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BACK TO FOREWORD & ENGINE INDEX RANG.DRFT.REPAIR MANUAL PAGES. FROM.
MANUAL
TO. MODEL .INDEX
CONTENTS
Title Section
General Information GI
GI
Ranger / Drifter G6 B1
Repair Engine F8/FE
WL, WL Turbo B2
Manual F2 B3
Lubrication System D
Cooling System E
G6 F1
WL, WL Turbo F2
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Fuel and Emission
Control Systems
F2 CIS F3
F2 CARB F4
Engine Electrical System G
Clutch H
M15M–D
M15MX–D J1
APPLICATION: Manual Transmission R15M–D

R15MX–D J2
This manual is applicable to vehicles
beginning with the Vehicle Identification Transfer J3
Numbers (VIN), and related materials
shown on the following page. Propeller Shaft L
Front and Rear Axles M
Steering System N
Braking System P
Suspension R
Body S
Body Electrical System T
Heater and Air Conditioner Systems U
Technical Data TD
Special Tools ST
ST
1999 Ford/Mazda Motor Company

All rights reserved. Reproduction by any means, electronic or
mechanical including photocopying, recording or by any
information storage and retrieval system or translation
in whole or part is not permitted without written
authorization from Ford/Mazda Motor Company.
PRINTED IN JAPAN, JAN.1999
F161–10–99A
RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
BACK.TO.MAIN.INDEX TO. MODEL .INDEX
VEHICLE IDENTIFICATION NUMBERS (VIN)

U.K. specs.
JMZ UN1B320W 100001–
JMZ UN8B320W 100001–
JMZ UN8F420W 100001–
European specs.
JMZ UN1*620W 100001–
JMZ UN1*62WW 100001–
JMZ UN1*320W 100001–
JMZ UN1*32WW 100001–
JMZ UN8*720W 100001–
JMZ UN8*72WW 100001–
JMZ UN8*320W 100001–
JMZ UN8*32WW 100001–
General specs. (L.H.D.)

MM7 UNY02100 100001–
MM7 UNY021WW 100001–
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MM7 UNYOW100 100001–
MM7 UNYOW1 WW 100001–
MM7 UN2*6*00 100001–
MM7 UN2*6*WW 100001–
MM7 UN3*6*00 100001–
MM7 UN3*6*WW 100001–
MM7 UN2*2*00 100001–
MM7 UN2*2*WW 100001–
General specs. (R.H.D.)
MM6 UNY02100 100001–
MM6 UNYOW100 100001–
RELATED MATERIALS
B Series Training Manual .......................................... 3333-10-99A
Engine Workshop Manual WL, WL Turbo ................ 1532-10-96C
Engine Workshop Manual G6 .................................... 1640-10-99A
Engine Workshop Manual F2 .................................... 1641-10-99A
Manual Transmission Workshop Manual
M15M-D M15MX-D .............................................................. 1645-10-99A
Manual Transmission Workshop Manual
R15M-D R15MX-D.................................................... 1642-10-99A
B Series Wiring Diagrams
(European, General specs. (L.H.D.)) ..................... 5449-10-99A
B Series Wiring Diagrams
(European, General specs. (R.H.D.)) .................... 5450-10-99A
CONTINUED
GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . GI-1 DYNAMOMETER . . . . . . . . . . . . . . . . . . . . . . . . GI–10
RANGE OF TOPICS . . . . . . . . . . . . . . . . . . . . . GI-1 INSTALLATION OF RADIO SYSTEM . . . . . . . . GI–10
SERVICING PROCEDURE . . . . . . . . . . . . . . . GI-1/2 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . GI–11
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI-3 ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . GI–11
ADVISORY MESSAGES . . . . . . . . . . . . . . . . . . GI-3 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . GI–11/13
TROUBLESHOOTING PROCEDURE . . . . . . GI-3/6 ELECTRICAL TROUBLESHOOTING
TEXT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . GI-6 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–13
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI-7 JACKING POSITIONS . . . . . . . . . . . . . . . . . . . . . . GI–14
FUNDAMENTAL PROCEDURES . . . . . . . . . . . . GI-8 VEHICLE LIFT (2 SUPPORTS) POSITIONS . . . GI–14
PROTECTION OF THE VEHICLE . . . . . . . . . . GI-8 SAFETY STAND POSITIONS . . . . . . . . . . . . . . . GI–14
PREPARATION OF TOOLS AND TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–15
MEASURING EQUIPMENT . . . . . . . . . . . . . . GI-8 TOWING HOOKS . . . . . . . . . . . . . . . . . . . . . . . . GI–16
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . GI-8 TIEDOWN HOOKS . . . . . . . . . . . . . . . . . . . . . . . GI–16
DISCONNECTION OF THE NEGATIVE IDENTIFICATION NUMBER LOCATIONS . . . . . GI–16
BATTERY CABLE . . . . . . . . . . . . . . . . . . . . . . GI-8 VEHICLE IDENTIFICATION NUMBER . . . . . . GI–16
REMOVAL OF PARTS . . . . . . . . . . . . . . . . . . . . GI-8 ENGINE IDENTIFICATION NUMBER . . . . . . . GI–16
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . GI-8 NEW STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . GI–17/19
INSPECTION DURING REMOVAL, ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . GI–19
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . GI-8 PRE-DELIVERY INSPECTION. . . . . . . . . . . . . .GI-20
ARRANGEMENT OF PARTS . . . . . . . . . . . . . . GI-8/9 PRE-DELIVERY INSPECTION TABLE . . . . . . GI-20
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CLEANING OF PARTS . . . . . . . . . . . . . . . . . . . GI-9
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . GI-9
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . GI-9
RUBBER PARTS AND TUBING . . . . . . . . . . . GI–19
HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . GI–19
TORQUE FORMULAS . . . . . . . . . . . . . . . . . . . . GI–10
VISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI–10
HOW TO USE THIS MANUAL SERVICING PROCEDURE

Inspection, Adjustment
RANGE OF TOPICS The procedures for inspections and adjustments
This manual contains the procedures for performing are divided into steps. Important points in regard
all of the required service operations. The to the location and contents of the procedures are
procedures are divided into the following five basic explained in detail and are shown in the
operations. illustrations.
(1) Removal/Installation
(2) Disassembly/Assembly
(3) Replacement SHOWS PROCEDURE ORDER
(4) Inspection FOR SERVICE
(5) Adjustment
Simple operations which can be performed easily
just by looking at the vehicle, such as
removal/installation of parts, jacking, vehicle lift,
cleaning of parts, and visual inspection, have been
omitted.
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
CONTINUED
GI–1
BACK.TO.CHAPTER.INDEX TO. MODEL .INDEX
HOW TO USE THIS MANUAL
Repair procedure
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit
together, and describes visual part inspection. However, only the removal/installation procedures which need to
be performed methodically have written instructions.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration. In addition, symbols indicating parts which require the use of special service tools for
removal/installation are also shown.
3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration
with the corresponding number. Occasionally, there are important points or information concerning a procedure.
Refer to this information when servicing the related part.
SHOWS SERVICE
Procedure ITEM (S) Indicates any relevant
references which need to be
followed during installation.
“Removal/Installation”
Portion
“Inspection After SHOWS SPECIAL

Installation” Portion SERVICE TOOL (SST)
SHOWS PROCEDURE ORDER FOR SERVICE OPERATION
FOR SERVICE
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Install the parts SHOWS APPLICATION
by performing POINTS OF GREASE, ETC.
Steps 1—3 in
reverse order SHOWS TIGHTENING
TORQUE
SPECIFICATIONS SHOWS EXPENDABLE PARTS
SHOWS DETAILS
SHOWS TIGHTENING
TORQUE UNITS
SHOWS THERE
ARE REFERRAL
NOTES FOR SERVICE
SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
SHOWS REFERRAL
NOTES FOR
SERVICE
CONTINUED
GI–2
SYMBOLS
TROUBLESHOOTING PROCEDURE
There are eight symbols indicating oil, grease, Basic Flow of Troubleshooting
sealant, and the use of SSTs. These symbols
show the points of applying or using such materials
during service.
Symbol Meaning Kind
SECTION F ONLY
Appropriate new
Apply oil engine oil or ACTUAL TROUBLESHOOTING PROCEDURES
gear oil
SECTION K
ONLY
Appropriate new
Apply brake fluid
brake fluid
Apply automatic Appropriate new

transaxle/ automatic
transmission transaxle/ IF
MENTIONED
fluid transmission fluid
Appropriate
Apply grease
grease
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Appropriate SECTION F
Apply sealant
sealant ONLY
Apply petroleum Appropriate On-board diagnosis

jelly petroleum jelly The service codes are important hints for repairing
malfunctions that are difficult to simulate. By
following the service code, perform the inspection
O-ring, gasket, to quickly and accurately diagnose the malfunction.
R Replace part
etc. The self-diagnostic function is used during
inspection. When a service code is shown,
specifying the cause of a malfunction, continue the
SST Use SST Appropriate SST inspection according to the items indicated by the
self-diagnostic function.
Engine tune-up (Section F)

ADVISORY MESSAGES
Any necessary adjustments are made after starting
You’ll find several Warnings, Cautions, Notes,
the engine.
Specifications and Upper and lower limits in this
manual.
Basic inspection (Section K)
The basic inspection is performed to quickly
Warning narrow down the possible causes after a
A Warning indicates a situation in which
malfunction occurs regardless of the symptoms.
serious injury or death could result if the ST The basic inspection is performed to also locate
warning is ignored. the region of many malfunction symptoms.
Caution Diagnostic index
A Caution indicates a situation in which The diagnostic index lists the symptoms of the
damage to the vehicle could result if the malfunctions. Select the symptoms pertaining or
caution is ignored. most closely pertaining to the actual malfunction.
Note Quick diagnosis chart (If mentioned)
A Note provides added information that will The quick diagnosis chart lists the diagnosis and
help you to complete a particular procedure. inspection procedures to be performed specifically
relating to the cause of the malfunction.
Specification
The values indicate the allowable range when Symptom troubleshooting
performing inspections or adjustments. Symptom troubleshooting quickly determines the
location of the malfunction according to the type of
Upper and lower limits symptoms.
The values indicate the upper and lower limits
that must not be exceeded when performing
inspections or adjustments. CONTINUED
GI–3
Procedures For Use

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

ORDER THE DETAILED PROCEDURES SHOW POINTS REQUIRING
ATTENTION IN REGARD TO
INSPECTION RESULTS
Perform malfunction diagnosis according to No. 26

“HOLD INDICATOR LIGHT DOES NOT ILLUMI-
NATE WHEN HOLD SWITCH IS TURNED ON” or
No. 27 “HOLD INDICATOR LIGHT ILLUMINATES
WHEN HOLD SWITCH IS NOT TURNED ON”
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Using the diagnostic index
The symptoms of the malfunctions are listed in the diagnostic index for system troubleshooting.
The exact malfunction symptoms can be selected using the details.
CONTINUED
GI–4
Using the quick diagnosis chart

The chart lists the relation between the symptoms and cause of the malfunction.
The chart is effective in quickly narrowing down the relation between the symptoms and cause of the
malfunction and specifying the region of the common cause when multiple malfunction symptoms occur.
The appropriate diagnostic inspection relating to the cause of the malfunction as specified by the symptoms can
be selected by looking down the diagnostic inspection column of the chart.
PARTS WHICH MAY BE THE CAUSE OF

PROBLEMS
ENGINE QUICK DIAGNOSTIC CHART
PART WHICH MAY BE

THE SYMPTOM
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CHOOSE THE ACTUAL
SYMPTOM
ST
CONTINUED
GI–5
Using the symptom troubleshooting

Symptom troubleshooting shows diagnosis procedure, inspection method, and proper action to take for each
trouble symptom.
TROUBLESHOOTING
HINTS describes TROUBLE SYMPTOM
possible point of
malfunction.
STEP shows the ACTION describes the

order of appropriate action to
troubleshooting. take as a result
(Yes/No) of
INSPECTION.
INSPECTION
describes an
inspection (method) to
quickly determine the
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failed part.
Reference page(s) for

the detailed procedure
to perform
INSPECTION is shown.
How to perform ACTION

is described in the relative
material shown.
TEXT SEQUENCE
The text sequence is as indicated by the arrows shown below.
Example:
CONTINUED
GI–6
UNITS
UNITS The actual converted values for 2.7 kgf/cm2 are

264 kPa and 38.4 psi. In the top specification, 2.7
Electric current A (ampere)
is used as an upper limit, so its converted values
Electric power W (watt) are rounded down to 260 and 38. In the bottom
Electric resistance (ohm) specification, 2.7 is used as a lower limit, so its
converted values are rounded up to 270 and 39.
Electric voltage V (volt)
mm (millimeter)
Length
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
kgf/cm2 (kilogram force per square
Positive pressure
centimeter)
psi (pounds per square inch)
Number of
rpm (revolutions per minute)
revolutions
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N·m (Newton meter)
kgf·m (kilogram force per meter)
Torque kgf·cm (kilogram force per centimeter)
ft·lbf (foot pound) force
in·lbf (inch pound) force
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
g (gram)
Weight
oz (ounce)
Conversion to SI Units
(Système International d’Unités)
All numerical values in this manual are based on SI
units. Numbers shown in conventional units are
converted from these values.
ST
Rounding off
Converted values are rounded off to the same
number of places as the SI unit value. For
example, if the SI unit value is 17.2 and the value
after conversion is 37.84, the converted value will
be rounded off to 37.8.
Upper and lower limits

When the data indicates upper and lower limits, the
converted values are rounded down if the SI unit
value is an upper limit and rounded up if the SI unit
value is a lower limit. Therefore, converted values
for the same SI unit value may differ after
conversion. For example, consider 2.7 kgf/cm2 in
the following specifications:
210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}
CONTINUED
GI–7
FUNDAMENTAL PROCEDURES
FUNDAMENTAL PROCEDURES REMOVAL OF PARTS

While correcting a problem, try also to determine
PROTECTION OF THE VEHICLE its cause. Begin work only after first learning which
Always be sure to cover fenders, seats, and floor parts and subassemblies must be removed and
areas before starting work. disassembled for replacement or repair. After
removing the part, plug all holes and ports to
prevent foreign material from entering.
PREPARATION OF TOOLS AND MEASURING

EQUIPMENT
Be sure that all necessary tools and measuring DISASSEMBLY
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equipment are available before starting any work. If the disassembly procedure is complex, requiring
many parts to be disassembled, all parts should be
marked in a place that will not affect their
performance or external appearance and identified
so that reassembly can be performed easily and
efficiently.
SPECIAL SERVICE TOOLS

Use special tools when they are required.
INSPECTION DURING REMOVAL, DISASSEMBLY

When removed, each part should be carefully
inspected for malfunctioning, deformation,
damage, and other problems.
DISCONNECTION OF THE NEGATIVE BATTERY

CABLE
Before beginning any work, turn the ignition switch
to LOCK, then disconnect the negative battery
cable and wait for more than 1 minute to allow the
backup power supply of the SAS unit to deplete its
stored power.
Disconnecting the battery cable will delete the ARRANGEMENT OF PARTS
memories of the clock, audio, and DTCs, etc. All disassembled parts should be carefully
Therefore, it is neccessary to verify those arranged for reassembly.
memories before disconnecting the cable. Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
CONTINUED
GI–8
Oil should be applied to the moving components of

parts.
Specified oil or grease should be applied at the
prescribed locations (such as oil seals) before
reassembly.
CLEANING OF PARTS
All parts to be reused should be carefully and
thoroughly cleaned using the appropriate method.
SXU00012
Warning
Using compressed air can cause dirt and ADJUSTMENT
other particles to fly out, causing injury to Use suitable gauges and/or testers when making
the eyes. Wear protective eye wear adjustments.
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whenever using compressed air.
SXU00013
RUBBER PARTS AND TUBING

REASSEMBLY Prevent gasoline or oil from spilling on rubber parts
Standard values, such as torques and certain or tubing.
adjustments, must be strictly observed in the
reassembly of all parts.
If removed, these parts should be replaced with new
ones:
1 Oil seals 2 Gaskets
3 O-rings 4 Lockwashers
5 Cotter pins 6 Nylon nuts
ST
SXU00014
HOSE CLAMPS
When reinstalling, position the hose clamp in the
original location on the hose, and squeeze the
clamp lightly with large pliers to ensure a good fit.
SXU00011
Sealant, a gasket, or both should be applied to the

specified locations. When sealant is applied, parts
should be installed before sealant hardens.
Hardened sealant causes leaks.
SXU00015
CONTINUED
GI–9
FUNDAMENTAL PROCEDURES, INSTALLATION OF RADIO SYSTEM
TORQUE FORMULAS INSTALLATION OF RADIO SYSTEM

When using a torque wrench-SST combination, the If a radio system is installed improprerly or if a high-
written torque must be recalculated due to the powered type is used, the CIS and other systems may
extra length that the SST adds to the torque be affected.
wrench. Recalculate the torque using the following When the vehicle is to be equipped with a radio,
formulas. Choose the formula that applies to you. observe the following precautions.
Torque Unit Formula 1. Install the antenna at the farthest point from control
kgf·m kgf·m [L/(L+A) ] modules.
2. Install the antenna feeder as far as possible from
kgf·cm kgf·cm [L/(L+A) ]
the control modules harness, and perpendicular to
ft·lbf ft·lbf [L/(L+A) ] wiring harnesses.
in·lbf in·lbf [L/(L+A) ] 3. Do not install a high-powered radio system.
A: The length of the SST past the torque wrench drive. 4. After installing the radio system, start and idle the
L: The length of the torque wrench. engine, then confirm that the engine is not
influenced by output waves from the system.
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SXU00016
VISE
When using a vise, put protective plates in the jaws
of the vise to prevent damage to parts.
SXU00017
DYNAMOMETER
When test-running a vehicle on dynamometer :
Place a fan, preferably a vehicle-speed
proportional type, in front of the vehicle.
Connect an exhaust gas ventilation unit.
Cool the exhaust pipes with a fan.
Keep the area around the vehicle uncluttered.
Watch the water temperature gauge.
CONTINUED
GI–10
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM Disconnecting Connectors

When disconnecting two connectors, grasp the
ELECTRICAL PARTS connectors, not the wires.
Battery Cable
Before disconnecting connectors or removing
electrical parts, disconnect the negative battery
cable.
SXU00020
Connectors can be disconnected by pressing or

pulling the lock lever as shown.
SXU00018
Wiring Harness
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To remove the wiring harness from the clip in the
engine room, pry up the hook of the clip using a
flathead screwdriver.
SXU00021
Locking Connector
When locking connectors, listen for a click that will
indicate they are securely locked.
CONNECTORS
Data Link Connector
Insert the probe into the service hole when
connecting a jumper wire to the data link
connector.
Caution
Inserting a jumper wire probe into the data
link connector terminal may damage the SXU00022
terminal.
Inspection
1. When a tester is used to check for continuity or to
measure voltage, insert the tester probe from the
wiring harness side.
SXU00019
SXU00023
2. Check the terminals of waterproof connectors from

the connector side, as they cannot be accessed
from the wiring harness side.
CONTINUED
GI–11
ELECTRICAL SYSTEM
Caution
To prevent damage to the terminal, wrap a
thin wire around the lead before inserting it
into the terminal.
SXU00027
Wiring Harness
Wiring color codes
Two-color wires are indicated by a two-color code
SXU00024
symbol.
Terminals The first letter indicates the base color of the wire
Inspection and the second the color of the stripe.
Pull lightly on individual wires to check that they CODE COLOR CODE COLOR
are secured in the terminal. B Black O Orange
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BR Brown P Pink
G Green R Red
GY Gray V Violet
L Blue W White
LB Light Blue Y Yellow
LG Light Green
B/R BR/Y
SXU00025 BLACK BROWN
Replacement
Use the appropriate tools to remove a terminal as
shown. When installing a terminal, be sure to insert RED YELLOW
it until it locks securely.
Insert a thin piece of metal from the terminal side
of the connector, and then, with the terminal
locking tab pressed down, pull the terminal out
SXU00028
from the connector.
TYPE A
Fuse
Replacement
TYPE B
1. When replacing a fuse, be sure to replace it with
one of the specified capacity. If a fuse again fails
after it has been replaced, the circuit probably has
a short and the wiring should be checked.
2. Be sure the negative battery terminal is
disconnected before replacing a main fuse.
SXU00026
Sensors, Switches, and Relays

Handle sensors, switches, and relays carefully. Do
not drop them or strike them against other objects.
SXU00029
CONTINUED
GI–12
ELECTRICAL SYSTEM
3. When replacing a pullout fuse, use the fuse puller. Ohmmeter

The ohmmeter is used to measure the resistance
PULLER between two points in a circuit, and to check for
continuity and short circuits.
Caution
Do not connect the ohmmeter to any circuit
to which voltage is applied. This will
damage the ohmmeter.
POWER SOURCE LINE
FUSE
SXU00030
ELECTRICAL TROUBLESHOOTING TOOLS

Jumper Wire
A jumper wire is used to create a temporary circuit. GROUND LINE
Connect the jumper wire between the terminals of
a circuit to bypass a switch.
OHMMETER SXU00034
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Caution
Do not connect a jumper wire from the
power source line to a body ground; this
may cause burning or other damage to
wiring harnesses or electronic components.
SXU00032
Voltmeter
The DC voltmeter is used to measure circuit
voltage. A voltmeter with a range of 15 V or more
is used by connecting the positive (+) probe (red
lead wire) to the point where voltage is to be
measured and the negative (–) probe (black lead
wire) to a body ground.
VOLTMETER POWER SOURCE LINE
BLACK LEAD
RED LEAD
GROUND
CONTINUED
GI–13
JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) POSITIONS,

SAFETY STAND POSITIONS
JACKING POSITIONS REAR
Warning
Improperly jacking a vehicle is dangerous.
The vehicle can slip off the jack and cause
serious injury. Use only the correct front
and rear jacking positions and block the
wheels.
Use safety stands to support the vehicle after it has

been lifted.
FRONT
SAFETY STAND POSITIONS

FRONT
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REAR
REAR
VEHICLE LIFT (2 SUPPORTS)

POSITIONS
FRONT
CONTINUED
GI–14
TOWING
TOWING (With Manual Transmission)

If the transmission, rear axle, and steering system are
Proper lifting and towing are necessary to prevent not damaged, the vehicle may be towed on all four
damage to the vehicle. wheels. If any of these components are damaged, use
Government and local laws must be followed. wheel dollies.
(With Automatic Transmission)
If excessive damage or other conditions prevent
towing the vehicle with the driving wheels off the
ground, use wheel dollies.
If all four wheels are on the ground, the vehicle may be

Wheel dollies towed only forward. Do not exceed 45 km/h (28 mph)
and a distance of 15 km (9.3 miles); you could damage
the transmission.
If speed must exceed 45 km/h (28 mph) or a towing

distance of 15 km (9.3 miles), use one of these
methods:
Place the rear wheels on dollies.
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Tow with the rear wheels off the ground.
Disconnect the propeller shaft.

Wheel dollies
If the transmission or rear axle is inoperative, tow with
the rear wheels off the ground.
Caution
Follow these instructions when towing the
vehicle with all wheels on the ground or
with the front wheels on the ground and the
Caution rear wheels raised.
Do not tow with sling-type equipment. This
could damage your vehicle. Use wheel-lift (44 Model)
or flatbed equipment. 1. Put the transfer case in 2H.
2. Set the transfer case at 2H and the hubs
at FREE.
(All Models)
1. Set the transmission in neutral.
2. Turn the engine switch to ACC position.
3. Release the parking brake.
Remember that power assist for the brakes

and steering will not be available when the
engine is not running.
If your Ford/Mazda has 44, change to 2-wheel drive

before having the vehicle towed. If this is not possible,
tow with all four wheels raised.
CONTINUED
GI–15
TOWING, IDENTIFICATION NUMBER LOCATIONS
TOWING HOOKS IDENTIFICATION NUMBER

Caution LOCATIONS
The towing hooks should be used only in VEHICLE IDENTIFICATION NUMBER
an emergency (e.g. to get the vehicle out of
a ditch or a snow bank).
When using the towing hooks, always pull
the cable or chain in a straight direction
with respect to the hook. Apply no
sideways force.
FRONT
44
ENGINE IDENTIFICATION NUMBER

G6
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TIEDOWN HOOKS
Caution
Do not use the hook loops under the front
for towing. They are designed ONLY for
tying down the vehicle when it is being
transported. Using them for towing will WL, WL Turbo
damage the bumper.
FRONT
42
F2 CIS
F2 CARB
44
CONTINUED
GI–16
NEW STANDARDS
NEW STANDARDS
Following is a comparison of the previous standard and the new standard.
New Standard Previous Standard
Remark
Abbreviation Name Abbreviation Name
AP Accelerator Pedal — Accelerator Pedal

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

Remark
— Injection Pump FIP Fuel Injection Pump #6

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

Remark
VAF
Volume Air Flow Sensor — Air flow Sensor
sensor
Warm Up Three Way Catalytic
WU-TWC — Catalytic Converter #5
Converter
WOT Wide Open Throttle — Fully Open
#5: Directly connected to exhaust manifold
ABBREVIATIONS
ACC . . . . . . . . . . . . . . Accessories
ATDC . . . . . . . . . . . . . After top dead center
ATF . . . . . . . . . . . . . . . Automatic transmission fluid
BTDC . . . . . . . . . . . . . Before top dead center
CARB . . . . . . . . . . . . . Carburetor
ELR . . . . . . . . . . . . . . Emergency locking retractor
EX . . . . . . . . . . . . . . . Exhaust
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FIP . . . . . . . . . . . . . . . Fuel injection pump
HI . . . . . . . . . . . . . . . . High
HLA . . . . . . . . . . . . . . Hydraulic lash adjuster
IG . . . . . . . . . . . . . . . . Ignition
IN . . . . . . . . . . . . . . . . Intake
INT . . . . . . . . . . . . . . . Intermittent
LH . . . . . . . . . . . . . . . . Left hand
L.H.D. . . . . . . . . . . . . . Left hand drive
LO . . . . . . . . . . . . . . . Low
LSD . . . . . . . . . . . . . . Limited slip differential
LSPV . . . . . . . . . . . . . Load sensing proportioning valve
M ................ Motor
MAX . . . . . . . . . . . . . . Maximum
MFW . . . . . . . . . . . . . Manual freewheel
MIN . . . . . . . . . . . . . . Minimum
P/S . . . . . . . . . . . . . . . Power steering
RFW . . . . . . . . . . . . . . Remote freewheel
RH . . . . . . . . . . . . . . . Right hand
R.H.D. . . . . . . . . . . . . Right hand drive
SAS . . . . . . . . . . . . . . Sophisticated air bag sensor
SST . . . . . . . . . . . . . . Special service tool
TNS . . . . . . . . . . . . . . Tail number side lights
2WD . . . . . . . . . . . . . . 2 wheel drive
4WD . . . . . . . . . . . . . . 4 wheel drive
42 . . . . . . . . . . . . . . 4 wheel – 2 drive
44 . . . . . . . . . . . . . . 4 wheel – 4 drive
CONTINUED
GI–19
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION
PRE-DELIVERY INSPECTION TABLE
Following items may be done at any time prior to
delivery to your customer.
EXTERIOR UNDER BONNET-ENGINE RUNNING AT
OPERATING TEMPERATURE
INSPECT and ADJUST, if necessary, the following
items to the specifications: CHECK the following items:
Glass, exterior bright metal and paint for damage Operation of dashpot
Initial ignition timing
Wheel lug nuts
Injection timing
Tire pressures
Idle speed
All weatherstrips for damage or detachment Operation of throttle position sensor
Operation of bonnet release and lock
Door operation and alignment ON HOIST
Headlight aiming CHECK the following items:
INSTALL the following parts:
Operation of freewheel hubs
Wheel caps Manual transmission oil level
UNDER BONNET-ENGINE OFF Transfer oil level
Front differential oil level
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INSPECT and ADJUST, if necessary, the following
Rear differential oil level
items to the specifications:
Underside fuel, coolant and hydraulic lines, fittings,
Fuel, coolant and hydraulic lines, fittings, connections
connections and components for leaks
and components for leaks
Tires for cuts or bruises
Engine oil level
Steering linkage, suspension, exhaust system and
Power steering fluid level (if equipped)
all underside hardware for looseness or damage
Brake and clutch master cylinder fluid levels
Windshield washer reservoir fluid level ROAD TEST
Radiator coolant and specific gravity CHECK the following items:
Tightness of water hose clamps
Brake operation
Tightness of battery terminals, electrolyte level and
Clutch operation
specific gravity Steering control
Drive belt tensions
Operation of meters and gauges 3 Squeaks, rattles
Accelerator cable and linkage for free movement
or unusual noise
CLEAN the spark plugs Engine general performance
INTERIOR Emergency locking retractors
Operation of transfer
INSTALL the following parts
Fuse for accessories
CHECK the operation of the following items: AFTER ROAD TEST
Seat controls (sliding and reclining) and headrest REMOVE seat and floor mat protective covers
Door locks CHECK for necessary owner's information material,
Ignition switch (Engine switch) and steering lock tools and spare tire in vehicle
All lights including warning and indicator lights
Horn, windshield wipers and washers (if equipped)
Wiper blades performance Clean the wiper blades and
windshield
Antenna
Cigarette lighter and clock
Tilt steering (if equipped)
Air conditioner at various modes (if equipped)
CHECK the following items:
Presence of spare fuse
Upholstery and interior finish
CHECK and ADJUST, if necessary, the following items:
Operation and fit of windows
Pedal height and free play of brake and clutch pedals
Parking brake CONTINUED
Gl-20
ENGINE
(G6)
DRIVE BELT ................................................................B1-1 HLA REMOVAL/INSTALLATION .....................B1-10/11
DRIVE BELT INSPECTION ................................B1-1/2 HLA TROUBLESHOOTING .............................B1-12
DRIVE BELT ADJUSTMENT .............................B1-2 FRONT OIL SEAL.......................................................B1-13
COMPRESSION INSPECTION ..................................B1-2 FRONT OIL SEAL REPLACEMENT.................B1-13
TIMING CHAIN .............................................................B1-3 REAR OIL SEAL .........................................................B1-14
TIMING CHAIN REMOVAL/ REAR OIL SEAL REPLACEMENT ..................B1-14
INSTALLATION ....................................................B1-3/5 ENGINE .......................................................................B1-15
CYLINDER HEAD GASKET ..................................B1-6 ENGINE REMOVAL/INSTALLATION ..............B1-15/16
CYLINDER HEAD GASKET ENGINE DISASSEMBLY/ASSEMBLY ..............B1-17
REPLACEMENT .................................................B1-6/9
HYDRAULIC LASH ADJUSTER (HLA).................B1-10
DRIVE BELT Deflection

mm {in}
DRIVE BELT INSPECTION
Drive belt *New Used
Drive Belt Deflection Check
10.0—12.0 12.0—14.0
1. Check the drive belt deflection when the engine Generator
{0.40—0.47} {0.48—0.55}
is cold, or at least 30 minutes after the engine 6.6—7.2 7.2—8.0
P/S
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has been stopped. Apply pressure 98 N {10 kgf, {0.26—0.28} {0.29—0.31}
22 Ibf} midway between the specified pulleys. 8.5—10.0 10.0—11.5
A/C
{0.34—0.39} {0.40—0.45}
*: A belt that has been on a running engine for less than five
minutes.
2. If the deflection is not within the specification, adjust it.
(Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
Drive Belt Tension Check
1. Belt tension can be checked in place of belt deflection.
Check the drive belt tension when the engine is cold, or
at least 30 minutes after the engine has been stopped.
Using the SST, check the belt tension between any two
pulleys.
N {kgf, Ibf}
Drive belt *New Used
491-588 393-490
Generator
{50-60,110-132} {40-50,88-110}
412—470 354—402
P/S {42-48,93—105} {36-41, 80—90}
557—641 471—556
A/C {56.7—65.4, {48.0—56.7,
125—143} 106—124}
* A belt that has been on a running engine for less than five minutes.
CONTINUED
B1-1
DRIVE BELT, COMPRESSION INSPECTION

2. If the tension is not within the specification, adjust it. COMPRESSION INSPECTION
(Refer to DRIVE BELT, DRIVE BELT Warning
ADJUSTMENT.) • When the engine and the oil are hot, they
DRIVE BELT ADJUSTMENT can badly burn. Be careful not to burn
1. Loosen mounting bolts A and B, and locknut C. yourself during removal/installation of each
2. Adjust the belt deflection or tension by turning the component.
adjusting bolt D. 1. Verify that the battery is fully charged. Recharge it
(Refer to DRIVE BELT, DRIVE BELT if necessary.
INSPECTION.) (Refer to section G, CHARGING SYSTEM,
3. Tighten mounting bolts A and B and locknut C. BATTERY INSPECTION, Battery.)
2. Warm up the engine to the normal operating
temperature.
3. Stop the engine and allow it to cool off for about
10 minutes.
4. Perform "Fuel Line Safety Procedure". Leave the
fuel pump relay removed.
(Refer to section F1, FUEL SYSTEM, BEFORE
REPAIR PROCEDURE.)
5. Disconnect the igniter connector.
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(Refer to section G, IGNITION SYSTEM,
IGNITION COIL REMOVAL/INSTALLATION.)
6. Remove the spark plugs.
7. Connect a compression gauge into the No.1 spark
plug hole.
8. Fully depress the accelerator pedal and crank the
engine.
9. Note the maximum gauge reading.
10. Inspect compression of each cylinder.
Compression
kPa {kgf/cm2, psi} [rpm]
Engine type
Item
G6
Standard 1255 {12.8, 182} [270]
Minimum 882.6 {9.0, 128} [270]
Maximum
196 kPa {2.0 kgf/cm 2, 28 psi}
difference between
11. If the compression in one or more cylinders is low
or the compression difference between cylinders
exceeds the maximum, pour a small amount of
clean engine oil into the cylinder and recheck the
compression.
(1) If the compression increases, the piston, the
piston rings, or cylinder wall may be worn
and overhaul is required.
(2) If the compression stays low, a valve may be
stuck or improperly seated and overhaul is
required.
(3) If the compression in adjacent cylinders stays
low, the cylinder head gasket may be
damaged or the cylinder head distorted and
overhaul is required.
12. Disconnect the compression gauge.
13. Install the spark plugs.
Tightening torque
15—22 N.m {1.5—2.3 kgf.m, 11—l6ft.lbf}
14. Connect the igniter connector.
15. Install the fuel pump relay.
CONTINUED
B1-2
TIMING CHAIN
TIMING CHAIN
TIMING CHAIN REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the generator.
3. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way.
(Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP
REMOVAL/INSTALLATION.)
4. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the
way.
5. Remove the cylinder head.
(Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)
6. Remove the water pump. (Refer to section E, WATER PUMP, WATER PUMP REMOVAL/INSTALLATION.)
7. Remove the oil pan. (Refer to section D, OIL PAN, OIL PAN REMOVAL/INSTALLATION.)
8. Disconnect the oil strainer stay.
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
11. Start the engine and check for engine oil and engine coolant leakage.
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1 A/C compressor bracket 10 Balancer chain, idler sprocket, crankshaft sprocket
2 Generator strap ☞ Installation Note
3 P/S oil pump bracket 11 Timing chain, timing sprocket, camshaft sprocket
☞ Installation Note
4 Generator bracket
12 Chain adjuster
5 Pulley lock bolt ☞ Installation Note
☞ Removal/Installation Note 13 Key
6 Crankshaft pulley
14 Timing chain lever
7 Chain cover ☞ Installation Note
8 Spacer 15 Timing chain guide
9 Balancer chain guide
CONTINUED
B1-3
TIMING CHAIN
Pulley Lock Bolt Removal/Installation Note 2. Assemble the camshaft sprocket to the timing
• Hold the crankshaft using the SST. chain so that the timing mark of camshaft
sprocket is aligned with the white link of timing
chain as shown.
Timing Chain Lever Installation Note 3. Secure the camshaft sprocket and the timing
chain with a wire to prevent disengagement.
• Install the chain lever and verify that it
Balancer Chain, Idler Sprocket, Crankshaft
moves smoothly in the direction indicated.
Sprocket Installation Note
1. Install the crankshaft sprocket as shown.
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2. Assemble the idler sprocket on to the idler shaft.
Chain Adjuster Installation Note
• Push the chain adjuster sleeve in (toward the
left) and insert the pin as shown into the lever to
hold the sleeve.
3. Set the balancer chain on the idler sprocket so

that the timing mark of the idler sprocket is
aligned with the brown link of the balancer chain
as shown.
Timing Chain, Timing Sprocket, Camshaft

Sprocket Installation Note
1. Install the timing chain and timing sprocket so
that the white link of the timing chain is aligned
with the timing mark of the timing sprocket as
shown.
CONTINUED
B1-4
TIMING CHAIN
4. Install the balancer chain so that the five 4. Loosen the chain guide C by adjusting bolt E.
alignment marks on the chain, sprocket and 5. Push the chain guide C with a force of 49 N
cylinder block align, and attach the idler sprocket {5.0 kgf, 11 Ibf} in the direction of the arrow,
to the cylinder block. then pull back the chain guide 3.2—3.8 mm
{0.13—0.14 in] and tighten the adjusting bolt E.
5. Hand-tighten the idler sprocket lock bolt.

Balancer Chain Guide Installation Note Note
1. Install the chain guide A and B. • The balancer chain must be replaced if chain
guide C bottoms when adjusting.
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6. Measure the timing chain slack.
Specification
Approx. 3.0 mm {0.12 in}
2. Install the chain guide C, and tighten the bolt D

and hand-tighten the adjusting bolt E.
3. Tighten the idler sprocket lock bolt.
CONTINUED
B1-5
CYLINDER HEAD GASKET

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

Distributor Drive Gear Removal Note
1. Turn the crankshaft clockwise so that the No.1
piston is at TDC of the compression stroke.
3. Secure the camshaft sprocket and the chain with a

wire as shown.
2. Verify that the camshaft sprocket mark is aligned
with the horizontal surface on the cylinder head.
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4. Remove the camshaft sprocket off the camshaft
3. Remove the seal cover. dowel pin.
4. Hold the crankshaft using the SST. Cylinder Head Removal Note
1. Remove the bolts A.
2. Loosen the cylinder head bolts a few turns in the
order shown.
5. Remove the lock bolt.

Camshaft Sprocket Removal Note
Cylinder Head Gasket Installation Note
1. Remove the service cover on the chain cover.
• Apply silicone sealant to the areas shown.
Thickness
Ø3.0 mm {0.12 in}
2. Push the chain adjuster sleeve in (toward the left)

and insert a pin as shown into the lever hole to
hold the sleeve.
CONTINUED
B1-8

Cylinder Head Installation Note Distributor Drive Gear Installation Note
1. Tighten the cylinder head bolts a few turns in the 1. Install the distributor drive gear with a new washer
order shown. and lock bolt.
2. Hold the camshaft with a screwdriver as shown.
2. Tighten the bolts A.

Camshaft Sprocket Installation Note
1. Install the camshaft sprocket onto the camshaft 3. Tighten the lock bolt.
dowel pin. 4. Apply silicone sealant to the areas shown.
2. Remove the wire securing the camshaft sprocket
and chain.
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5. Install the new seal cover.
Cylinder Head Cover Installation Note
3. Remove the retaining pin from the chain adjuster. 1. Verify that the grooves on the cylinder head cover
4. Install the service cover with a new gasket. are free of oil, water, and other foreign material.
Tightening torque 2. Coat a new gasket with silicone sealant, and install
7.9—10.7 it onto the cylinder head cover.
N.m {80—110 kgf.cm, 69.5—95.4 in.lbf} 3. Apply silicone sealant to the cylinder head as
shown.
4. Install the cylinder head cover.
CONTINUED
B1-9
HYDRAULIC LASH ADJUSTER (HLA)

HLA REMOVAL / INSTALLATION
Caution
• Removal and installation of the HLA must be carried out only when the problem cannot be solved by
the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)

2. Remove the distributor.
(Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.)
3. Remove the cylinder head cover.
6. Check the engine oil level,
(Refer to section D, ENGINE OIL, ENGINE OIL INSPECTION.)
(1) check the engine oil.
(2) check the idle speed, (Refer to section F1, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
8. Check the HLA troubleshooting.
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(Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
1 Distributor drive gear 2 Rocker arm

☞ CYLINDER HEAD GASKET, CYLINDER HEAD ☞ Removal Note & Installation Note
GASKET REPLACEMENT, Distributor Drive
Gear Removal Note 3 HLA
☞ CYLINDER HEAD GASKET, CYLINDER HEAD ☞ Installation Note
GASKET REPLACEMENT, Distributor Drive Gear
Installation Note
CONTINUED
B1-10

Rocker Arm Removal Note Rocker Arm Installation Note
1. Loosen the bolts a few turns in the order shown. Note
• The intake side shaft has twice as many oil
holes as the exhaust side shaft.
1. Assemble the rocker arm and shaft assembly as
shown in the figure according to the cap number
and mark.
2. Identify the rocker arm and shaft assembly parts

so that they can be reinstalled in the same
locations from which they were removed.
3. Remove the rocker arm and shaft assembly
together with the bolts.
2. Install the rocker arm and shaft.
HLA Installation Note
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1. Place each HLA in a container filled with clean 3. Tighten the bolts a few turns in the order shown.
engine oil.
Caution
• Do not push the pin too hard. It may damage
the HLA.
2. Bleed the air from the HLA by inserting a pin into
the plunger hole and pressing the plunger until it
no longer moves.
3. Pour engine oil into the oil reservoir in the rocker

arm.
4. Apply clean engine oil to HLA O-ring

CONTINUED
B1-11

HLA TROUBLESHOOTING
Problem Possible Cause Action
1. Noise when engine is started Oil leakage in oil passage or Run engine at 2,000—3,000 rpm.
immediately after oil is changed. in HLA If noise stops within 20 minutes*, HLA is normal.
If not, replace HLA.
2. Noise when engine is started after
Time required for engine oil to circulate within
sitting one day or more.
HLA includes tolerance for engine oil condition
and ambient temperature.
3. Noise when engine is started after Oil leakage in HLA (Refer to HYDRAULIC LASH ADJUSTER
new HLA is installed. (HLA), HLA TROUBLESHOOTING,
Valve Clearance Inspection.)
4. Noise continues more than 10 Insufficient oil pressure Check oil pressure.
minutes. If lower than specification, check for cause.
(Refer to section D, OIL PRESSURE INSPECTION)
Faulty HLA Press down HLA by hand.
If it does not move, HLA is normal.
If it moves, replace HLA.
(Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA
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Measure valve clearance.
(Refer to HLA, HLA TROUBLESHOOTING, Valve
Clearance Inspection.)
5. Noise during idle after high speed Incorrect oil amount Check oil level.
running. (Refer to section D, ENGINE OIL, ENGINE OIL
INSPECTION.)
Deteriorated oil Replace new engine oil.
(Refer to section D, ENGINE OIL, ENGINE OIL
REPLACEMENT.)
Valve Clearance Inspection

(Refer to CYLINDER HEAD GASKET, CYLINDER
HEAD GASKET REPLACEMENT.)
2. Measure valve clearance.
Valve clearance
0.15 mm {0.0059 in} max.
3. If valve clearance is more than 0.15 mm {0.0059 in},

replace the HLA. (Refer to HYDRAULIC LASH
ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.)
HEAD GASKET REPLACEMENT, Cylinder Head Cover
Installation Note.) CONTINUED
B1-12
FRONT OIL SEAL

FRONT OIL SEAL
FRONT OIL SEAL REPLACEMENT
2. Drain the engine coolant.
(Refer to section E, COOLING SYSTEM SERVICE
WARNINGS.)
(Refer to section E, ENGINE COOLANT, ENGINE
COOLANT REPLACEMENT.)
3. Remove the drive belt.
(Refer to DRIVE BELT, DRIVE BELT
ADJUSTMENT.)
4. Remove the cooling fan and water pump pulley.
5. Remove the radiator cowling.
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1 Pulley lock bolt
☞ TIMING CHAIN, TIMING CHAIN
☞ REMOVAL/INSTALLATION, Pulley Lock Bolt
☞ Removal/Installation Note
2 Crankshaft pulley
3 Front oil seal
☞ Removal Note
Front Oil Seal Removal Note

1. Cut the oil seal lip using a razor knife.
2. Remove the oil seal using a screwdriver protected
with a rag.
Front Oil Seal Installation Note

1. Apply clean engine oil to the oil seal lip.
2. Push the oil seal slightly in by hand.
3. Tap the oil seal in evenly using the SST and a
hammer.
CONTINUED
B1-13
REAR OIL SEAL

REAR OIL SEAL
REAR OIL SEAL REPLACEMENT
2. Remove the flywheel.
(Refer to section H, CLUTCH UNIT, CLUTCH
UNIT REMOVAL/INSTALLATION.)
1 Rear oil seal
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☞ Removal Note
Rear Oil Seal Removal Note
2. Remove the oil seal using a screwdriver
protected with a rag.
Rear Oil Seal Installation Note

1. Apply clean engine oil to the new oil seal lip.
hammer. CONTINUED
B1-14
ENGINE
ENGINE
ENGINE REMOVAL/INSTALLATION
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel.
Safety Procedure" in section F1.

(Refer to section E, COOLING SYSTEM SERVICE WARNINGS.)
(Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
3. Remove the air cleaner and fresh-air duct.
5. Disconnect the accelerator cable, bracket, heater hoses, and vacuum hoses.
6. Remove the radiator.
(Refer to section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.)
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8. Disconnect the fuel hoses.
(Refer to section F1, FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
9. Remove the transmission.
(Refer to section J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION.)
10. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the
way.
(Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP
11. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of
the way.
(1) check the engine oil, engine coolant, transmission oil, and fuel leakage.
(2) check the ignition timing, idle speed and idle mixture. (Refer to section F1, ENGINE TUNE-UP.)
15. Perform a road test.
CONTINUED
B1-15
ENGINE
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1 Engine mount nut 2 Engine
CONTINUED
B1-16
ENGINE
ENGINE DISASSEMBLY/ASSEMBLY
1. Remove the oil cooler. (Refer to section D, OIL COOLER, OIL COOLER REMOVAL/INSTALLATION.)
2. Remove the thermostat. (Refer to section E, THERMOSTAT, THERMOSTAT REMOVAL/INSTALLATION.)
3. Remove the spark plug.
4. Remove the oil pressure switch. (Refer to section D, OIL PRESSURE INSPECTION.)
5. Remove the intake-air system.
(Refer to section F1, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
6. Remove the exhaust system.
(Refer to section F1, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
7. Remove the oil filter. (Refer to section D, OIL FILTER, OIL FILTER REPLACEMENT)
8. Remove the distributor. (Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.)
10. Disassemble in the order indicated in the table.
11. Assemble in the reverse order of disassembly.
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1 Water bypass pipe 6 A/C idler
2 Water inlet pipe 7 P/S idler
3 A/C compressor bracket 8 Oil cooler bypass pipe
4 Generator bracket 9 Generator strap
5 P/S oil pump bracket 10 Engine mount
CONTINUED
B1-17
BACK.TO.MAIN.INDEX RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
TO. MODEL .INDEX
CONTENTS
Engine Title Section
Workshop General Information GI
Manual Engine B
F8 Technical Data TD
FE Special Tools ST
FOREWORD © 2001 Ford/Mazda Motor Corporation

This manual explains the disassembly, PRINTED IN JAPAN, APR. 1997
inspection, repair, and reassembly 1570-10-97D
procedures for the above-indicated
engines. In order to do these procedures
safely, quickly, and correctly, you must first
read this manual and any other relevant
service materials carefully.
The information in this manual is current
up to April, 1997. Any changes that occur
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after that time will not be reflected in this
particular manual. Therefore, the contents
of this manual may not exactly match the
mechanism that you are currently servicing.
Mazda Motor
Corporation
HIROSHIMA, JAPAN
CONTINUED
BACK.TO.CHAPTER.INDEX
TO. MODEL .INDEX
GENERAL INFORMATION
HOW TO USE THIS MANUAL .............. ................ Gl- 1 INSPECTION DURING REMOVAL,
RANGE OF TOPICS .................... .................... Gl- 1 DISASSEMBLY ............................................. Gl- 7
SERVICING PROCEDURE .............. ................ Gl- 1/2 ARRANGEMENT OF PARTS ........................... Gl- 7
SYMBOLS ............................. .......................... Gl- 3 CLEANING OF PARTS .................................... Gl- 7
ADVISORY MESSAGES .................................. Gl- 3 REASSEMBLY ................................................. Gl- 7
TEXT SEQUENCE ........................................... Gl- 3 ADJUSTMENT ................................................. Gl- 8
UNITS ................................................................... Gl- 4 RUBBER PARTS AND TUBING ....................... Gl- 8
NEW STANDARDS ............................................... Gl- 5 HOSE CLAMPS ............................................... Gl- 8
FUNDAMENTAL PROCEDURES ........... .............. Gl- 7 TORQUE FORMULAS ...................................... Gl- 8
PREPARATION OF TOOLS AND VISE ................................................................ Gl- 8
MEASURING EQUIPMENT .......................... Gl- 7 ELECTRICAL SYSTEM ........................................ Gl- 9
SPECIAL TOOLS ............................................. Gl- 7 CONNECTORS ................................................ Gl- 9
DISASSEMBLY ................................................ Gl- 7 ABBREVIATIONS.................................................. Gl- 10
HOW TO USE THIS MANUAL SERVICING PROCEDURE

Inspection, Adjustment
RANGE OF TOPICS • The procedures .for inspections and adjustments
• This manual contains the procedures for are divided into steps. Important points in regard
performing all of the required service operations. to the location and contents of the procedures are
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The procedures are divided into the following five explained in detail and are shown in the
basic operations. illustrations.
(1) Removal/Installation
(2) Disassembly/Assembly
(3) Replacement
(4) Inspection
(5) Adjustment
• Simple operations which can be performed easily
just by looking at the vehicle such as
removal/installation of parts, jacking, vehicle lift,
cleaning of parts, and visual inspection, have been
omitted.
CONTINUED
Gl-1
TO. MODEL .INDEX

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

SYMBOLS TEXT SEQUENCE
• There are eight symbols indicating oil, grease, • The text sequence is as indicated by the arrows
sealant, and the use of SSTs. These symbols shown below.
show the points of applying or using such Example:
Symbol Meaning Kind
New appropriate
Apply oil engine oil or gear
oil
New appropriate
Apply brake fluid
brake fluid
New appropriate
Apply automatic
automatic
transaxle /
transaxle/transmi
transmission fluid
ssion fluid
Appropriate
Apply grease
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grease
Appropriate
Apply sealant
sealant
Apply petroleum Appropriate

jelly petroleum jelly
O-ring, gasket,
Replace part
etc.
Appropriate
Use SST
SST
ADVISORY MESSAGES
You'll find several Warnings, Cautions, Notes,
Specifications and Upper and lower limits in this manual.
Warning
• A Warning indicates a situation in which serious
injury or death could result if the warning is
ignored.
Caution
• A Caution indicates a situation in which damage
to the vehicle could result if the caution is
ignored.
Note
• A Note provides added information that will help you
to complete a particular procedure.
Specification
• The values indicates the allowable range when
performing inspections or adjustments.
• The values indicate the upper and lower limits that
must not be exceeded when performing inspections
or adjustments.
CONTINUED
Gl-3
TO. MODEL .INDEX

UNITS
Electrical current A (ampere) • The actual converted values for 2.7 kgf/cm2 are
264 kPa and 38.4 psi. In the top specification, 2.7
Electric potential V (volt) is used as an upper limit, so its converted values
Electric power W (watt) are rounded down to 260 and 38. In the bottom
mm (millimeter) specification, 2,7 is used as a lower limit, so its
Length converted values are rounded up to 270 and 39.
in (inch)
kPa (kilo pascal)
Negative pressure mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
kgf/cm 2 (kilogram force per square
Positive pressure
centimeter)
psi (pounds per square inch)
Resistance Ω (ohm)
Speed rpm (revolution per minute)
N•m (Newton meter)
kgf•m (kilogram force per meter)
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Torque kgf•cm (kilogram force per centimeter)
ft•lbf (foot pound)

in•lbf (inch pound)
L (liter)
US qt (U.S. quart)
Imp qt (Imperial quart)
Volume ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
9 (gram)
Weight
oz (ounce)
Conversion to Sl Units
(Système International d'Unités)
• All numerical values in this manual are based on
81 units. Numbers shown In conventional units are
converted from these values,
Rounding off
• Converted values are rounded off to the same
number of places are the Sl unit value. For
example, if the 81 unit value is 17.2 and the value
after conversion is 37.84, the converted value will
be rounded off to 37.8.
• When the data indicates upper and lower limits,
the converted values are rounded down if the Sl
unit value is an upper limit and rounded up if the
Sl unit value is a lower limit. Therefore, converted
values for the same Sl unit value may differ after
2
conversion. For example, consider 2.7 kgf/cm in
the following specifications:
2
210—260 kPa { 2.1—2.7 kgf/cm , 30—38 psi }
270—310 kPa { 2.7—3.2 kgf/cm2 , 39—45 psi } CONTINUED
Gl-4
TO. MODEL .INDEX
NEW STANDARDS
NEW STANDARDS
• Following is a comparison of the previous standard and the new standard.
Previous Standard New Standard
Abbreviation Name Abbreviation Name Remark
— Accelerator Pedal AP Accelerator Pedal
— Air Cleaner ACL Air Cleaner
— Air Conditioning A/C Air Conditioning
— Airflow Meter VAF Volume Air Flow Sensor
— Airflow Sensor MAF Mass Air Flow Sensor
— Alternator GEN Generator
Transmission (Transaxle) Fluid
— ATF Thermosensor —
Temperature Sensor
— Atmospheric Pressure BARO Barometric Pressure
VB Battery Voltage B+ Battery Positive Voltage
OC Oxidation Catalytic Converter
TWC Three Way Catalytic Converter
Catalytic Converter
Warm Up Three Way Catalytic
WU-TWC #1
Converter
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— Circuit Opening Relay FPR Fuel Pump Relay #2
— Clutch Position CPP Clutch Pedal Position
— Crank Angle Sensor CMP Camshaft Position Sensor
— Crank Angle Sensor 2 CKP Crankshaft Position Sensor
— Diagnosis Connector DLC Data Link Connector
— Diagnosis/Self-Diagnosis OBD On-Board Diagnostic
— Direct Ignition DLI Distributorless Ignition
Transmission (Transaxle) Control
— EC-AT Control Unit TCM
Module
EGI Electronic Gasoline Injection System CIS Continuous Fuel Injection System
— Electronic Spark Ignition El Electronic Ignition #3
PCM Powertrain Control Module #4
ECU Engine Control Unit
ECM Engine Control Module
— Engine Modification EM Engine Modification
— Engine RPM Signal — Engine Speed Input Signal
— Evaporative Emission EVAP Evaporative Emission
— Exhaust Gas Recirculation EGR Exhaust Gas Recirculation
— Fan Control FC Fan Control
— Feedback System CLS Closed Loop System
— Flexible Fuel FF Flexible Fuel
— Fuel Pump FP Fuel Pump
— Fully Closed CTP Closed Throttle Position
— Fully Open WOT Wide Open Throttle
— Ground/Earth GND Ground
— 1C Regulator VR Voltage Regulator
#1: Directly connected to exhaust manifold

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

CONTINUED
Gl-6
TO. MODEL .INDEX
PREPARATION OF TOOLS AND MESURING
EQUIPMENT
• Be sure that all necessary tools and measuring
equipment are available before starting any work.
ARRANGEMENT OF PARTS
• All disassembled parts should be carefully
arranged for reassembly.
• Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
SPECIAL TOOLS
• Use special tools when they are required.
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CLEANING OF PARTS
• All parts to be reused should be carefully and
DISASSEMBLY thoroughly cleaned in the appropriate method.
• If the disassembly procedure is complex, requiring
many parts to be disassembled, all parts should be Warning
disassembled in a way that will not affect their • Using compressed air can cause dirt and
performance or external appearance and identified other particles to fly out, causing injury to
so that reassembly can be performed easily and the eyes. Wear protective eye wear "
efficiently. whenever using compressed air.
INSPECTION DURING REMOVAL, DISASSEMBLY REASSEMBLY

• When removed, each part should be carefully • Standard values, such as torques and certain
inspected for malfunctioning, deformation, adjustments, must be strictly observed in the
damage, and other problems. reassembly of all parts.
If removed, these parts should be replaced with new
ones:
1 Oil seals 2 Gaskets

3 O-rings 4 Lockwashers
5 Cotter pins 6 Nylon nuts
CONTINUED
GI-7
TO. MODEL .INDEX
HOSE CLAMPS
• When reinstalling, position the hose clamp in the
original location on the hose, and squeeze the
clamp lightly with large pliers to ensure a good fit.
1. Sealant, gasket, or both should be applied to the

specified locations. When sealant is applied, parts
should be installed before sealant hardens.
Hardened sealant causes leaks.
2. Oil should be applied to the moving components TORQUE FORMULAS
of parts. • When using a torque wrench-SST combination,
3. Specified oil or grease should be applied at the the written torque must be recalculated due to the
prescribed locations (such as oil seals) before extra length that the SST adds to the torque
reassembly. wrench. Recalculate the torque by using the
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following formulas. Choose the formula that
applies to you.
Torque Unit Formula

N•m N•m x [L/(L+A) ]
kgf• m kgf•m x [L/(L+A) ]
kgf•cm kgf•cm x [L/(L+A) ]
ft•lbf ft•lbf x [L/(L+A) ]
in•lbf in•lbf x [L/(L+A) ]
A: The length of the SST past the torque wrench
ADJUSTMENT drive.
• Use suitable gauges and testers when making L: The length of the torque wrench.
adjustments.
VISE
RUBBER PARTS AND TUBING • When using a vise, put protective plates in the
• Prevent gasoline or oil from getting on rubber jaws of the vise to prevent damage to parts.
parts or tubing.
GI-8 CONTINUED
TO. MODEL .INDEX
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM 2. Check the terminals of waterproof connectors from
CONNECTORS the connector side, as they cannot be accessed
from the wiring harness side.
Disconnecting Connectors
• When disconnecting two connectors, grasp the Caution
connectors, not the wires. • To prevent damage to the terminal, wrap a thin
wire around the lead before inserting it into the
terminal.
• Connectors can be disconnected by pressing or

pulling the lock lever as shown.
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Locking Connector
• When locking connectors, listen for a click that will
indicate they are securely locked.
Inspection
1. When a tester is used to check for continuity or to
measure voltage, insert the tester probe from the
wiring
harness side.
CONTINUED
GI-9
TO. MODEL .INDEX
ABBREVIATIONS
ABBREVIATIONS
EX ............................................ Exhaust
HLA ......................................... Hydraulic lash adjuster
IN ............................................. lntake
MAX ......................................... Maximum
SST ......................................... Special service tool
CONTINUED
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GI-10
TO. MODEL .INDEX
ENGINE
ENGINE OVERHAUL SERVICE WARNING .......... B- 1 CAMSHAFT END PLAY INSPECTION ................... B-26
ENGINE MOUNTING/DISMOUNTING ................... B- 1 ROCKER ARM AND ROCKER ARM SHAFT
MOUNTING ....................................................... B- 1/2 INSPECTION ..................................................... B-26/27
DISMOUNTING .................................................. B- 2 CYLINDER BLOCK INSPECTION/
ENGINE DISASSEMBLY/ASSEMBLY .................. B- 3 REPAIR ............................................................. B-27
TIMING BELT DISASSEMBLY/ASSEMBLY......... B- 3/5 PISTON INSPECTION ........................................... B-27
CYLINDER HEAD (I) DISASSEMBLY/ PISTON CLEARANCE INSPECTION/
ASSEMBLY .................................................... B- 6/12 REPAIR ............................................................. B-28
CYLINDER HEAD (II) DISASSEMBLY/ PISTON RING CLEARANCE INSPECTION ........... B-28
ASSEMBLY .................................................... B-12/13 PISTON PIN CLEARANCE INSPECTION .............. B-28/29
TIMING CHAIN DISASSEMBLY/ CRANKSHAFT INSPECTION ................................. B-29
ASSEMBLY .................................................... B-14/16 CRANKSHAFT OIL CLEARANCE
CYLINDER BLOCK (I) DISASSEMBLY/ INSPECTION/REPAIR ........................................ B-29/30
ASSEMBLY .................................................... B-17/19 CRANKSHAFT END PLAY
CYLINDER BLOCK (II) DISASSEMBLY/ INSPECTION/REPAIR ........................................ B-30
ASSEMBLY .................................................... B-20/22 CONNECTING ROD INSPECTION ........................ B-30
ENGINE INSPECTION/REPAIR ............................ B-23 CONNECTING ROD OIL CLEARANCE
CYLINDER HEAD INSPECTION/REPAIR ........... B-23 INSPECTION/REPAIR ........................................ B-31
VALVE INSPECTION ......................................... B-23/24 CONNECTING ROD SIDE CLEARANCE
VALVE GUIDE INSPECTION ............................. B-24 INSPECTION ..................................................... B-31
VALVE GUIDE REPLACEMENT ......................... B-24 PISTON AND CONNECTING ROD
VALVE SEAT INSPECTION/REPAIR ................. B-25 INSPECTION ..................................................... B-31
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VALVE SPRING INSPECTION ........................... B-25 TENSIONER SPRING INSPECTION ..................... B-31
CAMSHAFT INSPECTION ................................. B-26 GEAR CLEARANCE INSPECTION ........................ B-31/32
CAMSHAFT OIL CLEARANCE ROTOR CLEARANCE INSPECTION ..................... B-32/33
INSPECTION .................................................. B-26 PLUNGER SPRING INSPECTION ......................... B-33
ENGINE OVERHAUL SERVICE ENGINE MOUNTING/DISMOUNTING

WARNING MOUNTING
1. Install the SST (arms and attachment) to the
Warning cylinder block holes as shown, and hand-tighten
• Continuous exposure with USED engine oil the SST (bolts).
has caused skin cancer in laboratory mice.
Protect your skin by washing with soap and
water immediately after this work.
2. Assemble the SST (bolts, nuts, and plate) to the

specified positions.
CONTINUED
B-1
TO. MODEL .INDEX
ENGINE MOUNTING/DISMOUNTING
3. Adjust the SST (bolts) so that less than 20 mm
{0.79 in } of thread is exposed.
4. Make the SST (plate and arms) parallel by adjusting
the SST (bolts and nuts).
5. Tighten the SST (bolts and nuts) to affix the SST
firmly.
Warning
• The self-locking brake system of the engine
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stand may not be effective when the engine
is held In an unbalanced position.
This could lead to sudden, rapid movement
of the engine and mounting stand handle
and cause serious injury. Never keep the
engine in an unbalanced position, and
always hold the rotating handle firmly when
turning the engine.
6. Mount the engine on the SST (engine stand).
7. Drain the engine oil.

8. Install the oil drain plug.
Tightening torque
30–41 N.m {3.0–4.2 kgf.m, 22–30 ft.lbf }
DISMOUNTING
• Dismount in the reverse order of mounting.
CONTINUED
B-2
TO. MODEL .INDEX
ENGINE MOUNTING/DISMOUNTING
TIMING BELT DISASSEMBLY/ASSEMBLY
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1 Crankshaft pulley 6 Timing belt
• Refer to Disassembly Note • Refer to Disassembly Note
• Refer to Assembly Note • Refer to Assembly Note
2 Upper timing belt cover 7 Tensioner, tensioner spring
3 Lower timing belt cover • Refer to Assembly Note
8 Idler
4 Guide plate
5 Spark plug
CONTINUED
B-3
TO. MODEL .INDEX
Crankshaft Pulley Disassembly Note
• Hold the crankshaft by using the SST.
Timing Belt Assembly Note

Timing Belt Disassembly Note 1. Turn the crankshaft clockwise and align the timing
1. Turn the crankshaft clockwise and align the timing marks as shown.
marks as shown.
Camshaft pulley timing mark
Camshaft pulley timing mark F8: 4
F8: 4 FE: 2
FE: 2
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2. Install the timing belt.
2. Remove the spark plug. 3. Turn the crankshaft clockwise twice and align the
timing marks. If they are not aligned, remove the
Caution timing belt and repeat from
• The following will damage the belt and Timing Belt Assembly Note step 1.
shorten its life; forcefully twisting it. 4. Loosen the tensioner lock bolt to apply tension to
Turning it inside out, or allowing oil or the belt. Do not apply tension other than that of the
grease on It. tensioner spring.
5. Tighten the tensioner lock bolt. Be sure the
3. Mark the timing belt rotation on the belt for proper tensioner does not move together with the bolt
reinstallation. rotation.
6. Turn the crankshaft clockwise twice and check the
timing belt deflection at the point indicated by applying
moderate pressure 98 N {10 kgf , 22 Ibf } If it is
incorrect repeat from
Timing Belt Disassembly Note.
Timing belt deflection

New : 4.0―5.0 mm {0.16―0.19 In }
Used : 5.5―6.5 mm {0.22―0.25 in }
Tensioner, Tensioner Spring Assembly Note

1. Install the tensioner and tensioner spring.
2. Position the tensioner all the way to the intake
side and temporarily secure it by tightening the
lock bolt.
B-4
CONTINUED
TO. MODEL .INDEX
Crankshaft Pulley Assembly note
CONTINUED
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B-5
TO. MODEL .INDEX
CYLINDER HEAD(I) DISASSEMBLY/ASSEMBLY
Timing belt drive type
1 Cylinder head cover 4 Front housing

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2 Rocker arm 5 Camshaft
• Refer to Disassembly Note • Refer to Assembly Note
• Refer to Assembly Note 6 Cylinder head
3 Camshaft pulley • Refer to Disassembly Note
• Refer to Disassembly Note • Refer to Assembly Note
• Refer to Assembly Note 7 Cylinder head gasket
CONTINUED
B-6
TO. MODEL .INDEX
Rocker Arm Disassembly Note
• Loosen the bolts in two or three steps in the order
shown.
Front Housing Assembly Note

1. Apply clean engine oil to the oil seal.
Camshaft pulley Disassembly Note 3. Press the oil seal in evenly by using the SST.
• Hold the camshaft by using a screwdriver.
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Camshaft Pulley Assembly Note
Cylinder Head Disassembly Note • Install the camshaft pulley on the camshaft with
• Loosen the cylinder head bolts in two or three the knock pin fit into the hole at the timing mark.
steps in the order shown.
F8: 4
FE: 2
Cylinder Head Assembly Note

• Tighten the bolts in two or three steps in the order
shown.
Rocker Arm Assembly Note
1. Assemble the rocker arms, rocker arm shafts, and
camshaft bearing cap as shown in the figure.
Camshaft Assembly Note

• Be certain that the knock pin of the camshaft faces
straight up.
2. Tighten the bolts in two or three steps in the order

shown.
CONTINUED
B-7
TO. MODEL .INDEX
3. Tap in the seal cap by using a plastic hammer.
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Cylinder Head Cover Assembly Note
1. Apply silicone sealant to the shaded areas.
Thickness
∅1.5―2.0 mm {0.060―0.078 in }
2. Install the cylinder head cover and tighten the

bolts in two or three steps in the order shown.
CONTINUED
B-8
TO. MODEL .INDEX
Timing chain drive type
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1 Cylinder head cover 6 Camshaft sprocket
• Refer to Assembly Note • Refer to Disassembly Note
2 Chain adjuster • Refer to Assembly Note
• Refer to Disassembly Note 7 Cylinder head
3 Camshaft gear • Refer to Assembly Note
• Refer to Disassembly Note 8 Cylinder head gasket
4 Rocker arm • Refer to Assembly Note
• Refer to Disassembly Note
• Refer to Assembly Note
5 Camshaft
B-9 CONTINUED
TO. MODEL .INDEX
Chain Adjuster Disassembly Note Cylinder Head Disassembly Note
1. Turn the crankshaft until the FE mark of the 1. Remove the bolt A.
camshaft pulley is at the top as shown. 2. Loosen the remaining cylinder head bolts in two or
2. Check that the crankshaft pulley timing mark is three steps in the order shown.
aligned with the indicator pin.
Cylinder Head Gasket Assembly Note

3. Remove the chain adjuster. 1. Apply silicone sealant to the shaded area.
Camshaft Gear Disassembly Note

1. Pry up the washer tab.
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2. Install the cylinder head gasket.
3. Apply silicone sealant to the shaded area of the
cylinder head gasket.
2. Hold the camshaft with a screwdriver as shown.
Cylinder Head Assembly Note

Rocker Arm Disassembly Note 1. Tighten the cylinder head bolts in two or three
• Loosen the rocker arm shaft bolts in two or three steps in the order shown.
2. Tighten the remaining small cylinder head bolts.
B-10 CONTINUED
TO. MODEL .INDEX
Rocker Arm Assembly Note
1. Apply silicone sealant to the shaded area.
Camshaft Sproket Assembly Note

1. Install the camshaft sprocket to the camshaft,
aligning mark on the camshaft sprocket and timing 2. Tighten the bolt in two or three steps in the order
chain. shown.
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2. Hold the camshaft with a screwdriver as shown. 3. Tap in the new seal cap by using a plastic
hammer.
3. Bent the washer tab to lock the locknut.

Chain Adjuster Assembly Note
1. Lift the ratchet pawl and compress the chain
adjuster sleeve fully, then lock it with the pin lock.
CONTINUED
B-11
TO. MODEL .INDEX
Cylinder Head Cover Assembly Note CYLINDER HEAD (II) DISASSEMBLY/ASSEMBLY
1. Apply silicone sealant to the seal cap as shown. 1. Disassemble in the order indicated in the table.
2. Apply silicone sealant to the shaded areas.
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1 Valve keeper
3. Install the cylinder head cover and tighten the • Refer to Assembly Note
bolts in two or three steps in the order shown. 2 Upper valve spring seat
3 Valve spring (FE CIS: Single spring type)
4 Lower valve spring seat
5 Valve
6 Valve seal
Valve Keeper Disassembly Note

• Remove the valve keeper by using the SST.
Valve Seal Disassembly Note

• Remove the valve seal by using the SST.
CONTINUED
B-12
TO. MODEL .INDEX
Valve Spring Assembly Note
• Install the valve spring with the closer pitch toward
the cylinder head.
Valve Seal Assembly Note

1. Assemble the SST so that depth L is as specified.
Depth L Valve Keeper Assembly Note

F8, FE CARB: 19.2―19.6 mm {0.756―0.771 in } • Install the valve keeper by using the SST.
FE CIS: 21.4―22.2 mm {0.843―0.874 in }
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2. Press the valve seal onto the valve guide by hand.
3. Tap the SST by using a plastic hammer until its
lower end touches the cylinder head.
CONTINUED
B-13
TO. MODEL .INDEX
TIMING CHAIN DISASSEMBLY/ASSEMBLY
2. Assemble in the order of disassembly.
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1 Water pump 8 Timing chain guide
2 Crankshaft pulley 9 Oil strainer
• Refer to Disassembly Note 10 Oil pan
3 Timing chain cover • Refer to Assembly Note
• Refer to Disassembly Note 11 Oil pump cover
12 Inner rotor
4 Timing chain
• Refer to Assembly Note 13 Outer rotor
5 Timing gear 14 Spring seat
6 Crankshaft key 15 Pressure spring
7 Timing chain lever 16 Control plunger
CONTINUED
B-14
TO. MODEL .INDEX
Crankshaft Pulley Disassembly Note Timing Chain Assembly Note
• Hold the crankshaft by using the SST. 1. Install the timing chain as shown in the figure.
Oil Pan Disassembly Note

• Remove the oil pan by using the separator tool. 2. Support the timing chain by using a magnetic base.
Timing Chain Cover Assembly Note

1. Apply clean engine oil to the oil seal.
3. Press the oil seal in evenly by using the SST.
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Oil Pan Assembly Note
• Apply silicone sealant to the oil pan as shown.
Thickness
∅2.5―3.5 mm {0.099―0.137 in } 4. Apply silicone sealant to the mounting surface
along the inside of the bolt holes as shown.
Timing Chain Cover Disassembly Note

• Remove the oil seal by using a screwdriver
protected with a rag. 5. Tighten the timing chain cover installation bolt.
Tightening torque
A: 19―25 N.m {1.9―2.6 kgf.m , 14―18 ft.lbf }
B: 38―51 N.m {3.8―5.3 kgf.m , 28―38 ft.lbf }
CONTINUED
B-15
TO. MODEL .INDEX
Crankshaft Pulley Assembly Note
CONTINUED
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B-16
TO. MODEL .INDEX
CYLINDER BLOCK (I) DISASSEMBLY/ASSEMBLY
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2
1 Oil pan (Timing belt drive type) 8 Oil pump body (Timing belt drive type)
• Refer to Disassembly Note 9 Outer gear (Timing belt drive type)
• Refer to Assembly Note 10 Inner gear (Timing belt drive type)
2 Oil strainer (Timing belt drive type) 11 Oil pump cover (Timing belt drive type)
3 Oil baffle (FE CIS) 12 Spring seat (Timing belt drive type) .
• Refer to Assembly Note 13 Pressure spring (Timing belt drive type)
4 Timing belt pulley (Timing belt drive type) 14 Control plunger (Timing belt drive type)
• Refer to Disassembly Note 15 Rear cover
5 Flywheel • Refer to Assembly Note
• Refer to Disassembly Note 16 Water pump
6 End plate
7 Oil pump (Timing belt drive type)
CONTINUED
B-17
TO. MODEL .INDEX
Oil Pan Disassembly Note Oil Pump Disassembly Note
Note • Remove the oil seal by using a screwdriver
• Do not insert the separator tool between the protected with a rag.
oil baffle and cylinder block.
• Remove the oil pan by using the separator tool.
Rear Cover Disassembly Note

• Remove the oil seal by using a screwdriver
Oil Baffle Disassembly Note protected with a rag.
• Remove the oil baffle by using the separator tool.
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Water Pump Assembly Note
1. Verify that the rubber seal is securely fixed onto
Timing Belt Pulley Disassembly Note
the water pump.
2. If not, replace the rubber seal and reapply the
bonding agent.
3. Install the water pump.
Flywheel Disassembly Note Rear Cover Assembly Note

• Hold the crankshaft by using the SST. 1. Apply clean engine oil to the oil seal.
3. Press the oil seal in evenly by using the SST.
CONTINUED
B-18
TO. MODEL .INDEX
Oil Pump Assembly Note Oil Pan Assembly Note
1. Apply clean engine oil to the oil seal. • Apply Silicone sealant to the oil pan as shown.
3. Press the oil seal in evenly by using the SST. Thickness
∅2.0―3.0 mm {0.079―0.118 in }
Flywheel Assembly Note

1. Hold the crankshaft by using the SST.
2. Tighten the flywheel bolt in the order shown.
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Timing Belt Pulley Assembly Note
Oil Baffle Assembly Note

• Apply silicone sealant to the oil baffle as shown.
Thickness
∅2.0―3.0 mm {0.079―0.118 in }
CONTINUED
B-19
TO. MODEL .INDEX
CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY
1
2
Connecting rod cap
Lower connecting rod bearing
9 Main bearing cap
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3 Piston and connecting rod
10 Lower main bearing
• Refer to Assembly Note 11 Pilot bearing
4 Upper connecting rod bearing
5 Piston ring
12 Crankshaft
6 Piston pin
13 Upper main bearing
7 Piston
14 Cylinder block
8 Connecting rod
CONTINUED
B-20
TO. MODEL .INDEX
Piston and Connecting Rod Disassembly Note Pilot Bearing Disassembly Note
1. Assemble the SST as shown. • Remove the pilot bearing by using the SST.
Pilot Bearing Assembly Note

2. Insert SST No.2 into the piston pin as shown and
• Install the pilot bearing by using a suitable pipe.
fully screw in SST No.1.
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Main Bearing Cap Assembly Note
3. Set the piston and connecting rod on the SST as 1. Tighten the bolts in two or three steps in the order
shown. shown.
4. Press out the piston pin. Piston and Connecting Rod Assembly Note
1. Assemble the SST as shown.
Main Bearing Cap Disassembly Note
• Loosen the main bearing cap bolts in two or three
CONTINUED
B-21
TO. MODEL .INDEX
2. Insert SST No.2 into the piston pin as shown and
fully screw in SST No.1.
8. Verify that the second ring is installed with the

scraper face downward.
3. Set the SST (stopper bolt) so that dimension L is 9. Position the end gap of the oil ring as shown.
as specified.
Dimension L
60.0 mm {2.36 in }
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10. F mark facing the front of the engine.
4. Apply clean engine oil to the piston pin.

5. Insert the piston pin and the SST assembled in
step 2 into the piston and connecting rod.
6. Press the piston pin into the piston and connecting

rod until the SST (guide) contacts the SST (stopper
bolt).
7. While inserting the piston pin, check the pressure
force.
If it is less than the specification, replace the piston
pin or the connecting rod.
Pressure force
2.94―14.70 KN {300―1500 kgf , 660―3300 Ibf }
CONTINUED
B-22
TO. MODEL .INDEX
ENGINE INSPECTION/REPAIR
ENGINE INSPECTION/REPAIR VALVE INSPECTION
1. Measure the valve head margin thickness of each
CYLINDER HEAD INSPECTION/REPAIR valve. Replace the valve if necessary.
1. Carry out cooling flaw detection on the cylinder
head surface. Replace the cylinder head if Margin thickness
necessary. FE CIS
2. Inspect for the following and repair or replace if IN: 1.80―2.20 mm {0.071―0.086 in }
necessary. EX: 1.30―1.70 mm {0.052―0.006 in }
(1) Sunken valve seats F8, FE CARB
(2) Excessive camshaft oil clearance and end IN: 0.8―1.2 mm {0.032―0.047 in }
play EX: 1.3―1.7 mm {0.052―0.066 in }
3. Measure the cylinder head for distortion in the six
directions as shown.
Distortion
0.15 mm {0.006 in} max.
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2. Measure the length of each valve. Replace the
valve if necessary.
4. If the cylinder head distortion exceeds the maxi- Standard length

mum, repair by grinding the height or replace the FE CIS
cylinder head. If the cylinder head height is not IN: 115.61―116.01 mm {4.552―4.567 in }
within the specification, replace it. EX: 116.01―116.41mm {4.568―4.583 in }
F8, FE CARB
Standard height IN: 111.69―112.09 mm {4.398―4.412}
91.95―92.05 mm {3.621―3.624 in } EX: 111.49―111.89 mm {4.390―4.405 in }
Grinding Minimum length

0.20 mm {0.008 in } max. FE CIS
IN: 115.51 mm {4.548 in}
5. Measure the manifold contact surface distortion as EX: 115.71 mm {4.556 in}
shown. F8, FE CARB
IN: 111.39 mm {4.386 in}
Distortion EX: 111.19 mm {4.378 in}
0.15 mm {0.006 in } max.
3. Measure the stem diameter of each valve in X and
6. If the distortion exceeds the specification, grind Y directions at the three points (A, B, and C)
the surface or replace the cylinder head . shown. Replace the valve if necessary.
Grinding Standard diameter

0.20 mm {0.008 in } max. FE CIS
IN: 6.970―6.985 mm {0.2745―0.2749 in }
EX: 6.965―6.980 mm {0.2743―0.2748 in }
F8, FE CARB
IN: 8.030―8.045 mm {0.3162―0.3167 in }
EX: 8.025―8.040 mm {0.3160―0.3165 in }
Minimum diameter
FE CIS
IN: 6.920 mm {0.2724 in }
EX: 6.915 mm {0.2722 in }
F8, FE CARB
IN: 7.980 mm {0.3142 in }
EX: 7.975 mm {0.3140 in }
CONTINUED
B-23
TO. MODEL .INDEX
VALVE GUIDE INSPECTION Valve Guide Installation

1. Measure the inner diameter of each valve guide in X 1. Assemble the SSTs so that depth L is as specified.
and Y directions at the three points (A, B, and C)
shown. Depth L
Replace the valve guide if necessary. FE CIS: 19.8―20.3 mm {0.780―0.799 in }
F8, FE CARB: 19.1―19.6 mm {0.752―0.771 in }
Standard inner diameter
FE CIS
IN: 7.010―7.030 mm {0.2760―0.2767 in }
EX: 7.010―7.030 mm {0.2760―0.2767 in }
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F8, FE CARB
IN: 8.030―8.045 mm {0.3162―0.3167 in }
EX: 8.025―8.040 mm {0.3160―0.3165 in }
2. Tap the valve guide in from the side opposite the

combustion chamber until! the SST contacts the
cylinder head.
3. Verify that the valve guide projection height
(dimension) is within the specification.
Standard height
2. Measure the protrusion height (dimension A) of FE CIS: 19.8―20.3 mm {0.780―0.799 in }
each valve guide without lower valve spring seat. FB, FE CARB: 19.1―19.6mm {0.752―0.771 in }
Replace the valve guide if necessary.
Standard height
FE CIS: 19.8―20.3 mm {0.780―0.799 in }
F8, FE CARB: 19.1―19.6mm {0.752―0.711 in }
VALVE GUIDE REPLACEMENT

Valve Guide Removal
• Remove the valve guide from the combustion
chamber side by using the SST.
CONTINUED
B-24
TO. MODEL .INDEX
VALVE SEAT INSPECTION/REPAIR VALVE SPRING INSPECTION
1. Measure the seat contact width. 1. Apply pressing force to the pressure spring and
If necessary, resurface the valve seat by using a 45° check the spring height. Replace the valve spring if
valve seat cutter and/or resurface the valve face. necessary.
Standard width Pressing force

IN: 1.2―1.6 mm {0.048―0.062 in } FE CIS
EX: 1.2―1.6 mm {0.048―0.062 in } IN: 203.10―229.86 N
{20.71―23.44 kgf , 45.57― 51.56 Ibf }
EX: 240.37―272.03 N
{24.51―27.74 kgf , 53.93―61.02 Ibf }
F8, FE CARB
Inner: 117.19―136.01 N
{11.95―13.87 kgf , 26.29―30.51 Ibf }
Outer: 243.70―267.03 N
{24.85―27.23 kgf , 54.67―59.90 Ibf }
Standard height
FE CIS
IN: 41 mm {1.614 in }
EX: 41 mm {1.614 in }
2. Verify that the valve seating position is at the cen- F8, FE CARB
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ter of the valve face. Inner: 36.5 mm {1.437 in }
(1) If the seating position is too high, correct the Outer: 41.0 mm {1.614 in }
valve seat by using a 75° (FE CIS) or 60° (F8,
FE CARB) cutter, and a 45° cutter.
(2) If the seating position is too low, correct the
valve seat by using a 35° (IN) or 15° (EX)
cutter and a 45° cutter.
2. Measure the out-of-square of the valve spring.

Replace the valve spring if necessary.
Valve spring out-or-square

3. Check the sinking of the valve seat. Measure the FE CIS
protruding length (dimension L) of the valve stem. IN: 1.70 mm {0.067 in }
Replace the cylinder head if necessary. EX: 1.76 mm {0.069 in }
FB, FE CARB
Standard dimension L Inner: 1.5 mm {0.059 in }
F8, FE CARB: 46.5 mm {1.831 in } Outer: 1.8 mm {0.071 in }
FE CIS: 49.7 mm {1.957 in }
Maximum dimension L
F8, FE CARB: 47.0 mm {1.850 in }
FE CIS: 51.2 mm {2.016 in }
CONTINUED
B-25
TO. MODEL .INDEX
CAMSHAFT INSPECTION 2. Install the camshaft cap.
1. Set the No.1 and No.5 journals on V-blocks. (Refer to ENGINE DISASSEMBLY/ASSEMBLY
Measure the camshaft runout. Replace the CYLINDER HEAD (II) Camshaft Cap Assembly Note.)
camshaft if necessary. 3. Remove the camshaft cap.
(Refer to ENGINE DISASSEMBLY/ASSEMBLY,
Runout CYLINDER HEAD (II) Camshaft Cap Assembly Note.)
0.03 mm {0.0012 in } max. 4. Measure the oil clearance. Replace the cylinder
head if necessary.
2. Measure the cam lobe height at the two points as
shown. Replace the camshaft if necessary. Standard clearance
No.1, 5: 0.035―0.085 mm
{0.00138―0.00334 in }
Standard height
No.2, 3, 4: 0.065―0.115 mm
FE CIS
{0.00256―0.00453 in }
IN: 41.340 mm {1.6276 in }
EX: 41.847 mm {1.6475 in }
F8, FE CARB Maximum clearance
IN: 38.202 mm {1.5040 in } 0.15 mm {0.006 in }
EX: 38.202 mm {1.5040 in }
Fuel pump cam: 39.900 mm {1.5709 in }
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CAMSHAFT END PLAY INSPECTION
1. Install the camshaft and thrust plate.
3. Measure the journal diameters in X and Y 2. Measure the camshaft end play. Replace the
directions at the two points (A and B) as shown. camshaft and/or thrust plate if necessary.
Replace the camshaft if necessary.
Standard end play
Standard diameter 0.08―0.16 mm {0.00315―0.00629 in }
No.1, 5: 31.940―31.965 mm
{1.2575―1.2585 in } Maximum end play
No.2, 3, 4: 31.910―31.935 mm 0.20 mm {0.008 in }
{1 .2563―1.2572 in }
ROCKER ARM AND ROCKER ARM SHAFT
Minimum diameter INSPECTION
No.1, 5: 31.910 mm {1.2563 in } 1. Measure the rocker arm inner diameter.
No.2, 3, 4: 31.880 mm {1.2551 in }
Diameter
FE CIS: 19.000―19.033 mm
{0.7481―0.7493 in }
F8, FE CARB: 15.966―15.984 mm
{0.6286―0.6292 in }
CAMSHAFT OIL CLEARANCE INSPECTION

1. Position a plastigage atop the journals in the axial
direction.
2. Measure the rocker arm shaft diameter.
CONTINUED
B-26
TO. MODEL .INDEX
Diameter
FE CIS: 18.959―18.980 mm
{0.7465―0.7472 in }
F8, FE CARB: 15.966―15.984 mm
{0.6286―0.6292 in }
3. If the cylinder bore exceeds the wear limit, replace

the cylinder block or rebore the cylinder and install
the oversize pistons so that the specified
piston-to-cylinder clearance is obtained.
Note
3. Calculate the rocker arm-to-shaft clearance. • Base the boring diameter on the diameter of
Replace the rocker arm and/or rocker arm shaft if an oversize piston. All cylinders must be the
necessary. same diameter.
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Standard clearance
Cylinder bore mm { in }
FE CIS: 0.020―0.074 mm
{0.00079―0.00291 in } Size Diameter
F8, FE CARB: 0.016―0.061 mm
86.000―86.019
{0.00063―0.00240 in } Standard
{3.3859―3.3865}
CYLINDER BLOCK INSPECTION/REPAIR 86.250―86.269
1. Measure the distortion of the cylinder block top 0.25 {0.01} oversize
{3.3957―3.3964}
surface in the six directions as shown. Repair by 86.500―86.519
grinding or replace if necessary. 0.50 {0.02} oversize
{3.4056―3.4062}
Cylinder block distortion Wear limit
0.15 mm {0.006 in } max. 0.15 mm {0.006 in }
Cylinder block height PISTON INSPECTION
FE: 288.93―289.07 mm {11.376―11.380 in } • Measure the outer diameter of each piston at a
F8: 268.43―268.57 mm {10.569―10.573 in } right angle (90°) to the piston pin, 18.0 mm {0.709
in } below oil ring groove.
Grinding Piston diameter
0.20 mm {0.008 in } max. mm { in }
Size Diameter
85.943―85.965
Standard
{3.38358―3.38444}
86.193―86.215
0.25 {0.01} oversize
{3.39342―3.39428}
86.443―86.465
0.50 {0.02} oversize
{3.40327―3.40412}
2. Measure the cylinder bores in X and Y directions

at 65 mm {2.56 in } (F8), 70 mm {2.76 in } (FE)
below the top surface.
CONTINUED
B-27
TO. MODEL .INDEX
PISTON CLEARANCE INSPECTION/REPAIR PISTON PIN CLEARANCE INSPECTION
1. Calculate the piston-to-cylinder clearance. 1. Measure each piston pin hole diameter in X and Y
Replace the piston or rebore the cylinders to fit an directions at the four points (A, B, C, and D) as
oversized piston if necessary. shown.
Standard clearance Standard diameter

0.035―0.076 mm {0.0014―0.0029 in } 21.988―21.998 mm {0.8657―0.8660 in }
Maximum clearance
0.15 mm {0.006 in }
2. If the piston is replaced, the piston rings must also

be replaced.
PISTON RING CLEARANCE INSPECTION

1. Measure the piston ring-to-ring land clearance
around the entire circumference. Replace the
piston and piston ring if necessary.
Standard clearance
Top : 0.03―0.07 mm {0.0012―0.0027 in }
Second : 0.03―0.07 mm {0.0012―0.0027 in } 2. Measure each connecting rod small end inner
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Oil : 0.03―0.07 mm {0.0012―0.0027 in } diameter in X and Y directions as shown.
Standard diameter
Maximum clearance
21.943―21.961 mm {0.8639―0.8646 in }
0.15 mm {0.006 in }
2. Insert the piston ring into the cylinder by hand and

use the piston to push it to the bottom of the ring 3. Measure each piston pin diameter in X and Y
travel. directions at the four points (A, B, C, and D) as
3. Measure each piston ring end gap by using a shown.
feeler gauge. Replace the piston ring if necessary.
Standard diameter
Standard end gap 21.974―21.980 mm {0.8652―0.8653 in }
Top : 0.20―0.35 mm {0.008―0.013 in }
Second : 0.15―0.30 mm {0.006―0.011 in }
Oil rail : 0.20―0.70 mm {0.008―0.027 in }
Maximum end gap

1.0 mm {0.039 in }
4. Calculate the piston pin-to-piston pin bore

clearance.
Replace the piston and/or piston pin if necessary.
CONTINUED
B-28
TO. MODEL .INDEX
Standard clearance Crank pin
0.008―0.024 mm {0.00032―0.00094 in } mm { in }
Bearing size Diameter
5. Calculate the connecting rod small end-to-piston 50.940―50.955
pin clearance. Replace the connecting rod or Standard
{2.0056―2.0060}
piston pin.
50.690―50.705
0.25 {0.01} undersize
{1.9957―1.9962}
Standard clearance
- 0.037―0.013 mm {-0.0014―0.0006 in } 50.440―50.455
{1.9859―1.9864}
CRANKSHAFT INSPECTION 50.190―50.205
1. Measure the crankshaft runout. Replace the 0.75 {0.03} undersize
{1.9760―1.9765}
crankshaft if necessary.
Runout Out-of-round
0.03 mm {0.0012 in } 0.05 mm {0.002 in } max.
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2. Measure the journal diameter in X and Y direction CRANKSHAFT OIL CLEARANCE INSPECTION/
at the two points (A and B) as shown. Replace the REPAIR .
crankshaft or grind the journal and install the 1. Position a plastigauge atop the journals in the
undersize bearing if necessary. axial direction.
2. Install the main bearing cap.
Main journal (Refer to ENGINE DISASSEMBLY/ASSEMBLY.
mm { in }
CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY,
Bearing size Diameter
Main Bearing Cap Assembly Note.)
No.1, 2, 4, 5 : 59.937―59.955 3. Remove the main bearing cap.
{2.3598―2.3604} (Refer to ENGINE DISASSEMBLY/ASSEMBLY,
Standard
No.3 : 59.937―59.955 CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY,
{2.3598―2.3604} Main Bearing Cap Disassembly Note.)
No.1, 2, 4, 5 : 59.687―59.697 4. Measure the main journal oil clearance. If the
{2.3499―2.3502} clearance exceeds the maximum, replace the
No.3 : 59.687―59.691 main bearing or grind the main journal and install
{2.3499―2.3500} the undersize bearings so that the specified oil
No.1, 2, 4, 5 : 59.437―59.447 clearance is obtained.
{2.3401―2.3404}
0.50 {0.02} undersize Standard oil clearance
No.3 : 59.437―59.455
{2.3401―2.3407} No.1, 2, 4, 5:
No.1, 2, 4, 5 : 59.187―59.197 0.025―0.074 mm {0.00099―0.00291 in }
{2.3302―2.3305} No.3:
0.75 {0.03} undersize 0.031―0.074 mm {0.00123―0.00291 in }
No.3 : 59.187―59.205
{2.3302―2.3309}
Maximum oil clearance
0.10 mm {0.004 in }
Out-of-round
0.05 mm {0.002 in } max.
CONTINUED
B-29
TO. MODEL .INDEX
mm { in }
Bearing size Bearing thickness
2.004―2.007
Standard
{0.07890―0.07901}
2.129―2.139
{0.08382―0.08421}
No.1, 2, 4, 5 : 2.254―2.264
{0.08874―0.08913}
No.3 : 2.254―2.257
{0.08874―0.08885}
No.1, 2, 4, 5 : 2.379―2.389
{0.09367―0.09405}
No.3 : 2.379―2.382
{0.09367―0.09377}
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3. Remove the main bearing cap.
CRANKSHAFT END PLAY INSPECTION/REPAIR CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY,
1. Install the main bearing cap. Main Bearing Cap Disassembly Note.)
CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, CONNECTING ROD INSPECTION
Main Bearing Cap Assembly Note.) • Measure each connecting rod for bending and
2. Measure the crankshaft end play. If the end play distortion. Replace the connecting rod if
exceeds the maximum, replace the crankshaft necessary.
bearing or grind the crankshaft and Install an
undersize bearing so that the specified end play is Bending
obtained. 0.15 mm {0.006 in } max. /100 mm {3.937 in }
Standard end play Distortion

0.08―0.18 mm {0.00315―0.00708 in } 0.180 mm {0.0071 in } max. /50 mm {1.97 in }
Maximum end play Center-to-center distance

0.30 mm {0.012 in } FE: 151.95―152.05 {5.983―5.986 in }
F8: 135.95―136.05 {5.353―5.356 in }
Note
• When replacing the No.3 crankshaft bearing
replace all of the bearing as a set.
mm { in }
27.94―27.99
Standard
{1.1000―1.1019}
28.04―28.09
{1.1 040―1.1 060}
28.12―28.17
{1.1071―1.1090}
28.20―28.25
{1.1103―1.1122}
CONTINUED
B-30
TO. MODEL .INDEX
CONNECTING ROD OIL CLEARANCE
INSPECTION/REPAIR
1. Position a plastigauge atop the journals in the
axial direction.
2. Install the connecting rod cap.
(Refer to ENGINE DISASSEMBLY/ASSEMBLY.
CYLINDER BlOCK(II) DISASSEMBLY/ASSEMBLY,
Piston and Connecting Rod Assembly Note.)
3. Remove the connecting rod cap.
4. Measure the crankpin oil clearance. If the
clearance exceeds the maximum, replace the
connecting rod bearing or grind the crankpin and
use undersize bearings so that the specified
3. Remove the connecting rod cap.
clearance is obtained.
PISTON AND CONNECTING ROD INSPECTION
Standard oil clearance • Check the oscillation torque as shown. If the large
0.027―0.067 mm {0.0011―0.0026 in } end does not drop by its own weight, replace the
piston or the piston pin.
Maximum oil clearance
0.10 mm {0.004 in }
mm { in }
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1.505―1.510
Standard
{0.0593―0.0594}
1.630―1.635
{0.0642―0.0643}
1.755―1.760
{0.0691―0.0692}
1.880―1.885
{0.0741―0.0742}
TENSIONER SPRING INSPECTION
• Measure the free length of the tensioner spring.
Replace the tensioner spring if necessary.
Free length
F8: 63.0 mm {2.48 in }
FE CARB: 56.9 mm {2.24 in }
FE CIS: 53.9 mm {2.12 in }
CONNECTING ROD SIDE CLEARANCE

INSPECTION
1. Install the connecting rod cap.
CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY.
Piston and Connecting Rod Assembly Note.)
2. Measure the connecting rod large end side
clearance. GEAR CLEARANCE INSPECTION
Replace the connecting rod and cap if necessary. F8, FE CARB Timing Belt Drive Type
• Measure the following clearance. Replace the
gear and/or pump body if necessary.
Standard clearance
0.110―0.262 mm {0.005―0.010 in } Standard innergear tooth tip to cresent
clearance
Maximum clearance 0.267―0.380 mm {0.0106―0.0149 in }
0.30 mm {0.012 in }
Maximum innergear tooth tip to cresent
crearance
0.400 mm {0.0157 in }
B-31
CONTINUED
TO. MODEL .INDEX
ROTOR CLEARANCE INSPECTION

Standard outer gear tooth tip to cresent FE CIS
clearance • Measure the following clearance. Replace the
0.200―0.320 mm {0.0079―0.0125 in } rotor and/or pump body if necessary.
Maximum outer gear tooth tip to cresent Maximum Inner rotor tooth tip to outer rotor
clearance clearance
0.350 mm {0.0138 in } 0.18 mm {0.007 in }
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Standard side clearance Standard outer gear to pump body clearance
0.030―0.063 mm {0.00119―0.00248 in } 0.090―0.176 mm {0.0036―0.0069 in }
Maximum side clearance Maximum outer gear to pump body clearance

0.10 mm {0.004 in } 0.20 mm {0.008 in }
Standard outer rotor to body clearance Standard side clearance

0.030―0.063 mm {0.00119―0.00248 in } 0.03―0.09 mm {0.0012―0.0035 in }
Maximum body clearance Maximum side clearance

0.10 mm {0.004 in } 0.10 mm {0.004 in }
CONTINUED
B-32
TO. MODEL .INDEX
FE CARB Timing Chain Drive Type PLUNGER SPRING INSPECTION

• Measure the following clearance. Replace the • Measure the free length of the plunger spring.
rotor and/or pump body if necessary. Replace the plunger spring if necessary.
Standard Inner rotor tooth tip to outer rotor Free length

clearance 46.4 mm {1.827 in }
0.044―0.084 mm {0.0017―0.0033 in }
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Maximum Inner rotor tooth tip to outer rotor
clearance
0.18 mm {0.007 in }
Standard outer gear to pump body clearance

0.090―0.176 mm {0.0035―0.0069 in }
Maximum outer gear to pump body clearance

0.20 mm {0.008 in }
Standard side clearance

0.03―0.09 mm {0.0012―0.0035 in }
Maximum side clearance

0.10 mm {0.004 in }
CONTINUED
B-33
TO. MODEL .INDEX
TECHNICAL DATA
TECHNICAL DATA ......................................... TD-1/4
TECHNICAL DATA
Item Specification
Cylinder head
Height mm { in } 91.95—92.05 {3.621—3.624}
Distortion mm { in } 0.15 {0.006} max.
Grinding mm { in } 0.20 {0.008} max.
Valve clearance (F8, FE CARB) IN 0.30 {0.012} (Engine hot)
mm { in }
EX 0.30 {0.012} (Engine hot)
Valve and valve guide
FE CIS: 1.80—2.20 {0.071—0.086}
IN
Margin thickness F8, FE CARB: 0.8—1.2 {0.032—0.047}
mm { in } FE CIS: 1.30—1.70 {0.052—0.066}
EX
F8, FE CARB: 1.3—1.7 {0.052—0.066}
FE CIS: 115.61—116.01 {4.552—4.567}
Standard
IN F8, FE CARB: 111.69—112.09 {4.398—4.412}
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Valve length Minimum FE CIS: 115.51 {4.548}, F8, FE CARB: 111.39 {4.386}
mm { in } FE CIS: 116.01—116.41 {4.568—4.583}
Standard
EX F8, FE CARB: 111.49—111.89 {4.390—4.405}
Minimum FE CIS: 115.71 {4.556}, F8, FE CARB: 111.19{4.378}
FE CIS: 6.970—6.985 {0.2745—0.2749}
Standard
IN F8, FE CARB: 8.030—8.045 {0.3162—0.3167}
Valve stem diameter Minimum FE CIS: 6.920 {0.2724} F8, FE CARB: 7.980 {0.3142}
mm { in } Standard FE CIS: 6.965—6.980 {0.2743—0.2748}
EX F8, FE CARB: 8.025—8.040 {0.3160—0.3165}
Minimum FE CIS: 6.915 {0.2722} F8, FE CARB: 7.975 {0.3140}
IN FE CIS: 7.010—7.030 {0.2760—0.2767}
F8, FE CARB: 8.030—8.045 {0.3162—0.3167}
Guide inner diameter
EX FE CIS: 7.010—7.030 {0.2760—0.2767}
F8, FE CARB: 8.025—8.040 {0.3160—0.3165}
IN FE CIS: 19.8—20.3 {0.780—0.799}
Valve guide protrusion height F8, FE CARB: 19.1—19.6 {0.752—0.771}
mm { in } EX FE CIS: 19.8—20.3 {0.780—0.799}
F8, FE CARB: 19.1—19.6 {0.752—0.771}
Valve seat
Seat contact width IN 1.2—1.6 {0.048—0.062}
mm { in } EX 1.2—1.6 {0.048—0.062}
IN 45°
Seat angle
EX 45°
Standard F8, FE CARB: 46.5 {1.831} FE CIS: 49.7 {1.957}
IN
Seat sinking mm { in } Maximum F8, FE CARB: 47.0 {1.850} FE CIS: 51.2 {2.016}
(Valve protrusion height) Standard F8, FE CARB: 46.5 {1.831} FE CIS: 49.7 {1.957}
EX
Maximum F8, FE CARB: 47.0 {1.850} FE CIS: 51.2 {2.016}
CONTINUED
TD-1
TO. MODEL .INDEX
TECHNICAL DATA
Item Specification
Valve spring
H: 41.0 mm
203.10—229.86 {20.71—23.44, 45.57—51.56}
{1.614 in } (FE CIS)
H Inner: 36.5 mm
IN {1.437 in }
Inner: 117.19—136,01 {11,95—13.87, 26.29—30,51}
Outer: 41.0 mm
Outer: 243.70—267.03 {24.85—27.23, 54.67—59.90}
{1.614 in }
Pressing force at Valve (F8, FE CARB)
spring height H
N { kgf, lbf } H: 41.0 mm
240.37—272.03 {24.51—27.74, 53.93—61.02}
{1.614 in } (FE CIS)
H Inner: 36.5 mm
EX {1.437 in}
Inner: 117.19—136.01 {11.95—13.87, 26,29—30.51}
Outer: 41.0 mm
Outer: 243.70—267.03 {24.85—27.23, 54.67—59.90}
{1.614 in }
(F8, FE CARB)
FE CIS: 1.70 {0.067}
IN
Out-of-square F8, FE CARB: Inner 1.5 {0.059} outer 1.8 {0.071}
mm { in } FE CIS: 1.76 {0.069}
EX
F8, FE CARB: Inner 1.5 {0.059} outer 1.8 {0.071}
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Camshaft
Camshaft runout mm { in } 0.03 {0.0012} max.
IN FE CIS: 41,340 {1.6276} F8, FE CARB: 38.202 {1.5040}
Lobe height mm { in }
EX FE CIS: 41.847 {1.6475} F8, FE CARB: 38.202 {1.5040}
Standard 31.940—31.965 {1.2575—1.2585}
No.1, 5
Journal diameter Minimum 31.910 {1.2563}
mm { in } No.2, 3, Standard 31.910—31.935 {1.2563—1.2572}
4 Minimum 31.880 {1.2551}
No.1, 5 0.035—0.085 {0.00138—0,00334}
Camshaft bearing oil clearance
No.2, 3, 4 0.065—0.115 {0.00256—0.00453}
mm { in }
Maximum 0.15 {0.006}
Standard 0.08—0.16 {0.00315—0.00629}
Camshaft end play mm { in }
Maximum 0.20 {0.008}
Rocker arm and rocker arm shaft
FE CIS: 19.000—19.033 {0.7481—0.7493}
Rocker arm inner diameter mm { in }
F8, FE CARB: 15.966—15.984 {0.6286—0.6292}
FE CIS: 18.959—18.980 {0.7465—0.7472}
Rocker arm shaft diameter mm { in }
F8, FE CARB: 15.966—15.984 {0.6286—0.6292}
FE CIS: 0.020—0.074 {0.00079—0.00291}
Rocker arm to shaft clearance mm { in }
F8, FE CARB: 0.016—0.061 {0,00063—0.00240}
Cylinder block
FE; 288.93—289.07 {11.376—11.380}
Height mm { in }
F8: 268.43—268.57 {10.569—10.573}
Distortion mm { in } 0.15 {0.006} max.
Grinding mm { in } 0.20 {0.008} max.
Standard 86.000—86.019 {3.3859—3,3865}
Cylinder bore diameter
0.25 {0.01} oversize 86.250—86.269 {3.3957—3.3964}
mm { in }
0.50 {0.02} oversize 86.500—86.519 {3.4056—3.4062}
Wear limit mm { in } 0.15 {0,006}
CONTINUED
TD-2
TO. MODEL .INDEX
TECHNICAL DATA
Item Specification
Piston
Piston diameter Standard 85.943—85.965 {3.38358—3.38444}
Measured at 90° to pin
bore axis and 18.0 mm 0.25 {0.01} oversize 86.193—86.215 {3.39342—3.39428}
{0.709 in } below oil ring
groove mm { in } 0.50 {0.02} oversize 86.443—86.465 {3.40327—3.40412}
Standard 0.035—0.076 {0.0014—0.0029}
Piston-to-cylinder clearance mm { in }
Maximum 0.15 {0.006}
Piston ring
Top 0.03—0.07 {0.0012—0.0027}
Piston ring-to-ring groove clearance Second 0.03—0.07 {0.0012—0.0027}
mm { in } Oil 0.03—0.07 {0.0012—0.0027}
Maximum 0.15 {0.006}
Top 0.20—0.35 {0.008—0.013}
End gap (Measured in cylinder) Second 0.15—0.30 {0.006—0.011}
mm { in } Oil (rail) 0.20—0.70 {0.008—0.027}
Maximum 1.0 {0.039}
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Piston pin
Diameter mm { in } 21.974—21.980 {0.8652—0.8653}
Connecting rod small end-to-piston pin clearance mm { in } - 0.037— - 0.013 { -0.0014— - 0.0006}
Piston-to-piston pin clearance mm { in } 0.008—0.024 {0.00032—0.00094}
Crankshaft
Crankshaft runout mm { in } 0.03 {0.0012} max.
No.1, 2, 4, 5: 59.937—59.955 {2.3598—2.3604}
Standard
No.3: 59.937—59.955 {2.3598—2.3604}
No.1, 2, 4, 5: 59.687—59.697 {2.3499—2.3502}
Main journal diameter No.3: 59.687—59.691 {2.3499—2.3500}
mm { in } No.1, 2, 4. 5: 59.437—59.447 {2.3401—2.3404}
No.3: 59.437—59.455 {2.3401—2.3407}
No.1, 2, 4, 5: 59,187—59.197 {2.3302—2.3305}
No.3: 59.187—59.205 {2.3302—2.3309}
Out-of-round mm { in } 0.05 {0.002} max.
Standard 50.940—50.955 {2.0056—2.0060}
Crankpin diameter 0.25 {0.01} undersize 50.690—50.705 {1.9957—1.9962}
mm { in } 0.50 {0.02} undersize 50.440—50.455 {1.9859—1.9864}
0.75 {0.03} undersize 50.190—50.205 {1.9760—1.9765}
Out-of-round mm { in } 0.05 {0.002} max.
No.1, 2, 4, 5: 0.025—0.074 {0.00099—0.00291}
Main journal oil clearance Standard
No.3: 0.031—0.074 {0.00123—0.00291}
mm { in }
Maximum 0.10 {0.004}
Standard 0.08—0.18 {0.00315—0.00708}
Crankshaft end play mm { in }
Maximum 0.30 {0.012}
CONTINUED
TD-3
TO. MODEL .INDEX
TECHNICAL DATA
Item Specification
Connecting rod and connecting rod bearing
F8: 135.95—136.05 {5,353—5.356}
Length (Center to center) mm { in }
FE: 151.95—152.05 {5.983—5.986}
Bending mm { in } 0.15 {0.006} max./100 mm {3.937 in}
Distortion mm { in } 0.180 {0.0071} max./50 mm {1.97 in }
Connecting rod side clearance Standard 0.110—0.262 {0.005—0.010}
mm { in } Maximum 0.30 {0.012}
Connecting rod bearing oil clearance Standard 0.027—0.067 {0.0011—0.0026}
mm { in } Maximum 0.10 {0.004}
Tensioner spring
F8: 63.0 {2.48}, FE CARB: 56.9 {2.24},
Free length mm { in }
FE CIS: 53.9 {2.12}
Oil pump
FE CARB Timing chain drive type:
Inner rotor tooth tip to outer rotor Standard
0.044—0.084 {0.0017—0.0033}
clearance mm { in }
Maximum 0.18 {0.007} (FE CIS, FE CARB Timing chain type)
FE CIS, CARB Timing chain type:
Outer rotor to body clearance Standard
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0.090—0.176 {0.0035—0.0069}
mm { in }
Maximum FE CIS, CARB Timing chain type: 0.20 {0.008}
F8, FE CARB Timing belt drive type:
Standard
Inner gear tooth tip to crescent 0.267—0.380 {0.0106—0.0149}
clearance mm { in } F8, FE CARB Timing belt drive type:
Maximum
0.400 {0.0157}
P8, FE CARB Timing belt drive type:
Outer gear tooth tip to crescent Standard
0.200—0.320 {0.0079—0.0125}
clearance mm { in }
Maximum F8, FE CARB Timing belt drive type: 0.350 {0.0138}
Outer gear to pump body clearance Standard 0.030—0.063 {0.00119—0.00248}
mm { in } Maximum 0.10 {0.004}
F8, FE CARB Timing belt drive type:
0.030—0.063 {0.00120—0.0024}
Standard
Side clearance mm { in } FE CIS, FE CARB Timing chain drive type:
0.03—0.09 {0.0012—0.0035}
Maximum 0.10 {0.004}
Plunger spring
Free length mm { in } 46.4 {1.827}
CONTINUED
TD-4
TO. MODEL .INDEX
SPECIAL TOOLS
SPECIAL TOOLS ........................................... ST-1
SPECIAL TOOLS
49 0107 680A 49 L010 1A0 49 0636 100B
Engine stand Engine hanger Valve spring lifter

set arm
49 B012 0A2 49 0221 251A 49 S120 170
Pivot Valve guide Valve seal

remover and remover
installer
49 L012 0A2 49 L011 0A0B 49 E011 1A0
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Valve seal and Piston pin Ring gear brake
guide installer setting tool set set
49 1285 071 49 P005 204 49 S011 103
Needle bearing Oil seal installer Oil seal installer

puller
CONTINUED
ST-1
ENGINE
(WL, WL Turbo)
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2–1 ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . B2– 9
DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . B2–1/2 ROCKER ARM REMOVAL/
DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . B2–2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . B2– 9/11
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . B2–2 FRONT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . B2–11
VALVE CLEARANCE FRONT OIL SEAL REPLACEMENT . . . . . . . . B2–11/12
INSPECTION/ADJUSTMENT . . . . . . . . . . . . . B2–2 REAR OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . B2–12
COMPRESSION INSPECTION . . . . . . . . . . . . . . . B2–3 REAR OIL SEAL REPLACEMENT . . . . . . . . B2–12
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2–4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2–13
TIMING BELT REMOVAL/INSTALLATION . . . . B2–4/5 ENGINE REMOVAL/INSTALLATION . . . . . . B2–13/14
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . . . B2–6 ENGINE DISASSEMBLY/ASSEMBLY . . . . . B2–14
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . B2–6/8
DRIVE BELT Deflection (mm {in})

DRIVE BELT INSPECTION Drive belt *New Used Limit
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Drive Belt Deflection Check 7.0—9.0 8.0—10.0 16.0
Generator
1. Check the drive belt deflection when the engine is {0.28—0.35} {0.32—0.39} {0.63}
cold, or at least 30 minutes after the engine has 5.0—6.2 6.0—6.5 11.3
stopped. Apply pressure 98 N {10 kgf, 22 lbf} a
{0.20—0.24} {0.24—0.25} {0.44}
midway between the specified pulleys. A/C
9.5—11.8 11.0—12.5 18.0
MEASURING b
GENERATOR {0.38—0.46} {0.44—0.49} {0.71}
POINT
* A belt that has been on a running engine for less than
five minutes.
WATER 2. If the deflection is not within the specification,

PUMP adjust it.
GENERATOR
CRANKSHAFT
PULLEY 1. Belt tension can be checked in place of belt
deflection. Check the drive belt tension when the
MEASURING
POINT a engine is cold, or at least 30 minutes after the
A/C engine has stopped. Using the SST, check the belt
tension between any two pulleys.
A/C
COMPRESSOR
CRANKSHAFT 49 9200 020A
PULLEY
MEASURING
POINT b
WHEN MEASURED
WHEN SET
CONTINUED
B2–1
DRIVE BELT, VALVE CLEARANCE
Tension (N {kgf, lbf}) VALVE CLEARANCE

Drive belt *New Used Limit VALVE CLEARANCE INSPECTION/ADJUSTMENT
442—637 383—539 1. Remove the cylinder head cover.
177
Generator {45—65, {39—55, 2. Turn the crankshaft and align the timing mark so
{18, 40}
99—143} 86—121} that the piston of the No.1 or No.4 cylinder is at
403—519 354—431 TDC of compression.
181 3. Measure the valve clearances A with the No.1
A/C {41—53, {36—44,
{18.5, 41} cylinder at TDC of compression, and those of B
91—116} 80—96}
with the No.4 cylinder at TDC of compression.
* A belt that has been on a running engine for less than
five minutes. Valve clearance
IN: 0.05—0.15 mm {0.0020—0.0059 in}
2. If the tension is not within the specification, adjust [Engine cold]
it. 0.15 mm {0.0059 in}
(Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) [Engine hot (Reference)]
EX:0.15—0.25 mm {0.0060—0.0098 in}
[Engine cold]
DRIVE BELT ADJUSTMENT 0.25 mm {0.0098 in}
1. Loosen the mounting bolt and locknut A. [Engine hot (Reference)]
2. Adjust the belt deflection or tension by turning
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adjusting bolt B. A A A
(Refer to DRIVE BELT, DRIVE BELT INSPECTION.)
3. Tighten the mounting bolt and locknut A.
GENERATOR ENGINE
B FRONT
A 19—25
{1.9—2.6,
14—18}
WATER
PUMP B B B
GENERATOR
32—46 4. If not within the specification, adjust and recheck
CRANKSHAFT A {3.2—4.7, the valve clearance.
PULLEY 24—33} 5. Turn the crankshaft one full turn and measure the
B
remaining valve clearances. Adjust if necessary.
a
A/C 38—51
{3.8—5.3, A Tightening torque (locknut)
28—38} 16—20 N·m {1.6—2.1 kgf·m, 12—15 ft·lbf}
A/C
ADJUST
COMPRESSOR
CRANKSHAFT FEELER SCREW
PULLEY GAUGE
LOCKNUT
b N·m {kgf·m, ft·lbf}
4. Inspect the belt deflection or tension.

(Refer to DRIVE BELT, DRIVE BELT INSPECTION.)

(Refer to CYLINDER HEAD GASKET, CYLINDER HEAD
GASKET REPLACEMENT,
Cylinder Head Cover Installation Note.)
CONTINUED
B2–2
COMPRESSION INSPECTION
COMPRESSION INSPECTION (3) If the compression in adjacent cylinders stays

low, the cylinder head gasket may be damaged
Warning or the cylinder head distorted and overhaul is
When the engine and the oil are hot, they required.
can badly burn. Turn off the engine and wait 10. Remove the SST.
until they are cool. 11. Install the glow plug.
1. Verify that the battery is fully charged. Recharge it (Refer to Section F2, INTAKE AIR SYSTEM,
if necessary. GLOW PLUG REMOVAL/INSTALLATION.)
12. Connect the FCV (fuel cut valve) connector.
(Refer to Section G, CHARGING
SYSTEM, BATTERY INSPECTION, Battery.)
temperature.
3. Stop the engine and allow it to cool off for about 10
minutes.
Warning
Fuel line spills and leaks are dangerous.
Fuel can ignite and cause serious injuries
or death and damage. Fuel can also irritate
skin and eyes. To prevent fuel from
spurting out of the injection nozzle hole, do
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not ground the FCV (fuel cut valve) terminal.
4. Disconnect the FCV (fuel cut valve) connector.

5. Remove all the glow plugs.
(Refer to Section F2, INTAKE AIR SYSTEM,
GLOW PLUG REMOVAL/INSTALLATION.)
6. Install the SSTs into the glow plug hole.
49 S010 1A0
49 S013 102
7. Crank the engine and note the maximum gauge

reading.
8. Check each cylinder as above.
Compression
(kPa {kgf/cm2, psi} [rpm])
Engine
Item
WL, WL Turbo
Standard 2942 {30, 427} [200]
Minimum 2648 {27, 384} [200]
9. If the compression in one or more cylinders is low,

pour a small amount of clean engine oil into the
cylinder and recheck the compression.
(1) If the compression increases, the piston, the
piston rings, or cylinder wall may be worn and
(2) If the compression stays low, a valve may be
required.
CONTINUED
B2–3
TIMING BELT
TIMING BELT 3. Remove the tensioner and tensioner spring.

TIMING BELT REMOVAL/INSTALLATION Timing Belt Installation Note
1. Disconnect the negative battery cable. 1. Measure the tensioner spring free length. Replace
2. Remove in the order indicated in the table. the tensioner spring if necessary.
Free length
63.0 mm {2.48 in}
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
38—51 {3.8—5.3, 28—38}

N·m {kgf·m, ft·lbf}
FREE LENGTH
1 Timing belt cover
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+ Installation Note 2. Turn the crankshaft clockwise and align the timing
2 Tensioner, tensioner spring marks as shown.
3 Timing belt
+ Removal Note TIMING MARK
+ Installation Note TENSIONER
LOCK BOLT
Timing Belt Removal Note CAMSHAFT
PULLEY
Caution
Forcefully twisting the belt, turning it inside TENSIONER
SPRING
out, or allowing oil or grease on it will
TENSIONER
damage the belt and shorten its life.
TIMING MARK FIP PULLEY
Caution
FAULTY FAULTY FAULTY Overtensioning of the timing belt can cause
breakage of the belt and the camshaft.
ROTATION
ARROW 3. Verify that the FIP attaching bolts and nuts are
tightened to the specified torque. This must be
FAULTY done to prevent overtensioning of the timing belt
25 mm {1.0 in} MIN. after it has been installed.
4. Install the timing belt.
5. Install the tensioner, tensioner spring, and
1. Mark the timing belt rotation on the belt for proper hand-tighten the lock bolt.
reinstallation. 6. Turn the crankshaft clockwise twice, and align the
2. Turn the crankshaft clockwise and align the timing timing marks. If they are not aligned, remove the
marks as shown. timing belt and repeat from
Timing Belt Installation Note Step 2.
TIMING MARK
7. Loosen the tensioner lock bolt to apply tension to
the belt. Do not apply tension other than that of the
tensioner spring.
CAMSHAFT 8. Tighten the tensioner lock bolt. Be sure the
PULLEY tensioner does not move together with the bolt
rotation.
TENSIONER 9. Turn the crankshaft clockwise twice, and check the
SPRING
timing belt deflection as shown. If it is incorrect,
TENSIONER repeat from Timing Belt Removal Note.
TIMING MARK FIP PULLEY
CONTINUED
B2–4
TIMING BELT

9.0—10.0 mm {0.36—0.39 in} at
98 N {10 kgf, 22 lbf}
TENSIONER
LOCK BOLT
CAMSHAFT
PULLEY
DEFLECTION
CHECKING TENSIONER
POINT SPRING
TENSIONER
FIP PULLEY
Timing Belt Cover Installation Note

Tighten the timing belt cover bolts in the order
shown.
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CONTINUED
ST
B2–5

Warning
Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety
Procedures”.
(Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL SYSTEM.)

2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.)
(Refer to Section E,ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
3. Remove the intake manifold, air intake pipe and breather chamber.
(Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
4. Remove the injection nozzle.
(Refer to Section F2, FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.)
5. Remove the turbocharger. (WL Turbo)
(Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
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6. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.)
9. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
10. Check the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)
11. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)
(1) Inspect for engine oil, engine coolant, and fuel leakage.
(2) Inspect the idle speed. (Refer to Section F2, ENGINE TUNE-UP, PREPARATION, Idle Speed Adjustment.)
13. Inspect the compression. (Refer to COMPRESSION INSPECTION.)
5.0—8.8 N·m
{50—90 kgf·cm,
44—78 in·lbf}
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
18—19 {1.8—2.0, 13.1—14.4}

29 {3.0, 22} + (90°—105°) + (90°—105°)
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
38—51 {3.8—5.3, 28—38}
CONTINUED
B2–6
1 Drive belt
2 Cylinder head cover
+ Installation Note
3 Cylinder head bolt
+ Removal Note
+ Installation Note
4 Cylinder head
LENGTH
5 Cylinder head gasket
+ Installation Note
Cylinder Head Bolt Removal Note
1. Remove bolts A. 2. Apply clean engine oil to the threads and the seat
2. Loosen the cylinder head bolts in two or three face of each bolt and install them.
steps in the order shown. 3. Tighten the bolts in two or three steps in the order
shown in the figure.
A
Tightening torque
29 N·m {3.0 kgf·m, 22 ft·lbf}
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A
Cylinder Head Gasket Installation Note

Apply silicone sealant to the cylinder head as
shown. A
Thickness 4. Put a paint mark on each bolt head.

ø2.0—3.0 mm {0.08—0.11 in} 5. Using the marks as a reference, tighten the bolts
by turning each 90°—105° in the sequence shown.
16.0 mm 6. Further tighten each bolt by turning another
{0.63 in} 90°—105°.
40.5 mm ENGINE
{1.59 in} FRONT PAINT MARK
90°—105° 90°—105°
48.5 mm
{1.91 in}
9.0 mm
{0.35 in}
ST
Cylinder Head Bolt Installation Note PAINT MARK
1. Measure the length of each bolt. Replace the bolt if
necessary.
7. Tighten bolts A.
Cylinder head bolt (mm {in})
Standard Maximum Tightening torque
Bolt head mark 18—19 N·m {1.8—2.0 kgf·m, 13.1—14.4 ft·lbf}
length length
101.2—101.8
W 102.5 {4.035}
{3.985—4.007}
113.2—113.8
N 114.5 {4.508}
{4.457—4.480}
CONTINUED
B2–7

1. Apply silicone sealant to the cylinder head as
shown.
Thickness
ø1.5—2.5 mm {0.060—0.098 in}
2. Tighten cylinder head cover bolts A and B.
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Tightening torque
1.5—2.9 N·m {15—30 kgf·cm, 14—26 in·lbf}
ENGINE
FRONT
3. Tighten the cylinder head cover bolts in the order

shown.
Tightening torque
5.0—8.8 N·m {50—90 kgf·cm, 44—78 in·lbf}
CONTINUED
B2–8
ROCKER ARM
ROCKER ARM
ROCKER ARM REMOVAL/INSTALLATION
2. Remove the air intake pipe and breather chamber.
5.0—8.8 N·m
{50—90 kgf·cm,
44—78 in·lbf}
R
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11.3—14.2 N·m
{115—145 kgf·cm, 100—125 in·lbf}
16—20 {1.6—2.1, 12—15}
R
SST
7.9—10.7 N·m
{80—110 kgf·cm, 69.5—95.4 in·lbf}
30—41 {3.0—4.2, 22—30}
123—140 {12.5—14.3, 91—103}
1 Cylinder head cover 3 Seal plate

+ VALVE CLEARANCE, VALVE CLEARANCE + Installation Note
INSPECTION/ADJUSTMENT 4 Camshaft
+ CYLINDER HEAD GASKET, CYLINDER HEAD ST + Removal Note
GASKET REPLACEMENT, Cylinder Head Cover + Installation Note
Installation Note
5 Rocker arm
2 Camshaft pulley + Installation Note
+ Removal Note
6 Pivot
+ Installation Note
CONTINUED
B2–9
ROCKER ARM
Camshaft Pulley Removal Note

Hold the camshaft by using a wrench on the cast
hexagon.
2. Tighten the camshaft cap bolts gradually in three or

four steps in the order shown.
Camshaft Removal Note
Note
Mark the camshaft caps so that they can be
reinstalled in the position from which they were ENGINE
FRONT
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removed.
Loosen the camshaft cap bolts in three or four

3. Apply clean engine oil to the new oil seal.

5. Tap the oil seal into the cylinder head by using the
ENGINE
FRONT SST and a hammer.
6. To ensure that the oil seal is installed accurately,
measure distance between the end of the cylinder
head and the face of the oil seal.
49 S010 001
Rocker Arm Installation Note

If a new rocker arm is used, set dimension as
follows. 0.5—1.0 mm
{0.02—0.03 in}
Dimension A
0—4 mm {0—0.1 in}
HAMMER CYLINDER
HEAD OIL SEAL
Seal Plate Installation Note

Tighten the seal plate bolts in the order shown.
Camshaft Installation Note

1. Apply silicone sealant to the front camshaft cap
mounting surfaces as shown. Prevent sealant from
getting onto the camshaft journal, oil seal surface,
and camshaft thrust surface.
CONTINUED
B2–10
ROCKER ARM, FRONT OIL SEAL
Camshaft Pulley Installation Note FRONT OIL SEAL

Hold the camshaft by using a wrench on the cast
hexagon and tighten the pulley lock bolt. FRONT OIL SEAL REPLACEMENT
2. Drain the engine coolant. (Refer to Section E,
COOLING SYSTEM SERVICE WARNINGS.)
(Refer to Section E, ENGINE COOLANT, ENGINE
3. Remove the upper radiator hose.
4. Remove the radiator cowling and cooling fan.
(Refer to Section E, WATER PUMP, WATER
PUMP REMOVAL/INSTALLATION.)
7. Inspect the engine oil level.
8. Adjust the drive belt deflection.
SST
R
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SST
350—390
{35—40,
260—280}
1 Drive belt
2 Crankshaft pulley
+ Removal Note
+ Installation Note
3 Front oil seal
+ Removal Note
+ Installation Note
Crankshaft Pulley Removal Note
Hold the crankshaft by using the SST.
Caution
Turning the crankshaft after the crankshaft
pulley is removed can cause the timing
gear to become dislocated.
Removing the key can cause the key
groove to become misaligned.
49 S011 102A
CONTINUED
B2–11
FRONT OIL SEAL, REAR OIL SEAL
Front Oil Seal Removal Note REAR OIL SEAL

1. Cut the oil seal lip by using a razor knife.
2. Remove the oil seal by using a screwdriver REAR OIL SEAL REPLACEMENT
protected with a rag. 1. Disconnect the negative battery cable.
(Refer to Section H, CLUTCH UNIT, CLUTCH UNIT
RAG 3. Remove in the order indicated in the table.
5. Inspect the engine oil level. (Refer to Section D,
ENGINE OIL, ENGINE OIL INSPECTION.)
Front Oil Seal Installation Note

1. Apply clean engine oil to the new oil seal lip. SST R
3. Tap the oil seal in evenly by using the SST and a
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hammer.
measure the distance between the end of the gear
case cover and the face of the front oil seal. 1 Rear oil seal
GEAR CASE COVER + Removal Note
49 S010 301 + Installation Note

1. Cut the oil seal lip by using a razor knife.
0—0.4 mm 2. Remove the oil seal by using a screwdriver
{0—0.01 in}
protected with a rag.
HAMMER
FRONT OIL SEAL
Crankshaft Pulley Installation Note

Hold the crankshaft by using the SST.
RAG

3. Tap the oil seal in evenly by using the SST and a
49 S011 102A hammer.
measure the distance between the end of the rear
cover and the face of the rear oil seal.
REAR COVER
49 S011 103
0—0.5 mm {0—0.01 in}
HAMMER
REAR OIL SEAL
CONTINUED
B2–12
ENGINE
ENGINE
Warning
Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety
Procedures”.
(Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL SYSTEM.)
1. Remove the air intake pipe.

2. Remove the battery. (Refer to Section G, CHARGING SYSTEM, BATTERY REMOVAL/INSTALLATION.)
3. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.)
(Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
(Refer to section J2, TRANSMISSION, TRANSMISSION REMOVAL/INSTALLATION.)
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8. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
9. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)
(1) Inspect the engine oil, engine coolant, and fuel leakage.
(2) Inspect the idle speed.
(Refer to Section F2, ENGINE TUNE-UP, IDLE SPEED PREPARATION, Idle Speed Adjustment.)
9.9—14.7 N·m
19—25 {100—150 kgf·cm,
{1.9—2.6, 86.8—130 in·lbf}
14—18}
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf} 32—46 {3.2—4.7, 24—33}
20—30
{2.0—3.1, 15—22}
1 Cooling fan 5 P/S oil pump

2 Drive belt + Removal Note
3 Accelerator cable 6 Engine mount nut
4 A/C compressor 7 Engine

+ Removal Note + Removal/Installation Note
CONTINUED
B2–13
ENGINE
A/C Compressor Removal Note ENGINE DISASSEMBLY/ASSEMBLY

Remove the A/C compressor with the pipe still 1. Remove the intake-air system.
connected. Position the A/C compressor so that it (Refer to Section F2, INTAKE-AIR SYSTEM,
is out of the way. INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
P/S Oil Pump Removal Note (Refer to Section F2, EXHAUST SYSTEM,
Remove the P/S oil pump with the oil hose still EXHAUST SYSTEM REMOVAL/INSTALLATION.)
connected. Position the P/S oil pump so that it is 3. Remove the oil cooler.
out of the way. (Refer to Section D, OIL COOLER, OIL COOLER
Engine Removal/Installation Note 4. Disassemble in the ordre indicated in the table.
Install the engine hanger (JE48 10 561C) to the 5. Assemble in the reverse order of disassembly.
cylinder head by using bolt (99794 0820) or (M8
1.25, 6T, length 20 mm {0.79 in}) as shown.
12—17 {1.2—1.8, 9—13}
Tightening torque
19—25 N·m {1.9—2.6 kgf·m, 14—18 ft·lbf}
38—51
{3.8—5.3,
28—38}
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ENGINE
FRONT
32—46
{3.2—4.7, 38—51
24—33} 19—25 {1.9—2.6, 14—18} {3.8—5.3,
28—38}
1 Drive belt
2 Generator
3 Idler
4 A/C compressor bracket
5 Engine mount bracket
6 Oil pressure switch
+ Section D, OIL PRESSURE INSPECTION
7 Water pump pulley
CONTINUED
B2–14
ENGINE
(F2)
DRIVE BELT .................................................... B3- 1 HLA REMOVAL/INSTALLATION ................ B3-10/12
DRIVE BELT INSPECTION .......................... B3- 1 HLA TROUBLESHOOTING ........................ B3-13
DRIVE BELT ADJUSTMENT ........................ B3- 2 FRONT OIL SEAL ......................................... B3-14
COMPRESSION INSPECTION ........................ B3- 2/3 FRONT OIL SEAL REPLACEMENT ........... B3-14
TIMING BELT .................................................. B3- 4 REAR OIL SEAL ............................................. B3-15
TIMING BELT REMOVAL/INSTALLATION ... B3-4/6 REAR OIL SEAL REPLACEMENT ............. B3-15
CYLINDER HEAD GASKET ............................. B3- 7 ENGINE .......................................................... B3-16
CYLINDER HEAD GASKET ENGINE REMOVAL/INSTALLATION ......... B3-16/17
REPLACEMENT ......................................... B3- 7/9 ENGINE DISASSEMBLY/ASSEMBLY ........ B3-18
HYDRAULIC LASH ADJUSTER (HLA) ............ B3-10
DRIVE BELT Deflection mm {in}

DRIVE BELT INSPECTION Drive belt *New Used
Drive Belt Deflection Check 7.0—8.0 8.0—9.0
1. Check the drive belt deflection when the engine Generator {0.28—0.31} {0.32—0.35}
is cold, or at least 30 minutes after the engine
5.0—6.0 5.5—6.5
has stopped. Apply pressure 98 N {10 kgf, 22 Ibf} P/S {0.20—0.23} {0.22—0.25}
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midway between the specified pulleys.
10.0—12.0 12.0—14.0
A/C {0.40—0.47} {0.48—0.55}
* A belt that has been on a running engine for less
than five minutes.
2. If the deflection is not within the specification,
adjust it.
(Refer to DRIVE BELT, DRIVE BELT
ADJUSTMENT.)
1. Belt tension can be checked in place of belt
deflection. Check the drive belt tension when
the engine is cold, or at least 30 minutes after
the engine has stopped. Using the SST, check
the belt tension between any two pulleys.
CONTINUED
B3-1
DRIVE BELT, COMPRESSION INSPECTION

Tension N {kgf, Ibf} COMPRESSION INSPECTION
Drive belt *New Used Warning
• When the engine and the oil are hot, they
510—588 432—509
can badly burn. Be careful not to burn
Generator {52—60, 44—52,
yourself during removal/installation of each
115—132} 97—114}
component.
393—490 344—441 • Verify that the battery is fully charged. Recharge it if
P/S {40—50, {35—45, necessary.
88—110} 77—99} (Refer to Section G, CHARGING SYSTEM,
373—490 275—372 BATTERY INSPECTION, Battery.)
A/C {38—50, {28—38, • Warm up the engine to the normal operating
84—110} 62—83} temperature.
* A belt that has been on a running engine for less • Stop the engine and allow it to cool off for about 10
than five minutes. minutes.
2. If the tension is not within the specification, adjust • Perform "Fuel Line Safety Procedure". Leave the fuel
it. pump relay removed.
(Refer to DRIVE BELT, DRIVE BELT (Refer to Section F3-F4, FUEL SYSTEM, BEFORE
ADJUSTMENT.) REPAIR PROCEDURE.)
DRIVE BELT ADJUSTMENT • Disconnect the igniter connector (F2 CIS) or ignition
coil primary wire connector (F2 CARB).
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1. Loosen mounting bolts A and B, and locknut C.
• Remove the spark plugs.
2. Adjust the belt deflection or tension by turning the
generator or adjusting bolt D. • Connect a compression gauge into the No.1 spark
(Refer to DRIVE BELT, DRIVE BELT plug hole.
INSPECTION.) • Fully depress the accelerator pedal and crank the
engine.
3. Tighten mounting bolts A and B, and locknut C.
• Note the maximum gauge reading.
• Inspect compression of each cylinder.
Compression
kPa {kgf/cm2, psi} [rpm]
Engine type
Item
F2 CARB F2CIS
1196 {12.2, 173} 1226 {12.5, 178}
Standard [300] [300]
837 {8.54, 121} 858 {8.75, 124}
Minimum
[300] [300]
Maximum
2
difference 196 kPa {2.0 kgf/cm , 28 psi}
between cylinders
• If the compression in one or more cylinders is low or
the compression difference between cylinders
exceeds the maximum, pour a small amount of clean
engine oil into the cylinder and recheck the
compression.
• If the compression increases, the piston, the
piston rings, or cylinder wall may be worn and
• If the compression stays low, a valve may be
required.
• If the compression in adjacent cylinders stays
low, the cylinder head gasket may be damaged
or the cylinder head distorted and overhaul is
required.
• Disconnect the compression gauge.
• Install the spark plugs.
Tightening torque
15—22 N-m {1.5—2.3 kgf-m, 11—16 ft-lbf}
B3-2
CONTINUED
COMPRESSION INSPECTION
• Connect the igniter connector (F2 CIS) or ignition coil
primary wire connector (F2 CARB).
• Install the fuel pump relay.
CONTINUED
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B3-3
TIMING BELT
TIMING BELT
TIMING BELT REMOVAL/INSTALLATION
2. Remove the spark plugs.
4. Remove the cooling fan and cooling fan pulley.
(1) Inspect the pulleys and drive belt for runout and contact.
(2) Inspect the ignition timing.
(Refer to Section F3-F4, ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.)
1 Generator strap 6 Timing belt

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2 Cooling fan bracket ☞ Removal Note
3 Timing belt cover ☞ Installation Note
☞ Installation Note 7 Tensioner, tensioner spring
4 Crankshaft pulley ☞ Installation Note
5 Guide plate CONTINUED
B3-4
TIMING BELT
Timing Belt
Removal Note
1. Turn the crankshaft clockwise and align the
timing marks.
1
2. Install the tensioner.

3. Temporarily secure the tensioner with the spring
fully extended.
2. Loosen the tensioner lock bolt.

3. Push the tensioner in the direction of the ar
reduce tension of the timing belt and hand-
tighten the tensioner lock bolt. row to
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Timing Belt Installation Note
1. Verify that the timing belt pulley mark and
camshaft pulley mark are aligned with the timing
marks as shown.

1
Caution
• Forcefully twisting the belt, turning it
inside out, or allowing oil or grease on it
will damage the belt and shorten its life.
Note
• Mark the timing belt rotation on the belt for
proper reinstallation.
2. Install the timing belt so that there is no
looseness at the tension side.
Tensioner, Tensioner Spring Installation Note

1. Measure the tensioner spring free length. If not as
specified, replace the tensioner spring.
Free length
63.0 mm {2.48 in}
CONTINUED
B3-5
TIMING BELT
Caution
• Applying excessive tension can break the
timing belt. Be sure not to apply tension
other than that of the tensioner spring.
3. Loosen the tensioner lock bolt to apply
tension to the timing belt.
4. Turn the crankshaft clockwise twice and
verify that the timing belt pulley mark and
camshaft pulley mark are aligned with the
timing marks.
5. If not, repeat from Timing Belt Removal Note.
(Refer to Timing Belt Removal Note.)
Caution
• Prevent the tensioner from moving with the
tensioner lock bolt as it is turned.
Otherwise tension will become very high
and the timing belt may break.
6. Tighten the tensioner lock bolt.
7. Inspect the timing belt deflection at the point
indicated by applying moderate pressure 98 N {10
kgf, 22 Ibf}.
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New : 8.0—9.0 mm {0.32—0.35 in}
Used : 9.0—10.0 mm {0.36—0.39 in}
8. If not as specified, repeat from Timing Belt

Removal Note.
(Refer to Timing Belt Removal Note.)
Timing Belt Cover Installation Note

• Tighten the timing belt cover bolts in the order
shown.
CONTINUED
B3-6

Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety
Procedure" in section F3, F4.
(Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
(Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
3. Remove the timing belt, (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.)
(Refer to Section F3-F4, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
5. Remove the air cleaner. (F2 CARB)
6. Remove the air hose. (F2 CIS)
7. Disconnect the PCV hose.
8. Disconnect the accelerator cable and bracket (F2 CIS).
9. Disconnect the vacuum hoses, and engine harness connector.
10. Disconnect the fuel hoses. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
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(Refer to Section F3-F4, AFTER REPAIR PROCEDURE.)
11. Remove the dynamic chamber bracket. (F2 CIS)
12. Disconnect the heater hoses.
16. Inspect the compression. (Refer to COMPRESSION INSPECTION.)
17. Start the engine and inspect the idle speed.
(Refer to Section F3-F4, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
CONTINUED
B3-7
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1 Cylinder head cover 3 Cylinder head gasket
2 Cylinder head
☞ Removal Note
CONTINUED
B3-8

Cylinder Head Bolt Removal Note
• Loosen the cylinder head bolts a few turns in the
order shown.
Cylinder Head Bolt Installation Note

• Tighten the cylinder head bolts a few turns in the
order shown.
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1. Verify that the grooves on the cylinder head cover
are free of oil, water and other foreign material.
2. Apply sealant all around the cylinder head cover
side of the cylinder head cover gasket surface.
3. Install the cylinder head cover gasket into the
cylinder head cover.
4. Apply silicone sealant to the shaded area as
shown.
CONTINUED
B3-9

HLA REMOVAL/INSTALLATION
Caution
• Removal and installation of the HLA must be carried out only when the problem cannot be solved by
the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
5. Inspect the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)
(1) inspect the engine oil
(2) inspect the idle speed. (Refer to Section F3—F4, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
7. Inspect the HLA troubleshooting.
(Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
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1 Rocker arm component 3 Hydraulic lash adjuster (HLA)
☞ Removal Note ☞ Installation Note
2 Camshaft cap (F2 CARB)
☞ Installation Note CONTINUED
B3-10

Rocker Arm Component Removal Note
1. Loosen the bolts a few turns in the order shown.
4. Apply clean engine oil to HLA 0-ring.
Camshaft Cap (F2 CARS) Installation Note

• Apply silicone sealant to the shaded areas of
the cylinder head as shown.
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Rocker Arm Component Installation Note
Note
• The intake side shaft has twice as many oil
2. Identify the rocker arm and shaft assembly parts holes as the exhaust side shaft. (F2 CARB)
so that they can be reinstalled in the same
locations from which they were removed. 1. Assemble the rocker arms and shaft assembly as
3. Remove the rocker arm and shaft assembly shown in the figure.
together with the bolts.
Hydraulic Lash Adjuster (HLA) Installation Note
1. Place each HLA in a container filled with clean
engine oil.
Caution
• Do not push the pin too hard. It may
damage the HLA.
2. Bleed the air from the HLA by inserting a pin into
the plunger hole and pressing the plunger until it
no longer moves.
3. Pour engine oil into the oil reservoir in the rocker

arm. CONTINUED
B3-11
2. Apply silicone sealant to the shaded areas of the

cylinder head as shown.
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3. Install the rocker arm component.
4. Tighten the bolts a few turns in the order shown.
CONTINUED
B3-12

HLA TROUBLESHOOTING
Problem Possible Cause Action
1. Noise when engine is started Oil leakage in oil Run engine at 2,000—3,000 rpm.
immediately after oil is passage or in HLA If noise stops within 20 minutes*, HLA is normal.
changed. If not, replace HLA.
* Time required for engine oil to circulate within HLA
2. Noise when engine is started
includes tolerance for engine oil condition and
after sitting one day or more.
ambient temperature.
3. Noise when engine is started Oil leakage in HLA (Refer to HYDRAULIC LASH ADJUSTER (HLA),
after new HLA is installed. HLA TROUBLESHOOTING, Valve Clearance
Inspection.)
4. Noise continues more than Insufficient oil pressure Check oil pressure.
10 minutes. If lower than specification, check for cause.
(Refer to section D, OIL PRESSURE INSPECTION.)
Faulty HLA Press down HLA by hand.
If it does not move, HLA is normal.
If it moves, replace HLA.
Measure valve clearance.
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TROUBLESHOOTING, Valve Clearance Inspection.)
5. Noise during idle after high Incorrect oil amount Check oil level.
speed running. (Refer to Section D, ENGINE OIL, ENGINE OIL
INSPECTION.)
Deteriorated oil Replace new engine oil.
(Refer to Section D, ENGINE OIL, ENGINE OIL
REPLACEMENT.)
Valve Clearance Inspection
2. Measure valve clearance.
Valve clearance
0.15 mm {0.0059 in} max.
3. If valve clearance is more than 0.15 mm {0.0059

in}, replace the HLA.
(Refer to HYDRAULIC LASH ADJUSTER (HLA),
HLA REMOVAL/INSTALLATION.)
CONTINUED
B3-13
FRONT OIL SEAL

FRONT OIL SEAL
FRONT OIL SEAL REPLACEMENT
2. Remove the timing belt.
(Refer to TIMING BELT, TIMING BELT
5. Inspect the engine oil level.
(Refer to Section D, ENGINE OIL, ENGINE OIL
INSPECTION.) Front Oil Seal Installation Note
1. Apply clean engine oil to the oil seal lip.
hammer.
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1 Timing belt pulley
☞ Removal/Installation Note
2 Key
3 Front oil seal
☞ Removal Note
Timing Belt Pulley Removal/Installation Note

• Hold the crankshaft using the SST.
Front Oil Seal Removal Note

2. Remove the oil seal using a screwdriver
protected with a rag. CONTINUED
B3-14
REAR OIL SEAL

REAR OIL SEAL
REAR OIL SEAL REPLACEMENT
(Refer to Section H, CLUTCH UNIT, CLUTCH
UNIT REMOVAL/ INSTALLATION.)
1 Rear oil seal
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• Refer to Removal Note
• Refer to Installation Note

2. Remove the oil seal using a screwdriver protected with a
rag.

hammer.
CONTINUED
B3-15
ENGINE
ENGINE
Warning
• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
Procedure" in section F3, F4. (Refer to section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

3. Remove the air cleaner and air hose (F2, CIS).
5. Disconnect the accelerator cable, bracket (F2 CIS), heater hoses, high-tension leads, and vacuum hoses.
6. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.)
7. Remove the cooling fan and cooling fan pulley.
9. Disconnect the fuel hoses. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
(Refer to Section F3-F4, FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
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(Refer to Section J1-J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION.)
11. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way.
(Refer to Section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP
12. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way.
(1) Inspect the engine oil, engine coolant, transmission oil, and fuel leakage.
(2) Inspect the ignition timing, idle speed and idle mixture. (Refer to Section F3-F4, ENGINE TUNE-UP.)
CONTINUED
B3-16
ENGINE
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1 Engine mount nut 2 Engine
CONTINUED
B3-17
ENGINE
1. Remove the distributor. (Refer to Section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.)
3. Remove the thermostat. (Refer to Section E, THERMOSTAT, THERMOSTAT REMOVAL/INSTALLATION.)
4. Remove the intake-air system.
(Refer to Section F3-F4, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
(Refer to Section F3-F4, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
6. Remove the oil filter. (Refer to Section D, OIL FILTER, OIL FILTER REPLACEMENT.)
7. Remove the oil pressure switch. (Refer to Section D, OIL PRESSURE INSPECTION.)
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1 Generator strap 6 Dipstick
2 Cooling fan bracket 7 P/S oil pump bracket
3 Generator bracket 8 Gusset plate
4 Water inlet pipe 9 Engine mount
5 Water bypass pipe
CONTINUED
B3-18
LUBRICATION SYSTEM
OIL PRESSURE INSPECTION . . . . . . . . . . . . . . . . D–1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–3
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–2 OIL COOLER REMOVAL/INSTALLATION . . . . . D–3/4
ENGINE OIL INSPECTION . . . . . . . . . . . . . . . . . . D–2 OIL COOLER BODY INSPECTION . . . . . . . . . . D–4
ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . D–2 OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–4
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D–2 OIL PAN REMOVAL/INSTALLATION . . . . . . . . . D–4/5
OIL FILTER REPLACEMENT . . . . . . . . . . . . . . . . D–2
OIL PRESSURE INSPECTION G6 : 305—402 kPa

{3.1—4.1 kgf/cm2, 45—58 psi}
Warning [3,000 rpm]
Continuous exposure with USED engine oil WL : 452—529 kPa
has caused skin cancer in laboratory mice. {4.6—5.4 kgf/cm2, 66—76 psi}
Protect your skin by washing with soap and [3,000 rpm]
water immediately after this work. WL Turbo : 402—480 kPa
When the engine and the oil are hot, they {4.1—4.9 kgf/cm2, 59—69 psi}
can badly burn. Turn off the engine and wait [3,000 rpm]
until they are cool.
5. If the pressure is not as specified, inspect for the
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1. Remove the oil pressure switch. cause and repair or replace as necessary.
2. Screw the SST into the oil pressure switch 6. Stop the engine and wait until it becomes cool.
installation hole. 7. Remove the SST.
8. Apply silicone sealant to the oil pressure switch
F2, G6 threads as shown.
1.0—2.0 mm
{0.040—0.078 in}
49 0187 280
4.0—6.0 mm
{0.16—0.23 in}
WL,
WL TURBO
9. Install the oil pressure switch before the sealant
hardens.
Tightening torque
12—17 N·m {1.2—1.8 kgf·m, 9—13 ft·lbf}
10. Start the engine and inspect for oil leakage.

49 0187 280
3. Warm up the engine to normal operating

temperature.
4. Run the engine at the specified speed, and note
the gauge readings.
Note
The oil pressure can vary with viscosity and
temperature.
Oil pressure
F2 : 295—392 kPa
{3.0—4.0 kgf/cm2, 43—56 psi}
[3,000 rpm]
CONTINUED
D–1
ENGINE OIL, OIL FILTER
ENGINE OIL OIL FILTER

ENGINE OIL INSPECTION OIL FILTER REPLACEMENT
1. Position the vehicle on level ground. 1. Remove the oil filter by using the SST or the filter
2. Warm up the engine to normal operating wrench.
temperature and stop it.
3. Wait for five minutes.
4. Remove the dipstick and inspect for oil level and
condition. Verify that the oil level is within the F and
L marks on the dipstick.
5. Add or replace oil if necessary.
49 9014 001
ENGINE OIL REPLACEMENT
Warning
When the engine and the engine oil are hot,
they can badly burn. Don’t burn yourself
with either.
A vehicle that is lifted but not securely 2. Use a clean rag to wipe off the mounting surface
supported on safety stands is dangerous. It on the oil filter body.
can slip or fall, causing death or serious 3. Apply engine oil to the O-ring and tighten the filter
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injury. Never work around or under a lifted according to the installation directions on the side
vehicle if it is not securely supported on of the oil filter using the SST or the filter wrench.
safety stands. 4. Start the engine and inspect for oil leakage.
Continuous exposure with USED engine oil 5. Inspect for the oil level and add oil if necessary.
has caused skin cancer in laboratory mice. (Refer to ENGINE OIL, ENGINE OIL
Protect your skin by washing with soap and INSPECTION.)
water immediately after this work.
1. Position the vehicle on level ground.

2. Remove the oil filler cap and the oil pan drain plug.
3. Drain the oil into a container.
4. Install the drain plug by using a new washer.
Tightening torque
30—41 N·m {3.0—4.2 kgf·m, 22—30 ft·lbf}
5. Refill the engine oil with the specified type and

amount of engine oil.
6. Refit the oil filler cap.
7. Run the engine and inspect for oil leakage.
8. Inspect the oil level and add oil if necessary.
(Refer to ENGINE OIL, ENGINE OIL INSPECTION.)
Note
The actual oil level may vary from the specified
capacity in some cases.
Oil capacity (L {US qt, Imp qt})

Engine
Item WL, WL
F2 G6
Turbo
3.9 4.5 5.6
Oil replacement
{4.1, 3.4} {4.8, 4.0} {5.9, 4.9}
Oil and oil filter 4.2 4.7 6.3
replacement {4.4, 3.7} {5.0, 4.4} {6.7, 5.5}
Total 4.6 5.5 6.7
(dry engine) {4.9, 4.0} {5.8, 4.8} {7.1, 5.9}
CONTINUED
D–2
OIL COOLER
OIL COOLER
OIL COOLER REMOVAL/INSTALLATION
G6, WL, WL Turbo
2. Drain the engine coolant. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
3. Remove the turbocharger.
(Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) (WL Turbo model.)
4. Remove the oil filter. (Refer to OIL FILTER, OIL FILTER REPLACEMENT.)
5. Remove in the order shown in the figure.
7. Fill the radiator with the specified amount and type of engine coolant.
(Refer to section E, ENGINE COOLANT,ENGINE COOLANT REPLACEMENT.)
8. Inspect the engine oil level. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.)
9. Start the engine and inspect for engine coolant leakage.
G6
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30—39 {3.0—4.0, 22—28}
1 Water hose 3 Oil cooler

2 Nut
WL, WL TURBO
R
30—49 {3.0—5.0, 22—36}
R
R
7.9—10.7 N·m
{80—110 kgf·cm,
70—95 in·lbf}
19—25 {1.9—2.6, 14—18}

R
19—25 {1.9—2.6, 14—18}
1 Dipstick pipe 5 Oil cooler body

2 Radiator hose + Installation Note
3 Thermostat case 6 Oil cooler
4 Insulator
CONTINUED
D–3
OIL COOLER, OIL PAN
Oil Cooler Body Installation Note OIL PAN

WL, WL Turbo
Tighten the mounting bolts and nuts in the order OIL PAN REMOVAL/INSTALLATION
shown. 1. Disconnect the negative battery cable.
2. Drain the engine oil.
(Refer to ENGINE OIL, ENGINE OIL REPLACEMENT.)
3. Remove in the order shown in the figure.
5. Fill with the specified amount and type of engine
oil.
(Refer to ENGINE OIL, ENGINE OIL REPLACEMENT.)
6. Start the engine and inspect for engine oil leakage.
F2, G6
OIL COOLER BODY INSPECTION

WL, WL Turbo
Measure the spring free length. Replace the spring
if necessary.
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Standard free length
Bypass valve spring: 36.7 mm {1.44 in}
Pressure control valve spring: 54.7 mm {2.15 in} 7.9—10.7 N·m
{80—110 kgf·cm,
70—95 in·lbf}
BYPASS VALVE SPRING 30—41
{3.0—4.2, 22—30} 38—51
{3.8—5.3,
28—38}
38—51
{3.8—5.3,
PRESSURE CONTROL VALVE SPRING 28—38}
1 Gusset plate
2 Oil pan
+ Removal Note
+ Installation Note
CONTINUED
D–4
OIL PAN
Oil Pan Installation Note

WL, WL TURBO
94—115 Caution
{9.5—11.8, 69—85} If the bolts are reused, remove the old
sealant from the bolt threads. Tightening a
bolt that has old sealant on it can cause
bolt hole damage.
CRACKS
OLD SEALANT
55—80
1. Apply silicone sealant to the oil pan along the
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7.9—10.7 N·m
{5.6—8.2,
{80—110 kgf·cm,
inside of the bolt holes and overlap the ends.
41—59}
70—95 in·lbf}
Thickness
Ø2.0—3.0 mm {0.08—0.11 in}
1 Crossmember (4WD)
2 Oil pan
+ Removal Note
+ Installation Note
OIL PAN
Oil Pan Removal Note

1. Remove the oil pan mounting bolts.
Caution
Pry tools can easily scratch the cylinder
block or oil baffle and oil pan contact
surfaces. Prying off the oil pan can also
easily bend the oil pan flange.
2. Install the oil pan before the sealant hardens.
2. Use a separator tool to separate the oil pan.
SEPARATOR TOOL
CONTINUED
D–5
COOLING SYSTEM
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . E–1 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–4
ENGINE COOLANT LEVEL INSPECTION . . . . E–1 THERMOSTAT REMOVAL/INSTALLATION . . . . E–4/5
ENGINE COOLANT REPLACEMENT . . . . . . . . E–1/2 THERMOSTAT INSPECTION . . . . . . . . . . . . . . . E–5
ENGINE COOLANT LEAKAGE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–2 WATER PUMP REMOVAL/INSTALLATION . . . . E–6
RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–3 COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–7
RADIATOR CAP INSPECTION . . . . . . . . . . . . . . E–3 COOLING FAN REMOVAL/INSTALLATION . . . E–7
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E–3 COOLING FAN INSPECTION . . . . . . . . . . . . . . . E–7
RADIATOR REMOVAL/INSTALLATION . . . . . . . E–3
ENGINE COOLANT
Warning TYPE A
Removing the radiator cap or loosening the
radiator drain plug while the engine is
running, or when the engine and radiator DRAIN
are hot is dangerous. Scalding coolant and PLUG
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steam may shoot out and cause serious TYPE B
injury. It may also damage the engine and
cooling system.
Turn off the engine and wait until it is cool.
Even then, be very careful when removing
the cap. Wrap a thick cloth around it and 3. Drain the coolant into a container.
slowly turn it counterclockwise to the first 4. Flush the cooling system with water until all traces
stop. Step back while the pressure escapes. of color are gone.
When you’re sure all the pressure is gone, 5. Let the system drain completely.
press down on the cap –still using a cloth– 6. Tighten the radiator drain plug.
turn it, and remove it.
When the engine and the engine coolant are Tightening torque
hot, they can badly burn. Turn off the Type A: 1.5—2.9 N·m
engine and wait until they are cool before {15—30 kgf·cm, 14—26 in·lbf}
draining the engine coolant. Type B: 0.9—1.1 N·m
{9.0—12 kgf·cm, 7.9—10 in·lbf}
ENGINE COOLANT LEVEL INSPECTION
1. Remove the radiator cap. Caution
2. Verify that the coolant level is near the radiator filler The engine has aluminum parts that can be
neck. damaged by alcohol or methanol antifreeze.
3. Verify that the coolant level in the radiator reservoir Do not use alcohol or methanol in the
is between the FULL and LOW marks. cooling system. Use only
4. Add coolant if necessary. ethylene-glycol-based coolant.
Use only soft (demineralized) water in the
ENGINE COOLANT REPLACEMENT coolant mixture. Water that contains
1. Drain the coolant in the radiator reservoir. minerals will cut down on the coolant’s
2. Remove the radiator cap and loosen the radiator effectiveness.
drain plug.
7. Referring to the following graph and chart, select
proper gravity of the coolant. Slowly pour the
coolant into the radiator up to the coolant filler port.
Filling pace
1.0 L {1.1 US qt, 0.88 Imp qt}/min. [max]
CONTINUED
E–1
ENGINE COOLANT
Caution
Applying more than 103 kPa {1.05 kgf/cm2,
SPECIFIC COOLANT PROTECTION 14.9 psi} (F2) or 122 kPa {1.25 kgf/cm2, 17.7
GRAVITY
psi} (G6, WL, WL Turbo) can damage the
1,100
hoses, fittings, and other components, and
1,090
cause leakage.
1,080
1,070
49 9200 147
1,060 50%
40%
1,050
30%
1,040
1,030
49 9200 146
1,020
1,010
1,000
0
–10 0 10 20 30 40 50 60 70 80 90
5. Verify that the pressure is held. If not, inspect the
{ 14 } { 32 } { 50 } { 68 } { 86 } { 104 }{ 122 } { 140 } { 158 } { 176 } { 194 } system for coolant leakage.
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COOLANT TEMPERATURE °C { °F }
Antifreeze solution mixture percentage

Volume percentage Gravity
Coolant protection at 20°C
Water Coolant {68°F}
Above –16°C {3°F} 65 35 1,054
Above –26°C {–15°F} 55 45 1,066
Above –40°C {–40°F} 45 55 1,078
8. Fill the coolant into the reservoir up to the FULL

mark.
9. Fully install the radiator cap.
10. Start the engine and let it idle for approx. 10
minutes. If the coolant temperature becomes too
high, stop the engine to prevent it from
overheating.
11. After the engine warms up, run it at approx. 2,500
rpm for five minutes.
12. Increase the engine speed to approx. 3,000 rpm
for five seconds, then return to idle. Repeat several
times.
13. Stop the engine and wait until it is cool.
14. Inspect the coolant level. If it is low, repeat Steps
7—12.
15. Inspect for coolant leakage.
ENGINE COOLANT LEAKAGE INSPECTION

1. Inspect the coolant level.
(Refer to ENGINE COOLANT,
ENGINE COOLANT LEVEL INSPECTION.)
2. Remove the radiator cap.
3. Connect a radiator cap tester and the SST to the
radiator filler neck.
4. Apply pressure to the radiator.
Pressure
F2: 103 kPa {1.05 kgf/cm2, 14.9 psi}
G6, WL, WL Turbo:
122 kPa {1.25 kgf/cm2, 17.7 psi} CONTINUED
E–2
RADIATOR CAP, RADIATOR
RADIATOR CAP RADIATOR

RADIATOR CAP INSPECTION RADIATOR REMOVAL/INSTALLATION
Warning (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
Removing the radiator cap while the engine 2. Remove in the order indiacted in the table.
is running, or when the engine and radiator 3. Install in the reverse order of removal.
are hot is dangerous. Scalding coolant and 4. Fill the radiator with the specified amount and type
steam may shoot out and cause serious of engine coolant.
injury. It may also damage the engine and (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
cooling system. 7.9—10.7 N·m
Turn off the engine and wait until it is cool. {80—110 kgf·cm, 69.5—95.4 in·lbf}
Even then, be very careful when removing 18—26

the cap. Wrap a thick cloth around it and {1.8—2.7, 14—19}
slowly turn it counterclockwise to the first
stop. Step back while the pressure escapes. 18—26
{1.8—2.7,
When you’re sure all the pressure is gone, 14—19}
press down on the cap –still using a cloth–
turn it, and remove it.
1. Attach the radiator cap to a radiator cap tester with
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the SST. Apply pressure gradually.
2. Verify that the pressure becomes stable within the
specification.
Pressure
F2: 74—102 kPa
{0.75—1.05 kgf/cm2, 10.7—14.9 psi}
G6, WL, WL Turbo: 94—122 kPa
{0.95—1.25 kgf/cm2, 13.5—17.7 psi}
3. If the pressure is held for 10 seconds, the radiator

cap is normal. N·m {kgf·m, ft·lbf}
1 Radiator hose
49 9200 147
2 Lower radiator cowling
3 Radiator cowling
4 Radiator
CONTINUED
ST
E–3
THERMOSTAT
THERMOSTAT 1 Upper radiator hose

2
Thermostat cover
THERMOSTAT REMOVAL/INSTALLATION
1. Drain the engine coolant. (Refer to ENGINE 3 Thermostat
COOLANT, ENGINE COOLANT REPLACEMENT.) + Installation Note
3. Install in the reverse order of removal. WL, WL TURBO
4. Fill the radiator with the specified amount and type
of engine coolant.
(Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
F2
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
R 19—25
{1.9—2.6, 14—18}
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R
19—25 N·m {kgf·m, ft·lbf}

{1.9—2.6, 14—18}
1 Dipstick pipe

2 Lower radiator hose
3 Thermostat cover
1 Upper radiator hose 4 Thermostat
+ Installation Note
2 Thermostat cover
3 Thermostat Thermostat Installation Note
+ Installation Note F2, G6
1. Install the thermostat into the cylinder head with
the jiggle pin at the top.
G6 2. Install a new gasket with the seal print side facing
the cylinder head.
JIGGLE PIN
A
19—25
{1.9—2.6, 14—18}
A–A
R A
19—25
PRINT
{1.9—2.6, 14—18}
WL, WL Turbo
Install the thermostat into the thermostat cover,
aligning the projection on the gasket to the
thermostat cover as shown.
CONTINUED
E–4
THERMOSTAT
GASKET
PROJECTION
THERMOSTAT COVER
THERMOSTAT INSPECTION
Warning
During inspection, the thermostat and water
are extremely hot and they can badly burn.
Do not touch the thermostat and water
directly.
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Inspect the thermostat for the following and replace as
necessary.
Open valve in room temperature
Opening temperature and lift of the valve
Initial-opening temperature
F2: 83.5—89.5 °C {183—193 °F}
G6: 86.5—89.5 °C {188—193 °F} (Main valve)
83.5—86.5 °C {183—187 °F} (Sub valve)
WL, WL Turbo: 80—84 °C {176—183 °F}
Full open temperature
F2, G6 : 100 °C {212 °F}
WL, WL Turbo : 95 °C {203 °F}
Full open lift

G6 : 8.0 mm {0.31 in} min. (Main valve)
1.5 mm {0.06 in} min. (Sub valve)
F2, WL, WL Turbo: 8.5 mm {0.33 in} min.
CONTINUED
ST
E–5
WATER PUMP
WATER PUMP WL, WL TURBO
WATER PUMP REMOVAL/INSTALLATION

1. Remove the cooling fan.
(Refer to COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.)
2. Remove the timing belt (F2). 19—25
{1.9—2.6, 14—18}
(Refer to Section B2, TIMING BELT,
R
TIMING BELT REMOVAL/INSTALLATION.)
3. Drain the engine coolant. (Refer to ENGINE
COOLANT, ENGINE COOLANT REPLACEMENT.)
6. Fill the radiator with the specified amount and type
of engine coolant. (Refer to ENGINE COOLANT,
ENGINE COOLANT REPLACEMENT.)
F2
19—22
{1.9—2.3, 14—16}
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19—25
{1.9—2.6, 14—18} 1 Water pump
2 Idler
38—51
{3.8—5.3, 28—38}
G6
19—22
{1.9—2.2, 14—16}
CONTINUED
E–6
COOLING FAN
COOLING FAN
COOLING FAN REMOVAL/INSTALLATION
4. Adjust the drive belt (generator) deflection.
(Refer to Section B2,DRIVE BELT,
DRIVE BELT ADJUSTMENT.)
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F2, G6: 7.9—10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
WL, WL TURBO: 19—25 {1.9—2.6, 14—18}
1 Cooling fan
2 Water pump pulley
COOLING FAN INSPECTION

1. Rotate the cooling fan by hand and inspect for
abnormal noise and looseness. Replace the
cooling fan if necessary.
(Refer to COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.)
CONTINUED
E–7
FUEL AND EMISSION CONTROL SYSTEMS

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

Page 2 of 2
(G6 )
PID/DATA MONITOR AND RECORD TROUBLESHOOTING ...................................................F1-70
PROCEDURE ...................................................... F1-48 FOREWORD ............................................................F1-70
PLAYBACK OF STORED PIDS TROUBLESHOOTING ITEM TABLE .....................F1-70
PROCEDURE ...................................................... F1-48/49 QUICK DIAGNOSTIC CHART ...............................F1-71/74
DIAGNOSTIC SUPPORT PROCEDURE .......... F1-49 SYMPTOM TROUBLESHOOTING .......................F1-75/114
SIMULATION TEST PROCEDURE ........................ F1-50/51 DIAGNOSTIC INSPECTION..................................F1-115/120
AFTER REPAIR PROCEDURE ............................. F1-51 ENGINE SYSTEM INSPECTION .........................F1-120/127
DTC INSPECTION .................................................. F1-52/69
ENGINE TUNE-UP Not Using the SSTs (NGS tester)

ENGINE TUNE-UP PREPARATION 1. Warm up the engine to normal operating
Using the SSTs (NGS Tester) temperature.
1. Warm up the engine to normal operating 2. Shift the transmission into neutral.
temperature. 3. Turn off all electrical loads.
2. Shift the transmission into neutral. • A/C switch
3. Turn off all electrical loads. 4. Verify that the steering wheel is at straight ahead
• A/C switch position.
4. Verify that the steering wheel is at straight ahead Caution
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position. • Connecting the wrong DLC terminals
5. Connect the SSTs (NQS tester) to the DLC and may possibly cause a malfunction.
select "PID/DATA MONITOR AND RECORD". Carefully connect the specified
(Refer to ON-BOARD DIAGNOSTIC SYSTEM, terminals only.
ON-BOARD DIAGNOSTIC TEST, NGS Tester 5. Connect a dwell tachometer to the DLC terminal
Hook-up Procedure.) IG-.
IGNITION TIMING ADJUSTMENT

Using the SSTs (NGS Tester)
1. Perform "ENGINE TUNE-UP PREPARATION".
(Refer to ENGINE TUNE-UP, ENGINE TUNE-
UP PREPARATION.)
2. Verify that the RPM PID is within the
6. Access RPM PID. Press the trigger key to enter specification.
this selection.
(Refer to ON-BOARD DIAGNOSTIC SYSTEM, Specification
PID/DATA MONITOR AND RECORD 730—770 (750 ±20) rpm
PROCEDURE.) 3. If not as specified, adjust the idle speed.
7. Press SETUP (Key 8) and turn the test mode on. (Refer to ENGINE TUNE-UP, IDLE SPEED
8. Press CANCEL. ADJUSTMENT.)
9. Press START. 4. Connect the timing light to the high-tension lead
of the No. 1 cylinder.
5. Verify that the timing mark on the crankshaft
pulley is within the specification.
Specification
BTDC 4°—6°(5° ± 1°)
CONTINUED
F1-2
ENGINE TUNE-UP
6. If not as specified, loosen the distributor lock bolts
and turn the distributor to make the adjustment.
7. Tighten the distributor lock bolts to the specified
torque.
Tightening torque
19—25 N.m {1.9—2.6 kgf.m, 14—18 ft.lbf}
8. Press SETUP (Key 8) and turn the test mode off.
9. Press CANCEL.
4. Verify that the idle speed is within the
10. Verify that the timing mark on the crankshaft specification.
Specification
730—770 (750 ± 20) RPM
5. If not as specified, adjust the idle speed.

(Refer to ENGINE TUNE-UP, IDLE SPEED
ADJUSTMENT.)
6. Connect the timing light to the high-tension lead
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of the No.1 cylinder.
7. Verify that the timing mark on the crankshaft
Specification
BTDC 1°—30° Specification
BTDC 4°—6° (5° ± 1°)
Not Using the SSTs (NGS Tester) 8. If not as specified, loosen the distributor lock bolts
and turn the distributor to make the adjustment.
(Refer to ENGINE TUNE-UP, ENGINE TUNE-UP 9. Tighten the distributor lock bolts to the specified
PREPARATION.) torque.
2. If using the SST (System selector) to turn on the
test mode, perform the following: Tightening torque
(1) Connect the SST to the DLC. 19—25 N.m {1.9—2.6 kgf.m, 14—18 ft.lbf}
(2) Set switch A to position 1.
(3) Set the test switch to SELF TEST. 10. Disconnect the SST or jumper wire. 11. Verify
that the timing mark on the crankshaft pulley is
within the specification.
Specification
BTDC 1°—30°
3. If using a jumper wire to turn on the test mode,

perform the following:
Caution
• Connecting the wrong DLC
terminals may possibly cause a
malfunction. Carefully connect the
specified terminals only.
• Use a jumper wire to short terminal TEN
of the DLC to body GND.
CONTINUED
F1-3
ENGINE TUNE-UP
IDLE SPEED ADJUSTMENT Caution

Using the SSTs (NGS Tester) • Connecting the wrong DLC terminals
1. Perform "ENGINE TUNE-UP PREPARATION". may possibly cause a malfunction.
(Refer to ENGINE TUNE-UP, ENGINE TUNE-UP Carefully connect the specified
PREPARATION.) terminals only.
2. Verify that the RPM PID is within the • Use a jumper wire to short terminal TEN of
specification. the DLC to body GND.
Specification
730—770 (750 ± 20) RPM
Caution
• The TAS is set at the factory and must not
be adjusted. Any adjustment will
negatively affect the engine performance.
3. If not as specified, verify that the ignition timing is
within specification according to the "IGNITION
TIMING ADJUSTMENT", then adjust the idle 4. Verify that the idle speed is within the specification
speed by turning the AAS. using the dwell tachometer.
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Specification
730—770 (750 ± 20) RPM
Caution
• The TAS is set at the factory and must not
be adjusted. Any adjustment will
negatively affect the engine performance.
5. If not as specified, verify that the ignition timing is
within specification according to the "IGNITION
TIMING ADJUSTMENT', then adjust the idle
speed by turning the AAS.
4. Press SETUP (Key 8) to turn the test mode off.

5. Press CLEAR to clear previously selected items.
6. Disconnect the SSTs.
Not Using the SSTs (NGS Tester)
(Refer to ENGINE TUNE-UP, ENGINE TUNE-UP
PREPARATION.)
2. If using the SST (System selector) to turn on the
test mode, perform the following:
(1) Connect the SST to the DLC. 6. Disconnect the SST or a jumper wire.
(2) Set switch A to position 1. 7. Disconnect the dwell tachometer.
(3) Set the test switch to SELF TEST.
IDLE-UP SPEED INSPECTION
PREPARATION.)
2. Press SETUP (Key 8) and turn the test mode off.
3. Press CANCEL.
4. Press START.
5. Verify that the idle speed is normal.
(Refer to ENGINE TUNE-UP, IDLE SPEED
3. If using a jumper wire to turn on the test mode, ADJUSTMENT.)
perform the following: 6. Verify that the RPM PID is within the specification.
CONTINUED
F1-4
ENGINE TUNE-UP
Specification • Intake manifold vacuum
1
Load condition Idle-up speed (RPM)* (Refer to TROUBLESHOOTING, ENGINE
P/S ON*2 SYSTEM INSPECTION, Intake Manifold Vacuum
700—800 (750 ± 50) Inspection.)
A/C ON*3
1 • Fuel line pressure
* : Excludes temporary idle speed drop just after the
(Refer to TROUBLESHOOTING, ENGINE
electrical loads (E/L) are turned on.
2 SYSTEM INSPECTION, Fuel Line Pressure
* : Steering wheel is fully turned.
Inspection.)
: A/C switch and fan switch are on.
• Ignition timing control
7. If not as specified with all load conditions,
inspect the IAC valve.
SYSTEM INSPECTION, Ignition Timing Control
8. If not as specified with some load condition, Inspection.)
inspect the related input switches, harnesses,
and connectors. • If the systems and devices are normal, replace
the TWC.
Not Using the SSTs (NGS Tester)
(Refer to EXHAUST SYSTEM, EXHAUST
1. Perform "ENGINE TUNE-UP PREPARATION". SYSTEM REMOVAL/INSTALLATION.)
PREPARATION.)
Vehicles Without Oxygen Sensor O2S)
2. Verify that the idle speed is normal.
(Refer to ENGINE TUNE-UP, IDLE SPEED 1. Perform "ENGINE TUNE-UP PREPARATION".
ADJUSTMENT.) 2. Verify that the idle speed and ignition timing are
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3. Verify that the idle-up speed is within the within the specification.
specification. (Refer to IGNITION TIMING INSPECTION.)
(Refer to IDLE SPEED ADJUSTMENT.)
3. Insert an exhaust gas analyzer to the tailpipe.
Specification
1 4. Verify that the CO and HC concentrations are
Load condition Idle-up speed (rpm)* within the regulation.
P/S ON*2 5. If not, turn the adjust screw to adjust CO and HC
700—800 (750 ± 50)
A/C ON*3 concentration using the SST.
1
* : Excludes temporary idle speed drop just after the
electrical loads (E/L) are turned on.
2
* : Steering wheel is fully turned.
3
* : A/C switch and fan switch are on.
4. If not as specified with all load conditions, inspect
the IAC valve.
5. If not as specified with some load conditions,
inspect the related input switches, harnesses,
and connectors.
IDLE MIXTURE INSPECTION
Vehicles With Oxygen Sensor (O2S)
1. Perform "ENGINE TUNE-UP PREPARATION". 6. If not adjusted, inspect the following:
• On-board diagnostic system
PREPARATION.)
(Refer to ON-BOARD DIAGNOSTIC
2. Verify that the idle speed and ignition timing are
SYSTEM, ON-BOARD DIAGNOSTIC
within the specification.
TROUBLE CODE INSPECTION.)
(Refer to ENGINE TUNE-UP, IGNITION TIMING
INSPECTION.) • Variable resistor
(Refer to ENGINE TUNE-UP, IDLE SPEED (Refer to CONTROL SYSTEM, VARIABLE
ADJUSTMENT.) RESISTOR INSPECTION.)
3. Turn the test mode off. • Intake manifold vacuum
4. Warm up the engine by holding the engine speed (Refer to TROUBLESHOOTING, ENGINE
at 2500—3000 rpm for approx. 3 minutes. SYSTEM, INSPECTION, Intake Manifold
5. Insert an exhaust gas analyzer to the tailpipe. Vacuum Inspection.)
6. Verify that the CO and HC concentrations are • Fuel line pressure
within the regulation. (Refer to TROUBLESHOOTING, ENGINE
7. If not within the regulation, inspect the following: SYSTEM INSPECTION, Fuel line Pressure
• On-board diagnostic system Inspection.)
(Refer to ON-BOARD DIAGNOSTIC • Ignition timing control
SYSTEM, ON-BOARD DIAGNOSTIC (Refer to TROUBLESHOOTING, ENGINE
TROUBLE CODE INSPECTION.) SYSTEM INSPECTION, Ignition Timing
• O2S (Refer to CONTROL SYSTEM, Control Inspection.)
OXYGEN SENSOR O2S) INSPECTION.)
CONTINUED
F1-5
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM
VACUUM HOSE ROUTING DIAGRAM
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INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
Warning
• When the engine and intake-air system are hot, they can badly burn. Turn off engine and wait until
they are cool before removing the intake-air system.
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel
Line Safety Procedures".
(Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
(Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1. Complete the "BEFORE REPAIR PROCEDURE".
2. Drain the engine coolant from the radiator.
6. Complete the "AFTER REPAIR PROCEDURE".
CONTINUED
F1-6
INTAKE-AIR SYSTEM
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1 Air cleaner component 5 Throttle body component
2 Air intake hose 6 Dynamic chamber
3 MAP sensor 7 Fuel injector
4 Accelerator cable ☞ FUEL SYSTEM, FUEL INJECTOR
☞ ACCELERATOR CABLE INSPECTION/ REMOVAL/ INSTALLATION
ADJUSTMENT 8 Intake manifold
CONTINUED
F1-7
INTAKE-AIR SYSTEM
BYPASS AIR CONTROL (BAC) VALVE

REMOVAL/INSTALLATION
2. Disconnect the IAC valve connector.
3. Drain the engine coolant from the radiator.
(Refer to section E, ENGINE COOLANT, ENGINE
4. Remove the BAC valve.
6. If not as specified, replace the BAC valve.

(Refer to BAC VALVE
REMOVAL/INSTALLATION.) If as specified, but
IAC valve is failed, inspect for the following:
Open circuit
• Power circuit (IAC valve connector
terminal A and main relay terminal D)
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AIR VALVE INSPECTION
Operation Inspection
Note
1. Perform the following test only when directed.
1. Carry out the "Idle Air Control (IAC) Inspection".
SYSTEM INSPECTION, Idle Air Control (IAC)
Inspection.)
2. Remove the BAC valve.
(Refer to INTAKE-AIR SYSTEM, BAC VALVE
3. Add cold water into the engine coolant passage of
the BAC valve to reduce the air valve temperature.
4. Verify that the air valve operates when hot water is
added into the engine coolant passage of the BAC
valve. • GND circuit (IAC valve connector
5. If not as specified, replace the BAC valve, 6. Install terminal B and PCM connector terminal
the BAC valve. 2W)
IDLE AIR CONTROL (IAC) VALVE INSPECTION Short circuit
Resistance Inspection • IAC valve connector terminal B and
Note PCM connector terminal 2W to GND
2. Perform the following test only when directed, 7. Repair or replace faulty areas.
1. Carry out the "Idle Air Control (IAC) Inspection", 8. Connect the IAC valve connector.
(Refer to TROUBLESHOOTING, ENGINE 9. Connect the negative battery cable.
SYSTEM INSPECTION, Idle Air Control (IAC)
Inspection.)
2. If not as specified, perform the further inspection
for the IAC valve.
4. Disconnect the IAC valve connector.
5. Measure the resistance between the IAC valve
terminals using an ohmmeter.
Resistance
7.7—9.3 Ω [23 °C {73 °F}]
CONTINUED
F1-8
INTAKE-AIR SYSTEM
ACCELERATOR PEDAL REMOVAL/INSTALLATION
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1 Accelerator cable
☞ ACCELERATOR CABLE
INSPECTION/ADJUSTMENT
2 Accelerator pedal
ACCELERATOR CABLE
1. Measure the free play of the accelerator cable.
Free play
1—3 mm {0.04—0.11 in}
2. If not as specified, adjust by turning the locknut,

CONTINUED
F1-9
FUEL SYSTEM
FUEL SYSTEM
BEFORE REPAIR PROCEDURE
Warning
• Fuel vapor is hazardous. It can easily
ignite, causing serious injury and damage.
Always keep sparks and flames away from
fuel.
• Fuel line spills and leakage are dangerous.
skin and eyes. To prevent this, always 3. Install a hose clamp over the fuel hose within the
complete the following "Fuel Line Safety clamp installation range as shown, avoiding the
Procedures". original clamp position.
Note
CLAMP INSTALLATION RANGE
• Fuel in the fuel system is under high pressure
when the engine is not running.
Fuel Line Safety Procedures
1. Remove the fuel-filler cap and release the pressure
in the fuel tank.
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2. Disconnect the fuel pump relay connector located
under the passenger's side front side trim.
Fuel Leakage Inspection

Warning
• Fuel line spills and leakage are
dangerous. Fuel can ignite and cause
serious injuries or death and damage.
Always carry out the following procedure
with the engine stopped.
3. Start the engine. Caution
4. After the engine stalls, crank the engine several
• Connecting the wrong DLC terminal
times. may possibly cause a malfunction.
5. Turn off the ignition switch. Carefully connect the specified terminal
6. Reconnect the fuel pump relay connector. only.
AFTER REPAIR PROCEDURE 1. Short the DLC terminal F/P to body GND using a
Warning jumper wire.
or death and damage. When installing the
fuel hose, observe "Fuel Hose Installation"
and "Fuel Leakage Inspection" described
below.
Fuel Hose Installation
1. Replace damaged or deformed fuel hoses, fuel
pipes, and hose clamps.
2. When installing the fuel hose onto the fuel pipe, fit
the hose onto the pipe over 25 mm {0.98 in}. 2. Turn the ignition switch on to operate the fuel
When the pipe has a stopper, fit the hose until it pump body.
contacts the stopper. 3. Pressurize the system this way for at least 5
minutes to be sure of no leakage.
4. If there is fuel leakage, inspect for damaged fuel
hoses, hose clamps, and fuel pipe sealing surface
and replace as necessary.
5. After repair, assemble the system and repeat
Steps 1 to 3.
F1-10 CONTINUED
FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION
Warning
• Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire
may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of
the fuel pump unit when removing or installing.
1. Level the vehicle.

4. Drain the fuel from the drain plug.
STRETCH CAB 2WD, DOUBLE CAB 2WD
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CONTINUED
F1-11
FUEL SYSTEM
STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB
1 Joint hose
8 Fuel pump unit
9 Fuel-filler pipe
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2 Breather hose 10 Dust cover
☞ Installation Note 11 Fuel inlet pipe
3 Under guard
12 Nonreturn valve
4 Fuel hose
13 Evaporative gas check valve (two-way)
5 Fuel tank ☞ Installation Note
6 Evaporative hose 14 Check valve (two-way)
15 Evaporative chamber
7 Rollover valve
CONTINUED
F1-12
FUEL SYSTEM
Evaporative Gas Check Valve (Two-way)

Installation Note
• Install the arrow mark of the evaporative gas
check valve (two-way) facing the charcoal
canister.
Evaporative Hose Installation Note
• Fit each hose onto the respective fittings within the
specification, and install clamps as shown.
Length
Evaporative hose: 25—30 mm {0.99—1.18 in}
NONRETURN VALVE INSPECTION

1. Remove the nonreturn valve with the fuel inlet
pipe.
2. Verify that the nonreturn valve opening angle is
50—56° when pushed out from the fuel inlet pipe
side, and the clearance between the nonreturn
valve and the fuel inlet pipe end is within 1.5 mm
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Breather Hose Installation Note {0.06 in} when the nonreturn valve is returned to
• Fit each hose onto the respective fittings within the the closed position.
specification, and install clamp as shown.
Length Breather hose:

25—30 mm {0.99—1.18 in}
3. If not as specified, replace the nonreturn valve.

Joint Hose Installation Note
• Fit the joint hose onto the respective fittings FUEL PUMP UNIT REMOVAL/INSTALLATION
within the specification, and install clamps as
shown. 1. Remove the fuel pump unit.
Length (Refer to FUEL SYSTEM,FUEL TANK
Joint hose: 35—40 mm {1.4—1.5 in} REMOVAL/INSTALLATION.)
2. Install the fuel pump unit.
(Refer to FUEL SYSTEM,FUEL TANK
FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY

Warning
serious injuries or death and damage.
Fuel can also irritate skin and eyes. To
prevent this, do not damage the sealing
surface of the fuel pump unit when
removing or installing.
CONTINUED
F1-13
FUEL SYSTEM
STRETCH CAB 2WD, 2. If not as specified, perform the further inspection

DOUBLE CAB 2WD for the fuel pump unit.
Continuity Inspection
Note
• Perform the following test only when directed.
(Refer to FUEL SYSTEM, BEFORE REPAIR
PROCEDURE.)
3. Remove the fuel tank. (Refer to FUEL SYSTEM,
FUEL TANK REMOVAL/INSTALLATION.)
4. Inspect for continuity between fuel pump unit
connector terminals C and D.
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STRETCH CAB 4WD,
DOUBLE CAB 4WD, 5. If there is no continuity, replace the fuel pump
REGULAR CAB body. If as specified but the "Simulation Test" is
failed, inspect the following:
Fuel pump relay malfunction
Open circuit
• GND circuit (fuel pump unit connector terminal D
and body GND)
• Power circuit (fuel pump relay connector terminal
D and fuel pump unit connector terminal B
through common connector)
Short circuit
• Fuel pump relay connector terminal D and fuel
1 Rubber mount pump unit connector terminal B through common
2 Fuel filter (low-pressure) connector to GND
3 Clamp 6. Repair or replace faulty areas.
4 Fuel hose 7. Install the fuel tank.
5 Fuel pump body (Refer to FUEL SYSTEM, FUEL TANK
6 Fuel gauge sender unit
FUEL PUMP UNIT INSPECTION 8. Reconnect the negative battery cable.
Simulation Test 9. Complete the "AFTER REPAIR PROCEDURE".
1. Carry out the "Fuel Pump Operation Inspection", "Fuel (Refer to FUEL SYSTEM, AFTER REPAIR
Pump Control Inspection". PROCEDURE.)
(Refer to TROUBLESHOOTING, ENGINE SYSTEM
INSPECTION, Fuel Pump Operation Inspection.)
INSPECTION, Fuel Pump Control Inspection.)
CONTINUED
F1-14
FUEL SYSTEM
Fuel Pump Maximum Pressure Inspection 8. If not as specified, inspect the following:
Warning • Fuel pump relay
• Fuel filter (low-pressure, high-pressure) for
clogging
Fuel can ignite and cause serious injuries • Fuel line for clogging or leakage
or death and damage. Always carry out the
following procedure with the engine
stopped.
PROCEDURE.)
Note
• Perform the following test only when directed. 11. Disconnect the fuel pressure gauge.
1. Complete the "BEFORE REPAIR PROCEDURE". 12. Connect the negative battery cable.
PROCEDURE.)
(Refer to FUEL SYSTEM, AFTER REPAIR
2. Disconnect the negative battery cable. PROCEDURE.)
3. Connect a fuel pressure gauge to the fuel hose Fuel Pump Hold Pressure Inspection
between the pulsation damper and fuel main hose,
Warning
then plug the opening as shown.
•
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Fuel line spills and leakage are dangerous.
stopped.
Note
PROCEDURE.)
4. Connect the negative battery cable. 2. Disconnect the negative battery cable.
Caution 3. Connect a fuel pressure gauge to the fuel hose
• Connecting the wrong DLC terminal may between the pulsation damper and fuel main
possibly cause a malfunction. Carefully hose, then plug the opening as shown.
connect the specified terminal only.
5. Short the DLC terminal F/P to body GND using a
jumper wire.
4. Connect the negative battery cable.

Caution
6. Turn the ignition switch on to operate the fuel • Connecting the wrong DLC terminal may
pump body. Measure the fuel pump maximum possibly cause a malfunction. Carefully
pressure. connect the specified terminal only.
Fuel pump maximum pressure
500—630 kPa {5.0—6.5 kgf/cm2, 72—92 psi}
jumper wire.
7. Turn the ignition switch off and disconnect the
jumper wire. CONTINUED
F1-15
FUEL SYSTEM
6. Turn the ignition switch on for 10 seconds to

operate the fuel pump body.
7. Turn the ignition switch off. Measure the fuel pump
hold pressure after 5 minutes.
Fuel pump hold pressure
More than 340 kPa {3.5 kgf/cm2, 50 psi}
8. Disconnect the jumper wire.
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PROCEDURE.)
11. Disconnect the fuel pressure gauge.
1 Fuel hose
12. Reconnect the negative battery cable.
13. If not as specified, carry out the "PRESSURE 2 Protector
REGULATOR INSPECTION", "FUEL INJECTOR 3 Fuel filter (high-pressure)
INSPECTION" (Refer to FUEL SYSTEM, ☞ Removal Note
PRESSURE REGULATOR INSPECTION.) ☞ Installation Note
(Refer to FUEL SYSTEM, FUEL INJECTOR
INSPECTION.) Fuel Filter (High-pressure) Removal Note
14. Complete the "AFTER REPAIR PROCEDURE". • Before removing the fuel filter (high-pressure),
(Refer to FUEL SYSTEM, AFTER REPAIR paint marks on the fuel filter (high-pressure) and
PROCEDURE.) fuel filter bracket for correct reassembly.
FUEL FILTER (HIGH-PRESSURE)
PROCEDURE.)
4. Install in the reverse order or removal.
(Refer to FUEL SYSTEM, AFTER REPAIR Fuel Filter (High-pressure) Installation Note
PROCEDURE.) Replacing the fuel filter (high-pressure)
1. Paint a mark on the new fuel filter (high-pressure)
at the same spot as the removed fuel filter (high-
pressure).
2. Align the paint marks and install the fuel filter
(high-pressure) as shown.
CONTINUED
F1-16
FUEL SYSTEM
Replacing the fuel filter bracket

1. Paint a mark on the new fuel filter bracket at the same
spot as the removed fuel filter bracket.
2. Align the paint marks and install the fuel filter bracket as
shown.
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CONTINUED
F1-17
FUEL SYSTEM
FUEL INJECTOR REMOVAL/INSTALLATION
Warning
Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
1. Complete the "BEFORE REPAIR PROCEDURE" (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
3. Disconnect the fuel injector connectors and remove the harness from the fuel distributor.
6. Complete the "AFTER REPAIR PROCEDURE." (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
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1 Dynamic chamber 6 Fuel injector

2 Dynamic chamber gasket ☞ Installation note
7 Grommet
3 Fuel injector connector
4 Fuel hose 8 Fuel injector insulator
5 Fuel distributor CONTINUED
F1-18
FUEL SYSTEM
Fuel Injector Installation Note Open circuit

1. Use new fuel injector O-rings. • GND circuit (No.1 cylinder fuel injector connector
2. Verify that the O-rings and the fuel injector sealing terminal B and PCM connector terminal 2U)
surfaces are free of foreign materials. Clean with • GND circuit (No.2 cylinder fuel injector connector
gasoline if necessary. terminal B and PCM connector terminal 2V)
3. Apply a small amount of engine oil to the O-rings • GND circuit (No.3 cylinder fuel injector connector
and into the fuel distributor. terminal B and PCM connector terminal 2U)
4. Install the fuel injectors in the fuel distributor with a • GND circuit (No.4 cylinder fuel injector connector
light twisting motion so that the O-rings will not be terminal B and PCM connector terminal 2V)
folded.
• Power circuit (No.1 cylinder fuel injector connector
terminal A and main relay connector terminal D
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FUEL INJECTOR INSPECTION • Power circuit (No.4 cylinder fuel injector connector
Simulation Test terminal A and main relay connector terminal D
1. Carry out the "Fuel Injector Operation Inspection". through common connector)
SYSTEM INSPECTION, Fuel Injector Operation
Inspection.)
2. If not as specified, perform the further inspection for
the fuel injectors.
Resistance Inspection
Note
1. Disconnect the negative battery cable. Short circuit
2. Disconnect the fuel injector connectors. • No.1 cylinder fuel injector connector terminal B
and PCM connector terminal 2U to GND
3. Measure the resistance of the fuel injector using
an ohmmeter. • No.2 cylinder fuel injector connector terminal B
and PCM connector terminal 2V to GND
• No.3 cylinder fuel injector connector terminal B
and PCM connector terminal 2U to GND
• No.4 cylinder fuel injector connector terminal B
and PCM connector terminal 2V to GND
5. Repair or replace faulty areas.
6. Reconnect the fuel injector connectors.
Resistance Fuel Leakage Test
12—16Ω[20°C {68°F}] Warning
4. If not as specified, replace the fuel injector. • Fuel line spills and leakage are dangerous.
(Refer to FUEL SYSTEM, FUEL INJECTOR Fuel can ignite and cause serious injuries
REMOVAL/INSTALLATION.) If as specified but or death and damage. Always carry out the
"Simulation Test" is failed, inspect for the following: following procedure with the engine
stopped.
Note
CONTINUED
F1-19
FUEL SYSTEM
1. Complete the "BEFORE REPAIR PROCEDURE". 9. Turn the ignition switch off and remove the
(Refer to FUEL SYSTEM, BEFORE REPAIR jumper wire.
PROCEDURE.) 10. If not as specified, replace the fuel injector.
2. Disconnect the negative battery cable. 11. Complete the "AFTER REPAIR PROCEDURE",
3. Remove the fuel injectors together with the fuel (Refer to FUEL SYSTEM, AFTER REPAIR
distributor. (Refer to FUEL SYSTEM, FUEL PROCEDURE.)
INJECTOR REMOVAL/INSTALLATION.) Volume Test
4. Fasten the fuel injectors firmly to the fuel Warning
distributor with wire.
stopped.
Note
1. Complete the "BEFORE REPAIR
5. Connect the negative battery cable. PROCEDURE",
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Caution PROCEDURE.)
• Connecting the wrong DLC terminal may
3. Remove the fuel injectors together with the fuel
possibly cause a malfunction. Carefully
distributor.
connect the specified terminal only. (Refer to FUEL SYSTEM, FUEL INJECTOR
6. Short the DLC terminal F/P to body GND using a REMOVAL/INSTALLATION.)
jumper wire. 4. Fasten the fuel injectors firmly to the fuel
distributor with wire.
5. Connect the SST as shown in the figure.
7. Turn the ignition switch on to operate the fuel

pump body. Caution
8. Tilt the fuel injectors approx. 60 degrees and • Connecting the wrong DLC terminal may
verify that fuel leakage from the fuel injector possibly cause a malfunction. Carefully
nozzles is within the specification. connect the specified terminal only.
jumper wire.
Fuel leakage
Less than 1 drop/2 minutes
8. Turn the ignition switch on to operate the fuel

pump body.
9. Measure the injection volume of each fuel
injector using a graduated container.
F1-20 CONTINUED
FUEL SYSTEM
Injection volume 1. Complete the "BEFORE REPAIR PROCEDURE".

55—71 ml {55—71 cc, 1.9—2.3 fl oz}/15 sec. (Refer to FUEL SYSTEM, BEFORE REPAIR
10. Turn the ignition switch off and disconnect the PROCEDURE".)
jumper wire. 2. Disconnect the negative battery cable.
11. If not as specified, replace the fuel injector.
3. Connect a fuel pressure gauge between the
(Refer to FUEL SYSTEM, AFTER REPAIR pulsation damper and fuel main hose.
PROCEDURE.)
PRESSURE REGULATOR
Warning
skin and eyes. To prevent this, always
complete the "Fuel Line Safety
Procedures".
PROCEDURE.) 4. Connect the negative battery cable.
1. Complete the "BEFORE REPAIR
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PROCEDURE". 5. Start the engine and let it idle.
(Refer to FUEL SYSTEM, BEFORE REPAIR 6. Measure the fuel line pressure after approx. 2
PROCEDURE.) minutes.
2. Disconnect the negative battery cable. Fuel line pressure
3. Remove in the order indicated in the table. 210—250 kPa {2.1—2.6 kgf/cm2, 30—36 psi}
5. Complete the "AFTER REPAIR PROCEDURE". 7. Disconnect the vacuum hose from the pressure
(Refer to FUEL SYSTEM, AFTER REPAIR regulator and measure the fuel line pressure.
PROCEDURE.)
Fuel line pressure

270—310 kPa {2.7—3.2 kgf/cm2, 39—45 psi}
8. Turn the ignition switch off.
O
1 Vacuum hose (Refer to FUEL SYSTEM, BEFORE REPAIR
2 Fuel hose PROCEDURE.")
3 Pressure regulator 10. Disconnect the negative battery cable.
PRESSURE REGULATOR INSPECTION 11. Disconnect the fuel pressure gauge.
Simulation Test 12. Reconnect the fuel main hose to the fuel
1. Carry out the "Fuel Line Pressure Inspection". distributor.
(Refer to TROUBLESHOOTING, ENGINE 13. Reconnect the negative battery cable.
SYSTEM INSPECTION, Fuel Line Pressure
14. If not as specified, inspect the following:
Inspection.)
• Fuel pump maximum pressure
2. If not as specified, perform the further inspection • Fuel pump hold pressure
for the pressure regulator. • Fuel filter for clogging
Operation Inspection • Fuel injector for leakage
Note • Fuel pump relay
• Perform the following test only when directed. • Fuel line for improper routing, clogging, kinks
or leakage
CONTINUED
F1-21
FUEL SYSTEM
If all items above are okay, replace the pressure

regulator.
(Refer to FUEL SYSTEM, PRESSURE
REGULATOR REMOVAL/INSTALLATION.)
PROCEDURE.)
PRESSURE REGULATOR CONTROL (PRC)
SOLENOID VALVE INSPECTION Short circuit
Simulation Test • PRC solenoid valve connector terminal B and
1. Carry out the "Pressure Regulator Control (PRC) PCM connector terminal 2T through common
Inspection". connector to GND)
(Refer to TROUBLESHOOTING, ENGINE 5. Repair or replace faulty areas.
SYSTEM INSPECTION, Pressure Regulator 6. Install the PRC solenoid valve.
Control (PRC) Inspection.)
for the PRC solenoid valve,
PULSATION DAMPER REMOVAL/INSTALLATION
Airflow Inspection
Note
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• Perform the following test only when directed. PROCEDURE.)
1. Disconnect the negative battery cable. 2. Disconnect the negative battery cable.
2. Remove the PRC solenoid valve. 3. Remove the pulsation damper.
(Refer to INTAKE-AIR SYSTEM, VACUUM HOSE
ROUTING DIAGRAM.)
3. Inspect airflow between the ports under the following
conditions.
PROCEDURE.)
1 Fuel hose
2 Bolt
4. If not as spec tied, replace the PRC solenoid valve. 3 Pulsation damper
If as specified but the "Simulation Test" is failed, PULSATION DAMPER INSPECTION
inspect for the following: 1. Remove the pulsation damper.
Vacuum hose improper routing, kinks or (Refer to FUEL SYSTEM, PULSATION DAMPER
leakage REMOVAL/INSTALLATION.)
Open circuit 2. Visually inspect the pulsation damper for
• GND circuit (PRC solenoid valve connector damage and cracks. Also inspect that there is no
terminal B and PCM connector terminal 2T extreme rust, which will cause fuel leakage.
through common connector) 3. If either is observed, replace the pulsation
• Power circuit (PRC solenoid valve connector damper.
terminal A and main relay connector terminal D CONTINUED
F1-22
FUEL SYSTEM
FUEL PUMP RELAY INSPECTION • Power circuit (fuel pump relay connector
Simulation Test terminal A or C and IG switch connector
1. Carry out the "Fuel Pump Operation Inspection", terminal IG1 through common connector)
"Fuel Pump Control Inspection".
SYSTEM INSPECTION, Fuel Pump Operation
Inspection.)
SYSTEM INSPECTION, Fuel Pump Control
Inspection.)
for the fuel pump relay.
Note

2. Remove the fuel pump relay located under the
passenger's side front side trim.
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Short circuit
• Fuel pump relay connector terminal B and
PCM connector terminal 1H through common
connector to GND
3. Inspect for continuity between the fuel pump relay • Fuel pump relay connector terminal D and fuel
terminals using an ohmmeter. pump unit connector terminal B through
common connector to GND
6. Install the fuel pump relay.
4. If not as specified, replace the fuel pump relay. If as

specified but the "Simulation Test" is failed, inspect
for the following:
Fuel pump unit malfunction
Open circuit
• GND circuit (fuel pump relay connector terminal
B and PCM connector terminal 1H through
common connector)
• GND circuit (fuel pump relay connector terminal
D and fuel pump unit connector terminal B
CONTINUED
F1-23
EXHAUST SYSTEM
EXHAUST SYSTEM
EXHAUST SYSTEM INSPECTION
1. Start the engine and inspect the exhaust system component for exhaust gas leakage.
2. If leakage is found, repair or replace as necessary.
EXHAUST SYSTEM REMOVAL/INSTALLATION
Warning
• When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the exhaust system.

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1 After silencer 4 Front pipe

2 Main silencer 5 Insulator
3 TWO (Europe) 6 Exhaust manifold
Presilencer (Except Europe) CONTINUED
F1-24
EMISSION SYSTEM
EMISSION SYSTEM
EMISSION SYSTEM (ENGINE COMPARTMENT
SIDE) COMPONENT LOCATION
4. If not as specified, replace the rollover valve.

EVAPORATIVE GAS CHECK VALVE (TWO-
WAY) INSPECTION
1. Remove the evaporative gas check valve (two-
way).
(Refer to FUEL SYSTEM, FUEL TANK
2. Inspect airflow of the valve under the following
conditions.
Apply pressure below +2.9 kPa {+22

No airflow
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mmHg, +0.87 inHg} to port A
Apply pressure over +5.9 kPa {+44
Airflow
Apply pressure over -0.98 kPa
{-7.36 mmHg, -0.29 inHg} to port A Airflow
1 Charcoal canister
2 Purge solenoid valve
3 PCV valve
ROLLOVER VALVE INSPECTION
1. Remove the rollover valve.
2. Hold the valve as shown. Blow air into port A and
verify that there is airflow.
3. If not as specified, replace the evaporative gas

check valve (two-way).
CHECK VALVE (TWO-WAY) INSPECTION
1. Remove the check valve (two-way).
3. Turn the valve upside-down as shown. Blow conditions.
air into port A and verify that there is no
airflow. Apply pressure of -0.98—1-13.7 kPa
{-7.3—1-102 mmHg, -0.28— + 4.0 No airflow
inHg} to port A
Apply pressure over +18.6 kPa
Airflow
{+140 mmHg, +5.5 inHg} to port A
Apply pressure over -4.9 kPa
{-36.8 mmHg, -1.4 inHg} to port B Airflow
CONTINUED
F1-25
EMISSION SYSTEM
PURGE SOLENOID VALVE INSPECTION

Simulation Test
1. Carry out the "Purge Control Inspection".
INSPECTION, Purge Control Inspection.)
2. If not as specified, perform the further inspection for
the purge solenoid valve,
Airflow Inspection
Note
3. If not as specified, replace the check valve (two- 2. Remove the purge solenoid valve.
way). 3. Inspect airflow between the ports under the following
EVAPORATIVE CHAMBER INSPECTION conditions.
1. Remove the evaporative chamber.
2. Blow air into port A and verify that air flows out
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from the holes B on the evaporative chamber.
3. Visually inspect that there is no damage nor crack

on the evaporative chamber.
4. If not as specified, replace the evaporative
chamber.
5. Install the evaporative chamber.
4. If not as specified, replace the purge solenoid valve.
CHARCOAL CANISTER INSPECTION If as specified but the "Simulation Test" is failed,
1. Remove the charcoal canister. inspect for the following:
2. Plug the atmosphere side port and purge solenoid Vacuum hose improper routing, kinks or leakage.
valve side port of the charcoal canister. Open circuit
3. Blow air into the charcoal canister from the fuel • GND circuit (purge solenoid valve connector
tank side port and verify that there is no air terminal B and PCM connector terminal 2X
leakage. through common connector)
• Power circuit (purge solenoid valve connector
4. If there is air leakage, replace the charcoal

canister.
CONTINUED
F1-26
EMISSION SYSTEM
Short circuit
• Purge solenoid valve connector terminal B and
PCM connector terminal 2X through common
connector to GND
6. Install the purge solenoid valve.
POSITIVE CRANKCASE VENTILATION (PCV) VALVE
INSPECTION
1. Remove the PCV valve.
2. Blow through the valve and verify that air flows as
specified.
Specification
Condition Airflow
Air applied from port A Yes
Air applied from port B No
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3. If not as specified, replace the PCV valve.
CONTINUED
F1-27
CONTROL SYSTEM
CONTROL SYSTEM
CONTROL SYSTEM COMPONENT LOCATION
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1 PCM 8 O2S (Europe only)
2 MAF sensor 9 Variable resistor (Except Europe)
3 TP sensor 10 Clutch switch
4 CTP switch 11 Neutral switch
5 IAT sensor 12 PSP switch
6 ECT sensor 13 Main relay
7 CMP sensor (In distributor)
CONTINUED
F1-28
CONTROL SYSTEM
PCM REMOVAL/INSTALLATION • For input/output signals except those of the

1. Disconnect the negative battery cable. monitoring items, use a voltmeter to
measure the PCM terminal voltage.
2. Remove the cowl side panel (driver's side).
• When measuring the following PID value,
3. Remove in the order indicated in the table. perform the following:
4. Install in the reverse order of removal. • TP V PID (Refer to Not Using the SSTs
(NGS tester) at Constant Voltage Terminal
Inspection.)
(Refer to Not Using the SSTs (NGS tester)
at Ground (GND) Terminal Inspection.)
6. If PID value is not within the specification, follow

the instruction in action column.
Note
• Perform the SIMULATION TEST for the
output device (A/C RLY, FP RLY, IACV,
1 PCM PRGV) after PID/DATA measurement is
2 PCM connector completed.
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PCM INSPECTION
Using SSTs (NGS tester)
Note
• PIDs for the following parts are not available
on this model. Go to the appropriate part
inspection page.
1. Water temperature sender unit (Integrated with
ECT sensor)
(Refer to CONTROL SYSTEM, ENGINE
COOLANT TEMPERATURE (ECT) SENSOR
INSPECTION.)
2. CMP sensor (Refer to CONTROL SYSTEM,
CAMSHAFT POSITION (CMP) SENSOR
INSPECTION.)
3. Main relay (Refer to CONTROL SYSTEM,
MAIN RELAY INSPECTION.)
1. Connect the SSTs (NGS tester) to the DLC.
(Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-
BOARD DIAGNOSTIC TEST, NGS Tester Hook-up
Procedure.)
2. Turn the ignition switch on.
3. Select the "PID/DATA MONITOR AND RECORD"
function on the NGS tester display and press
TRIGGER.
(Refer to ON-BOARD DIAGNOSTIC SYSTEM,
PID/DATA MONITOR AND RECORD
PROCEDURE.)
4. Select the appropriate PID on the NGS tester
display and press START.
5. Measure the PID value.
Note
• The PID/DATA MONITOR function monitors
the calculated value of the input/output signals
in the PCM. Therefore, an output device
malfunction is not directly indicated as a
malfunction of the monitored value for the
output device. If a monitored value of an output
device is out of specification, inspect the
monitored value of the input device related to
the output control.
CONTINUED
F1-29
CONTROL SYSTEM
PID MONITOR Table

Monitor item Unit/ PCM
Condition/Specification Action
(Definition) Condition terminal
Ignition switch on: OFF Inspect following PIDs: RPM, TP V, ECT
A/C RLY
ON/OFF A/C switch on and fan switch on at V, A/C SW. Inspect A/C relay. 1J
(A/C relay) ☞ Section U
idle: ON
A/C switch and fan switch on at ignition

A/C SW Inspect A/C switch.
ON/OFF switch on: ON 1Q
(A/C switch) ☞ Section U
A/C switch off at ignition switch on: OFF
Inspect main relay.

B+ ☞ CONTROL SYSTEM, MAIN
(Battery positive V Constant: B+ RELAY INSPECTION 1B
voltage) Inspect battery.
☞ Section G
DTC P1195 is indicated.
BARO*2 Below 400 m {0.25 mile} above sea Follow DTC Troubleshooting
(Barometric kPa level: 100—103 kPa {1.01—1.05 -
pressure) kgf/cm2} ☞ ON-BOARD DIAGNOSTIC
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SYSTEM, DTC INSPECTION
BARO V*2 DTC P1195 is indicated.
(Barometric Below 400 m {0.25 mile} above sea Follow DTC Troubleshooting
V -
pressure signal level: 3.9—4.0 V ☞ ON-BOARD DIAGNOSTIC
voltage) SYSTEM, DTC INSPECTION
BRKSW Brake pedal depressed: ON Inspect brake switch.
ON/OFF ☞ Section P 1O
(Brake switch) Brake pedal released: OFF
Inspect CTP switch
CTP SW Accelerator depressed: OFF ☞ CONTROL SYSTEM, CLOSED
ON/OFF THROTTLE POSITION (CTP) 1N
(Idle switch) Accelerator released: ON
SWITCH INSPECTION
Engine coolant temperature 20 °C Inspect engine coolant temperature

ECT sensor. w CONTROL SYSTEM,
{68°F}: 20°C {68°F}
(Engine coolant °C °F ENGINE COOLANT TEMPERATURE 2Q
Engine coolant temperature 60 °C (ECT) SENSOR INSPECTION
temperature)
{140°F}: 60°C {140°F}
ECT V Inspect engine coolant temperature

(ECT signal Engine coolant temperature 20 °C sensor.
voltage) V {68 °F}; 2.2—2.4V ☞ CONTROL SYSTEM, ENGINE 2Q
After warms up: Below 1.0 V COOLANT TEMPERATURE
(ECT) SENSOR INSPECTION
Ignition switch on: 0,1—1.0 V

After warm up: 0.1—1.0 V
Inspect O2S.
FHO2S*1 (Oxygen Acceleration (after warm up):
V ☞ CONTROL SYSTEM, OXYGEN 2N
sensor) 0.5—1.0 V
SENSOR O2S) INSPECTION
Deceleration (after warm up):
0—0.5V
Inspect following PID: RPM.
FPRLY Ignition switch on: OFF Inspect fuel pump relay.
ON/OFF ☞ FUEL SYSTEM, FUEL PUMP 1H
(Fuel pump relay) Idle: ON Cranking: ON
RELAY INSPECTION
Inspect following PIDs: IATV, RPM, ECT

V, MAF V, TP V, NL SW, CLT SW, PSP
IACV SW, A/C SW, TEN.
(Idle air control ms Idle: 2.4—2.7 ms Inspect idle air control valve. 2W
valve) ☞ INTAKE-AIR SYSTEM, IDLE AIR
CONTROL (IAC) VALVE
INSPECTION
1
: Europe only
*2: Except Europe CONTINUED
F1-30
CONTROL SYSTEM
Monitor item Unit/

Condition/Specification Action PCM terminal
(Definition) Condition
IATDC Inspect IAT sensor rar -CONTROL
(Intake air °C Intake air temperature 20 °C {68 SYSTEM, INTAKE AIR 2L
temperature °F}:20°C{68 °F} TEMPERATURE (IAT) SENSOR
(Dynamic
chamber)) INSPECTION
IATDC V (IAT Inspect IAT sensor -CONTROL

signal voltage Intake air temperature 20 °C {68 °F}: SYSTEM, INTAKE AIR 2L
V
(Dymanic 2.5—2.7 V TEMPERATURE (IAT) SENSOR
chamber)) INSPECTION
Inspect following PIDs: MAF V, IAT V,

RPM, TP V, ECT V, PSP SW, NL SW,
Terminal TEN (DLC) A/C SW, TEN, Inspect CMP sensor.
IGT 2F
BTC short to ground: A—6 BTC -CONTROL SYSTEM, CAMSHAFT
(Ignition timing)
Idle: 1—30 BTC POSITION (CMP) SENSOR
INSPECTION Inspect idle speed and
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ignition timing. - ENGINE TUNE-UP.
Inspect following PIDs: MAF V, IAT V,

RPM, TP V, ECT V, NL SW, FHO2S,
INJ
Ignition switch on: 0.0 ms PSP SW, BRK SW, A/C SW, B+. 2U 2V
(Fuel injection ms
Idle: 3.0—5.0 ms Inspect CMP sensor. - CONTROL
duration)
SYSTEM, CAMSHAFT POSITION
(CMP) SENSOR INSPECTION
MAFV Inspect mass air flow sensor.

Ignition switch on: 1.0—2.0 V 20
(Mass air flow V CONTROL SYSTEM, MASS AIR
Idle: 1.9—2.8 V
signal voltage) FLOW (MAF) SENSOR INSPECTION
MT/AT*1 1L
(MT/AT distinction ON/OFF Constant: ON -
signal)
Inspect neutral switch. - CONTROL
NLSW Neutral position and clutch pedal SYSTEM, NEUTRAL SWITCH
1V
(Load/no load ON/OFF depressed: ON INSPECTION Inspect clutch switch.
condition signal) Others: OFF -CONTROL SYSTEM, CLUTCH
SWITCH INSPECTION
*1: Europe only CONTINUED
F1-31
CONTROL SYSTEM
Monitor item Unit/ PGM

Condition/Specification Action
(Definition) Condition terminal
Inspect following PIDs: ECTV, IAT V,
PRCV Ignition switch on: OFF RPM,TP V, B+.
(Pressure ON/OFF Idle: OFF Inspect PRC solenoid valve. 2T
regulator control) Engine start at hot condition: ON ☞ FUEL SYSTEM, PRC
SOLENOID VALVE INSPECTION
PRGV Inspect following PIDs: IATV, RPM,
(Purge solenoid Ignition switch on: 0% ECT V, MAP V, TP V, FHO2S, B+.
% Inspect purge solenoid valve. 2X
valve duty value) Idle: 0% ☞ EMISSION SYSTEM, PURGE
SOLENOID VALVE INSPECTION
Steering wheel fully turned: ON Inspect PSP switch.

PSP SW ☞ CONTROL SYSTEM, POWER
ON/OFF Steering wheel straight ahead 1P
(PSP switch) STEERING PRESSURE (PSP)
position: OFF SWITCH INSPECTION
Inspect CMP sensor.
RPM ☞ CONTROL SYSTEM,
RPM Idle: 700—770 RPM 2E
(Engine speed) CRANKSHAFT POSITION
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SENSOR INSPECTION
TEN Terminal TEN (DLC) short to
Inspect wiring from DLC terminal
(TEN terminal ON/OFF ground: ON 1K
TEN to PCM terminal 1L
(DLC)) Terminal TEN (DLC) open: OFF
TP V Inspect TP sensor.
Closed throttle position: 0.4—0.6 V ☞ CONTROL SYSTEM, THROTTLE
(TP sensor signal V 2M
Wide open throttle: 3.4—4.7 V POSITION (TP) SENSOR
voltage) INSPECTION
Turned fully clockwise: below 1.0 V Inspect variable resistor

VRV*2
V Turned fully counterclockwise: ☞ VARIABLE RESISTOR 2N
(Variable resistor)
Approx 4.0 V INSPECTION
Inspect vehicle speedometer sensor

Vehicle speed 20 km/h {mph}: 20 ☞ Section T, WARNING AND
VS km/h {mph} INDICATOR SYSTEM,
KPH INSTRUMENT CLUSTER 1M
(Vehicle speed) Vehicle speed 40 km/h {mph}: 40
INSPECTION
km/h {mph} Inspect vehicle speed sensor
*2: Except Europe

CONTINUED
F1 -32
CONTROL SYSTEM
Not Using the SSTs (NGS tester) at Constant 4. If there is no continuity, repair the related
Voltage Terminal Inspection harnesses.
1. Turn the ignition switch on. Not Using the SSTs (NGS Tester) at Power Supply
2. Measure the voltage between the TP sensor and Terminal Inspection
variable resistor (Except Europe) connector
(vehicle side) terminal A and body GND using a
voltmeter. 2. Disconnect the PCM connectors.
(1) When measurement voltage is 0 V. 3. Measure the voltage between the PCM battery power
① Turn the ignition switch off. terminal connectors and body GND using an
② Disconnect the TP sensor and variable ohmmeter.
resistor (Except Europe) connector (applied
Power supply terminal
to constant voltage).
1A
Power supply terminal voltage:
B+
4. If not as specified, repair the related harnesses and
replace the faulty fuses.
Not Using the SSTs (NGS Tester) at Serial

Communication Terminal Inspection
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2. Disconnect the PCM connectors.
③ Verify there is no continuity between 3. Verify there is continuity between PCM connector
the TP sensor and variable resistor terminal 1 D and DLC KLN terminal.
(Except Europe) connector (vehicle
side) terminal C and body GND using
an ohmmeter.
④ If there is continuity, repair the related
harnesses.
⑤ Using an ohmmeter, inspect for
continuity between the PCM connector
(vehicle side) terminal 2D and TP
sensor and variable resistor (Except
Europe) connector (vehicle side)
terminal C which is applied to 4. If there is no continuity, repair the related
constant voltage. harnesses.
⑥ If there is continuity, repair the related
harness.
Not Using the SSTs (NGS Tester) at Instrument Cluster
(2) When measurement voltage is B+. (Engine speed signal) Terminal Inspection
① Turn the ignition switch off. 1. Turn the ignition switch off.
② Disconnect the battery positive harness, then 2. Disconnect the PCM connector and instrument cluster
battery negative harness.
connector (26 pin).
③ Verify there is no continuity between the TP
sensor and variable resistor (Except Europe) 3. Verify there is continuity between PCM connector
connector (vehicle side) terminal C and terminal 2F and instrument cluster connector (20 pin)
battery positive harness using an ohmmeter. terminal 3B.
④ If there is continuity, repair the related
harnesses.
(3) When measurement voltage is approx. 5V.
• Constant voltage terminal of PCM is okay.
Not Using the SSTs (NGS tester) at Ground (GND)

Terminal Inspection
2. Disconnect the PCM connectors.
3. Inspect for continuity between the PCM GND
terminals and body GND using an ohmmeter. 4. If there is no continuity, repair the related harnesses.
PCM GND terminal

2A
2B
2C
CONTINUED
F1-33
CONTROL SYSTEM
Using voltmeter Note
Caution • With the PCM connector connected, body
• The PCM terminal voltages vary with ground the voltmeter negative (-) lead and
change in measuring conditions and vehicle measure voltage at each PCM terminal by
conditions. Always carry out a total inserting the voltmeter positive (+) lead.
inspection of the input systems, output 3. Measure the voltage at PCM terminal using a
systems, and PCM to determine the cause voltmeter.
of trouble. Otherwise, a wrong diagnosis 4. If any incorrect voltage is detected, inspect related
will be made. systems, wiring harnesses and connectors referring
to the action column in the terminal voltage list.
1. Remove the PCM.
2. Reconnect PCM connector and battery negative
terminal.
PCM Terminal Voltage (Reference)
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Terminal Signal Connected to Test condition Voltage (V) Action
Back-up • Inspect ROOM fuse.
1A Battery Constant B+
power supply • Inspect related harness.
Ignition switch off 0
1B Power supply Main relay • Inspect related harness.
Ignition switch on B+
1C — — — — —
Carry out inspection according to
DTC. DTC output is a part of serial
Serial DLC
1D communication. — • Inspect related harness.
communication (Terminal KLN)
Judgement by terminal voltage is
not possible.
Ignition switch on
DLC and terminal TEN No DTC stored Below 1.0
1E DTC output • Inspect related harness.
(Terminal FEN) (in DLC) short to
chassis ground DTC stored 0-B+
1F — — — — —
1G — —- — — —
• Inspect fuel pump relay.
Fuel pump control Fuel pump ☞ FUEL SYSTEM,FUEL
1H Cranking Below 1.0 PUMP INSPECTION
relay
• Inspect related harness.
Idle Below 1.0
1I — — — — —
A/C relay Ignition switch A/C switch on B+
on A/C switch off B+ • Inspect A/C relay.
1J A/C control ☞ section U
Ignition switch A/C switch on Below 1.0 • Inspect related harness.
off A/C switch off Below 1.0
Terminal TEN B+
(DLC) open
Diagnostic test DLC Ignition switch
1K Terminal TEN • Inspect related harness.
mode (Terminal TEN) on
(DLC) short to Below 1.0
ground
Transmission Ground 0
1L*1 Constant • Inspect related harness.
distinction
*1: Europe only
CONTINUED
F1-34
CONTROL SYSTEM

0 or • Inspect VSS.
Vehicle stopped
1M Vehicle speed VSS Approx. 5.0 ☞ section T
Vehicle running Approx. 5.0 • Inspect related harness.
Accelerator pedal • Inspect CTP switch.
B+ ☞ CLOSED THROTLE
Ignition switch depressed
1N CTP CTP switch POSITION (CTP)
on SWITCH INSPECTION
Accelerator pedal
Below 1.0
released • Inspect related harness.
Brake pedal depressed B+ • Inspect brake switch.
1O Brake Brake switch ☞ section P
Brake pedal released Below 1.0 • Inspect related harness.
Steering wheel • Inspect PSP switch.
straight ahead B+ ☞ POWER STEERING
Power steering position PRESSURE (PSP)
1P PSP switch Idle
pressure SWITCH INSPECTION
Steering wheel
Below 1.0 • Inspect related harness.
fully turned
A/C switch and • Inspect A/C switch.
Ignition switch Below 1.0
fan switch on ☞ section U
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1Q A/C A/C switch
on
A/C switch off B+ • Inspect related harness.
1R — — — — —
1S — — — — —
1T — — — — —
1U — — — — —
Transmission
neutral position or Below 1.0 • Inspect neutral switch.
☞ NEUTRAL SWITCH
clutch pedal
INSPECTION
Load/no load Neutral/clutch Ignition switch depressed
1V • Inspect clutch switch.
distinction switch on Other than ☞ CLUTCH SWITCH
transmission INSPECTION
B+
neutral or clutch • Inspect related harness.
pedal released
Fuel injector
2A Ground Constant Below 1.0 • Inspect related harness.
ground
2B Power ground Ground Constant Below 1.0 • Inspect related harness.
2C System ground Ground Constant Below 1.0 • Inspect related harness.
MAF sensor,
IAT sensor,
2D Analog ground ECT sensor, Constant Below 1.0 • Inspect related harness.
O2S,TP
sensor
• Inspect CMP sensor.
CMP sensor Ignition switch on 5.0 ☞ CAMSHAFT POSITION
2E SGT (integrated into (CMP) SENSOR
distributor) INSPECTION
Idle 1.8—2.3
• Inspect ignition control
Ignition switch on Below 1.0
Ignition control module.
2F IGT control ☞ section G
module
Idle 0.35—0.5
2G — — — — —
2H — — — — —
2I — — — — —
2J — — — — —
Constant voltage
2K TP sensor Ignition switch on 4.5—5.5 • Inspect related harness.
(Vref)
F1-35 CONTINUED
CONTROL SYSTEM

• Inspect IAT sensor.
☞ INTAKE AIR
Ignition switch TEMPERATURE (IAT)
2L IAT IAT sensor IAT 20° C {68°F} 2.15
on SENSOR INSPECTION
Accelerator pedal • Inspect TP sensor.
0.4—0.6
Ignition switch released ☞ THROTTLE POSITION (TP)
2M TP TP sensor SENSOR INSPECTION
on Accelerator pedal
3,4—4.7 • Inspect related harness.
depressed
Ignition switch on 0.55
Engine cold 0.0—1.0 • Inspect O2S.
1 Idle ☞ OXYGEN SENSOR (O2S)
2N* O2S O2S 0.0—1.0
INSPECTION
Acceleration After warm up 0.5—1.0 • Inspect related harness.
Deceleration 0.0—0.5
• Inspect variable resistor.

2 Varies according to the variable ☞ VARIABLE RESISTOR
2N* Variable resistor Variable resistor 0—4 INSPECTION
resistor adjustment
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Ignition switch on 1.45 • Inspect MAF sensor.
☞ MASS AIR FLOW (MAF)
Idle (after warm up) 2.15 SENSOR INSPECTION
2O Mass airflow MAP sensor
Engine speed 3000 rpm • Inspect related harness.
2.73
(after warm up)
2P — — — — —
IAT 20°C {68°F} 1.02 • Inspect ECT sensor.

☞ ENGINE COOLANT
Ignition switch TEMPERATURE (ECT)
2Q ECT ECT sensor
on SENSOR INSPECTION
After warm up 0.58 • Inspect related harness.
2R — — — — —
2S — — — — —
For 120 sec. after
ECT above 0 • Inspect PRC solenoid valve.
ignition switch on
90°C {194°F} ☞ FUEL SYSTEM, PRC
Pressure PRC solenoid SOLENOID VALVE
2T (Hot condition) For 120 sec. after
regulator control valve 0 INSPECTION
engine start
Others Ignition switch on B+ • Inspect related harness.
• Inspect fuel injector.

Fuel injector ☞ FUEL SYSTEM,FUEL
2U INJECTOR INSPECTION
No.1,No.3
Idle B+ • Inspect related harness.
Fuel injector
control
• Inspect fuel injector.
Fuel injector ☞ FUEL SYSTEM,FUEL
2V INJECTOR INSPECTION
No.2, No.4
Idle B+ • Inspect related harness.
Ignition switch on 0.2 • Inspect IAC valve.

☞ INTAKE-AIR SYSTEM, IAC
2W IAC IAC valve VALVE INSPECTION
Idle (after warm up) Approx 1.0
*1: Europe only
*2: Except Europe
CONTINUED
F1-36
CONTROL SYSTEM
Ignition switch on B+ • Inspect purge solenoid valve.

☞ EMISSION SYSTEM,
Purge PURGE SOLENOID VALVE
2X Purge control Idle B+
solenoid valve INSPECTION
Driving in gear
2Y — — — — —
• Inspect instrument cluster.
Tachometer Ignition switch on B+ ☞ FUEL SYSTEM, FUEL
Engine speed
2Z (integrated into INJECTOR INSPECTION
output
instrument cluster)
Idle 4.9—7.0 • Inspect related harness.
MASS AIR FLOW (MAF) SENSOR INSPECTION THROTTLE POSITION (TP) SENSOR INSPECTION
Note Note
• Perform the following test only when directed. • Perform the following test only when directed.
MAF Sensor Inspection Resistance Inspection
1. Visually inspect for the following on the MAF 1. Verify that the throttle valve is at closed throttle
sensor. position.
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• Damage 2. Inspect that the accelerator cable free play is
• Cracks within the specification.
• Terminal bends (Refer to INTAKE-AIR SYSTEM, ACCELERATOR
• Terminal rust CABLE INSPECTION / ADJUSTMENT.)
2. If any of the above are found, replace the MAF 3. If as specified but PID valve is out of specification,
sensor. If the MAF sensor PID value is out of measure the resistance between TP sensor
specification, inspect as follows and repair or terminals A and C using an ohmmeter.
replace as necessary: Specification
3. Disconnect the MAF sensor connector. Open 4—6KΩ
circuit
• MAF signal circuit (MAF sensor connector
terminal B and PCM connector terminal 20)
• Power circuit (MAF sensor connector
terminal C and main relay terminal D through
common connector) • GND circuit (MAF
sensor connector terminal A and PCM
connector terminal 2D through common
connector)
4. Disconnect the TP sensor connector.

5. If not as specified, replace the TP sensor. If as
specified, inspect for the following:
Open circuit
• Reference voltage circuit (TP sensor
connector terminal A and PCM connector
terminal 2K)
Short circuit
• TP signal circuit (TP sensor connector
• MAF signal circuit (MAF sensor connector
terminal B and PCM connector terminal 2M)
terminal B and PCM connector terminal 20
• GND circuit (TP sensor connector terminal C
to GND)
and PCM connector terminal 2D)
• Power circuit (MAF sensor connector
Short circuit
terminal C and main relay terminal D through
• Reference voltage circuit (TP sensor
common connector to GND)
terminal 2K)
5. Reconnect the MAF sensor connector.
• TP signal circuit (TP sensor connector
terminal B and PCM connector terminal 2M)
CONTINUED
F1-37
CONTROL SYSTEM
6. Repair or replace faulty areas. Specification (CTP)

7. Reconnect the TP sensor connector. TP sensor terminal C PCM terminal 2M voltage
THROTTLE POSITION (TP) SENSOR voltage (V) TP V (NGS tester) (V)
ADJUSTMENT
4.5—4.9 0.4—0.6
Caution
• Adjusting the TP sensor with the throttle 4.9—5.1 0.4—0.6
adjusting screw (TAS) can adversely 5.1—5.5 0.4—0.6
affect the engine. Do not adjust the TP 8. Tighten the TP sensor screw.
sensor with the TAS.
• Since the TP sensor is adjusted by the Tightening torque
manufacturer, adjusting the TP sensor 1.6—2.3 N.m {16—24 kgf.cm, 14—20 in.lbf}
excessively can adversely affect the 9. Use the NGS tester ("TP V" of PID/DATA
engine. Do not adjust the TP sensor MONITOR AND RECORD function) or voltmeter
excessively. to verify the TP sensor so that the voltage of PCM
1. Verify that the throttle valve is at closed throttle terminal 2M is within the specification below when
position. the throttle valve is wide open.
2. Disconnect the TP sensor connector. Specification (WOT)
3. Turn ignition switch on.
4. Measure and record the voltage of the TP sensor terminal C PCM terminal 2M voltage
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disconnected harness side connector terminal C voltage (V) TP V (NGS tester) (V)
using a voltmeter. 4.5—4.7 3.4—4.4
4.7—4.8 3.6—4.5
4.8—4.9 3.7—4.6
4.9—5.0 3.7—4.8
5.0—5.1 3.8—4.9
5.1—5.3 4.0—5.0
5.3—5.4 4.1—5.1
5.4—5.5 4.2—5.2
10. If not as specified, replace the TP sensor.

(Refer to CONTROL SYSTEM, THROTTLE
Specification POSITION (TP) SENSOR REMOVAL /
4.5—5.5 V INSTALLATION.)
THROTTLE POSITION (TP) SENSOR
5. Reconnect the TP sensor connector. REMOVAL/INSTALLATION
6. Loosen the TP sensor screw. 1. Disconnect the TP sensor connector.
2. Remove the TP sensor screws.
3. Remove the TP sensor from the throttle body.
7. Use the NGS tester ("TP V" of PID/DATA 4. Verify that the throttle valve is fully closed.
MONITOR AND RECORD function) or voltmeter 5. Install the TP sensor to the throttle body.
to adjust the TP sensor so that the voltage of
PCM terminal 2M is within the specification below 6. tighten the TP sensor screws.
Tightening torque
when the throttle valve is at the closed throttle
1.6—2.3 N.m {16—24 kgf.cm, 14—20 in.lbf }
position.
7. Verify that the throttle valve moves smoothly.
8. Reconnect the TP sensor connector.
CONTINUED
F1-38
CONTROL SYSTEM
9. Adjust the TP sensor. Short circuit

(Refer to CONTROL SYSTEM, THROTTLE • CTP signal circuit (CTP switch connector
POSITION (TP) SENSOR ADJUSTMENT.) terminal and PCM connector terminal 1 N to
CLOSED THROTTLE POSITION (CTP) SWITCH GND)
INSPECTION 4. Reconnect CTP switch connector.
Caution INTAKE AIR TEMPERATURE (IAT) SENSOR
• The CTP switch is set at the factory. Do not INSPECTION
try to adjust it. Resistance inspection
• Removing the closed throttle position Note
switch can negatively affect the engine. • Perform the following test only when directed.
1. Remove the IAT sensor.
Note 2. Heat the IAT sensor using the lamp.
• Perform the following test only when directed. 3. Measure the resistance of the IAT sensor using
1. Disconnect the CTP switch connector. an ohmmeter
2. Inspect for continuity between the CTP switch
terminal and a GND using an ohmmeter.
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Specification
Water temperature (°C {°F}) Resistance (kΩ)
20 {68} 2.09— 2.81
Specification
80 {176} 0.274 —0.802
Measuring condition Continuity
Closed throttle position Yes 4. If not as specified, replace the IAT sensor. If
Others No IAT sensor is okay, but PID value is out of
specification, inspect as follows and repair or
replace as necessary.
3. If not as specified, replace the throttle body. If the
Open circuit
CTP switch is okay, but PI D value is out of
• IAT signal circuit (IAT sensor connector terminal
specification, inspect as follows and repair or
A and PCM connector terminal 2L)
replace as necessary.
• GND circuit (IAT sensor connector terminal B
Open circuit and PCM connector terminal 2D)
• CTP signal circuit (CTP switch connector terminal
and PCM connector terminal 1N)
• GND circuit (CTP switch body to GND)
Short circuit
• IAT signal circuit (IAT sensor connector terminal
A and PCM connector terminal 2Lto GND)
5. Reconnect the IAT sensor connector.
CONTINUED
F1-39
CONTROL SYSTEM
INTAKE AIR TEMPERATURE (IAT) SENSOR ENGINE COOLANT TEMPERATURE
REMOVAL/INSTALLATION (ECT) SENSOR INSPECTION
1. Disconnect the negative battery cable. Note
2. Disconnect the IAT sensor connector. • Perform the following test only when directed.
3. Remove the IAT sensor. ECT Sensor Resistance Inspection
4. Install the IAT sensor. 1. Drain the engine coolant.
(Refer to Section E, COOLING SYSTEM
SERVICE WARNINGS.)
(Refer to Section E, ENGINE COOLANT,
2. Remove the ECT sensor.
3. Place the ECT sensor in water with a
thermometer, and heat the water gradually.
Tightening torque
7.9—11.7 N.m
{80—120 kgf.cm, 70—104 in.lbf}
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5. Connect the IAT sensor connector.
ENGINE COOLANT TEMPERATURE (ECT)
SENSOR REMOVAL/INSTALLATION
Warning
• When the engine is hot, it can badly burn.
Turn off the engine and wait until it is cool
before removing or installing the ECT
sensor.
SERVICE WARNINGS.)
2. Disconnect the ECT sensor connector. 4. Measure the resistance between the ECT sensor
3. Remove the ECT sensor. terminals A and B using an ohmmeter.
Specification
Water temperature (°C {°F}) Resistance (kΩ)
20 {68} 2.2—2.8
80 {176} 0.29—0.4
5. If not as specified, replace the ECT sensor. If the
ECT sensor is okay, but PID value is out of
specification, inspect for the following:
Open circuit
• ECT signal circuit (ECT sensor connector
4. Replace the gasket. terminal A and PCM connector terminal 2Q
5. Install in the reverse order of removal, through common connector)
Tightening torque • GND circuit (ECT sensor connector terminal
25—29 N.m {2.5—3.0 kgf.m, 19—21 ft.lbf} B and PCM connector terminal 2D through
6. Refill the engine coolant. common connector)
(Refer to Section E, COOLING SYSTEM Short circuit
SERVICE WARNINGS.) • ECT signal circuit (ECT sensor connector
(Refer to Section E, ENGINE COOLANT, ENGINE terminal A and PCM connector terminal 2Q
COOLANT REPLACEMENT.) through common connector to GND)
• GND circuit (ECT sensor connector terminal
B and PCM connector terminal 2D through
common connector to GND)
F1-40 CONTINUED
CONTROL SYSTEM
7. Install the ECT sensor.
8. Refill the engine coolant.
SERVICE WARNINGS.)
(Refer to Section E, ENGINE COOLANT,
CAMSHAFT POSITION (CMP) SENSOR
INSPECTION
Note
Voltage Inspection Short circuit
1. Remove the distributor. • SGT signal circuit (Distributor harness side
2. Disconnect the fuel injector connectors. connector terminal C and PCM harness side
3. Disconnect the high-tension lead. connector terminal 2E to GND)
4. Connect the distributor connector. • Power circuit (Distributor harness side
connector terminal B and main relay harness
Warning
side connector terminal D to GND)
• Turning the ignition switch on with the
9. If the harnesses are okay, replace the distributor
fuel injector connector still connected will
and adjust the ignition timing.
actuate the fuel injector.
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(Refer to ENGINE TUNE-UP, IGNITION TIMING
• Turning the ignition switch on with the ADJUSTMENT.)
distributor connector still connected will
generate sparks, which can cause OXYGEN SENSOR (O2S) INSPECTION
electrical shock. Disconnect the O2S Voltage Inspection
connector and prevent it from grounding
to the vehicle body. Note
5. Turn the ignition switch on. • Perform the following test only when directed.
6. Verify the following signal (voltage) from the PCM 1. Warm up the engine and run it at idle.
2E terminal using a voltmeter when the 2. Disconnect the O2S connector.
distributor is rotated by hand. 3. Connect the voltmeter test leads to the following
O2S terminals:
Specification
• (+) lead-O2S terminal A
Signal Terminal Voltage
• (-) lead-O2S terminal B
SGT 2E 4 pulses/rev. (Approx. 5.0 V)
7. If not as specified, inspect as follows and repair

or replace as necessary.
8. Disconnect the distributor connector.
Open circuit
• SGT signal circuit (Distributor harness side
connector terminal C and PCM harness side
connector terminal 2E)
• Power circuit (Distributor harness side
connector terminal B and main relay harness 4. Run the engine at 3000 rpm until the voltmeter
side connector terminal D) increases 0.5—0.7 V.
• GND circuit (Distributor harness side 5. Verify that the voltmeter needle moves when
connector terminal A and engine GND) racing the engine several times.
Specification
Engine condition Voltage (V)
Acceleration 0.5—1.0
Deceleration 0—0.5
6. If not as specified, replace the O2S. If the O2S is
okay, but PID value is out of specification, inspect
for following:
CONTINUED
F1-41
CONTROL SYSTEM
Open circuit
• O2S signal circuit (O2S connector terminal A and
PCM connector terminal 2N)
• GND circuit (O2S connector terminal B and PCM
connector terminal 2D)
Variable resistor condition Resistance (kΩ)

Turned fully clockwise 4-6
Turned fully counterclockwise Below 0.1
Short circuit
• O2S signal circuit (O2S connector terminal A and
PCM connector terminal 2N to GND) 4. If not as specified, replace the variable resistor.
7. Repair or replace faulty areas. 5. Adjust idle mixture.
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8. Reconnect the O2S connector. 6. If the variable resistor is okay, but PCM terminal
2N or 2K voltage is out of specification, inspect for
the following:
OXYGEN SENSOR (O2S)
Open circuit
1. Disconnect the battery negative terminal. • Reference voltage circuit (Variable resistor
2. Disconnect the O2S connector. terminal 2K)
3. Remove the O2S.
• Variable resistor signal circuit (Variable
4. Install in the reverse order of removal. resistor connector terminal B and PCM
connector terminal 2N)
Tightening torque
29-49 N.m {3—5 kgf.m, 22—36 ft.lbf} • GND circuit (Variable resistor connector
terminal C and PCM connector terminal 2D)
Short circuit
VARIABLE RESISTOR INSPECTION
• Reference voltage circuit (Variable resistor
1. Disconnect the connector from the variable connector terminal A and PCM connector
resistor. terminal 2K)
2. Connect an ohmmeter between the variable
• Variable resistor signal circuit (Variable
resistor terminal B and C.
resistor connector terminal B and PCM
connector terminal 2N)
7. If there is an open or short circuit, repair or
replace wiring harness.
8. If there is no open or short circuit, replace variable
3. Using the SST, verify that the resistance resistor.
increases in relation to the turning amount of the 9. Reconnect the variable resistor connector.
variable resistor. CLUTCH SWITCH INSPECTION
Note
1. Verify that the clutch switch is installed properly.
3. Remove the clutch switch.
(Refer to CONTROL SYSTEM, CLUTCH SWITCH
4. Inspect the continuity between the clutch switch
terminals A and B using an ohmmeter.
CONTINUED
F1-42
CONTROL SYSTEM
Specification
Specification
Transmission Continuity
In neutral Yes
Others No
4. If not as specified, replace the neutral switch. If the

neutral switch is okay, but PID value is out of
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5. If not as specified, replace the clutch switch. If the
clutch switch is okay, but PID value is out of Open circuit
specification, inspect for the following: • Load/no load distinction circuit (neutral switch
Open circuit connector terminal A and PCM connector
• Power circuit (Clutch switch connector terminal terminal 1V through common connector)
B and PCM connector terminal 1V through • GND circuit (neutral switch connector terminal
common connector) B and GND)
• GND circuit (Clutch switch connector terminal A
and GND)
Short circuit
• Power circuit (Clutch switch connector terminal
B and PCM connector terminal 1V to GND)
Neutral switch
• The neutral switch operation and related
harnesses continuity
(Refer to NEUTRAL SWITCH INSPECTION.
7. Install the clutch switch. Short circuit
(Refer to CONTROL SYSTEM, CLUTCH SWITCH • Load/no load distinction circuit (neutral switch
REMOVAL/INSTALLTION.) connector terminal A and PCM connector
8. Connect the negative battery cable. terminal 1V through common connector to
CLUTCH SWITCH REMOVAL/INSTALLATION GND) Clutch switch
1. Disconnect the negative battery cable. • The clutch switch operation and related harness
2. Disconnect the clutch switch connector. continuity.
3. Loosen the nuts and remove the clutch switch. (Refer to CONTROL SYSTEM, CLUTCH
4. Install the clutch switch. SWITCH INSPECTION.)
5. Adjust the clutch pedal height referring to the above 5. Repair or replace faulty areas.
and the height specification. 6. Reconnect the neutral switch connector.
(Refer to Section H, CLUTCH PEDAL, CLUTCH
PEDAL INSPECTION/ADJUSTMENT.) NEUTRAL SWITCH REMOVAL/INSTALLATION
6. Connect the clutch switch connector. 1. Disconnect the battery negative cable.
7. Connect the negative battery cable. 2. Disconnect the neutral switch connector.
NEUTRAL SWITCH INSPECTION 3. Remove the neutral switch.
Continuity inspection 4. Install the new washer and neutral switch.
Note
1. Disconnect the battery negative cable.
2. Disconnect the neutral switch connector.
3. Measure the continuity between the neutral switch
terminals A and B using an ohmmeter.
CONTINUED
F1-43
CONTROL SYSTEM
Short circuit
Tightening torque
• PSP signal circuit (PSP switch connector terminal
25—34 N.m {2.5—3.5 kgf.m, 19—25 ft.lbf}
and PCM connector terminal 1P through common
5. Connect the neutral switch connector. connector to GND) Power steering fluid
6. Connect the battery negative cable. (Refer to Section N, engine speed sensing power
POWER STEERING PRESSURE (PSP) SWITCH steering system.)
INSPECTION • Fluid level
• Fluid leakage
Continuity inspection
• Fluid pressure
Note 5. Repair or replace faulty areas.
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• Perform the following test only when directed. 6. Reconnect the PSP switch connector.
1. Disconnect the PSP switch connector. MAIN RELAY INSPECTION
2. Start the engine.
Note
3. Inspect for continuity between the PSP switch • Perform the following test only when directed.
terminal and GND using an ohmmeter. 1. Disconnect the negative battery cable.
2. Remove the main relay connector.
3. Inspect for continuity between terminals of the
relay using an ohmmeter.
Specification
Condition Continuity
Steering wheel in straight ahead Yes Specification
Steering wheel fully turned No
4. If not as specified, replace the PSP switch. If the

PSP switch is okay, but PID value is out of
Open circuit
4. If not as specified, replace the main relay. If the
• PSP signal circuit (PSP switch connector main relay is okay, inspect for the following:
terminal and PCM connector terminal 1P Open circuit
• Main relay power supply circuit (Main relay
• GND circuit (PSP switch body and GND) connector terminal A and ignition switch (IG1)
connector through common connector)
• PCM power supply circuit (Main relay
connector terminal C and battery positive
terminal through common connector)
CONTINUED
F1-44
CONTROL SYSTEM, ON-BOARD DIAGNOSTIC SYSTEM

• GND circuit (Main relay connector ON-BOARD DIAGNOSTIC SYSTEM
terminal B and GND) READ/CLEAR DIAGNOSTIC TEST RESULTS
Short circuit • This retrieves all stored DTCs in the PCM
• Main relay power supply circuit (Main and clears the DTC.
relay connector terminal A and ignition PARAMETER IDENTIFICATION (PID) ACCESS
switch (IG1) connector through common • The PID mode allows access to certain data
connector to GND) values, analog and digital inputs and outputs,
• PCM power supply circuit (Main relay calculated values and system status
connector terminal C and battery information. Since PID values for output
positive terminal through common devices are PCM internal data values, perform
connector to GND) the Simulation Test to identify which output
5. Repair or replace faulty areas. devices are malfunctioning.
6. Reconnect the main relay. Note
7. Reconnect the negative battery cable. • PID monitor item "PRCV" can be selected and
"ON" or "OFF' is displayed for vehicles without
MAIN RELAY REMOVAL/INSTALLATION the PRC system, but is not used for the
inspection because the corresponding part
(PRC solenoid valve) is not equipped.
2. Disconnect the main relay connector.
3. Remove the main relay.
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DIAGNOSTIC SUPPORT PROCEDURE
4. Install the reverse order of removal.
• These tests are the ability of the powertrain
Tightening torque control system to detect a change in certain
7.9—10.7 N.m input devices by following the instructions on
{80—110 kgf.cm, 69.5—95.4 in-Ibf} the NGS tester. There are two options: ALL
TEST and SINGLE TEST. ALL TEST takes
you through all diagnostic support tests.
SINGLE TEST enables you to perform
specific tests that relate to the particular
diagnosis that you are conducting. This test
MUST follow the instructions on the NGS
tester. If not, a "TEST CONDITIONS NOT
CORRECT' message will appear, or else the
test result will be FAULTY.
SIMULATION TEST
• Output devices can be turned on and off by
sending simulation command signals from
the NGS tester to the PCM. The "Idling
Test" and "Ignition ON Test" are available in
this test. These tests will verify the PCM
status, output devices, and related circuit
wiring harnesses.
Note
• "PRCV" of the simulation item can be selected
for vehicles without the PRC system, but is
not used for the inspection because the
corresponding part (PRC solenoid valve) is
not equipped.
ON-BOARD DIAGNOSTIC TEST
NGS Tester Hook-up Procedure
Note
• Make sure the ignition switch is at LOCK
position.
1. Insert the vehicle interface module and latest
program card into the hand-held NGS control unit.
CONTINUED
F1-45
ON-BOARD DIAGNOSTIC SYSTEM
3. Move the cursor to SELECT NEW VEHICLE

YEAR & MODEL Press the TRIGGER key to
enter this selection.
2. Plug the adapter harness connector into the

vehicle interface module and the DLC located at
the engine compartment.
3. Plug the NGS tester power connector into the
cigarette lighter. Alternatively, use a battery
hook-up adapter.
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4. Move the cursor to B-SERIES (UN). Press the
4. Listen to the double beep. The NGS tester is TRIGGER key to enter this selection.
now initialized. Begin the powertrain control
system functional test. EUROPE
DTC READING PROCEDURE
Note
• Start engine and keep it running. If the
engine will not start, turn the ignition switch
on during the procedure.
1. Perform the necessary vehicle preparation and
visual inspection. Hook the NGS tester up to the
vehicle.
2. Move the cursor to VEHICLE & ENGINE

SELECTION. Press the TRIGGER key to enter
this function.
CONTINUED
F1-46
EXCEPT EUROPE 9. Move the cursor to READ/CLEAR DIAGNOSTIC

TEST RESULTS. Press the TRIGGER key to
Note
• Make sure the selected vehicle is correct.
10. Press START.
5. A vehicle selection screen showing the selected
vehicle will be displayed. Move the cursor to the 11. Retrieve DTCs.
vehicle selected. Press the TRIGGER key. Not Using the SSTs (NGS Tester) Using
6. Move the cursor to DIAGNOSTIC DATA LINK on the SST (self-diagnosis checker)
the main menu screen. Press the TRIGGER key 1. Connect the SSTs to the DLC located in the
to enter into menu system diagnostics. engine compartment and ground the black
(negative) lead to the body.
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7. Move the cursor to PCM-POWERTRAIN
CONTROL MODULE. Press the TRIGGER key to
2. Set the select switch on the SST (self-diagnosis

checker) to A.
3. Turn the dial switch on the SST (system selector)
to 1, and the test switch to SELF TEST.
8. Move the cursor to DIAGNOSTIC TEST MODES.
5. Verify that the buzzer sounds for approximately 3
Press the TRIGGER key to enter this selection. seconds and code "88" flashes for 5 seconds. If
DTC is not detected, "00" will then be indicated.
Note
• If the "88" does not flash, inspect +B terminal
of the DLC, and the related harnesses and
connectors.
• If the "88" flashes and the buzzer sounds
more than 20 seconds, inspect the harness
between the PCM terminal and the DLC. If
the harness is normal, replace the PCM and
inspect.
6. If any DTCs is indicated, inspect the appropriate
area and repair as necessary.
Note
• A DTC consists of four numbers. They are
flashed one by one in the right window on the
display. ("1" is always shown on the left
window.)
CONTINUED
F1-47
7. After completion of repairs, erase all DTCs from 7. If any DTCs is indicated, inspect the appropriate
the memory. area and repair as necessary.
(Refer to AFTER REPAIR PROCEDURE, Not 8. After completion of repairs, erase all DTCs from
Using the SSTs (NGS tester).) the memory.
8. Remove the SSTs. (Refer to AFTER REPAIR PROCEDURE, Not
Using the SSTs (NGS Tester).)
9. Remove the voltmeter and jumper wire
PID/DATA MONITOR AND RECORD PROCEDURE

1. Perform the NGS Tester Hook-up Procedure.
2. Perform Steps 1 through 7 from the DTC
READING PROCEDURE.
3. Turn the ignition switch on or run the engine.
4. Move the cursor to PID/DATA MONITOR AND
RECORD. Press the TRIGGER key to enter this
selection.
Using the Voltmeter
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Caution
• Connecting the wrong DLC terminals may
connect the specified terminals only.
2. Using a jumper wire to short terminal TEN of the 5. Move the cursor to PID values to view. Press the
DLC to body GND. TRIGGER key. A star symbol will appear next to
3. Connect the negative battery lead of voltmeter the item when it is selected.
(20V range) to the DLC terminal FEN, and the Note
positive lead to the DLC terminal +B.
• Press the TRIGGER key once again to
deselect a PID.
• Press the CLEAR to deselect all PIDs.
6. Press START to begin.

7. When ready to capture and store the selected
PIDs, press the TRIGGER key.
8. Press the TRIGGER key again when ready to
save information.
9. Move the cursor to STORE RECORDING AREA
1. Press the TRIGGER key.

5. The voltmeter indicates B+ for approximately 3
seconds, then indicates 0V.
6. Read the DTCs indicated by the movement of the
voltmeter's needle. If DTC is not detected, the
needle does not move.
10. Follow the instructions displayed on the NGS

Note
tester to save the recording data.
• The DTC will be output as shown.
PLAYBACK OF STORED PIDS PROCEDURE
Note
• Look for abnormal behavior or values that
are clearly incorrect. Inspect the signals for
abrupt or unexpected changes.
CONTINUED
F1-48

• Look for agreement in related signals.
• Make sure signals act in proper sequence.
1. Select VIEW RECORDER AREAS.
4. Move the cursor to ALL TEST or SINGLE TEST.

Press the TRIGGER key.
Note
• ALL TEST inspects each item according to an
2. Select up to four PIDs to review in the table format established programmed order. With SINGLE
or two PIDs to review in the graph mode. TEST, enable to select and inspect any test
(1) Table format: Scroll through the PID data while
item in any order, one at a time.
analyzing the information. Look for sudden drops
or peaks in the values.
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5. Follow the instructions displayed on the NGS
tester and press the TRIGGER key.
Note
(2) Graph format: Scroll through the PID • To skip a test item, press OMIT.
data while analyzing the information. Look
for sudden drops or peaks in the linear • Before performing the test, the basic condition
on the test vehicle must be set up in order to
lines showing the transformation of values
get exact data. Press BASIC to view the basic
to the line graph.
condition instruction screen.
• If the screen shows PASSED, the system
operates correctly.
• If the screen shows FAULTY, the system
operates incorrectly.
DIAGNOSTIC SUPPORT PROCEDURE

1. Perform the NGS Tester Hook-up Procedure.
2. Perform Steps 1 through 8 from the DTC
READING PROCEDURE.
3. Move the cursor to DIAGNOSTIC SUPPORT
PROCEDURE. Press the TRIGGER key to enter
this selection. CONTINUED
F1-49

SIMULATION TEST PROCEDURE 8. Press the TRIGGER key.
Idling Test
1. Perform the NGS tester hook-up procedure.
2. Perform the Steps 1 through 7 from the DTC
READING PROCEDURE.
3. Start the engine and run it at idle.
4. Move the cursor to SIMULATION TEST. Press the
TRIGGER key to enter this selection.
9. The simulation is performed for 3 seconds, and a
"SIMULATION ACTIVATED PLEASE WAIT"
message is displayed during those 3 seconds.
5. Move the cursor to IDLING TEST. Press the

TRIGGER key to enter this selection.
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10. To perform the simulation again, press the
TRIGGER key. To exit the idling test, press the
CANCEL key.
Ignition ON Test
1. Perform Steps 1 through 7 from the DTCs
6. The screen will display a list of simulation items. READING PROCEDURE.
Select the appropriate simulation item for testing, 2. Turn the ignition switch on. Move the cursor to
then press the TRIGGER key. SIMULATION TEST. Press the TRIGGER key to
Note
• Only one simulation item can be selected at a
time.
3. Move the cursor to IGNITION ON TEST. Press

the TRIGGER key to enter this selection.
7. Press START.
Note
• If the screen displays "TEST CONDITION NOT
CORRECT", inspect the following signal
conditions and determine whether or not they
are normal:
• NLSW: ON
• RPM; above 550
CONTINUED
F1-50

AFTER REPAIR PROCEDURE
1. After repairs have been made, perform the DTCs
READING PROCEDURE.
2. Press CLEAR.
4. Press the CANCEL key.
5. Ensure that the customer's concern has been
4. The screen will display a list of simulation items. resolved.
Select the appropriate simulation item for testing,
then press the TRIGGER key. Not Using the SSTs (NGS Tester)
1. After repairs, disconnect the negative battery
cable for at least 20 seconds, and depress the
brake pedal. Reconnect the negative battery
cable.
temperature.
Note
• If the engine will not start, continue to operate
5. Press START.
the starter for 5-6 seconds.
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3. Perform the "DTC READING PROCEDURE"
again.
4. Verify that the DTC is not detected.
7. The simulation is performed for 3 seconds, and

a "SIMULATION ACTIVATED PLEASE WAIT"
message is displayed during those 3 seconds.
8. To perform the simulation again, press the

TRIGGER key. To exit the ignition on test,
press the CANCEL key. CONTINUED
F1-51

DTC INSPECTION DTC
Table
DTC No. Output pattern Display on the NGS tester Condition
MAF/VAF-CIRCUIT
P0100 MAF sensor circuit malfunction
MALFUNCTION
ECT-CIRCUIT
P0115 ECT sensor circuit malfunction
MALFUNCTION
P0120 TP-CIRCUIT MALFUNCTION TP sensor circuit malfunction
O2S 11-CIRCUITNO
P0134 O2S circuit no activity detected
ACTIVITY DETECTED
CAMSHAFT POS SENSOR-

P0340 SGT signal is not detected
CKT MALFUNCTION
EVAP SYSTEM-PURGE
P0443 Purge solenoid valve circuit malfunction
CTRL VALVE CKT MALF
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IDLE CONTROL SYSTEM-
P0505 IAC valve circuit malfunction
MALFUNCTION
P1110 IATS (D/C)-OPEN OR SHORT IAT sensor circuit malfunction
P1170 HO2S 11-INVERSION O2S is stuck
Barometric pressure sensor (in PCM)

P1195 EGRBS-OPEN OR SHORT
malfunction
P1250 PRC-OPEN OR SHORT PRC solenoid valve circuit malfunction
P1608 PCM (CPU)-MALFUNCTION PCM internal circuit malfunction
CONTINUED
F1-52

DTC Troubleshooting
DTC P0100 Mass air flow (MAP) sensor circuit malfunction
DETECTION Input voltage from MAF sensor is below 0.7 V or above 5.4 V when ignition switch is turned on.
CONDITION
• MAF sensor malfunction
• Blockage at MAP sensor
• Poor connection of connectors at MAF sensor and/or PCM
• Leakage in intake-air system
• Short to power supply circuit in wiring from MAF sensor terminal B to PCM terminal 20
POSSIBLE CAUSE
• Short to ground in wiring from MAF sensor terminal B to PCM terminal 20
• Open circuit in wiring from MAF sensor terminal B to PCM terminal 20
• Open circuit in wiring from MAF sensor terminal C to main relay terminal D
• Open circuit in wiring from MAF sensor terminal A to PCM terminal 2D
• Open circuit in wiring from PCM terminal 2C to engine ground.
STEP INSPECTION ACTION
1 Verify stored DTC. Yes Inspect for open circuit in following wiring harnesses, then
Have DTCs P0115, P0120, P0134, P0340, P0443, go to Step 12.
P0505, P1110, P1170, and/or P1250 been stored? • Main relay terminal D-purge solenoid valve, PRC
solenoid valve, IAC valve CMP sensor
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• PCM terminal 2D-throttle position sensor, intake-air
temperature sensor, engine coolant temperature
sensor, oxygen sensor
• Between PCM terminal 2C and engine ground
No Go to next step
2 Does MAP sensor connector or PCM connector have Yes Repair or replace connector, then go to Step 12.
poor connection? No Go to next step.
3 Is intake-air system okay? Yes Go to next step
No Repair or replace faulty parts, then go to Step 12.
4 Disconnect MAF sensor connector. Yes Go to next step.
Turn ignition switch on. No Inspect for open or short circuit in wiring harness (between
Is there battery positive voltage at MAF sensor main relay terminal D and MAF sensor terminal C), then
harness side connector terminal C? go to Step 12.
5 Disconnect PCM connector. MAF sensor connector is Yes Go to next step.
disconnected.
Is there continuity between MAF sensor harness side
connector terminal A and PCM harness side No Repair open circuit, then go to Step 12.
connector terminal 2D?
6 Is there continuity between MAF sensor harness side Yes Go to next step
connector terminal B and PCM harness side
connector terminal 20 No Repair open circuit, then go to Step 12.
7 Is there continuity from PCM harness side connector Yes Repair short to power circuit, then go to Step 12.
terminals 20 to 1B? No Go to next step
8 Is there continuity from PCM harness side connector Yes Repair short to ground circuit, then go to Step 12.
terminals 20 to body ground. No Go to next step.
9 Remove MAF sensor. Is there any foreign material at Yes Clean MAF sensor screen, then go to Step 12.
MAF sensor screen?
No Go to next step.
10 Connect MAF sensor connector. Connect NGS Yes Go to next step.
tester to DLC.
Turn ignition switch on.
Access MAF V PID.
Does MAF V PID change when air is blown into
mass airflow sensor? No Replace MAF sensor, then go to Step 12.
Note
• If NGS tester is not used, measure PCM
20 terminal voltage with circuit tester.
CONTINUED
F1-53

11 Clear DTC from memory. Yes Go to Step 1.
Is same DTC present after performing "AFTER No Intermittent poor connection in wiring harnesses or
REPAIR PROCEDURE"? connectors. Repair connectors and/or harnesses, then go
to next step.
12 Clear DTC from memory. Is there any DTC present Yes Go to applicable DTC inspection.
after performing "AFTER REPAIR PROCEDURE"?
No Troubleshooting completed.
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DTC P0115 Engine coolant temperature (ECT) sensor circuit malfunction
DETECTION Input voltage from ECT sensor is below 0.07 V or above 4.58 V when ignition switch is turned on.
CONDITION
• ECT sensor malfunction
• Poor connection of connectors at ECT sensor terminal and/or PCM
• Short to power supply circuit in wiring from ECT sensor terminal A to PCM terminal 2Q
POSSIBLE CAUSE • Short to ground in wiring from ECT sensor terminal A to PCM terminal 2Q
• Open circuit in wiring from ECT sensor terminal A to PCM terminal 2Q
• Open circuit in wiring from ECT sensor terminal B to PCM terminal 2D
• Open circuit in wiring from PCM terminal 2C to engine ground
1 Verify stored DTC. Yes Inspect for open circuit in following wiring harnesses, then
Have DTCs P0100, P0120, P0134, P1110, and/or go to Step 9.
P1170 been stored? • PCM terminal 2D-MAF sensor, O2S, IAT sensor,
and/or TP sensor
• PCM terminal 2C-engine ground
No Go to next step
2 Does ECT sensor connector or PCM connector have Yes Repair or replace connector, then go to Step 9.
poor connection? No Go to next step
3 Disconnect ECT sensor connector. Yes Go to next step
Turn ignition switch on. No Inspect for open or short circuit in wiring harness
Is there 5V at engine coolant temperature sensor (between PCM terminal 2Q and ECT sensor terminal A),
harness side connector terminal A then go to Step 9.
4 Disconnect PCM connector. Yes Go to next step.
ECT sensor connector is disconnected.
Is there continuity between ECT sensor harness side
No Repair open circuit, then go to Step 9
connector terminal 2D
5 Is there continuity from PCM harness side connector Yes Repair short to power circuit, then go to Step 9
terminals 2Q to 1B? No Go to next step.
terminals 2Q to body ground? No Go to next step
7 Is ECT sensor okay? Yes Go to next step
☞ CONTROL SYSTEM, ENGINE COOLANT No Replace ECT sensor, then go to Step 9.
TEMPERATURE (ECT) SENSOR INSPECTION
☞ CONTROL SYSTEM, ENGINE COOLANT
TEMPERATURE (ECT) SENSOR
REMOVAL/INSTALLATION.
F1-54 CONTINUED

Is same DTC present after performing "AFTER No Intermittent poor connection in wiring harness or
REPAIR PROCEDURE"? connector.
Repair connector and/or harness, then go to next
step.
9 Clear DTC from memory. Yes Go to applicable DTC inspection.
Is there any DTC present after performing "AFTER
REPAIR PROCEDURE"? No Troubleshooting completed.
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DTC P0120 Throttle position (TP) sensor circuit malfunction
DETECTION Input voltage from TP sensor is below 0.09 V or above 4.78 V when ignition switch is turned on.
CONDITION
• TP sensor malfunction
• Poor connection of connectors at TP sensor and/or PCM
• Short to power supply circuit in wiring from TP sensor terminal A to PCM terminal 2K
• Short to power supply circuit in wiring from TP sensor terminal C to PCM terminal 2D
• Short to power supply circuit in wiring from TP sensor terminal B to PCM terminal 2M
POSSIBLE CAUSE • Short to ground in wiring from TP sensor terminal B to PCM terminal 2M
• Short to ground in wiring from TP sensor terminal A to PCM terminal 2K
• Open circuit in wiring from TP sensor terminal A to PCM terminal 2K
• Open circuit in wiring from TP sensor terminal C to PCM terminal 2D
• Open circuit in wiring from TP sensor terminal B to PCM terminal 2M
• Open circuit in wiring from TP sensor terminal 2C to engine ground
1 Verify stored DTC. Yes Inspect for open or short circuit in following wiring
Have DTC P0100, P0115, P0134, P1110 and/or harnesses, then go to Step 11.
P1170 been stored. • PCM terminal 2D -MAP sensor, O2S, IAT
sensor, and/or ECT sensor
No Go to next step
2 Does TP sensor connector or PCM connector have Yes Repair or replace connector, then go to Step 11
3 Disconnect TP sensor connector. Yes Go to next step.
Is there 5V at TP sensor harness side connector (between PCM terminal 2K and TP sensor terminal
terminal A? A), then go to Step 11
4 Disconnect PCM connector. Yes Go to next step.
TP sensor is disconnected. Is there continuity
between TP sensor harness side connector terminal
C and PCM harness side connector terminal 2D. No Repair open circuit, then go to Step 11.
5 Is there continuity between TP sensor harness side Yes Go to next step.

No Repair or replace wiring harness, then go to Step 11.
connector terminal 2M.
CONTINUED
F1-55

6 Is there continuity from PCM harness side connector Yes Repair short to power supply circuit, then
terminals 2D to 1B? go to Step 11
No Go to next step.
terminal 2M to 1B go to Step 11.
No Go to next step.
terminals 2M to body ground? No Go to next step.
9 Connect TP sensor and PCM connectors. Yes Go to next step.
Connect NGS tester to DLC. Turn ignition
switch on. Access TP V PID. Does TP V
increase linear according to throttle valve
opening angle?
No Verify TP sensor, then go to Step 11.
Note
2M terminal voltage with circuit tester.
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REPAIR PROCEDURE"? connectors.
Repair connectors and/or harnesses, then go to next
step.
11 Clear DTC from memory. Yes Go to applicable DTC inspection
CONTINUED
F1-56

DTC P0134 Oxygen sensor (O2S) circuit no activity detected
DETECTION O2S signal does not exceed 0.45 V after the engine is started, or stays below 0.45 V for 180
CONDITION seconds after the engine has reached normal operating temperature.
• O2S malfunction
• Open or short circuit in wiring harness
• Poor connection of connector
• Fuel injector malfunction
• Pressure regulator malfunction
• Fuel pump malfunction
• Fuel delivery hose and/or fuel filter clogging or leakage
• Leakage in intake-air system
• Leakage in exhaust system
• Ignition coil and/or igniter malfunction Insufficient compression
POSSIBLE CAUSE • TP sensor malfunction
• Vacuum hose damage or looseness
Warning
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Following troubleshooting flow chart contains fuel system diagnosis and repair procedures.
Read following warnings before performing fuel system service:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
keep sparks and flames away from fuel
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always
complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE"
described in this manual
☞ FUEL SYSTEM, BEFORE REPAIR PROCEDURE
☞ FUEL SYSTEM, AFTER REPAIR PROCEDURE

1 Verify stored DTC. Yes Inspect and repair DTC P0100, P0115, P0120 or
Have DTC P0100 P0120, P0115 and/or P1110 been P1110 then go to Step 22.
stored? No Go to next step
2 Clear DTC. Yes Trouble is in process.
Verify RPM, ECT and VS PIDs. Go to next step.
Drive in normal mode for approx. 2 minutes under
same condition. Is DTC P0134 stored?
Note
• If NGS tester is not used, measure No Go to 'TROUBLESHOOTING, ENGINE SYMPTOM
follow PCM terminal voltages with TROUBLESHOOTING, Intermittent concerns".
circuit tester.
① SGT (terminal 2E)
② ECT sensor (terminal 2Q)
③ Vehicle speed (terminal 1M)
3 Implement PID/DATA MONITOR AND RECORD Yes Implement TROUBLESHOOTING, ENGINE

(ECT, RPM, TP V) from DIAGNOSTIC DATA LINK DIAGNOSTIC INSPECTION, Input Signal System
by using NGS tester. Is there any signal that is far Investigation Procedure" and repair or replace, then
out of specification when ignition switch is on, and go to Step 22.
engine is run at idle?
Note
• If NGS tester is not used, measure
following PCM terminal voltages with
circuit tester. No Go to next step.
① ECT sensor (terminal 2Q)
② SGT (terminal 2E)
③ TP sensor (terminal 2M)
CONTINUED
F1-57

4 Continue monitoring items in previous step. Yes Implement 'TROUBLESHOOTING, ENGINE
Is there any input signal, which causes drastic DIAGNOSTIC INSPECTION, Input Signal System
changes when it is set to be in trouble condition? Investigation Procedure" and repair or replace, then
go to Step 22.
No Go to next step.
5 Inspect exhaust system upstream from oxygen Yes Repair or replace faulty exhaust parts, then
sensor. go to Step 22.
Is there any gas leakage? ☞ EXHAUST SYSTEM, EXHAUST SYSTEM
No Go to next step
6 Inspect installation of O2S. Yes Go to next step.
Is it okay? No Install O2S properly, then go to Step 22.
☞ CONTROL SYSTEM, OXYGEN SENSOR (O2S)
7 Implement PID/DATA MONITOR AND RECORD Yes Go to next step.
(O2S) from DIAGNOSTIC DATA LINK using NGS
tester.
Is voltage on oxygen sensor as follows while racing
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engine (in neutral)?
• More than 0.45V when accelerator pedal is No Inspect and repair or replace faulty oxygen sensor
suddenly pressed: rich condition harness, connector or terminal, then go to Step 22.
• Less than 0.45V during fuel cut: lean condition ☞ CONTROL SYSTEM, OXYGEN SENSOR (O2S)
INSPECTION.
Note
2N terminal voltage with circuit tester.
8 Inspect for open, poor connection, and other Yes Repair or replace faulty harness, connector or
problems on following harnesses, connectors and terminal, then go to Step 22.
terminals (for fuel injector at each cylinder):
• Front main relay to fuel injector Are there any No Go to next step.
problems?
9 Inspect injection amount of each fuel injector. Yes Replace faulty fuel injectors, then go to Step 22.
☞ FUEL SYSTEM, FUEL INJECTOR ☞ FUEL SYSTEM, FUEL INJECTOR
INSPECTION, Fuel Injection Volume Test. REMOVAL/INSTALLATION.
Are there any fuel injectors in abnormal condition for
No Go to next step.
amount or condition of injection?
10 Inspect for air suction: Yes Repair or replace source of air suction, then
• From air cleaner to throttle body go to Step 22.
• From throttle body to dynamic chamber
• From dynamic chamber to intake manifold
Visually inspect for cracks and damage, and inspect No Go to next step.
fluctuation after spraying rust penetrating agent, then
select air suction area.
Can air suction be confirmed?
11 Inspect for suction in vacuum hose which has Yes Repair or replace source of air suction, then
negative pressure on intake manifold, in the same go to Step 22.
manner as previous step.
No Go to next step.
12 Inspect fuel line pressure under trouble condition. Yes Go to Step 17.
☞ TROUBLESHOOTING, ENGINE SYSTEM
INSPECTION, Fuel Pressure Inspection. No Go to next step.
Is fuel line pressure okay?
13 Inspect fuel pump maximum pressure. Yes Go to next step
☞ FUEL SYSTEM, FUEL PUMP UNIT
INSPECTION, Fuel Pump Maximum Pressure No Replace fuel pump, then go to Step 22.
Inspection. ☞ FUEL SYSTEM, FUEL PUMP UNIT
Is it okay? REMOVAL/INSTALLATION.
14 Inspect for clogging in fuel filter (high-pressure). Yes Go to next step.
Are there foreign materials on fuel side of fuel filter? No Go to Step 16.
F1-58
CONTINUED

15 Inspect inside of fuel tank for foreign materials and Yes Replace fuel filter (high-pressure), then go to Step 22.
stains. - FUEL SYSTEM, FUEL FILTER (HIGH-
Is inside of fuel tank okay? PRESSURE) REMOVAL/INSTALLATION.
No Clean inside of fuel tank and fuel filter (low-pressure).

Replace fuel filter (high-pressure), then go to Step 22.
-FUEL SYSTEM, FUEL FILTER (HIGH-PRESSURE)
16 Inspect for leakage and clogging in fuel line from fuel Yes Go to next step.
distributor to fuel pump.
Is it okay? No Repair or replace necessary, then go to Step 22.
17 Inspect for leakage in fuel line fuel filter (high- Yes Replace pressure regulator, then go to Step 22.
pressure) to fuel tank (return side). -FUEL SYSTEM, PRESSURE REGULATOR
No Repair or replace as necessary, the go to Step 22.
18 Verify blinking condition on each cylinder by setting Yes Go to Step 19.
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timing light on high-tension lead under trouble
condition. No Go to next step.
Does it blink regularly and stably?
19 Inspect resistance of ignition coil. Yes Go to next step.
☞ Section G, IGNITION COIL INSPECTION.
No Replace ignition coil, then go to Step 22.
Is it okay?
20 Warning Yes Air gets in from poor sealing on head gasket or other
• Removing the radiator cap when the areas between combustion chamber and engine
radiator is hot is dangerous. Scalding coolant passage.
coolant and steam may shoot out and Repair or replace faulty parts, then go to Step 22.
cause serious injury.
• When removing the radiator cap, wrap a
thick cloth around and turn it slowly.
Remove radiator cap. Implement procedure to

bleed air from engine coolant, then run engine at
idle. Are there any small bubbles which make
engine coolant white at filling opening? No Go to next step.
Note
• Large bubbles are normal since they are
remaining air coming out from engine coolant
passage.
21 Inspect engine compression. Yes Go to next step
☞ Section B1, COMPRESSION INSPECTION.
No Implement engine overhaul, the go to next step.
Is it okay?
22 Clear DTC. Yes Go to applicable DTC inspection.
Verify DTC after running vehicle.
Is there any DTC stored?
CONTINUED
F1-59

DTC P0340 SGT signal is not detected
DETECTION No SGT signal input from CMP sensor when engine is started and 2.1 seconds have passed
CONDITION
• CMP sensor malfunction
• CMP sensor air gap incorrect
• Short to power supply circuit in wiring from CMP sensor terminal C to PCM terminal 2E
• Short to ground in wiring from CMP sensor terminal C to PCM terminal 2E
POSSIBLE CAUSE • Short to ground in wiring from CMP sensor terminal B to main relay terminal D
• Open circuit in wiring from CMP sensor terminal C to PCM terminal 2E
• Open circuit in wiring from CMP sensor terminal B to main relay terminal D
• Open circuit in wiring from CMP sensor terminal A to body ground
1 Verify stored DTC. Yes Inspect for open circuit in following wiring harnesses,
Have DTC PP0100, P0443, P0505, and/or P1250 then go to Step 11. • Main relay terminal D-purg
been stored? solenoid valve, PRC solenoid valve, IAC solenoid
valve, MAF sensor
No Go to next step.
2 Does CMP sensor or PCM connector have poor Yes Repair or replace connector, then go to Step 11.
connection? No Go to next step
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3 Disconnect CMP sensor connector. Yes Go to next step.
Is there battery positive voltage at CMP sensor (between main relay terminal D and CMP sensor
harness side connector terminal B? terminal B), then go to Step 11.
4 Disconnect CMP sensor connector. Yes Go to next step.
Is there 5 V at CMP sensor harness side connector (between PCM terminal 2E and CMP terminal C),
terminal C? then go to Step 11.
5 Disconnect PCM connector and CMP sensor con- Yes Go to next step.
nector.
Is there continuity between CMP sensor harness
side connector terminal C and PCM harness side No Repair open circuit, then go to Step 11.
connector terminal 2E?
terminal 2E to 1B? No Go to next step.
terminal 2E to body ground? No Go to next step.
8 Is there continuity from CMP sensor harness side Yes Go to next step.
terminal A to body ground? No Repair open circuit, then go to Step 11.
9 Connect CMP sensor connector. Connect NGS Yes Go to next step.
tester to DLC.
Turn ignition switch on. Access RPM PID.
Does RPM PID change when engine is running?
No Replace distributor and adjust ignition timing, then go
Note to Step 11.
2E terminal voltage with circuit tester.
10 Clear DTC from memory. Yes Go to Step 1
REPAIR PROCEDURE"? connectors.
Repair connectors and/or harnesses, then go to next
step.
CONTINUED
F1-60
DTC P0443 Purge solenoid valve circuit malfunction

Open or short circuit is observed in purge solenoid valve system when ignition switch is turned on.
DETECTION CONDITION
• Purge solenoid valve malfunction
• Poor connection of connectors at purge solenoid valve and/or PCM
• Short to power supply circuit in wiring from purge solenoid valve B to PCM terminal 2X
POSSIBLE CAUSE • Short to ground in wiring from purge solenoid valve terminal B to PCM terminal 2X
• Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground
• Open circuit in wiring from purge solenoid valve terminal B to PCM terminal 2X
• Open circuit in wiring from purge solenoid valve terminal A to main relay terminal D
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1 Verify stored DTC. Yes Inspect for open circuit following wiring harnesses,
Have DTC P0100, P0505, P0340, and/or P1250 then go to Step 9.
been stored? • Main relay terminal D-PRC solenoid valve, IAC
solenoid valve, MAF sensor, CMP sensor
No Go to next step
2 Does purge solenoid valve connector or PCM Yes Repair or replace connector, then go to Step 9.
connector have poor connection? No Go to next step.
3 Disconnect purge solenoid valve connector. Yes Go to next step.
Is there battery positive voltage at purge solenoid (between main relay terminal D and purge solenoid
valve harness side connector terminal A? valve terminal A), then go to Step 9.
4 Disconnect PCM connector Purge solenoid valve is Yes Go to next step.
disconnected.
Is there continuity between purge solenoid valve
harness side connector terminal B and PCM harness No Repair open circuit, then go to step 9.
side connector terminal 2X?
terminal 2X to 1B? go to Step 9.
No Go to next step.
terminal 2X to body ground? No Go to next step.
7 Is purge solenoid valve okay? Yes Go to next step
☞ EMISSION SYSTEM, PURGE SOLENOID
VALVE INSPECTION No Replace purge solenoid valve, then go to Step 9.

Is same DTC present after performing "AFTER
No Intermittent poor connection in wiring harness or
REPAIR PROCEDURE"?
connector.
step.
F1-61 CONTINUED
DTC P0505 Idle air control (IAC) valve circuit malfunction

DETECTION Open or short circuit is observed in idle air control, system
CONDITION
IAC valve malfunction Poor connection of connectors at IAC valve and/or PCM Short to ground in
wiring from IAC valve terminal B to PCM terminal 2W Short to power supply circuit in wiring from
IAC valve terminal B to PCM terminal 2W Short to ground in wiring from IAC valve terminal A to
main relay terminal D Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground
POSSIBLE CAUSE Open circuit in wiring from IAC valve terminal B to PCM terminal 2W Open circuit in wiring from IAC
valve terminal A to main relay terminal D
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1 Verify stored DTC. Yes Inspect for open circuit following wiring harnesses,
Have DTC P0100, P0340, P0443, and/or P1250 then go to Step 9.
been stored. • Main relay terminal D-PRC solenoid valve, MAF
sensor, CMP sensor, purge solenoid valve
No Go to next step
2 Does IAC valve connector or PCM connector have Yes Repair or replace connector, then go to Step 9.
poor connection? No Go to next step
3 Disconnect IAC valve connector. Yes Go to next step.
Is there battery positive voltage at IAC valve harness (between main relay terminal D and IAC valve ter-
side connector terminal A? minal A), then go to Step 9.
4 Disconnect PCM connector IAC valve is Yes Go to next step.
disconnected.
Is there continuity between IAC valve harness side
connector terminal B and PCM harness side con- No Repair open circuit, then go to step 9.
nector terminal 2W?
5 Is there continuity from PCM harness side connector Yes Repair short to power supply circuit, then go to Step 9.
terminal 2W to 1B?
No Go to next step.
6 Is there continuity from PCM harness side connector Yes Repair short to ground circuit, then go to Step 9,
terminal 2W to body ground? No Go to next step
7 Is resistance between IAC valve component side Yes Go to next step.
connector A and B as specified?
No Replace IAC valve, then go to Step 9.

Specification
8.7—10.5 Ω [23 °C {73.4 °F}]
8 Clear DTC from memory. Yes Go to Step 1
step.
9 Clear DTC from memory. Yes Go to applicable DTC inspection
REPAIR PROCEDURE"? No Troubleshooting completed
F1-62
CONTINUED
DTC P1110 Intake air temperature (IAT) sensor circuit malfunction

DETECTION Input from IAT sensor is below 0.1 V or above 4.9 V when ignition switch is turned on
CONDITION
• IAT sensor malfunction
• Poor connection of connectors at IAT sensor terminal and/or PCM
• Short to power supply circuit in wiring from IAT sensor terminal A to PCM terminal 2L
POSSIBLE CAUSE • Short to GND in wiring from IAT sensor terminal A to PCM terminal 2L
• Open circuit in wiring from IAT sensor terminal A to PCM terminal 2L
• Open circuit in wiring from IAT sensor terminal B to PCM terminal 2D
• Open circuit in wiring from PCM terminal 2C to engine GND
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1 Verify stored DTC. Have DTC P0100, P0115, Yes Inspect for open circuit in following wiring harnesses,
P0120, P0134, P0335, and/or P1170 been stored? then go to Step 7.
• PCM terminal 2D-ECT sensor, MAP sensor, O2S,
CMP sensor and/or TP sensor
• PCM terminal 2C-engine GND
No Go to next step.
2 Does IAT sensor connector or PCM connector have Yes Repair or replace connector, then go to Step 9.
3 Disconnect IAT sensor connector. Yes Go to next step.
Is there 5V at IAT sensor harness side connector (between PCM terminal 2L and IAT sensor terminal A),
terminal A? then go to Step 9.
4 Disconnect PCM connector. IAT sensor connector is Yes Go to next step.
disconnected. Is there continuity between IAT
sensor harness side connector terminal B and PCM
harness side connector terminal 2D? No Repair open circuit, then go to Step 9.
terminals 2L to 1B? No Go to next step.
terminal 2D to body GND? No Go to next step.
7 Is IAT sensor okay? Yes Go to next step.
☞ CONTROL SYSTEM, INTAKE AIR No Replace IAT sensor, then go to Step 9.
TEMPERATURE (IAT) SENSOR INSPECTION
☞ CONTROL SYSTEM, INTAKE AIR
TEMPERATURE (IAT) SENSOR
Repair connector and/or harness, then go to next step.
CONTINUED
F1-63
DTCP1170 Oxygen sensor (O2S) is stuck

DETECTION When O2S signal stays above 0.45V for 20 seconds after engine has reached normal operating
CONDITION temperature.
• O2S deterioration
• Fuel injector malfunction
• Pressure regulator malfunction
• Fuel pump malfunction
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• Fuel delivery hose clogging or leakage
• Fuel return hose and/or fuel filter clogging
• Leakage in intake-air system or exhaust system PCV valve malfunction
• Purge solenoid valve malfunction or purge solenoid hoses are hooked up incorrectly
• Ignition coil malfunction Insufficient compression
POSSIBLE CAUSE • Poor connection of connector
• Vacuum hose damage or looseness
Warning
Following troubleshooting flowchart contains fuel system diagnosis and repair procedures.
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Al-
ways keep sparks and flames away from fuel.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious Injuries
or death and damage. Fuel can also Irritate skin and eyes. To prevent this, always com-
plete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described
in this manual.

1 Verify stored DTC. Yes Inspect and repair DTC P0100, P0110, P0115, or
Have DTCs P0100, P0110 P0115, and/or P0120 P0120.
been stored? Go to Step 26.
No Go to next step.
CONTINUED
F1-64

2 Clear DTC. Yes Trouble is in process. Go to next step.
Verify RPM, ECT and VS PIDS.
Drive vehicle approx. 1 minute under same
condition.
Is DTC P1170 stored?
Note No Go to TROUBLESHOOTING, ENGINE SYMPTOM

• If NGS tester is not used, measure TROUBLESHOOTING, Intermittent Concerns.
following PCM terminal voltage with
voltmeter.
① SGT (terminal 2E)
② ECT sensor (terminal 2Q)
③ Vehicle speed (terminal 1 M)
3 Implement PID/DATA.MONITOR AND RECORD Yes Implement TROUBLESHOOTING, ENGINE
(ECT, RPM, TP V) from DIAGNOSTIC DATA LINK DIAGNOSTIC INSPECTION, Input Signal System
using NGS tester. Is there any signal that is far out Investigation Procedure and repair or replace then
of specification when ignition switch is on, and go to Step 26.
engine is run at idle?
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Note
• If NGS tester is not used, measure
following PCM terminal voltage with No Go to next step.
voltmeter.
① ECT sensor (terminal 2Q)
② SGT (terminal 2E)
③ TP sensor (terminal 2K)
4 Continue monitoring items on previous PIDs. Yes Implement TROUBLESHOOTING, ENGINE
Is there any input signal which causes drastic DIAGNOSTIC INSPECTION, Input Signal System
changes when it is set to be in trouble condition? Investigation Procedure and repair or replace, then
go to Step 26.
No Go to next step.
5 Inspect exhaust system, upstream from O2S. Yes Repair or replace faulty exhaust parts, then
Is there any gas leakage? go to Step 26.
☞ EXHAUST SYSTEM, EXHAUST SYSTEM
No Go to next step.
6 Is O2S installed properly? Yes Go to next step.
No Install heated oxygen sensor properly, then
go to Step 26.
☞ CONTROL SYSTEM, OXYGEN SENSOR (O2S)
7 Implement FID/DATA MONITOR AND RECORD Yes Go to next step.
(O2S) from DIAGNOSTIC DATA LINK using NGS
tester. Is voltage on O2S as follows while racing
engine (in neutral)?
• More than 0.45V when accelerator pedal is No Inspect and repair or replace faulty O2S, harnesses,
suddenly pressed: rich condition connector or terminals, then go to Step 26.
• Less than 0.45V during fuel cut: lean ☞ CONTROL SYSTEM, OXYGEN SENSOR (O2S)
condition INSPECTION.
Note
2N voltages with voltmeter.
8 Inspect for open, poor connection and other Yes Repair or replace faulty harness, connector or
problems on the following harnesses, connectors, terminal, then go to Step 26.
and terminals (for fuel injector at each cylinder):
• From main relay to fuel injector
No Go to next step.
• From fuel injector to PCM Is there any trouble?
CONTINUED
F1-65

9 Inspect injection amount of each injector. Yes Replace faulty fuel injectors, then go to Step 26.
☞ FUEL SYSTEM, FUEL INJECTOR ☞ FUEL SYSTEM, FUEL INJECTOR
INSPECTION, Volume Test. REMOVAL/INSTALLATION.
Are there any injectors operating abnormally? (e.g.
No Go to next step.
injection amount, injection condition)
10 Inspect purge control system. Yes Go to next step.
INSPECTION, Purge Control Inspection. No By following system inspection, repair or replace faulty
Is it okay? parts, then go to Step 26.
11 Inspect PCV valve operation. Yes Go to next step.

☞ EMISSION SYSTEM, POSITIVE CRANKCASE
VENTILATION (PCV) VALVE INSPECTION.
No Replace PCV valve, then go to Step 26,
Is it okay?
12 Inspect fuel line pressure under trouble condition. Yes Inspect for leakage and injection amount.
☞ TROUBLESHOOTING, ENGINE SYSTEM ☞ FUEL SYSTEM, FUEL INJECTOR INSPECTION.
INSPECTION, Fuel Line Pressure Inspection. Replace faulty fuel injector, then go to Step 26.
Is fuel line pressure okay? No Go to next step.
13 Inspect pressure regulator. Yes Go to next step.
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☞ FUEL SYSTEM, PRESSURE REGULATOR No Replace pressure regulator, then go to Step 26.
INSPECTION.
☞ FUEL SYSTEM, PRESSURE REGULATOR
Is it okay?
REMOVAL/INSTALLATION,
14 Inspect air suction: Yes Repair or replace source of air suction, then
• From air cleaner to throttle body go to Step 26.
• From throttle body to dynamic chamber
• From dynamic chamber to intake manifold
Visually inspect for cracks and damage, and No Go to next step.
inspect fluctuation after spraying rust penetrating
agent, then select air suction area.
• Can air suction confirmed?
15 Inspect for air suction in vacuum hose, which has Yes Repair or replace source of air suction, then
negative pressure on intake manifold, in the same go to Step 26.
manner as previous step.
No Go to next step,
16 Inspect fuel line pressure under trouble condition. Yes Go to Step 22.
INSPECTION, Fuel Line Pressure Inspection. No Go to next step.
Is fuel line pressure okay?
17 Inspect fuel pump maximum pressure. Yes Go to next step.
☞ FUEL SYSTEM, FUEL PUMP UNIT
INSPECTION, Fuel Pump Maximum Pressure No Replace fuel pump body, then go to Step 26.
Inspection. ☞ FUEL SYSTEM, FUEL PUMP UNIT REMOVAL/
Is it okay? INSTALLATION.
18 Inspect for clogging in fuel filter (high-pressure). Is Yes Go to next step.
there foreign material in fuel on fuel pump side of
filter? No Go to Step 20.
19 Inspect inside of fuel tank for foreign material and Yes Replace fuel filter (high-pressure), then go to Step 26.
stains. ☞ FUEL SYSTEM, FUEL FILTER (HIGH-
Is inside of fuel tank okay? PRESSURE) REMOVAL/INSTALLATION.
No Clean inside of fuel tank and fuel filter (low-pressure).
Replace fuel filter, then go to Step 26.
20 Inspect for leakage and clogging in fuel line from Yes Go to next step.
distributor to fuel pump.
No Repair or replace source of fuel leakage or clogging,
Is it okay? then go to Step 26.
CONTINUED
F1-66

21 Inspect for leakage in fuel line from fuel filter (high- Yes Replace pressure regulator, then go to Step 26.
pressure) to fuel tank (return side). ☞ FUEL SYSTEM, PRESSURE REGULATOR
No Repair or replace source of fuel leakage, then
go to Step 26
22 Verify blinking condition on each cylinder by setting Yes Go to Step 24
timing light on high-tension lead under trouble
condition. No Go to next step.
Does it blink regularly and stably?
23 Inspect resistance of ignition coil. Yes Go to next step.
☞Section G, IGNITION COIL INSPECTION.
Is it okay? No Replace ignition coil, then go to Step 26.
24 Warning Yes Air gets in from poor sealing on head gasket or other
• Removing the radiator cap when the areas between combustion chamber and engine
radiator is hot is dangerous. Scalding coolant passage.
coolant and steam may shoot out and Repair or replace faulty parts, then go to Step 26.
cause serious injury.
• When removing the radiator cap, wrap a
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thick cloth around and turn it slowly.
Remove radiator cap. Implement procedure to
bleed air from engine coolant, then run engine at
idle. Are there any small bubbles, which make
engine coolant white at filling opening?
No Go to next step.
Note
• Large bubbles are normal since they are
remaining air coming out from engine
coolant passage.
25 Inspect engine compression. Yes Go to next step.

☞Section B1, COMPRESSION INSPECTION.
No Implement engine overhaul, then go to next step.
Is it okay?
26 Clear DTC. Yes Go to applicable DTC inspection.
Verify DTC after running vehicle.
Is there any DTC stored?
DTC P1195 Barometric pressure (BARO) sensor (in PCM)

DETECTION Input voltage from barometric pressure sensor is below 1.5 V or above 4.5 V when ignition switch
CONDITION is turned on.
POSSIBLE CAUSE • Barometric pressure sensor (in PCM) malfunction.
_ _ _ Replace PCM
☞ CONTROL SYSTEM, PCM
CONTINUED
F1-67
DTC P1250 PRESSURE REGULATOR CONTROL (PRC) solenoid valve circuit malfunction
DETECTION Open or short circuit is observed in PRC solenoid valve when Ignition switch is turned on
CONDITION
• PRC solenoid valve malfunction
• Poor connection of connectors at PRC solenoid valve and/or PCM
• Short to power supply circuit in wiring from PRC solenoid valve B to PCM terminal 2T
• Short to GND in wiring from PRC solenoid valve terminal B to PCM terminal 2T
POSSIBLE CAUSE • Short to GND in wiring from PRC solenoid valve terminal A to main relay terminal D
• Open circuit in wiring from PCM terminal 2T and/or 2C to engine GND
• Open circuit in wiring from PRC solenoid valve terminal B to PCM terminal 2T
• Open circuit in wiring from PRC solenoid valve terminal A to man relay terminal D
1 Verify stored DTC. Yes Inspect for open circuit in following wiring harnesses,
Have DTCs P0100, P0335, P0443 and/or P0505 then go to Step 9.
been stored? • Main relay terminal D-IAC valve, PRC solenoid
valve, MAF sensor, CMP sensor, purge solenoid
valve
• Between PCM terminal 2C and engine ground.
No Go to next step.
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2 Does PRC solenoid valve connector or PCM Yes Repair or replace connector, then go to Step 9.
3 Disconnect PRC solenoid valve connector. Yes Go to next step.
Turn ignition switch on. No Inspect for open or short circuit in wiring harness.
Is there battery positive voltage at harness side (between main relay terminal D and PRC solenoid
connector terminal A? valve terminal A), then go to Step 9.
4 Disconnect PCM connector. PRC solenoid valve is Yes Go to next step.
disconnected.
Is there continuity between PRC solenoid valve
harness side connector terminal B and PCM harness No Repair open circuit, then go to Step 9.
side connector terminal 2T?
5 Is there continuity between PCM harness side Yes Repair short to power supply circuit, then
connector terminals 2T and 1B? go to Step 9.
No Go to next step.
6 Is there continuity from PCM harness side connector Yes Repair short to GND circuit, then go to Step 9.
terminal 2T to body GND? No Go to next step.
7 Is PRC solenoid valve okay? Yes Go to next step.
☞ FUEL SYSTEM, PRESSURE REGULATOR
CONTROL (PRC) SOLENOID VALVE No Replace PRC solenoid valve, then go to Step 9.
INSPECTION
REPAIR PROCEDURE"? connectors. Repair connectors and/or harnesses,
then go to next step.

CONTINUED
F1-68

DTCP1608 PCM internal circuit malfunction
DETECTION PCM does not read DTC from output devices.
CONDITION
• PCM does not read DTC from output devices.
POSSIBLE CAUSE • Short to power supply circuit in wiring from output devices (purge solenoid valve, PRC solenoid
valve, IAC solenoid valve and/or fuel injectors) to PCM
1 Disconnect output devices and PCM connector. Yes Repair short to power supply circuit.
Is there continuity between the following Replace PCM.
connectors? ☞ CONTROL SYSTEM, PCM
• PCM harness side connector terminal 2X-1B REMOVAL/INSTALLATION
• PCM harness side connector terminal 2E-1B
• PCM harness side connector terminal 2W-1B No Replace PCM
• PCM harness side connector terminal 2U-1B ☞ CONTROL SYSTEM, PCM
• PCM harness side connector terminal 2V-1B REMOVAL/INSTALLATION
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CONTINUED
F1-69
TROUBLESHOOTING
TROUBLESHOOTING
FOREWORD
• Before proceeding with the following troubleshooting.
(1) Refer to section Gl to understand the basic troubleshooting procedure.
(2) Perform the diagnostic trouble code inspection.
(3) If the diagnostic trouble code is displayed, proceed with inspection steps for the code.
(4) When the engine can be started, perform "ENGINE TUNE-UP".
TROUBLESHOOTING ITEM TABLE

• Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart.
No. TROUBLESHOOTING ITEM DESCRIPTION
1 Melting of main or other fuses —
2 Will not crank Starter does not work.
Hard to start/long crank/erratic start/erratic Starter cranks engine at normal speed but engine requires excessive
3
crank cranking time before starting.
4 Engine stalls After start/at idle Engine stops unexpectedly at idle and/or after start.
5 Cranks normally but will not start Starter cranks engine at normal speed but engine will not run.
6 Slow return to idle Engine takes more time than normal to return to idle speed.
Engine speed fluctuates between specified idle speed and lower speed
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7 Engine runs rough/rolling idle
and engine shakes excessively.
Engine speed continues at fast idle after warm-up. Engine runs after
8 Fast idle/runs on
ignition switch is turned off.
Engine stops unexpectedly at beginning of deceleration or recovery
9 Low idle/stalls during deceleration
from deceleration.
Engine stops unexpectedly at beginning of acceleration or during
Engine stalls/quits Acceleration/cruise
acceleration. Engine stops unexpectedly while cruising.
Engine runs rough Acceleration/cruise Engine speed fluctuates during acceleration or cruising.
Misses Acceleration/cruise Engine misses during acceleration or cruising.
10
Acceleration/cruise/
Buck/jerk Vehicle bucks/jerks during acceleration, cruising, or deceleration.
deceleration
Hesitation/stumble Acceleration Momentary pause at beginning of acceleration or during acceleration.
Surges Acceleration/cruise Momentary minor irregularity in engine output.
11 Lack/loss of power Acceleration/cruise Performance is poor under load (e.g. power down when climbing hills).
Sound is produced when air/fuel mixture is ignited by something other
12 Knocking/pinging Acceleration/cruise
than spark plug (e.g. hot spot in combustion chamber).
13 Poor fuel economy Fuel economy is unsatisfactory.
14 Emissions compliance Emission compliance test is failed.
15 High oil consumption/leakage Oil consumption is excessive.
16 Cooling system concerns Overheating Engine runs at higher than normal temperature/overheats.
Engine takes excessive period for reaching normal operating

17 Cooling system concerns Runs cold
temperature.
18 Exhaust smoke Blue, black, or white smoke from exhaust system
19 Fuel odor (in engine compartment) Gasoline fuel smell or visible leakage
20 Engine noise Engine noise from under hood
21 Vibration concerns (engine) Vibration from under hood or driveline
A/C compressor magnetic clutch does not engage when A/C is turned
22 A/C does not work sufficiently
on.
A/C is always on/A/C compressor runs
23 A/C compressor magnetic clutch does not disengage.
continuously
24 A/C is not cut off under WOT conditions A/C compressor magnetic clutch does not disengage under WOT.
25 Exhaust sulphur smell Rotten egg smell (sulphur) from exhaust.
26 Intermittent concerns Symptom occurs randomly and is difficult to diagnose.
27 Constant voltage Incorrect constant voltage.
CONTINUED
F1-70
TROUBLESHOOTING
QUICK DIAGNOSTIC CHART

Possible factor
Starter motor malfunction (Mechanical or electrical)
Engine or transmission mounts improperly installed

Cooling system malfunction (Radiator, hoses, overflow
Starter circuit including ignition switch open
Improper tension or damaged drive belts
Water and anti-freeze mixed improperly

Charging system malfunction
Improper engine compression
Improper engine coolant level

Improper engine oil viscosity
Base engine malfunction

Improper engine oil level
system, thermostat, etc.)

Improper valve timing
Low or dead battery
Hydrolocked engine
Improper dipstick
Flywheel seized
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Troubleshooting item
1 Melting of main or other fuses
2 Will not crank x x x x x x
3 Hard to start/long crank/erratic start/erratic crank
4 Engine stalls After start/at idle X x x
5 Cranks normally but will not start X x x
6 Slow return to idle
7 Engine runs rough/rolling idle x x
8 Fast idle/runs on
9 Low idle/stalls during deceleration
Engine stalls/quits Acceleration/cruise x x
Engine runs rough Acceleration/cruise x x
Misses Acceleration/cruise x x
10 Acceleration/cruise/
Buck/jerk x x
deceleration
Hesitation/stumble Acceleration x x
Surges Acceleration/cruise x x
11 Lack/loss of power Acceleration/cruise x x
12 Knocking/pinging Acceleration/cruise x x
13 Poor fuel economy x x x x
14 Emissions compliance x x x x
15 High oil consumption/leakage x x x
16 Cooling system concerns Overheating x x X x
17 Cooling system concerns Runs cold x
18 Exhaust smoke x x
19 Fuel odor (in engine compartment)
20 Engine noise x x x
21 Vibration concerns (engine) x x
22 A/C does not work sufficiently.
A/C is always on/A/C compressor runs continuously
23
24 A/C is not cut off under WOT conditions
25 Exhaust sulphur smell
26 Intermittent concerns x
27 Constant voltage
CONTINUED
F1-71
TROUBLESHOOTING
Possible factor
Vacuum leakage (Vacuum hose damaged, mis-routing)

Air leakage from intake-air system (Tubes looseness,
Initial ignition timing misadjustment (CMP & crankshaft pulley
High-tension leads malfunction (Cracks , open, low

Ignition coil malfunction (e.g. open short or cracks)
CMP sensor damaged (e.g. open or short circuits)

Accelerator cable free play misadjustment
Air cleaner element clogged or restriction

Cooling fan seated improperly
IAC valve improper operation

Throttle body malfunction
crack, gaskets broken)
Spark plug malfunction

Engine overheating
misadjustment
resistance)
Fuel quality
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2 Will not crank
3 Hard to start/long crank/erratic star/erratic crank x x x x x x x
4 Engine stalls After start/at idle x x x x x x x x x x x
5 Cranks normally but will not start x x x x x x x x x x
6 Slow return to idle x
7 Engine runs rough/rolling idle x x x x x x x x x
8 Fast idle/runs on x
9 Low idle/stalls during deceleration x x
Engine stalls/quits Acceleration/cruise x x x x x x x x
Engine runs rough Acceleration/cruise x x x x x x x x
Misses Acceleration/cruise x x x x x x x x
10 Acceleration/cruise/
Buck/jerk deceleration x x x x x x x x
Hesitation/stumble Acceleration x x x x x x x x
Surges Acceleration/cruise x x x x x x x x
11 Lack/loss of power Acceleration/cruise x x x x x x x
12 Knocking/pinging Acceleration/cruise x
13 Poor fuel economy x x x x
14 Emissions compliance x x x x x
15 High oil consumption/leakage
16 Cooling system concerns Overheating
17 Cooling system concerns Runs cold
18 Exhaust smoke x x x
20 Engine noise x x
21 Vibration concerns (engine) x
22 A/C does not work sufficiently.
23 continuously
24 A/C is not cut off under WOT conditions
25 Exhaust sulphur smell x
26 Intermittent concerns x x x x x x
27 Constant voltage
F1-72 CONTINUED
TROUBLESHOOTING
Possible factor
Fuel pump body malfunction (Mechanical or electrical
Fuel leakage from fuel system (Including insulator,
Evaporative emission control system malfunction
Main relay malfunction (Mechanical or electrical)

Injectors malfunction (Leakage or clogging,
PRC solenoid valve improper operation
V-reference supply circuit malfunction

Improper air/fuel mixture ratio control
Exhaust system restricted or clogged

Fuel hoses restricted or clogged
Fuel filters restricted or clogged
Catalytic converter malfunction

Pressure regulator malfunction
ECT sensor malfunction

PCV valve malfunction
injector O-ring)
inoperative)
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Melting of main or other fuses 1
Will not crank 2
x x x x x x x x x Hard to start/long crank/erratic start/erratic crank 3
x x x x x x x x x x After start/at idle Engine stalls 4
x x x x x x x x x x x Cranks normally but will not start 5
x Slow return to idle 6
x x x x x x x x x Engine runs rough/rolling idle 7
x Fast idle/runs on 8
x x Low idle/stalls during deceleration 9
x x x x x x x x x x x Acceleration/cruise Engine stalls/quits
x x x x x x x x x x x Acceleration/cruise Engine runs rough
x x x x x x x x x x x Acceleration/cruise Misses
Acceleration/cruise/ 10
x x x x x x x x x x x Buck/jerk
deceleration
x x x x x x x x x x x Acceleration Hesitation/stumble
x x x x x x x x x x x Acceleration/cruise Surges
x x x x x x x Acceleration/cruise Lack/loss of power 11
x x Acceleration/cruise Knocking/pinging 12
x x x x x x x Poor fuel economy 13
x x x x x x x x x Emissions compliance 14
x High oil consumption/leakage 15
Overheating Cooling system concerns 16
Runs cold Cooling system concerns 17
x x x x x x Exhaust smoke 18
x x x Fuel odor (in engine compartment) 19
Engine noise 20
Vibration concerns (engine) 21
A/C does not work sufficiently. 22
23
continuously
A/C is not cut off under WOT conditions 24
x Exhaust sulphur smell 25
x x x x x x x x Intermittent concerns 26
Constant voltage 27
CONTINUED
F1-73
TROUBLESHOOTING
Possible factor
Neutral or clutch switch and related circuit malfunction
TP sensor misadjustment (Including looseness)

Variable resistor and related circuit malfunction
A/C relay (A/C control signal) circuit malfunction

Brake switch and related circuit malfunction
MAF sensor and related circuit malfunction
PSP switch and related circuit malfunction

TP sensor and related circuit malfunction
Improper refrigerant charging amount
VSS and related circuit malfunction
Wheels and tires improper balance
Suspension malfunction
Drive line malfunction
Improper ATF level
(Except Europe)
Clutch slippage
Brake dragging
Loose parts
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2 Will not crank
3 Hard to start/long crank/erratic start/erratic crank x
4 Engine stalls after start/at idle x x
5 Cranks normally but will not start
6 Slow return to idle
7 Engine runs rough/rolling idle x x x
8 Fast idle/runs on
9 Low idle/stalls during deceleration x x x x x x
Engine stalls/quits acceleration/cruise x x x x x x x
Engine runs rough acceleration/cruise x x x x x x x
Misses acceleration/cruise x x x x x x x
10 acceleration/cruise/
Buck/jerk x x x x x x x
deceleration
Hesitation/stumble acceleration x x x x x x x
Surges acceleration/cruise x x x x x x x
11 Lack/loss of power acceleration/cruise x x x x x
12 Knocking/pinging acceleration/cruise x
13 Poor fuel economy x x
14 Emissions compliance
15 High oil consumption/leakage
16 Cooling system concerns overheating x x
17 Cooling system concerns runs cold
18 Exhaust smoke
20 Engine noise x
21 Vibration concerns (engine) x x x
22 A/C does not work sufficiently. x x
A/C is always on/A/C compressor runs continuously x
23
24 A/C is not cut off under WOT conditions x x
25 Exhaust sulphur smell
26 Intermittent concerns x x x x x x
27 Constant voltage x x
CONTINUED
F1-74
BACK.TO.CHAPTER.INDEX RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
TO. MODEL .INDEX
SYMPTOM TROUBLESHOOTING:
Symptom 1-Melting of main or other fuses FI-75

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

MAIN (80 A) MAIN fuse
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Generator
Ignition switch
Starter
Ignition coil
Condenser
HEAD (30 A) HEAD fuse
• Generator
A/C (10A) A/C relay
• Generator
WIPER (15 A) WIPER fuse
• A/C relay
• A/C switch
STOP (15 A) STOP fuse
• Brake switch
FUEL INJ (30 A) Main relay
• Fuel injector
• PCM
• PRC solenoid valve
• Purge solenoid valve
• IAC valve
• MAF sensor
• CMP sensor
ROOM (10 A) ROOM fuse
• PCM
ENGINE (15 A) ENGINE fuse
• Main relay
• Fuel pump relay
Fuel pump relay
• Fuel pump
METER (15 A) METER fuse
• PCM
CONTINUED
F1-75
TROUBLESHOOTING
SYMPTOM 2 WILL NOT CRANK

DESCRIPTION • Starter does not work.
• Open circuit between ignition switch and starter
POSSIBLE
• Starter malfunction
CAUSE
• Seized/hydrolocked engine or flywheel
STEP INSPECTION RESULTS ACTION
1 Inspect for following: Yes Go to next step.
• Battery connection
• Battery condition No Service as necessary.
• Fuses Are all items okay? Repeat Step 1.
2 Is clicking sound heard from starter when Yes Go to next step.

ignition switch is turned to START? No Go to Step 4.
3 Inspect starting system. Yes Inspect for seized/hydrolocked engine or flywheel.
☞ Section G, STARTING SYSTEM, ☞ Section H, FLYWHEEL, FLYWHEEL
STARTER INSPECTION Is starting INSPECTION
system okay? No Repair or replace components as required.
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4 Do any other electrical accessories work? Yes Go to next step.
No Inspect charging system.
☞ Section G, CHARGING SYSTEM, GENERATOR
INSPECTION
5 Connect NGS tester to DLC. Yes No DTC is displayed:
Turn ignition switch on. Inspect following:
Retrieve any DTC. • START circuit in ignition switch
Is "NO CODES RECEIVED" or "SYSTEM • Open circuit between ignition switch and starter
PASSED" displayed?
No DTC is displayed:
Go to appropriate DTC test.
Communication error message is displayed:
Inspect for following:
• Open circuit between main relay and PCM
terminal 1B
• Open main relay GND circuit
• Main relay is stuck open.
• Open or poor GND circuit at PCM
• Poor connection of vehicle body GND
6 Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
F1-76
TROUBLESHOOTING
SYMPTOM 3 HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK

• Starter cranks engine at normal speed but engine requires excessive cranking time before starting.
DESCRIPTION
• Battery in normal condition.
• Spark leakage from high-tension leads
• Vacuum leakage Poor fuel quality
• Starting system malfunction
• Spark plug malfunction
• Air leakage from intake-air system
• Erratic signal from CMP sensor
• Air cleaner restriction PCV valve malfunction
• Inadequate fuel pressure
• MAF sensor contamination
• Restriction in exhaust system
POSSIBLE • Pressure regulator control (PRC) system malfunction
CAUSE
Warning
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damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR
PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
• Vacuum leakage
• Fuel quality (e.g. proper octane, contami-
nation, winter/summer blend)
• Loose bands on intake-air system No Service as necessary.
• Cracks on intake-air system parts
• Air cleaner restriction Are all items okay?

Turn ignition switch on. Go to next step.
Retrieve any DTC.
Is "NO CODES RECEIVED" or "SYSTEM
PASSED" displayed?
3 Is engine overheating? Yes Go to symptom troubleshooting No.16 for "Cooling system
concerns - Overheating".
No Go to next step.
4 Inspect for cracks on high-tension leads. Yes Repair suspected high-tension leads.
Are there any cracks on high-tension leads? No Go to next step.
5 Inspect spark plug conditions. Yes Spark plug is wet or covered with carbon:
Is spark plug wet, covered with carbon or Inspect for fuel leakage from fuel injector.
grayish white? Spark plug is grayish white:
Inspect for clogged fuel injector.
No Install spark plugs on original cylinders.
Go to next step.
6 Visually inspect CMP sensor. Yes Go to next step.
Is CMP sensor okay? No Replace malfunctioning parts.
7 Remove PCV valve and inspect PCV valve. Yes Go to next step.
Does PCV valve rattle? No Replace PCV valve.
CONTINUED
F1-77
TROUBLESHOOTING

8 Install fuel pressure gauge between fuel filter Yes Go to next step.
and fuel distributor.
No Zero or low:
Connect a jumper wire between F/P terminal at
Inspect fuel pump circuit.
DLC in engine compartment and GND.
☞ TROUBLESHOOTING, ENGINE SYSTEM Inspect for open fuel pump relief valve.
INSPECTION, Fuel Line Pressure Inspect for fuel leakage inside pressure regulator.
Inspection Inspect for clogged main fuel line.
Turn ignition switch on. Inspect PRC solenoid valve and related vacuum hose
Is fuel line pressure correct? and harnesses.
Fuel line pressure High:
2
270—310 kPa {2.7—3.2 kgf/cm , 39—45 psi} Inspect pressure regulator for high pressure cause.
Inspect for clogged fuel return line.
9 Is fuel line pressure held after ignition switch is Yes Go to next step.
turned off?
Fuel line pressure No Inspect pressure regulator diaphragm condition.
More than If condition is okay, inspect fuel injector.
2
150 kPa {1.5 kgf/cm ,21 psi} for 5 min. If condition is not okay, replace pressure regulator.
10 Disconnect vacuum hose from pressure Yes Go to next step.
regulator and plug hose.
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Start engine.
Does fuel line pressure remain within ± 20 kPa No Inspect for clogged fuel filter.
2
{0.21 kgf/cm , 3 psi} while driving vehicle?
11 Connect vacuum hose to pressure regulator. Yes Go to next step.

Install vacuum gauge to intake manifold.
No Connect vacuum hose to pressure regulator.
Start engine.
Start engine.
Does fuel pressure gauge reading increase as
vacuum gauge reading decreases and/or fuel Verify fuel pressure gauge reading changes as vacuum
pressure gauge reading decrease as vacuum changes.
gauge reading increases? If it changes, inspect vacuum line.
If it does not change, replace pressure regulator.
12 Disconnect a vacuum hose from purge solenoid Yes Inspect if purge solenoid valve sticks to open.
valve and plug opening end of vacuum hose.
Start engine.
Is starting condition improved? No Go to next step.
13 Inspect for contaminated MAP sensor. Yes Replace MAP sensor.

Is there any contamination? No Go to next step.
14 Is there restriction in exhaust system? Yes Inspect exhaust system.
No Go to next step.
15 Inspect starting system. Yes Inspect for loose connectors or poor terminal contact.
☞ Section G, STARTING SYSTEM,
STARTER INSPECTION No Repair or replace components as required.
Is starting system normal?
CONTINUED
F1-78
TROUBLESHOOTING
SYMPTOM 4 ENGINE STALLS - AFTER START / AT IDLE

DESCRIPTION • Engine stops unexpectedly at idle and/or after start.
• A/C system operation is improper.
• Air leakage from intake-air system parts
• Improper operation of IAC valve
• No signal from CMP sensor due to sensor related wire or wrong installation
• Vacuum leakage
• Low engine compression
• Poor fuel quality
• PCV valve malfunction
• Air cleaner restriction
• Electrical connector disconnection
• Open or short circuit in fuel pump body and related harness
POSSIBLE • No battery power supply to PCM or poor GND
CAUSE • Inadequate fuel pressure
• Fuel pump body mechanical malfunction
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• Fuel leakage from fuel injector
• Fuel injector clogging
• Pressure regulator control (PRC) system malfunction
Warning
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always
• keep sparks and flames away from fuel.
• Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death
• and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE
• REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.

1 Verify following: Yes Go to next step.
• Vacuum connection
• Air cleaner element
• No air leakage from intake-air system
• No restriction of intake-air system
• Proper sealing of intake manifold and
components attached to intake manifold No Service as necessary.
(e.g. IAC valve)
Repeat Step 11.
• Ignition wiring
• Electrical connections
• Smooth operation of throttle valve
Are all items okay?
2 Turn ignition switch on. Yes Go to next step.
Disconnect TP sensor connector.
Measure voltage at TP sensor connector
VREF terminal with ignition switch on. No Go to symptom troubleshooting No.27 "Constant voltage".
Voltage
4.5—5.5 V
Is voltage okay?
CONTINUED
F1-79
TROUBLESHOOTING

Retrieve any DTC.
No DTC Is displayed:
Is "NO CODES RECEIVED" or SYSTEM
PASSED" displayed?
Communication error message is displayed:
• Open circuit between main relay and PCM terminal 1B
• Main relay stuck open
• Open PCM GND circuit (terminal 2A, 2B or 2C)
4 Attempt to start engine at part throttle. Yes Inspect IAC valve and wiring harness.
Does engine run smoothly at part throttle? No Go to next step.
5 Connect NGS tester to DLC. Yes Go to next step.
Access RPM PID. No Inspect for following:
Is RPM PID indicating engine speed during • Open or short circuit In CMP sensor
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cranking of engine?
• Open or short circuit between CMP sensor and PCM
terminal 2E
• Open or short circuit in CMP sensor harnesses If CMP
sensor and harness okay, go to next step.
7 Inspect for cracks on high-tension leads Yes Repair suspected high-tension lead.
8 Is strong blue spark visible at each discon- Yes Go to next step.
nected high-tension lead while cranking If symptom occurs with A/C on, go to Step 14.
engine?
No Inspect for following:
• Open or short circuit in ignition coil
• Open circuit in high-tension leads
• Open circuit between igniter connector GND terminal
and body GND
• Open circuit between ignition switch and ignition coil
• Open circuit between ignition coil and condenser
• Open circuit between condenser and igniter
• Open circuit between ignition coil and igniter
• Open circuit between igniter and PCM terminal 2F
9 Inspect spark plug condition. Yes Spark plug is wet or covered with carbon:
Is spark plug wet, covered with carbon, or Inspect for fuel leakage from injector.
Go to next step.
10 Remove and shake PCV valve. Yes Go to next step.
11 Is there any restriction in the exhaust system? Yes Inspect exhaust system.
No Go to next step.
CONTINUED
F1-80
TROUBLESHOOTING

12 Install fuel pressure gauge between fuel main Yes Go to next step.
pipe and fuel distributor. No Zero or low:
Connect jumper wire between F/P terminal at
DLC and GND.
Turn ignition switch on. Is fuel line pressure Inspect for open fuel pump relief valve.
correct with ignition switch on? Inspect for fuel leakage inside pressure regulator.
Fuel line pressure Inspect for clogged main fuel line.
270—310kPa Inspect PRC solenoid valve, related vacuum hose and
2
{2.7—3.2 kgf/cm , 39—45 psi} related harnesses.
High:
Inspect pressure regulator for high pressure cause.
13 Visually inspect for fuel leakage at fuel injector, Yes Go to next step.
O-ring, and fuel line.
Service as necessary.
Does fuel line pressure hold after ignition No Inspect pressure regulator diaphragm condition.
switch is turned off? If condition is okay, inspect fuel injector.
Fuel line pressure If condition is not okay, replace pressure regulator.
More than 150 kPa {1.5 kgf/cm 2,21 psi} for 5
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min.
14 Note Yes Go to next step.
• The following test is for stall concerns
with A/C on. If other symptoms exist, go
to next step.
Connect pressure gauges to A/C low and high No If A/C is always on, go to symptom troubleshooting No.23
pressure side lines. Turn A/C on and measure "A/C is always on / A/C compressor runs continuously".
low side and high side pressure. For other symptoms, inspect following:
☞ Section U, REFRIGERANT SYSTEM • Refrigerant charging amount
SERVICE PROCEDURE, REFRIGER-
ANT PRESSURE CHECK
Is pressure within specifications?
15 Disconnect vacuum hose between purge Yes Inspect if purge solenoid valve sticks to open.
solenoid valve and dynamic chamber from Inspect evaporative emission control system.
purge solenoid side. Plug opening end of
vacuum hose.
Start engine. No Go to next step.
Is engine stall now eliminated?
16 Is air leakage felt or heard at intake-air system Yes Repair or replace.
components while racing engine to higher
speed? No Go to next step.
17 Is engine compression correct? Yes Inspect valve timing.

No Inspect for cause.
CONTINUED
F1-81
TROUBLESHOOTING
SYMPTOM 5 CRANKS NORMALLY BUT WILL NOT START

• Starter cranks engine at normal speed but engine will not run.
• Refer to "Engine stalls" if this symptom appears after engine stall.
DESCRIPTION • Fuel in tank.
• Battery in normal condition.
• No battery power supply to PCM
• Open PCM GND or vehicle body GND
• No signal from CMP sensor due to sensor related wire or incorrect installation
• Vacuum leakage
• Disconnected electrical connector
• Open or short circuit in fuel pump body and related harness
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POSSIBLE
CAUSE
• Fuel leakage from injector
• Fuel injector is clogged.
• Pressure regulator control (PRO) system malfunction
Warning
PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual.
• External fuel shut off or accessory (kill
switch, alarm etc.)
components attached to intake manifold No Service as necessary.
(e.g. IAC valve) Repeat Step 11.
• Ignition wiring
• Fuses
Are all items okay?
CONTINUED
F1-82
TROUBLESHOOTING

Retrieve any DTC. No DTC is displayed:
Is "NO CODES RECEIVED" or "SYSTEM Go to appropriate DTC test.
PASSED" displayed? Communication error message is displayed:
• Open circuit between main relay and PCM terminal
1B
• Main relay stuck open
• Open PCM GND circuit (PCM terminal 2A, 2B or 2C)
3 Turn ignition switch on. Yes Go to next step.
Disconnect TP sensor connector.
Measure voltage at TP sensor connector
VREF terminal with ignition switch on.
No Go to symptom troubleshooting No.27 "Constant voltage",
Voltage
4.5—5.5 V
Is voltage okay?
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4 Does engine start with throttle closed? Yes Go to Step 18.
No Go to next step.
5 Will engine start and run smoothly at part Yes Inspect IAC valve and wiring harness.
throttle? No Go to next step.
Access RPM PID. No Inspect for following:
Is RPM PID indicating engine speed when • Open or short circuit in CMP sensor
cranking engine? • Open or short circuit between CMP sensor and PCM
terminal 2E
• Open or short circuit in CMP sensor harnesses
If CMP sensor and harness are okay, go to next step.
Is there any cracks on high-tension leads? No Go to next step.
9 Is strong blue spark visible at each Yes Go to next step.
disconnected high-tension lead while cranking
No Inspect for following:
engine?
• Open or short circuit in ignition coil
• Open circuit in high-tension leads
• Open circuit between igniter connector GND terminal
and body GND
• Open circuit between ignition switch and ignition coil
• Open circuit between ignition coil and condenser
• Open circuit between condenser and igniter
• Open circuit between ignition coil and igniter
• Open circuit between igniter and PCM terminal 2F
10 Inspect spark plug conditions. Yes If spark plug is wet or covered with carbon, inspect for fuel
Is spark plug wet, covered with carbon, or leakage from injector.
grayish white? If spark plug is grayish white, inspect for clogged fuel
injector.
Go to next step.
12 Is there any restriction in exhaust system? Yes Inspect exhaust system.
No Go to next step.
CONTINUED
F1-83
TROUBLESHOOTING

Connect jumper wire between F/P terminal at Inspect fuel pump circuit.
DLC in engine compartment and GND. Inspect for open fuel pump relief valve.
Turn ignition switch on. Inspect for fuel leakage inside pressure regulator.
Is fuel line pressure correct when ignition switch Inspect for clogged main fuel line.
is cycled on/off five times? Inspect PRC solenoid, related vacuum hose, and har-
Fuel line pressure nesses.
270—3-10 kPa High:
2
{2.7—3.2 kgf/cm , 39—45 psi} Inspect pressure regulator for high pressure cause.
14 Visually inspect for fuel leakage at fuel injector Yes Go to next step.
O-ring and fuel line.
Is fuel line pressure held after ignition switch is No Inspect pressure regulator diaphragm condition.
turned off? If condition is okay, inspect fuel injector.
Fuel line pressure If condition is not okay, replace pressure regulator.
More than 150 kPa {1.5 kgf/cm 2, 21 psi} for 5
min.
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15 Disconnect vacuum hose between purge Yes Inspect if purge solenoid valve sticks to open mechanically.
purge solenoid valve side.
Plug opening end of vacuum hose.
Is starting condition improved?
16 Is air leakage felt or heard at intake-air system Yes Repair or replace.
components while racing engine to higher
speed? No Go to next step.

No Inspect for causes.
CONTINUED
F1-84
TROUBLESHOOTING
SYMPTOM 6 SLOW RETURN TO IDLE

DESCRIPTION • Engine takes more time than normal to return to idle speed.
POSSIBLE • Thermostat is stuck open.
CAUSE • Throttle body malfunction
Retrieve any DTC.
PASSED" displayed?
2 Remove thermostat and inspect operation. Yes Engine coolant temperature and thermostat are okay.
☞ Section E, THERMOSTAT, Go to next step.
THERMOSTAT INSPECTION No Access ECT V PID on NGS tester.
Is thermostat okay? Inspect for both ECT V PID and temperature gauge on
instrument cluster readings.
If temperature gauge on instrument cluster indicates normal
range but ECT V PID is not same as temperature gauge
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reading, inspect ECT sensor.
If temperature gauge on instrument cluster indicates cold
range but ECT V PID is normal, inspect temperature gauge
and heat gauge unit.
3 Is throttle body free of contamination? Yes Inspect for air leakage from intake-air system components
while racing engine to higher speed.
No Clean or replace throttle body.
CONTINUED
F1-85
TROUBLESHOOTING
SYMPTOM 7 ENGINE RUNS ROUGH/ROLLING IDLE

• Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively.
DESCRIPTION
• Idle speed is too slow and engine shakes excessively.
• Purge solenoid valve malfunction (if equipped)
• Disconnected electrical connectors
POSSIBLE • Fuel leakage from fuel injector
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CAUSE
• Engine overheating
• Vacuum leakage
• Pressure regulator control (PRC) system malfunction
Warning

• External fuel shut off or accessory
components attached to intake manifold
(e.g. IAC valve) No Service as necessary.
• Ignition wiring Repeat Step 1.
• Fuses
• Smooth operation of throttle valve.
Are all items okay?

Retrieve any DTC.
PASSED" display? No DTC is displayed:
3 Is engine overheating? Yes Go to symptom troubleshooting No.16 "Cooling system

No Go to next step.
CONTINUED
F1-86
TROUBLESHOOTING

• Following test is for engine running rough
idle with A/C on concerns. If other symp-
toms exist, go to next step.
Connect pressure gauge to A/C low and high
pressure side lines. Start engine and run it at No If A/C is always on, go to symptom troubleshooting No.23
idle. Turn A/C switch on. Measure low side "A/C is always on / A/C compressor runs continuously".
and high side pressures. For other symptoms, inspect following:
☞ Section U, REFRIGERANT SYSTEM • Refrigerant charging amount
SERVICE PROCEDURE, REFRIGER-
ANT PRESSURE CHECK
Are reading pressures within specification?
5 Note Yes Inspect power steering pressure switch operation and
• Following test is for engine running rough wiring harness between power steering pressure switch
with P/S on. If other symptoms exist, go connector and PCM connector terminal 1P.
to next step.
Start engine and run it at idle.
Access PSP SW PID. No Go to next step.
Inspect if PSP SW PID is on while turning
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steering wheel right to left.
Is PSP SW PID okay?
Is spark plug wet, covered with carbon, or Inspect for fuel leakage from injector.
Go to next step.
9 Start engine and disconnect IAC valve con- Yes Go to next step.
nector.
Does rpm drop or engine stall? No Inspect IAC valve and wiring harness.
pipe and fuel distributor. No Zero or low
Start engine and run it at idle. Inspect fuel pump circuit
Measure fuel line pressure at idle. Inspect for open fuel pump relief valve
Is fuel line pressure correct at idle? Inspect for fuel leakage inside pressure regulator
Fuel line pressure Inspect for clogged main fuel line
210—250 kPa Inspect PRC solenoid valve, related vacuum hose
2
{2.1—2.6 kgf/cm , 30—36 psi} and harnesses
High
• Inspect pressure regulator for high pressure cause
• Inspect for clogged fuel return line
O-ring, and fuel line. Service as necessary.
Does fuel line pressure hold after ignition
switch is turned off? No Inspect pressure regulator diaphragm condition.
Fuel line pressure If condition is okay, inspect fuel injector.
2
More than 150 kPa {1.5 kgf/cm ,21 psi} for 5 If condition is not okay, replace pressure regulator.
min.
CONTINUED
F1-87
TROUBLESHOOTING

12 Connect NGS tester to DLC, Start the engine Yes Go to next step.
and run it at idle.
Access FHO2S PID.
Is FHO2S PID okay?
No Inspect and repair or replace faulty O2S, harness,
• More than 0.45 V when accelerator pedal connector or terminal, then go to next step.
is suddenly depressed: rich condition
• Less than 0.45 V during fuel cut: lean
condition
13 Disconnect vacuum hose between purge Yes Inspect if purge solenoid valve sticks open mechanically.
purge solenoid valve side. Plug opening end of
vacuum hose.
Does engine condition improve?
14 Remove and shake PCV valve. Does PCV Yes Go to next step.
valve rattle? No Replace PCV valve.
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No Go to next step.
No Inspect for causes.
CONTINUED
F1-88
TROUBLESHOOTING
SYMPTOM 8 FAST IDLE/RUNS ON

DESCRIPTION • Engine speed continues at fast idle after warm-up.
• Engine runs after ignition switch is turned off.
POSSIBLE • ECT malfunction
CAUSE • Air leakage from intake-air system
• Throttle body malfunction
Access ECT PID. No ECT PID is higher than 112°C {234°F}:
Start and warm up engine to normal operating
Go to symptom troubleshooting No.16 "Cooling system
temperature.
Is ECT PID reading between 112°C {234°F}
ECT PID is less than 82°C {180°F}:
and 82°C {180°F}?
Go to symptom troubleshooting No.17 "Cooling system
concerns - Runs cold".
Turn ignition switch on. Retrieve any DTC. Go to next step.
PASSED" displayed?
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3 Is there air leakage felt or heard at intake-air Yes Repair or replace parts as necessary.
system components while racing engine to
higher speed? No Verify accelerator cable free play.
CONTINUED
F1-89
TROUBLESHOOTING
SYMPTOM 9 LOW IDLE/STALLS DURING DECELERATION

DESCRIPTION • Engine stops unexpectedly at beginning of deceleration or recovery from deceleration.
• Vacuum leakage
• IAC valve malfunction
POSSIBLE • MAF sensor or related circuit malfunction
CAUSE • TP sensor or related circuit malfunction
• Brake switch or related circuit malfunction
• Neutral/clutch switch or related circuit malfunction
1 Does engine idle roughly? Yes Go to symptom troubleshooting No.7 for "Engine runs
rough/Rolling idle".
No Go to next step.
• Proper routing and no damage of vacuum
lines
• IAC valve is connected properly. No Service as necessary.
• No air leakage from intake-air system Are Repeat Step 2.
all items okay?
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Retrieve any DTC.
PASSED" displayed?
4 Does idle speed drop or stall when discon- Yes Go to next step.
necting IAC valve?
No Inspect following:
• Circuit from IAC valve to PCM connector terminal 2W for
open and short
• IAC valve for sticking If okay, go to next step.
5 Disconnect vacuum hose between purge Yes Inspect evaporative emission control system.
solenoid valve and dynamic chamber from
No Go to next step.
Drive vehicle.
6 Connect NGS tester to DLC. Yes Go to symptom troubleshooting No.26 for "Intermittent
Access TP V, MAP V, VS, BRK SW and NL concerns".
SW PIDs.
Monitor each PID while driving vehicle.
• TP V PID No TP V PID: Inspect TP sensor.
• MAF V PID MAF V PID: Inspect MAF sensor.
• VS PID BRK VS PID: Inspect VSS.
• SW PID BRK SW PID: Inspect brake switch.
• NL SW PID
NL SW PID: Inspect neutral switch and clutch switch.
Are PIDs okay?
☞ CONTROL SYSTEM, PCM INSPECTION
CONTINUED
F1-90
TROUBLESHOOTING
ENGINE STALLS/QUITS - ACCELERATION/CRUISE

ENGINE RUNS ROUGH - ACCELERATION/CRUISE
MISSES - ACCELERATION/CRUISE
SYMPTOM 10
BUCK/JERK - ACCELERATION/CRUISE/DECELERATION
HESITATION/STUMBLE - ACCELERATION
SURGES - ACCELERATION/CRUISE
• Engine stops unexpectedly at beginning of acceleration or during acceleration.
• Engine stops unexpectedly while cruising.
• Engine speed fluctuates during acceleration or cruising.
• Engine misses during acceleration or cruising.
DESCRIPTION
• Vehicle bucks/jerks during acceleration, cruising or deceleration.
• Momentary pause at beginning of acceleration or during acceleration.
• Momentary minor irregularity in engine output.
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• Vacuum leakage
• Improper valve timing due to jumping out of timing belt
• Intermittent open or short in fuel pump circuit
POSSIBLE • Inadequate fuel pressure
CAUSE • Fuel pump mechanical malfunction
• Intermittent open or short of MAF sensor, TP sensor and VSS
• Clutch slippage
Warning
(e.g. IAC valve) No Service as necessary.
• Ignition wiring Repeat Step 1.
Are all items okay?
CONTINUED
F1-91
TROUBLESHOOTING

Retrieve any DTC.
PASSED" displayed?
3 Is engine overheating? Yes Go to symptom troubleshooting No.16 "Cooling system
No Go to next step.
Access RPM PID, B+ PID, TP V PID, MAF V No RPM PID:
PID, and VS PID. Inspect CMP sensor and related harness for vibration,
• RPM PID intermittent open/short circuit.
• B+PID B+ PID:
• TP V PID Inspect for open circuit intermittently.
• MAF V PID MAF V PID:
• VS PID Inspect for open circuit of MAF sensor and related wire
harness intermittently.
Drive vehicle while monitoring PIDs.
TP V PID:
Are PIDs within specification? Inspect if output signal from TP sensor changes smoothly.
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☞ CONTROL SYSTEM, PCM INSPECTION VS PID:
Inspect for open circuit of VSS and related wire harness
intermittently.
6 Inspect spark plug condition. Yes Spark plug is wet or covered with carbon:
Is spark plug wet, covered with carbon, or Inspect for fuel leakage from fuel injector.
Go to next step.
8 Verify that throttle lever is resting on throttle Yes Go to next step.
valve stop screw and/or throttle valve orifice
plug. No Adjust as necessary.
Is lever in correct position?
9 Are there restrictions in the exhaust system? Yes Inspect exhaust system.
No Go to next step.
pipe and fuel distributor.
Connect jumper wire between F/P terminal at No Zero or low:
DLC in engine compartment and GND. Inspect fuel pump circuit.
Turn ignition switch on. Inspect for open fuel pump relief valve.
Is fuel line pressure correct with ignition switch Inspect for fuel leakage inside pressure regulator.
on? Inspect for clogged main fuel line.
270—310kPa Inspect pressure regulator for high pressure cause.
2
{2.7—3.2 kgf/cm , 39—45 psi} Inspect for clogged fuel return line.
O-ring, and fuel line. Service as necessary.
Does fuel line pressure hold after ignition switch
is turned off? No Inspect pressure regulator diaphragm condition.
Fuel line pressure If condition is okay, inspect fuel injector.
2
More than 150 kPa {1.5 kgf/cm , 21 psi} for If condition is not okay, replace pressure regulator.
5 min.
CONTINUED
F1-92
TROUBLESHOOTING

12 Install vacuum gauge to intake manifold. Yes Go to next step.
Start engine. No Connect vacuum hose to pressure regulator.
Does fuel pressure gauge reading increase as Start engine.
vacuum gauge reading decreases and/or does Verify that fuel pressure gauge reading changes as vacuum
fuel pressure gauge reading decrease as changes.
vacuum reading increases? If it changes, inspect vacuum line.
• The following test is for engine stalling with
A/C on. If other symptoms exist, go to next
step.
Connect a pressure gauge to A/C low and high No If A/C is always on, go to symptom troubleshooting No.23
pressure side lines. Turn A/C on and measure "A/C is always on / A/C compressor runs continuously".
low side and high side pressure. Is pressure For other symptoms, inspect following:
within specifications?
• Refrigerant charging amount
☞ Section U, REFRIGERANT SYSTEM
SERVICE PROCEDURES, REFRIGER-
ANT PRESSURE CHECK
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Drive vehicle. No Go to next step.
15 Is engine compression correct? Yes Inspect following:
• Valve timing
• Clutch
CONTINUED
F1-93
TROUBLESHOOTING
SYMPTOM 11 LACK/LOSS OF POWER - ACCELERATION/CRUISE

DESCRIPTION • Performance is poor under load e.g. power down when climbing hills).
• Improper A/C system operation
• Purge control solenoid malfunction
• Brake dragging
• Vacuum leakage
• Intermittent open or short in fuel pump circuit
POSSIBLE • Inadequate fuel pressure
CAUSE • Fuel pump mechanical malfunction
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• Intermittent open or short of MAP sensor, TP sensor and VSS
• Clutch slippage
Warning

No Service as necessary.
Repeat Step 1.
(e.g. IAC valve)
Are all items okay?
2 Connect NGS tester to DLC. Yes No DTC Is displayed:
Retrieve any DTCs.
Is "NO CODES RECEIVED" or "SYSTEM No DTC is displayed:
PASSED" displayed? Go to appropriate DTC test.
3 Is engine overheating? Yes Go to symptom troubleshooting No. 16 "Cooling system

No Go to next step.
CONTINUED
F1-94
TROUBLESHOOTING

Access RPM PID, MAF V PID, TP V PID, and
No RPM PID:
VS PID.
Inspect CMP sensor and related harness for vibration
• RPM PID and/or intermittent open/short circuit.
• MAP V PID MAF V PID:
• TP V PID Inspect for intermittent open circuit of MAF sensor and
• VS PID related wire harness.
TP V PID:
Drive vehicle while monitoring PIDs. Inspect if TP sensor output increases smoothly.
VS PID:
Are PIDs within specification?
Inspect for intermittent open circuit of VSS and related
☞ CONTROL SYSTEM, PCM INSPECTION
wire harness.
Is spark plug wet, covered with carbon or Inspect for fuel leakage from fuel injector.
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Go to next step.
No Go to next step.
Connect jumper wire between F/P terminal at No Zero or low:
DLC in engine compartment and GND. Inspect fuel pump circuit.
Turn ignition switch on. Inspect for open fuel pump relief valve.
Is fuel line pressure correct with ignition switch Inspect for fuel leakage inside pressure regulator.
on? Inspect for clogged main fuel line.
270—310 kPa Inspect pressure regulator for high pressure cause.
2
{2.7—3.2 kgf/cm , 39—45 psi} Inspect for clogged fuel return line.
10 Install vacuum gauge to intake manifold. Yes Go to next step.
Start engine. No Connect vacuum hose to pressure-regulator.
Does fuel pressure gauge reading increase as Start engine.
vacuum gauge reading decreases and/or does Verify that fuel pressure gauge reading changes as vacuum
fuel pressure gauge reading decrease as changes.
vacuum reading increases? If it changes, inspect vacuum line.
• Following test is for engine stalling with
A/C on concern. If other symptoms exist,
go to next step.
Connect pressure gauge to A/C low and high No If A/C is always on, go to symptom troubleshooting No.23
side pressure lines. "A/C always on/ A/C compressor runs continuously".
Turn A/C on and measure low side and high For other symptoms, inspect following:
side pressure. • Refrigerant charging amount
Is the pressure within specifications?
☞ Section U, REFRIGERANT SYSTEM
SERVICE PROCEDURES, REFRIGER-
ANT PRESSURE CHECK
12 Inspect for A/C cut off operation. Yes Go to next step.
Does A/C cut-off work properly? No Inspect A/C cut-off system components.
CONTINUED
F1-95
TROUBLESHOOTING

No Go to next step.
Drive vehicle.
14 Is engine compression correct? Yes Inspect following:
• Valve timing
• Clutch
• Brake system for dragging
CONTINUED
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F1-96
TROUBLESHOOTING
SYMPTOM 12 KNOCKING/PINGING - ACCELERATION/CRUISE

• Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.g. hot spot in
DESCRIPTION
combustion chamber).
• Engine overheating due to cooling system malfunction
• Inadequate engine compression
Warning
POSSIBLE Read following warnings before performing fuel system service:
CAUSE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE
REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
Access ECT P1D.
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Verify ECT PID is less than 116°C {241 °F}
No Inspect cooling system for cause of overheating.
while driving.
Is ECT PID less than specification?
Retrieve any DTC. No DTC is displayed:
Is "NO CODES RECEIVED" or "SYSTEM Go to appropriate DTC test.
PASSED" displayed?
3 Is engine compression correct? Yes Go to next step.
Measure fuel line pressure at idle.
Inspect for open fuel pump relief valve.
Is fuel line pressure correct at idle?
Fuel line pressure Inspect for fuel leakage inside pressure regulator.
Inspect for clogged main fuel line.
210—250kPa
2
{2.1—2.6 kgf/cm , 30—36 psi} High:
5 Install vacuum gauge to intake manifold. Yes Inspect ignition timing.
Start engine. No Connect vacuum hose to pressure regulator.
Does fuel pressure gauge reading increase as
Start engine.
vacuum gauge reading decreases and/or does
fuel pressure gauge reading decrease as Verify that fuel pressure gauge reading changes as vacuum
vacuum reading increases? changes.
If it changes, inspect vacuum line.
CONTINUED
F1-97
TROUBLESHOOTING
SYMPTOM 13 POOR FUEL ECONOMY

DESCRIPTION • Fuel economy is unsatisfactory.
• Contaminated air cleaner element
• Engine cooling system malfunction
• Improper automatic transmission fluid level
• Weak spark
• Improper coolant level
• Brake dragging
POSSIBLE • Contaminated MAF sensor
CAUSE • Improper engine compression
• Exhaust system clogging
Warning
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1 Inspect following: Yes Go to next step.
• Air cleaner element for contamination
• Automatic transmission fluid level
• Fuel quality No Service as necessary.
• Coolant level Are all items okay? Repeat Step 1.
Retrieve any DTCs.
PASSED" display? Go to appropriate DTC test.
Access ECT PID.
Drive vehicle while monitoring PID. No Inspect for coolant leakage, cooling fan operation, or
☞ CONTROL SYSTEM, PCM INSPECTION thermostat operation.
Is PID within specification?
4 Is strong blue spark visible at each discon- Yes Inspect for following:
nected high-tension lead while cranking en- • Spark plug malfunction
gine? Repair or replace malfunctioning parts.
If okay, go to next step.
No Inspect the following:
• High-tension leads
• Ignition coil and connector
Start engine and run it at idle. Inspect fuel pump circuit.
Measure fuel line pressure at idle. Inspect for open fuel pump relief valve.
Is fuel line pressure correct at idle? Inspect for fuel leakage inside pressure regulator.
210—250kPa High:
2
{2.1—2.6 kgf/cm , 30—36 psi} Inspect pressure regulator for high pressure cause.
CONTINUED
F1-98
TROUBLESHOOTING

No Go to next step.
8 Is brake system functioning properly? Yes Go to next step.
9 Inspect for contaminated MAF sensor. Yes Replace MAP sensor.
Is there any contamination? No Go to next step.
CONTINUED
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F1-99
TROUBLESHOOTING
SYMPTOM 14 EMISSION COMPLIANCE

DESCRIPTION • Emission compliance test is failed.
• Vacuum line leakage or blockage
• Cooling system malfunction
• Leakage from intake manifold
• PCV valve malfunction or incorrect valve installation
• Exhaust system clogging
• Fuel tank ventilation system malfunction
• Charcoal canister damage
• Excessive carbon built up in combustion chamber
POSSIBLE • Improper engine compression Improper valve timing
CAUSE
Warning
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• Vacuum lines for leakage or blockage
• Proper maintenance schedule followed No Service as necessary.
• Intake-air system and air cleaner element Repeat Step 1.
concerns: obstructions, leakage or dirt
Are all items okay?
Retrieve any DTC.
PASSED" displayed?
3 Is any other drivability concern present? Yes Go to appropriate symptom troubleshooting.
No Go to next step.
4 Connect NGS tester to DLC. Access ECT PID. Yes Go to next step.
Warm up engine and run it at idle. Is ECT PID
correct? No Inspect for coolant leakage, cooling fan operation or
thermostat operation.
5 Is strong blue spark visible at each discon- Yes Inspect for following:
nected high-tension lead while cranking en- • Spark plug malfunction
gine? Repair or replace malfunctioning parts.
If okay, go to next step.
Start engine and run it at idle. Inspect fuel pump circuit.
Measure fuel line pressure at idle. Inspect for open fuel pump relief valve.
Is fuel line pressure correct at idle? Inspect for fuel leakage inside pressure regulator.
210—250 kPa { High:
2.1—2.6 kgf/cm2, 30—36 psi} Inspect pressure regulator for high pressure cause.
CONTINUED
F1-100
TROUBLESHOOTING

7 Does fuel line pressure remain at specification Yes Go to next step.
for 60 seconds when ignition switch is turned
on?
Fuel line pressure No Inspect pressure regulator for high pressure cause.
210—250kPa
{2.1—2.6 kgf/cm 2, 30—36 psi}
9 Is there restriction in the exhaust system? Yes Inspect exhaust system.
No Go to next step.
10 Inspect for fuel saturation inside charcoal Yes Replace charcoal canister.
canister.
Is excessive amount of liquid fuel present in No Inspect fuel tank vent system.
canister?
SYMPTOM 15 HIGH OIL CONSUMPTION/LEAKAGE
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DESCRIPTION • Oil consumption is excessive.
POSSIBLE • Improper dipstick
CAUSE • Improper engine oil viscosity
• Engine internal parts malfunction
2 Inspect for following: Yes Inspect internal engine parts such as valves, valve
• External leakage guides, valve stem seals, cylinder head drain passage,
• Proper dipstick piston rings.
• Proper engine oil viscosity
Are all items okay?
Repeat Step 2.
CONTINUED
F1-101
TROUBLESHOOTING
SYMPTOM 16 COOLING SYSTEM CONCERNS - OVERHEATING

DESCRIPTION • Engine runs at higher than normal temperature/overheats.
• Improper coolant level
• Blown fuses Coolant leakage/Improper coolant level
• Excessive A/C system pressure
• Improper water/anti-freeze mixture
• Fans reverse rotation
• Poor radiator condition
POSSIBLE • Thermostat malfunction
CAUSE
• Radiator hose damage
• Improper or damaged radiator cap
• Main cooling fan is inoperative.
• Coolant overflow system malfunction
• Improper tension of drive belt
• Drive belt damage
• Engine coolant level
• Coolant leakage
• Water and anti-freeze mixture
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• Radiator condition
• Collapsed or restricted radiator hoses No Service as necessary.
• Radiator pressure cap Repeat Step 1.
• Overflow system
• Fan rotational direction
• Fuses
Are all items okay?
Retrieve any DTC.
PASSED" displayed?
3 Start engine and run it at idle speed. Yes Go to Step 5.
Turn A/C switch on. No Inspect for following and repair or replace as necessary:
Does A/C compressor engage? • Refrigerant charging amount
• Open circuit between A/C relay and PCM terminal 1J
• Seized A/C magnetic clutch
• A/C magnetic clutch malfunction
If all Items are okay, go to next step.
Access A/C SW PID on NGS tester. No Inspect for following:
Start engine and run it at idle speed. • Refrigerant pressure switch operation
Turn A/C switch on. • A/C switch stuck open
Does A/C SW PID read ON? • Open or short circuit between refrigerant pressure
switch and PCM terminal 1Q
• Open circuit of blower motor fan switch and resistor
(if blower motor does not operate)
• Evaporator temperature sensor and A/C amplifier
5 Is drive belt okay? Yes Go to next step.
No Replace drive belt.
6 Is there any leakage around heater unit in Yes Inspect and service heater for leakage.
passenger compartment? No Go to next step.
7 Is there any leakage at coolant hoses and/or Yes Replace malfunctioning parts.
radiator? No Go to next step.
CONTINUED
F1-102
TROUBLESHOOTING
8 Cool down engine. Yes Engine coolant temperature and thermostat are okay,
Remove thermostat and inspect operation. inspect engine block for leakage or blockage.
☞ Section E, THERMOSTAT, No Access ECT V PID on NGS tester.
THERMOSTAT INSPECTION Inspect for both ECT V and temperature gauge readings.
Is thermostat okay? If temperature gauge on instrument cluster indicates normal
range but ECT V is not same as temperature gauge
reading, inspect ECT sensor.
If temperature gauge on instrument cluster indicates
overheating but ECT V is normal, inspect temperature
gauge and heat gauge unit.
SYMPTOM 17 COOLING SYSTEM CONCERNS - RUNS COLD

DESCRIPTION • Engine takes excessive period for reaching normal operating temperature.
POSSIBLE • Thermostat malfunction
CAUSE • Cooling fan system malfunction
1 Is customer complaint "Lack of passenger Yes Inspect A/C and heater system.
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compartment heat" only? No Go to next step.
2 Does engine speed continue at fast idle? Yes Go to symptom troubleshooting No.8 "Fast idle/runs on".
No Go to next step.
3 Remove thermostat and inspect operation. Yes Access ECT V PID on NGS tester.
☞ Section E, THERMOSTAT, Inspect for both ECT V PID and temperature gauge on
THERMOSTAT INSPECTION instrument cluster readings.
Is thermostat okay? If temperature gauge on instrument cluster indicates
normal range but ECT V PID is not same as temperature
gauge reading, inspect ECT sensor.
If temperature gauge on instrument cluster indicates cold
range but ECT voltage is normal, inspect temperature
gauge and heat gauge unit.
No Replace thermostat.
CONTINUED
F1-103
TROUBLESHOOTING
SYMPTOM 18 EXHAUST SMOKE

DESCRIPTION • Blue, black, or white smoke from exhaust system.
Blue smoke (Burning oil):
• Engine internal oil leakage
White smoke (Water in combustion):
• Cooling system (coolant loss) malfunction
• Engine internal coolant leakage
Black smoke (Rich fuel mixture):
• Intake-air system is collapsed or restricted.
• Fuel return line is restricted.
• Excessive fuel pressure
POSSIBLE • Improper engine compression
CAUSE • Injector fuel leakage
• Ignition system malfunction
Warning
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1 What color is smoke coming from exhaust Blue Burning oil is indicated. Go to next step.
system? White Water in combustion is indicated. Go to Step 3.
Black Rich fuel mixture is indicated. Go to Step 4.
2 Remove and shake PCV valve. Yes Inspect for following:
Does PCV valve rattle? • Damaged valve guide, stems or valve seals
• Blocked oil drain passage in cylinder head
• Piston rings are not seated, seized or worn
• Damaged cylinder bore
If other drivability symptoms are present, return to diagnostic
index to service any additional symptoms.
No Replace PCV valve.
3 Does cooling system hold pressure? Yes Inspect for following:
• Cylinder head gasket leakage
• Intake manifold gasket leakage
• Cracked or porous engine block
If other drivability symptoms are present, return to diagnostic
index to service any additional symptoms.
• Collapsed or restricted intake-air system No Service as necessary,
• Restricted fuel return line Repeat Step 4.
Are all items okay?
5 Connect NGS tester to DLC. Yes No DTC Is displayed:
Turn ignition switch on. Retrieve any DTC. Go to next step.
CONTINUED
F1-104
TROUBLESHOOTING

Inspect fuel pump circuit Inspect for open fuel pump relief
Measure fuel line pressure at idle.
valve Inspect for fuel leakage inside pressure regulator
Is fuel line pressure correct at idle? Inspect for clogged main fuel line
210—250 kPa
2 Inspect pressure regulator for high pressure cause
{2.1—2.6 kgf/cm ,30—36 psi} Inspect for clogged fuel return line

on?
210—250kPa
{2.1—2.6 kgf/cm 2,30—36 psi}
8 Is strong blue spark visible at each discon- Yes Inspect spark plugs.
nected high-tension lead while cranking en-
gine?
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CONTINUED
F1-105
TROUBLESHOOTING
SYMPTOM 19 FUEL ODOR (IN ENGINE COMPARTMENT)

DESCRIPTION • Gasoline fuel smell or visible leakage,
• Excessive fuel pressure
• Fuel tank vent system blockage
• Charcoal canister malfunction
Warning

1 Visually inspect for fuel leakage at fuel injector Yes Go to next step,
O-ring and fuel line.
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Install fuel pressure gauge between fuel main
Then stop engine. Does fuel line pressure No Inspect pressure regulator for high pressure cause.
remain at specification for 60 seconds when
ignition switch is turned on and off?
Fuel line pressure
210—250 kPa
{2.1—2.6 kgf/cm 2, 30—36 psi}
2 Inspect for blockage/restriction or open be- Yes Replace vacuum hose.

tween engine vacuum port and charcoal
canister.
Inspect for blockage in fuel tank vent system. No Go to next step.
Is fault indicated?
3 Inspect purge solenoid valve. Yes Go to next step.

☞ EMISSION SYSTEM, PURGE SOLENOID
VALVE INSPECTION Is solenoid No Replace purge solenoid valve.
operating properly?
Turn ignition switch on. Inspect charcoal canister for fuel saturation.
Retrieve any DTC. If excessive amount of liquid fuel is present, replace
Is "NO CODES RECEIVED" or "SYSTEM charcoal canister.
PASSED" displayed? No DTC is displayed:
CONTINUED
F1-106
TROUBLESHOOTING
SYMPTOM 20 ENGINE NOISE

DESCRIPTION • Engine noise from under hood
Squealing, clicking or chirping noise:
• Improper engine oil level
• Improper drive belt tension
Rattling noise:
• Loose parts Hissing sound noise:
• Vacuum leakage
POSSIBLE • Loose spark plug
CAUSE • Air leakage from intake-air system
Rumbling or grinding noise:
• Improper drive belt tension
Rapping or roar noise:
• Exhaust system looseness
Other noise:
• Camshaft friction gear noise
1 Is squealing, clicking or chirping sound Yes Inspect engine oil level or drive belts.
present? No Go to next step.
2 Is rumbling or grinding sound present? Yes Inspect drive belt.
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No Go to next step.
3 Is rattling sound present? Yes Inspect location of rattle for loose parts.
No Go to next step.
4 Is hissing sound present? Yes Inspect following:
• Vacuum leakage
• Spark plug looseness
• Intake-air system leakage
No Go to next step.
5 Is rapping or roaring sound present? Yes Inspect exhaust system for loose parts.
No Go to next step.
6 Is knocking sound present? Yes Go to symptom troubleshooting No.12 "Knocking/ pinging".
No If noise comes from inside engine, inspect for friction gear

noise.
SYMPTOM 21 VIBRATION CONCERNS (ENGINE)

DESCRIPTION • Vibration from under hood or driveline
POSSIBLECAU • Loose attaching bolts or worn parts
SE • Component malfunctions such as worn parts
1 Inspect following components for loose at- Yes Inspect following systems:
taching bolts or worn parts: • Wheels
• Cooling fan • Driveline
• Drive belt and pulleys • Suspension
• Engine mounts
No Readjust or retighten engine mount installation position.
Are all items okay?
Service as necessary for other parts.
CONTINUED
F1-107
TROUBLESHOOTING
SYMPTOM 22 A/C DOES NOT WORK SUFFICIENTLY.

DESCRIPTION • A/C compressor magnetic clutch does not engage when A/C switch is turned on.
• Improper refrigerant charging amount
• Open A/C magnetic clutch
• Open circuit between A/C relay and A/C magnetic clutch
POSSIBLE • Poor GND of A/C magnetic clutch
CAUSE • Refrigerant pressure switch is struck open.
• A/C relay is stuck open.
• Seized A/C compressor
• Open circuit between A/C switch and PCM through both refrigerant pressure switch and A/C amplifier
Retrieve any DTC.
Go to appropriate DTC test,
PASSED" displayed?
2 Disconnect A/C compressor connector. Yes Inspect for GND condition of magnetic clutch on A/C
Start engine and turn A/C switch on. compressor.
Is there correct voltage at terminal of A/C If GND condition is okay, inspect for open circuit of magnetic
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compressor magnetic clutch connector? clutch coil.
Specification
More than 10.5V No Go to next step.
3 Connect NGS tester to DLC. Yes Inspect for stuck open A/C relay.
Access A/C SW PID on NGS tester. Replace as necessary.
Start engine.
Turn A/C switch on and set blower fan at any
speed. No Go to next step.
Does A/C SW PI Dread ON?
4 Disconnect refrigerant pressure switch con- Yes Inspect for following:
nector. • Refrigerant charging amount
Connect a jumper wire between terminals of • Refrigerant pressure switch operation
refrigerant pressure switch connector. No Inspect for following:
Start engine and turn A/C switch on. • A/C switch is stuck open.
Does A/C work? • Open circuit between refrigerant pressure switch and
PCM terminal 1Q
• Open circuit of blower motor fan switch and resistor (if
blower motor does not operate)
• Evaporator temperature sensor and A/C amplifier
• Open circuit between A/C amplifier and refrigerant
pressure switch
CONTINUED
F1-108
TROUBLESHOOTING
SYMPTOM 23 A/C IS ALWAYS ON /A/C COMPRESSOR RUNS CONTINUOUSLY.

DESCRIPTION • A/C compressor magnetic clutch does not disengage.
• Stuck engagement
• A/C relay is stuck closed.
POSSIBLE • Short to GND between A/C switch and PCM
CAUSE • Short to GND circuit between A/C relay and PCM
• A/C relay to magnetic clutch circuit shorts to battery power
Retrieve any DTC.
2 Start engine and run it at idle. Yes Inspect for following:
Turn A/C switch on. • A/C relay is stuck closed.
Remove A/C relay. • Short to GND circuit between A/C relay and PCM
terminal 1J
Does A/C magnetic clutch disengage?
If both items okay, go to next step.
No Inspect if circuit between A/C relay and magnetic clutch
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shorts to battery power circuit.
If circuit is okay, inspect magnetic clutch engagement or
clearance.
3 Connect NGS tester to DLC. Yes Inspect for short to GND circuit between refrigerant
Access A/C SW PID on NGS tester. pressure switch and PCM terminal 10.
Start the engine and turn A/C switch on.
Read A/C SW PID while disconnecting re-
frigerant pressure switch connector.
Note
• A/C SW PID should read OFF when dis- No Go to next step.
connecting connector. If A/C SW PID
reading remains ON, short to GND circuit
may be present.
Does A/C SW PID reading remain ON?
4 Reconnect refrigerant pressure switch Yes Inspect for following:
connector. • Short to GND circuit between A/C switch and A/C
Read A/C SW PID while turning off A/C switch. amplifier
Note • Short to GND circuit between A/C amplifier and
• A/C SW PID should read OFF when turn- refrigerant pressure switch
ing A/C switch off. If A/C SW PID reading
remains ON, short to GND circuit may be No Inspect for stuck closed A/C switch.
present.
Does A/C SW PID reading remain ON?
CONTINUED
F1-109
TROUBLESHOOTING
SYMPTOM 24 A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE (WOT) CONDITIONS
DESCRIPTION • A/C compressor magnetic clutch does not disengage under WOT.
POSSIBLE • TP sensor misadjustment
CAUSE • TP sensor is loosely installed.
1 Does A/C compressor disengage when A/C Yes Go to next step.
switch is turned off? No Go to symptom troubleshooting No.23 "A/C is always on /
A/C compressor runs continuously".
Turn ignition switch on. Inspect TP sensor for proper adjustment.
Retrieve any DTC.
3 Verify test results. If okay, return to diagnostic index to service any additional symptoms,
CONTINUED
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F1-110
TROUBLESHOOTING
SYMPTOM 25 EXHAUST SULPHUR SMELL

DESCRIPTION • Rotten egg smell (sulphur) from exhaust
• Electrical connectors are disconnected or connected poorly
• Charcoal canister malfunction
• Vacuum lines are disconnected or connected improperly.
• Improper fuel pressure
Warning
1 Are any drivability or exhaust smoke concerns Yes Go to appropriate flow chart.
present? No Go to next step.
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• Vacuum lines Are all items okay?
Repeat Step 2.
Retrieve any DTC.
4 Install fuel pressure gauge between fuel filter Yes Go to next step.
and fuel distributor. No Zero or low:
Is fuel line pressure correct at idle? Inspect for open fuel pump relief valve.
210—250kPa Inspect for clogged main fuel line.
2
{2.1—2.6 kgf/cm ,30—36 psi} High:
on?
210—250kPa
{2.1—2.6 kgf/cm 2, 30—36 psi}
6 Inspect charcoal canister for fuel saturation. Is Yes Replace charcoal canister.
excessive amount of liquid fuel present in
No Inspect fuel tank vent system.
canister?
If fuel tank vent system is okay, since sulfur content can
vary in different fuels, suggest trying a different brand.
If fuel tank vent system is not okay, repair or replace
malfunctioning parts.
CONTINUED
F1-111
TROUBLESHOOTING
SYMPTOM 26 INTERMITTENT CONCERNS

DESCRIPTION • Symptom occurs randomly and is difficult to diagnose.
1 Talk to customer. Yes Go to next step.
Retrieve vehicle service history.
Does vehicle have a number of previous repairs
and components replaced for a certain No Go to Symptom Index.
symptom?
2 Connect NGS tester to DLC. Yes Inspect each wire for corrosion, bent or loose terminal
If input is switch-type component, turn on crimps.
manually.
Access PIDs for suspect component.
Lightly tap on suspect component, wiggle and No Go to next step.
pull each wire/connector at suspect component
or PCM.
Are any PID values out of range, or do they
suddenly change and go back into range?
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3 Start engine. Yes Inspect each wire for corrosion, bent or loose terminal
Lightly tap on suspect component, wiggle and crimps.
pull each wire/connector at suspect component
or PCM.
No Go to next step.
Are any PID values out of range, or do they
suddenly change and go back into range?
4 Start engine. Yes Fault occurred while spraying component:
Accurately spray water on suspect component Replace part and verify repair.
wire, component or vacuum line related to Fault occurred while spraying wiring:
possible fault area. Inspect each wire for corrosion, bent or loose terminals
Are any PID values out of range, or do they and poor wire terminal crimps.
suddenly change and go back into range, or was Fault occurred while spraying vacuum line:
there a noticeable engine misfire/ stumble? Repair vacuum hoses.
No Inspect wire and connector at suspect component for
corrosion, bent or loose terminals, poor wire terminal crimps
and high tension of wire. Repair as necessary.
CONTINUED
F1-112
TROUBLESHOOTING
SYMPTOM 27 CONSTANT VOLTAGE

DESCRIPTION Incorrect constant voltage
• Constant voltage circuit malfunction
POSSIBLE Note
CAUSE • TP sensor and variable resistor (Except Europe) use constant voltage.
1 Disconnect TP sensor connector. Yes Repair constant voltage circuit short to power in harness.
Turn ignition switch on. Measure voltage
between following TP sensor and variable
resistor (Except Europe) connector terminals: No Go to next step.
• Constant voltage terminal - GND terminal
Is constant voltage greater than 6.0 volts?
2 Is voltage across battery terminals greater than Yes Go to next step.
10.5 volts? No Inspect charging system.
3 Turn ignition switch off. Leave TP sensor and Yes Go to next step.
variable resistor (Except Europe) connector
disconnected.
Measure voltage between battery positive
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terminal and GND circuit at TP sensor No Go to Step 8.
connector.
Is voltage greater than 10.5 volts and within
1.0 volt of battery voltage?
4 Note Yes Go to Step 7.
• The purpose of this step is to determine if
NGS tester is communicating with PCM.
Turn ignition switch on. No Go to next step.
Attempt to access ECT PID. Can ECT PID be
accessed?
5 Turn ignition switch off. Yes Go to next step.
Leave TP sensor and variable resistor (Except
Europe) connector disconnected.
Disconnect PCM connector.
Turn ignition switch on. No Repair open circuit between PCM terminal 1B and main
Measure voltage between PCM connector relay.
terminals 1B and 2B.
Is voltage greater than 10.5 volts?
6 Leave TP sensor, variable resistor (Except Yes Inspect for constant voltage at TP sensor and variable
Europe) and PCM connectors disconnected. resistor (Except Europe) connector again.
Disconnect NGS tester from DLC. If constant voltage is still out of range, replace PCM.
Measure resistance between PCM connector
terminals 2K and 2B. No Repair constant voltage circuit short to GND.
Is resistance greater than 10,000 ohms?
7 Turn ignition switch off. Yes Inspect for constant voltage at TP sensor and variable
Leave TP sensor and variable resistor (Except resistor (Except Europe) connector again.
Europe) connector disconnected. If constant voltage is still out of range, replace PCM.
Measure resistance between PCM connector
terminal 2K and constant voltage circuit at No Repair open constant voltage circuit.
appropriate sensor connector.
Is resistance less than 5.0 ohms?
• The purpose of this step is to determine if
NGS tester is communicating with PCM.
Reconnect TP sensor and variable resistor
(Except Europe) connector.
No Go to Step 10.
Attempt to access ECT PID.
Can ECT PID be accessed?
CONTINUED
F1-113
TROUBLESHOOTING

9 Turn ignition switch off. Yes Reconnect sensor connector.
Disconnect NGS tester from DLC. Go to appropriate DTC test.
Measure resistance between GND circuit at
appropriate sensor connector and PCM No Repair open GND circuit.
connector terminal 2D.
Is resistance less than 5.0 ohms?
10 Turn ignition switch off. Yes Go to next step.
Measure resistance between battery negative
terminal and PCM terminals 2A, 2B and 2C. Is No Repair open GND circuit.
each resistance less than 5.0 ohms?
11 Turn ignition switch off. Yes GND circuits are okay.
Measure resistance between GND circuit at Inspect for constant voltage at TP sensor and variable
following sensor connector and GND: resistor (Except Europe) connector again.
• ECT sensor
• O2S
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• IAT sensor
• MAF sensor No Inspect for open GND circuit.
• TP sensor
• Variable resistor (Except Europe)
Is each resistance less than 5.0 ohms?
CONTINUED
F1-114
TROUBLESHOOTING
DIAGNOSTIC INSPECTION Procedure
Spark Plug Condition Inspection Purpose 1. Remove the spark plug.
Inspecting spark plugs condition can determine whether 2. Inspect spark plug condition.
problem is related to a specific cylinder or to all cylinders. 3. Go to appropriate troubleshooting chart for further
information.
Spark plug condition Troubleshooting chart

Specific plug is wet or covered with carbon. Symptom 1 Wet/carbon stuck on specific plug
Specific plug looks grayish white. Symptom 2 Grayish white with specific plug
All plugs are wet or covered with carbon. Symptom 3 Wet/carbon stuck on all plugs
All plugs look grayish white. Symptom 4 Grayish white with all plugs
SYMPTOM 1 Wet/carbon stuck on specific plug

• Spark—No spark visible or spark weak
• Air/fuel mixture—Excessive fuel injection volume
• Compression—No compression, low compression
• Faulty spark plug
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair
procedures.
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CAUSE
1 Is spark plug wet/covered with carbon by engine Yes Working up and down inspect all areas related to oil.
oil? No Go to next step.
2 Inspect spark plug for following: Yes Go to next step.
• Cracked insulator
• Heating value
No Replace spark plug.
• Air gap
• Worn electrode Is spark plug okay?
3 Inspect compression pressure at suspected faulty Yes Go to next step.
cylinder.
☞ Section B1, COMPRESSION INSPECTION No Repair or replace malfunctioning parts.
Is compression pressure correct?
4 Install all spark plugs. Yes Go to next step.
Carry out spark test at suspected faulty cylinder.
Is strong blue spark visible? (Compare with No Repair or replace malfunctioning parts.
normal cylinder)
5 Carry out fuel line pressure inspection. Yes Inspect fuel injector for following:
☞ TROUBLESHOOTING, ENGINE SYSTEM • Open or short in injector
INSPECTION. Fuel Line Pressure Inspection • Leakage
Is fuel line pressure correct? • Injection volume
Fuel line pressure No Zero or low:
270—310 kPa {2.7—3.2 kgf/cm 2, 39—45 psi} Inspect fuel pump circuit.
Inspect for fuel pump relief valve open.
Inspect for fuel leakage inside pressure regulator.
High:
CONTINUED
F1-115
TROUBLESHOOTING
SYMPTOM 2 Grayish white with specific plug

POSSIBLE • Air/fuel mixture—Insufficient fuel injection volume
CAUSE • Faulty spark plug
1 Inspect spark plug for following: Yes Go to next step.
• Heating value
• Air gap Is spark plug okay? No Replace spark plug.
2 Remove suspected fuel injector. Inspect for Yes Inspect for open circuit between suspected fuel injector
following: terminal and PCM connector terminal.
☞ FUEL SYSTEM, FUEL INJECTOR
INSPECTION
• Resistance No Replace fuel injector.
• Fuel injection volume Are all above items
okay?
SYMPTOM 3 Wet/carbon stuck on all plugs

• Spark—Spark weak
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• Air/fuel mixture—Too rich
• Compression—Low compression
• Clogging in intake/exhaust system
Warning
and damage. Fuel can also Irritate skin and eyes. To prevent this, always complete "BEFORE
1 Is air cleaner element free of restriction? Yes Go to next step.
No Replace air cleaner element.
2 Carry out spark test. Yes Go to next step.
Is strong blue spark visible at each cylinder? No Repair or replace malfunctioning parts.
3 Carry out fuel line pressure inspection. Yes Go to next step.
☞ TROUBLESHOOTING, ENGINE SYSTEM No Zero or low:
INSPECTION. Fuel Line Pressure Inspection
Is fuel line pressure correct?
2
270—310 kPa {2.7—3.2 kgf/cm , 37—45 psi} Inspect for clogged main fuel line.
High:
4 Inspect following PIDs: Yes Go to next step.
☞ CONTROL SYSTEM, PID/DATA MONITOR
INSPECTION
• MAF V No Repair or replace malfunctioning parts.
• ECT
• FHO2S (When engine can be started)
Are PIDs okay?
5 Carry out purge control inspection. (When engine Yes Go to next step.
can be started) Is purge control correct?
No Repair or replace malfunctioning parts.
6 Carry out compression inspection. Yes Inspect for clogging in exhaust system.
Is compression correct? No Repair or replace malfunctioning parts.
F1-116 CONTINUED
TROUBLESHOOTING
SYMPTOM 4 Grayish white with all plugs
• Air/fuel mixture—Too lean
Warning
POSSIBLE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
CAUSE sparks and flames away from fuel.
• Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious Injuries or death
and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE

1 When engine cannot be started, inspect intake-air Yes Repair or replace malfunctioning parts.
system for air leakage.
When engine can be started, carry out intake
manifold vacuum inspection. No Go to next step.
Is air sucked in from intake-air system?
2 Carry out fuel line pressure inspection. Yes Inspect following PIDs:
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☞ TROUBLESHOOTING, ENGINE SYSTEM ☞ CONTROL SYSTEM, PID/DATA MONITOR
INSPECTION, Fuel Line Pressure Inspection INSPECTION
Is fuel line pressure correct? • MAF V
• ECT
Fuel line pressure
• FHO2S (When engine can be started)
270—310 kPa {2.7—3.2 kgf/cm 2, 37—45 psi} Inspect for PCM GND condition.
No Zero or low:
Inspect for fuel leakage inside pressure regulator.
High:
CONTINUED
F1-117
TROUBLESHOOTING
Inspection Using an Oscilloscope (Reference) Finding unusual signals
Purpose While referring to the diagnostic trouble code inspection
Using an oscilloscope, inspection such as stuck section of the on-board diagnostic system, use the
solenoid valve is made possible without actually PID/DATA MONITOR AND RECORD function to inspect the
removing parts. input signal system relating to the problem.
1. Turn the ignition on and run it at idle. You can assume
that any signals that are out of specifications by a wide
margin are unusual.
2. When recreating the problem, any sudden change in
monitor input signals that is not consciously created by
the driver can be judged as unusual.
Locating the source of unusual signals

Caution:
When normal • Compare the NGS monitor voltage with the
Counter electromotive voltage A, generated when the three- measurement voltage using the DIGITAL
way solenoid valve or the fuel injector is turned off from on, MEASUREMENT SYSTEM function. If you use
shows irregular convergence because induced electromotive another tester, misreading may occur.
voltage B, generated by the plunger return operation, is • When measuring voltage, attach the tester GND
added to it. to the GND of the PCM that is being tested, or to
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the engine itself. If this is not done, the
measured voltage and actual voltage may differ.
• After connecting the pin to a waterproof
coupler, confirming continuity and measuring
the voltage, inspect the waterproof connector
for cracks. If there are any, use sealant to fix
them. Failure to do this may result in
deterioration of the harness or terminal from
water damage, leading to problems with the
vehicle.
Variable resistance type 1 (Throttle position (TP)

When plunger is stuck
sensor and variable resistor (Except Europe))
When the plunger is stuck, pulse convergence is smooth
because no induced electromotive voltage B is generated.
Investigate the input signal system

1. When you get an unusual signal, measure the #1 PCM
terminal voltage.
(1) If the #1 terminal voltage and the NGS monitor
Input Signal System Investigation Procedure voltage are the same, proceed to the next step.
1. Find an unusual signal. (Refer to procedures below) (2) If there is a difference of 0.5 V or more, inspect the
following points concerning the PCM connector.
2. Locate its source. (Refer to procedures below)
• Female terminal opening loose
3. Repair or replace the defective part.
4. Confirm that the unusual signal has been erased. • Coupler (pin holder) damage
• Pin discoloration (blackness)
• Harness/pin crimp is loose or disconnected.
2. When you get an unusual signal, measure the #2
sensor terminal voltage.
(1) If there is a 0.5 V or more difference between the
sensor and NGS voltages, inspect the harness for
open or short circuits.
F1-118 CONTINUED
TROUBLESHOOTING
(2) If the sensor and NGS voltages are the same, (2) If the sensor and NGS voltages are the same,
inspect the following points concerning the sensor inspect the following points concerning the
connector. If there are no problems, proceed to next sensor connector. If there are no problems,
investigation below. proceed to next investigation below.
• Female terminal opening looseness • Female terminal opening looseness
• Coupler (pin holder) damage • Coupler (pin holder) damage
• Pin discoloration (blackness) • Pin discoloration (blackness)
• Harness/pin crimp is loose or disconnected. • Harness/pin crimp is loose or disconnected.
Investigate the standard power supply system Investigate the electrical supply system
(1) Confirm that the #3 terminal is at 5 V. 1. Confirm that the sensor #3 terminal is B+.
(1) If the measured voltage on the #3 terminal is 5 V, (1) If the measured voltage on the #3 terminal is B+,
inspect the following points on the sensor inspect the following points on the sensor
connector. If there is no problem, proceed to next connector. If there is no problem, proceed to next
investigation below. investigation below.
(3) Female terminal opening looseness • Female terminal opening looseness
(4) Coupler (pin holder) damage • Coupler (pin holder) damage
(5) Pin discoloration (blackness) • Pin discoloration (blackness)
(2) If the #3 terminal measures other than 5 V, (2) If the #3 terminal measures other than B+, inspect
inspect for the following. for the following.
• Open or short circuit in harness • Open or short circuit in harness
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Investigate the GND system Investigate the GND system
1. Confirm that terminal sensor #5 is at 0 V. 1. Confirm that terminal sensor #4 is at 0 V.
(1) If it is at 0 V, inspect the sensor. If necessary, (1) If it is at 0 V, inspect the sensor. If necessary,
replace the sensor. replace the sensor.
(2) If not, inspect for the following. Open or short (2) If not at 0 V, inspect for the following. Open circuit
circuit in harness Female terminal opening in harness Female terminal opening looseness
looseness Coupler (pin holder) damage Pin Coupler (pin holder) damage Pin discoloration
discoloration (blackness) Harness/pin crimp is (blackness) Harness/pin crimp is loose or
loose or disconnected. disconnected.
Variable resistance type 2 (Mass air flow (MAP) sensor) Thermistor type (Intake air temperature (IAT) and
engine coolant temperature (ECT) sensors)
Investigate the input signal system

Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM
1. When you get an unusual signal, measure the #1 PCM terminal voltage.
terminal voltage. (2) If the #1 terminal voltage and the NGS monitor
(1) If the #1 terminal voltage and the NGS monitor voltage are the same, proceed to the next step.
voltage are the same, proceed to the next step. (3) If there is a difference of 0.5 V or more, inspect the
(2) If there is a difference of 0.5 V or more, inspect following points concerning the PCM connector.
the following points concerning the PCM (1) Female terminal opening looseness
connector. (2) Coupler (pin holder) damage
(3) Pin discoloration (blackness)
• Female terminal opening looseness (4) Harness/pin crimp is loose or disconnected.
• Coupler (pin holder) damage 2. When you get an unusual signal, measure the #2 sensor
• Pin discoloration (blackness) terminal voltage.
• Harness/pin crimp is loose or disconnected. (3) If there is a 0.5 V or more difference between the
2. When you get an unusual signal, measure the #2 sensor and NGS voltages, inspect the harness for
sensor terminal voltage. open or short circuits.
(1) If there is a 0.5 V or more difference between
the sensor and NGS voltages, inspect the
harness for open or short circuits.
CONTINUED
F1-119
TROUBLESHOOTING
(2) If the sensor and NGS voltages are the same, • Pin discoloration (blackness)
inspect for the following points concerning the • Harness/pin crimp is loose or disconnected.
sensor connector. If there are no problems,
proceed to next investigation below, ENGINE SYSTEM INSPECTION
• Female terminal opening looseness Main Relay Operation Inspection
• Coupler (pin holder) damage 1. Verify that the main relay clicks when the ignition switch
• Pin discoloration (blackness) is turned to on and off.
Investigate the GND system

1. Confirm that terminal sensor #3 is at 0 V.
(1) If it is at 0 V, inspect the sensor. If necessary,
replace the sensor.
(2) If not, inspect for the following. Open circuit in
harness Female terminal opening looseness
Coupler (pin holder) damage Pin discoloration
(blackness) Harness/pin crimp is loose or
disconnected.
Vehicle speed sensor (VSS)
2. If there is no operating sound, inspect the following.
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• Main relay
• Harness and connector between ignition switch and
main relay
Intake Manifold Vacuum Inspection

1. Verify air intake hoses are installed properly.
2. Start the engine and run it at idle.
3. Disconnect the vacuum hose between the intake
manifold and purge solenoid valve on the intake
1. Measure the #1 PCM terminal voltage and confirm that it manifold side.
is at 0 V or 5 V when the ignition switch is on and the 4. Connect a vacuum gauge to the intake manifold and
engine is at idle. measure the intake manifold vacuum.
(1) If it is at 0 V or 5 V, proceed to symptom
troubleshooting No.26 "Intermittent Concerns".
(2) If not, inspect the following points concerning the
PCM connector. If there are no problem, proceed to
next step.
• Female terminal opening loose
• Coupler (pin holder) damage
• Pin discoloration (blackness)
2. Measure the #2 sensor terminal voltage and confirm that

it is at 0 V or 5 V when the ignition switch is on and the
engine at idle.
(1) If it is at 0 V or 5 V, proceed to symptom Specification
troubleshooting No.26 "Intermittent Concerns". More than 60 kPa {450 mmHg, 18 inHg}
(2) If not, inspect the following points concerning the
sensor connector. If there are no problems, 5. If not as specified, inspect for the following:
proceed to next step. • Air suction at throttle body, intake manifold and
• Female terminal opening looseness PCV valve installation points
• Coupler (pin holder) damage • Fuel injector insulator
• Pin discoloration (blackness) • Accelerator cable free play
• Harness/pin crimp is loose or disconnected. • Engine compression (Refer to section B1.)
3. Confirm that the #3 terminal switch voltage is at 0 V. Note

(1) If it is at 0 V, inspect the sensor. If necessary, • Air suction can be located by engine speed change
replace the sensor. when lubricant is sprayed on the area where
(2) If not, inspect for the following. suction is occurring.
• Open circuit in harness
• Female terminal opening looseness
• Coupler (pin holder) damage
CONTINUED
F1-120
TROUBLESHOOTING
Idle Air Control (IAC) Inspection (3) Verify that DTC P0505 is not displayed. If DTC
Engine coolant temperature (ECT) compensation P0505 is shown, carry out DTC inspection.
inspection (4) Select the SIMULATION TEST function on the
1. Connect the SSTs (NQS tester) to DLC. NGS display.
(5) Change the duty value of the IAC valve to 100%
using the IACV PID.
(6) Verify that the idle speed increases.
① If the idle speed increases, replace the PCM.
② If the idle speed does not change, inspect the
following.
• IAC valve air passage
• Open or short circuit between IAC valve
connector terminals and PCM connector
terminal 2W
4. Warm up the engine to normal operating temperature
and run it at idle.
5. Select the PID/DATA MONITOR AND RECORD
2. Select the PID/DATA MONITOR AND RECORD function on the NGS display.
function on the NGS display.
6. Select the following PIDs.
3. Select the following PIDs.
• ECT • A/C SW
• IACV • IAC V
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• RPM • PSP SW
• RPM
4. Verify that the engine is cold, then start the engine.
5. Verify that the engine speed decreases as the 7. Turn the electrical loads on and verify that the engine
engine warms up. speed is within the specification.
6. If the engine speed does not decrease or decreases
slowly, carry out the following. Engine speed (rpm)
1
• ECT sensor inspection Load condition Idle-up speed (rpm)*
2
• IAC valve inspection P/S ON*
700—800 (750 ± 50)
A/CON*3
Load compensation inspection
*1 Excludes temporary idle speed drop just after the
1. Start the engine and run at idle. electrical loads (E/L) are turned on.
2
2. Disconnect the IAC valve connector and verify that the * : Steering wheel is fully turned.
3
engine rotation changes. * : A/C switch and fan switch are on.
Note
• Excludes temporary idle speed drop just after the
electrical loads are turned on.
8. If not as specified, carry out the following.

• A/C switch inspection
• PSP switch inspection
• IAC valve inspection
Fuel Line Pressure Inspection
Warning
3. If the engine condition does not change, do as follows. • Fuel line spills and leakage are dangerous.
(1) Connect the IAC valve connector. Fuel can ignite and cause serious injuries or
(2) Connect the SSTs (NGS tester) to DLC. death. Fuel can also irritate skin and eyes.
• To prevent this, always complete the "BEFORE
REPAIR PROCEDURE".
PROCEDURE.)

2. Connect a fuel pressure gauge between the fuel
filter and fuel distributor.
CONTINUED
TROUBLESHOOTING
• If fuel line pressure gradually increases, inspect the

fuel pump maximum pressure. If the fuel pump
maximum pressure is normal, inspect for clogging
between fuel pump body and pressure regulator.
Fuel Pressure Hold Inspection

Warning
• Fuel line spills and leakage are dangerous. Fuel
can ignite and cause serious injuries or death.
Fuel can also irritate skin and eyes.
• To prevent this, always complete the "BEFORE
REPAIR PROCEDURE".
3. Connect the negative battery cable. PROCEDURE.)
Caution
• Connecting the wrong DLC terminals may 1. Disconnect the negative battery cable.
possibly cause a malfunction. Carefully 2. Connect a fuel pressure gauge between the fuel filter and
connect the specified terminals only. fuel distributor.
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jumper wire.
5. Turn the ignition switch on and measure the fuel line 3. Connect the negative battery cable.
pressure.
Caution
Specification
2 • Connecting the wrong DLC terminals may
270—310 kPa {2.7—3.2 kgf/cm , 39—45 psi}
possibly cause a malfunction. Carefully connect
the specified terminals only.
6. Turn off the ignition switch and disconnect the jumper
wire.
4. Short the DLC terminal F/P to body GND using a jumper
7. If the pressure is higher than specified, inspect the fuel wire.
pump maximum pressure. If normal, inspect fuel return
hose or the pressure regulator for clogging.
8. If the pressure is lower than specified, measure the fuel
line pressure while pinching the return hose.
5. Turn the ignition switch on for approx. 10 sec. to operate

the fuel pump body.
6. Turn off the ignition switch and disconnect the jumper wire.
7. Observe the fuel pressure after 5 min.
Specification
2
More than 150 kPa {1.5 kgf/cm , 21 psi}
• If the fuel line pressure quickly increases, inspect
the pressure regulator and PRC solenoid valve.
8. If the pressure is lower than specified, measure the fuel
line pressure while pinching the return hose.
CONTINUED
F1-122
TROUBLESHOOTING
Inspection 1
• If the fuel line pressure holds, replace the pressure

regulator. (Refer to FUEL SYSTEM, PRESSURE
REGULATOR REMOVAL/INSTALLATION.)
• If fuel line pressure does not hold, inspect the fuel 2. Start the engine and let it idle.
leakage from fuel line and fuel injector. 3. Select the SIMULATION TEST function on the NGS
Pressure Regulator Control Inspection display.
Warning 4. Select IDLING TEST mode.
• Fuel line spills and leakage are dangerous. Fuel 5. Select PRCV PID.
can ignite and cause serious injuries or death. 6. Press START.
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Fuel can also irritate skin and eyes. 7. Turn the PRC solenoid valve from off to on and inspect if
• To prevent this, always complete the "BEFORE the fuel pressure changes.
REPAIR PROCEDURE". (1) If the pressure changes, inspect the following.
(Refer to FUEL SYSTEM, BEFORE REPAIR • ECT, IATDC and TP V PIDs
PROCEDURE.) (Refer to CONTROL SYSTEM, PID/DATA
1. Disconnect the negative battery cable. MONITOR INSPECTION.)
2. Connect a fuel pressure gauge between the fuel filter and (2) If the pressure does not change, do as follows.
fuel distributor. ① Select the SIMULATION TEST function on the
NGS display.
② Select IDLING TEST mode.
③ Select PRCV PID.
④ Press START.
⑤ Turn the PRC solenoid valve from off to on and
inspect if the operation sound of the valve is
heard.
⑥ If the operating sound is heard, inspect the
pressure regulator.
⑦ It the operating sound is not heard, inspect the
PRC solenoid valve.
Inspection 2
4. Measure the fuel line pressure under the following
conditions.
Specifications
2
Condition Fuel pressure [kPa {kgf/cm , psi}]
210—250
{2.1—2.6,
Idling
30—36}
During 120 270—310
sec. of hot {2.7—3.2, 210—250 270—310 2. Turn the ignition switch on.
start 39—45} {2.1—2.6, {2.7—3.2, 3. Select the SIMULATION TEST function on the NGS
30—36} 3&—45} display.
After 120 210—250
sec. of hot {2.1—2.6, 4. Turn the PRC solenoid valve from off to on using the
start 30—36} PRCV PID and inspect if the operating sound is heard.
(1) If the operating sound is heard, inspect for a
Not Normal Not Normal loose or damaged vacuum hose. (Pressure
Judgment Normal (Perform (Perform regulator—PRC solenoid valve—intake manifold)
Inspection 1) Inspection 2) (2) If the operating sound is not heard, inspect the
PRC solenoid valve)
CONTINUED
F1-123
TROUBLESHOOTING
Fuel Injector Operation Inspection
1 While cranking engine, inspect for fuel injector Yes Fuel injector operation is okay.
operating sound at each cylinder using a No Not heard at all cylinders:
soundscope. Is operating sound heard? Go to next step.
Not heard at some cylinders:
Go to Step 3.
2 Carry out main relay operation inspection. Yes Inspect following:
Is main relay operation okay? • Fuel injector power system related wiring harnesses
and connectors
• PCM connectors
• Fuel injector GND and related wiring harnesses and
connectors
No Repair or replace malfunctioning parts.
3 Change fuel injector connector of not operating Yes Go to next step.
fuel injector and operating fuel injector.
Is operating sound heard? No Replace fuel injector.
4 Are wiring harnesses and connectors of not Yes Inspect PCM terminal voltage of fuel injector signal.
operating fuel injector okay? (Open or short) No Repair or replace malfunctioning parts.
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Fuel Cut Control Inspection Fuel Pump Operation Inspection
1. Warm up engine and let it idle. 1. Connect the SSTs (NGS tester) to the DLC.
2. Turn off the electrical loads and A/C switch.
2. Remove the fuel-filler cap.

4. Select the PID/DATA MONITOR AND RECORD 4. Select the SIMULATION TEST function on the NGS
function on the NGS display. display.
5. Select RPM and INJ PIDs. 5. Turn the fuel pump relay from off to on using the FP
6. Press START. RLY PID and inspect if the operating sound is heard.
7. Monitor both PIDs while performing the following 6. If no operating sound is heard, measure the voltage at
steps. harness side fuel pump unit connector terminal B.
(1) Depress the accelerator pedal and increase the
engine speed to 4000 rpm. Specification
(2) Release the accelerator pedal (brake pedal is not Battery positive voltage (Ignition switch on)
depressed) and inspect that the fuel injector
duration time is 0 msec., and 2—5 msec. when the
engine speed drops below 1200 rpm.
8. If not as specified, carry out the following.
• ECT sensor inspection
• Neutral/clutch switch inspection
CONTINUED
F1-124
TROUBLESHOOTING
7. If the voltage is as specified, inspect the following.

• Fuel pump continuity
• Fuel pump GND
• Wiring harness between fuel pump relay and PCM
terminal 1 H
8. If not as specified, inspect the following.
1. Fuel pump relay
2. Wiring harness and connector (Main relay—fuel
pump relay—fuel pump unit)
Fuel Pump Control Inspection 4. Increase the engine speed and verify the ignition timing
1. Connect the SSTs (NGS tester) to the DLC. is advanced.
5. If the ignition timing is not advanced, carry out the
following.
• CMP sensor inspection
• MAP sensor inspection
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3. Select the SIMULATION TEST function on the NGS
display.
4. Select IG ON TEST mode.
5. Select FP RLY PID.
6. Press START.
7. Turn the fuel pump relay from off to on and inspect if
the operating sound of the fuel pump relay is heard.
8. If no operating sound is heard, inspect the fuel

pump relay.
9. If the fuel pump relay is normal, inspect the
following.
• Wiring harnesses and connectors (Main
relay—fuel pump relay—PCM)
Ignition Timing Control Inspection

1. Connect a timing light to the engine.
2. Crank the engine.
3. Verify that the timing mark (yellow) on the crankshaft
Specification
BTDC 9°—11°(10° ± 1°)
CONTINUED
F1-125
TROUBLESHOOTING
Spark Test
1. Remove the fuel pump relay.
2. Verify that each high-tension lead and connector is connected properly.
3. Inspect the ignition system in the following procedure.
Warning
• High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid
direct contact to the vehicle body during the following spark test.

1 Remove high-tension lead from spark plug. Yes Ignition system is okay.
Hold high-tension lead with pliers installed 5—10
No Some cylinders do not spark:
mm {0.20—0.39 in} from GND. Crank the engine
and verify that there is a strong blue spark. Go to next step.
(Inspect each cylinder.) All cylinders do not spark:
Go to Step 3.
2 Is high-tension lead resistance correct? Yes Inspect for cracks or damage of high-tension lead,
distributor and Ignition coil.
No Replace the high-tension lead.
3 Does PCM or ignition coil connector have poor Yes Repair or replace connector.
connection? No Go to next step.
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4 Is igniter okay? Yes Go to next step.
No Replace igniter.
5 Is ignition coil winding resistance okay? Yes Go to next step.
No Replace ignition coil.
6 Are distributor cap and rotor okay? Yes Go to next step.
No Replace distributor cap or rotor.
7 Are following parts okay? Yes Inspect for open or short in wiring harness and
• CMP sensor connector of CMP sensor.
• PCM terminal 2F voltage
Specification No Repair or replace malfunctioning part.
Approx. 1.5 V
CONTINUED
F1-126
TROUBLESHOOTING
Purge Control Inspection A/C CUT-OFF CONTROL INSPECTION
1. Start the engine. 1. Start the engine.
2. Disconnect the vacuum hose between the purge 2. Turn the A/C switch and fan switch on.
solenoid valve and the charcoal canister. 3. Verify that the A/C compressor magnetic clutch
3. Put a finger to the purge solenoid valve and verify that actuates.
there is no vacuum applied when the engine is cold. 4. If it does not actuate, go to symptom troubleshooting
4. If there is a vacuum, inspect the following. No.22 "A/C does not work sufficiently".
• Wiring harness and connectors (Purge solenoid Note
valve—PCM terminal 2X)
• Specification of A/C cut-off control time is from 2
• Purge solenoid valve to 5 seconds.
5. Warm up the engine to the normal operating 5. Fully open the throttle valve in a short period and verify
temperature. that the A/C compressor magnetic clutch does not
6. Stop the engine. actuate.
7. Connect the SSTs (NGS tester) to DLC. 6. If it actuates, inspect the following.
(1) Connect the SSTs (NGS tester) to DLC.
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8. Turn the ignition switch on. (2) Turn the A/C switch off.
9. Select the PID/DATA MONITOR AND RECORD (3) Turn the ignition switch on.
function on the NGS display. (4) Select the SIMULATION TEST function on the
10. Select ECT PID. NGS display.
11. Verify that the engine coolant temperature is above (5) Select IG ON TEST mode.
60°C {140°F}. (6) Select A/C RLY PID
12. If the SSTs (NGS tester) indicates below 60 °C {140 °F}, (7) Press START.
carry out the ECT sensor inspection.
(8) Turn the A/C relay from off to on and inspect if the
13. Select the SIMULATION TEST function on the NGS operating sound of the relay is heard.
display.
(9) If the operating sound is heard, inspect TP V PID.
14. Select PRGV PID.
(10) If the operating sound is not heard, inspect the
15. Press START. following.
16. Increase the duty value of the purge solenoid valve to • /C relay
50% and inspect if the operating sound of the valve is
heard. • Open or short to GND circuit in wiring
harnesses and connectors (Main relay—A/C
(1) If the operating sound is heard, inspect the loose
relay—PCM terminal 1J)
or damaged vacuum hose. (Intake manifold—
purge solenoid valve—charcoal canister) • A/C related parts
(2) If the operating sound is not heard, carry out the
purge solenoid valve inspection.
CONTINUED
F1-127
FUEL AND EMISSION

CONTROL SYSTEMS
(WL, WL Turbo)
ENGINE TUNE-UP . . . . . . . . . . . . . . . . . . . . . . . . . F2– 2 INJECTION NOZZLE
ENGINE TUNE-UP PREPARATION . . . . . . . . F2– 2 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . F2–19
IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . F2– 2 INJECTION NOZZLE INSPECTION . . . . . . . . F2–19/20
IDLE-UP SPEED ADJUSTMENT . . . . . . . . . . . F2– 2 FUEL CUT VALVE (FCV)
INJECTION TIMING ADJUSTMENT . . . . . . . . F2– 3 REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–20
INTAKE-AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . F2– 4 FUEL CUT VALVE (FCV) INSPECTION . . . . . F2–20/21
VACUUM HOSE ROUTING DIAGRAM . . . . . F2– 4 FICD SOLENOID VALVE NO.1, NO.2 INSPECTION
INTAKE-AIR SYSTEM F2–21
REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2– 5/7 TIMER CONTROL VALVE (TCV)
TURBOCHARGER INSPECTION . . . . . . . . . . F2– 8/9 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–22
GLOW PLUG REMOVAL/INSTALLATION . . . F2– 9 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . F2–23
GLOW PLUG INSPECTION . . . . . . . . . . . . . . . F2– 9 EXHAUST SYSTEM INSPECTION . . . . . . . . . F2–23
GLOW PLUG RELAY EXHAUST SYSTEM
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REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2– 9 REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–23/25
GLOW PLUG RELAY INSPECTION . . . . . . . . F2–10 EMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . F2–25
GLOW PLUG CORD INSPECTION . . . . . . . . F2–10 ROLLOVER VALVE INSPECTION . . . . . . . . . F2–25
ACCELERATOR PEDAL EVAPORATIVE CHAMBER INSPECTION . . . F2–25
REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . F2–10/11 EGR VALVE INSPECTION . . . . . . . . . . . . . . . . F2–26
ACCELERATOR CABLE EGR SOLENOID VALVE INSPECTION . . . . . F2–26
INSPECTION/ADJUSTMENT . . . . . . . . . . . . F2–11 EGR PIPE, EGR VALVE
IDLING KNOB, IDLING CABLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . F2–26
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–11 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . F2–27
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2–12 COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . F2–27
BEFORE REPAIR PROCEDURE . . . . . . . . . . F2–12 POWERTRAIN CONTROL MODULE (PCM)
AFTER REPAIR PROCEDURE . . . . . . . . . . . . F2–12 REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–28
FUEL TANK REMOVAL/INSTALLATION . . . . F2–13/15 POWERTRAIN CONTROL MODULE (PCM)
FUEL FILTER DISASSEMBLY/ INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–28/31
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2–15/16 NE SENSOR INSPECTION . . . . . . . . . . . . . . . F2–32
FUEL GAUGE SENDER UNIT ENGINE COOLANT TEMPERATURE (ECT)
REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–16 SENSOR INSPECTION . . . . . . . . . . . . . . . . . F2–32/33
FUEL GAUGE SENDER UNIT IDLE SWITCH INSPECTION . . . . . . . . . . . . . . F2–33
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–16 CONTROL LEVER POSITION SENSOR
FUEL FILTER AIR BLEEDING . . . . . . . . . . . . . F2–16 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–33/34
SEDIMENTOR WATER DRAINING . . . . . . . . . F2–16 ON-BOARD DIAGNOSTIC SYSTEM . . . . . . . . . F2–35
SEDIMENTOR SWITCH INSPECTION . . . . . F2–16/17 DTC READING PROCEDURE . . . . . . . . . . . . . F2–35
FUEL WARMER INSPECTION . . . . . . . . . . . . F2–17 AFTER REPAIR PROCEDURE . . . . . . . . . . . . F2–35
FUEL INJECTION PUMP (FIP) DTC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . F2–36/38
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F2–17 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . F2–39
FUEL INJECTION PUMP (FIP) FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . F2–39
REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–17/18 TROUBLESHOOTING ITEM TABLE . . . . . . . . F2–39
INJECTION NOZZLE SYMPTOM TROUBLESHOOTING . . . . . . . . . F2–40/60
REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2–18 SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . F2–61/64
CONTINUED
F2–1
ENGINE TUNE-UP
ENGINE TUNE-UP 4. After adjusting the idle speed, tighten the locknut
securely.
ENGINE TUNE-UP PREPARATION
1. Warm up the engine to normal operating IDLE-UP SPEED ADJUSTMENT
temperature. 1. Perform “Engine tune-up preparation”.
2. Turn the all electrical loads off. 2. Turn all electrical loads off in neutral shift position.
3. Connect a tachometer. 3. Apply vacuum of –53.3 kPa {–400 mmHg, –15.8
inHg} or over to actuator B, and measure the
IDLE SPEED ADJUSTMENT idle-up speed.
WL WL
1. Perform “Engine tune-up preparation”. ADJUSTING
SCREW B
2. Verify that the idle speed is within the specification. ADJUSTING
SCREW C
Specification
700—740 (72020) rpm
LOCKNUT B
3. If not within the specification, adjust the idle speed
by turning the IAS (idle adjustment screw).
ACTUATOR A
LOCKNUT
5.9—8.8 N·m ACTUATOR B
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{60—90 kgf·cm,
53—78 in·lbf}
WL, WL Turbo
ADJUSTING
SCREW B
IAS ADJUSTING
SCREW C
LOCKNUT B
4. After adjusting the idle speed, tighten the locknut

securely. ACTUATOR A
ACTUATOR B
WL Turbo
1. Perform “Engine tune-up preparation”.
2. Verify that the idle speed is within the specification. Specification
1200—1500 (1,350150) rpm
Specification
General (L.H.D.) : 760—800 (78020) rpm 4. If not within the specification, do as follows;
Europe and UK : 700—740 (72020) rpm (1) Loosen the locknut B.
(2) Adjust the idle-up speed by turning the
Caution adjusting screw B.
Turning the idle switch (Europe and UK (3) Tighten the locknut B.
only) with its connector connected can
break the harness. Be sure to disconnect Tightening torque
the connector when turning the idle switch 5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf}
more than one rotation.
5. Release actuator B to atmosphere and apply
3. If not as specified, loosen the idle switch locknut vacuum of –53.3 kPa {–400 mmHg, –15.8 inHg} or
and adjust the idle speed by turning the idle switch. over to actuator A, and measure the idle-up speed.
LOCKNUT Specification
11.8—14.7 N·m WL vehicle: 805—855 (83025) rpm
{120—150 kgf·cm,
104—130 in·lbf} WL Turbo, WL (Europe only):
825—875 (85025) rpm
6. If not as specified, adjust the idle-up speed by

IDLE SWITCH
turning adjusting screw C.
CONTINUED
F2–2
ENGINE TUNE-UP
INJECTION TIMING ADJUSTMENT 6. Turn the crankshaft counterclockwise to approx.

30° BTDC. (Align the SST installation hole on the
Warning crankshaft pulley.)
Fuel vapor is hazardous. It can very easily 7. Turn the crankshaft lightly right and left, and verify
ignite, causing serious injury and damage. that the dial gauge indicator does not move. Then
Always keep sparks and flames away from set the indicator to 0 mm {0 in}.
fuel. 8. Turn the crankshaft clockwise to position the
Fuel line spills and leaks are dangerous. indicator pin to 10° ATDC (white mark) and read
Fuel can ignite and cause serious injuries the dial indicator.
or death and damage. Fuel can also irritate INDICATOR PIN
observe the “Fuel Line Safety Procedures”, BTDC 0°
(YELLOW MARK)
“Fuel Hose Installation”.
Caution
After tightening the FIP mounting nuts and
bolt after loosening them, be sure to
inspect the timing belt tension. If the belt
tension is not inspected, the timing belt and
the camshaft may become damaged. (Refer ATDC 10° (WHITE MARK)
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to Section B2, TIMING BELT, TIMING BELT
REMOVAL/INSTALLATION, Timing Belt
Installation Note.) Specification
0.95—1.05 mm {0.038—0.041 in}
1. Remove the injection pipes (1.00.05 mm {0.0390.019 in})
(Refer to FUEL SYSTEM, FUEL INJECTION PUMP (FIP)
REMOVAL/INSTALLATION.) 9. If not as specified, adjust by loosening the FIP
2. Remove the cooling fan mounting nut and bolt and turn the FIP.
(Refer to Section E, COOLING FAN, COOLING FAN 10. Tighten the FIP mounting nuts and then the bolt.
3. Turn the crankshaft pulley at slow rotation to align Tightening torque
the timing mark (BTDC 0° : yellow mark) with 19—25 N·m {1.9—2.6 kgf·m, 14—18 ft·lbf}
indicator pin. MOUNTING NUT
INDICATOR PIN
BTDC 0 °
(YELLOW MARK)
MOUNTING BOLT
ATDC 10 ° (WHITE MARK)

11. Remove the SST.
4. Remove the hydraulic head plug from the injection 12. Install the hydraulic head plug and a new gasket.
pump.
5. Mount the SST into the plug hole on the hydraulic Tightening torque
head so that the dial indicator probe touches the 14—19 N·m {1.4—2.0 kgf·m, 11—14 ft·lbf}
plunger end of the pump and the dial indicator
indicates approx. 2.0 mm {0.079 in}. 13. Connect the injection pipes.
(Refer to FUEL SYSTEM, INJECTION NOZZLE
49 9140 074 REMOVAL/INSTALLATION.)
14. Bleed the air from the fuel filter.
(Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)
16. Check the timing belt tension.
(Refer to Section B2, TIMING BELT, TIMING BELT
REMOVAL/INSTALLATION,
Timing Belt Installation Note.)
CONTINUED
F2–3
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM
WL TO POWER
BRAKE UNIT
FICD SOLENOID
VALVE No.1
FICD SOLENOID
VALVE No.2
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FICD ACTUATOR
VACUUM PUMP
WL TURBO TO POWER
BRAKE UNIT
FICD SOLENOID
VALVE No.2
TO RFW
ACTUATOR
4WD ONLY
FICD SOLENOID
VALVE No.1
EGR VALVE
EGR SOLENOID
VALVE
FICD ACTUATOR
VACUUM PUMP
CONTINUED
F2–4
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
Warning
When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the intake-air system.
WL
2. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.)
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
7.9—10.7 N·m
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{80—110 kgf·cm,
70—95 in·lbf}
18.7—25.4
{1.9—2.6,
13.8—18.8}
2.0—2.9 N·m
{20—30 kgf·cm, 18—26 in·lbf}
2.0—2.9 N·m
{20—30 kgf·cm,
18—26 in·lbf}
7.9—11.7 N·m
{80—120 kgf·cm,
18.7—25.4 70—104 in·lbf}
{1.9—2.6,
13.8—18.8}
8.9—12.7 N·m
R {90—130 kgf·cm,
79—112 in·lbf}
7.9—11.7 N·m
{80—120 kgf·cm,
70—104 in·lbf}
1 Fresh-air duct 6 FICD solenoid valve No.1

2 Air cleaner 7 FICD solenoid valve No.2
3 Air hose 8 FICD solenoid valve bracket
4 Resonance chamber 9 Intake manifold
5 Air intake pipe
CONTINUED
F2–5
INTAKE-AIR SYSTEM
WL Turbo
2. Drain the engine coolant from radiator.
(Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.)
3. Remove the front mud guard.
(Refer to Section S, FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.)
4. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.)
7. Refill the engine coolant to radiator.
(Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.)
STEP 1
A 4.9 N·m {50 kgf·cm, 43 in·lbf}
4.9 N·m {50 kgf·cm, 43 in·lbf}
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7.9—11.7 N·m 2.0—2.9 N·m
{80—120 kgf·cm, {20—30 kgf·cm, 18—26 in·lbf}
8.9—12.7 N·m 70—104 in·lbf}
{90—130 kgf·cm,
79—112 in·lbf}
7.9—11.7 N·m
{80—120 kgf·cm,
70—104 in·lbf}
4.9 N·m
{50 kgf·cm, 43 in·lbf}
8.9—12.7 N·m
7.9—11.7 N·m {90—130 kgf·cm,
{80—120 kgf·cm, A 79—112 in·lbf}
70—104 in·lbf}
8.9—12.7 N·m
{90—130 kgf·cm,
79—112 in·lbf}
1 Fresh-air duct 5 Air intake pipe

2 Air cleaner 6 Air hose
3 Air intake hose 7 Charge air cooler
4 Air hose 8 Air hose
CONTINUED
F2–6
INTAKE-AIR SYSTEM
STEP 2
19—25
{1.9—2.6, 14—18}
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
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19—25
{1.9—2.6, 14—18}
19—25 {1.9—2.6, 14—18} R

19—25 {1.9—2.6, 14—18}
R
1 FICD solenoid valve No.1 4 FICD solenoid valve bracket

2 FICD solenoid valve No.2 5 Air intake pipe
3 EGR solenoid valve 6 Intake manifold
CONTINUED
F2–7
INTAKE-AIR SYSTEM
TURBOCHARGER INSPECTION
Wastegate Actuator Inspection
Caution
Compressed air used in the workshop is
highly pressurized and can damage the
actuator. Adjust the air pressure with a
A
transformer, and inspect the actual
pressure by using an air blower before
actual use. Stop blowing air if the rod
MIRROR
moved. TURBOCHARGER
4. Inspect all fins of compressor wheel while rotating

the compressor wheel by hand.
5. If the compressor wheel is interfering with the
housing, it is likely that more than two fins are
damaged, cracked or bent. Replace the
turbocharger.
Note
If scratches are found inside the housing but
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the fins are okay, the turbocharger is okay.
Scratches are made in the turbocharger made
1. Disconnect the air hose of the wastegate actuator by factory.
on the compressor housing side.
2. Apply the compressed air using the air gun.
3. Note the air pressure when the wastegate actuator
is moved.
Specification
107—115 kPa
{1.09—1.18 kgf/cm2, 15.5—16.8 psi}
WASTEGATE
ACTUATOR
Turbine Wheels Inspection

1. Remove the air hose.
(Refer to INTAKE-AIR SYSTEM,
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
ROD
2. Remove the joint pipe.
(Refer to EXHAUST SYSTEM,
EXHAUST SYSTEM REMOVAL/INSTALLATION.)
3. Set the small mirror as shown and inspect the
4. If not within the specification, replace the turbine wheel from view B.
turbocharger. (Refer to EXHAUST SYSTEM,
EXHAUST SYSTEM REMOVAL/INSTALLATION.) Note
To make work accurate, use a penlight to
Compressor Wheels Inspection inspect.
1. Remove the air hose.
2. Remove the joint pipe.
(Refer to EXHAUST SYSTEM,
EXHAUST SYSTEM REMOVAL/INSTALLATION.)
3. Set the small mirror as shown and inspect the B
compressor wheel from view A.
Note MIRROR
To make work accurate, use a penlight to TURBOCHARGER
inspect.
4. Inspect all fins of turbine wheel while rotating the
turbine wheel by hand.
CONTINUED
F2–8
INTAKE-AIR SYSTEM
5. If the turbine wheel is interfering with the housing, GLOW PLUG INSPECTION
it is likely that one or more fins are damaged, 1. Remove the glow plug cord.
cracked or bent. Replace the turbocharger. 2. Inspect the resistance between the glow plug
terminal and the cylinder head.
Note
Grinding marks on the shaft are normal. This Specification
mark is for adjusting the shaft balance at the Glow plug resistance
factory. Approx. 0.75 Ω [20 °C {68 °F}]
GLOW PLUG
GRINDING MARK
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GLOW PLUG REMOVAL/INSTALLATION
3. If not as specified, replace the glow plug.
Caution
Do not damage the heated section of the GLOW PLUG RELAY REMOVAL/INSTALLATION
glow plug. 1. Disconnect the negative battery cable.
Do not reuse a glow plug that has been 2. Remove glow plug relay.
dropped over a height of 10 cm {0.4 in}. 3. Install the glow plug relay.
When removing the glow plug, first loosen
it over one pitch by using a tool, then 8.9—12.7 N·m
loosen by hand. {90—130 kgf·cm,
79—112 in·lbf}
3. Install in the reverse order of removal. GLOW PLUG
RELAY
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
0.8—15 N·m
{8—15 kgf·cm,
7—13 in·lbf}
1 Glow plug cord

2 Glow plug
CONTINUED
F2–9
INTAKE-AIR SYSTEM
GLOW PLUG RELAY INSPECTION GLOW PLUG CORD INSPECTION

System Inspection 1. Remove the glow plug cord.
1. Carry out the “Glow system inspection”. (Refer to GLOW PLUG REMOVAL/INSTALLATION.)
(Refer to TROUBLESHOOTING, SYSTEM 2. Verify that the glow plug cord is not broken or bent.
INSPECTION, Glow System Inspection.) 3. Verify there is continuity at both ends of the glow
2. If not as specified, perform the further inspection plug cord.
for the glow plug relay. 4. If there is no continuity, replace the glow plug cord.
Continuity Inspection ACCELERATOR PEDAL REMOVAL/INSTALLATION

Note 1. Disconnect the negative battery cable.
Perform the following test only when directed. 2. Remove the column cover.
(Refer to Section N, MANUAL STEERING
1. Remove the glow plug relay. WHEEL AND COLUMN REMOVAL/INSTALLATION.)
2. Inspect for continuity between terminals C and D of 3. Remove in the order indicated in the table.
the glow plug relay under the following conditions. 4. Install in the reverse order of removal.
General (R.H.D.)
C D
C D
R
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A B
19—25
{1.9—2.6,
14—18}
A B
: Continuity
Step A B C D
1 B+ GND
2
19—25
{1.9—2.6, 14—18}
3. If there is no continuity, replace the glow plug relay.
(Refer to GLOW PLUG RELAY REMOVAL/INSTALLATION.)
If as specified but the
System Inspection is failed, inspect following:
Open circuit
Power circuit (Glow plug relay connector terminal A
R
(1-pin: R/B) and battery) 5.0 N·m {50 kgf·cm, 44 N·m {kgf·m, ft·lbf}
Power circuit (Glow plug relay connector terminal A
123456567 in·lbf}
(2-pin) and PCM connector terminal O)
1 Idling knob
GND circuit (Glow plug relay connector terminal A
(1-pin: R) and glow plug cord) 2 Idling cable
GND circuit (Glow plug relay connector terminal B 3 Brake switch connector
(2-pin) and engine GND)
4 Accelerator cable
Signal circuit (Glow plug relay connector terminal A + Installation Note
(1-pin: R) and PCM connector terminal I)
5 Spring pin
Short circuit 6 Clevis pin
Glow plug relay connector terminal A (1-pin: R/B) 7 E clip
and battery to GND.
8 Pin
Glow plug relay connector terminal A (2-pin) and
PCM connector terminal O to GND. 9 Bushing
Glow plug relay connector terminal A (1-pin: R) 10 Push rod
and PCM connector terminal I to GND. 11 Clevis
5. Install the glow plug relay. 12 Nut
13 Nut
14 Pedal component
+ Installation Note
CONTINUED
F2–10
INTAKE-AIR SYSTEM
Except General (R.H.D.) ACCELERATOR CABLE

1. Warm up the engine, then turn the engine switch
off.
LOCKNUT
7.9—10.7 N·m Free play

{80—110 kgf·cm,
69.5—95.4 in·lbf} 1—3 mm {0.04—0.11 in}
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3. If not as specified, adjust by turning locknut.
IDLING KNOB, IDLING CABLE INSPECTION

General (R.H.D.)
1 Accelerator cable 1. Verify that the accelerator pedal is in the idling
+ Installation Note
position, when the idling knob is not turned.
2 Accelerator pedal 2. Verify that the accelerator pedal moves in the
direction that engine speed increases, when the
Pedal Component Installation Note idling knob is turned to the right.
Carry out the “BRAKE PEDAL HEIGHT 3. Verify that the accelerator pedal returns to the
INSPECTION” procedure after installing the pedal idling position when the idling knob is turned to the
component. left.
(Refer to Section P, BRAKE PEDAL HEIGHT INSPECTION.)
Carry out the “CLUTCH PEDAL INSPECTION”
procedure after installing the pedal component.
(Refer to Section H, CLUTH PEDAL
INSPECTION/ADJUSTMENT.)
Accelerator Cable Installation Note

Carry out the “ACCELERATOR CABLE
INSPECTION/ADJUSTMENT” procedure after
installing the accelerator cable.
(Refer to ACCELERATOR CABLE
INSPECTION/ADJUSTMENT.) IDLING KNOB
CONTINUED
F2–11
FUEL SYSTEM
FUEL SYSTEM
Warning
Fuel vapor is hazardous. It can very easily
fuel.
Fuel in the fuel system is under high pressure

when the engine is not running.
Warning
complete the following “Fuel Line Safety
Procedures”.
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Fuel Line Safety Procedures
Avoid fuel line spills and leaks by completing the
following procedures.
(1) Remove the fuel-filler cap and release the
pressure in the fuel tank.
(2) When disconnecting a fuel hose, wrap a rag
around it to protect against fuel leakage.
(3) Plug the fuel hose after removal.
Warning
fuel hose, observe “Fuel Hose Installation”
described below.

Verify that there is no damage or deformation on
the fuel hose and fuel pipe when installing.
CONTINUED
F2–12
FUEL SYSTEM
Warning
Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire
may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.

2. Complete the “BEFORE REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
3. Remove the drain plug and drain the fuel from the fuel tank.
4. Remove the rear flap.
7. Complete the “AFTER REPAIR PROCEDURE”. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
STRETCH CAB 2WD, DOUBLE CAB 2WD
1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
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7.9–10.7 N·m {80—110 kgf·cm, 69.5—95.4 in·lbf}
R
WITH BOX
1.1–2.1 N·m
{11—22 kgf·cm,
10—19 in·lbf}
A B
SEAL
RUBBER
R R
R
2.5—4.6 N·m
{25—47 kgf·cm,
22—40 in·lbf}
2.5—3.5 N·m
{25—36 kgf·cm,
22—26 in·lbf}
11.8—16.6 N·m
{120—170 kgf·cm,
105—147 in·lbf}
11.8—16.6 N·m
{120—170 kgf·cm,
16—22 105—147 in·lbf}
{1.6—2.3, 12—16}
1.1—2.1 N·m 16—22

{11—22 kgf·cm, {1.6—2.3, 12—16}
10—19 in·lbf} R
32—46
WITHOUT BOX {3.2—4.7, 24—33}
EUROPE
DRAIN PLUG
26—32 {2.6—3.3, 19—23}
32—46 {3.2—4.7, 24—33}
EXCEPT EUROPE
CONTINUED
F2–13
FUEL SYSTEM
STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB
1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
1.1–2.1 N·m {11—22 kgf·cm, 10—19 in·lbf}
SEAL R
RUBBER
7.9—10.7 N·m
{80—110 kgf·cm, 69.5—95.4 in·lbf}
R
WITH BOX
B 1.1–2.1 N·m
A
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{11—22 kgf·cm,
10—19 in·lbf}
2.5—4.6 N·m
{25—47 kgf·cm,
22—40 in·lbf}
2.5—3.5 N·m
{25—36 kgf·cm,
22—26 in·lbf} 11.8—16.6 N·m
{120—170 kgf·cm,
105—147 in·lbf}
11.8—16.6 N·m
16—22 {120—170 kgf·cm,
{1.6—2.3, 12—16} 105—147 in·lbf}
1.1—2.1 N·m 16—22

{11—22 kgf·cm, {1.6—2.3, 12—16}
10—19 in·lbf}
R
32—46
{3.2—4.7, 24—33}
WITHOUT BOX
EUROPE
DRAIN HOSE
26—32 {2.6—3.3, 19—23} 32—46 {3.2—4.7, 24—33}
EXCEPT EUROPE
1 Evaporative chamber (If equipped) 7 Evaporative hose

2 Joint hose + Installation Note
+ Installation Note 8 Fuel gauge sender unit
3 Breather hose 9 Rollover valve
+ Installation Note 10 Fuel-filler pipe
4 Under guard 11 Dust cover
5 Fuel hose 12 Fuel inlet pipe
+ Installation Note
13 Check valve (two–way)
6 Fuel tank
14 Evaporative chamber
CONTINUED
F2–14
FUEL SYSTEM

Fit each hose onto the respective fittings within the
specification, and install clamps as shown.
Length
Evaporative hose: 25 mm {0.98 in}
9—12 mm 9—12 mm
{0.36—0.47 in} {0.36—0.47 in}
10 mm {0.39 in}
VIEW A VIEW B
FUEL FILTER DISASSEMBLY/ASSEMBLY

EVAPORATIVE HOSE 2. Complete the “BEFORE REPAIR PROCEDURE”.
PROCEDURE.)
Fuel Hose Installation Note 4. Assemble in the reverse order of removal.
Fit each hose onto the respective fittings within the 5. Complete the “AFTER REPAIR PROCEDURE”.
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specification, and install clamp as shown. (Refer to FUEL SYSTEM, AFTER REPAIR
PROCEDURE.)
Length 6. Bleed air from the fuel filter.
Fuel hose: 25 mm {0.98 in} (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)
7. Start the engine and verify that fuel does not leak
from the fuel system.
8. If fuel leaks, reassemble the fuel filter.
10 mm {0.39 in} WITH FUEL 19—25 {1.9—2.6, 14—18}
WARMER
WITHOUT FUEL WARMER
FUEL HOSE
Breather Hose Installation Note

Fit each hose onto the respective fittings within the
specification, and install clamp as shown.
Length
Breather hose: 25 mm {0.98 in}
10 mm {0.39 in} R
BREATHER HOSE
Joint Hose Installation Note

Fit the joint hose onto the respective fittings within
the specification, and install clamps as shown.
Length
Joint hose: 35 {1.4 in} CONTINUED
F2–15
FUEL SYSTEM
1 Connector SEDIMENTOR SWITCH INSPECTION

2 Fuel hose
3 Priming pump Note
4 Fuel filter Perform the following test only when directed.
+ Assembly Note
5 Sedimentor switch
2. Drain fuel from the fuel filter.
+ Assembly Note
(Refer to FUEL SYSTEM, SEDIMENTOR WATER
6 Drain plug DRAINING.)
7 Fuel warmer 3. Remove the sedimentor switch.
4. Inspect continuity of the sedimentor switch by
Sedimentor Switch Assembly Note using an ohmmeter.
Apply a small amount of fuel to a new O-ring.
Tighten the sedimentor switch enough to the fuel Float Continuity
filter by hand.
Up Yes
Fuel Filter Assembly Note Down No
Apply a small amount of fuel to the fuel filter
O-ring. Tighten the fuel filter approx. 3/4 by hand UP
after the O-ring contacts the priming pump.
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DOWN
FUEL GAUGE SENDER UNIT
REMOVAL/INSTALLATION FLOAT
REMOVAL/INSTALLATION)
FUEL GAUGE SENDER UNIT INSPECTION

(Refer to Section T, WARNING AND INDICATOR
SYSTEM, FUEL GAUGE SENDER UNIT
INSPECTION.)
5. If not as specified, replace the sedimentor switch.
If as specified, inspect following:
FUEL FILTER AIR BLEEDING
Open circuit
GND circuit (Sedimentor switch connector
Caution
terminal B and body GND)
Continuously cranking the engine for over
Power circuit (Sedimentor switch connector
30 seconds can damage the battery and the
terminal A and engine switch connector
starter.
terminal C)
Repeat cranking the engine for 30 seconds and
stop for 5—10 seconds until the engine starts. SEDIMENTOR SWITCH
SEDIMENTOR WATER DRAINING A B

2. Complete the “BEFORE REPAIR PROCEDURE”.
PROCEDURE.)
3. Loosen the drain plug located at the bottom of the HARNESS SIDE CONNECTOR
fuel filter. (VIEW FROM TERMINAL SIDE)
4. Pump the priming pump and drain the water.
5. After all the water has been drained, tighten the
drain plug. ENGINE SWITCH
6. Complete the “AFTER REPAIR PROCEDURE”.
(Refer to FUEL SYSTEM, AFTER REPAIR A B
PROCEDURE.)
A C
B D
HARNESS SIDE CONNECTOR
(VIEW FROM TERMINAL SIDE)
CONTINUED
F2–16
FUEL SYSTEM
Short circuit FUEL INJECTION PUMP (FIP)

GND circuit (Sedimentor switch connector REMOVAL/INSTALLATION
terminal B and body GND to power circuit)
Power circuit (Sedimentor switch connector Caution
terminal A and engine switch connector After removing/installing the FIP, be sure to
terminal C to GND) inspect the timing belt tension. If the belt
tension is not inspected, the timing belt and
6. Repair or replace faulty areas. the camshaft may become damaged.
7. Install the sedimentor switch. (Refer to section B2, TIMING BELT, TIMING BELT
8. Reconnect the negative battery cable. REMOVAL/INSTALLATION,
9. Bleed air from the fuel filter. Timing Belt Installation Note.)
(Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)
FUEL WARMER INSPECTION 2. Complete the “BEFORE REPAIR PROCEDURE”.
With fuel warmer (Refer to FUEL SYSTEM, BEFORE REPAIR
1. Disconnect the negative battery cable. PROCEDURE.)
2. Complete the “BEFORE REPAIR PROCEDURE”. 3. Remove the FICD solenoid valve bracket.
(Refer to FUEL SYSTEM, BEFORE REPAIR (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM
PROCEDURE.) REMOVAL/INSTALLATION.)
3. Remove the fuel warmer. 4. Remove the air intake pipe.
(Refer to FUEL SYSTEM, FUEL FILTER (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM
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DISASSEMBLY/ASSEMBLY.) REMOVAL/INSTALLATION.)
4. Verify that the resistance between terminal A and 5. Set the No.1 cylinder to TDC.
the fuel warmer body is within the specification 6. Remove in the order indicated in the table.
when vacuum of –26.6—–40.0 kPa 7. Install in the reverse order of removal.
{–200—–300mmHg, –7.9—–11.8 inHg} is applied 8. Complete the “AFTER REPAIR PROCEDURE”.
to port A of the fuel warmer. (Refer to FUEL SYSTEM, AFTER REPAIR
PROCEDURE.)
9. Inspect injection timing. (Refer to ENGINE
TUNE-UP, INJECTION TIMING ADJUSTMENT.)
10. Check the timing belt tension.
(Refer to Section B2,TIMING BELT, TIMING BELT
REMOVAL/INSTALLATION, Timing Belt Installation
Note.)
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
Specification
2.4—3.4 N·m
Water temperature °C {°F} Resistance (Ω) {25—35 kgf·cm,
22—30 in·lbf} 59—68
20 {68} 0.5—1.5 A
{6.0—7.0,
44—50}
19—25
5. If not as specified, replace the fuel warmer. {1.9—2.6,
14—18}
FUEL INJECTION PUMP (FIP) INSPECTION
Caution
FIP is sealed to maintain proper function.
Special tools and testers are required when A
disassembling the FIP. Disassembling the
FIP without special tools and testers will R
cause a malfunction.
Consult your distributor for disassembly if any FIP 25—29 19—25

internal parts are possibly malfunctioning. {2.5—3.0, 19—21} {1.9—2.6, 14—18} N·m {kgf·m, ft·lbf}
CONTINUED
F2–17
FUEL SYSTEM
1 Injection pipe 59—68 {6.0—7.0, 44—50}

27—32
2 Accelerator cable {2.7—3.3, R
20—23}
3 Fuel hose
4 Connector R
5 Vacuum hose R
6 Timing belt cover
+ Section B2, TIMING BELT, TIMING BELT
REMOVAL/INSTALLATION, Timing Belt Cover 2.4—3.4 N·m
Installation Note. {25—35 kgf·cm,
22—30 in·lbf}
7 FIP mounting bolt
8 FIP mounting nut
9 FIP
+ Removal Note
10 Key
FIP Removal Note

1. Remove the two FIP pulley mounting bolts. 25—29
2. Loosen the FIP pulley locknut. {2.5—3.0, 19—21}
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3. Remove the pulley with the SST.
49 S120 215A
1 Injection pipe
2 Fuel leak pipe
3 Fuel leak washer
4 Injection nozzle
+ Installation Note
5 Nozzle washer
6 Corrugated gasket
FIP PULLY + Installation Note
LOCKNUT
Corrugated Gasket Installation Note
INJECTION NOZZLE REMOVAL/INSTALLATION Install the bead side facing combustion chamber.
Caution Injection Nozzle Installation Note

Cover the outlet of the injection pipe and Install each injection nozzle onto the FIP, matching
fuel hose with a rag. their identification color rings as shown.
Catch the fuel with a rag.
INJECTION NOZZLE
1. Disconnect the negative battery cable. FIP
PROCEDURE.)
3. Remove the FICD solenoid valve bracket.
6. Complete the “AFTER REPAIR PROCEDURE”. COLOR RING
PROCEDURE.)
CONTINUED
F2–18
FUEL SYSTEM
INJECTION NOZZLE DISASSEMBLY/ASSEMBLY Injection Starting Pressure

1. Connect the injection nozzle to a nozzle tester.
Caution 2. Bleed the air by pumping the nozzle tester handle
The injection port is very small so it must several times.
be kept clean. Otherwise, foreign material 3. Slowly lower the nozzle tester handle and note the
may get stuck in the injection nozzle, pressure when injection starts.
causing damage.
Injection starting pressure
1. Disassemble in the order indicated in the table. 11.4—12.1 MPa
2. Assemble in the reverse order of disassembly. {116—124 kgf/cm2, 1650—1760 psi} (New)
More than 10.0 MPa
{102 kgf/cm2, 1450 psi} (Inspection)
4. If the injection starting pressure is not within the

specification, adjust it by installing the correct shim.
Note
Adding/subtracting 0.02 mm {0.0008 in}
29—49
{3.0—5.0, thickness shim increases/decreases the
22—36} starting pressure approx. 470 kPa {4.8
kgf/cm2, 68 psi}.
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1 Nozzle holder body ADJUSTING SHIM

+ Disassembly Note
2 Ring
3 Shim
4 Nozzle spring
5 Spring seat
6 Spacer
7 Needle valve
+ Assembly Note
8 Nozzle body Atomization
9 Retaining nut
1. Connect the injection nozzle to the nozzle tester.
2. Bleed the air by pumping the nozzle tester handle
several times.
Nozzle Holder Body Disassembly Note
3. Lower the handle several times as quickly as
Secure the retaining nut in a vise and remove the
possible so that a pulsating whistling sound is
nozzle holder body.
heard, and note the atomization pattern.
(1) Uniform, proper atomization
Needle Valve Assembly Note
(2) Incorrect injection angle and direction
When the nozzle body or the needle valve is
damaged, replace them as a set.
(1) (2)
INJECTION NOZZLE INSPECTION
Caution
Fuel and fuel tank used for the nozzle tester
must be kept clean. Otherwise, foreign
material may get stuck between the nozzle
and the nozzle tester, causing damage.
NORMAL FAULTY FAULTY
ANGLE DIRECTION
4. If necessary, disassemble and clean or replace the

injection nozzle.
CONTINUED
F2–19
FUEL SYSTEM
Nozzle Leakage 4. Remove the needle valve from the nozzle body.
1. Connect the injection nozzle to the nozzle tester. 5. Clean the needle valve and the nozzle body with
2. Bleed the air by pumping the nozzle tester handle clean light oil.
several times. 6. Verify that the needle valve moves smoothly in the
3. Apply 8.8 MPa {90 kgf/cm2, 1,280 psi} pressure to nozzle body.
the injection nozzle, and inspect for fuel leakage 7. If not, replace the nozzle assembly.
from the nozzle spray port.
CORRECT WRONG
FUEL CUT VALVE (FCV) REMOVAL/INSTALLATION

4. If fuel leaks, disassemble and clean or replace the Without immobilizer system
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injection nozzle. 1. Disconnect the negative battery cable.
Operating Inspection (Refer to FUEL SYSTEM, BEFORE REPAIR
1. Verify that the needle valve and nozzle body are PROCEDURE.)
not damaged. 3. Remove the FCV.
2. Verify that the nozzle body is not damaged. Hold 4. Install in the reverse order of removal.
the nozzle body upright and insert approximately
two thirds of the needle valve; then see if the
needle valve drops to the valve seat by its own NUT
2.0—2.4 N·m
weight when released. {20—25 kgf·cm,
18—21 in·lbf}
NEEDLE VALVE
FCV
15—25
{1.5—2.6, 11—18}
FUEL CUT VALVE (FCV) INSPECTION

NOZZLE
Without immobilizer system
BODY On-vehicle Inspection
Injection Nozzle Cleaning Note

1. Inspect the outer and inner surfaces of the injection Perform the following test only when directed.
nozzle for carbon accumulation.
2. If carbon is observed on the outer surface, remove 1. With the engine idling, disconnect the FCV
it by using a hard wood chip. connector and verify that the engine stops.
3. If carbon is observed inside of the nozzle, remove 2. If the engine does not stop, carry out the following
it by using a toothpick. inspection.
Off-vehicle Inspection
2. Remove the FCV.
3. Connect the battery positive voltage to the FCV
terminal and GND the FCV body,
4. Verify that the FCV stem is drawn into the FCV.
CONTINUED
F2–20
FUEL SYSTEM
: Continuity : Airflow
Terminal Port
Step
A B A B C
1
2 B+ GND
B A
GND B
B+
5. Replace the FCV if not as specified.

If as specified, inspect following:
C A
Open circuit
GND circuit (FCV body and engine switch 123456567
connector terminal IG1)
AIR FILTER
Power circuit (FCV connector terminal and
engine switch connector terminal IG1)
4. If not as specified, replace the faulty FICD solenoid
valve.
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ENGINE SWITCH
If as specified but the “System Inspection” is failed,
A B inspect following:
Vacuum hose improper routing, kinks or leakage.
Open circuit
GND circuit (FICD solenoid valve No.1 connector
A C terminal B and PCM connector terminal C)
B D terminal B and PCM connector terminal P)
HARNESS SIDE CONNECTOR Power circuit (FICD solenoid valve No.1 connector
(VIEW FROM TERMINAL SIDE) terminal A and engine switch connector terminal
IG1)
Short circuit Power circuit (FICD solenoid valve No.2 connector
GND circuit (FCV body and engine switch terminal A and engine switch connector terminal
connector terminal IG1 to GND) IG1)
Power circuit (FCV connector terminal and
engine switch connector terminal IG1 to GND) ENGINE SWITCH
A B
7. Install the FCV.
A C
FICD SOLENOID VALVE NO.1, NO.2 INSPECTION
System Inspection B D
1. Carry out the “FICD System Inspection”. HARNESS SIDE CONNECTOR
(Refer to TROUBLESHOOTING, (VIEW FROM TERMINAL SIDE)
SYSTEM INSPECTION, FICD System Inspection.)
Short circuit
for the FICD solenoid valve No.1, No.2.
terminal B and PCM connector terminal IG1)
Airflow Inspection
terminal B and PCM connector terminal P)
Note
Power circuit (FICD solenoid valve No.1 connector
Perform the following test only when directed.
terminal A and engine switch connector terminal
IG1 to GND)
Power circuit (FICD solenoid valve No.2 connector
2. Remove the FICD solenoid valve No.1, No.2.
terminal A and engine switch connector terminal
(Refer to INTAKE-AIR SYSTEM, INTAKE-AIR
IG1 to GND)
SYSTEM REMOVAL/INSTALLATION.)
3. Inspect for airflow between ports of the solenoid
valve.
6. Install the FICD solenoid valve No.1, No.2.
CONTINUED
F2–21
FUEL SYSTEM
TIMER CONTROL VALVE (TCV) INSPECTION

Europe and UK
1. Carry out the “Timer Control Valve (TCV) Control
Inspection”.
(Refer to TROUBLESHOOTING, SYSTEM INSPECTION,
Timer Control Valve (TCV) Control Inspection.)
for the TCV.
Note

2. Disconnect the FIP connector (8–pin terminal).
3. Verify that there is continuity between the FIP
connector terminal D and TCV body.
FIP
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A C E G
B D F H
COMPONENT SIDE CONNECTOR

4. If not as specified, send TCV to a distributor for

replacement. If the TCV is okay, but PCM terminal
voltage is out of specification, inspect as follows
and repair or replace as necessary.
Open circuit
Power circuit (FIP connector terminal D and
PCM connector terminal H)
Short circuit
FIP connector terminal D and PCM connector
terminal H to GND
6. Reconnect the FIP connector.
CONTINUED
F2–22
EXHAUST SYSTEM
EXHAUST SYSTEM
1. Start the engine and inspect each exhaust system component for exhaust gas leakage.
Warning
When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait

WL
TURKEY and GENERAL
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(R.H.D., L.H.D.)
EUROPE and UK
1 Tail pipe 4 Front pipe

2 Main silencer 5 Exhaust manifold insulator
3 Middle pipe (Turkey and General (R.H.D., 6 Exhaust manifold
L.H.D.)
OC (Europe and UK) CONTINUED
F2–23
EXHAUST SYSTEM
WL TURBO
cardiagn.com
EUROPE and UK
TURKEY and GENERAL

(R.H.D., L.H.D.)
1 Tail pipe 6 Joint pipe

2 Main silencer 7 Turbocharger
3 Middle pipe (General (L.H.D.)) + Removal Note
OC (Europe and UK) 8 Oil pipe
4 Front pipe + Installation Note
5 Exhaust manifold insulator 9 Exhaust manifold
CONTINUED
F2–24
EXHAUST SYSTEM, EMISSION SYSTEM
Oil Pipe Installation Note EMISSION SYSTEM

Be sure to confirm that the turbocharger is installed
correctly, then install the oil pipe. ROLLOVER VALVE INSPECTION
Water pipe (Refer to FUEL SYSTEM, FUEL TANK
Install the water pipe and tighten to the specified REMOVAL/INSTALLATION.)
torque. 2. Blow from port A and verify that there is airflow.
Tightening torque
24—35 N·m {2.4—3.6 kgf·m, 18—26 ft·lbf}
OIL PIPE A
3. Turn the valve over and blow from port A. Verify
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WATER PIPE that there is no airflow.
Turbocharger Removal Note

Do not drop the turbocharger.
Do not bend the wastegate actuator mounting or
rod.
Cover the intake, exhaust and oil passages to
prevent dirt or other objects from entering.
EVAPORATIVE CHAMBER INSPECTION

If equipped
1. Remove the evaporative chamber.
2. Blow from port A and verify that there is airflow
from port B.
3. If not as specified, replace the evaporative

chamber.
CONTINUED
F2–25
EMISSION SYSTEM
EGR VALVE INSPECTION 4. If not as specified, replace the EGR solenoid valve.
WL Turbo for Europe and UK If the EGR solenoid valve is okay, but PCM
Airflow Inspection terminal voltage is out of specification, inspect as
follows and repair or replace as necessary.
Note Vacuum hose improper routing, kinks or leakage.
Open circuit
1. Remove the EGR valve. Power circuit (EGR solenoid valve connector
2. Inspect for airflow between 1 and 2 when vacuum terminal A and PCM connector terminal 1R)
is applied using a vacuum pump as shown in the GND circuit (EGR solenoid valve connector
figure. terminal B and body GND through common
connector)
EGR SOLENOID VALVE
A B

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Vacuum (kPa {mmHg, inHg}) Airflow
Short circuit
Below –21.3—–25.3 EGR solenoid valve connector terminal A and PCM
Yes
{–160— –190, –6.3— –7.4} connector terminal 1R.
Except above No 5. Repair or replace faulty areas.
6. Install the EGR solenoid valve connector.
3. If not as specified, replace the EGR valve.
EGR PIPE, EGR VALVE REMOVAL/INSTALLATION
EGR SOLENOID VALVE INSPECTION WL Turbo for Europe and UK
WL Turbo for Europe and UK 1. Disconnect the negative battery cable.
Airflow Inspection 2. Remove in the order indicated in the table.
Note 7.9—10.7 N·m
19—25
{80—110 kgf·cm,
Perform the following test only when directed. 69.5—95.4 in·lbf} {1.9—2.6, 14—18}

2. Remove the EGR solenoid valve
(Refer to INTAKE-AIR SYSTEM, INTAKE-AIR
SYSTEM REMOVAL/INSTALLATION, WL Turbo.) 19—25
3. Inspect for airflow between ports of the solenoid {1.9—2.6, 14—18}
valve. 35—40
{3.5—4.0,
25—29}
: Continuity : Airflow
Terminal Port
Step
A B A B C
1 EGR pipe
1
2 EGR valve
2 B+ GND
B A
GND B
B+
C A
123456567
AIR FILTER
CONTINUED
F2–26
CONTROL SYSTEM
CONTROL SYSTEM
COMPONENT PARTS
WL TURBO
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WL TURBO
1 Glow indicator light 10 A/C relay

2 Temperature control dial 11 TCV*2
3 Engine switch 12 Control lever position sensor*2
4 PCM 13 Glow plug
5 FICD solenoid valve No.2 14 NE sensor
6 FICD solenoid valve No.1 15 Idle switch*2
7 EGR solenoid valve*1 16 Starter
8 ECT sensor 17 Glow plug relay
9 DLC
CONTINUED
*1: WL Turbo for Europe and UK
*2: Europe and UK
F2–27
CONTROL SYSTEM
POWERTRAIN CONTROL MODULE (PCM)

1. Disconnect the battery negative cable.
2. Remove the driver’s side front side trim.
(Refer to Section S, TRIM, FRONT SIDE TRIM
8.9—12.7 N·m
{90—130 kgf·cm, 78—112 in·lbf}
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1 PCM connector
2 PCM installation nut
3 PCM
POWERTRAIN CONTROL MODULE (PCM)

INSPECTION
Caution
The PCM terminal voltages vary with
change in measuring conditions and
vehicle conditions. Always carry out a total
inspection of the input systems, output
systems, and PCM to determine the cause
of trouble. Otherwise, a wrong diagnosis
will be made.
1. Remove the driver’s side front side trim.

2. Remove the PCM with the connector connected.
(Refer to POWERTRAIN CONTROL MODULE
(PCM) REMOVAL/INSTALLATION.)
Note
With the PCM connector connected, body
ground the voltmeter negative (–) lead and
measure the voltage at each PCM terminal by
inserting the voltmeter positive (+) lead.
3. Measure the voltage of each PCM terminals by

using a voltmeter.
4. If the output voltage is not normal while each input
voltage is normal, inspect the related device
systems. When they are normal, replace the PCM.
5. Install the PCM.
(Refer to POWERTRAIN CONTROL MODULE (PCM)
6. Install the driver’s side front side trim.
CONTINUED
F2–28
CONTROL SYSTEM
Terminal Voltage (Reference)

Europe and UK Turkey and General (R.H.D. ,L.H.D.)
S Q O M K I G E C A O M K I G E C A
T R P N L J H F D B P N L J H F D B
Termi- Connected Voltage

Signal Test condition Action
nal to (V)
A – – – – –
A*1 Constant Control Engine ON Approx. Inspect related harness.
voltage lever switch 5.0
position
osition
sensor OFF Below Inspect PCM.
EGR 1.0 Inspect related harness.
valve
Idle Approx.
position
sensor 5.0
B System Ground Constant Below Inspect related harness.

ground 1.0
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C FICD FICD sole- Idle ECT is below 20°C {68°F}. Below Inspect FICD solenoid
control noid valve 1.0 valve No.1.
No.1 + FUEL SYSTEM, FICD
SOLENOID VALVE No No.1,
1
ECT is above 20°C {68°F}. B+
No.2 INSPECTION
Inspect related harness
D Start Engine Engine switch is on. Below Inspect related harness
switch 1.0
(Starter) While cranking Approx.
10
E ECT ECT sensor Engine ECT is 20°C {68°F}. Approx. Inspect engine coolant
switch is on. 3.1 temperature sensor.
+ ECT SENSOR
After warm-up Approx. INSPECTION
0.8 Inspect related harness
F Engine NE sensor Engine switch is on. Approx. Inspect NE sensor.
speed 0 + NE SENSOR
(Input) Idle Approx. INSPECTION
0.05 Inspect related harness
G A/C Temperature Engine Temperature control dial is B+ Inspect microswitch.
(With A/C) control dial switch is on. off and fan switch is off. + Section U, CONTROL
SYSTEM, HEATER
CONTROL UNIT
INSPECTION
Temperature control dial is Below Inspect fan switch.
at position other than off 1.0 + Section U, CONTROL
and fan switch is on. SYSTEM, HEATER
CONTROL UNIT
INSPECTION
Inspect related harness
H – – – – –
H*1 Idle (Control Idle switch Engine Accelerator pedal is de- B+ Inspect idle switch.
lever open switch is on. pressed. + IDLE SWITCH
or close) Accelerator pedal is re- Below INSPECTION
leased. 1.0 Inspect related harness.
*1: Europe and UK
CONTINUED
F2–29
CONTROL SYSTEM

nal to (V)
I Glow plug Glow plug ECT is be- For less than approx. 15 B+ Inspect related harness
voltage low 60°C seconds after turning
{140°F}. engine switch on.
Over approx. 15 seconds Below
after turning engine switch 1.0
on.
For less than 10 minutes B+
after starting engine.
Over 10 minutes after Below
starting engine. 1.0
While cranking B+
ECT is For less than approx. 2 B+
above 60°C seconds after turning en-
{140°F}. gine switch on.
Over approx. 2 seconds Below
after turning engine switch 1.0
on.
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While cranking B+
J Power Engine Engine OFF Below Inspect engine switch.
supply switch switch 1.0 + Section T, POWER
SYSTEM,, IGNITION
ON B+ SWITCH INSPECTION
Inspect related harness.
J*1 Control le- Control le- Engine Accelerator pedal is fully Approx. Inspect control lever posi-
ver position ver position switch is on. open. 4.2 tion sensor.
((Detection)) sensor + CONTROL LEVER
Accelerator pedal is fully Approx. POSITION SENSOR
closed. 0.8—1.5 INSPECTION
K Engine Instrument Engine switch is on. B+ Inspect related harness.
speed (Out-
(Out cluster
put) Idle 6.9—7.1
L*1 Power Engine Engine OFF Below Inspect engine switch.

supply switch switch 1.0 + Section T, POWER
SYSTEM,, IGNITION
ON B+ SWITCH INSPECTION
L*2 A/C control A/C relay Engine switch is on. B+ Inspect A/C relay.
(With A/C) + SSection
ti U,
U CONTROL
Idle A/C is not operating B+
SYSTEM, A/C RELAY
A/C is operating Below INSPECTION
1.0 Inspect related harness.
M Glow indica- Glow indica- Engine switch is off. Below Inspect glow indicator
tor light
g con- tor light
g 1.0 light
g
trol Engine switch is on and within approx. 4.5 + Section T, WARNING
sec. (25 °C {77 °F}). AND INDICATOR
SYSTEM, WARNING
Over 4.5 seconds (25 °C {77 °F}) after B+ AND INDICATOR LIGHT
turning engine switch on. BULB REPLACEMENT
N*1 A/C control A/C relay Engine switch is on. B+ Inspect A/C relay.
(With A/C) + S ti U,
Section U CONTROL
Idle A/C is not operating B+
SYSTEM, A/C RELAY
A/C is operating Below INSPECTION
1.0 Inspect related harness.
N*2 – – – – –
*1: Europe and UK
*2: Turkey and General (R.H.D., L.H.D.) CONTINUED
F2–30
CONTROL SYSTEM

nal to (V)
O Glow sys- Glow plug Engine cool- For less than approx. 15 B+ Inspect glow plug relay.
tem relay ant tempera- seconds after turning en- + INTAKE-AIR SYSTEM,
ture is below gine switch on. GLOW PLUG RELAY
60°C Over approx. 15 seconds Below INSPECTION
{140°F}. after turning engine switch 1.0 Inspect related harness.
on.
For less than 10 minutes B+
after starting engine.
Over 10 minutes after Below
starting engine. 1.0
While cranking B+
Engine cool- For less than approx. 2 se- B+
ant tempera- conds after turning engine
ture is switch on.
above 60°C Over approx. 2 seconds Below
{140°F}. after turning engine switch 1.0
on.
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While cranking B+
P FICD FICD sole- Idle Temperature control dial Below Inspect FICD solenoid
control noid valve is not at OFF 1.0 valve No.2.
No.2 Engine coolant temper- + FUEL SYSTEM, FICD
ature is below 60°C SOLENOID VALVE No.1,
{140°F}. No.2 INSPECTION
Temperature control dial B+ Inspect related harness.
is not at OFF
Engine coolant temper-
ature is above 60°C
{140°F}.
Q – – – – –
Q*1 Timer TCV Engine switch is on. B+ Inspect TCV.
control + CONTROL SYSTEM,
Idle Below TIMER CONTROL VALVE
1.0 (TCV) INSPECTION
R – – – – –
R*3 EGR valve EGR Engine switch is on. B+ Inspect EGR solenoid
control solenoid valve.
valve + EMISSION SYSTEM,
SYSTEM
Idle Below EGR SOLENOID VALVE
1.0 INSPECTION
S – – – – –
S*1 Diagnostic Data link Engine Open terminal TEN B+ Inspect related harness.
test mode connector switch is on
on.
(DLC) (Ter- Short terminal TEN Below
minal TEN) 1.0
T – – – – –
T*1 DTC output Data link No DTC output Below Inspect related harness.
connector 1.0
(DLC) (Ter
(Ter-
minal FEN) DTC output 0—B+
*1: Europe and UK
*2: Turkey and General (R.H.D., L.H.D.) CONTINUED
*3: WL Turbo for Europe and UK
F2–31
CONTROL SYSTEM
NE SENSOR INSPECTION ENGINE COOLANT TEMPERATURE (ECT) SENSOR

INSPECTION
Note
Perform the following test only when directed. Note
1. Disconnect the NE sensor connector.
2. Measure the resistance between the NE sensor 1. Drain the engine coolant from the radiator.
connector terminals A and B by using an (Refer to Section E, ENGINE COOLANT, ENGINE
ohmmeter. COOLANT REPLACEMENT.)
2. Disconnect the ECT sensor connector.
3. Remove the ECT sensor.
A B 4. Place the sensor in water with a thermometer, and
heat the water gradually.
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Specification
800—920 Ω
3. If not as specified, replace the NE sensor.
Tightening torque
7.9—10.7 N·m A B
{80—110 kgf·cm, 69.5—95.4 in·lbf}
4. If NE sensor is okay, but PCM terminal F voltage is

out of specification, inspect the following:
Open circuit
Engine speed (input) circuit (NE sensor
terminal F)
GND circuit (NE sensor connector terminal B
and PCM connector terminal B) 5. Measure the resistance between engine coolant
Short circuit temperature sensor terminals A and B by using an
NE sensor connector terminal A and PCM ohmmeter.
connector terminal F to GND
5. Repair or replace faulty areas. Specification
6. Reconnect the NE sensor connector. Water temperature (°C {°F}) Resistance (kΩ)
20 {68} 2.27—2.73
80 {176} 0.29—0.34
6. If not as specified, replace the ECT sensor.

7. Refill the radiator with the specified engine coolant.
8. Install the ECT sensor.
Tightening torque
16—23 N·m {1.6—2.4 kgf·m, 12—17 in·lbf}
9. If ECT sensor is okay, but PCM terminal E voltage

is out of specification, inspect as follows:
CONTINUED
F2–32
CONTROL SYSTEM
Open circuit Open circuit

Reference voltage circuit (ECT sensor Power supply circuit (Idle switch connector terminal
connector terminal A and PCM connector E and PCM connector terminal 2H through
terminal E through common connector) common connector)
GND circuit (ECT sensor connector terminal B GND circuit (Idle switch connector terminal and
and PCM connector terminal B through body GND)
common connector)
Short circuit
ECT sensor connector terminal A and PCM
connector terminal E through common
connector to GND G E C A
10. Repair or replace faulty areas. H F D B
11. Reconnect the ECT sensor connector.
IDLE SWITCH INSPECTION HARNESS SIDE CONNECTOR

Europe and UK (VIEW FROM TERMINAL SIDE)
Note
Perform the following test only when directed. Short circuit
Power supply circuit (Idle switch connector terminal
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1. Disconnect the negative battery cable. E and PCM connector terminal H through common
2. Disconnect the 8-pin connector of FIP. connector to GND)
3. Inspect for continuity between the idle switch 6. Repair or replace faulty areas.
terminal E and ground using an ohmmeter. 7. Reconnect the 8-pin connector of FIP.
CONTROL LEVER POSITION SENSOR

INSPECTION
Europe and UK
A C E G Output Voltage Inspection
B D F H Note
COMPONENT SIDE CONNECTOR
(VIEW FROM TERMINAL SIDE) 1. Verify that the FIP control lever is fully closed.
2. Turn the engine switch on and measure the PCM
terminal J voltage.
Specification Specification
: Continuity Measuring condition Voltage (V)
Measuring
g Terminal Accelerator pedal is fully
condition Approx. 4.2
E GND open.
Not accelerated Accelerator pedal is fully
Approx. 0.8—1.5
Other closed.
3. If not as specified, replace the control lever

Caution position sensor. When the reading is out of
Turning the idle switch with its connector
specification, send the FIP with the control lever
connected can break the harness. Be sure position sensor to a distributor to repair. If the PCM
to disconnect the connector when turning terminal voltage is out of specification, inspect as
the idle switch more than one rotation. follows and repair or replace as necessary.
4. If not as specified, loosen the idle switch locknut Open circuit

Constant voltage circuit (Control lever position
and adjust the continuity by turning the idle switch.
5. If not as specified, replace the idle switch. If the sensor connector terminal B and PCM connector
idle switch is okay, but PCM terminal voltage is out terminal A through common connector)
Control lever position signal circuit (Control lever
of specification, inspect as follows and repair or
replace as necessary. position sensor connector terminal A and PCM
connector terminal J through common connector)
GND circuit (Control lever position sensor
connector terminal C and PCM connector terminal
B through common connector)
CONTINUED
F2–33
CONTROL SYSTEM
G E C A
H F D B

Short circuit
Control lever position sensor connector terminal B
and PCM connector terminal A through common
connector to GND
Control lever position sensor connector terminal A
and PCM connector terminal J through common
connector to GND
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5. Reconnect the 8-pin connector of FIP.
CONTINUED
F2–34
ON-BOARD DIAGNOSTIC SYSTEM Using the Voltmeter

1. Turn the engine switch off.
Europe and UK only 2. Connect the DLC located in the engine
DTC READING PROCEDURE compartment terminal TEN and GND using a
Using the SST (Self-Diagnosis Checker) jumper wire.
1. Connect the SSTs to the DLC located in the engine
compartment and GND the black (negative) lead to Caution
the body. Connecting the wrong DLC terminals may
49 B019 9A0 connect the specified terminals only.
DLC
3. Connect the negative battery lead of voltmeter
(20V range) to the DLC terminal FEN, and the
positive lead to the DLC terminal +B.
49 H018 9A1A
FEN
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2. Set the select switch on the SST (self-diagnosis
checker) to A.
3. Turn the dial switch on the SST (system selector) DLC
to 1, and the test switch to SELF TEST. GND
4. Turn the engine switch on. TEN +B
5. Verify that the buzzer sounds for approximately
3 seconds and code “88” flashes for 5 seconds. If 4. turn the engine switch on.
DTC is not detected, “00” will then be indicated. 5. The voltmeter indicates the battery positive voltage
for approximately 3 seconds, then indicates 0V.
Note 6. Read the DTCs indicated by the movement of the
If the “88” does not flash, inspect +B terminal of voltmeter’s needle. If DTC is not detected, the
the data link connector, and the related needle does not move.
harnesses and connectors. 7. If any DTCs are indicated, inspect the appropriate
If the “88” flashes and the buzzer sounds more areas and repair as necessary.
than 20 seconds, inspect the harness between 8. After completion of repairs, erase all DTCs from
the PCM terminal and the DLC. If the harness the memory. (Refer to AFTER REPAIR
is normal, replace the PCM and inspect. PROCEDURE.)
9. Remove the voltmeter and the jumper wire.
6. If any DTCs are indicated, inspect the appropriate
areas and repair as necessary. AFTER REPAIR PROCEDURE
1. After repairs, disconnect the negative battery cable
Note for at least 20 seconds, and depress the brake
A DTC consists of four numbers. They are pedal. Reconnect the negative battery cable.
flashed one by one in the right window on the 2. Warm up the engine to normal operating
display. (“1” is always shown on the left temperature.
window.)
When there are multiple malfunctions, the Note
codes are displayed in numerical order. If the engine will not start, keep the starter
operated for 5-6 seconds.
7. After completion of repairs, erase all DTCs from
the memory. (Refer to AFTER REPAIR 3. Perform the “DTC READING PROCEDURE”
PROCEDURE.) again.
8. Remove the SSTs. 4. Verify that the DTC is not detected.
CONTINUED
F2–35
DTC INSPECTION
DTC Table
DTC No. Indicator Pattern Condition
Engine coolant temperature (ECT) sensor
09
malfunction
12 Control lever position sensor malfunction
36 Glow plug relay malfunction
DTC 09 ENGINE COOLANT TEMPERATURE (ECT) SENSOR MALFUNCTION

DETECTION Input value to PCM is excessively high or low for more than 2.0 sec.
CONDITION
ECT sensor malfunction
POSSIBLE
Open or short circuit in wiring from ECT sensor terminal A to PCM terminal E
CAUSE
Open or short circuit in wiring from ECT sensor terminal B to PCM terminal B
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1 Does ECT sensor or PCM connector have Yes Repair or replace connector, then go to Step 6.
2 Disconnect ECT sensor connector. Yes Go to next step.
Turn engine switch on. Is there 5 V at No Inspect for open or short circuit in wiring harness. (PCM
connector terminal A? terminal B–ECT sensor terminal B)
3 Is there continuity between connector Yes Go to next step.
terminal A and PCM terminal E? No Repair or replace wiring harness, then go to Step 6.
4 Is ECT sensor okay? Yes Go to next step.
+ CONTROL SYSTEM, ENGINE
COOLANT TEMPERATURE (ECT) No Replace ECT sensor, then go to Step 6.
SENSOR INSPECTION
Is same code No. present after performing No Intermittent poor connection in harnesses or connector.
“After Repair Procedure”? Repair connectors and/or harnesses, then go to next step.
Is there any DTC present after performing
“After Repair Procedure”? No Troubleshooting completed.
PCM (20 PIN)

ECT SENSOR
E A B
J B
HARNESS SIDE CONNECTOR HARNESS SIDE CONNECTOR

(VIEW FROM HARNESS SIDE) (VIEW FROM TERMINAL SIDE)
CONTINUED
F2–36
DTC 12 CONTROL LEVER POSITION SENSOR MALFUNCTION

Input voltage from control lever positIon sensor is below 0.1 V or above 4.75 V when continued for 1.0
DETECTION
sec.
CONDITION
When idle switch is on, input voltage from control lever position sensor is below 0.35V or above 1.39V.
Control lever position sensor malfunction
Idle switch malfunction
Open circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal C to PCM termi-
nal B
POSSIBLE
Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal A to
CAUSE
PCM terminal J
Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal B to
PCM terminal A
Open or short circuit wiring from idle switch (FIP connector: 8pin) terminal E to PCM terminal H
1 Does control lever position sensor connector Yes Repair or replace connectors, then go to Step 7.
or PCM connector have poor connection? No Go to next step.
2 Disconnect control lever position sensor Yes Go to next step.
connector. Turn engine switch on. Is there No Inspect for open or short circuit in wiring harness. (PCM
5 V at connector terminal B?
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terminal A–control lever position sensor terminal B)
terminal A and PCM terminal J? No Repair or replace wiring harness, then go to Step 7.
4 Is there continuity between connector Yes Replace control lever position sensor, then go to Step 7.
terminal C and PCM terminal B? No Repair or replace wiring harness, then go to Step 7.
terminal E and PCM terminal H? No Repair or replace wiring harness, then go to Step 7.
6 Is idle switch okay? Yes Go to next step.
+ CONTROL SYSTEMSYSTEM, IDLE SWITCH
INSPECTION No Replace idle switch.

Is same code No. present after performing No Intermittent poor connection in harness or connector.
“After Repair Procedure”? Repair connector and/or harness, then go to next step.
CONTROL LEVER POSITION SENSOR

PCM (20 PIN)
G E C A
A
J B H F D B
HARNESS SIDE CONNECTOR HARNESS SIDE CONNECTOR

(VIEW FROM HARNESS SIDE) (VIEW FROM TERMINAL SIDE)
CONTINUED
F2–37
DTC 36 GLOW PLUG RELAY MALFUNCTION

When the glow plug relay is on, current voltage signal of the relay below 1.0 V is inputted to the PCM
DETECTION continuously for more than 1.0 sec.
CONDITION When the glow plug relay is off, signal of the relay current voltage above 4.0 V is inputted to the PCM
continuously for more than 1.0 sec.
Glow plug relay malfunction
POSSIBLE Open or short circuit in wiring from PCM terminal O to glow plug relay terminal A (BR)
CAUSE Open or short circuit in wiring from PCM terminal I to glow plug relay terminal A (B)
Open or short circuit in wiring from glow plug relay terminal A (R) to glow fuse
1 Does glow plug relay connector or PCM Yes Repair or replace connectors, then go to Step 5.
2 Remove glow plug relay. Yes Go to next step.
Is there continuity between connector
terminal A and PCM terminal O?
Is there continuity between connector No Repair or replace wiring harness.
terminal A (B) and PCM terminal I?
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terminal B and body GND? No Repair or replace wiring harness.
terminal A (R) and glow fuse? No Repair or replace wiring harness.
5 Is glow plug relay okay? Yes Go to next step.
+ INTAKE-AIR
INTAKE AIR SYSTEM,
SYSTEM GLOW PLUG
RELAY INSPECTION No Replace glow plug relay.

Is same code No. present after performing No Intermittent poor connection in harnesses or connectors.
“After Repair Procedure”? Repair connectors and/or harnesses, then go to next step.
GLOW PLUG RELAY

PCM (20 PIN)
A
A A
O I B
(WIRE (WIRE
COLOR: R) COLOR: B)
(VIEW FROM HARNESS SIDE) HARNESS SIDE CONNECTOR
CONTINUED
F2–38
TROUBLESHOOTING
TROUBLESHOOTING TROUBLESHOOTING ITEM TABLE

Confirm trouble symptom by using the following
FOREWORD diagnostic index, then go to appropriate
Before processing with the following troubleshooting, troubleshooting chart.
refer to section GI to understand the basic If a diagnostic trouble code is displayed, proceed
troubleshooting procedure. with inspection steps for the code.
No. TROUBLESHOOTING ITEMS DESCRIPTION

1 Melts main or other fuse —
2 Will not crank Starter does not work.
3 Hard start/long crank/erratic start/erratic crank Starter cranks engine at normal speed but engine requires
excessive cranking. Battery is in normal condition.
4 Engine stalls After start Engine stops unexpectedly at idle and/or after start.
At idle
5 Cranks normally but will not start Starter cranks engine at normal speed but engine will not
run.
Refer to “ENGINE STALLS” if this symptom appears after
engine stall.
Fuel is in tank
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Battery is in normal condition.
6 Slow return to idle/fast idle Engine takes more time than normal to return to idle speed.
Engine speed continues at fast idle after warm-up.
7 Engine runs rough/rolling idle Engine speed fluctuates between specified idle speed and
lower speed and excessive engine shake.
Idle speed is too slow and engine shakes excessively.
8 Runs on Engine runs after engine switch is turned off.
9 Engine stalls/quits Acceleration/cruise Engine stops unexpectedly at beginning of acceleration dur-
ing acceleration or while cruising.
Engine runs rough Acceleration/cruise Engine speed fluctuates during acceleration or cruising.
Misses Acceleration/cruise Engine misses during acceleration or cruising.
Buck/jerk Acceleration/cruise/ Vehicle bucks/jerks during acceleration, cruising, or decel-
deceleration eration.
Hesitation/stumble Acceleration Momentary pause at beginning of acceleration or during ac-
celeration.
Surges Acceleration/cruise Momentary minor irregularity in engine output.
10 Lack/loss of power Acceleration/cruise Performance is poor under load (i.e. power down when
climbing hills).
11 Poor fuel economy Fuel economy is unsatisfactory.
12 High oil consumption/leaks Oil consumption is excessive.
13 Cooling system concerns Overheating Engine runs at higher than normal temperature/overheats.
14 Cooling system concerns Runs cold Engine does not reach normal operating temperature.
15 Excessive black smoke Excessive black smoke is observed in exhaust gas.
16 Engine noise Engine noise from under hood.
17 Vibration concerns (engine) Vibration from under hood or driveline.
18 A/C does not work. A/C compressor magnetic clutch does not engage when A/C
is turned on.
19 A/C always on/A/C compressor runs continuously. A/C compressor magnetic clutch does not disengage.
20 Intermittent concerns Symptom occurs randomly and is difficult to diagnose.
CONTINUED
F2–39
TO. MODEL .INDEX
Symptom 1-Melts main or other fuse F2-40

Symptom 2-Will not crank F2-41
Symptom 3-Hard start/long crank/erratic start/erratic crank F2-42-43
Symptom 4-Engine stalls-after start/at idle F2-43-44
Symptom 5-Cranks normally but will not start F2-45-46
Symptom 6-Slow return to idle/fast idle F2-46
Symptom 7-Engine runs rough/rolling idle F2-47-48
Symptom 8-Runs on F2-49
Symptom 9-Engie stalls/quits-acceleration/cruise
- Engine runs rough – acceleration/cruise
- Misses-acceleration/cruise
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- Buck/jerk – acceleration/cruise/deceleration
- Hesitation/stumble – acceleration
- Surges – acceleration/cruise F2-49-50
Symptom 10-Lack/loss of power-acceleration/cruise F2-51-52
Symptom 11-Poor fuel economy F2-53
Symptom 12-High oil consumption/leaks F2-54
Symptom 13-Cooling system concerns-overheating F2-55
Symptom 14-Cooling system concerns-runs cold F2-55
Symptom 15-Excessive black smoke F2-56
Symptom 16-Engine noise F2-56-58
Symptom 17-Vibration concerns (engine) F2-58
Symptom 18-A/C does not work F2-58-59
Symptom 19-A/C is always on/a/c compressor runs continuously F2-59-60
Symptom 20-Intermittent concerns F2-60
CONTINUED
TROUBLESHOOTING
SYMPTOM 1 MELTS MAIN OR OTHER FUSE
TROUBLESHOOTING HINTS
Inspect the condition of the fuse.
Deterioration
Shorted harness
fuse
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Repair shorted harness and replace fuse Replace fuse
Damaged Fuse Related Wiring Harness

MAIN (100 A) Main fuse
Engine switch
Generator
PCM
Blower relay
Blower fan motor
A/C relay
Refrigerant pressure switch
HEAD (30 A) HEAD fuse
Generator
GLOW (60 A) Glow plug relay
Glow plugs
ENGINE (15 A) Engine fuse
PCM
FICD solenoid valve No.1
FCV
CONTINUED
F2–40
TROUBLESHOOTING
SYMPTOM 2 WILL NOT CRANK

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

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

SULTS
10 Remove and inspect injection nozzle as fol- Yes Remove FIP.
lows: Inspect FIP.
Clogged nozzle If FIP okay, inspect fuel line for clogging.
Incorrect valve opening pressure No Clogged nozzle or seized needle valve:
Faulty nozzle gasket Disassemble and clean or replace the injection nozzle.
Is injection nozzle okay? Incorrect valve opening pressure:
Adjust injection nozzle opening pressure.
Faulty nozzle gasket:
Replace nozzle gasket.
SYMPTOM 4 ENGINE STALLS – AFTER START/AT IDLE

DESCRIPTION Engine stops unexpectedly at idle and/or after start.
CAUSE Starting system malfunction Fuel filter clogging
Air cleaner restriction Incorrect injection timing
Incorrect idle speed FIP malfunction
Engine overheating Injection nozzle malfunction
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A/C system improper operation Low engine compression
Glow system malfunction FICD malfunction
SULTS
1 Note: Yes Go to “ON-BOARD DIAGNOSTIC FUNCTION” of
The following test should be performed immobilizer system.
on vehicles with immobilizer system.
Go to next step for vehicles without
immobilizer system.
system
No Go to next step.
Does immobilizer indicator light flash and
indicate?
y
Cracks on intake-air system parts No Service as necessary and repeat Step 2.
Air cleaner element restriction
Are all items okay?
3 Is engine overheating? Yes Go to flowchart No.13 for “COOLING SYSTEM
CONCERNS-OVERHEATING”.
No Go to next step.
4 Does engine run normally after warm-up? Yes Go to next step.
No Go to Step 6
5 Inspect glow system operation, Yes Go to next step.
+ SYSTEM INSPECTION, Glow System No Repair or replace any defective part according to glow
Inspection. system operation results.
Is quick start system operation normal? + SYSTEM INSPECTION, Glow System Inspection
6 Note: Yes Go to next step.
If the following test cannot be
performed due to engine stalls, go to
step.
next ste
No If A/C is always on, go to symptom troubleshooting
Connect the pressure gauge to A/C lines. No.19 “A/C always ON/A/C compressor runs continu-
Turn the fan switch on. ously”. For other symptoms, inspect following:
Is pressure within specification? Refrigerant charging amount.
+ section U, REFRIGERANT SYSTEM Cooling fan operation.
SERVICE PROCEDURES,
REFRIGERANT PRESSURE CHECK.
CONTINUED
F2–43
TROUBLESHOOTING

SULTS
7 Inspect FICD system operation. Yes Go to next step.
+ SYSTEM INSPECTION, FICD System No Inspect the following:
Inspection Engine coolant temperature sensor
Is FICD operation normal? + CONTROL SYSTEM, ENGINE COOLANT
TEMPERATURE SENSOR INSPECTION
Vacuum pump
Vacuum leakage around vacuum pump or fittings
FICD solenoid valves
+ FUEL SYSTEM, FICD SOLENOID VALVE No.1,
No.2 INSPECTION
FICD actuator
PCM terminal voltage, J
Open circuit between FICD solenoid No.1 connector
terminal B and PCM connector terminal C
Open circuit between FICD solenoid No.2 connector
terminal B and PCM connector terminal P
Repair or replace any defective part as necessary.
If FICD system is okay, go to next step.
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8 Depress accelerator pedal slightly. Yes Inspect and adjust idle speed.
Crank the engine. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT
If symptom still appears, go to next step.
Does engine start now? No Go to next step.
9 Inspect fuel leakage from fuel pipe. Yes Repair or replace as necessary.
Is timing belt okay? Damaged valve seat
Worn valve seat or valve guide
timing.
timing belt.
Is injection timing okay? No Adjust injection timing.
ADJUSTMENT
13 Inspect fuel filter for clogging. Yes Go to next step.
Is fuel filter okay? No Replace fuel filter cartridge.
14 Remove injection nozzle. Yes Go to next step.
Inspect injection nozzle for the following: No Clogged nozzle or seized needle valve:
Clogged nozzle Disassemble and clean or replace the injection nozzle.
Seized needle valve Incorrect valve opening pressure:
Incorrect valve opening pressure Adjust injection nozzle opening pressure.
Faulty nozzle gasket Faulty nozzle gasket:
Is injection nozzle okay? Replace nozzle gasket.
15 Is valve clearance correct? Yes Remove FIP.
Inspect FIP.
No Adjust valve clearance.
CONTINUED
F2–44
TROUBLESHOOTING
SYMPTOM 5 CRANKS NORMALLY BUT WILL NOT START

DESCRIPTION Starter cranks engine at normal speed but engine will not run.
Refer to “ENGINE STALLS” if this symptom appears after engine stall.
Fuel is in tank.
POSSIBLE Poor fuel quality Fuel filter clogged
CAUSE Air cleaner restriction Incorrect injection timing
FCV malfunction FIP malfunction
Low engine compression Injection nozzle malfunction
Fuel leakage
SULTS
1 Note: Yes Go to “ON-BOARD DIAGNOSTIC FUNCTION” of
The following test should be performed immobilizer system.
on vehicles with immobilizer system.
Go to next step for vehicles without
immobilizer system.
system
No Go to next step.
Does immobilizer indicator light flash and
indicate?
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Cracks on intake-air system parts No Service as necessary.
Air cleaner element restriction Repeat Step 2.
Fuses
Are all items okay?
3 Turn engine switch to ON. Yes Go to next step.
Is FCV operation sound heard? No Inspect for the following:
Stuck FCV
Open circuit in FCV
Open wiring harness between engine switch and
FCV.
Poor ground of FCV.
4 Measure engine compression. Yes Go to step 6.
Low tension Worn piston, piston ring or cylinder
Worn valve stem or valve guide
timing.
timing belt.
Is injection timing okay? No Adjust injection timing.
ADJUSTMENT
Clogged nozzle Disassemble and clean or replace the injection nozzle.
CONTINUED
F2–45
TROUBLESHOOTING

SULTS
9 Is valve clearance correct? Yes Remove FIP.
Inspect FIP.
SYMPTOM 6 SLOW RETURN TO IDLE/FAST IDLE

DESCRIPTION Engine takes more time than normal to return to idle speed.
Engine speed continues at fast idle after warm-up.
POSSIBLE Malfunction of ECT sensor Injection timing is incorrect.
CAUSE Thermostat stuck open Accelerator cable free play incorrect adjustment
FICD malfunction Idle speed incorrect adjustment
SULTS
1 Inspect FICD system operation. Yes Go to next step.
+ SYSTEM INSPECTION, FICD System No Inspect the following:
Inspection. ECT sensor
Is FICD operation normal? + CONTROL SYSTEM, ENGINE COOLANT
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TEMPERATURE (ECT) SENSOR INSPECTION
No.2 INSPECTION
FICD actuators.
PCM terminal voltage (J)
+ CONTROL SYSTEM, PCM INSPECTION
Short to ground circuit between FICD solenoid valve
No.1 connector terminal B and PCM connector ter-
minal C.
Short to ground circuit between FICD solenoid valve
No.2 connector terminal B and PCM connector ter-
minal P
+ ENGINE TUNE-UP, INJECTION TIMING No Adjust injection timing.
ADJUSTMENT. + ENGINE TUNE-UP, INJECTION TIMING
Is injection timing okay? ADJUSTMENT
3 Remove thermostat and inspect operation. Yes Inspect for free play of accelerator cable. Adjust free
+ section E, THERMOSTAT, THERMOSTAT play as necessary.
INSPECTION. If free play is okay, inspect and adjust idle and/or idle-
up speed.
Is thermostat okay? + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT
No Replace thermostat.
CONTINUED
F2–46
TROUBLESHOOTING
SYMPTOM 7 ENGINE RUNS ROUGH/ROLLING IDLE

DESCRIPTION Engine speed fluctuates between specified idle speed and lower speed and excessive engine
shake.
Idle speed is too slow and engine shakes excessively.
CAUSE Starting system malfunction Fuel filter clogged
Air cleaner restriction Incorrect injection timing
Incorrect idle speed FIP malfunction
Glow system malfunction FICD malfunction
SULTS
Air cleaner element restriction No Service as necessary and repeat Step 1.
2 Is engine overheating? Yes Go to flowchart No.13 for “COOLING SYSTEM CON-

CERNS-OVERHEATING”.
No Go to next step.
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3 Does engine run normally after warm-up? Yes Go to next step.
No Go to Step 5.
4 Inspect glow system operation. Yes Go to Step 6.
+ SYSTEM INSPECTION
INSPECTION, Glow System
Inspection. No Repair or replace any defective part according to glow
system operation results.
Is glow system operation normal? + SYSTEM INSPECTION, Glow System Inspection

If the following test cannot be
performed due to engine stalls, go to
step.
next ste
No If A/C is always on, go to symptom troubleshooting
Connect the pressure gauge to A/C (if No.19 “A/C always ON/ A/C compressor runs continu-
equipped) lines. Turn the blower switch on. ously”. For other symptoms, inspect following:
Is the pressure within specification? Refrigerant charging amount.
+ section U, REFRIGERANT SYSTEM Cooling fan operation.
SERVICE PROCEDURES,
REFRIGERANT PRESSURE CHECK.
6 Inspect for FICD system operation. Yes Go to next step.
+ SYSTEM INSPECTION, FICD System In- No Inspect the following:
spection Engine coolant temperature sensor
Is FICD operation normal? + CONTROL SYSTEM, ECT SENSOR INSPECTION
Vacuum pump
Vacuum leaks around vacuum pump or fittings
No.2 INSPECTION
Inspection
FICD actuators
PCM terminal voltage (J)
Open circuit between FICD solenoid valve No.1 con-
nector terminal B and PCM connector terminal C.
Open circuit between FICD solenoid valve No.2 con-
nector terminal B and PCM connector terminal P.
CONTINUED
F2–47
TROUBLESHOOTING

SULTS
7 Depress accelerator pedal slightly. Yes Inspect and adjust idle speed.
Crank the engine. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.
If symptom still appears, go to next step.
Does engine start now? No Go to next step.
8 Inspect fuel leakage from fuel pipe. Yes Repair or replace as necessary.
Is any fuel leakage found on fuel pipe? No Go to next step.
The following test should be performed
on vehicles with EGR system. Go to
next step for vehicles without EGR
system.
No Repair or replace as necessary.
Carry out EGR system inspection.
+ SYSTEM INSPECTION, EGR System
Inspection
Is EGR system okay?
10 Measure engine compression. Yes Go to Step12.
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11 Inspect timing belt for the following: Yes Inspect follows:
Breakage, damage, or cracks Damaged cylinder head gasket
Worn valve stem or valve guide
timing belt.
timing belt.
ADJUSTMENT
Clogged nozzle Disassemble and clean or replace the fuel injection
Seized needle valve nozzle.
Incorrect valve opening pressure Incorrect valve opening pressure:
Faulty nozzle gasket Adjust fuel injection nozzle opening pressure.
Is injection nozzle okay? Faulty nozzle gasket:
15 Is valve clearance correct? Yes Remove fuel injection pump.
Inspect fuel injection pump.
CONTINUED
F2–48
TROUBLESHOOTING
SYMPTOM 8 RUNS ON
DESCRIPTION Engine runs after engine switch is turned off.
POSSIBLE FCV malfunction
CAUSE
SULTS
1 Run the engine at idle speed. Yes Inspect for the following:
Disconnect the FCV connector. Short to power line between engine switch and
Verify that the engine stops. FCV.
Does the engine stop? Repair or replace wire harness.
No Inspect for FCV stuck to open.
ENGINE STALLS/QUITS-ACCELERATION/CRUISE
ENGINE RUNS ROUGH-ACCELERATION/CRUISE
MISSES-ACCELERATION/ CRUISE
SYMPTOM 9
BUCK/JERK-ACCELERATION/CRUISE/DECELERATION
HESITATION/STUMBLE-ACCELERATION
SURGES-ACCELERATION/CRUISE
Engine stops unexpectedly at beginning of acceleration, during acceleration or while cruis-
cardiagn.com
DESCRIPTION
ing.
Engine speed fluctuates during acceleration or cruising.
Engine misses during acceleration or cruising.
Vehicle bucks/jerks during acceleration, cruising, or deceleration.
Momentary pause at beginning of acceleration or during acceleration.
Momentary minor irregularity in engine output.
POSSIBLE Poor fuel quality Glow system malfunction
CAUSE Starting system malfunction Fuel filter clogged
Air leaks from intake-air system Incorrect injection timing
Air cleaner restriction FIP malfunction
Fuel leakage Clutch slippage
SULTS
1 Is idle speed stable? Yes Go to next step.
No Go to flowchart No.7 “ENGINE RUNS ROUGH/ROL-
LING IDLE”.
2 Is engine overheating? Yes Go to flowchart No.13 “COOLING SYSTEM CON-
CERNS OVERHEATING”.
No Go to next step.
3 Does symptom disappear after warm-up? Yes Go to next step.
No Go to Step 5.
4 Inspect for glow system operation. Yes Go to next step.
+ SYSTEM INSPECTION, Glow System No Repair or replace any defective part according to glow
Inspection. system operation results.
Is glow system operation normal? + SYSTEM INSPECTION, Glow System Inspection
5 Connect the pressure gauge to A/C lines. Yes Go to next step.
Turn the blower switch on. No If A/C is always on, go to symptom troubleshooting
Is the pressure within specifications? No.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNS
+ section U, REFRIGERANT SYSTEM CONTINUOUSLY”. For other symptoms, inspect fol-
SERVICE PROCEDURES, lowing:
REFRIGERANT PRESSURE CHECK. Refrigerant charging amount.
Cooling fan operation.
6 Inspect air cleaner for clogging. Yes Go to next step.
Is air cleaner okay? No Clean or replace air cleaner element.
CONTINUED
F2–49
TROUBLESHOOTING

SULTS
7 Note: Yes Retighten the hose band.
The following test should be performed If the concern is resolved, complete the inspection.
on turbocharger equipped model. For If the concern still exists, go to next step.
other models, go to Step 9.
Inspect the hose band between the following

parts:
Turbocharger
T b h compressor h i and
housing d air
i
No Go to next step.
cleaner
Turbocharger compressor housing and
charge air cooler.
Is the hose band loose?
8 Inspect for improper operation, kinks, clogs, Yes Turbocharger is okay.
or disconnection on the wastegate actuator. Go to next step.
+ INTAKE-AIR SYSTEM, WASTEGATE No Repair or replace as necessary.
ACTUATOR INSPECTION. If the concern is resolved, complete the inspection.
Is actuator okay? If the concern still exists, the turbocharger is okay.
Go to next step.
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Inspect injection nozzle for the following No Clogged nozzle or seized needle valve:
Clogged nozzle. Disassemble and clean or replace the injection nozzle.
Incorrect valve opening pressure. Adjust injection nozzle opening pressure.
Faulty nozzle gasket. Faulty nozzle gasket:
No Go to next step.
11 Inspect for fuel leakage from pipe. Yes Repair or replace as necessary.
12 Inspect fuel filter for clogs. Yes Go to next step.
Worn valve stem and valve guide
timing belt.
timing belt.
15 Inspect injection timing. Yes Inspect follows:
Is injection timing okay? Clutch slippage
FIP
No Adjust injection timing.
ADJUSTMENT
CONTINUED
F2–50
TROUBLESHOOTING
SYMPTOM 10 LACK/LOSS OF POWER-ACCELERATION/CRUISE

DESCRIPTION Performance is poor under load (i.e. power down when climbing hills).
POSSIBLE Poor fuel quality Fuel filter clogged
CAUSE Starting system malfunction Incorrect injection timing
Air leaks from intake-air system FIP malfunction
Air cleaner restriction Injection nozzle malfunction
Engine overheating Low engine compression pressure
A/C system improper operation Turbocharger malfunction
Clutch slippage Brake system drags
Fuel leakage EGR system malfunction (WL Turbo)
SULTS
1 Is idle speed stable? Yes Go to next step.
No Go to flowchart No.7 “ENGINE RUNS
ROUGH/ROLLING IDLE”.
2 Is engine overheating? Yes Go to flowchart No. 13 “COOLING CONCERNS
OVERHEATING”.
No Go to next step.
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Turn the fan switch on. No If A/C is always on, go to symptom troubleshooting No.19
Is the pressure within specification? “A/C ALWAYS ON/ A/C COMPRESSOR RUNS
+ section U, REFRIGERANT SYSTEM CONTINUOUSLY”. For other symptoms, inspect the
SERVICE PROCEDURES, following:
REFRIGERANT PRESSURE CHECK. Refrigerant charging amount.
Cooling fan operation.
4 Inspect air cleaner for clogging. Yes Go to next step.
Is air cleaner okay? No Clean or replace air cleaner element.
5 Note: Yes Retighten the hose band.
The following test should be performed If the concern is resolved, complete the inspection.
on turbocharger equipped model. For If the concern still exists, go to next step.
Inspect the hose band between the following

parts:
Turbocharger
T b h compressor h
housing
i and d air
i No Go to next step.
cleaner
Turbocharger compressor housing and
charge air cooler.
Is the hose band loose?
6 Inspect the wastegate actuator for improper Yes Go to next step.
operation, kinks, clogs, or disconnection. No Repair or replace as necessary.
+ INTAKE-AIR SYSTEM, WASTEGATE If the concern is resolved, complete the inspection.
ACTUATOR INSPECTION. If the concern still exists, the turbocharger is okay. Go to
Is actuator okay? next step.
7 Remove the parts necessary to inspect the Yes Replace the turbocharger.
turbocharger. Do not remove the turbocharger.
Inspect if the turbocharger primary compressor
wheel is bent,, damaged,
g , or interfering
g with the
housing on the vehicle. No Go to next step.
+ INTAKE-AIR SYSTEM, TURBOCHARGER
INSPECTION.
Is there any problem?
8 Inspect if the turbocharger compressor wheel Yes Replace the turbocharger.
locknut is loose or has fallen down inside
turbocharger. No Go to next step.
9 Turn the turbocharger compressor wheel by Yes Go to next step.
hand
hand.
Does the wheel turn easily and smoothly? No Replace the turbocharger.
CONTINUED
F2–51
TROUBLESHOOTING

SULTS
10 Inspect if the turbocharger turbine wheel is Yes Replace the turbocharger.
damaged, cracked, or interfering with the
housing on the vehicles.
Note: No Go to next step.

Inspect all fins on each turbine wheel.

11 Is any engine oil found inside the turbocharger Yes If an excessive amount of oil is found on the vehicle,
turbine housing? replace the turbocharger.
If a small amount of oil is found, wipe the oil off the
vehicle. Then, go to next step.
No Go to next step.
12 Is any engine oil found inside the turbocharger Yes Wipe the oil off the vehicle and install all removed parts
compressor housing? in Step 7. Then, go to next step.
No The turbocharger is okay. Install all removed parts in
Step 7. Then, go to next step.
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No Go to next step.
15 Inspect fuel leakage from pipe. Yes Repair or replace as necessary.
Is any fuel leakage found on fuel pipe? No Go to next step.
on vehicles with EGR system. Go to next
step for vehicles without EGR system.
Carry out EGR system inspection. No Repair or replace as necessary.

Inspection
Is EGR system okay?
No If tension or timing of timing belt is incorrect, adjust timing.
If timing belt is broken, damaged or cracked, replace timing
belt.
20 Inspect injection timing. Yes Inspect follows:
Is injection timing okay? Brake system dragging
Clutch slippage
FIP
No Inspect TCV (if equipped).
ADJUSTMENT
F2–52 CONTINUED
TROUBLESHOOTING

DESCRIPTION Fuel economy is unsatisfactory.
POSSIBLE Idle speed or idle-up speed Exhaust system clogged
CAUSE incorrect adjustment Injection timing incorrect
Accelerator cable free play Injection nozzle malfunction
incorrect adjustment FIP malfunction
Air cleaner restriction High idle speed
Engine cooling system malfunction High idle-up speed
Improper transmission fluid level FICD malfunction
Poor fuel quality Fuel leakage
Improper coolant level Brake dragging
Improper engine compression EGR system malfunction (WL Turbo)
SULTS
1 Inspect the following: Yes Go to next step.
Air cleaner element for restriction
Transmission fluid level No Service as necessary and repeat Step 1.
Coolant level
Are all items okay?
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2 Inspect for idle speed and idle-up speed. Yes Go to next step.
+ ENGINE TUNE-UP,
TUNE-UP IDLE-UP SPEED
ADJUSTMENT. No Go to flowchart No.6 “SLOW RETURN TO
Is idle-up speed within specifications? IDLE/FAST IDLE”.
3 Inspect fuel leakage from pipe. Yes Repair or replace as necessary.
Is any ffuel leakage ffound in ffuel pipe?
? No Go to next step.
No Go to next step.
6 Is brake system functioning properly? Yes Go to next step.
on vehicles with EGR system. Go to next
step for vehicles without EGR system.

Inspection
Is EGR system okay?
Is compression okay?
? No Go to next step.
timing belt .
timing belt.
10 Inspect injection timing. Yes Inspect for the following:
Is injection timing okay? FIP
No Adjust injection timing.
ADJUSTMENT
F2–53 CONTINUED
TROUBLESHOOTING
SYMPTOM 12 HIGH OIL CONSUMPTION/LEAKS

DESCRIPTION Oil consumption is excessive.
POSSIBLE Improper engine oil level Engine internal part malfunction
CAUSE Improper dipstick Oil leak
Improper engine oil viscosity Turbocharger malfunction
SULTS
Proper dipstick
Pro
Properer engine viscosity
Engine oil level No Service as necessary and repeat Step 1.
Are all items okay?
2 Note: Yes Replace the turbocharger.
on turbocharger equipped model. For
Remove the parts necessary to inspect the

turbocharger. Do not remove the turbochar-
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ger. No Go to next step.
Inspect if the turbocharger primary compres-
sor wheel is bent, damaged, or interfering with
the housing on the vehicle.
+ INTAKE-AIR SYSTEM, TURBOCHARGER
INSPECTION
locknut is loose or has fallen down inside
hand
hand.
Does the wheel turn easily and smoothly? No Replace the turbocharger.

housing on the vehicles.
Note: No Go to next step.

Inspect all fins on each turbine wheel.

No Go to next step.
7 Is any engine oil found inside the turbocharger Yes Wipe the oil off the vehicle. Then, go to next step.
compressor housing? No Go to next step.
8 Is any engine oil found around oil pipes at- Yes If the oil leaked from the damaged pipe, replace the oil
tached on the turbocharger center housing? pipe. Then, go to next step.
No Go to next step.
9 Is any engine oil found inside the air intake Yes Wipe the engine oil off.
pipes or Hoses? No The turbocharger is okay. Install all parts removed in
step 2. Then, go to next step.
10 Measure engine compression. Yes Inspect oil leakage from outside of engine.
Is compression okay? No Inspect for the following:
Damaged valve seat.
Worn valve stem and valve guide.
Worn or stuck piston ring.
Worn piston, piston ring, or cylinder.
F2–54 CONTINUED
TROUBLESHOOTING
SYMPTOM 13 COOLING SYSTEM CONCERNS—OVERHEATING

DESCRIPTION Engine runs at higher than normal temperature/overheats.
POSSIBLE Cooling fan malfunction Water temperature gauge or sender unit malfunc-
CAUSE Low drive belt tension tion
Drive belt damage Improper or damaged radiator cap
Improper coolant level Radiator hose damage
Thermostat malfunction Coolant leakage (engine internal, turbocharger, ex-
Radiator clogging ternal)
A/C system malfunction
SULTS
Engine coolant level
Coolant leakage
Radiator condition
Collapsed or restricted radiator hoses
Radiator pressure cap No Service as necessary and repeat Step 1.
Drive belt tension
Drive belt
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Are all items okay?
Turn the blower switch on. No If A/C is always on, go to symptom troubleshooting
Is the pressure within specification? No.19 “A/C ALWAYS ON/ A/C COMPRESSOR RUNS
+ section U, REFRIGERANT SYSTEM CONTINUOUSLY”. For other symptoms, inspect the
SERVICE PROCEDURES, following:
REFRIGERANT PRESSURE CHECK. Refrigerant charging amount
Cooling fan operation
3 Inspect water temperature sender unit. Yes Inspect thermostat.
Is water temperature sender unit okay? + section E, THERMOSTAT, THERMOSTAT
INSPECTION
No Replace water temperature sender unit.
SYMPTOM 14 COOLING SYSTEM CONCERNS—RUNS COLD

DESCRIPTION Engine does not reach normal operating temperature.
POSSIBLE Thermostat malfunction
CAUSE
SULTS
1 Remove the thermostat from vehicle. Yes Inspect water temperature sender unit operation.
Inspect thermostat. + section T, INSTRUMENT CLUSTER, WATER TEM-
+ section E, THERMOSTAT, THERMOSTAT PERATURE SENDER UNIT INSPECTION
INSPECTION.
INSPECTION
Is thermostat okay? No Replace thermostat.
CONTINUED
F2–55
TROUBLESHOOTING
SYMPTOM 15 EXCESSIVE BLACK SMOKE

DESCRIPTION Excessive black smoke is observed in exhaust gas.
POSSIBLE Air cleaner element restriction FIP malfunction
CAUSE Incorrect fuel injection timing Low engine compression
Injection nozzle malfunction EGR system malfunction (WL Turbo)
SULTS
1 Does any other symptom exist? Yes Go to appropriate flow chart.
No Go to next step.
2 Inspect air cleaner element for clogging. Yes Go to next step.
Is air cleaner element okay? No Repair or replace air cleaner element.
+ FUEL SYSTEM, TIMER CONTROL VALVE (TCV)
INSPECTION
ADJUSTMENT
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system.
No Repair or replace as necessary.
Carry out EGR system inspection.
Inspection
Is EGR system okay?
6 Measure engine compression. Yes Inspect fuel injection pump.
Is compression okay? No Inspect for the following:
Damaged valve seat.
Worn valve stem and valve guide.
Worn or stuck piston ring.
Worn piston, piston ring, or cylinder.
SYMPTOM 16 ENGINE NOISE

DESCRIPTION Engine noise from under hood.
POSSIBLE Engine internal damage Improper drive belt tension
CAUSE Timing belt displacement Air leaks from intake-air system
Injection nozzle malfunction Turbocharger operating noise
Loose attaching bolts or worn EGR system malfunction (WL Turbo)
parts
CONTINUED
F2–56
TROUBLESHOOTING

SULTS
1 Note: Yes Replace the turbocharger.
on turbocharger equipped model. For
Remove the necessary partsarts to inspect

ins ect the
Inspect if the turbocharger compressor wheel
is bent, damaged, or interfering with the hous-
ing on the vehicle.
locknut is loose or has fallen down inside the
hand
hand.
Does wheel turn easily and smoothly? No Replace the turbocharger.
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housing on the vehicle. No Go to next step.
No Go to next step.
6 Is any engine oil found inside the turbocharger Yes Wipe the oil off of the vehicle. Then, go to next step.
compressor housing? No Go to next step.
7 Is any exhaust gas leakage found around the Yes Remove turbocharger. Inspect for cracks on center
location where the turbocharger is attached to housing inlet surface.
the exhaust manifold? If cracks are found, replace turbocharger.
If no cracks are found, DO NOT replace turbocharger.
Replace gaskets, bolts, and nuts only. Then, go to next
step.
No Go to next step.
8 Are any of the attaching bolts of center hous- Yes Retighten the loose bolts.
ing and turbine housing loose? If any bolt is missing, attach the appropriate new bolt.
No Turbocharger is okay. Install all removed parts in
Step1. Go to next step.
9 Is squeal, click, or chirp sound present? Yes Inspect engine oil level or drive belt.
No Go to next step.
10 Is rumble or grind sound present? Yes Inspect drive belt.
No Go to next step.
11 Is rattle sound present? Yes Inspect location of rattle for loose parts.
No Go to next step.
12 Is hiss sound present? Yes Inspect for the following:
Vacuum leaks
Intake-air system leaks
No Go to next step.
13 Is rap or roar sound present? Yes Inspect exhaust system for loose parts.
No Go to next step.
CONTINUED
F2–57
TROUBLESHOOTING

SULTS
14 Inspect the injection timing. Yes Go to next step.
Is injection timing okay? No Inspect TCV (if equipped)
+ FUEL SYSTEM, TIMER CONTROL VALVE (TCV)
INSPECTION
ADJUSTMENT
system.
Inspection
Is EGR system okay?
16 Remove the fuel injection nozzle. Yes Inspect for the following:
Inspect for the following: Metal flow
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Clogged nozzle. Bent connecting rod
Seized needle valve Damaged valve seat
Incorrect valve opening pressure No After-leakege, clogged nozzle or seized needle valve:
Faulty nozzle gasket Disassemble and clean or replace the injection nozzle.
Fuel dripping (fuel leakage) Incorrect valve opening pressure:
Is injection nozzle okay? Adjust injection nozzle opening pressure.
Faulty nozzle gasket:
SYMPTOM 17 VIBRATION COCNERNS (ENGINE)

DESCRIPTION Vibration from under hood or driveline.
POSSIBLE Loose attaching bolts or worn parts
CAUSE Components malfunctions such as worn parts
SULTS
1 Inspect the following components for loose Yes Inspect the following:
attaching bolts or worn parts: Wheels
Cooling fan Transmission and mounts
Drive belt and pulley Driveline
Engine mounts Suspension
Exhaust system Service as necessary.
Are all items okay? No Readjust or retighten engine mount installation posi-
tion.
Service as necessary for other parts.
SYMPTOM 18 A/C DOES NOT WORK.

DESCRIPTION A/C compressor magnetic clutch does not engage when A/C is turned on.
POSSIBLE Improper refrigerant charging A/C relay is stuck open.
CAUSE amount Seized A/C compressor
Microswitch is stuck open. Frost switch is stuck open.
Open A/C magnetic clutch Open circuit in blower resistor
Open circuit in related wire har- Poor blower switch ground
nesses ECT sensor malfunction
Poor ground of A/C magnetic Improper magnet clutch clearance
clutch
A/C low/high pressure switch is
stuck open.
CONTINUED
F2–58
TROUBLESHOOTING

SULTS
1 Turn engine switch on. Yes Go to next step.
Set the fan switch to 1st, 2nd, 3rd, or 4th posi- No Inspect for the following:
tion. Poor ground of fan switch
Verify the blower motor is operating. Open circuit in blower resistor
Is blower motor okay? Poor contact of fan switch
Blower relay is stuck open.
Open circuit in blower relay coil
Seized blower motor
Open circuit in blower motor coil.
Open circuit between blower motor and resistor
Open circuit between fan switch and resistor
2 Turn the engine switch on. Yes Go to next step.
Set the fan switch to 1st, 2nd, 3rd, or 4th posi- No Inspect for the following:
tion. Frost switch is stuck open.
Measure the voltage at PCM connector termi- Poor contact of microswitch in heater control unit
nal G. Open circuit between PCM connector terminal G
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and frost switch connector terminal.
Specification: Open circuit between frost switch connector termi-
Less than 2.7 V nal and fan switch connector terminal.
Is voltage correct? Repair or replace as necessary.
3 Start the engine and run it at idle speed. Yes Go to next step.
Set the fan switch to 1st position. No Inspect for the following:
Measure the voltage at terminal of A/C relay Open circuit in A/C relay coil
connector terminal C. Poor contact in A/C relay
Specification: A/C relay stuck open
More than 10.5 V Open circuit between PCM connector terminal L
Is voltage correct? and A/C relay connector terminal.
Open circuit in battery supply line
Open circuit between engine switch and A/C relay
connector terminal
Engine coolant temperature sensor malfunction
4 Disconnect the A/C magnetic clutch connec- Yes Inspect for the following:
tor, Poor ground of A/C magnetic is clutch
Measure the A/C magnetic clutch connector Open circuit in magnet is clutch coil
terminal voltage. Refrigerant charging amount
Specification: Repair or replace as necessary.
More than 10.5 V No Inspect for the following:
Is voltage okay? Open circuit between pressure switch connector
terminal and A/C magnetic clutch connector termi-
nal
Refrigerant charging amount
A/C pressure switch is stuck open.
Magnetic clutch clearance
A/C compressor is seized.
SYMPTOM 19 A/C ALWAYS ON / A/C COMPRESSOR RUNS CONTINUOUSLY.

DESCRIPTION A/C compressor magnetic clutch does not disengage.
POSSIBLE Improper magnetic clutch clear- Short to power line between A/C relay and pressure
CAUSE ance switch
Short to ground circuit between A/C low/high pressure switch is stuck to close.
PCM and frost switch A/C relay is stuck to close.
Short to ground circuit between Frost switch is stuck to close.
PCM and A/C relay
CONTINUED
F2–59
TROUBLESHOOTING

SULTS
1 Turn the engine switch on. Yes Go to next step.
Turn the blower switch off. No Inspect for the following:
Measure the voltage at PCM connector termi- Short to ground circuit between PCM connector
nal G. terminal G and frost switch
Specification: Short to ground circuit between frost switch and
More than 2.7 V blower switch connector terminal
Is voltage correct? Repair or replace as necessary.
2 Start the engine and run it at idle speed. Yes Inspect for magnetic is clutch clearance.
Turn the blower switch off. Adjust it as necessary.
Measure the voltage at terminal of A/C relay No Inspect for the following:
connector terminal C. Short to ground circuit between PCM connector
Specification: terminal L and A/C relay terminal C
0V A/C relay is stuck to close.
Is voltage correct? Short to power line between A/C relay connector
terminal C and A/C pressure switch
Short to power line between pressure switch and
A/C compressor magnetic is clutch connector
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SYMPTOM 20 INTERMITTENT CONCERNS

DESCRIPTION Symptom occurs randomly and is difficult to diagnose.
SULTS
1 Talk to customer. Yes Go to next step.
Retrieve vehicle service history.
Does vehicle have a number of previous
revious re-
pairs and components replaced for a certain No Go to symptom index.
symptom?
2 Key off. Yes Inspect each wire for corrosion, bent or loose terminal
If input is switch-type component, turn on clamps.
manually.
Turn engine switch off.
Connect the voltmeter to the PCM terminals.
Lightly ta
tap on sus
suspect
ect com
component
onent, wiggle and
pull each wire/connector at suspect compo- No Go to next step.
nent or PCM.
Is any voltage out of range, or do they sud-
denly change and go back into range?
3 Start the engine and run it at idle speed. Yes Inspect each wire for corrosion, bent or loose terminal
Lightly tap on suspect component, wiggle and clamps.
pull each wire/connector at suspect compo-
nent or PCM
PCM.
Are any voltages out of range, or do they sud- No Go to next step.
denly change and go back into range?
4 Accurately spray water on suspect component Yes Fault area is identified.
wire, component, or vacuum line related to If fault occurred while spraying on component:
possible fault area. Replace part and verify repair.
Is any voltage out of range, or suddenly If fault occurred while spraying water:
change and go back into range, or was there Inspect each wire for corrosion, bent, loose terminals,
a noticeable engine stumble? or poor wire terminal clamps.
If fault occurred while spraying vacuum line:
Repair vacuum hoses.
No Inspect wire and connector at suspect component for
corrosion, bent, loose terminals, or poor wire terminal
crimps and high tension wire. Repair as necessary.
CONTINUED
F2–60
TROUBLESHOOTING
SYSTEM INSPECTION
FICD System Inspection
Fast-Idle Function
1. Verify that the FICD actuator rod is not pulled.
2. Verify that the engine is cold (ECT is below 20 °C
{68 °F}).
3. Turn fan switch off.
5. Verify that the FICD actuator rod is pulled.
11. If not, disconnect vacuum hose A from the FICD

actuator and inspect if there is vacuum.
VACUUM HOSE A
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6. If not, disconnect the vacuum hoses from the FICD
actuator and inspect if there is vacuum as shown.
FICD ACTUATOR
Caution
Special tools and testers are required when
FIP without special tools and testers will
12. If there is no vacuum, consult your distributor for

replacement of the FICD actuator.
Caution 13. If there is vacuum, inspect the following.
FIP is sealed to maintain proper function. FICD solenoid valve No.1
Special tools and testers are required when PCM terminal C, E voltages
disassembling the FIP. Disassembling the (Refer to CONTROL SYSTEM, POWERTRAIN
FIP without special tools and testers will CONTROL MODULE (PCM) INSPECTION.)
cause a malfunction. Wire harness between FICD solenoid valve
No.1 and PCM terminal C
7. If there is vacuum, consult your distributor for 14. Warm up the engine (ECT is above 60 °C {140
replacement of the FICD actuator. °F}).
8. If there is no vacuum, inspect the following. 15. Verify that the FICD actuator rod returns
FICD solenoid valve No.1 and No.2 completely.
Loose or damaged vacuum hoses between
FICD actuator, FICD solenoid valve No.1 and
No.2, and vacuum pump.
PCM terminal C, E and P voltages
(Refer to CONTROL SYSTEM, POWERTRAIN
CONTROL MODULE (PCM) INSPECTION.)
Wiring harness between FICD solenoid valve
No.1 and PCM terminal C.
Wiring harness between FICD solenoid valve
No.2 and PCM terminal P.
9. Warm up the engine. (ECT above 20 °C {68 °F}).
10. Verify that the FICD actuator rod returns for one
notch. 16. If not, disconnect vacuum hose B from the FICD
actuator and inspect if there is vacuum.
CONTINUED
F2–61
TROUBLESHOOTING
7. If there is no vacuum, inspect the following:

PCM terminal G and P voltages
VACUUM HOSE B (Refer to CONTROL SYSTEM,POWERTRAIN
CONTROL MODULE (PCM) INSPECTION)
Wiring harness between FICD solenoid valve No.2
connector terminal B and PCM terminal P
Turbocharger Boost Pressure

1. Disconnect the air hose between the intake pipe
and the boost compensator.
2. Connect a pressure gauge (range of measurement
is 93.3 kPa {700 mmHg, 27.6 inHg}).
Caution BOOST COMPENSATOR
PRESSURE GAUGE
disassembling the FIP. Disassembling the TO INTAKE
FIP without special tools and testers will PIPE
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17. If there is no vacuum, consult your distributor for
18. If there is vacuum, inspect the following.
PCM terminal E, G and P voltages
(Refer to CONTROL SYSTEM, POWERTRAIN 3. Warm up the engine.
CONTROL MODULE (PCM) INSPECTION.) 4. With the accelerator at the wide open throttle,
Wiring harness between FICD solenoid valve increase the engine speed to 4800—5000 rpm and
No.2 and PCM terminal P. verify that the boost pressure is within the
specification.
A/C Idle-up Function
1. Start the engine. Specification
2. Warm up the engine to normal operating 60.0—73.3 kPa
temperature and run it at idle speed. {0.62—0.74 kgf/cm2, 8.82—10.52 psi}
3. Set the fan switch at 1st position.
4. Verify that the FICD rod is pulled for one notch. 5. If not as specified, inspect the exhaust system.
5. If not, disconnect the vacuum hose B from the (Refer to EXHAUST SYSTEM, EXHAUST
FICD actuator and inspect if there is vacuum as SYSTEM INSPECTION.)
shown. 6. If the exhaust system is normal, inspect the
wastegate actuator. (Refer to INTAKE-AIR
SYSTEM, TURBOCHARGER INSPECTION,
Wastegate Actuator Inspection.)
VACUUM HOSE B 7. If the wastegate actuator is normal, inspect the
turbocharger. (Refer to INTAKE-AIR SYSTEM,
TURBOCHARGER INSPECTION.)
TCV Control Inspection (Europe and UK)

1. Crank the engine and verify that the TCV operation
sound is heard.
WL
Caution TCV
FIP without special tools and testers will
6. If there is vacuum, consult your distributor for

CONTINUED
F2–62
TROUBLESHOOTING
WL Turbo
TCV
2. If no operation sound is heard, inspect the TCV (in

the FIP).
3. If the TCV is normal, inspect the following:
PCM terminal Q voltage
CONTROL MODULE (PCM) INSPECTION)
Wire harness between TCV and PCM terminal
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Q
EGR System Inspection (if equipped)

1. Make sure that all hoses are securely connected in
the proper position.
2. Disconnect the vacuum hose from the EGR valve.
3. Start the engine at cold condition.
4. Verify that there is no vacuum at vacuum hose.
5. If there is vacuum, inspect the following:
EGR solenoid valve
PCM terminal R voltage
Wire harness between EGR solenoid valve and
PCM terminal R
temperature and run it at idle speed.
7. Verify that there is vacuum at vacuum hose.
8. If there is no vacuum, inspect the following:
EGR solenoid valve
PCM terminal R voltage
Wire harness between EGR solenoid valve and
PCM terminal R
9. Connect the vacuum pump to the EGR valve.
10. Apply the vacuum to the EGR valve and inspect if
the engine speed becomes unstable or the engine
stalls.
11. If the engine speed does not change, stop the
engine and inspect the EGR valve.
CONTINUED
F2–63
TROUBLESHOOTING
Glow System Inspection

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

CONTROL SYSTEMS
(F2 CARB)
ENGINE TUNE-UP .........................................................F4-2 CARBURETOR
ENGINE TUNE-UP PREPARATION ........................F4-2 DISASSEMBLY/ASSEMBLY ............................... F4-18/21
IGNITION TIMING ADJUSTMENT ...........................F4-2 CARBURETOR
IDLE SPEED ADJUSTMENT ...................................F4-2 INSPECTION/ADJUSTMENT .............................. F4-21/24
IDLE MIXTURE ADJUSTMENT ...............................F4-2/3 HIGH-ALTITUDE COMPENSATOR
DASHPOT (D/P) ADJUSTMENT ..............................F4-3 INSPECTION ......................................................... F4-24
THROTTLE POSITIONER (T/P) PTC HEATER INSPECTION ................................... F4-24
ADJUSTMENT ........................................................F4-3/4 SLOW FUEL CUT SOLENOID VALVE
A/C IDLE-UP ADJUSTMENT ...................................F4-4/5 INSPECTION ......................................................... F4-24
INTAKE-AIR SYSTEM .................................................F4-6 EXHAUST SYSTEM .................................................... F4-25
VACUUM HOSE ROUTING DIAGRAM ...................F4-6 EXHAUST SYSTEM INSPECTION ........................ F4-25
INTAKE-AIR SYSTEM EXHAUST SYSTEM
REMOVAL/INSTALLATION ..................................F4-7 REMOVAL/INSTALLATION ................................. F4-25
AIR CLEANER ELEMENT EMISSION SYSTEM .................................................... F4-26
INSPECTION ..........................................................F4-8 N0.1 PURGE CONTROL VALVE
IDLE COMPENSATOR INSPECTION ....................F4-8 INSPECTION ......................................................... F4-26
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AIR THERMO VALVE N0.2 PURGE CONTROL VALVE
INSPECTION ..........................................................F4-8 INSPECTION ......................................................... F4-26
VACUUM CONTROL DIAPHRAGM WATER THERMO VALVE INSPECTION .............. F4-26
INSPECTION ..........................................................F4-8 AIR VENT SOLENOID INSPECTION ...................... F4-26
ACCELERATOR PEDAL CHECK VALVE (TWO-WAY)
REMOVAL/INSTALLATION ..................................F4-9 INSPECTION ......................................................... F4-26
ACCELERATOR CABLE CHARCOAL CANISTER INSPECTION ................. F4-26
INSPECTION/ADJUSTMENT .............................. F4-9 ROLLOVER VALVE INSPECTION ......................... F4-26/27
FUEL SYSTEM ..............................................................F4-10 WATER THERMO VALVE
BEFORE REPAIR PROCEDURE.............................F4-10 REMOVAL/INSTALLATION ................................. F4-27
AFTER REPAIR PROCEDURE ...............................F4-10 PCV VALVE INSPECTION ...................................... F4-27
FUEL TANK REMOVAL/INSTALLATION ...............F4-11/13 CLOSED THROTTLE POSITION (CTP)
NONRETURN VALVE INSPECTION ......................F4-13 SWITCH ADJUSTMENT ...................................... F4-27
FUEL PUMP UNIT FLANGE THERMOSWITCH
REMOVAL/INSTALLATION...................................F4-13 INSPECTION ......................................................... F4-27
FUEL PUMP UNIT CONTROL SYSTEM .................................................... F4-28
DISASSEMBLY/ASSEMBLY ................................F4-13/14 COMPONENT LOCATION ...................................... F4-28
FUEL GAUGE SENDER UNIT PCM REMOVAL/INSTALLATION ........................... F4-29
REMOVAL/INSTALLATION ..................................F4-14 PCM INSPECTION .................................................... F4-29
FUEL GAUGE SENDER UNIT PTC HEATER RELAY INSPECTION ..................... F4-30
INSPECTION ..........................................................F4-14 THROTTLE POSITIONER T/P) SOLENOID
FUEL PUMP INSPECTION ......................................F4-14/15 VALVE INSPECTION ........................................... F4-30
FUEL LINE PRESSURE INSPECTION ..................F4-15 WATER THERMOSWITCH (INTAKE
FUEL LINE FLOW AMOUNT MANIFOLD SIDE) INSPECTION ......................... F4-30/31
INSPECTION ..........................................................F4-15/16 WATER THERMOSWITCH
FAST IDLE SPEED ADJUSTMENT ........................F4-16 REMOVAL/INSTALLATION ................................. F4-31
DASHPOT (D/P) INSPECTION ................................F4-16 TROUBLESHOOTING ................................................ F4-32
FUEL PUMP RELAY INSPECTION ........................F4-16/17 FOREWORD ............................................................. F4-32
SERVO DIAPHRAGM TROUBLESHOOTING ITEM TABLE ...................... F4-32
REMOVAL/INSTALLATION ..................................F4-17 QUICK DIAGNOSTIC CHART ................................. F4-33
CARBURETOR SYMPTOM TROUBLESHOOTING ......................... F4-34/47
REMOVAL/INSTALLATION ..................................F4-17
CONTINUED
F4-1
ENGINE TUNE-UP
ENGINE TUNE-UP
ENGINE TUNE-UP PREPARATION
1. Check the condition of the engine (plugs, leaks in
hoses, etc.)
2. Make sure all accessories are OFF.
3. Connect a tacho dwell tacho tester to the engine.
4. Warm up the engine and run it for three minutes
at 2,500—3,000 rpm in neutral.
IGNITION TIMING ADJUSTMENT
1. Perform the "ENGINE TUNE-UP PREPARATION.
IDLE MIXTURE ADJUSTMENT
2. Disconnect the vacuum hose for vacuum spark
1. Attach an exhaust gas analyzer and measure the
advance between the distributor and the CO concentration.
carburetor at the distributor side and plug it.
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2. Perform the "ENGINE TUNE-UP PREPARATION"
and "IDLE SPEED ADJUSTMENT."
3. While checking the ignition timing by using a
3. Verify that CO concentration in exhaust gas at the
timing light, adjust the crankshaft pulley alignment
tail pipe during idling is as specified in the table
mark position (yellow paint) by turning the
below.
distributor as specified.
Specification
For CO concentration (%)
BTDC: 5°—7°(6°±1°)
GULF 2.0—2.5 (2.0 )
General 2.0—3.0 (2.5 ±0.5)
4. If not within the specification, adjust the CO
concentration by turning the MAS (mixture adjust
screw).
5. Remove the blind cap. (GULF)
4. Reconnect the proper vacuum hose to the port.

IDLE SPEED ADJUSTMENT
1. Perform the "ENGINE TUNE-UP PREPARATION.
2. Verify that the idle speed is within the
specification.
6. Remove the spring pin.

3. If not within the specification, adjust the idle
speed by turning the TAS (throttle adjust screw)
CONTINUED
F4-2
ENGINE TUNE-UP
DASHPOT (D/P) ADJUSTMENT
and "IDLE SPEED ADJUSTMENT"
2. Increase the engine speed to 2,500 rpm.
3. Pull the throttle lever until the rod and arm of the
dashpot separate.
4. Slowly return the throttle lever from the position
above, then verify that the engine speed is as
specified when the arm contacts the rod.
Specification
1,900—2,100 (2,000 ± 100) rpm
5. If not as specified, loosen the dashpot locknut and
turn the dashpot body to adjust.
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7. Reconfirm that the engine speed is within the
specification.
6. After adjustment, tighten the locknut.
8. If not within the specification, adjust the idle
speed by turning the TAS (throttle adjust Tightening torque
screw). 9.8—17.6 N.m {100—180 kgf.cm, 87—156 in.lbf}
Note 7. Race the engine and again verify that the engine
speed returns smoothly to idle speed. 8. If not,
GULF only
repeat the above procedure to adjust the idle speed
• Run the engine at idle for 3—5 seconds, or D/P inspect
then fit a blind cap to the MAS (mixture (Refer to FUEL SYSTEM, DASHPOT (D/P) INSPECTION)
adjust screw) of the vehicles for the following
THROTTLE POSITIONER (T/P) ADJUSTMENT
markets.
GULF only
2. Disconnect the vacuum hose for vacuum spark
advance between the distributor and the carburetor
at the distributor side and plug it.
3. Disconnect the vacuum hose from the servo
diaphragm.
• Run the engine at idle for 3—5 seconds,

then tap in the spring pin as shown.
4. Connect the intake manifold vacuum directly to the

servo diaphragm, and verify that the engine speed is
as specified.
Specification
1,050—1,250 (1,150 ± 100) rpm
CONTINUED
F4-3
ENGINE TUNE-UP
5. If not within the specification, adjust the engine 6. Disconnect the vacuum hose for vacuum spark
speed by the adjust screw. advance between the distributor and the
carburetor at the distributor side and plug it.
7. Disconnect the vacuum hose from port B.
6. After adjusting the engine speed, reconnect the

vacuum hose to the proper port. Verify that the
servo diaphragm operates when the engine speed
is raced at 2,000 rpm or more. 8. Connect the intake manifold vacuum directly to
7. If the servo diaphragm does not operate, inspect port B, and verify that the engine speed is as
the T/P solenoid valve. specified.
8. If the solenoid valve is okay, replace the servo
Specification
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diaphragm.
1,050—1,250 (1,150 ±100) rpm
A/C IDLE-UP ADJUSTMENT
9. If not within the specification, adjust the engine
GULF only with, A/C
speed by the adjust locknut on the dual servo
1. Perform the "ENGINE TUNE-UP PREPARATION" diaphragm head.
2. Disconnect the vacuum hose from port A.
10. Reconnect the proper vacuum hose to port B.

11. After adjusting the engine speed reconnect the
vacuum hose to the proper port. Verify that the
servo diaphragm operates when the A/C is
operated.
3. Connect the intake manifold vacuum directly to 12. If the servo diaphragm does not operate, inspect
port A, and verify that the engine speed is as the A/C idle-up solenoid valve or T/P solenoid
specified. valve.
13. If the solenoid valve is okay, replace the dual
Specification servo diaphragm.
1,400—1,600 (1,500 ± 100) rpm
speed by the adjust screw. Except GULF, with A/C
2. Disconnect the vacuum hose from the servo
diaphragm.
3. Connect the intake manifold vacuum directly to
the servo diaphragm, and verify that the engine
speed is as spec tied.
5. Reconnect the proper vacuum hose to port A.

CONTINUED
F4-4
ENGINE TUNE-UP
Specification 1,400—1,600 (1,500 ±

100) rpm

speed by adjust screw.
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5. Reconnect the proper vacuum hose to port.
6. After adjusting the engine speed reconnect the vacuum
hose to the proper port. Verify that the servo diaphragm
operates when the A/C is operated.
7. If the servo diaphragm does not operate, inspect the A/C
idle-up solenoid valve.
8. If the solenoid valve is okay, replace the servo
diaphragm.
CONTINUED
F4-5
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM
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1 Air cleaner 12 Distributor
2 Carburetor 13 T/P solenoid valve
3 Vacuum control diaphragm 14 Servo diaphragm
4 Idle compensator 15 A/C idle-up solenoid valve
5 Air thermos sensor 16 Dual servo diaphragm
6 FICB solenoid valve 17 To intake manifold
7 High-altitude compensator 18 Fuel main line (to fuel tank)
8 FICB diaphragm 19 Fuel return line (to fuel tank)
9 Charcoal canister 20 To charcoal canister or ventilation
10 No.1 purge control valve 21 To carburetor
11 Water thermo valve 22 To check valve (two-way)
CONTINUED
F4-6
INTAKE-AIR SYSTEM
INTAKE - AIR SYSTEM REMOVAL/INSTALLATION
Warning
• When the engine and intake-air system are hot, they can badly bum. Turn off the engine and wait
until they are cool before removing the intake-air system.
Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)

2. Drain the engine coolant from the radiator. (Refer to Section E.)
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1 Air cleaner (in idle compensator, vacuum control 8 Intake manifold
diaphragm, shutter valve, air thermo sensor) 9 Water thermoswitch
2 Air cleaner element ☞ CONTROL SYSTEM, WATER THERMOSWITCH
3 Carburetor REMOVAL/INSTALLATION
4 Fuel hose 10 Intake manifold gasket
5 Accelerator cable 11 Water thermo valve
6 PTC heater gasket ☞ FUEL SYSTEM, WATER THERMO VALVE
7 PTC heater 12 Servo diaphragm
CONTINUED
F4-7
INTAKE-AIR SYSTEM
AIR CLEANER ELEMENT INSPECTION AIR THERMO VALVE INSPECTION
• Visually check the air cleaner element for Note
excessive dirt, damage or oil, replace if • Perform the following test only when directed.
necessary. 1. Disconnect the vacuum hose from the vacuum
IDLE COMPENSATOR INSPECTION control diaphragm.
1. Confirm that the valve is in the closed position 2. Verify that vacuum is felt at the vacuum hose
when the bimetal temperature is lower than the when the engine is cold (below 30 °C {86 °F}) and
specified temperature. idling.
Opening temperature 3. Warm up (above 30 °C {86 °F}) the engine and
63—71 °C {145.4—159.8 °F} verify that vacuum is not felt.
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2. To check, suck air from the tube A. If excessive air 4. If vacuum condition is not as specified in Steps 2
leakage is found, replace the idle compensator. and 3, replace the air thermo valve.
VACUUM CONTROL DIAPHRAGM INSPECTION

1. Disconnect the vacuum hose from the vacuum
control diaphragm.
2. Connect a vacuum pump to the vacuum control
diaphragm.
3. Apply more than 24 KPa {180 mmHg, 7.087
inHg} vacuum and verify that the shutter valve is
opened to the hot position.
3. When the bimetal temperature is more than

approx. 71 °C {159.8 °F}, confirm that the valve is
in the open position. If the valve is not open,
replace the idle compensator as an assembly.
4. Replace the vacuum control diaphragm if not

as specified.
CONTINUED
F4-8
INTAKE-AIR SYSTEM
ACCELERATOR PEDAL REMOVAL/INSTALLATION
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1 Accelerator cable
☞ ACCELERATOR CABLE
2 Accelerator pedal
ACCELERATOR CABLE
1. Verify that the throttle valve is entirely closed.
Free play
1—3 mm {0.04—0.11 in}
3. If not as specified, adjust by turning locknut A.
CONTINUED
F4-9
FUEL SYSTEM
FUEL SYSTEM
Warning
• Fuel vapor is hazardous. It can easily
fuel.
complete the following "Fuel Line Safety
Procedures". 3. Install a hose clamp over the fuel hose within the
Fuel Line Safety Procedures clamp installation range as shown, avoiding the
Note original clamp position.
• Fuel in the fuel system is under high
pressure also when the engine is not
running.
1. Remove the fuel-filler cap and release the pressure
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in the fuel tank.
2. Disconnect the fuel pump relay connector located
under the passenger's side front side trim.

4. After the engine stalls, crank the engine several
times.
5. Turn off the ignition switch.
6. Reconnect the fuel pump relay connector.

Warning
fuel hose, observe "Fuel Hose Installation"
and described below.
1. Replace damaged or deformed fuel hoses, fuel
pipes, and hose clamps.
2. When installing the fuel hose onto the fuel pipe, fit
the hose onto the pipe over 25 mm {0.98 in}.
When the pipe has a stopper, fit the hose until it
contacts the stopper.
CONTINUED
F4-10
FUEL SYSTEM
Warning
• Repairing a fuel tank that has not been properly steam cleaned can be dangerous.
Explosion or fire may cause death or serious injury. Always properly steam clean a
fuel tank before repairing it.
• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious
injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this,
do not damage the sealing surface of the fuel pump unit when removing or
installing.
1. Level the vehicle.

2. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
4. Drain the fuel from the drain plug.
7. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
DOUBLE CAB
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CONTINUED
F4-11
FUEL SYSTEM
REGULAR CAB
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Joint hose 7 Rollover valve
1
☞ Installation Note 8 Fuel pump unit
2 Breather hose w Installation Note 9 Fuel-filler pipe
10 Dust cover
3 Under guard
11 Fuel inlet pipe
4 Fuel hose
12 Non return valve
5 Fuel tank
Evaporative gas check valve (two-way)
13
6 Evaporative hose - Installation Note ☞ Installation Note
CONTINUED
F4-12
FUEL SYSTEM
Evaporative Gas Check Valve (Two-way)
Installation Note
• Install the arrow mark of the evaporative gas
check valve (two-way) facing the charcoal
canister.
• Fit each hose onto the respective fittings within
the specification, and install clamps as shown.
Length Evaporative hose:

25 mm {0.98 in}
NONRETURN VALVE INSPECTION

1. Remove the nonreturn valve with the fuel inlet
pipe.
2. Verify that the nonreturn valve opening angle is
50—56° when pushed out from the fuel inlet pipe
side, and the clearance between the nonreturn
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valve and the fuel inlet pipe end is within 1.5 mm
Breather Hose Installation Note {0.06 in} when the nonreturn valve is returned to
• Fit each hose onto the respective fittings within the closed position.
the specification, and install clamp as shown.
Length Breather hose:

25—30 mm {0.99—1.18 in}
Joint Hose Installation Note 3. If not as specified, replace the nonreturn valve.
• Fit the joint hose onto the respective fittings
within the specification, and install clamps as FUEL PUMP UNIT REMOVAUINSTALLATION
shown. 1. Remove the fuel pump unit.
Length Joint hose: REMOVAL/INSTALLATION.)
35—40 mm {1.4—1.5 in} 2. Install the fuel pump unit.
FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY
Warning
serious injuries or death and damage. Fuel
can also irritate skin and eyes. To prevent
this, do not damage the sealing surface of
the fuel pump unit when removing or
installing.
CONTINUED
F4-13
FUEL SYSTEM
DOUBLE CAB Fuel Pump Assembly Note
• After installing the fuel pump body to the
bracket; pull the pump down so that it is tight
against the bracket.
Fuel Hose Assembly Note

1. Do not apply excessive side force when pushing
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the fuel hose onto the fuel pump nipple.
2. Install the clamps as shown.
REGULAR CAB

FUEL GAUGE SENDER UNIT INSPECTION

(Refer to Section T, WARNING AND INDICATOR
SYSTEM, FUEL GAUGE SENDER UNIT
INSPECTION.)
FUEL PUMP INSPECTION

Note
1 Fuel pump unit connector • Perform the following test only when
2 Rubber mount directed,
3 Fuel filter (low-pressure) 1. Complete the "BEFORE REPAIR
4 Clamp PROCEDURE".
5 Fuel hose (Refer to FUEL SYSTEM, BEFORE REPAIR
☞ Assembly Note PROCEDURE.)
6 Fuel pump body 2. Disconnect the negative battery cable.
☞ Assembly Note 3. Remove the fuel tank.
7 Fuel gauge sender unit (Refer to FUEL SYSTEM, FUEL TANK
4. Inspect for continuity between fuel pump unit
connector terminals C and D.
F4-14
CONTINUED
FUEL SYSTEM
4. Connect the C and D terminals of the fuel

pump relay with a jumper wire.
5. If there is no continuity, replace the fuel pump

body. If there is continuity in the fuel pump but
the fuel pump does not operate, inspect as
follows and repair or replace as necessary. HARNESS SIDE CONNECTOR
Open circuit (VIEW FROM TERMINAL SIDE)
• GND circuit (fuel pump unit connector 5. Connect the negative battery cable.
terminal C and body GND) 6. Turn the ignition switch ON, and verify that fuel
• Power circuit (fuel pump relay connector pressure is as specified.
terminal C and fuel pump unit connector
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terminal D through common connector) Specification
20—25kPa {0.20—0.25 kgf/cm2, 2.8—3.6 psi}
7. If not as specified, perform the fuel pump
inspection.
(Refer to FUEL PUMP INSPECTION.)
FUEL LINE FLOW AMOUNT INSPECTION
HARNESS SIDE CONNECTOR Note
(VIEW FROM TERMINAL SIDE) • Perform the following test only when directed.
Short circuit
• Fuel pump relay connector terminal C and 1. Complete the "BEFORE REPAIR
fuel pump unit connector terminal D through PROCEDURE".
common connector to GND (Refer to FUEL SYSTEM, BEFORE REPAIR
6. Repair or replace faulty areas. If the harnesses PROCEDURE.)
are okay, inspect the fuel pump relay. 2. Disconnect the negative battery cable.
(Refer to FUEL SYSTEM, FUEL PUMP 3. Disconnect the main fuel hose (A), and insert the
RELAY INSPECTION.) end into a measuring beaker.
7. Install the fuel tank. 4. Connect the C and D terminals of the fuel pump
(Refer to FUEL SYSTEM, FUEL TANK relay with a jumper wire.
PROCEDURE.)
FUEL LINE PRESSURE
INSPECTION
Note
PROCEDURE.)
3. Disconnect the main fuel hose (A), and connect a
fuel pressure gauge to it.
CONTINUED
F4-15
FUEL SYSTEM

6. Turn the ignition switch on. Drive the fuel pump
for a minute and verify that the fuel flow amount
is within the specification.
FUEL PUMP RELAY INSPECTION
On-Vehicle Inspection
Specification
More than 1.150 cc {70.2 cu in} min. Note
7. If not as specified, perform the fuel pump
inspection. (Refer to FUEL PUMP INSPECTION.) 1. Remove the front left side trim.
2. Crank the engine while touching the fuel
FAST IDLE SPEED ADJUSTMENT
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pump relay by hand.
1. Warm up the engine to normal operation
3. Verify that clicking sound is heard or vibration is
temperature.
felt from the fuel pump relay white cranking the
2. Stop the engine. engine.
3. Plug the hoses of the idle compensator. 4. If there is no clicking sound or vibration, inspect
4. While holding the throttle valve slightly open, the harness for the following,
push the choke fully closed; then release the Open circuit
choke valve after releasing the throttle valve.
• Power circuit (fuel pump relay connector
5. Start the engine, but do not touch the accelerator
terminal A, D and ignition switch IG1)
pedal.
• GND circuit (fuel pump relay connector
6. Verify that the engine speed is 3,000—4,000
terminal B and PCM terminal H)
rpm. If the engine speed is not as specified, turn
the adjust screw to adjust.
Short circuit
• Fuel pump relay connector terminal A, D
and ignition switch IG1 to GND. 5. If the
harnesses are okay, perform the following
DASHPOT (D/P) INSPECTION off-vehicle inspection.
1. Open the throttle valve fully then push the dash Off-Vehicle Inspection
pot rod with a finger and make sure the rod goes 1. Remove the fuel pump relay.
into the dash pot slowly. 2. Inspect for continuity between the fuel pump relay
2. Release the finger and make sure the rod terminals by using an ohmmeter.
comes out quickly.
CONTINUED
F4-16
FUEL SYSTEM
Tightening torque
9.8—24 N.m
{100—250 kgf.cm-cm, 87—216 in.lbf}
CARBURETOR REMOVAL/INSTALLATION
(Refer to INTAKE-AIR SYSTEM INTAKE-AIR
SYSTEM REMOVAL/INSTALLATION.)
3. If not as specified, replace the fuel pump relay.
SERVO DIAPHRAGM REMOVAL/INSTALLATION
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1. Loosen the servo diaphragm installation nut.
2. Remove the servo diaphragm and the servo

diaphragm bracket from the intake manifold.
3. Separate the servo diaphragm from the bracket.

4. Install the servo diaphragm onto the bracket,
then hand-tighten the installation nut.
5. Install the servo diaphragm bracket to the intake
manifold.
Tightening torque
19—25N.m
{1.9—2.6 kgf.m, 14—18ft.lbf}
6. Tighten the installation nut to the specification.
CONTINUED
F4-17
FUEL SYSTEM
CARBURETOR DISASSEMBLY/ASSEMBLY
2. Assemble in the reverse order of disassembly. (Refer to Carburetor After Assembly Note.)
Caution
• Replace the O-rings, gaskets, and washers when assembling the carburetor. If not, it will possibly
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CONTINUED
F4-18
FUEL SYSTEM
1 Accelerator pump connecting rod

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

Disassembly/Assembly
1 Float and pin

2 Needle valve assembly
1 Vacuum hose
2 Accelerator pump connecting rod, spring, and lever
3 Connect spring
CONTINUED
F4-19
FUEL SYSTEM
Air Bleeds and Jets Disassembly/Assembly
1 CTP switch and spring

2 Slow fuel cut solenoid valve, needle valve, spring, and
gasket.
1 Secondary slow jet
2 Secondary slow air bleed (No.1)
3 Secondary main air bleed
4 Secondary main jet
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5 Primary main air bleed
6 Slow jet and plug
7 Primary slow air bleed (No.1)
8 Primary main jet
9 Primary slow air bleed (No.2)
10 Power jet
3 Accelerator pump plunger assembly and spring
Caution 4 Retaining clip
• Note the size of all jets and air bleeds so that 5 Strainer and accelerator pump inlet check ball
they will be reassembled in the correct
6 Check valve plug
position
7 Accelerator pump outlet check ball and spring
Note
• One bolt is inside the throttle body
11 Coasting richer air bleed (No.2)

12 Secondary slow air bleed (No.2)
13 Coasting richer air bleed (No.1)
8 Disconnect vacuum diaphragm connecting rod
14 Coasting richer jet
9 Throttle body (separate from main body)
Main Body Disassembly/Assembly 10 Vacuum diaphragm assembly and gasket
Caution
• After installing the idle switch, be sure to
adjust it.
CONTINUED
F4-20
FUEL SYSTEM
11 Diaphragm cover screws and cover (4) Adjust the CTP switch.
12 Spring and diaphragm (5) After the idle adjustment has been
13 Accelerator cable hanger completed, check the fast idle speed as
follows.
Throttle Body Disassembly/Assembly CARBURETOR INSPECTION/ADJUSTMENT
Caution Body, Valve, Jet
• Do not remove the throttle valve and shaft, the 1. Check for cracks on the air horn, distortion on the
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Venturis, or the choke valve and shaft. installing surface attached to the main body, and
wear on the contact surface of the choke valve
1. Disassemble in the following order.
shaft. If necessary, replace it.
2. Assemble in the reverse order of disassembly. (1)
2. Check for cracks and distortion on the throttle
When removing the mixture adjust screw, tap out
body, and wear on the contact surface of the
the spring pin as shown in the figure.
throttle valve shaft. If necessary, replace it.
3. Check for deformity, bends, and wear on the
levers, arms, and connecting rods. If necessary,
replace it.
Caution
• Do not use a piece of wire to clean the
jets. The wire may scratch, crack, or
deform the port of the jets and become
the cause of malfunctions.
4. Check for clogging in jets and air bleeds. If
necessary, clean with clean gasoline or kerosene
and dry with compressed air.
5. Check the taper part of the MAS, solenoid valves,
and needle valve (float) for cracks and dents, and
wear. If necessary, replace it.
6. Check the rubber part of the accelerator pump for
cracks and damage. If necessary, replace it.
Carburetor After Assembly Note

• Install the carburetor in the reverse order of
removal. After installation, note the following.
(1) Start the engine and check for leaks.
(2) Make the idle adjustment.
(3) After the idle adjustment is completed,
press in the spring pin.
CONTINUED
F4-21
FUEL SYSTEM
Diaphragms
1. Push the rod fully and plug the port by hand.
2. Verify that the rod does not return when the port is
plugged.
Clearance L
44—45 mm {1.732—1.772 in}
4. If not as specified, bend the float stopper B until

the proper clearance is obtained.
3. If the rod returns to the original position, replace

the diaphragm.
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Float Level Adjusting
1. Measure the clearance H between the float and air
horn.
Choke Valve
1. Use a vacuum pump to apply approximately 53
kPa {400 mmHg, 15.7 inHg} vacuum to the choke
diaphragm.
2. Push the choke valve lightly to close it, and check
the clearance R,
Clearance H
8—9 mm {0.315—0.354 in}
2. If not as specified, bend the float seat lip A until
the proper clearance is obtained.
Clearance R
1.72—2.22 mm {0.068—0.087 In}
3. Measure the clearance L between the bottom of 3. If the clearance is not as specified, adjust by
the float and air horn. bending the choke lever D.
CONTINUED
F4-22
FUEL SYSTEM
Fast-idle cam
1. Set the fast-idle cam to the second highest
position.
2. Adjust the throttle valve clearance G by turning the
adjust screw. (The clearance becomes larger as
the screw is turned clockwise.)
Clearance G
0.64—0.84 mm {0.025—0.033 in}
3. Set the fast idle cam at the second highest
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position.
4. Check the choke valve clearance R.
Clearance R
2.82—3.70 mm {0.111—0.146 in}
3. If the clearance is not as specified, adjust by
bending tab A.
Secondary throttle valve

1. The secondary throttle valve should start to open
when the primary throttle valve opens 48 ° —52 °
and should be completely open at the same time
the primary throttle valve is fully open.
2. Check the clearance between the primary throttle
valve and the throttle bore when the secondary
throttle valve starts to open.
3. If the clearance is not as specified, bend tab B to
adjust.
Clearance R
0.60—1.20 mm {0.024—0.047 in}
5. If necessary, adjust the choke valve clearance R by
bending the starting arm B. If large adjustments are
required, the choke rod should be bent.
Unloader system
1. Open the primary throttle valve fully.
2. Measure the choke valve clearance R.
CONTINUED
F4-23
FUEL SYSTEM
Clearance R
7.35—8.25 mm {0.289—0.325 in}
HIGH-ALTITUDE COMPENSATOR INSPECTION

1. Disconnect each air hose from the carburetor.
2. Check the high-altitude compensator by blowing
through each hose.
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500m {1,640 ft} or higher
(High altitude): Air passes.
Less than 500 m {1,640 ft }

(Low altitude): Air does not pass.
3. If not as specified, replace the high-altitude
compensator.
PTC HEATER INSPECTION

1. Disconnect the PTC heater connector.
2. Connect an ohmmeter between the
connector and the intake manifold, and
verify continuity.
3. If it is not correct, replace the PTC heater.
SLOW FUEL CUT SOLENOID VALVE

INSPECTION Operation Inspection
Note
1. Run the engine at idle speed.
2. Disconnect the carburetor connector (6-pin).
3. Disconnect the carburetor connector and
verify that the engine stops.
4. If the engine does not stop, replace the
slow fuel cut solenoid valve.
CONTINUED
F4-24
EXHAUST SYSTEM
EXHAUST SYSTEM
1. Start the engine and inspect the exhaust system component for exhaust gas leakage.
Warning
• When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait

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1 After pipe 4 Front pipe
2 Main silencer 5 Exhaust manifold
3 Pre-silencer
CONTINUED
F1-25
EMISSION SYSTEM
EMISSION SYSTEM 3. Turn the ignition switch to "ON" and "OFF". If
N0.1 PURGE CONTROL VALVE INSPECTION there is a "clicking" noise, the air vent solenoid
1. Blow through port A and verify that air does not valve is working properly.
flow.
2. Connect a vacuum pump and apply vacuum of
-14.7 KPa {-110 mmHg, -4.33 inHg} or above and
blow through port A again.
3. Verify that air flows from port A.
CHECK VALVE (TWO-WAY) INSPECTION

1. Remove the check valve (two-way).
conditions.
Condition Airflow
N0.2 PURGE CONTROL VALVE INSPECTION
Apply pressure below +2.9 kPa {+22
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1. Disconnect vacuum hose B from the pipe. No
2. Blow into the hose and make sure air flows freely.
Apply pressure over +5.9 kPa {+44
Yes
Apply pressure over -0.98 KPa
Yes
{-7.36 mmHg, -0.29 inHg} to port A
3. If not as specified, replace the charcoal canister.

WATER THERMO VALVE INSPECTION
1. Remove the water thermo valve.
2. Put the threaded part in a water-filled container and 3. If not as specified, replace the check valve (two-
slowly increase the water temperature. way).
3. Check the airflow of the valve under the following CHARCOAL CANISTER
conditions. INSPECTION
1. Remove the charcoal canister.
2. Visually check the charcoal canister for damage
and leakage.
3. Shake the charcoal canister upside down and
verify that no pieces of charcoal falls from either
nipple.
4. Replace the charcoal canister if necessary.
ROLLOVER VALVE
INSPECTION
(Refer to FUEL SYSTEM,FUEL TANK
Condition 2. Hold the valve as shown. Blow air into port A
Port
Below 50°C {122°F} Above50°C {122°F} and verify that there is airflow.
A-B No Airflow Airflow
C-D Airflow No Airflow
4. If not as specified, replace the water thermo valve.
AIR VENT SOLENOID INSPECTION
1. Remove the air cleaner.
2. Touch the finger onto the air vent solenoid valve.
CONTINUED
F4-26
EMISSION SYSTEM
3. Turn the valve upside-down as shown. Blow air CLOSED THROTTLE POSITION (CTP) SWITCH
into port A and verify that there is no airflow. ADJUSTMENT
1. Warm up the engine and run it at idle.
2. Connect a dwell tacho tester to the engine.
3. Connect a voltmeter to the CTP switch terminal.
4. Increase the engine speed to more than 2,000 rpm;
decelerate gradually and verify that the volt meter
indicates as follows.
Engine speed Voltage
At idle Approx. 12 V
1,000—1,200 (1,100
Less than 1.5 V
±100) rpm
WATER THERMO VALVE REMOVAL/NSTALLATION
5. If not as specified, turn the adjust screw to adjust.
2. Remove the water thermo valve from the intake
manifold.
3. Wrap sealing tape two or three times around the
threaded part of the valve before installing.
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FLANGE THERMOSWITCH INSPECTION
Note
4. Use a new washer and install in the reverse order Continuity Inspection
of removal. 1. Drain the coolant into a container.
(Refer to Section E, COOLING SYSTEM, ENGINE
Tightening torque COOLANT REPLACEMENT.)
25—39 N.m {2.5—4.0 kgf.m-m, 19—28 ft.lbf} 2. Remove the flange thermoswitch from the
PCV VALVE INSPECTION carburetor.
1. Remove the PCV valve. 3. Place the thermoswitch in water with a thermometer,
2. Check the airflow of the valve under the following and heat the water gradually.
conditions.
Condition Airflow
Blow from port A Yes
Blow from port B No
3. If not as specified, replace the PCV valve. 4. Inspect the thermoswitch terminals by using
an ohmmeter.
Specification
Water temperature (°C {°F}) Continuity
Below 67 {153} Yes
Above 67 {153} No
5. If not as specified, replace the flange thermoswitch.
CONTINUED
F4-27
CONTROL SYSTEM
CONTROL SYSTEM
COMPONENT LOCATION
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1 Ignition coil 4 T/P solenoid valve (GULF only)
2 Water thermoswitch 5 PTC heater relay
3 PCM 6 Fuel pump relay
CONTINUED
F4-28
CONTROL SYSTEM
PCM REMOVAL/INSTALLATION 1. Remove the PCM.
1. Disconnect the negative battery cable. 2. Reconnect PCM connector and battery negative
2. Remove the front left side trim. terminal.
3. Remove in the order indicated in the table. Note
4. Install in the reverse order of removal. • With the PCM connector connected, body
ground the voltmeter negative (-) lead and
PCM INSPECTION measure voltage at each PCM terminal by
Caution inserting the voltmeter positive (+) lead.
• The PCM terminal voltages vary with
3. Measure the voltage at PCM terminal using a
change in measuring conditions and
vehicle conditions. Always carry out a voltmeter.
total inspection of the input systems, 4. If any incorrect voltage is detected, inspect
output systems, and PCM to determine related systems, wiring harnesses and
the cause of trouble. Otherwise, a wrong connectors referring to the Action column in the
diagnosis will be made. terminal voltage list.
PCM Terminal Voltage (Reference)
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Below 1500 rpm B+ • T/P solenoid

Throttle T/P solenoid valve
*A Engine speed
positioner control valve
Above 1500 rpm Below 1.0
• Related wiring
harnesses
B — GND Constant Below 1.0 • Related wiring

harnesses
Coolant • FICB solenoid
Below 40°C {104°F}
FICB solenoid temperature B+ valve
C FICB control
valve Ignition SW ON • Related wiring
Other Below 1.0 harnesses
Idle Approx 11V • Igniter
D Ignition Igniter • Related wiring
Ignition SW ON Below 1.0 harnesses
E — — — — —
ON B+ • Ignition SW
F IG1 Ignition SW Ignition SW • Related wiring
OFF Below 1.0 harnesses
G — — — — —
• Fuel pump • Fuel pump ON • Fuel pump relay
B+
control relay • PTC heater
H Ignition SW
• PTC heater • PTC heater relay
control OFF Below 1.0
relay • Related wiring
Below 40°C {104°F} B+ • Water

Coolant Water Coolant thermoswitch
I
temperature thermoswitch temperature • Related wiring
Above 40°C {104°F} 0V
harnesses
• Fuel pump ON B+ • Fuel pump relay
• Fuel pump relay
control • PTC heater
J • PTC heater Ignition SW relay
• PTC heater
relay OFF Below 1.0 • Related wiring
control
harnesses
*: GULF only
F4-29 CONTINUED
CONTROL SYSTEM
PTC HEATER RELAY INSPECTION

1. Remove the PTC heater relay.
2. Inspect for continuity between the PTC heater
relay terminals by using an ohmmeter.
4. If not as specified, replace the T/P solenoid valve.

If as specified, inspect the following: Vacuum
hose improper routing, kinks or leakage.
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3. If not as specified, replace the PTC heater relay. Open circuit
• Power circuit (T/P solenoid valve connector
THROTTLE POSITIONER (T/P) SOLENOID VALVE terminal A and ignition switch IG1 through
INSPECTION common connector.)
Voltage Inspection • GND circuit (T/P solenoid valve connector
Note terminal B and PCM connector terminal A.) Short
• Perform the following test only when directed. circuit
• T/P solenoid valve connector terminal A and
1. Run the engine at idle. ignition switch IG1 through common connector to
2. Connect a voltmeter to terminals of the T/P GND
solenoid valve as shown. 5. Repair or replace faulty areas.
3. Measure the voltage as shown. 6. Install the T/P solenoid valve.
WATER THERMOSWITCH INSPECTION
Note
1. Drain the coolant into a container.
(Refer to Section E, COOLING SYSTEM,
2. Remove the water thermoswitch from the under
side of the intake manifold.
3. Place the thermoswitch in water with a
thermometer, and heat the water gradually.
Engine speed (rpm) Voltage (V)

Below 1,500 B+
Above 1,500 Below 1.0
8. If output voltage is as shown in the table above

but there is no airflow in the T/P solenoid valve,
perform the following airflow inspection.
Airflow Inspection
2. Remove the T/P solenoid valve. 4. Inspect the thermoswitch terminals by using an
3. Inspect for airflow between each port under the ohmmeter.
following condition.
F4-30 CONTINUED
CONTROL SYSTEM
Specification
Water temperature (°C {°F}) Continuity
Below 40 {104} Yes
Above 40 {104} No
5. If not as specified, replace the water

thermoswitch.
WATER THERMOSWITCH REMOVAL/INSTALLATION

3. Remove the water thermoswitch from the radiator.
4. The wrap sealing tape two or three times around the
threaded part of the switch before installing.
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5. Use a new washer and install in the reverse order of
removal.
Tightening torque
5.9—8.8 N.m {60—90 kgf.cm-cm, 53—78 in.lbf}
CONTINUED
F4-31
TROUBLESHOOTING
TROUBLESHOOTING
FOREWORD
• Before proceeding with the following troubleshooting;
(1) Refer to section Gl to understand the basic troubleshooting procedure.
(2) Perform the diagnostic trouble code inspection.
(3) If a diagnostic trouble code is displayed, proceed with inspection steps for the code.
(4) When the engine can be started, perform "ENGINE TUNE-UP".
TROUBLESHOOTING ITEM TABLE

• Confirm trouble symptom by using the following diagnostic index, then go to appropriate troubleshooting chart.
No. TROUBLESHOOTING ITEM DESCRIPTION

1 Cranks normally but won't start or hard start No combustion
2 Cranks normally but won't start or hard start (always) Requires excessive cranking time (more than 5 seconds)
3 Cranks normally but won't start or hard start (engine Requires excessive cranking of longer than 5 seconds for
cold) more than 3 times for engine to start.
4 Cranks normally but won't start or hard start (engine Requires excessive cranking time (more than 5 seconds)
warm)
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5 Rough idle/engine stalls at idle (always) —
6 Rough idle/engine stalls at idle (engine cold) Idling is stable when engine is warm.
7 Rough idle/engine stalls at idle (engine warm) Idling is stable when engine is cold.
8 Rough idle/engine stalls at idle when A/C or P/S ON Engine runs normally at idle with no load, but stalls or vibrates
(if equipped) excessively when load (A/C or P/S) is ON.
9 Engine suddenly stalls often —
10 High idle speed after warm-up —
11 Engine stalls at drive away —
12 Engine stalls on deceleration —
13 Hesitation —
14 Poor acceleration —
15 No power, fastest speed is low —
16 Knocking —
17 Afterburn occurs during deceleration —
18 Poor fuel economy —
CONTINUED
F4-32
TROUBLESHOOTING
QUICK DIAGNOSTIC CHART
Intake-air
Fuel system
Emission
system
Control
system
system
Engine
Engine
No Item electrical
Carburetor system
1 Cranks normally but won't start

or hard start O O O O O O O O O O O O

or hard start (always) O O O O O O O O O O O O

or hard start (engine cold) O O O O O O O O O O O O O

or hard start (engine warm) O O O O O O O O
5 Rough idle/engine stalls at idle

(always) O O O O O O O O O O O

(engine cold) O O O O

O O O O O O O
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(engine warm)
when A/C or P/S ON (If
equipped)
9 Engine suddenly stalls often O O O
10 High idle speed after warm-up O O O
11 Engine stalls at drive away O O O O O O O
12 Engine stalls on deceleration O
13 Hesitation O O O O O O O O O O O
14 Poor acceleration O O O O O O O O O O O O O
15 No power, fastest speed is low O O O O O O O O O O O O O
16 Knocking O O O O O O O
17 Afterburn occurs during decel-
eration O O
18 Poor fuel economy O O O O O O O O O O O O
Malfunctioning slow cut solenoid valve
Malfunctioning air vent solenoid valve
Misadjusted CO, HC concentration
Manufacturing accelerator pump
Misadjusted accelerator cable
Malfunctioning choke system
Malfunctioning water switch
Malfunctioning ignition coil

Malfunctioning spark plug
Malfunctioning fuel pump
Malfunctioning distributor
Clogged secondary main
Clogged secondary slow
Engine internal damage

Malfunctioning fuel line
Clogged primary main
Clogged primary slow
Malfunctioning starter
Malfunctioning hoses
Clogged air cleaner
Float lever
Battery
Measure compres- Lower than

sion pressure specification O
Spark inspection No spark O O O
F4-33
CONTINUED
TO. MODEL .INDEX
Symptom 1-Cranks normally but will not start or hard start F4-34
Symptom 2-Cranks normally but will not start or hard start (always) F4-35
Symptom 3-Cranks normally but will not start or hard start (engine cold) F4-36-37
Symptom 4-Cranks normally but will not start or hard start (engine warm) F4-37
Symptom 5-Rough idle/engine stalls at idle (always) F4-38
Symptom 6-Rough idle/engine stalls at idle (engine cold) F4-39
Symptom 7-Rough idle/engine stalls at idle (engine warm) F4-39
Symptom 8-Rough idle/engine stalls at idle-when a/c or p/s on (if equipped) F4-40
Symptom 9-Engine suddenly stalls often F4-40
Symptom 10-High idle speed after warm-up F4-41
Symptom 11-Engine stalls at drive away F4-41-42
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Symptom 12-Engine stalls on deceleration F4-42
Symptom 13-Hesitation F4-42-43
Symptom 14-Poor acceleration F4-43-44
Symptom 15-No power, fastest speed is low F4-44-45
Symptom 16-Knocking F4-46
Symptom 17-Afterburn occurs during deceleration F4-46
Symptom 18-Poor fuel economy F4-47
CONTINUED
TROUBLESHOOTING
SYMPTOM 1 CRANKS NORMALLY BUT WON'T START OR HARD START
1. Air/Fuel mixture too lean
• Air leak
2. Poor ignition or misfire
3. Slow fuel cut solenoid valve malfunction
4. Low engine compression
Warning
Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read
POSSIBLE following warnings before performing fuel system service:
CAUSE • Fuel vapor is hazardous. It can easily Ignite, causing serious injury and damage. Always keep
• Fuel line spills and teaks are dangerous. Fuel can ignite and cause serious Injuries or death and

1 Check if there is any air leakage. Is there any? Yes Repair or replace appropriate parts.
No Go to next step.
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2 Disconnect high-tension lead at idle, then check Yes Go to next step.
engine speed. Does it decrease equally at each
cylinder? No Refer to section G.
3 Check float level. Yes Go to next step.
Is it okay? No If float level is high, check float and needle valve.
If level is low, check for clogging between float to needle
valve and to fuel pump, and between fuel pump to fuel
tank.
4 Open and close throttle valve 2-3 times. Does Yes Check each jet and air bleed for clogging.
engine start? No Go to next step.
5 Check each spark plug. Yes Go to next step.
Are they okay? No Repair or replace spark plug.
6 Check ignition timing at idle. Yes Go to step 8.
Is it okay? No Go to next step.
7 Perform ignition timing adjustment. Yes Adjust ignition timing.
Can timing be adjusted? No Check both distributor and timing belt.
8 Check slow fuel cut solenoid. Yes Go to step 10.
9 Shake carburetor's connector (6-pin) with Yes Repair or replace wiring harness between slow fuel cut
ignition switch at ON. Is a "click" sound heard? solenoid valve and carburetor.
No Repair or replace slow fuel cut solenoid valve.
10 Check compression pressure. Yes Go to step 12.
11 Add oil through plug hole. Yes Check pistons and cylinders for wear,
Does engine start? No Check for the following:
• Burnt valve
• Worn piston, piston ring, or cylinder
• Damaged cylinder gasket
12 Check primary main, slow system. Yes Check for the following:
Is it okay? • Fuel filter (clogging)
• Float room (dust)
• Fuel hose (clogging)
• Fuel tank (dust)
No Clean or replace each jet and air bleed.
CONTINUED
F4-34
TROUBLESHOOTING
SYMPTOM 2 CRANKS NORMALLY BUT WON'T START OR HARD START (ALWAYS)

• Air leak
• Fuel level incorrect
• Restricted primary main, slow system
5. Air/Fuel mixture too rich
• Float level incorrect
POSSIBLE • Loose primary main jet
CAUSE Warning
following warnings before performing fuel system service:
REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. "
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1 Check if there is any air leakage. Is there any? Yes Repair or replace appropriate parts.
No Go to next step.
2 Disconnect high-tension lead at idle, then Yes Go to next step.
check engine speed. Does it decrease equally
at each cylinder? No Refer to Section G.
3 Check ignition timing at idle. Yes Go to Step 8.
Is it okay? No If float level is high, check float and needle valve. If level
is low, check for clogging between float to needle valve
and to fuel pump, and between fuel pump to fuel tank.
6 Open and close throttle valve 2-3 times. Yes Check each jet and air bleed for clogging.
Does engine start? No Go to next step.
8 Check slow fuel cut solenoid. Yes Go to Step 10.
10 Check compression pressure. Yes Go to Step 12.
11 Add oil through plug hole. Yes Check pistons and cylinders for wear.
• Burnt valve
CONTINUED
F4-35
TROUBLESHOOTING
SYMPTOM 3 CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE COLD)
• Air leak
• Choke system malfunction
• Loose primary main jet
POSSIBLE Warning
CAUSE Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read
• Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep
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1 Check if there is any air leakage. Yes Repair or replace appropriate parts.
Is there any? No Go to next step.
engine speed, Does it decrease equally at each
cylinder? No Refer to Section G.
tank.
4 Open and close throttle valve 2-3 times. Yes Check each jet and air bleed for clogging.
Does engine start? No Go to next step.
8 Check choke system. Yes Go to next step.
Is it okay? No Repair or replace choke system.
9 Check slow fuel cut solenoid. Yes Go to Step 11.
• Burnt valve
CONTINUED
F4-36
TROUBLESHOOTING

SYMPTOM 4 CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE WARM)
1. Percolation
• Air vent solenoid valve malfunction
• High float level
Warning
POSSIBLE Following troubleshooting flowchart contains fuel system diagnosis and repair procedures.
CAUSE Read following warnings before performing fuel system service:
• Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage.
Always keep sparks and flames away from fuel.
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1 Inspect spark plugs. Yes Repair or replace
Are spark plugs wet or covered with carbon? No Go to next step.
2 Check choke system. Yes Go to next step.
Is it okay? No Repair or replace choke system.
3 Check air vent solenoid valve. Yes Go to next step.
Is it okay? No Replace air vent solenoid valve.
4 Check float level? Yes Check for the following:
Is it okay? (float level is high.) • Fuel filter (clogging)
No Inspect both float and needle valve.
CONTINUED
F4-37
TROUBLESHOOTING
SYMPTOM 5 ROUGH IDLE/ENGINE STALLS AT IDLE (ALWAYS)

• Loose primary main jet
• Restricted primary slow air bleed
• Air leakage
• Restricted primary main jet
POSSIBLE Warning
CAUSE Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read
PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual.
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1 Check if there is any air leakage. Yes Repair or replace appropriate parts.
engine speed.
Does it decrease equally at each cylinder? No Refer to Section G.
3 Check idle-up system. Yes Go to next step.
Is it okay? No Repair or adjust system.
6 Check idling speed. Yes Go to Step 8.
7 Perform idling speed adjustment. Yes Adjust idling speed.
Can idling speed be adjusted? No Adjust or inspect idling mixture.
8 Check pcv valve. Yes Go to next step.
Is it okay? No Repair or replace pcv valve.
9 Check compression pressure? Yes Go to Step 11.
10 Drive vehicle. Yes Check pistons and cylinders for wear.
Does engine stop at takeoff? No Check for the following:
• Burnt valve
CONTINUED
F4-38
TROUBLESHOOTING
SYMPTOM 6 ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE COLD)

Warning
POSSIBLE
CAUSE
1 Check choke system (quick release). Yes Check for the following:
No Repair or replace choke system.
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SYMPTOM 7 ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE WARM)
1. Choke system malfunction
2. Float level incorrect
3. Air vent solenoid valve malfunction
Warning
POSSIBLE
CAUSE
1 Start and warm engine. Yes Go to next step.
Check choke valve.
Is it fully open? No Repair or replace choke system.
2 Inspect spark plugs. Yes Repair or replace spark plugs.
re spark plugs wet or covered with carbon? No Go to next step.
3 Check air vent solenoid valve. Yes Go to next step.
Is it okay? No Replace valve.
4 Check fuel check valve. Yes Go to next step.
Is it okay? No Repair or replace valve.
5 Check float level. Yes Check for the following:
F4-39 CONTINUED
TROUBLESHOOTING
SYMPTOM 8 ROUGH IDLE/ENGINE STALLS AT IDLE - WHEN A/C OR P/S ON (IF EQUIPPED
1. Idle-up system malfunction
• Solenoid valve malfunction
Warning
POSSIBLE • Fuel vapor is hazardous. It can easily ignite, causing serious Injury and damage. Always keep
1 Inspect idle-up system. Yes Follow steps for troubleshooting item
Is it okay? "Rough idle/engine stalls at idle (Always)".
No Adjust or repair system,
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SYMPTOM 9 ENGINE SUDDERLY STALLS OFTEN
1. Disconnected starter connector
2. Poor connection of starter connector
Warning
POSSIBLE • Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks
CAUSE and flames away from fuel.

1 Check starter connector. Yes Go to next step.
Is it disconnected or is it not properly con- No Properly connect connector, or repair or replace if necessary.
nected?
2 Check slow fuel cut valve. Yes Check for the following:
No Go to next step.
ignition switch at ON. solenoid valve and carburetor.
Is a "click" sound heard? No Repair or replace slow fuel cut solenoid valve.
CONTINUED
F4-40
TROUBLESHOOTING
SYMPTOM 10 HIGH IDLE SPEED AFTER WARM-UP

• Idle-up system malfunction
Warning
POSSIBLE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks
CAUSE and flames away from fuel.
1 Check throttle wiring. Yes Go to next step.
Is there sufficient slack in wiring? No Adjust or repair accelerator cable.
Is it okay? No Adjust or repair.
3 Check secondary throttle valve. Yes Go to next step.
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Is it closed? No Repair or inspect secondary diaphragm link.
4 Check float level. Yes Check for the following:
SYMPTOM 11 ENGINE STALLS AT DRIVE AWAY

• Restricted primary main system
• Accelerator pump malfunction
• Poor ignition or misfire
• Malfunctioning unloader system
Warning
CAUSE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks
and flames away from fuel.
1 Check system for air leakage. Yes Repair or replace parts as necessary.
3 Check accelerator pump. Yes Go to next step.
Is fuel pumped out when accelerator pump is
depressed? No Repair or replace accelerator pump.
4 Check distributor's vacuum advance. Yes Go to next step.
Is it correct? No Replace distributor vacuum control unit.
5 Check unloader system. Yes Go to next step.
Is it okay? No Repair or replace unloader system.
F4-41 CONTINUED
TROUBLESHOOTING

No Clean or replace each Jet and air bleed.
SYMPTOM 12 ENGINE STALLS ON DECELERATION

• Slow fuel cut solenoid valve malfunction
• Throttle positioner (T/P) malfunction (GULF only)
Warning
POSSIBLE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep
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Is it okay? No Repair or replace any parts as necessary.
2 Check slow fuel cut valve. Yes Go to Step 4.
4 Check dashpot's touch speed. Yes Check for the following:
Is it correct? • Fuel filter (clogging)
No Adjust dashpot.
SYMPTOM 13 HESITATION
• Spark advance control malfunction
• Restricted jets
• Air leakage
Warning
POSSIBLE
CAUSE
1 Check system for air leakage. Yes Repair or replace any parts as necessary.
CONTINUED
F4-42
TROUBLESHOOTING

3 Check centrifugal spark advance control. Yes Go to next step.
Is it okay? No Check for the following:
• Over advance (Inspect for governor spring damage.)
• Under advance (Inspect governor weight, cam op
eration.)
4 Check accelerator pump. Yes Go to next step.
Is fuel pumped out when accelerator pump is
depressed? No Repair or replace pump.
5 Check secondary diaphragm. Yes Go to next step.
Is it okay? No Replace secondary diaphragm.
6 Inspect spark plugs? Yes Go to next step.
Are they okay? No Clean or replace spark plugs.
7 Is linkage of primary and secondary valve Yes Go to next step.
smooth? No Repair or replace any parts as necessary.
8 Inspect every jet. Yes Check for the following:
Are they okay? • Fuel filter (clogging)
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No Clean or replace jets. Note
• Dirt and grime can be removed from jets by covering
the air horn with your hand.
SYMPTOM 14 POOR ACCELERATION

1. Spark advance control malfunction
2. Restricted intake/exhaust system
• Low float level
• Restricted jets, air bleeds
• Accelerator pump malfunction
4. Secondary diaphragm malfunction
• RPM limiter malfunction
POSSIBLE 6. Poor ignition
CAUSE Warning
2 Inspect intake system. Yes Go to next step.
Is it restricted? (especially air cleaner) No Repair or replace intake system.
3 Check choke valve. Yes Go to next step.
Is it fully open after warm-up? No Repair or replace choke system.
4 Check distributor, (centrifugal spark advance, Yes Go to next step.
vacuum spark advance)
It is okay? No Repair or replace distributor.
CONTINUED
F4-43
TROUBLESHOOTING

5 Inspect exhaust system. Yes Go to next step.
Is it okay? No Repair or replace exhaust system.
6 Inspect accelerator pump. Yes Go to next step.
It is okay? No Repair or replace accelerator pump.
valve and to fuel pump, and between fuel pump to fuel tank.
8 Inspect spark plugs. Yes Go to next step.
11 Add oil through plug hole. Yes Check pistons, rings, and cylinders for wear.
Does engine start?
No Check the following:
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• Cylinder heads, gaskets
• Valve clearance
12 Inspect all jets and air bleeds (including high Yes Clean or replace each jet and air bleed.
speed richer) of both primary and secondary
No Check for the following:
main passage.
• Fuel filter (clogging)
Is there blockage? • Float room (dust)
SYMPTOM 15 NO POWER, FASTEST SPEED IS LOW

• Centrifugal spark advance malfunction
• Restricted exhaust system
• Restricted air cleaner
Warning
• Fuel line spills and leaks are dangerous. Fuel can Ignite and cause serious Injuries or death and
1 Check system for air leakage. Yes Go to next step.
Is there any No Repair or replace any part as necessary.
2 Check engine. Yes Stop vehicle and let it idle to cool engine.
Does it seem to be overheating? Inspect coolant and engine oil.
No Go to next step.
Is it fully open after warm-up? No Repair or replace choke valve.
5 Check intake system. Yes Go to next step.
Is it restricted? (especially air cleaner) No Repair or replace intake system.
CONTINUED
F4-44
TROUBLESHOOTING

6 Check exhaust system. Yes Go to next step.
Is it restricted? No Repair or replace exhaust system.
Is it okay? (float level is low.) No If level is low, check for clogging between float to needle
tank.
8 Inspect spark plugs. Yes Go to next step.
10 Check centrifugal spark advance control. Is it Yes Go to next step.
okay?
No Check for the following:
• Over advance (Inspect for governor spring damage.)
• Under advance (Inspect governor weight, cam op-
eration.)
Is it okay?
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No Go to next step.
• Burnt valve
13 Check main (primary) system. Yes Go to next step.
Is it okay? No Check the following:
• Main jet
• Air bleed
Note
• Dirt and grime can be removed from jets by
covering the air horn with your hand.
14 Check main (secondary) system. Yes Check for the following:
No Check the following: •
Main jet
• Air bleed
Note
• Dirt and grime can be removed from jets by
covering the air horn with your hand.
CONTINUED
F4-45
TROUBLESHOOTING
SYMPTOM 16 KNOCKING
• Insufficient engine coolant
Warning
• Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious Injuries or death and
1 Check engine Yes Stop vehicle and let it idle to cool engine.
Does it seem to be overheating? Inspect coolant and engine oil,
No Go to next step.
2 Inspect spark plugs. Yes Replace fuel,
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Are spark plugs electrode free of carbon ac-
cumulation? No Clean or replace spark plugs.
SYMPTOM 17 AFTERBURN OCCURS DURING DECELERATION

• Slow fuel cut solenoid valve malfunction
• Throttle position (T/P) malfunction (GULF only)
• Dashpot malfunction
Warning
Following troubleshooting flowchart contains fuel system diagnosis and repair
POSSIBLE procedures. Read following warnings before performing fuel system service:
CAUSE • Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage.
Always keep sparks and flames away from fuel.
• Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or
death and damage. Fuel can also irritate skin and eyes. To prevent this, always
complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE"
described in this manual.
1 Check ignition timing at idle. Is it okay? Yes Go to Step 3.
No Go to next step.
2 Perform ignition timing adjustment. Can Yes Adjust ignition timing.
timing be adjusted? No Check both distributor and timing belt.
3 Inspect distributor, (centrifugal spark ad- Yes Go to next step.
vance, vacuum spark advance) It is okay?
No Repair or replace distributor.
4 Check thermostat. Is it okay? Yes Go to next step.
No Repair or replace thermostat.
5 Inspect every jet. Are they okay? Yes Check for the following: • Fuel filter (clogging) •
Float room (dust) • Fuel hose (clogging) • Fuel
tank (dust)
No Clean or replace jets.
CONTINUED
F4-46
TROUBLESHOOTING

• Incorrect adjustment of main adjust screw •
Incorrect adjustment of idle speed
Warning
and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE
1 Check system for air leakage. Yes Go to next step.
Is there any? No Repair or replace any part as necessary.
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4 Check idling speed. Yes Go to Step 6.
Is it correct? No Go to next step.
5 Perform idling speed adjustment. Yes Adjust idling speed.
Can it be adjusted? No Adjust or repair any part as necessary.
6 Check slow fuel cut solenoid valve. Yes Go to Step 8.
8 Check both CO and HC concentration. Yes Go to next step.
Are they okay? No Adjust CO and HC concentrations.
Is it fully open after warm-up? No Repair or replace choke system.
Is it okay? (float level is high.) No Check the following:
• Float
• Needle valve
11 Check distributor, (centrifugal spark advance, Yes Go to next step.
vacuum spark advance)
Is it okay? No Repair or replace distributor.

Is it normal? No Go to next step.
• Burnt valve
14 Is main jet loose? Yes Check for the following:
• Fuel filter (clogging)
No Clean or replace jets.
CONTINUED
F4-47
ENGINE ELECTRICAL SYSTEM

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . G– 1 IGNITION COIL INSPECTION . . . . . . . . . . . . . G–5/6
BATTERY REMOVAL/INSTALLATION . . . . . . G– 1 DISTRIBUTOR REMOVAL/INSTALLATION . . G–6/7
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . G– 1/2 DISTRIBUTOR DISASSEMBLY/ASSEMBLY . G–8
BATTERY RECHARGING . . . . . . . . . . . . . . . . . G– 2 DISTRIBUTOR INSPECTION (F2 CARB) . . . G–9
GENERATOR REMOVAL/INSTALLATION . . . G– 2/3 HIGH-TENSION LEAD
GENERATOR INSPECTION . . . . . . . . . . . . . . G– 3/4 REMOVAL/INSTALLATION . . . . . . . . . . . . . . G–9
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . G– 5 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . G–10
IGNITER INSPECTION . . . . . . . . . . . . . . . . . . . G– 5 STARTER REMOVAL/INSTALLATION . . . . . . G–10
IGNITION COIL REMOVAL/INSTALLATION . G– 5 STARTER INSPECTION . . . . . . . . . . . . . . . . . . G–10/11
CHARGING SYSTEM Battery Clamp Installation Note (RH)

Install the battery clamp as shown.
BATTERY REMOVAL/INSTALLATION
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3.5—4.9
{35—50, 31—43}
FRONT
75D26R
FRONT
N·m {kgf·cm, in·lbf} BATTERY INSPECTION

Battery
ST
1 Negative battery cable Inspect the battery in the following procedure.
2 Positive battery cable Step Inspection Action
3 Battery clamp Above Go to
+ Installation Note (RH) Measure open circuit 12.4 V Step 3.
1
4 Battery voltage of battery. Below Go to
5 Battery tray 12.4 V next step.
Above Go to
Quick charge for 30 12.4 V next step.
2 minutes and recheck
voltage. Below Replace
12.4 V battery.
Apply test load (see test
Battery is
load chart) to battery using Yes
okay.
y load tester and
a battery
3
record battery voltage after
15 seconds. Is voltage Replace
No
more than specification? battery.
CONTINUED
G–1
CHARGING SYSTEM
Test load chart 1. Place a battery in a pan of water to prevent it from

Battery Load (A) overheating. The water level should come up about
halfway on the battery. Keep water off the top of
34B19R 110
the battery.
55D23R 180
75D26L 195
75D26R 195
BATTERY
80D26R 195
95D31R 250
Battery positive voltage with load

Approximate
Minimum voltage(V)
battery temp.
21 °C {70 °F} 9.6
15 °C {60 °F} 9.5 2. Connect a battery charger to the battery.
3. Adjust the charging current as follows.
10 °C {50 °F} 9.4
4 °C {40 °F} 9.3 Battery type Slow charge Quick charge
– 1 °C {30 °F} 9.1 (5–hour rate) (A) (A)/(30 min.)
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– 7 °C {20 °F} 8.9 34B19R (27) 3.0—4.0 20
–12 °C {10 °F} 8.7 55D23R (48) 4.5—5.5 30
–18 °C { 0 °F} 8.5 75D26L (52) 5.5—6.5 35
75D26R (52) 5.5—6.5 35
Back-up Current
80D26R (55) 5.5—6.5 35
1. Verify that the ignition switch (engine switch) is at the
OFF position and that the key has been removed. 95D31R (64) 6.5—8.0 40
4. After the battery has been recharged, measure the
Caution battery positive voltage and verify that the battery
Operating electrical loads while measuring keeps specified voltage for more than 1 hour.
the back-up current can damage the circuit
tester. Specification
Above 12.4 V
3. Measure the back-up current between the negative
battery terminal and the negative battery cable. 5. If not as specified, replace the battery.
Back-up current GENERATOR REMOVAL/INSTALLATION

20 mA max.
Warning
4. If the current exceeds the maximum, remove the When the battery cables are connected,
fuse in the main fuse block and the fuse block one touching the vehicle body with generator
by one while measuring the back-up current. terminal B will generate sparks. This can
5. Inspect and repair harnesses and connectors of cause personal injury, fire, and damage to
the fuse at which the current reduces. the electrical components. Always
disconnect the battery before performing
BATTERY RECHARGING the following operation.
Caution 1. Disconnect the negative battery cable.

When disconnecting the battery, remove 2. Remove the fresh-air duct, air intake pipe and air
the negative cable first and install it last to hose. (WL, WL Turbo)
prevent damage to electrical components 3. Remove in the order indicated in the table.
or the battery. 4. Install in the reverse order of removal.
To avoid deformation or damage to the 5. Inspect the drive belt deflection/tension.
battery, remove the battery plugs while (Refer to Section B2, DRIVE BELT,
charging the battery. DRIVE BELT INSPECTION.)
Do not quick charge for over 30 minutes. It
CONTINUED
will damage the battery.
G–2
CHARGING SYSTEM
G6 WL, WL Turbo
5.0—6.8 N·m
{50—70 kgf·cm, 44—60 in·lbf}
20—30
{2.0—3.1, 15—22}
A
B
C
38—51
{3.8—5.3, A
19—25 28—38}
{1.9—2.6, 5.0—6.8 N·m
14—18} B {50—70 kgf·cm,
44—60 in·lbf}
38—51 C
{3.8—5.3, 28—38}
38—51
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{3.8—5.3, 28—38}
N·m {kgf·m, ft·lbf} N·m {kgf·m, ft·lbf}
F2 CARB, F2 CIS 1 Terminal B wire

2 Connector
5.0—6.8 N·m 3 Drive belt (generator)
{50—70 kgf·cm, 44—60 in·lbf}
4 Generator strap (G6)
16—22 5 Generator
{1.6—2.3,
12—16}
GENERATOR INSPECTION
Generator Warning Light
1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is
correct. (Refer to Section B2, DRIVE BELT,
DRIVE BELT INSPECTION.)
3. Turn the ignition switch (engine switch) on and
verify that the generator warning light illuminates.
4. If not, inspect the generator warning light and
wiring harnesses between the battery and
generator warning light and between the battery
and generator terminal L (G6, F2 CARB, F2 CIS), I
(WL, WL Turbo).
38—51 ST
{3.8—5.3, 28—38}
G6, F2 CARB, F2 CIS
S L CONTINUED
G–3
CHARGING SYSTEM
WL, WL Turbo
Standard voltage
Engine switch ON (V) Idle (V) [20°C {68°F}]
Terminal
WL, WL Turbo WL, WL Turbo
B B+ 14.05—14.85
A S I A B+ 14.05—14.85
S 0 7.025—7.425
I 2.0—4.0 13.00—14.85
6. If not as specified, disassemble and inspect the

generator.
5. Verify that the generator warning light goes out
Current
after engine starts.
6. If not, inspect the wiring harness between the S
2. Verify that the drive belt deflection/tension is
terminals of the generator (WL, WL Turbo) and the
correct. (Refer to Section B2, DRIVE BELT,
generator.
DRIVE BELT INSPECTION.)
Generator
4. Connect an ammeter, capable of reading 120 A or
Voltage
over, between generator terminal B and the wiring
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harness.
2. Verify that the drive belt deflection/tension is within
the specification. (Refer to Section B2, DRIVE
6. Turn all electrical loads off.
BELT, DRIVE BELT INSPECTION.)
7. Start the engine and increase the engine speed to
3. Turn off all electrical loads.
2,000—2,500 rpm.
4. Turn the ignition switch (engine switch) to START
8. Turn the following electrical loads on and verify that
position and verify that the generator turns
the current reading increases.
smoothly without any noise while the engine is
Headlights
running.
Blower motor
5. Measure the voltage at the terminals shown in the
Rear window defroster
table.
Note
G6, F2 CARB, F2 CIS
Current required for generating power varies
with electrical loads applied.
Standard current (Reference)

S L
Measuring conditions
Room temperature: 20 °C {68 °F}
Voltage: 13.5 V
Engine hot
Terminal B current (A)*

Standard voltage Engine speed
(rpm) G6, F2 CARB,
Ignition switch ON (V) Idle [20°C {68°F}] (V) WL, WL Turbo
Terminal F2 CIS
G6, F2 CARB, F2 CIS G6, F2 CARB, F2 CIS 1,000 Approx. 0—43 Approx. 0—58
B B+ 14.1—14.7 2,000 Approx. 0—62 Approx. 0—74
L Approx. 1 13.0—14.0 *: Must not be 0 A.
S B+ 14.1—14.7
9. If generator terminal B current will not increase,
WL, WL Turbo disassemble and inspect the generator.
A S I
CONTINUED
G–4
IGNITION SYSTEM
IGNITION SYSTEM G6, F2 CIS

8.9—12.7
IGNITER INSPECTION {90—130, 79—112}
G6, F2 CIS
1. Disconnect the igniter connector. 1.5—1.9
2. Turn the ignition switch on and measure the {15—20, 14—17}
voltage at connector terminal A using the
voltmeter.
G6, F2 CIS
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Specification 6.87—9.80
Battery positive voltage {70—100, 60.8—86.8]
N·m {kgf·cm, in·lbf}
3. Turn the ignition switch off and verify that there is

F2 CARB
continuity between terminal B and the body
8.9—12.7
ground. {90—130, 79—112}
4. While cranking the engine, measure the voltage at
terminal C using the voltmeter.
Specification
Approx. 0.5 V
5. If voltage and continuity are okay, replace the

igniter. (Refer to IGNITION SYSTEM, IGNITION
COIL REMOVAL/INSTALLATION.) 2.0—2.9
{20—30, 18—26}
IGNITION COIL REMOVAL/INSTALLATION
G6, F2 CARB, F2 CIS 6.87—9.80
{70—100, 60.8—86.8]
ST
1 Center lead
2 Connector
3 Ignition coil bracket
4 Condenser
5 Ignition coil
6 Igniter
IGNITION COIL INSPECTION

G6, F2 CARB, F2 CIS
Primary Coil Winding
1. Disconnect the ignition coil connector.
CONTINUED
G–5
IGNITION SYSTEM
2. Measure the resistance at the primary coil using an F2 CARB

ohmmeter.
Specification [20 °C {68 °F}]

G6, F2 CIS: 0.81—0.99 Ω
F2 CARB: 1.035—1.265 Ω (+)
G6, F2 CIS
4. If not as specified, replace the ignition coil.

(Refer to IGNITION SYSTEM, IGNITION COIL
DISTRIBUTOR REMOVAL/INSTALLATION
G6, F2 CARB, F2 CIS
F2 CARB
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4. Adjust the ignition timing.
(Refer to Section F2, ENGINE TUNE-UP,
IGNITION TIMING ADJUSTMENT.)
G6
3. If not as specified, replace the ignition coil.

(Refer to IGNITION SYSTEM, IGNITION COIL
Secondary Coil Winding

1. Disconnect the ignition coil connector.
2. Disconnect the center lead.
3. Measure the resistance at the secondary coil using
an ohmmeter.
Specification
10—16 k [20 °C {68 °F}]
19—25 {1.9—2.6, 14—18}
G6, F2 CIS
CONTINUED
G–6
IGNITION SYSTEM
F2 CARB Distributor Installation Note

Verify that the No.1 cylinder is at top dead center,
and align the distributor matching marks.
MATCHING MARKS
19—25 {1.9—2.6, 14—18}
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F2 CIS
19—25 {1.9—2.6, 14—18}

ST
1 Vacuum hose
2 High-tension lead
+ HIGH-TENSION LEAD
3 Connector
4 Distributor
+ Installation Note CONTINUED
G–7
IGNITION SYSTEM
DISTRIBUTOR DISASSEMBLY/ASSEMBLY
G6, F2 CARB, F2 CIS
G6 F2 CIS
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R
F2 CARB
1 Cap 8 Coupling set

2 Rotor 9 Governor set
3 Cover 10 Oil seal
4 Signal rotor 11 Bearing
5 Pick-up coil with igniter 12 Distributor body
6 Vacuum control unit 13 O-ring
7 Breaker
CONTINUED
G–8
IGNITION SYSTEM
DISTRIBUTOR INSPECTION (F2 CARB)

Centrifugal Spark Advance Control TIMING LIGHT
temperature. DIAPHRAGM A
2. Check to be sure that the idle speed and ignition
timing are correct.
(Refer to Section F2, ENGINE TUNE-UP.)
4. Disconnect the vacuum hose to the vacuum control
unit, and plug the end of the hose.
( ° ) 11—15
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VACUUM HOSE 0—2
0 20 53.3
{150, 5.9} {400, 15.7}
5. While gradually increasing the engine speed, use
ADVANCE (DEGREE) VACUUM ( kPa { mmHg , inHg })
the timing light to check the advance angle on
crankshaft pulley. 6. If necessary, disassemble and inspect the
distributor.
19—23
Pick-up Coil With Igniter Inspection
1. Connect an ohmmeter to the pick-up coil.
(°)
9—13
0—2
ADVANCE (DEGREE) 0 1,200 2,200 6,000
ENGINE SPEED ( rpm )
(1) Excess advance . . . weak governor spring (if

the governor spring is
broken, the advance will
rise very high)
(2) Insufficient advance . governor weight or cam 2. Measure the resistance.
malfunction
6. If necessary, disassemble and inspect the
distributor. ST Resistance
900—1,200 Ω
Vacuum Spark Advance Control 3. If it is not within specification, replace it.
temperature. HIGH-TENSION LEAD REMOVAL/INSTALLATION
2. Check to be sure that the idle speed and ignition
timing are correct.
Caution
(Refer to section F2, ENGINE TUNE-UP.)
D The high-tension leads must be reinstalled
to their original positions. Incorrect
4. Disconnect the vacuum hose to the vacuum control
installation can damage the leads and
unit, and plug the end of the hose.
cause power loss, and negatively affect the
5. Attach a vacuum pump to the diaphragm A and
electronic components.
check using the timing light while applying vacuum.
CONTINUED
G–9
STARTING SYSTEM
STARTING SYSTEM
WL, WL Turbo
STARTER REMOVAL/INSTALLATION
9.9—11.7 N·m
Warning {100—120 kgf·cm,
When the battery cables are connected, 87—104 in·lbf}
touching the vehicle body with starter
terminal B will generate sparks. This can
cause personal injury, fire, and damage to
the electrical components. Always
disconnect the battery before performing
the following operation.

2. Remove the battery. (WL, WL Turbo)
(Refer to CHARGING SYSTEM, BATTERY 38—51 {3.8—5.3, 28—38}
3. Remove the intake manifold bracket. (G6)
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G6, F2 CARB, F2 CIS 9.9—11.7 N·m
{100—120 kgf·cm,
87—104 in·lbf} N·m {kgf·m, ft·lbf}
38—51 {3.8—5.3, 28—38}
1 Terminal B wire
2 Terminal S wire
3 Starter
STARTER INSPECTION
On-vehicle Inspection
2. Crank the engine and verify that the starter turns
smoothly without any noise.
3. If not as specified, measure the voltage at
terminals S and B when the ignition switch (engine
switch) is at START position.
Specification
Above 8 V
4. If the voltage is within the specification, remove the

N·m {kgf·m, ft·lbf} starter and inspect the magnetic switch and the
starter.
5. If the voltage is not as specified, inspect the wiring
harness, ignition switch (engine switch).
No Load Test
2. Connect the starter, battery, voltmeter, and
ammeter as shown.
A
B
IGNITION M
SWITCH
(ENGINE V
SWITCH)
STARTER
BATTERY
TERMINAL S
CONTINUED
G–10
STARTING SYSTEM
3. Operate the starter and verify that it turns

smoothly.
4. Measure the voltage and current while the starter
is operating.
Specification
Engine type
Item F2 CARB, WL,
G6
F2 CIS WL Turbo
Voltage (V) 11.5 11.5 11
Current (A) Below 100 Below 60 Below 130
5. If not as specified, repair or replace the inner parts CONTINUED

as necessary.
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G–11
CLUTCH
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . H– 1 CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . . H– 7
CLUTCH FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . H– 1 CLUTCH RELEASE CYLINDER
CLUTCH FLUID INSPECTION . . . . . . . . . . . . . H– 1 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . H– 7
CLUTCH FLUID REPLACEMENT/AIR CLUTCH RELEASE CYLINDER
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H– 1/2 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . H– 7
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . H– 2 CLUTCH UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H– 8
CLUTCH PEDAL INSPECTION/ CLUTCH UNIT REMOVAL/INSTALLATION . . . H– 8/10
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . H– 2/3 CLUTCH COVER INSPECTION . . . . . . . . . . . . H–10
CLUTCH PEDAL REMOVAL/ CLUTCH DISC INSPECTION . . . . . . . . . . . . . . . H–11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . H– 3 CLUTCH RELEASE COLLAR
CLUTCH PEDAL DISASSEMBLY/ INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . H–11
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H– 4 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H–11
CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . . H– 5 PILOT BEARING INSPECTION . . . . . . . . . . . . . H–11
CLUTCH MASTER CYLINDER FLYWHEEL INSPECTION . . . . . . . . . . . . . . . . . H–11
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . H– 5
CLUTCH MASTER CYLINDER
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . H– 5/6
GENERAL PROCEDURES CLUTCH FLUID
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Clutch Pipe Removal/Installation CLUTCH FLUID INSPECTION
1. If any clutch pipe has been disconnected any time
during the procedure, add brake fluid, bleed the air, Note
and inspect for leakage after the procedure has The fluid in the reservoir must be maintained
been completed. between the MIN/MAX level during
2. If removing the clutch pipe, remove it using the replacement.
SST (49 0259 770B). If installing the clutch pipe,
modify the clutch pipe tightening torque to allow for CLUTCH FLUID REPLACEMENT/AIR BLEEDING
the use of a torque wrench–SST (49 0259 770B)
combination, and then tighten the clutch pipe using Caution
the SST (49 0259 770B). Clutch fluid will damage painted surfaces,
be careful not to spill clutch fluid on a
painted surface. If this should happen,
wash it off immediately.
Do not mix different brands of clutch fluid.
Do not reuse the clutch fluid that was
drained out.
1. Draw the fluid from the reserve tank with a suction
pump.
2. Remove the bleeder cap from the clutch release
cylinder and attach a vinyl hose to the bleeder plug.
3. Place the other end of the vinyl hose into a
container.
4. Slowly pump the clutch pedal several times.
5. With the clutch pedal depressed, loosen the
bleeder screw using the SST to let fluid escape.
Close the bleeder screw using the SST.
BLEEDER SCREW
49 0259 770B
CONTINUED
H–1
CLUTCH FLUID, CLUTCH PEDAL
1.Repeat steps 4 and 5 until only clean fluid is seen. CLUTCH PEDAL
2.Tighten the bleeder screw.
CLUTCH PEDAL INSPECTION/ADJUSTMENT
Tightening torque Clutch Pedal Height
5.9—8.8 N·m {60—90 kgf·cm, 52—78 in·lbf} 1. Measure the distance from the upper surface of the
pedal pad to the carpet.
3.Add fluid to the MAX mark.
4.Check for correct clutch operation. Pedal height
241.6—246.6 mm {9.52—9.70 in}
A 14—17
{1.4—1.8, 11—13}
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PEDAL HEIGHT
CARPET
2.If necessary, adjust the pedal height by turning

stopper bolt A and clutch switch (or adjust bolt) B.
CONTINUED
H–2
CLUTCH PEDAL
Clutch Pedal Free Play CLUTCH PEDAL REMOVAL/INSTALLATION

1. Depress the clutch pedal by hand until clutch 1. Disconnect the negative battery cable.
resistance is felt, and measure the pedal free play. 2.Remove in the order indicated in the table.
3.Install in the reverse order of removal.
Pedal free play 4.After installation, adjust the clutch pedal.
3.0—8.0 mm {0.12—0.31 in} (Refer to CLUTCH PEDAL
INSPECTION/ADJUSTMENT)
L.H.D.
D
19—25
{1.9—2.6,
14—18}
C
12—16
{1.2—1.7,
8.7—12.3}
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19—25
{1.9—2.6,
PEDAL 14—18}
FREE PLAY

6.9—9.80 N·m
2.If necessary, adjust the pedal free play by turning {70—100 kgf·cm,
61—86.8 in·lbf}
locknut C and adjusting push rod D. N·m {kgf·m, ft·lbf}
Clutch Release Point Inspection

1. Without depressing the clutch pedal, slowly shift 1 Clutch switch connector (G6, F2 CIS)
the shift lever into reverse position until the gears 2 Spring pin
contact. 3 Clevis pin
2.Gradually depress the clutch pedal and measure the
stroke distance from the point the gear noise stops 4 Nut
(release point) up to the full stroke end position. 5 Clutch pedal component
R.H.D.
Standard distance
G6, F2 CIS, F2 Carb
A: 14.6—37.5 mm {0.58—1.47 in}
Refer to section F2, INTAKE-AIR
(reference value)
SYSTEM, ACCELERATOR PEDAL
A REMOVAL/INSTALLATION.
WL, WL Turbo
Refer to section F2, INTAKE-AIR SYSTEM,
ACCELERATOR PEDAL
RELEASE REMOVAL/INSTALLATION.
POINT
FULL
STROKE
END
POSITION PEDAL STROKE
3.If the clutch pedal disengagement stroke is outside of

the specification, adjust the pedal height and pedal
free play, and verify the pedal stroke.
Pedal stroke
146.5—151.5 mm {5.8—5.9 in}
(reference value)
CONTINUED
H–3
CLUTCH PEDAL
CLUTCH PEDAL DISASSEMBLY/ASSEMBLY

Note
Apply lithium-based grease to the spring and
bush when assembling.
12—16
{1.2—1.7, 8.7—12.3}
14—17
{1.4—1.8,
11—13}
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R
1 Clutch switch (G6, F2 CIS)

2 Adjustment bolt (WL, WL Turbo, F2 Carb)
3 Nut
4 Stopper rubber
5 Retaining ring
6 Washer
7 Bush
8 Pin
9 Fork
10 Push rod
11 Nut
12 Pedal pad
13 Clutch pedal component
CONTINUED
H–4

CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION
6.9—9.8 {70—100, 60.8—86.7}
SST *
12.8—21.5
{130—220, 113—190}
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* 49 0259 770B
1 Clutch pipe 3 Clutch master cylinder

2 Nut 4 Gasket
CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY

84—112 N·m
{8.5—11.5 kgf·m,
61.5—83.1 ft·lbf}
CONTINUED
H–5
1 Snap ring
+ Disassembly Note
+ Assembly Note
2 Piston
3 Protector
4 Primary cap
5 Return spring
6 Tank cap
7 Reservoir
8 Bushing
9 Joint bolt
10 Gasket
11 One-way valve piston
12 Return spring
13 One way valve pin
14 Clutch master cylinder body
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Snap Ring Disassembly Note
Hold the piston down using a cloth-wrapped pin
punch.
Snap Ring Assembly Note

Hold the piston down using a cloth-wrapped pin
punch.
CONTINUED
H–6
CLUTCH RELEASE CYLINDER
CLUTCH RELEASE CYLINDER

CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION
22—26 {2.2—2.7, 16—19}
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16—22 {1.6—2.3, 12—16}
(LITHIUM BASED GREASE) N·m {kgf·m, ft·lbf}
1 E-clip 3 Bolt
2 Clutch hose 4 Clutch release cylinder
CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY

G6
5.9—8.8 N·m
{60—90 kgf·cm,
53—78 in·lbf}
EXCEPT
G6
1 Boot 5 Bleeder cap

2 Push rod 6 Bleeder screw
3 Piston and cap 7 Steel ball
4 Return spring 8 Clutch release cylinder body
CONTINUED
H–7
CLUTCH UNIT
CLUTCH UNIT
CLUTCH UNIT REMOVAL/INSTALLATION
G6 :92—98 {9.3—10.0, 67.3—72.3}

EXCEPT G6 :97—102 {9.8—10.5, 70.9—75.9}
ENGINE SIDE TRANSMISSION SIDE
SST
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18—26 {1.8—2.7, 14—19}
SST
SST
SST
(MOLYBDENUM SULFIDE)
1 Transmission 5 Clutch disc

+ Section J1, MANUAL TRANSMISSION, MANUAL + Installation Note
TRANSMISSION REMOVAL/INSTALLATION 6 Pilot bearing
+ Section J2, MANUAL TRANSMISSION, MANUAL + Removal Note
TRANSMISSION REMOVAL/INSTALLATION + Installation Note
2 Clutch release collar 7 Flywheel
3 Clutch release fork + Removal Note
4 Clutch cover + Installation Note
+ Removal Note
+ Installation Note CONTINUED
H–8
CLUTCH UNIT
Clutch Cover Removal Note Flywheel Installation Note

1. Install the SSTs. 1. Install the flywheel to the crankshaft.
2. Loosen each bolt one turn at a time in a crisscross 2. Hand-tighten the flywheel lock bolts.
pattern until spring tension is released. 3. Install the SST to the flywheel.
4. Apply sealant to the bolt threads before installing
49 E011 1A0 the bolt to prevent oil leakage from the bolt.
5. Gradually tighten the flywheel lock bolts in a
crisscross pattern.
G6
1
49 SE01 310A 5 7
3
4
49 E011 1A0 8 6
2
Pilot Bearing Removal Note
Note
The pilot bearing does not need to be removed
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unless you are replacing it. EXCEPT G6
Use the SSTs to remove the pilot bearing.
1
3 6
49 E011 1A0
5 4
2
49 1285 071
Pilot Bearing Installation Note

G6, F2 CIS, F2 Carb
Install a new pilot bearing using a pipe until depth
Flywheel Removal Note is as follows:
1. Hold the flywheel using the SST.
2. Remove the bolts evenly and gradually in a Depth
crisscross pattern. 4.0 mm {0.16 in}
G6
PILOT BEARING
CRANK
SHAFT
49 E011 1A0
Ä ÀÆ
Â Ã
Ç Å
Á
EXCEPT G6
1
3 6
49 E011 1A0
5 4
2
CONTINUED
H–9
CLUTCH UNIT
WL, WL Turbo CLUTCH COVER INSPECTION

Install a new pilot bearing using a pipe until 1. Measure the wear of the diaphragm spring figures.
protrusion height is as follows:
Depth
Protrusion height 0.6 mm {0.024 in} min.
0—0.2 mm {0—0.008 in}
DEPTH
PILOT BEARING
FLY WHEEL
2. Measure the flatness of the pressure plate using a

Clutch Disc Installation Note straight edge and a feeler gauge.
Hold the clutch disc in position using the SST.
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Clearance
0.5 mm {0.020 in} max.
49 SE01 310A
Clutch Cover Installation Note

1. Install the SSTs.
2. Tighten the bolts evenly and gradually in a 3. When checking the diaphragm spring fingers,
crisscross pattern. mount a dial indicator on the cylinder block.
4. Rotate the flywheel and check for misaligned
diaphragm spring fingers.
49 E011 1A0
Misalignment
0.6 mm {0.030 in} max.
49 SE01 310A
5. Replace the clutch cover if not as specified.
CONTINUED
H–10
CLUTCH UNIT
CLUTCH DISC INSPECTION FLYWHEEL

1. Using vernier calipers, measure the thickness of
the lining at a rivet head on both sides. PILOT BEARING INSPECTION
2. If clutch disc thickness is less than the minimum, 1. Without removing the pilot bearing from the
replace the clutch disc. flywheel, turn the bearing while applying force in
the axial direction.
Thickness
0.3 mm {0.012 in} min.
0.3 mm
{0.012 in}
2. If the bearing sticks or has excessive resistance,

replace it.
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3. Measure the clutch disc runout using a dial
indicator. FLYWHEEL INSPECTION
1. Install a dial indicator on the cylinder block.
Runout 2. Measure the flywheel runout using a dial indicator.
0.7 mm {0.027 in} max.
Runout
0.2 mm {0.079 in} max.
4. If runout is excessive, replace the clutch disc.
CLUTCH RELEASE COLLAR INSPECTION

3. If runout is excessive, replace the flywheel.
Caution
Cleaning the clutch release collar with
cleaning fluids or a steam cleaner can wash
the grease out of the sealed bearing.
Otherwise, clutch release collar may not
operate properly.
1. Turn the collar while applying force in the axial

direction.
2. If the collar sticks or has excessive resistance,

replace the clutch release collar. CONTINUED
H–11
MANUAL TRANSMISSION
(M15M-D, M15MX-D)
MANUAL TRANSMISSION .............................. J1-1 VEHICLE SPEEDOMETER SENSOR
TRANSMISSION OIL INSPECTION ................ J1-1 INSPECTION .....................................................J1-2
TRANSMISSION OIL REPLACEMENT ........... J1-1/2 MANUAL TRANSMISSION
OIL SEAL (M15M-D) REPLACEMENT............. J1-2 REMOVAL/INSTALLATION ................................J1-3/7
VEHICLE SPEEDOMETER SENSOR
REMOVAL/INSTALLATION ........................ J1-2
MANUAL TRANSMISSION
TRANSMISSION OIL INSPECTION
1. Remove the check plug A.
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2. Drain the oil into a container.
3. Clean the drain plug B.
2. Verify that the oil is at the brim of the check plug hole 4. Install the drain plug B with new washer.
as shown. If it is low, add the specified oil from the
check plug hole. Tightening torque
Specified oil B: 40—58 N.m {4.0—6.0 kgf.m, 29—43 ft.lbf}
Grade: 5. Add the specified oil from check plug A port until the
API service GL-4 or GL-5 level reaches the brim of check plug hole.
Viscosity:
SAE 75W-90 (All season) or
SAE 80W-90 (Above 10 °C {50 °F})
Capacity:
2.0 L {2.1 US qt, 1.8 Imp qt} (M15M-D)
2.5 L {2.6 US qt, 2.2 Imp qt} (M15MX-D)
3. Install a new check plug A.
Tightening torque
A: 25—39 N.m {2.5-4.0 kgf.m, 19—28 ft.lbf}
TRANSMISSION OIL REPLACEMENT

1. Remove the drain plug B with washer and the Specified oil
check plug A. Grade:
API service GL-4 or GL-5
Viscosity:
SAE 80W-90 (Above 10 °C {50 °F})
Capacity:
2.0 L {2.1 US qt, 1.8 Imp qt} (M15M-D)
2.5 L {2.6 US qt, 2.2 Imp qt} (M15MX-D)
6. Install a new check plug A.

Tightening torque
A: 25—39 N.m {2.5—4.0 kgf.m, 19—28 ft.lbf}
CONTINUED
J1-1
MANUAL TRANSMISSION
6. Install the vehicle speedometer sensor.
Tightening torque
7.9—10.7 N.m
{80—110 kgf.cm, 69.5—95.4 in.Ibf}
7. Connect the vehicle speedometer sensor connector.

8. Add the specified type and amount of transmission
oil.
(Refer to MANUAL TRANSMISSION,
TRANSMISSION OIL REPLACEMENT.)
VEHICLE SPEEDOMETER SENSOR INSPECTION

OIL SEAL (M15M-D) REPLACEMENT 1. Remove the vehicle speedometer sensor.
(Refer to MANUAL TRANSMISSION, VEHICLE
1. Drain the transmission oil.
SPEEDOMETER SENSOR REMOVAL/
2. Remove the propeller shaft. INSTALLATION.)
(Refer to section L, PROPELLER SHAFT (4x2),
2. Measure voltage between terminals of the vehicle
PROPELLER SHAFT REMOVAL/ INSTALLATION.)
speedometer sensor while the gear is turning.
3. Remove the oil seal using a screwdriver.
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Meter needle Action
Speedometer sensor is
normal.
Moves slightly under 5 V Inspect wiring harness.
(Instrument cluster-Vehicle
speedometer sensor)
Replace vehicle speedometer
Does not move
sensor.
4. Apply the specified oil to new oil seal.

5. Install the oil seal until it touches the case using a
suitable piece of pipe.
3. Install the vehicle speedometer sensor.

(Refer to MANUAL TRANSMISSION, VEHICLE
SPEEDOMETER SENSOR REMOVAL/
INSTALLATION.)
6. Install the propeller shaft.
PROPELLER SHAFT REMOVAL/ INSTALLATION.)
7. Add the transmission oil.
3. Disconnect the vehicle speedometer sensor
connector.
4. Remove the vehicle speedometer sensor.
5. Apply transmission oil to new O-ring and install it on
new vehicle speedometer sensor.
J1-2 CONTINUED
MANUAL TRANSMISSION
MANUAL TRANSMISSION REMOVAL/INSTALLATION
4x2(M15M-D)
2. Drain the transmission oil into a container.
3. Remove the propeller shaft.
(Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.)
4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.)
7. Add the specified type and amount of transmission oil.
(Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.)
8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
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1 Shift lever knob 12 Speedometer sensor connector
2 Console 13 Back-up light switch connector
3 Dust boot 14 Neutral switch connector (F2 CIS)
4 Change boot upper plate 15 Front pipe bracket
5 Boot 16 Clutch release cylinder
6 Dust boot 17 Crossmember
7 Gasket ☞ Removal Note
8 Wave washer 18 Transmission lower mount
9 Change bush 19 Transmission
☞ Removal Note
10 Change lever ☞ Installation Note
11 Change seat
CONTINUED
J1-3
MANUAL TRANSMISSION
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1 Shift lever knob 12 Speedometer sensor connector
3 Dust boot 14 Front pipe bracket
4 Change boot upper plate 15 Clutch release cylinder
5 Boot 16 Crossmember
6 Dust boot ☞ Removal Note
7 Gasket 17 Dynamic damper
☞ Removal Note & Installation Note
10 Change lever
11 Change seat
CONTINUED
J1-4
MANUAL TRANSMISSION
Crossmember removal note
• Securely support the transmission on
a transmission jack, then remove the
crossmember.
Transmission removal note

• Maintain the stability of the
transmission while removing it.
Transmission installation note

Warning
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• A transmission that is not securely
supported on a transmission jack is
dangerous. It can slip or fall, causing
serious injury. Never work without the
transmission jack until crossmember
installation is finished.
1. Place the transmission on a transmission

jack.
2. Maintain the stability of the transmission
while installing it.
CONTINUED
J1-5
MANUAL TRANSMISSION
4x4(M15MX-D)
2. Drain the transmission and transfer oil into a container.
3. Remove the front and rear propeller shaft,
(Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFT
(Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFT
7. Add the specified type and amount of transmission and transfer oil.
(Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.)
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1 Shift lever knob 12 Transfer under cover
2 Console 13 Speedometer sensor connector
3 Dust boot 14 Back-up light switch connector
4 Change boot upper mount 15 4x4 indicator switch connector
5 Boot 16 Front pipe bracket
6 Dust boot 17 Clutch release cylinder
7 Gasket 18 Crossmember
8 Wave washer ☞ MANUAL TRANSMISSION, MANUAL TRANS-
MISSION REMOVAL/INSTALLATION, 4x2 (M15M-D),
9 Change bush Crossmember removal Note
10 Change lever
11 Change seat
CONTINUED
J1-6
MANUAL TRANSMISSION
19 Transmission lower mount

20 Transmission and transfer
☞ Removal Note & Installation Note
Transmission and transfer removal note

• Maintain the stability of the transmission and transfer
while removing them .
Transmission and transfer installation note
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Warning
• A transmission and transfer that are not securely
supported on a transmission jack are dangerous. They
can slip or fall, causing serious injury. Never work
without the transmission jack until crossmember
1. Place the transmission and transfer on a transmission jack.

2. Maintain the stability of the transmission and transfer while
installing them.
CONTINUED
J1-7
MANUAL TRANSMISSION
(R15M–D, R15MX–D)
MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . J2–1 VEHICLE SPEEDOMETER SENSOR INSPECTION...J2–2
TRANSMISSION OIL INSPECTION . . . . . . . . . J2–1 MANUAL TRANSMISSION
TRANSMISSION OIL REPLACEMENT . . . . . . J2–1/2 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . J2–3/9
OIL SEAL (R15M–D) REPLACEMENT . . . . . . J2–2
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . J2–2
MANUAL TRANSMISSION TRANSMISSION OIL REPLACEMENT

1. Remove drain plugs A and B, and drain the oil into
TRANSMISSION OIL INSPECTION a container.
1. Remove the filler plug. 2. Clean the drain plug A.
FILLER PLUG 3. Install the drain plug A with new washer and a new
drain plug B.
Tightening torque
A: 40—58 N·m {4.0—6.0 kgf·m, 29—43 ft·lbf}
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B: 21—31 N·m {2.1—3.2 kgf·m, 16—23 ft·lbf}
FILLER PLUG
2. Verify that the oil is at the brim of the filler plug hole
as shown. If it is low, add the specified oil from the
filler plug hole.
Specified oil DRAIN PLUG B
Grade: DRAIN PLUG A
API service GL–4 or GL–5
Viscosity: 4. Remove the filler plug and add the specified oil
SAE 75W–90 (All season) or through the filler plug port until the level rises to the
SAE 80W–90 (Above 10°C {50°F}) bottom of the port.
Specified oil
Grade:
API service GL–4 or GL–5
Viscosity:
FILLER PLUG HOLE SAE 75W–90 (All season) or
SAE 80W–90 (Above 10°C {50°F})
Capacity:
2.8 L {3.0 US qt, 2.5 lmp qt} (R15M–D)
3.2 L {3.4 US qt, 2.8 lmp qt} (R15MX–D)
3. Install a new filler plug.
Tightening torque FILLER PLUG HOLE

25—39 N·m {2.6—4.0 kgf·m, 19—28 ft·lbf}
CONTINUED
J2–1
MANUAL TRANSMISSION
1. Install a new filler plug.
Tightening torque
25—39 N·m {2.6—4.0 kgf·m, 19—28 ft·lbf}
OIL SEAL (R15M–D) REPLACEMENT

PROPELLER SHAFT REMOVAL/INSTALLATION.)
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4. Apply the specified oil to the new oil seal.
5. Install the oil seal until it touches the case using a
suitable piece of pipe.
PIPE
6. Install the propeller shaft.

PROPELLER SHAFT REMOVAL/INSTALLATION.)
7. Add the transmission oil.

(Refer to section J1, MANUAL TRANSMISSION,
VEHICLE SPEEDOMETER SENSOR INSPECTION

(Refer to section J1, MANUAL TRANSMISSION,
VEHICLE SPEEDOMETER SENSOR INSPECTION.)
CONTINUED
J2–2
MANUAL TRANSMISSION
MANUAL TRANSMISSION REMOVAL/INSTALLATION
42 (R15M–D)
2. Drain the transmission oil into a container.
(Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.)
7. Add the specified amount and type of transmission oil.
7.9—10.7 N·m
F2 {80—110 kgf·cm,
69.5—95.4 in·lbf}
69—88
{7.0—9.0,
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51—65}
19—25 {1.9—2.6, 14—18}
A
69—88
{7.0—9.0,
51—65}
16—22
38—51 {1.6—2.3,
{3.8—5.3, 12—16}
28—38} 69—88
{7.0—9.0,
51—65}
69—88
{7.0—9.0, 16—22
A
51—65} {1.6—2.3,
12—16}
ST
38—51 38—51
{3.8—5.3, 32—46 {3.2—4.7, 24—33} 38—46
{3.8—5.3,
28—38} {3.8—4.7,
28—38}
22—28 {2.2—2.9, 16—20} 28—33}
7.9—10.7 N·m
{80—110 kgf·cm, 69.5—95.4 in·lbf} N·m {kgf·m, ft·lbf}
1 Shift lever knob 12 Vehicle speedometer sensor connector

2 Console 13 Back–up light switch connector
3 Dust boot 14 Neutral switch connector (F2 CIS)
7 Gasket + Removal Note
+ Removal note
10 Change lever + Installation note
11 Change seat
CONTINUED
J2–3
MANUAL TRANSMISSION
G6
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1 Shift lever knob 12 Vehicle speedometer sensor connector
3 Dust boot 14 Neutral switch connector
7 Gasket ☞ Removal Note
☞ Removal note
10 Change lever ☞ Installation note
11 Change seat
CONTINUED
J2-4
MANUAL TRANSMISSION
WL, WL TURBO
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
38—51
19—25 {1.9—2.6, 14—18} {3.8—5.3,
28—38}
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38—51 {3.8—5.3, 28—38}
16—22
{1.6—2.3,
12—16}
A 16—22
{1.6—2.3,
12—16}
32—46 {3.2—4.7, 24—33}
22—28 {2.2—2.9, 16—20} 38—46

{3.8—4.7, 28—33}
1 Shift lever knob 11 Change seat

2 Console 12 Vehicle speedometer sensor connector
3 Dust boot 13 Back-up light switch connector
7 Gasket + Removal Note

+ Removal note
10 Change lever + Installation note
CONTINUED
J2–5
MANUAL TRANSMISSION
Crossmember removal note

Securely support the transmission on a
transmission jack, then remove the crossmember.
Transmission removal note
Warning
Do not allow the transmission to fall from
the transmission jack.
Maintain the stability of the transmission while

removing it.
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Transmission installation note
Warning
A transmission that is not securely
supported on a transmission jack is
dangerous. It can slip or fall, causing
serious injury. Never work without the
transmission jack until crossmember
1. Place the transmission on a transmission jack.

2. Maintain the stability of the transmission while
installing them.
ST
CONTINUED
J2–6
MANUAL TRANSMISSION
44 (R15MX–D)
2. Drain the transmission and transfer oil into a container.
3. Remove the front and rear propeller shaft.
(Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFT
(Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFT
4. Remove the front pipe. (G6 engine)
(Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
8. Add the specified type and amount of transmission and transfer oil.
(Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.)
G6
7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
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R
38—51 {3.8—5.3, 28—38}
19—25
{1.9—2.6,
14—18}
38—51 {3.8—5.3, 28—38}

A
38—51 {3.8—5.3, 28—38} 16—22

{1.6—2.3, 32—46 {3.2—4.7, 24—33}
12—16}
69—88 7.9—10.7 N·m

{7.0—9.0, {80—110 kgf·cm,
51—65} 69.5—95.4 in·lbf}
A
37—50
{3.7—5.1,
27—36} 44—53 {4.4—5.3, 32—39}
38—51 {3.8—5.3, 28—38}
CONTINUED
J2–7
MANUAL TRANSMISSION
1 Shift lever knob 14 Back–up light switch connector

2 Console 15 Neutral switch connector
3 Dust boot 16 4x4 indicator switch connector
4 Change boot upper mount 17 Transfer neutral switch connector (RFW model)
5 Boot 18 Front pipe bracket
6 Dust boot 19 Clutch release cylinder
7 Gasket 20 Crossmember
8 Wave washer + MANUAL TRANSMISSION, MANUAL
TRANSMISSION REMOVAL/INSTALLATION,
9 Change bush 42 (R15M–D), Crossmember removal note
10 Change lever 21 Transmission lower mount
11 Change seat 22 Transmission and transfer
12 Transfer under cover + Removal note
13 Vehicle speedometer sensor connector + Installation note
WL, WL TURBO
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7.9—10.7 N·m
{80—110 kgf·cm,
69.5—95.4 in·lbf}
R
R
38—51
{3.8—5.3,
19—25 28—38}
{1.9—2.6, 14—18}
ST 38—51
{3.8—5.3, 28—38}
A
32—46
{3.2—4.7, 24—33}
16—22
{1.6—2.3,
12—16}
A 37—50
{3.7—5.1,
27—36}
44—53
{4.4—5.3, 32—39}
22—28
{2.2—2.9, 16—20}
CONTINUED
J2–8
MANUAL TRANSMISSION
1 Shift lever knob Transmission and transfer removal note

2 Console
Warning
3 Dust boot Do not allow the transmission to fall from
4 Change boot upper mount the transmission jack.
5 Boot
Maintain the stability of the transmission and
6 Dust boot transfer while removing them.
7 Gasket
8 Wave washer
9 Change bush
10 Change lever
11 Change seat
12 Transfer under cover
13 Vehicle speedometer sensor connector
14 Back–up light switch connector
15 Transfer neutral switch connector (RFW model)
16 4x4 indicator switch connector
Transmission and transfer installation note
17 Front pipe bracket
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18 Clutch release cylinder Warning
19 Crossmember A transmission and transfer that are not
+ MANUAL TRANSMISSION, MANUAL securely supported on a transmission jack
TRANSMISSION REMOVAL/INSTALLATION, are dangerous. They can slip or fall,
42 (R15M–D), Crossmember removal note causing serious injury. Never work without
20 Transmission lower mount the transmission jack until crossmember
21 Transmission and transfer
+ Removal note 1. Place the transmission and transfer on a
+ Installation note transmission jack.
2. Maintain the stability of the transmission and
transfer while installing them.
CONTINUED
J2–9
BACK.TO.MAIN.INDEX RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
TO. MODEL .INDEX
TRANSFER
TRANSFER ..................................................................J3-1 TRANSFER OIL REPLACEMENT................ J3-1
TRANSFER OIL INSPECTION ...............................J3-1
TRANSFER TRANSFER OIL REPLACEMENT

TRANSFER OIL INSPECTION 1. Remove the filler plug with washer and drain plug
1. Remove the filler plug with washer. with washer.
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2. Verify that the oil is at the brim of the filler plug hole
as shown. If it is low, add the specified oil from the 2. Drain the oil into a container.
filler plug hole. 3. Clean the filler and drain plugs.
4. Install the drain plug with new washer.
Specified oil
Grade: Tightening torque
API service GL-4 or GL-5 40—58 N.m {4.0—6.0 kgf.m, 29—43 ft.lbf}
Viscosity:
SAE 75W-90 (All season) or 5. Add the specified oil from filler plug port until the level
SAE 80W-90 (Above 10 °C {50 °F}) reaches the brim of filler plug hole.
Capacity:
2.0 L {2.1 USqt,1.8 lmp qt}
Specified oil
Grade:
API service GL-4 or GL-5
Viscosity:
SAE 80W-90 (Above 10 °C {50 °F})
Capacity:
2.0 L {2.1 USqt,1.8lmpqt}
3. Clean the filler plug.

4. Install the filler plug with new washer.
Tightening torque
40—58 N-m {4.0—6.0 kgf.m, 29—43 ft.lbf}
6. Install the filler plug with new washer.
Tightening torque
40—58 N-m {4.0-6.0 kgf.m, 29—43 ft.lbf}
CONTINUED
J3-1
PROPELLER SHAFT
PROPELLER SHAFT (42) . . . . . . . . . . . . . . . . . . L–1 FRONT PROPELLER SHAFT INSPECTION . . L–3
PROPELLER SHAFT REMOVAL/ FRONT PROPELLER SHAFT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . L–1 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . L–3/4
PROPELLER SHAFT INSPECTION . . . . . . . . . . L–2 REAR PROPELLER SHAFT (44) . . . . . . . . . . . . L–5
FRONT PROPELLER SHAFT (44) . . . . . . . . . . . L–2 REAR PROPELLER SHAFT REMOVAL/
FRONT PROPELLER SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . L–5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . L–2 REAR PROPELLER SHAFT INSPECTION . . . . L–5
PROPELLER SHAFT (42)

PROPELLER SHAFT REMOVAL/INSTALLATION
50—58
{5.0—6.0, 37—43}
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WL TURBO, G6: 49 S120 440
WL, F2 CIS, F2 CARB: 49 0259 440
SST
Propeller Shaft Installation Note
Align the marks made during removal, and install
37—52 {3.7—5.4, 27—39} the propeller shaft. If installing a new propeller
shaft, align the differential companion flange
precast marking with the tag on the propeller shaft.
1 Bolt, nut TAG
MARK
2 Nut
+ Installation Note
3 Propeller shaft
+ Removal Note
+ Installation Note
Propeller Shaft Removal Note

1. Before removing the propeller shaft, put marks on
the yoke and the companion flange on the
propeller shaft tag side for proper reinstallation.
TAG Nut Installation Note
MARK ST
Tighten the center bearing installation nuts with the
vehicle *unloaded.
*unloaded...Fuel tank is full; engine coolant and engine
oil are at specified levels; spare tire, jack and tools are
in designated position.
2. Remove the propeller shaft from the extension

housing and immediately install the SST to prevent
oil leakage.
CONTINUED
L–1
PROPELLER SHAFT (42), FRONT PROPELLER SHAFT (44)
PROPELLER SHAFT INSPECTION FRONT PROPELLER SHAFT (44)

1. Measure the propeller shaft runout using a dial
indicator. FRONT PROPELLER SHAFT REMOVAL/
INSTALLATION
Runout 1. Remove in the order indicated in the table.
0.4 mm {0.016 in} max. 2. Install in the reverse order of removal.
28—30
{2.8—3.1, 21—22}
2. If the runout is excessive, replace the propeller

shaft.
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3. Move the universal joint in the direction shown, and
inspect joint play.
Note
Starting torque
0.3—1.1 N·m
{3.0—12.0 kgf·cm, 2.7—10.4 in·lbf} N·m {kgf·m, ft·lbf}
1 Bolt, nut
2 Front propeller shaft
+ Removal Note
+ Installation Note
Front Propeller Shaft Removal Note

Before removing the front propeller shaft, put
marks on the yoke and the companion flange on
the propeller shaft tag side for proper reinstallation.
4. If there is excessive play or the starting torque is TAG

MARK
not within the specification, replace the propeller
shaft.
Front Propeller Shaft Installation Note

the front propeller shaft. If installing a new
propeller shaft, align the precast marking with the
tag on the front propeller shaft.
CONTINUED
L–2
FRONT PROPELLER SHAFT (44)
FRONT PROPELLER SHAFT

DISASSEMBLY/ASSEMBLY
TAG
MARK 1. Disassemble in the order indicated in the table.
R
R
R
FRONT PROPELLER SHAFT INSPECTION

1. Measure the front propeller shaft runout using a
R
dial indicator.
Runout
1 Snap ring
0.4 mm {0.016 in} max.
+ Disassembly Note
2 Universal joint yoke
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3 Universal joint
+ Disassembly Note
+ Assembly Note
4 Sliding yoke
5 Propeller shaft
Snap ring Disassembly Note

1. Mark the yoke and propeller shaft for proper
reassembly.
2. If the runout is excessive, replace the front MARK

propeller shaft.
3. Move the universal joint in the direction shown,
and inspect the joint play.
Note
Starting torque
0.3—0.7 N·m
{3.0—8.0 kgf·cm, 2.7—6.9 in·lbf}
2. Clamp the propeller shaft in a vise.

3. Remove the snap ring.
ST
Universal joint Disassembly Note
1. Push one bearing cup out of the propeller shaft by
tapping the yoke with a plastic hammer.
4. If there is excessive play or the starting torque is BEARING CUP

not within the specification, repair the front
propeller shaft.
(Refer to FRONT PROPELLER SHAFT (44),
FRONT PROPELLER SHAFT
DISASSEMBLY/ASSEMBLY.)
YOKE
CONTINUED
L–3
FRONT PROPELLER SHAFT (44)
1. Remove the opposite bearing cup in the same

manner.
2. Separate the propeller shaft and yoke.
3. Clamp the yoke in a vise.
4. Remove the bearing cups and the spider from the
yoke in the same manner as in Steps 1 and 2.
Universal joint Assembly Note

1. Verify that the inside of the bearing cup is filled with
1.15—1.45g {0.04—0.05 oz} grease. Add the
specified amount of disulphide molybdem grease
as necessary.
2. Set the new spider into the yoke and tap in a new 6. If there is excessive play or the starting torque is
bearing cup until the snap ring groove is exposed. not within the specification, replace the front
propeller shaft.
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SPIDER
3. Measure the snap ring clearance, then select and

install two new snap rings of equal thickness.
Snap ring thicknesses

mm {in}
1.22 {0.0480} 1.32 {0.0520}
1.24 {0.0488} 1.34 {0.0528}
1.26 {0.0496} 1.36 {0.0536}
1.28 {0.0504} 1.38 {0.0543}
1.30 {0.0512}
BEARING CUP
YOKE
SNAP RING
CLEARANCE
SPIDER
4. Install the remaining bearing cups and snap rings

as in Steps 1—3.
5. Move the universal joint in the direction shown, and
inspect joint play.
Note
Starting torque
0.3—0.7 N·m
{3.0—8.0 kgf·cm, 2.7—6.9 in ·lbf}
CONTINUED
L–4
REAR PROPELLER SHAFT (44)
REAR PROPELLER SHAFT (44) TAG

MARK
REAR PROPELLER SHAFT
50—58
{5.0—6.0, 37—43}
REAR PROPELLER SHAFT INSPECTION

1. Measure the rear propeller shaft runout using a dial
indicator.
Runout
0.4 mm {0.016 in} max.
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37—52
{3.7—5.4, 27—39}
50—58
{5.0—6.0, 37—43}
1 Bolt, nut
2. If the runout is excessive, replace the rear
2 Nut
propeller shaft.
+ PROPELLER SHAFT (42), PROPELLER
3. Move the universal joint in the direction shown.
SHAFT REMOVAL/INSTALLATION, Nut
Inspect starting torque and joint play.
Installation Note
3 Rear propeller shaft Note
+ Removal Note Starting torque
+ Installation Note 0.3—1.1 N·m
4 Dynamic damper (WL Turbo) {3.0—12.0 kgf·cm, 2.7—10.4 in·lbf}
Rear Propeller Shaft Removal Note

1. Before removing the rear propeller shaft, put marks
on the yoke and the companion flange on the rear
propeller shaft tag side for proper reinstallation. ST
TAG
MARK
4. If there is excessive play or the starting torque is

not within the specification, replace the rear
propeller shaft.
Rear Propeller Shaft Installation Note

the rear propeller shaft. If installing a new propeller
shaft, align precast marking with the tag on the
rear propeller shaft. CONTINUED
L–5
FRONT AND REAR AXLES

GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . M– 2 REMOTE FREEWHEEL (RFW)
FRONT AXLE (42) . . . . . . . . . . . . . . . . . . . . . . . M– 2 MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M–32
WHEEL HUB, STEERING KNUCKLE 44 INDICATOR SWITCH INSPECTION . . . M–32
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . M– 2 TRANSFER NEUTRAL SWITCH
WHEEL HUB, STEERING KNUCKLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . M–32/33
REMOVAL/INSTALLATION . . . . . . . . . . . . . . M– 3/5 RFW SWITCH INSPECTION . . . . . . . . . . . . . . M–33
FRONT AXLE (44) . . . . . . . . . . . . . . . . . . . . . . . M– 5 RFW MAIN SWITCH REMOVAL/
WHEEL HUB, STEERING KNUCKLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . M–33
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . M– 5 RFW MAIN SWITCH INSPECTION . . . . . . . . M–33
WHEEL HUB, STEERING KNUCKLE ONE-WAY CHECK VALVE INSPECTION . . . M–34
REMOVAL/INSTALLATION . . . . . . . . . . . . . . M– 6/8 LOCK AND FREE SOLENOID VALVES
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M– 9 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . M–34
REAR AXLE INSPECTION . . . . . . . . . . . . . . . . M– 9 RFW ACTUATOR INSPECTION . . . . . . . . . . . M–34
AXLE SHAFT REMOVAL/ RFW CONTROL MODULE INSPECTION . . . . M–35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . M– 9/11 RFW CONTROL MODULE
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M–12 REMOVAL/ INSPECTION . . . . . . . . . . . . . . M–35/36
DRIVE SHAFT REMOVAL/ JOINT SHAFT COMPONENT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . M–12 REMOVAL/INSTALLATION . . . . . . . . . . . . . . M–37
DRIVE SHAFT DISASSEMBLY/ JOINT SHAFT COMPONENT
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ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . M–13/15 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . M–38/39
OUTPUT SHAFT (MFW) JOINT SHAFT INSPECTION . . . . . . . . . . . . . . M–39
REMOVAL/INSTALLATION . . . . . . . . . . . . . . M–16 JOINT SHAFT COMPONENT ASSEMBLY . . . M–40/42
OUTPUT SHAFT CONTROL BOX REMOVAL/
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . M–17/18 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . M–42
REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . M–19 CONTROL BOX DISASSEMBLY/
REAR DIFFERENTIAL OIL INSPECTION . . . . M–19 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . M–43/44
REAR DIFFERENTIAL OIL SHIFT FORK INSPECTION . . . . . . . . . . . . . . . M–44
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . M–19 FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . M–45
REAR DIFFERENTIAL REMOVAL/ FRONT DIFFERENTIAL OIL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . M–20 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . M–45
STANDARD DIFFERENTIAL FRONT DIFFERENTIAL OIL
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . M–21/23 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . M–45
STANDARD DIFFERENTIAL ASSEMBLY . . . M–24/27 FRONT DIFFERENTIAL OIL SEAL
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . M–45
FRONT DIFFERENTIAL
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . M–46/47
FRONT DIFFERENTIAL DISASSEMBLY . . . . M–48/50
MANUAL FREEEWHEEL (MFW) FRONT DIFFERENTIAL ASSEMBLY . . . . . . . M–51/55
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M–32 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . M–56
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . M–32 REMOTE FREEWHEEL (RFW) . . . . . . . . . . . . M–56/62
CONTINUED
M–1
GENERAL PROCEDURES, FRONT AXLE (42)
GENERAL PROCEDURES FRONT AXLE (42)

Wheel and tire removal/installation WHEEL HUB, STEERING KNUCKLE INSPECTION
The removal and installation procedure for the Wheel Bearing Play Inspection
wheels and tires are not mentioned in this section. After jacking up the vehicle and supporting it at the
When a wheel is removed, tighten it to the specified places with safety stands, inspect for
specified torque. noticeable bearing play by holding the top and
(Refer to section TD, SUSPENSION, Wheels and Tires.) bottom of the tire.
Suspension arm removal/installation Wheel bearing axial play

Tighten any part of the suspension that uses 0 mm {0 in}
rubber bushings only after vehicle has been
lowered and unloaded.* Preload Adjustment
1. Verify that the tire rotates smoothly when rotated
*Unloaded: Fuel tank is full. Engine coolant and strongly, and that there is no rough feeling or is
engine oil are at specified level. Spare tire, abnormal noise from the bearing.
jack, and tools are in designated position. 2. Remove the brake caliper component and suspend
it by a rope.
Brake line disconnection/connection 3. Remove the hub cap, pull out the cotter pin and
remove the set cover.
Caution 4. Loosen the locknut to the extent that it can be
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Brake fluid will damage painted surfaces. If turned by hand.
brake fluid gets on a painted surface, wipe 5. Attach a pull scale to a hub bolt and measure the
it off immediately. frictional force.
6. Tighten the locknut until the reading reaches the
Tighten the brake pipe flare nut using the specified amount.
SST (49 0259 770B). Be sure to modify the brake
pipe fIare nut tightening torque to allow use of a Preload
torque wrench-SST combination. Frictional force plus
(Refer to section GI, FUNDAMENTAL 5.9—10.7 N {0.6—1.1 kgf, 1.4—2.4 lbf}
PROCEDURES, TORQUE FORMULAS.)
If any brake line has been disconnected any time 7. Install the set cover, and secure with a new cotter
during the procedure, add brake fluid, bleed the pin.
brakes, and inspect leakage after the procedure 8. Install the hub cap and brake caliper component.
has been completed.
Connectors disconnection/connection
Disconnect the negative battery cable before doing
any work that requires the handling of connectors.
Reconnect the negative battery cable only after the CONTINUED
work is completed.
M–2
FRONT AXLE (42)
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION

54—68 {5.5—7.0, 40—50}
SST
108—127 {11—13, 80—94}
R
R
SST SST
30—50 {3.0—5.2, 22—50} R

80—100
{8.1—10.2, R
59—73} SST
R
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R
R
SST SST
R
R
45—58 {4.5—6.0, 33—43}
19—25
118—156 {12—16, 87—115} {1.9—2.6,
14—18}
R R
1 Hub cap 11 Lower arm ball joint

2 Cotter pin + section R, FRONT SUSPENSION, TORSION
BAR SPRING AND LOWER ARM (42)
3 Set cover REMOVAL/INSTALLATION, Lower Arm Ball
4 Locknut Joint/Knuckle Removal Note
5 Washer 12 Upper arm ball joint
6 Brake caliper component + section R, FRONT SUSPENSION, UPPER
+ Removal Note ARM REMOVAL/INSTALLATION, Upper Arm
Ball Joint/Knuckle Removal Note
7 Hub and disc plate component
+ Installation Note 13 Steering knuckle
8 Dust cover 14 Disc plate
+ Removal Note
9 Tie-rod end ball joint
+ section N, MANUAL STEERING, STEERING 15 Wheel hub
GEAR AND LINKAGE REMOVAL/ + Removal Note
INSTALLATION, Tie-rod End Ball Joint 16 Hub bolt
Removal Note + Removal Note
10 Knuckle arm + Installation Note
CONTINUED
M–3
FRONT AXLE (42)
17 Outer bearing inner race

18 Oil seal
+ Installation Note
19 Inner bearing inner race
20 Inner bearing outer race
+ Removal Note
+ Installation Note
21 Outer bearing outer race
+ Removal Note
+ Installation Note
Brake Caliper Component Removal Note Outer Bearing Outer Race, Inner Bearing Outer
Remove the brake caliper component, and Race Installation Note
suspend it by a rope. Install the bearing outer race using the SSTs and a
press. For the other side, reverse the wheel hub
and install the outer race.
OUTSIDE BEARING
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49 H033 101
INSIDE BEARING
49 B025 001
Disc Plate, Wheel Hub, Hub Bolt Removal Note
Note Oil Seal Installation

The hub bolt does not need to be removed 1. After inserting the bearing in the hub, use the SST
unless it is being replaced. to tap in the oil seal until it is flush with the hub end
surface.
1. After putting markings on the disc plate and the 2. Apply grease to the oil seal lip.
wheel hub, remove the bolt and disassemble the
plate and hub.
49 F019 001
MARK
Hub Bolt Installation Note

Press new hub bolts into the wheel hub using a
2. Remove the hub bolt using a press as necessary. press.
Inner Bearing Outer Race, Outer Bearing Outer

Race Removal Note
Note
When the inner bearing outer race is removed,
the inner race and oil seal are removed
together.
Remove the bearing outer race using a suitable

round bar and a hammer. For the other side,
reverse the wheel hub and remove the outer race.
CONTINUED
M–4
FRONT AXLE (42), FRONT AXLE (44)
Hub and Disc Plate Component Installation Note FRONT AXLE (44)
1. Apply grease to the areas indicated in the figure.
WHEEL HUB, STEERING KNUCKLE INSPECTION
Wheel Bearing Play Inspection
(Refer to FRONT AXLE (42), WHEEL HUB,
STEERING KNUCKLE INSPECTION, Wheel Bearing
Play Inspection.)
Preload Adjustment
Caution
When replacing the locknut, tighten it using
the SST and turn the wheel hub a few times
to seat the bearing. Then, perform the
preload adjustment.
2. Install the hub and disc plate component, then
adjust the preload. 1. For RFW model, remove the hub cap and drive
(Refer to FRONT AXLE (42), WHEEL HUB, shaft end flange. For MFW model, remove the
STEERING KNUCKLE INSPECTION, freewheel hub component.
Preload Adjustment.) 2. Remove the spacer and set plate.
3. Remove the brake caliper component, and
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suspend it by a rope.
4. Loosen the locknut to the extent that it can be
turned by hand using the SST.
49 S231 635
5. Attach a pull scale to a hub bolt and measure the

frictional force.
6. Tighten the locknut until the reading reaches the
specified amount.
Preload
Frictional force plus
5.9—10.7 N {0.6—1.1 kgf, 1.4—2.4 lbf}
7. Install the set plate, spacer, freewheel hub or drive

shaft end flange, hub cap and brake caliper
component.
CONTINUED
M–5
FRONT AXLE (44)
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION

55—80 {5.6—8.2, 41—59}

R
SST R
SST SST
55—67
{5.6—6.9,
41—49} 54—68 {5.5—7.0}
R
R SST
30—51 R
{3.0—5.2,
R 22—37} SST R
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R
SST
SST
SST
R
SST
R R
19—25 {1.9—2.6, 14—18}
118—156 {12—16, 87—115}
40—44 {4.0—4.5, 29—32}
45—58 {4.5—6.0, 33—43}
(RFW MODEL)
(MFW MODEL)
25—29 {2.5—3.0, 19—21}
1 Hub cap 9 Dust cover

2 Drive shaft end flange 10 Tie-rod end ball joint
3 Freewheel hub component + Section N, MANUAL STEERING, STEERIG
GEAR AND LINKAGE REMOVAL/
4 Spacer INSTALLATION, Tie-rod End Ball Joint
5 Set plate Removal Note
6 Locknut 11 Disc plate
+ Removal Note + FRONT AXLE (42), WHEEL HUB, STEERING
+ Installation Note KNUCKLE REMOVAL/INSTALLATION, Disc Plate
7 Brake caliper component Removal Note
+ FRONT AXLE (42), WHEEL HUB, STEERING 12 Wheel hub
KNUCKLE REMOVAL/INSTALLATION, Brake + FRONT AXLE (42), WHEEL HUB, STEERING
Caliper Component Removal Note. KNUCKLE REMOVAL/INSTALLATION, Wheel
8 Hub and disc plate component Hub Removal Note
CONTINUED
M–6
FRONT AXLE (44)
13 Hub bolt Steering Knuckle Component Removal Note

+ FRONT AXLE (42), WHEEL HUB, STEERING 1. Remove the lower arm ball joint from the knuckle
KNUCKLE REMOVAL/INSTALLATION, Hub Bolt using the SST. (Refer to section R, FRONT
Removal Note SUSPENSION, TORSION BAR SPRING AND
+ FRONT AXLE (42), WHEEL HUB, STEERING LOWER ARM (42) REMOVAL/INSTALLATION,
KNUCKLE REMOVAL/INSTALLATION, Hub Bolt Lower Arm Ball Joint/Knuckle Removal Note.)
Installation Note 2. Remove the lower arm installation bolt and remove
the lower arm with the knuckle.
14 Outer bearing inner race
15 Oil seal Oil Seal Removal Note
+ Installation Note Remove the oil seal using a screwdriver.
16 Inner bearing inner race
17 Inner bearing outer race
+ FRONT AXLE (42) WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Inner
Bearing Outer Race, Outer Bearing Outer Race
Removal Note
+ Installation Note
18 Outer bearing outer race
+ FRONT AXLE (42) WHEEL HUB, STEERING
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KNUCKLE REMOVAL/INSTALLATION, Inner
Bearing Outer Race, Outer Bearing Outer Race
Removal Note
+ Installation Note Needle Bearing Removal Note
19 Nut Remove the needle bearing using the SST.
+ Section R, FRONT SUSPENSION, TORSION
BAR SPRING AND LOWER ARM (42) 49 S231 660
REMOVAL/INSTALLATION, Nut Installation Note
20 Shock absorber bolt
21 Upper arm ball joint
+ Section R, FRONT SUSPENSION, UPPER
ARM REMOVAL/INSTALLATION, Upper Arm
Ball Joint/Knuckle Removal Note
22 Steering knuckle component
+ Removal Note
23 Lower arm ball joint
24 Oil seal Needle Bearing Installation Note
+ Removal Note 1. Install the needle bearing using the SST and a
+ Installation Note press.
2. Apply grease to the needle bearing.
25 Spacer
26 Needle bearing
+ Removal Note 49 S033 108
+ Installation Note
27 Steering knuckle
Locknut Removal Note

Remove the locknut using the SST.
49 S231 635
CONTINUED
M–7
FRONT AXLE (44)
Oil Seal Installation Note Locknut Installation Note

1. Install the new oil seal using the SST and a press. 1. Install the locknut using the SST.
2. Apply grease to the oil seal lip.
49 S231 635
49 S033 107
2. Adjust the preload.

Outer Bearing Outer Race Installation Note (Refer to FRONT AXLE (44) WHEEL HUB,
Install the outer bearing outer race using the SST STEERING KNUCKLE INSPECTION, Preload Adjustment)
and press.
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49 F027 005
Inner Bearing Outer Race Installation Note

Install the inner bearing outer race using the SST
and a press.
49 F027 007
Oil Seal Installation Note

Install the new oil seal using the SST and a press.
49 S033 106
CONTINUED
M–8
REAR AXLE
REAR AXLE 4. If not as specified, adjust the bearing play.

(Refer to REAR AXLE, AXLE SHAFT
REAR AXLE INSPECTION REMOVAL/INSTALLATION, Bearing Inner Race,
Wheel Bearing Play Inspection Bearing Locknut Installation Note, Bearing play
1. Jack up the rear end and support it with safety adjustment.)
stands.
2. Verify that there is no abnormal noise and that the
tire rotates smoothly when forcefully rotated by
hand.
3. With a hand on top of the tire, inspect the bearing
play.
Wheel bearing axial play

0.05—0.25 mm {0.002—0.010 in}
AXLE SHAFT REMOVAL/INSTALLATION

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SST 275—313 {28—32, 203—231}
*
R R
SST R
SST
16—21 N·m SST
{1.6—2.2 kgf·cm,
12—15 in·lbf} SST
SST
R
108—127
{11—13, 80—94}
SST
R
CONTINUED
*49 0259 770B
M–9
REAR AXLE
1 Brake drum Bearing Housing Removal Note

Remove the bearing and bearing housing using the
2 Parking brake connecting pin
SSTs.
3 Brake pipe
4 Nut 49 S026 204
5 Axle shaft and back plate component
6 Shim 49 S026 205
7 Bearing locknut
+ Removal Note
49 S026 208
+ Installation Note
8 Lock washer
9 Bearing housing
+ Removal Note
10 Bearing inner race
+ Installation Note Bearing Outer Race Removal Note
After removing the bearing inner race and oil seal
11 Bearing spacer from the rear wheel hub, tap lightly using a suitable
12 Oil seal (bearing housing side) round bar to force out the outer race.
+ Installation Note
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13 Bearing outer race
+ Removal Note
+ Installation Note
14 Back plate component
15 Axle shaft
16 Hub bolt
17 Baffle
18 Oil seal (axle casing side)
+ Removal Note
+ Installation Note
Oil Seal (Axle Casing Side) Removal Note
Bearing Locknut Removal Note Remove the oil seal from the axle casing using a
screwdriver.
Note
Be careful when removing or installing the
bearing locknuts for the left wheels because OIL SEAL
they are left threaded (tightened by turning
counterclockwise).
Set the SSTs as shown in the figure, and remove

the bearing locknut from the rear axle shaft.
AXLE CASING
49 0603 635A Oil Seal (Axle Casing Side) Installation Note

1. Use the SST to tap the oil seal in until it is flush
with the end of the axle casing.
49 S120 645A
2. After installation, apply grease to the oil seal lip.
OIL SEAL
49 H025 001
AXLE CASING
CONTINUED
M–10
REAR AXLE
Bearing Outer Race, Oil Seal Bearing play adjustment

(Bearing Housing Side) Installation Note Adjust the bearing play in the axial direction (only
Press the bearing outer race and the oil seal using when the bearing is replaced).
the SSTs. (1) First insert one side of the rear axle shaft
component and push the end of the shaft to the
thrust block, then insert a shim(s) at point A so
OIL SEAL BEARING
OUTER
that the clearance between the end of the shaft
RACE and the thrust block becomes 0.65—0.95 mm
49 U027 003 {0.026—0.037 in}.
(2) Next insert the opposite shaft component and
49 F027 004 push the end of the shaft to the thrust block.
(3) Use a shim(s) at point A so that the clearance
between the end of the shaft and the thrust block
becomes 0.05—0.25 mm {0.002—0.010 in}.
Bearing play in axial direction

0.05—0.25 mm {0.002—0.010 in}
Bearing Inner Race, Bearing Locknut Installation
Note
Caution
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The torque wrench must be attached
PINION SHAFT
perpendicular to the SST.
A
1. Set the SST and then press the bearing inner race SHIM THRUST
in until 3 to 5 threads of the bearing locknut BLOCK
mounting screw of the axle shaft are visible above
the top of the bearing outer race.
49 S120 748
2. Remove the SST, and then install the bearing

locknut to the axle shaft.
3. Tighten the bearing locknut using the SST to press
in the bearing inner race.
4. Remove the SST and install the lock washer so
that its tab fits into the groove of the axle shaft.
5. Tighten the bearing locknut to the specified torque.
Bearing locknut tightening torque

275—313 N·m
{28.0—32.0 kgf·m, 203—231 ft·lbf}
49 0603 635A
49 S120 645A
CONTINUED
M–11
DRIVE SHAFT
DRIVE SHAFT
DRIVE SHAFT REMOVAL/INSTALLATION
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1 Wheel hub, steering knuckle 3 Snap ring
+ FRONT AXLE (44), WHEEL HUB, 4 Clip
STEERING KNUCKLE + Installation Note
2 Drive shaft
+ Removal Note
+ Installation Note
Drive Shaft Removal Note Clip Installation Note

Left side
Caution Install a new clip to the output shaft clip groove
Do not damage the dust cover or oil seal. with the opening facing upward.
Remove the drive shaft by prying with a bar Right side

inserted between the differential casing and the Install a new clip to the clip groove of the drive
drive shaft. shaft end with the opening facing upward.
CLIP
OPENING
28 mm {1.1 in}
Drive Shaft Installation Note

Be careful not to damage the oil seal with the shaft
spline when installing the drive shaft.
CONTINUED
M–12
DRIVE SHAFT
DRIVE SHAFT DISASSEMBLY/ASSEMBLY

2. Assemble in the reverse order of removal.
R
RIGHT SIDE
R
R
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R
LEFT SIDE
1 Boot band 6 Inner ring

+ Disassembly Note + Disassembly Note
+ Assembly Note + Assembly Note
2 Clip 7 Cage
3 Outer ring + Disassembly Note
+ Disassembly Note + Assembly Note
+ Assembly Note 8 Boot
4 Snap ring + Disassembly Note
5 Balls 9 Bell joint component
+ Disassembly Note 10 Drive shaft
+ Assembly Note
CONTINUED
M–13
DRIVE SHAFT
Boot Band Disassembly Note 3. Disassemble the balls, inner ring, cage from the
drive shaft as component.
Note 4. Turn the cage by approximately 30 degrees and
D The wheel side boot band does not need to be pull the cage and balls away from the inner ring.
removed unless replacing it.
30_
1. Pry up the locking clip using a screwdriver and
remove the band using pliers.
2. Slide the boot along the shaft to expose the joint.
Boot Disassembly Note
Note
D The wheel side boot does not need to be
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removed unless it is being replaced.
Outer Ring Disassembly Note
1. Wrap the shaft splines with tape.
Caution 2. Remove the boot.
D Mark with paint; do not use a punch.
1. Mark the cage and outer ring for proper assembly.

TAPE
2. Remove the clip using a screwdriver.
3. Remove the outer ring from the inner ring and the
balls.
4. Clean the grease away.
MARKS
Boot Assembly Note
Note
D The wheel side and differential side boots are
different.
Balls, Inner Ring, Cage Disassembly Note
Caution
D Mark with paint; do not use a punch.
100.5 mm 99.2 mm
1. Mark the drive shaft and inner ring for proper {3.9 in}
{4.0 in}
assembly.
WHEEL SIDE DIFFERENTIAL SIDE
1. With the splines of the shaft still wrapped in tape

from disassembly, assemble the boot.
2. Temporarily assemble the wheel side boot, new
boot bands, and differential side boot to the drive
MARKS shaft.
3. Remove the tape.
2. Disassemble the snap ring from the drive shaft
using a snap-ring pliers. CONTINUED
M–14
DRIVE SHAFT
Cage, Inner Ring, Balls, Snap Ring Assembly Note LEFT SIDE
1. Align the marks, and install the balls and cage to
the inner ring in the direction shown in the figure.
Caution
Install the cage with the offset facing the
snap ring groove. If incorrectly installed,
RIGHT SIDE
the drive shaft may become disengaged.
2. Install a new snap ring.
BALLS
CAGE
Standard length
Right side : 619.0—629.0 mm {24.4—24.7 in}
Left side : 551.0—561.0 mm {21.7—22.0 in}
3. Release trapped air from inside the boot using a

screwdriver covered with a rag.
SNAP RING INNER
GROOVE RING
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Outer Ring Assembly Note
Note
Use the specified grease supplied in the boot
kit.
1. Apply grease to the cage, inner ring, balls, and the

outer ring.
4. Set the new boot band to the boot groove.

Wheel side : 110—130 g {3.8—4.6 oz} 5. Fold the band back and use pliers to pull it tight.
Differential side : 95—105 g {3.4—3.7 oz} 6. Lock the end of the band by bending the locking
clips.
2. Align the marks, and install the outer ring onto the
shaft.
3. Install a new clip.
MARKS
Boot Band Assembly Note
Caution
Do not damage the boot.
For wheel side, apply grease only when
assembling the boot.
1. Apply grease to the inside of the boot.

2. Set the drive shaft to the standard length.
CONTINUED
M–15
DRIVE SHAFT
OUTPUT SHAFT (MFW) REMOVAL/INSTALLATION

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37—57
{3.7—5.5, 27—39}
1 Drive shaft 3 Screw

+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/ 4 Output shaft component
INSTALLATION + Removal Note
2 Bolt
Output Shaft Component Removal Note

Remove the output shaft by prying with a bar
inserted between the bearing housing of the output
shaft and the differential casing.
CONTINUED
M–16
DRIVE SHAFT
OUTPUT SHAFT DISASSEMBLY/ASSEMBLY

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SST
R
1 Clip 4 Bearing
+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/ + Disassembly Note
INSTALLATION, Clip Assembly Note + Assembly Note
2 Output shaft component 5 Output shaft
+ Disassembly Note 6 Bearing housing
+ Assembly Note
7 Oil seal
3 Oil seal + Assembly Note
+ Assembly Note
8 O-ring
Output Shaft Component Disassembly Note

Disassemble the output shaft component using a
press.
CONTINUED
M–17
DRIVE SHAFT
Bearing Disassembly Note Oil Seal Assembly Note

Remove the bearing from the output shaft Assemble the new oil seal by lightly tapping it
component using a press. using a plastic hammer.
Oil Seal Assembly Note Output Shaft Component Assmebly Note

Use the SST to assemble the new oil seal until it is Press the output shaft and bearing to the bearing
flush with the bearing housing end using the SST. housing.
49 M005 796
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Bearing Assembly Note
Caution
Press the bearing center and shaft center
vertically.
Press the new bearing to the output shaft.
CONTINUED
M–18
REAR DIFFERENTIAL
REAR DIFFERENTIAL Specified oil

Type
REAR DIFFERENTIAL OIL INSPECTION Standard differential:
API service GL–5, SAE 90
Caution LSD:
Position the vehicle level. API service GL–6, SAE 90
Capacity:
1. Remove the filler plug. 42:
2. Verify that the oil is at the brim of the filler plug 1.40 L {1.48 US qt, 1.23 lmp qt}
hole. If it is low, add the specified oil. 44:
1.85 L {1.96 US qt, 1.63 lmp qt}
Specified oil
Type 6. Install a new washer and the filler plug.
Standard differential:
API service GL–5, SAE 90 Tightening torque
LSD: 40—53 N·m {4.0—5.5 kgf·m, 29—39 ft·lbf}
API service GL–6, SAE 90
Capacity
42:
1.40 L {1.48 US qt, 1.23 lmp qt}
44:
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1.85 L {1.96 US qt, 1.63 lmp qt}
FILLER PLUG
WASHER
3. Install a new washer and the filler plug.
Tightening torque
40—53 N·m {4.0—5.5 kgf·m, 29—39 ft·lbf}
REAR DIFFERENTIAL OIL REPLACEMENT

1. Remove the filler and drain plugs.
2. Drain the differential oil into a container.
3. Wipe the plugs clean.

4. Install a new washer and the drain plug.
Tightening torque
40—53 N·m {4.0—5.5 kgf·m, 29—39 ft·lbf}
5. Add the specified oil from the filler plug hole until it
reaches the brim of the hole. CONTINUED
M–19
REAR DIFFERENTIAL
REAR DIFFERENTIAL REMOVAL/INSTALLATION
Caution
Clean away the old sealant before applying the new sealant.
Install the differential carrier within 10 minutes after applying sealant.
Allow the sealant to set at least 30 minutes after installation before filling the differential with the
specified oil.
1. Drain the differential oil. (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.)
2. Remove the rear propeller shaft.
(Refer to section L, REAR PROPELLER SHAFT (44), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.)
26—28 {2.6—2.9, 19—20}
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50—58
{5.0—6.0, 37—43}
1 Axle shaft and back plate component 2 Differential

+ REAR AXLE, AXLE SHAFT REMOVAL/ + Removal Note
INSTALLATION
Differential Removal Note

To prevent the differential from dropping, leave the
two bolts loosely tightened. Then hit the differential
carrier using a wooden hammer.
CONTINUED
M–20
REAR DIFFERENTIAL
STANDARD DIFFERENTIAL DISASSEMBLY

Disassemble in the order indicated in the table.
SST
SST
SST
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SST
SST
1 Differential component 14 Adjusting shim

+ Disassembly Note 15 Front bearing cup
2 Bearing cap + Disassembly Note
+ Disassembly Note 16 Oil buffle
3 Adjusting shim 17 Rear bearing cup
4 Side bearing cup + Disassembly Note
5 Side bearing cone 18 Carrier
+ Disassembly Note 19 Hex screw
6 Pinion nut 20 Ring gear
+ Disassembly Note
21 Roll pin
7 Companion flange + Disassembly Note
+ Disassembly Note
22 Pinion shaft
8 Oil seal
+ Disassembly Note 23 Thrust block
9 Thrust washer 24 Pinion gear
10 Drive pinion 25 Pinion gear thrust washer
+ Disassembly Note 26 Side gear
11 Front bearing cone 27 Side gear thrust washer
12 Collapsible spacer 28 Case
13 Rear bearing cone
+ Disassembly Note
CONTINUED
M–21
REAR DIFFERENTIAL
Differential Component Disassembly Note Pinion Nut Removal Note

Mount a carrier component to the SST or Hold the companion frange and remove the pinion
equivalent. nut.
T57L–500–B
Bearing Cap Disassembly Note Companion Flange Disassembly Note

Place a mark on one of the bearing caps so that Remove the companion flange using universal
the left and right bearing caps won’t get mixed up. puller.
Use the mark for matching at the time of assembly.
MARK
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Oil Seal Disassembly Note
Side Bearing Cone Disassembly Note Pull out the oil seal using the SST.
Warning
When pulling the side bearing cone, do not
allow differential component to fall. It can
strike legs or feet and may cause serious
injury.
Caution 308–047
Mark the left bearing in order to install in T77F–1102–A
the same position.
Remove the side bearing cone using a press and

the SST. Drive Pinion Disassembly Note
Remove the drive pinion by tapping with a plastic
hammer.
205–D064
D84L–1123–A
CONTINUED
M–22
REAR DIFFERENTIAL
Rear Bearing Cone Disassembly Note
Note
Mark or otherwise distinguish between the front
and rear cones so that they are not mixed up at
the time of reassembly.
Remove the rear bearing cone using the SST.
205–D064
D84L–1123–A
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Front Bearing Cup, Rear Bearing Cup Disassembly Front Bearing Outer Race, Rear Bearing Outer
Note Race Disassembly Note
Note Note
Mark or otherwise distinguish between the front • Mark or otherwise distinguish between the front
and rear cups so that they are not mixed up at and rear outer races so that they are not mixed
the time of reassembly. up at the time of reassembly.
Remove the bearing races using the • Remove the bearing outer races by using the two
SSTs (308 047 T77F–1102A and 100 001 T50T–100–A). grooves on the carrier and tapping the outer races
alternately.
100–001
T50T–100–A
3308–047
T77F–1102–A Knock Pin Disassembly Note
Caution
• Insert the bar from the knock pin hole at the
opposite side from where the ring gear is
installed.
• Secure the gear case in a vise and remove the
knock pin by using a 4 mm {0.16 in} diameter bar.
Roll Pin Disassembly Note
Caution
Insert the bar from the knock pin hole at the
installed.
Secure the gear case in a vise and remove the roll

pin using a small drift.
CONTINUED
M–23
REAR DIFFERENTIAL
STANDARD DIFFERENTIAL ASSEMBLY

Assemble in the order indicated in the table.
75—95 {7.6—9.7, 55—70}
SST SST
SST
130—150
{13.2—15.3,
R 96—110}
R SST
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SST
R
R R
SST
R
R
SST
298—500
{30.3—50.9, 220—368}
1 Case 16 Adjusting shim

2 Side gear thrust washer 17 Rear bearing cone
3 Side gear 18 Drive pinion
4 Pinion gear thrust washer + Assembly Note
5 Pinion gear 19 Collapsible spacer
6 Thrust block 20 Front bearing cone
7 Pinion shaft 21 Thrust washer
8 Roll pin 22 Oil seal

+ Assembly Note
9 Ring gear
23 Companion flange
10 Hex screw
24 Pinion nut
11 Side bearing cone
+ Assembly Note 25 Side bearing cup
+ Assembly Note
12 Carrier
26 Adjusting shim
13 Oil buffle + Assembly Note
14 Front bearing cup 27 Bearing cap
15 Rear bearing cup
+ Assembly Note
CONTINUED
M–24
REAR DIFFERENTIAL
Adjusting Shim Assembly Note 6. This measurement is the thickness needed for the
Pinion height Adjustment selective shim if there was no marking on the drive
1. Assemble the rear bearing cone over the SST and pinion. If the drive pinion is marked with a plus (+)
insert it into the rear bearing cup of the carrier. reading, the amount marked should be subtracted
2. Assemble the front bearing cone into the front from the feeler gauge measurement. If the drive
bearing cup and assemble the SSTs. pinion is marked with a minus (–) reading, the
amount marked should be added to the feeler
gauge measurement.
205–456
Rear Bearing Cone Assembly Note
Assemble the selected spacer on the drive pinion
and press the rear bearing inner race until it is
firmly seated on the shaft.
205–110, T76P–4020–A10
205–457
205–105, T76P–4020–A3 205–090

T75L–1165–B
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205–109, T76P–4020–A9
205–111, T76P–4020–A11 Drive Pinion Assembly Note

Drive pinion preload adjustment
Caution
3. Roll the SST component back and forth a few Never loosen pinion nut to decrease drive
times to seat the bearings while tightening the SST pinion preload torque, and never exceed
by hand. specified preload torque. If preload torque
is exceeded, a new collapsible spacer must
Tightening torque be installed and the torque sequence
27 N·m {2.8 kgf·m, 20 ft·lbf} repeated.
4. Center the SST (205–456) into the side bearing 1. Install the drive pinion, collapsible spacer and
bore. Install the bearing caps and tighten the bolt. companion flange to the carrier, and tighten the
pinion nut until all end play is removed.
Tightening torque 2. Continue to tighten in small increments until the
75—95 N·m {7.6—9.7 kgf·m, 55—70 ft·lbf} specified preload can be obtained.
Note Drive pinion preload

There should be drag on the feeler gauge
1.2—1.5 N·m
when it is inserted between the {12.2—15.3 kgf·cm, 10.6—13.2 in·lbf}
SSTs (205–110, T76P–4020–A10 and 205–456).
3. If the specified preload can’t be obtained within the
5. Insert the thickest feeler gauge possible between specified tightening torque range, replace the
the SSTs (205–110, T76P–4020–A10 and collapsible spacer and inspect again.
205–456).
205–110
T76P–4020–A10
FEELER GAUGE
205–456
CONTINUED
M–25
REAR DIFFERENTIAL
Case Assembly Note Front Bearing Cup, Rear Bearing Cup Assembly
Assemble the side gears, thrust washer, thrust Note
block, pinion gears, pinion shaft and knock pin. 1. Install the oil baffle in the outer bearing cup bore of
After assembling the knock pin, make a crimp so the carrier.
that the pin will not come out of the gear case. 2. Install the outer bearing cup and inner bearing cup
using the SST.
205–024
T76P–4616–A
Side Gear Thrust Washer Assembly Note

Adjust the backlash of the side gears and pinon Oil Seal Assembly Note
gear as follows. 1. Apply a light coat of oil to the lip of a new oil seal.
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(1) Set a dial gauge to the pinion gear as shown in 2. Assemble the new oil seal using the SST.
the figure.
(2) Secure one of the side gears.
(3) Move the pinion gear and measure the
backlash at the end of the pinion gear.
Standard backlash 205–007

0—0.1 mm {0—0.004 in} T56T–4676–B
(4) If the backlash exceeds the standard, use the

thrust washers to adjust.
Side Bearing Cone Assembly Note Side Bearing Cup, Adjusting Shim, Bearing Cap
Assembly Note
Caution Ring gear backlash adjustment
Bearings should be assembled to the 1. Install the gear case component on the carrier.
original positions. 2. Push the gear case component to the left side of
the carrier and measure the clearance between the
Press the side bearings into the gear case using side bearing and carrier. This measurement is the
the SST. left and right total shim thickness.
3. Divide the amount of shim in step 2 appropriately
between the right and left side, then install the
205–092
bearing cap.
T75L–1165–DA 4. Adjust the drive pinion, ring gear backlash and the
side bearing preload as follows.
(1) Mark the ring gear at four points at approx. 90°
intervals and mount a dial indicator to the
carrier so that the feeler comes in contact at a
90° angle with one of the ring gear teeth.
CONTINUED
M–26
REAR DIFFERENTIAL
DIAL INDICATOR
WITH BRACKETRY
RING
GEAR
5. Inspect the backlash at the three other marked

points and make sure that the minimum backlash
is more than 0.12 mm {0.005 in} and difference of
the maximum and minimum backlash value is less
than 0.08 mm {0.003 in}.
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6. If backlash is not as specified, correct the backlash
by switching shims from one side of the differential
case to the other.
7. Using a torque wrench, inspect the total rotating
torque of the pinion and differential component by
rotating the pinion three complete revolutions, and
then reading the rotating torque. The readings
should not exceed 2.4 N·m {24.0 kgf·cm,
20.8 in·lbf}. If the backlash is within specification
but the rotating torque is to high, the preload may
be adjusted by removing an equal amount of shims
from both sides of the differential.
8. Inspect the drive pinion and ring gear tooth
contact.
(1) Coat both surfaces of 6—8 teeth of the ring
gear uniformly with a thin red lead coating.
(2) While moving the ring gear back and forth by
hand, rotate the drive pinion several times and
inspect the tooth contact.
(3) If the tooth contact is good, wipe off the red
lead coating.
(4) If it is not good, adjust the pinion height, then
adjust the backlash.
CONTINUED
M–27
MANUAL FREEWHEEL (MFW) MECHANISM
REMOTE FREEWHEEL (RFW) MECHANISM
MANUAL FREEWHEEL (MFW) REMOTE FREEWHEEL

MECHANISM (RFW) MECHANISM
ON-VEHICLE INSPECTION 44 INDICATOR SWITCH INSPECTION
1. Jack up the front of the vehicle and support it on 1. Jack up the vehicle and support it on safety stands.
safety stands. 2. Remove the transfer case switch
2. Set the select lever in “2H” position. (44 indicator switch).
3. Set the freewheel hub control handle to the “FREE”
position, then turn the handle clockwise and
counterclockwise by hand, and inspect that it turns
smoothly.
4. Set the freewheel hub control handle to “LOCK”
position and inspect that the wheel turns with
considerable force applied to make it turn.
5. If not as specified, replace the freewheel hub
component as necessary.
3. Inspect for continuity between the terminals as
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shown using an ohmmeter.
Continuity Switch
Yes Depressed (ON)
No Released (OFF)
4. If not correct, replace the switch.
TRANSFER NEUTRAL SWITCH INSPECTION

1. Jack up the vehicle and support it on safety stands.
2. Remove the transfer case switch (neutral switch).
CONTINUED
M–32
1. Inspect for continuity at the switch using an RFW MAIN SWITCH REMOVAL/INSTALLATION
ohmmeter. 1. Remove the meter hood.
Continuity Switch (Refer to Section S, DASHBOARD AND
CONSOLE, METER HOOD
Yes Depressed (ON) REMOVAL/INSTALLATION.)
No Released (OFF) 2. Remove in the order indicated in the table.
OFF ON
12 mm {0.472 in}
13 mm {0.512 in}
À
2. If not correct, replace the switch. 1 RFW main switch
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RFW SWITCH INSPECTION RFW MAIN SWITCH INSPECTION
1. Jack up the vehicle and support it on safety stands. 1. Remove the RFW main switch.
2. Disconnect the RFW switch connector and remove 2. Inspect for continuity between the terminals as
the switch. shown using an ohmmeter.
: Continuity
Terminal
Switch
A B D F
OFF
ON
3. Inspect for continuity at the switch using an 123456567

ohmmeter.
Continuity Switch
Yes Depressed (ON)
No Released (OFF)

CONTINUED
M–33
ONE–WAY CHECK VALVE INSPECTION RFW ACTUATOR INSPECTION

1. Remove the one–way check valve. 1. Jack up the vehicle and support it on safety stands.
2. Blow through A and inspect that air flows from B. 2. Disconnect the vacuum hoses from the actuator.
3. Blow through B and inspect that air does not flow 3. Connect a vacuum pump tester to the actuator
from A. (free side) as shown.
4. Apply 26.66 kPa {200 mmHg, 7.87 inHg} vacuum,
B A
and verify that the rod moves toward the left
(driver’s side).
4. If not correct, replace the one–way check valve.
LOCK AND FREE SOLENOID VALVES INSPECTION
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1. Disconnect the vacuum hoses and the connector 5. Disconnect the vacuum pump tester.
from each solenoid valve. 6. Connect the vacuum pump tester to the actuator
2. Blow through each valve from port B. (lock side) as shown.
3. Inspect that air flows from the air filter. 7. Apply 26.66 kPa {200 mmHg, 7.87 inHg} vacuum,
and inspect that the rod moves toward the right
BLOW (passenger side).
B
A
AIR FILTER
4. Connect 12V and a ground to the terminals of each

valve.
5. Blow through each valve from port B. 8. If not correct, replace the actuator.
6. Inspect that air flows from port A.
B A
7. If not correct, replace the solenoid valve(s).

CONTINUED
M–34
RFW CONTROL MODULE INSPECTION

1. Remove the scuff plate. (Refer to section S, TRIM,
SCUFF PLATE REMOVAL/INSTALLATION.)
2. Remove the front side trim.
(Refer to section S, TRIM, FRONT SIDE TRIM
3. Turn the ignition switch on and inspect the RFW
control module terminal voltages, referring to the
Terminal Voltage Chart.
RFW CONTROL MODULE
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4. If not correct, replace the component(s), wiring,
and/or RFW control module.
REW CONTROL MODULE REMOVAL/INSPECTION

1. Remove the scuff plate. (Refer to section S, TRIM,
SCUFF PLATE REMOVAL/INSTALLATION.)
1 Connector
2 Nut
3 Bolt
4 RFW control module
CONTINUED
M–35
Terminal Voltage Chart
RFW CONTROL MODULE TERMINAL
B+: Battery positive voltage

Terminal Signal name Connected to Condition Voltage Inspection point
Solenoid OFF B+ Harness (Lock solenoid—RFW
A Lock solenoid Lock solenoid CM)
Solenoid ON Below 0.5 V Lock solenoid
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B Ground Body – Below 0.5 V Harness to ground point
Solenoid OFF B+ Harness (Free solenoid—RFW
C Free solenoid Free solenoid CM)
Solenoid ON Below 0.5 V Free solenoid
D – – – – –
44 indicator light OFF B+ Harness (44 indicator
44 indicator 44 indicator
E light RFW CM)
light—RFW
light light 44 indicator light ON Below 0.5 V 44 indicator light
Lock indicator light OFF B+ Harness (Lock indicator

Lock indicator LOCK
F light RFW CM)
light—RFW
light indicator light Lock indicator light ON Below 0.5 V Lock indicator light
Ignition swtich ON B+ Harness,, Fuse ((Battery-Ignition
y g
H Battery Battery
Ignition swtich OFF Below 0.5 V switch—RFW CM)
RFW main switch
B+ Harness (RFW main
RFW main RFW main released (OFF)
I switch—RFW
switch RFW CM)
switch switch RFW main switch
Below 0.5 V RFW main switch
depreased (ON)
RFW switch OFF B+ Harness ((RFW switch—RFW CM))
J RFW switch RFW switch
RFW switch ON Below 0.5 V RFW switch
44 indicator switch
B+ Harness (44 indicator
44 indicator 44 indicator OFF
K switch—RFW
switch RFW CM)
switch switch 44 indicator switch
Below 0.5 V 44 indicator switch
ON
Transfer neutral switch
B+ Harness (Transfer neutral
Transfer Transfer OFF
L switch—RFW
switch RFW CM)
neutral switch neutral switch Transfer neutral switch
Below 0.5 V Transfer neutral switch
ON
CONTINUED
M–36
JOINT SHAFT COMPONENT REMOVAL/INSTALLATION

1. Drain the front differential oil. (Refer to FRONT DIFFERENTIAL, DIFFERENTIAL OIL REPLACEMENT.)
23—26 {2.3—2.7, 17—19}
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SST
37—53 {3.7—5.5, 27—39}
37—53 {3.7—5.5, 27—39}
1 Drive shaft 4 Snap pin

+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/ 5 Joint shaft component, control box component
INSTALLATION
6 Gear sleeve
2 Vacuum hose
7 Output shaft
3 RFW switch connector + Removal Note
Output Shaft Removal Note

Remove the output shaft using the SST.
49 0813 215A
CONTINUED
M–37
JOINT SHAFT COMPONENT DISASSEMBLY

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SST
SST
SST
1 Control box 9 Bearing

2 Clip + Disassembly Note
3 Remote freewheel hub 10 Oil seal
4 Spacer 11 Joint shaft
5 Retaining ring 12 Needle bearing
6 Ball bearing 13 Clip

+ Disassembly Note 14 Casing
7 Adjustment shim (s) 15 Output shaft and gear sleeve
8 Dust seal
CONTINUED
M–38
Remote Free Wheel Hub Disassembly Note Oil Seal Disassembly Note
Remove the remote free wheel hub using the SST. Remove the oil seal using the SST.
49 0710 520 49 U027 004
Ball Bearing Disassembly Note JOINT SHAFT INSPECTION

1. Remove the ball bearing and the joint shaft using a 1. Measure the joint shaft runout.
press.
Maximum runout
0.03 mm {0.0012 in}
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2. Remove the ball bearing using a press.
2. If not correct, replace the joint shaft.
Bearing Disassembly Note

Remove the dust seal and bearing using the SST
and a suitable bar.
49 W027 001
CONTINUED
M–39
JOINT SHAFT COMPONENT ASSEMBLY

16—22 {1.6—2.3, 12—16}
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SST
SST R
SST
R
R
R SELECTIVE SST
SELECTIVE
SST R
SST
R SST
N·m {kgf·m , ft·lbf}
1 Output shaft and gear sleeve 9 Spacer

2 Casing + Assembly Note
3 Oil seal 10 Remote freewheel hub
4 Adjustment shim(s) 11 Clip
+ Assembly Note 12 Dust seal
5 Ball bearing + Assembly Note
+ Assembly Note 13 Needle bearing
6 Joint shaft 14 Clip
+ Assembly Note 15 Control box
7 Bearing
+ Assembly Note
8 Retaining ring CONTINUED
M–40
Oil Seal Assembly Note Joint Shaft Assembly Note

1. Apply differential oil to a new oil seal. Install the joint shaft using the SST and a press.
2. Install the new oil seal using the SST and a press.
49 U027 006
49 U027 006
Bearing Assembly Note

Ajustment Shim(s), Ball Bearing Assembly Note Install the bearing using the SSTs and a press.
1. Install the removed shim(s) and the ball bearing
using the SST and a press. 49 U027 005
49 U027 006
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49 U027 006
Spacer, Remote FreeWheel Hub Assembly Note

1. Install the removed spacer and the remote
2. Install a new retaining ring. freewheel hub using a suitable pipe and the SST
3. Measure the clearance between the ball bearing and a press.
and the retaining ring.
49 U027 005
2. Install a new clip.

4. If not as specified, adjust by adding or removing 3. Measure the clearance between the remote
shims. Use no more than two shims on either side. freewheel hub and the clip.
Maximum clearance
0.15 mm {0.0059 in}
Available shim thickness

0.15 mm {0.0059 in}, 0.30 mm {0.0118 in},
0.35 mm {0.0138 in}, 0.40 mm {0.0157 in},
0.50 mm {0.0197 in}
5. Remove the retaining ring.
CONTINUED
M–41
4. If not as specified, adjust by adding or removing

spacers. Use no more than two spacers on either
side.
Maximum clearance
0.15 mm {0.0059 in}
Available shim thickness

0.15 mm {0.0059 in}, 0.30 mm {0.0118 in},
0.35 mm {0.0138 in}, 0.40 mm {0.0157 in},
0.50 mm {0.0197 in}
Dust Seal Assembly Note

1. Install the new dust seal using the SST and a press.
49 M005 796
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CONTROL BOX REMOVAL/INSTALLATION
1. Drain the front differential oil.
(Refer to FRONT DIFFERENTIAL,
FRONT DIFFERENTIAL OIL REPLACEMENT.)
23—26 {2.3—2.7, 17—19}
Á
À
16—22
{1.6—2.3, 12—16}
Â N·m {kgf·m , ft·lbf}
1 Vacuum hose
2 RFW switch connector
3 Control box
CONTINUED
M–42
CONTROL BOX DISASSEMBLY/ASSEMBLY

R
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R
SST
N·m {kgf·m , ft·lbf}
1 Snap pin 9 Change rod

2 Washer 10 Shift fork
3 RFW actuator 11 Boot
4 RFW switch and washer + Assembly Note
5 Spring cap 12 Oil seal
+ Assembly Note
6 Spring and ball
13 Control box
7 Washer
8 Roll pin
+ Disassembly Note
+ Assembly Note
CONTINUED
M–43
Roll Pin Disassembly Note SHIFT FORK INSPECTION

Remove the roll pin as shown in the figure. 1. Measure the clearance between the gear sleeve
and the shift fork.
Standard clearance
0.1—0.40 mm {0.0040—0.0157 in}
Maximum clearance
0.50 mm {0.0197 in}
Oil Seal Assembly Note

Install a new oil seal using the SST and a press.
49 U027 007
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2. Inspect the output shaft and gear sleeve of the
splines for damage and wear.
3. If not correct, replace the output shaft and gear
sleeve as necessary.
Boot Assembly Note

Install the boot as shown in the figure.
Roll Pin Assembly Note

Install a new roll pin as shown in the figure.
CONTINUED
M–44
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL OIL INSPECTION
(Refer to REAR DIFFERENTIAL, REAR
DIFFERENTIAL OIL INSPECTION.)
Specified oil
Type
Above –18 °C {0 °F}: API GL–5, SAE 90
Below –18 °C {0 °F}: API GL–5, SAE 80
Capacity
MFW: 1.2 L {1.3 US qt, 1.1 lmp qt}
RFW: 1.5 L {1.6 US qt, 1.3 lmp qt}
FRONT DIFFERENTIAL OIL REPLACEMENT

DIFFERENTIAL OIL REPLACEMENT.)
Specified oil
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Type
Above –18 °C {0 °F}: API GL–5, SAE 90
Below –18 °C {0 °F}: API GL–5, SAE 80
Capacity
MFW: 1.2 L {1.3 US qt, 1.1 lmp qt}
RFW: 1.5 L {1.6 US qt, 1.3 lmp qt}
FRONT DIFFERENTIAL OIL SEAL REPLACEMENT

1. Remove the drive shaft.
(Refer to DRIVE SHAFT, DRIVE SHAFT
REMOVAL/INSTALLATION, Drive shaft removal
Note.)
2. Drain the differential oil.
4. Tap in the new oil seal to the differential using the
SST.
49 G030 795
5. Install the drive shaft.

(Refer to DRIVE SHAFT, DRIVE SHAFT
REMOVAL/INSTALLATION, Drive Shaft Installation
Note.)
6. Add the differential oil to the specified level.
(Refer to FRONT DIFFERENTIAL, FRONT
CONTINUED
M–45
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL REMOVAL/INSTALLATION

1. Drain the differential oil. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.)
(Refer to section L, FRONT PROPELLER SHAFT (44), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.)
MFW
APPLY SCREW LOCK AGENT

95—115 {9.5—11.8, 69—85}
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37—53 {3.7—5.5, 27—39}
63—93 {6.4—9.5, 47—68}
55—80 {5.6—8.2, 41—59}

1 Drive shaft 2 Front differential component

+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/ + Removal Note
INSTALLATION, Drive Shaft Removal Note 3 Differential bracket
CONTINUED
M–46
FRONT DIFFERENTIAL
RFW
APPLY LOCKING COMPOUND

94.2—115.7
{9.5—11.8, 68.8—85.3}
28—30
{2.8—3.1, 21—22}
23—26
{2.3—2.7, 17—19}
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94.2—115.7 62.8—93.1
{9.5—11.8, 68.8—85.3} {6.4—9.5, 46.3—68.7}
APPLY SCREW 37—53
LOCK AGENT {3.7—5.5, 27—39}
1 Drive shaft 4 Front differential, joint shaft component

+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/ + Removal Note
INSTALLATION, Drive Shaft Removal Note 5 Joint shaft, crossmember
2 Vacuum hose 6 Front differential
3 RFW switch component
Front Differential, Joint Shaft Component Removal 3. Remove the front differential and joint shaft
Note component from the vehicle using the transmission
1. Set the transmission jack on the differential. jack.
2. Remove the bolts and nuts indicated by arrows.
CONTINUED
M–47
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL DISASSEMBLY

SST
À
SST
È
É
Å
Ä
Ã SST
SST
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Ç
Æ
SST
Á SST
1 Bolt 7 Adjusting screw

2 Differential casing 8 Side bearing outer race
3 Oil baffle 9 Locknut
4 Differential component + Disassembly Note
+ Disassembly Note 10 Washer
5 Lock plate 11 Companion flange
6 Bearing cap + Disassembly Note
+ Disassembly Note
CONTINUED
M–48
FRONT DIFFERENTIAL
12 Oil seal Locknut Disassembly Note

+ Disassembly Note Hold the companion flange using the SST and
remove the locknut.
13 Drive pinion
+ Disassembly Note 49 S120 710
14 Front bearing inner race
15 Collapsible spacer
16 Rear bearing inner race
+ Disassembly Note
17 Spacer
18 Front bearing outer race
+ Disassembly Note
19 Rear Bearing outer race
+ Disassembly Note
20 Carrier Companion Frange Disassembly Note
21 Bolt Pull the companion flange out using the SST.
22 Ring gear
23 Knock pin
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+ Disassembly Note
49 0839 425C
24 Pinion shaft
25 Pinion gear
26 Thrust washer
27 Side gear
28 Thrust washer
29 Side bearing inner race
+ Disassembly Note
30 Gear case Oil Seal Disassembly Note
Remove the oil seal using a screw driver.
Differential Component Disassembly Note
Install the differential component on the SSTs.
49 M005 561
49 0107 680A Drive Pinion Disassembly Note

Remove the drive pinion by tapping with a plastic
Bearing Cap Disassembly Note hammer.
Place a mark on one of the bearing caps so that
the left and right bearing caps won’t get mixed up.
Use the mark for matching at the time of assembly.
MARK
CONTINUED
M–49
FRONT DIFFERENTIAL
Rear Bearing Inner Race Disassembly Note
Note
and rear inner races so that they are not mixed
up at the time of reassembly.
Remove the rear bearing inner race using the SST.
Side Bearing Inner Race Disassembly Note
49 H027 002 Caution

Mark the left bearing in order to install in
the same position.
Remove the side bearing inner race from the gear

case using the SST.
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Front Bearing Outer Race, Rear Bearing Outer 49 0839 425C
Race Disassembly Note
Note
and rear outer races so that they are not mixed
up at the time of reassembly.
Remove the bearing outer races using the two

grooves on the carrier and tapping the outer races
alternately.
Knock Pin Disassembly Note
Caution
Insert the bar from the knock pin hole at the
installed.
Secure the gear case in a vise and remove the

knock pin using a 4 mm {0.16 in} diameter bar.
CONTINUED
M–50
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL ASSEMBLY
Caution
Clean away the old sealant before applying the new sealant.
Install the differential carrier within 10 minutes after applying sealant.
Allow the sealant to set at least 30 minutes after installation before filling the differential with the
specified oll.

184—284
{13—29, 95—209}
23—27
{2.3—2.7, 17—19}
R
SST
14—51
{3.8—5.3, 28—38}
R
SST
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18—25 R R
{1.8—2.6, 14—18}
SST
SST R
69—83 SST R
{7.0—8.5,
51—61} SST
SST
SST
SST
R
1 Gear case 9 Side bearing inner race

2 Thrust washer 10 Bolt
+ Assembly Note 11 Carrier
3 Side gear 12 Front Bearing outer Race
4 Thrust washer + Assembly Note
5 Pinion gear 13 Rear bearing outer race
6 Pinion shaft + Assembly Note
7 Knock pin 14 Spacer
+ Assembly Note
8 Ring gear
+ Assembly Note 15 Rear bearing inner race
+ Assembly Note
CONTINUED
M–51
FRONT DIFFERENTIAL
16 Drive pinion Standard backlash

+ Assembly Note 0—0.1 mm {0—0.004 in}
17 Collapsible spacer
4. If the backlash exceeds the standard, use the
18 Front bearing inner race thrust washers to adjust.
19 Oil seal
+ Assembly Note Ring Gear Assembly Note
20 Companion flange
1. Coat the ring gear and gear case facing surfaces
with locking agent.
21 Washer 2. Install the ring gear and tighten the bolt to the
22 Locknut specified torque.
+ Assembly Note
23 Side bearing outer race Side Bearing Inner Race Assembly Note
+ Assembly Note
Caution
24 Adjusting screw
Bearings should be assembled to the
+ Assembly Note
original positions.
25 Bearing cap
+ Assembly Note Press the side bearings into the gear case using
26 Lock plate the SST.
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27 Baffle plate
28 Differential casing
29 Bolt
49 G030 338
Gear Case Assembly Note
Assemble the side gears, thrust washer, pinion
gears, pinion shaft and knock pin.
After assembling the knock pin, make a crimp so
that the pin will not come out of the gear case.
Front Bearing Outer Race Assembly Note

Press the front bearing outer race into the carrier
using the SST and a press.
49 F027 005
Thrust Washer Assembly Note

1. Set a dial gauge to the pinion gear as shown in the
figure.
2. Secure one of the side gears.
3. Move the pinion gear and measure the backlash at
the end of the pinion gear. Rear Bearing Outer Race Assembly Note
Press the rear bearing outer race into the carrier
using the SST and a press.
49 F027 004
CONTINUED
M–52
FRONT DIFFERENTIAL
Spacer Assembly Note 49 0727 570

Pinion height adjustment
Notes
Use the same spacer and nut.
Be careful to install collars A and B in the
correct position and facing in the correct
direction.
1. Assemble the spacer, rear bearing inner race and

SST (49 8531 568) on to the SST (49 8531 565). 49 0350 555
Secure the collar with the O-ring. Then install this
to the carrier. 7. Add the two (left and right) values obtained by the
2. Assemble the front bearing inner race, measurements taken in Step 6 and then divide the
SST (49 8531 567), companion flange, washer and total by 2. From this result, subtract the result
nut to the SST (49 8531 565). obtained by dividing the number inscribed on the
3. Tighten the nut to the extent that the end surface of the drive pinion by 100. (If there is
SST (49 8531 565) can be turned by hand. no figure inscribed, use 0.) This is the pinion height
adjustment value.
Note
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49 0350 555 For example, the measured results obtained at
49 8531 565 Step 6 are 0.06 mm and 0.04 mm, and the
figure inscribed on the end of the drive pinion is
–2:
0.06+0.04 pinion height

– –2 = 0.07 =
SPACER 2 100 adjustment value
REAR BEARING Therefore, replace it with a spacer 0.07 mm
49 8531 568 {0.003 in} thicker than the currently used one.
O RING
49 8531 567
FRONT BEARING
4. Place the SST on the surface plate and set the dial
indicator to zero. Rear Bearing Inner Race Assembly Note
Caution
Press in until the force required suddenly
increases.
Install the spacer selected for the pinion
height adjustment, confirm that the
installation direction is correct.
Press the rear bearing inner race in using the

49 0727 570 SSTs.
SPACER
5. Place the SST (49 0350 555) on top of the 49 F401 331
SST (49 8531 565), and then set the SST (49 0727 570) 49 G030 338
on top of the SST (49 0350 555).
6. Place the measuring probe of the dial indicator so
that it contacts the place where the side bearing is
installed in the carrier. Then measure left and right
side of the lower position.
CONTINUED
M–53
FRONT DIFFERENTIAL
Drive Pinion Assembly Note Locknut Assembly Note

Drive pinion preload adjustment 1. Assemble the companion flange and washer.
2. Tighten the new locknut using the SST with the
Caution determined torque while performing drive pinion
Do not install the oil seal. preload adjustment.
3. Verify that the preload is within the specification.
1. Install the drive pinion, spacer, front bearing,
collapsible spacer and companion flange to the Preload
carrier, and temporarily tighten the locknut. 0.9—1.3 N·m {9—14 kgf·cm, 7.9—12.1 in·lbf}
2. Adjust the preload of the drive pinon bearing as
follows.
(1) Turn the companion flange by hand to seat the
bearing.
(2) Use a torque wrench to tighten the locknut 49 S120 710
temporarily tightened in Step 1, and confirm
that the specified preload can be obtained
within the specified tightening torque range.
The torque applied at this time will be used
after the oil seal is installed.
Locknut tightening torque
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128—284 N·m {13—29 kgf·m, 95—209 ff·lbf}
Side Bearing Outer Race, Adjusting Screw, Bearing
Drive pinion preload Cap Assembly Note
0.9—13.4 N·m {9—14 kgf·cm, 7.9—12.1 in·lbf} Ring gear backlash adjustment
1. Install the differential gear component to the
carrier. After loosely tightening the bearing outer
49 S120 710 race and bearing cap mounting bolts, completely
tighten the adjustment screw by hand. Then, while
turning the ring gear, alternately tighten the left and
right adjustment screws using the SST.
49 0259 720
(3) If the specified preload can’t be obtained within

the specified tightening torque range, replace
the collapsible spacer and inspect again.
(4) Remove the locknut, washer and companion
flange.
Oil Seal Assembly Note 2. Adjust the drive pinion, ring gear backlash and the
Apply differential oil to the oil seal lip and press the side bearing preload as follows.
oil seal in until it touches the end of the differential (1) Mark the ring gear at four points at approx. 90°
carrier using the SST. intervals and mount a dial indicator to the
carrier so that the feeler comes in contact at a
90° angle with one of the ring gear teeth.
(2) Turn both bearing adjusters equally until the
backlash becomes 0.09—0.11 mm
{0.0035—0.0043 in} using the SST.
49 0259 720
49 U027 003
CONTINUED
M–54
FRONT DIFFERENTIAL
(3) Inspect for the backlash at the three other Toe and flank contact
marked points and make sure that the Replace the spacer with a thinner one, and move the
minimum backlash is more than 0.05 mm drive pinion outward.
{0.002 in} and difference of the maximum and
minimum backlash value is less than 0.07 mm TOE CONTACT FLANK CONTACT
{0.0028 in}.
Heel and face contact

Replace the spacer with a thicker one.
Bring the drive pinion inward.
(4) After adjusting the backlash, tighten the
adjustment screws equally until the distance HEEL CONTACT FACE CONTACT
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between both pilot sections on the bearing
caps (L) become as specified.
Bearing cap bolt tightening torque

38—51 N·m {3.8—5.3 kgf·m, 28—38 ft·lbf}
Standard distance
185.43—185.50 mm {7.300—7.303 in}
3. The inspection and adjustment procedure is as

follows:
(1) Coat both surfaces of 6—8 teeth of the ring
gear uniformly with a thin red lead coating.
(2) While moving the ring gear back and forth by
hand, rotate the drive pinion several times and
inspect the tooth contact.
(3) If the tooth contact is good, wipe off the red
lead coating.
(4) If it is not good, adjust the pinion height, then
adjust the backlash.
RED LEAD
CONTINUED
M–55
TROUBLESHOOTING
TROUBLESHOOTING
REMOTE FREEWHEEL (RFW)
Foreword
Refer to section GI, HOW TO USE THIS MANUAL, TROUBLESHOOTING PROCEDURE and thoroughly read
and understand the basic flow of troubleshooting in order to properly perform the basic procedures.
Precaution
This section only mentions unique symptoms of the trouble caused by RFW. Inspect and repair as necessary
for trouble caused by other sources.
Inspect the connector and terminal connections when inspecting the wiring harnesses. (The cause of the
malfunction may be a poor connection in the connectors, terminals, or wiring harnesses.)
Diagnostic Index
No TROUBLESHOOTING ITEM DESCRIPTION
1 No RFW operation from free to lock Free solenoid valve malfunction
(RFW indicator light does not illuminate) RFW indicator light bulb malfunction
RFW actuator malfunction
RFW switch malfunction
Print plate in instrument cluster malfunction
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METER 15 A fuse malfunction
ENGINE 15 A fuse malfunction
Transfer neutral switch malfunction
44 indicator switch malfunction
RFW control module malfunction
Lock solenoid valve malfunction
RFW control box malfunction
Air leakage from vacuum hose
One-way check valve malfunction
Related fuses and/or harness malfunction
2 No RFW operation from lock to free Lock solenoid valve malfunction
(RFW indicator light does not go off) RFW switch malfunction
RFW actuator malfunction
Print plate in instrument cluster malfunction
Engine 15 A fuse malfunction
RFW main switch malfunction
Transfer neutral switch malfunction
44 indicator switch malfunction
RFW control module malfunction
Free solenoid valve malfunction
RFW control box malfunction
Air leakage from vacuum hose
One-way check valve malfunction
Related fuses and/or harness malfunction
3 Noise Joint shaft bearing abrasion or damage
RFW hub abrasion
Joint shaft abrasion
4 Oil leakage RFW control box is poorly installed.
CONTINUED
M–56
TROUBLESHOOTING
Quick Diagnosis Chart

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

7 Is the ENG 15 A fuse okay? Yes Repair wiring harness between ENG 15 A fuse and
RFW control module.
Then go to Step 31.
No Replace the ENG 15 A fuse.
Then go to Step 31.
8 Disconnect free solenoid valve connector. Yes Connect free solenoid valve.
Measure voltage between free solenoid valve Then go to next step.
connector terminal A and ground. No Repair wiring harness between ENG 15 A fuse and
Is the voltage greater than 10 V? RFW control module.
Then go to Step 31.
9 Measure voltage between free solenoid valve Yes Go to next step.
connector terminal B and ground. No Inspect free solenoid valve.
10 Measure voltage between RFW control module Yes Go to next step.
connector terminal C and ground. No Repair wiring harness between free solenoid valve
Is the voltage greater than 10 V? and RFW control module.
Then go to Step 31.
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11 Disconnect lock solenoid valve connector. Yes Connect lock solenoid valve.
Measure voltage between lock solenoid valve Then go to next step.
Then go to Step 31.
12 Measure voltage between lock solenoid valve Yes Go to next step.
connector terminal B and ground. No Inspect lock solenoid valve.
connector terminal A and ground. No Repair wiring harness between lock solenoid valve
Then go to Step 31.
14 Turn ignition (engine) switch off. Yes Go to next step.
Is there continuity between RFW control module No Repair wiring harness between RFW control
connector terminal B and ground? module and ground.
Then go to Step 31.
15 Shift select lever to N position. Yes Go to Step 19.
Is there continuity between RFW control module
connector terminal L and ground? No Go to next step.
16 Is there continuity between transfer neutral switch Yes Repair wiring harness between RFW control
connector terminal A and ground? module and transfer neutral switch.
Then go to Step 31.
No Go to next step.
17 Inspect transfer neutral switch. Yes Go to next step.
Is it okay? No Replace transfer neutral switch.
Then go to Step 31.
18 Is there continuity between transfer neutral switch Yes Go to next step.
connector terminal B and ground? No Repair wiring harness between transfer neutral
switch and ground.
Then go to Step 31.
19 Shift select lever to 44 indicator position. Yes Go to Step 23.
connector terminal K and ground? No Go to next step.
20 Is there continuity between 44 indicator switch Yes Repair wiring harness between 44 indicator
connector terminal A and ground? switch and RFW control module.
Then go to Step 31.
No Go to next step.
CONTINUED
M–58
TROUBLESHOOTING

21 Inspect 44 indicator switch. Yes Go to next step.
Is it okay? No Replace 44 indicator switch.
Then go to Step 31.
22 Is there continuity between 44 indicator switch Yes Go to next step.
connector terminal B and ground? No Repair wiring harness between 44 indicator
switch and ground.
Then go to Step 31.
23 Shift select lever to 4H position. Yes Go to Step 27
connector terminal J and ground? No Go to next step.
24 Is there continuity between RFW switch Yes Repair wiring harness between RFW control
connector terminal A and ground? module and RFW switch.
Then go to Step 31.
No Go to next step.
25 Inspect RFW switch. Yes Go to next step.
Is it okay? No Replace RFW switch.
Then go to Step 31.
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26 Is there continuity between RFW switch Yes Go to next step.
connector terminal B and ground? No Repair wiring harness between RFW switch and
ground.
Then go to Step 31.
27 Inspect one-way check valve. Yes Go to next step.
Is it okay? No Replace one-way check valve.
Then go to Step 31.
28 Inspect RFW control box. Yes Go to next step.
Is it okay? No Replace RFW control box.
Then go to Step 31.
29 Inspect vacuum in vacuum hoses. Yes Go to next step.
Is it okay? No Repair vacuum in vacuum hoses.
Then go to Step 31.
30 Inspect RFW control module. Yes Go to next step.
Is it okay? No Repair or replace RFW control module.
Then go to next step.
31 Turn ignition (engine) switch on. Yes Troubleshooting completed.
Shift select lever from 2H to 4H position. Explain repairs to customer.
Does RFW operate from free to lock? No Inspect malfunction symptoms again, then repeat
from Step 1 if malfunction occurs again.
2 NO RFW OPERATION FROM LOCK TO FREE (RFW INDICATOR LIGHT DOES NOT GO OFF)
DESCRIPTION RFW does not change from lock to free.
RFW main switch malfunction ENGINE 15 A fuse malfunction
Transfer neutral switch malfunction RFW main switch malfunction
44 indicator switch malfunction RFW actuator malfunction
RFW control module malfunction RFW switch malfunction
Free solenoid valve malfunction Air leakage from vacuum reservoir or actuator system
Lock solenoid valve malfunction One-way check valve
RFW control box malfunction Print plate in instrument cluster malfunction
Related fuses and/or harnesses malfunction
1 Disconnect RFW control module connector. Yes Go to next step.
connector terminal F and ground? No Go to Step 3.
CONTINUED
M–59
TROUBLESHOOTING

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

15 Is there continuity between transfer neutral switch Yes Go to next step.
connector terminal B and ground? No Repair wiring harness between transfer neutral
switch and ground.
Then go to Step 32.
16 Shift select lever to 2H position. Yes Go to Step 20.
connector terminal K and ground? No Go to next step.
17 Is there continuity between 44 indicator switch Yes Repair wiring harness between RFW control module
connector terminal A and ground? and 44 indicator switch.
Then go to Step 32.
No Go to next step.
18 Inspect 44 indicator switch. Yes Go to next step.
Is it okay? No Replace 44 indicator switch.
Then go to Step 32.
19 Is there continuity between 44 indicator switch Yes Go to next step.
connector terminal B and ground? No Repair wiring harness between 44 indicator switch
and ground.
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Then go to Step 32.
20 Shift select lever to 4H position. Yes Go to Step 28.
connector terminal J and ground? No Go to next step.
21 Is there continuity between RFW switch Yes Repair wiring harness between RFW switch.
connector terminal A and ground? Then go to Step 32.
No Go to next step.
22 Inspect RFW switch. Yes Go to next step.
Is it okay? No Replace RFW switch.
Then go to Step 32.
23 Is there continuity between RFW switch Yes Go to next step.
connector terminal B and ground? No Repair wiring harness between RFW switch and
ground.
Then go to Step 32.
24 Push RFW main switch on. Yes Go to Step 28.
Is there continuity between RFW main switch
connector terminal I and ground? No Go to next step.
25 Is there continuity between RFW main switch Yes Repair wiring harness between RFW main switch
connector terminal F and ground? and RFW control module.
Then go to Step 32.
No Go to next step.
26 Inspect RFW main switch. Yes Go to next step.
Is it okay? No Replace RFW main switch.
27 Is there continuity between RFW main switch Yes Go to next step.
connector terminal D and ground? No Repair wiring harness between RFW main switch
and ground.
Then go to Step 32.
28 Inspect one-way check valve. Yes Go to next step.
Is it okay? No Replace one-way check valve.
Then go to Step 32.
29 Inspect RFW actuator. Yes Go to next step.
Is it okay? No Replace RFW actuator.
Then go to Step 32.
30 Inspect vacuum in vacuum hoses. Yes Go to next step.
Is it okay? No Repair vacuum in vacuum hoses.
Then go to Step 32.
CONTINUED
M–61
TROUBLESHOOTING

31 Inspect RFW control module. Yes Go to next step.
Is it okay? No Repair or replace RFW control module.
Then go to next step.
32 Turn ignition (engine) switch on. Yes Troubleshooting completed.
Move selector lever from 2H to 4H position. Explain repairs to customer.
Does RFW operate from free to lock? No Inspect malfunction symptoms again, then repeat
3 NOISE
DESCRIPTION Noise is heard from front differential.
Joint shaft bearing abrasion or damage Joint shaft abrasion
RFW hub abrasion Conventional front differential parts malfunction
1 Inspect joint shaft bearing. Yes Go to next step.
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Is it okay? No Replace joint shaft bearing.
2 Inspect RFW hub. Yes Go to next step.
Is it okay? No Replace RFW hub.
3 Inspect joint shaft. Yes Go to next step.
Is it okay? No Replace joint shaft.
4 Malfunction is caused by other than RFW. Yes Go to next step.
Inspect conventional front differential parts.
parts
Are they okay? No Replace defective part(s).
5 Has front differential noise stopped? Yes Troubleshooting completed.

Explain repairs to customer.
No Inspect malfunction symptoms again, then repeat
4 OIL LEAKAGE
DESCRIPTION The oil leaks from front differential.
Poor installation of the RFW control box Malfunction of conventional front differential parts
1 Is RFW control box installed completely? Yes Go to next step.
No Install RFW control box securely.
Then go to Step 3.
2 Malfunction is caused by something other than Yes Go to next step.
RFW.
Inspect conventional front differential parts. No Replace defective part(s).
Are they okay?
3 Is there any oil leakage from front differential? Yes Inspect malfunction symptoms again, then repeat
from Step 1 if malfunction still occurs.
Explain repairs to customer.
CONTINUED
M–62
STEERING SYSTEM
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . N–1 STEERING WHEEL AND COLUMN
MANUAL STEERING . . . . . . . . . . . . . . . . . . . . . . . . N–1 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N–12
STEERING WHEEL AND COLUMN STEERING WHEEL AND COLUMN
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N–1/2 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N–12
STEERING WHEEL AND COLUMN STEERING SHAFT INSPECTION . . . . . . . . . . . N–12
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . N–3/4 STEERING GEAR AND LINKAGE
STEERING SHAFT INSPECTION . . . . . . . . . . . N–4 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N–13
STEERING GEAR AND LINKAGE STEERING GEAR AND LINKAGE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N–5/6 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N–14/15
STEERING GEAR AND LINKAGE STEERING GEAR AND LINKAGE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N–7/9 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N–15
STEERING GEAR AND LINKAGE POWER STEERING OIL PUMP
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N–9 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N–16/18
POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . N–10 POWER STEERING OIL PUMP (F2 CIS, F2 CARB,
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . N–10 G6) DISASSEMBLY/ASSEMBLY . . . . . . . . . . . N–19/20
POWER STEERING FLUID INSPECTION . . . N–10/12 POWER STEERING OIL PUMP (WL, WL TURBO)
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N–21
GENERAL PROCEDURES MANUAL STEERING
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Wheels and tires removal/installation STEERING WHEEL AND COLUMN INSPECTION
The removal and installation procedures for the Steering Wheel Play Inspection
wheels and tires are not mentioned in this section. If the play exceeds specification, either the steering
When a wheel is removed, retighten it to the joints are worn or the backlash of the steering gear
specified torque. is excessive. With the wheels in the straight-ahead
(Refer to section TD,SUSPENSION, Wheels and Tires.) position, gently turn the steering wheel to the left
and right and verify that the play is within
Power steering components removal/installation specification.
If any power steering fluid line has been
disconnected anytime during the procedure, add Steering wheel play
ATF M–III or equivalent (e.g. Dexron II), bleed 0—30 mm {0—1.18 in}
the fluid lines, and inspect for leakage after the
procedure has been completed. Steering Wheel Looseness Inspection
Move the steering wheel as shown in the figure to
Connectors disconnection/connection inspect for column bearing wear, steering shaft
Disconnect the negative battery cable before doing joint play, steering wheel looseness, and column
any work that requires handling of connectors. looseness.
Reconnect the negative battery cable only after the
work is completed.
CONTINUED
N–1
MANUAL STEERING
Steering Wheel Effort Inspection

1. With the vehicle on a hard, level surface, put the
wheels in the straight-ahead position.
2. Remove the air bag module, if equipped.
(Refer to section T, AIR BAG SYSTEM,
DRIVER-SIDE AIR BAG MODULE
3. Measure the steering wheel effort using a torque
wrench.
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Steering wheel effort
4.5 N·m {460 kgf·cm, 399 in·lbf} max.
4. If not as specified, inspect the following: rotation

starting torque of pinion, rotation torque of each
ball joint, and steering joints.
CONTINUED
N–2
MANUAL STEERING
STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION

40—50
{4.0—5.0,
29—36}
40—50
{4.0—5.0, 29—36}
AIR BAG MODEL
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16—22
{1.6—2.3, 12—16}
16—22
{1.6—2.3, 12—16}
20—26
{2.0—2.7,
15—19}
18—24
{1.8—2.5, 14—18}
20—26
{2.0—2.7, 15—19}
1 Horn cap 6 Combination switch

2 Air bag module (with air bag) 7 Steering shaft
+ section T, AIR BAG SYSTEM, DRIVER-SIDE + Installation Note
AIR BAG MODULE REMOVAL/INSTALLATION 8 Universal joint
3 Locknut 9 Boot
4 Steering wheel 10 Intermediate shaft
+ Removal Note
11 Steering lock component
+ Installation Note
+ Removal Note
5 Column cover + Installation Note
CONTINUED
N–3
MANUAL STEERING
Steering Wheel Removal Note
Caution
Do not try to remove the steering wheel by
hitting the shaft with a hammer. The column
will collapse.
Set the wheels in the straight-ahead position,

remove the steering wheel using a suitable puller.
Steering Lock Component Removal Note

Use a chisel to make a groove in the heads of the
steering lock mounting bolts. Remove the bolts
using a screwdriver. Remove the steering lock B
A
component.
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Steering Wheel Installation Note
1. For vehicles with air bags, adjust the clock spring.
(Refer to section T, CLOCK SPRING, CLOCK
SPRING ADJUSTMENT.)
Steering Lock Component Installation Note 2. Install the steering wheel with the vehicle in the
Install the new steering lock mounting bolts. straight-ahead position.
Tighten the bolts until the heads break off.
STEERING SHAFT INSPECTION
Inspect the following, and replace the column
component as necessary.
1. Needle and ball bearing damage.
2. Steering shaft length.
Length
816.9—819.9 mm {32.17—32.27 in}
Steering Shaft Installation Note

1. Temporarily tighten the bolt A.
2. Tighten the nut B to the specified torque.
3. Tighten the bolt A to the specified torque.
Tightening torque
16—22 N·m {1.6—2.3 kgf·m, 12—16 ft·lbf}
3. Dust boot damage.
CONTINUED
N–4
MANUAL STEERING
STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION

1. With the wheels in the straight-ahead position, remove in the order indicated in the table.
37—54
{3.7—5.5, 27—39}
20—26
{2.0—2.7, 15—19}
45—58
{4.5—6.0, SST
33—43} 69—78
{7.0—8.0, 51—57}
45—58
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R {4.5—6.0,
33—43} SST
79—157
R {8.0—16.0,
58—115}
45—58
R SST
{4.5—6.0, 33—43}
37—54
{3.7—5.5,
27—39}
R
45—58
{4.5—6.0, 33—43}
SST
SST
1 Cotter pin 9 Washer

2 Nut 10 Bolt, nut, washer
3 Ball joint 11 Idler arm bracket
+ Removal Note 12 Bolt, nut, washer
4 Locknut 13 Bolt
5 Tie rod 14 Steering gear and pitman arm
6 Center link + Removal Note
7 Idler arm 15 Dust boot
+ Removal Note + Removal Note
8 Bushing + Installation Note
CONTINUED
N–5
MANUAL STEERING
Ball Joint, Idler Arm, Steering Gear and Pitman

Arm Removal Note
Remove the ball joint from the knuckle and center
link, the idler arm from the center link, and steering
gear and pitman arm from the center link using the
SST.
49 T028 3A0
Dust Boot Removal Note

1. Place the chisel against the boot and hold it at the
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angle shown.
2. Remove the dust boot by tapping it with a hammer.
Dust Boot Installion Note

1. Wipe the grease off the ball joint.
2. Put a small amount of lithium-based grease into a
new dust boot.
3. Install the dust boot using the SST and a press.
49 1243 785A
CONTINUED
N–6
MANUAL STEERING
STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY

25—34
{2.5—3.5, 25—34}
15—21
{1.5—2.2, 11—15}
15—24
{1.5—2.5, 11—18}
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R
128—166
{13.0—17.0, 95—122}
SST R
R
R
197—235
{20.0—24.0, 145—173} N·m {kgf·m, ft·lbf}
SST R
1 Nut 9 Adjusting screw

2 Pitman arm 10 Oil seal
+ Disassembly Note 11 Retaining ring
3 Clip 12 Locknut
4 Dust boot + Disassembly Note
+ Assembly Note 13 Oil seal
5 Locknut (side cover) 14 Adjusting nut
6 Sector shaft 15 Bearing
+ Disassembly Note
+ Assembly Note 16 Worm ball nut
+ Assembly Note
7 Side cover
17 Bearing
8 Adjusting shim
CONTINUED
N–7
MANUAL STEERING
Pitman Arm Disassembly Note Adjusting Nut Disassembly Note

Separate the pitman arm from the steering gear Remove the adjusting nut using the SST.
using the SST.
49 UB39 585A
49 U032 3A0
Worm Ball Nut Assembly Note

Locknut (Side Cover), Sector Shaft Disassembly 1. Inspect the worm ball nut preload using the SST.
Note
1. Loosen the locknut.
2. Remove the side cover attaching bolts.
3. Set the sector shaft in the middle position.
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4. Tap the sector shaft lower end using a plastic
hammer to loosen the sector shaft.
5. Lift and remove the sector shaft with the locknut
and the side cover from the gear housing.
49 0180 510B
Worm ball nut preload

1.0—1.3 N·m {10—14 kgf·cm, 8.7—12.1 in·lbf}
[Without the sector shaft]
2. If not as specified, adjust the preload.

(1) Loosen the locknut and turn the adjusting
screw using the SST.
Locknut Disassembly Note
Remove the locknut using the SST.
49 U032 201
49 U032 201
CONTINUED
N–8
MANUAL STEERING
(2) Tighten the locknut to the specified torque

using the SST.
Tightening torque
128—166 N·m {13—17 kgf·m, 95—122 ft·lbf}
49 U032 201
49 U034 209
5. Wipe away excessive grease.
STEERING GEAR AND LINKAGE INSPECTION

Steering Gear Backlash Adjustment
(3) Inspect the worm ball nut preload again. Caution

Adjust the backlash while keeping the
Sector Shaft Assembly Note steering gear in the center position.
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1. Set the adjusting screw and shim, in the “T” Otherwise, the backlash becomes
groove. excessively small and gears may be
2. Measure the clearance in the axial direction. damaged.
Turn the adjusting screw to adjust steering gear

backlash.
Backlash
0 mm
ADJUSTING
SHIM
3. Adjust the clearance to the specified value if the

clearance is more than the specified value.
Clearance
0—0.1 mm (0—0.004 in)
Adjusting shim thickness
1.97 mm {0.077 in} 2.00 mm {0.079 in}
2.03 mm {0.079 in} 2.06 mm {0.081 in}
2.09 mm {0.082 in}
Caution
Be careful not to damage the oil seal and
bearing.
4. Assemble the sector shaft in such a way that the

teeth of the sector shaft mesh with the center part
of the teeth of the worm ball nut.
Dust Boot Assembly Note

1. Wipe the grease off the ball joint.
2. Put a small amount of lithium-based grease into a
new dust boot.
3. Install the dust boot onto the ball joint.
4. Set the SST over the boot and install a new clip. CONTINUED
N–9
POWER STEERING
POWER STEERING POWER STEERING FLUID INSPECTION

Fluid Level Inspection
Inspect the power steering fluid level. Add fluid to
AIR BLEEDING the specified level as necessary.
1. Inspect the fluid level.
(Refer to POWER STEERING, POWER Fluid specification
STEERING FLUID INSPECTION, Fluid Level ATF M–III or equivalent (e.g. Dexron II)
Inspection.)
2. Jack up the front of the vehicle and support it on Fluid Leakage Inspection
safety stands.
3. Turn the steering wheel fully to the left and right Caution
several times with the engine not running. To prevent damage to the steering system,
4. Reinspect the fluid level. If it has dropped, add do not keep the steering wheel in the fully
fluid. turned position for more than 5 seconds.
5. Repeat Steps 3 and 4 until the fluid level stabilizes.
6. Lower the vehicle. 1. Start the engine and let it idle. Turn the steering
7. Start the engine and let it idle. wheel fully to the left and right to apply fluid
8. Turn the steering wheel fully to the left and right pressure.
several times.
9. Verify that the fluid is not foamy and that the fluid Note
level has not dropped. The points where fluid leakage may occur are
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10. Add fluid as necessary and repeat Steps 8 and 9. indicated in the figure.
2. Inspect for fluid leakage.
R.H.D. L.H.D.
F2 CIS F2 CIS
F2 CARB F2 CARB
WL WL
WL TURBO WL TURBO
G6 G6
CONTINUED
N–10
POWER STEERING
Fluid Pressure Inspection 7. Close the gauge valve completely. Increase the
1. Assemble the SSTs as shown in the figure. engine speed to 1,000—1,500 rpm and measure
the fluid pressure generated by the oil pump. If the
49 1232 670A pressure is not within the specification, replace the
oil pump component.
Oil pump fluid pressure

8.9—9.3 MPa
{90—95 kgf/cm2, 1280—1350 psi}
49 H002 671 THERMOMETER
50—60 °C {122—140 °F}
GAUGE
CLOSE VALVE
COMPLETELY
2. Mark both hose connections to ensure that the
hose is reinstalled in its original position.
3. Disconnect the pressure hose from the oil pump.
Attach the SST (49 G032 304).
Tightening torque
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G6:
32—47 N·m {3.2—4.8 kgf·m, 24—34 ft·lbf}
F2 CIS, F2 CARB, WL, WL Turbo: Caution
30—44 N·m {3.0—4.5 kgf·m, 22—32 ft·lbf} If the steering wheel is kept in the fully
turned position for more than 5 seconds,
4. Connect the SSTs (49 1232 670A and 49 H002 671) the fluid temperature will rise excessively
to the SST (49 G032 304). and adversely affect the oil pump.
G6
8. Open the gauge valve fully and increase the
engine speed to 1,000—1,500 rpm.
49 B032 304 9. Turn the steering wheel fully to left and right and
measure the fluid pressure generated at the gear
housing. If the pressure is not within the
specification, repair or replace the steering gear
component.
Gear housing fluid pressure

8.9—9.3 MPa
{90—95 kgf/cm2, 1280—1350 psi}
THERMOMETER
F2 CIS, F2 CARB, WL, WL TURBO 49 G032 3A4 50—60 °C {122—140 °F}
GAUGE
OPEN VALVE
COMPLETELY
49 H002 671
10. Remove the SSTs. Install and tighten the pressure

5. Bleed the air from the system. pipe to the specified torque.
6. Open the gauge valve fully. Start the engine and
turn the steering wheel fully left and right to raise Tightening torque
the fluid temperature to 50—60 °C {122—140 °F}. 30—44 N·m {3.0—4.5 kgf·m, 22—32 ft·lbf}
Caution 11. Bleed the air from the system.
If the valve is left closed for more than 5
seconds, the fluid temperature will increase
excessively and adversely affect the oil CONTINUED
pump.
N–11
POWER STEERING
Note
To determine whether the steering effort is
satisfactory or not, perform the inspection on
another vehicle of the same model and under
the same conditions, and compare the results.
The steering wheel effort varies with conditions
as shown below.
1. Road conditions, such as dry or wet, and
asphalt or concrete.
2. Tire conditions, such as brand, wear, and
tire pressure.
12. If not as specified, inspect the following points:

Air in system
Fluid leakage at hose or connectors
Function of oil pump and steering gear
STEERING WHEEL AND COLUMN

(Refer to MANUAL STEERING, STEERING WHEEL
AND COLUMN REMOVAL/INSTALLATION.)
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STEERING SHAFT INSPECTION
(Refer to MANUAL STEERING, STEERING SHAFT
INSPECTION.)
STEERING WHEEL AND COLUMN INSPECTION

Steering Wheel Play Inspection
AND COLUMN INSPECTION, Steering Wheel Play
Inspection.)
Steering Wheel Looseness Inspection

AND COLUMN INSPECTION, Steering Wheel
Looseness Inspection.)
Steering Wheel Effort Inspection

1. Inspect the following points:
Tire size and tire pressure
Fluid level
2. With the vehicle on a hard, level surface, put the
wheels in the straight-ahead position.
3. Start the engine and warm the power steering fluid
to 50—60 °C {122—140 °F}.
4. Remove the air bag module, if equipped.
(Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE
AIR BAG MODULE REMOVAL/INSTALLATION.)
5. Measure the steering wheel effort using a torque
wrench.
Steering wheel effort

7.8 N·m {80 kgf·cm, 69 in·lbf} max.
CONTINUED
N–12
POWER STEERING
STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION

32—47
{3.2—4.8, 24—34}
24—35
{2.4—3.6, 18—26}
37—54
{3.7—5.5, 27—39}
20—26
{2.0—2.7, 15—19}
SST
69—78
{7.0—8.0, 51—57}
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SST
R 79—157
{7.0—16.0, 58—115}
R R
45—58
{4.5—6.0, 33—43} SST
37—54
{3.7—5.5, 27—39}
R
45—58
{4.5—6.0, 33—43}
SST
SST
1 Cotter pin 11 Idler arm bracket

2 Locknut 12 Pressure pipe
3 Ball joint 13 Return pipe
+ MANUAL STEERING, STEERING GEAR AND 14 Bolt
LINKAGE REMOVAL/INSTALLATION, Ball
Joint Removal Note 15 Bolt, nut, washer
4 Locknut 16 Steering gear and pitman arm

+ MANUAL STEERING, STEERING GEAR AND
5 Tie rod LINKAGE REMOVAL/INSTALLATION, Steering
6 Center link Gear and Pitman Arm Removal Note
7 Idler arm 17 Dust boot
+ MANUAL STEERING, STEERING GEAR AND + MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, Idler LINKAGE REMOVAL/INSTALLATION, Dust
Arm Removal Note Boot Disassembly Note
8 Bushing + MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, Dust
9 Washer Boot Assembly Note
10 Bolt, nut, washer
CONTINUED
N–13
POWER STEERING
STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY

57—64
{5.7—6.5, 42—47}
30—44
{3.0—4.5, 22—32}
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R
R
R R
R
R
56—63
{5.7—6.5, 42—47} SST
R R
197—235
R SST {20.0—24.0,
145—173} N·m {kgf·m, ft·lbf}
1 Nut 8 O-ring
2 Pitman arm 9 Y packing
+ MANUAL STEERING, STEERING GEAR AND 10 Back up ring
LINKAGE DISASSEMBLY/ASSEMBLY, Pitman
Arm Disassembly Note 11 Oil seal
3 Clip 12 Back up ring
4 Dust boot 13 Y packing

+ MANUAL STEERING, STEERING GEAR AND 14 Dust cover
LINKAGE DISASSEMBLY/ASSEMBLY, Dust 15 Snap ring
Boot Assembly Note
16 Washer
5 Locknut
+ MANUAL STEERING, STEERING GEAR AND 17 Oil seal
LINKAGE DISASSEMBLY/ASSEMBLY, Locknut 18 Valve and piston component
(Side Cover), Sector Shaft Disassembly Note + Assembly Note
6 Sector shaft 19 O-ring
+ MANUAL STEERING, STEERING GEAR AND 20 Seal ring
LINKAGE DISASSEMBLY/ASSEMBLY, Locknut
21 Gear housing
(Side Cover) Sector Shaft Disassembly Note
7 Side cover
CONTINUED
N–14
POWER STEERING
Valve and Piston Component Assembly Note
Caution
Do not scratch the seal ring and O-ring on
the piston against the entrance to the
housing.
Insert the piston by slightly turning to the
left and right so as not to create flection at
the O-ring and seal ring.
Insert the valve and piston component to the gear

housing.
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STEERING GEAR AND LINKAGE INSPECTION
(Refer to MANUAL STEERING, STEERING GEAR
AND LINKAGE INSPECTION, Steering Gear Backlash
Adjustment.) CONTINUED
N–15
POWER STEERING
POWER STEERING OIL PUMP REMOVAL/INSTALLATION

3. For F2 CIS, F2 Carb and G6 engine model, adjust the drive belt.
(Refer to Section B2, DRIVE BELT,DRIVE BELT ADJUSTMENT.)
F2 CIS, F2 CARB
30—44
{3.0—4.5, 22—32}
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30—39
{3.0—4.0, 22—28}
SST
50—59
{5.0—6.0, 37—43}
CONTINUED
N–16
POWER STEERING
G6
19—25
{1.9—2.6, 14—18}
32—46
{3.2—4.7, 24—33}
32—47
{3.2—4.8, 24—34}
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50—59
{5.0—6.0, 37—43}
SST
CLAMP
POSITION
30 mm
{1.2 in}
1 Drive belt 5 Return hose

2 Locknut 6 Power steering fluid pressure switch connector
+ Removal Note (except F2 Carb)
3 Oil pump pulley 7 Power steering oil pump component
4 Pressure pipe (F2 CIS, F2 Carb), pressure hose
(G6)
Locknut Removal Note

Secure the pulley using the SST and remove the
locknut.
49 G032 354
CONTINUED
N–17
POWER STEERING
WL, WL TURBO
30—44
{3.0—4.5, 22—32}
19—25
{1.9—2.6, 14—18}
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19—25
{1.9—2.6,
14—18}
R
1 Pressure pipe 4 Power steering oil pump

2 Return hose 5 O-ring
3 Bolt and nut
CONTINUED
N–18
POWER STEERING
POWER STEERING OIL PUMP (F2 CIS, F2 CARB, G6) DISASSEMBLY/ASSEMBLY

1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs
are necessary.
R
15—19
{1.5—2.0,
11—14}
7.9—11.7 N·m
{80—120 kgf·cm, R
70—104 in·lbf}
9.9—13.7 N·m G6
{100—140 kgf·cm,
87—121 in·lbf} 22—25
{2.2—2.6, 16—18}
R
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R
F2 CIS
50—68
{5.0—7.0,
37—50}
R
R
F2 CARB
16—23
18—21 {1.6—2.4, 12—17}
22—25
{1.8—2.2, 14—16} {2.2—2.6, 16—18}
À
SST
1 Power steering oil pump component 13 Rear body

+ Disassembly Note + Assembly Note
2 Pressure switch component 14 O-ring
3 O-ring 15 Cam ring
4 Nut (G6) + Assembly Note
5 Connector (G6) 16 Rotor
6 Connector bolt 17 Vane

+ Assembly Note
7 O-ring
18 Pin
8 Control valve component
19 Side plate
9 Spring + Assembly Note
10 Suction pipe 20 O-ring
11 O-ring 21 Oil seal
12 Shaft component 22 Front body
CONTINUED
N–19
POWER STEERING
Power Steering Oil Pump Disassembly Note 3. Install the vanes in the rotor with the rounded edges
outward.
Caution
To secure the oil pump in a vise, use the SST
as shown to prevent damage to the pump.
ROUND EDGE
49 F032 301
Rear Body Assembly Note

After installing the rear body, manually turn the shaft
to verify that it rotates smoothly.
Side Plate Assembly Note
1. Install a new O-ring and the side plate to the front
body.
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2. Position the side plate using the rear body.
Vane, Cam Ring Assembly Note

1. Install the cam ring with the marks facing the front
body.
2. Install the rotor with the mark facing the rear body.
MARK
CONTINUED
N–20
POWER STEERING
POWER STEERING OIL PUMP (WL, WL TURBO) DISASSEMBLY/ASSEMBLY

1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs
are necessary.
7.9—11.7 N·m
{80—120 kgf·cm,
69.5—104.1 in·lbf}
22—25
{2.2—2.6, 16—18}
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R
SST
R
R
50—68
{5.0—7.0, 37—50}
1 Power steering oil pump component 10 Cam ring

+ POWER STEERING, POWER STEERING + POWER STEERING POWER STEERING
OIL PUMP (G6) REMOVAL/INSTALLATION, OIL PUMP (G6) REMOVAL/INSTALLATION,
Power Steering Cam Ring
Oil Pump Component Disassembly Note Assembly Note
2 Suction pipe 11 Rotor
3 O-ring 12 Vane
4 Connector + POWERSTEERING, POWER STEERING
OIL PUMP (G6) REMOVAL/INSTALLATION,
5 O-ring Vane
6 Control valve Assembly Note
7 Spring 13 Side plate
8 Rear body + POWER STEERING, POWER STEERING
+ POWER STEERING, POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION,
OIL PUMP (G6) REMOVAL/INSTALLATION, Side Plate
Rear Body Assembly Note
Assembly Note 14 O-ring
9 O-ring 15 Front body
CONTINUED
N–21
BRAKING SYSTEM
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . P– 1 LOAD SENSING PROPORTIONING
CONVENTIONAL BRAKE SYSTEM . . . . . . . . . . . P– 2 VALVE REMOVAL/INSTALLATION . . . . . . . . . P–11
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . P– 2 FRONT BRAKE (DISC) INSPECTION . . . . . . . P–12
VACUUM LINE INSPECTION . . . . . . . . . . . . . . P– 2 FRONT BRAKE (DISC) REMOVAL/
BRAKE PEDAL INSPECTION . . . . . . . . . . . . . . P– 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . P–13/14
BRAKE PEDAL REMOVAL/INSTALLATION . . P– 3 DISC PAD (FRONT) REPLACEMENT . . . . . . . P–14
BRAKE SWITCH INSPECTION . . . . . . . . . . . . . P– 4 CALIPER (FRONT) DISASSEMBLY/
MASTER CYLINDER REMOVAL/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . P– 4/6 REAR BRAKE (DRUM) INSPECTION . . . . . . . P–15
FLUID LEVEL SENSOR INSPECTION . . . . . . P– 6 REAR BRAKE (DRUM) REMOVAL/
MASTER CYLINDER DISASSEMBLY/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . P–15
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P– 7/8 BRAKE DRUM INSPECTION . . . . . . . . . . . . . . . P–16
POWER BRAKE UNIT INSPECTION . . . . . . . . P– 8 WHEEL CYLINDER DISASSEMBLY/
POWER BRAKE UNIT REMOVAL/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P–16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . P– 9 PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . . . P–16
VACUUM SWITCH INSPECTION . . . . . . . . . . . P– 9 PARKING BRAKE (STICK TYPE)
VACUUM SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . P–16
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . P–10 PARKING BRAKE (STICK TYPE)
VACUUM PUMP INSPECTION . . . . . . . . . . . . . P–10 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . P–16
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VACUUM PUMP REMOVAL/INSTALLATION . P–10 PARKING BRAKE LEVER (STICK TYPE)
LOAD SENSING PROPORTIONING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . P–17
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . P–11 PARKING BRAKE CABLE (STICK TYPE)
LOAD SENSING PROPORTIONING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . P–18/19
VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . P–11
GENERAL PROCEDURES Brake pipe flare nut tightening

Tighten the brake pipe flare nut by using the
Wheel and tires removal/installation SST (49 0259 770B). Be sure to modify the brake pipe
The removal and installation procedures for the flare nut tightening torque to allow for use of a
wheels and tires are not mentioned in this section. torque wrench-SST combination.
When a wheel is removed, retighten it to the (Refer to section GI, FUNDAMENTAL
specified tightening torque, referring to section TD. PROCEDURES, TORQUE FORMULAS.)
Brake lines disconnection/connection Connectors disconnection

Disconnect the negative battery cable before doing
Caution any work that requires handling of connectors.
Brake fluid will damage painted surfaces. If Reconnect the negative battery cable only after the
brake fluid get on a painted surface, wipe it work is completed.
off immediately.
If any brake line has been disconnected anytime

during the procedure, add brake fluid, bleed the
brakes, and inspect leakage after the procedure
has been completed.
Fluid specification
SAE J1703 or FMVSS116 DOT–3 or DOT–4
CONTINUED
P–1
CONVENTIONAL BRAKE SYSTEM
CONVENTIONAL BRAKE SYSTEM VACUUM LINE INSPECTION

1. Remove the clamps and the vacuum hose.
AIR BLEEDING 2. Apply both suction and pressure to the engine-side
hose (Gasoline) or vacuum pump side of the hose
Note (Diesel), and verify that air blows only toward that
The reservoir should be kept 3/4 full during side. If air flows in both directions or not at all,
bleeding. replace the vacuum hose.
The brakes should be bled whenever a brake
line is disconnected. If a hydraulic line is
disconnected at the master cylinder, start at the
slave cylinder farthest from the brake master
cylinder, and move to the next farthest slave
cylinder until all four cylinders have been bled. CHECK VALVE
If the disconnection point is anywhere except
the master cylinder, start at the point closest to
the disconnection, and move to the next
closest slave cylinder until all four cylinders ENG
have been bled.
1. Remove the bleeder cap and attach a vinyl tube to BRAKE PEDAL INSPECTION
the bleeder screw. Brake Pedal Height Inspection
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2. Place the other end of the vinyl tube in a clear Verify that the distance from the center of the
fluid-filled container. upper surface of the pedal pad to the floor pannel
3. One person should depress the brake pedal a few is as specified.
times, and then hold it in the depressed position.
4. A second person should loosen the bleeder screw, Pedal height
drain out the fluid and retighten the screw using the L.H.D.: 214—219 mm {8.43—8.81 in}
SST. R.H.D.:219—224 mm {8.63—8.81 in}
Tightening torque
Front:
9—14 N·m {92—142 kgf·cm, 80—123 in·lbf}
Rear: PEDAL HEIGHT
5.9—8.8 N·m {60—90 kgf·cm, 53—78 in·lbf}
49 0259 770B
5. Repeat steps 3 and 4 until no air bubbles are seen.

6. After air bleeding, inspect the following:
(1) brake operation
(2) fluid leakage
(3) fluid level
CONTINUED
P–2
Brake Pedal Height Adjustment

1. Disconnect the brake switch connector.
2. Loosen locknut B and turn switch A until it does not D
contact the pedal.
3. Loosen locknut D and turn rod C to adjust the height.
4. Tighten the bolt with locknut B so that clearance
between the bolt for brake light switch A and pedal
C
stopper is within the specification.
Specification
0.1—1.0 mm {0.004—0.039 in}
Tightening torque
14—17 N·m {140—180 kgf·cm, 122—156 in·lbf} 5. After adjustment, inspect the pedal height and the
brake light operation.
5. Connect the brake switch connector.
6. After adjustment, inspect the pedal play and the Pedal-to-floor Clearance Inspection
brake light operation. 1. Start the engine and verify that the distance from
the floor panel to the pedal pad center is as
specified when the pedal is depressed with a force
D of 589 N {60 kgf, 132 lbf}.
A
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Clearance
105 mm {4.2 in} min.
C B
Brake Pedal Play Inspection

1. Depress the pedal a few times to eliminate the
vacuum in the system.
2. Remove the snap pin, verify that the holes in the
fork and in the pedal are aligned, and reinstall the PEDAL-TO-FLOOR
pin. CLEARANCE
3. Gently depress the pedal by hand until resistance 2. If the distance is less than specified, inspect the
is felt (approx. 20N {2 kgf, 4.4 lbf}) and inspect following:
the free play. (1) Air in brake system
(2) Malfunction of the automatic adjuster
Pedal play (3) Excessive shoe clearance
3—8 mm {0.12—0.31 in}
BRAKE PEDAL REMOVAL/INSTALLATION
R.H.D.
The brake pedal is mounted on the bracket
integrated with the clutch pedal and accelerator
pedal. Refer to section F2, INTAKE AIR
SYSTEM, ACCELERATOR PEDAL
REMOVAL/INSTALLATION for the
brake pedal removal/installation.
L.H.D.
The brake pedal is mounted on the bracket
integrated with the clutch Pedal.
Refer to section H, CLUTCH PEDAL REMOVAL/
INSTALLATION for the brake pedal removal/installation.
Brake Pedal Play Adjustment
1. Remove the snap pin and clevis pin.
2. Loosen locknut D and turn rod C to align the holes
in the fork and in the pedal.
3. Install the clevis pin and the snap pin.
4. Tighten locknut D.
Tightening torque
24—34 N·m {2.4—3.5 kgf·m, 18—25 ft·lbf}
CONTINUED
P–3
BRAKE SWITCH INSPECTION R.H.D.

1. Disconnect the brake switch connector.
2. Inspect for continuity between the terminals of the
brake switch connector using the circuit tester.
: Continuity
Terminal
Condition SST
A B
R
When the brake pedal is
depressed.
When the brake pedal is
not depressed.
SST *
12.9—21.5
A {130—220, 113—190} 9.81—15.6
{100—160, 87—138}
B
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* 49 0259 770B
1 Brake fluid level sensor connector

3. If not as specified, replace the brake switch. 2 Brake pipe
3 Bracket (R.H.D.)
MASTER CYLINDER REMOVAL/INSTALLATION 4 Master cylinder
1. Remove in the order indicated in the table. + Installation Note
5 O-ring
L.H.D.
Master Cylinder Installation Note
1. Loosen the adjusting nut of the SST.
2. Place the SST on the power brake unit and tighten
the nut and washer.
SST Tightening torque

9.81—15.6 N·m
{100—160 kgf·cm, 87—138 in·lbf}
R
3. Apply 66.7 kPa {500 mmHg, 19.7 inHg} vacuum to
the power brake unit using a vacuum pump.
9.81—15.6
{100—160, 87—138}
SST *
12.9—21.5
{130—220, 113—190}
* 49 0259 770B N·m {kgf·cm, in·lbf}
49 B043 001
CONTINUED
P–4
4. Turn the adjusting nut of the SST counterclockwise Clearance at B

until the gauge rod just contacts the push rod end 1. Measure and record the height D1 of the gauge
of the power brake unit. Push lightly on the end of rod.
the gauge rod to be sure it is seated. Verify that
there is no gap between the adjusting nut and SST
body.
5. Remove the SST from the power brake unit.
(D1)
TOUCHING
49 B043 001
49 B043 001
2. Turn the adjusting nut until the SST body sets

TOUCHING
ADJUSTING NUT closely on the master cylinder. Turn only enough
for the body to touch.
3. Measure and record height D2 of the gauge rod.
6. Remove the SST from the power brake unit without ADJUSTING NUT
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disturbing the adjusting nut. Set the SST onto the
master cylinder as shown in the figure. (D2)
7. Push lightly on the end of the SST gauge rod to be
sure that it is contacting the bottom of the master
cylinder piston, but do not push so hard that the
piston moves. Note any clearance between the
SST body and the adjusting nut: clearance B, or
between the body and the master cylinder:
clearance C. Adjust the push rod as necessary as CLEARANCE (B)
outlined in “Adjustment” below. 49 B043 001
Adjustment
4. Subtract D1 from D2. Using the SST, turn the nut
Measurement Push rod to shorten the power brake unit push rod an
Clearance at B Too long amount equal to the difference.
Clearance at C Too short
49 B043 004
No clearance at B or C Okay
CLEARANCE (C)
49 B043 001
49 E043 003A
CLEARANCE (B)
CONTINUED
P–5
Clearance at C
1. Push lightly on the end of the SST gauge rod, and
measure the clearance between the adjusting nut
and the SST body.
CLEARANCE (C)
49 B043 001
2. Using the SSTs, turn the nut to lengthen the power

brake unit push rod an amount equal to the
clearance measured at B.
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49 B043 004
49 E043 003A
FLUID LEVEL SENSOR INSPECTION

1. Disconnect the sensor connector.
2. Connect an ohmmeter to the connector.
3. Starting with the fluid level above MIN, verify that
there is no continuity.
4. Remove the brake fluid and verify that there is
continuity when the level is below MIN.
: Continuity
Terminal
Fl id level
Fluid
A B
Below MIN.
Above MIN.
5. If not as specified, replace the sensor.
CONTINUED
P–6
MASTER CYLINDER DISASSEMBLY/ASSEMBLY
Caution
If the master cylinder body is damaged, replace the unit as a component. When securing the master
cylinder in a vise, tighten only the flange of the master cylinder.

À R
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R
1.0—1.5
{10—15, 8.7—13}
R
2.0—2.4 {20—25, 18—21}
N·m {kgf·cm , in·lbf}
1 Cap set 10 Cup

2 Screw 11 Primary piston stopper
3 Reservoir 12 Primary piston
4 Joint bushing 13 Stop screw
5 Fluid level sensor + Assembly Note
6 Snap ring 14 O-ring
7 Spacer 15 Secondary piston
8 Piston guide 16 Master cylinder body
9 O-ring
CONTINUED
P–7
Stop Screw and O-ring Assembly Note (Inspection using the testers)
1. Install a new O-ring onto the stop screw. 1. Connect the SSTs, vacuum gauge, and pedal
2. Push the primary piston component in full. depression force gauge as shown in the figure.
3. Install and tighten the stop screw.
Note
Tightening torque Use commercially available gauges and pedal
2.0—2.4 N·m {20—25 kgf·cm, 18—21 in·lbf} depression force gauge.
Bleed the air from the SST at gauge A.
49 U043 004
49 U043 005
A PEDAL DE-
A PRESSION
FORCE
GAUGE
VACUUM GAUGE
49 U043 006
POWER BRAKE UNIT INSPECTION
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Power Brake Unit Function Inspection 2. After bleeding the air from the SST, conduct the
(Simple method) test as described in the following steps.
Note a) Inspection for vacuum loss

Replace power brake unit component as Unloaded condition
necessary. 1. Start the engine.
2. Stop the engine when the vacuum gauge reading
Step 1 reaches 66.7 kPa {500 mmHg, 19.7 inHg}.
1. With the engine stopped, depress the pedal a few 3. Observe the vacuum gauge for 15 seconds. If the
times. gauge shows 63.3—66.7 kPa {475—500 mmHg,
2. With the pedal depressed, start the engine. 18.7—19.7 inHg}, the unit is operating.
3. If the pedal moves down slightly, immediately after
the engine starts, the unit is operating. Loaded condition
Step 2 2. Depress the brake pedal with a force of 196 N {20
1. Start the engine. kgf, 44 lbf}.
2. Stop the engine after it has run for 1 or 2 minutes. 3. With the brake pedal depressed, stop the engine
3. Depress the pedal with the usual force. when the vacuum gauge reading reaches 66.7 kPa
4. If the first pedal stroke is long and becomes shorter {500 mmHg, 19.7 inHg}.
with subsequent strokes, the unit is operating. 4. Observe the vacuum gauge for 15 seconds. If the
gauge shows 63.3—66.7 kPa {475—500 mmHg,
Note 18.7—19.7 inHg}, the unit is operating.
If a problem is found, inspect for damage on
the check valve or vacuum hose, and examine b) Inspection for hydraulic pressure
the installation. Repair as necessary, and 1. When the engine is stopped (vacuum 0 kPa {0
inspect it again. mmHg, 0 inHg}) and the fluid pressure is within
the specification, the unit is operating.
Step 3 Pedal force Fluid pressure
196 N
2. Depress the pedal with the usual force. 790 kPa {8 kgf/cm2, 114 psi} min
{20 kgf, 44 lbf}
3. Stop the engine with the pedal held depressed.
4. Hold the pedal down for about 30 seconds.
5. If the pedal height does not change, the unit is 2. Start the engine. Depress the brake pedal when
operating. the vacuum reaches 66.7 kPa {500 mmHg, 19.7
inHg}. If the fluid pressure is within the
specification, the unit is operating.
Pedal force Fluid pressure
196 N 8,240 kPa
{20 kgf, 44 lbf} {84 kgf/cm2, 1,200 psi} min
CONTINUED
P–8
POWER BRAKE UNIT REMOVAL/INSTALLATION 1 Vacuum switch connector (Diesel)

1. Remove the master cylinder. (Refer to
2 Vacuum hose
CONVENTIONAL BRAKE SYSTEM, MASTER
CYLINDER REMOVAL/INSTALLATION.) 3 Snap pin
2. Remove in the order indicated in the table. 4 Clevis pin
5 Nut
L.H.D.
6 Power brake unit
7 Gasket
8 Fork
9 Nut
R VACUUM SWITCH INSPECTION (DIESEL)

1. Remove the vacuum hose from the power brake unit.
2. Set the vacuum pump hose (commercially
available on the market) onto the power brake unit
19—25
as shown.
{1.9—2.6, 14—18}
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24—34
{2.4—3.5, 18—25}
3. Turn the engine switch on.

R.H.D.
4. Release the parking brake.
5. Apply vacuum to the power brake unit using the
vacuum pump (commercially available on the
market) and verify the operating condition of the
brake light warning light.
Brake warning
R Vacuum kPa {mmHg, inHg}
light
Below 10.71.3 {8010, 3.20.4} ON
Above 10.71.3 {8010, 3.20.4} OFF
19—25
{1.9—2.6, 14—18} 6. The vacuum switch is functioning normally if it
corresponds to the above specifications. Replace
the vacuum switch as necessary.
24—34
{2.4—3.5, 18—25}

CONTINUED
P–9
VACUUM SWITCH REMOVAL/INSTALLATION VACUUM PUMP INSPECTION (DIESEL)

(DIESEL) 1. Warm up the engine.
1. Remove in the order indicated in the table. 2. Disconnect the vacuum hose from the vacuum
2. Install in the reverse order of removal. pump and connect a vacuum gauge as shown in
the figure, then inspect the vacuum.
L.H.D.
Vacuum specification (In 20 seconds)
Engine speed 1,500 rpm
73.3 kPa {550 mmHg, 21.7 inHg}
Maximum vacuum
Engine speed 3,000 rpm
93.3 kPa {700 mmHg, 27.6 inHg}
20—24
{2.0—2.5, 15—18} N·m {kgf·m, ft·lbf}
R.H.D.
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3. If the pressure is less than the specification,
inspect for the following.
20—24 (1) Malfunction of the vacuum pump
{2.0—2.5, 15—18} N·m {kgf·m, ft·lbf} (2) Shortage of the lubrication oil pressure
1 Vacuum switch connector VACUUM PUMP REMOVAL/INSTALLATION

2 Vacuum switch (DIESEL)
+ Installation Note 1. Remove in the order indicated in the table.
Vacuum Switch Installation Note
1. Remove the old sealant.
Caution
Do not apply sealant to the tip of the
vacuum switch as a malfunction may occur.
2. Apply sealant to the area shown before installation
of the vacuum switch onto the power brake unit,
and then tighten it to the specified torque.
Tightening torque
20—24 N·m {2.0—2.5 kgf·m, 15—18 ft·lbf}
R
DO NOT APPLY
SEALANT ON
THIS AREA 19—25 {1.9—2.6, 14—18}
1 Vacuum hose
2 Bolt
3 Vacuum pump
4 O-ring
CONTINUED
P–10
LOAD SENSING PROPORTIONING VALVE LOAD SENSING PROPORTIONING VALVE

INSPECTION ADJUSTMENT
1. Place the vehicle on level ground. 1. Place the unloaded vehicle on level ground.
2. Inspect the tire inflations and set them to the Unloaded condition: Fuel tank is full. Engine
recommended pressure as necessary. coolant and engine oil are at
3. Prepare the vehicle with a person in the driver’s specified levels. Spare tire,
seat; include the standard vehicle tools, the spare jack, and tools are in
wheel and tire, and a full tank of fuel. designated position.
4. Connect pressure gauges (commercially available)
to the front and rear calipers. Note
A change of 5 mm {0.197 in} dimension L
results in a change of 853 kPa {8.7 kgf/cm2,
124 psi} for 42 and 1020 kPa {10.4 kgf/cm2,
148 psi} for 44.
2. Adjust main spring dimension L between the LSPV

and the adjustment link by loosening and
repositioning the LSPV.
(1) Decrease dimension L if the fluid pressure is
low.
(2) Increase dimension L if the fluid pressure is
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high.
Reference value
Note Dimension L
When applying the specified pressure, the brake 42: 147.5—154.5 mm {5.808—6.082 in}
pedal must not be “double pumped” or released. 44: 175.5—182.5 mm {6.910—7.185 in}
Approximately two seconds after setting the front
wheel cylinder fluid pressure, read the rear pres-
sure.
5. Bleed the air from the brake system.

6. Slowly depress the brake pedal until the front
pressure gauge indicates the specified pressure
shown in the table, then note the reading on the
rear pressure gauge. MAIN SPRING
kPa {kgf/cm2, psi}
Front pressure Rear pressure
4,900 {50, 711} 2,550 {26, 370} ADJUSTMENT LINK
9,810 {100, 1,422} 3,530 {36, 512}
LOADED AXLE CASING
A PERSON IN
DRIVER’S SEAT
BOLT
4,900 {50, 711} 9,810 {100, 1,422}

REAR PRESSURE FRONT PRESSURE
kPa {kgf/cm2, psi} 3. After adjustment, recheck the fluid pressure. If not
as specified, replace the LSPV as a component.
7. If not as specified, replace and adjust the LSPV.
LOAD SENSING PROPORTIONING VALVE
Caution
Do not disassemble the LSPV.
Do not move the nut A.

CONTINUED
P–11
3. After installation, adjust the main spring dimension. Disc Plate Thickness Inspection
(Refer to CONVENTIONAL BRAKE SYSTEM, 1. Measure the thickness of the disc plate.
LOAD SENSING PROPORTIONING VALVE
ADJUSTMENT.) Caution
12.8—21.5 N·m When it is necessary to machine the disc
{130—220 kgf·cm, 113—190 in·lbf} plate, if the disc plate is removed from the
SST * SST * 12.8—21.5 N·m vehicle then machined, excessive runout
{130—220 kgf·cm,
113—190 in·lbf} may result. Machine the disc plate with it
A installed on the vehicle.
Standard
24 mm {0.94 in}
Minimum
22 mm {0.87 in}
Minimum thickness after machining by using a
brake lathe on-vehicle
19—25 {1.9—2.6, 14—18}
22.8 mm {0.90 in}
2. If the thickness is not within the specification,

replace the disc plate.
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19—25
{1.9—2.6, 14—18}
* 49 0259 770B
1 Brake pipe
2 Nut
3 Bolt
4 Load sensing proportioning valve
Disc Plate Runout Inspection
FRONT BRAKE (DISC) INSPECTION 1. Verify that there is no wheel bearing looseness.
Disc Pad Thickness Inspection 2. Measure the runout at the outer edge of the
1. Jack up the front of the vehicle and support it on safe- contact surface of the disc pad.
ty stands.
2. Remove the wheel and tires. Runout
3. Look through the caliper inspection hole and 0.05 mm {0.002 in} max.
inspect the remaining thickness of the pads.
3. If the runout is not within the specification, repair or
Thickness replace the disc plate.
2.0 mm {0.08 in} min.
4. Replace the pads as a set (right and left wheels) if

either is at or less than the minimum thickness.
CONTINUED
P–12
FRONT BRAKE (DISC) REMOVAL/INSTALLATION

3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.
22—29
{2.2—3.0, 16—29}
R
29—34
{2.9—3.5, 21—25}
R
108—127
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{10.4—14.0, 80—94}
SST
1 Brake hose 6 Disc pad

2 Bolt + Installation Note
3 Guide pin 7 Plate
4 Dust boot 8 Guide plate
5 Caliper 9 Mounting support
CONTINUED
P–13
Disc Pad Installation Note CALIPER (FRONT) DISASSEMBLY/ASSEMBLY

1. Push the piston fully inward using the SST. 1. Disassemble in the order indicated in the table.
2. Install the disc pad. 2. Assemble in the reverse order of disassembly.
*
SST
9—14
{92—143, 80–123}
49 0221 600C
SST
DISC PAD (FRONT) REPLACEMENT

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29—34
{2.9—3.5, 21—25}
*49 0259 770B N·m {kgf·cm, in·lbf}

R
1 Piston
+ Disassembly Note
2 Dust seal
3 Piston seal
+ Disassembly Note
4 Bleeder cap, screw
5 Caliper body
Piston Disassembly Note

SST
Caution
Blow the compressed air slowly to prevent
the piston from suddenly popping out.
Place a piece of wood in the caliper, then blow

1 Bolt compressed air through the hole to force the piston
2 Caliper out of the caliper.
3 Disc pad
+ CONVENTIONAL BRAKE SYSTEM, FRONT
WOOD
BRAKE (DISC) REMOVAL/INSTALLATION,
Disc Pad Installation Note
4 Plate
5 Guide plate
Piston Seal Disassembly Note

Remove the piston seal from the brake caliper
using the SST.
CONTINUED
P–14
REAR BRAKE (DRUM) INSPECTION

Brake Lining Thickness Inspection
1. Remove the brake drum.
2. Inspect the remaining thickness of the lining.
Thickness
1.0 mm {0.04 in} min.
3. Replace both left and right brake shoes if either is

at or less than the minimum thickness.
REAR BRAKE (DRUM) REMOVAL/INSTALLATION

3. After installation.
(1) Depress the brake pedal a few times, then verify that the brakes do not drag.
(2) Inspect the parking brake lever stroke.
(Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION,
Parking Brake Lever Stroke Inspection.)
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9.8—12.7
{100—130, 87—112}
* SST
12.8—21.5
{130—220, 113—190} APPLY TO SHADED EREA
*49 0259 770B N·m {kgf·cm, in·lbf}
1 Brake drum 8 Adjust strut

2 Hold spring, washer 9 Brake shoe
3 Hold pin 10 Parking brake cable
4 Lower return spring 11 Operating lever
5 Upper return spring 12 Brake pipe
6 Pawl lever spring 13 Wheel cylinder
7 Pawl lever 14 Gasket
CONTINUED
P–15
CONVENTIONAL BRAKE SYSTEM, PARKING BRAKE SYSTEM
BRAKE DRUM INSPECTION PARKING BRAKE SYSTEM

1. Measure the inner diameter of the drum.
PARKING BRAKE (STICK TYPE) INSPECTION
Maximum diameter Parking Brake Lever Stroke Inspection
42: 271.5 mm {10.68 in} 1. Pull the parking brake lever a few times.
44: 296.5 mm {11.67 in} 2. Verify that the stroke is within the specification
when the parking brake lever is pulled with a force
of 98 N {10 kgf, 22 ibf}.
2. Apply chalk to the inside of the brake drum.
3. Inspect for scratches and uneven or abnormal Stroke
wear inside the drum as shown in the figure. 1—7 notches
3. If not as specified, adjust the parking brake lever

stroke.
PARKING BRAKE (STICK TYPE) ADJUSTMENT

Parking Brake Lever Stroke Adjustment
1. Before adjustment, depress the brake pedal
several times while the vehicle is moving in
reverse.
2. Loosen the locknut A and turn the adjustment nut
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B so that the stroke is within the above range.
3. After adjustment, tighten the locknut A.
4. Repair or replace the drum as necessary. Repair if
the problem is minor. Tightening torque
5. When repairing or replacing the drum, check the 6.9—9.8 N·m {70—100 kgf·cm, 43—86 in·lbf}
contact with the shoes.
6. Wipe the chalk off after inspection.
WHEEL CYLINDER DISASSEMBLY/ASSEMBLY B

2. Assemble in the reverse order of disassembly. A
R
SST *
4. After adjustment, inspect the following points.
5.9—8.8 (1) Turn the ignition (engine) switch on, pull the
{ 60—90 , 53—78 } parking brake lever one notch, and verify that
the brake warning light illuminates.
R (2) Verify that the rear brakes do not drag when
the wheels are turned by hand.
* 49 0259 770B N·m { kgf·cm , in·lbf }
1 Dust boot
2 Piston
3 Piston cap
4 Spring
5 Bleeder cap, screw
6 Cylinder body
CONTINUED
P–16
PARKING BRAKE SYSTEM
PARKING BRAKE LEVER (STICK TYPE) REMOVAL/INSTALLATION

3. After installation, inspect the parking brake lever stroke.
(Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION.)
12.8—18.6 {130—190, 113—164}
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6.9—9.8
{70—100, 43—86}
1 Clip 9 Pin and clip

2 Joint pin 10 Spring
3 Cable connector 11 Rachet pawl
4 Parking brake switch 12 Stopper
5 Clip 13 Fork joint
6 Pin 14 Spring
7 Clip and joint pin 15 Guide
8 Lever 16 Rod
CONTINUED
P–17
PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION

1. Remove the under guard. (Refer to section F1–F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
4. After installation, inspect the parking brake lever stroke.
(Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION.)
4x2
16—22 {1.6—2.3, 12—16}
16—22
{1.6—2.3,
12—16}
6.9—9.8 N·m
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{70—100 kgf·cm,
43—86 in·lbf}
4x4
16—22
{1.6—2.3, 12—16}
16—22 6.9—9.8 N·m

16—22 {1.6—2.3, 12—16} {70—100 kgf·cm,
{1.6—2.3, 12—16} 43—86 in·lbf}
16—22
{1.6—2.3,
12—16} 16—22
{1.6—2.3, 12—16} N·m {kgf·m, ft·lbf}
CONTINUED
P–18
LHD model with F2 and G6 engine
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1 Nut 7 Grommet
2 Bolt 8 Bolt
3 Spring 9 Spring (44)
4 Front brake cable 10 Clip
5 Bolt (44) 11 Rear cable (left)
6 Bracket (44) 12 Rear cable (right)
CONTINUED
P-19
SUSPENSION
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . R–1 TORSION BAR SPRING AND LOWER ARM
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . R–1 REMOVAL/INSTALLATION (4 4) . . . . . . . . . R– 9/11
WHEEL ALIGNMENT PREINSPECTION . . . . . R–1 LOWER ARM INSPECTION . . . . . . . . . . . . . . . . R–11
FRONT WHEEL ALIGNMENT . . . . . . . . . . . . . . R– 2/3 UPPER ARM REMOVAL/INSTALLATION . . . . R–12
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . R–3 UPPER ARM INSPECTION . . . . . . . . . . . . . . . . R–13
VEHICLE HEIGHT ADJUSTMENT . . . . . . . . . . R–3 STABILIZER AND TENSION ROD
FRONT SHOCK ABSORBER REMOVAL/ REMOVAL/INSTALLATION (4 2) . . . . . . . . . R–13/14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . R–5 STABILIZER REMOVAL/INSTALLATION (4 4) . R–14
FRONT SHOCK ABSORBER INSPECTION . . R–5 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . R–15
TORSION BAR SPRING AND LOWER ARM REAR SHOCK ABSORBER AND LEAF
REMOVAL/INSTALLATION (4 2) . . . . . . . . . R– 6/8 SPRING REMOVAL/INSTALLATION . . . . . . . R–15
GENERAL PROCEDURES WHEEL ALIGNMENT

Wheels and tires removal/installation WHEEL ALIGNMENT PREINSPECTION
D The removal and installation procedures for the 1. Inspect the inflation of each tire, and set to the
wheels and tires are not mentioned in this section. recommended pressure, as necessary.
If a wheel is removed, retighten it to the specified 2. Inspect the front wheel bearing play. Adjust the
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tightening torque, referring to section TD. bearing preload or replace bearing(s) as
necessary.
Suspension arms removal/installation (Refer to section M, FRONT AXLE (4 2), WHEEL
D Tighten any part of the suspension that uses HUB, STEERING KNUCKLE INSPECTION or
rubber bushings only after the vehicle has been FRONT AXLE (4 4), WHEEL HUB, STEERING
lowered and unloaded*. KNUCKLE INSPECTION.)
* Unloaded condition: Fuel tank is full. Engine 3. Inspect the wheel and tire runout at all wheels.
coolant and engine oil are at specified levels. (Refer to section TD, SUSPENSION, Wheels and Tires.)
Spare tire, jack, and tools are in designated 4. Inspect the ball joints and steering linkage for
position. excessive looseness.
5. Place the vehicle on level ground with no luggage
and passenger load.
6. The difference in height between the left and right
sides from the center of the wheel to the fender
brim must not exceed 10 mm {0.39 in}. If not
within the specification, adjust the vehicle height.
(Refer to FRONT SUSPENSION, VEHICLE
HEIGHT ADJUSTMENT.)
7. Shake the vehicle to settle the suspension.
CONTINUED
R–1
WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT

Specifications
Specification
Item
4 2 4 4
(mm {in}) 3"3 {0.12"0.12}
Total toe
toe-in
in
(degree) 0° 16’ "16’ 0° 14’ "14’
+2° +2°
Maximum steering
g Inner 35° 00’ –3° 33° 30’ –3°
Front wheel
heel alignment angle +2° +2°
Outer 33° 00’ 30° 00’
(*1Unloaded –3° –3°
condition) Camber angle*2 0° 56’ "30’ 1° 06’ "30’

Caster angle*3 1° 37’ "45’ 2° 02’ "45’
Steering axis inclination
8° 04’ 10° 15’
(reference value)
*1 Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated
position.
*2 Difference between left and right must not exceed 30’.
*3 Difference between left and right must not exceed 45’.
Maximum Steering Angle Adjustment Total Toe-in Adjustment
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1. Loosen the adjusting bolt locknut. 1. Loosen the tie-rod end locknuts.
2. Turn the adjusting bolt to provide the correct 2. Turn the tie rods by the same amount in the
turning angle. opposite direction.
3. After adjustment, tighten the locknut to the
specified torque. Note
D One turn of the tie rod (both sides) changes the
Tightening torque toe-in by about 30 mm {1.18 in}.
40—58 N·m {4.0—6.0 kgf·m, 29—43 ft·lbf} D The left and right tie rods are both right
4 2 threaded. To increase the toe-in, turn the right
tie rod toward the front of the vehicle and the
left tie rod equally toward the rear.
3. Tighten the tie-rod end locknuts.
Tightening torque
69—78 N·m {7.0—8.0 kgf·m, 51—57 ft·lbf}
TIE ROD
ADJUSTING BOLT
4 4
ADJUSTING BOLT CONTINUED
R–2
WHEEL ALIGNMENT, FRONT SUSPENSION
Caster and Camber Adjustment

FRONT SUSPENSION
1. Loosen the upper arm shaft bolt and insert or
remove adjustment shims to provide the correct VEHICLE HEIGHT ADJUSTMENT
angle. 1. Place the vehicle on level ground.
No.1—5 2. Inspect the front and rear tire pressure and adjust it
No.6—11 as necessary.
3. Measure the distance from the center of each front
wheel to the fender brim.
FRONT
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Left/right difference
10 mm {0.39 in} max.
Standard vehicle height (reference value) mm {in}

4 2
Cab type Vehicle height
Adjustment shim Regular Cab, Stretch Cab 427 {16.8}
No. Thickness (mm {in}) No. Thickness (mm {in}) Double Cab 422 {16.6}
1 1.0 {0.039} 7 1.0 {0.039}
2 1.6 {0.063} 8 1.6 {0.063} 4 4
3 2.0 {0.079} 9 2.0 {0.079} Cab type Tire size Vehicle height
4 3.2 {0.126} 10 3.2 {0.126} Regular
g Cab,, 205R16 519 {20.4}
Stretch Cab 235/75R15 515 {20.3}
5 4.0 {0.157} 11 4.0 {0.157}
6 0.6 {0.024} 205R16 510 {20.1}
Double Cab
235/75R15 506 {19.9}
Note
D Shims No.1—5 are used on either side. Do not
use more than two.
D Shims No.6—11 are used at the front and rear
of either sides. Do not use more than one.
D Camber: A change of shim thickness (at front
and rear) of 1 mm {0.039 in} results in a
change of about 15’.
D Caster: A change of shim thickness (at front or
rear only) of 1 mm {0.039 in} results in a
change of about 30’.
2. After adjustment, tighten the upper arm shaft bolt

to the specified torque.
Tightening torque
94—116 N·m {9.5—11.9 kgf·m, 69—86 ft·lbf} CONTINUED
R–3
FRONT SUSPENSION
1. If the difference between left and right is not within

the specification, adjust the vehicle height by
turning the torsion bar spring anchor bolt.
4 2
4 4 ANCHOR BOLT
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ANCHOR BOLT
CONTINUED
R–4
FRONT SUSPENSION
FRONT SHOCK ABSORBER REMOVAL/INSTALLATION

6—8 mm
{0.24—0.31 in}
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55—80 {5.6—8.2, 41—59}
1 Nut 3 Bolt
+ Installation Note 4 Washer and nut
2 Retainer, bushing 5 Shock absorber
Nut Installation Note FRONT SHOCK ABSORBER INSPECTION

Tighten the nut so that the exposed thread of the 1. Remove the front shock absorber from the vehicle.
shock absorber piston is 6—8 mm {0.24—0.31 in}. 2. Inspect for damage and oil leakage.
3. Inspect the rubber bushing for deterioration and
wear.
4. Compress and extend the shock absorber piston at
least three (3) times. Verify that the operational
force does not change and that there is no unusual
noise.
5. Compress the shock absorber piston and release
it. Verify that the piston extends fully at a normal
speed.
CONTINUED
R–5
FRONT SUSPENSION
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (42)

3. Inspect the vehicle height and adjust it as necessary.
APPLY THREAD
LOCKING COMPOUND
APPLY THREAD
LOCKING COMPOUND
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118—156 {12.0—16.0, 87—115}
118—156 {12.0—16.0, 87—115}
SST
R
1 Cotter pin 11 Torque plate

2 Nut 12 Lower arm spindle, washer, and nut
3 Lower arm ball joint/Knuckle arm 13 Rubber bushing
+ Removal Note + Removal Note
4 Bolt, washer, and nut (shock absorber) + Installation Note
5 Anchor bolt 14 Tension rod bolt
+ Removal Note 15 Stabilizer bolt, bushing, retainer, spacer, and nut
+ Installation Note + Installation Note
6 Anchor swivel 16 Lower arm
7 Bolt and washer 17 Bound bumper, washer, and nut
8 Torsion bar component 18 Bolts and washer (ball joint)
9 Anchor arm 19 Lower arm ball joint
10 Torsion bar spring 20 Clip
+ Removal Note + Installation Note
+ Installation Note 21 Lower arm ball joint boot
CONTINUED
R–6
FRONT SUSPENSION
Lower Arm Ball Joint/Knuckle Arm Removal Note Clip Installation Note
Separate the ball joint from the knuckle arm using 1. Install the SST to the ball joint stud with the stud
the SST. stands straight up.
2. Install the clip in the dust boot groove.
KNUCKLE
49 T028 3A0
49 U034 208
Anchor Bolt Removal Note

Mark the anchor bolt and swivel for reference Stabilizer Bolt, Bushing, Retainer, Spacer And Nut
during installation. Installation Note
Tighten the nuts so that 18—21 mm {0.71—0.82 in}
of thread is exposed at the end of the bolt.
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MATCHING MARK
18—21 mm
{0.71—0.82 in}
Torsion Bar Spring Removal Note

Mark the torsion bar spring and anchor arm and
the torsion bar spring and torque plate for Rubber Bushing Installation Note
reference during installation. Install a new bushing using the SST.
MATCHING MARK MATCHING MARK

49 UB39 615
Rubber Bushing Removal Note

Remove the rubber bushing from the body using
the SST.
49 UB39 615
CONTINUED
R–7
FRONT SUSPENSION
Torsion Bar Spring Installation Note

1. Before installation, check the identification mark on
the end of the torsion bar spring.
L: Left bar, R: Right bar
2. Align the marks made during removal, and connect

the torsion bar spring to the torque plate.
MATCHING MARK MATCHING MARK
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Anchor Bolt Installation Note
Install the anchor bolt, and tighten it until the marks
made during removal are aligned.
MATCHING MARK
Note
If the anchor bolt was not marked during
removal, install it as follows:
(1) Lower the front suspension until the upper
arm contacts the rebound stopper.
(2) Install the anchor arm so that the angle A is
34° "4.5°.
(3) Install the anchor bolt and tighten it 27.3
turns.
A
CONTINUED
R–8
FRONT SUSPENSION
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (44)

1. Remove the driveshaft snap ring.
4. Inspect the vehicle height and adjust it as necessary.
118—156 APPLY THREAD

118—156 {12.0—16.0, 87—115}
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{12.0—16.0, 87—115} LOCKING COMPOUND
SST R
1 Cotter pin 13 Lower arm spindle (front), washer and nut

2 Nut 14 Stabilizer bolt, bushing, retainer, spacer and nut
3 Lower arm ball joint/Knuckle arm + FRONT SUSPENSION, TORSION BAR
+ FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM
SPRING AND LOWER ARM REMOVAL/INSTALLATION (42), Stabilizer
REMOVAL/INSTALLATION (42), Lower Arm Bolt, Bushing, Retainer, Spacer, And Nut
Ball Joint/Knuckle Arm Removal Note Installation Note
4 Bolt, washer and nut (shock absorber) 15 Lower arm
5 Anchor bolt and washer 16 Bound bumper, washer, and nut

+ Installation Note 17 Bolt, washer and nut
6 Anchor swivel 18 Lower arm ball joint
7 Bolt and washer 19 Clip
8 Torsion bar spring component + FRONT SUSPENSION, TORSION BAR
SPRING AND LOWER ARM
9 Anchor arm REMOVAL/INSTALLATION (42), Clip
+ Removal Note Installation Note
+ Installation Note
20 Lower arm ball joint boot
10 Torsion bar spring
+ Removal Note 21 Lower arm bushing
+ Installation Note + Removal Note
+ Installation Note
11 Torque plate
12 Lower arm spindle (rear), washer and nut
CONTINUED
R–9
FRONT SUSPENSION
Anchor Arm Removal Note Lower Arm Bushing Installation Note

Mark the anchor arm and body for reference during 1. Apply soapy water to the new bushing.
installation. 2. Install the bushing using the SST.
49 U034 2A0
Torsion Bar Spring Removal Note Torsion Bar Spring Installation Note
Mark the torsion bar spring and anchor arm and 1. Before installation, inspect the identification mark
the torsion bar spring and torque plate for on the end of the torsion bar spring.
reference during installation.
L: Left bar, R: Right bar
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2. Align the marks made during removal, and connect
the torsion bar spring to the torque plate.
Anchor Arm Installation Note

the anchor arm onto the torsion bar spring.
Lower Arm Bushing Removal Note

Remove the lower arm bushing using the SST.
49 U034 2A0
CONTINUED
R–10
FRONT SUSPENSION
Anchor Bolt Installation Note

Install the anchor bolt, and tighten it until the marks
made during removal are aligned.
Note
If the anchor bolt was not marked during
removal, install it at follows:
(1) Lower the front suspension until the upper
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arm contacts the rebound stopper.
(2) Install the anchor arm so that the angle A is
60°"4.5°.
(3) Install the anchor bolt and tighten it 26.9
turns.
LOWER ARM INSPECTION

1. Remove the lower arm from the vehicle.
2. Inspect for damage, cracks, and bending.
3. Check the ball joint rotation torque.
(1) Rotate the ball joint five times.
(2) Connect the SST to the ball stud, and measure
the rotation torque using a pull scale.
(3) Replace it if not within the specification.
Pull scale reading

20—34 N {2.0—3.5 kgf, 4.4—7.7 lbf}
49 0180 510B
CONTINUED
R–11
FRONT SUSPENSION
UPPER ARM REMOVAL/INSTALLATION

3. Inspect the wheel alignment and adjust it as necessary.
R
SST
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1 Clip 6 Upper arm component
2 Cotter pin and nut 7 Bolt and washer
3 Upper arm ball joint/Knuckle arm 8 Upper arm ball joint
+ Removal Note 9 Clip
4 Bolt and washer + Installation Note
5 Adjustment shim 10 Upper arm ball joint boot
+ Removal Note
Upper Arm Ball Joint/Knuckle Arm Removal Note Clip Installation Note
Separate the upper arm ball joint from the knuckle 1. Install the SST to the ball joint stud with the stud
arm using the SST. stands straight up.
2. Install the clip in the dust boot groove.
49 T028 3A0
49 U034 209
KNUCKLE
Adjustment Shim Removal Note

Note the number, amount and position of the shims
so that they are reinstalled in the correct positions.
CONTINUED
R–12
FRONT SUSPENSION
UPPER ARM INSPECTION

1. Remove the upper arm from the vehicle. 49 0180 510B
2. Inspect for damage, cracks, and bending.
3. Check the ball joint rotation torque.
(1) Rotate the ball joint five times.
(2) Connect the SST to the ball stud, and measure
the rotation torque using a pull scale.
(3) Replace it if not within the specification.
Pull scale reading

5.0—24 N {0.5—2.5 kgf, 1.2—5.5 lbf}
STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (42)

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22—26 {2.2—2.7, 16—19}
APPLY THREAD
LOCKING COMPOUND
94—116 {9.5—11.9, 69—86}
94—127 {9.5—13.0, 69—94}
1 Nut 6 Stabilizer bracket

+ FRONT SUSPENSION, TORSION BAR 7 Bushing
SPRING AND LOWER ARM
REMOVAL/INSTALLATION (42), Stabilizer 8 Stabilizer bar
Bolt, Bushing, Retainer, Spacer, And Nut 9 Tension rod nut
Installation Note + Installation Note
2 Retainer 10 Bushing and retainer
3 Bolt 11 Bolt
4 Bushing, retainer and spacer 12 Tension rod
5 Bolt
CONTINUED
R–13
FRONT SUSPENSION
Tension Rod Nut Installation Note

Tighten the tension rod nuts so that length L is 98.5
mm {3.88 in}.
STABILIZER REMOVAL/INSTALLATION (44)

22—26 {2.2—2.7, 16—19}

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1 Nut 5 Retainer, bushing, and spacer

+ FRONT SUSPENSION, STABILIZER AND 6 Bolt
TENSION ROD REMOVAL/INSTALLATION
(42), Nut Installation Note 7 Stabilizer bracket
2 Retainer and bushing 8 Bushing
3 Bolt 9 Stabilizer bar
4 Retainer and bushing

CONTINUED
R–14
REAR SUSPENSION
REAR SUSPENSION
REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION
1. Support the frame with safety stands and place a jack under the differential casing. Remove in the order
indicated in the table. While supporting the differential casing with a jack, raise or lower the jack as necessary.
42
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64—78
{6.5—8.0, 48—57}
59—78 {6.0—8.0, 44—57}
R APPLY THREAD LOCKING

COMPOUND
78—98 R
{8.0—10.0, 58—72}
20—26 {2.0—2.7, 15—19.5} 54—73 {5.5—7.5, 40—54}
1 Nut, washer, retainer, and bushing 10 Spring pin

2 Nut, washer, retainer, and bushing 11 Nut and washer
3 Shock absorber 12 Shackle pin
4 Nut and washer 13 Shackle plate
5 Nut and washer 14 Leaf spring component
6 U-bolt 15 Leaf spring bushing
7 Spring clamp + Removal Note
+ Installation Note
8 Stopper rubber
9 Bolt and washer
CONTINUED
R–15
REAR SUSPENSION
44
99.1—112 {10.1—11.5, 73.1—83.1}

APPLY THREAD
LOCKING COMPOUND
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64—78
59—78 {6.0—8.0, 44—57}
{6.5—8.0, 48—57}
R
78—98 {8.0—10.0, 58—72}
20—26 {2.0—2.7, 15—19.5}
1 Bolt and nut 11 Bolt and washer

2 Washer, retainer, and bushing 12 Spring pin
3 Nut, washer, retainer, and bushing 13 Nut and washer
4 Shock absorber 14 Shackle pin
5 Nut and washer 15 Shackle plate
6 Nut and washer 16 Leaf spring component
7 U-bolt 17 Leaf spring bushing
8 Set plate + Removal Note
+ Installation Note
9 Spring clamp
10 Stopper rubber
CONTINUED
R–16
REAR SUSPENSION
Leaf Spring Bushing Removal Note

Secure the leaf spring in a vise and remove the
bushing using a chisel.
Leaf Spring Bushing Installation Note

Press in the bushing using a suitable pipe.
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CONTINUED
R–17
BODY
PAGE 1 OF 2
BONNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S– 2 EXTERIOR ATTACHMENT . . . . . . . . . . . . . . . . . . . S–21
BONNET REMOVAL/INSTALLATION . . . . . . . . S– 2/3 RADIATOR GRILLE
BONNET ADJUSTMENT . . . . . . . . . . . . . . . . . . S– 3 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–21
FRONT FENDER PANEL . . . . . . . . . . . . . . . . . . . . S– 4 COWL GRILLE
FRONT FENDER PANEL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–21
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S– 4 WINDSHIELD GARNISH
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S– 5 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–21/22
FRONT DOOR REMOVAL/INSTALLATION . . . S– 5 SIDE PROTECTOR REMOVAL . . . . . . . . . . . . . S–22
FRONT DOOR DISASSEMBLY/ASSEMBLY . . S– 6 SIDE PROTECTOR INSTALLATION . . . . . . . . S–22/23
FRONT DOOR ADJUSTMENT . . . . . . . . . . . . . S– 7 OVER FENDER
REAR DOOR REMOVAL/INSTALLATION . . . . S– 7 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–23
REAR DOOR DISASSEMBLY/ASSEMBLY . . . S– 8/9 TAILGATE
REAR DOOR ADJUSTMENT . . . . . . . . . . . . . . . S– 9 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . S–23
DOOR LOCK STRIKER TAILGATE ADJUSTMENT . . . . . . . . . . . . . . . . . S–23
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S– 9 ROPE HOOK REMOVAL/INSTALLATION . . . . S–24
REGULATOR HANDLE REMOVAL . . . . . . . . . . S– 9 MOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–24
REGULATOR HANDLE INSTALLATION . . . . . S– 9 WINDSHIELD UPPER MOLDING
POWER WINDOW SYSTEM . . . . . . . . . . . . . . . . . S–10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–24
POWER WINDOW MAIN SWITCH WINDSHIELD UPPER MOLDING
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REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . S–24
POWER WINDOW MAIN SWITCH WINDSHIELD SIDE MOLDING REMOVAL . . . S–24
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . S–10/12 WINDSHIELD SIDE MOLDING
POWER WINDOW SUBSWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . S–24
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–12 FRONT BELTLINE MOLDING
POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–24
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . S–12/13 REAR BELTLINE MOLDING
FRONT POWER WINDOW REGULATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–25
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–13 ROOF MOLDING
FRONT POWER WINDOW REGULATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . S–25
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . S–13 OUTSIDE MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . S–25
REAR POWER WINDOW REGULATOR MANUAL OUTSIDE MIRROR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–13/14 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–25
REAR POWER WINDOW REGULATOR POWER OUTSIDE MIRROR
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . S–14 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–25
POWER WINDOW MOTOR INSPECTION . . . S–14 POWER OUTSIDE MIRROR INSPECTION . . S–25/26
POWER DOOR LOCK SYSTEM . . . . . . . . . . . . . . S–15 POWER OUTSIDE MIRROR SWITCH
DOOR KEY CYLINDER SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–26
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–15 POWER OUTSIDE MIRROR SWITCH
DOOR KEY CYLINDER SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . S–26
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . S–15 REARVIEW MIRROR . . . . . . . . . . . . . . . . . . . . . . . . S–27
DOOR LOCK-LINK SWITCH REARVIEW MIRROR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . S–15 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–27
DOOR LOCK-LINK SWITCH INSPECTION . . . S–15 REAR WINDOW DEFROSTER . . . . . . . . . . . . . . . S–27
DOOR LOCK ACTUATOR REAR WINDOW DEFROSTER SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . S–15 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–27
DOOR LOCK ACTUATOR INSPECTION . . . . . S–16 REAR WINDOW DEFROSTER SWITCH
DOOR LOCK TIMER UNIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . S–27
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . S–16 FILAMENT INSPECTION . . . . . . . . . . . . . . . . . . S–27/28
DOOR LOCK TIMER UNIT INSPECTION . . . . S–17 FILAMENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . S–28
FUEL-FILLER LID AND OPENER . . . . . . . . . . . . S–19 REAR WINDOW DEFROSTER RELAY
FUEL-FILLER LID REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–28
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–19 REAR WINDOW DEFROSTER RELAY
FUEL-FILLER LID ADJUSTMENT . . . . . . . . . . S–19 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . S–28
BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–19 WINDOW GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . S–29
FRONT BUMPER WINDSHIELD REMOVAL . . . . . . . . . . . . . . . . . . S–29/30
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–19 WINDSHIELD INSTALLATION . . . . . . . . . . . . . . S–30/31
FRONT BUMPER QUARTER WINDOW GLASS
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . S–19 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–32
REAR BUMPER REAR WINDOW GLASS REMOVAL . . . . . . . . S–33
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–20 REAR WINDOW GLASS INSTALLATION . . . . S–33
REAR BUMPER DISASSEMBLY/ASSEMBLY . . S–20/21 DASHBOARD AND CONSOLE . . . . . . . . . . . . . . . S–34
S–1 CONTINUED
BONNET
PAGE 2 OF 2
BODY
DASHBOARD REMOVAL/INSTALLATION . . . S–34 C-PILLAR TRIM REMOVAL/INSTALLATION . . S–39
DASHBOARD DISASSEMBLY/ASSEMBLY . . S–35 QUARTER UPPER TRIM
DASHBOARD MEMBER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–39/40
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–36 QUARTER LOWER TRIM
COLUMN COVER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–40
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–36 BACK UPPER TRIM
FRONT CONSOLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–40
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–36 BACK LOWER TRIM
FRONT CONSOLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–40
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . S–36 FRONT DOOR TRIM
REAR CONSOLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–41
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–36 REAR DOOR TRIM
REAR CONSOLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–41
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . S–37 HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–42
GLOVE COMPARTMENT HEADLINER REMOVAL/INSTALLATION . . . . . S–42
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–37 FLOOR COVERING . . . . . . . . . . . . . . . . . . . . . . . . . S–42
METER HOOD FLOOR COVERING
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–37 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–42/43
TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–38 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–44
A-PILLAR TRIM SEAT BELT REMOVAL/INSTALLATION . . . . . . S–44/45
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REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–38 SEAT BELT INSPECTION . . . . . . . . . . . . . . . . . S–45/46
B-PILLAR TRIM BUCKLE REMOVAL/INSTALLATION . . . . . . . . . S–46
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–38 BUCKLE SWITCH INSPECTION . . . . . . . . . . . . S–47
B-PILLAR LOWER TRIM SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S–48
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–38 FRONT SEAT REMOVAL/INSTALLATION . . . . S–48
B-PILLAR UPPER TRIM FRONT SEAT DISASSEMBLY/ASSEMBLY . . . S–49/50
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–38 CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . S–51
FRONT SIDE TRIM REAR SEAT REMOVAL/INSTALLATION . . . . . S–51/52
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–39 REAR SEAT DISASSEMBLY/ASSEMBLY . . . . S–52/53
FRONT SCUFF PLATE SEAT WARMER SWITCH REMOVAL . . . . . . . S–54
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–39 SEAT WARMER SWITCH INSTALLATION . . . S–54
REAR SCUFF PLATE SEAT WARMER SWITCH INSPECTION . . . . . S–54
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S–39 SEAT WARMER UNIT INSPECTION . . . . . . . . S–54

TO. MODEL .INDEX
BONNET
3.0—3.9
{30—40,
27—34}
Warning Á
D Removing the bonnet without supporting it
can be dangerous. The bonnet may fall and
injure you. Always perform these
procedures together with at least another
person. À A
Â
A
BONNET REMOVAL/INSTALLATION
1. Pull out the windshield washer pipe. Å Ä
2. To remove the bonnet hinge, remove the front Ã
fender panel.
(Refer to FRONT FENDER PANEL, FRONT
FENDER PANEL REMOVAL/INSTALLATION.)
3. To remove the bonnet lock, remove the radiator Æ
grille. 7.9—10.7
{80—110,
4. Remove in the order indicated in the table. 69.5—95.4}
6. Adjust the bonnet.
(Refer to BONNET ADJUSTMENT.)
1 Shroud seal weatherstrip

2 Bonnet
3 Bonnet hinge
4 Bonnet stay
CONTINUED
S–2
BONNET
5 Bonnet lock Height Adjustment

1. Loosen the bonnet lock installation bolts and move
6 Bonnet release lever
the bonnet lock to reposition the bonnet.
7 Bonnet release cable
BOLT
BONNET ADJUSTMENT
1. Measure the gap and height between the bonnet
and the body.
Clearance
a: 2.7—5.3 mm {0.11—0.20 in}
b: –1.8—0.8 mm {–0.07—0.03 in} (sec. A—A)
c: –2.3—0.8 mm {–0.09—0.03 in} (sec. B—B)
d: –2.3—0.3 mm {–0.09—0.01 in} (sec. C—C)
e: 6.0—10.0 mm {0.24—0.39 in}
f: 7.0—13.0 mm {0.28—0.51 in}
2. Tighten the bonnet lock installation bolts.
50 {2.0} A A
30 {1.2}
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B B
D E C C
D
E
a
e
b , c, d
f
SEC. A—A SEC. D—D SEC. E—E

SEC. B—B
SEC. C—C mm {in}
2. If not as specified, adjust the gap and height.

(Refer to Gap Adjustment.)
(Refer to Height Adjustment.)
Gap Adjustment
1. Loosen the bonnet installation bolts and reposition
the bonnet.
BOLT
2. Tighten the bonnet installation bolts. CONTINUED
S–3
FRONT FENDER PANEL
FRONT FENDER PANEL

FRONT FENDER PANEL REMOVAL/INSTALLATION
2. Remove the front side turn light.
3. Remove the front bumper.
4. Remove the front turn light.
5. Remove the front flap.
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A
6.87—9.80 N·m
{70—100 kgf·cm,
60.8—86.7 in·lbf}
1 Mud guard
2 Front fender panel
CONTINUED
S–4
DOOR
DOOR Front Door Harness Removal Note
FRONT DOOR REMOVAL/INSTALLATION 1. Disconnect the connectors indicated in the table,
1. Disconnect the negative battery cable. if equipped.
2. Remove the door screen. Connector name
(Refer to FRONT DOOR Symbol
Driver's side Passenger's side
A Door lock-link switch Door lock actuator
3. To remove the front door hinge, remove the front
fender panel. Power window main Power window
B switch subswitch
(Refer to FRONT FENDER PANEL, FRONT
FENDER PANEL REMOVAL/INSTALLATION.) Power outside
4. To remove the checker, remove the speaker.
C
mirror
←
(Refer to section T, AUDIO, SPEAKER Front power window
REMOVAL/INSTALLATION.) D
regulator ←
5. Remove in the order indicated in the table. E Speaker ←
7. Adjust the front door. 2. Disengage the clips.
(Refer to FRONT DOOR ADJUSTMENT.)
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3. Remove the rubber boot and pull out the door
harness.
1 Front door harness

☞ Removal Note
2 Checker pin
3 Front door hinge
4 Front door
5 Checker
CONTINUED
S-5
DOOR
FRONT DOOR DISASSEMBLY/ASSEMBLY

1. Raise the rear edge of the front door glass 80 mm {3.1 in} from the fully lowered position.
3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.)
4. To remove the inner handle, peel off the door screen partially.
WITHOUT POWER WINDOW SYSTEM AND POWER DOOR LOCK SYSTEM
B
A
D
E
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6.87–9.80 H
{70–100, 60.8–86.7} 4.3–6.1
C {43–63,
38–54}
C
6.87–9.80 {70–100, 60.8–86.7}
WITH POWER WINDOW SYSTEM AND H

E
POWER DOOR LOCK SYSTEM
F A
8.9–12.7 J
{90–130, 79–112}
G
I 4.3–6.1
F
{43–63, 2.0–2.9 {20–30, 18–26}
38–54}
6.87–9.80
G {70–100, 60.8–86.7}
J
1 Inner handle 8 Front power window regulator

2 Door screen 9 Outer handle
3 Front door glass 10 Retainer
4 Glass run channel 11 Door key cylinder
5 Front glass guide 12 Front door lock (manual)
6 Rear glass guide 13 Front door lock (power)
7 Front manual window regulator 14 Door lock knob
CONTINUED
S–6
DOOR
FRONT DOOR ADJUSTMENT

1. Measure the clearance between the door and the 22—30
{2.2—3.1, 16—22}
body.
Clearance
a: 4.0—6.0 mm {0.16—0.23 in}
b: –1.5—1.0 mm {–0.059—0.039 in}
c: –2.0—0.5 mm {–0.078—0.019 in}
d: 4.5—8.5 mm {0.18—0.33 in}
e: 1.2 mm {0.047 in}
f: 3.5—6.5 mm {0.14—0.25 in}
g: 2.7 mm {0.11 in}
h: 5.5 mm {0.22 in}
D
D
C 8.9—12.7 N·m
C
E E {90—130 kgf·cm,
A A 79—112 in·lbf}
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B B d N·m {kgf·m, ft·lbf}
F
F e
1 Connector
a (+) a (+)
2 Checker pin
b c
3 Rear door hinge
(–) (–) SEC. C—C
SEC. B—B 4 Rear door
SEC. A—A
(+) f 5 Checker
f
b
g
(–) h
SEC. D—D SEC. E—E SEC. F—F
2. If not as specified, loosen the door hinge

installation bolts or the door lock striker installation
screws, and move them to reposition the door.
(Refer to FRONT DOOR REMOVAL/INSTALLATION.)
(Refer to DOOR LOCK STRIKER REMOVAL/INSTALLATION.)
3. Tighten the bolts or the screws.
REAR DOOR REMOVAL/INSTALLATION

2. Remove the door screen.
(Refer to REAR DOOR DISASSEMBLY/ASSEMBLY.)
3. To remove the checker, remove the ashtray
bracket.
(Refer to REAR DOOR DISASSEMBY/ASSEMBLY.)
6. Adjust the rear door.
(Refer to REAR DOOR ADJUSTMENT.) CONTINUED
S–7
DOOR
REAR DOOR DISASSEMBLY/ASSEMBLY

1. Close the rear door glass completely.
3. Remove the rear door trim. (Refer to TRIM, REAR DOOR TRIM REMOVAL/INSTALLATION.)
WITH POWER WINDOW SYSTEM
E
6.87—9.80
{70—100, 60.8—86.7} WITHOUT POWER WINDOW SYSTEM
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6.87—9.80
{70—100,
60.8—86.7}
B
2.5—3.5
{25—36, 22—31}
B 4.3—6.1
{43—63, 38—54}
D
A
C
D
6.87—9.80
{70—100, 60.8—86.7} C
1 Inner handle 7 Rear door glass

2 Door screen + Removal Note
3 Ashtray bracket 8 Glass run channel
4 Glass hole lid 9 Glass guide
5 Rear manual window regulator 10 Door lock knob
6 Rear power window regulator 11 Rear door lock

12 Outer handle
CONTINUED
S–8
DOOR
Rear Door Glass Removal Note DOOR LOCK STRIKER REMOVAL/INSTALLATION

D Draw out the rear door glass through the glass 1. Remove the screws.
hole. 2. Remove the door lock striker.
DOOR LOCK
STRIKER
SCREW 18–26
{1.8–2.7,
14–19}
REAR DOOR
REAR DOOR GLASS

REAR DOOR ADJUSTMENT 3. Install in the reverse order of removal.

1. Measure the clearance between the door and the
body. REGULATOR HANDLE REMOVAL
1. Remove the regulator handle clip using a rag as
Clearance shown.
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a: 3.5—6.5 mm {0.14—0.25 in}
b: –1.5—1.0 mm {–0.059—0.039 in}
c: 5.5 mm {0.22 in}
DD
A A
E E
B B
RAG
CLIP
C
C 2. Remove the regulator handle.
a a
(+) (+)
REGULATOR HANDLE INSTALLATION
b b
1. Install the clip in the regulator handle.
(–) (–) c 2. Set the door glass at the fully raised position and
push the regulator handle on as shown.
SEC. A–A SEC. B–B SEC. C–C
(+) a (+) a
b b
(–) (–)
SEC. D–D SEC. E–E
2. If not as specified, loosen the door hinge

installation bolts or the door lock striker installation CLIP FRONT
screws, and move them to reposition the door.
(Refer to REAR DOOR REMOVAL/INSTALLATION.)
(Refer to DOOR LOCK STRIKER REMOVAL/INSTALLATION.)
3. Tighten the bolts or screws.
CONTINUED
S–9
POWER WINDOW SYSTEM
POWER WINDOW SYSTEM POWER WINDOW MAIN SWITCH INSPECTION

Regular Cab, Stretch Cab
POWER WINDOW MAIN SWITCH 1. Remove the switch panel. (Refer to POWER
REMOVAL/INSTALLATION WINDOW MAIN SWITCH
1. Disconnect the negative battery cable. REMOVAL/INSTALLATION.)
2. Disengage the clip using a tape-wrapped flathead 2. Inspect for continuity between the power window
screwdriver. main switch terminals using an ohmmeter.
3. Pull the switch panel forward, and disengage the 3. When inspecting the driver’s side, connect the
hook. battery positive voltage to terminal F and connect
the ground to terminal D.
4. When inspecting the passenger’s side, turn the
power-cut switch to ON.
Power window switch

Driver’s side
: Continuity
BODY Switch Terminal
SWITCH PANEL
position F D A (H) B (I)
BODY
CLIP HOOK Manual close
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Off
Auto open
Manual open
( ): R.H.D.
Passenger’s side
: Continuity
Switch Terminal
position F D H (A) I (B)
4. Disconnect the power window main switch Close

connector.
5. Remove the screws to remove the power window Off
main switch from the switch panel.
Open
SWITCH PANEL ( ): R.H.D.
Power-cut switch
: Continuity
POWER
WINDOW Switch Terminal
MAIN SWITCH position D A (H) B (I) H (A) I (B)
ON
OFF
( ): R.H.D.
SCREW

CONTINUED
S–10
POWER WINDOW SYSTEM
Rear left
: Continuity
F
POWER-CUT SWITCH Switch Terminal
D position
MANUAL A H K I
OPEN
MANUAL OPEN Close
CLOSE
CLOSE
AUTO AUTO Off
CIRCUIT OPEN
O en
Open
H (A) I (B) ( ): R.H.D.

PASSENGER’S
SIDE Rear right
OPEN
: Continuity
CLOSE
Switch Terminal
A (H) B (I) position A H E C
DRIVER’S SIDE
Close
H ∗ ∗ A
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I F D B Off
( ) : R.H.D.
O en
Open
5. If not as specified, replace the power window main
( ): R.H.D.
switch.
Power-cut switch
Double Cab
: Continuity
1. Remove the switch panel.
(Refer to POWER WINDOW MAIN SWITCH Terminal
REMOVAL/INSTALLATION.) Switch L J D
2. Inspect for continuity between the power window position B
H (D (B (L E C K I
main switch terminals using an ohmmeter. (J)
) ) )
3. When inspecting the driver’s side, connect the ON
battery positive voltage to terminal A (L.H.D.) or F
(R.H.D.) and connect the ground to terminal H. OFF
4. When inspecting the passenger’s side and rear, ( ): R.H.D.
turn the power-cut switch to ON.
L.H.D.
Power window switch
Driver’s side
: Continuity
Switch Terminal
position A (F) H L (D) J (B)
Manual close A
H
Off
Auto open
Manual open
( ): R.H.D.
Passenger’s side D B K I E C
: Continuity PAS-
SENGER’S RIGH
Switch Terminal T
position A (F) H D (L) B (J)
J
Close
Off
Open
O en
( ): R.H.D. CONTINUED
S–11
POWER WINDOW SYSTEM
R.H.D. Rear
2. Remove the hook by inserting a tape-wrapped,
flathead screwdriver between the switch and the
rear door trim.
F A
H
HOOK
J E C K I
PAS-
SENGER’S
POWER WINDOW
K I E C A SUBSWITCH
D B
L J H F D B 3. Disconnect the connector, and remove the power
window subswitch.
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POWER WINDOW SUBSWITCH INSPECTION
1. Remove the power window subswitch. (Refer to
POWER WINDOW SUBSWITCH
5. If not as specified, replace the power window main REMOVAL/INSTALLATION.)
switch. 2. Inspect for continuity between the power window
subswitch terminals using an ohmmeter.
POWER WINDOW SUBSWITCH
REMOVAL/INSTALLATION Passenger’s side
Passenger’s side : Continuity
1. Disconnect the negative battery cable. Terminal
Switch position
2. Disengage the clip using a tape-wrapped flathead A B D E F
screwdriver.
3. Pull the power window subswitch forward, and Off
disengage the hook.
Close
Open
O en
BODY
CLIP
POWER
WINDOW
BODY SUBSWITCH E A
CLOSE F D B
OPEN
HOOK
Rear
: Continuity
Terminal
Switch position
A B D E F
Close
Off
4. Disconnect the power window subswitch
connector. Open
CONTINUED
S–12
POWER WINDOW SYSTEM
F B
D
F E D B A
CLOSE
OPEN
E A
3. If not as specified, replace the power window

subswitch.
FRONT POWER WINDOW REGULATOR

1. Raise the rear edge of the front door glass 80 mm
{3.1 in} from the fully lowered position.
2. Disconnect the negative battery cable. 3.0—4.9 N·m
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3. Remove the front glass guide and the rear glass {30—50 kgf·cm,
guide. 27—43 in·lbf}
(Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.)
5. Install in the reverse order of removal. 1 Bolt
2 Power window motor
+ Disassembly Note
+ Assembly Note
B 3 Frame
A
8.9—12.7 Power Window Motor Disassembly Note
{90—130, 79—112} D
D Make marks on the gear and base of the frame
C
before disassembling the power window motor.
A
B
BASE
MARK
D
C
6.87—9.80
{70—100, 60.8—86.7}
GEAR
Power Window Motor Assembly Note

D Align the marks of the gear and the frame to install
the power window motor.
1 Front power window regulator connector
2 Bolt REAR POWER WINDOW REGULATOR
3 Nut 1. Raise the rear door glass completely.
4 Front power window regulator 2. Disconnect the negative battery cable.
FRONT POWER WINDOW REGULATOR (Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.)
DISASSEMBLY/ASSEMBLY 4. Remove in the order indicated in the table.
1. Disassemble in the order indicated in the table. 5. Install in the reverse order of removal.
CONTINUED
S–13
POWER WINDOW SYSTEM
Power Window Motor Disassembly Note

D Make marks on the gear and base of the frame
before disassembling the power window motor.
MARK
A
BASE GEAR
D
C 6.87—9.80 N·m Power Window Motor Assembly Note
{70—100 kgf·cm, D Align the marks of the gear and base of the frame
60.8—86.7 in·lbf} to install the power window motor.
POWER WINDOW MOTOR INSPECTION
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1. Remove the power window motor.
(Refer to FRONT POWER WINDOW
REGULATOR DISASSEMBLY/ASSEMBLY.)
(Refer to REAR POWER WINDOW REGULATOR
1 Rear power window regulator connector DISASSEMBLY/ASSEMBLY.)
2 Bolt 2. Apply battery positive voltage to the power window
3 Rear power window regulator motor terminals and inspect the operation of the
power window motor.
REAR POWER WINDOW REGULATOR B+: Battery positive voltage
DISASSEMBLY/ASSEMBLY Connection
Motor operation
1. Disassemble in the order indicated in the table. B+ GND
A B Up
3.1—4.8 N·m
{31—49 kgf·cm, 27—42 in·lbf} B A Down
UP DOWN
A B
3. If not as specified, replace the power window

motor.
1 Bolt
2 Power window motor
+ Disassembly Note
+ Assembly Note
3 Frame
CONTINUED
S–14

DOOR LOCK-LINK SWITCH
Note
• The door lock-link switch is mounted to the
driver-side door lock.

2. Remove the driver-side door lock.
(Refer to DOOR, FRONT DOOR 5. If not as specified, replace the door lock-link
DISASSEMBLY/ASSEMBLY.) switch.
3. Remove the screws. DOOR LOCK ACTUATOR
4. Remove the door lock-link switch from the front REMOVAL/INSTALLATION
door lock. Front
Note
• The front door lock actuator is mounted to
the passenger-side door lock.
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2. Remove the passenger-side door lock.
(Refer to DOOR, FRONT DOOR
3. Remove the screws.
4. Remove the front door lock actuator from the
front door lock.
DOOR LOCK-LINK SWITCH INSPECTION

2. Remove the driver-side door screen.
3. Disconnect the door lock-link switch connector.
4. Inspect for continuity between the door lock-link
switch terminals using an ohmmeter.
CONTINUED
S-15
Rear
Note
• The rear door lock actuator is mounted to the
rear door lock.
2. Remove the rear door lock.
(Refer to DOOR, REAR DOOR
4. Disconnect the rod. 5. If not as specified, replace the door lock actuator.
5. Remove the rear door lock actuator from the rear
door lock.
DOOR LOCK TIMER UNIT
2. Remove the flasher unit.
(Refer to section T, EXTERIOR LIGHTING SYSTEM,
FLASHER UNIT REMOVAL/INSTALLATION.)
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DOOR LOCK ACTUATOR INSPECTION

(Refer to DOOR, REAR DOOR
1 Door lock timer unit connector
3. Disconnect the door lock actuator connector. 2 Nut
4. Apply battery positive voltage to the door lock 3 Bracket
actuator terminals and inspect the operation of the
door lock actuator. 4 Door lock timer unit

Terminal
Actuator operation
A B
GND B+ Lock
B+ GND Unlock
CONTINUED
S-16

DOOR LOCK TIMER UNIT INSPECTION
1. Remove the flasher unit.
(Refer to section T, EXTERIOR LIGHTING SYSTEM, FLASHER UNIT REMOVAL/INSTALLATION.)
2. Measure the voltage at the door lock timer unit terminals as indicated below.
3. Disconnect the door lock timer unit connector before inspecting for continuity at terminals A, C, D, and H.
4. If not as specified, inspect the parts listed under "Inspection area" and the related wiring harnesses.
5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the door lock
timer unit.
Terminal Voltage List (Reference)

Voltage (V)
Terminal Signal Connection Test condition Inspection area
/Continuity
A GND Body ground Constant: inspect for continuity to ground Yes -
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B Power supply D/L 30 A fuse Constant B+ D/L 30 A fuse
Door lock-link switch is at lock: inspect
No
Door lock-link for continuity to terminal H Door lock-link
C Unlock input
switch Door lock-link switch is at unlock: inspect switch
Yes
for continuity to terminal H
Door lock-link switch is at lock: inspect
Yes
Door lock-link for continuity to terminal H Door lock-link
D Lock input
switch Door lock-link switch is at unlock: inspect switch
No
for continuity to terminal H
Door lock Door lock actuators are locked 0 → B+ → 0 Door lock
E Lock output
actuator Other 0 actuator
Door lock Door lock actuators are unlocked 0 → B+ → 0 Door lock
F Unlock output
actuator Other 0 actuator
G - Not used - - -
Terminal A of
Constant: inspect for continuity to
H GND door lock timer Yes -
terminal A
unit
CONTINUED
S-17
FUEL-FILLER LID AND OPENER, BUMPER
FUEL-FILLER LID AND OPENER BUMPER

FUEL-FILLER LID REMOVAL/INSTALLATION FRONT BUMPER REMOVAL/INSTALLATION
1. Remove as indicated in the table. 1. Remove in the order indicated in the table.
2. Install in the reverse order of removal. 2. Install in the reverse order of removal.
63—93 {6.4—9.5, 47—68}

6.87—9.80 N·m
{70—100 kgf·cm,
60.8—86.7 in·lbf}
1 Fuel-filler lid
FUEL-FILLER LID ADJUSTMENT
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1. Measure the gap and height between the fuel-filler 6.87—9.80 N·m
{70—100 kgf·cm,
lid and the body. 60.8—86.7 in·lbf}
Clearance
a: 3.5—5.5 mm {0.14—0.21 in}
63—93 {6.4—9.5, 47—68}
b: –0.5—2.0 mm {–0.01—0.07 in}
A
1 Front bumper
a
2 Front bumper stay
FRONT BUMPER DISASSEMBLY/ASSEMBLY

b
A
0.2—0.8 {2—9, 2—7}

SEC.A–A
2. If not as specified, loosen the fuel-filler lid

installation bolts and reposition the fuel-filler lid. 6.87—9.80 {70—100, 60.8—86.7}
3. Tighten the fuel-filler lid installation bolts.
0.2—0.3 {2—4, 2—3} 12345678
1 Front bumper side fascia

2 Front bumper upper fascia
3 Front bumper lower fascia
CONTINUED
S–19
BUMPER
REAR BUMPER REMOVAL/INSTALLATION REAR BUMPER DISASSEMBLY/ASSEMBLY

With Step With Step
1. Remove the bolts, then remove the rear bumper. 1. Disassemble in the order indicated in the table.
6.87—9.80 N·m
{70—100 kgf·cm,
60.8—86.7 in·lbf}
32—46
{3.2—4.7,
24—33}
A
B A
6.87—9.80 N·m
BOLT REAR BUMPER {70—100 kgf·cm,
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79—116 60.8—86.7 in·lbf} A
{8.0—11.9, B
58.0—86.0}
0.30—0.78 N·m
{3.0—8.0 kgf·cm, B
2.7—6.9 in·lbf}
1 Side bumper step
Without Step + Removal Note
2 Center bumper step
2. Disconnect the rear fog light connector.
+ Removal Note
4. Install in the reverse order of removal. 3 Rear bumper fascia
4 Rear bumper stay
5 Rear bracket
6 Set plate
Side Bumper Step Removal Note

1. Disengage clips A using pliers.
2. Pull the side bumper step upward, then remove it.
A A A A
A A
SIDE BUMPER STEP
79—116
{8.0—11.9,
58.0—86.0} 16—22 CLIP A
{1.6—2.3,
12—16} Center Bumper Step Removal Note
2. Disengage clips A using pliers.
3. Disengage clips B, then remove the center bumper
1 Rear bumper stay step. 12345678
3 Rear bumper fascia CONTINUED
S–20
BUMPER, EXTERIOR ATTACHMENT
SCREW SCREW
B B B B EXTERIOR ATTACHMENT
A A A RADIATOR GRILLE REMOVAL/INSTALLATION
1. Pull the radiator grille toward you, then disengage
clips A to remove the radiator grille.
A A A A A A A A
SCREW CENTER BUMPER STEP SCREW
A A A
CLIP B CLIP A
CLIP
RADIATOR GRILLE
COWL GRILLE REMOVAL/INSTALLATION
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1. Remove the windshield wiper arm and blade.
(Refer to section T, WIPER AND WASHER,
WIPER ARM AND BLADE
2. Remove the weatherstrip.
3. Remove the screws, then remove the cowl grille.
SCREW
COWL GRILLE
WEATHERSTRIP
WINDSHIELD GARNISH REMOVAL/INSTALLATION

2. Pull the windshield garnish upward, then
disengage hook A from the cowl grille.
CONTINUED
S–21
EXTERIOR ATTACHMENT
CENTER SIDE
PROTECTOR
(REGULAR CAB)
FRONT SIDE PROTECTOR
b d d d
c a ca
e
SCREW
a a c c a
c
DOUBLE-SIDED ADHESIVE TAPE
WINDSHIELD CENTER SIDE
GARNISH REAR SIDE PROTECTOR
PROTECTOR
COWL GRILLE (STRETCH CAB)
d d d
b
a c c a
A e e e
A c a a c a
c c c
HOOK
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1. Install in the reverse order of removal. 4. Peel off the backing paper from the double-sided
adhesive tape and attach the side protector onto
SIDE PROTECTOR REMOVAL the body as shown.
Warning Clearance
D Using a razor knife with bare hands can a : 4.8—5.8 mm {0.19—0.22 in}
cause injury. Always wear gloves when b : 5.0—6.0 mm {0.20—0.23 in}
using a razor knife. c : 13.0—14.0 mm {0.51—0.55 in}
d : 16.5—17.0 mm {0.65—0.66 in}
1. Pry the side protector end 20—30 mm {0.8—1.1 e : 12.3—13.3 mm {0.49—0.52 in}
in} using a flathead screwdriver or a razor knife. f : 6.0—8.0 mm {0.24—0.31 in}
2. Pull the side protector, then remove it.
Regular Cab
Note
D The side protector is installed with CENTER SIDE PROTECTOR
double-sided adhesive tape. If the side
REAR SIDE f
protector is difficult to remove, soften the FRONT SIDE PROTECTOR
PROTECTOR
double-sided adhesive tape using a hot air a
blower. A
A
b
SIDE PROTECTOR INSTALLATION c
1. Remove the adhesive remaining on the side
protector (if it will be reused) and the body using a
SEC. A—A
razor knife.
2. Remove any grease or dirt from the adhesion
surface of the side protector (if it will be reused)
and the body. Stretch Cab
3. Attach double-sided adhesive tape to the side
protector as shown (if it will be reused). CENTER SIDE PROTECTOR
REAR SIDE f
Clearance FRONT SIDE PROTECTOR
PROTECTOR
a : 0—3.0 mm {0—0.11 in} a
b : 37.5 mm {1.48 in} A
c : 10.0 mm {0.39 in} A b d
d : 2.0—5.0 mm {0.08—0.19 in}
e : 25.0 mm {0.98 in}
SEC. A—A
CONTINUED
S–22
EXTERIOR ATTACHMENT
Double Cab
NUT
REAR SIDE PROTECTOR

FRONT SIDE PROTECTOR f
A e
A b
TAILGATE LOCK ROD

SEC. A—A
5. Remove the bolts, then remove the latch guide,

5. After installing the side protector to the body, apply latch and rod.
pressure of 50 N·m {5.0 kgf·m, 37 ft·lbf} or more
with a roller, etc. BOLT ROD
OVER FENDER REMOVAL/INSTALLATION LATCH GUIDE

2. Remove the fasteners.
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3. Disengage clips A of the over fender using a
fastener remover, then remove the over fender. LATCH
FRONT
CLIP
A A A
A
A
6. Remove the handle.
A 7. Assemble in the reverse order of disassembly.
TAILGATE ADJUSTMENT
OVER FENDER 1. Loosen the bolts.
FASTENER 2. Move the striker forward and rearward until the
tailgate will lock properly.
REAR
SCREW 3. After the correct adjustment is made, tighten the
A
A A bolts securely.
CLIP
A
A
BOLT
A
A
OVER FENDER STRIKER
SCREW
FASTENER
TAILGATE DISASSEMBLY/ASSEMBLY
1. Remove the cover.
2. Remove the nuts attaching the tailgate lock.
3. Disconnect the rods from the tailgate lock.
4. Remove the tailgate lock.
CONTINUED
S–23
EXTERIOR ATTACHMENT, MOLDING
ROPE HOOK REMOVAL/INSTALLATION MOLDING

1. Remove the screws and bolts, then remove the
rope hook. WINDSHIELD UPPER MOLDING REMOVAL
D Remove the windshield upper molding from the
windshield. (Refer to WINDOW GLASS,
WINDSHIELD REMOVAL.)
WINDSHIELD UPPER MOLDING INSTALLATION

ROPE HOOK D Install the windshield upper molding to the
SCREW
WINDSHIELD INSTALLATION.)
WINDSHIELD SIDE MOLDING REMOVAL

D Remove the windshield side molding from the
WINDSHIELD REMOVAL.)
ROPE HOOK WINDSHIELD SIDE MOLDING INSTALLATION
D Install the windshield side molding to the
WINDSHIELD INSTALLATION.)
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BOLT
FRONT BELTLINE MOLDING
1. Lower the front door glass fully.
2. Remove the manual outside mirror or the power
outside mirror.
2. Install in the reverse order of removal. (Refer to OUTSIDE MIRROR, MANUAL
OUTSIDE MIRROR REMOVAL/INSTALLATION.)
(Refer to OUTSIDE MIRROR, POWER OUTSIDE MIRROR
3. Pull the rear end of the front beltline molding to
disengage the hook.
FRONT BELTLINE MOLDING
HOOK
4. Pull the front beltline molding upward, then remove

clips A.
BELTLINE
MOLDING
CLIP
A A A
CONTINUED
S–24
MOLDING, OUTSIDE MIRROR
REAR BELTLINE MOLDING OUTSIDE MIRROR

1. Lower the rear door glass fully. MANUAL OUTSIDE MIRROR
2. Pull the rear end of the rear beltline molding to REMOVAL/INSTALLATION
disengage the hook. 1. Remove the inner garnish.
2. Remove the front door trim. (Refer to TRIM,
REAR BELTLINE MOLDING FRONT DOOR TRIM REMOVAL/INSTALLATION.)
4. Remove the manual outside mirror.
MANUAL OUTSIDE MIRROR
SCREW
HOOK
3. Pull the rear beltline molding upward, then remove

clips A.
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A 5. Install in the reverse order of removal.
POWER OUTSIDE MIRROR

BELTLINE REMOVAL/INSTALLATION
MOLDING
CLIP 1. Disconnect the negative battery cable.
2. Remove the inner garnish.
A A
A
FRONT DOOR TRIM REMOVAL/INSTALLATION.)
4. Partially peel off the door screen.
5. Disconnect the power outside mirror connector.
4. Install in the reverse order of removal. 7. Remove the power outside mirror.
ROOF MOLDING REMOVAL/INSTALLATION POWER OUTSIDE MIRROR
1. Pull the rear edge of roof molding upward, then SCREW
disengage clips A.
A
A
A
ROOF MOLDING
ROOF MOLDING
POWER OUTSIDE MIRROR
CLIP CONNECTOR
BODY
A
POWER OUTSIDE MIRROR INSPECTION
2. Install in the reverse order of removal. 2. Remove the inner garnish.
FRONT DOOR TRIM REMOVAL/INSTALLATION.)
4. Partially peel off the door screen.
5. Disconnect the power outside mirror connector.
6. Apply battery positive voltage to the power outside
mirror and inspect the operation of the power
outside mirror.
CONTINUED
S–25
OUTSIDE MIRROR
B+: Battery positive voltage : Continuity

Connection Mirror Switch Terminal
B+ GND operation position I L A D C B K
A C Up
Up
C A Down
C D Left Down
D C Right LH
Left
C A D
Right
Up
DOWN UP Down 123456567

* RH
M
RIGHT
LEFT Left
M
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Right
1. If not as specified, replace the power outside

mirror.
POWER OUTSIDE MIRROR SWITCH

2. Remove the fuse block cover.
3. Remove the fuse block installation screws, and
push the fuse block into the dashboard.
4. Insert your hand into the hole for the fuse block,
and press the hooks of the power outside mirror
switch.
5. Push the power outside mirror switch out, then
remove it.
6. Disconnect the power outside mirror switch
connector.
POWER OUTSIDE
MIRROR SWITCH
POWER
OUTSIDE
MIRROR
SWITCH
CONNECTOR
3. If not as specified, replace the power outside mirror
switch.
POWER OUTSIDE MIRROR SWITCH INSPECTION

1. Remove the power outside mirror switch.
(Refer to POWER OUTSIDE MIRROR SWITCH
2. Inspect for continuity between the power outside
mirror switch terminals using an ohmmeter.
CONTINUED
S–26
REARVIEW MIRROR, REAR WINDOW DEFROSTER
REARVIEW MIRROR REAR WINDOW DEFROSTER

REARVIEW MIRROR REMOVAL/INSTALLATION REAR WINDOW DEFROSTER SWITCH
Regular Cab REMOVAL/INSTALLATION
Note 2. Remove the meter hood.
D The rearview mirror is attached to the interior 3. Press the hooks of the rear window defroster
light. switch and push the switch out.
(Refer to section T, INTERIOR LIGHTING SYSTEM,
INTERIOR LIGHT REMOVAL/INSTALLATION, Regular Cab.)
Stretch Cab, Double Cab

2. Install in the reverse order of removal. HOOK
REAR WINDOW
DEFROSTER
SWITCH METER HOOD
2.0—3.9
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{20—40, 18—34}
REAR WINDOW DEFROSTER SWITCH

INSPECTION
N·m {kgf·cm, in·lbf} 1. Remove the rear window defroster switch.
2. Inspect for continuity between the rear window
defroster switch terminals using an ohmmeter.
1 Cover : Continuity : Bulb
2 Screw Switch Terminal
3 Rearview mirror position A B C D
ON
OFF
D A
: C A
: D B
C B
3. If not as specified, replace the rear window

defroster switch.
FILAMENT INSPECTION
1. Turn the ignition switch to ON position.
2. Turn the rear window defroster switch on.
Caution
D Directly touching the rear window defroster
filament with the lead of the circuit tester
will damage it. Wrap aluminum foil around
the end of the lead and test the filament by
touching it with the foil.
CONTINUED
S–27
REAR WINDOW DEFROSTER
Caution
LEAD OF THE CIRCUIT TESTER D Do not use the rear window defroster until
the paint is completely dry. It may cause
PUSH
other malfunctions if it is used before the
paint is dry.
5. Use a hot air blower heated to 150°C {302°F} for

FILAMENT
30 minutes or let the paint set for 24 hours at
25°C {77°F} to allow it to dry completely.
ALUMINUM FOIL REAR WINDOW DEFROSTER RELAY

1. Connect the positive ()) lead of the voltmeter to 1. Disconnect the negative battery cable.
the positive side of each filament and the negative 2. Disconnect the rear window defroster relay
(*) lead to ground. connector.
2. Gradually, slide the positive ()) lead from the 3. Slide the rear window defroster relay upward, then
positive side to the negative side and measure the remove it.
voltage. Verify that the voltage decreases
accordingly.
Measurement place Voltage (Reference value)
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REAR
(1) (2) Approx. 12 V Approx. 0 V WINDOW
DEFROSTER
RELAY
REAR WINDOW
DEFROSTER RELAY CONNECTOR
(2) (1)
NEGATIVE POSITIVE 4. Install in the reverse order of removal.
SIDE SIDE
REAR WINDOW DEFROSTER RELAY INSPECTION
1. Remove the rear window defroster relay.
(Refer to REAR WINDOW DEFROSTER
RELAY REMOVAL/INSTALLATION.)
3. If the voltage is not as specified or it changes 2. Inspect for continuity between the rear window
rapidly, the filament is faulty. Repair the filament. defroster relay terminals using an ohmmeter.
: Continuity B+: Battery positive voltage
FILAMENT REPAIR Terminal
1. Use white gasoline to clean around the damaged Step
A B C D
section of the filament.
2. Attach tape above and below the damaged section 1
of the filament. 2 B) GND
BROKEN FILAMENT TAPE
D A
C A
D B
SECTION TO BE REPAIRED
C B
3. Using a small brush or marking pen, repair the 3. If not as specified, replace the rear window
filament with silver paint or equivalent. defroster relay.
4. After approximately 2—3 minutes, carefully
remove the tape without disturbing the repaired
area.
CONTINUED
S–28
WINDOW GLASS
WINDOW GLASS Reusing Windshield

1. Make a hole through the sealant from the inside of
WINDSHIELD REMOVAL the vehicle using an awl.
1. Remove the cowl grille. 2. Pass the SST (piano wire) through the hole.
(Refer to EXTERIOR ATTACHMENT, PROTECTIVE TAPE 49 0305 870A
COWL GRILLE REMOVAL/INSTALLATION.)
2. Apply protective tape to the headliner, the body WINDSHIELD UPPER
and the dashboard. MOLDING R
Warning SEALANT
D Using a razor knife with bare hands can WINDSHIELD
cause injury. Always wear gloves when
using a razor knife. DAM
Note HEADLINER
D The windshield upper molding and windshield PROTECTIVE TAPE
side molding are replacement parts.
3. Wind each end of the wire around a bar.
3. Cut the lip of the windshield upper molding using a
razor knife. Note
D Use the entire length of piano wire to prevent it
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from breaking when cutting through the
WINDSHIELD
R UPPER MOLDING
sealant.
PROTECTIVE
TAPE
4. Working with another person, saw through the
sealant around the edge of the glass, being careful
not to damage the body.
LIP
Not Reusing Windshield
Warning
D Using a piano wire with bare hands can
cause injury. Always wear gloves when 49 0305 870A
using a piano wire.
Note 5. Remove the windshield.

D For the areas of the sealant that are difficult to
6. Remove the spacers from the body.
cut, use a piano wire and follow the procedures 7. Remove the spacer and the dam from the glass.
under “Reusing Windshield”. CENTER
1. Use a tool like that shown in the figure, and insert

the blade into the sealant.
2. Pull through the sealant around the edge of the DAM R
glass.
SPACER R
8. Remove the windshield upper molding and the

windshield side molding from the windshield.
3. Remove the windshield.

4. Remove the spacers from the body.
CONTINUED
S–29
WINDOW GLASS
WINDSHIELD UPPER MOLDING GLASS MARK

R
WINDSHIELD
WINDSHIELD SIDE MOLDING R WINDSHIELD

WINDSHIELD
SIDE MOLDING
WINDSHIELD INSTALLATION 7. Securely bond a dam along the circumference of

the glass 8.5 mm {0.33 in} from the upper edge
Warning and 14.5 mm {0.57 in} from the lower and side
Using a razor knife with bare hands can edge.
cause injury. Always wear gloves when 8. Install the spacer to the glass.
using a razor knife. CENTER
8.5 {0.33}
Caution 14.5 {0.57}
To prevent the sealant from cracking or the
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6.0 {0.24}
glass from being pushed out by air
pressure if a door is closed, open all of the
DAM
windows and leave them open until the
sealant has hardened.
CERAMIC
1. Cut away the old sealant using a razor knife so that SPACER 14.5 {0.57}
PARTING
1—2 mm {0.04—0.07 in} thickness of sealant 14.5 {0.57} LINE
mm {in}
remains around the circumference of the frame. If
all the sealant has come off in any one place, apply
some primer after degreasing, and allow it 30 9. Install spacers into the hole of the body.
minutes to dry. Then put on new sealant to create 10. Temporarily install the glass onto the body and
a 2 mm {0.08 in} layer. adjust the glass to body clearance.
2. Clean and degrease an approximately 50 mm 11. Make a mark on the glass directly above the
{1.97 in} wide strip around the circumference of V-notch of spacers.
the glass and the bonding area on the body. 12. Verify that the gap along the upper edge is
3. Align the center mark on the windshield upper 7.5 mm {0.30 in}.
molding with the glass mark. BODY MARKING
7.5 {0.30}
CENTER
4. Install the windshield upper molding from the
center toward both sides.
WINDSHIELD UPPER MOLDING
MARK
SPACER
GLASS MARK
mm {in}
13. Remove the windshield.

WINDSHIELD
Caution
5. Align the upper edge of the windshield side Keep the area free of dirt and grease, and
molding with the glass mark. do not touch the surface or the primer may
6. Install the windshield side molding from the upper not properly bond to the surface of the
part towards the lower part. glass and body, which may cause leaks to
occur.
14. Use a brush to apply primer to the bonding area of

the glass and body within the region shown. Use
only glass primer on the glass and body primer on
the body and molding. Allow it to dry for
approximately 30 minutes.
CONTINUED
S–30
WINDOW GLASS
8.5 {0.33} UPPER

GLASS 14.5 {0.57}
PRIMER BODY
WINDSHIELD
GLASS
PRIMER
BODY
BODY PRIMER
PRIMER
13.0 {0.51}
DAM
19.0 {0.75}
UPPER SEALANT ADJUST SEALANT
SIDE IN THIS AREA
14.5 {0.57}
SIDE
GLASS
PRIMER BODY
PRIMER WINDSHIELD
BODY
PRIMER 19.0
{0.75}
16.0 {0.63} BODY
LOWER DAM
WINDSHIELD
SIDE MOLDING
cardiagn.com
ADJUST SEALANT
WINDSHIELD IN THIS AREA
UPPER MOLDING BODY PRIMER mm {in}
15. Once the primer is dry, apply a 11.0 mm {0.43 in} Hardening time of sealant
high, 5.0 mm {0.20 in} wide bead of sealant along Time required
the dam around the entire circumference to fill the Surface
Temperature until car can be
gap between the dam and the edge of the hardening time
put into service
windshield.
5 °C {41 °F} Approx. 1.5 h Approx. 12 h
20 °C {68 °F} Approx. 1 h Approx. 4 h
5.0
{0.20} 35 °C {95 °F} Approx. 10 min Approx. 2 h
20. Use white gasoline to remove any sealant that

11.0 oozes out.
DAM
{0.43} 21. Install the cowl grille.
(Refer to EXTERIOR ATTACHMENT,
COWL GRILLE REMOVAL/INSTALLATION.)
mm {in}
16. Align the glass marks with the V-notches in

spacers and install the glass onto the body.
17. Press firmly inward on the glass to compress the
sealant.
18. Verify that the gap along the upper and side edge
is 7.5 mm {0.30 in}.
19. Adjust the sealant as indicated in the figure.
CONTINUED
S–31
WINDOW GLASS
QUARTER WINDOW GLASS REMOVAL/INSTALLATION

Stretch Cab
1. To remove the quarter window hinge, remove the quarter upper trim.
(Refer to TRIM, QUARTER UPPER TRIM REMOVAL/INSTALLATION.)
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1 Hinge cover 4 Quarter window glass
2 Quarter window hinge 5 Quarter window glass weatherstrip
3 Quarter window lock
CONTINUED
S–32
WINDOW GLASS
REAR WINDOW GLASS REMOVAL REAR WINDOW WEATHERSTRIP

1. Remove the headliner. (Refer to HEADLINER,
HEADLINER REMOVAL/INSTALLATION.)
2. Remove the rear window defroster connector if BODY
equipped.
3. While another person presses the rear window
glass, use the SST to push the lip of the rear
window weatherstrip from the inside.
REAR WINDOW WEATHERSTRIP
SOAPY WATER
5. Align the rear window glass with the rear window

weatherstrip and body.
6. While another person lightly taps the outside of the
rear window glass near the rear window
weatherstrip all around its circumference, pull one
LIP end of the SST and install the rear window glass.
49 0259 866A
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4. After the top of the rear window weatherstrip is
removed, push the rear window glass outside and
remove it with the rear window weatherstrip
attached.
5. Remove the rear window weatherstrip from the
rear window glass.
49 0259 866A
REAR WINDOW GLASS INSTALLATION
1. Clean and degrease the body and the rear window
glass.
2. Install the rear window weatherstrip to the rear 7. Install the rear window defroster connector if
window glass. equipped.
REAR WINDOW WEATHERSTRIP 8. Install the headliner.
(Refer to HEADLINER, HEADLINER
3. Fit the SST into the rear window weatherstrip and

cross the ends as shown, leave 200 mm {7.87 in}.
REAR WINDOW WEATHERSTRIP
49 0259 866A
200 {7.87}
mm {in}
4. Apply soapy water as shown. CONTINUED
S–33
DASHBOARD AND CONSOLE

DASHBOARD REMOVAL/INSTALLATION
2. Remove the driver-side air bag module.
(Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
3. Remove the passenger-side air bag module.
(Refer to section T, AIR BAG SYSTEM, PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.)
4. Remove the steering wheel.
(Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
5. Remove the installation bolts then lower the assembled steering shaft from the dashboard.
(Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.)
6. Remove the meter hood.
7. Remove the instrument cluster.
8. Remove the front console. (Refer to FRONT CONSOLE REMOVAL/INSTALLATION.)
9. Remove the glove compartment.
10. Remove the bonnet release cable installation nut.
11. Remove the A-pillar trims. (Refer to TRIM, A-PILLAR TRIM REMOVAL/INSTALLATION.)
12. Disconnect the wires for both the blower unit and the heater unit.
(Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT REMOVAL.)
(Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT INSTALLATION.)
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13. Remove the fuse block.
16. Adjust the wires for both the blower unit and the heater unit.
(Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT ADJUSTMENT.)
7.9—11.7
{80—120, 70—104}
7.9—11.7 {80—120, 70—104}
7.9—11.7 {80—120, 70—104}
1 Bolt 2 Dashboard
CONTINUED
S–34
DASHBOARD DISASSEMBLY/ASSEMBLY
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1 Defroster nozzle 4 Duct
2 Side demister nozzle 5 Dashboard crash pad
3 Center duct
CONTINUED
S–35
DASHBOARD MEMBER REMOVAL/INSTALLATION FRONT CONSOLE DISASSEMBLY/ASSEMBLY

1. Remove the dashboard. 1. Disassemble in the order indicated in the table.
(Refer to DASHBOARD REMOVAL/INSTALLATION.) 2. Assemble in the reverse order of disassembly.
2. Remove the bolts, then remove the dashboard
member.
DASHBOARD MEMBER
16—22
{1.6—2.3, 12—16}
16—22
BOLT
{1.6—2.3,
16—22 12—16}
{1.6—2.3,
12—16}
16—22
{1.6—2.3, 12—16}
COLUMN COVER REMOVAL/INSTALLATION
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1. Remove the screws, then remove the column
cover.
COLUMN
COVER
1 Screw
2 Front console
3 Boot
4 Set plate
SCREW REAR CONSOLE REMOVAL/INSTALLATION

2. Install in the reverse order of removal. 2. Pull the rear console upward, then remove it.
FRONT CONSOLE REMOVAL/INSTALLATION

1. Remove the rear console.
2. For manual transaxle vehicle, remove the shift
lever knob.
3. Remove the screws, then remove the front
console. REAR CONSOLE
Caution
In order to prevent noise caused by
interference with the dashboard, install the
screws to the rear of the front console
before installing the front of the front
console.
FRONT CONSOLE
SCREW
SCREW

CONTINUED
S–36
REAR CONSOLE DISASSEMBLY/ASSEMBLY METER HOOD REMOVAL/INSTALLATION

1. Disassemble in the order indicated in the table. 1. Remove the screws.
2. Assemble in the reverse order of disassembly. 2. Pull the meter hood toward you, then disengage
clips A and pins B.
SCREW
A B
A B
A
A B A
A A
CLIP
B PIN
A
3. Disconnect the connectors, then remove the meter

hood.
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1 Screw
2 Console lid outer
3 Console lid inner
4 Rear console
5 Console lid lock
6 Console lid hinge
7 Console lid bracket
GLOVE COMPARTMENT REMOVAL/INSTALLATION

1. Open the glove compartment and bend the sides
inward to disengage the pins.
2. Pull the glove compartment downward, then
disengage clips A.
PIN
PIN
A
CLIP
GLOVE COMPARTMENT
A

CONTINUED
S–37
TRIM
TRIM B-PILLAR LOWER TRIM REMOVAL/INSTALLATION

Double Cab
A-PILLAR TRIM REMOVAL/INSTALLATION 1. Remove the front scuff plate.
1. Remove the quarter upper trim. (Regular cab, 2. Remove the rear scuff plate.
stretch cab) (Refer to QUARTER UPPER TRIM 3. Turn over the seaming welt.
REMOVAL/INSTALLATION.) 4. Pull the B-pillar lower trim indicated by the arrow,
2. Remove the B-pillar upper trim. (Double cab) then disengage clips A and pin B.
(Refer to B-PILLAR UPPER TRIM 5. Remove the seat belt from B-pillar trim.
REMOVAL/INSTALLATION.) 6. Pull the B-pillar lower trim upward, then disengage
3. Pull the A-pillar trim toward you, then disengage hooks C from the body.
clips A and pin B.
4. Pull the A-pillar trim upward, then disengage the
hook.
CLIP
A A A
B A-PILLAR TRIM A A
A B
CLIP PIN
PIN A
A
B
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A
A B-PILLAR
HOOK LOWER TRIM
A B
HOOK
5. Install in the reverse order of removal. C
B-PILLAR TRIM REMOVAL/INSTALLATION C

Regular Cab C
1. Turn over the seaming welt.
2. Remove the seat belt upper anchor installation
bolt.
3. Remove the back upper trim.
4. Pull the B-pillar trim toward you, then disengage 7. Install in the reverse order of removal.
clips A and pins B.
5. Remove clip C. B-PILLAR UPPER TRIM REMOVAL/INSTALLATION
6. Remove the seat belt from the B-pillar trim. Double Cab
1. Remove the B-pillar lower trim.(Refer to B-PILLAR
LOWER TRIM REMOVAL/INSTALLATION.)
B 2. Remove the front seat belt upper anchor
A A installation bolt.
3. Remove the C-pillar trim.
(Refer to C-PILLAR TRIM REMOVAL/INSTALLATION.)
CLIP
4. Remove the fastener.
A 5. Pull the B-pillar upper trim toward you, then
A disengage clips A and pins B from the body.
A
A A A
A B
PIN
CLIP C CLIP
A
B-PILLAR
B A A A
B-PILLAR TRIM B UPPER TRIM
HOOK A FASTENER
B A B

CONTINUED
S–38
TRIM
FRONT SIDE TRIM REMOVAL/INSTALLATION

1. Remove the scuff plate. SCREW
2. Loosen the nut.
3. Pull the front side trim in the direction indicated by REAR SCUFF PLATE
the arrow, then remove it. B
A
A
NUT A B
CLIP PIN

FRONT SIDE
TRIM
C-PILLAR TRIM REMOVAL/INSTALLATION
Double Cab
1. Turn over the seaming welt.
4. Install in the reverse order of removal. 2. Remove the rear seat. (Refer to SEAT, SEAT
REMOVAL/INSTALLATION, Double Cab, Rear.)
FRONT SCUFF PLATE REMOVAL/INSTALLATION 3. Remove the rear seat belt upper anchor installation
cardiagn.com
1. Remove the screws. bolt.
2. Pull the front scuff plate upward, then disengage 4. Remove the fasteners.
pin A. 5. Pull the C-pillar trim toward you, then disengage
clips A and pin B.
6. Remove the seat belt from C-pillar trim.
A A
B CLIP
SCREW
A A
PIN
A
B
PIN
C-PILLAR TRIM
A
FRONT SCUFF PLATE
FASTENER
REAR SCUFF PLATE REMOVAL/INSTALLATION 7. Pull the C-pillar trim upward, then remove it from
Double Cab the body.
1. Remove the screw. 8. Install in the reverse order of removal.
2. Pull the rear scuff plate upward, then disengage
clips A and pin B. QUARTER UPPER TRIM REMOVAL/INSTALLATION
Stretch Cab
1. Remove the back upper trim.
2. Remove the upper anchor of the seat belt.
3. Remove the quarter window lock.
(Refer to WINDOW GLASS, QUARTER
WINDOW GLASS REMOVAL/INSTALLATION.)
4. Remove the hook.
6. Pull the quarter upper trim toward you, then
disengage clips A and pins B.
CONTINUED
S–39
TRIM
BACK UPPER TRIM REMOVAL/INSTALLATION

1. Pull the back upper trim toward you, then
A A
A
B
A BACK UPPER TRIM
A CLIP
HOOK
A A B A
A B
B A
A
PIN A
A A
A A B A A
A
A
PIN A
FASTENER A
CLIP B
A
QUARTER UPPER TRIM
A
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A
B
QUARTER LOWER TRIM REMOVAL/INSTALLATION
Stretch Cab 2. Install in the reverse order of removal.
1. Remove the quarter upper trim.
(Refer to QUARTER UPPER TRIM BACK LOWER TRIM REMOVAL/INSTALLATION
REMOVAL/INSTALLATION.) 1. Remove the fasteners, then remove the back lower
2. Remove the back lower trim. trim.
4. Pull the quarter lower trim toward you, then
QUARTER LOWER TRIM
FASTENER
B
B A
A
A
A
CLIP
PIN A
FASTENER
BACK LOWER TRIM

A B

CONTINUED
S–40
TRIM
FRONT DOOR TRIM REMOVAL/INSTALLATION 7. Extract the inner handle from the rear door trim.
1. Disconnect the negative battery cable if equipped 8. Pull the rear door trim upward, then disengage
with a power window system. hooks B.
2. Remove the regulator handle if equipped. 9. Install in the reverse order of removal.
3. Remove the inner garnish.
4. Remove the power window switch if equipped.
5. Remove the screws and the fastener.
6. Pull the front door trim toward you, then disengage
clips A.
7. Pull the front door trim upward, then disengage
hook B.
FASTENER FRONT DOOR TRIM
B
A
A
CLIP
A A
A A
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A A B
A
SCREW A HOOK
FASTENER FRONT DOOR TRIM

B
A
A
CLIP
SCREW A A
A
A B
A A
A
A HOOK
REAR DOOR TRIM REMOVAL/INSTALLATION

Double cab
1. Disconnect the negative battery cable if equipped
with power window.
2. Remove the regulator handle if equipped.
3. Remove the power window switch if equipped.
5. Remove the ashtray.
6. Pull the door trim toward you, then disengage clips
A.
INNER HANDLE CLIP
B
SCREW
A A A
A
A B
A
ASHTRAY A A HOOK
A
A
A
REAR DOOR TRIM

CONTINUED
S–41
HEADLINER, FLOOR COVERING
HEADLINER FLOOR COVERING

HEADLINER REMOVAL/INSTALLATION FLOOR COVERING REMOVAL/INSTALLATION
1. Remove the A-pillar trims. Regular Cab, Stretch Cab
2. Remove the B-pillar upper trims. 1. Remove the dashboard member.
(Refer to TRIM, B-PILLAR UPPER TRIM (Refer to DASHBOARD AND CONSOLE,
REMOVAL/INSTALLATION, Double Cab.) DASHBOARD MEMBER REMOVAL/INSTALLATION.)
3. Remove the quarter upper trims. 2. Remove the quarter lower trims.
(Refer to TRIM, QUARTER UPPER TRIM (Refer to TRIM, QUARTER LOWER TRIM
REMOVAL/INSTALLATION, Stretch Cab.) REMOVAL/INSTALLATION, Stretch Cab.)
4. Remove the C-pillar trims. 3. Remove the back lower trim.
(Refer to TRIM, C-PILLAR TRIM 4. Remove the front seats. (Refer to SEAT, SEAT
REMOVAL/INSTALLATION, Double Cab.) REMOVAL/INSTALLATION, Regular Cab.)
5. Remove the assist handle. (Refer to SEAT, SEAT REMOVAL/INSTALLATION,
6. Remove the rearview mirror. Stretch Cab, Double cab, Front.)
7. Remove the sunvisors and adapters. 5. Remove the rear seat. (Refer to SEAT, SEAT
8. Remove the interior light. REMOVAL/INSTALLATION, Stretch Cab,
(Refer to section T, INTERIOR LIGHTING SYSTEM, Double cab, Rear.)
INTERIOR LIGHT REMOVAL/INSTALLATION.) 6. Remove the rear console bracket.
9. Remove the fasteners, then remove the headliner. 7. Remove the lower anchor installation bolts of front
seat belts.
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8. Remove the front side trims.
9. Remove the air outlet ducts.
HEADLINER
(Refer to section U, BASIC SYSTEM, AIR
OUTLET DUCT REMOVAL/INSTALLATION.)
10. Remove the footrest.
11. Remove the fasteners, then remove the floor
covering.
FASTENER ASSIST HANDLE
FASTENER
ADAPTER
SUNVISOR
10. Remove the headliner from the vehicle through the

passenger-side door.
FLOOR COVERING
Double cab
HEADLINER 1. Remove the dashboard member.
(Refer to DASHBOARD AND CONSOLE,
DASHBOARD MEMBER REMOVAL/INSTALLATION.)
2. Remove the B-pillar lower trims.
11. Install in the reverse order of removal. (Refer to TRIM, B-PILLAR LOWER TRIM
3. Remove the C-pillar trims.
(Refer to TRIM,C-PILLAR TRIM REMOVAL/INSTALLATION)
CONTINUED
S–42
FLOOR COVERING
4. Remove the front seats and rear seat.

(Refer to SEAT, SEAT REMOVAL/INSTALLATION,
Stretch Cab, Double cab, Front.)
(Refer to SEAT, SEAT
REMOVAL/INSTALLATION, Stretch Cab, Double cab, Rear.)
5. Remove the rear console bracket.
6. Remove the lower anchor installation bolts of front
seat belts and rear seat belts.
8. Remove the air outlet duct.
(Refer to section U, BASIC SYSTEM,
AIR OUTLET DUCT REMOVAL/INSTALLATION.)
9. Remove the footrest.
10. Remove the fasteners, then remove the floor
covering.
FASTENER
Type 1
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FLOOR COVERING
Type 2
FLOOR COVERING
FASTENER

CONTINUED
S–43
SEAT BELT
SEAT BELT Stretch Cab

Front
SEAT BELT REMOVAL/INSTALLATION 1. Remove the quarter lower trim.
(Refer to TRIM, QUARTER LOWER TRIM
Caution REMOVAL/INSTALLATION.)
The ELR has a spring that will unwind if the 2. Remove in the order indicated in the table.
retractor’s cover is removed. The spring 3. Install in the reverse order of removal.
cannot be rewound by hand. If this occurs, 39—78
the ELR will not work properly. Therefore, {3.9—8.0, 29—57}
do not disassemble the retractor.
Regular Cab
Driver’s side and passenger’s side
1. Remove the B-pillar trim if equipped with a B-pillar
trim. (Refer to TRIM, B-PILLAR TRIM
REMOVAL/INSTALLATION, Regular Cab.)
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39—78
{3.9—8.0, 29—57}
39—78
{3.9—8.0, 29—57}
1 Anchor cover
2 Seat belt
Rear
39—78
{3.9—8.0, 29—57} 1. Remove the quarter lower trim.
(Refer to TRIM, QUARTER LOWER TRIM
1 Anchor cover
2 Retractor cover (if equipped)
3 Seat belt
Except driver’s side and passenger’s side

Except Europe and UK
1. Remove as indicated in the table.
39—78
{3.9—8.0, 29—57}
1 Seat belt
CONTINUED
S–44
SEAT BELT
Rear
1. Remove the C-pillar trim. (Refer to TRIM,
C-PILLAR TRIM REMOVAL/INSTALLATION.)
39—78 2. Remove in the order indicated in the table.
{3.9—8.0, 29—57} 3. Install in the reverse order of removal.
39—78
{3.9—8.0, 29—57}
39—78 39—78
{3.9—8.0, 29—57} {3.9—8.0, 29—57}
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1 Anchor cover
2 Seat belt
Double Cab
Front
1. Remove the B-pillar lower trim. 1 Anchor cover
(Refer to TRIM, B-PILLAR LOWER TRIM 2 Seat belt
REMOVAL/INSTALLATION, Double Cab.)
2. Remove in the order indicated in the table. SEAT BELT INSPECTION
3. Install in the reverse order of removal. Belt
1. Inspect the webbing for scars, tears, and wear.
2. Inspect the fitting for deformation or damage.
39—78
{3.9—8.0, 29—57}
3. If a problem is found, replace the seat belt.
ELR
1. Verify that the belt can be pulled out smoothly, and
that it moves smoothly when worn.
2. Verify that the retractor locks when the belt is
quickly pulled.
39—78
{3.9—8.0, 29—57} 3. Remove the retractor.
4. Make sure that the seat belt does not lock when
the retractor is tilted slowly up to 15° from the
1 Anchor cover mounted position. Make sure that the seat belt
2 Seat belt locks when the retractor is tilted 40° or more.
CONTINUED
S–45
SEAT BELT
RETRACTOR 39—78
{3.9—8.0, 29—57}
5. If any of the above-mentioned steps are not as 1 Front buckle

specified, replace the seat belt.
Stretch Cab
BUCKLE REMOVAL/INSTALLATION Rear
Bench Seat 1. Remove as indicated in the table.
Driver’s side and passenger’s side 2. Install in the reverse order of removal.
2. Remove as indicated in the table. 39—78
{3.9—8.0, 29—57}
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39—78
{3.9—8.0, 29—57}
N·m {kgf·m, ft·lbf} 1 Rear buckle
Double Cab
1 Buckle
Rear
1. Remove the seat cushion. (Refer to SEAT, REAR
Except driver’s side and passenger’s side SEAT REMOVAL/INSTALLATION, Double Cab.)
Except Europe and UK 2. Remove as indicated in the table.
1. Remove as indicated in the table. 3. Install in the reverse order of removal.
39—78
{3.9—8.0, 29—57}
39—78
{3.9—8.0, 29—57}

1 Rear buckle
1 Buckle
Bucket Seat
Front
2. Remove the side cover. (Refer to SEAT, FRONT
SEAT DISASSEMBLY/ASSEMBLY, Bucket Seat.)
4. Install in the reverse order of removal. CONTINUED
S–46
SEAT BELT
BUCKLE SWITCH INSPECTION
2. Disconnect the buckle switch connector.
3. Inspect for continuity between the buckle switch
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4. If not as specified, replace the buckle.
CONTINUED
S-47
SEAT
SEAT Bucket Seat

FRONT SEAT REMOVAL/INSTALLATION 2. Remove in the order indicated in the table.
Bench Seat 3. Install in the reverse order of removal.
35—63
{3.5—6.5, 26—47}
35—63
{3.5—6.5, 26—47}
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35—63
{3.5—6.5, 26—47}
35—63 N·m {kgf·m, ft·lbf}

{3.5—6.5, 26—47}
N·m {kgf·m, ft·lbf} 1 Connector

2 Cover
1 Front seat
+ Installation note 3 Front seat
+ Installation note
Front seat installation note
1. To install the seat, tighten the bolts in the order Front seat installation note
indicated in the figure. 1. To install the seat, tighten the bolts in the order
indicated in the figure.
FRONT
FRONT
LEFT RIGHT
SIDE SIDE DOOR TUNNEL
SIDE SIDE
2. Verify that the seat slider is securely locked in

position before fully tightening the bolts. 2. Verify that the seat slider is securely locked in
3. After installing the seat, slide it forward and position before fully tightening the bolts.
backward and verify that the seat slider securely 3. After installing the seat, slide it forward and
locks in position. backward and verify that the seat slider securely
locks in position.
CONTINUED
S–48
SEAT
FRONT SEAT DISASSEMBLY/ASSEMBLY

Bench Seat
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A
32—46
{3.2—4.7, 24—33}
1 Headrest 8 Seat back frame

2 Pole guide 9 Seat cushion trim
3 Recliner lever 10 Seat cushion pad
4 Side cover 11 Seat cushion frame
5 Lower cover 12 Cable
6 Seat back trim 13 Slide adjuster
7 Seat back pad 14 Connecting rod
CONTINUED
S–49
SEAT
Bucket Seat
3. When removing the cable (passenger’s seat), adjust the cable. (Refer to CABLE ADJUSTMENT.)
39—78 {3.9—8.0, 29—57}
PASSENGER’S SEAT
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37—53 B
{3.7—5.5, 27—39}
C
B
39—78
{3.9—8.0, 29—57}
1 Headrest 11 Slide adjuster No.3

2 Recliner lever 12 Pole guide
3 Side cover 13 Seat back trim
4 Front buckle 14 Seat back warmer unit (Europe only)
5 Spring (stretch cab) 15 Seat back pad
6 Cable (stretch cab) 16 Seat cushion trim
7 Wire 17 Seat cushion warmer unit (Europe only)
8 Connecting rod 18 Seat cushion pad
9 Slide adjuster No.1 19 Seat cushion frame
10 Slide adjuster No.2
CONTINUED
S–50
SEAT
CABLE ADJUSTMENT
Verify the slide adjuster slides and locks smoothly
when the slide adjuster lever is operated.
SEAT BACK
LEVER
BOLT
16—22
{1.6—2.3, 12—16}
SLIDE
LOCK SCREW
2.0—2.9 N·m
LEVER
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{20—30 kgf·cm,
18—26 in·lbf}
Hinge
1. Remove the back lower trim. (Refer to TRIM,
REAR SEAT REMOVAL/INSTALLATION BACK LOWER TRIM REMOVAL/INSTALLATION.)
Stretch Cab 2. Remove the fasteners, and then turn over the floor
Seat back covering.
1. Remove the back upper trim. 3. Remove the bolts, and then remove the hinge.
2. Remove the bolts. BOLT
3. Lift the seat back up in the direction of the arrow, 16—22
{1.6—2.3, 12—16}
then unhook it from the body.
HOOK SEAT BACK
HOOK
HOOK
HINGE
BOLT
6.87—9.80
{70—100, 60.8—86.7} N·m {kgf·m, ft·lbf}
Seat cushion
1. Lift up the rear seat cushion.
3. Remove the bolts, and then remove the seat
cushion.
CONTINUED
S–51
SEAT
Double Cab 1 Seat cushion trim

2 Seat cushion pad
35—63
{3.5—6.5,
26—47} 16—22
PULL {1.6—2.3,
12—16}
16—22
{1.6—2.3,
12—16}
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16—22
{1.6—2.3, 12—16} 35—63
{3.5—6.5,
26—47}
1 Seat cushion
2 Seat back
+ Installation note
3 Hinge
4 Striker
Seat back installation note

After installing the seat back, verify that it securely
locks to the striker.
REAR SEAT DISASSEMBLY/ASSEMBLY

Stretch Cab
CONTINUED
S–52
SEAT
Double Cab
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1 Headrest 6 Side cover
2 Pole guide 7 Stopper
3 Seat back trim 8 Seat back frame
4 Seat back pad 9 Seat cushion trim
5 Rear back catch 10 Seat cushion pad
CONTINUED
S–53
SEAT
SEAT WARMER SWITCH REMOVAL SEAT WARMER UNIT INSPECTION

1. Disconnect the negative battery cable. 1. Remove the front seat. (Refer to FRONT SEAT
2. Insert your hand under the dashboard near the REMOVAL/INSTALLATION, Bucket Seat.)
fuse block, grasp the hooks of the seat warmer 2. Inspect seat warmer unit at roor temperature of 20
switch and pull it forward to remove it. °C {68 °F}.
3. Disconnect the seat warmer switch connector, and 3. Apply battery positive voltage to the seat warmer
then remove the seat warmer switch. unit terminal A, connect the ground to terminal B,
and measure the temperature of the thermometal
switch with a thermometer.
A
HOOK
SEAT WARMER
CONNECTOR SWITCH
SEAT WARMER SWITCH INSTALLATION B
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1. Connect the seat warmer switch connector.
2. Insert the seat warmer switch in the hole to install
it.
3. Connect the negative battery cable. THERMOMETER
SEAT WARMER SWITCH INSPECTION

1. Remove the seat warmer switch.
(Refer to SEAT WARMER SWITCH REMOVAL.)
2. Inspect for continuity between the seat warmer
THERMOMETAL
SWITCH
: Continuity : Bulb
Terminal 4. When the temperature of the thermometal switch is
Switch position
D C F approximately 40 °C {104 °F}, inspect the
resistance between the seat warmer unit terminals
On
using an ohmmeter. Verify that the resistance
Off changes from approximately 4.8 Ω to
approximately 13.0 Ω.
5. Remove battery positive voltage from seat warmer
D unit terminals.
6. When the temperature of the thermometal switch is
: : approximately 30 °C {86 °F}, inspect the
resistance between the seat warmer unit terminals
F :
using an ohmmeter. Verify that the resistance
changes from approximately 13.0 Ω to
approximately 4.8 Ω.
C F 7. If any of the above-mentioned steps are not as
specified, replace the seat back pad (with seat
warmer unit) and seat cushion pad (with seat
warmer unit).
3. If not as specified, replace the seat warmer switch.
CONTINUED
S–54
BODY ELECTRICAL SYSTEM

PAGE 1 OF 2
POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . T– 3 FLASHER UNIT
FUSE SERVICE CAUTION . . . . . . . . . . . . . . . . . T– 3 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–11
MAIN FUSE REMOVAL/INSTALLATION . . . . . T– 3 FLASHER UNIT INSPECTION . . . . . . . . . . . . . . T–12
IGNITION SWITCH HEADLIGHT LEVELING ACTUATOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 3 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–12
IGNITION SWITCH INSPECTION . . . . . . . . . . . T– 3 HEADLIGHT LEVELING ACTUATOR
KEY REMINDER SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . T–13
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 3 REAR FOG LIGHT RELAY
KEY REMINDER SWITCH INSPECTION . . . . T– 4 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–14
CIGARETTE LIGHTER REAR FOG LIGHT RELAY INSPECTION . . . . T–14
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 4 RUNNING LIGHT RELAY
CIGARETTE LIGHTER INSPECTION . . . . . . . T– 4 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–14
EXTERIOR LIGHTING SYSTEM . . . . . . . . . . . . . . T– 5 RUNNING LIGHT RELAY INSPECTION . . . . . T–14/15
FRONT COMBINATION LIGHT INTERIOR LIGHTING SYSTEM . . . . . . . . . . . . . . . T–16
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 5 INTERIOR LIGHT
HEADLIGHT AIMING . . . . . . . . . . . . . . . . . . . . . . T– 5 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–16
HEADLIGHT BULB INTERIOR LIGHT INSPECTION . . . . . . . . . . . . T–16
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 5/6 DOOR SWITCH
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PARKING LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–17
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 6 DOOR SWITCH INSPECTION . . . . . . . . . . . . . . T–17
FRONT TURN LIGHT PANEL LIGHT CONTROL SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 6 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–17
FRONT TURN LIGHT BULB PANEL LIGHT CONTROL SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 6 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . T–18
FRONT SIDE TURN LIGHT WIPER AND WASHER . . . . . . . . . . . . . . . . . . . . . . T–19
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 6 WINDSHIELD WIPER MOTOR
REAR COMBINATION LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–19
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 7 WINDSHIELD WIPER MOTOR
REAR COMBINATION LIGHT BULB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . T–19
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 7 WINDSHIELD WIPER ARM AND BLADE
REAR FOG LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–19
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 7 WINDSHIELD WIPER ARM AND BLADE
REAR FOG LIGHT BULB ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . T–19
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 7 WINDSHIELD WIPER LINK
LICENSE PLATE LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–20
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 8 WINDSHIELD WASHER TANK
COMBINATION SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–20
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 8 WINDSHIELD WASHER MOTOR
COMBINATION SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–20
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . T– 8 WINDSHIELD WASHER MOTOR
LIGHT SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . T–20
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 8 WINDSHIELD WASHER NOZZLE
LIGHT SWITCH INSPECTION . . . . . . . . . . . . . . T– 8/9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T–20
HAZARD WARNING SWITCH WINDSHIELD WASHER NOZZLE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T– 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . T–20
HAZARD WARNING WINDSHIELD WASHER NOZZLE
SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . T– 9 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . T–21
REAR FOG LIGHT SWITCH REMOVAL . . . . . T–10 WINDSHIELD WASHER PIPE
REAR FOG LIGHT SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . T–10 WINDSHIELD WIPER AND WASHER
REAR FOG LIGHT SWITCH SWITCH REMOVAL/INSTALLATION . . . . . . . T–21
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . T–10 WINDSHIELD WIPER AND WASHER
HEADLIGHT LEVELING SWITCH SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . T–21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T–10 WARNING AND INDICATOR SYSTEM . . . . . . . . T–22
HEADLIGHT LEVELING SWITCH INSTRUMENT CLUSTER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . T–10 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–22
HEADLIGHT LEVELING SWITCH INSTRUMENT CLUSTER
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . T–10 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . T–22
BACK-UP LIGHT SWITCH INSTRUMENT CLUSTER INSPECTION . . . . . T–22/24
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–11 INSTRUMENT CLUSTER REPAIR . . . . . . . . . . T–24
BACK-UP LIGHT SWITCH INSPECTION . . . . T–11
CONTINUED
T–1
POWER SYSTEM

PAGE 2 OF 2
WARNING AND INDICATOR LIGHT
BULB REMOVAL/INSTALLATION . . . . . . . . . . T–24
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . T–24/25
WATER TEMPERATURE SENDER UNIT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T–25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . T–25
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . T–25
OIL PRESSURE SWITCH INSPECTION . . . . . T–25
HORN REMOVAL/INSTALLATION . . . . . . . . . . T–25
HORN RELAY REMOVAL/INSTALLATION . . . T–25/26
HORN RELAY INSPECTION . . . . . . . . . . . . . . . T–26
CLOCK REMOVAL/INSTALLATION . . . . . . . . . T–26
AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T–26
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AUDIO UNIT REMOVAL . . . . . . . . . . . . . . . . . . . T–26
AUDIO UNIT INSTALLATION . . . . . . . . . . . . . . . T–26
SPEAKER REMOVAL/INSTALLATION . . . . . . . T–26/27
SPEAKER INSPECTION . . . . . . . . . . . . . . . . . . . T–27
ROOF ANTENNA REMOVAL . . . . . . . . . . . . . . . T–27
ROOF ANTENNA INSTALLATION . . . . . . . . . . T–27
ROOF ANTENNA INSPECTION . . . . . . . . . . . . T–27/28
ANTENNA FEEDER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . T–28
ANTENNA FEEDER INSPECTION . . . . . . . . . . T–28
CONDENSER REMOVAL/INSTALLATION . . . T–28
CONTINUED
T–2
POWER SYSTEM
POWER SYSTEM IGNITION SWITCH INSPECTION

1. Remove the column cover.
FUSE SERVICE CAUTION 2. Disconnect the ignition switch connectors.
3. Inspect for continuity between the ignition switch
Caution terminals using an ohmmeter.
Determine and correct the cause of the : Continuity
burnt fuse before replacing it with the Ignition
g key
y Terminal
specified type. If the fuse is replaced before position 2A 2B 1D 1C 1B 1A
doing this, it may burn again.
LOCK
MAIN FUSE REMOVAL/INSTALLATION ACC
2. Remove in the order indicated in the table. ON
G6, WL, WL TURBO, F2 CIS START
2A 2B 2B 2A
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123456567
START
START
LOCK LOCK
ON ON ACC 1C 1A
ACC
1C 1D 1A 1B
1D 1B
F2 CARB
4. If not as specified, replace the ignition switch.
KEY REMINDER SWITCH REMOVAL/INSTALLATION

3. Disconnect the key reminder switch connector.
4. Remove the key reminder switch.
KEY REMINDER
SWITCH
1 Nut
2 Bolt
3 Main fuse
IGNITION SWITCH REMOVAL/INSTALLATION STEERING

1. Disconnect the negative battery cable. LOCK
3. Disconnect the ignition switch connectors.
4. Remove the screw to remove the ignition switch. 5. Install in the reverse order of removal.
IGNITION
SWITCH SCREW
CONNECTOR
IGNITION
SWITCH
T–3
POWER SYSTEM
KEY REMINDER SWITCH INSPECTION Socket Removal Note

1. Remove the column cover. 1. Pry up the stopper with a tape-wrapped
2. Disconnect the key reminder switch connector. screwdriver.
3. Inspect for continuity between the key reminder 2. Pull the socket by prying up the stopper.
: Continuity
Terminal
Key position
A B
Inserted
Removed
B A
CIGARETTE LIGHTER INSPECTION
Verify that the cigarette lighter plug will move
normally within 10—20 seconds, after pressing
the plug into the socket. If the plug does not move,
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B replace the cigarette lighter.
4. If not as specified, replace the key reminder switch.
CIGARETTE LIGHTER REMOVAL/INSTALLATION

2. Remove the center panel.
1 Cigarette lighter plug

2 Connector
3 Socket
+ Removal Note
4 Ring
CONTINUED
T–4
EXTERIOR LIGHTING SYSTEM
EXTERIOR LIGHTING SYSTEM If it is difficult to remove front combination light

with pliers
FRONT COMBINATION LIGHT Remove the adjusting screws and the screw by
REMOVAL/INSTALLATION loosening them.
1. Disconnect the negative battery cable. ADJUSTING
2. Remove the radiator grille. SCREW
(Refer to section S, EXTERIOR ATTACHMENT, SCREW
RADIATOR GRILLE REMOVAL/INSTALLATION.)
3. Remove the front turn light. (Refer to FRONT
TURN LIGHT REMOVAL/INSTALLATION.)
6. Adjust the headlight aiming.
(Refer to HEADLIGHT AIMING.)
ADJUSTING
SCREW
HEADLIGHT AIMING
1. Adjust the tire air pressure to the specification.
2. Position the unloaded vehicle on a level surface.
3. Seat one person in the driver’s seat.
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4. Start the engine and charge the battery fully.
5. Position the vehicle straight ahead and
perpendicularly to a wall.
6. Set the headlights 7.6 m {25 ft} from the wall.
7. While adjusting one headlight, disconnect the
connector of the other.
1 Front combination light connector
Caution
2 Front combination light
Always tighten the adjusting screws last.
+ Removal Note
When loosening the adjusting screws, loosen
3 Spring the screws first and then tighten them.
If the adjusting screws are tightened first,
Front Combination Light Removal Note then loosened, they will continue to loosen
Removal with pliers when the vehicle is in motion and may
cause the headlights to become misaligned.
Caution
When pressing the hook of the adjusting 8. Adjust the headlights by turning the adjusting
screws and the screw with the pliers, do not screws as shown in the figure. Loosen the screws
damage the front combination light first, then tighten them.
mounting.
IN-
1. Press the hook of the adjusting screws and the OUT-
WARD WARD
screw with the pliers.
2. Pull the front combination light out of the adjusting
screws and the screw.
ADJUSTING
SCREW UP
HOOK
DOWN
SCREW
HEADLIGHT BULB REMOVAL/INSTALLATION
Caution
A halogen bulb generates extremely high
FRONT COMBINATION LIGHT MOUNTING heat when it is used. If the surface of the
bulb is soiled, excessive heat will build up
and the light’s life will be shortened. When
replacing the bulb, hold the metal flange,
not the glass.
CONTINUED
T–5

1 Screw
2 Front turn light
3 Front turn light connector
1 Headlight bulb connector
2 Cover FRONT TURN LIGHT BULB
+ Installation Note REMOVAL/INSTALLATION
3 Headlight bulb 1. Disconnect the negative battery cable.
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Cover Installation Note 3. Install in the reverse order of removal.
Align the TOP mark with top side.
TOP MARK
1 Socket
PARKING LIGHT BULB REMOVAL/INSTALLATION 2 Front turn light bulb
2. Remove in the order indicated in the table. FRONT SIDE TURN LIGHT
3. Install in the reverse order of removal. REMOVAL/INSTALLATION
FRONT
1 Socket
REAR
2 Parking light bulb
FRONT TURN LIGHT REMOVAL/INSTALLATION 1 Front side turn light

1. Disconnect the negative battery cable. 2 Front side turn light connector
3. Install in the reverse order of removal. 3 Socket
4 Front side turn light bulb
CONTINUED
T–6
REAR COMBINATION LIGHT REAR FOG LIGHT REMOVAL/INSTALLATION

REMOVAL/INSTALLATION 1. Disconnect the negative battery cable.
1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table.
2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
WITHOUT REAR BUMPER
1 Rear fog light connector

1 Screw
2 Nut
2 Rear combination light
3 Spring washer
3 Rear combination light connector
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4 Rear fog light
REAR COMBINATION LIGHT BULB
REMOVAL/INSTALLATION WITH REAR BUMPER
2. Remove the rear combination light.
1 Rear fog light connector

2 Screw
3 Rear fog light
1 Screw REAR FOG LIGHT BULB

2 Lens REMOVAL/INSTALLATION
+ Removal Note 1. Disconnect the negative battery cable.
3 Rear turn light bulb
4 Back-up light bulb
5 Brake light/taillight bulb
Lens Removal Note

Push the hook upward with your finger.
HOOK
1 Screw
2 Lens
3 Rear fog light bulb
CONTINUED
T–7
LICENSE PLATE LIGHT REMOVAL/INSTALLATION COMBINATION SWITCH

1. Disconnect the negative battery cable. DISASSEMBLY/ASSEMBLY
2. Remove in the order indicated in the table. 1. Disassemble in the order indicated in the table.
3. Install in the reverse order of removal. 2. Assemble in the reverse order of disassembly.
1 Screw 1 Screw
2 License plate light 2 Windshield wiper and washer switch
3 License plate light bulb 3 Light switch
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4 Socket 4 Body
5 License plate light connector
LIGHT SWITCH REMOVAL/INSTALLATION
COMBINATION SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable.
1. Disconnect the negative battery cable. 2. Remove the column cover.
2. For vehicles without air bag system, remove the 3. Remove in the order indicated in the table.
horn cap. For vehicles with air bag system, remove 4. Install in the reverse order of removal.
the driver-side air bag module.
(Refer to AIR BAG SYSTEM, DRIVER-SIDE
AIR BAG MODULE REMOVAL/INSTALLATION.)
3. Remove the steering wheel.
(Refer to section N, MANUAL STEERING, STEERING
WHEEL AND COLUMN REMOVAL/INSTALLATION.)
4. For vehicles with air bag system, remove the clock
spring. (Refer to AIR BAG SYSTEM, CLOCK
SPRING REMOVAL/INSTALLATION.)
1 Light switch connector
2 Screw
3 Light switch
LIGHT SWITCH INSPECTION

Headlight Switch
1. Remove the light switch.
(Refer to LIGHT SWITCH REMOVAL/INSTALLATION.)
Note
When the flash-to-pass switch is on, the
contact of the low-high switch is at neutral.
1 Screw
2 Combination switch 2. Inspect for continuity between the light switch
3 Combination switch connector terminals using an ohmmeter.
CONTINUED
T–8
: Continuity 3. If not as specified, replace the light switch.

Switch position Terminal
HAZARD WARNING SWITCH
Flash- P D L F H
Light Dimmer REMOVAL/INSTALLATION
to-pass (B) (N) (H) (J) (L)
Off 2. Remove the meter hood.
OFF –
On (Refer to section S, DASHBOARD AND CONSOLE,
METER HOOD REMOVAL/INSTALLATION.)
Off
TNS – 3. Remove as indicated in the table.
On 4. Install in the reverse order of removal.
Off
Head-
Head Low
On
light
High –
( ): Light switch right side lever
(J) (N)
F D HOOK
OFF HEAD-
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OFF HEAD- LIGHT
TNS LIGHT TNS
FLASH 1 Hazard warning switch
-TO HIGH LOW
-PASS
HAZARD WARNING SWITCH INSPECTION
(Refer to section S, DASHBOARD AND CONSOLE,
H L P METER HOOD REMOVAL/INSTALLATION.)
2. Inspect for continuity between the hazard warning
(L) (H) (B)
: Continuity : Bulb
Switch Terminal
* * * E C A
(O) (M) (K) (*) (*) (*) position F D B A C I K H J
P N L * H F D * Off
(*) (J) (*) (B)
On
( ): LIGHT SWITCH RIGHT SIDE LEVER
3. If not as specified, replace the light switch.
H K F D
Turn Switch
1. Remove the light switch.
(Refer to LIGHT SWITCH REMOVAL/INSTALLATION.)
2. Inspect for continuity between the light switch
: Continuity
Terminal
Switch position
C (M) A (K) E (O)
Right
Off J A C I B
Left
( ): Light switch right side lever
(M)
C K I C A
* J H F D B
*
* (M) * E C A
(O) (K) (*) (*) (*)
P
(*) N * H
L (J) F D *
(*) (B)
3. If not as specified, replace the hazard warning
A E switch.
(K) (O)
( ): LIGHT SWITCH RIGHT SIDE LEVER
CONTINUED
T–9
REAR FOG LIGHT SWITCH REMOVAL HEADLIGHT LEVELING SWITCH REMOVAL

1. Disconnect the negative battery cable. 1. Disconnect the negative battery cable.
2. Insert your hand under the dashboard near the 2. Insert your hand under the dashboard near the
fuse block, grasp the hooks of the rear fog light fuse block, grasp the hooks of the headlight
switch and pull it forward to remove it. leveling switch and pull it forward to remove it.
3. Disconnect the connector to remove the rear fog 3. Disconnect the connector to remove the headlight
light switch. leveling switch.
HOOK HOOK
CONNECTOR CONNECTOR
REAR FOG
LIGHT SWITCH HEADLIGHT
LEVELING SWITCH
REAR FOG LIGHT SWITCH INSTALLATION HEADLIGHT LEVELING SWITCH INSTALLATION
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1. Connect the rear fog light switch connector. 1. Connect the headlight leveling switch connector.
2. Insert the rear fog light switch in the hole to install 2. Insert the headlight leveling switch in the hole to
it. install it.
3. Connect the negative battery cable. 3. Connect the negative battery cable.
REAR FOG LIGHT SWITCH INSPECTION HEADLIGHT LEVELING SWITCH INSPECTION

1. Remove the rear fog light switch. (Refer to REAR 1. Remove the headlight leveling switch.
FOG LIGHT SWITCH REMOVAL/INSTALLATION.) (Refer to HEADLIGHT LEVELING SWITCH
2. Inspect for continuity between the rear fog light REMOVAL/INSTALLATION.)
switch terminals using an ohmmeter. 2. Inspect for continuity between the headlight
: Continuity leveling switch terminals using an ohmmeter.
Terminal : Continuity : Resistance : Bulb
Switch position Terminal
A D F Switch position
Off C D A B
Neutral 0
R1+ R2+ R3
On
1
R2+R3
F
2
R3
A
3
F D
R1:1600 Ω 2: 560 Ω 3:300 Ω
A D C A
3. If not as specified, replace the rear fog light switch. 0 1 2 3

* C A
R1 R2 R3
* * * D B
D B
3. If not as specified, replace the headlight leveling

switch.
CONTINUED
T–10
BACK-UP LIGHT SWITCH FLASHER UNIT REMOVAL/INSTALLATION

1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table.
2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
25—34 {2.5—3.4, 19—24}
DRIVER-SIDE
FRONT SIDE TRIM
1 Back-up light switch connector

2 Back-up light switch
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3 Gasket
BACK-UP LIGHT SWITCH INSPECTION

1. Disconnect the back-up light switch connector.
2. Inspect for continuity between the back-up light
: Continuity
Shift lever Terminal
1 Nut
position A B
2 Flasher unit
Reverse 3 Flasher unit connector
Other
A B
3. If not as specified, replace the back-up light switch.

CONTINUED
T–11
FLASHER UNIT INSPECTION

1. Measure the voltage at the flasher unit terminals as indicated below.
2. Disconnect the flasher unit connector before inspecting for continuity at terminal C.
3. If not as specified, inspect the parts listed under “Inspection area” and the related wiring harnesses.
4. If the parts and wiring harnesses are okay but the system still does not work properly, replace the flasher unit.

C B
Voltage (V)
/Continuity
Alternates
Hazard warning switch on
B+ and 0
Hazard
Ignition switch at
Flasher unit Hazard warning B+ warning switch
A ON position
out ut
output switch Hazard warning Turn signal
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switch off Ignition switch at light
LOCK or ACC 0
position
Hazard warning switch on B+ HAZARD 10 A
Ignition switch at fuse
B+
Hazard warning ON position METER 15 A
B Power supply
su ly Hazard warning
switch Ignition switch at fuse
switch off Hazard
LOCK or ACC 0
position warning switch
Flasher unit Constant: inspect for continuity to

C GND Yes GND
ground ground
HEADLIGHT LEVELING ACTUATOR

2. Remove the radiator grille.
(Refer to section S, EXTERIOR ATTACHMENT,
RADIATOR GRILLE REMOVAL/INSTALLATION.)
3. Remove the front turn light.
(Refer to FRONT TURN LIGHT REMOVAL/INSTALLATION.)
4. Remove the front combination light.
(Refer to FRONT COMBINATION LIGHT
5. Remove the headlight leveling actuator connector
from the bracket.
6. Disconnect the headlight leveling actuator
connector.
7. Remove the nuts.
8. Remove the headlight leveling actuator.
HEADLIGHT
LEVELING
ACTUATOR
HEADLIGHT LEVELING
ACTUATOR CONNECTOR

CONTINUED
T–12
HEADLIGHT LEVELING ACTUATOR INSPECTION

1. Measure the voltage at the headlight leveling actuator terminals as indicated below.
Note
Because the headlight leveling actuator connector is waterproof, it is impossible to measure the voltage at
the headlight leveling actuator terminals. When inspecting, measure the voltage at the terminal of the part
which is connected to the headlight leveling actuator.
(1) To measure the voltage at the terminal A of the headlight leveling actuator, remove the column cover and
measure the voltage at the terminal N of the light switch connector.
(Refer to LIGHT SWITCH INSPECTION.)
(2) To measure the voltage at the terminal B of the headlight leveling actuator, remove the headlight leveling
switch with the connector connected and measure the voltage at the terminal C of the headlight leveling
switch connector. (Refer to HEADLIGHT LEVELING SWITCH INSPECTION.)
(3) Disconnect the headlight leveling actuator connector before inspecting for continuity at terminal C.
3. If the parts and wiring harnesses are okay but the system still does not work properly, replace the headlight
leveling actuator.

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A B C
Voltage ( V )
/Continuity
Headlight
Headlight illuminated B+
leveling
g Combination
A Combination switch
actuator switch
power supply Headlight unilluminated 0
Headlight leveling
6.2
switch at 0
Headlight leveling
Headlight 4.2
g
Headlight g
Headlight switch at 1
B leveling switch Headlight leveling switch
leveling switch switch on Headlight leveling
position 2.1
switch at 2
Headlight leveling
0
switch at 3
Headlight
leveling Constant : inspect for continuity
C GND Yes GND
actuator to ground
ground
CONTINUED
T–13
REAR FOG LIGHT RELAY RUNNING LIGHT RELAY REMOVAL/INSTALLATION

2. Remove the washer tank from the bracket.
Note 3. Remove the running light relay with the cover
Because the lock section of the relay is attached.
damaged easily, do not remove the relay from
the bracket unless replacement is necessary.
Always perform an inspection of the rear fog NUT
light relay before removal.

2. Disconnect the rear fog light relay connector.
3. Remove the rear fog light relay by prying the lock
section of the upper part with a flathead
screwdriver. RUNNING LIGHT
RELAY WITH COVER
REAR FOG 4. Remove the cover.

LIGHT RELAY 5. Disconnect the running light relay connector.
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COVER
BRACKET
REAR FOG LIGHT

RELAY CONNECTOR RUNNING LIGHT
RELAY
REAR FOG LIGHT RELAY INSPECTION RUNNING LIGHT

RELAY CONNECTOR
1. Remove the bracket and pull it toward you.
2. Inspect for continuity between the rear fog light
relay terminals using an ohmmeter. 6. Install in the reverse order of removal.
RUNNING LIGHT RELAY INSPECTION
Terminal
Step 1. Remove the running light relay.
A B C D (Refer to RUNNING LIGHT RELAY
1 REMOVAL/INSTALLATION.)
2. Inspect for continuity between the running light
2 B+ GND
relay terminals using an ohmmeter.
: Continuity : Diode
Test Terminal
C A cond -
condi
tion A B C D E F
C A
D B Constant
D B
B C A
3. If not as specified, replace the rear fog light relay.

E C A
F D B
F E D
CONTINUED
T–14
3. Connect the terminal A to the positive battery

terminal and the terminal D to the negative battery
terminal.
4. Verify that there is continuity between terminals A
and E, and that there is no continuity between
terminals B and F.
B C A
E C A
F D B
F E D
5. Connect the terminal C to the positive battery

terminal and the terminal D to the negative battery
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terminal.
6. Verify that there is no continuity between terminals
B and F, and between terminals A and E.
B C A
E C A
F D B
F E D
7. If not as specified, replace the running light relay.

CONTINUED
T–15
INTERIOR LIGHTING SYSTEM

INTERIOR LIGHT REMOVAL/INSTALLATION
ALL VEHICLES EXCEPT
REGULAR CAB
Interior Light Installation Note

Regular cab
Note
The spacer acts as a ground. If the spacer is
not installed in the position shown in the figure,
the interior light may not illuminate.
REGULAR CAB
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1. Tighten the screw fully. (More than 4 mm {0.2 in}
of thread should be exposed.)
2. Install the interior light.
SCREW
4.0 mm
{0.2 in}
1 Lens
+ Removal Note SPACER
INTERIOR LIGHT
2 Interior light bulb
3 Screw
4 Spacer
INTERIOR LIGHT INSPECTION
1. Remove the interior light.
5 Interior light (Refer to INTERIOR LIGHT REMOVAL/INSTALLATION.)
+ Installation Note 2. Inspect for continuity between the interior light
6 Interior light connector terminals using an ohmmeter.
: Bulb
Lens Removal Note Terminal
All vehicles except regular cab Step
A B Body GND
1. Insert a tape-wrapped flathead screwdriver into the
lens. ON
2. Twist the screwdriver to remove the lens. DOOR
OFF
B
A B
OFF ON
DOOR
A
Regular cab
Push the areas indicated by the arrows to pull out
3. If not as specified, replace the interior light.
the lens.
CONTINUED
T–16
DOOR SWITCH REMOVAL/INSTALLATION 1 Panel light control switch

1 Screw
2 Door switch
3 Door switch connector
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DOOR SWITCH INSPECTION
1. Remove the door switch.
2. Inspect for continuity between the door switch
: Continuity
Terminal
Switch condition
A Body GND
Pressed
Released
A A
BODY GND
3. If not as specified, replace the door switch.
PANEL LIGHT CONTROL SWITCH

HOOK
CONTINUED
T–17
PANEL LIGHT CONTROL SWITCH INSPECTION

1. Remove the meter hood without disconnecting the panel light control switch connector.
(Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.)
2. Measure the voltage at the panel light control switch as indicated below.
3. Disconnect the panel light control switch connector before inspecting for continuity at terminal G.
5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the panel light
control switch.

G A
H F D B
Voltage (V)/
Continuity
Panel light
Each Inspect using an oscilloscope
A control — Each illumination
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illumination + A terminal inspection
output
B — Not used — — —
Headlight switch at TNS or
Power B+ Light switch
D g switch
Light headlight position
supply TAIL 10 A fuse
Headlight switch at OFF position 0
F — Not used — — —
Panel light
control Constant: Inspect for continuity to
G GND Yes GND
switch ground
ground
H — Not used — — —
A Terminal Inspection
1. Measure the wave pattern of the A terminal on the
panel light control switch using an oscilloscope. V
PANEL LIGHT
CONTROL SWITCH OSCILLOSCOPE 5. Verify that the pattern on the screen matches the
pattern shown in the figure as the panel light
control switch is gradually turned to the darkest
2. Set the headlight switch to either the TNS or position.
headlight position.
3. Set the panel light control switch to the brightest V
position.
4. Verify that the pattern of the screen is as shown in B+
the figure.
0
1—3.2 ms
5—15.4 ms
CONTINUED
T–18
WIPER AND WASHER
WIPER AND WASHER WINDSHIELD WIPER ARM AND BLADE

WINDSHIELD WIPER MOTOR 1. Remove in the order indicated in the table.
REMOVAL/INSTALLATION 2. Install in the reverse order of removal.
1. Disconnect the negative battery cable. 3. Adjust the windshield wiper arm and blade.
2. Disconnect the connector. (Refer to WINDSHIELD WIPER ARM
3. Loosen the bolts. AND BLADE ADJUSTMENT.)
4. Pull the windshield wiper motor forward until the
connection between the windshield wiper motor 16—19
and windshield wiper link is in the engine room. {1.6—2.0,
5. Pry off the connection between the windshield 12—14}
wiper motor and windshield wiper link.
6. Remove the windshield wiper motor.
WINDSHIELD WIPER MOTOR

CONNECTOR
1 Cap
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2 Nut
WINDSHIELD
WIPER LINK 3 Windshield wiper arm
BOLT
4.0—6.8 {40—70, 35—60} N·m {kgf·cm, in·lbf} + Installation Note
4 Windshield wiper blade
5 Rubber brush
WINDSHIELD WIPER MOTOR INSPECTION
Windshield Wiper Arm Installation Note
1. Disconnect the windshield wiper motor connector.
Clean the windshield wiper arm connector shafts
2. Connect battery positive voltage and inspect the
with a wire brush before installing the windshield
operation of the windshield wiper motor as
wiper arms.
indicated below.
Terminal Operation
A High WINDSHIELD WIPER
ARM CONNECTOR SHAFT
C Low
WINDSHIELD WIPER ARM AND BLADE

ADJUSTMENT
A C 1. Operate the windshield wiper motor to set the
B D windshield wipers in the park position.
2. Align both ends of the wiper blades to the marks
3. Connect battery positive voltage to terminal C of on the ceramic section.
the windshield wiper motor to operate the CERAMIC SECTION
windshield wipers at low speed.
4. Disconnect battery positive voltage from terminal C
of the motor while the wipers are operating.
5. Verify that the wipers do not stop in the park
position.
6. Short between terminal C and B of the motor, and
connect battery positive voltage to terminal D of
the motor.
7. Verify that the wipers operate at low speed again,
then stop in the park position.
8. If not as specified, replace the windshield wiper MARK
motor. CONTINUED
T–19
WIPER AND WASHER
WINDSHIELD WIPER LINK

1. Remove the windshield wiper arm and blade.
(Refer to WINDSHIELD WIPER ARM AND BLADE
2. Remove the cowl grille.
3. Remove the windshield wiper motor.
(Refer to WINDSHIELD WIPER MOTOR
6. Adjust the windshield wiper arm and blade.
(Refer to WINDSHIELD WIPER ARM AND BLADE
ADJUSTMENT.) 1 Windshield washer motor
6.87—9.80 2 Grommet
{70—100, 60.8—86.7}
WINDSHIELD WASHER MOTOR INSPECTION
1. Disconnect the windshield washer motor
connector.
2. Connect battery positive voltage to terminal B and
ground to terminal A of the motor.
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3. Verify that the windshield washer motor operates.
1 Bolt
M
2 Windshield wiper link
A
WINDSHIELD WASHER TANK
REMOVAL/INSTALLATION B
1. Disconnect the negative battery cable. A
2. Disconnect the connector.
3. Disconnect the windshield washer pipe from the 4. If the motor does not operate, replace the
windshield washer motor. windshield washer motor.
4. Pull the windshield washer tank up and slide it off
the bracket. WINDSHIELD WASHER NOZZLE REMOVAL
1. Disconnect the windshield washer pipe from the
windshield washer nozzle.
CONNECTOR 2. Remove the windshield washer nozzle using a 10
WINDSHIELD mm {0.4 in} deep socket wrench from underneath
WASHER TANK
the bonnet.
WINDSHIELD
WASHER PIPE DEEP SOCKET WRENCH WINDSHIELD WASHER NOZZLE
BRACKET
WINDSHIELD WASHER MOTOR

2. Remove the windshield washer tank. WINDSHIELD WASHER NOZZLE INSTALLATION
3. Remove in the order indicated in the table. 1. Connect the windshield washer pipe to the
4. Install in the reverse order of removal. windshield washer nozzle.
2. Push the windshield washer nozzle into the
installation hole.
3. Adjust the windshield washer nozzle. (Refer to
WINDSHIELD WASHER NOZZLE ADJUSTMENT.)
CONTINUED
T–20
WIPER AND WASHER
WINDSHIELD WASHER NOZZLE ADJUSTMENT SCREW

Insert a needle or equivalent tool into the spray
holes of the windshield washer nozzle and adjust
the nozzle direction as shown.
WINDSHIELD
WIPER AND
WASHER
CENTER SWITCH
320 {12.6} 390 {15.4} CONNECTOR
100 100 6. Install in the reverse order of removal.

{3.9} {3.9}
WINDSHIELD WIPER AND WASHER SWITCH
INSPECTION
290
{11.4} 290 270 2. Remove the windshield wiper and washer switch.
{11.4} 180
{10.6}
{7.1} 3. Inspect for continuity between the windshield wiper
and washer switch terminals using an ohmmeter.
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: Continuity
Terminal
WINDSHIELD One-
MOLDING GLASS END LINE
Switch position G(E M(C N(D C(M
touch L(F)
END LINE ) ) ) )
Off 123
mm {in} OFF
On
Wiper
WINDSHIELD WASHER PIPE INT
switch
REMOVAL/INSTALLATION LO
1. Disconnect the windshield washer pipe from the
HI
windshield washer nozzle and the windshield
washer motor. Washer
On
2. Remove the clips. switch
3. Remove the windshield washer pipe. ( ): Wiper and washer switch left side lever
(D)
N
ONE-TOUCH WIPER
OFF SWITCH
HI HI OFF
LO INT
LO INT
CLIP WINDSHIELD INT
WASHER PIPE RELAY
H L M G C
4. Install in the reverse order of removal. (J) (F) (C) (E) (M)
WASHER
WINDSHIELD WIPER AND WASHER SWITCH SWITCH
2. Remove the column cover. 0 G * *
3. Disconnect the connector. (*) M (*) (E) C (A)
4. Remove the screws. N L * H * *
* (*) (*) (J) (*) (F) (D) *
5. Remove the windshield wiper and washer switch.
( ): WIPER AND WASHER SWITCH LEFT SIDE LEVER
4. If not as specified, replace the windshield wiper

and washer switch.
CONTINUED
T–21
WARNING AND INDICATOR SYSTEM
WARNING AND INDICATOR SYSTEM INSTRUMENT CLUSTER INSPECTION

Speedometer
INSTRUMENT CLUSTER REMOVAL/INSTALLATION 1. Adjust the tire air pressure to the specification.
1. Disconnect the negative battery cable. 2. Using a speedometer tester, verify that the
2. Remove the meter hood. speedometer indication is within the allowable
(Refer to section S, DASHBOARD AND CONSOLE, range indicated in the table.
3. Remove in the order indicated in the table. Speedometer
p tester
4. Install in the reverse order of removal. Allowable range (km/h)
indication (km/h)
20 18—22
40 36—44
60 54—66
80 72—88
100 90—110
120 108—132
140 126—154
160 144—176
180 162—198
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1 Screw 3. Verify that fluctuation of the speedometer needle is
2 Instrument cluster connector within the allowable range.
3 Instrument cluster
Needle fluctuation allowable range
Within 0.5 km/h
INSTRUMENT CLUSTER
DISASSEMBLY/ASSEMBLY
4. If the speedometer needle does not move or if the
indication is outside of the allowable range, inspect
Caution
the vehicle speedometer sensor and related wiring
If the print plate on the back of the
harness.
instrument cluster is damaged, the system
5. If the vehicle speedometer sensor and related
will not operate properly and it may become
wiring harness are normal, replace the instrument
the cause of trouble or malfunction.
cluster.
Tachometer
Using the SSTs (NGS kit) or a dwell tacho tester
Caution
If the engine speed exceeds the allowable
range, the engine could be damaged.
Therefore, when inspecting the tachometer,
do not allow the engine speed to exceed the
allowable range indication on the
tachometer.
1. Follow the appropriate procedure for using the

SSTs (NGS kit) or dwell tacho tester.
1 Screw
Using the SSTs (NGS kit)
(1) Connect the SSTs (NGS kit) to the data link
2 Bulb connector and battery.
3 Alarm
4 Front lens
5 Instrument cluster DIAGNOSTIC PROGRAM CARD
NGS KIT
CONTINUED
T–22
(2) Select “VEHICLE & ENGINE SELECTION” and : Resistance

press TRIGGER. (Select the model and Terminal
specifications of the vehicle you are testing.) Step
(3) Select “PCM-POWERTRAIN CTRL MODULE” FUEL + FUEL – GND COM
and press TRIGGER. 1 R1
(4) Select “PID/DATA MONITOR AND RECORD” 2 R2
and press TRIGGER. R1, R2: 140—200 Ω
(5) Select “RPM” and press TRIGGER.
(6) Press START.
Using a dwell tacho tester GND

Connect a dwell tacho tester to the terminals K and
FUEL+
B of the PCM connector.
COM
2. Verify that the tachometer indication is within the
allowable range indicated in the table. FUEL–
Dwell tacho tester

Allowable range (rpm)
indication (rpm)
650 583—705
12. Verify that the difference in resistance between R1
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1000 926—1060 and R2 is less than 6 Ω.
2000 1954—2120 13. If not as specified, replace the instrument cluster.
3000 2980—3180
Water Temperature Gauge
4000 4008—4240 1. Disconnect the water temperature sender unit
connector.
3. If the tachometer needle does not move or if the 2. Turn the ignition switch to ON position.
indication is outside of the allowable range, inspect 3. Verify that the needle is below C.
the PCM and related wiring harness. 4. Ground terminal A of the water temperature sender
4. If the PCM and related wiring harness are normal, unit’s vehicle side connector.
replace the instrument cluster.
Fuel Gauge
1. Disconnect the fuel gauge sender unit connector.
2. Connect the red lead of SST (Fuel And
Thermometer checker) to terminal B of the fuel
gauge sender unit connector and black lead to A
ground.
3. Set the resistance of SST (Fuel And Thermometer
checker) to 180 Ω.
49 N088 0A0
49 0839 285
5. Verify that the needle is above H.
6. If the needle does not move or moves irregularly,
* remove the instrument cluster.
(Refer to INSTRUMENT CLUSTER
C B 7. Measure the resistance between the water
temperature gauge terminals using an ohmmeter.
: Resistance
Terminal
4. Turn the ignition switch to ON position. Step
5. Verify that the needle is below E. TEMP + TEMP – V+ COM
6. Turn the ignition switch to LOCK position. 1 R1
7. Set the resistance of SST (Fuel And Thermometer 2 R2
checker) to 10 Ω.
8. Turn the ignition switch to ON position. R1, R2: 140—200 Ω
9. Verify that the needle is above F.
10. If the needle does not move or moves irregularly,
remove the instrument cluster.
(Refer to INSTRUMENT CLUSTER
11. Measure the resistance between the fuel gauge CONTINUED
T–23
WARNING AND INDICATOR LIGHT BULB

TEMP+
2. Remove the instrument cluster.
COM (Refer to INSTRUMENT CLUSTER
3. Turn the socket counterclockwise to remove the
bulb as shown in the figure.
V+ TEMP–
8. Verify that the difference in resistance between R1 BULB

and R2 is less than 6 Ω.
9. If not as specified, replace the instrument cluster.
INSTRUMENT CLUSTER REPAIR
Note
The needle of speedometer or tachometer may
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continue to rotate clockwise until it rests on the 4. Install in the reverse order of removal.
mask plate. If a customer complains of this
concern, repair the needle position according FUEL GAUGE SENDER UNIT INSPECTION
to the following steps. 1. For G6, F2 CIS, or F2 Carb engine vehicles, remove
the fuel pump unit. (Refer to section F2, FUEL
1. Verify the concern. SYSTEM, FUEL TANK REMOVAL/INSTALLATION.)
For WL or WL Turbo
TACHOMETER SPEEDOMETER engine vehicles, remove the fuel gauge sender unit.
(Refer to section F2, FUEL SYSTEM, FUEL TANK
2. Using an ohmmeter, measure and verify that the
resistance between terminals B and C (WL, WL
Turbo) or A and B (G6, F2 CIS, F2 Carb) of the fuel
gauge sender unit is as shown in the following
chart while slowly moving the unit arm from empty
to full.
Measuring point Resistance (Ω)
2. Turn the ignition switch to LOCK position. Full 18.4—26.4
3. Remove the ROOM fuse, then wait for 10 minutes 1/2 81.5—93.5
or more until the power supply in the instrument
cluster is spent. Empty 136—154
4. Turn the ignition switch to ON position.
5. Verify that the needle returns to zero. WL, WL TURBO * DOUBLE CAB
2WD, STRETCH
87.0 {3.43} *
TACHOMETER SPEEDOMETER 65.5 {2.58} CAB 2WD
FULL
169.7 {6.681} *
158.1 {6.224}
1/2
*
253.7 {9.988} B C
EMPTY
mm {in}
6. After the needle returns to zero, install the ROOM

fuse with the ignition switch at ON position. If the
needle does not return to zero, remove the front
lens and carefully move the needle to zero by
hand. (Refer to INSTRUMENT CLUSTER
CONTINUED
T–24
G6, F2 CIS, F2 CARB WATER TEMPERATURE SENDER UNIT

INSPECTION
67.5 {2.66}
1. Remove the water temperature sender unit.
2. Place the sender unit in a container of water.
FULL
3. Heat the water gradually.
4. Using an ohmmeter, measure and verify that the
160.1 {6.303} resistance between terminal of the sender unit and
1/2 the sender unit body is as shown below.
Water temperature (°C {°F }) Resistance (Ω)
255.7 {10.067} A B
EMPTY 49.8—50.2 {121.7—122.3} 189.4—259.6
mm {in}
3. If not as specified, replace the fuel gauge sender
unit.
(Refer to section F2, FUEL SYSTEM, FUEL TANK
(Refer to section F2, FUEL SYSTEM, FUEL PUMP UNIT
(Refer to section F2, FUEL SYSTEM, FUEL PUMP UNIT
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WATER TEMPERATURE SENDER UNIT REMOVAL
1. Disconnect the negative battery cable. 5. If not as specified, replace the water temperature
2. Disconnect the connector. sender unit.
3. Remove the water temperature sender unit.
OIL PRESSURE SWITCH INSPECTION
CONNECTOR 1. Verify that the oil pressure warning light illuminates
when the ignition switch is turned to ON position.
WATER
2. Verify that the oil pressure warning light goes off
TEMPERATURE when the engine is started.
SENDER UNIT 3. If the oil pressure warning light does not illuminate
or remains illuminated, inspect the oil pressure
warning light bulb and related wiring harness.
4. If the oil pressure warning light bulb and related
wiring harness are normal, inspect the oil pressure.
(Refer to section D, LUBRICATION SYSTEM, OIL
WATER TEMPERATURE SENDER UNIT PRESSURE INSPECTION.)
INSTALLATION 5. If the oil pressure is normal, replace the oil
1. Apply sealant from the third thread to the top pressure switch.
thread.
HORN REMOVAL/INSTALLATION
2. Disconnect the horn connector.
3. Remove the bolt.
4. Remove the horn.
BOLT
THIRD THREAD
6—8
{0.24—0.31} mm { in }
HORN
2. Install the water temperature sender unit.
Tightening torque
11.8—17.6 N·m HORN
{120—180 kgf·cm, 105—156 in·lbf} CONNECTOR
3. Connect the water temperature sender unit 5. Install in the reverse order of removal.
connector.
4. Connect the negative battery cable. HORN RELAY REMOVAL/INSTALLATION
2. Remove the driver-side front side trim.
CONTINUED
T–25
WARNING AND INDICATOR SYSTEM, AUDIO
3. Remove in the order indicated in the table. AUDIO

AUDIO UNIT REMOVAL
2. With the beveled parts of the SST (Removing tool)
facing inward, insert them into the unit.
3. Pull the SST (Removing tool) outward and
rearward to slide out the unit.
49 D066 801A
1 Nut
2 Horn relay connector
3 Horn relay
HORN RELAY INSPECTION
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1. Remove the horn relay. 4. Disconnect the connectors and antenna jack.
(Refer to HORN RELAY REMOVAL/INSTALLATION.)
2. Inspect for continuity between the horn relay AUDIO UNIT INSTALLATION
: Continuity B+: Battery positive voltage Caution
Terminal If the harness or the antenna feeder is
Step caught between the unit and dashboard, it
A B C D
may become the cause of trouble or
1 malfunctions. Make certain that the wiring
2 B+ GND harness and antenna feeder are not caught
between the unit and dashboard.
1. Connect the connectors and antenna jack.

D A 2. Insert the unit until each clip clicks.
C A
SPEAKER REMOVAL/INSTALLATION
D B 1. Disconnect the negative battery cable.
2. Remove the front door trim.
C B (Refer to section S, TRIM, FRONT DOOR TRIM
Caution
3. If not as specified, replace the horn relay. When removing or installing a speaker,
touching the radio cone paper could cause
CLOCK REMOVAL/INSTALLATION poor sound quality. When removing or
1. Disconnect the negative battery cable. installing a speaker, hold the speaker’s
2. Remove the meter hood. bracket and handle with care.
METER HOOD REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table.
3. Remove the screws and remove the clock. 4. Install in the reverse order of removal.
SCREW CLOCK SCREW
T–26
AUDIO
1 Screw SCREW
2 Speaker
+ Installation Note
3 Connector
Speaker Installation Note

When installing the speakers, position the
speakers so that the terminals face downward.
ROOF ANTENNA
SPEAKER INSPECTION
1. Remove the speaker.
(Refer to SPEAKER REMOVAL/INSTALLATION.)
ROOF ANTENNA INSTALLATION
2. Inspect for resistance between the speaker
1. Tape the antenna jack to the antenna drain hose.
: Resistance
Terminal
Test condition
A B
Constant R
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R: 4 Ω
2. Pass the roof antenna and antenna drain hose

through the A-pillar from the hole in the roof.
3. Connect the antenna feeder.
4. Install the screws.
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5. Install the driver-side front side trim.
3. Touch the leads of an ohmmeter to the speaker
terminals and verify that the speaker clicks. ROOF ANTENNA INSPECTION
Range 2. Remove the driver-side front side trim.
1 Ω (Refer to section S, TRIM, FRONT
SIDE TRIM REMOVAL/INSTALLATION.)
4. If not as specified, replace the speaker. 3. Disconnect the connection between the roof
antenna and the antenna feeeder.
ROOF ANTENNA REMOVAL 4. Verify that there is no continuity between roof
1. Disconnect the negative battery cable. antenna terminals A and B using an ohmmeter.
2. Remove the driver-side front side trim. 5. Inspect for continuity between the roof antenna
(Refer to section S, TRIM, FRONT terminals using an ohmmeter.
SIDE TRIM REMOVAL/INSTALLATION.) : Continuity
3. Disconnect the connection between the roof
antenna and the antenna feeder. Terminal
Step
A B C D
1
2
ANTENNA C
FEEDER
D
ROOF ANTENNA
B
A
4. Remove the screws and pull out the roof antenna. 123456567
CONTINUED
T–27
AUDIO
6. If not as specified, replace the roof antenna. CONDENSER REMOVAL/INSTALLATION

ANTENNA FEEDER REMOVAL/INSTALLATION 2. Remove in the order indicated in the table.
1. Disconnect the negative battery cable. 3. Install in the reverse order of removal.
(Refer to section S, TRIM, FRONT
3. Disconnect the connection between the antenna
feeder and the roof antenna.
4. Remove in the order indicated in the table. IGNITION
5. Install in the reverse order of removal. COIL
1 Screw
2 Clip
3 Nut
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4 Condenser
1 Clip
2 Antenna feeder
ANTENNA FEEDER INSPECTION

(Refer to section S, TRIM, FRONT
3. Disconnect the connection between the antenna
feeder and the roof antenna.
4. Verify that there is no continuity between the
antenna feeder terminals A and B using an
ohmmeter.
5. Inspect for continuity between the antenna feeder
: Continuity
Terminal
Step
A B C D
1
2
B
D C
A
123456567
6. If not as specified, replace the antenna feeder.

CONTINUED
T–28
HEATER AND AIR

CONDITIONER SYSTEMS
SERVICE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . U– 2 STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . . U–19
HANDLING REFRIGERANT . . . . . . . . . . . . . . . . U– 2 MAGNETIC CLUTCH
STORING REFRIGERANT . . . . . . . . . . . . . . . . . U– 2 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . U–20
SERVICE CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . U– 2 MAGNETIC CLUTCH CLEARANCE
HANDLING COMPRESSOR OIL . . . . . . . . . . . . U– 2 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . U–20/21
REFRIGERANT SYSTEM SERVICE MAGNETIC CLUTCH INSPECTION . . . . . . . . . U–21
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 3 A/C RELAY No.1
MANIFOLD GAUGE SET INSTALLATION . . . . U– 3 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–21
RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 3 A/C RELAY No.1 INSPECTION . . . . . . . . . . . . . U–22
CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 3/5 A/C RELAY No.2
REFILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 5/6 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–22
REFRIGERANT CHARGE CHECK . . . . . . . . . . U– 6/7 A/C RELAY No.2 INSPECTION . . . . . . . . . . . . . U–22
REFRIGERANT PRESSURE CHECK . . . . . . . U– 7 REFRIGERANT PRESSURE SWITCH
PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . U– 7 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–22
BASIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . U– 8 REFRIGERANT PRESSURE SWITCH
STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . . U– 8/9 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . U–23
BLOWER UNIT REMOVAL/INSTALLATION . . U–10 THERMOSWITCH INSPECTION . . . . . . . . . . . U–23/24
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BLOWER UNIT DISASSEMBLY/ASSEMBLY . U–10 BLOWER MOTOR
COOLING UNIT REMOVAL/INSTALLATION . . U–10/11 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–24
COOLING UNIT DISASSEMBLY/ASSEMBLY . U–12 BLOWER MOTOR INSPECTION . . . . . . . . . . . U–24
EVAPORATOR INSPECTION . . . . . . . . . . . . . . U–13 RESISTOR REMOVAL/INSTALLATION . . . . . . U–24
HEATER UNIT REMOVAL/INSTALLATION . . . U–13 RESISTOR INSPECTION . . . . . . . . . . . . . . . . . . U–25
HEATER UNIT DISASSEMBLY/ASSEMBLY . . U–14 CLIMATE CONTROL UNIT REMOVAL . . . . . . U–25
HEATER CORE INSPECTION . . . . . . . . . . . . . . U–15 CLIMATE CONTROL UNIT INSTALLATION . . U–25
A/C COMPRESSOR CLIMATE CONTROL UNIT
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–15 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . U–25/26
CONDENSER REMOVAL/INSTALLATION . . . U–16 CLIMATE CONTROL UNIT WIRE
CONDENSER INSPECTION . . . . . . . . . . . . . . . U–16 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . U–26/27
RECEIVER/DRIER CLIMATE CONTROL UNIT INSPECTION . . . . U–27
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–16/17 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . U–28
REFRIGERANT LINES FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U–28
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U–17/18 TROUBLESHOOTING INDEX . . . . . . . . . . . . . . U–28
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . U–19 SYMPTOM TROUBLESHOOTING . . . . . . . . . . U–28/39
CONTINUED
U–1
SERVICE WARNINGS, SERVICE CAUTIONS
SERVICE WARNINGS SERVICE CAUTIONS

HANDLING REFRIGERANT HANDLING COMPRESSOR OIL
D Avoid breathing air conditioning refrigerant or D Use FD46XG (G6, WL, WL turbo) or ZXL 100PG
lubricant vapor. Exposure may irritate eyes, (F2, F2 Cab) compressor oil for this vehicle.
nose and throat. If accidental system discharge Using a PAG oil other than FD46XG (G6, WL,
occurs, ventilate work area before resuming WL turbo) or ZXL 100PG compressor oil can
service. damage the A/C compressor.
D Do not pressure test or leak test R-134a service D Do not spill compressor oil on the vehicle. A
equipment and/or vehicle air conditioning drop of compressor oil on the vehicle surface
system with compressed air. Some mixtures of can eat away at the paint. If oil gets on the
air and R-134a have been shown to be vehicle, wipe it off immediately.
combustible at elevated pressures. These D FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2,
mixtures, if ignited, may cause injury or F2 Cab) compressor oil (PAG oil) has a higher
property damage. Additional health and safety moisture absorption efficiency than the
information may be obtained from refrigerant previously used mineral oil. If moisture mixes
manufacturers. with the compressor oil, the refrigerant system
D Do not allow the refrigerant to leak near fire or could be damaged. Therefore, install caps
any kind of heat. A poisonous gas may be immediately after using the compressor oil or
generated if the refrigerant gas contacts fire or removing refrigerant system parts to prevent
heat such as from cigarettes and heaters. moisture absorption.
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When carrying out any operation that can FD46XG (G6, WL, WL turbo) or ZXL
cause refrigerant leakage, extinguish or 100PG (F2, F2 Cab) COMPRESSOR
OIL
remove the above-mentioned heat sources and
maintain adequate ventilation.
D Handling liquid refrigerant is dangerous. A
drop of it on the skin can result in localized
frostbite. When handling the refrigerant, wear
gloves and safety goggles. If refrigerant MINERAL OIL
splashes into the eyes, immediately wash them
with clean water and consult a doctor.
STORING REFRIGERANT TIME

D The refrigerant container is highly pressurized. MOISTURE ABSORPTION
If it is subjected to high heat, it could explode,
scattering metal fragments and liquid
refrigerant that can seriously injure you. Store
the refrigerant at temperatures below 40 °C CONTINUED
{104 °F}.
U–2
REFRIGERANT SYSTEM SERVICE PROCEDURES
REFRIGERANT SYSTEM SERVICE TAP PIN SIDE AIR PURGE VALVE

49 C061 001
PROCEDURES
MANIFOLD GAUGE SET INSTALLATION 49 C061 005
1. Fully close the valves of the SST (49 C061 001). 49 C061 004
2. Connect the SSTs (49 C061 002, 49 C061 003) to
REFRIGERANT
the high- and low-pressure side joints of the TANK
SST (49 C061 001).
3. Connect the SSTs (49 C061 006A, 49 C061 007) SCALE
to the ends of the SSTs (49 C061 002,
49 C061 003). VACUUM PUMP
4. Connect the SSTs (49 C061 006A, 49 C061 007)
to the charging valves. 7. Open all the valves of the SST (49 C061 001).
49 C061 001 Caution
Close the SST (49 C061 001) valve
49 C061 002 immediately after stopping the vacuum
pump. If the valve is left open, the vacuum
49 C061 003 49 C061 006A pump oil will flow back into the refrigeration
CAP
cycle and cause a decrease in the efficiency
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49 C061 007 of the air conditioner.
CHARGING
CAP VALVE OF
HIGH-PRESSURE 8. Start the vacuum pump and let it operate for
CHARGING VALVE OF SIDE 15 minutes.
LOW-PRESSURE SIDE
RECOVERY 49 C061 001

Connect an R-134a recovery/recycling/recharging
device to the vehicle and follow the device
manufacturer’s instructions. CLOSE
CHARGING
Charging Recycled R-134a Refrigerant
Connect an R-134a recovery/recycling/recharging
device to the vehicle and follow the device
manufacturer’s instructions.
Charging New R-134a Refrigerant 9. Verify that high- and low-pressure side readings of
the SST (49 C061 001) are at –101 kPa
Caution {–760 mmHg, –29.9 inHg}. Close each valve of
Do not exceed the specification when the SST (49 C061 001).
charging the system with refrigerant. Doing
so will decrease the efficiency of the air
conditioner or damage the refrigeration 49 C061 001
cycle parts.
1. Install the SSTs (Manifold gauge set).

(Refer to MANIFOLD GAUGE SET INSTALLATION.)
2. Connect the tap pin side of the SST (49 C061 004)
to the air purge valve of the SST (49 C061 001).
3. Connect the SST (49 C061 005) to the center joint
of the SST (49 C061 001).
4. Connect the SST (49 C061 005) to the vacuum
pump.
5. Connect the SST (49 C061 004) to the refrigerant 10. Stop the vacuum pump and wait for 5 minutes.
tank. 11. Check the high- and low-pressure side readings of
6. Place the refrigerant tank on the scale. the SST (49 C061 001). If the reading has
changed, inspect for leakage and then repeat from
Regular amount of refrigerant step 7. If the reading has not changed, go to step
550 g {19.4 oz} 12.
12. Open the valve of the refrigerant tank.
13. Weigh the refrigerant tank.
CONTINUED
U–3
Warning Warning
If the refrigerant system is charged with a If charging the system with refrigerant
large amount of refrigerant when checking using service cans, running the engine with
for gas leakage, and if any leakage should the high-pressure side valve open is
occur, the refrigerant will be released into dangerous. Pressure within the service
the atmosphere. In order to prevent the cans will increase and the cans could
accidental release of refrigerant which can explode, scattering metal fragments and
destroy the ozone layer in the stratosphere, liquid refrigerant that can seriously injure
follow the proper procedures and charge you. Therefore, do not open the
with only a small amount of refrigerant high-pressure side valve while the engine is
when checking for gas leakage. running.
If charging the system with refrigerant
using service cans, running the engine with 17. Open the high-pressure side valve of the
the high-pressure side valve open is SST (49 C061 001) and charge with refrigerant until the
dangerous. Pressure within the service weight of refrigerant tank has decreased 300 g
cans will increase and the cans could {10.6 oz} from the amount in step 13.
explode, scattering metal fragments and
liquid refrigerant that can seriously injure 49 C061 001
you. Therefore, do not open the
high-pressure side valve while the engine is OPEN
running.
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14. Open the high-pressure side valve of the
SST (49 C061 001).
49 C061 001
OPEN
18. Close the high-pressure side valve of the

SST (49 C061 001).
49 C061 001
15. When the low-pressure side reading increases to

0.098 MPa {1.0 kgf/cm2, 14 psi}, close the
high-pressure side valve of the
SST (49 C061 001).
49 C061 001
Warning
If charging the system with refrigerant
using service cans, running the engine with
the high-pressure side valve open is
dangerous. Pressure within the service
cans will increase and the cans could
liquid refrigerant that can seriously injure
16. Inspect for leakage from the cooler pipe/hose high-pressure side valve while the engine is
connections using the SST (Gas leak tester). If running.
there is no leakage, go to step 17. If a leakage is
found at a loose joint, tighten the joint and inspect 19. Start the engine and actuate the A/C compressor.
for leakage again. If there is still leakage at the 20. Open the low-pressure side valve of the
same joint, discharge the refrigerant and then SST (49 C061 001) and charge with refrigerant until the
repair the joint. Repeat the charging procedure refrigerant tank is empty.
from step 7. If there is no leakage after tightening
the joint, go to step 17. CONTINUED
U–4
49 C061 001 TAP PIN SIDE AIR PURGE VALVE

49 C061 001
OPEN
49 C061 005
49 C061 004
REFRIGERANT
TANK
VACUUM PUMP
21. Close the low-pressure side valve of the 6. Open only the center valve of the SST (49 C061
SST (49 C061 001) and the valve of the refrigerant tank. (49 C061 001).
22. Stop the engine and A/C compressor.
23. Inspect for leakage using the SST (Gas leak Caution
tester). If there is no leakage, go to step 24. If Close the SST (49 C061 001) valve
leakage is found at a loose joint, tighten the joint immediately after stopping the vacuum
and inspect for leakage again. If there is still a leak pump. If the valve is left open, the vacuum
at the same joint, discharge the refrigerant and pump oil will flow back into the refrigeration
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then repair the joint. Repeat the charging cycle and cause a decrease in the efficiency
procedure from step 7. If there is no leakage after of the air conditioner.
tightening the joint, go to step 24.
24. Disconnect the SSTs (49 C061 006A, 7. Start the vacuum pump and let it run for 1 minute.
49 C061 007) from the charging valves.
25. Install the caps to the charging valves. 49 C061 001
CLOSE
49 C061 006A
49 0061 007
CAP
CAP
8. Close the center valve of the SST (49 C061 001).
REFILLING 49 C061 001
Caution
Do not exceed the specification when
charging the system with refrigerant. Doing
so will decrease the efficiency of the air
conditioner or damage the refrigeration
cycle parts.
1. Install the SSTs (Manifold gauge set).

(Refer to MANIFOLD GAUGE SET INSTALLATION.)
2. Connect the tap pin side of the SST (49 C061 004)
to the air purge valve of the SST (49 C061 001). 9. Stop the vacuum pump.
3. Connect the SST (49 C061 005) to the center joint 10. Open the valve of the refrigerant tank.
of the SST (49 C061 001).
4. Connect the SST (49 C061 005) to the vacuum Warning
pump. If charging the system with refrigerant
5. Connect the SST (49 C061 004) to the refrigerant using service cans, running the engine with
tank. the high-pressure side valve open is
dangerous. Pressure within the service
cans will increase and the cans could
liquid refrigerant that can seriously injure
high-pressure side valve while the engine is
running.
CONTINUED
U–5
11. Start the engine and actuate the A/C compressor.

12. Open the low-pressure side valve of the 49 C061 007 49 C061 006A
SST (49 C061 001).
49 C061 001 CAP
OPEN
CAP
REFRIGERANT CHARGE CHECK
Caution
13. Refer to refrigerant charge check and The FD46XG (G6, WL, WL turbo) or ZXL
refill with refrigerant. 100PG (F2, F2 Cab) compressor oil will
separate from refrigerant at high
L.H.D. temperatures of 50 °C {122 °F} or more. If
this happens, the sight glass will change to
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a milky-white color, and there is a
possibility that you might mistakenly
believe the refrigerant amount to be
insufficient and recharge with additional
refrigerant.
SIGHT GLASS If the system is overcharged with
refrigerant, the sight glass will become
clear and give a false indication. You will
mistakenly believe that the refrigerant
amount is correct.
Therefore, when checking the refrigerant
R.H.D. (WL, G6, F2 Cab)
amount, verify the refrigerant pressure and
cooler pipe temperature in addition to the
sight glass condition.
1. Warm up the engine and run it at a constant

1,500 rpm.
2. Set the fan switch at 4th.
3. Set the temperature control dial to MAX COLD.
4. Close all the doors and windows.
SIGHT GLASS 5. Check the refrigerant amount condition according
to the following table.
R.H.D.
(WL turbo)
SIGHT GLASS
14. Close the low-pressure side valve of the

SST (49 C061 001) and the valve of the refrigerant tank.
15. Stop the engine and the A/C compressor.
16. Disconnect the SSTs (49 C061 006A,
49 C061 007) from the charging valves.
17. Install the caps to the charging valves.
CONTINUED
U–6
Condition of Mpa
Amount Other conditions {kgf/cm2, psi}
sight glass HIGH-PRESSURE SIDE
2.0
High-pressure side cooler {21, 299}
pipe is warm;
low-pressure side cooler 1.5
{15, 213}
pipe is cool.
Insufficient
High- and low-pressure 1.0
{10, 142}
side readings are lower
Bubbles than normal.
Air cooling ability is low. 0.2
LOW-PRESSURE SIDE
{2.0, 28}
High-pressure side cooler
pipe is hot; low-pressure
side cooler pipe is cold. 0.1
High- and low-pressure {1.0, 14}
side readings are normal.
Clear
* If sight glass is
Correct
milky-white, pour water
into condenser for
approximately 20 PRESSURE READING OF MANIFOLD GAUGE
20 25 30 35 40 °C
seconds to cool it off, {68} {77} {86} {95} {104} {°F}
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Milky white then the sight glass will
AMBIENT TEMPERATURE
clear.
High-pressure side cooler
pipe is hot; low-pressure 9. If not as specified, troubleshoot the refrigerant
side cooler pipe is cold. system. (Refer to TROUBLESHOOTING.)
Over High- and low-pressure
side reading are higher PERFORMANCE TEST
Clear than normal.
Air cooling ability is low. Note
After servicing the refrigerant system, the test
6. If not as specified, troubleshoot the refrigerant is performed.
system. (Refer to TROUBLESHOOTING.)
1. Install the SSTs (manifold gauge set).
REFRIGERANT PRESSURE CHECK (Refer to MANIFOLD GAUGE SET INSTALLATION.)
1. Install the SSTs (Manifold gauge set). 2. Open the bonnet.
(Refer to MANIFOLD GAUGE SET INSTALLATION.) 3. Close all the doors and windows.
2. Open the bonnet. 4. Warm up the engine and run it at a constant
3. Close all the doors and windows. 1,500 rpm.
4. Warm up the engine and run it at a constant 5. Set the fan switch at 4th.
1,500 rpm. 6. Set the temperature control dial to MAX COLD.
5. Set the fan switch at 4th. 7. Record center ventilator right side temperature.
6. Set the temperature control dial to MAX COLD. 8. Determine and record ambient temperature.
7. Measure the ambient temperature and the high- 9. Verify that the temperature reading is in the shaded
and low-pressure side reading of the zone.
SST (49 C061 001). °C {°F}
8. Verify that the intersection of the pressure reading 6 {43}
of the SST (49 C061 001) and ambient 5 {41}
temperature is in the shaded zone. 4 {39}
3 {37}
2 {36}
1 {34}
0 {32}
20 25 30 35 40 °C
{68} {77} {86} {95} {104} {°F}
CENTER VENTILATOR AMBIENT TEMPERATURE
TEMPERATURE
10. If the performance is not within the shaded zone,

troubleshoot the refrigerant system.
(Refer to TROUBLESHOOTING.)
CONTINUED
U–7
BASIC SYSTEM
BASIC SYSTEM
STRUCTURAL VIEW
L.H.D. (G6) BLOWER UNIT
COOLING UNIT
HEATER UNIT
COOLER
PIPE
(LOW) HEATER
COOLER HOSE
PIPE
A/C
(HIGH)
COMPRESSOR
COOLER L.H.D. (WL, WL turbo)

HOSE
BLOWER UNIT
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(LOW)
CONDENSER COOLING UNIT
HEATER UNIT
RECEIVER/DRIER
COOLER
PIPE
(LOW) HEATER
HOSE
COOLER A/C
PIPE COMPRESSOR
(HIGH)
COOLER
HOSE
(HIGH)
CONDENSER
RECEIVER/DRIER
L.H.D. (F2, F2 Cab)
BLOWER UNIT
COOLING UNIT
HEATER UNIT
COOLER
PIPE
(LOW)
HEATER
COOLER HOSE
PIPE A/C
(HIGH) COMPRESSOR
COOLER
HOSE
(HIGH)
CONDENSER
RECEIVER/DRIER
CONTINUED
U–8
BASIC SYSTEM
R.H.D. (G6)
HEATER UNIT
HEATER COOLING UNIT

HOSE
A/C
COMPRESSOR BLOWER UNIT
COOLER
HOSE
(LOW)
COOLER
PIPE
(HIGH)
CONDENSER
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RECEIVER/DRIER COOLER
HOSE (HIGH)
R.H.D. (WL, WL turbo)
HEATER UNIT
HEATER
COOLING UNIT
HOSE
A/C
COMPRESSOR BLOWER UNIT
COOLER
HOSE (LOW)
COOLER SIGHT GLASS

PIPE
(HIGH)
CONDENSER
R.H.D. (F2 Cab) WL turbo

COOLER
RECEIVER/DRIER HOSE (HIGH)
HEATER UNIT
HEATER COOLING UNIT

HOSE
A/C BLOWER UNIT

COMPRESSOR
COOLER
HOSE (LOW)
COOLER
PIPE
(HIGH)
CONDENSER
RECEIVER/DRIER CONTINUED
U–9
BASIC SYSTEM
BLOWER UNIT REMOVAL/INSTALLATION R.H.D.

3. Remove the cooling unit.
(Refer to COOLING UNIT REMOVAL/INSTALLATION.)
4. Remove the passenger’s side front side trim
(L.H.D. only.)
B
C
A
A
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B
C
1 Blower motor
2 Resistor
3 Blower harness
4 Polyurethane protector
5 Inlet duct case (front)
6 Inlet duct case (rear)
7 Blower case (upper)
1 Connector 8 Blower case (lower)
2 Blower unit 9 Air intake door
10 Air intake link
BLOWER UNIT DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table. 11 Air intake crank
L.H.D.
COOLING UNIT REMOVAL/INSTALLATION
2. Discharge the refrigerant from the system.
(Refer to REFRIGERANT SYSTEM SERVICE
PROCEDURES, RECOVERY.)
PROCEDURES, CHARGING.)
4. Disconnect the air intake wire from the cooling unit.
(Refer to CONTROL SYSTEM, CLIMATE
CONTROL UNIT WIRE ADJUSTMENT.)
Caution
If moisture or foreign material enters the
refrigeration cycle, cooling ability will be
lowered and abnormal noise will occur.
B Always immediately plug all open fittings
C after removing any refrigeration cycle parts
A to keep moisture or foreign material out of
A the cycle.
B CONTINUED
C
U–10
BASIC SYSTEM
5. Remove in the order indicated in the table. Do not 1 Cooler hose (low)
allow compressor oil to spill. + REFRIGERANT LINES
6. Install in the reverse order of removal. REMOVAL/INSTALLATION, Refrigerant Lines
7. Carry out the refrigerant system performance test. Removal Note
(Refer to REFRIGERANT SYSTEM SERVICE + REFRIGERANT LINES
PROCEDURES, PERFORMANCE TEST.) REMOVAL/INSTALLATION, Refrigerant Lines
L.H.D. Installation Note
2 Cooler pipe (high)
+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Removal Note
R
+ REFRIGERANT LINES
15—21 N·m
Installation Note
{1.5—2.2 kgf·m, 3 Connector
130.2—190.9 in·lbf} R 6.9—9.8 N·m
{0.7—1.0 kgf·m, 4 Cooling unit
60.8—86.7 in·lbf} + Removal Note
+ Installation Note
R.H.D.
20—29 N·m
R Cooling Unit Removal Note (R.H.D. only)
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{2.0—3.0 kgf·m,
15—21 ft·lbf} Turn the cooling unit 90 degrees to the right, and
remove the cooling unit.
9.81—19.61 N·m
{100—200 kgf·cm,
86.8—173.5 in·lbf}
Cooling Unit Installation Note

When installing a new cooling unit (evaporator),
add FD46XG (G6, WL, WL turbo) or ZXL 100PG
(F2, F2 Cab) compressor oil into the refrigeration
cycle.
Supplement amount
40 ml {40 cc, 1.4 fl oz}
CONTINUED
U–11
BASIC SYSTEM
COOLING UNIT DISASSEMBLY/ASSEMBLY
Caution
Always immediately plug all open fittings
after removing any refrigeration cycle parts
to keep moisture or foreign material out of
the cycle.

1 Cooler case (upper)
L.H.D.
2 Cooler case (lower)
3 Thermoswitch clip
4 Thermoswitch
+ Assembly Note
5 Evaporator
6 Expansion valve
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+ Assembly Note
7 High pressure pipe
Expansion Valve Assembly Note

Replace the O-rings at the expansion valve joints
and apply compressor oil to the O-rings and
connect the joints.
Tighten the joint to the specified torque using two
open-end wrenches.
Assemble the heat-sensing tube as shown in the
figure.
20—24 N·m
{2.0—2.5 kgf·m,
15—18 ft·lbf}
R.H.D. 11.8—14.7 N·m

{120—150 kgf·cm,
105—130 in·lbf}
HEAT-SENSING TUBE
Thermoswitch Assembly Note

1. Insert the thermoswitch probe in location as shown
in the figure.
EVAPORATOR
40 mm
{1.6 in}
CONTINUED
U–12
BASIC SYSTEM
EVAPORATOR INSPECTION
1. Remove the cooling unit.
(Refer to COOLING UNIT REMOVAL/INSTALLATION.)
2. Remove the evaporator from the cooling unit.
3. Inspect for cracks, damage, and oil leakage. If any
problems are found, replace the evaporator.
4. Inspect for bent fins. If they are bent, use a
flat-head screwdriver to straighten them.
HEATER UNIT REMOVAL/INSTALLATION

(Refer to section E, ENGINE COOLANT,
ENGINE COOLANT REPLACEMENT.) (With heater core only)
3. Remove the dashboard.
DASH BOARD REMOVAL/INSTALLATION.)
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*
* WITH HEATER CORE ONLY
1 Heater hose
2 Heater unit CONTINUED
U–13
BASIC SYSTEM
HEATER UNIT DISASSEMBLY/ASSEMBLY

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*
* *
*
*
* WITH HEATER CORE ONLY
1 Heater core 9 Airflow mode crank (2)

2 Air mix rod 10 Airflow mode crank (3)
3 Air mix link 11 Airflow mode crank (4)
4 Air mix crank (1) 12 Airflow mode sub link (1)
5 Air mix crank (2) 13 Airflow mode sub link (2)
6 Air mix shaft 14 Heater case (1)
7 Airflow mode main link 15 Heater case (2)
8 Airflow mode crank (1) 16 Heater case (3)
CONTINUED
U–14
BASIC SYSTEM
HEATER CORE INSPECTION G6, WL, WL turbo

1. Remove the heater unit.
(Refer to HEATER UNIT REMOVAL/INSTALLATION.) 15—21
{1.5—2.2,
2. Remove the heater core from the heater unit. 11—15}
3. Inspect for cracks, damage, and coolant leakage. If
any are found, replace the heater core.
4. Inspect for bent fins. If any are bent, use a flathead
screwdriver to straighten them.
5. Verify that the heater core inlet and outlet are not
distorted or damaged. Repair with pliers if necessary. R
A/C COMPRESSOR REMOVAL/INSTALLATION

(Refer to REFRIGERANT SYSTEM SERVICE R
PROCEDURES, RECOVERY.) (Refer to REFRIGERANT
SYSTEM SERVICE PROCEDURES, CHARGING.)
3. Remove the drive belt (P/S + A/C). 24—35
{2.4—3.6,
4. Remove the air cleaner and air hose. (WL turbo 18—26}
only) (Refer to section F2, INTAKE-AIR SYSTEM,
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5. Loosen the A/C compressor bolts, then slide the
A/C compressor. (WL turbo only) N·m {kgf·m, ft·lbf}
F2, F2 Cab R
Caution
refrigeration cycle, cooling ability will be 30—39
{3.0—4.0,
lowered and abnormal noise will occur. 22—28}
Always immediately plug all open fittings after
removing any refrigeration cycle parts to keep
moisture or foreign material out of the cycle.
6. Remove in the order indicated in the table. Do not

allow compressor oil to spill.
7. Install in the reverse order of removal. N·m {kgf·m, ft·lbf}
8. Adjust the drive belt (P/S + A/C). (Refer to section
B2, DRIVE BELT, DRIVE BELT ADJUSTMENT.) 1 Connector
9. Carry out the refrigerant system performance test.
2 Cooler hose (high)
+ REFRIGERANT LINES
PROCEDURES, PERFORMANCE TEST.)
Installation Note
3 Cooler hose (low)
+ REFRIGERANT LINES
Installation Note
4 A/C compressor
+ Installation Note
A/C Compressor Installation Note

Remove the following amount of compressor oil
from the new A/C compressor when replacing the
A/C compressor.
Compressor oil to be removed = 180 ml

{180 cc, 6.08 fl oz} – [compressor oil from old
A/C compressor + 15 ml {15 cc, 0.5 fl oz} ]
CONTINUED
U–15
BASIC SYSTEM
CONDENSER REMOVAL/INSTALLATION Condenser Installation Note

1. Disconnect the negative battery cable. When installing a new condenser, add FD46XG
2. Discharge the refrigerant from the system. (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab)
(Refer to REFRIGERANT SYSTEM SERVICE compressor oil into the refrigeration cycle.
PROCEDURES, RECOVERY.) (Refer to
REFRIGERANT SYSTEM SERVICE Supplemental amount
PROCEDURES, CHARGING.) 30 ml {30 cc, 1.0 fl oz}
4. Remove the charge air cooler and air hose. (WL CONDENSER INSPECTION
turbo only) 1. Inspect for cracks, damage, and oil leakage. If any
(Refer to section F2, INTAKE-AIR SYSTEM, problems are found, replace the condenser.
INTAKE-AIR SYSTEM 2. Inspect for fins clogged by dust. If any are clogged,
REMOVAL/INSTALLATION.) remove the dust from the fins.
5. Remove the receiver/drier. 3. Inspect for bent fins. If any are bent, use a flathead
(Refer to RECEIVER/DRIER REMOVAL/INSTALLATION.) screwdriver to straighten them.
Caution RECEIVER/DRIER REMOVAL/INSTALLATION

If moisture or foreign material enters the 1. Disconnect the negative battery cable.
refrigeration cycle, cooling ability will be 2. Discharge the refrigerant from the system. (Refer to
lowered and abnormal noise will occur. REFRIGERANT SYSTEM SERVICE PROCEDURES,
Always immediately plug all open fittings RECOVERY.) (Refer to REFRIGERANT SYSTEM
cardiagn.com
after removing any refrigeration cycle parts SERVICE PROCEDURES, CHARGING.)
to keep moisture or foreign material out of 3. Remove the radiator grille.
the cycle.
Caution
6. Remove in the order indicated in the table. Do not If moisture or foreign material enters the
allow compressor oil to spill. refrigeration cycle, cooling ability will be
7. Install in the reverse order of removal. lowered and abnormal noise will occur.
8. Carry out the refrigerant system performance test. Always immediately plug all open fittings
(Refer to REFRIGERANT SYSTEM SERVICE after removing any refrigeration cycle parts
PROCEDURES, PERFORMANCE TEST.) to keep moisture or foreign material out of
the cycle.
4. Remove in the order indicated in the table. Do not

15—21 N·m allow compressor oil to spill.
{1.5—2.2 kgf·m, 5. Install in the reverse order of removal.
11—15 ft·lbf} 6. Carry out the refrigerant system performance test.
B 6.85—9.80 N·m
A {70—100 kgf·cm, 60.8—86.7 in·lbf}
C D
C A R
D R
1 Cooler pipe R
+ REFRIGERANT LINES
Installation Note
2 Bonnet lock stay
3 Condenser
+ Installation Note
CONTINUED
U–16
BASIC SYSTEM
1 Connector Caution
2 Cooler pipe
+ REFRIGERANT LINES lowered and abnormal noise will occur.
Installation Note after removing any refrigeration cycle parts
3 Condenser to keep moisture or foreign material out of
+ CONDENSER REMOVAL/INSTALLATION, the cycle.
Condenser Installation Note
4 Receiver/drier 3. Remove the radiator grille.
+ Installation Note 4. Remove the front bumper.
(Refer to section S, BUMPER, FRONT BUMPER
Receiver/drier Installation Note REMOVAL/INSTALLATION.)
When installing a new receiver/drier, add FD46XG 5. Remove the radiator. (WL turbo only)
(G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) 6. Remove in the order indicated in the table. Do not
compressor oil into the refrigeration cycle. allow compressor oil to spill.
Supplemental amount 8. Carry out the refrigerant system performance test.
35 ml {35 cc, 1.2 fl oz} (Refer to REFRIGERANT SYSTEM SERVICE
REFRIGERANT LINES REMOVAL/INSTALLATION
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PROCEDURES, RECOVERY.) (Refer to
REFRIGERANT SYSTEM SERVICE
L.H.D.
R R
B
R
B A
C R
E
D
F
R B
R
R A
D C A
C
F B
D
A
R R B
R
A
E
C E
CONTINUED
U–17
BASIC SYSTEM
R.H.D.
R
R R
E D
B
R
B
C C
A
R
A
D
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R A
D
C
A: 6.85—9.80 N·m {70—100 kgf·cm, 60.8—86.7 in·lbf}

B: 15—21 N·m {1.5—2.2 kgf·m, 11—15 ft·lbf}
C: 20—29 N·m {2.0—3.0 kgf·m, 15—21 ft·lbf}
D: 9.81—19.61 N·m {100—200 kgf·cm, 86.8—173.5 in·lbf}
E: 24—35 N·m {2.4—3.6 kgf·m, 18—26 ft·lbf}
1 Cooler hose (low) Refrigerant Lines Installation Note

+ Removal Note 1. When installing a new cooler pipe or hose, add
+ Refrigerant Lines Removal Note FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2
+ Refrigerant Lines Installation Note Cab) compressor oil into the refrigeration cycle.
2 Cooler hose (high)
Supplemental amount
+ Removal Note
Cooler hose (low): 8 ml {8 cc, 0.3 fl oz}
+ Refrigerant Lines Installation Note
Cooler hose (high): 5 ml {5 cc, 0.2 fl oz}
3 Cooler pipe (high) Cooler pipe: 3 ml {3 cc, 0.1 fl oz}
+ Refrigerant Lines Removal Note
+ Refrigerant Lines Installation Note 2. Apply compressor oil to the O-rings and connect
the joints.
Cooler Hose Removal Note 3. Tighten the joints.
WL turbo only (1) Tighten the nut or bolt of the joint by hand.
Loosen the A/C compressor bolts, then slide the (2) Tighten the joint to the specified torque. If it is a
A/C compressor, and remove the cooler hose bolt nut joint, tighten the nut using a spanner and
from the A/C compressor. torque wrench.
Refrigerant Lines Removal Note

Loosen the nut using two spanners, then remove
the cooler pipe or hose. CONTINUED
U–18
CONTROL SYSTEM
CONTROL SYSTEM
STRUCTURAL VIEW
L.H.D.
A/C RELAY No.2* REFRIGERANT PRESSURE SWITCH
A/C RELAY No.1 MAGNETIC CLUTCH
CLIMATE
CONTROL UNIT
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THERMOSWITCH
RESISTOR
BLOWER MOTOR
R.H.D.
REFRIGERANT PRESSURE SWITCH
MAGNETIC CLUTCH
A/C RELAY No.2*
A/C RELAY No.1 CLIMATE

CONTROL UNIT
THERMOSWITCH
RESISTOR
BLOWER MOTOR
CONTINUED
* F2 Cab only
U–19
CONTROL SYSTEM
MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY Stator Removal Note

1. Disassemble in the order indicated in the table. Set a straight-socket (17 mm {0.67 in}) on the shaft
2. Assemble in the reverse order of disassembly. of the A/C compressor to protect it.
3. Adjust the magnetic clutch clearance. Remove the stator using a pulley puller as shown
(Refer to MAGNETIC CLUTCH in the table.
CLEARANCE ADJUSTMENT.) STRAIGHT-SOCKET
10.1—15.0 N (17 mm {0.67 in})
{102—153
kgf 89—132
in·lbf}
Stator Installation Note

Install the stator perpendicularly using the SST and
a pulley puller as shown in the table.
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49 H061 005
1 Bolt
+ Removal/Installation Note
2 Pressure plate
+ Installation Note Pressure Plate Installation Note
When installing the pressure plate, carry out
3 Shim
magnetic clutch clearance adjustment.
4 Snap ring
5 A/C compressor pulley MAGNETIC CLUTCH CLEARANCE ADJUSTMENT
G6, WL, WL turbo Only
6 Stator
1. Set the A/C compressor on a level block.
+ Removal Note
2. Turn on the magnetic clutch by connecting the
+ Installation Note
battery positive voltage to the magnetic clutch
connector terminal and the ground to the A/C
Bolt Removal/Installation Note compressor body.
When removing or installing the bolt, hold the
3. Fix a dial gauge on a magnetic base and set the
pressure plate in place as shown in the table. measuring probe onto point A on the pressure
A/C COMPRESSOR plate surface.
BOLT
CONTINUED
U–20
CONTROL SYSTEM
4. Turn off the magnetic clutch by disconnecting the 3. If not within the specification, remove the pressure
ground from the A/C compressor body, then plate and adjust the clearance by changing the
measure the dial gauge readings. shim (0.1 mm {0.004 in}, 0.3 mm {0.012 in}, 0.5
5. Measure the clearance for point B and C on the mm {0.020 in}) or the number of shims.
pressure plate surface by repeating the above
steps 2 through 4. MAGNETIC CLUTCH INSPECTION
1. Disconnect the magnetic clutch connector.
Clearance 2. Connect battery positive voltage to terminal A of
0.35—0.75 mm {0.014—0.029 in} magnetic clutch and ground to the A/C compressor
MEASURING POINT body.
A B
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6. If the clearance is not as specified, adjust it by
changing the shim.
A
Note
The seven shim sizes from 0.7 mm {0.028 in}
to 1.3 mm {0.051 in} differ in 0.1 mm {0.004 in}
increments.
A
3. Verify that the magnetic clutch operates.

4. If not as specified, replace the stator.
A/C RELAY No.1 REMOVAL/INSTALLATION

F2, F2 Cab Only
1. Measure the clearance around the entire
circumference between the pressure plate and A/C
compressor pulley using a thickness gauge.
1 Connector
2 A/C relay No.1
2. Verify that the clearance is within the specification.
Clearance
0.3—0.6 mm {0.01—0.02 in} CONTINUED
U–21
CONTROL SYSTEM
A/C RELAY No.1 INSPECTION

1. Remove the A/C relay No.1.
2. Inspect for continuity between the A/C relay No.1 A B
: Continuity B+: Battery positive voltage C A
Terminal
Step
A B C D D B
1 C D
2 B+ GND
3. If not as specified, replace the A/C relay No.2.

C A
REFRIGERANT PRESSURE SWITCH REMOVAL/
C A INSTALLATION
D B
D B
123456567 PROCEDURES, RECOVERY.) (Refer to
cardiagn.com
REFRIGERANT SYSTEM SERVICE
3. If not as specified, replace the A/C relay No.1.
Caution
A/C RELAY NO.2 REMOVAL/INSTALLATION
after removing any refrigeration cycle parts
to keep moisture or foreign material out of
the cycle.

6. Carry out the refrigerant system performance test.
À
5.9—7.8 N·m
{60—80 kgf·cm,
1 Connector 53—69 in·lbf}
2 A/C relay No.2
A/C RELAY NO.2 INSPECTION

R
1. Remove the A/C relay No.2.
2. Inspect for continuity between the A/C relay No.2
Terminal
Step 1 Connector
B D A C
2 Refrigerant pressure switch
1
+ Installation Note
2 B+ GND
Refrigerant Pressure Switch Installation Note
Apply compressor oil to the O-ring and connect the
joint.
CONTINUED
123456567
U–22
CONTROL SYSTEM
REFRIGERANT PRESSURE SWITCH INSPECTION

1. Install the SSTs (manifold gauge set).
(Refer to MANIFOLD GAUGE SET INSTALLATION.) WITH HEATER
2. Disconnect the refrigerant pressure switch CORE
connector.
3. Verify the high-pressure side reading of the SST A B C
(Manifold gauge).
4. Inspect for continuity between the terminals of the WITHOUT
HEATER CORE
refrigerant pressure switch using an ohmmeter.
A B
0.18—0.21 3.0—3.3
{1.8—2.2, 26—31} {30—34, 427—483}
CONTINUITY
7. If not as specified, inspect on/off points of the
thermoswitch.
NO CONTINUITY To Inspect On/Off Points of the Thermoswitch

0.02 {0.25, 3.56} 0.4—0.7 2. Remove the cooling unit
OR LESS {4.0—8.0, 57—113} (Refer to BASIC SYSTEM, COOLING UNIT
MPa { kgf/cm2 , psi } REMOVAL/INSTALLATION.)
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3. Remove the thermoswitch.
(Refer to BASIC SYSTEM, COOLING UNIT
5. Connect the thermoswitch connector to the wiring
harness connector.
B A 6. Turn the ignition switch to ON position.
B A
7. Turn the A/C switch on.
8. Turn the fan switch on.
9. Immerse the sensor part of thermoswitch in a
container of ice water.
10. Connect the positive (+) and negative (–) probes of
the voltmeter to terminal A and terminal B of the
5. If not as specified, replace the refrigerant pressure thermoswitch respectively.
switch. 11. Inspect the voltage as shown below.
THERMOSWITCH INSPECTION WITH HEATER CORE
To Determine if the Switch is Functioning : Continuity
Terminal
2. Start the engine. Water temperature
temperat re
3. Turn the fan switch on. A C
4. Turn the A/C switch on. 3°C {37°F} or more
5. Connect the positive (+) and negative (–) probes of
1°C {34°F} or less
the voltmeter to terminal A and terminal B of the
thermoswitch respectively. (The wiring harness
WITHOUT HEATER CORE
connector must be connected to the thermoswitch
: Continuity
connector.)
6. Inspect the voltage as shown below. Temperature Terminal
control dial Water temperature
temperat re
position A B
WITH HEATER CORE
: Continuity 0—3°C {32—37°F}
MAX COLD
Terminal 3°C {37°F} or more
Magnetic clutch
cl tch
A C 7—11°C {45—52°F}
1/2 123456567
On 11°C {52°F} or more
Off 14—18°C {57—64°F}
MAX WARM
18°C {64°F} or more
WITHOUT HEATER CORE
: Continuity
Terminal
Magnetic clutch
cl tch
A B
123456567
On
Off
CONTINUED
123456567
U–23
CONTROL SYSTEM
BLOWER MOTOR INSPECTION

WITH HEATER 2. Disconnect the blower motor connector.
CORE 3. Connect battery positive voltage to terminal B and
ground to terminal A of the blower motor, and verify
A B C its operation.
WITHOUT
HEATER CORE
A B
12. If not as specified, replace the thermoswitch.

(Refer to BASIC SYSTEM, COOLING UNIT
BLOWER MOTOR REMOVAL/INSTALLATION

2. Remove the glove compartment. 4. If not as specified, replace the blower motor.
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4. Install in the reverse order of removal. RESISTOR REMOVAL/INSTALLATION
1 Connector
2 Blower motor
1 Connector
2 Resistor
CONTINUED
U–24
CONTROL SYSTEM
RESISTOR INSPECTION CLIMATE CONTROL UNIT INSTALLATION

1. Remove the glove compartment. 1. Connect the climate control unit connectors.
2. Disconnect the resistor connector. 2. Insert the climate control unit until each clip clicks.
3. Verify that the resistance between the terminals of
the resistor is as shown in the table.
Terminal Resistance (Ω)

1A–1B (2A) R1: 0.43—0.47
1A–1C R2: 1.04—1.16
1C–1D R3: 1.47—1.63
R3 R2 R1 1C 1A
3. Adjust the wire of the climate control unit.
1D 1B
(Refer to CLIMATE CONTROL UNIT WIRE ADJUSTMENT.)
4. Install the glove compartment.
2A
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1D 1C 1A 1B 2A
Climate Control Unit Removal/Installation Note
With heater core
Set the temperature control dial at MAX COLD, the
4. If not as specified, replace the resistor. airflow mode control dial at DEF.
CLIMATE CONTROL UNIT REMOVAL CLIMATE CONTROL UNIT

1. Disconnect the negative battery cable. DISASSEMBLY/ASSEMBLY
2. Remove the glove compartment. 1. Disassemble in the order indicated in the table.
3. Disconnect the air intake wire from the blower unit. 2. Assemble in the reverse order of disassembly.
4. Disconnect the air mix wire and airflow mode wire WITH HEATER CORE
from the heater unit.
5. With the beveled parts of the SST facing inward,
insert them into the climate control unit.
6. Pull the SST outward and rearward to slide out the
climate control unit.
49 D066 801A
7. Disconnect the climate control unit connectors.
CONTINUED
U–25
CONTROL SYSTEM
WITHOUT HEATER CORE CLIMATE CONTROL UNIT WIRE ADJUSTMENT

Air Intake Wire
1. Set the air intake lever at FRESH.
2. Set the air intake link to FRESH in the direction of
the arrow and insert a screwdriver into the set hole.
L.H.D.
AIR INTAKE WIRE
SET HOLE
R.H.D.
AIR INTAKE WIRE
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1 Dial SET HOLE
2 Knob
+ Removal Note
3 A/C switch
4 Panel
5 Fan switch 3. Connect the air intake wire to the air intake link.
4. Clamp the air intake wire to wire clamp.
6 Climate control unit harness
5. Verify that the air intake lever moves its full stroke.
7 Illumination bulb
8 A/C amplifer Air Mix Wire (With heater core only)
9 Air mix wire
1. Set the temperature control dial at MAX COLD.
2. Set the air mix link to MAX COLD in the direction of
10 Airflow mode wire the arrow and insert a screwdriver into the set hole.
11 Air intake wire
11 Cap
13 Body SET HOLE
Knob Removal Note

Use a wire to push the knob from the reverse side
and remove it as shown in the figure.
WIRE AIR MIX WIRE
KNOB 3. Connect the air mix wire to the air mix link.
4. Clamp the air mix wire to wire clamp.
5. Verify that the temperature control dial moves its
full stroke.
CONTINUED
U–26
CONTROL SYSTEM
Airflow Mode Wire Fan Switch

1. Set the airflow mode control dial at DEF. 1. Remove the climate control unit.
2. Set the airflow mode link to DEF in the direction of (Refer to CLIMATE CONTROL UNIT REMOVAL.)
the arrow and insert a screwdriver into the set hole. 2. Inspect for continuity between the fan switch
SET HOLE terminals using an ohmmeter.
: Continuity
Switch Terminal
position A B C D E F
0
1
2
AIRFLOW 3
MODE 4
WIRE
3. Connect the airflow mode wire to the airflow mode

link. F E B C D A
4. Clamp the airflow mode wire to wire clamp.
5. Verify that the airflow mode control dial moves its
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full stroke. 4 3 2 1 123456567
E C A
F D B
CLIMATE CONTROL UNIT INSPECTION 0
A/C Switch
1. Remove the climate control unit.
(Refer to CLIMATE CONTROL UNIT REMOVAL.)
2. Inspect for continuity between the A/C switch
terminals using an ohmmeter. 3. If not as specified, replace the fan switch.
: Continuity
Switch Terminal
position A B
OFF
ON
A C B
C B A
3. Connect battery positive voltage to terminal C and

123456567
ground to the terminal A.
5. Verify that the LED illuminaltes.
6. If not as specified, replace the A/C switch.
CONTINUED
U–27
TROUBLESHOOTING
TROUBLESHOOTING
FOREWORD
Refer to section GI. Thoroughly read and understand the basic flow of troubleshooting in order to properly
perform the procedures.
When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If
there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and
undamaged.
The areas for inspection (steps) are given according to various circuit malfunctions. Use the chart below to
verify the symptoms of the trouble in order to diagnose the appropriate area.
TROUBLESHOOTING INDEX
No. Malfunction symptom
1 Insufficient blown air volume and/or no blown air depending on airflow mode.
2 No blown air in any airflow mode.
Blown air volume does not change at any fan speed.
3 Airflow mode does not change.
4 Improper air circulation and/or no air circulation.
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5 No temperature control.(For climate control unit without variable thermistor only)
6 Air from vent not cold enough.
7 No cool air.
8 Noise while operating A/C system.
1 Insufficient blown air volume and/or no blown air depending on airflow mode.
1 Malfunction in VENT mode system
Steps 1—4
2 Malfunction in HEAT mode system
Step 5
3 Malfunction in DEFROSTER mode system
Steps 6—8
1 When airflow mode control dial is operated, is Yes Go to next step.
appropriate resistance felt and can it be moved
throughout its full range? No Go to Step 1 of troubleshooting index No. 3.
2 Does air blow out when in VENT mode? Yes Go to Step 5.

No Go to next step.
3 Is vent clogged? Yes Remove obstruction, then go to Step 9.
No Go to next step.
4 Is duct in dashboard properly installed? Yes Inspect duct for clogging, deformity and air
leakage, then go to Step 9.
No Install duct securely in the proper position, then
go to Step 9.
5 Does air blow out when in HEAT mode? Yes Go to next step.
No Inspect vent for clogging, then go to Step 9.
6 Does air blow out when in DEFROSTER mode? Yes Operation is okay. Recheck malfunction
symptoms.
No Go to next step.
7 Is vent clogged? Yes Remove obstruction, then go to Step 9.
No Go to next step.
8 Is defroster duct properly installed? Yes Inspect duct for clogging, deformity, and air
leakage, then go to next step.
No Install duct securely in the proper position, then
go to next step.
CONTINUED
U–28
CONTROL SYSTEM

9 Does air blow out? Yes Troubleshooting completed. Explain repairs to
customer.
No Recheck malfunction symptoms, then repeat from
Step 1 if malfunction recurs.
2 No blown air in any airflow mode.

Blown air volume does not change at any fan speed.
1 Blower motor, resistor, fan switch malfunction
Step 1
2 Blower unit malfunction
Steps 2—4
1 Inspect the following systems and electrical parts: Yes Go to next step.
Blower motor, resistor, fan switch. No Repair or replace malfunctioning part, then go to
Are they okay? Step 5.
2 Turn ignition switch to ON position. Yes Go to next step.
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Turn fan switch on.
on
Is noise coming from blower unit? No Go to Step 4.
3 Inspect fan in blower unit. Yes Go to next step.

Is fan free of interference from blower unit
case?
Is fan free of foreign material and No Remove obstruction, repair or replace fan and
obstructions? blower unit case, then go to Step 5.
Is fan okay?
4 Is blower unit intake vent clogged? Yes Remove obstruction, then go to next step.
No Inspect if there are any obstructions in passage
between blower unit and heater unit, then go to
next step.
5 Does air blow out? Yes Troubleshooting completed. Explain repairs to
customer.
3 Airflow mode does not change.

1 Malfunction in heater unit’s airflow mode main link, airflow mode rod, airflow mode cranks, airflow mode sub link, airflow
mode wire or wire clamp
Steps 1, 2
2 Bevel gear set (2) in climate control unit, airflow mode wire or wire clamp malfunction
Step 3
3 Malfunction in one or more heater unit doors
Steps 4, 5
1 Inspect heater unit’s airflow mode main link, Yes Go to next step.
airflow mode rod, airflow mode cranks, airflow
mode sub links, airflow mode wire and wire
clamp.
Is there ggrease on airflow mode main link,,
airflow mode cranks and airflow mode sub No Apply grease or install airflow mode main link,
links? airflow mode rod, airflow mode cranks and airflow
Are airflow mode main link, airflow mode rod, mode sub links securely in their proper positions,
airflow mode cranks, and airflow mode sub repair wire clamp, then go to Step 6.
links installed securely and in the proper
position?
Is wire clamp free of deformation?
Are above items all okay?
CONTINUED
U–29
TROUBLESHOOTING

2 Is airflow mode wire positioned securely and Yes Go to next step.
correctly in relation to the heater unit’s airflow No Adjust airflow mode wire or install it correctly, then
mode main link? go to Step 6.
3 Inspect climate control unit. Yes Go to next step.
Is bevel ggear set properly
y engaged?
g g
Is airflow mode wire properly installed in No Properly engage bevel gear set or install airflow
correct direction on bevel gear? mode wire in correct direction, repair or replace
Is wire clamp free of deformation? wire clamp, then go to Step 6.
Are above items okay?
4 Is there any foreign material or obstruction in any Yes Remove obstruction, then go to Step 6.
of heater unit’s doors? No Go to next step.
5 Are all doors within heater unit securely and Yes Inspect each door for cracks or damage, then go
properly positioned? to next step.
No Install malfunction doors securely in proper
position, then go to next step.
6 Does airflow mode change? Yes Troubleshooting completed. Explain repairs to
customer.
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4 Improper air circulation and/or no air circulation.

1 Malfunction in blower unit’s air intake crank, air intake link, air intake wire or wire clamp
Steps 1, 2
2 Climate control unit air intake wire or wire clamp malfunction
Step 3
3 Blower unit air intake door malfunction
Steps 4, 5
1 Inspect blower unit’s air intake crank, air intake Yes Go to next step.
link and wire clamp.
Is there grease
g on air intake crank and air
intake link? No Apply grease or install air intake crank and air
Are air intake crank and air intake link securely intake link properly and securely, repair wire
and properly positioned? clamp, then go to Step 6.
2 Is air intake wire positioned securely and correctly Yes Go to next step.
in relation to the blower unit’s air intake link? No Adjust air intake wire or install securely in correct
position, then go to Step 6.
Is air intake wire properly installed in correct
direction in relation to the air intake lever of
climate control unit? No Install air intake wire securely in correct position,
Is wire clamp free of deformation? repair or replace wire clamp, then go to Step 6.
4 Is there any foreign material or obstruction in Yes Remove obstruction, then go to Step 6.
blower unit’s air intake door? No Go to next step.
5 Is blower unit’s air intake door securely and Yes Inspect air intake door for cracks or damage, then
properly positioned? go to next step.
No Install air intake door securely in proper position,
6 Does air circulate? Yes Troubleshooting completed. Explain repairs to
customer.
CONTINUED
U–30
CONTROL SYSTEM
5 No temperature control.(Without variable thermistor in climate control unit only)

1 Malfunction in heater unit’s air mix rod, air mix link, air mix cranks, air mix shaft, air mix wire or wire clamp
Steps 2, 3
2 Bevel gear set (2) in climate control unit, air mix wire or wire clamp malfunction
Step 4
3 Heater unit air mix door malfunction
Steps 5, 6
1 Is coolant sufficiently warmed up? Yes Go to next step.
No Warm engine up, then go to Step 7.
2 Inspect heater unit’s air mix rod, air mix link, air Yes Go to next step.
mix cranks, air mix shaft and wire clamp.
Is there grease
g on air mix rod,, air mix link and
air mix cranks? No Apply grease or install air mix rod, air mix link, air
Are air mix rod, air mix link, air mix cranks, and mix cranks, and air mix shaft securely in their
air mix shaft securely installed in their proper proper positions, repair wire clamp, then
positions? go to Step 7.
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3 Is air mix wire securely installed in the correct Yes Go to next step.
position in relation to heater unit’s air mix link? No Adjust air mix wire or install securely in correct
Is bevel g
gear set properlyy engaged?
g g
Is air mix wire properly installed in correct No Properly engage bevel gear set or install air mix
position in relation to bevel gear? wire in correct position, repair or replace wire
Is wire clamp free of deformation? clamp, then go to Step 7.
5 Is there any foreign material or obstruction in Yes Remove obstruction, then go to Step 7.
heater unit’s air mix door? No Go to next step.
6 Is heater unit’s air mix door securely and properly Yes Inspect door for cracks or damage, then go to
installed? next step.
No Install door securely in proper position, then go to
next step.
7 Does unit operate in every temperature setting? Yes Troubleshooting completed. Explain repairs to
customer.
6 Air from vent not cold enough.

1 Drive belt malfunction
Step 1
2 Malfunction in blower unit or condenser
Steps 4, 5
3 Malfunction in receiver/drier or expansion valve (valve closes too much)
Steps 8, 9
4 Malfunction in refrigerant lines
Steps 10, 11
5 Malfunction in piping connections
Steps 1, 2, 13
6 A/C compressor system malfunction, insufficient compressor oil
Steps 15, 16
7 Compressor oil over-full, malfunction in expansion valve or heater unit air mix link system
Steps 17—20
CONTINUED
U–31
TROUBLESHOOTING

1 Inspect drive belt. Yes Go to next step.
+ Section B2, DRIVE BELT, DRIVE BELT No Adjust or replace drive belt, then go to Step 21.
INSPECTION + Section B2, DRIVE BELT, DRIVE BELT
ADJUSTMENT
Is it okay?
2 Carry out refrigerant system performance test. Yes Operation is normal. (Recheck malfunction
+ REFRIGERANT SYSTEM SERVICE symptoms.)
PROCEDURES PERFORMANCE TEST
PROCEDURES,
Is operation normal? No Go to next step.
3 Are refrigerant’s high-pressure and low-pressure Yes Go to next step.

values both high? No Go to Step 6.
4 Is blower unit intake clogged? Yes Remove obstruction, then go to Step 21. (If air
does not reach evaporator within cooling unit,
heat exchange does not occur and refrigerant
pressure rises. Therefore, removal of obstruction
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is necessary.)
No Go to next step.
5 Inspect condenser. Yes Add or subtract refrigerant to make specified
+ BASIC SYSTEM, CONDENSER INSPECTION amount, then go to Step 21. (Excessive amount
Is it okay? of refrigerant.)
No Replace condenser, or repair and clean
condenser fins, then go to Step 21.
6 Are refrigerant’s high-pressure and low-pressure Yes Go to next step.
values both low? No Go to Step 14.
7 Immediately after A/C compressor operates, does Yes Go to next step.
refrigerant’s
g high-pressure
g value momentarily y rise
to correct value, then fall and stay below it? (Is No Go to Step 10.
there negative pressure on low-pressure side?)
8 Turn A/C switch off and let air conditioner stop for Yes Go to next step.
10 minutes.
min tes
Start engine. No Start vacuum pump for 30 minutes and replace
Turn both A/C switch and fan switch on. receiver/drier, then go to Step 21. (Since
Does malfunction occur after A/C compressor receiver/drier has become saturated with water,
turns on? replacement is necessary.)
9 Is expansion valve heat-sensing tube within Yes Replace expansion valve, then go to Step 21.
cooling unit securely installed in proper position? (Since valve closes too much, replacement is
necessary.)
No Install heat-sensing tube securely in proper
10 Inspect refrigerant lines. Yes Go to next step.
Is piping free of damage and cracks?
Are piping connections free of oil grime?
(Visual inspection)
Are piping connections free of gas leakage?
Are piping installation points on condenser free
g leakage?
of gas g
Are piping installation points on receiver/drier No If piping or an A/C component is damaged or
free of gas leakage? cracked, replace it. Then go to Step 21. If there is
Are piping installation points on A/C no damage, go to Step 13.
compressor free of gas leakage?
Are piping installation points on cooling unit
free of gas leakage?
*Perform gas leak inspection using gas leak
tester.
CONTINUED
U–32
CONTROL SYSTEM

11 Are piping connections for evaporator in cooling Yes If the A/C compressor is making noise, add
unit free of gas leakage? 10 ml {10 cc, 0.34 fl oz} of compressor oil and
verify that malfunction does not occur.
Add or subtract refrigerant to make specified
amount, then go to Step 21.
No If piping is damaged or cracked, replace it. Then
go to Step 21. If there is no damage, go to next
step.
12 Are piping connections for evaporator in cooling Yes Tighten connections to specified torque. If the A/C
unit loose? compressor is making noise, add 10 ml {10 cc,
0.34 fl oz} of compressor oil and verify that
malfunction does not occur.
Tighten connections to specified torque, add or
subtract refrigerant to make specified amount,
then go to Step 21.
No If the A/C compressor is making noise, add
10 ml {10 cc, 0.34 fl oz} of compressor oil and
verify that malfunction does not occur.
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Replace O-ring on piping, add or subtract
refrigerant to make specified amount, then
go to Step 21.
13 Are piping connections loose? Yes Tighten connections to specified torque. If the A/C
compressor is making noise, add 10 ml {10 cc,
0.34 fl oz} of compressor oil and verify that
malfunction does not occur.
Tighten connections to specified torque, add or
subtract refrigerant to make specified amount,
then go to Step 21.
No If the A/C compressor is making noise, add 10 ml
{10 cc, 0.34 fl oz} of compressor oil and verify
that malfunction does not occur.
Replace O-ring on piping, add or subtract
refrigerant to make specified amount, then
go to Step 21.
14 Does refrigerant’s high-pressure value hardly Yes Go to next step. (Pressure hardly increases.)
increase? No Go to Step 17.
15 When engine is racing, does high-pressure value Yes Return to Step 3.
increase? No Go to next step.
16 After compressor oil is replenished each 10 ml Yes Troubleshooting completed. (Explain to customer
{10 cc, 0.34 fl oz}, does high-pressure value that cause was insufficient compressor oil.)
increase? No Replace A/C compressor, then go to Step 21.
(Cause is defective A/C compressor.)
17 Is only refrigerant low-pressure value high? Yes Go to Step 20.
No Go to next step.
18 Are heater unit’s air mix rod, air mix link, air mix Yes Go to next step.
cranks and air mix shaft securely and properly No Repair or install air mix rod, air mix link, air mix
installed? cranks and air mix shaft securely in proper
CONTINUED
U–33
TROUBLESHOOTING

19 1. Set the fan switch at 4th position. Yes Go to Step 21.
3. Set to FRESH mode.
4. Set the temperature control to MAX COLD.
5. Set to VENT mode.
6. Run engine at a constant 1,500 rpm for
10 minutes.
7. Run engine at idle speed for 1 minute.
8. 1 engine speed cycle is defined as going from
idle speed to 4,000 rpm and back to idle speed
over a period of 12 seconds.
Perform 5 cycles
cycles.
9. Run engine at idle speed for 30 seconds. No Carry out 1 to 10 of step 19 again until
10. Remove all compressor oil from A/C compressor oil is 105 ml {105 cc, 3.55 fl oz}.
compressor and verify that it is 105 ml {105 cc,
3.55 fl oz}.
11. If it is more than 105 ml {105 cc, 3.55 fl oz},
put only 105 ml {105 cc, 3.55 fl oz}
back into A/C compressor.
12. Carry out above steps 1 to 10 again and verify
that compressor oil is 105 ml {105cc, 3.55 fl
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oz}.
Is there 105 ml {105 cc, 3.55 fl oz} of
compressor oil in A/C compressor?
20 Is expansion valve heat-sensing tube within Yes Replace expansion valve, then go to next step.
cooling unit securely installed in proper position? (Since valve opens too much, replacement is
necessary.)
No Install heat-sensing tube securely in proper
position, then go to next step.
21 Does cool air blow out? (Are results of refrigerant Yes Troubleshooting completed. Explain repairs to
system performance test okay?) customer.
7 No cool air.
1 A/C compressor system malfunction
Step 2
2 Incorrect amount of refrigerant
Step 3
3 A/C switch indicator light malfunction
Steps 4—6
4 A/C relay system malfunction
(WL, WL turbo, F2 Cab) Steps 7, 11—13
(G6, F2) Steps 7, 11, 12
5 Refrigerant pressure switch malfunction
Step 8
6 PCM A/C cut-off control system
(WL, WL turbo) Steps 9, 26
(G6, F2) Step 9
7 PCM (IG1 signal) system malfunction
Steps 10, 25
8 Magnetic clutch system malfunction
Step 14
9 PCM (A/C signal) system malfunction
(WL, WL turbo) Steps 15, 20
(G6, F2) Steps 15, 19, 20
(F2 Cab) Step 15
10 Thermoswitch, A/C switch malfunction
(WL, WL turbo, G6, F2) Steps 21—24
(F2 Cab) Steps 16—18
CONTINUED
U–34
CONTROL SYSTEM

1 Does air blow out? Yes Go to next step.
No Go to Step 1 of troubleshooting indexes 1, 2.
2 Start engine. Yes Go to Step 1 of troubleshooting index 6.
Turn both A/C switch and fan switch on
on.
Does A/C compressor operate? No Go to next step.
3 Inspect refrigerant amount. Yes Go to next step.

+ REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST No Add or subtract refrigerant to specified level, then
Is it okay? go to Step 27.
4 Does A/C switch indicator light illuminate? Yes Go to Step 7.
No Go to next step
*5 Turn ignition switch to ON position. Yes Go to next step.
(With air mix wire) Remove airflow mode wire, air
intake wire and air mix wire. Remove climate
control unit.
(Without air mix wire) Remove airflow mode wire
and air intake wire. Remove climate control unit. No Repair wiring harness between fuse block and
A/C switch, then go to Step 27.
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Remove A/C switch from climate control unit and
connect A/C switch connector.
Test voltage at A/C switch terminal C (IG2 signal).
Is voltage approximately 12 V?
*6 Inspect A/C switch. Yes Inspect wiring harness between A/C switch and
+ CONTROL SYSTEM, CLIMATE CONTROL resistor, then go to Step 27.
UNIT INSPECTION
Is it okay? No Replace A/C switch, then go to Step 27.
7 Are A/C relay power supply fuses okay? Yes Go to next step.
No Check for a short to ground on blown fuse’s
circuit.
Install appropriate amperage fuse.
*8 Remove radiator grille. Disconnect refrigerant Yes Inspect refrigerant pressure switch, then
pressure switch connector. When refrigerant go to Step 27.
pressure switch connector terminals A and B (on No WL for ISRAEL: Undo short, reconnect
wiring harness side) are shorted, does cool air refrigerant pressure switch connector, then go to
blow out? Step 10.
Other models: Undo short, reconnect refrigerant
pressure switch connector, then go to next step.
*9 Check the DTC for the PCM ON-BOARD Yes Go to appropriate inspection procedure. (The
DIAGNOSTIC SYSTEM. engine coolant temperature sensor (DTC 09) or
Are the following DTCs displayed? throttle position sensor (DTC 0120), which sends
DTC 09 (WL or WL turbo) the PCM’s A/C cut off control input signal, may be
DTC 0120 (F2 or G6) the cause of the trouble.)
+ Section F2, ON-BOARD DIAGNOSTIC
SYSTEM, DIAGNOSTIC TROUBLE CODE
INSPECTION
No Go to next step.
*10 Turn ignition switch to ON position. Yes Go to Step 15.

Does magnetic clutch operate when A/C relay
connector terminal B (IG2 signal) is grounded? No Go to next step.
CONTINUED
U–35
TROUBLESHOOTING

Test voltage at the following A/C relay connector
terminals:
Terminal A (IG2 signal) No Repair wiring harness between fuse block and
Terminal C (A/C control signal) A/C relay, then go to Step 27.
*12 Test voltage at A/C relay terminal D (A/C control Yes G6 or F2: Go to Step 14.
signal). Other models: Go to next step.
Is voltage approximately 12 V? No Inspect A/C relay, then go to Step 27.
*13 Disconnect refrigerant pressure switch connector. Yes Reconnect refrigerant pressure switch connector,
Test voltage at refrigerant pressure switch then go to next step.
connector (on wiring harness side) terminal A
(A/C control signal). No Repair wiring harness between A/C relay and
Is voltage approximately 12 V? refrigerant pressure switch, then go to Step 27.
*14 Test voltage at magnetic clutch connector Yes Inspect magnetic clutch, then go to Step 27.
terminal A (A/C control signal). No G6 or F2: Repair wiring harness between A/C
Is voltage approximately 12 V? relay and magnetic clutch, then go to Step 27.
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Other models: Repair wiring harness between
refrigerant pressure switch and magnetic clutch,
then go to Step 27.
*15 Turn A/C switch off. Remove glove compartment. Yes F2 Cab: Go to next step.
Turn ignition switch to ON position. Test voltage Other models: Go to Step 21.
at the following thermoswitch connector terminal
(A/C signal):
Terminal B (with variable thermistor in climate No F2 Cab: Repair wiring harness between A/C relay
control unit) and thermoswitch, then go to Step 27.
Terminal A (without variable thermistor in G6 or F2: Go to Step 19.
climate control unit) Other models: Go to Step 20.
*16 Turn ignition switch to LOCK position. Yes Undo short, then go to next step.
Disconnect thermoswitch connector.
Start engine.
Turn both A/C switch and fan switch on.
When following thermoswitch connector terminals
shorted does cool
(on wiring harness side) are shorted,
air blow out? No Undo short, then go to Step 18.
Terminal A—C (with variable thermistor in
climate control unit)
Terminal B—C (without variable thermistor in
*17 Turn ignition switch to ON position. Yes Inspect thermoswitch, then go to Step 27.
Test voltage at the following thermoswitch
connector terminals (IG2 signal):
Terminal B (with variable thermistor in climate
control unit) No Repair wiring harness between fuse block and
Terminal A (without variable thermistor in thermoswitch, then go to Step 27.
*18 Turn ignition switch to ON position. Yes Inspect wiring harness between thermoswitch
Turn A/C switch on. and A/C switch, then go to Step 27.
Turn fan switch off.
Test voltage at A/C switch connector terminal A
(A/C signal). No Inspect A/C switch, then go to Step 27.
*19 Disconnect refrigerant pressure switch connector. Yes Repair wiring harness between thermoswitch and
Test voltage at refrigerant pressure switch refrigerant pressure switch, then go to Step 27.
connector ((on wiringg harness side)) terminal A
(A/C control signal). No Go to next step.
CONTINUED
U–36
CONTROL SYSTEM

*20 Turn ignition switch to ON position. Yes G6 or F2: Repair wiring harness between PCM and
Test voltage at the following PCM connector refrigerant pressure switch, then go to Step 27.
terminals (A/C signal): Other models: Repair wiring harness between
Terminal G (WL or WL turbo) PCM and thermoswitch, then go to Step 27.
Terminal Q (G6 or F2)
Is voltage approximately 12 V? No Inspect PCM, then go to Step 27.
*21 Turn ignition switch to LOCK position. Yes Undo short, then go to next step.
Disconnect thermoswitch connector.
Start engine.
Turn both A/C switch and fan switch on.
When following thermoswitch connector terminals
(on wiring harness side) are shorted,
shorted does cool
air blow out? No Go to Step 23.
Terminal B—C (without variable thermistor in
Terminal A—C (with variable thermistor in
22 Turn ignition switch to ON position. Yes Inspect thermoswitch, then go to Step 27.
Test voltage at the following thermoswitch
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(
connector terminals (IG2 g )
signal):
Terminal A (without variable thermistor in No Repair wiring harness between fuse block and
climate control unit) thermoswitch, then go to Step 27.
Terminal B (with variable thermistor in climate
control unit)
Turn A/C switch on.
Turn fan switch off.
Test voltage at A/C switch connector terminal A No Inspect A/C switch, then go to Step 27.
(A/C signal).
*24 Test voltage at thermoswitch connector terminal Yes Go to next step.
C (A/C signal). No Repair wiring harness between thermoswitch and
Is voltage approximately 12 V? A/C switch, go to Step 27.
*25 Test voltage at the following PCM connector Yes WL or WL turbo: Go to next step.
terminals (A/C signal): Other models: Recheck malfunction symptoms.
Terminal L (WL or WL turbo)
Terminal J (G6 or F2) No Repair wiring harness between A/C relay and
Is voltage approximately 12 V? PCM, then go to Step 27.
*26 Inspect the following input signal components: Yes Recheck malfunction symptoms.
Engine coolant temperature sensor and PCM
wiring harness (A/C cut-off control). No Replace input signal components, then go to next
Are they okay? step.
27 Does cool air blow out? (Is refrigerant system Yes Troubleshooting completed. Explain repairs to
performance test result correct?) customer.
CONTINUED
U–37
TROUBLESHOOTING
8 Noise while operating A/C system.

1 Magnetic clutch operation noise
Step 3
2 A/C compressor operation noise
Steps 4—8
3 A/C compressor slippage noise
Steps 9—11
4 Hose or refrigerant line interference noise
Step 12
1 Is there a squeaking or whirling sound (A/C Yes Go to Step 9.
compressor slippage noise)? No Go to next step.
2 Is there a rattling or vibrating sound (interference Yes Go to Step 12.
noise)? No Go to next step.
3 Is there a clicking sound (magnetic clutch Yes Adjust clearance between magnetic clutch
operation noise)? pressure plate and A/C compressor pulley, then
go to Step 13.
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+ CONTROL SYSTEM, MAGNETIC CLUTCH
CLEARANCE ADJUSTMENT
No Go to next step.
4 Is noise heard continuously for more than 3 Yes Go to next step.
seconds after A/C compressor comes on? No Condition is normal. (Noise normally occurs for
2—3 seconds immediately after A/C compressor
turns on.)
5 Inspect idle speed. Yes Go to next step.
+ Section F2, ENGINE TUNE-UP, IDLE SPEED
ADJUSTMENT
No Adjust idle speed, then go to Step 13.
Is it okay?
6 Drain compressor oil. Yes Go to next step.
Is it contaminated with metal particles? No Replace A/C compressor, then go to Step 13.
7 Is compressor oil whitish and mixed with water? Yes Replace entire A/C system (excluding heater),
then go to Step 13.
No Go to next step.
8 Is compressor oil darker than normal and Yes Replace A/C compressor and receiver/drier, then
contaminated with aluminum chips? go to Step 13. (Since A/C compressor may be
worn and receiver/drier may be clogged,
replacement of receiver/drier is necessary.)
No Condition is normal. Recheck malfunction
symptoms.
9 Inspect drive belt. Yes Go to next step.
+ Section B2, DRIVE BELT, DRIVE BELT
INSPECTION
No Adjust or replace drive belt, then go to Step 13.
Is it okay?
10 Is drive belt worn? Does it have foreign material Yes Remove obstruction, remove oil, or replace drive
imbedded in it, or have oil on it? belt, then go to Step 13.
No Go to next step.
CONTINUED
U–38
CONTROL SYSTEM

11 Inspect magnetic clutch. Yes Replace A/C compressor (excluding pressure
+ CONTROL SYSTEM, MAGNETIC CLUTCH plate, A/C compressor pulley, and stator), then go
INSPECTION to Step 13.
Is it okay? No Replace magnetic clutch, then go to Step 13.
12 Is noise coming from A/C compressor? Yes Visually inspect A/C compressor, replace
appropriate parts if necessary, then go to next
step.
No If noise is coming from refrigerant lines, repair
any detached or missing clips, tighten loose bolts,
13 Has A/C compressor noise stopped? Yes Troubleshooting completed. Explain repairs to
customer.
CONTINUED
cardiagn.com
U–39
TECHNICAL DATA
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . TD– 1 PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . TD–11
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD– 1/3 FRONT AND REAR AXLES . . . . . . . . . . . . . . TD–11
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . TD– 4 STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . TD–12
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . TD– 4 BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . TD–12
FUEL AND EMISSION CONTROL SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . TD–13/14
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD– 5/6 BODY ELECTRICAL SYSTEM . . . . . . . . . . . TD–14/15
ENGINE ELECTRICAL SYSTEM . . . . . . . . . TD– 6/10 HEATER AND AIR
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD–10 CONDITIONER SYSTEMS . . . . . . . . . . . . . TD–15
MANUAL TRANSMISSION . . . . . . . . . . . . . . . TD–10/11
TECHNICAL DATA
ENGINE
Engine
Item
G6
New 10.0—12.0 {0.40—0.47}
Generator
cardiagn.com
Used 12.0—14.0 {0.48—0.55}
Drive belt deflection
[[Applied pressure New 6.6—7.2 {0.26—0.28}
P/S
98 N {10 kgf, 22 lbf}] Used 7.2—8.0 {0.29—0.31}
(
(mm {i
{in})
})
New 8.5—10.0 {0.34—0.39}
A/C
Used 10.0—11.5 {0.40—0.45}
New 491—588 {50—60, 110—132}
Generator
Used 393—490 {40—50, 88—110}
Drive belt tension New 412—470 {42—48, 93—105}
P/S
(N {kgf, lbf}) Used 354—402 {36—41, 80—90}
New 557—641 {56.7—65.4, 125—143}
A/C
Used 471—556 {48.0—56.7, 106—124}
Standard 1255 {12.8, 182} [270]
Compression (kPa {kgf/cm2, psi} [rpm])
Minimum 882.6 {9.0, 128} [270]
Pushing distance of the front oil seal
0—0.7 {0—0.027}
(from the edge of the chain cover) (mm {in})
Pushing distance of the rear oil seal
0—0.5 {0—0.019}
(from the edge of the rear cover) (mm {in})
CONTINUED
TD–1
TECHNICAL DATA
Engine
Item
WL, WL Turbo
New 7.0—9.0 {0.28—0.35}
Generator Used 8.0—10.0 {0.32—0.39}
Limit 16.0 {0.63}
Drive belt deflection New 5.0—6.2 {0.20—0.24}
[A li d pressure 98
[Applied A/C (meas
(measuring
ring
Used 6.0—6.5 {0.24—0.25}
kgf 22 lbf}]
N {10 kgf, point
oint a)
((mm {{in})
}) Limit 11.3 {0.44}
New 9.5—11.8 {0.38—0.46}
A/C (meas
(measuring
ring
Used 11.0—12.5 {0.44—0.49}
point
oint b)
Limit 18.0 {0.71}
New 442—637 {45—65, 99—143}
Generator Used 383—539 {39—55, 86—121}
Drive belt tension Limit 177 {18, 40}
(N {kgf, lbf}) New 403—519 {41—53, 91—116}
A/C Used 354—431 {36—44, 80—96}
cardiagn.com
Limit 181 {18.5, 41}
IN 0.05—0.15 {0.0020—0.0059} (0.10"0.05 {0.0039"0.0020})

0.15 {0.0059} [Engine hot (Reference)]
Valve clearance [Engine cold] (mm {in})
EX 0.15—0.25 {0.0060—0.0098} (0.20"0.05 {0.0079"0.0020})
0.25 {0.0098} [Engine hot (Reference)]
Standard 2,942 {30, 427} [200]
Minimum 2,648 {27, 384} [200]
[Applied pressure 98 N {10 kgf, 22 lbf}] Standard 9.0—10.0 {0.36—0.39}
(mm {in})
Standard 101.2—101.8 {3.985—4.007}
Bolt head mark W
Cylinder
y head bolt Minimum 102.5 {4.035}
length (mm {in}) Standard 113.2—113.8 {4.457—4.480}
Bolt head mark N
Minimum 114.5 {4.508}
Camshaft oil seal tapping amount (mm {in}) 0.5—1.0 {0.02—0.03}
Front oil seal tapping amount (mm {in}) 0—0.4 {0—0.01}
Rear oil seal tapping amount (mm {in}) 0—0.5 {0—0.01}
CONTINUED
TD–2
TECHNICAL DATA
Engine
Item
F2 CARB F2 CIS
New 7.0—8.0 {0.28—0.31}
Generator
Used 8.0—9.0 {0.32—0.35}
Drive belt deflection
[[Applied pressure New 5.0—6.0 {0.20—0.23}
P/S
98 N {10 kgf, 22 lbf}] Used 5.5—6.5 {0.22—0.25}
(
(mm {i
{in})
})
New 10.0—12.0 {0.40—0.47}
A/C
Used 12.0—14.0 {0.48—0.55}
New 510—588 {52—60, 115—132}
Generator
Used 432—509 {44—52, 97—114}
Drive belt tension New 393—490 {40—50, 88—110}
P/S
(N {kgf, lbf}) Used 344—441 {35—45, 77—99}
New 373—490 {38—50, 84—110}
A/C
Used 275—372 {28—38, 62—83}
Standard 1196 {12.2, 173} [300] 1226 {12.5, 178} [300]
Minimum 837 {8.54, 121} [300] 858 {8.75, 124} [300]
cardiagn.com
Timingg belt deflection New 8.0—9.0 {0.32—0.35}
[Applied pressure 98 N {10 kgf, 22 lbf}] (mm {in}) Used 9.0—10.0 {0.36—0.39}
Pushing distance of the front oil seal
0 {0}
(from the edge of the chain cover) (mm {in})
Pushing distance of the rear oil seal
0—0.5 {0—0.019}
(from the edge of the rear cover) (mm {in})
CONTINUED
TD–3
TECHNICAL DATA
LUBRICATION SYSTEM
Engine
Item
F2 G6 WL WL Turbo
295—392 305—402 452—529 402—480
{3.0—4.0, {3.1—4.1, {4.6—5.4, {4.1—4.9,
Oil pressure (kPa {kgf/cm2, psi} [rpm])
43—56} 45—58} 66—76} 59—69}
[3000] [3000] [3000] [3000]
Oil replacement 3.9 {4.1, 3.4} 4.5 {4.8, 4.0} 5.6 {5.9, 4.9}
Oil capacit
capacity
Oil and oil filter replacement 4.2 {4.4, 3.7} 4.7 {5.0, 4.4} 6.3 {6.7, 5.5}
(L {US qt,
qt lmp
lm qt})
Total (dry engine) 4.6 {4.9, 4.0} 5.5 {5.8, 4.8} 6.7 {7.1, 5.9}
Engine oil API service SG API service CD
Above 30_C {86_F} SAE 40 —
0°C—40_C {32_F—104°F} SAE 30 —
–10°C—20_C {14_F—68°F} SAE 20W-20 —
Above –25_C {–13_F} SAE 10W-30*, 10W-40, 10W-50 —
Viscosity Above –10_C {14_F} SAE 20W-40, 20W-50 —
Below –20_C {–4_F} SAE 5W-20 —
cardiagn.com
Below 0_C {32_F} SAE 5W-30* —
–15°C—40_C {5_F—104°F} — — SAE 10W-30
Below 10_C {50_F} — — SAE 5W-30
D European specification vehicles use only those oils marked with an asterisk
COOLING SYSTEM
Engine
Item
F2 G6 WL WL Turbo
With heater 7.5 {7.9, 6.6} 9.4 {9.9, 8.3}
Coolant capacity
ca acity (L {US qt,
qt lmp
lm qt})
Without heater 6.9 {7.3, 6.1} 8.8 {9.3, 7.7}
Sub:
83.5—86.5
83.5—89.5 {183—187}
Opening temperature (_C {_F}) 80—84 {176—183}
{183—193} Main:
86.5—89.5
Thermostat {188—193}
Full-open temperature (_C {_F}) 100 {212} 95 {203}
Sub: 1.5
8.5 {0.33} {0.06} min.
Full-open lift (mm {in}) 8.5 {0.33} min.
min. Main: 8.0
{0.31} min.
74—102
Cap valve opening pressure
Radiator cap {0.75—1.05, 94—122 {0.95—1.25, 13.5—17.7}
(kPa {kgf/cm2, psi})
10.7—14.9}
CONTINUED
TD–4
TECHNICAL DATA

CIS vehicles
Engine
Item
G6 F2
Idle speed (rpm) 730—770 (750"20) 730—770 (750"20)
Injection timing (BTDC °/rpm) 4—6/750 5—7/750
A/C ON*2 700—800 (750"50) 780—880 (830"50)
Idle speed*11 (rpm)
P/S ON*3 700—800 (750"50)
CO concentration Within the regulation
HC concentration Within the regulation
Fuel pressure Hold pressure More than 340 {3.5, 50}
(kPa {kgf/cm2, psi}) Fuel pump maximum pressure 500—630 {5.0—6.5, 72—92}
Fuel leakage
Less than 1
(drop/2 minutes)
Injection volume
Fuel injector 55—71 {55—71, 1.9—2.3} 46—60 {46—60, 1.6—2.0}
(ml {cc, fl oz}/15 sec.)
Resistance
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12—16
(Ω) [20°C {68°F}]
Fuel pressure (at vacuum ON)
210—250 {2.1—2.6, 30—36}
Pressure regulator
Fuel pressure (at vacuum OFF*4)
270—310 {2.7—3.2, 39—45}
*1: Excludes temporary idle speed drop just after the loads (A/C, P/S) are turned on.
*2: A/C switch and fan switch are turned on.
*3: Steering wheel is fully turned.
*4: Hot condition at start.
DIESEL vehicles
Engine
Item
WL Turbo WL
760—800 (780"20)*1
Idle speed (rpm) 700—740 (720"20)
700—740 (720"20)*2
Injection timing ATDC 10°
107—115 {1.09—1.18,
Boost relief pressure (kPa {kgf/cm2, psi}) —
15.5—16.8}
805—855 (830"25)
When A/C is operated 825—875 (850"25)
Idle-up
Idle u sspeed
eed 825—875 (850"25)*3
(rpm) When P/S is operated — —
When engine is cold 1200—1500 (1350"150)
Injection pump Cam lift (mm {in}) 2.48 {0.098}
Injection starting pressure New: 11.4—12.2 {116—124, 1650—1760}
(MPa {kgf/cm2, psi}) Inspection: More than 10.0 {102, 1450}
Injection nozzle
No leakage when pressure of 8.8 MPa {90 kgf/cm2, 1280 psi})
Nozzle leakage
is applied.
Diesel smoke (%) Within the regulation
*1: General (L.H.D.)
*2: Europe and UK
*3: Europe
CONTINUED
TD–5
TECHNICAL DATA
CARB vehicles
Engine
Item
F2 CARB
Idle speed (rpm) 800—850 (800 +50
–0 )
Injection timing (BTDC°) 5—7 (6"1)

A/C Operated 1400—1600 (1500"100)
P/S Operated —
Idle up speed
Idle-up (rpm)
D/P Operated 1900—2100 (2000"100)
T/P Operated 1050—1250 (1150"100)
2.0—2.5 (2.0 +0.5 1 2
CO concentration (%) –0 )* , 2.0—3.0 (2.5"0.5)*
HC concentration (ppm) —
Discharge pressure (kPa {kgf/cm2, psi}) 20—25 {0.2—0.25, 2.8—3.6}
Fuel pump
um
Discharge amount cc {cu in} min. 1150 {70.2}
H 8—9 {0.315—0.354}
Float level (mm {in})
Carburetor L 44—45 {1.732—1.772}
Primary throttle opening angle (°) 48—52 {50"2}
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*1: GULF
*2: General
ENGINE ELECTRICAL SYSTEM

Engine
Item
G6
Electrolyte gravity 1.27—1.29
Back-up current *1 (mA) Max. 20
Test load chart
Battery type 80D26R 195
Battery (A)
Slow charge Battery type
80D26R (55) 5.5—6.5
(A) (5-hour rate)
Quick charge Battery type
80D26R (55) 35
(A/30 min.) (5-hour rate)
Rotor resistance (Between slip rings) (Ω) 3.7—4.4
Standard (mm {in}) 18.5 {0.73}
Brush length
Minimum (mm {in}) 5.0 {0.20}
Standard (N {kgf, lbf}) 4.8—6.0 {0.48—0.62, 1.06—1.36}
Brush sspring
ring force
Minimum (N {kgf, lbf}) 2.2 {0.22, 0.48}
B B+
Ignition switch
Generator Terminal L Approx. 1
ON
Standard voltage
g S B+
(V) B 14.1—14.7
Idle
Terminal L 13.0—14.0
[20C
[20 C {68F}]
{68 F}]
S 14.1—14.7
Generated current*2 1000 Approx. 0—43

Engine speed
s eed (r
(rpm)
m)
(Reference) (A) 2000 Approx. 0—62
*1: Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition
switch is at OFF position and the ignition key is removed.
*2: Must not be 0 A.
CONTINUED
TD–6
TECHNICAL DATA
Engine
Item
G6
Ignition
g Resistance Primary coil (Ω) 0.81—0.99
coil [20C {68F}] Secondary coil (kΩ) 10—16
ZFR5F–11*3, *5, ZFR6F–11*4, *5,
NGK
BKR5E*3, BKR6E*4
Type
Ty e
KJ16CR11*3, *5, KJ20CR11*4, *5
DENSO
K16PR–U*3, K20PR–U*4
Spark
S 1.0—1.1 {0.040—0.043}*5,
plug Plug gap (mm {in})
0.7—0.8 {0.028—0.031}
NGK
Resistance (kΩ) 3 0—7 5
3.0—7.5
DENSO
Tightening torque (N·m {kgf·m, ft·lbf}) 15—22 {1.5—2.3, 11—16}
No.1 lead 2.9—7.7
High
High- No.2 lead 4.3—10.8
Resistance
tension No.3 lead 5.4—13.5
(kΩ ) [20 C
C {68 F}]
F}]
l d
lead No.4 lead 6.6—16.2
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Center lead 4.5—11.2
Commutator Standard (mm {in}) 29.4 {1.16}
diameter Minimum (mm {in}) 28.8 {1.14}
Brush length
Minimum (mm {in}) 7.0 {0.28}
Starter Standard (N {kgf, lbf}) 180—243 {18.3—24.8, 40.3—54.5}
Brush sspring
ring force
Minimum (N {kgf, lbf}) 57.7 {5.88, 12.9}
Pinion gap (mm {in}) 3.0 {1.118}
Voltage (V) 11.5
No load test
Current (A) Below 100
*3: Standard plug
*4: Cold type plug
*5: Europe CONTINUED
TD–7
TECHNICAL DATA
Engine
Item
F2 CARB F2 CIS
Back-up current *1 (mA) Max. 20
Test load chart 34B19R 110 —
Battery ty
type
e
(A) 55D23R 180
Battery
Slow charge
g Battery
y type
y 34B19R (27) 3.0—4.0 —
(A) (5-hour rate) 55D23R (48) 4.5—5.5
Quick charge
g Battery
y type
y 34B19R (27) 20 —
(A/30 min.) (5-hour rate) 55D23R (48) 30
Rotor resistance (Between slip rings) (Ω) 3.7—4.4
Brush length
Minimum (mm {in}) 5.0 {0.20}
Standard (N {kgf, lbf}) 4.8—6.0 {0.48—0.62, 1.06—1.36}
Brush sspring
ring force
Minimum (N {kgf, lbf}) 2.2 {0.22, 0.48}
B B+
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Ignition switch
Generator Terminal L Approx. 1
ON
Standard voltage
g S B+
(V) B 14.1—14.7
Idle
Terminal L 13.0—14.0
[20C
[20 C {68F}]
{68 F}]
S 14.1—14.7
Generated current*2 1000 Approx. 0—43

Engine speed
s eed (r m)
(rpm)
(Reference) (A) 2000 Approx. 0—62
Ignition
g Resistance Primary coil (Ω) 1.035—1.265 0.81—0.99
coil [20C {68F}] Secondary coil (kΩ) 10—16
0—2/1200, 9—13/2200,
Centrifugal spark advance °/rpm —
19—23/6000
Distributor
0—2/20 {150, 5.9},
Vacuum spark advance °/kPa {mmHg, inHg} —
11—15/53.3 {400, 15.7}
BKR5E*5
BPR5ES–11*3
NGK BKR6E*3
BPR6ES–11*4
BKR7E*4
Type
Ty e
K16PR–U*5
W16EXR–U11*3
DENSO K20PR–U*3
Spark W20EXR–U11*4
K22PR–U*4
plug
lug
Plug gap (mm {in}) 0.7—0.8 {0.028—0.031} 1.0—1.1 {0.040—0.043}
NGK
Resistance (kΩ) 30 75
3.0—7.5
DENSO
Tightening torque (N·m {kgf·m, ft·lbf}) 15—22 {1.5—2.3, 11—16}
No.1 lead 2.75—7.07
High
High- No.2 lead 4.19—10.43
Resistance
tension No.3 lead 4.38—10.88
(kΩ ) [20 C
C {68 F}]
F}]
l d
lead No.4 lead 5.73—14.08
Center lead 2.00—5.33 3.9—9.9
*1: Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition
switch is at OFF position and the ignition key is removed.
*3: Standard plug
*4: Cold type plug
*5: Hot type plug
CONTINUED
TD–8
TECHNICAL DATA
Engine
Item
F2 CARB F2 CIS
Brush length
Minimum (mm {in}) 11.5 {0.46}
Starter Standard (N {kgf, lbf}) 19.2 {1.95, 4.25}
Brush sspring
ring force
Minimum (N {kgf, lbf}) 8.83 {0.90, 1.98}
Pinion gap (mm {in}) 0.5—2.0 {0.020—0.078}
Voltage (V) 11.5
No load test
Engine
Item
WL, WL Turbo
Back-up current *1 (mA) 20 max.
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75D26L 195
Test load chart
Battery type 75D26R 195
(A)
95D31R 250
Battery 75D26L (52) 5.5—6.5
Slow charge Battery type
75D26R (52) 5.5—6.5
(A) (5-hour rate)
95D31R (64) 6.5—8.0
75D26L (52) 35
Quick charge Battery type
75D26R (52) 35
(A/30 min.)
min ) (5-hour rate)
95D31R (64) 40
Rotor resistance (Between slip rings) (Ω) 2.50
Brush length
Minimum (mm {in}) 5.0 {0.20}
Standard (N {kgf, lbf}) 2.65 {0.27, 0.59}
Brush sspring
ring force
Minimum (N {kgf, lbf}) 1.18 {0.12, 0.26}
B B+
Engine
g switch A B+
Terminal
ON S 0
G
Generator I 2.0—4.0
Standard voltage
g
(V) B 14.05—14.85
Idle A 14.05—14.85
Terminal
[20C {68F}] S 7.025—7.425
I 13.00—14.85
Terminal B
1000 Approx. 0—58
Generated current*2 Engine
g speed current
(Reference) (A) (rpm) Terminal B
2000 Approx. 0—74
current
*1: Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the engine
switch is at OFF position and the engine key is removed.
CONTINUED
TD–9
TECHNICAL DATA
Engine
Item
WL, WL Turbo
Brush length
Minimum (mm {in}) 8.7 {0.34}
Starter Standard (N {kgf, lbf}) 27.0—33.0 {2.75—3.37, 6.05—7.41}
Brush sspring
ring force
Minimum (N {kgf, lbf}) —
Pinion gap (mm {in}) 3.0 {0.12}
Voltage (V) 11
No load test
CLUTCH
Item Specification
Clutch pedal
Height (mm {in}) 241.6—246.6 {9.52—9.70}
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Pedal free play (mm {in}) 3.0—8.0 {0.12—0.31}
Clutch disc
Runout limit (mm {in}) 0.7 {0.027} max.
Clutch fluid
Type SAE J1703 or FMVSS116 DOT-3 or DOT-4
MANUAL TRANSMISSION
M15M-D
Item Specification
Type API service GL-4 or GL-5
All-season SAE 75W-90
Transmission oil Viscosity Above
SAE 80W-90
10 C {50 F}
Capacity (L {US qt, lmp qt}) 2.0 {2.1, 1.8}
M15MX-D
Item Specification
SAE 80W-90
10 C {50 F}
Transfer oil Viscosity Above
SAE 80W-90
10 C {50 F}
R15M-D
Item Specification
SAE 80W-90
10 C {50 F}
CONTINUED
TD–10
TECHNICAL DATA
R15MX-D
Item Specification
SAE 80W-90
10 C {50 F}
Transfer oil Viscosity Above
SAE 80W-90
10 C {50 F}
PROPELLER SHAFT
Front propeller shaft Rear propeller shaft
Item Propeller shaft (42)
(44) (44)
Runout limit (mm {in}) 0.4 {0.016} 0.4 {0.016} 0.4 {0.016}
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Starting torque of universal 0.3—1.1 0.3—0.7 0.3—1.1
(N·m {kgf·cm, in·lbf}) {3.0—12.0, 2.7—10.4} {3.0—8.0, 2.7—6.9} {3.0—12.0, 2.7—10.4}

Item 42 44
Play (mm {in}) 0 {0}
Preload
0.4—0.7 {4.0—8.0, 3.5—6.9}
Front axle Wheel bearing (N·m {kgf·cm, in·lbf})
Pull scale reading
5.9—10.7 {0.6—1.1, 1.4—2.4}
(N {kgf, lbf})
Rear axle Wheel bearing play (mm {in}) 0.05—0.25 {0.002—0.010}
Shaft length
g Left side 551.0—561.0 {21.7—22.0}
Drive shaft
(mm {in}) Right side 619.0—629.0 {24.4—24.7}
Front –0.032—0.032 {–0.001—0.001}
Pinion height (mm {in})
Rear –0.254—0.254 {–0.010—0.010}
Backlash of side gear
g and differential Front 0—0.1 {0—0.003}
pinion (mm {in}) Rear —
Front 0.9—1.3 {9.0—14.0, 7.9—12.1}
Drive pinion
inion preload
reload (N·m {kgf·cm,
{kgf·cm in·lbf})
Rear 1.8—2.6 {18.0—27.0, 15.7—23.4}
Backlash of drive 0.09—0.11 {0.0036—0.0043} [Front]
Standard
pinion
inion and ring 0.12—0.20 {0.005—0.008} [Rear]
gear Minimum 0.05 {0.002} [Front], 0.12 {0.008} [Rear]
(mm {in}) Allowance variation 0.07 {0.003} [Front], 0.08 {0.005} [Rear]
Differential
Grade API service GL-5
Above-18C {0F}: SAE 90
Front —
Viscosity
y Below-18C {0F}: SAE 80
Standard Rear SAE 90
1.20 {1.27, 1.06} [MFW]
Oil Capacity Front —
1.50 {1.59, 1.32} [RFW]
(L {US qt
qt, lmp qt})
Rear 1.40 {1.48, 1.23} 1.85 {1.96, 1.63}
Grade API service GL-6
LSD Viscosity SAE 90
Capacity (L {US qt, lmp qt}) 1.40 {1.48, 1.23} 1.85 {1.96, 1.63}
CONTINUED
TD–11
TECHNICAL DATA
STEERING SYSTEM
Engine speed sensing
Item Manual steering
power steering
Play (mm {in}) 0—30 {0—1.18}
Steering wheel
Effort (N·m {kgf·cm, in·lbf}) 45 {460, 399} max. 7.8 {80, 69} max.
Backlash (mm {in}) 0 {0}
1.0—1.3 0.7—1.2
Worm shaft preload (N·m {kgf·cm, in·lbf})
Steering gear {10—14, 8.7—12.1} {6.5—12.5, 5.7—10.8}
Gear housing pressure 8.9—9.3
—
(MPa {kgf/cm2, psi}) {90—95, 1280—1350}
ATF M-III or equivalent
Grade API service GL-4, SAE 90
Oil (e.g. DexronRII)
Capacity (L {US qt, lmp qt}) 0.34 {0.36, 0.30} 1.1 {1.2, 1.0}
Power steering Oil pump fluid pressure 8.9—9.3
—
oil pump (MPa {kgf/cm2, psi}) {90—95, 1280—1350}
BRAKING SYSTEM
42
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Item 44
F2, G6 WL, WL Turbo
Brake pedal
L.H.D.: 214—219 {8.43—8.81}
Brake pedal height (mm {in})
R.H.D.: 219—224 {8.63—8.81}
Brake pedal play (mm {in}) 3—8 {0.12—0.31}
Brake pedal-to-floor clearance (mm {in}) 105 {4.2} min.
Power brake unit
Power brake unit
Fluid pressure when at 0 kPa {0 mmHg, 790 {8, 114} min.
pedal depressed at 0 in Hg}
196 N {20 kgf ,44 lbf}) Power brake unit at
(kPa {kgf/cm2, psi}) 66.7 kPa {500 8,240 {84, 1,200} min.
mmHg, 19.7 in Hg}
Vacuum pump
Vacuum specification [In 20 seconds]
[When engine speed 1,500 rpm] 73.3 {550, 21.7}
(kPa {mmHg, in Hg})
Maximum vacuum
[When engine speed 3,000 rpm] 93.3 {700, 27.6}
(kPa {mmHg, in Hg})
Braking force control device
Type LSPV
Rear fluid pressure when front pressure is
4,900 kPa {50 kgf/cm2, 711 psi} 2,550 {26, 370}
Front disc brake
Disc pad thickness limit (mm {in}) 2.0 {0.08}
Thickness limit (mm {in}) 22 {0.87}
Disc plate
late
Runout limit (mm {in}) 0.05 {0.002}
Rear drum brake
Brake lining thickness limit (mm {in}) 1.0 {0.04}
Drum maximum diameter (mm {in}) 271.5 {10.68} 296.5 {11.67}
Parking brake
Parking brake lever stroke
[When pulled at 98 N {10 kgf, 22 lbf}] 1—7
(notches)
Brake fluid
Type SAE J1703 or FMVSS116 DOT-3 or DOT-4
CONTINUED
TD–12
TECHNICAL DATA
SUSPENSION
Suspension
Item 4 2 4 4
(mm {in}) 3"3 {0.12"0.12}
Total toe-in
(Degree) 0_16’ "16’ 0_14’ "14’
Inner +2_ 33_30’ +2_
Front wheel 35_00’ –3_ –3_
Maximum
alignment
li steering angle
[unloaded*1] Outer 33_00’ +2_ 30_00’ +2_
–3_ –3_
Camber angle 0_56’"30’ 1_ 06’"30’
Caster angle*2 1_37’"45’ 2_02’"45’
Exposed thread of shock absorber piston (mm {in}) 6—8 {0.24—0.31}
Lower arm ball joint rotation torque 14—44 {0.7—4.5, 1.6—9.9}
(Pull scale reading) (N {kgf, lbf})
Upper arm ball joint rotation torque 3.4—32.5 {0.4—3.2, 0.9—7.0}
(Pull scale reading) (N {kgf, lbf})
Exposed thread of stabilizer control link bolt (mm {in}) 18—21 {0.71—0.82}
*1: Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in
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designated positions.
Adjust to the median when carrying out wheel alignment.
*2: Difference between left and right must not exceed 45’.
Wheels and Tires

Europe
Item 4 2 4 4
Front
Size 195R14C-8PR 205/75R14C 235/75R15 105S 205R16C-8PR
Rear
Up to full 200 {2.0, 28} 180 {1.8, 26}
passenger
Front 180 {1 8 26}
{1.8, 180 {1 8 26}
{1.8,
Full 220 {2.2, 31} 200 {2.0, 28}
Tire Air pressure
ressure loaded
(kPa {kgf/cm2, psi}) Up to full 180 {1.8, 26} 200 {2.0, 28} 180 {1.8, 26} 180 {1.8, 26}
passenger
Rear
Full 450 {4.5, 63} 250 {2.5, 35} 450 {4.5, 63}
loaded
Wear limit (mm {in}) 1.6 {0.06}
Size 14 5J 14 5 1/2J 15 6 1/2JJ 16 6JJ

14 5 1/2J
Wh l
Wheel
Offset (mm {in}) 40 {1.57} 25 {0.98} 35 {1.38}
Pitch circle diameter (mm {in}) 139.7 {5.45}
Tightening torque Standard wheel: 89—117 {9—12, 65—86}
(N·m {kgf·cm, in·lbf}) Styled wheel (16 6JJ): 118—147 {12—15, 87—108}
Wheel Horizontal 2.0 {0.078}
and tire Runout limit (mm {in})
Vertical 1.5 {0.059}
Imbalance limit (g {oz}) 10 {0.35}
D One balance weight: max. 60 g {2.1 oz}.
D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim.
D Do not use more than two balance weights on either side of the wheel.
CONTINUED
TD–13
TECHNICAL DATA
General
Item 42 44
Front 185R14C
185R14C- 195R14C
195R14C- 205R16C 235/75R15 P235/75R1 P235/75R1
205R16C-
Size
Rear 8PR 8PR 8PR 105S 5 105S 5 106S
Unloade
d
(Up to 180
full {1.8, 26}
Front passenger 180 180 {1.8, 26}
) {1.8, 26}
Loaded
(Full 200 200
Tire loaded) {2.0, 28} {2.0, 28}
Air pressure
ressure
(kPa {kgf/cm2, psi}) Unloade
d
(Up to
full 180 {1.8, 26}
Rear passenger
)
Loaded
(Full 450 {4.5, 63} 250 240 260
cardiagn.com
loaded) {2.5, 35} {2.4, 34} {2.6, 36}
Wear limit (mm {in}) 1.6 {0.06}

145J
Size 145J 145 166JJ 156 1/2JJ
1/2J
Wheel
Offset (mm {in}) 40 {1.57} 35 {1.38} 25 {0.98}
Pitch circle diameter (mm {in}) 139.7 {5.45}
Tightening torque Standard wheel: 89—117 {9—12, 65—86}
(N·m {kgf·cm, in·lbf}) Styled wheel (166JJ): 118—147 {12—15, 87—108}
Wheel Horizontal 2.0 {0.078}
and tire Runout limit (mm {in})
Vertical 1.5 {0.059}
Imbalance limit (g {oz}) 10 {0.35}
D One balance weight: max. 60 g {2.1 oz}.
D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim.
D Do not use more than two balance weights on the inner or outer side of the wheel.

Item Specification
Headlight High beam/Low beam* 60/552
Parking light 52
Front turn light 212
Brake light/taillight 21/52
Exterior light bulb capacity
ca acity (W)
Rear turn light 212
Back-up light 212
Rear fog light 211
License plate light 52
Stretch cab, Double cab 101
Interior light
Interior light bulb capacity (W) Regular cab 81
Instrument cluster illumination 3.44
CONTINUED
TD–14
TECHNICAL DATA
Oil pressure warning light 1.41

Generator warning light 1.41
Sedimentor warning light 1.41
Brake system warning light 1.41
Warning and indicator light Rear window defroster indicator light 1.41
bulb capacity (W) Glow indicator light 1.41
High beam indicator light 1.41
Turn indicator light 1.42
Air bag system warning light 1.41
44 indicator light 1.41
LOCK indicator light 1.41
*: Also remains illuminated when high beam turned on.
HEATER AND AIR CONDITIONER SYSTEMS

Specification
Item
G6, WL F2
cardiagn.com
Refrigerant Regular amount (g {oz}) 550 {19.4}
Sealed volume
Lubricating oil 180 {180, 6.08}
(ml {cc, fl oz})
A/C compressor
com ressor
Magnetic clutch clearance
0.35—0.75 {0.014—0.029} 0.3—0.6 {0.012—0.023}
(mm {in})
CONTINUED
TD–15
BACK TO MAIN INDEX TO. MODEL .INDEX
SPECIAL TOOLS
SPECIAL TOOLS.............................................. ST-1 FRONT AND REAR AXLES ......................... ST-3/5
ENGINE ........................................................ ST-1 STEERING SYSTEM ...................................ST-6
LUBRICATION SYSTEM ............................... ST-1 BRAKING SYSTEM ......................................ST-7
COOLING SYSTEM ...................................... ST-2 SUSPENSION ..............................................ST-7
FUELAND EMISSION BODY ...........................................................ST-7
CONTROL SYSTEMS ................................. ST-2 BODY ELECTRICAL SYSTEM .....................ST-8
CLUTCH ....................................................... ST-2 HEATER AND AIR
PROPELLER SHAFT .................................... ST-3 CONDITIONER SYSTEMS ......................ST-8
SPECIAL TOOLS
CONTINUED
ENGINE
49 S013 1A1 49 9200 020A 49 S011 103
Compression Belt tension Oil seal installer

gauge set gauge
cardiagn.com
49 8010301 49 S010 001 49 S011 102A
Oil seal installer Oil seal installer Crankshaft lock

tool
49 B025 001 49 G033 107A 49 S120 710
Body Dust cover Coupling flange

installer holder
49 P005 204 49 H011 101A
Oil seal installer Crankshaft lock

tool —
LUBRICATION SYSTEM
490187280 49 G014 001
Oil filter wrench
Oil pressure
gauge —
CONTINUED
ST-1
SPECIAL TOOLS
COOLING SYSTEM
49 9200
145
Radiator cap — —
tester adapter
set

49 8120 215B 49L018901 49H01S9A1A
Pulley puller Injector checker

Self-diagnosis
checker
1
49 B019 9A0 499140074 49 T088 0A3*
2
49 T088 0A5*
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System selector Cam lift
measuring device NGS set
SST No. for Program card varies with • 49 T088 037B (English & Danish)
language • 49 T088 038B (English & Norwegian)
Program card • 49 T088 030E (English & French) • 49 T088 039B (English & Czech)
• 49 T088 031 E (English & German) • 49 T088 041 B (English & Greek)
• 49 T088 032E (English & Dutch) • 49 T088 042B (English & Hungarian)
• 49 T088 033E (English & Swedish) 49 T088 043B (English & Polish)
• 49 T088 034C (English & Spanish) • 49 T088 044B (English & Spanish)
• 49 T088 035C (English & Portuguese) • 49 T088 045B (English & Portuguese)
• 49 T088 036C (English & Italian)
*1: Except Europe
*2: Europe only
CLUTCH
49 0259 770B 49 E011 1A0 49 SE01 310A
Clutch disc
Flare nut wrench Ring gear centering tool
brake set
49 1285 071
Needle bearing
puller — —
CONTINUED
ST-2
SPECIAL TOOLS
PROPELLER SHAFT
49 0259 440 49 S 120 440
Mainshaft holder Mainshaft holder

—

49 T028 3A0 49 T028 303 49 T028 304
Ball joint puller Body Attachment

set (Part of (Part of
49 T028 3A0) 49 T028 3A0)
49 H033 101 49 B025 001 49 F019 001
cardiagn.com
Bearing Body Oil seal installer
remover
49 S231 635 49 S231 660 49 S033 108
Front hub Needle bearing Bearing installer

locknut wrench puller
49 S033 107 49 S033 106 49 F027 007
Oil seal installer Oil seal installer Attachment ∅72
49 F027 005 49 S120 645A 49 0603 635A
Attachment ∅62 Rear shaft Rear shaft nut

holder wrench
49 S 120 748 49 F027 004 49 U027 003
Attachment Attachment ∅80 Oil seal installer
CONTINUED
ST-3
SPECIAL TOOLS
49 H025 001 49 M005 561 49 0727 570
Bearing installer Differential Pinion height

hanger carrier gauge body
49 8531 565 49 0305 555 49 0259 720
Drive model Gauge block Differential side

pinion bearing adjust
nut wrench
49 0839 425C 49 F027 005 49 S120 710
Bearing Attachment ∅62 Coupling flange

puller set (Part of holder
49 F027 0A1)
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49 H027 002 49 G030 795 49 G030 338
Bearing Oil seal installer Attachment E

remover
49 F401 331 49 S026 2A1 49 S026 204
Body Rear shaft Plate

(Part of bearing puller (Part of
49 F401 330B) 49 S026 2A1)
49 S026 205 49 S026 208 49 0710 520

Bearing puller
Rod Attachment
(Part of (Part of
49 S026 2A1) 49 S026 2A1)
49 W027 0A0 49 W027 001 49 U027 004
Oil seal Body Oil seal remover

installer set (Part of
49 W027 0A0)
49 M005 795 49 U027 005 49 U027 006
Oil seal installer Bearing installer Bearing installer
CONTINUED
ST-4
SPECIAL TOOLS
49 U027 007 49 0813 215A 49 F028 204

Tubular
Oil seal installer dowel puller Bushing installer
49 M005 796 49 U027 0A0 49 UN27 003
Body Collar A
(Part of L.S.D. replacer
49 M005 795) set
49 UN27 004 49 U027 008 49 F027 009
Collar B Gauge block Attachment

∅68 & ∅77
cardiagn.com
49 U027 009 49 UB71525 49 U027 010
Oil seal Bearing installer Bearing installer

installer
49 0107 680A 49 U027 011 49 U027 012
Engine stand Shaft Attachment A

(Part of (Part of
49 U027 0A0) 49 U027 0A0)
49 U027 013 49 U027 014
Attachment B Bolt
(Part of (Part of —
49 U027 0A0) 49 U027 0A0)
CONTINUED
ST-5
SPECIAL TOOLS
STEERING SYSTEM
49 T028 3A0 49 T028 303 49 T028 304
Ball joint Body Attachment

puller set (Part of (Part of
49 T028 3A0) 49 T028 3A0)
491232670A 49 1232 672 49 1232 673
Power steering Gauge Valve body

gauge set (Part of (Part of
49 1232 670A) 49 1232 670A)
49 H002 671 49 0180 510B 49 U032 3A0
Adapter Preload Pitman

measuring arm puller
cardiagn.com
attachment
49 B032 304 491243785A 49 U034 209
Adapter Dust boot Clip guide

installer
49 U032 201 49 G032 354 49 G032 3A4
Locknut wrench Adjust wrench Power steering

gauge adapter
set
CONTINUED
ST-6
SPECIAL TOOLS
BRAKING SYSTEM
49 U043 0A0 49 U043 004 49 U043 005
Oil pressure Oil pressure Joint

gauge set gauge (Part of
(Part of 49 U043 0A0)
49 U043 0A0)
49 U043 006 49 0259 770B 49 B043 001
Hose Flare nut wrench Adjust gauge

(Part of
49 U043 0A0)
49 0221 600C 49 E043 003A 49 0208 701 A
Disc brake Turning lock tool Boot air out tool

expand tool
cardiagn.com
49 B043 004
Socket wrench — —
SUSPENSION
49 T028 3A0 49 0180 510B 49 U034 208
Ball joint Preload Clip guide

puller set measuring
attachment
49 UB39 615 49 U034 2A0 49 U034 209
Bushing puller & Lower arm Clip guide

installer set bushing puller &
installer set
BODY
49 0305 870A 49 0259 866A
Window tool set Window

—
inserting
tool
CONTINUED
ST-7
SPECIAL TOOLS
49 H066 002 49 D066 002 49 0839 285
Deployment Adapter harness Fuel And

tool Thermometer
checker
(OLD)
49 N088 0A0 49 D066 801 A 49 T088 0A3*1

49 T088 0A5*2
Fuel And Removing tool
Thermometer NGS set
checker
(NEW)
SST No. for Program card varies with • 49 T088 037B (English & Danish)
Program card language • 49 T088 038B (English & Norwegian)
• 49 T088 030E (English & French) • 49 T088 039B (English & Czech)
• 49 T088 031E (English & German) • 49 T088 041 B (English & Greek)
cardiagn.com
• 49 T088 032E (English & Dutch) • 49 T088 042B (English & Hungarian)
• 49 T088 033E (English & Swedish) • 49 T088 043B (English & Polish)
• 49 T088 034C (English & Spanish) • 49 T088 044B (English & Spanish)
• 49 T088 035C (English & Portuguese) • 49 T088 045B (English & Portuguese)
• 49 T088 036C (English & Italian)
*1: Except Europe

*2: Europe only
HEATER AND AIR CONDITIONER SYSTEMS
49 C061 0A0A 49 C061 012 49 C061 013
Manifold Anti-back Gas leak tester

gauge set flow valve (R-134a)
(R-134a) (R-134a)
49 D066 801A 49 H061 005
Removing tool Attachment

—
ST-8

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BACK TO FOREWORD & ENGINE INDEX RANG.DRFT.REPAIR MANUAL PAGES. FROM.

Repair Engine F8/FE

Engine Electrical System G

APPLICATION: Manual Transmission R15M–D

Front and Rear Axles M

Body Electrical System T

Heater and Air Conditioner Systems U

1999 Ford/Mazda Motor Company

VEHICLE IDENTIFICATION NUMBERS (VIN)

General specs. (L.H.D.)

HOW TO USE THIS MANUAL SERVICING PROCEDURE

“Inspection After SHOWS SPECIAL

Apply automatic Appropriate new

Apply petroleum Appropriate On-board diagnosis

Engine tune-up (Section F)

Procedures For Use

SHOWS INSPECTION SHOWS ITEM NAMES FOR

Perform malfunction diagnosis according to No. 26

Using the quick diagnosis chart

PARTS WHICH MAY BE THE CAUSE OF

ENGINE QUICK DIAGNOSTIC CHART

PART WHICH MAY BE

Using the symptom troubleshooting

STEP shows the ACTION describes the

Reference page(s) for

How to perform ACTION

UNITS The actual converted values for 2.7 kgf/cm2 are

Upper and lower limits

210—260 kPa {2.1—2.7 kgf/cm2, 30—38 psi}

FUNDAMENTAL PROCEDURES REMOVAL OF PARTS

PREPARATION OF TOOLS AND MEASURING

SPECIAL SERVICE TOOLS

INSPECTION DURING REMOVAL, DISASSEMBLY

DISCONNECTION OF THE NEGATIVE BATTERY

Oil should be applied to the moving components of

RUBBER PARTS AND TUBING

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

FUNDAMENTAL PROCEDURES, INSTALLATION OF RADIO SYSTEM

TORQUE FORMULAS INSTALLATION OF RADIO SYSTEM

ELECTRICAL SYSTEM Disconnecting Connectors

Connectors can be disconnected by pressing or

2. Check the terminals of waterproof connectors from

SXU00025 BLACK BROWN

Sensors, Switches, and Relays

3. When replacing a pullout fuse, use the fuse puller. Ohmmeter

ELECTRICAL TROUBLESHOOTING TOOLS

JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) POSITIONS,

JACKING POSITIONS REAR

Use safety stands to support the vehicle after it has

SAFETY STAND POSITIONS

VEHICLE LIFT (2 SUPPORTS)

TOWING (With Manual Transmission)

If all four wheels are on the ground, the vehicle may be

If speed must exceed 45 km/h (28 mph) or a towing

Place the rear wheels on dollies.

Disconnect the propeller shaft.

Remember that power assist for the brakes

If your Ford/Mazda has 44, change to 2-wheel drive

TOWING HOOKS IDENTIFICATION NUMBER

ENGINE IDENTIFICATION NUMBER

AP Accelerator Pedal — Accelerator Pedal

New Standard Previous Standard

— Injection Pump FIP Fuel Injection Pump #6