cylinder head on cylinder block.
Installation
1.
Insert the hydraulic valve lifters (3), thrust pieces (2) and
cam followers (1) with MoS2 paste.
Note allocation.
2.
Apply a bead of Sealing Compound TB1207C to sealing

surface of cylinder head.
3.
Install the camshaft housing on cylinder head.
Torque-Angle Method
Cylinder head and camshaft housing with new cylinder head
bolts to cylinder block.
Cylinder head bolts in sequence shown.
Installation
1.
Install the rear toothed belt cover to camshaft housing.
2.
Install the camshaft pulley to camshaft.
3.
Install the camshaft housing cover to housing.
Installation
1.
Install the toothed belt on camshaft pulley.

See operation "Timing Adjust".
2.
Install the front toothed belt cover.
Installation
1.
Install the fastening bolts.
2.
Loosen the lower alternator fastening bolt.
3.
Install the alternator, power steering and V-belts.
Cylinder Head, Disassemble and Assemble
Removal
1.
Remove the hydraulic valve lifters.

Lay aside in installation positions.
2.
Remove the spark plugs, exhaust manifold and intake

manifold from cylinder head.
Removal
1.
Mark valves.
2.
Remove the tension valve springs with 5-8840-2594-0

(1).
3.
Remove valve keepers, valve spring cap and valve

spring.
Removal
1.
Remove the valve and valve stem seal.
2.
Remove the valve spacer ring (1-exhaust) and valve

spring seat (2-intake).
3.
Remove valve from cylinder head.
Clean
Sealing surfaces.
Inspection
Sealing surfaces for plane surface, guides, sliding and bearing
points for wear-see operation Cylinder Head. Overhaul.
Installation
1.
Coat the valves with engine oil and insert in cylinder

head.
2.
Install the valve spacer ring or valve rotator(exhaust) and

valve spring seal(intake).
3.
Push the accompanying assembly sleeve onto valve

stem and coat with engine oil.
4.
Insert a new valve stem seal with 5-8840-2601-0 (1).
5.
Drive the valve stem seal carefully in to stop with light

hammer blow.
Installation
1.
Install the valve springs and valve spring caps.
2.
Install the tension valve springs with 5-8840-2594-0 (1),

valve keeper.
Important!
Note markings made on valves.
Tighten (Torque)
Exhaust manifold and intake manifold with new gaskets to
cylinder head.
Thermostat housing with new seal ring to cylinder head:
Tighten (Torque)
Spark plugs with spark plug wrench to cylinder head.
Installation
1.
Coat hydraulic valves lifters (1) with oil.
2.
Insert them in cylinder head.

Note installation position.
Valve, Grind
Valves can be reused once or twice after regrinding-only if
there are no crater-like burns on the valve cone.
Excessive grinding can cause the upper valve head edge to
become too thin.
Important!
Valve stem protection must not exceed dimension A-use 58840-2596-0.
Do not regrind valve stem ends.
For all valve reworking note that angle of valve head is 44 and
the valve seat 45-see also Technical Data.
Valve, Grind In
Grind-In the valve to improve valve seating.
Grind-In by rhythmically lifting valves and turning uniformly.
Use commercially available grinding tool.
Important!
Use only fine-grained pastes for grinding.
Lubricate valve stem before grinding in.
Clean
After grinding, carefully clean valve and valve soat.
Valve Guide, Ream
Measure
Diameter of valve guide-dial gauge and internal measuring
instrument.
Important!
Valve oversizes are available ex-works.
Oversize identification, on the valve guide and on the valve
stem end with the following specified identificaton
flgures/letters-see also Technical Data.
Size
Identification Mark
Production Customer Service
Normal
0.075 mm
0.150mm
none
1
2
Reamer
K
K1
K2
Ream valve guide from the upper side of the cylinder head to
the next oversize (use 5-8840-2599-0).
After reaming, cross out identification mark and stamp in new
identification mark.
Valve Seating, Mill

Place cylinder head on block of wood.
Inlet and exhaust, Guide Drift and Valve Seat Cutter 5-88402593-0.
Valve seat-45, side face, upper correction-30, side face
(arrows on cutter).
Valve seat width:
Inlet-1.0 to 1.5 mm/0.04 to 0.06 in.
Exhaust-1.7 to 2.2 mm/0.072 to 0.088 in.
Inspection
Valve stem projection-use 5-8840-2596-0.
Important!
If dimension A is exceeded, use new valves.
Check valve stem projection again. If dimension A is
exceeded, replace cylinder head.
Cylinder Head, Overhaul

Cylinder head disassembled.
Valve, Grind
Important!
Ensure that there are no crater-like burns on the valve cone.
Regrinding possible once or twice.
Grinding of valve stem end is not permitted.
Angle at valve head-44
Inspection
Check valve stem projection as shown 5-8840-2596-0.
Valve, Grind in
Lubricate valve stem, use fine-graining grinding paste.
Lift up valve from seat rythmically using valve grinding tool (1)
for distribution of grinding paste.
Inspection
Check contact pattern (I) on valve seat and in cylinder head.
Clean
Valves, valve guides, cylinder head.
Flywheel
Removal
1.
Remove transmission and clutch.
2.
Remove flywheel while locking with 5-88400-446-0.

Flywheel to crankshaft - 65 Nm/6.5 kgfm.+30 to 45
Important!
Use new bolts.
Do not apply grease to the thread.
Installation
1.
Install clutch and transmission.
Component Parts
Flywheel and Ring gear. (Manual Transmission)
Starter Ring Gear (Manual Transmission)
Removal
1.
Remove flywheel according to the corresponding

operation.
2.
Drill starter ring gear underneath tooth gap approx.

8mm/0.30in. deep with 8mm/0.25in. diameter drill.
3.
Separate starter ring gear with chisel on the drilling point.
Installation
1.
Install starter ring gear with inner chamfered edge to

flywheel.
2.
Heat starter ring gear evenly to 180C /356F to 230C

/446F (yellow paint mark)
3.
Install flywheel according to the corresponding operation.
Inspection
Lateral run-out of starter ring gear - max. 0.5mm/0.02in.
Seal Ring, Crankshaft

(Oil Pump Housing)
Removal
1.
Remove toothed belt rear cover according to the

2.
Remove sealing ring by making hole in middle of ring,

turning in self-tapping screw and edging out.
Installation
1
Install the protective sleeve to the crankshaft.
2.
Coat the sealing lip with protective grease.
3.
Install the sealing ring.
4.
Install the sealing ring using 5-8840-0455-0.
5.
Install the rear toothed belt cover and toothed belt

according to the corresponding operations.
6.
Replace the sealing ring with a new one.
7.
Tighten the belt to the crankshaft.
Seal Ring, Crankshaft Rear
Removal
1.
Remove transmission and clutch.
2.
Remove flywheel or flex plate according to the

corresponding operations.
3.
Make hole in middle of sealing ring, turn in self-tapping

screw and edge out.
Installation
1.
Install protective sleeve.
2.
Coat sealing lip with Protective Grease.
3.
Install sealing ring using 5-8840-0459-0 and 5-88402597-0.
4.
Install flywheel, clutch and transmission.
Reassembly
Reassemble clutch assembly.
Disassembly
Disassemble clutch assembly to flywheel using 5-8840-2634-0
Torque Angle-Method
Clutch assembly to flywheel-17.6Nm/1.8 kgfm.
Oil Pan and Bearing Bridge
Removal
1.
Remove the crossmember.
2.
Shift downward the power steering unit

(and front axle [44 model only]).
3.
Loosen fixing bolts.
4.
Remove oil pan from oil pump and cylinder block.
5.
Remove oil intake pipe, oil intake pipe bracket, and oil
baffle plate.
6.
Remove the bearing bridge.
RTW46ASH002801
Clean
Sealing surfaces.
Installation
013RW004
1.
Apply a bead of Sealing Compound, TB120TC or

eguivalent to joint of oil pump.
2.
Apply the recommended light gasket to the oil pan fitting

surface as shown in the illustration.
3.
Install the bearing bridge.
4.
Install baffle plate, or reuse baffle plate.
Caution
Baffle plates can be retrofitted without difficulty - replace baffle
plate.
5.
Install oil intake pipe to oil pump and oil intake pipe
bracket to cylinder block.
6.
Install oil pan and new gasket to cylinder block and insert
bolts with Locking Compound 15 10 177 (90 167 347).
Maximum assembly time including torque check is 10
min.
7.
Return the power steering unit (and front axle [44 model
only]).
8.
Install the crossmember.
Tighten (Torque)
Oil intake pipe to oil pump -8Nm (0.8 kgfm)
Oil intake pipe bracket to cylinder block - 6 Nm (0.6 kgfm)
Oil pan to cylinder block - 8 Nm (0.8 kgfm)
Bearing bridge to cylinder block 8 Nm (0.8 kgfm)
OPERATIONS ON CRANK DRIVE

Con-Rod Bearing
Removal
1.
Remove oil pan and bearing bridge according to the

2.
Remove con-rod bearing cap and con-rod bearing after

marking both sides.
Clean
Con-rod journal, con-rod bearing cap
Installation
1.
Install new bearing shafts lightly coated with engine oil.
2.
Install con-rod bearing cap.
Torque-Angle Method
Con-rod bearing cap to con-rod - 35Nm (3.5 kgfm) +45 to
60
Important!
Use new bolts.
3.
Install oil pan and bearing bridge according to the

Piston with Con-Rod
Removal
1.
Remove cylinder head and oil pan according to the

2.
Remove piston with con-rod after marking con-rod

bearing cap.
Inspection
Remove and install all parts, if applicable.
Important!
Ring gap offset:
Piston rings - 180.
Oil scraper rings - 25 to 50 mm/1 to 2 in. from gap of
intermediate ring to the left and to the right.
Installation
1.
Install piston with con-rod by inserting with engine oil.
2.
Coat piston rings with engine oil and compress with

piston ring compressor.
Important!
Installation position:
Arrow / notch on piston head on timing side of engine
Beads on con-rod on clutch side
Torque-Angle Method
Piston to cylinder block.
Con-rod bearing cap to con-rod-35Nm (3.5 kgfm) +45 to 60
Important!
Use new bolts.
Installation
1.
Install oil pan and cylinder head according to the

2.
Install sealing Gasket or replace if damaged.
3.
Install camshaft housing to cylinder head.
4.
Install cylinder head according to the corresponding

operation.
Con-Rod
Removal
1.
Remove piston with con-rod according to the

2.
Disassemble con-rod piston assembly by pressing out

piston pin, using 5-8840-0468-0.
Installation
1.
Slide guide drift (5-8840-0468-0) in horizontal position

through piston and con-rod as far as side plate stops.
2.
Tighten bolts evenly so that the piston rests flush on the

rear plate.
3.
Remove centre piece from guide drift and insert piston

bolts (lubricated) into guide drift.

4.
Heat a new con-rod to 280C in the oil bath.
5.
Install the con-rod to the piston and insert the piston pin.
Important!
Since the con-rods have no weight balancing studs, re-working
is not possible.
Exchange con-rods in sets only.
Installation position, beads on con-rod point to the flattening on
the piston pin eye.
Firmly seated piston pin cannot be pushed in. Carry out
installation quickly.
Piston Rings
Removal
1.
Remove piston with con-rod according to the

2.
Remove piston rings using commercially available ring

installer or piston ring clamp pliers.
Clean
Piston ring grooves - ground piece of old piston ring
Inspection
Piston ring gap
For piston ring sizes, permissible piston ring gaps - see
"Technical Data"
Installation
RTW46ASH002401
1.
Install oil scraper ring.
2.
Offset ring gaps of steel band rings each 25 to 50 mm/1

to 2in. to the left or right of the intermediate ring gap.
3.
Install piston rings.
4.
Offset ring gaps by approx. 180.
5.
Install second piston ring with identification mark "TOP"

facing upwards.
6.
Install piston with con-rod according to the corresponding

operation.
OPERATIONS ON REMOVED ENGINE

Crankshaft
Removal
1.
Mount the engine on an engine overhaul stand with

appropriate adapters.
2.
Remove the aggregates, flywheel/drive disc, oil pan,

bearing bridge and oil pump according to the
3.
Mark the con-rod bearing cover.
4.
Remove the crankshaft bearing cover.
5.
Remove the crankshaft from cylinder block.
Inspection
Remove and install all parts if necessary.
Crankshaft pulse pickup sensor rotor inspection and repair.
Inspect the crankshaft pulse pickup sensor rotor for excessive
wear and damage.
Replace the crankshaft pulse pickup rotor if the inspection
results exceed wear and damage limits.
Installation
1.
Install the crankshaft pulse pickup sensor.

Torque: 13Nm (1.3 kgfm)
2.
Install new bearing shells into the cylinder block and

bearing cover.
3.
Coat the bearing shafts with engine oil.

For oversizes-see Technical Data
4.
Install a new crankshaft into the cylinder block.
Note
The sealing of the crankshaft can be corrected with light
blows with a rubber hammer on the crank arm (arrowed).

5.
Apply a bead of sealant (TB-1207C or equivalent) in the

grooves of both bearing shells.
Important!
After installation of bearing cover, press in sealing compound
again from above, until compound emerges at the joints.

Bearing cover to cylinder block - 50 Nm (5.1 kgfm) +40 to
50
Con-rod bearing cover to con-rod - 35 Nm (3.5 kgfm) +45 to
60.
Use new bolts.
6.
Install oil pump, oil pan, bearing bridge rear crankshaft

sealing, flywheel/drive plate, and aggregates according to
the corresponding operations.
Inspection
Bearing play - bearing cover removed
Measure
With "Plastigage" (ductile plastic threads)
Cut threads to length of bearing width and lay axiaity between
crankshaft journal and bearing shell (arrowed).
Install bearing cover with correct torque.
Important!
Grease crankshaft journal and lubricate bearing shell slightly
so that the thread does not tear when the bearing cover is
moved.
Crankshaft
Inspection
End play when bearing shells are installed.
Front end contact surfaces of flywheel/flexible plate.
Permissible end play - see "Technical Data "
Inspection
Out-of-round (run-out)-middle bearing shell removed when
mounting on front and rear bearing.
Permissible out-of-round - see "Technical Data"
Bearing Free Play Measurement

Two methods for measuring bearing free play are described 1. Plastigage method and 2. micrometer and gauge method.
The two procedures are suitable for measuring both con-rod
and main bearing free play.
For both methods ensure con-rod and main bearing caps are
identified (1) prior to removal as they are machine matched.
1.Plastigage Method
Removal
1.
Remove bearing cap and shell.
2.
Lightly coat journals and bearings with engine oil to

prevent Plastigage from tearing when cap is removed.
Installation
1.
Lay a length of Plastigage across width of crank pin and

fit bearing cap and shell using old bolts at this stage.
Important!
Do not allow crankshaft to rotate.

Main bearing cap bolt - 60 Nm (6.1 kgfm) +40 + to 50.
Con-rod bearing cap bolts - 35 Nm (3.6 kgfm) +45.
Removal
1.
Remove bearing cap and shell.
Measure
Width of Plastigage -use scale supplied with Plastigage.
If con-rod bearing clearance exceeds 0.031mm/0.001in or
main journal bearing clearance exceeds 0.04mm/0.02in. check crankshaft journal diameters - see corresponding
operation.
Replace bearing if crankshaft is within specification - see
"Technical Data"
Clean
Plastigage from journals.
Lightly coat journals and bearings with engine oil.
Installation
Install bearing cap and shell using new bolts.

Main bearing cap bolt - 60 Nm (6.1 kgfm) +40 to 50.
Con-rod bearing cap bolts - 35 Nm (3.9 kgfm) +45.
2.Micrometer and gauge method.

Crankshaft removed.
Installation
1.
Install caps and bearing shells to con-rods and cylinder

block.
Measure
Con-rod and main bearing diameters at three points I, II, III
(arrowed).
Divide the sum of the three measurements by three to obtain a
mean diameter.
The top illustration shows con-rod measuring points.
The second illustration shows main bearing measuring points.
Measure
Crankshaft main and con-rod bearing journals at points I and
II. Divide the sum of both measurements to obtain a mean
diameter.
Crankshaft must be replaced if mean diameter of main or conrod journals is below specified limit - see "Technical Data".
If crankshaft is serviceable subtract crankshaft mean journal
diameters from corresponding shell bearing mean diameters to
determine bearing clearance.
Permissible main bearing clearance - 0.015 to 0.04mm/0.0006
to 0.002in.
Permissible con-rod bearing clearance - 0.006 to
0.031mm/0.002 to 0.001in.
Bypass Valve
Removal
1.
Remove oil filter.
2.
Remove bypass valve by cutting thread in locking disc

with M 10 tap (3rd stage), turning in M 10 bolt and taking
out bypass valve from seating.
Installation
1.
Install bypass valve using drift (diameter approx.

15mm/0.6in.).
Oil Filter
Removal
1.
Remove oil filter using commercially available tool.
Installation
1.
Install oil filter by hand and oil seal ring.
2.
Fill up engine oil while preventing overflow.
Oil Pump
Removal
1.
Remove rear toothed belt cover, and oil pan according to

the corresponding operations.
2.
Remove oil filter, wiring plug from oil pressure switch, oil
pump from cylinder block, and oil pressure switch from
oil pump.
Clean
Sealing surfaces
Installation
1.
Install oil pressure switch to oil pump, oil pump to cylinder

block, oil pan, bearing bridge wiring plug, oil filter and
toothed belt cover.
Tighten (Torque)
Oil pressure switch to oil pump - 30 Nm (3.2 kgfm)
Oil pump to cylinder block - 6 Nm (0.6 kgfm)
Oil intake pipe to oil pump - 8 Nm (0.8 kgfm)
Intake pipe bracket to cylinder block - 8 Nm (0.8 kgfm)
*Insert bolts with Locktite (Refer to General Description
Recommended Liguid Gasket)
Oil Pump Safety Valve
Removal
1.
Remove closure plug.
2.
Remove seal ring.
3.
Remove spring.
4.
Remove piston.
Installation
1.
Install piston (observe installation position).
2.
Install spring.
3.
Install seal ring.
4.
Install closure plug.
Tighten (Torque)
Closure plug - 30 Nm (3.0 kgfm)
Oil Pump (Overhaul)
Removal
1.
Remove oil pump according to the corresponding

operation.
2.
Remove oil cover and pressure control valve.
Inspect
Clearance between gear pair and housing upper edge - see
Technical Data.
Check housing, cover and pressure control valve.
Installation
1.
Install pump cover with Sealing Compound 15 03 166 (90

094 714).
2.
Install oil pump safety valve according to the

3.
Install oil pump according to the corresponding operation.
OPERATIONS ON OIL CIRCULATION

Cylinder Head Safety Valve
Removal
1.
Remove cylinder head according to the corresponding

operation.
2.
Make hole in core plugs with pointed drift, turn in self

tapping screw and edge out.
Important!
Cover oil duct in cylinder head with piece of cloth.
3.
Pull out valve retainer, using commercially available tool.
4.
Remove ball and spring.
5.
Cut three threads in the ball seating with M 10 tap (3rd

stage).
6.
Coat tap with grease.
7.
Remove ball seating from cylinder head with

commercially available tool.
Do not damage cylinder head.
Installation
1.
Install new pressure valve into cylinder head - with

suitable pipe until stop.
2.
Install core hole plugs into cylinder head - with suitable

pipe to end of chamfer.
OPERATIONS ON COOLING SYSTEM

Caution!
Before working with the cooling system, be sure to confirm that
the temperature of the engine is cooled down.
Failure to observe this may cause burn.
Cooling System, Check for Leaks
Installation
1.
Install commercially available coolant checking

instrument onto compensation tank (Refer to section 6B;
Engine cooling).
2.
Check coolant level.
Inspection
Use 5-8840-0277-0 tester & 5-8840-2603-0 adaptor.
Cooling System, Fill Up and Bleed
Important!
Radiator and heater core are made from alminium.
To avoid corrosion, use only anti-freeze with corrosion
protection.
Replace Coolant
1.
Confirm the engine is cold enough.
2.
Open the radiator cap, pour coolant to the filler neck level
and close the cap.
3.
Pour coolant into the reservoir until MAX line is reached.
4.
Start the engine, run 2 ~ 3 minutes at idling speed and

switch off the engine.
5.
Refill coolant if the coolant level is lowered.
Important!
Do not loosen or open the radiator cap when coolant is hot.
Doing so may cause hot water or steam to splash out, resulting
in burn. When opening the radiator cap, be sure to confirm the
coolant is cold. Cover a thick cloth over the cap and loosen it
slowly to reduce pressure, then open the cap.
6. Close the radiator cap firmly and run the engine at
approx. 2000 rpm. In addition, set the heater temperature
adjuster to the max position to circulate coolant in the
heater conduit system.
7.
Confirm that the temperature gauge reads half or more

of full scale and that the thermostat is activated.
Then continue idling 5 minutes more and switch off the
engine, and allow it to cool.
8.
After the engine cools down, check the coolant level and
refill it if necessary. When the level is lowered extremely,
check the coolant conduit system and reservoir hose for
leak.
9.
Pour coolant into the reservoir to MAX level.
Refill Coolant
Important!
After closing the cooling system, let engine run warm until
thermostat opens (coolant approx. 92C/197.6F)
Inspection
Coolant level
Allow engine to cool. If necessary, refill coolant.
Check that cooling system self-bleeds during engine warmingup phase.
Ignition Timing, Check
No Adjustment
ENGINE EXTERNAL PARTS

Radiator
Removal
1.
2.
Loosen a drain plug to drain EC.
3.
Disconnect radiator inlet hose and outlet hose from the

engine.
4.
Remove fan guide(1), clips(2) on both sides and the

bottom lock, then remove lower fan guide(3) with fan
shroud(4).
5.
Disconnect the reserve tank hose(6) from radiator.
6.
Remove bracket(5).
7.
Lift up and remove the radiator assembly with hose,

taking care not to damage the radiator core with a fan
blade.
RTW46BSH000101
RTW36BMH000101
Installation
Follow the removal procedure in the reverse order to install the
radiator.
Thermostat
Removal
1.
Remove water outlet nozzles with thermostat from

thermostat housing.
2.
Remove coolant hose and collect coolant.
Important!
Remove and Install thermostat only together with water outlet
nozzles.
Tighten (Torque)
Water outlet nozzles to thermostat housing - 8 Nm (0.8 kgfm)
Installation
1.
Install coolant hose.
2.
Fill cooling system and bleed according to the

Water Pump
Removal
1.
Remove lower hose band from pipe band and collect

coolant.
2.
Remove front toothed belt cover according to the

3.
Remove water pump from cylinder block after releasing

tension on toothed belt.
Clean
Sealing surfaces
Coating sealing surfaces with Silicone Grease
Installation
1.
Install water pump to cylinder block with new rubber Oring.
2.
Apply tension to toothed belt according to the

3.
Install coolant hoses.
4.
Fill cooling system and bleed according to the

Alternator
Removal
1.
Remove ground cable from battery.
2.
Remove cable connection from alternator and V-belt.
3.
Remove alternator from retaining strap and lower

fastening.
Installation
1.
Install alternator by tightening firmly by hand.
2.
Install V-belt and apply tension according to the

3.
Install cable connections to alternator.
4.
Install ground cable to battery.
Starter
Removeal
1.
Remove cable connections from starter.
2.
Remove upper bolt of transmission side.
3.
Remove lower bolt of engine side.
Tighten (Torque)
Starter to cylinder block:
Engine side - 51 Nm (5.2 kgfm)
Transmission side - 75 Nm (7.6 kgfm)
Starter support to cylinder block - 25 Nm (2.5 kgfm)
Re-connect cables.
V-belt Tension of Alternator

Measure
Measure V-belt tension of alternator.
Permitted values for new V-belt are approx. 311-489N (31-50
kgf).
Note:
V-belt to deflection as loaded with 10kg : 8-12mm.
Adjust
Adjust V-belt tension by loosening clamping bracket and lower
alternator bracket and moving alternator.
Tighten (Torque)
Clamping bracket to alternator - 35 Nm (3.6 kgfm)
Lower alternator bracket - 25 Nm (2.6 kgfm)
V-Belt Tension of Power Steering Pump
Measure
Measure V-belt tension of power steering pump. Permitted
values for new belt are approx. 578-712N (59-73 kgf) and 534667N (54-68 kgf) for used belt.
Note:
V-belt to deflection as loaded with 10kg : 8-12mm.
Adjust
Adjust V-belt tension by loosening clamping bolt, lower pump
bracket, and adjusting nuts and moving steering pump.
Tighten (Torque)
Adjusting nuts - 18 Nm (1.8 kgfm)
Clamping bolt - 25 Nm (2.6 kgfm)
Lower pump bracket - 26 Nm (2.6 kgfm)
FUEL INJECTION SYSTEM

MAP SENSOR
Removal
1.
Disconnect the battery cable.
2.
Disconnect the electrical connector from the sensor.
3.
Remove the mounting bolts securing the sensor to the

manifold.
4.
Remove the sensor from the intake manifold.
Installation
1.
Push MAP sensor into the manifold.
2.
Install the mounting bolts and tighten them.
3.
Connect electrical connector.
4.
Connect the battery cable.
Pressure Regulator
Removal
1.
Remove vacuum hose.
2.
Remove fuel hoses.
3.
Remove pressure regulator.
Installation
1.
Install pressure regulator.
2.
Install fuel hoses.
3.
Install vacuum hoses.
ECM (Engine Control Module)
Removal
(2.4L)
1.
Disconnect the ECM connector.
2.
Remove the four hex bolts and nuts.
3.
Remove the ECM from the ECM bracket on engine.
Installation
(2.4L)
1.
Install the ECM to the ECM bracket on engine.
2.
Tighten the four screws to the bracket.
3.
Connect the connector.
ECT
Removal
1.
Remove wiring harness plug and coolant temperature

sensor.
Tighten (Torque)
Temperature sensor to intake pipe - 10 Nm (1.0 kgfm)
Wiring harness plug to temperature sensor
Inspection
Coolant level
Removal
1.
Remove wiring harness plug, hose clamps and idle

speed adjuster.
Installation
1.
Install idle speed adjuster, hose clamps and wiring

harness plug.
Ignition Coil
Removal
1.
Remove 2 bolts, plug and ignition coil.
Installation
1.
Install ignition coil, plug and bolts.
Crank Position Sensor
Removal
1.
Remove crank position sensor.
Installation
1.
Install crank position sensor.
FUEL INJECTOR
Removal
Caution: To reduce the risk of fire and personal injury, it is
necessary to relieve the fuel system pressure before
servicing the fuel system components.
Caution: After relieving the fuel system pressure, a small
amount of fuel may be released when servicing fuel lines
or connections. Reduce the chance of personal injury by
covering the fuel line fitting with a shop towel before
disconnecting the fittings. The towel will absorb any fuel
that may leak out. When the disconnect is completed,
place the towel in an approved container.
1.
Depressurize the fuel system.
2.
Disconnect the fuel inlet.
3.
Disconnect the fuel return line.
4.
Remove the fuel rail from the intake manifold.
5.
Remove the fuel injector from the fuel rail by disengaging

claws.
Installation
1.
Install the fuel injector to the fuel rail by engaging claws.
2.
Install the fuel rail to the intake manifold.
3.
Connect the fuel return line firmly.
4.
Connect the fuel supply line firmly.
Knock sensor
Removal
1.
Remove fixing bolts.
2.
Disconnect the connector at the other side.
Tighten (Torque)
Oxygen sensor in exhaust pipe - 30Nm (3.2 kgfm)
When re-using, insert oxygen sensor.
Oxygen Sensor (If applicable)
Removal
1.
Remove wiring harness plug.
2.
Remove oxygen sensor from the front exhaust pipe.
Tighten (Torque)
Oxygen sensor in exhaust pipe - 30 Nm (3.1 kgfm)
Throttle Valve Position Sensor
Removal
1.
Remove wiring harness connector.
2.
Remove throttle valve position sensor.
Installation
1.
Install throttle valve position sensor.
2.
Install wiring harness connector.
Accelerator Pedal and Cable
Removal
1.
Remove pad stopper from pedal stop bolt.
Installation
1.
Install pad stopper.
Inspection
Ensure that accelerator pedal is fully in idle position and
accelerator level at engine is in closed position.
Pull outer sleeve of accelerator cable towards pedal and check
that clip on sleeve is in slot nearest to grommet.
Reposition clip if necessary, and check that full throttle and idle
positions are obtained at engine lever.
Air Cleaner Filter

NOTE:
The air cleaner filter is not damaged with the edge of the air
cleaner housing.
Removal
(2.4L)
RTW46JSH000101
1.
Remove air cleaner cover and air cleaner element.
2.
Remove air intake nose.
3.
Remove lower air cleaner.
4.
Remove mud guard.
5.
Remove front fender cover.
6.
Remove outside air intake duct.
Inspection
Cleaning Method
Tap the air cleaner filter gently so as not to damage the paper
filter, or clean the element by blowing with compressed air of
about 490 kPa (71 psi) from the clean side if it is extremely
dirty.
Installation
(2.4L)
130RW002
1.
Install outside air intake duct.
2.
Install front fender cover.
3.
Install mud guard.
4.
Install lower air cleaner.
5.
6.
Install air cleaner element and air cleaner cover.
Spark Plug Thread
Recondition
Ream thread and recut using commercially available spark
plug thread drill (observe manufacturer's instructions).
Removal
Remove thread bush on spark plug. (dimensions (A) =
17mm/0.67in.)
Tighten (Torque)
Spark plug with thread bush into cylinder head - 25Nm (2.5
kgfm) - use.
TECHNICAL DATA
SOHC Gasoline Engine C24SE
Engine Oil Viscosity
The following engine oils can be used:
A = single-grade oils
B = multigrade oils
C = easy run oils
depending on the outside temperature.
Engine Oil Quality

It is important that the following API and CCMC classes are
used:
Engines
Single and multigrade oils
Easy run oils
Petrol
API-SF/CC, SF/CD, SG/CC,

SG/CD, CCMC/G4
API-SF/CC, SF/CD, SG/CD

CCMC-G5/PD2
Important!
CD engine oils designed by manufacturers specially for diesel
engines are not suitable for petrol engines, unless a sufficient
performance class for petrol engines (e.g. API-SF/CCMC-G4)
is also indicated.
Disposal.
Observe the relevant national regulations when disposing of
used oil.
Engine Oil Filling Quantities

Engine Model
2.4L
Initial filling
Filling quantity
(litres)
with filter change*
(litres)
4.80
4.25
MIN to MAX
(litres)
1.00
*Up to mark "MAX" on oil dipstick
Oil Pump
Backlash
Gaps in gears opposite housing
Oil pressure at idle speed
Oil drain plug
M14 1.5
0.1 to 0.2mm
0.03 to 0.1mm
Engine at operating
temperature (>70C oil and
approx. 80C coolant)
450 - 500 kpa
Cooling System
Radiator
Type:
Cross-flow
2
Radiator core surface in cm :
2000
Cooling system capacity (in litres):
7.2
Anti-freeze Mixture
Anti-freeze Mixture
Required
Quantity
Up to-10C
Quantity in litres
Up to-20C
Quantity in litres
Up to-30C
Quantity in litres
Up to-40C
Quantity of litres
(in litres)
Water
(80%)
AntiFreeze
(20%)
Water
(66%)
AntiFreeze
(34%)
Water
(56%)
AntiFreeze
(44%)
Water
(48%)
AntiFreeze
(52%)
7.2
5.7
1.5
4.7
2.5
4.0
3.2
3.4
3.8
Cooling System (continued)

Fan
Type
Number of blades
Distribution of blades
Diameter mm
Visco Clutch Fan

5
asymmetric
Radiator cap
Boiling point
123C
Opening pressure kPa (bar) 120 to 135 (1.20 to 1.35)
Thermostat
Start of opening
Fully opened
Type
92C
107C
Bypassed
Idle Speeds, CO Content, Ignition

Adjustment
Applicable System
Idle speed in min-1 (rpm)

Manual
CO content
in vol. %
Ignition timing in CA BTDC (adjustment

ensues at able speed,
ignition marks must align) with TDC
sensor measuring instrument:
Closed Loop System
825
*<0.4
*** 8 to 12
825
**1.0+0.2
-0.5
*** 8 to 12
Open Loop System
Note) * CO content adjustment not applicable.

** CO content adjustment refer to Section 6E1 (W/O catalytic converter system)
*** Ignition timing adjustment not possible.
Adjustment Values/Checking Values

Valve clearance
Inlet
Outlet
Hydraulic valve lash adjustment

No adjustment necessary
Spark plugs - electrode gap
1.0 ~ 1.1mm
Compression
The difference in compression

between the individual cylinders
in the engine must not exceed
100 kPa (1 bar).
Pressure loss
The pressure loss of an engine

in perfect condition per cylinder
is not more than max. 25%
Cylinder Head
Thickness - installed
mm
1.2
Valve seat width at cylinder head

inlet
outlet
mm
mm
1.0 to 1.5
1.7 to 2.2
Valve stem play inlet

outlet
mm
mm
0.018 to 0.052
0.038 to 0.072
Permissible valve stem to cone runout

inlet
mm
outlet
mm
0.03
0.33
Overall height of cylinder head

(Sealing surface to sealing surface) mm
95.5 0.25
Installation height
inlet and
outlet valves
dimension "A"
Installation height valve guide
mm
17.85 to 18.25
Distance Gauge
5-8840-2596-0
mm
83.50 to 83.80
Sealing surface peak-to-valley height mm
max. 0.025
Cylinder Head (continued)

Valve System
Valve lifter
valve play compensator

(hydraulic)
Valve rotators
(inlet or outlet)
outlet
Valve play
(warm or cold) inlet
outlet
mm
mm
0
0
Cylinder head height

Cylinder head bottom, face parallelism
mm
mm
280.30.075
0.05
Valve Dimensions
A in mm
B in
mm
1)
2)
Inlet valve
104.2
103.8
41.8
Outlet valve
104.0
103.6
36.5
C24SE
C(diameter in mm) and identification mark
Normal K
7.012
6.998
6.992
6.978
7.050
7.030
Oversize K1
0.075
7.087
7.073
7.087
7.053
7.125
7.105
Oversize K2
0.150
7.162
7.148
7.142
7.128
7.200
7.180
Oversize A
0.250
7.262
7.248
7.242
7.228
7.300
7.280
44
44
Valve stem
bore
1) Production
2) Customer service
The P and A department only supplies valves with a length of 103.8mm (inlet valve) and 103.6mm (outlet valve)
only
Camshaft
2.4L
K
Identification letter
Colour code
Normal size
0.1mm undersize
violet
Radial runout
mm
0.03
End play
mm
0.09 to 0.21
Cam lift
Inlet and outlet valve mm
6.67

Grinding Dimension for Camshaft Bearing Position
Bearing
Bearing journal
diameter in mm
normal
-0.1mm
1
42.470
42.370
42.455
42.355
Diameter
in housing
normal
42.525
42.425
-0.1mm
42.500
42.400
42.720
42.705
42.620
42.605
42.775
42.750
42.675
42.650
42.970
42.955
42.870
42.855
43.025
43.000
42.925
42.900
43.220
43.205
43.120
43.105
43.275
43.250
43.175
43.150
43.470
43.455
43.370
43.355
43.525
43.500
43.425
43.400
Crankshaft, Cylinder Block

Cylinder Grinding and Piston Dimensions
Size
Cylinder bore dia. in mm
over
to
Production 1
87.48
87.49
(2.4L)
87.49
87.50
Customer 87.99
88.00
service
(2.4L)
Piston diameter must be measured at the position "D".
*inclusive
Cylinder to Related piston dia. in mm

Crankshaft
housing
co-efficient
over
to
99
87.46
87.47
00
87.47
87.48
0+0.5
87.97
87.98
Piston head
coefficient
99
00
7+0.5
Cylinder Bore
Rebore cylinder
Permissible oversize to 0.5mm (see parts

microfiche)
After reboring, invalidate original crankcase
housing coefficient and drive in new oversize
coefficient
Permissible out-of-round:
0.013mm
Permissible taper:
0.013mm
Measure out-of-round in bore at 4 different
heights
Piston projection above upper edge of cylinder block
0.40mm
Piston
Type
Clearance
Recessed pistons
For short-blocks and cylinder blocks with
complete pistons, the clearance is 0.02 to
0.04mm
For replacement (oversize), depending on
available pistons, a clearance of 0.02 to
0.04mm is permissible
Crankshaft, Cylinder Block (continued)

Piston Rings
Height
mm
2.4L
1.2
Tapered ring Height
mm
1.5
Oil scraper
mm
2.5
Square ring
Height
Ring gap offset
180
Note that the upper steel band ring gap is offset 25 to 50mm to
the left and the lower 25 to 50mm to the right opposite the
intermediate ring gap.
Piston Pin
Length
Diameter
Type
Play
in piston
in con-rod
Installation
mm
mm
mm
61.5
21
Shrunk into con-rod
2.4L
0.010-0.015
none
When installing piston pins,
heat con-rods to approx.
280C in oil bath. This
temperature should under no
circumstances be exceeded.

The permissible weight variation of con-rods without piston and
bearing shell inside an engine is 8 g.
As the con-rods do not have balancing studs, reworking is not
possible.
Con-rods can only be replaced in sets.

Crankshaft
jounal
I, II, IV, V
Guide
bearing
III
Diameter
mm
Widtht
mm
Con-rod journal
1 to 4
Diameter
mm
Con-rod width
Width
mm
mm
26.580
26.460
26.390
26.338
Normal size
Bearing journal and colour code
Bearing shell identification mark

Colour code and embossed
from
to
>
to
57.9820 green
57.9885
57.9885 brown
57.9950
25.900
25.850
Crankshaft bearing
I, II, IV, V
Guide bearing
III
brown-662N
green-663N
brown-655N
green-658N
Crankshaft
jounal
I, II, IV, V
Guide
bearing
III
Diameter
mm
Widtht
mm
Identification mark
48.988
48.970
Con-rod bearing
1 to 4
Con-rod journal
1 to 4
Diameter
mm
Width
mm
Con-rod width
mm
0.25mm Undersize for Production and Customer Service


Identification mark
from
to
>
to
57.7320 green/
57.7385 blue
57.7385 brown/
57.7450 blue
26.580
26.460
26.100
26.050
48.738
48.720
Crankshaft bearing
I, II, IV, V
Guide bearing
III
Con-rod bearing
1 to 4
brown/blue-664 A
green/blue-655 A
brown/blue-657 A
green/blue-658 A
Crankshaft
jounal
I, II, IV, V
Guide
bearing
III
Diameter
mm
Widtht
mm
Con-rod journal
1 to 4
Diameter
mm
Width
mm
Con-rod width
mm
0.50mm Undersize Customer Service


Identification mark
from
to
>
to
57.4820 green/
57.4885 blue
57.4885 brown/
57.4950 blue
26.300
26.250
48.488
48.470
Crankshaft bearing
I, II, IV, V
Guide bearing
III
Con-rod bearing
1 to 4
brown/white-666 B
green/white-667 B
brown/blue-659 B
green/blue-660 B
26.580
26.460
Piston Pins
Dimensions
Length
Diameter
Type
Clearance
In piston
In con-rod
Installation
mm
mm
mm
mm
61.5
21
Shank-fit in con-rod
2.4L
0.010 to 0.015
0
See operation Con-rod, Replace
Con-rod
Permissible, weight variation of con-rods without pistons and bearing shells within an engine 8 g.
As the con-rods have no counterweights, re-working is not possible.
Con-rods must be replaced only as a set.
Crankshaft Grinding Dimensions
Crankshaft
bearing journals
Guide bearings
III
Con-Rod bearing journals

1 to 4
Con-rod
I, II, III, IV, V
diameter in
mm/colour code
width
in mm
diameter
in mm
width
in mm
width
in mm
Standard Size for Production and Service

from 57.974
to
white
57.981
26.002
25.950
48.988
48.970
26.580
26.450
26.390
26.338
over 57.981
green
to
57.988
over 57.988
brown
to
57.995

Crankshaft and con-rod journal Permissible out-of-round:
0.04mm
Out-of-round
Permissible variation of
middle crankshaft bearing
journal when seating shaft into
cylinder block: 0.03mm
Permissible end play
0.05 to 0.152mm
Permissible main bearing play
Bearing I to V0.015 to
0.04mm
Permissible con-rod play
0.006 to 0.031mm
Permissible con-rod and play
0.07 to 0.24mm

Flywheel
Starter ring gear
Before fitting, heat ring gear to 180C 230C
Lateral run-out
Permissible lateral run-out of installed

starter ring gear to flywheel: 0.5mm
Precision turning
Permissible removal of material in clutch

disc lining surface area: 0.3mm
In order to achieve the functional
relationship again after removal of material,
the same removal of material must take
place on the fore part of the flywheel
(contact for clutch assembly)
Dimension A: 2.1 to 2.2mm

Cylinder block
Top deck flatness
mm
Cylinder block height mm
0.05
2710.075
Recommended Torque Values

Nm (kgfm)
Bearing cover to cylinder block .......................................................................................
Bracket for alternator to cylinder block ............................................................................
Bracket for engine damping block to transmission .........................................................
Bracket for engine damping block to engine block .........................................................
Bracket for pump/compressor to engine block ...............................................................
Camshaft housing cover to housing ................................................................................
Camshaft timing gear to camshaft ..................................................................................
Clamping bracket for alternator to intake manifold .........................................................
Clamping bracket to alternator ........................................................................................
Con-rod bearing cap to con-rod ......................................................................................
Crankshaft pulley bolts ....................................................................................................
Cylinder head to cylinder block ........................................................................................
1)
60
40
2)
60
60
35
8
50
25
25
1)
35
20
1)2)
25
+90
Engine damping block to engine bracket ........................................................................
8.5
1)
Engine damping block to side member ........................................................................... 52
Exhaust manifold to cylinder head .................................................................................. 22
6.1
4.1
6.1
6.1
3.6
0.8
5.1
2.5
2.5
3.5
2.0
2.5
+40 to 50
+45 to 60
+90 +90
8.7
5.3
2.2
1) Use new bolts

2) Use new locking plates
Recommended Torque Values

Nm (kgfm)
1)
Flywheel to crankshaft ..................................................................................................... 65

Front exhaust pipe to exhaust manifold .......................................................................... 25
Guide sleeve for pressure bearing to transmission ......................................................... 22
Intake manifold to cylinder head ...................................................................................... 22
Lower alternator bracket ................................................................................................. 25
Oil drain plug to oil pan .................................................................................................... 45
2)
Oil intake pipe bracket to cylinder block ..........................................................................
6
Oil intake pipe to oil pump ...............................................................................................
8
2)3)
Oil pan to cylinder block ..................................................................................................
8
2)3)
Bearing bridge to cylinder block ......................................................................................
8
Oil pressure switch to oil pump ....................................................................................... 30
Pump for power steering (ribbed V-belt) to engine block ................................................ 30
Spark plugs in cylinder head ........................................................................................... 20
Starter support to cylinder block ...................................................................................... 25
Starter to cylinder block - engine side ............................................................................. 45
Starter to cylinder block - transmission side .................................................................... 75
Thermostat housing to cylinder head .............................................................................. 15
1)
Toothed belt drive gear to crankshaft .............................................................................. 130
Toothed belt front cover ..................................................................................................
4
Toothed belt rear cover ...................................................................................................
6
Toothed belt tension roller to oil pump ............................................................................ 20
(M10) ............................................................................ 45
Transmission to engine block ......................................................................................... 76
(M12) ............................................................................ 60
Water pump to cylinder block .......................................................................................... 17
1) Use new bolts
2) Use Locking Compound
3) Maximum installation time - 10 minutes
6.6 +30 to 45
2.5
2.2
2.2
2.5
4.6
0.6
0.8
0.8
0.8
3.2
3.2
2.3
2.5
4.6
7.6
1.5
13.3
0.4
0.6
2.3
4.6
7.7
6.1
1.7

ITEM NO.
ILLUSTRATION
PART NO.
PART NAME
5-8840-2634-0
Aligner
5-8840-2593-0
Cutter set
5-8840-2594-0
Spring Compressor
5-8840-0451-0
Installer
5-8840-0452-0
Remover / Installer
5-8840-2596-0
Distance Gauge
5-8840-0455-0
Assembly Sleeves
5-8840-2597-0
Installer
5-8840-0457-0
Remover / Installer
5-8840-0468-0
Remover / Installer

ITEM NO.
ILLUSTRATION
PART NO.
PART NAME
5-8840-0459-0
Installer
5-8840-0460-0
Installer
5-8840-0446-0
Flywheel Holder
5-8840-2598-0
Holding Wrench
5-8840-2599-0
Reamer Set
5-8840-2600-0
Socket Wrench
5-8840-2601-0
Installer
MEMO
ENGINE COOLING 6B-1
SECTION 6B
ENGINE COOLING
CONTENTS
PAGE
General Description........................................................................................................ 6B- 2
Service Precaution ......................................................................................................... 6B- 3
Diagnosis......................................................................................................................... 6B- 5
Draining and Refilling Cooling System......................................................................... 6B- 6
Water Pump..................................................................................................................... 6B- 7
Water Pump and Associated Parts........................................................................... 6B- 7
Removal ...................................................................................................................... 6B- 7
Inspection ................................................................................................................... 6B- 7
Installation .................................................................................................................. 6B- 8
Thermostat ...................................................................................................................... 6B- 9
Removal ...................................................................................................................... 6B- 9
Inspection ................................................................................................................... 6B- 9
Installation .................................................................................................................. 6B- 9
Fan clutch with Cooling Fan .......................................................................................... 6B- 9
Inspection and Repair................................................................................................ 6B- 9
Radiator ........................................................................................................................... 6B-11
Radiator and Associated Parts ................................................................................. 6B-11
Removal ...................................................................................................................... 6B-11
Inspection ................................................................................................................... 6B-12
Installation .................................................................................................................. 6B-13
Main Data and Specifications ........................................................................................ 6B-13
Special Service Tool....................................................................................................... 6B-14
6B-2 ENGINE COOLING
General Description
Legend
1 Water Pump
2 Thermostat
3 Radiator
4 Reserve Tank
5 Coolant Distributor
6 Cylinder Block and Head
7 Throttle Body
8 Heater
The Cooling System is a pressurized type, where the water

pump, which is cambelt driven, forces the circulation of
the coolant through the cylinder block and head. The
thermostat regulates the flow of coolant between the
radiator and the bypass circuit. The heater is part of the
bypass circuit. The throttle body pre-heat is a separate
circuit which is not regulated by the thermostat. An oil
cooler may be fitted as part of this circuit.
ENGINE COOLING 6B-3
Service Precaution
CAUTION:
Always use the correct fastener in the proper location.
When you replace a fastener, use ONLY the exact part
number for that application. ISUZU will call out those
fasteners that require a replacement after removal. ISUZU
will also call out the fasteners that require thread lockers
or thread sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely affect
the fastener torque and the joint clamping force, and may
damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following
these instructions can help you avoid damage to parts
and systems.
Water pump
The water pump is centrifugal type and is driven by timing belt.
Thermostat
The thermostat is a bypass type and is a wax pellet type with a
air hole.
Radiator
The radiator is a flow type with corrugated fins.
110RS001
6B-4 ENGINE COOLING
Antifreeze Solution
Calculating mixing ratio
Mixing ratio
=
Antifreeze solution (Lit/gal.)

Antifreeze solution (Lit/gal.) + Water (Lit/gal.)
NOTE: Antifreeze solution + Water = Total cooling system

capacity.
Total Cooling System Capacity
5.7Lit
Mixing ratio
Check the specific gravity of engine coolant in the cooling
system temperature ranges from 0C to 50C using a
suction type hydrometer, then determine the density of the
engine coolant by referring to the table.
NOTE: The LLC is 50% at all environment in order to prevent
the corrosion of cooling system parts.
ENGINE COOLING 6B-5
Diagnosis
Condition
Engine overheating
Engine overcooling
Engine slow to warm-up
Possible cause
Thermo mater unit faulty
Faulty thermostat
Faulty Engine Coolant temperature
sensor
Clogged radiator
Faulty radiator cap
Low engine oil level or use of
improper engine oil
Open or shorted Throttle Position
sensor circuit
Loosen V-belt tension
Collapsed hoses
Faulty Fan clutch
Faulty thermostat
Faulty thermostat
Thermo unit faulty
Correction
Replenish
Replace
Replace
Repair or replace
Clean or replace
Replace
Replenish or change oil
faulty parts
Repair or replace
Replace
Adjust belt tension or replace.
Replace
Replace
Replace
Replace
Replace
6B-6 ENGINE COOLING
Draining and Refilling Cooling

System
Before draining the cooling system, inspect the system and
perform any necessary service to ensure that it is clean, does
not leak and is in proper working order. The engine coolant
(EC) level should be between the "MIN" and "MAX" lines of
reserve tank when the engine is cold. If low, check for leakage
and add EC up to the "MAX" line. There should not be any
excessive deposit of rust or scales around the radiator cap or
radiator filler hole, and the EC should also be free from oil.
1. Completely drain the cooling system by opening the drain
plug at the bottom of the radiator.
WARNING: TO AVOID THE DANGER OF BEING BURNED,
DO NOT REMOVE THE CAP WHILE THE ENGINE AND
RADIATOR ARE STILL HOT. SCALDING FLUID AND
STEAM CAN BE BLOWN OUT UNDER PRESSURE.
Scrub and clean the inside of the reserve tank with soap
and water. Flush it well with clean water, then drain it. Install
the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution that is
at least 50 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to "MAX" line when the engine is
cold.
6. Block the drive wheels and firmly apply the parking brake.
Shift an automatic transmission to "P" (Park) or a manual
transmission to neutral.
7. Remove the radiator cap. Start the engine and warm it up at
2,500 - 3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck and the
EC level has gone down, replenish with the EC. Repeat this
procedure until the EC level does not go down. Then stop
the engine and install the radiator cap. Let the engine cool
down.
9. After the engine has cooled, replenish with EC up to the
"MAX" line of the reserve tank.
10. Start the engine. With the engine running at 3,000 rpm,
make sure there is no running water sound from the heater
core (behind the center console).
11. If the running water sound is heard, repeat steps 8 to 10.
ENGINE COOLING 6B-7
Water Pump
Water Pump and Associated Parts
Legend
2 O-Ring
3 Bolt
1 Water Pump Assembly
Removal
1.
2.
3.
4.
5.

Drain coolant.
Disconnect radiator hose (on inlet pipe side).
Remove timing belt, refer to "Timing Belt" in this manual.
Remove water pump assembly.
Inspection
Make necessary repair and parts replacement if extreme wear
or damage is found during inspection. Should any of the
following problems occur, the entire water pump assembly
must be replaced:
6B-8 ENGINE COOLING
Crack in the water pump body

EC leakage from the seal unit
Play or abnormal noise in the bearing
Cracks or corrosion in the impeller
Installation
1. Before installing water pump, coat sealing surface with
silicon grease.
2. Install water pump assembly and tighten bolts to the
specified torque.
Torque: 25 Nm (2.5 kgfm)
3. Timing belt
Install timing belt, refer to timing belt installation step in
"Timing Belt" in this manual.
4. Connect radiator hose and replenish EC.
ENGINE COOLING 6B-9
Thermostat
Removal
1.
2.
3.
4.
5.

Drain engine coolant from the radiator and engine.
Disconnect radiator hose from the inlet pipe.
Remove thermostat housing.
Remove thermostat from thermostat housing.
Inspection
Suspend the thermostat in a water-filled container using thin
wire. Place a thermometer next to the thermostat.
Do not directly heat the thermostat.
Gradually increase the water temperature. Stir the water so
that the entire water is same temperature.
Confirm the temperature when the valve first begins to open.
Valve opening temperature 92C (197.6F)
Confirm the temperature when the valve is fully opened.
Valve full open temperature 107C(224.6F)
Make necessary repair and parts replacement if extreme wear
or damage is found during inspection.
Installation
1. Before installing thermostat, coat sealing surface with
silicon grease.
2. Install O-ring.
3. Install thermostat housing and tighten bolts to the specified
torque.
4. Installation rubber hose.
5. Replenish engine coolant (EC).
6. Start engine and check for EC leakage.
Fan Clutch with Cooling Fan

damage or any other abnormal condition are found through
inspection.
Visually inspect for damage, leak (silicon grease) or other
1. Inspection (on-vehicle)
1) Turn the fan clutch by hand when in a low temperature
condition before starting the engine, and confirm that it
can be turned readily.
2)
Start the engine to warm it up until the temperature at the

fan clutch portion gets to around 80C. Then stop the
engine and confirm that the fan clutch can be turned with
considerable effort (clutch torque) when turned by hand.
6B-10 ENGINE COOLING

If the fan clutch rotates more readily, however, this
indicates that the silicon grease is leaking internally.
2. Inspection (in unit)
Warm up the bimetal of the fan clutch by using the heat gun
until the temperature gets to about 80C when measured
with the thermistor. Then confirm that the fan clutch can be
turned with considerable effort (clutch torque).
If the fan clutch retates more readily at this time, this
indicates that the silicon grease is leaking internally.
ENGINE COOLING 6B-11
Radiator
Legend
6 Reserve Tank Hose
7 Reserve Tank
8 Radiator Cap
9 Radiator Assembly
1 Radiator Hose
2 Drain Plug
3 Fan Guide, Lower
4 Fan Guide
5 Bracket
Removal
1.
2.
3.
4.
5.

Loosen a drain plug to drain engine coolant (EC).
Disconnect radiator inlet hose and outlet hose.
Disconnect the reserve tank hose from radiator.
Lift out the radiator assembly, taking care not to damage
the radiator core.
Inspection
Radiator Cap
Measure the valve opening pressure of the pressurizing valve
with a radiator filler cap tester.
Replace the cap if the valve opening pressure is outside the
standard range.
Valve opening pressure kPa (psi) 88.3 103.0
(13.5 15.7)
Cap tester: 5-8840-0277-0
Adapter: 5-8840-2603-0
Check the condition of the vacuum valve in the center of the
valve seat side of the cap. If considerable rust or dirt is found,
or if the valve seat cannot be moved by hand, clean or replace
the cap.
Valve opening vacuum kPa (psi) 1.9 - 4.9
(0.28 - 0.71)
Radiator Core
1. A bent fin may result in reduced ventilation and overheating
may occur. All bent fins must be straightened. Pay close
attention to the base of the fin when it is being straightened.

Thoroughly wash the inside of the radiator and the engine
coolant passages with cold water and mild detergent. Remove
all sign of scale and rust.

Use a radiator cap tester to force air into the radiator through
the filler neck at the specified pressure of 196 kPa (28.5 psi)
with a cap tester:
Cap tester: 5-8840-0277-0
Adapter: 5-8840-2603-0
ENGINE COOLING 6B-13
Installation
1. Install radiator assembly, taking care not to damage the
radiator core.
2. Install the radiator assembly.
3. Connect reserve tank hose.
4. Connect radiator inlet hose and outlet hose.
5. Pour engine coolant up to filler neck of radiator, and up to
MAX mark of reserve tank.
Important operation (in case of 100% engine coolant
change) procedure for filling with engine coolant.
Remove radiator cap.
Fill with engine coolant (EC) to the radiator filler neck.
Fill with EC to the "MAX" line on the reservoir tank.
Start the engine with the radiator cap removed and bring to
operating temperature by running engine at 2,500 - 3,000
rpm for 30 minutes.
By EC temperature gauge reading make sure that the
thermostat is open.
If air bubbles come up to the radiator filler neck, replenish
with EC. Repeat until the EC level does not drop any further.
Install the radiator cap and stop the engine.
Replenish EC to the "MAX" line on the reservoir tank and
leave as it is until the engine gets cool.
After the engine gets cool, start the engine and make sure
there is no water running noise heard from the heater core
while the engine runs at 3000 rpm.
Should water running noise be heard, repeat the same
procedure from the beginning.

Cooling system
Radiator
Heat radiation area
Radiator front area
Radiator dry (weight)
Engine coolant capacity
Engine coolant pump
Thermostat
Engine Coolant forced circulation

Tube type corrugated (2 tube in row)
66.3 kcal/h
2
7.08 m
2
028 m
3.1 kg
93.3 122.7 kpa
2.0L
Centrifugal type
Bypass type
5.7lit

ITEM NO.
ILLUSTRATION
PART NO.
PART NAME
5-8840-0277-0
Tester; radiator cap
5-8840-2603-0
Adapter; radiator cap
ENGINE FUEL (C24SE) 6C-1
ENGINE
ENGINE FUEL (C24SE)
CONTENTS
General Description............................................. 6C-2
Service Precaution............................................... 6C-3
Fuel Metering ........................................................ 6C-4
Fuel Filter ............................................................... 6C-5
Removal .............................................................. 6C-5
Inspection ........................................................... 6C-6
Installation.......................................................... 6C-6
Inspection ........................................................... 6C-6
In-Tank Fuel Filter............................................. 6C-6
Fuel Pump Flow Test ....................................... 6C-7
Fuel Pump .............................................................. 6C-8
Fuel Pump and Associated Parts ................. 6C-8
Removal .............................................................. 6C-8
Installation.......................................................... 6C-9
Fuel Tube / Quick - Connector Fittings .......... 6C-10
Precautions ........................................................ 6C-10
Cautions During Work ..................................... 6C-10
Removal...............................................................
Reuse of Quick-Connector .............................
Assembling Advice ...........................................
Fuel Pump Relay ...................................................
General Description..........................................
Fuel Tank ................................................................
Fuel Tank and Associated Parts....................
Removal...............................................................
Installation ..........................................................
Filler Neck...............................................................
Removal...............................................................
Installation ..........................................................
Fuel Gauge Unit ....................................................
Removal and Installation.................................
Fuel Filler Cap........................................................
General Description..........................................
Inspection............................................................
Main Data and Specifications ............................
Special Tool ........................................................
6C-10
6C-11
6C-11
6C-12
6C-12
6C-13
6C-13
6C-14
6C-14
6C-15
6C-15
6C-15
6C-15
6C-15
6C-16
6C-16
6C-16
6C-17
6C-18
6C-2 ENGINE FUEL (C24SE)
General Description
*
*
*
* Applicable to EVAP Emission Control System

** Not applicable to EVAP Emission Control System

When working on the fuel system, there are several things to
keep in mind:
Any time the fuel system is being worked on, disconnect the
negative battery cable except for those tests where battery
voltage is required.
Always keep a dry chemical (Class B) fire extinguisher near
the work area.
Replace all pipes with the same pipe and fittings that were
removed.
Clean and inspect "O" rings. Replace if required.
Always relieve the line pressure before servicing any fuel
system components.
Do not attempt repairs on the fuel system until you have
read the instructions and checked the pictures relating to
that repair.
All gasoline engines are designed to use only unleaded
gasoline. Unleaded gasoline must be used for proper emission
control system operation.
Its use will also minimize spark plug fouling and extend engine
oil life. Using leaded gasoline can damage the emission control
system and could result in loss of emission warranty coverage.
All cars are equipped with an Evaporative Emission Control
System. The purpose of the system is to minimize the escape
of fuel vapors to the atmosphere.
Service Precaution
CAUTION:
and systems.
Fuel Metering
Engine Control Module (ECM) is in complete control of this fuel
delivery system during normal driving conditions.
The intake manifold function, like that of a diesel, is used only
to let air into the engine. The fuel is injected by separate
injectors that are mounted over the intake manifold.
The Manifold Absolute Pressure (MAP) sensor measures the
changes in the intake manifold pressure which result from
engine load and speed changes, which the MAP sensor
converts to a voltage output.
This sensor generates the voltage to change corresponding to
the flow of the air drawn into the engine.
The changing voltage is transformed into an electric signal and
provided to the ECM.
With receipt of the signals sent from the MAP sensor, Intake
Air Temperature sensor and others, the ECM determines an
appropriate fuel injection pulse width feeding such information
to the fuel injector valves to effect an appropriate air/fuel ratio.
The Multiport Fuel Injection system utilizes an injection system
where the injectors turn on at every crankshaft revolution. The
ECM controls the injector on time so that the correct amount of
fuel is metered depending on driving conditions.
Two interchangeable "O" rings are used on the injector that
must be replaced when the injectors are removed.
The fuel rail is attached to the top of the intake manifold and
supplies fuel to all the injectors.
Fuel is recirculated through the rail continually while the engine
is running. This removes air and vapors from the fuel as well
as keeping the fuel cool during hot weather operation.
The fuel pressure control valve that is mounted on the fuel rail
maintains a pressure differential across the injectors under all
operating conditions. It is accomplished by controlling the
amount of fuel that is recirculated back to the fuel tank based
on engine demand.
See Section "Driveability and Emission" for more information
and diagnosis.
Fuel Filter
Fuel Filter and Associated Parts
Removal
loose connections or leakage. For the fuel system
diagnosis, see Section "Driveability and Emissions".
(2.4L)
2. Disconnect the quick connector from the fuel filter.
3. Pull off fuel filter from the holder to side member side.
4. Remove the fuel filter.
Fuel Filter
Inspection
1. Replace the fuel filter if the fuel leaks from fuel filter
body or if the fuel filter body itself is damaged.
2. Replace the filter if it is clogged with dirt or
sediment.
Installation
1. Install the filter to holder from side member side.
NOTE: Attend direction of fuel filter. (1) to engine side
(2) to fuel tank side.
RTW36CSH000301

the fuel filter.
NOTE: Pull of the left checker into the fuel pipe.
3. Tighten fuel filler cap until at least one click are
heard.
Inspection
After installation, start engine and check for fuel
leakage.
InTank Fuel Filter

The filter is located on the lower end of fuel pickup tube
in the fuel tank. It prevents dirt from entering the fuel
pipe and also stops water unless the filter is completely
submerged in the water. It is a selfcleaning type, not
requiring scheduled maintenance. Excess water and
sediment in the tank restricts fuel supply to the engine,
resulting in engine stoppage. In such a case, the tank
must be cleaned thoroughly.
Fuel Pump Flow Test

If reduction of fuel supply is suspected, perform the
following checks.
1. Make sure that there is fuel in the tank.
2. With the engine running, check the fuel feed pipe
and hose from fuel tank to injector for evidence of
leakage. Retighten, if pipe or hose connection is
loose. Also, check pipes and hoses for squashing
or clogging.
3. Insert the hose from fuel feed pipe into a clean
container, and check for fuel pump flow rate.
4. Connect the pump relay terminals (2) with a
jumper wire (1) as shown and start the fuel pump
to measure delivery.
RTW36CSH000201
CAUTION: Never generate sparks when connecting

a jumper wire.
Delivery
Delivery
15 seconds
0.38 liters minimum
If the measure value is out of standard, conduct the

pressure test.
Pressure test
For the pressure test to the fuel system, see Section 6E
Fuel Control System".
Fuel Pump
Fuel Pump and Associated Parts
RTW46FMF000401
Legend
(1) Fuel Feed Port
(7) Retainer Ring (Fuel Pump Lock)
(2) Fuel Return Port
(8) Seal; Fuel Pump
(3) Fuel Emission Port
(9) Fuel Tank Assembly

(5) Connector; Fuel Feed Pump & Sender
Removal
1. Remove fuel tank assembly (9). Refer to Fuel
Tank Removal" in this section.
3. Disconnect the quick connector (10) into the evapo
(10) Evapo Tube/Quick Connector

3. Remove the retainer ring (7) from the fuel tank
with the removal tool 5-8840-2602-0.
8. Check leak.
(1) Plug end of quick connector and breather hose
(Pull off the breather hose from fuel tank) and
tighten fuel filler cap until at least one click are
heard.
(2) Apply water soap around the fuel pump seal
area.
(3) Pressure air into the fuel tank from end of
2
breather pipe at 5psi (34.3 kPa/2.8kgf/cm )
over 15 seconds.
(4) Verify no bubbles around the fuel pump seal
area.
140R100035
4. Remove slowly the fuel pump (4) from the fuel

tank as no bend float arm.
NOTE: Cover opening for the fuel pump on fuel tank to
prevent any dust enthering.
5. Discard fuel pump seal (8) because it cannot be
reusable.
Installation
1. Clean the seal surface of the fuel tank and the fuel
pump.
NOTE: If there is dust on the seal surface, it becomes
cause of fuel leak.
2. Install the new fuel pump seal (8) to opening of the
fuel tank as along the groove.
3. Install slowly the fuel pump (4) into the fuel tank as
no bend float arm.
4. Set flange of the fuel pump on fuel pump seal as
mating convexity of the fuel pump and reentrant of
the fuel tank.
5. Lock slowly the retainer ring (7) to the fuel tank
with the remover tool 5-8840-2602-0.
6. Connector the quick conector (10) into the evapo
tube to fuel pump.
7. Connect the quick connector (6) into the fuel tube
to fuel pump.
NOTE: Pull off the left ckecker into the fuel pipe.
Fuel Tube / Quick Connector Fittings

Precautions
Disconnect battery
electrical shorts.
ground
cable
to
prevent
Pre-treat piping system or associated parts from

thermal damage or from spattering when welding
or similar heat-generating work.
141R100002
When disconnecting the fuel pipe, cover the area

with a cloth to prevent fuel from splashing as the
fuel pipe may still have some pressure in it.
connector in one hand, and pull out the connentor
with the other hand while pressing the square
relieve button of the connector, as illustrated.
140R100032
Legend
(1) O-ring
(2) Port
(3) Connector
(4) Plastic Tube
Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spilt
battery electorolyte.
Piping that has been splattered with battery electrolyte
or battery electrolyte soaked cloth that was wiped on the
piping cannot be used.
Removal
1. Open the fuel cap to relieve the fuel pressure in the
tank.
Use compressed air to remove any dirt on the fuel
quick connect fittings prior to disconnecting the
fittings.
140R100037
NOTE: Do not use tools of any kind. Only use bare

hands when disconnecting the connector. Use a
lubricant (light oil) and/or push and pull the connector
until the pipe is disconnected.
Cover the connectors that was removed with a
plastic bag, to prevent dust or rain water from
entering.
Assembling Advice
By applying engine oil or light oil to the pipe, port makes
pipe assembly easier. The pipe assembly should take
place immediately after applying oil (to prevent dust
from sticking to the pipe surface which may
decrease sealing ability).
2. Turn the ignition key to the ON" position and listen
for pump start-up sound. Inspect for leaks, the
fuel pressure will increase as the fuel pump is
actuated.
3. Perform leak inspection (step 2) several times.
140R100028
Replace the port and connector if scratch, dent or
crack is found.
Remove any dirt build up on the port when installing
the connector. Replace the connector, if there is any
forms of rust, dent, scratch.
After cleaning the port, insert it straight into the
connector until it clicks. After it clicks, try pulling at
49N (5kgf) it out to make sure that it is not drawn
and is securely locked.
140R100036
4. Start the engine and observe the engine idle speed.

The presence of dirt in the fuel system may affect
the fuel injection system.
Fuel Pump Relay

General Description
In order to control the fuel pump and sender assembly
(FPAS) operation, the FPAS relay is provided. When
the starter switch is turned to ON" position, the FPAS
relay operates the FPAS for 2 seconds.
When it is turned to START" position, the Engine
Control Module receives the reference pulse from the
Ignition Control Module and it operates the relay, again
causing the FPAS to feed fuel.
Fuel Tank
RTW46FLF000301
Legend
(7) Fuel Filler Hose
(1) Bolt; Fuel Tank
(2) Fuel Tank Band
(9) Fuel Filter
(3) Rear Side Shield
(10) Band; Under Shield
(4) Side Shield
(11) Under Shield
(5) Retainer
(12) Evapo Tube / Quick Connector Only Specified

Model
(6) Fuel Tank
Removal
dust entering.
4. Support underneath of the fuel tank with a lifter.
5. Remove the inner liner of the wheel house on rear
left side.
6. Remove fasten bolt to the filler neck from the
body.
tube from the fuel pipe and the evapo tube from
evapo joint connector.
8. Remove fasten bolt (1) to the tank band and the
tank band (2).
9. Disconnect the pump and sender connector on the
fuel pump and remove the harness from weld clip
on the fuel tank.
10. Lower the fuel tank (6).
NOTE: When the fuel tank is lowered from the vehicle,
dont scratch each hose and tube by around other pars.
Installation
1. Rise the fuel tank into position.
NOTE: Ensure hoses and tubes do not foul on other
component.
2. Connect the pump and sender connector to the
fuel pump and install harness to into the plastic clip
welded to the top of the fuel tank..
NOTE: The connector must be certainly connected
against stopper.
Ensure tank band anchor mates with guide hole on
frame.
3. Install the tank band to fasten bolt.
NOTE: The anchor of the tank band must be certainly
installed to guide hole on frame.
the fuel pipe and the evapo tube from evapo joint
connector.
NOTE: Pull off the left checker into the fuel pipe.
5. Install the filler neck to the body by bolt.
6. Install the inner liner of the wheel house on rear
side.
7. Remove lifter to support underneath of the fuel
tank.
8. Put back the vehicle.
9. Tigten the filler cap until at least three clicks are
heard.
Filler Neck
Removal
Installation


Each joint area of the hose (Restore axial
Each fasten area of the clamp (Restore axial
Each bolt in the clamp (Restore fasten length of
bolt in the clamp)
Torque: 2.5 N
m (0.25 kg
m / 2 lb ft) filler neck
side except flat deck model.
The band clip (Restore position and fasten
2. Put a marking the following point as the filler neck

assembly is restored.
Each joint area of the hose (to restore axial
Each fasten area of the clamp (to restore axial
Each bolt in the clamp (to restore fasten length
of bolt in the clamp)
The band clip (to restore position and fasten
NOTE: Cover end of each hose and pipe to prevent any
dust entering.
Fuel Gauge Unit

As for removal and installation of the Fuel Gauge Unit,
refer to Fuel Tank" of this section 6C as the fuel gauge
unit is combined with the fuel pump and sender
assembly.
Fuel Filler Cap

General Description
A vacuum valve and pressure valve are built into the
fuel filler cap which adjusts the fuel pressure in the fuel
tank to prevent fuel tank damage.
RTW36CSH000401
Legend
(1) Pressure Valve
(2) Vacuum Valve
(3) Seal Ring
Inspection
CAUTION: A replacement fuel filler cap must be the
same as the original. The fuel filler cap valve was
designed primarily for this application and must be
replaced with the same type or decreased engine
performance may occur.

Nm (kgm/ lb ft)
RTW46CLF000601
Special Tools
ILLUSTRATION
PART NO.
PART NAME
5884026020
(J39765)
Remover; fuel pump
retainer
ENGINE ELECTRICAL 6D1-1
SECTION 6D1
ENGINE ELECTRICAL
CONTENTS
PAGE
Battery ............................................................................................................................. 6D1- 2
General Description ................................................................................................... 6D1- 2
Service Precaution..................................................................................................... 6D1- 2
Diagnosis.................................................................................................................... 6D1- 3
Battery Charging ........................................................................................................ 6D1- 4
Jump Starting ............................................................................................................. 6D1- 4
Removal ...................................................................................................................... 6D1- 6
Installation .................................................................................................................. 6D1- 6
Main Data and Specifications ................................................................................... 6D1- 6
6D1-2 ENGINE ELECTRICAL
Battery
General Description
There are six battery fluid caps on top of the battery.
These are covered by a paper label.
The battery is completely sealed except for the six small vent
holes on the side. These vent holes permit the escape of small
amounts of gas generated by the battery.
This type of battery has the following advantages over
conventional batteries:
1. There is no need to add water during the entire service life
of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an extensive charge.
(A conventional battery will accept an excessive charge,
resulting in gassing and loss of battery fluid.)
3. The battery is much less vulnerable to self discharge than a
conventional type battery.
Service Precaution
CAUTION:
and systems.
Diagnosis
1. Visual Inspection
Inspect the battery for obvious physical damage, such as a
cracked or broken case, which would permit electrolyte loss.
Replace the battery if obvious physical damage is discovered
during inspection.
Check for any other physical damage and correct it as
necessary.
2. Hydrometer Check
3. Fluid Level Check

The fluid level should be between the upper level line (2) and
lower lever line (3) on side of battery.
a. CORRECT FLUID LEVEL - Charge the battery.
b. BELOW LOWER LEVEL - Replace battery.
4. Voltage Check
1. Put voltmeter test leads to battery terminals.
a. VOLTAGE IS 12.4V OR ABOVE - Go to Step 5.
b. VOLTAGE IS UNDER 12.4V - Go to procedure (2)
below.
2. Determine fast charge amperage from specification.
(See Main Data and Specifications in this section).
Fast charge battery for 30 minutes at amperage rate no
higher than specified value.
Take voltage and amperage readings after charge.
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF
AMPERAGE RATE - Replace battery.
b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF
AMPERAGE RATE - Drop charging voltage to 15V and
charge for 10 - 15 hours. Then go to Step 5.
c. VOLTAGE IS BETWEEN 12V AND 16V - Continue
charging at the same rate for an additional 3-1/2 hours.
Then go to Step 5.
d. VOLTAGE BELOW 12V - Replace Battery.
Battery Charging
Observe the following safety precautions when charging the
battery:
1. Never attempt to charge the battery when the fluid level is
below the lower level line on the side of the battery. In this
case, the battery must be replaced.
2. Pay close attention to the battery during charging
procedure.
Battery charging should be discontinued or the rate of
charge reduced if the battery feels hot to the touch.
Battery charging should be discontinued or the rate of
charge reduced if the battery begins to gas or spew
electrolyte from the vent holes.
3. In order to more easily view the hydrometer blue dot or ring,
it may be necessary to jiggle or tilt the battery.
4. Battery temperature can have a great effect on battery
charging capacity.
5. The sealed battery used on this vehicle may be either quick
charged or slow charged in the same manner as other
batteries.
Whichever method you decide to use, be sure that you
completely charge the battery. Never partially charge the
battery.
Jump Starting
Jump Starting with an Auxiliary (Booster)
Battery
CAUTION: Never push or tow the vehicle in an attempt to
start it. Serious damage to the emission system as well as
other vehicle parts will result.
Treat both the discharged battery and the booster battery
with great care when using jumper cables.
Carefully follow the jump starting procedure, being careful
at all times to avoid sparking.
WARNING: FAILURE TO CAREFULLY FOLLOW THE JUMP
STARTING PROCEDURE COULD RESULT IN THE
FOLLOWING:
1. Serous personal injury, particularly to your eyes.
2. Property damage from a battery explosion, battery acid, or
an electrical fire.
3. Damage to the electronic components of one or both
vehicles particularly.
Never expose the battery to an open flame or electrical spark.
Gas generated by the battery may catch fire or explode.
Remove any rings, watches, or other jewelry before working
around the battery. Protect your eyes by wearing an approved
set of goggles.
Never allow battery fluid to come in contact with your eyes or
skin.
Never allow battery fluid to come in contact with fabrics or
painted surfaces.

Battery fluid is a highly corrosive acid.
Should battery fluid come in contact with your eyes, skin,
fabric, or a painted surface, immediately and thoroughly rinse
the affected area with clean tap water.
Never allow metal tools or jumper cables to come in contact
with the positive battery terminal, or any other metal surface of
the vahicle. This will protect against a short circuit.
Always keep batteries out of reach of young children.

1. Set the vehicle parking brake.
If the vahicle is equipped with an automatic transmission,
place the selector level in the "PARK" position.
If the vehicle is equipped with a manual transmission, place
the shift lever in the "NEUTRAL" position.
Turn "OFF" the ignition.
Turn "OFF" all lights and any other accessory requiring
electrical power.
2. Look at the built-in hydrometer.
If the indication area of the built-in hydrometer is completely
clear, do not try to jump start.
3. Attach the end of one jumper cable to the positive terminal
of the booster battery.
Attach the other end of the same cable to the positive
terminal of the discharged battery.
Do not allow the vehicles to touch each other. This will
cause a ground connection, effectively neutralizing the
charging procedure.
Be sure that the booster battery has a 12 volt rating.
4. Attach one end of the remaining cable to the negative
terminal of the booster battery.
Attach the other end of the same cable to a solid engine
ground (such as the air conditioning compressor bracket or
the generator mounting bracket) of the vehicle with the
discharged battery.
The ground connection must be at least 450 mm (18 in.)
from the battery of the vehicle whose battery is being
charged.
WARNING: NEVER ATTACH THE END OF THE JUMPER
CABLE DIRECTLY TO THE NEGATIVE TERMINAL OF THE
DEAD BATTERY.
5. Start the engine of the vehicle with the good battery.
Make sure that all unnecessary electrical accessories have
been turned "OFF".
6. Start the engine of the vehicle with the dead battery.
7. To remove the jumper cables, follow the above directions in
reverse order.
Be sure to first disconnect the negative cable from the
vehicle with the discharged battery.

2
Removal
1
4
1.
2.
3.
4.
5.
Remove negative cable (1).

Remove positive cable (2).
Remove retainer screw and rods (3).
Remove retainer (4).
Remove battery (5).
Installation
1. Install battery.
2. Install retainer.
3. Instal retainer screw and rods.
NOTE: Make sure that the rod is hooked on the body side.
4. Install positive cable.
5. Install negative cable.

Model (JIS)
Voltage (V)
Cold Cranking Performance (Amp)
Reserve Capacity (Min)
34B19L
12
272
49
50D20L
12
306
78
IGNITION SYSTEM 6D2-1
SECTION 6D2
IGNITION SYSTEM
CONTENTS
PAGE
General Description........................................................................................................ 6D2- 2
Service Precaution ......................................................................................................... 6D2- 2
Diagnosis......................................................................................................................... 6D2- 2
Ignition Coil ..................................................................................................................... 6D2- 2
Removal ...................................................................................................................... 6D2- 2
Installation .................................................................................................................. 6D2- 2
Spark Plug ....................................................................................................................... 6D2- 3
Removal ...................................................................................................................... 6D2- 3
Inspection and Repair................................................................................................ 6D2- 3
Installation .................................................................................................................. 6D2- 4
Crankshaft Angle Sensor ............................................................................................... 6D2- 4
Removal ...................................................................................................................... 6D2- 4
Installation .................................................................................................................. 6D2- 4
Main Data and Specifications ........................................................................................ 6D2- 5
6D2-2 IGNITION SYSTEM
General Description
Ignition is done by the Ignition Module that fires.
Since the cylinder on exhaust stroke requires less energy to
fire its spark plug, energy from the ignition coils can be utilized
to fire the mating cylinder on compression stroke.
A notch in the timing disc on the crankshaft activates the crank
angle sensor which then sends information such as firing order
and starting timing of ignition coil to the ECM.
By receiving signals such as crank position, engine speed,
water temperature and Manifold Absolute Pressure (MAP), the
ECM controls the ignition timing.
Service Precaution
CAUTION:
and systems.
Diagnosis
Refer to Section Drivability and Emissions for the diagnosis to
electronic ignition system (El system).
Ignition Coil
Removal
2. Disconnect the Ignition coil connector.
3. Remove the ignition coil.
Installation
1. Install the ignition coil.
Connect ignition coil connector and ignition coil, then tighten
Spark Plug
Removal
1. Remove spark plugs.

The spark plug affects entire engine performance and
therefore its inspection is very important.
Check electrode and insulator for presence of cracks, and
replace if any.
Check electrode for wear, and replace if necessary.
Check gasket for damage, and replace if necessary.
Measure insulation resistance with an ohmmeter, and
replace if faulty.
Adjust spark plug gap to 1.0 - 1.1 mm (0.027 in) - 0.8 mm
(0.031 in).
Check fuel and electrical systems if spark plug is extremely
dirty.
Use spark plugs having low heat value (hot type plug) if fuel
and electrical systems are normal.
Use spark plugs having high heat value (cold type plug) if
insulator and electrode are extremely burned.
Sooty Spark Plugs

Much deposit of carbon or oil on the electrode and insulator of
spark plug reduces the engine performance.
Possible causes:
Too rich mixture
Presence of oil in combustion chamber
Incorrectly adjusted spark plug gap
Burning Electrodes
This fault is characterized by scorched or heavily oxidized
electrode or blistered insulator nose.
Possible causes:
Too lean mixture
Improper heat value
Measuring Insulation Resistance

Measure insulation resistance using a 500 volt megaohm
meter.
Replace spark plugs if measured value is out of standard.
Insulation resistance: 50 MW
W or more
Cleaning Spark Plugs

Clean spark plugs with a spark plug cleaner.
Raise the ground electrode to an angle of 45 to 60 degrees.
if electrode is wet, dry it gefore cleaning.
After spark plug is thoroughly cleaned, check insulator for
presence of cracks.
Clean threads and metal body with a wire brush.

File the electrode tip if electrode is extremely worn.
Bend the ground electrode to adjust the spark plug gap.
Installation
1. Spark plugs
Tighten spark plugs to the specified torque.
Crankshaft Angle Sensor

Removal
1. Disconnect battery ground cable
2. Disconnect the wiring connector from crankshaft angle
sensor.
3. Remove crankshaft angle sensor from cylinder block.
Installation
1. Install crankshaft angle sensor into the cylinder block.
Before installation, apply small amount of engine oil to the
O-ring.
2. Reconnect wiring connector to crankshaft angle sensor.

Ignition System
Ignition Form
Spark Plug
Type
No. of Coils and Type
Coil Location
Torque
Electronic Ignition System (El system) with Crankshaft angle Sensor

Electronic Spark Control
2 Solid State
Engine-mounted
20 Nm (2.0 kgfm)
MEMO
STARTING AND CHARGING SYSTEM 6D3-1
SECTION 6D3
STARTING AND CHARGING SYSTEM

CONTENTS
PAGE
Starting System .............................................................................................................. 6D3- 2
Service Precaution ......................................................................................................... 6D3- 2
Diagnosis......................................................................................................................... 6D3- 2
Starter .............................................................................................................................. 6D3- 3
Removal ...................................................................................................................... 6D3- 3
Installation .................................................................................................................. 6D3- 3
Disassembled View.................................................................................................... 6D3- 4
Inspection and Repair................................................................................................ 6D3- 5
Characteristic Test..................................................................................................... 6D3- 6
Charging System ............................................................................................................ 6D3- 7
General On-Vehicle Inspection...................................................................................... 6D3- 8
Generator......................................................................................................................... 6D3- 8
Removal ...................................................................................................................... 6D3- 8
Inspection ................................................................................................................... 6D3- 8
Installation .................................................................................................................. 6D3- 9
Diagnosis......................................................................................................................... 6D3-12
Disassembly ............................................................................................................... 6D3-13
Clean ........................................................................................................................... 6D3-14
Inspection ................................................................................................................... 6D3-14
Reassembly ................................................................................................................ 6D3-18
Inspection ................................................................................................................... 6D3-19
Technical Data ................................................................................................................ 6D3-21
6D3-2 STARTING AND CHARGING SYSTEM
Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter
switch, starter relay, etc. These main components are
connected.
Starter
The cranking system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion shaft.
When the starter switch is turned on, the contacts of magnetic
switch are closed, and the armature rotates. At the same time,
the plunger is attracted, and the pinion is pushed forward by
the shift lever to mesh with the ring gear.
Then, the ring gear runs to start the engine. When the engine
starts and the starter switch is turned off, the plunger returns,
the pinion is disengaged from the ring gear, and the armature
stops rotation. When the engine speed is higher than the
pinion, the pinion idles, so that the armature is not driven.
Service Precaution
CAUTION:
and systems.
Diagnosis
Condition
Starter does not run
Possible cause
Charging failure
Battery Failure
Terminal connection failure
Starter switch failure
Starter failure
Correction
Repair charging system
Replace Battery
Repair or replace terminal connector
and/or wiring harness
Repair or replace starter switch
Repair or replace starter
Starter
Removal
1. Remove the battery ground cable.
2. Remove harness connectors (1) and (2).
3. Remove bolts from starter.
Installation
1. Install starter assembly.
2. Install mounting bolts and tighten bolts to specified torque.
3. Connect harness.
4. Reconnect the battery ground cable.
Disassembled View
Legend
1 Bolt
2 Magnetic Switch
3 Gear Case
4 Piston
5 Piston Shaft
6 Center Bracket
7 Armature
8 Yoke Assembly
9 Brush and Brush Holder
10 Washer
11 Rear Cover
12 Through Bolt

Repair or replace necessary parts if extreme wear or damage
is found during inspection.
Armature
Check for continuity between commutator and segment.
Replace commutator if there is no continuity (i.e.,
disconnected).
Check for continuity between commutator and shaft.

Also, check for continuity between commutator and armature
core, armature core and shaft. Replace commutator if there is
continuity (i.e., internally grounded).
Brush
Measure the length of brush.
Replace with a new one, if it is below the limit.
Brush Holder
Check for continuity between brush holder (+) (4) and base (-).
Replace, if there is continuity (i.e., insulation is broken).
Magnetic Switch
Check for continuity of shunt coil between terminals S and M.
Replace, if there is no continuity (i.e., coil is disconnected).
Continuity of Series Coil

Check for continuity between terminals S and M.
Replace, if there is no continuity (i.e., coil is disconnected).
Continuity of Contacts
With the plunger faced downward, push down the magnetic
switch. In this state, check for continuity between terminals B
and M. Replace, if there is no continuity (i.e., contacts are
faulty).
Pinion
Check if the pinion rotates smoothly in drive direction by hand,
or if it is locked when it is rotated in reverse. If not, replace the
pinion.
Characteristic Test
For easily confirming the characteristics, conduct the noload
test as follows:
Rating as short as 30 seconds requires rapid testing.
Fix the starter on the test bench, and wire as shown in
illustration. When the switch is closed, the current flows and
the starter runs under no load. At this time, measure current,
voltage and speed to check if they satisfy the standard.
Legend
1 Volt Meter
2 Revolution Indicator
3 Battery
4 Ammeter
5 Switch
Charging System
General Description
The charging system is an IC integral regulator charging
system and its main components are connected as shown in
illustration.
The regulator is a solid state type and it is mounted along with
the brush holder assembly inside the generator installed on the
rear end cover.
The generator does not require particular maintenance such as
voltage adjustment. The rectifier connected to the stator coil
has eight diodes to transform AC voltage into DC voltage.
This DC voltage is connected to the output terminal of
generator.
10
11
1
6
7
11
12
9
8
2
Legend
1 Startor assembly
2 Housing
3 Slipring
4 Screws (2)
5 Regulator
6.Bolt (4)
7 Rectifier assembly
8 Retaining assembly
9 B+ terminal nut and washer
10 Pulley
11 Rotor assembly
12 Ball bearing
General On-Vehicle Inspection

The operating condition of charging system is indicated by the
charge warning lamp. The warning lamp comes on when the
starter switch is turned to "ON" position. The charging system
operates normally if the lamp goes off when the engine starts.
If the warning lamp shows abnormality or if undercharged or
overcharged battery condition is suspected, perform diagnosis
by checking the charging system as follows:
1. Check visually the belt and wiring connector.
2. With the engine stopped, turn the stator switch to "ON"
position and observe the warning lamp.
If lamp does not come on:
Disconnect wiring connector from generator, and ground
the terminal "L" on connector side.
If lamp comes on:
Repair or replace the generator.
Generator
Removal
2. Move drive belt tensioner to loose side using wrench then
remove drive belt.
3. Disconnect terminal "B" wiring connector and connector.
4. Remove generator assembly.
Generator Power and Circuit Diagram
Inspection
Legend
1 Load resistor, set parallel to battery
2 Battery
3 Voltmeter
4 Ammeter
5 Ignition Lock
6 Charge Telltale
7 Generator
1.
2.
3.
4.
5.
6.
7.
8.
9.
Disconnect battery.
Close off connecting cable from alternator terminal "B+".
Set ammeter (measuring range 100A) in disconnected line.
Connect controllable load resistor to battery terminal.
Set resistor in front of connection to "O"; connect first to
battery, then to resistor.
Connect tachometer.
Connect oscilloscope according to manufacturer's
instructions.
Connect battery.
Start engine and read off resulting current at various engine
speeds.
Generator Power
1. Adjust load resistor, if the required load currents are not
attained.
2. The shape of the voltage curves on oscilloscope curve
should be regular.
3. Test value: 5 to 7A.
4. If the required minimum current intensity is not attained, or
if the oscilloscope picture shows variations, the alternator
should be overhauled.
Regulated Voltage Circuit Diagram
Legend
1 Battery
2 Ignition Lock
3 Charge Telltale
4 Resistor, for attainment of load current with the battery set in
series
5 Voltmeter
6 Ammeter
7 Generator
Installation
1. Install generator assembly and bring generator assembly to
the position to be installed.
2. Install generator assembly and tighten to the specified
torque.
Torque:
Long bolt: 35 Nm (3.6 kgfm)
Short bolt: 20 Nm (2.0 kgfm)
3. Connect wiring harness connector.
4. Move drive belt tensioner to loose side using a wrench, then
install drive belt to normal position.
5. Reconnect battery ground cable.

The generator has four external connections; the "B+" lead to
battery positive, "L" lead to the warning lamp circuit(max. 2
watts), "S" lead to battery positive terminal for battery sensing
and an earth connection.
Explanation of type inscripiton

Example:KC-A--> 14V 50-90A.
K = Code for Stator OD(126mm OD).
C = Compact Generator.
A = Ausland (countries other than Germany)
> = Direction of rotation(clockwise).
14V = Generator Operating Voltage.
50A = Stabilised output at 25 C at 1800 RPM./13.5
Volts.
90A = Stabilised output at 25 C at 1800 RPM./13.5
Volts.
Generator Connetions.
B+ : Battery Main Connection (battery positive)
S : Battery Sense Connection(battery positive)
L : Waring lamp(via warning lamp to Ignition switch)
8+
SUPPRESSOR
CAPACITOR
0.5mf
ALTERNATOR ASSEMBLY
BATT.SENSE
1GN.SW.
12V BATT.
WARN.LAMP
1.2 WATT
S
L
HYBR10
300a*
REGULATOR ASSEMBLY
NOTE: * RESISTOR IS RECOMMENDED TO

ENSURE THAT THE GENERATOR
REMAINS FUNCTIONAL IN CASE OF
WARNING LAMP FAILURE
Warning
Do not reverse S and L connections as this will destroy the
warning lamp circuit of the regulator.
Ensure good electrical contact beween generator earth and
battery negative,
Operation
With the Iginiton switch turnded "ON", current is supplied via
the warning lamp to the "L" terminal of the regulator. Base
current is fed to T15 causing it to turn on, current then flows
from B+ through the rotor winding via the regulator brushes
and the collector emitter junction of T15 to earth completing
the circuit. The current in the rotor causes a magnetic field
between adjacent poles to be created, this field is rotated and
cuts the windings of the stator at right angles inducing a
voltage into them.
As the speed is increased this induced voltage increases and
results in curent being rectified in the 3 phase diode bridge and
supplied as DC to the B+ output and hence to the battery.
When the voltage at the B+ terminal of the battery reaches
around 14.2 volts, this voltage is monitored by the "S" lead and
turns the regulator Hybrid base current to T15 OFF removing
rotor current, resulting in a decrease in output voltage to below
the regulating voltage, T15 base current turns ON and the
whole cycle is repeated very rapidly.
D38 protects T15 and the regulator against the back voltage
developed across the rotor winding when T15 turns OFF.
The new generated EP regulators incorporate current limiting
in the warning lamp circuit.
Backup Regulation
The EP regulator will limit the output voltage to a safe level
should either the main B+ cable or the battery sense wire
become decoupled, the output voltage will be slightly above the
normal setting(1-3 volts).
Start up phase
When the Iginition switch is turned on and the engine is not
running, the current to the rotor is reduced by switching it on
and off at a 50% duty cycle, the frequency is approximately 4
KHz and may be audible at times.
This is quite normal, once the engine is started normal
regulation commences.
Warning lamp failure

Should the warning lamp fail, the generator will self excite by
deriving a small current from the phase connecion allowing the
voltage to build up to regulating level.
Note: no filed current will flow when the engine is cranking.
Diagnosis
The EP regulator incorporates diagnostics which will illuminate
the warning lamp as a result of fault conditions in the generator
and external circuitry.
These conditions include:
1. An open circuit in the regulator battery sensing wire (S
Terninal)
2. An open circuit or excessive voltage drop in the B+ cable.
3. An open circuit in the generator phase connection.
4. Overcharging of the battery.
5. Regulator output stage short circuit.
6. Open circuit rotor.
The regulator compares the voltage at B+ with the voltage at
the "S" terminal connceted to battery positive. If the voltage
differential exceeds a predetermined threshold, the regulator
will operate in backup mode to limit the output voltage to a safe
level. The warning lamp; will remain illuminated as along as
these conditions prevail.
Sources of high resistance which will trigger the warning lamp
are:
a. Poor contact in wiring harness connectors.
b. Poor contact between rectifier and regulator.
c. High resistance in fusible link assembly.
Caution:
When bench testing the generator it is important that the
warning lamp wattage of 2 watts is not exceeded.
Reversal of the "S" and "L" on the regulator will damage
the regulator.
The correct plug for the regulator is a 9 122 067 011 for the
Bosch tye and for the Shinagawa connector the number is
X02FW.
See appendix 1 for daignostic matrix.
Before testing or disassembling the generator please observe
the following points.
1. When testing the diodes with AC type testers the RMS.
Vlotage output must not exceed 12.0 volts, it is
recommended that the stator should be disconnected
during this test.
2. Where zener power diodes are used, the breakdown
voltage should be tested to ensure all diodes have the
same zener voltage.
3. Insulation tests on the rotor and stator should use a voltage
not exceeding 110v for a series test lamp. The rectifier
must be disconnected from the stator prior to testing.
4. When carrying out repairs to the charging system always
disconnected the battery negative first, and reconnect it
last.

5. During current output tests please make sure that the
ammeter is securely connceted into the charge circuit.
6. Some battery powered timing lights can produce high
transient voltages when connected or disconnected. Only
disconnect or connect timing lights when the engine is
switched off.
7. Make sure the warning lamp circuit is functioning normally
before commencing tests.
8. Battery isolation switches must only be operated when the
engine is stopped.
9. To protect the charging system when using 240 volt
chargers it is recommeneded that the battery is
disconnected whilst charging.
10.Due to the very low resistance value of the stator winding it
may not be possible to obtain accurate readings without
special equipment.
11.12 volts must never be connected to the "L" terminal of the
regulator as this will damage the lamp driver circuit.
12.No loads apart from the warning lamp can be connected to
the "L" termainal. The "W" terminal is provided for this
purpose.
Disassembly
1. Mark the relative positions of the end housings in relation to
the stator assembly to aid reassembly. Use a permanent
marking pen do not use centre punched as this can cause
misalignmnet of the housings.
2. Remove the EP regulator from the slipring end housing by
removing the two screws. Tilt the regulator slightly from the
plug connection until the regulator clears the housing, then
lift clear.
3. Remove the four through bolts.
4. Carefully remove the stator assembly along with the slipring
end housing taking care not to put strain on the stator wires.
5. To disconnect the stator from the rectifier assembly, grasp
the stator wires close to the wire loop with a pair of long
nosed pliers, heat the joint with a soldering iron, when the
point becomes plastic apply a slight twisting motion to the
wires, then pull upwards to release the wires. Remove the
stator.
This procedure opens the wire loop to release the stator
connections easily.
6. To remove the rectifier remove the three retaining screw
and the B+ terminal nut and washers.
Note: the B+ bolt and the positive heatsink retaining screw are
fitted with mica insulating washers.
These must be discarded and replaced with new washers and
heatsink compound.

7. To remove the pulley, mount an 8mm Allen key in the vice
with the short end upwards, place a 24mm ring spanner on
the puley nut, position the internal hexagon of the rotor
shaft onto the Allen ken, loosen the nut and remove the
pulley.
Note: the pulley has an integral boss which locks up against
the bearing,
therefore no thrust collar is provided.
8. Removing the rotor assembly. Remove the four retaining
screws from the drive end housing, withdraw the rotor
complete with the bearing.
Note: the rotor must not be pressed from the drive end housing
using a press as the bearing retaining plate and drive end
housing will be damaged or distorted. Parts removed in this
way must be replaced if the integrity of the generator is to be
maintained.
9. Remove the drive end bearing from the rotor shaft using a
chuck type puler, take care not to distort the fan assembly
during this process.
10.Remove the slipring end bearing using the same meghod
as in 9.
Clean
Thoroughly clean all components except the rotor and stator
with an approved cleaning agent. Ensure that all traced of oil
and dirt are removed. If an abrasive cleaner is used to remove
scale and paint from the housings take care not to abrade the
bearing and mounting spigot surfaces. The rotor and stator
must be cleaned with compressed air only, the use of solvents
could cause damage to the insulating materials.
Inspection
1. Rectifier assembly
The following test equipment is required.
The recitifier assembly is not repairable and must be replaced
if a faulty diode is detected during inspection.
(a) Adiode tester where the DC output at the test probes does
not exceed 14 volts or in the case of AC testers 12 volts
RMS. This is to ensue that when inspection rectifiers fitted
with zener power diodes the forward and reverse checks
are completer and are not masked by the diode turning on
due to the zener breakdown voltage.
(b) A zenere diode tester with a DC output in excess of 30
volts, the tester should also incorporate internal current
limiting set to 5 Ma. to prevent high currents during
inspection.
(c) Diodes can be destroyed during service due to high
temperature and overload, open circuits are usually a result
of excessive voltage.
6 diode
Diode connections
8 diode
Stator connection
D
C
B+Bolt
H
Negative heatsink
A
Starpoint
Positive heatsink
1.1
Power Diodes.
Apply the negative test probe of the diode tester or a

multimeter with a diode test feature to the positive heatsink
and the positive probe alternatevely to A,B,C, a low resistance
reading, or the forward voltage drop across the diode shoud be
obtained. Reverse the test probes, a high resistance reading or
a higher reverse voltage should be obtained.
Now connect the positive test probe to the negative heatsink
and the negative alternatively to D,E,F, a low resistance or
forward voltage drop across the diode should be obtained.
Reverse the test probes, a high resistance reading or a higher
reverse voltage should be obtained.
For 8 diode rectifier plates tests for G and H should be
included. When the reverse voltage test is done the applied
voltage should be less than 14 volts DC or 12 volts RMS for
AC testers.
1.2
Zener Diode
The basic tests in 1.1 should be undertaken first before the

diode zener voltage is tested. Diodes are grouped together
according to their zener voltag i.e. all diodes within a rectifier
must have the same zener voltage.
Connect the test probes as for the reverese test listed above
i.e. reverse biased apply the test voltage form the zener diode
tester (current limited to 5ma) and read to zener breakdown
voltage this should be a steady reading and not increase with
increased voltage from the tester.
Readings for Zener diode groups 011 to 042

Zener voltage at
5Ma.
Positive
diode
Negative
diode
Fordward
current Rating
17.8v-19.2v
18.8v-20.2v
19.8v-21.2v
20.8v-22.2v
21.8v-23.2v
22.8v-24.2v
011
013
015
017
019
021
012
014
016
018
020
022
25A
25A
25A
25A
25A
25A
17.8v-19.2v
18.8v-20.2v
19.8v-21.2v
20.8v-22.2v
21.8v-23.2v
22.8v-24.2v
031
033
035
037
039
041
032
034
036
038
040
042
35A
35A
35A
35A
35A
35A
Note: Diode number is stamped on the rear of the diode.

2. Stator
Inspect the stator insulation resistance to ground with an
insuation tester or a series test lamp up to 110 volts.
The insulation resistance must be greater than 1 megohm.
The winding reisistance is measured between phases using a
low reading ohmmeter designed for this purpose, the values
are given at the rear of this instruction.
3. Rotor
Inspect the rotor for insulation resistance to ground using an
insulation tester or a series test lamp up to 110 volts.
The insulation resistance must be grater than 1 megohm.
Measure the rotor resistance between the sliprings using an
ohmmeter or apply 12 volts across the sliprings and measure
the rotor current flow, then divide 12 by the measured current,
the results is the rotor resistance in ohms. values are given at
the rear of this instruction.
If the sliprings are worn or out of round they must be remachined to a minimum diameter or 26.7 mm and should have
a runout not exceeding 0.060mm. If the slipring is below these
limits it must be replaced with a new one.
Warning; extreme care must be exercised when machining
the slipring as it is possible for the turning tool to foul the

fan.
4. Replacing the brushes (inbuilt regulator)
Check the brushes for length, this is measured from the brush
holder to the end of the brush along it's centre line. Also
inspect for any sideways wear. If worn replace both brushes.
The minimum length is 3.8mm. Inspect the brush springs for
signs of corrosion or loss of tension or uneven tension.
Replacing the brushes, using a soldering iron apply heat to the
soldered joints on the rear of the brush holder of the regulator,
using a small lever prise up the retaining tabs to release the
brush lead and spring. Thread the new brush lead up the
brush holder along with the spring, pull the lead through the
tabs until the brush is protruding 12mm from the holder.
Bend down the tabs and solder the brush lead taking care not
to allow the solder to run up the lead which will reduce
flexibility. Use 60/40 resin cored solder.
5. Ball bearing
Please note the bearings used in this KCA generator are a
high
tolerance type, only fully sealed bearings of the same
specification are to be used as replacements. It is
recommended that the bearings be replaced during the
reconditioning process to restore the unit to original
specification.
6. Regulator
The regulator can only be tested when fitted into an altenator.
Warning: do not reverse"S" and "L" connections or put 12
volt supply to "L" terminal, this connection must not be
used as a supply source other than to supply the
requirements of the warning lamp 2(watts).
Such action will destroy the regulator warning lamp
circuit.
For test voltages refer to Generator output testing section.
See also additional information on regulator function earlier in
this instruction.
Reassembly
Generator
(a) Press new bearing onto slipring end of the rotor taking care
to aplly the force to the bearing inner race only, otherwise
the bearing will be noisy and it's life will be shortened.
(b) Fit a new bearing to the drive end housing, fit the bearing
plate, and four retaining screws, press the rotor into the
bearing, using a support tool to take the thrust against the
bearing inner.
The support is fitted from the pulley side of the bearing. In
this way the thrust is not taken by the drive end housing.
(c) To fit pulley, mount an 8mm Allen key in the vice with the
short end upwards, place a 24mm ring spanner on the shaft
nut, position the internal hexagon of the rotor shaft onto the
Allen key, tighten the nut to the required torque(See torque
chart)
(d) Inspect the bearing support ring for signs of damage, if in
doubt replace the ring by pressing it into the housing by
hand, do not use excessive force.
(e) To refit the rectifier, fit new mica washers to the positive
heatsink B+ bolt and retaining screw each washer must
have heatsink compound applied to both surfaces before
fitting.
Fit the three retaining screws to the rectifier then install into
slipring end housing. Tighten the B+ bolt to the reuired
torque.
(f) To refit the stator, make sure the spigot surface are clean
and free from damage, fit the stator into the slipring end
housing noting the correct lead connection positioning. Fit
the stator leads into the wire loops in the recrifier. Using a
pair of pliers squeeze the loop to retain the stator lead prior
to soldering. Repeat for each lead in turn, solder the leads
into position using 60/40 resin cored solder. Make sure the
leads will be clear of the internal fan when the rotor is
assmebled into the stator.
(g) Carefully install the rotor into the stator/slipring end housing
assembly, noting the alignment of the housings and through
bolt holes. Fit the through bolts making sure the stator is
seated correctly, tighten the through bolts to the correct
torque setting (uneven torque can produce magnetic noise
levels above normal).
(h) Fitting the regulator. Compress the brushes into the brush
holder by hand, slip the regulator through the opening in the
rear of the slipring end housing until the brushes come in
contact with the slipring. Press the regulator towards the
slipring until the holes are aligned then fit the retaining
screws and tighten.
Inspection
Generator
Before any in field testing can be undertaken it is important
that the battery's conditions is established and the terminals
are clean and tight.
Check the condition of the generator drive belt and ensure that
it is adjusted in accordance with the engine manufacturer's
recommnedations.
Battery conditions:
Note: This assessment may be difficult with maintenance free
assemblies.
Test the specific gravity of the individual cells the readings
should be within 10 points of each other, it is recommended
that the average SG should be 1.260 or higher.
A load test should be carried out to determine the ability of the
battery to supply and accept current. This is a good indicator
as to the general condition of the battery.
A load equal to the normal starting current should be placed
across the battery, the duration of this load test should not
exceed 10 seconds, during this time the terminal voltage
across the battery should not drop below 9.6 volts. Observe
each cell for signs of excessive gas liberation, usuall an
indication of cell failure.
If the battery test is clear proceed with the Generator tests as
follows.
Care should be taken when making the following connections.
It is recommended that the battery negative terminal be
disconnected before the test meters are connected, and
reconnecting the negative terminal when the meters are
inserted into the circuit under test. The warning lamp in the D+
circuit should not exceed 2 watts.
Regulating voltage test on the vehicle.

Connect a voltmeter to the generator, the positive lead to the
B+ terminal and the nagative lead to the generator casing.
Select the voltage range to suit the system, i.e. 20v for 12 volt
sysytems or 40v for 24 volt systems. Connect an ammeter in
series with the main output cable from the B+ terminal on the
generator, the range selected must be capable of reading the
maximum output from the generator.
Note the voltmeter reading before starting the engine. This
reading should increase when the engine is running indicating
generator output, start the engine and increase the engine
speed until the generator is running at 4000 rpm, switch on
vehicle loads of 5-10 A is indcated on the ammeter, the
voltmeter shoud read 14.0-14.2 v for a 12 volt system, for a 24
volt system the readings should be 5-10 A and 27.7-28.5 volts.
Load regulation test

Increase the engine speed until the generator is running at
6000 rpm, increase the load to 90% of full output a decrease in
the regulating voltage should not exceed 0.50 volts for 12 v
and 0.70 v for 24 v regulators of the readings obtained in the
previous test. If so, the regulator is defective.
Generator output test at full load

Increase engine speed until the altenator is running at 6000
rpm, switch on electrical loads until the generator voltage
drops to 13.5 volts for 12 v systems and 26 volts for 24 v
systems, full outut should be obtained under these conditions.
It may be necessary to adjust engine speed to maintain
altenator speed. If sufficient electrical loads are not available a
carbon pile resistance can be connected across the battery
and adjusted until maximum output is obtained.
Keep the time for this test to a minimum to avoid undue
heating and high engine speeds.
Technical Data
(mm)
Brush wear
Sliprings
Sliprings
Pole claws
Minimum Length
3.8
Minimum Diameter 26.7
Trueness
<0.06
Trueness
<0.05(93.250.05)
Torque
N.m(kgfm)
Pulley retaining nut
Capacitor retaining screw
Capacitor whiz nut
B+ terminal nut M8
B+ terminal rectifier nut
Regulator retaining screw
Rectifier retaining screw
Bearing retaining plate screw
Through bolt
54-68(5.5-6.9)
2.7-3.8(0.3-0.4)
1.5-2.2(0.1-0.2)
7.5-8.5(0.8-0.9)
6.0-7.5(0.6-0.8)
1.6-2.3(0.1-0.2)
1.6-2.3(0.1-0.2)
2.1-3.0(0.2-0.3)
3.8-5.5(0.4-0.6)
Winding resistance(between phases)

(W)
70 Amp generator
85 Amp generator
90 Amp generator
Stator
0.086+10%
2.60.13
0.058+10%
2.60.13
0.056+10%
2.60.13
Rotor
Warning lamp fault indication
Fault running
Generator out cable

O/C
Battery "S" cable O/C
Battery overcharged
Positive diode short
Negative diode short
Positive diode open
Negative diode open
Phase voltage sensing
cable open circuit
Power transistor
shorted
Warnign lamp driver
O/C
Generator not
running Ignition ON
Generator
Iginiton ON
ON
ON
ON
ON
OFF
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
ON
ON
ON
OFF
OFF

Output wave forms for phase and startpoint connections.
Note; the average of these two waveforms are identical from
no load to 100% output of rated load.
Voltage phase = Voltage startpoint
6.9v@ rated output
7.2v@ Zero output
Note: The phase frequency is one third of the startpoint

frequency.
ENGINE DRIVEABILITY AND EMISSIONS
6E1
ENGINE
C24SE ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
ABBREVIATIONS CHARTS .........................
ECM Circuit Diagram (1/2) ............................
ECM Circuit Diagram (2/2) ............................
GROUND POINT CHART - LHD G.EXP (1/4)
GROUND POINT CHART - RHD G.EXP (1/4)
LOCATION ...................................................
LOCATION ..............................................
LOCATION LHD ...................................
LOCATION RHD ...................................
CONNECTOR LIST ......................................
RELAY AND FUSE .......................................
(LHD & RHD) ...........................................
ECM WIRING DIAGRAM (1/9) .....................
ECM CONNECTOR PIN ASSIGNMENT &
OUTPUT SIGNAL ....................................
SENSORS ...............................................
Engine Control Module (ECM) ...................
Manifold Absolute Pressure (MAP) Sensor
Throttle Position Sensor (TPS) ..................
Idle Air Control (IAC) Valve .......................
Crankshaft Position (CKP) Sensor ............
Knock Sensor (KS) ....................................
Intake Air Temperature (IAT) Sensor ........
Vehicle Speed Sensor (VSS) ....................
Heated Oxygen (O2) Sensor .....................
METERING ..............................................
6E-6
6E-11
6E-12
6E-13
6E-17
6E-21
6E-23
6E-24
6E-25
6E-28
6E-30
6E-30
6E-32
6E-33
6E-34
6E-35
6E-36
6E-37
6E-38
6E-39
6E-40
6E-41
6E-42
6E-48
6E-48
6E-48
6E-49
6E-49
6E-50
6E-50
6E-50
6E-51
6E-51
6E-51
6E-52
Battery Voltage Correction Mode ...............

Clear Flood Mode ......................................
Deceleration Fuel Cutoff (DFCO) Mode ....
Engine Speed/ Vehicle Speed/ Fuel Disable
Mode ........................................................
Acceleration Mode .....................................
Fuel Cutoff Mode .......................................
Starting Mode ............................................
Run Mode ..................................................
Fuel Metering System Components ..........
Fuel Injector ...............................................
Fuel Pressure Regulator ............................
Fuel Rail .....................................................
Fuel Pump Electrical Circuit .......................
Thottle Body Unit .......................................
GENERAL DESCRIPTION FOR ELECTRIC
IGNITION SYSTEM .................................
Spark Plug .................................................
GENERAL DESCRIPTION FOR EVAPORATIVE
EMISSION SYSTEM ...............................
EVAP Emission Control System Purpose ..
EVAP Emission Control System Operation
System Fault Detection ..............................
POSITIVE CRANKCASE VENTILATION (PCV)
SYSTEM ..................................................
Crankcase Ventilation System Purpose ....
A/C CLUTCH DIAGNOSIS ........................
A/C Clutch Circuit Operation ......................
A/C Clutch Circuit Purpose ........................
A/C Request Signal ...................................
Overview ....................................................
Diagnostic Thought Process ......................
1. Verify the Complaint ..............................
2. Perform Preliminary Checks ..................
3. Check Bulletins and Troubleshooting Hints
4. Perform Service Manual Diagnostic Checks
5a and 5b. Perform Service Manual Diagnostic
Procedures ..............................................
5c. Technician Self Diagnoses ..................
5d. Intermittent Diagnosis ..........................
6E-52
6E-52
6E-52
6E-52
6E-52
6E-52
6E-52
6E-52
6E-53
6E-53
6E-53
6E-53
6E-53
6E-53
6E-54
6E-54
6E-57
6E-57
6E-57
6E-57
6E-59
6E-59
6E-60
6E-60
6E-60
6E-60
6E-61
6E-61
6E-61
6E-62
6E-62
6E-62
6E-63
6E-63
6E-63
6E-63
6E-64
6E2
5e. Vehicle Operates as Designed ............

6E-65
6. Re-examine the complaint .....................
6E-66
7. Repair and Verify Fix .............................
6E-66
GENERAL SERVICE INFORMATION ..........
6E-67
On-Board Diagnostic (OBD) ......................
6E-68
On-Board Diagnostic Tests .......................
6E-68
The Diagnostic Executive ..........................
6E-68
Diagnostic Information ...............................
6E-68
Check Engine Lamp ..................................
6E-68
Data Link Connector (DLC) .......................
6E-68
Tech 2 Operating Flow Cart (Start Up) ......
6E-70
(ENGINE DATA) .........................................
6E-72
(O2 SENSOR DATA) ..................................
6E-74
MISCELLANEOUS TEST .............................
6E-76
PLOTTING SNAPSHOT GRAPH .................
6E-78
Plotting Graph Flow Chart (Plotting graph after
obtaining vehicle information) ..................
6E-79
(Plotting Graph) .......................................
6E-80
SNAPSHOT DISPLAY WITH TIS2000 .........
6E-81
6E-98
Circuit Description .........................................
6E-90
Diagnostic Aids .............................................
6E-90
Test Description ............................................
6E-90
CHECK ....................................................
6E-91
NO CHECK ENGINE LAMP (MIL) ................
6E-94
6E-94
Diagnostic Aids ..........................................
6E-94
No Check Engine Lamp (MIL) ...................
6E-94
6E-96
6E-96
Diagnostic Aids ..........................................
6E-96
Check Engine Lamp (MIL) ON Steady ....
6E-96
FUEL METERING SYSTEM CHECK ...........
6E-98
AND FUEL INJECTOR BALANCE TEST
PROCEDURE .............................................
6E-98
6E-98
Injector Coil Test Procedure (Steps 1-6)
and Injector Balance Test Procedure
(Steps 7-11) .............................................
6E-99
Injector Coil Test Procedure (Steps 1-6)
and Injector Balance Test Procedure
(Steps 7-11) .............................................
6E-100
FUEL SYSTEM ELECTRICAL TEST ...........
6E-103
6E-103
Diagnostic Aids ..........................................
6E-104
Fuel Pressure Relief Procedure .................

6E-104
Fuel Pressure Gauge Installation ..............
6E-104
Fuel System Electrical Test .......................
6E-104
FUEL SYSTEM DIAGNOSIS ........................
6E-108
6E-108
6E-108
Fuel Pressure Relief Procedure .................
6E-109
Fuel Pressure Gauge Installation ..............
6E-109
Fuel System Diagnosis ..............................
6E-110
ECM DIAGNOSTIC TROUBLE CODES (DTC) 6E-113
MANIFOLD ABSOLUTE PRESSURE
CIRCUIT LOW INPUT ................................
6E-119
6E-119
Diagnostic Aids ..........................................
6E-119
Manifold Absolute Pressure Circuit Low
Input .........................................................
6E-120
MANIFOLD ABSOLUTE PRESSURE
CIRCUIT HIGH INPUT ...............................
6E-123
6E-123
Diagnostic Aids ..........................................
6E-124
Manifold Absolute Pressure Circuit High
Input .........................................................
6E-124
INTAKE AIR TEMPERATURE SENSOR LOW
INPUT .........................................................
6E-127
6E-127
Diagnostic Aids ..........................................
6E-127
Intake Air Temperature Sensor Low Input
6E-128
INTAKE AIR TEMPERATURE SENSOR HIGH
INPUT .........................................................
6E-131
6E-131
Diagnostic Aids ..........................................
6E-131
Intake Air Temperature Sensor High Input
6E-132
SENSOR LOW INPUT ................................
6E-136
6E-136
Diagnostic Aids ..........................................
6E-136
Engine Coolant Temperature Sensor Low
Input .........................................................
6E-137
SENSOR HIGH INPUT ...............................
6E-139
6E-139

Diagnostic Aids ..........................................
6E-139
Engine Coolant Temperature Sensor High
Input .........................................................
6E-140
THROTTLE POSITION SENSOR LOW
INPUT .........................................................
6E-143
6E-143
Diagnostic Aids ..........................................
6E-143
Diagnostic Trouble Code (DTC) P0122 Throttle
Position Sensor Low Input .......................
6E-144
THROTTLE POSITION SENSOR HIGH
INPUT ......................................................
6E-147
6E-147
Diagnostic Aids ..........................................
6E-147
Diagnostic Trouble Code (DTC) P0123 Throttle
Position Sensor High Input ......................
6E-148
O2 SENSOR CIRCUIT LOW VOLTAGE
(BANK 1 SENSOR 1) .................................
6E-150
6E-150
Diagnostic Aids ..........................................
6E-150
O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
6E-160
DIAGNOSTIC TROUBLE CODE (DTC) P0132 O2
SENSOR CIRCUIT HIGH VOLTAGE (BANK 1
SENSOR 1) ................................................
6E-155
6E-155
Diagnostic Aids ..........................................
6E-155
O2 Sensor Circuit High Voltage
(Bank 1 Sensor 1) ....................................
6E-156
O2 SENSOR NO ACTIVITY DEFECTED
(BANK 1 SENSOR 1) .................................
6E-159
6E-159
Diagnostic Aids ..........................................
6E-160
O2 Sensor Circuit No Activity Detected
(Bank 1 Sensor 1) ....................................
6E-160
O2 SENSOR HEATER CIRCUIT
(BANK 1 SENSOR 1) .................................
6E-163
6E-163
Diagnostic Aids ..........................................
6E-164
O2 Sensor Heater Circuit (Bank 1 Sensor 1) 6E-164
INJECTOR 1 CONTROL CIRCUIT .............
6E-167

Diagnostic Aids ..........................................
Injector 1 Control Circuit ..........................
KNOCK SENSOR (KS) MODULE CIRCUIT
Diagnostic Aids ..........................................
Knock
Sensor Module Circuit .............................
KNOCK SENSOR (KS) CIRCUIT ...............
Diagnostic Aids ..........................................
Knock Sensor Circuit ...............................
CRANKSHAFT POSITION (CKP) SENSOR
CIRCUIT RANGE/PERFORMANCE (58X) .
CIRCUIT LOW INPUT (58X) ......................
Diagnostic Aids ..........................................
Range/performance (58x) ........................
Crankshaft Position Sensor Circuit Low
Input (58x) ...............................................
IGNITION 1 CONTROL CIRCUIT ...............
IGNITION 2 CONTROL CIRCUIT ...............
Diagnostic Aids ..........................................
Ignition 1 Control Circuit ..........................
Ignition 2 Control Circuit ..........................
6E3
6E-167
6E-167
6E-167
6E-167
6E-168
6E-168
6E-168
6E-168
6E-168
6E-174
6E-174
6E-174
6E-174
6E-177
6E-177
6E-177
6E-178
6E-180
6E-180
6E-180
6E-181
6E-181
6E-181
6E-186
6E-186
6E-186
6E-186
6E-187
6E-187
6E4

EVAPORATIVE (EVAP) EMISSION CONTROL
SYSTEM PURGE CONTROL CIRCUIT .....
6E-191
6E-191
Diagnostic Aids ..........................................
6E-191
EVAP Emission Control System Purge
Control Circuit ..........................................
6E-192
VEHICLE SPEED SENSOR (VSS) CIRCUIT
LOW INPUT ................................................
6E-195
6E-195
Diagnostic Aids ..........................................
6E-195
Vehicle Speed Sensor Circuit Low Input .
6E-196
SYSTEM VOLTAGE LOW ..........................
6E-202
6E-202
Diagnostic Aids ..........................................
6E-202
Diagnostic Trouble Code (DTC) P0562 System
Voltage Low .............................................
6E-202
SYSTEM VOLTAGE HIGH .........................
6E-204
6E-204
Diagnostic Aids ..........................................
6E-204
Diagnostic Trouble Code (DTC) P0563 System
Voltage High ............................................
6E-204
ECM MEMORY CHECKSUM .....................
6E-206
6E-206
Diagnostic Aids ..........................................
6E-206
Diagnostic Trouble Code (DTC) P0601 ECM
Memory Checksum ..................................
6E-206
ECU PROGRAMMING ERROR .................
6E-207
6E-207
Diagnostic Aids ..........................................
6E-207
Diagnostic Trouble Code (DTC) P0602 ECU
Programming Error ..................................
6E-207
DTC P0650 MALFUNCTION INDICATOR LAMP
(MIL) CONTOROL CIRCUIT MALFUNCTION 6E-208
6E-208
Diagnostic Aids ..........................................
6E-208
Malfunction Indicator Lamp (MIL) Control
Circuit Malfunction ...................................
6E-209
FUEL SUPPLY SYSTEM RICH DURING
DECELERATION FUEL CUT OFF .............
6E-211
6E-211
Diagnostic Aids ..........................................
6E-211
Fuel Supply System Rich During

Deceleration Fuel Cutoff ..........................
6E-212
FUEL SUPPLY SYSTEM LEAN DURING
POWER ENRICHMENT .............................
6E-214
6E-214
Diagnostic Aids ..........................................
6E-215
Fuel Supply System Lean During Power
Enrichment ..............................................
6E-215
ECM SYSTEM RESET ...............................
6E-217
6E-217
Diagnostic Aids ..........................................
6E-217
Diagnostic Trouble Code (DTC) P1625 ECM
System Reset ..........................................
6E-217
IMMOBILIZER NO SIGNAL ........................
6E-218
6E-218
Diagnostic Aids ..........................................
6E-218
Immobilizer No Signal ..............................
6E-219
IMMOBILIZER WRONG SIGNAL ...............
6E-222
6E-222
Diagnostic Aids ..........................................
6E-222
Immobilizer Wrong Signal ........................
6E-223
WRONG SECURITY CODE ENTERED ..
6E-224
6E-224
Diagnostic Aids ..........................................
6E-224
Diagnostic Trouble Code (DTC) P1648 Wrong
Security Code Entered ............................
6E-225
IMMOBILIZER FUNCTION NOT
PROGRAMMED .........................................
6E-226
6E-226
Diagnostic Aids ..........................................
6E-226
Immobilizer Function Not Programmed ...
6E-227
TACHOMETER OUTPUT LOW VOLTAGE
6E-228
6E-228
Diagnostic Aids ..........................................
6E-228
Tachometer Output Low Voltage .............
6E-229
SYMPTOM DIAGNOSIS ...............................
6E-232
PRELIMINARY CHECKS .............................
6E-232
VISUAL/PHYSICAL CHECK .........................
6E-232
INTERMITTENT ...........................................
6E-232

ENGINE CRANKS BUT WILL NOT RUN .....
HARD START SYMPTOM ............................
ROUGH, UNSTABLE, OR INCORRECT IDLE,
STALLING SYMPTOM ...............................
SURGES AND/OR CHUGS SYMPTOM ......
CUTS OUT, MISSES SYMPTOM .................
LACK OF POWER, SLUGGISH OR SPONGY
SYMPTOM .................................................
POOR FUEL ECONOMY SYMPTOM ..........
EXCESSIVE EXHAUST EMISSIONS OR
ODORS SYMPTOM ...................................
DIESELING, RUN-ON SYMPTOM ...............
BACKFIRE SYMPTOM .................................
ON-VEHICLE SERVICE PROCEDURE .......
ENGINE CONTROL MODULE (ECM) ..........
SENSOR ....................................................
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR ....................................................
THROTTLE POSITION SENSOR (TPS) ......
IDLE AIR CONTROL (IAC) VALVE ..............
KNOCK SENSOR .........................................
POWER STEERING PRESSURE (PSP)
SWITCH .....................................................
HEATED OXYGEN SENSOR (HO2S) .........
EVAP CANISTER PURGE VALVE SOLENOID
FUEL PRESSURE RELIEF ..........................
FUEL RAIL ASSEMBLY ...............................
FUEL INJECTOR ..........................................
FUEL PRESSURE REGULATOR ................
IGNITION COIL ............................................
SPARK PLUGS ............................................
SPARK PLUG CABLES ................................
EMISSION CONTROL ; CO ADJUSTER (W/O
CATALYSTIC CONVERTER) ..................
SPECIAL SERVICE TOOLS .........................
6E-233
6E-236
6E-239
6E-242
6E-245
6E-248
6E-251
6E-254
6E-256
6E-258
6E-261
6E-262
6E-264
6E-264
6E-264
6E-265
6E-265
6E-266
6E-266
6E-267
6E-268
6E-268
6E-269
6E-269
6E-270
6E-270
6E-271
6E-273
6E-275
6E-275
6E-277
6E-277
6E-279
6E5
6E6
ABBREVIATIONS CHARTS
Abbreviations
Appellation
A/C
Air Conditioner
A/T
Automatic Transmission
ACC
Accessory
BLK
Black
BLU
Blue
BRN
Brown
CEL
Check Engine Lamp
CKP
Crankshaft Position
DLC
Data Link Connector
DTC
Diagnostic Trouble Code
DVM
Digital Volt Meter
ECM
Engine Control Module
ECT
EEPROM
Electrically Erasable & Programmable Read Only Memory
EVAP
Evaporative Emission
EVRV
Electric Vacuum Regulating Valve
EXH
Exhaust
FT
Fuel Temperature
GND
Ground
GRY
Gray
HOS2
Heated Oxygen Sensor
IAC
Idel Air Control
IAT
IG
Ignition
ITP
Intake Throttle Position
KS
Knock Sensor
M/T
Manual Transmission
MAP
MIL
OBD
On-Board Diagnostic
ORN
Orange
OT
Oil Temperature
PNK
Pink
RED
Red
SW
Switch
TB
Throttle Body
TEMP
Temperature
TP
Throttle Position
VCC
Voltage Constant Control
VSS
WHT
White
YEL
Yellow
6E7
COMPONENT LOCATORt
2
(1) Air Cleaner


(1) Intake Air Temperature (IAT) Sensor

6E8


(4) Injector #4 Cylinder (Under the ECM)
(1) Ignition Coil Module Assembly
(1) Heated Oxygen Sensor (HO2S)
6E9
(1) Knock Sensor (KS)

(2) Thermo Meter Sensor
(1) Manifold Absolute Pressure (MAP) Sensor

(1) EVAP Purge Solenoid
6E10
(1) Canister
(1) Fuel Tank

(2) Fuel Pump

(2) Transmission Assembly
(1) Power Steering Pressure Switch

(2) Power Steering Oil Pump Assembly
ECM Circuit Diagram (1/2)
6E11
6E12
ECM Circuit Diagram (2/2)

GROUND POINT CHART - LHD GENERAL EXPORT (1/4)
6E13
6E14

6E15
6E16

GROUND POINT CHART - RHD GENERAL EXPORT (1/4)
6E17
6E18

6E19
6E20

LOCATION
6E21
6E22

CABLE HARNESS & CONNECTOR LOCATION
6E23
6E24

CABLE HARNESS & CONNECTOR LOCATION LHD

CABLE HARNESS & CONNECTOR LOCATION RHD
6E25
6E26
6E27
6E28
CONNECTOR LIST
No.
Connector face
B-24
Green
Meter-B
Check connector
Fuel injector
E-7
B-63
White
CO Adjuster
E-6
B-62
White
Fuel injector
E-8
B-68
Fuel injector
E-9
Immobilizer
Fuel injector
E-18
C-2
Silver
C-56
Ignition coil
E-60
ECM
C-107
White
ECM
E-72
J/B E2
C-108
White
Connector face
C-122
B-58
Black
No.
Engine earth-A
E-74
J/B E1
C-121
Engine earth-B
E-77
IAT sensor
O2 sensor
No.
Connector face
E-84
E-85
F-2
Fuel pump & sensor
Engine room ~ INST
Silver
Battery (-)
Silver
Body earth (Ground)
Silver
Engine ground
X-2
Engine room ~ INST
H-9
Black
Relay; Fuel pump
X-11
H-18
White
Relay & Fuse box
P-10
H-7
Blue
Silver
P-6
H-6
White
Battery (+)
P-5
H-4
White
Silver
P-2
MAP sensor
White
Connector face
P-1
Knock sensor
White
No.
Black
Relay; Heater
X-14
Engine room ~ INST
H-31

H-34
Black
Relay; A/C Compressor
6E29
6E30

RELAY AND FUSE
LHD
RHD
6E31

RELAY & FUSE BOX
RELAY
No.
X-1
X-2
X-3
X-4
X-5
X-6
X-7
X-8
X-9
X-10
X-11
X-12
X-13
X-14
X-15
FUSE
NO.
EB-1
EB-2
EB-3
EB-4
EB-5
EB-6
EB-7
EB-8
EB-9
EB-10
EB-11
EB-12
EB-13
EB-14
EB-15
EB-16
Relay Name
RELAY; TAIL LIGHT
RELAY; FUEL PUMP
RELAY; HORN
RELAY; DIMMER
RELAY; FRT FOG
LIGHT (LHD only)
RELAY; STARTER
RELAY; COND, FAN
RELAY; HEATER
RELAY; HEAD LIGHT
RELAY; A/C COMP

RELAY; THERMO
Fuse Name
15A ECM
15A FRT FOG

15A ACG (S)
10A ILLUMI
10A TAIL
10A H/LIGHT-RH
10A H/LIGHT-RH-LOW
10A H/LIGHT-LH
10A H/LIGHT-LH-LOW
(LHD only)
20A FUEL PUMP
10A O2 SENSOR
10A H/LIGHT-RHHIGH (LHD only)
10A H/LIGHT-LHHIGH (LHD only)
10A A/C
10A HORN
10A HAZARD
SLOW BLOW FUSE

NO.
SBF-1
Slow Blow Fuse Name

100A MAIN
FUSE NO.
Slow Blow Fuse Name
SBF-6
SBF-2
SBF-7
SBF-3
SBF-8
30A BLOWER
SBF-9
50A IG 2
SBF-4
20A COND, FAN
SBF-5
40A IG 1
6E32

FUSE BOX
FUSE
No.
1
2
3
4
5
6
7
8
9
10
11
Capacity
10A
10A
15A
15A
10A
15A
15A
20A
15A
10A
Indication on label
ABS
TRAILER
BACK UP
METER
TURN
ELEC.IG
ENGINE
FRT WIPER
EGR
AUDIO
SLOW BLOW FUSE

No.
Capacity
22
20A
23
30A
Indication on label
RR DEF
POWER WINDOW
RELAY
Connector No.
C24SE
B-7
REAR DEFOGGER
No.
12
13
14
15
16
17
18
19
20
21
Capacity
15A
15A
20A
10A
10A
10A
15A
15A
10A
10A
B-8
POWER WINDOW
Indication on label
CIGER
AUDIO (+B)
DOOR LOCK
METER (+B)
ROOM
ANTI THEFT
STOP
ACC SOCKET
STARTER
SRS
B-40
ACC SOCKET

6E33
6E34

6E35
6E36

6E37
6E38

6E39
6E40

6E41
6E42

Connector J1 Port: View Looking Into ECM Case
PIN1
PIN16
1
17
16
32
PIN32
PIN17
Pin
No.
B/
Box
No.
J1-1
J1-1
Ground
J1-2
J1-2
J1-3
Pin Function
Wire
Color
Tester Position
ECM
Connection
Range
(+)
(-)
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
BLK/
WHT
Continuity
with
ground
Disconnect
J1-1
GND
Ground
BLK/
WHT
Continuity
with
ground
Disconnect
J1-2
GND
J1-3
Knock Sensor Signal
YEL
Less than
1V
J1-4
J1-4
No Connection
J1-5
J1-5
Canister Purge
Solenoid Valve
RED/
YEL
Less than
1V
J1-6
J1-6
Crankshaft Position
(CKP) Sensor (Ground)
RED
Approx.
0.58k
J1-7
J1-7
Throttle Position
Sensor (TPS) Output
Signal
BLU
Less than
1V
J1-8
J1-8
No. 3 Injector
GRN/
BLK
Less than
1V
J1-9
J1-9
No. 1 Injector
GRN/
WHT
Less than
1V
J1-10
J1-10
No Connection
J1-11
J1-11
No. 4 Injector
J1-12
J1-12
No Connection
J1-13
J1-13
Idle Air Control Valve

(IACV) Coil B High
GRN
Less than
1V
BLU/
RED
Less than
1V
Connect
DC V
J1-5
GND
Disconnect
J1-6
J1-21
Approx
0.8V
Connect
DC V
J1-7
J1-32
Wave form E or 12-14V
Connect
DC V
J1-8
GND
Connect
DC V
J1-9
GND
Wave form G or 12-14V

-
Approx 0.7V

-
J1-14
J1-14
No Connection
J1-15
J1-15
Throttle Position
Sensor (TPS) Power
Supply
RED
Less than
1V
J1-16
J1-16
MAP Sensor Ground
GRN
Continuity
with
ground
J1-17
J1-17
Ground
BLK/
WHT
Continuity
with
ground
J1-18
J1-18
Coil Module 2 (No. 2 &

3 Cylinder)
BLU
J1-19
J1-19
Coil Module 1 (No. 1 &

4 Cylinder)
GRN
J1-20
J1-20
No Connection
Connect
DC V
J1-11
GND
Connect
DC V
J1-13
GND
Connect
DC V
J1-15
J1-32
Connect
J1-16
GND
Connect
J1-17
GND
Wave form F
Wave form F
Approx. 5V

Pin
No.
B/
Box
No.
J1-21
J1-21
Crankshaft Position
(CKP) Sensor Signal
J1-22
J1-22
No.2 Injector
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
WHT
Wave form
or approx.
3.7V
Wave form
A or
approx.
7.8V
GRN/
WHT
Less than
1V
J1-23
J1-23
No Connection
J1-24
J1-24
MAP Sensor Signal
J1-25
J1-25
No Connection
J1-26
J1-26
No Connection
J1-27
J1-27
Engine Coolant Temp.

(ECT) Sensor Signal
GRY
Less than
1V
20: Approx. 2.4V / 40: Approx. 1.4V or

4.1V / 60 : Approx. 3.3V / 80 : Approx.
2.5V
J1-28
J1-28

(IACV) Coil A High
BLU
Less than
1V
J1-29
J1-29

(IACV) Coil B Low
BLU/
BLK
Less than
1V
J1-30
J1-30

(IACV) Coil A Low
BLU/
WHT
J1-31
J1-31
MAP Sensor Power

Supply
J1-32
J1-32
ECT Sensor, Knock

Sensor, Throttle
Position Sensor Ground
6E43
Tester Position
ECM
Connection
Range
(+)
(-)
Connect
AC V
J1-21
J1-6
Connect
DC V
J1-22
GND
GRY
Less than
1V
Approx.
4.8V
Approx.
1.3V
Approx.
0.9V
Connect
DC V
J1-24
J1-16
J1-26
Connect
DC V
J1-27
J1-32
Connect
DC V
J1-28
GND
Connect
DC V
J1-29
GND
Less than
1V
Connect
DC V
J1-30
GND
RED
Less than
1V
Approx.. 5V
Connect
DC V
J1-31
J1-16
GRN
Continuity
with
ground
Connect
J1-32
GND
6E44
Connector J2 Port: View Looking Into ECM Case

PIN17
PIN32
1
17
16
32
PIN1
PIN16
Tester Position
Pin
No.
B/
Box
No.
J2-1
J2-1
Intake Air Temp. (IAT)

Sensor Ground
GRN
J2-2
J2-2
RED/
WHT
J2-3
J2-3
Ignition Power Supply
BLU/
YEL
Less than
1V
J2-4
J2-4
To Data Link
Connector No. 6
BLU
J2-5
J2-5
No Connection
J2-6
J2-6
Oxygen Sensor
(Ground)
PNK
Continuity
with
ground
Connect
J2-6
GND
J2-7
J2-7
No Connection
J2-8
J2-8
No Connection
Pin Function
Wire
Color
Key SW
Off
Key SW
On
Engine
Idle
Engine
2000rpm
Continuity
with
ground
10-14V
10-14V
ECM
Connection
Range
(+)
(-)
Disconnect
J2-1
GND
Connect
DC V
J2-2
GND
Connect
DC V
J2-3
GND
J2-9
J2-9
No Connection
J2-10
J2-10
CO Adjust Signal
(W/O Catalystic
Converter)
YEL
J2-11
J2-11
Fuel Pump Relay
GRN/
WHT
10-14V
While relay
is activated;
10-14V
Relay is not
activated;
Less than
1V
Connect
DC V
J2-11
GND
J2-12
J2-12
No Connection
J2-13
J2-13
A/C Compressor
Relay
J2-14
J2-14
J2-15
J2-16
10-14V
GRY/
RED
Less than
1V
No Connection
J2-15
No Connection
J2-16
No Connection
J2-17
J2-17
CO Adjust (W/O
Catalystic Converter)
RED
J2-18
J2-18
RED/
WHT
J2-19
J2-19
No Connection
J2-20
J2-20
Power Steering
Pressure Switch
GRN/
YEL
Less than
1V
J2-21
J2-21
Oxygen Sensor
BLU
Less than
1V
J2-22
J2-22
Intake Air Temp. (IAT)

Sensor (Signal)
YEL/
GRN
Less than
1V
Connect
DC V
J2-13
GND
Connect
DC V
J2-18
GND

A/C comp. is not operated: 10-14V
10-14V
-
Pressure switch is turned on: Less than 1V

Pressure switch is turned off: 10-14V
Approx.
0.4V
Wave form D or 0.1 0.9V
20: Approx. 2.9V / 40: Approx. 1.8V V

/ 60 : Approx. 1.1V / 80 : Approx. 0.6V
Connect
DC V
J2-20
GND
Connect
DC V
J2-21
J2-6
Connect
DC V
J2-22
33

Pin
No.
B/
Box
No.
J2-23
J2-23

(VSS) Signal
(Immobilizer Control
Unit Terminal B8)
J2-24
J2-24
No Connection
J2-25
J2-25
Tachometer Output
Signal
J2-26
J2-26
Thermo Relay
GRN/
BLK
Less than
1V
J2-27
J2-27
No Connection
J2-28
J2-28
No Connection
J2-29
J2-29
No Connection
J2-30
J2-30
To Data Link
Connector No. 2
GRN
J2-31
J2-31
Oxygen Sensor Heater
BLU/
WHT
J2-32
J2-32
Check Engine Lamp

(Immobilizer Control
Unit Terminal B7)
BRN/
YEL
Pin Function
Wire
Color
Engine
Idle
Engine
2000rpm
6E45
Tester Position
ECM
Connection
Range
(+)
(-)
Connect
AC V
J2-23
GND
Key SW
Off
Key SW
On
WHT
BLK/
RED
Wave form
Wave form
B or
Approx.
4.5V
Connect
AC V
J2-25
GND
A/C request is activated: 10-14V

A/C request is not activated: Less than 1V
Connect
DC V
J2-26
GND
Continuity
with
ground
Wave
Form
Wave
Form D
Connect
J2-31
GND
Less than
1V
Less than
1V
Connect
DC V
J2-32
GND
Wave form C or Approx.

6.5V at 20km/h
Lamp is turned on: Less

than 1V
Lamp is turned off: 1014V
6E46
Reference Wave Form


Reference Wave Form
CH1
0V
0V
CH2
0V
Measurement Terminal: J1-21(+)

J1-6(-)
5ms/div
Ve h ic le S p e e d S e n s or (V S S ) R e fe re n c e W a ve F o rm
Measurement Terminal: CH1: J1-21(+) / CH2: J2-25(+) GND(-)

5ms/div
Heated Oxygen Sensor (HO2S) Reference Wave Form
C H1
0V
0V
C H2
0V
Measurement Term inal: CH1: ECM J2-23(+) / CH2: VSS 3(+) GND(-)
Measurem ent Scale: CH1: 10V/div / CH2: 10V/div 50m s/div
Measurem ent Condition: A pproximately 20km /h
Note: The vehicle is without im mobilizer system,

GND(-)
Measurement Scale: 500mV/div
500ms/div
Measurement Condition: Approximately 2000rpm in Closed Loop
Injector Control Signal Reference Wave Form
Ignition Coil Control Signal Reference Wave Form
0V
CH1
0V
CH2
0V
Measurement Terminal: J1-9(+) (No.1 Cylinder)

GND(-)
5ms/div
Measurement Terminal: CH1: J1-19(+) / CH2: J1-18(+)

GND(-)
10ms
EVAP Canister Purge Solenoid Reference Wave Form
0V
Measurement Terminal: J1-5(+) GND(-)

20ms/div
6E47
6E48

SENSORS
Knock signal
Throttle position
Vehicle speed
Power steering pressure
Air conditioning request on or off
Outputs (Systems controlled):
Ignition control
Fuel control
Idle air control
Fuel pump
EVAP canister purge
Air conditioning
Diagnostics functions
Manifold Absolute Pressure (MAP) Sensor
(1) J1 Port
(2) J2 Port
The engine control module (ECM) is located on the
intake manifold. The ECM controls the following.
Fuel metering system
Ignition timing
On-board diagnostics for electrical functions.
The ECM constantly observes the information from various sensors. The ECM controls the systems that affect
vehicle performance. And it performs the diagnostic
function of the system.
The function can recognize operational problems, and
warn to the driver through the check engine lamp, and
store diagnostic trouble code (DTC). DTCs identify the
problem areas to aid the technician in marking repairs.
4.5
4
3.5
Output Voltage (V)
The input / output devices in the ECM include analog to

digital converts, signal buffers, counters and drivers.
The ECM controls most components with electronic
switches which complete a ground circuit when turned
on.
C h arac teris tic of MA P S ens or -R ef erenc e5
3
2.5
2
1.5
1
0.5
0
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
Mani fold A bs olute P res s ure (K P a) (T ec h2 Reading)
Inputs (Operating condition read):

Battery voltage
Electrical ignition
Exhaust oxygen content
Intake manifold pressure
Crankshaft position
The MAP sensor is a strain gage. A pressure strains the

resistance on the silicon base. At that time the
resistance value changes. And it changes voltage. In
other words it measures a pressure value. It is installed
to the intake manifold. Output voltage of the MAP
sensor is low as pressure is low.

6E49

Coil
Coil
(EC M
Coil
(EC M
Coil
(EC M
Coil
(EC M
Step
A High
J1-28)
A
Low
J1-30)
B High
J1-13)
B
Low
J1-29)
On
On
On
On
On
On
On
On
(IAC Va lve Close Direction)
The idle air control valve (IAC) valve is two directional

and gives 2-way control. With power supply to the coils
controlled steps by the engine control module (ECM),
the IAC valve's pintle is moved to adjust idle speed,
raising it for fast idle when cold or there is extra load
from the air conditioning or power steering.
By moving the pintle in (to decrease air flow) or out (to
increase air flow), a controlled amount of the air can
move around the throttle plate. If the engine speed is
too low, the engine control module (ECM) will retract the
IAC pintle, resulting in more air moving past the throttle
plate to increase the engine speed.
If the engine speed is too high, the engine control
module (ECM) will extend the IAC pintle, allowing less
air to move past the throttle plate, decreasing the
engine speed.

C haract erist ic of TPS -R ef erenc e5
4. 5
4
3. 5
Output Voltage (V)
(IAC Valve Open Direction)
3
2. 5
2
1. 5
1
0. 5
0
0
10
20
30
40
50
60
70
80
90
100
Th rot t le An gle (%) (Tech2 R eading)

on the throttle body.
amount of the air delivered to the engine.
Engine coolant is directed through a coolant cavity in
the throttle body to warm the throttle valve and to
prevent icing.
The IAC pintle valve moves in small step called counts.

During idle, the proper position of the IAC pintle is
calculated by the engine control module (ECM) based
on battery voltage, coolant temperature, engine load,
and engine speed.
If the engine speed drops below a specified value, and
the throttle plate is closed, the engine control module
(ECM) senses a near-stall condition. The engine control
module (ECM) will then calculate a new IAC pintle valve
position to prevent stalls.
If the IAC valve is disconnected and reconnected with
the engine running, the idle speed will be wrong. In this
case, the IAC must be reset. The IAC resets when the
key is cycled On then Off. When servicing the IAC, it
should only be disconnected or connected with the
ignition Off.
The position of the IAC pintle valve affects engine startup and the idle characteristic of the vehicle.
If the IAC pintle is fully open, too much air will be
allowed into the manifold. This results in high idle
speed, along with possible hard starting and lean air/
fuel ratio.
6E50
Characteristic of ECT Sensor -Reference100000
Knock Sensor (KS)
The knock sensor (KS) contains an element that

converts detection of knock into an electrical signal, and
is mounted on cylinder block wall.
When the ECM receives a signal that indicates knock,
the ECM orders ignition timing to be adjusted to
compensate.
10000
The crankshaft position (CKP) sensor, which sends a

signal necessary for deciding on injection timing to the
ECM, is mounted on the left-hand side of the cylinder
block just back of the A/C compressor.
The crankshaft has a 58 teeth press-fit timing disc, from
which the CKP sensor reads the position of the
crankshaft at all the times. It converts this to an
electrical signal, which it sends to the ECM.
Using the 58 X signals per rotation and the timing-mark
signal sent by the CKP sensor, the ECM is able to
accurately calculate engine speed and crank position.
The ECM converts the 58 X signals into square signals.
This converted signal is sent from the ECM terminal J225 to the tachometer.
1000
100
10
-20
-10
10
20
30
40
50
60
70
80
90
100
110
120
Coolant Temp. (deg. C) (Tech2 Reading)

a high resistance.
temperature is hot.

Intake Air Temperature (IAT) Sensor
6E51

meter fuse.
Heated Oxygen (O2) Sensor
Characteristic of IAT Sensor -Ref erence100000
10000
1000
100
10
-20
-10
10
20
30
40
50
60
70
80
Intake Air Temp. (deg. C) (Tech2 Reading)
90
100
110
120

hot.
The heated oxygen sensor consists of a 4-wire low

temperature activated zirconia oxygen analyzer element
with heater for operating temperature of 315C, and
there is one mounted on each exhaust pipe.
A constant 450millivolt is supplied by the ECM between
the two supply terminals, and oxygen concentration in
the exhaust gas is reported to the ECM as returned
signal voltage.
The oxygen present in the exhaust gas reacts with the
sensor to produce a voltage output. This voltage should
constantly fluctuate from approximately 100mV to
1000mV and the ECM calculates the pulse width
commanded for the injectors to produce the proper
combustion chamber mixture.
Low oxygen sensor output voltage is a lean mixture
which will result in a rich commanded to compensate.
High oxygen sensor output voltage is a rich mixture
which result in a lean commanded to compensate.
When the engine is first started the system is in Open
Loop operation. In Open Loop, the ECM ignores the
conditions (ECT, time from start, engine speed &
oxygen sensor output) are met, the system enters
Closed Loop operation. In Closed Loop, the ECM
calculates the air fuel ratio based on the signal from the
oxygen sensors.
amount of time required for closed loop fuel control to
begin operation and allow accurate catalyst monitoring.
The oxygen sensor heater greatly decreases the
amount of time required for fuel control sensors to
become active.
Oxygen sensor heaters are required by catalyst monitor
and sensors to maintain a sufficiently high temperature
which allows accurate exhaust oxygen content readings
further away from the engine.
6E52

METERING
The fuel metering system starts with the fuel in the fuel
tank. An electric fuel pump, located in the fuel tank,
pumps fuel to the fuel rail through an in-line fuel filter.
The pump is designed to provide fuel at a pressure
above the pressure needed by the injectors.
A fuel pressure regulator in the fuel rail keeps fuel
available to the fuel injectors at a constant pressure.
A return line delivers unused fuel back to the fuel tank.
The basic function of the air/fuel metering system is to
control the air/fuel delivery to the engine. Fuel is
delivered to the engine by individual fuel injectors
mounted in the intake manifold.
The main control sensor is the heated oxygen sensor
located in the exhaust system. The heated oxygen
sensor reports to the ECM how much oxygen is in the
exhaust gas. The ECM changes the air/fuel ratio to the
engine by controlling the amount of time that fuel
injector is On.
The best mixture to minimize exhaust emissions is 14.7
parts of air to 1 part of gasoline by weight, which allows
the catalytic converter to operate most efficiently.
Because of the constant measuring and adjusting of the
air/fuel ratio, the fuel injection system is called a closed
loop system.
The ECM monitors signals from several sensors in
order to determine the fuel needs of the engine. Fuel is
delivered under one of several conditions called mode.
All modes are controlled by the ECM.
Battery Voltage Correction Mode

When battery voltage is low, the ECM will compensate
for the weak spark by increasing the following:
The amount of fuel delivered.
The idle RPM.
Clear Flood Mode

Clear a flooded engine by pushing the accelerator pedal
down all the way. The ECM then de-energizes the fuel
injectors. The ECM holds the fuel injectors de-energized
as long as the throttle remains above 75% and the
engine speed is below 800 RPM. If the throttle position
becomes less than 75%, the ECM again begins to pulse
the injectors ON and OFF, allowing fuel into the
cylinders.
Deceleration Fuel Cutoff (DFCO) Mode

flow. When deceleration is very fast, the ECM may cut
off fuel completely. Until enable conditions meet the
engine revolution less 1000 rpm or manifold absolute
pressure less than 10 kPa.
Engine Speed/ Vehicle Speed/ Fuel Disable

Mode
The ECM monitors engine speed. It turns off the fuel
injectors when the engine speed increases above 6000
RPM. The fuel injectors are turned back on when
engine speed decreases below 3500 RPM.
Acceleration Mode
The ECM provides extra fuel when it detects a rapid
increase in the throttle position and the air flow.
Fuel Cutoff Mode

No fuel is delivered by the fuel injectors when the
ignition is OFF. This prevents engine run-on. In addition,
the ECM suspends fuel delivery if no reference pulses
are detected (engine not running) to prevent engine
flooding.
Starting Mode
When the ignition is first turned ON, the ECM energizes
the fuel pump relay for two seconds to allow the fuel
pump to build up pressure. The ECM then checks the
engine coolant temperature (ECT) sensor and the
throttle position sensor to determine the proper air/fuel
ratio for starting.
The ECM controls the amount of fuel delivered in the
starting mode by adjusting how long the fuel injectors
are energized by pulsing the injectors for very short
times.
Run Mode
The run mode has the following two conditions:
Open loop
Closed loop
When the engine is first started, the system is in open
loop operation. In Open Loop, the ECM ignores the
signal from the heated oxygen sensor (HO2S). It
calculates the air/fuel ratio based on inputs from the TP,
ECT, and MAP sensors.
The system remains in Open Loop until the following
conditions are met:
The HO2S has a varying voltage output showing that
it is hot enough to operate properly (this depends on
temperature).
The ECT has reached a specified temperature.
A specific amount of time has elapsed since starting
the engine.
Engine speed has been greater than a specified RPM
since start-up.
The specific values for the above conditions vary with
different engines and are stored in the programmable
read only memory (PROM). When these conditions are
met, the system enters closed loop operation. In
closed loop, the ECM calculates the air/fuel ratio
(injector on-time) based on the signal from the HO2S.
This allows the air/fuel ratio to stay very close to 14.7:1.

Fuel Metering System Components
pressure will result in poor performance.
The fuel metering system is made up of the following

parts.
Fuel injector
Thottle Body Unit
Throttle body
Fuel rail
Fuel pressure regulator
ECM
Idle air control (IAC) valve
Fuel pump
Fuel Injector
The group fuel injection fuel injector is a solenoid
operated device controlled by the ECM. The ECM
energizes the solenoid, which opens a valve to allow
fuel delivery.
The fuel is injected under pressure in a conical spray
pattern at the opening of the intake valve. Excess fuel
not used by the injectors passes through the fuel
pressure regulator before being returned to the fuel
tank.
Fuel Pressure Regulator

The fuel pressure regulator is a diaphragm-operated
relief valve mounted on the fuel rail with fuel pump
pressure on one side and manifold pressure on the
other side. The fuel pressure regulator maintains the
fuel pressure available to the injector at three times
barometric pressure adjusted for engine load. It may be
serviced separately.
If the pressure is too low or poor performance, DTC
P0131 or P1171 will be the result. If the pressure is too
high, DTC P0132 or P1167 will be the result. Refer to
Fuel System Diagnosis for information on diagnosing
fuel pressure conditions.
Fuel Rail
The fuel rail is mounted to the top of the engine and
distributes fuel to the individual injectors. Fuel is
delivered to the fuel inlet tube of the fuel rail by the fuel
lines. The fuel goes through the fuel rail to the fuel
pressure regulator. The fuel pressure regulator
maintains a constant fuel pressure at the injectors.
Remaining fuel is then returned to the fuel tank.
Fuel Pump Electrical Circuit

When the key is first turned ON, the ECM energizes the
fuel pump relay for two seconds to build up the fuel
pressure quickly. If the engine is not started within two
seconds, the ECM shuts the fuel pump off and waits
until the engine is cranked. When the engine is cranked
and the 58X crankshaft position signal has been
detected by the ECM, the ECM supplies 12 volts to the
fuel pump relay to energize the electric in-tank fuel
pump.
An inoperative fuel pump will cause a no-start
condition. A fuel pump which does not provide enough
6E53

amount of air delivered to the engine. The Thottle
position sensor and IAC valve are also mounted on the
throttle body.
Vacuum ports located behind the throttle plate provide
the vacuum signals needed by various components.
Engine coolant is directed through a coolant cavity in
the throttle body to warm the throttle valve and to
prevent icing.
6E54
GENERAL DESCRIPTION FOR ELECTRIC

IGNITION SYSTEM
The engine use two ignition coils, one per two cylinders.
A two wire connector provides a battery voltage primary
supply through the ignition fuse.
The ignition control spark timing is the ECMs method of
controlling the spark advance and the ignition dwell.
The ignition control spark advance and the ignition dwell
are calculated by the ECM using the following inputs.
Engine speed
Engine coolant temperature (ECT) sensor
ECM and ignition system supply voltage
Ignition coil works to generate only the secondary
voltage be receiving the primary voltage from ECM.
The primary voltage is generated at the coil driver
located in the ECM. The coil driver generate the primary
voltage based on the crankshaft position signal. In
accordance with the crankshaft position signal, ignition
coil driver determines the adequate ignition timing and
also cylinder number to ignite.
Ignition timing is determined the coolant temperature,
intake air temperature, engine speed, engine load,
knock sensor signal, etc.
before the recommended replacement interval, locate

and correct the cause.
Carbon fouling of the spark plug is indicated by dry,
black carbon (soot) deposits on the portion of the spark
plug in the cylinder. Excessive idling and slow speeds
under light engine loads can keep the spark plug
temperatures so low that these deposits are not burned
off. Very rich fuel mixtures or poor ignition system output
may also be the cause. Refer to DTC P1167.
Oil fouling of the spark plug is indicated by wet oily
deposits on the portion of the spark plug in the cylinder,
usually with little electrode wear. This may be caused by
oil during break-in of new or newly overhauled engines.
Deposit fouling of the spark plug occurs when the
normal red-brown, yellow or white deposits of
combustion by-products become sufficient to cause
misfiring. In some cases, these deposits may melt and
form a shiny glaze on the insulator around the center
electrode. If the fouling is found in only one or two
cylinders, valve stem clearances or intake valve seals
may be allowing excess lubricating oil to enter the
cylinder, particularly if the deposits are heavier on the
side of the spark plug facing the intake valve.
Spark Plug
Although worn or dirty spark plugs may give satisfactory
operation at idling speed, they frequently fail at higher
engine speeds. Faulty spark plugs may cause poor fuel
economy, power loss, loss of speed, hard starting and
generally poor engine performance. Follow the
scheduled maintenance service recommendations to
ensure satisfactory spark plug performance. Refer to
Maintenance and Lubrication.
Normal spark plug operation will result in brown to
grayish-tan deposits appearing on the insulator portion
of the spark plug. A small amount of red-brown, yellow,
and white powdery material may also be present on the
insulator tip around the center electrode. These
deposits are normal combustion by-products of fuels
and lubricating oils with additives. Some electrode wear
will also occur. Engines which are not running properly
are often referred to as misfiring. This means the
ignition spark is not igniting the air/fuel mixture at the
proper time. While other ignition and fuel system causes
must also be considered, possible causes include
ignition system conditions which allow the spark voltage
to reach ground in some other manner than by jumping
across the air gap at the tip of the spark plug, leaving
the air/fuel mixture unburned. Misfiring may also occur
when the tip of the spark plug becomes overheated and
ignites the mixture before the spark jumps. This is
referred to as pre-ignition.
Spark plugs may also misfire due to fouling, excessive
gap, or a cracked or broken insulator. If misfiring occurs
Excessive gap means that the air space between the

center and the side electrodes at the bottom of the
spark plug is too wide for consistent firing. This may be
due to improper gap adjustment or to excessive wear of
the electrode during use. A check of the gap size and
comparison to the gap specified for the vehicle in
Maintenance and Lubrication will tell if the gap is too
wide. A spark plug gap that is too small may cause an
unstable idle condition. Excessive gap wear can be an
indication of continuous operation at high speeds or
with engine loads, causing the spark to run too hot.
Another possible cause is an excessively lean fuel
mixture.
Low or high spark plug installation torque or improper

seating can result in the spark plug running too hot and
can cause excessive center electrode wear. The plug
and the cylinder head seats must be in good contact for
proper heat transfer and spark plug cooling. Dirty or
damaged threads in the head or on the spark plug can
keep it from seating even though the proper torque is
applied. Once spark plugs are properly seated, tighten
them to the torque shown in the Specifications Table.
Low torque may result in poor contact of the seats due
to a loose spark plug. Over tightening may cause the
spark plug shell to be stretched and will result in poor
contact between the seats. In extreme cases, exhaust
blow-by and damage beyond simple gap wear may
occur.
Cracked or broken insulators may be the result of
improper installation, damage during spark plug regapping, or heat shock to the insulator material. Upper
insulators can be broken when a poorly fitting tool is
used during installation or removal, when the spark plug
is hit from the outside, or is dropped on a hard surface.
Cracks in the upper insulator may be inside the shell
and not visible. Also, the breakage may not cause
problems until oil or moisture penetrates the crack later.
6E55
A broken or cracked lower insulator tip (around the

center electrode) may result from damage during regapping or from heat shock (spark plug suddenly
operating too hot).
Damage during re-gapping can happen if the gapping
tool is pushed against the center electrode or the
insulator around it, causing the insulator to crack.
When re-gapping a spark plug, make the adjustment
by bending only the ground side terminal, keeping the
tool clear of other parts.
Heat shock breakage in the lower insulator tip

generally occurs during several engine operating
conditions (high speeds or heavy loading) and may
be caused by over-advanced timing or low grade
fuels. Heat shock refers to a rapid increase in the tip
temperature that causes the insulator material to
crack.
Spark plugs with less than the recommended amount of
service can sometimes be cleaned and re-gapped, then
6E56
returned to service. However, if there is any doubt about

the serviceability of a spark plug, replace it. Spark plugs
with cracked or broken insulators should always be
replaced.

EVAPORATIVE EMISSION SYSTEM
6E57
EVAP Emission Control System Operation

The EVAP canister purge is controlled by a solenoid
valve that allows the manifold vacuum to purge the
canister. The engine control module (ECM) supplies a
ground to energize the solenoid valve (purge on). The
EVAP purge solenoid control is pulse-width modulated
(PWM) (turned on and off several times a second). The
duty cycle (pulse width) is determined by engine
operating conditions including load, throttle position,
coolant temperature and ambient temperature. The duty
cycle is calculated by the ECM. the output is
commanded when the appropriate conditions have
been met. These conditions are:
The engine is fully warmed up.
The engine has been running for a specified time.
The IAT reading is above 10C (50F).
(1) Purge Solenoid Valve

(2) From Canistor to Purge Solenoid
(3) From Purge Solenoid to Intake
Purge/Vacuum Hoses. Made of rubber compounds,

these hoses route the gasoline fumes from their
sources to the canister and from the canister to the
intake air flow.
EVAP Canister. Mounted on a bracket ahead of the
fuel tank, the canister stores fuel vapors until the
ECM determined that engine conditions are right for
them to be removed and burned.
Poor idle, stalling and Poor driveability can be caused
by:
A malfunctioning purge solenoid.
A damaged canister.
Hoses that are split, cracked, or not connected
properly.
System Fault Detection
(1) Canistor
(2) Air Separator
EVAP Emission Control System Purpose

The basic evaporative emission control system used on
the charcoal canister storage method. The method
transfers fuel vapor from the fuel tank to an activated
carbon (charcoal) storage devise to hold the vapors
when the vehicle is not operating.
The canister is located on the rear axle housing by the
frame cross-member.
When the engine is running, the fuel vapor is purged
from the carbon element by intake air flow and
consumed in the normal combustion process.
The EVAP leak detection strategy is based on applying

vacuum to the EVAP system and monitoring vacuum
decay. At an appropriate time, the EVAP purge solenoid
is turned ON, allowing the engine vacuum to draw a
small vacuum on the entire evaporative emission
system.
After the desired vacuum level has been achieved, the
EVAP purge solenoid is turned OFF, sealing the
system. A leak is detected by monitoring for a decrease
in vacuum level over a given time period, all other
variables remaining constant.
If the desired vacuum level cannot be achieved in the
test described above, a large leak or a faulty EVAP
purge control solenoid valve is indicated.
Leaks can be caused by the following conditions:
Missing or faulty fuel cap
Disconnected, damaged, pinched, or blocked EVAP
purge line
Disconnected, damaged, pinched, or blocked fuel
tank vapor line
Disconnected or faulty EVAP purge control solenoid
valve
Open ignition feed circuit to the purge solenoid
6E58
Damaged EVAP canister

Leaking fuel sender assembly O-ring
Leaking fuel tank or fuel filler neck
The ECM supplies a ground to energize the purge
control solenoid valve (purge ON ). The EVAP purge
control is turned ON and OFF, several times a
second. The duty cycle (pulse width) is determined by
engine operating conditions including load, throttle
position, coolant temperature and ambient temperature.
The duty cycle is calculated by the ECM and the output
is commanded when the appropriate conditions have
been met.
The system checks for conditions that cause the EVAP
system to purge continuously by commanding the EVAP
purge solenoid OFF, EVAP purge solenoid duty ratio
0%. If fuel tank vacuum level increases during the test,
a continuous purge flow condition is indicated. This can
be caused by the following conditions:
EVAP purge solenoid leaking
EVAP purge and engine vacuum lines switched at the
EVAP purge control solenoid valve
EVAP purge control solenoid valve driver circuit
grounded

POSITIVE CRANKCASE VENTILATION
(PCV) SYSTEM
Crankcase Ventilation System Purpose

The crankcase ventilation system is used to consume
crankcase vapors in the combustion process instead of
venting them to the atmosphere. Fresh air from the
throttle body is supplied to the crankcase and mixed
with blow-by gases. This mixture is then passed through
the positive crankcase ventilation (PCV) port into the
intake manifold.
While the engine is running, exhaust gases and small
amounts of the fuel/air mixture escape past the piston
rings and enter the crankcase. these gases are mixed
with clean air entering through a tube from the air intake
duct.
During normal, part-throttle operation, the system is
designed to allow crankcase gases to flow through the
PCV hose into the intake manifold to be consumed by
normal combustion.
A plugged positive crankcase ventilation port or PCV
hose may cause the following conditions:
Rough idle.
Stalling or slow idle speed.
Oil leaks.
Sludge in the engine.
A leaking PCV hose would cause:
Rough idle.
Stalling.
High idle speed.
6E59
6E60
A/C CLUTCH DIAGNOSIS

A/C Clutch Circuit Operation
A 12-volt signal is supplied to the A/C request input of
the ECM when the A/C is selected through the A/C
control switch.
The A/C compressor clutch relay is controlled through
the ECM. This allows the ECM to modify the idle air
control position prior to the A/C clutch engagement for
better idle quality. If the engine operating conditions are
within their specified calibrated acceptable ranges, the
ECM will enable the A/C compressor relay. This is done
by providing a ground path for the A/C relay coil within
the ECM. When the A/C compressor relay is enabled,
battery voltage is supplied to the compressor relay is
enabled, battery voltage is supplied to the compressor
clutch coil.
The ECM will enable the A/C compressor clutch
whenever the engine is running and the A/C has been
requested. The ECM will not enable the A/C
compressor clutch if any of the following conditions are
met:
The engine speed is greater than 6000 RPM.
The ECT is greater than 122C (251F).
The throttle is more than 95% open.
A/C Clutch Circuit Purpose

The A/C compressor operation is controlled by the
engine control module (ECM) for the following reasons:
It improves idle quality during compressor clutch
engagement.
It improves wide open throttle (WOT) performance.
It provides A/C compressor protection from operation
with incorrect refrigerant pressures.
The A/C electrical system consists of the following
components:
The A/C control switch.
The A/C refrigerant pressure switches.
The A/C compressor clutch.
The A/C compressor clutch relay.
The ECM.
A/C Request Signal

This signal tells the ECM when the A/C mode is
selected at the A/C control switch. The ECM uses this
input to adjust the idle speed before turning on the A/C
clutch. The A/C compressor will be inoperative if this
signal is not available to the ECM.
Refer to A/C Clutch Circuit Diagnosis for A/C wiring
diagrams and diagnosis for the A/C electrical system.
6E61

Overview

6E62

customer complaint
Saves time by avoiding testing and/or replacing good
parts
perspectives
Guides you to determine what level of understanding
about system operation is needed:
Owners manual level
Owners manual level

What you should do
verify that the customer complaint is a valid failure of the
system.
complaint:
WHAT aftermarket and dealer-installed accessories
exist
Whether the severity of the problem has increased,
decreased or stayed the same

Vehicle road tests

What you should do

To detect if the cause of the complaint is VISUALLY
OBVIOUS
accurately search for a ISUZU Service Bulletin on
ISUZU Web site.
actions:
computers
Sense unusual
movements
noises,
smells,
vibrations


checks:
Tech II or other technical equipment for viewing DTCs
Component locations
Harness routing
Wiring schematics

Procedures for viewing DTCs

sections
or

Vehicle road test

6E63
NOTE: As estimated 30 percent of successful vehicle

What you should do


procedures:
Service manual
Technical equipment (for analyzing diagnostic data)

You should use the following resources for assistance in
checking for bulletins and troubleshooting hints:
Printed bulletins
Access ISUZU Bulletin Web site.
Videotapes
Service manual

What you should do

Diagnostic Checks

circuit(s)
What you should do

with:

characteristics:
Electrical:

service manual
How is the circuit powered (power distribution

How is the circuit grounded (ground distribution

charts)?
How is the circuit controlled or sensed (theory of

operation):
If it is a switched circuit, is it normally open or
normally closed?

Service manual
Technical equipment (for viewing DTCs
analyzing data)
and

repairs are diagnosed with these steps!
What you should do

Is the power switched or is the ground

switched?
Is it a variable resistance circuit (ECT sensor
or TP sensor, for example)?
Is it a signal generating device (MAF sensor of
VSS, for example)?
Does it rely on some mechanical/vacuum
device to operate?
Physical:
Where are the circuit components (component
Are there areas where wires could be chafed
or pinched (brackets or frames)?
Are there areas
temperatures?
subjected
to
extreme
6E64
Are there areas subjected to vibration or

movement
(engine,
transmission
or
suspension)?
Are there areas exposed to moisture, road salt
or other corrosives (battery acid, oil or other
fluids)?
Are there common mounting areas with other
systems/components?
Have previous repairs been performed to wiring,
connectors, components or mounting areas
(causing pinched wires between panels and
drivetrain or suspension components without
causing and immediate problem)?
Does the vehicle have aftermarket or dealerinstalled equipment (radios, telephone, etc.)

Divide (and separate, where possible) the system or
circuit into smaller sections
Confine the problem to a smaller area of the vehicle
(start with main harness connections while removing
panels and trim as necessary in order to eliminate
large vehicle sections from further investigation)
For two or more circuits that do not share a common
power or ground, concentrate on areas where
harnesses are routed together or connectors are
shared (refer to the following hints)
Hints
Loose connections:
in
terminals,
splices,

Service manual
Experience

Malfunctioning components (such as sticking relays,
solenoids, etc.)
EMI/RFI
frequency
interference)
problem.
What you should do

Incorrect connector/harness routing (usually in new

vehicles or after a repair has been made):
Open/high resistance in
at the component
If a number of components do no operate, begin tests
at the area of commonality (such as power sources,
ground circuits, switches or major connectors)
in
terminals,
splices,
terminals,
splices,
Component failure:
Opens/short and high resistance

complaint.
in
relays,
Aftermarket equipment affecting normal operation of

other systems
You may isolate circuits by:
Operating shared circuits and eliminating those that
function normally from the suspect circuit
If only one component fails to operate, begin testing

system(s).

problem
6E65

for a malfunction.
2. Heat
malfunction.
the component.
Hints
If only component fails to operate, begin testing the
component
If a number of components do not operate, begin test
at areas of commonality (such as power sources,
ground circuits, switches, main connectors or major
components)
Try the suspect part in a known good vehicle
See Symptom Simulation Tests on the next page for
problem simulation procedures. Refer to service manual
sections 6E and 8A for information about intermittent
diagnosis. Follow procedures for basic circuit testing in
service manual section 8A.

conditions of high humidity. In this case, apply water in a
light spray on the vehicle to duplicate the problem.
4. Electrical loads


Service manual
Bulletins
Tech II and Tech II upload function
connector

customer
What you should do

Circuit testing tools (including
harnesses and jumper wires)

kits/
Experience

1. Vibration

by:
Reviewing
checks
service
manual
functional/diagnostic
Examining bulletins and other service information for

supplementary information
the customer.

6E66

ISUZU field support
Experience

What you should do

Strategy Based Diagnostics. You also should repeat any
procedures that require additional attention.

Service manual
Accumulated information form a previous diagnostic
path
ISUZU field support

What you should do


Equipment
Aftermarket (add-on) electrical and vacuum equipment
is defined as any equipment which connects to the
vehicle's electrical or vacuum systems that is installed
on a vehicle after it leaves the factory. No allowances
have been made in the vehicle design for this type of
equipment.
NOTE: No add-on vacuum equipment should be added
to this vehicle.
NOTE: Add-on electrical equipment must only be
connected to the vehicle's electrical system at the
battery (power and ground).
Add-on electrical equipment, even when installed to
these guidelines, may still cause the electric system to
malfunction. This may also include equipment not
connected to the vehicle electrical system such as
portable telephones and radios. Therefore, the first step
in diagnosing any electric problem is to eliminate all
aftermarket electrical equipment from the vehicle. After
this is done, if the problem still exists, it may be
diagnosed in the normal manner.
Electrostatic Discharge Damage
6E67
Non-OEM Parts
with OEM parts.
Accordingly, if commercially sold
sensor or switch is installed, it makes a wrong diagnosis
and turns on the check engine lamp.
cause a false sensor reading and turn on the check
engine lamp.
The sensitivity of OBD diagnostics will cause the check
engine lamp to turn on if the vehicle is not maintained
properly. Restricted oil filters, fuel filters, and crankcase
deposits due to lack of oil changes or improper oil
viscosity can trigger actual vehicle faults that were not
previously monitored prior to OBD.
Poor vehicle
maintenance can not be classified as a non-vehicle
fault, but with the sensitivity of OBD diagnostics,
vehicle maintenance schedules must be more closely
followed.

Inspection
Perform a careful
visual and physical engine
Use the following
guidelines
when
performing
a
visual/physical
inspection:
Electronic components used in the ECM are often
designed to carry very low voltage. Electronic
components are susceptible to damage caused by
electrostatic discharge. Less than 100 volts of static
electricity can cause damage to some electronic
components. By comparison, it takes as much as 4000
volts for a person to feel even the zap of a static
discharge.
There are several ways for a person to become
charging are by friction and induction.
An example of charging by friction is a person sliding
across a vehicle seat.
Charge by induction occurs when a person with wellinsulated shoes stands near a highly charged object
and momentarily touches ground. Charges of the
same polarity are drained off leaving the person
highly charged with the opposite polarity. Static
charges can cause damage, therefore it is important
to use care when handling and testing electronic
components.
Inspect all vacuum hoses for punches,

cuts,

components.

NOTE: Lack of basic knowledge of this powertrain
when performing diagnostic procedures could result in
an incorrect diagnosis or damage to powertrain
6E68
On-Board Diagnostic (OBD)

On-Board Diagnostic Tests
ignition cycle.
currently active.
active.
suspected due to a driveability or emissions problem,

a Powertrain On-Board Diagnostic (OBD) System
Check must be performed. The procedures for these
checks are given in On-Board Diagnostic (OBD)
System Check. These checks will expose faults
which may not be detected if other diagnostics are
performed first.
The provision for communication with the contorl
module is the Data Link Connector (DLC). It is located
behind the lower front instrument panel. The DLC is
used to connect to a Tech2. Some common uses of the
Tech2 are listed below:
Clearing DTCs.

follows:
Commanding the check engine lamp on and off
When a malfunction is detected by the control module, a
diagnostic trouble code is set and the check engine
lamp is illuminated.
Check Engine Lamp
The check engine lamp looks the same as the check
engine lamp you are already familiar with, the Check
Engine lamp.
Basically, the check engine lamp is turned on when the
ECM detects a DTC that will impact the vehicle
emissions.
When the check engine lamp remains ON while the
engine is running, or when a malfunction is

2. Clear DTC(s).
Fail Records.
Following these steps is very important in verifying

Tech 2
to used a diagnostic Tech2. When reading DTC(s),
follow instructions supplied by Tech2 manufacturer.
Tech2 clear DTCs or clear information function.
Tech2 manufacturer.
Diagnosis With Tech 2

6E69
Tech 2 scan tool kit (No. 7000086), Tech 2 scan
tool (No. 7000057) and DLC cable (No.
3000095).
SAE 16/19 adapter (No. 3000098) (3), RS232
cable (4).
Connect the SAE 16/19 adapter (3) to the data
link connector of the vehicle.
Refer to SYMPTOM DIAGNOSIS.

If codes are set:
2. Clear the codes.
status.
intermittent. In this case, refer to DIAGNOSIS
AIDS.
diagnosis.
Tech 2 CONNECTION

NOTE: Be sure to check that the power is not supplied
to the Tech 2 when attaching or removing the PCMCIA
card.

Tech 2.
6E70
Tech 2 Operating Flow Cart (Start Up)

(UB) Trooper, Bighorn
(UE) Rodeo,/Amigo, Wizard/Mu
(TF/UC) LUV, Frontier, LAO-Rodeo
(TBR)
(N*) ELF, NPR, NQR
Press (ENTER) to Continue
Press ENTER key.

Main Menu
Select (TF/UC).
F0: Diagnostic
F0: Powertrain
F1: Service Programming System (SPS)
F1: Chassis
F2: View Capture Data
F3: Body
F3: Tool Option

F4: Download/ Upload Help
Select F0: Diagnostic.

Select F0: Powertrain.

(3) 2003
4JH1-TC Bosch
(2) 2002
4JH1-T Denso
(1) 2001
2.XL L4 HV240
(Y) 2000
3.5L V6 6VE1 Hitachi
(X) 1999
AW30-40LE
(W) 1998
AT JR405E
Select (3) 2003 or later.
Select 2.XL L4 HV240.
Select 2.XL L4 HV240 in Vehicle Identification menu and the following table is shown in the Tech 2 screen.

F0: Read DTC Infor By Priority
6E71
Lamp). It will display all type A and B DTCs that

requested the MIL and have failed within the last 40
warm-up cycles. In addition, it will display all type C and
D DTCs that have failed within the last 40 warm-up
cycles.
F2: DTC Information

F0: History
F1: MIL SVS or Message Requested
F2: Last Test Failed
F3: Test Failed Since Code Cleared
F4: Not Run Since Code Cleared
F5: Failed This Ignition
F1: Data Display

F0: Engine Data
F1: O2 Sensor Data
F2: Snapshot

F0: Lamps
F0: Malfunction Indicator Lamps
F1: Relays
F0: Fuel Pump Relay
F2: EVAP
F0: Purge Solenoid
F3: IAC System
F0: IAC Control
F1: IAC Reset
F4: Injector Balance Test
The purpose of the Diagnostic Trouble Codes mode is
to display stored trouble code in the ECM.
When Clear DTC Information is selected, a Clear
DTC Information, warning screen appears.
This screen informs you that by cleaning DTC's all
stored DTC information in the ECM will be erased.
Use the DTC Information mode to search for a specific
type of stored DTC information.
History
This selection will display only DTCs that are stored in
the ECM's history memory. It will not display Type B
DTCs that have not requested the MIL (Check Engine
MIL SVC or Message Request

This selection will display only DTCs that are requesting
the MIL. Type C and Type D DTCs cannot be displayed
using the MIL. Type C and D DTCs cannot be displayed
using this option.
This selection will report type B DTCs only after the MIL
has been requested.
Last Test Failed
This selection will display only DTCs that have failed the
last time the test run. The last test may have run during
a previous ignition cycle of a type A or type B DTC is
displayed. For type C and type D DTCs, the last failure
must have occurred during the current ignition cycle to
appear as last test fail.
Test Failed Since Code Cleared
The selection will display all active and history DTCs
that have reported a test failure since the last time
DTCs were cleared. DTCs that last failed more that 40
warm-up cycles before this option is selected will not be
displayed.
No Run Since Code Cleared
This selection will display up to DTCs that have not run
since the DTCs were last cleared. Since any displayed
DTCs have not run, their condition (passing or failing) is
unknown.
Failed This Ignition
This selection will display all DTCs
during the present ignition cycle.
that have failed
F1: Data Display

The purpose of the Data Display mode is to
See the Typical Scan Data section.
F2: Snapshot
Snapshot allows you to focus on making the condition
anticipation of the fault.
The snapshot will collect parameter information around
a trigger point that you select.
The purpose of Miscellaneous Test mode is to check
for correct operation of electronic system actuators.
6E72

Use the Typical Values Table only after the On-Board Diagnostic System Check has been completed, no DTC(s) were
noted, and you have determined that the on-board diagnostics are functioning properly. Tech 2 values from a
properly-running engine may be used for comparison with the engine you are diagnosing.
80 deg.)
Tech 2 Parameter
Units
Idle
2000rpm
Description
Engine Speed
rpm
775 - 875
1950 - 2050
The actual engine speed is measured by ECM from the

CKP sensor 58X signal.
Desired Idle Speed
rpm
825
800 - 850
The desired engine idle speed that the ECM

commanding. The ECM compensates for various engine
loads.
Engine Coolant
Temperature
C or F
80 - 90
80 - 90

voltage. When the engine is normally warm upped, this
data displays approximately 80 C or more.
Start Up ECT (Engine

Coolant Temperature)
C or F
Depends on ECT
at start-up
Depends on ECT
at start-up
Start-up ECT is measured by ECM from ECT sensor

output voltage when engine is started.
Intake Air
Temperature
C or F
Depends on
ambient temp
Depends on
ambient temp

Start Up IAT (Intake

Air Temperature)
C or F
Depends on IAT at
start-up
Depends on IAT at
start-up
Start-up IAT is measured by ECM from IAT sensor output

voltage when engine is started.
Manifold Absolute
Pressure
kPa
31 - 36
25 - 30
The MAP (kPa) is measured by ECM from MAP output

voltage. This data is changing by inlet manifold pressure.
Barometric Pressure
kPa
Depends on
altitude
Depends on
altitude

MAP sensor output voltage monitored during key up and
wide open throttle. This data is changing by altitude.
Throttle Position
2-4
Throttle position operating angle is measured by the

ECM from throttle position output voltage. This should
display 0% at idle and 99 - 100% at full throttle.
10
Calculated Air Flow
g/s
3.5 -4.50
8.0 - 10.0
This displays calculated air mount from MAP sensor

output. This data is changing by inlet manifold pressure.
11
Air Fuel Ratio
14.6:1
14.6:1
This displays the ECM commanded value. In closed loop,

this should normally be displayed around 14.2:1 - 14.7:1.
12
Spark Advance
CA
8 - 15
25 - 32
This displays the amount of spark advance being

commanded by the ECM.
13
Engine Load
2-5
5 - 10
This displays is calculated by the ECM form engine

speed and MAF sensor reading. Engine load should
increase with an increase in engine speed or air flow
amount.
14
Injection Pulse Width
ms
1.0 - 3.0
3.0 - 4.0
This displays the amount of time the ECM is

commanding each injector On during each engine cycle.
A longer injector pulse width will cause more fuel to be
delivered. Injector pulse width should increase with
increased engine load.
15
Fuel System Status
Open Loop/
Close Loop
Close Loop
Close Loop

signal from the oxygen sensors. When various conditions
(ECT, time from start, engine speed & oxygen sensor
output) are met, the system enters Closed Loop
operation. In Closed Loop, the ECM calculates the air
fuel ratio based on the signal from the oxygen sensors.
16
Knock Present
Yes/No
No
No
This displays knock sensor detection status. When

engine knock is occurred, displays "Yes".
17
Knock Counter
18
Knock Retard
CA
19
A/C Clutch Relay
On/Off
This displays the number of knock during a ignition cycle.
This displays the commanded ignition spark timing retard

timing based on the signal from the knock sensor.
Off
Off
This displays whether the ECM has commanded the A/C

compressor clutch On or Off.

Tech 2 Parameter
Units
6E73
Idle
2000rpm
Description
Off
Off

should display On when the air conditioner switch is
switched on.
0 - 10
0 - 10
canister purge solenoid valve.
20
A/C Request
Yes/No
21
EVAP Purge Solenoid

(Evaporative
Emission)
22
Fuel Pump
On/Off
On
On
This displays operating status for the fuel pump main

relay. This should display On when the key switch is
turned on and while engine is running.
23
Idle Air Control
Steps
20 - 30
65 - 75
This displays the ECM commanded position of the idle air

control valve pintle. A larger number means that more air
is being commanded through the idle air passage.
24
Idle Speed Variation
rpm
-25 - 0
1125 - 1225
This displays variation of actual engine speed & desired

idle speed.
25
Vehicle Speed
km/h or
mph

26
Ignition Voltage
10.0 - 14.5
10.0 - 14.5
This displays the system voltage measured by the ECM

at ignition feed.
27
Reference Voltage
5.00
5.00
28
Malfunction Indicator
Lamp
On/Off
Off
Off
This displays operating status for the Check Engine

Lamp. This should display On when the Check Engine
Lamp is turned on.
29
Time From Start
This displays the engine time elapsed since the engine

was started. If the engine is stopped, engine run time will
be reset to 00:00:00
6E74

TYPICAL SCAN DATA & DEFINITIONS (O2 SENSOR DATA)
Use the Typical Values Table only after the On-Board Diagnostic System Check has been completed, no DTC(s) were
noted, and you have determined that the on-board diagnostics are functioning properly. Tech 2 values from a
properly-running engine may be used for comparison with the engine you are diagnosing.
80 deg.)
Tech 2 Parameter
Units
Idle
2000rpm
Description
Engine Speed
rpm
710 - 875
1950 - 2050
The actual engine speed is measured by ECM from the

CKP sensor 58X signal.
Desired Idle Speed
rpm
825
800 - 850
The desired engine idle speed that the ECM

commanding. The ECM compensates for various engine
loads.
Engine Coolant
Temperature
C or F
80 - 90
80 - 90

voltage. When the engine is normally warm upped, this
data displays approximately 80 C or more.
Start Up ECT (Engine

Coolant Temperature)
C or F
Depends on ECT
at start-up
Depends on ECT
at start-up
Start-up ECT is measured by ECM from ECT sensor

output voltage when engine is started.
Intake Air
Temperature
C or F
Depends on
ambient temp
Depends on
ambient temp

Start Up IAT (Intake

Air Temperature)
C or F
Depends on IAT at
start-up
Depends on IAT at
start-up
Start-up IAT is measured by ECM from IAT sensor output

voltage when engine is started.
Manifold Absolute
Pressure
kPa
31 - 36
25 - 30
The MAP (kPa) is measured by ECM from MAP output

voltage. This data is changing by inlet manifold pressure.
Barometric Pressure
kPa
Depends on
altitude
Depends on
altitude

MAP sensor output voltage monitored during key up and
wide open throttle. This data is changing by altitude.
Throttle Position
2-4
Throttle position operating angle is measured by the

ECM from throttle position output voltage. This should
display 0% at idle and 99 - 100% at full throttle.
10
Calculated Air Flow
g/s
3.5 -4.50
8.0 - 10.0
This displays intake air amount. The mass air flow is

measured by ECM from the MAF sensor output voltage.
11
Air Fuel Ratio
14.6:1
14.6:1
This displays the ECM commanded value. In closed

loop, this should normally be displayed around 14.2:1 14.7:1.
12
Fuel System Status
Open Loop/
Close Loop
Close Loop
Close Loop

conditions (ECT, time from start, engine speed & oxygen
sensor output) are met, the system enters Closed Loop
operation. In Closed Loop, the ECM calculates the air
fuel ratio based on the signal from the oxygen sensors.
13
Engine Load
2-5
5 - 10
This displays is calculated by the ECM form engine

speed and MAF sensor reading. Engine load should
increase with an increase in engine speed or air flow
amount.
14
B1 O2 Sensor Ready
(Bank 1)
Yes/No
Yes
Yes
This displays the status of the exhaust oxygen sensor.

This display will indicate Yes when the ECM detects a
fluctuating oxygen sensor output voltage sufficient to
allow closed loop operation. This will not occur unless
the oxygen sensor is warmed up.
15
B1S1 Status
(Bank 1 Sensor 1)
Rich / Lean
Rich / Lean
Rich / Lean
This displays dependent on the exhaust oxygen sensor

output voltage. Should fluctuate constantly Rich and
Lean in closed loop.
16
Fuel Trim Learned
Yes/No
Yes
Yes
When conditions are appropriate for enabling long term

fuel trim corrections, fuel trim learn will display Yes.
This indicates that the long term fuel trim is responding
to the short term fuel trim. If the fuel trim lean displays
No, then long term fuel trim will not respond to changes

Tech 2 Parameter
Units
6E75
Idle
2000rpm
Description
15 - 20
1-2
This displays dependent on engine speed and calculated

intake air flow reading. A plot of engine speed versus
intake air flow amount is divided into the cells. Fuel trim
cell indicates which cell is currently active.
50 - 950
50 -950
This displays the exhaust oxygen sensor output voltage.

Should fluctuate constantly within a range between
10mV (lean exhaust) and 1000mV (rich exhaust) while
operating in closed loop.
17
Fuel Trim Cell
18
B1S1 O2 Sensor
(Bank1 Sensor 1)
mV
19
B1 Short Term Fuel

Trim (Bank 1)
-6 - 0
-6 - 0
The short term fuel trim to a bank represents a short term

correction to the bank fuel delivery by the ECM in
response to the amount of time the bank fuel control
oxygen sensor voltage spends above or below the
450mV threshold. If the oxygen sensor voltage has
mainly remained less than 450mV, indicating a lean air/
fuel, short term fuel trim will increase into the positive
range above 0% and the ECM will pass fuel. If the
oxygen sensor voltage stays mainly above the threshold,
short term fuel trim will decrease below 0% into the
negative range while the ECM reduces fuel delivery to
compensate for the indicated rich condition. Under
certain conditions such as extended idle and high
ambient temperatures, canister purge may cause short
term fuel trim to read in the negative range during normal
operation. Fuel trim values at maximum authority may
indicate an excessively rich or lean system.
20
B1 Long Term Fuel

Trim (Bank 1)
-10 - 0
-5 - 0
The long term fuel trim is delivered from the short term
fuel term values and represents a long term correction of
fuel delivery for bank in question. A value of 0% indicates
that fuel delivery requires no compensation to maintain
the ECM commanded air fuel ratio. A negative value
indicates that the fuel system is rich and fuel delivery is
being reduced (decreased injector pulse width). A
positive value indicates that a lean condition exists and
the ECM is compensating by add fuel (increased injector
pulse width). Because long term fuel trim tends to follow
short term fuel trim, a value in the negative range due to
canister purge at idle should not be considered unusual.
Fuel trim values at maximum authority may indicate an
excessively rich or lean system.
21
Injection Pulse Width
ms
3.0 - 1.0
3.0 - 4.0
This displays the amount of time the ECM is

commanding each injector On during each engine cycle.
A longer injector pulse width will cause more fuel to be
delivered. Injector pulse width should increase with
increased engine load.
22
Power Enrichment
Yes/No
No
No
The ECM provides the extra amount of fuel when it

detects a rapid increase in the throttle position and air
flow (Power Enrichment). Under this condition the ECM
should detect a rich condition (high oxygen sensor
voltage).
23
Deceleration
Cutoff
Active/
Inactive
Inactive
Inactive

flow. When deceleration is very fast, the ECM may cut off
fuel completely. Until enable conditions meet the engine
revolution less than 1000rpm or MAP less than 10kPa.
24
Time From Start
This displays the engine time elapsed since the engine

was started. If the engine is stopped, engine run time will
be reset to 00:00:00
Fuel
6E76
MISCELLANEOUS TEST
miscellaneous test menus. Especially when DTC
cannot be detected, a faulty circuit can be diagnosed by
testing each circuit by means of these menus.
Connect Tech 2 and select Powertrain, 2.XL L4
HV240 & Miscellaneous Test.
F0: Lamps
F0: Malfunction Indicator Lamp
When the Tech 2 is operated, Malfunction Indicator
Lamp (Check Engine Lamp) is turned on or off.
The circuit is normal if the Malfunction Indicator Lamp
(Check Engine Lamp) in the instrument panel is turned
on or off in accordance with this operation.
F1: Relays
F0: Fuel Pump Relay
When the Tech 2 is operated, fuel pump relay signal
turns ON or OFF.
The circuit is normal if fuel pump sound is generated in
accordance with this operation when key switch is
turned ON.
When the Tech 2 is operated, A/C clutch relay signal
turns ON or OFF.
The circuit is normal if A/C compressor clutch is
energized in accordance with this operation when the
engine is running.
F2: EVAP
F0: Purge Solenoid
When the Tech 2 is operated, duty ratio of EVAP purge
solenoid is changed 10%-by-10%.
Purge Solenoid
Engine Speed
800 RPM
Desired Idle Speed
762 RPM
80 C
Start Up ECT
50 C
30 C
Start Up IAT
25 C

EVAP Purge Solenoid
35kPa
30%
Press Increase key.

Then, EVAP Purge Solenoid is increases 10%-by10%.
Press Quit Key.
F3: IAC System

F0: IAC Control
When the Tech 2 is operated, Idle Air Control
increases or decreases 5steps-by-5steps up to
150steps.
The circuit is normal if idle engine speed is changed in
IAC Control
Engine Speed
800 RPM
Desired Idle Speed
762 RPM
80 C
Start Up ECT
50 C
30 C
Start Up IAT
25 C

Idle Air Control
35kPa
30 Steps
Press Increase key.

Then, Idle Air Control is increases 1osteps-by10steps up to 160steps. Engine speed is also
changed by this operation.
Press Quit Key.
F1: IAC Reset
When the Tech 2 is operated, Idle Air Control resets.
The circuit is normal if idle engine speed is droped in
IAC Reset
Engine Speed
800 RPM
Desired Idle Speed
762 RPM
80 C
Start Up ECT
50 C
30 C
Start Up IAT
25 C

Idle Air Control
35kPa
30 Steps
Press Increase key.

Then, Desired Idle speed is increases 50rpm-by50rpm up to 1550rpm. Engine speed is also changed
by this operation.
Press Quit Key.

F4: Injector Balance Test
When the Tech 2 is operated, selected injector turns ON
or OFF.
The circuit is normal if engine vibration is changed at
selected cylinder in accordance with this operation
when engine is idling.
Injector Balance Test
Engine Speed
800 RPM
Desired Idle Speed
762 RPM
80
Start Up ECT
50
30
Start Up IAT
25

Injector 1
35kPa
On
Press Injector Off key.

Then, engine speed drops and vibration occurs when
a cylinder is selected.
Press Quit Key.
6E77
6E78
PLOTTING SNAPSHOT GRAPH

060RX037

You can replay the snapshot data as needed. Therefore,
accurate diagnosis is possible, even though the vehicle
is not available.
6E79
D06RY00167
6E80
060RX0-40
6E81


below shown:


1. Start TIS2000.
screen.
information.

6. After ending transfer of the snapshot,
data
6E82
3.
Snapshot data is displayed with TIS2000

procedures.
1. Start TIS2000.

list on the screen.

screen.

window opens.

icon.

and select one parameter from the list of the window
lower part. Selected parameter is displayed nest to
the graph icon. Graph division can be selected in
the field on the parameter right side.
7. For displaying another parameter by graph, click the

parameter of the list, drug the mouse to the display
screen while pressing the mouse button and release
the mouse button. New parameter is displayed at
the position of the previous parameter.
For
displaying the graph display screen in full size,
move the cursor upward on the screen. When the
cursor is changed to the magnifying glass form, click
the screen. Graph screen is displayed on the whole
screen.

icons.
4. After selecting all parameters to be displayed (Max.
3 parameters), click [OK] button.


opens.
5. In this case, parameters are displayed only in graph
form. All parameters are displayed in one graph.
navigation icon.
6E83
6E84

Service Programming System (SPS) software contained
in TIS2000 is explained below.
NOTE:
are present, low battery voltage or poor electrical
connections should be the primary suspects.
Perform the SPS procedure again after rectifying
the fault/s.
5. On the screen of Diagnostic Tester and Processing

Program Selection, choose the one that will comply
with the following.
Tech-2 in use
IMPORTANT:
The Tech2 PCMCIA card is programmed with The
latest software release.
The latest release of TIS2000 is loaded on the PC.
The control unit to be programmed is connected
to the vehicle.
4. On the activating screen of TIS2000, choose
Service Programming System
6. Upon completion of the selection, push the button of

Next.

2. Demand of Data
turning on the power of Tech-2, push the Enter
switch.
engine)
6E85
5. Where vehicle data has been already saved in Tech

2, the existing data come on display. In this
the data or to continue obtaining anew data from the
control unit, choose either of them
3. In the main menu of Diagnostic Tester, push F1:

Service Programming System (SPS).
4. Push F0: Request Info of Tech-2.

Year, Vehicle Type.
procedure.
information from the control unit ECM and TCM (A/T
only) at the same time. With VIN not being
programmed into the new control unit at the time of
shipment, "obtaining information" is not complete
(because the vehicle model, engine model and
model year are specified from VIN). For the
procedure get additional information on vehicles,
instruction will be provided in dialog form, when
TIS2000 is in operation.
9. Following instructions by Tech-2, push the Exit
from the vehicle.
3. Data Exchange
1. Connect Tech-2 to P/C, turn on the power and click
the Next button of P/C.
2. Check VIN of the vehicle and choose Next.
Model Year
Model
Engine type
Transmission type
Immobilizer
Etc.
Destination code can be read from ID Plate affixed on
the figure, the destination code can be read as "RR3"
(Australia).
6E86
5. After choosing the data, click the Next button.

details of software within the database that match
the entered data will appear for confirmation. Click
the Program switch and then download the new
software onto Tech-2.
7. Data Transfer comes on display. The progress of
form of bar graph.
ABS connectors shall be removed from the vehicle.
comes on display.
start)
5. On the title screen of Tech-2, push the Enter
button.
6. Choose F1: Service Programming System on the
main screen and then choose Fl: Program ECU.
7. While data is being transferred, Programming in
Progress will be displayed on the Tech-2 screen.
8. Upon finishing the data transfer, Tech-2 will display
Reprogramming Was Successful. Push the Exit
button to bring program to completion
9. Following Procedure 2: Demand of Data, try over
again Information Obtaining and check to confirm

3
2
1
(2) Harness Adapter
addition, the engine control module (ECM) special
terminal can not let regular digital voltage meter prove
to access, because terminal shape is very fin pin type.
(3) Breaker Box
6E87
6E88

(2) Harness Adapter
(3) Breaker Box
Breaker box connection type A, check for open circuit
and short to ground circuit.
2


(2) Harness Adapter
(3) Breaker Box
Breaker box connection type B, check for short to
power supply circuit and power, signal voltage check

6E89
6E90
Circuit Description
Test Description

and tightness.

Diagnostic Chart:
1. The Check Engine Lamp (MIL) should be ON steady
with the ignition On, engine Off. If not, No Check
Engine Lamp (MIL) chart should be used to isolate the
malfunction.
2. Checks the Class 2 data circuit and ensures that the
ECM is able to transmit serial data.
controlling the Check Engine Lamp (MIL) and the Check
Engine Lamp (MIL) driver circuit is not shorted to
ground circuit.
4. If the engine will not start, Engine Cranks But Will
Not Run chart should be used to diagnose the fault.
6. The Tech2 parameters which is not within the typical
range may help to isolate the area which is causing the
problem.
12. This vehicle is equipped with ECM which utilizes an
electrically erasable programmable read only memory
(EEPROM).
Diagnostic Aids
the insulation.
Check for poor connections or a
6E91

Step
1
Action
Value(s)
Go to Step 3
Go to Step 7
Go to Step 4
Go to CHECK
ENGINE LAMP
On Steady
Go to Step 5
Go to Engine
Cranks But Will
Not Run
Go to DTC
Chart
Go to Step 6
Refer to
SYMPTOM
DIAGNOSIS
Refer to
TYPICAL
SCAN DATA
Repair faulty
harness and
verify repair
Go to Step 8
Repair faulty
harness and
verify repair
Go to Step 9

Does the engine start and continue to Run?
2. Select the Read DTC Infor By Priority in
3. Are any DTCs stored?
Go to Step 2

Malfunction Indicator Lamp in Lamps.
instructions.
Does the CHECK ENGINE lamp turn Off?
Go to No
CHECK
ENGINE Lamp

2. Attempt to display Engine Datawith the Tech 2.
Does the Tech 2 display Engine Data and O2
Sensor Data?
No

2. Check the CHECK ENGINE lamp (MIL).
Does the CHECK ENGINE lamp turn On?
Yes

Tech 2 Engine Data and O2 Sensor Data.
B58
16
V
8

ground circuit.
4
B58
6E92
Step
Action
Value(s)

ground circuit.
Yes
No
Less than 1V
Go to Step 10
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 11
Repair faulty
harness and
verify repair
Go to Step 12
Verify repair
Go to Step 13

4
V
10
B58

B-58
11

circuit.
12
C-56(J2)
B-58

release?
6E93
Step
Action
Value(s)
Yes
No
13
Replace the ECM.

Verify repair
6E94
Circuit Description
The check engine lamp should be illuminated and
steady for about five seconds with the ignition ON and
the engine stopped. Ignition feed voltage is supplied to
the check engine lamp bulb through the meter fuse.
The Engine Control Module (ECM) turns the check
engine lamp ON by grounding the check engine lamp
driver circuit.
Diagnostic Aids
An intermittent check engine lamp may be cased by a
poor connection, rubbed-through wire insulation, or a
wire broken inside the insulation.

following items:
Check for the

open in the check engine lamp driver circuit, or an
open in the instrument cluster ignition feed.
engine ground.

Step
1
Action
Check the Meter fuse (15A).
Value(s)
Yes
No
Verify repair
Go to Step 2

Step
Action

lamp circuit.
6E95
Value(s)
Yes
No
10 - 14.5V
Go to Step 5
Go to Step 3
Verify repair
Go to Step 4
Verify repair
Go to Step 5

release?
Verify repair
Go to Step 6
Replace the ECM.

Verify repair

3. Ignition On.
32
C56(J2)
V
3
Check the CHECK ENGINE lamp bulb.

lamp circuit.
2. Disconnect
connector.
the
meter connector
and
ECM

32
C56(J2)
17
B24
6E96
Circuit description
Diagnostic Aids

and steady for about five seconds with ignition ON and
the engine stopped. Ignition feed voltage is supplied
directly to the check engine lamp indicator. The Engine
Control Module (ECM) turns the check engine lamp
ON by grounding the check engine lamp driver circuit.
The check engine lamp should not remain ON with the
engine running and no DTC(s) set. A steady check
engine lamp with the engine running and no DTC(s)
suggests a short to ground in the check engine lamp
driver circuit.

Poor connection or damaged harness - Inspect the
damaged harness.
Check Engine Lamp (MIL) ON Steady

Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to Step 4

3. Ignition On.
Was the CHECK ENGINE lamp turned on?

Step
Action

lamp circuit.
6E97
Value(s)
Yes
No
Verify repair
Go to Step 3

Verify repair

release?
Verify repair
Go to Step 5
Replace the ECM.

Verify repair

connector.
and
ECM

32
C56(J2)
3
4
6E98
FUEL METERING SYSTEM CHECK

Some failures of the fuel metering system will result in
an Engine Cranks But Will Not Run symptom. If this
condition exists, refer to the Cranks But Will Not Run
chart. This chart will determine if the problem is caused
by the ignition system, the ECM, or the fuel pump
electrical circuit.
Refer to Fuel System Electrical Test for the fuel system
wiring schematic.
If there is a fuel delivery problem, refer to Fuel System
Diagnosis, which diagnoses the fuel injectors, the fuel
pressure regulator, and the fuel pump.
Followings are applicable to the vehicles with
closed Loop System:
If a malfunction occurs in the fuel metering system, it
usually results in either a rich HO2S signal or a lean
HO2S signal. This condition is indicated by the HO2S
voltage, which causes the ECM to change the fuel
calculation (fuel injector pulse width) based on the
HO2S reading. Changes made to the fuel calculation
will be indicated by a change in the long term fuel trim
values which can be monitored with a Scan Tool. Ideal
long term fuel trim values are around 0%; for a lean
HO2S signal, the ECM will add fuel, resulting in a fuel
trim value above 0%. Some variations in fuel trim values
are normal because all engines are not exactly the
same. If the evaporative emission canister purge is 02
status may be rich condition. 02 status indicates the
lean condition, refer to DTC P1171 for items which can
cause a lean HO2S signal.

AND FUEL INJECTOR BALANCE TEST
PROCEDURE
Test Description
Diagnostic Chart:
2. Relieve the fuel pressure by connecting 5-88400378-0 T-Joint to the fuel pressure connection on the
fuel rail.
Caution: In order to reduce the risk of fire and
personal injury, wrap a shop towel around the
fuel pressure connection. The towel will absorb
any fuel leakage that occurs during the
connection of the fuel pressure gauge. Place the
connection of the fuel pressure gauge is
complete.
Place the fuel pressure gauge bleed hose in an
With the ignition switch OFF open the valve on the
fuel pressure gauge.
3. Record the lowest voltage displayed by the DVM
after the first second of the test. (During the first
second, voltage displayed by the DVM may be
inaccurate due to the initial current surge.)
Injector Specifications:
Resistance Ohms
Voltage Specification at
10C-35C (50F-95F)
11.8-12.6
5.7-6.6
The voltage displayed by the DVM should be

within the specified range.
The voltage displayed by the DVM may increase
throughout the test as the fuel injector windings
warm and the resistance of the fuel injector
windings changes.

An erratic voltage reading (large fluctuations in
voltage that do not stabilize) indicates an
intermittent connection within the fuel injector.
5. Injector Specifications:
Highest Acceptable Voltage
Reading Above/Below
35C/10C (95F/50F)
Acceptable
Subtracted Value
9.5Volts
0.6Volt
6E99
7. The Fuel Injector Balance Test portion of this chart

(Step 7 through Step 11) checks the mechanical (fuel
delivery) portion of the fuel injector. An engine
cooldown period of 10 minutes is necessary in order
to avoid irregular fuel pressure readings due to Hot
Soak fuel boiling.
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)
CYLINDER
1
1st Reading (1)
296kPa
(43psi)
296kPa
(43psi)
296kPa
(43psi)
296kPa
(43psi)
2nd Reading (2)
205kPa
(29psi)
205kPa
(29psi)
196kPa
(28psi)
274kPa
(39psi)
Amount of Drop
(1st Reading-2nd Reading)
91kPa
(14psi)
91kPa
(14psi)
100kPa
(15psi)
22kPa
(4psi)
Av. Drop = 166kPa/24psi

10kPa/1.5psi
= 156 - 176kPa or
22.5 - 25.5psi
Faulty, Lean
(Too Little Fuel
Drop)
Faulty, Lean
(Too Little Fuel
Drop)
Faulty, Lean
(Too Little Fuel
Drop)
Faulty, Lean
(Too Little Fuel
Drop)
NOTE: These figures are examples only.
6E100
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check
10C (50F)
to
35C (95F)
Go to Step 3
Go to Step 5
5. Set the injector adapter cable to the next injector

and repeat steps 2, 3, and 4.
voltage reading outside of the specified values?
5.7-6.6V
Go to Step 4
Go to Step 7
Replace the faulty fuel injector(S). Refer to Fuel

Injector.
Go to Step 7
1. Turn the engine OFF.

NOTE: In order to prevent flooding of a single cylinder
and possible engine damage, relieve the fuel pressure
before performing the fuel injector coil test procedure.
2. Relieve the fuel pressure.
Description Number 2.
Refer
to
Test
3. Connect the 5-8840-2618-0 Fuel Injector Tester to

B+ and ground, and to the 5-8840-2589-0 Injector
Adapter Cable.
4. Remove the harness connector of the Fuel
Injector and connect the 5-8840-2589-0 Injector
Adapter Cable for F/I check.
fuel injector tester to the Coil Test 0.5 amp
position.
6. Connect the leads from the 5-8840-2392-0 Digital
Voltmeter (DVM) to the fuel injector tester. Refer
to the illustrations associated with the test
description.
7. Set the DVM to the tenths scale (0.0).
8. Observe the engine coolant temperature.
Is the engine coolant temperature within the specified
values?
3
1. Set the injector adapter cable to injector #1.

2. Press the Push to Start Test button on the fuel
injector tester.
test.
second of the test.

Step
5
Action
6E101
Value(s)
Yes
No
9.5V
Go to Step 4
Go to Step 6
0.6V
Go to Step 4
Go to Step 7
Go to Step 8
Go to Fuel
System
Diagnosis
Go to Step 9
Go to Fuel
System
Diagnosis
1. Set the Injector Adapter Cable to injector #1.

2. Press the Push to Start Test button on the fuel
injector tester.
test.
second of the test.
5. Set the Injector Adapter Cable to the next injector
and repeat steps 2, 3, and 4.
voltage reading above the specified value?
1. Identify the highest voltage reading recorded

(other than those above 9.5V).
2. Subtract the voltage reading of each injector from
the highest voltage selected in step 1. Repeat until
you have a subtracted value for each injector.
For any injector, is the subtracted value in step 2
greater than the specified value?

pressure connection. The towel will absorb any
fuel leakage that occurs during the connection of
the fuel pressure gauge. Place the Towel in an
approved container when the connection of the
fuel pressure gauge is complete.
1. Connect the 5-8840-0378-0 Fuel Pressure Gauge
to the fuel pressure test port.
2. Energize the fuel pump using the Scan Tool.
3. Place the bleed hose of the fuel pressure gauge
into an approved gasoline container.
4. Bleed the air out of the fuel pressure gauge.
5. With the fuel pump running, observe the reading
on the fuel pressure gauge.
Is the fuel pressure within the specified values?
296kPa376kPa
(43-55psi)
Turn the fuel pump OFF.

Does the fuel pressure remain constant?
6E102
Step
Action
Value(s)
Yes
No
1. Connect the 5-8840-0378-0 Fuel Injector Tester

and 5-8840-2589-0 Injector Adapter Cable to the
fuel injector harness connector.
11. Divide the total pressure drop by the number of

fuel injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that
is either higher than the average pressure drop or
value?
10kPa
(1.5psi)
Go to Step 10
Go to OBD
System Check
Re-test any fuel injector that does not meet the

specification. Refer to the procedure in Step 11.
NOTE: Do not repeat any portion of this test before
running the engine in order to prevent the engine from
flooding.
Does any fuel injector still have a pressure drop value
that is either higher than the average pressure drop or
value?
10kPa
(1.5psi)
Go to Step 11
Go to
Symptoms
Verify repair

fuel injector tester to the Balance Test 0.5-2.5
amp position.
3. Using the Scan Tool turn the fuel pump ON then
OFF in order to pressurize the fuel system.
pressure gauge after the fuel pressure stabilizes.
This is the first pressure reading.
5. Energize the fuel injector by depressing the Push
to Start Test button on the fuel injector tester.
pressure gauge after the fuel pressure gauge
needle has stopped moving. This is the second
pressure reading.
7. Repeat steps 1 through 6 for each fuel injector.
8. Subtract the second pressure reading from the
first pressure reading for one fuel injector. The
result is the pressure drop value.
9. Obtain a pressure drop value for each fuel injector.
10. Add all of the individual pressure drop values.
This is the total pressure drop.
10
11
1. Replace the faulty fuel injector(s). Refer to Fuel

Injector.
2. Disconnect the 5-8840-2589-0 Injector Adapter
Cable for F/I check and re-connect the original F/I
check connector.
6E103
FUEL SYSTEM ELECTRICAL TEST
Circuit Description
Diagnostic Aids
When the ignition switch is first turned ON, the engine

control module (ECM) energizes the fuel pump relay
which applies power to the in-tank fuel pump. The fuel
pump relay will remain ON as long as the engine is
running or cranking and the ECM is receiving 58X
crankshaft position pulses. If no 58X crankshaft position
pulses are present, the ECM de-energizes the fuel
pump relay within 2 seconds after the ignition is turned
ON or the engine is stopped.
The fuel pump delivers fuel to the fuel rail and injectors,
then to the fuel pressure regulator. The fuel pressure
regulator controls fuel pressure by allowing excess fuel
to be returned to the fuel tank. With the engine stopped
and ignition ON, the fuel pump can be turned ON by
using a command by the scan tool.

damaged harness.
Caution: To reduce the risk of fire and personal
injury:
before connecting a fuel pressure gauge.
Refer to Fuel Pressure Relief Procedure,
below.
fittings
with
a
shop
towel
before
disconnecting, to catch any fuel that may leak
out. Place the towel in an approved container
when the disconnect is completed.
6E104
Fuel Pressure Relief Procedure
Fuel Pressure Gauge Installation

relay center.
3. Start the engine and alow it to stall.
2. Install fuel pressure gauge 5-8840-0378-0 to the

fuel feed line located in front of and above the right
side valve cover.
Fuel System Electrical Test

Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check

Was the fuel pump operated, when the Tech 2 is
operated?
Go to Fuel
System
Diagnosis
Go to Step 3
Check the Fuel Pump fuse (20A).

Verify repair
Go to Step 4
Verify repair
Go to Step 5
Go to Step 6
Replace fuel
pump relay and
verify repair

Fuel Pump Relay in the Relays.
Check for poor/faulty connection at the fuel pump, fuel

pump relay or ECM connector. If a poor/faulty
11
C56(J2)
X2
F2
Using the DVM and check the fuel pump relay.

Fuel Pump Relay

120 - 150

Step
Action
supply circuit.
6E105
Value(s)
Yes
No
10 - 14.5V
Go to Step 8
Go to Step 7
Verify repair
Repair faulty
harness and
verify repair
Go to Step 9
10 - 14.5V
Go to Step 11
Go to Step 10

circuit.
X2
3
V
7

ECM fuse (15A) and fuel pump relay.
Using the DVM and check the fuel pump relay ground
circuit.
circuit.
11
C56(J2)
X2
4
supply circuit.
1
X2
6E106
Step
Action
Value(s)
Yes
No
10
Repair the open circuit between the fuel pump relay

and battery.
Verify repair
10 - 14.5V
Go to Step 13
Go to Step 12
Verify repair
Continuity
Go to Step 15
Go to Step 14
Repair the open circuit between the fuel pump and

body ground.
Verify repair

Verify repair
Go to Step 16

release?
Verify repair
Go to Step 17
11
Using the DVM and check the fuel pump power supply
circuit.
circuit.
F2
1
V
12
13

fuel pump relay and fuel pump.
Using the DVM and check the fuel pump ground
circuit.
F-2
14
15
16
6E107
Step
Action
Value(s)
Yes
No
17
Replace the ECM.

Verify repair
6E108
FUEL SYSTEM DIAGNOSIS
Circuit Description
Test Description
When the ignition switch is turned ON, the engine

control module (ECM) will turn ON the in-tank fuel
pump. The in-tank fuel pump will remain ON as long as
the engine is cranking or running and the ECM is
receiving 58X crankshaft position pulses. If there are no
58X crankshaft position pulses, the ECM will turn the intank fuel pump OFF 2 seconds after the ignition switch
is turned ON or 2 seconds after the engine stops
running.
The in-tank fuel pump is an electric pump within an
integral reservoir. The in-tank fuel pump supplies fuel
through an in-line fuel filter to the fuel rail assembly. The
fuel pump is designed to provide fuel at a pressure
above the pressure needed by the fuel injectors. A fuel
pressure regulator, attached to the fuel rail, keeps the
fuel available to the fuel injectors at a regulated
pressure. Unused fuel is returned to the fuel tank by a
separate fuel return line.

Diagnostic Chart.
2. Connect the fuel pressure gauge to the fuel feed line
as shown in the fuel system illustration. Wrap a shop
towel around the fuel pressure connection in order to
absorb any duel leakage that may occur when
installing the fuel pressure gauge. With the ignition
switch ON and the fuel pump running, the fuel
pressure indicated by the fuel pressure gauge
should be 283-376 kPa (41-55 psi). This pressure is
controlled by the amount of pressure the spring
inside the fuel pressure regulator can provide.
3. A fuel system that cannot maintain a constant fuel
pressure has a leak in one or more of the following
areas:
The fuel pump check valve.
The fuel pump flex line.
The valve or valve seat within the fuel pressure
regulator.

The fuel injector(s).
4. Fuel pressure that drops off during acceleration,
cruise, or hard cornering may case a lean condition.
A lean condition can cause a loss of power, surging,
or misfire. A lean condition can be diagnosed using a
Tech 2 Scan Tool.
Following are applicable to the vehicle with
closed Loop System:
If an extremely lean condition occurs, the oxygen
sensor(s) will stop toggling. The oxygen sensor
output voltage(s) will drop below 500 mV. Also, the
fuel injector pulse width will increase.
Important: Make sure the fuel system is not
operating in the Fuel Cut-Off Mode.
When the engine is at idle, the manifold pressure is
low (high vacuum). This low pressure (high vacuum)
is applied to the fuel pressure regulator diaphragm.
The low pressure (high vacuum) will offset the
pressure being applied to the fuel pressure regulator
diaphragm by the spring inside the fuel pressure
regulator. When this happens, the result is lower fuel
pressure. The fuel pressure at idle will vary slightly
as the barometric pressure changes, but the fuel
pressure at idle should always be less than the fuel
pressure noted in step 2 with the engine OFF.
16.Check the spark plug associated with a particular
fuel injector for fouling or saturation in order to
determine if that particular fuel injector is leaking. If
checking the spark plug associated with a particular
fuel injector for fouling or saturation does not
determine that a particular fuel injector is leaking,
use the following procedure:
Remove the fuel rail, but leave the fuel lines and
injectors connected to the fuel rail. Refer to Fuel
Rail Assembly in On-Vehicle Service.
Lift the fuel rail just enough to leave the fuel
injector nozzles in the fuel injector ports.
personal injury that may result from fuel
spraying on the engine, verify that the fuel rail is
positioned over the fuel injector ports and verify
that the fuel injector retaining clips are intact.
Pressurize the fuel system by connecting a 20
amp fused jumper between B+ and the fuel
pump relay connector.
Visually and physically inspect the fuel
injector nozzles for leaks.
17.A rich condition may result from the fuel pressure
being above 376 kPa (55 psi). A rich condition may
cause a 45 to set. Driveability conditions associated
6E109
with rich conditions can include hard starting

(followed by black smoke) and a strong sulfur smell
in the exhaust.
20.This test determines if the high fuel pressure is due
to a restricted fuel return line or if the high fuel
pressure is due to a faulty fuel pressure regulator.
21.A lean condition may result from fuel pressure below
333 kPa (48 psi). A lean condition may cause a 44 to
set. Driveability conditions associated with lean
conditions can include hard starting (when the
engine is cold), hesitation, poor driveability, lack of
power, surging, and misfiring.
22.Restricting the fuel return line causes the fuel
pressure to rise above the regulated fuel pressure.
Command the fuel pump ON with the scan tool. The
fuel pressure should rise above 376 kPa (55 psi) as
the fuel return line becomes partially closed.
NOTE: Do not allow the fuel pressure to exceed 414
kPa (60 psi). Fuel pressure in excess of 414 kPa (60
psi) may damage the fuel pressure regulator.
injury:
before connecting a fuel pressure gauge.
Refer to Fuel Pressure Relief Procedure,
below.
fittings
with
a
shop
towel
before
disconnecting, to catch any fuel that may leak
out. Place the towel in an approved container
when the disconnect is completed.
Fuel Pressure Relief Procedure

2. Located on the intake manifold which is at the top
right part of the engine.
Fuel Pressure Gauge Installation

2. Install fuel pressure gauge 5-8840-0378-0 to the
fuel feed line located on the upper right side of the
engine.
6E110
Fuel System Diagnosis

Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check
283-376 kPa
(41-55 psi)
Go to Step 3
Go to Step 17
Go to Step 4
Go to Step 12
2. Start the engine and observe the fuel pressure

gauge.
Did the reading drop by the amount specified after the
engine was started?
21-105 kPa
(3-15 psi)
Go to Step 5
Go to Step 9
Is fuel pressure dropping off during acceleration,

cruise, or hard cornering?
Go to Step 6
Check for
improper fuel
Verify repair
Go to Step 7
Verify that the correct fuel pump is in the vehicle.

Was a problem found in any of these areas?
Verify repair
Go to Step 8

Verify repair
21-105 kPa
(3-15 psi)
Go to Step 10
Go to Step 11
1. Turn the ignition OFF.

2. Turn the air conditioning system OFF.
3. Relieve fuel system pressure and install the fuel
pressure gauge.
4. Turn the ignition ON.
NOTE: The fuel pump will run for approximately 2
seconds. Use the Scan Tool to command the fuel
pump ON.

NOTE: The fuel pressure will drop when the fuel
pump stops running, then it should stabilize and
remain constant.
5
6
1. When the vehicle is at normal operating

temperature, turn the ignition ON to build fuel
pressure and observe the measurement on the
gauge.
Visually and physically inspect the following items for

a restriction:
The in-line fuel filter.
The fuel feed line.
Remove the fuel tank and visually and physically

inspect the following items:
The fuel pump strainer for a restriction.
The fuel line for a leak.
8
9
1. Disconnect the vacuum hose from the fuel

pressure regulator.
2. With the engine idling, apply 12-14 inches of
vacuum to the fuel pressure regulator.
gauge drop by the amount specified?
6E111
Step
Action
Value(s)
Yes
No
10
Locate and repair the loss of vacuum to the fuel

pressure regulator.
Verify repair
Replace the fuel pressure regulator.

Verify repair
2. After pressure has built up, turn off the pump and
clamp the supply hose shut with suitable locking
pliers.
Go to Step 13
Go to Step 15
13
Visually inspect the fuel supply line and repair any

leaks.
Verify repair
Go to Step 14
14
Remove the fuel tank and inspect for leaky hose or intank fuel line.
Verify repair
Go to Step 8
3. Run the fuel pump with the Scan Tool.

4. After pressure has built up, remove power to the
pump.
Go to Step 11
Go to Step 16
Locate and replace any leaking fuel injector(s).

Verify repair
376 kPa
(55 psi)
Go to Step 18
Go to Step 21

290-376 kPa
(42-55 psi)
Go to Step 19
Go to Step 20
Locate and correct the restriction in the fuel return

line.
Verify repair
Visually and physically inspect the fuel rail outlet

passages for a restriction.
Verify repair
Go to Step 11

gauge above the specified value?
0 kPa (0 psi)
Go to Step 22
Go to Step 23
11
12
15
1. If the pliers are still clamped to the fuel supply

hose, remove the locking pliers.
2. With suitable locking pliers, clamp the fuel return
line to prevent fuel from returning to the fuel tank.
16
17
18

gauge above the specified limit?
1. Relieve the fuel pressure. Refer to the Fuel
Pressure Relief.
2. Disconnect the fuel return line from the fuel rail.
3. Attach a length of flexible hose to the fuel rail
return outlet passage.
4. Place the open end of the flexible hose into an
19
20
21
6E112
Step
Action
22
1. Command the fuel pump ON with the Scan Tool.
23
Value(s)
2. Using suitable pliers which will not damage the

fuel hose, gradually apply pressure with the pliers
to pinch the flexible fuel return hose closed.
376 kPa
(55 psi)

gauge rise above the first specified value?
Caution: Do not let the fuel pressure exceed the
second specified value.
414 kPa
(60 psi)
Yes
No
Go to Step 11
Go to Step 7
Go to Step 7
Go to Fuel
System
Electrical Test
Chart
1. Command the fuel pump ON with the Scan Tool.

2. Remove the fuel filler cap and listen for the sound
of the fuel pump running.
3. Turn the pump off.
Was the fuel pump running?

Type A
6E113
ECM DIAGNOSTIC TROUBLE CODES (DTC)
Emission related.
Requests illumination of the MIL (Malfunction Indicator Lamp = Check Engine Lamp) of the first trip with a fail.
Stores a history DTC on the first trip.
Stores a freeze frame (If empty).
Stores a fail record.
Type B
Emission related.
Armed after one trip with fail.
Disarmed after one trip with a pass.
Requests illumination of the MIL on the second consecutive trip with a fail.
Store a history DTC on the second consecutive trip with a fail. (The DTC will be armed after the first fail.)
Stores a freeze frame on the second consecutive trip with a fail (If empty).
Stores a fail record when the first test fails (not dependent on consecutive trip).
Type D
Non emission related.
Does not request illumination of any lamp.
Stores a history DTC on the first trip.
Does not store a freeze frame.
Stores fail record when test fails.
6E114
Code
Type
DTC Name
Fail-Safe (Back Up)
Recovery Condition
Related
ECM
Pin No.
P0107
Manifold Absolute Pressure Circuit Low

Input
MAP sensor output is more than 12kPa.

The ECM uses default manifold
1. No DTC relating to TPS.
absolute
pressure
value
based
on
2. Throttle position is more than 0% if engine
engine speed and throttle position.
speed is below 1000rpm, or throttle
position more than 5% if engine speed is
more than 1000rpm.
3. MAP sensor output is below 12kPa.
1. Sensor power supply circuit open or short

to ground circuit.
2. Sensor signal circuit open or short to
ground circuit.
4. MAP sensor malfunction.
5. ECM malfunction.
J1-24/
J1-31
P0108
Manifold Absolute Pressure Circuit High

Input

2. Throttle position is below 15% if engine
speed is below 2500rpm, or throttle
position is below 35% if engine speed is
more than 2500rpm.
3. Engine run time is longer than 10
seconds.
4. MAP sensor output is more than 103kPa.
1. Sensor power supply circuit short to

voltage circuit.
2. Sensor signal circuit short to voltage
circuit.
3. Sensor ground circuit open or short to
voltage circuit.
5. MAP sensor malfunction.
6. ECM malfunction.
J1-16/
J1-24/
J1-31
P0112
1. No DTC relating to VSS.

seconds.
4. IAT sensor output is more than 149 deg.
C.
1. Sensor signal circuit short to ground

circuit.
3. ECM malfunction.
J2-22
P0113
1. No DTC relating to VSS & ECT sensor.

3. 3Engine coolant temperature is more than
-8 deg. C.
seconds.
5. Mass air flow is below 30g/s.
6. IAT sensor output is below -38 deg. C.
IAT sensor output is more than -38 deg. C.

voltage circuit.
voltage circuit.
5. ECM malfunction.
J2-1/
J2-22
P0117
Engine Coolant Temperature Sensor Low

Input

seconds.
2. ECT sensor output is more than 149 deg.
C.
ECT sensor output is below 149 deg. C.
1. Sensor signal circuit short to ground

circuit.
3. ECM malfunction.
J1-27
P0118
Engine Coolant Temperature Sensor High

Input

seconds.
2. ECT sensor output is below -38 deg. C.
ECT sensor output is more than -38 deg. C.

voltage circuit.
voltage circuit.
5. ECM malfunction.
J1-27/
J1-32
MAP sensor output is below 103kPa.
The ECM uses 20 deg. C condition IAT sensor output is below 149 deg. C.
as substitute.

coolant temperature value based
on intake air temperature and
engine run time.

Code
Type
DTC Name
P0122
Throttle Position Sensor Low Input
P0123
Throttle Position Sensor High Input
P0131
O2 Sensor Circuit Low Voltage (Bank 1

Sensor 1)
P0132
P0134
Fail-Safe (Back Up)
Related
ECM
Pin No.
1. Sensor power supply circuit open or short

to ground circuit.
ground circuit.
4. TPS malfunction.
5. ECM malfunction.
J1-7/
J1-15/
1. Sensor power supply circuit short to

voltage circuit.
2. Sensor signal circuit short to voltage
circuit.
voltage circuit.
5. TPS malfunction.
6. ECM malfunction.
J1-7/
J1-15/
J1-32
Open Loop fuel control.

1. No DTC relating to MAP sensor, TPS,
EVAP purge, ECT sensor, CKP sensor,
VSS, injector control circuit and ignition
control circuit.
60 deg. C.
3. O2 sensor bank 1 output voltage is below
50mV in Closed Loop condition.
O2 sensor bank 1 output voltage is more

than 50mV.
1. Sensor harness short to ground circuit.

3. ECM malfunction.
J2-6/
J2-21
O2 Sensor Circuit High Voltage (Bank 1

Sensor 1)

control circuit.
60 deg. C.
3. O2 sensor bank 1 output voltage is more
than 952mV in Closed Loop condition.
O2 sensor bank 1 output voltage is below

952mV.
1. Sensor harness short to voltage circuit.

6. Incorrect fuel pressure.
8. ECM malfunction.
J2-6/
J2-21
O2 Sensor Circuit No Activity Detected

(Bank 1 Sensor 1)

control circuit.
60 deg. C.
seconds.
4. Mass air flow is more than 7g/s.
5. O2 sensor bank 1 output voltage is
O2 sensor bank 1 output voltage is below

300mV consecutively.
OR
O2 sensor bank 1 output voltage is more
than 600mV consecutively.
1. Sensor harness open circuit.

6. Incorrect fuel pressure.
8. ECM malfunction.
J2-6/
J2-21
The ECM uses 0% condition as

substitute.
Recovery Condition
6E115
6E116
Code
Type
DTC Name
P0135
O2 Sensor Heater Circuit (Bank 1 Sensor

1)
1. No DTC relating to MAP sensor and ECT No fail-safe function.

sensor.
60 deg. C.
seconds.
5. O2 sensor bank 1 heater current more
than 10mA.
P0201
P0202
P0203
P0204
3. Injector voltage does not meet to the
battery voltage when the injector is
commanded Off or does not meet to the
0V when the injector is commanded On.
P0325
Knock Sensor Module Circuit
1. No DTC relating to MAP sensor.

50 deg. C.
4. Knock sensor filter module integrated
circuit malfunction.
P0327
Knock Sensor Circuit

50 deg. C.
4. Knock sensor harness short to ground or
P0336
Crankshaft Position Sensor Circuit Range/

Performance (58X)
2. Extra or missing pulse is detected
consecutively.
P0337
Crankshaft Position Sensor Circuit Low

Input (58X)
No pulse is detected during engine cranking.
Fail-Safe (Back Up)
Recovery Condition
Related
ECM
Pin No.
O2 sensor bank 1 heater circuit is correct

condition.
1. Heater harness open, short to ground or

2. O2 sensor heater malfunction.
3. ECM malfunction.
J2-31
Injector circuit is correct condition.
1. Injector harness open circuit, short to

ground or short to voltage circuit.
3. ECM malfunction.
J1-9
J1-22
J1-8
J1-11
ECM retards ignition timing 4 deg.

C.
Knock sensor is correct condition.
Correct pulse is detected consecutively.
1. KS harness open circuit.

3. KS sensor malfunction.
4. ECM malfunction.
J1-3/
J1-32
1. KS harness short to ground or short to

voltage circuit.
3. KS sensor malfunction.
4. ECM malfunction.
J1-3/
J1-32

5. Pluser malfunction.
8. ECM malfunction.
J1-6/
J1-21

5. Pluser malfunction.
8. ECM malfunction.
J1-6/
J1-21

DTC Name
Code
Type
P0351
#1 or #4cylinder ignition signals are not

P0352
#2 or #3 cylinder ignition signals are not

P0443

Control Circuit
EVAP purge solenoid circuit open, short to

P0502
Vehicle Speed Sensor Circuit Low Input
P0562
System Voltage Low
Battery voltage is below 11V.
P0563
System Voltage High
Battery voltage is above 16V.
P0601
ECM Memory Checksum
Memory are is OK.
ECM malfunction.
P0602
Memory are is OK.
ECM is not programmed.
P0650
Malfunction Indicator Lamp (MIL) Control

Circuit Malfunction
Check engine lamp circuit open, short to

Check engine lamp circuit is correct

condition.

ECT sensor, injector control circuit and
ignition control circuit.
3. Vehicle speed is below 3km/h in power
condition or 2km/h in deceleration
condition.
Fail-Safe (Back Up)
Recovery Condition
6E117
Consecutive ignition signals are detected.
Related
ECM
Pin No.
1. Ignition coil module 1 harness open

circuit, short to ground or short to voltage
circuit.
2. Ignition coil module malfunction.
3. ECM malfunction.
J1-19
1. Ignition coil module 2 harness open circuit,

short to ground or short to voltage circuit.
2. Ignition coil module malfunction.
3. ECM malfunction.
J1-18
EVAP purge solenoid circuit is correct

condition.
1. Solenoid harness open circuit, short to

3. ECM malfunction.
J1-5
ECM uses 0km/h condition as

substitute.
VSS circuit correct condition.
1. Sensor harness open circuit, short to

3. VSS malfunction.
4. ECM malfunction.
J2-23
Battery voltage is between 11V and 16V.
1. Battery power feed harness open circuit

2. ECM ground harness open or poor
connection.
6. ECM malfunction.

2. Battery jump start cable misconnect.
3. ECM malfunction.
1. Solenoid harness open circuit, short to

3. ECM malfunction.
J2-32
6E118
Code
Type
DTC Name
Fail-Safe (Back Up)
P1167

Deceleration Fuel Cutoff

control circuit.
than 550mV in deceleration fuel cutoff
mode.
P1171
Fuel Supply System Lean During Power

Enrichment
control circuit.
60deg. C.
3. Mass air flow is below 13.5m/s.
350mV in power enrichment mode.
P1625
ECM System Reset
ECM reset has occurred other than On.
P1626
P1631
1. ECM malfunction.
P1648
1. ECM malfunction.
P1649
Immobilizer Function Not Programmed
Immobilizer function is not programmed in the

ECM.
P1693
Tachometer Output Low Voltage
Tacho output circuit short to ground circuit.

Recovery Condition
O2 sensor output voltage is below 550mV.

circuit.
J2-6/
J2-21
O2 sensor output voltage is more than

350mV.

circuit.
8. ECM malfunction.
J2-6/
J2-21
Memory are is OK.
3. ECM malfunction.
No recovery.
1. ECM and immobilizer control unit

communication circuit open circuit, short to
2. ECM malfunction.
ECM malfunction.
Related
ECM
Pin No.
Tacho output circuit is correct condition.
1. Tacho output circuit short to ground circuit.

3. ECM malfunction.
J2-23/
J2-32
J2-25
6E119
DIAGNOSTIC TROUBLE CODE (DTC) P0107 MANIFOLD ABSOLUTE

PRESSURE CIRCUIT LOW INPUT
Code
Type
P0107
DTC Name
Manifold Absolute Pressure Circuit
Low Input

2. Throttle position is more than 0% if engine
speed is below 1000rpm, or throttle position more than 5% if engine speed is more
than 1000rpm.
3. MAP sensor output is below 12kPa.
Circuit Description
The manifold absolute pressure (MAP) sensor responds
to changes in intake manifold pressure. The MAP
sensor signal voltage to the engine control module
(ECM) varies from below 2 volts at idle (low manifold
pressure) to above 4 volts with the ignition ON, engine
not running or at wide-open throttle (high manifold
pressure).
A speed density method of determining engine load is
used on the 2.4L engine. This is calculated using inputs
from the MAP sensor, the CKP Sensor, and the Intake
Fail-Safe (Back Up)

The ECM uses default manifold absolute
pressure value based on engine speed
and throttle position.
Air Temperature (IAT) sensor. The MAP sensor is the

main sensor used in this calculation, and measuring
engine load is its main function.
The ECM monitors the MAP signals for voltages outside
the normal range (10-104 kPa) of the MAP sensor. If the
ECM detects a MAP signal voltage that is excessively
low, Diagnostic Trouble Code P0107 will be set.
Diagnostic Aids
Poor connection at ECM -
Inspect
harness
6E120

If these codes are also set, it could indicate a
problem with the 5 Volt reference circuit.
Damaged harness - Inspect the wiring harness for
damage, short to ground, short to battery positive,

and open circuit. If the harness appears to be OK,
observe the MAP display on the Tech 2 while moving

Manifold Absolute Pressure Circuit Low Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 9
Go to Step 6
Approximately
5.0V
Go to Step 8
Go to Step 7

3. Select F0: Read DTC Infor By Priority in F0:
1. Using the Tech2, ignition On and engine Off.

2. Select Clear DTC Information with the Tech2 and
3. Operate the vehicle and monitor the F5: Failed
This Ignition in F2: DTC Information.
Check for poor/faulty connection at the MAP sensor or

16
31
5
6
E60(J1)
E85
24
Visually check the MAP.

Using the DVM and check the MAP sensor power
supply circuit.
2. Disconnect the MAP sensor connector.
circuit.
E85
3

Step
Action

ECM and MAP sensor
6E121
Value(s)
Yes
No
Verify repair
Go to Step 11
Repair faulty
harness and
verify repair
Go to Step 9
Substitute a known good MAP sensor and recheck.

Go to Step 10
Go to Step 11
Replace the MAP sensor.

Verify repair

release?
Verify repair
Go to Step 12
E60(J1)
31
E85
3
Using the DVM and check the MAP sensor signal

circuit.
disconnected) Refer to 6E-88 page.
(ECM
3. Disconnect MAP sensor connector.

Breaker Box
J1-16
J1-24
E-85


2. Disconnect the MAP sensor connector and ECM
connector.
16
E60(J1) 24
E85
2
9
10
11
6E122
Step
Action
Value(s)
Yes
No
12
Replace the ECM.

Verify repair
6E123
DIAGNOSTIC TROUBLE CODE (DTC) P0108 MANIFOLD ABSOLUTE

PRESSURE CIRCUIT HIGH INPUT
Code
Type
P0108
DTC Name
Manifold Absolute Pressure Circuit
High Input
Fail-Safe (Back Up)
The ECM uses default manifold absolute

pressure value based on engine speed
2. Throttle position is below 15% if engine
and throttle position.
speed is below 2500rpm, or throttle position is below 35% if engine speed is more
than 2500rpm.
3. Engine run time is longer than 10 seconds.
Circuit Description
The manifold absolute pressure (MAP) sensor responds
to changes in intake manifold pressure. The MAP
sensor signal voltage to the engine control module
(ECM) varies from below 2 volts at idle (low manifold
pressure) to above 4 volts with the ignition ON, engine
not running or at wide-open throttle (high manifold
pressure).
A speed density method of determining engine load is
used on the 2.4L engine. This is calculated using inputs
from the MAP sensor, RPM, CKP Sensor, and the

Intake Air Temperature (IAT) sensor. The MAP sensor is
the main sensor used in this calculation, and measuring
engine load is its main function.
The ECM monitors the MAP signals for voltages outside
the normal range (10-104 kPa) of the MAP sensor. If the
ECM detects a MAP signal voltage that is excessively
high, Diagnostic Trouble Code P0108 will be set.
6E124
Diagnostic Aids
problem with the 5 Volt reference circuit.

Poor connection at ECM - Inspect harness

damage; an open circuit, a short to ground, or a short
to voltage. If the harness appears to be OK, observe
the MAP display on the Tech 2 while moving

Manifold Absolute Pressure Circuit High Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 11
Go to Step 6


Check for poor/faulty connection at the MAP sensor or

16
31
E60(J1)
24
Visually check the MAP sensor.

E85

Step
Action
Using the DVM and check the MAP sensor power

supply circuit.
6E125
Value(s)
Yes
No
Approximately
5.0V
Go to Step 8
Go to Step 7
Verify repair
Go to Step 13
Go to Step 9
Repair faulty
harness and
verify repair
Go to Step 10
Repair faulty
harness and
verify repair

E85
3
V
7

and MAP sensor.
31
E60(J1)
E85
3
Using the DVM and check the MAP sensor signal

circuit.
E85
2
V
Less than 1V
9
Using the DVM and check the MAP sensor ground

circuit.
2. Disconnect the MAP sensor connector .
E85
1
V
Less than 1V
6E126
Step
Action
Value(s)
Yes
No
10
Using the DVM and check the MAP sensor ground

circuit.
Repair faulty
harness and
verify repair
Go to Step 11
Substitute a known good MAP sensor and recheck.

Go to Step 12
Go to Step 13

Verify repair

release?
Verify repair
Go to Step 14
Replace the ECM.

Verify repair

(ECM

Breaker Box
J1-16
E-85

2. Disconnect the MAP sensor connector and ECM
connector.
16
E60(J1)
E85
1
11
12
13
14
6E127
DIAGNOSTIC TROUBLE CODE (DTC) P0112 INTAKE AIR TEMPERATURE

SENSOR LOW INPUT
Code
Type
P0112
DTC Name
Intake Air Temperature Sensor Low
Input
Fail-Safe (Back Up)
The ECM uses 20 deg. C condition as

1. No DTC relating to VSS.
substitute.
4. IAT sensor output is more than 149 deg. C.
Circuit Description
engine. The engine control module (ECM) applies 5
resistance is lower, causing the ECM to monitor a lower
voltage. Diagnostic Trouble Code P0112 will set when
the ECM detects an excessively low signal voltage
(short to ground) on the intake air temperature sensor

signal circuit.
Diagnostic Aids
damage, short to ground, short to battery and open
6E128
circuit. If the harness appears to be OK, observe the

IAT display on the Tech 2 while moving connectors
and wiring harnesses related to the IAT sensor. A
change in the IAT display will indicate the location of

the fault.

Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6



C56(J2)
C121
22
Remove the IAT sensor and visually check.


Step
6
Action
6E129
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 8
Repair faulty
harness and
verify repair
Go to Step 10

Temperature (C)
Resistance (9) (Approximately)
-20
32500
9910
20
3400
40
1509
60
670
80
329
100
182
120
101
IAT Sensor


circuit.
(ECM

ground circuit.
Breaker Box
J2-1
J2-22


ground circuit.
C56(J2)
22
6E130
Step
Action
Value(s)
Yes
No
Substitute a known good IAT sensor assembly and

recheck.
Go to Step 9
Go to Step 10
Replace the IAT sensor assembly.

Verify repair

release?
Verify repair
Go to Step 11
Replace the ECM.

Verify repair
9
10
11
6E131
DIAGNOSTIC TROUBLE CODE (DTC) P0113 INTAKE AIR TEMPERATURE

SENSOR HIGH INPUT
Code
Type
P0113
DTC Name
Intake Air Temperature Sensor High
Input
Fail-Safe (Back Up)
The ECM uses 20 deg. C condition as

1. No DTC relating to VSS & ECT sensor.
substitute.
3. 3Engine coolant temperature is more than 8 deg. C.
5. Mass air flow is below 30g/s.
6. IAT sensor output is below -38 deg. C.
Circuit Description
engine. The engine control module (ECM) applies 5
resistance is lower causing the ECM to monitor a lower
voltage. Diagnostic Trouble Code P0113 will set when

the ECM detects an excessively high signal voltage on
the intake air temperature sensor signal circuit.
Diagnostic Aids
6E132

observe the IAT display on the Tech 2 while moving


Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6



C56(J2)
22

C121

Step
6
Action
6E133
Value(s)
Yes
No
Standard
resistance
Go to Step 7
Go to Step 12
Approximately
5.0V
Go to Step 10
Less than 1V:

Go to Step 8
More than
specified value:
Go to Step 9
Verify repair
Go to Step 14
Verify repair
Go to Step 14

Temperature (C)
-20
32500
9910
20
3400
40
1509
60
670
80
329
100
182
120
101
IAT Sensor


circuit.
1
C121
V
8

sensor.
C56(J2) 22
1 C121

and IAT sensor.
C56(J2) 22
1 C121
6E134
Step
Action
Value(s)
Yes
No
10

circuit.
Less than 1V
Go to Step 11
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 14
Substitute a known good IAT sensor assembly and

recheck.
Go to Step 13
Go to Step 14
Replace the IAT sensor assembly.

Verify repair

release?
Verify repair
Go to Step 15

C121
V
11

circuit.
(ECM

C-121
Breaker Box
J2-1

C56(J2)
12
13
14
C121
6E135
Step
Action
Value(s)
Yes
No
15
Replace the ECM.

Verify repair
6E136
DIAGNOSTIC TROUBLE CODE (DTC) P0117 ENGINE COOLANT

TEMPERATURE SENSOR LOW INPUT
Code
Type
P0117
DTC Name
Engine Coolant Temperature Sensor
Low Input

2. ECT sensor output is more than 149 deg.
C.
Fail-Safe (Back Up)

The ECM uses default engine coolant
temperature value based on intake air
temperature and engine run time.
Circuit Description
Diagnostic Aids

thermistor mounted in the engine coolant stream. The
engine control module (ECM) applies a voltage (about 5
volts) through a pull-up resistor to the ECT signal circuit.
When the engine coolant is cold, the sensor (thermistor)
sensor resistance becomes lower, and the ECT signal
voltage measured at the ECM drops. Diagnostic Trouble
code P0117 set when the ECM detects an excessively
low signal voltage on the engine coolant temperature

observe the ECT display on the Tech 2 while moving
6E137

Engine Coolant Temperature Sensor Low Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 8
Go to Step 6
Standard
resistance
Go to Step 7
Go to Step 8



E60(J1)
32
5
6
E69
27

Temperature (C)
-20
26740
9120
20
3500
40
1464
60
664
80
333
100
175
120
102
ECT Sensor

6E138
Step
Action
Value(s)
Yes
No

circuit.
Repair faulty
harness and
verify repair
Go to Step 10

recheck.
Go to Step 9
Go to Step 10

Verify repair

release?
Verify repair
Go to Step 11
Replace the ECM.

Verify repair

(ECM

ground circuit.
Breaker Box
J1-27
J1-32


ground circuit.
32
9
10
11
27 E60(J1)
6E139
DIAGNOSTIC TROUBLE CODE (DTC) P0118 ENGINE COOLANT

TEMPERATURE SENSOR HIGH INPUT
Code
Type
P0118
DTC Name
Engine Coolant Temperature Sensor
High Input

2. ECT sensor output is below -38 deg.C.
Fail-Safe (Back Up)

The ECM uses default engine coolant
temperature value based on intake air
temperature and engine run time.
Circuit Description
Diagnostic Aids

thermistor mounted in the engine coolant stream. The
engine control module (ECM) applies a voltage (about 5
volts) through a pull-up resistor to the ECT signal circuit.
When the engine coolant is cold, the sensor (thermistor)
sensor resistance becomes less, and the ECT signal
voltage measured at the ECM drops. Diagnostic Trouble
code P0118 set when the ECM detects an excessively
high signal voltage on the engine coolant temperature

observe the ECT display on the Tech 2 while moving
6E140

Engine Coolant Temperature Sensor High Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6
Standard
resistance
Go to Step 7
Go to Step 12



E60(J1)
32
5
6
E69
27

Temperature (C)
-20
26740
9120
20
3500
40
1464
60
664
80
333
100
175
120
102
ECT Sensor


Step
Action
Value(s)

circuit.
6E141
Yes
No
Approximately
5.0V
Go to Step 10
Less than 1V:

Go to Step 8
More than
specified value:
Go to Step 9
Verify repair
Go to Step 14
Verify repair
Go to Step 14
Go to Step 11
Repair faulty
harness and
verify repair

E69
1
V
8

sensor.
27
E60(J1)
E69
1

and ECT sensor.
27
E60(J1)
E69
1
10

circuit.
E69
2
V
Less than 1V
6E142
Step
Action
Value(s)
Yes
No
11

circuit.
Repair faulty
harness and
verify repair
Go to Step 14

recheck.
Go to Step 13
Go to Step 14

Verify repair

release?
Verify repair
Go to Step 15
Replace the ECM.

Verify repair

(ECM

Breaker Box
J1-32
E-69

32
E60(J1)
E69
2
12
13
14
15
6E143
DIAGNOSTIC TROUBLE CODE (DTC) P0122 THROTTLE POSITION SENSOR

LOW INPUT
Code
Type
P0122
DTC Name
Throttle Position Sensor Low Input

Fail-Safe (Back Up)

The ECM uses 0% condition as substitute.
Circuit Description
Diagnostic Aids
The throttle position sensor circuit provides a signal

voltage that changes relative to throttle blade angle. The
signal voltage will vary from below 1 volt at closed
throttle to about 4 volts at wide open throttle (WOT).
The TPS signal is used by the engine control module
(ECM) for fuel control and most of the ECM-controlled
outputs. If the ECM detect a continuous short to ground
in the TPS or circuit, then a code P0122 will set.

observe the throttle position display on the Tech 2
while moving connectors and wiring harnesses
related to the TPS. A change in the display will
indicate the location of the fault.
6E144
Diagnostic Trouble Code (DTC) P0122 Throttle Position Sensor Low Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 10
Go to Step 6
Standard
resistance
Go to Step 7
Go to Step 10



as necessary.
E60(J1)
32
5
6
E68
15 7

Measurement
Terminal
Resistance (9)
1-2

WOT
2-3
1-3

WOT
TPS
1
3

Step
Action

circuit.
6E145
Value(s)
Yes
No
Approximately
5.0V
Go to Step 9
Go to Step 8
Verify repair
Go to Step 12

circuit.
E68
2
V
8

ECM and TPS.
15
E60(J1)
E68
2
6E146
Step
9
Action
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 12

Go to Step 11
Go to Step 12
Replace the TPS.

Verify repair

release?
Verify repair
Go to Step 12
Replace the ECM.

Verify repair

(ECM

E-86
Breaker Box
J1-7
J1-32

2. Disconnect the TPS connector and ECM
connector.
32
10
11
12
13
E60(J1)7
E68
3
6E147
DIAGNOSTIC TROUBLE CODE (DTC) P0123 THROTTLE POSITION SENSOR

HIGH INPUT
Code
Type
P0123
DTC Name
Throttle Position Sensor High Input
Circuit Description
The throttle position sensor circuit provides a voltage
signal that changes relative to throttle blade angle. The
signal voltage will vary from below 1 volt at closed
throttle to about 4 volts at wide open throttle (WOT).
The TPS is used by the engine control module (ECM)
for fuel control and most of the ECM-controlled outputs.
If the ECM detect a continuous short voltage in the TPS
or circuit, then a code P0123 will set.
Diagnostic Aids
Poor connection at ECM -
Inspect
harness
Fail-Safe (Back Up)

The ECM uses 0% condition as substitute.

problem with the 5 Volt reference circuit or
components itself.
damage, short to ground, short to battery positive and
open circuit. If the harness appears to be OK,
observe the Throttle Position sensor display on the
Tech 2 while moving connectors and wiring
harnesses related to the TP sensor. A change in the
6E148
Diagnostic Trouble Code (DTC) P0123 Throttle Position Sensor High Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6
Standard
resistance
Go to Step 7
Go to Step 12



as necessary.
E60(J1)
32
5
6
E68
15 7

Measurement
Terminal
Resistance (9)
1-2

WOT
2-3
1-3

WOT
TPS
1
3

Step
Action

circuit.
6E149
Value(s)
Yes
No
Approximately
5.0V
Go to Step 9
Go to Step 8
Verify repair
Go to Step 14
Go to Step 10
Repair faulty
harness and
verify repair
Go to Step 11
Repair faulty
harness and
verify repair

E68
2
V
8

and TPS.
15
E60(J1)
E68
2

E68
3
V
Less than 1V
10

E68
1
V
Less than 1V
6E150
Step
11
Action
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 14

Go to Step 13
Go to Step 14
Replace the TPS.

Verify repair

release?
Verify repair
Go to Step 14
Replace the ECM.

Verify repair

(ECM

Breaker Box
J1-32
E-86

2. Disconnect
connector.
the
TPS
connector
and
ECM

32
12
13
14
15
E60(J1)
E68
1
6E151
DIAGNOSTIC TROUBLE CODE (DTC) P0131 O2 SENSOR CIRCUIT LOW

VOLTAGE (BANK 1 SENSOR 1)
Code
Type
DTC Name
P0131
O2 SensorCircuit Low Voltage (Bank 1

Sensor 1)

control circuit.
60 deg. C.
50mV in Closed Loop condition.
Circuit Description
The engine control module (ECM) supplies a bias
sensor (HO2S) signal and low circuits. The oxygen
sensor varies the voltage within a range of about 1000
mV when the exhaust is rich, down through about 10
mV when exhaust is lean. The ECM constantly monitors
the HO2S signal during Closed Loop operation and
compensates for a rich or lean condition by decreasing
or increasing injector pulse width as necessary. If the
Fail-Safe (Back Up)

Bank 1 HO2S 1 voltage remains excessively low for an

extended period of time, Diagnostic Trouble Code
P0131 will be set.
Diagnostic Aids
Heated oxygen sensor wiring - The sensor pigtail
may be routed incorrectly and/or contacting the
exhaust system. Also, check for shorts to ground,
shorts to battery positive and open circuits.
6E152
Poor ECM to engine block grounds.

Fuel pressure - The system will go lean if pressure is
decrease. However, if fuel pressure is too low, a
Diagnostic Trouble Code P0131 may be set. Refer to
Lean injector(s) - Perform Injector Balance Test.
Vacuum leaks - Check for disconnected or damaged
vacuum hoses and for vacuum leaks at the intake
manifold, throttle body, EGR system, and PCV
system.
Exhaust leaks - An exhaust leak may cause outside

to be indicated.
Fuel contamination - Water, even in small amounts,
cause a lean exhaust to be indicated. Excessive
alcohol in the fuel can also cause this condition. For
the procedure to check for fuel contamination, Refer
to Fuel System Diagnosis.

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Approximatly
450mV
Go to Step 7
Go to Step 6



C56(J2) 6
31
E77
21
Using the DVM and check the O2 sensor circuit.

3. Check the circuit for short to heater ground or
ground circuit.
E77
1 2

Step
6
Action
6E153
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 15
No continuity
Go to Step 9
Go to Step 8
Verify repair
Go to Step 15

(ECM
3. Disconnect the O2 sensor.

Breaker Box
J2-21
J2-6
J2-31


2. Disconnect the O2 sensor connector and ECM
connector.
C-56(J2)
C-56(J2)


2. Disconnect the the O2 sensor connector.
3. Check the circuit for short to heater ground circuit.
O 2 Sensor

Repair the short to heater ground circuit.

6E154
Step
Action

2. Monitor the Manifold Absolute Pressure in the
data display.
Does the Tech 2 indicate correct Manifold Absolute
Pressure in accordance with engine speed or
acceleration?
10
Value(s)
Yes
No
Go to Step 11
Go to Step 10
Verify repair
Go to Step 11
Go to Step 13
Go to Step 12
Verify repair
Go to Step 13
Go to Step 14
Refer to Injector
Coil Test &
Injector
Balance Test
Procedure
Remove the MAP sensor and check for the following

conditions.
Objects blocking the MAP sensor.
11

IAC Control in the IAC System.
Was the engine speed changed, when the IAC valve
12

Objects blocking the IAC valve.
13

Refer to Injector Coil Test & Injector Balance Test
Procedure 6E-98 page.
14
15
16
17

Refer to Fuel System Diagnosis 6E-108 page.
Go to Step 15
Refer to Fuel
System
Diagnosis
Replace the O2 sensor.

Verify repair
Go to Step 16

release?
Verify repair
Go to Step 17
Replace the ECM.

Verify repair
6E155
DIAGNOSTIC TROUBLE CODE (DTC) P0132 O2 SENSOR CIRCUIT HIGH

VOLTAGE (BANK 1 SENSOR 1)
Code
Type
P0132
DTC Name
O2 Sensor Circuit High Voltage (Bank 1 1. No DTC relating to MAP sensor, TPS,
Sensor 1)
control circuit.
60 deg. C.
than 952mV in Closed Loop condition.
Circuit Description
sensor (HO2S) signal and low circuits. The oxygen
Fail-Safe (Back Up)

Bank 1 HO2S 1 voltage remains excessively high for an

extended period of time, Diagnostic Trouble Code
P0132 will be set.
Diagnostic Aids
Fuel pressure - The system will go rich if pressure is
increase. However, if fuel pressure is too high, a
6E156

Perform Injector Balance Test - Refer to Fuel
System Diagnosis.
Check the EVAP canister for fuel saturation - If full of
fuel, check canister control and hoses. Refer to
Evaporative (EVAP) Emission Control System.
diaphragm by checking the vacuum line to the
regulator for the presence of fuel.
An intermittent TPS output will cause the system to

go rich due to a false indication of the engine
accelerating.
Silicon contamination of the HO2S can also cause a
high HO2S voltage to be indicated. This condition is
indicated by a powdery white deposit on the portion
of the HO2S exposed to the exhaust stream. If
contamination is noticed, replace the affected HO2S.

O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)
Step
Action
Value(S)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Approximatly
450mV
Go to Step 7
Go to Step 6



C56(J2) 6
31
E77
21

E77
1 2

Step
6
Action
Value(S)
6E157
Yes
No
Less than 1V
Go to Step 15
Repair faulty
harness and
verify repair
No continuity
Go to Step 9
Go to Step 8
Verify repair
Go to Step 15
Go to Step 11
Go to Step 10
Verify repair
Go to Step 11
Go to Step 13
Go to Step 12

Was the DVM indicated specifed value?
E77
1 2
V V
7

3. Check the circuit for short to heater power supply
circuit.
O2 Sensor
2
4
4
8
9
Repair the short to heater power supply circuit.

data display.
acceleration?
10

conditions.
11

6E158
Step
12

Action
Value(S)
Yes
No
Verify repair
Go to Step 13
Go to Step 14
Refer to Injector
Coil Test &
Injector
Balance Test
Procedure

13

14
15
16
17

Go to Step 15
Refer to Fuel
System
Diagnosis

Verify repair
Go to Step 16

release?
Verify repair
Go to Step 17
Replace the ECM.

Verify repair
6E159
DIAGNOSTIC TROUBLE CODE (DTC) P0134 O2 SENSOR NO ACTIVITY

DEFECTED (BANK 1 SENSOR 1)
Code
Type
P0134
DTC Name
Fail-Safe (Back Up)
O2 Sensor Circuit No Activity Detected 1. No DTC relating to MAP sensor, TPS,

(Bank 1 Sensor 1)
control circuit.
60 deg.C.
4. Mass air flow is more than 7g/s.
5. O2 sensor bank 1 output voltage is
Circuit Description
sensor (HO2S) high and low circuits. The oxygen

Bank 1 HO2S 1 voltage remains at or near the 450 mV
bias for an extended period of time, Diagnostic Trouble
Code P0134 will be set, indicating an open sensor
signal or sensor low circuit.
6E160
Diagnostic Aids


O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Approximatly
450mV
Go to Step 7
Go to Step 6



C56(J2) 6
31
E77
21

E77
1 2

Step
6
Action
6E161
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 13
Go to Step 9
Go to Step 8
Verify repair
Go to Step 9
Go to Step 11
Go to Step 10

(ECM
3. Disconnect the O2 sensor.

E-77
Breaker Box
J2-6
J2-21


connector.
6
C56(J2)
21
E77

data display.
acceleration?

conditions.

6E162
Step
10

Action
Value(s)
Yes
No
Verify repair
Go to Step 11
Go to Step 12
Refer to Injector
Coil Test &
Injector
Balance Test
Procedure

11

12
13
14
15

Go to Step 13
Refer to Fuel
System
Diagnosis

Verify repair
Go to Step 14

release?
Verify repair
Go to Step 15
Replace the ECM.

Verify repair
6E163
DIAGNOSTIC TROUBLE CODE (DTC) P0135 O2 SENSOR HEATER CIRCUIT

(BANK 1 SENSOR 1)
Code
Type
DTC Name
P0135
O2 SensorHeater Circuit (Bank 1 Sensor 1)
Fail-Safe (Back Up)
1. No DTC relating to MAP sensor and ECT

sensor.
60 deg. C.
5. O2 sensor bank 1 heater current more than
10mA.
Circuit Description
amount of time required for Closed Loop fuel control
operation and to allow accurate catalyst monitoring. The
oxygen sensor heater greatly decreases the amount of
time required for fuel control sensors Bank 1 HO2S 1 1
to become active. Oxygen sensor heaters are required
by catalyst monitor sensors Bank 1 HO2S 2 to maintain
a sufficiently high temperature which allows accurate
exhaust oxygen content readings further from the
engine.
The engine control module (ECM) will run the heater
test only after a cold start (determined by engine coolant
and intake air temperature at the time of start-up) and
only once during an ignition cycle. When the engine is
started the ECM will monitor the HO2S voltage. When
the HO2S voltage indicates a sufficiently active sensor,
the ECM looks at how much time has elapsed since
start-up. If the ECM determines that too much time was
required for the Bank 1 HO2S 1 to become active, a
Diagnostic Trouble Code P0135 will set.
6E164
Diagnostic Aids

damage; shorts to ground, shorts to battery positive
and open circuits.


O2 Sensor Heater Circuit (Bank 1 Sensor 1)
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 11
Go to Step 6
Approximately
12.5W at 20C
Go to Step 7
Go to Step 11



C56(J2)
E77
31
5
6
3 4
Visually check the O2 sensor.

Using the DVM and check the O2 sensor.
2. Disconnect O2 sensor connector
3. Measure the resistance of heater.
O2 Sensor
3
4
4

Step
Action
Using the DVM and check the heater power supply

6E165
Value(s)
Yes
No
10 - 14.5V
Go to Step 9
Go to Step 8
Verify repair
Repair faulty
harness and
verify repair
Go to Step 10

E77
4
V
8

O2 Sensor fuse (10A) and O2 sensor.
Using the DVM and check the heater ground circuit.
(ECM

circuit.
E-77
Breaker Box
J2-31

connector.
circuit.
31
E56(J2)
E77
6E166
Step
10

Action
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 12

Verify repair
Go to Step 12

release?
Verify repair
Go to Step 13
Replace the ECM.

Verify repair
Using the DVM and check the heater ground circuit.

Was the DVM indicated voltage?
E77
V
11
12
13
6E167
DIAGNOSTIC TROUBLE CODE (DTC) P0201 INJECTOR 1 CONTROL CIRCUIT

Code
Type
DTC Name
P0201
P0202
P0203
P0204

3. Injector voltage does not meet to the battery voltage when the injector is commanded Off or does not meet to the 0V
when the injector is commanded On.
Circuit Description
The engine control module (ECM) has four individual
injector driver circuits. Each controls an injector. When a
driver circuit is grounded by the ECM, the injector is
Fail-Safe (Back Up)

activated. The ECM monitors the current in each driver

circuit. The ECM measures a voltage drop through a
fixed resistor and controls it. The voltage on each driver
is monitored to detect a fault. If the voltage is not what
the ECM expects to monitor on the circuit, a Diagnostic
6E168
Trouble Code is set. This Diagnostic Trouble Code is

also set if an injector driver is shorted to voltage.
Diagnostic Aids
An injector driver circuit that is open or shorted to
voltage will cause a Diagnostic Trouble Code P0201 to
set. It will also cause a misfire due to an inoperative
injector. A misfire Diagnostic Trouble Code will also be

set indicating which cylinder is inoperative.
Long term and short term fuel trims that are excessively
high or low are a good indication that an injector is
faulty.
Use Fuel Injector Coil Test Procedure to check for faulty
injectors.
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit

Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 11
Go to Step 6

Is the DTC P0201, P0202, P0203 or P0204 stored as
Present Failure?

Was the DTC P0201, P0202, P0203 or P0204 stored
in this ignition cycle?
Check for poor/faulty connection at the injector or

11
98
E-60(J1)
22
E-6/E-7/E-8/E-9
Visually check the injector for the affected cylinder.


Step
Action
Using the DVM and check the injector coil for the
affected cylinder.
6E169
Value(s)
Yes
No
Approximately
12.5W at 20C
Go to Step 7
Go to Step 11

2. Disconnect injector connector for the affected
cylinder.
3. Measure the resistance of injector coil.
Injector

6E170
Step
Action
Using the DVM and check the injector power supply

Value(s)
Yes
No
10 - 14.5V
Go to Step 9
Go to Step 8
Verify repair

cylinder.
No.1 Cylinder E-6
1
No.2 Cylinder E-7

1
No.3 Cylinder E-8

1
No.4 Cylinder E-9

1
V
8

IGN fuse (15A) and injector for the affected cylinder.

Step
Action
Using the DVM and check the injector signal circuit for
the affected cylinder.
6E171
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10
(ECM

cylinder.
circuit.
No. 1 Cylinder
E-6
Breaker Box
J1-9
No. 2 Cylinder
E-7
Breaker Box
J1-22
No. 3 Cylinder
E-8
No. 4 Cylinder
E-9
Breaker Box
J1-11
Breaker Box
J1-8
6E172
Step
9
Action
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 10

cylinder and ECM connector.
circuit.
No.1 Cylinder
E-60(J1)
E-6
2
No.2 Cylinder
E-60(J1)
E-7
2
22
No.3 Cylinder
E-60(J1)
E-8
2
No.4 Cylinder
E-60(J1)
E-9
2
11

Step
10
Action
6E173
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 12
Replace the injector for the affected cylinder.

Verify repair
Go to Step 12

release?
Verify repair
Go to Step 13
Replace the ECM.

Verify repair

cylinder.
No.1 CylinderE-6
2
V
No.2 CylinderE-7
2
V
No.3 CylinderE-8
2
V
No.4 CylinderE-9
2
11
12
13
6E174
DIAGNOSTIC TROUBLE CODE (DTC) P0325 KNOCK SENSOR (KS) MODULE

CIRCUIT
Code
Type
P0325
DTC Name
Knock Sensor Module Circuit

50 deg. C.
4. Knock sensor filter module integrated circuit malfunction.
Fail-Safe (Back Up)

ECM retards ignition timing 4 deg. C.
Circuit Description
signals from the Knock Sensor.
The knock sensor (KS) system is used to detect engine

detonation. The knock sensor produced an AC voltage
signal. The knock sensor sends this signal to the ECM.
The amplitude and the frequency of the AC voltage
signal depends upon the knock level being detected.
The ECM will then retard the spark timing based on the
Diagnostic Aids
Correct any abnormal engine noise before using the
diagnostic table.
Check for an open circuit.
Diagnostic Trouble Code (DTC) P0325 Knock Sensor Module Circuit

Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check

Step
2
Action
Value(s)
Yes
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Visually check the knock sensor.

Go to Step 10
Go to Step 6
Listen to the engine noise while raising and lowering

the engine speed.
Is a knock or audible noise present?
Go to Step 7
Go to Step 8
Repair the mechanical engine problem or a loose

bracket or component.
Verify repair


Check for poor/faulty connection at the knock sensor

E-60(J1)
E-84
32
5
6
6E175
6E176
Step
8
Action
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9
Substitute a known good knock sensor and recheck.

Go to Step 10
Go to Step 11
Replace the knock sensor.

Verify repair
Go to Step 11

release?
Verify repair
Go to Step 12
Replace the ECM.

Verify repair
Using the DVM and check the knock sensor circuit.

(ECM
3. Disconnect the knock sensor.

Breaker Box
J1-3
J1-32
E-84


2. Disconnect the knock sensor connector and ECM
connector.
E-60(J1)
E-84
32
9
10
11
12
6E177
DIAGNOSTIC TROUBLE CODE (DTC) P0327 KNOCK SENSOR (KS) CIRCUIT
Code
Type
P0327
DTC Name
Knock Sensor Circuit

50 deg. C.
4. Knock sensor harness short to ground or
Fail-Safe (Back Up)

ECM retards ignition timing 4 deg. C.
Circuit Description
Diagnostic Aids
The ECM uses the Knock Sensor (KS) in order to detect

engine detonation. This allows the ECM to retard the
Ignition Control (IC) spark timing based on the KS signal
the ECM receives. The knock sensors produce an AC
signal that rides on the 1.3 volts DC. The signals
amplitude and frequency are dependent upon the
amount of the knock being experienced.
The ECM determines whether the knock is occurring by
comparing the signal level on the KS circuit with a
voltage level on the noise channel. The normal engine
noise varies depending on the engine speed and load.
Then the ECM determines that an abnormally high
noise channel voltage level is being experienced, a
Diagnostic Trouble Code P0327 sets.

A poor connection at the ECM. Inspect the knock
sensor and the ECM connectors for: , broken locks,
improperly formed or damaged terminals.
Backed out terminals
Broken locks
Improperly formed or damaged terminals
Also, check the wiring harness for: shorts to ground,
shorts to battery positive, and open circuits.
A misrouted harness. Inspect the knock sensor
harness in order to ensure that it is not routed too
close to high voltage wires such as spark plug leads.
6E178
Diagnostic Trouble Code (DTC) P0327 Knock Sensor Circuit

Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 9
Go to Step 6
Repair faulty
harness and
verify repair
Go to Step 7


Check for poor/faulty connection at the knock sensor

E-60(J1)
E-84
32
5
6
Visually check the knock sensor.

2. Disconnect the knock sensor connector and ECM
connector.
ground circuit.
E-84
1

Step
7
Action
6E179
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
Substitute a known good knock sensor and recheck.

Go to Step 9
Go to Step 10
Replace the knock sensor.

Verify repair
Go to Step 10

release?
Verify repair
Go to Step 11
Replace the ECM.

Verify repair

2. Disconnect the knock sensor connector.
E-84
2
8
9
10
11
6E180
DIAGNOSTIC TROUBLE CODE (DTC) P0336 CRANKSHAFT POSITION (CKP)

SENSOR CIRCUIT RANGE/PERFORMANCE (58X)
DIAGNOSTIC TROUBLE CODE (DTC) P0337 CRANKSHAFT POSITION (CKP)
SENSOR CIRCUIT LOW INPUT (58X)
Code
Type
DTC Name
P0336

Range/Performance (58X)
P0337
Crankshaft Position Sensor Circuit Low No pulse is detected during engine cranking.
Input (58X)
Fail-Safe (Back Up)
2. Extra or missing pulse is detected consecutively.
Circuit Description
The 58X reference signal is produced by the crankshaft
position (CKP) sensor. During one crankshaft
revolution, 58 crankshaft pulses will be produced. The
engine control module (ECM) uses the 58X reference
signal to calculate engine RPM and crankshaft position.
The ECM constantly monitors the number of pulses on
the 58X reference circuit. If the ECM receives an

incorrect number of pulses on the 58X reference circuit,
Diagnostic Trouble Code P0336 will set. If the ECM
does not receive pluses on the 58X reference circuit,
Diagnostic Trouble Code P0337 will set.

Diagnostic Aids
Poor connection - Inspect the ECM harness and
6E181

damage; shorts to ground, shorts to battery positive
and open circuits. If the harness appears to be OK,
disconnect the ECM, turn the ignition on and observe
a voltmeter connected to the 58X reference circuit at
the ECM harness connector while moving connectors
and wiring harnesses related to the ECM. A change
in voltage will indicate the location of the fault.

Crankshaft Position Sensor Circuit Range/performance (58x)
Crankshaft Position Sensor Circuit Low Input (58x)
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Verify repair
Go to Step 6

Is the DTC P0336 or P0337 stored as Present
Failure?

cycle?

E-60(J1) 6
E-59
21
Visually check the CKP sensor. If a faulty installation

6E182
Step
6
Action
Value(s)
Yes
No
Approximately
0.58kW at
20C
Go to Step 10
Go to Step 7
Approximately
0.58kW at
20C
Go to Step 8
Go to Step 14

(ECM

Breaker Box
J1-6
J1-21

3. 3. Check the resistance of the CKP sensor.
6
E-60(J1)
21

CKP Sensor

Step
8
Action
6E183
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 9

(ECM

E-59

Breaker Box
J1-6
J1-21


6
E-60(J1)
21
E-60(J1)
E-59
6
21
6E184
Step
9
Action
Value(s)
Yes
No
Less than 1V
Verify repair
Go to Step 13
Go to Step 11
Verify repair
Go to Step 12
Repair faulty
harness and
verify repair
Go to Step 13

If the DVM indicated out of specified value, repair
E-59
V
10

and ECM.
Measurement Point
At ECM E60 (J1) connector 21 & 6

Approx. 3.7V in engine idle
Approx. 7.8V at 2000rpm

form?
0V

J1-6(-)
5ms/div
11

and visually check.
12

circuit.

Step
Action
13
14
15
16
17
6E185
Value(s)
Yes
No

Remove the
accessory parts
and verify repair
Go to Step 14

Go to Step 15
Go to Step 16

Verify repair
Go to Step 16

release?
Verify repair
Go to Step 17
Replace the ECM.

Verify repair
6E186
DIAGNOSTIC TROUBLE CODE (DTC) P0351 IGNITION 1 CONTROL CIRCUIT

DIAGNOSTIC TROUBLE CODE (DTC) P0352 IGNITION 2 CONTROL CIRCUIT
Code
Type
DTC Name
P0351
#1 or #4cylinder ignition signals are not

P0352
#2 or #3 cylinder ignition signals are not

Circuit Description
The ignition control circuit provides a zero volt or a 5 volt
signal to the ignition control module. The normal circuit
voltage is zero volts. When the module receives the 5
volt signal from the ECM, it provides a ground path for
the B+ voltage supplied to the ignition primary coil.
When the ECM turns off the 5 volts to the module, the
module will remove the ground path of the ignition
primary coils; causing the magnetic field produces a
voltage in the secondary coils which fires the spark
plug.
Fail-Safe (Back Up)

The circuit between the ECM and the ignition control

module is monitored for an open circuit, short to voltage,
and short to ground. When the ECM detects a problem
in the ignition control circuit, it will set DTC P0351 or
P0352.
Diagnostic Aids
Poor connection at the ECM - Inspect the harness

terminals, and poor terminal-to-wire connections.
damage; Open circuits, shorts to ground, or shorts to
Voltage. If the harness appears to be OK, observe
6E187
the Tech 2 display related to DTC P0351 or P0352

while moving the connector and wiring related to the
ignition system. A change in the display will indicate
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit

Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 12
Go to Step 6

Is the DTC P0351 or P0352 stored as Present
Failure?

cycle?
Check for poor/faulty connection at the ignition coil

module or ECM connector. If a poor/faulty connection
E-60(J1)
19
E-18
18
Visually check the ignition coil module.

6E188
Step
Action
Using the DVM and check the ignition coil module

signal circuit for the affected coil.
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7

2. Disconnect the ignition coil module connector.
3. Check the circuit for short to battery voltage circuit
for the affected coil.
Coil 2
Coil 1
E-18
E-18

Step
Action

circuit for the affected coil.
6E189
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
(ECM

4. Check the circuit for open or short to ground circuit
Coil 2
Breaker Box
J1-18
E-18
Coil 1
E-18
Breaker Box
J1-19

2. Disconnect the ignition coil module connector and
ECM connector.
3. Check the circuit for open or short to ground circuit
Coil 1
E-60(J1)
E-18
E-60(J1)
Coil 2
E-18
6E190
Step
Action
Value(s)
Yes
No
Using the DVM and check the ignition coil module

10 - 14.5V
Go to Step 10
Go to Step 9

IGN. Coil fuse (15A) and ignition coil module.
Verify repair
Replace the ignition coil module.

Verify repair
Go to Step 11

release?
Verify repair
Go to Step 12
Replace the ECM.

Verify repair

E-18
2
V
9
10
11
12
6E191
DIAGNOSTIC TROUBLE CODE (DTC) P0443 EVAPORATIVE (EVAP) EMISSION

CONTROL SYSTEM PURGE CONTROL CIRCUIT
Code
Type
DTC Name
P0443

Control Circuit

EVAP purge solenoid circuit open, short to
Fail-Safe (Back Up)

Circuit Description
Diagnostic Aids
The Engine Control Module (ECM) controls the

Evaporative Emission (EVAP) Canister Purge Solenoid
Valve through the use of a control (ground) circuit. If the
ECM commands the Purge solenoid to maximum duty
cycle (100%) but the voltage remains High (12 Volts);
or, if the ECM commands the Purge solenoid to
minimum duty cycle (0%) but the voltage remains Low
(0 volts), then DTC P0443 will set.
Poor connections, or a damaged harness - Inspect

the harness connectors for: backed-out terminals,
improper mating or damaged terminals. Also check
for open circuits, shorts to ground, and shorts to
voltage.
6E192

EVAP Emission Control System Purge Control Circuit
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
25 - 30W at
20C
Go to Step 6
Go to Step 9


Check for poor/faulty connection at the purge solenoid

valve or ECM connector. If a poor/faulty connection is
E-60(J1) 5
E-66
Using the DVM and check the purge solenoid valve.

2. Disconnect purge solenoid valve connector.
3. Measure the resistance of purge solenoid valve
coil.
EVAP Purge Solenoid


Step
Action

6E193
Value(s)
Yes
No
10 - 14.5V
Go to Step 8
Go to Step 7
Verify repair
Repair faulty
harness and
verify repair
Go to Step 9

E-66
2
V
7

Engine fuse (15A) and purge solenoid valve.
solenoid signal circuit.
(ECM

circuit.
Breaker Box
J1-5
E-66

2. Disconnect the purge solenoid valve connector
and ECM connector.
circuit.
E-60(J1)
1
E-66
6E194
Step
Action
Value(s)
Yes
No

signal circuit.
Repair faulty
harness and
verify repair
Go to Step 10
Substitute a known good purge solenoid valve and

recheck.
Go to Step 11
Go to Step 12
Replace the purge solenoid valve.

Verify repair
Go to Step 12

release?
Verify repair
Go to Step 13
Replace the ECM.

Verify repair

E-66
1
V
10
11
12
13
6E195
DIAGNOSTIC TROUBLE CODE (DTC) P0502 VEHICLE SPEED SENSOR (VSS)

CIRCUIT LOW INPUT
Code
Type
P0502
DTC Name
Vehicle Speed Sensor Circuit Low
Input
Fail-Safe (Back Up)
1. No DTC relating to MAP sensor, TPS, ECT ECM uses 0km/h condition as substitute.
sensor, injector control circuit and ignition
control circuit.
3. Vehicle speed is below 3km/h in power
condition or 2km/h in deceleration condition.
Circuit Description
Diagnostic Aids
The vehicle speed sensor has a magnet rotated by the

transmission output shaft. Attached to the sensor is a
hall effect circuit that interacts with the magnetic field
created by the rotating magnet. A 12-volt operating
supply for the speed sensor hall circuit is supplied from
the meter fuse.
Poor connection at ECM: Inspect harness connectors

6E196
Diagnostic Trouble Code (DTC) P0502 Vehicle Speed Sensor Circuit Low Input
Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 19
Go to Step 6


Check for poor/faulty connection at the VSS, meter,

immobilizer control unit (if equipped), ECM and other
connectors. If a poor/faulty connection is found, repair
C-56(J2)
23
B-68
8
6
B-24
E-44
9 10
27

check.

Step
6
Action
Value(s)
6E197
Yes
No
Refer to
Diagnostic Aids
and Go to Step
21
Refer the table
10 - 14.5V
Go to Step 9
Go to Step 8
Verify repair

2. Measure the VSS output voltage at sensor, meter,
immobilizer control unit (if equipped) and ECM.
Voltage (V)
(AC Range)
If No
Good
Approximately
7.0 V at 20km/h
Go to
Step 7

GND
Go to
Step 11

GND
Go to
Step 13

connector 6 & GND
Go to
Step 14

connector 8 & GND
Approximately
6.5V at 20km/h
ECM C56 (J2) connector 23 &

GND
Go to
Step 16
Go to
Step 17
If a oscilloscope is available, monitor the VSS signal.

Vehicle Speed Sensor (V SS) Reference Wave Form
CH1
0V
CH2
0V
Measurement Terminal: CH1: ECM J2-23(+) / CH2: VSS 3(+)

GND(-)
Measurement Scale: CH1: 10V/div / CH2: 10V /div
50ms/div
Measurement Condition: A pproxim ately 20km/h
Note: The vehicle is without immobilizer syste m,
CH1 signal is sam e as CH2.
Using the DVM and check the VSS power supply

circuit.
circuit.
1
E-44
V
8
Repair the open circuit between the VSS and meter

fuse.
6E198
Step
9
Action
Value(s)
Yes
No
Less than 1V
Go to Step 10
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 19
Go to Step 12
Repair faulty
harness and
verify repair

E-44
2
V
10

E-44
2
11

2. Disconnect
connector.
the
VSS
connector
and
meter

B-24
9
V
Less than 1V

Step
12
Action
6E199
Value(s)
Yes
No
Verify repair
Verify repair
Less than 1V
Go to Step 15
Repair faulty
harness and
verify repair
Verify repair

2. Disconnect the VSS connector
connector.
and
meter

circuit.
B-24
E-44
3
13
14

B-68
V
15

circuit.
B-24
B-68
10
6E200
Step
16
17
Action
Replace the immobilizer control unit (if equipped).
Value(s)
Yes
No
Verify repair
Less than 1V
Go to Step 18
Repair faulty
harness and
verify repair
Repair faulty
harness and
verify repair
Go to Step 21
Go to Step 20
Go to Step 21

(if equipped) and ECM connector.
3. Ignition On.
C-56(J2)
23
V
18

(ECM

(if equipped).
B-68
Breaker Box
J2-32

(if equipped) and ECM connector.
circuit.
C-56(J2)
23
B-68
8
19


Step
20
21
22
Action
6E201
Value(s)
Yes
No
Replace the VSS.

Verify repair
Go to Step 21

release?
Verify repair
Go to Step 22
Replace the ECM.

Verify repair
6E202
DIAGNOSTIC TROUBLE CODE (DTC) P0562 SYSTEM VOLTAGE LOW
Code
Type
P0562
DTC Name
System Voltage Low
Battery voltage is below 11V.
Fail-Safe (Back Up)

Circuit Description
Diagnostic Aids

voltage on the ignition feed terminal to the ECM. A
system voltage Diagnostic Trouble Code will set
whenever the voltage is below a calibrated value.
If the Diagnostic Trouble Code sets when an

accessory is operated, check for a poor connection or
excessive current draw.
Check for open circuits or shorts to ground on the
ECMs battery or ignition inputs.
Diagnostic Trouble Code (DTC) P0562 System Voltage Low

Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check

Step
2
Action
Value(s)
Yes
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
10 - 14.5V
Go to Step 6
Go to Step 5
10 - 14.5V
Go to Step 6
Check the
charging
system, charge
or replace the
battery
Verify repair
Go to Step 7
Verify repair
Go to Step 8

release?
Verify repair
Go to Step 9
Replace the ECM.

Verify repair


6E203

2. Monitor the Ignition Voltage in the data display.
headlights, etc..

battery terminal.

as necessary.
C-56(J2)
16
E-60(J1)
2 1
17
Check for poor/faulty connection of the ECM ground

at the inlet manifold. If a poor/faulty connection is
E-72
6E204
DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH
Code
Type
P0563
DTC Name
System Voltage High
Battery voltage is above 16V.
Fail-Safe (Back Up)

Circuit Description
whenever the voltage is above a calibrated value.

system voltage Diagnostic Trouble Code will set
Diagnostic Aids
Check for a faulty charging system components.
Diagnostic Trouble Code (DTC) P0563 System Voltage High

Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check

Step
2
Action
Yes
No
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 5
Check the
charging
system and Go
to Step 5
Verify
procedure
Go to Step 6

release?
Verify repair
Go to Step 7
Replace the ECM.

Verify repair

Value(s)


2. Monitor the Ignition Voltage in the data display.
headlights, etc..
Less than 16V
5
6
6E205
Is the battery jamp start cable incorrectly connecting?
6E206
DIAGNOSTIC TROUBLE CODE (DTC) P0601 ECM MEMORY CHECKSUM

Code
Type
P0601
DTC Name
ECM Memory Checksum
Fail-Safe (Back Up)

Circuit Description
must be programmed using a Tech 2.

transmission, and powertrain diagnostics operation.
EEPROM is not replaceable. When the ECM is
replaced or a calibration update is required, the ECM
Diagnostic Aids
Diagnostic Trouble Code P0601 indicates that the
contents of the EEPROM have changed since the
ECM was programmed. The only possible repair is
ECM reprogramming or replacement. Check service
bulletins to program the replacement ECM with the
correct software and calibration for the vehicle.
Diagnostic Trouble Code (DTC) P0601 ECM Memory Checksum

Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3

Go to Step 4
Refer to
Diagnostic Aids

release?
Verify repair
Go to Step 5
Replace the ECM.

Verify repair

6E207
DIAGNOSTIC TROUBLE CODE (DTC) P0602 ECU PROGRAMMING ERROR

Code
Type
P0602
DTC Name
Circuit Description
transmission, and powertrain diagnostics operation.
EEPROM is not replaceable. When the ECM is
Fail-Safe (Back Up)

replaced or a calibration update is required, the ECM

must be programmed using a Tech 2.
Diagnostic Aids
Diagnostic Trouble Code P0602 indicates when non
programmed ECM is used without service
programming system (SPS). The replacement ECM
must be programmed.
Diagnostic Trouble Code (DTC) P0602 ECU Programming Error

Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check

Go to Step 3
Refer to
Diagnostic Aids
Download the latest software to the ECM using the

SPS (Service Programming System).
Verify repair

6E208
DTC P0650 MALFUNCTION INDICATOR LAMP (MIL) CONTOROL CIRCUIT

MALFUNCTION
Code
Type
P0650
DTC Name
Malfunction Indicator Lamp (MIL) Con- Check engine lamp circuit open, short to
trol Circuit Malfunction
Fail-Safe (Back Up)

Circuit Description
Diagnostic Aids

and steady with ignition ON and the engine stopped.
Ignition feed voltage is supplied directly to the check
engine lamp indicator. The Engine Control Module
(ECM) turns the check engine lamp ON by grounding
the check engine lamp driver circuit. The check engine
lamp should not remain ON with the engine running
and no DTC(s) set. A steady check engine lamp with
the engine running and no DTC(s) suggests a short to
ground in the check engine lamp driver circuit.

damaged harness.
6E209

Malfunction Indicator Lamp (MIL) Control Circuit Malfunction
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Go to Step 5
Go to Step 6

Go to Step 9
Go to Step 7
Check the Check Engine lamp bulb.

Verify repair
Go to Step 7
Verify repair
Go to Step 8




C-56(J2)
32
B-24
17
6E210
Step
Action
Value(s)
Yes
No
Using the DVM and check the Check Engine lamp

circuit.
Repair faulty
harness and
verify repair
Go to Step 9

release?
Verify repair
Go to Step 10
Replace the ECM.

Verify repair

(ECM

circuit.
Breaker Box
J2-25
B-24

circuit.
32
10
C-56(J2)
17
B-24
6E211
DIAGNOSTIC TROUBLE CODE (DTC) P1167 FUEL SUPPLY SYSTEM RICH

DURING DECELERATION FUEL CUT OFF
Code
Type
P1167
DTC Name
Deceleration Fuel Cutoff

control circuit.
than 550mV in deceleration fuel cutoff
mode.
Circuit Description
adequate amounts of fuel during deceleration (fuel cut
off). The ECM monitors the voltage of the oxygen
sensor during fuel cut off. When a fuel cut off mode of
operation is requested during Closed Loop operation
(by deceleration), the ECM will provide more fuel to the
engine. Under these conditions the ECM should detect
a lean condition (low oxygen sensor voltage). If this
Fail-Safe (Back Up)

lean exhaust is not detected at this time, a Diagnostic

Trouble Code P1167 will set.
Diagnostic Aids
Fuel pressure - The system will go rich if pressure is
increase. However, if fuel pressure is too high, a
6E212
Perform
Injector Balance Test - Refer to Fuel
System Diagnosis.
Check the EVAP canister for fuel saturation - If full of
fuel, check canister control and hoses. Refer to
Evaporative (EVAP) Emission Control System.
diaphragm by checking the vacuum line to toe
regulator for the presence of fuel.
An intermittent TP sensor output will cause the

system to go rich due to a false indication of the
engine accelerating.
Silicon contamination of the HO2S can also cause a
high HO2S voltage to be indicated. This condition is
indicated by a powdery white deposit on the portion
of the HO2S exposed to the exhaust stream. If
contamination is noticed, replace the affected HO2S.

Fuel Supply System Rich During Deceleration Fuel Cutoff
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3



Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Does the Tech 2 indicate correct Throttle Position in
accordance with accelerator pedal operation?
Go to Step 6
Go to Step 5
Verify repair
Go to Step 12
Go to Step 8
Go to Step 7
Verify repair
Go to Step 13

Incorrectly installed.

data display.
acceleration?

conditions.

Step
Action

6E213
Value(s)
Yes
No
Go to Step 10
Go to Step 9
Verify repair
Go to Step 14
Go to Step 11
Refer to Injector
Coil Test &
Injector
Balance Test
Procedure

10

11
12
13
14
15
16
17

Go to Step 15
Refer to Fuel
System
Diagnosis
Replace the TPS.

Verify repair

Verify repair
Replace the IAC valve.

Verify repair

Verify repair
Go to Step 16

release?
Verify repair
Go to Step 17
Replace the ECM.

Verify repair
6E214
DIAGNOSTIC TROUBLE CODE (DTC) P1171 FUEL SUPPLY SYSTEM LEAN

DURING POWER ENRICHMENT
Code
Type
P1171
DTC Name
Fuel Supply System Lean During
Power Enrichment

control circuit.
60 deg. C.
3. Mass air flow is below 13.5m/s.
350mV in power enrichment mode.
Circuit Description
adequate amounts of fuel during heavy acceleration
(power enrichment). The ECM monitors the voltage of
the oxygen sensor during power enrichment. When a
power enrichment mode of operation is requested
during Closed Loop operation (by heavy acceleration),
Fail-Safe (Back Up)

the ECM will provide more fuel to the engine. Under

these conditions the ECM should detect a rich
condition (high oxygen sensor voltage). If this rich
exhaust is not detected at this time, a Diagnostic
Trouble Code P1171 will set. A plugged fuel filter or
restricted fuel line can prevent adequate amounts of fuel
from being supplied during power enrichment mode.

Diagnostic Aids
Heated oxygen sensor wiring - The sensor pigtail
may be routed incorrectly and contacting the exhaust
system.
Poor ECM to engine block ground.
Fuel pressure - The system will go lean if pressure is
decrease. However, if fuel pressure is too low, a
diagnostic Trouble Code P1171 may be set. Refer to
Lean injector(s) - Perform Injector Balance Test.
6E215
Vacuum leaks - Check for disconnected or damaged

vacuum hoses and for vacuum leaks at the intake
manifold, throttle body, and PCV system.
Exhaust leaks - An exhaust leak may cause outside
to be indicated.
Fuel contamination - Water, even in small amounts,
cause a lean exhaust to be indicated, Excessive
alcohol in the fuel can also cause this condition.
Refer to Fuel System Diagnosis for the procedure to
check for fuel contamination.

Fuel Supply System Lean During Power Enrichment
Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3



Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Does the Tech 2 indicate correct Throttle Position in
accordance with accelerator pedal operation?
Go to Step 6
Go to Step 5
Verify repair
Go to Step 12
Go to Step 8
Go to Step 7

Incorrectly installed.

data display.
acceleration?
6E216
Step
Action

conditions.
Value(s)
Yes
No
Verify repair
Go to Step 13
Go to Step 10
Go to Step 9
Verify repair
Go to Step 14
Go to Step 11
Refer to Injector
Coil Test &
Injector
Balance Test
Procedure

8


10

11
12
13
14
15
16
17

Go to Step 15
Refer to Fuel
System
Diagnosis
Replace the TPS.

Verify repair

Verify repair
Replace the IAC valve.

Verify repair

Verify repair
Go to Step 16

release?
Verify repair
Go to Step 17
Replace the ECM.

Verify repair
6E217
DIAGNOSTIC TROUBLE CODE (DTC) P1625 ECM SYSTEM RESET

Code
Type
P1625
DTC Name
ECM System Reset
ECM reset has occurred other than On.
Fail-Safe (Back Up)

Circuit Description
Diagnostic Aids
The engine control module (ECM) monitors unexpected

ECM reset. This will not turn on MIL light on, only
records code DTC P1625.
Check for the follwing conditions:

P1625 alone stored does not need diagnosis. Clear
DTC code.
NOTE: DTC P1625 is a DTC to record a ECM reset
history. If DTC P1625 is not reset and no engine
abnormality occurs after learing the DTC, no farther
diagnostic procedures are required.
Diagnostic Trouble Code (DTC) P1625 ECM System Reset

Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3


Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Is the Immobilizer function programmed in the ECM?
Verify repair
Go to Step 5

release?
Verify repair
Go to Step 6
Replace the ECM.

Verify repair
6E218
DIAGNOSTIC TROUBLE CODE (DTC) P1626 IMMOBILIZER NO SIGNAL
Code
Type
P1626
DTC Name

Circuit Description
The ECM decides whether that is an abnomality in the
the ECM when no response from immobiliser.
Diagnostic Aids
Poor connection at ECM and Immobilizer-Inspect
harness connectors for backed out terminals,
Fail-Safe (Back Up)


connection.
damage, If the harness appears to be OK, disconnect
the ECM and Immobilizer, turn the ignition ON and
observe a voltmeter connected to the suspect driver
circuit at the ECM and Immobilizer harnass connector
relates to the MIL. A change in voltage will indicate
6E219
Diagnostic Trouble Code (DTC) P1626 Immobilizer No Signal

Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B0007
Go to Step 5
Verify repair
Go to Step 6
Repair faulty
harness and
verify repair
Go to Step 7



Body.

C-56(J2)
32
B-68
23

lamp circuit.
3. Ignition On.
B-68
B-24
17
6E220
Step
Action

lamp circuit.
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 8
Repair faulty
harness and
verify repair
Go to Step 9
(ECM

circuit.
B-24
Breaker Box
J2-32


circuit.
32
C-56(J2)
B-68
7

and ECM connector.
3. Ignition On.
C-56(J2)
B-68
7
23

Step
9
Action
6E221
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Srtep 10

release?
Verify repair
Go to Step 11
Replace the ECM.

Verify repair

(ECM

4. Checkthecircuitforopenorshot togroundcircuit.
B-68
Breaker Box
J2-23

and ECM connector.
circuit.
C-56(J2)
23
B-68
8
10
11
6E222

IMMOBILIZER WRONG SIGNAL
Code
Type
P1631
DTC Name

Circuit Description
the ECM when received response was not correct.
Diagnostic Aids
Fail-Safe (Back Up)


connection.
6E223
Diagnostic Trouble Code (DTC) P1631 Immobilizer Wrong Signal

Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B0007
Go to Step 5

release?
Verify repair
Go to Step 6
Replace the ECM.

Verify repair



Body.
6E224

WRONG SECURITY CODE ENTERED
Code
Type
P1648
DTC Name

Circuit Description
the ECM when received incorrect security code.
Diagnostic Aids
Fail-Safe (Back Up)


connection.
6E225
Diagnostic Trouble Code (DTC) P1648 Wrong Security Code Entered

Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B0007
Go to Step 5

release?
Verify repair
Go to Step 6
Replace the ECM.

Verify repair



Body.
6E226

IMMOBILIZER FUNCTION NOT PROGRAMMED
Code
Type
P1649
DTC Name
Fail-Safe (Back Up)
Immobilizer Function Not Programmed Immobilizer function is not programmed in the 1. Engine does not start.
ECM.
Circuit Description
the ECM when security code & secret key not
programmed.
Diagnostic Aids

connection.
6E227
Diagnostic Trouble Code (DTC) P1649 Immobilizer Function Not Programmed

Step
Action

performed?
Value(s)
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4

Were the any DTC's B0002 or B0009 stored in this
ignition cycle?
Refer to
Immobilizer
Workshop
Manual & Go
to DTC Chart
B0002 or
B0009
Go to Step 5

release?
Verify repair
Go to Step 6
Replace the ECM.

Verify repair



Body.
6E228

TACHOMETER OUTPUT LOW VOLTAGE
Code
Type
P1693
DTC Name
Tachometer Output Low Voltage

Tacho output circuit short to ground circuit.
Circuit Description
Based on the information from the Crank Position
Sensor (CKP), X58 reference signal is generated at
each rotation of the crankshaft.
Engine Control Module (ECM) converts X58 reference
signal into the square wave signal which is used to drive
the pulse generator of the tachometer.
When the wave length of the output signal is long, the
tacho meter indicates the engine speed is low, and vise
versa.
This malfunction detects a low impedance short to
Fail-Safe (Back Up)

ground or open contact on the Tacho output, the

Diagnostic Trouble Code P1693 will be set.
Diagnostic Aids
Poor connections or a damaged harness - Inspect
the harness connections for: backed out terminals,
imprope, mating or damaged terminals. Also check
for open circuit, short to ground, and short to voltage.
This malfunction detects a low impedance short to
ground or open contact on the ECM out put circuit.
6E229
Diagnostic Trouble Code (DTC) P1693 Tachometer Output Low Voltage

Step
Action
Value(s)

performed?
Yes
No
Go to Step 2
Go to On Board
Diagnostic
(OBD) System
Check
Go to Step 3
Refer to
Diagnostic Aids
and Go to Step
3
Go to Step 4
Refer to
Diagnostic Aids
and Go to Step
4
Verify repair
Go to Step 5
Go to Step 10
Not available:
Go to Step 6
Fixed at low:
Go to Step 6
Fixed at High:
Go to Step 7


Check for poor/faulty connection at the ECM or meter

C-56(J2)
B-24
11
25
If a oscilloscope is available, monitor the Tachometer

wave form?
Reference Wave Form
CH1
0V
CH2
0V
Measurement Terminal: CH1: J1-21(+) / CH2: J2-25(+) GND(-)

5ms/div
6E230
Step
6
Action
Value(s)
Yes
No
Repair faulty
harness and
verify repair
Go to Step 7
Less than 1V
Go to Step 8
Repair faulty
harness and
verify repair
Remove the
accessory parts
and verify repair
Go to Step 9
Using the DVM and check the Tacho output circuit.

(ECM

circuit.
Breaker Box
J2-25
B-24

circuit.
25
C-56(J2)
B-24
11
Using the DVM and check the Tacho output circuit.

B-24
11
V
8


Step
9
10
11
Action
6E231
Value(s)
Yes
No
Replace the Tacho meter.

Verify repair
Go to Step 10

release?
Verify repair
Go to Step 11
Replace the ECM.

Verify repair
6E232
SYMPTOM DIAGNOSIS
PRELIMINARY CHECKS
Before using this section, perform the On-Board
Diagnostic (OBD) System Check and verify all of the
following items:
The engine control module (ECM) and malfunction
indicator lamp (MIL = Check Engine Lamp) are
operating correctly.
Tech 2 data is within normal operating range. Refer to
Typical Scan Data Values.
location.
connection, shown on the Emission Control System
Schematics. Check thoroughly for any type of leak or
restriction.
Air leaks at throttle body mounting area, manifold
absolute pressure (MAP) sensor and intake manifold
sealing surfaces.
Ignition wires for cracking, harness, and carbon
tracking.
INTERMITTENT
on the malfunction indicator lamp (MIL) or store a
Diagnostic Trouble Code. Do NOT use the Diagnostic
Trouble Code (DTC) charts for intermittent problems.
Poor mating of the connector halves or a terminal not
fully seated in the connector (backed out).
check.
Ignition coils shorted to ground and arcing at ignition
wires or plugs.
MIL (Check Engine Lamp) wire to ECM shorted to

ground.
diagrams.
Tech 2 has several features that can be used to located
an intermittent condition.
An intermittent MIL (Check Engine Lamp) with no stored
Diagnostic Trouble Code may be caused by the
following:
Ignition coil shorted to ground and arcing at ignition
wires or plugs.
MIL (Check Engine Lamp) wire to ECM short to
ground.
diagrams.
symptom tables.
Check the Broadcast Code of the ECM, and
compare it with the latest Isuzu service bulletins and/
or Isuzu EEPROM reprogramming equipment to
determine if an update to the ECMs reprogrammable
memory has been released.
To check the Broadcast Code, connect the Tech 2,
then look for ID info. then select Broadcast Code.
This should display a 4 character code, such as XBYA
(example only).
If the Broadcast Code is not the most current
available, it is advisable to reprogram the ECMs
changes.
6E233

DEFINITIONS: Engine cranks, but will not run. (The engine never start.)
NOTE: The replacement ECM must be programmed. Refer to section of the Service Programming System (SPS) in
this manual. Following ECM programming, the immobilizer system (if equipped) must be linked to the ECM.
Refer to section 11 Immobilizer System-ECM replacement for the ECM/Immobilizer linking procedure.
NOTE: The vehicle with immobilizer system, this system may be activated. Check the immobilizer system diagosis.
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check

Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check.
Verify repair
Go to Step 5
Go to Step 6
Verify & repair
Verify repair
Go to Step 7

operation.
Verify repair
Go to Step 8
1. Using a Tech 2, display the MAP sensor value.

2. Check for a faulty, plugged, or incorrectly installed
MAP sensor.
Verify repair
Go to Step 9
If oscilloscope is available, check the wave form of the

CKP signal.
Was the correct wave form found?
Go to Step 12
Go to Step 10
Check the CKP sensor wire for open or short circuit.

Verify repair
Go to Step 11
Replace CKP sensor.

Is there still problem?
Replace pulsar
ring.
Verify repair
3
4

Check the Ignition coil fuse (15A) and ECM fuse
(15A).
Was a fuse blown?
1. Ignition ON
2. Use a DVM to verify that battery voltage at the
ignition coil fuse, and the ECM fuse.
Was battery voltage presented at the fuses?
1. Visually/physically
conditions:
inspect
for
the
following
Restriction of air intake system. Check for a

restricted air filter element, or foreign objects
blocking the air intake system.
throttle bore, excessive deposits in the throttle
bore and on the throttle plate.
Check for a condition that causes a large
vacuum leak, such as an incorrectly installed or
faulty crankcase ventilation hose/brake booster
hose.
7
10
11
6E234
Step
Action
Value(s)
Yes
No
12
Visually/physically inspect the secondary ignition

wires. Check for the following conditions:
#1 cyl. 4.4kW
#2 cyl. 3.6kW
#3 cyl. 3.1kW
#4 cyl. 2.8kW
Verify repair
Go to Step 13
Go to Step 21
Go to Step 14
2. Check for an open or short circuit between the

ignition coil and the ECM.
Verify repair
Go to Step 15
1. Ignition On.
2. Using a Digital Voltmeter (DVM) check the ignition
wire coil at the ignition coil harness connector.
Was the voltage equal to the specified value?
Battery
voltage
Go to Step 16
Verify repair
2. With DVM, check for an open in the ground wire at

the ignition coil harness connector.
Was the ground wire OK?
Go to Step 17
Verify repair
Replace the ignition coil, verify the repair.

Is there still a problem?
Go to Step 18
Verify repair
Use an ohmmeter to check the ignition coil primary

winding resistance.
Was the primary winding resistance approximately
equal to the specified value?
0.8-18kW
Go to Step 19
Go to Step 20
Use an ohmmeter to check the ignition coil secondary

winding resistance.
Was the primary winding resistance hear around the
to the specified value?
2.5kW
Go to Step 21
Go to Step 20
Verify repair
Correct the
fouling
condition
Go to Step 22
Verify that all ignition wire resistance are less than

the specified value.
Verify that ignition wires are correctly routed to
eliminate cross-fitting.
Verify that ignition wires are not arcing to ground.
Spraying the secondary ignition wires with a light
mist of water may help locate an intermittent
problem.
13
1. Disconnect the spark plug high tension cable from

No.1 spark plug.
2. Install a spark tester at
disconnected ignition coil.
the end of the
3. Clip the spark tester to a good ground.

4. Observe the spark tester while the engine is
cranking.
Was a crisp blue spark observed? (Only one or two
sparks followed by no result is considered the same
as No Spark.)
14
15
16
17
18
19
20
21
1. Disconnect the ignition coil harness connector.
1. Ignition Off.
Replace the ignition coil.

1. Remove the spark plugs from all cylinders.
2. Visually inspect the spark plug electrodes.
3. Replace any spark plugs with loose or missing
electrodes or cracked insulators.
Did your inspection reveal any spark plugs exhibiting
excessive fouling?
6E235
Step
Action
Value(s)
Yes
No
22

(Refer to 6E-108 Fuel System Diagnosis) to
Verify repair
Go to Step 23
Refer to 6E-108 page Fuel System Diagnosisto

Verify repair
Go to Step 24
Verify repair
Go to Step 25
Tech 2 data
All electrical connections within a suspected
circuit and/or system
Verify repair
Go to Step 26

release?
Verify repair
Go to Step 27
Replace the ECM.

Verify Repair
23
24

Low compression
Leaking cylinder head gaskets
Worn camshaft
Camshaft drive belt slipped or stripped
25

following:
26
27
6E236
HARD START SYMPTOM

DEFINITIONS: Engine cranks, but does not start for a long time. Does eventually start, of may start and then
immediately stall.
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check.
Verify repair
Go to Step 5
Verify repair
Go to Step 6
5C
Go to Step 8
Go to Step 7

3
4

conditions:
inspect
for
the
following

blocking the air intake system
bore and on the throttle plate
hose.
5

operation.
Check engine coolant temperature (ECT) sensor for

shift in value.
1. After 8 hours with hood up and the engine not
running, connect the Tech 2.
2. Ignition On, engine not running.
3. Using Tech 2, compare Engine Coolant
Temperature to Intake Air Temperature.
Are ECT and IAT within the specified value of each
other?

Step
Action
Value(s)
1. Using a Tech 2, display the engine coolant

temperature and note the value.
6E237
Yes
No
Go to Step 8
Replace the
ECT sensor.
Verify repair
Verify repair
Go to Step 9
Verify that the all spark plug high-tension cables are

not arcing to ground.
Spraying the spark plug high-tension cables with a
light mist of water may help locate an intermittent
problem.
#1 cyl. 4.4kW
#2 cyl. 3.6kW
#3 cyl. 3.1kW
#4 cyl. 2.8kW
Verify repair
Go to Step 10

tester.
Verify repair
Go to Step 11

Verify repair
Go to Step 12
Check for a loose ignition control module ground.

Verify repair
Go to Step 13
2.5kW
Verify repair
Go to Step 14
2. Check the resistance of the engine coolant

temperature sensor.
Is the actual resistance near the resistance value in
the chart for the temperature that was noted?
Temperature (C)
-20
26740
9120
20
3500
40
1464
60
664
80
333
100
175
120
102
1. Using a Tech 2, display the MAP sensor value in

comparison with atmosphere temperature.
MAP sensor.
Visually/physically inspect all spark plug high-tension
cables. Check for the following conditions:
Verify that the resistance of all spark plug hightension cables are less than the specified value.
correctly fitted to eliminate cross-fitting.
10
11
12
13

range.
1. Check the ignition coil secondary resistance.

2. Replace the coil if it is greater than the specified
resistance.
Did the coil require replacement?
6E238
Step
Action
Value(s)
Yes
No
14
Drain sample fuel, visual inspection.

Any suspecion about the fuel, such as discoloration,
particle, contamination, water, unusual smell, then
drain the fuel from fuel tank.
Replace the fuel from know vehicle source.
If any suspicion of alcohol contamination, completely
drain the fuel, replace by fuel from known vehicle
source.
Verify repair
Go to Step 15

Verify repair
Go to Step 16
Verify repair
Go to Step 17
Verify repair
Go to Step 18

Verify repair
Go to Step 19

release?
Verify repair
Go to Step 20
Replace the ECM.

Verify Repair
15
16

17

Low compression
Worn camshaft
18

following:
Tech 2 data
19
20
6E239

Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check.
Verify repair
Go to Step 5
20-30 Steps
Go to Step 7
Go to Step 6
Verify repair
Go to Step 7

3
4
Was a visual/physical check performed?

PCV valve.

Engine fully warm
Accessories are Off
2. Using a Tech 2, monitor IAC position.
Is the IAC position within the specified values?
conditions:
inspect
for
the
following
Restriction of the air intake system. Check for a

hose.
6E240
Step
Action
Value(s)
Yes
No
1. Using a Tech 2, display the engine coolant

temperature and note the value.
Go to Step 8
Replace the
ECT sensor.
Verify repair
Verify repair
Go to Step 9
0%
Go to Step 10
Refer to
Diagnostic
Trouble Code
P0123 for
further
diagnosis

tester.
Verify repair
Go to Step 11

range.
Verify repair
Go to Step 12

Verify repair
Go to Step 13

Refer to DTC P1167 Fuel Supply System Rich During
Deceleration Fuel Cut Off.
Verify repair
Go to Step 14

Refer to DTC P1171 Fuel Supply System Lean
During Power Enrichment.
Verify repair
Go to Step 15

are connected any incorrect cylinder, correct as
necessary.
Verify repair
Go to Step 16
Verify repair
Go to Step 17
2. Check the resistance of the engine coolant

temperature sensor.
Is the actual resistance near the resistance value in
the chart for the temperature that was noted?
Temperature (C)
-20
26740
9120
20
3500
40
1464
60
664
80
333
100
175
120
102

MAP sensor.
10
11
12
13
14
15
16
Using Tech 2, monitor throttle position with the engine

idling.
Is the throttle position at the specified value and
steady?

6E241
Step
Action
Value(s)
Yes
No
17

Verify repair
Go to Step 18
Verify repair
Go to Step 19

Verify repair
Go to Step 20

release?
Verify repair
Go to Step 21
Replace the ECM.

Verify Repair
18

Low compression
Worn camshaft
Sticking or leaking valves
Valve timing
Broken valve springs
19

following:
Tech 2 data
20
21
6E242

DEFINITIONS: See the illustration below. Feels like the
vehicle speeds up and slows down with no charge in the
accelerator pedal.
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check.
Be sure that the driver understands A/C compressor

operation as explained in the owners manual. Inform
the customer how the A/C clutch operate.
Is the customer experiencing a normal condition?
System OK
Go to Step 5

MAP sensor.
Verify repair
Go to Step 6
Go to Step 7
Refer to
Diagnostic
Trouble Code
P0123 for
further
diagnosis
Check the knock sensor wire, shield wire, or

installation condition.
Verify repair
Go to Step 8
Run Engine.
it doesnt check for silicon or other contaminates from
fuel or use of improper sealant. The sensors may
have a white powdery coating. Silicon contamination
sends a rich exhaust signal which causes the ECM to
command an excessively lean air/fuel mixture.
Verify repair
Go to Step 9

3
4
Observe the throttle position display on the Tech 2

while slowly increasing throttle pedal.
Is the throttle position at the specified value and
steady in any position?
6E243
Step
Action
Value(s)
Yes
No
Check the fuel pressure. Refer to 6E-108 pageFuel

System Diagnosis.
Verify repair
Go to Step 10
Monitor B1S1 (Bank 1 Sensor 1) Status on the Tech

2.
Is the B1S1 (Bank 1 Sensor 1) Status in the rich
condition?
Verify repair
Go to Step 11

Verify repair
Go to Step 12

Verify repair
Go to Step 13

tester.
Verify repair
Go to Step 14

Verify repair
Go to Step 15
#1 cyl. 4.4kW
#2 cyl. 3.6kW
#3 cyl. 3.1kW
#4 cyl. 2.8kW
Verify repair
Go to Step 16
2.5kW
Verify repair
Go to Step 17
Verify repair
Go to Step 18

Verify repair
Go to Step 19

Verify repair
Go to Step 20

Verify repair
Go to Step 21
10
11
12
13
14
15

problem.
16

resistance.
17

range.
18
19
20
6E244
Step
21

Action
Value(s)
Yes
No
Verify repair
Go to Step 22
Tech 2 data
Verify repair
Go to Step 23

release?
Verify repair
Go to Step 24
Replace the ECM.

Verify Repair

Damaged or collapsed pipes
Internal muffler failure
22

following:
23
24
6E245

Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check.

Replace fuel
Go to Step 5

MAP sensor.
Verify repair
Go to Step 6
Go to Step 7
Refer to
Diagnostic
Trouble Code
P0123 for
further
diagnosis

Verify repair
Go to Step 8
Run Engine.
Verify repair
Go to Step 9
Check the fuel pressure. Refer to 6E-108 Fuel

System Diagnosis.
Verify repair
Go to Step 10

3
4
5

Does the throttle position increase steady with
increasing smoothly?
6E246
Step
Action
Value(s)
Yes
No
10

2.
condition?
Go to Step 11
Go to Step 12

Verify repair
Go to Step 12

Verify repair
Go to Step 13

tester.
Verify repair
Go to Step 14

Verify repair
Go to Step 15
#1 cyl. 4.4kW
#2 cyl. 3.6kW
#3 cyl. 3.1kW
#4 cyl. 2.8kW
Verify repair
Go to Step 16
2.5kW
Verify repair
Go to Step 17

Verify repair
Go to Step 18

Verify repair
Go to Step 19

Verify repair
Go to Step 20
11
12
13
14
15

problem.
16

resistance.
17
18
19

range.

Step
Action
20
6E247
Value(s)
Yes
No

Verify repair
Go to Step 21

release?
Verify repair
Go to Step 22
Replace the ECM.

Verify Repair

following:
Tech 2 data
21
22
6E248

increases.
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check.

and tight. Refer to the ECM wiring diagrams in
Electrical Diagnosis.
Verify repair
Go to Step 5
Check for a loose or short circuit of ignition coil

module voltage feed.
Verify repair
Go to Step 6
Check for a loose or short circuit of ignition coil

module ground.
Verify repair
Go to Step 7

problem.
#1 cyl. 4.4kW
#2 cyl. 3.6kW
#3 cyl. 3.1kW
#4 cyl. 2.8kW
Verify repair
Go to Step 7
Check the CKP sensor wire, shield wire, or installation

condition.
Verify repair
Go to Step 9

2.
condition?
Go to Step 10
Go to Step 11

3
4

6E249
Step
Action
Value(s)
Yes
No
10

Verify repair
Go to Step 11

2.
Is the B1S1 (Bank 1 Sensor 1) Status in the lean
condition?
Go to Step 12
Go to Step 13

Verify repair
Go to Step 13

hose.
Verify repair
Go to Step 14

are connected an incorrect cylinder, correct as
necessary.
Verify repair
Go to Step 15
Perform the Injector Coil/Balance Test (Refer to 6E98 page).

Verify repair
Go to Step 16
2. If fuel is present, replace the fuel pressure

regulator assembly.
Verify repair
Go to Step 17

tester.
Verify repair
Go to Step 18
Verify repair
Go to Step 19
11
12
13
conditions:
inspect
for
the
following

14
15
16
17
18
1. Check for fuel in the pressure regulator vacuum

hose.

range.
6E250
Step
Action
Value(s)
Yes
No
19

Verify repair
Go to Step 20
Verify repair
Go to Step 21

Verify repair
Go to Step 22

release?
Verify repair
Go to Step 23
Replace the ECM.

Verify Repair
Low compression
Worn camshaft
Valve timing
20

21

following:
Tech 2 data
22
23
6E251

DEFINITIONS: Engine delivers less than expected power. Attempting part-throttle acceleration results in little or no
increase in vehicle speed.
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check.
2. Replace the air filter element if necessary.

Was a repair required?
Verify repair
Go to Step 5

Verify repair
Go to Step 6

MAP sensor.
Verify repair
Go to Step 7
Verify repair
Go to Step 8
Go to Step 9
Refer to
Diagnostic
Trouble Code
P0123 for
further
diagnosis

Verify repair
Go to Step 10
Run Engine.
Verify repair
Go to Step 11

Diagnosis6E-108.
Verify repair
Go to Step 12

3
4

1. Remove and check the air filter element for dirt or
restrictions.

sensor value and warm up condition compared
with the typical data.
10
11

6E252
Step
Action
Value(s)
Yes
No
12

2.
condition?
Verify repair
Go to Step 13

Verify repair
Go to Step 14

Verify repair
Go to Step 15

tester.
Verify repair
Go to Step 16

range.
Verify repair
Go to Step 17
Drain sample fuel, visual inspection.

Any suspecion about the fuel, such as discoloration,
particle, contamination, water, unusual smell, then
drain the fuel from fuel tank.
Replace the fuel from know vehicle source.
If any suspencion of alcohol contamination,
completely drain the fuel, replace by fuel from known
vehicle source.
Verify repair
Go to Step 18
Verify repair
Go to Step 19
Verify repair
Go to Step 20
Verify repair
Go to Step 21
13
14
15
16
17
18

Internal muffler failure
19

Low compression
Worn camshaft
Loose timing belt
20

following:
Tech 2 data
6E253
Step
Action
Value(s)
Yes
No
21

release?
Verify repair
Go to Step 22
Replace the ECM.

Verify Repair
22
6E254

DEFINITIONS: A mild to severe ping, usually worse under acceleration. The engine makes a sharp metallic knocking
sound that changes with throttle opening. Prolonged detonation may lead to complete engine tailure.
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check.
Go to Step 5
Verify repair

Verify repair
Go to Step 6

System Diagnosis .
Verify repair
Go to Step 7

MAP sensor.
Verify repair
Go to Step 8
Verify repair
Go to Step 9
Go to Step 10
Refer to
Diagnostic
Trouble Code
P0123 for
further
diagnosis

Verify repair
Go to Step 11

Verify repair
Go to Step 12

3
4

1. If Tech 2 readings are normal (refer to Typical
Scan Data Values) and there are no engine
mechanical faults, fill the fuel tank with a known
quality gasoline.
2. Re-evaluate the vehicle performance.
Is detonation present?
1. Check for obvious overheating problems:

Low engine coolant
Restricted air flow to radiator
Incorrect coolant solution

10
11


Step
12
13
14
15
Action
6E255
Value(s)
Yes
No
Check spark plugs for proper heat range.

Were incorrect spark plugs installed?
Verify repair
Go to Step 13

engine cleaner.
2. Re-evaluate vehicle performance.
Is detonation still present?
Verify repair
Go to Step 14
Check for an engine mechanical problem. Perform a

cylinder compression check. Refer to Engine
Mechanical.
Verify repair
Go to Step 15

Verify repair
Go to Step 16

release?
Verify repair
Go to Step 17
Replace the ECM.

Verify Repair

following:
Tech 2 data
16
17
6E256

DEFINITIONS: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, economy
is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test.
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check.

3
4

Check owners driving habits.
Is the A/C On full time (defroster mode On)?
Go to Step 5
Go to Step 6

System OK
Visually/physically check: Vacuum hoses for splits,

kinks, and improper connections and routing as
shown on the Emission Control System Schematics.
Verify repair
Go to Step 7

Verify repair
Go to Step 8

to Engine Cooling.
Verify repair
Go to Step 9
Remove and check the air filter element for dirt or for
restrictions.
Verify repair
Go to Step 10
Verify repair
Go to Step 11

Verify repair
Go to Step 12

Verify repair
Go to Step 13
Check the fuel pressure. Refer to 6E-108 pageFuel

System Diagnosis.
Verify repair
Go to Step 14
10

MAP sensor.
11
12
13

6E257
Step
Action
Value(s)
Yes
No
14

2.
condition?
Verify repair
Go to Step 15

Verify repair
Go to Step 16

Verify repair
Go to Step 17
17

Go to Step 19
Go to Step 18
18

Verify Repair

Verify repair
Go to Step 20
Verify repair
Go to Step 21

Verify repair
Go to Step 22

release?
Verify repair
Go to Step 23
Replace the ECM.

Verify Repair
15
16
19
20

range.

Low compression
Worn camshaft
Valve timing
21

following:
Tech 2 data
22
23
6E258
EXCESSIVE EXHAUST EMISSIONS OR ODORS SYMPTOM

DEFINITIONS: Vehicle fails an emission test. There is excessive rotten egg smell. (Excessive odors do not
necessarily indicate excessive emissions.)
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check.
System OK
Go to Step 5
Replace with
unleaded fuel
Go to Step 6
Go to Step 17
Go to Step 7
2. Secure the fuel cap if necessary.

Go to Step 17
Go to Step 8

System Diagnosis .
Go to Step 17
Go to Step 9

PCV valve.
Go to Step 17
Go to Step 10

are connected to an incorrect cylinder, correct as
necessary.
Go to Step 17
Go to Step 11
Perform theInjector Coil/Balance Test(Refer to 6E98 page).

Go to Step 17
Go to Step 12
Check for a problem with the engine cooling system.

Go to Step 17
Go to Step 13
Check EVAP canister for fuel loading. Refer to

Evaporative Emission Control System.
Go to Step 17
Go to Step 14
Check the EVAP purge solenoid valve operation.

Is the valve operated normally?
Go to Step 17
Verify repair &

Go to Step 15
Verify repair &

Go to Step 16
Go to Step 17

3
4
5
6
10
11
12
13
14
15

Does the customer continual accelerate On/Off during
cold condition?
Check for vacuum leaks (vacuum lines, intake
manifold, throttle body, etc.)
Were any vacuum leaks found?
1. Check fuel cap for proper installation.

Internal catalytic converter failure

Step
Action
16

engine cleaner. Refer to the instructions on the top
engine cleaner can.
6E259
Value(s)
Yes
No

System OK
Go to Step 18
Perform the exhaust emission test.

System OK
Go to Step 18
Run Engine.
Verify repair
Go to Step 19
19

2.
condition?
Go to Step 20
Go to Step 21
20
1. Check items that can cause the engine to run rich.

Refer to Diagnostic Aids in DTC P1167 Fuel
Supply System Rich During Deceleration Fuel Cut
Off. Make any necessary repairs.
System OK
Go to Step 22
System OK
Go to Step 22
Verify repair
Go to Step 23
Verify repair
Go to Step 24
17
18

21
1. Check items that can cause the engine to run

lean. Refer to Diagnostic Aids in DTC P1171 Fuel
Supply System Lean During Power Enrichment.
Make any necessary repairs.
22

Low compression
Worn camshaft
Valve timing
23

following:
Tech 2 data
6E260
Step
Action
Value(s)
Yes
No
24

release?
Verify repair
Go to Step 25
Replace the ECM.

Verify Repair
25
6E261
DIESELING, RUN-ON SYMPTOM

DEFINITIONS: Engine continues to run after key is turned OFF, but runs very rough. If engine runs smoothly, check
the ignition switch and adjustment.
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check.
Check for a short between battery voltage and the

Verify repair
Go to Step 5
Check the fuel leaking from injector. Refer to Fuel

System Diagnostic.
Verify repair
Go to Step 6

Verify repair
Go to Step 7

release?
Verify repair
Go to Step 8
Replace the ECM.

Verify repair

3
4

following:
Tech 2 data
6E262
BACKFIRE SYMPTOM
DEFINITIONS: Fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise.
Step
Action
Value(s)
Yes
No

performed?
Go to Step 2
Go to OBD
System Check
Verify repair
Go to Step 3
Go to Step 4
Go to Visual /
physical Check.
Verify repair
Go to Step 5
Verify repair
Go to Step 6

problem.
#1 cyl. 4.4kW
#2 cyl. 3.6kW
#3 cyl. 3.1kW
#4 cyl. 2.8kW
Verify repair
Go to Step 7

System Diagnosis .
Verify repair
Go to Step 8
Check for an intermittent ignition system malfunction:

Intermittent ignition feed circuit or sensor ground
circuit to the crankshaft position sensor.
Verify repair
Go to Step 9
Refer to 6E-108 page Fuel System Diagnosis to

Verify repair
Go to Step 10

3
4

tester.
range.

Intermittent CKP 58X signal

Step
Action
10

6E263
Value(s)
Yes
No

Verify repair
Go to Step 11
Check leakage at exhaust system.

Check the intake and exhaust manifold for casting
flash. Refer to Engine Mechanical.
Verify repair
Go to Step 12

Verify repair
Go to Step 13

release?
Verify repair
Go to Step 14
Replace the ECM.

Verify repair
Low compression
Worn camshaft
Valve timing
11
12

following:
Tech 2 data
13
14
6E264

Location
Location
Left-hand side of the cylinder block. (Back of the A/C
compressor)
Removal Procedure
Removal Procedure
2. Disconnect the two connectors from the ECM.
3. Remove four bolts.
2. Remove the drive belt. Refer to Engine Mechanical

Section.
4. Remove the ECM from bracket.
3. Remove the A/C compressor from engine. Refer to

Engine Mechanical Section.
5. Loosen a bolt and remove the CKP sensor from the
cylinder block.
NOTE: Use caution to avoid any hot oil that might drip
out.
1. Put on the ECM to the bracket.
2. Tighten the ECM by four bolts with specified
tightening torque.
Tightening torque
Bolts: 8.0 - 12.0 Nm (0.8 - 1.2 kgfm)
3. Connect the two connectors to the ECM.
1. Install the CKP sensor to the cylinder block.
tightening torque.
Tightening Torque
Bolt: 6Nm (0.6kgfm)
3. Reinstall the A/C compressor to the engine.
4. Reinstall the accessory drive belt.

SENSOR
Location
6E265

Location
Removal Procedure
Removal Procedure

2. Disconnect a IAT sensor connector from the IAT
sensor.
3. Remove the IAT sensor from the intake duct.

thermostat housing.
NOTE: Cool down the engine before above procedures
are carried out.
1. Install the IAT sensor into intake air duct.
2. Connect a IAT sensor connector to the IAT sensor.
1. Apply sealer to threads of screw at the ECT sensor.
torque.
Tightening Torque
sensor.

6E266
MANIFOLD ABSOLUTE PRESSURE (MAP)

SENSOR
Location
Installed on the intake manifold.
THROTTLE POSITION SENSOR (TPS)

Location
Removal Procedure
Removal Procedure
2. Disconnect a MAP sensor connector from the MAP
sensor.

throttle body.
3. Loosen a bolt and remove the MAP sensor from the

intake manifold.
4. Remove the MAP sensor from the bracket.
1. Temporary tighten the TPS by two screws.
2. Connect a TPS connectors to the TPS.
1. Tighten the MAP sensor by a bolt with specified
tightening torque.
Tightening Torque
Bolt: 8Nm (0.8kgfm)
2. Connect a MAP sensor connector to the MAP
sensor.
3. Connect the Tech2 to the vehicle.

5. Select "Data Display" with the Tech2.
6. Check the throttle position data and adjust the TPS
position.
6E267
IDLE AIR CONTROL (IAC) VALVE

Location
Removal Procedure
2. Disconnect the IAC valve connector.
3. Loosen two screws and remove IAC valve from the
throttle body.
1. Tighten the IAC valve by two screws.
2. Connect a IAC valve connector to the MAP sensor.
Cleaning and Inspection

1. Clean the IAC valve O-ring sealing surface, pintle
2. Use carburetor cleaner and a parts cleaning brush
to remove carbon deposit.
Do not use a cleaner that contain methyl ethyl
ketone. This is an extremely strong solvent and not
necessary for this type of deposit.
3. Shiny spots on the pintle are normal and do not
4. Inspect the IAC valve O-ring for cuts, cracks or
distortion.
Measurement
Clean the IAC valve O-ring sealing surface, pintle
Use carburetor cleaner and a parts cleaning brush to
remove carbon deposit. Do not use a cleaner that
contain methyl ethyl ketone. This is an extremely
strong solvent and not necessary for this type of
deposit.
Shiny spots on the pintle are normal and do not
Inspect the IAC valve O-ring for cuts, cracks or
distortion. Replace the O-ring if damaged.
6E268
KNOCK SENSOR
Location
Right-hand side of the cylinder block.
POWER
SWITCH
STEERING
PRESSURE
(PSP)
Location
Installed on the power steering pump assembly.
Removal Procedure
2. Disconnect the knock sensor connector.
3. Loosen a bolt and remove knock sensor from the
cylinder block.
Removal Procedure
2. Disconnect the power steering pressure switch
connector.
3. Loosen and remove the power steering pressure
switch from the power steering pump.
1. Tighten the knock sensor by a bolt with specified
tightening torque.
Tightening Torque
2. Connect a knock sensor connector to the knock
sensor.
1. Install the power steering pressure switch to the
power steering pump.
2. Tighten the power steering pressure switch.
3. Connect a connector to the power steering pressure
switch.


Verify no power steering fluid leaking from the sensor

HEATED OXYGEN SENSOR (HO2S)
Location
Installed on the exhaust pipe.
EVAP
CANISTER
SOLENOID
PURGE
6E269
VALVE
Location
Removal Procedure
3. Loosen and remove the O2 sensor from the exhaust
pipe.
Removal Procedure
2. Disconnect a purge solenoid connector from the
purge solenoid.
3. Disconnect two hoses from the purge solenoid
valve.
4. Slide from the bracket and remove the purge
solenoid.
Inspection
Inspect the louvered end of the sensor for grease, dirt,
excessive carbon build up or other contamination.
1. Install the O2 sensor to the exhaust pipe.
2. Tighten the O2 sensor with specified tightening
torque.
Tightening Torque
3. Connect a O2 sensor connector to the O2 sensor.
Verify no exhaust gas leaking from the sensor threads
after replacement.
1. Insert EVAP purge solenoid valve onto the bracket.
2. Connect two hoses to the purge solenoid valve.
3. Connect a purge solenoid connector to the purge
solenoid.
6E270
FUEL PRESSURE RELIEF
FUEL RAIL ASSEMBLY

components.
Caution: After relieving the fuel system pressure, a
fitting with a short towel before disconnecting the
fittings. The towel will absorb any fuel that may leak
out. When the disconnect is completed, place the
towel in an approved container.
Removal Procedure
NOTE:
1. Remove the fuel filler cap.

relay box.
4. Crank the engine for about 30 seconds.
Use care when removing the fuel rail assembly in

order to prevent damage to the injector al connector
terminal and the injector spray tips.
Fitting should be capped and holes plugged during
servicing to prevent dirt and other contaminants from
entering open lines and passage.
Important: An eight-digit identification number is
stamped on side of the fuel injector. Refer to this
number when you service the fuel rail or when a
replacement part is required.
1. Disconnect 4 injector connectors.
2. Lift side-clip up on the fuel rail.
3. Disconnect fuel pressure regulator hose.
4. Disconnect wiring harness from the bands on the
fuel rail.
5. Remove the intake pipe.
6. Loosen flare nut.
A. Lift up the injectors carefully to separate them
from intake manifold.
B. Lift up the fuel rail with injectors as assembly.
Do not separate the fuel injectors from fuel rail.
C. If an injector become separated from fuel rail,
injector backup O-ring and injector retainer clip
must be replaced.
D. Drain residual fuel from fuel rail into an
approved container.
7. If removal of fuel pressure regulator is necessary,

Refer to Fuel Pressure Regulator Removal
Procedure.

8. If removal of fuel injector is necessary, Refer to Fuel
Injectors Removal Procedure.
6E271
8. Connect the fuel return line securely. Do not over

tighten.
fuel system. Check for leak. If fuel leak is observed,
stop engine immediately. Before correcting fuel
leak, be sure to depressurize system again.
1. Install the fuel injectors if necessary. Refer to Fuel
Injector Installation Procedure.
2. Install the fuel pressure regulator if necessary. Refer
to Fuel Pressure Regulator Installation Procedure.
3. Place the fuel injector rail assembly on the manifold
and insert the injectors into each port by pushing
fuel rail.
4. Install two fuel rail retaining bolts. Tighten fuel rail

retaining bolt to 19 Nm (1.9kgfm)
5. Place wiring harness in its place and secure it with
two nuts.
6. Connect all connector to each fuel injector.
7. Connect the fuel supply line securely. Do not over
tighten.
6E272
FUEL INJECTOR
Removal Procedure
NOTE: If the fuel injectors are leaking, the engine oil
may be contaminated with fuel. Check the oil for signs
of contamination and change the oil and filter if
necessary.
NOTE: Use care in removing the fuel injector in order to
prevent damage to the fuel injector al connector pins or
fuel injector nozzles. The fuel injector is an al
component and should not be immersed in any type of
cleaner as this may damage the fuel injector.
Inspection
1. Inspect O-ring for crack, damage or leaks.
2. Replace worn or damaged O-ring.
3. Lubricate the new O-rings with engine oil before
installation.
1. Lubricate the new O-ring with engine oil.
2. Install the O-ring backup on the fuel injector.
3. Install new O-ring on the fuel injector.
Important: Fuel injectors are serviced as complete

assembly only.
2. Disconnect al connector from fuel injector.
3. Remove the fuel rail. Refer to Fuel Rail Removal
Procedure.
4. Remove the fuel injector retainer clip.
5. Remove the fuel injector assembly from fuel rail.
6. Remove O-ring from the fuel injector.
7. Remove O-ring backup from fuel injector.
4. Install all four injector on the fuel rail.

5. Use new injector retainer clip to retain the injetor to
the fuel rail.
6. Coat the end of the fuel injector with engine oil.

7. Install fuel rail assembly. Tighten the nuts to 19 Nm
(1.9 kgfm). Refer to Fuel Rail Installation
Procedure.
Tighten the flare nut to 27 - 33 Nm (2.8 - 3.4 kgfm).
6E273
FUEL PRESSURE REGULATOR

Removal Procedure
components.
Caution: After relieving the fuel system pressure, a
fitting with a shop towel before disconnecting the
fittings. The towel will absorb any fuel that may leak
out. When the disconnect is completed, place the
towel in an approved container.
NOTE: Compressed air must never be used to test or
clean a fuel pressure regulator, as damage to the fuel
pressure regulator may occur.
NOTE: To prevent damage to the fuel pressure
regulator, do not immerse the pressure regulator in
solvent.
Removal Procedure
Pressure Relief Procedure.
3. Remove the fuel pump relay.
4. Disconnect the vacuum line form fuel pressure
regulator.
6E274
5. Remove the fuel pressure regulator retaining screw.

6. Remove the fuel pressure regulator from fuel rail.
2. Install the fuel pressure regulator retaining bracket

and tighten with a screw.
3. Connect vacuum line onto the fuel pressure
regulator.
1. Insert the fuel pressure regulator into the fuel rail.
4. Install the fuel pump relay.

fuel line.
7. Tighten the flare nut to 27 - 33 Nm (2.8 - 3.4 kgfm).
6E275
IGNITION COIL
SPARK PLUGS
Location
Back of the engine right-hand side.
Location
Installed on the left-hand side of cylinder head.
Removal Procedure
Removal Procedure
1. Disconnect the negative battery cable
2. Disconnect the ignition coil connector.
2. Remove the spark plug cable.
3. Disconnect four spark plug cables from the ignition

coil.
3. Remove the spark plug.
4. Loosen three bolts and remove ignition coil from the

bracket.
Inspection
1. Check the insulator for cracks. Replace the spark
plug if cracks are present.
1. Tighten the ignition coil by three bolts.
2. Check the electrode condition and replace the spark

plug if necessary.
2. Connect four spark plug cables to the ignition coil.

3. Connect a ignition coil connector to the ignition coil.
Verify proper connection of spark plug cables for each
cylinders.
If the spark plug electrodes and insulators are fouled

with carbon or oil, the engine will not operate efficiently.
There are a number of possible causes:
Fuel mixture is too rich.
6E276
Oil in the combustion chamber.

The spark plug gap is not set correctly.
If spark plug fouling is excessive, check the fuel and al
system for possible causes of trouble. If fuel and al
system are normal, install spark plugs of a higher heat
range which have the same physical dimensions as the
original equipment spark plugs.
The following symptoms are characteristics of spark
plugs that are running too hot:
Fuel mixture is too lean.
Heat range is incorrect.
Installation
1. Tighten the spark plug to the 25Nm (2.5kgfm).
2. Push the spark plug cable in until it snaps in.
If vehicle usage does not conform to normal driving

conditions, a more suitable spark plug may be
substituted.
If fuel and al system are normal, in most cases of this
sort, the problem can be corrected by using a colder
type spark plug with the same physical dimensions as
the original equipment spark plug.
3. Check the gaskets for damage and replace if
necessary.
4. Measure the spark plug gap. The specification is 1.0
to 1.1mm (0.039 to 0.043").
5. Adjust the spark gap by bending the grounded
electrode.
1. Install the spark plug to the cylinder head.
2. Tighten the spark plug with specified tightening
torque.
Tightening Torque
3. Connect the spark plug cable to the spark plug.
Verify proper connection of spark plug cables for each
cylinders.

SPARK PLUG CABLES
The cable contains a synthetic conductor which is easily
damaged. Never stretch or kink the cable. Disconnect
the cable from spark plug and the ignition coil.
The original equipment cables and the ignition coil are
marked to show correct location of the cables. If spark
plug cables or the ignition coil are replaced previously,
before cables are removed from the ignition coil, mark
the cables and the coil so they can be reconnected in
the same position.
Inspection
NOTE: Never puncture the spark plug cables insulation
with a needle or the pointed end of a probe into the
cable. An increase in resistance would be created which
would cause the cable to become defective.
6E277
EMISSION CONTROL ; CO ADJUSTER (W/

O CATALYSTIC CONVERTER)
CO : Carbon monoxide
Location
Under the leht-hand side of the front sheet.
Removal Procedure
1. Remove the left-hand side of the front sheet. Refer
to Sec.10 CAB Front Sheet.
2. Disconnect the CO adjuster connector.
1. If the cable has broken or cracked insulation, it must

be replaced.
2. If the terminals are corroded or loose, the cable
must be replaced.
3. Check that the cable resistance does not exceed
specified value.
#1 cylinder: 3.50kW - 5.24kW
3. Remove the CO adjuster.

1. Connect the CO adjuster connector.
2. Install the left-hand side of the front sheet. Refer to
Sec.10 CAB Front Sheet.
3. Check and adjust CO concentration.
Checking procedure
1. Operate the engine at normal temperature.
2. Turn all accessories switch OFF.
3. Place the select lever in the N range.
4. Start the engine at idle.
6E278

Adjustment Procedure
1. Warm-up the engine.
2. Turn OFF switches of all electrical equipment.
3. Open the CO adjuster cap.
4. Turn the CO adjuster screw checking the CO
concentration
.
5. Measure the CO concentration for 1-3 minutes, after

idlling the engine to allow the CO concentration to
stabilize.
6. Check the CO concentration.
7. If the value is not within specification, adjust the CO
concentration.
5. Adjust the CO concentration within specification.
Specification:
CO concentration : 0.6 1.0 %
NOTE: Apply the liquid gasket to the CO adjuster screw
after the adjustment.

ILLUSTRATION
TOOL NO.
TOLL NAME
5-8840-0285-0
(J 39200)
High Impedance
Multimeter
(Digital Voltmeter -DVM)
(1) PCMCIA Card
(2) RS232 Loop Back
Connector
(4) DLC Cable
(5) TECH 2
5-8840-0385-0
(J 35616-A/BT-8637)
Connector Test Adapter Kit
5-8840-0378-0
(J34730-E)
Port Fuel Injection
Diagnostic Kit
Breaker Box
5-8840-2589-0
Injector Adapter Cable
6E279
MEMO
ENGINE EXHAUST 6F-1
SECTION 6F
ENGINE EXHAUST
CONTENTS
PAGE
General Description........................................................................................................ 6F- 2
Service Precaution ......................................................................................................... 6F- 4
Exhaust Pipe ................................................................................................................... 6F- 5
Exhaust pipe and Associated parts.......................................................................... 6F- 5
Removal ...................................................................................................................... 6F- 5
Installation .................................................................................................................. 6F- 6
Inspection ................................................................................................................... 6F- 6
Front Exhaust Pipe ......................................................................................................... 6F- 7
Front Exhaust Pipe and Associated Parts ............................................................... 6F- 7
Removal ...................................................................................................................... 6F- 7
Installation .................................................................................................................. 6F- 7
Mid Pipe ........................................................................................................................... 6F- 8
Mid Pipe and associated Parts ................................................................................. 6F- 8
Removal ...................................................................................................................... 6F- 8
Installation .................................................................................................................. 6F- 8
Catalytic Converter (If applicable) ................................................................................. 6F- 9
Catalytic Converter and Associated Parts ............................................................... 6F- 9
Removal ...................................................................................................................... 6F- 9
Installation .................................................................................................................. 6F- 9
3 way Catalytic Converter System ............................................................................ 6F- 10
Exhaust Silencer............................................................................................................. 6F- 12
Exhaust Silencer and Associated Parts................................................................... 6F- 12
Removal ...................................................................................................................... 6F- 12
Installation .................................................................................................................. 6F- 13
Main Data and Specifications ........................................................................................ 6F- 14
Torque Specification.................................................................................................. 6F- 15
6F-2 ENGINE EXHAUST
General Description
RTW46AMF000501
ENGINE EXHAUST 6F-3

When inspecting or replacing exhaust system components,
make sure there is adequate clearance from all points on the
underbody to prevent overheating the floor pan and possible
damage to the passenger compartment insulation and trim
materials.
Check complete exhaust system and nearby body areas and
rear compartment lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose connections or
other deterioration which could permit exhaust fumes to seep
into the rear compartment or passenger compartment. Dust or
water in the rear compartment may be an indication of a
problem in one of these areas. Any faulty areas should be
corrected immediately.
Hangers
Various types of hangers are used to support exhaust
system(s). These include conventional rubber straps, rubber
rings, and rubber blocks.
The installation of exhaust system supports is very important,
as improperly installed supports can cause annoying vibrations
which can be difficult to diagnose.
Three Way Catalytic Converter (If applicable)

The three way catalytic converter is an emission control device
added to the exhaust system to reduce pollutants from the
exhaust gas stream.
CAUTION: The catalytic converter requires the use of
unleaded fuel only.
Periodic maintenance of the exhaust system is not required. If
the vehicle is raised for other service, it is advisable to check
the condition of the complete exhaust system.
A dual bed monolith catalytic converter is used in combination
with three way catalytic converter.
Catalytic Types:
Three way (Reduction/Oxidation) catalyst
The catalyst coating on the three way (reduction) converter
contains platinum and rhodium which lowers the levels of
nitrous oxide (NOx) as well as hydrocarbons (HC) and carbon
monoxide (Co).
Gasket
The gasket must be replaced whenever a new exhaust pipe,
muffler or catalytic converter is installed.
6F-4 ENGINE EXHAUST
Service Precaution
CAUTION:
and systems.
ENGINE EXHAUST 6F-5
Exhaust Pipe
Exhaust Pipe and Associated parts
RTW46FLF000401
Removal
(2.4L)
CAUTION
When you remove or install the front exhaust pipe, make
sure not to damage the fuel evaporative pipe.
1.
2.
3.
4.
5.
6.
7.
Damper rubber
Exhaust silencer
Mid pipe
Damper rubber
Front exhaust pipe fixing nut
Catalytic converter (If applicable)
Front exhaust pipe
6F-6 ENGINE EXHAUST
Installation
To install, follow the removal steps in the reverse order.
Important - Installation
1. Front Exhaust Pipe Flange Nut
Connect the exhaust pipe to the exhaust manifold.
Front exhaust pipe to manifold nut.
Torque
Nm (kgfm)
28 (2.9)
Inspection
Make the necessary adjustments, and part replacements if
excessive wear or damage is discover during inspection.
1.
2.
3.
4.
Front Exhaust Pipe

Center Exhaust Pipe and Catalytic Converter Flange Nut
Exhaust Pipe Damper Rubber
Exhaust Silencer with Rear Exhaust Pipe
Check the pipes for for corrosion, cracking , damage or

misalignment and repair if required.
Check the damper rubber for deterioration or damage and
repair if required.
ENGINE EXHAUST 6F-7
Front Exhaust Pipe (W/O Catalytic

Converter)
Front Exhaust Pipe and Associated Parts
RTW46F000101
Legend
1. Front Exhaust Pipe Fixing Nuts
2. Front Exhaust Pipe
3. Mid Exhaust Pipe Fixing Nuts
Removal
(2.4L)
1.
2.
3.
4.
5.

Raise the vehicle and support with suitable safety stands.
Remove the front exhaust pipe fixing nuts (1).
Remove mid pipe fixing nuts (3).
Remove front exhaust pipe (2).
Installation
1. Install front exhaust pipe (2) and tighten four nuts (1).
Torque:
Nuts: 28 Nm (2.9 kgfm)
2. Tighten two nuts (3).
6F-8 ENGINE EXHAUST
Mid Pipe
Mid Pipe and Associated Parts
RTW46FSF000201
Legend
1. Mid Exhaust Pipe
2. Mid Exhaust Pipe Fixing Nuts
3. Exhaust Silencer Fixing Nuts
Removal
(2.4L)
1.
2.
3.
4.
5.

Remove exhaust silencer fixing nuts (3).
Remove the pipe.
Installation
1. Install mid exhaust pipe (1) and tighten four fixing nuts
(2)(3) to the specified torque:
Torque:
Fixing nuts: 43 Nm (4.4 kgfm)
ENGINE EXHAUST 6F-9
Catalytic Converter (If applicable)

Catalytic Converter and Associated Parts
RTW46FSF000301
Legend
2. O2 Sensor Converter
3. Front Pipe Fixing Nuts
4. Mid Pipe Fixing Nuts
Removal
(2.4L)
1.
2.
3.
4.
5.
6.

Remove front pipe fixing nuts (3).
Remove the O2 sensor connector (2).
Remove the front exhaust pipe with catalytic converter (1).
Installation
1. Install Catalytic Converter (1) and tighten four to the
specified torque:
Torque:
Fixing nuts: 28 Nm (2.9 kgfm)
2. Tight two nuts (4)
Torque:
Nuts: 43 Nm (4.4 kgfm)
3. Connect the O2 sensor connector (2).
6F-10 ENGINE EXHAUST
3 WAY CATALYTIC CONVERTER

SYSTEM (If applicable)
N2
Inspection
Make the necessary adjustments, and part replacements if
excessive or damage is discovered during inspection.
Exhaust Pipe Assembly

1. Check connections for looseness or damage.
2. Check clamps for weakness, crack, or damage.
Catalytic Converter
Check for dents or damage.
If any part of the converter is damaged or dented, repair or
replace it.
Removal
1.
2.
3.
4.
Jack up the vehicle.

Check that the converter is cool.
Remove the bolts at the front and rear of the converter.
Remove the converter and gaskets.
ENGINE EXHAUST 6F-11

(2.4L model)
Installation
1. Place new gaskets on the converter front and rear pipes,
and connect the converter to the exhaust pipes.
2. Tighten the bolts with the specified torque.
3. Reinstall the bracket bolts and tighten them.
Exhaust Silencer
Exhaust Silencer and Associated Parts
RTW46FMF000701
Legend
1. Exhaust Silencer
2. Exhaust Silencer Fixing Nuts
3. Rubber
Removal
(2.4L)
1.
2.
3.
4.

Remove the damper rubber and nut (2)(3).
Remove exhaust silencer (1).
Installation
(2.4L)
1. Install the exhaust silencer and tighten two nuts and the
damper rubbers.
Torque:
Bolts: 43 Nm (4.4 kgfm)

Exhaust system
Pipe outside diameter thickness
Front pipe
Middle pipe
Rear pipe
Silencer
Type
Number of suspension points

Type
Catalytic converter type (If applicable)
mm(in)
mm(in)
mm(in)
44.5 1.5 (1.750.059)

50.8 1.5 (2.00 0.059)
50.8 1.5 (2.0 0.059)
Circular section-shell construction

of triple; double skin and end plates, internal
construction of baffles
and perforated tubes.
4
Rubber
Three way Catalytic Converter

Nm (kgfm)
43Nm (4.4 kgfm)
43Nm (4.4 kgfm)
MEMO
ENGINE LUBRICATION 6G-1
SECTION 6G
ENGINE LUBRICATION
CONTENTS
PAGE
General Description........................................................................................................ 6G- 2
Service Precaution ......................................................................................................... 6G- 3
Oil Pump .......................................................................................................................... 6G- 4
Oil Pump and Associated Parts ................................................................................ 6G- 4
Disassembly ............................................................................................................... 6G- 4
Inspection and Repair................................................................................................ 6G- 5
Reassembly ................................................................................................................ 6G- 5
Oil Pan ............................................................................................................................. 6G- 6
Oil Pan and Associated Parts ................................................................................... 6G- 6
Disassembly ............................................................................................................... 6G- 6
Inspection and Repair................................................................................................ 6G- 7
Reassembly ................................................................................................................ 6G- 7
6G-2 ENGINE LUBRICATION
General Description
Legend
1 Oil Strainer
2 Oil Pump
3 Relief Valve
4 Oil Filter
5 Safety Valve
6 Oil Gallery
7 Crankshaft Bearing
8 Crankshaft
9 Connecting Rod Bearing

10 Connecting Rod
11 Piston
12 Oil Gallery; Cylinder Head
13 Camshaft
14 Camshaft Journal
15 HLV
16 Check relief valve
17 Oil Pan
A gear-type oil pump is directly driven by the crankshaft and

draws oil from the oil pan, via the suction pipe. If then passes
the pressured oil through a full-flow disposable oil filter, to the
main oil gallery in the cylinder Block. An oil pump pressure
relief valve and oil filter bypass valve are incorporated in the
system.
From the main oil gallery in the cylinder block, the cylinder
head and crankshaft main bearings are supplied with oil.
The camshaft bearings and hydraulic tappets are supplied
through the main feed galleries in the cylinder head. Vent
valves allow air to be expelled from the oil galleries in the
cylinder head. The balance shaft journals are directly fed from
the crankshaft main bearings. The connecting rod bearings are
fed via passages in the crankshaft. The oil returns to the oil
pan via passages in the cylinder block.
Service Precaution
CAUTION:
and systems.
Oil Pump
Oil Pump and Associated Parts
Legend
1 Oil Pump Assembly
2 Oil Pressure Switch
3 Gasket
4 Sleeve
Disassembly
1.
2.
3.
4.
5.
6.
7.
Remove crankshaft timing pulley.

Remove oil pan.
Remove oil strainer.
Remove oil pressure switch.
Remove gasket.
Remove sleeve.

replacement if wear, damage or any other abnormal
conditions are found through inspection.
Body and Gears

The pump assembly must be replaced if one or more of the
conditions below is discovered during inspection:
Indentation of gear pair - Use feeler strip and straight edge.
Dimension: 0.03 mm to 0.10 mm
(0.0012 to 0.0039 in)
Oil Strainer
Check the oil strainer for cracking and scoring. If cracking and
scoring are found, the oil strainer must be replaced.
Reassembly
1. Install oil pressure switch to the oil pump.
2. Install the oil pump with the sleeve and the gasket.
3. Install oil strainer.
4. Install the oil pan.
Tighten the bolts:
15 Nm (1.5 kgfm)
5. Install crankshaft timing pulley.
Tighten the bolts:
20 Nm (2.0 kgfm)
Oil Pan
Oil Pan and Associated Parts
(2.4L 44 Model)
(2.4L 42 Model)
Important
Disassembly
1.
2.
3.
4.
5.
6.
Loosen a drain plug to drain oil.

Remove engine hood.
Remove engine rear mounting.
Remove transmission assembly.
Remove engine front mounting.
Raise the vehicle and support with switch stands, and then
remove engine.
7. Remove oil pan.

replacement if wear, damage or any other
abnormal conditions are found through
inspection.
Reassembly
To install, follows the disassembly steps in the reverse order.
Important
Sealer - Apply silicon into groove in oil pan lugs prior to fitment
of oil pan to block, remove excess sealer after oil pan
is bolted to block.
Torque
(2.4L 44 Model)
4
Bolts - Tighten bolts to the specified torque.

Torque : 20 Nm (2.0 kgfm)
Engine oil - Refill engine oil to the oil pan.
(Lit)
3
1
(2.4L 42 Model)
4
3
1
2
Replacement Oil Fill Volume

Without filter change
With filter change
2.4L
4.00
4.25
MEMO
ENGINE SPEED CONTROL SYSTEM (C24SE) 6H-1
ENGINE
ENGINE SPEED CONTROL SYSTEM (C24SE)
CONTENTS
Service Precaution...............................................
Accelerator Pedal Control Cable ......................
Removal ..............................................................
Inspection ...........................................................
Installation..........................................................
6H-1
6H-2
6H-2
6H-3
6H-3
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.

parts and systems.
6H-2 ENGINE SPEED CONTROL SYSTEM (C24SE)
Accelerator Pedal Control Cable
RHD MODEL
RTW46HLF000501
Removal
2) Rotate the ratchet ring in indirection an arrow
90.
ENGINE SPEED CONTROL SYSTEM (C24SE) 6H-3

throttle.
LHD MODEL
RTW46AMH000101
Inspection
Check the following items and replace the control
cable if any abnormality is found.
corrosion.
Installation
control pedal dash panel.
engine.
bracket.
2) Confirm marking of outer cap must be upper
side.
6H-4 ENGINE SPEED CONTROL SYSTEM (C24SE)
MEMO
INDUCTION 6J-1
SECTION 6J
INDUCTION
CONTENTS
PAGE
Service Precaution ......................................................................................................... 6J- 2
Air Cleaner Filter............................................................................................................. 6J- 2
Removal ...................................................................................................................... 6J- 2
Inspection ................................................................................................................... 6J- 2
Installation .................................................................................................................. 6J- 3
6J-2 INDUCTION
Service Precaution
CAUTION:
and systems.
Air Cleaner Filter

NOTE:
The air cleaner filter is not damaged with the edge of the air
cleaner housing.
Removal
RTW46JSH000101
1.
2.
3.
4.
5.
Remove positive ventilation hose connector.

Remove intake air temperature sensor.
Remove mass air flow sensor.
Remove air cleaner duct assembly.
Remove air cleaner element.
Inspection
Cleaning Method
Tap the air cleaner filter gently so as not to damage the paper
filter, or clean the element by blowing with compressed air of
about 490 kPa (71 psi) from the clean side if it is extremely
dirty.
INDUCTION 6J-3
Installation
1. Install air cleaner element.
2. Attach the air cleaner duct cover to the body completely,
then clamp it with the clip.
3. Install mass air flow sensor.
4. Install mass air temperature sensor.
5. Install positive crankcase ventilation hose connector.
6J-4 INDUCTION
MEMO
No. TFHEO-WE-0431
WORKSHOP MANUAL
TF SERIES
TRANSFER
SECTION 7D
TRANSFER CASE 7D-1
SECTION 7D
TRANSFER CASE
TABLE OF CONTENTS
PAGE
Service Precaution .......................................................................................................... 7D
General Description ........................................................................................................ 7D
Transfer Rear Oil Seal .................................................................................................... 7D
Transfer Rear Oil Seal and Associated Parts ............................................................ 7D
Removal ........................................................................................................................ 7D
Installation .................................................................................................................... 7D
Transfer Case Assembly ................................................................................................ 7D
Transfer Case Assembly and Associated Parts ........................................................ 7D
Removal ........................................................................................................................ 7D
Installation .................................................................................................................... 7D
Transfer Control Unit ...................................................................................................... 7D 10

Removal ........................................................................................................................ 7D 10
Installation .................................................................................................................... 7D 10
Transfer Disassembly ..................................................................................................... 7D 11
Removal ........................................................................................................................ 7D 11
Inspection and Repair .................................................................................................. 7D 20
Inspection and Repair (Transfer Case Assembly) ..................................................... 7D 20
Reassembly .................................................................................................................. 7D 24
Main Data and Specifications ........................................................................................ 7D 33
Special Tools ................................................................................................................ 7D 36
7D-2 TRANSFER CASE
Service Precaution
REPAIRS.

parts and systems.
TRANSFER CASE 7D-3
General Description
RUW34DLF000701
The transfer case is used to provide a means of

providing power flow to the front axle. The transfer case
also provides a means of disconnecting the front axle,
providing better fuel economy and quieter operation
when the vehicle is driven on improved roads where
four wheel drive is not required. In addition, the transfer
case provides an additional gear reduction when placed
in low range, which is useful when difficult off-road
conditions are encountered.
Use the 4WD switch on the center cluster panel to
select the drive range. The 4WD indicator lamp will be
lit when 4WD is selected.
7D-4 TRANSFER CASE
Transfer Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts
220R300018
Legend
(1)Rear Propeller Shaft
(2)Oil Seal
Removal
1. Disconnect the rear propeller shaft (1) from the
transfer case side.
2. Remove the oil seal from the transfer case.
Installation
1. Install oil seal and apply engine oil to the oil seal
outer surfaces.
2. Apply the recommended grease (BESCO L2) or
equivalent to the oil seal lip.
3. Use the oil seal installer 5-8840-2786-0 to install the
rear seal (2) to the transfer rear case.
TRANSFER CASE 7D-5
220R300021
4. Connect the rear propeller shaft.
7D-6 TRANSFER CASE
Transfer Case Assembly

Transfer Case Assembly and Associated Parts
RTW47DLF000501
Legend
(1)Rear Propeller Shaft
(2)Front Propeller Shaft
(3)Transfer Case Assembly
(4) Center Exhaust Pipe (6VE1 only)
TRANSFER CASE 7D-7
Removal
Installation
NOTE: Before removing transmission and transfer

assembly from vehicle, change the transfer mode to
2WD using the 4WD push button switch on dash panel.
1. Apply a thin coat of molybdenum disulfide grease to

the input shaft spline as shown in the figure.

2. Raise and support vehicle with suitable stands. Drain
transfer case fluid.
3. Remove the center exhaust pipe(5). (6VE1 only)
4. Remove rear propeller shaft (1) and front propeller
shaft (2)(3).
NOTE: Apply alignment marks on the flange at both
front and rear sides.
5. Disconnect harness connectors and clip.
Connector: transfer switch, 2WD-4WD actuator,
speed sensor.
NOTE: Avoid turning the vehicle ignition switch to the
ON position when the 2WD-4WD connector is removed
(battery connected).
If the ignition switch must be turned to the ON position,
the controller must first be removed (memory must be
cleared because the CHECK 4WD INDICATOR will
light).
6. Remove transfer case (4) from the vehicle.
260R300001
7D-8 TRANSFER CASE

2. Install transfer case (4) to the transmission. Tighten
transfer bolts as shown in the figure.
For M/T
261R300001
TRANSFER CASE 7D-9

For A/T
261R300002
3. Connect harness connectors and clip.

Connector: transfer switch, 2WD-4WD actuator,
speed sensor.
4. Install center exhaust pipe(5). (6VE1 only)
5. Install rear propeller shaft (1) and front propeller
shaft (2)(3).
7D-10 TRANSFER CASE
Transfer Control Unit
RTW37DLF000401
Legend
(1)Transfer Control Unit
(2)Protector
(3) Bolt
Removal
Installation

Remove the drivers seat.
2. Peel back the floor carpet on the driver's side of the
vehicle to expose the transfer control unit.
3. Disconnect the harness connector from the Transfer
control unit.
4. Remove the Transfer control unit.
1. Install the Transfer control unit.

2. Connect the harness connector to the Transfer
control unit.
TRANSFER CASE 7D-11
Transfer Disassembly
RTW47DLF000101
Legend
(1) Transfer Case
(2) Companion Flange, O-ring and Nut
(3) Stoneguard
(4) Detent Plug, Spring and Detent Ball
(5) 2-4 Switch ASM
(6) Switch Bracket
Removal
1. Remove the stoneguard.
2. Remove the drain plug from the transfer case to
drain the oil.
3. Remove the parts listed below.
(7)
(8)
(9)
(10)
(11)
Neutral Switch ASM

Speedometer Bush, Plate and Driven Gear
Transfer Actuator
Breather Hose
Heat Protector (Except Diesel Engine)
Speedometer bush, plate, and speedometer

driven gear
Breather hose (Between the transfer case and
the transfer actuator assembly)
Transfer actuator assembly
Switch bracket
7D-12 TRANSFER CASE

2-4 switch assembly (Gray harness cover)
Neutral switch assembly (Black harness cover)
Detent plugs, detent springs, and detent balls (2
parts each)
6. Strike the area around the front output shaft head

and the rear cover bolt holes with a plastic hammer
to remove the rear cover.
4. Use the companion flange holder (5-8840-0133-0) to

remove the end nut from the front companion flange.
5. Remove the bolts attaching the rear cover to the

transfer case.
220R300022
TRANSFER CASE 7D-13

7. Remove the parts listed below from the rear cover.
H-L sleeve
H-L shift assembly
2-4 sleeve, synchronizer key, and front
synchronizer spring (do not remove the rear
spring)
2-4 shift assembly
Shift drum and shift shaft
Sun gear needle bearing
Legend
(1)Sun Gear Needle Bearing
(2)H-L Sleeve
(3)2-4sleeve, synchronizer key, and front
synchronizer spring
(4)2-4 Shift ASM
(5)Shift Shaft
(6)H-L Shift ASM
(7)Shift Drum
8. Remove the oil pump strainer fixing bolts from the
rear cover.
9. Compress the retaining ring at the rear of the chain.
Strike the rear end of the main shaft with a plastic
hammer to remove the main shaft, transfer chain,
and front output shaft assembly from the rear cover.
Be careful not to damage the oil pump strainer.
226R30001
260R300001
7D-14 TRANSFER CASE

10. Remove the transfer chain and the front output shaft
from the main shaft.
11. Remove the main shaft snap ring.
12. Remove the speedometer drive gear, the ball
bearings, the retaining ring, and the oil pump
assembly.
13. Remove the sprocket snap ring.
14. Remove the thrust washer, the drive sprocket, the
inside ring, the outside ring, the block ring, and the
rear synchronizer spring.
RTW37DMF000101
Legend
(1)Rear synchronizer spring
(2)Block Ring
(3)Outside Ring
(4)Inside Ring
(5)Drive Sprocket
(6)Transfer Chain
(7)Front Output shaft
(8)Thrust Washer
(9)Sprocket Snap Ring

(10)Oil Pump ASM
(11)Oil Pump Retaining Ring
(12)Retaining Ring
(13)Ball Bearing
(14)Speedometer Drive Gear
(15)Main Shaft Snap Ring
TRANSFER CASE 7D-15

15. Remove the snap ring from the main shaft.
16 Use a press to remove the 2-4 hub from the main
shaft.
2260R300021
17. Spread the edges of the retaining ring while lightly

tapping on the sun gear input shaft end. Remove the
carrier and gear assembly from the transfer case.
Legend
(1)Outer Retaining Ring
(2)Carrier and Gear ASM
(3)Thrust needle Bearing
(4)Sungear Input Shaft
(5)Planetary DogTeeth
(6)Dog Teeth Snap Ring
20.Remove the carrier snap ring.
21.Use a press to remove the ball bearings.
226R300020
18 Remove the dog teeth snap ring from the carrier and
gear assembly.
19. Remove the planetary dog teeth and the sun gear
input shaft together with the thrust needle bearing.
22.Use the sliding hammer (5-8840-0084-0) and the

needle bearing replacer (5-8840-0027-0) to remove
the needle bearing from the center of the carrier and
gear assembly.
7D-16 TRANSFER CASE

27.Use a sliding hammer (5-8840-0084-0) and a needle
bearing replacer (5-8840-2788-0) to remove the
needle bearing from the front output shaft.
23. Remove the retaining ring (spiral type) together with

the internal gear and the damper ring.
P1010023
226R300004
Legend
(1)Dumper Ring
(2)Internal Gear
(3)Retaining Ring
25. Use a press to remove the front output shaft ball
bearings.
26. Remove the oil pump wire snap ring from the rear
cover.
TRANSFER CASE 7D-17

Internal Component Disassembly and Reassembly
H-L Shift Disassembly

1. Remove the guide roller.
2. Use a vise to compress the H-L shift spirng (inside
the assembly.
226R300017
Legend
(1)ARM; SHIFT
(2)BLOCK ASM; SHIFT
(3)RING; RETAINING, INNER
(4)COLLER (FRONT)
(5)SPRING
(6)COLLER (REAR)
(7)ROD; SHIFT
(8)RING; SNAP, OUTER
(9)ROLLER; GUIDE
(10)PIN ASM; SPRING
3. Remove the uter snap ring.

4. Remove the shift block assembly from the shift rod.
5. Use a socket and a vise to compress the shift block

spring (inside the assembly.
6. Remove the inner retaining ring.
7. Remove the collar (rear.
8. Remove the shift block spring.
9. Remove the collar (rear.
10.Removethe shift block assembly
11.Remove the uter snap ring.
12.Remove the shift arm.
13.Remove the front and rear companion flange.
7D-18 TRANSFER CASE

H-L shift reassembly
2-4 shift ASM
1. Install the shift arm to the shift rod.

2. Install the spring pin. The top of the pin must be
flush with the surrounding surface (no projection).
3. Install the front collar, the spring, and the rear collar
to the shift block in that order.
4. Use a socket and a vise to compress the shift block
spring.
5. Install the inner retaining ring. Be sure that the arm
aperture width is within the specified limit.
226R300016
226R300014
Legend
(1)25.62
(2)14.1mm
6. Install the shift lock assembly to the shift rod.

7. Use a socket and a vise to compress the H-L shift
spring.
8. Install the outer snap ring.
9. Install the guide roller.
Legend
(1)ROD; SHIFT
(2)ARM; SHIFT
(3)SPRING
(4)BLOCK ARM;SHIFT
(5)PIN ARM; SPRING
(6)ROLLER; GUIDE
(7)RING; SNAP
2-4 shift disassembly
1.
2.
3.
4.
5.
6.
7.
Remove the guide roller.

Compress the spring and remove the snap ring.
Remove the shift arm.
Remove the spring.
Remove the spring pin.
Remove the shift block assembly.
Remove the shift rod.
TRANSFER CASE 7D-19

2-4 shift reassembly
Oil pump reassembly
1. Install the shift block assembly to the shift rod.

2. Install the spring pin. The head of the pin must not
project beyond the surface (1) of the shift block.
1. Tighten the clamps to secure the hose.

2. Tighten the clamps to secure the screen.
NOTE: Be carefull in the direction of clamps.
RTW37DSH000101
226R300015
3.
4.
5.
6.
Install the spring.

Install the shift arm.
Compress the spring and install the snap ring.
Install the guide roller.
Oil pump disassembly

1. Remove the clamps securing the screen.
2. Remove the screen.
3. Remove the clamps securing the hose.
4. Remove the hose.
NOTE: To maintain and porotect oil pump function, the
pump is constructed so that it cannot be disassembled.
Under no conditions attempt to disassemble the pump.
Legend
(1) OIL PUMP ASM
(2) CLAMP
(3) HOSE
(4) SCREEN ASM
7D-20 TRANSFER CASE
2-4 and Neutral Switch
1. Make the necessary repair or parts replacement if

wear, damage or any other abnormal conditions are
found during inspection.
2. Wash all parts thoroughly in clean solvent. Be sure
all old lubricant, metallic particles, dirt, or foreign
material are removed from the surfaces of every
part. Apply compressed air to each oil feed port and
channel in each case half to remove any
obstructions or cleaning solvent residue.
Check the continuity of 2-4 and Neutral switch.

If defects are observed, replace the 4H and 4L
switch.
Inspection and Repair (Transfer

Case Assembly)
When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired
or replaced. Wash all the parts with clean detergent,
and check that old oil, metallic particles, dirt, or foreign
materials are completely removed. Blow the air into oil
holes and grooves to remove foreign materials or
residual detergent.
Chain
221R300001
Check whether the face that contacts the sprocket is

free from excessive wear or damage. If defects are
observed, replace the part.
If the chain interference mark is found on the inside
wall of the transfer cover or the chain is so slack that
a skipped engagement occurs between the chain
and sprocket, replace the chain.
Sprocket
Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.
If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.
Gear
Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
Remove minor flaws or scratches with oil stone. If
excessive wear or damage is observed, replace the
part.
261R300003
Switch
Stroke
1
2
2-4 Switch
Signal
Terminal
1 to 2
Open
Close
Neutral Switch
Signal
Terminal
1 to2
Close
Open
TRANSFER CASE 7D-21
Oil Pump
Ball Bearing Play
Remove foreign materials from the strainer. If the

strainer is damaged, replace it.
If the area into which the shaft is inserted is excessively
worn or damaged, replace the oil pump assembly.
1. Use a dial indicator to measure the ball bearing play.

2. If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Limit : 0.2 mm (0.008 in)
Clutch Hub Spline Play

Set a dial indicator to the clutch hub to be measured.
Move the clutch hub as far as possible to both the
right and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit,
the clutch hub must be replaced.
Clutch hub spline play
Standard : 0 0.1 mm (0 0.004 in)
Limit : 0.2 mm (0.008 in)
226R3043
Synchronizers
The synchronizer hubs and sliding sleeves are a
selected assembly and should be kept together as
originally assembled.
Clean synchronizer components with clean solvent and
air dry.
Inspect the components for the following:
226RS042
Bearings
1. Inspect the condition of all the needles and ball
bearings. Wash bearings thoroughly in a cleaning
solvent. Apply compressed air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.
Teeth for wear, scuffs, nicks, burrs or breaks.

Keys and springs for wear, cracks or distortion,
replace if these conditions are present.
If scuffed, nicked or burred conditions cannot be
corrected with a soft stone or crocus cloth, replace
the component.
7D-22 TRANSFER CASE
Block Ring and Insert Clearance

1. Use a vernier caliper to measure the clearance
between the block ring and the insert.
2. If the measured value exceeds the specified limit,
the block ring and the insert must be replaced.
Block ring and insert clearance
Standard : 3.86 4.14 mm (0.152 0.163 in)
Limit : 4.9 mm (0.193 in)
226R300019
Clutch Hub and Insert Clearance

1. Clutch Hub and Insert Clearance
2. Use a thickness gauge to measure the clearance
between the clutch hub and the insert.
3. If the measured value exceeds the specified limit, the
clutch hub and the insert must be replaced.
226RS037
2WD-4WD Synchronizer (3-Cone)
Clutch hub and insert clearance

Standard : 0.01-0.19 mm (0.0004-0.0075 in)
Limit : 0.3 mm (0.012 in)
1. Use a thickness gauge to measure the clearance

between the block ring and the dog teeth.
2. If the measured value exceeds the specified limit,
the 2WD-4WD synchronizer assembly must be
replaced.
Block ring and dog teeth clearance
Standard : 1.5 mm (0.059 in)
Limit : 0.8 mm (0.031 in)
226RS038
Detent Springs
1. Inspect the springs for distortion, cracks or wear.
Replace if these conditions are present.
TRANSFER CASE 7D-23
Detent Spring Free Length

1. Use a vernier caliper to measure the detent spring
free length.
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Standard :23.4 mm (0.92 in)
Limit :22.8 mm (0.90 in)
220RS013
Shift Arm
1. Inspect the shift arms for wear, distortion or scoring.
Replace if these conditions are present.
Shift Arm Thickness

1. Use a micrometer to measure the shift arm
thickness.
the shift arm must be replaced.
220RW035
Detent Spring Tension

1. Use a spring tester to measure the detent spring
tension.
Detent ball
Compressed height : 18.7 mm (0.736 in)
Standard : 68.6 ~ 88.2 N (7.0 ~ 9.0 kg/ 15.4 ~ 19.8
lb)
H-L Shift arm thickness

Standard : 7.6-7.85 mm (0.299-0.309 in)
Limit : 7.0 mm (0.276 in)
2-4 Shift arm thickness
Standard : 9.6-9.85 mm (0.378-0.388 in)
Limit : 9.0 mm (0.354 in)
7D-24 TRANSFER CASE
Reassembly
Transfer Reassembly
The rear cover oil seals and the rear output shaft ball
bearings cannot be reused. They must be replaced with
new ones when the transfer is reassembled.
1. Use the oil seal installer (5-8840-2785-0) to press
the new input shaft and/or front output shaft oil seals
into place (If replacement is required).
226R300004
Legend
(1)Dumper Ring
(2)Internal Gear
(3)Retaining Ring
Note the direction of the dumper ring installation as
figure.
226R300025
2. Use a press to install the ball bearings to the front

output shaft. Be sure that the bearings are fully
inserted and then install the snap ring.
3. Install the damper ring and the internal gear to the
transfer case. Be sure that the damper ring is
between the internal gear and the case.
TRANSFER CASE 7D-25

4. Use a press and the special tool (5-8840-2784-0) to
hold the internal gear against the damper ring. Install
the retaining ring (spiral type).
5. Use a press and the installer (5-8840-2782-0) to

force the needle bearing fully into the carrier and
gear assembly.
6. Use a press and an appropriate special tool to force

the ball bearings fully into the carrier and gear
assembly.
7. Install the carrier snap ring.

8. Install the thrust needle bearing, the sun gear input
shaft, the needle bearing, the planetary dog teeth,
and the dog teeth snap ring to the carrier and gear
assembly in that order.
9. Install the outer retaining ring to the tansfer case
10.Use a pair of snap ring pliers to install the carrier and
gear assembly.
NOTE: Be sure that the outer retaining ring fits snugly in
its groove.
7D-26 TRANSFER CASE

11.Use a press to install the 2-4 hub.
12.Install the hub snap ring.

13.Install the synchronizer key springs (2), the
synchronizer key, and the 2-4 sleeve to the 2-4 hub.
The key and the open end of the springs must be
facing in the opposite direction.
226R300003
Legend
(1)Retaining Ring
(2)Carrier and Gear ASM
(3)Thrust Needle Bearing
(4)Sungear Input Shaft
(5)Planetary Dog Teeth
(6)Dog Teeth Snapring
TRANSFER CASE 7D-27

14. Insert the H-L sleeve into the main shaft.
226R300023
Legend
(1)H-L Sleeve
(2)2-4 Sleeve
15. Install the sleeve to the H-L shift assembly.
16. Install the sleeve to the 2-4 shift assembly.
17. Coat the area around each of the shift assembly
insertion holes (transfer case) with transfer oil.
18. Install the main shaft together with the H-L shift
assembly and the 2-4 shift assembly to the shift
drum.
(3)Synchronizer Key and Key Spring
7D-28 TRANSFER CASE

19. Align the shift shaft splines with the shift drum and
install the shafts to the drum.
RTW320MF000201
Legend
(1)H-L Sleeve and Shift ASM
(2)2-4 Sleeve ASM with Main Shaft and Shift ASM
NOTE: Be careful in the direction of an assembly.
P1010041/020124
(3)Shift Shaft
(4)Shift Drum
20.Coat the main shaft with oil.
21.Align the block ring, the outside ring, and the inside
ring with the 2-4 hub assembly and install them.
22.Assemble the sprocket, transfer chain, and front
output shaft.
23.Install the sprocket, transfer chain, and front output
shaft to the main shaft and the transfer case.
TRANSFER CASE 7D-29

24. Align the sprocket thrust washer with the main shaft
groove and install it.
Legend
(1)Block Ring
(2)Outside Ring
(3)Inside Ring
(4)Sprocket
(5)Chain
(6)Front Output Shaft
(7)Thrust Washer
(8)Snap Ring
26.Measure the snap ring external diameter. If the
measured diameter is outside the specified range, a
larger or smaller snap ring must be used.
Snap ring outside diameter (Standard):
53.0 0.5 mm
226R300009
25. Select a snap ring that will allow minimum axial play.
Insert it to the main shaft installation groove.
mm (in)
Snap ring thickness
Identification color
2.15 (0.085)
Red
2.10 (0.083)
Not colored
2.05 (0.081)
Blue
2.00 (0.079)
White
27.Position the rear cover so that its mating surfaces

are facing up.
28.Use a press and the installer (5-8840-2783-0) to
install the front output shaft needle bearing. The
installer must be aligned with the bearing
manufacturer's name (stamped into the bearing).
29.Install the oil pump wire snap ring to the rear cover.
226R300008
7D-30 TRANSFER CASE
226R300005
Legend
(1)Wire Snapring
30. Temporarily install the speedometer drive gear to the
inside of the rear cover. Pay close attention to
installation direction.
31. Use a press and the installer (9-8522-1268-0) to
install the rear output shaft ball bearings. Do not
drive the ball bearings into place with a hammer.
226R300010
Legend
(1)Oil Pump ASM
(2)Wire Snapring
(3)Retaining Ring
(4)Ball Bearing
(5)Speedometer Gear Drive Gear
(6)Rear Cover
35.Apply Loctite FMD 127 to the mating surfaces of the
rear cover and the transfer case. Be sure that the
Loctite is evenly applied to the inside surfaces of the
bolt holes with no gaps.
32. Install the rear output shaft retaining ring.

33. Place the oil pump in its specified position.
34. Secure the pump strainer to the rear cover and
tighten the bolts to the specified torque.
Rear cover and transfer case bolt torque:
15 Nm (1.5 kgm/11 lb ft)
TRANSFER CASE 7D-31
226R300011
226R300012
36. Install the rear cover to the transfer case and tighten
the bolts to the specified torque.
Rear cover and transfer case bolt torque:
22 Nm (2.2 kgm/16 lbft)
37. Apply engine oil to the companion flange O-ring.
38. Install the O-ring to the front output shaft.
39. Secure the front companion flange with the
companion flange holder (5-8840-0133-0).
40. Install the end nuts and tighten them to the specified
torque.
Front companion flange end nut torque:
137 Nm (14 kgm/101 lbft)
RUW34DSH000301
Legend
(1) MAX 26mm (1.02 in)
(2) MIN 4mm (0.16 in)
42.Apply Loctite 575 to the threaded portion of the

detenteplugs.
41. Use a cold chisel to caulk the front companion

flange end nuts.
7D-32 TRANSFER CASE

43. Use the installer (5-8840-2787-0) to install the main
shaft end snap ring to the rear output shaft (from the
back end of the shaft). Be absolutely sure that the
snap ring is seated in the groove.
46.Install the neutral switch (black harness cover) to the

transfer case and tighten the bolts to the specified
torque.
Neutral start switch bolt torque:
39 Nm (4 kgm/29 lbft)
47.Install the 2-4 switch (gray harness cover) to the
transfer case and tighten the bolts to the specified
torque.
2-4 switch bolt torque: 39 Nm (4 kgm/29 lbft)
48.Install the switch bracket to the transfer case and
tighten the bolts to the specified torque.
Switch bracket bolt torque:
15 Nm (1.5 kgm/11 lbft)
49.Install the transfer actuator assembly to the transfer
case and tighten the bolts to the specified torque.
The actuator must be installed in the same direction
as the shaft.
Transfer actuator assembly bolt torque:
226R300022
44. Use the installer (5-8840-2786-0) to install the rear

output oil seal to the rear case.
45. Install the detent balls, the detent springs, and the
detent plugs (2 parts each) to the transfer case.
Tighten the plugs to the specified torque.
Detent plug torque: 19 Nm (1.9 kgm/14 lbft)
22 Nm (2.2 kgm/16 lbft)

50.Install the breather hose between the transfer
actuator and the transfer case.
51.Install the speedometer driven gear, the
speedometer bush, and the speedometer stay to the
transfer case. Tighten the bolts to the specified
torque.
Speedometer bolt torque:
15 Nm (1.5 kgm/11 lbft)
52.Install the drain plug to the transfer case and tighten
it to the specified torque.
Drain plug torque: 39 Nm (4 kgm/29 lbft)
53.Loosen and remove the filler plug. Add the specified
volume of transfer oil (5W-30) or the equivalent to
the transfer through the filler hole.
Transfer oil volume: 1.3 liters
54.Replace the filler plug and tighten it to the specified
torque.
Filler plug torque: 39 Nm (4 kgm/29 lbft)
55.Install the underguard and tighten the bolts to the
specified torque.
Underguard bolt torque: 39 Nm (4 kgm/29 lbft)
TRANSFER CASE 7D-33

Type
Control method
Gear ratio
Oil capacity
Type of lubricant
Synchronized type gears shifting between the 2 and 4 wheel drive mode.
Planetary type gears shifting between low" and high".
Remote control with the button switch on the instrument panel for gears
shifting among 2H" , 4H" and 4L".
High; 1.000
Low; 2.482
1.3 lit. (1.37 U.S. quart)
BESCO GEAR OIL TRANSAXLE (5W-30)
Refer to chart in Section 0
Nm (kgm/lb ft)
RTW47DLF000201
7D-34 TRANSFER CASE

Nm (kgm/lb ft)
RTW47DLF000401
TRANSFER CASE 7D-35

Nm (kgm/lb ft)
E07R300008
7D-36 TRANSFER CASE
Special Tools
ILLUSTRATION
PART NO.
PART NAME
ILLUSTRATION
PART NO.
PART NAME
5-8840-2786
Transfer case oil seal
installer
5-8840-2784-0
Ring gear installer
5-8840-0084-0
Sliding hammer
5-8840-0133-0
Flange holder
5-8840-0027-0
Rear output shaft needle
bearing replacer
5-8840-2782-0
Needle bearing installer
5-8840-2293-0
Punch; end nut
5-8840-2783-0
Needle bearing installer
5-8840-2788-0
Front output shaft needle
bearing replacer
5-8840-0007-0
Driver handle
5-8840-2785-0
Input shaft and/or front
output shaft oil seal
installer
5-8840-1268-0
Rear output shaft ball
bearing installer
TRANSFER CASE 7D-37

ILLUSTRATION
PART NO.
PART NAME
5-8840-2787-0
Snapring installer
7D-38 TRANSFER CASE
MEMO
TRANSFER CONTROL SYSTEM 7D1-1
SECTION 7D1
TRANSFER CONTROL SYSTEM

TABLE OF CONTENTS
PAGE
Service Precaution .................................................................................................... 7D1 -
General Description ................................................................................................... 7D1 -
System Components ................................................................................................. 7D1 -
Parts Location ...................................................................................................... 7D1 -
Functions of Switch and Indicator Lamp ................................................................. 7D1 - 11

Parts Location ............................................................................................................ 7D1 - 23
Circuit Diagram .......................................................................................................... 7D1 - 27
Connector List ........................................................................................................... 7D1 - 31
Diagnosis .................................................................................................................... 7D1 - 34
Before determining trouble ................................................................................. 7D1 - 34
Memory erasing procedure ....................................................................................... 7D1 - 40
Diagnosis from symptom .......................................................................................... 7D1 - 41
7D1-2 TRANSFER CONTROL SYSTEM
Service Precaution
WARNING:
THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT
SYSTEM (SRS). REFER TO THE SRS COMPONENT AND
WIRING LOCATION VIEW IN ORDER TO DETERMINE
WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS WIRING.
WHEN YOU ARE PERFORMING SERVICE ON OR NEAR
THE SRS COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW
WARNINGS COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE
UNNEEDED SRS SYSTEM REPAIRS.
CAUTION:
and systems.
General Description
RTW47DLF000301
Transfer Position and Drive Mode

Three drive modes can be selected through operation of 4WD switch.
Transfer Position
4WD SWITCH
2H
Mode
RWD
4H
4WD (HIGH)
LOW
4L
4WD (LOW)
NEUTRAL
2H & 4L (10 Sec)
NEUTRAL
HIGH
Drive mode
Rear wheel drive
High-speed
mechanical
lock-up four wheel drive
Low-speed
mechanical
lock-up four wheel drive
Towed by other vehicle

Summary of transfer control system
The transfer control system switches between the 2-wheel
drive (2H), 4-wheel drive high-speed (4H), 4-wheel drive lowspeed (4L), and neutral positions electrically when the driver
operate the switches.
This system has following functions.
1. Connection or disconnection of drive force distribution to
the front wheel front shaft (axle shaft) (The drive force
distribution to the front propeller is connected or
disconnected with the motor actuator.)
2. Try to repeat the connection or disconnection of the front
wheel drive function as described above.
3. Option: Shift on the fly type only.
Instruction of connection or disconnection of the drive force
transmission between the front wheel axle (axle shaft) and
front
wheel
(The motor actuator connects or disconnects the left front
wheel ad front wheel axle (axle shaft).).
4. Shifting of auxiliary transmission gears, connection or
disconnection of wheel and engine drive force (4H, 4L,
neutral).
5. Operation of indicator on the instrument panel.
6. Transmission of position signal to other controllers.
System Components
Parts Location
Speed sensor
Revolutions of the rear output shaft are decreased and taken
out by the speed/drive/driven gears installed in the transfer
case and the number of revolutions is detected with a speed
sensor.
About 4/3 pulses per revolution of the shaft is output.
4WD switch
The 4WD switch detects the movement of the shift rod driving
the 42 - 44 sleeve.
PUSH open is achieved with the PUSH open switch when the
shift rod is at the 42 position.
4
2 - 4
4 sleeve & Arm
The 42 - 44 sleeve moves directly in the 44 direction with
the 42 - 44 shift rod, but, when moving in 42 direction, a

spring standby mechanism is provided between the rod and
sleeve so that the rod is positioned at the 42 position, while
the sleeve is at the 44 position in sometime.
This mechanism is provided to protect the shift mechanism
from the force to prevent the movement of the sleeve
(torsional torque etc. of the drive system). By releasing the
preventive force, the sleeve can move to 42 state by the
spring force.
Neutral switch
The neutral switch detects the movement of the shift rod
driving the high-low sleeve.
PUSH close is achieved with the PUSH close switch when the
shift rod is positioned between the High and the Low, that is,
at the neutral state.
High-Low Sleeve & Arm
The spring standby mechanism is provided for the high-low
sleeve in both directions of the high-low shift rod. For this
reason, the rod position and the actual sleeve position may be
offset in some cases.
This system is provided to protect the shift mechanism from
the collision due to coincidence of the high and low phases of
the engaged splines. By giving rotational force to the
preventing phase coincidence, the splines are moved to the
proper engagement position by the spring force.
Shift actuator
The output shaft is rotated by the built-in motor and the
transfer position is switched.
Detection (limit) switches to detect the rotating angle of the
output shaft is provided to the actuator at 4 positions, which
are connected to the transfer controller through the vehicle
harness to constantly transmit the actuator operating angle
and changes in its transfer status.
4WD indicator (in meter panel)
This lamp indicates the following items
Valve check
Drive condition (2WD-4WD)
Operating condition (2Hz: Actuator in operation, mechanism
standby)
Restrictions on operation (4Hz, including indication of
interrupted operation due
to excessive load)
7B4-PDF2
4L indicator (in meter panel)

This lamp indicates following items.
Valve check
Driving status (High-Low)
Operating status (2Hz: Actuator in operation, mechanism
standby)
Restrictions on operation (4Hz)

7B4-PDF3
Neutral indicator (in operation switch panel)

This LED indicates following items.
LED check
Driving status (Neutral)
Operating status (2Hz: Actuator in operation, mechanism
standby)
Restrictions on operation (4Hz)
7B4-PDF4
Check 4WD warning light (in meter panel)

This light indicates following items.
Valve check
Faulty actuator limit SW, and fault of circuit related with the
limit switch
7B4-PDF5
4WD switch
Switch to transmit a switching command to the 2H, 4H,
Neutral, or 4L position.
It comprises 3 PUSH momentary switches. By keeping to push
the 2H and 4L switches for 10 seconds,
operation is instructed to the neutral position.
To shift from the neutral to other position, other required
switches should be pushed for 10 seconds.
825R300018
Transfer controller
Located below the right seat.
RTW37DLF000401
Legend
1. Transfer controller
2. Protector
3. Bolt
Transfer Acutuator
Method of confirming the actuator position detection
(limit) switch
The actuator indicates the continuity condition of combinations
as shown in the list below between the 4 detection (limit)
switch pins and GND pin along the direction of the notch of the
output shaft spline. Check that these combinations are as
specified.
The middle condition between these positions (4 patterns in
case of 2H-4H) is either of the combinations shown below
depending upon manufacturing variations of the switch plate.
2H
Direction of output
shaft notch (outline)
LS1
LS2
LS3
LS4
-54 to
-29
Close
Open
Close
Open
2H-4H
4H
-29 to 74
Close
Close
Close
Open
Open
Open
Close
Open
Open
Close
Close
Open
Open
Close
Close
Close
74 to
110
Open
Open
Close
Close
4H-N
110 to 179
Open
Open
Open
Close
Open
Close
Open
Close
N-L
4L
179 to
215
Open
Close
Open
Open
215 to
285
Close
Close
Open
Open
285 to
300
Close
Close
Open
Close
Continuity between each pin and GND pin. (Continuity also exists between CLOSE pins.)
Transfer Actuator Connector
7B4-PDF6

Method of checking the position detection switch harness
Disconnect the vehicle harness connector on the transfer
controller side and the vehicle harness connector on the
transfer actuator side as shown in the wiring diagram, and
check the continuity between the following connector pins and
that there is no continuity between those pins and GND or
power source.
Check that there is continuity between the GND pin and vehicle
GND on the transfer actuator and there is no continuity
between the GND pin and other power source.
RTW47DSF000301
Vehicle harness connector pin No. (connector of mating parts of the harness is shown in this figure)
Name of pin
LS1
LS2
LS3
LS4
GND
T/F controller side
T/F actuator side
R-14, 17
R-14, 6
R-14, 15
R-14, 14
R-15, 1, 9
5
4
7
6
8
Remarks
Function of Switch and indicator Lamp

Transfer-related indicator lamp and switch function
Actuator
detection
Check
Item
4WD
lamp
4L lamp
Neutral
lamp
4WD
warning
light
4WD
switch
(limit)
switches
LS1, LS2,
LS3. and
LS4
1 = on
Transfer
4WD
Transfer
neutral
switch
switch
SOF
actuator
switch
Or
Axle
Remarks
dummy
2 = off
2H
Off
Off
Off
Off
of
operation
Off
Off
Off
Off
Start of
operation
Blinking
(2HZ)
4H start
No
operation
1,0,1,0
Open
Open
Open
-----
1,0,1,0
Open
Open
Open
operation
sensor
Open
Open
Open
4H position
for 0.1
second
Switch
1,1,1,0
During
operation
(Synchro)
During
operation
Blinking
(2HZ)
Blinking
(Axle
drive)
(2HZ)
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
Off
No
operation
No
operation
No
0,0,1,0
0,1,1,0
0,1,1,1
1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1
2H to 4H
while
driving
2H to 4H
Open
Open
Open
using
synchro
and
retrial
0,0,1,1
Closed
Open
Open
Axle drive
0,0,1,1
Closed
Open
Open
Axle drive
0,0,1,1
Closed
Open
Closed
-----
for 0.1
second
0,0,1,1
Closed
Open
Closed
operation
sensor
operation
Axle
Blinking
waiting
(2HZ)
4H
On
Off
Off
Off
On
Off
Off
Off
On
Blinking
(2HZ)
Off
Off
No
operation
0,0,0,1
0,1,0,1
Closed
Open
Closed
Off
Blinking
(2HZ)
Off
Off
No
operation
0,0,0,1
0,1,0,1
Closed
Closed
Closed
4H to 4L
through
Closed
4H to 4L
through
Closed
4H to 4L
through
4L start
of
operation
Start of
operation
During
operation
Off
(N)
During
operation
Off
(N)
4L
waiting
4L
On
Blinking
(2HZ)
Blinking
(2HZ)
Blinking
(2HZ)
Off
Off
Off
Off
Off
Off
On
On
Off
Off
On
Off
Off
Off
4H start
of
operation
No
operation
4L position
(N)
During
operation
No
operation
No
operation
No
operation
No
operation
No
operation
Switch
0,1,0,0
4H to 4L
neutral
Closed
Closed
neutral
1,1,0,0
Closed
Closed
neutral
1,1,0,1
Closed
Closed
Closed
4H to 4L
while
waiting
1,1,0,1
Closed
Open
Closed
-----
1,1,0,1
Closed
Open
Closed
operation
sensor
4H position
for 0.1
second
while
driving
Switch

Actuator
Item
4WD
lamp
4L lamp
Neutral
lamp
Check
4WD
warning
4WD
switch
light
detection
(limit)
switches
LS1, LS2,
LS3. and
LS4
SOF
Transfer
Transfer
4WD
switch
neutral
switch
Closed
Open
1 = on
2 = off
During
operation
During
operation
On
Off
(N)
During
operation
4H
waiting
4H
Off
Off
Blinking
(2HZ)
Blinking
(2HZ)
Blinking
(2HZ)
Blinking
(2HZ)
Off
Off
Off
Off
Off
Off
Off
Off
On
Off
Off
Off
of
operation
On
Off
Off
Off
Start of
Blinking
operation
(2HZ)
2H start
During
operation
No
operation
No
operation
No
operation
No
operation
No
operation
1,1,0,1
actuator
switch
Or
Axle
dummy
Closed
4L to 4H
while
Closed
4L to 4H
through
Closed
4L to 4H
while
driving
1,1,0,0
Closed
Closed
neutral
0,1,0,1
0,0,0,1
Closed
Closed
driving
0,0,1,1
Closed
Closed
Closed
4L to 4H
while
waiting
0,0,1,1
Closed
Open
Closed
-----
0,0,1,1
Closed
Open
Closed
operation
sensor
Closed
Open
Closed
2H to 4H
while
driving
Open
Open
Closed
Axle drive
2H position
Off
Off
Off
for 0.1
second
No
operation
Remarks
Switch
0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0
0,1,1,1
Blinking
(2HZ)
Off
Off
Off
No
operation
Axle
waiting
Blinking
(2HZ)
Off
Off
Off
No
operation
1,0,1,0
Open
Open
Closed
Axle
waiting
2H
Off
Off
Off
Off
No
operation
1,0,1,0
Open
Open
Open
-----
(Axle)
0,1,1,0
0,0,1,0
1,1,1,0
2H to 4H retrial
Actuator
Item
4WD
lamp
4L lamp
Neutral
lamp
Check
4WD
warning
4WD
switch
light
detection
(limit)
switches
SOF
Transfer
Transfer
4WD
switch
neutral
switch
1,0,1,0
Open
Open
Open
-----
1,0,1,0
Open
Open
Open
-----
Open
Open
Open
2H to 4H
while
driving
LS1, LS2,
LS3. and
LS4
1 = on
2 = off
2H
Off
4H start
of
operation
Off
Start of
Blinking
operation
(2HZ)
Off
Off
Off
Off
Off
Off
Off
Off
Off
No
operation
4H
position
for 0.1
second
No
operation
actuator
switch
Or
1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1
Axle
dummy
During
operation
(Synchro)
(Go to 4H
Blinking
(2HZ)
Off
Off
Off
No
operation
1,1,1,0
0,0,1,0
0,1,1,0
2H to 4H
using
Open
Open
Open
1,0,1,0
Open
Open
Open
Return to
2H
1,0,1,0
Open
Open
Open
-----
0,1,1,1
if synchro
complete)
Remarks
synchro
and retrial
X2
Abandon
ed
operation
(2H)
Blinking
(4HZ)
Off
Off
Off
Off
Off
Off
Off
No
operation
2H
indication
after
10second
No
operation
Completion of transfer case H-L area and axle shift timing may cause some variation in 2Hz blinking pattern.

Operational limits (4H
4L)
(Vehicle speed, engine speed, and transmission position not specified)

Actuator
detection
Check
Item
4WD
lamp
4L lamp
Neutral
lamp
4WD
warning
light
4WD
switch
(limit)
switches
LS1, LS2,
LS3. and
LS4
1 = on
Transfer
4WD
Transfer
neutral
switch
switch
SOF
actuator
switch
Or
Axle
Remarks
dummy
2 = off
4H
4H start
of
operation
On
On
Off
Off
Off
Off
Off
Off
Open
4L
position
for 0.1
second
0,0,1,1
Closed
Open
Closed
-----
0,0,1,1
Closed
Open
Closed
-----
10
second
display
during
On
Blinking
(4HZ)
Off
Off
Open
0,0,1,1
Closed
Open
Closed
Off
Off
Open
0,0,1,1
Closed
Open
Closed
limitation
Go to 4H
after 10
seconds
On
Off
4H)
Operational limits (4L
Item
4L
4L start of
operation
4WD
lamp
On
On
4L lamp
On
On
On
Blinking
(4HZ)
Neutral
lamp
Off
Off
Check
4WD
warning
light
Off
Off
Actuator
detection
(limit)
4WD
switch
switches
LS1, LS2,
LS3. and
On
On
-----
Transfer
4WD
switch
Transfer
neutral
switch
1,1,0,1
Closed
Open
Closed
-----
1,1,0,1
Closed
Open
Closed
-----
LS4
1 = on
2 = off
No
operation
4H
position
for 0.1
second
SOF
actuator
switch
Or
Axle
dummy
Off
Off
Off
Off
Open
1,1,0,1
Closed
Open
Closed
1,1,0,1
Closed
Open
Closed
limitation
Go to 4L
after 10
seconds
during
limitation
(Vehicle speed, engine speed, and transmission position not specified)
10
second
display
during
No
operation
No
operation
Remarks
No
operation
during
limitation
-----
Under some conditions, a secondary operational indication may be received when the 4Hz operational indication
is present.

Skip operation
Actuator
detectio
Item
4WD
lamp
4L lamp
Neutral
lamp
Check
4WD
warning
light
4WD
switch
n (limit)
switches
LS1,
SOF
actuator
switch
Transfer
4WD
switch
Transfer
neutral
switch
1,0,1,0
Open
Open
Open
-----
1,0,1,0
Open
Open
Open
operation
sensor
Open
Open
Open
LS2,
LS3. and
LS4
Or
Axle
dummy
Remarks
1 = on
2 = off
2H
4L start of
operation
Off
Off
Off
Off
Off
Off
Off
Off
No
operation
4L
position
for 0.1
Switch
second
Start of
Blinking
Blinking
operation
(2HZ)
(2HZ)
Blinking
(2HZ)
Blinking
(2HZ)
During
operation
(Synchro)
Off
Off
No
operation
1,1,1,0
0,0,1,0
0,1,1,0
0,1,1,1
1,1,1,0
Off
Off
Off
Off
Off
Off
Off
Off
No
operation
0,0,1,0
0,1,1,0
0,1,1,1
2H to 4H
while
driving
2H to 4H
using
synchro
and retrial
Open
Open
Open
0,0,1,1
Closed
Open
Open
-----
No
operation
0,0,1,1
0,1,0,1
Closed
Open
Open
-----
Closed
Open
Closed
-----
operation
sensor
During
operation
(Passing
through
Off
Blinking
(2HZ)
No
operation
4H)
During
operation
(Passing
through
4H)
During
operation
(N)
Off
On
During
Blinking
(2HZ)
Blinking
(2HZ)
No
0,0,1,1
operation
0,1,0,1
Switch
On
Blinking
(2HZ)
Off
Off
No
operation
0,1,0,0
Closed
Open
Closed
On
Blinking
(2HZ)
Off
Off
No
operation
0,0,1,1
Closed
Open
Closed
while
driving
operation
(Axle
drive)
Blinking
(2HZ)
Blinking
(2HZ)
Off
Off
No
operation
0,0,1,1
Closed
Open
Open
-----
Off
Off
0,0,1,1
Closed
Open
Open
-----
Off
Off
No
operation
1,1,0,1
Closed
Closed
Closed
4H to 4L
while
Off
No
operation
1,1,0,1
operation
(N)
During
operation
(N)
4H to 4L
During
Axle
Blinking
Blinking
waiting
(2HZ)
(2HZ)
4L waiting
On
Blinking
(2HZ)
4L
On
On
Off
No
operation
waiting
Closed
Open
Closed
-----

Actuator
Item
4WD
lamp
4L lamp
Neutral
lamp
Check
4WD
lamp
detectio
n (limit)
switches
4WD
switch
LS1,
LS2,
LS3. and
Transfer
4WD
Transfer
neutral
switch
switch
LS4
1 = on
2 = off
SOF
actuator
switch
Or
Axle
dummy
2H
2H start of
operation
On
During
Blinking
Blinking
operation
(2HZ)
(2HZ)
During
operation
(Passing
On
Off
Off
Blinking
(2HZ)
Off
Off
Off
Blinking
(2HZ)
Off
Off
Blinking
(2HZ)
Off
During
operation
During
operation
(4H
Off
Off
through
N)
(Passing
through
N)
On
position
for 0.1
second
No
1,1,0,1
Closed
Open
Closed
Closed
Open
Closed
No
operation
1,1,0,0
Closed
Closed
Closed
Off
No
operation
0,1,0,0
Closed
Closed
Closed
Off
No
operation
0,0,1,1
Closed
Closed
Closed
During
operation
(Axle)
Blinking
(2HZ)
waiting for
start of H
shift
while
waiting for
start of H
Off
No
operation
Closed
Open
Closed
4L to 4H
through
4L to 4H
through
neutral
4L to 4H
0,1,1,1
Off
4L to 4H
while
driving
neutral
waiting)
Off while
Switch
operation
sensor
1,1,0,1
operation
Remarks
0,1,1,0
0,0,1,0
1,1,1,0
while
waiting
2H to 4H
while
driving
shift
During
operation
(Axle)
Blinking
(2HZ) at
end of H
Off at end
of H shift
Off
Off
No
operation
shift
0,1,1,1
0,1,1,0
0,0,1,0
Closed
Open
Closed
Axle
driving
1,0,1,0
Open
Open
Closed
-----
1,0,1,0
Open
Open
Open
-----
1,1,1,0
Axle
waiting
Blinking
(2HZ)
Off
Off
Off
No
operation
2H
Off
Off
Off
Off
No
operation
Completion of transfer case H-L area and axle shift timing may cause some variation in 2Hz blinking pattern.

Skip operation limitations (4L
2H)
specified)
(Vehicle speed, engine speed, and transmission position not
Actuator
Item
4WD
lamp
4L lamp
Neutral
lamp
Check
4WD
warning
4WD
switch
light
detection
(limit)
switches
SOF
Transfer
Transfer
4WD
switch
neutral
switch
1,1,0,1
Closed
Open
Closed
-----
1,1,0,1
Closed
Open
Closed
-----
LS1, LS2,
LS3. and
LS4
1 = on
2 = off
4L
Off
On
Off
Off
Open
actuator
switch
Or
Remarks
Axle
dummy
2H
4L start of
operation
10
second
display
during
limitation
Go to 4L
after 10
Off
On
Off
Off
position
for 0.1
second
No
Blinking
(4HZ)
Off
Off
Off
Open
1,1,0,1
Closed
Open
Closed
Off
ON
Off
Off
Open
1,1,0,1
Closed
Open
Closed
operation
during
limitation
-----
seconds
Skip operation limitations (2H

4L)
specified)
(Vehicle speed, engine speed, and transmission position not
Actuator
Item
4WD
lamp
4L lamp
Neutral
lamp
Check
4WD
warning
4WD
switch
light
detection
(limit)
switches
SOF
Transfer
Transfer
4WD
switch
neutral
switch
1,0,1,0
Open
Open
Open
-----
1,0,1,0
Open
Open
Open
-----
LS1, LS2,
LS3. and
LS4
1 = on
2 = off
2HL
Off
Off
Off
Off
Open
actuator
switch
Or
Remarks
Axle
dummy
2H
4L start of
operation
10
second
display
during
limitation
Go to 2H
after 10
Off
Off
position
for 0.1
second
Off
Off
Blinking
(4HZ)
Blinking
(4HZ)
Off
Off
Open
1,0,1,0
Open
Open
Open
Off
Off
Off
Off
Open
1,0,1,0
Open
Open
Open
No
seconds
Under some conditions, a secondary operational indication may be received when the 4Hz operational
indication is present.
operation
during
limitation
-----

2HNeutral2H
Actuator
detectio
n (limit)
switches
Check
Item
4WD
lamp
4L lamp
Neutral
lamp
4WD
warning
light
4WD
switch
LS1,
LS2,
LS3. and
Transfer
4WD
Transfer
neutral
switch
switch
LS4
1 = on
2 = off
2H
Neutral
start of
operation
Off
Off
Off
Off
Off
Off
Off
Blinking
(2HZ)
Off
Off
No
operation
Neutral
position
for 10
seconds
SOF
actuator
switch
Or
Axle
dummy
1,0,1,0
Open
Open
Open
-----
1,0,1,0
Open
Open
Open
Switch
operation
sensor
Open
Open
Open
1,1,1,0
Start of
operation
Off
During
operation
(Synchro)
During
operation
(Passing
Off
Off
Blinking
(2HZ)
Off
Off
No
operation
No
operation
0,0,1,0
0,1,1,0
0,1,1,1
1,1,1,0
0,0,1,0
0,1,1,0
Off
Off
Off
Off
Off
through
4H)
Blinking
(2HZ)
Off
No
operation
0,0,1,1
No
0,0,0,1
operation
0,1,0,1
No
operation
2H to 4H
while
driving
Open
Open
Open
0,1,1,1
Off
Remarks
2H to 4H
using
synchro
and retrial
Closed
Open
Closed
-----
Closed
Open
Closed
4H to 4L
while
driving
0,0,0,1
0,1,0,1
Closed
Closed
Closed
0,1,0,0
Closed
Closed
Closed
Switch
operation
sensor
0,1,0,0
Closed
Closed
Open
-----
0,1,0,0
Closed
Open
Closed
Switch
operation
During
operation
(Passing
through
Blinking
(2HZ)
Off
4H)
During
operation
(N)
During
operation
(N)
Off
Off
Neutral
Off
Off
Blinking
(2HZ)
Blinking
(2HZ)
On
Off
Off
Off
No
operation
No
operation
neutral
2H
2H start of
operation
Off
Off
On
Off
position
for 10
seconds
4H to 4L
through
sensor
During
operation
(Passing
through
Off
Blinking
(2HZ)
Off
Off
Off
Off
No
operation
0,1,0,0
Closed
Closed
Closed
0,1,0,1
0,0,0,1
Closed
Closed
Closed
4L to 4H
through
neutral
N)
During
operation
Off
Blinking
(2HZ)
No
operation
4L to 4H
while
driving

Actuator
detectio
n (limit)
switches
Check
Item
4WD
lamp
4L lamp
Neutral
lamp
4WD
warning
light
4WD
switch
LS1,
LS2,
LS3. and
Transfer
4WD
Transfer
neutral
switch
switch
LS4
1 = on
2 = off
SOF
actuator
switch
Or
Axle
dummy
During
operation
(4H
waiting)
During
operation
(Axle)
During
operation
(Axle)
Off
Blinking
(2HZ)
Blinking
(2HZ)
Off
Off
Off
Off
Off
No
operation
No
operation
0,0,1,1
Closed
Closed
Closed
(2HZ)
Off
Off
Off
No
operation
4L to 4H
while
waiting
0,1,1,1
0,1,1,0
0,0,1,0
2H to 4H
Closed
Open
Closed
Open
Open
Closed
1,1,1,0
Blinking
Remarks
0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0
while
driving
Axle
driving
Axle
waiting
Blinking
(2HZ)
Off
Off
Off
No
operation
1,0,1,0
Open
Open
Closed
-----
2H
Off
Off
Off
Off
No
operation
1,0,1,0
Open
Open
Open
-----
Operational restrictions (vehicle speed, engine speed, and transmission position) are applicable to transfer
shifts in both directions (HNeutralL).

4H
Neutral
4H
Item
4H
4WD
lamp
On
4L lamp
Off
Neutral
lamp
Off
Check
4WD
warning
light
Off
Actuator
detection
(limit)
4WD
switch
switches
LS1, LS2,
LS3. and
Transfer
4WD
switch
Transfer
neutral
switch
0,0,1,1
Closed
Open
Closed
-----
1,1,0,1
Closed
Open
Closed
-----
LS4
1 = on
2 = off
No
operation
Neutral
position
SOF
actuator
switch
Or
Axle
dummy
Remarks
Neutral
start of
operation
On
On
Off
Off
Start of
operation
Off
Off
Blinking
(2HZ)
Off
No
operation
1,1,0,0
Closed
Open
Closed
Off
Off
Blinking
(2HZ)
Off
No
operation
1,1,0,0
Closed
Closed
Closed
4L to N
with axle
Closed
4L to 4N
with axle
During
operation
(N)
During
operation
Off
Off
(N)
During
operation
(Axle)
Blinking
(2HZ)
Blinking
(2HZ)
Off
Off
Off
Off
for 10
seconds
No
operation
No
operation
4L to N
while
driving
driving
0,1,0,0
Closed
Closed
removed
0,1,1,1
0,1,1,0
0,0,1,0
1,1,1,0
Open
Open
Closed
Axle
driving
Axle
waiting
Blinking
(2HZ)
Off
Off
Off
No
operation
1,0,1,0
Open
Open
Closed
-----
Neutral
Off
Off
On
Off
No
operation
0,1,0,0
Closed
Closed
Open
-----
0,1,0,0
Open
Open
Open
Switch
operation
4H start
of
2H
Off
Off
Off
Off
operation
During
position
for 10
seconds
sensor
4L to 4H
Off
Blinking
(2HZ)
Off
Off
No
operation
1,1,0,0
Closed
Closed
Open
Off
Blinking
(2HZ)
Off
Off
No
operation
0,1,0,0
Closed
Closed
Open
During
operation
Off
Blinking
(2HZ)
Off
Off
No
operation
0,1,0,1
0,0,0,1
Closed
Closed
Open
4H
waiting
Blinking
(2HZ)
Off)
Off
Off
No
operation
0,0,1,1
Closed
Closed
Open
Blinking
(2HZ)
Off
Off
Off
No
operation
0,0,1,1
Closed
Open
Open
Axle
driving
Axle
waiting
Blinking
(2HZ)
Off
Off
Off
No
operation
0,0,1,1
Closed
Open
Open
-----
4H
On
Off
Off
Off
0,0,1,1
Closed
Open
Closed
-----
operation
(N)
During
operation
(N)
During
operation
(Axle)
No
operation
through
neutral
4L to 4H
through
neutral
4L to 4H
while
driving
4L to 4H
while
waiting


4L
Neutral
4L
Actuator
detection
Check
Item
4WD
lamp
4L lamp
Neutral
lamp
4WD
warning
light
4WD
switch
(limit)
switches
LS1, LS2,
LS3. and
LS4
1 = on
Transfer
4WD
Transfer
neutral
switch
switch
SOF
actuator
switch
Or
Axle
Remarks
dummy
2 = off
4L
Neutral
start of
On
On
Off
Off
No
operation
1,1,0,1
Closed
Open
Closed
-----
1,1,0,1
Closed
Open
Closed
-----
1,1,0,0
Closed
Open
Closed
4L to N
while
driving
Neutral
Off
Off
position
for 10
seconds
On
On
Off
Off
Off
Off
Blinking
(2HZ)
Off
No
operation
1,1,0,0
Closed
Closed
Closed
with axle
driving
Off
Off
Blinking
(2HZ)
Off
No
operation
0,1,0,0
Closed
Closed
Closed
with axle
removed
Blinking
(2HZ)
Off
Off
Off
No
operation
0,1,0,0
Closed
Closed
Closed
Axle
driving
Axle
waiting
Blinking
(2HZ)
Off
Off
Off
No
operation
0,1,0,0
Closed
Closed
Closed
-----
Neutral
Off
Off
On
Off
No
operation
0,1,0,0
Closed
Closed
Open
-----
0,1,0,0
Open
Open
Open
Switch
operation
operation
Start of
operation
During
operation
(N)
During
operation
(N)
During
operation
(Axle)
Blinking
(2HZ)
Off
No
operation
4L to N
4L to 4N
4L
4L start of
operation
Off
During
operation
(N)
4H
waiting
During
operation
(Axle)
Off
sensor
4H to 4L
Blinking
(2HZ)
Off
Off
No
operation
1,1,0,0
Closed
Closed
Open
Off
Blinking
(2HZ)
Off
Off
No
operation
1,1,0,0
Closed
Closed
Open
Off
Blinking
(2HZ)
Off
Off
No
operation
1,1,0,0
Closed
Closed
Open
On
Blinking
(2HZ)
Off
Off
No
operation
1,1,0,1
Closed
Closed
Open
Off
Off
Off
1,1,0,1
Closed
Open
Open
During
operation
(N)
On
Off
During
operation
(N)
Off
position
for 10
seconds
Blinking
(2HZ)
No
operation
through
neutral
4H to 4L
through
neutral
4H to 4L
through
neutral
4L while
waiting
Axle
driving
Axle
waiting
Blinking
(2HZ)
Off
Off
Off
No
operation
1,1,0,1
Closed
Open
Open
-----
4H
On
On
Off
Off
No
operation
1,1,0,1
Closed
Open
Closed
-----
Parts Location (RHD)
Parts Location (LHD)
RTW48AXF021601
PARTS LOCATION
RTW48AXF031701
CIRCUIT DIAGRAM (6VE1)
RTW48AXF007201
CIRCUIT DIAGRAM (C24SE)
RTW48AXF031601
CIRCUIT DIAGRAM (4JA1-TC/4JH1-TC)
RTW48AXF007101
CIRCUIT DIAGRAM (4JA1-L)
RTW48AXF028601
CONNECTOR LIST
No.
Connector face
B-24
Green
ECM
Meter-B
C-67
J/B I2
B-62
White
Connector face
C-57
(4JH1TC)
B-54
White
No.
Black
EHCU
C-94
(4JH1TC)
B-63
TCM
Gray
C-95
(6VE1)
White
B-64
Silver
Weld splice 1(Illumination)
White
J/B E2
C-108
Weld splice 2 (Ground)
White
J/B E1
C-109
B-66
White
TCM
C-107
B-65
Silver
White
4WD switch
C-2
Silver
Body-LH ; ground
C-118
(4JH1TC)
Silver
Engine room-RH ; Ground
C-36
White
C-119
(6VE1)
Silver
C-56
(4JH1TC)
Gray
Black
Auto cruise actuator
R-15
ECM
Black
Transfer controller
No.
Connector face
R-14
Black
Transfer controller
Natural
Green
E-35
(4JH1TC
C24SE)
Black
Engine ground
Neutral switch
Neutral switch
Motor actuator
White
Engine room ~ INST
White
Engine room ~ INST
Gray
H-23
(4JA1-L)
Engine room B ~ T/mission

H-29
(4JH1M/T)
4WD switch
White
H-31
(6VE1)
H-L neutral switch
White
Battery (+) ~ Engine room C
Engine room ~ T/mission
H-32
E-51
Black
H-22
(4JA1/H
1-M/T)
E-46
Brown
White
H-7
E-45
White
Battery (+) ~ Engine room
H-6
E44
Gray
White
H-4
(4JH1)
E-11
(4JH1)
(C24SE)
Natural
Green
E-12
(4JH1)
(C24SE)
Connector face
H-3
(4JH1A/T)
E-10
Silver
No.
Inhibiter switch
Withe
Engine room ~ Rear body
P-1
E-61
(6VE1)
Black
ECM
Silver
Battery (+)
No.
Connector face
P-2
Silver
Relay & Fuse box
P-5
Silver
Battery (-)
P-6
Silver
Body earth (Ground)
P-10
Silver
Engine ground
P-13
(4JH1)
Gray
Shift on the fly actuator
R-14
Black
2-4WD Control unit
R-15
Black
2-4WD Control unit
No.
Connector face
Diagnosis
Before determining a trouble (Non-trouble mode)
1. When shifting from 2H to 4H:
1-1-1 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Shft on the fly)
If the load is too large to shift the gears synchronously, the operation is repeated up to 3 times. If the shifting
is not effected after being repeated 3 times, the indicator frequency is changed from 2Hz to 4Hz and, at the
same time, the actuator condition is changed to 2H, indicator flashes at 4Hz for 10 seconds, and then goes
out.
Cause of excessive synchronous shifting load
Extremely low temperature (the oil viscosity of the front differential increases requiring a large load for
synchronization)
High speed (since the difference of relative revolutions of gears to be shifted synchronously is too large,
required work load per unit time becomes larger).
Step 1-1-1:
Stop the vehicle or decrease the speed and operate as required again.
1-1-2 When the flashing frequency of the 4WD indicator is changed from 2Hz to 4Hz (Rigid and free wheel
Hub) / Block out of meshing spline.
Step 1-1-2:
Run the vehicle forward and backward several meters and operate as required again.
1-2 When the flashing of 4WD indicator at 2Hz continues more than 11.5 seconds (repetition of 3 times of
above No.1 is counted) (Shift on the fly)
If there is difference of revolutions and phases between the front wheel and axle, connecting the front wheel
and axle is difficult.
Until shifting in the transfer and connection of the front wheel and axle are completed*, the indicator flashes
at a frequency of 2Hz. In the above case, the indicator continues flashing at a frequency of 2Hz until the
connection of the front axle is completed. (If the shifting in the transfer is not completed, the flashing
frequency is changed to 4Hz (above No.1).)
By correcting the difference of relative revolutions and deviation of phases, the shifting can be completed.
Step 1-2:
While the vehicle is running, make sure of safety around the vehicle and accelerate or decelerate the
vehicle while going straight.
When the vehicle is at a stop, run the vehicle forward and backward several meters.
2. When shifting from 4H to 2H

2-1 When 4WD indicator continues flashing at 2Hz
When shifting from 4H to 2H, the 4WD indicator continues flashing at 2Hz until separation in the transfer and
the separation of the front wheel axle are completed*. When torsional torque is accumulated in the drive
system, separation in the transfer and separation of the front axle* is difficult. In such a case, they can be
separated by removing the torsional torque of the drive system.
Step 2-1:
While the vehicle is running, make sure of safety around the vehicle and accelerate or decelerate the
vehicle while going straight.
When the vehicle is in stop, run the vehicle several meters forward and backward.
*: Shift on the fly only.
3. Shifting from 4H to 4L
3-1 When the 4L indicator flashes at 2Hz
When shifting from 4H to 4L, the 4L indicator continues flashing at 2Hz until shifting in the transfer case is
completed. The phases of the engaged splines may sometimes deviated preventing completion of shifting.
By correcting the deviation of phases, shifting is completed.
Step 3-1:
(In case of AT):
(In case of MT):
Set the select bar of the transmission to the D position.

Set the lever of the transmission to a position allowing running and engage the clutch
gently.
At this time, some rotating force acts on the engaged splines, phase is corrected and the engagement is
completed.
3-2 When the 4L indicator flashes at 2Hz for 10 seconds and then keeps ON again (AT vehicle)
This condition occurs when torsional torque has been generated between the transmission and road surface
and the transfer standby mechanism cannot absorb it completely.
Step 3-2:
Set the select lever of the transmission to the N position. (Stepping on the brake pedal is effective at
this time.)
3-3 When the 4L indicator flashes at a frequency of 4Hz
Shifting from 4H to 4L is restricted.
When the vehicle is running, the transmission lever is at the running range and the engine speed is high (L4:
3000rpm or more V6: 2000rpm), the transfer cannot be shifted from 4H to 4L (restriction on operation).
Restriction on operation (Except 4JA1-LT)
The 4H, neutral and 4L shifting mechanism has no synchronization function. Therefore, if relative rotations in the
mechanism become excessive, shifting exerts adverse influence on the internal mechanism of the transfer. To
avoid such a trouble, vehicle condition is detected to restrict the operation (vehicle speed, engine speed and TM
position).
Requirement to restrict the speed: Vehicle should be in stop.
For the reason of the detection logic, time to wait for start of operation may be required.
A/T: If the vehicle is in stop for a long time at the TM running range (D, 1, 2) before operating the AT, waiting
time becomes longer (from 1 second to 3 minutes at the maximum).
M/T: If the vehicle is at stop with the clutch stepped on at the T/M running position (1 R), the time to wait
becomes longer.
Waiting time means the time commencing from when other requirements (engine speed and T/M position) are
met to permission of the speed restriction. Operation during the waiting time is not permissible.
The waiting time is 1 second at the minimum and increases up to 5 seconds if the above condition continues 3
minutes. After that, the waiting time increases up to 3 minutes in 2 minutes.
When it is clear that the above condition has continued and reduction of waiting time is desirable, turn on or off
the ignition or start and stop the vehicle several meters.
Requirements for permission of restriction on engine speed: Engine speed should be decreased.
The engine speed of 3000rpm (V6: 2000rpm) or below is advisable.

Requirements for permission of restriction on T/M position restriction:
(AT) N range is recommendable

(MT) should be at the neutral.
These requirements for permission should be all met before the switch is operated. If the requirements are met
after operation, operation is not automatically effected but re-operation is required after permission is given.

Restriction on operation (4JA1-LT)
The 4H, neutral and 4L shifting mechanism has no synchronization function. Therefore, if relative rotations in the
mechanism become excessive, shifting exerts adverse influence on the internal mechanism of the transfer. To
avoid such a trouble, vehicle condition is detected to restrict the operation (vehicle speed, and TM position).
Requirement to restrict the speed: Vehicle should be in stop.
Requirements for permission of restriction on engine speed: Engine speed should be decreased.
The engine speed of 3000rpm (V6: 2000rpm) or below is advisable.

Requirements for permission of restriction on T/M position restriction:
should be at the neutral.

These requirements for permission should be all met before the switch is operated. If the requirements are met
after operation, operation is not automatically effected but re-operation is required after permission is given.
Note: Dont accelerate engine speed a the time of this operation.
Step 3-3:
Stop the vehicle. (Close the accelerator and decrease the engine speed to below L4: 3000rpm, V6:
2000rpm.)
(In case of AT): Set the transmission select lever to the N position.
(In case of MT): Set the transmission lever to the neutral position. (Stepping on the clutch is
recommendable.) Push the 4L button.
If shifting operation is not completed (the lamp flashes at 2Hz), perform the step 3-1.
4. Shifting from 4L to 4H
4-1 When 4L indicator continues flashing at 2HZ
When shifting from 4L to 4H, the 4L indicator continues flashing at 2Hz until the shifting in the transfer case is
completed. Phases of engaged splines may deviate and the operation may not completed in some cases.
Shifting is completed by correcting the deviation of the splines.
Step 4-1: (same as step 3-1)
(In case of AT):
Set the transmission select lever to the D position.
(In case of MT):
Shift the transmission lever to a position allowing running and engage the clutch
gently.
4-2 When the indicator continues flashing at 2Hz for 10 seconds and then keeps on at 4L again (AT
vehicle)
This condition occurs when torsional torque has generated between the transmission and the road surface
(use of the parking position on a slope) and resistance against the separation of the driving force cannot be
fully by the waiting mechanism of the transfer.
Shifting is possible by using the brake also at the neutral position of the transmission
Step 4-2: (Same procedure as the step 3-2)
Set the transmission select lever to the N position.
(Leaving the brake lever and stepping it again is recommendable.)
4-3 When the 4L indicator flashes at 4HZ
Shifting from 4L to 4H is restricted.
When the vehicle is running, transmission lever is at the running range, and the engine speed is high, the
transfer 4L cannot be shifted to 4H.

Step 4-3: (Same procedure as the step 3-3)
Stop the vehicle (close the accelerator and decrease the engine speed to L4: 3000rpm V6: 2000rpm or
below).
(In case of AT):
Set the transmission select lever to the N position.
(In case of MT):
Set the transmission lever to the neutral position (stepping on the clutch lever is
recommendable).
Push the 4H button.
If the shifting is not completed (indicator flashes at 2Hz), go to the step 4-1.
5. When shifting from 4H or 4L to neutral

(Same procedure is required when shifting from 2H but in such a case, requirements for shifting from
2H to 4H are also applied.)
5-1 Neutral indicator continues flashing at 2Hz
The neutral indicator continues flashing at 2Hz until 4H (4L) is completely separated in the transfer. If
torsional torque has accumulated between the transmission and road surface, separation may be difficult.
Step 5-1:
If the operation is not completed, execute the step 7 for confirmation.
(In case of AT):
Set the transmission select lever to the D position.

After confirming that the gears are at the neutral position, return the lever to the N
position.
(In case of MT):
Set the transmission lever to a vehicle running position and engage the clutch gently.
After confirming that the gears are at the neutral position, return the lever to the
neutral position
5-2 When the neutral indicator flashes at 4Hz

As in the case of shifting from 4L to 4H, restriction is imposed to the operation from 4L or 4H (including 2H).
If the transmission lever is at a running range and engine speed is high (L4: 3000rpm, V6: 2000rpm or more)
while the vehicle is running, operation from the 4L or 4H (including 2H) of the transfer to the neutral is
impossible (restriction on operation).
Step 5-2:
Stop the vehicle.
(In case of AT):
Set the transmission select lever to the N (or P) position.
(In case of MT):
Set the transmission lever to the neutral position (at this time, stepping on the clutch
is recommended).
Keep pushing the 2H and 4L button for 10 second.

Follow the start procedure for confirmation. (Confirmation of drive force not transferred; same as in the
step 5-1)
After the confirmation, set the transmission to the neutral position in case of MT or to the neutral
position in case of AT.
6. When shifting from neutral to 2H, 4H or 4L

6-1 When the 4L indicator or 4WD indicator flashes at 2Hz
Indicator flashing at 2Hz indicates that the engagement of the splines has not completed because of
deviation of the spline phases. By eliminating such a deviation, shifting is completed (same as in the step 3-1
and 4-1).
6-2 When the 4L indicator or 4WD indicator flashes at 4Hz
As in the case of shifting from 4L to 4H, restriction is imposed to the operation to 4L or 4H (including 2H). If
the transmission lever is at a running range and engine speed is high (3000rpm or more) while the vehicle is
running, operation from neutral of the transfer to the 4L or 4H (including 2H) is impossible (restriction on
operation).
Step 6-2:
Stop the vehicle.
(In case of AT):
Set the transmission select lever to the N (or P) position.
(In case of MT):
Set the transmission lever to the neutral position (at this time, stepping on the clutch
is recommended).
Keep pushing the4H or 4L or 2H button for 10 second.
Trouble diagnosis based on the operation switch, transfer indicator lamp and operating
sound Check 4WD indicator ON (operation guard based on the transfer actuator
position detection error)
This condition indicates a faulty circuit related with the detection (limit) switches of the system actuator.
Detection (limit) switches detect the actuator operating angle based on their combinations.
The controller monitors transition of the actuator based on the combination of the detection (limit) switch output.
If the transition based on the combinations indicates some trouble, it is memorized, shifting operation is stopped
when the trouble is counted 5 times, and the Check 4WD indicator lights up. At this time, the system permits
operation to 2H only.
When such a condition results, inspection of the transfer shift actuator, check of harness related with the
detection (limit) switch, and erasure of the memory of the controller are required.
(Refer to the memory erasure procedure for the erasure of the memory.)
At this time, the position indicator may flash at 4Hz. It means that a detection (limit) switch trouble wad
detected in the operation process shown by that position indicator (example: 4WD indicator when shifting from
2H to 4H).
Caution:
In the course of trouble diagnosis and correction, do not turn ON the ignition with the harness connector of
the transfer actuator disconnected. (Do not disconnect the harness connector of the transfer actuator
when the ignition is ON.)
If the controller is connected at this condition, a limit SW trouble is judged and the above-described
Check 4WD condition is brought about.
This can be reset by clearing the memory.
When it is required to disconnect the harness connector of the actuator and turning the ignition ON,
remove the controller at the same time or remove the IG power fuse of the transfer controller.
Memory erasing procedure

1. Prepare two pieces of short harness with the end sharped
like a needle (bout 20cm(7.9 in) long).
2. Turn OFF the ignition.
3. Remove the front left seat ASM.
4. Make the controller under the front left seat ASM (spread
the cut of the floor carpet).
5. Keeping the connector of the transfer controller connected,

set the short harness from the back of the connector as
illustrated.
6. Turn ON the ignition, wait for 2 seconds, and turn OFF the
ignition after confirming the relay sound.
7. Disconnect the short harness, turn ON the ignition again,
and confirm the Check 4WD lamp in the meter panel is
OFF.
8. Before erasing the memory, check that the circuit of the T/F
actuator position detection harness, etc. for it are normal.
Transfer Controller Pin Assignment
RTW47DSF000101
Diagnosis from symptom

Check4WD lighting up
Step
1
Action
Check what was done before
the trouble occurred.
Was the harness between the
transfer controller and actuator
disconnected with the ignition
kept ON for the purpose of
servicing the vehicle, etc.?
Or, was the ignition turned ON
(power supplied to the transfer
controller) with the harness of
the actuator removed?
Is the ignition switch ON?
Yes
If the power is supplied with the
actuator not connected, faulty
position detection switch is
considered.
Clear the memory and trace this
chart from the beginning.
Does the transfer-related

indicators (4WD, 4Lo, Check
4WD, neutral) light up for 2
seconds when the ignition
switch is turned ON?
Isnt the harness between the
Check4WD indicator and
transfer controller GND shorted?
Go to step 4.
Check the continuity of harness

between the transfer controller
and transfer actuator. Check
the power short and GND short.
Check the GND harness of the
transfer actuator.
Is a trouble noticed?
Check the limit switch of the
actuator.
Is a trouble noticed?
Go to step 3.
GND (body) short of the indicator

harness.
After repairing, trace this chart
from the beginning.
Repair the harness, clear the
memory and trace this chart from
the beginning.
Turn the ignition switch ON and

trace this chart from the
beginning.
Indicator lamp burnt out.
Disconnected harness wire .
from the beginning.
Go to step 5.
Go to step 6.
Clear the memory and trace this

Failed controller.
Replace the controller, clear the
memory and trace this chart from
the beginning.
To check the operation after completing the repair and clearing the memory, shift between 2H and 4L 5 times at
least.
To judge the condition more quickly, ask the customer the situation when the Check4WD lamp lighted up.
When the position indicator blinks at a frequency of 4Hz immediately after occurrence of a trouble, position of
failure which the indicator shows may be limited.
(Since it indicates the situation immediately before detection of failure whether the vehicle is running or standstill so
that possibility of failure around that point is high.)
Status of the transfer when the Check4WD lights up is not always the same. Immediately after occurrence of the
failure, 2H can be operated.
6
Failed actuator. Replace the

actuator, clear the memory and
beginning.
No
Go to step 2.
Cannot shift from 2WD to 4H or 4L.

When shifting from 2H to other position, the indicator (4WD, 4Lo, Check4WD, neutral)
does not respond.
Step
1
Action
Go to step 2.
Yes

Failed operation switch. Only 2H

is stuck at ON condition and 4H4L position is internally
disconnected. Or,
Failed controller
No
beginning.
Disconnected harness wire .
from the beginning.
Even after correction step 1-1(*), 4WD indicator blinks at 4Hz and changes to 2H after 10
seconds.
Step
1
Action
Yes
Go to step 2.

After 2 seconds, check that the
Check4WD lamp is ON or OFF.
Is the Check4WD lamp OFF?
Go to step 3.
Press the 4H button.

Is sound of relay heard from the
transfer control?
Is the sound of running motor
heard?
Go to step 5.
Go to step 4.
Failed control system of the

transfer mechanism. Check and
repair and trace this chart from
the beginning.
*Before determining a trouble (Non-trouble mode)
No
beginning.
Disconnected harness wire.
from the beginning.
Failed actuator position detection
switch (LS1, LS2, LS3, LS4,
GND).
Short or disconnection of harness
of this detection switch.
from the beginning.
Failed controller.
Replace the controller and trace
this chart from the beginning.
Failed actuator motor.
Disconnected controller motor
drive output circuit, GND short
circuit. +B fuse blown out.
Disconnection of that harness.
from the beginning.
Even after the correction step 1-2(*), the 4WD indicator still blinks at 2Hz when shifting
from 2H to 4H.
Step
1
Action
Check the air pressure and wear
of all the tires. Is any trouble
noticed?
Check the 4WD detection switch
on the transfer case, neutral
detection switch and each
harness. Is a trouble noticed?
Is there continuity in the harness

and front axle actuator? Isnt a
body short or disconnection
noticed?
Is a trouble noticed in the axle
detection harness between the
axle actuator and transfer
controller?
Yes
After adjusting the air pressure
and repairing the tire worn away,
try the correction step 1-2(*).
4WD detection switch is open or
the harness failed.
The neutral detection switch is
closed or the harness GND is
shorted.
Replace or repair and then trace
Go to step 4.
Disconnected harness.
After repairing trace this chart
from the beginning.
No
Go to step 2.
Go to step 3.
Body short or disconnection of

the harness between the transfer
controller and front axle actuator.
from the beginning.
Malfunction of axle actuator.
Refer to the paragraph of the
axle disconnect.
from the beginning.

Note:
The vehicle of manual hub and rigid hub dont have axle actuator.
When the above-mentioned procedure is followed, check the harness between the axle dummy output terminal and
the axle switch input terminal of transfer controller instead of axle actuator.
After operation, indicator of target position blinks for 1.5 sec. at 2Hz, return to 2H
condition (4WD indicator going out)
Step
1
Action
Keep to press the 4H button
(about 10 seconds).
Does the 4WD indicator blink at
2Hz for 15 seconds and then
blink at 4Hz?

Is the sound of relay heard from
the transfer controller?
heart?
Yes
Disconnection of controller motor
drive output circuit, or GND short.
+B fuse blown out.
Disconnection of that harness.
from the beginning.
Go to step 3.

the beginning.
No
Go to step 2.
Failed controller.
Disconnection or GND short of
controller motor drive output
circuit.
from the beginning.
Transfer cannot shift to a position other than 4H.

When shifting from 4H to other position, indicator (4WD, 4Lo, Check4WD, neutral) does
not respond (Only 4WD keeps lighting).
Step
1
Action
Yes
Go to step 2.

Then, only 4H lights up.
Go to step 3.

under the seat, and the sound of
running motor heard?
Failed controller.
After replacing the controller,
beginning.
No
Failed 4WD indicator and
harness.
from the beginning.
Indicator lamps other than the
4WD indicator are burnt out.
(Check for GND short circuit
between the 4WD indicator and
transfer controller.)
from the beginning.
*Failed operation switch. Or
disconnected or shorted of the
harness for the operation switch.
* The operation switch is an analog type switch which reads the internal composite resistance value at the time of
operation. If an abnormal value is detected, it is judged to be an instruction to 4H.
Even after the correction step 2-1(*), the 4WD indicator still blinks at 2Hz when shifting
from 4H to 2H.
Step
1
Action
Check all the tires for air
pressure and wear. Is any
trouble noticed?
Check the 4WD detection switch
on the transfer case and neutral
detection switch and each
harness. Is a trouble noticed?
Is there continuity in the harness

and axle actuator?
Isnt short or disconnection
noticed?
Isnt the connection mistaken?
Is a trouble noticed in the axle
detection harness between the
axle actuator and transfer
controller?
Yes
After adjusting the air pressure
and repairing the tire worn away,
try the correction step 2-1(*).
4WD detection switch is closed
or the GND short of harness.
The neutral detection switch is
closed or the harness GND is
shorted.
Replace or repair and then trace
Go to step 4.
GND short of harness
No
Go to step 2.
Go to step 3.
Body short, disconnection or

incorrect connection of the
harness between the transfer
controller and actuator.
from the beginning.
Malfunction of axle actuator.
Refer to the paragraph of axle
disconnect.
from the beginning.

Note:
The vehicle of manual hub and rigid hub dont have axle actuator.
When the above-mentioned procedure is followed, check the harness between the axle dummy output terminal and
the axle switch input terminal of transfer controller instead of axle actuator.
Though the indicator responds when shifting from 4H to 2H(or other position), it returns
to 4H.
Step
1
Action
Yes
Go to step 2.

After 2 seconds, check if the
Check4WD lamp lights up.
Is the Check4WD lamp OFF?
Go to step 3.

the transfer controller?
heart?
Go to step 5.
Go to step 4.

the beginning.
No
beginning.
from the beginning.
Failed actuator position detection
(limit) switch (LS1, LS2, LS3,
LS4, GND).
Short or disconnection of harness
of this detection switch.
Refer to paragraph of
Check4WD.
from the beginning.
Failed controller.
Disconnection of controller motor
drive output circuit or GND short.
from the beginning.
If the motor does not or cannot run at all (stuck transfer mechanism, disconnected motor, failed drive circuit), the
lamp blinks at 4Hz when the position is shifted to other position by pressing the button for more 10 seconds (20
seconds in case of neutral position).
From 4H to 4L; Even after the correction step 3-3(*), 4Lo indicator blinks at 4Hz
Step
1
2
Action
Turn ON the ignition switch and
check the valve. Do not start
the engine.
Has the valve check for 2
seconds been completed
normally?
Shift to 2H.
Can be shifted to 2H and then to
4H?
Yes
Turn it OFF once.
Go to step 3.
No
Go to step 2.
Refer to the paragraph about the
indicator when it does not react
when shifted from 2H to 4H.
After taking the remedy, trace
Go to step 4.
Set to N position in case of AT

and set to the neutral position in
case of MT and check if the
lamp blinks at 4Hz after
operation.
Start the engine and travel the

vehicle.
Does the speedometer run at
this time?
Failed T/M position switch and

harness (failure of TM1 and TM2
harness and their related
switches shown in the figure).
Incorrect wiring.
Repair as required and trace this
Go to step 6.
Refer to the paragraph about

shifting from 2H to 4H.
In particular, check if not at the
Check4WD condition, return to
this chart and trace it from the
beginning.
Shift back to 4H and go to step 5.
Check the harness between the Failed harness between the

transfer controller and speed
sensor.
sensor.
(Check the engine rotation
from the beginning.
detection harness at the same
(Repair the engine rotation
time.)
detection unit, if required.)
Is any trouble noticed?
Failed controller.
Travel the vehicle several
7
meters, stop it, meet the
permission requirements for
operation limits.
Did you wait for several seconds
after the requirements were
met?
6
Failure of speed sensor or

disconnection or short of harness
(for the meter).
from the beginning.
Go to step 7.
You did not wait for enough time.

Optimum waiting time is 1
second or maximum 3 minutes
depending on the previous
conditions.
operation without failure.
From 4L to 4H: After the correction step 4-3(*), 4Lo indicator blinks at 4H.
Step
1
2
Action
check the valve. Do not start
the engine.
normally?
4L?
Yes
Turn it OFF once.
Go to step 3.
No
Go to step 2.
when shifted from 2H to 4H.
Go to step 4.
(Impossible usually.)
Failed controller

case of MT and check if the
lamp blinks at 4Hz after
operation.

vehicle.
Does the speedometer run at
this time?

Incorrect wiring.
Go to step 6.
In case of Check 4WD, shifting to

2H is possible.
Returning to 4L is impossible.
Check4WD.
Press the operation switch of 4L
and go to step 5.
Check the harness between the Failed harness between the

sensor.
sensor.
from the beginning.
time.)
Failed transfer controller.
Travel
the
vehicle
several
7
operation limits.
after the requirements were
met?
6

(for the meter).
from the beginning.
Go to step 7.

conditions.
To neutral: After the correction step 5-2(*), neutral indicator blinks at 4Hz.
Check the function between H and L according to the chart for 4L to 4H instead of check
for the requirements of neutral.
Step
1
2
Action
check the valve. Do not start the
engine.
normally?
4L?
Yes
Turn it OFF once.
Go to step 3.

case of MT and check if the lamp
blinks at 4Hz after operation.

vehicle.
Does the speedometer run at this
time?

Incorrect wiring.
Go to step 6.
Check the harness between the

sensor.
time.)
Travel the vehicle several
operation limits.
after the requirements were met?
Go to step 4.
(Impossible usually.)
Failed controller
Failed harness between the

sensor.
from the beginning.
Failed controller.
No
Go to step 2.
when shifted from 2H to 4H
(7D1-37).
shifting from 2H to 4H.
In particular, check if not at the
Check4WD condition, return to
this chart and trace it from the
beginning.
In case of Check4WD, shifting to
2H is possible.
Returning to 4H is impossible.
Check4WD.
Shift back to 4H and go to step 5.

(for the meter).
from the beginning.
Go to step 7.

conditions.

For shifting to neutral, 2H and 4L switches should be kept pressed at the same time for 10 seconds.
For shifting from neutral to other position, 2H, 4H or 4L switch should be kept pressed for 10 seconds.
When shifting from neutral to other position, the lamp blinking at 2Hz indicates active condition.
When the lamp keeps blinking at 2Hz, follow the step for the case when the lamp keeps blinking at 2Hz when
shifting between positions.
No. TFT150-WE-0431
WORKSHOP MANUAL
TF SERIES
TRANSMISSION
AW30-40LE MODEL
SECTION 7A
TRANSMISSION CONTROL SYSTEM (AW3040LE) (V6 3.5L) 7A2-1
TRANSMISSION
TRANSMISSION CONTROL SYSTEM (AW3040LE) (V6 3.5L)
CONTENTS
Service Precaution ................................................. 7A2-2
General Description ............................................... 7A2-2
Electronic Control Diagram ............................... 7A2-3
Transmission Control Module (TCM) (1/2)...... 7A2-4
Transmission Control Module (TCM) (2/2)...... 7A2-5
TCM Point Table ................................................. 7A2-6
TCM Voltage & Resistance Check Sheet ....... 7A2-7
Control System Diagram.................................... 7A2-9
Control and Functions ........................................ 7A2-10
Gear Shift Control 3rd start ............................... 7A2-10
Mode Type ........................................................... 7A2-10
Mode Selection.................................................... 7A2-10
Comparison of mode .......................................... 7A2-11
3rd start Mode ..................................................... 7A2-11
Backup Mode....................................................... 7A2-11
Functions of Input / Output Components ........ 7A2-12
CAN bus systems in automatic transmission
control (AW30-40LE) ........................................ 7A2-13
High speed CAN bus.......................................... 7A2-13
Diagnosis................................................................. 7A2-13
Electronic Diagnosis ........................................... 7A2-13
Check Trans Indicator ........................................ 7A2-13
On Board Diagnostic Check.............................. 7A2-13
"Check Trans" Check ......................................... 7A2-14
Tech 2 OBD Connection.................................... 7A2-17
Snapshot Display With TIS2000 .................. 7A2-23
Service Programming System (SPS)............. 7A2-27
OBD Diagnostic Management System ............ 7A2-30
16 - Terminal Data Link Connector (DLC) ...... 7A2-31
Clear DTC ............................................................ 7A2-32
DTC Check .......................................................... 7A2-32
TCM Precaution .................................................. 7A2-32
Information On TCM........................................... 7A2-32
TCM Diagnostic Trouble Codes........................ 7A2-33
DTC P0560 (FLASHING CODE 25)
System Voltage Error ........................................... 7A2-34

Transmission Control Module (TCM)
Programming Error ................................................7A2-36
Transmission Range Sensor Circuit
Malfunction .............................................................7A2-38
Transmission Oil Temperature Sensor
Circuit Low Input ....................................................7A2-42
Transmission Oil Temperature Sensor
Circuit Hight Input ..................................................7A2-45
Input Speed Sensor Signal Error.........................7A2-48
Output Speed Sensor Signal Error .....................7A2-51
Torque Converter Clutch Electrical .....................7A2-54
Pressure Control Solenoid Electrical ..................7A2-57
Shift Solenoid S1 Electrical ..................................7A2-60
Shift Solenoid S2 Electrical ..................................7A2-63
ECM CAN Invalid...................................................7A2-66
Transmission Control Module ROM
Checksum Error .....................................................7A2-69
Transmission Control Module RAM
Error.........................................................................7A2-71
DTC U2104 (FLASHING CODE 65)
CAN BUSS OFF ....................................................7A2-73
7A2-2 TRANSMISSION CONTROL SYSTEM (AW3040LE) (V6 3.5L)
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.
parts and systems.
General Description
The AW30-40LE is a 4speed fully automatic
transmission. It uses a microcomputer as a control unit
to judge running conditions including throttle opening
rate and vehicle speed, then it sets the shifting point in
the optimum timing so that best driving performance
can be achieved.
In addition, the builtin shift mode select function can
select three shift modes according to the driver's
preference:
Normal mode Normal shift pattern.
3rd Start mode Starts in 3rd gear to reduce
slippage on ice or snow.
Power mode has a delayed up shift when more
powerful acceleration is required.
Also, the builtin failsafe function (backup mode")
assures driving performance even if the vehicle speed
sensor, throttle signal or any solenoid fails.
Further, the selfdiagnostic function conducts diagnosis
in a short time when the control system fails, thus
improving serviceability.
The major features of AW30-40LE are as follows:
A compact structure consisting of 2 sets of planetary
gears and flat torque converter.
Electronic control selects the optimum shift mode
according to the driving conditions.
Electronic control maintains the optimum hydraulic
pressure for clutch, band brake as well as
transmission so that shift feeling is improved.
Two sets of planetary gears reduce friction of power
train.
Also, a lockup mechanism in the torque converter
reduces fuel consumption.
Wide gear ratio and high torque rate of torque
converter provide excellent starting performance.
Electronic Control Diagram
RTW37AXF000101
Transmission Control Module (TCM) (1/2)
RTW48AXF028101
Transmission Control Module (TCM) (2/2)
RTW48AXF003101
TCM Point Table
RTW37ASF000101-1
PIN No.
SIGNAL NAME
PIN No.
SIGNAL NAME
A1
GND
B1
NEUTRAL START SW (R)
A2
PRESSURE CONTROL SOLENOID GND
B2
POWER LAMP
A3
B3
CHECK TRANS LAMP
A4
PRESSURE CONTROL SOLENOID
B4
PATTERN SELECT SW (3rd START)
A5
L-up SOLENOID
B5
SPEED SENSOR (+)
A6
STARTER SW(IG1)
B6
INPUT REVOLUTION SENSOR (+)
A7
CAN COMMUNICATION (-)
B7
NEUTRAL START SW (D)
A8
B8
NEUTRAL START SW (N)
A9
B9
NEUTRAL START SW (3)
A10
B10
3rd START LAMP
A11
T/M OIL TEMPERATURE SENSOR
B11
OIL TEMPERATURE WARNING LAMP
A12
T/M OIL TEMPERATURE SENSOR GND
B12
DIAGNOSIS TERMINAL
A13
B13
PATTERN SELECT SW (POWER)
A14
B14
SPEED SENSOR (-)
A15
SHIFT SOLENOID (S2)
B15
A16
SHIFT SOLENOID (S1)
B16
A17
CAN COMMUNICATION (+)
B17
INPUT REVOLUTION SENSOR (+)
A18
B18
NEUTRAL START SW (L)
A19
B19
NEUTRAL START SW (2)
A20
B20
NEUTRAL START SW (P)
A21
B21
TRANSMISFER LOW 4 SW
A22
B22
BRAKE LAMP SW
A23
GND
B23
DIAGNOSIS OUT PUT
A24
BATTERY
B24
B25
B26
CRUISE CONTROL UNIT
TCM Voltage & Resistance Check Sheet

CHECK ITEM
PIN No.
VALUE
NOTE
VIGN
A6A1
VIGN
Key ON
A6A23
VIGN
Key ON
Backup Power Supply
A24A1
+B (Always)
Inhibitor (Select) SW P
B20A1
P Range
VIGN
Except P
0V
R Range
VIGN
Except R
0V
N Range
VIGN
Except N
0V
D Range
VIGN
Except D
0V
2 Range
VIGN
Except 2
0V
1 Range
VIGN
Except 1
0V
3 Range
VIGN
Except 3
0V
ON
0V
OFF
VIGN
ON
0V
OFF
VIGN
ON
VIGN
OFF
0V
20C
4.6V
155C
1.1V
4L
0V
2H/4H
VIGN
ON
VIGN
OFF
0V
VIGN
VIGN
VIGN
D1
VIGN
D2
VIGN
D3
0V
D4
0V
Inhibitor (Select) SW R
Inhibitor (Select) SW N
Inhibitor (Select) SW D
Inhibitor (Select) SW 2
Inhibitor (Select)SW 1
Inhibitor (Select) SW 3
Power SW
3rd Start SW
Brake SW
AT Oil Temperature
Sensor
4L Signal
Diag SW
Shift Solenoid A (S1)
B1A1
B8A1
B7A1
B19A1
B18A1
B9A1
B13A1
B4A1
B22A1
A11A12
B21A1
B12A1
A16A1
Key ON
Key ON
Key ON
Key ON
Key ON
Key ON
Key ON
Key ON
Key ON
Key ON
Key ON
Engine run.
Key ON
Key ON
Engine run.

CHECK ITEM
PIN No.
Shift Solenoid B (S2)
A15A1
Lock-up Solenoid
Check Trans Lamp
AT Oil Temperature Lamp
Power Lamp
3 rd Start Lamp
AT Oil Temp Sensor

Resistance
A5A1
B3A1
B11A1
B2A1
B10A1
A11A12
VALUE
NOTE
0V
Engine run.
0V
Engine run. (Without the

Reverse range lock out)
0V
Engine run.
D1
0V
D2
VIGN
D3
VIGN
D4
0V
ON
VIGN
OFF
0V
ON
0V
OFF
VIGN
ON
0V
OFF
VIGN
ON
0V
OFF
VIGN
ON
0V
OFF
VIGN
20C
12kW
50C
1.5kW
155C
293W
(ex.) It is ON when the

vehicle speed is more than
65km/h.
Key ON
(The lamp is ON for 3
second after key ON)
Key ON
(The lamp is ON for 3
second after key ON)
Key ON
(The lamp is ON when the
Power switch is ON)
Key ON
(The lamp is ON when the
3rd Start switch is ON)
Key OFF
Pressure Control Solenoid

Resistance
A4A2
About
47W(20C)
Key OFF
Speed Sensor Resistance
B5B14
About
560W120W(20C)
Key OFF
Input Revolution Sensor

Resistance
B6B16
About
560W120W(20C)
Key OFF
Lock-up Solenoid
Resistance
A5A1
About
10W15W(20C)
Key OFF
Shift Solenoid A (S1)

Resistance
A16A1
About
10W15W(20C)
Key OFF
Shift Solenoid B (S2)

Resistance
A15A1
About
10W15W(20C)
Key OFF
Control System Diagram
RTW37AXF000201
Control and Functions

Shift Control
The transmission gear is shifted according to the shift
pattern selected by the driver. In shifting gears, the
gear ratio is controlled by the ON/ OFF signal using the
shift solenoid S1 and the shift solenoid S2.
Band Apply Control
The band apply is controlled when in the 32 downshift
(engine overrun prevention) and the garage shift (shock
control).
The band apply solenoid is controlled by the signal from
the Pulse Width Modulation (PWM) to regulate the flow
of the oil.
Torque Converter Clutch Control
The clutch ON/OFF is controlled by moving the
converter clutch valve through shifting Torque
Converter Clutch (TCC) solenoid using the ON/OFF
signal.
Line Pressure Control
The throttle signal allows the current signal to be sent
to the force motor. After receiving the current signal,
the force motor activates the pressure regulator valve
to regulate the line pressure.
OnBoard Diagnostic System
Several malfunction displays can be stored in the
Transmission Control Module (TCM) memory, and read
out of it afterward.
The serial data lines, which are required for the testing
of the final assembly and the coupling to other
electronic modules, can be regulated by this function.
FailSafe Mechanism
If there is a problem in the transmission system, the
TCM will go into a backup" mode.
The vehicle can still be driven, but the driver must use
the select lever to shift gears.
Torque Management Control
The transmission control side sends the absolute spark
advance signal to the engine control side while the
transmission is being shifted. This controls the engine
spark timing in compliance with the vehicle running
condition to reduce the shocks caused by the change of
speed.
ATF Warning Control
The oil temperature sensor detects the ATF oil
temperature to control the oil temperature warning,
TCC, and the 3rd start mode.
Reverse Lock Out Control
With the selector lever in reverse position, the TCM will
not close the PWM solenoid until the vehicle is below
15 km/h (9.3 mph), thus preventing reverse
engagement above this speed.
Downhill Control
This mode is automatically activated from NORMAL
mode only when downhill conditions are recognized.
The shift pattern is identical to NORMAL mode except
3-4 and 4-3 shift lines at low throttle modified to get
engine braking on a larger speed range.
Uphill Control
When uphill condition are recognized the 2-3 and 3-4
shift and TCC apply are down only when the engine
torque is sufficient in order to avoid shift hunting.
Gear Shift Control 3rd start

SELECT LEVER
RANGE
SHIFT PATTERN
D(Drive)
12TCC3TCC4TCC
3(Third)
12TCC3TCC
2(Second)
12(3)
L(First)
1(2)
TCC: Torque Converter Clutch

(Notice1): ( )" means over-revving prevention control.
Mode Type
Mode Type
Select lever position
Normal drive mode

(NOR)
Entire range (excluding R")
Power drive mode

(PWR)
Entire range (excluding R")
Mode Selection
SWITCH(SW)
Mode Type PWR/N
3RD
OR.S START
SW
LAMP
POWER
DRIVE
LAMP
3RD
START
LAMP
Normal
drive mode
(NOR)
OFF
OFF
OFF
OFF
Power
drive mod
(PWR)
ON
OFF
ON
OFF
3rd Start
mode
OFF
ON
OFF
ON
However, the 3rd start switch prevails over the

PWR/NOR switch.
The mode become normal drive mode when the 3rd
start switch is operated from ON to OFF.
Comparison of mode
1. The normal drive mode is set at the normal shift
points.
2. The shift points of the power drive mode are shifted
to the higher speed side, compared to the normal
drive mode.
3. The 3rd start mode is a special mode used
exclusively for starting in third gear.
3rd start Mode

1. The 3rd start switch will operate when switched on
after all of the following conditions are present:
a. The gear select position is D" range only.
b. Vehicle speed is 11 km/h (7 mph) or less.
c. Transmission oil temperature is 120C (248F)
or less.
d. Accelerator opening is at 8% or less.
2. Cancel Release
1. Cancellation by driver
a. Turning off the 3rd start mode switch
b. Shifting select position to 3", 2", or L" (3rd
start mode is not canceled by selecting N",
R", or P")
c. Ignition key is turned off.
2. Automatic cancellation
a. When vehicle runs at 34 km/h (21mph) or
more for 1 second or more
b. When transmission oil temperature reaches
120C (284F) or above
NOTE: The mode returns to normal drive mode or
power drive mode after the 3rd start mode is canceled.
Backup Mode
If a major system failure occurs which could affect
safety or damage the transmission under normal
vehicle operation, the diagnostic system detects the
fault and overrides the Transmission Control Module
(TCM).
The CHECK TRANS" light flashes to alert the driver,
and the transmission must be manually shifted as
follows:
Select lever position
Gear Ratio Selected
4 (Fourth)
Manual 3
4 (Fourth)
Manual 2
3 (Third)
Manual L
3 (Third)
Reverse
Shifts are firmer to prevent clutch slip and consequent

wear. The fault should be corrected as soon as
possible.
Functions of Input / Output Components

Component
I
n
p
u
t
Function
Transfer low signal
Detects the transfer High/Low position.
OD Cancel signal
Detects whether the cruise control unit is judged OD cancel mode.
Output revolution sensor

(Transmission)
Detects the vehicle speed.
Input revolution sensor

(Transmission)
Detects the input revolution (OD direct clutch drum revolution).
Engine revolution sensor
Detects the engine revolution with CAN.
Throttle position signal
Detects the throttle opening rate with CAN.
Detects the select lever position.
Pattern select switch
Detects whether the driver has selected "NORMAL" or "POWER" mode.
Brake lamp switch
Detects whether the driver has pressed the brake pedal or not.
Oil temperature sensor
Detects the oil temperature.
Diagnostic start switch
Starts self-diagnosis and displays a code for faulty part if any.
I Data link connector

n
p
u
t
/
O
u
t
p
u
t
When connected with Tech2 or tester, can communicate the data for function
check, etc.
Shift solenoid S1, S2
Selects shift point and gear position suited to the vehicle running condition on the
basis of TCM output.
Lock-up control solenoid SL
Control the lock-up clutch suited to the vehicle running condition on the basis of
TCM output.
O
u Pressure control solenoid
t STH
p "CHECK TRANS" lamp
u
t
Adjusts throttle pressure by energizing current of linear pressure control solenoid

to prevent the shift shock and to obtain shift smoothly.
When trouble has occurred to throttle position sensor, vehicle speed sensor, or
solenoid, "CHECK TRANS" lamp is blinked to warn the driver. If also displays the
trouble code.
A/T OIL TEMP warning

lamp
Lights when ATF oil temperature rises. (Turned on at greater than 146C
(295F). Turned off at less than 132C (270F).
POWER lamp
Lights when POWER MODE detected.
3rd Start lamp
Lights when 3rd Start MODE detected.
C Transmission Control
o Module (TCM)
m
p
u
t
e
r
Based on the signal from each switch and sensors, judges necessary shift point
and lock-up operation, and send signal to each solenoid.
CAN bus systems in automatic

transmission control (AW30-40LE)
The automatic transmission control system in AW3040LE uses high speed CAN bus system .The individual
CAN bus systems are connected via two interfaces and
can exchange information and data. This allows control
modules that are connected to different CAN bus
High speed CAN bus

Transmission control modules in the vehicle that require
continuous, rapid communication are connected to the
high speed CAN bus. For example, the automatic
transmission is continuously notified of the current
engine load status. Since the automatic transmission
control module has to react immediately to load status
changes, rapid communication is required between the
engine control module and the automatic transmission
control module. The high speed CAN bus in the AW3040LE is designed as a two-wire CAN bus (twisted pair).
The wires are shielded and twisted. The transfer rate is
500 K baud.
4. The go through SECTION" means to go through

the section" and then to go back to the place the
go through was written.
5. BASIC ELECTRIC CIRCUITS:
You should understand the basic theory of
electricity. This includes the meaning of voltage,
amps, ohms, and what happens in a circuit with an
open or shorted wire. You should also be able to
read and understand wiring diagrams.
Check Trans Indicator

Find CHECK TRANS indicator and verify if it is
A. Flashing: Go to DIAGNOSTIC CHECK.
B. Staying on: Go through CHECK TRANS CHECK.
C. Is never ON when the ignition key is turned on: Go
through CHECK TRANS CHECK
D. Is ON during 3 seconds at ignition but OFF after:
Normal operation. No DTC or malfunction.
RTW37ASH000401
RUW37ASF000401
Diagnosis
On Board Diagnostic Check

This test determines if the transmission or its input or
output connections or sensors are failing.
Electronic Diagnosis
1. Connect the Tech 2: Go through Tech 2 OBD

CONNECTION.
How To Diagnose The Problem
2. Turn on the ignition but not the engine.
1. To avoid incorrect diagnostics, this book needs to

be followed accurately. Unless stated, do not jump
directly to a section that could contain the
solution. Some important information may be
missed.
2. The sections in CAPITALS and bold are the main
sections that can be found in the contents.
3. The go to SECTION" means to continue to check
going to the section".
3. Push F0" on Tech 2 to see the Diagnostic Trouble

Code (DTC):

4. Do you have a DTC?
YES: write down all code numbers and do the DTC
CHECK
NO: the DTC can not help you find the problem.
1. Go through CHECK TRANS" CHECK
Check Trans" Check

1. Indicator is ON during 3 seconds at ignition but it is
OFF after the engine starts. The indicator is
working normally go to DIAGNOSTIC CHECK.
2. If it is flashing and the flash is 0.4 seconds ON

and 0.4 seconds OFF, this means that you
should have a DTC stored. Please recheck go
to DIAGNOSTIC CHECK and if you find the
same problem, replace the Powertrain Control
Module (TCM).
Normal
RTW37ASH000401
Normal
C07RY005-1
Abnormal
C07RY005-1
C07RY00042-1

2. Indicator is flashing and the flash is 0.4 seconds
ON and 0.4 seconds OFF always when ignition is
on (engine cranked or not). This means that there is
a malfunction. Go to DIAGNOSTIC CHECK.
Abnormal
C07RY00042-1
3. Indicator is staying ON always when Ignition is ON.

1. This means that connection between the lamp
and the indicator control unit is shorted to
ground.
2. Verify if instrument panel terminal
connector B23 is shorted to ground.
of
3. Verify if the indicator control unit connector C

95 terminal 3 is shorted to ground.
4. Verify that the instrument panel terminal 30 of
connector B24 is connected to battery.
5. If problem solved: Go to CHECK TRANS
INDICATOR.
NO: Replace Transmission Control Module
(TCM).
4. Indicator is staying OFF with the ignition ON
(engine OFF).
1. This means that connection between the lamp
and the indicator control unit is shorted to
battery or opened.
2. Verify if instrument panel terminal 2 of
connector B23 is shorted to battery or open.
3. Verify if the indicator control unit connector C
95 terminal 3 is shorted to battery or open.
4. Verify that the instrument panel terminal 2of
connector B23 is connected to battery. If not,
check the fuses and the connections (terminal
11 of connector H6) voltage.

5. If problem solved: Go to CHECK TRANS
INDICATOR.
NO: Replace Transmission Control Module
(TCM).
RTW37LF000701
Tech 2 OBD Connection

In order to access OBD Transmission Control Module
(TCM) data, use of the Tech 2 scan tool kit (7000086)
is required.
1. The electronic diagnosis equipment is composed of:
1. Tech 2 hand held scan tool unit (7000057) and
DLC cable (3000095).
901RW176
2. SAE 16/19 Pin Adapter (3000098)(1), RS232

Loop Back Connector (3000112)(2), and
PCMCIA Card (3000117)(3).
F07RW033

2. Connecting the Tech 2
901RW180
Legend
(1) PCMCIA Card
(4) DLC Cable
(2) RS 232 Loop Back Connector
(5) Tech 2

1. The Isuzu System PCMCIA card (1) inserts into
the Tech 2 (5).
2. Connect the SAE 16/19 adapter (3) to the DLC
cable (4).
3. Connect the DLC cable to the Tech 2 (5)

vehicle DLC (1).
8. The power up screen is displayed when you

power up the tester with the Isuzu systems
PCMCIA card. Follow the operating procedure
below.
060r300015
6. The vehicle ignition turns on.

060R100102
060RW009
NOTE: The RS232 Loop back connector is only to use

for diagnosis of Tech 2 and refer to user guide of the
Tech 2.

Once the test vehicle has been identified an
Application (Powertrain) Menu" screen appears.
Please select the appropriate application.
The following table shows, which functions are used for
the available equipment versions.
F0: Read DTC Info As stored By ECU
F2: DTC Information
F1: Data Display
F2: Snap Shot
F3: Miscllaneous Tests
F0: Lamps
F0: Power Lamp Test
F1: 3rd start Lamp Test
F2: AT Oil Temperature Lamp
F3: Check Light
F1: Solenoids
F0: Shift solenoid A (S1)
F1: Shift Solenoid B (S2)
F2: Pressure Control Solenoid (PCS)
RTW37ALH000101

The purpose of the Diagnostic Trouble Codes" mode is
to display stored TCM trouble codes.
When Diagnostic Trouble Codes" is selected an
Application Menu" screen appears.
Clear DTC Information
The purpose of the Clear DTC Information" mode is to
command the clearing of stored TCM trouble codes.
When Clear DTC Information" is selected, a Clear
DTC Information", warning screen appears. This screen
informs you that by cleaning DTC's, all stored DTC
information in controller will be erased".
Do you want to clear DTC's (Yes/No).
Press either the Yes or No key when answering.
Allow the vehicle to shift through all four forward gears
in a manner which attempts to repeat the failure
condition.
NOTE: When the trouble has not been repaired and
the trouble code cannot be erased, check the vehicle
again.
DTC Information
When DTC Information" is selected, an Application
Menu" appears with a list of DTC information function
keys addressing DTC specifics and their origins.
Function key selections may vary for particular vehicle
and/or system.
Data Display
The purpose of the Data Display" mode is to
When Data Display" is selected an Application Menu"
appears. Please select either Engine" or Transmission
Data Display".
See Transmission Data" on next page.
Snapshot
When Snapshot" is selected an Application Menu"
appears.
When Transmission Snapshot" application is selected
from the Application Menu", a Snapshot Menu"
appears, displaying several options. Snapshot" options
may vary from one system to another.
Snapshot" allows a recording of all vehicle parameters.
There parameters may then be replayed at a future
point in time.
This action allows you to focus on making the condition
anticipation of the fault. The snapshot will collect
parameter information around a trigger point that you
select.
When a snapshot is taken. It is recorded onto the

PCMCIA memory card. When the Tech 2 is powered
down. Snapshots are not lost.
Actuator Tests
The purpose of Actuator Tests" mode is to check for
correct operation of electronic system actuators.
Lamps
You can operate the lamps by pressing the ON" and
OFF" buttons.
Preconditions: none
Solenoid
Solenoid A(S1), Solenoid B(S2)
You can operate the solenoids by pressing the ON"
and OFF" buttons.
Preconditions: PN position, no vehicle speed, no
engine speed
Pressure Control Solenoid (PCS)
You can set desired PCS Current using the ON" (+20)
and OFF" (-20) button. The PC Solenoid Data informs
about PCS Current, Pressure and Duty Cycle.
Preconditions: PN position, no engine speed, no
vehicle speed
NOTE:
Freeze Frame
Freeze Frame is an element of the Diagnostic
Management System which stores various vehicle
information at the moment an emission-related fault
is stored in memory and when the Check Transe
Lamp is commanded on. These data can help to
identity the cause of a fault. Refer to Storing And
Erasing Freeze Frame Data for more detailed
information.

TRANSMISSION DATA
ITEM
UNIT
ENGIN RUNNING AT IDLE
Current Gear
1 st/2 nd/3 rd/4 th
1 st
Target Gear
1 st/2 nd/3 rd/4 th
1 st
Vehicle Speed
km/h
0 km/h
AT Output Speed (Automatic Transmission)
RPM
0 RPM
AT Input Speed (Automatic Transmission)
RPM
675~725 RPM
Engine Speed
RPM
675~725 RPM
Throttle Position Sensor Signal
0.00~7.00%
AT Oil Temperature (Automatic Transmission)
Depends on conditions
Transfer Low /Transfer High
Transfer HI
Desired PC Solenoid Pressure (STH)
kPa
34.3~97.0 kPa
Desired PC Solenoid Current (STH)
mA
835~1020 mA
PC Solenoid Actual Current (STH)
mA
835~1020 mA
Gear Ratio
:1
Depends on uper hood
RPM
0 RPM
Shift Position Actual
P/R/N/L/2/3
Inhibitor Switch
P/R/N/L/2/3
Transmission Check Light
On/Off
Off
AT Oil Temperature Lamp (Automatic

Transmission)
On/Off
Off
3 rd Start Lamp
On/Off
Off
Power Lamp
On/Off
Off
Shift Solenoid S1
On/Off
On
Shift Solenoid S2
On/Off
On
Shift Solenoid S3
On/Off
Off
Diag Switch Condition
On/Off
Off
Power Switch
On/Off
Off
Brake Switch
On/Off
Off
Cruise Switch
On/Off
Off
4L Signal
On/Off
Off
3 rd Start Switch
On/Off
Off
C
CA
Depends on conditions
On/Off
Off
CAN TPS
0.00%
CAN Signal Valid Counter (ECM)
0 ~ 255
CAN Signal Valid Counter (TCM)
0 ~ 255
TCM Status
TCC Slip Speed
Coolant Temperature
Torque Request (timing Retard)
Garage Shift Mode
0 CA

Snapshot data can be displayed with [Snapshot
Upload] function included in TIS2000.
below shown:

1. Start TIS2000.
screen.
3. Select [Upload from trouble diagnosis tool
(transfer from diagnosis tester)] or click the
information.
6. After ending transfer of the snapshot, data
3. Snapshot data is displayed with TIS2000
procedures.
1. Start TIS2000.
screen.
list on the screen.

1. Click the icon for graph display. [Graph

Parameter] window opens.
and select one parameter from the list of the
window lower part. Selected parameter is
displayed nest to the graph icon. Graph division
can be selected in the field on the parameter right
side.
icons.
4. After selecting all parameters to be displayed
(Max. 3 parameters), click [OK] button.
icon.
7. For displaying another parameter by graph, click

the parameter of the list, drug the mouse to the
display screen while pressing the mouse button
and release the mouse button. New parameter is
displayed at the position of the previous
parameter. For displaying the graph display screen
in full size, move the cursor upward on the screen.
When the cursor is changed to the magnifying
glass form, click the screen. Graph screen is
displayed on the whole screen.


opens.
5. In this case, parameters are displayed only in
graph form. All parameters are displayed in one
graph.
navigation icon.

Service Programming System (SPS) software
contained in TIS2000 is explained below.
NOTE:
are present, low battery voltage or poor
electrical connections should be the primary
suspects. Perform the SPS procedure again
after rectifying the fault/s.
IMPORTANT:
The Tech2 PCMCIA card is programmed with
the latest software release.
The latest release of TIS2000 is loaded on the
PC.
The control unit to be programmed is
connected to the vehicle.
1.
2.
3.
4.
5. On the screen of "Diagnostic Tester and

Processing Program Selection", choose the one
that will comply with the following.
Diagnostic tester in use
Connect Tech 2 to P/C.

Check to see if Hardware Key is plugged into Port.
Activate TIS 2000 by P/C.
On the activating screen of TIS2000, choose
"Service Programming System"

6. Upon completion of the selection, push the button
of "Continue".

2.Demand of Data
turning on the power of Tech-2, push the "Enter"
switch.
engine)
3. In the main menu of Diagnostic Tester, push "F1:
Service Programming System (SPS)".

Year, Vehicle Type, Controller Type (Engine).
7. After that. then push button and turn Ignition
switch tuned on, off, on following Tech-2 display.
Tech-2 will read information from controller after
this procedure.
information from the control unit chosen. In
replacing the control unit, please be sure to
undertake "Obtaining Information" from the new
unit. With VIN not being programmed into the new
control unit at the time of shipment, "obtaining
information" is not complete (because the vehicle
model, engine model and model year are specified
from VIN). For the procedure get additional
information on vehicles, instruction will be
provided in dialog form, when TIS2000 is in
operation.
9. Following instructions by Tech-2, push the "Exit"
and turn off the power of Tech-2, thereby
5. Where vehicle data has been already saved in

Tech-2, the existing data come on display. In this
the data or to continue obtaining anew data from
the control unit, choose either of them.
3.Data Exchange
1. Connect Tech-2 to P/C, turn on the power and
click the "Next" button of P/C.
Model Year
Model
Engine type
Transmission type
Destination code (vehicles for general
export)*1
Immobiliser
"Destination code can be read from ID Plate affixed on
Fig.-3, the destination code can be read as "EK4"
(Europe).

"details" of software within the database that
match the entered data will appear for
confirmation. Click the "Program" switch and then
download the new software onto Tech-2.
6. "Data Transfer" comes on display. The progress of
form of bar graph.
ABS connectors shall be removed from the
vehicle.
comes on display.
start)
5. On the title screen of Tech-2, push the "Enter"
button.
6. Choose "F: Service Programming System" on the
main screen and then choose "Fl: Programming".
7. While data is being transferred, "Downloading"
will be displayed on the Tech-2 screen.
8. Upon finishing the data transfer, Tech-2 will
display "Reprogramming Successful". Push the
"Exit" button to bring program to completion.
9. Following "Procedure 2: Demand of Data", try over

again "Information Obtaining" and check to
confirm if the data has been correctly re-loaded.
OBD Diagnostic Management System

Transmission Control Module (TCM) Location
P1010052
RTW37ASH000301
16 Terminal Data Link Connector (DLC)

OBD standardizes Data Link Connector (DLC)
configurations. The DLC, formerly referred to as the
ALDL, will be a 16terminal connector found on the
lower right side of the driver's side instrument panel. All
manufacturers must conform to this 16terminal
standard.
060R300015
810RT022
PIN 1 uart
PIN 2 J1850 Bus + L line on 2wire systems, or
single wire (ECM)
PIN 3 (Not used)
PIN 4 Chassis ground pin
PIN 5 Chassis ground pin
PIN 6 ECM diagnostic enable
PIN 7 KW2000
PIN 8 (Not used)
PIN 9 Primary UART
PIN 10 (Not used)
PIN 11 TCM diagnostic enable
PIN 12 ABS diagnostic or CCM diagnostic enable
PIN 13 SIR diagnostic enable
PIN 14 (Not used)
PIN 15 (Not used)
PIN 16 Battery power from vehicle unswitched (4
AMP MAX.)
Clear DTC
NOTE: If you clear the DTC (Diagnostic Trouble
Codes) you will not be able to read any codes recorded
during the last occurrence.
NOTE: To use the DTC again to identify a problem,
you will need to reproduce the fault or the problem.
This may require a new test drive or just turning the
ignition on (this depends on the nature of the fault).
1. IF you have a Tech 2:
1. Connect the Tech 2 if it is still not connected go
through Tech 2 OBD CONNECTION.

charging are by friction and induction. An example
of charging by friction is a person sliding across a
car seat, in which a charge of as much as 25,000
volts can build up. Charging by induction occurs
when a person with well insulated shoes stands
near a highly charged object and momentarily
touches ground. Charges for the same polarity are
drained off, leaving the person highly charged with
the opposite polarity. Static charges of either type
can cause damage, therefore, it is important to
use care when handling and testing electronic
components.
2. Push F1: Clear DTC Information" in the

Application Menu and answer Yes" to the
question Do you want to clear DTC's?"
NOTE: To prevent possible electrostatic discharge

damage:
a. When a malfunction still exists and the Tech

2 displays AW30-40 CODES NOT
CLEARED". This means that the problem is
still there or that the recovery was not done.
Please go to DTC CHECK.
2. Be sure to follow the guidelines listed below if

servicing any of these electronic components:
b. When a malfunction has been repaired and

the recovery is done the Tech 2 displays
AW30-40LE CODES CLEARED".
2. When you have no Tech 2, the storaged trouble
codes can be cleared by shorting the terminals
No.11 and No.4 or 5 (ground) of data link connector
with a lead wire for 1 ~ 6 seconds.
DTC Check
1. Diagnostic Trouble
identified by Tech 2.
Codes
(DTC)
have
been
2. You have written the list of the DTCs. The order of

the malfunctions has no meanings for this TCM.
Usually only one or two malfunctions should be set
for a given problem.
3. Check directly the DTCs you identified. The DTCs
are sorted by number. Refer to Diagnostic Trouble
Code (DTC) Identification in this section.
TCM Precaution
The TCM can be damaged by:
1. The electrostatic discharge
2. The short circuit of some terminals to voltage or to
ground.
Electrostatic Discharge Damage Description:
1. Electronic components used to control systems
are often designed to carry very low voltage, and
are very susceptible to damage caused by
electrostatic discharge. It is possible for less than
100 volts of static electricity to cause damage to
some electronic components. By comparison, it
takes as much as 4,000 volts for a person to even
feel the zap of a static discharge.
2. There are several ways for a person to become
1. Do not touch the TCM connector pins or soldered

components on the TCM circuit board.
3. Do not open the replacement part package until it is

time to install the part.
4. Avoid touching electrical terminals of the part.
5. Before removing the part from its package, ground
the package to a known good ground on the
vehicle.
6. Always touch a known good ground before handling
the part. This step should be repeated before
installing the part if the part has been handled
while sliding across the seat, while sitting down
from a standing position or while walking some
distance.
Information On TCM
1. The Transmission Control Module (TCM) is located
in the place of a clutch pedal and is the control
center of the electronic transmission control
system.
2. The TCM must be maintained at a temperature
below 85C (185F) at all times. This is most
essential if the vehicle is put through a paint baking
process. The TCM will become inoperative if its
temperature exceeds 85C (185F). Therefore, it is
recommended that the TCM be removed or that
temporary insulation be placed around the TCM
during the time the vehicle is in a paint oven or
other high temperature process.
3. The TCM is designed to process the various inputs
and then respond by sending the appropriate
electrical signals to control transmission upshift,
downshift, shift feel and torque converter clutch
engagement.
4. The TCM constantly interprets information from the
various sensors, and controls the systems that
affect transmission and vehicle performance. By
analyzing operational problems, the TCM is able to

perform a diagnostic function by displaying DTC(s)
and aid the technician in making repairs.
TCM Diagnostic Trouble Codes

The following table lists the diagnostic trouble codes supported by this vehicle application. If any DTCs not listed here
are displayed by a scan tool, the scan tool data may by faulty; notify the scan tool manufacture of any DTCs
displayed that are not included in the following table.
DTC
NUMBER
FLASH
CODE
DTC NAME
CHECK
TRANS"
P0560
25
System Voltage Error
P0602
63
Transmission Control Module (TCM) Programming Error
P0705
17
Transmission Range Sensor Circuit Malfunction
ON
P0712
15
Transmission Oil Temperature Sensor Circuit Low Input
ON
P0713
16
Transmission Oil Temperature Sensor Circuit Hight Input
ON
P0717
14
Input Speed Sensor Signal Error
ON
P0722
11
Output Speed Sensor Signal Error
ON
P0743
33
Torque Converter Clutch Electrical
ON
P0748
35
Pressure Control Solenoid Electrical
ON
P0753
31
Shift Solenoid S1 Electrical
ON
P0758
32
Shift Solenoid S2 Electrical
ON
P1767
67
ECM CAN (Control Area Network) Invalid
ON
P1790
61
Transmission Control Module ROM Checksum Error
ON
P1791
62
Transmission Control Module RAM Error
ON
U2104
65
CAN (Control Area Network) BUSS OFF
ON
DTC P0560 (FLASHING CODE 25) System Voltage Error
RTW37ALF000701
Circuit Description
Conditions For Clearing The DTC
The Transmission Control Module (TCM) monitors the

system voltage on the ignition feed terminal to the
TCM. A system voltage DTC will set whenever the
voltage is below or above a calibrated value.
The DTC can be cleared from the TCM history by

using a scan tool.
Condition for setting the DTC

When the TCM detects following conditions.
Ignition voltage is less than 9V or more than 18V.
Engine speed is more than 600 rpm.
Action Taken When The DTC Sets

DTC stored.
The DTC will be cleared from history when the

vehicle has achieved 40 warm-up cycles without a
failure reported.
After more than 1 second has elapsed after the
ignition key has been turned ON", short between
No.11 and No.4 (ground) of DLC (Data Link
Connector). Then, after 1 second, but within 6
seconds, discontinue shorting.
Diagnostic Aids
Inspect the wiring for poor electrical connection at
the TCM. Look for possible bent, backed out,
deformed or damaged terminals. Check for weak
terminal tension as well. Also check for a chafed wire
that could short to bare metal or other wiring.
Inspect for a broken wire inside the insulation.
DTC P0560 System Voltage Error

Step
1
Action
Was the powertrain On-Board Diagnostic (OBD)
System Check performed?
Using a DVM, measure the battery voltage at the
battery.
Value(s)
YES
NO
Go to Step 2
Go to OBD
System Check
11.5 V
Go to Step 3
Charge battery,
then go to Step
3
2000 RPM
12.8-14.1 V
Go to Step 4
Go to
Starting/Chargi
ng
Check for
excessive
curren draw
with ignition
OFF" engine
OFF".
Go to Step 5
Verify repair
Go to Step 6
Verify repair
Go to Step 7
Verify repair
Is the battery voltage greater than the specified

value?
3
1. Install a Tech 2.
2. Select Ignition Volts" on the Tech 2.
3. Start the engine and raise the engine speed to the
specified value.
headlights, high blower, etc.
Is the ignition voltage approximately equal to the
specified value?
1. Ignition OFF".
2. Disconnect the TCM connector at the TCM.
3. Using a DVM, measure the battery voltage at the
TCM connector C-94.
Is it approximately equal to battery voltage?
1. Check for faulty connections at the TCM harness

terminals.
2. Repair as necessary.
Was a repair necessary?
Check for an open battery feed circuit to the TCM.

Replace the TCM.

Important:
The replacement TCM must
programmed. (Refer to SPS for procedure.)
be
DTC P0602 (FLASHING CODE 63) Transmission Control Module (TCM)

Programming Error
Circuit Description
The Service Programming System (SPS) updates the
flash calibration files that are stored in a Transmission
Control
Module
(TCM).
The
calibration
file
custom-tailors a module to a certain vehicle. The
calibration file contains data for things such as spark
curves and fuel control. When troubleshooting a
driveability
problem, diagnosis may call for
reprogramming the controller with newer calibration
information to correct a customer concern and Vehicle
Identification Number (VIN).

When the TCM is not written VIN No.

DTC stored.

using a scan tool.
failure reported.
Diagnostic Aids
DTC P0602 is indicated when the TCM does not written
VIN No. A security lock is performed by SPS. And not
replace the TCM when DTC P0602 can repair by SPS.
DTC P0602 (FLASHING CODE 63) Transmission Control Module (TCM)

Programming Error
Step
1
Action
performed?
1. Install the scan tool.
Value(s)
YES
NO
Go to Step 2
Go to OBD
System Check
Go to Step 4
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
Verify repair
2. Key ON".
3. Check the Vehicle Identification Number (VIN) by
the scan tool.
Is VIN on the scan tool same as VIN of vehicles?
3
Write a VIN by the scan tool. (Refer to SPS for

procedure.)
Clear the DTC P0602 by the scan tool.

Perform the SPS and perform security lock. (Refer to

SPS for procedure)
Recheck the DTC by the scan tool.

1. Key OFF".
2. Wait a few seconds.
3. Key ON".
4. Review and record scan tool data.
5. Operate the vehicle with in scan tool data.
Replace the TCM.

Important:
be
DTC P0705 (FLASHING CODE 17) Transmission Range Sensor Circuit

Malfunction
RTW37ALF000501
Circuit Description
The neutral start switch gives the signals related to the
selector lever position (PRND32L) to the Transmission
Control Module (TCM). The neutral start switch turns on
when the select lever is shifted to the P, R, N, D, 3, 2 or
L range. The neutral start switch, which is connected to
the starter switch circuit, is available only when the
select lever is in the P or N range (Engine run).
The neutral start switch is connected to the
transmission manual shaft and installed in the
transmission case.

The TCM detects following "Condition 1" for 30 sec
continuously.
The TCM detects following "Condition 2" for 10 sec
continuously.
Condition 1("Open"):
When the TCM detects no signal of range sensor
more than 2.0 sec at following conditions.

Condition 2 ("Short"):
When the TCM detects 2 times or more signals of
range sensor more than 0.025 sec at following
conditions.
Vehicle speed is more than 19 mph.
Engine speed is more than 1500 rpm.
Diagnostic Aids
No slope control.

The TCM judges always D range position of range

sensor at "Condition 1".
Check range sensor for proper mounting and

adjustment.
No 3rd start mode.
The TCM judges the position of range sensor with

following priority at "Condition 2".
There is a priority in order of D, 3, 2, L, R, N, and P.
Check Trans ON.
DTC stored.

using a scan tool.
failure reported.
DTC P0705 (FLASHING CODE 17) Transmission Range Sensor Circuit

Malfunction
Step
1
Action
Was the powertrain On-Board Diagnostics (OBD)
System check performed ?
Value(s)
YES
NO
Go to Step 2
Go to OBD
System Check
Go to Step 3
Refer to
Diagnostic Aids
716V
Go to Step 7
Go to Step 4
716V
Verify repair
Go to Step 5
Less than
1W
Verify repair
Go to Step 6
2. Key ON"
Does the scan tool indicate DTC P0705 ?
3
Measure the voltage shifting the select lever every

position, between TCM connector terminals and
ground which performed selecting to every position.
1. Key OFF"
3. Key ON"
4. Connect the DMM to the TCM connector terminal
and ground.
Is the displayed voltage at every position normal ?
Measure the voltage between terminal the neutral

start switch and ground.
1. KeyOFF"
2. Disconnect the neutral start switch connector.
3. KeyON"
4. Connect the J39200 DMM to the each terminal of
the neutral start switch connector E79-3 and
ground.
If the problem found repair as necessary.
Measure the resistance shifting the select lever to

every position, between terminal neutral start switch
connector E79-3 and E79other terminal.
1. KeyOFF"
2. Disconnect the neutral start switch connector.
3. KeyON"
4. Connect the DMM to the each terminal of the
neutral start switch connector E79-3 and E79-5 or
E79-2 or E79-6 E79-8 or E79-7 or E79-9 or E7910.

Step
Action
Value(s)
YES
NO
Check the wire between terminal C-95 and E-79 for

open.
Verify repair
Verify repair

the TCM connector and neutral start switch.
7
Replace the TCM.

IMPORTANT; The replacement TCM must
be
DTC P0712 (FLASHING CODE 15) Transmission Oil Temperature Sensor

Circuit Low Input
RTW37AMF000201
Circuit Description
The oil temperature sensor is a thermistor sensor that

is installed in the transmission case and converts
temperature changes into continuous electric signals,
then outputs them to the Transmission Control Module
(TCM). When the ATF temperature is low, the
resistance of the sensor (thermistor) goes up, so that
the voltage of the TCM signal becomes high.
As the ATF is gradually warmed, the resistance of the
sensor goes down and the voltage becomes low. At the
normal operating ATF temperature (80C/176F) of the
transmission, the voltage of the TCM is about 3.7V.
The TCM judges oil temperature is 100C (212F).

The TCM detects following "Condition" for 5 min
continuously.
Condition ("Short"):
Oil temperature is more than 220C (428F).
Check Trans ON.

DTC stored.

using a scan tool.
failure reported.
Diagnostic Aids
that could short to bare metal or other wiring. Inspect
for a broken wire inside the insulation.
Check oil temperature sensor for proper mounting
and adjustment.

Circuit Low Input
Step
1
Action
Perform the transmission fluid checking procedure.
Refer to checking Transmission Fluid level and
Condition in Automatic Transmission 7A section.
Value(s)
YES
NO
Go to Step 2
Go to OBD
System Check
Go to Step 3
Refer to
Checking
Transmission
Fluid level and
Condition in
Automatic
Transmission
(AW30-40LE)
section
Go to Step 4
Refer to
Diagnostic Aids
5V
Go to Step 5
Go to Step 6
Verify repair
Was the fluid checking procedure performed ?

2. Key ON"
Measure the voltage of the transmission fluid

temperature sensor by the J39200 DMM.
1. Key OFF".
2. Disconnect the oil temperature sensor connector.
3. Key ON".
the oil temperature sensor connector E83-2 and
E83-1.
Does the scan tool indicate less than specified
value ?
Replace the transmission fluid temperature sensor.

Is the action complete ?

Step
Action
Value(s)
YES
NO
Measure the resistance of the wire by the J39200

DMM.
less than 1W
Verify repair
Go to Step 7
Verify repair
1. Key OFF".
3. Install a jumper wire from terminal E83-1 and E832 on the mission harness.
4. Connect the j39200 DMM to the each terminal of
the TCM connector C94-11 and C94-12.
Was the problem found ?
7
Replace the TCM.

Important:
The replacement
programmed.
(Refer to SPS for procedure.)
TCM
must
be

Circuit Hight Input
RTW37AMF000201
Circuit Description
The oil temperature sensor is a thermistor sensor that

is installed in the transmission case and converts
temperature changes into continuous electric signals,
then outputs them to the Transmission Control Module
(TCM). When the ATF temperature is low, the
resistance of the sensor (thermistor) goes up, so that
the voltage of the TCM signal becomes high.
As the ATF is gradually warmed, the resistance of the
sensor goes down and the voltage becomes low. At the
normal operating ATF temperature (80C/176F) of the
transmission, the voltage of the TCM is about 3.7V.
The TCM judges oil temperature is 100C (212F).

The TCM detects following "Condition" for 15 min
from ignition ON.
Condition ("Open"):
Fluctuation of high temperature fixed value is
2.3C (36F).
Fluctuation of low temperature fixed value is -10C
(14F).
Check Trans ON.

DTC stored.

using a scan tool.
failure reported.
No.11 and No.4
(ground) of DLC (Data Link
Diagnostic Aids
Check oil temperature sensor for proper mounting
and adjustment.

Circuit Hight Input
Step
1
Action
System Check performed ?
Refer to Checking Transmission Fluid Level and
condition Automatic Transmission7A section.
Value(s)
YES
NO
Go to Step 2
Go to OBD
System check
Go to Step 3
Refer to
checking
Transmission
Fluid Level and
Condition
Automatic
Transmission
(AW30-40LE)
section
Go to Step 4
Go to
Diagnostic Aids
0.4V
Go to Step 5
Go to Step 6
Verify repair
Was the fluid checking procedure performed ?
1. Install the scan tool ?

2. Key ON"
3. Review and record scan tool date.
Does the scan tool indicator DTC P0713 ?
Observe the voltage of the transmission fluid

temperature sensor on the TECH2 data.
1. Key OFF".
2. Disconnect the transmission fluid temperature
sensor connector E-83
3. Install a fused jumper wire from terminal E83-2 to
E83-1 on the mission harness.
4. Key ON".
Does the scan tool indicate more than specified
value ?
Replace the transmission fluid temperature sensor .

If the action complete ?

Step
6
Action
Measure the resistance of wire by the J39200 DMM.
Value(s)
YES
NO
less than 1W
Go to Step 8
Go to Step 7
Verify repair
Verify repair
1. Key OFF".
2. Disconnect the TCM connector
3. Install a fused jumper wire from terminal E83-1
and E83-2 on the mission harness.
value ?
7
Repair an open circuit.

Was the problem found ?
Replace the TCM

IMPORTANT ; The replacement TCM must be
DTC P0717 (FLASHING CODE 14) Input Speed Sensor Signal Error
MAW060MF001501
Circuit Description
OR
Input revolution information is provided to TCM by the

input revolution sensor. This sensor is located in the
transmission case.
The input revolution sensor is an electromagnetic pulse
pickup type that generates a speed signal according to
the revolution of the transmission OD direct clutch
drum. As a result, the sensor sends a sine wave signal
(AC) to the TCM, which converts this sine wave signal
(pulse voltage) to a RPM signal.
When the TCM output 2nd gear.

The TCM detects no pulse of input speed sensor
circuit signal after 3.5 sec.
(detection time: 0.03 sec at vehicle speed is 36 mph)

No engine torque control.
No line pressure control.
No lock-up control.
The TCM detects following conditions at 1000

times continuously.
No slope control.
When the TCM detects following conditions at the

same time.
DTC stored.
When output speed is over 775 rpm (16 mph) at

gear position is 1st or 2nd or 3rd.
Input speed signal is no pulse while output speed
signal are 12 pulses.
Check Trans ON.

No detect DTC P0722.

using a scan tool.

failure reported.
Diagnostic Aids
When diagnosing for a possible intermittent shortor
Check input speed sensor for proper mounting and
adjustment.
DTC P0717 (FLASHING CODE 14) Input Speed Sensor Signal Error
Step
1
Action
Value(s)
YES
NO
Go to Step 2
Go to OBD
system check
Go to Step 3
Refer to
Diagnostic Aids
3V
Refer to
Diagnostic Aids
Go to Step 4
2. Key ON".
3. Review and record scan tool data
Does the scan tool indicator DTC0717 ?
3
Measure voltage of the input revolution sensor by the

J39200 DMM.
1. Key ON".
2. Engine run.
3. Disconnect the input revolution sensor connector .
4. Measure the voltage between terminal the input
revolution sensor connector E80-1 and E80-2.
value ?

Step
4
Action
1. Key OFF".
Value(s)
YES
NO
560~680W
(20C)
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
560~680W
(20C)
Go to Step 9
Go to Step 7
Verify repair
Verify repair
Verify repair

3. Connect the input revolution sensor connector.
4. Measure the resistance between the
connector terminal C95-6 and C95-16.
TCM
Does the scan tool indicate specified value ?

5
1. Replace the TCM.

2. Install the scan tool(TECH2).
3. Make a road running test for the vehicle.
Important:
be
Dose the scan tool indicate DTC P0717 ?

6
Measure the resistance of input revolution sensor by

the J39200 DMM.
1. Key OFF".
2. Disconnect the input revolution sensor connector.
3. Measure the resistance between terminal input
revolution sensor side connector E80-1 and E802.
Does the scan tool indicate specified ?
Replace the input revolution sensor.

Replace the TCM.

IMPORTANT; The replacement TCM must
be

9
Check the wire between terminal C95-6 and E80-2 or

C95-16 and E80-1.
1. 1.Connect the J39200 DMM to the each of the
TCM connector and input revolution sensor.
Was the found problem ?
DTC P0722 (FLASHING CODE 11) Output Speed Sensor Signal Error
RTW37AMF000501
Circuit Description
Vehicle speed information is provided to the TCM by

the output revolution sensor. This sensor is located in
the transmission adapter housing.
The output revolution sensor is an electromagnetic
pulse pickup type that generates a speed signal
according to the revolution of the transmission output
shaft. As a result, the sensor sends a sine wave signal
(AC) to the TCM, which converts this sine wave signal
(pulse voltage) to a RPM signal.
The TCM uses input speed sensor as a vehicle

speed.
No slope control.
The TCM detects following conditions at 500 times

continuously.
(When gear positions are 1st, 2nd and 3rd.)
When the TCM detects following conditions at the
same time.
Output speed signal is no pulse while input speed
signal are 45 pulses.
(Detection time, 1st: 0.031 sec, 2nd: 0.057 sec, 3rd:
0.087 sec, at vehicle speed is 38 mph.)
No squat control.
No use 4th gear.
No lock-up control.
Check Trans ON.
DTC stored.
No reverse lockout control.

using a scan tool.

failure reported.
Diagnostic Aids
Check output speed sensor for proper mounting and
adjustment.
DTC P0722 (FLASHING CODE 11) Output Speed Sensor Signal Error
Step
1
Action
Value(s)
YES
NO
Go to Step 2
Go to OBD
system check
Go to Step 3
Refer to
Diagnotic Aids
3V
Refer to
Diagnostic Aids
Go to Step 4
2. Key ON".
3. Review and record scan tool data
Does the scan tool indicator DTC 0722 ?
3
Measure the voltage of the output revolution sensor

by the J39200 DMM.
1. Key OFF"
2. Lift the driving wheels.
3. Disconnect the output revolution sensor connector.
4. With engine idling in gear.
5. Measure the voltage between the output revolution
sensor connector terminal E81-1 and E81-2.
value ?

Step
Action
Value(s)
YES
NO
560~680W(2
0C)
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 8
560~680W(2
0C)
Go to Step 9
Go to Step 7
Verify repair
Verify repair
Verify repair
1. Key OFF".
3. Connect the output revolution sensor connector.
4. Measure the resistance between the TCM terminal
C95-5 and C95-14
Does the scan tool indicate specified value ?
5
1. Replace the TCM

2. Install the scan tool (TECH2).
3. Make a road running test for the vehicle.
Important:
be

6
Measure the resistance of output revolution sensor by

the J39200 DMM.
1. Key OFF"
2. Disconnect the output revolution sensor connector.
3. Measure the resistance between terminal output
revolution sensor side connector E81-1 and E812.
Does the scan tool indicate specified ?
Replace the output revolution sensor.

Replace the TCM.

Important:
be

9
Check the wire between terminal C95-5 and E81-1 or

C95-14 and E81-2.
1. Connect the J39200 DMM to the each the TCM
connector and output revolution sensor.
Was the found problem ?
DTC P0743 (FLASHING CODE 33) Torque Converter Clutch Electrical
RUW37ALF000601
Circuit Description
The lock-up solenoid SL of the torque converter clutch
(TCC) controls the lock-up clutch by a signal according
to the lock-up range judgment of the TCM when the
vehicle runs.
This function can improve the fuel consumption to
almost the same extent as the manual transmission.
The lock-up solenoid SL is put into B+ by the TCM, so
that the solenoid is actuated with the result of lock-up.

The TCM detects following conditions both "Condition
1" and "Condition 2" occur 2 times or more than it.
Condition 1 ("GND short"):
Voltage at connector pin is 0V for 0.3 sec

continuously when solenoid is ON".
Condition 2 ("Open or IG short"):
Voltage at connector pin is ignition voltage for 0.5
sec continuously when solenoid is OFF".

No lock-up control.
The TCM fixes to 1st gear when the vehicle speed is
less than 6 mph.
Check Trans ON.
DTC stored.

using a scan tool.
failure reported.
Diagnostic Aids
When diagnosing for a possible intermittent short
oropen condition, move the wiring harness while
DTC P0743 (FLASHING CODE 33) Torque Converter Clutch Electrical

Step
1
Action
Was the Powertrain On-Board Diagnostic (OBD)
Value(s)
YES
NO
Go to Step 2
Go to OBD
System Check
Go to Step 3
Refer to
Diagnostic Aids
8~16V
Go to Step 4
Go to Step 10
2. Key ON".
4. Operate the vehicle within scan tool data.
Does the scan tool indicate DTC P0743?
3
1. Key ON", engine run.

2. Place the selector lever in the "P" range.
3. Measure the voltage between terminal C94-5 and
terminal C94-1 on the TCM pigtail connector by
J39200 DMM.
Is the voltage specified value?

Step
4
Action
1. Key "OFF".
Value(s)
YES
NO
0V
Go to Step 5
Go to Step 7
11~15W
Go to Step 9
Go to Step 6
11~15W
Go to Step 7
Go to Step 8
Verify repair
Verify repair
Go to Step 10
Refer to
Diagnostic Aids
Verify repair
2. Disconnect the TCM connector (C-94).

3. Key "ON".
terminal C94-1 by J39200 DMM.
5
1. Key OFF".
2. Measure the resistance between terminal C94-5
and body ground by J39200 DMM.
Is the resistance specified value?
1. Disconnect the automatic transmission connector

(E-82).
2. Measure the resistance between terminal E82-7
1. Check for open or short in the wire between

terminal C94-5 and terminal E82-7.
2. Repair or replace the wire between terminal C94-5
and terminal E82-7.
Replace the SL solenoid.

1. Clear the DTC.

2. Perform the test-driving.
3. Check the DTC.
Was DTC P0743 stored?
10
Replace the TCM.

DTC P0748 (FLASHING CODE 35) Pressure Control Solenoid Electrical
RTW37ALF000601
Circuit Description
The pressure control solenoid is a PWM duty control
solenoid located in the valve body.
The pressure control solenoid is a TCM-controled
device used to regulate transmission throttle pressure
by energizing current from the TCM.
Monitor A/D value is more than 1000 (1.36A).

Condition 2("Open or GND short"):
When the TCM detects following condition for 70
msec continuously.
Monitor A/D value is less than 15 (20mA).

The TCM detects following "Condition 1" and "Condition
2".
Condition 1("Ignition short"):
When the TCM detects following condition for 0.5
sec continuously.
No squat control.
No lock-up control.
No slope control.
Check Trans ON.

DTC stored.

using a scan tool.
failure reported.
Diagnostic Aids
DTC P0748 (FLASHING CODE 35) Pressure Control Solenoid Malfunction

Step
1
Action
Value(s)
YES
NO
Go to Step 2
Go to OBD
System Check
Go to Step 3
Refer to
Diagnostic Aids
Go to Step 4
Refer to
checking
Transmission
Fluid level and
Condition in
Automatic
Transmission
(AW30-40LE)
section
2. Key ON".
3

Refer to checking Transmission Fluid level and
Condition in Automatic Transmission 7A section.
Was the fluid checking procedure performed?

Step
4
Action
Measure the resistance of pressure control solenoid.
1. Key OFF".
Value(s)
YES
NO
5 to 5.6W at
68F (20C)
Go to Step 5
Go to Step 8
5 to 5.6W at
68F (20C)
Go to Step 7
Go to Step 6
Verify repair
1.0-
Verify repair
Go to Step 9
Verify repair
Verify repair

and TCM connector.
3. Measure the resistance between
transmission terminal E82-2 and
transmission terminal E82-6.
automatic
automatic

5
Measure the resistance of wire between terminal

C94-2 and terminal C94-4
1. Key OFF".
2. Connect the automatic transmission connector.
and terminal C94-4.
Repair or Replace the wire between terminals C942,4 and terminals E82-6,2.
Observe the pressure control solenoid valve data on

the scan tool data.
1. Key ON".
Does the scan tool indicate is specified value?
Replace the pressure control sorenoid.

Replace the TCM.

Important:
programmed (Refer to SPS for procedure).
be
DTC P0753 (FLASHING CODE 31) Shift Solenoid S1 Electrical
RTW37ALF000601
Circuit Description
The shift solenoi S1 changes the hydraulic route with

the signals from the TCM according to the vehicle
speed and the throttle opening to control shifting. When
the solenoid S1 or S2 fails, the hydraulic circuit is
mechanically operated as a backup.
The TCM detects following "Condition 1" and "

Condition 2" for 2 times continuously at shifting.
Condition 1("GND short"):
Condition 2("Open or Ignition short"):
The TCM operates shifting as following pattern.

using a scan tool.
Normal
Fail
S1
S2
on
on
on
off
No squat control.

failure reported.
Diagnostic Aids

No lock-up control.
No slope control.
Check Trans ON.
DTC stored.
No detect DTC P0722

No detect DTC P0717

Step
1
Action
Value(s)
YES
NO
Go to Step 2
Go to OBD
System Check
Go to Step 3
Refer to
Diagnostic Aids
8~16V
Go to Step 4
Go to Step 10
2. Key ON".
3

J39200 DMM.

Step
4
Action
1. Key "OFF".
Value(s)
YES
NO
0V
Go to Step 5
Go to Step 7
11~15W
Go to Step 9
Go to Step 6
11~15W
Go to Step 7
Go to Step 8
Verify repair
Verify repair
Go to Step 10
Refer to
Diagnostic Aids
Verify repair

3. Key "ON".
5
1. Key OFF".

(E-82).

2. Repair or replace the wire between terminal C9416 and terminal E82-4.

1. Clear the DTC.

3. Check the DTC.
10
Replace the TCM.

RTW37ALF000601
Circuit Description
The solenoid S2 changes the hydraulic route with the

signals from the TCM according to the vehicle speed
and the throttle opening to control shifting. When the
solenoid S1 or S2 fails, the hydraulic circuit is
mechanically operated as a backup.
The TCM detects following "Condition 1" and "Condition

2" for 2 times continuously at shifting.
Condition 1 ("GND short"):
Condition 2 ("Open or Ignition short"):
The TCM operates shifting as following patterns.

using a scan tool.
Normal
Fail
S1
S2
on
on
on
off
No squat control.

failure reported.
Diagnostic Aids

that could short to bare metal or other wiring .
No lock-up control.
No slope control.
No torque reduction.
Check Trans ON.
DTC stored.



Step
1
Action
Value(s)
YES
NO
Go to Step 2
Go to OBD
System Check
Go to Step 3
Refer to
Diagnostic Aids
8~16V
Go to Step 4
Go to Step 10
2. Key ON".
3

J39200 DMM.

Step
4
Action
1. Key "OFF".
Value(s)
YES
NO
0V
Go to Step 5
Go to Step 7
11~15W
Go to Step 9
Go to Step 6
11~15W
Go to Step 7
Go to Step 8
Verify repair
Verify repair
Go to Step 10
Refer to
Diagnostic Aids
Verify repair

3. Key "ON".
5
1. Key OFF".

(E-82).

2. Repair or replace the wire between terminal C9415 and terminal E82-8.

1. Clear the DTC.

3. Check the DTC.
10
Replace the TCM.

DTC P1767 (FLASHING CODE 67) ECM CAN Invalid
RTW37AMF000401
Circuit Description
The automatic transmission control system in AW3040LE uses high speed CAN bus system. The individual
systems to communicate. Transmission control
modules in the vehicle that require continuous, rapid
communication are connected to the high speed CAN
bus. The automatic transmission is continuously notified
of the current engine load status. Since the automatic
transmission control module has to react immediately to
load status changes, rapid communication is required
between the engine control module and the automatic
transmission control module. The high speed CAN bus
in the AW30-40LE is designed as a two-wire CAN bus
(twisted pair). The wires are shielded and twisted. The
transmission rate is 500K band.
The TCM detects invalid signal for 0.18 sec. (After the
TCM leaves a communication start with the ECM for
0.64 sec)
The TCM detects above condition for 2.0 sec
continuously.

The line pressure is max.
The TCM judges APS(Accelerator Position Sensor)
angle is 0% at the time of shift operation.
No lock-up control.
No slope control.
Check Trans ON.
DTC stored.
No squat control.
Engine REV is 7000 rpm.

Coolant tempreature is 80C.
No detect DTC P0712, 0713.

using a scan tool.
failure reported.
Diagnostic Aids
Interference). Check that all wires are properly
routed away from coil, and generator. Also check for
is performed, turn OFF" on electronic autoparts
DTC P1767 (FLASHING CODE 67) ECM CAN Invalid

Step
1
Action
Value(s)
YES
NO
Go to Step 2
Go to OBD
System Check
Go to Step 3
Refer to
Diagnostic Aids
Go to Step 4
Refer to
Diagnostic Aids
About 120W
Go to Step 5
Go to Step 7
About 120W
Go to Step 6
Go to Step 8
Verify repair
Verify repair
Verify epair
2. Key ON".
3
Observe the valid data of the ECM on the scan tool.

Was the valid data of the ECM fixed or did not
synchronized?
Check the wire between the TCM connector and the

ECM connector by J39200 DMM.
1. Key OFF".
and terminal C94-17.
Check the resistance of the ECM..

1. Key OFF".
3. Measure the resistance between the ECM terminal
E60-70 and the ECM terminal E60-71.
Replace or Repair the wire between the TCM

connector C94-7,17 and the ECM connector E6070,71.
Replace the TCM.

Important:
programmed (Refer toSPS for procedure).
be

8
Replace the ECM.

Important:
The replacement ECM must
be
DTC P1790 (FLASHING CODE 61) Transmission Control Module ROM

Checksum Error
Circuit Description
The electrically erasable programable read only
memory (EEPROM) is a permanent memory chip that is
physically solenoid within the TCM. The EEPROM
contans the program and the calibration information
that the TCM needs to control powertrain operation.
EEPROM is not replace able. If the TCM is replaced,
the new TCM will need to be programmed. Equipment
containing the correct program and calibration for the
vehicle is required to program the TCM.

The TCM detects incorrect value of ROM checksum.

Check Trans ON.
DTC stored.

using a scan tool.
failure reported.
Diagnostic Aids
DTC P1790 (FLASHING CODE 61) Transmission Control Module ROM

Checksum Error
Step
1
Action
Was the Powertrain ON-Board Diagnostic (OBD)
Value(s)
YES
NO
Go to Step 2
Go to OBD
System Check
Go to Step 3
Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Verify repair
Verify repair
2. Key OFF" and keep the position for more than 30

seconds.
3. Key ON".
4. Check the DTC on the scan tool.
3
Perform the SPS for the TCM.

Recheck the DTC on the scan tool.

Replace the TCM.

Important:
be
DTC P1791 (FLASHING CODE 62) Transmission Control Module RAM Error
Circuit Description
DTC P1791 is recorded by TCM when there is
malfunction in the RAM.

When the TCM can not detect all RAM from following
step in initialize routine.
Step 1: The TCM writes FFh to the RAM .
Step 2: The TCM reads FFh from the RAM.
Step 3: The TCM writes 00h to the RAM.
Step 4: The TCM reads 00h from the RAM.
Action Taken The DTC Sets

Check Trans ON.
DTC stored.

using a scan tool.
failure reported.
Diagnostic Aids
DTC P1791 (FLASHING CODE 62) Transmission Control Module RAM Error
Step
1
Action
Value(s)
YES
NO
Go to Step 2
Go to OBD
System Check
Go to Step 3
Refer to
Diagnostic Aids
Verify repair
2. Key OFF" and keep the position for more than 30

seconds.
3. Key ON"
4. Check the DTC on the scan tool.
3
Replace the TCM.

Important:
be
DTC U2104 (FLASHING CODE 65) CAN BUSS OFF
RTW37AMF000401
Circuit Description
The automatic transmission control system in AW3040LE uses high speed CAN bus system. The individual
systems to communicate. Transmission control
modules in the vehicle that require continuous, rapid
communication are connected to the high speed CAN
bus. The automatic transmission is continuously notified
of the current engine load status. Since the automatic
transmission control module has to react immediately to
load status changes, rapid communication is required
between the engine control module and the automatic
transmission control module. The high speed CAN bus
in the AW30-40LE is designed as a two-wire CAN bus
(twisted pair). The wires are shielded and twisted. The
transmission rate is 500K band.
The TCM detects CAN BUS OFF for 0.18 sec (After the
TCM leaves a communucation start with the ECM for
0.64 sec) continously..

The throttle pressure is max.
The TCM judges APS(Accelerator Position Sensor)
angle is 0% at the time of shift operation.
No throttle pressure reduction.
No torque reduction.
No lock-up control.
No slope control.
No squat control.
Check Trans ON.
DTC stored.
Engine REV is 7000 rpm.
Coolant tempreature is 80C.

No detect DTC P0712, 0713.

using a scan tool.
failure reported.
Diagnostic Aids
Interference). Check that all wires are properly
routed away from coil, and generator. Also check for
is performed, turn OFF" on electronic auto parts
DTC U2104 (FLASHING CODE 65) CAN BUSS OFF

Step
1
Action
Value(s)
YES
NO
Go to Step 2
Go to OBD
System Check
Go to Step 3
Refer to
Diagnostic Aids
Go to step 4
Refer to
Diagnostic Aids
About 120W
Go to Step 7
Go to Step 5
About 120W
Go to step 6
Go to step 8
Verify repair
Verify repair
Verify repair
2. Key ON".
Does the scan tool indicate DTC U2104?
3
Observe the valid data of the ECM on the scan tool.

Was the valid data of the ECM fixed or did not
synchronized?
Check the wire between the TCM connector and the

ECM connector by J39200 DMM.
1. Key OFF".
and terminal C94-17.
Check the resistance of the ECM..

1. Key "OFF".
3. Measure the resistance between the ECM terminal
E60-70 and the ECM terminal E60-71.
Replace or Repair the wire between the TCM

connector C94-7,17 and the ECM connector E6070,71.
Replace the TCM.

Important:
be

8
Replace the ECM.

Important:
The replacement ECM must
be
ON-VEHICLE SERVICE (AW3040LE) 7A3-1
TRANSMISSION
ON-VEHICLE SERVICE (AW3040LE)
CONTENTS
Service Precaution ................................................. 7A3-2
Location of Clutch, Brake, One-Way Clutch
and Solenoid........................................................ 7A3-3
Operation of Clutch, Brake and One-Way
Clutch.................................................................... 7A3-4
Trnasmission Indentification.............................. 7A3-4
Speed Change and Lock-Up Pattern ............... 7A3-5
Overdrive and Lock-Up Operating
Conditions ............................................................ 7A3-5
Diagnosis................................................................. 7A3-6
Basic Troubleshooting........................................ 7A3-6
Manual Shifting Test........................................... 7A3-12
Stall Test .............................................................. 7A3-12
Time Lag Test ..................................................... 7A3-13
Hydraulic Test...................................................... 7A3-14
Road Test............................................................. 7A3-15
Shift Pont Chart and Lock-Up Point Chart.......... 7A3-19
Shift Pont Chart................................................... 7A3-19
Lock-Up Point Chart ........................................... 7A3-20
Transmission Fluid Level and Condition ............. 7A3-21
Inspection............................................................. 7A3-21
ATF Replacement .................................................. 7A3-22
Inspection............................................................. 7A3-22
Neutral Start Switch (Mode Switch) ..................... 7A3-23
Inspection............................................................. 7A3-23
Removal ............................................................... 7A3-23
Installation ............................................................ 7A3-23
Brake Signal............................................................ 7A3-24
Inspection............................................................. 7A3-24
Input and Output Revolution Sensor.................... 7A3-25
Inspection............................................................. 7A3-25
Pattern Select Switch............................................. 7A3-25
Inspection............................................................. 7A3-25
Solenoid................................................................... 7A3-26
Inspection............................................................. 7A3-26
ATF Temperature Sensor......................................7A3-27

Inspection .............................................................7A3-27
Select Lever....................................................... 7A3-28
Remove or Disconnect .......................................7A3-28
Install or Connect.................................................7A3-29
Shift Cable ......................................................... 7A3-31
Remove or Disconnect .......................................7A3-31
Install or Connect.................................................7A3-32
Torque specifications ..........................................7A3-33
Transmission Control Module (TCM)...................7A3-34
Removal................................................................7A3-34
Installation.............................................................7A3-34
Shift Solenoid and Lock-Up Solenoid...................7A3-35
Removal................................................................7A3-35
Installation.............................................................7A3-36
Valve Body Assembly and Pressure
Control Solenoid .................................................7A3-37
Removal................................................................7A3-37
Installation.............................................................7A3-39
Rear Oil Seal (Adapter Housing, 44) .................7A3-40
Removal................................................................7A3-40
Installation.............................................................7A3-40
Rear Oil Seal (Extension Housing, 42)..............7A3-41
Removal................................................................7A3-41
Installation.............................................................7A3-41
Transmission Assembly.........................................7A3-42
Transmission and Associated Parts .................7A3-42
Removal................................................................7A3-43
Installation.............................................................7A3-46
Major Components..............................................7A3-50
7A3-2 ON-VEHICLE SERVICE (AW3040LE)
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.

parts and systems.
Location of Clutch, Brake, One-Way Clutch and Solenoid
RUW37ALF000201
Legend
(1) Overdrive direct clutch (C0)
(8) One-way clutch (No.2) (F2)

(9) Shift solenoid (S1)
(2) Overdrive brake (B0)
(10) Shift solenoid (S2)
(3) Direct clutch (C2)
(11) One-way clutch (No.1) (F1)
(4) Second coast brake (B1)
(12) Pressure control solenoid (STH)
(5) Forward clutch (C1)
(13) Lock-up solenoid (SL)
(6) Second brake (B2)
(14) Overdrive one-way clutch (F0)
Operation of Clutch, Brake and One-Way Clutch
The identification plate is located on the right rear side

of the transmission.
Transmission Identification
Legend
(1) Transmission Model Number
(2) Production Serial Number
RUW37ASH004301
Speed Change and Lock-Up Pattern

If you select a speed as shown below by specifying
respective positions of transmission shift lever, transfer
switch and pattern select switch, the transmission
control computer controls speed change and lock-up
operations based on the specified pattern in accordance
with the degree of throttle opening and vehicle speed.
Pattern select sw.
position
Transmission shift position

D
NORMAL, POWER
1st[2nd][3rd][O/D]
1st[2nd][3rd]
1st2nd(3rd)
1st(2nd)
3rd START
3rd fixing
[ ]: The lock-up operation is available.

( ): Transmission is shifted at high speed to prevent overrun.
Overdrive and Lock-Up Operating Conditions

The overdrive and lock-up clutch operate if the following
conditions are satisfied.
Shift pattern position

Transmission shift position
Brake lamp switch
Throttle opening
Overdrive
Lock-up clutch
NORMAL
NORMAL
D range
OFF
Fully closed
Except fully closed
Accelerator
About 52 km/h (32 mph) or more
2nd: About 76 km/h (47 mph) or

more
Deceleration
About 42 km/h (26 mph) or more
3rd: About 56 km/h (35 mph) or

more
Vehicle speed
O/D: About 67 km/h (42 mph) or

more
Diagnosis
Basic Troubleshooting
AW3040LE transmission, with Transmission Control
Module (TCM), differs from the Mechanical Hydraulic
control
type
transmissions.
Accordingly,
its
troubleshooting procedure differs also.
Before troubleshooting an TCM, first determine whether
the problem is electrical or mechanical. To do this, just
refer to the basic troubleshooting flowchart provided
below.
If the cause is already known, using the basic

troubleshooting
chart
below
along
with
the
troubleshooting chart should speed the procedure.
F07R200005-X
Troubleshooting Chart
Numbers are arranged in order of probability.
Perform inspections starting with number one and

working up.
Manual Shifting Test
Stall Test
NOTE: With this test, it can be determined whether the

trouble lies within the electrical circuit or is a mechanical
problem in the transmission.
1. Disconnect TCM connector
Inspect manual driving operation
2. Inspect manual driving operation
Check that the shift and gear positions correspond
with the table.
If the L", 2", 3" and D" range gear positions are
difficult to distinguish, do perform the following road
test.
While driving, shift through the L", 2", 3" and D"
ranges. Check that the gear change corresponds to
the gear position.
If any abnormality is found in the above test, do
perform the stall, time lag or gear change tests.
RUW37ASH004101
3. Connect TCM connector

With the engine off, connect the TCM connector.
RUW37ALH000101
The object of this test is to check the overall

performance of the transmission and engine by
measuring the maximum engine speeds at the D" and
R" ranges.
NOTE:
1. Perform the test at normal operation
temperature (50 80C or 122 176F).
fluid
2. Do not continuously run this test longer than 5

seconds.
Measure Stall Speed
Time Lag Test
1. Chock the four wheels.

2. Mount an engine tachometer.
3. Fully apply the parking brake.
4. Step down strongly on the brake pedal with your left
foot.
5. Start the engine.
6. Turn off the A/C.
7. Shift into the D" range. Step all the way down on
the accelerator pedal with your right foot. Quickly
read the highest engine rpm.
Stall speed: 2100
150 rpm
8. Perform the same test in the R" range.
Evaluation
1. If the engine speed is the same for both ranges but
lower than the specified value:
Engine output is insufficient.
Stator one-way clutch is not operating properly.
NOTE: If more than 600 rpm below the specified value,
the torque converter could be faulty.
2. If the stall speed in D" range is higher than
specified:
Line pressure too low
Forward clutch slipping
No.2 one-way clutch not operating properly
3. If the stall speed in R" range is higher than
specified:
Direct clutch slipping
No.3 brake slipping
4. If the stall speed in the R" and D" ranges are
higher than specified:
Improper fluid level
F07RY00003
If the shift lever is shifted while the engine is idling,

there will be a certain time elapse or lag before the
shock can be felt. This is used for checking the
condition of the forward clutch, direct clutch, No.3
brake, and No.2 one-way clutch.
NOTE:
1. Perform the test at normal operation
temperature (50 80C or 122 176F)
fluid
2. Be sure to allow one minute interval between tests.

3. Make three measurements and take the average
value.
Hydraulic Test
Measure Time Lag

1. Fully apply the parking brake.
Check idling speed (A/C OFF).
3. Shift the shift lever from N" to D" range. Using a
stopwatch, measure the time it takes from shifting
the lever until the shock is felt.
Time lag: Less than 0.7 seconds
4. In same manner, measure the time lag for N"
R".
Time lag: Less than 1.2 seconds
Evaluation
1. If N" D" time lag is longer than specified:
Forward clutch malfunction
No.2 one-way clutch not operating properly
2. If N" R" time lag is longer than specified:
Direct clutch malfunction
No.3 brake malfunction
3. If both time lag is longer than specified:
RUW37ALH000201
Preparation
1. Warm up the transmission fluid.
2. Remove the transmission case test plug and mount
the hydraulic pressure gauge.
Oil pressure gauge: J29770A
NOTE: Perform the test at normal operation fluid
Measure Line Pressure

1. Fully apply the parking brake and chock the four
wheels.
1. 12, 23, 3OD and lock-up, up-shifts should take

place, and shift points should conform to those
shown in the automatic shift diagram.
2. Start the engine and check idling rpm.

3. Shift into D" range, step down strongly on the brake
pedal with your left foot and, while manipulating the
accelerator pedal with the right foot, measure the
line pressures at the engine speeds specified in the
table.
4. In the same manner, perform the test in R" range.
Engine
speed
Idling
Stall
Line pressure kPa (kg/cm /psi)

D" range
R" range
500
598
323 382
(5.1
6.1/73
87)
(3.3 3.9/47 55)
1,499 1,833
1,137 1,274
(15.318.7/218266)
(11.613.0/165185)
RUA370MH000101
Evaluation
1. If the measured values at all ranges are higher than
specified:
Pressure control solenoid defective
Primary regulator valve defective
2. If the measured values at all ranges are lower than
specified:
Primary regulator valve defective
Oil pump defective
Pressure control solenoid defective
3. If pressure is low in D" range only:
D" range circuit fluid leakage
4. If pressure is low in R" range only:
R" range circuit fluid leakage
RUA37ASH000101
Road Test
NOTE: Perform the test at normal operation fluid
D" Range Test in NORMAL",

POWER" Pattern Ranges
and
Shift into the D" range and hold the accelerator pedal
constant at the 50% and 100% throttle valve opening
positions.
Push in one of the pattern selector buttons and check
the following:
Evaluation
4. While running in D" range, 2nd, 3rd gears and OD,

check to see that the possible kick-down vehicle
speed limits for 21, 31, 32, OD3 and
OD2 kick-downs conform to those indicated on
the automatic shift diagram.
i. If there is no 12 upshift:
Solenoid S2 is stuck
12 shift valve is stuck
ii. If there is no 23 upshift:
23 shift valve is stuck
iii. If there is no 3OD upshift (throttle valve opening
1/2):
3OD shift valve is stuck
iv. If the shift point is defective:
Refer to TROUBLESHOOTING CHART in this
section.
v. If the lock-up is defective:
Refer to TROUBLESHOOTING CHART in this
section.
2. In the same manner, check the shock and slip at the
12, 23 and 3OD upshifts.
NOTE: Drive the vehicle on level ground.
Evaluation
If the shock is excessive:
Refer to TROUBLESHOOTING CHART in this section.
3. Run at D" range lock-up or OD gear and check for
abnormal noise and vibration.
NOTE: The check for the cause of abnormal noise and
vibration must be made with extreme care as it could
also be due to loss of balance in the propeller shaft,
differential, the torque converter, etc. or insufficient
bending, rigidity, etc. in the power train.
RUW37ASH000201
RUW37AMH000101
5. Check for abnormal shock and slip at kick-down.

6. While running in D" range, OD gear or lock-up",
shift to 2" and L" ranges and check the engine
braking effect at each of these ranges.
7. Also check to see that downshift is made from 32
or from OD to 3 and then to 2 immediately and that
21 downshift point is within the limits shown in the
diagram when tested by releasing the accelerator
pedal and shifting into position of L" while driving in
the third gear or in overdrive.

2" Range Test
Evaluation
i. If there is no engine braking effect in the 2" range:
Second coast (No.1) brake is defective.
ii. If there is no engine braking effect in the L" range:
First and reverse (No.3) brake is defective.
Shift into 2" range and, while driving with the

accelerator pedal held constantly at the specified point
(throttle valve opening 50% and 100%), push in one of
the pattern selectors (only for 4\4) and check on the
following points.
1. At each of the above throttle openings, check to see
that the 12 upshift takes place and that the shift
points conform to those shown on the automatic
shift diagram.
NOTE: There is no OD and no lock-up in the 2" range.
RUW37ASH000301
iii. Also check to see that downshift is made from 32

or from OD to 3 and then to 2 immediately and that
21 downshift point is within the limits shown in the
diagram when tested by releasing the accelerator
pedal and shifting into L" position while driving in
the third gear or in overdrive.
RTW46ASH000301
2. While running in the 2" range and 2nd gear,

release the accelerator pedal and check the
engine's braking effect.
3. Check for 21 downshift and abnormal noise at
acceleration and deceleration, and for shock at
upshift and downshift.
RUW37ASH000401
RUW37ASH000501

R" Range Test
L" Range Test

1. While running above 80 km/h (50 mph) in the D"
range, release your foot from the accelerator pedal
and shift into the L" range.
Then check to see that the 21 downshift occurs at
the specified point shown on the automatic shift
diagram.
Shift into the R" range and, while starting at full throttle,
check for slipping.
RUW37ASH000801
P" Range Test

RUW37ASH000601
2. While running in the L" range, check to see that

there is no upshift to 2nd gear.
3. While running in the L" range, release the
accelerator pedal and check the engine braking
effect.
4. Check for abnormal noise during acceleration and
deceleration.
RUW37ASH000701
Stop the vehicle on a grade (more than 9%) and after

shifting into the P" range, release the parking brake.
Then check to see that the parking lock pawl holds the
vehicle in place.
Shift Point Chart and Lock-Up Point Chart

Shift Point Chart
(H2, H4)
(REAR AXLE RATIO: 4.555)
(RADIUS OF TIRE: 0.350m)
NORMAL" mode
Up shift
km/h (mph)
Range
D
Throttle Opening
1
2
2
3
3
4
Fully opened
48 54 (30 34)
104 110 (65 68)
177 183 (110 114)
Half throttle
32 38 (20 24)
59 65 (37 40)
114 120 (71 75)
Fully opened
48 54 (30 34)
104 110 (65 68)
Half throttle
32 38 (20 24)
59 65 (37 40)
Fully opened
48 54 (30 34)
Half throttle
32 38 (20 24)
Throttle Opening
1
2
2
3
3
4
Fully opened
37 43 (23 27)
94 100 (58 62)
155 161(96 100)
Half throttle
15 21 (9 13)
33 39 (21 24)
65 71 (40 44)
Fully closed
9 15 (6 9)
20 26 (12 16)
39 45 (24 28)
Fully opened
37 43 (23 27)
94 100 (58 62)
Half throttle
15 21 (9 13)
33 39 (21 24)
Fully closed
9 15 (6 9)
20 26 (12 16)
Fully opened
37 43 (23 27)
94 100 (58 62)
Half throttle
15 21 (9 13)
94 100 (58 62)
Fully closed
9 15 (6 9)
94 100 (58 62)
37 43 (23 27)
Down shift
Range
D
km/h (mph)
POWER" mode
Up shift
km/h (mph)
Range
D
Throttle Opening
1
2
2
3
3
4
Fully opened
48 54 (30 34)
104 110 (65 68)
177 183 (110 114)
Half throttle
38 44 (24 27)
74 80 (46 50)
128 134 (80 83)
Fully opened
48 54 (30 34)
104 110 (65 68)
Half throttle
38 44 (24 27)
74 80 (46 50)
Fully opened
48 54 (30 34)
Half throttle
38 44 (24 27)

Down shift
km/h (mph)
Range
Throttle Opening
1
2
2
3
3
4
Fully opened
39 45 (24 28)
94 100 (58 62)
155 161(96 100)
Half throttle
21 27 (13 17)
50 56 (31 35)
95 101 (59 63)
Fully closed
13 19 (8 12)
24 30 (15 19)
47 53 (29 33)
Fully opened
39 45 (24 28)
94 100 (58 62)
Half throttle
21 27 (13 17)
50 56 (31 35)
Fully closed
13 19 (8 12)
24 30 (15 19)
Fully opened
39 45 (24 28)
94 100 (58 62)
Half throttle
21 27 (13 17)
94 100 (58 62)
Fully closed
13 19 (8 12)
94 100 (58 62)
39 45 (24 28)
3rd START" mode

km/h (mph)
Derange, winter mode ONOFF
32 38 (20 24)
Lock-Up Point Chart

(H2, H4)
(REAR AXLE RATIO: 4.555)
(RADIUS OF TIRE: 0.350m)
km/h (mph)
Throttle Opening: 20 %
Range
A/T Mode
Lock-up ON
Lock-up OFF
3rd
4th
3rd
4th
NORMAL
53 59 (33 37)
64 70 (40 43)
45 51 (28 32)
60 66 (37 41)
POWER
78 84 (49 52)
81 87(50 54)
68 74 (42 46)
73 79 (45 49)
Lock-up points in 2nd are following figures regardless

of throttle opening, whether NORMAL or POWER
mode.
Lock-up ON: 73 79 km/h (45 49 mph)
Lock-up OFF: 68 74 km/h (42 46 mph)
Transmission Fluid Level and Condition

Inspection
Park vehicle on level ground and set parking brake.
With the engine idling, move the shift lever through all
positions from P" to L", then return to position P".
Check to see if the level of fluid comes to HOT" range
of about 80C (176F) on the dipstick gauge.
If the level of fluid is too low, replenish to bring it to
maximum level in HOT" range.
Inspection of fluid condition. If the ATF is black or
smells burnt, replace it.
RUW37ASH002501
ATF Replacement
Inspection
NOTE: Do not overfill.
1. Remove the drain plug from oil pan and drain the
fluid.
RUW17ASH013401
2. Reinstall the drain plug securely.

Torque: 19 Nm (14 Ib ft)
3. With the engine OFF, add new fluid through the filler
tube.
Drain and refill
5.2 liter
Dry fill
8.7 liter
Fluid
BESCO ATF III
4. Start the engine and shift the selector into all

position from P" through L", and then shift into P".
5. With the engine idling, check the fluid level. Add
fluid up to the COLD" level on the dipstick.
6. The ATF level must be checked again for correct
level with the HOT" level.
NOTE: To prevent fluid leaks, the drain plug gasket
must be replaced each time this plug is removed.
Neutral Start Switch (Mode Switch)

3. Unstake the lock washer, and then remove the shaft
nut.
Inspection
With a circuit tester, make a continuity test on the
neutral start switch with the moving piece set in each
position.
4. Remove the neutral start switch.
Installation
noting the following points;
If a engine starts at any selector position except N or
P, the neutral start switch (mode switch) should be
adjusted.
1. Loosen the neutral start switch bolt and set the shift
selector to the N" range.
2. Align the groove and neutral basic line.
3. Hold in position and tighten the bolt and nut.
Torque:
Nut 7 Nm (61 Ib in)
Bolt 13 Nm (113 Ib in)
4. Lock the nut with the lock washer tubs at two points.
RUW17ASH013601
RTW37BSH000101
Removal
Preparation:
Disconnect negative () battery cable.
1. Remove the rear side ATF cooler pipe from the
transmission elbow.
2. Disconnect neutral start switch connector.
Brake Signal
Inspection
Check that the brake light comes on when the brake
pedal is depressed.
310RW020
Input and Output Revolution Sensor

Inspection
1. Disconnect the input and output revolution sensor
connector.
2. Use an ohmmeter to measure the resistance
between terminals 1 and 2.
Standard resistance
Input revolution sensor: 387 473
4\2), 560 680 W (at 20C, 4\4)
W (at 20C,
Output revolution sensor: 560 680 W (at 20C)
F07RY00018
Pattern Select Switch

Inspection
Inspect that there is continuity between each terminals.
RTW37ASH000501
Solenoid
2. Operation check
Check the solenoid operation by blowing into an oil
hole as shown in the figure.
Solenoid S1 and S2 (Normal close type)
Inspection
1. Resistance check
Using an ohmmeter, check the resistance
between each terminals (S1/S2/SL) and body.
Solenoid S1, S2 and lock-up solenoid SL
resistance:
11 15 W (at 20C)
When battery terminal is

disconnected
No air leaks

connected
Air passes through
Lock-up solenoid SL (Normal open type)
(Reference) 12 16 W (at 40C)

Using an ohmmeter, check the resistance
between each terminals (STH) and (STHG).
Pressure control solenoid resistance:

disconnected
Air passes through

connected
No air leaks
5 5.6W (at 20C)

(Reference) 5.4 6.1W (at 40C)
244RX00001
220L100001
NOTE: If the pressure control solenoid resistance is not

within speciation, replace the valve body assembly.
244RY00005
ATF Temperature Sensor

Inspection
1. Disconnect the front side ATF cooler pipe from the
elbow and remove the elbow.
2. Remove the ATF temperature sensor from the
transmission case.
3. Place the ATF temperature sensor in a container of
ATF.
RUW37ASH004001
4. Measure the resistance between each terminals,

while warming ATF.
Resistance: 0.5 30 kW (at 0C 120C)
5. If either of the measured values exceeds the
specified value, replace the ATF temperature
sensor.
Torque: 15 Nm (11 Ib ft)
Select Lever
RTW37ALF001101
Legend
(6) Base plate
(1) Rear console
(7) Grooved pin
(2) Front console
(8) Spring plate
(3) Select lever knob
(9) Lever assembly
(4) Upper housing
(10) Sleeve
(5) Lamp assembly
Remove or Disconnect
1.
2.
3.
4.
Block the wheels.

Remove the rear console and the front console.
Remove the 2 screws fixing the select lever knob.
5. Remove the knob together with the knob button and

spring from the lever.
6. Turn the sleeve counterclockwise to remove it. Make
a note of the number of turns required to free the
sleeve.
7. Remove the harness connectors from the base plate.

8. Remove the upper housing (held in place by 4
latched fasteners).
9. Remove the spring plate.
10. Remove the grooved pin.
11. Remove the lever assembly by pressing the rod
down (lever in N position).
12. If lamp replacement is required, remove the lamp
assembly from the lamp socket (align the socket
grooved portion and the lamp assembly protruding
portion).
1. Install the lever assembly to the base plate.

a. Insert and secure shaft.
b. Insert paw led end of shaft into base plate hole.
c. Insert grooved pin of shaft into detente aperture
(lever assembly in N position).
2.Install the spring plate.
a. Insert the grooved pin into the base plate detente
groove until it touches the front wall (lever
assembly in N position).
Install or Connect
NOTE
Apply MULTEMP No. 2 grease (or equivalent) to the
select lever. Refer to the illustration.
RTW37ASH001001
b. Install the spring plate tighten the screws to the

specified torque.
Screw torque
2 Nm (0.2 kgm/17 lb in)
c. Check that the grooved pin moves smoothly in

the detente groove (shift knob temporarily
installed).
3. Temporarily install the sleeve.
4. Install the lamp assembly to the lamp socket (if
removed at disassembly).
a. Align the recessed portion of the lamp socket with
the protruding portion of the lamp assembly.
b. Insert the lamp assembly into the lamp socket
and rotate it 90 degrees clockwise.
RTW37ALH000201
5. Attach the harness connectors to the base plate.

6. Move the lever to the P position.
7. Install the sleeve (rotate the sleeve clockwise the
same
number
of
turns
it
was
rotated
counterclockwise at disassembly).
8. Install the knob, the knob button, and the knob
spring.

9. Adjust the clearance (2) between the detente plate
and the pin by moving the select lever knob sleeve
(1).
Detente plate and pin clearance
mm(in)
0.2 - 1.0 (0.01 - 0.04)
255R300002
10. Install the 2 screws securing the knob and tighten

them to the specified torque.
Screw torque: 2 Nm (0.2kgm/17 lb in)
11. Install the upper housing. Make sure that the 4
latched fasteners are securely closed.
Shift Cable
RTW47ALF000101
Legend
(5) Bracket
(1) Select lever
(6) Clip
(2) Shift cable retaining pawl
(7) Shift cable
(3) Manual shaft select lever
(8) Select lever base
(4) Adjuster
1.
2.
3.
4.
5.
6.
Block the wheels.

Move the select lever to the N position.
Remove the rear console and front console.
Disconnect the shift cable from the select lever.
Press on the shift cable retaining pawl to remove the
cable from the select lever base.
7. Disconnect the shift cable from the transmission

side.
8. Remove the shift cable from the bracket.
9. Pull the shift cable free from the bottom of the
vehicle.
Install or Connect
1. Install the shift cable toward the inside of the cabin
from the bottom of the vehicle.
2. Push the shift cable into the select lever base.
3. Connect the shift cable to the select lever.
4. Fix the shift cable to the bracket.
Install the clip on the marking of shift cable.
5. Check that the select lever is in the N position.
6. Check that the transmission is in the N position.
9. Connect the shift cable to the manual shaft select

lever at the transmission side.
10. Insert the lock piece to the adjuster (cable length
adjustment).
11. Slide the cover on the adjuster and secure lock
piece.
P1010016-2
249R300002
7. Slide the cover in the direction shown by the arrow

(1).
8. Use an ordinary screwdriver to move the lock piece
from the position indicated by the arrow (2). Continue
to move the lock piece until the adjuster position
begins to change.
P1010012
11. Press the select lever knob button 5 times.

Then check that the select lever moves smoothly to
each of its positions.
13. Check that the shift position indicated by the select
lever and the actual shift position are the same.
14. Install the front console and rear console.
16. Remove the wheel blocks.
RTW37ALF001701
RTW37ALF001801
Removal
Installation
Preparation:
To install, follow the removal steps in reverse order.
1. Disconnect the TCM harness connectors.

2. Remove fixing nuts (2 pieces) and TCM with
bracket from the car.
NOTE: The TCM is fitted under instrument panel of the
driver's compartment by means of two stud bolts.
3. Remove fixing nuts (2 pieces) and remove TCM
from bracket.
Shift Solenoid and Lock-Up Solenoid

Removal
Preparation:
Drain the fluid.
Refer to ATF REPLACEMENT in this section.
1. Remove oil lever gage and oil filler tube.
2. Support transfer case (44) or rear cover (42)
with a transmission jack.
3. Remove engine rear mounting nuts.
NOTE: Do not turn over the transmission as this will

contaminate the valve body with foreign materials in the
bottom of the oil pan.
Remove oil pan by lifting the transmission case.
Oil pan seal cutter: J37228
Examine particles in oil pan
Remove the magnet and use it to collect any steel
chips.
Look carefully at the chips and particles in the oil
pan and on the magnet to anticipate what type of
wear you will find in the transmission:
Steel (magnetic) ..................bearing,
gear
and
clutch plate wear
Brass (non-magnetic) ..........bushing wear
F07RW008
4. Remove fule pipe heat protector on tansmission

corssmenber.
5. Remove fuel pipe from the crossmenber.
6. Remove transmission crossmenber.
7. Remove the nineteen bolts.
8. Remove oil pan, using seal cutter J37228.
RUW37ASH002901
240RY00008
9. Remove the oil strainer assembly.
244RY00003

10.Disconnect the solenoid wiring connectors from the
shift solenoid S1(1), S2(2), lock-up solenoid(3) and
pressure control solenoid(4).
249RY00011
249RY00012
11. Remove each retaining bolts and solenoids. (Except

pressure control solenoid:)
Pressure control solenoid cannot be removed.
Installation
To install, follow the removal steps in reverse order
noting the following point;
Refer to the section Reassembly of Major
Components(2) and Transmission Removal and
Installation.
Torque:
Solenoid S1, S2 bolt 7 Nm (61 Ib in)
Lock-up solenoid bolt 10 Nm (87 Ib in)
Valve Body Assembly and Pressure Control Solenoid
244RY00009
Removal
Preparation:
Drain the fluid.
Refer to ATF REPLACEMENT in this section.
1. Remove the nineteen bolts and oil pan.

NOTE:
Two or more persons are required for removal and
installation of the valve body assembly and pressure
control solenoid.
The check valve assembly (1) and the C0
accumulator piston springs (2) will fall from the
transmission case during removal of valve body
assembly.
Protect these parts from damage. The B0 (3), C2 (4),
and B2 (5) accumulator piston and springs may also
fall free and must be protected.
244RY00003
3. Disconnect the solenoid wiring connectors from the

solenoids.
4. Remove the twenty bolts from the valve body.
5. Remove the valve body assembly and pressure
control solenoid.
After removing valve body assembly from the
transmission case, loosen the solenoid clamp
bolt and remove the pressure control solenoid
from the upper valve body assembly.
Also disconnect the harness connector from the
pressure control solenoid.
244RY00018
244RY00006
Installation
To install, follow the removal steps in reverse order
noting the following point;
1. Reinstall the parts removed with the valve body
assembly to their assigned positions in the
transmission case (check valve assembly, C0
accumulator pistons, etc). Install the valve body
assembly to the transmission case.
Refer
to
REASSEMBLY
OF
MAJOR
COMPONENTS (2).
2. Solenoid clamp bolt
Torque : 7 Nm (61 Ib in)
3. Valve body fixing bolts
Each bolt location and length (mm) is indicated in
the figure.
NOTE: Tighten the bolts toward outside equally.
244R200078
4. Oil strainer fixing bolts

5. Oil pan fixing bolts
Rear Oil Seal (Adapter Housing, 44)

Removal
1. Remove the front and rear propeller shaft assembly
from the transfer case.
2. Remove the transfer case assembly from the
transmission case.
Refer to Section 4 DRIVELINE/AXLE.
3. Using a screwdriver, remove the rear oil seal.
Installation
1. Apply ATF to a new rear oil seal lip.
2. Using oil seal installer, install the rear oil seal to the
adapter housing.
Oil seal installer : J36797
RUW37ASH002401
3. Install the transfer case assembly.

Refer to section 4 DRIVE/AXLE.
4. Install the front and rear propeller shaft assembly.
Torque (Propeller shaft flange bolt) : 63 Nm (46
Ib ft)
Rear Oil Seal (Extension Housing, 42)

Removal
1. Remove the rear propeller shaft assembly.
2. Using a screwdriver, remove the rear oil seal.
Installation
1. Apply ATF to a new rear oil seal lip.
2. Using oil seal installer, install the rear oil seal to the
extension housing.
249L100005
3. Install the rear propeller shaft.

Torque (Flange bolt) : 63 Nm (46 Ib ft)
Transmission Assembly
Transmission and Associated Parts
Legend
(9) Under Cover
(1) Rear Propeller Shaft
(10) Flex Plate Torque Converter bolt
(2) Front Propeller Shaft (4WD only)
(11) Shift Cable
(3) Middle Exhaust Pipe
(12) Rear Mount Rubber
(4) Transfer Case Assembly (4WD only)
(13) Heat Protector
(5) Fuel Pipe Clip and Bracket
(14) Transmission Crossmember
(6) ATF Pipe and Clip
(15) Transmission Assembly (2WD)
(7) Oil Level Gauge and Guide Tube
(16) Transmission Assembly (4WD)
(8) Suspension Crossmember

6. Disconnect the transfer harness connectors and the
clips.(4WD only)
Removal
NOTE: Before removing transmission and transfer
assembly from vehicle, change the transfer mode to
2WD using the 4WD push button switch on dash panel.
2. Raise and support vehicle with suitable stands.
3. Remove front propeller shaft.(4WD only)
4. Remove rear propeller shaft.
NOTE: Apply alignment marks on the flange at the
differential side.
Speed sensor
2W-4W shift actuator
NOTE: Avoid turning the vehicle ignition switch to the
ON position when the 2WD-4WD connector is removed
(battery connected).
If the ignition switch must be turned to the ON position,
the controller must first be removed (memory must be
cleared because the CHECK 4WD INDICATOR will
light).
7. Support transfer case with a transmission
jack.(4WD only)
8. Remove the transfer case assembly from the
transmission.(4WD only)
9. Disconnect the shift cable.
10. Remove the fuel pipe clips with the fuel pipes from
the brackets and put aside it. Remove the fuel pipe
brakets from the transmission.
401RS023
5. Remove the middle exhaust pipe.
P1010010
11. Discinnect the transmission harness connectors

and clips.
12. Remove the oil level gauge and the guide tube.
13. Remove the suspension crossmember.
RTW37ASH0001

14. Remove the under covers.
16. Remove the heat protector and the fuel pipe clips
with fuel pipes on the transmission crossmember.
P1010012
15. Remove the flex plate torque converter bolts by

turning the crank shaft.
P1010005B
17.Disconnect the ATF pipes.

18. Remove the ATF pipe clips.
P1010005
P1010024

19.Support the transmission with a transmission jack.
22.Remove the protector and fuel pipe bracket.

Loosen the nut (1) and remove the protector (2).
Remove the bracket with the fuel pipes (3) and
put aside it.
220RS0001
20.Remove the transmission crossmember.

Remove engine rear mount nuts fixing on
transmission crossmember.
RTW37ASH001201
23.Remove the transmission assembly.

Remove transmission retaining nuts and bolts.
Remove transmission assembly from the vehicle.
P1010018
Remove the transmission

removing four fixing bolts.
crossmember
by
If necessary, remove the rear mount rubber from

the transmission.
21. Disconnect the air bleezer hose at the transmission.

Attach the transmission to the engine.
Installation
1. Install the rear
transmission.
mounting
rubber
on
the
Tighten engine transmission bolts as shown in

the figure.

2. Attach the transmission to the engine.
Slowly raise transmission jack until front of the
transmission is aligned with rear of the engine.
RTW37ALF000301

3. Install the protector and fuel pipe bracket.
9. Install flex plate torque converter bolts.
Install the bracket with the fuel pipes (3) to the

transmission.
Install the protector (2) and tighten nuts (1).
Align the flex plate torque converter bolt boss

with flex plate hole by turning the torque
converter.
Install flex plate torque converter bolts (6 pieces)
by turning the crankshaft.
Torque: 54 Nm (54 kgm/40 lb ft)
NOTE: Do not reuse the flex plate torque converter
bolt.
RTW37ASH001201
4. Connect the air bleezer hose on the transmission.
5. Install the transmission crossmember.
6. Install the heat protector and the fuel pipe clips with
fuel pipes on the transmission crossmember.
P1010005
10.Install the under covers to the transmission and

engine.
P1010005B
7. Install rear mount nuts.

8. Remove a transmission jack.
P1010012

18.Tighten oil cooler pipe clamp bolt at the engine
mount side.
11. Install the suspension crossmember.

12. Install filler tube and insert oil level gage.
13. Install select cable by connecting inner cable to
select lever and installing outer cable with bracket.
14. Install the fuel pipe brackets to the transmission.
Install the fuel pipe clips with the pipes to the
bracket.
P1010024
19. Install the transfer case assembly.(4WD only)

Apply a thin coat of molybdenum disulfide grease
to the input shaft spline as shown in the figure.
P1010010
15. Connect the transmission harness connectors and

clips.
16. Connect transmission oil cooler pipes to A/T.
17. Install oil cooler pipe clamp and bracket to the
converter housing.
260R300001
Install the transfer case assembly.

Tighten transmission transfer bolts as shown in
the figure.(4WD only)
24.Install the front propeller shaft.(4WD only)

NOTE: Align alignment marks on the flange.
261R300002
20. Connect transfer

clips.(4WD only)
harness
connectors
and
401RS023
Speed sensor
2W-4W shift actuator

21. Install the middle exhaust pipe.
RTW37ASH0001
22. Install the rear propeller shaft.

NOTE: Align alignment marks on the flange.
23. Install the center bearing on crossmember.
Major Components
Disassembly, inspection and reassembly of each
component group is indicated in the following chapter.
Before reassembly, make sure, again, that all
component groups are assembled correctly.
If something wrong is found in a certain component
group during assembly, inspect and repair this group
immediately.
General Assembly Notes:

1. The automatic transmission is composed of highly
precision-finished parts, necessitating careful
inspection before assembly because even a small
nick could cause fluid leakage or affect
performance.
2. Before assembling new clutch discs and brake

bands, soak them in automatic transmission fluid for
at least thirty minutes.
3. Apply automatic transmission fluid on the sliding or
rotating surfaces of parts before assembly.
4. Use petroleum jelly to keep small parts in their
palces.
5. Do not use adhesive cements on gaskets and
similar parts.
6. When assembling the transmission, be sure to use
new gaskets and O-rings.
7. Dry all parts with compressed air - never use shop
rags.
8. Be sure to install the thrust bearings and races in
the correct direction and position.
Bearing and Race
RUW36AMF000201
Mark
Front Race Diameter

Inside/Outside
Thrust Bearing Diameter

Inside/Outside
Rear Race Diameter

Inside/Outside
28.6 (1.13) / 46.5 (1.83)
28.9 (1.14) / 50.2 (1.98)
28.45 (1.12) / 47.23 (1.86)
29.1 (1.15) / 50.2 (1.98)
24.7 (0.97) / 41.8 (1.65)
24.2 (0.95) / 47.8 (1.88)
37.2 (1.46) / 58.8 (2.31)
33.7 (1.33) / 50.1 (1.97)
36.7 (1.44) / 50.85 (2.00)
33.7 (1.33) / 47.8 (1.88)
26.0 (1.02) / 48.9 (1.93)
26.0 (1.02) / 46.7 (1.84)
26.8 (1.06) / 47.0 (1.85)
35.15 (1.38) / 53.65 (2.11)
34.3 (1.35) / 47.8 (1.88)
33.7 (1.33) / 47.6 (1.87)
35.6 (1.40) / 47.7 (1.88)
28.5 (1.12) / 44.2 (1.74)
27.7 (1.09) / 44.2 (1.74)
10
39.38 (1.55) / 58.15 (2.29)
MEMO
UNIT REPAIR (AW3040LE)
7A41
TRANSMISSION
CONTENTS
Major Components (1)...................................
Major Components (1) and Associated
parts ...........................................................
Disassembly steps......................................
Components (1).............................................
Reassembly ................................................
Major Componets (2) and Associated
Parts...........................................................
Disassembly ...............................................
Reassembly ................................................
Major Components (3) and Associated
Parts...........................................................
Disassembly ...............................................
Reassembly ................................................
Diaassembly, Inspection and Reassembly
of minor Components.................................
Oil Pump ........................................................
Disassembly View ......................................
Disassembly ...............................................
Inspection and Repair.................................
Reassembly ................................................
OD Planetary Gear and OD Direct Clutch
Assembly (C0)..........................................
Disassembled View ....................................
Disassembly ...............................................
Reassembly ................................................
OD Support Assembly ...................................
Disassembly ...............................................
Reassembly ................................................
Direct Clutch Assembly (C-2) ........................
Disassembly ...............................................
Reassembly ................................................
Forward Clutch Asseembly (C-1)...................
Disassembly ...............................................
Reassembly ................................................
Front Planetary Gear .....................................
Disassembly ...............................................
Reassembly ................................................
7A43
7A43
7A43
7A45
7A45
7A47
7A47
7A48
7A411
7A416
7A416
7A417
7A425
7A437
7A438
7A438
7A438
7A439
7A441
7A443
7A443
7A444
7A447
7A448
7A453
7A453
7A453
7A454
7A455
7A458
7A458
7A459
7A460
7A461
7A464
7A464
7A465
7A466
7A467
7A471
7A471
7A471
7A471
7A472
Planetary Sun Gear and No.1 One-Way

Clutch .........................................................
Disassembly ...............................................
Reassembly ................................................
Second Brake Assembly (B2)......................
Disassembly ...............................................
Reassembly ................................................
Rear Planetary Gear Assembly and Output
Shaft ...........................................................
Disassembly ...............................................
Reassembly ................................................
First and Reverse Brake (B3) ......................
Disassembly ...............................................
Reassembly ................................................
Transmission Valve Body assembly ..............
Disassembly ...............................................
Reassembly ................................................
Lower Valve Body ..........................................
Cross Section .............................................
Disassembly ...............................................
Reassembly ................................................
Upper Valve Body ..........................................
Cross Section .............................................
Disassembly ...............................................
Reassembly ................................................
Transmission Case ........................................
Disassembly ...............................................
Reassembly ................................................
Torque Converter...........................................
Adapter Housing (4 4).................................
Disassembly ...............................................
Reassembly ................................................
Extension Housing (4 2) .............................
Disassembly ...............................................
Reassembly ................................................
Main Data and Specifications ........................
7A473
7A473
7A474
7A474
7A475
7A477
7A477
7A477
7A478
7A478
7A481
7A481
7A482
7A484
7A487
7A487
7A488
7A489
7A492
7A492
7A493
7A493
7A496
7A496
7A498
7A4103
7A4104
7A4109
7A4109
7A4111
7A4115
7A4116
7A4121
7A4121
7A4121
7A4122
7A4124
7A4124
7A4125
7A4125
7A4125
7A4125
7A4126
7A4126
7A4126
7A4126
7A4128
7A42
Special Tools .............................................. 7A4132
7A43
Major Components (1)

Major Components (1) and Associated parts
RTW37AMF000601
Legend
(1) Torque converter
(2) Select lever
(3) Neutral start switch (Mode switch)
(4) Elbow
(5) Oil temperature sensor
(6) Breather hose
(7) Input revolution sensor
E nd O FCallo ut
Disassembly steps
1. Remove the torque converter.
2. Remove the select lever.
(8) Output revolution sensor (44)

(9) Output revolution sensor (42)
(10) Speedometer sensor, speedometer driven gear
and plate (42)
(11) Extension housing (42)
(12) Adapter housing (44)
(13) Transmission assembly
7A44
3. Remove the neutral start switch (Mode switch).

Unstake the lock washer.
Remove the nut and bolt, and then remove the
neutral start switch.
13. Remove the transmission assembly.

Install special tool to the transmission unit.
Holding fixture: J37227
Holding fixture base: J328920
Remove the lock washer.
RUW37ASH003001
RTW37BSH000101
4. Remove the two elbows from transmission case.
240RY00001
5. Remove the oil temperature sensor.

6. Remove the breather hose.
7. Remove the Input revolution sensor.
8. Remove the output revolution sensor (44).
9. Remove the output revolution sensor (42).
10. Remove the speedometer sensor, speedometer
driven gear and plate (42).
11. Remove the extension housing (42).
12. Remove the adapter housing (44).
7A45
Components (1)
Reassembly
Align the neutral standard line and the switch

groove and tighten the adjusting bolt.
1. Install a new gasket and the extension housing

(42) to the transmission case.
Torque: 13Nm (113Ibin)

Bend the tabs of the lock washer.
Torque: 36Nm (27Ibft)

2. Install the speedometer driven gear, plate, and
speedometer sensor (42).
NOTE: Bend at least two of the lock washer tabs.
Torque:
Plate bolt 15 Nm (11 Ibft)
Speedometer sensor 25 Nm (18Ibft)
3. Install the adapter housing (44).
Remove any gasket material on the contacting
surfaces of the adapter housing and transmission
case.
RUW17ASH013601
5. Install the oil temperature sensor to the transmission

case.
241RY00020
Apply liquid gasket (TB1281B or its equivalent)

(1) and install the apply gaskets (2) to the adapter
housing as shown in the figure.
Install the adapter housing to the transmission
case.
4. Install the neutral start switch.
Using the transmission select lever, fully turn the
manual valve lever shaft back and return two
notches.
It is now in neutral.
Insert the neutral start switch onto the manual
valve lever shaft and temporarily tighten the
adjusting bolt.
Install the lock washer and nut.
RUW37ASH004001
7A46
6. Install the elbow.

Coat new O-rings with ATF, install them to the two
elbows.
Install the two elbows as shown in the figure.
Torque: 29Nm (3.0kgm/22Ibft)
RTW37BSH000601
7. Install the select lever.

8. Install the output revolution sensor (42).
9. Install the output revolution sensor (44).
10. Install the input revolution sensor.
11. Install the breather hose.
12. Install the torque converter.
Using calipers and a straightedge, measure the
distance from the installed surface of the
transmission housing to top of the torque converter
nut.
Correct distance: 13.5mm (0.53in)
240RY00005
7A47

Major Componets (2) and Associated Parts
RTW37ALF000801
Legend
(1) Converter housing
(2) Oil pan
(3) Oil strainer assembly
(4) Valve body
(5) Check valve, spring
(6) Spring
(7) Accumulator piston (B2)
(8) Accumulator piston (C2)
E nd O FCallo ut
(9)
(10)
(11)
(12)
(13)
(14)
Accumulator piston (B0)

Accumulator piston (C0)
Second brake drum gasket
Solenoid wiring
Snap ring, rotor, key (44)
Snap ring, speedometer sensor drive gear, ball
(42)
(15) Spacer, rotor, key, snap ring (42)
7A48
Disassembly
1. Remove the six bolts and remove the converter
housing.
Look carefully at the chips and particles in the oil

pan and on the magnet to anticipate what type of
wear you will find in the transmission:
Steel (magnetic) ...... bearing, gear and clutch
plate wear
Brass (non-magnetic)... bushing wear
240R200022
2. Remove the oil pan.

NOTE: Do not turn over the transmission as this will
contaminate the valve body with foreign materials in the
bottom of the oil pan.
240RY00008

Remove four bolts holding the oil strainer.
Remove the nineteen bolts.

Remove oil pan by lifting the transmission case.
Oil pan seal cutter: J37228
244RY00003
RUW37ASH002901
3. Examine particles in oil pan.

Remove the magnet and use it to collect any
steel chips.

5. Remove the valve body.
7A49
Remove the twenty bolts from valve body.
Disconnect the connectors from the solenoid S1

(1), S2 (2), lock-up solenoid (3) and pressure
control solenoid (4).
244R200078
6. Remove the check valve and spring.

7. Remove two springs from C0 accumulator piston.
249RY00011
240RY00028
249RY00012
7A410
8. Remove the accumulator piston (B2).
11. Remove the C0 accumulator piston.
9. Remove the accumulator piston (C2).

Remove accumulator pistons and springs from
transmission case.
240RY00012
12. Remove the second brake drum gasket.

13. Remove the solenoid wiring.
240RY00010
10. Applying compressed air to the oil hole, remove the

B0 accumulator piston and spring.
Turn over transmission, remove the solenoid

wiring stopper plate from the case.
Pull the wiring out of the transmission case.
14. Remove the snap ring, rotor and key (44).
Remove the snap ring from the output shaft.
Remove the rotor and key.
240RY00011
247R200002
15. Remove the snap ring, speedometer sensor drive

gear and ball (42).
Remove the speedometer sensor drive gear, and
ball.

16. Remove the spacer, rotor, key and snap ring (42).
Remove the spacer, rotor and key.
7A411
3. Install the spacer, ball, speedometer sensor drive

gear and snap ring (42).
Install the spacer, ball and speedometer sensor
drive gear.
Install the snap ring to the output shaft.
247L100001
Reassembly
247L100001
4. Install the key, rotor and snap ring (44).
1. Install the converter housing.
Install the key and rotor.

Torque:
M10 34Nm (25lbft)
M12 57Nm (42lbft)
247R200002
240R200022
2. Install the snap ring, key and rotor (42).

Install the key and rotor.
7A412
5. Install the second brake drum gasket.
7. Install the accumulator pistons.
Install a new second brake drum gasket to the

transmission case.
Coat the Oring with ATF and install it to the

piston.
Install the three springs and four accumulator
pistons to the bore as shown in th figure.
240RY00013
6. Individual piston operation inspection.

Check for the sound of operation while injecting
compressed air into the oil hole indicated in the
figure.
240RY00027
Piston
Outer diameter
Height
B2
36.8 mm (1.449 in)
62.5 mm (2.461 in)
C2
36.8 mm (1.449 in)
56.6 mm (2.228 in)
B0
31.8 mm (1.252 in)
52.0 mm (2.047 in)
C0
29.8 mm (1.173 in)
44.0 mm (1.732 in)
Spring
240RY00014
Legend
(1) OD direct clutch
(2) Direct clutch
(3) Forward clutch
(4) OD brake
(5) Second coast brake
(6) Second brake
(7) First and reverse brake
(A) C0 Accumulator piston hole
E nd OFCa llou t
NOTE: When inspecting the direct clutch, check with

the C0 accumulator piston hole closed. If there is no
noise, disassemble and check the condition of the parts.
mm (in)
Color
Free length
Outer
diameter
B2
74.6 (2.93)
19.7 (0.78)
BROWN
C2
(Outer)
68.5 (2.7)
20.2 (0.80)
BLUE
C2 (Inner)
42.1 (1.658)
14.7 (0.579)
PINK
B0
63.6 (2.504)
16.0 (0.630)
RED
C0
(Outer)
74.6 (2.937)
20.9 (0.823)
ORANGE
C0 (Inner)
46.0 (1.811)
14.0 (0.551)
YELLOW
7A413
9. Install the valve body.

Align the groove of the manual valve to the pin of
the lever.
240RY00029
240RY00017
Install the twenty bolts.

NOTE: Each bolt length (mm) is indicated in the figure.
Torque: 10Nm (87lbin)
240RY00010
8. Install new check valve and spring.
244R200078
240RY00016
7A414
10. Install the solenoid wiring.

Coat a new O-ring with ATF, and install it to the
solenoid wiring.
Insert the solenoid wiring to the case and install the
stopper plate.
Connect the connectors to the solenoid S1 (1), S2
(2), lock-up solenoid (3), and pressure control
solenoid (4).
11. Install a new oil strainer assembly with gaskets.
244RY00002
Install the oil strainer with the gaskets to the valve

body. Tighten the four bolts.
Torque: 10Nm (87lbin)
249RY00011
244RY00003
249RY00012

Install two magnets in oil pan.
Remove any gasket material and be careful not to
drop oil on the contacting surfaces of the
transmission case and oil pan.
Apply liquid gasket (TB1281 or its equivalent) to the
oil pan as shown in the figure.
NOTE: Install the oil pan as soon as the seal gasket is
applied.
240RY00019
Install and tighten the nineteen bolts.
240RY00020
Torque: 7.4Nm (65lbin)
7A415
7A416

Major Components (3) and Associated Parts
248L100001
Legend
(1) Oil pump
(2) Race
(3) OD planetary gear and OD direct clutch
(4) Race
(5) OD planetary ring gear
(6) Snap ring
(7) Flange, plate and disc (B0)
(8) Bearing and race
(9) Snap ring
(10) OD support
(11) Race
(12) Snap ring
(13) Second coast brake piston assembly
(14) Direct clutch and forward clutch
E nd O FCallo ut
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
E-ring and pin

Second coast brake band
Front planetary ring gear
Bearing and race
Race
Snap ring
Front planetary gear
Drum and one-way clutch
Snap ring
Flange, plate and disc (B2)
Snap ring
Rear planetary gear, second brake drum and
output shaft
(27) Bearing
Disassembly
1. Remove seven bolts fixing the oil pump to the
transmission case.
Remove the oil pump.
7A417
3. Remove the overdrive planetary gear and overdrive

direct clutch with thrust needle bearing from the
transmission case.
252L100001
4. Remove the race from OD planetary gear.

241RY00003
2. Remove race from oil pump.
252L100017
241RY00002
7A418
5. Remove the overdrive planetary ring gear from the

transmission case.
Available flange sizes

3.3 mm (0.130 in)
3.8 mm (0.150 in)
3.5 mm (0.138 in)
3.9 mm (0.154 in)
3.6 mm (0.142 in)
4.0 mm (0.158 in)
3.7 mm (0.146 in)
252RY00002
6. Check piston stroke of overdrive brake

Place a dial indicator onto the overdrive brake
piston as shown in the figure.
244RY00001
252RY00003
Measure the stroke applying and releasing the

compressed air (390 780 kPa or 57 114 psi) as
shown in the figure.
Piston stroke: 1.40 1.70 mm (0.0551 0.0669 in)
If the values are nonstandard, select another flange.
246RY00001

8. Remove one flange, four plates and four discs (B
0).
7A419
10. Using snap ring pliers, remove the snap ring.
246RY00002
246RY00026
9. Remove the thrust bearing and two races.
11. Remove the OD support.

Remove two bolts fixing the overdrive support
assembly to the transmission case.
247RY00003
252RY00004
7A420
Install two removed bolts to the OD support, and

pull out the OD support assembly.
There are two piston rods.

Rod length
78.4 mm (3.09 in)

79.9 mm (3.15 in)
252RY00005
12. Remove the race from OD support.

248RY00004
252RY00006
13. Check piston stroke of second coast brake (B1)

Place a mark on the second coast brake piston rod
Using feeler gauge, measure the stroke applying
the compressed air (390 780 kPa or 57 114 psi)
Piston stroke: 1.5 3.0mm (0.059 0.118in)
If the values are nonstandard, replace piston rod
and recheck piston stroke.
If piston stroke is nonstandard, replace brake band.
248RY00005

7A421
16. Remove the direct clutch and forward clutch from

the transmission case.
248RY00006
15. Applying compressed air to the oil hole, remove the

second coast brake piston assembly.
248RY00008
17. Remove the E-ring from the pin.

Remove the pin from the brake band.
248RY00007
248RY00009
7A422
18. Remove the second coast brake band from the

transmission case.
20. Remove the bearing and race.
247RY00005
248RY00010
21. Remove the race.
19. Remove the front planetary ring gear from the

transmission case.
247RY00006

247RY00004
248RY00011

NOTE: Hold the output shaft to prevent it from falling.
The output shaft falls when the snap ring is removed.
23. Remove the front
transmission case.
planetary
gear
from
7A423
25. Using two screwdrivers, remove the snap ring.
the
248RY00014
26. Remove, five discs and six plates (B2).

247RY00007
24. Remove sun gear input drum and one-way clutch.
248RY00015
248RY00012
7A424
27. Check pack clearance of first and reverse brake (B

3)
Using a feeler gauge, measure the clearance
between the plate and second brake drum as shown
in the figure.
29. Remove the rear planetary gear, second brake drum

and output shaft as an assembly.
Clearance: 0.6 1.12mm (0.0236 0.0440in)

If the values are nonstandard, replace the discs.
247R200001
30. Remove the assembled thrust bearing and race

from the transmission case.
248RY00016
248RY00018
248RY00017
Reassembly
1. Coat the assembled bearing and race with
petroleum jelly and install it onto the transmission
case.
Assembled bearing and race (Reference)
Bearing and race
Diameter
Inside
39.38 mm (1.550 in)
Outside
58.15 mm (2.289 in)
7A425
Align the splines of the transmission case and the

assembled rear planetary gear, second brake
drum and output shaft, indicated by A in the
figure.
247RY00010
3. Using snap ring pliers, install the snap ring.
247RY00008
2. Install the rear planetary gear, second brake drum

and output shaft.
Align the teeth of the second brake drum,
flanges, discs and plates as shown in the figure.
246RY00003
247RY00009
7A426
4. Check pack clearance of first and reverse brake.

Using a thickness gauge, measure the clearance
between the plate and second brake drum as shown
in the figure.
6. Install one-way clutch in the transmission case.
Clearance: 0.60 1.12mm (0.0236 0.0440in)

If the values are nonstandard, check for an improper
installation.
247RY00011
7. Install discs and plates (B2).

Instal the 2.5mm (0.098in) thick plate with the
rounded edge side of the plate facing the disc.
Alternately install five discs and six plates (Disc first)
248RY00016
5. Install second brake piston sleeve.
246RY00005
246RY00004

8. Install the snap ring.
7A427
10. Install the front planetary gear and bearing to the

sun gear.
NOTE: Confirm the bearing and race is installed
correctly.
Bearing and race diameter (Reference)
Inside
Outside
Bearing
35.6 mm (1.40 in)
47.7 mm (1.88 in)
Race
33.7 mm (1.33 in)
47.6 mm (1.87 in)
248RY00014
9. While turning the sun gear input drum clockwise,

install it into the one-way clutch
NOTE: Confirm the thrust washer is installed correctly.
247RY00012
With wooden blocks under the output shaft, stand

the transmission on the output shaft.
248RY00020
247RY00013
7A428
11. Using snap ring pliers, install the snap ring.
13. Insert the second coast brake band to the

transmission case.
248RY00011
12. Coat the bearing race with petroleum jelly and install
it onto the front planetary gear.
Bearing race diameter (Reference)
Bearing race
Diameter
Inside
34.3 mm (1.350 in)
Outside
47.8 mm (1.882 in)
248RY00010
14. Install the E-ring and pin.

Install the pin through the brake band.
248RY00021
247RY00014

Install the E-ring to the pin.
7A429
16. Coat the race with petroleum jelly and install it onto
the front planetary ring gear.
Race diameter (Reference)
Inside
Outside
Race
26.8 mm (1.055 in) 47.0 mm (1.850 in)
248RY00022
15. Coat the bearing and race with petroleum jelly and
install them onto the forward clutch.
Inside
Outside
Bearing
26.0 mm (1.024 in) 46.7 mm (1.839 in)
Race
26.0 mm (1.024 in) 48.9 mm (1.925 in)
247RY00015
Align the flukes of the discs in the forward clutch.
247RY00016
248RY00023
7A430
17. Align the spline of the front planetary gear with the
flukes of the discs and install the front planetary
gear to the forward clutch.
19. Install the assembled direct clutch, forward clutch

and front planetary ring gear into the transmission
case.
247RY00017
247RY00018
install them onto the ring gear.
Inside
Outside
Using vernier calipers, measure the distance

between the sun gear input drum and direct
clutch drum as shown in the figure.
Bearing
35.15 mm (1.384 in)
53.65 mm (2.112 in)
Race
35.15 mm (1.384 in)
53.65 mm (2.112 in)
Height: 2.5 4.5 mm (0.098 0.177 in)

If the values are nonstandard, check for an
improper installation.
248RY00024
247RY00019

Coat the assembled bearing and race with
petroleum jelly and install it onto the forward
clutch.
Assembled bearing and race diameter
(Reference)
Inside
Outside
Bearing
and race
33.7 mm (1.33 in)
7A431
21. Coat two new oil seals with ATF and install them to
the piston cover.
Install the spring, second coast brake piston
assembly and piston cover to the transmission
case.
Using snap ring pliers, install the snap ring.
47.8 mm (1.88 in)
248RY00027
248RY00025
22. Check piston stroke of second coast brake

Place a mark on the second coast brake piston rod
20. Assembly second coast brake piston assembly.

Coat the oil seal ring with ATF and install it to the
second coast brake piston.
Install the washer, spring and piston to the piston
rod. Install the E-ring.
248RY00005
Using wire gauge, measure the stroke by applying

the compressed air (390 780 kPa or 57 114 psi)
RUW37ASH004401
Legend
(1) Second coast brake piston
(2) Oil seal
(3) Piston rod
E nd OFCa llou t
7A432

installation.
24. Aim the bolt and oil holes of the overdrive support
toward the valve hole side, and align them with the
bolt hole of the transmission case and insert the
overdrive support.
248RY00004
the overdrive support assembly.
Inside
Outside
Race
36.7 mm (1.44 in)
252RY00005
25. Using snap ring pliers, install the snap ring as

50.8 mm (2.00 in)
252RY00008
252RY00007

Install and tighten the two bolts.
7A433
27. Install the (flat ring) 4.0 mm (0.157 in) thick flange
with the rounded edge side of the flange facing the
disc.
Alternately install four discs and four plates. (Disc
first)
Torque: 25Nm (19lbft)
252RY00004
26. Check end of output shaft.

Using a dial indicator, measure the end play of the
output shaft by hand.
End play: 0.27 0.86 mm (0.0106 0.0339 in)
252RY00009
28. Install the (stepped ring) flange with the flat side of
the flange facing the disc.
Install the snap ring.
Snap ring (Reference)
Inside diameter
167.9 mm (6.61 in)
247RY00020
246RY00001
7A434
29. Check piston stroke of overdrive brake.

Place a dial indicator onto the overdrive brake
piston as shown in the figure.
Remove the snap ring.
246RY00001
Remove one flange, four plates and four discs.

252RY00003
Measure the stroke by applying and releasing the

Piston stroke: 1.40 1.70 mm (0.0551 0.0669 in)
installation.
Available flange size
3.3 mm (0.130 in)
3.8 mm (0.150 in)
3.5 mm (0.138 in)
3.9 mm (0.154 in)
3.6 mm (0.142 in)
4.0 mm (0.158 in)
3.7 mm (0.146 in)
246RY00026
244RY00001

30. Coat the bearing and races with petroleum jelly and
install them onto the overdrive support.
Bearing and races diameter (Reference)
Inside
Outside
Race
(Front)
37.2 mm (1.465 in) 58.8 mm (2.315 in)
Bearing
and race
(Rear)
33.7 mm (1.327 in) 50.1 mm (1.972 in)
7A435
install them onto the planetary ring gear.
Inside
Outside
Bearing
and race
24.2 mm (0.953 in) 47.8 mm (1.882 in)
252RY00011
252RY00010
31. Install the overdrive planetary ring gear.
Install the (flat ring) 4.0 mm (0.157 in) thick flange

with the rounded edge side of the flange facing the
disc.
Alternately install four discs and three plates. (Disc
first)
Install the (stepped ring) flange with the flat side of
the flange facing the disc.
the planetary gear.
Inside
Outside
Race
24.7 mm (0.972 in) 41.8 mm (1.646 in)
252RY00002
252RY00001
7A436
34. Install the overdrive planetary gear and direct clutch.
the oil pump.
Inside
Outside
Race
28.6 mm (1.126 in) 46.5 mm (1.831 in)
252L100001

petroleum jelly and install it onto the direct clutch.
Inside
Outside
Bearing
and race
252RY00014
28.9 mm (1.138 in) 50.2 mm (1.976 in)
37. Coat the O-ring with ATF and install it around the
pump body.
Place the oil pump through the input shaft, and align
the bolt holes of the pump body with the
transmission case.
Hold the input shaft, and lightly press the oil pump
body to slide the oil seal rings on the stator shaft
through the direct clutch drum.
CAUTION:
Do not push on the oil pump strongly or the oil
seal ring will stick to the direct clutch drum.
Install the seven bolts.
Torque: 22 Nm (16 lbft)
38. Check input shaft rotation.
Make sure the input shaft rotates smoothly.
252L100018
241RY00003
Diaassembly,
Inspection
and
Reassembly of minor Components
NOTE: The instructions here are organized so that you
work on only one component group at a time.
This will help avoid confusion from similar-looking parts
of different subassemblies being on your workbench at
the same time.
The component groups are inspected and repaired from
the converter housing side.
As much as possible, complete the inspection, repair
and reassembly before proceeding to the next
component group. If a component group cannot be
reassembled because parts are being ordered, be sure
to keep all parts of that group in separate container
while proceeding with disassembly, inspection, repair
and reassembly of other component groups.
Recommended ATF type DEXRON III.
General Cleaning Notes:

1. All disassembled parts should be washed clean and
any fluid passages and holes should be blown
through with compressed air.
2. When using compressed air to dry parts, always aim
away from yourself to prevent accidentally spraying
automatic transmission fluid in your face.
3. The recommended automatic transmission fluid
should be used for cleaning.
Parts Arrangement:
1. After cleaning, the parts should be arranged in
proper order to allow performing inspection, repairs,
and reassembly with efficiency.
2. When disassembling a valve body, be sure to keep
each valve together with the corresponding spring.
3. New brakes and clutches that are to be used for
replacement must be soaked in transmission fluid
for at least thirty minutes before assembly.
General Assembly:
1. All oil seal rings, clutch discs, clutch plates, rotating
parts, and sliding surfaces should be coated with
transmission fluid prior to reassembly.
2. All gaskets and rubber O-ring should be replaced.
3. Make sure that the ends of a snap ring are not
aligned with one of the cutouts and are installed in
the groove correctly.
4. If a worn bushing is to be replaced, the
subassembly containing that bushing must be
replaced.
5. Check thrust bearings and races for wear or
damage. Replace if necessary.
6. Use petroleum jelly or vaseline to keep parts in
place.
7A437
7A438
Oil Pump
Disassembly View
241R200003
Legend
(1) Oil seal ring
(2) O-ring
(3) Stator shaft
(4) Oil pump drive gear

(5) Oil pump driven gear
(6) Oil pump body
E nd O FCallo ut
Disassembly
1. Use torque converter as work stand.
Remove 2 oil seal rings from stator shaft.
241RY00005

2. Remove the O-ring.
7A439
2. Check stator shaft bushing.

Using a dial indicator, measure the inside diameter
of the stator shaft bushing.
3. Remove the stator shaft.

4. Remove the oil pump drive gear.
5. Remove the oil pump driven gear.
6. Remove the oil pump body.
Remove 13 bolts, and then remove the stator shaft
from oil pump body.
Then remove drive and driven gear.
Maximum inside diameter: Front side: 21.58mm

(0.8496in)
Maximum inside diameter: Rear side: 27.08mm
(1.0661in)
If the inside diameter is greater than the maximum,
replace the stator shaft.
241RY00006
241RY00008

damage or any abnormal conditions are found through
inspection.
1. Check oil pump body bushing.
of the oil pump body bushing.
Maximum inside diameter: 38.19mm (1.5035in)
3. Check tip clearance of both gears.

Measure between the gear teeth
cresent-shaped part of the pump body.
and
the
Standard tip clearance: 0.11 0.14mm (0.0043

0.0055in)
Maximum tip clearance: 0.19mm (0.0075in)
If the tip clearance is greater than the maximum,
replace the drive gear, driven gear or pump body.

replace the oil pump body.
241RY00009
241RY00007
7A440
4. Check body clearance of driven gear.

Push the driven gear to one side of the body.
Use a feeler gauge, measure the clearance.
Standard body clearance: 0.07 0.15mm (0.0028
0.0059in)
6. Check oil seal.

Check for wear, damage or cracks.
If necessary, replace oil seal.
Pry off the oil seal with a screwdriver.
Maximum body clearance: 0.2mm (0.0079in)

If the body clearance is greater than the maximum,
241RY00012
Using special tool, install a new oil seal.

The oil seal end should be flush with the outer edge
of the pump body.
Coat the oil seal lip with multipurpose grease.
241RY00010
5. Check side clearance of both gears.

Using a steel straightedge and a feeler gauge,
measure the side clearance of both gears.
Standard side clearance: 0.02 0.05mm (0.0008
0.0020in)
Maximum side clearance: 0.1mm (0.004in)
If the side clearance is greater than the maximum,
241RY00013
241RY00011
Reassembly
7A441
5. Install the oil seal ring.
1. Place the oil pump body on the torque converter.

2. Coat the driven gear and drive gear with ATF.
3. Install the driven gear and drive gear.
Coat the oil seal rings with ATF.

Contract the oil seal rings as shown, and install
them onto the stator shaft.
NOTE: Do not spread the ring ends too much.
241RY00014
241RY00015
4. Align the stator shaft with the bolt holes.

Tighten the thirteen bolts.
6. Coat a new O-ring with ATF and install it to the oil

pump body.
O-ring size (Reference)
Inside diameter
204.9mm (8.067in)
Thickness
3.5mm (0.138in)
241RY00006
241RY00016
7A442
7. Check oil pump drive gear rotation.

Make sure the drive gear rotates smoothly when
installed to the torque converter.
241RY00017
7A443
OD Planetary Gear and OD Direct Clutch Assembly (C0)

Disassembled View
RTW37AMF000701
Legend
(1) OD direct clutch assembly
(2) OD planetary gear assembly
(3) Thrust bearing
(4) Snap ring
(5) Flange, disk and plate
(6) Snap ring
(7) Piston return spring
(8) OD direct clutch piston
(9) O-ring
E nd O FCallo ut
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Race and bearing asm

Snap ring
Ring gear flange
OD planetary ring gear
Race
Snap ring
Retaining plate
OD one-way clutch
Thrust washer
7A444
Disassembly
1. Check operation of one-way clutch.
Hold the OD direct clutch drum and turn the input
shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.
4. Check piston stroke of OD direct clutch (C0).

Place the oil pump onto the torque converter, and
then place the OD direct clutch assembly onto the
oil pump.
252L100005
RUW37ASH004501
2. Remove OD direct clutch assembly from OD

planetary gear assembly.
252L100004
3. Then remove thrust bearing with the race from OD

direct clutch drum.
Use a dial indicator, measure the OD direct clutch

piston stroke applying and releasing the
shown.
252L100016
7A445
Remove the OD direct clutch piston.
5. Remove snap ring from clutch drum.
252L100006
252L100008
6. Remove flange, two discs and two plates.
10. Remove two Orings from piston.
7. Place special tool on the spring retainer and

compress the return spring.
Using snap ring pliers, remove the snap ring.
Spring compressor : J233271
11. Remove bearing and race from OD planetary ring

gear.
RTW46BSH000301
252L100007
8. Remove piston return spring

9. Remove the OD direct clutch piston with O-ring.
Place the oil pump onto the torque converter and
then place the OD direct clutch onto the oil pump.
Holding the OD direct clutch piston by hand,
apply compressed air to the oil pump to remove
the OD direct clutch piston.
7A446
12. Remove snap ring.
15. Remove snap ring, using screwdriver.
252RY00022
13. Remove ring gear flange from OD planetary ring

gear.
252RY00024
16. Remove retaining plate from OD planetary gear.
252RY00025
252RY00023
17. Remove OD one-way clutch with outer race.
14. Remove the Race.
252RY00026

18. Remove the thrust washer.
7A447
3. Check OD direct clutch piston.

Check that the check ball is free by shaking the
piston. Check that the valve does not leak by
applying low-pressure compressed air.

1. Check discs.
Using a micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04mm (0.0803in)
If the thickness is less than the minimum, replace
the disc.
252RY00029
4. Check OD direct clutch drum bushings.

of the OD direct clutch drum bushings.
252RY00027

replace the OD direct clutch drum.
2. Check piston return spring

Using calipers, measure the free length of the return
spring.
Standard length: 15.8mm (0.622in)
252L100009
252RY00028
7A448
5. Check OD planetary gear bushing.

of replace the OD planetary gear bushing.
2. Install the one-way clutch into the outer race, with

the flanged side of the one-way clutch facing
upward.

replace the OD planetary gear.
252RY00033
3. Install OD one-way clutch with outer race to

overdrive planetary gear.
252RY00031
Reassembly
1. Install the thrust washer to the OD planetary gear,
facing the grooved side upward.
252RY00026
252RY00032

4. Install retaining plate, then install snap ring, using a
screwdriver.
7A449
6. Install ring gear flange to OD planetary ring gear.
252RY00023
252RY00024
7. Install snap ring, using a screwdriver.
5. Coat the race with petroleum jelly and install it to the

planetary gear.
Inside diameter
24.7mm (0.972in)
Outside diameter
41.8mm (1.646in)
252RY00022
252RY00034
7A450
8. Install the race and bearing asm onto the OD

planetary ring gear.
Race and bearing asm diameter (Reference)
Inside
Outside
Bearing
and race
24.2mm (0.953in)
11. Install piston return spring.
47.8mm (1.882in)
252L100012
RTW37ASH001101
12. Place special tool on the spring retainer, and

Install the snap ring with snap ring pliers.
Be sure the end gap of the snap ring is not aligned
with the spring retainer claw.
9. Coat new O-rings with ATF and install them on the

OD direct clutch piston.
10. Being careful not to damage the O-rings, press in
the OD direct clutch piston into the clutch drum,
using both hands.
252L100007
252L100011

13. Install two plates and two discs then install the
flange, with the flat side facing downward.
7A451
15. Check piston stroke of OD direct clutch (C0)

Place the oil pump onto the torque converter, and
then place the OD direct clutch assembly onto the
oil pump.
252L100013

252L100005
Using a dial indicator, measure the OD direct clutch

piston stroke by applying and releasing the
shown.
If the piston stroke is not within specification,
replace the disc and recheck the piston stroke.
If the piston stroke is nonstandard, select another
flange.
Flange sizes
Flange thickness
Flange thickness
3.8mm (0.150in)
3.4mm (0.134in)
3.7mm (0.146in)
3.3mm (0.130in)
3.6mm (0.142in)
3.2mm (0.126in)
3.5mm (0.138in)
3.1mm (0.122in)
252L100014
252L100016
7A452

petroleum jelly and install it with the race side facing
downward.
Bearing and race (Reference)
Inside diameter
28.9mm (1.138in)
Outside diameter
18. Check operation of one-way clutch

Hold the OD direct clutch drum and turn the input
shaft.
The input shaft should turn freely clockwise and
should lock counterclockwise.
50.2mm (1.976in)
RUW37ASH004501
252L100015
17. Align the flukes of discs in the direct clutch.

Install the OD direct clutch assembly onto the OD
planetary gear.
252L100004
Legend
(1) Free
(2) Lock
E nd OFCa llou t
7A453
OD Support Assembly
Disassembled View
252R200003
Legend
(1) Thrust bearing
(2) Race
(3) Thrust washer (plastic)
(4) Snap ring
(5)
(6)
(7)
(8)
(9)
Piston return spring

OD brake piston
O-ring
Oil seal ring
OD support
E nd O FCallo ut
Disassembly
1. Check OD brake piston movement.
Place the OD support assembly onto the direct
clutch assembly.
252RY00042
7A454
Apply compressed air into the oil passage as

shown, and be sure that the OD brake piston moves
smoothly.
7. Place the OD support onto the direct clutch

assembly.
Hold the OD brake piston so it is not slanted and
apply compressed air into the passage to remove
the OD brake piston.
Remove the OD brake piston.
252RY00043
2. Remove the thrust bearing.

3. Remove the race.
252RY00045
4. Remove the thrust washer (plastic).

compress the return spring with a shop press.
8. Remove the O-ring and oil seal rings from OD

support.

Remove the snap ring with a screwdriver.

damage or any abnormal conditions are found through
inspection.
1. Check piston return spring
spring.
RUW37ASH003101
6. Romove the piston return spring.
252RY00046
Reassembly
7A455
1. Coat the two oil seal rings with ATF.

Contract the oil seals as shown, and install them
onto the OD support.
NOTE: Do not spread the ring ends more than
necessary.
252RY00049
252RY00047

compress the return spring with a shop press.
Install the snap ring with a screwdriver.
with cutout portion of the OD support.
2. Coat two new O-rings with ATF and install them on

the OD brake piston.
3. Being careful not to damage the O-rings, press the
brake piston into the OD support, using both hands.
RUW37ASH003201
252RY00048
7A456
6. Coat the thrust washer (plastic) with petroleum jelly

and install it onto the OD support.
NOTE: Make sure that the lug fits into the hole on the
OD support.
8. Turn over OD support.

Coat the two races with petroleum jelly, and install
them onto the OD support.
Race and bearing diameter (Reference)
Inside
Outside
Race (A)
37.2mm (1.465in)
58.8mm (2.315in)
Bearing and
race (B)
33.7mm (1.327in)
50.1mm (1.972in)
252RY00051
7. Coat the race with petroleum jelly, and install it onto

the OD support.
Inside diameter
36.7mm (1.44 in)
Outside diameter
50.85 mm (2.00 in)
252RY00069
9. Check OD brake piston movement.

Place the OD support assembly onto the direct
clutch assembly.
252RY00052
252RY00042

Apply compressed air into the oil passage as
shown, and be sure that the OD brake piston moves
smoothly.
252RY00043
7A457
7A458
Direct Clutch Assembly (C-2)

Disassembled View
248R200001
Legend
(1) Clutch drum thrust washer (Plastic)
(2) Snap ring
(3) Flange
(4) Plate and disc
Five plates and five discs
E nd O FCallo ut
(5)
(6)
(7)
(8)
(9)
Snap ring
Direct clutch drum
Direct clutch piston
O-ring
Disassembly
Remove direct clutch drum assembly from forward
clutch assembly.
7A459
Using a dial indicator, measure the direct clutch

piston stroke by applying and releasing compressed
air (390 780 kPa or 57 114 psi) as shown.
Pack clearance: 0.4 0.7 mm (0.016 0.028 in)
248RY00028
1. Check piston stroke of direct clutch (C2).

Place the direct clutch assembly onto the OD
support assembly.
RUW37ASH004901
2. Remove the clutch drum thrust washer (Plastic)

from the rear end of direct clutch.
3. Remove the snap ring from the direct clutch drum.
4. Remove the flange, plates and discs.
248RY00029
248RY00002
6. Remove the piston return spring.
7A460
7. Place the direct clutch drum onto the OD support.

Holding the direct clutch piston by hand, apply
compressed air to the OD support to remove the
direct clutch piston.
Remove the direct clutch piston from direct clutch
drum.
2. Check discs.
Using micrometer, measure the thickness of the
discs.
Minimum thickness: 2.04mm (0.0803in)
If the thickness is less than the minimum, replace
the disc.
248RY00030
8. Remove two O-rings from piston.
252RY00027

1. Check piston return spring.
spring.
3. Check direct clutch piston.

Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying
low-pressure compressed air.
248RY00031
247RY00034

4. Check direct clutch drum bushing.
of the clutch drum bushing.
7A461

If the inside diamater is greater than the maximum,
replace the clutch drum.
248RY00034
4. Compress piston return spring and install snap ring

in groove.
Place special tool on the spring retainer, and
248RY00032
Be sure the end gap of the snap ring is not

aligned with the spring retainer claw.
Reassembly
direct clutch piston.
Spring compressor: J25048
2. Install direct clutch piston to direct clutch drum.

Being careful not to damage the O-rings, press in
the direct clutch piston into the clutch drum, using
both hands.
248RY00002
248RY00033
7A462
5. Install four plates and four discs.

Install in order : PDPDPDPD
P : Plate, D : Disc
7. Install the snap ring with a screwdriver.

with the cutout portion of the direct clutch drum.
248RY00062
248RY00036
6. Install the flange, with the flat side facing downward.
8. Check piston stroke of direct clutch (C2).

Place the direct clutch assembly onto the OD
support assembly.
248RY00035
248RY00029
Using a dial indicator, measure the direct clutch

replace the discs and recheck the piston stroke.
If the piston stroke is nonstandard, select another
flange.

Flange sizes
Flange thickness
Flange thickness
3.3mm (0.130in)
3.8mm (0.150in)
3.4mm (0.134in)
3.5mm (0.138in)
4.0mm (0.157in)
3.6mm (0.142in)
3.7mm (0.146in)
4.2mm (0.165in)
7A463
Align the flukes of discs in the direct clutch.

Install the direct clutch assembly onto the forward
clutch assembly.
Check that the distance from the direct clutch end to
the forward clutch end is 71.2mm (2.803in).
248RY00038
RUW37ASH004901
9. Coat the clutch drum thrust washer (plastic) with

petroleum jelly and install it onto the direct clutch.
NOTE: Make sure that the lugs fit into the cutout
portions on the direct clutch.
248RY00037
7A464
Forward Clutch Asseembly (C-1)

Disassembled View
248R200003
Legend
(1) Thrust bearing
(2) Race
(3) Snap ring
(4) Flange
(5) Disc and plate
Six discs and six plates
(6) Cushion plate
E nd O FCallo ut
(7)
(8)
(9)
(10)
(11)
(12
(13)
(14)
Snap ring
Piston
O-ring
O-ring
Oil seal ring
Thrust bearing
Forward clutch drum
Disassembly
7A465
2. Check piston stroke of forward clutch (C1).
Remove forward clutch assembly from direct clutch

assembly.
248R200008
248RY00039
1. Place wooden blocks, etc. to prevent forward clutch

shaft from touching the work stand, and place the
OD support on them.
Place the forward clutch onto the OD support and
remove the bearing and race.
Using a dial indicator, measure the forward clutch

3. Remove snap ring from clutch drum.
248RY00041
248RY00048
4. Remove the flange, disc and plate, and cushion

plate.
7A466

248RY00031
2. Check forward clutch drum bushing.

of the forward clutch drum bushing.
248RY00003

7. Place the forward clutch drum onto the OD support.
Holding the forward clutch piston by hand, apply
compressed air to the OD support to remove the
forward clutch piston.

If the inside diameter is greater then the maximum,
replace the forward clutch drum.
248RY00043
248RY00042
3. Check disc, plate and flange.

Check to see if the sliding surface of the disc, plate
and flange are worn or burnt. If necessary, replace
them.
10. Remove the oil seal rings and thrust bearing from
forward clutch drum.
If the lining of the disc is peeling off or discolored,

or even if parts of the printed numbers are
defaced, replace all discs.
8. Remove the O-rings from piston.

9. Remove the O-ring from forward clutch drum.

1. Check forward clutch piston
Check that check ball is free by shaking the piston.
Check that the valve does not leak by applying
low-pressure compressed air.

Before assembling new discs, soak them in ATF
for at least fifteen minutes.
7A467
Reassembly
1. Coat the assembled thrust bearing and race with
petroleum jelly and install it onto the forward clutch
drum, with the race side facing downward.
Bearing and race (Reference)
Inside diameter
33.7mm (1.327in)
Outside diameter
47.8mm (1.882in)
248RY00045

spring.
248RY00044
2. Coat the three oil rings with ATF.

Contract the oil seal rings as shown, and install
three oil seal rings onto the forward clutch drum.
NOTE: Do not spread the ring ends more than
necessary.
247RY00034
248RY00046
7A468
3. Coat a new O-ring with ATF and install O-ring on the

forward clutch drum.
248RY00065
248RY00047
4. Coat new O-rings with ATF and install two O-rings

on the forward clutch piston.
5. Being careful not to damage the O-rings, press the
forward clutch piston into the forward clutch drum.

248RY00049
248RY00003

8. Install cushion plate rounded side down as shown.
7A469
11. Install the snap ring with a screwdriver.

with the cutout portion of the forward clutch drum.
248RY00069
9. Install five discs and five plates.

Install in order: PDPDPDPDPD
248RY00041
10. And then install the flange, with the rounded edge
facing downward.
12. Check piston stroke of forward clutch (C1).

Using a dial indicator, measure the forward clutch
piston stroke by applying and releasing the
shown.
replace the discs, and recheck the piston stroke.
Available flange sizes
3.0mm (0.118in)
3.4mm (0.134in)
4.2mm (0.165in)
3.6mm (0.142in)
4.4mm (0.173in)
3.8mm (0.150in)
3.2mm (0.126in)
4.0mm (0.158in)
248RY00070
248R200008
7A470
13. Coat the race and thrust bearing with petroleum

jelly, and install them onto the forward clutch drum.
Inside
Outside
Race
26.0mm (1.024in)
48.9mm (1.925in)
Bearing
26.0mm (1.024in)
46.7mm (1.839in)
Check that the distance from the direct clutch end to

the forward clutch end is 71.2mm (2.803in).
248RY00038
248RY00048
14. Align the flukes of discs in the direct clutch.

Install the direct clutch assembly onto the forward
clutch assembly.
248RY00039
7A471
Front Planetary Gear

Disassembled View
247R200003
Legend
(1) Race
(2) Thrust bearing
(3) Race
(4) Front planetary gear
(5)
(6)
(7)
(8)
Race (Metal)
Thrust bearing
Race
Front planetary ring gear
E nd O FCallo ut
Disassembly
1. Remove the race from front planetary ring gear.
2. Remove the thrust bearing and race from front
planetary gear.
3. Remove the race (Metal), thrust bearing and race
between front planetary ring gear and front
planetary gear.

1. Check front planetary ring gear bushing
of the front planetary ring gear bushing.
replace the front planetary ring gear.
247RY00021
7A472
Reassembly
jelly.
Install the race and bearing to the rear side of the
front planetary gear.
Inside
Outside
Bearing
35.6mm (1.402in)
47.7mm (1.878in)
Race
33.7mm (1.327in)
47.6mm (1.874in)

jelly.
Install the race and bearing onto the rear side of the
front planetary ring gear.
Inside
Outside
Race
35.15 mm (1.38 in) 53.65 mm (2.11 in)
Bearing
35.15 mm (1.38 in) 53.65 mm (2.11 in)
247RY00025
247RY00023
2. Turn over the planetary gear and install the race

(metal).
Make sure that the lugs fit into the holes on the front
planetary gear.
Inside
Outside
Race
34.3mm (1.350in)
4. Turn over the planetary ring gear and install the race
onto the front side of the front planetary ring gear.
Inside
Outside
Race
26.8mm (1.055in)
47.0mm (1.850in)
47.8mm (1.882in)
247RY00026
247RY00024
7A473
Planetary Sun Gear and No.1 One-Way Clutch

Disassembled View
248R200005
Legend
(1) One-way clutch and second brake hub
(2) Thrust washer (plastic)
(3) Oil seal ring (Metal)
E nd O FCallo ut
(4)
(5)
(6)
(7)
Snap ring
Sun gear input drum
Snap ring
Planetary sun gear
7A474
Disassembly
5. Remove the snap ring with snap ring pliers.
1. Check operation of No.1 one-way clutch

Hold the planetary sun gear and turn the second
brake hub.
The second brake hub should turn freely clockwise
and should lock counterclockwise.
248RY00053
6. Remove the sun gear input drum.

7. Remove the snap ring from planetary sun gear.

RUW37ASH004601
Legend
(1) Free
(2) Lock
1. Check planetary sun gear bushing

of the planetary sun gear bushing.
Maximum inside diameter: 27.08 mm (1.066 in)
E nd OFCa llou t
2. Remove the one-way clutch and second brake hub.

3. Remove the trust washer (plastic).
4. Remove two oil seal rings (metal).

replace the planetary sun gear.
248RY00054
248RY00052
Reassembly
7A475
3. Install snap ring with snap ring pliers.
1. Install snap ring to planetary sun gear.
248RY00053
248RY00055
2. Place a wooden block, etc. as a work stand and

place the planetary sun gear onto it.
Install the sun gear input drum onto the planetary
sun gear.
4. Coat the two oil seal rings (metal) with ATF.

Install the two oil seal rings onto the planetary sun
gear.
248RY00052
248RY00056
7A476
5. Install thrust washer (plastic).

NOTE: Make sure that the lugs fit into the holes on the
sun gear input drum.
7. Check operation of No.1 one-way clutch

Hold the planetary sun gear and turn the second
brake hub.
The second brake hub should turn freely clockwise
and should lock counterclockwise.
248RY00057
6. Install assembled No.1 one-way clutch and second

brake hub onto planetary sun gear as shown.
RUW37ASH004601
Legend
(1) Free
(2) Lock
E nd OFCa llou t
248RY00058
7A477
Second Brake Assembly (B2)

Disassembled View
246R200001
Legend
(1) Second brake assembly
(2) Thrust washer (Plastic)
(3) Snap ring
(4) Spring retainer
(5)
(6)
(7)
(8)
(9)

Piston sleeve
Second brake piston
O-ring
Second brake drum
E nd O FCallo ut
Disassembly
1. Remove second brake assembly from output shaft.
246RY00007
7A478
2. Remove the hrust washer (plastic).

Remove the snap ring with snap ring pliers.

spring.
Standard length: 18.38 mm (0.724 in)
247RY00001
4. Remove the spring retainer and piston return spring.
247RY00034
5. Romove piston sleeve.

6. Holding the second brake piston by hand, apply
compressed air to the second brake drum to remove
the second brake piston.
Remove the second brake piston from the second
brake drum.
Reassembly
second brake piston.
246RY00009
246RY00008
7. Remove the o-rings from the second brake piston.
2. Being careful not to damage the O-rings, press in

the second brake piston into the second brake
drum.
3. Install piston sleeve.

7A479
7. Check second brake piston movement.

Make sure the second brake piston moves smoothly
when applying and releasing the low compressed
air to the second brake drum.
246RY00010
5. Install spring retainer.

246RY00011
8. Coat the thrust washer (plastic) with petroleum jelly

and install it to the second brake piston, with the
grooved side facing upward.
NOTE: Make sure that the cutout portions of the thrust
washer match the teeth of the spring retainer.
247RY00001
246RY00012
7A480
9. Install second brake assembly to output shaft.
246RY00014
7A481
Rear Planetary Gear Assembly and Output Shaft

Disassembled View
247R200005
Legend
(1) Second brake assembly
(2) Output shaft
(3) Oil seal ring
(4) Disc, plate and flange (B3)
Seven discs and seven plates
(5) Rear planetary gear assembly
(6) One-way clutch inner race
(7) Snap ring
E nd O FCallo ut
(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)
One-way clutch
Thrust washer (Plastic)
Thrust washer (Plastic)
Rear planetary gear
Thrust bearing and race
Snap ring
Ring gear flange
Rear planetary ring gear
7A482
Disassembly
4. Remove rear planetary gear from rear planetary ring

gear.
1. Remove second brake assembly from output shaft.
247RY00029
246RY00014
2. Remove oil seal ring from output shaft.
5. Check operation of No.2 one-way clutch.

Hold the planetary gear and turn the one-way clutch
inner race.
The one-way clutch inner race should turn freely
counterclockwise and should lock clockwise.
247RY00028
3. Remove the seven discs, seven plates and flange

(B3).
RUW37ASH004701
Legend
(1) Lock
(2) Free
E nd OFCa llou t

6. Remove the one-way clutch inner race from the rear
planetary gear.
247RY00031
7. Remove the snap ring with a screwdriver.
7A483
8. Remove the one-way clutch with retainers from the

planetary gear.
247RY00033
9. Remove the thrust washer (plastic) from front side

of rear planetary gear.
10. Remove the thrust washer (plastic) from rear side of
rear planetary gear.
11. Remove the thrust bearing and race from front side
of ring gear flange.
12. Remove the snap ring from rear planetary ring gear.
13. Remove the ring gear flange from rear planetary
ring gear.
14. Check disc, plate and flange.
Check to see if the sliding surface of the disc, plate
and flange are worn or burnt. If necessary, replace
them.
If the lining of the disc is peeling off or discolored,
or even if parts of the printed numbers are
defaced, replace all discs.
247RY00032
Before assembling new discs, soak them in ATF

for at least fifteen minutes.
248RY00045
7A484
Reassembly
1. Install ring gear flange to the rear planetary ring
gear.
2. Install snap ring to the rear planetary ring gear.
247RY00037
5. Install the one-way clutch with the flanged side

facing upward onto the rear planetary gear.
247RY00035
3. Coat the races and bearing with petroleum jelly, and

install them onto the rear planetary ring gear.
Races and bearing diameter (Reference)
Inside
Outside
Race (A)
28.5mm (1.122in)
44.2mm (1.740in)
Bearing and
race (B)
27.7mm (1.091in)
44.2mm (1.740in)
247RY00038
247RY00036
4. Coat the thrust washers (plastic) with petroleum

jelly.
Install the thrust washers onto both sides of the rear
planetary gear, facing the grooved side upward.
NOTE: Make sure that the lugs fit into the cutout
portions on the rear planetary gear.
247RY00039

7. While turning counterclockwise, install one-way
clutch inner race to rear planetary gear.
9. Install rear planetary gear onto rear planetary ring

gear.
247RY00040
8. Check operation of one-way clutch.

Hold the planetary gear and turn the one-way clutch
inner race.
The one-way clutch inner race should turn freely
counterclockwise and should lock clockwise.
7A485
247RY00029
10. Install the disc, plate and flange (B3).

Install a brake flange onto the rear planetary gear
assembly.
Install a clutch disc onto the rear planetary gear
assembly.
NOTE: The claw interval of the plate should be as
shown in the figure when viewing the clutch plate from
the arrow direction.
RUW37ASH004701
Legend
(1) Lock
(2) Free
E nd OFCa llou t
246RY00013
7A486
Install six clutch discs and six brake plates

alternately, starting with clutch disc, onto the rear
planetary gear assembly.
12. Install output

assembly.
shaft
into rear planetary
gear
247RY00042
247RY00047
13. Install second brake assembly to output shaft.
11. Coat the oil seal ring with ATF and install it to the
output shaft.
246RY00014
247RY00028
7A487
First and Reverse Brake (B3)

Disassembled View
246RY00024
Legend
(1) Thrust bearing and race
(2) Snap ring
(3) Piston return spring
(4) First and reverse brake piston No.2
E nd O FCallo ut
(5)
(6)
(7)
(8)
(9)
O-ring
Reaction sleeve
O-ring
First and reverse brake piston No.1
O-ring
7A488
Disassembly
1. Remove assembled thrust bearing and race from
transmission case.
3. Set special tool on the spring retainer, and

Remove the snap ring with snap ring pliers.
247RY00043
2. Check first and reverse brake piston movement.

Make sure that first and reverse brake piston moves
smoothly when applying and releasing the
compressed air into the transmission case.
247RY00002

5. Remove the first and reverse brake piston No.2.
Holding the first and reverse brake piston No.2 by
hand, apply compressed air to the transmission
case to remove the first and reverse brake piston
No.2.
Remove the first and reverse brake piston No.2.
If the piston does not pop out with compressed air,
lift the piston out with needle-nose pliers.
246RY00016
246RY00016

6. Remove the O-ring from first and reverse brake
piston No.2.
7. Remove the reaction sleeve.
Insert special tool behind the reaction sleeve and
gradually lift it out of the transmission case.
Reaction sleeve puller: J37236
7A489
Reassembly
1. Coat three new O-rings with ATF.
Install the two O-rings on the No.1 piston.
2. Install the O-ring on the reaction sleeve.
3. Install the first and reverse brake piston No.1 to the
reaction sleeve.
RUW37ASH003301
8. Remove the O-ring from reaction sleeve.
246RY00018
9. Remove the first and reverse brake piston No.1.

Insert special tool behind the first and reverse brake
piston No.1 and gradually lift it out of the
transmission case.
Piston puller: J37237
4. Coat a new O-ring with ATF and install it on the first

and reverse brake piston No.2.
RUW37ASH003401
246RY00019
10. Remove the O-rings from first and reverse brake

pistion No.1.
5. Install the first and reverse brake piston No.1 with

reaction sleeve onto the first and reverse brake
piston No.2.
7A490
6. Align the teeth of the first and reverse brake piston

No.2 into the proper grooves.
Being careful not to damage the O-rings, press in
the first and reverse brake piston No.2 with No.1
into the transmission case.
8. Set special tool as shown, and compress the return

spring with special tool.
246RY00020
7. Place piston return spring onto first and reverse

brake piston No.2.
247RY00002
9. Check first and reverse brake piston movement.

Make sure the first and reverse brake piston moves
smoothly when applying and releasing the
compressed air into the transmission case.
246RY00021
246RY00022

petroleum jelly.
Install the assembled bearing and race facing the
bearing side upward.
Inside diameter
39.38mm (1.550in)
Outside diameter
58.15mm (2.289in)
247RY00043
7A491
7A492
Transmission Valve Body assembly

Disassembled View
240R200039
Legend
(1) Detent spring
(2) Manual shift valve
(3) Upper valve body
(4) No.1 gasket (Upper valve body side)
E nd O FCallo ut
(5)
(6)
(7)
(8)
(9)
Valve body plate

Clamp
Pressure control solenoid
No.2 gasket (Lower valve body side)
Lower valve body
Disassembly
7A493
7. Remove the pressure control solenoid.

Hold the valve body plate to the upper valve body.
Lift off upper valve body and plate as a single unit.
1. Remove detent spring from valve body.
NOTE: Be careful that the check balls and strainers do

not fall out.
240R200040
2. Remove the manual shift valve.

3. Remove the upper valve body.
244R200061
4. Remove the no.1 gasket (Upper valve body side).
8. Remove the no.2 gasket (Lower valve body side).
5. Remove the valve body plate.
9. Remove the lower valve body.
Turn over assembly and remove thirty bolts.
Reassembly
1. Position a new No.1 gasket (1) on upper valve body.
Align the No.1 gasket at each bolt hole.
2. Position valve body plate (2) on No.1 gasket (1).
Align the plate at each bolt hole.
3. Position a new No.2 gasket (3) on valve body plate
(2).
Align the No.2 gasket at each bolt hole.
244R200049
6. Remove the clamp.
244R200073
7A494
4. Place upper valve body with plate and gaskets on

top of lower valve body.
Align each bolt hole and gasket in the valve body.
5. Install the pressure control solenoid and clamp.

6. Install thirty bolts to upper valve body.
Each bolt is indicated in the figure.
Length (mm)
Quantity
20
28
12
40
11
Torque: 6.4Nm (57Ibin)
244R200074
244R200050
7. Install manual shift valve.

8. Install detent spring.
240R200040
7A495
7A496
Lower Valve Body

Cross Section
RUW37AMF001901
7A497
Disassembled View
244R200075
Legend
(1) By-pass valve
(2) Spring
(3) Strainer
(4) Shift solenoid S1
(5) Shift solenoid S2
(6) Lock-up solenoid SL
(7) Clamp
(8) Accumulator sub-assembly
(9) Retainer
(10) Spring
(11) Ball
(12) Retainer
(13) Plug
(14) Spring
(15) 12 shift valve
(16) Retainer
(17) Spring
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
Low coast modulator valve

Retainer
Plug
Spring
Accumulator control valve
Retainer
Spring
Solenoid modulator valve
Retainer
Plug
Spring
Cut back valve
Retainer
Sleeve
Plunger
Plunger
Spring
Washer
Primary regulator valve
7A498
(37) Lower valve body

E nd O FCallo ut
Disassembly
NOTE: Confirm six retainers are installed correctly.
1. Remove by-pass valve and spring.
244R200066
3. Remove the shift solenoid S1 and shift solenoid S2.

244R200063
2. Remove three strainers.
Remove the fixing bolt.

Remove the shift solenoid S1 (2) and S2 (1) from
each bore.
Remove the O-rings from each solenoid.
4. Remove the lock-up solenoid SL
Remove the fixing bolt.
Remove the lock-up solenoid SL (3) from the
bore.
Remove the O-ring from solenoid.
5. Remove the accumulator sub-assembly
Remove the clamp.
Remove the accumulator sub-assembly (4) from
the bore.
244R200064
7A499
6. Remove the retainer (5).

Remove the spring and ball from the valve body.
244R200052
240R200042
7A4100
7. Remove the 12 shift valve retainer (12) with a

magnetic finger by pushing the plug.
244R200067
8. Remove the plug, spring and 12 shift valve.
9. Remove the retainer (16) for low coast modulator

valve by pushing the spring with a screwdriver.
244R200068
10. Remove the spring and low coast modulator valve.
244R200054
244R200056

11. Remove the retainer (19) for accumulator control
valve with a magnetic finger by pushing the plug.
7A4101
13. Remove the retainer (23) for solenoid modulator

valve(25) by pushing the spring with a screwdriver.
244R200069
244R200070
12. Remove the plug(20), spring(21) and accumulator

control valve(22).
14. Remove the spring(24) and solenoid modulator

valve(25).
244R200057
244R200058
7A4102
15. Remove the retainer(26) for cut back valve(29) with

a magnetic finger by pushing the plug.
17. Place a mark on the top of sleeve(31) and the

retainer (30) for primary requlator valve(36) where
they are positioned.
244R200071
16. Remove the plug(27), spring(28) and cut back

valve(29).
244R200059
NOTE: When reassembling, position the retainer in the

same position.
Remove the retainer(30) with a magnetic finger by
pushing the sleeve.
244R200065
244R200072

18. Remove the sleeve(31) with the plungers(32)(33),
spring(34) and washer.
Remove the two plungers(32)(33) from the sleeve.
Remove the primary regulator valve(36) from the
valve body(37).
244R200060
7A4103
2. Inspect valve springs

Check for damage, squareness, rust and distorted
coils.
Measure the spring free length and replace if less
than shown below.
mm (in)
Free
Color
Spring
length
(1) By-pass valve
21.3
(0.839)
YELLOW
(2) Steel ball
20.5
(0.807)
WHITE
(3) 12 shift valve
30.8
(1.213)
PURPLE
(4) Low coast modulator valve
30.4
(1.197)
LIGHT
GREEN
(5) Accumulator control valve
33.8
(1.331)
(6) Solenoid modulator valve
26.6
(1.047)
LIGHT
BLUE
(7) Cut back valve
34.0
(1.339)
DARK
BLUE
(8) Primary regulator valve
38.58
(1.519)
WITHE
1. Inspect strainer
Inspect strainer for residual adhesive and damage,
and clean and replace as necessary.
244R200051
244R200077
7A4104
Reassembly
NOTE: Install the retainer (30) to the same position on

the top of sleeve(31), as when disassembling.
1. Install the washer(35) onto the primary regulator

valve(36).
Install the primary regulator valve(36) with the
washer(35) into the bore of lower valve body.
Install the two plungers(32)(33) into the sleeve(31).
Align the mark on the top of sleeve(31) with the
mark on the retainer(30).
Install the sleeve(31) with the two plungers(32)(33)
and spring(34) into the bore.
244R200059
3. Install the cut back valve(29), spring(28) and

plug(27) into the bore.
244R200060
2. Install the retainer(30) by pushing the sleeve.
244R200065
244R200072

4. Install the retainer(26) by pushing the plug.
7A4105
6. Install the retainer(23) by pushing the spring.
244R200071
244R200070
5. Install the coast modulator valve(25) and spring(24)

into the bore.
7. Install the accumulator control valve(22), spring(21)

and plug(20) into the bore.
244R200058
244R200057
7A4106
8. Install the retainer(19) by pushing in the plug.
10. Install the retainer(16) by pushing the spring.
244R200069
244R200068
9. Install the low coast modulator valve(18) and

spring(17) into the bore.
11. Install the 12 shift valve(15), spring(14) and

244R200056
244R200054
7A4107
16. Install a new O-ring to the shift solenoid S2 (5) and

shift solenoid S1 (4).
Install the solenoids to the valve body.
244R200067
13. Install the ball(11), spring(10) and retainer (9) to the

valve body.
Torque: 6.9 Nm (60Ibin)
RUW37AMH000401
Legend
(4) Shift Solenoid S1
(5) Shift Solenoid S2
(6) Lock-up Solenoid SL
(8) Accumulator Sub-assembly
(9) Retainer
E nd OFCa llou t
NOTE: Make sure six retainers are installed correctly.
244R200052
14. Install the accumulator sub-assembly (8) and

clamp(7) to the valve body.
15. Install a new O-ring to the lock-up solenoid SL (6).
Install the solenoid to the valve body.
244R200066
7A4108
17. Install the three strainers(3) to the valve body as

shown.
244R200064
18. Install the spring(2) and by-pass valve(1) to the

valve body as shown.
244R200063
7A4109
Upper Valve Body

Cross Section
243R200052
7A4110
Disassembled View
243R200074
Legend
(1) Check ball
(2) Retainer
(3) Check valve NO.2
(4) Ball
(6) Retainer
(8) Ball
(10) Retainer
(11) Plug
(12) Secondary regulator valve
(13) Spring
(14) Retainer
(15) Plug
(16) Spring
(17) 23 shift valve
E nd O FCallo ut
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
Retainer
Plug
Spring
Reverse control valve
Retainer
Plug
Second coast modulator valve
Spring
Retainer
Plug
34 shift valve
Spring
Retainer
Sleeve
Plunger
Spring
Lock-up relay valve
Upper valve body
Disassembly
7A4111
2. Remove the ratainer (2) for check valve.
1. Remove the two types of check balls(1) from the

valve body.
Number of check ball : 11
243R200066
3. Remove the check valve NO.2(3), ball(4) and check

valve NO.1(5) from the valve body.
RUW37ASH004801
NOTE: Confirm eight retainers are installed correctly.
243R200062
243R200054
7A4112
4. Remove the retainer (6) for check valve.
6. Remove the retainer (10) for secondary regulator

valve with a magnetic finger by pushing the plug.
243R200067
5. Remove the check valve NO.2(7), ball(8) and check

valve NO.1(9) from the valve body.
243R200070
7. Remove the plug(11), secondary regulator valve(12)

and spring(13).
243R200062
243R200056

8. Remove the retainer (14) for 23 shift valve with a
7A4113
10. Remove the retainer (18) for reverse control valve

with a magnetic finger by pushing in the plug.
243R200069
243R200068
9. Remove the plug(15), spring(16) and 23 shift

valve(17).
11. Remove the plug(19), spring(20) and reverse

control valve(21).
243R200058
243R200060
7A4114
12. Remove the retainer (22) for second coast

modulator valve with a magnetic finger by pushing
the plug.
14. Remove the retainer (26) for 34 shift valve with a

243R200072
243R200073
13. Remove the plug(23), second coast modulator

valve(24) and spring(25).
15. Remove the plug(27), 34 shift valve(28) and

spring(29).
243R200064
243R200063

16. Remove the retainer (30) for lock-up relay valve with
a magnetic finger by pushing in the sleeve.
7A4115

1. Inspect valve springs
Check for damage, squareness, rust and distorted
coils.
Measure the spring free length and replace if less
than below.
mm (in)
Free
Color
Spring
length
243R200071
17. Remove the sleeve(31) with the plunger(32),

spring(33) and lock-up relay valve(34).
Remove the lock-up relay valve(34), spring(33) and
plunger(32) from the sleeve(31).
(1) Secondary regulator valve
32.9
(1.295)
PURPLE
(2) 23 shift valve
30.8
(1.213)
PURPLE
(3) Reverse control valve
25.6
(1.008)
(4) Second coast modulator

valve
25.3
(0.996)
ORANGE
(5) 34 shift valve
30.8
(1.213)
PURPLE
(6) Lock-up relay valve
23.4
(0.912)
RED
243R200065
243R200076
7A4116
Reassembly
3. Install the spring, 3-4 shift valve(28) and plug(27)

into the bore.
1. Install the plunger(32) and spring(33) into the

sleeve(31).
Install the lock-up relay valve(34) into the
sleeve(31).
Install the sleeve(31) with the plunger(32),
spring(33) and lock-up relay valve(34) into the bore.
243R200064
243R200065
2. Install the retainer(30).
243R200072
243R200071

5. Install the spring(25), second coast modulator
valve(24) and plug(23) into the bore.
7A4117
7. Install the reverse control valve(21), spring(20) and

243R200063
243R200060
243R200073
243R200068
7A4118
9. Install the 23 valve(17), spring(16) and plug(15)

into the bore.
11. Install the spring(13), secondary regulator valve(12)

and plug(11) into the bore.
243R200058
243R200056
243R200069
243R200070

13. Install the check valve NO.1(9), ball(8) and check
valve NO.2(7) to valve body.
15. Install the check valve NO.1(5), ball(4) and check

valve NO.2(3) to the valve body.
243R200062
7A4119
243R200062
243R200067
243R200066
7A4120
NOTE: Make sure eight retainers are installed correctly
243R200054
17. Install the two types of check balls(1) to the valve

body.
Number of check ball : 11
Check ball
Diameter
(A) Rubber ball
5.535mm (0.2179in
(B) Rubber ball
6.35mm (0.2500in
RUW37ASH004801
7A4121
Transmission Case
Disassembled View
249RY00001
Legend
(1) Spacer
(2) Pin
(3) Manual valve lever shaft
(4) Manual valve lever

(5) Oil seal
(6) Oil seal
E nd O FCallo ut
Disassembly
1. Using a chisel, cut off the spacer and remove it from
the shaft.
249RY00002
7A4122
Reassembly
2. Using a punch, drive out the pin.
1. Coat a new oil seal lip with multi purpose grease.

Using special tool, drive in the oil seal.
249RY00003
3. Pull the manual valve lever shaft out through the

case by the threads.
4. Take out the manual valve lever.
RTW37ASH000701
5. Using a screwdriver, remove the oil seals.
2. Assemble a new spacer to the manual valve lever.

3. Install the manual valve lever shaft to the
transmission case through the manual valve lever
by the threads.
249RY00004
249RY00005

4. Drive in the pin with the slot at a right angle to the
shaft.
249RY00006
5. Match the spacer hole to the lever staking hollow

and stake the spacer to the lever.
Make sure the manual valve lever shaft turns
smoothly.
249RY00003
7A4123
7A4124
Torque Converter
Insert special tool in end of torque converter.
Insert a turning tool into the inner race of the one-way
clutch.
One-way clutch testing tool : J35467
Insert the stopper so that it fits in the notch of the
converter hub and outer race of the one-way clutch.
RUW37ASH003501
1. One-way clutch test.

The
clutch
should
lock
when
turned
counterclockwise, and rotate freely and smoothly
clockwise. Less than 2.5Ncm (22Ibin) of torque
should be required to rotate the clutch clockwise. If
necessary, clean the converter and retest the clutch.
Replace the converter if the clutch still fails the test.
7A4125
Adapter Housing (4 4)
Disassembled View
241R200005
Legend
(1) Oil seal
(2) Adapter housing
E nd O FCallo ut
Disassembly
1. Using a screwdriver, remove the oil seal.
Reassembly
1. Using oil seal installer, install the new oil seal to the
adapter housing.
RUW37ASH002401
7A4126
Extension Housing (4 2)
Disassembled View
241R200007
Legend
(1) Gasket
(2) Tube
(3) Tube packing
(4) Oil seal

(5) Dust deflector
(6) Extension housing
E nd O FCallo ut
Disassembly
1. Remove the gasket.
2. Remove the tube.
3. Remove the tube packing.
4. Using a screwdriver, remove the oil seal.
NOTE: The oil seal can be removed without removing
the dust deflector.
5. Rrmove the dust deflector from extension housing.
Reassembly
1. Using oil seal installer, install the new oil seal to the
extension housing.
Oil seal installer : 5884027020
NOTE: The oil seal can be installed without removing
the dust deflector.
249L100005

2. Install the tube.
3. Install the tube packing.
4. Install the dust deflector.
5. Install the gasket.
7A4127
7A4128

Remaks
Model
AW3040LE
Engine
6VE1 (3.5L)
Type
Electronic control planetary gear type

3element 1stage 2phase type
(with lock-up mechanism)
Gear ratio
Oil used
1st
2.804
2nd
1.532
3rd
1.000
4th (O/D)
0.705
Reverse
2.394
Name
BESCO ATF III
Q'ty (l)
8.7
2100 150
Torque converter
Stall speed (rpm)
Friction element
Forward clutch
C1
Direct clutch
C2
OD direct clutch
C0
Second coast brake
B1
40mm
Second brake
B2
First and reverse brake
B3
Overdrive brake
B0
One-way clutch No.1
F1
22
One-way clutch No.2
F2
28
OD one-way clutch
F0
24
Number of discs
Band width or
Number of discs
Number of discs
Clutch
Number of
sprage
Planetary gear
Front planetary
Rear planetary
O/D planetary
Sun gear
42
Pinion gear
19
Ring gear
79
Sun gear
33
Pinion gear
23
Ring gear
79
Sun gear
33
Pinion gear
23
Ring gear
79
Number of teeth
7A4129
RTW37ALF002101
7A4130
Torque Specifications (Cont'd)

Nm (Ibft)
RTW37ALF001001
7A4131

Nm (Ibft)
RTW37ALF000901
7A4132
Special Tools
ILLUSTRATION
TOOL NO.
TOOL NAME
ILLUSTRATION
TOOL NO.
TOOL NAME
J37227
Holding fixture
J29770A
Oil pressure gauge
J328920
Holding fixture base
J25048
Spring compressor
J37228
Oil pan seal cutter
J37236
Reaction sleeve puller;
first and reverse brake
J233271
Spring compressor
J37237
Piston puller; first and
reverse brake
J9617
Oil seal installer; oil
pump
J372322
Oil seal installer;
manual valve shaft seal
installer & remover
J37233
Spring compressor; OD
brake piston
J35467
Onennway clutch
testing tool; torque
converter

ILLUSTRATION
TOOL NO.
TOOL NAME
J36797
Oil seal installer;
adapter housing (4 4)
J46197
Oil seal installer;
extension housing (4
2)
7A4133
7A4134
MEMO
No. TFAW3-WE-0431
WORKSHOP MANUAL
TF SERIES
CLUTCH
SECTION 7C
CLUTCH 7C-1
SECTION 7C
CLUTCH
TABLE OF CONTENTS
PAGE
Main Data and Specifications ......................................................................................... 7C- 2
General Description......................................................................................................... 7C- 3
Torque Specification ....................................................................................................... 7C-15
Servicing........................................................................................................................... 7C-19
Clutch................................................................................................................................ 7C-21
Clutch Control.................................................................................................................. 7C-32
Master Cylinder ................................................................................................................ 7C-33
Disassembly ................................................................................................................ 7C-33
Reassembly ................................................................................................................. 7C-34
Slave Cylinder (4J, C24SE) ............................................................................................. 7C-35
Disassembly ................................................................................................................ 7C-35
Reassembly ................................................................................................................. 7C-37
Slave Cylinder (6VE1) ...................................................................................................... 7C-38
Disassembly ................................................................................................................ 7C-38
Reassembly ................................................................................................................. 7C-40
Hydraulic Damper Cylinder............................................................................................. 7C-41
Troubleshooting .............................................................................................................. 7C-42
Special Service Tool........................................................................................................ 7C-51
7C-2 CLUTCH

ENGINE
6VE1
Clutch type
Size
Clamping force
4JA1-TC
4JH1-TC
4JA1-T(L)
C24SE
Dry single plate with diaphragm

mm (in)
260 (10.24)
225 (8.86)
250 (9.84)
240 (9.45)
kg(lb)
735 (1621)
500 (1103)
640 (1411)
560 (1235)
(7200)
(4900)
(6300)
(5500)
(N)
Pressure plate
Outside diameter
mm(in)
260 (10.24)
225 (8.86)
250 (9.84)
240 (9.45)
Inside diameter
mm(in)
170 (6.69)
150 (5.906)
160 (6.299)
160 (6.299)
at free
8.8 (0.346)
8.4 (0.331)
8.3 (0.327)
8.7 (0.342)
at compressed
8.2 (0.323)
7.8 (0.307)
7.8 (0.307)
8.0 (0.315)
Driven plate
Thickness
mm(in)
Clutch Cont. type

Pedal free play
Hydraulic
mm(in)
5.0-15.0 (0.2-0.6)
mm(in)
15.87 35 (0.625 1.38)
Master cylinder
BoreStroke
Slave cylinder
Bore Stroke
mm(in)
22.22 18.9
(0.875 0.744)
19.05 23
(0.749 0.906)
20.64 23
(0.813 0.906)
19.05 23
(0.749 0.906)
CLUTCH 7C-3
GENERAL DESCRIPTION
HYDRAULIC CONTROL TYPE
PUSH TYPE CLUTCH (4J C24SE)
PULL TYPE CLUTCH (6VE1)
A07RW046
7C-4 CLUTCH
The clutch assembly consists of the pressure plate, the clutch cover, the diaphragm spring pivot pin and the driven
plate assembly.
The clutch pedal is connected to the release bearing through the shift fork.
The driven plate assembly is installed between the flywheel and the pressure plate.
For 4J series engine and HEC engine models, the push-type clutch is used.
Diaphragm spring pressure holds the driven plate against flywheel and the pressure plate to provide the friction
necessary to engage the clutch.
Depressing the clutch pedal moves the shift fork against the release bearing.
The release bearing forces the diaphragm to overcome the force of the diaphragm spring and separate the driven
plate from the flywheel and pressure plate to disengage the clutch.
For 6VE1 engine model, the pull-type clutch is used. The pull-type clutch is disengaged by pulling the release lever
(release bearing) to disengage the pressure plate.
CLUTCH 7C-5
MASTER CYLINDER
C24SE/RHD
RTW47CSF000501
C24SE, 4J/LHD
RTW47CSF000201
7C-6 CLUTCH
6VE1/LHD
RTW47CSF000101
6VE1, 4J/RHD
RTW47CSF000401
The master cylinder converts mechanical energy into hydraulic energy.

Depressing the clutch pedal causes the push rod to move against the piston to close the return port.
Clutch fluid is forced out of the master cylinder.
Releasing the clutch pedal causes the return spring to force the piston back to its original position.
The return port is opened and the clutch fluid flows back into the fluid reservoir.
Quickly releasing the clutch pedal will cause the fluid pressure at the return spring side to be lower than the fluid
pressure at the push rod side.
This allows the fluid at the push rod side to quickly flow to the return spring side through a port in the piston head.
This equalizes the pressure at both sides of the piston.
CLUTCH 7C-7
SLAVE CYLINDER
6VE1
A07RS005
4J
C24SE
RTW47CSF000301
The slave cylinder converts hydraulic energy into mechanical energy.

Hydraulic fluid supplied by the master cylinder moves the slave cylinder piston to actuate the shift fork.
The mechanical energy produced by the slave cylinder is directly proportional to the diameters of the master
cylinder and the slave cylinder.
A bleeder screw is provided to bleed the slave cylinder.
7C-8 CLUTCH
HYDRAULIC DAMPER CYLINDER
RTW47CLF000101-X
The hydraulic damper cylinder is installed between the master cylinder and the slave cylinder to smooth out
variations in clutch pedal feel.
CLUTCH 7C-9
PRESSURE PLATE ASSEMBLY

6VE1
A07RS006
7C-10 CLUTCH
4JA1T(L)
RTW47CMF000101
4JA1TC/4JH1TC
CLUTCH 7C-11
C24SE
RTW37CMF000101
The pressure plate assembly consists of the clutch cover, the pressure plate with diaphragm spring.
Operating the clutch pedal causes the pressure plate to move in an axial direction to engage and disengage the
clutch.
7C-12 CLUTCH
DRIVEN PLATE ASSEMBLY

6VE1
RTW37CMF000201
CLUTCH 7C-13
4JA1T(L)
RTW47CMF000401
4JA1TC/4JH1TC
7C-14 CLUTCH
C24SE
RTW37CSF0003
The driven plate assembly consists of the plate and the facing.
The plate consists of the clutch center, the cushioning plate and the torsion springs.
The facing is riveted to both sides of the cushioning plate.
The cushioning plate provides a longer service life by minimizing wear and vibration at the clutch contact surfaces.
CLUTCH 7C-15
STANDARD BOLTS
The torque values given in the following table should be applied where a particular torque is not specified.
Nm (kgfm/lb ft)
Strength
4.8/4T
7T
8.8
Class
Refined
9.8/9T
Non-Refined
Bolt Identification
Bolt
Diameter
Pitch (mm)
Standard Hex.
Head Bolt
Flange Bolt
M6 1.0
M8 1.25
M10 1.25
6 (0.6 / 52 lb.in)
13 (1.3 / 113 lb.in)
27 (2.8 / 20)
7 (0.7 / 61 lb.in)
17 (1.7 / 12)
37 (3.8 / 27)
8 (0.8 / 69 lb.in)
20 (2.0 / 14)
42 (4.3 / 31)
24 (2.4 / 17)
50 (5.1 / 37)
M12 1.25
M14 1.5
M16 1.5
61 (6.3 / 45)
96 (9.8 / 71)
130 (13.3 / 96)
76 (7.8 / 56)
116 (11.8 / 85)
170 (17.3 / 125)
87 (8.9 / 64)
133 (13.6 / 98)
193 (19.7 / 143)
95 (9.7 / 70)
142 (14.5 / 105)
200 (20.4 / 148)
M18 1.5
M20 1.5
M22 1.5
188 (19.2 / 139)

258 (26.3 / 190)
332 (33.9 / 245)
244 (24.9 / 180)

337 (34.4 / 249)
453 (46.3 / 335)
278 (28.3 / 205)

385 (39.3 / 284)
517 (52.7 / 381)
287 (29.3 / 212)

396 (40.4 / 292)
530 (54.1 / 391)
M24 2.0
* M10 1.5
* M12 1.75
449 (45.8 / 331)

26 (2.7 / 20)
57 (5.8 / 42)
570 (58.2 / 421)

36 (3.7 / 27)
71 (7.2 / 52)
651 (66.3 / 480)

41 (4.2 / 30)
80 (8.2 / 59)
692 (70.6 / 511)

48 (4.9 / 35)
89 (9.1 / 66)
* M14 2.0
* M16 2.0
89 (9.1 / 66)
124 (12.7 / 92)
110 (11.2 / 81)

162 (16.5 / 119)
125 (12.7 / 92)

185 (18.9 / 137)
133 (13.6 / 98)

191 (19.5 / 141)
M6 1.0
M8 1.25
7 (0.7 / 61 lb.in)
15 (1.5 / 11)
8 (0.8 / 69 lb.in)
19 (1.9 / 14)
9 (0.9 / 78 lb.in)
22 (2.2 / 16)
26 (2.7 / 20)
M10 1.25
M12 1.25
M14 1.5
31 (3.2 / 23)
69 (7.0 / 51)
104 (10.6 / 77)
41 (4.2 / 30)
85 (8.7 / 63)
126 (12.8 / 93)
47 (4.8 / 35)
97 (9.9 / 72)
144 (14.6 / 106)
56 (5.7 / 41)
106 (10.8 / 78)
154 (15.7 / 114)
M16 1.5
M18 1.5
M20 1.5
145 (14.8 / 127)

-
188 (19.2 / 139)

-
214 (21.8 / 158)

-
221 (22.5 / 163)

-
M22 1.5
M24 2.0
* M10 1.5
30 (3.1 / 22)
40 (4.1 / 30)
46 (4.7 / 34)
54 (5.5 / 40)
* M12 1.75
* M14 2.0
* M16 2.0
64 (6.5 / 47)
97 (9.9 / 72)
137 (14.0 / 101)
78 (8.0 / 58)
119 (12.1 / 88)
178 (18.2 / 132)
89 (9.1 / 66)
135 (13.8 / 99.7)
203 (20.7 / 132)
99 (10.1 / 73)
144 (14.7 / 107)
210 (21.5 / 155)
The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materials such as
casting, etc.
FLARE NUTS
Pipe diameter mm (in)
Torque Nm (kgfm / lb ft)
Torque Nm (kgfm / lb ft)
4.76 (0.187)
16 (1.6 / 12)
10.00 (0.394)
54 (5.5 / 40)
6.35 (0.250)
26 (2.7 / 20)
12.00 (0.472)
88 (9.0 / 65)
8.00 (0.315)
44 (4.5 / 33)
15.00 (0.591)
106 (10.8 / 78)
7C-16 CLUTCH
Nm (kgfm/lb ft)
CLUTCH 7C-17
6VE1, 4J
Nm (kgfm/lb ft)
RTW37CLF000401
7C-18 CLUTCH
C24SE
Nm (kgfm/lb ft)
RTW37CLF000301
CLUTCH 7C-19
SERVICING
CLUTCH PEDAL PLAY

Inspection
Depress the clutch pedal lightly by hand, and measure to
determine if the free play is within the standard value.
Pedal Free Play
mm(in)
H
5.0-15.0 (0.2-0.6)
Adjustment of the clutch switch (or stopper bolt)

Turn the clutch switch or stopper bolt 1 until the switch bolt or
stopper bolt just touches the clutch pedal arm.
Adjust clutch switch or stopper bolt by backing it out half a turn,
and measure the clearance (L) between the clutch pedal arm
and the clutch switch bolt end or stopper bolt.
Lock the lock nut 2 .
Connect clutch switch connector.
Clutch switch and clutch pedal
Clearance
mm(in)
(L)
0.5-1.5 (0.020-0.059)
7C-20 CLUTCH
AIR BLEEDING
Bleed air from clutch operating cylinder according to the
following procedure.
Carefully monitor fluid level at master cylinder during bleeding
operation.
1. Set the paking brake.
2. Top up reservoir with recommended brake fluid.

3. Connect a transparent vinyl tube to air bleeder valve.
4. Fully depress clutch pedal several times.
5. With clutch pedal depressed, open bleeder valve to release

air.
6. Close bleeder valve.
7. Repeat steps 5 through 6 above until brake fluid flows from
air bleeder valve without air bubbles.
8. Bleed air from clutch damper according to the above
procedure.
9. Repeat the above bleeding procedure until the air
completely removed.
CLUTCH 7C-21
CLUTCH
RTW37CLF000201-X
Removal Steps
1. Transmission assembly
I 2. Pressure Plate assembly
I 3. Driven plate assembly
4. Release bearing
5. Shift fork
6. Flywheel assembly and crank bearing
Installation Steps
To install, follow the removal steps in the
reverse order.
7C-22 CLUTCH

1. Transmission Assembly
Refer to MANUAL TRANSMISSION of section 7B and 7B1
for REMOVAL AND INSTALLATION procedure.
2. Clutch Pressure Plate Assembly

3. Driven Plate Assembly
(1) Use the clutch pilot aligner 1 to prevent the driven plate
assembly 2 from falling free.
Clutch Pilot Aligner : 5-85253-001-0
(2) Loosen the clutch cover bolts in the numerical order shown
(3) Remove the pressure plate assembly 3 from the flywheel.
(4) Remove the driven plate from the flywheel.
4JH1-TC, C24SE
6VE1
201RS017
4. Release Bearing (6VE1)

5. Shift Fork (6VE1)
(1) Remove the release bearing (1) from the transmission
case.
(2) Remove the shift fork snap pin (2).
(3) Remove the shift fork pin and shift fork (3) from the fulcrum
bridge.
220RW088-X
CLUTCH 7C-23
6. Flywheel Assembly and Crank Bearing (6VE1)
(1) Remove flywheel assembly and crankshaft bearing. Do not
remove except for replacement.
(2) Use the remover 5-8840-2000-0 (J-5822) and sliding
hammer 5-8840-0019-0 (J-23907) to remove the crankshaft
bearing
015RW053

Follow the removal procedure in reverse order to perform the
installation procedure.
Pay careful attention to the important points during the
6. Flywheel Assembly and Crank Bearing (6VE1)
(1) Install flywheel assembly and crankshaft bearing. Use the
installer 5-8840-0125-0 (J-26516-A) and driver handle 58840-0007-0 (J-8092) to install the crankshaft bearing then
clean and lubricate with grease.
015RW054
(2) Install new flywheel fixing bolts in the order illustrated and
tighten them to the specified torque.
Nm (kgm/lb ft)
6VE1
54 (5.5/40)
NOTE: Do not reuse the bolt and do not apply oil or thread lock
to the bolt.
015RS047
7C-24 CLUTCH
5. Shift Fork (6VE1)
4. Release Bearing (6VE1)
(1) Apply molybdenum disulfide type grease to the pin hole
inner circumferences and thrust surfaces.
(2) Attach the shift fork to the front cover and insert the pin
from below of the front cover.
(3) Install the washer and snap pin.
201RW019
(4) Apply molybdenum disulfide type grease to the areas

shown in illustration.
201RW012
(5) Install the release bearing in the proper direction.

NOTE: Ensure release bearing is properly positioned during
installation, as shown in illustration.
201RW020
3. Driven plate Assembly

2. Clutch Pressure Plate Assembly
(1) Clean the flywheel surface.
(2) Clean the facing surface.
(3) Use the clutch pilot aligner 1 to install the driven plate
assembly 2 to the flywheel 3 .
CLUTCH 7C-25
(4) Clean the pressure plate surfaces.
(5) Align the pressure plate assembly 4 with the flywheel
knock pin 5 .
(6) Install the pressure plate assembly to the flywheel.
(7) Tighten the clutch cover bolts a little at a time in the
numerical order shown in the illustration.
Clutch Cover Bolt Torque
Nm (kgfm/lbft)
18 3 (1.8 0.3 / 13.0 2.2)
4JH1-TC, C24SE
6VE1
201RS017
(8) Remove the clutch pilot aligner.

Note:
Do not strike the clutch pilot aligner with a hammer to
remove it.
7C-26 CLUTCH

inspection.
PRESSURE PLATE ASSEMBLY

Visually inspect the pressure plate friction surface for
excessive wear and heat cracks.
If excessive wear or deep heat cracks are present, the
pressure plate must be replaced.
Pressure Plate Warpage

pressure plate friction surface flatness in four directions.
If any of the measured values exceed the specified limit, the
pressure plate must be replaced.
Pressure Plate Warpage
mm(in)
Limit
0.3 (0.012)
Clutch Cover
Visually inspect the entire clutch cover for excessive wear,
cracking , and other damage.
The clutch cover must be replaced if any of these conditions
are present.
1. Abrasion, scratches, cracks and deflection of friction face to

the disc, loose rivet and wear of ring
Grind small scratches, or replace the assembly if extreme
scratches are found.
CLUTCH 7C-27
Clutch Set Force

1. Invert the pressure plate assembly.
2. Place a metal sheet A on the pressure plate.
3. Compress the pressure plate assembly until the distance
B becomes specified.
Thickness and Distance
mm(in)
A
B
201R300011
6VE1
8.2 (0.323)
12 (0.472)
4JA1T(L)
7.8 (0.307)
20 (0.787)
4JA1TC/
4JH1TC
7.8 (0.307)
18 (0.71)
C24SE
8.0 (0.315)
7.9 (0.311)
4. Note the pressure plate gauge reading.

Driven Plate Clamping Load
N (kg/Ib)
Standard
6VE1
7200 (734/1618)
4JA1T(L)
5070 (517/1140)
4JA1TC/4JH1TC
6300 (642/1415)
C24SE
5500 (561/1237)
Diaphragm Spring Finger Height
RTW37CSH000101
1. Place a new driven plate or the appropriate spacer beneath

the pressure plate.
2. Fully compress the pressure plate and diaphragm spring.
There are two ways to do this.
Use a bench press to press down on the assembly from the
top.
Tighten the fixing bolts.
NOTE: Preload on diaphragm spring finger must be 49 - 98 N
(11 - 22 lb) in direction of release, when clutch cover assembly
is bolted to the flywheel.
7C-28 CLUTCH
3. Measure the spring height from base to spring tip "H". If the
measured value exceeds the specified limit, the pressure
plate assembly must be replaced.
Spacer Thickness
mm(in)
A
B
6VE1
8.2 (0.323)
12 (0.472)
4JA1T(L)
7.8 (0.307)
20 (0.787)
4JA1TC/
4JH1TC
7.8 (0.307)
18 (0.71)
C24SE
8.0 (0.315)
7.9 (0.311)
Finger Height
6VE1
49.9-51.9 (1.96-2.04)
4JA1T(L)
31-33 (1.22-1.30)
4JA1TC/
4JH1TC
39-41 (1.54-1.61)
C24SE
39-41 (1.54-1.61)
CLUTCH 7C-29
Release Bearing (6VE1)

1. Visually check the release bearing for excessive play, noise
and breakage.
2. If any of these conditions are discovered, the release
201RS011
3. When replacing the release bearing (3), replace both the

wedge collar (2) and wire ring (1) at the same time.
201RW010-X
Wedge Collar
1. Visually check the surfaces of the wedge collar making
contact with the release bearing for excessive wear and
damage.
2. Replace any exhibiting excessive wear or damage.
201RS013
Shift Fork
1. Visually check the surfaces of the shift fork making contact
with the release bearing for excessive wear and damage.
2. Remove any minor stepping or abrasion from shift fork with
an oil stone.
3. Replace any exhibiting excessive wear or damage.
201RS014
Release Bearing (4J, C24SE)

1. Visually inspect the surfaces of the release bearing making
contact with the shift fork for excessive wear and damage.
Replace any exhibiting excessive wear or damage.
2. Apply multi-purpose type grease (NLGI No.2 or No.3) to
contact surface between the release bearing and the shift
fork. (Do not apply grease to the sleeve inner face.)
7C-30 CLUTCH
Shift Fork
1. Visually inspect the surfaces of the shift fork making contact
with the release bearing for excessive wear and damage.
2. Remove any minor stepping or abrasion from the release
bearing with an oil stone.
Replace any exhibiting excessive wear or damage.
3. Apply multi-purpose type grease (NLGI No.2 or No.3) to
area.
DRIVEN PLATE ASSEMBLY

1. Visually inspect the torsion spring 1 for looseness,
breakage, and weakening.
If any of these conditions are discovered, the driven plate
assembly must be replaced.
2. Visually inspect the facing surfaces 2 for cracking and

excessive scorching.
Visually inspect the facing surfaces for the presence of oil
or grease.
If any of these conditions are discovered, the facing must
be cleaned or replaced.
3. Check that the driven plate moves smoothly on the

transmission top gear shaft spline.
Minor ridges on the top gear shaft spline may be removed
with an oil stone.
Driven Plate Warpage

1. Insert the clutch pilot aligner into the driven plate splined
hub.
The clutch pilot aligner must be held perfectly horizontal.
2. Set a dial indicator to the driven plate outside
circumference.
3. Slowly turn the driven plate.
Read the dial indicator as you turn the driven plate.
If the measured value exceeds the specified limit, the driven
plate assembly and/or the facing must be replaced.
Driven Plate Warpage
mm(in)
Standard
Limit
0.7 (0.028)
1.0 (0.039)
CLUTCH 7C-31
Driven Plate Splined Hub Spline Wear

1. Clean the driven plate splined hub.
2. Install the driven plate to the transmission top gear shaft
spline.
3. Set a surface gauge to the driven plate outside
circumference.
4. Slowly turn the driven plate counterclockwise.
Measure the spline rotation play as you turn the driven
plate.
If the measured value exceeds the specified limit, the driven
plate assembly must be replaced.
Driven Plate Splined Hub Spline Wear
mm(in)
Standard
Limit
0.5 (0.020)
1.0 (0.039)
Rivet Head Depression

Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression 1 from the facing surface
2.
Be sure to measure the rivet head depression on both sides of
the driven plate.
If the measured value is less than the specified limit, the facing
must be replaced.
Rivet Head Depression
mm(in)
Standard
Limit
Fly wheel side
P/Plate side
4J
6VE1
C24SE
1.35-1.95
1.65-2.25
0.2
(0.053-0.077)
(0.065-0.089)
(0.008)
1.65-2.25
1.65-2.25
0.2
(0.065-0.089)
(0.065-0.089)
(0.008)
7C-32 CLUTCH
CLUTCH CONTROL
Removal Steps
1. Pin
2. Jaw joint pin
3. Pedal assembly
4. Oil line
6. Oil line
7. Slave cylinder assembly
8. Damper cylinder assembly
Installation Steps
8. Damper cylinder assembly
7. Slave cylinder assembly
6. Oil line
4. Oil line
3. Pedal assembly
2. Jaw joint pin
1. Pin
CLUTCH 7C-33
MASTER CYLINDER
DISASSEMBLY
Disassembly Steps
1. Bolt : reservoir tank
2. Reservoir tank Comp
3. Yoke
4. Lock nut
5. Body sub assembly
7C-34 CLUTCH
REASSEMBLY
Reassembly Steps
1. Body sub assembly
2. Lock nut
3. Yoke
4. Reservoir tank Comp
5. Bolt : Reservoir Tank
CLUTCH 7C-35
SLAVE CYLINDER (4J, C24SE)

DISASSEMBLY
Disassembly Steps
I 1. Boot
2. Push rod
3. Piston and piston cup
4. Spring
5. Cylinder body
1. Boot
Brake fluid spilled on painted or plastic surfaces will cause
serious damage.
Take care not to spill brake fluid.
7C-36 CLUTCH

inspection.
Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it if
necessary.
Cylinder Bore and piston Clearance

1.
2.
3.
4.
Clean the cylinder body and the piston.

Use an inside dial indicator to measure the cylinder bore.
Use a micrometer to measure the piston diameter.
Calculate the clearance between the cylinder bore and the
piston diameter.
If the clearance exceeds the limit, the entire slave cylinder
assembly must be replaced.
Cylinder Bore and Piston Clearance
mm(in)
Standard
Limit
0.07 (0.0028)
0.15 (0.006)
Piston and Piston Cup

Visually inspect the disassembled piston and piston cup for
Replace the inner parts with new parts (Repair kit A) shown in
the illustration.
CLUTCH 7C-37
REASSEMBLY
Reassembly Steps
I 1. Cylinder body
2. Spring
I 3. Piston and piston cup
4. Push rod
5. Boot
1. Cylinder Body
1) Clean the cylinder body.
2) Apply brake fluid to the cylinder bore.
3. Piston and piston Cup

1) Apply brake fluid to the piston and piston cup.
2) Install the cups to the piston.
Note the installation direction of the piston cups in the
illustration.
3) Install the piston and piston cup to the cylinder body.
7C-38 CLUTCH
SLAVE CYLINDER (6VE1)

DISASSEMBLY
206RW004-X
Disassembly Steps
1. Boot
2. Push rod
3. Piston and piston cup
4. Spring
5. Cylinder body
CLUTCH 7C-39

inspection.
Cylinder Body
1. Clean the cylinder body.
2. Check the fluid return port for restrictions and clean it if
necessary.
206RS003
Piston and Piston Cup

1. Visually inspect the disassembled piston and piston cup for
2. Replace the inner parts with new parts shown in the
illustration.
206RS004
3. Measure the clearance between slave cylinder wall and

piston.
4. If the measured value exceeds the specified limit, the slave
cylinder assembly must be replaced.
mm(in)
Standard
Limit
0.07 (0.0028)
206RS005
0.15 (0.006)
7C-40 CLUTCH
REASSEMBLY
To reassemble, follow the disassembly steps in the reverse order, noting the following points:
1. Before installing the parts, apply a thin coat of rubber

grease.
2. Install cup in groove in piston with the lip turned to the front
of cylinder. Use care so as not to scratch the cylinder.
206RS006
CLUTCH 7C-41
HYDRAULIC DAMPER CYLINDER

inspection.
Visually check for oil leakage and other damage.

If oil leakage or other damage is discovered during the
inspection; the damper cylinder assembly must be replaced as
a unit.
7C-42 CLUTCH
TROUBLESHOOTING
Refer to this Section to quickly diagnose and repair clutch problems.
Each troubleshooting chart has three headings arranged from left to right.
(1) checkpoint (2) Trouble Cause (3) Countermeasure
This Section is divided into five sub-sections:
1. Clutch Slippage
2. Clutch Does Not Release Properly
3. Clutch Shudder
4. Clutch Noise
1) Clutch pedal Depressed (Clutch Disengaged)
2) Clutch pedal Not Depressed (Clutch Engaged)
5. Oil Leakage
CLUTCH 7C-43
1. CLUTCH SLIPPAGE
Checkpoint
Clutch pedal free play
Trouble Cause
Countermeasure
NG
No push rod play in the master

cylinder
Adjust the push rod play
NG
Insufficient grease on the front

cover contact surfaces
Clean and grease the release

bearing
NG
Transmission front cover

unevenly worn
Repair or replace the

transmission front cover
Too much grease
Clean the related parts and/or

replace the facing
OK
Release bearing
OK
Grease or oil adhering to the

facing
NG
NG
OK
Defective transmission front

cover oil seal

replace the facing
Replace the transmission front
cover oil seal
7C-44 CLUTCH
Checkpoint
Trouble Cause
Countermeasure

OK
facing
NG
Defective crankshaft rear oil

seal

replace the facing
Replace the crankshaft rear oil
seal
NG
Release bearing broken
Replace the release bearing
Worn facing
Replace the driven plate

assembly
Weak or broken clutch

diaphragm spring
Replace the clutch pressure

plate assembly
OK
NG
Facing
OK
Clutch diaphragm spring
NG
CLUTCH 7C-45
2. CLUTCH DOES NOT RELEASE PROPERLY

Checkpoint
Trouble Cause
NG
Countermeasure
Too much push rod play in the

master cylinder
Adjust the push rod play
Air in the hydraulic circuit
Bleed the hydraulic circuit
Driven plate warped or

unevenly worn
Insufficient grease on the

spline contact surface of the
splined hub
Clean and grease the splined

contact surface
Corrosion or step wear on the

top gear shaft spline
Clean or repair the top gear

shaft spline
Replace the top gear shaft
Pressure plate unevenly worn
Replace the pressure plate

assembly
OK
NG
Hydraulic circuit
OK
NG
Driven plate
NG
NG
OK
NG
Pressure plate
OK
7C-46 CLUTCH
Checkpoint
Trouble Cause
Countermeasure

OK
NG
Flywheel
Flywheel unevenly worn
Repair or replace the flywheel
Top gear shaft wobble is

causing pilot bearing wear
Replace the pilot bearing
OK
Crankshaft pilot bearing
NG
CLUTCH 7C-47
3. CLUTCH SHUDDER
Checkpoint
Trouble Cause
NG
Power train
Countermeasure
Poorly connected components

causing looseness and
abrasion
Tighten the connections

applicable parts
Pressure plate unevenly worn
Replace the pressure plate

assembly
Too much grease

replace the facing
Defective transmission front

cover oil seal

replace the facing
Replace the transmission front
cover oil seal
Defective crankshaft rear oil

seal

replace the facing
Replace the crankshaft rear oil
seal
Insufficient grease on the

spline contact surface of the
splined hub
Clean and grease the spline

contact surface
Corrosion or step wear on the

top gear shaft spline
Clean or repair the top gear

shaft spline
Replace the top gear shaft
OK
NG
Pressure plate
OK

facing
NG
NG
NG
OK
NG
Driven plate
NG
OK
7C-48 CLUTCH
Checkpoint
Trouble Cause
Countermeasure

OK
NG
Driven plate
Loose facing rivets

assembly
NG
Warpage and/or uneven wear

assembly
NG
Flywheel uneven wear
Repair or replace the flywheel
OK
Flywheel
CLUTCH 7C-49
4. CLUTCH NOISE
1) Clutch Pedal Depressed (Clutch Disengaged)
Checkpoint
Pedal shaft and sleeve
Trouble Cause
Countermeasure
NG
Insufficient grease at the

pedal shaft and sleeve
Clean and grease the pedal

shaft and sleeve
NG
Worn pedal shaft and/or

sleeve
Replace the pedal shaft with

the sleeve

maser cylinder piston and
push rod contact faces
Clean and grease the master

cylinder piston and push rod
contact faces
Loose or broken damper

spring

assembly

crankshaft pilot bearing (pilot
bearing worn)
Replace the crankshaft pilot

bearing
OK
Master cylinder piston and

push rod contact faces
NG
OK
NG
Driven plate
OK
NG
2) Clutch Pedal Not Depressed (Clutch Engaged)
Driven plate damper spring
NG
Weak or broken damper

spring

crankshaft pilot bearing (pilot
bearing worn)
Replace the crankshaft pilot

bearing
OK
NG
7C-50 CLUTCH
5. OIL LEAKAGE
Checkpoint
Master cylinder
Trouble Cause
Countermeasure
NG
Weak or damaged piston cup
Replace the body sub

assembly
NG
Loosely connected fluid pipe

and/or hose
Tighten the fluid pipe and/or

hose connections
Weak or damaged piston cup
Replace the piston cup
Loosely connected oil pipe
Tighten the oil pipe connection
Loosely connected oil pipe
Tighten the oil pipe
OK
Master cylinder fluid pipe and
hose
OK
NG
Slave cylinder
OK
Slave cylinder oil pipe
NG
OK
Fluid reservoir
NG
CLUTCH 7C-51

ITEM NO.
ILLUSTRATION
PART NO.
5-85253-001-0
PART NAME
Clutch pilot aligner
7C-52 CLUTCH
MEMO
No. TFCLU-WE-0431
WORKSHOP MANUAL
TF SERIES
TRANSMISSION
JR405E MODEL
SECTION 7A
CONSTRUCTION AND FUNCTION
7A1-1
SECTION 7A1

TABLE OF CONTENTS
PAGE
DESCRIPTION ..............................................................................................................................7A1- 3
CONSTRUCTION ....................................................................................................................7A1- 3
MAIN DATA AND SPECIFICATION .....................................................................................7A1- 4
NUMBER PLATE LOCATION ...............................................................................................7A1- 5
ELECTRONIC CONTROL COMPONENTS LOCATION ..................................................7A1- 6
TRANSMISSION CONTROL UNIT (TCM) PERIPHERAL CIRCUIT ..............................7A1- 7
STRUCTURE AND FUNCTION OF COMPONENT ...........................................................7A1- 8
TORQUE CONVERTER (WITH LOCK-UP FUNCTION) ..................................................7A1- 8
OIL PUMP .................................................................................................................................7A1- 9
INPUT SHAFT ..........................................................................................................................7A1- 10
OUTPUT SHAFT ......................................................................................................................7A1- 10
GEAR SHIFTING MECHANISM ............................................................................................7A1- 10
CONTROL VALVE ...................................................................................................................7A1- 14
OIL PASSAGE .........................................................................................................................7A1- 19
PARKING FUNCTION .............................................................................................................7A1- 20
INHIBITOR SWITCH ...............................................................................................................7A1- 21
TURBINE SENSOR .................................................................................................................7A1- 22
SPEED SENSOR .....................................................................................................................7A1- 22
THROTTLE POSITION SENSOR (TPS) .............................................................................7A1- 23
ENGINE SPEED SENSOR (=TDC SENSOR) ....................................................................7A1- 23
BRAKE SWITCH ......................................................................................................................7A1- 24
MODE SELECT SWITCH .......................................................................................................7A1- 24
TRANSMISSION CONTROL MODULE (TCM) ..................................................................7A1- 25
CONTROL MECHANISM ............................................................................................................7A1- 26
CONTENT OF FUNCTION AND CONTROL ......................................................................7A1- 26
CONTROL ITEM, INPUT AND OUTPUT .................................................................... 7A1- 29
LINE PRESSURE CONTROL ..................................................................................... 7A1- 30
7A1-2
PAGE
LOCK-UP CONTROL ..............................................................................................................7A1- 30
DIRECT ELECTRIC SHIFT CONTROL (DESC) ................................................................7A1- 31
LEARNING CONTROL ............................................................................................... 7A1- 33
MAJOR INPUT/OUTPUT COMPONENT AND THEIR FUNCTIONS .......................... 7A1- 34
CONTROL CIRCUIT BLOCK DIAGRAM .................................................................... 7A1- 35
GEAR TRAIN (TRANSMISSION MECHANISM) OPERATION AND
HYDRAULIC CIRCUIT ................................................................................................. 7A1- 36
CONSTRUCTION AND OPERATION ......................................................................... 7A1- 36
COMPONENT NAME AND FUNCTION ...................................................................... 7A1- 36
COMPONENT AND THEIR OPERATING CONDITION ............................................. 7A1- 37
7A1-3
DESCRIPTION
CONSTRUCTION
2WD
4WD
1
2
3
4
5
Converter Housing
Torque Converter
High Clutch
Reverse Clutch
2-4 Brake
6
7
8
9
10
Low Clutch
Low & Reverse Brake
Output Shaft
Extension Housing
Input Shaft
11
12
13
14
Oil Pump
Control Valve
Low One-way Clutch
Parking Gear
Figure 1. Construction of Automatic Transmission
The JR405E automatic transmission is electrically controlled by a microcomputer transmission control module
(TCM). There are four forward speeds and one reverse speed.
This JR405E automatic transmission employs a clutch pressure direct control system (Direct Electronic Shift
Control: DESC) using a duty cycle type solenoid, which ensures high shift quality.
This transmission also controls learning and constantly checks the time of each clutch and brake required for
the speed change to match this time with the target value for the optimum speed change.
The TCM will automatically select the most appropriate shift points and lock-up points depending on the
throttle opening angle, the vehicle speed and the vehicle load.
If any trouble arises in the vehicle sensor, throttle sensor, solenoid, etc., the fail-safe control function is
activated to keep the running performance.
Problems with the sensors, the solenoids can be quickly detected with the self diagnosis procedure described
in this manual.
The JR405E automatic transmission consists of the torque converter, the oil pump, the input shaft, the out put
shaft, the planetary gears and the control valve.
The gear train consists of two planetary gear sets and three multiple plate clutches in combination with two
multiple plate brakes and a one-way clutch.
7A1-4
MAIN DATA AND SPECIFICATION

Model
JR405E
Three Elements, One Stage & Two Phase Type
With Lock-up Function
Torque Converter Type

Torque Converter Stall Torque Ratio
1.8
Name
ATF
ATF DEXRON
Quantity
9.2L-9.6L
Cooling System
Gear Ratio
Clutch
Brake
Water Cooled Type (Radiator)
1st
2.786
2nd
1.546
3rd
1.000
4th (Over Drive)
0.694
Reverse
2.273
Low Clutch
L/C
High Clutch
H/C
Reverse Clutch
R/C
Low One-way Clutch
L/O.C
Low
&
Brake
L&R/B
2-4/B
Reverse
2-4 Brake
Front Planetary
Planetary Gear Unit

Rear Planetary
Sun Gear
33
Pinion
Gear
21
Ring Gear
75
Sun Gear
42
Pinion
Gear
17
Ring Gear
75
Number of Disc
Set
Number of Disc
Number of Teeth
7A1-5
NUMBER PLATE LOCATION
4WD
JATCO CORP
UK000

No. 1X80652

2 3 4
1 UK000
UK000 = 2WD
UK001 = 4WD
2 1
Production Year
1=2001
2=2002
3=2003
4=2004
5=2005
3 X
Product Month
19=JanuarySeptember
X=October
Y=November
Z=December
4 80652
Production Sequence Number
2WD
Serial Number Location

2WD:Back of the transmission rear mounting
4WD:Left side of the transmission rear mounting
Figure 2. Number Plate Location
7A1-6
ELECTRONIC CONTROL COMPONENTS LOCATION
Engine
Brake pedal
Engine speed sensor

Brake Switch
Select lever
Electrical source
Power Drive, 3rd Start select switch
Instrument panel (Meter)

Ignition
Battery voltage
Transmission
Speed meter (2WD Only)
Shift position indicator lamp
POWER DRIVE, 3rd START
indicator lamp
A/T OIL TEMP indicator lamp
CHECK TRANS indicator lamp
Transfer
4WD Only
Data link connector
4L mode switch
4WD Only
Transfer Control Module
Speed sensor
Turbine sensor
Inhibitor switch
ATF thermo sensor
High clutch oil pressure switch
2-4 brake oil pressure switch
Low & Reverse brake oil pressure
switch
Line pressure solenoid
Low clutch solenoid
High clutch solenoid
2-4 brake solenoid
Low & Reverse brake solenoid
Lock-up solenoid
TRANSMISSION CONTROL UNIT (TCM) PERIPHERAL CIRCUIT
Figure 4. TCM Peripheral Circuit
7A1-7
7A1-8
STRUCTURE AND FUNCTION OF COMPONENT

TORQUE CONVERTER (WITH LOCK-UP FUNCTION)
The torque converter is a device for transmitting the engine torque to the transmission. It transmits power
by means of oil when the lock-up is disengaged and by means of a lock-up piston when it is engaged.
The torque converter is of the symmetrical, three-element, single-stage, two-phase type.
As shown in the drawing, the symmetrical three-elements refer to three elements (components) consisting
of impeller (1), turbine (2) and stator (3) that are arranged symmetrically (figure 5).
"Single-stage" means that there is only one turbine as an output element; "two-phase" means that the
pump impeller acts as a torque converter when the turbine speed is comparatively low, and as a fluid
coupling when the speed is high.
1. Pump Impeller
2. Turbine Runner
3. Stator
Figure 5. Torque Converter
1. Pump Impeller
2. Turbine Runner
3. Stator
4. Converter Cover
5. One-way Clutch
6. Lock-up Piston
7. Torsion Damper
Figure 6. Construction of Torque Converter
Lock-up mechanism
"Lock-up" refers to a fixed state of the lock-up piston inside the torque converter and thus connects the
engine directly to the transmission.
The hydraulic pressure for the lock-up control is supplied from two circuits.
When the lock-up is disengaged (Figure 7)
When the lock-up is disengaged, the torque converter operating pressure is supplied from the oil passage
(A) to between the cover and the lock-up piston, and separates the lock-up piston clutch facing and
converter cover.
As a result, the engine drive power is transmitted from the converter cover to the pump impeller, the ATF
and to the turbine. The torque converter function as a fluid connector in this condition.
The torque converter operating pressure is supplied from the oil passage (A), passes through the oil
passage (B).
When the lock-up is engaged (Figure 8)
When the lock-up is engaged, the torque converter operating pressure is supplied from oil passage (B) to
the oil pump impeller, turbine, then to the stator side. The oil between the lock-up piston and converter
cover is drained.
Since the force acting on the right side of the lock-up piston is greater than force on the left side, it
connects the lock-up piston clutch facing with the converter cover, thereby increasing the transmission
efficiency.
Figure 7. Lock-up Control (Disengaged)
7A1-9
Figure 8. Lock-up Control (Engaged)
OIL PUMP
The oil pump generating oil pressure is a small-size trochoid gear type oil pump. It feeds oil to the torque
converter, lubricates the power train mechanism, and feeds the oil pressure to the oil pressure control unit
under pressure.
The oil pump is located behind the torque converter. Sine the inner rotor in the oil pump is fitted with the
drive sleeve of the torque converter, it works by the power from the engine.
Figure 9. Construction of Oil Pump
Figure 10. Location of Oil Pump
When the inner rotor in the oil pump rotates, ATF is sucked in from the oil pan, passed between the inner
rotor, outer rotor and crescent and discharged. This pressure discharged is sent to the pressure
regulator valve in the control valve and adjusted as required for operating the A/T. The flow rate under
pressure increases or decreases in proportion of the number of rotations.
Figure 11. Operation of Oil Pump
7A1-10
INPUT SHAFT
The input shaft has some oil holes, through which lubricating ATF is supplied to the torque converter,
bearings, etc.
The input shaft is fitted the turbine runner in the torque converter, reverse & high clutch drum and rear sun
gear by means of the spline. Therefore, the engine driving force received by the torque converter is
transmitted to the reverse & high clutch drum and rear sun gear.
OUTPUT SHAFT
The output shaft has some oil holes, through which the lubricating ATF is supplied to the bearings,
planetary gear unit, etc.
The output shaft transmits the engine driving force from the planetary gear to the propeller shaft.
The front internal gear is fitted with the rear carrier assembly by spline. The parking gear is also fitted by
spline. By fixing this gear mechanically, the output shaft is fixed as required when parking the vehicle.
GEAR SHIFTING MECHANISM
The JR405E consists of two sets of planetary gears, three multiple plate clutches, two multiple plate
brakes and a one-way clutch. They are activated in different combinations in any of four forward and one
reverse gear positions.
Principle of gear shifting (Figure 12)

Planetary gears have the advantage of a compact configuration because of the way they are constructed
with a single central shaft.
Also, unlike the manual transmission gears that require changing of gear mesh, the gear ratio of the
planetary gears can be changed more easily by locking, releasing or rotating only some of their parts.
A planetary gear is made up of a sun gear (1) at its center and pinion gears (2) each of which rotates
about its own center and also along the sun gear, as shown. They are all called in the internal gear (3).
Also, since the pinion gears are further supported by the planetary carrier (4), they rotate as a unit in the
same direction and at the same rate.
As shown above, each planetary gears are constructed of three elements; a sun gear, pinion gears, and
internal gear and a planetary carrier. Gear shifting is achieved by conditioning two of the three elements
namely the sun gear, internal gear and the planetary carrier.
The planetary gears are locked by the clutch, brake and one-way clutch according to the gear shifting.
1. Sun Gear
2. Pinion Gear
3. Internal Gear
4. Planetary Carrier
Figure 12. Planetary Gear
7A1-11
The JR405E consists of two sets of planetary gears, which are called front planetary gear and rear
planetary gear.
The sun gear of front planetary gear is fixed to the drive plates of 2-4 brake and reverse clutch.
The planetary carrier of front planetary gear is fixed to the drum of low clutch, the drive plates of low &
reverse brake and the hub of high clutch.
The internal gear of front planetary gear and the planetary carrier of rear planetary gear are connected as
one, and they are fixed to output shaft.
The sun gear of rear planetary gear is fixed to input shaft.
The internal gear of rear planetary gear is fixed to the hub of low clutch.
Clutch and Brake
Basic structure of the clutch and brake is shown in the figures below.
In the figure A, the clutch plates (drive plate and driven plate) are in the fluid so that they slip against each
other transmitting no power.
Figure B shows the condition where the oil pressure is acting on the piston. The clutch plates are fitted
to each other under pressure transmitting the rotations of the clutch drum to the clutch hub.
When the oil pressure is removed from the piston, the clutch returns to the condition in the figure A by the
return spring.
Figure 13. Basic Construction of Clutch and Brake
Low Clutch, High Clutch and Reverse Clutch (Multi-Plate Clutch)

The multi-plate clutch is composed of drive plates and driven plates. By applying the oil pressure onto
the end surface of the plates, the clutch is engaged or disengaged. The oil pressure is adjusted with the
control valve according to the signal from the TCM.
All clutches use dish plates to prevent uncontrolled operation of the clutches when engaged, causing a
shock.
For the reverse clutch, a piston check ball is used to release the oil pressure for the purpose of preventing
the clutch drag due to oil pressure generated by residual ATF because of the centrifugal force while the
clutch is racing (under no oil pressure).
For the low clutch and high clutch, a centrifugal balance chamber always full of ATF is provided to offset
the excessive oil pressure, for the purpose of preventing the clutch drag due to oil pressure generated by
residual ATF because of the centrifugal force while the clutch is racing (under no oil pressure).
The solenoid in the control valve is driven based on the speed change signal from TCM and moves the
shift valve, thereby engaging the drive plate and driven plate through the piston of each clutch.
Resultantly, elements of the planetary gear unit are combined.
When the oil pressure is removed, the piston returns to the original position by the force of the return
spring.
7A1-12
Figure 14. Basic Construction of Low Clutch

and High Clutch
Figure 15. Basic Construction of Reverse Clutch
Figure 16. Construction of Low Clutch
Figure 17. Construction of High Clutch
Figure 18. Construction of Reverse Clutch
7A1-13
2-4 Brake and Low & Reverse Brake (Multi-Plate Brake)

The multi-plate brake is composed of drive plates and driven plates. By applying the oil pressure onto
the end surface of the plates, the clutch is engaged or disengaged. The oil pressure is adjusted with the
control valve according to the signal from the TCM.
All brakes use dish plates to prevent uncontrolled operation of the clutches when engaged, causing a
shock.
The solenoid in the control valve is driven based on the speed change signal from TCM and moves the
shift valve, thereby engaging the drive plate and driven plate through the piston of each clutch.
Resultantly, rotation of each element of the planetary gear unit is fixed.
When the oil pressure is removed, the piston returns to the original position by the force of the return
spring.
Figure 19. Construction of 2-4 Brake
Figure 20. Construction of Low & Reverse Brake
Low One-way Clutch

The low one-way clutch employs the sprag which locks the counterclockwise rotation of the front planetary
carrier and rear internal gear.
The one-way clutch outer race is fitted with the low clutch drum and the inner race with the transmission
case.
The outer race rotates freely clockwise but, when it attempts to rotate counterclockwise, the sprag
functions to lock the outer race.
When the vehicle is traveling in 1st gear in the D, 3 or 2range, the low one-way clutch locks the rear
internal gear via the low clutch. It is left free in the 2nd, 3rd or 4th gear position.
Figure 21. Construction of Low One-way Clutch
7A1-14
CONTROL VALVE
Employing the direct electronic control (Direct Electronic Shift Control: DESC) for the clutch pressure has
simplified the oil pressure circuit, reduced the number of functional components and made the control
valve compact.
The control valve body is divided into the upper body and lower body. All solenoids, oil pressure switch
and ATF thermo sensor are installed to the lower body.
Three-way valve type solenoids providing high responsibility are employed. Some of the solenoids are
switched between ON and OFF and others repeat ON and OFF at 50Hz (duty cycle system).
Functionally, some supply output pressure when power is not supplied and others drain the output
pressure.
When the solenoid is driven based on the signal from the TCM, the oil pressure is changed. The valve is
operated by the difference of the oil pressure.
Figure 22. Construction of Valve Body
7A1-15
Line Pressure Solenoid

The line pressure solenoid is turned ON or OFF according to the signal from the TCM. It switches the
line pressure between high and low pressure.
While no power is supplied, the solenoid supplies high pressure.
Shift Solenoid
The shift solenoid is of the duty cycle type which are turned ON or OFF at 50Hz. The ratio of the ON and
OFF time can be freely controlled in the range of 0 - 100%.
While no power is supplied, the solenoid supplies output pressure.
The low clutch solenoid adjusts the low clutch pressure, the high clutch solenoid the high clutch pressure,
the 2-4 brake solenoid the 2-4 brake pressure and the low & reverse brake solenoid the low & reverse
brake pressure respectively.
Lock-up Solenoid
The lock-up solenoid is of the duty cycle type which is turned ON or OFF at 50Hz. The ratio of ON and
OFF time can be freely controlled in the range of 0-100%.
While no power is supplied, the solenoid drains the output pressure.
Figure 23. Shift Solenoid
Figure 25. Location of Solenoid
Figure 24. Lock-up Solenoid
7A1-16
Control Valve Fail-safe Function

To prevent interlocking due to engagement of more than three clutches and brakes at the same time, the
2-4 brake fail-safe valve A and B, and the low & reverse brake fail-safe valve A and B are provided.
When oil pressure is generated in the high clutch and the low clutch, the 2-4 brake solenoid is turned ON
to drain the oil pressure applied to the 2-4 brake.
When oil pressure is generated in the high clutch or 2-4 brake, the low & reverse brake solenoid is turned
ON to drain the oil pressure applied to the low & reverse brake.
Oil Pressure Switch

The oil pressure switch detects the oil pressure supply condition to the clutch and brake and sends the
detection result to the TCM.
The oil pressure switch is turned ON when the oil pressure reaches the switch working pressure and
turned OFF when the pressure decreases below the specified value.
The high clutch oil pressure switch detects the high clutch oil pressure, 2-4 brake oil pressure switch the
2-4 brake oil pressure, and the low & reverse brake oil pressure switch the low & reverse brake oil
pressure respectively.
Figure 27. Oil Pressure Switch
Figure 28. Location of Oil Pressure Switch
7A1-17
ATF Thermo Sensor

The ATF thermo sensor detects the ATF temperature in the oil pan and sends signal to the TCM.
The ATF thermo sensor is of the thermister type that the resistance value changes according to the ATF
oil temperature.
The lower is the ATF temperature, the larger is the resistance, and vice versa.
When the ATF temperature exceeds 145C, the TCM lights up the ATF temperature warning lamp in the
meter. When the ATF temperature decreases below 128C, the ATF temperature warning lamp goes out.
The ATF thermo sensor is installed to the lower control valve body and integrated with the harness
assembly.
ATF Temperature
(deg. C)
Resistance (Ohm)
(Approximately)
ATF Temperature
(deg. C)
Resistance (Ohm)
(Approximately)
-30
29,614
100
190
-20
16,705
110
149
-10
9,842
120
118
6,028
128
98
20
2,500
130
94
40
1,160
135
84
50
819
140
76
60
591
145
68
80
324
150
62
100,000.0
Resistance ()
10,000.0
1,000.0
100.0
-30
-20
10.0
-10
0
10
20
30
40
50
60
70
80
90
100
110
ATF Temperature (C)
Figure 29. Characteristic of Thermo Sensor
Figure 30. Location of Thermo Sensor
120
130
140
150
160
7A1-18
Terminal Assembly
Pin No.
6
12
5
11
4
10
3
9
2
8
1
7
Connected to
Low & Reverse Brake Oil Pressure Switch
Low & Reverse Brake Duty Solenoid
Ground Return
Lock-up Duty Solenoid
High Clutch Duty Solenoid
Low Clutch Duty Solenoid
2-4 Brake Duty Solenoid
Oil Thermo Sensor
Oil Thermo Sensor Ground
High Clutch Oil Pressure Switch
2-4 Brake Oil Pressure Switch
12 11
10
2
8
Connected TCMPin No.

B23
B12
B6
B22
B17
B8
B9
B7
B4
B14
B20
B1
1
7
Terminal Assembly
Figure 31. Pin Assignment
Inhibitor Switch
Figure 32. Location of Terminal Assembly
OIL PASSAGE
Figure 33. Oil Passage of Transmission Case
7A1-19
7A1-20
Figure 34. Oil Passage of Oil Pump
PARKING FUNCTION
By setting the select lever to the P range, the parking pawl is engaged with the parking gear and fixes the
output shaft.
By the movement of the select lever, the manual shaft on the side surface of the AT is moved. The
manual plate and parking rod in the AT are interlocked with the manual shaft. When the manual shaft
moves, the parking rod end pushes up the parking pawl.
The parking pawl is engaged with the parking gear when pushed up, and fixes the output shaft.
When the clutch is disengaged, it returns to the original position by the force of the return spring fixed to
the parking pawl.
Figure 35. Parking Function
CONSTRUCTION AND FUNCTION 7A1-21
INHIBITOR SWITCH
The inhibitor switch is installed on the right side of the transmission main unit to detect the select lever
position.
The inhibitor switch is connected with the starter SW circuit. The engine cannot be started when the
select lever is at any position other than the P or N range.
By moving the select lever, the combination of the inhibitor switch pins is changed. The current range of
TCM is detected based on the combination of the pins.
10
P
R
N
D
3
2
L
6
10
4
9
2
8
1
7
Terminal Assembly
Inhibitor Switch
Figure 37. Location of Inhibitor Switch
7A1-22 CONSTRUCTION AND FUNCTION
TURBINE SENSOR
The turbine sensor is a hall element. It is installed to the front of the transmission case. The turbine
sensor converts the rotations of the reverse & high clutch drum fitted with the input shaft by spline to
pulse signal and sends the signal to TCM.
One turn of the reverse & high clutch drum generates 32-pulse signal, which is sent to the TCM.
Figure 38. Turbine Sensor
SPEED SENSOR
The speed sensor is a hall element. It is installed to the rear of the transmission case. The speed sensor
converts the rotations of the parking gear fitted with the output shaft by spline to a pulse signal which is
sent to the TCM.
One turn of the parking gear generates a 16-pulse signal to be sent to the TCM.
Figure 39. Speed Sensor
Figure 40. Location of Turbine & Speed Sensor
THROTTLE POSITION SENSOR (TPS)
Opening of the accelerator pedal is converted to an electric signal which is transmitted from ECM to TCM.
Figure 41. Throttle Position Sensor
ENGINE SPEED SENSOR (=TDC SENSOR)
The engine speed sensor converts the crankshaft from the TDC (Top Dead Center) sensor rotation to a
pulse signal which is transmitted from ECM to TCM.
Ground
Figure 43. TDC Sensor
Signal
Shield Line
BRAKE SWITCH
The brake switch is installed to the brake pedal. When the driver steps on the brake pedal, an electric
signal is sent to the TCM.
Brake Switch
TCM A3
Brake Pedal
+12V
Accelerator Pedal
Figure 45. Brake Switch
MODE SELECT SWITCH
The mode select switch is installed beside the select lever. When the driver selects the PWR or 3rd, an
electric signal is sent to the respectively. It turns ON the indicator lamp in the meter.
The 3rd START mode can be used only in the D range.
2
6
1
5
Power
Gear Select Lever
3rd
1 (Illumination)
2 (Ground)
3 (TCM A24)
4 (No Connection)
5 (TCM A11)
6 (Ground)
Mode Select Switch
Figure 47. Mode Select Switch
Illumination
Lamp
TRANSMISSION CONTROL MODULE (TCM)
The TCM is fitted side of brake pedal by means of two stud bolts.
The TCM judges necessary line pressure, gear shifting point and lock-up operation based on electrical
signals from switches and sensors and sends appropriate signals to solenoids.

Connect to White Connector
Connect to Grey Connector

Pin No.
Pin Assignment
Pin No.
Pin Assignment
B1
2-4 Brake Oil Pressure Switch
A1
V BATT (Battery Back-up Power Supply)
B2
2 Range Switch
A2
P Range Switch
B3
Turbine Sensor
A3
Brake Switch
B4
ATF Thermo Sensor
A4
3rd Start Indicator Lamp
B5
Ground
A5
K-Line Signal (Tech 2 Serial Communication)
B6
A6
No Connection
B7
A7
Engine Speed Sensor
B8
A8
No Connection
B9
A9
No Connection
B10
N Range Switch
A10
Vehicle Speed Sensor Out (2WD Only)
B11
D Range Switch
A11
3rd START Select Switch
B12
Low & Reverse Brake Oil Pressure Switch
A12
4L Mode Switch (4WD Only)
B13
A13
No Connection
B14
ATF Thermo Sensor Ground
A14
No Connection
B15
Ground
A15
No Connection
B16
No Connection
A16
B17
A17
3 Range Switch
B18
Vign Ignition Power Supply)
A18
DIAG Switch (Test Switch)
B19
R Range Switch
A19
A/T OIL TEMP Indicator Lamp
B20
A20
CHECK TRANS Indicator Lamp
B21
L Range Switch
A21
POWER DRIVE Indicator Lamp
B22
Ground (Shift Solenoid)
A22
No Connection
B23
A23
No Connection
B24
Vign (Ignition Power Supply)
A24
POWER DRIVE Select Switch
CONTROL MECHANISM
CONTENT OF FUNCTION AND CONTROL
Item
Line pressure control
Description
TCM issues a signal according to the vehicle traveling, engine load and other conditions to
TCM and the ON/OFF type line pressure solenoid is driven to switch the line pressure to
high or low pressure.
The line pressure solenoid is switched to the low pressure side when the solenoid is turned
ON (power supplied) and to the high pressure side when turned OFF (no power supplied).
In the forward travel range (D, 3, 2, L range), the line pressure decreases lower than that in
the P, N, and R range through the oil pressure circuit for the forward travel range.
Gear shift control
The TCM issues a shift solenoid drive signal based on the traveling mode switch, inhibitor
switch, vehicle speed, throttle opening and other input signal to control the optimum gear
position automatically.
Speed change features have been set up to the TCM; the normal mode is suited to usual
traveling and the power mode is appropriate when the vehicle is loaded or accelerates the
speed.
In addition, speed change features used only for high oil temperature, hill climbing, and
down have been set up to the TCM, which are automatically switched depending on the
traveling conditions.
When the oil temperature is low (below 10C), speed change from the third to the fourth
speed is prohibited by the gear shift control.
Shift pattern selection

control
According to a vehicle condition, the TCM selects the following shift pattern.
Selection
Priority
High
Low
Shift Pattern
High Temperature
3rd Start
4L
Power SW Off
Down Slop
Power SW On
Power
Up Slope
Normal
- High temperature mode High temperature mode setting condition

ATF temperature: More than 123C
Above condition is met for more than 10 seconds.
High temperature mode cancel condition
ATF temperature: Less than 116C
Above condition is met for more than 10 seconds.
- 3rd start mode 3rd start mode setting condition
3rd start switch: On Off (Pushed)
Vehicle speed: Less than 11km/h
ATF temperature: Less than 115C
Throttle position: Less than 8%
Select lever position: D range
Above conditions are met at the same time.
3rd start mode reset condition
3rd start switch: On Off again(Pushed again)
Vehicle speed: More than 34km/h
Select lever position: Other than D range
At least, one of above conditions is met.
3rd Start
Lamp
OFF
ON
Power Drive
Lamp
OFF
OFF
OFF
ON
OFF

Item
Description
- 4L mode 4L mode setting condition
4L switch: On
4L mode reset condition
4L switch: Off
Vehicle speed: Less than 4km/h
- Down slope mode Down slope mode setting condition
Brake switch: On
Engine idle condition: More than 2.5 seconds
Select lever position: D or 3 range
Vehicle speed change: More than 1km/h
Down slope mode reset condition
Engine idle condition: Not idle condition
Select lever position: Other than D or 3 range
At least, one of above conditions is met.
- Power Mode When power drive switch is On at only D range or 3 range, the shift change is performed by
1 4 speed based on shift diagram set as power pattern.
- Up slope mode Up-slope reasoning value is calculated from the average throttle angle and the average
acceleration. Otherwise, up-slope reasoning value is calculated from the vehicle speed.
TCM judges as up-slope mode when the former is bigger than latter.
Lock-up control
The lock-up solenoid adjusts the pressure based on the signal from the TCM according to
the vehicle speed, throttle opening and other input signals based on the pre-set lock-up
point to control the lock-up.
Smooth lock-up control engages and disengages the clutch smoothly at the time of lock-up.
When the oil temperature is low (below 20C) or high (above 128C), lock-up is prohibited
even when the vehicle is at a lock-up speed.
The lock-up is disengaged also when the throttle is closed.
Direct electronic shift

control (DESC)
The duty cycle type solenoid is used for each clutch and brake. The solenoid adjusts the
clutch pressure to be suited to the engine load and vehicle traveling condition based on the
signal from the TCM. The pressure switch provided in the control valve oil passage sends
the oil pressure condition to the TCM to control the disengagement and engagement of the
clutch and brake directly and finely.
Learning control
Learning is controlled to correct the oil pressure control timing to engage or disengage the
clutch optimally in order to compensate changes of the engine performance and changes
of the transmission with time. It is controlled to bring the speed-change time closer to the
value pre-set to the TCM.

Item
Fail-safe function
Description
In case of malfunction of the vehicle speed sensor, throttle position sensor, all solenoids or
inhibitor switch, TCM automatically begins fail-safe control to minimize effects on driving.
The gear is fixed at the 3rd-speed position and power supply to the solenoid is shut off so
that the solenoid does not work nor lock up.
Self-diagnosis function
Parts required for controlling the automatic transmission are provided with a self-diagnosis
function. When any trouble occurs, the check trans indicator lamp blinks to warn the driver.
The trouble code is memorized in the TCM.
CONTROL ITEM, INPUT AND OUTPUT

Control item
Item
Speed sensor
Turbine sensor
Engine speed sensor
Brake switch
Input
Inhibitor switch
Mode select switch
4L switch (4WD Only)
ATF thermo sensor
Low & Reverse brake oil pressure
switch
Low clutch solenoid
Output

2-4 brake solenoid
Lock-up solenoid
Shift pattern indicator lamp
ATF temperature indicator lamp
Check trans indicator lamp
Line
pressure
control
Gear
shift
control
Shift
pattern
selection
Direct
SelfLock-up electronic Learning Fail-safe
function diagnosis
control
shift
control
function
control
(DECS)
LINE PRESSURE CONTROL
Either the throttle opening, vehicle speed, turbine rotational speed, ATF temperature or speed-change
range signal appropriate under the situation is issued from the TCM. The ON/OFF type line pressure
solenoid is actuated and switches the line pressure to high or low pressure.
The line pressure generated by the oil pump acts on the point A of the pressure regulator valve. When
the pressure control solenoid is turned ON by the signal from the TCM, the solenoid pressure does not
act. The line pressure is adjusted to match the spring force acting on the right side of the pressure
regulator valve.
When the pressure control solenoid is turned OFF, the solenoid pressure acts so that the line pressure is
adjusted to match the spring force acting on the right side of the pressure regulator valve.
As a result, the line pressure is adjusted to be low when the pressure control solenoid is ON and to be
high when the pressure control solenoid is OFF.

In the D, 3, 2 and L range, the line pressure through the oil pressure circuit acts onto the point B of the
pressure regulator valve and the pressure regulator valve moves so as to increase the pressure to be
drained, so that the line pressure is adjusted to be lower than the P, N, and R range by the difference of
area at the point B.
Figure 50. Line Pressure Control
LOCK-UP CONTROL
The lock-up solenoid adjusts the pressure and controls the lock-up based on the pre-set lock-up point,
according to the vehicle speed, throttle opening, engine rotations, turbine rotations and ATF temperature
input signal, based on the signal from the TCM.
Smooth lock-up control is employed to engage or disengage the clutch smoothly at the time of lock-up.
When the oil temperature is low (below 20C) or high (over 128C), lock-up is disengaged even though
the vehicle is at the lock-up speed.

The lock-up is disengaged also when the throttle is closed.
When the TCM determines the lock-up engagement, the DUTY ratio to supply power to the lock-up
solenoid is gradually increased (5% to 95%) and the oil between the lock-up piston and converter cover is
gradually
drained.
As a result, the lock-up piston is fitted slowly under pressure to the converter cover securing smooth lockup engagement.
Figure 51. Lock-up Control
DIRECT ELECTRIC SHIFT CONTROL (DESC)

Feature
Based on the each switch signals (low & reverse brake pressure, 2-4 brake pressure & high clutch
pressure) and sensors signals (turbine sensor, speed sensor, engine speed signal & throttle position
signal), duty cycle type solenoid adjusts the clutch pressure to match the engine load and vehicle
traveling condition. By this result, controlling the engagement and disengagement of the clutch and brake
pressure is directly and accurately controlled via TCM, which is not realized in previous accumulator type.
Operation
Instead of the previous system (on/off type of shift solenoid and shift valve), the combination of duty cycle
type solenoid and amplifier (Amp) valve are used to adjust the clutch pressure to match the engine load
and vehicle traveling condition based on the signal from the TCM, and the pressure switch provided in the
oil passage of the control valve transmits the oil pressure condition at that time to TCM, thus controlling
the engagement and disengagement of the clutch and brake directly and finely.
When the gear is shifted from the 2nd to 3rd, 3rd to 4th (O/D), 4th (O/D) to 3rd and 3rd to 2nd, the clutch
pressure on the engagement side and that on the disengagement side are simultaneously controlled.
As a result, engine racing or clutch drag is prevented securing smooth and quick speed change response
Direct Electric Shift Control
Previous Model
Figure 52. Direct Electric Shift Control (DESC)
LEARNING CONTROL
Oil pressure control timing is optimally corrected at the time of clutch engagement and disengagement
and controlled to bring the speed-change time to the value preset to the TCM and compensate the
changes of the engine performance and changes of the transmission with time.
When the gear is shifted, the clutch pressure 2 is optimally corrected so that the speed-change time is as
near as the target value 1 preset to the TCM and the changes in the engine performance and the
changes of the transmission with time can be compensated based on the past speed-change results.
When the clutch is operated to shift the gear, the time of the clutch oil pressure release timing 4 on the
disengagement side is optimally corrected so that the changes of the engine rpm
is optimum.
Note:
When the battery terminal is disconnected, contents of learning are cleared and resultantly the speed
change shock may increase. After the vehicle has traveled, learning is repeated and the shock
decreases gradually.
Figure 53. Learning Control
Input
MAJOR INPUT/OUTPUT COMPONENT AND THEIR FUNCTIONS

Speed sensor
Detects output shaft revolution and sends rpm signal to TCM.
Turbine sensor
Detects input shaft revolution and sends rpm signal to TCM.
Engine speed sensor
Inputs engine revolution from engine control computer.
Brake switch
Detects brake pedal operated by the driver and sends signal to

TCM.
Inhibitor switch
Detects select lever position and sends signal to TCM.
Mode select switch
Detects "Power Drive" or "3rd Start" selected by the driver and

sends signal to TCM.
4L switch (4WD Only)
Inputs 4L mode from transfer control computer.
ATF thermo sensor
Detects ATF temperature and sends signal to TCM.
Detects high clutch supply oil pressure and sends signal to

TCM.
Detects 2-4 brake supply oil pressure and sends signal to
TCM.
Detects low & reverse brake supply oil pressure and signal to
TCM.
Inputs throttle opening angle from engine control computer.

Low & Reverse brake oil pressure switch
Output

TCM
Judges necessary line pressure, gear shifting point and lock-up

operation based on electrical signals from switches and
sensors and sends appropriate signals to solenoids.
Regulates oil pump delivery pressure to the appropriate line

pressure for current driving condition based on signal from
TCM.
Low clutch solenoid
Selects appropriate gear shifting position for current driving

condition and regulates low clutch supply oil pressure based on
signal from TCM.

condition and regulates high clutch supply oil pressure based
on signal from TCM.
2-4 brake solenoid

condition and regulates 2-4 brake supply oil pressure based on
signal from TCM.

condition and regulates low & reverse brake supply oil
pressure based on signal from TCM.
Lock-up solenoid
Regulates lock-up pressure to appropriate level for current

driving conditions based on signal from TCM.
Mode indicator lamp
Indicates POWER DRIVE or 3 START switch position.
Speed meter signal (2WD Only)
Outputs vehicle speed to speed meter.
A/T OIL TEMP indicator lamp
Indicates A/T OIL TEMP indicator lamp in case of high

temperature.
Indicates CHECK TRANS indicator lamp in case of
malfunction.
CHECK TRANS indicator lamp
rd
CONTROL CIRCUIT BLOCK DIAGRAM

Speed sensor
Transmission
Control
Module
(TCM)
Turbine sensor
Low clutch solenoid
Brake switch
Inhibitor switch
2-4 brake solenoid
Power drive, 3rd start

switch
Low & reverse brake

solenoid
ATF oil thermo sensor
Lock-up solenoid
High clutch oil pressure

switch
ATF temperature
indicator lamp
2-4 brake oil pressure

switch
Speed meter (2WD

Only)
Low & reverse brake oil

pressure switch
Power, 3rd start indicator

lamp
Transfer control module

(4WD Only)
Check trans indicator

lamp
4L mode
Engine
speed
Engine Control Module

(ECM)
Throttle
angle
Self-diagnosis
function
Figure 54. Control Circuit Block Diagram
Data link connector
GEAR TRAIN (TRANSMISSION MECHANISM) OPERATION AND

HYDRAULIC CIRCUIT
CONSTRUCTION AND OPERATION
The JR405E consists of two sets of planetary gears, three multiple plate clutches, two multiple plate brakes
and one one-way clutch.
COMPONENT NAME AND FUNCTION

Low Clutch
Component Name
Symbol
L/C
Function
Connects the front planetary carrier to the rear
internal gear.
Engaged at 1st, 2nd and 3rd gear.
High Clutch
H/C
Connects the input shaft to the front planetary

carrier.
Engaged at 3rd and 4th (O/D) gear.
Reverse Clutch
R/C
Connects the input shaft to the front sun gear.

Engaged at Reverse gear.
Low & Reverse Brake
L&R/B
Locks the front planetary carrier.

Engaged at L range and Reverse gear.
2-4 Brake
2-4/B
Locks the front sun gear.

Engaged at 2nd and 4th (O/D) gear.
Low One-way Clutch
L/O.C
Allows the front planetary carrier to turn forward

(clockwise) but locks to opposite direction
(counterclockwise).
Operative when accelerating.
Low Clutch Solenoid
L/C.S
Regulates low clutch pressure.
High Clutch Solenoid
H/C.S
Regulates high clutch pressure.
Low & Reverse Brake Solenoid
L&R/B.S
Regulates low & reverse brake pressure.
2-4 Brake Solenoid
2-4/B.S
Regulates 2-4 brake pressure.
Lock-up Solenoid
High Clutch Oil Pressure SW
L/U.S
H/C.P/SW
Regulates lock-up clutch pressure.

Detects high clutch supply oil pressure.
Low & Reverse Brake Oil Pressure SW
L&R/B.P/SW
Detects low & reverse brake supply oil pressure.
2-4 Brake Oil Pressure SW
2-4/B.P/SW
Detects 2-4 brake supply oil pressure.
COMPONENT AND THEIR OPERATING CONDITION

Clutch
Select
Gear
lever
position position
Gear Lockup
Shift
Reverse
L/C
H/C
R/C
Brake
L/O.C L&R/B 2-4/B
Solenoid
L/C.S H/C.S
1st
D
2nd
3rd
4th
1st
2nd
3rd
4th(*1)
1st
2nd
3rd(*1)
4th(*1)
1st
2nd(*1)
3rd(*1)
4th(*1)
*1:Transmission is shifted at high speed to prevent engine over-run.

- Engaged or operated
- Operative when accelerating
L&R/
B.S
Pressure Switch
2-4/
B.S
L/U.S
H/
C.P/
SW
L&R/
B.P/
SW
2-4
B.P/
SW
P Range
Though the driving force of the input shaft is transmitted to the rear sun gear and reverse & high clutch drum,
the driving force is not transmitted to the output shaft since all of the clutches and brakes are not engaged.
Therefore, the vehicle can move at this condition. However, since the output shaft is mechanically locked
with the parking pawl, the rear planetary carrier and front internal gear are locked. For this reason, the
vehicle does not move.
N Range
Though the driving force of the input shaft is transmitted to the rear sun gear and reverse & high clutch drum,
the driving force is not transmitted to the output shaft, since all of the clutches and brakes are not engaged.
Therefore, the vehicle can move at this condition.
Reverse Gear in Range

The driving force from the input shaft is transmitted to the rear sun gear and reverse & high clutch drum. In the R
range, the reverse clutch is engaged and the driving force is transmitted to the front sun gear and rotates it
clockwise. The low & reverse brake is also engaged and the front planetary carrier is fixed so that the front pinion
gear does not rotate clockwise but can rotate counterclockwise. As a result, the output shaft rotates
counterclockwise and the vehicle goes back.
1st Gear in D, 3, 2 Range

The driving force from the input shaft is transmitted to the rear sun gear and reverse & high clutch drum.
Since the low clutch is engaged, the movement of the rear internal gear is restricted and, since the low oneway clutch acts at the same time, counterclockwise rotations of the rear internal gear are locked. As a result,
the driving force transmitted to the rear sun gear rotates the rear planetary carrier clockwise, is decreased in
speed and transmitted to the output shaft.
When decelerating, since the rotating speed of the rear planetary carrier (rear pinion gear) is higher than that
of the rear sun gear and therefore, the rear internal gear attempts to rotate clockwise. At this time, the low
one-way clutch does not act but races and therefore the rear internal gear rotates clockwise. That is, the
reverse torque from the driving shaft is not transmitted to the engine side and therefore, the engine brake
does not act.
1st Gear in L Range

The basic mechanism is the same as in the D, 3, and 2 Range. To apply the engine brake, the low & reverse
brake is engaged to restrict the movement of the low one-way clutch.
When decelerating, since the rear internal gear is fixed, reverse torque from the drive shaft is transmitted to
the engine side so that the engine brake is applied.
2nd Gear in D, 3, 2 Range

The driving force from the input shaft is transmitted to the rear sun gear and reverse & high clutch drum. As
in the case of the 1st gear, since the low clutch is engaged, the movement of the rear internal gear is
restricted. Since the 2-4 brake is engaged, the front sun gear is fixed. As a result, movement of the rear
internal gear is restricted, and the driving force transmitted to the rear sun gear rotates the rear planetary
carrier clockwise, and is decreased and output. The rotating speed of the rear planetary carrier is increased
as the rear internal gear rotates.
When decelerating, the engine brake is applied.
3rd Gear in D, 3 Range

The driving force from the input shaft is transmitted to the rear sun gear and reverse & high clutch drum. As
in the case of the 1st gear and 2nd gear, since the low clutch is engaged, the movement of the rear internal
gear is restricted. Since the high clutch is engaged, the driving force from the input shaft is directly
transmitted to the rear internal gear. As a result, the rpm of the rear sun gear and the rear internal gear
becomes the same as that of the input shaft so that the rear pinion gear rotates not independently but
together with the rear sun gear and rear internal gear.
When decelerating, the engine brake is applied.
4th Gear (O/D) in D Range

The driving force from the input shaft is transmitted to the rear sun gear and reverse & high clutch drum.
Since the 2-4 brake is engaged, the front sun gear is fixed. As a result, the front pinion gear rotates both
itself and together with other gears clockwise. This rotation increases the speed of rotation of the front
internal gear and is transmitted to the output shaft.
MEMO
DIAGNOSIS (JR405E) 7A2-1
SECTION 7A2
DIAGNOSIS
TABLE OF CONTENTS
PAGE
BASIC TROUBLE SHOOTING..................................................................................................7A2-6
CHECK TRANS INDICATOR & SELF DIAGNOSIS..............................................................7A2-7
DIAGNOSIS WITH TECH 2........................................................................................................7A2-9
TECH 2 CONNECTION .................................................................................................. 7A2-9
TECH 2 OPERATING FLOW CHART (START UP) ..............................................................7A2-10
TYPICAL SCAN DATA................................................................................................................7A2-13
MISCELLANEOUS TEST...........................................................................................................7A2-14
INTERMITTENT DIAGNOSIS ....................................................................................................7A2-16
SNAPSHOT DISPLAY WITH TIS 2000....................................................................................7A2-17
SERVICE PROGRAMMING SYSTEM (SPS)................................................................. 7A2-21
CIRCUIT DIAGRAM.....................................................................................................................7A2-24
PART LOCATION ........................................................................................................................7A2-26
CONNECTOR LIST .....................................................................................................................7A2-31
DIAGNOSIS TROUBLE CODE TABLE ...................................................................................7A2-33
FAIL-SAFE FUNCTION ..............................................................................................................7A2-35
DTC P0722 (FLASH CODE 11) VEHICLE SPEED SENSOR NO SIGNAL ......................7A2-36
DTC P0727 (FLASH CODE 13) ENGINE REVOLUTION SENSOR NO SIGNAL............7A2-38
DTC P0717 (FLASH CODE 14) TURBINE SPEED SENSOR NO SIGNAL......................7A2-40
DTC P0710 (FLASH CODE 15) ATF TEMPERATURE SENSOR FAILURE ....................7A2-42
DTC P0560 (FLASH CODE 16) SYSTEM VOLTAGE FAILURE ........................................7A2-43
DTC P0705 (FLASH CODE 17) INHIBITOR SWITCH FAILURE........................................7A2-44
DTC P1120 (FLASH CODE 22) THROTTLE SIGNAL FAILURE........................................7A2-46
DTC P1875 (FLASH CODE 25) GND RETURN CIRCUIT FAILURE .................................7A2-47
DTC P0753 (FLASH CODE 31) LOW & REVERSE BRAKE DUTY
SOLENOID FAILURE ................................................................................................................7A2-48
DTC P0758 (FLASH CODE 32) 2-4 BRAKE DUTY SOLENOID FAILURE ......................7A2-51
DTC P0763 (FLASH CODE 33) HIGH CLUTCH DUTY SOLENOID FAILURE................7A2-54
DTC P0768 (FLASH CODE 34) LOW CLUTCH DUTY SOLENOID FAILURE ................7A2-57
7A2-2 DIAGNOSIS (JR405E)
PAGE
DTC P0748 (FLASH CODE 35) LINE PRESSURE SOLENOID FAILURE.......................7A2-60
DTC P1860 (FLASH CODE 36) LOCK-UP DUTY SOLENOID FAILURE .........................7A2-62
DTC P1853 (FLASH CODE 26) LOW & REVERSE BRAKE PRESSURE
SWITCH FAILURE......................................................................................................................7A2-64
DTC P1858 (FLASH CODE 27) 2-4 BRAKE PRESSURE SWITCH FAILURE ................7A2-68
DTC P1863 (FLASH CODE 28) HIGH CLUTCH PRESSURE SWITCH FAILURE..........7A2-72
DTC P0731 (FLASH CODE 41) 1st GEAR RATIO ERROR ................................................7A2-76
DTC P0732 (FLASH CODE 42) 2nd GEAR RATIO ERROR...............................................7A2-76
DTC P0733 (FLASH CODE 43) 3rd GEAR RATIO ERROR................................................7A2-76
DTC P0734 (FLASH CODE 44) 4th GEAR RATIO ERROR ................................................7A2-76
DTC P1750 (FLASH CODE 51) LOW & REVERSE BRAKE FAIL-SAFE
VALVE FAILURE ........................................................................................................................7A2-78
DTC P1755 (FLASH CODE 52) 2-4 BRAKE FAIL-SAFE VALVE FAILURE ....................7A2-80
DTC P0602 Programming Error ................................................................................... 7A2-82
SYMPTOM DIAGNOSIS .............................................................................................................7A2-83
SYMPTOM DIAGNOSIS TABLE...............................................................................................7A2-84
No. A1: VEHICLE DOES NOT RUN IN D, 3, 2, L and RANGE ..........................................7A2-93
No. A2: VEHICLE DOES NOT RUN IN R RANGE ................................................................7A2-94
No. A3: VEHICLE DOES NOT RUN IN D, 3, 2 and RANGE...............................................7A2-95
No. B1: VEHICLE RUNS IN N RANGE ...................................................................................7A2-96
No. B2: POOR ACCELERATION AT STARTING .................................................................7A2-97
No. B3: ENGINE RACE UP DURING STARTING (SLIP) ....................................................7A2-100
No. B4: LARGE SHOCK WHEN SHIFT LEVER IS CHANGED TO N TO D
RANGE OR N TO R RANGE ....................................................................................................7A2-103
No. B5: ENGINE STALLS WHEN SELECTING FROM N RANGE TO R, D, 3, 2
OR L RANGE...............................................................................................................................7A2-104
No. B6: ENGINE STARTER DOES NOT RUN IN P OR N RANGE ...................................7A2-106
No. B7: ENGINE STARTER RUNS EXCEPT IN P OR N RANGE .....................................7A2-106
No. B8: EXTENDED TIME LAG WHEN SHIFT LEVER IS CHANGED TO N TO D........7A2-106
No. B9: EXTENDED TIME LAG WHEN SHIFT LEVER IS CHANGED TO N TO R........7A2-106
No. B10: BRAKE IS APPLIED IN R RANGE..........................................................................7A2-107
No. B11: INSUFFICIENT STARTING OR SHAKING IN D RANGE ...................................7A2-107
PAGE
No. B12: NOISE OR VIBRATION IS GENERATED AT STARTING ..................................7A2-107
nd
No. C1: ENGINE RACE UP (SLIP) WHEN GEAR IS SHIFTED UP TO 1st TO 2 ........7A2-108
rd
No. C2: ENGINE RACE UP (SLIP) WHEN GEAR IS SHIFTED UP TO 2nd TO 3 .......7A2-108
No. C3: ENGINE RACE UP (SLIP) WHEN GEAR IS SHIFTED UP TO 3rd TO 4th ........7A2-108
No. C4: ENGINE RACE UP (SLIP) WHEN GEAR IS SHIFT DOWN ................................7A2-108
OR KICK-DOWN TO 4th TO 3rd .................................................................................7A2-108
No. C5: ENGINE RACE UP (SLIP) WHEN GEAR IS SHIFT DOWN OR KICK-DOWN
TO 4th TO 2nd ..............................................................................................................................7A2-108
No. C6: ENGINE RACE UP (SLIP) WHEN GEAR IS SHIFT DOWN OR KICK-DOWN
nd
TO 3rd TO 2
.............................................................................................................................7A2-108
rd
No. C7: ENGINE RACE UP (SLIP) WHEN GEAR IS SHIFT DOWN TO 4th OR 3
TO 1st ............................................................................................................................................7A2-108
No. C8: ENGINE RACE UP (SLIP) OTHERS.........................................................................7A2-108
No. C9: BARKING FEEL WHEN GEAR IS SHIFTED UP TO 1st TO 2nd .........................7A2-111
No. C10: BARKING FEEL WHEN GEAR IS SHIFTED UP TO 2nd TO 3rd ......................7A2-111
th
No. C11: BARKING FEEL WHEN GEAR IS SHIFTED UP TO 3rd TO 4 .......................7A2-111
No. C12: LARGE SHOCK WHEN GEAR IS SHIFTED TO 1st TO 2ND OR 2nd TO 1st ..7A2-114
No. C13: LARGE SHOCK WHEN GEAR IS SHIFTED TO 2nd TO 3rd OR 3rd TO 2nd .7A2-114
No. C14: LARGE SHOCK WHEN GEAR IS SHIFTED TO 3rd TO 4th TO 3rd ................7A2-114
No. C15: LARGE SHOCK WHEN KICK-DOWN....................................................................7A2-114
No. C16: LARGE SHOCK WHEN NO ACCELERATION.....................................................7A2-114
No. C17: LARGE SHOCK WHEN GEAR IS SHIFTED DOWN TO 2nd TO
1st IN L RANGE..........................................................................................................................7A2-114
No. C18: LARGE SHOCK (OTHER) ........................................................................................7A2-114
No. C19: LARGE SHOCK WHEN VEHICLE SPEED IS DOWNED BY NO
ACCELERATOR PANEL OR VEHICLE IS STOPPED ........................................................7A2-114
No. C20: LARGE LOCK-UP SHOCK.......................................................................................7A2-114
No. C21: SHIFT DOWN OR ENGINE OVER-RUN WHEN THE ACCELERATION
PANE IS STEPPED ON IN 4th GEAR ....................................................................................7A2-114
NO. D1: FAULTY GEAR SHIFTING (DIFFERENT FROM SHIFT PATTERN)............... 7A2-115
NO. D2: GEAR IS SHIFTED FREQUENTLY ................................................................. 7A2-120
PAGE
NO. D3: GEAR SHIFT POINT IS LOW OR HIGH AT ALL POINT................................. 7A2-120
NO. D4: GEAR SHIFT POINT IS LOW OR HIGH AT LIMITED POINT ......................... 7A2-120
NO. D5: NO KICK-DOWN .............................................................................................. 7A2-120
NO. E1: NO GEAR SHIFT.............................................................................................. 7A2-121
NO. E2: ONLY 4TH GEAR (O/D) IS NOT SELECTABLE ............................................. 7A2-124
NO. E3: GEAR IS SHIFTED 2ND TO 3RD IN 2 RANGE ............................................... 7A2-126
NO. E4: GEAR IS SHIFTED 1ST TO 2ND IN L RANGE................................................ 7A2-126
NO. E5: GEAR IS SHIFTED 3RD TO 4TH IN 3 RANGE................................................ 7A2-126
NO. F1: LOW MAXIMUM SPEED OR POOR ACCELERATION ................................... 7A2-127
NO. F2: ENGINE RACES UP DURING ACCELERATION (SLIP) ................................. 7A2-130
NO. F3: NOISE OR VIBRATION DURING THE RUNNING IN R, D, 3, 2 OR L
RANGE.......................................................................................................................... 7A2-130
NO. F4: ENGINE BRAKE DOES NOT APPLY IN L RANGE......................................... 7A2-130
NO. F5: ENGINE STALLS BEFORE VEHICLE STOPS FROM RUNNING................... 7A2-131
NO. G1: VEHICLE MOVES IN P RANGE OR PARKING GEAR IS NOT
DISENGAGED OTHER THAN P RANGE ..................................................................... 7A2-131
NO. G2: CREEP FORCE IS LARGE.............................................................................. 7A2-131
NO. G3: CREEP FORCE IS SMALL .............................................................................. 7A2-132
NO. G4: LARGE NOISE DURING IDLING WITH THE VEHICLE IN STOP STATE...... 7A2-133
NO. H1: JUDDER OCCURS AT THE LOCK-UP ........................................................... 7A2-133
NO. H2: LARGE LOCK-UP SHOCK .............................................................................. 7A2-133
NO. H3: LOCK-UP POINT IS HIGH OR LOW ............................................................... 7A2-133
NO. I1: NO LOCK-UP .................................................................................................... 7A2-134
NO. J1: OIL LEAKS FROM BREATHER....................................................................... 7A2-136
NO. J2: OIL LEAKS BETWEEN ENGINE AND CONVERTER HOUSING.................... 7A2-136
NO. J3: OIL LEAKS BETWEEN MAIN CASE AND CONVERTER HOUSING.............. 7A2-136
NO. J4: OIL LEAKS BETWEEN MAIN CASE AND REAR HOUSING .......................... 7A2-136
NO. J5: OIL LEAKS FROM OIL PAN ............................................................................ 7A2-136
NO. J6: OIL LEAKS FROM MANUAL SHAFT OIL SEAL ............................................. 7A2-136
NO. J7: OIL LEAKS FROM OIL COOLER PIPE JOINT................................................ 7A2-136
NO. Z1: TRANSMISSION OVERHEAT.......................................................................... 7A2-136
NO. Z2: MODE LAMP (POWER DRIVE OR 3RD START) DOES NOT LIGHT UP
WHEN THE POWER MODE OR 3RD START MODE IS TURNED ON........................ 7A2-137
PAGE
NO. Z3: MODE LAMP (POWER DRIVE OR 3RD START) LIGHTS UP WHEN
THE POWER MODE OR 3RD START MODE IS TURNED OFF.................................. 7A2-137
NO. Z4: OIL TEMPERATURE WARNING LAMP LIGHTS UP ...................................... 7A2-137
NO. Z5: SELECT LEVER FEELING IS FAULTY. .......................................................... 7A2-137
NO. Z6: POOR FUEL CONSUMPTION ......................................................................... 7A2-138
NO. Z7: PATTERN SELECT SWITCH IS FAULTY........................................................ 7A2-138
NO. Z8: OIL IS SPLASHED DURING THE RUNNING .................................................. 7A2-138
NO. Z9: ABNORMAL SMELL ........................................................................................ 7A2-138
NO. Z10: ATF QUANTITY IS LOW OR HIGH ................................................................ 7A2-138
NO. Z11: ABNORMAL OIL PRESSURE........................................................................ 7A2-139
NO. Z12: REVERSE BUZZER DOES NOT RING.......................................................... 7A2-139
STALL TEST .................................................................................................................. 7A2-140
LINE PRESSURE TEST................................................................................................. 7A2-141
TIME LAG TEST............................................................................................................. 7A2-143
TEST DRIVE................................................................................................................... 7A2-144
SHIFT POINT CHART .................................................................................................... 7A2-147
SHIFT POINT DIAGRAM................................................................................................ 7A2-149
TCM VOLTAGE CHECK ................................................................................................ 7A2-154
BASIC TROUBLE SHOOTING

Transmission fluid pressure together with clutch and brake friction and other important transmission functions are
controlled by electrical signal from the Transmission Control Module (TCM).
Random diagnosis can produce inaccurate and misleading indications. It is important that diagnosing procedure be
carried out systematically.
Carefully follow the sequence outlined below to diagnose automatic transmission assembly.
Verify Customer Complain
Preliminary Check
(Visual Check/Test Drive)
NG
OK
Compare to Same Model
(If Available)
Check Service Bulletin
Follow the Bulletin
No Instruction
DTC Check
(Self-diagnosis/Tech 2)
(Once Clear Memory) Restored
NO DTC
Go to Symptom Diagnosis
Not Stored
Go to DTC Chart
Go to Intermittent Diagnosis
Follow the instructions
Not Solved
Use Service Programming
System (SPS)
Not Solved
Stall Test
NG
Transmission Overhaul
NG
OK
Line Pressure Test
OK
Repair & Verify Fix
CHECK TRANS INDICATOR & SELF DIAGNOSIS

Warning to the driver
"CHECK TRANS" is ON during 3 seconds at key switch ON
position.
When trouble has occurred to electrical components,
"CHECK TRANS" lamp is blinked (1.25 Hz) even during
driving to warn the driver.
The trouble is recorded by trouble code in TCM. When
temporary trouble code has been canceled, the "CHECK
TRANS" lamp stops blinking. This blinking can be stopped
by setting the key off. But the trouble code remains
memorized in TCM.
CHECK
TRANS
NOTE:
Key SW ON
ON
OFF
3 Sec.
(Lamp Check)
Illumination Pattern at Normal Condition
1. If the "CHECK TRANS" lamp is staying ON always at key

switch ON position, this means that connection between the
lamp and TCM is shorted to ground.
Verify connection and wire between the TCM A20 terminal
and lamp short to ground.
2. If the "CHECK TRANS" lamp is staying OFF at key switch
ON position (Engine off), this means that connection
between the lamp and TCM is opened or meter fuse (15A)
is burnt out.
Verify connection and wire between the TCM A20 terminal
and lamp open circuit and meter fuse (15A).
Key SW ON
0.4 Sec.
ON
OFF
3 Sec. 3.2 Sec.
0.4 Sec.
(Lamp Check)
Illumination Pattern at Trouble Condition
Off
Acc
On
CHECK TRANS
V Acc
TCM
Meter Fuse C5 (15A)

Fuse Box & Relay Box

(Cabin)

Meter

Self-diagnosis code (Flash code) display

The stored trouble codes can be identified by shorting the
terminal No. 11 and No. 4 or 5 (ground) of data link
connector with a lead wire.
Indication Method:
1. Terminal No. 11 and No. 4 or 5 (ground) of data link
connector are short circuited.
2. Turn the key switch to the ON position.
3. In case no trouble code existence, normal code (12) is
indicated repeatedly.
4. In case the plural trouble codes have occurred at a time,
each codes are indicated three rimes in numerical order.
Data Link Connector Short Circuit

0.4 Sec
0.4 Sec
Normal Code (12)

ON
Trouble Code Clear Method:

If you have Tech 2:
OFF

3.2 Sec.
1.2 Sec.
0.4 Sec
Follow the procedure "DIAGNOSIS WITH TECH 2" in this

manual.
3.2 Sec.
0.4 Sec
Trouble Code (32)
ON
If you have no Tech 2:

Remove ECM (B) slow blow fuse (30A) for at least 10 seconds.
OFF
3.2 Sec.
1.2 Sec.
NOTE:
If you clear the DTC you will not be able to read any codes
recorded during the last occurrence.
To use the DTC again to identify a problem, you will need
to reproduce the fault or the problem. This may require a
new test drive or just turning the key switch on (this
depends on the nature of the fault).
3.2 Sec.
Self-diagnosis Start
Flash Code Illumination Pattern

12
14
14
14
32
32
32
DIAGNOSIS WITH TECH 2

In this JR405E transmission, troubleshooting can be performed for electrical faults using the Tech 2 scan tool.
If the "CHECK TRANS" lamp blinks, or if an electrical fault in the transmission may probably exit, check trouble
codes using the Tech 2 scan tool.
In the diagnostic procedures described in this manual, first repair the faulty positions indicated by trouble code in
order of numbers and then perform troubleshooting for the faulty positions that are not indicated by trouble code.
For correct troubleshooting, it is necessary to first repair the trouble codes of lower order numbers, then to repair
the trouble codes of higher order numbers in sequence.

Refer to F1: Data Display and identify the electrical faults that are not indicated by trouble code.
Refer to "SYMPTOM DIAGNOSIS".
If codes are set:

1.
2.
3.
4.
5.
Record all trouble codes displayed by Tech 2 and check id the codes are intermittent.
Clear the codes.
Drive the vehicle for a test to reproduce the faulty status.
Check trouble codes again using the Tech 2.
If no codes is displayed by test driving, the fault is intermittent. In this case, refer to "INTERMITTENT
DIAGNOSIS".
6. If a code is present, refer to DTC Chart for diagnosis.
TECH 2 CONNECTION
Tech 2 scan tool is used to electrically diagnose the automatic
transmission system and to check the system. The Tech 2
enhances the diagnosis efficiency though all the
troubleshooting can be done without the Tech 2.
Tech 2 scan tool kit (No. 7000086), Tech 2 scan tool
(No. 7000057) and DLC cable (No. 3000095).
SAE 16/19 adapter (No. 3000098) (1), RS232 loop back
connector (No. 3000112) (2) and PCMCIA card (No.
3000117) (3).
Connect the SAE 16/19 adapter (2) to the DLC cable (3).
Connect the SAE 16/19 adapter (2) to the data link
connector of the vehicle.
Turn the key switch of the vehicle ON and press the
"PWR" key of the Tech 2.

NOTE:
Be sure to check that the power is not supplied to the
Tech 2 when attaching or removing the PCMCIA card.
TECH 2 OPERATING FLOW CART (START UP)
Select "AT JR405E" in Vehicle Identification menu and the following table is shown in the Tech 2 screen.

F0: Read DTC Infor As Stored By ECU
F1: Data Display
F2: Snapshot
F0: Lamp
F0: Power Lamp Test
F1: 3rd Start Lamp Test
F2: AT Oil Temperature Lamp Test
F3: Transmission Check Light Test
F1: Solenoids
F0: Low & Reverse Brake Solenoid
F1: 2-4 Brake Solenoid
F2: High Clutch Solenoid
F3: Low Clutch Solenoid
F4: Line Pressure Solenoid
F5: Lock Up Duty Solenoid
F4: Programming
F0: Program VIN
F1: Lock ECU

The purpose of the "Diagnostic Trouble Codes" mode is to
display stored trouble code in the TCM.
When "Clear DTC Information" is selected, a "Clear DTC
Information", warning screen appears. This screen informs you
that by cleaning DTC's "all stored DTC information in the TCM
will be erased".
After clearing codes, confirm system operation by test driving
the vehicle.
F1: Data Display

The purpose of the "Data Display" mode is to continuously
monitor data parameters.
The current actual values of all important sensors and signals
in the system are display through F1mode.
See the "Typical Scan Data" section.
F2: Snapshot
"Snapshot" allows you to focus on making the condition occur,
rather than trying to view all of the data in anticipation of the
fault. The snapshot will collect parameter information around a
trigger point that you select.

The purpose of "Miscellaneous Test" mode is to check for
correct operation of electronic system actuators.
F4: Programming (Factory Use Only):

The purpose of "Programming" is to program VIN in the ECM
and lock the programmed data.
TYPICAL SCAN DATA
MISCELLANEOUS TEST
The state of each circuit can be tested by using miscellaneous test menus. Especially when DTC cannot be
detected, a faulty circuit can be diagnosed by testing each circuit by means of these menus.
Even DTC has been detected, the circuit tests using these menus could help discriminate between a mechanical
trouble and an electrical trouble.
Connect Tech 2 and select "Powertrain", "JR 405E" & "Miscellaneous Test".
F0: Lamps
The circuit is normal if the warning light in the meter panel comes on and goes out in accordance with Tech 2
instruction.
Lamps
F0: Power Lamp Test
F2: AT Oil Tempeature Lamp Test
F3: Transmission Check Light Test
F0: Power Lamp Test

Power Lamp Test
Power Lamp
Off

F2: AT Oil Temperature Lamp Test
F3: Transmisstion Check Light Test
- Press "Active" key.

Then, "POWER DRIVE" indicator lamp is turned on in the
meter panel.
- Press "Inactive" key.
Then, "POWER DRIVE" indicator lamp is turned off in the
meter panel.
- Press "Quit" Key to cancel the test.
Test procedure is same as "F0: Power Lamp Test".

The circuit is normal if the warning light in the meter panel
comes on and goes out in accordance with Tech 2 instruction.
F1: Solenoids
The circuit is normal if clicking sound is generated in accordance with Tech 2 instruction.
Solenoids
F2: High Clutch Solenoid

Low & Reverse Brake Solenoid
Low & Reverse Brake Duty
0%

F2: High Clutch Brake Solenoid
- Press "Active" key.

Then, duty datio is indicated 100 % and "clicking sound" is
generated from the transmission control valve.
- Press "Inactive" key.
Then, duty datio is indicated 0 % and "clicking sound" is
generated from the transmission control valve.
- Press "Quit" Key to cancel the test.
Test procedure is same as "F0: Low & Revese Brake

Solenoid"
The circuit is normal if clicking sound is generated in
accordance with Tech 2 instruction.
INTERMITTENT DIAGNOSIS
If the Tech 2 displays any codes as intermittent, or if after a test drive any codes does not reappear, the problem is
most likely a faulty electrical connection or loose wiring.
Terminals should always be the prime suspect.
Intermittent rarely occur in sophisticated electronic components such as the TCM.
When an intermittent problem is encountered, check suspect circuits for:
Poor terminal to wire connection.
Terminals not fully seated in the connector body.
Improperly formed or damaged terminals.
Loose, dirty or damaged terminals.
Any time you have an intermittent in more than one circuit, check whether the circuits share a common ground
connection.
Pinched or damaged wires.
Electric interference.
Check for improperly installed electrical options, such as light, radios, etc.
Use the F2: Snapshot mode of the Tech 2 to help isolate the cause of an intermittent fault. The snapshot mode will
record information before and after the problem occurs. Set the snapshot to "Trigger" on the suspected code or, if
you notice the reported symptom during test drive, trigger the snapshot manually.
After the snapshot has been triggered, command the Tech 2 to play back the flow of data recorded from each of the
various sensors. Sings of intermittent fault in a sensor circuit are a sudden unexplainable jump in data values out of
the normal range.
SNAPSHOT DISPLAY WITH TIS2000 (For Snapshot Data Analysis)

Procedures for transferring and displaying Tech2 snapshot data by using TIS2000 [Snapshot Upload] function is
described below.
Snapshot data can be displayed with [Snapshot Upload] function included in TIS2000.
By analyzing these data in various methods, trouble conditions can be checked.
Snapshot data is displayed by executing the three steps below shown:

After recording the snapshot in Tech2, transfer the data from Tech2 to PC by the below procedures.
1. Start TIS2000.
2. Select [Snapshot Upload] on the TIS2000 start screen.
3. Select [Upload from trouble diagnosis tool (transfer from diagnosis tester)] or click the corresponding icon of
the tool bar.
4. Select Tech2, and transfer the recorded snapshot information.
6. After ending transfer of the snapshot, data parameter list is displayed on the screen.
3. Snapshot data is displayed with TIS2000 [Snapshot Upload] function.

Snapshot is stored in the PC hard disk or floppy disk, and can be displayed any time.
Stored snapshot can be displayed by the below procedures.
1. Start TIS2000.
2. Select [Snapshot Upload] on the TIS2000 start screen.
3. Select [Open the existing files] or click the corresponding icon of the tool bar.
5. Open the snapshot, to display the data parameter list on the screen.
Graph display
Values and graphs (Max. 3 graphs):
1. Click the icon for graph display. [Graph Parameter] window opens.
2. Click the first graph icon of the window upper part, and select one parameter from the list of the window lower
part. Selected parameter is displayed nest to the graph icon. Graph division can be selected in the field on the
parameter right side.
3. Repeat the same procedures with the 2nd and 3rd icons.
4. After selecting all parameters to be displayed (Max. 3 parameters), click [OK] button.
5. Parameter selected is displayed in graph form on the right of the data parameter on the screen.
6. Graph display can be moved with the navigation icon.
7. For displaying another parameter by graph, click the parameter of the list, drug the mouse to the display screen
while pressing the mouse button and release the mouse button. New parameter is displayed at the position of
the previous parameter. For displaying the graph display screen in full size, move the cursor upward on the
screen. When the cursor is changed to the magnifying glass form, click the screen. Graph screen is displayed
on the whole screen.

1. Click the 6 graph icon. [Graph Parameter] window opens.
2. Click the graph icon, select the parameter to be displayed from the list and change divisions according to
necessity.
3. Repeat the same procedures with the graph icons, from the 2nd to 6th.
5. In this case, parameters are displayed only in graph form. All parameters are displayed in one graph.
6. The graph display screen can be moved with the navigation icon.

The procedure to program the control unit by using Service Programming System (SPS) software contained in TIS
2000 is explained in steps below.
Important: Perform the following checks before attempting to program the control unit:
The Tech 2 PCMCIA card is programmed with the latest software release.
The latest release of TIS2000 is located on the PC.
The control unit to be programmed is connected to the vehicle.
4. On the activating screen of TIS2000, choose "Service Programming System"
5. On the screen of "Diagnostic Tester and Processing Program Selection", choose the one that will comply with
the following.
Diagnostic Tech2 in use
New programming by the existing module or new programming by the replaced/new module.
6. Upon completion of the selection, push the button of "Next".
2. Demand of Data
1. Connect Tech-2 to the vehicle. When activated by turning on the power of Tech-2, push the "Enter" switch.
2. Turn on the ignition switch (without starting the engine).
3. In the main menu of Diagnostic Tester, push "F1: Service Programming System (SPS)".
5. Where vehicle data has been already saved in Tech 2, the existing data come on display. In this instance, as
Tech-2 starts asking whether to keep the data or to continue obtaining anew data from the control unit,
choose either of them.
6. If you select continue, you have to select Model Year, Vehicle Type.
7. After that, push button and turn Ignition switch tuned on, off, on following Tech-2 display. Tech-2 will read
information from controller after this procedure.
8. During obtaining information, Tech-2 is receiving information from the control unit ECM and TCM at the same
time. With VIN not being programmed into the new control unit at the time of shipment, "obtaining
information" is not complete (because the vehicle model, engine model and model year are specified from
VIN). For the procedure get additional information on vehicles, instruction will be provided in dialog form,
when TIS2000 is in operation.
9. Following instructions by Tech-2, push the "Exit" switch of Tech-2, turn off the ignition of the vehicle and turn
off the power of Tech-2, thereby removing from the vehicle.
3. Data Exchange
1. Connect Tech-2 to P/C, turn on the power and click the "Next" button of P/C.
3. Select Transmission in the System Type selection.
4. When a lack of data is asked from among the following menu, enter accordingly.
Model Year
Model
Engine type
* 1: How to read the destination code:
Destination code can be read from service ID Plate affixed on vehicle, while on service ID Plate the destination
code is described at the right-hand edge of Body Type line. In the figure, the destination code can be read as "RR3"
for Australia.

5. When all the necessary information is entered, the "details" of software within the database that match the
entered data will appear for confirmation. Click the "Program" switch and then download the new software
onto Tech-2.
6. "Data Transfer" comes on display. The progress of downloading will be displayed on the screen in the form of
bar graph.
7. Upon finishing the data transfer, turn off the power of Tech-2, removing from P/C.
4. Programming of TCM
1. Check to see if batteries are fully charged, while ABS connectors shall be removed from the vehicle.
3. Turn on the power of Tech-2 and the title screen comes on display.
4. Turn on the ignition (without allowing the engine to start)
5. On the title screen of Tech-2, push the "Enter" button.
6. Choose "F1: Service Programming System" on the main screen and then choose "F1: Programming ECU".
7. While data is being transferred, "Programming in Progress" will be displayed on the Tech-2 screen.
8. Upon finishing the data transfer, Tech-2 will display "Reprogramming was Successful". Push the "Exit" button
to bring program to completion.
9. Following "Procedure 2: Demand of Data", try over again "Information Obtaining" and check to confirm if the
data has been correctly re-loaded.
10. Upon finishing confirmation, turn off the ignition of the vehicle and then turn off the power of Tech-2,
CIRCUIT DIAGRAM
RTW48AXF026101
RTW48AXF026201
PARTS LOCATION (1) RHD
PARTS LOCATION (2) LHD
PARTS LOCATION (3) 4JH1-TC
RTW48AXF006101
PARTS LOCATION (4)
RTW38DXF007601
PARTS LOCATION (5)
CONNECTOR LIST
TCM
No.
Connector face
Meter-A
Meter-B
Weld splice 3 (Earth)
Silver
C-44
B-50
White
Silver
C-2
B-24
Green
Connector face
B-73
B-23
Green
No.
Power/3rd start switch
B-54
White
Stop lamp switch
C-56
(4JH1-TC)
White
J/B I2
B-56
ECM-A
C-57
(4JH1-TC)
White
J/B I4
B-58
ECM-B
C-94
(6VE1)
(4JH1-TC)
Black
Check connector
B-62
Gray
TCM
C-95
(6VE1)
(4JH1-TC)
White
B-63
White
TCM
C-107
B-64
Silver
White
White
J/B E2
C-109
Weld splice 1 (Illumination)
Silver
Body-LH ; ground
E-10
B-68
(4JH1TC,
6VE1)
White
Immobilizer C/U
Silver
Engine; ground
No.
Connector face
No.
Connector face
H-23
E-30
(4JH1-TC)
(6VE1)
(4JH1-TC)
Gray
A/T speed sensor
E-31
White
P-1
(4JH1-TC)
Gray
Turbine sensor
E-44
Gray
Silver
Battery (+)
P-2
E-51
Silver
Relay & Fuse box
P-5
(4JH1-TC)
Black
Inhibiter switch
Silver
Battery (-)
P-6
E-54
(4JH1-TC)
Black
A/T term ASM
H-4
Silver
Body earth (Ground)
P-10
(6VE1)
(4JH1-TC)
White
H-6
White
Engine room ~ INST
Engine room ~ INST
H-18
(RHD)
White
Engine room ~ INST
H-22
(6VE1)
(4JH1-TC)
White
Engine ground
R-15
H-7
White
Silver
Black
2-4 WD control unit
DIAGNOSIS TROUBLE CODE TABLE

Flash Code
(P-Code)
11 (P0722)
CHECK TRANS Flash Pattern
CHECK
TRANS
Warning
Description
Vehicle Speed Sensor No Signal
ON
12 (-)
Normal
13 (P0727)
Engine
Signal
14 (P0717)
Turbine Speed Sensor No Signal
ON
15 (P0710)
ATF Temperature Sensor Failure
OFF
16 (P0560)
System Voltage Failure
ON
17 (P0705)
Inhibitor Switch Failure
ON
22 (P1120)
Throttle Signal Failure
ON
25 (P1875)
GND Return Circuit Failure
ON
26 (P1853)
Low & Reverse Brake Pressure

Switch Failure
ON
27 (P1858)
2-4 Brake Pressure Switch Failure
ON
28 (P1863)
High Clutch
Failure
ON
31 (P0753)
Low & Reverse

Solenoid Failure
32 (P0758)
2-4BrakeDutySolenoidFailure
33 (P0763)
Revolution
Sensor
Pressure
No
Switch
Brake
Duty
High Clutch Duty Solenoid Failure
ON
ON
ON
ON
Description
CHECK
TRANS
Warning
34 (P0768)
Low Clutch Duty Solenoid Failure
ON
35 (P0748)
Line Pressure Solenoid Failure
ON
36 (P1860)
Lock-up Duty Solenoid Failure
ON
41 (P0731)
1stGearRatioError
ON
42 (P0732)
2ndGearRatioError
ON
43 (P0733)
3rdGearRatioError
ON
44 (P0734)
4thGearRatioError
ON
51 (P1750)
Low & Reverse Brake Fail-safe

Valve Failure
ON
52 (P1755)
2-4BrakeFail-safeValveFailure
ON
ON
Flash Code
(P-Code)
- (P0602)
CHECK TRANS Flash Pattern
No Flash Code
FAIL-SAFEFUNCTION
Flash Code
(P-Code)
Description
CHECK
TRANS
Warning
Gear
Fail-Safe Condition
Line
Shift
Pressure
Lock-up
Solenoid
Solenoid
Remark
11
Vehicle peed Sensor No
ON
3rdFix
All Stop
Inhibited
(P0722) Signal
13
Engine Revolution Sensor
ON
Inhibited
(P0727) No Signal
14
Turbine Speed Sensor No
ON
3rdFix
All Stop
Inhibited
(P0717) Signal
15
ATF Temperature Sensor
OFF
3,2,L
Inhibited
*1
(P0710) Failure
16
System Voltage Failure
ON
3rdFix
All Stop
Inhibited
*2
(P0560)
17
Inhibitor Switch Failure
ON
3rdFix
All Stop
Inhibited
(P0705)
22
Throttle Signal Failure
ON
3rdFix
All Stop
Inhibited
(P1120)
25
GND Return Circuit
ON
3rdFix
All Stop
Inhibited
*2
(P1875) Failure
26
Low & Reverse Brake
ON
No Fail-safe Function
(P1853) Pressure Switch Failure
27
2-4 Brake Pressure
ON
(P1858) Switch Failure
28
High Clutch Pressure
ON
(P1863) Switch Failure
31
Low & Reverse Brake
ON
3rdFix
All Stop
Inhibited
(P0753) Duty Solenoid Failure
32
ON
3rdFix
All Stop
Inhibited
(P0758) Failure
33
ON
3rdFix
All Stop
Inhibited
(P0763) Failure
34
ON
3rdFix
All Stop
Inhibited
(P0768) Failure
35
ON
Stop
(P0748) Failure
36
ON
Inhibited
(P1860) Failure
41
1stGearRatioError
ON
(P0731)
42
2ndGearRatioError
ON
(P0732)
43
3rdGearRatioError
ON
(P0733)
44
4thGearRatioError
ON
(P0734)
51
Low & Reverse Brake
ON
3rdFix
All Stop
Inhibited
(P1750) Fail-safe Valve Failure
52
2-4 Brake Fail-safe Valve
ON
3rdFix
All Stop
Inhibited
(P1755) Failure
ON
(P0602)
*1: When the engine speed is more than 470 rpm for 10 minuets, the lock-up and gear shift to 4th (over-drive) are
allowed.
*2: In case of fail-safe valve failure, gear shift to 4th (over-drive) is inhibited.
DTC P0722 (Flash Code 11) Vehicle Speed Sensor No Signal

Key SW
TCM
Speed
Sensor
E30
(2)
(1)
(3)
YEL/RED
H23
(4)
YEL/RED
C95
(13)
B13
BLK
E10
Speed Sensor
Turbine Sensor
Setting Condition:
When the vehicle speed exceeds 5 km/h with the turbine speed over 1000 rpm for 5 seconds, after 25.5
seconds elapsed in D, 3, 2 or L range.
Fail Safe:
When the vehicle is running, the gear position selected at the trouble detection is held and the lock-up is
inhibited.
After the vehicle stopped, all solenoid operations stop (OFF) and the gear is fixed to the 3rd.
Possible Cause:
Speed sensor malfunction.
Sensor wheel (parking gear) malfunction.
Large sensing gap between speed sensor and sensor wheel (parking gear).
Sensor wire open circuit, short circuit to battery or short circuit to ground between speed sensor terminal 1 and
TCM terminal B13 (C95).
Sensor wire open circuit or short circuit to ground of the harness between speed sensor terminal 2 and power
supply circuit.
Sensor wire open circuit or short circuit to battery between speed sensor terminal 3 and ground circuit.
Poor connection of each connector.
Reference:
When the vehicle speed 20km/h at L range in 1st gear, following signal is outputted.
Measurement terminal: B13 (C95) and B5 (C95)
-AC range by circuit tester: Approximately 6.8 V
-Oscilloscope: Following wave form can be found.
Vehicle Speed Sensor Reference Wave Form
0V
Measurement Terminal: B13 (+)

B5 (-)
5ms/div
Measurement Condition: Vehicle speed 20km/h at L range in 1st gear
DTC P0727 (Flash Code 13) Engine Revolution Sensor No Signal
TDC
Sensor
TCM
ECM
E9
(1)
(2)
(3)
WHT
RED
C57
(98)
(90)
C56
(27)
BLK/RED
C94
(7)
A7
(101)
C56 (ECM-A)
Setting Condition:
The engine speed becomes 0 rpm for 2 seconds while the vehicle is running at the over 40 km/h.
Fail Safe:
Lock-up is inhibited.
Possible Cause:
Crank position sensor malfunction.
Sensor wheel (flywheel) malfunction.
Large sensing gap between speed sensor and sensor wheel (flywheel).
Faulty input signal from crank position sensor to ECM.
Signal wire open circuit or short circuit to battery between ECM A24 and TCM terminal A7 (C94).
Reference:
When the engine speed 2000rpm, following signal is outputted.
Measurement terminal: A7 (C94) and B5 (C95)
-AC range by circuit tester: Approximately 6.2V
Engine Speed Sensor Reference Wave Form
0V
Measurement Terminal: A7 (+)

B5(-)
10ms/div
Measurement Condition: At engine speed 2000rpm
DTC P0717 (Flash Code 14) Turbine Speed Sensor No Signal

Key SW
TCM
Turbine
Sensor
WHT
E31
(2)
(1)
(3)
BRN/RED
H23
(9)
BRN/RED
C95
(3)
B3
BLK
E10
Speed Sensor
Turbine Sensor
Setting Condition:
The turbine speed below 300 rpm for 2 seconds while the vehicle is running at the speed over 40 km/h with the
engine speed over 1500 rpm in the D, 3, 2, or L range.
Fail Safe:
inhibited.
Possible Cause:
Turbine speed sensor malfunction.
Sensor wheel (reverse & high clutch drum) malfunction.
Large sensing gap between speed sensor and sensor wheel (reverse & high clutch drum).
Sensor wire open circuit, short circuit to battery or short circuit to ground between turbine speed sensor terminal
1 and TCM terminal B3 (C95).
Sensor wire open circuit or short circuit to ground between turbine speed sensor terminal 2 and power supply
circuit.
Sensor wire open circuit or short circuit to battery between turbine speed sensor terminal 3 and ground circuit.
Reference:
When the vehicle speed 20km/h at L range in 1st gear, following signal is outputted.
-AC range by circuit tester: Approximately 6.5 V
Turbine Sensor Reference Wave Form
0V

B5 (-)
500 micro sec/div
Measurement Condition: Vehicle speed 20km/h at L range in 1st gear
DTC P0710 (Flash Code 15) ATF Temperature Sensor Failure

ATF
Temp.
Sensor
Terminal
Assembly
E54
(2)
TCM
BLU
H23
(8)
C95
(4)
B4 (+)
(14)
B14 (-)
BLU/BLK
BLU/BLK
(8)
BLU
(3)
Setting Condition:
The condition in which the voltage of oil temperature sensor is below 0.1V (146C) and ATF temperature
warning lamp ON in the P or N range lasts for more than 5 minutes.
Or
The vehicle speed exceeds 20 km/h and the voltage of oil temperature sensor exceeds 2.43V (-40C) for more
than 10 seconds.
Fail Safe:
The lock-up is inhibited, and TCM is controlled ATF temperature 80C condition as substitute.
When the engine speed is more than 470 rpm for 10 minuets, the lock-up and gear shift to 4th (over-drive) are
allowed.
Possible Cause:
Oil temperature sensor wire open circuit or short circuit.
Oil temperature sensor malfunction.
Power supply wire open circuit, short circuit to battery or short circuit to ground between oil temperature sensor
and TCM terminal B4 (C95).
Ground wire open circuit or short circuit to battery between oil temperature sensor terminal and TCM terminal
B14 (C95).
Reference:
Following output voltage and resistance can be measured by circuit tester.
ATF Temperature
20 C
40 C
60 C
Output Voltage
1.55V
1.08V
0.7V
Resistance
2,500
1,160
590
ATF Temperature
80 C
100 C
120 C
Output Voltage
0.5V
0.3V
0.2V
Resistance
320
190
120
DTC P0560 (Flash Code 16) System Voltage Failure

TCM
Battery
BLK/YEL
H23
(15)
C94
(1)
BLK
C95
(5)
BLK
BLK
(15)
A1 (+B)
B5
B15
Setting Condition:
The supply voltage is below 10V and the engine speed exceeds 1000 rpm for more than 1 second.
Fail Safe:
inhibited.
After the vehicle stopped, all solenoid operations stop (OFF) and the gear is fixed to the 3rd. (In case of fail-safe
valve failure, gear shift to 4th (over-drive) is inhibited.)
Possible Cause:
Alternator or battery malfunction.
Power supply wire open circuit or short circuit to ground between power supply and TCM terminal A1 (C94).
Ground wire open circuit or short circuit to battery between ground location and TCM terminal B5 (C95) or B15
(C95).
DTC P0705 (Flash Code 17) Inhibitor Switch Failure

Inhibitor SW
TCM
P
E51
(2)
YEL/VIO
(4)
N
RED/YEL
RED/BLK
(8)
PNK/BLK
(6)
RED/BLK
BLU
(5)
(4)
BLU
RED/YEL
BLK/GRN
(1)
(7)
PNK/BLU
PNK/BLK
(9)
C94
(2)
A2 (P)
(3)
A17 (3)
C95
(2)
B2 (2)
(10)
B10 (N)
(11)
B11 (D)
(19)
B19 (R)
(21)
B21 (L)
(5)
PNK/BLU
(6)
B
(3)
(2)
WHT
BLK/WHT
(10)
(7)
(38)
(15)
BLK
(3)
(37)
H4
Terminal Assembly
YEL/VIO
BLK/GRN
Start SW
H22
(1)
Inhibitor Switch
WHT
BLK/WHT
BLK
Key Switch
Starter Relay
ICU (W/ Immobiliser)
Ground (W/O Immobiliser)
Setting Condition:
No range signal is entered from the inhibitor switch with the engine speed over 500 rpm for 2 seconds.
Or
Multiple signals are entered from the inhibitor switch for 1 second.
Fail Safe:
inhibited.
Possible Cause:
Inhibitor switch incorrect adjustment.
Inhibitor switch malfunction.
Open circuit or short circuit to battery between inhibitor switch terminal 2 and TCM terminal A2 (C94), terminal 4
and TCM terminal B19 (C95), terminal 8 and TCM terminal B10 (C95), terminal 5 and TCM terminal B11 (C95),
terminal 1 and TCM terminal A17 (C94), terminal 9 and TCM terminal B2 (B95), or terminal 6 and TCM terminal
B21 (C95), or short between respective harness.
Power supply wire open circuit or short circuit to ground between inhibitor switch terminal 3 and power supply
circuit.
Reference:
Following continuity can be measured by circuit tester.
P
R
N
D
3
2
L
10
DTC P1120 (Flash Code 22) Throttle Signal Failure

TPS
ECM
TCM
C56
(49)
C56
(29)
(38)
RED/WHT
C94
(16)
A16
(57)
(69)
C56 (ECM-A)
Setting Condition:
No throttle signal is sent from the ECM for 0.4 seconds.
Fail Safe:
inhibited.
Possible Cause:
Throttle position sensor malfunction.
Signal wire open circuit or short circuit to battery of the harness between ECM 29 (C56) and TCM terminal A16
(C94).
Reference:
At throttle position 0%, OFF duty signal 10% is sent from ECM terminal 29 (C56) to TCM terminal A16 (C94).
At throttle position 100% (WOT), OFF duty signal 90% is sent from ECM terminal 29 (C56) to TCM terminal A16
(C94).
Voltage
7.14ms
Voltage
7.14ms
Time
0.714ms
Off duty 10% =Throttle Position 0%
Time
6.426ms
DTC P1875 (Flash Code 25) GND Return Circuit Failure

Control Valve
Terminal
Assembly
L&R Brake Solenoid
TCM
E54
BLU/BLK
H23
(11)
BLU/BLK
C95
(6)
B6
(7)
B7
(8)
B8
(9)
B9
(22)
B22 (GND)
(5)
2-4 Brake Solenoid
BLK/YEL
BLK/YEL
(9)
(5)
RED
RED
Low Clutch Solenoid
(10)
(7)
WHT/BLU
WHT/BLU
(3)
(11)
(2)
GRY/RED
(1)
GRY/RED
Setting Condition:
Ground return circuit is failed 7 times continuously after the low & reverse brake duty solenoid output signal turn
on.
Fail Safe:
All solenoid operations are stopped (OFF), the gear is fixed to the 3rd, and the lock-up is inhibited. (In case of
fail-safe valve failure, gear shift to 4th (over-drive) and lock-up are inhibited.)
Possible Cause:
Ground return wire open circuit between terminal assembly terminal 11 and TCM terminal B22 (C95).
DTC P0753 (Flash Code 31) Low & Reverse Brake Duty Solenoid Failure
Control Valve
Terminal
Assembly
L&R Brake Solenoid
TCM
E54
BLU/BLK
H23
(11)
BLU/BLK
C95
(6)
B6
(7)
B7
(8)
B8
(9)
B9
(22)
B22 (GND)
(5)
2-4 Brake Solenoid
BLK/YEL
BLK/YEL
(9)
(5)

RED
RED
Low Clutch Solenoid
(10)
(7)
WHT/BLU
WHT/BLU
(3)
(11)
(2)
GRY/RED
(1)
GRY/RED

Gear Position & Shift Solenoid Operation
TCM terminal
Range
Gear
Reverse
D, 3, 2
1st
2nd
3rd
4th
B8
(High clutch
solenoid)
1st
2nd
3rd
4th
B9
(Low clutch
solenoid)
B7
(2-4 brake
solenoid)
B6
(Low & reverse
brake solenoid)
: On (Operated)
: Off (Not operated)

Setting Condition:
The low & reverse brake duty solenoid signal is open circuit or short circuit.
(The voltage different from the output ON/OFF signals was detected while the TCM monitors the solenoid output
voltage.)
Fail Safe:
When the vehicle is running, the operation of the low & reverse brake duty solenoid and the lock-up solenoid is
stopped (OFF), the gear position selected at the trouble detection is held, and the lock-up is inhibited.
Possible Cause:
Low & reverse brake duty solenoid malfunction.
Open (Off) circuit or short (On) circuit harness of the low & reverse brake duty solenoid.
Open circuit, short circuit to battery or short circuit to ground between low & reverse brake duty solenoid terminal
5 and TCM terminal B6 (C96).
Insufficient ground condition of the low & reverse brake duty solenoid.

Reference:
When the low & reverse brake solenoid is operated, following signal is outputted.
Low & Reverse Brake Duty Solenoid Reference W ave Form
0V

B22 (-)
10ms/div
Measurement Condition: P, N range in idle
0V

B22 (-)
10ms/div
Measurement Condition: R range in idle
DTC P0758 (Flash Code 32) 2-4 Brake Duty Solenoid Failure
Control Valve
Term inal
Assem bly
L&R Brake Solenoid
TCM
E54
BLU/BLK
H23
(11)
BLU/BLK
C95
(6)
B6
(7)
B7
(8)
B8
(9)
B9
(22)
B22 (GND)
(5)
2-4 Brake Solenoid
BLK/YEL
(9)
BLK/YEL
(5)
RED
Low Clutch Solenoid
(10)
RED
(7)
WHT/BLU
(3)
(11)
WHT/BLU
(2)
GRY /RED
(1)
GRY /RED

TCM terminal
Range
Gear
Reverse
D, 3, 2
1st
2nd
3rd
4th
B8
(High clutch
solenoid)
1st
2nd
3rd
4th
B9
(Low clutch
solenoid)
B7
(2-4 brake
solenoid)
B6
(Low & reverse
brake solenoid)
: On (Operated)

Setting Condition:
The 2-4 brake duty solenoid signal is open circuit or short circuit.
voltage.)
Fail Safe:
When the vehicle is running, the operation of the 2-4 brake duty solenoid and the lock-up solenoid is stopped
(OFF), the gear position selected at the trouble detection is held, and the lock-up is inhibited.
Possible Cause:
2-4 brake duty solenoid malfunction.
Open (Off) circuit or short (On) circuit of the 2-4 brake duty solenoid.
Open circuit, short circuit to battery or short circuit to ground of the harness between 2-4 brake duty solenoid
terminal 9 and TCM terminal B7 (C95).
Insufficient ground condition of the 2-4 brake duty solenoid.

Reference:
When the 2-4 brake duty solenoid is operated, following signal is outputted.
2-4 Brake Duty Solenoid Reference W ave Form
0V

B22 (-)
10ms/div
0V

B22 (-)
10ms/div
Measurement Condition: D range 4th gear
DTC P0763 (Flash Code 33) High Clutch Duty Solenoid Failure
Control Valve
Term inal
Assem bly
L&R Brake Solenoid
TCM
E54
BLU/BLK
H23
(11)
BLU/BLK
C95
(6)
B6
(7)
B7
(8)
B8
(9)
B9
(22)
B22 (GND)
(5)
2-4 Brake Solenoid
BLK/YEL
(9)
BLK/YEL
(5)
RED
Low Clutch Solenoid
(10)
RED
(7)
WHT/BLU
(3)
(11)
WHT/BLU
(2)
GRY /RED
(1)
GRY /RED

TCM terminal
Range
Gear
Reverse
D, 3, 2
1st
2nd
3rd
4th
B8
(High clutch
solenoid)
1st
2nd
3rd
4th
B9
(Low clutch
solenoid)
B7
(2-4 brake
solenoid)
B6
(Low & reverse
brake solenoid)
: On (Operated)

Setting Condition:
The high clutch duty solenoid signal is open circuit or short circuit.
voltage.)
Fail Safe:
When the vehicle is running, the operation of the high clutch duty solenoid and the lock-up solenoid is stopped
Possible Cause:
High clutch duty solenoid malfunction.
Open (Off) circuit or short (On) circuit of the high clutch duty solenoid.
Open circuit, short circuit to battery or short circuit to ground between high clutch duty solenoid terminal 10 and
Insufficient ground condition of the high clutch duty solenoid.

Reference:
When the high clutch duty solenoid is operated, following signal is outputted.
High Clutch Duty Solenoid Reference W ave Form
0V

B22 (-)
10ms/div
0V

B22 (-)
10ms/div
Measurement Condition: D range 3rd, 4th gear
DTC P0768 (Flash Code 34) Low Clutch Duty Solenoid Failure
Control Valve
Term inal
Assem bly
L&R Brake Solenoid
TCM
E54
BLU/BLK
H23
(11)
BLU/BLK
C95
(6)
B6
(7)
B7
(8)
B8
(9)
B9
(22)
B22 (GND)
(5)
2-4 Brake Solenoid
BLK/YEL
(9)
BLK/YEL
(5)
RED
Low Clutch Solenoid
(10)
RED
(7)
WHT/BLU
(3)
(11)
WHT/BLU
(2)
GRY /RED
(1)
GRY /RED

TCM terminal
Range
Gear
Reverse
D, 3, 2
1st
2nd
3rd
4th
B8
(High clutch
solenoid)
1st
2nd
3rd
4th
B9
(Low clutch
solenoid)
B7
(2-4 brake
solenoid)
B6
(Low & reverse
brake solenoid)
: On (Operated)

Setting Condition:
The low clutch duty solenoid signal is open circuit or short circuit.
voltage.)
Fail Safe:
When the vehicle is running, the operation of the low clutch duty solenoid and the lock-up solenoid is stopped
Possible Cause:
Low clutch duty solenoid malfunction.
Open (Off) circuit or short (On) circuit harness of the low clutch duty solenoid.
Open circuit, short circuit to battery or short circuit to ground between low clutch duty solenoid terminal 3 and
Insufficient ground condition of the low clutch duty solenoid.

Reference:
When the low clutch duty solenoid is operated, following signal is outputs.
Low Clutch Duty Solenoid Reference W ave Form
0V

B22 (-)
10ms/div
0V

B22 (-)
10ms/div
DTC P0748 (Flash Code 35) Line Pressure Solenoid Failure

Control Valve
Terminal
Assembly
Lock-up Solenoid
TCM
E54
BLK
(4)
H23
BLK
(14)
C95
(17)
B17
(23)
B23

VIO
VIO
(6)
(6)
Setting Condition:
The line pressure solenoid signal is open circuit or short circuit.
voltage.)
Fail Safe:
The operation of the line pressure solenoid is stopped (OFF).
Possible Cause:
Line pressure solenoid malfunction.
Line pressure solenoid harness open (Off) circuit or short (On) circuit.
Open circuit, short circuit to battery or short circuit to ground between line pressure solenoid terminal 6 and TCM
terminal B23 (C95).
Insufficient ground condition of the line pressure solenoid.

Reference:
When the line pressure solenoid is operated, following signal is outputted.
-At N rage: 10 - 14.5V
-At D range: Less than 1V
DTC P1860 (Flash Code 36) Lock-up Duty Solenoid Failure

Control Valve
Terminal
Assembly
Lock-up Solenoid
TCM
E54
BLK
(4)
H23
BLK
(14)
C95
(17)
B17
(23)
B23

VIO
VIO
(6)
(6)
Setting Condition:
The lock-up duty solenoid signal is open circuit or short circuit.
voltage.)
Fail Safe:
The lock-up is inhibited.
Possible Cause:
Lock-up duty solenoid malfunction.
Open (Off) circuit or short (On) circuit of the lock-up duty solenoid.
Open circuit, short circuit to battery or short circuit to ground between lock-up duty solenoid terminal 4 and TCM
terminal B17 (C95).
Insufficient ground condition of the lock-up duty solenoid.
Reference:
When the lock-up duty solenoid is operated, following signal is outputted.
-AC range by circuit tester: Approximately 2.2 9.0V at Lock-up / Approximately 1.0 2.0 V at Unlock-up
Lock-up Duty Solenoid Reference Wave Form
0V

B5 (-)
5ms/div
Measurement Condition: Lock-up condition
0V

B5 (-)
5ms/div
Measurement Condition: Unlock-up condition
DTC P1853 (Flash Code 26) Low & Reverse Brake Pressure Switch Failure
Control Valve
2-4 Brake Pressure SW
Terminal
Assembly
E54
(7)
L&R Brake Pressure SW

(12)
H23
RED/YEL
YEL
(10)
RED/YEL
YEL
(1)
B1
(12)
B12
(20)
B20
H22
High Clutch Pressure SW

(1)
WHT/BLK
Pre-setting Condition:
(12)
TCM
C95
No gear shifting.
No Check Trans indicator lamp.
No system voltage failure.
No inhibitor switch failure.
Low & reverse brake duty solenoid 0 or 100 %.
ATF temperature more than 60C.
ATF input voltage more than 0.1V.
Engine speed more than 500 rpm.
(8)
WHT/BLK
Setting Condition:
During the running, the low & reverse brake pressure switch does not turn on though hydraulic pressure is
supposed to be generated in the low & reverse brake.
(All pre-setting conditions are met for 2.5 seconds, Low & reverse brake duty solenoid 0% and low & reverse
brake pressure switch off in R range)
Or
During the running, the low & reverse brake switch does not turn off though no hydraulic pressure is supposed to
be generated in the low & reverse brake.
(All pre-setting conditions are met for 2.5 seconds, 4th gear, all pressure switch on and gear ratio 0.652 - 0.735
in D range.)
Fail Safe:
No fail safe function
Possible Cause:
Low & reverse brake duty solenoid malfunction.
Low & reverse brake pressure switch wire open circuit or short circuit.
Open circuit, short circuit to battery or short circuit to ground between low & reverse brake pressure switch
Low & reverse brake hydraulic circuit malfunction in the control valve.
Reference:
When the low & reverse brake pressure switch is operated, following signal is outputted.
-At other than R rage or L range in 1st gear: More than 10V
-At R range or L range in 1 st gear: Less than 1V

Step
Action
1 Clear the DTC from the memory once.
Turn the ignition switch off once, then restart the engine and shift to
4th gear in the D range. When about 10 seconds elapsed, does the
CHECK TRANS lamp blink?
Is the DTC P0753 (31) Low & Reverse Brake Duty Solenoid Failure
stored?
No
Go to Step 2
Refer DTC clear

method in this
manual.
Go to Step 3
Go to Step 7
Go to P0753 (31)
Section
Go to Step 4
Go to Step 5
Repair the harness

or connector.
Go to Step 12
Go to Step 6
Repair the
connector or pin.
Go to Step 12
Connect the Tech 2 and select the item for low & reverse brake
pressure switch. Is the indication of low & reverse brake pressure
switch turned off when the terminal assembly connector is
disconnected?
Turn the key switch off and disconnect the terminal assembly
connector. Are the pins correct?
Remove the oil pan. Is the continuity correct between terminal

assembly terminal 12 and low & reverse brake pressure switch
connector?
12
Yes
Repair the harness Replace pressure

or connector.
switch.
Go to Step 12
Go to Step 12
Start the engine and select the R range. When about 10 seconds
elapsed, does the CHECK TRANS lamp blink?
Go to Step 8
Go to P0753 (31)
Section
Go to Step 9
Repair the harness

or connector.
Go to Step 12
Connect the Tech 2, and with the key switch in OFF position, short
the terminals 11 and 12 on the vehicle harness side. Does the
indication of the low & reverse brake pressure switch on the Tech 2
becomes on when the key switch is turned on?

Step
9
10
Action
Yes
No
Go to Step 10
Repair the harness

or connector.
Go to Step 12
Go to Step 11
Repair the harness

or connector.
Go to Step 12
Check if the trouble is caused by a poor connection of terminal

assembly connector.
With the key switch in OFF position, is the connection condition of
the connector and harness correct?
assembly terminal 12 and low & reverse brake pressure switch
connector?
12
11
Is the result OK when the oil pan is removed and the low & reverse
brake pressure switch is checked? Refer the ON VEHICLE
SERVICE SECTION in this manual for the procedure.
12
Clear the DTC from the memory and perform the work after repair. Is
the same DTC code outputted again in the subsequent DTC check?
13
Are the other DTCs outputted?
Repair the control Replace pressure

valve.
switch.
Go to Step 12
Go to Step 12
Replace the TCM
Go to Step 13
Go to Other DTC
Section
Action is completed
DTC P1858 (Flash Code 27) 2-4 Brake Pressure Switch Failure
Control Valve
Terminal
Assembly
E54
(7)

(12)
(1)
No gear shifting.
2-4 brake duty solenoid 0 or 100 %.
RED/YEL
YEL
(12)
(10)
TCM
C95
RED/YEL
YEL
(1)
B1
(12)
B12
(20)
B20
H22
H23
WHT/BLK
(8)
WHT/BLK
Setting Condition:
During the running, the 2-4 brake pressure switch does not turn on though hydraulic pressure is supposed to be
generated in 2-4 brake.
(All pre-setting conditions are met for 2.5 seconds, 2-4 brake pressure switch off, high clutch pressure switch on
and gear ratio more than 0.65 or less than 0.74 with 4th gear in D range.)
Or
During the running, the 2-4 brake switch does not turn off though no hydraulic pressure is supposed to be
generated in the 2-4 brake.
(All pre-setting conditions are met for 2.5 seconds, 2-4 brake pressure switch on in D or N range.)
Fail Safe:
Possible Cause:
2-4 brake duty solenoid malfunction.
2-4 brake pressure switch wire open circuit or short circuit.
Open circuit, short circuit to battery or short circuit to ground between 2-4 brake pressure switch terminal 7 and
2-4 brake hydraulic circuit malfunction in the control valve.
Reference:
When the 2-4 brake pressure switch is operated, following signal is outputted.
-At other than 2nd or 4th gear: More than 10V
-At 2nd or 4th gear: Less than 1V

Step
Action
1 Clear the DTC from the memory once.
2
Turn the ignition switch off once, then restart the engine and in D
range. When about 10 seconds elapsed, does the CHECK TRANS
lamp blink?
Is the DTC P0758 (32) 2-4 Brake Duty Solenoid Failure stored?
Yes
No
Go to Step 2
Refer DTC clear

method in this
manual.
Go to Step 3
Go to Step 7
Go to P0758 (32)
Section
Go to Step 4
Go to Step 5
Repair the harness

or connector.
Go to Step 12
Go to Step 6
Repair the
connector or pin.
Go to Step 12
Connect the Tech 2 and select the item for 2-4 brake pressure
switch. Is the indication of 2-4 brake pressure switch turned off when
the terminal assembly connector is disconnected?

assembly terminal 7 and 2-4 brake pressure switch connector?

or connector.
switch.
Go to Step 12
Go to Step 12
7
Start the engine and shift to 4th gear in the D range. When about 10
seconds elapsed, does the CHECK TRANS lamp blink?
Go to Step 8
Go to P0758 (32)
Section
Go to Step 9
Repair the harness

or connector.
Go to Step 12
indication of the 2-4 brake pressure switch on the Tech 2 becomes
on when the key switch is turned on?

Step
9
10
Action
Yes
No
Go to Step 10
Repair the harness

or connector.
Go to Step 12
Go to Step 11
Repair the harness

or connector.
Go to Step 12
Repair the control

valve.
Go to Step 12
Replace pressure
switch.
Go to Step 12
Replace the TCM
Go to Step 13

assembly connector.

assembly terminal 7 and 2-4 brake pressure switch connector?
11
Is the result OK when the oil pan is removed and the 2-4 brake
pressure switch is checked?
12
Clear the DTC from the memory and perform the work after repair. Is
the same DTC code outputted again in the subsequent DTC check?
13

Go to Other DTC
Section
Action is completed
DTC P1863 (Flash Code 28) High Clutch Pressure Switch Failure
Control Valve
Terminal
Assembly
E54
(7)

(12)
(1)
No gear shifting.
2-4 brake duty solenoid 0 or 100 %.
RED/YEL
YEL
(12)
(10)
TCM
C95
RED/YEL
YEL
(1)
B1
(12)
B12
(20)
B20
H22
H23
WHT/BLK
(8)
WHT/BLK
Setting Condition:
During the running, the high clutch pressure switch does not turn on though hydraulic pressure is supposed to be
generated in high clutch.
(All pre-setting conditions are met for 2.5 seconds, high clutch pressure switch off, 2-4 brake pressure switch on
and gear ratio more than 0.65 or less than 0.74 with 4th gear in D range.)
Or
During the running, the high clutch pressure switch does not turn off though no hydraulic pressure is supposed
to be generated in the high clutch.
(All pre-setting conditions are met for 2.5 seconds, high clutch pressure switch on in P, R or N range.)
Fail Safe:
Possible Cause:
High clutch duty solenoid malfunction.
High clutch pressure switch open circuit or short circuit.
Open circuit, short circuit to battery or short circuit to ground of the harness between high clutch pressure switch
High clutch hydraulic circuit malfunction in the control valve.
Reference:
When the high clutch pressure switch is operated, following signal is outputted.
-At other than 3rd or 4th gear: More than 10V
-At 3rd or 4th gear: Less than 1V

Step
Action
Clear the DTC from the memory once.

Turn the ignition switch off once, then restart the engine and in R
range. When about 10 seconds elapsed, does the CHECK TRANS
lamp blink?
Is the DTC P0763 (33) High Clutch Duty Solenoid Failure stored?
Yes
No
Go to Step 2
Refer DTC clear

method in this
manual.
Go to Step 3
Go to Step 7
Go to P0763 (33)
Section
Go to Step 4
Go to Step 5
Repair the harness

or connector.
Go to Step 12
Go to Step 6
Repair the
connector or pin.
Go to Step 12
Connect the Tech 2 and select the item for high clutch pressure
switch. Is the indication of high clutch pressure switch turned off
when the terminal assembly connector is disconnected?

assembly terminal 1 and high clutch pressure switch connector?

or connector.
switch.
Go to Step 12
Go to Step 12
7
Start the engine and shift to 4th gear in the D range. When about 10
seconds elapsed, does the CHECK TRANS lamp blink?
Go to Step 8
Go to P0763 (33)
Section
Go to Step 9
Repair the harness

or connector.
Go to Step 12
indication of the high clutch pressure switch on the Tech 2 turn on
when the key switch is turned on?

Step
9
10
Action
Yes
No
Go to Step 10
Repair the harness

or connector. Go to
Step 12
Go to Step 11
Repair the harness

or connector.
Go to Step 12
Repair the control

valve.
Go to Step 12
Replace pressure
switch.
Go to Step 12
Replace the TCM
Go to Step 13

assembly connector.

assembly terminal 1 and high clutch pressure switch connector?
11
Is the result OK when the oil pan is removed and the high clutch
pressure switch is checked?
12
Clear the DTC from the memory and perform the work after repair.
Is the same DTC code outputted again in the subsequent DTC
check?
13

Go to Other DTC
Section
Action is completed
DTC P0731 (Flash Code 41) 1st Gear Ratio Error

DTC P0732 (Flash Code 42) 2nd Gear Ratio Error
DTC P0733 (Flash Code 43) 3rd Gear Ratio Error
DTC P0734 (Flash Code 44) 4th Gear Ratio Error
No other DTCs.
2 seconds elapsed after D, 3, 2, or 1 range was selected.
Vehicle is running at the vehicle speed over 10 km/h with the turbine speed over 1000 rpm.
Except at the gear shifting.
No fail safe valve malfunction.
Setting Condition:
In the case pre-setting conditions are met, the TCM calculates the turbine speed that corresponds to the gear ratio
of the outputted solenoid pattern in about 7 seconds after each gear shift has completed, and when the output shaft
speed against the turbine speed exceeds 500 rpm.
Fail Safe:
Possible Cause:
Turbine sensor or speed sensor malfunction.
Shift solenoid malfunction.
Clutch slipping.
Step
Action
1 Turn the key switch on and check the DTC. Are the DTC other
than gear ratio error outputted?
2
Clear the DTC from the memory. Turn the key switch off once,
and then start the engine. Does the CHECK TRANS blink
when the gear shift is repeated 3 times from 1st to 4th in the D
range?
Yes
No
Go to Other DTC
Section
Go to Step 2
Go to Other DTC
Section
Go to Step 3
Check again the DTC. Are all codes indicating gear ratio error
outputted?
Even if one of DTC

indicating gear ratio
error is outputted
Go to step 5
Go to Step 4
DTC indicating gear

ratio error are not
outputted at all.
Go to step 9
Go to Step 9
Replace turbine speed

sensor.
Go to Step 9
Go to Step 6
Go to Step 9
Check the turbine sensor and the speed sensor for function. Is
the result OK?
Are the color and smell of ATF normal?

Step
6
Action
Yes
No
Go to Step 7
Correct the quantity of

ATF.
Go to Step 9
Go to Step 8
Replace the solenoid

that does not generate
the operation sound.
Go to Step 9
Go to Step 10
Either control valve, oil

pump or power train
parts (clutch, brake)
will be faulty. Replace
or overhaul the
transmission unit.
Go to step 10
Go to Step 10
Either control valve, oil

pump or power train
parts (clutch, brake)
will be faulty. Replace
or overhaul the
transmission unit.
Go to step 10
Replace the TCM
Go to Step 11
Go to Other DTC
Section
Action is completed
Is the quantity of ATF correct?
Connect the Tech 2 and test the solenoids of respective

solenoids for low & reverse brake, 2-4 brake, high clutch and
low clutch. Is operation sound heard from each solenoid?
Check the line pressure during the idling and at the engine stall
speed. Is the line pressure correct?
Run the vehicle, and is the gear shifted from 1st to 4th
correctly?
10
Clear the DTC from the memory and perform the work after
repair. Is the same DTC code outputted again in the
subsequent DTC check?
11
DTC P1750 (Flash Code 51) Low & Reverse Brake Fail-safe Valve Failure
Control Valve Upper Body
Control Valve Lower Body
Low & Reverse Brake Fail Valve (B)
Low & Reverse Brake Fail Valve (A)
Setting Condition:
When the oil pressure generated and low & reverse brake pressure switch operates off/on twice, the TCM
detected an operation failure of the low & reverse brake fail-safe valve in D, 3, 2, L range.
Fail Safe:
inhibited.
Possible Cause:
Stick of low & reverse brake fail-safe valve.

Low & reverse brake pressure switch does not turn on.
Short circuit to ground of harness low & reverse brake pressure switch.
Poor connection of each connector of harness in low & reverse brake pressure switch.
Step
Action
1 Turn the key switch on and check the DTC. Is only the DTC for
low & reverse brake fail-safe valve failure outputted?
2
Yes
No
Go to Step 2
Go to Other DTC
Section
Go to Other DTC
Section
Go to Step 3
Go to Step 4
The low & reverse

brake fail-safe valve
may be faulty
temporarily.
Go to step 5

control valve.
Go to Step 5
Go to Other DTC
Section
Replace the TCM
Go to Step 6
Go to Other DTC
Section
Action is completed
and then start the engine. Does the CHECK TRANS blink
when the D range is selected and about 10 seconds elapsed?
Run the vehicle, shift the gear from 1st to 4th, stop the vehicle,
and again shift the gear from 1st to 4th. Does the CHECK
TRANS blink at this time?
Turn the key switch on and check the DTC. Is only the DTC for
the low & reverse brake fail-safe valve failure outputted?
DTC P1755 (Flash Code 52) 2-4 Brake Fail-safe Valve Failure
Control Valve Upper Body
Control Valve Lower Body
2-4 Brake Fail Valve (B)
2-4 Brake Fail Valve (A)
Setting Condition:
When the oil pressure generated and 2-4 brake pressure switch operates off/on twice, the TCM detected an
operation failure of the low & reverse brake fail-safe valve in D, 3, 2, L range.
Fail Safe:
inhibited.
Possible Cause:
Stick of 2-4 brake fail-safe valve.

2-4 brake pressure switch does not turn on.
Short to ground of harness 2-4 brake pressure switch.
Faulty fitting of each connector of harness in 2-4 brake pressure switch.
Step
Action
1 Turn the key switch on and check the DTC. Is only the DTC for
2-4 brake fail-safe valve failure outputted?
2
Yes
No
Go to Step 2
Go to Other DTC
Section
Go to Other DTC
Section
Go to Step 3
Go to Step 4
The 2-4 brake fail-safe

valve may be faulty
temporarily.
Go to step 5

control valve.
Go to Step 5
Go to Other DTC
Section
Replace the TCM
Go to Step 6
Go to Other DTC
Section
Action is completed
and then start the engine. Does the CHECK TRANS blink when
the D range is selected and about 10 seconds elapsed?
Run the vehicle, shift the gear from 1st to 4th, stop the vehicle,
and again shift the gear from 1st to 4th. Does the CHECK
TRANS blink at this time?
Turn the key switch on and check the DTC. Is only the DTC for
the 2-4 brake fail-safe valve failure outputted?
DTC P0602 Programming Error

Setting Condition:
When reprogramming operation is stopped under Service Programming System (SPS).
When non programmed TCM (blank TCM) is used without Service Programming System (SPS).
Fail Safe:
Lock-up is inhibited.
All solenoid operations stop (OFF) and the gear is fixed to the 3rd.
Possible Cause:
Low battery voltage while Service Programming System (SPS) is operated.
No programmed TCM (blank TCM) is used.
Recover DTC:
Reprogram the TCM using with Service Programming System (SPS).
SYMPTOM DIAGNOSIS
Symptom
Condition
Vehicle does not

In D, 3, 2, L, and R ranges
run
In R range
In D, 3, 2, and L ranges
Description
Vehicle does not run though the accelerator
pedal is stepped on.
Vehicle does not run in R range only.
It runs normally in D, 3, 2, and L ranges.
Vehicle does not run in D, 3, 2, and L
ranges only.
A1
A2
A3
It runs normally in R range.

Trouble at
starting
Vehicle runs in N range
Creep appears in N range.
B1
Vehicle moves unless the brake pedal is

stepped on in N range.
Poor acceptation
Starting acceleration is poor.
B2
Engine races up during starting (slip)
The engine speeds up but vehicle speed

does not increase when the accelerator
pedal is stepped on at the starting.
B3
Large shock when shift lever is changed to

N to D range or N to R range
Large shock is felt when selecting D or R

range from N range during the idling after
warming up.
B4
Engine stalls when selecting from N range

to R, D, 3, 2, or L range
The engine stalls when selecting from N or

P range to a run range during the engine
idling.
B5
Engine starter does not run in P or N range
The engine starter does not run though the

P or N range is selected.
B6
Engine starter runs except in P or N range
The engine starter runs though the R or D,

3, 2or L range is selected.
B7
Extended time lag when shift lever is

changed to N to D
The shift time lag is longer than standard

value when shift lever is changed to N to D.
B8
Extended time lag when shift lever is

changed to N to R
The shift time lag is longer than standard

value when shift lever is changed to N to R.
B9
Brake is applied in R range

Insufficient starting or shaking in D range
Brake is applied suddenly in R range.

Insufficient starting or shaking in D range.
B10
B11
Noise or vibration
Noise or vibration is generated in the vicinity

of AT at starting.
B12
SYMPTOM DIAGNOSIS TABLE
SYMPTOM DIAGNOSIS
Symptom
Faulty shifting
Condition
Description
The engine speed up when the accelerator

Engine race up (slip) when gear is shifted up
pedal is stepped on for acceleration and the
to 1st to 2nd
gear is shifted up.
C1

Engine race up (slip) when gear is shifted up
to 2nd to 3rd
gear is shifted up.
C2

Engine race up (slip) when gear is shifted up pedal is stepped on for acceleration and the
to 3rd to 4th
gear is shifted down or for kick-down during
steady run.
C3
Engine race up (slip) when gear is shift

down or kick-down to 4th to 3rd

gear is shifted down or for kick-down.
C4

down or kick-down to 4th to 2nd

C5

down or kick-down to3rd to 2nd

C6

down or kick-down to4th or 3rd to 1st

C7
Engine race up (slip) others

gear is shifted down or for kick-down during
steady run.
C8
Brake feeling appears when the accelerator

Braking feel when gear is shifted up to 1st to
nd
2
gear is shifted up.
C9
Braking feel when gear is shifted up to 2nd

to 3rd

gear is shifted up.
C10
Braking feel when gear is shifted up to 3rd

to 4th

gear is shifted up.
C11
Large shock when gear is shifted to 1st to

2nd or 2nd to 1st
Large shock is felt when the accelerator

gear is shifted up or down.
C12
Large shock when gear is shifted to 2nd to

3rd or 3rd to 2nd

C13

Symptom
Condition
Description
Large shock when gear is shifted to 3rd to

4th or 4th to 3rd

C14
Large shock when kick-down

pedal is stepped on for kick-down.
C15
Large shock when no acceleration

pedal is not stepped on.
C16
Large shock when gear is shifted down to

2nd to 1st in L range
Large shock is felt when the shift lever is

selected in L range.
C17
Large shock (other)

C18
Large shock when vehicle speed is downed

by no accelerator pedal or vehicle is
pedal is not stepped on.
stopped.
C19
Large lock-up shock
Large shock is felt at lock-up.
C20
Shift down or engine over-run when the

accelerator pedal is stepped on in 4th gear
Shift down or engine over-run above the

kick-down area.
C21
SYMPTOM DIAGNOSIS
Symptom
Faulty shift point
Condition
Description
Faulty gear shifting (different from shift

pattern)
Gear is shifted, different from the specified

shift pattern.
D1
Gear is shifted frequently
Gear is shifted down immediately though the

accelerator pedal is stepped on a little in D,
3, 2, or L range.
D2
Gear shift point is low or high at all point
Gear shift point is deviated from the shift

diagram.
D3
Gear is not shifted up properly though the

vehicle is accelerated.
Gear is not shifted immediately and enough
acceleration cannot be obtained though the
accelerator pedal is stepped on.
Gear shift point is low or high at limited area
Gear shift point is deviated from the shift

diagram.
D4
Gear is not shifted up properly though the

vehicle is accelerated.
Gear is not shifted immediately and enough
acceleration cannot be obtained though the
accelerator pedal is stepped on.
No gear shift
No kick-down
Kick-down (shift down) is not performed

though the accelerator pedal is fully stepped
on in the kick-down speed range.
D5
No gear shift
Range is fixed without shifting the gear of

1st to 2nd, 2nd to 3rd, and 3rd to 4th.
E1
Gear may be shifted or may not be shifted.

Only 4th gear is not selectable
Gear is not shifted up from 3rd to 4th though

the vehicle is accelerated.
E2
Gear is shifted 2nd to 3rd in 2 range

Gear is shifted 1st to 2nd in L range
Gear is shifted 3rd to 4th in 3 range
Gear is shifted 2nd to 3rd in 2 range.

Gear is shifted 1st to 2nd in L range.
Gear is shifted 3rd to 4th in 3 range.
E3
E4
E5

Symptom
Condition
Faulty during the

Low maximum speed or poor acceleration
running
Description
F1
Acceleration is slow though the accelerator

pedal is stepped on during the running.
Engine races up during acceleration (slip)
The engine speeds up but vehicle speed

does not increase when the accelerator
pedal is stepped on at the starting.
F2
Only the engine speeds up but vehicle

speed does not increase when the
accelerator pedal is stepped on for
acceleration during the running.
Noise or vibration during the running in R, D, Noise or vibration is generated in the vicinity
3, 2, or L range
of AT during the running.
The engine brake does not apply, allowing
the vehicle to run freely when the
Engine brake does not in apply L range
accelerator pedal is released at low speed in
L range.
The engine stalls simultaneously with the
Engine stalls before vehicle stops from
vehicle stop when the brake pedal is
running
stepped on to stop the vehicle during the
running.
Faulty in the
stopping
Vehicle moves in P range, or parking gear is Vehicle moves though it stops at a slope
not disengaged other than P range
and P range is selected.
F3
F4
F5
G1
The engine stalls and vehicle does not move

though other than P range is selected and
the accelerator pedal is stepped on.
Faulty lock-up
No lock-up
Creep force is large
Vehicle accelerates in D, 3, 2, L, and R

ranges though the accelerator pedal is not
stepped on.
G2
Creep force is small
Vehicle does not move though a run range

is selected on a flat road during the idling.
G3
Large noise during idling with the vehicle in

stop state
The transmission is noisy during the idling

speed in all ranges.
G4
Judder occurs at the lock-up

Large lock-up shock
Lock-up point is high or low
The vehicle body judders at lock-up.

Lock-up point is excessive high or low.
H1
H2
H3
No lock-up
Lockup is not performed in spite of the lockup area.
I1
SYMPTOM DIAGNOSIS
Symptom
Oil Leak
Other
Condition
Breather
Description
Oil leaks from breather.
J1
Between engine and converter housing
Oil leaks between engine and converter

housing.
J2
Between converter housing and main case
Oil leaks between converter housing and

main case.
J3
Between main case and rear housing
Oil leaks between main case and rear

housing.
J4
Oil pan
Oil leaks from oil pan.
J5
Manual shaft oil seal

Oil cooler pipe
Oil leaks from manual shaft oil seal.

Oil leaks from oil cooler pipe joint.
J6
J7
Transmission overheat
You smell the transmission burning.

The transmission smokes.
Z1
Mode lamp does not light up when the

power mode or 3rd start mode is turned on
The mode lamp on the instrument panel

does not light up though the power mode or
3rd start mode is turned on with the ignition
switch in ON position.
Z2
Mode lamp lights up when the power mode

or 3rd start mode is turned off
The mode lamp on the instrument panel

lights up though the power mode or 3rd start
mode is turned off with the ignition switch in
ON position.
Z3
Oil temperature warning lamp lights up
Sometimes, the oil temperature warning

lamp lights up.
Z4
Select lever feeling is faulty

Poor fuel consumption
Select lever feeling is faulty.

Poor fuel consumption.
Z5
Z6
Pattern select switch is faulty
Shift pattern does not change though the

pattern select switch is turned on.
Z7
Oil is splashed during the running

Abnormal smell
Oil quantity is low or high
Abnormal oil pressure
Reverse buzzer does not ring
Oil is splashed during the running.

Abnormal smell.
Oil quantity is low or high.
Oil pressure is low or high.
Reverse buzzer does not ring in R range.
Z8
Z9
Z10
Z11
Z12
No. A1: Vehicle Does Not Run in D, 3, 2, L and R Range

Description:
Vehicle does not run though the accelerator pedal is stepped on.
Diagnosis Hints:
Some trouble in the AT main unit is supposed (since the vehicle can run even if the TCM is defective). However,
since the trouble of the main unit may be originated from the sensor system or output system, these systems
should be also checked to prevent reproduce of the trouble.
Possible Cause:
Slip of clutch (low clutch, low one-way clutch, reverse clutch, low & reverse brake).
If slip of clutch is caused, a DTC (gear ratio error) is stored.
Shortage or faulty quality of ATF.
Dropped line pressure.
Trouble in control valve body (faulty operation, sticking, clogged oil passage).
Disordered select cable (select indicator light indicates D, 3, 2, L or R but the hydraulic system is not in the D, 3,
2, L, or R range).
Faulty torque generated.
Trouble in the torque converter (faulty operation, sticking), insufficient engine output.
Malfunction of parking mechanism.
Step
Action
1 Dislocation or disordered of select lever.
Does the vehicle move when the brake is released in a
position other than the P range and the vehicle is pushed?
Are the quantity, contamination and smell normal?
Yes
No
Go to Step 2
Adjust the select cable.
Go to DTC Chart
Go to Step 3
If the ATF level is low,
replenish up to the
specified level.
Go to Step 4
If ATF is extremely
black and
contaminated and
smells burnt, slip of the
clutch is supposed.
Overhaul the AT unit.
Go to Step 5
Repair the defect or

replace.
Trouble in the AT
assembly or control
valve.

replace.
Is the stall revolution correct in all range? Refer the STALL

TEST section in this manual.
Is the line pressure correct? Refer the LINE PRESSURE

No. A2: Vehicle Does Not Run in R Range

Description:
Vehicle does not run in R range only.
It runs correctly in D, 3, 2, and L ranges.
Diagnosis Hints:
Possible Cause:
Slip of clutch (reverse clutch, low & reverse brake).
Disordered select cable (select indicator light indicates R but the hydraulic system is not in the R range).
Step
Action
Yes
No
Go to Step 2
Go to DTC Chart
Go to Step 3
replenish up to the
specified level.
Go to Step 4
If ATF is extremely
black and
contaminated and
clutch is supposed.
Go to Step 5

replace.
Trouble in the AT
assembly or control
valve.

replace.
Is the stall revolution correct in R range? Refer the STALL


No. A3: Vehicle Does Not Run in D, 3, 2 and L Range

Description:
Vehicle does not run in D, 3, 2 and L range only.
It runs correctly in R ranges.
Diagnosis Hints:
Possible Cause:
Slip of clutch (low clutch and low one-way clutch).
Disordered select cable (select indicator light indicates D, 3, 2 and L but the hydraulic system is not in the D, 3, 2
and L range).
Step
Action
Yes
No
Go to Step 2
Go to DTC Chart
Go to Step 3
replenish up to the
specified level.
Go to Step 4
If ATF is extremely
black and
contaminated and
clutch is supposed.
Go to Step 5

replace.
Trouble in the AT
assembly or control
valve.

replace.
Is the stall revolution correct in D, 3, 2 and L range? Refer

the STALL TEST section in this manual.

No. B1: Vehicle Runs in N Range

Description:
Creep appears in N range.
Vehicle moves unless the brake pedal is stepped on in N range.
Diagnosis Hints:
Basically a trouble in the AT main unit. However, some trouble in the sensor system or output system may have
some influence on the trouble in the main unit and therefore these systems should be also checked to prevent
reproduce of the trouble.
Possible Cause:
Seized clutch (low clutch, low one-way clutch, reverse clutch, low & reverse brake).
Trouble in the control valve (faulty operation, sticking, clogged oil passage).
Dislocated select lever (the select indicator light indicates the N range but the hydraulic system is in the D, 3, 2
or L range).
Step
Action
Yes
No
Go to Step 2
Go to DTC Chart
Go to Step 3
replenish up to the
specified level.
If ATF is extremely
black and
contaminated and
Trouble in the AT smells burnt, slip of the
assembly or control
clutch is supposed.
valve.
No. B2: Poor Acceleration at Starting

Description:
Diagnosis Hints:
In addition to the low engine output, faulty gear shifting of AT or fixing at the 3rd position may be possible.
Therefore, in case of such a trouble that "maximum speed is low, and acceleration is poor", it should be cleared
up whether the trouble is originated from the engine system of AT system by a running test, inspection of stall
revolution, etc.
Possible Cause:
Clogged air cleaner, out of injection timing, dropped compression pressure, etc.
Fixing at 3rd position (fail-safe activated).
Since the gear is fixed at the 3rd position because of the fail-safe function, a trouble that "Maximum
speed is low, and acceleration is poor" is resulted. In this case, the DTC is memorized.
When TCM stops operation because of faulty TCM ground, the gear is fixed at the 3rd position because
of a mechanical reason. In this case, no DTC is memorized.
Disordered inhibitor switch.
Incorrect properties of throttle opening signal (serial communication) of throttle position sensor.
Throttle opening signal (serial communication) of the throttle position sensor does not change in
proportion to the throttle opening. In this case, fixing at the high or low gear results in such a trouble
that "Maximum Speed is Low and Acceleration is Poor".
Slip of clutch (low clutch, high clutch).
Trouble in the torque converter system (faulty operation).
Step
Action
Yes
1
Test Drive.
Is the gear smoothly shifted in the order of 1st to 2nd, 2nd to 3rd, Clogged air cleaner,
3rd to 4th gear and lock up?
out of injection
timing, dropped
compression
pressure, etc.
2
Gear ratio trouble diagnosis.
Travel in the following sequence for about 7 seconds or more in
each range: Start in the L range (1st) to 2 range (2nd) to 3 range
(3rd) to D range (4th) (to detect the gear ratio trouble exactly, this
process should be carried out)
Go to Step 3
3
Go to DTC Chart
No
Go to Step 2
Go to Step 3
Go to Step 4

Step
Action
4
Yes
No
If the ATF level is

low, replenish up to
Go to Step 5
If ATF is extremely
black and
contaminated and
smells burnt, slip of
the clutch is
supposed.
Overhaul the AT
unit.
Go to Step 6
Adjust the inhibitor

switch.
Inspection of inhibitor switch using a Tech 2 or circuit tester.

When the select lever is operated, is the data display in the Tech 2
correct or voltage at each range correct?
Inhibitor SW
TCM
P
E51
(2)
H22
(1)
YEL/VIO
YEL/VIO
BLK/GRN
RED/YEL
(4)
N
(8)
RED/BLK
PNK/BLK
(6)
RED/BLK
BLU
(5)
3
(4)
BLK/GRN
(1)
BLU
RED/YEL
(7)
PNK/BLU
2
(9)
PNK/BLK
C94
(2)
A2 (P)
(3)
A17 (3)
C95
(2)
B2 (2)
(10)
B10 (N)
(11)
B11 (D)
(19)
B19 (R)
(21)
B21 (L)
(5)
PNK/BLU
(6)
Start SW
(2)
B
(3)
WHT
(38)
BLK/WHT
(10)
(15)
BLK
(7)
WHT
Starter Relay
(37)
H4
TCM terminal
Key Switch
BLK/WHT
(3)
BLK

A2
B19
B10
B11
B17
B2
B21
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V
-
Range
P
10
14.5V

Step
Action
Inspect the output voltage and throttle opening signal of the throttle
position sensor using a Tech 2 or circuit tester.
Is a voltage value in proportion to the throttle opening output?
TPS
ECM
C56
(49)
A47 (GND)
(38)
A35 (Output)
A55 (+5V)
(69)
A69 (Idle SW)
No
Go to Step 7

replace.
Go to Step 8
Check the power

source harness and
earth harness (bolt
tightening to the
body).
Go to Step 6

replace.
TCM
A26
(57)
Yes
C56
(28)
RED/WHT
C94
(16)
A16
Check of power supply to and earth of TCM.

Are the power supply and earth proper?
TCM
Battery
BLK/YEL
H23
(15)
BLK
C94
(1)
BLK
BLK
A1 (+B)
C95
(5)
B5
(15)
B15
Is the stall revolution correct in D, 3, 2 and L range? Refer the

STALL TEST section in this manual.
Is the line pressure correct? Refer the LINE PRESSURE TEST

section in this manual.
Trouble in the AT
assembly or control Repair the defect or
valve.
replace.
No. B3: Engine Race Up During Starting (Slip)

Description:
The engine speeds up but vehicle speed does not increase when the accelerator pedal is stepped on at the
starting.
Diagnosis Hints:
Possibility of slip of clutch is supposed. If slip of clutch has occurred, a DTC of "Gear ratio error" is stored.
Possible Cause:
Slip of clutch.

Step
Action
1
Yes
No
Go to Step 2
Go to Step 2
Go to DTC Chart
Go to Step 3
If the ATF level is
Go to Step 4
If ATF is extremely
black and
contaminated and
the clutch is
supposed.
Overhaul the AT
unit.
Go to Step 5

replace.
Go to Step 6

replace.
Are the engine speed and other engine system correct?
Inspection of electrical or mechanical fault

Is the signal from each pressure switch changed synchronously?
Control Valve
Terminal
Assembly
E54
(7)

(12)
(1)
Range
P
R
N
D, 3, 2
Gear
Reverse
1st
2nd
3rd
4th
1st
2nd
3rd
4th
RED/YEL
YEL
(12)
(10)
TCM
C95
RED/YEL
YEL
(1)
B1
(12)
B12
(20)
B20
H22
TCM terminal
H23
WHT/BLK
B20
(High clutch
pressure SW)
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
-
(8)
WHT/BLK
B1
(2-4 brake pressure
SW)
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
-
B12 (Low & reverse

brake pressure SW)
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V

Step
Action
6
Inspect the output voltage and throttle opening signal of the
throttle position sensor using a Tech 2 or circuit tester.
TPS
ECM
C56
(49)
A47 (GND)
(38)
A35 (Output)
A55 (+5V)
(69)
A69 (Idle SW)
No
Go to Step 7

replace.
Go to Step 8
Check the power

source harness and
earth harness (bolt
tightening to the
body).
Go to Step 9

replace.
TCM
A26
(57)
Yes
C56
(28)
C94
(16)
RED/WHT
A16

TCM
Battery
BLK/YEL
H23
(15)
BLK
C94
(1)
BLK
BLK
A1 (+B)
C95
(5)
B5
(15)
B15


Trouble in the AT
valve.
replace.
No. B4: Large Shock When Shift Lever is Changed to N to D

Range or N to R Range
Description:
Large shock is felt when selecting D or R range from N range during the idling after warming up.
Diagnosis Hints:
Check the entire condition of the vehicle for unusual other than AT including faulty engine mount, exhaust
hanger, etc.
When the fail-safe operation, select shock may grow worse. In such a case, check for the DTC. If no DTC is
issued, shock due to faulty operation of the control valve or burnt clutch is considered.
Possible Cause:
High engine idling.

Dislocated select lever, improper inhibitor switch adjusting point.
Faulty or insufficient tightening of engine mount, exhaust mount.
Play of suspension.
Burnt clutch.
Too low or high line pressure.
Faulty input signal system.
Faulty control valve. (faulty operation or sticking of accumulator)
No. B5: Engine Stalls When Selecting From N Range to

R, D, 3, 2 or L Range
Description:
The engine stalls when selecting from N or P range to a run range during the engine idling.
Diagnosis Hints:
As causes attributable to the engine, faulty idle up, insufficient engine output, etc. are considered.
As a cause of the AT system, faulty lockup piston system (lockup engine stall) is considered.
If the oil through resistance increases remarkably due to clogged oil cooler or some other reason, or if the ATF
level decreases, the lock-up piston works causing the engine stall.
Possible Cause:
Disordered idling speed, faulty idle up, faulty engine output, shortage output.
Insufficient ATF quantity (dropped level).
Clogged oil cooler (foreign substance mixed in).
Faulty lock-up piston (clogged oil passage of solenoid drive circuit, faulty operation).
Step
Action
1
Yes
No
Go to Step 2
Go to Step 2
Go to DTC Chart
Go to Step 3
If the ATF level is
Go to Step 4
If ATF is extremely
black and
contaminated and
the clutch is
supposed.
Overhaul the AT
unit.
Go to Step 5

replace.
Check of engine idle up speed

Does the idle speed increase when the air conditioning or other
electric load is turned on?

Step
Action
5
When the D range is selected from D at idling speed, is the signal
to the lock-up solenoid turned off using the Tech 2 or circuit
tester?
Yes
No
Go to Step 6
Find a cause to turn

on the lockup
solenoid
Terminal
Assembly
Control Valve
Lock-up Solenoid
TCM
E54
BLK
(4)
H23
BLK
(14)
C95
(17)
B17
(23)
B23

VIO
(6)
Lock-up
TCM terminal
At lock-up
At unlock-up
VIO
(6)
B17
Approx. 2.2 - 9.0 V (AC range)
Approx. 1.0 - 2.0 V (AC range)
Check of clogging of oil cooler

When blowing the oil cooler outlet with air, does some foreign
substance come out?
Clogged lock-up
solenoid oil
passage. Faulty
Clean or replace the operation of lock-up
oil cooler.
piston.
Go to Step 7
Faulty control valve.

Go to Step 8

replace.

Trouble in the AT
valve.
replace.
No. B6: Engine Starter Does Not Run in P or N Range

No. B7: Engine Starter Runs Except in P or N Range
Description:
The engine starter does not run though the P or N range is selected.
The engine starter runs though the R or D, 3, 2or L range is selected.
Possible Cause:
Disordered select cable.
Disordered Inhibitor switch, disconnection or short-circuit of inhibitor switch.
No. B8: Extended Time Lag When Shift Lever is Changed to N to D

Description:
The shift time lag is longer than standard value when shift lever is changed to N to D.
Possible Cause:
Forward range line pressure is low.

Slip of low & reverse clutch.
Slip of low one-way clutch.
Faulty low clutch duty solenoid operation.
No. B9: Extended Time Lag When Shift Lever is Changed to N to R

Description:
The shift time lag is longer than standard value when shift lever is changed to N to R.
Possible Cause:
Reverse range line pressure is low.

Slip of low & reverse brake.
Slip of reverse clutch.
Faulty low & reverse brake duty solenoid operation.
No. B10: Brake is Applied in R Range

Description:
Brake is applied suddenly in R range.
Diagnosis Hints:
Basically a trouble in the AT main unit. However, some trouble in the sensor system or output system may have
some influence on the trouble in the main unit and therefore these systems should be also checked to prevent
reproduce of the trouble.
Possible Cause:
Seized clutch (low clutch, high clutch, 2-4 brake).

Disordered select cable (select indicator light indicates R but the hydraulic system is not in the R range).
No. B11: Insufficient Starting or Shaking in D Range

Description:
Insufficient starting or shaking in D range.
Possible Cause:
Slip of clutch (low clutch, low one-way clutch, reverse clutch, low & reverse brake).
No. B12: Noise or Vibration is Generated at Starting

Description:
Noise or vibration is generated in the vicinity of AT at starting.
Diagnosis Hints:
Cause other than AT can be also considered. It is effective means to reproduce a running condition using a lift
up, chassis dynamo, etc. to investigate the origin (generating condition) of noise and vibration.
Caution:
Lifting up some unit to test it accompanies danger. Provide safety measures as far as possible and
carry out the test with sufficient care.
Possible Cause:
Following sources of noise or vibration other than the AT can be considered.
Noise from differential gears.
Noise from propeller shaft.
The bearing support in the middle of the propeller shaft has fatigued, and the bend angle of the propeller shaft
has changed, causing vibration at the time of start.
Unbalanced and poor uniformity of tires cause vibration.
No. C1: Engine Race Up (Slip) When Gear is Shifted Up to 1st to

2nd
No. C2: Engine Race Up (Slip) When Gear is Shifted Up to 2nd to
3rd
No. C3: Engine Race Up (slip) When Gear is Shifted Up to 3rd to
4th
No. C4: Engine Race Up (Slip) When Gear is Shift Down or Kickdown to 4th to 3rd
No. C5: Engine Race Up (Slip) When Gear is Shift Down or Kickdown to 4th to 2nd
No. C6: Engine Race Up (Slip) When Gear is Shift Down or Kickdown to 3rd to 2nd
No. C7: Engine Race Up (Slip) When Gear is Shift Down or Kickdown to 4th or 3rd to 1st
No. C8: Engine Race Up (Slip) Others
Description:
The engine speed up when the accelerator pedal is stepped on for acceleration and the gear is shifted up.
The engine speed up when the accelerator pedal is stepped on for acceleration and the gear is shifted down or
for kick-down during steady run.
The engine speed up when the accelerator pedal is stepped on for acceleration and the gear is shifted down or
for kick-down during steady run.
Diagnosis Hints:
Possible Cause:
Slip of clutch.

Step
Action
1
Yes
No
Go to Step 2
Go to Step 2
Go to DTC Chart
Go to Step 3
If the ATF level is
Go to Step 4
If ATF is extremely
black and
contaminated and
the clutch is
supposed.
Overhaul the AT
unit.
Go to Step 5

replace.
Go to Step 6

replace.

Control Valve
Terminal
Assembly
E54
(7)

(12)
(1)
Range
P
R
N
D, 3, 2
Gear
Reverse
1st
2nd
3rd
4th
1st
2nd
3rd
4th
RED/YEL
YEL
(12)
(10)
TCM
C95
RED/YEL
YEL
(1)
B1
(12)
B12
(20)
B20
H22
TCM terminal
H23
WHT/BLK
B20
(High clutch
pressure SW)
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
-
(8)
WHT/BLK
B1
(2-4 brake pressure
SW)
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
-
B12 (Low & reverse

brake pressure SW)
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V

Step
Action
6
TPS
ECM
C56
(49)
A47 (GND)
(38)
A35 (Output)
(57)
A55 (+5V)
(69)
A69 (Idle SW)
No
Go to Step 7

replace.
Go to Step 8
Check the power

source harness and
earth harness (bolt
tightening to the
body).
Go to Step 9

replace.
TCM
A26
Yes
C56
(28)
C94
(16)
RED/WHT
A16

TCM
Battery
BLK/YEL
H23
(15)
BLK
C94
(1)
BLK
BLK
A1 (+B)
C95
(5)
B5
(15)
B15


Trouble in the AT
valve.
replace.
No. C9: Barking Feel When Gear is Shifted Up to 1st to 2nd

No. C10: Barking Feel When Gear is Shifted Up to 2nd to 3rd
No. C11: Barking Feel When Gear is Shifted Up to 3rd to 4th
Description:
Brake feeling appears when the accelerator pedal is stepped on for acceleration and the gear is shifted up.
Diagnosis Hints:
Possible Cause:
Slip of clutch.

Step
Action
Yes
No
Go to Step 2
Go to Step 2
Go to DTC Chart
Go to Step 3
If the ATF level is
Go to Step 4
If ATF is extremely
black and
contaminated and
the clutch is
supposed.
Overhaul the AT
unit.
Go to Step 5

replace.
Go to Step 6

replace.

Control Valve
Terminal
Assembly
E54
(7)

(12)
(1)
Range
P
R
N
D, 3, 2
Gear
Reverse
1st
2nd
3rd
4th
1st
2nd
3rd
4th
RED/YEL
YEL
(12)
(10)
TCM
C95
RED/YEL
YEL
(1)
B1
(12)
B12
(20)
B20
H22
TCM terminal
H23
WHT/BLK
B20
(High clutch
pressure SW)
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
-
(8)
WHT/BLK
B1
(2-4 brake pressure
SW)
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
-
B12 (Low & reverse

brake pressure SW)
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V

Step
Action
6
TPS
ECM
No
Go to Step 7

replace.
Go to Step 9
Check the power

source harness and
earth harness (bolt
tightening to the
body).
Go to Step 10

replace.
TCM
C56
(49)
A47 (GND)
(38)
A35 (Output)
(57)
A55 (+5V)
(69)
A69 (Idle SW)
A26
Yes
C56
(28)
C94
(16)
RED/WHT
A16

TCM
Battery
BLK/YEL
H23
(15)
BLK
10
C94
(1)
BLK
BLK
A1 (+B)
C95
(5)
B5
(15)
B15


Trouble in the AT
valve.
replace.
No. C12: Large Shock When Gear is Shifted to 1st to 2nd or 2nd
to 1st
No. C13: Large Shock When Gear is Shifted to 2nd to 3rd or 3rd to
2nd
No. C14: Large Shock When Gear is Shifted to 3rd to 4th or 4th to
3rd
No. C15: Large Shock When Kick-down
No. C16: Large Shock When No Acceleration
No. C17: Large Shock When Gear is Shifted Down to 2nd to 1st in
L Range
No. C18: Large Shock (Other)
No. C19: Large Shock When Vehicle Speed is Downed by No
Accelerator Pedal or Vehicle is Stopped
Description:
Large shock is felt when the accelerator pedal is stepped on for acceleration and the gear is shifted up or down.
Large shock is felt when the accelerator pedal is stepped on for kick-down.
Large shock is felt when the accelerator pedal is not stepped on.
Large shock is felt when the shift lever is selected in L range.
Diagnosis Hints:
Basically same causes as "No. C1 - C8: Engine races up (slip)" are considered.
No. C20: Large lock-up shock

Description:
Diagnosis Hints:
Out of properties of input sensor or faulty lock-up piston pressure system are considered.
Trouble diagnosis flow is basically the same as "No. I1: No lock-up".
No. C21: Shift Down or Engine Over-run When The Accelerator

Pedal is Stepped on in 4th Gear
Description:
Shift down or engine over-run above the kick-down area.
Diagnosis Hints:
Basically same causes as "No. C1 - C8: Engine races up (slip)" are considered.
No. D1: Faulty Gear Shifting (Different from Shift Pattern)

Description:
Gear is shifted, different from the specified shift pattern.
Diagnosis Hints:
When inspecting faulty gear shifting, it is important to distinguish between the fault of electric system and
mechanical system (AT main unit).
Fault of electric system.
Monitor the output signal (each solenoid driving signal) using with Tech 2. If a trouble signal is sent to the
solenoid synchronously with the faulty gear shifting, the fault is originated in the electric system.
Monitor the input signal (signal from each sensor) using with Tech 2 and find an input signal by which the output
signal (each solenoid driving signal) is subjected to fault.
Fault of the electric system may be derived from temperature or vibration. For instance, though the engine is
normal while it is cold, fault may occur when the engine is warmed up or vehicle is running.
Fault of mechanical system.
If the gear is incorrectly shifted irrespective of operating signal (ON-OFF) of each solenoid, the faulty is
originated from the machine system (AT).
If the clutch slips, ATF smells burnt, contaminated to be black or the stall speed increases.
Possible Cause:
Slip of clutch.
Fixing at 3rd position (fail-safe activated)
Since the gear is fixed at the 3rd position because of the fail-safe function, a trouble that "Faulty gear
shifting" is resulted. In this case, the DTC is memorized.
The throttle opening signal which is sent by serial communication from ECM and TCM is an important
signal for gear shifting. In case of ECM fault or when the throttle position sensor does not issue voltage
signal according to the throttle opening, the gear is not shifted by stepping over the accelerator.
If the output voltage of the throttle position sensor changes freely even though the throttle opening is
constant, the gear is shifted incorrectly.
Faulty speed sensor.

When signal from the speed sensor becomes out of order, it may be judged a result of changed vehicle
speed and faulty gear shifting may be the causes.
Trouble in control valve body (faulty operation, sticking, clogged oil passage)
Step
Action
1
Dislocation or disordered of select lever.
Does the vehicle move when the brake is released in a position
other than the P range and the vehicle is pushed?

Yes
No
Go to Step 2
Adjust the select

cable.
Go to Step 3
Go to Step 3
Go to DTC Chart
Go to Step 4

If the ATF level is
Go to Step 5
If ATF is extremely
black and
contaminated and
the clutch is
supposed.

Step
5
Action
Yes
No
Go to Step 6
In case of fault in
the machine
system, repair that
portion or replace
the unit.
Slip of clutch or fault
of control valve.

Is signal to each solenoid and pressure switch changed
synchronously to the faulty gear shift?
Terminal
Assembly
Control Valve
L&R Brake Solen oid
TCM
E54
H23
(11)
BLU/BLK
BLU/BLK
C95
(6)
B6
(7)
B7
(8)
B8
(9)
B9
(22)
B22 (GND)
(5)
2-4 Brake Solenoid
BLK/YEL
BLK/YEL
(9)
(5)

RED
Low Clu tch Solenoid
RED
(10)
(7)
WHT/BLU
WHT/BLU
(3)
(11)
T C M te rm in a l
Range
P
(2)
B9
(L o w c lu tch
s o le n o id )
-
3 rd
4 th
1st
3 rd
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
-
A p p ro x. 6 .8 V
(A C ra n g e )
-
4 th
R e ve rs e
D, 3, 2
1st
2nd
2nd
Control Valve
(12)
(1)
Reverse
1st
2nd
3rd
4th
1st
2nd
3rd
4th
A p p ro x. 6 .8 V
(A C ra n g e )
B6
(L o w & re ve rs e
b ra k e s ole n o id )
A p p ro x. 6 .2 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
-
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
-
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
-
H23
RED/YEL
YEL
(12)
(10)
TCM
C95
RED/YEL
YEL
(1)
B1
(12)
B12
(20)
B20
H22
Gear
E54
TCM terminal
B7
(2 -4 b rak e
s o le n o id )
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
-
Terminal
Assembly
(7)
GRY/RED
B8
(H ig h clu tch
s o le n o id )
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
A p p ro x. 6 .8 V
(A C ra n g e )
-
Gear
Range
P
R
N
D, 3, 2
(1)
GRY/RED
WHT/BLK
B20
(High clutch
pressure SW)
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
-
(8)
WHT/BLK
B1
(2-4 brake pressure
SW)
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
More than 10V
-
B12 (Low & reverse

brake pressure SW)
More than
More than
More than
More than
More than
More than
More than
More than
More than
10V
10V
10V
10V
10V
10V
10V
10V
10V

Step
Action
6
Yes
No
Go to Step 7

switch.
Go to Step 8

replace.
Inhibitor SW
TCM
P
E51
(2)
H22
(1)
YEL/VIO
YEL/VIO
BLK/GRN
RED/YEL
(4)
N
(8)
RED/BLK
PNK/BLK
(6)
RED/BLK
BLU
(5)
3
(4)
BLK/GRN
(1)
BLU
RED/YEL
(7)
PNK/BLU
2
(9)
PNK/BLK
C94
(2)
A2 (P)
(3)
A17 (3)
C95
(2)
B2 (2)
(10)
B10 (N)
(11)
B11 (D)
(19)
B19 (R)
(21)
B21 (L)
(5)
PNK/BLU
(2)
(6)
Start SW
B
(3)
WHT
(38)
BLK/WHT
(10)
(15)
BLK
(7)
WHT
Key Switch
BLK/WHT
(3)
Starter Relay
BLK
(37)
H4
TCM terminal

A2
B19
B10
B11
B17
B2
B21
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V
-
Range
P
10
14.5V
-
10
14.5V
TPS
ECM
C56
(49)
A47 (GND)
(38)
A35 (Output)
TCM
A26
(57)
A55 (+5V)
(69)
A69 (Idle SW)
C56
(28)
RED/WHT
C94
(16)
A16

Step
Action
8
Inspect the output signal of the speed sensor using a Tech 2 or
circuit tester.
Is the data display in the Tech 2 correct or output voltage correct
in the circuit tester?
Yes
No
Go to Step 9

replace.
Go to Step 10
Check the power

source harness and
earth harness (bolt
tightening to the
body).
Go to Step 11

replace.
Key SW
TCM
Speed
Sensor
E30
(2)
(1)
(3)
WHT
YEL/RED
H23
(4)
C95
(13)
YEL/RED
B13
BLK
E10
TCM terminal
Condition
20km/h at L range in 1st gear
B13
Approx. 6.5V (AC range)

TCM
Battery
H23
(15)
BLK
10
11
C94
(1)
BLK/YEL
BLK
BLK
A1 (+B)
C95
(5)
B5
(15)
B15


Trouble in the AT
valve.
replace.
No. D2: Gear is Shifted Frequently

Description:
Gear is shifted down immediately though the accelerator pedal is stepped on a little in D, 3, 2, or L range.
Diagnosis Hints:
Basically, the same cause as "No. D1: Faulty gear shifting" is considered. However, as possible cause, fault
input signal of throttle position sensor or speed sensor, fault input signal of inhibitor switch, or fault of TCM
power source, earth, ground return wire are considered first.
Then, slip of the clutch, fault of the control valve are considered.
No. D3: Gear Shift Point is Low or High at All Point

No. D4: Gear Shift Point is Low or High at Limited Point
Description:
Gear shift point is deviated from the shift diagram.
Gear is not shifted up properly though the vehicle is accelerated.
Gear is not shifted immediately and enough acceleration cannot be obtained though the accelerator pedal is
stepped on.
Diagnosis Hints:
If the cause is not faulty gear shift, throttle position sensor disordered or fault input of speed sensor is
considered. Output signal of the throttle position sensor is changed to linear one.
(Refer the paragraph about the faulty throttle position sensor of "No. D1: Faulty gear shifting".)
No. D5: No Kick-down

Description:
The engine speeds up but vehicle speed does not increase when the accelerator pedal is stepped on at the
starting.
Diagnosis Hints:
When the gear shift is normal only without kick-down, possibility of fault of the throttle position sensor. Check
that the throttle voltage increases linearly in proportion to the throttle opening.
(Refer the paragraph about the faulty throttle position sensor of "No. D1: Faulty gear shifting".)
No. E1: No Gear Shift

Description:
Range is fixed without shifting the gear of 1st to 2nd, 2nd to 3rd, and 3rd to 4th.
Gear may be shifted or may not be shifted.
Diagnosis Hints:
Fixing at some gear speed, signal error from throttle position sensor or trouble in the AT main unit are supposed.
Possible Cause:
Slip of clutch (low clutch, high clutch and 2-4 brake).
Since the gear is fixed at the 3rd position because of the fail-safe function, a trouble that "No gear shift"
is resulted. In this case, the DTC is memorized.
that "No Gear Shift".
Trouble in control valve body (faulty operation, sticking, clogged oil passage)
Step
Action
1
process should be carried out).
Yes
No
Go to Step 2
Go to Step 2
Go to DTC Chart
Go to Step 3
If the ATF level is

Go to Step 4
If ATF is extremely
black and
contaminated and
the clutch is
supposed.
Overhaul the AT
unit.

Step
Action

When the select lever is operated, is the data display in the Tech
2 correct or voltage at each range correct?
Yes
No
Go to Step 5

switch.
Go to Step 6

replace.
Inhibitor SW
TCM
P
E51
(2)
H22
(1)
C94
(2)
A2 (P)
RED/YEL
(3)
A17 (3)
RED/BLK
C95
(2)
B2 (2)
(10)
B10 (N)
(11)
B11 (D)
(19)
B19 (R)
(21)
B21 (L)
YEL/VIO
YEL/VIO
BLK/GRN
R
(4)
N
(8)
PNK/BLK
(6)
RED/BLK
BLU
(5)
3
(4)
BLK/GRN
(1)
BLU
RED/YEL
(7)
PNK/BLU
2
(9)
PNK/BLK
(5)
PNK/BLU
(6)
Start SW
(2)
B
(3)
WHT
(38)
BLK/WHT
(10)
(15)
BLK
(7)
WHT
Key Switch
BLK/WHT
(3)
Starter Relay
BLK
(37)
H4
TCM terminal
A2

B19
B10
B11
B17
B2
B21
Range
P
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V

TPS
ECM
C56
(49)
A47 (GND)
(38)
A35 (Output)
TCM
A26
(57)
A55 (+5V)
(69)
A69 (Idle SW)
C56
(28)
RED/WHT
C94
(16)
A16

Step
Action
6
Yes
No
Go to Step 7
Check the power

source harness and
earth harness (bolt
tightening to the
body).

replace.
Go to Step 8
Go to Step 9

replace.
TCM
Battery
BLK/YEL
H23
(15)
BLK
C94
(1)
BLK
BLK
A1 (+B)
C95
(5)
B5
(15)
B15
Inspection of speed sensor and turbine sensor

Have the speed sensor and turbine sensor failed at the same
time? (No DTC is stored at the time of trouble)

Trouble in the AT
valve.
replace.
No. E2: Only 4th gear (O/D) is Not Selectable

Description:
Gear is not shifted up from 3rd to 4th though the vehicle is accelerated.
Possible Cause:

ATF thermo sensor detects low oil temperature (4th gear is prohibited temperature less than 10C.).
Clogged oil passage of low clutch duty solenoid.
Step
Action
1
Dislocation or disordered of select lever.
Does the vehicle move when the brake is released in a position
other than the P range and the vehicle is pushed?

Yes
No
Go to Step 2
Adjust the select

cable.
Go to Step 3
Go to Step 3
Go to DTC Chart
Go to Step 4

If the ATF level is
Go to Step 5
If ATF is extremely
black and
contaminated and
the clutch is
supposed.
Overhaul the AT
unit.

Step
Action
5
Yes
No
Go to Step 6

switch.
Go to Step 7

replace.
Go to Step 8

replace.
Inhibitor SW
TCM
P
E51
(2)
H22
(1)
YEL/VIO
YEL/VIO
BLK/GRN
RED/YEL
(4)
N
RED/BLK
(8)
PNK/BLK
(6)
RED/BLK
BLU
(5)
3
(4)
BLK/GRN
(1)
BLU
RED/YEL
(7)
PNK/BLU
PNK/BLK
(9)
L
C94
(2)
A2 (P)
(3)
A17 (3)
C95
(2)
B2 (2)
(10)
B10 (N)
(11)
B11 (D)
(19)
B19 (R)
(21)
B21 (L)
(5)
PNK/BLU
(2)
(6)
B
(3)
Start SW
WHT
(38)
BLK/WHT
(10)
WHT
(15)
BLK
(7)
Key Switch
BLK/WHT
(3)
Starter Relay
BLK
(37)
H4
TCM terminal

A2
B19
B10
B11
B17
B2
B21
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V
-
Range
P
Te rm ina l
A ssem bly
E54
(2 )
(8 )
TCM
B LU
H 23
(8 )
B LU /B LK
TCM terminal
Temperature (deg. C)
20
10
14.5V
Inspection of ATF oil thermo sensor.

Is the ATF oil temperature sensor terminal voltage correct?
After running using the Tech 2 data display function, is the ATF
temperature higher than 10C?
ATF
Tem p.
S en sor
10
14.5V
-
(3 )
B LU
B LU /B LK
C 95
(4)
B 4 (+ )
(14 )
B 1 4 (-)
B4 (Output voltage)
1.55
40
1.08
60
0.7
80
0.5
100
0.3
120
0.2

Trouble in the AT
valve.
replace.
No. E3: Gear is Shifted 2nd to 3rd in 2 Range

No. E4: Gear is Shifted 1st to 2nd in L Range
No. E5: Gear is Shifted 3rd to 4th in 3 Range
Description:
Gear is shifted 2nd to 3rd in 2 range
Gear is shifted 1st to 2nd in L range
Gear is shifted 3rd to 4th in 3 range
Possible Cause:
No. F1: Low Maximum Speed or Poor Acceleration

Description:
Acceleration is slow though the accelerator pedal is stepped on during the running.
Diagnosis Hints:
In addition to the low engine output, faulty gear shifting of AT or fixing at the 3rd position may be possible.
Therefore, in case of such a trouble that "maximum speed is low, and acceleration is poor", it should be cleared
up whether the trouble is originated from the engine system of AT system by a running test, inspection of stall
revolution, etc.
Possible Cause:
Clogged air cleaner, out of injection timing, dropped compression pressure, etc.
Since the gear is fixed at the 3rd position because of the fail-safe function, a trouble that "Maximum
speed is low, and acceleration is poor" is resulted. In this case, the DTC is memorized.
Disordered inhibitor switch .
that "Maximum Speed is Low and Acceleration is Poor".
Slip of clutch (low clutch, high clutch).
Step
Action
1
Test Drive.
Is the gear smoothly shifted in the order of 1st to 2nd, 2nd to 3rd,
3rd to 4th gear and lock up?

Yes
No
Clogged air
cleaner, out of
injection timing,
dropped
compression
pressure, etc.
Go to Step 2
Go to Step 3
Go to Step 3
Go to DTC Chart
Go to Step 4

Step
Action
4
Yes
No
If the ATF level is

Go to Step 5
If ATF is extremely
black and
contaminated and
the clutch is
supposed.
Overhaul the AT
unit.
Go to Step 6

switch.

Inhibitor SW
TCM
P
E51
(2)
H22
(1)
C94
(2)
A2 (P)
RED/YEL
(3)
A17 (3)
RED/BLK
C95
(2)
B2 (2)
(10)
B10 (N)
(11)
B11 (D)
(19)
B19 (R)
(21)
B21 (L)
YEL/VIO
YEL/VIO
BLK/GRN
R
(4)
N
(8)
PNK/BLK
(6)
RED/BLK
BLU
(5)
3
(4)
BLK/GRN
(1)
BLU
RED/YEL
(7)
PNK/BLU
2
(9)
PNK/BLK
(5)
PNK/BLU
(2)
(6)
Start SW
B
(3)
WHT
(38)
BLK/WHT
(10)
(15)
BLK
(7)
WHT
Starter Relay
(37)
H4
TCM terminal
A2
Key Switch
BLK/WHT
(3)
BLK

B19
B10
B11
B17
B2
B21
Range
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V
-
10
14.5V

Step
Action
6
TPS
ECM
No
Go to Step 7

replace.
Go to Step 8
Check the power

source harness and
earth harness (bolt
tightening to the
body).
Go to Step 6

replace.
TCM
C56
(49)
A47 (GND)
(38)
A35 (Output)
(57)
A55 (+5V)
(69)
A69 (Idle SW)
A26
Yes
C56
(28)
C94
(16)
RED/WHT
A16

TCM
Battery
BLK/YEL
H23
(15)
BLK
C94
(1)
BLK
BLK
A1 (+B)
C95
(5)
B5
(15)
B15


Trouble in the AT
valve.
replace.
No. F2: Engine Races Up During Acceleration (Slip)

Description:
The engine speed up when the accelerator pedal is stepped on for acceleration and the gear is shifted up or
down.
Only the engine speeds up but vehicle speed does not increase when the accelerator pedal is stepped on for
acceleration during the running.
Diagnosis Hints:
Basically same causes as "No. C1 - C8: Engine races up (slip) by shift up or shift down" are considered.
When the condition of No. C1-C8 grows worse, symptom of No. F2 results.
No. F3: Noise or Vibration During the Running in R, D, 3, 2 or L Range

Description:
Noise or vibration is generated in the vicinity of AT during the running.
Diagnosis Hints:
Cause other than AT can be also considered. It is effective means to reproduce a running condition using a lift
up, chassis dynamo, etc. to investigate the origin (generating condition) of noise and vibration.
Caution:
Lifting up some unit to test it accompanies danger. Provide safety measures as far as possible and
carry out the test with sufficient care.
Possible Cause:
Following sources of noise or vibration other than the AT can be considered.
Noise from differential gears.
Noise from propeller shaft.
The bearing support in the middle of the propeller shaft has fatigued, and the bend angle of the propeller shaft
has changed, causing vibration at the time of start.
Unbalanced and poor uniformity of tires cause vibration.
No. F4: Engine Brake Does Not Apply in L Range

Description:
The engine brake does not apply, allowing the vehicle to run freely when the accelerator pedal is released at low
speed in L range.
Possible Cause:
Slip of clutch (low & reverse brake)
Faulty input/output signal system.
Low & reverse brake duty solenoid
Faulty control valve (faulty operation, sticking).
No. F5: Engine Stalls Before Vehicle Stops from Running

Description:
The engine stalls simultaneously with the vehicle stop when the brake pedal is stepped on to stop the vehicle
during the running.
Possible Cause:
Trouble on the engine system side (fuel injection control, engine speed control, etc.) is considered.
Refer to "No. B5: Engine stalls when selecting from N range to R, D, 3, 2 or L range".
No. G1: Vehicle Moves in P Range or Parking Gear is Not

Disengaged other than P Range
Description:
Vehicle moves though it stops at a slope and P range is selected.
The engine stalls and vehicle does not move though other than P range is selected and the accelerator pedal is
stepped on.
Possible Cause:
Trouble of the parking mechanism (noise or shock may result).
Disordered selector cable (only when traveling in the P range).
If the vehicle moves in the N range, follow the procedure of "No. B1: Vehicle runs in N range".
No. G2: Creep Force is Large

Description:
Vehicle accelerates in D, 3, 2, L, and R ranges though the accelerator pedal is not stepped on.
Possible Cause:
Too high engine idling speed (not attributable to AT).
No. G3: Creep Force is small

Description:
Vehicle does not move though a run range is selected on a flat road during the idling.
Diagnosis Hints:
When the creep force is small in all ranges, low engine output is considered. Another possible cause is slip of
clutch. If the creep is normal only in the R range, operation of the fail-safe function due to a trouble in the electrical
system is considered.
Possible Cause:
Slip of clutch (low clutch).
Low engine output (low idling speed, out of injection timing, lowered compression pressure, etc.).
Disconnection or short circuit of solenoid valve output.
Clogged oil passage of solenoid valve output.
Faulty ground return line in AT assembly.
If the ground return line earth is faulty, clutch pressure may decrease causing slip of the clutch.
Step
Action
1
Travel in the following sequence for about 7 seconds or
more in each range: Start in the L range (1st) to 2 range
(2nd) to 3 range (3rd) to D range (4th) (to detect the gear
ratio trouble exactly, this process should be carried out)
2
Yes
No
Go to Step 2
Go to Step 2
Go to DTC Chart
Go to Step 3
replenish up to the
specified level.
Go to Step 4
If ATF is extremely
black and
contaminated and
clutch is supposed.
Go to Step 5

replace.
Go to Step 6

replace.
Trouble in the AT
assembly or control
valve.

replace.
Are the idling speed and other engine system normal?
Is the stall revolution normal in D, 3, 2 and L range? Refer

the STALL TEST section in this manual.
Is the line pressure normal? Refer the LINE PRESSURE
No. G4: Large Noise During Idling with the Vehicle in Stop State
Description:
The transmission is noisy during the idling speed in all ranges.
Diagnosis Hints:
Causes such as solenoid operating sound or faulty oil pump are considered.
Distinguishing to some extent is possible by stopping the solenoid operation temporarily, checking the correlation
for the former case and, changing the line pressure and confirming the correlation with noise.
As a matter of course, noise may be generated around the engine, for instance, other than the AT and should be
checked carefully.
Note:
When the noise is generated only at the time of gear shift, it may be the sound of flowing ATF or gear
noise. If the sound varies depending on the gear speed to be shifted, it may be the gear noise generated
from the planetary gear and its related components. If the sound varies depending on the vehicle
speed, it may be the gear noise of the output system, and if varying depending on the engine speed, it
may be the gear noise of the input system or faulty torque converter.
In either case, sound may be "noise" depending on the origin and resonance object. When the object
generating the sound (resonance object) and the sound source (vibration source) are different,
investigation of the cause may be difficult.
No. H1: Judder Occurs at the Lock-up

Diagnosis Hints:
The vehicle body judders at lock-up.
Diagnosis Hints:
Slip due to burning of the lockup piston or insufficient fastening due to dropped working pressure are considered.
Note:
When the lock-up piston has burnt, foreign material mixed in the oil cooler is considered. In such a
case, inspect the oil cooler circuit for clogging of the oil cooler.
No. H2: Large Lock-up Shock

No. H3: Lock-up Point is High or Low
Description:
Lock-up point is excessive high or low.
Diagnosis Hints:
Out of properties of input sensor or faulty lock-up piston pressure system are considered.
No. I1: No Lock-up

Description:
Lockup is not performed in spite of the lock-up area.
Diagnosis:
Lockup is not performed in spite of the lock-up area.
Monitor the signal to the lock-up solenoid while carrying out a running test.
When the output signal to the lock-up solenoid is correctly sent causing no lock-up, clogged lock-up solenoid oil
passage or malfunction of the lock-up piston may be considered.
Even the lock-up area, the output signal to the lock-up solenoid is not sent, fault of the ATF thermo sensor
controlling the lockup is considered. (Lock-up is not operated at ATF temperature less than 11C or more than
128C.)
Note:
When the lock-up piston has burnt, foreign material mixed in the oil cooler is considered. In such a
case, inspect the oil cooler circuit for clogging of the oil cooler
Possible Cause:
ATF thermo sensor detects low oil temperature (Lock-up is prohibited temperature less than 10C.).
Clogged oil passage of lock-up duty solenoid.
Step
1
Action
Yes
No
Go to DTC Chart
Go to Step 2

If the ATF level is
Go to Step 3
If ATF is extremely
black and
contaminated and
the clutch is
supposed.
Overhaul the AT
unit.

Step
Action
3
When the ATF oil temperature is above 20C and the vehicle
speed is 80km/h, is ON signal issued to the lock-up solenoid
using the Tech 2 or circuit tester?
Yes
No
Clogged oil
passage of lock-up
solenoid or faulty
operation of lockup piston.
Go to Step 4
Terminal
Assembly
Control Valve
Lock-up Solenoid
TCM
E54
H23
BLK
(4)
C95
BLK
(14)
(17)
B17
(23)
B23

VIO
VIO
(6)
Lock-up
(6)
TCM terminal
At lock-up
At unlock-up
B17
Approx. 2.2 - 9.0V (AC range)
Approx. 1.0 2.0V (AC range)
Inspection of ATF oil thermo sensor.

Is the ATF oil temperature sensor terminal voltage correct?
After running using the Tech 2 data display function, is the ATF
temperature higher than 10C?
AT F
Tem p.
S enso r
Term in al
A ssem bly
E54
(2)
(8)
TCM
BLU
H 23
(8)
B L U /B LK
TCM terminal
Temperature (deg. C)
20
(3)
B LU
B LU /B LK
C95
(4)
B 4 (+)
(1 4)
B 14 (-)
B4 (Output voltage)
1.55
40
1.08
60
0.7
80
0.5
100
0.3
120
0.2
Monitor the electric

system input
sensor signal and
find a signal
causing no lockup.
replace.
No. J1: Oil Leaks from Breather

Description:
Oil leaks from breather.
Possible Cause:
ATF quantity is excessively.
No. J2: Oil Leaks Between Engine and Converter Housing

No. J3: Oil Leaks Between Main Case and Converter Housing
No. J4: Oil Leaks Between Main Case and Rear Housing
No. J5: Oil Leaks from Oil Pan
No. J6: Oil Leaks from Manual Shaft Oil Seal
No. J7: Oil Leaks from Oil Cooler Pipe Joint
Description:
Oil leaks between engine and converter housing.

Oil leaks between converter housing and main case.
Oil leaks between main case and rear housing.
Oil leaks from oil pan.
Oil leaks from manual shaft oil seal.
Oil leaks from oil cooler pipe joint.
Possible Cause:
Faulty oil seal or sealing of contact surface is considered.
No. Z1: Transmission Overheat

Description:
You smell the transmission burning.
The transmission smokes.
Possible Cause:
Slip of clutch.
Clogged oil cooler (foreign substance mixed)
ATF stirred excessively (too much ATF).
Faulty torque converter operating pressure.
Faulty lock-up piston.
No. Z2: Mode Lamp (Power Drive or 3rd Start) Does Not Light Up
When The Power Mode or 3rd Start Mode is Turned On
Description:
The mode lamp on the instrument panel does not light up though the power mode or 3rd start mode is turned on
with the ignition switch in ON position.
Possible Cause:
Faulty mode select switch is considered.
Bulb burn out.
No. Z3: Mode Lamp (Power Drive or 3rd Start) Lights Up When
The Power Mode or 3rd Start Mode is Turned Off
Description:
The mode lamp on the instrument panel lights up though the power mode or 3rd start mode is turned off with the
ignition switch in ON position.
Possible Cause:
No. Z4: Oil Temperature Warning Lamp Lights up

Description:
Sometimes, the oil temperature warning lamp lights up.
Possible Cause:
When the vehicle is stuck in the mud or continues to accelerate under overload, and ATF temperature exceeds
145 C, the oil temperature warning lamp lights up.
If the oil temperature warning lamp lights up under usual service condition, following causes are considered.
ATF level has increased for some fault.
Refer to "No. Z1: Transmission overheat".
Lights up due to error of the ATF oil thermo sensor.
No. Z5: Select Lever Feeling is Faulty.

Description:
Select lever feeling is faulty.
Possible Cause:
Disordered select lever.
Faulty Manual plate.
No. Z6: Poor Fuel Consumption

Description:
Poor fuel consumption.
Diagnosis Hints:
Basically same causes as "No. C1 - C8: Engine races up (slip) by shift up or shift down" are considered.
No. Z7: Pattern Select Switch is Faulty

Description:
Shift pattern does not change though the pattern select switch is turned on.
Possible Cause:
No. Z8: Oil is Splashed During the Running

Description:
Oil is splashed during the running
Possible Cause:
ATF quantity is too high.
No. Z9: Abnormal Smell

Description:
Abnormal smell.
Diagnosis Hints:
Basically a trouble in the AT main unit.
No. Z10: ATF Quantity is Low or High

Description:
Oil quantity is low or high.
Possible Cause:
In case of oil level is high.
ATF temperature is low when ATF quantity is checked.
In case of oil level is low.
ATF leaks is considered. Check the AT main unit and cooler circuit.
No. Z11: Abnormal Oil Pressure

Description:
Oil pressure is low or high.
Possible Cause:
Basically, the same cause as "No. C1 - C8: Engine races up (slip) by shift up or shift down" is considered.
In case of oil pressure is low, faulty oil pump is considered.
No. Z12: Reverse Buzzer Does Not Ring

Description:
Reverse buzzer does not ring in R range.
Possible Cause:
Disordered select lever.
STALL TEST
CAUTION:
Because A/T may break down, do not perform the stall test continuously.
Procedure
1.
2.
3.
4.
5.
6.
7.
Chock the four wheels.

Warm up the engine.
Apply the parking brake.
Step on the foot brake fully.
Set the select lever to either D, 3, 2, L or R range.
Step on the accelerator pedal fully.
When the engine speed becomes constant, record that
value quickly.
Stall Speed
Standard: 2600150 rpm
Evaluation
1. If the stall speed is higher than standard value in all
ranges.
Low line pressure.
Abraded oil pump.
Faulty operation of low clutch.
Adjustment error of or faulty inhibitor switch.
ATF leaking from
transmission case.
oil
pump,
control
valve,
or
Fixed pressure regulator valve and pilot valve.

2. If the stall speed is higher than standard value in D, 3, 2
and L ranges.
Slip of low clutch.
3. If the stall speed is higher than standard value in R
range.
4. If the stall speed is lower than standard value in all
ranges.
Slip of one-way clutch (in torque converter).
Faulty engine.
LINE PRESSURE TEST

Procedure
1. Chock the four wheels.
2. Remove the test plug of the transmission case and fit the oil
pressure gauge.
3. Warm up the engine.
4. Apply the parking brake.
5. Step on the foot brake fully.
6.Set the select lever to either D, 3, 2, L or R range.
7. Record the oil pressure at idling.
8. When stepping over the accelerator pedal fully and the
engine speed becomes constant, record the oil pressure
quickly.
Line Pressure
Standard:
Engine
Speed
Line Pressure (Kpa)

D, 3, 2 or L Range
R Range
Idling
350 - 480
450 - 650
Stall
1,050 - 1,250
1.400 - 1,630
Evaluation
1. If the line pressure is lower than standard value at
idling in all ranges.
Abraded oil pump.
Faulty operation of each solenoid.
Sticking of pressure regulator valve or pilot valve.
Fatigued pressure regulator valve or pilot valve spring.
ATF leaking from oil strainer, oil pump, pressure
regulator valve, torque converter relief valve or pressure
relief valve.
idling in D, 3, 2 and L ranges.
ATF leaking from low clutch hydraulic circuit.
idling in R range.
ATF leaking from reverse hydraulic circuit.
ATF leaking from low and reverse brake hydraulic
circuit.

idling in L and R ranges.
ATF leaking from low and reverse brake hydraulic
circuit.
5. If the line pressure is higher than standard value at
idling in all ranges.
Throttle opening signal reception error.
Faulty oil temperature sensor.
Faulty operation of low clutch solenoid.
Sticking pilot valve.
Sticking pressure regulator valve or plug.
6. If the line pressure is lower than standard value at stall
speed in all ranges.
Throttle opening signal reception error.
Faulty operation of line pressure solenoid.
Faulty operation of low clutch solenoid.
Sticking pilot valve.
Sticking pressure regulator valve or plug.
1. Oil Cooler Out

2. R Range Line Pressure Detection Port
(Low & Reverse Brake Pressure Detection Port)
3. D, 3, 2 & L Range Line Pressure Detection Port
(Low Clutch Pressure Detection Port)
4. Oil Cooler In
TIME LAG TEST

Procedure
1.
2.
3.
4.
5.
6.
Chock the four wheels.

Warm up the engine.
Apply the parking brake.
Step on the foot brake fully.
Set the select lever from N to D or N to R range.
Record the time from when moving the select button until
feeling shock.
Time Lag
Standard:
N to D Range: Below 0.7 Seconds
N to R Range: Below 1.2 Seconds
Evaluation
1. If the time lag is out of standard value when shifting N
to D range.
Forward range line pressure is low.
Slip of low clutch.
Trouble in control valve body (faulty operation, sticking,
clogged oil passage).
Faulty low clutch duty solenoid operation.
2. If the time lag is out of standard value when shifting N
to R range.
Reverse range line pressure is low.
Trouble in control valve body (faulty operation, sticking,
clogged oil passage).
Faulty low & reverse brake duty solenoid operation.
TEST DRIVE
NOTE:
Perform the test at normal operation ATF temperature 50 80C.
Drive the vehicle on level ground so as not to change to
up and down hill control.
1. D range test in Normal and Power shift pattern.
1) Shift into the D range and hold the accelerator pedal
constant at the 50% and 100% throttle angle.
2) 1-2, 2-3, 3-4 and lock-up, up-shift should take place, and
shift points should confirm to those shown in the
diagram.
3) Also check to see that downshift is made from 4-3, 3-2
and 2-1 down-shift point is within the limits shown in the
diagram.
2. 3 range test in Normal and Power shift pattern.
1) Shift into the 3 range and hold the accelerator pedal
2) 1-2, 2-3 and lock-up, up-shift should take place, and
shift points should confirm to those shown in the
diagram.
3) While running in the 3 rages, does not up-shift 3-4.
4) Also check to see that down-shift is made from 4-3, 3-2
diagram.
3. 2 range test in Normal shift pattern.
1) Shift into the 2 range and hold the accelerator pedal
2) 1-2 and up-shift should take place, and shift points
should confirm to those shown in the diagram.
3) While running in the 2 rages, does not up-shift 2-3 or 34, and lock-up does not operate.
diagram.
4. L range test in Normal shift pattern.
1) While running in the L rages, does not up-shift 1-2, 2-3
or 3-4, and lock-up does not operate.
diagram.

5. R range test.
1) Shift into the R range and while starting at full throttle,
check for slipping.
6.P range test.
1) Stop the vehicle on a grade and after shifting into the P
range, release the parking brake. Then check to see that
the parking lock pawl holds the vehicle in place.
Evaluation
Gear
Shift
1. If there is no 1 to 2 up-shift.
2-4 brake malfunction.
Select
Lever
Position
Gear
Position
2-4 brake duty solenoid stick.
Reverse
Refer to symptom diagnosis "No. D1: Faulty Gear

Shifting" or DTC section "Gear Ratio Error".
1st
2-4 brake hydraulic circuit failed.
2nd
3rd
High clutch hydraulic circuit failed.
4th
High clutch duty solenoid stick.
1st
2nd
3rd
4th(*1)
2. If there is no 2 to 3 up-shift.
High clutch malfunction.

3. If there is no 2 to 4 (O/D) up-shift.
2-4 brake malfunction.
1st
2-4 brake hydraulic circuit failed.
2nd
2-4 brake duty solenoid stick.
3rd(*1)

4th(*1)
L
1st
2nd(*1)
3rd(*1)
4th(*1)
*1: Transmission is shifted at high speed to

prevent engine over-run.
4. If there is no lock-up in 2, 3 and 4.

Lock-up piston malfunction.
Lock-up hydraulic circuit failed.
Lock-up duty solenoid stick.
Refer to symptom diagnosis "No. I1: No Lock-up" or
DTC section "Lock-up Duty Solenoid Failure".

5. If there is no reverse.
Reverse clutch malfunction.
Reverse clutch hydraulic circuit failed.
Low & reverse brake hydraulic circuit failed.
Low & reverse brake duty solenoid stick.
Refer to symptom diagnosis "No. A2: Vehicle Dose Not
Run in R Range" or DTC section "Low & Reverse
Brake Duty Solenoid Failure".
6. If there is no parking.
Parking pawl malfunction.
Refer to symptom diagnosis "No. G1: Vehicle Moves in
P Range or Parking Gear in Not Disengaged other
than P Range".
NOTE:
The check for the cause of abnormal noise and vibration
must be made with extreme care as it could also be due to
loss of balance in propeller shaft, differential, the torque
converter, etc. Or insufficient bending, rigidity, etc. in the
powertran.
SHIFT POINT CHART

D Range
Normal Mode
Gear
Throttle
Position
Velocity (km/h)
Power Mode
Output Shaft
Speed (rpm)
12
50% 25 - 31 27 - 33
100% 36 - 42 37 - 43
23
50% 46 - 52 49 - 55
100% 75 - 81 79 - 85
34
50% 80 - 86 84 - 90
100% 118 - 124 125 - 131
43
0% 27 - 33 29 - 35
50% 52 - 58 55 - 61
100% 102 - 108 108 - 114
32
0%
6 - 12
6 - 12
50% 28 - 34 30 - 36
100% 61 - 67 64 - 70
21
0%
6 - 12
6 - 12
50%
9 - 15 10 - 16
100% 27 - 33 29 - 35
4.300
4.300
Axle Gear Ratio
0.349
0.368
Tire Radius
Velocity (km/h)
4L Mode
Output Shaft
Speed (rpm)
930 29 - 35 31 - 37
1271 36 - 42 38 - 44
1612 55 - 61 58 - 64
2542 75 - 81 79 - 85
2697 83 - 89 88 - 94
3967 118 - 124 125 - 131
992 27 - 33 29 - 35
1798 70 - 76 74 - 80
3440 102 - 108 108 - 114
279
6 - 12
6 - 12
1023 44 - 50 47 - 53
2077 61 - 67 64 - 70
279
6 - 12
6 - 12
403 18 - 24 19 - 25
992 27 - 33 29 - 35
4.300
4.300
0.349
0.368
Velocity (km/h)
1054 28 - 34 30 - 36
1271 32 - 38 34 - 40
1891 52 - 58 55 - 61
2542 67 - 73 71 - 77
2821 80 - 86 84 - 90
3967 107 - 113 113 - 119
992 27 - 33 29 - 35
2387 67 - 73 71 - 77
3440 93 - 99 98 - 104
279
6 - 12
6 - 12
1550 43 - 49 46 - 52
2077 56 - 62 59 - 65
279
6 - 12
6 - 12
682 17 - 23 18 - 24
992 25 - 31 27 - 36
4.300
4.300
0.349
0.368
Output Shaft
Speed (rpm)
1023
1147
1798
2294
2697
3595
992
2294
3130
279
1488
1922
279
651
930
3 Range
Normal Mode
Gear
12
Throttle
Position
Velocity (km/h)
50% 25 - 31 27 - 33
100% 36 - 42 38 - 44
23
50% 46 - 52 49 - 55
100% 75 - 81 79 - 85
43
0% 118 - 124 125 - 131
50% 118 - 124 125 - 131
100% 118 - 124 125 - 131
32
0%
6 - 12
6 - 12
50% 28 - 34 30 - 36
100% 61 - 67 64 - 70
21
0%
6 - 12
6 - 12
50%
9 - 15 10 - 16
100% 27 - 33 29 - 35
4.300
4.300
Axle Gear Ratio
0.349
0.368
Tire Radius
Power Mode
Output Shaft
Speed (rpm)
Velocity (km/h)
930 29 - 35 31 - 37
1271 36 - 42 38 - 44
1612 55 - 61 58 - 64
2542 75 - 81 79 - 85
3967 118 - 124 125 - 131
3967 118 - 124 125 - 131
3967 118 - 124 125 - 131
279
6 - 12
6 - 12
1023 44 - 50 47 - 53
2077 61 - 67 64 - 70
279
6 - 12
6 - 12
403 18 - 24 19 - 25
992 27 - 33 29 - 35
4.300
4.300
0.349
0.368
4L Mode
Output Shaft
Speed (rpm)
Velocity (km/h)
1054 28 - 34 30 - 36
1271 32 - 38 34 - 40
1891 52 - 58 55 - 61
2542 67 - 73 71 - 77
3967 107 - 113 113 - 119
3967 107 - 113 113 - 119
3967 107 - 113 113 - 119
279
6 - 12
6 - 12
1550 43 - 49 45 - 51
2077 57 - 63 59 - 65
279
6 - 12
6 - 12
682 17 - 23 18 - 24
992 25 - 31 27 - 33
4.300
4.300
0.349
0.368
Output Shaft
Speed (rpm)
1023
1147
1798
2294
3595
3595
3595
279
1488
1922
279
651
930
2 Range
Normal Mode
Gear
Throttle
Position
Velocity (km/h)
4L Mode
Output Shaft
Speed (rpm)
12
50% 25 - 31 27 - 33
100% 36 - 42 38 - 44
43
0% 119 - 125 125 - 131
50% 119 - 125 125 - 131
100% 119 - 125 125 - 131
32
0% 75 - 81 79 - 85
50% 75 - 81 79 - 85
100% 75 - 81 79 - 85
21
0%
6 - 12
6 - 12
50%
9 - 15 10 - 16
100% 27 - 33 29 - 35
4.300
4.300
Axle Gear Ratio
0.349
0.368
Tire Radius
Velocity (km/h)
930 28 - 34 30 - 36
1271 32 - 38 34 - 40
3967 107 - 113 113 - 119
3967 107 - 113 113 - 119
3967 107 - 113 113 - 119
2542 67 - 73 71 - 77
2542 67 - 73 71 - 77
2542 67 - 73 71 - 77
279
6 - 12
6 - 12
403 17 - 23 18 - 24
992 25 - 31 27 - 33
4.300
4.300
0.349
0.368
Output Shaft
Speed (rpm)
1023
1147
3595
3595
3595
2294
2294
2294
279
651
930
L Range
Normal Mode
Gear
43
Throttle
Position
Velocity (km/h)
0% 118 - 124 125 - 131

50% 118 - 124 125 - 131
100% 118 - 124 125 - 131
32
0% 75 - 81 79 - 85
50% 75 - 81 79 - 85
100% 75 - 81 79 - 85
21
0% 36 - 42 38 - 44
50% 36 - 42 38 - 44
100% 36 - 42 38 - 44
4.300
4.300
Axle Gear Ratio
0.349
0.368
Tire Radius
4L Mode
Output Shaft
Speed (rpm)
Velocity (km/h)
3967 107 - 113 113 - 119

3967 107 - 113 113 - 119
3967 107 - 113 113 - 119
2542 67 - 73 71 - 77
2542 67 - 73 71 - 77
2542 67 - 73 71 - 77
1271 32 - 38 34 - 40
1271 32 - 38 34 - 40
1271 32 - 38 34 - 40
4.300
4.300
0.349
0.368
Output Shaft
Speed (rpm)
3595
3595
3595
2294
2294
2294
1147
1147
1147
SHIFT POINT DIAGRAM
TCM VOLTAGE CHECK

TCM voltage check is done to check for transmission and TCM
problems which cannot be detected by self-diagnosis.
Additionally, it severs as a back-up check for self-diagnosis.
Measure the voltage drop and make a continuity test for each of
sensors, solenoids and switches.
If the voltage is within the specified range and continuity exists,
that particular area of the TCM and transmission assembly is
normal.
If voltage deviation or lack of continuity is discovered, disconnect
the applicable parts and check of them individually.
Inspection Tool
Use a circuit tester and an oscilloscope to measure voltage and
circuit continuity.
Insert the test probes from the connector wiring side. TCM
terminals are extremely small.
Wrap a piece of thin wire around the probe of tester.
This will make measurement easier.
TCM Pin Assignment

Connect to White Connector
No.
Wire
Color
A1
RED
A2
YEL/
P Range Switch
VIO
(Battery
Back-up
Input
Input
RED
A4
PNK/
3rd Start Indicator Lamp
WHT
A5
K-line
signal
GRN
communication)
-
Power
Connected to
Battery
Measurement Measurement
Item
Condition
Voltage
At P range
A3
A6
Input /
Output
Pin Name
V BATT
Supply)
Connect to Grey Connector
Brake Switch
Input
(Tech
-
Inhibitor switch
Brake switch
Output 3rd start lamp

2
serial Input/
Tech 2
Output
-
Voltage
Voltage
Voltage
Standard
Inspection
Point at
Trouble
10 14.5V
Related
harness
10 14.5V
Related
harness
Inhibitor
At other than
Less than 2V
switch
P range
At
brake
10 14.5V
stepped
Related
harness
At brake no
Less than 2V Brake switch
stepped
Related
harness
At lamp OFF
10 14.5V
At lamp ON
Less than 2V Lamp
Related
harness
-
No.
A7
Wire
Color
Pin Name
BLK/
Engine Speed Sensor
RED
Input /
Output
Input
Connected to
Item
Condition
At 2000rpm.
Voltage (Wave Circuit tester
(+) to A7 pin,
form)
(-) to B5 pin.
ECM
Inspection
Point at
Trouble
Standard
Pulse
generated (At
AC range
approx. 6.2V)
Related
harness
Engine
Speed
Sensor
ECM
A8
A9
BLK/
A10
Vehicle Speed Sensor Out (2WD Only) Output Speed meter
YEL
GRN/
A11
3rd Start Select Switch
WHT
BLU/
A12
4L Mode Switch (4WD Only)
WHT
A13
A14
A15
Input
Input
3rd start switch
Transfer control
unit
At run in L
range in 1st
Voltage (Wave gear 20 km/h.
Circuit tester
form)
(+) to A10 pin,
(-) to B5 pin.
Voltage
Voltage
TCM
Less than 2V
Related
harness
At switch off
10 14.5V
3rd start
switch
At 4L
Less than 2V
Related
harness
At other than
4L
10 14.5V
4L switch
RED/
WHT
Input
Input
A18
YEL/
DIAG Switch
BLK
A19
ORG/
A/T OIL TEMP Indicator Lamp
BLU
Output
GRN/
CHECK TRANS Indicator Lamp
YEL
Output
A21 PNK POWER DRIVE Indicator Lamp
Output
A22
A23
Pulse
generated (At Speed
AC range
sensor
approx. 6.5V) Speed meter
BLK/
A17
3 Range Switch
GRN
A20
Related
harness
At switch
pushed
At fully close
A16
Input
ECM
Inhibitor switch
Wave form
(140Hz Duty
signal) *1
At fully open
Voltage
Data link
connector
Voltage
AT OIL TEMP
indicator lamp
Voltage
CHECK TRANS
indicator Lamp
Voltage
POWER DRIVE
indicator lamp
Voltage
Related
Off duty 10%
harness
ECM
Off duty 90%
Throttle
position
sensor
At 3 range
10 14.5V
Related
harness
At other than
3 range
Less than 2V
Inhibitor
switch
At key switch
ON
10 14.5V
Related
harness
At short circuit
Related
of DIAG
Less than 2V
harness
switch
Related
harness
At lamp OFF
10 14.5V
At lamp ON
Less than 2V Lamp
At lamp OFF
10 14.5V
At lamp ON
Less than 2V Lamp
At lamp OFF
10 14.5V
At lamp ON
Less than 2V Lamp
Related
harness
Related
harness
No.
Wire
Color
A24
GRN/
Power Drive Select Switch
YEL
B1
B2
Pin Name
RED/
2-4 Brake Pressure Switch
YEL
PNK/
2 Range Switch
BLK
Input /
Output
Input
Input
Input
Connected to
Power drive
switch
2-4 brake
pressure switch
Inhibitor switch
Input
B3
B4
BRN/
Turbine Sensor
RED
BLU
ATF Thermo Sensor
Turbine sensor
Input
Item
Condition
Voltage
Voltage
Voltage
At lamp OFF
10 14.5V
Voltage
Ground
Voltage
Inspection
Point at
Trouble
Related
harness
At lamp ON
Less than 2V Lamp
At other than
2nd or 4th
gear
More than 10 Related

V
harness
At 2nd or 4th
gear
Less than 2V
Pressure
switch
At 2 range
10 14.5V
Related
harness
At other than
2 range
Less than 2V
Inhibitor
switch
At run in L
range in 1st
form)
Circuit tester
(+) to B3 pin,
(-) to B5 pin.
ATF thermo
sensor
Standard
Related
Pulse
harness
generated (At
AC range
Turbine
approx. 6.5V) sensor
ATF temp.
20C
Approx. 1.55
V
Related
harness
ATF temp.
60C
Approx. 0.7V
Thermo
sensor
Normally
Less than 2V
Related
harness
B5
BLK
B6
BLU/
BLK
Low & reverse

Output brake duty
solenoid
P, N range.
form)
(+) to B6 pin,
(-) to B22 pin.
Pulse
Related
generated (At harness
AC range
Duty solenoid
approx. 6.2V)
B7
BLK/
YEL
2-4 brake duty

Output
solenoid
P, N range.
form)
(+) to B7 pin,
(-) to B22 pin.
Pulse
Related
AC range
Duty solenoid
approx. 6.2V)
RED
High clutch duty

Output
solenoid
P, N range.
form)
(+) to B8 pin,
(-) to B22 pin.
Pulse
Related
AC range
Duty solenoid
approx. 6.2V)
Low clutch duty

solenoid
4th gear in D
range. Circuit
Voltage (Wave
tester (+) to
form)
B9 pin, (-) to
B22 pin.
Related
Pulse
harness
generated (At
AC range
Duty solenoid
approx. 6.2V)
B8
B9
Ground
WHT/
RED
RED/
B10
N Range Switch
BLK
B11 BLU D Range Switch
Output
Input
Input
Inhibitor switch
Inhibitor switch
Voltage
Voltage
At N range
10 14.5V
Related
harness
At other than
N range
Less than 2V
Inhibitor
switch
At D range
10 14.5V
Related
harness
At other than
D range
Less than 2V
Inhibitor
switch
No.
Wire
Color
Pin Name
B12 YEL Low & Reverse Brake Pressure Switch
Input /
Output
Input
Connected to
Low & reverse

brake pressure
switch
Item
Condition
Voltage
Standard
Inspection
Point at
Trouble
At other than
R range, L
V
harness
range 1st gear
Pressure
At R range, L
Less than 2V
switch
range 1st gear
B13
YEL/
RED
B14
BLU/
ATF Thermo Sensor Ground
BLK
Input
Vehicle speed
sensor
ATF thermo
sensor
B15 BLK Ground
Ground
B16
B17 BLK Lock-up Duty Solenoid
B18 WHT V ign (Ignition Power Supply)
RED/
B19
R Range Switch
YEL
WHT/
B20
BLK
PNK/
B21
L Range Switch
BLK
B22
GRY/
Ground Return
RED
B23 VIO
Output
Input
Input
Input
Input
Lock-up duty
solenoid
Key switch
Inhibitor switch
High clutch
pressure switch
Inhibitor switch
Output Shift solenoid
Line pressure
Output
solenoid
At run in L
range in 1 st
form)
Circuit tester
(+) to B13 pin,
(-) to B5 pin.
Related
Pulse
harness
generated (At
AC range
Vehicle
approx. 6.8V)
speed sensor
Continuity
Normally
Continuity
Related
harness
Voltage
Normally
Less than 2V
Related
harness
Pulse
At lock-up.
generated (At
Related
Circuit tester
AC range
harness
(+) to B17 pin,
approx. 2.2 (-) to B5 pin.
9.0V)
Voltage (Wave
form)
Pulse
At unlock-up.
generated (At
Circuit tester
Duty solenoid
AC range
(+) to B17 pin,
approx. 1.0 (-) to B5 pin.
2.0V)
Voltage
Voltage
Voltage
Voltage
Continuity
Voltage
Related
harness
At key switch
ON
10 14.5V
At key switch
OFF
Less than 2V Fuse
At R range
10 14.5V
Related
harness
At other than
R range
Less than 2V
Inhibitor
switch
At other than
3rd or 4th
gear

V
harness
At 3rd or 4th
gear
Less than 2V
Pressure
switch
At L range
10 14.5V
Related
harness
At other than
L range
Less than 2V
Inhibitor
switch
Normally
Continuity
Related
harness
At N range
10 14.5V
Related
harness
At D range
stall
Less than 2V Solenoid
No.
Wire
Color
Input /
Output
Pin Name
B24 WHT V ign (Ignition Power Supply)
Input
Connected to
Item
Condition
Key switch
Voltage
At key switch
10 14.5V
ON
Inspection
Point at
Trouble
Related
harness
At Key switch
Less than 2V Fuse
OFF
Voltage
7.14ms
Voltage
7.14ms
Standard
Time
Time
0.714ms
6.426ms
Engine Speed Sensor Reference Wave Form
Vehicle Speed Sensor Output Reference Wave Form
0V
0V

B5 (-)
10ms/div
Measurement Condition: At engine speed 2000rpm

B5 (-)
50ms/div
Measurement Condition: Vehicle speed 20km/h at L range
in 1st gear
Turbine Sensor Reference Wave Form
Vehicle Speed Sensor Reference Wave Form
0V

B5 (-)
500micro sec/div
in 1st gear
0V

B5 (-)
5ms/div
in 1st gear

Low & Reverse Brake Duty Solenoid Reference Wave Form
2-4 Brake Duty Solenoid Reference Wave Form
0V
0V

B22 (-)
10ms/div

B22 (-)
10ms/div
High Clutch Duty Solenoid Reference Wave Form
Low Clutch Duty Solenoid Reference Wave Form
0V
0V

B22 (-)
10ms/div

B22 (-)
10ms/div
0V
0V

B5 (-)
5ms/div
Measurement Condition: Unlock-up condition

B5 (-)
5ms/div
Measurement Condition: Lock-up condition
MEMO
ON-VEHICLE SERVICE (JR405E) 7A3-1
SECTION 7A3
ON-VEHICLE SERVICE (JR405E)

TABLE OF CONTENTS
PAGE
Description ...................................................................................................................... 7A3 2
Automatic Transmission Fluid (ATF) ............................................................................. 7A3 2
ATF Level ......................................................................................................................... 7A3 2
ATF Change ..................................................................................................................... 7A3 3
Transmission Control Module (TCM) ............................................................................ 7A3 4
Throttle Position Sensor ................................................................................................ 7A3 5
Inhibitor Switch ............................................................................................................... 7A3 6
Speed Sensor .................................................................................................................. 7A3 8
Turbine Sensor ................................................................................................................ 7A3 9
Power and 3rd Start Switch ........................................................................................... 7A3 9
Select Lever ..................................................................................................................... 7A3 10
Shift Cable ....................................................................................................................... 7A3 13
Solenoids, Oil Pressure Switch and Oil Temperature Sensor .................................... 7A3 16
Control Valve Assembly ................................................................................................. 7A3 18
Flushing the Transmission Fluid Cooler and Line ....................................................... 7A3 19
Transmission Assembly ................................................................................................. 7A3 20
7A3-2 ON-VEHICLE SERVICE (JR405E)
DESCRIPTION
Before performing on-vehicle service on the automatic
transmission, check that the engine idling speed and
general engine condition are normal.
AUTOMATIC TRANSMISSION FLUID (ATF)

Inspect
Remove the transmission dipstick to check the condition
of the ATF.
Clean the dipstick and look for gum or varnish.
Gum or varnish indicate scorching of the clutch band
and other parts.
The transmission control module, the transmission unit,
and the vehicle must be carefully checked if gum or
varnish is present.
ATF LEVEL
Inspect
Hot Level
1. Warm up the engine and the transmission by driving
the vehicle on the road so that the temperature
reaches around 80C (176F).
Do not turn the engine off.
2. Park the vehicle on a level surface.
3. Apply the parking brake firmly.
4. Let the engine run at idle.
Move the select lever slowly through all the gear
ranges.
Stop in each gear range just long enough for the
transmission to engage.
5. Return the select lever to either P or N.
7. Wipe the dipstick clean with a paper towel.

8. Reinsert the dipstick and wait several seconds.
9. Remove the dipstick.
The ATF level should be inside the H range on the
dipstick.
242R300001
If the ATF level is below the H range, ATF must be

added.
C07RW009
6. Remove the ATF level dipstick.
Cold Level
The vehicle must not have been driven so that the
temperature reaches around 20C (68F) before the
cold level check is made.
1. Park the vehicle on a level surface.
2. Apply the parking brake firmly.
3. Start the engine and allow it to warm up.
The engine coolant temperature gauge needle
should be midway between the C mark and H
mark.
4. Let the engine run at idle.
Move the select lever slowly through all the gear
ranges.
Stop in each range just long enough for the
transmission to engage.
5. Return the select lever either P or N.
6. Remove the ATF level dipstick.
7. Wipe the dipstick clean with a paper towel.
8. Reinsert the dipstick and wait several seconds.
9. Remove the dipstick.

The ATF level should be inside the C range on the
dipstick.
If the ATF level is below the C range, ATF must be
added.
242R300002
ATF CHANGE
1. Start the engine and allow it to idle until the ATF
reaches a temperature of 40-50C
2. Park the vehicle on level ground and block the
wheels.
3. Stop the engine.
4. Raise vehicle and support with suitable safety
stands.
5. Remove the drain plug from the oil pan and drain the
ATF (approximately 6 liters).
6. Remove the oil pan.
7. Inspect the oil pan (details written below).
Note:
Use new gasket. Clean the oil pan and magnet.
Oil pan bolt torque : 8 Nm (69 lbin)
9. Replace the gasket and install the drain plug.
Drain plug torque : 35 Nm (26 lbft)
Note:
Do not reuse old washer (gasket).
Clean the drain plug (especially the threaded section).
10. Pour about 5 liters of new ATF. Then, add more ATF
carefully as necessary using the dipstick.
Refer to ATF LEVEL previously in this section.
Note:
Keep the engine idle (do not stop it) during the oil level
adjustment.
11. Remove the safety stands and wheel blocks.
Inspect
1. Check the drain plug tip for adhesion of foreign
substances.
2. Check the drained ATF for color, smell and inclusion
of foreign substances.
3. Check the oil pan bottom and magnet for adhesion of
foreign substances.
If a problem is discovered during those checks, the
Automatic transmission must be overhauled.
Note:
The torque converter and the oil strainer need replaced
with new ones if the drained ATF contains large
amounts of metallic or facing flakes.
In addition, flush the ATF cooler circuit
RTW37ALF001901
Remove and Disconnect
Install or Connect

2. Remove the connectors.
3. Remove the fixing nuts and remove the TCM (1)
from the bracket.
Note:
The TCM is fitted under instrument panel of the drivers
compartment by means of three stud bolts.
Follow the removal steps in the reverse order. Be

absolutely sure that the connectors are securely
fastened.
AT CONT

3. If the reading is beyond the specified value, loosen
the throttle position sensor fixing bolts, and turn it
right or left, so that the specified output voltage be
obtained.
After adjusting, tighten the throttle position sensor
fixing screws (2).
P1010052
The throttle position sensor (1) is fitted on the throttle

valve body.
Adjust
1. Turn the starter switch to the ON position.
2. Measure the voltage between TPS connector
terminals (B) (output) and (A) (ground).
Note:
Do not remove the sensor connector.
Make sure that power source (5.0 0.01 V) is
measured between TPS connector terminals (C) and
(A) before measurement at step 2.
Standard voltage :
Throttle Angle
TPS
Idling (0%)
0.2 - 0.3 V
WOT (100%)
3.4 4.1 V
RTW37ASH0013
826R300013
INHIBITOR SWITCH
The inhibitor switch is attached to the right side of the
transmission.
4. Tighten the 2 inhibitor switch bolts to the specified

touque.
Torque: 5.5 Nm (48 lbin)
Inspect
1.
2.
3.
4.
Block the wheels.

Disconnect the harness connectors.
Use a ohmmeter to check the inhibitor switch
continuity between the following terminals as shown
in figure.
5. Place the select lever in the N range.
47INH-SW01
5. Connect the shift cable to the lever.

249R300001
6. Move the select lever to either side.

Check the inhibitor switch continuity between the
terminals shown in Step (4).
The continuity readings should remain fairly steady
as the select lever is moved.
If there is no continuity or the continuity is
intermittent, the inhibitor switch must be adjusted.
1.
2.
3.
4.
5.
Remove the cable bracket (1) from the transmission.

Disconnect the shift cable (2) from the lever (3).
Disconnect the harness connectors.
Remove the inhibitor switch bolts.
Remove the inhibitor switch (4) from the
transmission.
Adjust
1. Disconnect the shift calbe from the lever.
2. Loosen the inhibitor switch bolts.
3. Use the inhibitor switch set plate to align the neutral
holes (manual shaft and inhibitor switch).
Turn the inhibitor switch to adjust it.
Inibitor switch set plate: 5-8840-2763-0
Note:
Inhibitor switch adjustment is very important.
If the inibitor switch is not correctly adjusted, the
automatic transmission will not function normally.
238R300001
Install or Connect
1. Install the inhibitor switch (4) to the transmission.
Temporarily tighten the inhibitor switch bolts.
2. Move the manual shaft select lever to the N range.
249R300002
3. Use the inhibitor switch set plate to align the neutral

Inhibitor switch set plate: 5-8840-2763-0
Note:
If the inhibitor switch is not correctly adjusted, the
4. Tighten the 2 inhibitor switch bolts to the specified
torque.
Torque: 5.5 Nm (48 lbin)
47INH-SW01
5.
6.
7.
8.
9.
Install the cable bracket (1) to the transmission.

Connect the shift cable (2) to the lever (3).
Connect the harness connector.
Remove the wheel blocks.
SPEED SENSOR
The speed sensor is attached to the right side of the
transmission.
Inspect
1. During the driving at speed of 20km/h (12mph) with
L range in low gear, measure the voltage between
the TCM connector terminals (B13) and (B5) with a
digital voltmeter.
Standard voltage : approx. 7V (AC range)
240L300001
Legend
1. Inhibitor switch
2. Speed sensor
3. Turbine sensor
RTW47ASH000801
2. If the voltage is out of the standard value, check the

speed sensor pole piece for presence of foreign
meterials and the speeed sensor cable for short or
open circuit.
Result of the inspection is normal, replace the speed
sensor.
Torque: 6 Nm (52 lbin)
TURBINE SENSOR
The turbine sensor is attached to the right side of the
transmission.
Inspect
1. During the driving at speed of 20km/h (12mph) with
L range in low gear, measure the voltage between
the TCM connector terminals (B3) and (B5) with a
digital voltmeter.
Standard voltage : approx. 7V (AC range)
2. If the voltage is out of the standard value, check the
turbine sensor pole piece for presence of foreign
materials and the turbine sensor cable for short or
open circuit.
Result of the inspection is normal, replace the
turbine sensor.
Torque: 6 Nm (52 lbin)
POWER AND 3RD START SWITCH

Inspect
1.
2.
3.
4.
5.
Block the wheels.

Pry out the switch from the floor console.
Disconnect the harness connector.
Check continuity between terminal (5) and (6) at third
(3rd) position.
6. Check continuity between terminals (3) and (6) at
power (PWR) position.
7. Replace the power and 3rd start switch when the
result of inspection is found abnormal.
238R300003
SELECT LEVER
RTW37ALF001101
Legend
1.
2.
3.
4.
5
Rear console
Front console
Select lever knob
Upper housing
Lamp assembly
1.
2.
3.
4.
5.
Block the wheels.

Remove the rear console and the front console.
Remove the 2 screws fixing the select lever knob.
Remove the knob together with the knob button and
spring from the lever.
6
7
8
9
10
Base plate
Grooved pin
Spring plate
Lever assembly
Sleeve
6. Turn the sleeve counterclockwise to remove it. Make

a note of the number of turns required to free the
sleeve.
7. Remove the harness connectors from the base plate.
8. Remove the upper housing (held in place by 4
latched fasteners).
9. Remove the spring plate.

10. Remove the grooved pin.
11. Remove the lever assembly by pressing the rod
down (lever in N position).
12. If lamp replacement is required, remove the lamp
assembly from the lamp socket (align the socket
grooved portion and the lamp assembly protruding
portion).
Install or Connect
NOTE
Apply MULTEMP No. 2 grease (or equivalent) to the
select lever. Refer to the illustration.
1. Install the lever assembly to the base plate.

a. Insert and secure shaft.
b. Insert pawled end of shaft into base plate hole.
c. Insert grooved pin of shaft into detente aperture
(lever assembly in N position).
2.Install the spring plate.
a. Insert the grooved pin into the base plate detente
groove until it touches the front wall (lever
assembly in N position).
RTW37ASH001001
b. Stack the short spring plate tighten the screws to

Screw torque
2 Nm (0.2kgm/17 lb ft)
c. Check that the grooved pin moves smoothly in

the detente groove (shift knob temporarily
installed).
3. Temporarily install the sleeve.
4. Install the lamp assembly to the lamp socket (if
removed at disassembly).
a. Align the recessed portion of the lamp socket with
the protruding portion of the lamp assembly.
b. Insert the lamp assembly into the lamp socket
and rotate it 90 degrees clockwise.
RTW37ALH000201
5. Attach the harness connectors to the base plate.

6. Move the lever to the P position.
7. Install the sleeve (rotate the sleeve clockwise the
same
number
of
turns
it
was
rotated
counterclockwise at disassembly).
8. Install the knob, the knob button, and the knob
spring.

9. Adjust the clearance (2) between the detente plate
and the pin by moving the select lever knob sleeve
(1).
Detente plate and pin clearance
mm(in)
0.2 - 1.0 (0.01 - 0.04)
255R300002
10. Install the 2 screws securing the knob and tighten

them to the specified torque.
Screw torque: 2 Nm (0.2kgm/17 lb in)
11. Install the upper housing. Make sure that the 4
latched fasteners are securely closed.
SHIFT CABLE
RTW47ALF000201
Legend
1.
2.
3.
4.
Select lever
Select lever base
Shift cable
Bracket
1.
2.
3.
4.
5.
6.
Block the wheels.

Move the select lever to the N position.
Remove the rear console and front console.
Disconnect the shift cable from the select lever.
Press on the shift cable retaining pawl to remove the
cable from the select lever base.
5.
6.
7.
8.
Adjuster
Manual shaft select lever
Shift cable retaining pawl
Clip
7. Disconnect the shift cable from the transmission

side.
8. Remove the shift cable from the bracket.
9. Pull the shift cable free from the bottom of the
vehicle.
Install or Connect
1. Install the shift cable toward the inside of the cabin
from the bottom of the vehicle.
2. Push the shift cable into the select lever base.
3. Connect the shift cable to the select lever.
4. Fix the shift cable to the bracket.
Install the clip on the marking of shift cable.
5. Check that the select lever is in the N position.
6. Check that the transmission is in the N position.
9. Connect the shift cable to the manual shaft select

lever at the transmission side.
10. Insert the lock piece to the adjuster (cable length
adjustment).
11. Slide the cover on the adjuster and secure lock
piece.
P1010016-2
249R300002
7. Slide the cover in the direction shown by the arrow

(1).
8. Use an ordinary screwdriver to move the lock piece
from the position indicated by the arrow (2). Continue
to move the lock piece until the adjuster position
begins to change.
P1010012
11. Press the select lever knob button 5 times.

Then check that the select lever moves smoothly to
each of its positions.
13. Check that the shift position indicated by the select
lever and the actual shift position are the same.
14. Install the front console and rear console.
E07R300015
SOLENOIDS, OIL PRESSURE SWITCH AND OIL TEMPERATURE

SENSOR
244L300003
Legend
1. High clutch oil pressure switch connector
(wire color: Gray)
2. 2-4 brake oil pressure switch connector
(wire color: Brown)
3. Low and reverse brake oil pressure switch connector
(wire color: White)
4. Low and reverse brake duty solenoid connector
(wire color: Pink and White)
5. High clutch duty solenoid connector
(wire color: Green and Gray)
6. Lock-up duty solenoid connector

(wire color: Yellow and Black)
7. 2-4 brake duty solenoid connector
(wire color: Blue and Brown)
8. Low clutch duty solenoid connector
(wire color: Orange and Black)
9. Line pressure solenoid connector
(wire color: Pink)
Install or connect
1. Block the wheels.

3. Drain the fluid.
Refer to ATF CHANGE in this section.
4. Remove the 19 bolts and oil pan.
5. Inspect the bottom of the oil pan and strainer netting
for foreign material (clutch facing and metal
shavings).
If there is an excessive accumulation of foreign
material, the oil strainer must be replaced.
Further inspection is required to determine the
source of the foreign material.
6. Remove the harness assembly (including oil
temperature sensor).
7. Remove the 11 bolts and the solenoid fixing plate.
8. Remove the 6 solenoids and 3 oil pressure switchs.
1. Install the O-rings to each of the solenoids.

2. Install the 6 solenoids and 3 oil pressure switchs.
Line pressure solenoid bolt torque:
8 Nm (69 lbin)
Oil pressure switch bolt torque:
4.4 Nm (39 lbin)
3. Install the solenoid fixing plate together with the
harness brackets.
Solenoid fixing plate bolt
(A)
(B)
Number
Length (Color)
4
7
16 mm (0.63 in) (Gold)

45 mm (1.77 in) (Silver)
Bolt torque : 8 Nm (69 lbin)

4. Install the harness assembly.
5. If removed, install the oil strainer.
Number
Length (Color)
9
4

Oil strainer bolt
Inspect
Oil pressure switch
2
Apply compressed air (392 kPa/4.0 kg/cm ) to the oil

pressure switch to check the oil pressure switch
continuity between the connector and screw.
(C)
(D)
Oil temperature sensor (harness assembly)
6. Install the new gasket and oil pan.

Check the oil temperature sensor resistance between

harness terminals 7 and 6 (ground).
Oil temperature sensor resistance:
2,400~2,600 ohms (20C)
7. Fill the fluid.

244L300011
Solenoid
Measure the resistance of each solenoid.
Resistance:
Brown connector 3.0~3.4 ohms (20C)
Gray connector 12.0~13.2 ohms (20C)
White connector 12.2~13.4 ohms (20C)
CONTROL VALVE ASSEMBLY
244L300001
3. Drain the fluid.
4. Remove the 19 bolts and oil pan.
5. Inspect the bottom of the oil pan and strainer netting
for foreign material (clutch facing and metal
shavings).
If there is an excessive accumulation of foreign
material, the oil strainer must be replaced.
Further inspection is required to determine the
source of the foreign material.
6. Disconnect the 2 harness connectors leading to the
control valve.
7. Remove the 12 bolts and the control valve assembly.

Number of bolts
Length
10 (A)
2 (B)
40 mm (1.57 in)
30 mm (1.18 in)
Note:
Take care not to disturb the manual valve (inside the
control valve assembly).
Do not allow the pin to fall free (the pin prevents the
valve from turning).
Install or Connect
1. Align the manual valve and the manual plate of the
transmission case.
3. Connect the 2 harness connectors.

4. If removed, install the oil strainer.
Refer to Solenoids, Oil Pressure Switch and Oil
Temperature Sensor previously in this section.
5. Install the new gasket and oil pan.
6. Fill the fluid.
43ASSY119
2. Install the control valve assembly and tighten the 12

Number of bolts
Length
Color
10 (A)
40 mm (1.57 in)
Gold
2 (B)
30 mm (1.18 in)
Gold
FLUSHING THE TRANSMISSION FLUID COOLER AND LINE

The fluid cooler and lines may be flushed under the
following condition. This will help prevent more trouble
after the transmission is repaired.
1. When the abnormal amount of debris are found.
2. When the abnormal wear or chips on gears and
shafts are found while overhauling.
3. When the abnormal clutch facing wear and oil
contamination are found.
Procedures
2. Disconnect negative battery cable.
3. Raise vehicle and support with suitable safety
stands.
4. Disconnect fluid cooler lines at transmission case
and fluid cooler.
5. Flush and back-flush the fluid cooler and lines using
solvent and compressed air.
Note:
DO NOT exceed 197 kPa (29 psi) air pressure or
damage may result to oil cooler.
6. Remove all remaining solvent from the system with

compressed air.
7. Flush the cooling system again with Automatic
Transmission Fluid (ATF).
After the final flush, connect all lines.
Cooler line joint connector torque :
44 Nm (33 lbft)
8. Replenish ATF
9. Start engine to test the system for the free flow of
fluid. If the flow is restricted, the cooler assembly or
lines must be replaced.
Repeated cleaning and flushing may not remove all
debris from the fluid cooler circuit.
Move the select lever through the various ranges and
return to neutral.
Check for fluid level.
If the fluid level is below the specified range, ATF
must be added.
10. Connect negative battery cable.
11. Remove safety stands.
12. Remove wheel blocks.
TRANSMISSION ASSEMBLY
RTW37ALF001401
Legend
1.
2.
3.
4.
5.
6.
Shift Cable
Propeller Shaft
Engine Harness
ATF Level Dipstick
Under Cover
Bolt
3. Raise the vehicle and support with the suitable safety
stands.
7. ATF Pipe
8. Crossmember
9. Bracket
10. Starter Motor
11. Bolt
12. Automatic Transmission

11. Rotate the ring gear and remove the 6 torque
converter bolts.
4. Remove the shift cable from the transmission.
P1010068
5. Remove the rear propeller shaft assembly.

6. Loosen (do not remove) the nuts securing the
exhaust manifold and the exhaust pipe.
7. Disconnect the harness connectors from the
transmission.
8. Remove the fuel pipe bracket.
P1010016
12. Remove the automatic transmission fluid cooling

pipe.
P1010060
P1010013
13. Place a jack beneath the engine to support it.

14. Remove the 3rd crossmember.
15. Remove the transmission mount.
16. Lower the jack beneath the engine slightly to tilt the
engine and transmission. Do not allow the radiator
and air conditioner hoses to stretch.
17. Remove the bolts attaching the transmission to the
engine.
18. Lower the transmission from beneath the vehicle.
Take care not to damage the breathers.
Install or Connect
1. Install the transmission to the engine and tighten the
bolts.
Bolt torque : M10 40 Nm (30 lbft)
M12 76 Nm (56 lbft)
P1010014
9. Remove the ATF level dipstick and tube.

10. Remove the undercover.
2. Install the cable bracket to the transmission.

3. Connect the engine harness connectors.
4. Install the 3rd crossmember.

Bolt and Nut torque : 67 Nm (49 lbft)
Bolt torque : 50 Nm (37 lbft)
10. Tighten the nuts securing the exhaust manifold and

the exhaust pipe.
5. Install the automatic transmission fluid cooling pipe.

6. Install the torque converter bolts.
11. Install the rear propeller shaft assembly.

Flange bolt torque : 63 Nm (46 lbft)
Center bearing bracket bolt torque :
69 Nm (51 lbft)
7. Install the undercover.

8. Install the ATF level dipstick and tube.
9. Install the fuel hose bracket.
12. Install the shift cable.

14. Remove the safety stands.
15. Remove the wheels blocks.
RTW37ALF001501
UNIT REPAIR (JR405E) 7A4-1
SECTION 7A4
UNIT REPAIR (JR405E)

TABLE OF CONTENTS
PAGE
Automatic Transmission Disassembly ..................................................................... 7A4 -
Control Valve Assembly ............................................................................................ 7A4 - 11

Control Valve Upper Body ........................................................................................ 7A4 - 18
Control Valve Lower Body ........................................................................................ 7A4 - 23
Oil Pump Assembly ................................................................................................... 7A4 - 28
Clutch Pack (Reverse and High Clutch Assembly) ................................................. 7A4 - 33
Carrier and Low Clutch Assembly ........................................................................... 7A4 - 41
Transmission Case .................................................................................................... 7A4 - 54
Bearing and Bearing Race Installation Position ..................................................... 7A4 - 66
Automatic Transmission Reassembly ..................................................................... 7A4 - 69
Service Standard ....................................................................................................... 7A4 - 83
Special Service Tool .................................................................................................. 7A4 - 85
7A4-2 UNIT REPAIR (JR405E)
AUTOMATIC TRANSMISSION
DISASSEMBLY
Cleaning the automatic transmission
1. Use compressed steam and /or cleaning oil to thoroughly
clean the outside of the transmission before disassembly.
CAUTION:
Steam under high pressure may cause dirt particles
adhering to the transmission to fly through the air at great
speed. These particles can cause serious eye injury. Wear
protective goggles when steam-cleaning the outside of
the transmission.
2. During disassembly, clean the removed parts with cleaning
oil. Dry the parts with compressed air.
Use Compressed air to clean the transmission oil holes
and oil passages.
Automatic transmission disassembly cautions
Perform the disassembly procedure in a dust-free

environment to prevent the entry of foreign material into
the transmission.
Inspect each transmission part as you remove it.
Carefully check the oil pan and the magnet for foreign
material. This is a good way to estimate transmission
condition.
Use your bare hands or vinyl gloves to disassemble the
transmission. Do not use ordinary work gloves (loose
threads from the gloves may fall into the transmission and
cause problems).
Use a plastic hammer to loosen the transmission case
and other aluminum parts during disassembly. Strike
around the parts lightly with the hammer. Do not pry
aluminum parts away from each other with a screwdriver
or similar object.
Arrange the disassembled parts neatly in the order they
were removed. Cover the parts with a plastic sheet or
similar object to protect them from dust.
Disassembly steps
1. Torque converter
Pull the torque converter free.
NOTE:
Place a pan beneath the torque converter to catch
automatic transmission fluid (ATF) spillage.
Draining the ATF from the torque converter.
2. Turbine sensor and speed sensor
Remove the turbine sensor from the transmission case.
01ASSY101
Remove the speed sensor from the transmission case.
02ASSY103
3. Inhibitor switch
Remove the 2 bolts and the inhibitor switch from the
transmission case.
03ASSY106
240L300002
4. Oil pan
Lift and support the transmission with the holding fixture
and holding fixture base.
Holding fixture: 5-8841-0841-0
Holding fixture base: 5-8840-0003-0
Remove the drain plug from the oil pan and drain the
ATF from the oil pan.
Rotate the automatic transmission so that the converter
housing is facing up and drain the ATF.
Rotate the automatic transmission so that the oil pan is
facing up.
Remove the 19 bolts and the oil pan.

Inspect the bottom of the oil pan and strainer netting for
foreign material (clutch facing and metal shavings).
If there is an excessive accumulation of foreign material,
the oil strainer must be replaced.
Further inspection is required to determine the source of
the foreign material.
04CV37
5. Control valve assembly

Disconnect the 2 harness connectors leading to the
control valve.
45CV29
244L300001
Remove the 12 bolts and the control valve assembly.

Number of bolts
10 (A)
2 (B)
Length
40 mm (1.57 in)
30 mm (1.18 in)
NOTE:
Take care not to disturb the manual valve (inside the
control valve assembly).
Do not allow the pin to fall free (the pin prevents the valve
from turning).
42ASSY118

6. Converter housing
Position the automatic transmission so that
converter housing is facing up.
Remove the 8 bolts and the converter housing.
the
10ASSY116
7. O-ring
Remove the O-ring from the input shaft.
11ASSY068
8. Oil pump assembly and bearing race

Remove the 8 bolts.
Use a slide hammer to remove the oil pump assembly
NOTE:
To prevent damage to the oil pump bolt hole threads,
hand-tighten the slide hammer as far as possible.
Remove the bearing race from the oil pump assembly.
Inspect the bearing race surfaces for damage.
12ASSY067
9. Input shaft
Pull the input shaft free.
14ASSY057
10.Clutch pack (Reverse and high clutch assembly) and

bearing
Pull the clutch pack free.
Remove the bearing from the clutch pack.
15ASSY049

11.High clutch hub, bearing, and bearing race
Remove the clutch hub, bearing (with bearing race),
and the bearing race.
Remove the bearing (with bearing race) and the bearing
race from the high clutch hub.
16ASSY047
12.Front sun gear, bearing, and bearing race

Remove the bearing, the front sun gear, and the bearing
race.
Remove the bearing and the bearing race from the front
sun gear.
17ASSY040
13.2-4 brake retainer

Remove the brake seal ring and the sleeve.
19ASSY113
Attach the spring compressor to the transmission case.

Spring compressor: 5-8840-2764-0
23ASSY030
Force out the 2-4 brake retainer and remove the snap
ring.
NOTE:
Overturning the spring compressor will damage the 2-4
brake retainer.
Remove the spring compressor.
24ASSY029

Remove the 2-4 brake retainer and return spring.
25ASSY019
14.Carrier assembly (Carrier and low clutch assembly),

bearing, bearing race, and 2 4 brake assembly
Pull the carrier assembly, the bearing, the bearing race
and the 2-4 brake assembly (Dish plate, retaining plate,
drive plate, and driven plate) from the transmission case
at the same time.
Remove the bearing, the bearing race, and the 2-4
brake assembly from the carrier assembly.
26ASSY026
Remove the 3 brake springs from the transmission case.
27U-SPG02
15.Low and reverse brake

Pull the low and reverse brake free.
28L&R06
16.Rear extension (2WD) or Adapter case (4WD)

Rotate the transmission case so that the oil pan opening
is facing up.
Remove the 10 bolts and the rear extension (2WD) or
the adapter case (4WD).

17.Output shaft
Pull the output shaft from the transmission case.
29ASSY091
Remove the bearing (with bearing race) from the

transmission case.
30ASSY089
18.Parking pawl, shaft, spring, and spacer

Remove the parking pawl, shaft, spring and spacer from the
transmission case.
31ASSY124
19.Actuator support
Remove the actuator support from the transmission case.
36ASSY075
20.Low one-way clutch inner race and bearing

Loosen the 7 bolts securing the low one-way clutch inner
race.
NOTE:
Loosen the bolts a little at a time as uniformly as possible
to prevent the inner race from tilting and becoming
jammed.
Remove the 6 bolts. Support the low one-way clutch
inner race with your hand and remove the final bolt.
37ASSY074

Remove the bearing and the low one-way clutch inner
race from the transmission case.
Remove the bearing from the low one-way clutch inner
race.
39ASSY006
21.Low and reverse brake return spring

Remove the low and reverse brake return spring from the
transmission case.
40ASSY005
22.Low and reverse brake piston

2
Force compressed air (329kPa/4.0kg/cm ) through the
transmission case oil passages.
41L&R02
Remove the low and reverse brake piston from the

transmission case.
42ASSY004
CONTROL VALVE ASSEMBLY

Disassembly steps
1. Oil strainer
Remove the 13 bolts and the oil strainer from the control
valve assembly.
01CV40
2. Harness assembly
Remove the harness assembly.
02CV26
3. Solenoid fixing plate

4. Harness bracket
Remove the 11 bolts and the solenoid fixing plate
together with the harness bracket.
04CV21
05CV20

5. Solenoid
6. Oil pressure switch
Remove the 6 solenoids together and the 3 oil pressure
switchs.
06CV19
7. Control valve upper body

8. Control valve lower body
9. Separation plate
Remove the 17 bolts securing the control valve upper
body, the control valve lower body, and the separation
plate.
07CV17
Separate the upper body, the lower body, and the

separation plate.
NOTE:
Take care not to drop or lose the parts at the inside of the
control valve.
08CV16
Inspection
Inspect the separation plate for wear and other damage.
Reassembly steps
Coat the parts with ATF before installing them.
3. Separation plate
Assembly the control valve upper body, the lower body, and
the separation plate.
11CV18
244L300002
Number
Control valve rocket 2 (Plus 2 nuts)
bolts and nuts (A)
Length (Color)
50 mm (1.97 in) (Gold)
Upper body and

lower body fixing
bolts
(B)
(C)
13
16 mm (0.63 in) (Gold)
Line pressure
solenoid fixing bolt
(D)
Torque: 8 Nm (69 Ibin)
244L300003
Legend
1. High clutch oil pressure switch connector
(wire color: Gray)
2. 2-4 brake oil pressure switch connector
(wire color: Brown)
3. Low and reverse brake oil pressure
switch connector (wire color: White)
4. Low and reverse brake duty solenoid
connector (wire color: Pink and White)
5. High clutch duty solenoid connector
(wire color: Green and Gray)
6. Lock-up duty solenoid connector (wire

color: Yellow and Black)
7. 2-4 brake duty solenoid connector (wire
color: Blue and Brown)
8. Low clutch duty solenoid connector (wire
color: Orange and Black)
9. Line pressure solenoid connector (wire
color: Pink)
12CV19
13CV20
4. Solenoid
Install the O-rings to each of the solenoids.
Install the 6 solenoids together and the 3 oil pressure
switchs.
NOTE:
Be sure the high clutch oil pressure switch is marked.
Torque:
Oil pressure switch bolts 4.4 Nm (39 Ibin)
Line pressure solenoid bolt (Single gold-colored bolt 16
mm) 8 Nm (69 Ibin)
7. Harness bracket
Install the solenoid fixing plate together with the harness
bracket.
Solenoid fixing plate bolt

(A)
(B)
Number
Length (Color)
4
7
16 mm (0.63 in) (Gold)

14CV21
8. Harness assembly
Install the harness assembly.
15CV26

9. Oil strainer
Install the oil strainer.
Number
Length (Color)
9
4

Oil strainer bolt

(C)
(D)
16CV40
CONTROL VALVE UPPER BODY
09CV02
Legend
1. Manual valve, and pin
2. Retainer plate, spring, and 2-4 brake
accumulator
3. Retainer plate, plug, and low and
reverse brake fail valve B
4. Retainer plate, plug, spring, and reverse
stall valve
5. Retainer plate, spring, and low and
reverse brake solenoid accumulator
6. Retainer plate, spring, and pilot valve
7. Retainer plate, spring, and low clutch
solenoid accumulator
8. Retainer plate, plug, spring, and low
clutch amp valve A
9. Retainer plate, plug, spring, and 2-4

brake fail valve B
10. Retainer plate, sleeve, plug, spring, and
lock-up control valve
brake amp valve
12. Retainer plate, plug, spring, and high
clutch amp valve
13. Retainer plate, spring, and high clutch
15. Spring
16. Steel ball
Disassembly steps
Remove the 11 steel balls and spring from the control
valve upper body.
244L300005
Legend
1. Steel ball: A 10 (Silver)
B 1 (Black)
2. Spring
3. Separation plate
Remove the control valves from the control valve upper
body.
NOTE:
Place the control valve where it will not get mixed up with
the other parts.
Inspection
Valve
Inspect each of the valves for denting and other damage.
Spring
Inspect each of the springs for wear and fatigue.
Valve specifications
244L300006

No.
Valve
nomenclature
Diameter
(mm / in)
Length
(mm / in)
Manual
12.0 /
0.472
82.0 /
3.228
2 4 brake
accumulator
15.0 /
0.591
37.5 /
1.476
Low and reverse

brake fail (B)
10.0 /
0.394
52.0 /
2.047
Reverse stall
8.0 /
0.315
50.0 /
1.969
Low and reverse

brake solenoid
accumulator
14.0 /
0.551
19.5 /
0.768
Pilot
12.0 /
0.472
38.5 /
1.516
Low clutch
solenoid
accumulator
14.0 /
0.551
19.5 /
0.768
Low clutch amp

(A)
12.0 /
0.472
53.5 /
2.106
2 4 brake fail
(B)
10.0 /
0.394
39.0 /
1.535
10
Lock-up control
12.9 /
0.508
57.5 /
2.264
11
2 4 brake amp
12.0 /
0.472
53.5 /
2.106
Configuration
12
High clutch amp
12.0 /
0.472
53.5 /
2.106
13
High clutch
solenoid
accumulator
14.0 /
0.551
19.5 /
0.768
Spring specifications
No.
Valve nomenclature
1
2
3
4
5
Manual
2 4 brake accumulator
Low and reverse brake fail (B)
Reverse stall
Low and reverse solenoid brake
accumulator
Pilot
Low clutch solenoid accumulator
Low clutch amp (A)
2 4 brake fail (B)
Lock-up control
2 4 brake amp
High clutch amp
High clutch solenoid accumulator
6
7
8
9
10
11
12
13
---43.9 / 1.728
22.0 / 0.866
31.5 / 1.240
31.4 / 1.236
Outside
diameter (mm
/ in)
---11.0 / 0.433
7.0 / 0.276
7.0 / 0.276
9.8 / 0.386
Linear
diameter (mm
/ in)
---2.0 / 0.079
0.6 / 0.024
1.0 / 0.039
1.3 / 0.051
32.0 / 1.260
31.4 / 1.236
23.0 / 0.906
24.8 / 0.976
27.0 / 1.063
23.0 / 0.906
23.0 / 0.906
31.4 / 1.236
11.0 / 0.433
9.8 / 0.386
11.0 / 0.433
8.5 / 0.335
14.0 / 0.551
11.0 / 0.433
11.0 / 0.433
9.8 / 0.386
1.3 / 0.051
1.3 / 0.051
0.5 / 0.020
0.9 / 0.035
1.1 / 0.043
0.5 / 0.020
0.5 / 0.020
1.3 / 0.051
Free length
(mm / in)
Number of
coils
---13.1
10.0
12.8
9.3
9.2
9.3
13.2
7.8
5.7
13.2
13.2
9.3
Reassembly steps
Install the control valve to the upper body.
Install the 11 steel balls and spring to the upper body.
CONTROL VALVE LOWER BODY
10CV11
Legend
1. Retainer plate, spring, and steel ball
2. Retainer plate, plug, spring, and
pressure regulator valve
3. Retainer plate, spring, and high clutch
accumulator
4. Retainer plate, plug, low and reverse
brake fail valve A, and spring
5. Retainer plate, plug, spring, and fail
valve
6. Retainer plate, plug, low and reverse
brake amp valve, and spring
8. Oil filter
9. Solenoid
10. Line pressure solenoid
11. Lock-up solenoid
12. Harness bracket

14. Harness assembly
brake fail valve A
16. Retainer plate, plug, spring, and low
clutch amp valve B
17. Retainer plate, spring, and torque
converter relief valve
18. Oil strainer
20. Retainer plate, spring, and 2-4 brake
Disassembly steps
Remove the oil filter from the control valve lower body.
244L300009
Legend
1. Oil filter
2. Separation plate
Remove the control valve from the control valve lower
body.
NOTE:
Place the control valve where it will not get mixed up with
the other parts.
Inspection
Valve
Inspect each of the valves for denting and other damage.
Spring
Inspect each of the springs for wear and fatigue.
Valve specifications
244L300008

No.
14
Valve
nomenclature
Pressure relief
Diameter
(mm / in)
----
Length
(mm / in)
----
15
Pressure
regulator
16.0 /
0.630
89.5 /
3.524
16
Low and reverse

brake fail (A)
10.0 /
0.394
52.0 /
2.047
17
Fail
12.0 /
0.472
53.5 /
2.106
18
Low and reverse

brake amp
12.0 /
0.472
55.5 /
2.185
19
2 4 brake fail
(A)
10.0 /
0.394
65.5 /
2.579
20
Low clutch amp

(B)
12.0 /
0.472
53.0 /
2.087
21
Torque
converter relief
10.0 /
0.394
37.4 /
1.472
22
2 4 brake
solenoid
accumulator
14.0 /
0.551
19.5 /
0.768
23
High clutch
accumulator
10.0 /
0.394
31.0 /
1.220
Configuration
Spring specifications
No.
Free length
(mm / in)
Valve nomenclature
14
15
16
17
18
19
20
21
Pressure relief
Pressure regulator
Low and reverse brake fail (A)
Fail
Low and reverse brake amp
2 4 brake fail (A)
Low clutch amp (B)
22
23
2 4 brake solenoid accumulator

High clutch accumulator
Torque converter relief
49.0 / 1.929
30.5 / 1.201
22.0 / 0.866
23.0 / 0.906
19.5 / 0.768
24.8 / 0.976
26.0 / 1.024
More than 47.2
/ 1.858
31.4 / 1.236
51.0 / 2.008
Outside
diameter (mm
/ in)
7.6 / 0.299
14.0 / 0.551
7.0 / 0.276
11.0 / 0.433
7.9 / 0.311
8.5 / 0.335
11.0 / 0.433
9.2 / 0.362
Linear
diameter (mm
/ in)
1.1 / 0.043
1.4 / 0.055
0.6 / 0.024
0.5 / 0.020
0.5 / 0.020
0.9 / 0.035
0.5 / 0.020
1.6 / 0.063
9.8 / 0.386
6.5 / 0.256
1.3 / 0.051
0.8 / 0.031
Number of
coils
17.3
5.7
10.0
13.2
6.9
7.8
6.9
20.2
9.3
23.5
Oil pressure switch

2
Apply compressed air (392 kPa/4.0 kg/cm ) to the oil pressure

switch to check the oil pressure switch continuity between the
connector and screw.
Oil temperature sensor (harness assembly)

Check the oil temperature sensor resistance between harness
terminals 7 and 6 (ground).
Oil temperature sensor resistance: 2,400
2,600 ohms
(20
)
244L300011
Solenoid
Measure the resistance of each solenoid.
Resistance:
Brown connector 3.0~
~3.4 ohms (20C)
Gray connector 12.0~
~13.2 ohms (20C)
White connector 12.2~
~13.4 ohms (20C)
Reassembly steps
Install the control valve to the control valve lower body.
Install the oil filter to the control valve lower body.
OIL PUMP ASSEMBLY
01PUMP32
Legend
1. Oil seal
2. O-ring (small)
3. Oil pump housing
4. Inner rotor
5. Outer rotor
6. Oil pump cover

7. O-ring (large)
8. Seal ring (large)
9. Seal ring (small)
10. Bearing race
Disassembly steps
1. Oil pump cover
2. Oil pump housing
Loosen the 8 bolts evenly a little at a time.
02PUMP07

Separate the oil pump cover from the oil pump housing
by tapping on each of the bolts with a plastic hammer.
04PUMP10
3. Inner rotor
Remove the inner rotor from the oil pump housing.
06PUMP13
4. Outer rotor
Remove the outer rotor form the oil pump housing.
07PUMP14
5. O-ring (small)
Remove the O-ring (small) from the oil pump housing.
15PUMP18
6. O-ring (large)
Remove the O-ring (large) from the oil pump cover.
08PUMP09

7. Seal ring
Remove the 4 seal rings from the oil pump cover.
09PUMP05
Inspection
11PUMP43
Oil pump cover

Install new seal rings to the oil pump cover.
NOTE:
The seal ring with the large inside diameter fits into the
primary mating surface of the cover.
Measure the gap between the seal ring and the seal ring
groove.
If the measured gap is outside the specified range, the
oil pump cover must be replaced.
Seal ring and seal ring groove gap: 0.10~
~0.25 mm
(0.0039~
~0.0098 in)
Inner rotor
Install the inner rotor to the oil pump housing.
Use a straight edge to measure the side clearance
between the oil pump housing and the inner rotor.
If the measured clearance is outside the specified range,
the inner rotor must be replaced.
Oil pump housing and inner rotor side clearance:
0.02~0.04 mm (0.0008~0.0016 in)
12PUMP45
Outer rotor
Install the outer rotor to the oil pump housing.
Measure the gap between the outer rotor and the
crescent.
If the measured gap is outside the specified range, the
outer rotor must be replaced.
Outer rotor and crescent gap:
0.02~0.15 mm (0.0008~0.0059 in)
13PUMP46
Reassembly steps
1. O-ring (small)
Install new O-ring (small) to the oil pump housing.
15PUMP18
2. Outer rotor
3. Inner rotor
Install the outer rotor and the inner rotor to the oil pump
housing.
16PUMP29
NOTE:
The identification mark on the inner rotor must be facing
the inside of the oil pump housing.
17PUMP42
4. Oil pump cover

5. Oil pump housing
Install the oil pump cover to the oil pump housing.
Tighten the 8 bolts to the specified torque.
18PUMP07
6. O-ring (large)
Install the O-ring (large) to the oil pump cover.
7. Seal ring
Install the 4 seal rings to the oil pump cover.
CLUTCH PACK (REVERSE AND

HIGH CLUTCH ASSEMBLY)
01R&H17
Legend
1. Reverse and high clutch drum
2. Seal ring (reverse clutch)
3. Lip seal (reverse clutch)
4. Reverse clutch piston
5. Seal ring (small, high clutch)
6. Seal ring (large, high clutch)
7. High clutch piston
8. Return spring
9. High clutch cover
10. Snap ring
11. Dish plate (high clutch)

12. Driven plates (5, high clutch)
13. Drive plates (5, high clutch)
14. Retaining plate (high clutch)
15. Snap ring (high clutch)
16. Dish plate (reverse clutch)
17. Driven plates (2, reverse clutch)
18. Drive plates (2, reverse clutch)
19. Retaining plate (reverse clutch)
20. Snap ring (reverse clutch)
Disassembly steps
1. Snap ring
Remove the reverse clutch snap ring.
02R&H18

2. Retaining plate, drive plate, driven plate and dish plate
Remove the reverse clutch retaining plate, the 2 drive
plates, the 2 driven plates, and the dish plate.
03R&H21
3. Snap ring
Remove the high clutch snap ring.
04R&H22
4. Retaining plate, drive plate, driven plate and dish plate

Remove the high clutch retaining plate, the 5 drive plates,
the 5 driven plates, and the dish plate.
05R&H25
07R&H28
5. Snap ring
7. Return spring
Install the spring compressor to the reverse and high
clutch drum.
Carefully press the high clutch cover down .
Take care not to damage the return spring.
Remove the high clutch cover and the return spring.

Install the reverse and high clutch drum to the oil pump.
Force compressed air into the oil pump oil channels.
Remove the high clutch piston and the reverse clutch
piston.
08R&H36
09R&H37
10.Seal ring (high clutch)

Remove the 2 seal rings from the high clutch piston.
12R&H39
11.Seal ring (reverse clutch)

Remove the 2 seal rings from the reverse clutch piston.
13R&H38
Inspection
Drive plate
Measure the drive plate facing thickness at 3 points.
Calculate the average value.
If the average value is less than the specified limit, the
drive plate must be replaced.
Drive plate facing thickness:
Standard 2.0 mm (0.079 in)
Limit 1.8 mm (0.071 in)

Return spring
Check the number of effective return spring coils.
If the number is less than the specified minimum, the
return spring must be replaced.
Effective return spring coils (standard): 10.2
Measure the return spring outside diameter, free length,
and linear diameter.
If any of the measured values exceed the specified limit,
the return spring must be replaced.
Return spring measurements (standard):
Outside diameter 8.0 mm (0.315 in)
Free length 27.1 mm (1.067 in)
Linear diameter 1.1 mm (0.043 in)
Reverse clutch piston
2
Apply compressed air (392 kPa/4.0 kg/cm ) to the
reverse clutch piston from the outside to the inside.
The flow of air should be blocked.
10R&H40
Apply compressed air (392 kPa/4.0 kg/cm ) to the

reverse clutch piston from inside to the outside.
The flow of air should be unrestricted.
11R&H44
Reassembly steps
1. Seal ring (high clutch)
Install new seal rings to the high clutch piston.
12R&H39

2. Seal ring (reverse clutch)
Install new seal rings to the reverse clutch piston.
13R&H38
As shown in a figure, oil seal lip is attached.
RTW47ASH000601

Install the reverse clutch piston to the reverse and high
clutch drum.
14R&H32

Install the high clutch piston to the reverse clutch piston.
15R&H31
5. Return spring
Install the return spring to the high clutch piston.
16R&H33

Carefully center the high clutch cover and install it.
NOTE:
If the clutch cover is not centered, the cover outside seal
gum will be forced into the piston area where it will be
damaged.
17R&H30
18R&H27
7. Snap ring
Install the spring compressor to the reverse and high
clutch drum.
Use the spring compressor to carefully force the high
clutch cover down.
NOTE:
To avoid damage to return springs, use only as much
force as is required to press the high clutch cover into
place.
Install the new snap ring to the reverse and high clutch
drum.
19R&H28
8. Dish plate, drive plates, driven plates, and retaining

plate
Install the high clutch dish plate (1), the 5 driven plates (2),
the 5 drive plates (3), and retaining plate (4).
20R&H25
9. Snap ring
NOTE:
It is careful in the attachment direction of dish plate (1).
RTW47ASH000501

10.Dish plate, drive plates, driven plates, and retaining
plate
Install the reverse clutch dish plate (1) the 2 driven plates
(2), the 2 drive plates (3), and retaining plate (4).
21R&H21
11.Snap ring
NOTE:
If is careful in the attachment direction of dish plate (1).
248L300003
Install the reverse and high clutch drum to the oil pump
assembly.
2
Force compressed air (392 kPa/4.0 kg/cm ) through the
oil pump oil passages to check high clutch operation.
If the clutch does not operate, the seal ring may be
damaged or the parts may have been installed in the
wrong order.
22R&H35
23CLEAR02
Measure the clearance between the high clutch retaining

plate and the snap ring.
If the clearance is outside the specified range, replace
the existing retaining plate with a new plate of the proper
size (thickness).
High clutch retaining plate and snap ring clearance
(A): 1.2~1.6 mm (0.047~0.063 in)
Available high clutch retaining plate thicknesses
4.6 mm (0.181 in)
4.8 mm (0.189 in)

5.0 mm (0.197 in)
5.2 mm (0.205 in)
5.4 mm (0.213 in)
248L300004

oil pump oil passages to check reverse clutch operation.
If the clutch does not operate, the seal ring may be
wrong order.
24R&H34
25CLEAR04
Measure the clearance between the reverse clutch

retaining plate and the snap ring.
size (thickness).
Reverse clutch retaining plate and snap ring
clearance (B):
0.6~0.9 mm (0.024~0.035 in)
Available reverse clutch retaining plate thicknesses
4.8 mm (0.189 in)
5.0 mm (0.197 in)
5.2 mm (0.205 in)
5.4 mm (0.213 in)
CARRIER AND LOW CLUTCH

ASSEMBLY
01C&L12
Legend
1. Snap ring
2. Front carrier
3. Bearing (with bearing race)
4. Rear sun gear
5. Bearing
6. Rear carrier
7. Bearing race
8. Bearing
9. Rear internal gear
10. Bearing race
11. Snap ring
12. Retaining plate
13. Drive plates (7, low clutch)
14. Driven plates (6, low clutch)
15. Driven plate (1, 2 mm thick, low clutch)

16. Dish plate
17. Snap ring
18. Cancel cover
19. Return spring
20. Low clutch piston
21. Seal ring (small)
22. Seal ring (large)
23. Low clutch drum
24. Bearing
25. Snap ring
26. Low one-way clutch
27. Side plate
28. Snap ring
Disassembly steps
1. Snap ring
Remove the snap ring from the low clutch drum.
02C&L-SUB03
2. Front carrier
Remove the front carrier from the low clutch assembly.
03C&L-SUB05
04C&L-SUB06
05C&L-SUB07

4. Rear sun gear
5. Bearing
6. Rear carrier
7. Bearing race
8. Bearing
9. Rear internal gear
10.Bearing race
Remove the bearing (with bearing race), the rear sun gear,
the bearing, the rear carrier, the bearing race, the bearing,
and rear internal gear.
06C&L-SUB08
07C&L-SUB09
08C&L-SUB10
09C&L-SUB11
Remove the bearing race from the rear internal gear.
10C&L-SUB12

11.Snap ring
Remove the low clutch snap ring.
11C&L-SUB13
12.Retaining plate, drive plate, driven plate, and dish plate

Remove the low clutch retaining plate, the 7 drive plates,
the 7 driven plates, and the dish plate.
12C&L-SUB15
13.Snap ring
Install the spring compressor to the low clutch drum.
Carefully press the cancel cover down.
Take care not to damage the return spring.
13C&L-SUB18
14C&L-SUB19
14.Cancel cover
Remove the cancel cover.
31C&L-SUB20

15.Return spring
Remove the return spring.
30C&L-SUB21
16.Low clutch piston

Insert the low one-way clutch inner race to the low clutch
drum.
Force compressed air through the oil passages of the
low one-way clutch inner race to remove the low clutch
piston.
15C&L-SUB38
29C&L-SUB22
17.Snap ring
Raise the low one-way clutch side.
Remove the low one-way clutch snap ring.
16C&L-SUB25
18.Side plate
Remove the side plate.
17C&L-SUB27

19.Low one-way clutch
Remove the low one-way clutch.
18C&L-SUB28
20.Snap ring
Remove the snap ring from the low clutch drum.
19C&L-SUB29
21.Bearing
Remove the bearing.
20C&L-SUB31
Inspection
Drive plate
Measure the drive plate facing thickness at 3 points.
Calculate the average value.
If the average value is less than the specified limit, the
drive plate must be replaced.
Drive plate facing thickness:
Standard 2.0 mm (0.079 in)
Limit 1.8 mm (0.071 in)
Return spring
Check the number of effective return spring coils.
If the number is less than the specified minimum, the
return spring must be replaced.
Measure the return spring outside diameter, free length,
and linear diameter.
the return spring must be replaced.
Return spring measurements (standard):
Outside diameter 9.7 mm (0.382 in)

Free length 36.4 mm (1.433 in)
Linear diameter 1.2 mm (0.047 in)
Reassembly steps
1. Bearing
Install the bearing into the low clutch drum.
21C&L-SUB31
2. Snap ring
Install the snap ring to the low clutch drum.
22C&L-SUB30
3. Low one-way clutch

Install the low one-way clutch to the low clutch drum.
23C&L-SUB28
NOTE:
The flanged side of the low one-way clutch must face the
outside.
24C&L-SUB33

4. Side plate
Install the side plate.
25C&L-SUB27
5. Snap ring
26C&L-SUB26
27C&L-SUB58
Attach the low one-way clutch inner race to the low

clutch drum in the opposite direction of normal position.
Rotate the one-way clutch inner race clockwise. It
should turn smoothly with little resistance.
Rotate the low one-way clutch inner race
counterclockwise.
It should immediately lock (rotation is impossible).
If it does not, check the low one-way clutch installation
direction.
Inspect and replace the low one-way clutch if required.
Remove the low one-way clutch inner race.
Reverse the low clutch drum.
6. Low clutch piston
Install new seal rings to the low clutch piston.
28C&L-SUB32

Install the low clutch piston to the low clutch drum.
29C&L-SUB22
7. Return spring
Install the return spring to the low clutch piston.
30C&L-SUB21
8. Cancel cover
Carefully center the cancel cover and install it.
NOTE:
If the cancel cover is not centered, the cover outside seal
ring gum will be forced into the low clutch piston area
where it will be damaged.
31C&L-SUB20
Install the spring compressor to the low clutch.

32C&L-SUB18
9. Snap ring
Use the spring compressor to carefully force the cancel
cover down.
NOTE:
To avoid damage to the return spring, use only as much
force as is required to press the cancel cover into place.
Install new snap ring to the low clutch drum.
33C&L-SUB19

10.Dish plate, drive plate, driven plate, and retaining plate
Install the low clutch dish plate (1), the 2 mm thick driven
plate (2), the 7 drive plate (3), the other 6 driven plates (4),
and the retaining plate (5).
NOTE:
Dish plate side with the identification mark must face the
driven plate.
34C&L-SUB15
11.Snap ring
NOTE:
It is careful in the attachment direction of dish plate.
248L300006
Inspection
35C&L-SUB38
36CLEAR06
Insert the low one-way clutch inner race to the low clutch
drum.
2
oil passages of the low one-way clutch inner race to
check low clutch operation.
If the low clutch does not operate, the seal rings may be
wrong order.
Measure the clearance between the low clutch retaining
plate and the snap ring.
the existing plate with a new plate of the proper size
(thickness).
Low clutch retaining plate and snap ring clearance:
0.9~1.3 mm (0.035~0.051 in)
Available low clutch retaining plate thicknesses
3.8 mm (0.150 in)
4.0 mm (0.157 in)

4.2 mm (0.165 in)
4.4 mm (0.173 in)
4.6 mm (0.181 in)
4.8 mm (0.189 in)
248L300007
12.Bearing race
13.Rear internal gear
14.Bearing
Install the bearing race and the bearing to the rear internal
gear.
NOTE:
Apply Vaseline to the fitting surfaces of the rear internal
gear to prevent the bearing race and the bearing from
falling during the installation process.
37C&L-SUB40
38C&L-SUB43
Install the rear internal gear to the low clutch drum.
39C&L-SUB60

15.Bearing race
16.Rear carrier
17.Bearing
Install the bearing race and the bearing to the rear carrier.
NOTE:
Apply Vaseline to the fitting surfaces of the rear carrier to
prevent the bearing race and the bearing from falling
during the installation process.
40C&L-SUB46
41C&L-SUB49
Install the rear carrier to the low clutch drum.
42C&L-SUB61
18.Rear sun gear

Install the rear sun gear to the low clutch drum.
43C&L-SUB07
19.Bearing (with bearing race)

20.Front carrier
Install the bearing (with bearing race) to the front carrier.
NOTE:
Apply Vaseline to the fitting surfaces of the front carrier to
prevent the bearing from falling during the installation
process.
44C&L-SUB52

21.Snap ring
Install the front carrier to the low clutch drum.
45C&L-SUB04
TRANSMISSION CASE
02CASE-BK06
Legend
1. Transmission case
2. Spring pin (slender)
3. Spring pin (fat)
4. Manual plate
5. Detent spring
6. Parking rod
7. Manual shaft
8. Oil seal
9. Inhibitor switch
01L&R-CS05
Legend
1. Seal ring
2. Low one-way clutch inner race
3. Return spring
4. Low and reverse brake piston
5. Seal ring
6. Lip seal
8. Snap ring
9. Retaining plate
10. Driven plate
11. Drive plate
12. Dish plate
Disassembly steps
1. Harness assembly
Remove the fixing bolt and the harness assembly.
04CASE-AY52

2. Parking rod
Use a pin punch to force out the parking rod spring pin.
05CASE-AY30
Rotate the manual plate as you pull the parking rod free.
06CASE-AY37
3. Detent spring
Remove the fixing bolt and the detent spring.
08CASE-AY45
4. Manual shaft and manual plate

Remove the manual shaft spring pin.
09CASE-AY28
Remove the manual shaft together with the manual

plate.
10CASE-AY21

5. Oil seal
Using a screwdriver, remove the oil seal from the
transmission case.
11CASE-AY01
Inspection
2 4 brake drive plate
Measure the 2-4 brake drive plate facing thickness at 3
points and calculate the average value.
If the average value is less than the specified limit, the 2-4
brake drive plate must be replaced.
2 4 brake drive plate facing thickness:
Standard = 2.0 mm (0.079 in)
Limit = 1.8 mm (0.071 in)
Low and reverse brake drive plate
Measure the low and reverse brake drive plate facing
thickness at 3 points and calculate the average value.
If the average value is less than the specified limit, the low
and reverse drive plate must be replaced.
Low and reverse brake drive plate facing thickness:
Standard = 2.0 mm (0.079 in)
Limit = 1.8 mm (0.071 in)
2 4 brake return spring
Check the number of effective 2-4 brake return spring
coils.
Effective return spring coils (Standard): 10.2
Measure the 2-4 brake return spring outside diameter,
free length, and linear diameter.
the 2-4 brake return spring must be replaced.
2 4 brake return spring measurements (Standard):
Outside diameter = 6.9 mm (0.272 in)
Free length = 22.5 mm (0.886 in)
Linear diameter = 1.1 mm (0.043 in)
Low and reverse brake return spring
Check the number of effective low and reverse brake
return spring coils.
Measure the low and reverse brake return spring outside
diameter, free length, and linear diameter.
the low and reverse return spring must be replaced.
Low and reverse brake return spring measurements
(Standard):
Outside diameter = 11.2 mm (0.441 in)

Free length = 22.3 mm (0.878 in)
Linear diameter = 1.1 mm (0.043 in)
Reassembly steps
1. Oil seal, manual shaft, and manual plate
Use the oil seal installer to force the manual plate oil
seal into place.
Oil seal installer: 5-8840-2758-0
12CASE-AY06
Install the manual shaft together with the manual plate.
14CASE-AY21
Drive the spring pin into the transmission case.
15CASE-AY26
2. Parking rod
Rotate the manual plate while installing the parking rod.
16CASE-AY37

Use a pin punch to drive the manual plate spring pin into
place.
18CASE-AY43
3. Detent spring
Install the detent spring and tighten the fixing bolt to the
specified torque.
21CASE-AY48
4. Harness assembly
Apply automatic transmission fluid to the new O-ring and
install them to the harness assembly.
Install the harness assembly to the transmission case.
Tighten the fixing bolt to the specified torque.
23CASE-AY53

Install new seal rings to the low one-way clutch inner
race.
24ASSY003
Measure the gap between the seal ring and the ring
groove.
If the measured valve is outside the specified range the
low one-way clutch inner race must be replaced.
Sealing ring and ring groove gap:
0.10~0.25 mm (0.0004~0.001 in)
25ASSY126

6. Low and reverse brake piston
Install new seal rings to the low and reverse piston.
26L&R01
As shown in a figure, sealing lip is attached.
RTW47ASH000701
Install the low and reverse brake piston to the

transmission case.
27ASSY004
7. Return spring
Install the return spring to the low and reverse brake
piston.
28ASSY005

Install the low one-way clutch inner race to the
transmission case.
Temporarity tighten the 7 fixing bolts.
29ASSY006

Tighten each of the bolts a little at a time to the specified
torque.
Be sure that the return spring and the low one-way
clutch inner race installation position does not change as
you tighten the bolts.
Torque: 24 Nm (17 Ibft)
31ASSY074
9. Dish plate, driven plate, drive plate, and retaining plate

(low and reverse brake)
Install the dish plate (1) followed by the 6 driven plates
(2) and drive plates (3) sets.
32ASSY007
33ASSY008
34ASSY009
Install the N-type spring.
35N-SPG02
RTW37AMF0001-X
Install the retaining plate (4).
36ASSY10
37ASSY011

oil passages of the transmission case to check low and
reverse brake operation.
If the low and reverse brake does not operate, check the
seal rings for damage and replace if necessary. Also
check that no parts have been installed out of place.
38L&R03
39L&R04
Measure the clearance between the low and reverse

retaining plate and the snap ring.
If the clearance is out side the specified range, replace
size (thickness).
Low and reverse retaining and snap ring clearance:
0.7~1.1 mm (0.028~0.043 in)
Available low and reverse brake retaining plate
thickensses
5.2 mm (0.205 in)
5.4 mm (0.213 in)
5.6 mm (0.220 in)
5.8 mm (0.228 in)
6.0 mm (0.236 in)
249L300003
10.Dish plate, drive plate, driven plate, and retaining plate

(2-4 brake)
NOTE:
It is careful in the attachment direction of dish plate (1).
If 2-4 brake clearance measurement is required, it must be
done now.
Brake clearance cannot be measured after the carrier
assembly has been installed.
Install the 2-4 brake dish plate to the transmission case
(plate contact surface).
402-4B08

Install the drive plate, driven plate, and the retaining
plate.
412-4B09
422-4B10
432-4B11
11.2 4 brake piston and 2 4 brake retainer

Install new seal ring to the 2-4 brake piston.
Install the 2-4 brake piston to the 2-4 brake retainer.
442-4B12
Install the 2-4 brake piston and the 2-4 brake retainer to
the transmission case.
Pay close attention to the retainer projection from the
case groove.
452-4B15

Install the spring compressor to the transmission case.
NOTE:
Be sure that the spring compressor is perfectly centered
(an off-center special tool will damage the return spring).
Use the spring compressor to force the 2-4 brake
retainer.
472-4B17
NOTE:
To avoid damaging the return spring, apply as little force
as possible to the 2-4 brake retainer.
482-4B18

oil passages of the transmission case to operate and
break-in the 2-4 brake.
492-4B22
502-4B19
Measure the clearance between the 2-4 brake retainer

and the retaining plate.
the existing brake retainer with a new one of the proper
size (thickness).
2 4 brake retainer and retaining plate clearance:
1.0~1.4 mm (0.039~0.055 in)
Available 2-4 brake retaining plate thicknesses
5.4 mm (0.213 in)
5.6 mm (0.220 in)
5.8 mm (0.228 in)
6.0 mm (0.236 in)
6.2 mm (0.244 in)
6.4 mm (0.252 in)
Use the spring compressor to release the 2-4 brake.
RTW47ASH000401
BEARING AND BEARING RACE

INSTALLATION POSITION
A07L300001

1. Bearing and bearing race
Bearing
Bearing race
Outside diameter
46 mm (1.811 in)
45 mm (1.772 in)
01BRG16

Outside diameter
Bearing
46 mm (1.811 in)
Bearing race (black color) installation direction Facing the
front of the transmission.
02BRG02

Bearing
Bearing race
Outside diameter
65 mm (2.559 in)
64 mm (2.520 in)
03BRG04

Bearing
Bearing race
Outside diameter
73 mm (2.874 in)
72 mm (2.835 in)
04BRG05

Outside diameter
Bearing
53 mm (2.087 in)
05BRG06

6. Bearing
Bearing
Outside diameter
53 mm (2.087 in)
06BRG07

Bearing
Bearing race
Outside diameter
78 mm (3.071 in)
76 mm (2.992 in)
07BRG08

Bearing
Bearing race
Outside diameter
53.4 mm (2.102 in)
51 mm (2.008 in)
08BRG09

Outside diameter
Bearing
64 mm (2.520 in)
rear of the transmission.
09BRG18
10.Bearing (with bearing race)

Outside diameter
Bearing
64 mm (2.520 in)
10BRG17
AUTOMATIC TRANSMISSION
REASSEMBLY
Assembly cautions
Use your bare hands or vinyl gloves to reassemble the

transmission. Do not use ordinary work gloves (loosen
threads from the gloves may fall into the transmission
and cause problems).
Before installing the drive plates, immerse them in the
recommended automatic transmission fluid (BESCO
ATF II or ATF III). If the drive plate is new, it must be
immersed for at least two hours to ensure oil penetration
and saturation of the facing.
Apply ATF to all sliding and contact surfaces before
assembly. Also apply ATF to seal rings and O-rings.
Assemble the parts carefully to avoid damaging them.
Replace any snap ring that appears worn, bent out of
shape, or otherwise damaged.
If any part contacting the transmission case is damaged,
it must be replaced with a new part.
Be careful not to damage the plates during reassembly
(oil leakage from the plate will result).
If you are reusing a seal, remove the old adhesive agent
and clean the surface with cleaning oil before applying
the new adhesive agent.
Wait at least two hours after installing the oil seals
before installing the plates.
Do not replace O-rings, snap rings, bearings, and/or
bearing races with inferior substitutes.
Power train
01HUB-H04
Legend
1. O-ring
2. Input shaft
3. Bearing
4. Reverse and high clutch assembly
5. Bearing
6. High clutch hub
7. Bearing race
8. Bearing
9. Front sun gear
10. Bearing race
11. Bearing
12. Carrier and low clutch assembly
13. Bearing
Reassembly steps
Rotate the transmission case so that the converter housing
installation surfaces are facing up.
2. Bearing
Install the bearing to the low and one-way clutch inner race.
Refer to the item Transmission Case for more detailed
information.
NOTE:
Apply Vaseline to the bearing to prevent them from failing
during the installation procedure.
02ASSY012

3. Carrier and low clutch assembly
Install the carrier and low clutch assembly to the
transmission case.
NOTE:
Do not allow the low clutch drum end to protrude beyond
the 2-4 brake plate contact surface (transmission case).
03ASSY013
4. Bearing
Install the bearing to the carrier and low clutch assembly.
04ASSY014
5. Driven plate, drive plate, retaining plate, and dish plate

(2 4 brake)
Install the 2-4 brake 5 driven plate (1), 5 drive plates (2),
retaining plate (3), and dish plate (4) in that order.
NOTE:
The thickest driven plate (5.6 mm) must be installed
at the bottom (transmission case plate surface).
Dish plate side with the identification mark must
face the retaining plate.
05ASSY015
06ASSY016
07ASSY017
08ASSY018
RTW47ASH000401
6. 2 4 brake spring
Install the 2-4 brake springs (3) to the transmission case.
09U-SPG2
248L300009

7. Return spring and 2 4 brake retainer
Align the transmission case groove and the 2-4 brake
retainer projection.
Install the return spring and the 2-4 brake retainer.
10ASSY019
11ASSY028
Install the spring compressor to the transmission case.

NOTE:
Carefully center the spring compressor to prevent damage
to the return spring.
Push the 2-4 brake retainer into place.
NOTE:
Do not push the brake retainer too far.
Damage to the return spring will result.
12ASSY029
14ASSY031
8. Sleeve and seal ring

Install the new sleeve and seal ring to the transmission
case.
17ASSY113

2

transmission case oil passage to 2-4 brake operation.
If the 2-4 brake does not operate, the seal ring may be
wrong order.
192-4B22
9. Bearing race, front sun gear, and bearing

Install the bearing race to the front sun gear.
NOTE:
Apply Vaseline to the bearing race and bearing to prevent
them from falling during the installation procedure.
20ASSY037
Install the front sun gear to the transmission case.
21ASSY040
Install the bearing to the front sun gear.
22ASSY042
10.High clutch hub and bearing race

Install the bearing race to the high clutch hub.
NOTE:
Apply Vaseline to the bearing race.
23ASSY045

Install the high clutch hub and the bearing race to the
transmission case.
24ASSY047
11.Clutch pack (reverse and high clutch assembly)

Install the bearing (with bearing race) to the clutch pack.
NOTE:
The black side (bearing race) of the bearing must
contact the clutch pack.
Apply Vaseline to the bearing.
25R&H42
Install the clutch pack and bearing to the transmission

case.
26ASSY049
Install the bearing to the clutch pack.

NOTE:
27ASSY051
Total end play measurement

Install the bearing race (oil pump) to the clutch pack.
Measure the distance (A) between the oil pump
installation surface and the bearing race.
RTW47ASH000101
RTW47ASH000201
Measure the distance (B) between the bearing race

installation surface and the machined surface.
Calculate the total end play using the following formula.
Total end play = distance (A) distance (B)
If the measured and calculated end play is outside the
specified range, replace the existing bearing race with a
bearing race of the proper size (thickness).
Total end play = 0.25~0.55 mm (0.0098~0.0217 in)
Available oil pump bearing race thicknesses
1.4 mm (0.055 in)
1.6 mm (0.063 in)
1.8 mm (0.071 in)
2.0 mm (0.079 in)
2.2 mm (0.087 in)
2.4 mm (0.094 in)
RTW47ASH000201
12.Input shaft
Install the input shaft.
28ASSY058
13.Oil pump assembly

Install a new O-ring to the outside of the oil pump.
Install the bearing race to the oil pump.
NOTE:
Apply Vaseline to the bearing race.
29PUMP02

Apply ATF to the O-ring at the outside of the oil pump.
Install the oil pump assembly to the transmission case.
Apply sealing agent (TB1215) to the threaded surfaces
of the 8 fixing bolts and tighten to the specified torque.
30ASSY067
14.O-ring
Install a new O-ring to the input shaft.
31ASSY068
15.Converter housing
Install the converter housing and tighten the bolts to the
specified torque.
32ASSY116
16.Actuator support
Install the actuator support.
33ASSY075
17.Parking pawl, shaft, spring, and spacer

Install the parking pawl, the shaft, the spring, and the
spacer.
34ASSY077
35ASSY082
36ASSY084
37ASSY086
38OUTPUT25
29ASSY089
18.Output shaft
Install a new seal ring to the output shaft assembly.
Measure the gap between the seal ring and the ring
groove.
If the gap is outside the specified range, the output shaft
must be replaced.
Seal ring and ring groove gap:
0.10~0.25 mm (0.0039~0.0098 in)
Install the bearing to the case.
NOTE:
Apply Vaseline to the bearing (with bearing race).
The black side (bearing race) of the bearing must be
visible.

Push the output shaft into place.
40ASSY091
19.Rear extension (2WD) or adapter case (4WD)

Use the oil seal installer to install the oil seal to the rear
extension (2WD) or adapter case (4WD).
Oil seal installer:
5-8840-2769-0 (2WD)
5-8840-2770-0 (4WD)
Install the bearing (with bearing race) to the rear
extension (2WD) or adapter case (4WD).
NOTE:
The black side (bearing race) of the bearing must be
visible.
41ASSY096
Apply sealing agent (TB1216B) to the rear extension

(2WD) or adapter case (4WD) contact surfaces.
249L300005
Install the rear extension (2WD) or adapter case (4WD)

to the transmission case and tighten the 10 bolts to the
specified torque.
249L300006

20.Control valve assembly
Align the manual valve and the manual plate of the
transmission case.
43ASSY119
Install the control valve assembly and tighten the 12

Number of bolts
Length
Color
10 (A)
40 mm (1.57 in)
Gold
2 (B)
30 mm (1.18 in)
Gold
44ASSY121
Connect the harness assembly and control valve

assembly connectors.
45CV29
244L300001
47INH-SW01
21.Oil pan
Install a new gasket and the oil pan.
22.Inhibitor switch
Secure the inhibitor switch (1) by hand-tightening the 2
bolts.
Use the inhibitor switch set plate to align the neutral
Inhibitor switch set plate: 5-8840-2763-0
NOTE:
If the inhibitor switch is not correctly adjusted, the
Tighten the 2 inhibitor switch bolts to the specified
torque.
RTW47ASH001001
RTW47ASH000901
Torque: 5.5 Nm (48 Ibin)

Remove the holding fixture from the transmission case.
23.Speed sensor and turbine sensor
Apply ATF to the new O-rings and install them the speed
sensor (2) and the turbine sensor (3).
Install the speed sensor and the turbine sensor. Tighten
the bolt to the specified torque.
24.Torque converter
Pour the new ATF into the torque converter.
Shake the torque converter to thoroughly clean the
inside.
Drain the ATF from the torque converter.
Pour the new ATF into the torque converter.
NOTE:
If significant amounts of foreign material (clutch facing,
metallic fragments, etc.) are found in the automatic
transmission at time of disassembly, the existing torque
converter must be replaced with a new one.
Install the torque converter.
Measure the torque converter end play (A).
If the measured value is greater than the specified
minimum, the torque converter is correctly installed.
Torque converter end pay (Minimum): 67 mm (2.64
in)
SERVICE STANDARD
ATF
Oil pump
Low clutch
Name
Quantity
Seal ring clearance
Housing and inner rotor side clearance
Outer rotor and crescent clearance
Number of drive plate / driven plate
Drive plate facing thickness Standard
Limit
Retaining plate and snap ring clearance
Available low clutch retaining plate thickness
Return spring
High clutch
Number of coil
Outside diameter
Free length
Linear diameter
Limit
Available high clutch retaining plate thickness
Return spring
Reverse clutch
Low one-way
clutch
Low & reverse
brake
Number of coil
Outside diameter
Free length
Linear diameter
Limit
Available reverse clutch retaining plate thickness
Seal ring clearance

Limit
Available low & reverse brake retaining plate
thickness
BESCO ATF II or ATF III

L
9.2 9.6
mm (in) 0.10 0.25 (0.0039 0.0098)
mm (in) 0.02 0.04 (0.0008 0.0016)
mm (in) 0.02 0.15 (0.0008 0.0059)
7/7
mm (in)
2.0
(0.079)
mm (in)
1.8
(0.071)
mm (in)
0.9 1.3
(0.035 0.051)
mm (in)
3.8
(0.150)
4.0
(0.157)
4.2
(0.165)
4.4
(0.173)
4.6
(0.181)
4.8
(0.189)
9.9
mm (in)
9.7
(0.382)
mm (in)
36.4
(1.433)
mm (in)
1.2
(0.047)
5/5
mm (in)
2.0
(0.079)
mm (in)
1.8
(0.071)
mm (in)
1.2 1.6
(0.047 0.063)
mm (in)
4.6
(0.181)
4.8
(0.189)
5.0
(0.197)
5.2
(0.205)
5.4
(0.213)
10.2
mm (in)
8.0
(0.315)
mm (in)
27.1
(1.067)
mm (in)
1.1
(0.043)
2/2
mm (in)
2.0
(0.079)
mm (in)
1.8
(0.071)
mm (in)
0.6 0.9
(0.0236 0.035)
mm (in)
4.8
(0.189)
5.0
(0.197)
5.2
(0.205)
5.4
(0.213)
mm (in) 0.10 0.25 (0.0039 0.0098)
6/6
mm (in)
mm (in)
mm (in)
mm (in)
2.0
1.8
0.7 1.1
5.2
5.4
5.6
5.8
6.0
(0.079)
(0.071)
(0.028 0.043)
(0.205)
(0.213)
(0.220)
(0.228)
(0.236)
SERVICE STANDARD (Contd)

Return spring
2-4 brake
Number of drive / driven plate

Limit
Retaining plate and retaining plate clearance
Available 2-4 brake retaining plate thickness
Return spring
Output shaft
Total end play
Number of coil
Outside diameter
Free length
Linear diameter
Number of coil
Outside diameter
Free length
Linear diameter
Seal ring clearance

Total end play
Available oil pump bearing race thickness
Torque converter end play
mm (in)
mm (in)
mm (in)
4.8
11.2
22.3
1.1
(0.441)
(0.878)
(0.043)
5/5
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
2.0
1.8
1.0 1.4
5.4
5.6
5.8
6.0
6.2
6.4
10.2
6.9
22.5
1.1
0.10 0.25
0.25 0.55
1.4
1.6
1.8
2.0
2.2
2.4
67.0
(0.079)
(0.071)
(0.039 0.055)
(0.213)
(0.220)
(0.228)
(0.236)
(0.244)
(0.252)
(0.272)
(0.886)
(0.043)
(0.0039 0.0098)
(0.0098 0.0217)
(0.055)
(0.063)
(0.071)
(0.079)
(0.087)
(0.094)
(2.638)

ILLUSTRATION
PART NO.
PART NAME
5-8841-0841-0
Holding Fixture
5-8840-0003-0
Holding Fixture Base
5-8840-2764-0
2-4 Brake Spring Compressor
5-8840-2767-0
High Clutch Spring Compressor
5-8840-2759-0
Low Clutch Spring Compressor
5-8840-2761-0
Oil Pump Oil Seal Installer
5-8840-2769-0
Rear Extension Oil Seal Installer
5-8840-2770-0
Rear Adapter Oil Seal Installer
5-8840-2758-0
Manual Shaft Oil Seal Installer
ILLUSTRATION
PART NO.
5-8840-2763-0
PART NAME
Inhibitor Switch Set Plate
MEMO
No. TFJR4-WE-0431
WORKSHOP MANUAL
TF SERIES
MANUAL TRANSMISSION
(MSG MODELS)
SECTION 7B
MSG MODEL 7B-1
SECTION 7B
MANUAL TRANSMISSION
(MSG MODELS)
TABLE OF CONTENTS
PAGE
Main Data and Specifications .................................................................................... 7B -
General Description.................................................................................................... 7B -
Torque Specification .................................................................................................. 7B -
Repair Kit .................................................................................................................... 7B -
Removal and Installation ........................................................................................... 7B -
Disassembly ............................................................................................................... 7B -
15
Inspection and Repair ............................................................................................... 7B -
25
Reassembly ................................................................................................................ 7B -
29
Special Service Tool .................................................................................................. 7B -
42
7B-2 MSG MODEL

Transmission type
Fully synchronized 5-forward gears with a constant

mesh type reverse gear.
Transmission Control
Direct control with the gear shift lever on the floor.
Gear ratio
Oil capacity
Weight ; approx.
MSG5K
1st :
4.122
2nd :
2.493
3rd :
1.504
4th :
1.000
5th :
0.855
Rev :
3.720
lit. (US gal.)
1.55(0.41)
kg(lbs)
33.3(73.8)
MSG MODEL 7B-3
GENERAL DESCRIPTION
The MSG type transmission is fully synchronized 5-speed unit with blocking ring type synchronizers and a constant
mesh type reverse gear.
The unit consists principally of a case with an integral clutch housing, intermediate plate, rear cover and gears.
The top of the rear cover is a quadrant box containing the transmission control mechanism.
The case and rear cover are cast aluminum alloy to reduce weight.
7B-4 MSG MODEL
STANDDARD BOLTS
The torque values given in the following table should be applied where a particular torque is not specified.
Nm (kgfm/lbft)
Strength
4.8/4T
7T
8.8
Class
Refined
9.8/9T
Non-Refined
Bolt Identification
Bolt
Diameter
Pitch (mm)
Standard Hex.
Head Bolt
Flange Bolt
No mark
M6 1.0
M8 1.25
6 (0.6 / 52 lb.in)
13 (1.3 / 113 lb.in)
7 (0.7 / 61 lb.in)
17 (1.7 / 12)
8 (0.8 / 69 lb.in)
20 (2.0 / 14)
24 (2.4 / 17)
M10 1.25
M12 1.25
M14 1.5
27 (2.8 / 20)
61 (6.3 / 45)
96 (9.8 / 71)
37 (3.8 / 27)
76 (7.8 / 56)
116 (11.8 / 85)
42 (4.3 / 31)
87 (8.9 / 64)
133 (13.6 / 98)
50 (5.1 / 37)
95 (9.7 / 70)
142 (14.5 / 105)
M16 1.5
M18 1.5
M20 1.5
130 (13.3 / 96)

188 (19.2 / 139)
258 (26.3 / 190)
170 (17.3 / 125)

244 (24.9 / 180)
337 (34.4 / 249)
193 (19.7 / 143)

278 (28.3 / 205)
385 (39.3 / 284)
200 (20.4 / 148)

287 (29.3 / 212)
396 (40.4 / 292)
M22 1.5
M24 2.0
* M10 1.5
332 (33.9 / 245)

449 (45.8 / 331)
26 (2.7 / 20)
453 (46.3 / 335)

570 (58.2 / 421)
36 (3.7 / 27)
517 (52.7 / 381)

651 (66.3 / 480)
41 (4.2 / 30)
530 (54.1 / 391)

692 (70.6 / 511)
48 (4.9 / 35)
* M12 1.75
* M14 2.0
* M16 2.0
57 (5.8 / 42)
89 (9.1 / 66)
124 (12.7 / 92)
71 (7.2 / 52)
110 (11.2 / 81)
162 (16.5 / 119)
80 (8.2 / 59)
125 (12.7 / 92)
185 (18.9 / 137)
89 (9.1 / 66)
133 (13.6 / 98)
191 (19.5 / 141)
M6 1.0
7 (0.7 / 61 lb.in)
8 (0.8 / 69 lb.in)
9 (0.9 / 78 lb.in)
M8 1.25
M10 1.25
M12 1.25
15 (1.5 / 11)
31 (3.2 / 23)
69 (7.0 / 51)
19 (1.9 / 14)
41 (4.2 / 30)
85 (8.7 / 63)
22 (2.2 / 16)
47 (4.8 / 35)
97 (9.9 / 72)
26 (2.7 / 20)
56 (5.7 / 41)
106 (10.8 / 78)
M14 1.5
M16 1.5
M18 1.5
104 (10.6 / 77)

145 (14.8 / 127)
-
126 (12.8 / 93)

188 (19.2 / 139)
-
144 (14.6 / 106)

214 (21.8 / 158)
-
154 (15.7 / 114)

221 (22.5 / 163)
-
M20 1.5
M22 1.5
M24 2.0
* M10 1.5
* M12 1.75
* M14 2.0
30 (3.1 / 22)
64 (6.5 / 47)
97 (9.9 / 72)
40 (4.1 / 30)
78 (8.0 / 58)
119 (12.1 / 88)
46 (4.7 / 34)
89 (9.1 / 66)
135 (13.8 / 99.7)
54 (5.5 / 40)
99 (10.1 / 73)
144 (14.7 / 107)
* M16 2.0
137 (14.0 / 101)
178 (18.2 / 132)
203 (20.7 / 132)
210 (21.5 / 155)
The asterisk * indicates that the bolts are used for female-threaded parts that are made of soft materials such as
casting, etc.
FLARE NUTS
Torque Nm (kgfm/lbft)
Torque Nm (kgfm/lbft)
4.76 (0.187)
16 (1.6 / 12)
10.00 (0.394)
54 (5.5 / 40)
6.35 (0.250)
26 (2.7 / 20)
12.00 (0.472)
88 (9.0 / 65)
8.00 (0.315)
44 (4.5 / 33)
15.00 (0.591)
106 (10.8 / 78)
MSG MODEL 7B-5

Nm (kgfm/lbft)
RTW47BXF000101
7B-6 MSG MODEL
REPAIR KIT
RTW47BLF000201
1. Case to front cover gasket

2. Control box gasket
3. Plate gasket
4. Filler plug O-ring

5. Drain plug O-ring
MSG MODEL 7B-7

important points as well as the order of operation. Be sure that you understand everything in this Section before
you begin.

Battery Cable
Disconnect the negative (-) cable from the battery terminal.
Engine Hood
Apply setting marks to the engine hood and the engine hood
hinges before removing the engine hood.
Gear Shift Lever

1. Place the gear shift lever in the neutral position.
2. Remove the gear shift lever knob.
3. Remove the front console assembly.
4. Remove the gear shift lever grommet and dust cover.
5. Remove the gear shift lever cover bolts.
6. Remove the gear shift lever.
Note:
Cover the shift lever hole to prevent the entry of foreign
material into the transmission.
Lifting the Vehicle

2. Place chassis stands at the front and the rear of the
vehicle.
Transmission Oil Draining

1. Remove the transmission oil drain plug.
2. Replace the drain plug after draining the oil.
7B-8 MSG MODEL
Exhaust Pipe
1. Remove the exhaust pipe bracket from the transmission
case.
2. Remove the exhaust pipe.
Rear Propeller Shaft (Single Shaft Type)

1. Remove the propeller shaft flange yoke at the drive pinion
side 1 .
2. Remove the propeller shaft from the transmission main
shaft spline 2 .
Rear Propeller Shaft (Dual Shaft Type)

1. Apply setting marks to the 2nd propeller shaft flange yoke.
This will prevent mispositioning during the installation
procedure.
2. Remove the 2nd propeller shaft flange yoke bolts at the
drive pinion side 1 .
3. Remove the center bearing retainer bolts 2 .
4. Remove the 1st propeller shaft with the center bearing and
the 2nd propeller shaft.
Pull the 1st propeller shaft toward the rear of the vehicle
until the spline yoke is free of the transmission main shaft.
Harness Connector
Disconnect the back up light switch connector and the
speedometer sensor connector.
Slave Cylinder
Remove the slave cylinder from the transmission case.
MSG MODEL 7B-9
Engine Lifting Hanger

1. Attach the engine lifting hanger to the front portion of the
engine.
2. Attach the lifting wire to both ends of the engine lifting
hanger.
Starter Motor
Remove the starter motor motor from the engine rear plate.
Transmission
1. Support the transmission with a transmission jack.
2. Remove the engine rear mounting bracket bolts and nuts 1
from the transmission 2 .
3. Remove the bracket from No.3 crossmember.
4. Loosen the nuts for the rear mounting rubber.
5. Remove the rear mounting rubber 3 from the transmission
4.
6. Remove the gear control box from the transmission.
7. Remove the transmission from the engine.
The removal of the transmission will require the cooperative
efforts of two mechanics.
1) Remove the transmission nuts and bolts 1 from the
engine rear plate.
2) Place a transmission jack 2 beneath the transmission .
Do not raise the transmission jack.
7B-10 MSG MODEL

3) Manually move the transmission as far as possible toward
the rear of the vehicle (into the space between the No.3
crossmember 3 and the floor panel 4 .
4) Lower the clutch housing end of the transmission toward the
transmission jack.
The rear of the transmission is supported by the No.3
crossmember at this time.
5) Firmly grasp the transmission rear cover (1st mechanic).
Raise the transmission jack toward the transmission (2nd
mechanic).
Carefully lower the transmission onto the transmission jack.
The transmission must be centered on the transmission
jack.
8. Carefully pull the transmission jack with the transmission
from beneath the vehicle.
MSG MODEL 7B-11

Follow the removal procedure in the reverse order to perform
the installation procedure.
Pay careful attention to the important points during the
Transmission
1. Apply a thin coat of molybdenum disulfide grease to the top
gear shaft spline.
2. Place the transmission on a transmission jack.
3. Carefully move the transmission jack and transmission into
position behind the engine.
4. Slowly operate the transmission jack to raise the

transmission until the rear of the transmission is at the
same level as the No.3 crossmember 1 .
5. Manually support the transmission rear cover.
Move the transmission into position between the No.3
crossmember and the floor panel 2 .
6. Slowly raise the transmission jack until the front of the

transmission is aligned with the rear of the engine.
The slope of the engine and the transmission must be the
same.
7. Install the gear control box the transmission.
8. Align the top gear shaft spline with the clutch drive plate
spline.
9. Install the transmission to the engine.
Tighten the transmission nuts and bolts as shown in the
figure.
7B-12 MSG MODEL
RTW37BLF000901
10.Install the rear mounting rubber 3 to the transmission 2 .

Install the rear mounting rubber 3 to the No.3
crossmember 4 .
11.Tighten the rear mounting rubber nuts 1 to the specified
forque.
Rear Mounting Rubber Nut Torque
Nm (kgfm/lbft)
41 (4.2 / 30)
Mounting Bolt Torgue
Nm (kgfm/lbft)
41 (4.2 / 30)
MSG MODEL 7B-13
Starter Motor
1. Install the starter motor to the engine rear plate.
2. Tighten the starter motor bolts to the specified torque.
Starter Motor Torque
Nm (kgfm/lbft)
78 (8.0 / 58)
Slave Cylinder
Install the slave cylinder to the transmission case.
Slave Cylinder Bolt Torque
Nm (kgfm/lbft)
78 (8.0 / 58)
Harness Connector
Connect the back up light switch connector and speedometer
sensor connector.
Rear Propeller Shaft (Single Shaft Type)

1. Insert the splined yoke 1 with the propeller shaft into the
transmission main shaft spline 2 .
2. Install the propeller shaft flange yoke 3 to the drive pinion
side.
3. Tighten the propeller shaft flange yoke bolt to the specified
torque.
Propeller Shaft Flange Yoke Bolt Torque
Nm (kgfm/lbft)
M8 : 35.3 (3.6 / 26)
M10 : 62.7 (6.4 / 46.3)
Rear Propeller Shaft (Dual Shaft Type)

1. Place the center bearing and retainer 1 together with the
1st propeller shaft 2 and 2nd propeller shaft 7 on the No.4
crossmember 3 .
2. Insert the splined yoke 4 into the transmission main shaft
spline 5 .
3. Tighten the center bearing retainer bolts 6 to the specified
torque.
Center Bearing Retainer Bolt Torque
Nm (kgfm/lbft)
60.8 (6.2 / 44.8)
4. Connect the 2nd propeller shaft 7 and drive pinion side 8 .
Be sure to align the setting marks applied at disassembly.
5. Tighten the coupling bolts to the specified torque.
Propeller Shaft Flange Yoke Bolt
Torque
Nm (kgfm/lbft)
M8 : 35.3 (3.6 / 26)
M10 : 62.7 (6.4 / 46.3)
7B-14 MSG MODEL
Exhaust Pipe
1. Install the exhaust pipe to the exhaust manifold and the
2nd exhaust pipe.
2. Install the exhaust pipe bracket to the transmission case.
Gear Shift Lever

1. Replenish the transmission case with the specified engine
oil.
Transmission Case Oil
lit(US gal.)
1.55 (0.41)
2. Install the gear shift lever to the gear control box.
3. Tighten the gear shift lever cover bolts to the specified
torque.
Shift Lever Cover Bolt Torque
Nm(kgfm/lbft)
19.6 (2.0 / 14.5)
4. Install the dust cover and the grommet.
5. Install the front console assembly.
6. Install the gear shift lever knob.
Lowering the Vehicle

1. Place a jack beneath the vehicle.
2. Raise the jack to remove the chassis stands.
3. Lower the vehicle to the ground.
Engine Hood
Align the setting marks(applied at removal)on the engine hood
and the engine hood hinges to install the engine hood.
Battery Cable
Connect the negative (-) cable to the battery terminal.
MSG MODEL 7B-15
DISASSEMBLY
MAJOR COMPONENTS
RTW47BLF000301
Disassembly Steps
1. Clutch shift block and release bearing
2. Clutch shift fork
3. Speedometer sensor
4. Speedometer driven gear assembly
5. Gear control box assembly
I 6. Front cover with oil seal
I 7. Counter gear snap ring

I 8. Bearing snap ring
9. Rear cover with oil seal
11. Intermediate plate with gear assembly
7B-16 MSG MODEL
6. Front Cover with Oil Seal
Remove the front cover with oil seal from the transmission
case.
7. Counter Gear Snap Ring

8. Bearing Snap Ring
Use pair of snap ring pliers to remove the snap ring.
MSG MODEL 7B-17
MAJOR COMPONENT
INTERNAL PARTS
Disassembly steps
1. Detent assembly
2. Shift fork assembly & interlock pin
3. Rev. and 5th gear assembly
4. Counter gear shaft assembly

5. Top & main gear shaft assembly
7B-18 MSG MODEL
MINOR COMPONENTS
DETENT, SHIFT ARM ASSEMBLY AND INTERLOCK PIN
Disassembly Steps
1. Detent spring plate and gasket
2. Detent spring
I 3. Detent ball
4. Rev. - 5th shaft rod
5. Rev. - 5th shaft arm
6. 1st - 2nd shift rod
I 7. 3rd - 4th shift rod

I 8. 3rd - 4th shift arm
I 9. 1st - 2nd shift arm
10. Interlock pin
11. Intermediate plate and gear assembly
MSG MODEL 7B-19
3. Detent Ball
7.
8.
9.
1)
3rd - 4th Shift Rod

3rd - 4th Shift Arm
1st - 2nd Shift Arm
Hold a round bar against the shift arm end.
This will prevent damage to other components.
2) Use a spring pin remover to remove the shift arm spring pin
from the shift arm and the shift rod.
Spring Pin Remover : 9-8529-2201-0
Discard the used spring pin.
3) Move the 3rd - 4th shift rod forward.
Take care not to lose the interlock pins.
7B-20 MSG MODEL
REVERSE GEAR AND 5TH GEAR
Disassembly Steps
1. Bearing snap ring
2. Speedometer drive gear and lock ball
3. Bearing spacer
4. Mainshaft end ball bearing
5. Thrust ring snap ring
6. Thrust washer thrust ring
7. Thrust washer and lock ball
8. Counter reverse gear nut and washer
I 9. Counter end ball bearing
I10. Counter 5th gear
11. Counter reverse gear
12. 5th gear
13. 5th block ring
14. Needle bearing
I15. Mainshaft lock nut and washer

I16. Rev. - 5th synchronizer assembly
17. Reverse gear
18. Needle bearing
19. Needle bearing collar
20. Thrust washer
21. Counter reverse gear lock nut
22. Thrust washer
23. Reverse idler gear
24. Thrust washer
25. Reverse idler shaft
I26. Bearing snap ring
I27. Bearing snap ring
I28. Intermediate plate
MSG MODEL 7B-21
9.Counter End Ball Bearing
10.Counter 5th Gear
Use the gear remover to remove the counter 5th gear with the
ball bearing.
Gear Remover : 5-8840-0013-0 (J-22888)
15. Mainshaft Lock Nut and Washer

1) Engage the 3rd - 4th synchronizer with the 3rd gear.
2) Engage the 1st - 2nd synchronizer with the 1st gear.
3) Attach the holding fixture to the mainshaft and the
countergear.
Holding Fixture : 5-8840-2001-0 (J-29768)
4) Use the lock nut wrench to remove the lock nut.

Lock Nut Wrench: 5-8840-0353-0 (J-36629)
16.Rev. - 5th Synchronizer Assembly

1) Remove the synchronizer assembly as a set.
2) Disassemble the synchronizer assembly.
1 Springs
2 Sleeve
3 Clutch Hub
4 Inserts
26.Bearing Snap Ring

1) Insert the snap ring pliers 1 into the counter gear bearing
snap ring hole 2 .
The snap ring hole is in the intermediate plate 3 .
2) Use the snap ring pliers to force open the counter gear
bearing snap ring.
Tap on the front of the intermediate plate.
The ball bearing snap ring will come free.
7B-22 MSG MODEL

27.Bearing Snap Ring
28.Intermediate Plate
1) Insert the snap ring pliers into the mainshaft bearing snap
ring hole.
The snap ring hole is in the intermediate plate 1 .
2) Use the snap ring pliers 2 to force open the mainshaft
bearing snap ring 3 .
Hold the snap ring open with the pliers.
3) Push the intermediate plate toward the rear of the
transmission to remove it.
The ball bearing snap ring will come free.
MSG MODEL 7B-23
TOP GEAR SHAFT, MAINSHAFT GEAR AND COUNTER GEAR
Disassembly Steps
I 1. Top shaft snap ring
I 2. Top gear shaft
I 3. Ball bearing
4. Needle bearing
5. 4th block ring
6. Mainshaft snap ring
I 7. 3rd - 4th synchronizer assembly
8. 3rd block ring
9. 3rd gear
10. Needle bearing
I11. Mainshaft ball bearing
12. 1st gear thrust washer
13. 1st gear

15. Needle bearing
16. 1st block ring
I17. 1st - 2nd synchronizer assembly
18. 2nd block ring
19. 2nd gear
20. Needle bearing
21. Mainshaft
I22. Rear ball bearing
I24. Front ball bearing
25. Counter gear
7B-24 MSG MODEL
1.
2.
3.
1)
2)
Top Gear Shaft Snap Ring

Top Gear Shaft
Ball Bearing
Use a pair of snap ring pliers to remove the snap ring.
Use a bench press and the bearing remover to remove the
ball bearing.
Bearing Remover : 5-8840-0015-0 (J-22912-01)
7. 3rd - 4th Synchronizer Assembly

2) Disassembly the synchronizer assembly.
1 Springs
2 Sleeve
3 Clutch Hub
4 Inserts
11.Mainshaft Ball Bearing

Use a bench press and the bearing remover to remove the ball
bearing.
Bearing Remover : 5-8840-0015-0 (J-22912-01)
17.1st - 2nd Synchronizer Assembly

2) Disassembly the synchronizer assembly.
1 Springs
2 Sleeve
3 Clutch Hub
4 Inserts
22.Rear Ball Bearing

24.Front Ball Bearing
Use a bench press and the bearing remover to remove the ball
bearing.
Bearing Removar : 5-8840-0015-0 (J-22912-01)
MSG MODEL 7B-25

inspection.
SHIFT ARM THICKNESS

Use a micrometer to measure the shift arm thickness.
If the measured value is less than the specified limit, the shift
arm must be replaced.
Shift Arm Thickness
mm(in)
Standard
Limit
1st-2nd
9.6-9.8 (0.378-0.386)
9.0 (0.354)
3rd-4th
6.95-7.2 (0.273-0.283)
6.5 (0.256)
Rev.-5th
6.8-6.9 (0.268-0.272)
6.3 (0.248)
DETENT SPRING FREE LENGTH

Use a venier caliper to measure the detent spring free length.
If the measured value is less than the specified limit, the
detent spring must be replaced.
mm(in)
Standard
Limit
25.6 (1.01)
23.6 (0.93)
DETENT SPRING TENSION

Use a spring tester to measure the valve spring tension.
N(kg/lb)
Compressed
Standard
Limit
Height mm(in)
22.1 (0.870)
61.8-65.7
55.9
(6.3-6.7/13.9-14.8)
(5.7/12.6)
BLOCK RING AND DOG TEETH

CLEARANCE
Use a thickness gauge to measure the clearance between the
block ring and the dog teeth.
If the measured value exceeds the specified limit, the block
ring must be replaced.
Block Ring and Dog Teeth Clearance
mm(in)
Standard
Limit
1st,2nd
2.0 (0.078)
1.3 (0.051)
3rd, 4th, 5th
1.5 (0.059)
0.8 (0.032)
7B-26 MSG MODEL
BLOCK RING AND INSERT CLEARANCE

block ring and the insert.
If the measured value exceeds the specified limit, the block
ring and the insert must be replaced.
mm(in)
Standard
Limit
1st,2nd
3.46-3.74 (0.136-0.147)
3rd, 4th, 5th
3.51-3.79 (0.138-0.149)
4.0 (0.157)
CLUTCH HUB AND INSERT CLEARANCE

clutch hub and the insert.
If the measured value exceeds the specified limit, the clutch
hub and the insert must be replaced.
mm(in)
Standard
Limit
0.01 - 0.19 (0.0004 - 0.0075)
0.3 (0.012)
MAINSHAFT RUN - OUT

1. Install the mainshaft to a grinding machine.
2. Use a dial indicator to measure the mainshaft central
portion run-out.
If the measured mainshaft run-out exceeds the specified
limit, the mainshaft must be replaced.
Mainshaft Run - Out
mm(in)
Limit
Less than 0.03 (0.0012)
GEAR INSIDE DIAMETER

Use an inside dial indicator to measure the gear inside
diameter.
If the measured value is less than the specified limit, the gear
must be replaced.
Gear Inside Diameter
mm(in)
Standard
Limit
1st
45.00-45.01
Rev.
(1.7717-1.7720)
2nd
41.00-41.01
3rd
(1.6142-1.6146)
5th
34.03-34.04
(1.3398-1.3402)
45.10 (1.7756)
41.10 (1.6181)
34.10 (1.3425)
MSG MODEL 7B-27
REVERSE IDLER GEAR AND IDLER

GEAR SHAFT CLEARANCE
1. Use a micrometer to measure the idler gear shaft diameter.
2. Use an inside dial indicator to measure the idler gear inside
diameter.
3. Calculate the idler gear and idler gear shaft clearance.
Idler gear inside diameter - idler gear shaft diameter = idler
gear and idler gear shaft clearance.
If the measured value exceeds the specified limit, the idler
gear and/or the idler gear shaft must be replaced.
Idler Gear and Idler Gear Shaft Clearance
mm(in)
Standard
Limit
0.041 - 0.074 (0.0016 - 0.0029)
0.150 (0.0059)
CLUTCH HUB SPLINE PLAY

1. Set a dial indicator to the clutch hub to be measured.
2. Move the clutch hub as far as possible to both the right and
the left.
It the measured value exceeds the specified limit, the
clutch hub must be replaced.
mm(in)
Standard
Limit
0.019 (0 - 0.075)
0.20 (0.0079)
7B-28 MSG MODEL
BALL BEARING PLAY

Use a dial indicator to measure the ball bearing play.
Ball Bearing Play
Limit
0.2 (0.0079)
mm(in)
FRONT COVER OIL SEAL

Oil Seal Removal
Use a screwdriver to pry the oil seal from the front cover.

1. Use the oil seal installer to install the oil seal to the front
cover.
Oil Seal Installer : 5-8840-0026-0 (J-26540)
2. Apply engine oil to the oil seal lip.
REAR COVER OIL SEAL

Oil Seal Removal
Use a screwdriver to pry the oil seal from the rear cover.

1. Use the oil seal installer to install the oil seal to the rear
cover.
Oil Seal Installer : 5-8522-0050-0 (J-29769)
2. Apply engine oil to the oil seal lip.
MSG MODEL 7B-29
REASSEMBLY
MAJOR COMPONENT
INTERNAL PARTS
Reassembly steps
1. Top & main gear shaft assembly
2. Counter gear shaft assembly
3. Rev. and 5th gear assembly
4. Shift fork assembly & interlock pin

5. Detent assembly
7B-30 MSG MODEL
MINOR COMPONENTS
TOP GEAR SHAFT, MAINSHAFT GEAR AND COUNTER GEAR
Reassembly Steps
1. Mainshaft
I 2. Needle bearing
I 3. 2nd gear
4. 2nd block ring
I 5. 1st-2nd synchronizer assembly
6. 1st block ring
I 7. Needle bearing collar
I 8. Needle bearing
I 9. 1st gear
I10. 1st gear thrust washer
I11. Mainshaft ball bearing
I12. Needle bearing
I13. 3rd gear
14. 3rd block ring

I15. 3rd-4th synchronizer assembly
I16. Mainshaft snap ring
17. Needle bearing
18. 4th block ring
I19. Top gear shaft
I20. Ball bearing
21. Top gear shaft snap ring
22. Counter gear
23. Front ball bearing
I25. Rear ball bearing
MSG MODEL 7B-31
2. Needle Bearing
3. 2nd Gear
1) Apply the engine oil to the 2nd needle bearing and the 2nd
gear.
2) Install the needle bearing and the 2nd gear to the
mainshaft.
The dog teeth of the 2nd gear must be facing the rear side
5. 1st-2nd Synchronizer Assembly
1) Apply the engine oil to the clutch hub spline.
2) Install the synchronizer assembly to the mainshaft.
The outside sleeve heavy chamfering must be facing the
rear of the transmission.
1 Chamfer Angle = 30
2 Chamfer Angle = 45
7. Needle Bearing Collar

Use a bench press and the collar installer to install the needle
bearing collar.
Collar Installer : 5-8840-0178-0 (J-33851)
8. Needle Bearing
9. 1st Gear
1) Apply the engine oil to the 1st needle bearing and the 1st
gear.
2) Install the needle bearing and the gear to the mainshaft.
The dog teeth of the 1st gear must be facing the front side
10.1st Gear Thrust Washer

Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the 1st gear side.
7B-32 MSG MODEL

11.Mainshaft Ball Bearing
1) Apply the engine oil to the ball bearing inside
circumference.
2) Use a bench press and the bearing installer to install the
bearing.
The bearing snap ring groove must be facing the front of
the transmission.
Bearing Installer : 5-8840-0015-0 (J-22912-01)
12.Needle Bearing
13.3rd Gear
1) Apply the engine oil to the 3rd needle bearing and the 3rd
gear.
2) Install the needle bearing and the gear to the mainshaft.
The dog teeth of the 3rd gear must, be facing the front side
15.3rd-4th Synchronizer Assembly

1) Apply the recommended lubricating oil to the clutch hub
spline.
The sleeve light chamfering 1 and the clutch hub heavy
boss 2 must be facing the rear of the transmission.
16.Mainshaft Snap Ring

1) Select the snap ring which will provide the minimum
clearance between the mainshaft and the snap ring.
There are four snap ring sizes available.
The snap rings are numbered to indicate their thickness.
Mainshaft and Snap Ring Clearance
mm(in)
Standard
0 - 0.05 (0.002)
Snap Ring Availability

Thickness
mm(in)
Identification Number
1.50 (0.059)
1.55 (0.061)
1.60 (0.063)
1.65 (0.065)
2) Use a pair of snap ring pliers to install the snap ring to the
mainshaft.
MSG MODEL 7B-33

19.Top Gear Shaft
20.Ball Bearing
Use a bench press and the installer to install the ball bearing
to the top gear shaft.
The snap ring groove must be facing the front of the
transmission.
25.Rear Ball Bearing

Use a bench press and the bearing installer to install the
bearing to the counter gear.
7B-34 MSG MODEL
REVERSE GEAR AND 5TH GEAR
Reassembly Steps
I 1. Intermediate plate
I 2. Reverse idler shaft
5. Thrust washer
I 6. Reverse idler gear
7. Thrust washer
I 8. Counter reverse gear lock nut
I 9. Thrust washer
11. Needle bearing
12. Reverse gear
I13. Rev.-5th synchronizer assembly
I14. Mainshaft lock nut and washer
15. Needle bearing

16. 5th block ring
17. 5th gear
I18. Thrust washer and lock ball
19. Counter reverse gear
20. Counter 5th gear
21. Counter end ball bearing
I22. Counter reverse gear nut and washer
I23. Thrust washer thrust ring
I24. Thrust ring snap ring
25. Mainshaft end ball bearing
26. Bearing spacer
27. Speedometer drive gear and lock ball
MSG MODEL 7B-35
1. Intermediate Plate
2. Reverse Idler Shaft
1) Install the reverse idler shaft to the intermediate plate.
2) Tighten the reverse idler shaft bolt to the specified torque.
Idler Shaft Bolt Torque
Nm(kgfm/lbft)
18.6 (1.9 / 13.7)
3) Set the mainshaft with gear assembly 1 and the counter

gear assembly 2 to the holding fixture 3 .
Holding Fixture : 5-8840-2001-0 (J-29768)
4) Place the holding fixture (with the mainshaft and the
counter shaft) in a vise.
5) Mesh the 3rd-4th synchronizer to the 3rd gear.
Mesh the 1st-2nd synchronizer to the 1st gear.
6) Install the intermediate plate to the mainshaft and the
counter gear ball bearings.
6. Reverse Idler Gear
8. Counter Reverse Gear Lock Nut
1) Apply the engine oil to the idler shaft and the reverse gear
inside circumference.
2) Install the reverse gear to the idler shaft.
3) Install a new counter reverse gear lock nut.
Never reinstall the old lock nut.
4) Tighten the reverse gear lock nut to the specified torque.
Lock Nut Torque
Nm (kgfm/lbft)
107.8 (11 / 79.6)
9. Thrust Washer
1) Apply the engine oil to both sides of the thrust washer.
2) Install the thrust washer to the mainshaft.
The thrust washer oil groove must be facing the reverse
gear side.
7B-36 MSG MODEL

13.Rev.-5th Synchronizer Assembly
1) Apply the engine oil to the clutch hub spline.
The sleeve heavy chamfer 1 and the insert short side 2
must be facing to the rear side of the transmission.
14.Mainshaft Lock Nut and Washer

1) Install a new lock nut and washer to the mainshaft.
Never reinstall the used lock nut and washer.
2) Use the lock nut wrench to tighten the lock nut to the
specified torque.
Lock Nut Wrench : 5-8840-0353-0 (J-36629)
Lock Nut Torque
Nm(kgfm/lbft)
107.8 (11 / 79.6)
22.Counter Reverse Gear Nut and Washer

Tighten the counter gear lock nut to the specified torque.
Reverse Gear Nut Torque
Nm(kgfm/lbft)
107.8 (11 / 79.6)
18.Thrust Washer and Lock Ball
23.Thrust Washer Thrust Ring
24.Thrust Ring Snap ring
1) Install the thrust washer with lock ball together with the
thrust ring to the mainshaft.
2) Use a pair of snap ring pliers to install the snap ring.
3) Use a thickness gauge to measure the clearance between

the 5th gear and the thrust washer.
5th Gear and Thrust Washer Clearance
mm(in)
Standard
0.1 - 0.3 (0.004 - 0.012)
If required, replace the existing thrust washer with a new
thrust washer to bring the clearance to specification.
MSG MODEL 7B-37

There are six thrust washer sizes available.
Thrust Washer Availability
7.8 (0.307)
7.9 (0.311)
8.1 (0.319)
8.2 (0.323)
mm(in)
8.0 (0.315)
8.3 (0.327)
4) Position the thrust ring snap ring gap 1 and the thrust ring
gap 2 so that they are separated at a 90 angle.
7B-38 MSG MODEL
DETENT AND SHIFT ARM ASSEMBLY
Reassembly Steps
1. Intermediate plate and gear assembly
I 2. 1st-2nd shift arm
I 3. 3rd-4th shift arm
4. Interlock pin
5. 3rd-4th shift rod
6. 1st-2nd shift rod
I 7. Rev.-5th shift arm

8. Rev.-5th shift rod
9. Detent ball
10. Detent spring
I11. Detent spring plate and gasket
MSG MODEL 7B-39
2.
3.
7.
1)
1st-2nd Shift Arm

3rd-4th Shift Arm
Rev.-5th Shift Arm
Hold a round bar against the shift rod end lower face to
protect it against damage.
2) Use a spring pin installer to install the spring pin to the shift
arm and the shift rod.
Never reinstall the used spring pins.
11.Detent spring Plate and Gasket.
1) Install the new detent plete and new gasket onto the
transmission case into the correct direction.
2) Tighten the detent spring plate bolts to the specified torque.
Detent Spring Plate Bolt Torque
Nm(kgfm/lbft)
18.6 (1.9 / 13.7)
7B-40 MSG MODEL
MAJOR COMPONENTS
RTW47BLF000401
Reassembly steps
1. Intermediate plate with gear assembly
I 2. Rear cover with oil seal
I 3. Transmission case
I 4. Bearing snap ring
5. Counter gear snap ring
I 6. Front cover with oil seal

7. Speedometer driven gear
8. Gear control box assembly
9. Speedpmeter sensor
10. Clutch shift fork
11. Clutch shift block and release bearing
MSG MODEL 7B-41
RTW47BSH000201
RTW47BSH000301
2. Rear Cover with Oil Seal

1) Align the pins at the lower side of the rear cover with the
holes in the lower side of the intermediate plate.
2) Apply recommended liquid gasket or its equivalent to the
rear cover fitting surfaces.
3) Install the rear cover to the intermediate plate.
4) Tighten the rear cover bolts to the specified torque.
Rear Cover Bolt Torque
Nm(kgfm/lbft)
37.2 (3.8 / 27.5)
Note:
Take care not to twist or puncture the oil seal during the
3. Transmission Case
4. Bearing Snap Ring
1) Apply the engine oil to the transmission case top gear shaft
ball bearing fitting faces.
2) Apply recommended liquid gasket or its equivalent to the
transmission case fitting surfaces.
3) Install the transmission case to the intermediate plate.
4) Pull the top gear shaft from the transmission case until the
ball bearing snap ring grove protrudes from the
transmission case front cover fitting faces.
5) Use a pair of snap ring pliers to install the snap ring to the
ball bearing.
6. Front Cover with Oil Seal
1) Clean and apply recommended liquid gasket or its
equivalent to the through bolt threads.
2) Install the new gasket and tighten the new cover bolt to the
specified torgue.
Front Cover Bolt Torgue
Nm(kgfm/lb.ft)
24.5 (2.5 / 18.1)
10.Shift Fork
Apply molybdenum disulfide type grease to the areas as
shown in the figure and install shift fork (Diesel engine).
RTW47BSH000101
7B-42 MSG MODEL

ITEM NO.
ILLUSTRATION
PART NO.
PART NAME
MTL-42
9-8529-2201-0
Spring pin remover
MTL-1
5-8840-0013-0
(J-22888)
Gear remover
MTL-9
5-8840-2001-0
(J-29768)
Holding fixture
MTL-35
5-8840-0353-0
(J-36629)
Mainshaft nut wrench
MTL-3
5-8840-0015-0
(J-22912-01)
Bearing remover/installer
MTL-13
5-8840-0026-0
(J-26540)
Front cover oil seal

installer
MTL-14
5-8522-0050-0
(J-29769)
Rear cover oil seal

installer
MTL-21
5-8840-0178-0
(J-33851)
Mainshaft collar installer
No. TFMSG-WE-0431
WORKSHOP MANUAL
TF SERIES
MANUAL TRANSMISSION
(MUA MODELS)
SECTION 7B1
MANUAL TRANSMISSION
7B1-1
SECTION 7B1
TRANSMISSION
MANUAL TRANSMISSION MUA

CONTENTS
2)
MUA (4
PAGE
Service Precaution .......................................................................................................... 7B1 3

General Description ........................................................................................................ 7B1 4
Rear Oil Seal (4
2) ........................................................................................................... 7B1 5
Transmission (4
2) ......................................................................................................... 7B1 7
Disassembled View..................................................................................................... 7B1 7
Removal ....................................................................................................................... 7B1 8
Installation ................................................................................................................... 7B1 12
Transmission Case .......................................................................................................... 7B1 18
Major Component ........................................................................................................ 7B1 18
Disassembly ................................................................................................................ 7B1 19
Reassembly ................................................................................................................. 7B1 20
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 23
Disassembly ................................................................................................................ 7B1 24
Inspection and Repair................................................................................................. 7B1 25
Reassembly ................................................................................................................. 7B1 26
Reverse Gear and 5th Gear ............................................................................................ 7B1 27
Disassembly ................................................................................................................ 7B1 29
Reassembly ................................................................................................................. 7B1 31
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 38
Disassembly ................................................................................................................ 7B1 40
Reassembly ................................................................................................................. 7B1 45
Main Data and Specifications ......................................................................................... 7B1 51
7B1-2
MANUAL TRANSMISSION
Troubleshooting............................................................................................................... 7B1 55
Special Tools (4
2) .......................................................................................................... 7B1 62
4)
MUA (4
Service Precaution .......................................................................................................... 7B1 63
General Description ........................................................................................................ 7B1 64
Transmission (4
4) ......................................................................................................... 7B1 65
Removal ....................................................................................................................... 7B1 66
Installation ................................................................................................................... 7B1 70
Transmission Case .......................................................................................................... 7B1 77
Major Component ........................................................................................................ 7B1 77
Disassembly ................................................................................................................ 7B1 78
Reassembly ................................................................................................................. 7B1 79
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod,
and Interlock Pin ........................................................................................................... 7B1 82
Disassembly ................................................................................................................ 7B1 83
Reassembly ................................................................................................................. 7B1 84
Reverse Gear and 5th Gear ............................................................................................ 7B1 85
Disassembly ................................................................................................................ 7B1 86
Reassembly ................................................................................................................. 7B1 88
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft ......................................... 7B1 94
Disassembly ................................................................................................................ 7B1 96
Inspection and Repair.............................................................................................. 7B1 98
Reassembly .............................................................................................................. 7B1 101
Main Data and Specifications ..................................................................................... 7B1 107
Troubleshooting ........................................................................................................... 7B1 111
Special Tools (4
4) ...................................................................................................... 7B1 118
MANUAL TRANSMISSION
Service Precaution
7B1-3

parts and systems.
7B1-4
MANUAL TRANSMISSION
General Description
MUA Transmission (4
2)
A07R300006
The MUA is a constant mesh transmission,

synchronized in all speeds. The transmission has been
designed to provide low shift effort and low gear noise.
Principle parts of the transmission are the integral clutch

housing, the intermediate plate, the rear cover, and the
gears.
The transmission control box is built into the
transmission.
MANUAL TRANSMISSION
7B1-5
2)
Rear Oil Seal (4
Disassembled View
220R300030
Legend
(2) Rear Oil Seal
Removal
1. Raise and support vehicle with suitable jack stands.
2. Remove propeller shaft flange yoke bolts and nuts
at the differential side.
3. Remove center bearing from crossmenber.
4. Remove prepeller shaft from the transmission main
shaft spline.
Refre to the section Rear Propeller Shaft.
5. Use a screwdriver to pry the rear oil seal from the
rear cover.
Installation
1. Install a new oil seal (2) using the installer 5-85220050-0.
220RS044
2. Insert the splined yoke into the transimission

mainshaft spline.
3. Install the propeller shaft flange yoke to the drive
pinion flange.
7B1-6
MANUAL TRANSMISSION

4. Install center bearing on crossmember.
5. Check transmission fluid level.
6. Lower vehicle.
MANUAL TRANSMISSION
7B1-7
2)
Transmission (4
Disassembled View
RTW47BLF000701
Legend
(1) Gear Control Lever Knob
(10) Slave Cylinder
(2) Rear Floor Console (bucket seat)
(11) Nut : rear mount to Crossmember
(4) Grommet Assembly
(13) Nut : rear mount to transmission
(5) Gear Control Lever
(15) Starter (Diesel engine only)
(7) Exhaust Pipe Nut (Diesel engine only)
(16) Transmission Retaining Nut and Bolt
(8) Exhaust Pipe (6VE1 only)
(9) Fuel Pipe Bracket
7B1-8
MANUAL TRANSMISSION
Removal
5. Remove grommet assembly (4).

2. Remove gear control lever knob (1).
3. Remove rear floor console (2). (Bucket seat)
Refer to the section Floor Console.
4. Remove front floor console (3).
745R300006
Legend
(1) Knob
RTW47BMH000101
MANUAL TRANSMISSION
6. Remove gear control lever (5).
8. Remove rear propeller shaft (6).
differential side.
7B1-9
10. Remove the exhaust pipe (8). (6VE1 only)
RTW37ASH0001
11. Disconnect harness connectors and clips on the

transmission.
Neutral Switch
401RS023
9. Loosen the front exhaust pipe fixing nuts (7) at the

engine side but not remove them. (Diesel engine
only)
Back up Switch
Car Speed Sensor
12. Remove the fuel pipe bracket (9) with pipes from the
transmission (17).
Diesel engine
220R300012
150R300003
Legend
(1) Bolt
(2) Nut
(3) Fuel Pipe Assembly
7B1-10
MANUAL TRANSMISSION
14. Support transmission with a transmission jack.
6VE1, C24NE
Scan-1
13. Remove slave cylinder (10) and put aside it.
220RS001
15. Remove engine rear mount nuts (11) fixing on cross

member from transmission crossmember (12).
16. Remove engine rear mount nuts (13) fixing on
transmission.
Diesel engine
220LV019
6VE1
220R300029
Legend
(1) Transmission
(2) Nut : rear mount to transmission
(4) Nut : rear mount to crossmember
206RW002
MANUAL TRANSMISSION
17. Remove the middle part of transmission
crossmember (12) by removing four fixing bolts and
nuts.
501R300008
7B1-11
20. Use the clutch release bearing remover 5-88402291-0 (J-39207) to disconnect the clutch release
bearing from the clutch pressure plate. (6VE1 only)
220RW109
Release bearing disconnection

1. Pull the shift fork toward the transmission to
press the clutch release bearing against the
clutch.
2. Insert the clutch release bearing remover
between the wedge collar and the release
bearing.
3. Turn the remover to separate the release
bearing.
18. Take out the rear mount rubber (14).

19. Remove starter (15) (Diesel engine only).
060L100070
7B1-12
MANUAL TRANSMISSION
NOTE: Be sure not to insert the remover between the

wedge collar and the clutch.
220RW019
Legend
(1) Pressure Plate Assembly
(2) Release Bearing
(3) Wedge Collar
21. Remove transmission retaining nuts and bolts(16).
Remove transmission assembly (17) from the
vehicle.
Installation
220RW063
220RW064

the top gear shaft spline.
2. Slowly operate the transmission jack until the front
of transmission is aligned with the rear of the
engine.
The slope of the engine and the transmission must
be the same.
3. Align the top gear shaft spline with the clutch driven
plate spline.
MANUAL TRANSMISSION
7B1-13
4. Install the transmission assembly (17) to the engine.

Tighten the transmission nuts and bolts (16) as
Diesel engine
RTW37BLF000901
7B1-14
MANUAL TRANSMISSION
6VE1
RTW37BLF0001
MANUAL TRANSMISSION
7B1-15
C24NE
RTW37BLF0002
5. Apply a force of about 113N (26 Ib) to the tip of the

shift fork in the direction of the transmission to
engage the clutch pressure plate and release
bearing. (6VE1 only)
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage
each other.
Check to see if they are securely engaged by pushing
the tip of the shift fork toward the engine while applying
a force of about 25 N (5.5 lb). If the shift fork will not
move, then they are securely engaged.
220RS006
7B1-16
MANUAL TRANSMISSION
6. Install starter(15). (Diesel engine only)

NOTE: Tighten the lower bolt temporarily.
After installing the fuel pipe assembly, tighten the bolt to
6VE1, C24NE
Torque: 76 N
m (7.7 kg
m/56 lb
ft)
7. Install the rear support rubber (14) on the
transmission and tighten the nuts to the specified
torque.
Torque: 52 N
m (5.3 kg
m/38 lb
ft)
8. Install the middle part of transmission crossmember
(12) and bolts.
Tighten the nuts to the specified torque.
Torque: 67 N
m (6.8 kg
m/49 lb
ft)
9. Install engine rear mount nuts (11) fixing on
transmission crossmember (12).
Torque: 52 N
m (5.3 kg
m/38 lb
ft)
Remove the transmission jack from transmission
side.
10. Apply grease to top hole portion of the shift fork.
Install slave cylinder (10) and tighten the bolts to the
specified torque.
Torque: 76 N
m (7.7 kg
m/56 lb
ft)
11. Install the fuel pipe brackets (9) on the transmission.
Install the fuel pipe assembly to the fuel brackets.
Torque: Bolt & Nut
Nut
Scan-1
12. Connect transmission harness connectors and clip.

Connector: neutral switch, car speed sensor, and
backup switch.
13. Tighten exhaust pipe fixing nuts (7) to the specified
torque. (Diesel engine only)
Torque: 67 N
m (6.8 kg
m/49 lb
ft)
76 N
m (7.7 kg
m/56 lb
ft)
m (3.8 kg
m/28 lb
ft)
37 N
Diesel engine
150R300003
220R300012
Legend
(1) Bolt
(2) Nut
MANUAL TRANSMISSION
7B1-17
14. Install the exhaust pipe (8). (6VE1)

Torque: 67 N
m (6.8 kg
m/49 lb
ft)
RTW37ASH000101
15. Install rear propeller shaft (6).

Torque: 63 N
m (6.4 kg
m/46 lb
ft)
16. Install center bearing on crossemember.
Torque: 69 N
m (7.0 kg
m/51 lb
ft)
17. Install gear control lever (5).
Torque: 19 N
m (1.9 kg
m/14 lb
ft)
18. Install grommet assembly (4).
Torque: Screw
Nut
1.4 N
m (0.14 kg
m/12 lb
in)
7 N
m (0.7 kg
m/61 lb
in)
RTW47BMH000101
Legend
(2) Floor Panel
(3) Front
19. Install front floor console (3) and rear floor console
(2).
20. Install gear control lever knob (1).
To the female thread portion, adhesive (TB1344 or
LOCTITE 222 or equiv.) of 3 - 4 drops to be applied
and transmission knob tightened.
Torque: 9 N
m (0.9 kg
m/78 lb
in)
After tightening to specified torque, knob
rewrenched until direction of shift pattern due
positioned.
7B1-18
MANUAL TRANSMISSION
Transmission Case
Major Component
RTW37BLF0005
Legend
(1) Gear Control Box Assembly and Gasket
(9) Front Cover (with Oil Seal)
(2) Speedometer Sensor and Driven Gear
(10) Top Gear Bearing Snap Ring
(3) Rear Cover Assembly
(11) Release Bearing : C24NE
(4) Intermediate Plate with Gear Assembly
(12) Shift Fork : C24NE
(5) Transmission Case
(13) Fulcrum Bridge : 6VE1
(6) Release Bearing (with Spring) : Diesel engine
(14) Release Bearing : 6VE1
(7) Shift Fork : Diesel engine
(15) Shift Fork : 6VE1
(8) Counter Front Bearing Snap Ring
MANUAL TRANSMISSION
Disassembly
1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case
and drain the lubricant.
3. Remove the clutch release bearing with spring
(6)(11) from the transmission case.
4. Remove the shift fork (7)(12), and boot. (Diesel
engine, C24NE)
5. Remove the shift fork snap pin. (6VE1)
6. Remove the shift fork pin and shift fork from the
fulcrum bridge. (6VE1)
7B1-19
7. Remove the fulcrum bridge from the transmission

case. (6VE1)
RTW37ASH0002
Legend
(1) Fulcrum bridge
8. Remove the front cover (9) and gasket from the

transmission case.
9. Remove snap ring (8) fixing counter front bearing.
10. Use a pair of snap ring pliers to remove the snap
ring (10) fixing top gear bearing.
RTW47BSH000601
Legend
(1) Shift fork pin
(2) Shift fork
(3) Release bearing
226RS001
11. Remove the speedometer sensor (2).

Remove the plate (2).
Remove the driven gear bushing and driven gear
(2).
NOTE : Apply a reference mark to the driven gear
bushing before removal.
12. Remove gear control box assembly (1).
7B1-20
MANUAL TRANSMISSION
13. Remove the rear cover assembly (3) from the

transmission case (5) and intermediate plate (4).
14. Remove intermediate plate with gear assembly (4)
from transmission case (5).
Reassembly
1. Apply recommended liquid gasket (LOCTITE 17430)
or its equivalent to the transmission case (5),
intermediate plate (4) and rear cover (3) fitting
surfaces.
2. Install the intermediate plate with gear assembly (4)
to the transmission case (5).
Pull out the top gear shaft until the ball bearing snap
ring groove protrudes from the transmission case
front cover fitting face.
4. Install a new gasket and gear control box assembly

(1).
Install the harness clips and brackets and then
tighten four new gear control box bolts to the
specified torque.
Torque: 20 N
m (2.0 kg
m/14 lb
ft)
Avoid subjecting the main shaft to sudden shock or

stress.
3. Install the rear cover with oil seal (3) on the
intermediate plate with gear (4) by performing the
following steps.
Cover the shaft splines with adhesive tape.
This will prevent damage to the oil seal lip.
261R300004
5. Install the O-ring (4) to the speedometer driven gear

bushing (3).
Install the driven gear to the speedometer driven
gear bushing (3).
6. Install the speedometer driven gear assembly (2) to
the transmission rear cover (3).
Install the plate (1) to the transmission rear cover
(3).
Torque: 15 N
m (1.5 kg
m/11 lb
ft)
MANUAL TRANSMISSION
7. Install the speedometer sensor (2).

Torque: 27 N
m (2.8 kg
m/20 lb
ft)
7B1-21
Use the oil seal installer 5-8840-0026-0 to install

the oil seal to the front cover.
220R3000020
225R300001
8. Install top gear bearing snap ring (10) and counter

front bearing snap ring (8).
Use a pair of snap ring pliers to install the snap
rings to the mainshaft and countershaft.
The snap rings must be fully inserted into the
bearing snap ring groove.
9. Front cover with oil seal (9).
Front Cover Oil Seal Replacement
Remove the oil seal from the front cover.
Apply engine oil to a new oil seal outer
circumference.
Apply recommended grease to the oil seal lip.
10. Install a new gasket and front cover (9) to the

transmission case.
NOTE: Take care not to damage the oil seal.
Notes When Tightening the Bolt:
After cleaning the bolt hole, dry it thoroughly with air.
After cleaning the screw face of a removed bolt or
new one, dry it thoroughly. Apply recommended
liquid gasket (LOCTITE 242) or its equivalent before
tightening it.
Tighten six front cover bolts to the specified torque.
m (2.6 kg
m/19 lb
ft)
Torque: 25 N
11. Apply molybdenum disulfide type grease to the
areas as shown in the figure and install shift fork (7).
(Diesel engine, C24NE)
F07L100026
7B1-22
MANUAL TRANSMISSION
12. Install the fulcrum bridge to the transmission case.

(6VE1)
15. Install the washer and snap pin. (6VE1)
m (3.9 kg
m/28 lb
ft)
Torque: 38 N
RTW37ASH0002
Legend
(1) Fulcrum bridge
13. Apply molybdenum disulfide type grease to the pin

hole inner circumferences and thrust surfaces.
(6VE1)
14. Attach the shift fork to the fulcrum bridge and insert
the pin from below of the fulcrum bridge. (6VE1)
RTW47BMH000201
16. Pack the inside recess (A) and coat the back (B) of
the release bearing with molybdenum disulfide type
grease as shown in the figure.
A07RW075
17. Install the release bearing (6) on the front cover,

joining it to the shift frok.
MANUAL TRANSMISSION
7B1-23
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and
Interlock Pin
Disassembled View
RTW47BLF000501
Legend
(1) Detent Spring Plate and Gasket
(7) 1st-2nd Shift Rod
(2) Detent Spring
(8) 3rd-4th Shift Rod
(3) Detent Ball
(9) 3rd-4th Shift Arm
(4) Spring
(10) 1st-2nd Shift Arm
(5) Rev-5th Shift Rod
(11) Interlock Pin
(6) Rev-5th Shift Arm and Reverse Inhibitor
(12) Intermediate Plate and Gear Assembly
7B1-24
MANUAL TRANSMISSION
Disassembly
1. Remove detent spring plate and gasket (1), detent
spring (2) and detent ball (3).
Use a magnetic hand to remove the detent balls
from the intermediate plate.
230RS0004
Be careful not to lose the interlock pins, when

pulling out the shift rod rearward.
Interlock pins are located between the shifter
rods in the intermediate plate.
220RS011
2. Remove spring (4).

3. Remove rev-5th shift rod (5), and rev-5th shift arm
and reverse inhibitor (6).
Remove 1st-2nd shift rod (7), 3rd-4th shift rod (8),
3rd-4th shift arm (9), and 1st-2nd shift arm (10).
Hold a round bar against the shift rod end.
230RS0005
Remove the rev-5th, 1st-2nd and 3rd-4th shift

rods carefully.
4. Remove interlock pin (11) from intermediate plate
and gear assembly (12).
230RS003
Use a spring pin remover to remove the shift

arm spring pins from the shift arms and the shift
rods.
MANUAL TRANSMISSION
7B1-25

Make the necessary adjustments, and part
replacements if excessive wear or damage is
Shift Arm Thickness

Use a micrometer to measure the shift arm
thickness.
Shift Arm Thickness

Standard
9.60 - 9.85 mm
1st-2nd
(0.378 - 0.388 in)
3rd-4th
9.60 - 9.80 mm
Rev.5th
(0.378 - 0.386 in)
Limit
9.0 mm
(0.354 in)
220RS012

Use a spring tester to measure the detent spring
tension.
Compressed height
20 mm (0.787 in)
Standard
87.2 - 97.1 N
(19.6 - 21.8 lb)
230RS006

Use a vernier caliper to measure the detent spring
free length.

Standard
26.8 mm (1.06 in)
Limit
26.2 mm (1.03 in)
220RS013
SOUTH AFRICA 5th-Rev Only

Standard
Outer
27.6 mm (1.09 in)
Inner
26.6 mm (1.05 in)
Limit
27.0 mm (1.06 in)
26.0 mm (1.02 in)
SOUTH AFRICA 5th-RV Only

Compressed
Outer
20 mm (0.787 in)
Inner
20 mm (0.787 in)
Standard
93.5 103.3 N
(21.0 23.3 lb)
26.4 36.3 N
(5.9 8.2 lb)
7B1-26
MANUAL TRANSMISSION
Reassembly
1. Install rev-5th shift arm and reverse inhibitor (6) and
rev-5th shift rod (5).
Apply oil to the reverse inhibitor inner surface.
Install the shift rod in the intermediate plate (12).
Hold a round bar against the shift rod end lower
face to protect it against damage.
Install a new spring pin.
Never reinstall the used spring pin.

5. Put detent balls (3) in the intermediate plate holes.
Apply oil to the detent balls.
6. Install detent springs (2) and detent spring plate and
gasket (1).
Install a new gasket and the detent spring plate.
Tighten the detent spring plate bolts to the
specified torque.
Torque: 25 N
m (2.5 kg
m/18 lb
ft)
Install the interlock pin (11) in the intermediate

plate (12).
Do not allow the interlock pin to fall from the
intermediate plate (12).
2. Install 1st-2nd shift arm (10) and 3rd-4th shift arm(9)

to intermediate plate and gear assembly (12).
3. Install 3rd-4th shift rod (8) and 1st-2nd shift rod (7).
plate and gear assembly (12).
Install the 3rd-4th shift rod (8) in the intermediate
plate (12).
intermediate plate.
Install the interlock pin (11) and then 1st-2nd

shift rod (7) in the intermediate plate (12).
intermediate plate.

230RS007
220RS030
Legend
(1) Warped
MANUAL TRANSMISSION
7B1-27
Reverse Gear and 5th Gear

Disassembled View
226R300027
Legend
(1) Bearing Snap Ring
(11) Reverse Idler Gear Assembly
(2) Ball Bearing
(12) Idle Shaft Pin
(13) Thrust Washer
(4) Speedometer Drive Gear
(14) Reverse Idler Gear
(5) Clip
(15) Reverse Idler Shaft
(6) Retainer Snap Ring
(7) Retainer
(17) Ball Bearing
(8) Thrust Plate
(18) Counter 5th Gear
(9) Thrust Washer and Lock Ball
(19) Counter Reverse Gear
(10) Reverse Idler Gear Snap Ring
(20) 5th Gear
7B1-28
MANUAL TRANSMISSION
(21) 5th Block Ring
(26) Reverse Gear
(22) Needle Bearing
(27) Needle Baring
(23) Mainshaft Nut
(28) Bearing Plate and Screw
(24) Rev-5th Synchronizer Assembly
(25) Reverse Block Ring
(30) Intermediate Plate
MANUAL TRANSMISSION
Disassembly
1. Use a pair of snap ring pliers to remove the bearing
snap ring (1).
2. Set the bearing remover 5-8840-2155-0 and puller
5-8840-2027-0 to the bearing (2) and the mainshaft
end to remove the ball bearing (2).
7B1-29
6. Remove the reverse idler gear assembly (11) from

the intermediate plate (30).
226RS005
262L100001
3. Remove the bearing snap ring (3), clip (5),

speedometer drive gear (4), retainer snap ring (6)
and retainer (7).
4. Remove thrust plate (8) and thrust washer and lock
ball (9).
5. Use a pair of snap ring pliers to remove reverse idler
gear snap ring (10).
7. Remove idle shaft pin (12), thrust washer (13),

reverse idler gear (14), and reverse idler shaft (15).
ring (16).
9. Attach a universal puller to the counter gear shaft.
Use a universal puller to remove the ball bearing
(17) and the counter 5th gear (18).
226RS006
10. Remove counter reverse gear (19).
226RS004
7B1-30
MANUAL TRANSMISSION
11. Remove 5th gear (20), 5th block ring (21), and
needle bearing (2 piece type) (22).
226RW210
226RS007
Use the mainshaft nut wrench 5-8840-2156-0 to

remove the mainshaft nut (23).
12. Remove the mainshaft nut (23) according to

following steps.
Attach the holding fixture 5-8840-2160-0 and base
5-8840-0003-0 to the mainshaft and the counter
gear.
226RW211
226RW212
Engage the 3rd-4th synchronizer with the 3rd

gear.
Engage the 1st-2nd synchronizer with the 1st
gear.
MANUAL TRANSMISSION
7B1-31
13. Use screw drivers between the reverse gear (26)

and bearing plate (28) to remove the Rev-5th
synchronizer assembly (24) together with reverse
block ring (25) and reverse gear (26).
226RS011
17. Hold the snap ring open with the pliers.

Push the intermediate plate (30) toward the rear of
the transmission to remove it.
226RS010
14. Remove needle bearing (27).

15. Use the torx bit wrench (T45) 5-8840-0047-0 to
remove the bearing plate and screw(28) from the
intermediate plate.
The bearing snap ring (29) will come free.

Refer to Top Gear Shaft, Main Gear Shaft, and Counter
Gear in this section for inspection and repair.
Reassembly
1. Mesh the counter gear with the mainshaft assembly.
Set the holding fixture 5-8840-2160-0 to the
mainshaft and the counter gear and then install it on
the base 5-8840-0003-0.
Install the intermediate plate (30) on the gear
assembly.
220RW137
16. Use the snap ring pliers (1) to remove the mainshaft
bearing snap ring (2) (29).
226RW212
7B1-32
MANUAL TRANSMISSION
2. Install bearing snap ring (29).

3. Apply recommended thread locking agents
(LOCTITE 242) or its equivalent to each of the
bearing plate screw threads.
Install bearing plate and screw (28).
Tighten the screws to the specified torque by using
torx bit wrench 5-8840-0047-0.
Torque: 15 N
m (1.5 kg
m/11 lb
ft)
5. Assemble rev-5th synchronizer assembly (24) by

performing the following steps.
1. Turn the clutch hub face (1) toward the sleeve
groove (2) (rear side) on the outer
circumference.
2. Check that the inserts (3) fit snugly into the
clutch hub (5) ring insert grooves.
3. Check that the inserts springs (4) are fitted to
the inserts as shown in the illustration.
4. Check that the clutch hub (5) and the sleeve (6)
slide smoothly.
5. Install the synchronizer assembly (24) to the
mainshaft.
The clutch hub face with the heavy boss must be
facing the reverse gear side.
220RW137
4. Install needle bearing (27), reverse gear (26), and

reverse block ring (25).
226RS013
226RS049
MANUAL TRANSMISSION
6. Mesh the 1st-2nd and 3rd-4th synchronizers with
both the 1st and 3rd gears (double engagement).
7B1-33
8. Use a punch to stake the mainshaft nut (23).
226RW153
226RS015
This will prevent the mainshaft from turning.

7. Install the new mainshaft hub nut.
tighten the mainshaft nut (23) to the specified
torque.
Torque: 137 N
m (14 kg
m/101 lb
ft)
9. Install needle bearing (22), 5th block ring (21), and

5th gear (20).
10. Apply engine oil to the counter reverse gear (19) and
the reverse gear (26).
Install the counter reverse gear (19) to the counter
shaft.
The reverse gear projection must be facing the
intermediate plate.
226RW214
226RW151
7B1-34
MANUAL TRANSMISSION
11. Install the counter 5th gear (18) to the counter shaft.
There are six snap ring sizes available.

The snap rings are color&dash;coded to indicate
their thickness.
226RS019
12. Install ball bearing (17) and bearing snap ring (16)
by performing the following steps:
Select the snap ring which will provide the
minimum clearance between the ball bearing
and the snap ring.
226RS021
Ball Bearing and Snap Ring Clearance

Standard: 0 - 0.15 mm (0 - 0.0059 in)
Thickness
Color Coding
1.1 mm (0.043 in)
White
1.2 mm (0.047 in)
Yellow
1.3 mm (0.051 in)
Blue
1.4 mm (0.055 in)
Pink
1.5 mm (0.059 in)
Green
1.6 mm (0.063 in)
Brown
226RS020

ring(13) to the counter gear shaft.
The snap ring must be fully inserted into the
counter gear shaft snap ring groove.
13. Assemble reverse idler shaft (15), reverse idler gear

(14), thrust washer (13), and idle shaft pin (12) into
reverse idler gear assembly (11).
The trust washer should be assembled as oil groove
faces to gear side.
MANUAL TRANSMISSION
14. Select reverse idler gear snap ring (10) which will
provide the minimum clearance between the
intermediate plate (30) and the snap ring (10).
7B1-35

ring to the reverse idler shaft.
reverse idler shaft snap ring groove.
15. Install thrust washer and lock ball (9) by performing

the following steps:
Use a thickness gauge to measure the
clearance between the 5th gear and the thrust
washer.
Standard: 0.10 - 0.25 mm (0.004 - 0.010 in))
Measure clearance "A" as shown in the figure.
226RS022
There are three snap ring sizes available.

The snap rings are color-coded to indicate their
thickness.
Intermediate Plate and Snap Ring Clearance

Standard: 0 - 0.15 mm (0 - 0.0059 in)
Thickness
Color Coding
1.2 mm (0.047 in)
White
1.3 mm (0.051 in)
Yellow
1.4 mm (0.055 in)
Blue
226RS023
Select appropriate thrust washer from chart.

There are four thrust washer sizes available.
Thickness Color
Clearance
A mm (in)
mm (in)
Coding
mm (in)
8.05 - 8.1
0.15 - 0.25
7.9 (0.311) White
(0.317-0.319) (0.006-0.010)
8.1 - 8.2
0.1 - 0.25
8.0 (0.315) Yellow
(0.319-0.323) (0.004-0.010)
8.2 - 8.3
0.1 - 0.25
8.1 (0.319) Green
(0.323-0.327) (0.004-0.010)
8.3 - 8.36
0.1 - 0.21
8.2 (0.323)
Blue
(0.327-0.329) (0.004-0.008)
226RS021
The thrust washers are color coded to indicate

their thickness as shown in the figure.
7B1-36
MANUAL TRANSMISSION
19. Install the bearing snap ring (1).
226RS024
Apply grease to the thrust washer and the lock

ball.
Install the thrust washer and the lock ball.

16. Install thrust plate (8) and retainer (7).
17. Install the retainer snap ring (6), clip (5),
speedometer drive gear (4) and bearing snap ring
(3).
18. Apply engine oil to the bearing (2) inner and outer
circumference.
Use the installer 5-8840-2159-0 to install the ball
bearing (2) to the mainshaft.
226L100002
MANUAL TRANSMISSION
7B1-37
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft
Disassmebled View
226RS026
7B1-38
MANUAL TRANSMISSION
Legend
(1) Top Gear Shaft Snap Ring
(16) 1st Outside Ring
(2) Top Gear Shaft
(17) 1st Block Ring
(3) Ball Bearing
(18) Needle Bearing
(4) Needle Bearing
(19) Clutch Hub Snap Ring
(5) Top Block Ring
(20) 1st-2nd Synchronizer Assembly
(6) Mainshaft Snap Ring
(21) 2nd Block Ring
(7) 3rd-4th Synchronizer Assembly
(22) 2nd Outside Ring
(8) 3rd Block Ring
(23) 2nd Inside Ring
(9) 3rd Gear
(24) 2nd Gear
(10) Needle Bearing
(25) Needle Bearing
(11) Needle Bearing Collar
(26) Mainshaft
(12) Mainshaft Ball Bearing
(13) 1st Gear Thrust Bearing
(28) Front Roller Bearing
(14) 1st Gear
(29) Center Roller Bearing
(15) 1st Inside Ring
(30) Counter Gear Shaft
MANUAL TRANSMISSION
Disassembly
1. Use a pair of snap ring pliers to remove the top gear
shaft snap ring(1).
2. Remove top gear shaft(2) with ball bearing(3).
3. Use a bench press and the bearing remover 5-88400015-0 to remove the ball bearing(3).
7B1-39
6. Use a bench press and the bearing remover 5-88400015-0 to remove the 3rd-4th synchronizer
assembly (7) as a set.
Disassemble the synchronizer assembly.
226RW217
226RW216
4. Remove needle bearing (4) and top block ring (5),

mainshaft snap ring.
5. Use a pair of snap ring pliers to remove the
mainshaft snap ring (6).
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
7. Remove 3rd block ring (8), 3rd gear (9), and needle
bearing (10).
8. Use a bench press and the bearing remover 5-88400015-0 to remove the 1st gear(14) together with the
mainshaft ball bearing(12), 1st gear thrust bearing
(13), and needle bearing collar (11).
226RS008
226RW218
7B1-40
MANUAL TRANSMISSION
9.Disassemble 1st inside ring (15), 1st outside ring (16),

and 1st block ring (17).
10.Remove needle bearing (18).
11.Use a pair of snap ring pliers to remove the clutch
hub snap ring (19).
13. Remove needle bearing (25) from mainshaft (26).

14. Remove bearing snap ring (27).
15. Remove the front roller bearing (28) by performing
the following steps.
Remove the ring, outer race and bearing
assembly by using a bench press and remover
5-8840-0015-0.
Remove the inner race by using a bench press
and remover 5-8840-0015-0.
226RS031
12.Use bench press and the bearing remover 5-88400015-0 to remove the 2nd gear (24) together with
1st-2nd synchronizer assembly (20), 2nd block ring
(21), 2nd outside ring (22), and inside ring (23).
226RW219
16. Remove center roller bearing (29) from counter gear

shaft (30).
226RW220
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
MANUAL TRANSMISSION


Use a thickness gauge to measure the clearance
226RS035

the block ring must be replaced.

Standard
Limit
1.5 mm (0.059 in)
0.8 mm (0.032 in)
7B1-41
7B1-42
MANUAL TRANSMISSION
1st-2nd Synchronizer (3-CONE)

Block and Insert Clearance

Standard
3.46 - 3.76 mm
3rd-4th
(0.136 - 0.148 in)
3.86 4.16 mm
1st-2nd
(0.152 - 0.164 in)
3.59 - 3.91 mm
Rev.5th
(0.141 - 0.154 in)
Limit
4.0 mm
(0.158 in)
4.9 mm
(0.193 in)
4.1 mm
(0.161 in)

226RS036

the 1st-2nd synchronizer assembly must be
replaced.

Standard
Limit
1.5 mm (0.059 in)
0.8 mm (0.032 in)

Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and the insert.
226RS038

the clutch hub and the insert must be replaced.
Standard
1st-2nd
0.01 0.21 mm
3rd-4th
(0.004 - 0.0083 in)
0.09 0.31 mm
Rev-5th
(0.0035 - 0.0122 in)
226RS037

Limit
0.3 mm
(0.012 in)
0.4 mm
(0.016 in)
MANUAL TRANSMISSION
Mainshaft Run-out

Standard
1st
45.000 - 45.013 mm
(1.771 - 1.772 in)
3rd
52.000 - 52.013 mm
2nd
(2.047 - 2.048 in)
48.000 - 48.013 mm
Rev.
(1.889 - 1.890 in)
32.000 - 32.013 mm
5th
(1.259 - 1.260 in)
Install the mainshaft to V-blocks.

Use a dial indicator to measure the mainshaft
7B1-43
Limit
45.100 mm
(1.776 in)
52.100 mm
(2.051 in)
48.100 mm
(1.894 in)
32.100 mm
(1.246 in)
Reverse Idler Gear and Idler Gear Shaft

Clearance
Use a micrometer to measure the idler gear shaft
diameter.
Use an inside dial indicator to measure the idler
gear inside diameter.
226RS039
If the measured mainshaft run-out exceeds the

specified limit, the mainshaft must be replaced.
Mainshaft Run-out
Limit: 0.05 mm (0.0020 in)

Use an inside dial indicator to measure the gear
inside diameter.
226RS041
Calculate the idler gear and idler gear shaft

clearance.
Idler gear inside diameter-idler gear shaft diameter =
idle gear and idler gear shaft clearance.
the idle gear and/or the idler gear shaft must be
replaced
Standard: 0.041 - 0.074 mm (0.0016 -0.0029 in)
Limit: 0.150 mm (0.0059 in)
226RS040

the gear must be replace.
7B1-44
MANUAL TRANSMISSION

Set a dial indicator to the clutch hub to be
measured.
226RS043
Reassembly
226RS042

right and the left.
Standard
1st-2nd
0 - 0.1 mm
3rd-4th
(0 - 0.004 in)
0 - 0.2 mm
Rev. 5th
(0 - 0.008 in)
1. Install center roller bearing (29) to counter gear

shaft (30).
Apply engine oil to the bearing inner and outer
circumferences.
Install the roller bearing in the proper direction.
NOTE: Check that outer race moves only in the
direction of arrow.
Limit
0.2 mm
(0.008 in)
0.3 mm
(0.012 in)
Ball Bearing Play

Ball Bearing Play
Limit: 0.2 mm (0.008 in)
226RS044
2. Install front roller bearing (28) by performing the

following steps.
Use bearing installer 5-8840-2194-0 to install the
front roller bearing inner race to the counter gear
shaft (30).
Install the outer race and roller assembly.
The snap ring groove must be facing the
transmission front side.
MANUAL TRANSMISSION

ring.
7B1-45
5. Assemble 2nd inside ring (23), 2nd outside ring (22),

and 2nd block ring (21) on 2nd gear (24).
Apply engine oil to the synchronizer ring friction
surfaces.
RTW47BSH000501
Legend
(1) Ring
(2) Outer Race and Roller Assembly
(3) Inner Race
226RS047
3. Install bearing snap ring (27) to counter gear shaft

(30).
4. Apply engine oil to the needle bearing (25) and the
2nd gear (24) thrust surfaces.
Install the needle bearing (25) and the 2nd gear (24)
to the mainshaft (26).
The 2nd gear (24) dog teeth must be facing the
transmission rear side.
226RS046
Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) 2nd Gear
(5) Needle Bearing
6. Assemble 1st-2nd synchronizer assembly (20) by
performing the following steps:
clutch hub (5) insert grooves.
slide smoothly.
7B1-46
MANUAL TRANSMISSION
266RS049

mainshaft (26).
facing the 2nd gear side.
226RS050

The snap rings are color coded to indicate their
thickness as shown in the figure.
226RS021
226RS048
8. Install clutch hub snap ring(19) by performing the

following steps:
minimum clearance between the 1st-2nd clutch
hub and the snap ring.
Clutch Hub and Snap Ring Clearance

Standard: 0 - 0.1 mm (0 - 0.004 in)

Thickness
1.80 mm (0.071 in)
1.85 mm (0.073 in)
1.90 mm (0.075 in)
Color Coding
White
Yellow
Blue

ring (19) to the mainshaft (26).
mainshaft snap ring groove.
MANUAL TRANSMISSION
7B1-47
10. Install the 1st gear thrust bearing and the race(13) to
the main shaft.
The thrust bearing side must be facing the
226RS031
9. Install needle bearing (18), 1st block ring (17), 1st

outside ring (16), 1st inside ring (15), and 1st gear
(14).
Apply engine oil to the needle bearing, 1st gear
thrust surfaces and synchronizer ring friction
surfaces.
The 1st gear dog teeth must be facing the
226RS054
11. Apply engine oil to the mainshaft ball bearing (12)

and the mainshaft (26).
Install the ball bearing (12) and needle bearing collar
(11) to the mainshaft (26).
The ball bearing snap ring groove must be facing
the transmission rear side.
Use a bench press and installer 9-8522-1165-0 to
slowly force the collar into place.
226RS053
Legend
(1) 1st Gear
(2) Needle Bearing
(3) Inside Ring
(4) Outside Ring
(5) Block Ring
226RS055
7B1-48
MANUAL TRANSMISSION
3rd gear (9) thrust surfaces.
Install the needle bearing (10) and the 3rd gear (9)
to the mainshaft.
The 3rd gear dog teeth must be facing the
226RS049
15. Select and install mainshaft snap ring(6) in the

following way:
Select the snap ring which will provide the minimum
clearance between the 3rd-4th clutch hub and the
snap ring.
226RS056
13. Install 3rd block ring (8).

14. Check and install 3rd-4th synchronizer assembly (7)
by the following steps:
clutch hub insert grooves.
2. Check that the insert springs (4) are fitted to the
inserts as shown in the illustration.
slide smoothly.
4. Install the synchronizer assembly to the
mainshaft.
facing the 3rd gear side.
226RS058

226RW221
MANUAL TRANSMISSION
7B1-49
16. Install top block ring (5).

Apply grease to the needle bearing (4) inner and
outer circumferences and install needle bearing (4)
in the top gear shaft (2).
17. Use a bench press to install the top gear shaft ball
bearing (3) to the top gear shaft (2).
226RS021

Standard: 0 - 0.1 mm (0 - 0.004 in)
Thickness
1.80 mm (0.071 in)
1.85 mm (0.073 in)
1.90 mm (0.075 in)
Color Coding
White
Yellow
Blue

ring to the mainshaft.
226RS059
The snap ring groove of the ball bearing (3) must be

facing the transmission front side.
18. Use a pair of snap ring pliers to install the top gear
shaft snap ring (1) to the top gear shaft (2).
7B1-50
MANUAL TRANSMISSION

MUA 5G
Transmission type
Fully synchronized forward and reverse gears
Control method
Gear ratio: Transmission
Transmission oil capacity

Type of lubricant
MUA 5S
Remote control with the gear shift lever on the floor.

1st
4.008
4.357
2nd
2.301
2.502
3rd
1.427
1.501
4th
1.000
1.000
5th
0.828
0.809
Rev.
3.651
3.970
2.95 lit. (3.12 US qt)
Engine oil: Refer to the chart in "SECTION 0"
MANUAL TRANSMISSION
7B1-51
RTW47BLF001201
About arrow mark, refer to Transmission (MUA) Installation in this section.
7B1-52
MANUAL TRANSMISSION
RTW47BLF000901
MANUAL TRANSMISSION
7B1-53
RTW47BLF000601
7B1-54
MANUAL TRANSMISSION
TROUBLESHOOTING
1. ABNORMAL NOISE
1) NOISY IN NEUTRAL
Checkpoint
Gear oil
Trouble Cause
Countermeasure
NG
Insufficient or improper gear

oil
Replenish or replace the gear

oil
NG
Worn flywheel pilot bearing
Replace the flywheel pilot
Worn or broken bearing(s)
Replace the bearing(s)
Worn or scuffed gear tooth

contact surfaces
Replace the gear(s)
Worn splines
Replace the main shaft and

the synchronizer clutch hub
Transmission misalignment
Realign the transmission
OK
Flywheel pilot bearing
OK
Bearings (Mainshaft,
countershaft, and transfer
shaft)
NG
OK
Gears (Mainshaft,
countershaft, reverse idler
gear and transfer gears)
NG
OK
Mainshaft splines
Synchronizer clutch hub
splines
NG
OK
Transmission
NG
MANUAL TRANSMISSION
7B1-55
2) NOISY OPERATION
Checkpoint
Gear oil (Metallic rattling)
Trouble Cause
Countermeasure
NG
Insufficient or improper engine

oil

oil
NG
NG
Worn, chipped, or cracked

gear(s)
Replace the gear(s)
Free running gears seizing on

the thrust face or the inner
face
Replace the gear(s)
Lack of backlash between

meshing gears
Replace the gear(s)
OK
Bearings (Hissing, thumping
or bumping)
OK
Gears (Growling, humming, or

grinding)
OK
Gears (Squealing at high

speeds)
NG
OK
Gears (Gear whining)
NG
7B1-56
MANUAL TRANSMISSION
2. HARD SHIFTING
Checkpoint
Gear oil
Trouble Cause
Countermeasure
NG

oil
Replenish or replace the

engine oil
NG
Improper clutch pedal free

play
Readjust the clutch pedal free

play
NG
Hard operating change lever

caused insufficient grease
Repair or regrease the change

lever assembly
NG
Worn change lever sliding

portions

applicable parts and regrease
Sleeve movement failure
Repair or replace the sleeve
Worn shift rod and/or sliding

faces
Replace the shidt rod and/or

the quadrant box
OK
OK
Change lever operation
OK
Change lever play
OK
Shift block sleeve movement
NG
OK
Shift rod and quadrant box

sliding faces, and other parts
NG
MANUAL TRANSMISSION
Checkpoint
Trouble Cause
Countermeasure
Continued from the previous

OK
Shift arm and synchronizer
sleeve
NG
Worn shift arm and/or

synchronizer sleeve groove
Replace the worn parts
NG
Worn thrust washer, collar,

and/or gear thrust faces
Worn synchronizer parts
OK
Mainshaft and countershaft

thrust play
OK
Synchronizer assembly
NG
7B1-57
7B1-58
MANUAL TRANSMISSION
3. WALKING OR JUMPING OUT OF GEAR

Checkpoint
Trouble Cause
Insufficient stroke caused by

sliding position wear and
excessive play
Worn detent ball
Replace the detent ball
Detent spring weak or broken
Repair or replace the detent

spring
NG

faces
Replace the shift rod and/or

the quadrant box
NG

NG

NG
Change lever play
Countermeasure
OK
NG
Detent ball
OK
NG
Detent spring
OK

sliding faces
OK

sleeve
OK

thrust play
MANUAL TRANSMISSION
Checkpoint
Trouble Cause
7B1-59
Countermeasure

OK
countershaft, and individual
gears)
NG
Worn or broken bearings(s)
Worn splines

Weak or broken spring
Replace the spring
OK
Mainshaft splines
splines
NG
OK
NG
7B1-60
MANUAL TRANSMISSION
4. OIL LEAKAGE
Checkpoint
Trouble Cause
NG
Oil level
Countermeasure
Oil level too high
Drain the oil to the correct

level
Improper gear oil
Loose plug(s)
Tighten the plug(s) and

replenish the oil
NG
Defective or improperly
installed gasket(s)
Replace the gasket(s)
NG
Air breather not installed

Air breather clogged
Install the air breather

Replace the air breather
Worn or scratched oil seal
OK
NG
Gear oil
OK
Drain plug and/or filler plug
NG
OK
Gaskets
OK
Air breather
OK
NG
OK
Rear cover oil seal
NG
MANUAL TRANSMISSION
7B1-61
2)
Special Tools (4
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-2155-0
Bearing remover
5-8840-2027-0
Puller
5-8840-2160-0
Holding fixture
5-8840-0003-0
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-2159-0
Mainshaft end bearing
installer
5-8840-0015-0
Bearing
remover/installer
5-8840-2797-0
Rear case oil seal
installer
5-8840-0026-0

installer
5-8840-2156-0
9-8522-1165-0
Wrench
Mainshaft collar remover
5-8840-0047-0
Tork bit wrench
5-8840-0007-0
(T45)
Driver handle
7B1-62
MANUAL TRANSMISSION
Service Precaution

parts and systems.
MANUAL TRANSMISSION
7B1-63
General Description
MUA Transmission (4
4)
A07R300003
The MUA is a constant mesh transmission,

synchronized in all speeds. The transmission is
designed for a great reduction of the shift effort and the
quietest possible operation.
Principle parts of the transmission are the integral clutch

housing, the intermediate plate, the rear case, and the
gears.
The transmission control box is built into the
transmission.
7B1-64
MANUAL TRANSMISSION
4)
Transmission (4
Disassembled View
RTW47BLF001001
Legend
(1) Gear Control Lever Knob
(10) Transmission-Transfer Fixing Bolt
(2) Rear Floor Console (bucket)
(11) Transfer Assembly
(12) Fuel Pipe Bracket
(13) Slave Cylinder
(5) Gear Control Lever
(14) Rear Mount Nut
(7) Front Propeller Shaft
(16) Starter (Diesel engine only)
(8) Exhaust Pipe Nut (Diesel engine)
(17) Transmission Retaining Nut and Bolt
(9) Exhaust Pipe Assembly (6VE1)
MANUAL TRANSMISSION
Removal
7B1-65
5. Remove grommet assembly (4).

2. Remove gear control lever knob (1).
3. Remove rear floor console (2). (Bucket seat)
4. Remove front floor console (3).
745R300006
Legend
(1) Knob
RTW47BMH000101
7B1-66
MANUAL TRANSMISSION
6. Remove gear control lever (5).

8. Remove rear propeller shaft (6).
differential side.
9. Remove front propeller shaft (7).
11. Remove the exhaust pipe (9). (6VE1 only)
RTW37ASH000101

transfer.
Actuator connector
Car Speed Sensor
401RS023
10. Loosen the front exhaust pipe fixing nuts (8) at the
engine side but not remove them. (Diesel engine
only)
810R300069
150R300004
Legend
(1) Neutral Switch Connector: Transmission
(2) Back up Switch Connector
(3) Speed Sensor Connector
(4) Actuator Connector
(5) 2W - 4W Switch Connector
(6) Neutral Switch Connector: Transfer
MANUAL TRANSMISSION
13. Remove transmission-transfer fixing bolts (10), and
remove the transfer assembly (11) from the
transmission.
transmission.
Neutral switch; Transmission
Back up Switch
2W-4W Switch
Neutral Switch; Transfer
15. Remove the fuel pipe brackets (12) with pipes from
the transmission (18).
7B1-67
16. Remove slave cylinder (13) and put aside it.
Diesel engine
220LV019
17. Support transmission with a transmission jack.
220R300012
Legend
(1) Bolt
(2) Nut
6VE1, C24NE
220RS0001
18. Remove engine rear mount nuts (14) from

transmission crossmember (15).
Scan-2
7B1-68
MANUAL TRANSMISSION
19. Remove engine rear mount bolts fixing

transmission.
22. Remove starter (16). (Diesel engine only)
220R300009
20. Remove the middle part of transmission

crossmember (15) by removing four fixing bolts and
nuts.
501R30007
21. Take out the rear support rubber.
060L100070
23. Use the clutch release bearing remover 5-88402291-0 (J-39207) to disconnect the clutch release
bearing from the clutch pressure plate. (6VE1 only)
220RW109
Release bearing disconnection

1. Pull the shift fork toward the transmission to
press the clutch release bearing against the
clutch.
2. Insert the clutch release bearing remover
between the wedge collar and the release
bearing.
3. Turn the remover to separate the release
bearing.
MANUAL TRANSMISSION
7B1-69
NOTE: Be sure not to insert the remover between the

wedge collar and the clutch.
220RW019
Legend
(1) Pressure Plate Assembly
(2) Release Bearing
(3) Wedge Collar
24. Remove transmission retaining nuts and bolts(17).

Remove transmission assembly (18) from the
vehicle.
Installation
220RW063
220RW064

the top gear shaft spline.
2. Slowly operate the transmission jack until the front
of transmission is aligned with the rear of the
engine.
The slope of the engine and the transmission must
be the same.
3. Align the top gear shaft with the clutch driven plate
spline.
7B1-70
MANUAL TRANSMISSION
4. Install the transmission assembly (18) to the engine.

Tighten the transmission nuts and bolts as shown in
the figure.
Diesel engine
RTW37BLF000901
MANUAL TRANSMISSION
7B1-71
6VE1
RTW37BLF0001
7B1-72
MANUAL TRANSMISSION
RTW37BLF000201
5. Apply a force of about 113N (26 Ib) to the tip of the

shift fork in the direction of the transmission to
engage the clutch pressure plate and release
bearing. (6VE1 only)
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage
each other.
Check to see if they are securely engaged by pushing
the tip of the shift fork toward the engine while applying
a force of about 25 N (5.5 lb). If the shift fork will not
move, then they are securely engaged.
220RS006
MANUAL TRANSMISSION
6. Install starter(16).(Diesel engine)
NOTE: Tighten the lower bolt temporarily.
After installing the fuel pipe assembly, tighten the bolt to
7B1-73
6VE1, C24NE
Torque: 76 N
m (7.7 kg
m/56 lb
ft)
7. Install the rear support rubber on the transmission
and tighten the bolts to the specified torque.
Torque: 50 N
m (5.1 kg
m/37 lb
ft)
8. Install the middle part of transmission crossmember
(15) and bolts.
Tighten the nuts to the specified torque.
Torque: 67 N
m (6.8 kg
m/49 lb
ft)
9. Install engine rear mount nuts (14).
Torque: 52 N
m (5.3 kg
m/38 lb
ft)
Remove the transmission jack from transmission
side.
10. Apply grease to top hole portion of the shift fork.
Install slave cylinder (13) and tighten the bolts to the
specified torque.
Scan-2
12. Connect transmission harness connectors and clips.

Connector: transfer neutral switch, 2W - 4W switch,
backup switch, transmission neutral switch.
Torque: 76 N
m (7.7 kg
m/56 lb
ft)
11. Install the fuel pipe brackets on the transmission.
Install the fuel pipe assembly to the fuel pipe
brackets
Torque: Bolt & Nut
Nut
76 N
m (7.7 kg
m/56 lb
ft)
37 N
m (3.8 kg
m/28 lb
ft)
Diesel engine
810R300069
220R300012
Legend
(1) Bolt
(2) Nut
Legend
(1) Neutral Switch Connector: Transmission
(2) Backup Switch Connector
(3) Speed Sensor Connector
(4) Actuator Connector
(5) 2W - 4W Switch connector
(6) Neutral Switch Connector: Transfer
13. Apply grease (BESCO L2 or equivalent) on the

splined portion of the output shaft.
14. Connect the transfer to the transmission.
7B1-74
MANUAL TRANSMISSION
15. Install the transmission-transfer bolts and nut and

tighten them to the specified torque.
m (4.2 kg
m/30 lb
ft)
Torque: 41 N
18. Install the exhaust pipe (9). (6VE1)

Torque: 67 N
m (6.8 kg
m/49 lb
ft)
RTW37ASH000101
261R300005
19. Install front propeller shaft (7).

Refer to the section Front Propeller Shaft.
20. Install rear propeller shaft (6).
Torque: 63 N
m (6.4 kg
m/46 lb
ft)
21. Install the center bearing on crossmember.
Torque: 69 N
m (7.0 kg
m/51 lb
ft)
22. Install gear control lever (5).
m (1.9 kg
m/14 lb
ft)
Torque: 19 N
MANUAL TRANSMISSION
21. Install grommet assembly (4).
Torque: Screw
1.4 N
m (0.14 kg
m/12 lb
in)
Nut
7 N
m (0.7 kg
m/61 lb
in)
RTW47BMH000101
Legend
(2) Floor Panel
(3) Front
24. Install front floor console (3) and rear floor console
(2).
25. Install gear control lever knob (1).
To the female thread portion, adhesive (TB1344 or
LOCTITE 222 or equiv.) of 3 - 4 drops to be applied
and transmission knob tightened.
Torque: 9 N
m (0.9 kg
m/78 lb
in)
After tightening to specified torque, knob
rewrenched until direction of shift pattern due
positioned.
7B1-75
7B1-76
MANUAL TRANSMISSION
Transmission Case
Major Component
RTW47BLF000101
Legend
(1) Gear Control Box Assembly and Gasket
(2) Rear Case Assembly
(8) Front Cover (with Oil Seal)

(9) Top Gear Bearing Snap Ring
(3) Intermediate Plate with Gear Assembly
(10) Release Bearing : C24NE
(4) Transmission Case
(11) Shift Fork : C24NE
(5) Release Bearing (with Spring): 4JH1-TC
(12) Fulcrum Bridge : 6VE1
(6) Shift Fork: 4JH1-TC
(13) Release Bearing : 6VE1
(7) Counter Front Bearing Snap Ring
(14) Shift Fork : 6VE1
MANUAL TRANSMISSION
Disassembly
1. Clean the exterior of the unit with solvent.
2. Remove the drain plug from the transmission case
and drain the lubricant.
3. Remove the clutch release bearing with spring (5)
4. Remove the shift fork, and boot. (Diesel engine,
C24NE)
5. Remove the shift fork snap pin. (6VE1)
6. Remove the shift fork pin and shift fork from the
fulcrum bridge. (6VE1)
7B1-77
7. Remove the fulcrum bridge from the transmission

case. (6VE1)
RTW37ASH0002
Legend
(1) Fulcrum bridge
8. Remove the front cover (8) and gasket from the

transmission case.
9. Remove snap ring (7) fixing counter front bearing.
ring (9) fixing top gear bearing.
RTW47BSH000601
Legend
(1) Shift fork pin
(2) Shift fork
(3) Release bearing
226RS001
11. Remove gear control box assembly (1).

12. Remove the rear case assembly (2) from the
transmission case (4) and intermediate plate (3).
13. Remove intermediate plate with gear assembly (3)
from transmission case (4).
7B1-78
MANUAL TRANSMISSION
Rear Oil Seal Replacement
220R300026
220R300025
Legend
(1) Installer 5-8840-2797-0
(2) Grip 5-8840-0007-0
1. Remove the oil seal from the rear case and discard
the used oil seal.
2. Apply engine oil to new oil seal outer surfaces.
3. Apply recommended grease (BESCO L2) or
equivalent to the oil seal lip.
4. Use the oil seal installer 5-8840-2797-0 and grip 58840-0007-0 to install the oil seal to the rear case.
Reassembly
Notes When Tightening the Bolt:

After cleaning the bolt hole, dry it thoroughly with air.
After cleaning the screw face of a removed bolt or
new one, dry it thoroughly. Apply recommended
liquid gasket (LOCTITE 242) or its equivalent on
them before tightening it.
4. Install a new gasket and gear control box assembly
(1).
Install the harness clips and brackets and then
tighten four new gear control box bolts to the
specified torque.
Torque: 20 N
m (2.0 kg
m/14 lb
ft)
1. Apply recommended liquid gasket (LOCTITE 17430)

or its equivalent to the transmission case (4),
intermediate plate (3) and rear case (2) fitting
surfaces.
2. Install the intermediate plate with gear assembly (3)
to the transmission case (4).
Pull out the top gear shaft until the ball bearing snap
ring groove protrudes from the transmission case
front cover fitting face.
Avoid subjecting the mainshaft to sudden shock or
stress.
3. Install the rear case with oil seal (2) on the
intermediate plate with gear (3) by performing the
following steps.
Cover the shaft splines with adhesive tape.
This will prevent damage to the oil seal lip.
Tighten the transmission rear case bolts and

nuts to the specified torque.
Torque: 37 N
m (3.8 kg
m/27 lb
ft)
261R300004
MANUAL TRANSMISSION
5. Install top gear bearing snap ring (9) and counter
front bearing snap ring (7).
rings to the mainshaft and countershaft.
The snap rings must be fully inserted into the
bearing snap ring groove.
6. Front cover with oil seal (8).
Front Cover Oil Seal Replacement
Remove the oil seal from the front cover.
Apply engine oil to a new oil seal outer
circumference.
Apply recommended grease to the oil seal lip.
Use the oil seal installer 5-8840-0026-0 to install
the oil seal to the front cover.
7B1-79
8. Apply molybdenum disulfide type grease to the

areas as shown in the figure and install shift fork (6).
(Diesel engine, C24NE)
F07L100026
9. Install the fulcrum bridge to the transmission case.

(6VE1)
Torque: 38 N
m (3.9 kg
m/28 lb
ft)
220R3000020
RTW37ASH0002
Legend
(1) Fulcrum bridge
10. Apply molybdenum disulfide type grease to the pin
hole inner circumferences and thrust surfaces.
(6VE1)
11. Attach the shift fork to the fulcrum bridge and insert
the pin from below of the fulcrum bridge. (6VE1)
7B1-80
MANUAL TRANSMISSION
12. Install the washer and snap pin. (6VE1)
RTW47BMH000201
13. Pack the inside recess (A) and coat the back (B) of
the release bearing with molybdenum disulfide type
grease as shown in the figure.
A07RW075
14. Install the release bearing (5) on the front cover,

joining it to the shift fork.
MANUAL TRANSMISSION
7B1-81
Intermediate Plate with Gear Assembly, Detent, Shift Arm, Shift Rod, and
Interlock Pin
Disassembled View
RTW47BLF000501
Legend
(1) Detent Spring Plate and Gasket
(7) 1st-2nd Shift Rod
(2) Detent Spring
(8) 3rd-4th Shift Rod
(3) Detent Ball
(9) 3rd-4th Shift Arm
(4) Spring
(10) 1st-2nd Shift Arm
(5) Rev-5th Shift Rod
(11) Interlock Pin
(6) Rev-5th Shift Arm and Reverse Inhibitor
(12) Intermediate Plate and Gear Assembly
7B1-82
MANUAL TRANSMISSION
Disassembly
1. Remove detent spring plate and gasket (1), detent
spring (2) and detent ball (3).
Use a magnetic hand to remove the detent balls
from the intermediate plate.
230RS0004
Be careful not to lose the interlock pins, when

pulling out the shift rod rearward.
Interlock pins are located between the shifter
rods in the intermediate plate.
220RS011
2. Remove spring (4).

3. Remove rev-5th shift rod (5), and rev-5th shift arm
and reverse inhibitor (6).
Remove 1st-2nd shift rod (7), 3rd-4th shift rod (8),
3rd-4th shift arm (9), and 1st-2nd shift arm (10).
Hold a round bar against the shift rod end.
230RS0005
Remove the rev-5th, 1st-2nd and 3rd-4th shift

rods carefully.
4. Remove interlock pin (11) from intermediate plate
and gear assembly (12).
230RS003
Use a spring pin remover to remove the shift

arm spring pins from the shift arms and the shift
rods.
MANUAL TRANSMISSION
7B1-83

Make the necessary adjustments, and part
Shift Arm Thickness

Use a micrometer to measure the shift arm
thickness.
Shift Arm Thickness

Standard
9.60 - 9.85 mm
1st-2nd
(0.378 - 0.388 in)
3rd-4th
9.60 - 9.80 mm
Rev.5th
(0.378 - 0.386 in)
Limit
9.0 mm
(0.354 in)
220RS012

Use a spring tester to measure the detent spring
tension.

Compressed height
20 mm (0.787 in)
Standard
87.2 - 97.1 N
(19.6 - 21.8 lb)
230RS006

Use a vernier caliper to measure the detent spring
free length.
Standard
26.8 mm (1.06 in)
SOUTH AFRICA 5th-Rev Only
Standard
Outer
27.6 mm (1.09 in)
Inner
26.6 mm (1.05 in)
Limit
26.2 mm (1.03 in)
220RS013
Limit
27.0 mm (1.06 in)
26.0 mm (1.02 in)
SOUTH AFRICA 5th-RV Only

Compressed
Outer
20 mm (0.787 in)
Inner
20 mm (0.787 in)
Standard
93.5 103.3 N
(21.0 23.3 lb)
26.4 36.3 N
(5.9 8.2 lb)
7B1-84
MANUAL TRANSMISSION
Reassembly
1. Install rev-5th shift arm and reverse inhibitor (6) and
rev-5th shift rod (5).
Apply oil to the reverse inhibitor inner surface.
Install the shift rod in the intermediate plate (12).

5. Put detent balls (3) in the intermediate plate holes.
Apply oil to the detent balls.
6. Install detent springs (2) and detent spring plate and
gasket (1).
Install a new gasket and the detent spring plate.
Tighten the detent spring plate bolts to the
specified torque.
Torque: 25 N
m (2.5 kg
m/18 lb
ft)

plate (12).
intermediate plate (12).
2. Install 1st-2nd shift arm (10) and 3rd-4th shift arm(9)

to intermediate plate and gear assembly (12).
3. Install 3rd-4th shift rod (8) and 1st-2nd shift rod (7).
plate and gear assembly (12).
Install the 3rd-4th shift rod (8) in the intermediate
plate (12).
intermediate plate.
Install the interlock pin (11) and then 1st-2nd

shift rod (7) in the intermediate plate (12).
intermediate plate.

230RS007
220RS030
Legend
(1) Warped
MANUAL TRANSMISSION
7B1-85
Reverse Gear and 5th Gear

Disassembled View
226R300024
Legend
(1) Collar Snap Ring
(15) Counter 5th Gear
(2) Oil Seal Collar
(16) Counter Reverse Gear
(3) Ball Bearing
(17) 5th Gear
(4) Retainer
(18) 5th Block Ring
(5) Thrust Plate
(19) Needle Bearing
(6) Thrust Washer and Lock Ball
(20) Mainshaft Nut
(7) Reverse Idler Gear Snap Ring
(21) Rev-5th Synchronizer Assembly
(8) Reverse Idler Gear Assembly
(22) Reverse Block Ring
(9) Idle Shaft Pin
(23) Reverse Gear
(10) Thrust Washer
(24) Needle Baring
(11) Reverse Idler Gear
(25) Bearing Plate and Screw
(12) Reverse Idler Shaft
(27) Intermediate Plate
(14) Ball Bearing
7B1-86
MANUAL TRANSMISSION
Disassembly
1. Use a pair of snap ring pliers to remove the collar
snap ring (1).
2. Set the retaining ring remover 5-8840-2158-0 and
puller 5-8840-2027-0 to the retainer (4) and the
mainshaft end.
6. Remove the reverse idler gear assembly (8) from

the intermediate plate (27).
226RS005
262RW079
3. Remove the retainer (4) together with the bearing

(3) and the oil seal collar (2).
The universal puller may be used in place of the
retaining ring remover.
7. Remove idle shaft pin (9), thrust washer (10),

reverse idler gear (11), and reverse idler shaft (12).
ring (13).
9. Attach a universal puller to the counter gear shaft.
Use a universal puller to remove the ball bearing
(14) and the counter 5th gear (15).
4. Remove thrust plate (5) and thrust washer and lock

ball (6).
5. Use a pair of snap ring pliers to remove reverse idler
gear snap ring (7).
226RS006
10. Remove counter reverse gear (16).
226RS004
MANUAL TRANSMISSION
7B1-87
11. Remove 5th gear (17), 5th block ring (18), and
needle bearing (2 piece type) (19).
226RS007
226RW210

remove the mainshaft nut (20).
12. Remove the mainshaft nut (20) according to

following steps.
Attach the holding fixture 5-8840-2160-0 and base
5-8840-0003-0 to the mainshaft and the counter
gear.
226RW211
226RW212
Engage the 3rd-4th synchronizer with the 3rd

gear.
Engage the 1st-2nd synchronizer with the 1st
gear.
7B1-88
MANUAL TRANSMISSION
13. Use screw drivers between the reverse gear (23)

and bearing plate (25) to remove the Rev-5th
synchronizer assembly (21) together with reverse
block ring (22) and reverse gear (23).
226RS011
17. Hold the snap ring open with the pliers.

Push the intermediate plate (27) toward the rear of
the transmission to remove it.
226RS010
14. Remove needle bearing (24).

15. Use the torx bit wrench (T45) 5-8840-0047-0 to
remove the bearing plate and screw(25) from the
intermediate plate.
The bearing snap ring will come free.

Refer to Top Gear Shaft, Main Gear Shaft, and Counter
Gear in this section for inspection and repair.
Reassembly
1. Mesh the counter gear with the mainshaft assembly.
Set the holding fixture 5-8840-2160-0 to the
mainshaft and the counter gear and then install it on
the base 5-8840-0003-0.
Install the intermediate plate (27) on the gear
assembly.
220RW137
16. Use the snap ring pliers (1) to remove the mainshaft
bearing snap ring (2) (26).
226RW212
MANUAL TRANSMISSION
2. Install bearing snap ring (26).
3. Apply recommended thread locking agents
(LOCTITE 242) or its equivalent to each of the
bearing plate screw threads.
Install bearing plate and screw (25).
Tighten the screws to the specified torque by using
torx bit wrench 5-8840-0047-0.
Torque: 15 N
m (1.5 kg
m/11 lb
ft)
7B1-89
5. Assemble rev-5th synchronizer assembly (21) by

performing the following steps.
1. Turn the clutch hub face (1) toward the sleeve
groove (2) (rear side) on the outer
circumference.
clutch hub (5) ring insert grooves.
slide smoothly.
mainshaft.
facing the reverse gear side.
220RW137
4. Install needle bearing (24), reverse gear (23), and

reverse block ring (22).
226RS013
226RS049
7B1-90
MANUAL TRANSMISSION
6. Mesh the 1st-2nd and 3rd-4th synchronizers with

both the 1st and 3rd gears (double engagement).
8. Use a punch to stake the mainshaft nut (20).
226RW153
226RS015
This will prevent the mainshaft from turning.

7. Install the new mainshaft hub nut.
tighten the mainshaft nut (20) to the specified
torque.
Torque: 137 N
m (14 kg
m/101 lb
ft)
9. Install needle bearing (19), 5th block ring (18), and

5th gear (17).
10. Apply engine oil to the counter reverse gear (16) and
the reverse gear (23).
Install the counter reverse gear (16) to the counter
shaft.
The reverse gear projection must be facing the
intermediate plate.
226RW214
226RW151
MANUAL TRANSMISSION
11. Install the counter 5th gear (15) to the counter shaft.
7B1-91
There are six snap ring sizes available.

The snap rings are color&dash;coded to indicate
their thickness.
226RS019
12. Install ball bearing (14) and bearing snap ring (13)
by performing the following steps:
minimum clearance between the ball bearing
and the snap ring.
226RS021
Ball Bearing and Snap Ring Clearance

Standard: 0 - 0.15 mm (0 - 0.0059 in)
Thickness
Color Coding
1.1 mm (0.043 in)
White
1.2 mm (0.047 in)
Yellow
1.3 mm (0.051 in)
Blue
1.4 mm (0.055 in)
Pink
1.5 mm (0.059 in)
Green
1.6 mm (0.063 in)
Brown
226RS020

ring(13) to the counter gear shaft.
counter gear shaft snap ring groove.
13. Assemble reverse idler shaft (12), reverse idler gear

(11), thrust washer (10), and idle shaft pin (9) into
reverse idler gear assembly (8).
The trust washer should be assembled as oil groove
faces to gear side.
7B1-92
MANUAL TRANSMISSION
14. Select reverse idler gear snap ring (7) which will
provide the minimum clearance between the
intermediate plate (27) and the snap ring (7).

ring to the reverse idler shaft.
reverse idler shaft snap ring groove.
15. Install thrust washer and lock ball (6) by performing

the following steps:
Use a thickness gauge to measure the
clearance between the 5th gear and the thrust
washer.
Standard: 0.10 - 0.25 mm (0.004 - 0.010 in))
Measure clearance "A" as shown in the figure.
226RS022

The snap rings are color-coded to indicate their
thickness.
Intermediate Plate and Snap Ring Clearance

Standard: 0 - 0.15 mm (0 - 0.0059 in)
Thickness
Color Coding
1.2 mm (0.047 in)
White
1.3 mm (0.051 in)
Yellow
1.4 mm (0.055 in)
Blue
226RS023
Select appropriate thrust washer from chart.

There are four thrust washer sizes available.
Thickness Color
Clearance
A mm (in)
mm (in)
Coding
mm (in)
8.05 - 8.1
0.15 - 0.25
7.9 (0.311) White
(0.317-0.319) (0.006-0.010)
8.1 - 8.2
0.1 - 0.25
8.0 (0.315) Yellow
(0.319-0.323) (0.004-0.010)
8.2 - 8.3
0.1 - 0.25
8.1 (0.319) Green
(0.323-0.327) (0.004-0.010)
8.3 - 8.36
0.1 - 0.21
8.2 (0.323)
Blue
(0.327-0.329) (0.004-0.008)
226RS021
The thrust washers are color coded to indicate

their thickness as shown in the figure.
MANUAL TRANSMISSION
7B1-93
18. Apply engine oil to the oil seal collar inner

circumference.
Install the oil seal collar (2) to the mainshaft by using
the installer 5-8840-2159-0.
19. Install the oil seal collar snap ring (1).
226RS024
Apply grease to the thrust washer and the lock

ball.
Install the thrust washer and the lock ball.

16. Install thrust plate (5) and retainer (4).
17. Apply engine oil to the bearing inner and outer
circumference.
Use the installer 5-8840-2159-0 to install the ball
bearing (3) to the mainshaft.
226L100002
7B1-94
MANUAL TRANSMISSION
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft
Disassmebled View
226RS026
MANUAL TRANSMISSION
Legend
(1) Top Gear Shaft Snap Ring
(16) 1st Outside Ring
(2) Top Gear Shaft
(17) 1st Block Ring
(3) Ball Bearing
(18) Needle Bearing
(4) Needle Bearing
(19) Clutch Hub Snap Ring
(5) Top Block Ring
(20) 1st-2nd Synchronizer Assembly
(6) Mainshaft Snap Ring
(21) 2nd Block Ring
(7) 3rd-4th Synchronizer Assembly
(22) 2nd Outside Ring
(8) 3rd Block Ring
(23) 2nd Inside Ring
(9) 3rd Gear
(24) 2nd Gear
(10) Needle Bearing
(25) Needle Bearing
(11) Needle Bearing Collar
(26) Mainshaft
(12) Mainshaft Ball Bearing
(13) 1st Gear Thrust Bearing
(28) Front Roller Bearing
(14) 1st Gear
(29) Center Roller Bearing
(15) 1st Inside Ring
(30) Counter Gear Shaft
7B1-95
7B1-96
MANUAL TRANSMISSION
Disassembly
1. Use a pair of snap ring pliers to remove the top gear
shaft snap ring(1).
2. Remove top gear shaft(2) with ball bearing(3).
3. Use a bench press and the bearing remover 5-88400015-0 to remove the ball bearing(3).
6. Use a bench press and the bearing remover 5-88400015-0 to remove the 3rd-4th synchronizer
assembly (7) as a set.
226RW217
226RW216
4. Remove needle bearing (4) and top block ring (5),

mainshaft snap ring.
5. Use a pair of snap ring pliers to remove the
mainshaft snap ring (6).
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
7. Remove 3rd block ring (8), 3rd gear (9), and needle
bearing (10).
8. Use a bench press and the bearing remover 5-88400015-0 to remove the 1st gear(14) together with the
mainshaft ball bearing(12), 1st gear thrust bearing
(13), and needle bearing collar (11).
226RS008
226RW218
MANUAL TRANSMISSION
9.Disassemble 1st inside ring (15), 1st outside ring (16),
and 1st block ring (17).
10.Remove needle bearing (18).
11.Use a pair of snap ring pliers to remove the clutch
hub snap ring (19).
7B1-97
13. Remove needle bearing (25) from mainshaft (26).

14. Remove bearing snap ring (27).
15. Remove the front roller bearing (28) by performing
the following steps.
Remove the ring, outer race and bearing
assembly by using a bench press and remover
5-8840-0015-0.
Remove the inner race by using a bench press
and remover 5-8840-0015-0.
226RS031
12.Use bench press and the bearing remover 5-88400015-0 to remove the 2nd gear (24) together with
1st-2nd synchronizer assembly (20), 2nd block ring
(21), 2nd outside ring (22), and inside ring (23).
226RW219
16. Remove center roller bearing (29) from counter gear

shaft (30).
226RW220
Legend
(1) Springs
(2) Sleeve
(3) Clutch Hub
(4) Inserts
7B1-98
MANUAL TRANSMISSION


226RS035

the block ring must be replaced.

Standard
Limit
1.5 mm (0.059 in)
0.8 mm (0.032 in)
MANUAL TRANSMISSION
1st-2nd Synchronizer (3-CONE)

Block and Insert Clearance

Standard
3.46 - 3.76 mm
3rd-4th
(0.136 - 0.148 in)
3.86 4.16 mm
1st-2nd
(0.152 - 0.164 in)
3.59 - 3.91 mm
Rev.5th
(0.141 - 0.154 in)
7B1-99
Limit
4.0 mm
(0.158 in)
4.9 mm
(0.193 in)
4.1 mm
(0.161 in)

226RS036

the 1st-2nd synchronizer assembly must be
replaced.

Standard
Limit
1.5 mm (0.059 in)
0.8 mm (0.032 in)

Use a vernier caliper or thickness gauge to measure
the clearance between the block ring and the insert.
226RS038

the clutch hub and the insert must be replaced.
Standard
1st-2nd
0.01 0.21 mm
3rd-4th
(0.004 - 0.0083 in)
0.09 0.31 mm
Rev-5th
(0.0035 - 0.0122 in)
226RS037

Limit
0.3 mm
(0.012 in)
0.4 mm
(0.016 in)
7B1-100
MANUAL TRANSMISSION
Mainshaft Run-out

Standard
1st
45.000 - 45.013 mm
(1.771 - 1.772 in)
3rd
52.000 - 52.013 mm
2nd
(2.047 - 2.048 in)
48.000 - 48.013 mm
Rev.
(1.889 - 1.890 in)
32.000 - 32.013 mm
5th
(1.259 - 1.260 in)
Install the mainshaft to V-blocks.

Use a dial indicator to measure the mainshaft
Limit
45.100 mm
(1.776 in)
52.100 mm
(2.051 in)
48.100 mm
(1.894 in)
32.100 mm
(1.246 in)
Reverse Idler Gear and Idler Gear Shaft

Clearance
Use a micrometer to measure the idler gear shaft
diameter.
Use an inside dial indicator to measure the idler
gear inside diameter.
226RS039
If the measured mainshaft run-out exceeds the

specified limit, the mainshaft must be replaced.
Mainshaft Run-out
Limit: 0.05 mm (0.0020 in)

Use an inside dial indicator to measure the gear
inside diameter.
226RS041
Calculate the idler gear and idler gear shaft

clearance.
Idler gear inside diameter-idler gear shaft diameter =
idle gear and idler gear shaft clearance.
the idle gear and/or the idler gear shaft must be
replaced
Standard: 0.041 - 0.074 mm (0.0016 -0.0029 in)
Limit: 0.150 mm (0.0059 in)
226RS040

the gear must be replace.
MANUAL TRANSMISSION
7B1-101

Set a dial indicator to the clutch hub to be
measured.
226RS043
Reassembly
226RS042

right and the left.
Standard
1st-2nd
0 - 0.1 mm
3rd-4th
(0 - 0.004 in)
0 - 0.2 mm
Rev. 5th
(0 - 0.008 in)
1. Install center roller bearing (29) to counter gear

shaft (30).
Apply engine oil to the bearing inner and outer
circumferences.
Install the roller bearing in the proper direction.
NOTE: Check that outer race moves only in the
direction of arrow.
Limit
0.2 mm
(0.008 in)
0.3 mm
(0.012 in)
Ball Bearing Play

Ball Bearing Play
Limit: 0.2 mm (0.008 in)
226RS044
2. Install front roller bearing (28) by performing the

following steps.
front roller bearing inner race to the counter gear
shaft (30).
Install the outer race and roller assembly.
The snap ring groove must be facing the
7B1-102
MANUAL TRANSMISSION

ring.
226RS045
Legend
(1) Ring
(2) Outer Race and Roller Assembly
(3) Inner Race
5. Assemble 2nd inside ring (23), 2nd outside ring (22),

and 2nd block ring (21).
Apply engine oil to the synchronizer ring friction
surfaces.
226RS047
3. Install bearing snap ring (27) to counter gear shaft

(30).
2nd gear (24) thrust surfaces.
Install the needle bearing (25) and the 2nd gear (24)
to the mainshaft (26).
The 2nd gear (24) dog teeth must be facing the
transmission rear side.
226RS046
Legend
(1) Block Ring
(2) Outside Ring
(3) Inside Ring
(4) 2nd Gear
(5) Needle Bearing
6. Assemble 1st-2nd synchronizer assembly (20) by

performing the following steps:
clutch hub (5) insert grooves.
slide smoothly.
MANUAL TRANSMISSION
7B1-103
266RS049

mainshaft (26).
The clutch hub face (with the heavy boss) must be
facing the 2nd gear side.
226RS050

226RS021
226RS048
8. Install clutch hub snap ring(19) by performing the

following steps:
minimum clearance between the 1st-2nd clutch
hub and the snap ring.

Standard: 0 - 0.1 mm (0 - 0.004 in)
Thickness
1.80 mm (0.071 in)
1.85 mm (0.073 in)
1.90 mm (0.075 in)
Color Coding
White
Yellow
Blue

ring (19) to the mainshaft (26).
7B1-104
MANUAL TRANSMISSION
10. Install the 1st gear thrust bearing and the race(13) to
the main shaft.
The thrust bearing side must be facing the
226RS031
9. Install needle bearing (18), 1st block ring (17), 1st

outside ring (16), 1st inside ring (15), and 1st gear
(14).
Apply engine oil to the needle bearing, 1st gear
thrust surfaces and synchronizer ring friction
surfaces.
The 1st gear dog teeth must be facing the
226RS054
11. Apply engine oil to the mainshaft ball bearing (12)

and the mainshaft (26).
Install the ball bearing (12) and needle bearing collar
(11) to the mainshaft (26).
The ball bearing snap ring groove must be facing
the transmission rear side.
Use a bench press and installer 9-8522-1165-0 to
slowly force the collar into place.
226RS053
Legend
(1) 1st Gear
(2) Needle Bearing
(3) Inside Ring
(4) Outside Ring
(5) Block Ring
226RS055
MANUAL TRANSMISSION
7B1-105
3rd gear (9) thrust surfaces.
Install the needle bearing (10) and the 3rd gear (9)
to the mainshaft.
The 3rd gear dog teeth must be facing the
226RS049
15. Select and install mainshaft snap ring(6) in the

following way:
Select the snap ring which will provide the minimum
clearance between the 3rd-4th clutch hub and the
snap ring.
226RS056
13. Install 3rd block ring (8).

14. Check and install 3rd-4th synchronizer assembly (7)
by the following steps:
clutch hub insert grooves.
2. Check that the insert springs (4) are fitted to the
inserts as shown in the illustration.
slide smoothly.
4. Install the synchronizer assembly to the
mainshaft.
facing the 3rd gear side.
226RS058

226RW221
7B1-106
MANUAL TRANSMISSION
16. Install top block ring (5).
Apply grease to the needle bearing (4) inner and
outer circumferences and install needle bearing (4)
in the top gear shaft (2).
17. Use a bench press to install the top gear shaft ball
bearing (3) to the top gear shaft (2).
226RS021

Standard: 0 - 0.1 mm (0 - 0.004 in)

Thickness
1.80 mm (0.071 in)
1.85 mm (0.073 in)
1.90 mm (0.075 in)
Color Coding
White
Yellow
Blue

ring to the mainshaft.
226RS059
The snap ring groove of the ball bearing (3) must be

facing the transmission front side.
18. Use a pair of snap ring pliers to install the top gear
shaft snap ring (1) to the top gear shaft (2).
MANUAL TRANSMISSION
7B1-107

Transmission type
Control method
Gear ratio: Transmission
Transmission oil capacity

Type of lubricant
1st
2nd
3rd
4th
5th
Rev.
MUA5G
MUA5S
Fully synchronized forward and reverse gears
Remote control with the gear shift lever on the floor.
4.008
4.357
2.301
2.502
1.427
1.501
1.000
1.000
0.828
0.809
3.651
3.970
2.95 lit. (3.12 US qt)
Engine oil: Refer to the chart in "SECTION 0"
7B1-108
MANUAL TRANSMISSION
RTW47BLF001101
About arrow mark, refer to Transmission (MUA) Installation in this section.
MANUAL TRANSMISSION
7B1-109
RTW47BLF000801
7B1-110
MANUAL TRANSMISSION
RTW47BLF000601
MANUAL TRANSMISSION
7B1-111
TROUBLESHOOTING
1. ABNORMAL NOISE
1) NOISY IN NEUTRAL
Checkpoint
Gear oil
Trouble Cause
Countermeasure
NG

oil

oil
NG
Worn flywheel pilot bearing
Replace the flywheel pilot
Worn or scuffed gear tooth

contact surfaces
Replace the gear(s)
Worn splines

Transmission misalignment
Realign the transmission
OK
Flywheel pilot bearing
OK
countershaft, and transfer
shaft)
NG
OK
Gears (Mainshaft,
countershaft, reverse idler
gear and transfer gears)
NG
OK
Mainshaft splines
splines
NG
OK
Transmission
NG
7B1-112
MANUAL TRANSMISSION
2) NOISY OPERATION
Checkpoint
Gear oil (Metallic rattling)
Trouble Cause
Countermeasure
NG
Insufficient or improper engine

oil

oil
NG
NG
Worn, chipped, or cracked

gear(s)
Replace the gear(s)
Free running gears seizing on

the thrust face or the inner
face
Replace the gear(s)
Lack of backlash between

meshing gears
Replace the gear(s)
OK
Bearings (Hissing, thumping
or bumping)
OK
Gears (Growling, humming, or

grinding)
OK
Gears (Squealing at high

speeds)
NG
OK
Gears (Gear whining)
NG
MANUAL TRANSMISSION
7B1-113
2. HARD SHIFTING
Checkpoint
Gear oil
Trouble Cause
Countermeasure
NG

oil
Replenish or replace the

engine oil
NG
Improper clutch pedal free

play
Readjust the clutch pedal free

play
NG
Hard operating change lever

caused insufficient grease
Repair or regrease the change

lever assembly
NG
Worn change lever sliding

portions

applicable parts and regrease
Sleeve movement failure
Repair or replace the sleeve

faces
Replace the shidt rod and/or

the quadrant box
OK
OK
Change lever operation
OK
Change lever play
OK
Shift block sleeve movement
NG
OK

sliding faces, and other parts
NG
7B1-114
MANUAL TRANSMISSION
Checkpoint
Trouble Cause
Countermeasure
Continued from the previous

OK
sleeve
NG

NG

Worn synchronizer parts
OK

thrust play
OK
NG
MANUAL TRANSMISSION
7B1-115
3. WALKING OR JUMPING OUT OF GEAR

Checkpoint
Trouble Cause
Insufficient stroke caused by

sliding position wear and
excessive play
Worn detent ball
Replace the detent ball
Detent spring weak or broken
Repair or replace the detent

spring
NG

faces
Replace the shift rod and/or

the quadrant box
NG

NG

NG
Change lever play
Countermeasure
OK
NG
Detent ball
OK
NG
Detent spring
OK

sliding faces
OK

sleeve
OK

thrust play
7B1-116
MANUAL TRANSMISSION
Checkpoint
Trouble Cause
Countermeasure

OK
countershaft, and individual
gears)
NG
Worn or broken bearings(s)
Worn splines

Weak or broken spring
Replace the spring
OK
Mainshaft splines
splines
NG
OK
NG
MANUAL TRANSMISSION
4. OIL LEAKAGE
Checkpoint
Trouble Cause
NG
Oil level
Countermeasure
Oil level too high
Drain the oil to the correct

level
Improper gear oil
Loose plug(s)
Tighten the plug(s) and

replenish the oil
NG
Defective or improperly
installed gasket(s)
Replace the gasket(s)
NG
Air breather not installed

Air breather clogged
Install the air breather

Replace the air breather
OK
NG
Gear oil
OK
Drain plug and/or filler plug
NG
OK
Gaskets
OK
Air breather
OK
NG
OK
Rear cover oil seal
NG
7B1-117
7B1-118
MANUAL TRANSMISSION
4)
Special Tools (4
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-2158-0
5-8840-2027-0
Puller
5-8840-2160-0
Holding fixture
5-8840-0003-0
ILLUSTRATION
TOOL NO.
TOOL NAME
5-8840-2159-0
Mainshaft end bearing
installer
5-8840-0015-0
Bearing
remover/installer
5-8840-2797-0
Rear case oil seal
installer
5-8840-0026-0

installer
5-8840-2156-0
9-8522-1165-0
Wrench
5-8840-0047-0
Tork bit wrench
5-8840-0007-0
(T45)
Driver handle
No. TFMUA-WE-0431
WORKSHOP MANUAL
TF SERIES
ELECTRICAL-BODY AND CHASSIS
SECTION 8
ELECTRICAL-BODY AND CHASSIS 8A-1
SECTION 8A
ELECTRICAL-BODY AND CHASSIS

TABLE OF CONTENTS
PAGE
General Information ........................................................................................................ 8A-
Notes for Working on Electrical Items .......................................................................... 8A-
Symbols and Abbreviations ........................................................................................... 8A- 11

Symbols ...................................................................................................................... 8A- 11
Abbreviations ............................................................................................................. 8A- 12
Parts for Electrical Circuit .............................................................................................. 8A- 13
Wiring .......................................................................................................................... 8A- 13
Fuse ............................................................................................................................. 8A- 15
Fusible Link ................................................................................................................ 8A- 15
Relay ............................................................................................................................ 8A- 16
Diode ........................................................................................................................... 8A- 17
Connector ................................................................................................................... 8A- 18
Battery ......................................................................................................................... 8A- 19
Reading the Circuit Diagram .......................................................................................... 8A- 22
Parts Location ............................................................................................................ 8A- 22
Circuit Diagram ........................................................................................................... 8A- 23
Connector List............................................................................................................. 8A- 23
Main Data and Specifications ........................................................................................ 8A- 24
Bulb Specifications .................................................................................................... 8A- 24
Relay and Fuse ................................................................................................................ 8A- 26
Relay and Fuse Box Location ................................................................................... 8A- 26
Relay Location ............................................................................................................ 8A- 28
8A-2 ELECTRICAL-BODY AND CHASSIS
PAGE
Fuse and Slow Blow Fuse Location (Relay and Fuse Box) .................................... 8A- 31
Fuse Location ............................................................................................................. 8A- 33
Diode Location ........................................................................................................... 8A- 34
Fuse Block Circuit ...................................................................................................... 8A- 35
Fuse Block Circuit (C24SE) ....................................................................................... 8A- 35
Fuse Block Circuit (6VE1) ......................................................................................... 8A- 37
Fuse Block Circuit (4JA1-TC/4JH1-TC) - RHD ......................................................... 8A- 39
Fuse Block Circuit (4JA1-TC/4JH1-TC) LHD ......................................................... 8A- 41
Fuse Block Circuit (4JH1-L) ...................................................................................... 8A- 43
Grounding Point ............................................................................................................. 8A- 45
Ground Point .............................................................................................................. 8A- 45
Ground Point Location .............................................................................................. 8A- 61
Main Cable harness Routing .......................................................................................... 8A- 63
C24SE / 6VE1 / 4JA1-L / 4JH1-TC .............................................................................. 8A- 63
Instrument Harness .................................................................................................... 8A- 71
System Repair ................................................................................................................. 8A- 73
Start and Charging ..................................................................................................... 8A- 73
Engine Control Module (ECM) ................................................................................... 8A- 89
Exhaust Gas Recalculation (EGR): 4JA1-L Only ...................................................... 8A- 109
Lighting ....................................................................................................................... 8A- 114
Front Fog Light ........................................................................................................... 8A- 136
Rear Fog Light ............................................................................................................ 8A- 144
Head Light Leveling ................................................................................................... 8A- 149
Illumination ................................................................................................................. 8A- 154
Hazard Warning Flasher, Turn Signal Light, Back Up Light,
Horn and Stop Light ................................................................................................. 8A- 161
Dome Light, Spot Light and Warning Buzzer .......................................................... 8A- 181
Windshield Wiper and Washer .................................................................................. 8A- 196
Transmission Control Module (TCM) ....................................................................... 8A- 214
Meter, Warning Light and Indicator Light ................................................................ 8A- 223
Heater and Air Conditioning ...................................................................................... 8A- 281
Power Door Lock ....................................................................................................... 8A- 293
PAGE
Power Window ........................................................................................................... 8A- 310
Audio, Clock and Cigarette Lighter .......................................................................... 8A- 329
Power Door Mirror ...................................................................................................... 8A- 337
Rear Defogger ............................................................................................................ 8A- 349
SRS-Air Bag ................................................................................................................ 8A- 358
Transfer Case Control Module .................................................................................. 8A- 361
Anti-Lock Brake System ............................................................................................ 8A- 373
Immobilizer ................................................................................................................. 8A- 376
Keyless Entry ............................................................................................................. 8A- 385
Anti Theft .................................................................................................................... 8A- 400
Auto Cruise ................................................................................................................. 8A- 412
Trailer Hitch ................................................................................................................ 8A- 415
Connector List ................................................................................................................ 8A- 418
GENERAL INFORMATION
The body and chassis electrical system operates on a twelve volt power supply with negative ground polarity.
The main harness consists of the engine harness, the instrument harness, the body harness, and the chassis
harness.
The harnesses use a split corrugated tube to protect the wires from the elements.
Wire size is determined by current flow, circuit length, and voltage drop.
All wires have color-coded insulation.
Wire color-codes are shown in the circuit diagrams.
This makes it easier to trace circuits and to make the proper connections.
Each circuit consists of the following:
1. Power source - The battery and the alternator
2. Wires - To carry electrical current through the circuit
3. Fuses - To protect the circuit against current overload
4. Relays - To protect voltage drop between the battery and the circuit parts and to protect the switch points against
burning
5. Switches - To open and close the circuit
6. Load - Any device, such as a light or motor, which converts the electrical current into useful work
7. Ground - To allow the current to flow back to the power source
NOTES FOR WORKING ON ELECTRICAL ITEMS

BATTERY CABLE
Battery
Disconnecting the Battery Cable

1. All switches should be "OFF" position.
3. Disconnect the battery positive cable.
CAUTION:
It is important that the battery ground cable be
disconnected first.
Disconnecting the battery positive cable first can result in
a short circuit.
Connecting the Battery Cable

Follow the disconnecting procedure in the reverse order to
connect the battery cables.
CAUTION:
Clean the battery terminal and apply light coat of grease to
prevent terminal corrosion.
CONNECTOR HANDLING
Disconnecting the Connectors
Some connectors have a tang lock to hold the connectors
together during vehicle operation.
Some tang locks are released by pulling them towards you 1 .
Other tang locks are released by pressing them forward 2 .
Determine which type of tang lock is on the connector being
handled.
Firmly grasp both sides (male and female) of the connector.

Release the tang lock and carefully pull the two halves of the
connector apart.
Never pull on the wires to separate the connectors.
This will result in wire breakage.
Connecting the Connectors

Firmly grasp both sides (male and female) of the connector.
Be sure that the connector pins and pin holes match.
Be sure that both sides of the connector are aligned with each
other.
Firmly but carefully push the two sides of the connector
together until a distinct click is heard.
Connector Inspection
Use a circuit tester to check the connector for continuity.
Insert the test probes from the connector wire side.
CAUTION
Never insert the circuit tester test probes into the
connector open side to test the continuity.
Broken or open connector terminals will result.
Waterproof Connector Inspection

It is not possible to insert the test probes into the connector
wire side of a waterproof connector.
Use one side of a connector 1 with its wires cut to make the
test.
Connect the test connector to the connector 2 to be tested.
Connect the test probes to the cut wires to check the connector
continuity.
Connector Pin Removal

Connector Housing Tang Lock Type
1. Insert a slender shaft 3 into the connector housing open
end 4 .
2. Push the tang lock 5 up (in the direction of the arrow in the
illustration).
Pull the wire 6 with pin 7 free from the wire side of the
connector.
Pin Tang Lock Type

1. Insert a slender shaft 3 into the connector housing open
end 4 .
2. Push the tang lock 8 flat (toward the wire side of the
connector).
Pull the wire 6 with pin 7 free from the wire side of the
connector.
Connector Pin Insertion

1. Check that the tang lock 8 is fully up.
2. Insert the pin 7 from the connector wire side 9 .
Push the pin in until the tang lock closes firmly.
3. Gently pull on the wires 6 to make sure that connector pin
is firmly set in place.
Fuse Replacement
The replacement fuse must have the same amperage
specification as the original fuse.
Never replace a burn out fuse with a fuse of a different
amperage specification.
Doing so can result in an electrical fire or other serious circuit
damage.
Parts Handling
Be careful for parts handling and any part should not be
dropped or thrown, otherwise short circuit or disorder may
result.
Wiring Harness
1. When assembling the parts, be careful not to bite or wedge
the wiring harness.
2. All electrical connections must be kept clean and tight.

3. Use a grommet or guard tube to protect the wiring harness
from contacting a sharp edge or surface.
4. Position the wiring harness with enough clearance from the

other parts and guard the wiring harness with a vinyl tube to
avoid direct contact.
5. The wiring harness between engine and chassis should be

long enough to prevent chafing or damage due to various
vibrations.
SPLICING WIRE
Open the Harness
If the harness is taped, remove the tape.
To avoid wire insulation damage, use a sewing "seam ripper"
(available from sewing supply stores) to cut open the harness.
If the harness has a black plastic conduit, simply pull out the
desired wire.
Cut the wire

Begin by cutting as little wire off the harness as possible.
You may need the extra length of wire later if you decide to cut
more wire off to change the location of a splice.
You may have to adjust splice locations to make certain that
each splice is at least 1-1/2" (40 mm) away from other splices,
harness branches, or connectors.
Strip the insulation

When replacing a wire, use a wire of the same size as the
original wire.
Check the stripped wire for nicks or cut strands.
If the wire is damaged, repeat the procedure on a new section
of wire.
The two stripped wire ends should be equal in length.
Crimp the Wires

Select the proper clip to secure the splice.
To determine the proper clip size for the wire being spliced,
follow the directions included with your clips.
Select the correct anvil on the crimper.
(On most crimpers your choice is limited to either a small or
large anvil.)
Overlap the two stripped wire ends and hold them between
your thumb and forefinger.
Then, enter the splice clip under the stripped wires and hold it
in place.
Open the crimping tool to its full width and rest one handle
on a firm flat surface.
Center the back of the splice clip on the proper anvil and
close the crimping tool to the point where the back of the
splice clip touches the wings of the clip.
Make sure that the clip and wires are still in the correct
position. Then, apply pressure until the crimping tool closes.
Before crimping the ends of the clip, be sure that:

The wires extend beyond the clip in each direction.
No strands of wire are cut loose.
No insulation is caught under the clip.
Crimp the splice again, once on each end.
Do not let the crimping tool extend beyond the edge of the clip
or you may damage or nick the wires.
Solder
Apply 60/40 rosin core solder to the opening in the back of the
clip.
Follow the manufacturer's instructions for the solder equipment
you are using.
Tape the Splice

Center and roll the splicing tape.
The tape should cover the entire splice.
Roll on enough tape to duplicate the thickness of the insulation
on the existing wires.
Do not flag the tape.
Flagged tape may not provide enough insulation, and the
flagged ends will tangle with the other wires in the harness.
If the wire does not belong in a conduit or other harness

covering, tape the wire again.
Use a winding motion to cover the first piece of tape.
SYMBOLS AND ABBREVIATIONS

SYMBOLS
Symbol
Meaning of Symbol
Symbol
Meaning of Symbol
Fuse
Bulb
Fusible link
Double filament bulb
Fusible link wire
Motor
Switch
Variable resistor Rheostat
Switch
Coil (inductor), solenoid,

magnetic valve
Switch (Normal close type)
Contact wiring
Relay
Battery
Diode
Connector
Electronic Parts
Light emitting diode
Resistor
Reed switch
Speaker
Condenser
Buzzer
Horn
Circuit breaker
Vacuum switching valve
ABBREVIATIONS
Abbreviation
A
Meaning of abbreviation
Ampere (S)
Abbreviation
LH
Meaning of abbreviation
Left hand
ABS
Anti-lock brake system
LWB
Long wheel base
ASM
Assembly
MPI
Multipart fuel injection
AC
Alternating current
M/T
Manual transmission
A/C
Air conditioner
QOS
Quick On Start system
ACC
Accessories
RH
Right hand
Carburetor
RR
Rear
CARB
C/B
Circuit breaker
CSD
Cold start device
DIS
Direct ignition system
RWAL
SRS
ST
Rear wheel anti-lock brake system

Supplemental restraint system
Start
EBCM
Electronic brake control module
STD
Standard
ECGI
Electronic control gasoline injection
SW
Switch
ECM
SWB
Short wheel base
ECU
Electronic control unit
TCM
EFE
Early fuel evaporation
42
Two-wheel drive
VSV
44
Four-wheel drive
FL
Fusible link
FRT
Front
H/L
Headlight
IC
Integrated circuit
IG
Ignition
kW
Kilowatt
WOT
W/
W/O
Volt
Vacuum switching valve
Watt (S)
Wide open throttle
With
Without
PARTS FOR ELECTRICAL CIRCUIT

WIRING
Wire Color
All wires have color-coded insulation.
Wires belonging to system's main harness will have a single
color.
Wires belonging to a system's sub-circuits will have a colored
stripe.
Striped wires use the following code to show wire size and
colors.
Example: 0.5 G / R
Red (Stripe color)
Green (Base color)
2
Wire size (0.5mm )
Abbreviations are used to indicate wire color within a circuit
diagram.
Refer to the following table.
Wire Color-Coding
Color-Coding
Meaning
Color-Coding
Meaning
Black
BR
Brown
White
LG
Light green
Red
GR
Grey
Green
Pink
Yellow
LB
Light blue
Blue
Violet
Orange
Distinction of Circuit by Wire Base Color

Base color
Circuits
Base color
Starter circuit and grounding circuit
Charging circuit
L, O, BR,
Lighting circuit
LG, GR,
Signal circuit
P, LB, V
Circuits
Instrument circuit
Other circuits
Wire Size
Wire size is specified with the metric gauge system.
The metric gauge system gives the wire size in cross sectional
area measured in square millimeters.
Wire Size Specifications

Outside diameter
Allowable current
(mm )
(mm)
(A)
0.3
0.372
1.8
0.5
0.563
2.0
12
0.85
0.885
2.2
16
1.25
1.287
2.5
21
2.091
2.9
28
3.296
3.6
37.5
5.227
4.4
53
7.952
5.5
67
15
13.36
7.0
75
20
20.61
8.2
97
Normal size
Cross sectional area

2

Normal
Blown
Normal
Blown
FUSE
Fuses are the most common form of circuit protection used in
vehicle wiring.
A fuse is a thin piece of wire or strip of metal encased in a
glass or plastic housing.
It is wired in series with the circuit it protects.
When there is an overload of current in a circuit, such as a
short of a ground, the wire or metal strip is designed to burn
out and interrupt the flow of current.
This prevents a surge of high current from reaching and
damaging other components in the circuit.
Determine the cause of the overloaded before replacing the
fuse.
Never replace a blown fuse with a fuse of a different amperage
specification.
damage.
A blown fuse is easily identified.
FUSIBLE LINK
The fusible link is primarily used to protect circuits where high
amounts of current flow and where is would not be practical to
use a fuse.
For example, the starter circuit.
When a current overload occurs, the fusible link melts open
and interrupts the flow of current so as to prevent the rest of
the wiring harness from burning.
Determine the cause of the overload before replacing the
fusible link.
The replacement fusible link must have the same amperage
specification as the original fusible link.
Never replace a blown fusible link with fusible link of a different
amperage specification.
damage.
A blown fusible link is easily identified.
Fusible Link Specifications

Type
Rating
Case Color
Maximum Circuit Current (A)
Connector
20A
Connector
30A
Pink
15
Connector
40A
Green
20
Bolted
50A
Red
25
Bolted
60A
Yellow
30
Bolted
80A
Black
40
10
RELAY
Battery and load location may require that a switch be placed
some distance from either component.
This means a longer wire and a higher voltage drop 1 . The
installation of a relay between the battery and the load reduces
the voltage drop 2 .
Because the switch controls the relay, amperage through the
switch can be reduced.
Relay Specifications and Configurations

Name/
Color
Rated
voltage/ Coil
resistance
Internal circuit
Name/
color
Rated
Voltage/Coil
resistance
1T
(MICRO
ISO)
/Black
12V
Approx. 92W
Minimum
operating
voltage: 7V at
20C (77F)
12V Approx.
1M (MINI 94W Minimum
operating
ISO)
voltage: 7V at
/Black
20C (77F)
1M
(MICRO
ISO)
/Black
12V
Approx. 132-3
W Minimum
operating
voltage: 7V at
20C (77F)
12V Approx.
94W Minimum
operating
voltage: 7V at
20C (77F)
1M
(power)/
Black
* Relay contact shown in the wiring diagram indicates condition before actuation.
Internal circuit
DIODE
Diode Specifications and Configurations
MARK/
COLOR
SHAPE
CONSTRUCTION
THERE SHOULD BE CONTINUITY IN

EITHER A OR B WHEN A CIRCUIT
CHECKING
TESTER IS CONNECTED WITH
DIODE TERMINAL
TERMINAL NO.
BLACK
CONNECTION
PATTERN
TERMINAL NO.
CONNECTION
PATTERN
BLACK
A
B
TERMINAL NO.
CONNECTION
PATTERN
BLACK
A
B
TERMINAL NO.
+
+
+
+
+
+
Maximum Rating (Temp.=25C)

Rating
Peak reverse voltage
400V
Transient peak reverse voltage
500V
Average output current
1.5A
Working ambient temperature

Storage temperature
-30C~80C
-40C~100C
+
+
Items
PATTERN
BLACK
CONNECTION
Remarks
Temp.=40C
CONNECTOR
The connector pin shape determines whether the connector is
male or female.
The connector housing configuration does not determine
whether a connector is male or female.
The symbol illustrated in the figure is used as connector in the

circuit this section.
Connector is identified with a number.
The applicable terminal number is shown for each connector.
Connector terminal numbers are clearly shown.

Male side connector terminal numbers are in sequence from
upper right to lower left.
Female side connector terminal numbers are in sequence from
upper left to lower right.
NOTE:
For those connectors on which specific terminal numbers
on symbols are shown, the terminal numbers or symbols
are used in the circuit diagram, irrespective of the above
rule.
BATTERY
Inspection
1. Check the battery terminals 1 for corrosion.
2. Check the battery cables 2 for looseness.
3. Check the battery case 3 for cracks and other damage.
4. Check the battery electrolyte level.
Battery-1
Battery Replacement
Battery-2
1. Disconnect the battery ground cable 1 .

2. Disconnect the battery positive cable 2 .
3. Remove the battery clamp 3 .
4. Remove the battery
Caution:
It is important that the battery ground cable be removed
first.
Removing the battery positive cable first can result in a
short circuit.
Jump Starting the Engine with a Booster Battery

The following description assumes that you are using a booster
battery mounted on a second vehicle.
The listed steps (with some minor modifications) are also
applicable if you are using a naked booster battery or special
battery charging equipment.

Caution:
Never push or tow the vehicle in an attempt to start it.
Extensive damage to the emission system and other
vehicle parts will result.
(Only catalytic converter vehicle)
Treat both the discharged battery and the booster battery
with great care when using jumper cables.
Carefully follow the procedure outlined below.
Always be aware of the dangers of sparking.
Failure to follow the following procedure can result in:
a. Serious personal injury, specially to your eyes.
b. Extensive property damage from a battery explosion,
battery acid discharge, or electrical file.
c. Extensive damage to the electronic components of
both vehicles.
Do not use a 24 volt booster battery.
Serious damage to the vehicle's electrical system and
electronic components will result.

1. Set the parking brake on both vehicles.
2. If one or both vehicles is equipped with a manual
transmission, place the gear shift in the "NEUTRAL"
position.
3. Turn off the ignition on both vehicles.
4. Turn off all vehicle lights and accessories.
5 Be sure that the two vehicles are not touching.
Attach the end of one jumper cable to the booster battery
positive terminal.
6 Attach the other end of the same cable to the discharged
battery positive terminal.
7. Once again, check that the booster battery has a 12 volt
rating.
8. Attach one end of the remaining booster cable to the
booster battery negative terminal.
9. Attach the other end of the booster cable to a solid ground
(such as the air conditioner compressor mounting bracket
or the alternator mounting bracket) in the engine room of
the vehicle with the discharged battery.
Be sure that the ground connection is at least 500 mm (20
in) from the discharged battery.

Caution:
Do not attach the booster cable to the discharged battery
negative terminal.
11. Start the engine of the vehicle with the booster battery.
Check that all unnecessary electrical accessories are off.
12. Start the engine of the vehicle with the discharged battery.
13. Remove the jumper cables in the reverse order to which
they were attached.
Caution:
Be absolutely sure to remove the negative jumper cable
from the vehicle with the discharged battery first.
READING THE CIRCUIT DIAGRAM

In this manual, each system has its own parts location illustration and circuit diagram.
And connector configurations used in the circuit diagram are shown at the end of this manual.
PARTS LOCATION: The parts location shows the location of the connectors 1 and the harnesses 2 used in the
each system.
CIRCUIT DIAGRAM: The circuit diagram shows the power supply 3 , the load or loads 4 and the grounding
point(s) 5 .
CONNECTOR LIST: The connector configuration shows each connector's number 6 , configuration 7 and the pin
numbers 8 , parts name 9 , connector color 10 .
PARTS LOCATION
RTW38DMF000201
CIRCUIT DIAGRAM
CONNECTOR LIST

BULB SPECIFICATIONS
This illustration based on LHD
RTW8AMF000501
Bulb No.
Rated Power
V-W
Number
of Bulbs
Lens
Color
H4
12-60/55
White
W5W
12-5
RED
H3
12-55
White
PY21W
12-21
White
Clearance light
W5W
12-5
White
Side turn signal light
W5W
12-5
White with
amber
inner lens
Rear turn signal light
PY21W
12-21
White
P21W
12-21
Red
P21/5W
12-21/5
Red
Back up light
P21W
12-21
White
License plate light
W5W
12-5
White
A/C-Heater control light
12-0.7
Dome light
12-10
White
Spot light
12-5
White
Light Name
Headlight
High mounted stop light
Fog light
Front turn signal light
Rear fog light

Tail and stop light
Remarks
Halogen
Bulb Lens color

Amber
Bulb Lens color

Amber
Light Name
Illumination light
Indicator/
Warning
light
Rated Power
V-W
Number of
Bulbs
Lens
Color
14-2
White
Green
Turn Signal
14-1.12
W/O Tacho 5
W/ Tacho 7
2
High Beam
14-1.12
Blue
Low Fuel
14-1.12
Amber
A/T Oil Temp
14-1.12
Red
Brake system
14-1.12
Red
4WD
14-1.12
Green
Seat belt
14-1.12
Red
Oil pressure
14-1.12
Red
ABS
14-1.12
Amber
SEDIMENTER
14-1.12
Red
AIR BAG
14-1.12
Red
Brake
14-1.12
Red
Charge
14-1.12
Red
Check Trans
14-1.12
Red
Check 4WD
14-1.12
Red
Power drive
14-1.12
Amber
3rd start
14-1.12
Green
4L
14-1.12
Green
Cruise Set
14-1.12
Green
Check Engine
14-1.12
Amber
Front Fog
14-1.12
Green
Rear foglight
14-1. 12
Amber
Glow
14-1.12
Amber
LED
Green
LED
Green
LED
Green
LED
Green
LED
Green
LED
Green
LED
Green
A/T shift
indicator
Remarks
RELAY AND FUSE

RELAY AND FUSE BOX LOCATION (RHD)
RELAY AND FUSE BOX LOCATION (LHD)
RTW48ALF000201
RELAY LOCATION (RELAY AND FUSE BOX)

RELAY & FUSE BOX
RHD
NO.
RELAY (C24SE)
RELAY (6VE1)

X-3
X-4
X-5
X-6
X-7
X-8
X-9
X-10
X-11
X-12
RELAY; HORN
RELAY; DIMMER
RELAY; FOG LIGHT
RELAY; STARTER
RELAY; COND, FAN
RELAY; HAZARD-RH
RELAY; HAZARD-LH
RELAY; HEATER
RELAY; HEAD
LIGHT
X-13
RELAY; ECM MAIN
X-15 RELAY; THERMO
RELAY
(4JA1-TC/4JH1-TC)
RELAY; FRT FOG
RELAY (4JA1-L)
RELAY; FRT FOG

LIGHT
RELAY; GLOW
RELAY; CSD
RELAY; GLOW
RELAY; COND, FAN
RELAY; RR FOG
RELAY; STARTER
RELAY; STARTER
RELAY; COND, FAN
RELAY LOCATION (RELAY AND FUSE BOX)

RELAY & FUSE BOX
LHD
NO.
RELAY (C24SE)

RELAY (6VE1)
X-3 RELAY; HORN
X-4 RELAY; DIMMER
X-5 RELAY; FRT FOG

RELAY; FOG LIGHT
LIGHT
X-6 RELAY; STARTER
X-7 RELAY; COND, FAN
X-8
X-9
X-10
X-11 RELAY; HEATER

X-12 RELAY; HEAD
LIGHT
X-13

X-15 RELAY; THERMO
RELAY; ECM MAIN
RELAY
(4JA1-TC 4JH1-TC)
RELAY; FRT FOG
RELAY; GLOW
RELAY (4JA1-L)
RELAY; FRT FOG

LIGHT
RELAY; GLOW
RELAY; COND, FAN

RELAY; RR FOG
RELAY; STARTER
SHORT
CONNECTOR
(with cooler)
RELAY; CSD
RELAY; COND, FAN
RELAY LOCATION
(CABIN)
RELAY
Connector No.
C24SE
6VE1
4JA1-TC, 4JH1-TC
4JA1-L
B-7
REAR DEFOGGER
B-8
POWER WINDOW
B-40
ACC SOCKET
FUSE AND SLOW BLOW FUSE LOCATION (RELAY AND FUSE BOX)
RELAY & FUSE BOX
RHD
FUSE
FUSE NO.
EB-1
EB-2
EB-3
EB-4
EB-5
EB-6
EB-7
EB-8
EB-9
EB-10
EB-11
EB-12
EB-13
EB-14
EB-15
EB-16
*
C24SE
15A ECM
15A FRT FOG

10A ACG (S)
10A ILLUMI
10A TAIL
10A H/LIGHT-RH
10A H/LIGHT-LH
20A FUEL PUMP
10A O2 SENSOR
ENGINE MODEL
6VE1
4JA1-TC / 4JH1-TC
20A ECM
10A ECM
10A RR FOG
10A ECM (B)
10A TCM
15A FRT FOG
15A FRT FOG
10A TAIL-LH
10A H/LIGHT RH-LOW
10A H/LIGHT LH-LOW
10A TRA ILER

10A O2 SENSOR
10A AC G (S)
20A FUEL PUMP
10A H/LIGHT RH-HIGH

10A H/LIGHT LH-HIGH
10A A/C
10A 4WD
10A 4WD
10A HORN
15A HAZARD
10A HAZARD
4JA1-L
10A ACG (S)

10A ILLUMI
10A TAIL
10A H/LIGHT RH
10A H/LIGHT LH
SLOW BLOW FUSE

FUSE NO.
SBF-1
SBF-2
SBF-3
SBF-4
SBF-5
SBF-6
SBF-7
SBF-8
SBF-9
C24SE
100A MAIN
20A COND, FAN

40A IG 1
30A BLOWER
50A IG 2
ENGINE MODEL
4JA1-TC / 4JH1-TC
80A MAIN
20A COND, FAN
60A GLOW
30A ECM
40A ABS-1
30A ABS-2
6VE1
4JA1-L
20A COND, FAN

50A GLOW
FUSE AND SLOW BLOW FUSE LOCATION (RELAY AND FUSE BOX)
RELAY & FUSE BOX
LHD
FUSE
FUSE NO.
EB-1
EB-2
EB-3
EB-4
EB-5
EB-6
* Saudi Arabia
C24SE
15A ECM
15A FRT FOG
ENGINE MODEL
6VE1
4JA1-TC / 4JH1-TC
20A ECM
10A ECM
10A RR FOG
10A ECM (B)
4JA1-L
10A ACG (S)
10A TCM
10A ACG (S)
15A FRT FOG
10A TAIL-LH
15A FRT FOG

10A TAIL-LH
EB-7
10A H/LIGHT-RH
*10A H/LIGHT-RH-LOW
10A H/LIGHT RH-LOW
10A H/LIGHT-RH
10A H/LIGHT-RH-LOW
EB-8
10A H/LIGHT-LH
*10A H/LIGHT-LH-LOW
20A FUEL PUMP
10A O2 SENSOR
10A O2 SENSOR
20A FUEL PUMP
*10A H/LIGHT-RH-HIGH

*10A H/LIGHT-LH-HIGH
10A A/C
10A 4WD
10A 4WD
10A H/LIGHT LH-LOW
10A H/LIGHT-LH
10A H/LIGHT-LH-LOW
EB-9
EB-10
EB-11
EB-12
EB-13
EB-14
EB-15
EB-16
10A HORN
15A HAZARD
10A HAZARD
10A TRA ILER

10A AC G (S)
10A H/LIGHT RH-HIGH
10A H/LIGHT LH-HIGH
SLOW BLOW FUSE

FUSE NO.
SBF-1
SBF-2
SBF-3
SBF-4
SBF-5
SBF-6
SBF-7
SBF-8
SBF-9
C24SE
100A MAIN
20A COND, FAN

40A IG 1
30A BLOWER
50A IG 2
ENGINE MODEL
6VE1
4JA1-TC / 4JH1-TC

80A MAIN
20A COND, FAN
60A GLOW
30A ECM
40A ABS-1
30A ABS-2
4JA1-L
20A COND, FAN

50A GLOW
FUSE LOCATION
FUSE BOX
RHD/LHD
RTW38DMF000101
FUSE

&

*

+

.

/

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)$
$
%

-$0(
%

&

*

+

.

/

SLOW BLOW FUSE

-

-
-

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$$

DIODE LOCATION
RELAY & FUSE BOX
C24SE
No.
X-16
X-17
RHD
LHD
A/C
6VE1
RHD
TCM
A/T, A/C
LHD
A/C
DIODE
4JA1-TC / 4JH1-TC
RHD
LHD
TCM
A/C
4JA1-L
RHD
A/C
A/C
LHD
FUSE BLOCK CIRCUIT C24SE
Sheet 1/2
RTW48AXF000101
FUSE BLOCK CIRCUIT C24SE
Sheet 2/2
RTW48AXF026901
FUSE BLOCK CIRCUIT 6VE1
Sheet 1/2
RTW48AXF000301
FUSE BLOCK CIRCUIT 6VE1
Sheet 2/2
RTW48AXF026701
FUSE BLOCK CIRCUIT 4JA1-TC / 4JH1-TC (RHD)
Sheet 1/2
RTW48AXF000401
FUSE BLOCK CIRCUIT 4JA1-TC / 4JH1-TC (RHD)
Sheet 2/2
RTW48AXF026801
FUSE BLOCK CIRCUIT 4JA1-TC / 4JH1-TC (LHD)
Sheet 1/2
RTW48AXF000501
FUSE BLOCK CIRCUIT 4JA1-TC / 4JH1-TC (LHD)
Sheet 2/2
RTW48AXF027001
FUSE BLOCK CIRCUIT 4JA1-L
Sheet 1/2
RTW48AXF000801
FUSE BLOCK CIRCUIT 4JA1-L
Sheet 2/2
RTW48AXF027101
Grounding Point
GROUND POINT (RHD) G.EXP
Sheet 1/4
RTW48AXF026001
Sheet 2/4
RTW48AXF026301
Sheet 3/4
RTW48AXF025901
Sheet 4/4
RTW48AXF028401
GROUND POINT (RHD) EUROPE
Sheet 1/4
RTW48AXF025701
Sheet 2/4
RTW48AXF025801
Sheet 3/4
RTW46EXF001501
Sheet 4/4
RTW46EXF001601
GROUND POINT (LHD) G.EXP
Sheet 1/4
RTW48AXF026001
Sheet 2/4
RTW48AXF028701
Sheet 3/4
RTW48AXF028801
Sheet 4/4
RTW48AXF028901
GROUND POINT (LHD) EUROPE
Sheet 1/4
RTW48AXF029001
Sheet 2/4
RTW48AXF029101
Sheet 3/4
RTW48AXF029201
Sheet 4/4
RTW48AXF029301
GROUND POINT LOCATION
P-5
P-6
GROUND POINT LOCATION

C24NE
6VE1
4JA1-TC/4JH1-TC
C24NE
MAIN CABLE HARNESS ROUTING

C24SE / 6VE1 / 4JA1-L / 4JH1-TC
RTW38DXF007401
C24SE / 6VE1 / 4JA1-L / 4JH1-TC (RHD)
RTW48AXF004101
C24SE / 6VE1 / 4JA1-L / 4JH1-TC (LHD)
RTW48AXF004101
C24SE
6VE1
4JA1-TC / 4JH1-TC
RTW38DX007601
4JA1-L
RTW48ALF000101
C24SE / 6VE1 / 4A1-TC / 4JA1-TC / 4JH1-TC
RTW48AXF031801
INSTRUMENT HARNESS (RHD)
810R300071
INSTRUMENT HARNESS (LHD)
RTW48AXF004001
SYSTEM REPAIR
START AND CHARGING
PARTS LOCATION (RHD)
RTW48AXF012601
RTW48AXF012701
PARTS LOCATION (LHD)
RTW48AXF012801
RTW48AXF012901
PARTS LOCATION
RTW38DLF000201-X
CIRCUIT DIAGRAM C24SE (RHD)
RTW48AXF027301
CIRCUIT DIAGRAM 6VE1 (RHD)
RTW48AXF027401
CIRCUIT DIAGRAM 4JA1-TC / 4JH1-TC (RHD) G.EXP
RTW48AXF008501
CIRCUIT DIAGRAM 4JA1-TC / 4JH1-TC (RHD) EUROPE
RTW48AXF008701
CIRCUIT DIAGRAM 4JA1-L (RHD)
RTW48AXF008301
CIRCUIT DIAGRAM C24SE (LHD)
RTW48AXF009001
CIRCUIT DIAGRAM 6VE1 (LHD)
RTW48AXF008901
CIRCUIT DIAGRAM 4JA1-TC / 4JH1-TC (LHD) G.EXP
RTW48AXF008601
CIRCUIT DIAGRAM 4JA1-TC / 4JH1-TC (LHD) EUROPE
RTW48AXF008801
CIRCUIT DIAGRAM 4JA1-L (LHD)
RTW48AXF008401

STARTER SWITCH
Removal
1. Steering Lock Assembly

Refer to Section 3B" STEERING COLUMN" for steering
lock assembly removal steps.
2. Starter Switch
Installation
starter switch.

STARTER SWITCH
Switch Connections
Terminal No.
Starter
switch key
position
LOCK
B-62 B-62 B-62

1
4
2
(B2) (ACC) (IG2)
B-63
1
(ST)
B-63
3
(B1)
Removed
OFF
ACC
Inserted
ON
START
Starter relay
Check continuity between the relay terminals.
1
- 4 ............................. No continuity
(When battery voltage is applied between 2 and 3 )

1
825R300046
- 4 ............................. Continuity
B-62
3
(IG1)

RTW48AXF013201 & RTW48AXF013501
RTW48AXF013401 & RTW48AXF013501
PARTS LOCATION C24SE
PARTS LOCATION 6VE1
PARTS LOCATION 4JA1-TC / 4JH1-TC
RTW38DXF007601
PARTS LOCATION
RTW48AXF031801
PARTS LOCATION
RTW48AXF013001
CIRCUIT DIAGRAM C24SE
Sheet 1/2
RTW48AXF027501
Sheet 2/2
RTW48AXF001301
CIRCUIT DIAGRAM 6VE1
Sheet 1/3
RTW48AXF001401
Sheet 2/3
RTW48AXF027601
Sheet 3/3
RTW48AXF001601
CIRCUIT DIAGRAM 4JH1-TC
Sheet 1/2
RTW48AXF031201
Sheet 2/2
RTW48AXF027701
CIRCUIT DIAGRAM 4JA1-TC
Sheet 1/2
RTW48AXF031301
CIRCUIT DIAGRAM 4JA1-TC
Sheet 2/2
RTW48AXF031401

ECM (ENGINE CONTROL MODULE):
C24SE
Removal
1. Lift both the ECM harness connector locking levers and

remove the two harness connectors form the ECM.
2. Remove the four socket head screws securing the ECM to
the mounting bracket.
3. Remove the ECM from the engine compartment.
4. Pull out the ECM.

5. Disconnect both red and tan connectors.
Refer to the Section 6E-ENGINE of this Manual.
SPS (Service Programming System) and immobiliser
programming (if equipped) is/are necessary
Installation
ECM.
Pay close attention to the important points mentioned in the
following paragraphs.
Connector
Be absolutely sure that ECM is securely connected.
This will prevent a poor contact and open circuit.

6VE1
Removal
1. Pull both the red ECM harness connector locks toward the
front of the vehicle, and remove the two harness connectors
form the ECM.
2. Remove the four hex-head screws securing the ECM to the
common chamber.
3. Remove the ECM from the engine compartment.
4. Pull out the ECM.

5. Disconnect both red and tan connectors.
Installation
ECM.
Connector

4JA1-TC / 4JH1-TC
Removal
1. Remove the passenger side front seat refer to Section 10

CAB.
2. Remove the passenger side front door opening scuff plate.
3. Raise the carpet to gain access to the four hex-head bolts
securing the ECM and ECM cover to the floorpan.
4. Remove the four hex-head bolts.
5. Pull the two harness connector locks away from the
harness connectors and then remove the connectors form
the ECM.
6. Remove the ECM from the vehicle.
Installation
ECM.
Torque passenger seat securing bolts to the specified value
refer to Section 10 CAB
Connector

FUEL PUMP
Removal

Refer to the Section 6C-ENGINE FUEL of this Manual.
Disconnect the fuel pipe.
Installation
fuel pump.
Rubber Seal
Be absolutely sure that the fuel pump rubber seals correctly
seated.
Connector
Be absolutely sure that the fuel pump connector is securely
connected.
This will prevent a poor contact and an open circuit.
EXHAUST GAS RECALCULATION (EGR): 4JA1-L ONLY

RTW48AXF0136 & RTW48AMF000101
RTW48AXF013701
RTW48AXF01381 & RTW48AMF000101
RTW48AXF013901
CIRCUIT DIAGRAM
RTW48AXF010801
LIGHTING
RTW48AXF014501 & RTW48AXF014601
RTW48AXF014701 & RTW48AXF014801
CIRCUIT DIAGRAM (RHD) G.EXP
RTW48AXF014401
CIRCUIT DIAGRAM (RHD) EUROPE
RTW48XF026501
CIRCUIT DIAGRAM (LHD) G.EXP
RTW48AXF014201
CIRCUIT DIAGRAM (LHD) EUROPE
RTW48AXF014301
TROUBLE SHOOTING
HEADLIGHT
1. Both the headlights (high and low beam) do not light
Checkpoint
Ground point contact (C-36)
Trouble Cause
Countermeasure
NG
Poor ground point contact
Repair the wiring
NG
Poor switch contact or sw

faulty

combination switch
NG
Poor relay contact or relay

faulty
Reinstall or replace the

lighting relay
Open circuit between battery

positive terminal and lighting
relay
Repair open circuit
Open circuit between lighting

relay and lighting switch
Repair open circuit or

connector contact
Open circuit
Repair open circuit
OK
Combination switch continuity
OK
Lighting relay
OK
Voltage between
5 X-12 - ground and
2 X-12 - ground
NG
OK
Voltage between 1 B-60 ground
NG
OK
Wiring continuity between
B-60 - C-36
NG

2. High or low beam does not light on both headlights
Checkpoint
Dimmerpassing switch
continuity
Trouble Cause
NG
Countermeasure
Poor switch contact or switch

faulty

combination switch

headlight and dimmerpassing
switch

connector contact
OK
Voltage between
4 X-4 - ground and
4 B-60 - ground
NG
3. RH (or LH) high and low beam does not light

Fuse No. EB-7 (10A) or
No. EB-8 (10A) (Relay and
fuse box)
(No. EB-7 RH, No. EB-8: LH)
NG
Poor installation or blown fuse
Reinstall or replace fuse No.

EB-7 or No. EB-8
Blown filament or air leakage
Replace the headlight bulb
Open circuit and/or poor

connector contact
Repair or replace the wire

and/or connector
OK
Headlight connector continuity
NG
OK
connector 3 C-19 - fuse No.
EB-7 or 3 C-26 fuse No.
EB-8
NG
4. High or low beam does not light on one headlight (RH or LH)
Headlight connector continuity
NG
Blown filament
Replace the headlight

assembly

switch

connector contact
OK
switch
NG

5. Headlight does not go out
Checkpoint
Lighting relay continuity
between connector 1 X-12
- 2 X-12 (Should be no
continuity)
Trouble Cause
NG
Countermeasure
Relay point fused
Replace the lighting relay
point fused or faulty
Replay the combination switch
Switch point fused or faulty

combination switch
Short circuit
Repair short circuit

between 4 X-12 - 3 B-60
and 4 X-1 - 2 B-60
Lens dirty
Clean the light lens
Bulb filament faulty
Replace the headlight bulb
Poor ground point contact
Repair the wiring
OK
Lighting switch continuity
between connector 3 B-60
-1 B-60 when switch is
OFF(Should be no continuity)
NG
OK
Dimmerpassing switch continuity between connector
3 B-60 - 1 B-60 when switch
is not operating
(Should be no continuity)
NG
OK
Check if headlight goes out
when connector C-30 is
disconnected
NG
6. Insufficient headlight brightness
Headlight lens
NG
OK
Headlight bulb
NG
OK
Dimmerpassing switch
Wire continuity between connector 1 B-60 - C-36
NG

7. Passing light does not function when dimmer switch is operated
Checkpoint
Dimmer switch
Trouble Cause
NG
Countermeasure
Poor switch point contact
Repair or replace the dimmer

switch
Open circuit
Repair open circuit between

4 X-12 - 3 B-60
OK
Voltage between
3 B-60 - ground (Should
be battery voltage present)
NG
8. Headlight beam does not change when dimmer switch is operated
Dimmer switch
NG
Loose beam lever or foreign

material in switch
Repair or replace the dimmer

switch
TAIL LIGHT, LICENSE PLATE LIGHT, CLEARANCE LIGHT

1. All lights do not light
Checkpoint
Fuse No. EB-6 (10A, Relay

and fuse box)
Trouble Cause
NG
Countermeasure
Poor fuse contact or blown
Reinstall or replace the fuse

No. EB-6
NG
Poor switch point or connector

contact

combination switch
NG

faulty
Reinstall or replace the tail

relay
NG
Bulb burned out or poor

connector contact
Replace the bulb or repair

connector contact
NG
Open circuit or poor connector

contact

connector contact
OK
between connector
2 B-60 - 1 B-60
OK
Tail relay
2. Tail light does not light
Tail light bulb continuity
OK
Continuity between connector
3 F-5 - 4 F-5 (RH)
or 3 F-6 - 4 F-6 (LH)
TAIL LIGHT-LH, LICENSE PLATE LIGHT, CLEARANCE LIGHT

1. All lights do not light (EC-LHD)
Checkpoint

and fuse box)
Trouble Cause
NG
Countermeasure

No. EB-6
NG

contact

combination switch
NG

faulty

relay
NG

connector contact

connector contact
NG

contact

connector contact
OK
between connector
2 B-60 - 1 B-60
OK
Tail relay
OK
or 3 F-6 - 4 F-6 (LH)
TAIL LIGHT-RH
1. All lights do not light (EC-LHD)
Checkpoint

and fuse box)
Trouble Cause
NG
Countermeasure

No. EB-6
NG

contact

combination switch
NG

faulty

relay
NG

connector contact

connector contact
NG

contact

connector contact
OK
between connector
2 B-60 - 1 B-60
OK
Tail relay
OK
3 F-5 - 4 F-5 (RH)

3. License plate light does not light
Checkpoint
License plate light bulb

continuity
Trouble Cause
Countermeasure
NG

connector contact

connector contact
NG

contact

connector contact
NG

connector contact

connector contact
OK
Continuity between
connector 1 F-7 - 2 F-7
4. Clearance light does not light
Clearance light bulb continuity
LIGHTING SYSTEM
HEADLIGHT
Removal
1. Remove the radiator grille center bolt.
2. Use a screwdriver to raise the clip and release the lock.
Place a clean rag beneath the screwdriver tip to protect the
body painted surfaces.
3. Remove the radiator grille.
4. Remove the front bumper.
5. Disconnect the headlight connector.
6. Remove the headlight assembly.
7. Remove the headlight cover.
Remove the gaid.
8. Remove the headlight.
HALOGEN HEADLIGHT
Removal
1. Remove the head light socket.
2. Remove the headlight cover.
3. Out side the lock spring.
4. Remove the bulb.
Installation
headlight.
Connector
Be absolutely sure that the headlight connector is securely
connected.
This will prevent a contact and an open circuit.
LIGHTING SWITCH
Removal
2. Remove the steering wheel 1 .
Refer to the STEERING Section of this manual.
3. Remove the Instrument panel lower cover 2 .
4. Remove the steering column cover 3 .

6. Remove the lighting switch from the steering shaft.
Installation
lighting switch.
Connector
Be absolutely sure that the lighting switch connector is securely
connected.
Wire Harness
Do not pinch the wire harnesses between the cluster and the
meter hood during the cluster installation procedure.
Wire damage will result.
FRONT TURN LIGHT

Removal
1. Turn the socket counterclockwise to disconnect it from the
front turn light housing.
2. Pull the bulb from the socket.
RTW38DSH000601
Installation
front turn light.
Connector
Be absolutely sure that the clearance light connector is
securely connected.
CLEARANCE LIGHT
Removal
1. Turn the socket counterclockwise to disconnect it from the
clearance light housing.
2. Pull the bulb from the socket.
RTW38DSH000601
Installation
clearance light.
Connector
Be absolutely sure that the clearance light connector is
securely connected.
LICENSE PLATE LIGHT

Removal
1. Remove the lens cover 1 and the connector 2 .
2. Pull the bulb 3 to remove it.
Installation
license plate light.
Bulb
Be absolutely sure that the license plate light bulb is correctly
installed.
HEADLIGHT BEAM SWITCH

(COMBINATION SWITCH)
Removal
1.
2.
3.
4.
5.
6.
Disconnect the battery ground cable.

Remove the screws on the lower part of the steering wheel.
Remove the horn pad.
Remove the wiring connector.
Remove the steering wheel fixing nuts.
Remove the steering wheel.
Refer to the "STEERING" Section of this manual.
7. Remove the Instrument panel lower cover.
8. Remove the steering column cover.
10. Remove the headlight beam switch (lever) from the steering
shaft (combination switch).
Installation
headlight beam switch (lever).
Connector
Be absolutely sure that the headlight beam switch connector is
securely connected.
Wire Harness
Do not pinch the wire harnesses between the cluster and the
meter hood during the cluster installation procedure.
AIMING OF HEADLIGHT
Check and adjust the inflation pressures, clean the headlight,
park the vehicle on a level surface and insure that vehicle is at
curb weight.
VERTICAL ADJUSTMENT
Use a screwdriver for vertical adjustment.
HORIZONTAL ADJUSTMENT
Use a screwdriver horizontal adjustment.
Installation
Noting the following point:
1. After installing the headlight, be sure to adjust the headlight
aim.
HEADLIGHT ADJUSTMENT
Preparation
Place the vehicle with 1 person in driver seat on a level surface
and check to see if the inflation pressure of the tires is correct,
the lenses are clean, the battery is sufficiently charged, and
adjust to place vehicle by using the screen.
1. Set a vertical screen on a level surface.
2. Toward the screen 1 from the bulb center mark of the
headlight, extend parallel lines to the floor. Mark point A
and B on the screen at the intersection of parallel line and
the screen.
3. Draw vertical lines through point A and B on the screen.

4. Keep the vehicle 2 1m apart from the screen 1 .
5. Draw a horizontal line through point A and B on the screen
1.
6. Turn the headlight low beam on.

7. Adjust the CUTLINE 11.6 mm below the horizontal line H .
8. Adjust the BENDING POINT to the vertical line V .
NOTE:
Always adjust vertical adjustment first.

LIGHTING SWITCH
B-60
B-60
Lighting Switch Connections

Terminal
SW
No.
position
OFF
Switch side
Harness side
Tail
Headlight
HEADLIGHT BEAM SWITCH

B-60
B-60
Headlight Beam and Passing Switch

Connections
Terminal NO.
SW position
HI
Switch side
Harness side
At Dimmer position
LO
At Passing Position
LIGHTING RELAY, TAIL RELAY

2
- 1 ............................. No continuity

2
- 1 ............................. Continuity
GLOVE BOX ILLUMINATION

Removal
1. Remove the bulb cover 1 .
2. Remove the bulb 2 .
Installation
POWER/3rd START SW
Removal
Refer to the Front consol Section 10 of this manual.
2. Remove the power/3rd start switch.
3. Remove the bulb.
Installation
A/T LEVER LIGHT BULB

Removal
Refer to the Front consol Section 10 of this manual.
1. Remove the A/T lever cover.
2. Remove the light bulb 1 .
Installation
FRONT FOG LIGHT

RTW48AXF015001 & RTW48AXF015101
RTW48AXF015201 & RTW48AXF015301
CIRCUIT DIAGRAM (RHD)
RTW48AXF007801
RTW48AXF008001
CIRCUIT DIAGRAM (LHD)
RTW48AXF007901
RTW48AXF014901
FRONT FOG LIGHT

Removal
1.
2.
3.
4.
Remove the radiator grille.

Remove the front bumper
Disconnect the fog light connector.
Remove the fog light.
5. Remove the bulb from the socket.

Remove the socket by turning it counterclockwise.
Installation
fog light.
Bulb
Be absolutely sure that the fog light bulb is correctly installed.
FRONT FOG LIGHT ADJUSTMENT

Vertical Adjustment
Turn the adjusting screw (1) with a screwdriver to adjust the
aim of the fog light vertically.
FRONT FOG & REAR FOG SWITCH
RTU4Z0SH000601
Inspection
Check to see if there is any continuity between the terminals of
the front fog light switch.
Replace the switch when the result of inspection is found
abnormal.
RTW48ASH000401
Removal
Preparation:
1. Ventilation grille
2. Harness connector
3. Front fog light & Rear fog light switch
To remove the switch, push the lock from the back side of
the cluster assembly.
4. Remove the bulb.
Installation
To install, follow the removal steps in the reverse noting the
following point.
1. Push in the switch with your fingers until it locks securely.
RTW48ASH000301
REAR FOG LIGHT

RTW48AXF015401 & RTW48AXF015501
RTW48AXF015601 & RTW48AXF015701
RTW48AXF008201
RTW48AXF008101
REAR FOG LIGHT

Removal
1. Remove the screws 1 .
2. Remove the lens cover 2 .
3. Rear fog push turn the bulb 3 counterclockwise to
disconnect it from the light housing.
RTW48ASH000701
Installation
rear fog light.
Bulb
Be absolutely sure that the license plate light bulb is correctly
installed.
FRONT FOG & RR FOG SWITCH
RTU4Z0SH000601
Inspection
the leveling switch.
abnormal.
RTW48ASH000401
Removal
Preparation:
3. Front fog light & Rear fog light switch
4. Remove the bulb.
HEADLIGHT LEVELING
RTW48AXF015801 & RTW48AXF015901
RTW48AXF015801 & RTW48AXF015901
RTW48AXF014001
RTW48XF014101
HEADLIGHT LEVELING SWITCH

Incorrect beam angle due to load change can be corrected.
A four position switch, 0-3, can alter the beam angle through
1.7 degrees on the long wheel base model and 2.17 degrees
on the short wheel base model.
Inspection
the leveling switch.
abnormal.
825R300049
Removal
Preparation:
3. Headlight leveling switch
Installation
To install, follow the removal steps in the reverse noting the
following point.
ILLUMINATION
RTW38DMF016201 & RTW38DMF016301
RTW48AXF016401 & RTW48AXF016501
CIRCUIT DIAGRAM (RHD) G.EXP
RTW48AXF011901
RTW48AXF012001
CIRCUIT DIAGRAM (LHD) G.EXP
RTW48AXF011801
RTW48AXF012101
ILLUMINATION SWITCH
RTU4Z0SH000901
Inspection
the switch.
abnormal.
RTW48ASH000601
Removal
RTW48ASH000501
Preparation:
1. Instrument
panel
driver
lower
cover
assembly
Refer to the removal steps Sec.10
2. Harness switch
3. Illumination control
4. Remove the bulb.
HAZARD WARNING FLASHER, TURN SIGNAL LIGHT, BACK UP

LIGHT, HORN AND STOP LIGHT
RTW48AXF016601 & RTW48AXF016701
RTW48AXF0168 & RTW48AXF16901
PARTS LOCATION
RTW38DXF007501
PARTS LOCATION
RTW48AXF013001
CIRCUIT DIAGRAM
RTW48AXF027801
TROUBLESHOOTING
STOPLIGHT AND HIGH MOUNTED STOPLIGHT
1. One side of stoplight does not light
Checkpoint
Stoplight bulb continuity
Trouble Cause
Countermeasure
NG
Burned out bulb or poor

connector contact

connector contact
NG

contact

connector contact
NG

contact

connector contact

SBF-9 (50A)
or 1 C-108 - 4 C-107
OK
Continuity between
9 H-9 - 2 F-6 (LH) (or
2 F-5 (RH))
OK
Continuity between
C-109 - 4 F-6 (LH) (or
4 F-5 (RH))
2. Both sides of stoplight do not light
Fuse No. SBF-9 (50A, Fuse

and Relay box)
or 1 C-108 - 4 C-107
NG
Fuse No. C-18 (15A)
Fuse No. C-18 (15A)
OK
Stop light switch (or brake

switch) function
NG
Incorrect the switch installation

or adjustment
Adjust the switch installation

position

contact between stoplight
switch (or brake switch) and
stoplight

connector contact
OK
Voltage between 2 F-6
ground or 2 F-5 - ground
with brake pedal depressed
(Should be battery voltage
present)
NG
3. High mounted stoplight does not light

Checkpoint
Grounding point C-2
Trouble Cause
NG
Poor grounding point contact
Countermeasure
Repair grounding point contact

C-2
OK
Continuity between 3 L-5 1 L-5
NG
High mounted stoplight

malfunction
Repair or replace the high

mounted stoplight
NG

contact
Repair an open circuit or

connector contact between
3 L-5 - 8 H-6
OK
Voltage between 1 L-5 ground with brake pedal
depressed
present)
TURN SIGNAL LIGHT AND HAZARD WARNING LIGHT

1. Turn signal light does not light on both sides (RH and LH)
Checkpoint
Fuse No. EB-16 (10A, Fuse

box)
Trouble Cause
NG
Countermeasure

fuse

EB-16 (10A)
Flasher unit malfunction
Replace the flasher unit
NG

contact

connector contact
NG
Poor switch point contact or

faulty switch

combination switch
OK
Short circuit between
connector 3 B-61 - 1 B-61
when turn signal switch
operates with starter switch
in ON position (Turn
signal light should be ON)
NG
OK
Continuity between
connector 2 B-61 -ground
(Should be continuity)
OK
Turn signal switch continuity
between connector
5 B-60 - 6 B-60 and
5 B-60 - 7 B-60 when
turn signal switch operates

2. Turn signal light does not light on one side (RH or LH)
Checkpoint
Turn signal switch continuity
Trouble Cause
Countermeasure
NG

faulty switch

combination switch
NG

contact

connector contact
NG

contact

connector contact

fuse

No. EB-16 (10A)
Hazard SW. malfunction
Repair or replace the hazard

SW.
Open circuit or poor

fuse No. EB-16 (10A) 5 B-16

connector contact
Burned out bulb

open circuit
OK
(RH)
Continuity between
3 C-18 - 7 B-60 (FRT),
1 C-1 - 7 B-60 (SIDE)
1 F-5 - 7 B-60 (RR)
OK
(LH)
Continuity between
3 C-25 - 6 B-60 (FRT),
1 C-35 - 6 B-60 (SIDE)
1 F-6 - 6 B-60 (RR)
3. Hazard warning light does not light

and fuse box)
NG
OK
Hazard SW. continuity
NG
OK
Voltage between 5 B-16 ground (Should be battery
voltage present)
NG
4. Flashing rate too fast (One side)
Inspect bulb
NG
BACKUP LIGHT
1. Backup light does not light on one side (RH or LH)
Checkpoint
Backup light bulb continuity
Trouble Cause
NG
Countermeasure
Burned out bulb or poor

connector contact

connector contact
Poor ground contact
OK
Grounding point
NG
2. Backup light does not light on both sides
Fuse No. C-4 (15A, Fuse box)
NG

fuse

C-4 (15A)
NG
Poor switch point contact of

faulty switch
Repair or replace the switch
NG

contact

connector contact
OK
Back up light switch (mode

switch) continuity
OK
Voltage between 5 F-6
(5 F-5 ) - ground with
starter switch ON and shift
lever into reverse position
present)
HORN
1. Both sides of horn do not sound
Checkpoint
Fuse No EB-15 (10A, Relay

and fuse box)
Trouble Cause
NG
Countermeasure

fuse

EB-15 (10A)
Poor ground contact
Repair the grounding point
Poor relay contact or faulty

horn relay
Reinstall or replace the horn

relay

contact between fuse No. EB15 (10A) and horn relay

reconnect the connector
NG

faulty switch
Repair or replace the horn

switch
NG

contact

connector contact
OK
Grounding point
NG
OK
Horn relay
NG
OK
Voltage between connector
3 X-3 - ground or 1 X-3
- ground (Should be battery
voltage present)
NG
OK
Remove steering pad and

steering wheel
OK
Horn switch continuity
OK
Continuity between
4 X-3 - 10 B-60
2 X-3 - 1 C-20 (1 C-21 )

2. One side of horn does not blow
Checkpoint
Horn continuity between

connectors
Trouble Cause
NG
Countermeasure
Faulty horn assembly
Replace the horn assembly

contact

reconnect the connector
Discharged battery
Recharge or replace the

battery
Stain foreign material in the

horn
Clfean and/or remove the

foreign material
OK
Voltage between 1 C-20
(1 C-21 ) - ground with
horn switch depressed
present)
NG
3. Insufficient horn volume
Battery condition
NG
OK
Horn
NG

REAR COMBINATION LIGHT
Stoplight
Removal
1. Open the rear gate.
2. Remove the screws of rear combination light.
3. Remove the rear combination light assembly.
4. Turn the bulb 2 counterclockwise to remove it.
Installation
rear combination light.
Bulb
Be absolutely sure that each bulb is correctly installed.
HIGH MOUNTED STOPLIGHT

Remove the bulb socket
1. Remove the high mounted stoplight ASM.
Remove the screws.
Disconnect the connector.
2. Remove the bulb socket.

Turn the bulb 1 counterclockwise to remove it.
Installation
Bulb
SIDE TURN LIGHT

Removal
1. Remove the lens 1 .
Pull the light/bulb toward you while pushing the light
housing in the rear direction of the vehicle to release its
lock.
Remove the socket by turning it counterclockwise.
2. Pull the bulb 2 to remove it.
Installation
side turn light.
Bulb
Be absolutely sure that the side turn light bulb is correctly
installed.

Turn Signal Light
Removal
2. Remove the screws.
Installation
Bulb
Be absolutely sure that the rear combination light bulb is
correctly installed.
TURN SIGNAL SWITCH

Removal
2. Remove the steering wheel 1 .
Refer to the STEERING Section of this Manual.
3. Remove the instruments panel lower cover 2 .
4. Remove the steering column cover 3 .

6. Remove the turn signal switch from the steering shaft.
Installation
turn signal switch (lever).
Connector
Be absolutely sure that the turn signal switch connector is
securely connected.
This will prevent a poor contact and at an open circuit.

Back Up Light
Removal
2. Remove the screws.
Installation
Bulbs
HAZARD WARNING FLASHER SWITCH

Removal

2. Instrument Panel Cluster Assembly
Refer to Section 10 BODY for instrument panel cluster
assembly removal steps.
3. Hazard Warning Switch
Disconnect the switch connector.
To remove the switch, push the lock from the back side
of the cluster assembly.
Installation
To install, follow the removal procedure in the reverse order.
Connector
Be absolutely sure that the hazard warning flasher switch
connector is securely connected.
BACK UP LIGHT SWITCH

Removal
2. Disconnect the connector 1 .
3. Remove the back up light switch from the transmission 2 .
Installation
back up light switch.
Back up Light Switch Threads

Apply liquid gasket to the threaded portion and install the back
up light switch.
Connector
Be absolutely sure that the back up light connector is securely
connected.
HORN
Removal
1. Remove the radiator grille.
Refer to the HEADLIGHT removal procedure.
2. Loosen the horn bolt.
3. Disconnect the horn connector.
Installation
horn.
Pay close attention to the important point mentioned in the
Connector
Be absolutely sure the horn connector is securely connected.
HORN SWITCH
Removal
2. Disable the SRS (Refer to Disabling the SRS in this
section).
4. Check the position of the pins in a hole. Push the pin in the
direction of an arrow.
5. Push the four pins at f5~6 mm bar.
6. Cancel the lock four pins.

7. Disconnect the SRS air bag connector and horn lead
connector located behind the air bag assembly and remove
the air bag assembly.
Installation
1. Connect the SRS bag connector and horn lead connector.
2. Align the each snap stud of driver air bag to the hole of
steering wheel.
3. Push the SRS air bag area1 and area2. At that time confirm
the audible noise of each stud.
4. Enable the SRS (Refer to Enabling the SRS in this
section).

TURN SIGNAL SWITCH
B-60
B-60
Lighting Switch Connections

Terminal No.
SW position
Left
Switch side
Harness side
Turning
direction
Neutral
Right
B-16
HAZARD WARNING FLASHER SWITCH

Hazard Warning Flasher Switch Connections
Terminal
No.
SW position
ON
Switch side
OFF
DOME LIGHT, SPOT LIGHT AND WARNING BUZZER

RTW48AXF017001 & RTW48AXF017101
RTW48AXF017201 & RTW48AXF017301
CIRCUIT DIAGRAM WITHOUT ANTI THEFT (RHD) G.EXP
RTW48AXF009701
CIRCUIT DIAGRAM WITH ANTI THEFT (RHD) G.EXP
RTW48AXF009801
CIRCUIT DIAGRAM WITHOUT ANTI THEFT (RHD) EUROPE
RTW48AXF032001
CIRCUIT DIAGRAM WITH ANTI THEFT (RHD) EUROPE
RTW48AXF010001
CIRCUIT DIAGRAM WITH ANTI THEFT (LHD) G.EXP
RTW48AXF009601
CIRCUIT DIAGRAM WITH ANTI THEFT (LHD) G.EXP
RTW48AXF031901
CIRCUIT DIAGRAM WITHOUT ANTI THEFT (LHD) EUROPE
RTW48AXF009901
CIRCUIT DIAGRAM WITH ANTI THEFT (LHD) EUROPE
RTW48AXF032101
TROUBLESHOOTING
1. Dome light dose not light
Checkpoint
Dome light bulb continuity
Trouble Cause
Countermeasure
NG
Burned out the bulb
Replace the dome light bulb
NG
Switch malfunction
Repair or replace the dome

light assembly
NG

contact

connector contact
NG
Switch malfunction or foreign

material switch
Repair or replace the door

switch
Short circuit
Repair short circuit or

connector contact
OK
Dome light switch function
OK
Continuity between
connector 5 H-12 - 1 L-1
2. Dome light does not go out
Door switch function (Both

side)
OK
Continuity between
connector 2 L-1 -ground
when shutting the door
(Should be no continuity)
NG

DOME LIGHT
Removal
1.
2.
3.
4.
5.
Remove the dome light lens 1 free.

Remove two dome light fixing screws.
Remove the wiring connector.
Remove the dome light.
Pull the bulb 2 to remove it.
Installation
dome light.
Bulb
Be absolutely sure that the dome light bulb is correctly
installed.
DOOR SWITCH
Removal
1.
2.
3.
4.

Loosen the screw 1 .
Remove the door switch.
Disconnect the door switch connector 3 .
Installation
spot light.
Connector
Be absolutely sure that the door switch connector is securely
connected.
SPOT LIGHT (MAP Light)

Removal
1. Grasp the spot light housing 1 with both hands.
Pull the housing straight down.
This will release the clip.
3. Turn socket 3 counterclockwise to remove it.
Installation
spot light.
Connector
Be absolutely sure that the spot light connector is securely
connected.
Bulb
Be absolutely sure that the spot light bulb is correctly installed.
WARNING BUZZER (ALARMER

CONTROL UNIT)
Removal
2. Remove the glove box
Remove the screw.
3. Remove the Alarmer C/U assembly
Remove the screw.
RTW48ASH000801
Installation
warning buzzer.
Connector
Be absolutely sure that the warning buzzer connector is
securely connected.

DOOR SWITCH
R-9
R-10
R-1
R-6
Door Switch Connections

Connector
No.
SW
position
Terminal No.
R-9
R-10
R-1
R-6
Body Ground
PUSHED
RELEASED
WARNING BUZZER
1. Warning Buzzer Circuit
Warning function
Operational conditions
The buzzer sounds when both the tail relay and the FRT door switch-drive
side are turned on. To stop the sound of the buzzer, turn on the starter
switch.
Taillights left on
2. Warning Buzzer Harness Side Connector Circuit

Disconnect the warning buzzer connector and check
continuity and voltage between the warning buzzer harness
side connector terminals.
B-45
Harness side
Terminal Wire
NO.
color
Connecting to
G/R
Tail relay
Fuse CB-5
B/W
Door SW
(FRT-LH)
Ground
Check item
Voltage
Continuity
Connecting
terminal
Check condition
Standard
3-Ground
Lighting SW ON
Approx. 12V
6-Ground
Starter SW ON
Approx. 12V
1-Ground
FRT door-LH
2-Ground
Open
Continuity
Close
No continuity
Continuity
WINDSHIELD WIPER AND WASHER

RTW48AXF017601 & RTW48AXF017701
CIRCUIT DIAGRAM WITHOUT INTERMITTENT RELAY (RHD)
RTW48AXF027901
CIRCUIT DIAGRAM WITH INTERMITTENT RELAY (RHD)
RTW48AXF028001
CIRCUIT DIAGRAM WITHOUT INTERMITTENT RELAY (LHD)
RTW48AXF004501
CIRCUIT DIAGRAM WITH INTERMITTENT RELAY (LHD)
RTW48AXF004401
TROUBLESHOOTING
WINDSHIELD WIPER
1. Wiper dose not operate at any switch position
Checkpoint
RHD:
Fuse No. C-9 (20A)
Trouble Cause
Countermeasure
NG

No. RHD: C-9 (20A)
NG

contact

connector contact
SW. malfunction
Replace the wiper & washer

SW.
Repair grounding point C-2

contact
Wiper motor malfunction
Replace the wiper motor

contact

connector contact
OK
Voltage between 3 B-59 and
the ground (Should be battery
voltage present)
OK
Continuity in the wiper &

washer SW.
NG
OK
Grounding point C-2
NG
OK
1. Wiper motor function when
connecting the motor
connector 3 C-4 to the
battery (+) terminal, and 1
C-4 to the (-) terminal
(Should the wiper motor
rotate at a low speed)
2. Wiper motor function when
battery (+) terminal, 1 C-4
to the (-) terminal (Should
the wiper motor rotate at a
high speed)
NG
OK
Continuity between 1 C-4
and C-36
NG

2. Wiper dose not operate at INT position
Checkpoint
Continuity between the wiper
& washer SW connector
terminals 4 B-59 and 2 B-59
at the INT position
Trouble Cause
Countermeasure
NG
SW. malfunction

SW.
NG
NG

contact

connector contact
Relay malfunction
Replace the intermittent relay
OK
Grounding point C-36
OK
Voltage between the
intermittent relay harness side
connector terminal 4 C-3
and the ground at the INT
position (Should be battery
voltage present)
OK
Intermittent relay function
NG
3. Wiper does not operate at LO position

Wiper motor function
1. Disconnect the wiper &
washer SW. connector
2. Turn the starter SW. on
3. Short-circuit between the
wiper & washer SW.
harness side connector
terminals.
4. B-59 and 5 B-59
5. Check to see if the wiper
motor rotates at a low
speed
NG
SW. malfunction

SW.
OK
Wiper & washer SW. function
NG

4. Wiper does not operate at HI position
Checkpoint
& washer SW. connector
terminals 4 B-59 at the HI
position
Trouble Cause
NG
Countermeasure

contact

connector contact

contact

connector contact
OK
Wiper motor function when
C-4 to the (-) terminal
(Should the wiper motor rotate
at a high speed)
NG
OK
Continuity between 4 B-59
and 2 C-4
NG
5. Rotation of the wiper motor does not stop
Continuity in the wiper &

washer SW.
NG
SW. malfunction

SW.
OK
NG

6. Auto-stop function of the wiper motor does not operate
Checkpoint
& washer SW. connector
at the OFF position
Trouble Cause
NG
Countermeasure

contact

connector contact

contact
Repair an open circuit or a

poor connection of the
connectors between the fuse
No. RHD: C-9 (20A) and 4
OK
1. Disconnect the wiper motor
connector
2. Connect the motor
connector 5 B-59 to the
battery (+) terminal and 1
C-4 to the (-) terminal,
and then change the
connection of the battery (+)
terminal to the connector 4
C-4 while the motor
rotating at a low speed
3. Check to see if the wiper
motor stops at the auto stop
position when connecting
the connector terminals 3
C-4 and 1 C-4 in this
condition
NG
OK
Voltage between the wiper
motor harness side connector
terminal 4 C-4 and the
ground (Should be battery
voltage present)
NG
C-4
OK
Continuity between the
intermittent relay harness side
connector 6 C-3 and the
wiper motor harness side
connector 6 C-4
NG

contact

connector contact
NG
Relay malfunction
Replace the intermittent relay
OK
Intermittent relay function
WASHER
1. Washer motor does not operate
Checkpoint
RHD:
Fuse No. C-9 (20A)
Trouble Cause
NG
Countermeasure

No. RHD: C-9 (20A)
SW. malfunction

SW.
OK
& washer SW. side connector
when the washer button is
depressed
NG
OK
Voltage between the wiper &
washer SW. harness side
connector terminal 7 B-59
and the ground (Should be
battery voltage preset)
NG

contact
Repair or an open circuit or a

No. RHD: C-9 (20A) and 7
B-59
OK
Voltage between the washer
motor harness side connector
terminal 2 C-17 and the
ground when the washer
button is depressed (Should
be battery voltage present)
NG

contact
Repair or an open circuit or a

connectors between 2 C-17
and 1 B-59
NG

contact
NG
Motor malfunction
Replace the washer motor
NG

contact

connector contact
OK
Grounding point C-36
OK
Washer motor function when
connecting the motor side
battery (+) terminal, and the
connector 1 C-17 to the (-)
terminal (Should the washer
motor rotate)
OK
Continuity between 1 C-17
and C-36

WIPER AND WASHER SWITCH
Removal
Refer to the removal steps of the LIGHTING SWITCH
(COMBINATION SWITCH) in LIGHTING of this section.
Installation
wiper and washer switch.
Connector
Be absolutely sure that the wiper and washer switch connector
is securely connected.

Control Switch Connections
B-59
Terminal
No.
SW position
Mist
Off
Switch side
INT
Lo
Hi
Wash
Wiper Motor Inspection

Connector
Low Speed Inspection

1. Clamp the wiper motor in a vise.
The moving parts must be clear of the vise.
2. Connect the connector terminals to the battery.
Refer to the illustration.
3. Check the wiper motor low speed operation.
High Speed Inspection

3. Check the wiper motor high speed operation.
Auto-Stop Inspection
3. Check the wiper motor low speed operation.
4. Disconnect the positive battery terminal.
This will stop the motor.
5. Connect the connector terminals No. 3 and No. 6 with a
lead wire.
6. Reconnect the positive battery terminal to connector
terminal No. 4.
This will restart the motor.
7. Check the auto-stop operation.
Washer Motor Inspection

1.
2.
3.
4.
Fill the washer tank with washing solution.

Disconnect the motor connector.
Apply battery voltage to the washer motor connector.
Check the washer motor operation.
WIPER MOTOR AND LINKAGE

Removal
1. Disconnect the wiper arm nut cap 1 .
2. Remove the wiper arm nut 2 .

3. Remove the wiper arm with blade.
4. Disconnect the wiper motor connector 3 .

5. Remove the wiper motor bracket screws 4 .
6. Disconnect the wiper motor from the wiper linkage at the

crank arm 5 .
7. Remove the vent cowl cover 6 .

Remove the 6 screw.

8. Remove the wiper linkage 7 from the access hole.
Installation
wiper motor and linkage.
Wiper Linkage
Take care not to scratch the painted surfaces of the body when
installing the wiper linkage to the body.
In case crank arm of wiper motor is removed, confirm the
position of auto stop prior to reinstall the crank arm to the wiper
motor.
Crank Arm Nut Torque
Nm (kgm/lb ft)
20 - 26 (2.0 - 2.6 / 14.5 - 18.8)
Wiper Blade Position

Confirm the auto stop position of wiper motor prior to the
installation of the wiper blade and arm.
The distance between the vent cowl cover rubber seal 1 and
the wiper blade edge 2 is about 527.5 mm (2.050.3 in) 3
407.5 mm (1.570.3 in).
880R300006
Wiper Arm Nut

Tighten the wiper arm nut to the specified torque.
Wiper Arm Nut Torque
Nm (kgm/lb ft)
27 - 35 (2.75 - 3.57/19.94 - 25.85)
Windshield Washer Spray

Be sure that the engine hood is completely closed before
checking the windshield washer spray adjustment.
Windshield Washer Spray Position: Refer to the illustration.
RTW38DSF000201
Connector
Be absolutely sure that the wiper motor connector is securely
connected.
Note:
Windshield wiper arm and blade assembly configurations
are different for the right-hand and left-hand side of the
vehicle.
Be careful not to confuse the right-hand and left-hand side
assemblies.
WASHER TANK MOTOR

Removal
1. Remove the head light.
Refer to the head light in this manual.
2. Remove the inner riner.
3. Pull out the clip washer filler.
4. Remove the washer tank nuts.

5. Disconnect the water hose 2 .
6. Pull out the washer tank motor 3 .
Installation
washer tank motor.
Connector
Be absolutely sure that the washer tank motor connector is
securely connected.

RTW48AXF017801 & RTW48AXF017901
RTW48AXF018001 & RTW48AXF018101
PARTS LOCATION 6VE1
PARTS LOCATION 4JH1-TC
RTW38DXF007601
PARTS LOCATION
RTW38DLF000201
Sheet 1/2
RTW48AXF028101
Sheet 2/2
RTW48AXF003101
Sheet 1/2
RTW48AXF0026101
Sheet 2/2
RTW48AXF003301
METER, WARNING LIGHT AND INDICATOR LIGHT

RTW48AXF018401 & RTW48AXF018501
RTW48AXF018601 & RTW48XF018701
PARTS LOCATION 6VE1
RTW38DXF007601
PARTS LOCATION 4JA1-L
RTW48AMF000301
PARTS LOCATION
RTW48AXF018201
PARTS LOCATION
RTW48AXF018301
CIRCUIT DIAGRAM C24SE / 6VE1 (RHD)
Sheet 1/3
RTW48AXF006301
CIRCUIT DIAGRAM C24SE / 6VE1 (RHD)
Sheet 2/3
RTW48AXF006501
CIRCUIT DIAGRAM C24SE / 6VE1 RHD
Sheet 3/3
RTW48AXF006701
Sheet 1/3
RTW48DXF005001
Sheet 2/3
RTW48AXF005101
Sheet 3/3
RTW48AXF005201
Sheet 1/3
RTW48AXF006901
Sheet 2/3
RTW48AXF007401
Sheet 3/3
RTW48AXF007601
Sheet 1/3
RTW48AXF004601
Sheet 2/3
RTW48AXF004701
Sheet 3/3
RTW48AXF004801
CIRCUIT DIAGRAM C24SE / 6VE1 (LHD)
Sheet 1/3
RTW48AXF006401
CIRCUIT DIAGRAM C24SE / 6VE1 (LHD)
Sheet 2/3
RTW48AXF006601
CIRCUIT DIAGRAM C24NE / 6VE1 (LHD)
Sheet 3/3
RTW48AXF006801
Sheet 1/3
RTW48AXF007001
Sheet 2/3
RTW48AXF007501
Sheet 3/3
RTW48AXF007701
Sheet 1/3
RTW48AXF005301
Sheet 2/3
RTW48AXF005401
Sheet 3/3
RTW48AXF005501
Sheet 1/3
RTW48AXF009501
Sheet 2/3
RTW48AXF004701
Sheet 3/3
RTW48AXF004901
TROUBLESHOOTING
SPEEDOMETER
1. Speedometer and odometer do not function
Checkpoint
Check the vehicle speed
sensor output
(4 pulses/1 rotation)
Trouble Cause
Countermeasure
NG

malfunction
Replace the vehicle speed

sensor
NG

contact
Repair an open circuit in the

circuit or a poor connection at
the connectors
Speedometer malfunction
Replace the case baseboard

assy

malfunction, or open circuit or
poor connector contact

sensor, or repair an open
circuit in the circuit or a
connectors

assy
OK
Continuity between the vehicle
speed sensor and the meter,
or the fuse RHD: C-5 (15A)
and the ground
OK
Use a meter tester to check

the speedometer function
NG
2. Speedometer pointer fluctuates

(May be wide fluctuation)
Check the speed sensor
output by using the
oscilloscope
NG
OK

the speedometer function
NG

3. Speedometer pointer jumps erratically
Checkpoint
Check the vehicle speed
sensor output by using the
oscilloscope
Trouble Cause
NG
Countermeasure

malfunction, or open circuit or
poor connector contact

sensor, or repair an open
circuit in the circuit or a poor
connection at the connectors

assy
OK
Use meter tester to check the

speedometer function
NG
Inspection of a waveform by oscilloscope

1. Connect a resistance of 1.3 to 5k ohm (1.4W or more) between the harness side connectors 30 B-24 and 9
B-24 of the meter.
2. Install a speedometer tester.

2. Turn on the starter SW.
3. Check the waveform at the time when the vehicle speed is at 60km/h.
4. Trip odometer does not reset

Check at other kilometer
figures given by meter tester
(Reset should be made to
zero kilometer)
NG
Faulty reset mechanism

assy
TACHOMETER
1. Tachometer does not function when engine is running
Checkpoint
Pulse between connector
B-24 and the ground when
engine is running (Should be
pulse present)
Trouble Cause
NG
Countermeasure
Tacho sensor malfunction, or

open circuit or poor connector
contact
Replace the tacho sensor, or

repair open circuit or
connector contact
Tachometer malfunction

assy
Tachometer malfunction

assy
OK
Tachometer function
NG
2. Meter pointer fluctuates

(May be wide fluctuation)

the tachometer function
NG
TEMPERATURE GAUGE AND THERMO UNIT

1. No temperature indicates at all
Checkpoint
Thermo unit continuity
between connector E-19
(C24NE & 6VE1: E-85 ) and
the ground
Trouble Cause
Countermeasure
NG
Thermo unit malfunction
Replace the thermo unit
NG
Gauge malfunction

assy
NG

contact

connector contact
OK
Gauge function
1. Disconnect the unit
connector then connect
3.4W bulb to wire harness
side with ground
2. Check indicating point
when starter SW. is ON
position (Temperature
should indicate)
OK
Continuity between 1 E-19
(C24NE & 6VE1: E-85 ) and
13 B-24
2. Temperature gauge incorrect readings in all ranges

Thermo unit resistance
between connector 1 E-19
(C24NE & 6VE1: E-85 ) and
the ground when
disconnecting the connector
(Specified resistance should
indicate)
NG
Replace the thermo unit
FUEL GAUGE AND FUEL TANK UNIT

1. No fuel level indicates at all
Checkpoint
Trouble Cause
Countermeasure

Tank unit continuity between
connector 3 F-2 and ground
NG
Open circuit inside the tank

unit
Replace the tank unit
NG
Gauge malfunction

assy
NG

contact

connector contact
OK
Fuel gauge function
1. Disconnect the tank unit
connector then connect
3.4W bulb to wire harness
side
2. Check indicating point
when starter SW. is ON
position (Fuel level should
indicate)
OK
Continuity between
connectors 14 B-24 and 3
F-2
2. Fuel gauge gives incorrect readings in all ranges

Tank unit resistance position
with the float at checking
points (Specified resistance
should indicate)
NG
Tank unit malfunction
Replace the tank unit
WARNING AND INCIDATOR LIGHT

1. When the parking brake lever is pulled, the indicator light does not light up
Checkpoint
Brake indicator light bulb

continuity
Trouble Cause
Countermeasure
NG
Bulb burned out or loose

contact
Replace or reinstall the bulb
NG
Incorrect SW. adjustment or

poor SW. point contact
Adjust or replace the parking

brake SW.
NG

contact

connector contact
NG
Parking brake SW.

malfunction
Replace the parking brake

SW.
OK
Parking brake SW. installation
position and function
OK
parking brake SW. connector
1 C-39 (Lever: 1 R-4 ) and
9 B-23
OK
parking brake SW. connector
1 C-39 (Lever: 1 R-4 ) and
the ground when the parking
brake is operated

2. Even when the parking brake lever is pulled, the indicator light does not go off
Checkpoint
Parking brake SW. installation
position and function
NG
Trouble Cause
Countermeasure
Incorrect the parking brake

SW. adjustment or brake SW.
faulty
Adjust the SW. installation

position or replace the parking
brake SW.
OK
Check to see if the indicator
light goes off when the parking
brake SW. connector 1 C-39
(Lever: 1 R-4 ) is
di
t d
NG
Brake fluid level SW. or

vacuum SW. faulty or short
circuit
Replace the brake fluid level

SW., or vacuum SW., or
repair a short circuit between
the parking brake SW.
connector 1 C-39
(Lever: 1 R-4 ) and 9 B-23
or the brake fluid level SW.
connector 2 C-37 and 9
B-23 , (or the vacuum SW.
connector 1 C-38 and 9
B-23 : 4JH1-TC ONLY)
3. Oil pressure warning light does not go off while engine is running
Engine oil pressure
NG
Refer to ENGINE Section
Refer to ENGINE Section
NG
Short circuit
Repair a short circuit between

1 E-1 and 3 B-24
NG
Oil pressure unit (or oil

pressure SW) faulty
Replace the oil pressure unit

(or the oil pressure SW.)
OK
Check to see the warning light
goes off when the oil pressure
SW. connector
1 E-1 is disconnected
OK
Continuity between the oil

pressure SW. connector
1 E-1 and the body ground
when the engine is operating

METER ASSEMBLY
Removal
1. Meter Cluster Assembly
Refer to the removal steps of INSTRUMENT PANEL in
Section 10 CAB
2. Meter Assembly
Remove three screws of the meter assembly.
Disconnect the meter connectors.
Installation
meter.
Connector
Be absolutely sure that the meter connectors are securely
connected.
Wire Harness
Do not pinch the wire harness between the cluster and the
meter hood during the meter assembly installation procedure.
WARNING LIGHT BULB, INDICATOR

LIGHT BULB AND ILLUMINATION LIGHT
BULB
Removal
Turn the bulb socket counterclockwise and pull the bulb out.
Installation
To Install, follow the removal steps in the reverse order.
FUEL TANK UNIT

Removal
Dismount the fuel tank first, then remove the fuel tank unit.
1. Remove the rear inner liner -LH
Remove the clip
2. Remove the filler neck.
Remove the screw
3. Remove the ground with cable.
4. Remove the fuel tank band.
T/M jack unit on the vehicle.
Disconnect fuel line quick connectors.
5. Remove the fuel tank unit from the fuel tank.
Installation
Rubber Seal
Be absolutely sure that the fuel tank unit rubber seal is
correctly seated.
Connector
Be absolutely sure that the fuel tank unit connector is securely
connected.
VEHICLE SPEED SENSOR (INSTALLED

ON THE TRANSMISSION)
Removal
2. Remove the vehicle speed sensor body by rotating it.
Installation
To Install, follow the removal steps in the reverse order, noting
the following point.
Tighten the vehicle speed sensor to the specified torque.
Vehicle Speed Sensor Tightening Torque
Nm (kgfm/lb.ft)
25 4.9 (2.5 0.5/18 3.6)

Warning, indicator and illumination light position
Without tachometer (C24NE)
RTW38AXF026601
With Tachometer (6VE1)
RTW48AXF006201
With Tachometer (4JA1-TC / 4JH1-TC)
RTW48AXF006101
With Tachometer (4JA1-L)
RTW48AXF006001
SPEEDOMETER AND TACHOMETER

Speedometer On-Vehicle Inspection
Check the speedometer accuracy with a speedometer tester.
Carefully follow the tester manufacturers instructions.
Manual Transmission
RTW38DSH000201
Auto Transmission
km/h meter
km/h
Permissible Range
Indication
RTW38DSH000101
Auto Transmission (mPH)
20
40
60
80
100
120
140
160
G.EXP
EC, SAUDI
ISRAEL, SA
17.5 - 22.5
37.5 - 42.5
57.5 - 62.5
77.5 - 82.5
97.6 - 103.4
117.6 - 123.4
137.6 - 143.4
157.2 - 163.8
20 25
40 45
60 65
80 85
99.8 105.6
119.8 125.6
139.8 145.6
159.4 - 166
mPH meter
Indication
20
40
60
80
100
km/h
Permissible Range
G.EXP
UK
18.5 - 21.5
48.5 - 41.5
58.5 - 61.5
79.1 - 82.5
98.9 102.7
20 23
40 43
60 63
80 83.4
99.8 103.6
RTW48ASH000201
Tachometer On-Vehicle Inspection

1. Attach a tune-up tester to the engine.
3. Compare the tachometer reading and the tester reading.
If the tachometer indication is outside the permissible
range, the tachometer must be replaced.
4. Gradually increase and decrease the engine speed.
Note the movement of the tachometer needle.
If the needle movement is sluggish, the tachometer must be
replaced.
6VE1
RTW38DSH000401
rpm
Indication
Permissible Range
750
1,000
2,000
3,000
4,000
5,000
6,000
7,000
690-770
900-1,060
1,820-2,070
2,820-3,120
3,820-4,180
4,820-5,180
5,820-6,180
6,820-7,180
4JH1-TC
RTW38DSH000501
rpm
Indication
Permissible Range
750
2,000
3,000
4,000
5,000
690-810
1,875-2,125
2,850-3,150
3,820-4,180
4,820-5,180
Tachometer Off-Vehicle Inspection

Remove the tachometer from the meter assembly and
measure the resistance value and the current consumption
between each terminal.
SELF DIAGNOSTIC FUNCTION

Check that the speedometer, tachometer, fuel gauge, and
temperature gauge operate properly.
821R300033
Entering the self-diagnostic mode

1. Push in and hold the Change Indicator and Reset knob.
2. Turn the ignition ON.
3. When the LCD odometer turns ON, release the Change
Indicator and Reset knob.
4. Push in and release the Change Indicator and Reset knob
three times in quick succession.
The meter cluster is now in Self-diagnostic mode.
NOTE: Steps 2-4 must be performed within 7 seconds.
The meter cluster will not enter Self-diagnostic mode if any of
the following conditions occur:
1. The Change Indicator and Reset knob is not depressed
when the ignition is turned ON.
2. The Change Indicator and Reset knob is released within
600ms of turning the ignition ON.
3. The Change Indicator and Reset knob is not depressed
and released three times within 7 seconds.

Self diagnostic mode
LCD condition
All LCDs are lit during he transition from self-diagnostic
decision mode to self-diagnostic mode
The odometer/trip indicator scrolls throng its entire range
approximately once every 600 ms. All digits are lit (segment
check indication). This continues until the self-diagnostic
mode is terminated.
Meter and gauge indications

Meter and gauge indications with the change indicator and
reset knob on (self-diagnostic mode) are as shown in the
following table.
RTW38DSF000101
Speedometer
Tachometer
Fuel gauge
100 kilometers per hour

3,000 rpm
Mid-point on the dial
Temperature gauge
All indications return to zero when the change indicator and
reset knob is turned off.
The self-diagnostic mode and the self-diagnostic decision
mode are cancelled when the ignition switch is turned to the
OFF position. They also cancel when a speed pulse is sensed.
If either of the self-diagnostic modes are cancelled by turning
the ignition switch to the OFF position, the diagnostic unit
remains in the stand-by condition.
If cancellation occurs when a speed pulse is sensed, the unit
remains in the ordinary operating condition.
Meter connector pin arrangement

Without Tachometer
Terminal
No.
1
2
3
Connector No. B-23
Terminal
Connector No. B-24
C24SE
No.
1
C24SE
ABS CONT. (BRAKE)
4LO
OIL PRESSURE
4WD
CHECK 4WD
7
8
9
BRAKE
10
CHARGE
11
13
14
15
16
17
ILLUMI (-)
18
ILLUMI (+)
SPEED (+)
10
4P OUTPUT
11
TURN (RIGHT)
12
12
STARTER
13
TEMP
14
FUEL
15
FRONT FOG
16
17
CHECK ENGINE
18
AIR BAG
19
SEAT BELT
20
BEAM (+)
21
TURN (LEFT)
22
BEAM (-)
23
BEAM (+)
24
25
26
POWER GND
27
SPEED (-)
28
GND UNIT
29
+B
30
IGN
Connector No. B-23

Terminal
Connector place
SOUTH
AFRICA
SAUDI
ARABIA
ISRAEL
EC
UK
OTHER
ABS CONT. (BRAKE)
CHECK TRANS
A/T-P
A/T-R
A/T-2
A/T-L
7
8
9
BRAKE
10
CHARGE
11
TURN (R)
12
A/T-N
13
A/T-D
14
A/T-3
15
DIFF. LOCK
16
A/T OIL TEMP
17
ILL (-)
18
ILL (+)
RTW48AXF005901
Connector No. B-24

Terminal
Connector place
SOUTH
AFRICA
SAUDI
ARABIA
ISRAEL
EC
UK
OTHER
RR FOG
FRONT FOG
LOW COOLANT
CRUISE SET
SEDIMENTER
4LO
OIL PRESS
4WD
CHECK 4WD
GLOW
7
8
POWER DRIVE
SPEED (+)
10
4P OUTPUT
11
TACHO
12
STARTER
13
TEMP
14
FUEL
15
16
ABS CONT. (ABS)
17
CHECK ENGINE
18
AIR BAG
19
20
SEAT BELT
BEAM (+)
21
TURN (LEFT)
22
BEAM (-)
23
24
BEAM (+)
FRONT FOG

3rd START (A/T)
25
26
POWER GND
27
SPEED (-)
28
GND UNIT
29
+B
30
IGN
Thermo Unit Inspection

INSPECTION
Use a circuit tester to measure the thermo unit resistance.
Replace the unit when the result of inspection is found
abnormal.
Temperature
Check
condition
140R300007
Resistance
value (W)
60C
115C
(140F)
(239F)
168 3.5
30.9 2.0
+2.5
Fuel Tank Unit Inspection

Measure the fuel tank unit resistance between the connector
terminals 1 F-2 and 3 F-2 while shifting the float from E
to F point.
Fuel Tank Resistance
Float position
Level
mm
F (B)
217.5
1/2 (A)
105.1 (C24SE,
4JA1-L, 6VE1)
112.8 (4JA1-TC,
4JH1-TC)
E (C)
16.2
041R300002
Standard resistance
W
+2.2
17 0.8
45 4.5
120 2.0
Low Fuel Indicator Light Inspection

1. Disconnect the fuel tank unit wire connector.
2. Turn the key switch on. Check that the bulb lights.
If operation is not correct, remove and check the bulb or circuit.
or If check whether low fuel turns on fuel input (B-24) at the
time of open and key on.
* meter is check at low fuel
Check level sensor operation

1. Remove the fuel tank unit.
2. Apply battery voltage between terminal (B) and (C) through
a 1.12 watt bulb. Check that the bulb lights.
Note:
It will take a short time for the bulb light.
3. Submerge the sensor in fuel. Check that the bulb goes out.
If operation is not correct, replace the fuel tank unit.
140R300006
BRAKE SYSTEM WARNING LIGHT

The brake system warning light comes on while the parking
brake is set and the engine run position.
Note:
The parking brake indicator light circuit is designed to
prevent driving of the vehicle with the parking brake on.
It does not indicate the condition of the parking brake
system.
The parking brake switch is in parallel with the brake fluid
switch.
The brake system warning light also comes on when reservoir

brake fluid level falls below the specified limit with the parking
brake released and the engine run position.
VEHICLE SPEED SENSOR (INSTALLED

ON THE TRANSMISSION)
The speed sensor is installed on the rear portion of the
transmission.
The number of pulses generated is four pulses per one rotation
of the pinion shaft.
RTW38DLF000201
Vehicle Speed Sensor Inspection

1. Connect the vehicle speed sensor connector 1 E-44 to the
battery (+) terminal and 2 E-44 to the (-) terminal.
2. Connect a resistance of 1.3K ohm to 5K ohm (1/4 W or
more) between connectors 1 E-44 and 3 E-44
CAUTION:
Be extremely careful not to connect the battery (+)
terminal to the connector 3 E-44 .
This may damage the vehicle speed sensor.
3. Rotate the shaft of the vehicle speed sensor slowly and
measure the voltage at the both ends with a digital tester.
The voltage, with one rotation of shaft fluctuates four times in
the following range: 10 to 14V - 2V or less.
HEATER AND AIR CONDITIONING

RTW48AXF018801 & RTW48AXF018901
RTW48AXF019001 & RTW48AXF019101
PARTS LOCATION (C24SE)
PARTS LOCATION 6VE1
PARTS LOCATION
4JA1-TC / 4JH1-TC
4JA1-L
RTW38DXF007601 & RTW48ALF000101
PARTS LOCATION
RTW38DXF007501
CIRCUIT DIAGRAM C24SE / 6VE1
RTW48AXF029701
CIRCUIT DIAGRAM 4JA1-TC / 4JH1-TC
RTW48AXF003501
CIRCUIT DIAGRAM 4JA1-L
RTW48AXF003601
CIRCUIT DIAGRAM WITH COOLER C24SE
RTW48AXF005701
CIRCUIT DIAGRAM WITH COOLER 4JA1-TC / 4JH1-TC
RTW48AXF005801
CIRCUIT DIAGRAM WITH COOLER 4JA1-L
RTW48AXF005601
POWER DOOR LOCK

RTW48AXF019201 & RTW48AXF019301
RTW48AXF019401 & RTW48AXF019501
CIRCUIT DIAGRAM WITHOUT ANTI THEFT (RHD)
RTW48AXF011601
CIRCUIT DIAGRAM WITH ANTI THEFT (RHD)
RTW48AXF011301
CIRCUIT DIAGRAM WITH SUPER LOCK (RHD ONLY)
Sheet 1/3
RTW48AXF025401
Sheet 2/3
RTW48AXF024801
Sheet 3/3
RTW48AXF024901
CIRCUIT DIAGRAM WITHOUT ANTI THEFT (LHD)
RTW48AXF011701
CIRCUIT DIAGRAM WITH ANTI THEFT (LHD)
RTW48AXF011401
TROUBLESHOOTING
QUICK CHART FOR CHECK POINTS
Check Points
Fuse
C-14
(20A)
Trouble Mode
1. All the doors do not
lock and unlock
2. All the doors do not
get locked (or
unlocked)
3. Drivers side door
does not get locked
(or unlocked)
4. FRT passengers side
door does not get
locked (or unlocked)
5. RR door-RH does not
get locked (or
unlocked)
6. RR door-LH does not
get locked (or
unlocked)
7. Door lock does not
operate when
operating from the
drivers seat side
Power
Window &
Door Lock
Switch
Door
Lock
Switch
Drivers
side
Drivers
side
Key CYLN
Der switch
Door Lock Actuator

Cable
D/S
P/S
Passen
gers
side
RR-RH
RR-LH
Harness

1. All the doors do not lock and unlock
Checkpoint
Fuse No. C-14 (20A, Fuse

box)
Trouble Cause
Countermeasure
NG

No. C-14 (20A)
NG

contact
NG

contact

connector contact
NG

contact

connector contact
SW. malfunction
Replace the drivers side

power window & door lock
SW.
OK
Grounding point C-2
OK
Voltage between the drivers
side power window & door
lock SW harness side
connector terminal 1 D-5
battery voltage present)
OK
Continuity between 4 D-4

and C-2
OK
Drivers side power window &
door lock SW. function
NG
2. All the doors do not get locked (or unlocked)

Continuity between the drivers
side power window & door
lock SW harness side
connector terminals 14 D-20
and 6 D-20
NG

contact

connector contact
SW. malfunction
Replace the drivers side

SW.
OK
Drivers side power window &
door lock SW. function
NG

3. Drivers side door does not get locked (or unlocked)
Checkpoint
Door lock SW. function
Trouble Cause
NG
SW. malfunction
Countermeasure
Replace the door lock SW.
4. FRT passengers side door does not get locked (or unlocked)
FRT passengers side door

lock actuator function
NG
Actuator malfunction
Replace the FRT passengers

side door lock actuator
5. RR door-RH does not get locked (or unlocked)
RR door lock actuator-RH

function
NG
Replace the RR door lock

actuator-RH
6. RR door-LH does not get locked (or unlocked)
RR door lock actuator-LH

function
NG
Replace the RR door lock

actuator-LH
7. Door lock does not operate when operated from the drivers seat side
Grounding point C-2
NG

contact
NG
SW. malfunction
Replace the door lock SW.
OK
Continuity between the door
lock SW. side connector
terminals 1 D-4 and 2 D-4
when the SW is locked and
between is unlocked 2 D-4
and 4 D-4 when the SW.

DRIVER SEAT SIDE POWER WINDOW &
DOOR LOCK SWITCH
Removal
2. Removes the screw in pull cup with the screwdriver.
3. Remove the switch bezel by pushing the spring with the tip
of a screwdriver.
This photo is based on 2 doors
ATTENTION:
When removing a switch bezel lift from the front in the
bezel.
It follows the front with the screwdriver.
The clip has broken when lifting from the rear in the bezel.
Installation
DRIVERS SIDE DOOR LOCK SWITCH

Removal
1. Door Lock ASM
Refer to the removal steps of the DOORS in section 10
BODY.
2. Door Lock Switch
Installation
FRT PASSENGERS SIDE DOOR LOCK

ACTUATOR
Removal
1. Door Lock ASM
Refer to the removal steps of the DOORS in Section 10
BODY.
2. Door Lock Actuator
Remover the actuator fixing bolts.
Disconnect the door lock link rod.
Disconnect the actuator connector.
Installation
RR DOOR LOCK ACTUATOR-LH & RH

Removal
1. Door Lock ASM
Refer to the removal steps of the DOORS in section 10
BODY.
2. Door Lock Actuator
Remove the actuator fixing bolts.
Disconnect the door lock link rod.
Disconnect the actuator connector.
Installation

D-20
Driver Seat Side Power Window & Door Lock

Switch
D-5
1. Harness Side Connector Circuit

Check voltage and continuity between the switch harness
side connector terminals as shown in the following table.
Harness side
Terminal
No.
Wire
color
14 (D-20)
L/R
13 (D-20)
L/Y
3 (D-5)
L/R
Ground
4 (D-5)
L/R
Door lock
actuator (Lock)
5 (D-5)
Door lock
actuator
(Unlock)
1 (D-5)
LG/W
Fuse
C-14 (20A)
Connecting to
Check item
Door lock SW
(Lock)
Door lock SW
(Unlock)
Continuity
(Resistance)
Voltage
Connectin
g terminal
Check condition
Standard
14-Ground
Driver seat
side door
Lock
Continuity
Unlock
No continuity
13-Ground
Driver seat
side door
Lock
No continuity
Unlock
Continuity
3-Ground
Continuity
4-5
Continuity
There is some
resistance
5-4
Continuity
There is some
resistance
1- Ground
Battery voltage
(Approx. 12V)
D-20
D-5
2. Switch Side Connector Circuit

Remove the switch connector, and check continuity and
voltage between the switch connector terminals.
(Connect the (+) terminal of the battery to 1 D-5 and the
(-) terminal to 3 D-5 .)
3 D-5 - 4 D-5 ..................Continuity
3 D-5 - 5 D-5 ..................Continuity
Harness side
(Then, ground 3 D-5 .)

4 D-5 ...........Current flow for approx. 1 second
(Disconnect the ground of 14 D-20 , and ground 13 D-20 .)
5 D-5 ...........Current flow for approx. 1 second
D-5
Harness side
3. Door Lock Operation Test

After confirming that there is continuity between the switch
harness side connector terminals 4 D-5 and 5 D-5 ,
apply the battery voltage to each of the terminals to conduct
the operation test.
When the door lock will not operate, check the door lock
actuator for any trouble.
Connecting terminals
Operation
5 (L)
4 (L/R)
+
Unlock
Lock
Drivers Side Door Lock Switch

1. Switch Side Connector Circuit
Check continuity between the switch connector terminals
Terminal No.
1
2
3
SW position
D-4
Lock
Unlock
Switch side
Front Passengers Side Door Lock Actuator

D-9
Actuator side
1. Actuator Side Connector Circuit

Apply the battery voltage to the actuator connector
terminals to check the operation.
When the door lock actuator is checked on the vehicle and
there is no continuity, and when the door lock actuator itself
is checked and no trouble is found, check the circuit
between the door lock actuator and the driver seat side
power window & door lock switch for any failure.
Operation
1
2
+
Lock
Unlock
Rear Door Lock Actuator -LH & RH

D-14
D-18
Actuator side
1. Actuator Side Connector Circuit

Apply the battery voltage to the actuator connector
terminals to check the operation.
When the door lock actuator is checked on the vehicle and
there is no continuity, and when the door lock actuator itself
is checked and no trouble is found, check the circuit
between the door lock actuator and the driver seat side
power window & door lock switch for any failure.
Operation
1
2
+
Lock
Unlock
POWER WINDOW
RTW48AXF019601
RTW48AXF019701
RTW48AXF019801
RTW48AXF019901
RTW48AXF029601
RTW48AXF010501
TROUBLESHOOTING
QUICK CHART FOR CHECK POINTS
Check Points
Trouble Mode
All windows will not operate

Lock SW does not function
Drivers Window:
Window does not operate
One-touch operation for
DOWN movement will not
operate
Window operates in only
one direction
Front window on passenger
seat side:
when operating the drivers
SW
when operating the
passengers SW
Window does operate in
only one direction when
operating the drivers SW
operating the passengers
seat side SW
Rear window on left (or right)
side:
Window on left (or right)
side does not operate
when operating the drivers
SW
operating the drivers SW
operating the RR-LH (or
RH) side SW
SBF-11
SBF-9
Relay;
Power
Window
Power Window & Door

Lock Switch
Power Window
Switch
Drivers
Side
RR-LH
Passengers
Side
RRRH
Power Window Motor

Drivers
Side
Passengers
Side
RR-LH
RRRH
Cable
Harness
DIESEL W/SRS MODEL

1. All windows do not operate
Checkpoint
Fuse SBF-11 (30A, Fuse box)
Trouble Cause
Countermeasure
NG

SBF-11 (30A)
NG
Circuit breaker malfunction
Replace the circuit breaker

SBF-9 (50A)
Repair grounding points C-2

contact
Power window relay

malfunction
Replace the power window

relay

contact

connectors between 1 C-108
and 2 B-8
NG

contact

connectors between 1 B-8
and 1 B-56 and 6 D-5
NG

contact

connectors between 3 D-5
and C-2 , or 3 B-8 (12
C-107 ) and C-2
OK
SBF-9 (50A, Fuse box)
function
OK
Grounding points C-2
NG
OK
Power window relay function
NG
OK
Voltage between the power
window relay harness side
connector terminal 2 B-8
NG
OK
Voltage between 6 D-5 and
the ground (Should be battery
voltage present)
OK
Voltage between C-2 and

the ground

Checkpoint
Trouble Cause
Countermeasure

OK
Driver seat side power window
& door lock SW. function
NG
SW. malfunction
Replace the driver seat side

SW.
2. Lock switch does not function

Checkpoint

Trouble Cause
NG
SW. malfunction
Countermeasure
SW.
3. Window on the drivers side does not operate

Checkpoint

Trouble Cause
NG
Countermeasure
SW. malfunction

SW.
Motor malfunction

power window motor

contact

connector contact
OK
1. Driver seat side power
window motor function
when connection the motor
connector 1 D-1 to the
D-1 to the (-) terminal
(Should the motor rotate in
the UP direction of the
window)
2. Driver seat side power
window motor function
when connecting the motor
connector 2 D-1 to the
D-1 to the (-) terminal
(Should the motor rotate in
the DOWN direction of the
window)
NG
OK
and 1 D-1 , or 8 D-5 and 2
D-1
NG

DOOR LOCK SWITCH
(2 DOORS MODEL)
Removal
This photo is based on RHD

2. Removes the screw in pull cup with the tip of a screwdriver.
of a screwdriver.
ATTENTION:
bezel.
Installation
FRONT PASSENGERS POWER WINDOW

& DOOR LOCK SWITCH
(2 DOORS MODEL)
Removal

of a screwdriver.
ATTENTION:
bezel.
Installation

DOOR LOCK SWITCH
(4 DOORS MODEL)
Removal

of a screwdriver.
ATTENTION:
bezel.
Installation

& DOOR LOCK SWITCH
(4 DOORS MODEL)
Removal

of a screwdriver.
ATTENTION:
bezel.
Installation
REAR POWER WINDOW & DOOR LOCK

SWITCH-LH & RH
Removal
of a screwdriver.
ATTENTION:
bezel.
Installation
DRIVER SEAT SIDE POWER WINDOW

MOTOR
Removal
1. Window Regulator ASM
Refer to the removal steps of the WINDOW
REGULATOR/POWER WINDOW MOTOR in Section
10 BODY.
2. Power Window Motor
Loosen the fixing bolts to remove the power window
motor from the regulator.
Installation

MOTOR
Removal
1. Window Regulator ASM
Refer to the removal steps of the WINDOW
REGULATOR/POWER WINDOW MOTOR in Section
10 BODY.
2. Power Window Motor
Loosen the fixing bolts to remove the power window
motor from the regulator.
Installation
REAR POWER WINDOW MOTOR-LH &

RH
Refer to the DRIVER SEAT SIDE POWER WINDOW
MOTOR removal and installation steps in this section.

Power Window Relay
B-8

2 - 1 ......................... No continuity
2 - 1 ......................... Continuity
D-20
D-5
Driver Seat Side Power Window & Door Lock

Switch
Disconnect the switch connector, and check voltage and
continuity between the harness side connector terminals as
shown in the following table.
Harness side
Terminal
No.
Wire
color
G/R
BR/R
BR/W
Connectin
g terminal
Check condition
Standard
Voltage
6-Ground
Starter SW ON
Approx.
12V
Power window
motor
Continuity
7-8
Ground
Continuity
3-Ground
Connecting to
Check item
Power window
relay
Continuity
Continuity
Front Passengers Power Window & Door Lock

Switch
D-10
Harness side

shown in the following table.

Terminal
No.
Wire
color
11
G/R
12
BR/R
10
BR/W
Connecting to
Check item
Connectin
g terminal
Check condition
Standard
Power window
relay
Voltage
11-Ground
Starter SW ON
Approx.
12V
Power window
motor
Continuity
12-10
Continuity
Ground
Continuity
5-Ground
Continuity
Rear Power Window Switch-LH & RH

D-12
D-16

shown in the following tables.
Harness side
D-12 (RR-LH)
Terminal
No.
Wire
color
G/R
BR/R
BR/W
Connecting to
Check item
Connectin
g terminal
Check condition
Standard
Power window
relay
Voltage
6-Ground
Starter SW ON
Approx.
12V
Power window
motor
Continuity
8-7
Continuity
Ground
Continuity
3-Ground
Continuity
D-16 (RR-RH)
Terminal
No.
Wire
color
G/R
BR/R
BR/W
Connecting to
Check item
Connectin
g terminal
Check condition
Standard
Power window
relay
Voltage
6-Ground
Starter SW ON
Approx.
12V
Power window
motor
Continuity
8-7
Continuity
Ground
Continuity
3-1
Continuity
Driver Seat Side Power Window Motor

D-5
Harness side
1. Driver Seat Side Power Window & Door Lock Switch

Connector Circuit
Disconnect the switch connector, apply the battery voltage
(12V) to the harness side connector terminals and check
operation.
Operation
direction
7 (BR/R)
8 (BR/W)
-
DOWN
UP
2. Driver Seat Side Power Window Motor Connector

Circuit
(12V) to the motor side connector terminals and check
operation.
Operation
direction
1
2
+
DOWN
UP
Front Passengers Power Window Motor

D-10
Harness side
1. Front Passengers Power Window Switch & Door Lock

Switch Connector Circuit
Disconnect the motor connector, apply the battery voltage
operation.
Operation
direction
12 (BR/R)
10 (BR/W)
-
DOWN
UP
2. Front Passengers Power Window Motor Connector

Circuit
operation.
Operation
direction
1
2
+
DOWN
UP
Rear Passengers Power Window Motor-LH

D-12
Harness side
1. Rear Power Window Switch-LH Connector Circuit

operation.
Operation
direction
8 (BR/R)
7 (BR/W)
-
DOWN
UP
2. Rear Power Window Motor-LH Connector Circuit

operation.
Operation
direction
1
2
+
DOWN
UP
Rear Power Window Motor-RH

D-16
Harness side
1. Rear Power Window Switch-RH Connector Circuit

operation.
Operation
direction
8 (BR/R)
7 (BR/W)
-
DOWN
UP
2. Rear Power Window Motor-RH Connector Circuit

operation.
Operation
direction
1
2
+
DOWN
UP
AUDIO, CLOCK AND CIGARETTE LIGHTER

RTW48AXF020001 & RTW48AXF020101
RTW48AXF020201 & RTW48AXF020301
Sheet 2/1
RTW48AXF029801
Sheet 2/2
RTW48AXF011201
Sheet 1/2
RTW48AXF030001
Sheet 2/2
RTW48AXF011001
TROUBLESHOOTING
CIGARETTE LIGHTER
1. Lighter does not pop out after being pushed in. It does not become hot.
Checkpoint
Audio system (System should

receive power)
Trouble Cause
Countermeasure
NG
Poor Fuse No. C-12 (15A,

Fuse box) contact or blown

No. C-12 (15A)
NG

contact
Replace the lighter
NG

contact

connector contact
NG

contact

connector contact
OK
Lighter continuity between
center part and outer area
OK
Voltage between connector 1
B-21 and the ground at
starter SW. is ACC position
present)
OK

1 B-22 and the ground
2. Lighter pops out prematurely before becoming hot
Lighter and casing
NG
Deformed lighter or casing
Repair or replace the lighter

and/or casing
NG
Deformed lighter and casing
Repair or replace the lighter

and/or casing
3. Lighter becomes too hot
Lighter and casing

AUDIO
Refer to Section 9 ACCESSORIES for details.
CIGARETTE LIGHTER
Removal
1.
2.
3.
4.
5.
6.
7.

Remove the center cluster ASM.
Remove the lighter 1 .
Disconnect the connector 2 .
Loosen the ring nut 3 at the back side.
Remove the outer case 4 .
Remove the lighter holder 5 from the bezel.
Installation
lighter.
Connector
Be absolutely sure that the lighter connector is securely
connected.
ACC SOCKET
Removal
1.
2.
3.
4.
5.

Remove the center cluster ASM.
Remove the holder nut 1 .
Remove the ACC Socket 2
Installation
lighter.
POWER DOOR MIRROR

RTW48AXF020401 & RTW48AXF020501
RTW48AXF020601 & RTW48AXF020701
RTW48AXF012401
RTW48AXF012201
TROUBLESHOOTING
QUICK CHART FOR CHECK POINT
Check Point
Trouble Mode
1. Mirrors on the both sides do not operate
2. Mirror on the left (or right) side does not
operate
3. Mirrors on the both sides operate only in
the vertical
(or horizontal) direction
4. Mirror on the left side operates only in
the vertical
(or horizontal)direction
5. Mirror on the right side operates only in
the vertical
(or horizontal) direction
Fuse
C-11
(10A)
Door Mirror
Control
Switch
Door Mirror
LH
RH
Cable
Harness
DOOR MIRROR CONTROL SWITCH

1. Mirrors on the both sides do not operate
Checkpoint
Fuse No. C-11 (10A, Fuse

box)
Trouble Cause
Countermeasure
NG

No. C-11 (10A)
NG

contact
NG

contact

No. C-11 (10A) and 4 D-19
NG

contact

connector contact
NG
SW. malfunction
Replace the door mirror

control SW.
NG

contact

connector contact
OK
Grounding point C-2
OK
Voltage between the door
mirror control SW. harness
side connector terminal
4 D-19 and the ground
present)
OK
Continuity between the door
mirror control SW harness
side connector terminal
8 D-19 and C-2
OK
Door mirror control SW.
function
OK
and 2 H-24 (or 2 H-25 )

2. Mirror on the right side does not operate
Checkpoint

function
Trouble Cause
Countermeasure
NG
SW. malfunction

control SW.
NG
Mirror malfunction on the left

(or right)

mirror
NG

contact

connector contact
OK
Mirror function on the left (or
right) side
OK
Continuity between
7 D-19 and 2 D-7 (7 D-19
and 2 D-2 )
3. Mirrors on the both sides operate only in the vertical (or horizontal) direction

function
NG
SW. malfunction

control SW.

4. Mirror on the left side operates only in the vertical (or horizontal) direction
Checkpoint

function
Trouble Cause
Countermeasure
NG
SW. malfunction

control SW.
NG
Door mirror malfunction

mirror
NG

contact

connector contact
OK
Door mirror function
OK
Continuity between
4 D-19 and 4 D-7 (10
D-19 and 1 D-2 )
5. Mirror on the right side operates only in the vertical (or horizontal) direction

function
NG
Door mirror control

malfunction

control SW.
NG
Door mirror malfunction

mirror
NG

contact

connector contact
OK
Door mirror function
OK
Continuity between
4 D-19 and 4 D-2 (10
D-19 and 1 D-2 )

DOOR MIRROR CONTROL SWITCH
Removal
2. Door trim pad Assembly
Refer to section 10 BODY for door trim pad assembly
removal steps.
3. Door Mirror Control Switch
Remove the power window switch bezel.
Remove the screw.
Disconnect the switch connector.
To remove the switch panel assembly.
Installation
DOOR MIRROR
Refer to the DOOR MIRROR in section 10 BODY.

Door Mirror Control Switch
D-19
1. Switch side Connector Circuit

Check continuity between the switch connector terminals
while operating the door mirror control switch as shown in
the following table.
Switch side
RTW48AMF000601
MV, MH, b, and e terminals have internal connections (circuitry).

4-point switch (Will not operate at intermediate positions.)
D-19
Harness side

Remove the connector No. D-19 of the mirror control
switch and check voltage and continuity of the harness side
connector.
When there is no continuity at the terminal No. 2, 3, 9
and 10, it is considered that the circuit with terminal No.
7 (W/B) is defective.

When there is no continuity at either one of the circuit
No, 5, 7, 8, or 10, the motor in the mirror of the circuit or
the circuit itself is defective.
Terminal
No.
Wire
color
Check item
Connecting
terminal
W/B
LH mirror & RH
mirror
Continuity
R/Y
Fuse C-11 (10A)
Voltage
10
W/R
RH mirror-LH/RH
10-7
B/W
RH mirror-Up/Down
2-7
B/R
LH mirror-Up/Down
3-7
Ground
8-Ground
W/G
LH mirror-LH/RH
9-7
Connection to
Continuity
Check condition
Standard
7-Ground
No continuity
4-Ground
Starter SW ACC
position
Approx.
12V
Continuity
Door Mirror
D-19
Harness side
1. Door Mirror Control Switch Connector Circuit

Disconnect the switch connector D-19 , apply the battery
voltage to the harness side connector terminals and check
its function.
Connector
D-19
No.
Operating
Terminal
9
No.
Mirror
Right
Left
10
direction
Left
Right
Up
Down
Left
Right
Up
Down
D-2
D-7
2. Door Mirror Connector Circuit

Disconnect the door mirror connector, apply the battery
voltage to the door mirror side connector ( D-2 and D-7 )
terminals and check its function.
Door mirror side
Connector No.
Terminal No.
D-2
Up
Down
Operation
D-7
Left
Right
REAR DEFOGGER
RTW48AX020801 & RTW48AXF020901
RTW48AXF021001 & RTW48AXF021101
RTW48AXF029901
RTW48AXF010701
TROUBLE SHOOTING
Rear defogger inoperative
Checkpoint
Fuse No. C-7 (15A, Fuse box)

and 9 B-56
Trouble Cause
Countermeasure
NG

No. C-7 (15A) and 9 B-56
NG

SBF-10 (20A)
Switch malfunction
Replace the rear defogger

switch
NG
Relay malfunction
Replace the rear defogger

relay
NG
Repair grounding point D-2

contact
NG

contact
OK
SBF-10 (20A, Fuse box)
OK
Rear defogger switch function
NG
OK
Rear defogger relay function
OK
Grounding point C-2
OK
Voltage between 1 L-4 ground when the starter switch
and the rear defogger switch
are at on position (should be
Repair open circuit or poor

fuse No. C-7 (15A) and 3
B-7 , SBF-10 (20A) and 1
B-7 , 2 B-7 (3 B-55 ) and
1 L-4 , 4 B-7 (3 B-54 )
and 3 B-46 or 1 B-46 and
C-2

Checkpoint
Trouble Cause
Countermeasure

OK
Continuity between 1 L-7

and C-2
NG

contact

connector contact between 1
L-7 and C-2
NG
Broken heat wire of rear

defogger
Repair heat wire
OK
Continuity between rear
defogger terminals

REAR DEFOGGER SWITCH
Removal
1. Instrument Panel Cluster Assembly
Refer to Section 10 BODY for center cluster panel
assembly removal steps.
2. Rear Defogger Switch (With HVAC control unit)
Refer to Section 1 HVAC HVAC control unit assembly
removal steps.
865R300008
Installation
rear defogger switch.

B-57
REAR DEFOGGER SWITCH

Rear Defogger Switch Connections
Terminal No.
SW position
ON
OFF
Switch side
B-7
REAR DEFOGGER RELAY

2 - 1 ......................... No continuity
2 - 1 ......................... Continuity
INSPECTION OF REAR DEFOGGER HEAT

WIRE
Heat wires are printed on the inner side of glass.
To clean, use a soft cloth and wipe horizontally along the
wires.
Never use glass cleaner or equivalent.
When measuring voltage, wind a piece of tin foil around the
tip of the negative probe and press the foil against the wire
with your finger as shown.
(1) Turn the ignition switch on.
(2) Turn the defogger switch on.
(3) Measure the voltage between the three points on the heat
wire and the (-) terminal with a voltmeter.
(4) Check that the voltage becomes smaller from A to B to C .

(5) If there is a place where the voltage suddenly changes to
0V, there is a broken wire between there and the power
side.
(6) Move the tester probe from the position where the voltage
changes to 0V toward the power side and find where the
voltage suddenly increases.
REPAIR OF BROKEN HEAT WIRE

(1) Clean broken wire tips with white gasoline.
(2) Place masking tape along both sides of wire to be repaired.
(3) Thoroughly mix the repair agent (Dupont paste No. 4817 or
equivalent).
(4) Using a fine tip brush, apply a small amount to the wire.
(5) After a couple of minutes, remove the masking tape.
(6) Allow to stand at least 24 hours.
SRS-AIR BAG
RTW48AXF021201 & RTW48AXF021301
RTW48AXF021401 & RTW48AXF021501
CIRCUIT DIAGRAM
RTW48AXF024101
TRANSFER CASE CONTROL MODULE

RTW48AXF021701 & RTW48AXF021801
RTW48AXF021901 & RTW48AXF022001
PARTS LOCATION 6VE1
RTW38DXF007601
PARTS LOCATION
RTW48AXF021601
PARTS LOCATION
RTW48AXF031701
RTW48AXF007201
RTW48AXF031601
CIRCUIT DIAGRAM 4JA1-TC / 4JH1-TC
RTW48AXF007101
CIRCUIT DIAGRAM 4JA1-L
RTW48AXF028601
2WD-4WD Switch
Removal
1. Remove the center cluster ASM
3. Remove the 2WD-4WD switch.
825R300018
Installation
ANTI-LOCK BRAKE SYSTEM

RTW48AXF022101 & RTW48AXF022201
RTW48AXF022301 & RTW48AXF022401
CIRCUIT DIAGRAM
RTW48AXF007301
IMMOBILIZER
RTW48AXF022701 & RTW48AXF022801
RTW48AXF022901 & RTW48AXF023001
PARTS LOCATION 6VE1
PARTS LOCATION
RTW48AXF021601
CIRCUIT DIAGRAM C24SE / 6VE1
RTW48AXF009301
CIRCUIT DIAGRAM 4JA1-TC / 4JH1-TC (RHD)
RTW48AXF031501
RW48AXF009401
CIRCUIT DIAGRAM 4JA1-TC / 4JH1-TC (LHD)
RTW48AXF009101
KEYLESS ENTRY
RTW48AXF024201 & RTW48AXF024301
RTW48AXF024401 & RTW48AXF024501
Sheet 1/2
RTW48AXF023501
Sheet 2/2
RTW48AXF023601
Sheet 1/2
RTW48AXF023701
Sheet 2/2
RTW48AXF023801
Remove Key Assembly

Replacing the battery in the remote control unit
Replace the battery as soon as the range of the remote control
starts to become reduced.
Open the underside of the remote control unit by removing the
battery cover with a screwdriver as shown in the illustration.
Replace the battery, ensuring that it is inserted correctly.
Replace the battery cover so that it engages audibly. The
battery change must be performed within 3 minutes, otherwise
the remote control will have to be reprogrammed. Make sure
that you dispose of old batteries in accordance with
environmental protection regulations.
Remote key
604RW055
TECH-2 OPERATION AND PROGRAMING

KEYLESS ENTRY
General Description
When the anti-theft and keyless entry control unit and/or the
transmitters (remote keys) are replaced, the security codes
and/or transmitter ID codes must be programmed by using he
Tech-2. The following pages show the procedures to program
in regard to the anti-theft and keyless entry system. Please
refer to Tech-2 scan tool users guide in detail.
901RW180
Legend
(1) PCMCIA Card
(4) DLC Cable

(5) Tech2
Tech-2 Features
060RW009
1. Tech-2 is a 12volt system. Do not apply 24 volts.

2. After connecting and/or installing the vehicle
communication interface (VCI) module, PCMCIA
card and data link connector (DLC) to the Tech2, connect the tool to the vehicle DLC.
3. Make sure the Tech-2 is OFF when removing or
installing the PCMCIA card.
4. The Tech-2 has the capability of two snapshot.
5. The PCMCIA card is sensitive to magnetism and
static electricity, so care should be taken in the
handling of the card.
6. The Tech-2 can not plot a graph when replaying
a snapshot.
7. Always return to the Main Menu by pressing the
EXIT key several times before shutting down.
8. To clear diagnostic trouble codes (DTCs), open
Application Menu and press "Clear DTC ".
Getting Started
Tech-2, the following steps must be performed:
Tech-2.
2. Connect the SAE 16/19 adapter to the DLC
cable.
3. Connect the DLC cable to the Tech-2.
5. Connect the Tech-2 SAE 16/19 adapter to the
vehicle DLC.
060R300015
Operating Procedure
The power up screen is displayed when you power up
the tester with the Isuzu systems PCMCIA card.
Follow the operating procedure.
060R100102
RTW38DLH000201
Menu
The left table shows witch functions are used for the
available equipment versions.
NOTE: Marked items are not applied for keyless entry
system.
DTC
On OBD has three options available in the Tech-2
DTC mode to display the enhanced information
available.
Read DTC Info Ordered By Priority.
Read DTC Info As Stored By ECU.
Clear DTC and Alarm Code Info.

To clear Diagnostic Trouble Codes (DTCs), Use the
diagnostic scan tool Clear DTC Information function.
Tech-2 Data Display

The Tech-2 data values represent values that would
be seen on a normally-keyless entry system.
RTW38DLH000101
Actuator Test
Unlock/Lock Test
Check whether opening and closing of a door lock
can be performed by operation of Tech-2.
1. Turn the key OFF.
2. Turn the key ON.
3. Check the display and test menu.
4. Operate the Tech-2.
RTW38DSH001601
Turn Signal Test

Check the turn signal lamp lights up by operation of
Tech-2.
1. Turn the key OFF.
2. Turn the key ON.
3. Check the display and test menu.
4. Operate the Tech-2.
RTW38DSH001701
Programming
Erase Remove Key
To erase remove control key code in the control unit.
1. Check the display of Tech-2 and press Confirm
key.
060R200289
2. Enter security code.

3. Press Not Okay or Okay key.
RTW38DSH001001

key.
RTW38DSH001101

key.
RTW38DSH001201
Program Remote Key

To program remote control key code in the control
unit.
key.
060R200289

2. Check the following table in the display of Tech-2.
3. Operate the remote key.
RTW38DSH001301

key.
RTW38DSH001401
5. Check the display of Tech-2 and press No or

Yes key.
RTW38DSH001501
ANTI THEFT
RTW48AXF024601 & RTW48AXF024701
PARTS LOCATION WITH SUPER LOCK (RHD)
RTW48AXF025501 & RTW48AXF025601
Sheet 1/2
RTW48AXF023901
Sheet 2/2
RTW48AXF024001
CIRCUIT DIAGRAM ANTI THEFT WITH SUPER LOCK (RHD)
Sheet 1/3
RTW48AXF025401
Sheet 2/3
RTW48AXF024801
Sheet 3/3
RTW48AXF024901
Sheet 1/2
RTW48AXF025001
Sheet 2/2
RTW48AXF025101
ANTI THEFT INDICATOR

Removal
2. Remove the side ventilation grille.
RTW3A0SH001301
3. Disconnect the indicator connector and screw from the

backside of the side ventilation grille to remove the anti theft
indicator.
RTW08ASH000101
Installation
To install, follow the removal steps in the reverse order, noting
ANTITHEFT AND KEYLESSENTRY CONTROL UNIT

Refer to Antitheft And Keylessentry Control Unit in this
section.
AUTO CRUISE
PARTS LOCATION 6VE1
RTW48AXF022501 & RTW48AXF022601
PARTS LOCATION
RTW48AMF000401
CIRCUIT DIAGRAM
RTW48AXF028201
TRAILER HITCH
RTW48AXF023101 & RTW48AXF023201
RTW48AXF023301 & RTW48AXF023401
CIRCUIT DIAGRAM
RTW48AXF012501
CONNECTOR LIST
No.
Connector face
B-1
~
No.
B-17
NOT USED
B-6
B-19
B-7
B-20
Black
Rear defogger relay
B-8
Black
Connector face
White
NOT USED
Cigar lighter illumination
B-21
Power Window Relay
B-9
White
Cigar lighter
B-22
NOT USED
Black
B-10
White
Clock
B-11
~
Cigar lighter
B-23
Green
Meter-A
B-24
NOT USED
B-12
Green
B-13
B-25
~
White
Fan switch
Meter-B
NOT USED
B-27
B-24
B-14
Gray
Audio
B-15
Green
Ground Driver Side
B-30
NOT USED
NOT USED
B-29
B-31
B-16
White
Hazard switch
SDM
No.
Connector face
B-32
No.
Connector face
B-44
NOT USED
Keyless Entry (B)
B-33
B-45
Illumination control
B-34
White
Alarmer control unit
B-46
NOT USED
Gray
B-35
Yellow
B-47
Infrator; passenger side
White
Yellow
Infrator; Driver side
B-37
Black
NOT USED
White
B-40
B-50
Acc socket relay
B-41
White
Acc socket
Power/3rd start switch
NOT USED
B-52
B-53
B-42
White
A/T Lever
B-51
~
Natural
G/sensor
B-49
B-39
Black
Glove box illumination
B-48
B-36
Rear defogger timer
Acc socket
B-43
White
J/B I1
B-54
Keyless Entry (A)
White
J/B I2
No.
Connector face
B-55
White
Connector face
B-65
J/B I3
B-56
White
No.
Silver
Weld splice 2 (Ground)
B-66
J/B I4
B-57
White
44 switch
B-67
(6VE1)
White
HVAC control unit
Black
Cruise main
B-68
B-58
(6VE1)
(4JH1-TC)
Black
Check connector
B-69
B-59
White
Immobilizer
Combination switch-A
B-60
Door lock switch

B-70
(6VE1)
(4JH1-TC)
White
Combination switch-B
B-71
B-61
Black
Flasher relay
B-62
White
Horn
Yellow
SRS
B-73
B-64
Silver
Yellow
B-72
B-63
White
Immobilizer Coil
Black
Weld Splice 3
B-74
Weld splice 1 (Illumination)
White
Cellular phone
No.
Connector face
B-75
Black
Rear fog C/U
B-76
White
Front & rear fog light switch
B-77
(4JA1-L)
White
Immobilizer C/U
B-78
White
Immobilizer antenna coil
B-79
White
Short connector (cooler only)
B-80
Black
Hazard relay (RH)
B-81
Black
Hazard relay (LH)
No.
Connector face
No.
Connector face
No.
Connector face
C-22
C-1
Gray
Side turn lamp-RH
C-2
Front turn lamp-RH

C-23
NOT USED
Silver
C-3
C-24
(6VE1)
(4JH1-TC)
INT Relay
C-4
C-25
NOT USED
Lightblue
Front wiper motor
C-5
~
Triple pressure switch
C-26
NOT USED
C-16
Black
C-17
C-27
Gray
Front wiper motor
C-18
Clearance lamp-LH
C-28
~
Clearance lamp-RH
C-19
Black
NOT USED
C-29
C-30
Head lamp-RH
C-20
Black
Engine hood switch
C-31
(6VE1)
(4JH1-TC)
Horn ; high note

C-21
Black
Head lamp-LH
NOT USED
C-34
C-35
Horn ; Low note
Gray
Side turn lamp-LH
No.
Connector face
No.
Connector face
C-54
C-36
(6VE1)
(4JH1-TC)
Silver
C-37
Black
Brake fluid level switch
Orange
C-55
ABS sensor Front-LH
Brown
C-38
C-56
(4JH1-TC)
(C24SE)
Thermo AMP
Vacuum switch
C-39
ECM
C-56
(4JA1-TC
4JH1-TC)
Parking brake switch (stick type)

C-40
~
ECM-A
C-57
(4JA1-TC
NOT USED
4JH1-TC)
C-43
ECM-B
C-44
C-58
~
White
Stop lamp switch
C-45
~
NOT USED
C-62
C-63
(6VE1)
NOT USED
(4JH1-TC)
C-49
Gray
C-64
C-50
Front Fog lamp-RH
(6VE1)
(4JH1-TC)
Condenser fan
C-51
~
NOT USED
Gray
C-65
~
C-52
C-66
C-53
C-67
(6VE1)
(6VE1)
(4JH1-TC)
(4JH1-TC)
Orange
ABS sensor Front-RH
Black
Front Fog lamp-LH
NOT USED
EHCU
No.
Connector face
C-68
~
No.
Connector face
C-106
NOT USED
NOT USED
C-76
C-77
C-107
Clutch switch
C-78
~
White
J/B E2
C-108
NOT USED
C-93
White
C-94
C-109
J/B E1
(6VE1)
Gray
TCM-(A)
Silver
Body-LH ; ground
C-110
C-94
(4JH1-TC)
White
TCM
C-114
C-95
C-115
(6VE1)
(4JH1-TC)
White
TCM-(B)
C-95
NOT USED
Brown
EVRV
C-116
(4JH1-TC)
White
TCM
C-96
~
C-117
(6VE1)
NOT USED
(4JH1-TC)
C103
Anti theft horn
C-104
C-118
(4JH1-TC)
Brown
Resister
C-105

C-119
(6VE1)
White
Blower motor
Auto cruise actuator
No.
Connector face
C-120
(6VE1)
Auto cruise control

C-121
(C24SE)
IAT sensor
C-122
(C24SE)
White
Co adjuster connector
C-123
(4JA1/A1TC)
Black
EVRV; T/C
C-124
Black
Lowe pressure sensor
C-125
White
Therrmoswitch (Air)
C-126
White
QOS controlunit
No.
Connector face
No.
Connector face
Power window motor-RH
D-2
White
Remote mirror-RH
Front speaker-RH
Door lock actuator driver side
Power window driver side
Power window motor-LH
Remote mirror-LH
Speaker-LH
Rear speaker-LH
Black
Door lock actuator Rear-LH
Brown
Power window motor Rear-RH
White
Power window switch-RH
Black
Rear speaker-RH
D-18
Door lock actuator passenger side

(keyless & antitheft)
D-9
Black
Black
D-17
D-9
Black
Power window switch Rear-LH
D-16
D-8
Black
White
D-15
D-7
White
Power window motor Rear-LH
D-14
D-6
Brown
Brown
D-13
D-5
White
Power window switch passenger side
D-12
D-4
Black
White
D-11
D-3
Black
Connector face
D-10
D-1
Brown
No.
Black
Door lock actuator Rear-RH
D-19
Door lock actuator passenger side
White
Remote mirror switch driver side
No.
Connector face
D-20
White
Power window switch driver side
D-21
White
Tweeter-RH
D-22
White
Tweeter-LH
D-23
White
Door lock & super actuator front (RH)
D-24
White
Key cylinder switch front (RH)
D-25
White
Door lock & super lock actuator front (LH)
D-26
White
Key cylinder switch front (LH)
D-27
White
Door lock & super lock actuator RR (RH)
D-28
White
Door lock & super lock actuator RR (LH)
No.
Connector face
No.
Connector face
No.
Connector face
E-10
E-1
(4JH1-TC)
White
Oil pressure switch
Silver
E-2
E-11
(C24SE)
(6VE1)
Engine ground
(6VE1)
Magnetic clutch
Neutral switch
E-3
E-11
(4JH1-TC)
(4JH1-TC)
Black
Magnetic clutch AC COMP
E-4
~
Natural
green
Neutral switch
E-12
(6VE1)
NOT USED
E-5
Neutral switch
E-6
E-12
(C24SE)
(4JH1-TC)
(6VE1)
(6VE1)
Fuel injector
(C24SE)
E-6
Natural
green
Neutral switch
E-13
(4JH1-TC)
NOT USED
E-17
Injector pump
E-7
E-18
(C24SE)
(C24SE)
(6VE1)
(6VE1)
Fuel injector
Ignition coil
(C24SE)
E-8
E-19
(C24SE)
(4JH1-TC)
(6VE1)
(6VE1)
Fuel injector
(C24SE)
E-9
Blue
E-20
(C24SE)
(6VE1)
(6VE1)
Fuel injector
(C24SE)
E-22
(4JH1-TC)
(4JH1-TC)
T.D.C sensor
NOT USED
E-21
E-9
Gray
Thermo meter unit
Brown
TPS 1 main
No.
Connector face
No.
Connector face
E-44
E-23
(4JH1-TC)
Gray
TPS 2 main
E-24
~
Gray
E-45
(4JH1-TC)
NOT USED
E-29
Gray
E-30
E-46
(4JH1-TC)
(4JH1-TC)
Gray
A/T speed sensor
E-31
2WD-4WD switch
Brown
H-L neutral switch
E-47
(4JH1-TC)
Gray
Turbine sensor
E-32
~
NOT USED
E-48
E-49
(4JH1-TC)
NOT USED
E-34
Glow plug
E-35
E-50
(4JH1-TC)
NOT USED
(C24SE)
Black
E-36
~
Motor actuator
E-51
(6VE1)
NOT USED
E-40
Fuel injector
E-41
E-51
(4JH1-TC)
(4JH1-TC)
Black
Coolant temp sensor
E-42
Black
Inhibiter switch
E-52
(6VE1)
Natural
green
Backup lamp switch
E-43
Fuel injector
E-53
(6VE1)
Natural
green
Backup lamp switch
Ignition coil
No.
Connector face
No.
E-54
E-62
(6VE1)
(6VE1)
Connector face
Ignition coil
Cam position sensor
E-54
E-64
(4JH1-TC)
(C24SE)
(6VE1)
Black
A/T term ASM
Oil pressure switch (P/STRG)
E-55
E-65
(6VE1)
(C24SE)
(6VE1)
Ignition coil
Thermo unit
E-56
E-66
(6VE1)
(C24SE)
(6VE1)
Ignition coil
Duty solenoid
E-67
E-57
(6VE1)
NOT USED
Ignition coil
E-58
E-68
(6VE1)
(C24SE)
Ignition coil
E-59
E-68
(C24SE)
(6VE1)
(6VE1)
(6VE1) Crank position sensor (C24SE)

E-60
E-69
(C24SE)
(6VE1)
ECM
Temperature sensor
E-60
E-70
(6VE1)
(C24SE)
ECM-A
IACV
E-61
E-70
(6VE1)
(6VE1)
ECM-B
IACV
No.
Connector face
E-71
No.
Connector face
E-80
(6VE1)
NOT USED
Cylinder revolution
E-72
E-81
(C24SE)
(6VE1)
(6VE1)
Engine earth-A
Speed sensor
E-73
E-82
(6VE1)
(6VE1)
Engine earth-A
Transmission wire
E-74
E-83
(C24SE)
(6VE1)
(6VE1)
Engine earth-B
Oil temperature sensor
E-75
E-84
(C24SE)
(C24SE)
(6VE1)
Oil pressure switch
Knock sensor
E-76
E-85
(6VE1)
(C24SE)
MAP sensor
EGR valve
E-77
E-86
(C24SE)
(4JA1-L)
O2 sensor
Silver
E-77
E-87
(6VE1)
(4JA1-L)
O2 sensor RH-Front
White
E-78
E-88
(6VE1)
(4JA1-L)
O2 sensor LH-Front
Silver
E-79
E-89
(6VE1)
(4JA1-L)
White
Thermo switch; QOS
Solenoid CSD
Thermo switch; EGR
Immobilizer engine control unit
No.
Connector face
F-1
White
Fuel filter
F-2
White
Fuel pump & sensor
F-3
NOT USED
F-4
Gray
ABS sensor
F-5
Gray
Rear combination lamp-RH
F-6
Gray
Rear combination lamp-LH
F-7
Gray
License plate lamp
F-8
Black
Rear fog light RH
F-9
Black
Rear fog light - LH
No.
Connector face
No.
Connector face
Connector face
H-10
H-1
White
No.
H-2
White
INST ~ Front Door-RH
H-11
NOT USED
NOT USED
H-3
H-12
(6VE1,
4JH1-TC)
White
Black
INST ~ Roof
H-13
H-4
(C24SE)
White
White
INST ~ Door -LH
H-14
H-4
(6VE1,
4JA1-TC,
4JH1-TC)
White
H-5
White
Rear body ~ Rear door-LH
H-15
NOT USED
White
H-16
H-6
White
Engine room ~ INST
H-7
White
Rear body ~ Rear door-RH
H-17
White
Engine room ~ INST
H-8
White
Chassis ~ License plate lamp
H-18
NOT USED
White
H-9
~
Blue
Engine room ~ INST
H-19
H-21
NOT USED
No.
Connector face
No.
H-22
H-31
(6VE1)
(C24SE)
Connector face
(4JH1-TC)
White
H-23
H-32
(6VE1)
(C24SE)
(4JH1-TC)
(6VE1)
White
Engine room ~ Rear body
H-23
H-33
(4JA1-L)
(4JH1-TC)
White
Engine room B ~ T/misson

H-34
H-24
(C24SE)
Black
INST ~ Front door-RH
Black
INST ~ Front door-LH
H-26
White
INST ~ Rear body
H-27
Black
INST ~ Rear body
H-28
White

H-35
H-25
Sub harness connector
H-29
(C24SE)
Battery(+) ~ Engine room

H-30
(6VE1)
(4JH1-TC)
Engine room ~ INST
Trailer
No.
Connector face
L-1
White
Doom lamp
L-2
NOT USED
L-3
NOT USED
L-4
Black
Rear defogger driver side
L-5
White
High mounted stop lamp
L-6
NOT USED
L-7
Black
Rear defogger passenger side
L-8
NOT USED
L-9
Gray
Spot lamp
No.
Connector face
No.
Connector face
M-1
~
NOT USED
M-25
M-25
(6VE1)
2WD-4WD Switch
M-27
(6VE1)
H-L Neutral Switch

M-28
(6VE1)
Motor Actuator
No.
Connector face
No.
Connector face
No.
Connector face
P-9
P-1
Silver
Battery (+)
P-2
Silver
ACG (B)
P-10
Silver
Relay & Fuse box
P-3
Silver
Engine ground
P-11
Brown
Starter (S)
P-4
Silver
Fuse & relay box
P-12
NOT USED
Silver
Starter (B)
P-13
P-4
Silver
Starter (B)
P-5
Gray
Shift on the fly actuator
P-14
Silver
Battery (-)
P-6
White
Fuse & relay box
P-15
Silver
Body earth (Ground)
P-7
Silver
2nd battery (+)
P-16
NOT USED
Silver
P-8
(C24SE)
(4JH1-TC
Green
ACG (L)
P-8
(6VE1)
White
ACG (L)
2nd battey (-)
No.
Connector face
Connector face
R-12
R-1
Black
No.
Front door switch-LH
R-2
Pretensioner - RH
R-13
NOT USED
Pretensioner - LH
R-3
R-14
Gray
Seat belt switch
R-4
Natural
R-15
Parking brake switch (Lever type)
R-5
NOT USED
R-6
Black
Front door switch-RH
R-7
~
NOT USED
R-8
R-9
Black
Rear speaker-LH
R-10
Black
2-4WD control
Rear speaker-RH
R-11
Seat belt switch
2-4WD control
No.
Connector face
T-1
NOT USED
T-2
NOT USED
T-3
Gray
License plate lamp-LH
T-4
Gray
License plate lamp-RH
No.
Connector face
No.
Connector face
No.
Connector face
X-8
X-1
(4JH1-TC)
Black
Relay ; Tail lamp
X-2
Black
X-9
(C24SE)
(6VE1)
(6VE1)
(4JH1-TC)
Black
Relay ; Starter
Relay ; Front Fog lamp
X-2
Black
Relay ; Hazard-RH
X-10
(4JH1-TC)
(6VE1)
(4JH1-TC)
Black
Relay ; Front Fog lamp
X-3
Black
Relay ; Hazard-LH
X-11
Relay ; Horn
Black
Relay ; Heater
X-12
X-4
Relay ; Dimmer
X-5
Black
Relay ; Head lamp
X-13
(6VE1)
(6VE1)
(4JH1-TC)
Black
Relay ; Front Fog Lamp
X-5
Black
Relay ; ECM MAIN
X-14
(4JH1-TC)
Black
Relay ; Spill valve
X-6
Black
Relay ; A/C Compressor
X-15
(C24SE)
(6VE1)
Relay ; Starter
X-6
Black
Relay ; Thermo
X-16
(4JA1-L)
(6VE1)
(4JH1-TC)
Black
Relay ; CSD
X-7
Black
DIODE
X-17
Relay ; Condenser Fan
Black
DIODE
CRUISE CONTROL SYSTEM 8B-1
SECTION 8B
CRUISE CONTROL SYSTEM

TABLE OF CONTENTS
PAGE
Service Precaution .........................................................................................................................8B- 3
General Description .......................................................................................................................8B- 3
Brake Switch ...................................................................................................................................8B- 5
Removal .......................................................................................................................................8B- 5
Installation ..................................................................................................................................8B- 5
Adjustment ..................................................................................................................................8B- 6
Clutch switch ...................................................................................................................................8B- 6
Removal and Installation ........................................................................................................8B- 6
Adjustment ..................................................................................................................................8B- 6
Starter Switch ..................................................................................................................................8B- 6
Removal .......................................................................................................................................8B- 6
Installation ..................................................................................................................................8B- 6
Cruise Control Main Switch .........................................................................................................8B- 7
Removal .......................................................................................................................................8B- 7
Installation ..................................................................................................................................8B- 7
Cruise Control Switch (Combination Switch) ........................................................................8B- 7
Cruise Control Unit ........................................................................................................................8B- 8
Removal .......................................................................................................................................8B- 8
Installation ..................................................................................................................................8B- 8
Cruise Actuator ...............................................................................................................................8B- 8
Actuator Cable Diagram ..........................................................................................................8B- 9
Removal .......................................................................................................................................8B- 9
Installation ..................................................................................................................................8B- 9
Adjustment ..................................................................................................................................8B- 9
Mode Switch ....................................................................................................................................8B- 9
8B-2 CRUISE CONTROL SYSTEM
Diagnosis ..........................................................................................................................................8B- 10
DTC Display Condition ............................................................................................................8B- 10
DTC Display Format .................................................................................................................8B- 11
Circuit Diagram ..........................................................................................................................8B- 11
DTC 1-1 Motor System Short Circuit ....................................................................................8B- 13
DTC 1-2 Clutch Open or Short Circuit .................................................................................8B- 14
DTC 1-3 Mechanical Defect ....................................................................................................8B- 15
DTC 1-4 Close Side of Motor System ..................................................................................8B- 16
DTC 2-1 Signal of Vehicle Speed Malfunction ..................................................................8B- 17
DTC 3-1 Turning On Switch at All time or at the same time ..........................................8B- 18
Service Precaution
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAIN SYSTEM (SRS). REFER TO THE SRS
COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS
SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR OTHER WISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the proper location. When you replace a faster, use ONLY the
exact part number for that application. Dealer will call out those fasteners that require a replacement after
removal. Dealer will also call out the fasteners that require thread lockers or thread sealant. UNLESS
OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors)
on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener
torque and joint Clamping force, and may damaged the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following these instructions can help you avoid damage to
parts and systems.
General Description
The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received.
When the main switch AUTO CRUISE is turned on with the vehicle in the running mode, the battery voltage is
applied to the control unit. When a signal from the control unit while the vehicle is in this state, the cruise control
actuator is activated to operate the system. Also, while the system is operating, the AUTO CRUISE indicator light
in the meter assembly lights up.
LTW48BSH000101
1. SET/COAST Switch Function

1. Set Function: When the SET/COAST switch is pressed and released with the main switch on, the speed at
which the vehicle is running at that moment is stored in the memory, and the vehicle automatically runs at the
stored speed.
2. COAST-down Function: When the SET/COAST switch is kept on while the vehicle in running, the vehicle
decelerates during that time. The speed at which vehicle is running when the control switch is pressed in the
memory, and the vehicle automatically returns to the stored speed.
3. Tap-down Function: When the SET/COAST switch is pressed and released instantaneously while the
vehicle is running, the vehicle decelerates a mile for each on/off operation. The vehicle speed at which the
vehicle was running when the SET/COAST was released last is stored in the memory, and the vehicle
automatically returns to this stored speed.
2. RESUME/ACCEL Switch Function

1. Resume Function: When the RESUME/ACCEL switch is turned on/off after the system is temporarily
deactivated by pressing the brake or clutch pedal while the vehicle is running, the vehicle resumes the speed
stored before the system was released, and the vehicle automatically runs at the stored speed.
2. Accelerate Function: When the RESUME/ACCEL switch is kept on the vehicle accelerates its speed during
that time. The vehicle speed at which the vehicle was running when the switch was turned off is stored in the
memory, and the vehicle automatically returns to this speed.
3. Tap-up Function: When the RESUME/ACCEL switch is turned on and off instantaneously while the vehicle
is running, the vehicle decelerates a mile for each on/off operation. The vehicle speed at which the vehicle
was running when the switch was turned off last is stored in the memory, and the vehicle automatically
returns to this stored speed.
3. CANCEL Function
1. Temporary Cancellation:
Brake pedal is pressed.
Clutch pedal is pressed. (M/T)
Select lever is shifted to any position other than D, 3, 2 or L. (A/T)
Cancel switch is operated.
Vehicle speed exceeds about 12.5mph over the vehicle speed stored in the memory.
Turning the RESUME/ACCEL switch will return the vehicle to the speed stored in the cruise control memory.
2. Complete Cancellation:
Starter switch or the main switch is turned off.
Fail-safe function is activated.
Vehicle speed is about 38 km/h mph.
Speed becomes 20 (12.5) km/h (mph) or less form the speed memorized by Control unit.
Brake Switch
Removal
2. Remove the brake switch.
Disconnect the connector (1).
Loosen lock nuts of the switch (2).
Remove the switch by turning it (3).
RTW3A0MH000101
Installation
the following points.
1. Check to see if the brake pedal has been returned by the
return spring to the specified position.
2. Turn the switch clock-wise until the tip of the threaded
portion of the brake switch contacts the pedal arm.
3. Turn the switch counter-clock-wise until the space between
the tip of the threaded portion and the pedal arm is 0.2 to
1.2 mm (0.01-0.06 in.) as shown in the figure.
RTW3A0SH000901
Adjustment
RTW3A0SH001201
1. Check to be sure that the brake pedal has been completely

returned by the return spring.
2. Disconnect the switch connector.
3. Release the lock (2) by turning the switch (1) counter-clockwise.
4. After doing so, pull the pedal arm (3) to you a little so that
the pedal arm is not pushed in.
5. Making the pedal arm not movable with one hand, push in
the whole switch with the other hand until the plunger of the
switch is pushed in and the switch itself hits the rubber of
the pedal arm.
In the condition, turn the switch clock-wise until "click"
sound is made and lock it.
By doing this, the switch is adjusted at 0.2 to 1.2mm (0.010.06 in.) clearance.
Clutch Switch
Refer to the Clutch Control removal and installation steps in
Clutch section.
Adjustment
1. Turn the clutch switch or stopper bolt 1 until the switch bolt
or stopper bolt just touches the clutch pedal arm.
2. Adjust clutch switch or stopper bolt by backing it out half a
turn, and measure the clearance (L) between the clutch
pedal arm and the clutch switch bolt end or stopper bolt.
3. Lock the lock nut 2 .
4. Connect the clutch switch connector.
Clutch switch and clutch and clutch pedal clearance
mm (in)
Limit
0.5-1.5 (0.020-0.059)
Starter Switch
Removal
1. Steering Lock Assembly
Refer to the Steering Lock assembly removal steps of
"Steering Column" in Power-Assisted Steering System
section.
2. Starter Switch
Installation
431R300001

starter switch.
Cruise Control Main Switch

Removal
2. Remove the side ventilation grille.
RTW3A0SH001301
3. Disconnect the switch connector and push the lock from the
backside of the side ventilation grille to remove the cruise
control main switch.
RTW3A0SH001401
Installation
Cruise Control Switch (Combination Switch)

Refer to the Lighting Switch (Combination Switch) removal and
installation steps of Lighting System in Body and Accessories
section.
Cruise Control Unit

Removal
1.
2.
3.
4.

Remove the dash side trim panel (LH) (1).
Remove a fixing nut to remove the cruise control unit (2).
Installation
RTW3A0SH001101
Cruise Actuator
Actuator Cable Diagram
RTW3A0SF000301
Legend
(1) Cruise Actuator Assembly
(2) Cruise Control Cable
(3) Accelerator Cable

(4) Throttle Link (Cruise Control Side)
Removal
1. Disconnect the battery cable.
2. Remove the cruise actuator Assembly (4).
Disconnect the connector (3).
Remove the cable end (1) from the throttle link (cruise
control side).
Loosen a fixing nut of the cruise control cable (2).
Remove fixing screws of the actuator (5).
RTW3A0SH001001
Installation
1. Take care not to bend the cable excessively.
Adjustment
After installing the cruise actuator, the following steps must be
carried out for cruise control cable adjustment.
1. Install the cruise control cable end (3) to the throttle link (4).
2. Put the screw portion of the cable in the bracket (5).
3. Put the nut (1) to the bracket and then tighten the nut (2).
CAUTION: Don't move a position of the nut (1) from
supplied condition.
RTW3A0SH001501
4. If the distance between the throttle link (4) and the throttle
link lever (6) is out of the specified range, loosen the nut (2)
to adjust it.
Mode Switch
Refer to the Mode Switch removal and installation steps in
Automatic Transmission section.
Diagnosis
The cruise control unit uses the cruise main indicator light and diagnosis the failure, when the control unit detects
abnormality on the table below.
PART
Actuator
Cruise control unit

Switch
POSSIBLE CAUSE
DETECTION PERIOD
DTC
Motor system short circuit
Energizing motor
1-1
Clutch system short circuit
Energizing clutch
1-2
Clutch system open circuit
Energizing clutch
1-2
Mechanical defect
Cruise controlling
1-3
Close side of motor system open circuit
Cruise controlling
1-1
Close side of motor system open circuit
While starter sw on
1-4
Clutch output abnormality
While starter sw on
1-4
Signal of vehicle speed disconnection
Cruise controlling
2-1
Signal of vehicle speed abnormality
Cruise controlling
2-1
Turning on switch at all times
While starter sw on
3-1
Turning on switch at the same time
While starter sw on
3-1
DTC : Diagnostic Trouble Code
DTC Display Condition

1. With the vehicle stationary and the ignition ON, activate the Cruise Cancel switch three times within 2 seconds.
2. If there are no DTCs stored in the Cruise control unit, the LED on the Cruise Main switch will blink rapidly (2Hz).
3. Any DTCs stored in the Cruise control unit will be displayed by the CRUISE SET warning lamp in the meter
cluster.
4. Read the set DTCs by referring to then charts on this page.
NOTE:
The DTC display mode will be aborted if either the vehicle speed rises above 10km/h or the RESUME switch is
operated.
The control module stores the DTC in a volatile memory that is the memory is only active while the ignition is
ON.
Turning the ignition to the OFF position will clesr any stored DTCs.
DTC Display Format

1. When no DTCs are detected. (The unit : sec.)
F08RW003
2. When two or more DTCs are detected. (The unit : sec.)
F08RW009
CIRCUIT DIAGRAM
RTW48AXF003801
DTC 11 Motor System Short Circuit

Step
Action
1. Turn the starter switch off.

2. Disconnect the actuator connector C-119.
3. Measure resistance between actuator side
connector terminal 1 and 2.
If control plate position is fully opened or fully
closed, resistance can not be measure.
Is there resistance within range specified in the
value(s) column?
Measure continuity between harness side connector
C-119 terminal 1 and the ground, terminal 2 and the
ground, and terminals 1 and 2.
Are the results same as specified in the value(s)
column?
Value(s)
YES
NO
More than
4.2W
Go to Step 2
Replace the
actuator
No
continuity
Replace the
control unit
Repair or
replace the
harness
DTC 12 Clutch System Open or Short Circuit

Step
1
Action
Value(s)
YES
NO

2. Disconnect the actuator connector C119.
value(s) column?
34.7
42.4W
Go to Step 2
Replace the
actuator
1. Disconnect the brake switch connector C44.

2. Check continuity between switch side connector
terminal 3 and 4.
Is there continuity between terminals?
Go to Step 3
Replace the
switch
Go to Step 4
Replace open
circuit
No
continuity
Replace the
control unit
Repair short
circuit
1. Reconnect the brake switch connector C44.

2. Check continuity between harness side connector
C120 terminal 6 and connector C44 terminal 3,
connector C119 terminal 4 and connector C120
terminal 8.
Check continuity between harness side connector
C119 terminal 3 and the ground, connector C119
terminal 4 and the ground, connector C120
terminal 6 and the ground.
column?
DTC 13 Mechanical Defect

Step
1
Action
Value(s)
YES
NO
Go to Step 2

3. Connect the battery positive terminal with the
actuator side connector terminal 3 and the battery
negative terminal with terminal 4.
Does the control plate move by hand?
Connect the battery positive terminal with the
actuator side connector terminal 1 and 3, and the
battery negative terminal with terminal 2 and 4.
Does the control plate move to full open side?
Replace the
actuator
Go to Step 3
Replace the
actuator
Connect the battery positive terminal with the

actuator side connector terminal 2 and 3, and the
battery negative terminal with terminal 1 and 4.
Does the control plate move to full close side?
Go to Step 4
Replace the
actuator
Replace the
control unit
Repair or
replace
harness
Is there continuity between harness side connector

connector C119 terminal 2 and connector C120
terminal 15?
DTC 14 Close Side of Motor System Open Circuit

Step
1
Action
Value(s)
YES
NO

If control plate position is fully opened or fully
closed, resistance can not be measured.
value(s) column?
More than
4.2W
Go to Step 2
Replace the
actuator
Replace the
control unit
Repair or
replace the
harness
Is there continuity between harness side connector

harness side connector C119 terminal 2 and
connector C120 terminal 15?
DTC 21 Signal of Vehicle Speed Malfunction

Step
1
Action
Check the DTC for engine.
Is the vehicle speed sensor DTC set?
Check continuity between harness side connector

E44 terminal 3 and connector C120 terminal 9.
Check the continuity between harness side
connector E44 terminal 3 and ground, connector
C120 terminal 9 and ground.
column?
Value(s)
YES
NO
Go to DTC for
engine
Go to Step 2
Go to Step 3
Replace open
circuit
Replace the
control unit
Repair short
circuit
No continuity
DTC 31 Turning On Switch at All time or at the same time

Step
1
Action
Value(s)
YES
NO

2. Disconnect the auto cruise control unit connector
C-120.
3. Turn the starter switch on.
4. Turn the cruise control switch cancel.
5. Check voltage at the harness side connector C
120 terminal 10, terminal 3 and terminal 4.
0V
Go to Step 3
Go to Step 2
0V
Replace the
cruise control
switch
Repair short
circuit
No continuity
Go to Step 5
Go to Step 4
No continuity
Replace the
cruise control
switch
Repair short
circuit
Replace the
control unit
Replace open
circuit

2. Disconnect the cruise control switch connector B
59.
3. Check voltage at the harness side connector C
120 terminal 10, terminal 3 and terminal 4.
2. Turn the cruise control switch cancel.
3. Check the continuity between harness side
connector C120 terminal 10 and terminal 3,
connector C120 terminal 10 and terminal 4.
column?
1. Disconnect the cruise control switch connector B
59.
2. Check the continuity between harness side
connector C120 terminal 10 and terminal 4.
column?
Check the continuity between harness side
connector C120 terminal 10 and connector B59
terminal 10.
No. TFCEL-WE-0431
WORKSHOP MANUAL
TF SERIES
ACCESSORIES
&
RESTRAINTS
SECTION 9
ACCESSORIES 9-1
SECTION 9
ACCESSORIES
TABLE OF CONTENTS
PAGE
Parts Location ...................................................................................................................9-2
Circuit Diagram .................................................................................................................9-6
Connector List ..................................................................................................................9-10
Radio ..................................................................................................................................9-12
Front Speaker ....................................................................................................................9-13
Tweeter ..............................................................................................................................9-14
Rear Speaker (Extend Cab)...............................................................................................9-15
Rear Speaker (Crew Cab)..................................................................................................9-16
Clock ...................................................................................................................................9-17
Antenna .............................................................................................................................9-18
9-2 ACCESSORIES
PARTS LOCATION
RHD
RTW48AXF020001
ACCESSORIES 9-3
RHD
RTW48AXF020101
9-4 ACCESSORIES
PARTS LOCATION
LHD
RTW48AXF020201
ACCESSORIES 9-5
LHD
RTW48AXF020301
9-6 ACCESSORIES
CIRCUIT DIAGRAM
RHD
RTW48AXF011101
ACCESSORIES 9-7
RTW48AXF011201
9-8 ACCESSORIES
LHD
RTW48AXF010901
ACCESSORIES 9-9
RTW48AXF011001
9-10 ACCESSORIES
CONNECTOR LIST
No.
Connector face
B-10
White
Clock
Audio
Cigar lighter illumination
Cigar lighter
Cigar lighter
Acc socket relay
Acc socket
Silver
Weld splice 2
Silver
Weld splice 3
Black
Engine room RH ground
White
J/B E1
C-109
Acc socket
Black
Body LH ground
D-3
B-43
Anti theft control unit

B-55
White
Weld splice 1
C-108
B-42
White
Silver
C-2
B-41
Natural
Ignition switch
B-73
B-40
Black
White
B-65
B-22
Black
J/B I4
B-64
B-21
White
White
B-62
B-20
White
Connector face
B-56
B-14
Gray
No.
Black
Front speaker -RH
D-8
J/B I3
Black
Front speaker -LH
ACCESSORIES 9-11
No.
Connector face
D-13
Black
Rear speaker -LH
Rear speaker -RH
Remote mirror switch drive side
Tweeter -RH
Tweeter -LH
Engine room ~ INST
Rear body ~ Rear door -LH
Rear body ~ Rear door -RH
Relay & Fuse box
Silver
Battery (-)
Silver
Body earth
Silver
Engine ground
Black
Rear speaker -LH
R-8
Engine room ~ INST
H-24
Black
Silver
R-7
H-18
White
Battery (+)
P-10
H-16
White
Silver
P-6
H-14
White
INST ~ Rear body
P-5
H-6
White
Black
P-2
D-22
White
INST ~ Front door -LH
P-1
D-21
White
Black
H-27
D-19
White
Connector face
H-25
D-17
Black
No.
INST ~ Front door -RH
Black
Rear speaker -RH
9-12 ACCESSORIES
RADIO
RTW48AMF000201
Removal
1.
2.
3.
4.
5.
6.
8.
8.
9.
Remove the ash try

Remove the HVAC control
Remove the 2 crews unit on the HVAC
Remove the center cluster cover assembly
Remove the ash try bracket
Disconnect the connector for Audio
Remove the 4 screws on the radio
Disconnect the Antenna feeder plug
Pull out the radio
Installation
ACCESSORIES 9-13
FRONT SPEAKER
Removal
1. Remove the Door Trim Panel
Refer to section 10 FRONT DOOR ASSEMBLY for
door trim panel removal steps.
2. Remove the Front Speaker
Remove the screw.
Installation
9-14 ACCESSORIES
TWEETER
Removal
1. Remove the Door Trim Panel
Refer to section 10 FRONT DOOR ASSEMBLY for
door trim panel removal steps.
2. Remove the Tweeter
Remove the three screws.
RTW390SH000101
Installation
ACCESSORIES 9-15
REAR SPEAKER (EXTEND CAB)

Removal
1. Remove the Speaker Grille
Pull the grille to release the locks.
2. Remove the Rear Speaker
Remove the three screws.
Installation
9-16 ACCESSORIES
REAR SPEAKER (CREW CAB)

Removal
1. Remove the Rear Door Trim Panel
Refer to section 10 REAR DOOR ASSEMBLY for door
trim panel removal steps.
2. Remove the Rear Speaker
Remove the screw.
RTW390MH000101
Installation
ACCESSORIES 9-17
CLOCK
Removal
1. Remove the center cluster ASM
3. Remove the clock.
Installation
9-18 ACCESSORIES
ANTENNA
Removal
1. Remove the antenna screw 1 .
2. Disconnect the feeder cable 3 connector.
3. Remove the antenna cable 2 .
4. Pull out antenna downward.
Remove and install the antenna as illustrated.
Antenna unit is located on the roof panel driver side.
Installation
SUPPLEMENTAL RESTRAINT SYSTEM 9A-1
RESTRAINTS
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
SERVICING
PAGE
Service Precaution ............................................................................................................9A- 3
General Description ......................................................................................................9A- 4
Restraint Devices .....................................................................................................9A- 4
System Description ..................................................................................................9A- 5
SRS Component And Wiring Location View...............................................................9A- 6
Component Description ...............................................................................................9A- 8
SRS Control Unit ......................................................................................................9A- 8
"Air Bag" Warning Lamp..........................................................................................9A- 8
SRS Coil Assembly...................................................................................................9A- 9
Air Bag Assemblies ..................................................................................................9A- 9
Seat Belt with Pretensioner (If so equipped) .........................................................9A- 10
Steering Column.......................................................................................................9A- 10
Knee Bolster .............................................................................................................9A- 10
Definitions......................................................................................................................9A- 10
Diagnosis .......................................................................................................................9A- 12
Diagnostic Trouble Codes .......................................................................................9A- 12
Scan Tool Diagnostics .............................................................................................9A- 12
Use Of Special Tools................................................................................................9A- 12
SRS Connector Body Face Views................................................................................9A- 13
Repairs And Inspections Required After An Accident...............................................9A- 14
Accident With Deployment-Component Replacement And Inspections .............9A- 14
Accident With or Without Deployment-Component Inspection ...........................9A- 14
SRS Control Unit Replacement Guidelines............................................................9A- 14
Wiring Damage .........................................................................................................9A- 14
SRS Connector (Plastic Body And Terminal Metal Pin) Damage .........................9A- 14
SRS Wire Pigtail Damage.........................................................................................9A- 14
9A-2 SUPPLEMENTAL RESTRAINT SYSTEM
PAGE
On-Vehicle Service........................................................................................................9A- 15
Service Precaution ...................................................................................................9A- 15
Disable The SRS.......................................................................................................9A- 15
Enabling The SRS.....................................................................................................9A- 15
Handling / Installation / Diagnosis ..........................................................................9A- 15
Air Bag Assembly Handling / Shipping / Scrapping...................................................9A- 16
Live (Undeployed) Air Bag Assembly .....................................................................9A- 16
Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag
Assemblies.................................................................................................................9A- 16
Deployed Air Bag Assembly (Driver Side)..............................................................9A- 16
Air Bag Assembly Scrapping Procedure................................................................9A- 17
Deployment Outside Vehicle (Driver Air Bag Assembly) ......................................9A- 17
Deployment Outside Vehicle (Passenger Air Bag Assembly) ..............................9A- 20
Deployment Inside Vehicle (Vehicle Scrapping Procedure) .................................9A- 22
Deployed Air Bag Assembly Handling....................................................................9A- 25
Tech2 Scan Tool............................................................................................................9A- 26
Getting Started..........................................................................................................9A- 26
Service Precautions for SRS Component Service .....................................................9A- 27
Disabling The SRS....................................................................................................9A- 27
Enabling The SRS.....................................................................................................9A- 27
Handling / Installation / Diagnosis ..........................................................................9A- 27
Inspections Required After An Accident ................................................................9A- 27
SRS Connectors ................................................................................................................9A- 28
Removal .........................................................................................................................9A- 28
Installation .....................................................................................................................9A- 29
SRS Control Unit................................................................................................................9A- 30
Service Precautions......................................................................................................9A- 30
Removal .........................................................................................................................9A- 30
Installation .....................................................................................................................9A- 30
Driver Air Bag Assembly ...................................................................................................9A- 32
Removal .........................................................................................................................9A- 32
Installation .....................................................................................................................9A- 33
PAGE
Steering Wheel...................................................................................................................9A- 35
Removal .........................................................................................................................9A- 35
Installation .....................................................................................................................9A- 36
SRS Coil Assembly............................................................................................................9A- 37
Removal. ........................................................................................................................9A- 37
Installation. ....................................................................................................................9A- 38
Steering Column ................................................................................................................ 9A- 40
Removal .........................................................................................................................9A- 40
Installation .....................................................................................................................9A- 41
Passenger Air Bag Assembly ...........................................................................................9A- 44
Removal .........................................................................................................................9A- 44
Installation .....................................................................................................................9A- 45
Pretensioner Seat Belt (If so quipped).............................................................................9A- 46
Removal .........................................................................................................................9A- 46
Installation .....................................................................................................................9A- 46
Main Data and Specifications ...........................................................................................9A- 47
Fastener Tightening Specification...............................................................................9A- 47
Special Tools......................................................................................................................9A- 48
5-8840-2421-0 SRS Driver/Passenger Load Tool........................................................9A- 48
5-8840-0285-0 DVM........................................................................................................9A- 48
Scan Tool .......................................................................................................................9A- 48
5-8840-0385-0 Connector Test Adapter Kit .................................................................9A- 49
5-8840-2468-0 SRS Deployment Tool ..........................................................................9A- 49
5-8840-2420-0 SRS Deployment Fixture......................................................................9A- 49
5-8840-2796-0 SRS Adapter for Load Tool ..................................................................9A- 49
5-8840-2795-0 SRS Adapter for Deployment Tool ......................................................9A- 50
5-8521-0016-0 Steering Wheel remover ......................................................................9A- 50
Service Precaution
Restraint Devices

TO THE SRS SERVICE INFORMATION. FAILURE
TO FOLLOW WARNINGS COULD RESULT IN
INJURY, OR OTHERWISE UNNEEDED SRS
SYSTEM REPAIRS.
other corrosion inhibitors) on threaded fasteners
or fastener joint interfaces. Generally, such
coatings adversely affect the fastener torque and
the joint clamping force, and may damage the
fastener. When you install fasteners, use the
correct tightening sequence and specifications.
Following these instructions can help you avoid
damage to parts and systems.
General Description
CAUTION: When fasteners are removed, always
reinstall them at the same location from which
they were removed.
If a fastener needs to be
replaced, use the correct part number fastener for
that application.
If the correct part number
fastener is not available, a fastener of equal size
and strength (or stronger) may be used.
Fasteners that are not reused, and those requiring
thread locking compound will be called out. The
correct torque value must be used when installing
fasteners that require it. If the above conditions
are not followed, parts or system damage could
result.
827RW006
Legent
(1) Deployed Air Bag
(2) Knee Bolster
(3) Seat Belt
The Supplemental Restraint System (SRS) helps
supplement the protection offered by the driver and
front passenger seat belts by deploying an air bag
from the center of the steering wheel and from the
front of the passenger side of the instrument panel.
The air bag deploys when the vehicle is involved in a
frontal crash of sufficient force up to 30 degrees off the
centerline of the vehicle. To further absorb the crash
energy there is a knee bolster located beneath the
instrument panel for both the driver and passenger,
and the steering column is collapsible.
827RW005
System Description
The SRS consists of the SRS control unit, the driver
air bag assembly, the SRS coil assembly, the
passenger air bag assembly and the AIR BAG
warning lamp in the instrument cluster. The SRS
control unit, SRS coil assembly (driver side only),
driver air bag assembly, passenger air bag assembly
and connector wire make up the deployment loops.
The function of the deployment loops is to supply
current through air bag assembly, which will cause
deployment of the air bags in the event of a frontal
crash of sufficient force, up to 30 degrees off the
centerline of the vehicle. The air bag assemblies are
only supplied enough current to deploy when the SRS

control unit detects vehicle velocity changes severe
enough to warrant deployment.
The SRS control unit contains a sensing device which
converts vehicle velocity change to an electrical signal.
The electrical signal generated is processed by the
SRS control unit and then compared to a value stored
in memory. When the generated signal exceeds the
stored value, the SRS control unit will cause current to
flow through the air bag assembly deploying the air
bags.
RTW49JLF000101
SRS Component And Wiring Location View - RHD
RTW49JMF000301
SRS Component And Wiring Location View - LHD
RTW49JMF000401
Component Description
SRS Control Unit
WARNING: DURING SERVICE PROCEDURES, BE
VERY CAREFUL WHEN HANDLING A SRS
CONTROL UNIT NEVER STRIKE OR JAR THE SRS
CONTORL UNIT. NEVER POWER UP THE SRS
WHEN THE SRS CONTROL UNIT IS NOT RIGIDLY
ATTACHED TO THE VEHICLE.
ALL SRS
CONTROL UNIT AND MOUNTING BRACKET
FASTENERS MUST BE CAREFULLY TORQUED
AND THE ARROW MUST BE POINTED TOWARD
THE FRONT OF THE VEHICLE TO ENSURE
PROPER OPERATION OF THE SRS. THE SRS
CONTROL UNIT COULD BE ACTIVATED WHEN
POWERED WHILE NOT RIGIDLY ATTACHED TO
THE
VEHICLE
WHICH
COULD
CAUSE
DEPLOYMENT AND RESULT IN PERSONAL
INJURY.
The SRS control unit is connected to the SRS wiring

harness by a 52pin connector. This harness
connector uses a shorting clip across certain terminals
in the contact area. This shorting clip connects the
AIR BAG warning lamp to ground when the SRS
control unit harness connector is disconnected or CPA
(Connector Position Assurance) is not inserted even if
completely connected. This will cause the AIR BAG
warning lamp to come ON steady whenever the
ignition switch is at the ON or START positions with
the SRS control unit disconnected.
The SRS control unit is designed to perform the

following functions in the SRS:
1. Energy Reserve The SRS control unit maintains
24Volt Loop Reserve (24VLR) energy supply to
provide deployment energy when ignition voltage is
lost in a frontal crash.
2. Frontal Crash Detection The SRS control unit
monitors vehicle velocity changes to detect frontal
crashes which are severe enough to warrant
deployment.
3. Air Bag Deployment When a frontal crash of
sufficient force is detected, the SRS control unit
will cause enough current to flow through the air
bag assembly to deploy the air bag.
4. Malfunction Detection The SRS control unit
performs diagnostic monitoring of SRS electrical
components and sets a diagnostic trouble code
when a malfunction is detected.
5. Frontal Crash Recording The SRS control unit
records information regarding SRS status during
frontal crash.
6. Malfunction Diagnosis The SRS control unit
displays SRS diagnostic trouble codes and system
status information through the use of a scan tool.
7. Driver Notification The SRS control unit warns
the vehicle driver of SRS malfunctions by
controlling the Air Bag warning lamp.
060R300008
Legent
(1) SRS Control Unit
(2) SRS Harness
(3) Connector Position Assurance
Air Bag Warning Lamp

Ignition voltage is applied to the AIR BAG warning
lamp when the ignition switch is at the ON or START
positions. The SRS control unit controls the lamp by
providing ground with a lamp driver. The AIR BAG
warning lamp is used in the SRS to do the following:
1. Verify lamp and SRS control unit operation by
flashing SEVEN (7) times when the ignition switch
is first turned ON.
2. Warn the vehicle driver of SRS electrical system
malfunctions which could potentially affect the
operation of the SRS. These malfunctions could
result in nondeployment in case of a frontal crash
or deployment for conditions less severe than
intended.
The AIR BAG warning lamp is the key to driver
notification of SRS malfunctions. For proper lamp
operation, refer to the SRS Diagnostic System Check
in this section.
Air Bag Assemblies
060R300007
The air bag assembly consist of an inflatable air bag

assembly and an inflator. When the vehicle is in a
frontal crash of sufficient force.
The SRS control unit causes current flow through the
deployment loops. Current passing through the inflator
ignites the material in the air bag assembly. The gas
produced from this reaction rapidly inflates the air bag
assembly.
There is a shorting clip on the driver air bag assembly
connector which connects the SRS coil assembly. The
shorting clip shorts across the driver air bag assembly
circuits when driver air bag assembly connector is
disconnected.
The circuit to the driver air bag assembly is shorted in
this way to help prevent unwanted deployment of the
air bag when servicing the driver air bag assembly, the
steering column or other SRS components.
SRS Coil Assembly

The SRS coil assembly consists of two current
carrying coils. This is attached to the steering column
and allow rotation of the steering wheel while
maintaining continuous contact of the driver
deployment loop to the driver air bag assembly.
There is a shorting clip on the yellow connector near
the base of steering column which connects the SRS
coil to the SRS wiring harness.
The shorting clip shorts to the SRS coil and driver air
bag assembly when the yellow connector is
disconnected. The circuit to the driver air bag
assembly is shorted in this way to help prevent
unwanted deployment of the air bag when servicing
the steering column or other SRS components.
060R300012
There is a shorting clip on the passenger air bag

assembly connector which connects to the SRS
harness. The shorting clip shorts across the
passenger air bag assembly circuit when the
passenger air bag assembly connector is
disconnected. The circuit to the passenger air bag
assembly is shorted in this way to help prevent
unwanted deployment of the air bag when servicing
the passenger air bag assembly, the instrument panel
or other SRS components.
060R300047
Steering Column
The steering column absorbs energy and is designed
to compress in a frontal crash to decrease the chance
of injury to the driver.
060R300013
Seat Belt with Pretensioner (If so

equipped)
The seat belt comprises a seat belt and a cylinder (a
cylinder filled with powder and an ignition device). In
cases of frontal collision which cause a shock
exceeding a specified level, the controller lets current
flow to the inflation circuit. The current ignites the
cylinder of the seat belt, producing gas. The gas helps
tighten the seat belt to restrain firmly the drivers upper
half in his seat.
060R300038
Knee Bolster
The knee bolsters are used to absorb energy to
protect knees and control the forward movement of
the vehicle's front seat occupants during a frontal
crash, by limiting leg movement.
Definitions
Air Bag
An inflatable cloth cushion designed to deploy in
certain frontal crashes. It supplements the protection
offered by the seat belts by distributing the impact load
more evenly over the vehicle occupant's head and
torso.
Asynchronous
Performed in a nonperiodic fashion, (i.e., no defined
time or interval).
RTW49JSH000201
B+
Battery voltage, (B+) The voltage available at the
battery at the time of the indicated measurement.
With the key ON and the engine not running, the
system voltage will likely be between 12 and 12.5
volts. At idle, the voltage may be 14 to 16 volts. The
voltage could be as low as 10 volts during engine
cranking.
Bulb Check
The SRS control unit will cause the AIR BAG warning
lamp to flash seven times and then go OFF
whenever the ignition switch transitions to the ON
position from any other ignition switch position and no
malfunctions are detected.

Continuous Monitoring
Tests performed by the SRS control unit on the SRS
every 100 milliseconds while Ignition 1 voltage is in
the normal operating voltage range at the SRS control
unit.
Formerly DLC a connector which allows
communication with an external computer, such as a
scan tool.
Datum Line
A base line parallel to the plane of the underbody or
frame from which all vertical measurements originate.
Deploy
To inflate the air bag.
Deployment Loops
The circuits which supply current to the air bag
assemblies to deploy the air bag.
Diagnostic Trouble Code (DTC)
Formerly Code, a numerical designator used by the
SRS control unit to indicate specific SRS malfunctions.
Driver Current Source
An output of the SRS control unit which applies current
into the driver air bag assembly circuit during the
Initiator Assembly Resistance Test.
Initiator Assembly Resistance Test

Tests performed once each ignition cycle when no
malfunctions are detected during TurnON or
Continuous Monitoring. This test checks for the
correct SRS control unit configuration for the vehicle,
shorts to Ignition 1 in the deployment loops, high
resistance or opens in the Driver Side and
Passenger Side circuits and measures the resistance
of the inflator assembly consisting of 1) Initiators, 2)
SRS coil assembly (driver side only), 3) Connectors
and associated wiring.
Normal Operating Voltage Range
The voltage measured between the SRS control unit
Ignition 1 terminals and Ground terminals is
between 9 and 16 volts.
Passenger Current Source
An output of the SRS control unit which applies current
into the passenger air bag assembly circuit during the
Initiator Assembly Resistance Test.
Passenger Air Bag Assembly
An assembly located in the front of the passenger side
of the instrument panel consisting of an inflatable bag,
an inflator and an initiator.
Scan Tool
An external computer used to read diagnostic
information from onboard computers via the data link
connector.
SRS control unit
SRS control unit which provides reserve energy to the
deployment loops, deploys the air bags when required
and performs diagnostic monitoring of all SRS
components.
Serial Data
Information representing the status of the SRS.
SRS
Supplemental Restraint System.
SRS Coil Assembly
An assembly of two currentcarrying coils in the driver
deployment loop that allows the rotation of the steering
wheel while maintaining the continuous contact of the
driver deployment loop to the driver air bag assembly.
SRS Wiring Harness
The wires and connectors that electrically connect the
components in the SRS.
TurnON
Test which the SRS control unit performs on the SRS
once during each ignition cycle immediately after
Ignition 1 voltage is applied to the SRS control unit
and before Continuous Monitoring.
Diagnosis
Scan Tool Diagnostics

TROUBLESHOOTING THE SRS, DO NOT USE
ELECTRICAL TEST EQUIPMENT SUCH AS A
BATTERYPOWERED
OR
ACPOWERED
VOLTMETER, OHMMETER, ETC., OR ANY TYPE
OF ELECTRICAL EQUIPMENT OTHER THAN THAT
SPECIFIED IN THIS MANUAL. DO NOT USE A
NONPOWERED
PROBETYPE
TESTER.
FOLLOWED
CAREFULLY,
OTHERWISE
PERSONAL INJURY MAY RESULT.
A scan tool is used to read current and history

diagnostic trouble codes and to clear all diagnostic
trouble codes after a repair is completed. The scan
tool must be updated to communicate with the SRS
through a replaceable cartridge before it can be used
for SRS diagnostics. To use the scan tool, connect it
to the data link connector and turn the ignition switch
ON. The scan tool reads serial data from the SRS
control unit Serial Data line terminal 21 to the data
link connector terminal 2.

The SRS Diagnostic System Check must always be
the starting point of any SRS diagnosis. The SRS
Diagnostic System Check checks for proper AIR
BAG warning lamp operation and checks for SRS
diagnostic trouble codes using the scan tool.
1. Current diagnostic trouble codes Malfunctions
that are presently being detected.
Current
diagnostic trouble codes are stored in RAM
(Random Access Memory).
2. History diagnostic trouble codes All malfunctions
detected since the last time the history memory
was cleared. History diagnostic trouble codes are
stored in EEPROM.
Use Of Special Tools

BATTERYPOWERED
OR
ACPOWERED
VOLTMETER, OHMMETER, ETC, OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN THAT
SPECIFIED IN THIS MANUAL. DO NOT USE A NON
POWERED
PROBETYPE
TESTER.
FOLLOWED
CAREFULLY,
OTHERWISE
PERSONAL INJURY MAY RESULT. YOU SHOULD
BE FAMILIAR WITH THE TOOLS LISTED IN THIS
SECTION UNDER THE HANDLING SRS SPECIAL
TOOLS.
You should be able to measure voltage and
resistance. You should be familiar with proper use of
a scan tool such as the Tech 2 Diagnostic Computer,
SRS Driver/Passenger Load Tool 5-8840-2421-0,
Connector Test Adapter Kit 5-8840-0385-0 and the
DVM (Digital Multimeter) 5-8840-0285-0.
SRS Connector Body Face Views
RTW49JMF000201
Legend
(1) SRS control unit
(2) Driver Air Bag Assembly
(3) Passenger Air Bag Assembly
(4) Air Bag Warning Lamp

(5) DLC
(6) Pretensioner Seat Belt
Repairs And Inspections Required

After An Accident
Accident With or Without Deployment

Component Inspection
If any SRS components are damaged, they must be

replaced. If SRS component mounting points are
damaged, they must be replaced.
Certain SRS system components and rotation parts

must be inspected after any crash, whether the air bag
deployed or not. Those components are:
Never use SRS parts from another vehicle. This

does not include remanufactured parts purchased
from an authorized dealer; they may be used for
SRS repairs.
Do not attempt to service the SRS control unit, the
SRS coil assembly, or the air bag assembly.
Service of these items is by replacement only.
Verify the part number of replacement air bag
assembly.
Steering column Refer to Inspection Required

After an Accident in this manual.
Knee bolsters and mounting points Inspect for
any distortion, bending, cracking, or other damage.
I/P steering column reinforcement plate Inspect
for any distortion, bending, cracking, or other
damage.
I/P braces Inspect for any distortion, bending,
cracking, or other damage.
Seat belts and mounting points Refer to Seat
Belts in Section Seat Belt of this workshop
manual.
CAUTION: Never use the air bag assembly from

another vehicle and difference model year air bag
assembly.
Use only new air bag assembly proper to the
TFR/S which is being repaired.
CAUTION: Proper operation of the sensors and
supplemental restraint system (SRS) requires that
any repairs to the vehicle structure return it to the
original production configuration. Deployment
requires, at a minimum, replacement of the SRS
control unit, air bag assembly and dimensional
inspection of the steering column. Any visible
damage to the SRS control unit mounting bracket
(s) requires replacement, and the steering column
must be dimensionally inspected, whether
deployment occurred or not.
Accident With Deployment Component

Replacement And Inspections
Certain SRS components must be replaced or
inspected for damage after a frontal crash involving air
bag deployment. Those components are:
Air bag assembly
SRS control unit
CAUTION: Refer to SRS control unit
Replacement Guidelines below for important
information on SRS control unit replacement in
both deployment and non deployment crashes.
SRS coil assembly Inspect wiring and connector
for any signs of scorching, melting, or damage due
to excessive heat. Replace if damaged. Refer to
section SRS Coil Assembly in this manual.
SRS Control Unit Replacement Guidelines

SRS control unit replacement policy requires
replacement of SRS control unit, after crash involving
air bag deployment when SRS Warning Lamp turn
ON, SRS Diagnosis should be done according to
Section Restraint Control System.
Wiring Damage
If any SRS wire harness is damaged, it should be
replaced. Don't repair SRS harness. It is replace only.
SRS Connector (Plastic Body And

Terminal Metal Pin) Damage
If any connector or terminal in the SRS wire harness
(except pigtails) is damaged, it should be replaced.
SRS Wire Pigtail Damage

If the wiring pigtail (a wire or wires attached directly to
the device, not by a connector) is damaged, the entire
component (with pigtail) must be replaced. Examples
of pigtail components are the driver air bag
assembly, the passenger air bag assembly, and the
SRS coil assembly.
OnVehicle Service
Enabling The SRS
Service Precaution
Installation
assembly.
WARNING: WHEN PERFORMING SERVICE ON OR

AROUND SRS COMPONENTS OR SRS WIRING,
FOLLOW THE PROCEDURES LISTED BELOW TO
TEMPORARILY DISABLE THE SRS. FAILURE TO
FOLLOW PROCEDURES COULD RESULT IN
INJURY OR OTHERWISE UNNEEDED SRS
REPAIRS.
Turn ignition switch to LOCK and remove key.
The SRS control unit in DriverPassenger SRS can

maintain sufficient voltage to cause a deployment for
up to 15 seconds after the ignition switch is turned
OFF, the battery is disconnected, or the fuse
powering the SRS control unit is removed.
Many of the service procedures require removal of the
SRS fuse, and disconnection of the air bag assembly
from the deployment loop to avoid an accidental
deployment. If the air bag assembly is disconnected
from the deployment loop as noted in the Disabling
the SRS procedure that follows, service can begin
immediately without waiting for the 15 second time
period to expire.
1. Connect yellow connector passenger air bag

assembly.
2. Install glove box assembly. Refer to Passenger air
bag assembly replacement in this manual.
3. Connect yellow connector at the base of steering
column.
4. Install AIR BAG fuse SRS to the side of the
driver side of instrument panel fuse block or
connect battery.
Turn ignition switch to ON and verify that the AIR
BAG warning lamp flashes seven times and then
turns OFF. If it does not operate as described,
perform the SRS Diagnostic System Check in this
manual.
Disabling The SRS
Handling / Installation / Diagnosis
Removal
Turn the ignition switch to LOCK and remove key.
1. Remove SRS fuse SRS, from the side of the
driver side of instrument panel fuse block or
disconnect battery.
2. Disconnect yellow connector at the base of
steering column.
3. Remove glove box assembly, refer to Passenger
Air Bag Assembly Replacement in this manual.
4. Disconnect yellow connector behind the glove box
assembly.
CAUTION: With the SRS fuse removed and
ignition switch ON, the AIR BAG warning lamp
will be ON. This is normal operation and does
not indicate an SRS malfunction.
1. Air bag assembly should not be subjected to

temperatures above 65C (150F).
2. Air bag assembly, and SRS control unit should not
be used if they have been dropped from a height
of 100 centimeters (3.28 feet) or more.
3. When a SRS control unit is replaced, it must be
oriented with the arrow on the sensor pointing
toward the front of the vehicle. It is very important
for the SRS control unit to be located flat on the
mounting surface, parallel to the vehicle datum
line.
It is important that the SRS control unit
mounting surface is free of any dirt or other foreign
material.
4. Do not apply power to the SRS unless all
components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble
code.
5. The SRS Diagnostic System Check must be the
starting point of any SRS diagnostics. The SRS
Diagnostic System Check will verify proper AIR
BAG warning lamp operation and will lead you to
the correct chart to diagnose any SRS
malfunctions. Bypassing these procedures may
result in extended diagnostic time, incorrect
diagnosis, and incorrect parts replacement.
Air Bag Assembly Handling /

Shipping / Scrapping
Live (Undeployed) Air Bag Assembly
Special care is necessary when handling and storing a
live (undeployed) air bag assembly. The rapid gas
generation produced during deployment of the air bag
could cause the air bag assembly, or an object in front
of the air bag assembly, to be thrown through the air in
the unlikely event of an accidental deployment.
060R300011
WARNING: WHEN CARRYING A LIVE AIR BAG

ASSEMBLY, MAKE SURE THE BAG OPENING IS
POINTED AWAY FROM YOU.
IN CASE OF AN
ACCIDENTAL DEPLOYMENT, THE BAG WILL
THEN DEPLOY WITH MINIMAL CHANCE OF
INJURY.
NEVER CARRY THE AIR BAG
ASSEMBLY BY THE WIRES OR CONNECTOR ON
THE UNDERSIDE OF THE MODULE.
827RS044
Air Bag Assembly Shipping Procedure

For Live (Undeployed) Air Bag
Assemblies
Service personnel should refer to the latest Service
Bulletins for proper SRS air bag assembly shipping
procedures.
Deployed Air Bag Assembly (Driver Side)

You should wear gloves and safety glasses. After the
air bag assembly has been deployed, the surface of
the air bag may contain a powdery residue. This
powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by products of the
chemical reaction. Sodium hydroxide dust (similar to
lye soap) is produced as a by product of the
deployment reaction. The sodium hydroxide then
quickly reacts with atmospheric moisture and is
converted to sodium carbonate and sodium
bicarbonate (baking soda). Therefore, it is unlikely
that sodium hydroxide will be present.
Air Bag Assembly Scrapping Procedure

During the course of a vehicle's useful life, certain
situations may arise which will necessitate the disposal
of a live (undeployed) air bag assembly. This
information covers proper procedures for disposing of
a live air bag assembly.
Before a live air bag assembly can be disposed of, it
must be deployed. A live air bag assembly must not
be disposed of through normal refuse channels.
WARNING: FAILURE TO FOLLOW PROPER
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR
BAG ASSEMBLY DISPOSAL PROCEDURES CAN
RESULT IN AIR BAG DEPLOYMENT WHICH MAY
CAUSE PERSONAL INJURY. AN UNDEPLOYED
AIR BAG ASSEMBLY MUST NOT BE DISPOSED
OF THROUGH NORMAL REFUSE CHANNELS.
THE UNDEPLOYED AIR BAG ASSEMBLY
CONTAINS SUBSTANCES THAT CAN CAUSE
SEVERE ILLNESS OR PERSONAL INJURY IF THE
SEALED CONTAINER IS DAMAGED DURING
DISPOSAL.
DISPOSAL IN ANY MANNER
INCONSISTENT WITH PROPER PROCEDURES
MAY BE A VIOLATION OF FEDERAL, STATE, AND /
OR LOCAL LAW.
In situations which require deployment of a live air bag
assembly, deployment may be accomplished inside or
outside the vehicle. The method employed depends
upon the final disposition of the particular vehicle, as
noted in Deployment Outside Vehicle and
Deployment Inside Vehicle in this section.
WARNING: FAILURE TO FOLLOW PROCEDURES

IN THE ORDER LISTED MAY RESULT IN
PERSONAL
INJURY.
NEVER
CONNECT
DEPLOYMENT HARNESS TO ANY POWER
SOURCE BEFORE CONNECTING DEPLOYMENT
HARNESS TO THE DRIVER AIR BAG ASSEMBLY.
DEPLOYMENT
HARNESS
SHALL
REMAIN
SHORTED AND NOT BE CONNECTED TO A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED.
THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN A
POWER SOURCE IS CONNECTED TO IT. WEAR
SAFETY GLASSES THROUGHOUT THIS ENTIRE
DEPLOYMENT AND DISPOSAL PROCEDURE.
NOTE: This information applies only to driver air bag
assembly.
Refer to Deployment Outside Vehicle
(Passenger Air Bag assembly) in this section for
information on passenger air bag assembly scrapping.
1. Turn ignition switch to LOCK, remove key and
put on safety glasses.
2. Inspect 5-8840-2468-0 SRS Deployment Harness
and appropriate pigtail adapter for damage.
If
harness or pigtail adapter is damaged, discard and
obtain a replacement.
3. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other. SRS deployment harness shall remain
shorted and not be connected to a power source
until the air bag is to be deployed.
Deployment Outside Vehicle (Driver Air

Bag Assembly)
Deployment outside the vehicle is proper when the
vehicle is to be returned to service. This includes, for
example, situations in which the vehicle will be
returned to useful service after a functionally or
cosmetically deficient air bag assembly is replaced.
Deployment and disposal of a malfunctioning air bag
assembly is, of course, subject to any required
retention period.
For deployment of a live (undeployed) air bag
assembly outside the vehicle, the deployment
procedure must be followed exactly. Always wear
safety glasses during this deployment procedure until
a deployed air bag assembly is scrapped or until an
undeployed air bag assembly is shipped. Before
performing the procedures you should be familiar with
servicing the SRS and with proper handling of the air
bag assembly. Procedures should be read fully
before they are performed.
The following procedure requires use of 5-8840-246806 SRS deployment harness with appropriate pigtail
adapter. Do not attempt procedure without 5-88402468-0 adapter.
827RS004
4. Connect the appropriate pigtail adapter to the SRS

deployment harness.
5. Remove the driver air bag assembly from vehicle.
Refer to Inflator Module Removal in this manual.

WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
ASSEMBLY UNATTENDED ON A BENCH OR
OTHER SURFACE, ALWAYS FACE THE AIR BAG
AND TRIM COVER UP AND AWAY FROM THE
SURFACE. THIS IS NECESSARY SO THAT A FREE
SPACE IS PROVIDED TO ALLOW THE AIR BAG TO
EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL DEPLOYMENT.
FAILURE TO
FOLLOW PROCEDURES MAY RESULT IN
PERSONAL INJURY.
6. Place the driver air bag assembly on a work bench
or other surface away from all loose or flammable
objects with its trim cover facing up, away from the
surface.
060R300029
060R300028
7. Clear a space on the ground about 183 cm (six

feet) in diameter where the driver air bag assembly
is to be deployed. A paved, outdoor location
where there is no activity is preferred. If an
outdoor location is not available, a space on the
shop floor where there is no activity and sufficient
ventilation is recommended. Ensure no loose or
flammable objects are within the deployment area.
8. Place the driver air bag assembly, with its trim

cover facing up, on the ground in the space just
cleared.
9. Stretch the SRS deployment harness and pigtail
adapter from the driver air bag assembly to its full
length.
10. Place a power source near the shorted end of the
SRS deployment harness.
Recommended
application: 12 volts minimum, 2 amps minimum.
A vehicle battery is suggested.
11. Connect the driver air bag assembly to the pigtail
adapter on the SRS deployment harness.
Deployment harness shall remain shorted and not
be connected to a power source until the air bag is
to be deployed. The driver air bag assembly will
immediately deploy the air bag when a power
source is connected to it.
NOTE: Ensure that the pigtail adapter is firmly seated
into the driver air bag assembly connector. Failure to
fully seat the connectors may leave the shorting bar
located in the driver air bag assembly connector
functioning (shorted) and may result in nondeployment
of the driver air bag assembly.
12. Verify that the area around the driver air bag
assembly is clear of all people and loose or
flammable objects.
13. Verify that the driver air bag assembly is resting
with its trim cover facing up.
14. Notify all people in the immediate area that you
intend to deploy the driver air bag.
The
deployment will be accompanied by a substantial
noise which may startle the uninformed.
15. Separate the two banana plugs on the SRS
deployment harness.

NOTE: When the air bag deploys, the driver air bag
assembly may jump about 30 cm (one foot) vertically.
This is a normal reaction of the driver air bag to the
force of the rapid gas expansion inside the air bag.
NOTE: When the air bag deploys, the rapid gas
expansion will create a substantial noise. Notify all
people in the immediate area that you intend to deploy
the driver air bag.
WARNING: DEPLOYMENT HARNESS SHALL
REMAIN SHORTED AND NOT BE CONNECTED TO
A POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED.
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT HARNESS TO
THE POWER SOURCE SHOULD ALWAYS BE THE
LAST STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE.
FAILURE TO
FOLLOW PROCEDURES IN THE ORDER LISTED
MAY RESULT IN PERSONAL INJURY.
16. Connect the SRS deployment harness wires to the
power source to immediately deploy the driver air
bag.
Recommended application: 12 volts
minimum, 2 amps minimum. A vehicle battery is
suggested.
17. Disconnect the SRS deployment harness from the
power source.
18. Short the two SRS deployment harness leads
other.
19. In the unlikely event that the driver air bag
assembly did not deploy after following these
procedures, proceed immediately with Steps 24
through 26. If 19. the driver air bag assembly did
deploy, proceed with Steps 20 through 23.
20. Put on a pair of shop gloves and safety glasses to
protect your hands and
eyes from possible
irritation and heat when handling the deployed
driver air bag assembly. After the air bag assembly
has been deployed, the surface of the air bag may
contain a powdery residue. This power consists
primarily of cornstarch (used to lubricate the bag
as it inflates) and by products of the chemical
reaction. Sodium hydroxide dust (similar to lye
soap) is produced as a by product of the
quickly reacts with the atmospheric moisture and
is converted to sodium carbonate and sodium
that sodium hydroxide will be present after
deployment.
WARNING: SAFETY PRECAUTIONS MUST BE

OBSERVED WHEN HANDING A DEPLOYED AIR
BAG ASSEMBLY.
AFTER DEPLOYMENT, THE
METAL SURFACES OF THE AIR BAG ASSEMBLY
WILL BE VERY HOT. ALLOW THE INFLATOR
MODULE TO COOL BEFORE HANDLING ANY
METAL PORTION OF IT. DO NOT PLACE THE
DEPLOYED AIR BAG ASSEMBLY NEAR ANY
FLAMMABLE OBJECTS. FAILURE TO FOLLOW
PROCEDURES MAY RESULT IN FIRE OR
PERSONAL INJURY.
AFTER A DRIVER AIR BAG ASSEMBLY HAS BEEN
DEPLOYED, THE METAL CANISTER AND
SURROUNDING AREAS OF THE DRIVER AIR BAG
ASSEMBLY WILL BE VERY HOT. DO NOT TOUCH
THE METAL AREAS OF THE DRIVER AIR BAG
ASSEMBLY FOR ABOUT TEN MINUTES AFTER
DEPLOYMENT. IF THE DEPLOYED DRIVER AIR
BAG ASSEMBLY MUST BE MOVED BEFORE IT IS
COOL, WEAR GLOVES AND HANDLE BY THE AIR
BAG OR TRIM COVER.
21. Disconnect the pigtail adapter from the driver air
bag assembly as soon after deployment as
possible. This will prevent damage to the pigtail
adapter or SRS deployment harness due to
possible contact with the hot driver air bag
assembly canister. The pigtail adapter can be
reused. They should, however, be inspected for
damage after each deployment and replaced if
necessary.
22. Dispose of the deployed driver air bag assembly
through normal refuse channels after it has cooled
for at least 30 minutes.
23. Wash your hands with mild soap and water
afterward.
NOTE: The remaining steps are to be followed in the
unlikely event that the driver air bag assembly did not
deploy after following these procedures.
24. Ensure that the SRS deployment harness has
been disconnected from the power source and that
its two banana plugs have been shorted together
by fully seating one banana plug into the other.
25. Disconnect the pigtail adapter from the driver air
bag assembly.
ASSEMBLY OR WHEN LEAVING A LIVE
INFLATOR MODULE UNATTENDED ON A BENCH
OR OTHER SURFACE, ALWAYS FACE THE BAG
AND TRIM COVER UP AND AWAY FROM THE
SURFACE.
THIS IS NECESSARY SO THAT A
FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG TO EXPAND IN THE UNLIKELY EVENT OF
ACCIDENTAL DEPLOYMENT.
FAILURE TO
FOLLOW PROCEDURES MAY RESULT IN
PERSONAL INJURY.

26. Temporarily store the driver air bag assembly with
its trim cover facing up, away from the surface
upon which it rests.
Deployment Outside Vehicle (Passenger

Air Bag Assembly)
WARNING: FAILURE TO FOLLOW PROPER SRS
AIR BAG ASSEMBLY DISPOSAL PROCEDURES
CAN RESULT IN AIR BAG DEPLOYMENT WHICH
MAY CAUSE PERSONAL INJURY. UNDEPLOYED
AIR BAG ASSEMBLIES MUST NOT BE DISPOSED
DISPOSAL.
MAY BE A VIOLATION OF FEDERAL, STATE
AND/OR LOCAL LAWS.
Deployment out of the vehicle is proper when the
vehicle is to be returned to service. This includes, for
example, situations in which a functionally or
cosmetically deficient air bag assembly is replaced.
Deployment and disposal of an air bag assembly is, of
course, subject to any required retention period.
For deployment of a live air bag assembly out of the
vehicle, the deployment procedure must be followed
exactly. Always wear safety glasses during this
deployment procedure until the deployed air bag
assembly is scrapped. Before performing the
procedures, you should be familiar with servicing the
SRS system and with proper handling of the air bag
assembly. Procedures should be read fully before
they are performed.
The following procedure requires use of 5-8840-24680 SRS Deployment Harness with the appropriate
pigtail adapter. The procedure also requires the use
of 5-8840-2420-0 Passenger Side SRS Module
Deployment Fixture. Do not attempt this procedure
without 5-8840-2468-0 and adapter, and 5-8840-24200.
IN THE ORDER LISTED MAY RESULT IN
PERSONAL INJURY.
NEVER CONNECT
DEPLOYMENT HARNESS TO ANY POWER
SOURCE BEFORE CONNECTING DEPLOYMENT
HARNESS TO THE AIR BAG ASSEMBLY.
DEPLOYMENT
HARNESS
SHALL
REMAIN
DEPLOYED.
POWER SOURCE IS CONNECTED TO IT. WEAR
SAFETY GLASSES THROUGHOUT THIS ENTIRE
DEPLOYMENT AND DISPOSAL PROCEDURE.
NOTE: This information applies only to passenger air

bag assembly.
Information for disposing of a live
driver air bag assembly can be found in Deployment
Outside Vehicle (Driver Air Bag Assembly) in this
section.
1. Turn ignition switch to LOCK remove key, and
2. Inspect 5-8840-2468-0 SRS Deployment Harness
and appropriate pigtail adapter for damage.
If
harness or pigtail is damaged, discard and obtain
a replacement.
3. Short the two SRS Deployment Harness leads
other.
The SRS Deployment Harness shall
remain shorted and not be connected to a power
source until the air bag is to be deployed.
827RS003
4. Connect the appropriate pigtail adapter to the SRS

Deployment Harness
827RS004

5. Remove passenger air bag assembly from vehicle.
Refer to Passenger Air Bag Assembly Removal .
6. Clear a space on the ground approximately 183
cm (six feet) in diameter where the fixture with
attached air bag assembly is to be placed for
deployment.
A paved outdoor location where
there is no activity is preferred. If an outdoor
location is not available, a space on the shop floor
where is no activity and sufficient ventilation is
recommended.
Ensure that no loose or
flammable objects are within the deployment area.
7. Place the 5-8840-2420-0 on the bench vice. This
is necessary to provide sufficient stabilization of
the fixture during deployment.
8. Attach the passenger air bag assembly in the 58840-2420-0. An air bag assembly must be
mounted such that the bag will deploy upward.
SECURELY HANDTIGHTEN ALL FASTENERS
PRIOR TO DEPLOYMENT.
NOTE: Ensure that the pigtail adapter is firmly seated

into the air bag assembly connector. Failure to fully
seat the connectors may leave the shorting bar located
in the air bag assembly connector functioning (shorting
the deployment circuit) and may result in
nondeployment of the air bag assembly.
12. Verify that the area around the passenger air bag
assembly is clear of all people and loose or
flammable objects.
13. Verify that the passenger air bag assembly is
firmly and properly in 5-8840-2420-0.
14. Notify all people in the immediate area of your
intention to deploy the passenger air bag
assembly. The deployment will be accompanied
by a substantial noise which may startle the
uninformed.
15. Separate the two banana plugs on the SRS
deployment harness.
NOTE: When the air bag deploys, the driver air bag
assembly may jump about 30 cm (one foot) vertically.
This is a normal reaction of the driver air bag to the
force of the rapid gas expansion inside the air bag.
the air bag assembly.
901RW199
9. Stretch the SRS Deployment Harness and pigtail

adapter from the air bag assembly to its full
length.
10. Place a power source near the shorted end of the
SRS deployment harness.
(Recommended
A vehicle battery is suggested.)
11. Connect the air bag assembly to the pigtail adapter
on the SRS deployment harness.
The SRS
Deployment Harness shall remain shorted and not
be connected to a power source until the air bag is
to be deployed.
The air bag assembly will
immediately deploy the air bag when a power
source is connected to it.
WARNING: DEPLOYMENT HARNESS SHALL

A POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED.
CONNECTING THE DEPLOYMENT HARNESS TO
THE POWER SOURCE SHOULD ALWAYS BE THE
LAST STEP IN THE AIR BAG ASSEMBLY
FAILURE TO
MAY RESULT IN PERSONAL INJURY.
16. Connect the SRS deployment harness wires to the
power source to immediately deploy the air bag
assembly. Recommended application : 12 volts
minimum, 2 amps minimum. A vehicle battery is
suggested.
17. Disconnect the SRS deployment harness from the
power source.
18.Short the two SRS deployment harness leads
other.
19. In the unlikely event that the passenger air bag
assembly did not deploy after following these
procedures, proceed immediately with Steps 24
through 26. If the passenger air bag assembly
deployed as intended, proceed with Steps 20
through 23.

20.The passenger inflator requires no special
precaution after deployment. 95% of the
particulate emission are potassium ckloride (KLC),
which is commonly sold as an edible saltsubstitutes. even if water is applied. Post
deployment products are relatively pH neutral.
Disposing the inflator by burying it in a landfill will
not produce any hazardous products. As with any
dusty environment, safety goggles, dust mask and
gloves should be worn.
OBSERVED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY.
WILL BE HOT. ALLOW THE AIR BAG ASSEMBLY
TO COOL BEFORE HANDLING ANY METAL
PORTION OF IT. DO NOT PLACE THE DEPLOYED
INFLATOR MODULE NEAR ANY FLAMMABLE
OBJECTS. FAILURE TO FOLLOW PROCEDURES
MAY RESULT IN FIRE OR PERSONAL INJURY.
AFTER AN AIR BAG ASSEMBLY HAS BEEN
DEPLOYED, THE METAL CANISTER AND
SURROUNDING AREAS OF THE AIR BAG
ASSEMBLY WILL BE HOT. DO NOT TOUCH THE
METAL AREAS OF THE AIR BAG ASSEMBLY FOR
ABOUT THIRTY MINUTES AFTER DEPLOYMENT.
IF THE DEPLOYED AIR BAG ASSEMBLY MUST BE
MOVED BEFORE IT IS COOL, WEAR GLOVES AND
HANDLE BY THE AIR BAG ITSELF.
21. Disconnect the pigtail adapter from the air bag
assembly as soon after deployment as possible to
avoid damage to the pigtail adapter or SRS
deployment harness from contacting the hot air
bag assembly canister. The pigtail adapter and
SRS deployment harness are designed to be
reused. They should, however, be inspected for
damage after each deployment and replaced if
necessary.
22. Dispose of the deployed air bag assembly through
normal refuse channels after it has cooled for at
least 30 minutes.
23. Wash your hands with mild soap and water
afterward.
unlikely event that the air bag assembly did not deploy
after following the above procedures.
24. Ensure that the SRS deployment harness has
been disconnected from the power source and that
its two banana plugs have been shorted together
by fully seating one banana plug into the other.
25. Disconnect the pigtail adapter from the air bag
assembly.

OTHER SURFACE, ALWAYS FACE THE BAG UP
AND AWAY FROM THE SURFACE.
THIS IS
NECESSARY SO THAT A FREE SPACE IS
PROVIDED TO ALLOW THE AIR BAG TO EXPAND
IN THE UNLIKELY EVENT OF ACCIDENTAL
DEPLOYMENT.
FAILURE TO FOLLOW
PROCEDURES MAY RESULT IN PERSONAL
INJURY.
26. Temporarily store the air bag assembly with the
bag facing up, away from the surface upon which it
rests.
Deployment Inside Vehicle (Vehicle

Scrapping Procedure)
Deployment inside vehicle is proper when the vehicle
is to be destroyed or salvaged for component parts.
This includes, but is not limited to, the following
situations:
1. The vehicle has completed its useful life.
2. The vehicle has been damaged beyond repair in a
nondeployment type accident.
3. The vehicle has been stripped or damaged beyond
repair in a theft.
4. The vehicle will be salvaged for component parts
to be used on a vehicle with a different Vehicle
Identification Number (VIN) as opposed to being
rebuilt as same VIN. Never use SRS components
from another vehicle.
WARNING: FAILURE TO FOLLOW PROPER SRS
AIR BAG ASSEMBLY DISPOSAL PROCEDURES
CAN RESULT IN AIR BAG DEPLOYMENT WHICH
MAY CAUSE PERSONAL INJURY. UNDEPLOYED
AIR BAG ASSEMBLIES MUST NOT BE DISPOSED
DISPOSAL.
MAY BE A VIOLATION OF FEDERAL, STATE
AND/OR LOCAL LAWS.
1. Turn ignition switch to LOCK, remove key and
2. Remove all loose objects from front seats.
3. Disconnect driver air bag assembly, yellow
connector located at the base of the steering
column.
4. Cut the driver air bag assembly yellow harness
connector from the vehicle leaving at least 15 cm
(six inches) of wire at the connector.

5. Strip 13 mm (1/2 inch) of insulation from yellow
green and yellow black wire lead of the
connector.
6. Cut two 900 cm (30 feet) deployment wires from
2
0.8 mm (18 gauge) or thicker multistrand wire.
These wires will be used to fabricate the driver
deployment harness.
7. Strip 13 mm (1/2 inch) of insulation from both ends
of the wires cut in the previous step.
8. Short the wires by twisting together one end from
each. Deployment wires shall remain shorted and
not be connected to a power source until the air
bag is to be deployed.
IN THE ORDER LISTED COULD RESULT IN
PERSONAL INJURY.
NEVER CONNECT
DEPLOYMENT WIRES TO ANY POWER SOURCE
BEFORE CONNECTING DEPLOYMENT WIRES TO
THE AIR BAG ASSEMBLY LEADS. DEPLOYMENT
WIRES SHALL REMAIN SHORTED AND BE NOT
CONNECTED TO A POWER SOURCE UNTIL THE
AIR BAG IS TO BE DEPLOYED. THE AIR BAG
ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR
BAG WHEN A POWER SOURCE IS CONNECTED
TO IT. WEAR SAFETY GLASSES THROUGHOUT
THIS ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
9. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure.
10. Bend twisted connection made in the previous step
flat and wrap tightly with electrical tape to insulate
and secure.
11. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment
wire.
12. Connect the deployment harness to the driver air
bag assembly, yellow connector at the base of the
steering column. Route deployment harness out
the driver side of the vehicle.
WARNING: DEPLOYMENT WIRES SHALL REMAIN
DEPLOYED.
THE AIR BAG ASSEMBLY WILL IMMEDIATELY
DEPLOY THE AIR BAG WHEN A POWER SOURCE
IS CONNECTED TO IT.
Connecting the deployment wires to the power
source should always be the final step in the air
bag assembly deployment procedure.
Failure to follow procedures in the order listed
could result in personal injury.
13. Disconnect passenger air bag assembly, yellow
connector located behind glove box assembly.
14.Cut the passenger air bag assembly harness

connector from the vehicle leaving at least 15 cm
(six inches) of wire at the connector.
15. Strip 13 mm (1/2 inch) of insulation from blue
white and pinkblue wire lead of the connector.
16. Cut two 900 cm (30 feet) deployment wires from
2
0.8 mm (18 gauge) or thicker multistrand wire.
These wires will be used to fabricate the
passenger deployment harness.
17. Strip 13 mm (1/2 inch) of insulation from both ends
of the wires cut in the previous step.
18. Short the wires by twisting together one end from
each. Deployment wires shall remain shorted and
not be connected to a power source until the air
bag is to be deployed.
IN THE ORDER LISTED COULD RESULT IN
PERSONAL INJURY.
NEVER CONNECT
DEPLOYMENT WIRES TO ANY POWER SOURCE
BEFORE CONNECTING DEPLOYMENT WIRES TO
THE AIR BAG ASSEMBLY LEADS. DEPLOYMENT
WIRES SHALL REMAIN SHORTED AND NOT BE
CONNECTED TO A POWER SOURCE UNTIL THE
AIR BAG IS TO BE DEPLOYED. THE AIR BAG
ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR
BAG WHEN A POWER SOURCE IS CONNECTED
TO IT. WEAR SAFETY GLASSES THROUGHOUT
THIS ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
19. Twist together one connector wire lead to one
deployment wire.
The connection should be
mechanically secure.
20. Bend twisted connection made in the previous step
flat and wrap tightly with electrical tape to insulate
and secure.
21. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment
wire.
22. Connect the deployment harness to the passenger
air bag assembly, yellow connector located behind
the glove box assembly.
Route deployment
harness out the passenger side of the vehicle.
DEPLOYED.
CONNECTING
THE
DEPLOYMENT
WIRES
SHOULD ALWAYS BE THE FINAL STEP IN THE
AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE.
FAILURE TO FOLLOW PROCEDURES IN THE
ORDER LISTED COULD RESULT IN PERSONAL
INJURY.

23. Verify that the inside of the vehicle and the area
surrounding the vehicle are clear of all people and
loose or flammable objects.
24. Stretch the driver and passenger deployment
harness to their full length.
25. Completely cover windshield area and front door
window openings with a drop cloth, blanket or
similar item. This reduces the possibility of injury
due to possible fragmentation of the vehicle's
glass or interior.
26. Notify all people in the immediate area that you
intend to deploy the air bags. The deployment will
be accompanied by a substantial noise which may
startle the uninformed.
27. Separate the two ends of the driver deployment
harness wires.
POWER SOURCE UNTIL THE AIR BAG IS TO A
DEPLOYED.
CONNECTING THE DEPLOYMENT WIRES TO THE
POWER SOURCE SHOULD ALWAYS BE THE
FINAL STEP IN THE AIR BAG ASSEMBLY
FAILURE TO
COULD RESULT IN PERSONAL INJURY.
the air bags.
28. Connect the driver deployment harness wires to a
power source to immediately deploy the driver air
bag assembly.
Recommended application: 12
volts minimum, 2 amps minimum. A vehicle
battery is suggested.
29. Separate the two ends of the passenger
deployment harness wires.
POWER SOURCE UNTIL THE AIR BAG IS TO A
DEPLOYED.
CONNECTING THE DEPLOYMENT WIRES TO THE
POWER SOURCE SHOULD ALWAYS BE THE
FINAL STEP IN THE AIR BAG ASSEMBLY
FAILURE TO
30.Connect the passenger deployment harness wires

to a power source to immediately deploy the
passenger air bag assembly. Recommended
A vehicle battery is suggested.(Driver air bag
assembly) Put on a pair of shop gloves and safety
glasses to protect your hands and eyes from
possible irritation and heat when handling the
deployed air bag assembly. After an air bag
assembly has been deployed, the surface of the
air bag may contain a powdery residue. This
powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by products of
the chemical reaction. Sodium hydroxide dust
(similar to 30.
lye soap) is produced as a by
product of the deployment reaction. The sodium
hydroxide then quickly reacts with atmospheric
moisture and is converted to sodium carbonate
and sodium bicarbonate (baking soda). Therefore,
it is unlikely that sodium hydroxide will be present
after deployment.(Passenger air bag assembly)
The passenger inflator requires no special
precaution after deployment. 95% of the
particulate emission are potassium chloride (KLC),
which is commonly sold as an edible saltsubstitutes. even if water is applied. Post
deployment products are relatively pH neutral.
Disposing the inflator by burying it in a landfill will
not products any hazardous products. As with any
dusty environment, safety goggles, dust mask and
gloves should be worn.
OBSERVED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY.
WILL BE VERY HOT.
ALLOW THE AIR BAG
ASSEMBLY TO COOL BEFORE HANDLING ANY
METAL PORTION OF IT.
DO NOT PLACE THE
HOT DEPLOYED AIR BAG ASSEMBLY NEAR ANY
FLAMMABLE OBJECTS. FAILURE TO FOLLOW
PROCEDURES COULD RESULT IN FIRE OR
PERSONAL INJURY.
After an air bag assembly has been deployed, the
metal canister and surrounding areas of the air
bag assembly will be very hot. Do not touch the
metal areas of the air bag assembly for about 30
minutes after deployment. If the deployed air bag
assembly must be moved before it is cool, wear
gloves and handle by the air bag or trim cover.
31. Short the driver deployment harness wires by
twisting together one end from each. Repeat this
procedure for the passenger deployment harness.
32. Carefully remove drop cloth from vehicle and clean
off any fragments or discard drop cloth entirely.
33. Disconnect driver deployment harness and
passenger deployment harness from vehicle and
discard.

34.In the unlikely event that either or both of the air
bag assemblies did not deploy after following
these procedures, proceed immediately with Steps
36 through 37. If the air bag assembly deployed,
proceed to step 35.
35. With both air bags deployed, the vehicle may be
scrapped in the same manner as a nonSRS
equipped vehicle.
unlikely event that the air bag assembly did not deploy
after following these procedures.
36. Remove the undeployed air bag assembly (s) from
the vehicle. For driver air bag assembly refer to in
the Drive Air Bag Assembly Removal in this
manual. For passenger air bag assembly refer to
in the Passenger Air Bag Assembly Removal in
this manual.
OTHER SURFACE, ALWAYS FACE THE BAG AND
TRIM COVER UP, AWAY FROM THE SURFACE.
THIS IS NECESSARY SO THAT A FREE SPACE IS
PROVIDED TO ALLOW THE AIR BAG TO EXPAND
IN THE UNLIKELY EVENT OF ACCIDENTAL
DEPLOYMENT.
FAILURE
TO
FOLLOW
PROCEDURES COULD RESULT IN PERSONAL
INJURY.
37. Temporarily store the air bag assembly with the air
bag opening facing up, away from the surface
upon which it rests.
Deployed Air Bag Assembly Handling

Put on a pair of shop gloves and safety glasses to
protect your hands and eyes from possible irritation
and heat when handling the deployed air bag
assembly.
After the air bag assembly has been deployed, the
surface of the air bag may contain a powdery residue.
This powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by products of the
chemical reaction. Sodium hydroxide dust (similar to
lye soap) is produced as a by product of the
quickly reacts with atmospheric moisture and is
converted to sodium carbonate and sodium
that sodium hydroxide will be present after
deployment.
Tech 2 Scan Tool

060R300015
6. Turn on the vehicle ignition switch.

901RW200
Legent
(1) PCMCIA Card
(4) DLC Cable
(5) Tech-2
Getting Started
1.
2.
3.
4.
5.

Insert the Isuzu System PCMCIA card (1) into the
Tech 2 (5).
cable (4).
Connect the DLC cable to the Tech 2 (5)
Make sure of the vehicle ignition is off.
Connect the Tech 2 SAE 16/19 adapter to the
vehicle DLC connector.
060RW009
NOTE:The RS232 Loop back connector is only used

to diagnosis Tech 2. Refer to user guide of the Tech 2.
Service Precautions for SRS

Component Service
reinstall them at the same location from which
they were removed. If a fastener needs to be
replaced, use the correct part number fastener for
that application.
If the correct part number
fastener is not available, a fastener of equal size
and strength (or stronger) may be used. fasteners
that are not reused, and those requiring thread
locking compound will be called out. The correct
torque value must be used when installing
fasteners that require it. If the above conditions
are not followed, parts or system damage could
result.
AROUND SRS COMPONENTS OR SRS WIRING,
TEMPORARILY DISABLE THE SRS. FAILURE TO
FOLLOW PROCEDURES COULD RESULT IN
INJURY OR OTHERWISE UNNEEDED SRS
REPAIRS.
The SRS control unit in DriverPassenger SRS can
maintain sufficient voltage to cause a deployment for
up to 15 seconds after the ignition switch is turned
OFF, the battery is disconnected, or the fuse
powering the SRS control unit is removed.
Many of the service procedures require removal of the
SRS fuse, and disconnection of the air bag assembly
from the deployment loop to avoid an accidental
deployment. If the air bag assembly is disconnected
from the deployment loop as noted in the Disabling
the SRS procedure that follows, service can begin
immediately without waiting for the 15 second time
period to expire.
Disabling The SRS

Removal
Turn the ignition switch to OFF and turn the steering
wheel so that the vehicle's wheels are pointing straight
ahead.
1. Remove SRS fuse SRS from left dash side lower
fuse block or disconnect battery.
2. Disconnect yellow connector at the base of
steering column.
3. Remove glove box assembly; Refer to Passenger
air bag assembly replacement in this section.
4. Disconnect passenger air bag assembly yellow
connector behind the glove box assembly.
CAUTION: With the SRS fuse removed and
ignition switch ON, the AIR BAG warning lamp
will be ON. This is normal operation and does
not indicate an SRS malfunction.
Enabling The SRS

Installation
Turn ignition switch to LOCK and remove key.
1. Connect yellow connector passenger air bag
assembly.
2. Install glove box assembly. Refer to Passenger
Air Bag Assembly Replacement in this section.
3. Connect yellow connector at the base of the
steering column.
4. Install AIR BAG fuse SRS to left dash side
lower fuse block or connect battery.
Turn ignition switch to ON and verify that the AIR
BAG warning lamp flashes seven times and then
turns OFF. If it does not operate as described,
perform the SRS Diagnostic System Check in this
section.
Handling / Installation / Diagnosis

1. Air bag assembly should not be subjected to
temperatures above 65C (150F).
2. Air bag assembly, and SRS control unit should not
be used if they have been dropped from a height
of 100 centimeters (3.28 feet) or more.
3. When a SRS control unit is replaced, it must be
oriented with the arrow on the SRS control unit
pointing toward the front of the vehicle. It is very
important for the SRS control unit to be located flat
on the mounting surface, parallel to the vehicle
datum line. It is important that the SRS control unit
mounting surface is free of any dirt or other foreign
material.
4. Do not apply power to the SRS unless all
components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble
code.
5. The SRS Diagnostic System Check must be the
Diagnostic System Check will verify proper AIR
BAG warning lamp operation and will lead you to
the correct chart to diagnose any SRS
malfunctions. Bypassing these procedures may
result in extended diagnostic time, incorrect
diagnosis, and incorrect parts replacements.
Inspections Required After An Accident

CAUTION: Certain SRS components must be
replaced after a frontal crash involving air bag
deployment.
In all types of accidents regardless of Air Bag
deployment, visually inspect all of the following
components and replace as required:
Driver air bag assembly

Passenger air bag assembly
Steering wheel
SRS coil assembly
Steering column
Knee bolster and instrument panel mounting
attachments
Driver seat and belt
Passenger seat and belt
SRS control unit
SRS control unit always should be checked according
to SRS Control Unit Replacement Guidelines.
CAUTION: Refer to SRS control unit Replacement
Guidelines below for important information on
SRS control unit replacement in both deployment
and nondeployment crashes.
Removal
To remove the connector, hold the cover insulator (1)
and pull it. The cover insulator slides and lock will be
released. Do not hold the socket insulator (2).
Inspect SRS coil assembly wiring and steering wheel

for any sign of scorching, melting, or damage due to
excessive heat. If coil assembly wire or steering wheel
is damaged, replace them. The steering column and
wheel must be dimensionally checked to determine if
they are damaged. Refer to steering wheel of in this
manual.
Never use SRS parts from another vehicle. This does
not include remanufactured parts purchased from an
authorized Isuzu Retailer; they may be used for SRS
repairs.
Do not attempt to repair the SRS control unit, the SRS
harness, the SRS coil assembly, the air bag assembly,
the steering wheel, or the steering column. Service of
these items is replacement only. Verify replacement
part numbers.
CAUTION: Proper operation of the SRS control
unit and supplemental restraint system (SRS)
requires that any repairs to the vehicle structure
return it to its original production configuration.
SRS Connectors
CAUTION: The special yellow color connectors are
used for supplemental restraint system-air bag
circuit. When removing the cable harness, do not
pull the cables otherwise, cable disconnection
may occur. When connect the SRS connector,
insert the connector completely. Imperfect locking
may cause malfunction of SRS circuit.
827RW028
Installation
To install the connector, hold the socket insulator (1)
and insert it. The cover insulator slides and connector
will be locked. Do not hold the cover insulator (2).
827RW027
SRS Control Unit

Service Precautions
WARNING: DURING SERVICE PROCEDURES, BE
VERY CAREFUL WHEN HANDLING SRS control
unit. NEVER STRIKE OR JAR SRS control unit.
UNDER SOME CIRCUMSTANCES, IT COULD
CAUSE
DEPLOYMENT
AND
RESULT
IN
PERSONAL INJURY OR IMPROPER OPERATION
OF THE SUPPLEMENTAL RESTRAINT SYSTEM
(SRS) . SRS control unit MOUNTING BRACKET
BOLTS MUST BE CAREFULLY TORQUED TO
ASSURE PROPER OPERATION. NEVER POWER
UP THE SRS WHEN SRS control unit IS NOT
RIGIDLY ATTACHED TO THE VEHICLE. THE SRS
control unit COULD BE ACTIVATED WHEN
POWERED WHILE NOT RIGIDLY ATTACHED TO
THE
VEHICLE
WHICH
COULD
CAUSE
DEPLOYMENT AND RESULT IN PERSONAL
INJURY.
WARNING: PROPER OPERATION OF THE SRS
CONTROL UNIT REQUIRES THE SRS CONTROL
UNIT TO BE RIGIDLY ATTACHED TO THE
VEHICLE STRUCTURE AND THAT THE ARROW
ON THE SENSOR BE POINTING TOWARD THE
FRONT OF THE VEHICLE.
SRS control unit is specifically calibrated and is keyed
to the SRS control unit location SRS wiring harness.
Caution should be used to ensure proper location of
the SRS control unit. The keying of the SRS control
unit to its location and wiring harness connectors
should never be modified in the field.
Removal
1. Disable the SRS (Refer to Disabling the SRS in
this section).
2. Remove the transmission knob (for M/T) and
transfer lever knob.
3. Remove the front console assembly and
disconnect wiring harness connector.
4. Pull CPA (Connector Position Assurance) out and
push connector lock down to disconnect the SRS
control unit harness connector.
5. Remove the three SRS control unit fixing bolts and

remove SRS control unit.
RTW49JSH000101
Legent
(2) SRS Harness
Installation
1. Install the SRS control unit on bracket and fixing
bolts and tighten the fixing bolts to the specified
torque.
Torque: 7 2 Nm (0.7 0.2 kgm/61 lb in)
2. Connect the SRS control unit harness connector
and after that, put CPA into connector.
3. Install the front console.
4. Install the transmission knob (for M/T) and transfer
lever knob.

5. Enable the SRS. (Refer to Enabling the SRS in
this section)
RTW49JSH000101
Legent
(2) SRS Harness
Driver Air Bag Assembly

Service Precautions

FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A
SMALL AMOUNT OF SODIUM HYDROXIDE, A BY
PRODUCT OF THE DEPLOYMENT REACTION,
THAT IS IRRITATING TO THE SKIN AND EYES.
MOST OF THE POWER ON THE AIR BAG
ASSEMBLY IS HARMLESS. AS A PRECAUTION,
WEAR GLOVES AND SAFETY GLASSES WHEN
HANDLING A DEPLOYED AIR BAG ASSEMBLY,
AND WASH YOUR HANDS WITH MILD SOAP AND
WATER AFTERWARDS.
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE.
IN THE CASE OF AN ACCIDENTAL DEPLOYMENT,
THE BAG WILL THEN DEPLOY WITH MINIMAL
CHANCE OF INJURY. WHEN PLACING ALIVE AIR
BAG ASSEMBLY ON A BENCH OR OTHER
SURFACE, ALWAYS FACE BAG AND TRIM COVER
UP, AWAY FROM THE SURFACE. NEVER REST A
STEERING COLUMN ASSEMBLY ON THE
STEERING WHEEL WITH THE AIR BAG
ASSEMBLY
FACE
DOWN
AND
COLUMN
VERTICAL. THIS IS NECESSARY SO THAT A FREE
SPACE IS PROVIDED TO ALLOW THE AIR BAG
ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT
OF ACCIDENTAL DEPLOYMENT. OTHERWISE,
060R300025

pin in the direction of an arrow.
NOTE: In the event deployment has occurred, inspect

coil assembly wire for any signs of scorching, melting
or any other damage due to excessive heat. If the coil
has been damaged, replace it.
Removal
1. Disable the SRS (Refer to Disabling the SRS in
this section).
060R300032

4. Push the four pins at 5~6 mm bar.

lead connector located behind the air bag
assembly and remove the air bag assembly.
060R300045
5. Cancel the lock four pins.

6. Disconnect the SRS air bag connector pin.
060R300041
Installation
1. Connect the SRS air bag connector and horn lead
connector.
060R300042
060R300041

2. Connect the SRS air bag connector pin.
060R300020
060R300042
3. Align the each snap stud of driver air bag to the

hole of steering wheel.
4. Push the SRS air bag area1 and area2. At that

time confirm the audible noise of each stud.
060R300036
060R300030
5. Enable the SRS (Refer to Enabling the SRS in

this section).
assembly.
Steering Wheel
Service Precautions
2. Remove steering wheel attachment nut.

WATER AFTERWARDS.
SURFACE, ALWAYS FACE BAG AND RIM COVER
ASSEMBLY
FACE
DOWN
AND
COLUMN
060R300009
3. Apply a setting mark across the steering wheel

original position.
In the event deployment has occurred, inspect coil

assembly wire for any signs of scorching, melting or
any other damage due to excessive heat. If the coil
Removal
1. Remove the SRS air bag assembly. (Refer to
Driver Air Bag Assembly in this section)
060R300024
4. Move the tires to the straight ahead position before

removing the steering wheel. Install steering wheel
puller onto steering wheel and remove steering
wheel with 5-8521-0016-0.
5. Feed wiring through the wheel and remove wheel.
CAUTION: Never apply force to the steering wheel
in direction of the shaft by using a hammer or
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as
an energy absorbing unit.
Installation
marks.
060R300024

RTW33BSH000601
2. Tighten the steering wheel fixing nut to the

specified torque.
Torque : 34 N
m (3.5 kg
m/25 lb ft)
3. Install the SRS air bag assembly. (Refer to Driver
Air Bag Assembly in this section)
SRS Coil Assembly

Service Precautions
2. Remove the steering wheel attachment nut.

WATER AFTERWARDS.
ASSEMBLY
FACE
DOWN
AND
COLUMN
060R300009

original position.
NOTE: In the event deployment has occurred, inspect

coil assembly wire for any signs of scorching, melting
or any other damage due to excessive heat. If the coil
Removal
060R300024

Driver Air Bag Assembly in this seciton)

removing the steering wheel and remove wheel
with 5-8521-0016-0.
5. Feed wiring though the wheel and remove wheel.
6. Remove the steering lower cover and engine hood
opening lever.
7. Remove the driver knee bolster assembly.
9. Remove air conditioning lower duct.
10.Disconnect the wiring harness connectors located
at the base of steering column.

in the direction of the shaft by using a hammer or
11. Remove the combination switch assembly with
SRS coil.
NOTE: SRS coil is a part of combination switch
assembly, which cannot be replaced separately.
Therefore, be sure not to remove the SRS coil from
the combination switch assembly.
Installation
coil.
about 3 turns and align the neutral mark.
CAUTION:
When
turning
the
SRS
coil
is felt. Forced further turning may damage the
cable in the SRS coil.
826RW014
Legend
(1) Neutral mark
3. Connect the wiring harness connectors located at
4. Install the air conditioning lower duct.
5. Install the steering column cover.
wiring.
825RS048

opening lever.
marks.
060R300024

RTW33BSH000601
9. Tighten the steering

specified torque.
wheel fixing nut to the
Torque: 35 N
m (3.5 kg
m/25 lb ft)
Air Bag Assembly in this section).
Steering Column
Service Precautions
2. Remove the steering wheel attachment nut.

WATER AFTERWARDS.
ASSEMBLY
FACE
DOWN
AND
COLUMN
060R300009

original position.
In the event deployment has occurred, inspect coil

assembly wire for any signs of scorching, melting or
any other damage due to excessive heat. If the coil
Removal
Driver Air Bag Assembly in this section)
060R300024

removing the steering wheel and removing wheel
with 5-8521-0016-0.
5. Feed wiring though the wheel and remove wheel.
6. Remove the steering lower cover and engine hood
opening lever.

7. Remove the driver knee bolster assembly.
16.Apply a setting mark across the universal joint and

steering shaft to reassemble the parts in their
original position.
RTW49JSH000401
Legend
(1) RHD
(2) LHD
at the base of steering column.
in direction of the shaft by using a hammer or
060R300038
17.Remove steering column assembly.
Installation
1. Install the steering column assembly and align the
setting marks on the universal joint and steering
shaft made during removal.
10. Remove the combination switch assembly with

SRS coil.
SRS coil is a part of combination switch assembly,
which cannot be replaced separately. Therefore, be
sure not to remove the SRS coil from the combination
switch assembly.
11.Remove the snap ring.
12. Remove the cushion rubber.
13. Disconnect shift lock cable (A/T only).
14.Disconnect the starter switch harness connector
located base of steering column.
15. Remove steering lock cylinder assembly.
060R300038
2. Tighten the steering column fixing bolts (dash

panel side) to the specified torque.
Torque: 20 N
m (2.0 kg
m/14 lb ft)
3. Tighten the steering column fixing bolts (Pedal
bracket) to the specified torque.
m (2.0 kg
m/14 lb ft)
Torque: 20 N

4. Tighten the universal joint to the specified torque.
Torque: 31 N
m (3.2 kg
m/23 lb ft)
5. Install steering lock cylinder assembly.
6. Connect shift lock cable (For A/T)
7. Install cushion rubber.
coil.
10. Connect the wiring harness connector located on
about 3 turns and align the neutral mark.
CAUTION:
When
turning
the
SRS
coil
is felt. Forced further turning may damage to the
cable in the SRS coil.
825RS048
13.Install the steering wheel and align the setting

marks.
826RW014
Legend
(1) Neutral mark
12.Install steering column cover.
wiring.

RTW33BSH000601
14.Tighten the steering wheel fixing nut to the

specified torque.
Torque: 35 N
m (3.5 kg
m/25 lb ft)
Air Bag Assembly in this section)
Passenger Air Bag Assembly

Service Precautions
WATER AFTERWARDS.
ASSEMBLY
FACE
DOWN
AND
COLUMN
4. Remove passenger air bag assembly fixing bolts

and nuts. Universal joint is used when removing a
nut.
060R300043
WARNING: IN THE EVENT DEPLOYMENT HAS

OCCURRED, INSPECT COIL ASSEMBLY WIRE
FOR ANY SIGNS OF SCORCHING, MELTING OR
ANY OTHER DAMAGE DUE TO EXCESSIVE HEAT.
IF THE COIL HAS BEEN DAMAGED, REPLACE IT.
060R300044
Removal
1. Disable the SRS. (Refer to Disabling the SRS in
this section)
2. Remove glove box.
3. Remove glove box cover.
5. Remove passenger air bag assembly.

6. Disconnect passenger air bag assembly harness
connector.
Installation
1. Connect passenger air bag assembly harness
connector.
2. Install passenger air bag assembly.
3. Install passenger air bag assembly fixing bolts and
nuts. Universal joint is used when removing a nut.
Torque: 8 N
m (0.8 kg
m/78 lb in)
060R300043
060R300044
4. Install glove box cover.

5. Install glove box.
6. Enable the SRS. (Refer to Enabling the SRS in
this section)
Pretensioner Seat Belt (If so quipped)

Service Precaution
Removal

AROUND THE PRETENSIONER SEAT BELT OR
THE PRETENSIONER SEAT BELT WIRING,
TEMPORARILY DISABLE THE PRETENSIONER
SEAT BELT.
FAILURE TO FOLLOW PROCEDURES COULD
RESULT IN POSSIBLE THE PRETENSIONER SEAT
BELT DEPLOYMENT, PERSONAL INJURY OR
OTHERWISE UNNEEDED THE PRETENSIONER
SEAT BELT REPAIR.
AS A PRECAUTION, WEAR GLOVES AND SAFETY
GLASSES
WHEN
PERFORMING
THE
PRETENSIONER SEAT BELT. WHEN DEPLOY A
LIVE PRETENSIONER SEAT BELT AT OUTSIDE
THE VEHICLE, DEPLOYMENT HARNESS SHALL
A POWER SOURCE UNTIL THE PRETENSIONER
SEAT BELT IS TO BE DEPLOYED. THE
PRETENSIONER SEAT BELT WILL IMMEDIATELY
DEPLOY WHEN A POWER SOURCE IS
CONNECTED
TO
IT.
CONNECTING
THE
DEPLOYMENT HARNESS SHOULED ALWAYS BE
THE FINAL STEP IN THE PRETENSIONER SEAT
BELT DEPLOYMENT PROCEDURE. FAILURE TO
Parts Location
RTW49JSH000301
Legend
(1) Seat
(2) Bolt
(3) Pretensioner Harness
(4) Pretensioner
1.
2.
3.
4.
Turn ignition switch to LOCK, remove key.

Remove the foot rest located behind the seat.
Remove the cover on seat slide.
Disconnect the pretensioner connector at the
base of the seat.
5. Remove four fixing bolts the seat slide and
remove seat.
6. Remove the seat cover.
7. Remove the pretensioner seat belt assembly.
Installation
1.
2.
3.
4.
Install the pretensioner seat belt assembly.

Install the seat cover.
Install the seat on seat slide and four fixing bolts.
Connect the yellow pretensioner connector at the
base of the seat.
5. Install the cover on seat slide.
6. Install the foot rest located behind the seat.

Fastener Tightening Specification
N
m
kg
m
Ft.lb
SRS control unit
0.7
Steering wheel fixing bolt
35
3.5
25
Steering column (dash panel side fixing bolts)
20
2.0
14
Steering column (Pedal bracket fixing bolt)
20
2.0
14
Steering column (Universal joint fixing bolt)
31
3.2
23
Passenger Air Bag fixing bolt & nut
0.8
5.8
Pretensioner seat belt bolt
55
5.6
40
Application
Special Tools
BATTERYPOWERED
OR
ACPOWERED
VOLTMETER, OHMMETER, ETC., OR ANY TYPE
OF ELECTRICAL EQUIPMENT OTHER THAN THAT
SPECIFIED IN THIS MANUAL.
DO NOT USE A
NONPOWERED
PROBETYPE
TESTER.
FOLLOWED
CAREFULLY,
OTHERWISE
PERSONAL INJURY MAY RESULT.
By substituting the resistance of the load tool when

called for, a determination can be made as to whether
an inflator circuit component is causing system
malfunction and which component is causing the
malfunction. The load tool should be used only when
specifically called for in the diagnostic procedures.
5-8840-0285-0 DVM
5-8840-2421-0 SRS Driver/Passenger Load

Tool
901RS163
The 5-8840-0285-0 DVM is the preferred DVM for use

in SRS diagnosis and repair. However, 5-8840-03660 may be used if 5-8840-0285-0 is not available. No
other DVMs are approved for SRS diagnosis and
repair.
901RS146
The SRS Driver/Passenger Load Tool 5-8840-2421-0

is used only when called for in this section. It is used
as a diagnostic aid and safety device to prevent
inadvertent air bag assembly deployment.
The load tool has three yellow connectors attached to
its case.
The three small connectors are electrically functional
and serve as resistive load substitutions.
No more than two connectors are used at any time.
One of the small connectors is used to substitute for
the load of the driver air bag assembly when it is
connected at the top of the column to the SRS coil
assembly. Another small connector is used to
substitute for the load of the driver air bag assembly
and the SRS coil assembly when it is connected at the
base of the column to the SRS wiring harness. The
third small connector is used to substitute for the load
of the passenger air bag assembly when connected to
the passenger air bag assembly harness connector.
Scan Tool
901RW176

The Tech 2 is used to read and clear SRS Diagnostic
Trouble Codes (DTCs). Refer to the Tech 2
Operators, Manual for specific information on how to
use the Tech 2.
5-8840-2420-0 SRS Deployment Fixture
5-8840-0385-0 Connector Test Adapter Kit
901RV056
The 5-8840-2420-0 SRS Deployment Fixture must be

used for deployment of the undeployed passenger
side air bag.
901RS151
5-8840-2796-0 SRS Adapter for Load Tool
The 5-8840-0385-0 Connector Test Adapter Kit must

be used whenever a diagnostic procedure requests
checking or probing a terminal. Using the appropriate
adapter will ensure that no damage to the terminal will
occur from the DVM prove, such as spreading or
bending. The adapter will also give an idea of
whether contact tension is sufficient, helping to find an
open or intermittent open due to poor terminal contact.
5-8840-2468-0 SRS Deployment Tool
901RW107
The 5-8840-2796-0 SRS Adapter for Load Tool must

be used with 5-8840-2421-0 SRS Driver/Passenger
Load Tool.
901RW106
The 5-8840-2468-0 SRS Deployment Tool must be

used for deployment of the undeployed air bag.
5-8840-2795-0 SRS Adapter for

Deployment Tool
901RW107
The 5-8840-2795-0 SRS Adapter for Deployment Tool

must be used with 5-8840-2468-0 SRS Deployment
Tool.
5-8521-0016-0 Steering Wheel remover
LNW28BSH003101
RESTRAINT CONTROL 9A1-1
RESTRAINTS
RESTRAINT CONTROL SYSTEM
PAGE
Service Precaution.............................................................................................................9A1- 2
Diagnosis Information ..................................................................................................9A1- 3
Diagnostic Procedures .................................................................................................9A1- 3
Diagnostic Codes ..........................................................................................................9A1- 3
How To Read Trouble Codes .......................................................................................9A1- 3
How To Clear Trouble Codes .......................................................................................9A1- 3
Scan Tool Diagnostics..................................................................................................9A1- 3
Basic Knowledge Required ..........................................................................................9A1- 3
Basic Electrical Circuits ...............................................................................................9A1- 4
"Flash Code" Diagnostics ............................................................................................9A1- 4
DATA LIST (Tech2) ........................................................................................................9A1- 5
Diagnostic Trouble Codes ............................................................................................9A1- 6
System Schematic .............................................................................................................9A1- 7
Chart A SRS control unit Integrity Check ........................................................................9A1-10
Chart B "AIR BAG" Warning Lamp Comes "ON" Steady................................................9A1-12
Chart C "AIR BAG" Warning Lamp Does Not Come "ON" Steady .................................9A1-14
DTC B0016 (Flash Code 16) Passenger Airbag Squib Circuit (Stage1) Low
Resistance ........................................................................................................................9A1-17
DTC B0017 (Flash Code 17) Passenger Airbag Squib Circuit (Stage1) High
Resistance ........................................................................................................................9A1-20
DTC B0018 (Flash Code 18) Passenger Airbag Squib Circuit (Stage1) Voltage
Range/Performance .........................................................................................................9A1-23
DTC B0022 (Flash Code 22) Driver Airbag Squib Circuit (Stage1) Low
Resistance ........................................................................................................................9A1-26
DTC B0024 (Flash Code 24) Driver Airbag Squib Circuit (Stage1) Voltage
Range/Performance ...........................................................................................................9A1-29
DTC B0026 (Flash Code 26) Driver Airbag Squib Circuit (Stage1) High
Resistance ........................................................................................................................9A1-32
DTC B0033 (Flash Code 33) ECU Connector Poor Connection .....................................9A1-35
9A1-2 RESTRAINT CONTROL SYSTEM
DTC B0051 (Flash Code 51) Squib Circuit Activated (Clash) .........................................9A1-37
DTC B0053 (Flash Code 53) Deployment Command Despite Present Trouble
Code ..................................................................................................................................9A1-39
DTC B0057 (Flash Code 57) Passenger Pretensioner Squib Circuit Low
Resistance ........................................................................................................................9A1-41
DTC B0058 (Flash Code 58) Passenger Pretensioner Squib Circuit High
Resistance ........................................................................................................................9A1-44
DTC B0059 (Flash Code 59) Passenger Pretensioner Squib Circuit Voltage
Range/Performance .........................................................................................................9A1-47
DTC B0064 (Flash Code 64) Driver Pretensioner Squib Circuit Low Resistance.........9A1-50
DTC B0065 (Flash Code 65) Driver Pretensioner Squib Circuit High Resistance ........9A1-53
DTC B0066 (Flash Code 66) Driver Pretensioner Squib Circuit Voltage Range/
Performance .....................................................................................................................9A1-56
DTC B0670 (Flash Code 63) Airbag Telltale Circuit Malfunction ...................................9A1-59
DTC B1000 (Flash Code 72) SDM Internal Fault ..............................................................9A1-61
Service Precaution
REPAIRS.

parts and systems.
reinstall them at the same location from which they
were removed. if a fastener needs to be replaced,
use the correct part number fastener for that
application. if the correct part number fastener is
not available, a fastener of equal size and strength
(or stronger) may be used. fasteners that are not
reused, and those requiring thread locking
compound will be called out. the correct torque
value must be used when installing fasteners that
require it. if the above conditions are not followed,
parts or system damage could result.
BATTERY-POWERED OR AC-POWERED
VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN THAT
SPECIFIED IN THIS MANUAL. DO NOT USE A NON
POWERED, PROBE-TYPE TESTER.
INJURY MAY RESULT.
The diagnostic procedures used in this section are
designed to aid in finding and repairing SRS problems.
Outlined below are the steps to find and repair SRS
problems quickly and effectively. Failure to carefully
follow these procedures may result in extended
diagnostic time, incorrect diagnosis and incorrect parts
replacement.
1. Perform The SRS Diagnostic System Check.
The SRS Diagnostic System Check should always
be the starting point of any SRS diagnostics. The
SRS Diagnostic System Check checks for proper
AIR BAG warning lamp operation and checks for
SRS trouble codes using both Flash Code and
Scan Tool Methods.
2. Refer To The Proper Diagnostic Chart As
Directed By The SRS Diagnostic System
Check.
The SRS Diagnostic System Check will lead you to
the correct chart to diagnose any SRS problems.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis and incorrect
parts replacement.
3. Repeat The SRS Diagnostic System Check

After Any Repair Or Diagnostic Procedures Have
Been Performed.
Preforming the SRS Diagnostic System Check
after all repair or diagnostic procedures will assure
that the repair has been made correctly and that no
other conditions exist.
Diagnostic Codes
The SRS control unit maintains a history record of all
diagnostic codes that have been detected since the
SRS codes were last cleared during service.
1. Active Codes - Faults that are presently detected this
ignition cycle. Active codes are stored in RAM
(Random Access Memory).
2. History Codes - All faults detected since the last time
the history fault memory was cleared. History codes
are stored in EEPROM. (Electronically Erasable
Programmable Read only Memory)
How To Read Trouble Codes

All codes (Active and history) can be read (or cleared)
by using a scan tool or equivalent.
If a PDT is not available, have the vehicle serviced by
HOLDEN dealer.
How To Clear Trouble Codes

Trouble codes can only be cleared by using a Scan
Tool. If a scan tool is not available then inform the
owner of the stored codes and suggest that the codes
are cleared upon the next visit to an Isuzu dealership.
Scan Tool Diagnostics

A scan tool can be used to read current and history
codes and to clear all history codes after a repair is
complete. The scan tool must be updated to
communicate with the SRS through a replaceable
cartridge or a manufacturer's update before it can be
used for SRS diagnostics. To use the scan tool,
connect it to the DLC connector and turn the ignition
switch ON. Then follow the manufacturer's directions
for communication with the SRS. The scan tool reads
serial data from the SRS control unitSRS control unit
Serial Data output (terminal 21) to the DLC connector
(terminal 2).
Basic Knowledge Required

Before using this section of the Service Manual, there is
some basic knowledge which will be required. Without
this knowledge, you will have trouble using the
diagnostic procedures in this section. Use care to
prevent harm or unwanted deployment. Read all

cautions in the service manual and on warning labels
attached to SRS components.
Basic Electrical Circuits

You should understand the basic theory of electricity
including series and parallel circuits, and understand
the voltage drops across series resistors. You should
know the meaning of voltage (volts), current (amps),
and resistance (ohms). You should understand what
happens in a circuit with an open or a shorted wire. You
should be able to read and understand a wiring
diagram.
Flash Code Diagnostics

Flash code diagnostics can be used to read active
codes and to determine if history codes are present but
cannot be used to clear codes or read history codes.
Flash code diagnostics is enabled by grounding by
terminal 4 shorting to terminal 13 of the DLC connector
with the ignition switch ON. Grounding terminal 4 of
the DLC connector pulls the Diagnostics Request
input (Terminal 1) of the SRS control unit low and
signals the SRS control unit to enter the flash code
diagnostic display mode.
060R300052

The SRS control unit displays the trouble codes by
flashing the warning lamp. Each code that is displayed
will consist of a number of flashes which represents the
tens digit, a 1.2 second pause, following by a number of
flashes which represents the ones digit of the code.
Each code is displayed one time before moving on to
the next code. After all of the codes have been
displayed, the entire code sequence will continually by
repeated until ground is removed from terminal 4 of the
DLC connector.
Two special codes exist when reading in the flash code

mode (Flash Code 12 and Flash Code 13). Flash
Code 12 will always be the first code displayed when
the flash code mode is enable Code 12 is not an
indication of a SRS problem but an indication that the
flash code mode has been enabled. If there are no
active or history codes present, the SRS control unit will
display code 12 until ground is removed from the DLC
connector at terminal 4. flash Code 13 will be
displayed if history codes are present. To read the
history codes a scan tool must be used.
060R300051
DATA LIST (Tech 2)

DISPLAY on Tech 2 UNIT
VALUE
Driver Airbag Loop
Enabled/Disabled
Passenger Airbag Loop
Enabled/Disabled
System Voltage
V
12.0
Driver Seat Belt Status
Not Backled/Backled

Choose and trace an appropriate flowchart by the numbers listed below to find fault and repair.
DTC
(Flash
Code)
(12)
(13)
B0016
(16)
B0017
(17)
B0018
(18)
B0022
(22)
B0024
(24)
B0026
(26)
B0033
(33)
B0051
(51)
B0053
(53)
B0057
(57)
B0058
(58)
B0059
(59)
B0064
(64)
B0065
(65)
B0066
(66)
B0670
(63)
B1000
(72)
Description
Diagnostic Display Mode (Flash Code only)
Diagnostic Display Mode (Flash Code only)
Passenger Airbag Squib Circuit Low Resistance
Passenger Airbag Squib Circuit High Resistance
Passenger Airbag Squib Circuit Voltage Range / Performance
Driver Airbag Squib Circuit Low Resistance
Driver Airbag Squib Circuit Voltage Range / Performance Resistance
Driver Airbag Squib Circuit High Resistance
ECU Connector Poor Connection
Squib Circuit Activated (Clash)
Deployment Command Despite Present Trouble Code
Passenger Pretensioner Squib Circuit Low Resistance
Passenger Pretensioner Squib Circuit High Resistance
Passenger Pretensioner Squib Circuit Voltage Range / Performance
Driver Pretensioner Squib Circuit Low Resistance
Driver Pretensioner Squib Circuit High Resistance
Driver Pretensioner Squib Circuit Voltage Range / Performance Resistance
Airbag Telltale Circuit Malfunction
SDM Internal Fault (SDM= SRS control unit)
System Schematic
RTW49JLF000101
SRS Diagnostic System Check

The diagnostic procedures used in this section are
designed to find and repair SRS malfunctions. To get
the best results, it is important to use the diagnostic
charts and follow the sequence listed below:
A Perform the SRS Diagnostic System Check.
The SRS Diagnostic System Check must be the
Diagnostic System Check checks for proper AIR
BAG warning lamp operation, the ability of the SRS
control unit to communicate through the Serial
Data line and whether SRS diagnostic trouble codes
exist.
B Refer to the proper diagnostic chart as directed by

the SRS Diagnostic System Check.
The SRS Diagnostic System Check will lead you to
the correct chart to diagnose any SRS malfunctions.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis and incorrect
parts replacement.
C Repeat the SRS Diagnostic System Check after
any repair or diagnostic procedures have been
preformed.
Performing the SRS Diagnostic System Check
after all repair or diagnostic procedures will ensure
that the repair has been made correctly and that no
other malfunctions exist
Circuit Description
Diagnostic Aids
When the ignition switch is first turned ON, Ignition 1

voltage is applied from the SRS fuse to the SRS
control unit at the Ignition 1 input terminals 35. The
SRS control unit responds by flashing the AIR BAG
warning lamp seven times, while performing tests on
the SRS.
The order in which diagnostic trouble codes are

diagnosed is very important. Failure to diagnose the
diagnostic trouble codes in the order specified may
result in extended diagnostic time, incorrect diagnosis
and incorrect parts replacement.
Notes On System Check Chart

1. The AIR BAG warning lamp should flash seven
times after ignition is first turned ON.
2. After the AIR BAG warning lamp flashes seven
times, it should turn OFF
3. This test checks for the proper operation of the
Serial Data line. This test will also determine
whether history diagnostic trouble codes are stored
and, if so, identify them.
4. Improper operation of the AIR BAG warning lamp
is indicated. This test differentiates a warning lamp
stays ON condition from a warning lamp does not
come ON condition.
5. This test checks for proper operation of the Serial
Data line. This test will also identify the stored
diagnostic trouble codes and whether they are
current or history.
SRS Diagnostic System Check

Step
Action
Yes
No
Go to Step 2
Go to Step 3
Note the Air Bag warning lamp as ignition switch is turned ON.
Does the AIR BAG warning lamp flash seven 7 times?
Note the AIR BAG warning lamp after it flashed 7 times.

Go to Step 4
Go to Step 5
Does the AIR BAG warning lamp go OFF?
Note the AIR BAG warning lamp as ignition switch is turned
Go to Chart B.
Go to Chart C.
ON.
Does the AIR BAG warning lamp come ON steady?
1. Note the AIR BAG warning lamp as that ignition switch is
Ignition switch
SRS is functional
turned ON.
OFF.
and free of
Ignition switch OFF.
When DTC B1000 is malfuncitons, no
further diagnosis is
set, go to DTC
2. Connect a scan tool to data link connector.
required.
B1000
Chart.
3. Follow direction given in the scan tool instruction manual.
If
scan
tool indicated
For all other history
Ignition switch ON.
NO DATA
codes refer to
4. Request the SRS diagnostic trouble code display, recode all
Diagnostic Aids RECEIVED, refer to
history diagnostic trouble code(s). specify as such, on repair
chassis electrical
For that specific
order
section 8.
DTC.
Is (are) diagnostic trouble code(s) displayed?
A history DTC
indicates the
malfunction has
been repaired or is
intermittent.

Step
5
Action
Yes
No
1. Ignition switch OFF.

Ignition switch
If scan tool indicates
OFF.
No Data Received,
2. Connect a scan tool to data link connector.
When DTC B0053 is refer to chassis
3. Follow directions as given in the scan tool instruction
electrical section 8.
set, go to DTC
manual.
B0053 chart.
4. Ignition switch ON.
When
DTC B0051 is
5. Request the SRS diagnostic trouble code display, Recode
set,
go to DTC
all diagnostic trouble code(s), specifying as current or history
B0051
chart.
on repair order.
When
DTC
B0018
Is (are) diagnostic trouble code (s) displayed?
is set, go to DTC
B0018 chart.
When DTC B0024
is set, go to DTC
B0024 chart.
Diagnose remaining
current DTCs from
lowest to highest.
When only history
DTCs exist, refer to
Diagnostics Aids
for that specific
DTC.
A history DTC
indicates the
malfunction has
been repaired or is
intermittent.
Chart A SRS control unit Integrity Check
RTW49JLF000101
Circuit Description
Chart Test Description
When the SRS control unit recognizes Ignition 1

voltage, applied to terminals 35, is greater than 9
volts, the AIR BAG warning lamp is flashed 7 times to
verify operation. At this time the SRS control unit
performs TurnON tests followed by Continuous
Monitoring tests. When a malfunction is detected, the
SRS control unit sets a current diagnostic trouble code
and illuminates the AIR BAG warning lamp. The SRS
control unit will clear current diagnostic trouble codes
and move them to a history file when the malfunction is
no longer detected and/or the ignition switch is cycled,
except for DTCs B0051 and B0053.
Number(s) below refer to step number(s) on the

diagnostic chart:
1. This test confirms a current malfunction. If no
current malfunction is occurring (history DTC set)
the Diagnostic Aids for the appropriate diagnostic
trouble code should be referenced. The SRS control
unit should not be replaced for a history diagnostic
trouble code.
2. This test checks for a malfunction introduced into the
SRS during the diagnostic process. It is extremely
unlikely that a malfunctioning SRS control unit would
cause a new malfunction to occur during the
diagnostic process.

3. When all circuitry outside the SRS control unit has
been found to operate properly, as indicated by the
appropriate diagnostic chart, then and only then
should the SRS control unit be replaced.
Chart A SRS control unit Integrity Check

WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SRS CONTROL
UNIT. NEVER STRIKE OR JAR THE SRS CONTROL UNIT. NEVER POWER UP THE SRS WHEN THE SRS
CONTROL UNIT IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SRS CONTROL UNIT AND MOUNTING
BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD
THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SRS CONTROL UNIT
COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD
CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY
Step
1
Action
Yes
1. This chart assumes that the SRS Diagnostic System The symptom or
Check and either a symptom chart or a diagnostic trouble DTC is no longer
occurring.
code chart diagnosis have been performed. When all
Clear SRS
circuitry outside the SRS control unit has been found to
diagnostic trouble
operate properly, as indicated by the appropriate diagnostic
codes.
chart, and the symptom or DTC remains current, the
Repeat SRS
following
Diagnostic System
2. Diagnostic procedures must be performed to verify the need
Check
for SRS control unit replacement.
4. Reconnect all SRS components, ensure all components are
properly mounted.
5. Ensure the ignition switch has been OFF for at least 15
seconds.
6. Note AIR BAG warning lamp as ignition switch is turned
ON.
Does warning lamp flash 7 times then go OFF?
Using a scan tool request diagnostic trouble code display.
Go to Step 3
Is the same symptom or DTC occurring as was when the SRS
Diagnostic System Check was first performed?
1. Clear SRS Diagnostic Trouble Codes.

2. Ignition switch OFF for at least two minutes.
3. Note AIR BAG warning lamp as ignition switch is turned
ON.
Does warning lamp flash 7 times then go OFF?
Reconnect all SRS components, ensure all components are

properly mounted.
No
Go to Step 2
Ignition switch
OFF.
Go to the
appropriate chart for
the indicated
malfunction.
SRS is functional
Ignition switch
and free of
OFF.
malfunctions.
Replace SRS control
No further diagnosis
unit.
is required.
Go to Step 4
Go to Step 4
Repeat the SRS
Diagnostic System
Check
Go to Step 4
Chart B AIR BAG Warning Lamp Comes ON Steady
RTW49JLF000101
Circuit Description

voltage is applied from the METER fuse to AIR
BAG, warning lamp which is connected to SRS
Warning Lamp, terminal 39. The SRS fuses apply
system voltage to the Ignition 1 inputs, terminals 35.
The SRS control unit responds by flashing the AIR
BAG warning lamp 7 times. If Ignition 1 is less than
9 volts, the AIR BAG warning lamp will come ON
solid with no DTCs set.

diagnostic chart:
2. This test checks for an open in the Ignition 1 circuit
to the SRS control unit.
3. This test checks for the voltage of Ignition 1.
4. This test determines whether the malfunction is a
short to ground in SRS waring lamp circuit.
Chart B AIR BAG warning lamp comes ON Steady

Step
Action
Yes
No
1. When measurements are requested in this chart use 5-88400285-0 DVM with correct terminal adapter from 5-88400385-0.
3. Connect scan tool to data link connector, follow directions as
given in the scan tool instruction MANUAL.
5. Request SRS diagnostic trouble code display.
Dose scan tool indicate No Data Received?
Go to Step 2
Go to Step 3

2. Inspect SRS control unit harness connector connection to
SRS control unit.
Is it securely connected to the SRS control unit?
Ignition switch
OFF.
Replace SRS
control unit.
Go to Step 5
Connect SRS
control unit
securely to de
activate shorting
clip in SRS control
unit harness
connector.
Go to Step 5
Using scan tool, request SRS data list.

Is ignition more than 9 volts?
Go to Step 4
Ignition switch
OFF.
Replace SRS
control unit.
Go to Step 5

2. Disconnect SRS coil and passenger air bag assemblies.
yellow connector located at base of steering column and
behind the glove box assembly.
Disconnect SRS control unit.
3. Disconnect the connector of SRS Warning Lamp of
instrument cluster.
4. Measure resistance from SRS control unit harness connector
terminal 40 to ground.
Does 5-8840-0285-0 DVM display OL (Infinite)?
Go to Chart A
Replace SRS
harness.
Go to Step 5

properly mounted.
Repeat the SRS

Diagnostic System
Check
Go to Step 5
Chart C AIR BAG Warning Lamp Does Not Come ON Steady
RTW49JLF000101
Circuit Description
voltage is applied from the METER fuse to the AIR
BAG warning lamp which is connected to SRS
Warning Lamp, terminal 39. The SRS fuse apply
system voltage to the Ignition 1 inputs, terminals 35.
The SRS control unit responds by flashing the AIR
BAG warning lamp seven times. If Ignition 1 is more
than 16 volts, the AIR BAG warning lamp will be still
OFF solid with no DTCs set.

diagnostic chart:
1. This test decides whether power is available to SRS

control unit warning lamp power feed circuit.
2. This test determines whether the voltage is present
in the warning lamp circuit.
3. This test determines if the malfunction is in the
instrument cluster.
4. This test checks for open in the warning lamp
circuitry.
5. This test isolates the SRS warning lamp circuit and
checks for a short in the SRS warning lamp circuit to
B+.
8. This test checks for a short from the SRS control
unit warning lamp power feed circuit to ground.
9. This test determines whether the short to ground is
due to a short in the wiring.
Chart C AIR BAG Warning Lamp Does Not Come ON Steady

Step
Action
Yes
No
1. When measurements are requested in this chart, use 5-88400285-0 DVM with correct terminal adapter from 5-88400385-0.
3. Remove and inspect METER fuse to the AIR BAG
warning lamp.
Is fuse good?
Go to Step 2
Go to Step 7

Yellow connector located at base of steering column and
3. Disconnect SRS control unit.
5. Measure voltage on SRS control unit harness connector from
terminal 39 to terminal 40 (ground).
Is system voltage present on terminal 39?
Go to Step 4
Go to Step 3

2. Remove instrument meter cluster.
3. Check for proper connection to instrument cluster at SRS
warning lamp circuit terminal.
4. If ok, then remove and inspect AIR BAG bulb.
Is bulb good?
Go to Step 5
Replace bulb.
Go to Step 6

2. Disconnect instrument meter cluster harness connector.
4. Measure voltage on SRS control unit harness connector from
Is voltage 1 volt or less?
Go to Chart A
Replace SRS
harness.
Go to Step 6
Service instrument
1. Install bulb.
meter cluster.
2. Measure resistance from instrument meter cluster harness
Install instrument
connector SRS warning lamp circuit terminal to SRS control
meter cluster.
unit harness connector terminal 7.
Go to Step 6
Is resistance 5.0 ohms or less?
Replace SRS
harness.
Go to Step 6

properly mounted.
Repeat the SRS

Diagnostic System
Check
Go to Step 6
Perform chart C.
Go to Step 8
Go to Step 1
1. Replace METER fuse.

2. Ignition switch ON wait 10 Seconds then ignition switch Off.
3. Remove and inspect METER fuse.

Is fuse good?
Install METER
fuse.
Go to Step 10
Go to Step 9

Step
Action
Yes
No

Yellow connectors located at base of steering column and
3. Replace METER fuse.
4. Ignition switch ON wait 10 seconds.
6. Remove and inspection METER fuse.
Is fuse good?
Install METER
fuse.
Go to Chart A
Replace SRS
harness.
Replace METER
fuse.
Go to Step 10
10

properly mounted.
Repeat the SRS

Diagnostic System
Check
Go to Step 10
DTC B0016 (Flash Code 16) Passenger Airbag Squib Circuit Low Resistance
RTW49JLF000101
Circuit Description
DTC Will Set When
When the ignition switch is turned ON, the SRS

control unit will perform tests to diagnose critical
malfunctions within itself. Upon passing these tests
Ignition 1, and deployment loop voltages
are
measured to ensure they are within their respective
normal voltage ranges. The SRS control unit then
proceeds with the Resistance Measurement Test.
Passenger Bag Low terminal 47 is grounded through
a resistor and the passenger current source connected
to Passenger Bag High terminal 48 allows a known
amount of current to flow. By monitoring the voltage
difference between Passenger Bag High and
Passenger Bag Low, the SRS control unit calculates
the combined resistance of the passenger air bag
assembly, harness wiring circuits Passenger Bag High
and Passenger Bag Low connector terminal contact.
The combined resistance of the passenger air bag

assembly, harness wiring circuits Passsenger Bag
High and Passenger Bag Low, and connector
terminal contact is above a specified value. This test
is run once each ignition cycle during the Resistance
Measurement Test when:
1. No higher priority faults are detected during Turn
ON,
2. Ignition 1 voltage is in the specified value.
Action Taken
SRS control unit turns ON the AIR BAG warning
lamp and sets a diagnostic trouble code.
DTC Will Clear When
Diagnostic Aids
The ignition switch is turned OFF.
An intermittent condition is likely to be caused by a short

between circuits Passenger Bag High and Passenger
Bag Low or a malfunctioning shorting clip on the
passenger air bag assembly which would require
replacement of the air bag assembly. The test for this
diagnostic trouble code is only run while AIR BAG
warning lamp is performing the bulb check. When a
scan tool Clear Codes command is issued and the
malfunction is still present, the DTC will not reappear
until the next ignition cycle.
DTC Chart Test Description

diagnostic chart:
2. This test determines whether the malfunction is in
the SRS control unit.
3. This test verifies connection of the yellow connector.
4. This test cheeks for proper operation of the shorting
clip in the yellow connector.
5. The test checks for a malfunction passenger air bag
assembly.
6. This test determines whether the malfunctioning is
due to shortening in the wiring.
DTC B0016 (Flash Code 16) Passenger Airbag Squib Circuit Low Resistance
Step
Action
Yes
No
Was the SRS Diagnostic System Check performed?
Go to Step 2
Repeat the SRS

Diagnostic System
Check
1. Check the passenger air bag squib circuit for short to voltage
or short to ground.
2. If the problem found, repair as necessary.
Verify repair
Go to Step 3
1. Ignition switch Off.

2. Make sure the passenger air bag assembly yellow connector
located behind the glove box assembly is seated properly.
Is the yellow connector connected properly?
Go to Step 4
Seat passenger air

bag assembly
yellow connector
properly.
Go to Step 7
1. Disconnect and inspect the passenger air bag assembly

yellow connector located behind the glove box assembly.
2. If ok, reconnect the passenger air bag assembly connector.
Is DTC B0016 Current?
Go to Step 5
Go to Step 7

2. Disconnect SRS coil and passenger air bag assembly, yellow
connector located at the base of the steering column and
3. Connect 5-8840-2421-0 SRS driver/passenger load tool and
appropriate adapters to SRS coil and passenger air bag
assembly harness connectors.
Is DTC B0016 current?
Go to Step 6
Ignition switch
Off.
Replace the
passenger air bag
assembly.
Go to Step 7

2. There has been a decrease in the total circuit resistance of
the passenger inflator deployment loop
Replace SRS
harness.
Go to Step 7
Go to Chart A

Step
Action
Yes
No
Repeat the SRS

Diagnostic System
Check
Go to Step 7
the passenger inflator deployment loop.

3. Use the high resolution ohmmeter mode of the DVM while
checking circuits Passenger Bag High and Passenger Bag
Low, and SRS control unit connector terminal 48 and 47
to locate the root cause.
Was a fault found?
7
1. Reconnect all components, ensure all component are

properly mounted.
2. Clear diagnostic trouble codes.
DTC B0017 (Flash Code 17) Passenger Airbag Squib Circuit High Resistance
RTW49JLF000101
Circuit Description
DTC Will Set When

Ignition 1, and deployment loop voltages are
Passenger Bag Low terminal 47 is grounded through
a resister and the passenger current source connected
to Passenger Bag High terminal 48 allows a known
difference
between Passenger Bag High and
Passenger Bag Low the SRS control unit calculates
the combined resistance of the passenger air bag
and Passenger Bag Low connector terminal contact.
The combined resistance of the passenger air bag

and Passenger Bag Low, and connector terminal
contact is above a specified value. This test is run
once each ignition cycle during the Resistance
ON,
Action Taken
DTC Will Clear When
Diagnostic Aids
An intermittent condition is likely to be caused by a poor

connection at the passenger air bag assembly harness
connector terminals 1 and 2, SRS control unit
terminal 48 and 47, or a poor wire to terminal
connection in circuits Passenger Bag High and
Passenger Bag Low. This test for this diagnostic
trouble code is only run while the AIR BAG warning
lamp is performing the bulb check. When a scan tool
Clear Codes command is issued and the malfunction
is still present, the DTC will not reappear until the next
ignition cycle.

diagnostic chart:
3. This test verifies proper connection of the yellow
connector.
4. This test checks for proper contact and/or corrosion
of the yellow connector terminals.
5. The test checks for a malfunctioning passenger air
bag assembly.
6. This test determines whether the malfunction is due
to high resistance in the wiring.
DTC B0017 (Flash Code 17) Passenger Airbag Squib Circuit High Resistance
Step
Action
Yes
No
Was the SRS Diagnostic System Check Performed?
Go to Step 2
Go to The SRS
Diagnostic System
Check
1. Check the passenger air bag squib circuit for open.

Verify repair
Go to Step 3

located behind the glove box assembly is seated properly.
Go to Step 4
Seat passenger Air

Bag assembly
yellow connector
properly.
Go to Step 7

yellow connector located behind the glove box assembly.
Go to Step 5
Go to Step 7

connector located at the base of the steering column and
3. Connect 5-8840-2421-0 SRS driver / passenger load tool and
appropriate adapters to SRS coil and passenger air bag
Go to Step 6
Ignition switch
Off.
Replace the
passenger air bag
assembly.
Go to Step 7

Step
Action
Yes
No

2. There has been an increase in the total circuit resistance of
checking circuits Pasenger Bag High and Passenger Bag
Low, and SRS control unit connector terminal 48 and 47
to locate the root cause.
Was a fault found?
Replace SRS
harness.
Go to Step 7
Go to Chart A
1. Reconnect all components ensure all component are properly Repeat the SRS
Diagnostic System
mounted.
Check
Was This step finished?
Go to Step 7
DTC B0018 (Flash Code 18) Passenger Airbag Squib Circuit Voltage
Range/Performance
RTW49JLF000101
Circuit Description
DTC Will Set When

malfunctions within itself. Upon passing these tests,
normal voltage ranges.
The SRS control unit monitors the voltages at Driver
Bag Low terminal 46 and Passenger Bag Low
terminal 47 to detect short to ground/+B in the air bag
assembly circuits.
Neither of the two air bag assemblies is open.

Ignition 1 is within the normal operating voltage range.
Once these conditions are me and the voltage at
Passenger Bag Low is out of a specified value, DTC
B0018 will set. This test is run once each ignition cycle
and Continuous Monitoring.
Action Taken
DTC Will Clear When
Diagnostic Aids
This malfunction is no longer occurring and the ignition

switch is turned OFF.

to ground/+B in the passenger air bag assembly circuit.
Inspect circuits Passenger Bag High and Passenger
Bag Low carefully for cutting or chafing. If the wiring
pigtail of the passenger air bag assembly is damaged,
the component must be replaced.

Number(s) below refer to circled number(s) on the
diagnostic chart.
2. This test determines whether the SRS control unit is
malfunctioning.
3. This test isolates the malfunction to one side of the
passenger air bag assembly yellow connector behind
glove box compartment.
Passenger Bag High circuit.
Passenger Bag Low circuit.
Driver Bag High circuit.
Driver Bag Low circuit.
DTC B0018 (Flash Code 18) Passenger Airbag Squib Circuit Voltage Range/Performance
Step
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check
4. Check the passenger air bag squib circuit for short to voltage,
short to ground and open.
Go to Step 3

2. Disconnect passenger air bag assembly yellow connector
3. Leave driver air bag assembly connected.
4. Connect SRS driver / passenger load tool 5-8840-2421-0 and
appropriate adapter to passenger air bag assembly harness
connector.
Go to Step 4
Ignition switch
OFF.
Replace
passenger air bag
assembly .
Go to Step 8

2. Disconnect SRS driver / passenger load tool
3. Measure resistance on SRS control unit harness connector
from terminal 48 to terminal 40 (ground).
Does 5-8840-0285-0 display OL (Infinite)?
Go to Step 5
Replace SRS
Harness.
Go to Step 8
Measure resistance on SRS control unit harness connector from

Go to Step 6
Replace SRS
Harness.
Go to Step 8

Step
Action
Yes
No

terminal 48 to terminal 35 (ignition).
Go to Step 7
Replace SRS
Harness.
Go to Step 8

7

Go to Chart A
Go to Step 8

8
1. Reconnect all components and ensure all component are

properly mounted.
Replace SRS
Harness.
Go to the SRS
Diagnostic system
Check
Go to Step 8
DTC B0022 (Flash Code 22) Driver Airbag Squib Circuit Low Resistance
RTW49JLF000101
Circuit Description
The SRS control unit then proceeds with the

Resistance Measurement Test Driver Bag Low
terminal 46 is grounded through a current sink and
the driver current source connected to Driver Bag
High terminal 45 allows a known amount of current to
flow.
By monitoring the voltage difference between
Driver Bag High and Driver Bag Low the SRS control
unit calculates the combined resistance of the driver air
bag assembly, SRS coil assembly, harness wiring
circuits Driver Bag High and Driver Bag Low and
connector terminal contact.
DTC Will Set When
The combined resistance of the driver air bag

assembly, SRS Coil assembly, harness wiring circuits
Driver Bag High and Driver Bag Low, and connector
terminal contact is above a specified value. This test is
run once each ignition cycle during the Resistance
ON

diagnostic chart:
connector at the base of the steering column.
4. This test checks for proper operation of the shorting
5. This test isolate the malfunction to one side of the
SRS coil assembly yellow connector located at the
base of steering column.
to shortening in the wiring.
the SRS coil
assembly or the driver air bag
assembly.
Action Taken
lamp and sets DTC B0022.
DTC Will Clear When

Diagnostic Aids
between circuit Driver Bag High or Driver Bag Low
or a malfunctioning shorting clip on the driver air bag
assembly or SRS coil assembly which would require
replacement of the component. The test for this
diagnostic trouble code is only run while the AIR BAG
DTC B0022 (Flash Code 22) Driver Airbag Squib Circuit Low Resistance
Step
Action
Yes
No
Perform the SRS Diagnostic System Check.

Go to Step 2
Go to the SRS
Diagnostic System
Check
1. Check the driver air bag squib circuit for short to voltage or
short to ground.
Verify repair
Go to Step 3

2. Make sure the SRS coil assembly yellow connector located
at the base of steering column is seated properly.
Is the connector connected properly?
Go to Step 4
Seat driver air bag

assembly
connector
properly.
Go to Step 8
1. Disconnect and inspect the SRS coil assembly yellow

connector located base of steering column.
2. If ok, reconnect the SRS coil assembly yellow connector.
Go to Step 5
Go to Step 8

Step
Action
Yes
No

connector located at the base of steering column and behind
the glove box assembly.
appropriate adapter to SRS coil and passenger air bag
Go to Step 6
Go to Step 7

the driver deployment loop.
checking circuits Driver Bag High and Driver Bag Low,
and SRS control unit connector terminal 45 and 46 to
locate the root cause.
Was a fault found?
Replace SRS
harness.
Go to Step 8
Go to Chart A

2. Disconnect SRS driver / passenger load tool from driver air
bag assembly harness connector.
3. Connect SRS driver / passenger load tool 5-8840-2421-0 to
the top of steering column connector.
4. Reconnect SRS coil assembly harness connector as the base
of steering column.
Ignition switch
off.
Replace SRS coil
assembly.
Go to Step 8
Ignition switch
OFF.
Replace driver air
bag assembly.
Go to Step 8

properly mounted.
Go to the SRS
Diagnostic System
Check
Go to Step 8
DTC B0024 (Flash Code 24) Driver Airbag Squib Circuit Voltage
Range/Performance
RTW49JLF000101
Circuit Description
DTC Will Set When

The SRS control unit monitors the voltage at Driver
Bag Low terminal 46 and Passenger Bag Low
terminal 47 to detect shorts to ground/+B in the air bag
assembly circuits.
Neither of the two air bag assemblies is open.

This test is run once each ignition cycle and
Continuous Monitoring. Once these conditions are
met and the voltage at Driver Bag Low is out of a
specified value, DTC B0024 will set.
Action Taken
DTC Will Clear When

The malfunction is no longer occurring and the ignition
is turned OFF.
Diagnostic Aids

diagnostic chart:
malfunctioning
SRS coil assembly yellow 2pin connector at the
base of the steering column.
the SRS coil assembly or the driver air bag
assembly.

to ground/+B in the driver air bag assembly circuit.
Inspect circuits Driver Bag High and Driver Bag Low
carefully for cutting or chafing.
DTC B0024 (Flash Code 24) Driver Airbag Squib Circuit Voltage Range/Performance
Step
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check
4. Check the driver air bag squib circuit for short to voltage or
short to ground and open.
Go to Step 3

2. Disconnect SRS coil assembly yellow connector located at
base of the steering column. leave passenger air bag
assembly connected.
appropriate adapter to SRS coil assembly harness
connector.
4. ignition switch ON.
Go to Step 4
Go to Step 8

3. Disconnect SRS driver / passenger load tool.
45 to terminal 40 (ground).
Does 5-8840-0285-0 display OL (infinite)?
Go to Step 5
Replace SRS
harness.
Go to Step 9

Go to Step 6
Replace SRS
harness.
Go to Step 9

Step
Action
Yes
No

Go to Step 7
Replace SRS
harness.
Go to Step 9

Go to Chart A
Replace SRS
harness.
Go to Step 9

2. Disconnect SRS driver / passenger load tool 5-8840-2421-0
from SRS coil assembly harness connector.
appropriate adapter to driver air bag assembly harness
connector. located top of the steering column connector.
of steering column.
Ignition switch
OFF.
Replace SRS coil
assembly.
Go to Step 9
Ignition switch
OFF.
Replace driver air
bag assembly.
Go to Step 9
Go to the SRS
1. Reconnect all components ensure all component are properly
Diagnostic
System
mounted.
Check
Go to Step 9
DTC B0026 (Flash Code 26) Driver Airbag Squib Circuit High Resistance
RTW49JLF000101
Circuit Description

Resistance Measurement Test Driver Bag Low
terminal 46 is grounded through a current sink and the
driver current source connected to Driver Bag High
terminal 45 allows a known amount of current to flow.
By monitoring the voltage difference between Driver
Bag High and Driver Bag Low, the SRS control unit
calculates the combined resistance of the driver air bag
assembly, SRS coil assembly, harness wiring circuits
Driver Bag High and Driver Bag Low and connector
terminal contact.
DTC Will Set When
The combined resistance of the driver air bag

assembly, SRS Coil assembly, harness wiring circuits
Driver Bag High and Driver Bag Low, and connector
ON

diagnostic chart:
connector at the base of the steering column.
of the connector terminals at the base of steering
column.
base of the steering column.
the SRS coil assembly or the driver air bag
assembly.
Action Taken
DTC Will Clear When

Diagnostic Aids
connection at terminals 1 and 2 of the SRS coil
connector at the base of the steering column, terminal
1 and 2 of the driver air bag assembly connector at
the top of the steering column, SRS control unit
terminals 45 and 46 or a poor wire to terminal
connection in circuit Driver Bag High or Driver Bag
Low The test for this diagnostic trouble code is only
run while the AIR BAG warning lamp is performing
the bulb check. When a scan tool Clear Codes
command is issued and the malfunction is still present,
the DTC will not reappear until the next ignition cycle.
DTC B0026 (Flash Code 26) Driver Airbag Squib Circuit High Resistance
Step
Action
Yes
No

Go to Step 2
Repeat the SRS

Diagnostic System
Check
1. Check the driver air bag squib circuit for open.

Verify repair
Go to Step 3

base of steering column is seated properly.
Go to Step 4
Seat SRS coil

assembly
connector
properly.
Go to Step 8

Step
Action
Yes
No
1. Disconnect and inspect the SRS coil assembly yellow

connector located base of steering column.
2. If ok, reconnect the SRS coil assembly yellow connector.
Go to Step 5
Go to Step 8

2pin connector located at the base of steering column and
appropriate adapter to SRS coil and passenger air bag
Go to Step 6
Go to Step 7

2. There has been a increase in the total circuit resistance of
checking circuits Driver Bag High and Driver Bag Low,
and SRS control unit connector terminal 45 and 46 to
locate the root cause.
Was a fault found?
Replace SRS
harness.
Go to Step 8
Go to Chart A

2. Disconnect SRS driver / passenger load tool from SRS coil
assembly harness connector.
3. Connect SRS driver / passenger load tool 5-8840-2421-0 on
the top of steering column.
of steering column.
Ignition switch
OFF.
Replace SRS coil
assembly.
Go to Step 8
Ignition switch
OFF.
Replace driver air
bag assembly.
Go to Step 8
1. Reconnect all components ensure all component are

properly mounted.
Repeat the SRS

Diagnostic System
Check
Go to Step 8
DTC B0033 (Flash Code33) ECU Connector Poor Connection
RTW49JLF000101
Circuit Description
Action Taken
The connector of SRS control unit is connected

completely.
ECPA(Electrical
Connector
Position
Assurance) circuit is closed after that.
SRS control unit supervises it by self-diagnosis.
Connect completely the SRS control unit.
DTC Will Set When

ECPA circuit is open.
DTC Will Clear When

DTC (Flash Code33) B0033 ECU Connector Poor Connection

Step
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check
Ignition switch OFF

Reconnect the ECPA on SRS control unit connector yellow 52pin connector located at the base of instrument panel center.
Ignition switch ON
Go to Step 3
Reconnect the
ECPA properly.
Clear Diagnostic trouble codes.

Go to Step2
Go to SRS
Diagnostic System
Check
Go to Step 3
DTC B0051 (Flash Code 51) Squib Circuit Activated (Crash Detected)
RTW49JLF000101
Circuit Description
Action Taken
The SRS control unit contains a sensor which converts

vehicle velocity changes to an electrical signal. The
electrical signal generated is processed by the SRS
control unit and then compared to a value stored in
memory. When the generated signal exceeds the
bags and causing DTC B0051 to set.

lamp records Crash Data, and sets a diagnostic
trouble code.
DTC Will Set When

diagnostic chart:
2. If air bag assembly(s) has not deployed, DTC B0051
may have falsely set.
3. If DTC B0051 has set with no signs of frontal impact,
the diagnostic trouble code has falsely set.
The SRS control unit detects a frontal crash, up to 30

degrees off the centerline of the vehicle, of sufficient
force to warrant deployment of the air bags.
DTC Will Clear When

The SRS control unit is replaced.
DTC B0051 (Flash Code 51) Squib Circuit Activated (Crash Deteted)
WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SRS CONROL UNIT.
NEVER STRIKE OR JAR THE SRS CONTROL UNIT. NEVER POWER UP THE SRS WHEN THE SRS CONTROL
UNIT IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SRS CONTROL UNIT AND MOUNTING BRACKET
FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE
FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SRS CONTROL UNIT CAUSE
DEPLOYMENT AND RESULT IN PERSONAL INJURY.
Step
Action
Yes
No
Go to Step 2.
Go to the SRS
Diagnostic System
Check

Have air bag assemblies deployed?
Replace
components and
perform
inspections as
directed in
repairs and
inspections
required after an
accident in this
section.
clear diagnostic
trouble codes.
Repeat SRS
Diagnostic System
Check
Go to Step 3
Inspect front of vehicle and undercarriage for sings of impact.

Were signs of impact found?
Replace
components and
perform
inspections as
directed in
Repairs and
Inspections
Required After An
Accident in this
section.
Clear diagnostic
trouble codes.
Repeat SRS
Diagnostic System
Check
Ignition switch
OFF.
Replace SRS
control unit.
Reconnect all SRS
system
components,
ensure all
components are
properly mounted.
Repeat SRS
Diagnostic System
Check
DTC B0053 (Flash Code 53) Deployment Command Despite Present Trouble
Code
RTW49JLF000101
Circuit Description
DTC Will Set When
The SRS control unit contains a sensor which converts

vehicle velocity changes to an electrical signal. The
electrical signal generated is processed by the SRS
control unit and then compared to a value stored in
memory. When the generated signal exceeds the
bags. DTC B0053 is set accompanying with DTC
B0051 when a deployment occurs while an air bag
assembly circuit fault is present that could possible
result in a no deployment situation in one or both air bag
assemblies.
The SRS control unit detects a frontal crash, up to 30

degrees off the centerline of the vehicle, of sufficient
force to warrant deployment of the air bags and an
inflator circuit fault is present.
Action Taken
lamp records Crash Data, and sets a diagnostic
trouble code.
DTC Will Clear When

The SRS control unit is replaced.

diagnostic chart:
2. If air bag assembly have not deployed, DTC B0053
may have falsely set.
3. If DTC B0053 has set with no signs of frontal impact,
the diagnostic trouble code has falsely set.
DTC B0053 (Flash Code 53) Deployment Command Despite Present Trouble Code
COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH
COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY.
Step
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check

Have air bag assembles deployed?
Replace
components and
perform
inspections as
directed in
Repairs And
Inspections
Required After An
Accident in this
section.
Clear diagnostic
trouble codes.
Repeat the SRS
Diagnostic System
Check
Go to Step 3
Inspect front of vehicle and undercarriage for signs of impact.

Were signs of impact found?
Replace
components and
perform
inspections as
directed in
Repairs And
Inspections
Required After An
Accident in this
section.
Clear diagnostic
trouble codes.
Repeat SRS
Diagnostic System
Check
Ignition switch
OFF.
Replace SRS
control unit.
Reconnect all SRS
system
components,
ensure all
components are
properly mounted.
Repeat the SRS
Diagnostic System
Check
DTC B0057 (Flash Code 57) Passenger Pretensioner Squib Circuit Low
Resistance
RTW49JLF000101
Circuit Description
Passenger Pretensioner Low terminal 43 is
grounded through a resistor and the passenger current
source connected to Passenger Pretensioner High

Passenger Pretensioner High and Passenger
Pretensioner Low, the SRS control unit calculates the
combined resistance of the passenger air bag
assembly, harness wiring circuits Passenger
Pretensioner High and Passenger Pretensioner Low
DTC Will Set When
Diagnostic Aids
The combined resistance of the passenger pretensioner

assembly, harness wiring circuits Passsenger
Pretensioner High and Passenger Pretensioner Low,
and connector terminal contact is above a specified
value. This test is run once each ignition cycle during
the Resistance Measurement Test when:
ON,

between circuits Passenger Pretensioner High and
Passenger Pretensioner Low or a malfunctioning
shorting clip on the passenger pretensioner assembly
which would require replacement of the pretensioner
assembly. The test for this diagnostic trouble code is
only run while AIR BAG warning lamp is performing
the bulb check. When a scan tool Clear Codes
command is issued and the malfunction is still present,
the DTC will not reappear until the next ignition cycle.
Action Taken
DTC Will Clear When


diagnostic chart:
3. This test verifies connection of the yellow connector.
4. This test cheeks for proper operation of the shorting
5. The test checks for a malfunction passenger
pretensioner assembly.
6. This test determines whether the malfunctioning is
due to shortening in the wiring.
DTC B0057 (Flash Code 57) Passenger Pretensioner Squib Circuit Low Resistance
Step
Action
Yes
No
Go to Step 2
Repeat the SRS

Diagnostic System
Check
1. Check the passenger pretensioner squib circuit for short to

valtage or short to ground.
2. If the broblem found, repair as necessary.
Verify repair
Go to Step 3

located at the base of the passenger seat.
Go to Step 4
Seat passenger
pretensioner
assembly yellow
connector
properly.
Go to Step 7

yellow connector located at the base of the passenger seat.
Go to Step 5
Go to Step 7

2. Disconnect SRS coil and passenger pretensioner assembly,
3. Connect 5-8840-2421-0 SRS driver/passenger load tool and
appropriate adapters to passenger pretensioner assembly
harness connectors.
Go to Step 6
Ignition switch
Off.
Replace the
passenger
pretensioner
assembly.
Go to Step 7

checking circuits Passenger pretensioner High and
Passenger Pretensioner Low, and SRS control unit
connector terminal 44 and 43 to locate the root cause.
Was a fault found?
Replace SRS
harness or repair
chassis harness.
Go to Step 7
Go to Chart A

properly mounted.
Repeat the SRS

Diagnostic System
Check
Go to Step 7
DTC B0058 (Flash Code 58) Passenger Pretensioner Squib Circuit High
Resistance
RTW49JLF000101
Circuit Description
Passenger Pretensioner Low terminal 43 is
grounded through a resister and the passenger current
source connected to Passenger Pretensioner High

Pretensioner Low the SRS control unit calculates the
combined resistance of the passenger pretensioner
assembly, harness wiring circuits Passenger
Pretensioner High and Passenger Pretensioner Low
DTC Will Set When
Diagnostic Aids
The combined resistance of the passenger air

pretensioner assembly, harness wiring circuits
Pretensioner Low, and connector terminal contact is
above a specified value. This test is run once each
ignition cycle during the Resistance Measurement
Test when:
ON,

connection at the passenger pretensioner assembly
harness connector terminals 1 and 2, SRS control
unit terminal 44 and 43, or a poor wire to terminal
connection in circuits Passenger Pretensioner High
and Passenger Pretensioner Low. This test for this
Action Taken
DTC Will Clear When


diagnostic chart:
connector.
of the yellow connector terminals.
5. The test checks for a malfunctioning passenger
pretensioner assembly.
DTC B0058 (Flash Code 58) Passenger Pretensioner Squib Circuit High Resistance
Step
Action
Yes
No
Was the SRS Diagnostic System Check Performed?
Go to Step 2
Go to The SRS
Diagnostic System
Check
1. Check the passenger pretensioner circuit for open.

Verify repair
Go to Step 3

located at the base of the passenger seat.
Go to Step 4
Seat passenger
pretensioner
assembly yellow
connector
properly.
Go to Step 7
1. Disconnect and inspect the passenger pretensioner assembly

2. If ok, reconnect the passenger pretensioner assembly
connector.
Go to Step 5
Go to Step 7

2. Disconnect passenger pretensioner assembly, yellow
connector located at the base of the passenger seat.
3. Connect 5-8840-2421-0 SRS driver / passenger load tool and
appropriate adapters to passenger pretensioner assembly
harness connectors.
Go to Step 6
Ignition switch
Off.
Replace the
passenger
pretensioner
assembly.
Go to Step 7

2. There has been an increase in the total circuit resistance of
the passenger loop.
checking circuits Pasenger Pretensioner High and
Passenger Pretensioner Low,
and SRS control unit
connector terminal 44 and 43 to locate the root cause.
Was a fault found?
Replace SRS
harness or repair
chassis harness.
Go to Step 7
Go to Chart A
1. Reconnect all components ensure all component are properly Repeat the SRS
Diagnostic System
mounted.
Check
Was This step finished?
Go to Step 7
Range/Performance
RTW49JLF000101
Circuit Description
DTC Will Set When

Ignition 1, and pretensioner loop voltages are
The SRS control unit monitors the voltages at Driver
Pretensioner Low terminal 41 and Passenger
Pretensioner Low terminal 43 to detect short to
ground/+B in the pretensioner assembly circuits.
Neither of the air bag and the pretensioner are belt

open. Ignition 1 is within the normal operating voltage
range. Once these conditions are met and the voltage
at Passenger Pretensioner Low is out of a specified
value, DTC B0059 will set. This test is run once each
ignition cycle and Continuous Monitoring.
Action Taken
DTC Will Clear When
Diagnostic Aids
This malfunction is no longer occurring and the ignition

switch is turned OFF.

to ground/+B in the passenger pretensioner assembly
circuit. Inspect circuits Passenger Pretensioner High
and Passenger Pretensioner Low carefully for cutting
or chafing. If the wiring pigtail of the passenger
pretensioner assembly is damaged, the component
must be replaced. A careful inspection of Passenger
Pretensioner High and Passenger Pretensioner Low,
including the passenger pretensioner assembly pgtail is
essential to ensure that the replacement SRS control
unit will not be damaged.

diagnostic chart.
malfunctioning.
passenger pretensioner assembly yellow connector
at the base of the passenger seat.
Passenger Pretensioner High circuit.
Passenger Pretensioner Low circuit.
Range/Performance
Step
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check
4. Check the passenger pretensioner air bag squib circuit for
short to voltage, short to ground and open.
Go to Step 3

2. Disconnect passenger pretensioner assembly yellow
connector at the base of the passenger seat.
3. Leave driver air bag assembly connected.
appropriate adapter to passenger air bag assembly harness
connector.
Go to Step 4
Ignition switch
OFF.
Replace
passenger
pretensioner
assembly .
Go to Step 8

2. Disconnect SRS driver / passenger load tool
from terminal 44 to terminal 40 (ground).
Go to Step 5
Replace SRS
Harness.
Go to Step 8

Go to Step 6
Replace SRS
Harness.
Go to Step 8

Step
Action
Yes
No

Go to Step 7
Replace SRS
Harness.
Go to Step 8

7

Go to Chart A
Go to Step 8

8
1. Reconnect all components and ensure all component are

properly mounted.
Replace SRS
Harness.
Go to the SRS
Diagnostic system
Check
Go to Step 8
DTC B0064 (Flash Code 64) Driver Pretensioner Squib Circuit Low Resistance
RTW49JLF000101
Circuit Description

Resistance Measurement Test Driver Pretensioner
Low terminal 41 is grounded through a current sink
and the driver current source connected to Driver
Pretensioner High terminal 42 allows a known
difference between Driver Pretensioner High and
Driver Pretensioner Low the SRS control unit
calculates the combined resistance of the driver
pretensioner assembly, harness wiring circuits Driver
Pretensioner High and Driver Pretensioner Low and
DTC Will Set When
Diagnostic Aids
The combined resistance of the driver pretensioner

assembly, harness wiring circuits Driver Pretensioner
High and Driver Pretensioner Low, and connector
terminal contact is above a specified value. This test is
ON

between circuit Driver Pretensioner High or Driver
Pretensioner Low or a malfunctioning shorting clip on
the driver pretensioner assembly which would require
replacement of the component. The test for this
Action Taken
DTC Will Clear When


diagnostic chart:
connector at the base of the driver seat.
4. This test checks for proper operation of the shorting
base of the driver seat.
to shortening in the wiring.
the driver pretensionerassembly.
DTC B0064 (Flash Code 64) Driver Pretensioner Squib Circuit Low Resistance
Step
Action
Yes
No

Go to Step 2
Go to the SRS
Diagnostic System
Check
1. Check the driver pretensioner squib circuit for short to voltage

or short to ground.
Verify repair
Go to Step 3

2. Make sure the pretensioner assembly yellow connector
located at the base of the driver seat connected properly.
Go to Step 4
Seat driver
pretensioner
assembly
connector
properly.
Go to Step 8

Step
Action
Yes
No
1. Disconnect and inspect the pretensioner yellow connector

located base of the driver seat.
2. If ok, reconnect the Pretensioner assembly yellow connector.
Go to Step 5
Go to Step 8

2. Disconnect deive pretensioner assembly, yellow connector
located at the base of the driver seat.
appropriate adapter to drive pretensioner assembly harness
connectors.
Go to Step 6
Go to Step 7

checking circuits Driver Pretensioner High and Driver
Pretensioner Low, and SRS control unit connector terminal
42 and 41 to locate the root cause.
Was a fault found?
Replace SRS
harness or repair
chassis harness.
Go to Step 8
Go to Chart A

2. Disconnect SRS driver / passenger load tool from driver
pretensioner assembly harness connector.
3. Connect SRS driver / passenger load tool 5-8840-2421-0 to
the top of steering column connector.
4. Reconnect pretensioner harness connector as the base of the
driver seat.
Ignition switch
off.
Replace SRS coil
assembly.
Go to Step 8
Ignition switch
OFF.
Replace driver
pretensioner
assembly.
Go to Step 8

properly mounted.
Go to the SRS
Diagnostic System
Check
Go to Step 8
DTC B0065 (Flash Code 65) Driver Pretensioner Squib Circuit High
Resistance
RTW49JLF000101
Circuit Description

Resistance Measurement Test Driver Pretensioner
Low terminal 41 is grounded through a current sink
and the driver current source connected to Driver
Pretensioner High terminal 42 allows a known
difference between Driver Pretensioner High and
Driver Pretensioner Low, the SRS control unit
calculates the combined resistance of the driver
pretensioner assembly, SRS coil assembly, harness
wiring circuits Driver Pretensioner High and Driver
Pretensioner Low and connector terminal contact.
DTC Will Clear When
Diagnostic Aids

connection at the drive pretensioner harness connector
terminals 1 and 2, SRS control unit terminals 42
and 41, or a poor wire to terminal connection in circuit
Driver Pretensioner High or Driver Pretensioner Low
The test for this diagnostic trouble code is only run while
the AIR BAG warning lamp is performing the bulb
check. When a scan tool Clear Codes command is
issued and the malfunction is still present, the DTC will
not reappear until the next ignition cycle.
DTC Will Set When

The combined resistance of the driver pretensioner
assembly, harness wiring circuits Driver Pretensioner
High and Driver Pretensioner Low, and connector
ON
Action Taken

diagnostic chart:
connector at the base of the driver seat.
of the connector terminals at the base of the driver
seat.
the driver pretensioner assembly.
DTC B0065 (Flash Code 65) Driver Pretensioner Squib Circuit High Resistance
Step
Action
Yes
No

Go to Step 2
Repeat the SRS

Diagnostic System
Check
1. Check the driver pretensioner squib circuit for open.

2. If the problem found repair as necessary.
Verify repair
Go to Step 3

Go to Step 4
Seat pretensioner
assembly
connector
properly.
Go to Step 8

Step
Action
Yes
No
1. Disconnect and inspect the pretensioner assembly yellow

connector located base of the driver seat.
2. If ok, reconnect the pretensioner yellow connector.
Go to Step 5
Go to Step 8

2. Disconnect diver pretensioner assembly, yellow connector
located at the base of driver seat.
appropriate adapter to driver pretensioner assembly harness
connectors.
Go to Step 6
Go to Step 7

2. There has been a increase in the total circuit resistance of the
driver deployment loop.
checking circuits Driver Pretensioner High and Driver
Pretensioner Low, and SRS control unit connector terminal
42 and 41 to locate the root cause.
Was a fault found?
Replace
pretensioner
harness.
Go to Step 8
Go to Chart A

2. Disconnect pretensioner load tool from pretensioner
assembly harness connector.
3. Connect pretensioner load tool
5-8840-2421-0 and
connector.
driver seat.
Ignition switch
OFF.
Replace
pretensioner
assembly.
Go to Step 8
Ignition switch
OFF.
Replace driver
pretensioner
assembly.
Go to Step 8
1. Reconnect all components ensure all component are

properly mounted.
Repeat the SRS

Diagnostic System
Check
Go to Step 8
DTC B0066 (Flash Code 66) Driver Pretensioner Squib Circuit Voltage
Range/Performance
RTW49JLF000101
Circuit Description
DTC Will Set When

The SRS control unit monitors the voltage at Driver
Pretensioner Low terminal 41 and Passenger
Pretensioner Low terminal 43 to detect shorts to
ground/+B in the air bag assembly circuits.
Neither of the pretensioner is open.

This test is run once each ignition cycle and
Continuous Monitoring. Once these conditions are met
and the voltage at Driver Pretensioner Low is out of a
specified value, DTC B0066 will set.
Action Taken
DTC Will Clear When
Diagnostic Aids
The malfunction is no longer occurring and the ignition

is turned OFF.

to ground/+B in the driver pretensioner circuit. Inspect
circuits Driver Pretensioner High and Driver
Pretensioner Low carefully for cutting or chafing.

diagnostic chart:
malfunctioning
pretensioner assembly yellow connector at the base
of the driver seat.
Driver Pretensioner High circuit.
Driver Pretensioner Low circuit.
Driver Pretensioner High circuit.
Driver Pretensioner Low circuit.
the driver pretensioner assembly.
DTC B0066 (Flash Code 66) Driver Pretensioner Squib Circuit Voltage Range/Performance
Step
Action
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check
4. Check the driver pretensioner squib circuit for short to
voltage, short to ground and open.
Verify repair
Go to Step 3

2. Disconnect pretensioner yellow connector located at base of
the driver seat. leave passenger pretensioner assembly
connected.
appropriate adapter to pretensioner harness connector.
4. ignition switch ON.
Go to Step 4
Go to Step 8

3. Disconnect SRS driver / passenger load tool.
42 to terminal 40 (ground).
Go to Step 5
Replace SRS
harness or repair
chassis harness.
Go to Step 9

Step
Action
Yes
No

Go to Step 6
Replace SRS
harness.
Go to Step 9

Go to Step 7
Replace SRS
harness or repair
chassis harness.
Go to Step 9

Go to Chart A

2. Disconnect SRS driver / passenger load tool 5-8840-2421-0
from pretensioner assembly harness connector.
connector.
driver seat.
Replace SRS
harness or repair
chassis harness.
Go to Step 9
Ignition switch
OFF.
Replace driver
pretensioner
assembly.
Go to Step 9
Go to the SRS
1. Reconnect all components ensure all component are properly
Diagnostic System
mounted.
Check
Go to Step 9
Go to Step 9
DTC B0670 (Flash Code 63) Airbag Telltale Circuit Malfunction
RTW49JLF000101
Circuit Description
DTC Will Set When
When the ignition switch is turned ON, battery voltage

is applied to the AIR BAG warning lamp and to the
Ignition 1 input terminal 35. The SRS control unit
responds by flashing the AIR BAG warning lamp
seven times. The SRS control unit monitors the lamp
driver output by comparing the output state at SRS
Warning Lamp terminal 39 to the microprocessor
commanded state. When Ignition 1 is in the specified
value, and the output state does not match the
commanded state of the lamp driver for 500
milliseconds, DTC B0670 is set.
Ignition 1 voltage is in the specified value and the

output state at the SRS Warning Lamp terminal does
not match the commanded state of the lamp driver for
500 milliseconds. This test is run every 100
milliseconds during Continuous Monitoring tests and
once per each ignition cycle at the beginning.
Action Taken
SRS control unit attempts to turn ON the AIR BAG
warning lamp and sets a diagnostic trouble code.
DTC Will Clear When


Refer to Charts B and C to diagnose warning lamp
circuit malfunctions.
DTC B0670 (Flash Code 63) Airbag Telltale Circuit Malfunction

Step
Action
1. Malfunctions within the AIR BAG warning lamp circuitry will

set this diagnostic trouble code.
2. These malfunctions are addressed in the SRS Diagnostic
System Check via Chart B and Chart C.
3. Failure to properly perform the SRS Diagnostic System
Check may result in misdiagnosis.
5. Clear SRS diagnostic trouble codes.
Is DTC B0670 set?
Yes
No
Go to Step 2
Go to the SRS
Diagnostic System
Check
Ignition switch
OFF.
Go to Chart A
Repeat the SRS

Diagnostic System
Check
DTC B1000 (Flash Code 72) SDM Internal Fault (SDM=SRS control unit)
RTW49JLF000101
Circuit Description
DTC Will Set When
DTC B1000 is an indication of a potential internal SRS

control unit malfunction and will set if any of the
following conditions are detected:
1) Microprocessor energy reverse time failure.
2) EEPROM read / write failure.
3) ROM check sum.
4) Calibration check sum fault.
5) Inflators reserve voltage low.
6) Inflators electronic sensor active signal not detected
during commanded deployment.
7) QSDD (High-side/Low-side) FET failure.
8) Frontal accelerometer failure.
9) Phase lock loop lost lock.
10) QSDD communication fault.
Any of the above indicated malfunctions are detected by

the SRS control unit. The malfunctions described
above are tested mainly during Continuous Monitoring
and some ones run each ignition cycle.
Action Taken
DTC Will Clear When

SRS control unit is replaced.
DTC B1000 (Flash Code 72) SDM Internal Fault (SDM=SRS control unit)
COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH
COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY.
CAUTION: If DTC B1000 can not clear by Tech2, it is necessary to replace the SRS control unit.
Step
1
Action
Yes
No
Ignition switch
OFF.
Replace SRS
control unit.
Go to the SRS
Diagnostic System
Check
Repeat the SRS

Diagnostic System
Check
No. TFRET-WE-0431
WORKSHOP MANUAL
TF SERIES
CAB
SECTION 10
CAB 10-1
SECTION 10
CAB
TABLE OF CONTENTS
PAGE
Windshield..........................................................................................................................10- 2
Rear Window Assembly ....................................................................................................10- 7
Front Door Assembly ........................................................................................................10- 10
Rear Door Assembly (Crew Cab)......................................................................................10- 20
Instrument Panel................................................................................................................10- 28
Floor Console.....................................................................................................................10- 34
Console Box (Without Floor Console) .............................................................................10- 38
Headlining ..........................................................................................................................10- 39
Interior Trim Panels ........................................................................................................... 10- 44
Fuel Filler Lid Opener Lever/Cable...................................................................................10- 55
Quarter Glass (Extend Cab) ..............................................................................................10- 70
Font Seat ............................................................................................................................10- 71
Rear Seat (Crew Cab) ........................................................................................................10- 74
Jump Seat (Extend Cab) ...................................................................................................10- 75
Front Seat Belt ...................................................................................................................10- 76
Rear Seat Belt (Crew Cab) ................................................................................................10- 80
Rear Seat Belt (Extend Cab) .............................................................................................10- 84
Front Wheel Extension......................................................................................................10- 87
Rear Wheel Extension .......................................................................................................10- 88
Tail Gate Assembly............................................................................................................10- 89
10-2 CAB
WINDSHIELD
REMOVAL
RTW4A0LF000901
Removal Steps
1. Interior trim panels (Front side)
/Headlining/Instrument panel assembly
2. Wiper arm assembly
3. Room mirror
4. Side moulding
5. Vent cowl cover
6. Windshield stopper
7. Upper moulding
8. Windshield glass
9. Engine hood rear seal
CAB 10-3

3. Room Mirror
Remove the screw and pull the room mirror to upper side.
8. Windshield Glass
Remove the windshield glass, carefully following the steps
listed below:
1) Use a knife to cut through part of the adhesive caulking
material.
2) Secure one end of a piece of steel piano wire (0.02 inches
in diameter) to a piece of wood that can serve as a handle.
3) Use a pair of needle nose pliers to insert the other end of
the piano wire through the adhesive caulking material at the
edge of the windshield glass.
4) Secure the other end of the piano wire to another piece of
wood.
5) With the aid of an assistant, carefully move the piano wire
with a sawing motion to cut through the adhesive caulking
material around the entire circumference of the windshield
glass.
6) Lift the windshield from the body.
7) Clean any remaining adhesive caulking material from the
area of the body which holds the windshield.
8) Use a soft rag and unleaded gasoline to wipe off any
adhesive remaining on the windshield glass.
10-4 CAB
INSTALLATION
RTW4A0LF001201
Installation Steps
1. Engine hood rear seal
2. Upper moulding
3. Windshield glass
4. Windshield stopper
5. Vent cowl cover
6. Side moulding
7. Room mirror
8. Wiper arm assembly
9. Interior trim panels (Front side)
/Headlining/Instrument panel assembly
CAB 10-5

1. Engine Hood Rear Seal
Install the engine hood rear seal as shown in the illustration.
1 : Seal
2 : Clip
3 : Rear (windshield glass side)
4 : Front
3. Windshield Glass
1) Clean the windshield glass bonding surface.
adhesive remaining on the body.
3) Mount the body window glass as shown in the illustration.
Attach spacers at five locations.
Always use new spacer.
RTW3A0SH000201
4) Install the windshield upper molding.

Peel off the tear-away paper from the windshield upper
molding, and start applying it with one end of the glass
and cut away the surplus at the other end of the glass
for length adjustment.
Always use new upper molding.
5) Temporary install the windshield support.
6) Apply primer 1 Sunstar #435-98 or equivalent to the body
side bonding surface. The primer should extend at least 25
mm (1 in).
Apply primer Sunstar #435-40 or equivalent to the
windshield glass side bonding surface.
The primer should extend 16.5 mm (0.6 in) and 25 mm (1.0
in) from end of the glass.
10-6 CAB
7) Apply the window glass sealing adhesive 2 .
If you are using an air gun, air pressure should be
maintained at 147 - 294 kpa.
After drying primer completely, apply a sealing adhesive
(Sunstar #557 or equivalent) along the edge of the glass so
that the sealing adhesive has a 20 mm (0.79 in) junction at
middle of the vase of the glass.
Note :
Open time (1 min. or more) should be set after application
of the primer.
Bonding shall be done within 5 minutes after the sealing
adhesive has been applied.
8) Adjust the setting of the windshield glass with suction discs.

Set the windshield with sealing adhesive applied to entire
circumference in the body panel. Specifically, adjust
windshield support with the upper molding making contact
with the body panel, press the glass, and tighten the
windshield support.
9) Use unleaded gasoline and a soft cloth to wipe away any

excess adhesive.
Cure the bonding at a temperature of 68 - 86F (20 30C) for twenty-four hours.
Check that the windshield does not leak water.
8. Wiper Arm Assembly
Set the wiper arm/blade so that the tips of both blades
are positioned the specified value of A and B from the
upper edge of the cowl cover as shown in the figure.
A
40 mm (1.57 in)
52 mm (2.05 in)
Tighten the wiper arm assembly fixing nuts to the

specified torque.
Torque
Nm (kgfm/lbft)
31 (3.1/23)
CAB 10-7
REAR WINDOW ASSEMBLY

REMOVE AND INSTALLATION
Removal Steps
Installation Steps
1. Interior trim panels/Headlining

2. Rear defogger connector (W/Rear
defogger)
3. Rear window
3. Rear window
2. Rear defogger connector (W/Rear
defogger)
1. Interior trim panels/Headlining
10-8 CAB

3. Rear Window Glass
Remove the glass, carefully following the steps listed below :
1) Use a knife to cut through part of the adhesive caulking
material.
2) Secure one end of a piece of steel piano wire (0.02 inches
in diameter) to a piece of wood that can serve as a handle.
3) Use a pair of needle nose pliers to insert the other end of
the piano wire through the adhesive caulking material at the
edge of the rear window glass.
4) Secure the other end of the piano wire to another piece of
wood.
5) With the aid of an assistant, carefully move the piano wire
with a sawing motion to cut through the adhesive caulking
material around the entire circumference of the rear window
glass.
6) Lift the rear window glass from the body.
7) Clean any remaining adhesive caulking material from the
area of the body which holds the rear window glass.
adhesive remaining on the rear window glass.

3. Rear Window Glass
1) Clean the rear window glass bonding surface.
adhesive remaining on the body.
3) Install the fastener tape to body panel flange.
4) Apply primer 1 sunster #435-40 or equivalent to the rear
window glass side bonding surface.
The primer should extend 23 mm (0.9 in.) form end of the
glass.
CAB 10-9
5) Apply the rear window glass seling adhesive 2 .
If you are using an air gun, air pressure should be
maintained at 147 294 kpa.
After drying primer completely, apply a sealing adhesive
(Sunstar #557 or equivalent) along the edge of the glass so
that the sealing adhesive has a 20 mm (0.79 in.) junction at
left corner of the base of the glass.
Note:
Open time (1 min. or more) should be set after application
of the primer.
Bonding shall be done within 5 minutes after the sealing
adhesive has been applied.
6) Insert the glass supports into the panel and then push the
glass against the panel to affix it in place.
Wipe away any adhesive that oozes out around the edges.
7) Check that the rear window glass does not leak water.
10-10 CAB
FRONT DOOR ASSEMBLY

Removal Steps
Installation Steps
1. Door harness
2. Checker arm screw
3. Lower hinge bolt
4. Upper hinge bolt
5. Door assembly
5. Door assembly
4. Upper hinge bolt
3. Lower hinge bolt
2. Check arm screw
1. Door harness

1. Door Harness
Remove the harness bracket and disconnect the door
harness connectors.
CAB 10-11
2. Check Arm Screw
3. Lower Hinge Bolt

Position a wood block under the door for protection and
support the door assembly with hands at removal or
installation.

3. Lower Hinge Bolt; Hinge to Door
Torque
Nm (kgfm/lbft)
34 (3.5/25)
2. Check Arm Screw; Check Arm to Body
Torque
24 (2.4/17)
Nm (kgfm/lbft)
10-12 CAB
DISASSEMBLY

RTW4A0LF000701
Disassembly Steps
1. Switch bezel/Window regulator handle
2. Power window switch
3. Bezel
4. Door mirror cover
5. Door trim panel
6. Tweeter (Required Option)
7. Door mirror assembly
8. Outer waste seal
9. Bracket
10. Speaker assembly
11. Waterproof sheet
12. Inside lever
13. Window glass
14. Window regulator/Power window

regulator
15. Glass run
16. Glass run rear channel / Glass ran rear
channel with Door lock control or Anti
theft (EC)
17. Door lock assembly/Door lock assembly
with super lock
18. Outside handle protector (EUROPE)
19. Outside handle
20. Door lock cylinder protector (EUROPE)
21. Door lock cylinder / Door lock cylinder
with door lock switch (EC)
22. Door harness assembly
23. Anti rattler
CAB 10-13
1. Switch Bezel/Window Regulator Handle
Remove the 2 screws and disconnect the connectors.
To remove the regulator handle, remove the clip at the

root of the handle by using wire.
2. Power Window Switch

Remove the 3 screws.
3. Bezel
Remove the screw.
4. Door Mirror Cover

Pull out the upper clip, and then take out the cover
upward.
5. Door Trim Panel
Pull out the trim panel at the 8 clip positions (Power
window type).
10-14 CAB
Remove the 2 screws and pull out the trim panel at the 8
clip positions (Window regulator handle type).
6. Tweeter (Required option)

Disconnect the tweeter harness connector and remove
the 3 screws.
RTW3A0SH000701
7. Door Mirror Assembly

Remove 3 fixing bolts and then remove the connector.
8. Outer Waste Seal
9. Bracket
10.Speaker Assembly
Remove the fixing screw and then remove the
connector.
11.Waterproof Sheet
Take care not to damage the sheet when peeling it off.
12.Inside Lever
Disconnect the door lock cables.
CAB 10-15
13.Window Glass
Remove 2 bolts through the access hole and pull out the
window glass upward.
14.Window Regulator/Power Window Regulator
Remove the 4 fixing bolts and the 2 fixing nuts.
Disconnect the power window motor connector.
15.Glass Run
Pull it out from the door frame of the channel.
16.Glass Run Rear Channel
Remove the bolt.
Bolt is removed after removing door lock cylinder switch
harness. (Expect EC)
17.Door Lock Assembly

Disconnect the lock cable from the anti rattler.
Remove the 3 fixing screws and the bolt.
Disconnect the linkage at the outside handle and the
lock cylinder.
Disconnect the harness connector.
18.Outside Handle Protector (EUROPE)

Remove the fixing bolt from the outside handle.
19.Outside Handle
20.Door Lock Cylinder Protector (EUROPE)
Remove the fixing bolt from the outside handle.
21.Door Lock Cylinder
Remove the 2 fixing bolts from the outside handle.
10-16 CAB
REASSEMBLY

RTW4A0LF000801
Reassembly Steps
1. Anti rattler
3. Door lock cylinder / Door lock cylinder
with door lock switch (EC)
4. Door lock cylinder protector (EUROPE)
5. Outside handle
6. Outside handle protector (EUROPE)
7. Door lock assembly / Door lock
assembly with super lock
8. Glass run rear channel / Glass ran rear
channel with Door lock control or Anti
theft (EC)
9. Glass run
10. Window regulator / Power window
regulator
11. Window glass

12. Inside lever
15. Bracket
16. Outer waste seal
17. Door mirror assembly
18. Tweeter (Required option)
19. Door trim panel
20. Door mirror cover
21. Bezel
23. Switch bezel / Window regulator handle
CAB 10-17
3. Door Lock Cylinder
Tighten the door lock cylinder fixing bolts to the specified
torque.
Torque
Nm (kgfm/lbin)
9 (0.9/78)
4. Door Lock Cylinder Protector (EUROPE)

Tighten the door lock cylinder protector fixing bolt to the
specified torque.
Torque
Nm (kgfm/lbin)
9 (0.9/78)
5. Outside Handle
Tighten the outside handle fixing bolts to the specified
torque.
Torque
Nm (kgfm/lbin)
9 (0.9/78)
6. Outside Handle Protector (EUROPE)

Tighten the outside handle protector fixing bolt to the
specified torque.
Torque
Nm (kgfm/lbin)
9 (0.9/78)
11.Window Glass
Insert the window glass into position by tilting it as
necessary, then set it against the channel of the window
regulator.
Attach the window glass to the window regulator with the

2 bolts.
10-18 CAB
23.Window Regulator Handle
Install the regulator handle as illustrated when closing
the window glass.
CAB 10-19
ADJUSTMENT (FRONT)
Door Hinge
Door alignment can be obtained by moving door hinges.
Prior to adjustment, remove the fender and set the door
temporarily.
Loosen hinge to door bolts when adjusting steps between the
door and body.
Loosen hinge to body bolts to adjust the clearance between the
door and body.
Door Striker
Loosen the striker screws and adjust the position of the striker
by holding a piece of wood against the striker and tapping it
with a hammer.
To obtain correct adjustment, move the position of the striker
vertically so that the lower face of the dovetail becomes parallel
to the striker.
10-20 CAB
REAR DOOR ASSEMBLY (CREW CAB)

Removal Steps
Installation Steps
1. Door harness
2. Checker arm screw
3. Lower hinge bolt
4. Upper hinge bolt
5. Door assembly
5. Door assembly
4. Upper hinge bolt
3. Lower hinge bolt
2. Check arm screw
1. Door harness

1. Door Harness
Remove the center pillar lower trim cover and disconnect
the door harness connector.
2. Check Arm Screw
CAB 10-21
3. Lower Hinge Bolt
Position a wood block under the door for protection and
support the door assembly with hands at removal or
installation.

3. Lower Hinge Bolt; Hinge to Door
Torque
Nm (kgfm/lbft)
34 (3.5/25)
2. Check Arm Screw; Check Arm to Body
Torque
24 (2.4/17)
Nm (kgfm/lbft)
10-22 CAB
DISASSEMBLY
RTW3A0LF000601
Disassembly Steps

3. Bezel
4. Door trim panel
5. Bracket
6. Speaker assembly
7. Waterproof sheet
8. Inside lever
9. Outer waste seal

regulator
11. Glass run rear channel
12. Door lock assembly
13. Glass run
14. Window glass
15. Outside handle
17. Anti rattler
CAB 10-23
1. Switch Bezel/Window Regulator Handle
Remove the 2 screws and disconnect the connector.
RTW3A0SH000401
To remove the regulator handle, remove the clip at the

root of the handle by using wire.
2. Power Window Switch

Pry the 4 clip positions.
3. Bezel
Remove the screw.
4. Door Trim Panel
Pull out the trim panel at the 7 clip positions (Power
window type).
RTQ3A0SH000501
Remove the 2 screws and pull out the trim panel at the 7
clip positions (Window regulator handle type).
10-24 CAB
5. Bracket
6. Speaker assembly
Remove the fixing bolt and then remove the connector.
7. Waterproof Sheet
Take care not to damage the sheet when peeling it off.
8. Inside Lever
Disconnect the door lock cables.
9. Outer Waste Seal
10.Window Regulator/Power Window Regulator
Remove the 2 bolts fixing the window glass through the
access hole.
Move the window glass upward and hold it with adhesive
tape.
Remove the 5 bolts fixing the window regulator.
Disconnect the power window motor connector.
11.Glass Run Rear Channel
Remove the bolt.
12.Door Lock Assembly
Disconnect the lock cable from the anti rattler.
Remove the 3 fixing screws and the bolt.
Disconnect the linkage and harness connector.
13.Glass Run
Remove the adhesive tape and move the window glass
downward.
Pull it out from the door frame of the channel.
14.Window Glass
Pull out the window glass upward.
15.Outside Handle
Remove the 2 fixing bolts.
CAB 10-25
REASSEMBLY
RTW3A0LF000701
Reassembly Steps
1. Anti rattler
3. Outside handle
4. Window glass
5. Glass run
6. Door lock assembly
7. Glass run rear channel
regulator
9. Outer waste seal

10. Inside lever
13. Bracket
14. Door trim panel
15. Bezel
10-26 CAB
3. Outside Handle
Tighten the outside handle fixing bolts to the specified
torque.
Torque
Nm (kgfm/lbin)
9 (0.9/78)
17.Window Regulator Handle

Install the regulator handle as illustrated when closing
the window glass.
CAB 10-27
ADJUSTMENT (REAR)
Door Hinge
Door alignment can be obtained by moving door hinges.
Prior to adjustment, set the door temporarily.
Loosen hinge to door bolts when adjusting steps between the
door and body.
Loosen hinge to body bolts to adjust the clearance between the
door and body.
Door Striker
Loosen the striker screws and adjust the position of the striker
by holding a piece of wood against the striker and tapping it
with a hammer.
To obtain correct adjustment, move the position of the striker
vertically so that the lower face of the dovetail becomes parallel
to the striker.
10-28 CAB
INSTRUMENT PANEL
REMOVAL

RTW4A0LF001001
Disassembly Steps
1. Front console assembly
2. Glove box
assembly
4. Driver knee bolster assembly
5. Driver air bag
6. Steering wheel/ steering cowl
7. Meter cluster assembly
8. Dash side trim cover
9. Front pillar trim cover
10. Front cover
11. Side cover
12. Instrument panel & Cross beam
assembly
13. Ashtray case

14. Center cluster assembly
16. Storage box assembly
17. Ashtray bracket
18. Meter assembly
20. Glove box cover
21. Passenger air bag (if so equipped)
22. Side ventilation grille
23. Vent duct assembly/Defroster nozzle
assembly
24. Instrument harness assembly
25. Instrument panel
26. Cross beam
CAB 10-29
1. Front Console Assembly
Refer to Floor Consol in this section.
2. Glove Box
Remove 2 fixing screws and pulling the handle.
3. Instrument Panel Driver Lower Cover Assembly

1) Remove the engine hood opener 2 fixing screws.
2) Remove the lower cover one fixing screw.
3) Pull out the cover (Stick type parking brake only).
4) Pull out the lower cover assembly.
4. Driver Knee Bolster Assembly

Remove 4 fixing bolts.
Caution:
For precaution on installation or removal of SRS-air bag
system, refer to section 9 Supplemental Restraint System
(SRS) - AIR BAG
5. Driver Air Bag
6. Steering Wheel/Steering Cowl
Refer to Section 3B STEERING COLUMN for steering
lock assembly removal steps.
7. Meter Cluster Assembly
Pull out the 4 clip positions.
10-30 CAB
12.Instrument Panel & Cross Beam Assembly
1) Remove the two bolts fixing the steering column to the
cross beam and the two bolts fixing the brake pedal
bracket to the cross beam.
2) Remove the two bolts fixing the parking brake bracket to

the cross beam (Stick type parking brake only).
3) Disconnect the control cables at the blower unit and

heater unit.
Remove the front & side cover from the instrument
panel.
4) Remove the fasteners fixing the instrument panel &
cross beam assembly to the body panel.
5) Disconnect the instrument harness connectors.
CAB 10-31
13.Ashtray Case
Pull out the ashtray case.
14.Center Cluster Assembly
1) Pull out the cluster at the 6 clip positions.
2) Disconnect the cigarette lighter, accessory socket,
hazard switch and clock connectors.
15.Control Lever Assembly
Remove the 2 fixing screws.
17.Ashtray Bracket
Remove the 3 fixing screws and illumination connector.
Caution:
For precautions on installation or removal of SRS-air bag
system, refer to section 9 "Supplemental Restraint System
(SRS) - AIR BAG".
21.Passenger Air Bag
Remove 2 fixing bolts, 2 fixing nuts and connector.
22.Side Ventilation Grille.
Pull out the grilles and disconnect switch connector
(Drivers side).
23.Vent Duct Assembly/Defroster Nozzle Assembly
Refer to section 1 HVAC for defroster nozzle and
ventilation duct removal steps.
25.Instrument Panel
Remove the clip and 6 fixing bolts.
26.Cross Beam
10-32 CAB
INSTALLATION

RTW4A0LF001101
Installation Steps
1. Cross beam
2. Instrument panel
3. Instrument harness assembly
4. Vent duct assembly/Defroster nozzle
assembly
5. Side ventilation grille
6. Passenger air bag
7. Glove box cover
9. Meter assembly
10. Ashtray bracket
11. Storage box assembly
13. Center cluster assembly
14. Ashtray case

15. Instrument panel & Cross beam
assembly
16. Side cover
17. Front cover
20. Meter cluster assembly
21. Steering wheel/Steering cowl
22. Driver air bag
23. Driver knee bolster assembly
assembly
25. Glove box
26. Front console assembly
CAB 10-33
15.Instrument Panel & Crass Beam Assembly
1) Tighten the 4 bolts fixing the cross beam and body panel
Torque
Nm (kgfm/lbft)
19 (1.9/14)
2) A Bolt: Steering Column to Cross Beam
Torque
Nm (kgfm/lbft)
20 (2.0/14)
B Bolt: Pedal Bracket to Cross Beam
Torque
Nm (kgfm/lbft)
15 (1.5/11)
3) C Bolt: Parking Brake Bracket to Cross Beam

Torque
Nm (kgfm/lbft)
15 (1.5/11)
21.Steering Wheel/Steering Cowl

Tighten the steering wheel fixing nut to the specified
truque.
Torque
Nm (kgfm/lbft)
35 (3.6/26)
10-34 CAB
FLOOR CONSOLE
745R300001
A/T Model
Removal Steps
1. Rear floor console (Bucket seat model
only)
2. Front floor console
3. A/T switch
Installation Steps
3. A/T switch
only)
CAB 10-35

1. Rear Floor Console (Bucket Seat Model Only)
1) Open the rear console lid and remove 2 screws.
2) Pull out the front part of rear console at the 2 clip
positions.
2. Front Floor Console
1) Remove the 2 screws.
2) Pull out the rear part of front console at the 2 clip
positions and disconnect the switch connecter.
3) Remove the front console by pull out it rear ward.
10-36 CAB
745r300002
M/T Model
Removal Steps
only)
2. Shift knob
Installation Steps
2. Shift knob
only)
CAB 10-37

1. Rear Floor Console (Bucket Seat Model Only)
1) Open the rear console lid and remove 2 screws.
2) Pull out the front part of rear console at the 2 clip
positions.
3. Front Floor Console
1) Remove the 2 screws.
2) Pull out the rear part of front console at the 2 clip
positions.
3) Remove the front console by pull out it rear ward.
10-38 CAB
CONSOLE BOX (WITHOUT FLOOR CONSOLE)

RTW4A0MF000201
M/T Model
Removal Steps
1. Screw
2. Console box
Installation Steps
2. Console box
1. Screw
CAB 10-39
HEADLINING
EXTEND CAB Model
Removal Steps
1. Interior trim panels

2. Sunvisor/Sunvisor holder
3. Spot light
4. Assist grip
5. Hole cover
6. Coat hook
7. Dome light
8. Headlining
Installation Steps
8. Headlining
7. Dome light
6. Coat hook
5. Hole cover
4. Assist grip
3. Spot light
10-40 CAB

RTW3A0LF001101
REGULAR CAB Model
Removal Steps
4. Assist grip
5. Hole cover
7. Dome light
8. Headlining
Installation Steps
8. Headlining
7. Dome light
5. Hole cover
4. Assist grip
CAB 10-41

RTW3A0LF001001
CREW CAB Model
Removal Steps

3. Spot light
4. Assist grip
5. Hole cover
6. Coat hook
7. Dome light
8. Headlining
Installation Steps
8. Headlining
7. Dome light
6. Coat hook
5. Hole cover
4. Assist grip
3. Spot light
10-42 CAB

1. Interior Trim Panels
Refer to Interior Trim Panels in this section.
2. Sunvisor/Sunvisor Holder
1) Remove the 2 screws fixing the sunvisor.
2) Remove the screw fixing the sunvisor holder.
3. Spot Light
Pull out the spot light and disconnect the connector.
4. Assist Grip
Remove the 2 fixing screw.
6. Coat Hook
Open the cover and remove the fixing screw.
7. Dome Light
1) Remove the dome light lens and the fixing screws.
2) Disconnect the dome light connector.
CAB 10-43
8. Headlining
Pull out the headlining with the retainer from roof rear
header panel as direction of shown in the illustration.
Note :
Remove steps (2-7) can be removed from the headlining in
any order.
10-44 CAB
INTERIOR TRIM PANELS

RTW3A0MF001301
EXTEND CAB Model
Removal Steps
Installation Steps
1. Sill plate
4. Rear upper cushion
5. Jack cover
6. Rear end trim cover
7. Rear speaker grille/Rear speaker
8. Body side rear lower trim cover
9. Door finisher
10. Tongue side seat belt
11. Body side rear upper trim cover

10. Torque side seat belt
9. Door finisher
7. Rear speaker grille/Rear speaker
5. Jack cover
4. Rear upper cushion
3. Front pillar trim assembly
1. Sill plate
CAB 10-45

3. Front Pillar Trim Cover
Turn up the finisher and pry the trim cover clips free
from the body panel.
Then remove the trim cover by pulling upward at the
lower part of it.
4. Rear Upper Cushion

Slide the upper cushion upward to remove it.
6. Rear End Trim Cover
Pry the trim cover clips free from the body panel, and
slide the trim cover upward to remove it.
7. Rear Speaker Grille/Rear Speaker

1) Remove the rear speaker grille (1).
2) Remove the 3 screws fixing the rear speaker (2) and
disconnect the connector (3).
8. Body Side Rear Lower Trim Cover

Pry the trim cover clips free from the body panel.
10-46 CAB
10. Tongue Side Seat Belt
1) Pull out the adjuster knob.
2) Open the through ring anchor cover and remove the
seat belt upper anchor bolt.
RTW3A0SH000301
11. Body Side Rear Upper Trim Cover

CAB 10-47

Tighten the seat belt upper anchor bolt to the specified
torque.
Torque
Nm (kgfm/lbft)
40 (4.1/30)

Insert the hooks on the back upper portion of trim cover
to the body panel.
10-48 CAB
RTW40MF000301
REGULAR CAB Model
Removal Steps
1. Sill plate
4. Door finisher
Installation Steps
4. Door finisher
1. Sill plate
CAB 10-49


Then remove the trim cover by pulling upward at the
lower part of it.


RTW3A0SH000301
10-50 CAB
8. Body Side Rear Upper Trim Cover

torque.
Torque
Nm (kgfm/lbft)
40 (4.1/30)

to the body panel.
CAB 10-51
RTW4A0MF000401
CREW CAB Model
Removal Steps
Installation Steps
1. Front sill plate/Rear sill plate

4. Center pillar lower trim cover
5. Front door finisher
6. Cover
9. Rear door finisher
10. Front tongue side seat belt
11. Center pillar upper trim cover
12. Rear tongue side seat belt

12. Rear tongue side seat belt
11. Center pillar upper trim cover
10. Front tongue side seat belt
9 Rear door finisher
6. Cover
5. Front door finisher
1. Front sill plate/Rear sill plate
10-52 CAB

1. Front Sill Plate/Rear Sill Plate
Pull out the 4 clip positions (Front).
Pull out the 2 clip positions (Rear).

Then remove the trim cover by pulling upward a the
lower part of it.
4. Center Pillar Lower Trim Cover

Pry the trim cover lips free from the body panel.


10.Front Tongue Side Seat Belt
CAB 10-53
RTW3A0SH000301
11.Center Pillar Upper Trim Cover

13.Body Side Rear Upper Trim Cover


12. Rear Tongue Side Seat Belt
torque.
Torque
Nm (kgfm/lbft)
40 (4.1/30)
10-54 CAB
10. Front Tongue Side Seat Belt
torque.
Torque
Nm (kgfm/lbft)
40 (4.1/30)

to the body panel.
CAB 10-55
FUEL FILLER LID OPENER LEVER/CABLE

REMOVAL (REGULAR CAB RHD MODEL)
686R300015
Removal Steps
1. Front sill plate
2. Fuel filler lid opener cover
3. Fuel filler lid opener lever
4. Rear wheel housing extension panel
5. Fuel filler lid cable assembly
10-56 CAB

REMOVAL (EXTEND CAB RHD MODEL)
686R300016
Removal Steps
1. Front sill plate
CAB 10-57

REMOVAL (REGULAR CAB LHD MODEL)
RTW4A0LF000101
Removal Steps
1. Front sill plate
10-58 CAB

REMOVAL (EXTEND CAB LHD MODEL)
RTW4A0LF000201
Removal Steps
1. Front sill plate
CAB 10-59

1. Front Sill Plate
2. Fuel Filler Lid Opener Cover

3. Fuel Filler Lid Opener Lever

Remove the 2 opener fixing bolts and disconnect the
cable.
5. Fuel Filler Lid Cable Assembly

Remove some fixing clips, turn the cable holder on the
side of recess in 90 counterclockwise and remove it
from the recess. Pull out the grommet to frontward of
vehicle and remove the cable assembly.
10-60 CAB

REMOVAL (CREW CAB RHD MODEL)
686R300010
Removal Steps
1. Front sill plate
2. Rear sill plate
CAB 10-61

REMOVAL (CREW CAB LHD MODEL)
RTW4A0LF000301
Removal Steps
1. Front sill plate
2. Rear sill plate
10-62 CAB

1. Front Sill Plate
Pull out 4 clip positions.
2. Rear Sill Plate
Pull out 2 clip positions.
4. Fuel Filler Lid Opener Cover

5. Fuel Filler Lid Opener Lever

Remove the 2 opener fixing bolts and disconnect the
cable.

Remove some fixing clips, turn the cable holder on the
side of recess in 90 counterclockwise and remove it
from the recess. Pull out the grommet to frontward of
vehicle and remove the cable assembly.
CAB 10-63
INSTALLATION (REGULAR CAB RHD MODEL)
686R300017
Installation Steps
5. Front sill plate
10-64 CAB
INSTALLATION (EXTEND CAB RHD MODEL)
686R300019
Installation Steps
5. Front sill plate
CAB 10-65
INSTALLATION (CREW CAB RHD MODEL)
686R300013
Installation Steps

6. Rear sill plate
7. Front sill plate
10-66 CAB
INSTALLATION (REGULAR CAB LHD MODEL)
RTW4A0LF000401
Installation Steps
5. Front sill plate
CAB 10-67
INSTALLATION (EXTEND CAB LHD MODEL)
RTW4A0LF000501
Installation Steps
5. Front sill plate
10-68 CAB
INSTALLATION (CREW CAB LHD MODEL)
RTW4A0LF000601
Installation Steps

6. Rear sill plate
7. Front sill plate
CAB 10-69

Install the cable holder of cable assembly to the recess
and push the grommet in to the back panel. Fix the clips
to the pointed places.
Note:
noting the following points.
Do not make extreme curve on the cable.
Install the cable from inside of the cab.
10-70 CAB
QUARTER GLASS (EXTEND CAB)

RTW4A0MF000101
Removal Steps
Installation Steps
1. Body side rear trim covers

2. Hinge/Faster
3. Quarter glass
4. Weather strip
4. Weather strip
3. Quarter glass
2. Hinge/Faster
1. Body side rear trim covers

1. Body Side Rear Trim Covers
Important Operation Installation

4. Weather Strip
Install the weather strip by aligning to corners with white
mark to the upper coners on the body panel.
CAB 10-71
FRONT SEAT
RTW3A0MF000301
Removal Steps
Installation Steps
1. Front cover
2. Rear cover
3. Bolt
4. Seat assembly
5. Side seat belt buckle/Pretensioner seat
belt/Center seat belt
6. Seat adjuster
6. Seat adjuster
4. Seat assembly
3. Bolt
2. Rear cover
1. Front cover
10-72 CAB

1. Front Cover
While pushing the cover downward, pull it.
4. Seat Assembly
Disconnect the seat belt warning harness connector
(Drivers side only).
5. Side Seat Belt Buckle/Pretensioner Seat Belt/Center
Seat Belt
Remove the seat belt fixing screw and the warning
harness connector clip (Bucket seat model).
Remove the pretensioner seat belt fixing screw and the

warning harness connector (With pretensioner seat belt
model).
RTW4A0SH000101-X
Remove the seat belt fixing screws and the warning

harness connector clip (Bench seat model).
24.jpg

5. Buckle Side Seat Belt/Pretensioner Seat Belt/Center
Seat Belt
Tighten the seat belt fixing screws to the specified
torque.
Torque
Nm (kgfm/lbft)
40 (4.1 / 30)
CAB 10-73
3. Bolt: Seat Assembly to Floor Panel
The fixing procedure of a bolt
(1) Front inboard
(2) Front outboard
(3) Rear inboard
(4) Rear inboard
Torque
40 (4.1 / 30)
Nm (kgfm/lbft)
10-74 CAB
REAR SEAT (CREW CAB)

RTW3A0SF000101
Removal Steps
Installation Steps
1. Nut
2. Rear seat assembly
2. Rear seat assembly

1. Nut

1. Nut
Pull the strap to release the seat back lock and fold
down the seat back.

1. Nut
Torque
Nm (kgfm/lbft)
40 (4.1 / 30)
CAB 10-75
JUMP SEAT (EXTEND CAB)

RTW3A0MF001201
Removal Steps
Installation Steps
1. Cover
2. Bolt
3. Jump seat assembly
4. Storage box
4. Storage box
3. Jump seat assembly
2. Bolt
1. Cover

2. Bolt
Bolt Torque
Nm (kgm/lbft)
40 (4.1 / 30)
10-76 CAB
FRONT SEAT BELT

(TONGUE SIDE SEAT BELT)
Removal Steps
Installation Steps

2. Lower anchor bolt
3. Knob
4. Upper anchor bolt
5. Retractor fixing bolt
7. Adjustable shoulder anchor fixing bolts

3. Knob
CAB 10-77

3. Knob
Pull out the knob.
Open the through ring anchor cover and remove the
RTW3A0SH000301

Bolt torque
Nm (kgfm/lbft)
40 (4.1 / 30)
Bolt torque
Nm (kgfm/lbft)
40 (4.1 / 30)

Bolt torque
Nm (kgfm/lbft)
40 (4.1 / 30)

Bolt torque
Nm (kgfm/lbft)
40 (4.1 / 30)
10-78 CAB

(SIDE SEAT BELT BUCKLE/PRETENSIONER SEAT BELT/
CENTER SEAT BELT)
RTW3A0MF000401
Removal Steps
Installation Steps
1. Front seat assembly


1. Front seat assembly
CAB 10-79

1. Front Seat Assembly
Refer to Front Seat in this section.
2. Side Seat Belt Buckle/Pretensioner Seat Belt/Center
Seat Belt
Remove the seat belt fixing screw and the warning
harness connector clip (Bucket seat model).
Remove the pretensioner seat belt fixing screw and the

warning harness connector (With pretensioner seat belt
model).
RTW4A0SH000101-X
Remove the seat belt fixing screws and the warning

harness connector clip (Bench seat model).
24.jpg

2. Side Seat Belt Buckle/Pretensioner Seat Belt /Center
Seat Belt
Tighten the seat belt fixing screws to the specified
torque.
Torque
Nm (kgfm/lbft)
40 (4.1 / 30)
1. Front Seat Assembly

Tighten the seat assembly fixing bolts to the specified
torque.
Torque
Nm (kgfm/lbft)
40 (4.1 / 30)
10-80 CAB
REAR SEAT BELT (CREW CAB)

Removal Steps
Installation Steps

3. Knob

3. Knob
CAB 10-81

3. Knob
Pull out the knob.
RTW3A0SH000301

Bolt torque
Nm (kgfm/lbft)
40 (4.1 / 30)
Bolt torque
Nm (kgfm/lbft)
40 (4.1 / 30)

Bolt torque
Nm (kgfm/lbft)
40 (4.1 / 30)

Bolt torque
Nm (kgfm/lbft)
40 (4.1 / 30)
10-82 CAB

(REAR CENTER SEAT BELT/REAR SEAT BELT BACKLE)
RTW3A0LF000901
Removal Steps
Installation Steps
1. Nut
2. Rear seat belt buckle
3. Cover
5. Bolt
6. Rear center seat belt

5. Bolt
3. Cover
1. Nut
CAB 10-83

3. Cover
Pry the lower portion of the cover and remove it.
RTW3A0SH000601


Install the seat belt webbing through the through ring on
the back panel as shown in the illustration.
RTW3A0SH001601
5. Bolt: Rear Center Seat Belt to Floor Panel

Torque
Nm (kgfm/lbft)
40 (4.1 / 30)
1. Nut: Rear Seat Assembly/Rear Seat Belt Buckle to Floor
Panel
Torque
Nm (kgfm/lbft)
40 (4.1 / 30)
10-84 CAB
REAR SEAT BELT (EXTEND CAB)

RTW3A0MF000701
Removal Steps
Installation Steps


CAB 10-85

Refer to Interior Trim Panels in this section..
seat belt upper anchor bolt
RTW3A0SH000301

Bolt torque
Nm (kgfm/lbft)
40 (4.1 / 30)

Bolt torque
Nm (kgfm/lbft)
40 (4.1 / 30)

Bolt torque
Nm (kgfm/lbft)
40 (4.1 / 30)
10-86 CAB

(REAR SEAT BELT BACKLE)
RTW3A0SF000201
Removal Steps
Installation Steps
1. Cover
2. Bolt

2. Bolt
1. Cover

1. Cover
Refer to Jump Seat (Extend Cab) in this section.
2. Bolt: Jump Seat Assembly/Rear Seat Belt Buckle to

Floor Panel
Torque
Nm (kgfm/lbft)
40 (4.1 / 30)
CAB 10-87
FRONT WHEEL EXTENTION

Removal Steps
1. Screw
2. Front wheel extension
Installation Steps
2. Front wheel extension
1. Screw

2. Front Wheel Extension
pull out the 5 clip positions
10-88 CAB
REAR WHEEL EXTENTION

RTW4A0MF000501
Removal Steps
1. Screw
2. Rear wheel extension
Installation Steps
2. Rear wheel extension
1. Screw

2. Rear Wheel Extension
Pull out the 6 clip positions (Extend cab)
Pull out the 5 clip positions (Crew cab)
CAB 10-89
TAIL GATE ASSEMBLY

CENTER PULL HANDLE MODEL
Removal Steps
Installation Steps
1. Hole cover plate

2. Outside handle assembly
3. Tail gate lock assembly
4. Tail gate link
5. Tail gate
6. Tail gate hinge
7. Tail gate lock striker
7. Tail gate lock striker

6. Tail gate hinge
5. Tail gate
4. Tail gate link
3. Tail gate lock assembly
2. Outside handle assembly
1. Hole cover plate
10-90 CAB

2. Outside Handle Assembly
Disconnect the lock link and remove the 2 fixing bolts.
5. Tail Gate
1) Removing the tailgate assembly may require two people.
2) Remove the tailgate hinge fixing bolts.

7. Tail Gate Lock Striker
Tighten the lock striker fixing bolts to the specified
torque.
Torque
Nm(kgfm/lbft)
15 (1.5 / 11)
6. Tail Gate Hinge

Tighten the hinge fixing bolts to the specified torque.
C: Bolt
Torque
Nm(kgfm/lbft)
40 (4.1 / 30)
5. Tail Gate
1) A: Bolts
Torque
Nm(kgfm/lbin)
13 (1.3 / 113)
2) B: Bolt
Torque
Nm(kgfm/lbin)
25 (2.5 / 18)
3) Check the tailgate and rear body.

a. Clearance: 5.0 mm (0.20 in.)
b. Height (Step): Flush
c. Height (Step): Flush
3. Tail Gate Lock Assembly
Tighten the lock assembly fixing bolts to the specified
torque.
Torque
Nm(kgfm/lbft)
15 (1.5 / 11)
2. Outside Handle Assembly

Tighten the outside handle assembly fixing bolts to the
specified torque and if remove the key cylinder (if
equipped) tighten it to the specified torque.
Torque
Nm(kgfm/lbin)
9 (0.9 / 78)
No. TFCAB-WE-0431
WORKSHOP MANUAL
TF SERIES
SECURITY
SECTION 11
IMMOBILIZER SYSTEM 11A-1
SECTION 11A
IMMOBILIZER SYSTEM
CONTENTS
Service Precaution ................................................. 11A-2
General Description ............................................... 11A-3
What happens without proper transponder
operation? .......................................................... 11A-6
No proper transponder is available, what
should be done for the system? ...................... 11A-6
Caution to the operation..................................... 11A-6
Summary of operation........................................ 11A-6
What your organization should provide for
your customer .................................................... 11A-6
Car Pass ............................................................. 11A-6
Security code management .............................. 11A-6
Essential tool (Scan tool : Tech-2) .................. 11A-6
Circuit Diagram ................................................. 11A-7
Parts Location......................................................... 11A-10
Immobilizer control unit (ICU); For Electronic
Control Engine (6VE1, C24SE, 4JH1-TC,
4JA1-TC) .......................................................... 11A-11
Pin-outs; For Electronic Control Engine
(6VE1, C24SE, 4JH1-TC, 4JA1-TC)............... 11A-12
Immobilizer control unit (ICU); Mechanical
Control Engine (4JA1-T) .................................. 11A-13
Immobilizer coil (Antenna) ................................... 11A-15
Transponder (Key) ............................................ 11A-15
Immobilizer warning lamp ................................. 11A-15
Engine control module (ECM) .......................... 11A-15
Car Pass Card .................................................. 11A-16
Loss of car pass card ......................................... 11A-16
Instructions on Filling Out the form "Data
request, car pass" ............................................. 11A-16
Important Instructions ........................................ 11A-17
lmportant information on Programming ............. 11A-19
Security code ...................................................... 11A-19
Entering a code .................................................. 11A-19
Transponder (Key) ............................................. 11A-19
Important ............................................................. 11A-19
Tech-2 Scan Tool .................................................. 11A-20
Tech-2 Features ................................................. 11A-21
Getting Started ................................................... 11A-21
Operating Procedure ......................................... 11A-22
Menu .................................................................... 11A-23
DTC ......................................................................11A-23
Clear DTC Information .......................................11A-23
Tech-2 Data Display ...........................................11A-23
Check Vehicle Identification Number (VIN) ....11A-23
Reset Immobilizer (Reset Immobilizer
Control Unit) .......................................................11A-23
Reset Engine Control Module (Reset ECM) ...11A-24
Erase transponder key .......................................11A-24
Programming Immobilizer Function .................11A-25
Programming ICU ...............................................11A-26
Programming ECM .............................................11A-27
Programming ICU and ECM .............................11A-28
Transponder program ........................................11A-28
Data List ...............................................................11A-30
Diagnostic procedure ............................................11A-31
Clearing Diagnostic Trouble Codes ....................11A-31
Verifying Vehicle Repair ........................................11A-31
Diagnostic Aids ......................................................11A-31
Check the condition for system parts ..............11A-31
Check the Electro-Magnetic Interference
(EMI) ....................................................................11A-31
Check the other items ........................................11A-31
Check the operation ...........................................11A-31
Diagnostic Trouble Code (DTC) list ....................11A-32
IMMOBILIZER SYSTEM CHECK ........................11A-33
NO IMMOBILIZER WARNING LAMP .................11A-36
IMMOBILIZER WARNING LAMP ON STEADY 11A-37
B0001 REPLACE ELECTRONIC CONTROL
UNIT (ECU) (IMMOBILIZER FAULT) ................11A-38
B0002 IMMOBILIZER NOT PROGRAMMED ....11A-39
B0003 TRANSPONDER KEY PROBLEM ..........11A-40
B0004 IMMOBILIZER COIL CIRCUIT
(ANTENNA COIL FAULT) ...................................11A-42
B0005 COMMUNICATION LINE W VOLTAGE
LOW .......................................................................11A-43
B0006 COMMUNICATION LINE W VOLTAGE
HIGH .......................................................................11A-44
B0007 NO ENGINE REQUEST RECEIVED ......11A-45
B0008 WRONG TRANSPONDER KEY .............11A-47
B0009 NO TRANSPONDER KEY
PROGRAMMED ...................................................11A-48
11A-2 IMMOBILIZER SYSTEM

B0010 UNKNOWN TRANSPONDER KEY ....... 11A-49
B0011 TRANSPONDER KEY PROBLEM
(Only 4JA1-T Engine) ...................................... 11A-50
B0012 WRONG TRANSPONDER KEY
(Only 4JA1-T Engine) ...................................... 11A-52
B0013 IMMOBILIZER NOT PROGRAMMED
(Only 4JA1-T Engine) ...................................... 11A-53
B0014 NO TRANSPONDER KEY
PROGRAMMED (Only 4JA1-T Engine) ........... 11A-54
B0015 VEHICLE SPEED SIGNAL LOW
(Only 4JA1-T Engine) ....................................... 11A-55
B0016 VEHICLE SPEED SIGNAL HIGH
(Only 4JA1-T Engine) ...................................... 11A-56
B0023 IMMOBILIZER COIL CIRCUIT

(ANTENNA COIL FAULT)
(Only 4JA1-T Engine) ...................................... 11A-57
(Only 4JA1-T Engne) ....................................... 11A-58
B0055 EEPROM ERROR ................................. 11A-59
Special Tool ............................................................11A-60
Service Precaution
FOLLOW
WARNINGS
COULD
RESULT
IN
REPAIRS.

parts and systems.
General Description
While the system is on :
The immobilizer system consists of the four major

components which are Engine Control Module (ECM),
Immobilizer Control Unit (lCU), transponder, and scan
tool (Tech-2).
This system can be activated by a correctly programmed
transponder and starter switch is set to OFF.
This system can be deactivated by a correctly
programmed transponder key connected with a correctly
programmed ECM and a correctly programmed lCU.
The starter cut off relay deactivates function of starter,

and the fuel injector power source is deactivated also.
Check Engine lamp is flashing.
Warning buzzer is operating.
(With antitheft system)
Gasoline Engine (6VE1, C24SE)
LTW3BALF000101

Diesel Engine With ECM (4JH1-TC/4JA1-TC)
LTW3BALF000201

Diesel Engine With Engine Immobilizer Unit (4JA1-T Mechanical Control Engine)
RAW4B0LF000101
What happens without proper transponder

operation?
What your organization should provide for

your customer
One of the function of transponder is to deactivate or

activate starter function. lf the proper transponder is not
used, starter cannot be operated. Because starter relay
stays off, cranking engine is not possible.
After the starter relay is activated, transponder signal
triggers to let lCU calculate by transponder address
signal and immobilizer algorithm.
When the result matches with necessary condition, it
makes injector power source be activated.
If transponder does not send correct signal, lCU and
ECM do not activate injector system on.
Therefore the vehicle cannot be operated.
Car Pass
For a new owner, your dealership must hand Car Pass
card, which has identification numbers of new owner's
vehicle immobilizer system. This information is very
important in case of repair or lost of transponder.
The followings are necessary items provided by your
responsibility.
No proper transponder is available, what

should be done for the system?
When any proper transponder is not available, a new
transponder should be programmed. Up to 5
transponders can be provided with a scan tool (Tech-2)
and by proper procedure.
In addition to the absence of proper transponder, it may
happen particular secret code to the particular vehicle is
missing. ln this case, the secret code must be provided
by your organization.
Otherwise transponder cannot be programmed in any
way.
lf the essential for a scan tool (Tech-2) for programming
and proper software for Tech-2 are not available, there
is no permanent way to fix system. Temporary replace
with new ECM, new ICU and new transponder without
any secret code can make the system be deactivated,
but it does not last long. Such a replacement does not
solve any condition. Even after replacement, the system
is activated automatically in short time and then no
operation of the vehicle can be made in any way.
Tech-2 should be provided in your organization.
Caution to the operation

lf an attempt is made to start the engine while the
immobilizer system is activated, the check engine lamp
flashes and the engine will not start.
Summary of operation
Switch on: Set the ignition and starter switch to OFF.
(Activate)
Switch off: Set the ignition and starter switch to ON by
using the transponder key. (Deactivate)
1) Car pass with identification for a new owner

2) Blank car pass card when it is for reissue
3) Instruction to dealers how to use car pass card
Security code management
Your organization must keep security codes for all
vehicles as confidential data. Once the security codes
are lost, anybody who have the security code can
access immobilizer system. Your organization has
responsibility of any missing vehicles caused by stolen
security code.
Essential tool (Scan tool : Tech-2)
Your dealership must have Tech-2, and Tech-2 updated
software for immobilizer system.
Circuit Diagram
Gasoline Engine (6VE1, C24SE)
RAW4B0LF000501

Diesel Engine With ECM (4JH1-TC/4JA1-TC)
RTW4B0LF000101

Diesel Engine With Engine Immobilizer Unit (4JA1-T Mechanical Control Engine)
RAW4B0LF000401
Parts Location
LTW3BAMF000101
Legend
(1) Immobilizer Control Unit (ICU)
(2) Immobilizer Coil
(3) Cross Beam

(4) Steering Shaft
Immobilizer control unit (ICU); For

Electronic Control Engine (6VE1,
C24SE, 4JH1-TC, 4JA1-TC)
Immobilizer control unit (ICU) permits engine starting,
when the security code which compares the security
code registered into the transponder (key) and the
security code registered into ICU, and is similarly
registered into ICU and engine control unit (ECM) is
compared and it is judged that it is normal. When the
code registered into the key is unusual, and when not
recognizing a security code, ICU does not permit
starting of engine.
RUW38HSF000101
Pin-outs; For Electronic Control Engine (6VE1, C24SE, 4JH1-TC, 4JA1-TC)
RUW38HSF000201
No.
A-1
A-2
A-3
B-1
B-2
B-3
B-4
B-5
B-6
B-7
B-8
Pin Function
Antenna coil positive
Antenna coil negative

Starter Relay (6VE1, C24SE Engine) / Immobilizer Relay (4JH1-TC/4JA1-TC Engine)
Ground
Voltage from ignition switch ON
Back up voltage supply
To Tech-2
Vehicle speed sensor (6VE1, C24SE Engine) / Not used (4JH1-TC/4JA1-TC Engine)
Communication: carry on line from ECM to ICU (Check engine lamp)
Communication: carry on line from ICU to ECM (Communication line W)
Immobilizer control unit (ICU);

Mechanical Control Engine (4JA1-T)
Immobilizer control unit (ICU) permits engine starting,
when the security code which compares the security
code registered into the transponder (key) and the
security code registered into ICU, and is similarly
registered into ICU and engine immobilizer unit (DDS-1)
is compared and it is judged that it is normal. When the
code registered into the key is unusual, and when not
recognizing a security code, engine immobilizer unit
does not permit starting of engine by the fuel cut valve
on the fuel pump.
The engine immobilizer unit is located with fuel cut
valve on fuel pump 4JA1-T engine.
The immobilizer control unit decides whether there is an
abnormality the security code based on the engine
immobilizer unit security code.
When the problem found, the engine immobilizer unit
stops fuel fupply by the fuel cut valve.
RAW4B0SF000101
Pin-outs
RUW48HSF000201
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Pin Function
Back up voltage supply
Voltage from ignition switch ON
Lamp
Antenna coil positive

Ground
Engine immobilizer unit
To Tech2
Antenna coil negative

Starter cut relay
Immobilizer coil (Antenna)
Check engine lamp
Immobilizer coil is install in order that ICU may check

the security code memorized by the transponder (key).
Check engine lamp displays failure or a system

operation of a immobilizer system by flash of a lamp.
RUW38HSH000301
LTW3BASH000201
Transponder (Key)
Engine control module (ECM)
Transponder is installed in the inside of a key.

Transponder has memorized the security code of a
immobilizer system.
ECM will stop engine, if it communicates with ICU and

abnormalities are detected by a key and the immobilizer
system.
LTW3BASH000101
Legend
(1) Transponder (Key)
LTW3BASH000301
Legend
(1) ECM (6VE1 engine)
(2) ECM (C24SE engine)
(3) ECM (4JH1-TC engine)
Car Pass Card

Each vehicle has a car pass, which is issued to the
customer on delivery of the vehicle along with the other
papers.
RUW38HMF000201
Notes:
This car pass is an important document and must be
treated with the same care as the vehicle papers.
It must not be kept in the vehicle. The customer must
present the car pass for operations involving the
immobilizer or the engine control unit.
Instructions on Filling Out the form "Data

request, car pass"
To be provided by the dealership.
The data requested under items 1-10 must be provided
completely, including the authorized dealership number,
the vehicle Identification number (VIN) and engine
type/number (Engine type/No).
Loss of car pass card

If the car pass is lost, the data can be requested from
your proper organization name. This request will only be
processed if accompanied by the enclosed form and
proof of ownership. Once the data is received, it can be
entered in a blank car pass and given to the customer.
The unused car pass should be destroyed.
Mark missing data / desired data with a cross:

Security code (for diagnosis and programming with
Tech-2)
Mechanical key Number
Complete the form by entering the data and
signature/authorized dealership stamp and send it along
with proof of ownership (Vehicle lD or invoice) to
address provided in the form. The requested data will
be sent by Fax to the dealership that made the request
after your organization has confirmed that the info is
corrected.
Important Instructions
Only data corresponding to the delivery status of the
vehicle can be issued. Car pass data requests will only
be processed if the first column is filled out completely.
Signed and sent to your organization along with proof of
ownership.
Information via telephone is only possible in exceptional
circumstances via your service organization.
As for the delivery of new vehicles, the customer must
be informed about all features of the car pass that are
relevant to vehicle security, for example, that the car
pass should be kept in a safe place(not in the vehicle)
and should be presented when an authorized your
organization name workshop is visited, The exact
phrasing can be found in the relevant Owner's Manual.
RUW38HXF000201
lmportant information on Programming

Security code
The security code protects the immobilizer control unit
against unauthorized programming and data access
from Tech-2. The security code consists of a 4 digit
code number and is programmed into the immobilizer
control unit and Engine Control Module (ECM).
New control units are not programmed with a security
code.
If the control units are replaced, the security code
entered in the car pass, transponder lD, etc.
Must be programmed into the new control unit with
Tech-2.
The security code can only be programmed with Tech-2
once and must therefore be performed with great care.
Once programmed, the security code cannot be
overwritten. An already used immobilizer can be reused
in a different car by initializing the immobilizer. After that
you can program the security code again. For initializing
command you need the current security code.
If the immobilizer control unit is returned, always
enclosed the security code that is allocated to that
control unit. If this is not done, we can not process the
case and the warranty will not be recognized.
Entering a code
If the Tech-2 display requests that the
security code
mechanical key number
Vehicle Identification No.
be entered, process as follows;
To input a digit you need to use the up and down
buttons of the Tech-2. By using the numeric buttons the
according digit will be displayed at the current position
and the cursor will move to the next position.
For letters you need to use the up and down buttons of
the Tech-2. The up and down key might be used for
digits as well. By using the up and down buttons the
displayed digit or letter will be increased or decreased.
To move to the next position you need to use the moveto-right-button.
With the two buttons, move-to-right and move-to-left
you can select the position of number you want to
change.
This will allow you to correct a wrong number.
After the number is completed you need to press the
Enter button to accept the number. Correction is now no
longer possible.
Use the OKAY soft key to program the number and the
NOT OKAY soft key to abort the programming.
Transponder (Key)
If a transponder key is lost:
If a transponder key is lost, all transponder keys in the
immobilizer control system must be erased.
Transponder keys can be ordered via the "Your proper
organization name such as part and accessory
department" as previously by providing the mechanical
key number.
The mechanical key number is provided on the car
pass.
Thereafter, existing and new transponder keys are
programmed consecutively using Tech-2. The vehicle
can then no longer be started using lost key.
5 transponder keys can be provided:
Each transponder has different Identifications. If a
customer wants more than 2 transponder keys,
maximum 5 transponder keys can be provided by
additional programming by Tech-2.
lf a new ignition key with different mechanical key
number needs to be installed:
If installation of an ignition lock with a different
mechanism key number is necessary (an ignition lock
which belongs to the mechanical key number has to be
ordered first), all transponder keys must first be erased
and the two transponder keys which belong to the
ignition lock that is now installed must be programmed.
The new mechanical key number must be programmed
now into the immobilizer. The mechanical key number
in the car pass is to be changed as well.
Important:
After successful programming, the engine control can
only be used for vehicles with immobilizer and
transponder.
Faults that occur in connection with the immobilizer
control unit are recognized by the engine control unit
and as long as "IMMOBILOZER" is not programmed,
are indicated by a flashing of the check engine lamp.
If the immobilizer and engine control unit are replaced
at the same time, the immobilizer control unit must be
programmed first before the "IMMOBILIZER" function in
the engine control unit can be activated.
Tech 2 Scan Tool

LTW3BALF000501-X
Legend
(1) PCMCIA Card
(3) DLC Cable
(4) Tech-2
(5) RS232C Cable
Tech-2 Features
1. Tech-2 is a 12volt system. Do not apply 24 volts.
card and data link connector (DLC) to the Tech-2,
connect the tool to the vehicle DLC.
3. Make sure the Tech-2 is OFF when removing or
4. The Tech-2 has the capability of two or three
snapshots.
6. The Tech-2 can not plot a graph when replaying a
snapshot.
7. Always return to the Main Menu by pressing the
EXIT key several times before shutting down.
Application Menu and press "Clear DTC ".
Getting Started
Before operating the Isuzu PCMCIA card with the Tech
2, the following steps must be performed:
Tech 2.
2. Connect the SAE 16/19 adapter to the DLC cable.
3. Connect the DLC cable to the Tech 2.
vehicle DLC.
RHD (For example)
060R300015
6. Tune on the vehicle ignition (key) switch.

7. Power the Tech-2 ON and verify the Tech-2 power
up display.
060RW009
Operating Procedure
The power up screen is displayed when you power up
the tester with the Isuzu systems PCMCIA card.
LTW3BALH000101
060R100102
Menu
Tech-2 Data Display
The following table shows which functions are used for

the available equipment versions.
Use the Tech 2 Data Values only after the On-Board

Diagnostic System Check has been completed, no
DTC(s) were noted, and you have determined that the
on-board diagnostics are functioning properly.
The Tech 2 data values represent values that would be
seen on a normally-immobilizer system.

!
"
#

$
" $%

&

!

##
'
"

(

& $
)*
+
##

###
'

# $
)*

Check Vehicle Identification Number (VIN)

1. Select "Body" and "Immobilizer".
2. Select "Additional Function" and "Read ECU
Identification".
3. Shows up VIN on tech-2 display.
Reset Immobilizer (Reset Immobilizer

Control Unit)
NOTE: Before going to programming process, Tech-2

indicates instruction as follows.

2. Select
"Additional
Function"
and
"Reset
Immobilizer".
3. Enter the security code and press Confirm.
4. Reset Immobilizer screen shows up with warning.
See the following screen.
060R200279
060R200289
DTC
On OBD has two options available in the Tech 2 DTC
mode to display the enhanced information available.
Read DTC Info Ordered By Priority
Read DTC Info As Stored By ECU

diagnostic scan tool "clear DTC information" function.

5. When reset is completed, the following screen
shows up.
7. Programming is completed.
060R200278
060R200278
Reset Engine Control Module (Reset ECM)

2. Select "Additional Function" and "Reset Engine
Control Module".
3. The following screen shows up.
8. When the procedure is completed waits 10

seconds and then turn the Key on.
The fail lamp begins to flash.
9. Turn the ignition on, then engine dose not run.
10. Reset is completed.
Erase transponder key

2. Select
"Additional
Function
and
"Erase
Transponder-Keys".
3. See immobilizer status on Tech-2 screen and type
security code. If the status dose not allow the
programming, only immobilizer status is displayed.
4. See illustration of caution.
060R200289
4. Confirm the following screen shows up.

5. Input the security code, then press the soft key of
"Not Okay" or "Okay".

CAUTION
Programming Immobilizer Function

Caution:
1) Do not replace ICU and ECM at the same time
2) Change ICU at first or ECM and other one
change follows.
1. Select "Body" and "immobilizer".
2. Select "Programming" on Tech-2 display.
3. Check the display, then press the "Confirm" key.
060R200286
Erase
LTW3BASH000401
4.
5.
6.
7.
060R200285
4. See programming result on display.
Install the "Hardware Key" on PC.

Connect RS232 cable to the PC and Tech2.
Turn on the PC, then start software "TIS 2000".
Select "Security Access" in the TIS 2000 screen.

8. Select "Next" in the TIS 2000 screen and wait a
few seconds.
9. When programming is enabled (Approved), then
press "close" in the TIS 2000 screen.
(Finish the "TIS 2000" operation.)
10. Select "Program Immobiliser Function" on Tech-2
display.
Programming ICU and ECM
060R200283
Programming ICU
1. Follow Programming Immobilizer Function steps 1
through 14.
2. Input a program option, by moving the cursor on
the selection, then pres "Enter" key.
060R200289

"Not Okay" or "Okay".
14. Select the engine type then, press "Enter" key.
the selection, then press "Enter" key.
Programming ICU
Programming ECM
060R200283
3. Enter the security code.

4.
Input the security code, then press the soft key of

"Okay" or "Not Okay".
Programming ECM
through 14.
060R200284
5.
6.
7.
8.
9.
Enter VIN.
Enter Mechanical key number.
Turn ON ignition.
Select an engine system.
See the programming result.
Tech-2 displays the result of programming as the
following.
Follow those instructions
Selected Programming is not possible due to
wrong System Status!
Immobilizer Not Programmed!
Immobilizer Already Programmed!
ECM Not Programmed!
ECM Already Programmed!
10. Transponder key must be reprogrammed,
because all transponder information is erased.
When ICU is programmed. See Transponder
programming.
060R200283

060R200284
5. Turn on the Ignition.

6. Select an Engine system.

7. See the display of programming result.
Tech-2 displays the result of programming as the
following.
Follow those instructions
Selected Programming is not possible due to
wrong System Status!
Immobilizer Not Programmed!
Immobilizer Already Programmed!
ECM Not Programmed!
ECM Already Programmed!
because all transponder information is erased.
When ICU is programmed. See Transponder
programming.


through 14.
060R200284
5.
6.
7.
8.
Input the security code.

Enter VIN.
Enter Key No.
Select an engine system.
See programming result display and follow
instructions of the display.
because all transponder information on ICU is
erased when ICU is programmed. See
Transponder programming.
10. Follow Programming ECM steps 2 through 8.
Transponder program
060R200283

2. Select "Programming" and "Program TransponderKeys".
(Follow Programming Immobilizer Function steps 1
through 14.)
3. See immobilizer status on Tech-2 screen, and
enter security code. If the status does not allow the
programming, only immobilizer status is displayed.

4.
Insert Non-programmed Transponder-key and

press soft key of "Confirm".
060R200288
5. "Turn On ignition key", is displayed if the ignition is

off.
6. The transponder status is displayed if the status
does not allow the programming.
7. When
programming
starts
"Programming
Transponder - key!" is displayed.
8. Turn off Ignition key.
9. Turn On Ignition key.
10. If the programming was not successful, the
transponder status is only displayed.
11. To program more illustration press soft key.
RUW38SH000601
12. See programming result.
Data List

#
&
(
)
*
+
,

#

#

&

(

"-
"
./0
!"
"-/"

!3

$!!! %
%
'%

%
'%

%
'%

%
'%

%
'%

'

/!1'/!1

"
2!1
!1
2!1
!1
!"

Diagnostic procedure
Once the cause of DTC is repaired or gone,
engine can be operated normally, and present
DTC becomes history code.
History code is canceled by no repeat failure on 25
consequence ignition key on afterward.
History code cannot be canceled by battery
connector disconnected.
Diagnostic Aids
Check the condition for system parts.
Installation condition, poor connection, damage,
system parts malfunction. Harness, Fuse, Relay,
Immobilizer coil (antenna), Key, Meter, Immobilizer
control unit (ICU), Engine control module (ECM).
NOE: Breakage of immobilizer fuse does not operate
immobilizer system. Check engine lamp flashes at this
time.

Check the Electro-Magnetic Interference (EMI)
IMPORTANT: Do not clear DTCs unless directed to do
so by the service information provided for each
diagnostic procedure. When DTCs are cleared, the
Failure Record data which may help diagnose an

comprehensive for vehicles with immobilizer system
2. Clear DTC(s).
Fail Records.
4. Monitor the DTC status information for the DTC
which has been diagnosed until the diagnostic test
associated with that DTC runs.
Following these steps are very important in verifying
repairs on immobilizer systems. Failure to follow these
steps could result in unnecessary repairs.
Location of vehicle check

Move the vehicle to a new location and perform
the check again.
Non-OEM Parts.
Switch is "OFF" or remove the Non-OEM parts and
perform the check again.
Other
Remove the accessory and another key from key.
Check the other items.
Battery voltage is low.
Immobilizer programming functions.
Must be programmed immobilizer system.
Registration for security code, immobilizer control
unit parts number.
Key switch operation.
Immobilizer system may detect a history DTC by
the timing of ON-OFF of a key switch.
Active the immobilizer system.
Keyless entry system is malfunction.
Anti theft system is malfunction.
Check the operation
Check the operation "Lock / unlock" by using transmitter
(key) on the vehicle.
Diagnostic Trouble Code (DTC) list with ECM

Immobilizer Control Unit (ICU)
DTC
Description
Note
B0001
REPLACE ELECTRONIC CONTROL UNIT This error code appears if a RAM /ROM Error was
(ECU) (IMMOBILIZER FAULT)
detected or the EEPROM is defect.
B0002
IMMOBILIZER NOT PROGRAMMED
Immobilizer control unit is not programmed.
B0003
TRANSPONDER KEY PROBLEM
Reading of Transponder information failed with ignition

on transponder has a fault.
Hardware fault in reading circuit.
B0004
IMMOBILIZER COIL CIRCUIT (ANTENNA Immobilizer coil has a fault.

COIL FAULT)
B0005
COMMUNICATION LINE W VOLTAGE LOW
Short circuit to ground or open circuit.
B0006
COMMUNICATION LINE W VOLTAGE HIGH
Short circuit to 12V.
B0007
NO ENGINE REQUEST RECEIVED
No ECM Challenge.
B0008
WRONG TRANSPONDER KEY
Incorrect security code response received.
B0009
NO TRANSPONDER KEY PROGRAMMED
Transponder security code table empty
B0010
UNKNOWN TRANSPONDER KEY
Transponder security code not valid.
Engine Control Module (ECM: Gasoline Engine {6VE1, C24SE})
DTC
Note
Description
P1626
No Response From Immobilizer
Refer to Engine Control system section
P1631
Received Response Was Not Correct
P1648
Received Incorrect Security Code
P1649
Security Code & Security Key Not

Programmed
Engine Control Module (ECM: Diesel Engine {4JH1-TC, 4JA1-TC})
DTC
Description
Note
P1610
Seeds and Key File Destroyed
P1611
P1612/ Immobilizer No or Wrong Signal

P1613
P1649
Diagnostic Trouble Code (DTC) list with Engine Immobilizer Unit (4JA1-T Diesel Engine)
Engine Immobilizer Unit
Code
(DTC)
Description
Detecting Condition
B0011
TRANSPONDER KEY PROBLEM
Transponder code unsuccessfully read 5 consecutive

time. (No completely read in 500ms transponder code)
B0012
WRONG TRANSPONDER KEY
Immobilizer program no executed.
B0013
IMMOBILIZER NOT PROGRAMMED
Processing program no executed.
B0014
NO TRANSPONDER KEY PROGRAMMED
Processing to save the transponder key in the control unit

not Executed.
B0015
FREQUENCY SIGNAL Lo
Lo level (less than 2.5) input during the Hi level was being
output to the communication line.
B0016
FREQUENCY SIGNAL Hi (Diesel)
Hi level (more than 2.5v) input during the Lo level was

being output to the communication line.
B0023
ANTENNA COIL OPEN
Antenna coil not connected.
B0024
WRONG TRANSPONDER RESPONSE
Transponder response signal with challenge is wrong.
B0055
EEPROM ERROR
Write and read cannot be correctly made to and from the

EEPROM in the control unit.
IMMOBILIZER SYSTEM CHECK

Step
Action
Value(s)
Yes
No
1. Key position is "ON," engine "OFF."

2. Observe the check engine lamp.
Note: When a key switch is turned ON, check engine
lamp will turn on and a check engine lamp will be
turned off after a few seconds.
Go to Step 2
Go to "No
Immobilizer
warning lamp"
Go to Step 3
Go to
"Immobilizer
warning lamp on
steady"
Is the check engine lamp "ON"?

2

Note: When a key switch is turned ON, check engine
lamp will turn on and a check engine lamp will be
turned off after a few seconds.
Is the check engine lamp "OFF"?
(Check engine lamp does not flash)
1.
2.
3.
4.
Key position is "OFF."

Install a scan tool.
Key position is "ON."
Attempt to display immobilizer data with the scan
tool.
Does the scan tool display immobilizer data?
Go to Step 9
Go to Step 4
1. Key position is "OFF," disconnect the immobilizer

control unit (ICU).
2. Check the DLC (Data Link Connector) circuit for
an open, short to ground, or short to voltage.
open or short to ground and the DLC ground
circuit for an open.
Repair or replace the DLC (Data Link Connector)
circuit.
Go to Step 5
Go to Step 6
Go to Step 3
Go to Step 7
Go to Step 8
Go to Step 3
Go to Step 3
Go to Step 10
Go to Step 13

6
1. Check the ICU circuit for an open, short to ground,

or short to voltage. Also, check the ICU ignition
feed circuit for an open or short to ground and the
ICU ground circuit for an open.
Repair or replace the ICU ignition feed and ground
circuits.
Replace the immobilizer control unit (ICU).

IMPORTANT: The replacement ICU must be
programmed the immobilizer data by the scan tool.
Select "Display DTCs" with the scan tool.


Step
Action
Value(s)
Yes
No
10
Review and record for scan tool Failure Records data

and DTCs.
Go to Step 11
Go to applicable
DTC table after
Go to Step 12
Go to Step 12
Go to Step 12
Go to applicable
DTC table
Go to Step 14
Go to Step 15
Go to Step 20
Go to Step 16
Go to Step 18
Go to Step 17
Go to Step 18
Go to Step 19
Go to Step 20
System OK
Refer to
Diagnostic Aids
11

Following the DTC is stored.
Are there DTC B0001 or B0055 stored?
12
13
Clear the DTCs by "Clear the Information "with scan

tool.
Did the DTCs Cleared?
Select "Display DTCs" with the scan tool.
14

Note: If a key switch is turned ON, check engine lamp
will turn on and a check engine lamp will be turned off
after a few seconds.
Is the check engine lamp "flash"?
15
Check the engine control system.

(Refer to section 6E: system check and DTCs)
IMPORTANT: The replacement ECM must
programmed the immobilizer data by scan tool.
be
(Except 4JA1-L Engine)

16
Check the key.

Is a key peculiar to a vehicle?
17
Change into a peculiar key.

IMPORTANT: If replace the key, after replace lock
cylinders, perform the following below the items.
18
Replace the keys and key cylinders.

Program the immobilizer system.
(Refer to "Important information on Programming")
Check the immobilizer programming functions.
Immobilizer control unit (ICU).
Engine control module (ECM).
Transponder (Key).
19
20

Operate the DTCs by "Clear the Information" with
scan tool.
Did the engine start?
NO IMMOBILIZER WARNING LAMP

Step
Action
Value(s)
Yes
No
Check the meter fuse for the instrument cluster

Go to Step 3
Go to Step 2
Verify repair
Is the fuse normal?

Replace the fuse.
Go to Step 3

3
1.
2.
3.
4.
Key position is "OFF".

Disconnect the meter.
Disconnect the engine control module (ECM).
Check the circuit between meter and ECM for an
open, short to round, or short to voltage.
Also, check the meter circuit for an open or short to
ground and the DLC ground circuit for an open.
Repair or replace the meter circuit.
Go to Step 4
Go to Step 5
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 7
Go to Step 9
Go to Step 8
Verify repair

5

Repair or replace the meter.
1. Key position is "OFF".

2. Check the check engine lamp bulb.
Is the check engine lamp bulb normal?
Replace the check engine lamp bulb.
Go to Step 9

9
10

2. Connect the meter.
3. Connect the engine control module (ECM).
4. Key position is "ON".
Note: If a key switch is turned ON, check engine lamp
will turn on and a check engine lamp will be turned off
after a few seconds.
Replace the engine control module (ECM).
IMPORTANT: The replacement ICU must
programmed the immobilizer data by scan tool.
be
Verify repair
Go to Step 10
Verify repair
CHECK IMMOBILIZER WARNING LAMP ON STEADY

Step
Action
Value(s)
Yes
No

2. Disconnect the immobilizer control unit (ICU).
3. Disconnect the engine control module (ECM).
Go to Step 2
Go to Step 5

2. Disconnect the meter.
Repair or replace the meter.
Go to Step 3
Go to Step 4
Verify repair
Go to Step 5

4
Repair or replace the meter circuit.

(Between meter and ICU/ECM)
Check the immobilizer control unit (ICU) circuit.
Verify repair
Go to Step 5
Go to Step 6
Go to Step 7
Verify repair
1. Ignition "OFF," disconnect the ICU.

Also, check the ICU ignition feed circuit for an open or
short to ground and the ICU ground circuit for an
open.
6

Repair or replace the immobilizer unit (ICU) circuit.
Go to Step 7

7

2. Connect the meter.
3. Connect the immobilizer control unit (ICU).
4. Connect the engine control module (ECM).
5. Key position is "ON".
Verify repair
Refer to
Diagnostic Aids
B0001 REPLACE ELECTRONIC CONTROL UNIT (ECU) (IMMOBILIZER FAULT)

Step
Action
Value(s)
Yes
No
Was the "Immobilizer System Check" performed?
Go to Step 2
Go to Immobilizer
System Check
Recheck the DTC.
Go to Step 3
1. Key position is OFF.

2. Install the scan tool on vehicle.
3. Key position is ON.
4. Check the DTC on scan tool.
Is DTC B0001 stored?
Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Verify repair
Verify repair

open.
4


programmed the security data by scan tool.
be
B0002 IMMOBILIZER NOT PROGRAMMED

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Go to Step 3
Go to Step 5

Recheck the DTC.
Go to Step 4
Verify repair
1. Key position is OFF and keep the position for

more than 30 seconds.
Verify repair
Verify repair
Go to Step 6
Verify repair


5


Replace the key and lock cylinder assembly and
immobilizer system (ICU and ECM).
IMPORTANT:
ICU and ECM are not replacing simultaneously.
After replace lock cylinders, perform the following
below the items.
B0003 TRANSPONDER KEY PROBLEM

Step
Action
Value(s)
Yes
No
Go to Step 2 Go to Immobilizer
System Check
Check the key.
Go to Step 3

Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5

Recheck the DTC.
Go to Step 5
Verify repair
1. Key position is OFF and keep the position for more

than 30 seconds.
Recheck the DTC.
Go to Step 6
Verify repair
1. Non-OEM parts switch is "OFF" or remove the NonOEM parts.

2. Remove the accessory and another key from key.
3. Move the vehicle to a new location.
than 30 seconds.
Check the immobilizer coil (antenna) circuit.
Go to Step 7
Go to Step 8

Repair or replace the immobilizer coil (antenna) circuit.
Verify repair

Recheck the DTC.
Go to Step 9
Verify repair
All transponder (Key).


(immobilizer coil circuit : 3 pin connector)
3. Check the immobilizer coil circuit for an open, short
to ground, or short to voltage.
short to ground and the ICU ground circuit for an open.

than 30 seconds.

Step
Value(s)
Yes
No
Go to Step 10
Go to Step 11
11

Recheck the DTC.
Go to Step 12
Verify repair
12

than 30 seconds.
Replace the transponder (Key).
Verify repair
Action
IMPORTANT: The replacement ICU
10
must
be

IMPORTANT: The replacement transponder (key) must

be programmed the security data by scan tool.
B0004 IMMOBILIZER COIL CIRCUIT (ANTENNA COIL FAULT)

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Go to Step 3
Go to Step 4

Repair or replace the immobilizer coil (antenna).
Verify repair

Recheck the DTC.
Go to Step 5
Verify repair

Verify repair

open.

be
B0005 COMMUNICATION LINE W VOLTAGE LOW

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Recheck the DTC.
Go to Step 3

Check the immobilizer communication W line circuit.
Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Verify repair
Verify repair
1.
2.
3.
4.
Key position is OFF.

Disconnect the immobilizer control unit (ICU).
Check the immobilizer communication W line
circuit for an open, short to ground, or short to
voltage.
Also, check the ICU and ECM ignition feed circuits for
an open or short to ground and the ICU and ECM
ground circuit for an open.

Repair or replace the immobilizer communication W
line circuit.
be
B0006 COMMUNICATION LINE W VOLTAGE HIGH

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Recheck the DTC.
Go to Step 3

Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Verify repair
Verify repair
1.
2.
3.
4.

voltage.

line circuit.
be
B0007 NO ENGINE REQUEST RECEIVED

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Recheck the DTC on ICU.
Go to Step 3

Check the immobilizer communication line circuit.
Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Verify repair

Recheck the DTC on ICU.
Go to Step 6
Verify repair

Recheck the DTC on ECM.
Go to Step 7
Go to Step 9
Go to Step 8
Go to Step 11
Go to Step 11
Go to Step 12
1.
2.
3.
4.

Check the immobilizer communication line circuit
for an open, short to ground, or short to voltage.

Repair or replace the immobilizer communication line
circuit.

Are below DTCs stored?
P1649 (6VE1, C24SE) , P1611/P1614 (4JH1-TC)
Perform the immobilizer programming functions.
P1649 (6VE1, C24SE) , P1611/P1614 (4JH1-TC)

Step
Value(s)
Yes
No
Go to Step 10
Go to Step 11
10

Go to Step 11
Go to Step 12
11

P1649 (6VE1, C24SE), P1611/P1614 (4JH1-TC)
Replace the engine control module (ECM).
Go to Step 12
12

Go to Step 13
Go to Step 2
13

P1626 (6VE1, C24SE), P1612/P1613 (4JH1-TC)
Verify repair
Action


be

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Check the key.
Go to Step 3

Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Transponder (Key).
Go to Step 5

Recheck the DTC.
Go to Step 6
Verify repair

Go to Step 7
Transponder (Key).
IMPORTANT: The replacement transponder (key)

must be programmed the security data by scan tool.
7
Recheck the DTC.
Go to Step 8
Verify repair

Verify repair

be
B0009 NO TRANSPONDER KEY PROGRAMMED

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Check the key.
Go to Step 3

Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Transponder (Key).
Go to Step 5
Transponder (Key).
Recheck the DTC.
Go to Step 6
Verify repair

Go to Step 7
Go to Step 8
Verify repair
Verify repair

7

Recheck the DTC.

be
B0010 UNKNOWN TRANSPONDER KEY

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Check the key.
Go to Step 3

Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Transponder (Key).
Go to Step 5

Recheck the DTC.
Go to Step 6
Verify repair

Go to Step 7
Go to Step 8
Verify repair
Verify repair
Transponder (Key).

7

Recheck the DTC.

be
B0011 TRANSPONDER KEY PROBLEM (Only 4JA1-T Engine)

Step
Action
Value(s)
Yes
No
Go to Step 2 Go to Immobilizer
System Check
Check the key.
Go to Step 3

Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5

Recheck the DTC.
Go to Step 5
Verify repair

than 30 seconds.
Recheck the DTC.
Go to Step 6
Verify repair
1. Non-OEM parts switch is "OFF" or remove the NonOEM parts.

2. Remove the accessory and another key from key.
than 30 seconds.
Go to Step 7
Go to Step 8

Repair or replace the immobilizer coil (antenna) circuit.
Verify repair

Recheck the DTC.
Go to Step 9
Verify repair


short to ground and the ICU ground circuit for an open.

than 30 seconds.

Step
Value(s)
Yes
No
Go to Step 10
Go to Step 11
11

Recheck the DTC.
Go to Step 12
Verify repair
12

than 30 seconds.
Verify repair
Action
IMPORTANT: The replacement ICU
10
must
be

IMPORTANT: The replacement transponder (key) must

be programmed the security data by scan tool.
B0012 WRONG TRANSPONDER KEY (Only 4JA1-T Engine)

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Check the key.
Go to Step 3

Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Transponder (Key).
Go to Step 5

Recheck the DTC.
Go to Step 6
Verify repair

Go to Step 7
Go to Step 8
Verify repair
Verify repair
Transponder (Key).

7

Recheck the DTC.

be
B0013 IMMOBILIZER NOT PROGRAMMED (Only 4JA1-T Engine)

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Go to Step 3
Go to Step 5

Recheck the DTC.
Go to Step 4
Verify repair

Verify repair
Verify repair
Go to Step 6
Verify repair


5

Engine control immobilizer unit.

Replace the key and lock cylinder assembly and
immobilizer system (ICU and Engine immobilizer
unit).
IMPORTANT:
ICU and Engine immobilizer unit are not
replacing simultaneously.
After replace lock cylinders, perform the
following below the items.
B0014 NO TRANSPONDER KEY PROGRAMMED (Only 4JA1-T Engine)

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Check the key.
Go to Step 3

Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Transponder (Key).
Go to Step 5

Recheck the DTC.
Go to Step 6
Verify repair

Go to Step 7
Go to Step 8
Verify repair
Verify repair
Transponder (Key).

7

Recheck the DTC.

be
B0015 FREQUENCY SIGNAL LOW (Only 4JA1-T Engine)

Step
1
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Recheck the DTC.
Go to Step 3

Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Verify repair
Verify repair
1.
2.
3.
4.

Disconnect the Engine immobilizer unit.
voltage.
Also, check the ICU and Engine immobilizer unit
ignition feed circuits for an open or short to ground
and the ICU and Engine immobilizer unit ground
line circuit.
B0016 FREQUENCY SIGNAL HIGH (Only 4JA1-L Engine)

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Recheck the DTC.
Go to Step 3

Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Verify repair
Verify repair

3. Disconnect the engine control module (Engine
immobilizer unit).
4. Check the immobilizer communication W line
voltage.
Also, check the ICU and Engine immobilizer unit
ignition feed circuits for an open or short to ground
and the ICU and Engine immobilizer unit ground
4

line circuit.
be
B0023 IMMOBILIZER COIL CIRCUIT (ANTENNA COIL FAULT)

(Only 4JA1-T Engine)
Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Go to Step 3
Go to Step 4

Repair or replace the immobilizer coil (antenna).
Verify repair

Recheck the DTC.
Go to Step 5
Verify repair

Verify repair

open.

be
B0024 WRONG TRANSPONDER KEY (Only 4JA1-T Engine)

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Check the key.
Go to Step 3

Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Transponder (Key).
Go to Step 5

Recheck the DTC.
Go to Step 6
Verify repair

Go to Step 7
Transponder (Key).

7
Recheck the DTC.
Go to Step 8
Verify repair

Verify repair

be
B0055 EEPROM ERROR

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to Immobilizer
System Check
Recheck the DTC.
Go to Step 3

Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5
Verify repair
Verify repair

open.
4


be
Special Tools
ILLUSTRATION
PART NO.
PART NAME
Tech-2
Scan Tool
5-8840-0366-0
Digital Multi Meter
ANTITHEFT SYSTEM 11B 1
SECTION 11B
ANTITHEFT SYSTEM
CONTENTS
PAGE
Service Precaution ........................................................................................................ 11B 3
General Description ...................................................................................................... 11B 4
Activating the anti-theft system.............................................................................. 11B 4
Antitheft system alarm operating conditions ........................................................ 11B 4
Function of a keyless entry system......................................................................... 11B 4
Status LED ................................................................................................................. 11B 4
Hazard relay............................................................................................................... 11B 4
Switches .................................................................................................................... 11B 4
Receiver...................................................................................................................... 11B 5
Range of communication ......................................................................................... 11B 5
Diagnosis ................................................................................................................... 11B 5
Transmitter (into remote key).................................................................................. 11B 5
Transmitter (into remote key) power...................................................................... 11B 5
Super lock .................................................................................................................. 11B 5
No proper transmitter is available, what should be done for the system ?........ 11B 6
DIAGRAMS AND SCHEMATICS ................................................................................... 11B 7
SYSTEM WIRING DIAGRAMS.................................................................................. 11B 7
COMPONENT WIRING LOCATORS (LHD) ............................................................... 11B 8
WIRING DIAGRAM (LHD).......................................................................................... 11B 9
WIRING DIAGRAM (RHD with keyless)................................................................... 11B 13
WIRING DIAGRAM (Super Lock).............................................................................. 11B 14
WIRING DIAGRAM (RHD) ......................................................................................... 11B 16
WIRING DIAGRAM (RHD) ......................................................................................... 11B 17
Antitheft control unit (A).......................................................................................... 11B 21
11B 2 ANTITHEFT SYSTEM
Pin-outs ...................................................................................................................... 11B 21

Pin- Assignment ........................................................................................................ 11B 22
lmportant information on Programming .................................................................... 11B 23
Security code............................................................................................................. 11B 23
Entering a code ......................................................................................................... 11B 23
Tech-2 Scan Tool............................................................................................................ 11B 24
Tech-2 Features ......................................................................................................... 11B 25
Getting Started ......................................................................................................... 11B 25
Operating Procedure................................................................................................. 11B 26
Menu .......................................................................................................................... 11B 27
DTC ............................................................................................................................. 11B 27
Clear DTC Information .............................................................................................. 11B 27
Tech-2 Data Display................................................................................................... 11B 27
Actuator Test ............................................................................................................. 11B 27
Unlock / Lock Test..................................................................................................... 11B 27
Arm / Disarm Signal Test ......................................................................................... 11B 28
Horn Signal Test ........................................................................................................ 11B 28
Turn Signal Test......................................................................................................... 11B 28
Theft LED Test ........................................................................................................... 11B 28
Programming............................................................................................................. 11B 29
Erase remote keys..................................................................................................... 11B 29
Program Remote Keys.............................................................................................. 11B 30
ProgramAntitheft Waring......................................................................................... 11B 31
Program Country Code............................................................................................. 11B 32
Program Vehicle Options.............................................................................................. 11B 33
Tech-2 Data List ......................................................................................................... 11B 34
DIAGNOSIS .................................................................................................................... 11B 35
Diagnostic procedure................................................................................................ 11B 35
Clearing Diagnostic Trouble Codes ......................................................................... 11B 35
Verifying Vehicle Repair............................................................................................ 11B 35
Diagnostic Aids ......................................................................................................... 11B 35
Check the condition for system parts ..................................................................... 11B 35
Check the Electro-Magnetic Interference (EMI) ..................................................... 11B 35
Check the other items .............................................................................................. 11B 35
Check the operation.................................................................................................. 11B 35
Diagnostic Trouble Code (DTC) list.......................................................................... 11B 36
Antitheft System Check ........................................................................................... 11B 37
No Antitheft Lamp .................................................................................................... 11B 38
DTC13 Security code not yet programmed ............................................................ 11B 39
DTC14 No remote key programmed ....................................................................... 11B 40
DTC16 Door lock actuators short circuit to ground............................................... 11B 41
DTC20 Broken wire to door lock actuators ............................................................ 11B 42

DTC21 Remote key 1 with random code out of capture range ............................ 11B 43
DTC28 Input immobiliser short circuit to ground .................................................. 11B 48
DTC29 Broken wire to immobiliser ......................................................................... 11B 49
DTC31 Actuator driver door defect ......................................................................... 11B 50
DTC32 Actuator passenger door defect.................................................................. 11B 51
DTC36 Broken wire to driver door........................................................................... 11B 52
DTC37 Broken wire to passenger door ................................................................... 11B 53
DTC41 Driver door micro switch unlock defect ..................................................... 11B 54
DTC42 Driver door micro switch lock defect.......................................................... 11B 55
DTC43 Driver door micro switch dead lock defect ................................................ 11B 56
DTC44 Passenger door micro switch lock defect................................................... 11B 57
DTC45 Passenger door micro switch unlock defect .............................................. 11B 58
DTC47 Battery voltage for door lock actuators is missing ................................... 11B 59
DTC50 A/D converter defect or battery voltage less than 9 volt ......................... 11B 60
DTC51 E E P ROM defect .......................................................................................... 11B 61
DTC52 E E P ROM not programmed by ISUZU ...................................................... 11B 62
DTC55 Control unit defect........................................................................................ 11B 63
DTC123 Output flasher short circuit to grpund or broken wire ........................... 11B 64
DTC125 Output alarm horn broken wire ................................................................ 11B 65
Service Precaution
WARNING:
THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND
WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR
NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION.
FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION:
Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact
part number for that application. ISUZU will call out those fasteners that require a replacement after
removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS
OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors)
on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener
torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following these instructions can help you avoid damage
to parts and systems.
General Description
The Antitheft system consists of the four major
components which are Antitheft Control Unit
(ACU), Antitheft horn, key (remote key), and scan
tool (Tech-2).
This system can be activated by a correctly
programmed key (remote key) and starter switch is
set to OFF.
This system can be deactivated by a correctly
programmed key (remote key) connected with a
correctly programmed ACU and a correctly
programmed lCU.
When the vehicle doors, and engine hood are
locked, the antitheft alarm system is designed to
protect your vehicle and valuables from theft.
Any attempt to forcibly open any door, the engine
hood without using the vehicle key (or remote
control) will cause the hazard lights to flash on and
off and the horn to sound intermittently. This will
continue for 30 seconds before the system
automatically shuts itself off.
Please operate the door either the key lock or
remote control after closing all doors to arm the
alarm system.
Miss waning will be detected when the passenger
door is opened with locked condition and then this
door is closed.
During the first 10 seconds:
LED Lights up; Test, switch - on delay
LED Flashes; Door, bonnet, open or system
fault
Activating the anti-theft system

1. When the key switch is turned to the ACC
position or removed from the starter switch.
2. Closing and locking all the doors, and the
engine hood will cause the indicator light to
come on.
3. Approximately 10 seconds later, the indicator
light will flash. The anti-theft system is now in
operation.
Antitheft system alarm operating conditions
When the antitheft system is engaged, the alarm
will operate under the following condition;
1. Whenever some forcibly attempts to open a
door, the engine hood without using the key.
2. Whenever some forcibly attempts to remove a
door key cylinder.
3. Whenever someone unlocks a door with door
lock knob.
4. Whenever the engine hood release handle is
operated.
Function of a keyless entry system
With a keyless entry system the car can be locked
or unlocked from any position around the car up to
a specified distance, by using the potable radio
remote transmitter inside key (remote key).
Status LED
While the system is in delay the alarm system is
active and LED flashes at 0.5Hz with or without
activated interior protection.
After approx. 10 seconds:

Flashes; System on
Lights up; Test, switch - off
for approx.
Hazard relay
The hazard warning lights will be activated by an
external relay. The output is low active.
Switches
All switches to ground. This makes it possible for
failure analysis to detect a short circuit or a broken
wire to each switch. To use this feature it is
necessary to place a 1.8k resistor in parallel to the
required switch.
RTU4Z0SH001101

Receiver
The receiver is integrated into the control unit.
To lower the idle current the receiver is equipped
with a standby mode. The antenna is integrated on
the printed circuit board.
Depending on the mounting position of the control
unit the antenna can be connected externally.
Range of communication
The range of communication between remote key
and receiver is intended to be least 3 m from centre
of the car.
Diagnosis
For diagnostic purpose the communication with an
internal diagnostic device ( Tech-2 ) is possible.
Transmitter (into remote key) power
The transmitted power is less than 10 m W.
Battery life time for transmitter power
The minimum life time of battery is 2 years with 15
lock/unlock cycles per day.
While the battery is changed, the data retention
will be at least 3 minutes without pressing a
button.
901RW176
Transmitter (into remote key)

Electronics integrated in remote key container
for TFR/TFS.
Antenna integrated in remote key container.
Frequency band is 433.92 MHz.
Two function buttons (Door lock/Door unlock)
Two status LEDs for TF (Door lock/Door unlock)
Super lock
(Mechanical anti-theft locking system)
To Lock:
All doors must be closed; press the lock button on
the remote control unit again within 10 seconds
after locking or turn key in driver's door lock
towards rear of vehicle again within 10 seconds
after locking, then turn it back to the vertical
position and remove.
Lock buttons on all doors are positioned such that
doors cannot be opened.
To unlock:
Press unlock button on remote control unit or turn
key in driver's door lock towards front of vehicle,
then turn it back to the vertical position and
remove. If a problem is found, open the driver door
as necessary.
No proper transmitter is available, what

should be done for the system?
When any proper transmitter is not available, a new
transmitter should be programmed. Up to 5
transmitters can be provided with a scan tool
(Tech-2) and by proper procedure.
In addition to the absence of proper transmitter, it
may happen particular secret code to the particular
vehicle is missing. ln this case, the secret code
must be provided by your organization.
Otherwise transmitter cannot be programmed in
any way.
lf the essential for a scan tool (Tech-2) for
programming and proper software for Tech-2 are
not available, there is no permanent way to fix
system. Temporary replace with new ACU, new ICU
and new transmitter without any secret code can
make the system be deactivated, but it does not last
long. Such a replacement does not solve any
condition. Even after replacement, the system is
activated automatically in short time and then no
operation of the vehicle can be made in any way.
Tech-2 should be provided in your organization.
Security code management
Your organization must keep security codes for all
vehicles as confidential data. Once the security
codes are lost, anybody who have the security code
can access antitheft system. Your organization has
responsibility of any missing vehicles caused by
stolen security code.
Essential tool (Scan tool: Tech-2)
Your dealership must have Tech-2, and Tech-2
updated software for immobilizer system.
DIAGRAMS AND SCHEMATICS

SYSTEM WIRING DIAGRAMS
lock
80A
super lock
assist door
10A
20A
10A
Ignition switch
ACC
10A
auto door lock
rear door(RH)
antitheft horn
rear door(LH)
power supply
unlock
door lock cylinder
assist door
(unlock)
lock
lock
driver door
(unlock)
lock
auto door lock switch
assist door
unlock
without
super lock
unlock
ANTITHEFT CONTROL UNIT
power supply
door lock motors
hazard relay(RH)
flashers(RH)
hazard relay(LH)
driver door
lock
flashers(LH)
engine hood contact switch
status LED
assist door
door contact switch
rear door(RH)
disarm
rear door(LH)
with super
immobilizer controller
lock
driver door
daiagnostc conector
ground
BATTERY
alarm trigger
(12V)
driver door
CONTROLLER
ANTI-THEFT
WARNING LIGHT ; LH
FRT TURN SIGNAL , HAZARD
ENGINE HOOD SW
ANTI-THEFT HORN
WARNING LIGHT ; RH
FRT TURN SIGNAL , HAZARD
WARNING LIGHT ; RH
SIDE TURN SIGNAL , HAZARD
FRT DOOR LOCKACTUATOR ; RH
FRT DOOR KEY SW ; RH
RR DOOR LOCK ACTUATOR ; RH
WARNING LIGHT ; LH
RR TURN SIGNAL , HAZARD
WARNING LIGHT ; LH
SIDE TURN SIGNAL , HAZARD
ANTI-THEFT INDICATER
RELAY ; HAZARD
FRT DOOR LOCKACTUATOR ; LH
FRT DOOR KEY SW ; LH
RR DOOR LOCK ACTUATOR ; LH
RR DOOR SW ; LH
FRT DOOR SW ; LH
RR DOOR SW ; RH
FRT DOOR SW ; RH
COMPONENT WIRING LOCATORS (LHD)
RAW4C0XF000201
C-117
C-2
D-26
D-9
C-30
H-8
H-24
H-10
D-18
P-6
P-5
P-1
2nd Battery
(EUROPE)
H-26
P-2
R-6
H-16 R-10
L-9
L-1
H-6
H-25
H-7
SBF-1
EB-1
FUSE
DIODE
D-20
SBF-9 SLOW BLOW FUSE
EB16
X-16, X-17
RELAY
C20 FUSE
X-15
C-1
B-8,B-7,B-40 RELAY
JUNCTION BLOCK
R-9
X-1
H-13
C-109
R-1
H-14
L-7
D-24
D-4
D-14
WIRING DIAGRAM (LHD)
RTW48AXF025201
H-25
H-13
H-7
Antenna
cable
B-52
H-6
B-58 Horn
switch
B-71
B-55
B-56
B-62
B-63
C-108
IG1&IG2
B-65
B-73
B-80(RH)
B-81(LH)
H-10
H-27
H-26
H-24
B-44
B-43
RTW48AXF025301
RTW48AXF025301

A
SBF-1
80A (4JA1/4JH1)
100A (6VE1/C24SE)
MAIN
P-2
8
B/R
SBF-5 40A
SBF-9
IG.1
IG.2
5
3
W/B
C-108
P-1
50A
JANCTION BLOCK
C-108
P-5
B-63
B-62
3
3
W
8
20
B/Y
W/B
B1
B2
SW.
P-10
C-17
20A
IG1
ST
IG2
10A
ROOM LAMP
ACC
3
B/Y
ENGINE
C-16
10A
ANTI THEFT
DOOR LOCK
4
C-108
B-62
B-62
C-11
0.85R/Y
10A
C-117
AUDIO
HORN;
B-55
B-56
B-56
ANTI THEFT
B-56
C-117
1.25
0.5
LG/W
R/Y
10
0.5
0.5
R/W
R/W
H-8
0.85
O/W
0.85O/W
B-43
B-43
ACC
DOOR LOCK
POWER
MOTOR
SUPPLY
20
B-44
H-6
B-44
5
H-12
ANTI THEFT C/U(with KEYLESS ENTRY)
LOCK
UN LOCK
B-43
B-43
2
B-44
6
B-44
1
0.5
1
ALARMER C/U
R/L
L-1
(BUZZER)
0.5
0.5
R/W
0.5
L-9
B/W
LG/R
DOME
4
H-13
H-25
H-10
0.5
0.5
LG/R
R/L
D-20
6
D-20
PASSENGER SIDE
0.5
R/L
AUTO DOOR LOCK SW.
0.5
MAP
LIGHT
LIGHT
H-24
LG/R
DRIVER SIDE
AUTO DOOR LOCK SW.
3
D-10
L-9
L-1
2
4
D-10
0.5
0.5
0.5
B/W
R/B
R/G
1.25
B
10
7
H-12
H-12
L-7
0.5
RR DEF
R/G
13
14
H-26
H-26
(POWER WINDOW SW.)
(1)
1.25
B
H-26
H-26
B-73
0.5
WELD
R/G
SPLICE
WITH POWER WINDOW
2.0
B
2
H-7
0.5
0.5
0.5
0.5
0.5
0.5
R/B
R/G
R/B
R/G
R/B
R/G
1=with ALARMER C/U(BUZZER) only
R-6
1
R-6
2
R-1
R-1
2
R-10
R-10
DOOR SW-RR LH
0.5
R/G
DOOR SW-RR RH
0.5
B/W
DOOR SW-PASS
BODY
C-14
OFF
STARTER
DOOR SW-DR
P-6
B
1
2
R-9
2.0
C-109
R-9
BODY-CTR
RTW48AXF025001
RTW48AXF025001

A
2
W
EB-16
10A
HAZARD
HAZARD SW
0.5
0.5
G
3
B-81
B-80
HAZARD
HAZARD
RELAY-LH
RELAY-RH
B-81
B-81
B-80
B-81
B-80
B-80
RR COMBI
RR COMBI
LH
RH
0.5
G/Y
10A
C-15
METER (+B)
DATA LINK
B-56
CONNECTOR
0.5
0.5
B-58
R/Y
G/Y
16 15 14 13 12 11 10
8
0.5
Y/L
28
0.5
0.5
0.85
B
B-44
B-44
FLASHER
5
H-6
CONTROL
1.25
B

C-109
UNLOCK
B-44
B-44
15
B-44
16
LOCK
UNLOCK
B-43
B-43
18
B-73
B-44
B-44
11
1.25L
11
15
1.25
1.25L
H-26
L/R
1.25
1.25L/R
L/Y
D-26
H-13
BR/B
L/R
D-4
LOCK
D-4
H-10
H-10
1.25
0.5
0.5
3
L/R
D-4
L/Y
D-24
D-24
H-24
0.5
KEY
H-10
D-9
L/R
D-9
0.5
1.25
4
BR/B
H-16
H-10
1.25
BR/B
3
D-9
H-16
D-18
D-18
D-18
H-14
1.25
BR/B
6
H-14
1.25
1.25
L/R
3
H-14
H-16
1.25
BR/B
1.25
L/R
D-14
D-14
D-14
D-26
H-13
1.25
UN LOCK
L/R
H-25
0.5
UN LOCK
0.5
UN LOCK
H-13
H-13
0.5
LOCK
BR/R
L/R
0.5
2
B
0.5
1.25
0.5BR/B
LOCK
L/R
8
H-18
H-26
H-26
UN LOCK
1.25
0.5LG/W
LOCK
0.5
BR/B
SPLICE
0.5BR/R
0.5BR/B
1.25
0.5
WELD
0.85 B
1.25L/R
L/Y
BODY-CTR
B-43
1
B-52
B-52
ENGINE HOOD SW
LOCK
C-30
C-30
2
2
0.5
0.5
KEY
CYLINDER
CYLINDER
SW.
SW.
DRIVER
D-26
D-4
DOOR LOCK
2
2
0.5
0.5
ACTUATOR
DRIVER
H-7
PASSENGER
D-24
D-9
DOOR LOCK
2
2
0.5
0.5
ACTUATOR
PASSENGER
D-18
2
1.25
H-14
1.25
B
B-73
WELD
SPLICE
C-109
H-7
2B
B-73
C-2
C-109
ENGINE
BODY-CTR
WELD
SPLICE
6
H-26
BODY-CTR
2
B
1.25B
WELD
SPLICE
RR-LH
L/W
H-16
SPLICE
WELD
ACTUATOR
1.25
B-73
DOOR LOCK
ACTUATOR
RR-RH
L/W
B-65
D-14
DOOR LOCK
ROOM-RH
B-73
WELD
SPLICE
RTW48AXF025101
B-43
B-44
H-7
B-73
IG1&IG2
Horn B-58
swittch
B-71
B-55H-26
B-56
B-62
B-63
C-108
H-18
B-52
WIRING DIAGRAM (RHD with keyless)
RTW48AXF024701
C-2
C-117
C-30
D-23
D-24
D-20
H-24
H-10
P-10
H-18
D-27
P-6
P-5
P-1
2nd Battery
(EUROPE)
H-26
P-2
R-6
L-9
C20 FUSE
H-16 R-10
C-1
L-1
B-8,B-7,B-40 RELAY
JUNCTION BLOCK
H-13
SBF-9 SLOW BLOW FUSE
EB16
FUSE
SBF-1
EB-1
RELAY
DIODE
X-16, X-17
X-15
R-9
X-1
H-25
R-1
H-14
L-7
D-26
D-10
D-25
D-28
WIRING DIAGRAM (Super Lock)
RTW48AXF025501
B-43
B-44
B-73
IG1&IG2
Horn B-58
swittch
B-71
B-55H-26
B-56
B-62
B-63
C-108
H-18
RTW48AXF025601
WIRING DIAGRAM (RHD)

A
(4JA1/4JH1)
SBF-1 80A
100A (6VE1/C24SE)
MAIN
P-2
8
B/R
SBF-5 40A
IG.1
P-1
P-5
8
B
P-6
20
B/Y
BODY
ENGINE
STARTER
SW.
P-10
SBF-9 50A
IG.2
3
W/B 2
C-108
5
W 1
C-108
B-63
3 3
W
B1
B-62
3 2
W/B
B2
IG1
3
B/Y 3
B-62
ST
IG2
JANCTION BLOCK
C-14 20A
DOOR LOCK
OFF
C-17 10A
ANTI THEFT
C-16 10A
ROOM LAMP
ACC
3
L 4
B-62
0.85R/Y
C-108 6
2
C-117
C-11 10A
AUDIO
B-56
0.5
R/Y
3
B-43
ACC
B-55
4
B-56
8
B-56
4
1.25
LG/W
0.5
R/W
9
B-43
DOOR LOCK
MOTOR B
4
B-44
POWER
SUPPLY
C-117
1
HORN;
ANTI THEFT
1
H-18
0.5
R/W
5
B-44
5
H-12

B-44
0.5
B/W
D-20 D-20
0.5
LG/R
1
ALARMER C/U
(BUZZER)
2
L-1
0.5
R/W
L-9
DOME
LIGHT
4
7
H-13 H-25
AUTO DOOR LOCK SW.
PASSENGER SIDE
AUTO DOOR LOCK SW.

DRIVER SIDE
0.5
R/L
B-44
D-10
0.5
R/L
3
4
D-10
L-1
0.5
R/B
0.5
B/W
13
H-26
(POWER WINDOW SW.)
0.5
R/G
R-6
0.5
R/G
0.5
R/G
RR DEF
(1) 1.25
9
H-26
2
H-26
B-73
R-6
R-1
WELD
SPLICE
0.5
R/G
0.5
R/B
DOOR SW-PASS
DOOR SW-DR
0.5
B/W
R-1
7
H-12
L-7
0.5
R/G
WITH POWER WINDOW
L-9
1.25 2
B
10
H-12
14
H-26
0.5
R/G
0.5
R/B
1
MAP
LIGHT
DOOR SW-RR RH
4
7
H-10 H-24
0.5
LG/R
R-10
R-10
R-9
R-9
2.0
B
H-18
0.5
R/G
0.5
R/B
DOOR SW-RR LH
LOCK UN LOCK
B-43 B-43
2
6
0.5
R/L
0.5
LG/R
2.0
B
1
C-2
ENGINE
ROOM RH
RTW48AXF023901
WIRING DIAGRAM (RHD)

A
2
W
EB-16
10A
HAZARD
HAZARD SW
0.5
0.5
G
3
X-10
X-9
HAZARD
HAZARD
RELAY-LH
RELAY-RH
X-10
X-10
X-9
X-10
X-9
X-9
RR COMBI
RR COMBI
LH
RH
0.5
G/Y
10A
C-15
METER (+B)
12
H-7
3
DATA LINK
B-56
CONNECTOR
0.5
0.5
B-58
R/Y
G/Y
16 15 14 13 12 11 10
8
0.5
Y/L
28
0.5
0.5
0.85
B
B-44
B-44
FLASHER
H-18
CONTROL
1.25
B

C-2
ALARM
UNLOCK
B-44
B-44
15
TRIGGER LOCK
B-44
16
UNLOCK
B-43
18
B-73
B-44
B-43
B-44
11
1.25L
15
1.25
1.25L
H-26
L/R
1.25
1.25L/R
L/Y
D-24
H-10
BR/B
L/R
D-4
LOCK
D-4
H-13
H-13
1.25
0.5
0.5
3
L/R
D-4
L/Y
D-26
D-26
H-25
0.5
H-13
D-9
3
D-9
D-9
0.5
1.25
L/R
BR/B
H-16
H-13
1.25
BR/B
H-16
D-18
D-18
D-18
H-14
1.25
BR/B
6
H-14
1.25
1.25
L/R
3
H-14
H-16
1.25
BR/B
1.25
L/R
D-14
D-14
D-14
D-24
H-10
1.25
UN LOCK
L/R
H-24
0.5
UN LOCK
0.5
UN LOCK
H-10
H-10
0.5
LOCK
BR/R
L/R
0.5
2
B
0.5
1.25
0.5BR/B
LOCK
L/R
8
H-18
H-26
H-26
UN LOCK
1.25
0.5LG/W
LOCK
0.5
SPLICE
0.5BR/R
0.5BR/B
BR/B
WELD
0.85 B
1.25
0.5
ROOM-RH
11
1.25L/R
L/Y
ENGINE
B-43
1
B-52
B-52
ENGINE HOOD SW
LOCK
C-30
C-30
2
2
0.5
B
KEY
KEY
CYLINDER
CYLINDER
SW.
SW.
D-24
D-4
DOOR LOCK
2
2
0.5
0.5
ACTUATOR
DRIVER
3
H-18
D-26
D-9
DOOR LOCK
2
2
0.5
0.5
ACTUATOR
PASSENGER
D-18
2
1.25
D-14
DOOR LOCK
L/W
RR-LH
L/W
1.25
WELD
SPLICE
C-2
C-2
C-2
B-73
WELD
1.25
H-14
1.25B
SPLICE
H-18
H-16
B-73
ACTUATOR
1.25
RR-RH
DOOR LOCK
ACTUATOR
5
0.5
6
H-26
ENGINE
ROOM-RH
C-2
H-18
2B
ENGINE
ENGINE
ENGINE
ROOM-RH
ROOM-RH
ROOM-RH
B-73
WELD
SPLICE
RTW48AXF024001

A
(4JA1/4JH1)
SBF-1 80A
100A (6VE1/C24SE)
MAIN
P-2
8
B/R
SBF-5 40A
IG.1
P-1
P-5
8
B
P-6
20
B/Y
BODY
ENGINE
STARTER
SW.
P-10
SBF-9 50A
IG.2
3
W/B 2
C-108
5
W 1
C-108
B-63
3 3
W
B1
B-62
3 2
W/B
B2
IG1
3
B/Y 3
B-62
ST
IG2
JANCTION BLOCK
C-14 20A
DOOR LOCK
OFF
C-17 10A
ANTI THEFT
C-16 10A
ROOM LAMP
ACC
3
L 4
B-62
0.85R/Y
C-108 6
2
C-117
C-11 10A
AUDIO
B-56
0.5
R/Y
3
B-43
ACC
B-55
4
B-56
8
B-56
4
1.25
LG/W
0.5
R/W
9
B-43
DOOR LOCK
MOTOR B
4
B-44
POWER
SUPPLY
C-117
1
HORN;
ANTI THEFT
1
H-18
0.5
R/W
5
B-44
5
H-12
ANTI THEFT C/U with SUPER LOCK

B-44
0.5
B/W
AUTO DOOR LOCK SW.

DRIVER SIDE
D-20
6
BD-20
1
ALARMER C/U
(BUZZER)
2
L-1
0.5
R/W
L-9
DOME
LIGHT
4
7
H-13 H-25
0.5
LG/R
AUTO DOOR LOCK SW.

PASSENGER SIDE
0.5
R/L
B-44
D-10
0.5
R/L
3
4
D-10
L-1
0.5
R/B
0.5
B/W
13
H-26
(POWER WINDOW SW.)
0.5
R/G
R-6
0.5
R/G
0.5
R/G
RR DEF
(1) 1.25
9
H-26
2
H-26
B-73
R-6
R-1
WELD
SPLICE
0.5
R/G
0.5
R/B
DOOR SW-PASS
DOOR SW-DR
0.5
B/W
R-1
7
H-12
L-7
0.5
R/G
WITH POWER WINDOW
L-9
1.25 2
B
10
H-12
14
H-26
0.5
R/G
0.5
R/B
1
MAP
LIGHT
DOOR SW-RR RH
4
7
H-10 H-24
0.5
LG/R
R-10
R-10
R-9
R-9
2.0
B
H-18
0.5
R/G
0.5
R/B
DOOR SW-RR LH
LOCK UN LOCK
B-43 B-43
2
6
0.5
R/L
0.5
LG/R
2.0
B
1
C-2
ENGINE
ROOM RH
RTW48AXF025401

A
2
W
EB-16
10A
HAZARD
HAZARD SW
0.5
0.5
G
3
X-10
3
X-9
X-10
1
X-9
HAZARD
HAZARD
RELAY-LH
RELAY-RH
X-10
X-10
4
X-9
X-9
RR COMBI
RR COMBI
LH
RH
0.5
G/Y
12
H-7
0.5
G/Y
28
B-44
FLASHER
CONTROL

ALARM
TRIGGER LOCK
LOCK
B-44
B-44
15
UNLOCK
B-43
18
SUPER LOCK
B-43
B-44
24
1.25L
1.25L/R
0.5BR/B
1.25
L
1.25
1.25L
L/R
0.5
1.25O
BR/B
1.25
L/R
1.25L/R
D-23
6
D-23
L/R
D-23
D-25
D-26
KEY
KEY
CYLINDER
CYLINDER
SW.
1.25
BR/B
L/R
10
H-13
H-25
1.25
1
D-25
D-25
D-25
D-25
LOCK
D-23
0.5
0.5
2
5
H-13
UN LOCK
UN LOCK
D-23
D-24
H-25
H-13
1.25
L/R
LOCK
H-24
UN LOCK
1.25
BR/B
10
H-10
LOCK
0.5
0.5
L/R
5
H-10
UN LOCK
H-24
LOCK
2
H-10
SW.
D-24
D-23
7
2
0.5
0.5
DOOR LOCK
ACTUATOR
DRIVER
D-26
D-25
7
2
0.5
0.5
B-73
B-73
WELD
WELD
SPLICE
SPLICE
DOOR LOCK
ACTUATOR
PASSENGER
RTW48AXF024801
RTW48AXF024801
10A
C-15
METER (+B)
DATA LINK
B-56
CONNECTOR
0.5
IMMOBILIZER C/U
B-58
R/Y
16 15 14 13 12 11 10
8
B-68
0.5
0.3
V
Y/L
0.5
0.5
B-44
0.85
B
B-44
H-18
1.25
B

C-2
B-73
B-44
11
ENGINE
B-43
B-44
ROOM-RH
11
WELD
SPLICE
0.85 B
0.5BR/R
B
0.5LG/W
H-18
9
0.5
H-26
H-26
BR/R
5
H-26
H-26
1.25
L
1.25
L/R
D-27
D-27
6
D-27
D-27
1.25
BR/B
H-14
1.25
L/R
D-28
H-14
D-28
D-28
6
D-28
3
D-28
1
B-52
B-52
1
C-30
C-30
2
2
0.5
B
LOCK
UN LOCK
D-27
L/R
6
H-14
1.25
1.25
LOCK
3
H-14
H-16
UN LOCK
1.25
BR/B
H-16
UN LOCK
0.5
6
H-16
LOCK
H-16
LOCK
BR/B
UN LOCK
0.5
15
ENGINE HOOD SW
3
H-18
5
0.5
B
1.25
7
1.25
D-14
DOOR LOCK
ACTUATOR
1.25
RR-RH
L/W
RR-LH
L/W
DOOR LOCK
ACTUATOR
H-18
B
D-18
2
B
C-2
C-2
C-2
H-16
H-14
1.25B
ENGINE
ENGINE
ENGINE
ROOM-RH
ROOM-RH
ROOM-RH
1.25
B
6
H-26
ENGINE
ROOM-RH
C-2
H-18
2B
B-73
WELD
SPLICE
RTW48AXF024901
RTW48AXF024901
Antitheft control unit (A)
TYP:O-AM 433,92 MHz
897
361
7050
BARCODE
RAA4C0MF000101
Pin-outs
28 27 26 25 24 23 22 21 20 19 18 17 16 15
14 13 12 11 10 9
5 4 3 2 1
10
11
12
RAA4C0MF000201
Pin-Assignment
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
No.
1
2
3
4
5
6
7
8
9
10
11
12
Pin Assignment 28 PIN

Contact switch driver door
Contact switch doors
Power supply antitheft

horn
Contact switch engine compartment
Diagnosis
Status LED
Lock driver side door lock cylinder

Unlock driver side door lock cylinder
Micro Switch, lock / unlock door lock motor
Flasher control
Pin Assignment 12 PIN
Key in
Micro Switch, unlock, auto door lock

Lock, locking motors
Unlock, locking motors
Power supply locking motors
Ground
lmportant information on Programming

Security code
The security code protects the antitheft control unit
against unauthorized programming and data
access from Tech-2. The security code consists of a
4 digit code number and is programmed into the
antitheft Control Module (ACU).
New control units are not programmed with a
security code.
If the control units are replaced, the security code
entered in the transmitter (into remote key).
Must be programmed into the new control unit
with Tech-2.
The security code can only be programmed with
Tech-2 once and must therefore be performed with
great care.
Once programmed, the security code cannot be
overwritten. An already used antitheft can be
reused in a different car by initializing the antitheft.
After that you can program the security code again.
For initializing command you need the current
security code.
If the antitheft control unit is returned, always
enclosed the security code that is allocated to that
control unit. If this is not done, we can not process
the case and the warranty will not be recognized.
Entering a code
If the Tech-2 display requests that the
security code
Vehicle Identification No.
Country code (Select 213 Germany in all items)
be entered, process as follows;
To input a digit you need to use the up and down
buttons of the Tech-2. By using the numeric
buttons the according digit will be displayed at the
current position and the cursor will move to the
next position.
For letters you need to use the up and down
buttons of the Tech-2. The up and down key might
be used for digits as well. By using the up and
down buttons the displayed digit or letter will be
increased or decreased.
To move to the next position you need to use the
move-to-right-button.
With the two buttons, move-to-right and move-toleft you can select the position of number you want
to change.
This will allow you to correct a wrong number.
After the number is completed you need to press
the Enter button to accept the number. Correction
is now no longer possible.
Use the OKAY soft key to program the number and

the NOT OKAY soft key to abort the programming.
Tech-2 Scan Tool

From 98 MY, Isuzu dealer service departments are recommended to use Tech-2. Please refer to Tech-2 scan
tool user guide.
LTW3BALF000501
Legend
(1) PCMCIA Card
(3) DLC Cable
(4) Tech-2
(5) RS232C Cable

Tech-2 Features
1. Tech-2 is a 12volt system. Do not apply 24
volts.
card and data link connector (DLC) to the Tech2, connect the tool to the vehicle DLC.
3. Make sure the tech-2 is OFF when removing or
4. The Tech-2 has the capability of two or three
snapshot.
6. Always return to the Main Menu by pressing
the EXIT key several times before shutting
down.
Application Menu and press Clear DTC.
Getting Started
Tech-2, the following steps must be performed:
Tech-2.
2. Connect the SAE 16/19 adapter to the DLC
cable.
3. Connect the DLC cable to the Tech-2.
5. Connect the Tech-2 SAE 16/19 adapter to the
vehicle DLC.
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
060R300015
6. Turn the vehicle ignition (key) switch.

7. Power the Tech-2 ON and verify the Tech-2
power up display.
Press (ENTER) To Continue
060RW009

Operating Procedure
The power up screen is displayed when you power
up the tester with the Isuzu systems PCMCIA card.
Select one of the following
Vehicle Type(S)
(UB) Trooper
(UE) Rodeo/Amigo
(UP) AXIOM
(TF) LUV,Frontier,LAO-Rodeo
(Vehicle Type ENTER)
Press (ENTER) To Continue
(ENTER)
Vehicle Type
F0 : Diagnostics
F0 : Powertrain
F1 : View Capture Data
F1 : Chassis
F2 : Body
F2 : Tool Options
(F2 ENTER)
F3 : Down load/Up load Help
(F0 ENTER)

Body
Model Year(S)
Antitheft
(Model year ENTER)

060R100102

Menu
The following table shows which functions are
used for the available equipment versions.

diagnostic scan tool clear DTC information
function.

F0: Read DTC Info Ordered By Priority
F1: Read DTC Info As Stored By ECU
F3: Read Alarm Codes
F1: Data Display
F2: Snap Shot
F3: Actuator Test
F0: Unlock/Lock Test
F1: Arm/Disarm Signal Test
F2: Horn Signal Test
F3: Turn Signal Test
F4: Theft LED Test
F4: Programming
F0: Erase Remote Keys
F1: Program Remote Keys
F2: Program Anti Theft Warning
F3: Program Country Code
F4: Program Vehicle Options
Tech-2 Data Display

Use the Tech-2 Data Values only after the On-Board
Diagnostic System Check has been completed, no
DTC (s) were noted, and you have determined that
the on-board diagnostics are functioning properly.
The Tech-2 data values represent values that would
be seen on a normally-Antitheft system.
Actuator Test
The actuator tests are used to check abnormalities
in the antitheft control system.
The actuators are operated by the ECU based on
the Tech-2 command signal.
Observe the actuators to check abnormalities in the
antitheft system.
Note: Before going to programming process, Tech2 indicates instruction as follows.
Unlock/Lock Test
The unlock/lock test is used to check abnormalities
in the door lock control system.
1. Select Body and Antitheft.
2. Select Actuator Test and Unlock/Lock Test.
3. Observe the door lock function.
4. Press the lock bottom.
5. Press the unlock bottom.
Unlock/Lock Test
Electronic System; Anti Theft Warning
See Checking Procedure Before

Programming!
Unlock/Lock
Unlock
Confirm
060R200289
DTC
On OBD has two options available in the Tech-2
DTC mode to display the enhanced information
available.
Read DTC Info Ordered By Priority
Read DTC Info As Stored By ECU
Quit
Unlock
Lock
RAW4B0SH000101

Arm/Disarm Signal Test
Arm/Disarm signal test is used to check
abnormalities in arm/disarm signal circuit.
2. Select Actuator Test and Arm/Disarm Signal
Test.
3. Observe the data list.
4. Insert the key into door key cylinder.
5. Remove the key into door key cylinder.
Turn Signal Test

Turn signal test is used to check abnormalities in
turn signal circuit.
2. Select Actuator Test and Turn Signal Test.
3. Observe the flasher lamp.
4. Push active bottom.
5. Check the flasher lamp function.
Turn Signal Test
Arm/Disarm Signal Test
Turn Signal
Arm/Disarm Signal
Quit
Quit
Inactive 12V
Disarmed
Disarmed
Inactive
Active
Arm
RAW4B0SH000401
RAW4B0SH000201
Horn Signal Test

Horn signal test is used to check abnormalities in
horn signal circuit.
2. Select Actuator Test and Horn Signal Test.
3. Observe the alarm sound.
5. Check the alarm sound function.
Theft LED Test

Theft LED test is used to check abnormalities in
theft LED signal circuit.
2. Select Actuator Test and Turn Signal Test.
3. Observe the antitheft LED.
5. Check the antitheft function.
Theft LED Test
Horn Signal Test

Horn Signal
Quit
Theft LED
Inactive 12V
Inactive
Active
Quit
Off
Off
On
RAW4B0SH000501
RAW4B0SH000301

Programming
Programming antitheft function is used to input
security code for the antitheft system by tech 2.
If the remote key or ECU replaced, program as
necessary.
Erase Remote Keys
2. Select Programming.
3. Select Erase Remote Keys.
Security Code
0000
Press ENTER Key to continue
Programming
F0;
Erase Remote Keys
F1;
Program Remote Key
F2;
Program Anti Theft Warning
F3;
Program Country Code
F4;
Program Vehicle Option
Not
Okay
Okay
060R200284
RAW4B0SH000601

Programming!
Confirm
060R200289

Program Remote Keys
3. Select Program Remote Keys.
Programming
F0;
Erase Remote Keys
Security Code
0000
F1;
Program Remote Key
F2;
F3;
F4;
Not
Okay
Okay
060R200284
5. Input the security code.

RAW4B0SH000601

Programming!
Confirm
060R200289

Program Antitheft Warning
3. Select Program Antitheft Warning.
Programming
F0;
Erase Remote Keys
Security Code
0000
F1;
Program Remote Key
F2;
F3;
F4;
Not
Okay
Okay
060R200284
5. Input the security code.

RAW4B0SH000601

Programming!
Confirm
060R200289

3. Select Program Country Code.
Programming
F0;
Erase Remote Keys
Security Code
0000
F1;
Program Remote Key
F2;
F3;
F4;
Not
Okay
Okay
060R200284
5. Input the country code.

Select 213 Germany in all items.
RAW4B0SH000601

Programming!
Confirm
060R200289

Program Vehicle Options
3. Select Program Vehicle Options .
Programming
F0;
Erase Remote Keys
Security Code
0000
F1;
Program Remote Key
F2;
F3;
F4;
Not
Okay
Okay
060R200284
5. Input the vehicle options.

RAW4B0SH000601

Programming!
Confirm
060R200289

Tech-2 Data List
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
Streings
Battery Voltage
KEY-IN Status
CDLS-Motor Voltage (Central Door Locking System)
Accident Sensor (Crash Sensor)
Remote Key
Remote-Key Detected
Key Function Detected
Prev. Detected Remote-Key (Previously)
Previously Key Function
Remote-Key 1 Status
Remote-Key 2 Status
Remote-Key 3 Status
Remote-Key 4 Status
Remote-Key 5 Status
Front Door Unlock Switch
Front Door Lock Switch
Front Door Lock Status
Auto Door Unlock Switch
Auto Door Lock Switch
Auto Door Lock Status
Trunk Signal Switch
Doorknob Switch
Doorknob Status
Trunk Doorknob Switch
Trunk Doorknob Status
Driver Door Switch
Driver Door Status
All Door Switch
All Door Status
Doorlock Tamper Switches
Engine Hood Switch
Engine Hood Status
Trunk Switch
Trunk Status
Pane Breakage Connected
Pane Breakage Status
CDLS-Motor Current (Central Door Locking System)
CDLS-Motor Unlock (Central Door Locking System)
CDLS-Motor Lock (Central Door Locking System)
Overflow Protection
Turn Signal
Horn Connected
Horn Signal
Theft LED
CDLS-Status (Central Door Locking System)
Selftest Request
Last Use
Theft Status
Alarm Status
Security Wait Time
Units
V
ON/OFF
V
Active/Inactive
Active/Inactive
Remote Key No.
Lock/Unlock
Remote Key No.
Lock/Unlock
In Range/Not Programmed
Active/Inactive
Active/Inactive
Active/Inactive
Active/Inactive
Active/Inactive
Active/Inactive
*Not used
Open/Closed
Open/Closed
Lock/Unlock
*Not used
Open/Closed
*Not used
Lock/Unlock
Open/Closed
Open/Closed
Open/Closed
Open/Closed
Open/Closed
Open/Closed
Open/Closed
*Not used
Open/Closed
*Not used
Open/Closed
*Not used
Yes/No
*Not used
Disabled/Abled
A
V
V
Active/Inactive
Active/Inactive
Yes/No
Active/Inactive
ON/OFF
Lock/Unlock
Active/Inactive
Disabled/Abled
Active/Inactive
Active/Inactive
DIAGNOSIS
Diagnostic procedure
Once the cause of DTC is repaired or gone,
engine can be operated normally, and present
DTC becomes history code.
History code is canceled by no repeat failure on
25 consequence ignition key on afterward.
History code cannot be canceled by battery
connector disconnected.

IMPORTANT: Do not clear DTCs unless directed to
do so by the service information provided for each
diagnostic procedure. When DTCs are cleared, the
Failure Record data which may help diagnose an

comprehensive for vehicles with immobilizer
system diagnostic. Following a repair, the
technician should perform the following steps:
2. Clear DTC (s).
3. Operate the vehicle within conditions noted in
the Fail Records.
4. Monitor the DTC status information for the DTC
which has been diagnosed until the diagnostic
Following these steps are very important in
verifying repairs on immobilizer systems. Failure to
follow these steps could result in unnecessary
repairs.
Diagnostic Aids
Poor connections.
Miss routed harness.
Poor connection at ACU-Inspect harness
mating, broken locks, improperly formed or
connection.
damage.
If the harness appears to be OK, observe the

data display on the Tech2 while moving
switch or actuator.
A change in the display will indicate the location
of the fault.
If DTC cannot be duplicated, the information
included in the Failure Records data can be
useful in determined vehicle mileage since the
DTC was last set.
If it is determined that the DTC occurs
intermittently, performing the DTC Diagnostic
Chart may isolate the cause of the fault.
NOTE: Breakage of antitheft fuse does not operate
antitheft system. Check LED lamp flashes at this
time.
Check the Electro-Magnetic Interference (EMI)
Location of vehicle check
Move the vehicle to a new location and perform
the check again.
Non-OEM Parts.
Switch is OFF or remove the Non-OEM parts
and perform the check again.
Other
Remove the accessory and another key from
key.
Check the other items.
Battery voltage is low.
Antitheft programming functions.
Must be programmed antitheft system.
Registration for security code, antitheft control
unit parts number.
Key switch operation.
Antitheft system may detect a history DTC by
the timing of ON-OFF of a key switch.
Active the antitheft system.
Keyless entry system is malfunction.
Immobilizer system is malfunction.
Check the operation
Check the operation "Lock / unlock" by using
transmitter (key) on the vehicle.

Diagnostic Trouble Code (DTC) List For Antitheft
DTC
13
14
16
20
21
22
23
24
25
28
29
31
32
36
37
41
42
43
44
45
47
50
51
52
55
123
125
Description
Security code not yet programmed
No remote key programmed
Door lock actuators short circuit to ground
Broken wire to door lock actuators
Remote key 1 with random code out of capture range
Input immobiliser short circuit to ground
Broken wire to immobiliser
Actuator driver door defect
Actuator passenger door defect
Broken wire to driver door
Broken wire to passenger door
Driver door switch unlock defect
Driver door switch lock defect
Driver door switch dead lock defect
Passenger door switch lock defect
Passenger door switch unlock defect
Battery voltage for door lock actuators is missing
A/D converter defect or battery voltage less than 9 volt
E E P ROM defect
E E P ROM not programmed by ISUZU
Control unit defect
Output flasher short circuit to grpund or broken wire
Output alarm horn broken wire

Antitheft System Check
Step
1
Action
Yes
No
Go to Step 2
Go to
No antitheft
lamp
Go to
DTC table
Go to Step 3

Install the Tech-2.
Key position is ON or OFF.
Attempt to display antitheft data with the
Tech-2.
Does the Tech-2 display antitheft data?
Go to Step 9
Go to Step 4
1. Key position is OFF, disconnect the

antitheft control unit (ACU).
2. Check the DLC (Data Link Connector) circuit
for an open, short to ground, or short to
voltage.
open or short to ground and the DLC ground
Go to Step 5
Go to Step 6
Repair or replace the DLC (Data Link Connector)

circuit.
Go to Step 3
1. Check the ACU ground circuit for an open, or

short to voltage. Also, check the ACU ignition
feed circuit for an open or short to ground
and the ACU ground circuit for an open.
Verfy repair
Go to Step 7
Replace the antitheft control unit (ACU).

IMPORTANT: The replacement ACU must be
programmed the antitheft data by Tech-2.
Go to Step 8
Select Display DTCs with the Tech-2.

Go to applicable
DTC table
System OK
Go to
applicable
section
1. Key position is ACC, shut all doors and

bonnet.
2. Observe the antitheft lamp.
Note: When a key switch is ACC, antithft
lamp will turn on and a antitheft lamp (LED)
will be flashing after 10 seconds.
Is the antitheft lamp "ON or flashing?
Key position is ON, engine OFF.
Observe the antitheft lamp.
Key position is turned ACC.
Check the antitheft lamp will be turned
flashing and lamp will be turned ACC after 10
seconds.
Is the antitheft lamp flashing?
Value (s)
1.
2.
3.
4.
1.
2.
3.
4.
1. Observe the antitheft data list on Tech-2.


No Antitheft Lamp
Step
1
Action
Value (s)
Yes
No
Check the fuse for the antitheft power feed

circuit. (10A)
If a problem found, repair as necessary.
Was the probem found?
Verify repair
Go to Step 2
1. Check the ACU ground circuit for an open, or

short to voltage. Also, check the ACU ignition
feed circuit for an open or short to ground
and the ACU ground circuit for an open.
Verfy repair
Go to Step 3
1. Check the antitheft lamp LED circuit for an

open, or short to voltage.
Verify repair
Go to Step 4

2. Install the Tech-2.
3. Key position is ACC or OFF.
4. Observe to display lamp data with the Tech-2.
Does the Tech-2 display antitheft lamp data ON?
Go to Step 5
Go to Step 6
Verify repair
Verify repair
Replace the antitheft lamp.

programmed the antitheft data by Tech-2.

DTC 13 Security Code not yet programmed
Step
1
Action
Value (s)
Yes
No
Was the Antitheft System Check.

performed?
Go to Step 2
Go to Antitheft
System Check
Check the key.

Go to Step 3
Refer to
Diagnostic Aids
Check the Antitheft programming functions by

Tech-2.
All transmitter (Remote Key).
If a problem is found, reprogramming as necessary.
(Refer to Important information on Programming)
Go to Step 4
Go to Step 5
Recheck the DTC.

1. Key position is OFF and keep the position
for more than 30 seconds.
3. Check the DTC on Tech-2.
Is DTC 13 stored?
Go to Step 5
Verify repair
Recheck the DTC.

1. Non-OEM parts switch is OFF or remove
the Non-OEM parts.
2. Remove the accessory and another key from
key.
6. Check the DTC on Tech-2.
Is DTC 13 stored?
Go to Step 6
Verify repair
Replace the Antitheft control unit (ACU).

programmed the security data by the Tech-2.
Is DTC 13 stored?
Go to Step 7
Verify repair
Replace the key and lock cylinder assembly with

Antitheft system (ACU ).
IMPORTANT:
ACU is not replacing simultaneously.
After replace lock cylinders, perform the
following below the items.
Replace the keys and key cylinders.
Program the Antitheft system.
(Refer to Important information on
Programming)
Verify repair

DTC 14 No Remote Key Progurammed
Step
1
Action
Value (s)
Yes
No
Was the Antitheft System Check

performed?
Go to Step 2
Go to antitheft
System Check
Check the key.

Go to Step 3
Refer to
Diagnostic Aids
Check the antitheft programming functions.

Transmitter (Remote Key).
Go to Step 4
Go to Step 5
Perform the antitheft programming functions.

Programming)
Go to Step 5
Recheck the DTC.

3. Check the DTC on the Tech-2.
Is DTC 14 stored?
Go to Step 6
Verify repair
Replace the transmitter (Remote Key).

IMPORTANT: The replacement transmitter
(Remote Key) must be programmed the security
data by the Tech-2.
Go to Step 7
Recheck the DTC.

Is DTC 14 stored?
Go to Step 8
Verify repair

Verify repair

DTC 16 Door Lock Actuators Short Circuit to Ground
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Check the door lock actuators circuit.

2. Disconnect the antitheft control unit (ACU).
3. Check the door lock actuator circuit for short
to ground.
If the problem found, repair as necessary.
Verify repair
Go to Step 3
Recheck the DTC.

Is DTC 16 stored?
Go to Step 5
Verify repair

Verify repair

DTC 20 Broken wire to door lock actuators
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

2. Install the Tech-2 on vehicle.
Is DTC 20 stored?
Go to Step 3
Refer to
Diagnostic Aids
Check the door lock actuator circuit.

3. Disconnect the door lock motor.
4. Check the antitheft/door lock motor line
circuit for an open, short to ground.
Also, check the ignition feed circuits for an
open or short to ground and the ACU ground
Go to Step 4
Go to Step 5
Repair or replace the antitheft/door lock motor

circuit.
Verify repair

programmed the security data by the tech2.
Verify repair

DTC 21 Remote Key 1 With Random Code Out Of Capture Range
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Check the key.

Go to Step 3
Refer to
Diagnostic Aids
Check the antitheft programming functions to the

peculiar key with the Tech-2
Go to Step 4
Go to Step 5

Programming)
Go to Step 5
Recheck the DTC.

Is DTC 21 stored?
Go to Step 6
Verify repair

data by Tech-2.
Go to Step 7
Recheck the DTC.

Is DTC 21 stored?
Go to Step 8
Verify repair

Verify repair

Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Check the key.

Go to Step 3
Refer to
Diagnostic Aids

Go to Step 4
Go to Step 5

Programming)
Go to Step 5
Recheck the DTC.

Is DTC 22 stored?
Go to Step 6
Verify repair

IMPORTANT: The replacement Transmitter
data by Tech-2.
Go to Step 7
Recheck the DTC.

Is DTC 22 stored?
Go to Step 8
Verify repair

Verify repair

Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Check the key.

Go to Step 3
Refer to
Diagnostic Aids

Go to Step 4
Go to Step 5

Programming)
Go to Step 5
Recheck the DTC.

Is DTC 23 stored?
Go to Step 6
Verify repair
Replace the Transmitter (Remote Key).

IMPORTANT: The replacement Transmitter
data by Tech-2.
Go to Step 7
Recheck the DTC.

Is DTC 23 stored?
Go to Step 8
Verify repair

Verify repair

Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Check the key.

Go to Step 3
Refer to
Diagnostic Aids

Go to Step 4
Go to Step 5

Programming)
Go to Step 5
Recheck the DTC.

Is DTC 24 stored?
Go to Step 6
Verify repair

data by Tech-2.
Go to Step 7
Recheck the DTC.

Is DTC 24 stored?
Go to Step 8
Verify repair

Verify repair

Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Check the key.

Go to Step 3
Refer to
Diagnostic Aids

Go to Step 4
Go to Step 5

Programming)
Go to Step 5
Recheck the DTC.

Is DTC 25 stored?
Go to Step 6
Verify repair

data by Tech-2.
Go to Step 7
Recheck the DTC.

Is DTC 25 stored?
Go to Step 8
Verify repair

Verify repair

DTC 28 Input Immobilizer short circuit to ground
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 28 stored?
Go to Step 3
Refer to
Diagnostic Aids
Check the driver door locking motor function.

line circuit.
4. Check the antitheft/Immobilizer communication line circuit for short to voltage, short to
ground.
Also, check the ICU and ACU ignition feed
circuits for an open or short to ground and
the ICU and ACU ground circuit for an open.
Go to Step 4
Go to Step 5
Repair or replace the antitheft/Immobilizer

communication line circuit.
Verify repair

Verify repair

DTC 29 Broken Wire To Immobilizer
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 29 stored?
Go to Step 3
Refer to
Diagnostic Aids
Check the antitheft/immobilizer communication

line circuit.
4. Check the antitheft/Immobilizer communication line circuit for an open, short to
ground.
Also, check the ICU and ACU ignition feed
circuits for an open or short to ground and
the ICU and ACU ground circuit for an open.
Go to Step 4
Go to Step 5
Repair or replace the antitheft/Immobilizer

communication line circuit.
Verify repair

Verify repair

DTC 31 Actuator Driver Door Defect
Step
1
Action
Value (s)
Yes
No
Was the Antitheft System Check"

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 31 stored?
Go to Step 3
Refer to
Diagnostic Aids
Check the driver door locking motor function.

4. Observe to display locking motor data with
the Tech-2.
5. Turn ON by driver door lock.
Does the Tech-2 display ON voltage?
Go to Step 4
Go to Step 5

2. Observe to display unlocking motor data with
the Tech-2.
3. Turn OFF by driver door lock.
Does the Tech-2 display ON voltage?
Refer to
Diagnostic Aids,
and then go to
step 5
Go to Step 5
1. Check the driver door locking motor circuit for

Also, check the motor connector for damage.
2. If a problem found, repair as necessary.
Verify repair
Go to Step 6
1. Repair or replace the driver door lockoing

motor.
Is DTC 31 stored?
Go to Step 7
Verify repair

Verify repair

DTC 32 Actuator Passenger Door Defect
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

3 Key position is ON.
Is DTC 32 stored?
Go to Step 3
Refer to
Diagnostic Aids
Check the passenger locking motor function.

4. Observe to display locking motor data with
the Tech-2.
5. Turn ON by passenger door lock.
Does the Tech-2 display ON valtage?
Go to Step 4
Go to Step 5

2. Observe to display unlocking motor data with
the Tech-2.
3. Turn OFF by passenger door lock.
Does the Tech-2 display ON valtage?
Refer to
Diagnostic Aids,
and then go to
step 5
Go to Step 5
1. Check the passenger doorlocking motor

circuit for an open, short to ground, or short
to voltage.
Verify repair
Go to Step 6
1. Repair or replace the passenger door locking

motor.
Is DTC 32 stored?
Go to Step 7
Verify repair

Verify repair

DTC 36 Broken Wire To Driver Door
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 36 stored?
Check the driver door lock function.

4. Observe to display door lock data with the
Tech-2.
Does the Tech-2 display Closed?
Go to Step 3
Refer to
Diagnostic Aids
Go to Step 4
Go to Step 5

Tech-2.
Does the Tech-2 display Open ?
Refer to
Diagnostic Aids,
and then go to
step 5
Go to Step 5
1. Check the driver door lock circuit for an open,

short to ground, or short to voltage.
Verify repair
Go to Step 6
1. Repair or replace the driver door lock.

Is DTC 36 stored?
Go to Step 7
Verify repair

Verify repair

DTC 37 Broken Wire To Passenger Door
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 37 stored?
Go to Step 3
Refer to
Diagnostic Aids
Check the passenger door lock function.

Tech-2.
Does the Tech-2 display Closed ?
Go to Step 4
Go to Step 5

Tech-2.
Refer to
Diagnostic Aids,
and then go to
step 5
Go to Step 5
1. Check the passenger door lock circuit for an

open, short to ground, or short to voltage.
Verify repair
Go to Step 6
1. Repair or replace the passenger door lock.

Is DTC 37 stored?
Go to Step 7
Verify repair

Verify repair

DTC 41 Driver Door Lock Switch Unlock Defect
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 41 stored?
Go to Step 3
Refer to
Diagnostic Aids

4. Observe to display door lock switch data with
the Tech-2.
Go to Step 4
Go to Step 5

Tech-2.
Refer to
Diagnostic Aids,
and then go to
step 5
Go to Step 5
1. Check the driver door lock switch circuit for

Also, check the door lock connector for
damage.
Verify repair
Go to Step 6
1. Repair or replace the driver door lock switch.

Is DTC 41 stored?
Go to Step 7
Verify repair

Verify repair

DTC 42 Driver Door Lock Switch lock Defect
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 42 stored?
Go to Step 3
Refer to
Diagnostic Aids

the Tech-2.
Go to Step 4
Go to Step 5

Tech-2.
Refer to
Diagnostic Aids,
and then go to
step 5
Go to Step 5

damage.
Verify repair
Go to Step 6
Go to Step 7
Verify repair
Verify repair

Is DTC 42 stored?

DTC 43 Driver Door Lock Switch Super lock Defect
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 43 stored?
Go to Step 3
Refer to
Diagnostic Aids

the Tech-2.
Go to Step 4
Go to Step 5

Tech-2.
Does the Tech-2 display Open?
Refer to
Diagnostic Aids,
and then go to
step 5
Go to Step 5

damage.
Verify repair
Go to Step 6

Is DTC 43 stored?
Go to Step 7
Verify repair

Verify repair

DTC 44 Passenger Door Lock Switch lock Defect
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 44 stored?
Go to Step 3
Refer to
Diagnostic Aids

the Tech-2.
Go to Step 4
Go to Step 5

Tech-2.
Refer to
Diagnostic Aids,
and then go to
step 5
Go to Step 5
1. Check the passenger door lock switch circuit

voltage.
damage.
Verify repair
Go to Step 6
1. Repair or replace the passenger door lock

switch.
Is DTC 44 stored?
Go to Step 7
Verify repair

Verify repair

DTC 45 Passenger Door Lock Switch Unlock Defect
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 44 stored?
Go to Step 3
Refer to
Diagnostic Aids

the Tech-2.
Does the Tech-2 display Closed ?
Go to Step 4
Go to Step 5

Tech-2.
Refer to
Diagnostic Aids,
and then go to
step 5
Go to Step 5
1. Check the passenger door lock switch circuit

voltage.
damage.
Verify repair
Go to Step 6
1. Repair or replace the passenger door lock

switch.
Is DTC 45 stored?
Go to Step 7
Verify repair

Verify repair

DTC 47 Battery Voltage For Door Lock Actuators Is Missing
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 47 stored?
Go to Step 3
Refer to
Diagnostic Aids
12V
Go to Step 5
Go to Step 4
Verify repair
Refer to
Diagnostic Aids
12V
Go to Step 6
Go to Step 7
1. Check the door lock motor circuit for an open,

Also, check the door lock motor connector for
damage.
Verify repair

Verify repair
Check the antilock system voltage.

4. Observe to display system voltage data with
the Tech-2.
Is the voltage near the specified value ?
2. Check the battery voltage.
(Chage battery)
Check the door lock motor output voltage.
2. Connect a digital volt meter to measure
voltage.
between ACU terminal 7 and body ground.
4. Observe to display voltage with the DVM.
5. Door lock ON.

DTC 50 A/D Converter Defect Or Battery Voltage Less Than 9 Volt
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 50 stored?
Go to Step 3
Refer to
Diagnostic Aids
12V
Go to Step 7
Go to Step 4

2. Check the battery voltage.
(Chage battery)
Verify repair
Go to Step 5
1. Check the ignition feed circuit for an open,

short to ground.
Also, check the ACU ground circuit for
damage.
Verify repair
Refer to
Diagnostic Aids

Verify repair
Check the antilock system voltage.

4. Observe to display system voltage data with
the Tech-2.

DTC 51 E E P R OM Defect
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 51 stored?
Go to Step 3
Refer to
Diagnostic Aids

Verify repair

DTC 52 E E P R O M Not Programmed By ISUZU
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Check the antitheft programming functions for

EOL information with the Tech-2.
Go to Step 3
Go to Step 4

IOL information
Programming)
Go to Step 4
Recheck the DTC.

Is DTC 52 stored?
Go to Step 8
Verify repair

Verify repair

DTC 55 Control unit defect
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 55 stored?
Go to Step 3
Verify repair

Verify repair

DTC 123 Output flasher short circit to ground or broken wire
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

2. Install the tech2 on vehicle.
4. Check the DTC on the tech2.
Is DTC 123 stored?
Go to Step 3
Refer to
Diagnostic Aids
1. Check the flasher circuit for an open, short to

ground, or short to voltage.
Also, check the flasher connector for damage.
Verify repair
Go to Step 4
Check the flasher function.

2. Connect a jamper wire between ACU terminal
28 and body ground.
4. Observe to operate flasher lamp.
If the problem found about the flasher lamp
circuit, repair as necessary.
Verify repair
Go to Step 5

Verify repair

DTC 125 Output Alarm Horn Broken Wire
Step
1
Action
Value (s)
Yes
No

performed?
Go to Step 2
Go to antitheft
System Check
Recheck the DTC.

Is DTC 125 stored?
Go to Step 3
Refer to
Diagnostic Aids
1. Check the alarm horn circuit for an open,

Also, check the alarm horn connector for
damage.
Verify repair
Go to Step 4
Check the alarm horn function.

2. Connect a jamper wire between ACU terminal
5 and body ground.
4. Observe to operate sound with the alarm
horn.
If the problem found about the alarm horn,
replace as necessary.
Verify repair
Go to Step 5

Verify repair
MEMO
No. TFSCR-WE-0431

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WORKSHOP MANUAL

TFR / TFS SERIES

TFR/S Series Workshop Manual

Heating and Airconditioning

Frame and Cab

Steering Suspension,Whells and Tires

Transmission AW30-40LE Model

Transmission JR405E Model

Manual Transmission (MSG Models)

Sec.7B1 Manual Transmission (MUA Models)

Electrical-Body and Chassis

Accessories & Restraints

GENERAL INFORMATION 0A-1

0A-2 GENERAL INFORMATION

GENERAL REPAIR INSTRUCTIONS

GENERAL INFORMATION 0A-3

NOTES ON THE FORMAT OF THIS MANUAL

0A-4 GENERAL INFORMATION

6. The following symbols appear throughout the Workshop Manual.

........ Important operation requiring extra care

........ Specified torque

........ ISUZU special tool(s) required or recommended

........ Directional indication

........ Other special tool(s) required or recommended

........ Lubrication (Oil)

........ Lubrication (Grease)

........ Torque Angle Method

........ Liquid gasket application

GENERAL INFORMATION 0A-5

0A-6 GENERAL INFORMATION

VEHICLE IDENTIFICATION PLATE

BODY AND OPTION IDENTIFICATION

GENERAL INFORMATION 0A-7

Lifting Points and Supportable Point-Locations

0A-8 GENERAL INFORMATION

LIFTING POINT; FRONT

SUPPORTABLE POINT; FRONT

LIFTING POINT; REAR

SUPPORTABLE POINT; REAR

GENERAL INFORMATION 0A-9

0A-10 GENERAL INFORMATION

GENERAL INFORMATION 0A-11

SQUARE CENTIMETERS TO SQUARE INCHES

CUBIC CENTIMETERS TO CUBIC INCHES

0A-12 GENERAL INFORMATION

LITERS TO GALLONS (U.S.)

GALLONS (IMP.) TO LITERS

LITERS TO GALLONS (IMP.)

GENERAL INFORMATION 0A-13

0A-14 GENERAL INFORMATION

KILOGRAMS PER SQUARE CENTIMETERS TO POUNDS PER SQUARE INCHES

KILOGRAMS PER SQUARE CENTIMETERS TO KILO PASCAL

KILO PASCAL TO KILOGRAMS PER SQUARE CENTIMETERS

GENERAL INFORMATION 0A-15

KILOGRAMMETERS TO FOOT POUNDS

0A-16 GENERAL INFORMATION

MAINTENANCE AND LUBRICATION 0B-1

MAINTENANCE AND LUBRICATION

0B-2 MAINTENANCE AND LUBRICATION

MAINTENANCE SCHEDULE (For GENERAL EXPORT)

(Use odometer reading

Idling speed and acceleration

* D Engine oil (4JH1-TC)