Мануал по исузу аксиом - Большая энциклопедия инструкций и руководств

ПРОБЛЕМА:
Так как основные работы по ремонту, обслуживанию и улучшению автомобиля я делаю сам,
и владение ИЖ 21261-070 4х4 в свое время меня научило надеяться только на свои силы,
так как аппарат был ещё реже чем AXIOM, и никакой сервис бы мне не помог либо это стоило баснословных средств. Поэтому знакомство всегда начинаю с приобретение Руководства или Справочника по автомобилю.
Так как AXIOM выпускался сравнительно не долго 2001-2004 (как и ИЖ 21261-070 2004-2005), + в стране их не так много — дельного руководства на русском языке нет.
Слава богу есть большой труд на 2100 страниц на английском языке.
Вот ссылка на него
Руководство общее на английском — yadi.sk/i/2YBkSUzOzOs95A
Но в этом ворохе страниц легко запутаться, тем более тем кто не особо силен в техническом английском.

РЕШЕНИЕ:
1. Разделить общее руководство на темы
2. Перевести на русский язык

Потратив один выходной сделал себе базу — надеюсь кому-то пригодится

1. Isuzu Axiom-1-26 — Общее yadi.sk/i/QGunXh45ufwXQQ
2. Isuzu Axiom-27-151 — Отопление и Кондиционер yadi.sk/i/RATeDFnN3YfNaw
3. Isuzu Axiom-152-201 — Рулевое yadi.sk/i/DhxVlWQEJyoE8Q
4. Isuzu Axiom-202-226- Передняя подвеска yadi.sk/i/DfK8FCKgaKP8dw
5. Isuzu Axiom-226-262- Задняя подвеска yadi.sk/i/2i8KymQ6TMGTDg
6. Isuzu Axiom-263-313-Управление подвеской и шины yadi.sk/i/dZtc3mHzyvcy9w
7. Isuzu Axiom-314-372 — Мосты yadi.sk/i/eg-9kany—8eYw
8. Isuzu Axiom-373-497 — Схема TOD yadi.sk/i/t9R8h4e_uJMPHA
9. Isuzu Axiom-498-583-Карданы, привода ступицы yadi.sk/i/2XVcEHMGBs9fxw
10. Isuzu Axiom-584-619 — Раздатка yadi.sk/i/rpugLN4OVBFcKg
11. Isuzu Axiom-620-676 — Тормоза система управления yadi.sk/i/EQXLmOXsa1FyFw
12. Isuzu Axiom-620-810 — Тормоза основное yadi.sk/i/xwRl-uM_VEC_ow
13. Isuzu Axiom-677-681 — Тормоза ABS yadi.sk/i/SocauYT5TqgPWA
14. Isuzu Axiom-811-1559 — Двигатель_механическая часть yadi.sk/i/7jNV3PdtdoP2zw
15. Isuzu Axiom-811-1559 — Двигатель_Система охлаждения yadi.sk/i/YrkZfp6uQApA8A
16. Isuzu Axiom-811-1559 — Двигатель_Стартер, Генератор, АКБ yadi.sk/i/3U4Qls1bFNf2YQ
17. Isuzu Axiom-811-1559 — Двигатель_Топливная система yadi.sk/i/ANfcgNmAgN35Dg
18. Isuzu Axiom-811-1559 — Двигатель_ЭБУ, датчики диагностика yadi.sk/i/fHa8-W7j_ZpgBg
19. Isuzu Axiom-1560-1567 — Выхлоп yadi.sk/i/ZYfTcBJWMXkgaw
20. Isuzu Axiom-1568-1584 Двигатель дополнение yadi.sk/i/VTAN8b2grHIelQ
21. Isuzu Axiom-1585-1776 -АКПП yadi.sk/i/Wx3n9WrF_iJxZA
22. Isuzu Axiom-1777-1798- Освещение yadi.sk/i/ZTp4mf4HPaQtGA
23. Isuzu Axiom-1799-1812 — Омыватель yadi.sk/i/e3Y7kreIc81IDA
24. Isuzu Axiom-1813-1835- Мультимедиа yadi.sk/i/kF49cOCNyXDIEg
25. Isuzu Axiom-1836-1876 — Электрика yadi.sk/i/dSLhcvQy_R56dg
26. Isuzu Axiom-1877-1938 — Кузов yadi.sk/i/0tqRSF-_ZylxzQ
27. Isuzu Axiom-1939-1969 — Замки и сиденья yadi.sk/i/-PhKnaUsP9ddWw
28. Isuzu Axiom-1979-2014 — Салон yadi.sk/i/cxQzirf7vJPOTg
29. Isuzu Axiom-2015-2100 — SRS и круиз yadi.sk/i/rjanpEFRTpxMNA

Всем ровных дорог!

Источник

Руководство на английском языке по техническому обслуживанию и ремонту Isuzu Amigo/Axiom/Trooper/Rodeo/VehiCross 1999-2002 годов выпуска.

Автор: —
Издательство: Isuzu Motors
Год издания: —
Страниц: 23403
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Схемы электрооборудования на английском языке Isuzu Axiom 2002 года выпуска.

Автор: —
Издательство: Isuzu Motors
Год издания: —
Страниц: —
Формат: PDF
Размер: 2,4 Mb

Схемы электрооборудования на английском языке Isuzu Axiom 2003 года выпуска.

Автор: —
Издательство: Isuzu Motors
Год издания: —
Страниц: —
Формат: PDF
Размер: 13,3 Mb

Источник

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Источник

FOREWORD This manual includes special notes, important points, service data, precautions, etc. That are needed for the maintenance, adjustments, service, removal and installation of vehicle components. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. All rights are reserved to make changes at any time without notice. Arrangement of the material is shown in the table of contents on the right-hand side of this page. A black spot on the first page of each section can be seen on the edge of the book below each section title. These point to a more detailed table of contents preceding each section.

This manual applies to 2002 models.

TABLE OF CONTENTS GENERAL INFORMATION General Information Maintenance and Lubrication HEATING, VENTILATION AND AIR CONDITIONING HVAC System STEERING Power-Assisted System SUSPENSION Front Suspension Rear Suspension Wheel and Tire System Intelligent Suspension System DRIVELINE/AXLE Differential (Front) Differential (Rear) Driveline Control System Driveline Control System (TOD) Drive Shaft System Transfer Case (TOD) BRAKE Brake Control System Anti-Lock Brake System Power-Assisted Brake System Parking Brake System (4×4 model) Parking Brake System (4×2 model) ENGINE Engine Mechanical Engine Cooling Engine Fuel Engine Electrical Ignition System Starting and Charging System Driveability and Emissions Engine Exhaust Engine Lubrication Engine Speed Control System Induction TRANSMISSION Automatic Transmission Transmission Control System BODY AND ACCESSORIES Lighting System Wiper/Washer System Entertainment Wiring System Meter and Gauge Body Structure Seats Security and Locks Sun Roof/Convertible Top Exterior/Interior Trim RESTRAINTS Seat Belt System Supplemental Restraint System (Air Bag System) Restraint Control System CONTROL SYSTEM Cruise Control System

GENERAL INFORMATION CONTENTS General Information . . . . . . . . . . . . . . . . . . . . . Maintenance and Lubrication . . . . . . . . . . . . .

General Information CONTENTS General Repair Instruction . . . . . . . . . . . . . . . . Illustration Arrows . . . . . . . . . . . . . . . . . . . . . . . Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . Theft Prevention Standard . . . . . . . . . . . . . . . .

General Repair Instruction 1. If a floor jack is used, the following precautions are recommended. Park vehicle on level ground, “block” front or rear wheels, set jack against the recommended lifting points (see “Lifting Instructions” in this section), raise vehicle and support with chassis stands and then perform the service operations. 2. Before performing service operations, disconnect ground cable from the battery to reduce the chance of cable damage and burning due to short circuiting. 3. Use a cover on body, seats and floor to protect them against damage and contamination. 4. Brake fluid and anti–freeze solution must be handled with reasonable care, as they can cause paint damage. 5. The use of proper tools and recommended essential and available tools, where specified, is important for efficient and reliable performance of service repairs. 6. Use genuine Isuzu parts. 7. Used cotter pins, plastic clips, gaskets, O–rings, oil seals, lock washers and self–locking nuts should be discarded and new ones should be installed, as normal function of the parts cannot be maintained if these parts are reused. 8. To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nuts separate is very important, as they vary in hardness and design depending on position of installation. 9. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air, and make certain they are free from restrictions. 10. Lubricate rotating and sliding faces of the parts with oil or grease before installation. 11. When necessary, use a sealer on gaskets to prevent leakage. 12. Carefully observe all specifications for bolt and nut torques.

Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . Standard Bolts Torque Specifications . . . . . . Abbreviations Charts . . . . . . . . . . . . . . . . . . . . Service Parts Identification Plate . . . . . . . . . .

13. When removing or replacing parts that require refrigerant to be discharged from the air conditioning system, be sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle Refrigerant–134a. 14. When a service operation is completed, make a final check to be sure the service has been done properly and the problem has been corrected. 15. SUPPLEMENTAL RESTRAINT SYSTEM The vehicle is equipped with a Supplemental Restraint System (SRS) – Air Bags. This system is not to be serviced without consulting the appropriate service information. Consult Section 9J “SRS System” if work is to be done on the front of the vehicle such as bumper, sheet metal, seats, wiring, steering wheel or column. Also review SRS system information if any arc welding is to be done on the vehicle. The SRS system equipped vehicle can be identified by: 1. “AIR BAG” warning light on the instrument cluster. 2. A Code “K” or “M” for fifth digit of Vehicle Identification Number.

Illustration Arrows Arrows are designed for specific purposes to aid your understanding of technical illustrations. Arrow Type

Identification Vehicle Identification Number (VIN) This is the legal identification of the vehicle. it is located on the left bottom of the windshield. It can be easily seen through the windshield from outside the vehicle.

Engine Serial Number The gasoline engine serial number is stamped on the left rear lower area of the cylinder block above the starter.

Automatic : Stamped on the identification plate, located on the left side of the transmission above the mode switch.

Theft Prevention Standard The 11 major components listed below will be marked with 17 digit VIN at the stage of production. In addition its service parts will be marked with manufacturer’s trade mark, “R” mark and “DOT” mark. Reference Figure No.

3– Engine hood 4– Front door 5– Rear door 6– Fender 7– Rear Quarter panel 8– Front bumper 9– Back door left side 10– Back door right side 11– Rear bumper

Anti Theft Stamping/Label/Plate Location The stamping, label and plate locations are indicated by arrows in the illustration below. NOTE: 1. VIN plate locations for production. 2. Stamping locations for service parts. Engine

Body Label Instructions Do not peel off the masking tape until completion of paint work when replacing these parts, as the tape is affixed on the label attached to service parts for body of the anti–theft component. NOTE: Be sure to pull off the masking tape after paint work has been completed. Do not attempt to remove this label for any reason.

Precautions in pulling off the masking tape 1. Use only your finger nail or a similar blunt instrument to peel off the masking tape. Use of a sharp object will damage the underlying anti–theft label. 2. Be careful not to damage the paint around the label.

Lifting Instructions CAUTION: B If a lifting device other than the original jack is used, it is most important that the device be applied only to the correct lifting points. Raising the vehicle from any other point may result in serious damage.

B When jacking or lifting a vehicle at the frame side rail or other prescribed lift points, be certain that lift pads do not contact the catalytic converter, brake pipes or cables, or fuel lines. Such contact may result in damage or unsatisfactory vehicle performance.

Lifting Point: Front B When using a floor jack, lift on the Convex portion of the skid plate.

B Position the chassis stands at the bottom of the frame sidemember, behind the front wheel.

B Position the chassis stands at the bottom of the frame sidemember, just behind the trailing link bracket.

Lifting Point: Rear B Position the floor jack at the center of the rear axle case when lifting the vehicle.

Legend (1) Trailing Link Bracket Supportable Point: Rear B Position the chassis stands at the bottom of the rear axle case.

Standard Bolts Torque Specifications The torque values given in the following table should be applied where a particular torque is not specified. Strength Class

Bolt Diameter × Pitch (mm) M 6X1.0 M 8X1.25 M 10X1.25 * M10X1.5 M12X1.25 * M12X1.75 M14X1.5 * M14X2.0 M16X1.5 * M16X2.0 M18X1.5 M20X1.5 M22X1.5 M24X2.0

4 – 8 N·m (3 – 6 lb ft) 8 – 18 N·m (6 – 13 lb ft) 21 – 34 N·m (15 – 25 lb ft) 20 – 33 N·m (14 – 25 lb ft) 49 – 74 N·m (36 – 54 lb ft) 45 – 69 N·m (33 – 51 lb ft) 77 – 115 N·m (56 – 85 lb ft) 72 – 107 N·m (53 – 79 lb ft) 104 – 157 N·m (77 – 116 lb ft) 100 – 149 N·m (74 – 110 lb ft) 151 – 226 N·m (111 – 166 lb ft) 206 – 310 N·m (152 – 229 lb ft) 251 – 414 N·m (185 – 305 lb ft) 359 – 539 N·m (265 – 398 lb ft)

5 – 10 N·m (4 – 7 lb ft) 12 – 23 N·m (9 – 17 lb ft) 28 – 46 N·m (20 – 34 lb ft) 28 – 45 N·m (20 – 33 lb ft) 61 – 91 N·m (45 – 67 lb ft) 57 – 84 N·m (42 – 62 lb ft) 93 – 139 N·m (69 – 103 lb ft) 88 – 131 N·m (65 – 97 lb ft) 135 – 204 N·m (100 – 150 lb ft) 130 – 194 N·m (95 – 143 lb ft) 195 – 293 N·m (144 – 216 lb ft) 270 – 405 N·m (199 – 299 lb ft) 363 – 544 N·m (268 – 401 lb ft) 431 – 711 N·m (318 – 524 lb ft)

The asterisk * indicates that the bolts are used for female–threaded parts that are made of soft materials such as casting, etc.

– 17 – 30 N·m (12 – 22 lb ft) 37 – 63 N·m (27 – 46 lb ft) 36 – 60 N·m (27 – 44 lb ft) 76 – 114 N·m (56 – 84 lb ft) 72 – 107 N·m (53 – 79 lb ft) 114 – 171 N·m (84 – 126 lb ft) 107 – 160 N·m (79 – 118 lb ft) 160 – 240 N·m (118 – 177 lb ft) 153 – 230 N·m (113 – 169 lb ft) 230 – 345 N·m (169 – 255 lb ft) 317 – 476 N·m (234 – 351 lb ft) 425 – 637 N·m (313 – 469 lb ft) 554 – 831 N·m (409 – 613 lb ft)

Abbreviations Charts List of automotive abbreviations which may be used in this manual A — Ampere(s) ABS — Antilock Brake System AC — Alternating Current A/C — Air Conditioning ACCEL — Accelerator ACC — Accessory ACL — Air Cleaner Adj — Adjust A/F — Air Fuel Ratio AIR — Secondary Air Injection System Alt — Altitude AMP — Ampere(s) ANT — Antenna ASM — Assembly A/T — Automatic Transmission/Transaxle ATDC — After Top Dead Center ATF — Automatic Transmission Fluid Auth — Authority Auto — Automatic BARO — Barometric Pressure Bat — Battery B+ — Battery Positive Voltage Bbl — Barrel BHP — Brake Horsepower BPT — Backpressure Transducer BTDC — Before Top Dead Center ° C — Degrees Celsius CAC — Charge Air Cooler Calif — California cc — Cubic Centimeter CID — Cubic Inch Displacement CKP — Crankshaft Position CL — Closed Loop CLCC — Closed Loop Carburetor Control CMP — Camshaft Position CO — Carbon Monoxide Coax — Coaxial Conn — Connector Conv — Converter Crank — Crankshaft Cu. In. — Cubic Inch CV — Constant Velocity Cyl — Cylinder(s) DI — Distributor Ignition Diff — Differential Dist — Distributor DLC — Data Link Connector DOHC — Double Overhead Camshaft DTC — Diagnostic Trouble Code DTM — Diagnostic Test Mode DTT — Diagnostic Test Terminal DVM — Digital Voltmeter (10 meg.) DVOM — Digital Volt Ohmmeter EBCM — Electronic Brake Control Module ECM — Engine Control Module ECT — Engine Coolant Temperature EEPROM — Electronically Erasable Programmable Read Only Memory EGR — Exhaust Gas Recirculation EI — Electronic Ignition ETR — Electronically Tuned Receiver EVAP — Evaporation Emission

Exh — Exhaust ° F — Degrees Fahrenheit Fed — Federal (All States Except Calif.) FF — Front Drive Front Engine FL — Fusible Link FLW — Fusible Link Wire FP — Fuel Pump FRT — Front ft — Foot FWD — Front Wheel Drive 4WD — Four Wheel Drive 4 x 4 — Four Wheel Drive 4 A/T — Four Speed Automatic Transmission/Transaxle Gal — Gallon GEN — Generator GND — Ground Gov — Governor g — Gram Harn — Harness HC — Hydrocarbons HD — Heavy Duty Hg — Hydrargyrum (Mercury) HiAlt — High Altitude HO2S — Heated Oxygen Sensor HVAC — Heater–Vent–Air–Conditioning IAC — Idle Air Control IAT — Intake Air Temperature IC — Integrated Circuit / Ignition Control ID — Identification / Inside Diameter IGN — Ignition INJ — Injection IP — Instrument Panel IPC — Instrument Panel Cluster Int — Intake ISC — Idle Speed Control J/B — Junction Block kg — Kilograms km — Kilometers km/h — Kilometer per Hour kPa — Kilopascals kV — Kilovolts (thousands of volts) kW — Kilowatts KS — Knock Sensor L — Liter lb ft — Foot Pounds lb in — Inch Pounds LF — Left Front LH — Left Hand LR —Left Rear LS — Left Side LWB — Long Wheel Base L–4 — In–Line Four Cylinder Engine MAF — Mass Air Flow MAN — Manual MAP — Manifold Absolute Pressure Max — Maximum MC — Mixture Control MFI — Multiport Fuel Injection MIL — Malfunction Indicator Lamp Min — Minimum mm — Millimeter MPG — Miles Per Gallon MPH — Miles Per Hour M/T — Manual Transmission/Transaxle MV — Millivolt

GENERAL INFORMATION N — Newtons NA — Natural Aspirated NC — Normally Closed N·M — Newton Meters NO — Normally Open NOX — Nitrogen, Oxides of OBD — On-Board Diagnostic OD — Outside Diameter O/D — Over Drive OHC — Overhead Camshaft OL — Open Loop O2 — Oxygen O2S — Oxygen Sensor PAIR — Pulsed Secondary Air Injection System P/B — Power Brakes PCM — Powertrain Control Module PCV — Positive Crankcase Ventilation PRESS — Pressure PROM — Programmable Read Only Memory PNP — Park/Neutral Position P/S — Power Steering PSI — Pounds per Square Inch PSP — Power Steering Pressure Pt. — Pint Pri — Primary PWM — Pulse Width Modulate Qt. — Quart REF — Reference RF — Right Front RFI — Radio Frequency Interference RH — Right Hand RPM — Revolutions Per Minute RPM Sensor — Engine Speed Sensor RPO — Regular Production Option RR — Right Rear RS — Right Side RTV — Room Temperature Vulcanizing RWAL — Rear Wheel Antilock Brake RWD — Rear Wheel Drive SAE — Society of Automotive Engineers Sec — Secondary SFI — Sequential Multiport Fuel Injection SI — System International SIR — Supplemental Inflatable Restraint System SOHC — Single Overhead Camshaft Sol — Solenoid SPEC — Specification Speedo — Speedometer SRS — Supplemental Restraint System ST — Start / Scan Tool Sw — Switch SWB — Short Wheel Base SYN — Synchronize Tach — Tachometer TB — Throttle Body TBI — Throttle Body Fuel Injection TCC — Torque Converter Clutch TCM — Transmission Control Module TDC — Top Dead Center Term — Terminal TEMP — Temperature TOD— Torque On Demand TP — Throttle Position TRANS — Transmission/Transaxle TURBO — Turbocharger

TVRS — Television & Radio Suppression TVV — Thermal Vacuum Valve TWC — Three Way Catalytic Converter 3 A/T — Three Speed Automatic Transmission/Transaxle 2WD — Two Wheel Drive 4 x 2 — Two Wheel Drive U–joint — Universal Joint V — Volt(s) VAC — Vacuum VIN — Vehicle Identification Number VRRRE — Vehicle Refrigerant Recovery and Recycling Equipment V–ref — ECM Reference Voltage VSS — Vehicle Speed Sensor VSV — Vacuum Switch Valve V–6 — Six Cylinder “V” Engine V–8 — Eight Cylinder ”V” Engine W — Watt(s) w/ — With w/b — Wheel Base w/o — Without WOT — Wide Open Throttle

Service Parts Identification Plate The Vehicle Information Plate (Service Parts ID plate) is provided on all vehicle models. It is located on the center dash wall inside the engine compartment. The plate lists the VIN (Vehicle Identification Number), paint information and all production options and special equipment on the vehicle when it was shipped from the factory.

GENERAL INFORMATION Maintenance and Lubrication CONTENTS Maintenance Schedule List . . . . . . . . . . . . . . . Explanation of Complete Vehicle Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recommended Fluids and Lubricants . . . . Lubricant Viscosity Chart . . . . . . . . . . . . . . . . .

Recommended Liquid Gasket . . . . . . . . . . . Recommended Thread Locking Agents . . . Maintenance Service Data . . . . . . . . . . . . . . . .

If the vehicle is usually operated under any of the severe driving conditions listed below, it is recommended that the applicable maintenance services be performed at the specified interval shown in the chart below. Severe driving conditions:

The maintenance instructions in this Maintenance Schedule are based on the assumption that the vehicle will be used as designed: B to carry passengers and cargo within the limitations specified on the tire placard located on the inside of the glove compartment door; B to be driven on reasonable road surfaces within legal operating limits; B to be driven on a daily basis, as a general rule, for at least several miles/kilometers; B to be driven on unleaded fuel Unusual or severe operating conditions will require more frequent vehicle maintenance, as specified in the following sections. ITEMS

B Towing a trailer, using a camper or car top carrier. B Repeated short trips of less than 8 Km (5 miles) with outside temperature remaining below freezing. B Extensive idling and/or low speed driving for long distances, such as police, taxi or door–to–door delivery use. B Operating on dusty, rough, muddy or salt spread roads.

Brief explanations of the services listed in the preceding Maintenance Schedule are presented below. Replace all questionable parts and note any necessary repairs as you perform these maintenance procedures.

Clean the front of the radiator core and air conditioning condenser, at 60,000 miles (96,000 km) intervals.

A fluid loss in any system (except windshield washer) may indicate a problem. Repair the system at once. Engine oil level Check level and add if necessary. The best time to check the engine oil level is when the oil is warm. After stopping the engine with the vehicle on a level surface, wait a few minutes for the oil to drain back to the oil pan. Pull out the oil level indicator (dipstick). Wipe it clean and push the oil level indicator back down all the way. Pull out the oil level indicator, keeping the tip down, and look at the oil level on it. Add oil, if needed, to keep the oil level above the “ADD” mark and between the “ADD” and “FULL” marks in the operating range area. Avoid overfilling the engine since this may cause engine damage. Push the oil level indicator back down all the way after taking the reading. If you check the oil level when the oil is cold, do not run the engine first. The cold oil will not drain back to the pan fast enough to give a true oil level. Engine coolant level and condition Check engine coolant level in the coolant reservoir and add engine coolant if necessary. Inspect the engine coolant and replace it if dirty or rusty.

Check the lubricant level after every 7,500 miles (12,000 km) of operation and add lubricant to level of filler hole if necessary. Replace the front and rear axle lubricant at 15,000 miles (24,000 km) and 30,000 miles (48,000 km) and after every 30,000 miles (48,000 km) of operation thereafter.

Air Cleaner Element Replacement Replace the air cleaner under normal operating conditions every 30,000 miles (48,000 km). Operation of the vehicle in dusty areas will necessitate more frequent replacement.

Spark Plug Replacement Replace the plugs at 100,000 miles (160,000 km) intervals with the type specified at the end of this section.

Cooling System Service Drain, flush and refill system with new engine coolant. Refer to “Recommended Fluids and Lubricants” in this section, or ENGINE COOLING (SEC.6B).

Timing Belt Replacement Replacement of the timing belt is recommended at every 100,000 miles (160,000 km). Failure to replace the timing belt may result in serious damage to the engine.

Valve Clearance Adjustment Incorrect valve clearance will result in increased engine noise and reduced engine output. Retorque the camshaft bracket bolts before checking and adjusting the valve clearance. Check and adjust the valve clearance whenever increased engine noise is heard.

Tire Rotation Rotate tires every 7,500 miles (12,000 km).

Front Wheel Bearings Lubricant Replacement (Vehicles Produced Before July/31/2001) Clean and repack the front wheel bearings at 30,000 miles (48,000 km) intervals. Refer to DRIVE SHAFT SYSTEM (SEC. 4C).

Front Wheel Bearings Check (Vehicles Produced After Aug./1/2001) Inspect hub unit bearing at every 60,000 miles (96,000 km). If there is abnormal condition, replace hub unit bearing.

Windshield washer fluid level Check washer fluid level in the reservoir and add if necessary. Power steering system reservoir level Check and keep at the proper level. Brake master cylinder reservoir level Check fluid. Keep fluid at proper level. A low fluid level can indicate worn disc brake pads which may need to be serviced. Hydraulic clutch system Check fluid level in the reservoir. Add fluid as required. Battery fluid level Check fluid level in the battery.

Fluid Leak Check Check for fuel, water, oil or other fluid leaks by looking at the surface beneath the vehicle after it has been parked for a while. Water dripping from the air conditioning system after use is normal. If you notice gasoline fumes or fluid at any time, locate the source and correct it at once.

Engine Oil and Oil Filter Replacement Always use API SE, SF, SG, SH or ILSAC GF–1 quality oils of the proper viscosity. When choosing an oil, consider the range of temperatures the car will be operated in before the next oil change. Then, select the recommended oil viscosity from the chart.

Always change the oil and the oil filter as soon as possible after driving in a dust storm.

Engine Cooling System Inspection Inspect the coolant/anti–freeze. If the coolant is dirty or rusty, drain, flush and refill with new coolant. Keep coolant at the proper mixture for proper freeze protection, corrosion inhibitor level and best engine operating temperature. Inspect hoses and replace if cracked, swollen or deteriorated. Tighten the hose clamps if equipped with screw–type clamps. Clean outside of radiator and air conditioning condenser. Wash filler cap and neck. To help ensure proper operation, a pressure test of both the cooling system and the cap is also recommended.

Exhaust System Inspection Visually inspect the exhaust pipes, muffler, heat shields and hangers for cracks, deterioration, or damage. Be alert to any changes in the sound of the exhaust system or any smell of fumes. These are signs the system may be leaking or overheating. Repair the system at once, if these conditions exist. (See also “Engine Exhaust Gas Safety” and “Three Way Catalytic Converter” in the Owner’s manual.)

Fuel Cap, Fuel Lines, and Fuel Tank Inspection Inspect the fuel tank, the fuel cap and the fuel lines every 60,000 miles (96,000 km) for damage which could cause leakage. Inspect the fuel cap and the gasket for correct sealing and physical damage. Replace any damaged parts.

Drive Belt Inspection Check the serpentine belt driving for cracks, fraying, wear, and correct tension every 30,000 miles (48,000 km). Replace as necessary.

Wheel Alignment, Balance and Tires Operation Uneven or abnormal tire wear, or a pull right or left on a straight and level road may show the need for a wheel alignment. A vibration of the steering wheel or seat at normal highway speeds means a wheel balancing is needed. Check tire pressure when the tires are “cold” (include the spare). Maintain pressure as shown in the tire placard, which is located on the driver’s door lock pillar.

Steering System Operation Be alert for any changes in steering operation. An inspection or service is needed when the steering wheel is harder to turn or has too much free play, or if there are unusual sounds when turning or parking.

Brake Systems Operation Watch for the “BRAKE” light coming on. Other signs of possible brake trouble are such things as repeated pulling to one side when braking, unusual sounds when braking or between brake applications, or increased brake pedal

travel. If you note one of these conditions, repair the system at once. For convenience, the following should be done when wheels are removed for rotation: Inspect lines and hoses for proper hookup, bindings, leaks, crack, chafing etc. Inspect disc brake pads for wear and rotors for surface condition. Inspect other brake parts, including parking brake drums, linings etc., at the same time. Check parking brake adjustment. Inspect the brakes more often if habit or conditions result in frequent braking.

Parking Brake and Transmission Park Mechanism Operation Park on a fairly steep hill and hold the vehicle with the parking brake only. This checks holding ability. On automatic transmission vehicles, shifting from “P” position to the other positions cannot be made unless the brake pedal is depressed when the key switch is in the “ON” position or the engine is running. WARNING: BEFORE CHECKING THE STARTER SAFETY SWITCH OPERATION BELOW, BE SURE TO HAVE ENOUGH ROOM AROUND THE VEHICLE. THEN FIRMLY APPLY BOTH THE PARKING BRAKE AND THE REGULAR BRAKE. DO NOT USE THE ACCELERATOR PEDAL. IF THE ENGINE STARTS, BE READY TO TURN OFF THE KEY PROMPTLY. TAKE THESE PRECAUTIONS BECAUSE THE VEHICLE COULD MOVE WITHOUT WARNING AND POSSIBLY CAUSE PERSONAL INJURY OR PROPERTY DAMAGE.

Starter Safety Switch Operation Check by trying to start the engine in each gear while setting the parking brake and the foot brake. The starter should crank only in “P” (Park) or “N” (Neutral).

Accelerator Linkage Lubrication Lubricate the accelerator pedal fulcrum pin with chassis grease.

Steering and Suspension Inspection Inspect the front and rear suspension and steering system for damaged, loose or missing parts or signs of wear. Inspect power steering lines and hoses for proper hookup, binding, leaks, cracks, chafing, etc.

Body and Chassis Lubrication Lubricate the key lock cylinders, the hood latch, the hood and door hinges, the door check link, the parking cable guides, the underbody contact points, and the linkage.

Propeller Shaft Inspection and Lubrication Check the propeller shaft flange–to–pinion bolts for proper torque to 63 N•m (46 lb ft) for front and rear propeller shaft.

Automatic Transmission Fluid Replacement Under harsh operating conditions, such as constant driving in heavy city traffic during hot weather, or in hilly or mountainous terrain, change the transmission fluid and service the sump filter after every 20,000 miles (32,000 km) of operation. More over, the remaining life percentage of ATF can be estimated by using TECH–II as an auxiliary tool to judge the right time for ATF replacement. The remaining life percentage is calculated from ATF’S heat history. When it is close to 0%, ATF replacement is recommended.

Auto Cruise Control Inspection Check to see if the clearance between cruise link and accelerator link is normal. Also check that the connected properly.

Accelerator Linkage Inspection Inspect for interference, binding, and damaged or missing parts. Check accelerator pedal for smooth operation and even pedal effort. Replace parts as needed.

FLUID/LUBRICANT API SE, SF, SG, SH or ILSAC GF-1 Engine oil (See oil chart on the following page for proper viscosity)

Mixture of water and good quality ethylene glycol base type antifreeze.

DOT-3 hydraulic brake fluid.

DEXRON -III Automatic transmission fluid.

DEXRON -IIE or DEXRON -III Automatic transmission fluid.

GL-5 gear lubricant (Standard differential) GL-5 Limited slip differential gear lubricant together with limited slip differential lubricant additive (Part No. 8-01052-358-0) or equivalent (If equipped with optional limited slip differential) (See oil chart in this section for proper viscosity)

Hood latch assembly a. Pivots and spring anchor

b. Release pawl

Lubricant Viscosity Chart Lubricants should be carefully selected according to the lubrication chart. It is also important to select viscosity of lubricants according to the ambient temperature by referring to the following table.

Three Bond 1207B Three Bond 1207C Three Bond 1215 Three Bond 1280 Three Bond 1281

NOTE: 1. It is very important that the liquid gaskets listed above or their exact equivalent be used on the vehicle. 2. Be careful to use the specified amount of liquid gasket. Follow the manufacturer’s instructions at all times.

1. Completely remove all lubricant and moisture from the bolts and the female-threaded surfaces of the parts to be joined. The surfaces must be perfectly dry. 2. Apply LOCTITE to the bolts.

3. Be absolutely sure to remove all lubricants and moisture from the connecting surfaces before applying the liquid gasket. The connecting surfaces must be perfectly dry. 4. Do not apply LOCTITE 17430, LOCTITE 515 and LOCTITE 518 between two metal surfaces having a clearance of greater than 0.25 mm (0.01 in). Poor adhesion will result.

3. Tighten the bolts to the specified torque. After tightening, be sure to keep the bolts free from vibration and torque for at least an hour until LOCTITE hardens. NOTE: When the application procedures are specified in this manual, follow them.

* Unless otherwise specified on tire information label on the vehicle.

U.S. Measure

19.5 Gal.

*Crankcase capacities shown are approximate refill capacities. After refill, recheck oil level.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) HVAC SYSTEMS CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Heating and Ventilation System . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Unit and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Core and / or Mode Door . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Mode Control Link Unit . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Temperature Control Link Unit . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . Blower Assembly and Associated Parts . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Link Unit and / or Mode door . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower Motor and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Heater Duct, Defroster Nozzle and Ventilation Duct . . . . . . . . . . . . . . . . . . . . . . . . . Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning System . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning System . . . . . . . . . . . . . . . . . .

1A–3 1A–3 1A–3 1A–6 1A–6 1A–6 1A–6 1A–7 1A–7 1A–8 1A–8 1A–8 1A–9 1A–9 1A–9 1A–10 1A–11 1A–11 1A–11 1A–11 1A–12 1A–12 1A–12 1A–12 1A–13 1A–13 1A–13 1A–14 1A–15 1A–15 1A–15 1A–15 1A–16 1A–16 1A–16 1A–17 1A–18 1A–18 1A–24 1A–31

Individual Inspection . . . . . . . . . . . . . . . . . . . . . General Repair Procedure . . . . . . . . . . . . . . Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Assembly . . . . . . . . . . . . . . . . . . . Compressor Assembly and Associated Parts (6VE1) . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . New Compressor Installation . . . . . . . . . . . . Condenser Assembly . . . . . . . . . . . . . . . . . . . . Condenser Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condenser Fan Motor . . . . . . . . . . . . . . . . . . . . Condenser Fan Motor and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receiver / Drier . . . . . . . . . . . . . . . . . . . . . . . . . Receiver / Drier and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Switch and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evaporator Assembly . . . . . . . . . . . . . . . . . . . . Evaporator Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duct Sensor, Evaporator Core and/or Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Line . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Line and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data And Specifications . . . . . . . . . . . . .

1A–31 1A–31 1A–33 1A–38 1A–38 1A–38 1A–39 1A–39 1A–40 1A–40 1A–40 1A–41 1A–42 1A–42 1A–42 1A–42 1A–43 1A–43 1A–43 1A–43 1A–44 1A–44 1A–44 1A–44 1A–45 1A–45 1A–45 1A–46 1A–47 1A–47 1A–47 1A–48 1A–49 1A–49 1A–49 1A–50 1A–51

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Precaution . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Clutch Assembly (DKV-14G Type) Parts Location View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . Oil Specification . . . . . . . . . . . . . . . . . . . . . . . Handling of Oil . . . . . . . . . . . . . . . . . . . . . . . . Compressor Oil Check . . . . . . . . . . . . . . . . . Checking and Adjusting Oil Quantity for Used Compressor . . . . . . . . . . . . . . . . . . . . . Checking and Adjusting for Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . Contamination of Compressor Oil . . . . . . . . Oil Return Operation . . . . . . . . . . . . . . . . . . . Replacement of Component Parts . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Air Conditioning System . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . . Automatic Air Conditioner Parts Configuration . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . Functions and Features . . . . . . . . . . . . . . . . Automatic Air Conditioner Block Diagram . Control Panel Layout . . . . . . . . . . . . . . . . . . . Air Control Functions . . . . . . . . . . . . . . . . . . . Control Panel Switch Operation . . . . . . . . . Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System . . . . . . . . . . . . . . . . . . . Overview of Automatic Control of Automatic Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . Automatic Air Conditioning System . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting, Its Overview and Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Air Conditioner Control Unit Power Supply Diagnosis . . . . . . . . . . . . . . . . . . . . .

1A–53 1A–53 1A–53 1A–54 1A–55 1A–55 1A–55 1A–57 1A–57 1A–59 1A–59 1A–59 1A–59 1A–59 1A–60 1A–60 1A–60 1A–60 1A–61 1A–63 1A–64 1A–64 1A–64 1A–65 1A–70 1A–71 1A–72 1A–73 1A–74

Performance and Movement checklist for Automatic Air Conditioner Related Parts . Troubleshooting With Self-Diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection By Failed Location . . . . . . . . . . . . . Inspection of the Sensors . . . . . . . . . . . . . . . Inspection of the Intake Actuator System . Inspection of the Mix Actuator System . . . . Inspection of the Mode Actuator System . . Inspection of the Fan Motor System . . . . . . Inspection of the Magnetic Clutch System Individual Inspection . . . . . . . . . . . . . . . . . . . On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . Power Transistor . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Heater/Air Conditioner Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . In Car Sensor . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambient Sensor . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Duct Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode Actuator . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mix Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intake Actuator . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1A–89 1A–91 1A–97 1A–97 1A–101 1A–104 1A–107 1A–110 1A–115 1A–118 1A–121 1A–121 1A–121 1A–121 1A–121 1A–121 1A–121 1A–122 1A–122 1A–122 1A–122 1A–122 1A–122 1A–123 1A–123 1A–123 1A–123 1A–123 1A–123 1A–124 1A–124 1A–124 1A–124 1A–124 1A–124 1A–125 1A–125 1A–125

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

Heating and Ventilation System General Description Heater When the engine is warming up, the warmed engine coolant is sent into the heater core. The heater system supplies warm air into the passenger compartment to warm it up. Outside air is circulated through the heater core of the heater unit and then into the passenger compartment. By controlling the mixture of outside air and heater core air, the most comfortable passenger compartment temperature can be selected and maintained. The temperature of warm air sent to the passenger compartment is controlled by the temperature control knob. This knob acts to open and close the air mix door, thus controlling the amount of air passed through the heater core.

The air selector switch (Mode SW), with its different modes, also allows you to select and maintain the most comfortable passenger compartment temperature. The air source select switch is used to select either “FRESH” for the introduction of the outside air, or “CIRC” for the circulation of the inside air. When the switch is set to “FRESH”, the outside air is always taken into the passenger compartment. When setting the switch to “CIRC” position, the circulation of air is restricted only to the inside air with no introduction of the outside air and the air in the passenger compartment gets warm quickly. However, the switch is normally set to “FRESH” to prevent the windshield from clouding.

Press this button to select either Fresh Air Intake or CIRC (inside air circulation). There is an indicator light inside the button. This light indicates that the CIRC mode is “ON”. Fresh Air Intake is the default setting for both DEFROST and FOOT/DEFROST.

When the temperature control switch is in the “18°C (65°F)” position, the air mix door closes to block the air flow to the heater core. When the temperature control switch is in the “32°C (90°F)” position, the air mix door opens to allow air to pass through the heater core and heat the passenger compartment. Selecting the desired temperature will control the air flow through the heater core, allowing control of the cabin temperature.

Fan Control Switch This switch controls the blower motor speed to regulate the amount of air delivered to the defrost, foot, and ventilation ducts: 1. L0 2. M1 3. M2 4. M3 5. HI

Legend (1) Instrument Panel Assembly (2) Cross Beam Assembly (3) Instrument Panel Bracket W/Suspension Control Unit (4) Ventilation Lower Duct

Removal 1. Disconnect the battery ground cable. 2. Drain the engine coolant. 3. Discharge and recover refrigerant (with air conditioning). B Refer to Refrigerant Recovery in this section. 4. Remove the Instrument panel assembly. B Refer to Instrument Panel Assembly in Body and Accessories section. 5. Remove instrument panel bracket w/suspension control unit. B Refer to Cross Beam Assembly in Body and Accessories section. 6. Cross Beam Assembly. B Refer to Cross Beam Assembly in Body and Accessories section.

Rear Heater Duct Evaporator Assembly Heater Unit Assembly Heater Hose Power Transistor Connector

7. Disconnect power transistor connector. 8. Remove evaporator assembly. B Refer to Evaporator Assembly in this section. 9. Remove ventilation lower duct. 10. Remove rear heater duct. B Remove foot rest, carpet and 3 clips. 11. Disconnect mode/mix actuator connector. 12. Remove heater unit assembly. B Disconnect heater hoses at heater unit.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. When handling the PCM and the control unit, be careful not to make any improper connection of the connectors.

2. When installing the heater unit, defroster nozzle and center vent duct, be sure that the proper seal is made, without any gap between them.

Legend (1) Heater Core (2) Case (Temperature Control) (3) Heater Unit (4) Mix Actuator

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 11. Pull out the mode door while raising up the catch of the door lever.

Removal 1. Disconnect the battery ground cable. 2. Drain the engine coolant. 3. Discharge and recover refrigerant (with air conditioning). B Refer to Refrigerant Recovery in this section. 4. Remove heater unit. B Refer to Heater Unit in this section. 5. Remove duct. 6. Remove mix actuator. 7. Remove mode actuator. 8. Remove case (Mode control) and do not remove link unit at this step. 9. Remove case (Temperature control) separate two halves of core case.

Inspection Check for foreign matter in the heater core, stain or the core fin defacement.

Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Check that each mode door operates properly.

10. Remove heater core (1).

Removal 1. Disconnect the battery ground cable. 2. Drain engine coolant. 3. Discharge and recover refrigerant (with air conditioning) B Refer to Refrigerant Recovery in this section. 4. Remove heater unit. B Refer to Heater Unit in this section. 5. Remove mode actuator. 6. Remove the case (Mode control) from heater unit. 7. Remove washer and the mode main lever. 8. Remove rod. 9. Press the tab of the sub-lever inward, and take out the sub-lever.

1A–10 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 10. Pull out the door lever while raising up the catch of the door lever. 11. Remove clip.

Installation To install, follow the remove steps in the reverse order, noting the following points: 1. Apply grease to the mode sub-lever and to the abrasive surface of the heater unit. 2. After installing the link unit, check to see if the link unit operates correctly.

1. Disconnect the battery ground cable. 2. Drain engine coolant. 3. Discharge and recover refrigerant (with air conditioning). B Refer to Refrigerant Recovery in this section. 4. Remove heater unit. B Refer to Heater Unit in this section. 5. Remove mix actuator. 6. Remove the case (Temperature control) from the heater unit. 7. Remove rod. 8. Remove sub-lever. 9. Pull out the door lever while raising up the catch of the door lever. 10. Remove clip.

To install, follow the removal steps in the reverse order, noting the following points: 1. Apply grease to the sub-lever and to the abrasive surface of the heater unit. 2. After installing the link unit, check to see if the link unit operates correctly.

Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant (with air conditioning). B Refer to Refrigerant Recovery in this section. 3. Remove instrument panel assembly. B Refer to Instrument Panel Assembly in Body and Accessories section. 4. Disconnect power transistor connector. 5. Remove evaporator assembly. B Refer to Evaporator Assembly in this section.

Installation To install, follow the removal steps in the reverse order.

Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant (with air conditioning). B Refer to Refrigerant Recovery in this section. 3. Remove blower assembly. B Refer to Blower Assembly in this section. 4. Remove intake actuator. 5. Remove max high relay. 6. Remove lower case. 7. Separate the upper case and slit the lining parting face with a knife.

1A–14 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 8. Pull out the mode door while raising up the catch of door lever. 9. Remove sub-lever. 10. Remove door lever.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Apply grease to the door lever and to the abrasive surface of the upper case. 2. Apply an adhesive to the parting face of the lining when assembling the upper case.

Removal 1. Disconnect the battery ground cable. 2. Remove blower motor connector. 3. Remove attaching screw. 4. Remove blower motor assembly. 5. Remove clip. 6. Remove fan. 7. Remove blower motor.

Installation To install, follow the removal steps in the reverse order.

Rear Heater Duct, Defroster Nozzle and Ventilation Duct Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts

Legend (1) Defroster Nozzle (2) Cross Beam Assembly (3) Center Ventilation Duct and Side Defroster Duct

Removal 1. Disconnect the battery ground cable. 2. Remove instrument panel assembly. B Refer to Instrument Panel Assembly in Body and Accessories section. 3. Remove center ventilation duct and side defroster duct. B Remove 5 screws.

(4) Instrument Panel Bracket W/Suspension Control Unit (5) Instrument Panel Assembly (6) Rear Heater Duct (7) Ventilation Lower Duct

4. Remove instrument panel brackets w/suspension control unit. B Refer to Cross Beam Assembly in Body and Accessories section. 5. Remove cross beam assembly. B Refer to Cross Beam Assembly in Body and Accessories section. 6. Remove ventilation lower duct.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–17 7. Remove rear heater duct. B Remove foot rest carpet and 3 clips. 8. Remove defroster nozzle.

Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Connect each duct and nozzle securely leaving no clearance between them and making no improper matching.

Air Conditioning System General Description Air Conditioning Refrigerant Cycle Construction

Legend (1) Duct Sensor (2) Evaporator Core (3) Evaporator Assembly (4) Temperature Sensor (5) Blower Motor (6) Expansion Valve (7) Pressure Switch (8) Receiver/Drier

The refrigeration cycle includes the following four processes as the refrigerant changes repeatedly from liquid to gas and back to liquid while circulating.

Condenser Compressor Magnetic Clutch Mode (HEAT) Control Door Temp. Control Door (Air Mix Door) Heater Core Mode (VENT) Control Door Heater Unit Mode (DEF) Control Door

Evaporation The refrigerant is changed from a liquid to a gas inside the evaporator. The refrigerant mist that enters the evaporator vaporizes readily. The liquid refrigerant removes the required quantity of heat (latent heat of vaporization) from the air around the evaporator core cooling fins and rapidly vaporizes. Removing the heat cools the air, which is then radiated from the fins and lowers the temperature of the air inside the vehicle. The refrigerant liquid sent from the expansion valve and the vaporized refrigerant gas are both present inside the evaporator as the liquid is converted to gas. With this change from liquid to gas, the pressure inside the evaporator must be kept low enough for vaporization to occur at a lower temperature. Because of that, the vaporized refrigerant is sucked into the compressor.

Compression The refrigerant is compressed by the compressor until it is easily liquefied at normal temperature. The vaporized refrigerant in the evaporator is sucked into the compressor. This action maintains the refrigerant inside the evaporator at a low pressure so that it can easily vaporize, even at low temperatures close to 0°C (32°F). Also, the refrigerant sucked into the compressor is compressed inside the cylinder to increase the pressure and temperature to values such that the refrigerant can easily liquefy at normal ambient temperatures.

It compresses low-pressure and low-temperature refrigerant vapor from the evaporator into high-pressure and high-temperature refrigerant vapor to the condenser. It pumps refrigerant and refrigerant oil through the air conditioning system. This vehicle is equipped with a five-vane rotary compressor. The specified amount of the compressor oil is 150cc (5.0 fl. oz.). The oil used in the HFC-134a system compressor differs from that used in R-12 systems. Also, compressor oil to be used varies according to the compressor model. Be sure to avoid mixing two or more different types of oil. If the wrong oil is used, lubrication will be poor and the compressor will seize or malfunction. The magnetic clutch connector is a waterproof type.

Magnetic Clutch The compressor is driven by the drive belt from the crank pulley of the engine. If the compressor is activated each time the engine is started, this causes too much load to the engine. The magnetic clutch transmits the power from the engine to the compressor and activates it when the air conditioning is ON. Also, it cuts off the power from the engine to the compressor when the air conditioning is OFF. Refer to Compressor in this section for magnetic clutch repair procedure.

Condensation The refrigerant inside the condenser is cooled by the outside air and changes from gas to liquid. The high temperature, high pressure gas coming from the compressor is cooled and liquefied by the condenser with outside air and accumulated in the receiver/drier. The heat radiated to the outside air by the high temperature, high pressure gas in the compressor is called heat of condensation. This is the total quantity of heat (heat of vaporization) the refrigerant removes from the vehicle interior via the evaporator and the work (calculated as the quantity of heat) performed for compression.

Expansion The expansion valve lowers the pressure of the refrigerant liquid so that it can easily vaporize. The process of lowering the pressure to encourage vaporization before the liquefied refrigerant is sent to the evaporator is called expansion. In addition, the expansion valve controls the flow rate of the refrigerant liquid while decreasing the pressure. That is, the quantity of refrigerant liquid vaporized inside the evaporator is determined by the quantity of heat which must be removed at a prescribed vaporization temperature. It is important that the quantity of refrigerant be controlled to exactly the right value.

Condenser The condenser assembly is located in front of the radiator. It provides rapid heat transfer from the refrigerant to the cooling fins. Also, it functions to cool and liquefy the high-pressure and high-temperature vapor sent from the compressor by the radiator fan or outside air.

1A–20 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) A condenser may malfunction in two ways: it may leak, or it may be restricted. A condenser restriction will result in excessive compressor discharge pressure. If a partial restriction is present, the refrigerant expands after passing through the restriction. Thus, ice or frost may form immediately after the restriction. If air flow through the condenser or radiator is blocked, high discharge pressures will result. During normal condenser operation, the refrigerant outlet line will be slightly cooler than the inlet line. The vehicle is equipped with the parallel flow type condenser. A larger thermal transmission area on the inner surface of the tube allows the radiant heat to increase and the ventilation resistance to decrease. The refrigerant line connection has a bolt at the block joint, for easy servicing.

A receiver/drier may fail due to a restriction inside the body of the unit. A restriction at the inlet to the receiver/drier will cause high pressure. Outlet restrictions will be indicated by low pressure and little or no cooling. An excessively cold receiver/drier outlet may indicate a restriction. The receiver/drier of this vehicle is made of aluminum with a smaller tank. It has a 300cc refrigerant capacity. The refrigerant line connection has a bolt at the block joint, for easy servicing.

Triple Pressure Switch (V6, A/T) Triple pressure switch is installed on the upper part of the receiver/drier. This switch is constructed with a unitized type of two switches. One of them is a low and high pressure switch (Dual pressure switch) to switch “ON” or “OFF” the magnetic clutch as a result of irregularly high–pressure or low pressure of the refrigerant. The other one is a medium pressure switch (Cycling switch) to switch “ON” or “OFF” the condenser fan sensing the condenser high side pressure. Compressor

Legend (1) Pressure Switch (2) Receiver Drier (3) Condenser & Receiver Tank Assembly (4) Condenser Fan

Receiver / Drier The receiver/drier performs four functions: B As the quantity of refrigerant circulated varies depending on the refrigeration cycle conditions, sufficient refrigerant is stored for the refrigeration cycle to operate smoothly in accordance with fluctuations in the quantity circulated. B The liquefied refrigerant from the condenser is mixed with refrigerant gas containing air bubbles. If refrigerant containing air bubbles. If refrigerant containing air bubbles is sent to the expansion valve, the cooling capacity will decrease considerably. Therefore, the liquid and air bubbles are separated and only the liquid is sent to the expansion valve. B The receiver/drier utilizes a filter and drier to remove the dirt and water mixed in the cycling refrigerant.

Expansion Valve This expansion valve is an external pressure type and it is installed at the evaporator intake port. The expansion valve converts the high pressure liquid refrigerant sent from the receiver/drier to a low pressure liquid refrigerant by forcing it through a tiny port before sending it to the evaporator. This type of expansion valve consists of a temperature sensor, diaphragm, ball valve, ball seat, spring adjustment screw, etc. The temperature sensor contacts the evaporator outlet pipe, and converts changes in temperature to pressure. It then transmits these to the top chamber of the diaphragm. The refrigerant pressure is transmitted to the diaphragm’s bottom chamber through the external equalizing pressure tube. The ball valve is connected to the diaphragm. The opening angle of the expansion valve is determined by the force acting on the diaphragm and the spring pressure.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–21 The expansion valve regulates the flow rate of the refrigerant. Accordingly, when a malfunction occurs to this expansion valve, both discharge and suction pressure decreases, resulting in insufficient cooling capacity of the evaporator. The calibration has been changed to match the characteristics of HFC-134a.

The evaporator core with a laminate louver fin is a single-sided tank type where only one tank is provided under the core.

Evaporator The evaporator cools and dehumidifies the air before the air enters the passenger compartment. High-pressure liquid refrigerant flows through the expansion valve into the low-pressure area of the evaporator. The heat in the air passing through the evaporator core is lost to the cooler surface of the core, thereby cooling the air. As heat is lost between the air and the evaporator core surface, moisture in the vehicle condenses on the outside surface of the evaporator core and is drained off as water. When the evaporator malfunctions, the trouble will show up as an inadequate supply of cool air. The cause is typically a partially plugged core due to dirt, or a malfunctioning blower motor.

The duct sensor is the sensor to detect temperature change of the side of evaporator blower coming by fresh recirculation of intake door or “on” “off” of compressor. The temperature is converted to resistant rate. And it works as thermostat to control to prevent freezing of evaporator. This sensor is installed in the upper case of evaporator.

Restriction in the refrigerant line will be indicated by: 1. Suction line — A restricted suction line will cause low suction pressure at the compressor, low discharge pressure and little or no cooling. 2. Discharge line — A restriction in the discharge line generally will cause the discharge line to leak. 3. Liquid line — A liquid line restriction will be evidenced by low discharge and suction pressure and insufficient cooling. Refrigerant flexible hoses that have a low permeability to refrigerant and moisture are used. These low permeability hoses have a special nylon layer on the inside.

Legend (1) Sensor Part (2) Evaporator Core (3) Duct Sensor Assembly (4) Evaporator Assembly

Legend (1) Reinforcement Layer (Polyester) (2) External Rubber Layer (3) Internal Rubber Layer (4) Resin Layer (Nylon)

Legend (1) Liquid Line (High-Pressure Pipe) (2) Clip (3) Discharge Line (High-Pressure Hose) (4) Pressure Switch (5) Receiver/Drier

Condenser Air Guide Condenser & Receiver Tank Assembly Condenser Fan Compressor Suction Line (Low-Pressure Hose) Evaporator Assembly

Diagnosis Air Conditioning Cycle Diagnosis Condition No cooling or insufficient cooling.

Insufficient velocity of cooling air.

Magnetic clutch does not run.

Refer to “Magnetic Clutch Diagnosis” in this section.

Compressor is not rotating properly. Drive belt is loose or broken.

Adjust the drive belt to the specified tension or replace the drive belt.

Compressor is not rotating properly. Magnetic clutch face is not clean and slips.

Clean the magnetic clutch face or replace.

Compressor is not rotating properly. Incorrect clearance between magnetic drive plate and pulley.

Adjust the clearance. Refer to Compressor in this section.

Compressor is not rotating properly. Compressor oil leaks from the shaft seal or shell.

Compressor is not rotating properly. Compressor is seized.

Insufficient or excessive charge of refrigerant.

Discharge and recover the refrigerant. Recharge to the specified amount.

Leaks in the refrigerant system.

Check the refrigerant system for leaks and repair as necessary. Discharge and recover the refrigerant. Recharge to the specified amount.

Condenser is clogged or insufficient radiation.

Clean the condenser or replace as necessary.

Temperature control link unit of the heat unit is defective.

Repair the link unit.

Unsteady operation due to a foreign substance in the expansion valve.

Replace the expansion valve.

Poor operation of the electronic thermostat.

Check the electronic thermostat and replace as necessary.

Evaporator clogged or frosted.

Check the evaporator core and replace or clean the core.

Air leaking from the cooling unit or air duct.

Check the evaporator and duct connection, then repair as necessary.

Blower motor properly.

Refer to Fan Control Lever (Fan Switch) Diagnosis in this section.

*For the execution of the charging and discharging operation in the table above, refer to Recovery, Recycling, Evacuating and Charging in this section.

Checking The Refrigerant System With Manifold Gauge Since Refrigerant-134a (HFC-134a) is used in the air conditioning system in this vehicle, be sure to use manifold gauges, charging hoses and other air conditioning service tools for HFC-134a when checking the refrigerant system. Conditions: B B B B B B B

Run the engine at idle Air conditioning switch is “ON” Run the blower motor at “HIGH” position (5 positions) Temperature control set to “MAX COLD” (65°F) Air source selector at “CIRC” Open the engine hood Close all the doors

Normal Pressure: B At ambient temperature: approx. 25–30°C (77–86°F). B At low-pressure side: approx. 147.1–294.2 kPa (21.3–42.7 psi). B At high-pressure side: approx. 1372.9–1863.3 kPa (199.1–270.2 psi). Refer to the table on the refrigerant pressure-temperature relationship. HFC-134a Pressure-Temperature Relationship Pressure

1A–26 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Connect The Manifold Gauge Low-pressure hose (LOW) — Suction side High pressure hose (HI) — Discharge side

Condenser clogged or dirty.

Discharge (High Gauge) Pressure Abnormally High. Insufficient cooling.

Excessive refrigerant in system.

Discharge and recover refrigerant. Recharge to specified amount.

Discharge (High Gauge) Pressure Abnormally High. High pressure gauge drop. (After stopping A/C, the pressure drops approx. 196 kPa (28 psi) quickly)

Air in system.

Evacuate and charge refrigerant system.

Discharge (High Gauge) Pressure Abnormally Low. Insufficient cooling

Insufficient refrigerant in system.

Check for leaks. Discharge and recover the refrigerant. Recharge to the specified amount.

Discharge (High Gauge) Pressure Abnormally Low. Low pressure gauge indicates vacuum.

Clogged or defective expansion valve.

Replace the expansion valve.

Discharge (High Gauge) Pressure Abnormally Low. Frost or dew on refrigerant line before and after the receiver/drier or expansion valve, and low pressure gauge indicates vacuum.

Restriction caused by debris or moisture in the receiver/drier.

Check system for restriction and replace the receiver/drier.

Discharge (High Gauge) Pressure Abnormally Low. High and low pressure gauge balanced quickly. (After turned off A/C)

Repair or replace the compressor.

Poor compression due to a defective compressor gasket.

Repair or replace the compressor.

Suction (Low Gauge) Pressure Abnormally High. Low pressure gauge (Low pressure gauge is lowered after condenser is cooled by water.)

Excessive refrigerant in system.

Discharge and recover refrigerant Recharge to specified amount.

Suction (Low Gauge) Pressure Abnormally High. Low pressure hose temperature. (Low pressure hose temperature compressor around the com ressor refrigerant line connector is lower than around evaporator.)

Unsatisfactory valve operation due to defective temperature sensor of expansion valve.

Replace the expansion valve.

Expansion valve opens too long.

Replace the expansion valve.

Suction (Low Gauge) Pressure Abnormally High. High and low pressure gauge balanced quickly. (After turned off A/C)

Compressor gasket is defective.

Repair or replace the compressor.

Suction (Low Gauge) Abnormally Low. Insufficient cooling.

Insufficient refrigerant in system.

Check for leaks. Discharge and recover the refrigerant. Recharge to specified amount.

Expansion valve clogged.

Replace the expansion valve.

Suction (Low Gauge) Pressure Abnormally Low. Frost on the expansion valve inlet line

Cooling fan properly.

Check the cooling fan operation.

Suction (Low Gauge) Pressure Abnormally Low Receiver/drier inlet and outlet refrigerant line temperature. (A distinct difference in temperature develops.)

Receiver/Drier clogged.

Replace the receiver/drier.

Suction (Low Gauge) Pressure Abnormally Low. Expansion valve outlet refrigerant line. (Not cold and low pressure gauge indicates vacuum.)

Expansion valve temperature sensor is defective.

Replace the expansion valve.

Suction (Low Gauge) Pressure Abnormally Low. When the refrigerant line is clogged or blocked, the low pressure gauge reading will decrease, or a vacuum reading may be shown.

Clogged or blocked refrigerant line.

Replace refrigerant line.

Suction (Low Gauge) Pressure Abnormally Low. Evaporator core is frozen.

Thermo switch defective.

Replace thermo switch.

Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally High. Insufficient cooling.

Excessive refrigerant in system.

Discharge and recover the refrigerant, the Recharge to the specified amount.

Condenser clogged or dirty.

Clean the condenser fin.

Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally High. Suction (Low) pressure hose (Not cold).

Air in system.

Evacuate and charge refrigerant.

Suction (Low Gauge) and Discharge (High Gauge) Pressure Abnormally Low. Insufficient cooling

Insufficient refrigerant in system.

Check for leaks. Discharge and recover refrigerant. Recharge to specified amount.

Condenser Fan Diagnosis While the air conditioning is ON, the cycling switch in the triple pressure switch senses the refrigerant pressure, and activates the condenser fan to improve the cooling capacity of the condenser when the refrigerant pressure exceeds a set pressure value. The condenser fan stops when the air conditioning is turned “OFF” or when the pressure goes down below the set pressure value.

Condition Condenser fan does not run.

Refer to “Chart A”.

Refer to “Chart B”.

Switch defective or insufficient refrigerant.

Repair open circuit between Condenser Fan fuse (30A) and No.X16-5.

Repair open circuit between fuse (10A) and C21-3.

Repair open circuit.

Poor ground or open circuit between chassis side connector terminal No.X16-4 (or No.C16-2) and body ground (No.C10).

Repair open circuit.

Replace the triple pressure switch.

Replace the condenser fan relay.

1. Disconnect condenser fan relay (X-16). 2. Check to see if battery voltage is present at the chassis side relay terminal NO. X16-5. Is there a battery voltage?

1. Reconnect condenser fan relay (X-16). 2. Check to see if battery voltage is present at chassis side connector terminal No.C21-3. Is there a battery voltage?

Check to see if continuity between chassis side relay terminal No.X16-2 and the chassis side connector terminal No.C21-4. Is there a continuity?

Check to see if continuity between chassis side connector terminal No. C16-1 and chassis side relay terminal No.X16-1. Is there a continuity?

Action 1. Disconnect the triple pressure connector. Does condenser fan stop?

1. Disconnect the connector and check for continuity between pressure switch side connector terminals (1) and (2). 2. Reconnect the connector to activate the A/C switch, and check to see if there is continuity between the chassis side connector terminals (3) and (4) and the fan operates.

Condenser Fan 1. Disconnect the condenser fan connector. 2. Connect the battery positive terminal to the condenser fan side connector terminal No.C-16-1 and negative to the No.C-16-2. 3. Check that condenser fan is rotating correctly.

There are certain procedures, practices and precautions that should be followed when servicing air conditioning systems: B Keep your work area clean. B Always wear safety goggles and protective gloves when working on refrigerant systems. B Beware of the danger of carbon monoxide fumes caused by running the engine. B Beware of discharged refrigerant in enclosed or improperly ventilated garages. B Always disconnect the negative battery cable and discharge and recover the refrigerant whenever repairing the air conditioning system. B When discharging and recovering the refrigerant, do not allow refrigerant to discharge too fast; it will draw compressor oil out of the system. B Keep moisture and contaminants out of the system. When disconnecting or removing any lines or parts, use plugs or caps to close the fittings immediately. Never remove the caps or plugs until the lines or parts are reconnected or installed. B When disconnecting or reconnecting the lines, use two wrenches to support the line fitting, to prevent from twisting or other damage. B Always install new O-rings whenever a connection is disassembled. B Before connecting any hoses or lines, apply new specified compressor oil to the O-rings. B When removing and replacing any parts which require discharging the refrigerant circuit, the operations described in this section must be performed in the following sequence: 1. Use the J-39500 (ACR4: HFC-134a Refrigerant Recovery / Recycling / Recharging / System) or equivalent to thoroughly discharge and recover the refrigerant. 2. Remove and replace the defective part. 3. After evacuation, charge the air conditioning system and check for leaks.

Repair Of Refrigerant Leaks Refrigerant Line Connections Install new O-rings, if required. When disconnecting or connecting lines, use two wrenches to prevent the connecting portion from twisting or becoming damaged.

O-rings (2) must be fitted in the groove (1) of refrigerant line.

Insert the nut into the union. First, tighten the nut by hand as much as possible, then tighten the nut to the specified torque. 852R200001

When connecting the refrigerant line at a block joint, securely insert the projecting portion of the joint portion into the connecting hole on the unit side and secure with a bolt. Apply the specified compressor oil to the O-rings prior to connecting. CAUTION: Compressor (PAG) oil to be used varies according to the compressor model. Be sure to apply oil specified for the model of compressor.

Leak Check Inspection of refrigerant leak Refrigerant leak may cause an adverse effect not only on the performance and durability of each component of the air–conditioner, but also on the global atmosphere. Therefore, it is most important to repair refrigerant leak when there is any leak found.

Action 1. Evacuate the refrigerant system. 2. Charge the refrigerant. Is there any refrigerant leak?

1. Operate the compressor for more than 5 minutes to raise the pressure on the high pressure side. Is there any refrigerant leak at high pressure components?

Inspection Steps Check the components of air–conditioner to see if there occurs any refrigerant leak along the flow of refrigerant. NOTE: B To avoid refrigerant leak detection error, avoid refrigerant vapor and cigarette smoke presence when performing the inspection. Also, select a location that is not susceptible to wind, in case refrigerant vapor is found it will not be blown off. B Inspection should be conducted chiefly on the pipe connections and sections where a marked oil contamination is found. When refrigerant is leaking, oil inside is also leaking at the same time. B It is possible to visually check the leak from inside the cooling unit. Follow the method below when performing the inspection. Remove the drain hose or resistor of the cooling unit, and insert a leak detector to see if there are signs of leakage. High Pressure Side 1. Discharger section of compressor. 2. Inlet/outlet section of condenser. 3. Inlet/outlet section of receiver driver. 4. Inlet section of cooling unit. Low Pressure Side 1. Outlet section of cooling unit. 2. Intake section of compressor.

Major Checking Points of Refrigerant Leak Compressor B Pipe connection B Sealing section of shaft B Mating section or cylinder Condenser B Pipe connection B Welds of condenser body

Repair refrigerant system.

Compressor operation to be confirmed.

Receiver driver B Pipe connection B Attaching section of pressure switch B Section around the sight glass Evaporator unit (cooling unit) B Pipe connections B Connections of expansion valve B Brazed sections of evaporator NOTE: B The evaporator and expansion valve are contained in the case. Remove the drain hose or the resistor of the cooling unit and insert a leak detector when checking for any leak. Flexible hose B Pipe connection B Caulking section of the hose B Hose (cracks, pinholes, flaws) Pipe B Pipe connection B Pipe (cracks, flaws) Charge valve NOTE: B The charge valve, which is used to connect the gauge manifold, is normally provided with a resin cap. When the valve inside gets deteriorated, refrigerant will leak out.

Leak at Refrigerant Line Connections 1. Check the torque on the refrigerant line fitting and, if too loose, tighten to the specified torque. B Use two wrenches to prevent twisting and damage to the line. B Do not over tighten. 2. Perform a leak test on the refrigerant line fitting.

1A–34 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 3. If the leak is still present, discharge and recover the refrigerant from the system. 4. Replace the O-rings. B O-rings cannot be reused. Always replace with new ones. B Be sure to apply the specified compressor oil to the new O-rings. 5. Retighten the refrigerant line fitting to the specified torque. B Use two wrenches to prevent twisting and damage to the line. 6. Evacuate, charge and retest the system.

WARNING: B SHOULD HFC-134A CONTACT YOUR EYE(S), CONSULT A DOCTOR IMMEDIATELY. B DO NOT RUB THE AFFECTED EYE(S). INSTEAD, SPLASH QUANTITIES OF FRESH COLD WATER OVER THE AFFECTED AREA TO GRADUALLY RAISE THE TEMPERATURE OF THE REFRIGERANT ABOVE THE FREEZING POINT. B OBTAIN PROPER MEDICAL TREATMENT AS SOON AS POSSIBLE. SHOULD THE HFC-134A TOUCH THE SKIN, THE INJURY MUST BE TREATED THE SAME AS SKIN WHICH HAS BEEN FROSTBITTEN OR FROZEN.

If the compressor inlet or outlet hose is leaking, the entire hose must be replaced. The refrigerant hose must not be cut or spliced for repair. 1. Locate the leak. 2. Discharge and recover the refrigerant. 3. Remove the hose assembly. B Cap the open connections at once. 4. Connect the new hose assembly. B Use two wrenches to prevent twisting or damage to the hose fitting.

The refrigerant must be discharged and recovered by using the J-39500 (ACR4:HFC-134a Refrigerant Recovery/Recycling/Recharging/System) or equivalent before removing or mounting air conditioning parts. 1. Connect the high and low charging hoses of the ACR4(or equivalent) as shown below.

B Tighten the hose fitting to the specified torque. 5. Evacuate, charge and test the system.

Compressor Leaks If leaks are located around the compressor shaft seal or shell, replace or repair the compressor.

Recovery, Recycling, Evacuation and Charging of HFC-134a Air conditioning systems contain HFC-134a. This is a chemical mixture which requires special handling procedures to avoid personal injury. B Always wear safety goggles and protective gloves. B Always work in a well-ventilated area. Do not weld or steam clean on or near any vehicle-installed air conditioning lines or components. B If HFC-134a should come in contact with any part of the body, flush the exposed area with cold water and immediately seek medical help. B If it is necessary to transport or carry any container of HFC-134a in a vehicle, do not carry it in the passenger compartment. B If it is necessary to fill a small HFC-134a container from a large one, never fill the container completely. Space should always be allowed above the liquid for expansion. B HFC-134a and R-12 should never be mixed as their compositions are not the same. B HFC-134a PAG oil tends to absorb moisture more quickly than R-12 mineral oil and, therefore, should be handled more carefully. B Keep HFC-134a containers stored below 40°C (104°F).

Legend (1) Low Side (2) High Side 2. Recover the refrigerant by following the Manufacturer’s Instructions. 3. When a part is removed, put a cap or a plug on the connecting portion so that dust, dirt or moisture cannot get into it.

Refrigerant Recycling Recycle the refrigerant recovered by J-39500 (ACR4:HFC-134a Refrigerant Recovery / Recycling / Recharging / System) or equivalent. For the details of the actual operation, follow the steps in the ACR4(or equivalent) Manufacturer’s Instructions.

8. If no leaks are found, again operate the vacuum pump for 20 minutes or more. After confirming that the gauge manifold pressure is at 750 mmHg (30 inHg), close both hand valves. 9. Close positive shutoff valve. Stop the vacuum pump and disconnect the center hose from the vacuum pump.

Charging The Refrigerant System There are various methods of charging refrigerant into the air conditioning system. These include using J-39500 (ACR4:HFC-134a Refrigerant Recovery/Recycling/Recharging/System) or equivalent and direct charging with a weight scale charging station. Charging Procedure B ACR4(or equivalent) Method For the charging of refrigerant recovered by ACR4(or equivalent), follow the manufacturer’s instruction.

Legend (1) Low Side (2) High Side NOTE: Explained below is a method using a vacuum pump. Refer to the ACR4(or equivalent) manufacturer’s instructions when evacuating the system with a ACR4(or equivalent). Air and moisture in the refrigerant will cause problems in the air conditioning system. Therefore, before charging the refrigerant, be sure to evacuate air and moisture thoroughly from the system. 1. Connect the gauge manifold. B High-pressure valve (HI) — Discharge-side. B Low-pressure valve (LOW) — Suction-side. 2. Discharge and recover the refrigerant. 3. Connect the center hose of the gauge manifold set to the vacuum pump inlet. 4. Operate the vacuum pump, open shutoff valve and then open both hand valves. 5. When the low-pressure gauge indicates approximately 750 mmHg (30 inHg), continue the evacuation for 5 minutes or more. 6. Close both hand valves and stop the vacuum pump. 7. Check to ensure that the pressure does not change after 10 minutes or more. B If the pressure changes, check the system for leaks. B If leaks occur, retighten the refrigerant line connections and repeat the evacuation steps.

Legend (1) Low Side (2) High Side B Direct charging with a weight scale charging station method 1. Make sure the evacuation process is correctly completed. 2. Connect the center hose of the manifold gauge to the weight scale.

1A–36 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 3. Connect the low pressure charging hose of the manifold gauge to the low pressure side service valve of the vehicle. 4. Connect the high pressure charging hose of the manifold gauge to the high pressure side service valve of the vehicle.

6. Perform a system leak test: B Charge the system with approximately 200 g (0.44 lbs) of HFC-134a. B Make sure the high pressure valve of the manifold gauge is closed. B Check to ensure that the degree of pressure does not change. B Check for refrigerant leaks by using a HFC-134a leak detector. B If a leak occurs, recover the refrigerant. Repair the leak and start all over again from the first step of evacuation.

Legend (1) Low Side (2) High Side (3) Refrigerant Container (4) Weight Scale 5. Place the refrigerant container(3) up right on a weight scale(4). Note the total weight before charging the refrigerant. a. Open the refrigerant container valve. b. Open the low side vale on the manifold gauge set. Refer to the manufacturer’s instructions for a weight scale charging station.

7. If no leaks are found, continue charging refrigerant to the air conditioning system. B Charge the refrigerant until the scale reading decreases by the amount of the charge specified. Specified amount: 700 g (1.54 lbs) B If charging the system becomes difficult: 1. Run the engine at idle and close all the vehicle doors. 2. Turn A/C switch “ON”. 3. Set the fan switch to its highest position. 4. Set the air source selector lever to “CIRC”. 5. Slowly open the low side valve on the manifold gauge set. WARNING: BE ABSOLUTELY SURE NOT TO OPEN THE HIGH PRESSURE VALVE OF THE MANIFOLD GAUGE. SHOULD THE HIGH PRESSURE VALVE BE OPENED, THE HIGH PRESSURE REFRIGERANT WOULD FLOW BACKWARD, AND THIS MAY CAUSE THE REFRIGERANT CONTAINER TO BURST.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–37 8. When finished with the refrigerant charging, close the low pressure valve of the manifold gauge and container valve. 9. Check for refrigerant leaks.

Checking The A/C System 1. Run the engine and close all the vehicle doors. 2. Turn A/C switch “ON”, set the fan switch to its highest position. 3. Set the air source switch to “CIRC”, set the temperature switch to the full cool position. 4. Check the high and low pressure of the manifold gauge. B Immediately after charging refrigerant, both high and low pressures might be slightly high, but they settle down to the pressure guidelines shown below: B The ambient temperature should be between 25–30°C (77–86°F). B The pressure guideline for the high-pressure side is approximately 1372.9–1863.3 kPa (199.1–270.2 psi). B The pressure guideline for the low-pressure side is approximately 147.1–294.2 kPa (21.3–42.7 psi). B If an abnormal pressure is found, refer to Checking The Refrigerant System With Manifold Gauge in this section. 5. Put your hand in front of the air outlet and move the temperature switch of the control panel to different positions. Check if the outlet temperature changes as selected by the control switch.

Legend (1) Compressor Bracket (2) Magnetic Clutch Harness Connector (3) Compressor (4) O-ring

Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant B Refer to Refrigerant Recovery in this section. 3. Disconnect magnetic clutch harness connector.

To Evaporator Suction Line (Low-Pressure Hose) Discharge Line (High-Pressure Hose) To Condenser Serpentine Belt

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–39 4. Remove serpentine belt. B Move serpentine belt tensioner to loose side using wrench then remove serpentine belt.

4. Connect magnetic clutch harness connector.

New Compressor Installation The new compressor is filled with 150cc (5.0fl.oz.)of compressor oil and nitrogen gas. When mounting the compressor on the vehicle, perform the following steps; 1. Gently release nitrogen gas from the new compressor. B Take care not to let the compressor oil flow out. B Inspect O-rings and replace if necessary.

Legend (1) Auto Tensioner (2) Idle Pulley (3) Cooling Fan Pulley (4) Serpentine Belt (5) Power Steering Oil Pump (6) Air Conditioner Compressor (7) Crankshaft Pulley (8) Generator 5. Disconnect refrigerant line connector. B When removing the line connector, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 6. Remove compressor.

2. Turn the compressor several times by hand and release the compressor oil in the rotor. 3. When installing on a new system, the compressor should installed as it is. When installing on a used system, the compressor should be installed after adjusting the amount of compressor oil. (Refer to Compressor in this section)

Installation 1. Install compressor. B Tighten the compressor fixing bolts to the specified torque. Torque: 19 N•m (14 lb•ft) 2. Connect refrigerant line connector. B Tighten the refrigerant line connector fixing bolts to the specified torque. Torque: 15 N•m (11 lb•ft) B O-rings cannot be reused. Always replace with new ones. B Be sure to apply new compressor oil to the O-rings when connecting refrigerant lines. 3. Install serpentine belt. B Move serpentine belt tensioner to loose side using wrench, then install serpentine belt to normal position.

Legend (1) Refrigerant Line (2) Pressure Switch Connector (3) Condenser & Receiver Tank Assembly (4) Condenser Air Guide (5) Front Bumper Assembly

(6) Engine Hood Front End W/Engine Hood Lock & Bumper Stay (7) Front Center Bumper Retainer (8) Front Side Bumper Retainer (RH) (9) Head Light (R/LH) (10) Front Side Turn Signal Light (R/LH) (11) Horn (R/LH)

4. Remove front center bumper retainer. 5. Remove front side bumper retainer (RH). 6. Remove condenser air guide. 7. Remove engine hood front end with engine hood lock & bumper stay. B Apply setting mark to the engine hood lock fixing position before removing it.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–41 8. Remove horn (R/LH). 9. Remove front side turn signal light (R/LH). 10. Remove head light (R/LH). 11. Disconnect pressure switch, ambient sensor and condenser fan connector. 12. Disconnect refrigerant line. B When removing the line connector, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 13. Remove condenser & receiver tank assembly. B Handle with care to prevent damaging the condenser or radiator fin.

Installation 1. Install condenser & reciver tank assembly. B If installing a new condenser, be sure to add 30cc (1.0 fl. oz.) of new compressor oil to a new one. B Tighten the condenser fixing bolts to the specified torque. Torque: 6 N•m (52 lb in) 2. Connect refrigerant line. B Tighten the inlet line connector fixing bolt to the specified torque. Torque: 15 N•m (11 lb ft) B Tighten the outlet line connector fixing bolt to the specified torque. Torque: 6 N•m (52 lb in) B O-rings cannot be reused. Always replace with new ones. B Be sure to apply new compressor oil to the O-rings when connecting the refrigerant line. 3. Connect pressure switch, ambient sensor and condenser fan connector. 4. Install head light (R/LH). 5. Install front side turn signal light (R/LH). 6. Install horn (R/LH). 7. Install engine hood front end with engine hood lock & bumper stay. B Align the setting mark when installing. 8. Install condenser air guide. 9. Install front side bumper retainer (RH). 10. Install front center bumper retainer. 11. Install front bumper assembly.

Legend (1) Condenser Fan Assembly (2) Condenser Air Guide (3) Front Bumper Assembly

Removal 1. Disconnect the battery ground cable. 2. Remove the front bumper assembly. B Refer to the Front Bumper in Body Structure section. 3. Remove the condenser air guide. 4. Remove the horn (RH). 5. Remove the condenser fan assembly. B Disconnect the fan motor connector and remove the 3 fixing bolts. 6. Remove the shroud. B Remove the 3 fixing nuts. B Loosen the condenser fixing nut and disconnect the fan motor connector from bracket. 7. Remove the fan. B Remove the fan fixing C-ring and plate. 8. Remove the condenser fan motor.

Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Route the fan motor harness in its previous position, and fix it securely with clip and bracket.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. If installing a new receiver/drier, be sure to add 30cc (1.0 fl. oz.) of new compressor oil to a new one. 2. Put the receiver/drier in the bracket and connect with the refrigerant line. Check that no excessive force is imposed on the line. Fasten the bracket bolt to the receiver/drier. 3. Tighten the refrigerant line to the specified torque. Torque: 6 N•m (52 lb in) 4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-rings when connecting the refrigerant line.

Legend (1) Front Side Turn Signal Light (LH) (2) Refrigerant Line (3) Head Light (LH) (4) Front Bumper Assembly (5) Receiver / Drier (6) Pressure Switch Connector

Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. B Refer to Refrigerant Recovery in this section. 3. Remove front bumper assembly. B Refer to the Front Bumper in Body Structure section. 4. Remove front side turn signal light (LH). 5. Remove head light (LH). 6. Disconnect pressure switch connector. 7. Disconnect refrigerant line. B When removing the line connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 8. Remove receiver/drier. B Loosen the bolt, then, using care not to touch or bend the refrigerant line, carefully pull out the receiver/drier.

Installation To install, follow the removal steps in the reverse order, noting the following point: 1. O-ring cannot be reused. Always replace with a new one. 2. Be sure to apply new compressor oil to the O-ring when connecting pressure switch. 3. Tighten the pressure switch to the specified torque. Torque: 13 N•m (113 lb in)

Legend (1) Pressure Switch Connector (2) Front Side Turn Signal Light (LH) (3) Head Light (LH) (4) Front Bumper Assembly (5) Pressure Switch

Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. B Refer to “Refrigerant Recovery in this section. 3. Remove the front bumper assembly. B Refer to the Front Bumper in Body Structure section. 4. Remove the front side turn signal light (LH). 5. Remove the head light (LH). 6. Disconnect pressure switch connector. 7. Disconnect pressure switch. B When removing the switch connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

Legend (1) Refrigerant Line (2) Drain Hose (3) Dash Side Trim Panel (4) Power Transistor and Duct Sensor Connector

Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. B Refer to Refrigerant Recovery in this section. 3. Remove glove box. 4. Disconnect power transistor (2) and duct sensor connector (1). 5. Remove sill plate. 6. Remove dash side trim panel. 7. Remove passenger lower bracket. 8. Disconnect drain hose.

1A–46 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 9. Disconnect drain hose. 10. Disconnect refrigerant line. B Use a back-up wrench when disconnecting and reconnecting the refrigerant lines. B When removing the refrigerant line connected part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line. 11. Remove evaporator assembly.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. To install a new evaporator assembly, add 50cc (1.7 fl. oz.) of new compressor oil to the new core. 2. Tighten the refrigerant outlet line to the specified torque. Torque: 25 N•m (18 lb ft) 3. Tighten the refrigerant inlet line to the specified torque. Torque: 15 N•m (11 lb ft) 4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-rings when connecting lines.

Legend (1) Lining (2) Expansion Valve (3) O-ring (4) Evaporator Assembly (5) Lower Case

Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. B Refer to Refrigerant Recovery in this section. 3. Remove evaporator assembly. B Refer to Evaporator Assembly in this section. 4. Remove the duct sensor fixing clip. Pull the sensor from the evaporator assembly. 5. Remove clip. 6. Remove attaching screw. 7. Remove upper case. 8. Remove lower case. B Slit the case parting face with a knife since the lining is separated when removing the evaporator.

1A–48 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) B Lift to remove the upper case.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. The sensor is installed on the core with the clip. 2. The sensor must not interfere with the evaporator core. 3. When installing the new evaporator core, install the duct sensor (2) to the evaporator core (1) specified position with the clip in the illustration.

9. Remove evaporator core.

10. Remove expansion valve. B Tear off the insulator carefully. B Remove the sensor fixing clip. B Use a back-up wrench when disconnecting all refrigerant pipes.

4. O-rings cannot be reused. Always replace with new ones. 5. Be sure to apply new compressor oil to the O-rings when connecting lines. 6. Be sure to install the sensor and the insulator on the place where they were before. 7. To install a new evaporator core, add 50cc (1.7 fl. oz.) of new compressor oil to the new core. 8. Tighten the refrigerant lines to the specified torque. Refer to Main Data and Specifications for Torque Specifications in this section. 9. Apply an adhesive to the parting face of the lining when assembling the evaporator assembly.

Legend (1) Clip and Clamp (2) Liquid Line (High-Pressure Pipe) (3) Discharge Line (High-Pressure Hose) (4) Condenser Air Guide

Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. B Refer to Refrigerant Recovery in this section. 3. Remove the front bumper assembly. B Refer to the Front Bumper in Body Structure section. 4. Remove the condenser air guide.

Front Bumper Assembly Front Side Turn Signal Light (LH) Head Light (LH) Suction Line (Low-Pressure Pipe)

5. Remove the front side turn signal light (LH). 6. Remove the head light (LH). 7. Remove clip and clamp. 8. Disconnect liquid line (High-pressure pipe). 9. Disconnect suction line (Low-pressure pipe) using a back-up wrench. 10. Disconnect suction line (Low-pressure hose) using a back-up wrench.

1A–50 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 11. Disconnect discharge line (High-pressure hose) using a back-up wrench. B Use a backup wrench when disconnecting and reconnecting the refrigerant lines. B When removing the refrigerant line connecting part, the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line.

Installation To install, follow the removal steps in the reverse order, noting the following point: 1. O-rings cannot be reused. Always replace with new ones. 2. Be sure to apply new compressor oil to the O-rings when connecting lines. 3. Tighten the refrigerant line to the specified torque. Refer to Main Data and Specifications for Torque Specifications in this section.

Main Data And Specifications General Specifications Heater Unit Temperature control

Approx. 2.4 m@

Triple pressure switch Low pressure control ON: 206.0±30.0 kPa (29.8±4.3 psi) OFF: 176.5±19.6 kPa (25.6±2.8 psi) Medium pressure control ON: 1471.0±98.1 kPa (213.3±14.2 psi) OFF: 1078.7±117.7 kPa (156.4±17.7 psi) High pressure control ON: 2353.6±196.1 kPa (341.3±28.4 psi) OFF: 2942.0±196.1 kPa (426.6±28.4 psi)

Compressor Service Precaution WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS ON-VEHICLE SERVICE INFORMATION. FAILURE TO FOLLOW CAUTIONS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

General Description When servicing the compressor, keep dirt or foreign material from getting on or into the compressor parts and system. Clean tools and a clean work area are important for proper service. The compressor connections and the outside of the compressor should be cleaned before any ”On–Vehicle” repair, or before removal of the compressor. The parts must be kept clean at all times and any parts to be reassembled should be cleaned with Trichloroethane, naphtha, kerosene, or equivalent solvent, and dried with dry air. Use only lint free cloths to wipe parts. The operations described below are based on bench overhaul with compressor removed from the vehicle, except as noted. They have been prepared in order of accessibility of the components. When the compressor is removed from the vehicle for servicing, the oil remaining in the compressor should be discarded and new compressor oil added to the compressor. Compressor malfunction will appear in one of four ways: noise, seizure, leakage or low discharge pressure. Resonant compressor noises are not cause for alarm; however, irregular noise or rattles may indicate broken parts or excessive clearances due to wear. To check seizure, de–energize the magnetic clutch and check to

see if the drive plate can be rotated. If rotation is impossible, the compressor is seized. Low discharge pressure may be due to a faulty internal seal of the compressor, or a restriction in the compressor. Low discharge pressure may also be due to an insufficient refrigerant charge or a restriction elsewhere in the system. These possibilities should be checked prior to servicing the compressor. If the compressor is inoperative, but is not seized, check to see if current is being supplied to the magnetic clutch coil terminals. The compressor oil used in the HFC–134a system compressor differs from that used in R–12 systems. Also, compressor oil to be used varies according to the compressor model. Be sure to avoid mixing two or more different types of oil. If the wrong oil is used, lubrication will be poor and the compressor will seize or malfunction.

DKV-14G Type Compressor DKV–14G is equipped with five–vane rotary compressor. These vanes are built into a rotor which is mounted on a shaft. When the shaft rotates, the vanes built into the cylinder block assembly are operated by centrifugal force. This changes the volume of the spare formed by the rotor and cylinder, resulting in the intake and compression of the refrigerant gas. The discharge valve and the valve stopper, which protects the discharge valve, are built into the cylinder block assembly. There is no suction valve but a shaft seal is installed between the shaft and head; a trigger valve, which applies back pressure to the vanes, is installed in the cylinder block and a refrigerant gas temperature sensor is installed in the front head. The specified quantity of compressor oil is contained in the compressor to lubricate the various parts using the refrigerant gas discharge pressure.

2. Remove drive plate by using drive plate puller J-33944-A (2) and forcing screw J-33944-4 (1).

Removal 1. Using drive plate holder J-33939 (1) to prevent the drive plate from rotating, then remove the drive plate bolt.

3. Remove shim (s). 871RX029

1A–56 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 4. Remove snap ring (1) by using snap ring pliers.

6. Loosen screw and disconnect the field coil wire connector.

5. Remove pulley assembly by using pulley puller pilot J-38424 (2), pulley puller J-8433 (1) and pulley puller leg J-24092-2 (3).

7. Loosen three screws and remove the field coil.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–57 3. Install pulley assembly by using pulley installer J-33940-A (2) and drive handle J-8092 (1).

Inspection and Repair Drive Plate If the frictional surface shows signs of damage due to excessive heat, the drive plate and pulley should be replaced.

Pulley Assembly Check the appearance of the pulley assembly. If the frictional surface of the pulley shows signs of excessive grooving due to slippage, both the pulley and drive plate should be replaced. The frictional surfaces of the pulley assembly should be cleaned with a suitable solvent before reinstallation.

Coil Check coil for loose connector or cracked insulation.

Installation 1. Install field coil. B Align the located portion (1) of the field coil and compressor.

4. Install snap ring. 5. Install shim (s). 6. Install the drive plate to the compressor drive shaft together with the original shim(s)(1). Press the drive plate by hand.

B Tighten the mounting screw to the specified torque. Torque: 5N·m (44 lb in) 2. Connect the lead wire connector with the rubber hold and tighten the screw.

1A–58 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 7. Install drive plate bolt by using drive plate holder J-33939 (1) to prevent the drive plate from rotating.

B Check to be sure that the clutch clearance is between 0.3-0.6 mm (0.01-0.02 in.)

B Tighten the drive plate bolt to the specified torque. Torque: 13 N·m (113 lb in) B After tightening the drive plate bolt, check to be sure the pulley rotates smoothly.

Legend (1) Dial Gauge (2) Pulley Assembly (3) Field Coil Wire Connector B If necessary, install adjusting shim(s). B Adjusting shims are available in the following thickness. Thickness B 0.1 mm (0.0039 in.) B 0.3 mm (0.0118 in.) B 0.5 mm (0.0197 in.)

Compressor Oil Oil Specification B The HFC-134a system requires a synthetic (PAG) compressor oil whereas the R-12 system requires a mineral compressor oil. The two oils must never be mixed. B Compressor (PAG) oil varies according to compressor model. Be sure to use oil specified for the model of compressor. B Always use HFC-134a Vane Rotary Type Compressor Oil (AIPDN Part No.2-90188-301-0)

Handling of Oil B The oil should be free from moisture, dust, metal powder, etc. B Do not mix with other oil. B The water content in the oil increases when exposed to the air. After use, seal oil from air immediately. (HFC-134a Vane Rotary Compressor Oil absorbs moisture very easily.) B The compressor oil must be stored in steel containers, not in plastic containers.

Compressor Oil Check The oil used to lubricate the compressor is circulating with the refrigerant. Whenever replacing any component of the system or a large amount of gas leakage occurs, add oil to maintain the original amount of oil. Oil Capacity Capacity total in system: 150cc (5.0 fl.oz) Compressor (Service parts) charging amount: 150 cc (5.0 fl.oz)

Checking and Adjusting Oil Quantity for Used Compressor 1. Perform oil return operation. Refer to Oil Return Operation in this section. 2. Discharge and recover refrigerant and remove the compressor. 3. Drain the compressor oil and measure the extracted oil with a measuring cylinder. 4. If the amount of oil drained is much less than 90 cc (3.0 fl. oz.), some refrigerant may have leaked out. Conduct a leak tests on the connections of each system, and if necessary, repair or replace faulty parts. 5. Check the compressor oil contamination. (Refer to Contamination of Compressor Oil in this section.) 6. Adjust the oil level following the next procedure below.

7. Install the compressor, then evacuate, charge and perform the oil return operation. 8. Check system operation. When it is impossible to preform oil return operation, the compressor oil should be checked in the following order: 1. Discharge and recover refrigerant and remove the compressor. 2. Drain the compressor oil and measure the extracted oil with a measuring cylinder. 3. Check the oil for contamination. 4. If more than 90 cc (3.0 fl. oz.) of oil is extracted from the compressor, supply the same amount of oil to the compressor to be installed. 5. If the amount of oil extracted is less than 90 cc (3.0 fl. oz.), recheck the compressor oil in the following order. 6. Supply 90 cc (3.0 fl. oz.) of oil to the compressor and install it onto the vehicle. 7. Evacuate and recharge with the proper amount of refrigerant. 8. Perform the oil return operation. 9. Remove the compressor and recheck the amount of oil. 10. Adjust the compressor oil, if necessary. (Collected Amount)

Checking and Adjusting for Compressor Replacement 150 cc (5.0 fl.oz.) of oil is charged in compressor (service parts). So it is necessary to drain the proper amount of oil from the new compressor. 1. Perform oil return operation. 2. Discharge and recover the refrigerant and remove the compressor. 3. Drain the compressor oil and measure the extracted oil. 4. Check the compressor oil for contamination. 5. Adjust the oil level as required. (Amount of oil drained from used compressor)

6. Evacuate, charge and perform the oil return operation. 7. Check the system operation.

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

Oil Return Operation There is close affinity between the oil and the refrigerant. During normal operation, part of the oil recirculates with the refrigerant in the system. When checking the amount of oil in the system, or replacing any component of the system, the compressor must be run in advance for oil return operation. The procedure is as follows: 1. Open all the doors and the engine hood. 2. Start the engine and air conditioning switch to “ON” and set the fan control knob at its highest position. 3. Run the compressor for more than 20 minutes between 800 and 1,000 rpm in order to operate the system. 4. Stop the engine.

Replacement of Component Parts When replacing the system component parts, supply the following amount of oil to the component parts to be installed. (Component parts to be installed)

50 cc (1.7 fl. oz.)

30 cc (1.0 fl. oz.)

10 cc (0.3 fl. oz.)

R-134a Vane Rotary Type Compressor Oil (AIPDN Part No.2-90188-301-0) 150 cc (5.0 fl.oz.)

MAGNETIC CLUTCH Type Rated voltage Current consumption Starting torque Direction of rotation Weight

Electromagnetic single-plate dry clutch 12 Volts D.C. 3.7 A 49 N·m (36 lb·ft) Clockwise (Front-side view) 3.0 kg (6.6 lbs.)

TOOL NO. TOOL NAME

Automatic Air Conditioning System General Description Using a variety of sensors, this automatic air conditioner accurately senses outside air temperature, solar radiation quantity, evaporator’s blowing temperature, and interior temperature, then enters these data to the automatic air conditioner control unit (equipped with the built-in micro-computer). The data provided to the control unit enables to automatically control blow temperature

and blow air quantity, turn on or off the compressor and switch the blow port as well as switching between the fresh air intake and interior air circulation. Resetting the automatic function allows you to switch to the manual control mode. The self-diagnoisis function of the automatic air conditioner control unit (with the built-in micro-computer) allows the unit to access and diagnose a failed part easier and quicker.

Legend (1) In Car Sensor (2) Sun Sensor (3) Ambient Sensor (4) Intake Actuator (5) Blower Unit (6) Max – High Relay (7) Display

Audio & Switch Assembly Evaporator Assembly Duct Sensor Mix Actuator Heater Unit Automatic Air Conditioner Control Unit Mode Actuator

Functions and Features Automatic air conditioning control unit The control unit features a prominent control and display panel that clearly shows air conditioner operational settings (delivered air volume, air outlet location, inside/outside air circulation, and set temperature). Desired temperature can be set in –17°C (1°F) increments. The current setting appears on the digital display. Automatic temperature control Vehicle interior temperature is maintained at the set level. It is unaffected by changes in vehicle speed, outside air temperature, and number of passengers. Maximum cooling and heating Moving the switch to the 18°C (65°F) position provides maximum cooling. Moving the switch to the 32°C (90°F) position provides maximum heating. Automatic air flow control Air flow is automatically and precisely regulated in response to set temperature change and/or changes in heater unit mixing door aperture. Automatic air outlet selection Appropriate air outlets (VENT, BE-LEVEL, FOOT, or DEF) are selected in response to changes in outlet temperatures. The mode switch permits manual selection of the desired air outlet. Air source (Fresh air intake from outside the vehicle or recirculation of the air inside the vehicle) selection Automatic switching between outside air (FRESH), recirculated inside air (RECIRC), or a combination of the two (MIX) occurs in response to changes in outlet temperatures.The intake switch permits manual selection of the air source (FRESH or RECIRC). Mixing of the two sources is not possible during manual operation. When the defrost mode switch (DEF) is pressed, the system automatically switches to outside air intake. Cooler start-up control When the vehicle is parked in a hot area for an extended period of time, the evaporator becomes hot. When the cooler is turned on, hot air is blown into the vehicle until the evaporator cools down. The cooler start-up control prevents blower operation until the evaporator is able to provide cool air. Heater start-up control When the vehicle is parked in a cold area for an extended period of time, the heater core becomes cold. When the heater is turned on, cold air is blown into the vehicle until the heater core heats up. The heater start-up control prevents blower operation to the air outlets until the heater core is able to provide warm air. Air is delivered through the defrost outlets. Solar radiation offset The sun sensor uses a photodiode to precisely determine the amount of solar radiation affecting the vehicle. The cooler operates in response to this radiation to quickly correct the vehicle interior temperature.

Switch position memory Current switch positions are stored in memory when the ignition switch is turned off. When the ignition switch is turned on again, the switches automatically return to the position they were in when the ignition switch was turned off. This simplifies the restarting procedure. Self-diagnosis function The self-diagnosis switches on the control panel permit easy system troubleshooting. Refer to “Self-Diagnosis” later in this Section.

Legend (1) Temperature Control Switch (2) Auto Switch (3) DEF Mode Switch (4) Rr DEF Mode Switch

Legend (1) DEF Door (2) Air Mix Door (3) Evaporator Core (4) Fresh Air Intake (5) Interior Air Intake (6) Blower Unit

Switch Operation During manual outside air intake (FRESH), pressing the AUTO switch cancels manual outside air intake. The display panel shows the current set temperature, the current air outlet(s), and the blower speed. The intake switch LED shows the current air source. The A/C switch LED is on. Air volume, air outlet operation, and air source are controlled automatically. The compressor is on. During manual inside air recirculation (REC), pressing the AUTO switch does not cancel inside air recirculation. The intake switch LED is on. When the OFF switch is pressed, the display panel clears except for the air outlet indication. Blower and compressor operation stop. The air source switches from automatic to outside air. During manual inside air recirculation (REC), pressing the OFF switch does not cancel inside air recirculation. The intake switch LED is on.

When the fan switch is pressed, air outlet volume (fan speed) can be manually controlled. Other control switches are unaffected. The display panel clears AUTO indication. 1. FAN switch is pressed during automatic fan control (AUTO) Fan control (AUTO)→Press Y fan switch→Fan speed increases from automatic set speed to HI Fan control (AUTO)→Press B fan switch→Fan speed decreases from automatic set speed to LO 2. Fan switch is pressed when the fan is off. Fan (OFF)→Press Y fan switch→The fan operates at LO speed Fan (OFF)→Press B fan switch→The fan operates at LO speed 3. Fan switch is pressed when the fan is in manual operation. Manual (LO)→Press Y fan switch→Manual operation (LO)→ (M1)→(M2)→(M3)→(HI) Manual (HI)→Press B fan switch→Manual operation (HI)→(M3)→(M2)→(M1)→(LO) Press the mode switch to manually select the air outlet(s). Each time the switch is pressed, the air outlets change in the progression shown below. Mode switch (Automatic control of air outlets)→VENT→BI-LEVEL→FOOT→DEF/FOOT

When the A/C switch is pressed, the LED light goes out and the compressor turns off. If the switch is pressed again, the LED light turns on and the compressor begins to operate. The air conditioner will not operate if the fan switch is off. During manual DEF or D/F operation, the A/C LED will turn on or off in response to switch operation. However, the compressor remains on regardless of switch position.

When the defrost switch (DEF) is pressed, air flows from the defroster outlets. The compressor is on and blower speed is automatically controlled. Air intake is from outside the vehicle (FRESH). The defroster symbol appears on the display. When the defrost switch (DEF) is pressed again, the unit returns to the settings in use before the defroster was turned on.

1A–76 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Pressing the intake switch permits manual control of air intake and/ or recirculation. I n t a k e S w i t c h If the intake switch is pressed during manual DEF or D/F, the intake switch LED briefly turns on. However, outside air intake (FRESH) continues. T e m p e r a t u r e C o n t r o l S w i t c h

The display panel temperature setting can be set from 18°C (65°F) to 32°C (90°F). Pressing and immediately releasing the Y switch increases the temperature setting in -17°C (1°F) increments. If the switch is pressed and held, the temperature setting increases rapidly. Pressing and immediately releasing the B switch decreases the temperature setting in -17°C (1°F) decrements. If the switch is pressed and held, the temperature setting decreases rapidly. When the temperature setting is at 32°C (90°F), the unit is set to maximum heat mode. When the temperature setting is at 18°C (65°F), the unit is set to maximum cooling mode.

Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System Automatic Air Conditioner Control Unit Equipped with the built-in micro-computer, this control unit operates on signals from sensors and input signals from switches to offer total control of the blower fan, and actuators used for the mode door, intake door and air mix door. Its self-diagnosis function enables quicker access to a failed part and its more accurate troubleshooting.

In Car Sensor It is a sensor used for detecting room temperature of a vehicle. This sensor converts a given room temperature into a resistance value before entering the data to the automatic air conditioner control unit. This in car sensor unites the power driven aspirator and the motor fan so that a small amount of room air may be constantly fed to the sensor. This sensor is provided on the right side of meter cluster.

Duct Sensor The duct sensor is the sensor to detect temperature change of the side of evaporator blower coming by fresh recirculation of intake door or “on” “off” of compressor. The temperature is converted to resistant rate. And it works as thermostat to control to prevent freezing of evaporator. This sensor is installed in the upper case of evaporator.

Ambient Sensor This sensor is used for detecting temperature outside the vehicle. It converts a given outside air temperature into a resistance value before entering the data to the automatic air conditioner control unit. Thermal effects from the condenser and radiator during idling after a run can be measured and offset the automatic amplifier. This sensor is provided on the side plate situated at upper right side of the condenser.

It is a photodiode used for detecting quantity of solar radiation. This sensor converts the offset signal generated by changes in the interior temperature (which results from fluctuations in solar radiation) into photoelectric current to enter into the automatic air conditioner control unit. This sensor is provided at top of the center cluster upper.

Receiving base current from the automatic air conditioner control unit, the power transistor implements stage-less speed change of the blower fan motor. This transistor is provided on the evaporator.

Max Hi Relay This relay turned on or off by the signal from the automatic air conditioner control unit. As the Max Hi relay is turned on, supply voltage is directly fed to the blower fan motor to select the Max Hi mode.

Actuator The actuators are power driven type containing a small motor. Receiving output current from the automatic air conditioner control unit, actuators drive the heater and blower unit mode doors. Actuators consist of the mode actuator used for switching the mode (blow port selection), the mix actuator used for changing aperture of the air mix door, the intake actuator used for switching the intake mode(fresh air/interior air) actuator.

Legend (1) Mix Actuator (2) Intake Actuator (3) Blower Unit (4) Mode Actuator (5) Heater Unit

The mode and mix actuators are common actuators with the built-in potentiometer. For the intake actuator, the contact switch type is selected. The potentiometer is a register assembled to the printed circuit board of the mix and mode actuators. It detects the air mix door position specified by rotation of the output axis as a ratio of the variable terminal (VM) voltage against the reference voltage (VDD: 5V), then signals the value to the automatic air conditioner control unit.

The actuator changes the motor speed using the gear and drives each door rotating the output axis united with the sliding contact.

Position of the air mix door is determined by the controller on the automatic air conditioner control unit. As the heat or cool side of the controller is grounded, the transistor on the driver is activated and, thus, the motor rotation is turned on. The sliding contact connected to the motor sends the position detection signal from the potentiometer to the automatic air conditioner control unit. As the set temperature and interior temperature are balanced, the controller returns to the neutral and the motor rotation is stopped.

As target position of the mode door is decided on the controller of the control unit, the control unit reads the position detection signal from the actuator to select the clockwise or counter clockwise motor rotation direction. Grounding the controller VENT or DEF side after the direction selection activates the transistor on the driver, thus turning on the motor rotation. Accompanying the motor rotation, the sliding contact rotates, too. When the target position is reached, the controller on the control unit returns to the neutral and the motor stops.

Movement of Intake Actuator The controller on the automatic heater/air conditioner control unit selects an intake mode to be used. As the Terminal No.5 C-33 is grounded via the sliding contact on the terminal plate, the transistor on the driver is activated, thus turning on the motor rotation. Then, accompanying move of the motor, the sliding contact rotates until grounding of the Terminal No.5 C-33 is removed, thus stopping the motor. Grounding terminal

Overview of Automatic Control of Automatic Air Conditioner The automatic air conditioner on this vehicle has the following features: Interior temperature control. Air flow control. Mode (blow port) control. Intake (switching between fresh air and interior air) control. Heater start timing control. Cooler start timing control. Evaporator anti-freeze control.

Automatic Air Conditioning System System Overview (Chart) Conditions both inside and outside the vehicle are detected by sensors (in-car temperature sensor, ambient temperature sensor, duct sensor, sun sensor, speed sensor, and water temperature sensor). These sensors send signals to the control unit. Potentiometer position sensors send data to the control unit. Signals related to control panel settings are also sent to the control unit.

In response to the signals received, the control unit automatically adjusts air-mix door aperture (outlet air temperature), fan speed (forced air volume), and air intake (outside air, recirculated inside air, or a mixture of the two).

When the temperature control switch is set to a specific temperature, a signal is sent to the A/C control unit. Other signals are sent to the control unit from the various sensors. This data is analyzed by the control unit which creates a composite data signal that is compared with the signal received from the potentiometer. The result determines the direction of mix actuator rotation. The mix actuator reacts to the composite air mix door opening angle signal. Opening angle is increased or decreased to maintain the temperature at the selected level. When the compressor is off, the air mix door moves toward the COOL side. When the compressor turns on, the temperature of the air being discharged from the outlet vents is regulated. When the temperature control is set to 18°C (65°F), the air mix door moves to the FULL COOL position. When the control is set to 32°C (90°F), the door moves to the FULL HOT position. In the VENT position, the air mix door moves from FULL COOL to a 60% aperture. This prevents hot air from being discharged into the vehicle.

In the Auto Mode Automatic operation When the AUTO switch or the DEF switch is pressed, a signal indicating the forced air volume is sent to the A/C auto-control unit. Other signals are sent to the control unit from the various sensors. This data is analyzed by the control unit which creates a composite data signal. Based on this signal, the base voltage of the power transistor is varied to change the blower voltage. This results in a non-stepped change in blower motor speed. When the temperature control switch is set to either 18°C (65°F) or 32°C (90°F), blower motor speed is in the MAX-HI mode. In the Manual Mode Manual operation When the fan switch is manually set to a specified air volume, a signal is sent to the A/C auto-control-unit. In response to this signal, the auto-control unit controls the blower voltage. When the fan switch is set to HI, the max-hi relay operates to increase blower motor speed to the MAX-HI mode.

Mode (Blow Port) Control The A/C control unit receives temperature setting data as well as temperature and solar radiation level data from the various sensors. Based on this data, the control unit compiles a composite TMO signal. The TMO signal allows the outlet positions to be changed in a set pattern (VENT→BI-LEVEL→FOOT→DEFROST/FOOT). The mode actuator acts in response to mode position. It compares data signals received from the target mode, the door position, and mode door position to determine the direction of rotation. If the temperature is set to 18°C (65°F), cool air is discharged from the head outlets. If t he temperature is set to 32°C (90°F), warm air is discharged from the foot outlets. In manual mode, existing air outlet settings remain unchanged when the temperature is set to 18°C (65°F) or 32°C (90°F). <Mode switch operation> Press the mode switch to change to the outlet mode. Blower operation (outlet mode position) can now be switched between the VENT, BI-LEVEL, FOOT, and DEF positions.

The DEF position can be selected from the outlet mode.

Intake (Fresh air/interior air switching) Control During automatic operation, the A/C control unit responds to the temperature setting signal together with signals from the various sensors to generate a general signal that controls operation in a prescribed pattern. If either or both the fan and the cooler are off, air intake is from outside the vehicle. If the temperature control switch is set to either 18°C (65°F) or 32°C (90°F), the air inside the vehicle is recirculated. 1. Manual switch operation Press the intake switch to change between outside air intake and recirculated inside air. 2. Defrost switch operation Air intake is from outside the vehicle. 3. Mode switch operation During automatic operation, outside air intake or recirculated inside air is selected as appropriate. During manual operation or when the DEF mode is selected, air intake is from outside the vehicle.

C01R200004

C01R200003

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–85

Compressor Control

Cooler Start-up Control

In the automatic control mode, the automatic air conditioner control unit turns on or off the compressor with the evaporator anti-freeze mechanism using the evaporation sensor. And, when outside air is detected to be low through the outside air temperature sensor signal, the control unit turns off the compressor using the compressor control function. Manual Control

When cooler operation is started with the air discharge mode is in the VENT or B/L position and the in-car temperature higher than 26°C (78°F) (detected by the in-car sensor), cooler start-up control occurs. For the first 7 seconds of cooler operation, the fan remains OFF. It then switches to AUTO LO. Air discharge volume then increases in linear increments to the pre-set level. Cooler start-up control occurs the first time the engine is started or the cooler switch is moved from OFF to AUTO. It will not occur during subsequent switch movements.

In the automatic control mode, pressing the A/C (air conditioning) switch turns off the compressor. Pressing the DEF mode switch automatically turns on the compressor.

C06R200001

C01R200002

Heater Start-up Control Heater start-up control occurs when the air discharge mode is in the BI=LEVEL, FOOT, or DEF/FOOT position and the heater core temperature is less than 14°C (58°F). Air discharge volume remains in the AUTO LO mode until the engine coolant temperature rises above 14°C (58°F). The volume then increases in linear increments to the pre-set level.

840R200010

1A–86 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Troubleshooting Troubleshooting, Its Overview and Procedures The automatic air conditioner equips with the “Self-Diagnosis Function” to check its major components. This function makes access to the sensors, actuators and blower fan motor system easier when checking them up and, when a failed part is located, this function restores its original performance.

When implementing the troubleshooting, this self-diagnosis function narrows the range to be searched at the first step, then check relevant parts one by one according to the “Checking Procedures by Failed Location”. As for a location this function is unappreciable, the system accurately determines characteristics of a given trouble and checks relevant parts according to the “Checking Procedures by Failed Location”. The following illustrates basic troubleshooting flow.

Basic Troubleshooting Flow

F01RX009

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–87

Auto Air Conditioner Control Unit Power Supply Diagnosis This check is required because a trouble on the auto amplifier (control unit) power supply circuit or grounding circuit prevents accurate troubleshooting.

D08R200034

Condition Power source does not supply to auto air conditioner control unit.

Possible cause —

Correction Refer to Chart A

1A–88 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart “A”: Check of Auto Amplifier Power Supply System Step

1 2 3

Action

5 6

Go to Step 2

Replace the fuse

—

Go to Step 3

Replace the fuse

Approx. 12V

Go to Step 5

Go to Step 4

Is the action complete?

—

Go to Step 4

—

Is there continuity between the harness side connector terminal No.I19–16 and the ground?

—

Go to Step 7

Go to Step 6

—

Go to Step 5

—

Approx. 12V

Go to Step 9

Go to Step 8

—

Go to Step 7

—

Approx. 12V

—

Go to Step 10

—

Verify repair

—

Is the fuse F–7 normal? Disconnect the auto A/C control unit connector I–19.

Repair an open circuit between the fuse C–5 and terminal No.I19–8.

Repair an open circuit between terminal No.I19–16 and the ground No.B–9. Turn the lighting switch on. Is the battery voltage applied between the harness side connector terminal No.I19–12 and the ground?

Repair an open circuit between the lighting switch and terminal No.I19–12. Is the action complete?

Turn the starter switch on. Is the battery voltage applied between the harness side connector terminal No.I19–7 and the ground?

—

Is the action complete? 7

Yes

Is the fuse C–5 normal?

Is the battery voltage applied between the harness side connector terminal No.I32–8 and the ground? 4

Value(s)

Repair an open circuit between the fuse F–7 and terminal No.I19–7. Is the action complete?

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–89

Performance and Movement checklist for Automatic Air Conditioner Related Parts Start the engine, and when the engine coolant reached 50°C (122°F) check performance and movement of the related parts according the following checklist.

Performance Check Using the Manual Switch No No.

Item

Procedure Condition

Air discharge temperature (Ai (Air–mix i door d operation)

Auto–switch ON

Air discharge volume (Fan operation)

Fan switch ON

Criteria

Set temperature to 18°C (65°F).

Cold air discharge.

Set temperature to 32°C (90°F).

Hot air discharge.

1. Set temperature to 25°C (77°F). 2. Press the OFF switch.

Fan does not operate. There is no air discharge.

1. Set temperature to 25°C (77°F). 2. Press the fan Y switch.

Fan operates. Fan speed increases each time the switch is pressed (LO to HI in 5 increments).

Air discharge temperature (Mode door operation)

Fan in manual 5–speed operation

1. Set temperature to 25°C (77°F). 2. Press the mode switch. 3. Move through the 5 modes (VENT→BI–LEVEL →FOOT→DEF/FO OT→DEF).

B Panel display lights for each mode. B Air discharge outlet position changes for each mode.

Inside/outside air mode (Intake door operation)

Auto–switch ON

1. Set temperature to 25°C (77°F). 2. Press the intake switch. 3. Press the fan Y switch. 4. Set the fan to the highest speed. 5. Press the intake switch.

B Intake switch LED turns from on to off. B Air discharge sound changes.

Compressor

Outside air temperature above 0°C (32°F) and vehicle interior at normal temperature

1. Set temperature to 25°C (77°F). 2. Press the OFF switch. 3. Press the auto–switch. 4. Press the air conditioner switch.

B When the auto–switch is pressed, the LED in the air conditioner switch turns on and the compressor begins operation. B When the air conditioner switch is pressed, the LED in the air conditioner switch turns off and the compressor stops operation.

Operation

1A–90 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Check of Auto Function No No.

Item

Procedure Condition

Criteria

Operation

AUTO display highlighted on display panel. Cold air discharge. Set temperature to 18°C 18 C (65 (65°F) F).

Automatic operation

Auto-switch ON

Gradually increase the temperature setting from 18°C (65°F) to 31.5°C (89°F).

VENT mode. Intake switch LED on. Fan speed bar graph display at MAX6dash;HI A/C switch LED on. Temperature of air discharge increases with increase in setting temperature. Air discharge volume changes. Panel display shows VENT, BI–LEVEL, FOOT, or DEF/FOOT.

Hot air discharge. A/C bar graph display disappears. Set temperature to 32°C (90°F). (90°F)

Foot mode. Intake LED switch off. Fan speed bar graph display at MAX-HI A/C switch LED on.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–91

Troubleshooting With Self-Diagnosis Function Overview of Self-Diagnosis Function Sensors (input) and actuators (output) are used to check circuit function and provide essential data on these circuits. For more detailed information, refer to the [Inspection and Repair] Sections for the applicable system or component. The Table below shows how to turn the self-diagnosis function on and off.

Self-Diagnosis Operation Procedure

865R200033

1A–92 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Step

Action

Value(s)

Yes

1. Allow the engine to idle until it completely warms up. 2. Turn the starter switch to the OFF position. 3. Place a 60–watt lamp approximately 15 cm from the sun sensor. NOTE: This procedure is best performed at night or in a dark, unlit area. Is the action complete?

—

Go to Step 3

Replace display unit

—

Go to Step 4

Replace audio unit

—

Go to Step 6

Go to Step 5

—

Go to Step 1

—

Go to Step 8

Go to Step 7

—

Go to Step 1

—

Go to Step 10

Go to Step 9

—

Go to Step 1

—

Go to Step 12

Go to Step 11

NOTE: A ’1’ should appear in the set temperature segment of the display. Does ’0’ appear in the outside air segment of the display?

—

Press the COMPUTER MODE key. Does DIAG AIRCON appear on the display?

Go to Step 2

Simultaneously press and hold the RESET key and the CLOCK key (display unit). Move the starter switch to start the engine. Does DIAG appear on the display?

—

Repair or replace damaged parts. NOTE: Refer to Step 1 Trouble Code Table. Is the action complete?

Press and release the Y fan switch (one time only). NOTE: A ’2’ should appear in the set temperature segment of the display. Does ’0’ appear in the outside air segment of the display?

Repair or replace damaged parts. NOTE: Refer to Step 2 Trouble Code Table. Is the action complete?

Press and release the Y fan switch (one time only). NOTE: B B

Refer to Step 3 Sensor Output Check for a sample output value. A ’3’ should appear in the set temperature segment of the display.

Does the correct sensor output value appear in the outside air segment of the display? 9

Repair or replace damaged parts. NOTE: Refer to Trouble Spot Inspection. Is the action complete?

Press and release the Y fan switch one time only. NOTE: Refer to Step 4 (Operation Check) for display readings and inspection steps. Are all parts operating normally?

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–93 Step

Action

Value(s)

Yes

Repair or replace damaged parts. NOTE: Refer to Trouble Spot Inspection. Is the action complete?

—

Go to Step 1

—

Go to Step 15

Go to Step 13

—

Go to Step 14

—

Go to Step 15

Replace display unit

—

1. Press and release the fan switch (one time only). 2. Press the DEF switch several times. NOTE: A ’3’ should appear in the set temperature segment of the display. Does the correct sequence pattern (1, 2, 1, 2) appear in the outside air segment of the display?

Perform diagnosis for DEF switch, intake actuator, and AUTO A/C control unit. Have the diagnosis procedures been completed.

1. Press and release the fan switch (one time only). 2. Press the DEF switch several times. Are all parts operating normally?

Turn the starter switch OFF. Is the action complete?

1A–94 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

STEP 1: Trouble Code Table Trouble Code

Defective Part

Trouble Code

Defective Part

In Car Sensor Open Circuit

–1

In Car Sensor Short Circuit

Ambient Sensor Open Circuit

–2

Ambient Sensor Short Circuit

Sun Sensor Open Circuit

–3

Sun Sensor Short Circuit

Duct Sensor Open Circuit

–4

Duct Sensor Short Circuit

Mix Potentiometer Open Circuit

–5

Mix Potentiometer Short Circuit

Mode Encoder Open Circuit

Intake Encoder Open Circuit

No Defective Part

STEP 2: Trouble Code Table Trouble Code

Defective Part

Trouble Code

Defective Part

In Car Sensor Open Circuit

–1

In Car Sensor Short Circuit

Ambient Sensor Open Circuit

–2

Ambient Sensor Short Circuit

Not Used

–3

Sun Sensor Short Circuit

Duct Sensor Open Circuit

–4

Duct Sensor Short Circuit

Mix Potentiometer Open Circuit

–5

Mix Potentiometer Short Circuit

Mode Encoder Open Circuit

Intake Encoder Open Circuit

No Defective Part

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–95

STEP 3: Sensor Output Check

865R200035

1A–96 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

STEP 4: Operation Check

865R200032

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–97

Inspection By Failed Location Inspection of the Sensors When the self-diagnosis function has determined that trouble is present on the sensors, check them according to the following flow chart.

F01RY00005

1A–98 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart 1: In Car Sensor

D08R200029

Step

2 3

4 5

Action

Yes

Disconnect the in car sensor connector. (No.I-17) Is performance of the sensor normal? (Refer to the later section on “Individual Inspection”)

—

Go to Step 2

Replace the in car sensor

Is there continuity between the harness side connector No.I20–1 and No.I17–3?

—

Go to Step 4

Go to Step 3

Is the action complete?

—

Go to Step 2

—

Is there continuity between the harness side connector No.I20–11 and No.I17–4?

—

Go to Step 6

Go to Step 5

—

Go to Step 4

—

Verify repair

—

Repair an open circuit between terminal No.I20–1 and No.I17–3.

Repair an open circuit between terminal No.I20–11 and No.I17–4. Is the action complete?

Value(s)

Replace the auto air conditioner control unit. Is the action complete?

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–99

Chart 2: Ambient Sensor

D08R200030

Step

Action

Go to Step 2

Replace the ambient sensor

Go to Step 4

Go to Step 3

—

Verify repair

—

Verify repair

—

Connect the ambient sensor connector.

Refer to the later section Is resistance between the harness side connector on “Individual No.I20–2 and No.I20–11 normal? inspection” Repair an open circuit between terminal No.I20–2 and No.C19–1 or No.I20–11 and No.C19–2. Is the action complete?

Yes

Disconnect ambient sensor connector. (No.C–19) Is performance of the ambient sensor normal? (Refer to the later section on “Individual inspection”)

Value(s)

Replace the auto air conditioner control unit. Is the action complete?

1A–100 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart 3: Sun Sensor

D08R200059

Step

2 3

4 5

Action

Yes

Disconnect the sun sensor connector. (No.I–15) Is performance of the sun sensor normal? (Refer to the later section on individual inspection)

—

Go to Step 2

Replace the sun sensor.

Is there continuity between the harness side connector terminal No.I20–3 and No.I15–2?

—

Go to Step 4

Is the action complete?

—

Go to Step 2

—

Is there continuity between the harness side connector terminal No.I20–11 and No.I15–1?

—

Go to Step 6

Go to Step 5

—

Go to Step 4

—

Verify repair

—

Repair an open circuit between terminal No.I20–3 and No.I15–2.

Repair an open circuit between terminal No.I20–11 and I15–1. Is the action complete?

Value(s)

Replace the auto air conditioner control unit. Is the action complete?

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–101

Inspection of the Intake Actuator System

D08R200060

1A–102 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Condition

Possible cause

Correction

Does not work at all

—

Refer to Chart A

Control failure

—

Refer to Chart B

Chart A: Does Not Work At All Step

1 2 3 4

Action

7 8 9

Go to Step 2

Replace the fuse

—

Go to Step 3

Replace the fuse

—

Go to Step 4

Replace the relay

Approx 12V

Go to Step 6

Go to Step 5

—

Go to Step 4

—

Approx 12V

Go to Step 8

Go to Step 7

Is the action complete?

—

Go to Step 6

—

Is there continuity between the harness side connector terminal No.I19–11 and No.C33–4?

—

Go to Step 10

Go to Step 9

—

Verify repair

—

Verify repair

—

Is the fuse F–7 normal? Is the relay X–1 normal? Turn on the ignition switch. (the engine is run.)

Repair an open circuit between terminal No.C33–3 and No.X1–1. Is the battery voltage applied between the harness side connector terminal No.C33–4 and ground? Replace the intake actuator motor.

Repair an open circuit between No.I19–11 and C33–4. Is the action complete?

—

Is the action complete? 6

Yes

Is the fuse FL–1 normal?

Is the battery voltage applied between the harness side connector terminal No.C33–3 and ground? 5

Value(s)

Replace the auto air conditioner control unit. Is the action complete?

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–103

Chart B: Failure on the Intake Control Step

1 2 3

Action

5 6

7 8

9 10

11 12

Go to Step 2

Replace the fuse

—

Go to Step 3

Replace the relay

—

Go to Step 5

Go to Step 4

Is the action complete?

—

Verify repair

—

Is there continuity between the harness side connector terminal No.C33–5 and No.I20–11?

—

Go to Step 7

Go to Step 6

Is the action complete?

—

Go to Step 5

—

Is there continuity between the harness side connector terminal No.C33–6 and No.I20–12?

—

Go to Step 9

Go to Step 8

Is the action complete?

—

Go to Step 7

—

Is there continuity between the harness side connector terminal No.C33–1 and No.I20–13?

—

Go to Step 11

Go to Step 10

Is the action complete?

—

Go to Step 9

—

Is there continuity between the harness side connector terminal No.C33–2 and No.I20–14?

—

Go to Step 13

Go to Step 12

—

Go to Step 11

—

Go to Step 14

Go to Step 15

—

Verify repair

—

Verify repair

—

Is the relay No.X–1 normal? Turn on the ignition switch. (the engine is run.) Replace or repair the auto air conditioner control unit.

Repair an open circuit between terminal No.C33–5 and No.I20–11.

Repair an open circuit between terminal No.C33–6 and No.I20–12.

Repair an open circuit between terminal No.C33–1 and I20-13.

Repair an open circuit between harness No.C33–2 and No.I20–14. 1. Disconnect the intake actuator connector No.C33. 2. Is the battery voltage applied between harness side connector terminal No.C33–6 and ground? No.C33–2 and ground? No.C33–1 and ground? Replace or repair the intake actuator. Is the action complete?

—

Is the action complete? 13

Yes

Is the fuse No.F–7 normal?

Is the intake actuator stopped? 4

Value(s)

Replace or repair the air conditioner control unit. Is the action complete?

1A–104 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Inspection of the Mix Actuator System

D08R200032

Condition

Possible cause

Correction

Does not work at all

—

Refer to Chart A

Control failure

—

Refer to Chart B

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–105

Chart A: Does Not work At All Step

Action

5 6

—

Go to Step 3

Go to Step 2

—

Varify repair

—

Go to Step 5

Go to Step 4

—

Verify repair

—

Go to Step 7

Go to Step 6

Is the action complete?

—

Go to Step 5

—

Is there continuity between the harness side connector terminal No.I19–5 and No.C43–8?

—

Go to Step 9

Go to Step 8

—

Verify repair

—

Verify repair

—

Replace the auto air conditioner control unit. Using the temperature control switch, select 32°C (90°F) for the temperature. Is the battery voltage applied on a regular interval basis between the harness side connector terminal No.C43–6 (+) and No.C43–8 (-)?

Yes

1. Turn on the ignition switch (the engine is run). 2. Disconnect the mix actuator connector (C–43). 3. Short-circuit the chassis harness side connector terminal No.C43–3 and No.C43–7. 4. Using the temperature control switch, select 18°C (65°F) for the temperature. Is the battery voltage applied on a regular interval basis between the harness side connector terminal No.C43–6 (-) and No.C43–8 (+)?

Value(s)

Replace the auto air conditioner control unit. Is there continuity between the harness side connector terminal No.I19–6 and No.C43–6? Repair an open circuit between terminal No.I19–6 and No.C43–6.

Repair an open circuit between terminal No.I19–5 and No.C43–8. Is the action complete?

Replace the mix actuator. Is the action complete?

1A–106 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart B: Mix Actuator Control Failure Step

Action

3 4

5 6

Go to Step 3

Go to Step 2

Is the action complete?

—

Varify repair

—

Is there continuity between the harness side connector terminal No.C43–3 and No.I20–11?

—

Go to Step 5

Go to Step 4

Is the action complete?

—

Go to Step 3

—

Is there continuity between harness side connector terminal No.C43–7 and No.I20–5?

—

Go to Step 7

Go to Step 6

—

Go to Step 5

—

Go to Step 9

Go to Step 8

Is the action complete?

—

Go to Step 7

—

Is sum of the voltage between the following chassis harness side connector terminals approximately 5V? No.I20–15 and No.I20–5, No.I20–5 and No.I20–11

—

Go to Step 11

Go to Step 10

—

Verify repair

—

Verify repair

—

Repair or replace the air mix door or the link unit.

Repair an open circuit between terminal No.C43–3 and No.I20–11.

Repair an open circuit between terminal No.C43–7 and No.I20–5. Is there continuity between the harness side connector terminal No.C43–2 and No.I20–15? Repair an open circuit between terminal No.C43–2 and No.I20–15.

Replace the actuator. Is the action complete?

—

Is the action complete? 7

Yes

Turn the ignition switch (the engine is run). Dose the mix actuator fully stroke when 32°C (90°F) and 18°C (65°F) of the temperature control switch?

Value(s)

Replace the auto air conditioner control unit. Is the action complete?

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–107

Inspection of the Mode Actuator System

D08R200035

Condition

Possible cause

Correction

Does not work at all

—

Refer to Chart A

Control failure

—

Refer to Chart B

1A–108 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart A: Does Not Work At All Step

Action

Go to Step 3

Go to Step 2

—

Varify repair

—

Go to Step 5

Go to Step 4

—

Varify repair

—

Go to Step 7

Go to Step 6

Is the action complete?

—

Go to Step 5

—

Is there continuity between the harness side connector terminal No.C42–5 and No.I19–3?

—

Go to Step 9

Go to Step 8

—

Verify repair

—

Verify repair

—

Replace the auto air conditioner control unit. Turn on the DEF mode switch. Is the battery voltage provided on a regular interval between the chassis side connector terminal No.C42–5 (+) and No.C42–1 (-)?

4 5 6

7 8

Replace the auto air conditioner control unit. Is there continuity between the harness side connector terminal No.C42–1 and No.I19–4? Repair an open circuit between terminal No.C42–1 and No.I19–4.

Repair an open circuit between terminal No.C42–5 and No.I19–3. Is the action complete?

—

Is the action complete? 3

Yes

1. Turn on the ignition switch (the engine is run). 2. Disconnect the mode actuator connector (C–42) 3. Select VENT pressing the mode actuator. Is the battery voltage provided on a regular interval between the harness side connector terminal No.C42–1 (+) and No.C42–5 (-)?

Value(s)

Replace the mode actuator.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–109

Chart B: Mode Actuator Control Failure Step

Action

3 4

5 6

7 8

10 11 12

—

Go to Step 3

Go to Step 2

Is the action complete?

—

Go to Step 1

—

Is there continuity between the harness side connector terminal No.C42–9 and No.I20–11?

—

Go to Step 5

Go to Step 4

Is the action complete?

—

Go to Step 3

—

Is there continuity between the harness side connector terminal No.C42–3 and No.I20–10?

—

Go to Step 7

Go to Step 6

Is the action complete?

—

Go to Step 5

—

Is there continuity between harness side connector terminal No.C42–4 and No.I20–8?

—

Go to Step 9

Go to Step 8

Is the action complete?

—

Go to Step 7

—

Is sum of the voltage between the following harness side connector terminal approximately 5V? Voltage between No.I20–8 and No.I20–10 plus voltage between No.I20–8 and No.I20–11

Go to Step 11

Go to Step 10

Is the action complete?

—

Verify repair

—

Dose the mode actuator work normally through manual operation?

—

Go to Step 13

Go to Step 12

—

Verify repair

—

Verify repair

—

Repair or replace the mode door or the link unit.

Repair an open circuit between terminal No.C42–9 and No.I20–11.

Repair an open circuit between terminal No.C42–3 and No.I20–10.

Repair an open circuit between terminal No.C42–4 and No.I20–8.

Replace the actuator.

Replace the sensor. Is the action complete?

Yes

Turn on the ignition switch (the engine is run). Dose the mode actuator fully stroke when the defrost mode and the vent mode are selected?

Value(s)

Replace the auto air conditioner control unit. Is the action complete?

1A–110 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Inspection of the Fan Motor System

D08R200058

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–111

Condition

Possible cause

Correction

The fan dose not rotate at all

—

Refer to Chart A

The fan dose not rotate in the MAX–HI mode

—

Refer to Chart B

The fan dose not rotate in any mode other than MAX–HI

—

Refer to Chart C

The fan dose not stop

—

Refer to Chart D

Chart A: Fan Does Not Rotate At All Step

1 2 3

Action

5 6

7 8

—

Go to Step 2

Replace the fuse

—

Go to Step 3

Replace the relay

—

Go to Step 5

Go to Step 4

Is the action complete?

—

Go to Step 3

—

Is there continuity between the harness side connector terminal No.C36–2 and ground (No.C–10)?

—

Go to Step 7

Go to Step 6

Is the action complete?

—

Is the battery voltage applied between the harness side connector terminal No.C36–2 and No.C36–1?

—

Go to Step 8

Go to Step 9

—

Verify repair

—

Verify repair

—

Are the relay No.X–1 and No.C–35 normal? Turn on the ignition switch (the engine is run).

Repair an open circuit between terminal No.C36–1 and No.F–5 and F–6 fuse.

Repair an open circuit between terminal No.C36–2 and ground.

Replace the blower motor. Is the action complete?

Yes

Are the fuse No.F–5, F–6 and No.F–7 normal?

Is the battery voltage applied between the harness side connector terminal No.C36–1 and ground? 4

Value(s)

Refer to chart B and C. Is the action complete?

1A–112 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart B: Fan Does Not Rotate in MAX HI Mode Step

1 2

Action

4 5

6 7

8 9

—

Go to Step 2

Replace the relay

—

Go to Step 4

Go to Step 3

Is the action complete?

—

Go to Step 3

—

Is there continuity between the harness side connector terminal No.C35–1 and ground (No.C–10)?

—

Go to Step 6

Go to Step 5

Is the action complete?

—

Go to Step 4

—

Is the battery voltage applied between the harness side connector terminal No.C35–2 and ground?

—

Go to Step 8

Go to Step 7

Is the action complete?

—

Go to Step 6

—

Is the battery voltage applied between the harness side connector terminal No.I19–2 and ground?

—

Go to Step 10

Go to Step 9

—

Verify repair

—

Verify repair

—

1. Turn on the ignition switch (the engine is run). 2. Set the fan switch to the MAX-HI.

Repair an open circuit between terminal No.C36–2 and No.C35–5.

Repair an open circuit between terminal No.C35–1 and ground (No.C–10).

Repair an open circuit between terminal No.C35–2 and No.F–7 fuse.

Repair an open circuit between terminal No.C35–4 and No.I19–2. Is the action complete?

Yes

Is the MAX-HI relay (C–35) normal?

Is there continuity between the harness side connector terminal No.C36–2 and No.C35–5? 3

Value(s)

Replace the auto air conditioner control unit. Is the action complete?

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–113

Chart C: Fan Does Not Rotate In Any Mode Other Than MAX HI Step

4 5

6 7

Action

Yes

Is the power transistor performance normal? (Refer to the later section on “individual inspection”)

—

Go to Step 2

Replace the power transistor

—

Go to Step 4

Go to Step 3

—

Go to Step 2

—

Go to Step 6

Go to Step 5

Is the action complete?

—

Go to Step 4

—

Is there continuity between the harness side connector terminal No.C34–2 and No.I20–19?

—

Go to Step 8

Go to Step 7

—

Go to Step 6

—

Verify repair

—

Is there continuity between the harness side connector terminal No.C36–2 and No.C34–1, No.C36–2 and No.I20–17? Repair an open circuit between terminal. No.C36–2 and C34–1 No.C36–2 and I20–17 Is there continuity between the harness side connector terminal No.C34–3 and ground (No.C–10)? Repair an open circuit between terminal No.C34–3 and ground.

Repair an open circuit between terminal No.C34–2 and No.I20–19. Is the action complete?

Value(s)

Replace the auto air conditioner control unit. Is the action complete?

1A–114 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Chart D: Fan Does Not Stop Step

Action

3 4

Go to Step 3

Go to Step 2

Is the action complete?

—

Verify repair

—

Is the max high relay normal? (Refer to the later section on “individual inspection”.)

—

Go to Step 4

Replace the relay

—

Go to Step 6

Go to Step 5

—

Go to Step 4

—

Go to Step 7

Replace the power transistor

—

Replace the auto A/C control unit

—

Repair a short circuit between connector No.C36–2 and No.C35–5, No.C36–2 and No.C34–1, or No.C36–2 and I20–17.

Reinstall the max high relay. Repair a short circuit between connector No.C35–4 and No.I19–2. Is the action complete?

—

Does the blower motor start operating? 5

Yes

1. Disconnect the max high relay, the power transistor connector C–34 and the auto A/C control unit connector I–20. 2. Turn on the ignition switch. Does the blower motor stop?

Value(s)

Is the power transistor normal? (Refer to the later section on “individual inspection”.) Reinstall the power transistor. Does the blower motor start operating?

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–115

Inspection of the Magnetic Clutch System 6VE1 Engine

D08R200037

1A–116 HEATING, VENTILATION AND AIR CONDITIONING (HVAC) Condition

Possible cause

Magnetic clutch does not work

Correction Refer to Chart A

—

Chart A: Magnetic Clutch Does Not work Step

1 2 3 4

Action

7 8

11 12

13 14

Yes

Is the fuse No.F–7 normal?

—

Go to Step 2

Replace the fuse

Is the relay No.X–2 (compressor relay) No.X–8 (A/C thermo relay) and No.X–1 (heater relay) normal?

—

Go to Step 3

Replace the relay

Is there continuity between the pressure switch side connector terminal No.C21–1 and No.C21–2?

—

Go to Step 5

Go to Step 4

Pressure switch defective or refrigerant pressure improper. Pressure switch replaced or refrigerant pressure adjusted?

—

Go to Step 3

—

Go to Step 7

Go to Step 6

Magnetic clutch replaced or earth replaced?

—

Go to Step 5

—

Is there continuity between the harness side connector terminal No.X2–1 and No.E2–1?

—

Go to Step 9

Go to Step 8

Is the action complete?

—

Go to Step 7

—

Is the battery voltage applied between the harness side connector terminal No.X2–5 and ground, No.X2–2 and ground?

—

Go to Step 11

Go to Step 10

Is the action complete?

—

Go to Step 9

—

Is the battery voltage applied between the harness side connector terminal No.I20–18 and ground?

—

Go to Step 13

Go to Step 12

Is the action complete?

—

Go to Step 11

—

Is the battery voltage applied between the harness side connector terminal No.C21–2 and ground?

—

Go to Step 15

Go to Step 14

Is the action complete?

—

Go to Step 13

—

Is the battery voltage applied between the harness side connector terminal No.X8–5 and ground, No.X8–2 and ground?

—

Go to Step 17

Go to Step 16

—

Go to Step 15

—

1. Turn the ignition switch on. (the engine is run.) 2. Turn the air conditioner switch on. Is the battery voltage applied between the harness side connector terminal No.E2–1 and the ground?

Value(s)

Magnetic clutch defective or earth defective.

Repair an open circuit between terminal No.X2–1 and No.E2–1.

Repair an open circuit between terminal No.X2–5 and fuse No.F–7, No.X2–2 and fuse No.F–7.

Repair an open circuit between terminal No.I20–18 and No.X2–4.

Repair an open circuit between terminal No.C21–2 and fuse No.F–7.

Repair an open circuit between terminal No.X8–5 and No.C21–1, No.X8–2 and fuse No.F–7. Is the action complete?

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–117

Chart A: Magnetic Clutch Does Not work (Cont’d) Step

Action

Value(s)

Is the battery voltage applied between the harness side connector terminal No.I19–14 and ground?

—

Go to Step 19

Go to Step 18

Is the action complete?

—

Go to Step 17

—

Is there continuity between the harness side connector terminal No.X8–1 and PCM (F45)?

—

Go to Step 21

Go to Step 20

Is the action complete?

—

Go to Step 19

—

Is there continuity between the harness side connector terminal No.X2–4 and PCM (F4)?

—

Go to Step 23

Go to Step 22

Is the action complete?

—

Go to Step 21

—

Is there continuity between the harness side connector terminal No.I20–4 and ground?

—

Go to Step 25

Go to Step 24

—

Go to Step 23

—

Replace the auto air conditioner control unit

Replace the PCM

19 20

21 22

23 24

Repair an open circuit between terminal No.X8–3 and I19–14.

Repair an open circuit between terminal No.X8–1 and PCM (F45).

Repair on open circuit between terminal No.X2–4 and PCM (F4).

Repair an open circuit between terminal No.I20–4 and PCM (S47). Is the action complete?

Yes

1. Connect the connector of PCM. 2. Connect the connector terminal No.I19–14 which is on the harness side on the auto air conditioner control unit. Magnetic clutch works?

CAUTION: There are conditions which air conditioner system dose not operate except trouble as follows. 1. The throttle is griater than 90%. 2. The ignition voltage is below 10.5 volts. 3. The engine speed greater than 4500 RPM for 5 seconds or 5400 RPM. 4. The engine coolant temperature (ECT) is greater than 125°C (257°F). 5. The intake air temperature (IAT) is less than 5°C (41°F). 6. The power steering pressure switch signals a high pressure condition.

1A–118 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Sun Sensor

Individual Inspection In Car Sensor 1. Disconnect the in car sensor connector (I–17). 2. Measure resistance between the in car sensor side terminal No.I17–3 and No.I17–4.

1. Disconnect the sun sensor connector (I–15). 2. Measure the current value on the sun sensor when placed it approximately 15 cm away from 60W incandescent lamp.

D06R200001

Ambient Sensor 1. Disconnect the connector (C–19) on the ambient sensor. 2. Measure resistance between the ambient sensor side terminals.

C01R200015

C01R200014

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–119

Power Transistor

In Car Sensor

1. Remove the power transistor connector (C–34) from the evaporator assembly. 2. Check the conduction between the power transistor side terminals.

1. Turn on the ignition switch (the engine is started). Start the air conditioner in “Auto”. 2. Make sure that the in car sensor suctions cigarette smokes and such.

In Car Sensor 1. Dismount the in car sensor from the automatic heater/air conditioner control unit. Connect (+) end and (–) end of the battery to the aspirator motor side terminals No.I17–1 and No.I17–2, respectively, then check if the motor runs normally.

C01R200006

MAX HI Relay 1. Remove the MAX – HI relay connector (C–35) from the blower assembly. 2. Check the conduction between the MAX – HI relay side terminals.

C01R200010

C01R200011

1A–120 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Heater (X–1) And Compressor (X–2) Relay 1. Disconnect relays and check for continuity and resistance between relay terminals. B For handling of these relays, refer to Heater Relay in this section.

Triple Pressure Switch 1. Disconnect the connector and check for continuity between pressure switch side connector terminals (1) and (2). 2. Reconnect the connector to activate the A/C switch, and check to see if there is continuity between the chassis side connector terminal (3) and (4) and the fan operates.

C01R200011

Thermostat (X–8) Relay 1. Disconnect relays and check for continuity and resistance between relay terminals. B For handling of these relays, refer to Heater Relay in this section.

C01R200012

875R200020

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–121

On-Vehicle Service Power Transistor

Automatic Heater/Air Control Unit

Conditioner

874R200014

Legend (1) Glove Box (2) MAX HI Relay (3) Power Transistor Connector (4) Power Transistor

Removal 1. Remove the glove box. 2. Remove the MAX–HI relay. 3. Disconnect the power transistor connector. 4. Remove the power transistor.

Installation To install, follow the removal step in the reverse order.

865R200007

Legend (1) Display (2) Audio & Switch Assembly (3) Automatic Air Conditioner Control Unit (4) Knee Pad (RH) (5) Center Cluster (6) Center Cluster Upper (7) Knee Pad (LH)

Removal 1. Disconnect the battery ground cable. 2. Remove the knee pad (R/LH). 3. Remove the center cluster upper. 4. Remove the center cluster. B Refer to Instrument Panel Assembly in Body Stractur section. 5. Disconnnect the six connectors. 6. Remove the automatic air conditioner control unit.

Installation To install, follow the removal step in the reverse order.

1A–122 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

In Car Sensor

Ambient Sensor

865R200001

Legend (1) Meter Cluster (2) In Car Sensor

Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster. B Refer to Instrument Panel Assembly in Body Structure section. 3. Remove the in car sensor.

875R200018

Legend (1) Ambient Sensor (2) Ambient Sensor Connector (3) Horn (LH)

Removal 1. Disconnect the battery ground cable. 2. Remove the horn (LH). 3. Disconnect the ambient sensor connector. 4. Remove the ambient sensor.

Installation

To install, follow the removal step in the reverse order.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–123

Sun Sensor

Duct Sensor

865R200002

Legend (1) Sun Sensor (2) Center Cluster Upper

Removal 1. Disconnect the battery ground cable. 2. Remove the center cluster upper. 3. Disconnect the sun sensor connector. 4. Remove the sun sensor.

Installation To install, follow the removal step in the reverse order.

874R200010

Legend (1) Sensor Part (2) Evaporator Core (3) Duct Sensor Assembly (4) Evaporator Assembly

Removal 1. Disconnect the battery ground cable. 2. Remove the evaporator assembly. B Refer to evaporator assembly in this section. 3. Remove the duct sensor assembly.

Installation To install, follow the removal step in the reverse order.

1A–124 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

Mode Actuator

Mix Actuator

840R200005

Legend (1) Driver Knee Bolster Assembly (2) Instrument Panel Driver Lower Cover Assembly (3) Actuator Rod (4) Mode Actuator

Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel driver lower cover assembly. 3. Remove the driver knee bolster assembly. B Refer to the Instrument Panel Assembly in Body Structure section. 4. Remove the actuator rod. 5. Remove the mode actuator.

Installation To install, follow the remove step in the reverse order.

840R200006

Legend (1) Center Cluster Upper (2) Center Cluster (3) Knee Pad (RH) (4) Actuator Rod (5) Mix Actuator (6) Knee Pad (LH) (7) Audio & Switch Assembly

Removal 1. Disconnect the battery ground cable. 2. Remove the knee pad (R/RH). 3. Remove the center cluster upper. 4. Remove the center cluster. B Refer to the Instrument Panel Assembly in Body Structure section. 5. Disconnect the six connectors. 6. Remove the Audio & Switch Assembly. 7. Remove the actuator rod. 8. Remove the mix actuator.

Installation To install, follow the remove step in the reverse order.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–125

Intake Actuator

873R200003

Legend (1) Evaporator Assembly (2) Intake Actuator (3) Intake Actuator Connector

Removal 1. Disconnect the battery ground cable. 2. Discharge and recover refrigerant. B Refer to Refrigerant Recovery in this section. 3. Remove the evaporator assembly. B Refer to Evaporator Assembly section. 4. Disconnect the intake actuator connector. 5. Remove the intake actuator.

Installation To install, follow the remove step in the reverse order.

SECTION POWER–ASSISTED STEERING SYSTEM

2A–1

AXIOM

STEERING POWER-ASSISTED STEERING SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Power Steering System Test . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding The Power Steering System . . . . . . Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . Flushing The Power Steering System . . . . . . Steering Wheel Free Play Inspection . . . . . . Front End Alignment Inspection and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Unit . . . . . . . . . . . . . . . . . . . . . Power Steering Unit and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation (4×2 Model) . . . . . . . . . . . . . . . . Installation (4×4 Model) . . . . . . . . . . . . . . . . Power Steering Unit Disassembled View . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump . . . . . . . . . . . . . . . . . . . . Power Steering Pump and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Steering Pump Disassembled View Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Transfer Gear Assembly . . . . . . . . . . . . . . . . . Transfer Gear Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2A–2 2A–2 2A–8 2A–10 2A–11 2A–11 2A–11 2A–11 2A–11 2A–12 2A–12 2A–16 2A–17 2A–18 2A–18 2A–18 2A–19 2A–19 2A–20 2A–21 2A–21 2A–21 2A–22 2A–22 2A–23 2A–23 2A–23 2A–23 2A–24 2A–24 2A–25 2A–25 2A–27 2A–28 2A–28

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Supplemental Restraint System Steering Wheel & Column . . . . . . . . . . . . . . . . . . . . . . . Service Precaution . . . . . . . . . . . . . . . . . . . . SRS Connectors . . . . . . . . . . . . . . . . . . . . . . Inflator Module . . . . . . . . . . . . . . . . . . . . . . . . . . Inflator Module and Associated Parts . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Combination Switch . . . . . . . . . . . . . . . . . . . . . Combination Switch and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . Lock Cylinder and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Inspection . . . . . . . . . . . . . . . . . . . . . Steering Column . . . . . . . . . . . . . . . . . . . . . . . . Steering Column and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Inspection . . . . . . . . . . . . . . . . . . . . . Supplemental Restraint System Steering Wheel & Column and Associated Parts . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .

2A–28 2A–28 2A–28 2A–29 2A–29 2A–29 2A–31 2A–31 2A–31 2A–32 2A–32 2A–33 2A–33 2A–33 2A–35 2A–36 2A–36 2A–36 2A–38 2A–40 2A–40 2A–40 2A–42 2A–43 2A–44 2A–44 2A–44 2A–46 2A–48 2A–49 2A–50 2A–50 2A–50

2A–2 POWER–ASSISTED STEERING SYSTEM

Service Precaution

Diagnosis

Since the problems in steering, suspension, wheels and tires involve several systems, they must all be considered when diagnosing a complaint. To identify the symptom, always road test the vehicle first. Proceed with the following preliminary inspections and correct any defects which are found. 1. Inspect tires for proper pressure and uneven wear. 2. Raise vehicle on a hoist, then inspect front and rear suspension and steering linkage for loose or damaged parts. 3. Spin the front wheels. Inspect for out-of-round tires, out-of-balance tires, loose and/or rough wheel bearings.

General Diagnosis Condition Vehicle Pulls

Possible cause Mismatched or uneven tires.

Replace tire.

Tires not adequately inflated.

Adjust tire pressure.

Broken or sagging springs.

Replace spring.

Radial tire lateral force.

Replace tire.

Improper wheel alignment.

Adjust wheel alignment.

Brake dragging in one wheel.

Repair brake.

Loose, bent or broken front or rear suspension parts.

Tighten or replace the appropriate suspension part(s).

Faulty shock absorbers.

Replace shock absorber.

Parts in power defective. Abnormal or Excessive Tire Wear

Correction

steering

valve

Replace power steering unit.

Sagging or broken spring.

Replace spring.

Tire out of balance.

Balance or replace tire.

Improper wheel alignment.

Check front end alignment.

Faulty shock absorber.

Replace shock absorber.

Hard driving.

Replace tire.

Overloaded vehicle.

Replace tire and reduce load.

Tires not rotated periodically.

Replace or rotate tire.

Worn or loose road wheel bearings.

Replace wheel bearing.

Wobbly wheel or tires.

Replace wheel or tire.

Tires not adequately inflated.

Adjust the pressure.

POWER–ASSISTED STEERING SYSTEM Condition Wheel Hop Shimmy, Shake or Vibration

Hard Steering

Too Much Play In Steering

Possible cause

Correction

Blister or bump on tire.

Replace tire.

Improper shock absorber operation.

Replace shock absorber.

Tire or wheel out of balance.

Balance wheels or replace tire/or wheel.

Loose wheel bearings.

Replace wheel bearing.

Worn steering linkage ball joints.

Replace ball joints.

Worn upper or lower end ball joints.

Replace ball joints.

Excessive wheel run–out.

Repair or replace wheel and/or tire.

Blister or bump on tire.

Replace tire.

Excessive loaded radial run–out of tire/wheel assembly.

Replace tire or wheel.

Improper wheel alignment.

Check wheel alignment.

Loose or worn steering linkage.

Tighten or replace steering linkage.

Loose steering unit.

Tighten steering unit.

Tires not adequately inflated.

Adjust tire pressure.

Loose, bent or broken front or rear suspension parts.

Tighten or replace the appropriate suspension parts.

Faulty shock absorber.

Replace shock absorber.

Hub bearing preload misadjustment.

Adjust preload.

Parts in power defective.

Replace power steering unit.

steering

valve

Bind in steering linkage ball studs, upper or lower end ball joint.

Replace ball joint.

Improper wheel alignment.

Check wheel alignment.

Tire not adequately inflated.

Inflate tires to proper pressure.

Bind in steering column or shaft.

Repair or replace.

Improper power steering system operation.

Repair or replace. Refer to Power steering system diagnosis

Wheel bearings worn.

Replace wheel bearings.

Loose steering unit or linkage.

Retighten or repair.

Worn or loose universal joint.

Poor Steering Wheel Returnability

2A–3

steering

shaft

Retighten or replace steering shaft.

Worn steering linkage ball joints.

Replace ball joints.

Worn upper or lower end ball joints.

Replace ball joints.

Bind in steering linkage ball joints.

Replace ball joints.

Bind in upper or lower end ball joints.

Replace ball joints.

Bind in steering column and shaft.

Repair or replace.

Bind in steering gear.

Check and repair steering gear.

Improper wheel alignment.

Adjust wheel alignment.

Tires not adequately inflated.

Adjust tire pressure.

Loose steering wheel nut.

Retighten.

Worn wheel bearing.

Replace.

2A–4 POWER–ASSISTED STEERING SYSTEM Condition Abnormal Noise

Possible cause

Correction

Worn, sticky or loose upper or lower ball joint, steering linkage ball joints or drive axle joints.

Replace.

Faulty shock absorbers.

Replace.

Worn upper or lower control arm bushing.

Replace.

Loose stabilizer bar.

Retighten bolts or replace bushings.

Loose wheel nuts.

Tighten nuts. Check for elongated wheel nut holes. Replace wheel if required.

Wandering or Poor Steering Stability

Erratic Steering When Braking

Loose suspension bolts or nuts.

Retighten suspension bolts or nuts.

Broken or otherwise damaged wheel bearings.

Replace wheel bearing.

Broken suspension springs.

Replace spring.

Loose steering unit.

Retighten mounting bolt.

Faulty steering unit.

Replace steering unit.

Mismatched or unevenly worn tires.

Replace tire or inflate tires to proper pressure.

Loose steering linkage ball joints.

Replace ball joints.

Faulty shock absorbers.

Replace shock absorber.

Loose stabilizer bar.

Tighten or replace stabilizer bar or bushings.

Broken or sagging springs.

Replace spring (pairs).

Improper wheel alignment.

Adjust wheel alignment.

Worn wheel bearings.

Replace wheel bearings.

Broken or sagging springs.

Replace spring (pairs).

Leaking caliper.

Repair or replace caliper.

Warped discs.

Replace brake disc.

Badly worn brake pads.

Replace brake pads.

Tires are inflated unequally.

Inflate tires to proper pressure.

POWER–ASSISTED STEERING SYSTEM

2A–5

Power Steering System There is some noise in all power steering systems. One of the most common is a hissing sound when the steering wheel is fully turned and the car is not moving. This noise will be most evident when the steering wheel is operated while the brakes are applied. There is no relationship Condition Rattle or Chucking Noise

Poor Return of Steering Wheel to Center

between this noise and steering performance. Do not replace the valve unless the “hissing” noise is extremely objectionable. A replacement valve will also have a slight noise, and is not always a cure for the condition.

Possible cause

Correction

Pressure hose touching other parts of vehicle.

Adjust hose position. Do not bend tubing by hand.

Tie rod ends loose.

Tighten or replace tie rod end.

Loose steering unit mounting.

Tighten steering unit mounting.

Improper front wheel alignment.

Adjust front wheel alignment.

Wheel bearing worn.

Replace front wheel bearing.

Tie rod end binding.

Replace tie rod end.

Ball joint binding.

Replace ball joint.

Tight or bearing.

frozen

steering

shaft

Replace steering assembly.

Sticky or plugged steering unit valve.

Flush or replace steering unit.

Entry of air in the power steering system.

Bleed the system.

Momentary Increase In Effort When Turning Wheel Fast To Right or Left

High internal leakage.

Repair steering gear.

Power steering fluid level low.

Replenish fluid.

Steering Wheel Surges or Jerks When Turning Especially During Parking

Insufficient pump pressure.

Repair pump assembly.

Sticky steering unit valve.

Flush or replace steering unit.

Power steering fluid level low.

Replenish fluid.

Air in system.

Bleed hydraulic system.

Tie rod end loose.

Tighten tie rod end.

Wheel bearing worn.

Replace wheel bearing.

Sticky steering unit valve.

Flush or replace steering unit.

Insufficient pump pressure.

Repair pump assembly.

Excessive internal pump leakage.

Repair pump assembly.

Excessive internal steering gear leakage.

Repair steering gear.

Power steering fluid level low.

Replenish fluid.

Pressure switch of the power steering pump or its harness is faulty.

Repair or replace.

Excessive Wheel Kick Back or Loose Steering

Hard Steering or Lack or Power Assist

Unstable Engine Idling or Stalling When Turning

2A–6 POWER–ASSISTED STEERING SYSTEM

Power Steering Pump Foaming milky power steering fluid, low fluid level, and possible low pressure can be caused by air in the fluid, or loss of fluid due to internal pump leakage. Check for leak and correct. Bleed the system. Extremely cold temperatures will cause air bubbles in the system if the

fluid level is low. If the fluid level is correct and the pump still foams, remove the pump from the vehicle and check housing for cracks. If the housing is cracked, replace the pump housing.

Condition

Possible cause

Low Pressure Due to Steering Pump

Relief valve sticking or inoperative.

Replace relief valve.

Side plate not flat against cam ring.

Replace side plate.

Extreme wear of cam ring.

Replace cam ring.

Scored side plate or rotor.

Replace side plate or rotor.

Vanes sticking in rotor slots.

Repair or replace vanes and rotor.

Cracked or broken side plate.

Replace side plate.

High internal leakage.

Repair internal leakage.

Low Pressure Due to Steering Gear

Scored housing bore.

Replace housing.

Growling Noise In Steering Pump

Excessive back pressure in hoses or steering unit caused by restriction.

Repair steering unit or pump.

Scored side plate or rotor.

Replace side plate or rotor.

Worn cam ring.

Replace cam ring.

Air in the fluid.

Bleed hydraulic system.

Low fluid level.

Replenish fluid.

Pump mounting loose.

Tighten mounting bolt.

Vanes sticking in rotor slots.

Repair or replace vanes and rotor.

Vane improperly installed.

Repair rotor and vane.

Swishing Noise In Steering Pump

Damaged relief valve.

Replace relief valve.

Whining Noise In Steering Pump

Scored side plate and vanes.

Replace side plate and vanes.

Groaning Noise In Steering Pump

Rattling Noise In Steering Pump

Correction

Steering Column Lock System Condition

Possible cause

Will Not Unlock Will Not Lock

Key Cannot “OFF LOCK” “OFF-LOCK”

Removed

Correction

Damaged lock cylinder.

Replace lock cylinder.

Damaged park lock cable.

Replace park lock cable.

Lock spring broken or worn.

Replace lock cylinder.

Damaged lock cylinder.

Replace lock cylinder.

Ignition switch stuck.

Repair or replace ignition switch.

Park lock cable damaged.

Replace park lock cable.

Ignition switch is not set correctly.

Correct ignition switch.

Damaged lock cylinder.

Replace lock cylinder.

Faulty shift lock mechanism.

Repair or replace the shift lock mechanism.

Column Condition Noise in Column

Possible cause

Correction

Universal joint loose.

Tighten joint.

Shaft lock snap ring not seated.

Place snap ring in proper position.

POWER–ASSISTED STEERING SYSTEM

2A–7

Turn Signal Switch This diagnosis covers mechanical problems only. Refer to Turn Signal Switch in Electrical section for electrical diagnosis. Condition

Possible cause

Turn Signal Will Not Stay In Turn Position

Foreign material or loose parts preventing movement of yoke.

Repair or replace signal switch.

Broken or missing canceling spring.

Replace signal switch.

Turn Signal Will Not Cancel

detent

Correction

Loose switch mounting screws.

Tighten mounting screws.

Switch or anchor bosses broken.

Replace turn signal switch.

Broken, missing or out of position detent, return or canceling spring.

Replace turn signal switch.

Worn canceling cam.

Replace turn signal switch.

Turn signal switch arm loose.

Tighten arm screw.

Broken or distorted yoke.

Replace turn signal switch.

Loose or misplaced springs.

Replace turn signal switch.

Foreign parts and/or material.

Repair turn signal switch.

Loose turn signal switch mounting screws.

Tighten mounting screws.

Broken lane change pressure pad or spring hanger.

Replace turn signal switch.

Broken, missing or misplaced lane change spring.

Replace turn signal switch.

Base of wire damaged.

Replace turn signal switch.

Hazard Switch Cannot Be Turned Off

Foreign material between hazard switch to turn signal switch body.

Repair or replace hazard switch.

No Turn Signal Lights

Electrical failure in chassis harness.

Refer to Electrical section.

Inoperative turn signal flasher unit.

Replace flasher unit.

Loose chassis harness connector.

Repair loose connector.

Burned-out or damaged turn signal bulb.

Replace bulb.

High resistance connection ground at bulb socket.

Repair bulb socket.

Turn Signal Difficult To Operate

Turn Signal Will Not Indicate Lane Change

Front or Rear Turn Signal Lights Not Flashing

Loose chassis harness connector.

Repair loose connector.

2A–8 POWER–ASSISTED STEERING SYSTEM

General Description The hydraulic power steering system consists of a pump, an oil reservoir, a steering unit, a pressure hose and a return hose.

Power Steering Unit

A02RW001

The power steering unit is rack and pinion type. The toe–in angle can be adjusted by turning the rod on each side. The steering housing cannot be disassembled.

Hydraulic Pump

A02RX002

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

2A–9

Pressure Switch When hydraulic pressure reaches 3430 kPa (500 psi), the pressure switch of the power steering pump closes causing the Powertrain Control Module (PCM) to actuate the throttle valve, which increases the engine rpm to prevent the overload-induced engine speed slow down. The switch opens when hydraulic pressure drops to 2940 kPa (430 psi).

Steering Column

431RY00009

WARNING: TO AVOID DEPLOYMENT WHEN TROUBLE-SHOOTING THE SRS SYSTEM, DO NOT USE ELECTRICAL TEST EQUIPMENT, SUCH AS BATTERY-POWERED OR A/C-POWERED VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN SPECIFIED IN THIS MANUAL. DO NOT USE A NON-POWERED PROBE-TYPE TESTER.

INSTRUCTION IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT. When servicing a vehicle equipped with Supplemental Restraint System, pay close attention to all WARNINGS and CAUTIONS. For detailed explanation about SRS, refer to Restraints section.

2A–10 POWER–ASSISTED STEERING SYSTEM The steering column has three important features in addition to the steering function: 1. The column is energy absorbing, designed to compress in a front-end collision to minimize the possibility of injury to the driver of the vehicle. 2. The ignition switch and lock are mounted conveniently on the column. 3. With the column mounted lock, the ignition and steering operation can be locked to prevent theft of the vehicle.

The column can be disassembled and reassembled. However, to insure the energy absorbing action, use only the specified screws, bolts and nuts as designated, and tighten them to the specified torque. Handle the column with care when it is removed from the vehicle. A sharp blow on the end of steering shaft or shift lever, or dropping the assembly could shear or loosen the fasteners that maintain column rigidity.

Power Steering System Test Test Procedure

C02RW001

Legend (1) Fluid Reservoir

Test of fluid pressure in the power steering system is performed to determine whether or not the oil pump and power steering unit are functioning normally. The power steering system test is used to identify and isolate hydraulic circuit difficulties. Prior to performing this test, the following inspections and corrections, if necessary, must be made. B Inspect pump reservoir for proper fluid level. B Inspect pump belt for proper tension. B Inspect pump driver pulley condition.

(2) Power Steering Unit (3) Power Steering Pump

1. Place a container under the pump to catch the fluid when disconnecting or connecting the hoses. 2. With the engine NOT running, disconnect the pressure hose at the power steering pump and install power steering tester J-29877-A. The gage must be between the shutoff valve and pump. Open the shutoff valve. 3. Check the fluid level. Fill the reservoir with power steering fluid, to the “Full” mark. Start the engine, then turn the steering wheel and momentarily hold it against a stop (right or left). Turn the engine off and check the connections at tester for leakage.

POWER–ASSISTED STEERING SYSTEM 4. Bleed the system. Refer to Bleeding the Power Steering System in this section. 5. Start the engine and check the fluid level. Add power steering fluid if required. When the engine is at normal operating temperature, increase engine speed to 1500 rpm. CAUTION: Do not leave shutoff valve fully closed for more than 5 seconds, as the pump could become damaged internally. 6. Fully close the shutoff valve. Record the highest pressures. B If the pressure recorded is within 9300–9800 kPa (1350–1420 psi), the pump is functioning within its specifications. B If the pressure recorded is higher than 9800 kPa (1420 psi), the valve in the pump is defective. B If the pressure recorded is lower than 9300 kPa (1350 psi), the valve or the rotating group in the pump is defective. 7. If the pump pressures are within specifications, leave the valve open and turn (or have someone else turn) the steering wheel fully in both directions. Record the highest pressures and compare with the maximum pump pressure recorded in step 6. If this pressure cannot be built in either side of the power steering unit, the power steering unit is leaking internally and must be replaced. 8. Shut the engine off, remove the testing gauge. 9. Reconnect the pressure hose, check the fluid level and make the needed repairs. 10. If the problem still exists, the steering and front suspension must be thoroughly examined.

Maintenance The hydraulic system should be kept clean and fluid level in the reservoir should be checked at regular intervals and fluid added when required. Refer to Recommended Fluids and Lubricants in General Information section for the type of fluid to be used and the intervals for filling. If the system contains some dirt, flush it as described in this section. If it is exceptionally dirty, the pump must be completely disassembled before further usage. (The steering unit cannot be disassembled.) All tubes, hoses, and fittings should be inspected for leakage at regular intervals. Fittings must be tight. Make sure the clips, clamps and supporting tubes and hoses are in place and properly secured. Power steering hoses and lines must not be twisted, kinked or tightly bent. Air in the system will cause spongy action and noisy operation. When a hose is disconnected or when fluid is lost, for any reason, the system must be bled after refilling. Refer to Bleeding the Power Steering System in this section. B Inspect belt for tightness. B Inspect pulley for looseness or damage. The pulley should not wobble with the engine running. B Inspect hoses so they are not touching any other parts of the vehicle. B Inspect fluid level and fill to the proper level.

2A–11

Fluid Level 1. Run the engine until the power steering fluid reaches normal operating temperature, about 55°C (130°F), then shut the engine off. 2. Check the level of fluid in the reservoir. 3. If the fluid level is low, add power steering fluid as specified in General Information to the proper level and install the receiver cap. 4. When checking the fluid level after the steering system has been serviced, air must be bled from the system. Refer to Bleeding the Power Steering System in this section.

Bleeding The Power Steering System When a power steering pump or unit has been installed, or an oil line has been disconnected, the air that has entered the system must be bled out before the vehicle is operated. If air is allowed to remain in the power steering fluid system, noisy and unsatisfactory operation of the system may result.

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

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

2A–12 POWER–ASSISTED STEERING SYSTEM 4. Install all the lines and hoses. Fill the system with new power steering fluid and bleed the system as described in Bleeding The Power Steering System. Operate the engine for about 15 minutes. Remove the pump return line at the pump inlet and plug the connection on the pump. While refilling the reservoir, check the draining fluid for contamination. If foreign material is still evident, replace all lines, disassemble and clean or replace the power steering system components. Do not re-use any drained power steering fluid.

Camber: This illustration shows view from the front of the vehicle.

Steering Wheel Free Play Inspection

480RS004

430R200001

1. With the tires in the straight-ahead position, check the amount of steering wheel play by turning the wheel in both directions until the tires begin to move.

Camber is the vertical tilting inward or outward of the front wheels. When the wheels tilt outward at the top, the camber is positive (+). When the wheels tilt inward at the top, the camber is negative (-). The amount of tilt measured in degrees from the vertical is called the camber angle (1). If camber is extreme or unequal between the wheels, improper steering and excessive tire wear will result. Negative camber causes wear on the inside of the tire, while positive camber causes wear to the outside. Caster: This illustration shows view from the side of the vehicle.

NOTE: The wheel free play should be checked with the engine running. Free play: 0 – 30 mm (0 – 1.18 in) 2. Also check the steering wheel for play and looseness in the mount by moving it back and forth and sideways. When test driving, check for hard steering, steering shimmy and tendency to pull to one side.

Front End Alignment Inspection and Adjustment General Description “Front End Alignment” refers to the angular relationship between the front wheels, the front suspension attaching parts and the ground. Proper front end alignment must be maintained in order to insure efficient steering, good directional stability and to prevent abnormal tire wear. The most important factors of front end alignment are wheel toe-in, wheel camber and axle caster.

480RS005

POWER–ASSISTED STEERING SYSTEM Caster (1) is the vertical tilting of the wheel axis either forward or backward (when viewed from the side of the vehicle). A backward tilt is positive (+) and a forward tilt is negative (-). On the short and long arm type suspension you cannot see a caster angle without a special instrument, but if you look straight down from the top of the upper control arm to the ground, the ball joints do not line up (fore and aft) when a caster angle other than 0 degree is present. With a positive angle, the lower ball joint would be slightly ahead (toward the front of the vehicle) of the upper ball joint center line. Toe-in: This illustration shows view from the top of the vehicle.

2A–13

6. Inspect the wheel and tires for run-out. Refer to Wheel Replacement in Wheel and Tire System section. 7. Inspect the trim height. If not within specifications, the correction must be made before adjusting caster. 8. Inspect the steering unit for looseness at the frame. 9. Inspect shock absorbers for leaks or any noticeable noise. Refer to Shock Absorber in Suspension section. 10. Inspect the control arms or stabilizer bar attachment for looseness. Refer to Suspension section. 11. Inspect the front end alignment using alignment equipment. Follow the manufacturer’s instructions. 12. Park the vehicle on a level surface.

Trim Height Adjustment Adjust the trim height (1) by means of the adjusting bolt on the height control arms. CAUTION: When adjusting front end alignment, be sure to begin with trim height first, as it may change other adjusted alignments.

480RS003

Toe-in is the measured amount the front wheels are turned in. The actual amount of toe-in is normally a fraction of a degree. Toe-in is measured from the center of the tire treads or from the inside of the tires. The purpose of toe-in is to insure parallel rolling of the front wheels and to offset any small deflections of the wheel support system which occurs when the vehicle is rolling forward. Incorrect toe-in results in excessive toe-in and unstable steering. Toe-in is the last alignment to be set in the front end alignment procedure.

450RS003

Inspection Before making any adjustments affecting caster, camber or toe-in, the following front end inspection should be made. 1. Inspect the tires for proper inflation pressure. Refer to Main Data and Specifications in Wheel and Tire System section. 2. Make sure that the vehicle is unladen condition (With no passenger or loading). 3. Make sure that the spare tire is installed at the normal position. 4. Inspect the front wheel bearings for proper adjustment. Refer to Front Hub and Disc Overhaul in Suspension section. 5. Inspect the ball joints and tie rod ends. If excessive looseness is noted, correct before adjusting. Refer to Steering Linkage in this section.

410RS001

2A–14 POWER–ASSISTED STEERING SYSTEM 1. Check and adjust the tire inflation pressures. 2. Park the vehicle on a level ground and move the front of the vehicle up and down several times to settle the suspension. 3. Make necessary adjustment with the adjusting bolt on the height control arms. Trim height: 119 ± 5 mm (4.69 ± 0.2 in)

NOTE: Difference of the caster shim front/rear thickness should be 3.6 mm (0.142 in) or less. Overall thickness of caster shim and camber shim should be 10.8 mm (0.425 in) or less. Tighten the fulcrum pin bolt to the specified torque. Torque: 152 N·m 112 ( lb ft)

Camber Adjustment

Caster Adjustment The caster angle can be adjusted by means of the caster shims (1) installed between the chassis frame (2) and fulcrum pins. Caster angle: 2°30’ ± 1°

The camber angle can be adjusted by means of the camber shims (2) installed in position between the chassis frame (1) and fulcrum pins Camber angle: 0° ± 30’ King pin inclination: 12°30’ ± 30’

CAUTION: Left and right side must be equal within 30’.

450RW007 450RW006

450RS005 450RS002

POWER–ASSISTED STEERING SYSTEM

2A–15

NOTE: Overall thickness of caster shim and camber shim should be 10.8 mm (0.425 in) or less. Tighten the fulcrum pin bolt to the specified torque. Torque: 152 N·m (112 lb ft) Position of shims

Caster shim

Camber angle

Caster angle

When removed

Decreases

When removed

When added

Increases

—

When removed

Unchanged

Decreases

—

When added

Unchanged

Increases

When added

Decreases

Unchanged

When removed

Increases

Unchanged

Front side

Rear side

When added

Camber shim

Toe-in Adjustment 1. To adjust the toe-in angle, loosen the lock nuts (2) on the tie rod (1) and turn the tie rod. Turn both rods the same amount, to keep the steering wheel centered . Toe-in: 0 to +2 mm (0 to +0.08 in)

433RW003

2. Tighten the lock nut to the specified torque. Torque: 98 N·m (72 lb ft)

2A–16 POWER–ASSISTED STEERING SYSTEM

Main Data and Specifications General Specification 2°30’ ± 1°

Caster

0° ± 30’

Camber

12°30’ ± 30’

King pin inclination Toe-in Max. steering angle

0 to +2 mm (0 to +0.08 in) inside outside

32.6° (+0°30’ to –2°30’ ) 31.8°

Torque Specification

E02RX001

POWER–ASSISTED STEERING SYSTEM

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

J–29877–A Tester; Power steering

J–39213 Adapter; Power steering tester

2A–17

2A–18 POWER–ASSISTED STEERING SYSTEM

Power Steering Unit Power Steering Unit and Associated Parts

440R100001

Legend (1) Bracket (2) Transfer Gear Assembly

(3) Universal Joint Assembly (4) Power Steering Unit Assembly (5) Crossmember

Removal 1. Remove the stone guard. 2. Remove the transfer gear assembly and universal joint assembly. Make a setting mark across the coupling flange and transfer gear assembly to ensure reassembly of the parts in the original position. 3. Drain power steering fluid. 4. Remove the tie rod end assembly from knuckle. Use tie rod end remover J–29107.

433RW002

2A–19

POWER–ASSISTED STEERING SYSTEM 5. Disconnect the feed line and return line from steering unit. Remove the clips on the crossmember and frame. Wire the power steering line to frame. NOTE: Take care to prevent foreign matter from entry when disconnect the power steering line.

6. Remove the power steering unit. 4×2 model: 1. Remove the crossmember.

power

steering

unit

from

the

Installation (4×2 Model) 1. Install power steering unit to crossmember. Tighten fixing bolt to specified torque. Torque: 116 N·m (85 lb ft) 2. Connect the feed line and return line. Torque: 25 N·m (18 lb ft) 3. Install tie–rod end assembly to knuckle. Torque: 118 N·m (87 lb ft) 4. a. Align the setting marks made at removal. Install the universal joint assembly to the transfer gear assembly. Temporary tighten the universal joint bolt. b. Install the universal joint assembly to the power steering unit assembly. Temporary tighten the universal joint bolt.

435RW001

4×4 model: 1. Remove the torsion bar. Refer to Front Suspension in Suspension section. 2. Remove the lower control arm bolt (Frame side). Refer to Front Suspension in Suspension section. 3. Apply a setting mark across the crossmember and frame so parts can be reassembled in their original position.

c. Install the transfer gear assembly with the shim to frame. Torque: 54 N·m (40 lb ft) d. Tighten the universal joint bolt to the specified torque. Torque: 31 N·m (23 lb ft) 5. Install the stone guard. 6. Bleed the system. Refer to Bleeding the Power Steering System in this section.

Installation (4×4 Model) 1. Install power steering unit to crossmember. Tighten fixing bolt to specified torque. Torque: 116 N·m (85 lb ft) 2. Install power steering unit with crossmember to frame by aligning the setting marks made when removing. Tighten crossmember mounting bolt to specified torque. Torque: 173 N·m (128 lb ft) 3. Install lower control arm bolt. Refer to Front Suspension in Suspension section. 4. Install torsion bar. Refer to Front Suspension in Suspension section. 431RX013

4. Remove the crossmember fixing bolt. 5. Remove the power steering unit crossmember.

with

the

5. Connect the feed line and return line. Torque: 25 N·m (18 lb ft) 6. Install tie–rod end assembly to knuckle. Torque: 118 N·m (87 lb ft)

2A–20 POWER–ASSISTED STEERING SYSTEM 7. a. Align the setting marks made at removal. Install the universal joint assembly to the transfer gear assembly. Temporary tighten the universal joint bolt.

8. Install the stone guard. 9. Bleed the system. Refer to Bleeding the Power Steering System in this section.

b. Install the universal joint assembly to the power steering unit assembly. Temporary tighten the universal joint bolt. c. Install the transfer gear assembly with the shim to frame. Torque: 54 N·m (40 lb ft) d. Tighten the universal joint bolt to the specified torque. Torque: 31 N·m (23 lb ft)

Power Steering Unit Disassembled View

440R100002

Legend (1) Tie-rod End (2) Lock Nut (3) Clip (4) Bellows (5) Band

(6) (7) (8) (9) (10) (11)

Tie-rod Assembly Tab Washer Oil Line Valve Housing Assembly Mounting Rubber Dust Cover

POWER–ASSISTED STEERING SYSTEM

Disassembly

2A–21

Reassembly

NOTE: The valve housing is made of aluminum and care should be exercised when clamping in a vise, etc. to prevent distortion or damage.

1. Install mounting rubber and dust cover (If removed). 2. Install oil line.

1. Loosen lock nut and remove tie–rod end. 2. Remove clip (3) and band (5), then remove bellows (4). 3. Remove tie-rod assembly. To remove, move the boot toward the tie-rod end, then remove tab washer.

3. Install tie-rod assembly with tab washer. Apply grease to ball joint, install tie-rod and tab washer, then tighten to specified torque.

4. Remove oil line, mounting rubber and dust cover.

Inspection and Repair Inspect the following parts for wear, damage or any abnormal conditions.

Tie-rod End If looseness or play is found when checked by moving the end of ball joint at tie-rod end, replace tie-rod end.

Tie-rod Assembly If the resistance is insufficient or play is felt when checked by moving the ball on the tie-rod, replace the tie-rod assembly.

Rubber Parts If wear or damage is found through inspection, replace with new ones.

Torque: 13 N· m (113 lb in)

Torque: 83 N·m (61 lb ft) After tightening, bend tab washer against width across flat of inner ball joint. 4. Apply a thin coat of grease to the shaft for smooth installation. Then install bellows. 5. Install band and clip. 6. Install tie-rod end and tighten lock nut. Torque: 98 N·m (72 lb ft)

2A–22 POWER–ASSISTED STEERING SYSTEM

Main Data and Specifications General Specifications Power Steering unit

Type

Rack and pinion

Rack stroke

152 mm (5.98 in)

Lock to lock

3.64

Torque Specifications

440R100003

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

J–29107 Tie rod end remover

POWER–ASSISTED STEERING SYSTEM

2A–23

Power Steering Pump Power Steering Pump and Associated Parts

436RX001

Legend (1) Pump Assembly (2) Hose, Suction

Removal 1. Remove the drive belt. 2. Place a drain pan below the pump. 3. Disconnect the suction hose. 4. Disconnect the flexible hose. 5. Remove the power steering fixing bolt and remove the pump assembly.

(3) Hose, Flexible (4) Bolt

Installation 1. Install the pump assembly to the pump braket, tighten the fixing bolt to the specified torque. Torque: 46 N·m (34 lb ft) 2. Install the flexible hose. Tighten the eye bolt to specified torque. Torque: 54 N·m (40 lb ft) 3. Install the drive belt. 4. Connect the suction hose, then fill and bleed system. Refer to Bleeding the Power Steering System in this section.

2A–24 POWER–ASSISTED STEERING SYSTEM

Power Steering Pump Disassembled View

442RX001

Legend (1) Bolt (2) Suction Pipe (3) O-ring (4) Shaft Assembly (5) Oil Seal (6) Front Housing (7) O-ring (8) O-ring (9) Side Plate (10) Rotor and Vane (11) Pin

Disassembly 1. Clean the oil pump with solvent (plug the discharge and suction ports to prevent the entry of solvent). Be careful not to expose the oil seal of shaft assembly to solvent. 2. Remove the bolt, suction pipe and O-ring. 3. Remove the connector, O-ring, relief valve and spring. 4. Remove the pressure switch assembly. 5. Remove the bolt, rear housing and O-ring. 6. Remove the snap ring.

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Cam Pump Cartridge Assembly O-ring Snap Ring Rear Housing Bolt Spring Relief Valve O-ring Connector Pressure Switch Assembly

7. Remove the shaft assembly. 8. Remove the oil seal. CAUTION: When removing the oil seal, be careful not to damage the housing. 9. Remove the pump cartridge assembly from the front housing. 10. Remove two O-rings.

POWER–ASSISTED STEERING SYSTEM

Inspection and Repair Make all necessary adjustments, repairs, and part replacements if wear, damage, or other problems are discovered during inspection.

Rotor

2A–25

Sliding faces of the vane should be free from wear. (Particularly the curved face at the tip that contact with the cam should be free from wear and distortion). When part replacement becomes necessary, the pump cartridge should be replaced as a subassembly.

Cam The inner face of the arm should have a uniform contact pattern without a sign of step wear. When part replacement becomes necessary, the pump cartridge should be replaced as a subassembly.

Side Plate The sliding faces of parts must be free from step wear (more than 0.01 mm), which can be felt by the finger nail. The parts with minor scores may be reused after lapping the face.

Relief Valve The sliding face of the valve must be free from burrs and damage. The parts with minor scores may be reused after smoothing with emery cloth (#800 or finer).

Shaft 442RS002

Check that the groove in the vane is free from excessive wear and that the vane slides smoothly. When part replacement becomes necessary, the pump cartridge should be replaced as a subassembly.

Vane

Oil seal sliding faces must be free from a step wear which can be felt by the finger nail. Bushing fitting face must be free from damage and wear.

O-ring, Oil Seal, Snap Ring Be sure to discard used parts, and always use new parts for installation. Prior to installation, lubricate all seals and rings with power steering fluid.

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

Reassembly 1. Install oil seal to front housing. Be sure to discard used oil seal, and always use new parts for installation.

442RS003

CAUTION: When installing the oil seal, be careful not to damage the oil seal contacting surface of the housing. 2. Install shaft assembly.

2A–26 POWER–ASSISTED STEERING SYSTEM 3. Install the vanes to roter with curved face in contact with the inner wall of cam.

442RS005

4. Install rotor and vanes to cam. 5. Install pin to front housing. 6. Install two new O-rings to front housing. Be sure to discard used O-ring. 7. Install side plate. CAUTION: When installing side plate, be careful not to damage its inner surface. Damaged side plate may cause poor pump performance, pump seizure or oil leakage. 8. Install pump cartridge assembly to front housing. 9. Install snap ring to shaft end. 10. Install rear housing with a new O-ring. Be sure to discard used O-ring. Then install bolt and tighten it to specified torque. Torque: 24 N·m (17 lb ft) 11. Install suction pipe with a new O-ring. Be sure to discard used O-ring. Then install bolt and tighten it to specified torque. Torque: 10 N·m (87 lb in) 12. Install relief valve and spring. 13. Install connector with a new O-ring. Be sure to discard used O-ring. Tighten the connector to specified torque. Torque: 59 N·m (43 lb ft) 14. Install pressure switch assembly and tighten it to specified torque. Torque: 18 N·m (13 lb ft)

POWER–ASSISTED STEERING SYSTEM

2A–27

Main Data and Specifications General Specifications Oil pump

Type Operating fluid

Vane ATF DEXRON–III

Torque Specifications

E02RX004

2A–28 POWER–ASSISTED STEERING SYSTEM

Transfer Gear Assembly Transfer Gear Assembly and Associated Parts

441R200001

Legend (1) Transfer Gear Assembly (2) Bolt, Universal Joint (Steering Shaft Side) (3) Fixing Bolt Nut

Removal 1. Apply a setting mark across the universal joint (steering shaft side) and transfer gear assembly to reassemble the parts in their original position. 2. Remove universal joint bolt (steering shaft side). 3. Apply a setting mark across the universal joint assembly and the transfer gear assembly to reassemble the parts in their original position. 4. Remove universal joint bolts (both of transfer gear assembly side and power steering unit assembly side). 5. Loosen fixing bolts and nut and remove transfer gear assembly with shim.

(4) Shim (5) Universal Joint Assembly (6) Bolt, Universal Joint (Steering Unit Side)

Installation 1. Install the transfer gear assembly to the universal joint (steering shaft side) align the setting marks made at removal. Then tighten the universal joint bolt. 2. Install the universal joint assembly to the power steering unit assembly align the setting marks made at removal. Then temporary tighten the universal joint bolt (both of transfer gear assembly side and power steering unit assembly side). 3. Install the transfer gear assembly with the shim to frame. Torque: 54 N·m (40 lb ft)

Inspection and Repair The transfer gear assembly cannot be disassembled. If damage or abnormal condition are found, replace the entire transfer gear assembly.

4. Tighten the universal joint bolts to the specified torque. Torque: 31 N·m (23 lb ft)

POWER–ASSISTED STEERING SYSTEM

2A–29

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

WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AN AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. TO AVOID DEPLOYMENT WHEN TROUBLESHOOTING THE SRS SYSTEM, DO NOT USE ELECTRICAL TEST EQUIPMENT, SUCH AS BATTERY-POWERED OR A/C-POWERED VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN SPECIFIED IN THIS MANUAL. DO NOT USE A NON-POWERED PROBE-TYPE TESTER. INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT.

SRS Connectors CAUTION: The special yellow color connectors are used for supplemental restraint system-air bag circuit. When removing the cable harness disconnect the connector by unlocking at two places, outside (1) and inside (2). Do not pull the wires or disconnection may occur. When connecting the double lock type SRS connector, insert the connector completely then lock the connector. Imperfect locking may cause the SRS circuit to malfunction.

2A–30 POWER–ASSISTED STEERING SYSTEM

Removal

Installation

To remove the connector, hold the cover insulator(1) and pull it. The cover insulator slides and lock will be released. Do not hold the socket insulator(2).

To install the connector, hold the soket insulator(1) and insert it. The cover insulator slides and connector will be locked. Do not hold the cover insulator(2).

827RW028 827RW027

POWER–ASSISTED STEERING SYSTEM

2A–31

Inflator Module Inflator Module and Associated Parts

827RW071

Legend (1) Horn Lead (2) SRS Connector

(3) Fixing Bolt (4) Inflator Module

Removal 1. Turn the steering wheel so that the vehicle’s wheels are pointing straight ahead. 2. Turn the ignition switch to “LOCK”. 3. Disconnect the battery “–” terminal cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column. 5. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly .

827RW070

2A–32 POWER–ASSISTED STEERING SYSTEM 6. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module.

The inflator module consists of a cover, air bag, inflator, and retainer. Inspect the inflator module mainly for the following: B Check for holes, cracks, severe blemishes and deformation on the cover. B Check that the retainer is not deformed. B Check for defects such as damage and breakage in the lead wire for the igniter. Replace the inflator module if a defect is found during inspection.

Installation 1. Install inflator module. 2. Support the module and carefully connect the module connector and horn lead. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 3. Tighten bolts to specified torque. 827RW073

7. Remove inflator module.

Inspection and Repair WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT .

827RW072

Torque: 9 N·m (78 lb in) 4. Connect the yellow 2-way SRS connector located under the steering column. 5. Connect the battery “–” terminal cable. 6. Set ignition to “ON” while watching warning light. Light should flash 7 times and then go off. If lamp does not operate correctly, refer to Restraints section.

POWER–ASSISTED STEERING SYSTEM

2A–33

Steering Wheel Steering Wheel and Associated Parts

827RW069

Legend (1) Horn Lead (2) SRS Connector

CAUTION: Once the steering column is removed from the vehicle, the column is extremely susceptible to damage. Dropping the column assembly on its end could collapse the steering shaft or loosen the slide block which maintains column rigidity. Leaning on the column assembly could cause the jacket to bend or deform. Any of the above damage could impair the column’s collapsible design. If it is necessary to remove the steering wheel, use only the specified steering wheel puller. Under no conditions should the end of the shaft be hammered upon, as hammering could loosen the slide block which maintains column rigidity.

(3) Steering Wheel (4) Steering Wheel Fixing Nut (5) Inflator Module

Removal 1. Turn the steering wheel so that the vehicle’s wheels are pointing straight ahead. 2. Turn the ignition switch to “LOCK”. 3. Disconnect the battery ground cable, and wait at least 5 minutes. 4. Disconnect the yellow 2-way SRS connector located under the steering column.

2A–34 POWER–ASSISTED STEERING SYSTEM 5. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly.

827RW070

6. Disconnect the yellow 2-way SRS connector located behind the inflator module. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT.

8. Remove steering wheel fixing nut. 9. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position, then remove steering wheel.

430RW021

10. Move the front wheels to the straight ahead position, then use steering wheel remover J–29752 to remove the steering wheel. CAUTION: Never apply force to the steering wheel shaft using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit.

430RX005

827RW073

7. Disconnect horn lead.

POWER–ASSISTED STEERING SYSTEM

Installation 1. Install steering wheel by aligning the setting marks made when removing. CAUTION: Never apply force to the steering wheel shaft using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 2. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 N·m (25 lb ft) 3. Connect horn lead. 4. Support the module and carefully connect the SRS connector. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinches. 5. Tighten bolts to specified torque. Torque: 9 N·m (78 lb in) 6. Connect the yellow 2-way SRS connector located under the steering column. 7. Connect the battery “–” terminal cable. 8. Turn the ignition switch to the “ON” position and observe the warning lamp. The lamp should flash 7 times. If the lamp does not operate correctly, refer to Restraints section.

2A–35

2A–36 POWER–ASSISTED STEERING SYSTEM

Combination Switch Combination Switch and Associated Parts

431R200003

Legend (1) Steering Column Cover (2) Steering Wheel (3) Inflator Module

(4) Combination Switch and SRS Coil Assembly (5) Instrument Panel Lower Cover (6) Driver Knee Bolster (reinforcement)

CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the “LOCK” position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the engine hood opening lever, then remove instrument panel lower cover. 6. Remove the driver knee bolster (reinforcement).

POWER–ASSISTED STEERING SYSTEM 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module, then remove inflator module.

2A–37

WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT.

827RW070

827RW072

8. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Move the front wheels to the straight ahead position, then use steering wheel remover J–29752 to remove the steering wheel.

827RW073

430RW021

2A–38 POWER–ASSISTED STEERING SYSTEM CAUTION: Never apply force to the steering wheel shaft using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit.

Installation 1. Install combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. Then turn the SRS coil counter clockwise to full, return about 3 turns and align the neutral mark. CAUTION: Turn the SRS coil counter clockwise until some resistance is felt, or damage may occur to the SRS coil.

430RX005

9. Remove steering column cover. 10. Disconnect the wiring harness connectors located under the steering column then remove combination switch and SRS coil assembly.

825RW016

825RW288

POWER–ASSISTED STEERING SYSTEM 2. When installing the steering column cover, be sure to route each wire harness as illustrated so that the harnesses do not catch on any moving parts.

825RW017

Legend (1) Steering Column Cover (2) Starter Switch Harness (3) Combination Switch Harness (4) Inflator Module Harness 3. Align the setting marks made when removing then install steering wheel. CAUTION: Never apply force to the steering wheel shaft using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 4. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 N·m (25 lb ft) 5. Support the inflator module and carefully connect the SRS connector and horn lead. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 6. Tighten bolts to specified torque. Torque: 9 N·m (78 lb in) 7. Install driver knee bolster (reinforcement). 8. Install instrument panel lower cover then Install the engine hood opening lever. 9. Connect the SRS connector. 10. Connect the battery “-” terminal cable. 11. Turn the ignition switch to the “ON” position and observe the warning lamp. The lamp should flash 7 times. If the lamp does not operate correctly, refer to Restraints section.

2A–39

2A–40 POWER–ASSISTED STEERING SYSTEM

Lock Cylinder Lock Cylinder and Associated Parts

431RX005

Legend (1) Inflator Module (2) Steering Wheel (3) Steering Column Cover (4) Combination Switch and SRS Coil Assembly (5) Snap Ring

(6) (7) (8) (9) (10)

Cushion Rubber Lock Cylinder Assembly Instrument Panel Lower Cover Driver Knee Bolster (reinforcement) Shift Lock Cable (for A/T)

CAUTION: The wheels of the vehicle must be straight ahead and the steering column in the ”LOCK” position before disconnecting the steering wheel. Failure to do so will cause the coil assembly to become uncentered which will cause damage to the coil assembly. 5. Remove the engine hood opening lever and steering lower cover. 6. Remove driver knee bolster (reinforcement).

2A–41

9. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position.

430RW021 827RW070

8. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module.

827RW073

430RX005

2A–42 POWER–ASSISTED STEERING SYSTEM WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT.

14. Remove snap ring. 15. Remove cushion rubber. 16. Remove shift lock cable (for A/T). 17. Disconnect the starter switch harness connector located under the steering column then remove lock cylinder assembly.

Installation 1. Install lock cylinder assembly. 2. Install shift lock cable (for A/T). 3. Install cushion rubber. 4. Install snap ring. 5. Install Combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column. 6. Turn the SRS coil counter clockwise to full, return about 3 turns and align the neutral mark. CAUTION: Turn the SRS coil counter clockwise until some resistance is felt, or damage may occur to the SRS coil.

827RW072

11. Remove steering column cover. 12. Disconnect the wiring harness connectors located under the steering column. 13. Remove the combination switch assembly with SRS coil.

825RW016

825RW288

POWER–ASSISTED STEERING SYSTEM 7. When installing the steering column cover, be sure to wire (through each harness) as illustrated so that the harnesses starter switch, combination switch and SRS coil may not catch wiring.

825RW017

Legend (1) Steering Column Cover (2) Starter Switch Harness (3) Combination Switch Harness (4) Inflator Module Harness 8. Install steering wheel by aligning the setting marks made during removal. CAUTION: Never apply force to the steering wheel shaft using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 9. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 N·m (25 lb ft) 10. Support inflator module and carefully connect the SRS connector and horn lead, then install inflator module. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 11. Tighten fixing bolts to specified torque. Torque: 9 N·m (78 lb in) 12. Install driver knee bolster (reinforcement). 13. Install instrument panel lower cover, then install the engine hood opening lever. 14. Connect the yellow 2-way SRS connector located under the steering column. 15. Connect the battery ground cable.

2A–43

System Inspection Turn the ignition switch to the “ON” position and observe the warning lamp. The lamp should flash 7 times. If the lamp does not operate correctly, refer to Restraints section.

2A–44 POWER–ASSISTED STEERING SYSTEM

Steering Column Steering Column and Associated Parts

431R200002

Legend (1) Inflator Module (2) Steering Wheel (3) Steering Column Cover (4) Combination Switch and SRS Coil Assembly (5) Snap Ring (6) Cushion Rubber

(7) (8) (9) (10) (11) (12)

Lock Cylinder Assembly Shift Lock Cable (For A/T) Steering Column Assembly Second Steering Shaft Instrument Panel Lower Cover Driver Knee Bolster (reinforcement)

4. Disconnect the yellow 2-way SRS connector located under the steering column. CAUTION: The wheel of the vehicle must be straight ahead and the steering column in the “LOCK” position before disconnecting the steering column from the steering gear. Failure to do so will cause the SRS coil assembly to become uncentered which will cause damage to the SRS coil assembly.

POWER–ASSISTED STEERING SYSTEM 5. Remove the engine hood opening lever, then remove instrument panel lower cover. 6. Remove driver knee bolster (reinforcement). 7. Loosen the inflator module fixing bolt from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly.

2A–45

10. Apply a setting mark (1) across the steering wheel and shaft so parts can be reassembled in their original position. Move the front wheels to the straight ahead position, then use steering wheel remover J–29752 to remove the steering wheel.

430RW021

827RW070

8. Disconnect the yellow 2-way SRS connector and horn lead located behind the inflator module. 9. Remove inflator module. WARNING: THE INFLATOR MODULE SHOULD ALWAYS BE CARRIED WITH THE TRIM COVER AWAY FROM YOUR BODY AND SHOULD ALWAYS BE LAID ON A FLAT SURFACE WITH THE URETHANE SIDE UP. THIS IS NECESSARY BECAUSE FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY MAY RESULT.

430RX005

11. Remove steering column cover. 12. Disconnect the wiring harness connectors located under the steering column.

827RW072

2A–46 POWER–ASSISTED STEERING SYSTEM 13. Remove the combination switch assembly with SRS coil.

Inspection If the abnormal conditions are found through inspection, replace the steering column assembly.

Column Capsule Check capsules on steering column bracket assembly; all must be securely seated in bracket slots and checked for any loose conditions when pushed or pulled by hand.

825RW288

14. Remove snap ring. 15. Remove cushion rubber. 16. Remove shift lock cable (For A/T). 17. Disconnect the starter switch harness connector located under the steering column, then remove lock cylinder assembly. 18. Apply a setting mark across the second steering shaft and transfer gear assembly to reassemble the parts in their original position, then remove the steering column assembly and second steering shaft.

431RW030

Check clearance between capsule and bracket. If must be within 1mm (0.039 in).

NOTE: A setting mark can be easily made if the shaft is withdrawn a little by loosening the steering shaft universal joint.

431RW031

431RW009

POWER–ASSISTED STEERING SYSTEM

2A–47

Column Tube

Shaft Length

Check for collapse by measuring the distance as shown in the figure. Standard distance: 162.2-165.8 mm (6.386-6.528 in)

Check the shaft length from the upper end of the slide joint to the end of the shaft. If column length is not in specifications, steering column should be replaced. Standard length: 291.7 – 295.7 mm (11.484 – 11.642 in)

431RY00010 431R200001

Column Universal Joint for Tilt Mechanism Check steering column assembly for any resistance by rotating the universal joint. If resistance is felt then replace the steering column assembly.

Shaft Universal Joint (Lower End)

Sheared Injected Plastic Pin

Shaft Bellows Pipe

Check the sheared injected plastic pins for any loose conditions or damage.

Use a straightedge to inspect the shaft bellows pipe for straightness. Replace if the clearance is more than the specifications. Standard: Less than 1mm (0.039 in)

If the resistance is felt when checked by rotate the joint, replace the steering column assembly.

431RY00011

431RW035

2A–48 POWER–ASSISTED STEERING SYSTEM

Tilt Mechanism Tilt mechanism should moves smoothly. While locked the tilt mechanism, be sure the steering column latch securely by pushing the steering wheel upward and downward.

11. Turn the SRS coil counter clockwise to full, return about 3 turns and align the neutral mark. CAUTION: Turn the SRS coil counter clockwise until a resistance is felt or damage to the SRS coil may occur from over turning.

Installation 1. Pass through the steering column assembly to the dash panel hole. Temporary tightening the steering column bolt(cross beam). 2. Tighten the steering column bolts(dash panel) to the specified torque. Torque: 20 N·m (14 lb ft) 3. Tighten the steering column nuts (cross beam) to the specified torque. Torque: 17 N·m (12 lb ft) 4. Install the universal joint assembly to the transfer gear assembly align the setting marks made at removal. Then tighten the universal joint bolt. Torque: 31 N·m (23 lb ft) 5. Install the second steering shaft to the universal joint assembly, then tighten the universal joint bolt to the specified torque.

825RW016

12. When installing the steering column cover, be sure to route each wire harness as illustrated so that the harnesses do not catch any moving parts.

Torque: 31 N·m (23 lb ft) 6. Install lock cylinder assembly. 7. Install shift lock cable (For A/T). 8. Install cushion rubber. 9. Install snap ring. 10. Install combination switch and SRS coil assembly. After installation of combination switch assembly, connect the combination switch wiring harness connector and the SRS 2-way connector located under the steering column.

825RW017

Legend (1) Steering Column Cover (2) Starter Switch Harness (3) Combination Switch Harness (4) Inflator Module Harness

POWER–ASSISTED STEERING SYSTEM 13. Install steering wheel and align the setting marks made when removing. CAUTION: Never apply force to the steering wheel shaft using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 14. Tighten the steering wheel fixing nut to the specified torque. Torque: 34 N·m (25 lb ft) 15. Support the module and carefully connect the module connector and horn lead, then install inflator module. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of inflator to prevent lead wire from being pinched. 16. Tighten bolts to specified torque. Torque: 9 N·m (78 lb in) 17. Install driver knee bolster (reinforcement). 18. Install instrument panel lower cover. 19. Install the engine hood opening lever. 20. Connect the yellow 2-way SRS connector and horn lead located under the steering column. 21. Connect the battery ground cable.

System Inspection Turn the ignition switch “ON” and observe if the warning lamp flashes 7 times. If the warning lamp does not operate correctly, refer to Restraints section.

2A–49

2A–50 POWER–ASSISTED STEERING SYSTEM

Supplemental Restraint System Steering Wheel & Column and Associated Parts Main Data and Specifications Torque Specifications

430RY00002

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

J–29752 Steering wheel remover

SECTION FRONT SUSPENSION

3C–1

AXIOM

SUSPENSION CONTENTS Front Suspension . . . . . . . . . . . . . . . . . . . . . . . Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . Wheel and Tire System . . . . . . . . . . . . . . . . . .

3C–1 3D–1 3E–1

Intelligent Suspension Control . . . . . . . . . . . .

3F–1

FRONT SUSPENSION CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer Bar and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torsion Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torsion Bar and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Knuckle and Associated Parts . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3C–1 3C–2 3C–2 3C–5 3C–5 3C–5 3C–5 3C–5 3C–6 3C–6 3C–6 3C–6 3C–6 3C–7 3C–7 3C–7 3C–8 3C–8 3C–10 3C–10 3C–10 3C–11 3C–11

Upper Control Arm . . . . . . . . . . . . . . . . . . . . . . Upper Control Arm and Associated Parts . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Control Arm . . . . . . . . . . . . . . . . . . . . . . Lower Control Arm and Associated Parts . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . Upper Ball Joint and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . Lower Ball Joint and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .

3C–13 3C–13 3C–13 3C–14 3C–14 3C–16 3C–16 3C–16 3C–17 3C–18 3C–19 3C–19 3C–19 3C–20 3C–20 3C–21 3C–21 3C–21 3C–22 3C–22 3C–23 3C–25

3C–2

FRONT SUSPENSION

General Description The front suspension is designed to allow each wheel to compensate for changes in the road surface level without greatly affecting the opposite wheel. Each wheel is independently connected to the frame by a steering knuckle, ball joint assemblies, and upper and lower control arms. The front wheels are held in proper relationship to each other by two tie-rods which are connected to steering arms on the knuckles, and to a steering unit. All models have a front suspension system consisting of control arms, stabilizer bar, shock absorber and a torsion bar. The front end of the torsion bar is attached to the lower control arm. The rear of the torsion bar is mounted into a height control arm at the crossmember. Vehicle trim height is controlled by adjusting this arm. Shock absorbers are mounted between the brackets on the frame and the lower control arms. The lower portion of

each shock absorber is attached to the lower control arm. The upper portion of each shock absorber extends through a frame bracket and is secured with two rubber bushings, two retainers and a nut. Ball joint assemblies are bolted to the outer end of the upper and lower control arm and are attached to the steering knuckle. The inner ends of the upper control arm have pressed in bushings. Bolts, passing through the bushing, attach the control arm to the frame. The inner ends of the lower control arm are attached to the frame by bolts passing through the bushings. Side roll of the front suspension is controlled by a spring steel stabilizer bar. It is mounted in rubber bushings, which are held to the frame by brackets. The ends of the stabilizer bar are connected to the lower control arms by links.

Diagnosis Condition Vehicle Pulls

Possible cause Mismatched or uneven tires.

Replace tire.

Tires not adequately inflated.

Adjust tire pressure.

Broken or sagging springs.

Replace spring.

Radial tire lateral force.

Replace tire.

Improper wheel alignment.

Adjust wheel alignment.

Brake dragging in one wheel.

Repair brake.

Loose, bent or broken front or rear suspension parts.

Tighten or replace the appropriate suspension part(s).

Faulty shock absorbers.

Replace shock absorber.

Parts in power defective. Abnormal or Excessive Tire Wear

Wheel Hop

Correction

steering

valve

Replace power steering unit.

Sagging or broken spring.

Replace spring.

Tire out of balance.

Balance or replace tire.

Improper wheel alignment.

Check front end alignment.

Faulty shock absorber.

Replace shock absorber.

Hard driving.

Replace tire.

Overloaded vehicle.

Replace tire and reduce load.

Tires not rotated periodically.

Replace or rotate tire.

Worn or loose road wheel bearings.

Replace wheel bearing.

Wobbly wheel or tires.

Replace wheel or tire.

Tires not adequately inflated.

Adjust the pressure.

Blister or bump on tire.

Replace tire.

Improper shock absorber operation.

Replace shock absorber.

FRONT SUSPENSION Condition Shimmy, Shake or Vibration

Hard Steering

Too Much Play In Steering

Possible cause

Correction

Tire or wheel out of balance.

Balance wheels or replace tire/or wheel.

Loose wheel bearings.

Replace wheel bearing.

Worn steering linkage ball joints.

Replace ball joints.

Worn upper or lower end ball joints.

Replace ball joints.

Excessive wheel runout.

Repair or replace wheel and/or tire.

Blister or bump on tire.

Replace tire.

Excessive loaded radial runout of tire/wheel assembly.

Replace tire or wheel.

Improper wheel alignment.

Check wheel alignment.

Loose or worn steering linkage.

Tighten or replace steering linkage.

Loose steering unit.

Tighten steering unit.

Tires not adequately inflated.

Adjust tire pressure.

Loose, bent or broken front or rear suspension parts.

Tighten or replace the appropriate suspension parts.

Faulty shock absorber.

Replace shock absorber.

Hub bearing preload misadjustment.

Adjust preload.

Parts in power defective.

Replace power steering unit.

steering

valve

Bind in steering linkage ball studs, upper or lower ball joint.

Replace ball joint.

Improper wheel alignment.

Check wheel alignment.

Tire not adequately inflated.

Inflate tires to proper pressure.

Bind in steering column or shaft.

Repair or replace.

Improper power steering system operation.

Repair or replace. Refer to Steering section.

Wheel bearings worn.

Replace wheel bearings.

Loose steering unit or linkage.

Retighten or repair.

Worn or loose universal joint.

Poor Steering Wheel Returnability

3C–3

steering

shaft

Retighten or replace steering shaft.

Worn steering linkage ball joints.

Replace ball joints.

Worn upper or lower end ball joints.

Replace ball joints.

Bind in steering linkage ball joints.

Replace ball joints.

Bind in upper or lower ball joints.

Replace ball joints.

Bind in steering column and shaft.

Repair or replace.

Bind in steering gear.

Check and repair steering gear.

Improper wheel alignment.

Adjust wheel alignment.

Tires not adequately inflated.

Adjust pressure.

Loose steering wheel nut.

Retighten.

Worn wheel bearing.

Replace.

3C–4

FRONT SUSPENSION Condition

Abnormal Noise

Wandering or Poor Steering Stability

Erratic Steering When Braking

Low or Uneven Trim Height

Suspension Bottoms

Body Leans

Cupped Tires

Possible cause

Correction

Worn, sticky or loose upper or lower ball joint, steering linkage ball joints or drive axle joints.

Replace.

Faulty shock absorbers.

Replace.

Worn upper or lower control arm bushing.

Replace.

Loose stabilizer bar.

Retighten bolts or replace bushings.

Loose wheel nuts.

Tighten nuts. Check for elongated wheel nut holes. Replace wheel if required.

Loose suspension bolts or nuts.

Retighten suspension bolts or nuts.

Broken or otherwise damaged wheel bearings.

Replace wheel bearing.

Broken suspension springs.

Replace spring.

Loose steering unit.

Retighten mounting bolt.

Faulty steering unit.

Replace steering unit.

Mismatched or unevenly worn tires.

Replace tire or inflate tires to proper pressure.

Loose steering linkage ball joints.

Replace ball joints.

Faulty shock absorbers.

Replace shock absorber.

Loose stabilizer bar.

Tighten or replace stabilizer bar or bushings.

Broken or sagging springs.

Replace spring (pairs).

Improper wheel alignment.

Adjust wheel alignment.

Worn wheel bearings.

Replace wheel bearings.

Broken or sagging springs.

Replace spring (pairs).

Leaking caliper.

Repair or replace caliper.

Warped discs.

Replace brake disc.

Badly worn brake pads.

Replace brake pads.

Tires are inflated unequally.

Inflate tires to proper pressure.

Broken or sagging springs.

Replace springs (In pairs).

Vehicle overloaded.

Reduce load.

Incorrect springs.

Adjust or replace torsion bar.

Vehicle overloaded.

Reduce load.

Faulty shock absorber.

Replace shock absorber.

Incorrect, broken or sagging springs.

Replace springs.

Loose stabilizer bar.

Tighten stabilizer bar bolts or replace bushings.

Faulty shock absorber, struts or mounting.

Replace shock absorber.

Broken or sagging springs.

Replace springs (In pairs).

Vehicle overloaded.

Reduce load.

Worn wheel bearings.

Replace wheel bearing.

Excessive tire or wheel run out.

Replace tire or wheel.

Worn ball joints.

Replace ball joints.

Tire out of balance.

Adjust tire balance.

FRONT SUSPENSION

3C–5

Shock Absorber Shock Absorber and Associated Parts

450R200001

Legend (1) Nut (2) Rubber Bushing and Washer (3) Bolt and Nut (4) Shock Absorber

Removal 1. Raise the vehicle and support it with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel Replacement in this section. 3. Remove bolt and nut. 4. Remove ISC Actuator and Bracket. Refer to Intelligent Suspension. 5. Remove nut. 6. Remove rubber bushing and washer. 7. Remove shock absorber. 8. Remove rubber bushing and washer.

Inspection and Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts :

(5) (6) (7) (8)

Rubber Bushing and Washer Actuator Bracket Actuator Screw

B Shock absorber B Rubber bushing

Installation 1. Install rubber bushing and washer. 2. Install shock absorber. 3. Install rubber bushing and washer. 4. Install nut, then tighten it to the specified torque. Torque: 20 N·m (14 lb ft) 5. Install ISC Actuator and Bracket. Refer to Intelligent Suspension. 6. Install bolt and nut, then tighten to the specified torque. Torque: 93 N·m (69 lb ft)

3C–6

FRONT SUSPENSION

Stabilizer Bar Stabilizer Bar and Associated Parts

410R200001

Legend (1) Rubber Bushing (2) Bracket and Bolt (3) Link

Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove the stone guard. 3. Remove wheel and tire assembly. Refer to Wheel Replacement in this section. 4. Remove nut. CAUTION: Be careful not to break the ball joint boot. 5. Remove link. 6. Remove bracket. 7. Remove stabilizer bar. 8. Remove rubber bushing.

Inspection and Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection.

(4) Nut (5) Stabilizer Bar (6) Washer

Check the following parts : B Stabilizer bar B Rubber bushing B Link ball joint

Installation 1. Install rubber bushing. 2. Install stabilizer bar. 3. Install bracket, then tighten it to the specified torque. Torque: 25 N·m (18 lb ft) 4. Install link and Washer. 5. Install nut, then tighten it to the specified torque. Torque: 50 N·m (37 lb ft)

FRONT SUSPENSION

3C–7

Torsion Bar Torsion Bar and Associated Parts

410RS003

Legend (1) Adjust Bolt, End Piece and Seat

(2) Height Control Arm (3) Torsion Bar

Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2. Apply the setting marks(1) to the adjust bolt and end piece, then remove adjust bolt, end piece and seat.

410RS004

3C–8

FRONT SUSPENSION

3. Apply the setting marks(2) to the height control arm and torsion bar, then remove height control arm.

Installation 1. Apply grease to the serrated portions, then install torsion bar. Make sure the bars are on their correct respective sides and align the setting marks(3).

410RS005

4. Apply the setting marks(3) to the torsion bar and lower control arm, then remove torsion bar. 410RS007

410RS006 410RS006

FRONT SUSPENSION 2. Apply grease to the portion that fits into the bracket then install height control arm and align the setting marks(2).

3C–9

4. Apply grease to the serrated portions. 5. Install adjust bolt and seat, then turn the adjust bolt to the setting mark(1) applied during disassembly. NOTE: Adjust the trim height. Refer to Front End Alignment Inspection and Adjustment in Steering section.

410RS005

3. Apply grease to the bolt portion of the end piece(4). Apply grease to the portion of the seat(5) that fits into the bracket.

410RS008

410RS004

3C–10

FRONT SUSPENSION

Knuckle Knuckle and Associated Parts

410RW006

Legend (1) Torsion Bar (2) Lower Ball Joint, Nut and Cotter Pin (3) Back Plate (4) Knuckle Assembly (5) Knuckle

Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel in this section. 3. Remove the brake caliper. Refer to Disc Brakes in Brake section.

(6) (7) (8) (9) (10)

Needle Bearing (4WD MODEL) Thrust Washer (4WD MODEL) Oil Seal (4WD MODEL) Upper Ball Joint, Nut and Cotter Pin Wheel Speed Sensor

4. Remove the hub assembly. Refer to Front Hub and Disk in this section. 5. Remove tie–rod end from the knuckle. Refer to Power Steering Unit in Steering section. 6. Remove the speed sensor from the knuckle. 7. Loosen torsion bar by height control arm adjust bolt, then remove torsion bar. Refer to Torsion Bar in this section. 8. Remove wheel speed sensor.

FRONT SUSPENSION 9. Remove back plate. 10. Remove lower ball joint by using remover J–29107.

3C–11

15. Remove needle bearing by using remover J–23907 (Except 2WD model).

CAUTION: Be careful not to damage the ball joint boot.

901RW044

901RW163

11. Remove upper ball joint by using remover J–36831. CAUTION: Be careful not to damage the ball joint boot.

Installation 1. Apply appropriate amount of multipurpose type grease to the new bearing (Approx. 5 g) and install needle bearing by using installer J–36838 and J–8092 (Except 2WD model).

901RW162

12. Remove knuckle assembly. 13. Remove oil seal (Except 2WD model). 14. Remove washer (Except 2WD model).

901RW045

3C–12

FRONT SUSPENSION

2. Apply multipurpose type grease to the thrust washer, and install washer with chamfered side facing knuckle (Except 2WD model). 3. Use a new oil seal, and apply multipurpose type grease to the area surrounded by the lip (approx. 2 g). Then use installer J–36837 and J–8092 to install oil seal. After fitting the oil seal to the installer, drive it to the knuckle using a hammer or bench press until the tool front face contacts with the thrust washer (Except 2WD model).

901RW167

4. Install knuckle assembly. 5. Install upper ball joint and tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 N·m (72 lb ft) 6. Install lower ball joint and tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 147 N·m (108 lb ft) 7. Install back plate. 8. Install wheel speed sensor. 9. Install torsion bar, refer to Torsion Bar in this section. NOTE: Adjust the trim height. Refer to Front End Alignment Inspection and Adjustment in Steering.

FRONT SUSPENSION

3C–13

Upper Control Arm Upper Control Arm and Associated Parts

450R200004

Legend (1) Bolt and Plate (2) Camber Shims (3) Caster Shims (4) Nut Assembly (5) Upper Control Arm Assembly (6) Fulcrum Pin

Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel in this section.

(7) (8) (9) (10) (11) (12)

Bushing Plate Nut Speed Sensor Cable Nut and Cotter Pin Upper Ball Joint

3. Remove the brake caliper and disconnect brake pipe. Refer to Disc Brakes in Brake section. 4. Support lower control arm with a jack. 5. Remove speed sensor cable. 6. Remove nut and cotter pin then use remover J–36831.

3C–14

FRONT SUSPENSION

CAUTION: Be careful not to damage the ball joint boot.

901RW160

16. Remove fulcrum pin. 901RW162

7. Remove upper ball joint. 8. Remove bolt and plate. 9. Remove nut assembly. 10. Remove camber shims and note the positions and number of shims. 11. Remove caster shims and note the positions and number of shims. 12. Remove upper control arm assembly. 13. Remove nut. 14. Remove plate. 15. Remove bushing by using remover J–29755.

Inspection and Repair Make necessary parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: B Upper control arm B Bushing B Fulcrum pin

Installation 1. Install fulcrum pin. 2. Install bushing by using installer J–29755 and J–39376.

901RW161

901RW164

FRONT SUSPENSION

901RW159

3. Install plate. 4. Install nut and tighten fulcrum pin nut finger–tight. NOTE: Torque fulcrum pin nut after adjusting buffer clearance.

3C–15

450RS013

Legend (1) Projection (2) Outward 6. Install the caster shims(2) between the chassis frame and fulcrum pin. 7. Install the camber shims(1) between the chassis frame and fulcrum pin.

Buffer clearance: 15 mm (0.59 in) Torque: 108 N·m (80 lb ft)

450R200002

5. Install upper control arm assembly with the fulcrum pin projections turned inward.

450RS014

8. Install nut assembly. 9. Install bolt and plate, then tighten the bolt to the specified torque. Torque: 152 N·m (112 lb ft) 10. Install upper ball joint and tighten it to the specified torque. Torque: 57 N·m (42 lb ft) 11. Install nut and cotter pin then tighten the nut to the specified torque, with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 N·m (72 lb ft) 12. Install speed sensor cable.

3C–16

FRONT SUSPENSION

Lower Control Arm Lower Control Arm and Associated Parts

450R200003

Legend (1) Nut, Front (2) Bush, Front (3) Bolt, Front (4) Nut, Rear (5) Bush, Rear (6) Bolt, Rear (7) Bolt, Lower Ball Joint

Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel in this section.

(8) (9) (10) (11) (12) (13) (14)

Bolt, Torsion Bar Arm Torsion Bar Arm Bracket and Nut Torsion Bar Lower Control Arm Lower Ball Joint and Nut Shock Absorber Stabilizer Link

3. Remove the tie-rod end from the knuckle. Refer to Power Steering Unit in Steering section. 4. Remove the retaining ring from the front axle driving shaft to release the shaft from hub(Except 2WD model). Refer to Front Hub and Disc in Driveline/Axle section. 5. Support lower control arm with a jack.

FRONT SUSPENSION 6. Remove front nut. 7. Remove rear nut. 8. Remove torsion bar, refer to Torsion Bar in this section. 9. Remove torsion bar arm bracket. 10. Disconnect the stabilizer link at the lower control arm. 11. Remove the shock absorber lower end from the lower control arm. 12. Remove the lower ball joint from the lower control arm. 13. Remove front bolt. 14. Remove rear bolt. 15. Remove lower control arm. 16. Remove torsion bar arm bolt. 17. Remove lower ball joint bolt. 18. Remove front bushing by using remover J–36833.

3C–17

19. Remove rear bushing by using remover J–36834.

901RW051

901RW154

901RW052

901RW155

3C–18

FRONT SUSPENSION 11. Install torsion bar arm bracket and tighten it to the specified torque.

Installation 1. Install rear bushing by using installer J–36834.

Torque: 116 N·m (85 lb ft) 12. Install Torsion bar, refer to Torsion Bar in this section. 13. Install rear nut and tighten lower link nut finger–tight. NOTE: Torque lower control arm nut after adjusting buffer clearance. Buffer clearance: 15 mm (0.59 in) Torque: 235 N·m (174 lb ft)

901RW053

2. Install front bushing by using installer J–36833.

450R200002

14. Install front nut then tighten lower link nut finger-tight. NOTE: Torque lower control arm nut after adjusting buffer clearance . Buffer clearance: 15 mm (0.59 in) Torque: 186 N·m (137 lb ft) NOTE: Adjust the trim height. Refer to Front End Alignment Inspection and Adjustment in Steering section.

901RW156

3. Install lower ball joint bolt. 4. Install torsion bar arm bolt. 5. Install lower control arm. 6. Install rear bolt. 7. Install front bolt. 8. Install lower ball joint and tighten it to the specified torque. Torque: 116 N·m (85 lb ft) 9. Install shock absorber and tighten it to the specified torque. Torque: 93 N·m (69 lb ft) 10. Install stabilizer link and tighten it to the specified torque. Torque: 50 N·m (37 lb ft)

450R200002

FRONT SUSPENSION

3C–19

Upper Ball Joint Upper Ball Joint and Associated Parts

450RW004

Legend (1) Bolt and Nut

Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove the speed sensor from the knuckle.

(2) Upper Ball Joint (3) Nut and Cotter Pin

3C–20

FRONT SUSPENSION

3. Remove upper ball joint nut and cotter pin, then use remover J–36831 to remove the upper ball joint from the knuckle.

B After moving the ball joint 4 or 5 times, attach nut then measure the preload. Starting torque: 0.5 –3.2 N·m (0.4–2.4 lb ft)

CAUTION: Be careful not to damage the ball joint boot.

450RS024

901RW162

4. Remove bolt and nut. 5. Remove upper ball joint.

If the above limits specified are exceeded, replace the ball joint assembly.

Installation

Inspection and Repair Make necessary parts replacement if wear, damage, corrosion or any other abnormal conditions are found through inspection. B Inspect the lower end boot for damage or grease leak. Move the ball joint as shown in the figure to confirm its normal movement. B Inspect screw/taper area of ball for damage. B If any defects are found by the above inspections, replace the ball joint assembly with a new one.

450RS023

1. Install upper ball joint. 2. Install bolt and nut, then tighten them to the specified torque. Torque: 57 N·m (42 lb ft) 3. Install nut and cotter pin, then tighten the nut to the specified torque with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 98 N·m (72 lb ft)

FRONT SUSPENSION

3C–21

Lower Ball Joint Lower Ball Joint and Associated Parts

450RW011

Legend (1) Bolt (2) Lower Ball Joint

(3) Nut (4) Nut and Cotter Pin

Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel in this section. 3. Remove the tie-rod end from the knuckle. Refer to Power Steering Unit in Steering section. 4. Remove the retaining ring from the front axle driving shaft to release the shaft from hub(Except 2WD model). Refer to Front Hub and Disc in Driveline/Axle section. 5. Support lower control arm with a jack. 6. Remove lower ball joint nut and cotter pin, then use remover J–29107 to remove the lower ball joint from the knuckle. CAUTION: Be careful not to damage the ball joint boot. 901RW163

3C–22

FRONT SUSPENSION

7. Remove nut. 8. Remove bolt. 9. Remove lower ball joint.

Installation 1. Install lower ball joint. 2. Install bolt. 3. Install nut and tighten it to the specified torque.

Inspection and Repair Make necessary parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. B Inspect the lower end boot for damage or grease leak. Move the ball joint as shown in the figure to confirm its normal movement . B Inspect screw/taper area of ball for damage. B If any defects are found by the above inspections, replace the ball joint assembly with a new one.

450RS026

B After moving the ball joint 4 or 5 times, attach nut the measure the preload. Starting torque: 0.5–6.4 N·m (0.4–4.7 lb ft)

450RS024

B If the above limits specified are exceeded, replace the ball joint assembly.

Torque: 116 N·m (85 lb ft) 4. Install ball joint nut, then tighten it to the specified torque with just enough additional torque to align cotter pin holes. Install new cotter pin. Torque: 147 N·m (108 lb ft)

FRONT SUSPENSION

Main Data and Specifications General Specifications Front suspension

Type

Torsion bar spring

Length

1142 mm (45.0 in)

Diameter

29.0 mm (1.14 in)

Front shock absorber

Stabilizer bar

Type

Independent wishbone arms, torsion bar spring with stabilizer bar.

Hydraulic, double acting, telescopic

Piston diameter

30.0 mm (1.18 in)

Stroke

115.0 mm (4.53 in)

Compressed length

255.0 mm (10.04 in)

Extended length

370.0 mm (14.57 in)

Diameter

25.0 mm (0.98 in)

3C–23

3C–24

FRONT SUSPENSION

Torque Specifications

E03R200003

FRONT SUSPENSION

3C–25

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

ILLUSTRATION

TOOL NO. TOOL NAME

J–23907 Remover;Needle bearing

J–36833 Remover and Installer kit; Lower arm front bushing

J–36838 Installer; Needle bearing

J–36834 Remover and Installer kit; Lower arm rear bushing

J–8092 Grip

J–36831 Ball joint remover

J–36837 Installer; Oil seal

J–29107 Tie-rod end remover

J–39376 Installer; Upper arm bushing

J–29775 Remover and Installer Upper arm bushing

SECTION REAR SUSPENSION

3D–1

AXIOM (Vehicles Produced Before July/31/2001)

SUSPENSION REAR SUSPENSION CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil Spring and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailing Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailing Link and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3D–1 3D–1 3D–2 3D–5 3D–5 3D–5 3D–6 3D–6 3D–7 3D–7 3D–7 3D–7 3D–7 3D–8 3D–8 3D–8 3D–8 3D–9

Upper Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upper Link and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lateral Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lateral Rod and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . Stabilizer Bar and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .

3D–10 3D–10 3D–10 3D–10 3D–11 3D–12 3D–12 3D–12 3D–12 3D–13 3D–14 3D–14 3D–14 3D–14 3D–15 3D–16 3D–18

Service Precaution

General Description

The rear suspension is a 5-link, coil spring type suspension with a stabilizer bar, consisting of two trailing links, two upper links, lateral rod, shock absorber, and stabilizer. In this suspension, the links are specially arranged to enable the rear axle to move freely, thereby expanding suspension stroke, reducing friction, and improving lateral rigidity and roll control. All these result in improved stability, riding comfort, and rough road maneuverability. Each link connects the axle housing with the frame through a runner bushing. The axle housing is supported by the trailing links and upper links longitudinally and by the lateral rod latitudinally.

3D–2

REAR SUSPENSION

Diagnosis Condition Vehicle Pulls

Possible cause Mismatched or uneven tires.

Replace tire.

Tires not adequately inflated.

Adjust tire pressure.

Broken or sagging springs.

Replace spring.

Radial tire lateral force.

Replace tire.

Improper wheel alignment.

Adjust wheel alignment.

Brake dragging in one wheel.

Repair brake.

Loose, bent or broken front or rear suspension parts.

Tighten or replace the appropriate suspension part(s).

Faulty shock absorbers.

Replace shock absorber.

Parts in power defective. Abnormal or Excessive Tire Wear

Wheel Hop Shimmy, Shake or Vibration

Correction

steering

valve

Replace power steering unit.

Sagging or broken spring.

Replace spring.

Tire out of balance.

Balance or replace tire.

Improper wheel alignment.

Check front end alignment.

Faulty shock absorber.

Replace shock absorber.

Hard driving.

Replace tire.

Overloaded vehicle.

Replace tire and reduce load.

Tires not rotated periodically.

Replace or rotate tire.

Worn or loose road wheel bearings.

Replace wheel bearing.

Wobbly wheel or tires.

Replace wheel or tire.

Tires not adequately inflated.

Adjust the pressure.

Blister or bump on tire.

Replace tire.

Improper shock absorber operation.

Replace shock absorber.

Tire or wheel out of balance.

Balance wheels or replace tire/or wheel.

Loose wheel bearings.

Replace wheel bearing.

Worn steering linkage ball joints.

Replace ball joints.

Worn upper or lower end ball joints.

Replace ball joints.

Excessive wheel runout.

Repair or replace wheel and/or tire.

Blister or bump on tire.

Replace tire.

Excessive loaded radial runout of tire/wheel assembly.

Replace tire or wheel.

Improper wheel alignment.

Check wheel alignment.

Loose or worn steering linkage.

Tighten or replace steering linkage.

Loose steering unit.

Tighten steering unit.

Tires not adequately inflated.

Adjust tire pressure.

Loose, bent or broken front or rear suspension parts.

Tighten or replace the appropriate suspension parts.

Faulty shock absorber.

Replace shock absorber.

Hub bearing preload misadjustment.

Adjust preload.

Parts in power defective.

Replace power steering unit.

steering

valve

REAR SUSPENSION Condition Hard Steering

Too Much Play In Steering

Possible cause

Abnormal Noise

Wandering or Poor Steering Stability

Correction

Bind in steering linkage ball studs, upper or lower ball joint.

Replace ball joint.

Improper wheel alignment.

Check wheel alignment.

Tire not adequately inflated.

Inflate tires to proper pressure.

Bind in steering column or shaft.

Repair or replace.

Improper power steering system operation.

Repair or replace. Refer to Steering section.

Wheel bearings worn.

Replace wheel bearings.

Loose steering unit or linkage.

Retighten or repair.

Worn or loose universal joint.

Poor Steering Wheel Returnability

3D–3

steering

shaft

Retighten or replace steering shaft.

Worn steering linkage ball joints.

Replace ball joints.

Worn upper or lower end ball joints.

Replace ball joints.

Bind in steering linkage ball joints.

Replace ball joints.

Bind in upper or lower ball joints.

Replace ball joints.

Bind in steering column and shaft.

Repair or replace.

Bind in steering gear.

Check and repair steering gear.

Improper wheel alignment.

Adjust wheel alignment.

Tires not adequately inflated.

Adjust pressure.

Loose steering wheel nut.

Retighten.

Worn wheel bearing.

Replace.

Worn, sticky or loose upper or lower ball joint, steering linkage ball joints or drive axle joints.

Replace.

Faulty shock absorbers.

Replace.

Worn upper or lower control arm bushing.

Replace.

Loose stabilizer bar.

Retighten bolts or replace bushings.

Loose wheel nuts.

Tighten nuts. Check for elongated wheel nut holes. Replace wheel if required.

Loose suspension bolts or nuts.

Retighten suspension bolts or nuts.

Broken or otherwise damaged wheel bearings.

Replace wheel bearing.

Broken suspension springs.

Replace spring.

Loose steering unit.

Retighten mounting bolt.

Faulty steering unit.

Replace steering unit.

Mismatched or unevenly worn tires.

Replace tire or inflate tires to proper pressure.

Loose steering linkage ball joints.

Replace ball joints.

Faulty shock absorbers.

Replace shock absorber.

Loose stabilizer bar.

Tighten or replace stabilizer bar or bushings.

Broken or sagging springs.

Replace spring (pairs).

Improper wheel alignment.

Adjust wheel alignment.

3D–4

REAR SUSPENSION Condition

Erratic Steering When Braking

Low or Uneven Trim Height

Suspension Bottoms

Body Leans

Cupped Tires

Possible cause

Correction

Worn wheel bearings.

Replace wheel bearings.

Broken or sagging springs.

Replace spring (In pairs).

Leaking caliper.

Repair or replace caliper.

Warped discs.

Replace brake disc.

Badly worn brake pads.

Replace brake pads.

Tires are inflated unequally.

Inflate tires to proper pressure.

Broken or sagging springs.

Replace springs (In pairs).

Vehicle overloaded.

Reduce load.

Incorrect springs.

Adjust or replace torsion bar.

Vehicle overloaded.

Reduce load.

Faulty shock absorber.

Replace shock absorber.

Incorrect, broken or sagging springs.

Replace springs.

Loose stabilizer bar.

Tighten stabilizer bar bolts or replace bushings.

Faulty shock absorber, struts or mounting.

Replace shock absorber.

Broken or sagging springs.

Replace springs (In pairs).

Vehicle overloaded.

Reduce load.

Worn wheel bearings.

Replace wheel bearing.

Excessive tire or wheel run out.

Replace tire or wheel.

Worn ball joints.

Replace ball joints.

Tire out of balance.

Adjust tire balance.

REAR SUSPENSION

3D–5

Coil Spring Coil Spring and Associated Parts

460R200001

Legend (1) Stabilizer Bar (2) Upper Link Fixing Bolt and Nut (3) Rubber Plate

Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2. Support the rear axle case with a jack. 3. Disconnect brake hose at the crossmember. 4. Remove breather hose. 5. Remove upper link fixing bolt, nut and rubber plate on the rear axle case (left-side only).

(4) (5) (6) (7)

Coil Spring Insulator Shock Absorber Breather Hose

6. Disconnect the stabilizer bar at the stabilizer link. 7. Remove the shock absorber from the axle case. 8. Remove spring insulator. 9. Remove the insulator and coil spring while lowering the rear axle case. CAUTION: Be sure not to let the brake hose, parking brake cable, and breather hose extend to their full length.

3D–6

REAR SUSPENSION

3. Install the insulator on the coil spring. Jack up the axle case gently with the top of the coil spring set to the spring seat on the frame side.

Installation 1. Install coil spring and make sure that the coil spring is installed in the proper position. Paint mark(1) should be downward.

460RW013

4. Install shock absorber and make sure that installed in the proper position. (Refer to Intelligent Suspension) Tighten the nut lightly, then retighten it to the specified torque after the vehicle is at curb height. NOTE: When mounting shock absorber, be sure not to use grease on bushings or any other nearby part. Torque: 78 N·m (58 lb ft) 5. Install stabilizer bar. 460RW001

2. Fit the end of the coil spring to the coil spring seat and mount the coil spring on the rear axle case.

Torque: 31 N·m (23 lb ft) 6. Install upper link with rubber plate and tighten fixing bolt. Torque: 137 N·m (101 lb ft) 7. Install breather hose. 8. Connect brake hose and bleed the brake system. Refer to Bleeding the Brake Hydraulic System in Brake section.

460RW004

REAR SUSPENSION

3D–7

Shock Absorber Shock Absorber and Associated Parts

461R200001

Legend (1) Nut, Bush and Washer

Removal 1. Remove shock absorber fixing nut, bush and washer (upper side). 2. Remove shock absorber fixing nut and washer (lower side). 3. Remove shock absorber.

Inspection and Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts: B Shock absorber B Rubber bushing NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part.

(2) Shock Absorber (3) Nut and Washer

Installation 1. Install shock absorber. When mounting shock absorber, make sure to be installed in the proper position and not to use grease on bushings or any other nearby part. (Refer to Intelligent Suspension) 2. Install nut and washer (lower side), then tighten the nut lightly. Retighten to the bolt and nut specified torque after the vehicle is at curb height. Torque: 78 N·m (58 lb ft) 3. Install nut, bush and washer (upper side), then tighten the nut lightly. Retighten to the nut specified torque after the vehicle is at curb height. Torque: 20 N·m (14 lb ft)

3D–8

REAR SUSPENSION

Trailing Link Trailing Link and Associated Parts

460RW005

Legend (1) Bolt and Nut (Axle side)

(2) Protector (Left side only) (3) Bolt (Frame side)

Removal 1. Remove the parking brake cable from the trailing link. 2. Remove the trailing link fixing bolt, nut and protector. 3. Remove trailing link.

Inspection and Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. 1. Trailing link 2. Rubber bushing B Remove the rubber bushing by using remover J–39214.

901RW058

REAR SUSPENSION B Install the rubber bushing by using installer J–39214. NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part.

901RW059

Installation 1. Install trailing link. Make sure that the trailing link is in its correct position. NOTE: When mounting trailing link, be sure not to use grease on bushings or any other nearby part.

460RW011

2. Install bolt, nut and protector. Tighten the bolts and nuts lightly, then retighten them to the specified torque after the vehicle is at curb height. Torque: 137 N·m (101 lb ft) 3. Install parking brake cable. CAUTION: The parking brake cable should not be overstrained or slackened.

3D–9

3D–10

REAR SUSPENSION

Upper Link Upper Link and Associated Parts

460RW006

Legend (1) Bolt and Nut (Axle side) (2) Rubber Plate

(3) Upper Link (4) Protector (Left side only) (5) Bolt (Frame side)

Removal 1. Remove fuel tank. Refer to Engine Fuel in Engine section. 2. Remove the speed sensor cable from the upper link. 3. Remove bolt, nut, rubber plate and protector. 4. Remove upper link.

Inspection and Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. 1. Upper link 2. Rubber bushing B Remove the rubber bushing by using remover J–43008. 460RY00006

REAR SUSPENSION B Install the rubber bushing by using to installer J–43008. NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part.

460RY00007

Installation 1. Install upper link. Make sure that the upper link is in its correct position. NOTE: When mounting upper link, be sure not to use grease bushings or any other nearby part.

460RW012

2. Install bolt, nut, rubber plate and protector. Tighten the bolts and nuts lightly, then retighten them to the specified torque after the vehicle is at curb height. Torque: 137 N·m (101 lb ft) 3. Install speed sensor cable. 4. Install fuel tank.

3D–11

3D–12

REAR SUSPENSION

Lateral Rod Lateral Rod and Associated Parts

460RW007

Legend (1) Bolt and Nut (Frame side)

(2) Lateral Rod (3) Nut and Washer (Axle side)

Removal 1. Remove nut and washer. 2. Remove bolt and nut. 3. Remove lateral rod.

Inspection and Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. 1. Lateral rod 2. Rubber bushing (Frame side) B Remove the rubber bushing (Frame side) by using remover J–39215.

901RW060

REAR SUSPENSION

3D–13

B Install the rubber bushing (Frame side) by using Installer J–39215. NOTE: When mounting rubber bushings, do not use grease on bushings or any other nearby parts.

901RW063

Installation 901RW061

3. Rubber bushing (Axle side) B Remove the rubber bushing (Axle side) by using remover J–39792.

1. Install lateral rod and make sure that the lateral rod is in its correct position. NOTE: When mounting lateral rod, be sure not to use grease on bushings or any other nearby part.

460RW008 901RW062

B Install the rubber bushing (Axle side) by using installer J–39792.

Legend (1) Frame Side (2) Axle Side 2. Install bolt and nut (Frame side). Tighten the bolt and nut lightly, then retighten them to the specified torque after the vehicle is at curb height. Torque: 137 N·m (101 lb ft) 3. Install nut and washer (Axle side). Tighten the nut lightly, then retighten the nut to the specified torque after the vehicle is at curb height. Torque: 78 N·m (58 lb ft)

3D–14

REAR SUSPENSION

Stabilizer Bar Stabilizer Bar and Associated Parts

460RW009

Legend (1) Bracket and Bolt (2) Link

Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel in this section. 3. Remove bolt and nut. 4. Remove link. 5. Remove bracket. 6. Remove rubber bushing.

(3) Bolt and Nut (4) Stabilizer Bar (5) Rubber Bushing

REAR SUSPENSION

Installation 1. Install rubber bushing. 2. Install bracket to axle housing and tighten to the specified torque. Torque: 25 N·m (19 lb ft) 3. Install link. 4. Install bolt and nut, then tighten the nut to the specified torque. Torque: 31 N·m (27 lb ft)

460RW010

3D–15

3D–16

REAR SUSPENSION

Main Data and Specifications General Specifications Rear suspension

Type

Coil spring

Free length

Shock absorber

Stabilizer bar

5–Link, coil spring type with stabilizer bar. 370.5 mm (14.59 in)

Spring diameter

12.4 mm (0.49 in)

Coil diameter (inner)

105 mm (4.13 in)

Effective No. of turns

5.21

Total No. of turns

6.71

Type

Hydraulic, double acting, telescopic

Piston diameter

30 mm (1.18 in)

Stroke

159 mm (6.26 in)

Extended length

518 mm (20.39 in)

Compressed length

359 mm (14.13 in)

Diameter

18 mm (0.71 in)

REAR SUSPENSION

3D–17

Torque Specifications

E03R200002

3D–18

REAR SUSPENSION

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

J–39214 Remover and Installer; Trailing link bushing

J–43008 Remover and Installer; Upper link bushing

J–39792 Remover and Installer; Lateral rod bushing (Axle side)

J–39215 Remover and Installer; Lateral rod bushing (Frame side)

REAR SUSPENSION

3D–19

AXIOM (Vehicles Produced After Aug./1/2001)

REAR SUSPENSION CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coil Spring and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . Shock Absorber and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailing Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailing Link and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3D–19 3D–19 3D–20 3D–23 3D–23 3D–23 3D–24 3D–24 3D–25 3D–25 3D–25 3D–25 3D–25 3D–26 3D–26 3D–26 3D–26 3D–27

3D–28 3D–28 3D–28 3D–28 3D–29 3D–30 3D–30 3D–30 3D–30 3D–31 3D–32 3D–32 3D–32 3D–32 3D–33 3D–34 3D–36

Service Precaution

General Description

3D–20

REAR SUSPENSION

Diagnosis Condition Vehicle Pulls

Possible cause Mismatched or uneven tires.

Replace tire.

Tires not adequately inflated.

Adjust tire pressure.

Broken or sagging springs.

Replace spring.

Radial tire lateral force.

Replace tire.

Improper wheel alignment.

Adjust wheel alignment.

Brake dragging in one wheel.

Repair brake.

Loose, bent or broken front or rear suspension parts.

Tighten or replace the appropriate suspension part(s).

Faulty shock absorbers.

Replace shock absorber.

Parts in power defective. Abnormal or Excessive Tire Wear

Wheel Hop Shimmy, Shake or Vibration

Correction

steering

valve

Replace power steering unit.

Sagging or broken spring.

Replace spring.

Tire out of balance.

Balance or replace tire.

Improper wheel alignment.

Check front end alignment.

Faulty shock absorber.

Replace shock absorber.

Hard driving.

Replace tire.

Overloaded vehicle.

Replace tire and reduce load.

Tires not rotated periodically.

Replace or rotate tire.

Worn or loose road wheel bearings.

Replace wheel bearing.

Wobbly wheel or tires.

Replace wheel or tire.

Tires not adequately inflated.

Adjust the pressure.

Blister or bump on tire.

Replace tire.

Improper shock absorber operation.

Replace shock absorber.

Tire or wheel out of balance.

Balance wheels or replace tire/or wheel.

Loose wheel bearings.

Replace wheel bearing.

Worn steering linkage ball joints.

Replace ball joints.

Worn upper or lower end ball joints.

Replace ball joints.

Excessive wheel runout.

Repair or replace wheel and/or tire.

Blister or bump on tire.

Replace tire.

Excessive loaded radial runout of tire/wheel assembly.

Replace tire or wheel.

Improper wheel alignment.

Check wheel alignment.

Loose or worn steering linkage.

Tighten or replace steering linkage.

Loose steering unit.

Tighten steering unit.

Tires not adequately inflated.

Adjust tire pressure.

Loose, bent or broken front or rear suspension parts.

Tighten or replace the appropriate suspension parts.

Faulty shock absorber.

Replace shock absorber.

Hub bearing preload misadjustment.

Adjust preload.

Parts in power defective.

Replace power steering unit.

steering

valve

REAR SUSPENSION Condition Hard Steering

Too Much Play In Steering

Possible cause

Abnormal Noise

Wandering or Poor Steering Stability

Correction

Bind in steering linkage ball studs, upper or lower ball joint.

Replace ball joint.

Improper wheel alignment.

Check wheel alignment.

Tire not adequately inflated.

Inflate tires to proper pressure.

Bind in steering column or shaft.

Repair or replace.

Improper power steering system operation.

Repair or replace. Refer to Steering section.

Wheel bearings worn.

Replace wheel bearings.

Loose steering unit or linkage.

Retighten or repair.

Worn or loose universal joint.

Poor Steering Wheel Returnability

3D–21

steering

shaft

Retighten or replace steering shaft.

Worn steering linkage ball joints.

Replace ball joints.

Worn upper or lower end ball joints.

Replace ball joints.

Bind in steering linkage ball joints.

Replace ball joints.

Bind in upper or lower ball joints.

Replace ball joints.

Bind in steering column and shaft.

Repair or replace.

Bind in steering gear.

Check and repair steering gear.

Improper wheel alignment.

Adjust wheel alignment.

Tires not adequately inflated.

Adjust pressure.

Loose steering wheel nut.

Retighten.

Worn wheel bearing.

Replace.

Misassemble Transfer Gear ASM

Reassemble Transfer Gear to proper portion

Worn, sticky or loose upper or lower ball joint, steering linkage ball joints or drive axle joints.

Replace.

Faulty shock absorbers.

Replace.

Worn upper or lower control arm bushing.

Replace.

Loose stabilizer bar.

Retighten bolts or replace bushings.

Loose wheel nuts.

Tighten nuts. Check for elongated wheel nut holes. Replace wheel if required.

Loose suspension bolts or nuts.

Retighten suspension bolts or nuts.

Broken or otherwise damaged wheel bearings.

Replace wheel bearing.

Broken suspension springs.

Replace spring.

Loose steering unit.

Retighten mounting bolt.

Faulty steering unit.

Replace steering unit.

Mismatched or unevenly worn tires.

Replace tire or inflate tires to proper pressure.

Loose steering linkage ball joints.

Replace ball joints.

Faulty shock absorbers.

Replace shock absorber.

Loose stabilizer bar.

Tighten or replace stabilizer bar or bushings.

Broken or sagging springs.

Replace spring (pairs).

Improper wheel alignment.

Adjust wheel alignment.

3D–22

REAR SUSPENSION Condition

Erratic Steering When Braking

Low or Uneven Trim Height

Suspension Bottoms

Body Leans

Cupped Tires

Possible cause

Correction

Worn wheel bearings.

Replace wheel bearings.

Broken or sagging springs.

Replace spring (pairs).

Leaking caliper.

Repair or replace caliper.

Warped discs.

Replace brake disc.

Badly worn brake pads.

Replace brake pads.

Tires are inflated unequally.

Inflate tires to proper pressure.

Broken or sagging springs.

Replace springs (In pairs).

Vehicle overloaded.

Reduce load.

Incorrect springs.

Adjust or replace torsion bar.

Trim Height out of spec

Adjust Trim height

Vehicle overloaded.

Reduce load.

Faulty shock absorber.

Replace shock absorber.

Incorrect, broken or sagging springs.

Replace springs.

Trim Height out of spec

Adjust Trim height

Loose stabilizer bar.

Tighten stabilizer bar bolts or replace bushings.

Faulty shock absorber, struts or mounting.

Replace shock absorber.

Broken or sagging springs.

Replace springs (In pairs).

Vehicle overloaded.

Reduce load.

Worn wheel bearings.

Replace wheel bearing.

Excessive tire or wheel run out.

Replace tire or wheel.

Worn ball joints.

Replace ball joints.

Tire out of balance.

Adjust tire balance.

REAR SUSPENSION

3D–23

Coil Spring Coil Spring and Associated Parts

460R200004

Legend (1) Stabilizer Bar (2) Upper Link Fixing Bolt and Nut (3) Rubber Plate

(4) (5) (6) (7)

Coil Spring Insulator Shock Absorber Breather Hose

3D–24

REAR SUSPENSION

3. Install the insulator on the coil spring. Jack up the axle case gently with the top of the coil spring set to the spring seat on the frame side.

Installation 1. Install coil spring and make sure that the coil spring is installed in the proper position. Paint mark(1) should be downward.

460RW013

4. Install shock absorber and tighten the nut lightly, then retighten it to the specified torque after the vehicle is at curb height. NOTE: When mounting shock absorber, be sure not to use grease on bushings or any other nearby part. Torque: 78 N·m (58 lb ft) 5. Install stabilizer bar at the stabilizer link. Torque: 31 N·m (23 lb ft) 460RW001

2. Fit the end of the coil spring to the coil spring seat and mount the coil spring on the rear axle case.

6. Install upper link with rubber plate and tighten fixing bolt. Torque: 137 N·m (101 lb ft) 7. Install breather hose. 8. Connect brake hose and bleed the brake system. Refer to Bleeding the Brake Hydraulic System in Brake section.

460RW004

REAR SUSPENSION

3D–25

Shock Absorber Shock Absorber and Associated Parts

461RW001

Legend (1) Nut, Bush and Washer

Removal 1. Remove shock absorber fixing nut, bush and washer (upper side). 2. Remove shock absorber fixing nut and washer (lower side). 3. Remove shock absorber.

(2) Shock Absorber (3) Nut and Washer

Installation 1. Install shock absorber. When mounting shock absorber, be sure not to use grease on bushings or any other nearby part. 2. Install nut and washer (lower side), then tighten the nut lightly. Retighten to the bolt and nut specified torque after the vehicle is at curb height. Torque: 78 N·m (58 lb ft) 3. Install nut, bush and washer (upper side), then tighten the nut lightly. Retighten to the nut specified torque after the vehicle is at curb height. Torque: 20 N·m (14 lb ft)

3D–26

REAR SUSPENSION

Trailing Link Trailing Link and Associated Parts

460RW005

Legend (1) Bolt and Nut (Axle side)

(2) Protector (Left side only) (3) Bolt (Frame side)

Removal 1. Remove the parking brake cable from the trailing link. 2. Remove the trailing link fixing bolt, nut and protector. 3. Remove trailing link.

901RW058

REAR SUSPENSION B Install the rubber bushing by using installer J–39214. NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part.

901RW059

Installation 1. Install trailing link. Make sure that the trailing link is in its correct position. NOTE: When mounting trailing link, be sure not to use grease on bushings or any other nearby part.

460RW011

3D–27

3D–28

REAR SUSPENSION

Upper Link Upper Link and Associated Parts

460RW006

Legend (1) Bolt and Nut (Axle side) (2) Rubber Plate

(3) Upper Link (4) Protector (Left side only) (5) Bolt (Frame side)

Removal 1. Remove fuel tank. Refer to Engine Fuel in Engine section. 2. Remove the speed sensor cable from the upper link. 3. Remove bolt, nut, rubber plate and protector. 4. Remove upper link.

REAR SUSPENSION B Install the rubber bushing by using to installer J–43008. NOTE: When mounting rubber bushings, be sure not to use grease on bushings or any other nearby part.

460RY00007

Installation 1. Install upper link. Make sure that the upper link is in its correct position. NOTE: When mounting upper link, be sure not to use grease bushings or any other nearby part.

460RW012

3D–29

3D–30

REAR SUSPENSION

Lateral Rod Lateral Rod and Associated Parts

460RW007

Legend (1) Bolt and Nut (Frame side)

(2) Lateral Rod (3) Nut and Washer (Axle side)

Removal 1. Remove nut and washer. 2. Remove bolt and nut. 3. Remove lateral rod.

901RW060

REAR SUSPENSION

3D–31

B Install the rubber bushing (Frame side) by using Installer J–39215. NOTE: When mounting rubber bushings, do not use grease on bushings or any other nearby parts.

901RW063

Installation 901RW061

3. Rubber bushing (Axle side) B Remove the rubber bushing (Axle side) by using remover J–39792.

1. Install lateral rod and make sure that the lateral rod is in its correct position. NOTE: When mounting lateral rod, be sure not to use grease on bushings or any other nearby part.

460RW008 901RW062

B Install the rubber bushing (Axle side) by using installer J–39792.

3D–32

REAR SUSPENSION

Stabilizer Bar Stabilizer Bar and Associated Parts

460R200003

Legend (1) Bracket and Bolt (2) Link

Removal 1. Raise the vehicle and support the frame with suitable safety stands. 2. Remove wheel and tire assembly. Refer to Wheel in this section. 3. Remove nut. 4. Remove link. 5. Remove bracket. 6. Remove rubber bushing.

(3) Nut (4) Stabilizer Bar (5) Rubber Bushing

REAR SUSPENSION

Installation 1. Install rubber bushing. 2. Install bracket to axle housing and tighten to the specified torque. Torque: 25 N·m (18 lb ft) 3. Install link. 4. Install nut, then tighten the nut to the specified torque. Torque: 50 N·m (37 lb ft)

460R200002

3D–33

3D–34

REAR SUSPENSION

Main Data and Specifications General Specifications Rear suspension

Type

Coil spring

Free length

Shock absorber

Stabilizer bar

5–Link, coil spring type with stabilizer bar. 370.5 mm (14.59 in)

Spring diameter

12.4 mm (0.49 in)

Coil diameter (inner)

105 mm (4.13 in)

Effective No. of turns

5.21

Total No. of turns

6.71

Type

Hydraulic, double acting, telescopic

Piston diameter

30 mm (1.18 in)

Stroke

159 mm (6.26 in)

Extended length

518 mm (20.39 in)

Compressed length

359 mm (14.13 in)

Diameter

18 mm (0.71 in)

REAR SUSPENSION

3D–35

Torque Specifications

E03R200006

3D–36

REAR SUSPENSION

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

J–39214 Remover and Installer; Trailing link bushing

J–43008 Remover and Installer; Upper link bushing

J–39792 Remover and Installer; Lateral rod bushing (Axle side)

J–39215 Remover and Installer; Lateral rod bushing (Frame side)

SECTION WHEEL AND TIRE SYSTEM

3E–1

AXIOM

SUSPENSION WHEEL AND TIRE SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel and Associated Parts . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3E–1 3E–2 3E–3 3E–11 3E–11 3E–11

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Replacement . . . . . . . . . . . . . . . . . . . . . . General Balance Procedure . . . . . . . . . . . . . . Balancing Wheel and Tire . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

3E–11 3E–12 3E–12 3E–12 3E–13 3E–14

3E–2

WHEEL AND TIRE SYSTEM

General Description

480R200001

Replacement wheels or tires must be equivalent to the originals in load capacity, specified dimension and mounting configuration. Improper size or type may affect bearing life, brake performance, speedometer/odometer calibration, vehicle ground clearance and tire clearance to the body and chassis. All models are equipped with metric sized tubeless steel belted radial tires. Correct tire pressures and driving habits have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp braking increase premature and uneven wear.

WHEEL AND TIRE SYSTEM

3E–3

Diagnosis Condition Vehicle Pulls

Possible cause Mismatched or uneven tires.

Replace tire.

Tires not adequately inflated.

Adjust tire pressure.

Broken or sagging springs.

Replace spring.

Radial tire lateral force.

Replace tire.

Improper wheel alignment.

Adjust wheel alignment.

Brake dragging in one wheel.

Repair brake.

Loose, bent or broken front or rear suspension parts.

Tighten or replace the appropriate suspension part(s).

Faulty shock absorbers.

Replace shock absorber.

Parts in power defective. Abnormal or Excessive Tire Wear

Wheel Hop Shimmy, Shake or Vibration

Correction

steering

valve

Replace power steering unit.

Sagging or broken spring.

Replace spring.

Tire out of balance.

Balance or replace tire.

Improper wheel alignment.

Check front end alignment.

Faulty shock absorber.

Replace shock absorber.

Hard driving.

Replace tire.

Overloaded vehicle.

Replace tire and reduce load.

Tires not rotated periodically.

Replace or rotate tire.

Worn or loose road wheel bearings.

Replace wheel bearing.

Wobbly wheel or tires.

Replace wheel or tire.

Tires not adequately inflated.

Adjust the pressure.

Blister or bump on tire.

Replace tire.

Improper shock absorber operation.

Replace shock absorber.

Tire or wheel out of balance.

Balance wheels or replace tire/or wheel.

Loose wheel bearings.

Replace wheel bearing.

Worn steering linkage ball joints.

Replace ball joints.

Worn upper or lower end ball joints.

Replace ball joints.

Excessive wheel runout.

Repair or replace wheel and/or tire.

Blister or bump on tire.

Replace tire.

Excessive loaded radial runout of tire/wheel assembly.

Replace tire or wheel.

Improper wheel alignment.

Check wheel alignment.

Loose or worn steering linkage.

Tighten or replace steering linkage.

Loose steering unit.

Tighten steering unit.

Tires not adequately inflated.

Adjust tire pressure.

Loose, bent or broken front or rear suspension parts.

Tighten or replace the appropriate suspension parts.

Faulty shock absorber.

Replace shock absorber.

Hub bearing preload misadjustment.

Adjust preload.

Parts in power defective.

Replace power steering unit.

steering

valve

3E–4

WHEEL AND TIRE SYSTEM Condition

Hard Steering

Too Much Play In Steering

Possible cause Bind in steering linkage ball studs, upper or lower ball joint.

Replace ball joint.

Improper wheel alignment.

Check wheel alignment.

Tire not adequately inflated.

Inflate tires to proper pressure.

Bind in steering column or shaft.

Repair or replace.

Improper power steering system operation.

Repair or replace. Refer to Steering section.

Wheel bearings worn.

Replace wheel bearings.

Loose steering unit or linkage.

Retighten or repair.

Worn or loose universal joint.

Poor Steering Wheel Returnability

Abnormal Noise

Wandering or Poor Steering Stability

Correction

steering

shaft

Retighten or replace steering shaft.

Worn steering linkage ball joints.

Replace ball joints.

Worn upper or lower end ball joints.

Replace ball joints.

Bind in steering linkage ball joints.

Replace ball joints.

Bind in upper or lower ball joints.

Replace ball joints.

Bind in steering column and shaft.

Repair or replace.

Bind in steering gear.

Check and repair steering gear.

Improper wheel alignment.

Adjust wheel alignment.

Tires not adequately inflated.

Adjust pressure.

Loose steering wheel nut.

Retighten.

Worn wheel bearing.

Replace.

Worn, sticky or loose upper or lower ball joint, steering linkage ball joints or drive axle joints.

Replace.

Faulty shock absorbers.

Replace.

Worn upper or lower control arm bushing.

Replace.

Loose stabilizer bar.

Retighten bolts or replace bushings.

Loose wheel nuts.

Tighten nuts. Check for elongated wheel nut holes. Replace wheel if required.

Loose suspension bolts or nuts.

Retighten suspension bolts or nuts.

Broken or otherwise damaged wheel bearings.

Replace wheel bearing.

Broken suspension springs.

Replace spring.

Loose steering unit.

Retighten mounting bolt.

Faulty steering unit.

Replace steering unit.

Mismatched or unevenly worn tires.

Replace tire or inflate tires to proper pressure.

Loose steering linkage ball joints.

Replace ball joints.

Faulty shock absorbers.

Replace shock absorber.

Loose stabilizer bar.

Tighten or replace stabilizer bar or bushings.

Broken or sagging springs.

Replace spring (pairs).

Improper wheel alignment.

Adjust wheel alignment.

WHEEL AND TIRE SYSTEM Condition Erratic Steering When Braking

Low or Uneven Trim Height

Suspension Bottoms

Body Leans

Cupped Tires

Possible cause

3E–5

Correction

Worn wheel bearings.

Replace wheel bearings.

Broken or sagging springs.

Replace spring (pairs).

Leaking caliper.

Repair or replace caliper.

Warped discs.

Replace brake disc.

Badly worn brake pads.

Replace brake pads.

Tires are inflated unequally.

Inflate tires to proper pressure.

Broken or sagging springs.

Replace springs (In pairs).

Vehicle overloaded.

Reduce load.

Incorrect springs.

Adjust or replace torsion bar.

Vehicle overloaded.

Reduce load.

Faulty shock absorber.

Replace shock absorber.

Incorrect, broken or sagging springs.

Replace springs.

Loose stabilizer bar.

Tighten stabilizer bar bolts or replace bushings.

Faulty shock absorber, struts or mounting.

Replace shock absorber.

Broken or sagging springs.

Replace springs (In pairs).

Vehicle overloaded.

Reduce load.

Worn wheel bearings.

Replace wheel bearing.

Excessive tire or wheel run out.

Replace tire or wheel.

Worn ball joints.

Replace ball joints.

Tire out of balance.

Adjust tire balance.

Irregular and Premature Wear

480RS001

Irregular and/or premature wear has many causes. Some of them are incorrect inflation pressures, lack of tire rotation, poor driving habits or improper wheel alignment. Incorrect inflation is common cause of tire premature wear.

NOTE: Due to their design, radial tires tend to wear faster in the shoulder area, particularly on the front tires. This makes regular rotation especially necessary. After rotation, be sure to check wheel nut torque, and set tire pressures.

3E–6

WHEEL AND TIRE SYSTEM

Tire Rotation Tire rotation is recommended to equalize wear for longer tire life.

indicators may appear as wide bands. When the indicators appear in two or more grooves at three locations, tire replacement is recommended.

Inflation of Tires

480RS002

Legend (1) Spare Tire

710RW002

If the following conditions are noted, rotate the tires: B Front tire wear is different from rear. B Uneven wear exists across the tread of any tire. B Left and right front tire wear is unequal. B Left and right rear tire wear is unequal. Check wheel alignment if the following conditions are noted: B Left and right front tire wear is unequal. B Wear is uneven across the tread of any front tire. B Front tire treads have a scuffed appearance with “feather” edges on one side of the tread ribs or blocks.

Tread Wear Indicators

480RS006

The original equipment tires have built-in tread wear indicators(1) to show when tires need replacement. These

Tire pressure, in cold condition (after vehicle has set for three hours or more, and driven less than one mile), should be checked monthly or before any extended trip. Tire pressure increases approximately 15% when the tires become hot during driving. Tire pressure specification is shown on the label located on the left door lock pillar. NOTE: Check the tire pressure whenever irregular wear is found. Tire inflation greatly affects tire wear. If the alignment check does not reveal any alignment problems, check the condition of the shock absorbers and wheel/tire balance.

Diagnosis List If the following conditions are noted, rotation is required. 1. Front tire wear is different from rear. 2. Uneven wear exists across the tread of any tire. 3. Left and right front tire wear is unequal. 4. Left and right rear tire wear is unequal. If the following conditions are noted, check the wheel alignment. 1. Left and right front tire wear is unequal. 2. Uneven wear exists across the tread of any tire. 3. Front tire treads have scuffed appearance with “feather” edges on one side of tread ribs or blocks. 4. There is cupping, flat spotting etc. Higher than recommended pressure can cause: 1. Hard ride. 2. Poor steering stability. 3. Rapid and uneven wear at center of the tread. Lower than recommended pressure can cause: 1. Tire squeal on turns. 2. Hard steering. 3. Rapid and uneven wear on the edges of the tread. 4. Tire rim bruises and rupture.

WHEEL AND TIRE SYSTEM 5. Tire cord breakage. 6. High tire temperatures. 7. Reduced handling. 8. Reduced fuel economy. Unequal pressure on same axle can cause: 1. Uneven braking. 2. Steering lead. 3. Reduced handling. 4. Swerve on acceleration.

3E–7

Radial Tire Lead/Pull “Lead/Pull” is vehicle deviation from a straight path, on a level road with no pressure on the steering wheel. Lead is usually caused by: 1. Poorly manufactured radial tires. 2. Uneven brake adjustment. 3. Wheel alignment. The way in which a tire is built can produce lead in a car. An example of this is placement of the belt. Off-center belts on radial tires can cause the tire to develop a side force while rolling straight down the road and the tire will tend to roll like a cone. The “Radial Tire Lead/Pull Correction” chart should be used to make sure that front wheel alignment is not mistaken for tire lead. Rear tires will not cause lead/pull.

Radial Tire Waddle

480R200006

Waddle is side-to-side movement at the front and/or rear of the car. It can be caused by the steel belt not being straight within the tire, or by excessive lateral runout of the tire or wheel. It is most noticeable at low speed, about 8 to 48 km/h (5 to 30 mph). It may also cause rough ride at 80 to 113 km/h (50 to 70 mph). The car can be road tested to see which end of the car has the faulty tire. If the tire causing the waddle is on the rear, the rear end of the car will “waddle”. From the driver’s seat, it feels as if someone is pushing on the side of the car. If the faulty tire is on the front, the waddle is more easily seen. The front sheet metal appears to be moving back and forth. It feels as if the driver’s seat is the pivot point in the car. Another more time-consuming method of determining the faulty tire is substituting tire and wheel assemblies that are known to be good. Follow these steps: 1. Drive the car to determine if the waddle is coming from the front or rear. 2. Install tire and wheel assemblies known to be good (from a similar car) in place of those on the end of the car which is waddling. If the waddle cannot be isolated to front or rear, start with the rear tires. 3. Road test again. If improvement is noted, install the original tire and wheel assemblies one at a time until the faulty tire is found. If no improvement is noted, install tires known to be good in place of all four. Then, install the originals one at a time until the faulty tire is found.

3E–8

WHEEL AND TIRE SYSTEM

Radial Tire Lead/Pull Correction Chart Step 1

Action

Switch front tires side to side and road test again. Was a problem corrected?

Did the vehicle lead in same direction?

Put tires back in original position and check alignment. Was a problem corrected?

End.

Go to Step 2

If roughness results,replace tires.

Go to Step 3

Go to Step 4

Go to Step 5

End.

Go to Step 5

Replace tire.

Install a known good tire in place of other front tire. If lead corrected, replace tire.

1. Inflate tires to recommended pressure. 2. Road test vehicle on level uncrowned road. Was a problem corrected?

Yes

Install known good tire on one front side. Was a problem corrected?

Typical examples of abnormal tire ahead wear and major causes:

Tread wear one-sided.

CAUTION: Similar wear patterns can be caused by worn suspension parts, misalignment of wheels and tires, and other suspension related problems. Spotty wear – wear localized on shoulder sections, and in an extreme cases, the tire becomes polygonal in shape.

480RW003

1. Rotating parts out of balance. 2. Tire or wheel out of round. 3. Hub or knuckle out of round or distorted.

480RW002

1. Tire or wheel out of round or distorted. 2. Hub or knuckle out of round or distorted. 3. Play in hub bearings or ball joint. 4. Rotating parts out of balance.

WHEEL AND TIRE SYSTEM Localized tread wear.

3E–9

Wear in shoulders at points opposed to each other.

480RW004

1. Once spotty wear develops in tread due to hard braking or abrupt starting, localized wear tends to be promoted. Shoulder wear (generally wear develops in outer shoulder):

480RW006

1. Tire or wheel out of round or distorted. 2. Play in bearings or ball joint. Premature wear in shoulders.

480RW007

1. Flexing of tire excessive due to under-inflation. 480RW005

1. Camber or toe-in incorrect. 2. Shoulder wear caused by repeated hard-cornering.

3E–10

WHEEL AND TIRE SYSTEM

One sided feather edging.

480RW008

1. Wear caused by repeated hard cornering. 2. Camber or toe-in incorrect.

WHEEL AND TIRE SYSTEM

3E–11

Wheel Wheel and Associated Parts

480R200004

Legend (1) Wheel Lug Nut (2) Alumi Wheel and Tire

Removal

NOTE: Valve caps should be on the valve stems to keep dust and water out.

1. Loosen wheel lug nut by approximately 180° (half a rotation), then raise the vehicle and remove the nuts. 2. Remove wheel and tire. NOTE: Never use heat to loosen a tight wheel lug nut. The application of heat to the hub can shorten the life of the wheel and may cause damage to wheel bearings.

Installation 1. Install wheel and tire. 2. Install wheel lug nut, and lower the vehicle. Tighten the wheel lug nuts to the specified torque in numerical order. Torque: 118 N·m (87 lb ft) CAUTION: Before installing wheels, remove any build-up of corrosion on the wheel mounting surface and brake disc mounting surface by scraping and wire brushing. Installing wheels without good metal-to-metal contact at mounting surfaces can cause wheel nuts to loosen, which can later allow a wheel to come off while the vehicle is moving.

480R200003

3E–12

WHEEL AND TIRE SYSTEM

Tire Tire Replacement

Wheel Inspection

When replacement is necessary, the original metric tire size should be used. Most metric tire sizes do not have exact corresponding alphanumeric tire sizes. It is recommended that new tires be installed in pairs on the same axle. If necessary to replace only one tire, it should be paired with tire having the most tread, to equalize braking traction.

Damaged wheels and wheels with excessive run-out must be replaced. Wheel run out at rim (Base on hub Bore): Aluminum 1– Vertical play: Less than 0.55 mm (0.022 in) 2– Horizontal play: Less than 0.55 mm (0.022 in)

CAUTION: Do not mix different types of tires such as radial, bias and bias-belted tires except in emergencies, because vehicle handling may be seriously affected and may result in loss of control.

Tire Dismounting Remove valve cap on valve step and deflate the tire. Then use a tire changing machine to mount or dismount tires. Follow the equipment manufacturer’s instruction. Do not use hand tools or tire lever alone to change tires as they may damage the tire beads or wheel rim.

Tire Mounting Rim bead seats should be cleaned with a wire brush or coarse steel wool to remove lubricants, and light rust. Before mounting a tire, the bead area should be well lubricated with an approved tire lubricant. After mounting, inflate the tire to 196kPa (28 psi) so that beads are completely seated. Inflate the air to specified pressure and install valve cap to the stem. WARNING: NEVER STAND OVER TIRE WHEN INFLATING. BEAD MAY BREAK WHEN BEAD SNAPS OVER RIM’S SAFETY HUMP AND CAUSE SERIOUS PERSONAL INJURY. NEVER EXCEED 240 KPA (35 PSI) PRESSURE WHEN INFLATING. IF 240 KPA (35 PSI) PRESSURE WILL NOT SEAT BEADS, DEFLATE, RE-LUBRICATE AND RE-INFLATE. OVER INFLATION MAY CAUSE THE BEAD TO BREAK AND CAUSE SERIOUS PERSONAL INJURY.

Tire Repair There are many different materials on the market used to repair tires. Manufacturers have published detailed instructions on how and when to repair tires. These instructions can be obtained from the tire manufacturer if they are not included with the repair kit.

480RS012

General Balance Procedure Deposits of mud, etc. must be cleaned from the inside of the rim. The tire should be inspected for the following: match mount paint marks, bent rims, bulges, irregular tire wear, proper wheel size and inflation pressure. Then balance according to the equipment manufacturer’s recommendations. There are two types of wheel and tire balance. Static balance is the equal distribution of weight around the wheel. Assemblies that are statically unbalanced cause a bouncing action called tramp. This condition will eventually cause uneven tire wear.

WHEEL AND TIRE SYSTEM

3E–13

Balancing Wheel and Tire On-vehicle Balancing On-Vehicle balancing methods vary with equipment and tool manufacturers. Be sure to follow each manufacturer’s instructions during balancing operation.

Off-vehicle Balancing Most electronic off-vehicle balancers are more accurate than the on-vehicle spin balancers. They are easy to use and give a dynamic balance. Although they do not correct for drum or disc unbalance (as on- vehicle spin balancing does), they are very accurate.

480RS013

Legend (1) Heavy Spot Wheel Shimmy (2) Add Balance Weights Here Dynamic balance is the equal distribution of weight on each side of the wheel center-line so that when the tire spins there is no tendency for the assembly to move from side to side. Assemblies that are dynamically unbalanced may cause shimmy.

480RS015

480RS014

Legend (1) Heavy Spot Wheel Hop (2) Add Balance Weights Here WARNING: STONES SHOULD BE REMOVED FROM THE TREAD TO AVOID OPERATOR INJURY DURING SPIN BALANCING AND TO OBTAIN A GOOD BALANCE.

3E–14

WHEEL AND TIRE SYSTEM

Main Data and Specifications General Specifications Wheels

Standard tire

Size

17 × 7JJ

Offset

38.0 mm (1.50 in)

P.C.D., wheel studs

139.7 mm (5.50 in)

Size

P235/65R17

Pressure(Front)

180 kPa (26 psi)

Pressure(Rear)

180 kPa (26 psi)

Torque Specifications

480R200005

SECTION INTELLIGENT SUSPENSION

3F–1

AXIOM

SUSPENSION INTELLIGENT SUSPENSION CONTROL CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . PIN ASSIGNMENT TABLE . . . . . . . . . . . . . System Components . . . . . . . . . . . . . . . . . . . Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustable Damping Force Shock Absorber Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . Vertical G-Sensor . . . . . . . . . . . . . . . . . . . . . . Lateral G-Sensor . . . . . . . . . . . . . . . . . . . . . . Acronyms and Abbreviations . . . . . . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . Service Precautions . . . . . . . . . . . . . . . . . . . Computer System Service Precautions . . . General Service Precautions . . . . . . . . . . . . Parts Handling . . . . . . . . . . . . . . . . . . . . . . . . FLASHING CODES . . . . . . . . . . . . . . . . . . . . CLEAR DTC . . . . . . . . . . . . . . . . . . . . . . . . . . INTERMITTENT CONDITIONS . . . . . . . . . BULB CHECK . . . . . . . . . . . . . . . . . . . . . . . . . DTC CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . Connector List . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Trouble Code (DTC) Identification . . . . . . . . . . . . . . . . . . . . . . . . . DTC2 Actuator Coil Over Current . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . DTC3 Actuator Coil/Position Sensor Open Circuit or Short . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . .

3F–2 3F–2 3F–4 3F–4 3F–4 3F–4 3F–4 3F–4 3F–5 3F–5 3F–5 3F–5 3F–5 3F–5 3F–5 3F–5 3F–5 3F–6 3F–7 3F–8 3F–8 3F–8 3F–14 3F–16 3F–17 3F–17 3F–17 3F–19 3F–19

Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . DTC4 G-Sensor Open Circuit or Short . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . DTC5 Vehicle Speed Sensor Open Circuit or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . DTC6 Stop Lamp Switch Open Circuit or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . DTC7 Engine Speed Signal Open Circuit or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . DTC9 Control Unit Abnormality . . . . . . . . . . . . Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Shock Absorber . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3F–19 3F–22 3F–22 3F–22 3F–23 3F–23 3F–23 3F–25 3F–25 3F–25 3F–27 3F–27 3F–27 3F–28 3F–32 3F–33 3F–33 3F–34 3F–35 3F–35 3F–35 3F–36 3F–37 3F–37 3F–37

3F–2

INTELLIGENT SUSPENSION

Service Precaution WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

General Description Intellignet suspension control uses a microcomputer as a control unit to judge running conditions including engine revolution from Powertrain Control Module, vehicle speed from vehicle speed sensor, a brake switch signal, and vertical and lateral G-sensor signal, then sets optimum damping force so that best running stability can be achieved.

INTELLIGENT SUSPENSION

3F–3

826R200007

3F–4

INTELLIGENT SUSPENSION

PIN ASSIGNMENT TABLE PIN No.

NAME

PIN No.

NAME

PIN No.

NAME

PIN No.

NAME

GND

KI-FR B

KI-RR PSW

STOP

KI-FR D

KI-RL Vcc

T-SW

Vdd

KI-FL B

KI-FR GND

M-SW

KI-FR A

KI-FL D

KI-FR Vs

Txd

KI-FR C

KI-RR B

KI-FL PSW

Vig

KI-FL A

KI-RR D

KI-FL Vs

KI-FL C

KI-RL B

KI-FL GND

G3 GND

KI-RR A

KI-RL D

KI-RR GND

G3 Vs

KI-RR C

Vig

KI-RL PSW

KI-RL A

GND

KI-RL GND

KI-RL C

KI-FR Vcc

M.L

E/G

Vbat

KI-FR Vout

G3 Vcc

W.L

GND

KI-FR PSW

G3 Vout

GND

KI-FL Vout

GND

KI-FL Vcc

Rxd

Vdd

KI-RR Vcc

VSP

GND

NC: NO CONNECTION

Warning Lamp

System Components Control Unit, 3 Vertical G-sensors, Lateral G-sensor, 4 Actuators, 4 Adjustable Damping Force Shock Absorbers, and Warning Lamp.

Control Unit The Control Unit consists of Adjustable Damping Force Shock Absorber control circuits, fault detector, and a fail-safe. It drives the actuator according to the signal from each sensor. The Control Unit has a self-diagnosing function which can indicate faulty circuits during diagnosis. The Control Unit is mounted in the center of the instrument panel.

Actuator Front actuators installed on front shock absorbers and rear actuator installed inside rear shock absorbers control damping force of shock absorber by the Control Unit signal.

Adjustable Damping Force Shock Absorber This type shock absorber is used in front and rear intelligent suspension. According to running condition the Control Unit changes shock absorber damping force and obtains good running stability.

821R200011

Vehicles equipped with the Intelligent Suspension Control have an amber warning lamp in the instrument panel. The warning lamp will illuminate if a malfunction in the Intelligent Suspension Control is detected by the Control Unit. In case of an important electronic malfunction, the Control Unit will turn“ON” the warning lamp.

INTELLIGENT SUSPENSION

Vertical G-Sensor

General Diagnosis

Front G-sensors installed inside front actuators and the rear G-sensor installed on the rear left frame side detect the vehicle vertical gravity and send a signal to the Control Unit.

General Information

Lateral G-Sensor The G-sensor installed inside the Control Unit detects the vehicle turning speed and sends a signal to the Control Unit.

Acronyms and Abbreviations Several acronyms and abbreviations are commonly used throughout this section: BATT Battery DLC Data Link Connector DTC Diagnostic Trouble Code FL Front Left FR Front Right GND Ground HARN Harness IG Ignition PCM Powertrain Control Module RL Rear Left RR Rear Right SW Switch W/L Warning Lamp Vout Voltage output

3F–5

Intelligent Suspension Control troubles can be classified into two types, those which can be detected by the warning lamp and those which can be detected as a vehicle abnormality by the driver. In either case, locate the fault in accordance with the“BASIC DIAGNOSTIC FLOWCHART” and repair. Please refer to Section 3 for the diagnosis of mechanical troubles such as abnormal noise, vehicle pulls, excessive tire wear, wheel hop and shimmy, shake or vibration.

Service Precautions Required Tools and Items: B Box Wrench B Special Tool Some diagnosis procedures in this section require the installation of a special tool. J-39200 High Impedance Multimeter When circuit measurements are requested, use a circuit tester with high impedance.

Computer System Service Precautions The Intelligent Suspension Control interfaces directly with the Control Unit which is a control computer that is similar in some regards to the Powertrain Control Module. These modules are designed to withstand normal current draws associated with vehicle operation. However care must be taken to avoid overloading any of the Control Unit circuits. In testing for opens or shorts, do not ground or apply voltage to any of the circuits unless instructed to do so by the appropriate diagnostic procedure. These circuits should only be tested with a high impedance multimeter (J-39200) or special tools as described in this section. Power should never be removed or applied to any control module with the ignition in the “ON” position.Before removing or connecting battery cables, fuses or connectors, always turn the ignition switch to the“OFF” position.

General Service Precautions The following are general precautions which should be observed when servicing and diagnosing the Intelligent Suspension Control and/or other vehicle systems. Failure to observe these precautions may result in Intelligent Suspension Control damage. B If welding work is to be performed on the vehicle using an electric arc welder, the Control Unit connectors should be disconnected before the welding operation begins. B The Control Unit connectors should never be connected or disconnected with the ignition“ON”.

Parts Handling Be careful when handling the actuator, control unit, or G-sensor. They should not be dropped or thrown, because the semi-conductor G-sensor tip damage may result.

3F–6

INTELLIGENT SUSPENSION

FLASHING CODES 1. ON BOARD DIAGNOSIS (SELF-DIAGNOSIS) 1. The Control Unit conducts a self-test of most of the wiring and components in the system each time the key is turned ON. If a fault is detected the Control Unit will store a Diagnostic Trouble Code (DTC) in memory. It’s a number that corresponds to a specific problem. 2. When the problem detected is important: the warning lamp turns on until the fault is repaired and the Control Unit memory is cleared. 2. DIAGNOSTIC TROUBLE CODES (DTC) 1. DTC can be expressed by flashing times of warning lamp by shorting together terminals 3 and 4 or 5 of the Diagnosis Connector (C-39) located left side of instrument panel.

350R200002

Normal

Abnormal

F03RY00001

F03R200001

Legend (1) Diagnostic Trouble Code 2 (2) Diagnostic Trouble Code 3

INTELLIGENT SUSPENSION It depends below in the case that the code that also, shows a malfunction place is added.

3F–7

2. After this, the warning lamp will be OFF for 3.5 seconds and then will flash each DTC. a. When there are more than 9 flashes this means that the indicator is constantly flashing, OFF for 4 seconds ON for 0.5 seconds. In this case there is no DTC stored in memory. b. When there are less than 9 flashes you will see DTC codes in ascending order.

CLEAR DTC

F03R200002

Legend (1) Diagnostic Trouble Code 2 (2) Diagnostic Trouble Code 3 + Position Code 2 Position Code 1: Actuator Front RH, G-sensor Front RH 2: Actuator Front LH, G-sensor Front LH 3: Actuator Rear RH, G-sensor Rear 4: Actuator Rear LH, Lateral G-sensor

Remark: If you clear the DTC (Diagnosis Trouble Codes) you will not be able to read any codes recorded during the last Trouble. Remark: To be able to use the DTC again to identify a problem you will need to reproduce the fault or the problem. This may require a new test drive or just turning the ignition on (this depends on the nature of the fault). 1. Short the Diagnosis Connector C-39 terminal 3 to terminal 4 or 5 (ground). B IF it is flashing and the flash is 0.5 seconds ON and 4 seconds OFF without interruption, this means that there is no DTC. The DTCs are already cleared.

350R200002

2. IF a code is flashed, wait until the lamp is flashing. 3. Conduct brake switch ON/OFF 6 or more times on condition that one operation is within 2 seconds.

3F–8

INTELLIGENT SUSPENSION

INTERMITTENT CONDITIONS

DTC CHECK

If the Warning Lamp flashes a diagnostic trouble code as intermittent, or if after a test drive a DTC does not reappear though the detection conditions for this DTC are present: the problem is most likely a faulty electrical connection or loose wiring. Terminals and grounds should always be the prime suspect. Intermittents rarely occur inside sophisticated electronic components such as the Control Unit. Use the DTC information to understand which wires and sensors are involved. When an intermittent problem is encountered, check suspect circuits for: 1. Poor terminal to wire connection. 2. Terminals not fully seated in the connector body (backed out). 3. Improperly formed or damaged terminals. 4. Loose, dirty, or corroded ground connections: HINT: Any time you have an intermittent in more than one circuit, check whether the circuits share a common ground connection. 5. Pinched or damaged wires. 6. Electro-Magnetic Interference (EMI): HINT: Check that all wires are properly routed away from spark plug wires, distributor wires, coil, and generator. Also check for improperly installed electrical options, such as lights, 2-way radios, etc.

BULB CHECK When the starter switch is turned on in the normal state, the Control Unit turns on the Warning Lamp to check the bulb. After the engine starts, the Warning Lamp turns off.

F03RY00003

1. Diagnosis Trouble Codes (DTC) have been identified by FLASHING CODES. 2. You have written the list of the DTC. The order of the malfunctions has no meanings for this Control Unit. Usually only one or two malfunctions should be set for a given problem. 3. Check directly the DTCs you identified. The DTC are sorted by number: DIAGNOSTIC TROUBLE CODES.

INTELLIGENT SUSPENSION

3F–9

Basic Diagnosis Flow

C07RY00022

3F–10

INTELLIGENT SUSPENSION

Circuit Diagram

826R200008

INTELLIGENT SUSPENSION

3F–11

826R200009

3F–12

INTELLIGENT SUSPENSION

826R200010

INTELLIGENT SUSPENSION

3F–13

Parts Location

810R200001

Legend (1) C–9 (2) C–8 (3) H–8, H–11, H–14 (4) I–24, I–23 , I–22 (5) I–31 (6) F–7 (7) C–39 (8) F–8 (9) F–6 (10) H–19

(11) (12) (13) (14) (15) (16) (17) (18) (19) (20)

H–9, H–10 C–30 C–31 H–5, H–6 C–26 E–34, E–35 C–46, C–45, C–44 I–10 E–23 C–10

3F–14

INTELLIGENT SUSPENSION

Connector List No.

Connector face

No.

C–8

C–46

C–9

E–23

C–10

E–34

C–26

E–35

C–30

F–6

C–31

F–7

C–39

F–8

C–44

H–5

C–45

H–6

Connector face

INTELLIGENT SUSPENSION No.

Connector face

No.

H–8

I–24

H–9

I–31

H–10

H–11

H–14

H–19

I–10

I–22

I–23

Connector face

3F–15

3F–16

INTELLIGENT SUSPENSION

Diagnostic Trouble Code (DTC) Identification DTC No.

DTC NAME

CODE MEMORY

WARNING LAMP

Actuator Coil Over Current

Yes

OFF

Actuator Coil/Position Sensor Open Circuit or Short

Yes

G–Sensor Open Circuit or Short

Yes

Vehicle Speed Sensor Open Circuit or Short

Yes

OFF

Stop Lamp Switch Open Circuit, Short or Contact Point Trouble

Yes

OFF

Engine Speed Signal Open Circuit or Short

Yes

OFF

Control Unit Abnormality

Yes

OFF

INTELLIGENT SUSPENSION

3F–17

DTC2 Actuator Coil Over Current Circuit Description

Diagnostic Aids

B Inspect the wiring for poor electrical connections between the control unit 24 way connector and the actuator connectors. Look for possible bent, backed out, deformed, or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.

DTC2 Actuator Coil Over Current Step

Action

Go to Step 4

Go to Step 3

—

Go to Step 4

—

6.4–7.2W

Go to Step 5

Go to Step 6

6.4–7.2W

Go to Step 7

Go to Step 6

—

Go to Step 7

—

6.4–7.2W

Go to Step 8

Go to Step 9

6.4–7.2W

Go to Step 10

Go to Step 9

—

Go to Step 10

—

6.4–7.2W

Go to Step 11

Go to Step 12

6.4–7.2W

Go to Step 13

Go to Step 12

1. Measure the resistance between the shock absorber side connector F–7 terminals 3 and 4. 1. Measure the resistance between the shock absorber side connector F–7 terminals 7 and 8. Replace the rear shock absorber RR. 1. Measure the resistance between the shock absorber side connector F–8 terminals 3 and 4. Is the resistance within the specified value?

6.4– 7.2W

Replace the actuator FL.

Is the resistance within the specified value? 9

Go to Step 3

1. Measure the resistance between the actuator side connector C–31 terminals 3 and 4.

Is the resistance within the specified value? 8

Go to Step 2

1. Measure the resistance between the actuator side connector C–31 terminals 1 and 2.

Is the resistance within the specified value? 6

6.4– 7.2W

Replace the actuator FR.

Is the resistance within the specified value? 5

1. Measure the resistance between the actuator side connector C–9 terminals 3 and 4. Is the resistance within the specified value?

Yes

1. Turn off the starter switch. 2. Disconnect the actuator connectors C–31, C–9, F–8, and F–7. 3. Measure the resistance between the actuator side connector C–9 terminals 1 and 2. Is the resistance within the specified value?

Value(s)

1. Measure the resistance between the shock absorber side connector F–8 terminals 7 and 8. Is the resistance within the specified value?

3F–18

INTELLIGENT SUSPENSION

DTC2 Actuator Coil Over Current (Cont’d) Step

12 13

Action

15 16

Yes

Replace the rear shock absorber RL. —

Go to Step 16

—

Go to Step 15

Go to Step 14

—

Go to Step 16

—

Go to Step 16

—

Go to “Basic Diagnosis Flow”.

Go to Step 16

If all steps are correct, check the continuity between the control unit connector C–46 terminal 1 and connector terminal C46–4, C46–17, C46–5, C46–18, C46–6, C46–19, C46–7, C46–20, C46–8, C46–21, C46–9, C46–22, C46–10, C46–23, C46–11, and C46–24. Is there continuity?

Value(s)

Repair the circuit. Replace the control unit. 1. Reconnect all components, ensure all components are properly mounted. 2. Clear the DTC. Was this step finished?

INTELLIGENT SUSPENSION

3F–19

DTC3 Actuator Coil/Position Sensor Open Circuit or Short Circuit Description

Diagnostic Aids

The A, B, C, and D are the actuator motor coil terminals. DC 12V driving voltage is applied between terminals A and C and terminals B and D so that the shock absorber oil valves are rotated at every 7.5° step feed. The PSW is actuator position signal and detects relative angles between the piston–rod and the control-rod. The actuator outputs the PSW to the control unit.

B Inspect the wiring for poor electrical connections between the control unit 16 way connector and the actuator connectors. Look for possible bent, backed out, deformed, or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.

DTC3 Actuator Coil/Position Sensor Open Circuit or Short Step

2 3 4 5 6 7 8 9 10 11 12 13 14 15

Action

Value(s)

Yes

1. Turn off the starter switch. 2. Disconnect the actuator connectors C–46, C–31, C–9, F–8, and F–7. Is there continuity between the connector C–9 terminals 1 and 2?

—

Go to Step 2

Go to Step 3

Is there continuity between the connector C–9 terminals 3 and 4?

—

Go to Step 4

Go to Step 3

—

Go to Step 4

—

Is there continuity between the connector C–31 terminals 1 and 2?

—

Go to Step 5

Go to Step 6

Is there continuity between the connector C–31 terminals 3 and 4?

—

Go to Step 7

Go to Step 6

—

Go to Step 7

—

Is there continuity between the connector F–7 terminals 3 and 4?

—

Go to Step 8

Go to Step 9

Is there continuity between the connector F–7 terminals 7 and 8?

—

Go to Step 10

Go to Step 9

—

Go to Step 10

—

Is there continuity between the connector F–8 terminals 3 and 4?

—

Go to Step 11

Go to Step 12

Is there continuity between the connector F–8 terminals 7 and 8?

—

Go to Step 13

—

Go to Step 13

—

Is there continuity between the connector C–9 terminal 1 and connector C–46 terminal 4?

—

Go to Step 14

Go to Step 15

Is there continuity between the connector C–9 terminal 3 and connector C–46 terminal 17?

—

Go to Step 16

Go to Step 15

—

Go to Step 16

—

Replace the actuator FR.

Replace the actuator FL.

Replace the rear shock absorber RR.

Replace the rear shock absorber RL.

Repair the circuit.

3F–20

INTELLIGENT SUSPENSION

DTC3 Actuator Coil/Position Sensor Open Circuit or Short (Cont’d) Step

Action

Value(s)

Is there continuity between the connector C–9 terminal 2 and connector C–46 terminal 5?

—

Go to Step 17

Go to Step 18

Is there continuity between the connector C–9 terminals 4 and connector C–46 terminal 18?

—

Go to Step 19

Go to Step 18

—

Go to Step 19

—

Is there continuity between the connector C–31 terminal 1 and connector C–46 terminal 6?

—

Go to Step 20

Go to Step 21

Is there continuity between the connector C–31 terminal 3 and connector C–46 terminal 19?

—

Go to Step 22

Go to Step 21

—

Go to Step 22

—

Is there continuity between the connector C–31 terminal 2 and connector C–46 terminal 7?

—

Go to Step 23

Go to Step 24

Is there continuity between the connector C–31 terminal 4 and connector C–46 terminal 20?

—

Go to Step 25

Go to Step 24

—

Go to Step 25

—

Is there continuity between the connector F–7 terminal 4 and connector C–46 terminal 8?

—

Go to Step 26

Go to Step 27

Is there continuity between the connector F–7 terminal 8 and connector C–46 terminal 21?

—

Go to Step 28

Go to Step 27

—

Go to Step 28

—

Is there continuity between the connector F–7 terminal 3 and connector C–46 terminal 9?

—

Go to Step 29

Go to Step 30

Is there continuity between the connector F–7 terminal 7 and connector C–46 terminal 22?

—

Go to Step 31

Go to Step 30

—

Go to Step 31

—

Is there continuity between the connector F–8 terminal 4 and connector C–46 terminal 10?

—

Go to Step 32

Go to Step 33

Is there continuity between the connector F–8 terminal 8 and connector C–46 terminal 23?

—

Go to Step 34

Go to Step 33

—

Go to Step 34

—

Is there continuity between the connector F–8 terminal 3 and connector C–46 terminal 11?

—

Go to Step 35

Go to Step 36

Is there continuity between the connector F–8 terminal 7 and connector C–46 terminal 24?

—

Go to Step 37

Go to Step 36

—

Go to Step 37

—

Go to Step 38

Go to Step 41

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

Yes

Repair the circuit.

Repair the circuit. 1. Disconnect the terminals C–45, C–8, C–30, F–7, and F–8. Is there continuity between the connector–terminal C45–29 and C8–6, C45–37 and C30–6, C45–33 and F7–2, C45–41 and F8–2?

INTELLIGENT SUSPENSION

3F–21

DTC3 Actuator Coil/Position Sensor Open Circuit or Short (Cont’d) Step

Action

Value(s)

Is there continuity between the connector C–46 terminal 1 (GND) and the connector C–45 terminals 29, 33, 37, and 41?

—

Go to Step 41

Go to Step 39

Is there the continuity between connector-terminal C45–27 and C45–35, C45–31 and C45–39, C45–32 and C45–40, and C45–34 and C45–42?

—

Go to Step 41

Go to Step 40

Is there the continuity between connector C–46 terminal 1 and connector C–45 terminals 27, 31, 32, and 34?

—

Go to Step 41

Go to Step 42

—

Go to Step 44

—

Go to Step 43

Go to Step 44

—

Go to Step 44

—

Go to “Basic Diagnosis Flow”.

Go to Step 44

41 42

Repair the circuit. 1. If all steps are correct, replace following units one by one in the following order. Give a test drive and if normal, reinstall it. 1) actuator FR, 2) actuator FL, rear shock absorber, 3) RR and 4) RL. Does the DTC3 remain?

Yes

Replace the control unit. 1. Reconnect all components, ensure all components are properly mounted. 2. Clear the DTC. Was this step finished?

3F–22

INTELLIGENT SUSPENSION

DTC4 G-Sensor Open Circuit or Short Circuit Description

Diagnostic Aids

The G-sensor sends the voltage (Vout) corresponding to the vehicle vertical gravity to the control unit. The control unit supplies DC 5V power (Vcc) to each G-sensor. The control unit watches the G-sensor operation through Vcc signal.

B Inspect the wiring for poor electrical connections between the control unit connectors and the actuator connectors. Look for possible bent, backed out, deformed, or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.

DTC4 G-Sensor Open Circuit or Short Step

Action

Yes

1. Turn off the starter switch. 2. Disconnect the connectors C–45, C–44, C–8, C–30, and F–6. Is there the continuity between the connector-terminal C45–28 and C8–5, C45–30 and C30–5, and C44–45 and F6–1?

—

Go to Step 2

Go to Step 5

Is there continuity between the connector-terminal C45–27 and C8–3, C45–31 and C30–3, and C44–44 and F6–2?

—

Go to Step 3

Go to Step 5

Is there the continuity between the connector-terminal C45–36 and C8–2, C45–38 and C30–2, and C44–56 and F6–3?

—

Go to Step 4

Go to Step 5

—

Go to Step 5

Go to Step 7

—

Go to Step 6

—

Go to Step 7

—

Go to “Basic Diagnosis Flow.”

Go to Step 7

1. Disconnect the connectors C–46, C–45, and C–44. Is there the continuity between the connector-terminal C45–28 and C45–35, C45–30 and C45–39, C44–45 and C44–55, C45–27 and C45–35, C45–31 and C45–39, C44–44 and C44–55, C45–36 and C45–35, C45–38 and C45–39, and C44–56 and C44–55?

Value(s)

Repair the circuit. Replace following units one by one in the following order. Give a test drive and if normal, reinstall it. 1) G3-sensor 2) Actuator FL 3) Actuator FR 4) Control Unit 1. Reconnect all components, ensure all components are properly mounted. 2. Clear the DTC. Was this step finished?

INTELLIGENT SUSPENSION

3F–23

DTC5 Vehicle Speed Sensor Open Circuit or Short Circuit Description

Diagnostic Aids

Output speed information is provided to the control unit by the vehicle speed sensor. The vehicle speed sensor produces a pulsing AC voltage. The AC voltage level and number of pulses increases as the speed of the vehicle increases. The control unit then converts the pulsing voltage to vehicle speed.

B Inspect the wiring for poor electrical connections between the control unit 48 way connector and the speed sensor connectors. Look for possible bent, backed out, deformed, or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.

DTC5 Vehicle Speed Sensor Open Circuit or Short Step

Action

Go to Step 2

Go to Step 3

0V and 12V

Go to Step 7

Go to Step 5

—

Go to Step 4

Go to Step 6

—

Go to Step 5

Go to Step 6

—

Go to Step 8

—

Go to Step 8

—

1. Check the continuity between the control unit connector C–46 terminal 1 and control unit connector C–44 terminal 48. Is there continuity?

—

1. Turn off the starter switch and disconnect the control connectors C–46 and C–44. 2. Check the continuity between the vehicle speed sensor connector terminal 3 and meter B connector I–23 terminal 7. Is there continuity?

1. Open the throttle and rev up engine speed. 2. Using a volt meter, measure the voltage between the meter B connector I–23 terminals 7 and 16 (GND). Does the voltage change alternately at the specified values?

Yes

1. Jack up and support the rear axle on the stand. 2. Change the transfer mode to 2WD, using TOD switch on instrument panel. 3. Shift the transmission lever in a forward position and rotate the rear wheels. Does the speedo-meter operate?

Value(s)

Repair or replace the vehicle speed sensor. Repair the circuit between the vehicle speed sensor connector terminal 3 and the meter B connector I–23 terminal 7 or the circuit between the control unit connector C–44 terminal 48 and the speed sensor connector terminal 3.

3F–24

INTELLIGENT SUSPENSION

DTC5 Vehicle Speed Sensor Open Circuit or Short (Cont’d) Step

Action

Value(s)

Yes

Repair the circuit between the connector H–6 terminal 16 and the control unit connector C–44 terminal 48 or replace the control unit. —

Go to Step 8

—

Go to “Basic Diagnosis Flow.”

Go to Step 8

1. Reconnect all components, ensure all components are properly mounted. 2. Clear the DTC. Was this step finished?

About the vehicle speed sensor connector termainal 3, Refer to section Wiring System in Body and Accessories.

INTELLIGENT SUSPENSION

3F–25

DTC6 Stop Lamp Switch Open Circuit or Short Circuit Description

Diagnostic Aids

The brake switch is used to indicate brake pedal status. The normally opened brake switch signal voltage circuit is opened. Brake switch supplies a B+ signal on circuit RED to the control unit when the brakes are applied. The control unit uses this signal to work dive control when the brakes are applied.

B Inspect the wiring for poor electrical connections at the control unit and brake switch. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. B Check customer driving habits and/or unusual driving conditions (i.e. stop and go, highway). B Check brake switch for proper mounting and adjustment.

DTC6 Stop Lamp Switch Open Circuit or Short Step

Action

Go to Step 4

—

Go to Step 7

Go to Step 5

—

Go to Step 13

—

Go to Step 8

Go to Step 6

—

Go to Step 9

Go to Step 10

—

Go to Step 8

Go to Step 10

—

Go to Step 13

Go to Step 10

Check circuit terminal I–31 terminal 4 for a short to voltage. Ignition switch “on”. Is the test light “on”?

Go to Step 3

Check the brake switch short (I–31 terminal 1 and I–31 terminal 4). Was a problem found?

—

Disconnect brake switch connector I–31 and ignition switch “on”. Is the test light “on”?

Go to Step 2

Repair the open in battery feed circuit terminal I–31 terminal 1 to the brake switch. If fuse is open, check circuit terminal I–31 terminal 4 for a short to ground. Is the replacement complete?

—

Go to Diagnostic Aids

1. Connect the test light to ground. 2. Back probe circuit terminal I–31 terminal 4 at the brake switch. Is the test light “off”?

1. Connect the test light to ground. 2. Back probe ignition feed circuit terminal I–31 terminal 1 at the brake switch. Is the test light “on”?

Yes

1. With the engine “off”, turn the ignition switch “on”. If ABS code is set, check applicable fuse. 2. Apply then release the brake pedal. Does the brake lamp come on when the brake pedal is applied and does it come off when the brake pedal is released?

Value(s)

1. Disconnect the control unit connector C–44. 2. Check circuit terminal I–31 terminal 4 for a short to voltage. Was a problem found?

3F–26

INTELLIGENT SUSPENSION

DTC6 Stop Lamp Switch Open Circuit or Short (Cont’d) Step

Action

Go to Step 13

—

Go to Diagnostic Aids

Go to Step 11

—

Go to Step 13

Go to Step 12

—

Go to Step 13

—

Begin diagnosis again Go to Step 1

Replace the control unit. Is the replacement complete?

—

Check the control unit for faulty or intermittent connections. Was a problem found and corrected?

1. Turn the ignition “off”. 2. Reconnect the control unit connector C–44 Turn the ignition “on”. Does the brake lamp come on when the brake pedal is applied and does it come off when the brake pedal is released?

Yes

Replace the brake switch. Is the replacement complete?

Value(s)

1. After the repair is complete, clear the DTC. 2. Conduct a test drive. 3. Review the DTC. Has the last test failed or is the current DTC displayed?

Go to Repair verified

INTELLIGENT SUSPENSION

3F–27

DTC7 Engine Speed Signal Open Circuit or Short Circuit Description

Diagnostic Aids

PCM (Powertrain Control Module) converts signals from the crankshaft position sensor into the engine speed signals (pulse) and sends these to the control unit and tachometer.

B Inspect the wiring for poor electrical connections at the control unit connector. Look for possible bent, backed out, deformed, or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. B Check harness routing for a potential short to ground in circuit BLK/RED.

DTC7 Engine Speed Signal Open Circuit or Short Step

Action

Value(s)

Yes

NOTE: Confirm that DTC P0336 or P0337 does not exist. If either exists, warning lamps, “CHECK ENGINE” and “CHECK TRANS” are turned on. Repair the engine, referring to section 6E Driveability and Emission. 1. Turn on the starter switch. 2. Start the engine. 3. Open the throttle and rev up engine speed. Does the tachometer operate according to engine speed?

5 6

Go to Step 3

Go to Step 2

—

Go to Step 6

—

Go to Step 4

Go to Step 5

—

Go to Step 6

—

Go to Step 6

—

Begin diagnosis again Go to Step 1

Repair the tachometer, referring to section 8D Wiring System in Body and Accessories. 1. Turn off the starter switch. 2. Check continuity between the control unit connector C–44 terminal 59 and PCM connector E–34 terminal F7. Is there continuity ?

—

Replace the control unit. Repair the circuit. 1. Reconnect all components, ensure all components are properly mounted. 2. Clear the DTC. 3. Conduct a test drive. Has the last test failed or does the current DTC exist?

Repair verified

3F–28

INTELLIGENT SUSPENSION

DTC9 Control Unit Abnormality Replace the control unit.

DTC9–1 Control Unit Blown Fuse for FR Actuator Step

Action

6 7

6.4– 7.2W

Go to Step 2

Go to Step 3

6.4– 7.2W

Go to Step 4

Go to Step 3

—

Go to Step 7

—

Go to Step 5

Go to Step 6

—

Go to Step 7

—

Go to Step 7

—

Go to “Basic Diagnosis FLow”.

Go to Step 7

Replace the actuator FR. 1. If all steps are correct, check the continuity between the control unit connector C–46 terminal 1 and connector-terminal C46–4, C46–17, C46–5, C46–18. Is there continuity?

1. Measure the resistance between the actuator side connector C–9 terminals 3 and 4. Is the resistance within the specified value?

Yes

1. Turn off the starter switch. 2. Disconnect the actuator connector C–9. 3. Measure the resistance between the actuator side connector C–9 terminals 1 and 2. Is the resistance within the specified value?

Value(s)

Repair the circuit. Replace the control unit. 1. Reconnect all components, ensure all components are properly mounted. 2. Clear the DTC. Was this step finished?

INTELLIGENT SUSPENSION

3F–29

DTC9–2 Control Unit Blown Fuse for FL Actuator Step

Action

6 7

6.4– 7.2W

Go to Step 2

Go to Step 3

6.4– 7.2W

Go to Step 4

Go to Step 3

—

Go to Step 7

—

Begin diagnosis again Go to Step 5

—

Go to Step 7

—

Go to Step 7

—

Go to “Basic Diagnosis FLow”.

Go to Step 7

Replace the actuator FL. 1. If all steps are correct, check the continuity between the control unit connector C–46 terminal 1 and connector-terminal C46–6, C46–19, C46–7, C46–20. Is there continuity?

1. Measure the resistance between the actuator side connector C–31 terminals 3 and 4. Is the resistance within the specified value?

Yes

1. Turn off the starter switch. 2. Disconnect the actuator connector C–31. 3. Measure the resistance between the actuator side connector C–31 terminals 1 and 2. Is the resistance within the specified value?

Value(s)

Go to Step 6

Repair the circuit. Replace the control unit. 1. Reconnect all components, ensure all components are properly mounted. 2. Clear the DTC. Was this step finished?

3F–30

INTELLIGENT SUSPENSION

DTC9–3 Control Unit Blown Fuse for RR Shock Absorber Step

Action

6 7

6.4– 7.2W

Go to Step 2

Go to Step 3

6.4– 7.2W

Go to Step 4

Go to Step 3

—

Go to Step 7

—

Begin diagnosis again Go to Step 5

—

Go to Step 7

—

Go to Step 7

—

Go to “Basic Diagnosis FLow”.

Go to Step 7

Replace the shock absorber RR. 1. If all steps are correct, check the continuity between the control unit connector C–46 terminal 1 and connector-terminal C46–8, C46–21, C46–9, C46–22. Is there continuity?

1. Measure the resistance between the shock absorber side connector F–7 terminals 7 and 8. Is the resistance within the specified value?

Yes

1. Turn off the starter switch. 2. Disconnect the shock absorber connector F–7. 3. Measure the resistance between the shock absorber side connector F–7 terminals 3 and 4. Is the resistance within the specified value?

Value(s)

Go to Step 6

Repair the circuit. Replace the control unit. 1. Reconnect all components, ensure all components are properly mounted. 2. Clear the DTC. Was this step finished?

INTELLIGENT SUSPENSION

3F–31

DTC9–4 Control Unit Blown Fuse for RL Shock Absorber Step

Action

6 7

6.4– 7.2W

Go to Step 2

Go to Step 3

6.4– 7.2W

Go to Step 4

Go to Step 3

—

Go to Step 7

—

Begin diagnosis again Go to Step 5

—

Go to Step 7

—

Go to Step 7

—

Go to “Basic Diagnosis FLow”.

Go to Step 7

Replace the shock absorber RL. 1. If all steps are correct, check the continuity between the control unit connector C–46 terminal 1 and connector-terminal C46–10, C46–23, C46–11, C46–24. Is there continuity?

1. Measure the resistance between the shock absorber side connector F–8 terminals 7 and 8. Is the resistance within the specified value?

Yes

1. Turn off the starter switch. 2. Disconnect the shock absorber connector F–8. 3. Measure the resistance between the shock absorber side connector F–8 terminals 3 and 4. Is the resistance within the specified value?

Value(s)

Go to Step 6

Repair the circuit. Replace the control unit. 1. Reconnect all components, ensure all components are properly mounted. 2. Clear the DTC. Was this step finished?

3F–32

INTELLIGENT SUSPENSION

Control Unit Control Unit and Associated Parts

828R200001

Legend (1) Front Console (2) Connector

(3) Control Unit (4) Front

INTELLIGENT SUSPENSION

3F–33

Removal 1. Disconnect the battery ground cable. 2. Remove the front console assembly. Refer to Consoles in Body and Accessories section. 3. Disconnect the connector from the control unit. View A

828RY00002

Legend (1) Nut (2) Screw

4. Remove 4 nuts. 5. Disconnect the control unit with brackets. 6. Remove 4 screws. 7. Disconnect the control unit from brackets.

Installation To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8N·m (69 lb in)

(3) Control Unit (4) Bracket

3F–34

INTELLIGENT SUSPENSION

Front Actuator Front Actuator and Associated Parts RH

450RY00004

Legend (1) Connector (2) Clip (3) Actuator (4) Shock Absorber (5) Front (6) Bracket

450RY00003

Legend (1) Connector (2) Clip (3) Actuator (4) Shock Absorber (5) Front (6) Bracket

INTELLIGENT SUSPENSION

Removal

3F–35

Inspection and Repair

1. Disconnect the battery ground cable. 2. Disconnect the connector from the harness and remove the connector from the bracket. 3. Remove the clip.

View B

Refer to shock Abosorber in this section.

Installation 1. Install the shock absorber. Refer to Shock Absorber in this section. 2. Install the washer and nut (5), then tighten it to the specified torque. Torque: 15 N·m (11 lb ft) 3. Install the bracket and nut (3), then tighten it to the specified torque. Torque: 39 N·m (29 lb ft) NOTE: Fix the lower nut with wrench not to turn and tighten upper nut. 4. Fit the top of the shock absorber rod in the connection part of the actuator. NOTE: The mating section is width fitting across flats. If these normally fit, the distance between the actuator lower face and the bracket upper face is about 1 mm. 5. Install 2 screws then tighten it to the specified torque. 3 N·m (26 lb in)

450RY00005

Legend (1) Screw (2) Actuator (3) Nut (4) Bracket (5) Nut (6) Washer (7) Shock Absorber 1. Remove 2 screws. 2. Remove the actuator. 3. Remove the nut (3). 4. Disconnect bracket. 5. Remove the nut (5). 6. Disconnect the washer. 7. Remove the shock absorber. Refer to Shock Absorber in this section.

6. Connect the connector to the harness and insert the connector to the bracket. 7. Connect the actuator harness with the clip. 8. Connect the battery ground cable.

3F–36

INTELLIGENT SUSPENSION

Rear Shock Absorber Rear Shock Absorber and Associated Parts LH

461R100003

Legend (1) Connector (2) Clip (3) Rear Shock Absorber (4) Bracket (5) Bolt

(6) (7) (8) (9) (10) (11)

G-Sensor Front Upper Right Connector Gusset

INTELLIGENT SUSPENSION

Removal 1. Disconnect the battery ground cable. 2. Disconnect the connector (1) from the harness and remove the connector (1) from the bracket (4). 3. Remove the clip (2). 4. Remove the rear shock absorber (3). Refer to Shock Absorber in this section. 5. Disconnect the connector (10) from the harness and remove the connector (10) from the gusset (11). 6. Remove the 2 bolts (5). 7. Disconnect the G-sensor (6).

Inspection and Repair Refer to Shock Absorber in this section.

Installation 1. Set the G-sensor on the gusset (11). 2. Install 2 bolts (5) then tighten it to the specified torque. Torque: 7 N·m (61 lb in) 3. Connect the connector (10) to the harness and insert the connector (10) to the gusset (11). 4. Install the rear shock absorber (3). Refer to Shock Absorber in this section. 5. Connect the connector (1) to the harness and insert the connector (1) to the bracket (4). 6. Insert the clip (2) to the bracket (4). 7. Connect the battery ground cable.

3F–37

SECTION DIFFERENTIAL (FRONT)

4A1–1

AXIOM

DRIVELINE/AXLE CONTENTS Differential (Front) . . . . . . . . . . . . . . . . . . . . . . . Differential (Rear) . . . . . . . . . . . . . . . . . . . . . . . Driveline Control System . . . . . . . . . . . . . . . . .

4A1 4A2 4B1

Driveline Control System (TOD) . . . . . . . . . . . Drive Shaft System . . . . . . . . . . . . . . . . . . . . . . Transfer Case (TOD) . . . . . . . . . . . . . . . . . . . .

4B2 4C 4D2

Differential (Front) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Shaft Oil Seal . . . . . . . . . . . . . . . . . . . . . Pinion Shaft Oil Seal and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Drive Axle Assembly . . . . . . . . . . . . . . . Front Drive Axle Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4A1–1 4A1–2 4A1–2 4A1–3 4A1–3 4A1–3 4A1–4 4A1–4 4A1–5 4A1–5 4A1–6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Assembly . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Cage Assembly . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . .

4A1–6 4A1–8 4A1–8 4A1–9 4A1–11 4A1–20 4A1–20 4A1–20 4A1–21 4A1–21 4A1–23 4A1–25

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

4A1–2

DIFFERENTIAL (FRONT)

Front Drive Axle Diagnosis Condition

Possible cause

Oil Leak At Front Axle

Correction

Worn or defective oil seal.

Replace the oil seal.

Front axle housing cracked.

Repair or replace.

Too much gear oil.

Correct the oil level.

Oil seal worn or defective.

Replace the oil seal.

Pinion flange loose or damaged.

Tighten or replace.

Noises In Front Axle Drive Shaft Joint

Broken or worn drive shaft joints and bellows (BJ and DOJ).

Replace the drive shaft joints and bellows.

“Clank” When Accelerating From “Coast”

Loose drive shaft joint to output shaft bolts.

Tighten.

Damaged inner drive shaft joint.

Replace.

Excessive drive shaft joint angle.

Repair.

Worn or damaged drive shaft joints.

Replace.

Sticking spider assembly (inner drive shaft joint).

Lubricate or replace.

Sticking joint assembly (outer drive shaft joint).

Lubricate or replace.

Out of balance or out of round tires.

Balance or replace.

Front end out of alignment.

Align.

Insufficient gear oil.

Replenish the gear oil.

Wrong or poor grade gear oil.

Replace the gear oil.

Drive pinion to ring gear backlash incorrect.

Adjust the backlash.

Worn or chipped ring gear, pinion gear or side gear.

Replace the ring gear, pinion gear or side gear.

Pinion shaft bearing worn.

Replace the pinion shaft bearing.

Wheel bearing worn.

Replace the wheel bearing.

Differential bearing loose or worn.

Tighten or replace.

Wheel bearing preload too tight.

Adjust the wheel bearing preload.

Incorrect front alignment.

Adjust the front alignment.

Steering unit loose or worn.

Tighten or replace.

Tire worn or improperly inflated.

Adjust the inflation or replace.

Front or rear suspension parts loose or broken.

Tighten or replace.

Wheel bearing worn or improperly adjusted.

Adjust or replace.

Incorrect front alignment.

Adjust the front alignment.

Worn ball joint or bush.

Replace the ball joint or bush.

Steering unit loose or worn.

Tighten or replace.

Tire worn or improperly inflated.

Replace or adjust the inflation.

Shock absorber worn.

Replace the shock absorber.

Oil Leak At Pinion Shaft

Shudder or Acceleration

Vibration

Vibration At Highway Speeds Noises in Front Axle

Wanders and Pulls

Front Wheel Shimmy

During

DIFFERENTIAL (FRONT)

4A1–3

Pinion Shaft Oil Seal Pinion Shaft Oil Seal and Associated Parts

415R200001

Legend (1) Flange Nut (2) Flange

(3) Oil Seal (4) Outer Bearing (5) Collapsible Spacer

Removal 1. Raise the vehicle and support it at the frame. The hoist must remain under the front axle housing. 2. Drain the front axle oil by loosening the drain plug(1).

412RS001

4A1–4

DIFFERENTIAL (FRONT)

3. Remove the front propeller shaft. Refer to Front Propeller Shaft in this section. 4. Remove flange nut by using pinion flange holder J–8614–01.

Installation 1. Install collapsible spacer. Discard the collapsible spacer and install a new one. 2. Install outer bearing.

used

NOTE: Do not drive in, but just temporarily set in the outer bearing by hand, which should be indirectly pressed in finally by tightening the flange nut. 3. Install oil seal, use oil seal installer J–24250 to install a new oil seal that has been soaked in axle lubricant.

415RS018

5. Remove flange. 6. Remove oil seal. 7. Remove outer bearing by using remover J–39602.

415RS002

4. Install flange. 5. Install flange nut, refer to Differential Assembly Overhaul for flange nut reassembly in this section. NOTE: Discard the used nut and install a new one.

415RS001

8. Remove collapsible spacer.

DIFFERENTIAL (FRONT)

4A1–5

Front Drive Axle Assembly Front Drive Axle Assembly and Associated Parts

412R200003

Legend (1) Propeller Shaft (2) Mounting Nut (3) Front Axle Case Assembly and Front Drive Shaft Assembly (4) Washer

(5) (6) (7) (8) (9)

Mounting Bolt Tie–rod End; Power Steering Unit Knuckle and Back Plate Hub and Disc Assembly Suspension Crossmember

4A1–6

DIFFERENTIAL (FRONT) CAUTION: When removing the knuckle, be careful not to damage the oil seal inside of the knuckle.

Removal 1. Jack up the vehicle and support it using jack stand. 2. Remove the tire and wheel. 3. Remove the stone guard. 4. Remove the brake caliper fixing bolt and hang the caliper. Refer to Disc Brakes in Brake section. 5. Remove the antilock brake system speed sensor. Refer to Front Wheel Speed Sensor in Brake section. 6. Remove the hub and disc assembly. Refer to Front Hub and Disc in this section. 7. Remove the propeller shaft, refer to Front Propeller Shaft in this section. 8. Loosen the height control arm of the torsion bar, then remove the torsion bar from lower control arm. Refer to Torsion Bar in Suspension section. 9. Remove the suspension crossmember. 10. Remove the lower nut (1) of the stabilizer link. 11. Remove the lower bolt and nut (2) of the shock absorber.

410RW008

17. Support the differential case by the jack. 18. Remove the front axle mounting bolts and nuts, lower the jack slowly. Remove the left side drive shaft end from the knuckle, then lower the axle assembly from the vehicle. CAUTION: 1. Make sure the axle assembly is supported securely when performing repairs. 2. Do not damage the power steering unit when performing the repairs. 3. Do not damage the shift–on–the fly hose bracket when performing the repairs.

Installation

412RW057

12. Remove the tie-rod end from the knuckle. Refer to Power Steering Unit in Steering Section. 13. Disconnect the hose of the shift on the fly. 14. Disconnect the actuator connector. 15. Remove the bolts and nuts of the lower control arm (Frame side), then disconnect the lower control arm from frame. 16. Disconnect between the right side upper control arm and the knuckle, then remove the knuckle with lower control arm.

1. Support the differential case with a jack. 2. Jack up the front drive axle assembly, install the left side drive shaft to the knuckle, then install the mount bolts and nuts. CAUTION: 1. Do not damage the power steering unit when performing the repairs. 2. Do not damage the shift–on–the fly hose bracket when performing the repairs. 3. When installing the drive shaft to the knuckle, be careful not to damage the oil seal inside of the knuckle.

DIFFERENTIAL (FRONT) 3. Tighten the mounting bolts and nuts to the specified torque. Torque: 168 N·m (124 lb ft)

4A1–7

18. Install the tire and wheel. 19. Lower the vehicle, adjust the trim height. Refer to Trim Height Adjustment in Steering section. 20. Tighten the bolts and nuts of the lower control arm to the specified torque. Refer to Lower Control Arm in Suspension section.

412R200004

4. Install the right side knuckle with lower control arm to the upper control arm. Refer to Knuckle in Suspension section. CAUTION: Carefully insert the drive shaft into the knuckle, to avoid damaging the oil seal. 5. Align the bolt hole of the lower control arm, then install the bolts and nuts. NOTE: Adjust the buffer clearance before tightening the bolts and nuts of the lower control arm. 6. Install the hose of the shift on the fly. 7. Install the actuator connector of the shift on the fly. 8. Install the tie-rod end of the power steering unit to the knuckle, tighten the nut to the specified torque. Torque: 118 N·m (87 lb ft) 9. Install lower bolts and nuts of the shock absorber, tighten it to the specified torque. Torque: 93 N·m (69 lb ft) 10. Install lower nuts of the stabilizer link, tighten it to the specified torque. 11. Install the suspension crossmember. 12. Install the torsion bar. Refer to Torsion Bar in Suspension section. 13. Install the front propeller shaft. Refer to Front Propeller Shaft in this section. 14. Install the hub and disc assembly and adjust the bearing preload. Refer to Front Hub and Disc in this section. 15. Install the wheel speed sensor of the antilock brake system. 16. Install the brake caliper. Tighten the bolt of the caliper bracket to the specified torque. Torque: 50 N·m (37 lb ft) 17. Install the stone guard.

4A1–8

DIFFERENTIAL (FRONT)

Differential Assembly Disassembled View

415R200002

Legend (1) Differential Assembly (2) Flange Nut (3) Flange (4) Oil Seal (5) Outer Bearing (6) Outer Bearing Outer Race (7) Differential Carrier (8) Bearing Cap (9) Bolt (10) Collapsible Spacer (11) Inner Bearing Outer Race

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23)

Inner Bearing Adjust Shim Pinion Gear Diff Cage Assembly Side Bearing Outer Race Side Bearing Adjust Shim Bolt Axle Case Final Drive Damper Damper Bolt Damper Bracket

DIFFERENTIAL (FRONT)

Disassembly 1. Remove differential carrier fixing bolt. 2. Remove differential assembly. 3. Using holding fixture J–37264 and holding fixture base J–3289–20, fix the differential assembly to the bench.

4A1–9

6. Remove differential cage assembly. 7. Remove side bearing outer race, after removal, keep the right and left hand side bearing assemblies separate to maintain inner and outer race combinations. 8. Remove side bearing, using remover J–42379 and adapter J–8107–2. B Select insert; 303173 and collet halves; 44801 in remover kit J–42379.

425RS008

4. Remove bearing cap bolt. 5. Apply a setting mark to the side bearing cap and the differential carrier then remove bearing cap.

415RW003

9. Remove adjust shim, note the thickness and position of the shims removed. 10. Remove the flange nut using holding wrench J–8614–01.

425RS009

415RS018

4A1–10 DIFFERENTIAL (FRONT) 11. Remove flange using a universal puller. 12. Remove the drive pinion assembly using a soft metal rod and a hammer.

425RS012

18. Remove the inner bearing outer race (1) and the outer bearing outer race (2) by using a brass bar and a hammer.

425RS014

13. Remove collapsible spacer. 14. Remove the inner bearing using remover J–42379. B Select insert; 303173 and collet halves; 44801 in remover kit J–42379.

425RS015

415RW004

15. Remove adjust shim. 16. Remove oil seal. 17. Remove outer bearing.

DIFFERENTIAL (FRONT) 19. Remove damper and bracket.

4A1–11

2. Using installer J–7818 and grip J–8092, install Inner bearing outer race.

425RW042 415RW014

Reassembly 1. Using installer J–7817 and grip J–8092, install outer bearing outer race.

415RW013

3. Install adjust shim and adjust drive pinion mounting distance: 1. Apply gear oil to the inner and outer drive pinion bearing. Clean the pinion setting gauge set. Then install the gauge set together with the inner and outer bearings.

4A1–12 DIFFERENTIAL (FRONT) 2. Tighten the nut to the specified torque.

4. Set the dial indicator to “0”. Place it on the mounting post of the gauging arbor with the contact button touching the indicator pad. Force the dial indicator downward until the needle has made a half turn clockwise. Tighten down the dial indicator in this position.

Torque: 2.3 N·m (20 lb in)

425RW030

Legend (1) Pilot : J–21777–42 (2) Pilot : J–42479–2 (3) Gauge Plate : J–42479–1 (4) Nut and Stud : J–21777–43

425RS020

3. Clean the side bearing bores. Install the dial indicator with the discs and arbor. Install and tighten the bearing caps to the specified torque.

Legend (1) Dial Indicator (2) Ganging Arbor (3) Plunger (4) Gauge Plate 5. Position the plunger on the gauge plate. Move the gauging arbor slowly back and forth and locate the position at which the dial indicator shows the greatest defection. At this point, once again set the dial indicator to “0”. Repeat the procedure to verify the “0” setting.

Torque: 97 N·m (72 lb ft)

425RW031

Legend (1) Dial Indicator: J–8001 (2) Gauge Plate: J–42479–1 (3) Disc (2 pcs.): J–23597–8 (4) Arbor: J–23597–1

425RS021

DIFFERENTIAL (FRONT) 6. After the ZERO setting is obtained, rotate the gauging arbor until the dial indicator rod does not touch the gauging plate. Record the number the dial indicator needle points to.

425RS022

Legend (1) Example=Dial indicator reading of 0.085 7. Record the pinion depth code on the head of the drive pinion. The number indicates a necessary change in the pinion mounting distance. A plus number indicates the need for a greater mounting distance (which can be achieved by decreasing the shim thickness). A minus number indicates the need for a smaller mounting distance (which can be achieved by increasing the shim thickness). If examination reveals pinion depth code “0”, the pinion is “nominal”.

425RS023

4A1–13

4A1–14 DIFFERENTIAL (FRONT) 8. Select the shim using chart; Pinion marking Dial indicator reading (Inches)

–1

–2

–3

–4

–5

–6

0.023

–7

0.030

0.024 0.025 0.026

0.029 0.030 0.031

0.034 0.035 0.036

0.032

0.030

0.032

0.030

0.032

0.034

0.030

0.032

0.034

0.030

0.032

0.034

0.036

0.030

0.032

0.034

0.036

0.030

0.032

0.034

0.036

0.038

0.030

0.032

0.034

0.036

0.038

0.030

0.032

0.034

0.036

0.038

0.040

0.032 0.033

0.030

0.027 0.028

0.030 0.030

0.030

0.032

0.034

0.036

0.038

0.040

0.030

0.032

0.034

0.036

0.038

0.040

0.042

0.030

0.032

0.034

0.036

0.038

0.040

0.042

0.037

0.030

0.032

0.034

0.036

0.038

0.040

0.042

0.044

0.038

0.030

0.032

0.034

0.036

0.038

0.040

0.042

0.044

0.039

0.032

0.034

0.036

0.038

0.040

0.042

0.044

0.046

0.040

0.032

0.034

0.036

0.038

0.040

0.042

0.044

0.046

0.041

0.034

0.036

0.038

0.040

0.042

0.044

0.046

0.048

0.042

0.034

0.036

0.038

0.040

0.042

0.044

0.046

0.048

0.043

0.036

0.038

0.040

0.042

0.044

0.046

0.048

0.050

0.044

0.036

0.038

0.040

0.042

0.044

0.046

0.048

0.050

0.045

0.038

0.040

0.042

0.044

0.046

0.048

0.050

0.052

0.046

0.038

0.040

0.042

0.044

0.046

0.048

0.050

0.052

0.047

0.040

0.042

0.044

0.046

0.048

0.050

0.052

0.048

0.040

0.042

0.044

0.046

0.048

0.050

0.052

0.049

0.042

0.044

0.046

0.048

0.050

0.052

0.050

0.042

0.044

0.046

0.048

0.050

0.052

0.051

0.044

0.046

0.048

0.050

0.052

0.044

0.046

0.048

0.050

0.052

0.053

0.046

0.048

0.050

0.052

0.054

0.046

0.048

0.050

0.052

0.055

0.048

0.050

0.052

0.056

0.048

0.050

0.052

0.057

0.050

0.052

0.058

0.050

0.052

0.059

0.052

0.060

0.052

DIFFERENTIAL (FRONT) 4. Place the shim on the drive pinion. Install the inner bearing onto the pinion using an installer J–6133–01 and a press.

4A1–15

NOTE: Discard used flange nut and install new one and do not over tighten the flange nut.

NOTE: Do not apply pressure to the roller cage and apply pressure only to the inner race.

415RW006

3. Adjust pinion bearing preload. 425RS024

5. Discard the used collapsible spacer and install a new one. 6. Install pinion gear. 7. Install outer bearing. 8. Use oil seal installer J–24250 to install a new oil seal that has been soaked in front axle lubricant. NOTE: Take care to use a front differential oil seal, NOT the rear differential oil seal.

a. Measure the bearing preload by using a torque meter. Note the scale reading required to rotate the flange. b. Continue tightening flange nut until the specified starting torque is obtained. Starting torque: New bearing 0.7–1.1 N·m (5.64–9.98 lb in) Used bearing 0.4–0.5 N·m (2.86–4.94 lb in) NOTE: Do not tighten the flange nut more than 678 N·m(500 lb ft).

415RS011

9. Install flange. 10. Install flange nut. 1. Apply lubricant to the pinion threads. 2. Tighten the nut to the specified torque using the pinion flange holder J–8614–01. Torque: 177–275N·m (130–203 lb ft)

425R200001

4. Using punch J–39209, stake the flange nut at two points.

4A1–16 DIFFERENTIAL (FRONT) NOTE: When staking, be sure to turn the nut to insure that there is no change in bearing preload. Make sure of preload again as instructed in 3.

415R200004

11. Install adjust shim. 1. Attach the side bearing to the differential assembly without shims. Support the opposite side using a pilot to prevent bearing damage.

2. Insert the differential cage assembly with bearing outer races into the side bearing bores of the carrier.

425RS030

3. Using two sets of feeler gauges, insert a feeler stock of sufficient thickness between each bearing outer race and the carrier to remove all end play. Make certain the feeler stock is pushed to the bottom of the bearing bores. Mount the dial indicator J–8001 on the carrier so that the indicator stem is at right angles to a tooth on the ring gear.

425RS029

Legend (1) Drive handle:J–8092 (2) Installer:J–24244 (3) Pilot:J–8107–2

425RS031

DIFFERENTIAL (FRONT) 4. Adjust feeler gauge thickness from side to side until ring gear backlash is in the specified range.

4A1–17

12. Install the side bearings together with the selected shims.

Backlash: 0.13–0.20 mm(0.005 –0.008 in)

425RS029

425RS032

With zero end play and correct backlash established, remove the feeler gauge packs, determine the thickness of the shims required and add 0.025 mm (0.001 in) to each shim pack to provide side bearing preload. Always use new shims. 5. Use bearing remover J–42379 and pilot J–8107–2 to remove side bearing. B Select insert; 303173 and collet halves;44801 in remover kit J–42379.

Legend (1) Drive Handle:J–8092 (2) Installer: J–24244 (3) Pilot: J–8107–2 13. Install side bearing outer race. 14. Install differential cage assembly. 15. Install bearing cap then align the setting marks(1) applied at disassembly.

425RS035 415RW003

4A1–18 DIFFERENTIAL (FRONT) 16. Tighten the cap bolt to the specified torque. Torque: 97 N·m (72 lb ft)

425RS038

425RS036

Gear Tooth Adjustment

Contact

Pattern

Check

and

1. Apply a thin coat of prussian blue or equivalent to at least 7–8 ring gear teeth. Rotate the ring gear and inspect the contact point of the impressions and make the necessary adjustments as described in the next page.

Legend (1) Heel (2) Toe (3) Concave Side(Coast) (4) Convex Side(Drive)

425RS039

DIFFERENTIAL (FRONT) 17. Install differential assembly. 1. Clean the faces of the front axle case and differential carrier. Apply Three Bond TB1215 or equivalent to the sealing side of the axle case and the carrier. 2. Attach the differential case and the carrier assembly to the front axle case and tighten the nuts and bolts. Torque: 25 N·m (19 lb ft)

415RS014

3. Fill the axle case with hypoid gear lubricant, up to the base of the filler hole. Lubricant capacity: 1.25 liter(1.32 US qt) 18. Install damper. 1. Clean the faces and bolt thread hole of differential carrier. 2. Install the bracket with new bolts. 3. Install the damper to the bracket with new bolts. Torque: 25 N·m (19 lb ft)

425RW042

4A1–19

4A1–20 DIFFERENTIAL (FRONT)

Differential Cage Assembly Disassembled View

415R200005

Legend (1) Pinion Gear (2) Thrust Washer (3) Side Gear (4) Cross Pin

(5) (6) (7) (8)

Ring Gear Bolt Differential Cage Lock Pin

Disassembly 1. Remove bolt. 2. Remove ring gear. 3. Remove lock pin.

425RS042

DIFFERENTIAL (FRONT) 4. Remove the cross pin, using a soft metal rod and a hammer.

3. Tighten the fixing bolts in a diagonal sequence as illustrated.

425RS043

5. Remove pinion gear. 6. Remove side gear. 7. Remove thrust washer.

Inspection and Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. 1. Ring gear, pinion gear 2. Bearing 3. Side gear, pinion gear, cross pin 4. Differential cage, carrier 5. Thrust washer 6. Oil seal

4A1–21

415RS016

Reassembly 1. Install thrust washer. 2. Install side gear. 3. Install the pinion gear with thrust washer by engaging it with the side gears while turning both pinion gears simultaneously in the same direction.

Ring gear replacement: 1. The ring gear should always be replaced with the drive pinion as a set. 2. Discard used bolts and install new ones. Torque: 108 N·m (80 lb ft)

425RS048

4A1–22 DIFFERENTIAL (FRONT) 4. Install cross pin. B Be sure to install the cross pin so that it is in alignment with the lock pin hole in the differential cage.

425RS049

5. Install lock pin. After lock pin installation, stake the cage to secure the lock pin. 6. Install ring gear and tighten the bolts in diagonal sequence as illustrated. Torque: 108 N·m (80 lb ft) NOTE: Discard used bolts and install new ones.

415RS016

DIFFERENTIAL (FRONT)

4A1–23

Main Data and Specifications General Specifications Axle tube Type

It consists of a duct, a cast iron housing and an axle tube.

Gear type

Hypoid

Gear ratio

4.300

Differential type Oil capacity Type of lubricant Axle shaft type Hub locking Type

Two pinion liter (US qt)

1.25 (1.32) (Differential) 0.12 (0.13) (Actuator Housing: Shift on the fly) GL–5 (75W–90) Constant velocity joint (Birfield joint type and double offset joint) Rigid

Torque Specifications

412R200005

4A1–24 DIFFERENTIAL (FRONT)

415R200003

DIFFERENTIAL (FRONT)

4A1–25

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

ILLUSTRATION

TOOL NO. TOOL NAME

J–8614–01 Holder; Pinion flange

J–7817 Installer; Outer bearing outer race

J–24250 Installer; Oil seal

J–7818 Installer; Inner bearing outer race

J–37264 Differential holding fixture (Use with J–3289–20 base)

J–8092 Driver handle

J–3289–20 Holding fixture base

J–21777–42 Pilot

J–42379 Remover; Side/Pinion bearing

J–21777–43 Nut and stud

J–8107–2 Adapter; Side bearing plug

J–42479–1 Gauge plate

4A1–26 DIFFERENTIAL (FRONT) ILLUSTRATION

TOOL NO. TOOL NAME

ILLUSTRATION

TOOL NO. TOOL NAME

J–8001 Dial indicator

J–42479–2 Pilot

J–23597–8 Disc

J–39209 Punch; End nut lock

J–23597–1 Arbor

J–6133–01 Installer; Pinion bearing

J–24244 Installer; Side bearing

J–39602 Remover; Outer bearing

SECTION DIFFERENTIAL (REAR)

4A2–1

AXIOM

DRIVELINE/AXLE Differential (Rear) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Housing and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle Shaft, Oil Seal and Bearing . . . . . . . . . . Axle Shaft and Associated Parts . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Oil Seal and Associated Parts . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Assembly . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Inspecting the Axle Before Disassembly . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .

4A2–1 4A2–2 4A2–3 4A2–5 4A2–5 4A2–5 4A2–7 4A2–7 4A2–7 4A2–8 4A2–8 4A2–8 4A2–10 4A2–10 4A2–10 4A2–11 4A2–11 4A2–13 4A2–13 4A2–14 4A2–14

Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Side Bearing Preload Adjustment . . . . . . . . Pinion Installation . . . . . . . . . . . . . . . . . . . . . . Determination of Backlash & Preload Shims Backlash Adjustment . . . . . . . . . . . . . . . . . . . Gear Tooth Pattern Check . . . . . . . . . . . . . . Adjustments Affecting Tooth Contact . . . . . Differential Case Assembly . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Limited Slip Differential Assembly . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data And Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .

4A2–16 4A2–16 4A2–20 4A2–21 4A2–22 4A2–23 4A2–23 4A2–24 4A2–25 4A2–25 4A2–26 4A2–26 4A2–26 4A2–27 4A2–27 4A2–27 4A2–29 4A2–29 4A2–31 4A2–32

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

4A2–2

DIFFERNTIAL (REAR)

General Description

Limited Slip Differential (LSD)

The rear axle assembly is of the semi–floating type in which the vehicle weight is carried on the axle housing . The center line of the pinion gear is below the center line of the ring gear (hypoid drive). All parts necessary to transmit power from the propeller shaft to the rear wheels are enclosed in a salisbury type axle housing (a carrier casting with tubes pressed and welded into the carrier). A removable aluminum cover at the rear of the axle housing permits rear axle service without removal of the entire assembly from the vehicle. The 8.9 inch ring gear rear axle uses a conventional ring and pinion gear set to transmit the driving force of the engine to the rear wheels. This gear set transfers this driving force at a 90 degree angle from the propeller shaft to the drive shafts. The axle shafts are supported at the wheel end of the shaft by a roller bearing. The pinion gear is supported by two tapered roller bearings. The pinion depth is set by a shim pack located between the gear end of the pinion and the roller bearing that is pressed onto the pinion. The pinion bearing preload is set by crushing a collapsible spacer between the bearings in the axle housing. The ring gear is bolted onto the differential case with 10 bolts. The differential case is supported in the axle housing by two tapered roller bearings. The differential and ring gear are located in relationship to the pinion by using selective shims and spacers between the bearing and the differential case. To move the ring gear, shims are deleted from one side and an equal amount are added to the other side. These shims are also used to preload the bearings which are pressed onto the differential case. Two bearing caps are used to hold the differential into the rear axle housing. The differential is used to allow the wheels to turn at different rates of speed while the rear axle continues to transmit the driving force. This prevents tire scuffing when going around corners and prevents premature wear on internal axle parts. The rear axle is sealed with a pinion seal, a seal at each axle shaft end, and by a liquid gasket between the rear cover and the axle housing.

The axle assembly may be equipped with an limited slip differential (LSD). It is similar to the standard differential except that part of the torque from the ring gear is transmitted through clutch packs between the side gears and differential case. The LSD construction permits differential action when required for turning corners and transmits equal torque to both wheels when driving straight ahead. However, when one wheel tries to spin due to a patch of ice, etc., the clutch packs automatically provide more torque to the wheel which is not trying to spin. In diagnosing customer complaints, it is important to recognize two things: 1. If, both wheels slip, with unequal traction, the LSD has done all it can possibly do. 2. In extreame cases of differences in traction, the wheel with the least traction may spin after the LSD has transferred as much torque as possible to the non-slipping wheel. Limited Slip Differntials impose additional requirements on lubricants, and require a special lubricant or lubricant additive. Use 80W90 GL–5 LSD lubricant.

Rear Axle Identification The Bill of Material and build date information(1) is stamped on the right axle tube on the rearward side. The axle ratio is identified by a tag(3) which is secured by a cover bolt. If the axle has limited-slip differntial, it also will be identified with a tag(2) secured by a cover bolt.

425RX001

DIFFERENTIAL (REAR)

Diagnosis Many noises that seem to come from the rear axle actually originate from other sources such as tires, road surface, wheel bearings, engine, transmission, muffler, or body drumming. Investigate to find the source of the noise before disassembling the rear axle. Rear axles, like any other mechanical device, are not absolutely quiet but should be considered quiet unless some abnormal noise is present. To make a systematic check for axle noise, observe the following: 1. Select a level asphalt road to reduce tire noise and body drumming. 2. Check rear axle lubricant level to assure correct level, and then drive the vehicle far enough to thoroughly warm up the rear axle lubricant. 3. Note the speed at which noise occurs. Stop the vehicle and put the transmission in neutral. Run the engine speed slowly up and down to determine if the noise is caused by exhaust, muffler noise, or other engine conditions. 4. Tire noise changes with different road surfaces; axle noises do not. Temporarily inflate all tires to 344 kPa (50 psi) (for test purposes only). This will change noise caused by tires but will not affect noise caused by the rear axle. Rear axle nose usually stops when coasting at speeds under 48 km/h (30 mph); however, tire noise continues with a lower tone. Rear axle noise usually changes when comparing pull and coast, but tire noise stays about the same. Distinguish between tire noise and rear axle noise by noting if the noise changes with various speeds or sudden acceleration and deceleration. Exhaust and axle noise vary under these conditions, while tire noise remains constant and is more pronounced at speeds of 32 to 48 km/h (20 to 30 mph). Further check for tire noise by driving the vehicle over smooth pavements or dirt roads (not gravel) with the tires at normal pressure. If the noise is caused by tires, it will change noticeably with changes in road surface. 5. Loose or rough front wheel bearings will cause noise which may be confused with rear axle noise; however, front wheel bearing noise does not change when comparing drive and coast. Light application of the brake while holding vehicle speed steady will often cause wheel bearing noise to diminish. Front wheel bearings may be checked for noise by jacking up the wheels and spinning them or by shaking the wheels to determine if bearings are loose. 6. Rear suspension rubber bushings and spring insulators dampen out rear axle noise when correctly installed. Check to see that there is no link or rod loosened or metal–to–metal contact.

4A2–3

7. Make sure that there is no metal–to–metal contact between the floor and the frame. After the noise has been determined to be in the axle, the type of axle noise should be determined, in order to make any necessary repairs.

Gear Noise Gear noise (whine) is audible from 32 to 89 km/h (20 to 55 mph) under four driving conditions. 1. In drive under acceleration or heavy pull. 2. Driving under load or under constant speed. 3. When using enough throttle to keep the vehicle from driving the engine while the vehicle slows down gradually (engine still pulls slightly). 4. When coasting with the vehicle in gear and the throttle closed. The gear noise is usually more noticeable between 48 and 64 km/h (30 and 40 mph) and 80 and 89 km/h (50 and 55 mph).

Bearing Noise Bad bearings generally produce a rough growl or grating sound, rather than the whine typical of gear noise. Bearing noise frequently “wow–wows” at bearing rpm, indicating a bad pinion or rear axle side bearing. This noise can be confused with rear wheel bearing noise.

Rear Wheel Bearing Noise Rear wheel bearing noise continues to be heard while coasting at low speed with transmission in the neutral. Noise may diminish by gentle braking. Jack up the rear wheels, spin them by hand and listen for noise at the hubs. Replace any faulty wheel bearings.

Knock At Low Speeds Low speed knock can be caused by worn universal joints or a side gear hub counter bore in the cage that is worn oversize. Inspect and replace universal joints or cage and side gears as required.

Backlash Clunk Excessive clunk on acceleration and deceleration can be caused by a worn rear axle pinion shaft, a worn cage, excessive clearance between the axle and the side gear splines, excessive clearance between the side gear hub and the counterbore in the cage, worn pinion and side gear teeth, worn thrust washers, or excessive drive pinion and ring gear backlash. Remove worn parts and replace as required. Select close–fitting parts when possible. Adjust pinion and ring gear backlash.

4A2–4

DIFFERNTIAL (REAR)

Rear Axle Noise Condition Noise in Drive

Noisy when coasting

Intermittent noise Constant noise

Noisy on turns

Possible cause Excessive backlash.

pinion

ring

Correction gear

Adjust.

Worn pinion and ring gear.

Replace

Worn pinion .bearings.

Replace.

Loose pinion bearings.

Adjust.

Excessive pinion end play.

Adjust.

Worn side bearings.

Replace.

Loose side bearings.

Adjust.

Excessive ring gear run-out.

Replace.

Low oil level.

Replenish.

Wrong or poor grade oil.

Replace.

Bent axle housing.

Replace.

Axle noise heard when driving will usually be heard also on coasting, although not as loud.

Adjust or replace.

Pinion and ring gear too tight (audible when slowing down and disappears when driving).

Adjust.

Warped bevel ring.

Replace.

Loose differential case bolts.

Tighten.

Flat spot on pinion or ring gear teeth.

Replace.

Flat spot on bearing.

Replace.

Worn pinion splines.

Replace.

Worn axle shaft dowel holes.

Replace.

Worn hub studs.

Replace.

Bent axle shaft.

Replace.

Worn differential side gears and pinions.

Replace.

Worn differential shaft.

Replace.

Worn axle shaft splines.

Replace.

Limited Slip Differential Condition

Possible cause

Correction

Does not lock

Broken clutch plates.

Replace the clutch plates.

Chatters in turns

Lubricant contaminated.

Drain lube when hot. Wipe carrier clean. Refill with lube specified in Main Data and Specifications at the end of this section.

Clutch plates dateriorated.

Replace clutch plates.

Broken clutch plates.

Replace clutch plates.

Damaged case.

Replace unit.

Broken differential gears.

Replace gears.

Noise (in addition to normal clutch engagement)

DIFFERENTIAL (REAR)

4A2–5

Axle Housing Axle Housing and Associated Parts

420RW030

Legend (1) Lower Link (2) Stabilizer (3) Upper Link (4) Rear Propeller shaft (5) Shock Absorber

(6) (7) (8) (9) (10)

Lateral Rod Brake Hose Coil Spring Parking Cable Axle Assembly

Removal 1. Raise the vehicle and support it with suitable safety stands. The hoist must remain under the rear axle housing. 2. Take out brake fluid. Refer to Hydraulic Brakes in Brake section. 3. Remove rear wheels and tires. Refer to Wheel Replacement in Suspension section. 4. Remove propeller shaft. Refer to Rear Propeller Shaft in this section. 5. Drain the rear axle oil into a proper container. 6. Remove parking brake cable, release the connection between the cable fixing clip equalizer. Refer to Parking Brakes in Brake section. 7. Move the clip aside and pull out the breather hose. 8. Disconnect the ABS connectors (1) and remove the brackets attached to the frame and center link. 350RW023

4A2–6

DIFFERNTIAL (REAR)

9. Loosen the brake tube flare nut, remove the clip and take out the brake tube.

12. Remove the lateral rod fixing bolt and nut from the frame. 13. Remove the upper link mounting bolt and nut (3) from the axle housing.

350RW020

10. Remove the shock absorber. 11. Remove the stabilizer linkage mounting bolts and nuts (2) from the frame side.

460RW015

14. Remove the lower link fixing bolt and nut (4) from the axle housing.

350RW024 460RW016

15. Jack down and remove the coil spring and insulator. 16. Axle housing assembly can be separated from the vehicle upon completion of steps 1 – 15. 17. Remove the brake caliper fixing bolt, loosen the flare nut, release the clip and take out the brake caliper together with the flexible hose. 18. Remove brake disc. 19. Remove antilock brake system speed sensor fixing bolt and the clip and bracket on the axle housing. 20. Remove the brake pipe clip and fixing bolt on the axle housing and take out the brake pipe.

DIFFERENTIAL (REAR)

Installation 1. Install brake pipe. 2. Connect Antilock brake system (ABS) speed sensor and harness, refer to 4–Wheel Anti–Lock Brake System (ABS) in Brake section. 3. Install brake disc. 4. Install brake caliper. Refer to Disk Brakes in Brake section. 5. Install axle housing assembly. 6. Install coil spring and insulator. 7. Install the lower link fixing bolt and nut to the axle housing. For the procedures in items 7–11, refer to Suspension section. 8. Install the upper link bolt and nut to the axle housing.

4A2–7

9. Install the lateral rod fixing nut and bolt to the frame side. 10. Install the stabilizer linkage mounting nut and bolt to the frame side. 11. Install the shock absorber. 12. Install brake tube flare nut, Refer to Disk Brakes in Brake section. 13. Install ABS connector and bracket. 14. Connect breather hose. 15. Install parking brake cable, Refer to Parking Brakes in Brake section. 16. Bleed brakes. Refer to Hydraulic Brakes in Brake section.

Axle Shaft, Oil Seal and Bearing Drum Brake Model

Axle Shaft and Associated Parts Disc Brake Model

420RX001

420RW008

Legend (1) Axle Shaft (2) Backing Plate (3) Oil Seal (4) Bearing (5) Axle Housing (6) Lock Washer (7) Nut

4A2–8

DIFFERNTIAL (REAR)

Removal 1. Raise the vehicle. 2. Remove rear wheels and brake calipers or drums. Do not let calipers hang from the vehicle by the brake line or hose. Use a wire to hang the caliper to the frame to prevent damage to the caliper.

8. Remove oil seal, retainer, and emergency brake assembly. 9. Remove inner race from shaft with OTC–1126 bearing splitter and press.

3. Remove four nuts and lockwashers. 4. Remove shaft assembly from the axle housing. 5. Remove snap ring and bearing cup. 6. Break retainer ring with hammer and chisel.

420RS028

Inspection B Shaft for spalling or grooves from seal wear. B Retainer – bent or damaged. B Replace items if required. 420RS026

7. Break bearing cage with hammer and chisel.

Installation 1. Emergency brake assembly. 2. Install retainer. Note direction – do not install backwards.

420RS027

420RS029

DIFFERENTIAL (REAR) 3. Install oil seal. Note direction. 4. Install bearing assembly, using installer and press.

4A2–9

5. Install retainer ring, using installer and press.

420RS033

420RS030

NOTE: Install bearing with cup towards inboard side.

6. Install snap ring. 7. Install axle shaft assembly into housing. 8. Install bolts, lockwashers, and nuts. Tighten the retainer nuts to the specified torque. Torque : 75 N·m (55 lb ft)

420RS031

4A2–10

DIFFERNTIAL (REAR)

Pinion Oil Seal Pinion Oil Seal and Associated Parts

420RW013

Legend (1) Flange Nut and Washer (2) Flange

(3) Oil Seal (4) Outer Oil Seal Slinger (5) Outer Pinion Bearing (Cup and Cone)

Removal 1. Remove the rear propeller shaft. Refer to Rear Propeller Shaft in this section. 2. Drain the rear axle oil. 3. Check and record preload with an inch pound torque wrench. This will give combined pinion bearing, seal, carrier bearing, axle bearing and seal preload.

425RW018

DIFFERENTIAL (REAR) 4. Remove flange nut and washer by using pinion flange holder J–8614–01 after raising up its staked parts completely.

4A2–11

6. Remove oil seal. 7. Remove pinion oil seal slinger. 8. Remove outer bearing by using remover J–39602.

425RW037

5. Remove flange by using SST J–8614–1 ∼ 3. B Have a suitable container in place to catch lubricant.

425RS090

9. Remove collapsible spacer.

Installation 1. Install collapsible spacer, discard the used collapsible spacer and install a new one. 2. Install outer bearing. NOTE: Do not drive in, but just temporarily set in the outer bearing by hand, which should be indirectly pressed in finally by tightening the flange nut.

425RW038

4A2–12

DIFFERNTIAL (REAR)

3. By using the seal installer J–37263, install a new oil seal (1) that has grease on seal lip.

425RS004

4. Install flange. 5. The pinion washer and a new nut while holding the pinion flange with J–8614–01. B Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Once there is not end play in the pinion, the preload torque should be checked. B Remove J–8614–01. Using an inch-pound torque wrench, check to make sure the pinion preload is equal to or slightly over the reading recorded during removal.

425RW018

6. Install propeller shaft to the frange. 7. Install bolt and nut. Tighten the bolt and nut to the specified torque. Torque: 63 N·m (46 lb ft)

DIFFERENTIAL (REAR)

4A2–13

Differential Assembly Disassembled View

420RW018

Legend (1) ABS Speed Sensor (2) Housing (3) Outer Pinion Bearing (Cup and Cone) (4) Outer Oil Slinger (5) Oil Seal (6) Companion Flange Assembly (7) Pinion Nut Washer (8) Pinion Nut (9) Collapsible Spacer (10) Baffle Plate (11) Inner Pinion Bearing (Cup and Cone) (12) Inner Oil Slinger (13) Pinion gear adj. Shim-Selective (Position) (14) Ring gear and Pinion Gear Assembly (15) Exciter Ring (16) Differential Case

(17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32)

Lock Pin Axle Vent Gasket Cover and Clip Assembly Fill Plug (with Magnet) Mounting Bracket Side Bearing Cap Bolt Side Bearing Cap Ring Gear Bolts Differential Adjustment Shims (Side Bearing Preload and Ring Gear/Pinion Backlash) Side Bearing (Cup and Cone) Differential Shaft Differential Side Gears Side Gear Thrust Washer Pinion Mate Gears Thrustwasher-Differential Pinion Mate Gear

4A2–14

DIFFERNTIAL (REAR) 4. Remove Differential case. B Pry the case from the axle housing at the differential “window”.

Inspecting the Axle Before Disassembly 1. Remove the axle cover from the rear axle and drain the axle lubricant into a suitable container. 2. Check ring gear backlash. Refer to Backlash Adjustment in this section. This information can be used to determine the cause of the axle problem. It will also help when setting up the shim packs for locating and preloading the differential cage. 3. Check case for metal chips and shavings. Determine where these chips and shavings come from, such as a broken gear or bearing cage. B If possible, determine the cause of the axle problem before disassembly.

Disassembly 1. Remove axle shafts. B Refer to axle shaft replacement in this section. 2. Remove ABS sensor. 3. Remove bearing caps and bolts. B Mark the caps and the housing as left and right. CAUTION: Bearing caps are machined with the housing and must be assembled in the same position as removed. Note the matched letter stamped on the caps and carrier. When assembled, the letters on the caps must agree in both the hosizontal and vertical position with the letters on the carrier.

420RW010

5. Remove side bearing outer races and shims. B Mark the races and shims as left and right, and place them with the bearing cups. 6. Remove differential side bearings using remover J–42379 and plug J–39830. B Select insert ; 303174 and collet halves ; 44801 in remover kit J–42379.

415RW003 420RW003

7. Remove ring gear bolts. B Ring gear bolts use right handed threads. CAUTION: DO not pry the ring gear from the case. This will damage the ring and the differential case.

DIFFERENTIAL (REAR) 8. Remove ring gear from the differential. B Drive the ring gear off with a brass drift if necessary.

4A2–15

12. Remove collapsible spacer(1).

B Check drive pinion bearing preload.

415RW011

425RW018

B Check the pinion assembly for looseness by moving it back and forth. (Looseness indicates excessive bearing wear.) 9. Remove pinion flange nut and washer. B Use flange holder J–8614–01 to hold the pinion flange. 10. Remove pinion flange. B Use flange holder J–8614–01 to remove the pinion flange.

13. Remove outer seal, outer oil slinger and outer pinion bearing. 14. Remove inner bearing, inner oil slinger and shim from the pinion. B Press the bearing off the pinion using remover J–42379.

415RW004

B Select insert ; 303174 and collet halves ; 44801 in remover kit J–42379. B Remove the shim.

415RS018

11. Remove pinion from the axle housing. B Thread the pinion nut halfway onto the pinion. B Drive the pinion out of the housing with a hammer and a soft drift. B Remove the nut and then remove the pinion.

15. Remove bearing cups and baffle plate from the axle housing using a hammer and a punch. B Work the cups out of the housing evenly, moving the punch back and forth between one side of the cup and the other. B The baffle plate will be destroyed and should be replaced with a new one.

4A2–16

DIFFERNTIAL (REAR)

16. Remove exciter ring. B Remove the exciter ring from the differential using a mallet or a brass hammer if it is required. NOTE: Discard the exciter ring after removal.

B The sealing surface of the pinion flange for nicks, burrs, or rough tool marks which would cause damage to the seal’s inside diameter and result in an oil leak. B Replace all worn or broken parts. B Ring and pinion gears are matched sets and are both replaced anytime a replacement of either is necessary.

Bearings B Bearings visually and by feel. B The bearings should feel smooth when oiled and rotated while applying as much hand pressure as possible. The large end of the bearing rollers for wear. This is where tapered roller bearing wear is most evident.

425RS097

Cleaning Do not steam clean drive parts which have ground and polished surfaces such as gears, bearings, and shafts. These parts should be cleaned in a suitable solvent. All parts should be disassembled before cleaning. Parts should be thoroughly dried immediately after cleaning. Use soft, clean, lintless rags. Parts may be dried with cimpressed air. Do not allow the bearings to spin while drying them with compressed air.

Inspection and Repair It is very important to carefully and thoroughly inspect all drive unit parts before reassembly. Thorough inspection of the drive parts for wear or stress and subsequent replacement of worn parts will eliminate costly drive component repair after reassembly.

B Bearing cups for wear, cracks, brinelling and scoring. B Bearing and cups are only replaced as sets. B If the rear axle was operated for an extended period of time with very loose bearings, the ring gear and drive pinion will also require replacement. B Low mileage bearings may have minute scratches and pits on the rollers and the bearing cups from the initial pre-load. Do not replace a bearing for this reason. B Bearing cups for cracks or chips.

Shims B Shims for cracks and chips. Damaged shims should be replaced with an equally sized service shim.

Reassembly 1. Install pinion bearing races and baffle plate using outer bearing race installer J–8611–01 / inner bearing race installer J–42836 and drive handle J–8592. NOTE: Baffle plate must be installed, when install the inner pinion bearing race.

Axle Housing B The carrier bore for nicks or burrs that would prevent the outer diameter of the pinion seal from sealing, Remove any burrs that are found. B The bearing cap bores for nicks or burrs. Remove any burrs that are found. B The housing for cracks. Replace the housing if any cracks are found. B The housing for foreign material such as metal chips, dirt, or rust.

Pinion and Ring Gear B Pinion and ring gear teeth for cracking, chipping, scoring, or excessive wear. B Pinion splines for wear. B Pinion flange splines for wear. 425RW019

DIFFERENTIAL (REAR)

4A2–17

10. Assemble discs J–39837–1, arbor J–23597–1 and dial indicator J–8001 to the side bearing bores. NOTE: The bearing bores must be clean and burr-free.

425RW020

2. Clean all the gauge parts. 3. Lubricate the outer and inner bearings with axle lubricant. 4. Place the bearings into the pinion bearing races. 5. Place the inner oil slinger onto the inner pinion bearing. NOTE: The inner oil slinger must be placed between gauge plate and inner pinion bearing when measuring the pinion depth. 6. Install gauge plate J–39837–2, inner J–42827 stud and nut J–21777–43 and outer pilot J–42824 to the pinion bore.

420RW005

7. Hold the stud stationary at the flats of the stud (and). Tighten the stud nut Torque: 2.2 N·m (1.6 lb ft) 8. Rotate the gauge plate and bearings several complete revolutions to seat the bearings. 9. Tighten the stud nut until a torque of 1.6 to 2.2 N·m (1.2 to 1.6 lb ft.) is required to keep the gauge plate in rotation.

420RW005

11. Install the side bearing caps and tighten the bolts to the specified torque. Torque: 108 N·m (80 lb ft) 12. Rotate the gauge plate until the gauging area is parallel with the discs. 13. Position the arbor assembly in the carrier so that the plunger is centered on the gauge area of the gauge plate.

4A2–18

DIFFERNTIAL (REAR)

14. Set the dial indicator to “0”. Place it on the mounting post of the gauging arbor with the contact button touching the indicator pad. Force the dial indicator downward until the needle has made a half turn clockwise. Tighten down the dial indicator in this position.

16. After the ZERO setting is obtained, rotate the gauging arbor until the dial indicator rod does not touch the gauging plate. Record the number the dial indicator needle points to.

425RS022

425RS020

Legend (1) Dial Indicator (2) Ganging Arbor (3) Plunger (4) Gaug Plate 15. Position the plunger on the gauge plate. Move the gauging arbor slowly back and forth and locate the position at which the dial indicator shows the greatest defection. At this point, once again set the dial indicator to “0”. Repeat the procedure to verify the “0” setting.

Legend (1) Example=Dial indicator reading of 0.085 17. Record the pinion depth code on the head of the drive pinion. The number indicates a necessary change in the pinion mounting distance. A plus number indicates the need for a greater mounting distance (which can be achieved by decreasing the shim thickness). A minus number indicates the need for a smaller mounting distance (which can be achieved by increasing the shim thickness). If examination reveals pinion depth code “0”, the pinion is “nominal”.

425RS023

425RS021

DIFFERENTIAL (REAR)

4A2–19

18. Select the shim using the chart; Dial Indicator Reading (inches)

Marking (inches) +3

–1

–2

0.027

–3 0.030

0.028

0.030

0.031

0.030

0.031

0.032

0.030

0.031

0.032

0.033

0.030

0.031

0.032

0.033

0.034

0.030

0.031

0.032

0.033

0.034

0.035

0.029 0.030 0.031 0.032 0.033

0.030

0.031

0.032

0.033

0.034

0.035

0.036

0.034

0.031

0.032

0.033

0.034

0.035

0.036

0.037

0.035

0.032

0.033

0.034

0.035

0.036

0.037

0.038

0.036

0.033

0.034

0.035

0.036

0.037

0.038

0.039

0.037

0.034

0.035

0.036

0.037

0.038

0.039

0.040

0.038

0.035

0.036

0.037

0.038

0.039

0.040

0.041

0.039

0.036

0.037

0.038

0.039

0.040

0.041

0.042

0.040

0.037

0.038

0.039

0.040

0.041

0.042

0.043

0.041

0.038

0.039

0.040

0.041

0.042

0.043

0.044

0.042

0.039

0.040

0.041

0.042

0.043

0.044

0.045

0.043

0.040

0.041

0.042

0.043

0.044

0.045

0.046

0.044

0.041

0.042

0.043

0.044

0.045

0.046

0.047

0.045

0.042

0.043

0.044

0.045

0.046

0.047

0.048

0.046

0.043

0.044

0.045

0.046

0.047

0.048

0.049

0.047

0.044

0.045

0.046

0.047

0.048

0.049

0.050

0.048

0.045

0.046

0.047

0.048

0.049

0.050

0.051

0.049

0.046

0.047

0.048

0.049

0.050

0.051

0.052

0.050

0.047

0.048

0.049

0.050

0.051

0.052

0.053

0.051

0.048

0.049

0.050

0.051

0.052

0.053

0.052

0.049

0.050

0.051

0.052

0.053

0.050

0.051

0.052

0.053

0.054

0.051

0.052

0.053

0.055

0.052

0.053

0.056

0.053

4A2–20

DIFFERNTIAL (REAR)

19. Remove bearing caps and depth gauging tools. 20. Install the correct pinion shim and inner oil slinger onto pinion. NOTE: Do not install pinion gear into housing at this time. 21. If the exciter ring was removed, install the new exciter ring onto the differential case by pressing using the ring gear as a pilot.

23. Install new ring gear bolts. B Tighten the ring gear bolts alternately in stages, gradually pulling the ring gear onto the differential case. Tighten the ring gear bolts in sequence Torque: 108 N·m (80 lb ft) NOTE: Discard used bolts and install new ones.

425RS047 415RS016

22. Install ring gear(1) to the differential case(2)

Side Bearing Preload Adjustment 1. The side bearing preload adjustment must be made before installing the pinion. 2. The side bearing preload is adjusted by changing the thickness of both the left and right shims equally. This maintain the original backlash. 3. Install master side bearings J–39836 onto the case. Remove all nicks, burrs, dirt etc., from the hubs to allow the master bearings to rotate freely.

425RW021

425RW026

DIFFERENTIAL (REAR) 4. Assemble the differential case into the housing (less pinion). Install bearing caps and finger tight bolts. Mount a dial indicator with a magnetic base to the housing and indicate on the flange or head of screw. Force the differential assembly as far as possible in the dirction towards the indicator. With force still applied, set indicator at zero(0).

4A2–21

Pinion Installation B The bearing cups should have been installed in Pinion Depth Adjustment in this section. 1. Place the shim(1) and inner oil slinger(2) on the pinion gear, then install the pinion inner bearing(3) using installer J–42828.

NOTE: Dial indicator set should be capable of a minimum travel of 5.08 mm (0.2 in).

425RW023

425RS107

5. Force the differetial assembly as far as it will go in the opposite direction. Repeat these steps until the same reading is obtained. 6. RECORD THE READING OF THE INDICATOR. This amount, in shims, will be included in the final assembly shim stack to establish side bearing preload and ring gear and pinion backlash. 7. After marking sure the readings are correct, remove the indicator and differetial assembly from the housing.

B Drive the bearing until the bearing cone seats on the pinion shims. 2. Install a new collapsible spacer. B Lubracate the pinion bearings with axle lublicant. 3. Install pinion to the axle housing. 4. Install outer pinion bearing onto the pinion. B Hold the pinion forward from inside the case while driving the bearing onto the pinion. 5. Install oil seal slinger. 6. Install pinion oil seal using installer J–37263. 7. Install the pinion flange to the pinion by tapping it with a rawhide hammer until a few threads show through the pinion flange. 8. Install pinion washer and a new nut while holding the pinion flange with flange holder J–8614–01. B Tighten the nut until the pinion end play is just taken up. Rotate the pinion while tightening the nut to seat the bearings. Torque:217-678 N·m (160-500 lb ft) Once there is no end play in the pinion, the preload torque should be checked. B Remove flange holder J–8614–01. Using an inch-pound torque wrench, check the pinion preload by rotating the pinion with the wrench.

4A2–22

DIFFERNTIAL (REAR) 8. The remaining amount of shims, which is the difference between the overall found in step 6 of Side Bearing Pre-load Adjustment and step(7) above, should be placed on the other side of the differential case, plus additional 0.38 mm (0.015 in) for obtaining preload and backlash. 9. Place the required amount of shims on each hub as determined in the previous steps and assemble side bearing cone by using installer J–21784 and handle J–8592.

425RW018

Preload should be at 1.0 to 1.6 N·m (8 to 14 in lbs.) on new bearings, or 0.46 to 0.69 N·m (4 to 6 in lbs.) for used bearings. B If the preload torque is below the preloads given above, continue torquing the nut in small increments. Check the preload after each tightening. Each tightening increases the bearing preload by several pounds. If the bearing preload is exceeded, the pinion will have to be removed, and a new collapsible spacer installed. B Once a preload of 1.0 to 1.4 N·m (8 to 12 in lbs.) has been obtained, rotate the pinion several times to assure that the bearings have seated. Recheck the preload, and adjust if necessary.

Determination of Backlash & Preload Shims 1. Install master side bearings onto the case. 2. Install differential assembly into the carrier. 3. Install the bearing cap and finger tight bolts. 4. Set up the dial indicator. 5. Force the differential assembly away from the pinion gear until it is completely seated against the cross bore face of the carrier. 6. With force still applied to the differential case, place the tip of dial indicator on a machined surface of the differential case, if available, or on the head of a ring gear screw, and set the indicator at zero(0). 7. Force the ring gear to mesh with the pinion gear. Rock the ring gear slightly to make sure the gear teeth are meshed. Repeat this procedure several times until the same reading is obtained each time. Be sure the indicator reads zero(0) each time the ring gear is forced back into contact with the cross bore face. This reading will be the necessary amount of shims to be placed between the differential case and side bearing cone on the ring gear side.

425RW022

10. Total torque to rotate — Increase of pinion torque to rotate due to differential case assembly shall not exceed 3.4 N·m (30 in lbs.) divided by the gear ratio. 11. Assembly the spreader J–24385–B and indicator to the carrier as shown in figure. Spread the carrier 0.5 mm (0.02 in) for differential installation.

420RW004

CAUTION: Do not spread the carrier over 0.5 mm (0.02 in). 12. Remove the indicator.

DIFFERENTIAL (REAR)

4A2–23

11. Install the cover with sealant.

Backlash Adjustment 1. Install the differential case assembly and bearing caps. 2. Rotate the case several times to seat the bearings. 3. Remove the spreader. 4. Install the side bearing cap bolts. Tighten side bearing cap bolts Torque: 108 N·m (80 lb ft) 5. Install a dial indicator to the case using a magnetic base. 6. Place the indicator stem at the heel end of a tooth. B Set the dial indicator so that the stem is in line with the gear rotation and perpendicular to the tooth angle.

Torque: 40 N·m (30 lb ft) 12. Fill the axle lubricant.

Gear Tooth Pattern Check Checking the ring gear to pinion tooth pattern is to be done only after setting up the axle according to the methods in this section. The pattern check is NEVER to be used as an initial check, or instead of checking pinion depth and backlash adjustments. This check is only to be verify the correct adjustment of the gear set after set up.

425RS038

425RS087

7. Check and record the backlash at three points around the ring gear. B The pinion must be held stationary when checking backlash. B The backlash should be the same at each point within 0.07 mm (0.003 in). If the backlash varies more than 0.07 mm (0.003 in), check for burrs, a distorted case flange, or uneven bolting conditions. 8. Backlash at the minimum lash point measured should be between 0.13 and 0.20 mm (0.005 and 0.008 in) for all new gear sets. 9. If the backlash is not within specifications, move the ring gear in or out from the pinion by increasing the thickness of one shims, and decreasing the thickness of the other shim by the same amount. This will maintain the correct rear axls side bearing preload. B Moving 0.05 mm (0.002 in) worth of shim from one side of the differential to the other will change the backlash adjustment by 0.03 mm (0.001 in). 10. After obtaining correct tooth contact described in later, install ABS speed sensor.

Legend (1) Heel (2) Toe (3) Concave Side (Coast) (4) Convex Side (Drive) 1. Wipe all oil out of the carrier, and carefully clean each tooth of the ring gear. 2. Use gear marking compound 1052351 or equivalent and apply this mixture sparingly to all ring gear teeth, using a medium-stiff brush. When properly used, the area of pinion tooth contact will be visible when hand load is applied. 3. Tighten the bearing cap bolts to the specified torque. 4. Expand the brake shoes until a torque of 54 to 68 N·m (40 to 50 lb ft.) is required to turn the pinion. A test made without loading the gears will not give a satisfactory pattern. Turn the pinion flange with a wrench so that the ring gear rotates one full revolution, then reverse the rotation so that the ring gear rotates one revolution in the opposite direction. 5. Observe the pattern on the ring gear teeth and compare this with figure.

4A2–24

DIFFERNTIAL (REAR)

425RS039

Adjustments Affecting Tooth Contact Two adjustments can be made which will affect tooth contact pattern: backlash, and the position of the drive pinion in the case. The effects of bearing preloads are not readily apparent on head loaded tooth contact pattern tests; however, these adjustments should be within specifications before proceeding with backlash and drive pinion adjustments. The position of the drive pinion is adjusted by increasing or decreasing the distance between the pinion head and the centerline of the ring gear. Decreasing the distance will move the pinion closer to the centerline of the ring gear. Increasing the distance will move the pinion farther away from the centerline of the ring gear. Backlash is adjusted by means of the side bearing adjusting shims which move the entire case and ring gear assembly closer to, or farther from, the drive pinion. (The adjusting shims are also used to set side bearing preload.) If the thickness of the right shim is increased (along with decreasing the left shim thickness), backlash will increase. The backlash will decrease if the left shim thickness is increased (along with a decrease in right shim thickness).

DIFFERENTIAL (REAR)

4A2–25

Differential Case Assembly Disassembled View

425RW014

Legend (1) Thrust Washer (for Pinion Gear) (2) Pinion Mate Gear (3) Thrust Washer(for Side Gear) (4) Side Gear

(5) (6) (7) (8)

Differential Shaft Lock Pin Bolt Differential Case

4A2–26

DIFFERNTIAL (REAR)

Disassembly

Reassembly

1. Remove lock pin using a small drift.

1. Install side gear with thrust washer. 2. Install the pinion mate gear with thrust washer by engaging it with the side gears while turning both pinion mate gears simultaneously in the same direction.

425RS098

2. Remove the differential shaft by using a soft metal rod and a hammer. 425RS048

3. Install differential shaft. 1. Be sure to install the differential shaft so that it is in alignment with the lock pin hole in the differential case.

425RS043

3. Remove pinion mate gear and thrust washer. 4. Remove side gear and thrust washer.

Inspection and Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. B Ring gear, pinion gear B Bearing B Side gear, pinion mate gear, differential shaft B Differential case, carrier B Thrust washer B Oil seal

425RS049

4. Install lock pin. After lock pin installation, stake the case to secure the lock pin.

DIFFERENTIAL (REAR)

4A2–27

Limited Slip Differential Assembly Disassembled View

425RW004

Legend (1) Thrust Washer–Differential Pinion Mate Gear (2) Pinion Mate Gear (3) Dished Spacer (4) Disc (5) Plate

(6) (7) (8) (9) (10) (11)

Differential Plate Retainer Lock Pin Differential Case Ring Gear Bolts Differential Shaft Differential Side Gear

Disassembly 1. Place the holder J–39824 into a vise. Position the differential on the holder with the ring gear side down. 2. Remove Lock pin (1) from differential shaft using a punch. 3. Remove Differential shaft (2) using hammer and punch. Place shop towel behind case to prevent differential shaft from dropping out of case.

425RW005

4A2–28

DIFFERNTIAL (REAR)

4. Assemble clutch pack unloading tool . a. Install cap J–34174–1 to the bottom differential side gear. b. Install threaded screw cap J–34174–2 to top differential side gear. Thread forcing screws J–22342–15 into threaded screw cap until it becomes centered into the bottom cap.

NOTE: B You may have to adjust the forcing screw slightly to allow the case to rotate. 7. Assemble LSD service adapter J–39834 onto long drive handle J–8592.Insert it into differential shaft hole of case. Pull on handle and rotate case until pinion mate gears can be removed.

901RW153

c. Tighten forcing screw until tight enough to collapse dished spacers and allow looseness between side and pinion mate gears. 5. Both pinion mate gear thrust washers using a shim stock (1) of 0.51 mm (0.020 in.) or equivalent tool to push out washers.

901RW068

8. Remove pinion mate gears. 9. Hold side gear top clutch pack (1) with one hand and remove positraction unloading tools.

425RW008

10. Remove top side gear and clutch pack. 425RW007

6. Relieve tension of dished spacers by loosening forcing screw.

NOTE: B Keep the stack of plates and discs intact and in exactly the same position while they are being removed. 11. Remove case from holder. Turn case with flange or ring gear side up to allow side gear and clutch pack to be removed from case.

DIFFERENTIAL (REAR) 12. Remove differential plate retainer from both clutch packs to allow separation of the plates and discs. NOTE: B Keep the discs and plates in the same order as they were removed.

4A2–29

Reassembly 1. Lubricate thrust face of side gears, plates and discs with the proper limited slip rear axle lubricant. 2. Assemble plates and discs in exactly in the same position as they were removed, regardless of whether they are new or original. 3. Install differential plate retainer to ears of plates. NOTE: B Make sure both retainers are Completely seated on ears of plates. 4. Install clutch pack and side gear into bottom side gear bore. Make sure clutch pack stays assembled to side gear splines, and that retainers are completely seated into pockets of case. NOTE:

425RW009

Legend (1) Differential Plate (2) Differential Disc (3) Dished Spacer (4) Side Gear

B To prevent clutch pack from falling out of case, hold clutch pack in place by hand while repositioning case on bench. 5. Install other side gear and clutch pack. Make sure clutch pack stays assembled to side gear splines, and retainers are completely seated into pockets of case. 6. Hold clutch pack in position and assemble screw cap J–34174–2, cap J–34174–1 and forcing screw J–22342–15. Tighten forcing screw into bottom cap to hold both clutch packs in position. 7. With tools assembled to case, position case on holder J–39824 by aligning splines of side gear with those of shaft. Tighten forcing screw to compress clutch packs in order to provide clearance for pinion mate gears.

Inspection and Repair Cleaning B All parts with solvent.

Visual Inspection B Clean all parts with solvent. B Plates and Discs. If any one disc or plate in either stack shows evidence of excessive wear or scoring, the complete stack is to be replaced on both sides. B Side Gears and Pinion Mate Gears. The gear teeth of these parts should be checked for extreme wear and possible cracks. The external teeth of the side gear, which retain the concentric groove discs, should also be checked for wear or cracks. B If replacement of one gear is required due to wear, etc., then both side gears, pinion mate gears, and thrust washers are to be replaced. B Differential Shaft. If excessive wear is evident, the differential shaft should be replaced. B Differential Plate Retainers. If wear is evident on any one of the differential plate retainers, all four retainers must be replaced. B Differential Case. If scoring, wear or metal pickup is evident on the machined surfaces, replacement of the case is necessary.

901RW069

8. Install pinion mate gears. B Place the pinion mate gears into the differential 180 degrees apart.

4A2–30

DIFFERNTIAL (REAR)

9. While holding gears in place, insert LSD service adapter J–39834 with long drive handle J–8592 in differential shaft hole of case. Pull on long drive handle J–8592 and rotate case, allowing gears to turn. Make sure that holes in pinion mate gears align with holes in case.

12. Position differential shaft in case and drive in with hammer. Be sure lock pin hole of differential shaft (5) is properly aligned to allow installation of lock pin (3). Be sure that thrust washers and differential pinion mate gears are aligned with the differential case (4). Install new lock pin to proper depth using a punch. Stake metal of case over pin in two places, 180 degrees apart.

901RW070

B It may be necessary to adjust tension on forcing screw to rotate case. 10. Tighten forcing screw to compress the clutch packs, to allow installation of spherical thrust washers. 11. Lubricate spherical thrust washers (2), and assemble into case (1). Use a small screw driver to push washers into place. Remove tools.

425RW012

425RW013

DIFFERENTIAL (REAR)

4A2–31

Main Data And Specifications General Specifications Rear axle Type Rear axle Size

Salisbury, Semi–floating 226 mm (8.9 in)

Gear type

Hypoid

Gear ratio

4.300

Differential type

Two pinion

Lubricant Grade

GL–5: (Standard differential) GL–5, LSD: (Limited slip differential)

Locking Differential Lubricant

Capacity

80W90 GL–5 (USE Limited Slip Differential Gear Lubricant or Friction Modifier Organic Additive) 1.77 liter (1.87 US qt)

Torque Specifications

E04RX002

4A2–32

DIFFERNTIAL (REAR)

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

ILLUSTRATION

TOOL NO. TOOL NAME

J–8614–01 Pinion flange holder

J–42836 Installer; Inner bearing outer race

J–37263 Installer; Pinion oil seal

J–42824 Pilot;Outer

J–42379 Remover; Bearing

J–21777–43 Nut & Stud

J–39830 Adapter; Side bearing plug

J–42827 Pilot;Inner

J–8611–01 Installer; Outer bearing outer race

J–39837–2 Gauge plate

J–8592 Grip

J–8001 Dial indicator

DIFFERENTIAL (REAR) ILLUSTRATION

TOOL NO. TOOL NAME

J–39837–1 Disc (2 required)

J–23597–1 Arbor

J–42828 Installer; Pinion bearing

J–21784 Installer; Side bearing

J–39602 Remover; Outer bearing

J–24385–B Spreader

ILLUSTRATION

4A2–33

TOOL NO. TOOL NAME J–39858 Clutch pack unloading tool kit Includes J–34174–1/J–34174–2 Screw cap and Cap J–22342–15 Forcing screw

J–39834 Limited–slip differential (LSD) service adapter

J–39824 Holder

J–39836 Side bearing preload master bearings

SECTION DRIVELINE CONTROL SYSTEM 4B1–1 AXIOM

DRIVELINE/AXLE DRIVELINE CONTROL SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Shift On The Fly System . . . . . . . . . . . . . . . . . Outline of Shift on The Fly System . . . . . . . . . Functions of Indicator Lamp . . . . . . . . . . . . . . Shift On The Fly Electrical Equipment . . . . . . Axle Shaft Connection and Disconnection . .

4B1–1 4B1–2 4B1–2 4B1–4 4B1–5 4B1–5

Shift On The Fly Controller . . . . . . . . . . . . . . . Shift On The Fly Controller and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4B1–7 4B1–7 4B1–7 4B1–7

4B1–2 DRIVELINE CONTROL SYSTEM

Shift On The Fly System Outline of Shift on The Fly System The shift on the fly system switches between 2 wheel drive (2WD) and 4 wheel drive (4WD) electronically by the driver turning the TOD switch on the instrument panel. This system will control the following operations. (Shifting between “4H” and “4L” must be performed by TOD switch.) 1. Transmitting the torque to the front propeller shaft. 2. Connecting front wheels to, and disconnecting them from, the front axles by axle motor actuator. 3. Indicating on instrument panel. 4. 4WD out signal to other Electronic Brake Control Module (EBCM).

System Diagrams

412R200008

DRIVELINE CONTROL SYSTEM 4B1–3

Normal Operation The axle disconnect controller is driven by the signal from TOD control unit and the axle motor actuator connects (or disconnects when the 4WD switch is deactivated) the front wheels to the front axles. Time Chart of Shifting Under Normal Condition

F04R200002

4WD out signal to other Electronic Brake Control Module : TOD Control Unit of shift on the fly sends 4WD out signal to other Electronic Brake Control Module as below. 4WD out signal (Period)

Vehicle Condition

Transfer position switch

Front axle switch

120 ms

2WD

2WD (Open)

240 ms

4WD

4WD (Close)

4B1–4 DRIVELINE CONTROL SYSTEM

Functions of Indicator Lamp TOD Switch and Indication of Drive Mode The TOD switch sends signals to the TOD control unit which selects drive modes and controls the shift on the fly system (axle disconnect : ADC). TOD switch t t state

Drive mode

Rear-wheel drive (RWD)

TOD

Electronic torque split 4WD (HIGH) (TOD)

Low range mechanical direct 4WD (LOW) (4L)

Transfer shift condition

Permissible during driving (less than 100 km/h or 62 mph)

AT: Neutral Brake: Applied Th car stops The t (less (l than 2 km/h or 1.2 mph and less than 1500 rpm)

Transfer position detection

Shift on the fly

4HSW

4LSW

Axle SW

ADC circuit

OFF

Turning on electricity

OFF

Turning off electricity

OFF

Turning off electricity

TOD indicator state

ADC: Shift on the fly SW: Switch Bulb check :The bulb of indicator lamp is checked for 2 seconds when ignition key is turned on. Bulb Check When the starter switch is turned on, the TOD indicator lamps comes on as shown below. NOTE: Once the starter switch is turned on, all the TOD indicator lamps are lit for two seconds even if the transfer lever is in any position.

C07RW016

DRIVELINE CONTROL SYSTEM 4B1–5

Shift On The Fly Electrical Equipment Axle Shaft Connection and Disconnection

412R200006

Axle Disconnect Controller

Actuator Assembly

412RY00004

828RY00009

4B1–6 DRIVELINE CONTROL SYSTEM

828RY00010

Legend (1) Output Signal (2) Output Signal (3) 12V (4) Input Signal (5) GND 1. Connect 12V with terminal (3) and the ground with the terminal (6). 2. Send the signal to the terminal (4) 2WD → 4WD less than 2.4V 4WD → 2WD more than 9.0V 3. Confirm the output signal from the terminals (1) & (2) (2 seconds output) INPUT SIGNAL

OUTPUT SIGNAL (2 seconds)

2WD → 4WD

Less than 2.4V

12V

4WD → 2WD

More than 9.0V

12V

4. If the trouble occurs afther above test, charge the Axle Disconnect Controller to the new one.

DRIVELINE CONTROL SYSTEM 4B1–7

Shift On The Fly Controller Shift On The Fly Controller and Associated Parts

828RY00003

Legend (1) Nut

Removal 1. Disconnect the battery ground cable. 2. Remove the front console assembly. Refer to Consoles in Body and Accessories section. 3. Disconnect the connector from the controller. 4. Remove the nut. 5. Remove the controller.

(2) SOF Controller (3) Connector

Installation To install, follow the removal steps in the reverse order, noting the following points. Torque: Nut (1) 8 N·m (69 Ib in)

SECTION DRIVE LINE CONTROL SYSTEM (TOD)

4B2–1

AXIOM

DRIVELINE/AXLE DRIVELINE CONTROL SYSTEM (TOD) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Transfer Position and Drive Mode . . . . . . . . TOD Control . . . . . . . . . . . . . . . . . . . . . . . . . . TOD Indicator Control . . . . . . . . . . . . . . . . . . Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . System Components . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Front and Rear Speed Sensors . . . . . . . . . . Electromagnetic Coil . . . . . . . . . . . . . . . . . . . Multi Plate Disk Clutch Pack . . . . . . . . . . . . Mechanical Lock Sleeve . . . . . . . . . . . . . . . . High-Low Planetary Gear Set . . . . . . . . . . . 4H and 4L Switch . . . . . . . . . . . . . . . . . . . . . . Transfer Connector (12-pin type) . . . . . . . . Transfer Connector (8-pin type) . . . . . . . . . TOD Indicator Lamps (on the instrument panel) . . . . . . . . . . . . . . Check Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . TOD ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . High-Low Shift Motor . . . . . . . . . . . . . . . . . . . Motor Position and Encoder Position Code Encode Position Plate . . . . . . . . . . . . . . . . . . Shift High Range and Low Range . . . . . . . .

4B2–1 4B2–2 4B2–2 4B2–3 4B2–3 4B2–3 4B2–4 4B2–4 4B2–5 4B2–5 4B2–5 4B2–5 4B2–6 4B2–6 4B2–6 4B2–6 4B2–7 4B2–7 4B2–8 4B2–9 4B2–10 4B2–10 4B2–10

Functions of TOD Switch and Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–11 TOD Switch and Indication of Drive Mode . 4B2–11 Check Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–13 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–14 General Information Diagnosis . . . . . . . . . . 4B2–14 Self-diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–14 Precautions on Diagnosis . . . . . . . . . . . . . . . 4B2–16 Basic Diagnostic Flow Chart . . . . . . . . . . . . . . 4B2–18 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–19 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–20 Connector List . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–24 Checking Failed Pin . . . . . . . . . . . . . . . . . . . . . 4B2–26 Connector Pin Assignment . . . . . . . . . . . . . . 4B2–26 Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–28 Checking Failed TOD Control Unit Pin . . . . . 4B2–30 Tech 2 Scan Tool . . . . . . . . . . . . . . . . . . . . . . 4B2–32 Getting Started . . . . . . . . . . . . . . . . . . . . . . . . 4B2–33 Operating Procedure . . . . . . . . . . . . . . . . . . . 4B2–33 Diagnostic Trouble Codes . . . . . . . . . . . . . . . . 4B2–35 Diagnosis from Trouble Codes . . . . . . . . . . . . 4B2–36 Trouble Diagnosis Depending on The Status of TOD Indicator . . . . . . . . . . . . . . . . . . . . . . . . 4B2–67 Diagnosis from Symptom . . . . . . . . . . . . . . . . . 4B2–102 CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

4B2–2

DRIVE LINE CONTROL SYSTEM (TOD)

General Description

412R200008

TOD (Torque on Demand) system is traction state control system to vehicle.

Transfer Position and Drive Mode Three drive modes can be selected through operation of TOD switch and transfer lever. Transfer Position

TOD SWITCH

Mode

HIGH

RWD

TOD

4WD (HIGH)

Electronically controlled torque split four wheel drive

4WD (LOW)

Low-speed mechanical lock-up four wheel drive

LOW

The electronic control unit (ECU) judges the signals from the TOD switch and controls the transfer drive mode and shift-on-the-fly system status.

Drive mode Rear wheel drive

DRIVE LINE CONTROL SYSTEM (TOD)

TOD Control The TOD position usually drives the rear wheels, and transmits the torque to the front wheels with the help of electronically controlled torque split mechanism according to running conditions encountered. The driving force is directly transmitted to the rear wheels. This force is split by the transfer and delivered to the front wheels. The magnitude of the torque transmitted to the front wheels is controlled by changing the pressing force of the multi plate disk clutch built in the transfer unit. The pressing force of the clutch is controlled by changing the duty ratio to the electromagnetic coil mounted to the rear of the clutch. When the clutch is completely disengaged, the rear wheels are driven. When the clutch is completely engaged, a rigid four wheel drive mode is obtained. The torque split status is controlled continuously between the rear wheel and four wheel drive modes. This system includes front and rear speed sensors, and receives throttle position sensor and engine speed information from the PCM, ABS control unit signal, brake switch signal, and shift motor position information. The control unit receives signals sent from these sensors and changes the pressing force of the multi-plate disk clutch to determine the torque distribution on the front and rear wheels. Therefore, when the slip of the rear wheels is increased against the current torque level in the normal rear wheel drive mode, the control unit detects the slip condition, determines the optimum torque based on the feedback control logic, and increases the torque to the front wheels. The control unit uses the signal from the throttle position sensor to predict the future vehicle condition and the intention of the driver with respect to acceleration and deceleration, and determines the initial torque distribution using these data and the information from the speed sensors. In case of small circle turning in the parking lot, for example, the control unit minimizes the clutch pressing force to restrict a braking phenomenon. When the ABS becomes active, the control unit optimizes the clutch pressing force to ensure stable braking.

TOD Indicator Control The TOD indicator on the instrument panel informs the driver of the current working status of the transfer unit. The information is the drive mode (2H, TOD, 4L, transition). The indicator can display occasional errors and corresponding error codes.

Abbreviations ABS

Anti-lock Brake System

ADC

Axle Disconnect (Shift on the fly system)

Battery Voltage

VIGN

Ignition Voltage

4B2–3

4B2–4

DRIVE LINE CONTROL SYSTEM (TOD)

System Components Parts Location

A04R200004

Legend (1) Mechanical Lock Sleeve (2) Drive Chain (3) Clutch Pack (4) Electromagnetic Clutch Solenoid (5) Output Shaft (6) Rear Output Coupling (7) Rear Speed Sensor (8) Drive Sprocket (9) Spring (10) Return Spring (11) Lockup Shift Fork (12) Front Speed Sensor (13) High-Low Shift Motor (14) Driven Sprocket

(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29)

Shift Shaft Front Output Coupling Front Output Shaft Shift Cam Torsional Spring High-Low Shift Fork Shift Rod Input Shaft Reduction Hub High-Low Planetary Gear High Position Low Position Oil Pump Free Position Lock Position

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–5

Front and Rear Speed Sensors

Multi Plate Disk Clutch Pack

The sensors are built in the transfer case, and detect the rotation of rotors directly coupled to the propeller shafts. Thirty rectangular pulses are output per one rotation of the propeller shaft.

Transmits the torque determined by the clutch pressing force to the front propeller shaft via the front drive chain.

262RW029

261RW045

Mechanical Lock Sleeve Couples the front and rear propeller shaft mechanically when the transfer shaft is in the 4L position.

Electromagnetic Coil Receives the duty signals from the TOD control unit and controls the pressing force of the clutch pressure cam.

262RW028

261RW044

4B2–6

DRIVE LINE CONTROL SYSTEM (TOD)

High-Low Planetary Gear Set

Transfer Connector (12-pin type)

Establishes an auxiliary transmission mechanism. When the TOD switch is set to the 2H or TOD position, the reduction gear ratio is 1.000 and the corresponding driving force is generated. When the TOD switch is set to the 4L position, the reduction gear ratio is 2.480 and the corresponding driving force is generated.

Transmits the input and output signals of the speed sensors, electromagnetic coil, and 4H and 4L switche to the vehicle harness. A waterproof 12-pin type is used.

261RW046

Transfer Connector (8-pin type) 262RW030

4H and 4L Switch

Transmits the output signals of the shift motor position to the vehicle harness and power for the shift motor to the transfer. A waterproof 8-pin type is used.

Detects the shift position of the transfer from the movement of the shift rod and outputs signals to the TOD control unit.

261RY00039

261RW002

DRIVE LINE CONTROL SYSTEM (TOD)

TOD Indicator Lamps (on the instrument panel) Inform the following items. B Bulb check B Drive mode B ABS IN status B BRAKE ON status

4B2–7

Check Lamp Inform the following items. B Bulb check B Fail (fail alarm) B Trouble code

821R200016

4B2–8

DRIVE LINE CONTROL SYSTEM (TOD)

TOD ECU This control unit is mounted to the clutch pedal position via a special bracket.

826R200019

Legend (1) Brake Pedal Bracket

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–9

High-Low Shift Motor

F07R200002

Legend (1) Reduction Hub (2) Mechanical Lock Sleeve (Including the built-in Spring) (3) Lockup Shift Fork (4) Return Spring (5) To TOD Control Unit (6) Fixed Contact Point (7) Encoder (8) Worm gear (9) Rotate (10) Shift Motor (11) The shift cam (12) can be turned freely around the shift shaft (14).

When the TOD switch is changed to the 4L (or TOD) position from the TOD (or 4L) position, the TOD control unit drives the high–low shift motor according to the signal. The transfer is shifted to low range from high range (or to high range from low range) by the shift motor. The high-low shift motor can run, only when the operation meets the following conditions to prevent an unexpected shift between high and low range by a operation error. 1. The car stops. (less than 2 km/h or 1.2 mph and less than 1500 rpm.)

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25)

Shift Cam Torsional Spring Shift Shaft Shift Rod High-Low Shift Fork High Low 2H and TOD Position Direct Four Wheel Drive (4L Position) Earth High Low High Low

2. The AT selector position is neutral. 3. The brake is applied. (brake switch is on.) The shift motor has a built-in encoder which watches motor rotation position. The control unit controls the rotation of the shift motor based on the position code detected by the encoder. The encoder position plate turns together with the shift shaft and switches on or off the current from the 4 (four) fixed contact points on the case, then the control unit recognizes the rotation position of the shift motor.

4B2–10 DRIVE LINE CONTROL SYSTEM (TOD)

Motor Position and Encoder Position Code High-Low shift Motor Encoder Signal

High-Low Shift Motor Position Position a

Position b

Position c

Position d

High End

OFF

Near High End

OFF

High Position

OFF

Middle Zone (1)

Middle Zone (2)

OFF

Neutral Position

OFF

Middle Zone (3)

OFF

Low Position

OFF

Low End

OFF

State of Motor High Position

Low Position

Encode Position Plate

F04R100005

Legend (1) OFF Aria (2) ON Aria

Shift High Range and Low Range When the car is stops (less than 2km/h or 1.2 mph and less than 1500 rpm), the AT selector position is neutral, the brake is applied, and the TOD switch is changed to 4L from TOD (or to TOD from 4L), the high-low shift motor starts by power applied from the TOD control unit and turns the shift shaft through the worm gear. The shift shaft turns the shift cam through the torsional spring. The end of the shift cam moves the lockup shift fork and the spiral groove on the outside of the shift cam slides the high–low shift fork.

(3) (4) (5)

Low High Earth

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–11

Functions of TOD Switch and Indicator Lamp TOD Switch and Indication of Drive Mode The TOD switch sends signals to the TOD control unit which selects drive modes and controls the shift on the fly system (axle disconnect : ADC). TOD switch state

Drive mode

Rear-wheel drive (RWD)

TOD

Electronic torque split 4WD (TOD)

Low range mechanical direct 4WD (4L)

Transfer position detection

Transfer shift condition

Permissible during driving (less than 100 km/h or 62 mph)

AT: Neutral Brake: Applied The car sto stopss (less than 2 km/h or 1.2 mph and less than 1500 rpm)

Shift on the fly

4HSW

4LSW

Axle SW

ADC circuit

OFF

Turning on electricity

OFF

Turning off electricity

OFF

Turning off electricity

TOD indicator state

ADC: Shift on the fly SW: Switch TOD control unit terminal No.

TOD Switch state

TOD indicator

TOD indicator state

TOD switch

7(Front)

8(Rear)

19(Auto)

30(2H)

43(4L)

OFF

TOD

OFF

4B2–12 DRIVE LINE CONTROL SYSTEM (TOD) Indication During Transition of Shift Rod When the TOD switch is turned, and the signals from the AXLE switch do not comply with the signal conditions of the 4H and 4L switch, the indicator lamp state selected on the TOD switch and light-off mode are repeatedly output at an interval of 1.0 second.

NOTE: After the TOD switch is turned to the specified position and the AXLE switch generates compliant signals, the normal output status is returned.

C07R100010

Bulb Check When the starter switch is turned on, the TOD indicator lamps go on as shown below.

NOTE: Once the starter switch is turned on, all the TOD indicator lamps are lit for two seconds even if the TOD switch is in any position.

C07RW016

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–13

Simplified checking method of ABS IN and BRAKE ON signals: In the event that any of the signal inputs listed below are observed while the self-diagnostic code is being displayed (the self-diagnostic connector is short-circuited to GND), you can simply check the ABS IN and BRAKE ON signals as shown in the figures below.

C07R200002

Check Lamp Check Lamp Bulb Check When the starter switch is turned on in the normal state, the control unit turns on the CHECK lamp to check the bulb.

C07RW019

4B2–14 DRIVE LINE CONTROL SYSTEM (TOD)

Diagnosis General Information Diagnosis The troubles on TOD are classified into the group that can be identified by the lighting status of the TOD indicator lamps and those that can be recognized as abnormal phenomena of the vehicle by the driver. The troubles that can be identified by the lighting status of the TOD indicator lamps are examined by the procedures “Diagnosis from Trouble Codes” and “Trouble Diagnosis Depending on The Status of TOD Indicator”. The troubles that can be recognized as abnormal phenomena of the vehicle by the driver are examined by the procedure “Diagnosis from symptom”.

Self-diagnosis The control unit has a function of self-diagnosis. If a trouble occurs in the course of system startup, the control unit blinks the CHECK lamp and saves the trouble code.

C07RW021

NOTE: If an intermittent fault occurs, the control unit stops blinking upon removal of the fault. The trouble code is saved to the control unit.

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–15

Indication Method of Trouble Code B Turn on the starter switch, while the engine does not start. B Short-circuit terminal 8 of the self-diagnostic connector to GND (terminal 4 or 5) to display the trouble code on the CHECK lamp.

826R200011

B If no trouble codes exist, code “12” is displayed continuously. B If trouble codes exist, code “12” is displayed three times, and the trouble codes, starting from the smaller code number, are displayed three times respectively.

C07RY00018

4B2–16 DRIVE LINE CONTROL SYSTEM (TOD) How to Clear The Trouble Code The trouble codes saved to the control unit can be deleted by the following procedure if the starter switch is being in the OFF position. 1. Short-circuit terminal 8 of the self-diagnostic connector to GND (terminal 4 or 5). 2. Turn on the starter switch while maintaining the state of step1, and stop short-circuiting terminal 8 to GND within five seconds.

826R200011

3. If the conditions shown in steps 1 and 2 are met, the trouble codes saved to the control unit are cleared. (After the codes are completely deleted, the code 12 that indicates the normal condition is continuously displayed.)

Precautions on Diagnosis Replacement of Control Unit The control unit itself rarely fails. In most cases, the harnesses have failed (i.e. short-circuit) to cause secondary troubles. Other cases include that the cause has been unknown due to intermittent occurrence of troubles and the troubles are removed accidentally along with replacement of control unit, resulting in misjudgment of cause. Therefore, before replacing the control unit, check the connector joints and whether the unspecified current flows in the control unit due to short-circuit between harnesses. Trouble Intermittently Observed Troubles intermittently observed are mostly attributable to temporary imperfect connection of harnesses and connectors. When such troubles are found, check the associated circuit according to the following procedure. 1. Check whether improper connectors are plugged in or connector terminals are completely engaged. 2. Check whether the terminals are deformed or damaged. If yes, remove the deformation or damage and connect the terminals securely.

3. It is likely that wires in the harness are falsely broken. Therefore, in examination of failed harness circuit, shake the harness for check to such extent that the harness will not be damaged. Test Run of Failed TOD Vehicle If the TOD indicator lamps experienced faulty operation even once in the past, the failed portion can be identified by use of the procedure “Diagnosis from Trouble Codes” or “Trouble Diagnosis Depending on the Status of TOD Indicator”. If the troubles that are only recognized as abnormal phenomena of the vehicle by the driver are observed, conduct the test run in the following procedure to reproduce the faulty phenomena and diagnose the fault for each phenomenon. 1. Start the engine, and check that the TOD indicator lamps are turned on for about two seconds for initial check; the CHECK lamp goes off; and the TOD indicator lamps display the specified drive mode. (If the CHECK lamp starts blinking, read the trouble codes and identify the failed portion.) 2. While keeping the vehicle standstill, operate the TOD switch to change the modes: 2H mode→TOD mode→4L mode→TOD mode→2H mode. Check that the TOD indicator lamps correctly display the status whenever the mode is changed. If the transition status is displayed during the shift operation, run the vehicle a little to complete shifting. 3. Slowly start the vehicle in the TOD mode, and add the power to accelerate to at least 40 km/h (25 mph)and maintain the speed for about two minutes. Apply the brake to completely stop the vehicle. Repeat this test pattern at least three times. 4. Turn the steering to the right end (or left end) in the TOD mode, and slowly start the vehicle and make a circle five times. Next, conduct the same test in the 2H mode. 5. Slowly start the vehicle in the TOD mode, and accelerate to at least 40 km/h (25 mph). Keep the established speed, carefully change the mode in the sequence “TOD mode→2H mode →TOD mode” while checking that the shift is complete in each mode change. After the test, apply the brake to completely stop the vehicle. 6. Slowly start the vehicle in the TOD mode, and accelerate to at least 40 km/h (25 mph). Apply the brake strongly so that the ABS works, and completely stop the vehicle. 7. Slowly start the vehicle in the 4L mode, and accelerate to at least 20 km/h (13 mph). Apply the brake to completely stop the vehicle. If the CHECK lamp starts blinking during the test run, read the trouble codes and give appropriate maintenance according to the diagnostic procedure. If the TOD indicator lamps are lit abnormally during the run, check the lighting condition and give appropriate maintenance according to the diagnostic procedure. Even if the phenomena are not observed, try to reproduce the abnormal state reported by the customer to the possible extent.

DRIVE LINE CONTROL SYSTEM (TOD) Post-Repair Check As long as the starter is not turned off, the TOD indicator lamps continue blinking even after the failed portion is repaired. Therefore, upon completion of repair, be sure to turn off the starter switch once and then turn on it to conduct the test run sequence specified in steps 1 through 7 above and check that the TOD indicator lamps no longer show any faulty status.

4B2–17

4B2–18 DRIVE LINE CONTROL SYSTEM (TOD)

Basic Diagnostic Flow Chart

C07R100011

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–19

Parts Location

D04R200019

Legend (1) C–10 (2) C–6 (3) C–5 (4) H–13 H–14 (5) A–1 (6) A–2 (7) I–31 (8) C–41 (9) I–23 (10) I–24

(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)

I–25 C–39 H–10 C–37 C–38 C–26 C–29 H–3 H–5 E–35 E–34 E–41 H–7

4B2–20 DRIVE LINE CONTROL SYSTEM (TOD)

Circuit Diagram

D04R200026

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–21

D04R200002

4B2–22 DRIVE LINE CONTROL SYSTEM (TOD)

D04R200020

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–23

D04R200004

4B2–24 DRIVE LINE CONTROL SYSTEM (TOD)

Connector List No.

Connector face

No.

A-1

C-41

A-2

E-23

C-6

E-34

C-10

E-41

C-26

H-5 6VD1

C-29

H-3

C-37

H-7

C-38

H-10

C-39

H-11

Connector face

DRIVE LINE CONTROL SYSTEM (TOD) No. H-13

I-23

I-24

I-25

I-31

Connector face

4B2–25

4B2–26 DRIVE LINE CONTROL SYSTEM (TOD)

Checking Failed Pin Connector Pin Assignment B TOD control unit pin assignment

D04RY00011

No.

NAME

CONTENTS

N.C

ENG REV

N.C

Not used

N.C

Not used

N.C

Not used

N.C

Not used

IND.A

Display Front

IND. C

Display Rear

N.C

Not used

N.C

Not used

EMC

Clutch Solenoid

REF

Speed Reference

COM (–)

VIG

Ignition

TPS

TPS (PWM)

TECH 2

TECH–2

N. C

Not used

N. C

Not used

IND. B

Display Auto

CHK TOD

Check TOD

N.C

PWR GND

ADC (+)

COM GND

Shift Motor Position GND

MTR POS3

Shift Motot Position 3

Not used Engine Speed

Speed GND

Not used Power Ground Axle Disconnect Output

DRIVE LINE CONTROL SYSTEM (TOD) No.

NAME

CONTENTS

MTR POS1

POSC

AT Position C

POSA

AT Position A

DIAG

Diagnostic Input

TOD SW A

4H SW

4H Switch Input

FT. SIG

Front Speed Signal

ABS IN

ABS In

MTR H-L

Power Shift Motor H-L

4WD OUT

4WD Signal Output

BRAKE SW

Brake Switch Input

MTR POS4

Shift Motor Position 4

MTR POS2

Shift Motor Position 2

LIGHTING SW

Lighting Switch Input

POSB

AXLE SW

Axle Switch Input

TOD SWB

TOD Switch B (4L)

4L SW

RR. SIG

Rear Speed Signal

GND. 1

ECU Ground 1

GND. 2

ECU Ground 2

MTR L-H

Shift Motor Position 1

TOD Switch A (2H)

Power Bat

AT Position B

4L Switch Input

Power Shift Motor L-H

4B2–27

4B2–28 DRIVE LINE CONTROL SYSTEM (TOD)

Reference B Transfer connector pin assignment (connector on the transfer case) for inspection of transfer pins.

810RW310

No.

NAME

CONTENTS

Ref. (Rer. )

Rear speed sensor reference output

Ref. (Frt. )

Front speed sensor reference output

SW GND

4H SW (+)

4H SW plus terminal

RR. SIG

Rear Speed Sensor Signal

FT. SIG

Front Speed Sensor Signal

POWER GND

SOL (+)

Electromagnetic solenoid

COM (–) (Rer. )

Rear speed sensor GND

COM (–) (Frt. )

Front speed sensor GND

4L SW (+)

Power GND

Not used 4L SW Plus Terminal

DRIVE LINE CONTROL SYSTEM (TOD)

8–6

No.

NAME

CONTENTS

MTR POS2

Shift Motor Position 2

MTR POS3

Shift Motor Position 3

MTR POS4

Shift Motor Position 4

MTR L-H

Power Shift Motor L-H

POS RETURN

MTR POS1

Shift Motor Position 1

MTR H-L

Power Shift Motor H-L

Shift Motor Position GND

Not Used

4B2–29

4B2–30 DRIVE LINE CONTROL SYSTEM (TOD)

Checking Failed TOD Control Unit Pin NOTE: 1. Unplug the ECU connector and the pins, unless otherwise specified. 2. Before removing the ECU, turn off the ignition switch. 3. If the standard values are not observed, check the pins with other testers. Check Pin No.

Circuit to be tested

Ignition Switch Position

Engine State

Unit Scale/ Range

Measure between Pin No.

Standard Value

Note

P-GND

OFF

STOP

22, 47

Continuity : OK

GNDI

OFF

STOP

46, 47

Continuity : OK

GND 2

OFF

STOP

47, GND

Continuity : OK

4H SW

OFF

STOP

31, 47

No continuity (high, 4L) : OK

4L SW

OFF

STOP

44, 47

No continuity (high) and continuity (4L) : OK

AXLE SW

RUN

42, 47

Continuity(TOD, 4L) : OK

Remove ECU connector and start the engine. Move the vehicle forth and back to connect axle surely.

DIAG

OFF

STOP

29 (TOD), 8 (DLC Connector)

Continuity : OK

DLC connector terminal 8

IND.A

STOP

DCV

7 (+), 47 (–)

8.0 ∼14.5 V

when the indicator lamp is turned off.

CHECK TOD

STOP

DCV

20 (+), 47 (–)

8.0 ∼14.5 V

When the indicator lamp is turned off.

ABS IN

STOP

DCV

33 (+), 47 (–)

6.0 ∼11.0 V

REF

STOP

DCV

12 (+), 47 (–)

5 ∼9 V

Connect ECU

FRT.(+)

STOP

DCV

32 (+), 47 (–)

0.7 ∼6 V

Connect ECU and move the vehicle (off one tooth of speed sensor ring) making sure of voltage change.

RR.(+)

STOP

DCV

45 (+), 47 (–)

0.7 ∼6 V

Connect ECU and move the vehicle (off one tooth of speed sensor ring) making sure of voltage change.

COM(-)

STOP

DCV

13 (+), 47 (–)

Connect ECU

VIG

STOP

DCV

14 (+), 47 (–)

8 ∼14.5 V

OFF

STOP

DCV

34 (+), 47 (–)

8.0 ∼14.5 V

BRAKE SW

OFF

STOP

DCV

37 (+), 47 (–)

8 ∼14.5 V

Press brake pedal

TPS

STOP

DCV

15 (+), 47 (–)

PWM duty cycle 10%(MAX) – 90 %(MIN)

Step on the accelerator pedal and make sure that duty cycle changes.

DRIVE LINE CONTROL SYSTEM (TOD) Check Pin No.

Circuit to be tested

Ignition Switch Position

Engine State

Unit Scale/ Range

Measure between Pin No.

Standard Value

4B2–31

Note

4WD OUT

OFF

STOP

36, 47

7 ∼12 kW

Disconnect battery GND terminal

EMC(+)

OFF

STOP

11, 22

1.0 ∼5.0 W

Disconnect battery GND terminal

TOD SW A

STOP

DCV

30 (+), 47 (–)

SW: TOD, 4L: 0 V SW:2H:8.0 ∼ 14.5 V

TOD SWB

STOP

DCV

43 (+), 47 (–)

SW: 2H, TOD:0V SW: 4L: 8.0 ∼ 14.5V

LIGHT

STOP

DCV

40 (+), 47 (–)

SW OFF : 0 V SW ON : 8.0 ∼ 14.5 V

IND B

STOP

DCV

19 (+), 47 (–)

8.0 ∼14.5 V

When the indicator lamp is turned off

IND C

STOP

DCV

8 (+), 47 (–)

8.0 ∼ 14.5 V

When the indicator lamp is turned off

AT POSC

STOP

DCV

27 (+), 47 (–)

ON:D, 3, 2, 1 OFF:PRN

ON:8.0 ∼ 14.5 V OFF:0V

AT POSB

STOP

DCV

41 (+), 47 (–)

ON:R, N, D, 3 OFF:P, 2, 1

ON:8.0 ∼ 14.5 V OFF:0V

AT POSA

STOP

DCV

28 (+), 47 (–)

ON:P, R, 3, 2 OFF:N, D, 1

ON:8.0 ∼ 14.5 V OFF:0V

ENG REV

RUN

2, 47

Waveform (PWM)

50 ms (1000 rpm)

4B2–32 DRIVE LINE CONTROL SYSTEM (TOD)

Tech 2 Scan Tool From 98 MY, Isuzu dealer service departments are recommended to use Tech 2. Please refer to Tech 2 scan tool user guide.

901RW257

Legend (1) PCMCIA Card (2) SAE 16/19 Adaptor

(3) DLC Cable (4) Tech 2

DRIVE LINE CONTROL SYSTEM (TOD)

Getting Started

4B2–33

Operating Procedure

B Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. The Isuzu 02 System PCMCIA card (1) inserts into the Tech 2 (4). 2. Connect the SAE 16/19 adapter (2) to the DLC cable (4). 3. Connect the DLC cable to the Tech 2 (4) 4. Mark sure the vehicle ignition is off. 5. Connect the Tech 2 SAE 16/19 adapter to the vehicle DLC connector.

The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card. Follow the operating procedure below.

826R200011

6. The vehicle ignition turns on. 7. Power up the Tech 2. 8. Verify the Tech 2 power up display.

060R100102

060RW009

4B2–34 DRIVE LINE CONTROL SYSTEM (TOD)

060R200079

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–35

Diagnostic Trouble Codes Code

Tech 2 code (P code)

Item

Diagnosis

Check flow No.

—

Start code

Normal

—

P1735

Ref

Shorted GND

P1731

Front speed sensor

Input abnormality (open, sig or com)

P1736

Ref

Shorted VB

P1737

Front speed sensor

Input abnormality

P1774

Inhibitor switch

Input abnormality

P1716

TPS

Shorted or disconnected wiring, abnormality in input

—

ECU

CPU abnormality

P1733

Rear speed sensor

Input abnormality (open, sig or com)

P1738

Rear speed sensor

Input abnormality

P1760

ADC (+) & AXLE SW

Output abnormality

P1721

EMC (+)

Shorted VB, disconnected coil/wiring or shorted GND

P1761

ADC (+)

Shorted VB or disconnected wiring

P1762

ADC (+)

Shorted GND

—

ECU

CPU abnormality

P1712

ECU

CPU abnormality

P1714

ECU

CPU abnormality

P1741

Hight-Low shift motor

Shorted GND or disconnected wiring

P1773

Hight-Low shift motor

User operation error (not failure)

P1743

Hight-Low shift motor

Motor moving more than 5s

P1755

Hight-Low shift motor

Input abnormality of motor position signal

TPS : Throttle Position Sensor EMC : Electromagnetic coil ADC : Shift on the fly (Axle Dis Connect)

4B2–36 DRIVE LINE CONTROL SYSTEM (TOD)

Diagnosis from Trouble Codes B Diagnose the fault that have been saved to the control unit according to the system self-diagnostic function.

Check flow

Trouble code

Phenomenon

Standard

23, 36, 37, 38

The ECU has failed.

—

P1712, P1714

Step 1

Action Turn on the starter switch. Is the trouble reproduced?

Replace the ECU and conduct the test run. Go to Step 3

Go to Step 2

Replace the ECU and conduct the test run. Go to Step 3

The trouble is not reproduced. Refer to “Trouble intermittently observed”. Go to Step 3

Verify the repair.

Return to Step 3

1. Clear the trouble codes. 2. Conduct the test run. Is the trouble reproduced during the test run?

Yes

1. Check that all the parts are mounted. 2. Clear the trouble codes. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–37

Check flow

Trouble code

Phenomenon

Standard

Front speed sensor signal open or short sspeed GND short, eed sensor com open.

0.2V > sensor voltage

P1731

NOTE: The following procedure shows the case that the front or rear sensor common grounding line is broken.

D04R200005

4B2–38 DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–38) and (C–37). Is there the continuity between (C–37) terminal 10 and 25?

5 6

Go to Step 4

Go to Step 2

Repair the circuit. Go to Step 7

Go to Step 3

Replace the front speed sensor. Go to Step 7

Repair the circuit. Go to Step 7

Go to Step 5

Refer to other trouble check flow.

Go to Step 6

Repair the circuit. Go to Step 7

Replace front and rear speed sensor. Go to Step 7

Repair the circuit. Go to Step 7

Verify the repair.

Return to Step 7

1. Disconnect the transfer connector (A–1). Is there the continuity between the connector (C–37) terminal 10 and the connector (A–1) terminal 6, the connector (C–38) terminal 12 and connector (A–1) terminal 2, and the connector (C–38) terminal 13 and connector (A–1) terminal 10?

1. Start the engine. 2. Select TOD mode. Is there the memory except DTC 14(P1731)?

Yes

Is the memory DTC 24(P1733)?

Is there the continuity between harnesses of terminal 32 and 45 (vehicle side terminal of the front and rear speed sensor)? Is there the continuity between harnesses of terminal 12 and 13 (vehicle side terminal of the speed sensor COM(–) and ref)?

1. Check that all the parts are mounted. 2. Clear the trouble code. Is the step complete?

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–39

Check flow

Trouble code

Phenomenon

Standard

Rear speed sensor signal open or short sspeed GND short, eed sensor COM open.

0.2 V > sensor voltage

P1733

NOTE: The following procedure shows the case that the front or rear sensor common grounding line is broken.

D04R200005

4B2–40 DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

5 6

Go to Step 2

Repair the circuit. Go to Step 7

Go to Step 3

Replace the rear speed sensor. Go to Step 7

Repair the circuit. Go to Step 7

Go to Step 5

Refer to other trouble cheek flow.

Go to Step 6

Repair the circuit Go to Step 7

Replace front and rear speed sensor. Go to Step 7

Repair the circuit. Go to Step 7

Verify the repair

Return to Step 7

1. Disconnect the transfer connector (A–1). Is there the continuity between the connector (C–37) terminal 23 and the connector (A–1) terminal 5, the connector (C–38) terminal 12 and connector (A–1) terminal 1, and the connector (C–38) terminal 13 and connector (A–1) terminal 9?

Go to Step 4

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–38) and (C–37). Is there the continuity between the connector (C–37) terminal 23 and 25?

1. Start the engine. 2. Select TOD mode. Is there the memory except DTC 24(P1733)?

Yes

Is the memory DTC 14(P1731)?

1. Check that all the parts are mounted. 2. Clear the trouble code. Is the step complete?

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–41

Check flow

Trouble code

Phenomenon

Standard

The front speed sensor no pulse.

Hi level : 4.5 ∼ 6.0 V Lo level : 0.7 ∼ 2.0 V Frequency (F) = 700-850 Hz (at 50 km/h or 31 mph)

P1737

NOTE: Find the trouble in which the pulse corresponding to the running speed is not input.

D04R200005

4B2–42 DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

Yes

Go to Step 2

Repair and inspection front speed sensor tone wheel. Go to Step 6

Go to Step 3

The trouble is not reproduced. Refer to “Troubles intermittently observed”.

Repair the circuit. Go to Step 6

Go to Step 4

Replace the front speed sensor. Go to Step 5

Repair the circuit. Go to Step 5

Replace ECU. Go to Step 6

Go to Step 6

Repeat the “Diagnosis Flow”.

Return to Step 6

1. Connect TECH 2. While running in TOD mode, does TECH–2’s front speed sensor indication change with vehicle speed?

1. Clear the trouble code. While running at 40 km/h or 25 mph in TOD mode for 30 consecutive sec, is the trouble code reissued?

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–38) and (C–37). Is there the continuity between the connector (C–37) terminal 10 and 25?

1. Clear the trouble code. While running at 40 km/h or 25 mph in TOD mode for 30 consecutive sec, is the trouble code reissued?

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–43

Check flow

Trouble code

Phenomenon

Standard

The rear speed sensor no pulse.

Hi level : 4.5 ∼ 6.0 V Lo level : 0.7 ∼ 2.0 V Frequency (F) = 700-850 Hz (at 50 km/h or 31 mph)

P1738

NOTE: Find the trouble in which the pulse corresponding to the running speed is not input.

D04R200005

4B2–44 DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

Yes

Go to Step 2

Repair and inspection front speed sensor tone wheel. Go to Step 6

Go to Step 3

The trouble is not reproduced. Refer to “Troubles intermittently observed”.

Repair the circuit. Go to Step 5

Go to Step 4

Replace the rear speed sensor. Go to Step 5

Repair the circuit. Go to Step 5

Replace ECU. Go to Step 6

Go to Step 6

Repeat the “Diagnosis Flow”.

Return to Step 6

1. Connect TECH 2. While running in TOD mode, does TECH–2’s rear speed sensor indication change with vehicle speed?

1. Clear the trouble code. While running at 40 km/h or 25 mph in TOD mode for 30 consecutive sec, is the trouble code reissued?

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–38) and (C–37). Is there the continuity between the connector (C–37) terminal 23 and 25?

1. Clear the trouble code. While running at 40 km/h or 25 mph in TOD mode for 30 consecutive sec, is the trouble code reissued?

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD)

Check flow

Trouble code

Phenomenon

Standard

13 (P1735)

The reference is short-circuited to GND.

Reference ] 5 V

15 (P1736)

The reference is short-circuited to VB.

4B2–45

If the reference wire (12) is short-circuited to GND, the speed signal is not generated. If the wire is short-circuited to the battery voltage, the signal level becomes faulty.

D04R200005

4B2–46 DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

Yes

Does the voltage between terminals 12 and 47 meet the standard 5V?

Refer to “Trouble intermittently observed”.

Go to Step 2

Go to Step 3

Go to Step 7

Go to Step 4

The ECU is failed. Replace the ECU. Go to Step 8

Go to Step 5

Short to GND between (C–38)12 and (H–7)2. Repair the circuit. Go to Step 8

Replace the rear speed sensor. Go to Step 8

The reference harness for the rear speed sensor is short–circuited to GND. Repair the circuit. Go to Step 6

Replace the front speed sensor. Go to Step 8

The reference harness for the rear speed sensor is short–circuited to GND. Repair the circuit. Go to Step 8

Repair the circuit. Go to Step 8

The ECU has failed. Replace the ECU. Go to Step 8

Repeat the “Diagnosis Flow”

Go to Step 8

1. Start the engine.

Is the voltage below the standard?

1. Turn off the starter switch. 2. Disconnect the ECU connector. Is the continuity established between vehicle harness terminals (C–38)12 and (C–37)25?

1. Disconnect the H-7 connector. Is the continuity established between floor harness connector terminals (H-7)2 and (H-7)15?

1. Disconnect the A-1 connector. Is the continuity established between transfer harness connector male terminals (A–1)1 and (A–1)7?

1. Disconnect the A-1 connector. Is the continuity established between transfer harness connector terminals (A–1)2 and (A–1)7?

1. Turn off the starter switch. 2. Disconnect the ECU connector. 3. Turn on the starter switch. Is the battery voltage observed between harness connector terminals (C–38)12 and (C–37)25?

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD)

Check flow

Trouble code

Phenomenon

Standard

21 (P1716)

The voltage of the throttle position sensor (TPS) is faulty.

See below table.

4B2–47

NOTE: The signal voltage from the TPS deviates from the standard range.

D04R200025

4B2–48 DRIVE LINE CONTROL SYSTEM (TOD)

D04RY00012

DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

Yes

Go to Step 2

Charge or replace the battery. Go to Step 7

Go to Step 3

Go to Step 4

Refer to “Trouble intermittently observed”.

The ECU has failed. Replace the ECU. Go to Step 7

Go to Step 5

Go to Step 6

Repair the harness. Go to Step 7

Go to Step 7

Replace the TPS. Go to Step 7

Repeat the “Diagnosis Flow”.

Go to Step 7

1. Turn off the starter switch. Is the battery voltage normal?

1. Turn on the starter switch. Does the voltage between terminals 15 and 47 fall within the standard range?

1. Clear the trouble code. 2. Turn on the starter switch. Is there DTC21 (P1716)?

1. Turn off the starter switch. 2. Disconnect the ECU connector. 3. Turn on the starter switch. Does the voltage between terminals (C–38)15 and (C–37)25 fall within the standard range above?

6 7

4B2–49

Is the harness healthy?

Is the TPS healthy? 1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

4B2–50 DRIVE LINE CONTROL SYSTEM (TOD)

Check flow

Trouble code

Phenomenon

Standard

17 (P1774)

The input from the mode switch is abnormal.

—

D04R200025

DRIVE LINE CONTROL SYSTEM (TOD) Step

Action

Is the TOD control unit the regular part? (Verity the part number.)

3 4

Yes

Go to Step 2

Replace with the regular part. Go to Step 2

Does the voltage between the terminal 28 and 47 accord with the table 1 corresponding to the AT selector positions?

Go to Step 3

Go to Step 5

Does the voltage between the terminal 41 and 47 accord with the table 1 corresponding to the AT selector positions?

Go to Step 4

Go to Step 6

Refer to “Trouble intermittently observed”.

Go to Step 7

Repair the circuit between the connector terminal (C–37) 6 and (E–41) 8. Go to step 8

Replace the inhibitor switch. Go to Step 8

Repair the circuit between the connector terminal (C–37) 19 and (E–41) 7. Go to Step 8

Replace the inhibitor switch. Go to Step 8

Repair the circuit between the connector terminal (C–37) 5 and (E–41) 6. Go to Step 8

Replace the inhibitor switch. Go to Step 8

Verify the repair.

Go to Step 8

1. Turn on the starter switch.

Does the voltage between the terminal 27 and 47 accord with the table 1 corresponding to the AT selector positions? 1. Disconnect the AT mode connector (E–41). Does the continuity between the inhibitor switch terminal 5 (D) and 8 (A) accord with the table 2 corresponding to the AT selector positions?

1. Disconnect the AT mode connector (E–41). Does the continuity between the inhibitor switch terminal 5 (D) and 7 (B) accord with the table 2 corresponding to the AT selector positions?

1. Disconnect the AT mode connector (E–41). Does the continuity between the inhibitor switch terminal 5 (D) and 6 (C) accord with the table 2 corresponding to the AT selector positions?

4B2–51

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

4B2–52 DRIVE LINE CONTROL SYSTEM (TOD) Table 1 Unit: V AT selector position

Voltage between terminal 28 and 47

Voltage between terminal 41 and 47

Voltage between terminal 27 and 47

Table 2 Continuity between terminals of inhibitor switch connector (E–41) AT selector position

Continuity between terminal 8(A) and 5(D)

Continuity between terminal 7(B) and 5(D)

Continuity between terminal 6(C) and 5(D)

YES

DRIVE LINE CONTROL SYSTEM (TOD)

Check flow

Trouble code

Phenomenon

Standard

31 (P1721)

The electromagnetic coil is broken or shorted to the battery or GND.

—

4B2–53

D04R200005

4B2–54 DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

Is the battery voltage always observed between terminals 11 and 22?

1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Is the resistance between the connector (C–38) terminal 11 and 22 1.0 ∼ 5.0W?

Go to Step 5

Go to Step 4

Go to Step 6

The harness is short–circuited on the battery. Repair the circuit. Go to Step 8

Go to Step 6

The harness is broken. Repair the circuit. Go to Step 8

Replace the transfer electromagnetic coil (solenoid clutch). Go to Step 8

The ECU has failed. Replace the ECU Go to Step 8

Go to Step 7

The harness is disconnection or short to GND. Repair the circuit. Go to Step 8

Replace the transfer electromagnetic coil (solenoid clutch). Go to Step 8

Repeat the “Diagnosis Flow”.

Return to Step 8

1. Disconnect the A–1 connector. Is the continuity established between transfer connector terminals (A–1)8 and (A–1)7?

Go to Step 3

1. Connect the ECU connector. 2. Start the engine. 3. Set the TOD mode. Does the voltage between terminals 11 and 22 indicate at least 0.4V?

Go to Step 2

Refer to “Trouble intermittently observed”.

1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. Is the continuity established between terminals (C–38)11 and (C–38)22?

1. Clear the trouble code. 2. Start the engine 3. Set the TOD mode. Is there DTC31 (P1721)?

Yes

Is the resistance between the transfer connector (A–1) terminal 8 and 7 1.0 ∼ 5.0W?

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD)

Check flow

Trouble code

Phenomenon

Standard

28 (P1760)

The shift on the fly system (front axle disconnect) works incorrectly.

—

4B2–55

NOTE: The shift on the fly system is not changed between 2WD and 4WD modes normally. CAUTION: If code 32 or 33 is also observed, remove the trouble associated with code 32 or 33 first.

D04R200023

4B2–56 DRIVE LINE CONTROL SYSTEM (TOD) Step

Yes

Is the battery voltage observed between terminals 23 and 47?

Go to Step 2

Go to Step 5

Is 5V observed between terminals 42 and 47?

Go to Step 3

Go to Step 6

1. Set the transfer to the TOD mode.

Go to Step 4

The ECU has failed. Replace the ECU. Go to Step 7

The phenomenon is not reproduced. Refer to “Troubles intermittently observed”.

The shift on the fly system is failed (refer to Section 4B1 and 4C). Go to Step 7

The ECU has failed. Replace the ECU. Go to Step 7

See “Trouble Diagnosis Depending on The Status of TOD Indicator”.

The shift on the fly system has failed (refer to Section 4B1 and 4C). Go to Step 7

The ECU has failed. Replace the ECU. Go to Step 7

Verify the repair.

Return to Step 7

Action 1. Turn on the starter switch. 2. Set the transfer to the 2H mode.

Does the voltage between terminals 23 and 47 indicate 0∼1V?

Does the voltage between terminals 42 and 47 indicate 0V?

Does the TOD indicator show the 2H mode?

Set the transfer to the TOD mode. Does the voltage between terminals 23 and 47 indicate 0∼1V?

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD)

Check flow

Trouble code

Phenomenon

Standard

32 (P1761)

The on/off signal (ADC) line of the shift on the fly system (front axle disconnect) is broken, or the line is short-circuited to the battery.

—

4B2–57

NOTE: The on/off signal line of the shift on the fly system is broken, or the line is short–circuited to the battery.

D04R200023

4B2–58 DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

1. Disconnect the battery ground cable. Is there the continuity between the connector terminal (C–37) 1 and (C–38) 14?

1. Disconnect the battery ground cable. Is there the continuity between the connector terminal (C–37) 1 and (C–37) 12?

Is the resistance between the connector terminal (C–37) 1 and (C–37) 25 less than 1W?

1. 2. 3. 4.

Turn off the starter switch. Connect ECU connector. Turn on the starter switch. Set the transfer to the 2H mode.

Is the battery voltage observed between the connector (C–37) terminals 1 and 25?

Go to Step 2

The harness is broken. Repair the circuit. Go to Step 6

The harness is short-circuited to VIGN. Repair the circuit. Go to Step 6

Go to Step 3

The harness is short-circuited to VB. Repair the circuit. Go to Step 6

Go to Step 4

The harness is short-circuited to GND. Repair the circuit. Go to Step 6

Go to Step 5

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”, or refer to “Sec 4B1 Shift on the Fly”.

The ECU has failed. Replace the ECU. Go to Step 6

Verify the repair.

Return to Step 6

1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. 3. Disconnect ADC control unit connector (C–41). Is the continuity established between terminals (C–37) 1 and (C–41) 4? After checking, connect the ADC control unit connector.

Yes

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD)

Check flow

Trouble code

Phenomenon

Standard

33 (P1762)

The ADC line is short-circuited to GND.

—

4B2–59

NOTE: B The on/off signal line of the shift on the fly system is short–circuited to GND. B The system enters into the fail-safe mode because of fusing or system protection. (If a short–circuit is observed on GND, the output to the on/off signal line becomes 0V.)

D04R200023

4B2–60 DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

Is the resistance between terminals (C–37) 1 and (C–37) 25 less than 1W?

1. Connect the ECU connector. 2. Turn on the starter switch. 3. Set the transfer to the 2H mode. Is the battery voltage observed between the connector (C–37) terminal 1 and 25?

Go to Step 2

The harness is broken. Repair the circuit. Go to Step 4

The signal line circuit of the shift on the fly system is short-circuited to GND. Repair the circuit. Go to Step 4

Go to Step 3

The phenomenon is not reproduced. Refer to “Trouble intermittently observe”, or refer to “Sec 4B1 Shift on the Fly”.

The ECU has failed.Replace the ECU. Go to Step 4.

Verify the repair.

Return to Step 4

1. Turn off the starter switch. 2. Disconnect the ECU connector from ECU. 3. Disconnect the ADC control unit connector (C–41). Is there the continuity between the connector terminal (C–37) 1 and (C–41) 4? After checking, connect the ADC control unit connector.

Yes

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

DRIVE LINE CONTROL SYSTEM (TOD)

Check flow

Trouble code

Phenomenon

Standard

41 (P1741)

The High-Low motor circuit is broken. The circuit is short–circuited to GND.

—

43 (P1743)

The High-Low motor has moved consecutive more than 5 sec.

—

4B2–61

D04R200007

4B2–62 DRIVE LINE CONTROL SYSTEM (TOD) Step 1

2 3

Action

Yes

When the motor is not moving, is the voltage between the terminals 35 and 47 8.0 ∼ 14.5V?

Go to Step 2

Go to Step 3

When the motor is not moving, is the voltage between the terminal 48 and 47 8.0 ∼ 14.5V?

Go to Step 5

Go to Step 3

Go to Step 4

Repair the circuit. Go to Step 11

Go to Step 5

Repair the circuit Go to Step 11

Go to Step 6

Go to Step 7

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

Go to Step 8

Go to Step 9

Replace the ECU. Go to Step 11

Go to Step 9

Replace the ECU. Go to Step 11

Go to Step 10

Replace the high-low motor asm. Go to Step 11

Repair the transfer asm. Go to Step 11

Replace the high–low motor asm. Go to Step 11

Verify the repair

Return to Step 11

1. Turn on the starter switch.

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–37) and transfer connector (A–2). Is there the continuity between the connector terminal (C–37) 13 and (A–2) 7?

4 5

Is there the continuity between the connector terminal (C–37) 26 and (A–2) 4? 1. Connect the ECU connector (C–37) and transfer connector (A–2). 2. Turn on the starter switch Is the transfer shifted to the low range from the high range?

1. Is the transfer shifted to the high range from the low range.

1. After the starter switch is turned off, turn on the starter switch. 2. Right after the TOD switch is changed to the 4L position from the TOD position, measure the voltage for 5 seconds. Is the voltage between terminal 48 and 47 0V while the motor is moving and 8.0 ∼ 14.5V after the motor moving stops?

1. After the starter switch is turned off, turn on the starter switch. 2. Right after the TOD switch is changed to the TOD position from 4L position, measure the voltage for 5 seconds. Is the voltage between terminals 35 and 47 0V while motor is moving and 8.0 ∼14.5V after the motor moving stops?

1. Remove the motor asm with the connector (A–2) from the transfer. 2. Connect the ECU connector (C–37). 3. Turn on the starter switch. When the TOD switch is changed to the 4L position from the TOD position, does the shaft in the motor asm rotate to the Low direction?

When the TOD switch is changed to the TOD position from the 4L position, does the shaft in the motor asm rotate to the High direction? 1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

NOTE: B Confirm the operation conditions when changing high and low range. – The car stops. (less than 2 km/h or 1.2 mph and engine speed less than 1500 rpm)

– The AT selector position is neutral. – The brake is applied (brake switch: ON) B Verify the completion of changing the high/low range by the TOD indicator on the instrument panel.

DRIVE LINE CONTROL SYSTEM (TOD)

Check flow

Trouble code

Phenomenon

Standard

42 (P1773)

Error operation was carried out under high–low motor running.

—

Step 1 2

3 4

Action

Yes

Is the transfer changed to the low range from the high range?

Go to Step 2

Go to Step 3

Is the transfer changed to the high range from the low range?

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

Go to Step 3

Go to Step 4

See “Diagnosis from Symptom”.

Go to Step 5

Remove the trouble associated with codes except DTC 42 first. Confirm the DTC again. Go to Step 5

The transfer is changed in both ranges by the correct operation. Operate the transfer according to “Owner’s Manual”.

Go to Step 6

Go to Step 7

See “Diagnosis from Symptom”.

Replace the ECU. Go to Step 8

Remove the trouble associated with codes except DTC 42 first. Confirm the DTC again. Go to Step 5

Verify the repair.

Go to Step 8

1. Clear the trouble code.

Is the trouble code memoried? Is the memory DTC42 (P1773)?

1. Clear the trouble code. 2. Confirm the condition and operation of the transfer range changing and check the state of the TOD indicator. Change the transfer to the low from the high and vice versa. Is the transfer changed to the low from the high and to the high from the low?

6 7

4B2–63

Is the trouble code memoried? Is the memory DTC 42 (P1773)?

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

NOTE: B Confirm the operation conditions when changing high/low range. – The car stops. (less than 2 km/h or 1.2 mph and engine speed: less than 1500 rpm) – The AT selector position is neutral. – The brake is applied (brake switch: ON)

B Verify the completion of changing the high/low range by the TOD indicator on the instrument panel. B This code does not indicate the trouble of the transfer or ECU, and is memoried when an error operation is carried out under high-low motor running. Therefore this code is not memoried if the transfer is operated according to “Owner’s Manual”.

4B2–64 DRIVE LINE CONTROL SYSTEM (TOD)

Check flow

Trouble code

Phenomenon

Standard

55 (P1755)

High-Low motor position signal is abnormal. Circuit is shorted to GND.

—

D04R200007

DRIVE LINE CONTROL SYSTEM (TOD) Step

Yes

Is the transfer changed to the low range from the high range?

Go to Step 2

Go to Step 4

Is the transfer changed to the high range from the low range?

Go to Step 3

Go to Step 5

1. Clear the trouble code. 2. Turn on the starter switch.

Go to Step 1

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

Go to Step 8

Go to Step 6

Go to Step 8

Go to Step 7

Go to Step 8

The encoder has failed. Replace the high-low motor asm. Go to Step 9

Go to Step 8

The encoder has failed. Replace the high-low motor asm. Go to Step 9

The circuit in which there is no continuity is broken. Repair the circuit. Go to Step 9

Verify the repair.

Go to Step 9

Action

4B2–65

1. Turn on the starter switch.

Is the memory DTC 55 (P1755)?

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–37). Is the continuity between the terminals ranged within the any case (case1, 2 or 3) in the following table (1)?

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–37). Does the continuity between the terminals comply with the following table (2)?

1. Turn off the starter switch. 2. Disconnect the transfer connector (A–2). Is the continuity between the male terminals ranged within the any case (case1, 2 or 3) in the following table (3)?

1. Turn off the starter switch. 2. Disconnect the transfer connector (A-2). Does the continuity between male terminals comply with the following table (4)?

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–37) and transfer connector (A–2). Is there the continuity between connector terminal (C–37) 4 and (A–2) 6, (C–37) 17 and (A–2) 1, (C–37) 3 and (A–2) 2, (C–37) 16 and (A–2) 3, and (C–37) 2 and (A–2) 5?

1. Check that all the parts are mounted. 2. Clear the trouble code. Is this step complete?

NOTE: B Confirm the operation conditions when changing high and low range. – The car stops. (less than 2 km/h or 1.2 mph and engine speed: less than 1500 rpm) – The AT selector position is neutral. – The brake is applied (brake switch: ON) B Verify the completion of changing the high/low range by the TOD indicator on the instrument panel. B When changing high/low range, start the engine to prevent the battery dead.

4B2–66 DRIVE LINE CONTROL SYSTEM (TOD) Table (1) (high position standard) Continuity between terminals:

Case

26 and 24

39 and 24

25 and 24

38 and 24

YES

Table (2) (low position standard) Continuity between terminals: 26 and 24

39 and 24

25 and 24

38 and 24

YES

YES or NO

Table (3) (high position standard) Continuity between the connector (A–2) terminals:

Case

6 and 5

1 and 5

2 and 5

3 and 5

YES

Table (4) (low position standard) Continuity between the connector (A–2) terminals: 6 and 5

1 and 5

2 and 5

3 and 5

YES

YES or NO

DRIVE LINE CONTROL SYSTEM (TOD)

Trouble Diagnosis Depending on The Status of TOD Indicator Functional check with TOD indicator light is conducted prior to check on Charts A–H. B After the starter is switched on, check and see if the status has become as tabulated below.

C04R200003

B If the status is as tabulated above, there is no problem. If not as tabulated above, inspect the harness.

4B2–67

4B2–68 DRIVE LINE CONTROL SYSTEM (TOD)

Chart A

Indicator drive circuit

Function of circuit

The circuit informs the indicator of the working condition of the ECU.

Fail condition

All the TOD indicator lamps and CHECK lamp are lit.

Indicator lamp state

TOD switch position

—

2H/TOD/4L

—

D04R200023

DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action Turn on the starter switch. Is the battery voltage observed between terminals 14 and 47?

Check that all the parts are mounted. Is this step complete?

4B2–69

Yes

The ECU has failed. Replace the ECU. Go to Step 2

Check the battery circuit. Go to Step 2

Repeat the “Diagnosis Flow”.

Return to Step 2

4B2–70 DRIVE LINE CONTROL SYSTEM (TOD)

Chart B–1

The TOD switch A circuit wires are broken or short-circuited to the GND

Function of circuit

—

Fail condition

Even after the TOD switch position is selected from TOD to 2H, the indicator lamp status is not changed.

Indicator lamp state

TOD switch position

—

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–71

D04R200022

4B2–72 DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

Yes

Go to Step 2

Repair the TOD switch circuit. Go to Step 4

Go to Step 3

Repair the TOD switch circuit. Go to Step 4

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

Repair the TOD switch circuit. Go to Step 4

Verify the repair.

Return to Step 4

1. Turn on the starter switch. When the TOD switch is selected to the TOD position, is 0V observed between terminal 30 and 47, and 43 and 47? Does the voltage between the terminals 7 and 47, 19 and 47, and 8 and 47 comply with the TOD mode in the following table?

When the TOD switch is selected to the 2H position, is 12 V observed between terminals 30 and 47 and is 0V observed between terminal 43 and 47? Does the voltage between the terminals 7 and 47, 19 and 47, and 8 and 47 comply with the 2H mode is the following table?

When the TOD switch is selected to the 4L position, is 0V observed between terminals 30 and 47 and is 12V observed between terminal 43 and 47? Does the voltage between terminals 7 and 47, 19 and 47, and 8 and 47 comply with the 4L mode in the following table?

Check that all the parts are mounted. Is this step complete?

Table: Indicator Voltage Unit: V TOD switch mode

Terminals measured Front 7 and 47

AUTO 19 and 47

Rear 8 and 47

8.0 ∼ 14.5

TOD

8.5 ∼ 14.5

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–73

Chart B–2

The TOD switch A circuit is shorted to battery.

Function of circuit

—

Fail condition

Even after the transfer mode is selected from 2H to TOD, the indicator lamp state does not change.

Indicator lamp state

TOD switch position

TOD

4B2–74 DRIVE LINE CONTROL SYSTEM (TOD)

D04R200022

DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

Yes

Go to Step 2

Replace TOD indicator lamp bulb. Go to Step 6

Go to Step 3

Replace TOD indicator lamp bulb. Go to Step 6

Go to Step 4

Repair the TOD switch circuit. Go to Step 6

Go to Step 5

Repair the TOD switch circuit. Go to Step 6

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

Repair the TOD switch circuit. Go to Step 6

Verify repair.

Go to Step 6

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–38). Is the continuity established between the connector terminals (C–38) 14 and (C–38) 7?

Is the continuity established between the connector terminals (C–38) 14 and (C–38) 19?

4B2–75

1. Turn off the starter switch and connect the ECU connector. 2. Turn on the starter switch. When the TOD switch is selected to the TOD position, is 0V observed between terminals 30 and 47, and 43 and 47? Does the voltage between the terminals 7 and 47, 19 and 47, and 8 and 47 comply with the TOD mode in the following table?

When the TOD switch is selected to the 2H position, is 12V observed between terminals 30 and 47, and 0V observed between terminals 43 and 47? Does the voltage between the terminals 7 and 47, 19 and 47, and 8 and 47 comply with the 2H mode in the following table?

When the TOD switch is selected to the 4L position, is 0V observed between the terminal 30 and 47 and 12V observed between the terminal 43 and 47? Does the voltage between the terminals 7 and 47, 19 and 47, and 8 and 47 comply with the 4L mode in the following table?

1. Check that all the parts are mounted. Is this step complete?

Table: Indicator terminal voltage Unit: V TOD switch mode

Terminals measured Front 7 and 47

AUTO 19 and 47

Rear 8 and 47

8.0 ∼ 14.5

TOD

8.0 ∼ 14.5

4B2–76 DRIVE LINE CONTROL SYSTEM (TOD)

Chart B–3

The TOD switch B circuit is shorted to GND or broken.

Function of circuit

—

Fail condition

Even after the transfer mode is selected from TOD to 4L, the indicator lamp state does not change.

Indicator lamp state

TOD switch position

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–77

D04R200022

4B2–78 DRIVE LINE CONTROL SYSTEM (TOD)

Step 1

Action

Yes

Go to Step 2

Repair the TOD switch circuit. Go to Step 4

Go to Step 3

Repair the TOD switch circuit. Go to Step 4

The phenomenon is not reproduced. Refer to “Trouble intermittentry observed”.

Repair the TOD switch circuit. Go to Step 4

Verify repair.

Go to Step 4

1. Turn on the starter switch. When the TOD switch is selected to the TOD position, is 0V observed between terminals 30 and 47, and 43 and 47? Does the voltage between the terminals 7 and 47, 19 and 47, and 8 and 47 comply with the TOD mode in the following table?

1. Check that all the parts are mounted. Is this step complete?

Table: Indicator terminal voltage Unit: V TOD switch mode

Terminals measured Front 7 and 47

AUTO 19 and 47

Rear 8 and 47

8.0 ∼ 14.5

TOD

8.0 ∼ 14.5

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–79

Chart B–4

The TOD switch B circuit is shorted to battery.

Function of circuit

—

Fail condition

Even after the transfer mode is selected from 4L to TOD, the indicator lamp state does not change.

Indicator lamp state

TOD switch position

TOD

4B2–80 DRIVE LINE CONTROL SYSTEM (TOD)

D04R200022

DRIVE LINE CONTROL SYSTEM (TOD)

Step 1

Action

Yes

Go to Step 2

Replace TOD indicator lamp bulb. Go to Step 5

Go to Step 3

Repair the TOD switch circuit. Go to Step 5

Go to Step 4

Repair the TOD switch circuit. Go to Step 5

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

Repair the TOD switch circuit. Go to Step 5

Verify repair.

Go to Step 5

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–38). Is the continuity established between the connector terminals (C–38) 14 and (C–38) 19?

4B2–81

1. Check that all the parts are mounted. Is this step complete?

Table: Indicator terminal voltage Unit: V TOD switch mode

Terminals measured Front 7 and 47

AUTO 19 and 47

Rear 8 and 47

8.0 ∼ 14.5

TOD

8.0 ∼ 14.5

4B2–82 DRIVE LINE CONTROL SYSTEM (TOD)

Chart C–1

4H switch circuit is short-circuited to GND.

Function of circuit

—

Fail condition

When the TOD switch is selected to 4L from TOD, all the indicator lamps are turned off.

Indicator lamp state

TOD switch position

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–83

D04R200022

4B2–84 DRIVE LINE CONTROL SYSTEM (TOD) Step

Action

1. Turn on the starter switch. 2. The car stops, the AT selector is N position and the brake is applied. When the TOD switch is changed to the TOD position, is 12V observed between terminals 31 and 47 (4H switch)?

Go to Step 2

Go to Step 9

Go to Step 3

Go to Step 9

Go to Step 4

Replace the TOD indicator lamp bulb, or repair the circuit. Go to Step 13

Go to Step 5

Replace the TOD indicator lamp bulb, or repair the circuit. Go to Step 13

Go to Step 6

Replace the TOD indicator lamp bulb, or repair the circuit. Go to Step 13

Go to Step 7

The ECU has frailed. Replace the ECU. Go to Step13

Go to Step 8

The ECU has failed. Replace the ECU. Go to Step 13

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

The ECU has failed. Replace the ECU. Go to Step 13

Go to Step 11

Go to Step 10

1. The car stops the AT selector is N position and the brake is applied. When the TOD switch is changed to the 4L position, is 12V observed between terminals 31 and 47 (4H switch)?

Yes

1. Turn off the starter switch. Is there the continuity terminal 14 and 7?

Is there the continuity between the terminals 14 and 19?

Is there the continuity between the terminal 14 and 8?

1. Turn on the starter switch. 2. The car stops the AT selector is N position and the brake is applied. When the TOD switch is changed to the 4L position, is 0V observed between terminal 7 and 47? (for 2 seconds after the starter switch ON) ?

Is 0V observed between terminal 19 and 47? (for 2 seconds after the starter switch ON)

Is 0V observed between terminal 8 and 47? (for 2 seconds after the starter switch ON)

1. The car stops, the AT selector is N position, and the brake is applied. 2. The TOD switch is changed to the TOD (or 2H) position. 3. Turn off the starter switch. 4. Disconnect the ECU connector (C–37). Is there the continuity between the connector (C–37) terminal 9 and 25?

DRIVE LINE CONTROL SYSTEM (TOD) Step

Action

1. Connect the ECU connector (C–37) and turn on the starter switch. 2. The car stops, the AT selector is N position, and the brake is applied. 3. Change the TOD switch to the 4L position. 4. Turn off the starter switch and disconnect the ECU connector (C–37). Is there the continuity between the connector (C–37) terminal 9 and 25?

Yes

Go to Step 11

The ECU has failed. Replace the ECU. Go to Step 13

Go to Step 12

The harness is broken between terminal (H–7) 4 and (C–37) 9. Repair the circuit. Go to Step 13

Repair the transfer. Go to Step 13

The harness between the connector terminal (C–37) 9 and (A–1) 4 is short-circuited to GND. Repair the circuit. Go to Step 13

Verify the repair.

Return to Step 13

1. Disconnect the connector (H–7). Is the continuity established between the transfer connector terminals (H–7)4 and (C–37) 9?

1. Connect the connector (H–7). 2. Disconnect the connector (A–1). Is there the continuity between the connector terminal (A–1) 4 and (C–37) 9?

4B2–85

Check that all the parts are mounted. Is this step complete?

4B2–86 DRIVE LINE CONTROL SYSTEM (TOD)

Chart D–1

4L switch circuit wires are broken or the battery circuit is short-circuited.

Function of circuit

—

Fail condition

When the TOD switch is changed to the 4L position, the indicator 4L mode goes on and off.

Indicator lamp state

TOD switch position

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–87

D04R200022

4B2–88 DRIVE LINE CONTROL SYSTEM (TOD) Step

Action

1. Turn on the starter switch. 2. The car stops, the AT selector is the N position, and the brake is applied. When the TOD switch is changed to the TOD (or 2H) position, is 12V observed between terminals 44 and 47 (4L switch)?

Is 0V observed between the terminal 44 and 47?

1. Turn off the starter switch and connect the EUC connector. 2. The car stops, the AT selector is the N position, and the brake is applied. When the TOD switch is changed to the 4L position, is 0V observed between terminals (C–37) 22 and (C–37) 25 (4L switch)?

1. Turn off the starter switch and connect the ECU connector. 2. Turn on the starter switch. 3. The car stops, the AT selector is the N position, and the brake is applied. 4. Change the TOD switch to the 4L position. 5. After the transfer has changed to the 4L mode, turn off the starter switch. 6. Disconnect the ECU connector. Is there the continuity between the connector (C–37) terminal 22 and 25?

Go to Step 4

Go to Step 3

Refer to “Diagnosis from symptom”.

The ECU has failed.Replace the ECU. Go to Step 10

Go to Step 10

Go to Step 5

Go to Step 6

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

Go to Step 6

Go to Step 9

Go to Step 7

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

Go to Step 8

Repair the transfer. Go to Step 10

Repair the circuit between (C–37) 22 and (A–1) 12. Go to Step 10

1. Turn off the starter switch and connect ECU connector. 2. Turn on the starter switch. 3. The car stops, the AT selector is the N position, and the brake is applied. 4. Change the TOD switch to the TOD (or 2H) position. 5. After the transfer has changed to the TOD (or 2H) mode, turn off the starter switch and disconnect the ECU connector (C–37). Is there the continuity between the connector (C–37) terminal 22 and 25?

Go to Step 2

1. The car stops, the AT selector is the N position, and the brake is applied. When the TOD switch is changed to the TOD (or 2H) position, is 12V observed between the connector (C–37) terminal 22 and 25?

1. The car stops, the AT selector is the N position, and the brake is applied. When the TOD switch is changed to the 4L position, does the transfer become the 4L state?

Yes

1. Turn off the starter switch and connect the ECU connector. 2. Turn on the starter switch. 3. The car stops, the AT selector is the N position, and the brake is applied. 4. Change the TOD switch to the TOD (or 2H) position. 5. After the transfer has changed to the TOD (or 2H) mode, turn off the starter switch. 6. Disconnect the transfer connector (A–1). Is there the continuity between the connector terminal (A–1) 12 and GND?

DRIVE LINE CONTROL SYSTEM (TOD) Step

Action

1. Turn off the starter switch and connect the connector (A–1). 2. Turn on the starter switch. 3. The car stops, the AT selector is N position, and the brake is applied. 4. Change the TOD switch to the 4L position. 5. After the transfer has changed to the 4L mode, turn off the starter switch. 6. Disconnect the transfer connector (A–1). Is there the continuity between the connector terminal (A–1) 12 and GND?

4B2–89

Yes

Repair the circuit between (C–37)22 and (A–1)12. Go to Step 10

Repair the transfer. Go to Step 10

Verify the repair.

Go to Step 10

Check that all the parts are mounted. Is this step complete?

4B2–90 DRIVE LINE CONTROL SYSTEM (TOD)

Chart D–2

The 4L switch circuit is short-circuited to GND.

Function of circuit

—

Fail condition

When the TOD switch is changed to the 2H or TOD position, the indicator 2H or TOD mode goes on and off.

Indicator lamp state

TOD switch position

2H or TOD

DRIVE LINE CONTROL SYSTEM (TOD)

4B2–91

D04R200022

4B2–92 DRIVE LINE CONTROL SYSTEM (TOD) Step

Action

1. The car stops, the AT selector is the N position, and the brake is applied. When the TOD switch is changed to the TOD (or 2H) position, is 12V observed between terminals 44 and 47 (4L switch)?

1. The car stops, the AT selector is the N position, and the brake is applied. When the TOD switch is changed to the 4L position, is 0V observed between terminals 44 and 47 (4L switch)?

1. Connect the ECU connector (C–37) and turn on the starter switch. 2. The car stops, the AT selector is the N position, and the brake is applied. 3. Select the TOD switch to the 4L position. 4. Turn off the starter switch and disconnect the ECU connector (C–37). Is there the continuity between the connector (C–37) terminal 22 and 25?

Go to Step 3

Refer to “Trouble intermittently observed”.

Go to Step 3

Go to Step 5

Go to Step 4

The ECU has failed.Replace the ECU. Go to Step 9

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step 7

GND is short-circuited between terminals (C–37) 2 and (H–7) 5. Repair the circuit. Go to Step 9

Repair the transfer. Go to Step 9

Go to Step 8

1. Connect the connector (H–7) and turn on the starter switch. 2. The car stops, the AT selector is the N position, and the brake is applied. 3. Select the TOD switch to the 4L position. 4. After the transfer has changed to the 4L mode, turn off the starter switch and disconnect the connector (H–7). Is there the continuity between the connector terminal (H–7) 5 and (C–37) 25?

Go to Step 2

1. Connect the ECU connector (C–37) and turn on the starter switch. 2. The car stops, the AT selector is the N position, and the brake is applied. 3. Select the TOD switch to the TOD (or 2H) position. 4. Turn off the starter switch and disconnect the connector (H–7). Is there the continuity between the connector terminal (H–7) 5 and (C–37) 25?

1. The car stops, the AT selector is the N position, and the brake is applied. 2. Select the TOD switch to the TOD (or 2H) position. Is there the continuity between the connector (C–37) terminal 22 and 25?

Yes

1. Connect the connector (H–7) and turn on the starter switch. 2. The car stops, the AT selector is the N position, and the brake is applied. 3. Select the TOD switch to the TOD (or 2H) position. 4. After the transfer has changed to the TOD (or 2H) mode, turn off the starter switch and disconnect the connector (A–1). Is there the continuity between the connector terminal (A–1) 12 and GND?

DRIVE LINE CONTROL SYSTEM (TOD) Step

Action

1. Connect the connector (A–1) and turn on the starter switch. 2. The car stops, the AT selector is the N position, and the brake is applied. 3. Select the TOD switch to the 4L position. 4. After the transfer has changed to the 4L mode, disconnect the connector (A–1). Is there the continuity between the connector terminal (A–1) 12 and GND?

4B2–93

Yes

GND is short-circuited between terminals (A–1) 12 and (H–7) 5. Repair the circuit. Go to Step 9

Repair the transfer. Go to Step 9

Verify the repair.

Go to Step 9

Check that all the parts are mounted. Is this step complete?

4B2–94 DRIVE LINE CONTROL SYSTEM (TOD)

Chart E–1

AXLE switch circuit wires are broken.

Function of circuit

—

Fail condition

Both the TOD and 4L modes are disabled. (The transition status is not removed.)

Indicator lamp state

TOD switch position

TOD

D04R200023

DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

Yes

When the TOD switch is selected to the TOD position, is 0V observed between terminals 42 and 47?

Go to Step 2

Go to Step 4

Go to Step 3

Go to Step 4

The phenomenon is not reproduced. Refer to “Troubles intermittently observed”.

The ECU has failed.Replace the ECU. Go to Step 8

When the TOD switch is selected to the 2H position, is the battery voltage observed between the terminal 23 and 47.

Go to Step 5

Go to Step 7

When the TOD switch is selected to the TOD position (TOD mode), is 0 ∼ 1V observed between terminals 23 and 47?

Go to Step 6

Go to Step 7

Repair the circuit or check the “Front Axle Disconnect”. (Refer to section 4B) Go to Step 8

Go to Step 7

Examine the trouble based on “Diagnosis from Trouble Codes”.

The ECU has failed. Replace the ECU. Go to Step 8

Verify the repair.

Go to Step 8

Start the engine.

1. The car stops, the AT selector is N position, and the brake is applied. 2. Select the TOD switch to the 4L position. Is 0V observed between terminals 42 and 47?

1. The car stops, the AT selector is N position, and the brake is applied. When the TOD switch is selected to the 4L position, is 12V observed between the terminal 19 and 47?

5 6

4B2–95

1. The car stops, the AT selector is N position, and the brake is applied.

1. The car stops, the AT selector is N position, and the brake is applied. When the TOD switch is selected to the 4L position, is 0V observed between terminals 23 and 47?

Is any of the trouble codes 28 (P1760), 32 (P1761) and 33 (P1762) recorded?

Check that all the parts are mounted. Is this step complete?

4B2–96 DRIVE LINE CONTROL SYSTEM (TOD)

Chart E–2

The AXLE switch circuit is short-circuited to GND.

Function of circuit

—

Fail condition

Even after the TOD switch is selected to the 2H position, the 2H mode is not enabled. (The transition status is not removed.)

Indicator lamp state

TOD switch position

D04R200023

DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

Yes

When the TOD switch is selected to the TOD position, is 0V observed between terminals 42 and 47?

Go to Step 2

Go to Step 6

Go to Step 3

Go to Step 6

Go to Step 4

Go to Sep 6

Go to Step 5

Replace the ECU. Go to Step 10

The phenomenon is not reproduced. Refer to “Troubles intermittently observed”.

The ECU has failed.Replace the ECU. Go to Step 10

Go to Step 7

Go to Step 9

Go to Step 8

Go to Step 9

Repair the circuit or check the “Front Axle Disconnect”. (Refer to section 4B) Go to Step 10

Go to Step 9

Examine the trouble based on “Diagnosis from Trouble Codes”.

The ECU has failed. Replace the ECU. Go to Step 10

Verify the repair.

Go to Step 10

Start the engine.

1. The car stops, the AT selector is N position, and the brake is applied. When the TOD switch is selected to the 4L position, is 0V observed between terminals 42 and 47?

1. The car stops, the AT selector is N position, and the brake is applied. 2. Select the TOD switch to the 2H position. Is 5V observed between terminals 42 and 47?

Is 12V observed between terminals 7 and 47?

Is 12V observed between terminals 19 and 47?

1. The car stops, the AT selector is N position, and the brake is applied. When the TOD switch is selected to the 2H position, is the battery voltage observed between terminals 23 and 47?

1. The car stops, the AT selector is N position, and the brake is applied. When the TOD switch is selected to the TOD position, is 0V observed between terminals 23 and 47?

4B2–97

1. The car stops, the AT selector is N position, and the brake is applied. When the TOD switch is selected to the 4L position, is 0V observed between terminals 23 and 47?

Is any of the trouble codes 28 (P1760), 32 (P1761) and 33 (P1762) recorded?

Check that all the parts are mounted. Is this step complete?

4B2–98 DRIVE LINE CONTROL SYSTEM (TOD)

Chart G

The trouble codes are displayed.

Function of circuit

—

Fail condition

Indicator lamp state

TOD switch position

—

D04R200009

DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

Yes

Go to Step 2

The ECU has failed. Replace the ECU. Go to Step 3

Go to Step 3

Open the self-diagnostic connector. Go to Step 3

Verify the repair.

Go to Step 3

Disconnect the ECU connector from ECU. Is there the continuity established between terminals (C–37)7 and (C–37)25?

4B2–99

Is the self-diagnostic connector short-circuited?

1. Check that all the parts are mounted. 2. Clear the trouble codes. Is this step complete?

4B2–100 DRIVE LINE CONTROL SYSTEM (TOD)

Chart H

Lighting switch circuit

Function of circuit

Reads in the status of lighting switch, and reduces the indicator at night.

Fail condition

Even if the lighting switch is pressed on and off, brightness does not change.

Indicator lamp state

TOD switch position

All position (exsample TOD mode)

D04R200009

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–101 Step 1

Action

Yes

Go to Step 2

Lighting switch battery circuit short. Repair the circuit. Go to Step 4

Go to Step 3

Wires are broken in lighting switch circuit. Repair the circuit. Go to Step 4

The phenomenon is not reproduced. Refer to “Troubles intermittently observed”

The ECU has failed. Replace the ECU. Go to Step 4

Verify the repair.

Go to Step 4

1. Turn on the starter switch. 2. Turn off the lighting switch. Is 0V observed between the EUC terminal 40 and 47?

Turn lighting switch “ON”. Is the battery voltage observed between ECU terminal 40 and 47?

While the lighting switch is pressed on and off, does the brightness of the indicator change?

Check that all the parts are mounted. Is this step complete?

4B2–102 DRIVE LINE CONTROL SYSTEM (TOD)

Diagnosis from Symptom Troubles that are not indicated by the warning lamp are listed in the table below. These troubles are caused by the faults that cannot be detected by the self-diagnostic function of the control unit. If this type of trouble is observed, interview the customer and conduct test runs to reproduce the trouble, cross-check the reported trouble with the listed phenomena, and diagnose and analyze the trouble on the item by item basis. Phenomena

Major cause

Corrective action

The tight corner braking is observed when the vehicle is subject to full steering.

B B B B

The standard tires are not used. The tire pressure is incorrect. The tires are worn inuniformity. The transfer or wiring is imperfect. B The limited slip differential is failed.

Check and recondition the vehicle according to Chart 1.

Even if the TOD switch is selected to the TOD position, the F4WD mode is not active, resulting in remarkable rear wheel spin.

B The transfer or wiring is imperfect. B The shift on the fly system is failed.

Check and recondition the vehicle according to Chart 2.

B When the TOD switch is selected to the TOD position, the drive resistance of the F4WD system is too large to get sufficient running speed. B Noised drive line.

B The standard tires are not used. B The tires are worn inuniformity. B The transfer or wiring is imperfect. B The limited slip differential is failed.

Check and recondition the vehicle according to Chart 1.

The shift on the fly system (front axle disconnect) generates gear noises.

B The wiring is imperfect. B The shift on the fly system is failed.

Check and recondition the vehicle according to Chart 3.

The braking distance gets long even when the ABS is active.

B The wiring is imperfect. B The ABS is failed.

Check and recondition the vehicle according to Chart 4.

The transfer does not change to the low range from the high range.

Check and recondition the vehicle according to chart 5.

The transfer does not change to the high range from the low range.

B The transfer or wiring is imperfect. B The TOD switch is imperfect. B The AT inhibitor switch is imperfect. im erfect. B The brake switch is imperfect. B The engine speed signal is imperfect. B The speed sensor is imperfect.

The transfer stays neutral and the vehicle does not run.

B The transfer is imperfect.

Check and recondition the vehicle according to chart 7.

Check and recondition the vehicle according to chart 6.

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–103

Chart 1

The tight corner braking is observed.

Function of circuit

—

Fail condition

When the vehicle is subject to full steering in the TOD mode, the drive resistance gets large or the judder occurs. Otherwise, the above phenomenon is observed only when the brake is applied.

D04R200021

4B2–104 DRIVE LINE CONTROL SYSTEM (TOD) Step

Yes

Go to Step 2

Replace the tires with specified ones, and service the new tires. Go to Step 16

Go to Step 3

Inflate the tires with specified pressure. Go to Step 16

Go to Step 4

Replace the tires with specified ones, and service the new tires. Go to Step 16

Go to Step 5

Replace the tires with specified ones, and service the new tires. Go to Step 16

Go to Step 6

Go to Step 11

Does the tight corner braking occur? Is the judder with chug-chug sound observed? * Use caution on the operation.

Go to Step 7

Go to Step 14

Is an LSD mounted to the rear differential?

Go to Step 8

Go to Step 9

Is the genuine LSD oil used in the rear differential? Go to Step 9

Replace the differential oil. Go to Step 16

Go to Step 10

Check the engine. Go to Step 16

The ECU has failed. Replace the ECU. Go to Step 16

Replace the speed sensors. Go to Step 16

Go to Step 12

Conduct full steering under WOT. Go to Step 5

Go to Step 13

Repair the circuit of the ECU connector terminal 33 (ABS IN). Go to Step 16

Action Are the front and rear tires in specified size?

Is the tire pressure correct?

Are the tires free from abnormal wear?

Are different types of tires used?

1. Start the engine. 2. Select the TOD switch to the TOD position. 3. Fully turn the steering to the left (or right) end, and select the D range and start the creep run. Does the tight corner braking occur? Is the judder with chug-chug sound observed? * Use caution on the operation.

1. Select the TOD switch to the 2H position. 2. Fully turn the steering to the left (or right) end, and select the D range and start the creep run.

Does the engine output the power correctly?

Do the speed sensors work correctly? (Check trouble codes.)

Is the tight corner braking observed only when the brake is applied?

1. Turn on the starter switch. Is 8 ∼ 10 V observed between terminals 33 and 47?

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–105 Step

Action

Yes

1. Apply the brake and fully turn the steering to the left (or right) end, and start the creep run.

Repair the transfer assembly. Go to Step 16

The ECU has failed. Replace the ECU. Go to Step 16

Go to Step 15

Go to Step 10

The phenomenon is not reproduced. Refer to “Troubles intermittently observed”.

Repair the transfer assembly. Go to Step 16

Verify the repair

Go to Step 16

Does the voltage between terminals 11 and 22 range between 0.1 and 1.0V? 14

1. Select the TOD switch to the TOD position. 2. Fully turn the steering to the left (or right) end, and select the D range and start the creep run. Does the voltage between terminals 11 and 22 range between 0.1 and 1.0V?

1. Select the TOD switch to the 2H position. 2. Jack up the right front wheel. Does the front tire rotate smoothly?

Check that all the parts are mounted. Is this step complete?

*NOTE: Before checking this item, run the vehicle more than 10 meters with the steering wheel in straight position so that the 4L mechanical lock sleeve can be released certainly.

4B2–106 DRIVE LINE CONTROL SYSTEM (TOD)

Chart 2

The TOD mode is not active.

Function of circuit

—

Fail condition

The rear wheels spin in the TOD mode, so the driving torque is not transmitted to the front wheels. The indicator lamps will not show the 4L and TOD status.

D04R200021

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–107 Step 1

Action Is the trouble code 31(P1721) recorded?

Is any of the trouble codes 28(P1760), 32(P1761) and 33(P1762) recorded?

Examine the trouble based on “Diagnosis from Trouble Codes”.

Go to Step 2

Examine the trouble based on “Diagnosis from Trouble Codes”.

Go to Step 3

Go to Step 4

Examine the trouble based on “Trouble Diagnosis Depending on The Status of TOD Indicator”.

Go to Step 5

Repair the transfer assembly. Go to Step 7

Go to Step 6

The ECU has failed. Replace the ECU. Go to Step 7

The TOD clutch is worn. Repair the transfer assembly. Go to Step 7

The ECU has failed. Replace the ECU. Go to Step 7

Verify the repair.

Go to Step 7

When the TOD switch is selected to the specified position, do the TOD indicator lamps show the correct status?

Select the TOD switch to the 4L position, fully turn the steering to the left (or right) end, and start the creep run. Does the tight corner braking occur? 1. Select the TOD switch to the TOD position. 2. Turn on the starter switch. Does the voltage between terminals 11 and 22 indicate at least 3V while the throttle is completely open?

Yes

Does the voltage between terminals 11 and 22 indicate at least 0.1V while the throttle is completely closed?

Check that all the parts are mounted. Is this step complete?

4B2–108 DRIVE LINE CONTROL SYSTEM (TOD)

Chart 3

The shift on the fly system generates gear noises. (The fuel economy is bad in the 2H mode.)

Function of circuit

—

Fail condition

When the vehicle is run in the 2H mode, the shift on the fly system generates gear noises or the front wheel gears are engaged to generate a shock.

D04R200021

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–109 Step 1

Action

Go to Step 2

Examine the trouble based on “Trouble Diagnosis Depending on the Status of TOD Indicator”.

Examine the trouble based on “Diagnosis from Trouble Codes”.

Go to Step 3

Go to Step 4

Go to Step 5

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

The shift on the fly system is failed (refer to Section 4B1 and 4C).

Repair the battery circuit. Go to Step 6

Repair the battery and charging system. Go to Step 6

Verify the repair.

Go to Step 6

Do the indicator lamps show the correct status?

Is any of the trouble codes 28(P1760), 32(P1761) and 33(P1762) recorded?

Turn on the starter switch. Is the battery voltage observed between terminals 14 and 47?

Yes

When the TOD Switch is selected to the 2H position, are the front axle gears correctly disengaged (and when the left front tire is jacked up and turned, is the front propeller shaft standstill)?

Does the battery voltage maintain the correct level?

Check that all the parts are mounted. Is this step complete?

4B2–110 DRIVE LINE CONTROL SYSTEM (TOD)

Chart 4

The braking distance gets long even when the ABS is active.

Function of circuit

—

Fail condition

Enough deceleration is not obtained and the braking distance gets long even when the ABS is active in the 2H mode.

D04R200021

DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

Yes

Go to Step 2

Repair the brake and ABS. (Refer to section 5A and 5B)

Go to Step 3

Repair the battery system. Go to Step 5

Go to Step 4

The ECU has failed. Replace the ECU. Go to Step 5

Are the brake and ABS systems healthy?

Turn on the starter switch. Is the battery voltage observed between terminals 14 and 47? 1. Select the TOD switch to the 2H position.

Does the voltage between terminals 36 and 47 range between 7.5 and 16V (0.12 seconds make a cycle)? 4

4B2–111

1. Turn off the starter switch. 2. Disconnect the connector (C–37). Is there the continuity between the connector terminal (C–37) 14 and (C–6) 8?

Check that all the parts are mounted. Is this step complete?

The phenomenon is not reproduced. Refer to “Trouble intermittently observed». Verify the repair.

Repair the harness. Go to Step 5 Go to Step 5

4B2–112 DRIVE LINE CONTROL SYSTEM (TOD)

Chart 5

The transfer does not change to low from high.

Function of circuit

—

Fail condition

When the TOD switch is selected to the 4L position, the transfer does not change to the low range.

D04R200018

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–113 Step 1

Action

Yes

Examine the trouble based on “Diagnosis from Trouble Codes”.

Go to Step 2

Examine the trouble based on “Diagnosis from Trouble Codes”.

Go to Step 3

Examine the trouble based on “Diagnosis from Trouble Codes”.

Go to Step 4

Go to Step 5

Examine the trouble based on “Trouble Diagnosis Depending on the Status of TOD Indicator”.

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

Go to Step 6

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

Go to Step 7

Examine the trouble based on “Trouble diagnosis Depending on The Status of TOD Indicator”.

Go to Step 8

Is the battery voltage observed between the terminal 37 and 47?

Go to Step 10

Go to Step 9

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–37) and the brake switch connector (I–31).

The brake switch is abnormal. Repair or replace the brake switch. Go to Step 13

Repair the harness. Go to Step 13

Go to Step 12

Go to Step 11

Repair or replace the AT mode switch. Go to Step 13

Repair the circuit which has no continuity. Go to Step 13

1. Turn on the starter switch. Is any of the trouble codes 41 (P1741), 42 (P1773), 43 (P1743) and 55 (P1755) recorded?

Is any of the trouble codes 13 (P1735), 14 (P1731), 15 (P1736), 16 (P1737), 24 (P1733), and 27 (P1738) recorded?

Is the trouble code 17 (P1774) recorded?

1. Turn on the starter switch. 2. The car stops, engine speed is less than 1500 rpm, the AT selector is N position, and select the TOD switch to the 4L position. Do the front lamp and rear lamp in the indicator blink?

1. Step on the brake pedal. Is the transfer changed to the 4L mode?

8 9

When the vehicle is moved forth and back, is the transfer changed to the 4L mode?

Does the continuity corresponding to the encoder position between the terminals comply with the 4L position in the following table (continuity)?

1. Step on the brake pedal.

Is there the continuity between the connector terminal (C–37) 15 and (I–31) 4? 10

1. Select the AT selector to the N position. Is the voltage between the terminals ranged within the following table (voltage)?

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–37). 3. Disconnect the AT mode switch connector (E–41). Is there the continuity between the following connector terminals? (C–37)6 and (E–41)8 (C–37)19 and (E–41)7 (C–37)5 and (E–41)6

4B2–114 DRIVE LINE CONTROL SYSTEM (TOD) Step 12

Action

Replace the ECU. Go to Step 13

The engine pulse signal is abnormal. Repair or replace the PCM. Go to Step 13

Verify the repair.

Go to Step 13

1. Start the engine. Is the engine pulse signal between terminal 2 and 47 at engine speed under 1500 rpm within the standard? Standard: less than 4500 Hz

Yes

Check that all the parts are mounted. Is this step complete?

Continuity between terminal in 4L position (Table: continuity) Terminals No.

26 and 24

39 and 24

25 and 24

38 and 24

Continuity of 4L position

YES

YES or NO

Standard (Table: voltage) Unit: V Terminals

28 and 47

41 and 47

27 and 47

Voltage

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–115

Chart 6

The transfer does not change to high from low.

Function of circuit

—

Fail condition

When the TOD switch is selected to the TOD, the transfer does not change to the high range.

D04R200018

4B2–116 DRIVE LINE CONTROL SYSTEM (TOD) Step 1

Action

Yes

Examine the trouble based on “Diagnosis from Trouble Codes”.

Go to Step 2

Examine the trouble based on “Diagnosis from Trouble Codes”.

Go to Step 3

Examine the trouble based on “Diagnosis from Trouble Codes”.

Go to Step 4

Go to Step 5

Examine the trouble based on “Trouble Diagnosis Depending on the Status of TOD Indicator”.

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

Go to Step 6

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

Go to Step 7

Examine the trouble based on “Trouble diagnosis Depending on The Status of TOD Indicator”.

Go to Step 8

Is the battery voltage observed between the terminal 37 and 47?

Go to Step 10

Go to Step 9

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–37) and the brake switch connector (I–31).

The brake switch is abnormal. Repair or replace the brake switch. Go to Step 13

Repair the harness. Go to Step 13

Go to Step 12

Go to Step 11

Repair or replace the AT mode switch. Go to Step 13

Repair the circuit which has no continuity. Go to Step 13

1. Turn on the starter switch. Is any of the trouble codes 41 (P1741), 42 (P1773), 43 (P1743) and 55 (P1755) recorded?

Is any of the trouble codes 13 (P1735), 14 (P1731), 15 (P1736), 16 (P1737), 24 (P1733), and 27 (P1738) recorded?

Is the trouble code 17 (P1774) recorded?

1. Turn on the starter switch. 2. The car stops, engine speed is less than 1500 rpm, the AT selector is N position, and select the TOD switch to the TOD position. Do the front, rear, and AUTO lamps in the indicator blink?

1. Step on the brake pedal. Is the transfer changed to the TOD mode?

8 9

When the vehicle is moved forth and back, is the transfer changed to the TOD mode?

Is the continuity corresponding to the encoder position between the terminals ranged within the any case (case 1, 2 and 3) of TOD position in the following table (continuity)?

1. Step on the brake pedal.

Is there the continuity between the connector terminal (C–37) 15 and (I–31) 4? 10

1. Select the AT selector to the N position. Is the voltage between the terminals ranged within the following table (voltage)?

1. Turn off the starter switch. 2. Disconnect the ECU connector (C–37) and brake switch connector (I–31). 3. Disconnect the AT mode switch connector (E–41). Is there the continuity between the following connector terminals? (C–37)6 and (E–41)8 (C–37)19 and (E–41)7 (C–37)5 and (E–41)6

DRIVE LINE CONTROL SYSTEM (TOD) 4B2–117 Step 12

Action

Replace the ECU. Go to Step 13

The engine pulse signal is abnormal. Repair or replace the PCM. Go to Step 13

Verify the repair.

Go to Step 13

1. Start the engine. Is the engine pulse signal between terminal 2 and 47 at engine speed under 1500 rpm within the standard? Standard: less than 4500 Hz

Yes

Check that all the parts are mounted. Is this step complete?

Continuity in TOD position (Table: continuity) Continuity between terminals

Case 26 and 24

39 and 24

25 and 24

38 and 24

YES

Standard (Table: voltage) Unit: V Terminals

28 and 47

41 and 47

27 and 47

Voltage

4B2–118 DRIVE LINE CONTROL SYSTEM (TOD)

Chart 7

The transfer does not change to low from high.

Function of circuit

—

Fail condition

When the TOD switch is selected to the 4L position, the transfer does not change to the low position. (The transfer stays neutral and the vehicle does not run.)

Step 1

Action

Go to Step 2

Go to Step 3

The phenomenon is not reproduced. Refer to “Trouble intermittently observed”.

Go to Step 3

Examine the trouble based on “Diagnosis from Trouble Codes”.

The transfer is abnormal. Repair the transfer. Go to Step 4

Verify the repair.

Go to Step 4

1. Turn on the starter switch. 2. Set the TOD switch to the any position. Is the transfer changed to high or low?

Yes

Is the transfer changed to high from low and the low from high?

Is any of the trouble codes 41 (P1741), 42 (P1773), 43 (P1743), and 55 (P1755) recorded?

Check that all the parts are mounted. Is this step complete?

SECTION DRIVE SHAFT SYSTEM

4C–1

AXIOM (Vehicles Produced Before July/31/2001)

DRIVELINE/AXLE DRIVE SHAFT SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Hub and Disc (2WD Model) . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Front Hub and Disc (4WD Model) . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Front Drive Shaft Joint . . . . . . . . . . . . . . . . . . . Front Drive Shaft Joints Replacement . . . . Front Axle Drive Shaft . . . . . . . . . . . . . . . . . . . Front Axle Drive Shaft and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Bushing Replacement . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Shift On The Fly System . . . . . . . . . . . . . . . . . Shift On The Fly System and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4C–1 4C–2 4C–2 4C–3 4C–3 4C–3 4C–4 4C–5 4C–8 4C–8 4C–8 4C–10 4C–10 4C–13 4C–13 4C–14 4C–14 4C–15 4C–16 4C–16 4C–17 4C–19

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . Front Propeller Shaft . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . Front Propeller Shaft and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Rear Propeller Shaft . . . . . . . . . . . . . . . . . . . . . Rear Propeller Shaft and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slip Joint Disassembly . . . . . . . . . . . . . . . . . Universal Joint Disassembly . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Universal Joint Reassembly . . . . . . . . . . . . . Slip Joint Reassembly . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . .

4C–20 4C–21 4C–23 4C–26 4C–28 4C–29 4C–29 4C–30 4C–30 4C–31 4C–31 4C–32 4C–35 4C–36 4C–36 4C–36 4C–36 4C–37 4C–38 4C–40 4C–41 4C–42 4C–43

4C–19

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

4C–2

DRIVE SHAFT SYSTEM

General Description This publication contains essential removal, installation, adjustment and maintenance procedures. The front axle utilizes a central disconnect type front axle/transfer case system.

The drive axles are completely flexible assemblies, consisting of inner and outer constant velocity (CV) drive shaft joints connected by an axle shaft. For description of front propeller shaft and universal joint, refer to Front Propeller Shaft in this section.

Diagnosis Condition

Possible cause

Oil Leak At Front Axle

Correction

Worn or defective oil seal.

Replace the oil seal.

Front axle housing cracked.

Repair or replace.

Too much gear oil.

Correct the oil level.

Oil seal worn or defective.

Replace the oil seal.

Pinion flange loose or damaged.

Tighten or replace.

Noises In Front Axle Drive Shaft Joint

Broken or worn drive shaft joints and bellows (BJ and DOJ).

Replace the drive shaft joints and bellows.

“Clank” When Accelerating From “Coast”

Loose drive shaft joint to output shaft bolts.

Tighten.

Damaged inner drive shaft joint.

Replace.

Excessive drive shaft joint angle.

Repair.

Worn or damaged drive shaft joints.

Replace.

Sticking spider assembly (inner drive shaft joint).

Lubricate or replace.

Sticking joint assembly (outer drive shaft joint).

Lubricate or replace.

Out of balance or out of round tires.

Balance or replace.

Front end out of alignment.

Align.

Insufficient gear oil.

Replenish the gear oil.

Wrong or poor grade gear oil.

Replace the gear oil.

Drive pinion to ring gear backlash incorrect.

Adjust the backlash.

Worn or chipped ring gear, pinion gear or side gear.

Replace the ring gear, pinion gear or side gear.

Pinion shaft bearing worn.

Replace the pinion shaft bearing.

Wheel bearing worn.

Replace the wheel bearing.

Differential bearing loose or worn.

Tighten or replace.

Wheel bearing preload too tight.

Adjust the wheel bearing preload.

Incorrect front alignment.

Adjust the front alignment.

Steering unit loose or worn.

Tighten or replace.

Tire worn or improperly inflated.

Adjust the inflation or replace.

Front or rear suspension parts loose or broken.

Tighten or replace.

Wheel bearing worn or improperly adjusted.

Adjust or replace.

Incorrect front alignment.

Adjust the front alignment.

Worn ball joint or bush.

Replace the ball joint or bush.

Steering unit loose or worn.

Tighten or replace.

Tire worn or improperly inflated.

Replace or adjust the inflation.

Shock absorber worn.

Replace the shock absorber.

Oil Leak At Pinion Shaft

Shudder or Acceleration

Vibration

Vibration At Highway Speeds Noises in Front Axle

Wanders and Pulls

Front Wheel Shimmy

During

DRIVE SHAFT SYSTEM

4C–3

Front Hub and Disc (2WD Model) Disassembled View

411RX001

Legend (1) Bolt (2) Cover and Gasket (3) Lock Washer and Lock Screw (4) Hub Nut (5) Outer Bearing

(6) (7) (8) (9) (10) (11)

Hub and Disc Assembly ABS Sensor Ring Inner Bearing Oil Seal Bolt Wheel Pin

Disassembly 1. Before disassembly, jack up the front of vehicle and support frame with jack stands. 2. Remove the two bolts from the rear side of the knuckle arm, then remove the brake caliper, with the brake hose attached. Use a wire to attach the brake caliper to the upper link. Refer to Disk Brakes in Brake section. 3. Remove cover bolt. 4. Remove cover and gasket. 5. Remove lock washer and Lock screw. 6. Remove hub nut, using front hub nut wrench J–36827.

901RW054

4C–4

DRIVE SHAFT SYSTEM

7. Remove hub and disc assembly. 8. Remove ABS sensor ring. 9. Remove outer bearing. 10. Remove oil seal. 11. Remove inner bearing. 12. Use a brass bar to remove the outer bearing outer race(1), oil seal, inner bearing and inner bearing outer race(2) from the hub.

B Clamp hub and disc assembly in vise, using protective pads. Remove six(6) disc-to-hub retaining bolts.

411RS021

B Place hub on a suitable work surface and remove wheel studs, as required, using a hammer.

411RS002

13. Remove bolt. 14. If necessary, replace the wheel pin in the following manner. B Scribe mark(1) on hub to disc before disassembly to insure proper assembly.

411RS004

Inspection and Repair

411RS003

Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. B Hub B Hub bearing oil seal B Knuckle spindle B Disc B Caliper B ABS sensor ring For inspection and servicing of disc caliper and related parts, refer to Disc Brake in Brake section.

DRIVE SHAFT SYSTEM

Reassembly 1. Install wheel pin. B Place hub on a wood workbench or a block of wood approx. 6” by 6” to protect the wheel stud ends and threads.

4C–5

3. Install inner bearing. Install the outer race by driving it into the hub by using installer J–36829 and grip J–8092.

B Install wheel stud, using a hammer. NOTE: Be sure wheel stud is started squarely and seats completely.

411RS023

4. Install outer bearing. Install the outer race by driving it into the hub by using installer J–36828 and grip J-8092.

411RS005

2. Align scribe marks(1) and attach the hub to disc then tighten the bolts to the specified torque. Torque: 103 N·m (76 lb ft)

901RW056

411RS003

4C–6

DRIVE SHAFT SYSTEM

5. Install oil seal by using installer J–36830 and grip J–8092. Apply Multipurpose grease (NLGI No. 2 or equivalent) to the lip portion.

8. Install hub nut. Turn the place where there is a chamfer in the tapped hole to the outer side, then attach the nut by using front hub nut wrench J–36827.

901RW057

6. Inatall ABS sensor ring, then tigthen the bolts to the specified torque. Torque: 18 N·m (13 lb ft) 7. Install hub and disc assembly. B Apply grease in the hub.

901RW054

Preload Adjustment 1. Tighten the hub nut to 29.4 N·m (21.7 lb ft), then fully loosen the nut. 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin.

B Apply wheel bearing type grease (NLGI No.2 or equivalent) to the outer and inner bearing. Hub

35 g (1.23 oz)

Outer bearing

10 g (0.35 oz)

Inner bearing

15 g (0.53 oz)

Bearing Preload New bearing and New oil seal

19.6 – 24.5 N (4.4 – 5.5 lb)

Used bearing and New oil seal

11.8 – 17.7 N (2.6 – 4.0 lb)

If the measured bearing preload is outside the specifications, adjust it by loosening or tightening the hub nut.

411RS011

DRIVE SHAFT SYSTEM 9. Install lock washer and lock screw. B Turn the side with larger diameter of the tapered bore to the vehicle outer side, then attach the washer. B If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. B If the bolt holes are still out of alignment, turn in the nut just enough to obtain alignment. B Screw is to be fastened tightly so its head may come lower than the surface of the washer.

411RS012

10. Install cover and gasket then tighten the cover bolt. Torque: 59 N·m (43 lb ft) 11. Install brake caliper and tighten fixing bolt.

4C–7

4C–8

DRIVE SHAFT SYSTEM

Front Hub and Disc (4WD Model) Disassembled View

411RW001

Legend (1) Bolt (2) Cap (3) Snap Ring and Shim (4) Hub Flange (5) Lock Washer and Lock Screw (6) Hub Nut

Disassembly 1. Before disassembly, select the 2WD position with the 4WD switch. 2. Jack up the front of vehicle and support frame with jack attached.

(7) (8) (9) (10) (11) (12) (13)

Outer Bearing Bolt Hub and Disc Assembly Wheel Pin ABS Sensor Ring Inner Bearing Oil Seal

3. Remove the two bolts from the rear side of the knuckle arm, then remove the brake caliper, with the brake hose attached. Use a wire to attach the brake caliper to the upper link. Refer to Disk Brakes in Brake section. 4. Remove Bolt. 5. Remove cap.

DRIVE SHAFT SYSTEM 6. Remove snap ring and shim. 7. Remove hub flange. 8. Remove lock washer and lock screw. 9. Remove hub nut, using front hub nut wrench J–36827.

4C–9

16. Remove bolt. If necessary, replace the wheel pin in the following manner. B Scribe mark(1) on the hub to disc before disassembly to insure proper assembly. B Clamp the hub and disc assembly in a vise, using protective pads. Remove the 6 disc–to–hub retaining bolts.

901RW054

10. Remove hub and disc assembly. 11. Remove ABS sensor ring. 12. Remove outer bearing. 13. Remove oil seal. 14. Remove inner bearing. 15. Use a brass bar to remove the outer bearing outer race(1), oil seal, inner bearing and inner bearing outer race(2) from the hub.

411RS003

B Place hub on a suitable work surface and remove wheel studs, as required, by using a hammer.

411RS004

411RS002

4C–10

DRIVE SHAFT SYSTEM

Inspection and Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. B Hub B Hub bearing, oil seal B Knuckle spindle B Disc B Caliper B Shift on the fly system parts (Cap, Hub flange, Shim, Snap ring) B ABS sensor ring For inspection and servicing of disc caliper and related parts, refer to Disc Brakes in Brake section.

2. Align scribe marks(1) and attach the hub to the disc, then tighten the bolts to the specified torque. Torque: 103 N·m (76 lb ft)

Reassembly 1. Install wheel pin. B Place the hub on a wood workbench or a block of wood approx. 6” by 6” to protect the wheel stud ends and threads. B Insert a wheel stud using a hammer. NOTE: Be sure the wheel stud is started squarely and seats completely.

411RS003

3. Install inner bearing. Install the outer race by driving it into the hub by using insatller J–36829 and grip J–8092.

901RW055

411RS005

DRIVE SHAFT SYSTEM 4. Install outer bearing. Install the outer race by driving it into the hub by using install J–36828 and grip J–8092.

4C–11

Grease Amount Hub

35 g (1.23 oz)

Outer bearing

10 g (0.35 oz)

Inner bearing

15 g (0.53 oz)

901RW056

5. Install oil seal by using installer J–36830 and grip J–8092. Apply Multipurpose grease (NLGI No.2 or equivalent) to the lip portion.

411RS009

Legend (1) Inner Bearing (2) Hub (3) Outer Bearing 8. Install hub nut. Turn to the place where there is a chamfer in the tapped hole to the outer side, then attach the nut by using front hub nut wrench J–36827.

901RW057

6. Install ABS sensor ring, then tighten the bolts to the specified torque. Torque: 18 N·m (13 lb ft) 7. Install hub and disc assembly. B Apply grease in the hub. B Apply wheel bearing type grease NLGI No. 2 or equivalent to the outer and inner bearing. 901RW054

4C–12

DRIVE SHAFT SYSTEM

Preload Adjustment 1. Tighten the hub nut to 29 N·m (22 lb ft), then fully loosen the nut. 2. Tighten the hub nut to the value given below, using a spring scale on the wheel pin. New bearing and New oil seal

19.6 – 24.5 N (4.4 – 5.5 lb)

Used bearing and New oil seal

11.8 – 17.7 N (2.6 – 4.0 lb)

If the measured bearing preload is outside the specifications, adjust it by loosening or tightening the hub nut.

411RS012

10. Apply adhesive (LOCTITE 515 or equivalent) to both joining flange faces then install hub flange. 11. Install snap ring and shim. B Adjust the clearance between the free wheeling hub body and the snap ring. Clearance: 0 mm–0.3 mm (0 in–0.012 in) Shims Available: 0.2 mm, 0.3 mm, 0.5 mm, 1.0 mm (0.008 in, 0.012 in, 0.020 in, 0.039 in)

411RS011

9. Install lock washer and lock screw. B Turn the side with larger diameter of the tapered bore to the vehicle outer side, then attach the washer. B If the bolt holes in the lock plate are not aligned with the corresponding holes in the nut, reverse the lock plate. B If the bolt holes are still out of alignment, turn in the nut just enough to obtain alignment. B Screw is to be fastened tightly so its head may come lower than the surface of the washer. 411RW002

12. Install hub cap. 13. Tighten the bolts to the specified torque. Torque: 59 N·m (43 lb ft) 14. Install brake caliper and tighten fixing bolt.

DRIVE SHAFT SYSTEM

4C–13

Front Drive Shaft Joint Front Drive Shaft Joints Replacement B Refer to Front Drive Axle Assembly Replacement in this section, and refer to Front Hub and Disc Overhaul in Suspension section.

Front Hub Bearing Preload Check Check the hub bearing preload at the wheel pin. New bearing and New oil seal: 19.6 – 24.5 N (4.4 – 5.5 lb) Used bearing and New oil seal: 11.8 – 17.7 N(2.6 – 4.0 lb)

411RS011

Inspection Of Shift On The Fly System Gear Oil

412RY00008

1. Open filler plug and make sure that the oil up to the plug port. If the oil is short, replenish with gear oil GL–5 grade. 2. Tighten the filler plug to specified torque. Torque: 78 N·m (58 lb in)

4C–14

DRIVE SHAFT SYSTEM

Front Axle Drive Shaft Front Axle Drive Shaft and Associated Parts

412RY00036

Legend (1) Axle Case and Differential (2) Snap Ring (3) Bearing (4) Snap Ring (5) Oil Seal (6) Bracket (7) DOJ Case (8) Circlip (9) Bolt (10) Drive Shaft Joint Assembly (11) Ball

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Snap Ring Ball Retainer Ball Guide Band Bellows Band Band Bellows Band BJ Shaft Dust Seal

DRIVE SHAFT SYSTEM

Disassembly NOTE: For the left side, follow the same steps as right side.

4C–15

4. Remove drive shaft joint assembly. 5. Remove the six balls (1) with a screwdriver or equivalent.

1. Raise the hooked end of the band with a screwdriver or equivalent.

412RS012

6. Using snap ring pliers, remove the snap ring (1) fastening the ball retainer to the center shaft. 412RS009

2. Remove band(1). 3. Pry off circlip (1) with a screwdriver or equivalent.

412RS013

412RS010

4C–16

DRIVE SHAFT SYSTEM

7. Remove ball retainer, ball guide and bellows. 8. Raise the hooked end of the band with a screwdriver or equivalent.

Bushing Replacement B Remove the bushings using a remover J–39378–1 and hammer.

412RS014

9. Remove band(1). 10. Remove bellows. 11. Remove dust seal. 12. Remove BJ shaft assembly. 13. Remove the mounting bracket fixing bolts, and then remove DOJ case assembly from the axle case. 14. Remove snap ring and bearing. 15. Remove snap ring and oil seal. 16. Remove bracket.

412RS015

B By using installer J–39378–2 and base J–39378–3, press fit the bushings into the bracket.

Inspection And Repair Make necessary correction or parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts. 1. Drive shaft joint assembly 2. DOJ case, ball, ball guide, ball retainer 3. Bellows 4. Bearing 5. Dust seal, oil seal

412RS016

DRIVE SHAFT SYSTEM

4C–17

Reassembly 1. Install DOJ case to bracket. 2. Install oil seal and fix snap ring. 3. Install bearing and fix snap ring. 4. Install bracket to axle case. Tighten the bracket bolt to the specified torque. Torque: 116 N·m (85 lb ft) 5. Apply 150g of the specified grease in BJ. 6. Install dust seal. 7. Apply a thin coat of grease to the shaft for smooth installation then install bellows. 8. Install band. Note the setting direction. After installation, check that the bellows is free from distortion.

412RS013

13. Align the track on the ball (1) retainer with the window in the cage, and install the six balls into position.

412RS017

9. Install another bellows and fix band. 10. Install the ball guide with the smaller diameter side ahead onto the shaft. 11. Install ball retainer. 12. Using snap ring pliers, install the snap ring (1) securing the ball retainer to the shaft.

412RS018

14. Pack 150g of the specified grease in DOJ case, then install drive shaft joint assembly. After reassembly, move the DOJ longitudinally several times to get to fit.

4C–18

DRIVE SHAFT SYSTEM

15. Install the circlip (1) so that open ends are positioned away from the ball groove.

16. Install bellows. Adjust the air pressure within the bellows by inserting a screwdriver or equivalent, so that it equals atmospheric pressure.

412RS019 412RS021

17. Install band. After installation, check that the bellows is free from distortion.

412RS020

Legend (1) Outer Case (2) Circlip (3) Open Ends

DRIVE SHAFT SYSTEM

4C–19

Shift On The Fly System Shift On The Fly System and Associated Parts

412RY00007

Legend (1) Filler Plug (2) Bolt (3) Oil Seal (4) Snap Ring(External) (5) Inner Shaft Bearing (6) Snap Ring(Internal) (7) Inner Shaft

(8) (9) (10) (11) (12) (13) (14) (15)

Needle Bearing Clutch Gear Sleeve Housing Front Axle Drive Shaft(LH side) with Bracket Bolt Actuator Assembly Bolt

4C–20

DRIVE SHAFT SYSTEM 10. Remove inner shaft bearing.

Disassembly 1. Remove filler plug and gasket, drain oil. 2. Loosen mounting bracket fitting bolts and remove front axle drive shaft from front axle case. 3. Remove actuator assembly and draw out actuator ASM. 4. Remove housing. 5. Remove sleeve. 6. Remove clutch gear. 7. Remove snap ring from front axle case by using snap ring pliers.

NOTE: Be careful not to damage the shaft.

412RW015

11. Remove needle bearing from inner shaft by using a remover J–26941 and sliding hammer J–2619–01.

412RW017

8. Take out inner shaft from front axle case. 9. Remove snap ring from inner shaft by using snap ring pliers.

412RS045

12. Remove oil seal from front axle case. NOTE: Be careful not to damage the front axle case.

412RW016

DRIVE SHAFT SYSTEM

4C–21

Inspection And Repair

Inner Shaft Run–Out

Inspect the removed parts. If there are abnormalities such as wear and damage, take corrective action or replace.

With both end centers supported, rotate the shaft slowly and measure deflection with a dial gauge. Limit: 0.5 mm (0.02 in)

Visual Check

NOTE: Do not heat the shaft to correct its bend.

1. Check and see if the inner shaft has such abnormalities as wear and damage.

412RS026

412RW014

Inner Shaft Bearing

2. Replace the shaft if any signs of deterioration in the gear is present.

412RW006

420RS008

Legend (1) Inner Shaft Bearing (2) Inner Shaft (3) Clutch Gear 1. Inspect the inner shaft bearing for any signs of deterioration, replace if uneven. 2. Insert the clutch gear and inspect the needle bearing. 3. Replace the needle bearing if found to be uneven.

4C–22

DRIVE SHAFT SYSTEM

Sleeve Condition

Clutch Gear Condition

Check and see that there is not wear damage, or cracking in the sleeve.

Check for wear, damage, crack or any other deterioration in the clutch gear.

NOTE: Close inspection of the groove and inner gear are required because those are important parts.

Clutch Gear Function

Sleeve Function

412RY00038

Test the sleeve for smoothness by sliding it across the clutch gear, replace the clutch gear if its difficult to slide. 412RY00039

Test the sleeve for smoothness by sliding it between the inner shaft and the clutch gear, replace the sleeve if its difficult to slide. NOTE: Gear oil should be applied to the contact surface of gear. Check the width of sleeve center groove. Limit: 7.1 mm (0.28 in)

NOTE: When inspecting, gear oil should be applied to the contact surface of gear.

Clutch Gear Journal Diameter Make sure of the size illustrated. Limit: 36.98 mm (1.456 in)

412RY00037

412RW022

DRIVE SHAFT SYSTEM

4C–23

NOTE: Be careful not to permit the entry of water or dust into of the actuator.

Actuator Check for damage, cracking or other abnormality.

Dimentional Check Measure illustrated sizes 1, 2, and 3.

Functional Check

412RY00041

412RY00010

Limit 1=64.3 mm (2.53 in) 2=6.7 mm (0.26 in) 3=6.7 mm (0.26 in)

Reassembly 1. Install the new oil seal which has been immersed in differential gear oil, by using an oil seal installer J–41693 and grip J–8092.

412RY00009

Verify functionality by applying voltage (12V) to terminals 3 and 4 and set the tester to terminal 1 and 2 according to the table bellow.

State

Trminal 3

Trminal 4

Electric circuit between terminal 1&2

+12V

Ground

2WD

Ground

+12V

NONE

4WD

Functio n

If there is an abnormality, replace the actuator as an assembly.

412RW034

4C–24

DRIVE SHAFT SYSTEM

2. Install a new needle bearing into inner shaft by using a Installer J–41694 and grip J–8092.

NOTE: Be sure to install the snap ring properly.

412RW017 412RS051

3. Place a new snap ring(internal) in inner shaft. Install a new inner shaft bearing into the inner shaft.

7. Apply differential gear oil to clutch gear, then install clutch gear. 8. Apply differential gear oil to sleeve, then install sleeve. 9. Clean contact surface with the front axle and actuator mounting surface. Apply liquid gasket to the contact surface on the front axle case, then install in the housing.

412RS044

4. Install snap ring(external). NOTE: Be careful not to damage the inner shaft. 5. Clean the housing contact surface of the front axle case and insert inner shaft assembly into the front axle case. NOTE: Be careful not to damage seal. 6. Install snap ring internal in the groove of front axle case.

412RW023

10. Tighten bolts to specified torque. Torque: 75N·m(55 lb ft) 11. Clean the actuator contact surface with the housing then Install and tighten shift position switch to specified torque. Torque: 39N·m (29 lb ft)

DRIVE SHAFT SYSTEM 12. Apply liquid gasket to the contact surface on the actuator side.

412RW012

13. Align shift arm with the groove of sleeve and install the actuator. 14. Tighten bolts to specified torque. Torque: 9N·m(78 lb in) 15. Install front axle drive shaft and mounting bracket. Tighten fitting bolts to specified torque. Torque: 116N·m (85 lb ft) 16. Pour specified amount of differential gear oil to filler plug. Front Differential Oil Capacity: 1.4lit (1.48US qt) Actuator Housing Oil Capacity: 0.12lit(0.13US qt) 17. Install filler plug through gasket and tighten to specified torque. Torque: 78N·m (58lb ft)

4C–25

4C–26

DRIVE SHAFT SYSTEM

Main Data and Specifications General Specifications Front drive axle oil capacity

1.25 liter (1.32 US qt)(Differential) 0.12 liter (0.13 US qt)(Actuator Housing:Shift on the fly)

Type of lubricant Axle shaft type

GL–5 (75W–90) Refer to chart in General Information Constant velocity joint(Birfield joint type and double offset joint)

Torque Specifications

412RY00040

DRIVE SHAFT SYSTEM

4C–27

E04RW001

4C–28

DRIVE SHAFT SYSTEM

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

ILLUSTRATION

TOOL NO. TOOL NAME

J–39378 Remover and Installer; Front Axle mount bushing

J–36827 Wrench; Hub nut

J– 26941 Remover; Bearing needle

J–36829 Installer; Inner bearing

J–2619–01 Hammer; Sliding

J–36828 Installer; Outer bearing

J–41693 Installer; Oil seal

J–36830 Installer; Oil seal

J–41694 Installer; Bearing needle

J–8092 Grip

DRIVE SHAFT SYSTEM

4C–29

Propeller Shaft General Description

401R200001

Legend (1) Front Propeller Shaft (2) Rear Propeller Shaft; Aluminum Tube with Flange Yoke Type (for 4×2 model) (3) Rear Propeller Shaft; Steel Tube Type (for 4×4 model)

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

B Park, turn the engine off and apply the parking brake to secure the vehicle. B Carefully attach the propeller shaft to the vise, do not overtighten the vise when securing the propeller shaft, this may cause deformation.

4C–30

DRIVE SHAFT SYSTEM

Front Propeller Shaft General Description Since the propeller shaft is balanced carefully, welding or any other modifications are not permitted. Alignment marks should be applied to each propeller shaft before removal.

401R200004

DRIVE SHAFT SYSTEM

4C–31

Front Propeller Shaft and Associated Parts

401R200006

Legend (1) Bolt, and Washer (Front Axle Side) (2) Front Propeller Shaft (with TOD)

(3) Bolt and Washer (Transfer Side) (4) BJ Constant Velocity Joint (5) LJ Constant Velocity Joint

Removal 1. Jack up the vehicle and support it on the chassis stands. 2. Gear shift lever should be placed in neutral position and parking brake released. 3. Remove the exhaust and transfer protectors. NOTE: Apply alignment marks on the flange at the front propeller shaft both front and rear side.

401RS020

4C–32

DRIVE SHAFT SYSTEM

401RW053

401RW051

Installation NOTE: Never install the shaft assembly backwards. Completely remove the black paint from the connecting surface of flange coupling on each end of propeller shaft. Clean so that no foreign matter will be caught in between. 1. Align the mark which was applied at removal. Install front propeller shaft and tighten the bolts to the specified torque. Torque: 63 N·m (46 lb ft) 2. Install the exhaust and transfer protectors.

Constant Velocity Joint NOTE: LJ and BJ constant velocity joints are unremovable types. Check the joint for play and the boot for damage, wear, and leak of grease. If abnormality is found, replace propeller shaft as an assembly. 401RW052

4. Remove bolt, nut and washer (Front axle side). 5. Remove bolt, nut and washer (Transfer side). 6. Remove front propeller shaft. NOTE: When removing, installing or carring the front propeller shaft, be sure to wrap a piece of cloth around the part of the boot with which fittings may interfere so that the boot can be protected. The boot may be damaged if bending force is applied to the constant velocity joint of the shaft.

DRIVE SHAFT SYSTEM

4C–33

Play in Constant Velocity Joint

Boot of Constant Velocity Joint

Position the shaft in a vise between two pieces of wood, then secure. Test for shaft movement by attempting to move back and forth, and side to side. Secure as needed.

Check the following: boot (2) for crack, damage and grease leakage, the boot band (1) for looseness and damage, and both sides of the joint for gease leakage coming from the cover press-in parts (3).

401RW048 401RW050

401RW047 401RW049

4C–34

DRIVE SHAFT SYSTEM

Front Axle Flange Run-out 1. Set a dial gage at right angle near the outer circumference of the flange face and check the run-out of the flange face.

3. If vibration is felt during the 4H AUTO drive, disconnct the propeller shaft at the front axle. Reinstall the propeller shaft at 60°, 120°, 180°, 240°, and 300° and conduct test drive in each position and check if there is vibration.

Limit: 0.15 mm (0.006 in)

401RW044 401RW046

2. Set a dial gage at right angle near the inner circumference and check the run-out of the flange. Limit: 0.15 mm (0.006 in)

401RW045

DRIVE SHAFT SYSTEM

4C–35

Main Data and Specifications General Specifications Engine

6VE1(3.5 L)

Transmission

A/T with TOD

Construction

Hollow steel tube with constant velocty joints.

Outside diameter

40.0 mm (1.57 in)

Length

597 mm (23.50 in)

Torque Specifications

401R200005

4C–36

DRIVE SHAFT SYSTEM

Rear Propeller Shaft Rear Propeller Shaft and Associated Parts

401R200002

Legend (1) Bolt, Nut and Washer (Transfer Side)

Removal 1. Raise the vehicle on a hoist. NOTE: Apply alignment marks on the flange at the rear propeller shaft both front and rear side. 2. Remove transfer side bolt, nut and washer (except spline yoke type). 3. Remove rear axle side bolt, nut and washer. 4. Remove rear propeller shaft. NOTE: Plug the hole of the transmission rear end to prevent oil leakage (spline yoke type only).

(2) Rear Propeller Shaft (3) Bolt, Nut and Washer (Rear Axle Side)

Installation NOTE: Never install the shaft assembly backwards. Never insert bar between yoke lugs when tightening or removing bolts. Completely remove the dust or foreign matter from the connecting surface of flange coupling on each end of the propeller shaft. 1. Align the mark which is applied at removal. 2. Install rear propeller shaft and tighten the bolts to the specified torque. Torque: 63 N·m(46 lb ft)

DRIVE SHAFT SYSTEM

4C–37

Slip Joint Disassembly

401RX00001

Legend (1) Spline Yoke and Universal Joint Assembly (2) Clamp

1. Lay the shaft horizontally on a bench and secure. 2. Indicate the original assembled position by marking the phasing of the shaft prior to disassembly. 3. Using the flat blade of a screwdriver, pry the loose end of the boot clamp upwards and away from the propeller shaft boot. Be careful not to damage the boot.

(3) Boot (4) Clamp (5) Tube and Universal Joint Assembly

4. When boot clamps becomes loose, remove by hand. 5. Repeat for the other boot clamp. 6. Remove the slip yoke assembly from the driveshaft, by securing the boot with one hand and pulling on the slip yoke. 7. Remove the boot from the shaft assembly.

4C–38

DRIVE SHAFT SYSTEM

Universal Joint Disassembly

401RX00007

Legend (1) Spline Yoke (2) Spider (3) Propeller Shaft Assembly (4) Spider

NOTE: Aluminum is softer than steel. Care must be taken not to remove excessive material or damage bearing holes. If the vehicle has aluminum tube type propeller shaft, flange yoke, boot kit, journal kit can be replaced. If other parts are damaged, replace propeller shaft assembly.

(5) (6) (7) (8)

Flange Yoke Bearing Snap Ring Flange Yoke

DRIVE SHAFT SYSTEM 1. Apply alignment marks on the yokes of the universal joint, then remove the snap ring.

4C–39

2. Set the yoke in the arbor press with a piece of tube stock beneath it. Place a solid plug on the upper bearing and press it through to release the lower bearing.

401RW024

If the snap ring is stuck in position, remove paint from the hole in the yoke or tap around the edge of the bearing lightly with a soft drift.

401RW027

3. If the bearing will not pull out by hand after pressing, tap the base of the lug near the bearing to dislodge it. 4. To remove the opposite bearing, turn the yoke over and straighten the spider in the open spider hole. Then carefully press on the end of the spider so the remaining bearing moves straight out of the bearing spider hole. If the spider or bearing are cocked, the bearing will score the walls of the spider hole and ruin it.

401RW025

401RW026

4C–40

DRIVE SHAFT SYSTEM

5. Repeat this procedure on the remaining bearing to remove the spider from the yoke.

Inspection B Propeller shaft for run-out Aluminum tube type. Static run-out limit : 1.0 mm(0.04 in) TIR full length of tubing maximum. (TIR : Total Indicator Reading) B Propeller shaft for runout (Steel tube type). Static runout limit : 0.13 mm(0.005 in) TIR on the neck of the slip tube shaft (with a boot). 0.25 mm(0.010 in) TIR on the ends of the tubing 3 inch from the welds. 401RW028

B Preload of the universal joint. Preload should be 0 to 49 N (0 to 11.0 lb). Joints should rotate smoothly and freely and should exhibit no rough or ratchety movement.

0.38 mm(0.015 in) TIR at the linear center of the tube. 0.38 mm(0.015 in) TIR for the full length of tube with 30” or less of tubing. (TIR: Total Indicator Reading)

401RW019

401RW017

B Play in universal joint. Limit: Less than 0.15 mm(0.006 in) B Spider pin should be smooth and free from fretting or galling. Visible signs of needle presence is normal, but wear should not be felt.

B Inspect splines of slip joint for wear. The nylon-coated spline should be free from nicks and dings and the underlying steel spline should not be visible. After cleaning the nylon coating spline, the coating should exhibit only slight indication of wear. Grease volume is approximately 10 grams of grease in total. Grease should be evenly applied to both the female and the male slip splines using a small brush. After assembly of the slip joint, the sliding joint should be fully worked from the full collapsed to the full extended position.

DRIVE SHAFT SYSTEM B Aluminum tube type only: Inspect the aluminum tubing for surface scratches and dents. These scratches may not exceed 0.2 mm (0.008 in) in depth.

4C–41

Universal Joint Reassembly 1. Pack the four grease cavities of the spider with a high quality, extreme pressure N.L.G.I. Grade 2 grease. Do not add additional grease to bearing cup assembly. 2. Move one end of the spider to cause a trunnion to project through the spider hole beyond the outer machined face of the yoke lug. Place a bearing over the trunnion diameter and align it to the spider hole. Using an arbor press, hold the trunnion in alignment with the spider hole and place a solid plug on the upper bearing. Press the bearing into the spider hole enough to install a snap ring.

401RW022

B Aluminum tube type only: Visually inspect the circle welds and fittings for any signs of cracks or signs of deterioration. If there are any cracks that exceed 0.2 mm (0.008 in) in depth, the assembly must be replaced. B Aluminum tube type only: Check to be sure there are no missing balance weights. If balance weights are missing and void has occurred in the aluminum tubing greater than 0.2 mm (0.008 in), the assembly must be replaced. 401RW026

3. Install a snap ring. NOTE: Be sure the snap rings are properly seated in the grooves. 4. Repeat steps 2 and 3 to install the opposite bearing. If the joint is stiff, strike the yoke ears with a soft hammer to seat the bearing. 5. Align the setting marks and join the yokes.

4C–42

DRIVE SHAFT SYSTEM

Slip Joint Reassembly

401RX00001

Legend (1) Spline Yoke and Universal Joint Assembly (2) Clamp

1. Apply grease evenly to both the female and male splines. 2. Apply a small amount of grease by finger to the outer lips of the boot. 3. Slide the boot (smaller diameter side) onto the spline yoke shaft being careful not to damage the spline coating or boot. 4. Insert the spline yoke shaft spline into the tube assembly being careful to maintain proper phasing. The spider holes should be in line as originally marked prior to disassembly. 5. Position boot onto tube and yoke shaft in its assembled position. 6. Attach boot clamps and secure using pliers.

(3) Boot (4) Clamp (5) Tube and Universal Joint Assembly

7. Be sure clamp is properly seated and secure. CAUTION: Only use a similar type or same as the original type clamp. Using any other clamp may create an imbalanced shaft or lead to grease leakage.

DRIVE SHAFT SYSTEM

4C–43

Main Data and Specifications General Specifications Engine Transmission Type (See illustration) Length between two spiders center) Universal joint type

2WD Model

4WD Model

6VD1

A/T

1323.0mm (52.09in)

1030.0mm (40.55in) Cardan type

Torque Specifications

401R200007

4C–44

DRIVE SHAFT SYSTEM

AXIOM (Vehicles Produced After Aug./1/2001)

DRIVE SHAFT SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Hub and Disc (2WD Model) . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Front Hub and Disc (4WD Model) . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Front Drive Shaft Joint . . . . . . . . . . . . . . . . . . . Front Drive Shaft Joints Replacement . . . . Front Axle Drive Shaft . . . . . . . . . . . . . . . . . . . Front Axle Drive Shaft and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Bushing Replacement . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Shift On The Fly System . . . . . . . . . . . . . . . . . Shift On The Fly System and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .

4C–44 4C–45 4C–45 4C–46 4C–46 4C–46 4C–47 4C–48 4C–49 4C–49 4C–49 4C–50 4C–51 4C–52 4C–52 4C–53 4C–53 4C–54 4C–55 4C–55 4C–55 4C–59 4C–59 4C–59 4C–61 4C–63

Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Propeller Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Universal Joint . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis of Propeller Shaft and Universal Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Propeller Shaft . . . . . . . . . . . . . . . . . . . . . Front Propeller Shaft and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Universal Joint Disassembly . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Universal Joint Reassembly . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Rear Propeller Shaft . . . . . . . . . . . . . . . . . . . . . Rear Propeller Shaft and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Slip Joint Disassembly . . . . . . . . . . . . . . . . . Universal Joint Disassembly . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Universal Joint Reassembly . . . . . . . . . . . . . Slip Joint Reassembly . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . .

4C–66 4C–68 4C–69 4C–69 4C–70 4C–71 4C–72 4C–72 4C–72 4C–72 4C–73 4C–74 4C–75 4C–76 4C–77 4C–78 4C–79 4C–79 4C–79 4C–79 4C–80 4C–81 4C–83 4C–84 4C–85 4C–86

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

DRIVE SHAFT SYSTEM

4C–45

Diagnosis Condition

Possible cause

Oil Leak At Front Axle

Correction

Worn or defective oil seal.

Replace the oil seal.

Front axle housing cracked.

Repair or replace.

Too much gear oil.

Correct the oil level.

Oil seal worn or defective.

Replace the oil seal.

Pinion flange loose or damaged.

Tighten or replace.

Noises In Front Axle Drive Shaft Joint

Broken or worn drive shaft joints and bellows (BJ and DOJ).

Replace the drive shaft joints and bellows.

“Clank” When Accelerating From “Coast”

Loose drive shaft joint to output shaft bolts.

Tighten.

Damaged inner drive shaft joint.

Replace.

Excessive drive shaft joint angle.

Repair.

Worn or damaged drive shaft joints.

Replace.

Sticking spider assembly (inner drive shaft joint).

Lubricate or replace.

Sticking joint assembly (outer drive shaft joint).

Lubricate or replace.

Out of balance or out of round tires.

Balance or replace.

Front end out of alignment.

Align.

Insufficient gear oil.

Replenish the gear oil.

Wrong or poor grade gear oil.

Replace the gear oil.

Drive pinion to ring gear backlash incorrect.

Adjust the backlash.

Worn or chipped ring gear, pinion gear or side gear.

Replace the ring gear, pinion gear or side gear.

Pinion shaft bearing worn.

Replace the pinion shaft bearing.

Hub unit bearing worn.

Replace the hub unit bearing.

Differential bearing loose or worn.

Tighten or replace.

Incorrect front alignment.

Adjust the front alignment.

Steering unit loose or worn.

Tighten or replace.

Tire worn or improperly inflated.

Adjust the inflation or replace.

Front or rear suspension parts loose or broken.

Tighten or replace.

Hub unit bearing worn.

Replace.

Incorrect front alignment.

Adjust the front alignment.

Worn ball joint or bush.

Replace the ball joint or bush.

Steering unit loose or worn.

Tighten or replace.

Tire worn or improperly inflated.

Replace or adjust the inflation.

Shock absorber worn.

Replace the shock absorber.

Oil Leak At Pinion Shaft

Shudder or Acceleration

Vibration

Vibration At Highway Speeds Noises in Front Axle

Wanders and Pulls

Front Wheel Shimmy

During

4C–46

DRIVE SHAFT SYSTEM

Front Hub and Disc (2WD Model) Disassembled View

411R200011

Legend (1) Disc Rotor (2) Hub unit, Bearing

(3) Wheel Pin (4) Bolt

Disassembly 1. Raise the vehicle with a jack. Support the frame with chassis stands. 2. Remove the brake caliper from the bracket. Secure the caliper with a wire so that it does not interfere with the work process. Refer to Front disc caliper assembly in Section 5C of this Manual. 3. Remove the disk rotor Apply penetrating oil to the bearing and disc rotor contact surfaces if the surfaces are stuck together because of rust. 4. Inspect the hub unit bearing. Refer to Inspection below. 5. Use a dial gauge to measure the bearing axial rattle. Bearing axial rattle: 0.05 mm max 411R200002

DRIVE SHAFT SYSTEM If abnormal conditions are discovered during inspection, go to Step 6. If there are no abnormal conditions, reassemble the front disc rotor and caliper.

4C–47

10. If necessary, replace the wheel pin in the following manner. B Place hub on a suitable work surface and remove wheel studs, as required, using a hammer.

NOTE: Hub, wheel bearing and spindle is integrated to the hub unit bearing so it must not be disassembled. If it has abnormal rattle or noise, replace the hub unit bearing. 6. Remove the ABS sensor connector.

411RS004

Inspection 411R200004

Legend (1) ABS Sensor Connector (2) Bolt 7. Remove the 4 bolts fixing the hub unit bearing to the knuckle. Apply penetrating oil to the bearing and knuckle contact surfaces if the surfaces are stuck together because of rust. 8. Temporarily install long bolts to 2 of the fixing bolt holes (the bolts must have the same diameter and thread width). 9. Strike the long bolts with a hammer to loosen and remove the hub unit bearing from the knuckle. Take care not to drop the bearing.

Inspect the parts listed below for abrasion, breakage, and other abnormal conditions. Repair, or replace the parts as required. B Disc B Caliper B Wheel pin B Hub unit bearing

4C–48

DRIVE SHAFT SYSTEM

Reassembly 1. Install wheel pin.

411RS005

B Place hub on a wood workbench or a block of wood approx. 6” by 6” to protect the wheel stud ends and threads. B Install wheel stud, using a hammer. NOTE: Be sure wheel stud is started squarely and seats completely. 2. Install the hub unit bearing to the knuckle. Tighten the bolts to the specified torque. Hub unit bearing bolt Torque: 103±10 N·m (10.5 ± 1 kg·m) If there is rust on the bearing and knuckle contact surfaces, use sandpaper to remove it before installation. 3. Install the ABS sensor connector. 4. Install the disc rotor. 5. Install the brake caliper to the bracket. Refer to Front disc caliper assembly in Section 5C of this Manual.

DRIVE SHAFT SYSTEM

4C–49

Front Hub and Disc (4WD Model) Disassembled View

411R200010

Legend (1) Disc Rotor (2) Hub Unit, Bearing

Disassembly 1. Move the transfer case lever to the 2WD position. 2. Raise the vehicle with a jack. Support the frame with chassis stands. 3. Remove the brake caliper from the bracket. Secure the caliper with a wire that it does not interfare with the work process.

(3) Wheel Pin (4) ABS Sensor Ring (5) Bolt

Refer to Front disc caliper assembly in Section 5C of this Manual. 4. Remove the disk rotor. Apply penetrating oil to the bearing and disc rotor contact surfaces if the surfaces are stuck together because of rust. 5. Inspect the hub unit bearing. Refer to inspection below.

4C–50

DRIVE SHAFT SYSTEM

6. Use a dial gauge to measure the bearing axial rattle. Bearing axial rattle: 0.05 mm max

Legend (1) Bolt 11. Strike the long bolts with a hammer to loosen and remove the hub unit bearing from the knuckle. B Take care not to strike the front drive shaft. B Take care not to drop the bearing. 12. Remove the ABS rotor sensor from the bearing. 13. If necessary, replace the wheel pin in the following manner. B Place hub on a suitable work surface and remove wheel studs, as required, using a hammer.

411R200002

If abnormal conditins are discovered during inspection, go to Step 7. If there are no abnormal conditions, reassemble the front discrotor and caliper. NOTE: Hub, wheel bearing and spindle is integrated to the hub unit bearing so it must not be disassembled. If it has abnormal rattle or noize, replace the hub unit bearing. 7. Loosen the caulking around the front drive shaft nuts. 8. Remove the nuts and discard them (they cannot be reused). 9. Remove the 4 bolts fixing the hub unit bearing to the knuckle. Apply penetrating oil to the bearing and knuckle contact surfaces if the surfaces are stuck together because of rust. 10. Temporarily install long bolts to 2 of the fixing bolt holes (the bolts must have the same diameter and thread width).

411R200012

411RS004

Inspection Inspect the parts listed below for abrasion, breakage, and other abnormal conditions. Repair or replace the parts as required. B Disc B Caliper B Drive shaft oil seal B ABS sensor rotor B Wheel pin B Hub unit bearing

DRIVE SHAFT SYSTEM

4C–51

7. Tighten the front drive shaft nuts to the specified torque.

Reassembly 1. Install the wheel pin. B Place hub on a wood workbench or a block of wood approx. 6” by 6” to protect the wheel stud ends and threads.

Front drive shaft nut Torque: 245±19.6 N·m (25±2 kg·m)

B Install the wheel stud, using a hammer. NOTE: Be sure wheel stud is started squarely and seats completely.

411R200005

8. Caulk the front drive shaft nuts. The caulking must be free of cracks.

411RS005

2. Install the ABS rotor sensor to the hub unit bearing. Tighten the bolts to the specified torque. ABS rotor sensor bolt Torque: 18.7±5 N·m (1.9±0.5 kg·m) 3. Install the hub unit bearing to the knuckle. Tighten the bolts to the specified torque. Hub unit bearing bolt Torque: 103±10 N·m (10.5±1 kg·m) If there is rust on the bearing and knuckle contact surfaces, use sandpaper to remove it before installation. Take care not to push the front drive shaft and oil seal out of position. 4. Hand tighten the front drive shaft nuts. Use new nuts. 5. Install the disc rotor. 6. Install the brake caliper to the bracket. Refer to Front disc caliper assembly in Section 5C of this Manual.

411R200006

4C–52

DRIVE SHAFT SYSTEM

Front Drive Shaft Joint Front Drive Shaft Joints Replacement B Refer to Front Drive Axle Assembly Replacement in this section, and refer to Front Hub and Disc Overhaul in Suspension section.

Front Hub Bearing Preload Check Check the hub bearing preload at the wheel pin. New bearing and New oil seal: 24.5 N (4.4 – 5.5 lb) Used bearing and New oil seal: 11.8– 17.7 N(2.6 – 4.0 lb)

Inspection Of Shift On The Fly System Gear Oil

412RY00008

1. Open filler plug and make sure that the oil is up to the plug port. If the oil is short, replenish with gear oil GL–5 grade. 2. Tighten the filler plug to the specified torque. Torque: 78 N·m (58 lb in)

DRIVE SHAFT SYSTEM

4C–53

Front Axle Drive Shaft Front Axle Drive Shaft and Associated Parts

412R200009

Legend (1) Axle Case and Differential (2) Snap Ring (3) Bearing (4) Snap Ring (5) Oil Seal (6) Bracket (7) DOJ Case (8) Circlip (9) Bolt (10) Drive Shaft Joint Assembly (11) Ball

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Snap Ring Ball Retainer Ball Guide Band Bellows Band Band Bellows Band BJ Shaft Dust Seal

4C–54

DRIVE SHAFT SYSTEM

Disassembly NOTE: For the left side, follow the same steps as right side.

4. Remove drive shaft joint assembly. 5. Remove the six balls (1) with a screwdriver or equivalent.

1. Raise the hooked end of the band with a screwdriver or equivalent.

412RS012

6. Using snap ring pliers, remove the snap ring (1) fastening the ball retainer to the center shaft. 412RS009

2. Remove band(1). 3. Pry off circlip (1) with a screwdriver or equivalent.

412RS013

7. Remove ball retainer, ball guide and bellows. 412RS010

DRIVE SHAFT SYSTEM 8. Use a hammer and chisel to remove the 3 pawls (above the large and small boot bands on the BJ side). CAUTION: Take care not to damage the bellows during band removal.

4C–55

Bushing Replacement B Remove the bushings using a remover J–39378–1 and hammer.

412RS015

412R100009

9. Remove band(1). 10. Remove bellows. 11. Remove dust seal from BJ. 12. Remove BJ shaft assembly. 13. Remove the mounting bracket fixing bolts, and then remove DOJ case assembly from the axle case. 14. Remove snap ring and bearing. 15. Remove snap ring and oil seal. 16. Remove bracket.

B By using installer J–39378–2 and base J–39378–3, press fit the bushings into the bracket.

412RS016

Reassembly 1. Install DOJ case to bracket. 2. Install oil seal and fix snap ring. 3. Install bearing and fix snap ring. 4. Install bracket to axle case. Tighten the bracket bolt to the specified torque. Torque: 116 N·m (85 lb ft) 5. Apply 150g of the specified grease in BJ. 6. Install dust seal for BJ. 7. Apply a thin coat of grease to the shaft for smooth installation then install bellows.

4C–56

DRIVE SHAFT SYSTEM

CAUTION: During bellows assembly, be sure to insert both ends of the bellows into the BJ ASM and shaft grooves.

8. Install band. Note the setting direction. After installation, check Standard Caulk Measure.Use the special tool pliers J–35910 to caulk the bands to the specified value.

412R100007

Legend (1) Bellows (2) Shaft

412R100012

Standard Caulk Measure B 1.2mm (0.05in) <= (1) and (2) <= 4.0mm (0.16in) B (1) – (2) or (2) – (1) <= 0.4mm (0.016in) 9. Install another bellows and fix band. 10. Install band. Note the setting direction. After installation, check that the bellows is free from distortion. (DOJ SIDE ONLY)

412R100013

Legend (1) BJ ASM (2) Bellows 412RS017

11. Install another bellows and fix band. 12. Install the ball guide with the smaller diameter side ahead onto the shaft.

DRIVE SHAFT SYSTEM 13. Install ball retainer. 14. Using snap ring pliers, install the snap ring (1) securing the ball retainer to the shaft.

4C–57

17. Install the circlip (1) so that open ends are positioned away from the ball groove.

412RS019

412RS013

15. Align the track on the ball (1) retainer with the window in the cage, and install the six balls into position.

412RS020

412RS018

16. Pack 150g of the specified grease in DOJ case, then install drive shaft joint assembly. After reassembly, move the DOJ longitudinally several times to get to fit.

Legend (1) Outer Case (2) Circlip (3) Open Ends

4C–58

DRIVE SHAFT SYSTEM

18. Install bellows. Adjust the air pressure within the bellows by inserting a screwdriver or equivalent, so that it equals atmospheric pressure.

412RS021

19. Install band. After installation, check that the bellows is free from distortion.

DRIVE SHAFT SYSTEM

4C–59

Shift On The Fly System Shift On The Fly System and Associated Parts

412RY00007

Legend (1) Filler Plug (2) Bolt (3) Oil Seal (4) Snap Ring(External) (5) Inner Shaft Bearing (6) Snap Ring(Internal) (7) Inner Shaft

Disassembly 1. Remove filler plug and gasket, drain oil. 2. Loosen mounting bracket fitting bolts and remove front axle drive shaft from front axle case.

(8) (9) (10) (11) (12) (13) (14) (15)

Needle Bearing Clutch Gear Sleeve Housing Front Axle Drive Shaft(LH side) with Bracket Bolt Actuator Assembly Bolt

3. Remove actuator assembly and draw out actuator ASM. 4. Remove housing. 5. Remove sleeve. 6. Remove clutch gear.

4C–60

DRIVE SHAFT SYSTEM

7. Remove snap ring from front axle case by using snap ring pliers.

10. Remove inner shaft bearing. NOTE: Be careful not to damage the shaft.

412RW017

8. Take out inner shaft from front axle case. 9. Remove snap ring from inner shaft by using snap ring pliers.

412RW015

11. Remove needle bearing from inner shaft by using a remover J–26941 and sliding hammer J–2619–01.

412RS045 412RW016

12. Remove oil seal from front axle case. NOTE: Be careful not to damage the front axle case.

DRIVE SHAFT SYSTEM

4C–61

Inspection And Repair Inspect the removed parts. If there are abnormalities such as wear and damage, take corrective action or replace.

Visual Check 1. Inspect the inner shaft for wear and damage.

412RS026

Inner Shaft Bearing

412RW014

2. Replace the shaft if any signs of deterioration in the gear is present.

412RW006

Legend (1) Inner Shaft Bearing (2) Inner Shaft (3) Clutch Gear

420RS008

Inner Shaft Run–Out With both end centers supported, rotate the shaft slowly and measure deflection with a dial gauge. Limit: 0.5 mm (0.02 in) NOTE: Do not heat the shaft to correct its bend.

1. Inspect the inner shaft bearing for any signs of deterioration, replace if uneven. 2. Insert the clutch gear and inspect the needle bearing. 3. Replace the needle bearing if found to be uneven.

Sleeve Condition Check for wear damage, or cracking in the sleeve. NOTE: Close inspection of the groove and inner gear are required because those are important parts.

4C–62

DRIVE SHAFT SYSTEM

Sleeve Function

Clutch Gear Function

412RY00039

412RY00038

Test the sleeve for smoothness by sliding it across the clutch gear, replace the clutch gear if its difficult to slide. NOTE: When inspecting, gear oil should be applied to the contact surface of gear.

Clutch Gear Journal Diameter Make sure of the size illustrated. Limit: 36.98 mm (1.456 in)

412RW022 412RY00037

Clutch Gear Condition Check for wear, damage, crack or any other deterioration in the clutch gear.

Actuator Check for damage, cracking, or other abnormality.

DRIVE SHAFT SYSTEM

4C–63

NOTE: Be careful not to permit the entry of water or dust into of the actuator.

Functional Check

Dimentional Check Measure illustrated sizes 1, 2, and 3.

412RY00041

412RY00010

Limit 1=64.3 mm (2.53 in) 2=6.7 mm (0.26 in) 3=6.7 mm (0.26 in)

Reassembly 1. Install the new oil seal which has been immersed in differential gear oil, by using an oil seal installer J–41693 and grip J–8092.

412RY00009

Verify functionality by applying voltage (12V) to terminals 3 and 4 and set the tester to terminal 1 and 2 according to the table bellow.

State

Trminal 3

Trminal 4

Electric circuit between terminal 1 &2

+12V

Ground

2WD

Ground

+12V

NONE

4WD

Function

If there is an abnormality, replace the actuator as an assembly. 412RW034

4C–64

DRIVE SHAFT SYSTEM

2. Install a new needle bearing into inner shaft by using a Installer J–41694 and grip J–8092.

NOTE: Be sure to install the snap ring properly.

412RW017 412RS051

3. Place a new snap ring(internal) in inner shaft. Install a new inner shaft bearing into the inner shaft.

412RS044

412RW023

10. Tighten bolts to specified torque. Torque: 75N·m(55 lb ft) 11. Clean the actuator contact surface with the housing then Install and tighten shift position switch to the specified torque. Torque: 39N·m (29 lb ft)

DRIVE SHAFT SYSTEM 12. Apply liquid gasket to the contact surface on the actuator side.

412RW012

13. Align shift arm with the groove of sleeve and install the actuator. 14. Tighten bolts to specified torque. Torque: 9N·m(78 lb in) 15. Install front axle drive shaft and mounting bracket. Tighten fitting bolts to specified torque. Torque: 116N·m (85 lb ft) 16. Pour specified amount of differential gear oil to filler plug. Front Differential Oil Capacity: 1.25lit (1.32US qt) Actuator Housing Oil Capacity: 0.12lit(0.13US qt) 17. Install filler plug through gasket and tighten to specified torque. Torque: 78N·m (58lb ft)

4C–65

4C–66

DRIVE SHAFT SYSTEM

Main Data and Specifications General Specifications Front drive axle oil capacity

1.25 liter (1.32 US qt)(Differential) 0.12 liter (0.13 US qt)(Actuator Housing:Shift on the fly)

Type of lubricant Axle shaft type

GL–5 (75W–90) Refer to chart in General Information Constant velocity joint(Birfield joint type and double offset joint)

Torque Specifications

412RY00040

DRIVE SHAFT SYSTEM

4C–67

E04R200004

4C–68

DRIVE SHAFT SYSTEM

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

ILLUSTRATION

TOOL NO. TOOL NAME

J–39378 Remover and Installer; Front Axle mount bushing

J–36830 Installer; Oil seal

J– 26941 Remover; Bearing needle

J–35910 Pliers; Band bellows, drive shaft

J–2619–01 Hammer; Sliding

J–41693 Installer; Oil seal

J–41694 Installer; Bearing needle

J–8092 Grip

DRIVE SHAFT SYSTEM

4C–69

Propeller Shaft General Description

401RX002

Legend (1) Front Propeller Shaft (2) Rear Propeller Shaft; Aluminum Tube with Spline Yoke Type

(3) Rear Propeller Shaft; Aluminum Tube with Flange Yoke Type (4) Rear Propeller Shaft; Steel Tube Type (for 4×4, 6VD1, A/T model)

B Alignment marks should be applied to each propeller shaft before removal. B Park, turn the engine off and apply the parking brake to secure the vehicle. B Carefully attach the propeller shaft to the vise, do not overtighten the vise when securing the propeller shaft, this may cause deformation.

4C–70

DRIVE SHAFT SYSTEM

Phasing The propeller shaft is designed and built with the yoke lugs (ears) in line with each other. This design produces the smoothest running shaft possible, called phasing.Vibration can be caused by an out–of–phase propeller shaft.The propeller shaft will absorb vibrations from speeding up and slowing down each time the universal joint spins.This vibration would be the same as a person snapping a rope and watching the ”wave” reaction flow to the end.A propeller shaft working in phase would be similar to two persons snapping a rope at the same time, and watching the ”waves” meet and cancel each other out.In comparison, this would be the same as the universal joints on a propeller shaft.A total cancellation of vibration produces a smooth flow of power in the driveline.It is very important to apply a reference mark to the propeller shaft before removal, to assure installation alignment.

Universal Joint

401RW015

Legend (1) Spider (2) Yoke A universal joint consists of two Y-shaped yokes connected by a crossmember called a spider. The spider is shaped like a cross. Universal joints are designed to handle the effects of various loadings and front or rear axle windup during acceleration. Within the designed angle variations, the universal joint will operate efficiently and safely. When the design angle is changed or exceeded the operational life of the joint may decrease. The bearings used in universal joints are of the needle roller type. The needle rollers are held in place on the trunnions by round bearing cups. The bearing cups are held in the yokes by snap rings.

DRIVE SHAFT SYSTEM

4C–71

Diagnosis of Propeller Shaft and Universal Joint Condition

Possible cause

Universal Joint Noise.

Correction

Worn universal joint bearings.

Replace.

Improper lubrication.

Lubricate as directed.

Loose flange bolts.

Tighten to specifications.

Ping, Snap, or Click in Drive Line (Usually Heard on Initial Load after the Transmission is in Forward or Reverse Gear)

Loose bushing bolts on the rear springs or upper and lower control arms.

Tighten the bolts to specified torque.

Loose or out-of-phase end yoke.

Remove end yoke, turn 180 degrees from its original position, lubricate the splines and reinstall. Tighten the bolts and pinion nut to specified torque.

Knocking or Clanking Noise in the Driveline when in High or Neutral Gear at 16km/h(10mph)

Worn or damaged universal joint

Replace the universal joint.

Squeak

Lack of lubricant.

Lubricate joints and splines. Also check for worn or brinelled parts.

Loose or missing bolts at the flanges.

Replace or tighten bolts to specified torque.

Incorrectly set front joint angle.

Install shim under the transmission support mount to change the front joint angle.

Worn universal joint.

Replace.

Incorrect shaft runout.

Replace.

Shaft out of balance.

Adjust.

Transmission rear housing bushing, transfer case housing bushing worn.

Replace.

Yoke spline jammed.

Replace.

Rough surface on splined yoke; burred nicked or worn.

Replace the seal. Minor burrs can be Smoothed by careful use of crocus cloth or fine stone honing. Replace the yoke if badly burred.

Defective transmission rear oil seal.

Replace the transmission rear oil seal and replenish the transmission oil.

Shudder Speed)

Acceleration

(Low

Vibration

Excessive Leak at the Front Spline Yoke of Rear Propeller Shaft

4C–72

DRIVE SHAFT SYSTEM

Front Propeller Shaft Front Propeller Shaft and Associated Parts

401RW093

Legend (1) Bolt, Nut and Washer (Front Axle Side)

(2) Front Propeller Shaft (3) Bolt, Nut and Washer (Transfer Side)

2. Remove bolt, nut and washer (Front axle side). 3. Remove bolt, nut and washer (Transfer side). 4. Remove front propeller shaft.

Removal 1. Raise the vehicle on a hoist. NOTE: Apply alignment marks on the flange at the front propeller shaft both front and rear side.

Installation NOTE: Never install the shaft assembly backwards. Never insert bar between yoke lugs when tightening or removing bolts. Completely remove the black paint from the connecting surface of flange coupling on each end of propeller shaft. Clean so that no foreign matter will be caught in between. 1. Align the mark which is applied at removal. Install front propeller shaft and tighten the bolts to the specified torque. Torque: 63 N·m (46 lb ft)

401RS020

DRIVE SHAFT SYSTEM

4C–73

Disassembly

401RW032

(3) Boot (4) Clamp (5) Tube Assembly

Legend (1) Sleeve Yoke (2) Clamp

1. Lay the shaft horizontally on a bench and secure. 2. Indicate the original assembled position (1) by marking the phasing of the shaft prior to disassembly.

401RW037

3. Using the flat blade of a screwdriver, pry the loose end of the boot clamp upwards and away from the propeller shaft boot. Be careful not to damage the boot. 4. When boot clamps becomes loose, remove by hand. 5. Repeat for the other boot clamp. 6. Remove the slip yoke assembly from the driveshaft, by securing the boot with one hand and pulling on the slip yoke. 7. Remove the boot from the shaft assembly.

4C–74

DRIVE SHAFT SYSTEM

Universal Joint Disassembly

401RW031

Legend (1) Flange Yoke (2) Snap Ring

(3) Spider (4) Needle Roller Bearing

1. Using a soft drift, tap the outside of the bearing cup assembly to loosen snap ring. Tap bearing only hard enough to break assembly away from snap ring. Remove snap ring from yoke. Turn joint over, tap bearing away from snap ring, then remove opposite snap ring. Apply alignment marks (1) on the yokes of the universal joint, then remove snap ring.

401RW018

DRIVE SHAFT SYSTEM

4C–75

2. Set the yoke in the arbor press with a piece of tube stock beneath it. Place a solid plug on the upper bearing assembly and press it through to release the lower bearing assembly.

401RW038

Propeller shaft run–out

401RW020

3. If the bearing assembly will not pull out by hand after pressing, tap the base of the lug near the bearing assembly to dislodge it. 4. To remove the opposite bearing, turn the yoke over and straighten the spider in the open hole. Then carefully press on the end of the spider so the remaining bearing moves straight out of the bearing spider hole. If the spider or bearing are cocked, the bearing will score the walls of the spider hole and ruin the yoke. 5. Repeat this procedure on the remaining bearing to remove the spider from the yoke. 6. Make sure of proper position for reinstallation by applying setting marks, then remove spider .

Support the propeller shaft on V-blocks (2) and check for run-out by holding the probe of a dial indicator (1) in contact with the shaft. Static run-out limit: 0.13 mm (0.005 in) TIR on the neck of the slip tube shaft (with a boot). 0.25 mm (0.010 in) TIR on the ends of the tubing 3 inch from the welds. 0.38 mm (0.015 in) TIR at the linear center of the tube. 0.38 mm (0.015 in) TIR for the full length of tube with 30” or less of tubing. (TIR : Total Indicator Reading)

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

Spider pin for wear Spider pin should be smooth and free from fretting or galling. Visible signs of needle presence is normal, but wear should not be felt.

401RS027

4C–76

DRIVE SHAFT SYSTEM

Spline

Universal Joint Reassembly

The nylon-coated spline should be free from nicks and dings and the underlying steel spline should not be visible. After cleaning the nylon coating spline, the coating should exhibit only slight indicator of wear. Grease volume is approximately 10 grams of grease in total. Grease should be evenly applied to both the female and the male slip splines using a small brush. After assembly of the slip joint, the sliding joint should be fully worked from the full collapsed to the full extended position.

Play in the universal joint Limit: Less than 0.15 mm (0.006 in)

1. Install spider to flange yoke. Be sure to install the spider by aligning the setting marks made during disassembly. 2. Pack the four grease cavities of the spider with a high quality, extreme pressure N.L.G.I. Grade 2 grease. Do not add additional grease to the bearing cup assembly. 3. Move one end of the spider to cause a trunnion to project through the spider hole beyond the outer machined face of the yoke lug. Place a bearing over the trunnion diameter and align it to the spider hole. Using an arbor press, hold the trunnion in alignment with the spider hole and place a solid plug on the upper bearing. Press the bearing into the spider hole enough to install a snap ring.

401RW023

Preload of the universal joint

401RW020

Preload should be 0 to 49 N(0 to11.0 lb). Joints should rotate smoothly and freely and should exhibit no rough or ratchety movement.

4. Install a snap ring. Be sure the snap rings are properly seated in the grooves. 5. Repeat steps 3 and 4 to install the opposite bearing. If the joint is stiff, strike the yoke ears with a soft hammer to seat needle bearings.

401RW019

DRIVE SHAFT SYSTEM

4C–77

6. Align setting marks (1) and join the yokes.

401RW018

7. Install snap ring.

Reassembly

401RW032

Legend (1) Sleeve Yoke (2) Clamp

(3) Boot (4) Clamp (5) Tube Assembly

4C–78

DRIVE SHAFT SYSTEM

1. Apply grease evenly to both the female and male splines. 2. Apply a small amount of grease by finger to the outer lips of the boot. 3. Slide the boot onto the yoke shaft being careful not to damage the spline coating or boot. 4. Insert the yoke shaft spline into the sleeve being careful to maintain proper phasing. The spider holes should be in line and as per originally marked prior to disassembly.

5. Position boot onto sleeve and yoke shaft in final position over boot grooves. 6. Attach boot clamps and secure using pliers. 7. Be sure clamp is properly seated and secure.

Main Data and Specifications General Specifications Transmission Length (between two spiders center)

M/T

A/T

367.2 mm (14.81 in)

542.2 mm (21.35 in)

Torque Specifications

401RX001

DRIVE SHAFT SYSTEM

4C–79

Rear Propeller Shaft Rear Propeller Shaft and Associated Parts

401RX003

Legend (1) Bolt, Nut and Washer (Transfer Side)

(2) Rear Propeller Shaft (3) Bolt, Nut and Washer (Rear Axle Side)

4C–80

DRIVE SHAFT SYSTEM

Slip Joint Disassembly

401RX00001

Legend (1) Spline Yoke and Universal Joint Assembly (2) Clamp

(3) Boot (4) Clamp (5) Tube and Universal Joint Assembly

DRIVE SHAFT SYSTEM

4C–81

Universal Joint Disassembly

401RX00007

Legend (1) Spline Yoke (2) Spider (3) Propeller Shaft Assembly (4) Spider

(5) (6) (7) (8)

Flange Yoke Bearing Snap Ring Flange Yoke

4C–82

DRIVE SHAFT SYSTEM

1. Apply alignment marks on the yokes of the universal joint, then remove the snap ring.

2. Set the yoke in the arbor press with a piece of tube stock beneath it. Place a solid plug on the upper bearing and press it through to release the lower bearing.

401RW024

If the snap ring is stuck in position, remove paint from the hole in the yoke or tap around the edge of the bearing lightly with a soft drift.

401RW027

401RW025

401RW026

5. Repeat this procedure on the remaining bearing to remove the spider from the yoke.

DRIVE SHAFT SYSTEM

4C–83

0.38 mm(0.015 in) TIR for the full length of tube with 30” or less of tubing. (TIR: Total Indicator Reading)

401RW017

B Play in universal joint. Limit: Less than 0.15 mm(0.006 in) B Spider pin should be smooth and free from fretting or galling. Visible signs of needle presence is normal, but wear should not be felt.

B Preload of the universal joint. Preload should be 0 to 49 N (0 to 11.0 lb). Joints should rotate smoothly and freely and should exhibit no rough or ratchety movement.

401RW019

4C–84

DRIVE SHAFT SYSTEM

B Aluminum tube type only: Inspect the aluminum tubing for surface scratches and dents. These scratches may not exceed 0.2 mm (0.008 in) in depth.

401RW022

DRIVE SHAFT SYSTEM

4C–85

Slip Joint Reassembly

401RX00001

Legend (1) Spline Yoke and Universal Joint Assembly (2) Clamp

(3) Boot (4) Clamp (5) Tube and Universal Joint Assembly

7. Be sure clamp is properly seated and secure. CAUTION: Only use a similar type or same as the original type clamp. Using any other clamp may create an imbalanced shaft or lead to grease leakage.

4C–86

DRIVE SHAFT SYSTEM

Main Data and Specifications General Specifications 2WD Model Engine

4WD Model

Y22SE

Transmission

6VD1

M/T

A/T

M/T

A/T

M/T

A/T

Type (See illustration)

Length between two spiders center)

1314.4mm (51.75in)

1334.7mm (52.55in)

1298.4mm (51.12in)

1323.0mm (52.09in)

1191.2mm (46.9in)

1021.2mm (40.21in)

Universal joint type

Cardan type

Torque Specifications

401R100001

SECTION TRANSFER CASE (TOD)

4D2–1

AXIOM

DRIVELINE/AXLE TRANSFER CASE (TOD) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Removal and Installation of Tfansfer Case Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOD Control Unit . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly and Reassembly of Major Components . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Cover Assembly . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . .

4D2–1 4D2–2 4D2–3 4D2–4 4D2–4 4D2–6 4D2–6 4D2–6 4D2–8 4D2–8 4D2–8 4D2–9 4D2–9 4D2–10 4D2–10 4D2–13 4D2–13 4D2–14

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Pack and Clutch Cam (Transfer Case Assembly) . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Chain, Sprocket and Mechanical Lock (Transfer Case Assembly) . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Case Assembly . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair (Transfer Case Assembly) . . . . . . . . . . . . . . Main Data and Specification . . . . . . . . . . . . . . General Specification . . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . Torque Specifications (Cont’d) . . . . . . . . . . . Torque Specifications (Cont’d) . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .

4D2–15 4D2–16 4D2–16 4D2–18 4D2–20 4D2–21 4D2–22 4D2–24 4D2–24 4D2–26 4D2–28 4D2–32 4D2–32 4D2–33 4D2–34 4D2–35 4D2–36

4D2–2 TRANSFER CASE (TOD)

General Description

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The Torque-On-Demand (TOD) is electronically-controlled torque-split 4-wheel system with the following features.

an drive

Shifting Between High and Low Ranges The shifting mechanism consists of the cam and shaft rail assembly, the high/low shift motor and the encoder. The encoder is built-in to the motor. The encoder senses high/low range shift motor rotation position and sends this data to the TOD control unit. Based on this data, the TOD control unit adjusts motor rotation speed or stops the motor. The shifting between the high and low ranges using the TOD switch only is possible. The vehicle must be stopped or nearly stopped (vehicle speed less than 2 km/h (1.2 mph) and engine speed less than 1,500 rpm), the automatic transmission selector level must be in the neutral (N) position, and the brakes must be applied.

Electronically-controlled Wet-type Multiple Disc Clutch The clutch automatically provides the optimum drive power to the front wheels of the vehicle in response to varying road surface conditions when the vehicle is operated in the TOD mode. The delivered power ranges from 0% to 100% of power train output. Superior operational stability is maintained over a wide range of operating conditions.

Front Output Drive Front output drive is provided by a chain. This reduces the loud noise associated with 4-wheel drive operation.

Oil Pump Lubrication An oil pump is used to lubricate the transfer. This ensures stable multiple-disc clutch operation and maintains the lubricating oil at a constant temperature.

TRANSFER CASE (TOD)

4D2–3

Removal and Installation of Tfansfer Case Assembly

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Legend (1) Transfer Protector (2) Front Propeller Shaft Assembly (3) Speedometer Sensor Harness Connector (4) Rear Propeller Shaft Assembly

(5) (6) (7) (8)

Center Exhaust Pipe Transfer Case Bolt Transfer Case Assembly Transfer Case Harness Connector

4D2–4 TRANSFER CASE (TOD)

Removal 1. Disconnect the battery ground cable. 2. Remove the transfer protector. 3. Disconnect the rear propeller shaft assembly from the transfer case. 4. Disconnect the front propeller shaft assembly from the transfer case. 5. Remove the center exhaust pipe. 6. Disconnect the speedometer sensor harness connector from the speedometer sensor, and remove the harness clamp from the connector bracket of the transfer case. 7. Disconnect the engine harness connector from the transfer harness connector. 8. Support the transfer case with a transmission jack. 9. Remove the transfer bolts. 10. Remove the transfer case assembly.

Installation 1. Apply grease (Besco L2 or its equivalent) to the input shaft spline.

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2. Install the transfer case assembly to the transmission assembly. 3. Install the transfer bolts to the specified torque (Refer to next page). Torque: 46 N·m (34 lb ft) 4. Connect the engine harness connector to the transfer harness connector. 5. Install the breather hose up to bottom of the transfer case breather and clip them firmly. 6. Securely insert the breather hose into the cutout portion of the transfer case.

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TRANSFER CASE (TOD)

4D2–5

7. Install the speedometer harness clamp to the connector bracket of the transfer case, and then connect the harness connector to the speedometer sensor.

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8. Install the center exhaust pipe. Torque: 43 N·m (32 lb ft) 9. Connect the front and rear propeller shaft assembly to the transfer case. Torque: 63 N·m (46 lb ft) 10. Install the transfer protector. Torque: 37 N·m (27 lb ft) 11. Connect the battery ground cable.

4D2–6 TRANSFER CASE (TOD)

Transfer Rear Oil Seal

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Legend (1) Transfer Rear Oil Seal

(2) End Nut, Washer, Oil Seal and Rear Companion Flange (3) Rear Propeller Shaft Assembly

Removal 1. Disconnect the rear propeller shaft assembly from the transfer case. 2. Using the flange holder J–8614–11, remove the end nut. 3. Using the universal puller, remove the companion flange, washer and oil seal. 4. Remove the transfer rear oil seal from the transfer case.

Installation 1. Apply oil to the circumference of the transfer rear oil seal.Fill the oil seal lip with grease (Besco L2 or its equivalent). 2. Using the oil seal installer J–42804, install the transfer rear oil seal to the transfer case. 261RY00017

TRANSFER CASE (TOD) NOTE: When installing the oil seal, pay attention to the direction.

4D2–7

5. Securely stake the end nut at one spot. NOTE: Be sure to confirm that there is no clack at the staked portion of the end nut after staking.

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Legend (1) Inside (2) Outside

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3. Install the companion flange. 4. Install the oil seal and washer, and using the flange holder J–8614–11, install the new end nut to the specified torque. Torque: 167 N·m (123 lb ft)

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6. Connect the rear propeller shaft assembly to the transfer case. Torque: 63 N·m (46 lb ft)

4D2–8 TRANSFER CASE (TOD)

TOD Control Unit

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Legend (1) Bracket (2) TOD Control Unit

Removal 1. Disconnect the battery ground cable. 2. Disconnect the harness connector from the TOD control unit. 3. Remove the bracket retaining nuts (3 pieces) and the bracket with TOD control unit. 4. Remove the TOD control unit from the bracket.

Installation 1. Install the TOD control unit to the bracket. 2. Install the bracket with TOD control unit to the chassis. 3. Connect the harness connector to the TOD control unit. 4. Connect the battery ground cable.

TRANSFER CASE (TOD)

4D2–9

Unit Repair Disassembly and Reassembly of Major Components

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Legend (1) Front Companion Flange, Oil Seal, Washer, and End Nut (2) 4H and 4L Switch (3) Harness Assembly (4) Harness Bracket (5) Shift Motor Assembly (6) Rear Companion Flange, Oil Seal, Washer and End Nut

(7) (8) (9) (10) (11) (12)

Speedometer Sensor and Driven Gear Plate and Bracket Connector Bracket Breather Hose Transfer Case Assembly Transfer Cover Assembly

4D2–10 TRANSFER CASE (TOD)

Disassembly 1. Remove the drain plug from the transfer case and drain the oil. 2. Remove the speedometer sensor and driven gear. 3. Remove the front and rear speed sensor of the harness assembly from the transfer cover assembly.

6. Remove the 4H and 4L switch from the transfer case. 7. Remove the shift motor assembly from the transfer cover. 8. Using the flange holder J–8614–11, remove the end nut. Remove the washers, oil seals, front and rear companion flange.

NOTE: Use care to prevent damage to speed sensor when removing speed sensor. 4. Disconnect the clutch solenoid coil, 4H and 4L switch harness connector. B Remove the harness bracket from the transfer cover.

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9. Remove the transfer cover retaining bolts and the transfer cover assembly from the transfer case assembly. NOTE: When removing the transfer cover assembly, use care to prevent damage to oil seal. 261RY00009

5. Remove the connector bracket from the transfer case. B Remove the harness assembly and shift motor harness connector from the connector bracket.

10. Remove the breather hose from the transfer case.

Reassembly 1. Apply recommended liquid gasket (LOCTITE 598 or its equivalent) uniformly to the transfer case and cover fitting surface.

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TRANSFER CASE (TOD) 4D2–11 2. Install the plate, bracket, connector bracket and ground cable of the harness assembly, and tighten the transfer cover retaining bolts (16 pieces) to specified torque.

5. Securely stake the end nut at one spot. NOTE: Be sure to confirm that there is no clack at the staked portion of the end nut after staking.

Torque: 31 N·m (23 lb ft)

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3. Install the front and rear companion flange. 4. Install the oil seal and washer, and using the flange holder J–8614–11, install the new end nut to the specified torque. Torque: 167 N·m (123 lb ft)

4D2–12 TRANSFER CASE (TOD) 6. Apply recommended liquid gasket (LOCTITE 598 or its equivalent) to the transfer cover and shift motor assembly fitting surface.

12. Install the driven gear and speedometer sensor to the transfer case. Torque: 25 N·m (19 lb ft)

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7. Install the shift motor assembly to the transfer cover assembly. Torque: 10 N·m (87 lb in) 8. Install the 4H and 4L switch.

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13. Remove the filler plug and fill the transfer case with ATF DEXRON–II or III. 14. Wind the sealing tape around the filler plug thread and tighten the plug to the specified torque. Torque: 25 N·m (19 lb ft)

Torque: 24 N·m (17 lb ft) 9. Install the harness assembly and shift motor harness connector to the connector bracket. 10. Install the front and rear speed sensors to the transfer cover. Torque: 5 N·m (43 lb in) 11. Connect the harness assembly connector to the clutch solenoid coil harness connector and 4H and 4L switch. B Fix the harness with harness bracket.

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15. Install the breather hose to the transfer case.

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TRANSFER CASE (TOD) 4D2–13

Transfer Cover Assembly

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Legend (1) Coil Assembly (2) Snap Ring (3) Ball Bearing

(4) (5) (6) (7)

Speed Gear and Tone Wheel Ball Bearing Transfer Cover (With Oil Seal) Oil Drain Plug and Oil Filler Plug

Disassembly 1. Using a precision screwdriver or a suitable tool, push down the lock to unlatch the terminal for the coil assembly, and pull the terminal out. NOTE: Use care to prevent damage to harness terminal and connector.

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4D2–14 TRANSFER CASE (TOD) 2. Remove the coil assembly set nuts (3 pieces) and coil assembly from the transfer cover.

4. Strike the speed gear and tone wheel with a rod or other appropriate tool from the rear side of the transfer cover assembly, and remove the ball bearing, speed gear and tone wheel. NOTE: Use care to prevent damage to the speed gear teeth.

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3. Using snap ring pliers, remove the snap ring from the transfer cover. 261RY00012

5. Using the bearing remover J–42805 and slide hammer J–2619–01, remove the ball bearing of the front output shaft from the transfer cover.

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Inspection and Repair Refer to “Inspection and Repair (Transfer Case Assembly)” in this section.

TRANSFER CASE (TOD) 4D2–15

Reassembly Transfer cover oil seal replacement 1. Remove the oil seal from the transfer cover assembly. 2. Apply oil to the circumference of the new oil seal and fill the lip with grease (BESCO L2 or its equivalent). 3. Using the oil seal installer J–42804, install the oil seal to the transfer cover assembly.

7. Install the ball bearing of the front output shaft to the transfer cover. 8. Install the speed gear and tone wheel. 9. Install the ball bearing to the transfer cover. 10. Using snap ring pliers, install the snap ring to the transfer cover. NOTE: The snap ring must be fully inserted into the transfer cover snap ring groove.

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Shift shaft oil seal replacement 4. Remove the oil seal from the transfer cover assembly. 5. Apply oil the circumference of the new oil seal. 6. Using the oil seal installer J–33951, install the oil seal to the transfer cover assembly. The drive in depth must be 9.4 ∼ 10.4 mm (0.370 ∼ 0.409 in). The knurled end of the installer (indicated by the arrow) must be flush with the oil seal installation surface.

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11. Install the coil assembly to the transfer cover and tighten the set nuts (3 pieces) to the specified torque. Torque: 10 N·m (87 lb in) 12. Install the connector to the harness terminal of the coil assembly.

NOTE: Use care to prevent tilt to oil seal when installing oil seal to the case.

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4D2–16 TRANSFER CASE (TOD)

Clutch Pack and Clutch Cam (Transfer Case Assembly)

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Legend (1) Transfer Case Assembly (2) Snap Ring (3) Wave Spring (4) Cam Pulley (5) Cam Ball

(6) (7) (8) (9) (10) (11)

Cam and Coil Housing Assembly Thrust Bearing Armature Plate Insulator Washer Clutch Pack Assembly Lockup Fork Spring

Disassembly 1. Remove the lockup fork spring. 2. Remove the thrust bearing and cam and coil housing assembly from the output shaft. NOTE: When the cam and coil housing assembly is removed, the cam balls may be detached together with the housing. Pay attention not to lose the ball.

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TRANSFER CASE (TOD) 4D2–17 3. Remove the cam ball (3 pieces). 4. Remove the cam pulley.

6. Using snap ring pliers, remove the snap ring. NOTE: Use care to prevent damage to snap ring.

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5. Remove the wave spring.

7. Remove the armature plate, insulator washer and clutch pack assembly as a package.

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4D2–18 TRANSFER CASE (TOD) 3. Using snap ring pliers, install the snap ring to the output shaft.

Reassembly 1. Install the clutch pack assembly which the multi clutch plate is orderly installed to the output shaft. NOTE: B Install the clutch pack assembly while adjusting the phase of both the clutch housing and drive sprocket. B During installation, the plate of the clutch pack assembly may slide out of this fixed position (the correct position is shown in the illustration). If this occurs, remove all of the clutch plates of the clutch pack assembly and reinstall them to their correct position.

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4. Install the wave spring to the output shaft.

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2. Install the insulator washer and armature plate to the clutch pack assembly.

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TRANSFER CASE (TOD) 4D2–19 5. Install the cam pulley. 6. Place a ball on each groove of the cam pulley.

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7. Install the cam and coil housing to the output shaft. 8. Install the thrust bearing. 9. Install the lockup fork spring.

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4D2–20 TRANSFER CASE (TOD)

Chain, Sprocket and Mechanical Lock (Transfer Case Assembly)

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Legend (1) Transfer Case Assembly (2) Cam and Shaft Rail Assembly (3) Front Output Shaft (4) Chain (5) Lower Drive Sprocket (6) Front Tone Wheel (7) Drive Sprocket (8) Spacer (9) Shift Fork and Rail Assembly (10) Lockup Rail

(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)

Spring Pin Shift Fork Assembly Lockup Fork Lockup Fork Spring Reduction Hub Rear Output Shaft Oil Pump Assembly (with Strainer) Thrust Washer Lockup Hub Lockup Collar Assembly Magnet

TRANSFER CASE (TOD) 4D2–21 6. Remove the magnet from the strainer set position together with the oil pump assembly.

Disassembly 1. Remove the spacer. 2. Remove the front tone wheel, lower drive sprocket, drive sprocket and chain together from the front and rear output shaft.

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7. Remove the output shaft. 8. Remove the cam and shaft rail assembly. 266RY00010

3. Remove the lockup collar assembly and lockup fork together.

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4. Remove the lockup hub. 5. Remove the thrust washer.

9. Remove the shift fork and rail assembly, and reduction hub. 10. Remove the spring pin from the shift fork and rail assembly. 11. Remove the shift fork assembly from the lockup rail. 12. Remove the front output shaft from the transfer case.

4D2–22 TRANSFER CASE (TOD)

Reassembly 1. Apply ATF to the inside of the ball bearing. 2. Install the front output shaft to the transfer case.

7. Install the thrust washer. 8. Install the lockup hub. 9. Install the cam and shaft rail assembly.

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3. Install the shift fork assembly to the lockup rail and fix the assembly with the snap ring. 4. Install the shaft fork and rail assembly and reduction hub to the transfer case.

10. Install the lockup collar assembly and lockup fork together.

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5. Install the output shaft to the transfer case. 6. Install the oil pump assembly to the output shaft and attach the magnet to the strainer set position.

TRANSFER CASE (TOD) 4D2–23 11. Apply ATF to the chain and engage it to both sprockets. 12. Mount the chain and sprocket assembly to both output shafts. NOTE: When installing chain, the copper colored ring of the chain (indicated by the arrow) to be installed in direction of rear. 13. Install the front torn wheel to the front output shaft. 14. Install the spacer to the drive sprocket assembly.

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4D2–24 TRANSFER CASE (TOD)

Transfer Case Assembly

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Legend (1) Transfer Case (with Oil Seal) (2) Ball Bearing (3) Ring Gear (4) Snap Ring (5) Input Shaft and Carrier Assembly (6) Snap Ring (7) Ball Bearing

(8) (9) (10) (11) (12) (13) (14)

Snap Ring Circular Hub Carrier Assembly Snap Ring Thrust Plate Sun Gear Input Shaft Assembly (with Bearing and Bushing)

Disassembly 1. Using snap ring pliers, open the snap ring from the gap on the carrier assembly. While opening the snap ring, remove the input shaft assembly, carrier assembly and thrust plate together from the transfer case.

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TRANSFER CASE (TOD) 4D2–25 2. Remove the snap ring from the transfer case.

4. Using the bearing remover J–22912–01, remove the ball bearing from the input shaft.

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3. Using snap ring pliers, remove the snap ring.

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5. Remove the circular hub. 6. Remove the snap ring from the carrier assembly.

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7. Remove the thrust plate from the carrier assembly.

4D2–26 TRANSFER CASE (TOD) 8. Remove the snap ring before the ring gear.

10. Remove the ball bearing of the front output shaft from the transfer case.

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9. Using the ring gear remover J–42806 and a bench press, remove the ring gear from the transfer case.

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Reassembly Oil Seal Replacement 1. Remove the oil seal of the front output shaft and input shaft from the transfer case. 2. Apply the circumference of the new oil seal and fill the lip with grease (BESCO L2 or its equivalent). 3. Using the oil seal installer J–42807, install the front output shaft oil seal to the transfer case.

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NOTE: Removing ring gear needs a high-load press. This means the transfer case may be damaged. To remove and replace the ring gear, it is recommended that the transfer case assembly should be replaced.

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TRANSFER CASE (TOD) 4D2–27 4. Using the oil seal installer J–42808, install the input shaft oil seal to the transfer case.

6. Install the snap ring. 7. Install the thrust plate to the carrier assembly. Attach the snap ring to the carrier assembly. 8. Install the carrier assembly to the input shaft. 9. With care the direction of circular hub, mount it to the input shaft.

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5. Using the ring gear installer J–42809 and a bench press, install the ring gear to the transfer case. NOTE: Pay attention to the following points. B Identify the correct direction of gear.

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10. Press the ball bearing to the input shaft so that the snap ring will be attached to the input shaft.

B Do not damage the gear. B Do not press-fit the ring gear slantingly. B Press-fit the ring gear to the innermost. B Remove burrs generated by press-fitting. B If the transfer case has serrations, match them with those of the gear and press-fit the gear.

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11. Install the snap ring to the input shaft. 12. Install the ball bearing of the front output shaft to the transfer case.

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4D2–28 TRANSFER CASE (TOD) 13. Install the snap ring of the input shaft bearing to the transfer case.

Chain B Check whether the face that contacts the sprocket is free from excessive wear or damage. If defects are observed, replace the part. B If the chain interference mark is found on the inside wall of the transfer cover or the chain is so slack that a skipped engagement occurs between the chain and sprocket, replace the chain.

Sprocket B Check whether the sprocket tooth surface is excessively worn or damaged, and there is evidence of burrs, chipping, wear, or damage on the gear spline. Remove minor flaws or scratches with oil stone. If excessive wear or damage is observed, replace the part. B If excessive wear or damage is observed on the sprocket inside sliding surface, replace the part.

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14. Using snap ring pliers, open the snap ring from the gap on the carrier assembly. While opening the snap ring, securely attach the input shaft and carrier assembly to the transfer case.

B Check whether the gear tooth surface is excessively worn or damaged, and there is evidence of burrs, chipping, wear, or damage on the gear spline. Remove minor flaws or scratches with oil stone. If excessive wear or damage is observed, replace the part.

Thickness of Reduction Hub B Measure the thickness with a micrometer. B If the measurement exceeds the limit, replace the reduction hub. Standard : 3.05–3.30 mm (0.120–0.130 in) Allowable limit : 2.5 mm (0.098 in)

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Inspection and Repair (Transfer Case Assembly) When wear, damage, or any other defects are observed during the inspection, the part or parts must be repaired or replaced. Wash all the parts with clean detergent, and check that old oil, metallic particles, dirt, or foreign materials are completely removed. Blow the air into oil holes and grooves to remove foreign materials or residual detergent.

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TRANSFER CASE (TOD) 4D2–29

Lockup Collar Assembly B Install the lockup hub, drive sprocket assembly, and lockup collar assembly to the output shaft. B If the lockup collar assembly does not move smoothly, replace the lockup collar assembly. NOTE: Apply ATF to the rear engaging the gear.

Width of Lockup Collar B Using calipers, measure the lockup collar groove for width of wear. B If the measurement exceeds the limit, replace the lockup collar assembly. Standard : 7.16–7.32 mm (0.282–0.288 in) Allowable limit : 7.9 mm (0.311 in)

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Lockup Fork and Rail B Check the lockup fork and rail for wear, distortion, and scratches. If defects are observed, replace the parts.

Thickness Lockup Fork If the measurement exceeds the limit, replace the lockup fork. Standard : 6.99–7.09 mm (0.275–0.279 in) Allowable limit : 6.3 mm (0.248 in)

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Shift Fork and Rail Assembly Check the shift fork and rail for wear, distortion, and scratches. If defects are observed, replace the parts.

Thickness of Shift Fork B If the measurement exceeds the limit, replace the shift fork. Standard : 3.41–3.79 mm (0.134–0.149 in) Allowable limit : 4.4 mm (0.173 in)

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4D2–30 TRANSFER CASE (TOD)

Bearing Check the profile of the needle, roller, ball, and thrust bearings. Wash the bearings with clean detergent completely, and dry with air. NOTE: If the bearing is rotated excessively, the rollers may be damaged. So, rotate the bearing slowly with your hand. Apply grease to the bearing, and check the smoothness of the bearing while slowly rotating the race with your hand. Allowable limit : 0.23 mm (0.009 in)

Legend (1) Clutch Housing (2) Clutch Plate (3) Insulator Washer (4) Armature Plate

Coil Assembly B Check the resistance of the coil with a tester. If defects are observed, replace the coil assembly. Standard : 1.7±0.3W (at ordinary temperature) Allowable limit : 1.0∼5.0W

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Lockup Fork Spring Check the lockup fork spring for distortion, cracking, and wear. If defects are observed, replace the part.

Multi Plate Disk Clutch B If the burned, mirror-surfaced clutch facing, or scraping is observed on the clutch plates, clutch housing, armature plate, and insulator washer, replace the parts.

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Cam Pulley, Cam Ball, and Cam & Coil Housing B Check the cam balls and cam for excessive wear or damage. If defective, replace the parts.

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TRANSFER CASE (TOD) 4D2–31

4H and 4L Switch

Shift Motor Assembly

B Check the continuity of 4H and 4L switch. If defects are observed, replace the 4H and 4L switch.

B Check the resistance of the shift motor assembly (between terminal 4 to 7) with a tester. If defects are observed, replace the shift motor assembly. Standard : 0.63±0.2W (at ordinary temperature)

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8–6

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Switch Stroke

4H Switch Signal

4L Switch Signal

The corresponding g position of TOD switch

Terminal 2 to Switch Body

Terminal 1 to 3

Open

2H, TOD

Open

Neutral

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Oil Pump B Remove foreign materials from the strainer. If the strainer is damaged, replace it. B If the area into which the shaft is inserted is excessively worn or damaged, replace the oil pump assembly.

4D2–32 TRANSFER CASE (TOD)

Main Data and Specification General Specification Type

Electronically controlled torque split four wheel drive with two wheel drive. 2WD: Rear two wheel drive TOD: Electronically controlled torque split four wheel drive. 4L: Low speed mechanical lockup four wheel drive. Rear drive: Direct drive Front drive: Chain drive Low range deceleration: Planetary gear drive

Control system

Switch control

Gear ratio

High: 1.000 Low: 2.480

Lubrication system

Built-in oil pump Forced lubrication

Type of lubricant

ATF DEXRON–II or III

Oil capacity

1.35 liters. (1.43 US.quart)

Clutch discs number

Planetary gear teeth number

Sun gear: 58 Pinion gear: 15 Ring gear: 86

TRANSFER CASE (TOD) 4D2–33

Torque Specifications

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4D2–34 TRANSFER CASE (TOD)

Torque Specifications (Cont’d)

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TRANSFER CASE (TOD) 4D2–35

Torque Specifications (Cont’d)

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4D2–36 TRANSFER CASE (TOD)

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

ILLUSTRATION

TOOL NO. TOOL NAME

J–8614–11 Flange Holder

J–42806 Ring Gear Remover

J–42804 Rear Oil Seal Installer

J–42807 Front Output Shaft Oil Seal Installer

J–33951 Shift Shaft Oil Seal Installer

J–42808 Input Shaft Oil Seal Installer

J–42805 Bearing Remover

J–42809 Ring Gear Installer

J–2619–01 Slide Hammer

J–22912–01 Bearing Remover

SECTION BRAKE CONTROL SYSTEM

5A–1

AXIOM

BRAKES CONTENTS Brake Control System . . . . . . . . . . . . . . . . . . . . Anti–lock Brake System . . . . . . . . . . . . . . . . . . Power–assisted Brake System . . . . . . . . . . . . Parking Brakes (4×4 Model) . . . . . . . . . . . . . . Parking Brakes (4×2 Model) . . . . . . . . . . . . . .

5A–1 5B–1 5C–1 5D1–1 5D2–1

Brake Control System CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Functional Description . . . . . . . . . . . . . . . . . System Components . . . . . . . . . . . . . . . . . . . Electronic Hydraulic Control Unit (EHCU) . ABS Warning Light . . . . . . . . . . . . . . . . . . . . Wheel Speed Sensor . . . . . . . . . . . . . . . . . . G-Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Normal and Anti-lock Braking . . . . . . . . . . . Brake Pedal Travel . . . . . . . . . . . . . . . . . . . . Acronyms and Abbreviations . . . . . . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . ABS Service Precautions . . . . . . . . . . . . . . . Computer System Service Precautions . . . General Service Precautions . . . . . . . . . . . . Note on Intermittents . . . . . . . . . . . . . . . . . . . Test Driving ABS Complaint Vehicles . . . . . “ABS” Warning Light . . . . . . . . . . . . . . . . . . . Normal Operation . . . . . . . . . . . . . . . . . . . . . Tech 2 Scan Tool . . . . . . . . . . . . . . . . . . . . . . DATA LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . ACTUATOR TEST . . . . . . . . . . . . . . . . . . . . . Tech 2 Service Bleed . . . . . . . . . . . . . . . . . . Basic Diagnostic Flow Chart . . . . . . . . . . . . Basic Inspection Procedure . . . . . . . . . . . . . EHCU Connector Pin-out Checks . . . . . . . . . Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . Connector List . . . . . . . . . . . . . . . . . . . . . . . . Part Location . . . . . . . . . . . . . . . . . . . . . . . . . Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate . . . . . . . . . . . Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2) . . . . . . . . . . . . . . . . . . . . . . . . Chart A-2 Uneven Braking Occurs While ABS Works . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2) . . . . . . . . . . . . .

5A–2 5A–3 5A–4 5A–10 5A–10 5A–10 5A–10 5A–10 5A–10 5A–10 5A–11 5A–11 5A–11 5A–11 5A–11 5A–11 5A–11 5A–12 5A–12 5A–12 5A–13 5A–16 5A–17 5A–21 5A–22 5A–23 5A–24 5A–25 5A–28 5A–29 5A–30 5A–30 5A–31 5A–31 5A–31

Chart A-3, TA-3 The Wheels Are Locked . Chart A-4 Brake Pedal Feed Is Abnormal . Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking Diagnostic Trouble Codes . . . . . . . . . . . . . . . . Diagnosis By “ABS” Warning Light Illumination Pattern . . . . . . . . . . . . . . . . . . . . . Diagnostic Trouble Codes (DTCs) . . . . . . . Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated. . . . . . . . . . . . . . . . . . Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications)) . . . . . . . . . . . . . . . . . . . . . Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications)) . . . . . . . . . . . . . . . . . . . . . Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications)) . . . . . . . . . . . . . . . . . . . . . Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications)) . . . . . . . . . . . . . . . Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications)) . . . . . . . . . . . . . . . Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications)) . . . . . . . . . . . . . . . Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input Signal Failure (DTC 24 (Flash out) / C0282 (Serial communications)) . . . . . . . . . . . . . . . Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications)) . . . . . . . . . . . . . . . Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial communications)) . . . . . . . . . . . . . . . Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications)) . . . . . . . . . . . . . . . Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications)) . . . . . . . . . . . . . . .

5A–32 5A–32 5A–33 5A–34 5A–36 5A–37 5A–39 5A–39 5A–40 5A–40 5A–40 5A–41 5A–41

5A–42 5A–42 5A–43 5A–43 5A–43

5A–2

BRAKE CONTROL SYSTEM

Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial communications)) . . . . . . . . . . . . . . . 5A–44 Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial communications)) . . . . . . . . . . . . . . . 5A–44 Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial communications)) . . . . . . . . . . . . . . . 5A–44 Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial communications)) . . . . . . . . . . . . . . . 5A–45 Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial communications)) . . . . . . . . . . . . . . . 5A–45 Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial communications)) . . . . . . . . . . . . . . . 5A–46 Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial communications)) . . . . . . . . . . . . . . . 5A–47 Chart B-20 FL Speed Sensor Missing Signal (DTC 61 (Flash out) / C0226, C0227 (Serial communications)) . . . . . . . . . . . . . . . 5A–48

Chart B-21 FR Speed Sensor Missing Signal (DTC 62 (Flash out) / C0222, C0223 (Serial communications)) . . . . . . . . . . . . . . . Chart B-22 Rear Speed Sensor Missing Signal (DTC 63 (Flash out) / C0236, C0237 (Serial communications)) . . . . . . . . . . . . . . . Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) / C0229 (Serial communications)) . . . . . . . . Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial communications)) . . . . . . . . . . . . . . . . . . . . . Unit Inspection Procedure . . . . . . . . . . . . . . . . Chart C-1-1 FL Sensor Output Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart C-1-2 FR Sensor Output Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart C-1-3 Rear Sensor Output Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart TC-1 Sensor Output Inspection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .

5A–49 5A–50 5A–51 5A–52 5A–53 5A–53 5A–54 5A–54 5A–55 5A–56

BRAKE CONTROL SYSTEM

5A–3

General Description The Anti-lock Brake System (ABS) works on all four wheels. A combination of wheel speed sensor and Electronic Hydraulic Control Unit (EHCU) can determine when a wheel is about to stop turning and adjust brake pressure to maintain best braking. This system helps the driver maintain greater control of the vehicle under heavy braking conditions. NOTE: The Electronic Hydraulic Control Unit (EHCU) comprises the Hydraulic Unit (H/U) and the coil Integrated Module.

C05RW004

Legend (1) Electronic Line (2) Hydraulic Line (3) Hydraulic Unit (H/U)

(4) (5) (6) (7)

Coil Integrated Module Front Wheel Speed Sensor Rear Wheel Speed Sensor Proportioning and Bypass (P&B) Valve

5A–4

BRAKE CONTROL SYSTEM

Functional Description Hydraulic Unit (H/U) Solenoid Valve

C05RW012

Legend (1) Isolation Valve (2) Dump valve

BRAKE CONTROL SYSTEM

5A–5

Normal Braking During normal (non anti-lock) braking, the solenoid valves has current flow. The dump valve is closed and the isolation valve is opened due to spring force. Brake fluid travels through the centre of the isolation valve (normally open) around the dump valve (normally closed) then to the brake pistons.

C05RW010

Legend (1) Brake (2) Master Cylinder

5A–6

BRAKE CONTROL SYSTEM

Pressure Isolation (Pressure Maintain) The electro-hydraulic control unit is activated when the brakes are applied. If the information from the wheel speed sensors indicates excessive wheel deceleration (imminent lockup), the first step in the anti-lock sequence is to isolate the brake pressure being applied by the brake pedal. The microprocessor in the coil integrated module sends a voltage to the coil to energize and close the isolation valve. This prevents any additional fluid pressure applied by the brake pedal from reaching the wheel. With the isolation valves closed, unnecessary increase in the brake pressure is prevented.

C05RW011

Legend (1) Brake (2) Master Cylinder

BRAKE CONTROL SYSTEM

5A–7

Pressure Reduction Once the brake pressure is isolated, it must be reduced to allow the wheels to unlock. This is accomplished by dumping a portion of the brake fluid pressure into a low pressure accumulator. The microprocessor activates the normally closed dump valve to open, allowing fluid from the wheels to be dumped into the accumulator. This is done with very short activation pulses opening and closing the dump valve passageway. Brake pressure is reduced at the wheel and allows the wheel to begin rotating again. The fluid from the brake piston is stored in the accumulator against spring pressure and a portion of this fluid also primes the pump. The dump valves are operated independently to control the deceleration of the wheel.

C05RW009

Legend (1) Brake (2) Master Cylinder

5A–8

BRAKE CONTROL SYSTEM

Pressure Increase (Re-apply) The re-apply sequence is initiated to achieve optimum braking. The isolation valve is momentarily opened to allow master cylinder and pump pressure to reach the brakes. This controlled pressure rise continues until the wheel is at optimum brake output or until the brake pressure is brought up to the master cylinder output pressure. If more pressure is required, more fluid is drawn from the master cylinder and applied to the brakes. The driver may feel slight pedal pulsations, or pedal drop, this is normal and expected.

As fluid is re-applied to the brakes, the wheel speed will reduce. If the wheels approach imminent lockup again, the module will isolate, dump and re-apply again. This cycle occurs in millisecond intervals, allowing several cycles to occur each second. It is a much faster and more controlled way of “pumping the pedal”.

C05RW014

Legend (1) Brake (2) Master Cylinder

BRAKE CONTROL SYSTEM

5A–9

Brake Release At the end of the anti-lock stop, when the brake pedal is released, the pump will remain running for a short time to help drain any fluid from the accumulators. As this fluid returns into the system, the spring forces the piston back to its original position. The isolation valve opens and fluid may return to the master cylinder. Conventional braking is then resumed.

C05RW013

Legend (1) Brake (2) Master Cylinder

5A–10

BRAKE CONTROL SYSTEM

System Components Electronic Hydraulic Control Unit (EHCU), three Wheel Speed Sensors, Warning Light, and G-sensor.

Electronic Hydraulic Control Unit (EHCU) The EHCU consists of ABS control circuits, fault detector, and a fail-safe. The signal received from each sensor activates the hydraulic unit accordingly and cancels the ABS to return to normal braking if a malfunction occurs in the ABS system. The EHCU has a self-diagnosing function which can indicate faulty circuits during diagnosis. The EHCU is mounted on the engine compartment rear right side. It consists of a Motor, Plunger Pump, Solenoid Valves. Solenoid Valves: Reduces or holds the caliper fluid pressure for each front disc brake or both rear disc brakes according to the signal sent from the EHCU. Reservoir: Temporarily holds the brake fluid that returns from the front and rear disc brake caliper so that pressure of front disc brake caliper can be reduced smoothly. Plunger Pump: Feeds the brake fluid held in the reservoir to the master cylinder. Motor: Drives the pump according to the signal from EHCU. Check Valve: Controls the brake fluid flow.

ABS Warning Light

If the “ABS” light stays “ON” after the ignition switch is turned to the “ON” position, or comes “ON” and stays “ON” while driving, the Anti-lock Brake System should be inspected for a malfunction according to the diagnosis procedure.

Wheel Speed Sensor It consists of a sensor and a rotor. The sensor is attached to the knuckle on the front wheels and to the rear axle case on the rear differential. The front sensor rotor is attached to the each brake rotor by bolts. The rear rotor is press-fit in the differential case. The magnetic flux generated from electrodes magnetized by a magnet in the sensor varies due to rotation of the rotor, and the electromagnetic induction generates alternating voltage in the coil. This voltage draws a “sine curve” with the frequency proportional to rotor speed and it allows detection of wheel speed.

G-Sensor The G-sensor installed inside the EHCU detects the vehicle deceleration speed and sends a signal to the EHCU. In 4WD operation, all four wheels may be decelerated in almost the same phase, since all wheels are connected mechanically. This tendency is noticeable particularly on roads with low friction coefficient, and the ABS control is adversely affected. The G-sensor judges whether the friction coefficient of road surface is low or high, and changes the EHCU’s operating system to ensure ABS control.

Normal and Anti-lock Braking

821R200015

Vehicles equipped with the Anti-lock Brake System have an amber “ABS” warning light in the instrument panel. The “ABS” warning light will illuminate if a malfunction in the Anti-lock Brake System is detected by the Electronic Hydraulic Control Unit (EHCU).In case of an electronic malfunction, the EHCU will turn “ON” the “ABS” warning light and disable the Anti-lock braking function. The “ABS” light will turn “ON” for approximately three seconds after the ignition switch is turned to the “ON” position.

Under normal driving conditions, the Anti-lock Brake System functions the same as a standard power assisted brake system. However, with the detection of wheel lock-up, a slight bump or kick-back will be felt in the brake pedal. This pedal “bump” will be followed by a series of short pedal pulsations which occurs in rapid succession. The brake pedal pulsation will continue until there is no longer a need for the anti-lock function or until the vehicle is stopped. A slight ticking or popping noise may be heard during brake applications when the Anti-lock features is being used. When the Anti-lock feature is being used, the brake pedal may rise even as the brakes are being applied. This is also normal. Maintaining a constant force on the pedal will provide the shortest stopping distance.

Brake Pedal Travel Vehicles equipped with the Anti-lock Brake System may be stopped by applying normal force to the brake pedal. Although there is no need to push the pedal beyond the point where it stops or holds the vehicle, by applying more force the pedal will continue to travel toward the floor. This extra brake pedal travel is normal.

BRAKE CONTROL SYSTEM

Acronyms and Abbreviations Several acronyms and abbreviations are commonly used throughout this section: ABS Anti-lock Brake System CIM Coil Integrated Module CKT Circuit DLC Data Link Connector EHCU Electronic Hydraulic Control Unit FL Front Left FR Front Right GEN Generator H/U Hydraulic Unit MV Millivolts RR Rear RPS Revolution per Second VDC DC Volts VAC AC Volts W/L Warning Light WSS Wheel Speed Sensor

General Diagnosis General Information ABS troubles can be classified into two types, those which can be detected by the ABS warning light and those which can be detected as a vehicle abnormality by the driver. In either case, locate the fault in accordance with the “BASIC DIAGNOSTIC FLOWCHART” and repair. Please refer to Section 5C for the diagnosis of mechanical troubles such as brake noise, brake judder (brake pedal or vehicle vibration felt when braking), uneven braking, and parking brake trouble.

ABS Service Precautions Required Tools and Items: B Box Wrench B Brake Fluid B Special Tool

5A–11

Some diagnosis procedures in this section require the installation of a special tool. J-39200 High Impedance Multimeter When circuit measurements are requested, use a circuit tester with high impedance.

Computer System Service Precautions The Anti-lock Brake System interfaces directly with the Electronic Hydraulic Control Unit (EHCU) which is a control computer that is similar in some regards to the Powertrain Control Module. These modules are designed to withstand normal current draws associated with vehicle operation. However, care must be taken to avoid overloading any of the EHCU circuits. In testing for opens or shorts, do not ground or apply voltage to any of the circuits unless instructed to do so by the appropriate diagnostic procedure. These circuits should only be tested with a high impedance multimeter (J-39200) or special tools as described in this section. Power should never be removed or applied to any control module with the ignition in the “ON” position. Before removing or connecting battery cables, fuses or connectors, always turn the ignition switch to the “OFF” position.

General Service Precautions The following are general precautions which should be observed when servicing and diagnosing the Anti-lock Brake System and/or other vehicle systems. Failure to observe these precautions may result in Anti-lock Brake System damage. B If welding work is to be performed on the vehicle using an electric arc welder, the EHCU and valve block connectors should be disconnected before the welding operation begins. B The EHCU and valve block connectors should never be connected or disconnected with the ignition “ON” . B If only the rear wheels are rotated using jacks or drum tester, the system will diagnose a speed sensor malfunction and the “ABS” warning light will illuminate. But actually no trouble exists. After inspection stop the engine once and re-start it, then make sure that the “ABS” warning light does not illuminate. If the battery has been discharged The engine may stall if the battery has been completely discharged and the engine is started via jumper cables. This is because the Anti-lock Brake System (ABS) requires a large quantity of electricity. In this case, wait until the battery is recharged, or set the ABS to a non-operative state by removing the fuse for the ABS (50A). After the battery has been recharged, stop the engine and install the ABS fuse. Start the engine again, and confirm that the ABS warning light does not light.

Note on Intermittents As with virtually any electronic system, it is difficult to identify an intermittent failure. In such a case duplicating the system malfunction during a test drive or a good description of vehicle behavior from the customer may be helpful in locating a “most likely” failed component or

5A–12

BRAKE CONTROL SYSTEM

circuit. The symptom diagnosis chart may also be useful in isolating the failure. Most intermittent problems are caused by faulty electrical connections or wiring. When an intermittent failure is encountered, check suspected circuits for damage: B Suspected harness damage. B Poor mating of connector halves or terminals not fully seated in the connector body (backed out). B Improperly formed or damaged terminals.

Test Driving ABS Complaint Vehicles In case of an intermittent ABS lamp illumination, see “Diagnosis by ABS Warning Light illumination Pattern” or go to 5A–37. In some cases, the vehicle may need to be test driven by following the test procedure below. 1. Start the engine and make sure that the “ABS” W/L goes OFF. If the W/L remains ON, it means that the Diagnostic Trouble Code (DTC) is stored. Therefore, read the code and locate the fault. NOTE: The DTC cannot be cleared if the vehicle speed does not exceed 12 km/h (8 mph) at DTC, even though the repair operation is completed. 2. Start the vehicle and accelerate to about 30 km/h (19 mph) or more. 3. Slowly brake and stop the vehicle completely. 4. Then restart the vehicle and accelerate to about 40 km/h (25 mph) or more. 5. Brake at a time so as to actuate the ABS and stop the vehicle. 6. Be cautious of abnormality during the test. If the W/L is actuated while driving, read the DTC and locate the fault. 7. If the abnormality is not reproduced by the test, make best efforts to reproduce the situation reported by the customer. 8. If the abnormality has been detected, repair in accordance with the “SYMPTOM DIAGNOSIS” . NOTE: B Be sure to give a test drive on a wide, even road with a small traffic. B If an abnormality is detected, be sure to suspend the test and start trouble diagnosis at once.

“ABS” Warning Light When ABS trouble occurs to actuate “ABS” warning light, the trouble code corresponding to the trouble is stored in the EHCU. Only ordinary brake is available with ABS being unactuated. Even when “ABS” warning light is actuated, if the starter switch is set ON after setting it OFF once, the EHCU checks up on the entire system and, if there is no abnormality, judges ABS to work currently and the warning light is lit normally even though the trouble code is stored. NOTE: Illumination of the “ABS” warning light indicates that anti-lock braking is no longer available. Power assisted braking without anti-lock control is still available.

Normal Operation “ABS” Warning Light When the ignition is first moved from “OFF” to “RUN” , the amber “ABS” warning light will turn “ON” . The “ABS” warning light will turn “ON” during engine starting and will usually stay “ON” for approximately three seconds after the ignition switch is returned to the “ON” position. The warning light should remain “OFF” at all other times.

BRAKE CONTROL SYSTEM

5A–13

Tech 2 Scan Tool From 98 MY, Isuzu dealer service departments are recommended to use Tech 2. Please refer to Tech 2 scan tool user guide.

901RW257

Legend (1) PCMCIA Card (2) SAE 16/19 Adaptor

(3) DLC Cable (4) Tech–2

5A–14

BRAKE CONTROL SYSTEM

Getting Started B Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. The Isuzu 98 System PCMCIA card (1) inserts into the Tech 2 (4). 2. Connect the SAE 16/19 adapter (2) to the DLC cable (3). 3. Connect the DLC cable to the Tech 2 (4). 4. Make sure the vehicle ignition is off. 5. Connect the Tech 2 SAE 16/19 adapter to the vehicle DLC.

Operating Procedure The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card. Follow the operating procedure below.

826R200011

6. The vehicle ignition turns on. 7. Power up the Tech 2. 8. Verify the Tech 2 power up display.

060R100102

060RW009

BRAKE CONTROL SYSTEM

060R200078

5A–15

5A–16

BRAKE CONTROL SYSTEM

DATA LIST The data displayed by DATA LIST are as follows: Display

Content

OK/NG Criteria for Data

Front Left Wheel Speed Front Right Wheel Speed Rear Wheel Speeds

km/h (MPH)

B Start the vehicle and make sure of linear change in each wheel speed. B Turn each wheel by hand and make sure that each speed data change.

Warning Lamp

ON/OFF

B To be OFF usually

ABS State

ON/OFF

B To be OFF usually

ABS Relay

Active/Inactive

B To be Active usually

4 Wheel Drive

Active/Inactive

B 2WD: Inactive B 4WD: Active

Brake Switch

Active/Inactive

B Inactive (Released) B Active (Pressed)

Brake Fluid Level

Normal or not

B To be Normal usually

Return Pump

Active/Inactive

B To be Inactive usually

DRP (Dynamic Rear Proportioning)

Active/Inactive

B To be Inactive usually

Rear Dump Valve Commanded

Active/Inactive

B To be Inactive usually

Active/Inactive

B To be Inactive usually

Active/Inactive

B To be Inactive usually

G–Sensor

Voltage

B 2.50V when vehicle is stopped

Battery Voltage

Voltage

B Between 10–16.9V

Rear Dump Valve Feedback Rear Isolation Valve Commanded Rear Isolation Valve Feedback FL Dump Valve Commanded FL Dump Valve Feedback FL Isolation Valve Commanded FL Isolation Valve Feedback FR Dump Valve Commanded FR Dump Valve Feedback FR Isolation Valve Commanded FR Isolation Valve Feedback

BRAKE CONTROL SYSTEM

5A–17

ACTUATOR TEST This mode is used to exercise the ABS actuators and make sure they operate normally. Prior to the test, pay attention to the cautions below. (When checking the solenoid valve system, be sure to jack up the vehicle.) CAUTION: B Before testing, be sure that the brakes work normally. B Make sure that the battery is fully charged.Conduct the test by two persons (A TECH 2 operator and a vehicle checker). B Be sure to start ACTUATOR TEST with the engine stopped. B Before testing, make sure that electrical trouble, if any, has been completely repaired. Conducting tests of ABS solenoid with electrical circuit problem remaining uncorrected could damage the control unit.

F05R200001

5A–18

BRAKE CONTROL SYSTEM

F05R200002

BRAKE CONTROL SYSTEM

5A–19

F05R200003

5A–20

BRAKE CONTROL SYSTEM

F05R200004

BRAKE CONTROL SYSTEM

5A–21

Tech 2 Service Bleed

F05R200005

5A–22

BRAKE CONTROL SYSTEM

F05R200006

Basic Diagnostic Flow Chart Step 1

Action

Verify DTC through: “F0: Diagnostic Trouble Codes.” Is the DTC stored in the EHCU?

1. Repair of faulty part. 2. Clear DTC. 3. Inspection of “ABS” W/L Illumination pattern with ignition SW “ON”. 4. Test drive. Does trouble repeat?

Go to Step 2

Go to Step 4

Clear code and check for repeatability. Go to Step 3

Go to Step 5

Repeat the diagnosis it the symptom or DTC appears again Go to Step 1

Go to Step 5

Clear code and check for repeatability Go to Step 3

Trouble diagnosis based on symptom (Refer to Symptom Diagnosis) Go to Step 3

Finished

Go to Step 5

Verify DTC through: “F0: Diagnostic Trouble Codes.” Is the DTC stored in the EHCU?

1. Verify complaint with the customer. 2. Questioning to customer. 3. Basic inspection (Refer to Basic inspection procedure) Using TECH 2?

Yes

1. Reconnect all components. Ensure that all component are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

BRAKE CONTROL SYSTEM

5A–23

Basic Inspection Procedure 1. Basic Inspection of Service Brake Step 1

2 3 4 5

Action

Yes

Go to Step 2

Replenish with fluid Go to Step 2

Repair Go to Step 3

Go to Step 3

Go to Step 4

Repair Go to Step 4

Go to Step 5

Repair Go to Step 5

Finished

Go to Step 5

Yes

Go to Step 2

Repair Go to Step 2

Finished

Go to Step 2

Is the fluid level normal?

Does fluid leak? Is the booster functioning properly? Is the pad and rotor within specs? Reconnect all components. Ensure all component are properly mounted. Was this step finished?

2. Ground Inspection Step 1 2

Action Is there good contact with the ABS ground points? Reconnect all components. Ensure that all component are properly mounted.

5A–24

BRAKE CONTROL SYSTEM

EHCU Connector Pin-out Checks B Disconnect Electronic Hydraulic Control Module. B Perform checks with high impedance digital multimeter J-39200 or equivalent. No.

Circuit to be Tested

Ignition Switch Position

Multimeter Scale/Range

Measure between Pin Number

Nominal Value

Power supply

OFF

20DCV

1 (C–5) 2 (C–5)

11.5V to 14.5V

Ignition enable

OFF

20DCV

1 (C–6) 7 (C–6)

0V to 0.1V

20DCV

1 (C–6) 7 (C–6)

11.5V to 14.5V

Note

Stoplamp switch

OFF

20DCV

13 (C–6) 7 (C–6)

10.5V to 14.5V

Ground connection

OFF

200W

7 (C–6) Ground

Less than 2W

OFF

2 (C–5) Ground

Less than 0.2W

OFF

2kW

2 (C–6) 10 (C–6)

2.0kW to 2.8kW

OFF

200kW

2 (C–6) 7 (C–6)

more than 100kW

Insulation Resistance

OFF

200mACV

2 (C–6) 10 (C–6)

more than 200mV

Turn wheel at 1RPS

OFF

2kW

3 (C–6) 11 (C–6)

2.0kW to 2.8kW

Internal Resistance

OFF

200kW

3 (C–6) 7 (C–6)

more than 100kW

Insulation Resistance

OFF

200mACV

3 (C–6) 11 (C–6)

more than 200mV

Turn wheel at 1RPS

OFF

2kW

4 (C–6) 12 (C–6)

1.2kW to 2.0kW

Internal Resistance

OFF

200kW

4 (C–6) 7 (C–6)

more than 100kW

Insulation Resistance

OFF

200mACV

4 (C–6) 12 (C–6)

more than 200mV

Turn wheel at 1RPS

FL speed sensor

FR speed sensor

RR speed sensor

Press brake pedal

Internal Resistance

BRAKE CONTROL SYSTEM

5A–25

Circuit Diagram

D05R200004

5A–26

BRAKE CONTROL SYSTEM

D05R200002

BRAKE CONTROL SYSTEM

5A–27

D05R200003

5A–28

BRAKE CONTROL SYSTEM

Connector List No.

Connector face

No.

B-15

H-5

C-1 C-28

H-8

C-5

C-6

C-10 C-16 E-23

C-27

C-37

H-14

H-16

H-20

I-18

I-23

C-39 I-24

F-4 X-15

Connector face

BRAKE CONTROL SYSTEM

5A–29

Part Location

810R200002

Legend (1) Battery (2) Fuse & Relay Box (3) C–16 (4) C–5 (5) C–6 (6) H–8, 14 (7) I–18 (8) Starter Switch

(9) (10) (11) (15) (16) (17) (19) (21)

I–24 C–39 F–4 C–10 C–28 H–5 E–23 C–1

5A–30

BRAKE CONTROL SYSTEM

Symptom Diagnosis The symptoms that cannot be indicated by warning light can be divided in the following five categories: 1. ABS works frequently but vehicle does not decelerate. 2. Uneven braking occurs while ABS works. 3. The wheels lock during braking. 4. Brake pedal feel is abnormal. 5. Braking sound (from EHCU) is heard while not braking. These are all attributed to problems which cannot be detected by EHCU self-diagnosis. Use the customer complaint and test to determine which symptom is present. Then follow the appropriate flow chart listed below. No No.

Symptom Sym tom

Diagnostic Flow Charts Without TECH 2

With TECH 2

ABS works frequently but vehicle does not decelerate.

Chart A-1

Chart TA-1

Uneven braking occurs while ABS works.

Chart A-2

Chart TA-2

The wheels are locked.

Chart A-3

Chart TA-3

Brake pedal feel is abnormal.

Chart A-4

—

Braking sound (from EHCU) is heard while not braking.

Chart A-5

Chart TA-5

Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate Step

Action

Is braking force distribution normal between front and rear of vehicle?

2 3

Yes

Go to Step 2

Repair brake parts. Go to Step 7

Go to Step 3

Repair axle parts. Go to Step 7

Repair wheel speed sensor. Go to Step 7

Go to Step 4

Replace or repair sensor or sensor ring. Go to Step 7

Go to Step 5

Go to Step 6

Replace wheel speed sensor or repair harness. Go to Step 7

Go to Step 7

Replace TOD control unit or repair harness. Go to Step 7

Repeat the “Basic diagnostic flow chart”

Go to Step 7

Are axle parts installed normally? Is there play in each or any wheel speed sensor?

Is there damage, or powdered iron sticking to each or any wheel speed sensor/sensor ring?

Is the output of each wheel speed sensor normal? (Refer to Chart C-1 or TC-1)

Is the input of TOD control unit normal?

Reconnect all components, ensure all components are properly mounted. Was this step finished?

BRAKE CONTROL SYSTEM

5A–31

Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2) Step 1

Action

Go to Step 2

Replace wheel speed sensor. Go to Step 3

Go to Step 3

Go to Step 2

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Yes

Repair. Go to Step 5

Go to Step 2

Repair. Go to Step 5

Go to Step 3

Go to Step 4

Replace sensor or repair harness. Go to Step 5

Replace H/U. Go to Step 5

Reconnect brake pipe correctly. Go to Step 5

Repeat the “Basic diagnostic flow chart”

Go to Step 5

Return to Chart A-1. Was the Chart A-1 finished?

1. Connect TECH 2. 2. Make sure of the output conditions of each sensor. Is the output of each sensor normal?

Yes

Reconnect all components, ensure all components are properly mounted. Was this step finished?

Chart A-2 Uneven Braking Occurs While ABS Works Step 1 2 3

Action Is there play in each or any sensor? Damage or powdered iron sticking to each or any sensor/sensor ring? Is the output of each sensor normal? (Refer to Chart C-1 or TC-1)

Is brake pipe connecting order correct?

Reconnect all components, ensure all components are properly mounted. Was this step finished?

Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2) Step 1

Action

Check piping by TECH 2 ACTUATOR TEST Is the piping normal?

Go to Step 2

Go to Step 3

Replace EHCU. Go to Step 4

Repair the pipe. Go to Step 4

Go to Step 4

Go to Step 3

Repeat the “Basic diagnostic flow chart”

Go to Step 4

Repair and check the wheel speed sensor (Refer to Chart B-20 to B-23 , C-1 or TC-1). Was the each chart finished?

1. Connect TECH 2. 2. Make sure of the output conditions of each sensor. Is the output of each sensor normal?

Yes

Reconnect all components, ensure all components are properly mounted. Was this step finished?

5A–32

BRAKE CONTROL SYSTEM

Chart A-3, TA-3 The Wheels Are Locked Step

Action

Yes

Is ABS working?

Go to Step 2

Go to Step 4

Is vehicle speed under 10 km/h (6mph)?

Go to Step 3

Normal.

Is sensor output normal? (Chart C-1 or TC-1) Go to Step 4

Replace sensor or repair harness. Go to Step 6

Go to Step 5

Replace TOD control unit or repair harness. Go to Step 6

Replace EHCU. Go to Step 6

Repair. Go to Step 6

Repeat the “Basic diagnostic flow chart”

Go to Step 6

Yes

Go to Step 2

Go to Step 3

Go to Step 4

Harness NG between brake SW and EHCU. Go to Step 6

Go to Step 5

Replace stop light fuse. Go to Step 6

Go to Step 6

Repair body grounded harness. Go to Step 6

Repair stop light harness. Go to Step 6

Replace brake SW. Go to Step 6

Repeat the “Basic diagnostic flow chart”

Go to Step 6

Is front TOD control unit normal?

Is hydraulic unit grounded properly?

Reconnect all components, ensure all components are properly mounted. Was this step finished?

Chart A-4 Brake Pedal Feed Is Abnormal Step

Action

Is the stop light actuated when the brake pedal is depressed?

1. Turn the ignition switch off. 2. Disconnected EHCU connector. Is the check voltage EHCU connector terminals 13 to 7 when brake pedal is depressed than battery voltage?

Is stop light fuse normal?

Is the check continuity between EHCU connector terminals, 7 to body grounded?

Is brake SW normal?

Reconnect all components, ensure all components are properly mounted. Was this step finished?

BRAKE CONTROL SYSTEM

5A–33

Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking Step 1

Action Is this the first vehicle start after engine start?

Is vehicle speed under 10 km/h (6 mph)?

Check for the following condition: B At the time of shift down or clutch operation. B At the time of low road friction drive (ice or snow road) or rough road drive. B At the time of high-speed turn. B At the time of passing curb. B At the time of operating electrical equipment switches. B At the time of racing the engine (over 5000 rpm). Did it occur under any one condition above?

4 5 6

Is there play in each or any sensor/wheel speed sensor rings? Damage or powdered iron sticking to each or any sensor/wheel speed sensor ring? Is each sensor output normal? (Refer to Chart C-1 or TC-1).

Reconnect all components, ensure all components are properly mounted. Was this step finished?

Yes

Normal. (It is self checking sound.)

Go to Step 2

Normal. (It is self checking sound.)

Go to Step 3

ABS may sometimes be actuated even when brake pedal is not applied.

Go to Step 4

Repair. Go to Step 7

Go to Step 5

Repair. Go to Step 7

Go to Step 6

Check harness/ connector for suspected disconnection If no disconnection is found, replace Coil integrated module. Go to Step 7

Repair. Go to Step 7

Repeat the “Basic diagnostic flow chart”

Go to Step 7

5A–34

BRAKE CONTROL SYSTEM

Diagnostic Trouble Codes Choose and trace an appropriate flowchart by the numbers listed below to find fault and repair. Code Flash out

Serial Communications

Diagnosis

Item

Chart No.

—

C0285

2 WD Controller in 4WD Vehicle Controller

Wiring

B-8

C0271

RAM read/write error

C0272

ROM checksum error

C0270

ALU function error

B-2

C0273

Inoperative isolation item

Coil Integrated M d l Module

C0284

Loop time overrun

C0277

Low ignition voltage

C0278

High ignition voltage

Wiring

B-3

C0269

Excessive dump time

15 17 18

C0274

Excessive isolation time

C0276

G-Sensor Failure

C0281

Brake switch Failure

C0282

Open or shorted 4×4 input signal (4WD only)

C0267

Open motor circuit or shorted ECU output

C0268

Stalled motor or open ECU output

C0265

Open relay circuit

C0266

Shorted relay circuit

C0245

FL Open isolation solenoid or shorted ECU output

C0247

FL Shorted isolation solenoid or open ECU output

C0246

FL Open dump solenoid or shorted ECU output

C0248

FL Shorted dump solenoid or open ECU output

C0241

FR Open isolation solenoid or shorted ECU output

C0243

FR Shorted isolation solenoid or open ECU output

C0242

FR Open dump solenoid or shorted ECU output

C0244

FR Shorted dump solenoid or open ECU output

C0251

Rear Open isolation solenoid or shorted ECU output

C0253

Rear Shorted isolation solenoid or open ECU output

C0252

Rear Open dump solenoid or shorted ECU output

C0254

Rear Shorted dump solenoid or open ECU output

35 41 42 43 44 45 46

B-4 Coil Integrated Module

B-5 B-6 B-7

Wiring

B-8

Motor

B-9

Relay

B-10 B-11 B-12 B-13

Solenoid B-14 B-15 B-16

BRAKE CONTROL SYSTEM Code Diagnosis

Item

5A–35 Chart No.

Flash out

Serial Communications

C0225

FL Open or shorted sensor

B-17

C0221

FR Open or shorted sensor

B-18

C0235

Rear Open or shorted sensor

B-19

C0226

FL Missing sensor signal

C0227

FL Sensor signal dropout

C0222

FR Missing sensor signal

C0223

FR Sensor signal dropout

C0236

Rear Missing sensor signal

C0237

Rear Sensor signal dropout

C0229

Simultaneous dropout of front sensor signal

C0238

Wheel speed error

—

C0286

Shorted indicator lamp

62 63

B-20 Sensor or Wiring B-21 B-22 B-23 Vehicle or Sensor

B-24

Wiring

—

5A–36

BRAKE CONTROL SYSTEM

Diagnosis By “ABS” Warning Light Illumination Pattern In the event that there is abnormality in the “ABS” warning light illumination pattern while the key is in the ON position or if the warning light is actuated while driving, refer to the flow chart below for the correct diagnostic procedure. No.

Condition

“ABS” Warning Light Illumination Pattern

Diagnostic

Warning light is actuated normally

Normal

Warning light is not lit

Warning light lighting circuit trouble→Go to Chart B-1

Warning light remains ON

Diagnostic trouble codes are stored. Display diagnostic trouble codes and diagnose on a code basis according to the flow charts.

Warning light is actuated while driving

Diagnostic trouble codes are stored. Display diagnostic trouble codes and diagnose on a code basis according to the flow charts.

Warning light goes at 12 km/h (8 mph) or higher (After repairing the faulty part)

Even after repairing the faulty part the warning light (W/L) dose not go out if vehicle is at a stop. Turn the ignition switch to the ON position and drive the vehicle at 12 km/h (8 mph) or higher to make sure that the warning light goes out.

BRAKE CONTROL SYSTEM

Diagnostic Trouble Codes (DTCs) When the warning light in the meter remains ON, the EHCU stores the fault identification and disables the ABS. How to display and erase DTCs: NOTE: B DTCs can be displayed also by TECH 2. Use “Diagnostic Trouble Codes” mode.

5A–37

1. How to start DTC display: B Confirm that the vehicle has come to a complete stop (with the wheels standing still) and that the brake pedal is not depressed. (Unless these two condition are satisfied, DTC display cannot be started.) B With IGN OFF, connect #12 terminal with #4 terminal or # 5 terminal (GND) . Then turn IGN ON.

The DLC is located behind the driver side kick panel

350R200001

B Keep #12 terminal connected with #4 terminal or # 5 terminal (GND) during DTC display. (If #12 terminal is separated from #4 terminal or # 5 terminal (GND) during display, display will stop.) 2. DTC display: B DTC is displayed by blinking warning light. B Double-digit display. B First, normal DTC 12 is displayed three times and then any other DTCs are displayed three times. (If no other DTCs have been stored, the display of DTC 12 will be repeated.)

3. How to erase code: B Conduct brake switch ON/OFF operation 6 or more times within 3 seconds of self-diagnosis startup. B The code cannot be erased if more than 3 seconds have passed since self-diagnosis startup, or if self-diagnosis has started with brake switched on (brake pedaled).

B05RW005

5A–38

BRAKE CONTROL SYSTEM

4. Notes B If the following should occur during Diagnostic Trouble Code (DTC) display, the display will be discontinued. After initial check, the status that is under the control of ABS will be returned : – The vehicle starts (The wheels turn) or the brake pedal is depressed. B Up to 3 different codes can be stored. B If the ABS should turn OFF due to an intermittent defect, the system will be restored at the next key cycle, if the initial check finds no abnormality (when IGN is switched from OFF to ON). 5. An example of DTC display

B05R100001

After displaying DTC 12 three times, one DTC after another is displayed, starting with the most recent one. (However, display is discontinued after about 5 minutes.)

B05R100002

The DTC 12 is displayed repeatedly. (display is discontinued after about 5 minutes after)

BRAKE CONTROL SYSTEM

5A–39

Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated. Step 1 2

Action Is W/L fuse disconnected? Is W/L burnt out?

Replace fuse. Go to Step 5

Go to Step 2

Replace W/L bulb. Go to Step 5

Go to Step 3

Go to Step 4

Repair harness and connector. Go to Step 5

Check harness for suspected disconnection No fault found: Replace EHCU. Go to Step 5

Repair harness and connector. Go to Step 5

Repeat the “Basic diagnostic flow chart”

Go to Step 5

1. Turn the key off. 2. Disconnect coil integrated module connector (C-6). 3. Turn the key ON. Is the check voltage between coil integrated module connector (C-6) terminals 6 and 7 the battery voltage?

Yes

Is there the continuity between coil integrated module connector (C-6) terminals, 1 and 7 and body ground.

Reconnect all components, ensure all components are properly mounted. Was this step finished?

Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications)) Step 1

Action

1. 2. 3. 4.

Go to Step 2

Repair the body ground harness. Go to Step 3

Replace EHCU. Go to Step 3

Inspect in accordance with the DTC displayed.

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Turn the key off, connect the coil integrated module connector. Erase the trouble code. Turn Ignition off, then on, to perform system self-check. If warning light remains on, display trouble codes once again.

Is the trouble code the DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications)? 3

1. Turn the key off. 2. Disconnected coil integrated module connector. 3. Inspect coil integrated module ground. Is there the continuity between the coil integrated module connector terminals, 2 (C-5) and 7 (C-6) and body ground?

Yes

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

5A–40

BRAKE CONTROL SYSTEM

Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications)) Step 1

Action

Go to Step 2

Charge or replace battery. Go to Step 2

Check harness connector for suspected disconnection Fault found: Repair, and perform system self-check No fault found: replace EHCU. Go to Step 3

Repair harness or connector. Go to Step 3

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Is the battery voltage normal? (Battery capacity check)

1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Turn the key on. Is the voltage between coil integrated module connector (C-6) terminals 1 and 7, higher than 10V?

Yes

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications)) Step

Action

Check for anything causing extended ABS activation, such as locked brakes or an erratic speed sensor signal. Was a problem found?

1. The key turned off. 2. Replace EHCU. 3. Reconnect all components, ensure all components are properly mounted. Was this step finished?

Yes

Repair or Replace

Go to Step 2

Repeat the “Basic diagnostic flow chart”

Go to Step 2

Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications)) Step

Action

Check for anything causing extended ABS activation, such as locked brakes or an erratic speed sensor signal. Was a problem found?

1. The key turned off. 2. Replace EHCU. 3. Reconnect all components, ensure all components are properly mounted. Was this step finished?

Yes

Repair or Replace

Go to Step 2

Repeat the “Basic diagnostic flow chart”

Go to Step 2

BRAKE CONTROL SYSTEM

5A–41

Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications)) Step

Action

1. Turn the key off. 2. Replace EHCU. 3. Reconnect all components, ensure all components are properly mounted. Was this step finished?

Yes

Repeat the “Basic diagnostic flow chart”

Go to Step 1

Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications)) Step

Action

Is the stop light actuated when the brake pedal is depressed?

1. Turn the key off. 2. Disconnected coil integrated module connector. Is the check voltage between coil integrated module connector (C-6) terminals 13 to 7 when brake pedal is depressed the battery voltage?

4 5

Is the check that pins C-5 connector 2, and C-6 connector 7 have good ground?

Yes

Go to Step 2

Go to Step 4

Go to Step 3

Harness between brake SW and coil integrated module is faulty. Go to Step 6

Check harness / connector for disconnection Fault found: Repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6

Repair. Go to Step 6

Go to Step 5

Replace. Go to Step 6

Abnormal harness in stop light circuit. Repair the harness. Go to Step 6

Replace. Go to Step 6

Repeat the “Basic diagnostic flow chart”

Go to Step 6

Is stop light fuse normal? Is brake SW normal?

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

5A–42

BRAKE CONTROL SYSTEM

Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input Signal Failure (DTC 24 (Flash out) / C0282 (Serial communications)) Step 1

Action

Go to Step 2

Repair. Go to Step 3

Replace EHCU. Go to Step 3

Replace TOD control unit. Go to Step 3

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Remove coil integrated module connector. Is the coil integrated module connector (C-6) terminal 8 line normally?

Yes

Is the TOD control unit normally?

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications)) Step

Action

1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Measure the voltage between terminal 1 of the coil integrated module connector (C-5) and body ground.

Yes

Go to Step 2

Repair fuse/harness between battery and coil integrated module connector (C-5) terminal 1. Go to Step 5

Go to Step 3

Connect to the connector. Go to Step 3

Go to Step 4

Replace EHCU. Go to Step 5

Repeat the “Basic diagnostic flow chart”

Go to Step 5

Is the voltage equal to the battery voltage?

Is the harness from the hydraulic unit connected to the coil integrated module connector? Is the hydraulic unit harness in good condition?

Is the resistance of hydraulic unit connector terminals 1 and 2 between 0.2 and 1.0 ohms?

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

BRAKE CONTROL SYSTEM

5A–43

Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial communications)) Step

Action

1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Measure the voltage between terminal 1 of the coil integrated module connector (C-5) and body ground. Is the voltage equal to the battery voltage?

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Yes

Replace EHCU. Go to Step 2

Repair fuse and harness between coil integrated module connector (C-5) terminal 1 and battery. Go to Step 2

Repeat the “Basic diagnostic flow chart”

Go to Step 2

Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications)) Step 1

Action

Go to Step 2

Go to “EHCU Connector Pin–out Checks.”

Go to Step 3

Repair the connector. Repeat the “Basic Diagnostic Flow Chart.”

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Was the “EHCU Connector Pin–out Checks” performed?

1. Turn the key switch to off. 2. Disconnect the 2–way EHCU connector (C–5) from the EHCU. 3. Inspect the connector for damage or corrosion. Is the connector free from damage or corrosion?

Yes

1. Replace the Coil Integrated Module. 2. Reconnect all components, ensure all components are properly mounted. Was this step finished?

Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications)) Step 1

Action

Go to Step 2

Go to “EHCU Connector Pin–out Checks.”

Go to Step 3

Repair the connector. Repeat the “Basic Diagnostic Flow Chart.”

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Was the “EHCU Connector Pin–out Checks” performed?

1. Turn the key switch to off. 2. Disconnect the 2–way EHCU connector (C–5) from the EHCU. 3. Inspect the connector for damage or corrosion. Is the connector free from damage or corrosion?

Yes

1. Replace the Coil Integrated Module. 2. Reconnect all components, ensure all components are properly mounted. Was this step finished?

5A–44

BRAKE CONTROL SYSTEM

Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial communications)) Step 1

Action

Go to Step 2

Go to “EHCU Connector Pin–out Checks.”

Go to Step 3

Repair the connector. Repeat the “Basic Diagnostic Flow Chart.”

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Was the “EHCU Connector Pin–out Checks” performed?

1. Turn the key switch to off. 2. Disconnect the 2–way EHCU connector (C–5) from the EHCU. 3. Inspect the connector for damage or corrosion. Is the connector free from damage or corrosion?

Yes

1. Replace the Coil Integrated Module. 2. Reconnect all components, ensure all components are properly mounted. Was this step finished?

Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial communications)) Step 1

Action

Go to Step 2

Go to “EHCU Connector Pin–out Checks.”

Go to Step 3

Repair the connector. Repeat the “Basic Diagnostic Flow Chart.”

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Was the “EHCU Connector Pin–out Checks” performed?

1. Turn the key switch to off. 2. Disconnect the 2–way EHCU connector (C–5) from the EHCU. 3. Inspect the connector for damage or corrosion. Is the connector free from damage or corrosion?

Yes

1. Replace the Coil Integrated Module. 2. Reconnect all components, ensure all components are properly mounted. Was this step finished?

Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial communications)) Step 1

Action

Go to Step 2

Go to “EHCU Connector Pin–out Checks.”

Go to Step 3

Repair the connector. Repeat the “Basic Diagnostic Flow Chart.”

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Was the “EHCU Connector Pin–out Checks” performed?

1. Turn the key switch to off. 2. Disconnect the 2–way EHCU connector (C–5) from the EHCU. 3. Inspect the connector for damage or corrosion. Is the connector free from damage or corrosion?

Yes

1. Replace the Coil Integrated Module. 2. Reconnect all components, ensure all components are properly mounted. Was this step finished?

BRAKE CONTROL SYSTEM

5A–45

Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial communications)) Step 1

Action

Go to Step 2

Go to “EHCU Connector Pin–out Checks.”

Go to Step 3

Repair the connector. Repeat the “Basic Diagnostic Flow Chart.”

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Was the “EHCU Connector Pin–out Checks” performed?

1. Turn the key switch to off. 2. Disconnect the 2–way EHCU connector (C–5) from the EHCU. 3. Inspect the connector for damage or corrosion. Is the connector free from damage or corrosion?

Yes

1. Replace the Coil Integrated Module. 2. Reconnect all components, ensure all components are properly mounted. Was this step finished?

Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial communications)) Step

Action

Yes

1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Measure the resistance between coil integrated module connector (C-6) terminals 2 and 10.

Check for faults in harness between speed sensor and coil integrated module. Fault found: Repair, and perform system self-check. No fault found: Replace coil integrated module. Go to Step 3

Go to Step 2

Repair harness abnormality between sensors and coil integrated module. Go to Step 3

Replace sensor. Go to Step 3

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Is the resistance between 2.0k and 2.8k ohms?

Measure the FL speed sensor resistance at the sensor connector. Is the resistance between 2.0k and 2.8k ohms?

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

5A–46

BRAKE CONTROL SYSTEM

Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial communications)) Step

Action

Yes

1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Measure the resistance between coil integrated module connector (C-6) terminals 3 and 11.

Check for faults in harness between speed sensor and coil integrated module. Fault found: Repair, and perform system self-check. No fault found: Replace coil integrated module. Go to Step 3

Go to Step 2

Repair harness abnormality between sensors and coil integrated module. Go to Step 3

Replace sensor. Go to Step 3

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Is the resistance between 2.0k and 2.8k ohms?

Measure the FR speed sensor resistance at the sensor connector. Is the resistance between 2.0k and 2.8k ohms?

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

BRAKE CONTROL SYSTEM

5A–47

Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial communications)) Step

Action

Yes

1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Measure the resistance between coil integrated module connector (C-6) terminals 4 and 12.

Check for faults in harness between speed sensor and coil integrated module. Fault found: Repair, and perform system self-check. No fault found: Replace EHCU. Go to Step 3

Go to Step 2

Repair harness abnormality between sensors and coil integrated module. Go to Step 3

Replace sensor. Go to Step 3

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Is the resistance between 1.0k and 1.7k ohms?

Measure the Rear speed sensor resistance at the sensor connector. Is the resistance between 1.0k and 1.7k ohms?

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

5A–48

BRAKE CONTROL SYSTEM

Chart B-20 FL Speed Sensor Missing Signal (DTC 61 (Flash out) / C0226, C0227 (Serial communications)) Step

Action

1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Measure the FL speed sensor resistance between coil integrated module connector (C-6) terminals 2 and 10.

2 3

Yes

Is the resistance between 2.0k and 2.8k ohms?

Go to Step 2

Go to Step 3

Is there play sensor/sensor rotor?

Repair. Go to Step 6

Go to Step 4

Repair harness abnormality between sensors and coil integrated module. Go to Step 6

Replace sensor. Go to Step 6

Repair. Go to Step 6

Go to Step 5

Check for faults in harness between speed sensor and coil integrated module. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6

Replace sensor. Go to Step 6

Repeat the “Basic diagnostic flow chart”

Go to Step 6

Measure the FL speed sensor resistance at the sensor connector. Is the resistance between 2.0k and 2.8k ohms?

4 5

Damage and powdered iron sticking to sensor/sensor ring? Is sensor output normal? (Chart C-1-1 or TC-1)

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

NOTE: Even after repairing the faulty part the warning light (W/L) does not go out if the vehicle is at a stop. Turn the ignition switch to the ON position and drive the vehicle at 12 km/h (8 mph) or higher to make sure that the warning light goes out.

BRAKE CONTROL SYSTEM

5A–49

Chart B-21 FR Speed Sensor Missing Signal (DTC 62 (Flash out) / C0222, C0223 (Serial communications)) Step

Action

1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Measure the FR speed sensor resistance between coil integrated module connector (C-6) terminals 3 and 11.

2 3

Yes

Is the resistance between 2.0k and 2.8k ohms?

Go to Step 2

Go to Step 3

Is there play sensor/sensor rotor?

Repair. Go to Step 6

Go to Step 4

Repair harness abnormality between sensors and coil integrated module. Go to Step 6

Replace sensor. Go to Step 6

Repair. Go to Step 6

Go to Step 5

Check for faults in harness between speed sensor and coil integrated module. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6

Replace sensor. Go to Step 6

Repeat the “Basic diagnostic flow chart”

Go to Step 6

Measure the FR speed sensor resistance at the sensor connector. Is the resistance between 2.0k and 2.8k ohms?

4 5

Damage and powered iron sticking to sensor/sensor ring? Is sensor output normal? (Chart C-1-2 or TC-1)

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

5A–50

BRAKE CONTROL SYSTEM

Chart B-22 Rear Speed Sensor Missing Signal (DTC 63 (Flash out) / C0236, C0237 (Serial communications)) Step

Action

1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Measure the Rear speed sensor resistance between coil integrated module connector (C-6) terminals 4 and 12.

2 3

Yes

Is the resistance between 1.0k and 1.7k ohms?

Go to Step 2

Go to Step 3

Is there play sensor/sensor rotor?

Repair. Go to Step 6

Go to Step 4

Repair harness abnormality between sensors and coil integrated module. Go to Step 6

Replace sensor. Go to Step 6

Repair. Go to Step 6

Go to Step 5

Check for faults in harness between speed sensor and coil integrated module. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 6

Replace sensor. Go to Step 6

Repeat the “Basic diagnostic flow chart”

Go to Step 6

Measure the rear speed sensor resistance at the sensor connector. Is the resistance between 1.0k and 1.7k ohms?

4 5

Damage and powered iron sticking to sensor/sensor ring? Is sensor output normal? (Chart C-1-3 or TC-1)

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

BRAKE CONTROL SYSTEM

5A–51

Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) / C0229 (Serial communications)) Step

Action

1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Measure the FL speed sensor resistance between coil integrated module connector (C-6) terminals 2 and 10. Is the resistance between 2.0k and 2.8k ohms?

Measure the FL speed sensor resistance at the sensor connector. Is the resistance between 2.0k and 2.8k ohms?

Measure the FR speed sensor resistance at the sensor connector. Is the resistance between 2.0k and 2.8k ohms?

5 6 7

Go to Step 2

Go to Step 3

Go to Step 5

Go to Step 4

Repair harness abnormality between sensors and coil integrated module. Go to Step 2

Replace sensor. Go to Step 2

Repair harness abnormality between sensors and coil integrated module. Go to Step 5

Replace sensor. Go to Step 5

Repair. Go to Step 6

Go to Step 6

Repair. Go to Step 7

Go to Step 7

Check for faults in harness between speed sensor and coil integrated module. Fault found: repair, and perform system self-check. No fault found: replace EHCU. Go to Step 8

Replace sensor. Go to Step 8

Repeat “Basic diagnostic flow chart”

Go to Step 8

Measure the FR speed sensor resistance between coil integrated module connector (C-6) terminals 3 and 11. Is the resistance between 2.0k and 2.8 k ohms?

Yes

Damage and powered iron sticking to sensor/sensor ring? Is there play sensor/sensor rotor? Is sensor output normal? (Chart C-1-1&C-1-2 or TC-1)

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

5A–52

BRAKE CONTROL SYSTEM

Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial communications)) Step

Action

Using TECH 2?

1. Connect TECH 2. 2. Select Snap shot manual trigger. 3. With wheel speed data displayed, run the vehicle when speed has arrived at 30 km/h (18 mph). 4. Check speed data on each wheel (refer to the criterion given below). * 1 Is the abnormal sensor condition found?

3 4 5

6 7

Is there play in sensor/sensor ring? Is there powdered iron sticking to sensor/sensor ring? Is there a broken tooth or indentation in sensor ring?

Is there play in wheel bearing?

Yes

Go to Step 2

Go to Step 3

Replace. Go to Step 8

Go to Step 3 All the sensors should follow the following flowchart (without using TECH 2).

Repair. Go to Step 8

Go to Step 4

Repair. Go to Step 8

Go to Step 5

Replace sensor ring. Go to Step 8

Go to Step 6

Adjust or repair. Go to Step 8

Go to Step 7

Replace EHCU. Go to Step 8

Repair, and perform system self-check. Go to Step 8

Repeat ‘Basic diagnostic flow chart”

Go to Step 8

Is the check wiring between sensor and coil integrated module normal?

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble code. Was this step finished?

Sensor Signal Abnormality Criteria using TECH 2 1. While driving, the speed of one or two wheels is 25% or more higher or lower than that of the other wheels. 2. The speed of one or two wheels is 10 km/h (6 mph) or more higher or lower than that of the other wheels. 3. During steady driving, wheel speed changes abruptly. *1 The vehicle must run on a level paved road. NOTE: Even after repairing the faulty part the warning light (W/L) does not go out if the vehicle is at a stop. Turn the ignition switch to the ON position and drive the vehicle at 12 km/h (8 mph) or higher to make sure that the warning light goes out. It is important to verify that the correct tires are installed on vehicle.

BRAKE CONTROL SYSTEM

5A–53

Unit Inspection Procedure This section describes the following inspection procedures referred to during Symptom Diagnosis and Diagnosis By “ABS” Warning Light Illumination Pattern

Sensor Output Inspection

without TECH 2

with TECH 2

Chart C-1-1 to C-1-3

Chart TC-1

Chart C-1-1 FL Sensor Output Inspection Procedure Step

Action

1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Jack up the vehicle with all four wheels off the ground. Measure the AC voltage between coil integrated module connector terminals while turning FL wheel at a speed of 1 RPS: Is the voltage between coil integrated module connector (C-6) terminals 2 and 10 less than 200 mV?

1. Disconnect the wheel speed sensor. 2. Measure resistance between the wheel speed sensor connector terminals 1 and 2. Is the check between connector (C-28) terminals 1 and 2 within 2.0k — 2.8k ohms?

Reconnect all components, ensure all components are properly mounted. Was this step finished?

Yes

Go to Step 2

OK. Go to Step 3

Connector is faulty, or open or short circuit of harness between wheel speed sensor connector and coil integrated module. Inspect and correct the connector or harness. Go to Step 3

Wheel speed sensor is faulty. Replace the wheel speed sensor. Go to Step 3

Repeat the “Basic diagnostic flow chart”

Go to Step 3

5A–54

BRAKE CONTROL SYSTEM

Chart C-1-2 FR Sensor Output Inspection Procedure Step

Action

1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Jack up the vehicle with all four wheels off the ground. Measure the AC voltage between coil integrated module connector terminals while turning FR wheel at a speed of 1 RPS: Is the voltage between coil integrated module connector (C-6) terminals 3 and 11 less than 200 mV?

1. Disconnect the wheel speed sensor. 2. Measure resistance between the wheel speed sensor connector terminals 1 and 2. Is the check between connector (C-1) terminals 1 and 2 within 2.0k — 2.8k ohms?

Reconnect all components, ensure all components are properly mounted. Was this step finished?

Yes

Go to Step 2

OK. Go to Step 3

Connector is faulty, or open or short circuit of harness between wheel speed sensor connector and coil integrated module. Inspect and correct the connector or harness. Go to Step 3

Wheel speed sensor is faulty. Replace the wheel speed sensor. Go to Step 3

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Yes

Go to Step 2

OK. Go to Step 3

Connector is faulty, or open or short circuit of harness between wheel speed sensor connector and coil integrated module. Inspect and correct the connector or harness. Go to Step 3

Wheel speed sensor is faulty. Replace the wheel speed sensor. Go to Step 3

Repeat the “Basic diagnostic flow chart”

Go to Step 3

Chart C-1-3 Rear Sensor Output Inspection Procedure Step

Action

1. Turn the key off. 2. Disconnect coil integrated module connector. 3. Jack up the vehicle with all four wheels off the ground measure the AC voltage between coil integrated module connector terminals while turning Rear wheel at a speed of 1 RPS: Is the check between coil integrated module connector (C-6) terminals 4 and 12 than under 200 mV?

1. Disconnect the wheel speed sensor. 2. Measure resistance between the wheel speed sensor connector terminals 1 and 2. Is the check between connector (F-4) terminals 1 and 2 within 1.0k — 1.7k ohms?

Reconnect all components, ensure all components are properly mounted. Was this step finished?

BRAKE CONTROL SYSTEM

5A–55

Chart TC-1 Sensor Output Inspection Procedure Step 1

Action

Check the sensor harness for suspected disconnection (check while shaking harness/connector). Is the sensor harness connection normal?

Check the sensor rotor. Is the sensor rotor normal?

Go to Step 6

Go to Step 2

Replace speed sensor. Go to Step 4

Repair. Go to Step 3

Go to Step 6

Go to Step 4

Replace speed sensor. Go to Step 5

Replace sensor rotor. Go to Step 5

Go to Step 6

Repair harness or connector between coil integrated module and speed sensor. Go to Step 6

Repeat the “Basic diagnostic flow chart”

Go to Step 6

Check the wheel speed of each sensor by Data List. Is the vehicle speed normal?

1. Connect TECH 2. 2. Check the wheel speed of each sensor by Data List. Is the vehicle speed normal?

Yes

Check the harness between coil integrated module and speed sensor. Is the harness connection normal?

Reconnect all components, ensure all components are properly mounted. Was this step finished?

5A–56

BRAKE CONTROL SYSTEM

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

J–35616 Connector test adapter kit

J–39200 High impedance multimeter

7000086–ISU Tech 2 Set (1) PCMCIA Card (2) SAE 16/19 Adapter (3) DLC Cable (4) Tech 2

SECTION ANTI–LOCK BRAKE SYSTEM

5B–1

AXIOM

BRAKES ANTI-LOCK BRAKE SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Electronic Hydraulic Control Unit . . . . . . . . . . Electronic Hydraulic Control Unit and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Speed Sensor . . . . . . . . . . . . . . .

5B–1 5B–2 5B–2 5B–2 5B–3 5B–3 5B–3 5B–3 5B–4

Front Wheel Speed Sensor and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel Speed Sensor . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5B–4 5B–4 5B–4 5B–4 5B–5 5B–5 5B–5 5B–5

5B–2

ANTI–LOCK BRAKE SYSTEM

Electronic Hydraulic Control Unit Electronic Hydraulic Control Unit and Associated Parts

350R100003

Legend (1) EHCU (2) Bolt

(3) Bracket (4) Bolt and Nut

Removal 1. Remove brake pipes. B After disconnecting brake pipe, cap or tape the openings of the brake pipe to prevent the entry of foreign matter. 2. Remove three bracket fixing bolts. 3. Disconnect red clip from harness connector.

350RW018

ANTI–LOCK BRAKE SYSTEM 4. Remove harness connector. 5. Remove EHCU ASM. 6. Remove EHCU.

5B–3

Installation To install, follow the removal steps in the reverse order, noting the following points: Torque Hydraulic unit fixing nuts : 22 N·m (16 lb ft) Ground cable : 14 N·m (10 lb ft) Brake pipe (joint bolts) : 16 N·m (12 lb ft) B After installing the hydraulic unit, bleed brakes completely. See Section 5A “Hydraulic Brakes”.

Disassembled View

350RW025

Legend (1) Fixing Bolts (2) Coil Integrated Module (3) Hydraulic Unit (H/U)

Disassembly 1. Remove fixing bolts from EHCU. 2. Remove coil integrated module from hydraulic unit.

Reassembly To reassembly, follow the disassembly steps in the reverse order, noting the following points: Torque Fixing bolts: 4.4 N·m (39 lb in)

5B–4

ANTI–LOCK BRAKE SYSTEM

Front Wheel Speed Sensor Front Wheel Speed Sensor and Associated Parts

350RS033

Legend (1) Speed Sensor Connector (2) Sensor Cable Fixing Bolt (Upper side)

Removal 1. Remove speed sensor connector. 2. Remove sensor cable fixing bolt (Upper side). 3. Remove sensor cable fixing bolt (Lower side). 4. Remove the speed sensor cable fixing bolt. 5. Remove speed sensor.

Inspection and Repair 1. Check the speed sensor pole piece for presence of foreign materials; remove any dirt, etc. 2. Check the pole piece for damage; replace speed sensor if necessary. 3. Check the speed sensor cable for short or open circuit, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. 4. Check the sensor ring for damage including tooth chipping, and if damaged, replace the sensor ring assembly. Refer to removal of the sensor ring in Section 4C “Front hub and disc”.

(3) Sensor Cable Fixing Bolt (Lower side) (4) Sensor Cable Fixing Bolt (Sensor side) (5) Speed Sensor

Installation 1. Install speed sensor and take care not to hit the speed sensor pole piece during installation. 2. Install speed sensor fixing bolt and tighten the fixing bolt to the specified torque. Torque: 11 N·m (95 lb in) 3. Install speed sensor cable fixing bolt (Lower side) and tighten the fixing bolt to the specified torque. Torque : 24 N·m (17 lb ft) 4. Install speed sensor cable fixing bolt (Upper side) and tighten the fixing bolt to the specified torque. Torque : 6 N·m (52 lb in) NOTE: Confirm that a white line marked on the cable is not twisted when connecting the speed sensor cable. 5. Install speed sensor connector.

ANTI–LOCK BRAKE SYSTEM

5B–5

Rear Wheel Speed Sensor Removal

Installation

1. Disconnect harness connector (1). 2. Remove sensor fixing bolt (2) . 3. Remove speed sensor (3).

1. Install speed sensor (3). 2. Tighten the sensor fixing bolt (2) to the specified torque. Torque : 24 N·m (17 lb ft) 3. Connect harness connector (1).

350R100004

Inspection and Repair 1. Check speed sensor pole piece for presence of foreign materials; remove any dirt, etc. 2. Check the pole piece for damage, and replace speed sensor if necessary. 3. Check speed sensor cable for short or open, and replace with a new one if necessary. To check for cable short or open, bend or stretch the cable while checking for continuity. 4. Check the sensor ring for damage including tooth chipping, and if damaged, replace the axle shaft assembly. Refer to removal of the sensor ring in Section 4A2 “Differential (Rear)”.

350R100004

SECTION POWER–ASSISTED BRAKE SYSTEM

5C–1

AXIOM (Vehicles Produced Before July/31/2001)

BRAKES POWER-ASSISTED BRAKE SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . Filling Master Cylinder Reservoir . . . . . . . . Deterioration of Brake Fluid . . . . . . . . . . . . . Leakage of Brake Fluid . . . . . . . . . . . . . . . . . Bleeding Brake Hydraulic System . . . . . . . . Flushing Brake Hydraulic System . . . . . . . . Brake Pipes and Hoses . . . . . . . . . . . . . . . . Brake Hose Inspection . . . . . . . . . . . . . . . . . Front Caliper Brake Hose . . . . . . . . . . . . . . . . Front Caliper Brake Hose and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Brake Hose . . . . . . . . . . . . . . . . . . . Rear Axle Brake Hose and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . P & B (Proportioning and Bypass) Valve . . . . P & B (Proportioning and Bypass) Valve Sectional View . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Pedal Height . . . . . . . . . . . . . . . . . Checking Pedal Travel . . . . . . . . . . . . . . . . . Brake Pedal and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stoplight Switch . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Fluid Reservoir Tank . . . . . . . . . . . . . . . . . . . . . Fluid Reservoir Tank and Associated Parts

5C–2 5C–2 5C–6 5C–7 5C–10 5C–10 5C–10 5C–10 5C–10 5C–11 5C–11 5C–11 5C–12 5C–12 5C–12 5C–12 5C–13 5C–13 5C–13 5C–13 5C–14 5C–14 5C–14 5C–15 5C–15 5C–15 5C–15 5C–16 5C–17 5C–17 5C–17 5C–18 5C–18 5C–18 5C–19 5C–19 5C–19 5C–19 5C–20 5C–21 5C–21

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master Cylinder Assembly . . . . . . . . . . . . . . . . Master Cylinder Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Booster Assembly . . . . . . . . . . . . . . . Vacuum Booster Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exterior Components . . . . . . . . . . . . . . . . . . . . Exterior Components and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Booster Overhaul . . . . . . . . . . . . . . . . Vacuum Booster . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brake Pads . . . . . . . . . . . . . . . . . . . Front Disc Brake Pads Inspection . . . . . . . . Front Disc Brake Pads and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brake Rotor . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Brake Rotors . . . . . . . . . . . . . . . . Refinishing Brake Rotors . . . . . . . . . . . . . . . Front Disc Brake Caliper Assembly . . . . . . . . Front Disc Brake Caliper Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brake Caliper . . . . . . . . . . . . . . . . . Front Disc Brake Caliper Disassembled View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .

5C–21 5C–21 5C–22 5C–22 5C–22 5C–22 5C–23 5C–24 5C–24 5C–25 5C–25 5C–25 5C–26 5C–26 5C–28 5C–28 5C–28 5C–29 5C–29 5C–29 5C–29 5C–30 5C–31 5C–32 5C–32 5C–32 5C–33 5C–33 5C–35 5C–35 5C–35 5C–35 5C–36 5C–36 5C–37 5C–37 5C–39 5C–39 5C–39

5C–2

POWER–ASSISTED BRAKE SYSTEM

Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Rear Disc Brake Pads (4×4 Model) . . . . . . . . Brake Pads Inspection . . . . . . . . . . . . . . . . . Brake Pads and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Disc Brake Rotor (4×4 Model) . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Brake Rotors . . . . . . . . . . . . . . . . Refinishing Brake Rotors . . . . . . . . . . . . . . . Rear Drum (In Disc) Inside Diameter Check Rear Disc Brake Caliper Assembly (4×4 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Disc Brake Caliper Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Disc Brake Caliper (4×4 Model) . . . . . . Rear Disc Brake Caliper Disassembled View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5C–40 5C–40 5C–42 5C–43 5C–43 5C–43 5C–44 5C–44 5C–46 5C–46 5C–46 5C–46 5C–47 5C–48 5C–48 5C–48 5C–49 5C–50

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications (4×4 Model) Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Lining and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Lining Inspection . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drum Brake Adjustment (4×2 Model) . . . . . Servicing The Brake Drum . . . . . . . . . . . . . . Wheel Cylinder Assembly (4×2 Model) . . . . . Wheel Cylinder Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . .

5C–51 5C–51 5C–51 5C–53 5C–54 5C–54 5C–54 5C–55 5C–55 5C–56 5C–56 5C–57 5C–57 5C–57 5C–57 5C–58 5C–58 5C–58 5C–58 5C–60

5C–50

Service Precaution

General Description

Master Cylinder Assembly

330RS001

POWER–ASSISTED BRAKE SYSTEM The master cylinder contains two pistons that supply the hydraulic pressure for a dual–circuit braking system. The primary piston provides the fluid pressure to the front brakes, while the secondary piston provides the fluid pressure to the rear brakes. If the pressure is lost from either system, the remaining system will function to stop the vehicle.

5C–3

CAUTION: 1. The master cylinder is not repairable. If found defective, it must be replaced as a complete assembly. 2. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. (Refer to Bleeding Brake Hydraulic System in this section.) 3. The torque values specified unlubricated fasteners.

are

for

dry,

4. Perform service operations on a clean bench free from all mineral oil materials.

Brake Booster

331RS001

This booster is a tandem vacuum unit with a diaphragm effective diameter 205mm (8.072 in) + 230mm (9.056 in). In normal operating mode, with the service brakes in the released position, the tandem vacuum booster operates with vacuum on both sides of its diaphragms. When the brakes are applied, air at atmospheric pressure is admitted to both sides of the diaphragm to provide the power assist. When the service brake is released, the atmospheric air is shut off from both sides of the diaphram. The air is then drawn from the booster through the vacuum check valve to the vacuum source.

CAUTION: 1. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 2. The torque values specified unlubricated fasteners.

are

for

dry,

3. The vacuum booster is not repairable and must be replaced as complete assembly.

5C–4

POWER–ASSISTED BRAKE SYSTEM

Disc Brake Front Disc Brake

A05RW001

Rear Disc Brake (4×4 Model)

A05RW002

The disc brake assembly consists of a caliper, piston, rotor, pad assembly and support bracket. The caliper assembly has a single bore and is mounted to the support bracket with two mounting bolts. The support bracket allows the caliper to move laterally against the rotor. The caliper is a one–piece casting with the inboard side containing the piston bore. A square cut rubber seal is located in a groove in the piston bore which provides the hydraulic seal between the piston and the cylinder wall. NOTE: 1. Replace all components included in repair kits used to service this caliper. 2. Lubricate rubber parts with clean brake fluid to ease assembly.

3. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 4. Replace pads in axle sets only. 5. The torque values specified are for dry, unlubricated fasteners. 6. Perform the service operation on a clean bench free from all mineral oil materials. Operation Hydraulic pressure, created by applying the brake pedal, is converted by the caliper to a stopping force. This force creates a clamping action of the piston pressing towards the rotors (outward) and the caliper slides inward toward the vehicle. This clamping action forces the linings against the rotor, creating friction to stop the vehicle.

POWER–ASSISTED BRAKE SYSTEM

5C–5

Leading/Trailing Drum Brakes (4×2 Model)

A05RS003

This drum brake assembly is a leading/trailing shoe design. Both brake shoes are held against the wheel cylinder pistons by the upper return spring and to the fixed anchor plate by the lower return spring. When the brakes are applied, the wheel cylinder pistons expand pushing both shoes out contact the drum. With forward wheel rotation, the forward brake shoe will wrap into the drum and becomes self-energized. With reverse wheel rotation, the rear brake shoe is self-energized. Force from the brake shoes is transferred to the anchor plate through the braking plate to the axle flange. Adjustment is automatic and occurs on any service brake application. Also, with leading/trailing brakes, it is normal for the front shoe to wear at a faster rate than the rear shoe.

5C–6

POWER–ASSISTED BRAKE SYSTEM

Diagnosis Road Testing The Brakes Brake Test Brakes should be tested on a dry, clean, reasonably smooth and level roadway. A true test of brake performance cannot be made if the roadway is wet, greasy or covered with loose dirt where all tires do not grip the road equally. Testing will also be adversely affected if the roadway is crowned so as to throw the weight of the vehicle toward wheels on one side or if the roadway is so rough that wheels tend to bounce. Test the brakes at different vehicle speeds with both light and heavy pedal pressure; however, avoid locking the wheels and sliding the tires. Braking without locking the tires will stop the vehicle in less distance than braking to a skid (which has no brake efficiency). More tire to road friction is present while braking without locking the tires than braking to a skid. The standard brake system is designed and balanced to avoid locking the wheels except at very high deceleration levels. It is designed this way because the shortest stopping distance and best control is achieved without brake lock–up. Because of high deceleration capability, a firmer pedal may be felt at higher deceleration levels. External Conditions That Affect Brake Performance 1. Tires: Tires having unequal contact and grip on the road will cause unequal braking. Tires must be equally inflated, identical in size, and the thread pattern of right and left tires must be approximately equal. 2. Vehicle Loading: A heavily loaded vehicle requires more braking effort. 3. Wheel Alignment: Misalignment of the wheels, particularly in regard to excessive camber and caster, will cause the brakes to pull to one side.

Brake Fluid Leaks With engine running at idle and the transmission in “Neutral”, depress the brake pedal and hold a constant foot pressure on the pedal. If pedal gradually falls away with the constant pressure, the hydraulic system may be leaking. Check the master cylinder fluid level. While a slight drop in the reservoir level will result from normal lining wear, an abnormally low level in reservoir indicates a leak in the system. The hydraulic system may be leaking internally as well as externally. Refer to Master Cylinder Inspection. Also, the system may appear to pass this test but still have slight leakage. If fluid level is normal, check the vacuum booster push rod length. If an incorrect length push rod is found, adjust or replace the push rod. Check the brake pedal travel and the parking brake adjustment. When checking the fluid level, the master cylinder fluid level may be lower than the “MAX” mark if the front and rear linings are worn. This is normal.

Warning Light Operation When the ignition switch is in the START position, the “BRAKE” warning light should turn on and go off when the ignition switch returns to the ON position. The following conditions will activate the “BRAKE” light: 1. Parking brake applied. The light should be on whenever the parking brake is applied and the ignition switch is on. 2. Low fluid level. A low fluid level in the master cylinder will turn the “BRAKE” light on. 3. During engine cranking the “BRAKE” light should remain on. This notifies the driver that the warning circuit is operating properly.

POWER–ASSISTED BRAKE SYSTEM

5C–7

General Diagnosis Condition

Possible cause

Brake Pull

Brake Roughness (Pulsates)

Excessive Pedal Effort

Chatter

Correction

Tire inflation pressure is unequal.

Adjust

Front wheel alignment is incorrect.

Adjust

Unmatched tires on same axle.

Tires with approx. the same amount of tread should be used on the same axle.

Restricted brake pipes or hoses.

Check for soft hoses and damaged lines. Replace with new hoses and new double“walled steel brake piping.

Water or oil on the brake pads.

Clean or replace.

Brake pads hardened.

Replace

Brake pads worn excessively.

Replace

Brake rotor worn or scored.

Grind or replace.

Disc brake caliper malfunctioning.

Clean or replace.

Front hub bearing preload incorrect.

Adjust or replace.

Loose suspension parts.

Check all suspension mountings.

Loose calipers.

Check and tighten the bolts to specifications.

Excessive lateral runout.

Check per instructions. If not within specifications, replace or machine the rotor.

Parallelism not within specifications.

Check per instructions. If not within specifications, replace or machine the rotor.

Wheel bearings not adjusted.

Adjust wheel bearings to correct specifications

Pad reversed (steel against iron).

Replace the brake pad and machine rotor to within specifications.

Malfunctioning vacuum booster.

Check the vacuum booster operation and repair, if necessary.

Partial system failure.

Check the front and rear brake system for failure and repair. Also, check the brake warning light. If a failed system is found, the light should indicate failure.

Excessively worn pad.

Check and replace pads in sets.

Piston in caliper stuck or sluggish.

Remove caliper and rebuild.

Fading brakes due to incorrect pad.

Remove and replace with original equipment pad or equivalent.

Vacuum leak to vacuum booster.

Check for ruptured or loose hose.

Check the direction of check valve within vacuum hose.

Correct vacuum hose direction.

Grease on the brake pads.

Replace or clean.

5C–8

POWER–ASSISTED BRAKE SYSTEM Condition

Excessive Brake Pedal Travel

Brake Drag

Grabbing or Uneven Braking Action (All conditions listed under “Pulls”)

Brake Noisy

Possible cause

Correction

Air in hydraulic circuit.

Bleed the hydraulic circuit.

Level of brake fluid in the reservoir too low.

Replenish brake fluid reservoir to specified level and bleed hydraulic circuit as necessary.

Master cylinder push rod clearance excessive.

Adjust

Leakage in hydraulic system.

Correct or replace defective parts.

Master cylinder pistons not returning correctly.

Adjust the stop light switch and vacuum booster push rod. If necessary, rebuild.

Restricted brake pipes or hoses.

Check for soft hoses or damaged pipes, and replace with new hoses and new double–walled steel brake piping.

Parking brake maladjusted.

Adjust

Parking brake insufficient.

Adjust

lining

clearance

Brake pedal free play insufficient.

Adjust the brake pedal height or power cylinder operating rod.

Piston in the master cylinder sticking.

Replace

Piston in the disc brake caliper sticking.

Replace piston seals.

Brake pads sticking in caliper.

Clean

Return spring weakened.

Replace

Parking brake binding.

Overhaul the parking brakes and correct.

Front hub bearing preload incorrect.

Adjust or replace.

Parking brake shoes not returning.

Correct or replace the brake back plate and brake shoe as necessary.

Obstructions in hydraulic circuit.

Clean

Rotor warped excessively.

Grind or replace.

Rear brake drum distorted.

Grind or replace.

Parking cable sticking.

Grind or replace.

Malfunctioning vacuum booster.

Check operation and correct as necessary.

Binding brake pedal mechanism.

Check and lubricate, if necessary.

Corroded caliper assembly.

Clean and lubricate.

Brake pads are worn.

Replace

Brake pads are hardened.

Replace

Brake pads are in poor contact with rotor.

Correct

Brake disc(s) warped, worn or damaged.

Grind or replace.

Disc brake fatigued.

Replace

anti–squeak

shims

Front hub bearings are loose or preload is incorrect.

Adjust or replace.

Brake disc is rusted.

Grind or replace.

POWER–ASSISTED BRAKE SYSTEM Condition Poor Brake Action

Possible cause

Correction

Master cylinder faulty.

Correct or replace.

Vacuum booster faulty.

Correct or replace.

Level of brake fluid in reservoir too low.

Replenish and bleed.

Air in hydraulic circuit.

Bleed

Disc brake caliper faulty.

Clean or replace.

Water or oil on brake pads.

Clean or replace.

Brake pads in poor contact with the rotor.

Correct

Brake pads worn.

Replace

Brake disc rusted.

Grind or replace.

Check valve in vacuum hose faulty.

Correct or replace.

5C–9

5C–10 POWER–ASSISTED BRAKE SYSTEM

Hydraulic Brakes Filling Master Cylinder Reservoir CAUTION: Use only specified brake fluid. Do not use any fluid which contains a petroleum base. Do not use a container which has been used for petroleum based fluids or a container which is wet with water. Petroleum based fluid will cause swelling and distortion of rubber parts in the hydraulic brake system. Water mixed with brake fluid lowers the fluid boiling point. Keep all fluid containers capped to prevent contamination. Always fill the master cylinder reservoir when the engine is cold. Never allow the brake fluid to come in contact with the painted surfaces. The master cylinder reservoir must be kept properly filled to ensure adequate reserve and to prevent air and moisture from entering the hydraulic system. However, because of expansion due to heat absorbed from the brakes and the engine, the reservoir must not be overfilled. The brake fluid reservoir is on the master cylinder, which is located under the hood on the left side of the cowl. Thoroughly clean reservoir cap before removal to avoid getting dirt into reservoir. Remove the diaphragm. Add fluid as required to bring level to the “MAX” mark on the reservoir tank. Use “DOT 3” Hydraulic Brake Fluid. If the fluid cap diaphragm is stretched, return it to the original position before installing.

Deterioration of Brake Fluid Using any other brake fluid than specified or brake fluid with mineral oil or water mixed in will drop the boiling point of brake fluid. It may, in turn, result in vapor lock or deteriorated rubber parts of the hydraulic system. Be sure to change the brake fluid at specified intervals. If the rubber parts are deteriorated, remove all the system parts and clean them with alcohol. Prior to reassembly, dry the cleaned parts with air to remove the alcohol. Replace all the hoses and rubber parts of the system.

Leakage of Brake Fluid With engine idling, set shift lever in the neutral position and continue to depress brake pedal at a constant pedal application force. Should the pedal stroke become deeper gradually, leakage from the hydraulic pressure system is possible. Perform visual inspection for any signs of leakage.

Bleeding Brake Hydraulic System A bleeding operation is necessary to remove air from the hydraulic brake system whenever air is introduced into the hydraulic system. It may be necessary to bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipes at the master cylinder. If a brake pipe is disconnected at one wheel, only that wheel cylinder/caliper needs to be bled. If the pipes are

disconnected at any fitting located between the master cylinder and brakes, then the brake system served by the disconnected pipe must be bled. 1. For 4–Wheel Antilock Brake System (ABS) equipped vehicle, be sure to remove the ABS main fuse 60A located at the relay and fuse box before bleeding air. If you attempt to bleed air without removing the main fuse, air cannot be let out thoroughly, and this may cause damage to the hydraulic unit. After bleeding air, be sure to replace the ABS main fuse back to its original position. 2. Set the parking brake completely, then start the engine. NOTE: The vacuum booster will be damaged if the bleeding operation is performed with the engine off. 3. Remove the master cylinder reservoir cap. 4. Fill the master cylinder reservoir with brake fluid. Keep the reservoir at least half full during the air bleeding operation 5. Always use new brake fluid for replenishment. 6. When replenishing the brake fluid reservoir, carefully pour in the brake fluid to prevent air bubbles from entering the brake system. When the master cylinder is replaced or overhauled, first bleed the air from the master cylinder, then from each wheel cylinder and caliper following the procedures described below. Bleeding the Master Cylinder 7. Disconnect the rear wheel brake pipe (1) from the master cylinder. Check the fluid level and replenish as necessary. If replenished, leave the system for at least one minute. 8. Depress the brake pedal slowly once and hold it depressed. 9. Completely seal the delivery port of the master cylinder with your finger, where the pipe was disconnected then release the brake pedal slowly. 10. Release your finger from the delivery port when the brake pedal returns completely. 11. Repeat steps 8 through 10 until the brake fluid comes out of the delivery port during step 8. NOTE: Do not allow the fluid level in the reservoir to go below the half–way mark. 12. Reconnect the brake pipe (1) to the master cylinder and tighten the pipe. 13. Depress the brake pedal slowly once and hold it depressed. 14. Loosen the rear wheel brake pipe (1) at the master cylinder. 15. Retighten the brake pipe, then release the brake pedal slowly. 16. Repeat steps 13 through 15 until no air comes out of the port when the brake pipe is loosened NOTE: Be very careful not to allow the brake fluid to come in contact with painted surfaces.

POWER–ASSISTED BRAKE SYSTEM

5C–11

28. After the bleeding operation is completed on the each individual wheel, check the level of the brake fluid in the reservoir and replenish up to the “MAX” level as necessary. 29. Attach the reservoir cap. If the diaphragm inside the cap is deformed, reform it and install. 30. Stop the engine.

Flushing Brake Hydraulic System

330RW012

17. Bleed the air from the front wheel brake pipe connection (2) by repeating steps 7 through 16. Bleeding the Caliper 18. Bleed the air from each wheel in the order listed below: B Right rear caliper or wheel cylinder B Left rear caliper or wheel cylinder B Right front caliper B Left front caliper Conduct air bleeding from the wheels in the above order. If no brake fluid comes out, it suggests that air is mixed in the master cylinder. In this case, bleed air from the master cylinder in accordance with steps 7 through 17, and then bleed air from the caliper or wheel cylinder. 19. Place the proper size box end wrench over the bleeder screw. 20. Cover the bleeder screw with a transparent tube, and submerge the free end of the transparent tube in a transparent container containing brake fluid. 21. Pump the brake pedal slowly three (3) times (once/sec), then hold it depressed. 22. Loosen the bleeder screw until fluid flows through the tube. 23. Retighten the bleeder screw. 24. Release the brake pedal slowly. 25. Repeat steps 21 through 24 until the air is completely removed. It may be necessary to repeat the bleeding procedure 10 or more times for front wheels and 15 or more times for rear wheels. 26. Go to the next wheel in the sequence after each wheel is bled. Be sure to monitor reservoir fluid level. 27. Depress the brake pedal to check if you feel “sponginess” after the air has been removed from all wheel cylinders and calipers. If the pedal feels “spongy”, the entire bleeding procedure must be repeated.

It is recommended that the entire hydraulic system be thoroughly flushed with clean brake fluid whenever new parts are installed in the hydraulic system. Approximately one quart of fluid is required to flush the hydraulic system. The system must be flushed if there is any doubt as to the grade of fluid in the system or if fluid has been used which contains the slightest trace of mineral oil. All rubber parts that have been subjected to a contaminated fluid must be replaced.

Brake Pipes and Hoses The hydraulic brake system components are interconnected by special steel piping and flexible hoses. Flexible hoses are used between the frame and the front calipers, the frame and rear axle case and the rear axle and the rear calipers. When the hydraulic pipes have been disconnected for any reason, the brake system must be bled after reconnecting the pipe. Refer to Bleeding the Brake Hydraulic System in this section.

Brake Hose Inspection The brake hose should be inspected at least twice a year. The brake hose assembly should be checked for road hazard, cracks and chafing of the outer cover, and for leaks and blisters. Inspect for proper routing and mounting of the hose. A brake hose that rubs on suspension components will wear and eventually fail. A light and mirror may be needed for an adequate inspection. If any of the above conditions are observed on the brake hose, adjust or replace the hose as necessary. CAUTION: Never allow brake components such as calipers to hang from the brake hoses, as damage to the hoses may occur.

5C–12 POWER–ASSISTED BRAKE SYSTEM

Front Caliper Brake Hose Front Caliper Brake Associated Parts

Hose

and

Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the brake pipes to the specified torque Torque: 19 N·m (14 lb ft) 2. Tighten the bolt to the specified torque. Torque: 35 N·m (26 lb ft) NOTE: Always use new gaskets and be sure to put the hooked edge of the flexible hose end into the anti–rotation cavity. After installing the brake hoses, bleed the brakes as described in this section.

352RW001

Legend (1) Bolt and Gasket (2) Clip (3) Hose (4) Brake Pipe

Removal 1. Raise the vehicle and support it with suitable safety stands. 2. Remove the wheel and tire assembly. 3. Clean dirt, grease, and other foreign material off the hose fittings at both ends. 4. Disconnect brake pipe. 5. Remove clip. 6. Remove bolt and gasket. 7. Remove hose.

POWER–ASSISTED BRAKE SYSTEM

5C–13

Rear Axle Brake Hose Rear Axle Brake Hose and Associated Parts

Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the brake pipes to the specified torque Torque: 19 N·m (14 lb ft) 2. Tighten the bolt to the specified torque. Torque: 15 N·m (11 lb ft) After installing the brake hoses, bleed the brakes as described in this section.

352RW002

Legend (1) Brake Pipe (2) Clip (3) Bolt (4) Brake Pipe (5) Hose

Removal 1. Raise the vehicle and support it with suitable safety stands. 2. Remove wheel and tire assembly. 3. Clean dirt, grease, and other foreign material off the hose fittings at both ends. 4. Disconnect brake pipe. 5. Remove clip. 6. Remove brake pipe. 7. Remove bolt. 8. Remove hose.

5C–14 POWER–ASSISTED BRAKE SYSTEM

Brake Pipe Removal

Installation

1. Raise the vehicle and support it with suitable safety stands. 2. Remove wheel and tire assembly as necessary. 3. Clean dirt, grease, and other foreign material off the pipe fittings at both ends. 4. Remove brake pipe (1).

To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the brake pipes to the specified torque. Master cylinder and Proportioning and Bypass valve sides Torque: 15 N·m (11 lb ft) Others Torque: 16 N·m (12 lb ft) After installing the brake pipes, bleed the brakes as described in this section.

330RW011

5. Remove plastic clip (2).

330RW002

POWER–ASSISTED BRAKE SYSTEM

5C–15

P & B (Proportioning and Bypass) Valve P & B (Proportioning and Bypass) Valve Sectional View

Removal 1. The P&B valve is not repairable and must be replaced as a complete assembly. Care must be taken to prevent brake fluid from contacting any painted surface. 2. Remove hydraulic pipes (1) and plug the pipes (1) to prevent the loss of fluid or the entrance of dirt. 3. Remove bolt (3). 4. Remove P&B valve (2).

350RW014

Legend (1) Master Cylinder (Secondary) (2) Master Cylinder (Primary) (3) Rear Brake (4) Front Brake The P&B valve contains two sections, each serving a different function. The proportioning section of the P&B valve proportions outlet pressure to the rear brakes after a predetermined rear input pressure has been reached. This is done to prevent rear wheel lock up on the vehicles with light rear wheel loads. The valve has a by–pass feature which assures full system pressure to the rear brakes in the event of front brake system malfunction. Also full front pressure is retained in the event of rear brake malfunction. The P&B valve is not repairable and must be replaced as complete assembly.

350RW026

Installation 1. Install P&B valve (2). 2. Install bolt (3) and tighten the bolt to the specified torque. Torque: 22 N·m (16 lb ft) 3. Install hydraulic pipes (1) and tighten the bolt to the specified torque. Torque: 15 N·m (11 lb ft) 4. After installing the brake pipes, bleed the brakes as refer to Bleeding Brake Hydraulic System in this section.

5C–16 POWER–ASSISTED BRAKE SYSTEM

Main Data and Specifications Torque Specifications

E05R200001

POWER–ASSISTED BRAKE SYSTEM

5C–17

Brake Pedal Checking Pedal Height The push rod serves as the brake pedal stopper when the pedal is fully released. Brake pedal height adjustment should be performed as follows:

Adjust Brake Pedal

310RY00005

NOTE: While adjusting the stoplight switch, make sure that the threaded part of the stoplight switch does not push the brake pedal. h. Tighten the stoplight switch lock nut. i. Connect the stoplight switch connector. 310RY00004

1. Measure the brake pedal height after making sure the pedal is fully returned by the pedal return spring. Pedal height must be measured after starting the engine and receiving it several times.

Checking Pedal Travel

Pedal Free Play: 6-10 mm (0.23-0.39 in) Pedal Free Play: 173-185 mm (6.81-7.28 in) NOTE: Pedal free play must be measured after turning off the engine and stepping on the brake pedal firmly five times or more. 2. If the measured value is not within the above range, adjust the brake pedal as follows: a. Disconnect the stoplight switch connector. b. Loosen the stoplight switch lock nut. c. Rotate the stoplight switch so that it moves away from the brake pedal. d. Loosen the lock nut (1) on the push rod. e. Adjust the brake pedal to the specified height by rotating the push rod in the appropriate direction. f. Tighten the lock nut to the specified torque. Torque: 20 N·m (15 lb ft) g. Adjust the stoplight switch (2) to the specified clearance (between the switch housing and the brake pedal) by rotating the switch housing. Clearance: 0.5–1.0 mm (0.02–0.04 in)

310RY00004

1. Pedal height must be measured after starting the engine and revving it several times to apply vacuum to the vacuum booster fully. NOTE: Pedal height must be 95 mm (3.7 in) or more when about 50 kg (110.25 lb) of stepping force is applied. 2. If the measured value is lower than the above range, air may still be present in the hydraulic system Perform the bleeding procedure.

5C–18 POWER–ASSISTED BRAKE SYSTEM

Brake Pedal and Associated Parts

310RY00006

Legend (1) Brake Pedal Bracket Assembly (2) Fulcrum Pin and Nut (3) Connector (4) Snap Pin (5) Return Spring

Removal 1. Disconnect the battery “–” terminal cable, and wait at least 5 minutes. 2. Disconnect the yellow 3 way SRS connector located under the steering column. 3. Remove the engine hood opening lever. 4. Remove lower cover (8). 5. Remove driver knee bolster (10). 6. Disconnect the stop light switch connector (3). Disconnect the anti-theft control module connector. Refer to Body and Accessories section in this Manual. 7. Remove snap pin (4) and push rod pin (7). 8. Remove the steering column shaft fixing bolt and nut (9) on the steering wheel side, and lower the steering column shaft. 9. Remove the brake pedal bracket assembly (1). 10. Remove return spring (5). 11. Remove fulcrum pin and nut (2).

(6) (7) (8) (9) (10)

Peadl Assembly Push Rod Pin Lower Cover Bolts and Nut Driver Knee Bolster

12. Remove pedal assembly (6).

Installation 1. Apply grease to the entire circumference of the fulcrum pin. 2. Install pedal assembly (6) and fulcrum pin and nut (2). Tighten the nut (2) to the specified torque. Torque: 35 N·m (26 lb ft) 3. Install the brake pedal bracket assembly (1). Tighten the bolts and nuts soecified torque. Torque: 15 N·m (11 lb ft) 4. Install return spring (5). 5. Adjust pedal free travel. Refer to Brake Pedal Adjustment in this section. 6. Tighten the steering column fixing bolt (9) (dash panel) to the specified torque. Torque: 20 N·m (14 lb ft)

POWER–ASSISTED BRAKE SYSTEM 7. Tighten the steering column fixing nut (9) (Cross Beam) to the specified torque. Torque: 17 N·m (12 lb ft) 8. Apply grease to the entire circumference of the Push rod pin (7). 9. Install push rod pin (7). 10. Install snap pin (4). 11. Connect the anti-theft control module connector. Refer to Body and Accessories section in this manual.

5C–19

12. Connect the stop light switch connector (3). 13. Install driver knee bolster (10) and lower cover (8). 14. Install the engine hood opening lever. 15. Connect the yellow 3 way SRS connector located under the steering column. 16. Connect the battery “–” terminal cable.

Stoplight Switch Parts Location

Installation 1. Adjust the stop light switch to the specified clearance (between switch housing and brake pedal) by rotating the switch housing. Clearance : 0-0.2 mm (0-0.08 in) NOTE: Do not attempt to force the push rod into position during the stop light switch installation and adjustment procedure.

310RW008

Legend (1) Connector (2) Switch (3) Lock Nut

Removal 1. Disconnect connector (1) 2. Remove lock nut (3). 3. Remove switch (2).

310RY00005

2. Connect connector (1). 3. Install lock nut (3).

5C–20 POWER–ASSISTED BRAKE SYSTEM

Main Data and Specifications General Specifications Pedal free play

6–10 mm (0.23 –0.39 in)

Pedal Height

173–185 mm (6.81–7.28 in)

Torque Specifications

310RY00007

POWER–ASSISTED BRAKE SYSTEM

5C–21

Fluid Reservoir Tank Fluid Reservoir Tank and Associated Parts

330RW003

(3) O–ring (4) Retainer

Legend (1) Fluid Reservoir (2) Electrical Connector

Removal

Installation

NOTE: Before removing the fluid reservoir, remove the brake fluid from the fluid reservoir.

To install, follow the removal steps in the reverse order, noting the following points: 1. O–ring (1) must be set onto the fluid reservoir (2), before installing fluid reservoir.

1. Disconnect electrical connector. 2. Remove retainer (1).

330RW005 330RW004

3. Remove fluid reservoir and the fluid level sensor built into the fluid reservoir. The fluid level sensor cannot be removed for servicing. 4. Remove O–ring.

5C–22 POWER–ASSISTED BRAKE SYSTEM

Master Cylinder Assembly Master Cylinder Assembly and Associated Parts

330RW010

Legend (1) Electrical Connector (2) Master Cylinder (3) 2 attaching Nuts

Removal CAUTION: When removing the master cylinder from the vacuum booster, be sure to get rid of the internal negative pressure of the vacuum booster (by, for instance, disconnecting the vacuum hose) in advance. If any negative pressure remains in the vacuum booster, the piston may possibly come out when the master cylinder is being removed, letting the brake fluid run out. While removing the master cylinder, further, do not hold the piston as it can be easily pulled out. Outside surface of the piston is the surface on which seals are to slide. Care should be taken to keep the surface free of cuts and dents. 1. Disconnect electrical connector. 2. Remove brake pipes and after disconnecting the brake pipe, cap or tape the openings of the brake pipe to prevent the entry of foreign matter. 3. Remove 2 attaching nuts. 4. Remove P&B valve and bracket.

(4) P&B Valve and Bracket (5) Brake Pipes (6) Spacer and 2 gaskets

5. Remove master cylinder. 6. Remove spacer and the 2 gaskets.

Inspection and Repair Master Cylinder The master cylinder is not repairable and must be replaced as a complete assembly if found defective.

Inspection Excessive brake pedal travel, malfunction or dragging brake suggests that the master cylinder is defective. In such cases perform the following visual check: Visual Check Make parts replacement as required if wear, distortion, nicks, cuts, corrosion, or other abnormal conditions are found through the following parts inspection: B Master cylinder body B Fluid reservoir B O–ring

POWER–ASSISTED BRAKE SYSTEM

5C–23

Functional Inspection of Master Cylinder Piston Push the primary piston (1) with your fingers to check that it travels smoothly. If the motion is questionable, replace the master cylinder as a complete assembly.

330RW009

NOTE: When checking the front (or primary) side, be sure to mount the master cylinder plug in the rear (or secondary) port. “0” Line 330RW007

Functional Inspection of Master Cylinder Inspect the master cylinder for functionality described below. Replace if necessary. Install the primary piston holder (3) J–39242 (including the master cylinder attachment (5) and master cylinder plug (7)) onto the master cylinder (4). Make sure the spacer (2) (2 bolts) with its adjusting bolt is screwed in up to the “0” line

“5” Line

Apply air pressure to the front and rear ports

No pressure rise.

Pressure increase of 0.5 kg/cm2 or more

Remarks

Checks port into the atmospheric pressure chamber

Checks air tightness of the pressure chamber

NOTE: 1. Do not use an air compressor, as the air from the compressor is mixed with compressor oil. 2. When installing the master cylinder onto the vacuum booster, always adjust the vacuum booster push rod. (Refer to Vacuum Booster in this section). 3. After the master cylinder is installed onto the vehicle, check for leakage, pedal travel and pedal free play.

Installation 1. Install spacer and the 2 gaskets. 2. Install master cylinder. When replacing the master cylinder or vacuum booster or both, always measure the vacuum booster push rod protrusion and adjust it as necessary (Refer to Vacuum Booster in section). 330RW008

Connect the master cylinder attachment (5) J–39242 with the end of the radiator cap tester (6) J–24460–01, and apply air pressure with the cap tester. Make sure there is no rise in pressure while adjusting the bolt to the “5” line. There should be a pressure increase of 0.5 kg/cm2 or more.

3. Install P&B valve and bracket. 4. Install 2 attaching nuts and tighten the attaching nuts to the specified torque. Torque: 13 N·m (113 lb in)

5C–24 POWER–ASSISTED BRAKE SYSTEM 5. Install brake pipes and tighten the brake pipe to the specified torque. Master cylinder and P&B valve sides

Special Tools ILLUSTRATION

Torque: 15 N·m (11 lb ft)

TOOL NO. TOOL NAME

Others Torque: 16 N·m (12 lb ft)

J-39242 Primary Piston Holder (including master cylinder attachment and master cylinder plug

6. Connect electrical connector.

Main Data and Specifications General Specifications Type

Dual–circuit

Piston bore diameter

25.4 mm (1.000 in)

J-24460-01 Radiator Cap Tester

Torque Specifications

E05R200002

POWER–ASSISTED BRAKE SYSTEM

5C–25

Vacuum Booster Assembly Vacuum Booster Assembly and Associated Parts

331RW005

Legend (1) Pin (2) Vacuum Booster Fixing Nut (3) Vacuum Hose

Removal 1. Before removing the vacuum booster assembly, disconnect and remove the brake pipes. 2. Remove master cylinder, refer to Master Cylinder Removal in this section. CAUTION: When removing the master cylinder from the vacuum booster, be sure to get rid of the internal negative pressure of the vacuum booster (by, for instance, disconnecting the vacuum hose) in advance. If any negative pressure remains in the vacuum booster, the piston may possibly come out when the master cylinder is being removed, letting the brake fluid run out. Do not hold the piston while removing the master cyliner, the piston can be easily pulled out. Outside surface of the piston is the surface on which seals are to slide. Care should be taken to keep the surface free of cuts and dents. 3. Remove vacuum hose.

(4) Master Cylinder (5) Vacuum Booster (6) Snap Pin

4. Disconnect the yoke clevis from the brake pedal. 5. Remove vacuum booster fixing nut. 6. Remove vacuum booster.

5C–26 POWER–ASSISTED BRAKE SYSTEM

Inspection and Repair

Installation

Vacuum Hose (The built in check valve) 1. Inspect the check valve (2), which is installed inside the vacuum hose. 2. Air should pass freely from the vacuum booster (3) to the engine (1). 3. Air should not pass from the engine (1) to the vacuum booster (3). If it does, the check valve is inoperative and the vacuum hose built in the check valve must be replaced.

1. Perform vacuum booster and vacuum booster push rod adjustment. NOTE: When replacing either the master cylinder or vacuum booster, be sure to measure push rod, and adjust if required. 2. Remove retainer from vacuum booster front shell using a small screwdriver. Then gently draw plate and seal assembly out of the shell inside.

331RS003

360RY00004

3. Set push rod gauge J–39216 on vacuum booster, and apply negative pressure by means of vacuum pump J–23738–A so that the pressure in the vacuum booster becomes 500 mm Hg. NOTE: Be sure to apply NEGATIVE pressure after installing a push rod gauge on the vacuum booster.

331RS004

POWER–ASSISTED BRAKE SYSTEM 4. Measure dimension (4). Dimension (4) (Standard): –0.1–0.1 mm (–0.0039–0.0039 in)

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5. If dimension (4) is out of the standard range, adjust push rod using the Push Rod Support J–39241.

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6. Mount plate and seal assembly in vacuum booster front shell. Then install the retainer. 7. Install vacuum booster fixing nut and tighten the specified torque. Torque: 15 N·m (11 lb ft) 8. Install yoke clevis. 9. Connect vacuum hose and make sure that the arrow on the hose points in the direction of the engine. 10. Install master cylinder, refer to Master Cylinder Installation in this section.

5C–27

5C–28 POWER–ASSISTED BRAKE SYSTEM

Exterior Components Exterior Components and Associated Parts

331RW006

Legend (1) Yoke Clevis (2) Lock Nut (3) Retaining Clip (4) Valve Body Guard (5) Silencer

(6) (7) (8) (9) (10) (11)

Filter 2 Gaskets and Spacer Vacuum Booster Retainer Plate and Seal Assembly Master Cylinder

Removal 1. Remove master cylinder. Refer to Master Cylinder in this section. 2. Remove vacuum booster. Refer to Vacuum Booster in this section. 3. Remove yoke clevis. 4. Remove lock nut. 5. Remove retaining clip. 6. Remove valve body guard. 7. Remove silencer. 8. Remove filter. 9. Remove 2 gaskets and spacer. 10. Remove retainer, using a small screwdriver to pry out the retainer. Gently pull out the plate and seal assembly from the shell. 331RS003

POWER–ASSISTED BRAKE SYSTEM

Inspection and Repair Visual Check Make necessary parts replacement if cuts, nicks, excessive wear, or other abnormal conditions are found through inspection. Check the following parts: B Yoke clevis B Valve body guard B Silencer B Filter plate and seal assembly

Installation 1. Install plate and seal assembly. 2. Install retainer.

3. Install 2 gaskets and spacer. 4. Install filter. 5. Install silencer. 6. Install valve body guard. 7. Install retainer. 8. Install lock nut and yoke clevis and tighten to the specified torque. Torque: 20 N·m (15 lb ft) 9. Install vacuum booster, refer to Vacuum Booster in this section. 10. Install master cylinder, refer to Master Cylinder in this section and after installation, perform brake pedal check and adjustment. Refer to Brake Pedal in this section.

Vacuum Booster Overhaul Vacuum Booster The vacuum booster cannot be disassembled for repair. Replace a defective vacuum booster with a new one.

5C–29

5C–30 POWER–ASSISTED BRAKE SYSTEM

Main Data and Specifications General Specifications Vacuum booster diaphragm diameter (Front)

205 mm (8.07 in)

Vacuum booster diaphragm diameter (Rear)

230 mm (9.06 in)

Push rod stroke

More than 32.0 mm (1.26 in)

Plunger diameter

10.25 mm (0.40 in)

Push rod diameter

27.4 mm (1.08 in)

Torque Specifications

330R200001

POWER–ASSISTED BRAKE SYSTEM

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

J-39216 Push Rod Gauge

J-23738-A Vacuum Pump

J-39241 Push Rod Support

5C–31

5C–32 POWER–ASSISTED BRAKE SYSTEM

Front Disc Brake Pads Front Disc Brake Pads Inspection Check the outer pad by looking at each caliper from above. Check the thickness on the inner pad by looking down through the inspection hole on the top of the caliper. Whenever the pad is worn to about the thickness of the pad base, the pad should be removed for further measurements. The pad should be replaced anytime the pad thickness (1) is worn to within 1.00 mm (0.039 in) of the pad itself. Wear indicators are installed on disc brake pads, disc brake pads need replacement when the wear indicator is heard. Minimum limit (1): 1.0 mm (0.039 in)

302RS002

Front Disc Brake Pads and Associated Parts

302RW003

Legend (1) Lock Bolt (2) Caliper Assembly

(3) Pad Assembly (4) Clip (5) Outer Side

POWER–ASSISTED BRAKE SYSTEM

Removal

5C–33

Installation

NOTE: If a squealing noise occurs from the front brake while driving, check the pad wear indicator plate. If the indicator plate contacts the rotor, the disc pad assembly should be replaced.

1. Install clip.

B Draw out two–thirds of the brake fluid from the reservoir. B Raise the vehicle and support it with suitable safety stands. 1. Remove wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 2. Remove lock bolt (1).

302RS005

2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (2). Wipe off extruded grease after installing. Install pad assembly with shim.

302RW004

3. Rotate caliper assembly and support the caliper assembly so that the brake hose is not stretched or damaged. 4. Remove pad assembly with shim. 5. Remove Clip.

302RW005

Legend (2) Inner Shim (3) Wear Indicator (4) Inner Side

5C–34 POWER–ASSISTED BRAKE SYSTEM

302RW006

3. Carefyully use adjustable pliers to bottom the piston into the caliper bore. Do not pull or twist the flexible hose or damage will occur. Install caliper assembly. Set caliper assembly in place.

302RS008

4. Install lock bolt (5) and tighten the bolt to the specified torque. Torque: 74 N·m (54 lb ft)

302RW018

5. Install wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 6. Pump the brake pedal several times to make sure that the pedal is firm. Check the brake fluid level in the reservoir after pumping the brakes.

POWER–ASSISTED BRAKE SYSTEM

5C–35

Front Disc Brake Rotor Inspection

Parallelism

In the manufacturing of the brake rotor, all the tolerances regarding surface finish, parallelism and lateral runout are held very closely. Maintaining these tolerances provides the surface necessary to assure smooth brake operation.

Parallelism is the measurement of thickness of the rotor at four or more points around the circumference of the rotor. All measurement must be made at 29 mm (1.14 in) from the edge of the rotor. The rotor thickness must not vary more than 0.010 mm (0.0004 in) from point to point. Maximum runout: 0.010 mm (0.0004 in)

Lateral Runout Lateral runout is the movement of the rotor from side to side as it rotates on the spindle. This could also be referred to as “rotor wobble”. This movement causes the piston to be knocked back into its bore. This results in additional pedal travel and a vibration during braking.

Checking Lateral Runout 1. Adjust the wheel bearing correctly, refer to Differential in Section 4A1. 2. Attach the dial indicator accordingly so that the stem contacts the rotor surface to approximately 29mm (1.14 in) from the rotor edge. 3. Rotate the rotor one complete turn and inspect for signs of lateral runout. Lateral runout should not exceed 0.13 mm (0.005 in). Maximum runout: 0.13 mm (0.005 in)

411RS018

Replacing Brake Rotors When installing new brake rotors, do not refinish the surfaces. These parts are at the correct level of surface finish.

Refinishing Brake Rotors

411RS019

Accurate control of the rotor tolerances is necessary for proper performance of the disc brakes. Machining of the rotor should be done only with precision equipment. All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. The minimum wear dimension is 24.60 mm (0.969 in). The minimum refinish dimension is 24.97 mm (0.983 in). When refinishing rotors, always use sharp cutting tools or bits. Dull or worn tools leave a poor surface finish which will affect initial braking performance. Vibration dampening attachments should always be used when refinishing braking surfaces. These attachments eliminate tool chatter and will result in better surface finish. After refinishing, replace any rotor that does not meet the minimum thickness of 24.97 mm (0.983 in). Do not use a brake rotor that exceeds the manufacturers specifications. Minimum wear dimension: 24.60 mm (0.969 in) Refinish dimension: 24.97 mm (0.983 in)

5C–36 POWER–ASSISTED BRAKE SYSTEM

411RW003

Front Disc Brake Caliper Assembly Front Disc Brake Caliper Assembly and Associated Parts

302RW008

Legend (1) Guide Bolt (2) Brake Flexible Hose (3) Lock Bolt

(4) (5) (6) (7)

Caliper Assembly Clip Support Bracket with Pad Assembly Pad Assembly

POWER–ASSISTED BRAKE SYSTEM

Removal 1. Raise the vehicle and support with suitable safety stands. 2. Concernig wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 3. Remove the bolt and gaskets, then disconnect the flexible hose from the caliper and after disconnecting the flexible hose (1), cap or tape the openings to prevent entry of foreign material.

5C–37

9. Remove pad assembly with shim and mark the lining locations if they are to be reinstalled. 10. Remove clip.

Installation 1. Install clip.

302RS005

302RW009

4. Since the brake fluid flows out from the connecting coupler, place a drain pan under the vehicle. 5. Remove guide bolt (2). 6. Remove lock bolt (3).

2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (4). Wipe off extruded grease after installing. Install pad assembly with shim.

302RW011

302RW010

7. Remove caliper assembly. 8. Remove support bracket with pad assembly and take care not to damage the flexible brake hose when removing the support bracket.

Legend (4) Inner Shim (5) Wear Indicator (6) Inner Side

5C–38 POWER–ASSISTED BRAKE SYSTEM 3. Install support bracket and tighten the bolt (7) to the specified torque. Torque: 155 N·m (115 lb ft)

6. Install brake flexible hose, always use new gaskets and be sure to put the hooked edge of the flexible hose end into the anti–rotation cavity then tighten the I–bolt (10) to the specified torque. Torque: 35 N·m (26 lb ft)

302RW012

4. Install caliper assembly. 5. Install lock bolt (9) and guide bolt (8) and tighten the bolt to the specified torque. Torque: 74 N·m (54 lb ft)

302RW013

302RW014

7. Install wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 8. Bleed brakes. Refer to Hydraulic Brakes in this section.

POWER–ASSISTED BRAKE SYSTEM

5C–39

Front Disc Brake Caliper Front Disc Brake Caliper Disassembled View

302RW015

Legend (1) Guide Bolt (2) Lock Bolt (3) Bleeder with Cap (4) Caliper Body

(5) (6) (7) (8) (9)

Dust Boot: Guide Bolt and Lock Bolt Piston Seal Piston Dust Boot: Piston Dust Boot Ring

Disassembly 1. Remove guide bolt. 2. Remove lock bolt. 3. Remove dust boot: guide bolt and lock bolt. 4. Remove dust boot ring, using a small screwdriver.

302RS016

5C–40 POWER–ASSISTED BRAKE SYSTEM 5. Insert a block of wood into the caliper and force out the piston by blowing compressed air into the caliper at the flexible hose attachment. This procedure must be done prior to removal of the dust boot. Remove piston. WARNING: DO NOT PLACE YOUR FINGERS IN FRONT OF THE PISTON IN AN ATTEMPT TO CATCH OR PROTECT IT WHEN APPLYING COMPRESSED AIR. THIS COULD RESULT IN PERSONAL INJURY. CAUTION: Use just enough air to ease the piston out of the bore. If the piston is blown out, it may be damaged.

Reassembly 1. Install caliper body. 2. Install bleeder with cap and tighten the cap to the specified torque. Torque: 8 N·m (69 lb in) 3. Apply special rubber grease to the piston seal and cylinder wall, then insert the piston seal into the cylinder. The special rubber grease is included in the repair kit.

302RS018

302RS017

6. Remove dust boot: piston. 7. Remove piston seal. 8. Remove bleeder with cap. 9. Remove caliper body.

4. When inserting the piston into the cylinder, use finger pressure only and do not use a mallet or other impact tool, since damage to the cylinder wall or piston seal can result. Install piston.

Inspection and Repair Make necessary parts replacement, if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: B Rotor B Cylinder body B Cylinder bore B Piston B Guide bolt, lock bolt B Support bracket NOTE: The piston seal, boot ring and dust boot are to be replaced each time the caliper is overhauled. Discard these used rubber parts and replace them with new ones. 302RS019

POWER–ASSISTED BRAKE SYSTEM 5. Apply special grease (approximately 1 g) to the piston and attach the dust boot to the piston and caliper. Insert the dust boot ring into the dust boot.

302RS020

6. Install guide bolt and lock bolt dust boot. 7. Install the dust boot on the support bracket after applying special grease (approximately 1 g) onto the dust boot inner surface. Apply special grease onto the lock bolt and guide bolt setting hole of the support bracket.

302RS021

8. Install lock bolt and guide bolt and tighten the bolt to the specified torque. Torque: 74 N·m (54 lb ft)

5C–41

5C–42 POWER–ASSISTED BRAKE SYSTEM

Main Data and Specifications General Specifications Type

Floating, pin slide

Pad dimension

55 cm@ (8.52 in@)

Adjusting method Piston diameter Disc type

Self–adjusting 60.33 mm (2.38 in) Ventilated

Disc thickness

26 mm (1.02 in)

Disc effective diameter

222 mm (8.74 in)

Torque Specifications

E05RW004

POWER–ASSISTED BRAKE SYSTEM

5C–43

Rear Disc Brake Pads (4×4 Model) Brake Pads Inspection Check the outer pads by looking at each caliper from above. Check the thickness on the inner pad by looking down through the inspection hole in the top of the caliper. Whenever the pad is worn to about the thickness of the pad base, the pad should be removed for further measurements. The pad should be replaced anytime the pad thickness (1) is worn to within 1.0 mm (0.039 in) of the pad itself. Wear indicators are installed on disc brake pads, disc brake pads need replacement when the wear indicator is heard. Minimum limit (1): 1.0 mm (0.039 in)

302RW016

Brake Pads and Associated Parts

306RW001

Legend (1) Caliper Assembly (2) Clip

(3) Lock Bolt (4) Pad Assembly

5C–44 POWER–ASSISTED BRAKE SYSTEM

Removal

Installation

NOTE: If a squealing noise occurs from the rear brake while driving, check the pad wear indicator plate. If the indicator plate contacts the rotor, the disc pad assembly should be replaced.

1. Install clip (2).

306RW003

2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims. Wipe off extruded grease after installing. Install pad assembly with shim.

306RW002

3. Rotate caliper assembly and support the caliper assembly so that the brake hose is not stretched or damaged. 4. Remove pad assembly with shim. 5. Remove clip.

306RW004

Legend (3) Inner Shim (4) Wear Indicator

POWER–ASSISTED BRAKE SYSTEM

306RW005

3. Carefyully use adjustable pliers to bottom the piston into the caliper bore. Do not pull or twist the flex hose or damage will occur.

302RS008

4. Install lock bolt (5) and tighten the bolt to the specified torque. Torque: 44 N·m (32 lb ft) 5. Install wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 6. Pump the brake pedal several times to make sure that the pedal is firm. Check the brake fluid level in the reservoir after pumping the brakes.

5C–45

306RW006

5C–46 POWER–ASSISTED BRAKE SYSTEM

Rear Disc Brake Rotor (4×4 Model) Inspection

Parallelism

Parallelism is the measurement of thickness of the rotor at four or more points around the circumference of the rotor. All measurement must be made at 22 mm (0.87 in) from the edge of the rotor. The rotor thickness must not vary more than 0.010 mm (0.0004 in) from point to point. Maximum parallelism: 0.010 mm (0.0004 in)

Replacing Brake Rotors When installing new brake rotors, do not refinish the surfaces. These parts are at the correct level of surface finish.

Refinishing Brake Rotors

306RY00013

Accurate control of the rotor tolerances is necessary for proper performance of the disc brakes. Machining of the rotor should be done only with precision equipment. All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. The minimum wear dimension is 16.6 mm (0.654 in). The minimum refinish dimension is 16.97 mm (0.668 in). When refinishing rotors, always use sharp cutting tools or bits. Dull or worn tools leave a poor surface finish which will affect initial braking performance. Vibration dampening attachments should always be used when refinishing braking surfaces. These attachments eliminate tool chatter and will result in better surface finish.

POWER–ASSISTED BRAKE SYSTEM After refinishing, replace any rotor that does not meet the minimum thickness of 16.97 mm (0.668 in). Do not use a brake rotor that exceeds the manufacturers specifications. Minimum wear dimension: 16.6 mm (0.654 in) Refinish dimension: 16.97 mm (0.668 in)

420RW002

Rear Drum (In Disc) Inside Diameter Check Check the rear drum inside diameter by measuring at more than two portions as shown in the illustration. If the inside diameter is greater than the limit, replace the rear rotor. Standard: 210.0 mm (8.27 in) Limit: 211.4 mm (8.32 in)

420RS035

5C–47

5C–48 POWER–ASSISTED BRAKE SYSTEM

Rear Disc Brake Caliper Assembly (4×4 Model) Rear Disc Brake Caliper Assembly and Associated Parts

306RW007

(4) (5) (6) (7)

Legend (1) Brake Flexible Hose (2) Clip (3) Lock Bolt

Removal 1. Raise the vehicle and support with suitable safety stands. 2. Remove wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 3. Remove the bolt and gaskets, then disconnect the flexible hose from the caliper and after disconnecting the flexible hose (1), cap or tape the openings to prevent entry of foreign material.

Support Bracket Guide Bolt Pad Assembly with Shim Caliper Assembly

5. Remove lock bolt (3). 6. Remove guide bolt (2).

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306RW008

4. Since the brake fluid flows out from the connecting coupler, place a drain pan under the vehicle.

7. Remove caliper assembly. 8. Remove support bracket with pad assembly and take care not to damage the flexible brake hose when removing the support bracket. 9. Remove pad assembly with shim and mark the lining locations if they are to be reinstalled. 10. Remove clip.

POWER–ASSISTED BRAKE SYSTEM

5C–49

3. Install support bracket and tighten the bolt (7) to the specified torque.

Installation 1. Install clip (4).

Torque: 103 N·m (76 lb ft)

306RW010

2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (5). Wipe off extruded grease after installing. Install pad assembly with shim.

306RW012

4. Install caliper assembly. 5. Install lock bolt and guide bolt (8) and tighten the bolt to the specified torque. Torque: 44 N·m (32 lb ft)

306RW011

Legend (5) Inner Shim (6) Wear indicator

306RW013

6. Install brake flexible hose, always use new gaskets and be sure to put the hooked edge of the flexible hose end into the anti–rotation cavity then tighten the eye–bolt (9) to the specified torque. Torque: 35 N·m (26 lb ft)

5C–50 POWER–ASSISTED BRAKE SYSTEM 7. Install the wheel and tire assembly, refer to Wheels and Tires System in Section 3E. 8. Bleed brakes. Refer to Hydraulic Brakes in this section.

302RW017

Rear Disc Brake Caliper (4×4 Model) Rear Disc Brake Caliper Disassembled View

306RW014

Legend (1) Guide Bolt (2) Lock Bolt (3) Bleeder with Cap (4) Caliper Body

(5) (6) (7) (8) (9)

Piston Seal Piston Dust Boot: Piston Dust Boot Ring Dust Boot: Guide Bolt and Lock Bolt

POWER–ASSISTED BRAKE SYSTEM

Disassembly 1. Remove guide bolt. 2. Remove lock bolt. 3. Remove dust boot; guide bolt and lock bolt. 4. Remove dust boot ring, using a small screwdriver.

5C–51

6. Remove dust boot: piston. 7. Remove piston seal. 8. Remove bleeder with cap. 9. Remove caliper body.

Inspection and Repair Make necessary parts replacement, if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: B Rotor B Cylinder body B Cylinder bore B Piston B Guide bolt, lock bolt B Support bracket NOTE: The piston dust seal and dust boot are to be replaced each time the caliper is overhauled. Discard these used rubber parts and replace with new ones.

Reassembly 302RS016

5. Insert a block of wood into the caliper and force out the piston by blowing compressed air into the caliper at the flexible hose attachment. This procedure must be done prior to removal of the dust boot. Remove piston. WARNING: DO NOT PLACE YOUR FINGERS IN FRONT OF THE PISTON IN AN ATTEMPT TO CATCH OR PROTECT IT WHEN APPLYING COMPRESSED AIR. THIS COULD RESULT IN PERSONAL INJURY.

1. Install caliper body. 2. Install bleeder with cap and tighten the cap to the specified torque. Torque: 8 N·m (69 lb ft) 3. Install piston seal and apply special rubber grease to the piston seal and cylinder wall, then insert the piston seal into the cylinder. The special rubber grease is included in the repair kit.

CAUTION: Use just enough air to ease the piston out of the bore. If the piston is blown out, it may be damaged.

302RS018

4. When inserting the piston into the cylinder, use finger pressure only and do not use a mallet or other impact tool, since damage to the cylinder wall or piston seal can result. Install piston. 302RS017

5C–52 POWER–ASSISTED BRAKE SYSTEM

302RS019

5. Apply special grease (approximately 1g) to the piston and attach the dust boot to the piston and caliper. Insert the dust boot ring into the dust boot.

302RS020

6. Install guide bolt and lock bolt dust boot. 7. Install the dust boot on the support bracket after applying special grease (Approx. 1g) onto the dust boot inner surface. Also apply special grease onto the lock bolt and guide bolt setting hole of the support bracket.

302RS021

8. Install lock bolt and guide bolt and tighten the bolt to the specified torque. Torque: 44 N·m (32 lb ft)

POWER–ASSISTED BRAKE SYSTEM

5C–53

Main Data and Specifications (4×4 Model) General Specifications Type

Floating, pin slide

Pad dimension

33 cm@ (5.11 in@)

Adjusting method Piston diameter Disc type Disc thickness Disc effective diameter

Self–adjusting 41.3 mm (1.63 in) Ventilated 18 mm (0.71 in) 269.2 mm (10.60 in)

Torque Specifications

E05RW005

5C–54 POWER–ASSISTED BRAKE SYSTEM

Brake Lining Brake Lining and Associated Parts

305RW001

Legend (1) Wheel and Tire Assembly (2) Drum (3) Hold-down Spring and Cup (4) Hold-down Spring and Cups (5) Lower Return Spring (6) Upper (other) Return Spring (7) Trailing Shoe Assembly with Parking Brake Lever (8) Leading Shoe Assembly with Upper (inner) Return Spring

Removal 1. Raise the vehicle and support with suitable safety stands. 2. Remove wheel and tire assembly (1). B Refer to “Wheel and Tires” in Wheel and Tire System section. 3. Remove Drum (2). B If difficulty is encountered in removing the drum: – Mark the position of the drum to the axle. – Make sure the parking brake is released.

(9) (10) (11) (12) (13) (14) (15) (16)

Upper (inner) Return Spring Auto Adjuster Lever Parking Brake Lever Adjuster Assembly Wave Washer Retainer Hold-down Pin Hold-down Pin

– Use a rubber mallet to tap gently on the outer rim of the drum and/or around the inner drum. Be careful to avoid damaging the drum. 4. Remove upper (other) return spring (6) and auto adjuster lever. 5. Remove lower return spring (5). 6. Remove hold-down spring and cups (4) and hold-down pin (15). 7. Remove adjuster assembly (12) 8. Remove leading shoe assembly (8) with upper (inner) return spring (9).

POWER–ASSISTED BRAKE SYSTEM NOTE: Do not over stretch the return spring.

5C–55

Installation 1. Apply grease lightly to back place A.

305RS003

9. Remove upper (inner) return spring (9). 10. Remove hold-down spring and cup (3) and hold-down pin (16). 11. Remove Trailing shoe assembly (7) with parking brake lever (16). 12. Remove parking brake cable from parking brake lever (11). 13. Remove retainer (14), wave washer (13), and parking brake lever (11).

Brake Lining Inspection Check the shoe assemblies for wear by removing brake drum. Replace the shoe assemblies, if lining thickness is less than 1.0 mm (0.039 in). The shoe assemblies have a wear indicator that makes a noise when the linings wear to a degree where replacement is required. Minimum limit: 1.0 mm (0.039 in)

305RW002

Legend (1) Place A (3 portions for each side) 2. Install parking brake lever (11), wave washer (13), and retainer (14). 3. Install trailing shoe assembly (7) with parking brake lever (16). 4. Install the parking brake cable to parking brake lever (11). 5. Install hold-down pin (16) and hold-down spring and cup (3). 6. Install upper (inner) return spring (9). 7. Install leading shoe assembly (8) with upper (inner) return spring (9). NOTE: Do not over stretch the return spring.

305RS003

305RS001

8. Install adjuster assembly (12). 9. Install hold-down pin (15) and hold-down spring and cups (4).

5C–56 POWER–ASSISTED BRAKE SYSTEM 10. Install lower return spring (5). B Use brake spring tool. 11. Install auto adjuster lever (10). 12. Install upper (outer) return spring (6). B Use brake spring tool. 13. Install brake drum (2). B Adjust the brakes, refer to Drum Brake Adjustment in this section. 14. Install wheel and tire assembly (1). B Refer to “Wheels and Tires ” in wheel and Tire System section.

Drum Brake Adjustment (4×2 Model) NOTE: All brakes are self-adjusting. Brakes are adjusted by repeated stepping on the brake pedal. (After stepping on the pedal and releasing it, the rear auto adjuster, in the rear brake, produces a clicking sound. The same operation should be repeated until the sound disappears.) Take the following steps after overhauling the rear brake assembly. 1. Move the parking brake handle to its fully released position. 2. Parking cable must be loosened sufficiently. (Loosen the adjust nut and the lock nut.) 3. Repeat stepping on the brake pedal firmly, and releasing it until the clicking sound can no longer be heard. If the difference between the brake drum inside diameter and diameter of the brake shoes is adjusted to be 0,5 mm, the number of times for depressing the brake pedal can be reduced. 4. Remove the drum. Measure the brake drum inside diameter and diameter of the brake shoes. Shoe clearance: 0.25-0.4 mm (0.0098-0.0157 in) If incorrect, check the brake auto-adjusting system.

Servicing The Brake Drum Whenever the brake drums are removed, they should be thoroughly cleaned and inspected for cracks, scores, deep grooves and out-of-round.

Cracked, Scored or Grooved Drum A cracked drum is unsafe and must be replaced. Do not attempt to weld a cracked drum. Smooth any slight scores. Heavy or extensive scoring will cause excessive brake lining wear, and it will probably be necessary to machine the drum braking surface. If the brake linings are slightly worn and the drum is grooved, the drum should be polished with fine emery cloth but should not be machined. At this stage, eliminating all the grooves in the drum and smoothing the ridges on the lining would require the removal of too much metal and lining. If left alone, the grooves and ridges match and satisfactory service can be obtained. If brake linings are to be replaced, a grooved drum should be machined. Using a grooved drum with new linings will create inefficient braking performance and cause the linings to wear quicker.

Out-Of-Round Drum An out-of-round drum makes accurate brake shoe adjustment impossible and is likely to cause excessive wear to other parts of the brake mechanism due to its eccentric action. An out-of-round drum can also cause severe and irregular tire tread wear as well as a pulsing brake pedal. When the braking surface of a brake drum exceeds the specification limit of 0.15 mm (0.006 in) in out-of-round, the drum should be machined to true up the braking surface. Out-of-round can be accurately measured with an inside micrometer fitted with proper extension rods. When measuring a drum for out-of-round and wear, take measurements at the open and closed edges of machines surfaces and at right angles to each other. Maximum out-of-round: 0.15 mm (0.006 in)

5. Rotate the adjust nut until all slack disappears from the cable. Set the adjust nut. 6. Applying about 30 kg (66 lb) of force, pull the parking brake handle to its fully set position three or four times. 7. If the parking brake is properly adjusted, the travel between the fully disengaged position and the fully engaged position will be between 9 and 11 notches. If the traveling range is not within these limits, again repeat steps 1 through 5. After adjusting has been done, check to see if the rear wheel rotates smoothly without drag when turned by hand.

420RS034

POWER–ASSISTED BRAKE SYSTEM

Machining The Drum If a drum is to be machined, only enough metal should be removed to obtain a true, smooth braking surface. If a drum does not clean-up when machined to a maximum diameter, it must be replaced. Removal of more metal will

5C–57

affect dissipation of heat and may cause distortion of the drum. After refinishing, replace any drum that exceeds a maximum inside diameter of 296.5 mm (11.673 in). Do not use a brake drum that is not within the specification. Maximum inside diameter: 296.5 mm (11.673 in)

Wheel Cylinder Assembly (4×2 Model) Wheel Cylinder Assembly and Associated Parts

305RW003

Legend (1) Brake Linings (2) Wheel Cylinder

Removal 1. Remove brake linings (1). B Refer to Brake Lining and Associated Parts in this section. 2. Remove brake pipe (4). B Plug the opening in the line to prevent fluid loss and contamination. 3. Remove bolts (3) and wheel cylinder (2).

(3) Bolts (4) Brake Pipe

Installation 1. Install wheel cylinder (2) and tighten bolts (3) to the specified torque. Torque: 10 N·m (8 lb ft) 2. Install brake pipe (4) and tighten the nut to the specified torque. Torque: 16 N·m (12 lb ft) 3. Install brake linings (1). B Refer to Brake Lining Replacement in this section. B Bleed brake system. Refer to Hydraulic Brake in this section.

5C–58 POWER–ASSISTED BRAKE SYSTEM NOTE: Replace the piston cups and boots each time the wheel cylinder is overhauled. Discard these used rubber parts and replace with new ones.

Disassembled View

Reassembly 1. Lubricate the cylinder bore with clean rubber grease.

305RS006

Legend (1) Boot (2) Piston Assembly (3) Piston Cup (4) Return Spring (5) Bleeder (6) Wheel Cylinder

305RS007

2. Install bleeder (5) to wheel cylinder (6). Torque: 10 N·m (8 lb ft)

Disassembly 1. Remove boot (1) and piston assembly (2). 2. Remove piston cup (3) from piston assembly (2). 3. Remove return spring (4) and bleeder (5) from wheel cylinder (6).

305RS008

POWER–ASSISTED BRAKE SYSTEM 3. Install new piston cups (3) on each piston so that the flared end of the cups are turned to the inboard side of the pistons. Attach the return spring (4) and the boot (1) to the piston.

305RS009

4. Apply DELCO silicone lube No. 5459912 (or equivalent) to the piston and the inner face of the boots. 5. Install piston assembly (2) to wheel cylinder (6).

5C–59

5C–60 POWER–ASSISTED BRAKE SYSTEM

Main Data and Specifications General Specifications Rear drum brake Type

Leading-trailing, non-servo

Drum inside diameter

295 mm (11.6 in)

Wheel cylinder diameter

22.22 mm (7/8 in)

Torque Specifications

E05RW010

POWER–ASSISTED BRAKE SYSTEM

5C–61

AXIOM (Vehicles Produced After Aug./1/2001)

POWER-ASSISTED BRAKE SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . Filling Master Cylinder Reservoir . . . . . . . . Deterioration of Brake Fluid . . . . . . . . . . . . . Leakage of Brake Fluid . . . . . . . . . . . . . . . . . Bleeding Brake Hydraulic System . . . . . . . . Flushing Brake Hydraulic System . . . . . . . . Brake Pipes and Hoses . . . . . . . . . . . . . . . . Brake Hose Inspection . . . . . . . . . . . . . . . . . Front Caliper Brake Hose . . . . . . . . . . . . . . . . Front Caliper Brake Hose and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle Brake Hose . . . . . . . . . . . . . . . . . . . Rear Axle Brake Hose and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . P & B (Proportioning and Bypass) Valve . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Pedal Height . . . . . . . . . . . . . . . . . Checking Pedal Travel . . . . . . . . . . . . . . . . . Brake Pedal and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stoplight Switch . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Master Cylinder Assembly . . . . . . . . . . . . . . . . Master Cylinder Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5C–62 5C–62 5C–66 5C–67 5C–70 5C–70 5C–70 5C–70 5C–70 5C–71 5C–71 5C–71 5C–72 5C–72 5C–72 5C–72 5C–73 5C–73 5C–73 5C–73 5C–74 5C–74 5C–74 5C–75 5C–75 5C–75 5C–76 5C–77 5C–77 5C–77 5C–78 5C–78 5C–78 5C–79 5C–79 5C–79 5C–79 5C–80 5C–81 5C–81 5C–81 5C–81

Master Cylinder Assembly . . . . . . . . . . . . . . . . Master Cylinder Assembly Desassembled View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Desassembly . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Vacuum Booster Assembly . . . . . . . . . . . . . . . Vacuum Booster Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Exterior Components . . . . . . . . . . . . . . . . . . . . Exterior Components and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum Booster Overhaul . . . . . . . . . . . . . . . . Vacuum Booster . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Front Disc Brake Pads . . . . . . . . . . . . . . . . . . . Front Disc Brake Pads Inspection . . . . . . . . Front Disc Brake Pads and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brake Rotor . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Brake Rotors . . . . . . . . . . . . . . . . Refinishing Brake Rotors . . . . . . . . . . . . . . . Front Disc Brake Caliper Assembly . . . . . . . . Front Disc Brake Caliper Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Disc Brake Caliper . . . . . . . . . . . . . . . . . Front Disc Brake Caliper Disassembled View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Rear Disc Brake Pads (4×4 Model) . . . . . . . .

5C–82 5C–82 5C–82 5C–82 5C–83 5C–83 5C–84 5C–85 5C–85 5C–85 5C–86 5C–87 5C–87 5C–87 5C–88 5C–88 5C–88 5C–88 5C–89 5C–90 5C–90 5C–90 5C–91 5C–91 5C–93 5C–93 5C–93 5C–93 5C–95 5C–95 5C–95 5C–96 5C–98 5C–98 5C–98 5C–99 5C–99 5C–100 5C–101

5C–62 POWER–ASSISTED BRAKE SYSTEM Brake Pads Inspection . . . . . . . . . . . . . . . . . Brake Pads and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Disc Brake Rotor (4×4 Model) . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Brake Rotors . . . . . . . . . . . . . . . . Refinishing Brake Rotors . . . . . . . . . . . . . . . Rear Drum (In Disc) Inside Diameter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Disc Brake Caliper Assembly (4×4 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Disc Brake Caliper Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Disc Brake Caliper (4×4 Model) . . . . . . Rear Disc Brake Caliper Disassembled View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . .

5C–101 5C–101 5C–102 5C–102 5C–104 5C–104 5C–104 5C–104 5C–105 5C–106 5C–106 5C–106 5C–107 5C–108 5C–108 5C–109 5C–109

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications (4×4 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Lining and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Lining Inspection . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drum Brake Adjustment (4×2 Model) . . . . . Servicing The Brake Drum . . . . . . . . . . . . . . Wheel Cylinder Assembly (4×2 Model) . . . . . Wheel Cylinder Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

Service Precaution

General Description

Master Cylinder Assembly

5C–109 5C–111 5C–112 5C–112 5C–112 5C–113 5C–113 5C–114 5C–114 5C–115 5C–115 5C–115 5C–115 5C–116 5C–116 5C–116 5C–116 5C–118

330R200002

5C–63

CAUTION: 1. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. (Refer to Bleeding Brake Hydraulic System in this section.) 2. The torque values specified unlubricated fasteners.

are

for

dry,

3. Perform service operations on a clean bench free from all mineral oil materials.

Brake Booster

331R200001

This booster is a tandem vacuum unit with a diaphragm effective diameter 205mm + 230mm (8.07in + 9.06in). In normal operating mode, with the service brakes in the released position, the tandem vacuum booster operates with vacuum on both sides of its diaphragms. When the brakes are applied, air at atmospheric pressure is admitted to both sides of the diaphragm to provide the power assist. When the service brake is released, the atmospheric air is shut off from both sides of the diaphram. The air is then drawn from the booster through the vacuum check valve to the vacuum source.

CAUTION: 1. If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the brake system. 2. The torque values specified unlubricated fasteners.

are

for

dry,

3. The vacuum booster is not repairable and must be replaced as complete assembly.

5C–64 POWER–ASSISTED BRAKE SYSTEM

Disc Brake Front Disc Brake

A05R200001

Rear Disc Brake (4×4 Model)

A05RW002

The disc brake assembly consists of a caliper, piston, rotor, pad assembly and support bracket. The caliper assembly has a fornt dual bore, rear single bore and is mounted to the support bracket with two mounting bolts. The support bracket allows the caliper to move laterally against the rotor. The caliper is a one–piece casting with the inboard side containing the piston bore. A square cut rubber seal is located in a groove in the piston bore which provides the hydraulic seal between the piston and the cylinder wall. NOTE: 1. Replace all components included in repair kits used to service this caliper. 2. Lubricate rubber parts with clean brake fluid to ease assembly.

POWER–ASSISTED BRAKE SYSTEM

5C–65

Leading/Trailing Drum Brakes (4×2 Model)

A05RS003

This drum brake assembly is a leading/trailing shoe design. Both brake shoes are held against the wheel cylinder pistons by the upper return spring and to the fixed anchor plate by the lower return spring. When the brakes are applied, the wheel cylinder pistons expand pushing both shoes out contacting the drum. With forward wheel rotation, the forward brake shoe will wrap into the drum and becomes self-energized. With reverse wheel rotation, the rear brake shoe is self-energized. Force from the brake shoes is transferred to the anchor plate through the braking plate to the axle flange. Adjustment is automatic and occurs on any service brake application. Also, with leading/trailing brakes, it is normal for the front shoe to wear at a faster rate than the rear shoe.

5C–66 POWER–ASSISTED BRAKE SYSTEM

POWER–ASSISTED BRAKE SYSTEM

5C–67

General Diagnosis Condition

Possible cause

Brake Pull

Brake Roughness (Pulsates)

Chatter

Excessive Pedal Effort

Excessive Brake Pedal Travel

Correction

Tire inflation pressure is unequal.

Adjust

Front wheel alignment is incorrect.

Adjust

Unmatched tires on same axle.

Tires with approx. the same amount of tread should be used on the same axle.

Restricted brake pipes or hoses.

Check for soft hoses and damaged lines. Replace with new hoses and new double walled steel brake piping.

Water or oil on the brake pads.

Clean or replace.

Brake pads hardened.

Replace

Brake pads worn excessively.

Replace

Brake rotor worn or scored.

Grind or replace.

Disc brake caliper malfunctioning.

Clean or replace.

Front hub bearing preload incorrect.

Adjust or replace.

Loose suspension parts.

Check all suspension mountings.

Loose calipers.

Check and tighten the bolts to specifications.

Excessive lateral runout.

Check per instructions. If not within specifications, replace or machine the rotor.

Parallelism not within specifications.

Check per instructions. If not within specifications, replace or machine the rotor.

Pad reversed (steel against iron).

Replace the brake pad and machine rotor to within specifications.

Malfunctioning vacuum booster.

Check the vacuum booster operation and repair, if necessary.

Partial system failure.

Check the front and rear brake system for failure and repair. Also, check the brake warning light. If a failed system is found, the light should indicate failure.

Excessively worn pad.

Check and replace pads in sets.

Piston in caliper stuck or sluggish.

Remove caliper and rebuild.

Fading brakes due to incorrect pad.

Remove and replace with original equipment pad or equivalent.

Vacuum leak to vacuum booster.

Check for ruptured or loose hose.

Check the direction of check valve within vacuum hose.

Correct vacuum hose direction.

Grease on the brake pads.

Replace or clean.

Air in hydraulic circuit.

Bleed the hydraulic circuit.

Level of brake fluid in the reservoir too low.

Replenish brake fluid reservoir to specified level and bleed hydraulic circuit as necessary.

Master cylinder push rod clearance excessive.

Adjust

Leakage in hydraulic system.

Correct or replace defective parts.

5C–68 POWER–ASSISTED BRAKE SYSTEM Condition Brake Drag

Grabbing or Uneven Braking Action (All conditions listed under “Pulls”)

Brake Noisy

Possible cause

Correction

Master cylinder pistons not returning correctly.

Adjust the stop light switch and vacuum booster push rod. If necessary, rebuild.

Restricted brake pipes or hoses.

Check for soft hoses or damaged pipes, and replace with new hoses and new double–walled steel brake piping.

Parking brake maladjusted.

Adjust

Parking brake insufficient.

Adjust

lining

clearance

Brake pedal free play insufficient.

Adjust the brake pedal height or power cylinder operating rod.

Piston in the master cylinder sticking.

Replace

Piston in the disc brake caliper sticking.

Replace piston seals.

Brake pads sticking in caliper.

Clean

Return spring weakened.

Replace

Parking brake binding.

Overhaul the parking brakes and correct.

Front hub bearing preload incorrect.

Adjust or replace.

Parking brake shoes not returning.

Correct or replace the brake back plate and brake shoe as necessary.

Obstructions in hydraulic circuit.

Clean

Rotor warped excessively.

Grind or replace.

Rear brake drum distorted.

Grind or replace.

Parking cable sticking.

Grind or replace.

Malfunctioning vacuum booster.

Check operation and correct as necessary.

Binding brake pedal mechanism.

Check and lubricate, if necessary.

Corroded caliper assembly.

Clean and lubricate.

Brake pads are worn.

Replace

Brake pads are hardened.

Replace

Brake pads are in poor contact with rotor.

Correct

Brake disc(s) warped, worn or damaged.

Grind or replace.

Disc brake fatigued.

Replace

anti–squeak

shims

Front hub bearings are loose or preload is incorrect.

Adjust or replace.

Brake disc is rusted.

Grind or replace.

POWER–ASSISTED BRAKE SYSTEM Condition Poor Brake Action

Possible cause

Correction

Master cylinder faulty.

Correct or replace.

Vacuum booster faulty.

Correct or replace.

Level of brake fluid in reservoir too low.

Replenish and bleed.

Air in hydraulic circuit.

Bleed

Disc brake caliper faulty.

Clean or replace.

Water or oil on brake pads.

Clean or replace.

Brake pads in poor contact with the rotor.

Correct

Brake pads worn.

Replace

Brake disc rusted.

Grind or replace.

Check valve in vacuum hose faulty.

Correct or replace.

5C–69

5C–70 POWER–ASSISTED BRAKE SYSTEM

Hydraulic Brakes Filling Master Cylinder Reservoir

Bleeding Brake Hydraulic System

CAUTION: Use only specified brake fluid. Do not use any fluid which contains a petroleum base. Do not use a container which has been used for petroleum based fluids or a container which is wet with water. Petroleum based fluid will cause swelling and distortion of rubber parts in the hydraulic brake system. Water mixed with brake fluid lowers the fluid boiling point. Keep all fluid containers capped to prevent contamination. Always fill the master cylinder reservoir when the engine is cold. Never allow the brake fluid to come in contact with the painted surfaces. The master cylinder reservoir must be kept properly filled to ensure adequate reserve and to prevent air and moisture from entering the hydraulic system. However, because of expansion due to heat absorbed from the brakes and the engine, the reservoir must not be overfilled. The brake fluid reservoir is on the master cylinder, which is located under the hood on the left side of the cowl. Thoroughly clean reservoir cap before removal to avoid getting dirt into reservoir. Remove the diaphragm. Add fluid as required to bring level to the “MAX” mark on the reservoir tank. Use “DOT 3” Hydraulic Brake Fluid. If the fluid cap diaphragm is stretched, return it to the original position before installing.

A bleeding operation is necessary to remove air from the hydraulic brake system whenever air is introduced into the hydraulic system. It may be necessary to bleed the hydraulic system at all four brakes if air has been introduced through a low fluid level or by disconnecting brake pipes at the master cylinder. If a brake pipe is disconnected at one wheel, only that wheel cylinder/caliper needs to be bled. If the pipes are disconnected at any fitting located between the master cylinder and brakes, then the brake system served by the disconnected pipe must be bled. 1. For 4–Wheel Antilock Brake System (ABS) equipped vehicle, be sure to remove the ABS main fuse 60A located at the relay and fuse box before bleeding air. If you attempt to bleed air without removing the main fuse, air cannot be let out thoroughly, and this may cause damage to the hydraulic unit. After bleeding air, be sure to replace the ABS main fuse back to its original position. 2. Set the parking brake completely, then start the engine.

NOTE: The vacuum booster will be damaged if the bleeding operation is performed with the engine off. 3. Remove the master cylinder reservoir cap. 4. Fill the master cylinder reservoir with brake fluid. Keep the reservoir at least half full during the air bleeding operation 5. Always use new brake fluid for replenishment. 6. When replenishing the brake fluid reservoir, carefully pour in the brake fluid to prevent air bubbles from entering the brake system. When the master cylinder is replaced or overhauled, first bleed the air from the master cylinder, then from each wheel cylinder and caliper following the procedures described below. Bleeding the Master Cylinder 7. Disconnect the rear wheel brake pipe (1) from the master cylinder. Check the fluid level and replenish as necessary. If replenished, leave the system for at least one minute. 8. Depress the brake pedal slowly once and hold it depressed. 9. Completely seal the delivery port of the master cylinder with your finger, where the pipe was disconnected then release the brake pedal slowly. 10. Release your finger from the delivery port when the brake pedal returns completely. 11. Repeat steps 8 through 10 until the brake fluid comes out of the delivery port during step 8.

POWER–ASSISTED BRAKE SYSTEM NOTE: Do not allow the fluid level in the reservoir to go below the half–way mark. 12. Reconnect the brake pipe (1) to the master cylinder and tighten the pipe. 13. Depress the brake pedal slowly once and hold it depressed. 14. Loosen the rear wheel brake pipe (1) at the master cylinder. 15. Retighten the brake pipe, then release the brake pedal slowly. 16. Repeat steps 13 through 15 until no air comes out of the port when the brake pipe is loosened NOTE: Be very careful not to allow the brake fluid to come in contact with painted surfaces.

5C–71

24. Release the brake pedal slowly. 25. Repeat steps 21 through 24 until the air is completely removed. It may be necessary to repeat the bleeding procedure 10 or more times for front wheels and 15 or more times for rear wheels. 26. Go to the next wheel in the sequence after each wheel is bled. Be sure to monitor reservoir fluid level. 27. Depress the brake pedal to check if you feel “sponginess” after the air has been removed from all wheel cylinders and calipers. If the pedal feels “spongy”, the entire bleeding procedure must be repeated. 28. After the bleeding operation is completed on the each individual wheel, check the level of the brake fluid in the reservoir and replenish up to the “MAX” level as necessary. 29. Attach the reservoir cap. If the diaphragm inside the cap is deformed, reform it and install. 30. Stop the engine.

Flushing Brake Hydraulic System

330R200004

5C–72 POWER–ASSISTED BRAKE SYSTEM

Front Caliper Brake Hose Front Caliper Brake Associated Parts

Hose

and

Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the brake pipes to the specified torque Torque: 16 N·m (12 lb ft) 2. Tighten the bolt to the specified torque. Torque: 35 N·m (26 lb ft) NOTE: Always use new gaskets and be sure to put the hooked edge of the flexible hose end into the anti–rotation cavity. After installing the brake hoses, bleed the brakes as described in this section.

352RW001

Legend (1) Bolt and Gasket (2) Clip (3) Hose (4) Brake Pipe

POWER–ASSISTED BRAKE SYSTEM

5C–73

Rear Axle Brake Hose Rear Axle Brake Hose and Associated Parts

Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the brake pipes to the specified torque Torque: 16 N·m (12 lb ft) 2. Tighten the bolt to the specified torque. Torque: 15 N·m (11 lb ft) After installing the brake hoses, bleed the brakes as described in this section.

352RW002

Legend (1) Brake Pipe (2) Clip (3) Bolt (4) Brake Pipe (5) Hose

5C–74 POWER–ASSISTED BRAKE SYSTEM

Brake Pipe Removal

Installation

To install, follow the removal steps in the reverse order, noting the following points. 1. Tighten the brake pipes to the specified torque. Master cylinder and P&B valve sides Torque: 12 N·m (104 lb in) Others Torque: 16 N·m (12 lb ft) After installing the brake pipes, bleed the brakes as described in this section.

330R200003

5. Remove plastic clip (2).

330RW002

POWER–ASSISTED BRAKE SYSTEM

5C–75

P & B (Proportioning and Bypass) Valve P & B (Proportioning and Bypass) Valve Sectional View

350RW014

350R200003

Installation 1. Install P&B valve (2). 2. Install bolt (3) and tighten the bolt to the specified torque. Torque: 22 N·m (16 lb ft) 3. Install hydraulic pipes (1) and tighten the bolt to the specified torque. Torque: 12 N·m (104 lb in) 4. After installing the brake pipes, bleed the brakes as described in Bleeding Brake Hydraulic System in this section.

5C–76 POWER–ASSISTED BRAKE SYSTEM

Main Data and Specifications Torque Specifications

E05R200007

POWER–ASSISTED BRAKE SYSTEM

5C–77

Brake Pedal Checking Pedal Height The push rod serves as the brake pedal stopper when the pedal is fully released. Brake pedal height adjustment should be performed as follows:

Adjust Brake Pedal

310RY00005

1. Measure the brake pedal height after making sure the pedal is fully returned by the pedal return spring. Pedal height must be measured after starting the engine and stepping on it several times.

Checking Pedal Travel

Pedal Free Play: 6-10 mm (0.23-0.39 in) Pedal Height: 173-185 mm (6.81-7.28 in) NOTE: Pedal free play must be measured after turning off the engine and stepping on the brake pedal firmly five times or more. 2. If the measured value is not within the above range, adjust the brake pedal as follows: a. Disconnect the stoplight switch connector. b. Loosen the stoplight switch lock nut. c. Rotate the stoplight switch so that it moves away from the brake pedal. d. Loosen the lock nut (1) on the push rod. e. Adjust the brake pedal to the specified height by rotating the push rod in the appropriate direction. f. Tighten the lock nut to the specified torque. Torque: 20 N·m (15 lb ft) g. Adjust the stoplight switch (2) to the specified clearance (between the switch housing and the brake pedal) by rotating the switch housing. Clearance: 0.5–1.0 mm (0.02–0.04 in)

310R200002

5C–78 POWER–ASSISTED BRAKE SYSTEM

Brake Pedal and Associated Parts

310RY00006

Legend (1) Brake Pedal Bracket Assembly (2) Fulcrum Pin and Nut (3) Connector (4) Snap Pin (5) Return Spring

Removal 1. Disconnect the battery “–” terminal cable, and wait at least 5 minutes. 2. Disconnect the yellow 3 way SRS connector located under the steering column. 3. Remove the engine hood opening lever. 4. Remove lower cover (8). 5. Remove driver knee bolster (10). 6. Disconnect the stop light switch connector (3). Disconnect the anti-theft control module connector. Refer to Body and Accessories section. 7. Remove snap pin (4) and push rod pin (7). 8. Remove the steering column shaft fixing bolt and nut (9) on the steering wheel side, and lower the steering column shaft. 9. Remove the brake pedal bracket assembly (1). 10. Remove return spring (5). 11. Remove fulcrum pin and nut (2).

(6) (7) (8) (9) (10)

Peadl Assembly Push Rod Pin Lower Cover Bolts and Nut Driver Knee Bolster

12. Remove pedal assembly (6).

5C–79

Stoplight Switch Parts Location

310RW008

Legend (1) Connector (2) Switch (3) Lock Nut

Removal 1. Disconnect connector (1) 2. Remove lock nut (3). 3. Remove switch (2).

310RY00005

2. Connect connector (1). 3. Install lock nut (3).

5C–80 POWER–ASSISTED BRAKE SYSTEM

Main Data and Specifications General Specifications Pedal free play

6–10 mm (0.23 –0.39 in)

Pedal Height

173–185 mm (6.81–7.28 in)

Torque Specifications

310RY00007

POWER–ASSISTED BRAKE SYSTEM

5C–81

Master Cylinder Assembly Master Cylinder Assembly and Associated Parts

330R200006

Legend (1) Electrical Connector (2) Master Cylinder

(3) 2 attaching Nuts (4) P&B Valve and Bracket (5) Brake Pipes

Removal

Inspection

CAUTION: When removing the master cylinder from the vacuum booster, be sure to get rid of the internal negative pressure of the vacuum booster (by, disconnecting the vacuum hose) in advance. If any negative pressure remains in the vacuum booster, the piston may possibly come out when the master cylinder is being removed, letting the brake fluid run out. While removing the master cylinder, do not hold the piston as it can be easily pulled out. Outside surface of the piston is the surface on which seals are to slide. Care should be taken to keep the surface free of cuts and dents.

Excessive brake pedal travel, malfunction or dragging brake suggests that the master cylinder is defective. In such cases perform the following visual check:

1. Disconnect electrical connector. 2. Remove brake pipes and after disconnecting the brake pipe, cap or tape the openings of the brake pipe to prevent the entry of foreign matter. 3. Remove 2 attaching nuts. 4. Remove P&B valve and bracket. 5. Remove master cylinder.

5C–82 POWER–ASSISTED BRAKE SYSTEM

Master Cylinder Assembly Master Cylinder Assembly Desassembled View

330R200005

Legend (1) Spring Pin (2) Reserve Tank and Reserve Tank Cap (3) O–ring

Desassembly 1. Remove the spring pin. 2. Remove the reserve tank and the reserve tank cap. The brake fulid level switch is built–in to the reserve tank and cannot be removed. 3. Remove the O–ring. 4. Remove the snap ring. 5. Remove the primary piston assembly. 6. Invert the cylinder body and push on the secondary piston until the pin falls free.

(4) Primary Piston Assembly (5) Secondary Piston Assembly (6) Cylinder Body

7. Remove the secondary piston assembly. 8. Remove the cylinder body.

Inspection Excessive brake pedal travel, malfunction or dragging brake suggests that the master cylinder is defective. In such cases perform the following visual check:

POWER–ASSISTED BRAKE SYSTEM

Visual Check Make parts replacement as required if wear, distortion, nicks, cuts, corrosion, or other abnormal conditions are found through the following parts inspection: B Master cylinder body B Fluid reservoir B O–ring B Wash each part in brake fluid before beginning the inspection procedure. B Check the inside surfaces of the master cylinder for abrasion, corrosion, and other damage. Replace the cylinder if necessary. B Check the return port for clogging. Clean the port with a wire and compressed air if nesessay. B Check the piston and piston cup for abrasion, damage, and wear. Replace the piston assembly if any of these conditions exist. B Check the return spring. Replace the spring if it is weak. B Check the snap ring. Replace the snap ring if it is stretched or weak.

Reassembly 1. Wash each master cylinder internal part in brake fluid before beginning installation. 2. Install the cylinder body. 3. Press the secondary piston assembly into the cylinder body and hold it. Thread the pin through the long hole of the piston to secure the piston assembly. 4. Install the primary piston assembly. 5. Install the snap ring. 6. Install the O–ring 7. Install the reserve tank and the reserve tank cap. 8. Install the spring pin.

5C–83

Installation 1. Install master cylinder. When replacing the master cylinder or vacuum booster or both, always measure the vacuum booster push rod protrusion and adjust it as necessary (Refer to Vacuum Booster in section). 2. Install P&B valve and bracket. 3. Install 2 attaching nuts and tighten the attaching nuts to the specified torque. Torque: 13 N·m (113 lb in) 4. Install brake pipes and tighten the brake pipe to the specified torque. Master cylinder and P&B valve sides Torque: 12 N·m (104 lb in) Others Torque: 16 N·m (12 lb in) 5. Connect electrical connector.

5C–84 POWER–ASSISTED BRAKE SYSTEM

Main Data and Specifications General Specifications Type

Dual–circuit

Piston bore diameter

25.4 mm (1.000 in)

Torque Specifications

E05R200005

POWER–ASSISTED BRAKE SYSTEM

5C–85

Vacuum Booster Assembly Vacuum Booster Assembly and Associated Parts

331R200004

Legend (1) Snap Pin (2) Vacuum Booster Fixing Nut (3) Vacuum Hose

Removal 1. Before removing the vacuum booster assembly, disconnect and remove the brake pipes. 2. Remove master cylinder, refer to Master Cylinder Removal in this section. CAUTION: When removing the master cylinder from the vacuum booster, be sure to get rid of the internal negative pressure of the vacuum booster (by, disconnecting the vacuum hose) in advance. If any negative pressure remains in the vacuum booster, the piston may possibly come out when the master cylinder is being removed, letting the brake fluid run out. Do not hold the piston while removing the master cyliner, the piston can be easily pulled out. Outside surface of the piston is the surface on which seals are to slide. Care should be taken to keep the surface free of cuts and dents. 3. Remove vacuum hose. 4. Disconnect the yoke clevis from the brake pedal.

(4) Master Cylinder (5) Vacuum Booster (6) Pin

5. Remove vacuum booster fixing nut. 6. Remove vacuum booster.

5C–86 POWER–ASSISTED BRAKE SYSTEM

Inspection and Repair Vacuum Hose (The built in check valve) 1. Inspect the check valve (2), which is installed inside the vacuum hose. 2. Air should pass freely from the vacuum booster (3) to the engine (1). 3. Air should not pass from the engine (1) to the vacuum booster (3). If it does, the check valve is inoperative and the vacuum hose built in the check valve must be replaced. HEC ENGINE

360RW001

6VD1 ENGINE

360RY00004

POWER–ASSISTED BRAKE SYSTEM

5C–87

Exterior Components Exterior Components and Associated Parts

331R200006

Legend (1) 2 Gaskets and Spacer (2) Vacuum Booster

(3) Plate and Seal Assembly (4) Retainer (5) Master Cylinder

Removal 1. Remove master cylinder. Refer to Master Cylinder in this section. 2. Remove vacuum booster. Refer to Vacuum Booster in this section. 3. Remove 2 gaskets and spacer. 4. Remove retainer, plate and seal assembly.

331RS003

5C–88 POWER–ASSISTED BRAKE SYSTEM

Inspection and Repair

Installation

Visual Check Make necessary parts replacement if cuts, nicks, excessive wear, or other abnormal conditions are found through inspection. NOTE: The parts listed below must be replaced with new ones whenever the master cylinder is removed. 1. Plate and seal assembly 2. Retainer

1. Install plate and seal assembly. 2. Install retainer. 3. Install vacuum booster, refer to Vacuum Booster in this section. 4. Install master cylinder, refer to Master Cylinder in this section and after installation, perform brake pedal check and adjustment. Refer to Brake Pedal in this section.

Vacuum Booster Overhaul Vacuum Booster The vacuum booster cannot be disassembled for repair. Replace a defective vacuum booster with a new one.

POWER–ASSISTED BRAKE SYSTEM

5C–89

Main Data and Specifications General Specifications Vacuum booster diaphragm diameter (Front)

205 mm (8.07 in)

Vacuum booster diaphragm diameter (Rear)

230 mm (9.06 in)

Push rod stroke

More than 32.0 mm (1.26 in)

Plunger diameter

10.25 mm (0.40 in)

Push rod diameter

27.4 mm (1.08 in)

Torque Specifications

E05R200004

5C–90 POWER–ASSISTED BRAKE SYSTEM

Front Disc Brake Pads Front Disc Brake Pads Inspection Check the outer pad by looking at each caliper from above. Check the thickness on the inner pad by looking down through the inspection hole in the top of the caliper. Whenever the pad is worn to about the thickness of the pad base, the pad should be removed for further measurements. The pad should be replaced anytime the pad thickness (1) is worn to within 1.00 mm (0.039 in) of the pad itself. Wear indicators are installed on disc brake pads, disc brake pads need replacement when the wear indicator is heard. Minimum limit (1): 1.0 mm (0.039 in)

302RS002

Front Disc Brake Pads and Associated Parts

302R200026

Legend (1) Pin Bolt (2) Caliper Assembly

(3) Pad Assembly (4) Clip (5) Outer Side

POWER–ASSISTED BRAKE SYSTEM

Removal

5C–91

Installation

NOTE: If a squealing noise occurs from the front brake while driving, check the pad wear indicator plate. If the indicator plate contacts the rotor, the disc pad assembly should be replaced.

1. Install clip.

302R200023

2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (2). Wipe off extruded grease after installing. Install pad assembly with shim.

302R200028

3. Rotate caliper assembly and support the caliper assembly so that the brake hose is not stretched or damaged. 4. Remove pad assembly with shim. 5. Remove Clip.

302R200024

Legend (2) Inner Shim (3) Wear Indicator (4) Inner Side

5C–92 POWER–ASSISTED BRAKE SYSTEM 3. Carefyully use adjustable pliers to bottom the piston into the caliper bore. Do not pull or twist the flexible hose or damage will occur. Install caliper assembly. Set caliper assembly in place. 4. Install lock bolt (5) and tighten the bolt to the specified torque. Torque: 45 N·m (33 lb ft)

302R200008

POWER–ASSISTED BRAKE SYSTEM

5C–93

Front Disc Brake Rotor Inspection

Parallelism

Checking Lateral Runout 1. Adjust the wheel bearing correctly, refer to Differential in Section 4A. 2. Attach the dial indicator accordingly so that the stem contacts the rotor surface to approximately 29mm (1.14 in) from the rotor edge. 3. Rotate the rotor one complete turn and inspect for signs of lateral runout. Lateral runout should not exceed 0.13 mm (0.005 in). Maximum runout: 0.13 mm (0.005 in)

411R200007

Replacing Brake Rotors When installing new brake rotors, do not refinish the surfaces. These parts are at the correct level of surface finish.

Refinishing Brake Rotors

411R200008

Accurate control of the rotor tolerances is necessary for proper performance of the disc brakes. Machining of the rotor should be done only with precision equipment. All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. The minimum wear dimension is 24.60 mm (0.969 in). The minimum refinish dimension is 26.00 mm (1.024 in). When refinishing rotors, always use sharp cutting tools or bits. Dull or worn tools leave a poor surface finish which will affect initial braking performance. Vibration dampening attachments should always be used when refinishing braking surfaces. These attachments eliminate tool chatter and will result in better surface finish. After refinishing, replace any rotor that does not meet the minimum thickness of 26.00 mm (1.024 in). Do not use a brake rotor that exceeds the manufacturers specifications.

5C–94 POWER–ASSISTED BRAKE SYSTEM Minimum wear dimension: 24.60 mm (1.024 in) Refinish dimension: 26.00 mm (1.024 in)

411R200009

POWER–ASSISTED BRAKE SYSTEM

5C–95

Front Disc Brake Caliper Assembly Front Disc Brake Caliper Assembly and Associated Parts

302R200027

Legend (1) Brake Flexible Hose (2) Pin Bolt (3) Caliper Assembly

(4) (5) (6) (7)

Pad Assembly Clip Support Bracket with Pad Assembly Outer Side

302R200007

5C–96 POWER–ASSISTED BRAKE SYSTEM 4. Since the brake fluid flows out from the connecting coupler, place a drain pan under the vehicle. 5. Remove pin bolt (2).

2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (4). Wipe off extruded grease after installing. Install pad assembly with shim.

302R200020

6. Remove caliper assembly. 7. Remove support bracket with pad assembly and take care not to damage the flexible brake hose when removing the support bracket. 8. Remove pad assembly with shim and mark the lining locations if they are to be reinstalled. 9. Remove clip.

302R200025

Legend (4) Inner Shim (5) Wear Indicator (6) Inner Side 3. Install support bracket and tighten the bolt (7) to the specified torque. Torque: 155 N·m (115 lb ft)

Installation 1. Install clip.

302R200009

302R200023

POWER–ASSISTED BRAKE SYSTEM 4. Install caliper assembly. 5. Install pin bolt (8) and tighten the bolt to the specified torque. Torque: 45 N·m (33 lb ft)

302R200010

6. Install brake flexible hose, always use new gaskets and be sure to put the hooked edge of the flexible hose end into the anti–rotation cavity then tighten the I–bolt (9) to the specified torque. Torque: 35 N·m (26 lb ft)

302R200021

7. Install wheel and tire assembly, referring to Wheels and Tires System in Section 3E. 8. Bleed brakes. Refer to Hydraulic Brakes in this section.

5C–97

5C–98 POWER–ASSISTED BRAKE SYSTEM

Front Disc Brake Caliper Front Disc Brake Caliper Disassembled View

302R200018

Legend (1) Bleeder with Cap (2) Caliper Body

(3) Piston (4) Piston Seal (5) Dust Boot: Piston

Disassembly 1. Insert a block of wood into the caliper and force out the piston by blowing compressed air into the caliper at the flexible hose attachment. This procedure must be done prior to removal of the dust boot. Remove piston. WARNING: DO NOT PLACE YOUR FINGERS IN FRONT OF THE PISTON IN AN ATTEMPT TO CATCH OR PROTECT IT WHEN APPLYING COMPRESSED AIR. THIS COULD RESULT IN PERSONAL INJURY. CAUTION: Use just enough air to ease the piston out of the bore. If the piston is blown out, it may be damaged.

302R200012

POWER–ASSISTED BRAKE SYSTEM

5C–99

2. Remove dust boot: piston. 3. Remove piston seal. 4. Remove bleeder with cap. 5. Remove caliper body.

Inspection and Repair Make necessary parts replacement, if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: B Rotor B Cylinder body B Cylinder bore B Piston B Guide pin, lock pin B Support bracket NOTE: The piston seal, boot ring and dust boot are to be replaced each time the caliper is overhauled. Discard these used rubber parts and replace them with new ones.

Reassembly 1. Install caliper body. 2. Install bleeder with cap and tighten the cap to the specified torque. Torque: 8 N·m (69 lb in)

302R200015

5. Apply special grease (approximately 1 g) to the piston and attach the dust boot to the piston and caliper. Insert the dust boot ring into the dust boot. 6. Install guide bolt and lock bolt dust boot. 7. Install the dust boot on the support bracket after applying special grease (approximately 1 g) onto the dust boot inner surface. Apply special grease onto the lock pin and guide pin setting hole of the support bracket.

3. Apply special rubber grease to the piston seal and cylinder wall, then insert the piston seal into the cylinder. The special rubber grease is included in the repair kit.

302R200022

302R200013

4. When inserting the piston into the cylinder, use finger pressure only and do not use a mallet or other impact tool, since damage to the cylinder wall or piston seal can result. Install piston.

Legend (1) Guide Pin (2) Lock Pin (3) Pin Boot 8. Install pin bolt and tighten the bolt to the specified torque. Torque: 45 N·m (33 lb ft)

5C–100POWER–ASSISTED BRAKE SYSTEM

Main Data and Specifications General Specifications Type Pad dimension Adjusting method Piston diameter Disc type

Floating, pin slide 48.7 cm@ (7.55 in@) Self–adjusting 45.4 mm (1.79 in) ×2 Ventilated

Disc thickness

26 mm (1.02 in)

Disc effective diameter

242 mm (9.53 in)

Torque Specifications

E05R200008

POWER–ASSISTED BRAKE SYSTEM 5C–101

302RW016

Brake Pads and Associated Parts

306RW001

Legend (1) Caliper Assembly (2) Clip

(3) Lock Bolt (4) Pad Assembly

5C–102POWER–ASSISTED BRAKE SYSTEM

Removal

Installation

NOTE: If a squealing noise occurs from the rear brake while driving, check the pad wear indicator plate. If the indicator plate contacts the rotor, the disc pad assembly should be replaced.

1. Install clip (2).

B Draw out two–thirds of the brake fluid from the reservoir. B Raise the vehicle and support it with suitable safety stands. 1. Remove wheel and tire assembly, referring to Wheels and Tires System in Section 3E. 2. Remove lock bolt (1)

306RW003

2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims. Wipe off extruded grease after installing. Install pad assembly with shim.

306RW002

3. Rotate caliper assembly and support the caliper assembly so that the brake hose is not stretched or damaged. 4. Remove pad assembly with shim. 5. Remove clip.

306RW004

Legend (3) Inner Shim (4) Wear Indicator

POWER–ASSISTED BRAKE SYSTEM 5C–103

306RW005

3. Carefyully use adjustable pliers to bottom the piston into the caliper bore. Do not pull or twist the flex hose or damage will occur.

302RS008

4. Install lock bolt (5) and tighten the bolt to the specified torque. Torque: 44 N·m (32 lb ft)

306R200003

5. Install wheel and tire assembly, referring to Wheels and Tires System in Section 3E. 6. Pump the brake pedal several times to make sure that the pedal is firm. Check the brake fluid level in the reservoir after pumping the brakes.

5C–104POWER–ASSISTED BRAKE SYSTEM

Rear Disc Brake Rotor (4×4 Model) Inspection

Parallelism

Checking Lateral Runout 1. Adjust the wheel bearing correctly, referring to Differential in Section 4A. 2. Attach the dial indicator accordingly so that the stem contacts the rotor surface to approximately 29mm (1.14 in) from the rotor edge. 3. Rotate the rotor one complete turn and inspect for signs of lateral runout. Lateral runout should not exceed 0.13 mm (0.005 in). 1. The lateral runout should not exceed 0.13 mm (0.005 in) Maximum runout: 0.13 mm (0.005 in) 420RS013

Replacing Brake Rotors When installing new brake rotors, do not refinish the surfaces. These parts are at the correct level of surface finish.

Refinishing Brake Rotors

306RY00013

Accurate control of the rotor tolerances is necessary for proper performance of the disc brakes. Machining of the rotor should be done only with precision equipment. All brake rotors have a minimum thickness dimension cast into them. This dimension is the minimum wear dimension and not a refinish dimension. The minimum wear dimension is 16.6 mm (0.654 in). The minimum refinish dimension is 16.97 mm (0.668 in). When refinishing rotors, always use sharp cutting tools or bits. Dull or worn tools leave a poor surface finish which will affect initial braking performance. Vibration dampening attachments should always be used when refinishing braking surfaces. These attachments eliminate tool chatter and will result in better surface finish. After refinishing, replace any rotor that does not meet the minimum thickness of 16.97 mm (0.668 in). Do not use a brake rotor that exceeds the manufacturers specifications.

POWER–ASSISTED BRAKE SYSTEM 5C–105 Minimum wear dimension: 16.6 mm (0.654 in) Refinish dimension: 16.97 mm (0.668 in)

420RW002

420RS035

5C–106POWER–ASSISTED BRAKE SYSTEM

Rear Disc Brake Caliper Assembly (4×4 Model) Rear Disc Brake Caliper Assembly and Associated Parts

306RW007

(4) (5) (6) (7)

Legend (1) Brake Flexible Hose (2) Clip (3) Lock Bolt

Removal 1. Raise the vehicle and support with suitable safety stands. 2. Remove wheel and tire assembly, referring to Wheels and Tires System in Section 3E. 3. Remove the bolt and gaskets, then disconnect the flexible hose from the caliper and after disconnecting the flexible hose (1), cap or tape the openings to prevent entry of foreign material.

Support Bracket Guide Bolt Pad Assembly with Shim Caliper Assembly

4. Since the brake fluid flows out from the connecting coupler, place a drain pan under the vehicle. 5. Remove lock bolt (3). 6. Remove guide bolt (2).

306RW009

306RW008

POWER–ASSISTED BRAKE SYSTEM 5C–107 10. Remove clip.

3. Install support bracket and tighten the bolt (7) to the specified torque. Torque: 103 N·m (76 lb ft)

Installation 1. Install clip (4).

306RW012

306RW010

2. Apply special grease (approximately 0.2 g) to both contacting surfaces of the inner shims (5). Wipe off extruded grease after installing. Install pad assembly with shim.

4. Install caliper assembly. 5. Install lock bolt and guide bolt (8) and tighten the bolt to the specified torque. Torque: 44 N·m (32 lb ft)

306R200004 306RW011

Legend (5) Inner Shim (6) Wear indicator

5C–108POWER–ASSISTED BRAKE SYSTEM 7. Install the wheel and tire assembly, referring to Wheels and Tires System in Section 3E. 8. Bleed brakes. Refer to Hydraulic Brakes in this section.

302RW017

Rear Disc Brake Caliper (4×4 Model) Rear Disc Brake Caliper Disassembled View

306RW014

Legend (1) Guide Bolt (2) Lock Bolt (3) Bleeder with Cap (4) Caliper Body

(5) (6) (7) (8) (9)

Piston Seal Piston Dust Boot: Piston Dust Boot Ring Dust Boot: Guide Bolt and Lock Bolt

POWER–ASSISTED BRAKE SYSTEM 5C–109

Disassembly 1. Remove guide bolt. 2. Remove lock bolt. 3. Remove dust boot; guide bolt and lock bolt. 4. Remove dust boot ring, using a small screwdriver.

6. Remove dust boot: piston. 7. Remove piston seal. 8. Remove bleeder with cap. 9. Remove caliper body.

Inspection and Repair Make necessary parts replacement, if wear, damage, corrosion or any other abnormal conditions are found through inspection. Check the following parts: B Rotor B Cylinder body B Cylinder bore B Piston B Guide bolt, lock bolt B Support bracket NOTE: The piston dust seal and dust boot are to be replaced each time the caliper is overhauled. Discard these used rubber parts and replace with new ones.

Reassembly 302RS016

CAUTION: Use just enough air to ease the piston out of the bore. If the piston is blown out, it may be damaged.

302RS018

5C–110 POWER–ASSISTED BRAKE SYSTEM

302RS019

5. Apply special grease (approximately 1g) to the piston and attach the dust boot to the piston and caliper. Insert the dust boot ring into the dust boot.

302RS020

302RS021

8. Install lock bolt and guide bolt and tighten the bolt to the specified torque. Torque: 44 N·m (32 lb ft)

POWER–ASSISTED BRAKE SYSTEM 5C–111

Main Data and Specifications (4×4 Model) General Specifications Type

Floating, pin slide

Pad dimension

33 cm@ (5.11 in@)

Adjusting method Piston diameter Disc type Disc thickness Disc effective diameter

Self–adjusting 41.3 mm (1.63 in) Ventilated 18 mm (0.71 in) 269.2 mm (10.60 in)

Torque Specifications

E05RW005

5C–112 POWER–ASSISTED BRAKE SYSTEM

Brake Lining Brake Lining and Associated Parts

305RW001

Removal 1. Raise the vehicle and support with suitable safety stands. 2. Remove wheel and tire assembly (1). B Refer to Wheel and Tires in Wheel and Tire System section. 3. Remove Drum (2). B If difficulty is encountered in removing the drum: – Mark the position of the drum to the axle. – Make sure the parking brake is released.

(9) (10) (11) (12) (13) (14) (15) (16)

Upper (inner) Return Spring Auto Adjuster Lever Parking Brake Lever Adjuster Assembly Wave Washer Retainer Hold-down Pin Hold-down Pin

POWER–ASSISTED BRAKE SYSTEM 5C–113 NOTE: Do not over stretch the return spring.

Installation 1. Apply grease lightly to back place A.

305RS003

305RW002

305RS003

305RS001

5C–114 POWER–ASSISTED BRAKE SYSTEM 8. Install adjuster assembly (12). 9. Install hold-down pin (15) and hold-down spring and cups (4). 10. Install lower return spring (5). B Use brake spring tool. 11. Install auto adjuster lever (10). 12. Install upper (outer) return spring (6). B Use brake spring tool. 13. Install brake drum (2). B Adjust the brakes, refer to the Drum Brake Adjustment in this section. 14. Install wheel and tire assembly (1). B Refer to Wheels and Tires in wheel and Tire System section.

Servicing The Brake Drum Whenever the brake drums are removed, they should be thoroughly cleaned and inspected for cracks, scores, deep grooves and out-of-round.

Shoe clearance: 0.25-0.4 mm (0.0098-0.0157 in) If incorrect, check the brake auto-adjusting system. 5. Rotate the adjust nut until all slack disappears from the cable. Set the adjust nut. 6. Applying about 30 kg (66 lb) of force, pull the parking brake handle to its fully set position three or four times. 7. If the parking brake is properly adjusted, the travel between the fully disengaged position and the fully engaged position will be between 9 and 11 notches. If the traveling range is not within these limits, again repeat steps 1 through 5. After adjusting has been done, check to see if the rear wheel rotates smoothly without drag when turned by hand. 420RS034

POWER–ASSISTED BRAKE SYSTEM 5C–115

Wheel Cylinder Assembly (4×2 Model) Wheel Cylinder Assembly and Associated Parts

305RW003

Legend (1) Brake Linings (2) Wheel Cylinder

(3) Bolts (4) Brake Pipe

5C–116 POWER–ASSISTED BRAKE SYSTEM

Disassembled View

Reassembly 1. Lubricate the cylinder bore with clean rubber grease.

305RS006

Legend (1) Boot (2) Piston Assembly (3) Piston Cup (4) Return Spring (5) Bleeder (6) Wheel Cylinder

305RS007

2. Install bleeder (5) to wheel cylinder (6). Torque: 10 N·m (8 lb ft)

Disassembly 1. Remove boot (1) and piston assembly (2). 2. Remove piston cup (3) from piston assembly (2). 3. Remove return spring (4) and bleeder (5) from wheel cylinder (6).

Inspection and Repair 1. Make necessary parts replacement if wear, damage, corrosion or any other abnormal condition are found through inspection. Check the following parts; B Wheel cylinder body B Cylinder bore B Piston B Return spring B Bleeder NOTE: Replace the piston cups and boots each time the wheel cylinder is overhauled. Discard these used rubber parts and replace with new ones.

305RS008

POWER–ASSISTED BRAKE SYSTEM 5C–117 3. Install new piston cups (3) on each piston so that the flared end of the cups are turned to the inboard side of the pistons. Attach the return spring (4) and the boot (1) to the piston.

305RS009

4. Apply DELCO silicone lube No. 5459912 (or equivalent) to the piston and the inner face of the boots. 5. Install piston assembly (2) to wheel cylinder (6).

5C–118 POWER–ASSISTED BRAKE SYSTEM

Main Data and Specifications General Specifications Rear drum brake Type

Leading-trailing, non-servo

Drum inside diameter

295 mm (11.6 in)

Wheel cylinder diameter

22.22 mm (7/8 in)

Torque Specifications

E05RW010

SECTION PARKING BRAKE SYSTEM (4×4 Model) 5D1–1 AXIOM

BRAKES PARKING BRAKE SYSTEM (4×4 Model) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Lever and Front Cable . . . . . . Parking Brake Lever Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5D1–1 5D1–1 5D1–2 5D1–3 5D1–3 5D1–3 5D1–3

Service Precaution WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fasteners joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fasteners. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

Parking Brake Rear Cable . . . . . . . . . . . . . . . . Parking Brake Rear Cable and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Parking Brake Adjustment . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

5D1–4 5D1–4 5D1–5 5D1–5 5D1–6 5D1–6 5D1–7

General Description Pulling up the parking brake lever by hand will set the parking brake. By means of a ratchet type lock, the lever can be held in that position until it is released. The position of the lever is transmitted through cable/lever systems to the rear wheels. These parts are designed to obtain sufficient braking force even when parking on slopes. When the parking brake is set, or when the ignition SW is in the“ON” position, the brake warning light illuminates. The rear wheel parking brake is a duo–servo brake (mechanical inside expansion type) built in the rear disc brake. Parking brake adjustment is made through the adjusting hole (bored through back plate). Parking brake lever stroke should be adjusted to 6–8 notches. Refer to Parking Brake Adjustment in this section.

5D1–2 PARKING BRAKE SYSTEM (4×4 Model)

Operation When pulled in the direction “A”, the parking lever presses the secondary shoe against the brake drum using the lever/shoe joint “B” as a fulcrum and pushes the strut in the direction “C”. The strut ,in turn, presses the primary shoe against the brake drum. Counter force “D” to the primary shoe is transmitted again to the secondary shoe through the fulcrum “B”. The secondary shoe contacts the drum thereby producing braking effect. Clearance which may result from worn parking brake shoe lining can be adjusted by turning the adjusting screw. Refer to Parking Brake Adjustment in this Section.

A05RS002

Legend (1) Direction “A” (2) Lever/Shoe Joint “B” as a fulcrum (3) Direction “C” (4) Counter Force “D” (5) Parking Lever (6) Secondary Shoe (7) Adjusting Screw Notch

(8) (9) (10) (11) (12) (13) (14)

Parking Cable Guide Primary Shoe Strut Shoe Expanding Direction Parking Brake Cable Guide Adjusting Hole Plug Adjusting Screw Notch

PARKING BRAKE SYSTEM (4×4 Model) 5D1–3

Parking Brake Lever and Front Cable Parking Brake Lever Assembly and Associated Parts

311R200001

Legend (1) Rear Console (2) Switch Connector (3) Bolt (4) Adjust Nut and Lock Nut

Removal 1. Remove rear console (1). B Refer to Body and Accessories section in this manual. 2. Disconnect switch connector (2). 3. Remove bolt (3). 4. Remove adjust nut and lock nut (4). 5. Pull out equalizer (6) from trunnion pin (5). 6. Disconnect trunnion pin (5) from Parking brake lever (8). 7. Disconnect parking brake rear cable (7).

(5) (6) (7) (8)

Trunnion Pin Equalizer Parking Brake Rear Cable Parking Brake Lever

Installation 1. Apply grease (BESCO L–2 or equivalent) to the connecting portion of the rear cable (7) and equalizer (6). 2. Connect parking brake rear cable (7) to equalizer 3. Install trunnion pin (5) to parking brake lever (8). 4. Insert equalizer (6) into trunnion pin (5) and tighten adjust nut and lock nut (4). B To adjust the parking brake lever, see “Parking Brake Adjustment” in this section. Lock Nut Torque: 13 N·m (113 lb in) 5. Tighten the parking brake lever fixing bolt (3) to the specified torque. Torque: 15 N·m (11 lb ft) 6. Connect switch connector (2). 7. Install rear console (1). B Refer to Body and Accessories section in this manual.

5D1–4 PARKING BRAKE SYSTEM (4×4 Model)

Parking Brake Rear Cable Parking Brake Rear Cable and Associated Parts

311RY00004

Legend (1) Rear Wheels (2) Caliper Assembly (3) Rotor (Drum) (4) Holding Spring (5) Upper Return Spring (6) Lower Return Spring (7) Shoe Assembly

(8) (9) (10) (11) (12) (13) (14) (15)

Cable Fixing Bolt Bolt Bolt Bolt (Only Long Wheel Base Model) Nut Nut Retainer Rear Cable

PARKING BRAKE SYSTEM (4×4 Model) 5D1–5

Removal 1. Remove rear wheels (1). 2. Remove 2 bolts to remove the caliper assembly (2) from the support bracket. Refer to “Rear Disc Brakes” in Power Assisted Brake System section. Temporarily hang the caliper with wire etc. 3. Remove rotor (drum) (3). 4. Remove holding spring (4), upper return spring (5) and lower return spring (6). 5. Previously remove the rear cable from the parking brake lever, then remove the brake shoe assembly (7).

6. Install shoe assembly (7). After installation of the shoe and cable assembly, apply special grease (included in the repair kit) to the following portions indicated in the figure.

308RS005

7. Install lower return spring (6) and upper return spring (5). The parking brake lever side (secondary side) return spring must be installed on the outer side of the primary side return spring.

308RW004

Legend (1) Parking Brake Lever 6. Remove cable fixing bolt (8) and bolt (9) (10) (11). 7. Remove nut (12). 8. Remove nut (13) and retainer (14). 9. Remove rear cable (15).

Installation 1. Apply grease (BESCO L–2 or equivalent) to the connecting portion of the rear cable and equalizer. Install rear cable (15). 2. Install retainer (14). B Tighten nut (13) to the specified torque. Torque: 41N·m (30lb ft) 3. Tighten nut (12) to the specified torque.

308RS003

Legend (1) Outer Side (2) Parking Lever

Torque: 15N·m (11lb ft) 4. Tighten bolt (11) (10) (9) to the specified torque. Torque: 6.5N·m (57lb in) B To adjust the parking brake, refer to Parking Brake Adjustment in this section. 5. Tighten the cable fixing bolt (8) to the specified Torque: 6.5N·m (57lb in)

8. Install holding spring (4). 9. Install rotor (drum) (3). 10. Install caliper assembly (2). 11. Install rear wheels (1).

5D1–6 PARKING BRAKE SYSTEM (4×4 Model)

Inspection and Repair Parking Brake Lining Inspection Check the shoe assemblies for wear by removing the brake drum. Replace the shoe assemblies if the lining thickness is less than 1.0 mm (0.039 in). Minimum limit: 1.0 m (0.039 in)

7. When poor braking effect possibly resulting from insufficient break–in is felt, or just after replacement of parking brake shoe, be sure to conduct break–in as follows: 8. Forward 50 km/h (30 mph) × 400 m (About 30 seconds) with a lever pull force of 15 kg (33 lb). 9. Backward 10 km/h (6 mph) × 50 m (About 18 seconds) with a lever pull force of 15 kg (33 lb). NOTE: Break–in procedures must be performed under safe conditions and traffic rules. B If braking effect still remains poor after the above break–in, wait for some time until parking brake shoe cools down and repeat the procedures 8. and 9. noted above. B On completion of break–in, inspect parking brake lever stroke, and if the lever does not come within the specified number of notches when pulled up, readjust. B Excessive break–in may cause premature wear of the parking brake lining.

308RS004

Parking Brake Rotor (Drum) Inspection Refer to “Rear Disc Brakes” in Power-Assisted Brake System section for inspection procedure of the rotor (drum).

Parking Brake Adjustment 1. Prior to lever stroke adjustment, adjust rear brake shoe/rotor (drum) gap. Perform this procedure with loosening the adjust nut of the hand brake lever. 2. Remove the adjusting hole plug (rubber) and turn the shoe adjusting screw downward with a small screwdriver so that shoes will expand until they get into close touch with the rotor. (Turn down the adjusting screw notch by notch until the rotor does not turn.) 3. Turn the adjusting screw in the opposite direction (upward) until the rotor can be turned lightly. Standard number of notches to turn upward: 7 or 8 notches Turn the rotor and make sure that there is no brake dragging. 4. After the rear brake shoe/rotor (drum) gap has been adjusted, perform parking brake cable adjustment. 5. Turn the adjusting nut so that the parking brake lever travels 6–8 notches when pulled up with a force of 30 kg (66 lb). 6. Make sure there is no brake dragging. Then tighten the cable lock nut Torque : 13 N·m (113 lb in)

PARKING BRAKE SYSTEM (4×4 Model) 5D1–7

Main Data and Specifications General Specifications Model Type Drum inside diameter Parking brake lever stroke

Duo–servo 210 mm(8.27 in) 6–8 notches When pulled with a force of 30 kg (66 lb)

Torque Specifications

311R200002

SECTION PARKING BRAKE SYSTEM (4X2 Model) 5D2–1 AXIOM

BRAKES PARKING BRAKE SYSTEM (4×2 Model) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Parking Brake Lever . . . . . . . . . . . . . . . . . . . . . Parking Brake Lever Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5D2–1 5D2–1 5D2–2 5D2–2 5D2–2 5D2–2

Parking Brake Rear Cable . . . . . . . . . . . . . . . . Parking Brake Rear Cable and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Adjustment . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

5D2–3 5D2–3 5D2–4 5D2–4 5D2–4 5D2–5

General Description Pulling up the parking brake lever by hand will set the parking brake. By means of a ratchet type lock, the lever can be held in that position until it is released. The position of the lever is transmitted through cable/lever systems to the rear wheels. These parts are designed to obtain sufficient braking force even when parking on slopes. When the parking brake is set, or when the ignition SW is in the“ON” position, the brake warning light illuminates. The rear wheel parking brake is a leading/trailing brake (mechanical inside expansion type). Parking brake adjustment is made through the adjusting hole (bored through back plate). Parking brake lever stroke should be adjusted to 6 notches. Refer to Parking Brake Adjustment in this section.

5D2–2

PARKING BRAKE SYSTEM (4X2 Model)

Parking Brake Lever Parking Brake Lever Assembly and Associated Parts

311R200001

Legend (1) Rear Console (2) Switch Connector (3) Bolt (4) Adjust Nut and Lock Nut

Removal 1. Remove rear console (1). B Refer to Body and Accessories section in this manual. 2. Disconnect switch connector (2). 3. Remove bolt (3). 4. Remove adjust nut and lock nut (4). 5. Pull out equalizer (6) from trunnion pin (5). 6. Disconnect trunnion pin (5) from parking brake lever (8). 7. Disconnect parking brake rear cable (7).

(5) (6) (7) (8)

Trunnion Pin Equalizer Parking Brake Rear Cable Parking Brake Lever

Installation 1. Apply grease (BESCO L–2 or equivalent) to the connecting portion of the rear cable (7) and equalizer (8). 2. Connect parking brake rear cable (7) to equalizer (6). 3. Install trunnion pin (5) to parking brake lever (8). 4. Insert equalizer (6) into trunnion pin (5) and tighten adjust nut and lock nut (4). B To adjust the parking brake lever, see “Parking Brake Adjustment” in this section. Lock Nut Torque: 13 N·m (113 lb in) 5. Tighten parking lever fixing bolt (3) to the specified torque. Torque: 15 N·m (11 lb ft) 6. Connect switch connector (2). 7. Install rear console (1). B Refer to Body and Accessories section in this manual.

PARKING BRAKE SYSTEM (4X2 Model) 5D2–3

Parking Brake Rear Cable Parking Brake Rear Cable and Associated Parts

311RY00006

Legend (1) Rear Wheels (2) Drums (3) Clip and Bolt (4) Clip and Bolt

(5) (6) (7) (8) (9)

Clip and Bolt (Only Long Wheel Base Model) Nut Nut Retainer Rear Cable

5D2–4

PARKING BRAKE SYSTEM (4X2 Model)

Removal

Parking Brake Adjustment

1. Remove rear wheels (1) and drums (2). 2. Remove bolt (3) (4) (5). 3. Remove nut (6). 4. Remove nut (7) and retainer (8). 5. Remove rear brake shoe assemblies. Refer to “Brake Lining Assembly and Associated Parts” in Power Assisted Brake System section. 6. Use offset box wrench (13 mm hex.) to compress the locking lugs on the cable, then remove the rear cable (9) from the Backing plate.

NOTE: All brakes are self adjusting. Brakes are adjusted by repeated stepping on the brake pedal. (After stepping on the pedal and releasing it, the rear auto–adjuster, in the rear brake, produces a clicking sound. The same operation should be repeated until the sound disappears.) Take the following steps after overhauling the rear brake assembly. 1. Move the parking brake lever to its fully released position. 2. Parking cable must be loosened sufficiently. (Loosen the adjust nut and the lock nut.). 3. Repeat stepping on the brake pedal firmly, and releasing it until the clicking sound can no longer be heard. If the difference between the brake drum inside diameter and diameter of the brake shoes is adjusted to be 0.5 mm, the number of times for depressing the brake pedal can be reduced. 4. Remove the drum. Measure the brake drum inside diameter and diameter of the brake shoes. Shoe clearance: 0.25 mm to 0.40 mm (0.0098 in to 0.0157 in) If incorrect, check the brake auto–adjusting system.

311RS012

Legend (1) Offset Box Wrench

Installation 1. Install rear cable (9). 2. Install retainer (8). 3. Tighten nut (7) to the specified torque. Torque : 41 N·m (30 lb ft) B To adjust the parking brake, refer to Parking Brake Adjustment in this section. 4. Tighten nut (6) to the specified torque. Torque : 15 N·m (11 lb ft) 5. Tighten bolt (5) (4) (3) to the specified torque. Torque : 6.5 N·m (57 lb in) 6. Install rear drums (2) and wheels (1).

5. Rotate the adjust nut of hand brake lever until all slack disappears from the cable. Set the adjust nut. 6. Applying about 30 kg (66 lb) of force, pull the parking brake lever to its fully set position three or four times. 7. If the parking brake is properly adjusted, the travel between the fully disengaged position and the fully engaged position will be 6 notches. If the traveling range is not within these limits, repeat steps 1 through 5 again . After adjusting has been done, check to see if the rear wheel rotates smoothly without drag when turned by hand.

PARKING BRAKE SYSTEM (4X2 Model) 5D2–5

Main Data and Specifications General Specifications Model Type

Leading–Trailing

Drum inside diameter

295 mm (11.6 in)

Parking brake lever stroke

6–8 notches When pulled with a force of 30 kg (66 lb)

Torque Specifications

311R200003

SECTION ENGINE MECHANICAL (6VE1 3.5L)

6A–1

AXIOM

ENGINE CONTENTS Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Charging System . . . . . . . . . . . .

6A 6B 6C 6D1 6D2 6D3

Driveability and Emissions . . . . . . . . . . . . . . . . Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . Engine Speed Control System . . . . . . . . . . . . Induction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6E 6F 6G 6H 6J

ENGINE MECHANICAL (6VE1 3.5L) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Cover LH . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Cover RH . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common Chamber . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold LH . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Manifold RH . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Stem Oil Controller , Valve Spring and Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piston, Piston Ring and Connecting Rod . . .

6A–2 6A–3 6A–4 6A–19 6A–19 6A–20 6A–21 6A–21 6A–21 6A–22 6A–22 6A–22 6A–24 6A–24 6A–24 6A–25 6A–25 6A–25 6A–26 6A–26 6A–26 6A–27 6A–27 6A–28 6A–32 6A–32 6A–33 6A–35 6A–35 6A–35 6A–37 6A–37 6A–37 6A–38

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Main Bearings . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head and Associated Parts . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Spring, Oil Controller, Valve, Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Camshaft and Associated Parts . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft and Associated Parts . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair for Bearings . . . . . . Inspection and Repair for Crankshaft . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .

6A–38 6A–39 6A–40 6A–40 6A–41 6A–45 6A–45 6A–45 6A–46 6A–46 6A–47 6A–49 6A–49 6A–50 6A–50 6A–50 6A–51 6A–53 6A–53 6A–53 6A–54 6A–57 6A–60 6A–60 6A–60 6A–61 6A–63 6A–67 6A–67 6A–67 6A–68 6A–70 6A–71

6A–2

ENGINE MECHANICAL (6VE1 3.5L)

Piston and Connecting Rod . . . . . . . . . . . . . . . Piston, Connecting Rod and Associate Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . .

6A–75 6A–75 6A–75 6A–76 6A–80 6A–82

Cylinder Block and Associated Parts . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specification . . . . . . . . . . . . . . Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6A–82 6A–82 6A–83 6A–84 6A–87 6A–93

ENGINE MECHANICAL (6VE1 3.5L)

6A–3

General Description

Cylinder Block

Engine Cleanliness And Care

The cylinder block is made of aluminum die–cast casting for 75°V–type six cylinders. It has a rear plate integrated structure and employs a deep skirt. The cylinder liner is cast and the liner inner diameter and crankshaft journal diameter are classified into grades. The crankshaft is supported by four bearings of which width is different between No.2, No.3 and No.1, No.4; the width of No.3 bearing on the body side is different in order to support the thrust bearing. The bearing cap is made of nodular cast iron and each bearing cap uses four bolts and two side bolts.

An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in the thousandths of a millimeter (ten thousandths of an inch). Accordingly, when any internal engine parts are serviced, care and cleanliness are important. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically stated. B A liberal coating of engine oil should be applied to all friction areas during assembly to protect and lubricate the surfaces on initial operation. B Whenever valve train components, pistons, piston rings, connecting rods, rod bearings, and crankshaft journal bearings are removed for service, they should be retained in order. B At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. B Battery cables should be disconnected before any major work is performed on the engine. Failure to disconnect cables may result in damage to wire harness or other electrical parts. B The six cylinders of this engine are identified by numbers; Right side cylinders 1, 3 and 5, Left side cylinders 2, 4 and 6, as counted from crankshaft pulley side to flywheel side.

General Information on Engine Service The following information on engine service should be noted carefully, as it is important in preventing damage and contributing to reliable engine performance. B When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small clearance between the oil pan and the oil pump strainer, jacking against the oil pan may cause damage to the oil pick–up unit. B The 12–volt electrical system is capable of damaging circuits. When performing any work where electrical terminals could possibly be grounded, the ground cable of the battery should be disconnected at the battery. B Any time the intake air duct or air cleaner is removed, the intake opening should be covered. This will protect against accidental entrance of foreign material into the cylinder which could cause extensive damage when the engine is started.

Cylinder Head The cylinder head, made of aluminum alloy casting employs a pent–roof type combustion chamber with a spark plug in the center. The intake and exhaust valves are placed in V–type design. The ports are cross–flow type.

Valve Train Intake and exhaust camshaft on both banks are driven with a camshaft drive gear by the timing belt. The valves are operated by the camshaft and the valve clearance is adjusted to select suitable thickness shim.

Intake Manifold The intake manifold system is composed of the aluminum cast common chamber and intake manifold attached with six fuel injectors.

Exhaust Manifold The exhaust manifold is made of nodular cast iron.

Pistons and Connecting Rods Aluminum pistons are used after selecting the grade that meets the cylinder bore diameter. Each piston has two compression rings and one oil ring. The piston pin made of chromium steel is offset 1mm toward the thrust side, and the thrust pressure of piston to the cylinder wall varies gradually as the piston travels. The connecting rods are made of forged steel. The connecting rod bearings are graded for correct size selection.

Crankshaft and Bearings The crankshaft is made of Ductile cast–iron. Pins and journals are graded for correct size selection for their bearing.

6A–4

ENGINE MECHANICAL (6VE1 3.5L)

Engine Diagnosis First of all the engine diagnose to check the fuel quantity, the engine level and the engine coolant level.

Hard Starting 1. Starting Motor Does Not Turn Over Troubleshooting Procedure Turn on headlights and starter switch. Condition Headlights go considerably

out

Possible cause or

dim

Correction

Battery run down or under charged

Recharge or replace battery

Terminals poorly connected

Clean battery posts and terminals and connect properly

Starting motor coil circuit shorted

Overhaul or replace

Starting motor defective

Overhaul or replace

2. Ignition Trouble — Starting Motor Turns Over But Engine Does Not Start tester. Before starting the engine, make sure that the Spark Test spark plug tester is properly grounded. To avoid electrical Disconnect an ignition coil from any spark plug. Connect shock, do not touch the part where insulation of the the spark plug tester (For example J–26792), start the ignition coil is broken while the engine is running. engine, and check if a spark is generated in the spark plug Condition Spark jumps across gap

No sparking takes place

Possible cause

Correction

Spark plug defective

Clean, adjust spark gap or replace

Ignition timing incorrect

Refer to Ignition System

Fuel not reaching fuel injector(s) or engine

Refer to item 3 (Trouble in fuel system)

Valve timing incorrect

Adjust

Engine lacks compression

Refer to item 4 (Engine lacks compression)

Ignition coil disconnected or broken

Connect properly or replace

Electronic module

Replace

Ignition

System

with

Poor connections in engine harness

Correct

Powertrain Control Module cable disconnected or defective

Correct or replace

3. Trouble In Fuel System Condition Starting motor turns over and spark occurs but engine does not start start.

Possible cause

Correction

Fuel tank empty

Fill

Water in fuel system

Clean

Fuel filter clogged

Replace filter

Fuel pipe clogged

Clean or replace

Fuel pump defective

Replace

Fuel pump circuit open

Correct or replace

Evaporative Emission System circuit clogged

Control

Multiport Fuel Injection System faulty

Correct or replace Refer to “Electronic Fuel Injection” section

ENGINE MECHANICAL (6VE1 3.5L)

6A–5

4. Engine Lacks Compression Condition Engine lacks compression

Possible cause

Correction

Spark plug loosely fitted or spark plug gasket defective

Tighten to specified torque or replace gasket

Valve timing incorrect

Adjust

Cylinder head gasket defective

Replace gasket

Valve incorrectly seated

Lap valve

Valve stem seized

Replace valve and valve guide

Valve spring weakened or broken

Replace

Cylinder or piston rings worn

Overhaul engine

Piston ring seized

Overhaul engine.

Engine Compression Test Procedure 1. Start and run the engine until the engine reaches normal operating temperature. 2. Turn the engine off. 3. Remove all the spark plugs. 4. Remove ignition coil fuse (15A) and disable the ignition system. 5. Remove the fuel pump relay from the relay and fuse box. 6. Engage the starter and check that the cranking speed is approximately 300 rpm. 7. Install cylinder compression gauge into spark plug hole. 8. With the throttle valve opened fully, keep the starter engaged until the compression gage needle reaches the maximum level. Note the reading. 9. Repeat the test with each cylinder. If the compression pressure obtained falls below the limit, engine overhaul is necessary. Limit; 1000 kPa (145 psi)

6A–6

ENGINE MECHANICAL (6VE1 3.5L)

Rough Engine Idling or Engine Stalling Condition Trouble in fuel injection system

Trouble in emission control system

Others

Possible cause

Correction

Throttle shutting off incomplete

Correct or replace

Throttle position sensor circuit open or shorted

Correct or replace

Fuel injector circuits open or shorted

Correct or replace

Fuel injectors damaged

Replace

Fuel pump relay defective

Replace

Mass Airflow Sensor circuit open or poor connections

Correct or replace

Mass Airflow Sensor defective

Replace

Manifold Absolute Pressure Sensor circuit open or poor connections

Correct or replace

Manifold Absolute Pressure Sensor defective

Replace

Engine Coolant Temperature Sensor circuit open or poor connections

Correct or replace

Engine Coolant Temperature Sensor defective

Replace

Intake Air Temperature sensor circuit open or poor connections

Correct or replace

Intake Air defective

Replace

Temperature

sensor

Ion Sensing Module cable broken or poor connections

Correct or replace

Ion Sensing Module defective

Replace

Vehicle Speed Sensor circuit open or shorted

Correct or replace

Vehicle Speed Sensor defective

Replace

Powertrain Control Module defective

Replace

Exhaust Gas Recirculation Valve circuit open or poor connections

Correct or replace

Exhaust Gas Recirculation Valve faulty

Replace

Canister purge valve circuit open or poor connections

Correct or replace

Canister purge valve defective

Replace

Evaporative Emission Canister Purge control valve defective

Replace

Trouble in ignition system

Refer to “Hard Start”

Engine lacks compression

Refer to “Hard Start”

Valve incorrectly seated

Lap valve

Air Cleaner Filter clogged

Replace filter element

Valve timing incorrect

Readjust

Idle air control valve broken

Replace

Fast idle solenoid defective

Replace

Positive Crankcase Ventilation valve defective or clogged

Replace

ENGINE MECHANICAL (6VE1 3.5L)

6A–7

Rough Engine Running Condition Engine misfires periodically

Engine knocks periodically

Engine lacks power

Possible cause

Correction

Ignition coil layer shorted

Replace

Spark plugs fouling

Clean or install hotter type plug

Spark plug(s) insulator nose leaking

Replace

Fuel injector(s) defective

Replace

Powertrain control module faulty

Replace

Spark plugs running too hot

Install colder type spark plugs

Powertrain control module faulty

Replace

Ion Sensing module faulty

Refer or replace

Spark plugs fouled

Clean

Fuel injectors defective

Replace

Mass Airflow Sensor or Intake Airflow Sensor circuit defective

Correct or replace

Manifold Absolute Pressure (MAP) Sensor or Manifold Absolute Pressure Sensor circuit defective

Correct or replace

Engine Coolant Temperature Sensor or Engine Coolant Temperature Sensor circuit defective

Correct or replace

Powertrain Control Module faulty

Replace

Intake Air Temperature Sensor or Intake Air Temperature Sensor circuit defective

Correct or replace

Throttle Position Sensor or Throttle Position Sensor circuit defective

Correct or replace

ION Sensing Module or ION Sensing Module circuits defective

Correct or replace

6A–8

ENGINE MECHANICAL (6VE1 3.5L)

Hesitation Condition Hesitation on acceleration

Hesitation at high speeds (Fuel pressure too low)

Hesitation at high speeds (Fuel injector not working normally)

Possible cause

Correction

Throttle Position Sensor adjustment incorrect

Replace throttle valve assembly

Throttle Position Sensor circuit open or shorted

Correct or replace

Mass Airflow Sensor circuit open or poor connections

Correct or replace

Mass Airflow Sensor defective

Replace

Manifold Absolute Pressure (MAP) Sensor circuit open or shorted

Correct or replace

MAP Sensor defective

Replace

Intake Air Temperature (IAT) Sensor circuit open or poor connections

Correct or replace

Ion Sensing Module circuit open or poor connections

Correct or replace

Ion Sensing Module defective

Replace

IAT Sensor defective

Replace

Fuel tank strainer clogged

Clean or replace

Fuel pipe clogged

Clean or replace

Fuel filter clogged

Replace

Defective fuel pump system

Check and replace

Fuel Pressure Control Valve leaking

Replace

Power supply or ground circuit for Multiport Fuel Injection System shorted or open

Check and correct or replace

Fuel Injector defective

Replace

Cable of Multiport Fuel Injection System circuit open or poor connections

Correct or replace

ENGINE MECHANICAL (6VE1 3.5L) Condition Hesitation at high speeds

Possible cause

Correction

Powertrain Control Module defective

Replace

Throttle Position Sensor broken or poor connections

Correct or replace

cable

Throttle Position Sensor defective

Replace

Engine Coolant Temperature Sensor circuit open or shorted

Correct or replace

Engine Coolant Temperature Sensor defective

Replace

Mass Airflow Sensor circuit open or poor connections

Correct or replace

Mass Airflow Sensor defective

Replace

MAP Sensor cable broken or poor connections

Correct or replace

MAP Sensor defective

Replace

IAT Sensor circuit open or poor connections

Correct or replace

IAT Sensor defective

Replace

Ion Sensing Module circuit open or poor connections

Correct or replace

Ion Sensing Module defective

Replace

Throttle valve not fully opened

Check and correct or replace

Air Cleaner Filter clogged

Replace filter element

Power supply voltage too low

Check and correct or replace

6A–9

6A–10

ENGINE MECHANICAL (6VE1 3.5L)

Engine Lacks Power Condition Trouble in fuel system

Trouble in intake or exhaust system

Ignition failure

Possible cause

Correction

Fuel Pressure Control Valve not working normally

Replace

Fuel injector clogged

Clean or replace

Fuel pipe clogged

Clean

Fuel filter clogged or fouled

Replace

Fuel pump drive circuit not working normally

Correct or replace

Fuel tank not sufficiently breathing due to clogged Evaporative Emission Control System circuit

Clean or replace

Water in fuel system

Clean

Inferior quality fuel in fuel system

Use fuel of specified octane rating

Powertrain Control Module supplied poor voltage

Correct circuit

Throttle Position Sensor broken or poor connections

Correct or replace

cable

Throttle Position Sensor defective

Replace

Mass Airflow Sensor not working normally

Replace

Manifold Absolute Pressure Sensor not working normally

Replace

Intake Air Temperature Sensor not working normally

Replace

Engine Coolant Temperature Sensor circuit open or shorted

Correct or replace

Engine Coolant Temperature Sensor defective

Replace

Powertrain Control Module defective

Replace

Air Cleaner Filter clogged

Replace filter element

Air duct kinked or flattened

Correct or replace

TWC defective

Repair

————

Refer to Hard Start Troubleshooting Guide

Heat range of spark plug inadequate

Install spark plugs of adequate heat range

Ignition coil defective

Replace

ENGINE MECHANICAL (6VE1 3.5L) Condition Engine overheating

Possible cause

6A–11

Correction

Level of Engine Coolant too low

Replenish

Fan clutch defective

Replace

Incorrect fan installed

Replace

Thermostat defective

Replace

Engine Coolant pump defective

Correct or replace

Radiator clogged

Clean or replace

Radiator filler cap defective

Replace

Level of oil in engine crankcase too low or wrong engine oil

Change or replenish

Resistance increased

Clean exhaust system or replace defective parts

exhaust

system

Throttle Position Sensor adjustment incorrect

Replace with Throttle Valve ASM

Throttle Position Sensor circuit open or shorted

Correct or replace

Cylinder head gasket damaged

Replace

Engine overcooling

Thermostat defective

Replace (Use a thermostat set to open at 82°C (180°F))

Engine lacks compression

————

Refer to Hard Start

Others

Tire inflation pressure abnormal

Adjust to recommended pressures

Brake drag

Adjust

Clutch slipping

Adjust or replace

Level of oil in engine crankcase too high

Correct level of engine oil

Exhaust Gas Recirculation Valve defective

Replace

6A–12

ENGINE MECHANICAL (6VE1 3.5L)

Engine Noisy Abnormal engine noise often consists of various noises originating in rotating parts, sliding parts and other moving parts of the engine. It is, therefore, advisable to locate the source of noise systematically. Troubleshooting Procedure for Crankshaft Journals or Crankshaft Bearing Noise Condition

Possible cause

Correction

Noise from crank journals or from crank bearings (Faulty and crank y crank journals j bearings usually make dull noise that becomes more evident when accelerating)

Oil clearance increased due to worn crank journals or crank bearings

Replace crank bearings and crankshaft or regrind crankshaft and install the undersize bearing

Crankshaft out of round

Replace crank bearings and crankshaft or regrind crankshaft and install the undersize bearing

Crank bearing seized

Crank bearing seized Replace crank bearings and crankshaft or regrind crankshaft and install the undersize bearing

Troubleshooting Procedure for Connecting Rods or Connecting Rod Bearing Noise Short out each spark plug in sequence using insulated spark plug wire removers. Locate cylinder with defective bearing by listening for abnormal noise that stops when spark plug is shorted out. Condition Noise from connecting rods or from connecting rod bearings (Faulty connecting rods or y g connecting rod bearings usually make an abnormal noise slightly higher than the crank bearing noise, which becomes more evident when engine is accelerated)) g

Possible cause

Correction

Bearing or crankshaft pin worn

Replace connecting rod bearings and crankshaft or regrind crankshaft pin and install the undersize bearing

Crankpin out of round

Replace connecting rod bearings and crankshaft or regrind crankshaft pin and install the undersize bearing

Connecting rod bent

Correct or replace

Connecting rod bearing seized

Replace connecting rod bearings and crankshaft or regrind crankshaft pin and install the undersize bearing

Troubleshooting Procedure for Piston and Cylinder Noise Abnormal noise stops when the spark plug on the cylinder with defective part is shorted out. Condition

Possible cause

Piston and cylinder noise (Faulty piston or cylinder usually makes k a combined bi d mechanical h i l thumping g noise which increases when engine is suddenly accelerated but diminishes gradually as the engine warms up)

Piston clearance increased due to cylinder wear

Replace piston and cylinder body

Piston seized

Replace piston and cylinder body

Piston ring broken

Replace piston and cylinder body

Piston defective

Replace pistons and others

Correction

Troubleshooting Procedure for Piston Pin Noise Short out each spark plug and listen for change in engine noise. Condition Piston pin noise (Piston makes noise each time it goes up and down)

Possible cause Piston pin or piston pin hole worn

Correction Replace piston, piston pin and connecting rod assy

ENGINE MECHANICAL (6VE1 3.5L)

6A–13

Troubleshooting Procedure for Slapping or Hitting etc Noise The slapping sound stops when spark plug on bad cylinder is shorted out. Condition Timing belt noise

Possible cause

Correction

Timing belt tension is incorrect

Replace pusher or adjust the tension pulley or replace timing belt

Tensioner bearing defective

Replace

Timing belt defective

Replace

Timing pulley defective

Replace

Timing belt comes in contact with timing cover

Replace timing belt and timing cover

Valve clearance incorrect

Replace adjusting shim

Valve and valve guide seized

Replace valve and valve guide

Valve spring broken or weakened

Replace

Valve seat off–positioned

Correct

Camshaft worn out

Replace

Crankshaft noise

Crankshaft end play excessive (noise occurs when clutch is engaged)

Replace thrust bearing

Engine knocking

Preignition due to use of spark plugs of inadequate heat range

Install Spark Plugs of adequate heat range

Carbon deposits chambers

Clean

Valve noise

Others

combustion

Fuel too low in octane rating

Replace fuel

Wide Open Throttle enrichment system failure

Refer to Section 6E

Selection incorrect

Caution operator of incorrect gear selection

transmission

gear

Engine overheating

Refer to “Engine Lacks Power”

Water pump defective

Replace

Drive belt slipping

Replace auto tensioner or drive belt

6A–14

ENGINE MECHANICAL (6VE1 3.5L)

Abnormal Combustion Condition Trouble in fuel system

Trouble in emission control system

Trouble in ignition system

Possible cause

Correction

Fuel pressure control valve defective

Replace

Fuel filter clogged

Replace

Fuel pump clogged

Clean or replace

Fuel tank or fuel pipe clogged

Clean or replace

Fuel injector clogged

Clean or replace

Fuel pump relay defective

Replace

Power supply cable for fuel pump broken or poor connections

Reconnect, correct or replace

Mass Airflow (MAF) Sensor circuit open or defective

Correct or replace

MAF Sensor defective

Replace

Manifold Absolute Pressure Sensor circuit open or shorted

Correct or replace

Manifold Absolute Pressure Sensor defective

Replace

Engine Coolant Temperature (ECT) Sensor circuit open or shorted

Correct or replace

ECT Sensor defective

Replace

Throttle Position Sensor adjustment incorrect

Readjust

Throttle Position Sensor defective

Replace

Throttle Position Sensor connector poor connections

Reconnect

Vehicle Speed Sensor cable poor connections or defective

Correct or replace

Vehicle Speed Sensor loosely fixed

Fix tightly

Vehicle Speed Sensor in wrong contact or defective

Replace

Powertrain Control Module cable poor connections or defective

Correct or replace

Heated Oxygen Sensor circuit open

Correct or replace

Heated Oxygen Sensor defective

Replace

Signal vacuum hose loosely fitted or defective

Correct or replace

EGR Valve circuit open or shorted

Correct or replace

Exhaust Gas Recirculation Valve defective

Replace

ECT Sensor circuit open or shorted

Correct or replace

Canister Purge Valve circuit open or shorted

Correct or replace

Canister Purge Valve defective

Replace

ECT Sensor defective

Replace

Positive Crankcase Ventilation (PCV) valve and hose clogged

Correct or replace

Evaporator system

Refer to Section 6E

————

Refer to “Engine Lacks Power”

ENGINE MECHANICAL (6VE1 3.5L) Condition Trouble in cylinder head parts

Possible cause Carbon deposits chamber

Correction

combustion

Remove carbon

Carbon deposit on valve, valve seat and valve guide

Remove carbon

6A–15

6A–16

ENGINE MECHANICAL (6VE1 3.5L)

Engine Oil Consumption Excessive Condition

Possible cause

Oil leaking

Correction

Oil pan drain plug loose

Retighten or replace gasket

Crankcase fixing bolts loosened

Retighten

Oil pan setting bolts loosened

Retighten

Oil pan gasket broken

Replace gasket

Front cover retaining bolts loose or gasket broken

Retighten or replace gasket

Head cover fixing bolts loose or gasket broken

Retighten or replace gasket

Oil filter adapter cracked

Replace

Oil filter attachings bolt loose or rubber gasket broken

Retighten or replace oil filter

Crankshaft front or rear oil seal defective

Replace oil seal

Oil pressure unit loose or broken

Retighten or replace

Blow–by gas hose broken

Replace hose

Positive Crankcase Ventilation Valve clogged

Clean

Engine/Transmission coupling failed

Replace oil seal

Oil leaking into combustion chambers due to poor oor seal in valve system

Valve stem oil seal defective

Replace

Valve stem or valve guide worn

Replace valve and valve guide

Oil leaking into combustion chambers due to poor seal in cylinder parts t

Cylinders and excessively

Replace cylinder body assembly and pistons

Positive Crankcase System malfunctioning Others

Ventilation

Piston ring positioned

pistons gaps

worn

incorrectly

Correct

Piston rings set with wrong side up

Correct

Piston ring sticking

Replace cylinder body assembly and pistons

Piston ring and ring groove worn

Replace pistons and others

Return ports in oil rings clogged

Clean piston and replace rings

Positive Crankcase Ventilation Valve clogged

Clean

Improper oil viscosity

Use oil of recommended S.A.E. viscosity

Continuous high speed driving and/or severe usage such as trailer towing

Continuous high speed operation and/or severe usage will normally cause increased oil consumption

ENGINE MECHANICAL (6VE1 3.5L)

6A–17

Fuel Consumption Excessive Condition Trouble in fuel system

Possible cause

Correction

Mixture too rich or too lean due to trouble in fuel injection system

Refer to “Abnormal Combustion”

Fuel cut function does not work

Refer to “Abnormal Combustion”

Trouble in ignition system

Misfiring or abnormal combustion due to trouble in ignition system

Refer to “Hard Start” or “Abnormal Combustion”

Others

Engine idle speed too high

Reset Idle Air Control Valve

Fuel system leakage

Correct or replace

Clutch slipping

Correct

Brake drag

Correct

Selection incorrect

transmission

gear

Excessive Exhaust Gas Recirculation flow due to trouble in Exhaust Gas Recirculation system

Caution operator of incorrect gear selection Refer to “Abnormal Combustion”

Lubrication Problems Condition Oil pressure too low

Oil contamination

Oil not reaching valve system

Possible cause

Correction

Wrong oil in use

Replace with correct engine oil

Relief valve sticking

Replace

Oil pump not operating properly

Correct or replace

Oil pump strainer clogged

Clean or replace strainer

Oil pump worn

Replace

Oil pressure gauge defective

Correct or replace

Crankshaft bearing or connecting rod bearing worn

Replace

Wrong oil in use

Replace with correct engine oil

Oil filter clogged

Replace oil filter

Cylinder head gasket damage

Replace gasket

Burned gases leaking

Replace piston and piston rings or cylinder body assembly

Oil passage in cylinder head or cylinder body clogged

Clean or correct

Engine Oil Pressure Check 1. Check for dirt, gasoline or water in the engine oil. a. Check the viscosity of the oil. b. Check the viscosity of the oil. c. Change the oil if the viscosity is outside the specified standard. d. Refer to the “Maintenance and Lubrication” section of this manual. 2. Check the engine oil level. The level should fall somewhere between the “ADD” and the “FULL” marks on the oil level dipstick. If the oil level does not reach the “ADD” mark on the oil level dipstick, engine oil must be added.

3. Remove the oil pressure unit. 4. Install an oil pressure gauge. 5. Start the engine and allow the engine to reach normal operating temperature (About 80°C). 6. Measure the oil pressure. Oil pressure should be: 392–550 kPa (56.9–80.4 psi) at 3000 rpm. 7. Stop the engine. 8. Remove the oil pressure gauge. 9. Install the oil pressure unit. 10. Start the engine and check for leaks.

6A–18

ENGINE MECHANICAL (6VE1 3.5L)

Malfunction Indicator Lamp The instrument panel “CHECK ENGINE” Malfunction Indicator Lamp (MIL) illuminates by self diagnostic system when the system checks the starting of engine, or senses malfunctions. Condition “CHECK ENGINE” MIL does not illuminate at the starting of engine

“CHECK ENGINE” MIL illuminates, and stays on

Possible cause

Correction

Bulb defective

Replace

MIL circuit open

Correct or replace

Command signal circuit to operate self diagnostic system shorted

Correct or replace

Powertrain Control Module (PCM) cable loosely connected, disconnected or defective

Correct or replace

PCM defective

Replace

Deterioration of heated sensor internal element

oxygen

Replace

Heated oxygen sensor connector terminal improper contact

Reconnect properly

Heated oxygen sensor lead wire shorted

Correct

Heated oxygen sensor circuit open

Correct or replace

Deterioration of engine coolant temperature sensor internal element

Replace

Engine coolant temperature sensor connector terminal improper contact

Reconnect properly

Engine coolant temperature sensor lead wire shorted

Correct

Engine coolant temperature sensor circuit open

Correct or replace

Throttle position sensor open or shorted circuits

Correct or replace

Deterioration of crankshaft position sensor

Replace

Crankshaft position sensor circuit open or shorted

Correct or replace

Vehicle speed sensor circuit open

Correct or replace

Manifold absolute pressure sensor circuit open or shorted

Correct or replace

Intake air temperature sensor circuit open or shorted

Correct or replace

Fuel injector circuit open or shorted

Correct or replace

PCM driver transistor defective

Replace PCM

Malfunctioning of PCM RAM (Random Access Memory) or ROM (Read Only Memory)

Replace PCM

ENGINE MECHANICAL (6VE1 3.5L)

6A–19

Cylinder Head Cover LH Removal 1. Disconnect battery ground cable. 2. Remove engine cover from the dowels on the common chamber.

060RY022

Legend (1) Ignition Coil Connector (2) Bolt (3) Ignition Coil Assemblies F06RY001

3. Disconnect positive crankcase ventilation hose. 4. Remove ground cable fixing bolt on cylinder head cover. 5. Ignition coil connector and ignition coil. B Disconnect the three connectors from the ignition coils.

6. Disconnect fuel injector harness connector then remove fuel injector harness bracket bolt. 7. Remove eight fixing bolts, then the cylinder head cover.

B Remove harness bracket bolt on cylinder head cover. B Remove fixing bolts on ignition coils.

010RW001

NOTE: Where do you refer the tech in case of bolt removal difficulties.

6A–20

ENGINE MECHANICAL (6VE1 3.5L)

Installation 1. Install cylinder head cover. B Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely. B Apply sealant (TB-1207B or equivalent) of bead diameter 2-3 mm at eight place of arched area of camshaft bearing cap on front and rear sides. B The cylinder head cover must be installed with in 5 minutes after sealant application to prevent hardening of sealant. B Tighten bolts to the specified torque. Torque : 9 N·m (78 lb in)

060RY022

Legend (1) Ignition Coil Connector (2) Bolt (3) Ignition Coil Assembly CAUTION: Ignition coil assembly #6 is different from ignition coil assembly from #1 to #5. Ignition coil assembly #6 is short type. So, note it when installing ignition coil assembly of #6.

010RW008

2. Install fuel injection harness bracket and tighten bolt to the specified torque. Torque : 9 N·m (78 lb in) 3. Connect ignition coil connector and ignition coil, then tighten bolt to the specified torque. Torque : 4 N·m (35 lb in)

060RY00002

Legend (1) Long Type Ignition Coil Assemblies (# 1 ∼ # 5) (2) Short Type Ignition Coil Assembly (# 6) 4. Connect ground cable and tighten bolts to the specified torque. Torque : 9 N·m (78 lb in) 5. Install positive crankcase ventilation hose. 6. Install engine cover mating with the dowels.

ENGINE MECHANICAL (6VE1 3.5L)

6A–21

Cylinder Head Cover RH Removal

Installation

1. Disconnect battery ground cable. 2. Remove engine cover from the dowele on the common chamber.

1. Install cylinder head cover. B Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely. Apply sealant (TB-1207B or equivalent) bead (diameter 2-3 mm) at eight places of arched areas of camshaft bracket on front and rear sides. B The cylinder head cover must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. B Tighten bolts to the specified torque. Torque : 9 N·m (78 lb in)

F06RY001

3. Disconnect ventilation hose from cylinder head cover. 4. Disconnect three ignition coil connectors from ignition coils and remove harness bracket bolts on cylinder head cover then remove ignition coil fixing bolts on ignition coils and remove ignition coils. 5. Disconnect fuel injector harness connector then remove fuel injector harness bracket bolt. 6. Remove eight fixing bolts then the cylinder head cover. 014RW019

2. Tighten fuel injector harness bracket bolts to specified torque then reconnect fuel injector harness connector. Torque : 7.8 N·m (69 lb in) 3. Connect ignition coil connector and tighten ignition coil fixing bolts to specified torque. Torque : 4 N·m (35 lb in) 4. Connect ventilation hose to cylinder head. 5. Install engine cover mating with the dowels.

010RW002

6A–22

ENGINE MECHANICAL (6VE1 3.5L)

Common Chamber 9. Remove two bolts from common chamber rear side to remove fuel hose bracket. 10. Remove common chamber four bolts and four nuts then remove the common chamber.

Removal 1. Disconnect battery ground cable. 2. Remove air cleaner duct assembly.

013RY00001

Legend (1) Positive Crankcase Ventilation Hose Connector (2) Intake Air Temperature Sensor (3) Air Cleaner Duct Assembly (4) Air Flow Sensor 3. Disconnect vacuum booster hose from common chamber. 4. Disconnect connector from manifold absolute pressure sensor, Ion sensing module, throttle position sensor, solenoid valve, electric vacuum sensing valve, and EGR valve. 5. Disconnect vacuum hose on canister VSV and positive crankcase ventilation hose, fuel rail assembly with pressure control valve bracket. 6. Remove ventilation hose from throttle valve and intake duct and remove water hose. 7. Remove the four throttle body fixing bolts. 8. Remove exhaust gas recirculation valve assembly fixing bolt and nut on common chamber and remove EGR valve assembly.

025RY002

Legend (1) Common Chamber (2) Throttle Valve Assembly (3) Bolt

Installation 1. Install common chamber and tighten bolts and nuts to the specified torque. Torque : Bolt : 25 N·m (18 lb ft) Nut : 25 N·m (18 lb ft) 2. Install fuel hose bracket and tighten bolts to specified torque. Torque : 10 N·m (87 lb in) 3. Install exhaust gas recirculation valve assembly and tighten bolt and nut to the specified torque. Torque : 25 N·m (18 lb ft) 4. Install throttle body and tighten bolts to the specified torque. Torque : 25 N·m (18 lb ft) 5. Install ventilating hose to throttle valve and intake duct. 6. Connect vacuum hoses on canister VSV and positive crankcase ventilation hose. Tighten bolts for fuel rail assembly with pressure control valve bracket. Torque : 25 N·m (18 lb ft)

ENGINE MECHANICAL (6VE1 3.5L) 7. Connect each connector. 8. Connect vacuum booster hose. 9. Connect the Ion sensing module connectors as shown in the illustration.

060RY00111

Legend (1) Green Connector (2) Blue Connector (3) Identification Mark (6VE1 Engine Only) 10. Install air cleaner duct assembly.

013RY00001

Legend (1) Positive Crankcase Ventilation Hose Connector (2) Intake Air Temperature Sensor (3) Air Cleaner Duct Assembly (4) Mass Air Flow Sensor

6A–23

6A–24

ENGINE MECHANICAL (6VE1 3.5L)

Exhaust Manifold LH Removal

Installation

1. Disconnect battery ground cable. 2. Disconnect O2 sensor connector. 3. Remove exhaust front pipe three stud nuts from exhaust side and two bolts from rear end of exhaust front pipe.

1. Install exhaust manifold and tighten exhaust manifold fixing nuts to the specified torque with new nuts. Torque: 57 N·m (42 lb ft) 2. Install exhaust front pipe and tighten three stud nuts and two bolts to the specified torque. Torque : Stud nuts: 67 N·m (49 lb ft) Bolts: 43 N·m (32 lb ft)

150R100011

Legend (1) Exhaust Front Pipe LH (2) O2 Sensor 4. Remove exhaust manifold eight fixing nuts and remove exhaust manifold from the engine.

150R100011

Legend (1) O2 Sensor (2) Exhaust Front Pipe LH 3. Reconnect O2 sensor connector.

ENGINE MECHANICAL (6VE1 3.5L)

6A–25

Exhaust Manifold RH Removal

Installation

1. Disconnect battery ground cable. 2. Remove torsion bar. Refer to removal procedure in Front Suspension section. 3. Remove exhaust front pipe three stud nuts and two bolts then disconnect exhaust front pipe.

1. Install exhaust manifold and tighten nuts to the specified torque. Torque : 57 N·m (42 lb ft) 2. Install exhaust front pipe and tighten three stud nuts and two bolts to the specified torque. Torque: Stud nuts: 67 N·m (49 lb ft) Bolts: 43 N·m (32 lb ft) 3. Install the torsion bar and readjust the vehicle height. Refer to installation and vehicle height adjustment procedure for front suspension.

150R100013

Legend (1) Exhaust Front Pipe RH (2) O2 Sensor 4. Remove exhaust manifold eight fixing nuts then the exhaust manifold.

6A–26

ENGINE MECHANICAL (6VE1 3.5L)

Crankshaft Pulley Removal

Legend (1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Idle Pulley (8) Driver Belt

1. Disconnect battery ground cable. 2. Remove air cleaner assembly.

5. Remove cooling fan assembly four fixing nuts, then the cooling fan assembly. 6. Remove crankshaft pulley assembly using J-8614-01 crankshaft holder, hold crankshaft pulley then remove center bolt and pulley.

Installation 1. Install crankshaft pulley using J-8614-01 crankshaft holder, hold the crankshaft pulley and tighten center bolt to the specified torque. Torque : 167 N·m (123 lb ft) 013RY00001

Legend (1) Positive Crankcase Ventilation Hose Connector (2) Intake Air Temperature Sensor (3) Air Cleaner Duct Assembly (4) Air Flow Sensor 3. Remove radiator upper fan shroud from radiator. 4. Move serpentine belt tensioner to loose side using wrench then remove serpentine belt.

850RW001

2. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque : 22 N·m (16 lb ft) for fan pulley and fan bracket. Torque : 7.5 N·m (66.4 lb in) for fan and clutch assembly. 3. Move serpentine belt tensioner to loose side using wrench, then install serpentine belt to normal position. 4. Install radiator upper fan shroud. 5. Install air cleaner assembly.

ENGINE MECHANICAL (6VE1 3.5L)

6A–27

Timing Belt Removal 1. Disconnect battery ground cable. 2. Remove air cleaner assembly. 3. Remove radiator upper fan shroud from radiator. 4. Move drive belt tensioner to loose side using wrench then remove drive belt.

11. Remove right side timing belt cover then left side timing belt cover. 12. Remove lower timing belt cover 13. Remove pusher. CAUTION: The pusher prevents air from entering the oil chamber. Its rod must always be facing upward.

850RW001 014R100020

Legend (1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Idle Pulley (8) Drive Belt 5. Remove cooling fan assembly four nuts, then the cooling fan assembly. 6. Remove cooling fan drive pulley assembly. 7. Remove idle pulley assembly. 8. Remove serpentine belt tensioner assembly. 9. Remove power steering pump assembly. 10. Remove crankshaft pulley assembly using J-8614-01 crankshaft holder, hold crankshaft pulley remove center bolt, then the pulley.

Legend (1) Up Side (2) Down Side (3) Direction For Installation (4) Locking Pin (5) Apply a force of 980 N (220 lb) when compressing the pusher rod. 14. Remove timing belt. CAUTION: 1. Do not bend or twist the belt, otherwise its core could be damaged. The belt should not be bent at a radius less than 30 mm (1.1811 in). 2. Do not allow oil or other chemical substances to come in contact with the belt. They will shorten the life. 3. Do not attempt to pry or stretch the belt with a screw driver or any other tool during installation. 4. Store timing belt in a cool and dark place. Never expose the belt direct sunlight or heat.

6A–28

ENGINE MECHANICAL (6VE1 3.5L)

Installation NOTE: For correct belt installation, the letter on the belt must be able to be read as viewed from the front of the vehicle.

1. Install timing belt. 1. Align groove of crankshaft timing pulley (2) with mark on oil pump (1). Align the mark on the crankshaft timing pulley (3) with alignment mark (white dotted line) on the timing belt (4). Secure the belt with a double clip or equivalent clip. NOTE: When timing marks are aligned, No.2 piston will be on Top Dead Center.

014RW005

Legend (1) Crankshaft Timing Pulley (2) RH Bank Camshaft Drive Gear Pulley (3) Water Pump Pulley (4) Idle Pulley (5) LH Bank Camshaft Drive Gear Pulley (6) Tension Pulley (7) Alignment Mark on Oil Pump. (8) Alignment Mark on Timing Belt

014RW003

Legend (1) Alignment Mark on Oil Pump (2) Groove on Crankshaft Timing Pulley (3) Alignment Mark on Crankshaft Timing Pulley (4) Alignment Mark on Timing Belt 2. Align the alignment mark on the RH bank camshaft drive pulley (2) to the alignment mark of the cylinder head cover RH (3). The camshaft pulley is not 1:1 with the camshafts. It is necessary to rotate the camshaft pulley until the camshaft lobes are in the position as shown in the diagram on page 6A–34. The camshaft pulley alignment mark should also align with alignment mark on the cylinder head cover. It may require up to four revolutions of the camshaft pulley to achieve alignment of all marks.

014RW006

Legend (1) Timing Belt (2) Engine Rotation Direction (3) Cylinder Head Side

ENGINE MECHANICAL (6VE1 3.5L) 3. Align the alignment mark (white line) on the timing belt (1) with alignment mark on the RH bank camshaft drive pulley (2) (on the left side as viewed from the front of the vehicle) and put the timing belt on the camshaft drive pulley. Secure the belt with a double clip or equivalent clip.

6A–29

NOTE: It is recommended for easy installation that the belt be secured with a double clip or equivalent clips after it is installed to each pulley.

014RW00005

014RW00004

Legend (1) Alignment Mark on Timing Belt (White line). (2) Alignment Mark on Camshaft Drive Pulley. (3) Alignment Mark on Cylinder Head Cover RH. 4. Align the alignment mark on the LH bank camshaft drive pulley (2) to the alignment mark of the cylinder head cover LH (3). The camshaft pulley is not 1:1 with the camshafts. It is necessary to rotate the camshaft pulley until the camshaft lobes are in the position as shown in the diagram on page 6A–34. The camshaft pulley alignment mark should also align with alignment mark on the cylinder head cover. It may require up to four revolutions of the camshaft pulley to achieve alignment of all marks. 5. Align the alignment mark (white line) on the timing belt (1) with the alignment mark on the LH bank camshaft drive pulley (2). When aligning the timing marks, use a wrench to turn the camshaft drive pulley, then set the timing mark between timing belt and camshaft drive pulley and put the timing belt on the camshaft drive pulley. Secure the belt with a double clip or equivalent clip.

Legend (1) Alignment Mark on Timing Belt (White line). (2) Alignment Mark on Camshaft Drive Pulley. (3) Alignment Mark on Cylinder Head Cover LH. 6. Install crankshaft pulley temporarily and tighten center bolt by hand (do not use a wrench). Turn the crankshaft pulley clockwise to give some belt slack between the crankshaft timing pulley and the RH bank camshaft drive pulley. 2. Install pusher and tighten bolt to the specified torque. Torque : 25 N·m (2.5 kg·m/18 lb ft) 1. Install the pusher while pushing the tension pulley to the belt. 2. Pull out pin from the pusher. NOTE: When reusing the pusher, press the pusher with approximately 100Kg to retract the rod, and insert a pin (1.4 mm (0.055 in) piano wire).

6A–30

ENGINE MECHANICAL (6VE1 3.5L) 3. Install timing belt cover. Remove crankshaft pulley that was installed in step 1 item 5. Tighten bolts to the specified torque. Torque: 19 N·m (14 lb ft)

014R100020

Legend (1) Up Side (2) Down Side (3) Direction for Installation (4) Locking Pin (5) Apply a force of 980 N (220 lb) when compressing the pusher rod.

020RW004

After release the push rod from the locking pin, the rod projection is approximate 5 mm (0.1969 in).

Legend (1) Timing Belt Cover RH (2) Timing Belt Cover LH (3) Timing Belt Cover Lower

014R100032

Legend (1) Tensioner Pulley (2) Crankshaft Pulley Rotation Direction (3) Crankshaft Pulley (4) Pusher Assembly 3. Remove double clips or equivalent clips from timing belt pulleys. Turn the crankshaft pulley by six turns and check for timing mark alignment.

020RW003

Legend (1) Timing Belt Cover (2) Rubber Bushing (3) Sealing Rubber (4) Cylinder Body 4. Install crankshaft pulley using J-8614-01, hold the crankshaft pulley and tighten center bolt to the specified torque. Torque : 167 N·m (123 lb ft)

ENGINE MECHANICAL (6VE1 3.5L) 5. Install fan pulley bracket and tighten fixing bolts to the specified torque. Torque : 22 N·m (16 lb ft) 6. Install power steering pump assembly and tighten to the specified torque. Torque : M8 bolt : 22 N·m (16 lb ft) M10 bolt : 46 N·m (34 lb ft) 7. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque : 22 N·m (16 lb ft) for fan pulley and fan bracket. Torque : 7.5 N·m (66.4 lb in) for fan and clutch assembly. 8. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position.

850RW001

Legend (1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Idle Pulley (8) Drive Belt 9. Install radiator upper fan shroud. 10. Install air cleaner assembly.

6A–31

6A–32

ENGINE MECHANICAL (6VE1 3.5L)

Camshaft 9. Remove three fixing bolts from camshaft drive gear retainer, then camshaft drive gear assembly.

Removal 1. Disconnect battery ground cable. 2. Remove crankshaft pulley. B Refer to removal procedure for Crankshaft Pulley in this manual. 3. Remove timing belt. B Refer to removal procedure for Timing Belt in this manual. 4. Remove cylinder head cover LH. B Refer to removal procedure for Cylinder Head Cover LH in this manual. 5. Remove cylinder head cover RH. B Refer to removal procedure for Cylinder Head Cover RH in this manual. 6. Remove twenty fixing bolts from inlet and exhaust camshaft bearing cap on one side bank, then camshaft bearing cap.

014RW026

Legend (1) Right Bank (2) Left Bank (3) Timing Mark on Retainer

014RW027

7. Remove camshaft assembly. 8. Remove fixing bolt for camshaft drive gear pulley.

ENGINE MECHANICAL (6VE1 3.5L)

6A–33

Installation 1. Install camshaft drive gear assembly and tighten three bolts to the specified torque. Torque : 10 N·m (87 lb in) 2. Tighten bolt for camshaft drive gear assembly pulley to the specified torque. Torque : 98 N·m (72 lb ft) 3. Tighten sub gear setting bolt. 1. Use J-42686 to turn sub gear to right direction until it aligns with the M5 bolt hole between camshaft driven gear and sub gear. 2. Tighten the M5 bolt to a suitable torque to prevent the sub gear from moving.

014RW020

Legend (1) Intake Camshaft Timing Gear for Right Bank (2) Intake Camshaft Timing Gear for Left Bank (3) Exhaust Camshaft Timing Gear (4) Discrimination Mark (LI: Left bank intake, RI: Right bank intake) (LE: Left bank exhaust, RE: Right bank exhaust)

014RW041

4. Install camshaft assembly and camshaft bearing caps, tighten twenty bolts on one side bank to the specified torque. 1. Apply engine oil to camshaft journal and bearing surface of camshaft bearing caps. 2.

Align timing mark on intake camshaft (one dot for right bank, two dot for left bank) and exhaust camshaft (one dots for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot).

014RW023

Legend (1) Right Bank Camshaft Drive Gear (2) Left Bank Camshaft Drive Gear (3) Timing Mark on Drive Gear (4) Dowel Pin

6A–34

ENGINE MECHANICAL (6VE1 3.5L)

014RW024

(3) Alignment Mark on Camshaft Drive Gear (4) Alignment Mark on Camshaft (5) Alignment Mark on Retainer

Legend (1) Right Bank (2) Left Bank

3. Tighten twenty bolts on numerical order an one side bank as shown in the illustration. Torque : 10 N·m (87 lb in)

014RW031

5. Install cylinder head cover RH. B Refer to installation procedure for CYLINDER HEAD COVER RH in this manual. 6. Install cylinder head cover LH. B Refer to installation procedure for CYLINDER HEAD COVER LH in this manual. 7. Install timing belt. B Refer to installation procedure for TIMING BELT in this manual. 8. Install crankshaft pulley. B Refer to installation procedure for CRANKSHAFT PULLEY in this manual.

ENGINE MECHANICAL (6VE1 3.5L)

6A–35

Cylinder Head Removal

Installation

1. Remove engine hood. 2. Disconnect battery ground cable. 3. Drain radiator coolant. 4. Drain engine oil. 5. Remove crankshaft pulley. B Refer to removal procedure for Crankshaft Pulley in this manual. 6. Remove timing belt. B Refer to removal procedure for Timing Belt in this manual. 7. Remove cylinder head cover LH. B Refer to removal procedure for Cylinder Head Cover LH in this manual. 8. Remove cylinder head cover RH. B Refer to removal procedure for Cylinder Head Cover RH in this manual. 9. Remove common chamber. B Refer to removal procedure for Common Chamber in this manual. 10. Remove cylinder head assembly. 1. Loosen head bolts in reverse of tightening sequence.

1. Install cylinder head assembly to cylinder block. A. Put cylinder head gasket on the cylinder block. NOTE: There is discrimination mark “R” for right bank and “L” for left bank on the cylinder head gasket as shown in the illustration. Do not reuse cylinder head gasket.

2. Remove cylinder head assembly. 011RW005

B. Align dowel pin hole to dowel pin on the cylinder block. C. Position cylinder head on the cylinder block. D. Tighten two bolts temporarily by hand to prevent the cylinder head assembly from moving. E. Using J-24239-01 cylinder head bolt wrench, tighten bolts in numerical order as shown in the illustration to the specified torque.

014RW028

Legend (1) Cylinder Head (2) Cylinder Head Bolt (3) Camshaft

6A–36

ENGINE MECHANICAL (6VE1 3.5L)

NOTE: Do not reuse cylinder head bolts. Do not apply any lubricant to the cylinder head bolts. Torque : Temporary : 29 N·m (22 lb ft) Final : 64 N·m (47 lb ft)

014RW029

2. Install common chamber. B Refer to installation procedure for Common Chamber in this manual. 3. Install cylinder head cover RH. B Refer to installation procedure for Cylinder Head Cover RH in this manual. 4. Install cylinder head cover LH. B Refer to installation procedure for Cylinder Head Cover LH in this manual. 5. Install timing belt. B Refer to installation procedure for Timing Belt in this manual. 6. Install crankshaft pulley. B Refer to installation procedure for Crankshaft Pulley in this manual.

ENGINE MECHANICAL (6VE1 3.5L)

6A–37

Valve Stem Oil Controller , Valve Spring and Valve Guide Removal

Installation

1. Disconnect battery ground cable. 2. Drain engine oil. B Drain engine coolant. 3. Remove cylinder head assembly. B Refer to removal procedure for Cylinder Head in this manual. 4. Remove camshaft. B Refer to removal procedure for Camshaft in this manual. 5. Remove tappets with shim.

1. Install valve guide using J-42899 valve guide installer. 2. Install oil controller using J-38537 oil controller installer. 3. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using J-8062 valve spring compressor and J-42898 valve spring compressor adapter to install the split collars.

NOTE: Do not damage shim surface. 6. Remove valve springs using J-8062 valve spring compressor and J-42898 valve spring compressor adapter then remove upper valve spring seat and lower seat.

014RW042

7. Remove oil controller using J-37281 oil controller remover, remove each valve stem oil controller. 8. Remove valve guide using J-37985 valve guide replacer.

4. Install tappet with shim. 5. Install camshaft assembly. B Refer to installation procedure for Camshaft in this manual. 6. Install cylinder head assembly. B Refer to installation procedure for Cylinder Head in this manual. 7. Fill engine oil until full level. 8. Fill engine coolant.

6A–38

ENGINE MECHANICAL (6VE1 3.5L)

Piston, Piston Ring and Connecting Rod Removal

F06RW011

Legend (1) Cylinder Head (2) Crankcase with Oil Pan (3) Oil Pipe

1. Remove cylinder head assembly. B Refer to removal procedure for Cylinder Head in this manual.

(4) Oil Strainer (5) Oil Gallery (6) Piston with Connecting Rod Assembly

2. Remove crankcase with oil pan. B Refer to removal procedure for Oil Pan and Crankcase in this manual.

ENGINE MECHANICAL (6VE1 3.5L)

6A–39

3. Remove oil strainer fixing bolts, remove oil strainer assembly with O-ring.

015RW003

050RW002

Legend (1) Oil Pump (2) Oil Strainer (3) Oil Gallery (4) From Oil Filter (5) To Oil Filter 4. Remove three fixing bolts, oil pipe with O-ring. 5. Remove eight fixing bolts, oil gallery. 6. Remove piston with connecting rod assembly. (before removing the bearing cap, remove carbon on the top of cylinder bore and push piston with connecting rod out from the top of cylinder bore.)

Legend (1) Piston Front Mark (2) Piston Grade (3) Connecting Rod Front Mark 2. Install oil gallery and tighten the bolts in two steps, in the order shown in illustration. Torque : 1st step : 29 N·m (22 lb ft) 2nd step : 55°–65°

Installation 1. Install piston with connecting rod assembly. B Apply engine oil to cylinder bore, connecting rod bearing and crank pin. When installing the piston, its front mark must face the engine front side. B The bearing cap number must be the same as connecting rod number. B Apply engine oil to the thread and seating surface of each nut. B Tighten nuts to the specified torque. Torque : 54 N·m (40 lb ft) B After tightening the nuts, make sure that the crankshaft rotates smoothly. NOTE: Do not apply engine oil to the bearing back faces and connecting rod bearing fitting surfaces.

051RS009

3. Install oil pipe with O-ring. Torque : 10 N·m (87 lb in) 4. Install oil strainer assembly with O-ring. Torque : 25 N·m (18 lb ft) 5. Install crankcase with oil pan. B Refer to installation procedure for Oil Pan and Crankcase in this manual. 6. Install cylinder head assembly. B Refer to installation procedure for Cylinder Head in this manual.

6A–40

ENGINE MECHANICAL (6VE1 3.5L)

Crankshaft and Main Bearings Removal

F06RY002

Legend (1) Engine Assembly (2) Crankshaft Pulley (3) Timing Belt Cover (4) Timing Belt (5) Crankcase with Oil Pan (6) Oil Pipe (7) Oil Strainer

1. Remove engine assembly. B Refer to removal procedure for Engine Assembly in this manual. 2. Remove timing belt. B Refer to removal procedure for Timing Belt in this manual.

(8) (9) (10) (11) (12) (13) (14) (15)

Oil Pump Assembly Cylinder Body Side Bolt Oil Gallery Flywheel Rear Oil Seal Retainer Connecting Rod Cap Crankshaft Main Bearing Cap Crankshaft and Main Bearing

3. Remove oil pan and crankcase. B Refer to removal procedure for Oil Pan and Crankcase in this manual. 4. Remove oil pipe with O-ring. 5. Remove oil strainer assembly with O-ring.

ENGINE MECHANICAL (6VE1 3.5L)

6A–41

6. Remove oil pump assembly. B Refer to removal procedure for Oil Pump in this manual. 7. Remove cylinder body side bolts. 8. Remove oil gallery. 9. Remove flywheel. 10. Remove rear oil seal retainer. B Refer to removal procedure for Rear Oil Seal in this manual. 11. Remove connecting rod caps. 12. Remove crankshaft main bearing caps. 13. Remove crankshaft and main bearings.

Installation 1. Install crankshaft and main bearings. B Install main bearing in the cylinder block and main bearing cap respectively. Apply new engine oil to upper and lower main bearings. NOTE: B B B B B B

Do not apply engine oil to the bearing back faces. Make sure that main bearings are in correct position. Install crankshaft with care. Apply engine oil to the thrust washer. Install thrust washer on No.3 journal. Oil grooves in thrust washer must face the crankshaft.

015RS013

2. Install crankshaft main bearing caps. B Apply engine oil to the thread and seating surface of each bearing cap fixing bolt. NOTE: B Do not apply engine oil to the bearing back faces. B Install bearing caps, starting with cylinder block front side. B Tighten main bearing fixing bolts to the specified torque. Torque : 39 N·m (29 lb ft) B After tightening the bolts, make sure that the crankshaft rotates smoothly. 3. Install connecting rod caps. B The cap number must be same as connecting rod number. B Apply engine oil to the thread and seating surface of each nut. B Tighten nuts to the specified torque. Torque : 54 N·m (40 lb ft) B After tightening the nuts, make sure that the crankshaft rotates smoothly. 4. Install rear oil seal retainer. B Remove oil on cylinder block and retainer fitting surface. B Apply sealant (TB1207B or equivalent) to retainer fitting surface as shown in illustration.

015RS012

B The oil seal retainer must be installed within 5 minutes after sealant application to prevent premature hardening of sealant.

6A–42

ENGINE MECHANICAL (6VE1 3.5L)

015RW002

Legend (1) Around Bolt Holes (2) Around Dowel Pin B Apply engine oil to oil seal lip and align a dowel pin hole in the cylinder block with that in the retainer. B Tighten retainer fixing bolts to the specified torque. Torque : 18 N·m (13 lb ft)

015RS018

6. Install oil gallery. B Clean contact surface of oil gallery and main bearing cap. Apply engine oil to oil gallery fixing bolts and tighten the bolts in two steps, in the order shown. Torque : 1st step : 29 N·m (22 lb ft) 2nd step : 55°–65° 7. Install cylinder body side bolts and tighten bolts in order to the specified torque. Torque : 39 N·m (29 lb ft) NOTE: Do not apply the oil to the bolts.

015RW001

5. Install flywheel. B Clean tapped holes in the crankshaft. B Remove oil on crankshaft and flywheel fitting surface. NOTE: B Do not reuse the bolts. B Do not apply oil or thread lock to the bolts. B Tighten fixing bolts to the specified torque. Torque : 54 N·m (40 lb ft)

012RS007

8. Install oil pump assembly. B Remove oil on cylinder block and oil pump mounting surface. B Apply sealant (TB1207B or equivalent) to the oil pump mounting surface. B The oil pump assembly must be installed within 5 minutes after sealant application to prevent premature hardening of sealant.

ENGINE MECHANICAL (6VE1 3.5L) B Apply engine oil to oil seal lip. B Install oil pump in the cylinder block and tighten fixing bolts to the specified torque. Torque : 25 N·m (18 lb ft)

6A–43

B Properly apply a 4.5 mm (0.7 in) wide bead of sealant (TB1207C or equivalent) to the crankcase mounting surface. The bead must be continuous. B The crankcase must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. B Tighten fixing bolts to the specified torque. Torque : 10 N·m (87 lb in)

051RW002

Legend (1) Around Bolt Holes (2) Around Dowel Pin 013RW010

051RW001

9. Install oil strainer with O-ring, tighten to the specified torque. Torque : 25 N·m (18 lb ft) 10. Install oil pipe with O-ring, tighten fixing bolts to the specified torque. Torque : 25 N·m (18 lb ft) 11. Install crankcase. B Remove oil on crankcase mounting surface and dry the surface.

013RW004

12. Install oil pan B Remove oil on oil pan mounting surface and dry the surface. B Properly apply a 4.5 mm (0.7 in) wide bead of sealant (TB1207C or equivalent) to the oil pan mounting surface. The bead must be continuous. B The oil pan must be installed within 5 minutes after sealant application to prevent premature hardening of sealant.

6A–44

ENGINE MECHANICAL (6VE1 3.5L)

B Tighten fixing bolts to the specified torque. Torque : 25 N·m (18 lb ft)

013RW003

013RW002

13. Install timing belt. B Refer to installation procedure for Timing Belt in this manual. 14. Install engine assembly. B Refer to installation procedure for Engine Assembly in this manual.

ENGINE MECHANICAL (6VE1 3.5L)

6A–45

Rear Oil Seal Removal 1. Remove transmission assembly. B See Transmission section in this manual. 2. Remove flywheel. 3. Remove rear oil seal using a seal remover. NOTE: Take care not to damage the crankshaft or oil seal retainer when removing oil seal.

Installation 1. Apply engine oil to oil seal lip and install oil seal using J-39201.

015RS018

3. Install transmission. B See Transmission section in this manual. CAUTION: When assembling the engine and transmission, confirm that dowels have been mounted in the specified positions at the engine side. NOTE: Take care that dowel positions are different between the manual transmission and the automatic transmission. Otherwise, the transmission may be damaged.

015RS017

2. Install flywheel. B Clean tapped holes in the crankshaft. B Remove oil on the crankshaft and flywheel mounting surface. B Tighten fixing bolts to the specified torque. NOTE: Do not reuse the bolts and do not apply oil or thread lock to the bolts. Torque : 54 N·m (40 lb ft)

012RS009

6A–46

ENGINE MECHANICAL (6VE1 3.5L)

Engine Assembly Removal

035R200001

1. Disconnect battery ground and positive cable. 2. Remove battery. 3. Make alignment mark on the engine hood and hinges before removal in order to return the hood to original position exactly. 4. Remove engine hood. 5. Drain radiator coolant. 6. Disconnect Ion sensing module harness connectors, and manifold absolute pressure sensor harness connectors from sensor on common chamber. 7. Disconnect throttle position sensor harness connectors from throttle body. 8. Disconnect air duct with air cleaner cover. 9. Remove air cleaner assembly. 10. Disconnect canister vacuum hose. 11. Disconnect vacuum booster hose. 12. Disconnect three engine harness connectors. 13. Disconnect harness connector to transmission (left front side of engine compartment), disconnect shift on the fly harness connector from front side of front axle and remove transmission harness bracket from engine left side. 14. Disconnect ground cable between engine and frame. 15. Disconnect bonding cable connector on the back of right dash panel. 16. Disconnect bonding cable terminal on the left bank. 17. Disconnect starter harness connector from starter. 18. Disconnect generator harness connector from generator. 19. Disconnect coolant reserve tank hose from radiator. 20. Remove radiator upper and lower hoses.

21. Remove upper fan shroud. 22. Remove cooling fan assembly four fixing nuts, then the cooling fan assembly. 23. Move drive belt tensioner to loose side using wrench then remove drive belt. 24. Remove power steering pump fixing bolts, then power steering pump. Place the power steering pump along with piping on the body side. 25. Remove air conditioning compressor fixing bolts from bracket and place the compressor along with piping on the body side. 26. Remove four O2 sensor harness connectors (two each bank) from exhaust front pipe. 27. Remove three exhaust pipe fixing nuts from each bank. 28. Remove two exhaust pipe fixing nuts from each exhaust pipe, then move exhaust pipe to rear side of vehicle. 29. Remove flywheel dust covers. 30. Disconnect two heater hoses from engine. 31. Disconnect fuel hoses from right side of transmission. CAUTION: Plug fuel pipes on engine side and fuel hoses from fuel tank. 32. Remove transmission assembly. Refer to Transmission section in this manual. 33. Support the engine by engine hoist. 34. Remove two left side engine mount fixing bolts from engine mount on chassis side. 35. Remove two right side engine mount fixing bolts from engine mount on chassis side. 36. Remove engine assembly.

ENGINE MECHANICAL (6VE1 3.5L)

6A–47

Installation CAUTION: When assembling the engine and transmission, confirm that dowels have been mounted in the specified positions at the engine side. NOTE: Take care that dowel positions are different between the manual transmission and the automatic transmission. If the engine is assembled in the condition that the dowels have not been mounted in the specified positions, the transmission may be damaged.

150R200002

Legend (1) Exhaust Front Pipe RH (2) O2 Sensor

012RS009

1. Install engine assembly. Tighten engine mount fixing bolts to frame to the specified torque. Torque: 41 N·m (30 lb ft) 2. Reconnect fuel hose to fuel pipe on engine. 3. Install transmission assembly. Refer to Transmission section in this manual. 4. Reconnect two heater hoses to engine. 5. Install flywheel dust covers. 6. Install exhaust pipe and temporally tighten two (each bank) rear exhaust flange nuts then tighten three stud nuts (each bank) between exhaust manifold and exhaust pipe, finally tighten rear side nuts to the specified torque. Torque: Nuts: 43 N·m (32 lb ft) Stud nuts: 67 N·m (49 lb ft)

150R200003

Legend (1) O2 Sensor (2) Exhaust Front Pipe LH 7. Reconnect O2 sensor connector. 8. Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque : 22 N·m (16 lb ft) for fan pulley and fan bracket. Torque : 7.5 N·m (66.4 lb in) for fan and clutch assembly.

6A–48

ENGINE MECHANICAL (6VE1 3.5L)

9. Install air conditioner compressor to engine and tighten to the specified torque. Torque : M8 bolts : 22 N·m (16 lb ft) M10 bolts : 43 N·m (32 lb ft) 10. Install power steering pump, tighten fixing bolt to the specified torque. Torque : M8 bolts : 22N·m (16 lb ft) M10 bolts : 46 N·m (34 lb ft) 11. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position.

24. Install air cleaner assembly. 25. Reconnect air duct. 26. Reconnect throttle position connector.

sensor

harness

025RY001

Legend (1) Throttle Position Sensor Connector (2) Throttle Valve Assembly 27. Reconnect manifold absolute pressure sensor harness connectors. 28. Reconnect ion sensing module connectors as shown in the illustration. 850RW001

Legend (1) Crankshaft Pulley (2) Cooling Fan Pulley (3) Tensioner (4) Generator (5) Air Conditioner Compressor (6) Power Steering Oil Pump (7) Idle Pulley (8) Drive Belt 12. Install upper fan shroud. 13. Reconnect radiator upper and lower hoses. 14. Reconnect coolant reserve tank hose to radiator. 15. Reconnect generator harness connector. 16. Reconnect starter harness connector. 17. Reconnect bonding cable terminal on left bank 18. Reconnect bonding cable terminal on the back of right dash panel. 19. Reconnect ground cable between engine and chassis. 20. Reconnect harness connector to transmission and install transmission harness bracket on engine left side. 21. Reconnect three engine harness connectors. 22. Reconnect vacuum booster hose. 23. Reconnect canister vacuum hose.

060RY00111

Legend (1) Green Connector (2) Blue Connector (3) Identification Mark (6VE1 Engine Only) 29. Install engine hood to the original position. B Refer to installation procedure for Body section in this manual.

ENGINE MECHANICAL (6VE1 3.5L)

6A–49

Cylinder Head Cylinder Head and Associated Parts

011RW008

Legend (1) Spark Plug (2) Cylinder Head Bolt (3) Camshaft Drive Gear Pulley Fixing Bolt (4) Camshaft Drive Gear Pulley (5) Camshaft Bearing Cap Fixing Bolt (6) Camshaft Bearing Cap (7) Camshaft Exhaust

(8) (9) (10) (11) (12) (13) (14)

Camshaft Intake Retainer Fixing Bolt Retainer Assembly Tappet with Shim Split Collar Valve Spring and Spring Upper Seat Valve

6A–50

ENGINE MECHANICAL (6VE1 3.5L)

Disassembly

Inspection and Repair

NOTE: B During disassembly, be sure that the valve train components are kept together and identified so that they can be reinstalled in their original locations. B Before removing the cylinder head from the engine and before disassembling the valve mechanism, perform a compression test and note the results. 1. Remove camshaft drive gear pulley fixing bolt (3), then pulley (4). 2. Remove camshaft bearing cap fixing bolt (5), camshaft bearing cap (6), then camshaft exhaust (7), and intake side (8). 3. Remove tappet with shim (11). 4. Use the J–8062 valve spring compressor and J–42898 valve spring compressor adapter to remove the split collar (12), valve spring with upper seat (13) and valve (14).

1. Inspect cylinder head gasket and mating surfaces for leaks, corrosion and blow–by. If the gasket has failed, determine the cause. – Insufficient torque on head bolts – Improper installation – Loose or warped cylinder head – Missing dowel pins – Warped case surface 2. Inspect cylinder head for cracks, especially between valve seats and in the exhaust ports. 3. Inspect cylinder head deck for corrosion, sand particles in head and porosity. CAUTION: B Do not attempt to weld the cylinder head. Replace it. B Do not reuse cylinder head bolts. 4. Inspect cylinder head deck, common chamber and exhaust manifold mating surfaces for flatness. These surfaces may be reconditioned by milling. If the surfaces are “out of flat” with “round” by more than specification, the surface should be ground to within specifications. Replace the head if it requires machining beyond the repairable limit. Head surface and manifold surface Standard: 0.05 mm (0.002 in) or less Warpage limit: 0.2 mm (0.0079 in) Maximum Repairable limit: 0.2 mm (0.0079 in) Head height Standard height : 133.2 mm (5.2441 in) Warpage limit : 0.2 mm (0.0079 in) Maximum Repairable limit : 133.0 mm (5.2362 in)

014RW042

5. Remove spark plug (1). CAUTION: Do not remove the spark plugs when the head and plugs are hot. Clean dirt and debris from spark plug recess areas before removal.

Clean Cylinder head Carefully remove all varnish, soot and carbon from the bare metal. Do not use surface conditioning disc on any gasket sealing surface.

011RW019

5. Water jacket sealing plugs seating surfaces.

ENGINE MECHANICAL (6VE1 3.5L)

6A–51

Reassembly 1. Install Spark plug and tighten all the spark plugs to specified torque. Torque: 18 N·m (13 lb ft) 2. Tighten sub gear setting bolt. 1. Use J–42686 gear spring lever to turn sub gear to right direction until the M5 bolt aligns with the hole between camshaft driven gear and sub gear. 2. Tighten the M5 bolt to a suitable torque to prevent the sub gear from moving.

014RW020

Legend (1) Intake Camshaft Timing Gear for Right Bank (2) Intake Camshaft Timing Gear for Left Bank (3) Exhaust Camshaft Timing Gear (4) Discrimination Mark LI: Left Bank Intake RI: Right Bank Intake LE: Left Bank Exhaust RE: Right Bank Exhaust 014RW025

3. Install camshaft drive gear assembly and tighten three bolts to the specified torque. Torque: 10 N·m (87 lb in) 4. Install camshaft assembly and camshaft bearing cap, tighten twenty bolts on one side bank to the specified torque. 1. Apply engine oil to camshaft journal and bearing surface of camshaft bearing cap. 2. Align timing mark on intake camshaft (one dot for right bank, two dots for left bank) and exhaust camshaft (one dot for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot).

014RW023

Legend (1) Right Bank Camshaft Drive Gear (2) Left Bank Camshaft Drive Gear (3) Timing Mark on Drive Gear (4) Dowel Pin

6A–52

ENGINE MECHANICAL (6VE1 3.5L)

014RW024

(3) Alignment Mark on Camshaft Drive Gear (4) Alignment Mark on Camshaft (5) Alignment Mark on Retainer

Legend (1) Right Bank (2) Left Bank

3. Tighten twenty bolts in numerical order on each bank as shown in the illustration. Torque: 10 N·m (87 lb in)

014RW031

5. Tighten bolt for camshaft drive gear assembly pulley to the specified torque. Torque: 98 N·m (72 lb ft)

ENGINE MECHANICAL (6VE1 3.5L)

6A–53

Valve Spring, Oil Controller, Valve, Valve Guide Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts

014RW039

Legend (1) Camshaft Bearing Cap Fixing Bolts (2) Camshaft Assembly Inlet (3) Camshaft Assembly Exhaust (4) Shim (5) Tappet (6) Split Collar

Disassembly 1. Remove camshaft bearing cap fixing bolts (1). 2. Remove camshaft assembly (intake).

(7) (8) (9) (10) (11) (12)

Spring Upper Seat Valve Spring Oil Controller Spring Lower Seat Valve Guide Valve

3. Remove camshaft assembly (Exhaust side). 4. Remove shim (4) and tappet (5).

6A–54

ENGINE MECHANICAL (6VE1 3.5L)

5. Use the J–8062 valve spring compressor and J–42898 valve spring compressor adapter to remove split collar.

2. Measure the valve spring squareness with a steel square and replace the valve springs if the measured value exceeds the specified limit. Limit : 2 mm (0.079 in)

014RW042

6. Remove valve spring. 7. Remove valve. 8. Remove oil controller and spring lower seat. 9. Remove the valve guide using the J–42899 valve guide replacer.

Inspection and Repair Valve Spring

014RS005

3. Using a spring tester to compress the springs to the installed height, measure the compressed spring tension, and replace the springs if the measured tension is below the specified limit. At installed height: 35.0 mm (1.38 in) Standard: 196 N (44 lb) Limit: Less than 181 N (41 lb)

CAUTION: Visually inspect the valve springs and replace them if damage or abnormal wear is evident. 1. Measure the free height of the springs. The springs must be replaced if the free height is below the specified limit. Standard : 44.6 mm (1.756 in) Limit : 43.6 mm (1.717 in)

014RS006

Valve Guide CAUTION: Take care not to damage the valve seat contact surface, when removing carbon adhering to the valve head. Carefully inspect the valve stem for scratches or abnormal wear. If these conditions are present, the valve and the valve guide must be replaced as a set. 014RS004

ENGINE MECHANICAL (6VE1 3.5L) 1. Measure the valve stem diameter with a micrometer. If the valve stem diameter is less than the specified limit, the valve and the valve guide must be replaced as a set.

6A–55

Valve Guide Replacement 1. Using Valve guide replacer: J–42899, drive out the valve guide from the combustion chamber side.

Diameter of Valve Stem Intake Standard : 5.977 mm–5.959 mm (0.2353 in–0.2346 in) Limit : 5.90 mm (0.2323 in) Exhaust Standard : 5.952 mm–5.970 mm (0.2343 in–0.2350 in) Limit : 5.90 mm (0.2323 in)

014RS008

2. Apply engine oil to the outside of the valve guide. Using valve guide replacer J–42899, drive in a new valve guide from the camshaft side, and check the valve guide height. Valve guide upper end height: 13.0 mm (0.5118 in) (Measured from the cylinder head upper face)

014RS007

2. Measure the inside diameter of the valve guide with a micrometer. Subtract the measured outer diameter of the valve stem from the measured inner diameter of the valve guide. If the value exceeds the specified limit, the valve and the valve guide must be replaced as a set. Inside Diameter of the Vale Guide Inlet clearance Standard : 0.023 mm–0.056 mm (0.0009 in–0.0002 in) Limit : 0.20 mm (0.00787 in) Exhaust clearance Standard : 0.030 mm–0.063 mm (0.0012 in–0.0025 in) Limit : 0.20 mm (0.00787 in)

014RW046

3. Check the clearance. If the clearance is less than the specified value, ream the inside diameter of valve guide. Using a sharp 6 mm reamer, ream the valve guide to obtain the specified clearance.

6A–56

ENGINE MECHANICAL (6VE1 3.5L)

Valve Seat 1. Measure the protrusion of the valve stem when a new valve is installed in the cylinder head. If the protrusion of the valve stem exceeds the limit, replace the valve seat insert or the cylinder head assembly. Protrusion of valve stem Intake Standard: 39.32 mm (1.5480 in) Limit: 39.47 mm (1.5539 in) Exhaust Standard: 39.3 mm (1.5472 in) Limit: 39.45 mm (1.5531 in)

Contact Surface Angle on Valve Seat on Valve 1. Measure contact surface angle on valve seat. 2. If the measured value exceeds the limit, replace valve, valve guide and valve seat as a set. Valve contact surface angle: 45°

014RS012

Valve Seat Insert Correction

014RW047

2. Measure the valve seat contact width. Make the necessary corrections if the seat contact surface is damaged or rough or if the contact width wear exceeds the limit.

1. Remove the carbon from the valve seat insert surface. 2. Use a valve cutter to minimize scratches and other rough areas. This will bring the contact width back to the standard value. Remove only the scratches and rough areas. Do not cut away too much. Take care not to cut away unblemished areas of the valve seat surface. Valve seat angle degree: 90°

Valve seat contact width Standard: 1.1 mm (0.0433 in) Limit: 1.7 mm (0.0669 in)

014RW059

014RS011

ENGINE MECHANICAL (6VE1 3.5L) 3. Apply abrasive compound to the valve seat insert surface. 4. Insert the valve into the valve guide. 5. Turn the valve while lapping it to fit the valve seat insert. 6. Check that the valve contact width is correct. 7. Check that the valve seat insert surface is in contact with the entire circumference of the valve.

6A–57

4. Carefully clean the valve seat press–fit section on the cylinder head side. 5. Heat the press–fit section with steam or some other means to cause expansion. Cool the valve seat with dry ice or some other means. 6. Insert the press–fit section into the valve seat horizontally. Standard fitting interference: 0.14 mm–0.09 mm (0.0055 in–0.0035 in) 7. After insertion, use a seat grinder to grind finish the seating face. Carefully note the seating angle, the contact width, and the depression. 8. Lap the valve and the seat.

Reassembly 1. Install valve guide (1) to cylinder head. Apply engine oil to the outside of the valve guide. Using valve guide replacer J–42899, drive in a new valve guide from the camshaft side. 2. Install oil controller (3) and spring lower seat (2). Using oil controller replacer J–37281, drive in a new oil controller.

014RS014

Valve Seat Insert Replacement 1. Arc weld the rod at several points. Be careful not to damage the aluminum section. 2. Allow the rod to cool for a few minutes. This will cause the valve seat to shrink. 3. Strike the rod and pull it out.

014RW058

014RS015

6A–58

ENGINE MECHANICAL (6VE1 3.5L)

3. Install valve to valve guide. Before installing valve guide apply engine oil to the outside of the valve stem. 4. Install valve spring to cylinder head. Attach the valve spring to the lower spring seat. The painted area of the valve spring should be facing downward.

Valve Clearance Adjustments NOTE: To adjust valve clearance, apply engine oil to the cam as well as to the adjusting shim (2) with the cylinder head built on the cylinder block, give a few turns to the camshaft by means of timing pulley tightening bolt, and measure valve clearance when the nose of cam is just opposite of maximum cam lift (1) as shown in illustration below.

014RS020

5. Install lower valve spring seat, valve spring and upper valve spring seat then put split collars on the upper spring seat, using the J–8062 valve spring compressor and J–42898 valve spring compressor adapter to install the split collars.

014RW081

Legend (1) Cam (2) Shim (3) Tappet

Valve Clearance Standard Value (cold) Intake: 0.23 mm–0.33 mm (0.0091 in–0.0130 in) Exhaust: 0.25 mm–0.35 mm (0.0098 in–0.0138 in)

Selection of Adjusting Shim

014RW042

6. Install tappet with shim. 7. Install camshaft assembly. B Refer to installation procedure for Camshaft in this manual.

Shim to be selected = (Thickness of removed shim) + (Valve clearance measurement – Standard value) Based on the above formula, the best suited shim should be selected from 41 types of shim (differently thick at 0.02mm (0.0008 in) intervals from 2.40mm (0.0945 in) through 3.2mm (0.1260 in) thick). Install the shim and check valve clearance.

ENGINE MECHANICAL (6VE1 3.5L)

6A–59

Replacement of Shim Let the cam push down the edge of tappet by using J–42689 valve clearance adjusting tool and push out the shim with a flat blade screw driver as shown in illustrations below.

014RW084

014RW082

014RW083

6A–60

ENGINE MECHANICAL (6VE1 3.5L)

Camshaft Camshaft and Associated Parts

014R100028

Legend (1) Camshaft Bracket Fixing Bolt (2) Camshaft Bracket (3) Camshaft Assembly Intake (4) Camshaft Assembly Exhaust (5) Pulley Fixing Bolt

(6) (7) (8) (9) (10) (11)

Camshaft Drive Gear Pulley Retainer Fixing Bolt Retainer Camshaft Drive Gear Oil Seal O–ring

Disassembly 1. Remove fixing bolt (5) for camshaft drive gear pulley using the J–43041 universal holder.

014RW060

ENGINE MECHANICAL (6VE1 3.5L) 2. Remove twenty fixing bolts from intake and exhaust camshaft bracket on one side bank, then camshaft brackets (2).

6A–61

Inspection and Repair 1. Use a micrometer to measure the cam lobe height and uneven wear. Replace the camshaft if either the lobe height or the uneven wear exceeds the specified limit. Lobe height : 44.709 mm (1.7602 in) Uneven wear : 0.05 mm (0.0020 in)

014RW027

3. Remove camshaft assembly (3), (4) with camshaft end plug. 4. Remove three fixing bolts (7) from camshaft drive gear retainer (8), then camshaft drive gear assembly. 5. Use the snap ring pliers to remove the snap ring(1). 6. Remove the wave washer(2), sub gear(3) and spring camshaft gear(4) from the camshaft assembly(5).

014RW043

2. Use a micrometer to measure the diameter and the uneven wear of the camshaft journals. Replace the camshaft if the diameter or the uneven wear exceeds the specified limit. Journal Diameter Standard : 25.972 mm–25.993 mm (1.0225 in–1.0233 in) Limit : 25.8 mm (1.0157 in) Uneven wear : 0.05 mm (0.0020 in)

014R100018

Legend (1) Snap Ring (2) Wave Washer (3) Sub Gear (4) Spring; Camshaft Gear (5) Camshaft Assembly 014RS023

6A–62

ENGINE MECHANICAL (6VE1 3.5L)

3. Place the camshaft on V–blocks. Slowly rotate the camshaft and measure the runout with a dial indicator. Replace the camshaft if the runout exceeds the specified limit. Runout Limit : 0.1 mm (0.0039 in)

2. Subtract the camshaft outside diameter from the camshaft bracket housing inside diameter. Oil Clearance Standard : 0.027 mm–0.078 mm (0.0011 in–0.0031 in) Limit : 0.11 mm (0.0043 in)

014RW037 014RW044

4. Measure the camshaft journal oil clearance. 1. Measure the camshaft bracket housing inside diameter. NOTE: Tighten camshaft bracket (2) to specified torque before measuring the camshaft bracket inside diameter. Torque : 10 N·m (89 lb in)

5. Replace the cylinder head and/or camshaft if the measured oil clearance exceeds the specified limit. 1. Carefully clean the camshaft journal, the camshaft bracket, and the cylinder head. 2. Install camshaft assembly and camshaft brackets (2), tighten twenty bolts (1) on one side bank to the specified torque. Torque: 10 N·m (89 lb in)

014RW031 014RW031

ENGINE MECHANICAL (6VE1 3.5L) 3. Measure the camshaft thrust clearance with a dial indicator. Replace the camshaft and/or the cylinder head if the camshaft thrust clearance exceeds the specified limit. Camshaft thrust Clearance Standard : 0.03 mm–0.08 mm (0.0012 in.–0.0031 in.)

6A–63

3. Align the dowel pin on the sub gear to the clearance of the spring ; camshaft gear made in step 2 and install the sub gear (3). 4. Install the wave washer (2). Use snap ring pliers to install the snap ring (1).

Limit : 0.12 mm (0.0047 mm)

014R100018

014RW035

Reassembly 1. Install camshaft drive gear assembly and tighten three bolts to specified torque.

5. Tighten sub gear setting bolt. a. Use J–42686 gear spring lever to pre-load the sub gear. Turn the sub gear in a clockwise direction until the M5 bolt hole aligns with the hole in the camshaft driven gear. b. Install the M5 bolt and tighten to a suitable torque to prevent the sub gear from moving.

Torque: 10 N·m (89 lb in) 2. Install the spring ; camshaft gear(1) into the camshaft assembly. Ensure the clearance is between the right side of the spring; camshaft gear (1) and the dowel pin (2).

014RW041

6. Align the timing mark on the retainer and dowel pin of the camshaft drive gear. 7. Install camshaft assembly and camshaft brackets, tighten twenty bolts on one side bank to the specified torque. 014R100017

6A–64

ENGINE MECHANICAL (6VE1 3.5L)

a. Apply engine oil to camshaft journal and bearing surface of camshaft bracket. b. Align timing mark on intake camshaft (one dot for right bank, two dots for left bank) and exhaust camshaft (one dot for right bank, two dots for left bank) to timing mark on camshaft drive gear (one dot).

014R100026

Legend (1) Alignment Mark for Left Bank (Two Dots) (2) Discrimination Mark for Left Bank Intake Camshaft Gear (3) Camshaft Timing Gear for Left Bank Intake 014R100016

Legend (1) Alignment Mark on the Camshaft Gear (2) Alignment Mark on the Camshaft Drive Gear

014R100027

014R100025

Legend (1) Discrimination Mark for Right Bank Intake Camshaft Gear (2) Alignment Mark for Right Bank (One Dot) (3) Camshaft Timing Gear for Right Bank Intake

Legend (1) Discrimination Mark LE : Left Bank Exhaust RE : Right Bank Exhaust (2) Alignment Mark One Dot for Right Bank Two Dots for Left Bank (3) Camshaft Timing Gear for Exhaust

ENGINE MECHANICAL (6VE1 3.5L)

6A–65

c. Tighten twenty bolts in numerical order on one side bank as shown in the illustration. Torque: 10 N·m (89 lb in)

014R100023

Legend (1) Timing Mark on the Camshaft Drive Gear for Right Bank Exhaust Camshaft (2) Timing Mark on the Camshaft Drive Gear for Right Bank Intake Camshaft (3) Dowel Pin

014RW031

8. If the oil seal requires replacement, use the J–42985 to install the oil seal.

014RW034

014R100024

Legend (1) Timing Mark on the Camshaft Drive Gear for Left Bank Intake Camshaft (2) Timing Mark on the Camshaft Drive Gear for Left Bank Exhaust Camshaft (3) Dowel Pin

6A–66

ENGINE MECHANICAL (6VE1 3.5L)

9. If the camshaft end plug requires replacement, use the J–42985 to install the camshaft end plug.

014R100031

10. Tighten bolt for camshaft drive gear pulley to the specified torque using the J–43041 universal holder. Torque: 98 N·m (72 lb ft)

014RW060

ENGINE MECHANICAL (6VE1 3.5L)

6A–67

Crankshaft Crankshaft and Associated Parts

013RW009

Legend (1) Cylinder Head Assembly (2) Crankcase with Oil Pan (3) Oil Pipe and O-ring (4) Oil Strainer and O-ring (5) Oil Pump Assembly (6) Cylinder Block Side Bolts (7) Oil Gallery

Disassembly 1. Remove cylinder head assembly (1). Refer to “Cylinder Head” in this manual. 2. Remove crankcase with oil pan (2). Refer to “Oil Pan and Crankcase” in this manual.

(8) (9) (10) (11) (12) (13) (14)

Piston and Connecting Rod Assembly Flywheel Rear Oil Seal Retainer and Oil Seal Main Bearing Cap Crankshaft Main Bearing Cap Fixing Bolts Oil Gallery Fixing Bolts

CAUTION: Take care not to damage or deform the sealing flange surface of crankcase. 3. Remove oil pipe and O-ring (3). 4. Remove oil strainer and O-ring (4). 5. Remove oil pump assembly (5). 6. Remove crankcase side bolts (6).

6A–68

ENGINE MECHANICAL (6VE1 3.5L)

7. Remove oil gallery (7). 8. Remove piston and connecting rod assembly (8). Refer to “Piston, Piston Ring and Connecting Rod” in this manual. 9. Remove flywheel (9). 10. Remove rear oil seal retainer (10). 11. Remove main bearing cap (11). 12. Remove crankshaft (12).

Inspection and Repair for Bearings 1. Inspect Crankshaft Set the dial indicator as shown in the illustration and measure the crankshaft thrust clearance. If the thrust clearance exceeds the specified limit, replace the thrust bearings as a set. Thrust Clearance Standard : 0.06 mm–0.24 mm (0.0024 in–0.0094 in)

015RS004

3. Remove the crankshaft. Remove the main bearings.

Limit : 0.30 mm (0.0118 in)

4. Clean the upper and lower bearings as well as the crankshaft main journal. 5. Check the bearings for damage or excessive wear. The bearings must be replaced as a set if damage or excessive wear is discovered during inspection. 6. Set the upper bearings and the thrust washers to their original positions. Carefully install the crankshaft. 7. Set the lower bearings to the bearing cap original position. 8. Apply plastigage to the crankshaft journal unit as shown in the illustration. NOTE: Do not set the plastigage on the oil hole.

015RS003

Main Bearing Clearance 1. Remove the bearing caps and measure the oil clearance. 2. Remove the main bearing cap fixing bolts in the sequence shown in the illustration. Arrange the removed main bearing caps in the cylinder number order. Remove the main bearings.

015RS005

ENGINE MECHANICAL (6VE1 3.5L) 9. Install main bearing caps, oil gallery and crank case bolts in the order shown, and tighten each bolt to the specified torque. NOTE: Do not apply engine oil to the crank case side bolts. Main bearing cap bolts. Torque: 39 N·m (29lb ft)

6A–69

11. Measure the plastigage width and determine the oil clearance. If the oil clearance exceeds the specified limit, replace the main bearings as a set and/or replace the crankshaft. Standard : 0.019 mm–0.043 mm (0.0007 in–0.0017 in) Limit : 0.08 mm (0.0031 in)

Oil gallery fixing bolts. Torque: 1st step: 29 N·m (22 lb ft) 2nd step 55°∼ 65° Crank case side bolts Torque : 39 N·m (29lb ft) NOTE: Do not allow the crankshaft to rotate.

015RS008

12. Clean the plastigage from the bearings and the crankshaft. Remove the crankshaft and the bearings.

Crankshaft Inspection

015RS006

10. Remove the main bearing caps in the sequence shown in the illustration.

015RS004

Inspect the surface of the crankshaft journal and crank pins for excessive wear and damage. Inspect the oil seal fitting surfaces for excessive wear and damage. Inspect the oil ports for obstructions.

6A–70

ENGINE MECHANICAL (6VE1 3.5L)

Inspection and Repair for Crankshaft 1. Carefully set the crankshaft on the V–blocks. Slowly rotate the crankshaft and measure the runout. If the crankshaft runout exceeds the specified limit, the crankshaft must be replaced. Runout : 0.04 mm (0.0016 in)

Crankshaft Bearing Selection When installing new crankshaft bearings or replacing bearings, refer to the selection table below. Select and install the new crankshaft bearings, paying close attention to the cylinder block journal hole. 1. Diameter size mark (1) and the crankshaft journal.

015RS010 015RS007

2. Measure the diameter and the uneven wear of main journal and crank pin. If the crankshaft wear exceeds the specified limit, crankshaft must be replaced. Main journal diameter : 63.918 mm–63.933 mm (2.5165 in–2.5170 in)

2. Diameter size mark (1). The diameter size marks are stamped on the No.1 crankshaft balancer as shown in the illustration.

Crank pin diameter : 53.922 mm–53.937 mm (2.1229 in.–2.1235 in.) Uneven wear limit : 0.005 mm (0.0002 in)

015RS011

NOTE: Take care to ensure the bearings are positioned correctly.

015RS009

ENGINE MECHANICAL (6VE1 3.5L)

6A–71

Legend (1) Number 1 and 4 main bearing upper and lower (2) Number 2 and 3 main bearing upper (3) Number 2 and 3 main bearing lower

015RS012

mm ( in)

1 Size Mark

Main Bearing Bore Diameter

68.994-69.000 (2.7163-2.7165)

68.987-68.993 (2.7160-2.7163)

68.980-68.986 (2.7157-2.7160)

Crank Shaft Main Journal Diameter

2 Size Mark

Crank Shaft Bearing Size Mark (Upper Side)

63.918-63.925 (2.5165-2.5167)

Blue

63.926-63.933 (2.5168-2.5170)

63.918-63.925 (2.5165-2.5167)

0.029-0.048 (0.0011-0.0019)

63.926-63.933 (2.5168-2.5170)

0.027-0.046 (0.0011-0.0018)

63.918-63.925 (2.5165-2.5167)

63.926-63.933 (2.5168-2.5170)

Brown

Crank Shaft Bearing Size Mark (Lower Side)

Oil Clearance (Reference)

Blue

0.030-0.049 (0.0012-0.0019)

Brown

Green

Yellow

0.028-0.047 (0.0011-0.0019)

0.028-0.047 (0.0011-0.0019) 0.026-0.045 (0.0010-0.0018)

Reassembly 1. Crankshaft (12) B Install the main bearings to the cylinder block and the main bearing caps. B Be sure that they are positioned correctly. B Apply new engine oil to the upper and lower main bearing faces. NOTE: Do not apply engine oil to the main bearing back faces.

015RS012

6A–72

ENGINE MECHANICAL (6VE1 3.5L)

B Carefully mount the crankshaft.

B Apply engine oil to the oil seal lip.

B Apply engine oil to the thrust washer.

B Align the cylinder block dowel pin holes with the rear retainer dowel pins.

B Assemble the thrust washer to the No.3 bearing journal. The oil grooves must face the crankshaft.

B Tighten the rear retainer fixing bolts. New bolts should be used when installing rear retainer. Torque: 18 N·m (13 lb ft) NOTE: Be very careful not to disengage the oil seal garter spring during installation of the rear retainer. If the seal was removed from retainer for replacement, apply engine oil to the oil seal lip and install the oil seal using J–39201 oil seal installer.

015RS013

2. Rear oil seal (10) B Remove the oil from the cylinder block and the retainer mounting surface. B Apply sealant (TB–1207B or equivalent) to the retainer mounting surface, following the pattern shown in the illustration. The retainer must be installed within 5 minutes after sealant application to prevent premature hardening of sealant.

015RW001

015RS017

015RW002

Legend (1) Around Bolt Holes (2) Around Dowel Pin

3. Flywheel (9) 1. Thoroughly clean and remove the oil from the threads of crankshaft. 2. Remove the oil from the crankshaft and flywheel mounting faces. 3. Mount the flywheel on the crankshaft and then install the washer.

ENGINE MECHANICAL (6VE1 3.5L)

6A–73

4. Hold the crankshaft to prevent from rotating then install the bolts in the order shown to the specified torque.

B Insert the piston/connecting rod assemblies into each cylinder with the piston ring compressor. The front marks must be facing the front of the engine.

Torque: 54 N·m (40 lb ft)

B Match the numbered caps with the numbers on the connecting rods. Align the punched marks on the connecting rods and caps.

NOTE: Do not reuse the bolt and do not apply oil or thread lock to the bolt.

B Apply engine oil to the threads and seating faces of the nuts. B Tighten the nuts. Torque: 54 N·m (40 lb ft) After tightening the cap nuts, check to see that the crankshaft rotates smoothly. NOTE: Do not apply engine oil to the bearing back faces.

015RS018

4. Piston and connecting rod assembly (8) B Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins. Check to see that the piston ring end gaps are correctly positioned.

015RS020

5. Install oil gallery (7) and tighten the bolts in 2 steps, in the order shown. 1st step: 29 N·m (22 lb ft) 2nd step: 55°∼ 65°

015RS019

Legend (1) No.1 Compression Ring (2) No.2 Compression Ring (3) Oil Ring Side Rail Upper (4) Oil Ring Side Rail Lower (5) Piston Front Mark 051RS009

6A–74

ENGINE MECHANICAL (6VE1 3.5L)

6. Cylinder block side bolts (6) B Tighten all the bolts to the specified torque in the order shown. NOTE: Do not apply engine oil to the crank case side bolts. Torque: 39 N·m (29 lb ft)

013RW010

Legend (1) Portion Between Bolt Holes (2) Bolt Hole Portion 11. Install cylinder head assembly, refer to “Cylinder head” in this manual. 012RS001

7. Install oil pump assembly (5), refer to “Oil pump” in this manual. 8. Install oil strainer and O-ring (4). 9. Install oil pipe and O-ring (3) and tighten the bolts. Torque: 25 N·m (18 lb ft) 10. Install crankcase with oil pan (2). 1. Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The surfaces must be perfectly dry. 2. Apply a correct width bead of sealant (TB— 1207C or its equivalent) to the contact surfaces of the oil pan. There must be no gaps in the bead. 3. The crankcase assembly must be installed within 5 minutes after sealant application. 4. Tighten the bolts and nuts to the specified torque. Torque : 10 N·m (87 lb in)

ENGINE MECHANICAL (6VE1 3.5L)

6A–75

Piston and Connecting Rod Piston, Connecting Rod and Associate Parts

015RW019

Legend (1) Cylinder Head Assembly (2) Cylinder Head Gasket (3) Crankcase with Oil Pan (4) Oil Pipe and O-ring (5) Oil Strainer and O-ring (6) Oil Gallery

Disassembly 1. Remove cylinder head assembly (1). Refer to “Cylinder Head Removal” in this manual. 2. Remove cylinder head gasket (2). 3. Remove crankcase with oil pan (3). Refer to“Oil Pan and Crankcase” in this manual. 4. Remove oil pipe and O-ring (4).

(7) (8) (9) (10) (11) (12)

Piston and Connecting Rod Assembly Piston Ring Piston Pin Piston Connecting Rod Connecting Rod Cap

5. Remove oil strainer and O-ring (5). 6. Remove oil gallery (6). 7. Remove connecting rod cap with connecting rod lower bearing (12). 8. Remove piston and connecting rod assembly (7). NOTE: Before removing piston and connecting rod assembly, measure thrust clearance.

6A–76

ENGINE MECHANICAL (6VE1 3.5L)

015RS031

B Remove any ridge or carbon build up from the top end of the cylinder. 9. Remove the piston rings (8) with a piston ring expander. Arrange the removed piston rings in the cylinder number order.

015RS023

Legend (1) Press Ram (2) Piston (3) Connecting Rod (4) Piston Pin 11. Piston (10) 12. Connecting rod (11)

Inspection and Repair Pistons Carefully clean away all the carbon adhering to the piston head and the piston ring grooves. NOTE: Never use a wire brush to clean the pistons. Damage will result. Visually check each piston for cracking, scoring, and other signs of excessive wear. If any of the above conditions are found, the piston must be replaced.

Piston Diameter 015RS022

10. Remove the piston pin (9) using J–24086–C piston pin service set and piston support with a press. NOTE: Keep the parts removed from each cylinder separate. All parts must be reinstalled in their original positions. Heating the connecting rod will permit easy removal of the piston pin.

1. Measure the piston outside diameter with micrometer at the piston grading position and a right angle to the piston pin. Piston grading position (from piston head) Piston grading position : 43.0 mm (1.6929 in)

ENGINE MECHANICAL (6VE1 3.5L)

015RV014

6A–77

012RS002

The size mark (1) for piston outside diameter is represented as shown in Figure.

Piston Rings

Outside Diameter Size Mark A : 93.360 mm–93.370 mm (3.6756 in–3.6760 in)

Any worn or damaged part discovered during engine overhaul must be replaced with a new one. 1. Ring end gap measurement B Insert the piston ring into the bore.

Size Mark B : 93.371 mm–93.380 mm (3.6760 in–3.6764 in)

B Push the ring by the piston, at a right angle to the wall, into the point at which the cylinder bore diameter is the smallest.

Size Mark C : 93.381 mm–93.390 mm (3.6764 in–3.6768 in)

B Measure the ring end gap. Compression Ring 1st ring Standard:

0.300 mm–0.400 mm (0.0118 in–0.0157 in)

Limit:

1.0 mm (0.0394 in)

2nd ring Standard:

0.450 mm–0.600 mm (0.0177 in–0.0236 in)

Limit:

1.2 mm (0.0472 in)

Oil ring Standard:

0.150 mm–0.450 mm (0.0059 in–0.0177 in)

Limit: 015RS025

Measure the cylinder bore inside diameter (refer to “Cylinder Block” in this manual).

1.05 mm (0.0413 in)

6A–78

ENGINE MECHANICAL (6VE1 3.5L)

015RS026

015RS028

B Positioning mark (1) is painted as shown in the illustration.

Piston Pin

Marked T : No.1 Compression ring

NOTE: Do not reuse the old piston pin. 1. Use a micrometer to measure the new piston pin outside diameter in both directions at three different positions. 2. Measure the inside diameter of the connecting rod small end. If the fitting interference between the small end and pin does not conform to the specified value, the connecting rod must be replaced.

Marked T2 : No.2 Compression ring

Standard : 0.023 mm–0.038 mm (0.0009 in–0.0015 in)

015RS027

2. Measure the clearance between the piston ring groove and the piston ring with a feeler gauge. If the piston ring groove / piston ring clearance exceeds the specified limit, the piston must be replaced. Compression Ring Clearance Standard : 0.025 mm–0.065 mm (0.0006 in.–0.0015 in) Limit : 0.1mm (0.0059 in)

015RS029

ENGINE MECHANICAL (6VE1 3.5L)

6A–79

3. Insert the new pin into the piston and rotate it. If the pin rotates smoothly with no backlash, the clearance is normal. If there is backlash or roughness, measure the clearance. If the clearance exceeds the specified limit, the piston must be replaced. Clearance Standard : 0.010 mm–0.017 mm (0.0004 in.–0.0007 in) Limit : 0.040 mm (0.0016 in)

Connecting Rods 1. Check the connecting rod alignment If either the bend or the twist exceeds the specified limit, the connecting rod must be replaced. Bend per 100 mm (3.937 in) Limit: 0.15 (0.0059) Twist per 100 mm (3.937 in) Limit: 0.20 (0.0078)

015RS031

3. Measure the oil clearance between the connecting rod and the crankshaft. 1. Remove the connecting rod cap nuts and the rod caps (12). Arrange the removed rod caps in the cylinder number order. 2. Clean the rod bearings and the crankshaft pins. 3. Carefully check the rod bearings. If even one bearing is found to be damaged or badly worn, the entire bearing assembly must be replaced as a set. Reinstall the bearings in their original positions. Apply plastigage to the crank pin.

015RS030

2. Measure the connecting rod thrust clearance. Use a feeler gauge to measure the thrust clearance at the large end of the connecting rod If the clearance exceeds the specified limit, the connecting rod must be replaced. Standard : 0.16 mm–0.35 mm (0.0063 in.–0.0138 in) Limit : 0.40 mm (0.0157 in)

015RS032

4. Reinstall the rod caps (12) to their original positions. Tighten the rod cap nuts. Torque: 54 N·m (40 lb ft) NOTE: Do not allow the crankshaft to rotate.

6A–80

ENGINE MECHANICAL (6VE1 3.5L)

5. Remove the rod caps. 6. Measure the width of the plastigage and determine the oil clearance. If the oil clearance exceeds the limit, replace the rod bearing as a set. Standard : 0.019 mm–0.043 mm (0.0007 in–0.0017 in)

7. Clean the plastigage from the bearings and the crankshaft pins.

Con–rod Bearing Selection Select and install the new connecting rod bearings, paying close attention to the connecting rod big end diameter size mark (1). NOTE: Take care not to confuse the alignment mark (2) and the size mark (1) during the installation procedure.

Limit : 0.08 mm (0.0031 in)

015RS008 015RS034

mm ( in) 1 Size Mark

Big end Bore Diameter

56.994-57.000 (2.2439-2.2441)

56.988-56.994 (2.2436-2.2439)

56.982-56.988 (2.2434-2.2436)

Crankshaft Pin Diameter

53.922-53.937 (2.1229-2.1235)

Connecting Rod Bearing Thickness (Reference)

Color of Size Mark

Oil Clearance (Reference)

1.512-1.516 (0.0595-0.0597)

Yellow

0.025-0.054 (0.0010-0.0021)

1.508-1.512 (0.0594-0.0595)

Green

0.027-0.056 (0.0011-0.0022)

1.504-1.508 (0.0592-0.0594)

Pink

0.029-0.058 (0.0011-0.0023)

Reassembly 1. Install connecting rod 2. Install piston 3. Install piston pin B Apply a thin coat of engine oil to the piston pin. Try to insert the piston pin into the piston pin hole with normal finger pressure. NOTE: When changing piston / connecting rod combinations, do not change the piston / piston pin combination and do not reuse the old piston pin. B Attach the piston to the connecting rod with the piston front mark and the connecting rod front mark on the same side.

015RS036

ENGINE MECHANICAL (6VE1 3.5L) B With J–24086–C Piston pin service set and a press, press fit the piston pin. NOTE: Heat the connecting rod small end to a suitable temperature to ensure smooth installation.

6A–81

B Install piston rings in the following sequence. 1. Oil ring 1. Expander ring 2. Upper side rail 3. Lower side rail 2. 2nd compression ring 3. 1st compression ring B The compression rings must be set with the T or T2 mark facing up. Marked T : No.1 Compression ring Marked T2 : No.2 Compression ring B After installation, apply engine oil to the entire circumference of the piston rings. Check to see that all the rings rotate smoothly.

015RS037

Legend (1) Press Ram (2) Piston (3) Connecting Rod (4) Piston Pin 4. Install piston ring with the piston ring expander. The compression ring must be set with the T mark (1) facing up. Marked T : No.1 Compression ring Marked T2 : No.2 Compression ring

015RS038

5. Install piston and connecting rod assembly. B Insert the bearings into the connecting rods and caps. Apply new engine oil to the bearing faces and nuts. B Tighten the connecting rod cap nuts Torque : 54 N·m (40 lb ft) NOTE: Do not apply engine oil to the bearing back faces. 6. Oil gallery, refer to “Crankshaft and main bearing” in this manual. 7. Oil strainer and O-ring. 8. Oil pipe and O-ring. 9. Install crankcase with oil pan, refer to “Oil pan and Crankcase” in this manual. 10. Install cylinder head gasket. 11. Install Cylinder head assembly. B Refer to “Cylinder head” in this manual. 015RS027

6A–82

ENGINE MECHANICAL (6VE1 3.5L)

Cylinder Block Cylinder Block and Associated Parts

012RW010

Legend (1) Cylinder Head Assembly (2) Cylinder Head Gasket (3) Crankcase with Oil Pan (4) Oil Pipe and O-ring (5) Oil Strainer and O-ring (6) Oil Pump Assembly (7) Cylinder Block Side Bolts

Disassembly 1. Remove cylinder head assembly. 2. Remove cylinder head gasket. 3. Remove crankcase with oil pan. 4. Remove oil pipe and O-ring.

(8) (9) (10) (11) (12) (13) (14)

Oil Gallery Piston and Connecting Rod Assembly Flywheel Rear Oil Seal Retainer Assembly Main Bearing Cap Crankshaft Cylinder Block

5. Remove oil strainer and O-ring. 6. Remove oil pump assembly. 7. Remove crankcase side bolts. 8. Remove oil gallery. 9. Remove piston and connecting rod assembly. 10. Remove flywheel.

ENGINE MECHANICAL (6VE1 3.5L) 11. Remove rear oil seal retainer assembly. 12. Remove main bearing cap. 13. Remove crankshaft. 14. Remove cylinder block.

6A–83

Cylinder Bore Use a cylinder gauge to measure the cylinder bore diameter in both the axial and thrust directions. Each measurement should be made at six points.

Inspection and Repair 1. Remove the cylinder head gasket and any other material adhering to the upper surface of the cylinder block. Be very careful not to allow any material to accidentally drop into the cylinder block. Be very careful not to scratch the cylinder block. 2. Carefully remove the oil pump, rear oil seal retainer, and crankcase assembly installation surface seal. 3. Wipe the cylinder block clean. 4. Visually inspect the cylinder block. If necessary, use a flaw detector to perform a dye penetrate and hydraulic (or air pressure) test. If cracking or other damage is discovered, the cylinder block must either be repaired or replaced.

Flatness

CAUTION: Be very careful not to allow any material to accidentally drop into the upper surface of the cylinder block. Be very careful not to scratch the upper surface of the cylinder block. Cylinder Bore Inside Diameter Limit : 93.530 mm (3.6823 in) If the measurement exceed the specified limit, the cylinder block must be replaced. Diameter Grade A : 93.400 mm–93.410 mm (3.6772 in–3.6776 in) Grade B : 93.411 mm–93.420 mm (3.6776 in–3.6779 in) Grade C : 93.421 mm–93.430 mm (3.6780 in–3.6783 in)

1. Using a straight–edge and feeler gauge, check that the upper surface of the cylinder block is not warped. CAUTION: Be very careful not to allow any material to accidentally drop into the upper surface of the cylinder block. Be very careful not to scratch the upper surface of the cylinder block. 2. The cylinder block must be reground or replaced if the warpage exceeds the limit. Warpage Limit : 0.15 mm (0.0059 in) Maximum repairable limit: 0.15 mm (0.0059 in)

012RS005

NOTE: For information on piston diameter, please refer to the section ”Inspection of the Piston and Connecting Rod Assembly” in this manual. B The ”Grade” mark (1) is stamped at the position illustrated.

012RS004

6A–84

ENGINE MECHANICAL (6VE1 3.5L) B Carefully mount the crankshaft. B Apply engine oil to the thrust washer. B Assemble the thrust washer to the No. 3 bearing journal. The oil grooves must face the crankshaft.

012RS006

Reassembly 1. Install cylinder block. 2. Install crankshaft. B Install the main bearings to the cylinder block and the main bearing caps. B Be sure that they are positioned correctly. B Apply new engine oil to the upper and lower main bearing faces. NOTE: Do not apply engine oil to the bearing back faces.

015RS013

3. Install rear oil seal retainer. B Remove oil on cylinder block and retainer fitting surface. B Apply sealant (TB1207B or equivalent) to retainer fitting surface as shown in illustration. B The oil seal retainer must be installed within 5 minutes after sealant application to prevent premature hardening of sealant.

015RS012

Legend (1) Number 1 and 4 main bearing upper and lower. (2) Number 2 and 3 main bearing upper. (3) Number 2 and 3 main bearing lower.

015RW002

Legend (1) Around Bolt Holes (2) Around Dowel Pin

ENGINE MECHANICAL (6VE1 3.5L) B Apply engine oil to oil seal lip and align a dowel pin hole in the cylinder block with that in the retainer. B Tighten retainer fixing bolts to the specified torque.

6A–85

5. Install piston and connecting rod assembly. B Apply engine oil to the cylinder bores, the connecting rod bearings and the crankshaft pins. NOTE: Do not apply engine oil to the bearing back faces.

Torque: 25 N·m (18 lb ft)

B Check to see that the piston ring end gaps are correctly positioned.

015RW001

4. Install flywheel 1. Thoroughly clean and remove the oil from the threads of crankshaft. 2. Remove the oil from the crankshaft and flywheel mounting faces. 3. Mount the flywheel on the crankshaft and then install the washer. 4. Holding the crankshaft stationary, tighten the flywheel bolts in the order shown. Torque: 54 N·m (40 lb ft) NOTE: Do not reuse the bolts and do not apply oil or thread lock to the bolts.

015RS018

015RS019

Legend (1) No.1 Compression Ring (2) No.2 Compression Ring (3) Oil Ring Side Rail Upper (4) Oil Ring Side Rail Lower (5) Piston Front Mark B Insert the piston/connecting rod assemblies into each cylinder with the piston ring compressor. B The front marks (1) must be facing the front of the engine.

015RS020

6A–86

ENGINE MECHANICAL (6VE1 3.5L)

6. Install oil gallery and tighten the bolts in 2 steps in the order shown. 1st step : 29 N·m (22 lb ft) 2nd step : 55°∼ 65°

8. Install oil pump assembly. Refer to “Oil Pump” in this manual. 9. Install oil strainer and O-ring. 10. Install oil pipe and O-ring. 11. Install crankcase with oil pan. 1. Completely remove all residual sealant, lubricant and moisture from the sealing surfaces. The surfaces must be perfectly dry. 2. Apply a correct width bead of sealant (TB– 1207C or its equivalent) to the contact surfaces of the crankcase. There must be no gaps in the bead. 3. The oil pan must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. 4. Tighten the bolts and nuts to the specified torque. Torque : 10 N·m (87 lb in)

012RS007

7. Install cylinder block side bolts (1) and tighten crankcase bolts in sequence shown in the illustration. Torque : 39 N·m (29 lb ft)

013RW010

Legend (1) Portion Between Both Holes (2) Bolt Hole Portions 12. Install cylinder head gasket. 13. Install cylinder head assembly. Refer to “Cylinder Head” in this manual. 012RW005

ENGINE MECHANICAL (6VE1 3.5L)

6A–87

Main Data and Specification General Specification Item Engine type, number of cylinders and arrangement Form of combustion chamber

Specifications 6VE1 Water cooled, four cycle V6 Pent-roof type

Valve mechanism

4-Cams, 4-Valves, DOHC Gear & Belt Drive

Cylinder liner type

Casted in cylinder drive

Total piston displacement Cylinder bore x stroke

3494 cc 93.4mm x 85mm (3.677 in x 3.346 in)

Compression ratio Compression pressure at 300rpm Engine idling speed rpm Valve clearance

9.1 1.37 MPa (14.0 Kg/cm2) Non adjustable (750) Intake: 0.28 mm (0.11 in) Exhaust: 0.30mm (0.12in)

Oil capacity Ignition timing Spark plug Plug gap

5.3 liters Non adjustable (20° BTDC at idle rpm) PK16PR11, RC10PYP4, K16PR-P11 1.0 mm–1.1 mm(0.0394 in – 0.0433 in)

6A–88

ENGINE MECHANICAL (6VE1 3.5L)

Torque Specifications Ignition coil, Spark plug, Crankshaft position sensor and Under cover

E06R100001

ENGINE MECHANICAL (6VE1 3.5L)

6A–89

Cylinder head cover, Cylinder head, Camshaft bearing cap, Common chamber, EGR valve and EGR pipe, Ion sensing module

E06R100002

6A–90

ENGINE MECHANICAL (6VE1 3.5L)

Crankshaft main bearing, Flywheel, Crankcase, Oil pan, Timing belt tensioner, Timing pulley, Timing belt cover, Oil pump, Oil gallery, Oil strainer and water pump

E06R100004

ENGINE MECHANICAL (6VE1 3.5L)

6A–91

Connecting rod and Water pump

E06RW011

6A–92

ENGINE MECHANICAL (6VE1 3.5L)

Engine mount

E06RW003

ENGINE MECHANICAL (6VE1 3.5L)

6A–93

Special Tool ILLUSTRATION

TOOL NO. TOOL NAME

ILLUSTRATION

TOOL NO. TOOL NAME

J–21687–02 Remover; tie rod end

J–42985 Installer; Camshaft oil seal

J–36390 Wrench; Oil filter

J–39206 Installer; Pilot bearing

J–8062 Compressor; Valve spring (1) J–42898 Adapter; Compressor, Valve spring (2)

J–8614–01 Holder; Crankshaft

J–37281 Remover; Oil controller

J–37228 Seal cutter

J–38537 Installer; Oil controller

J–39201 Installer; Real oil seal

J–29107 Universal pitman arm puller

J–39202 Installer; Oil pump oil seal

6A–94

ENGINE MECHANICAL (6VE1 3.5L)

ILLUSTRATION

TOOL NO. TOOL NAME

J–24239–1 Cylinder head bolt wrench

J–42899 Replacer; Valve guide (1,2) J–42687 Installer; Valve guide (1) J–37985–1 Remover; Valve guide (2)

J–42689 Adjusting Tool; Valve clearance

J–42686 Lever; Gear spring

J–43041 Holder; Universal

SECTION ENGINE COOLING (6VE1 3.5L)

6B–1

AXIOM

ENGINE ENGINE COOLING (6VE1 3.5L) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining and Refilling Cooling System . . . . . Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Pump and Associated Parts . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostat and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6B–1 6B–2 6B–4 6B–5 6B–6 6B–6 6B–6 6B–6 6B–6 6B–7 6B–7 6B–7 6B–7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator and Associated Parts . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belt and Cooling Fan . . . . . . . . . . . . . . . Drive Belt and Associated Parts . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6B–7 6B–8 6B–8 6B–8 6B–9 6B–10 6B–11 6B–11 6B–11 6B–11 6B–11 6B–12 6B–13

6B–2

ENGINE COOLING (6VE1 3.5L)

General Description

030RW001

Legend (1) Water Pump (2) Thermostat (3) Radiator (4) Reserve Tank (5) Cooling Fan (6) Cylinder Block

(7) (8) (9) (10) (11) (12) (13)

Cylinder Head Right Bank Throttle Body Cylinder Block Cylinder Head Left Bank Heater

The cooling system is a pressurized Engine Coolant (EC) forced circulation type which consists of a water pump, thermostat cooling fan, radiator and other components. The automatic transmission fluid is cooled by the EC in the radiator.

Water Pump The EC pump is a centrifugal impeller type and is driven by a timing belt.

030RS001

ENGINE COOLING (6VE1 3.5L)

6B–3

B Calculating mixing ratio

Thermostat The thermostat is a wax pellet type with a air hole(1) and is installed in the thermostat housing.

F06RW005

031RW002

Radiator The radiator is a tube type with corrugated fins. In order to raise the boiling point of the coolant, the radiator is fitted with a cap in which the valve is operated at 88.2 ∼ 117.6 kPa (12.8 ∼ 17.0 psi) pressure. (No oil cooler provided for M/T)

NOTE: Antifreeze solution + Water = Total cooling system capacity. B Total Cooling System Capacity B A/T 10.0Lit (2.64Us gal)

110RW023

Antifreeze Solution B Relation between the mixing ratio and freezing temperature of the EC varies with the ratio of anti–freeze solution in water. Proper mixing ratio can be determined by referring to the chart. Supplemental inhibitors or additives claiming to increase cooling capability that have not been specifically approved by Isuzu are not recommended for addition to the cooling system.

B06RW002

6B–4

ENGINE COOLING (6VE1 3.5L)

B Mixing ratio Check the specific gravity of engine coolant in the cooling system temperature ranges from 0°C to 50°C using a suction type hydrometer, then determine the density of the engine coolant by referring to the table.

B06RW003

Diagnosis Engine Cooling Trouble Condition Engine overheating

Possible cause

Correction

Low Engine Coolant level

Replenish

Incorrect fan installed

Replace

Thermo meter unit faulty

Replace

Faulty thermostat

Replace

Faulty Engine Coolant temperature sensor

Repair or replace

Clogged radiator

Clean or replace

Faulty radiator cap

Replace

Low engine oil level or use of improper engine oil

Replenish or change oil

Clogged exhaust system

Clean exhaust system or replace faulty parts

Faulty Throttle Position sensor

Replace throttle valve assembly

Open or shorted Throttle Position sensor circuit

Repair or replace

Damaged cylinder head gasket

Replace

Engine overcooling

Faulty thermostat

Replace

Engine slow to warm–up

Faulty thermostat

Replace

Thermo unit faulty

Replace

ENGINE COOLING (6VE1 3.5L)

Draining and Refilling Cooling System Before draining the cooling system, inspect the system and perform any necessary service to ensure that it is clean, does not leak and is in proper working order. The engine coolant (EC) level should be between the “MIN” and “MAX” lines of reserve tank when the engine is cold. If low, check for leakage and add EC up to the “MAX” line. There should not be any excessive deposit of rust or scales around the radiator cap or radiator filler hole, and the EC should also be free from oil. Replace the EC if excessively dirty. 1. Completely drain the cooling system by opening the drain plug (2) at the bottom of the radiator.

110RW002

2. Remove the radiator cap. WARNING: TO AVOID THE DANGER OF BEING BURNED, DO NOT REMOVE THE CAP WHILE THE ENGINE AND RADIATOR ARE STILL HOT. SCALDING FLUID AND STEAM CAN BE BLOWN OUT UNDER PRESSURE. 3. Disconnect all hoses from the EC reserve tank. Scrub and clean the inside of the reserve tank with soap and water. Flush it well with clean water, then drain it. Install the reserve tank and hoses. 4. Refill the cooling system with the EC using a solution that is at least 50 percent antifreeze but no more than 70 percent antifreeze. 5. Fill the radiator to the base of the filler neck. Fill the EC reserve tank to “MAX” line when the engine is cold. 6. Block the drive wheels and firmly apply the parking brake. Shift an automatic transmission to “P” (Park) or a manual transmission to neutral. 7. Remove the radiator cap. Start the engine and warm it up at 2,500 ∼ 3,000 rpm for about 30 minutes. 8. When the air comes out from the radiator filler neck and the EC level has gone down, replenish with the EC. Repeat this procedure until the EC level does not go down. Then stop the engine and install the radiator cap. Let the engine cool down.

6B–5

9. After the engine has cooled, replenish with EC up to the “MAX” line of the reserve tank. 10. Start the engine. With the engine running at 3,000 rpm, make sure there is no running water sound from the heater core (behind the center console). 11. If the running water sound is heard, repeat steps 8 to 10.

6B–6

ENGINE COOLING (6VE1 3.5L)

Water Pump Water Pump and Associated Parts

030RS002

Legend (1) Timing Belt (2) Idle Pulley

Removal 1. Disconnect battery ground cable. 2. Drain coolant. 3. Radiator hose (on inlet pipe side). 4. Remove timing belt. Refer to “Timing Belt” in this manual. 5. Remove Idle pulley. 6. Remove water pump assembly. 7. Remove gasket.

(3) Water Pump Assembly (4) Gasket

NOTE: To prevent the oil leakage, apply the LOCTITE 262 or an equivalent, to the arrow marked fixing bolt thread.

Inspection Make necessary repair and parts replacement if extreme wear or damage is found during inspection. Should any of the following problems occur, the entire water pump assembly must be replaced. B Crack in the water pump body B EC leakage from the seal unit B Play or abnormal noise in the bearing B Cracks or corrosion in the impeller 030RW008

Installation 1. Install gasket, clean the mating surface of gasket before installation. 2. Install water pump assembly and tighten bolts to the specified torque. Torque: 25 N·m (18 lb ft) B Tightening order The tightening order are in the illustrate.

3. Idle pulley B Install idle pulley and tighten bolt to the specified torque. Torque: 52 N·m (38 lb ft) 4. Timing belt B Install timing belt. Refer to timing belt installation step in “Timing Belt” in this manual. 5. Connect radiator inlet hose and replenish EC. 6. Connect battery ground cable.

ENGINE COOLING (6VE1 3.5L)

6B–7

Thermostat Thermostat and Associated Parts

031RS003

031RW001

Legend (1) Thermostat Housing (2) Thermostat (3) Outlet Pipe

Removal 1. Disconnect battery ground cable. 2. Drain engine coolant from the radiator and engine. 3. Disconnect radiator hose from the inlet pipe. 4. Remove thermostat housing. 5. Remove thermostat(2).

Inspection Suspend the thermostat in a water–filled container using thin wire. Place a thermometer next to the thermostat. Do not directly heat the thermostat. Gradually increase the water temperature. Stir the water so that the entire water is same temperature.

Confirm the temperature when the valve first begins to open. Valve opening temperature 74.5C ∼ 78.5°C (166.1°F ∼ 173.3°F) Confirm the temperature when the valve is fully opened. Valve full open temperature and lift More than 8.5mm (0.33 in) at 90°C (194°F) Make necessary repair and parts replacement if extreme wear or damage is found during inspection.

Installation 1. Install thermostat into the outlet pipe(4) making sure that the air hole is in the up position. 2. Install thermostat housing and tighten bolts to the specified torque. Torque: 25 N·m (18 lb ft) 3. Installation rubber hose. 4. Replenish engine coolant (EC). 5. Start engine and check for EC leakage.

6B–8

ENGINE COOLING (6VE1 3.5L)

Radiator Radiator and Associated Parts

110RW010

Legend (1) Oil Cooler Hose For Automatic Transmission (2) Radiator Hose (3) Fan Guide, Lower

Removal 1. Disconnect battery ground cable. 2. Loosen a drain plug(2) to drain EC. 3. Disconnect oil cooler hose(1) on automatic transmission (A/T). 4. Disconnect radiator inlet hose and outlet hose from the engine.

(4) Reserve Tank Hose (5) Radiator Assembly (6) Reserve Tank

5. Remove fan guide(1), clips(3) on both sides and the bottom lock, then remove fan guide lower(3) with fan shroud(4).

110RW001

110RW002

ENGINE COOLING (6VE1 3.5L)

6B–9

6. Disconnect the reserve tank hose(4) from radiator.

110RS006

110RX001

7. Lift up and remove the radiator assembly with hose, taking care not to damage the radiator core with a fan blade. 8. Remove rubber cushions on both sides at the bottom.

Inspection Radiator Cap Measure the valve opening pressure of the pressurizing valve with a radiator filler cap tester. Replace the cap if the valve opening pressure is outside the standard range. Valve opening pressure kPa (psi) 93.3 ∼ 122.7 (13.5 ∼17.8) Cap tester: J–24460–01 Adapter: J–33984–A Check the condition of the vacuum valve in the center of the valve seat side of the cap. If considerable rust or dirt is found, or if the valve seat cannot be moved by hand, clean or replace the cap. Valve opening vacuum kPa (psi) 0 ∼ 6.9 (0 ∼ 1.0)

Radiator Core 1. A bent fin may result in reduced ventilation and overheating may occur. All bent fins must be straightened. Pay close attention to the base of the fin when it is being straightened. 2. Remove all dust, bugs and other foreign material.

Flushing the Radiator Thoroughly wash the inside of the radiator and the engine coolant passages with cold water and mild detergent. Remove all signs of scale and rust.

Cooling System Leakage Check Use a radiator cap tester to force air into the radiator through the filler neck at the specified pressure of 150 kPa (22 psi) with a cap tester: B Leakage from the radiator B Leakage from the coolant pump B Leakage from the water hoses B Check the rubber hoses for swelling.

6B–10

ENGINE COOLING (6VE1 3.5L)

Cap tester: J–24460–01 Adapter: J–33984–A

7. Connect battery ground cable. 8. Pour engine coolant up to filler neck of radiator, and up to MAX mark of reserve tank.

110RX002

110RW012

Important operation (in case of 100% engine coolant change) procedure for filling with engine coolant.

Installation 1. Install rubber cushions on both sides of radiator bottom. 2. Install radiator assembly with hose, taking care not to damage the radiator core with a fan blade. 3. Connect reserve tank hose (4). 4. Install lower fan guide (3). 5. Connect radiator inlet hose and outlet hose to the engine. 6. Connect oil cooler hose (1) to automatic transmission.

Engine Coolant Filling Up Procedure 1. Make sure that the engine is cool. WARNING: WHEN THE COOLANT IS HEATED TO A HIGH TEMPERATURE, BE SURE NOT TO LOOSEN OR REMOVE THE RADIATOR CAP. OTHERWISE YOU MIGHT GET SCALDED BY HOT VAPOR OR BOILING WATER. TO OPEN THE RADIATOR CAP, PUT A PIECE OF THICK CLOTH ON THE CAP AND LOOSEN THE CAP SLOWLY TO REDUCE THE PRESSURE WHEN THE COOLANT HAS BECOME COOLER. 2. Open radiator cap pour coolant up to filler neck. 3. Pour coolant into reservoir tank up to “MAX” line. 4. Tighten radiator cap and start the engine. After idling for 2 to 3 minutes, stop the engine and reopen radiator cap. If the water level is lower, replenish. 5. After replenishing with coolant tighten radiator cap, warm up the engine at about 2000 rpm. Set heater adjustment to the highest temperature position, and let the coolant circulate also into heater water system. 6. Check to see the thermometer, continuously idle for 5 minutes and stop the engine. 7. When the engine has been cooled, check filler neck for water level and replenish if required. Should extreme shortage of coolant is found, check the coolant system and reservoir tank hose for leakage. 8. Pour coolant into the reservoir tank up to “MAX” line.

110RX001

ENGINE COOLING (6VE1 3.5L)

6B–11

Drive Belt and Cooling Fan Drive Belt and Associated Parts

015RW005

Legend (1) Crankshaft Pulley (2) Generator (3) Power Steering Pump

The drive belt adjustment is not required as automatic drive belt tensioner is equipped.

Removal Move the tension pulley drive belt loosen side, remove the drive belt.

Inspection Check drive belt for wear or damage, and replace with a new one as necessary.

(4) (5) (6) (7)

Water Pump and Cooling Fan Pulley Idle Pulley Tension Pulley Drive Belt

Installation Install cooling fan assembly and tighten bolts/nuts to the specified torque. Torque : 22 N·m (16 lb ft) for fan pulley and fan bracket. Torque : 7.5 N·m (66.4 lb in) for fan and clutch assembly.

6B–12

ENGINE COOLING (6VE1 3.5L)

Main Data and Specifications General Specifications A/T Cooling system Radiator Heat radiation capacity

Engine coolant forced circulation Tube type corrugated (2 tube in row) 85,500 kcal/h

Heat radiation area

14.02m@ (150.9ft@)

Radiator front area

0.263m@ (2.83ft@)

Radiator dry weight

56N (12.6lb)

Radiator cap valve opening pressure Engine coolant capacity Engine coolant pump Delivery

93.3 ∼ 122.7kpa (13.5 ∼ 17.8psi) 2.4lit (0.6 US gal) Centrifugal impeller type 300 (317) or more

Pump speed

5000 ± 50 rpm

Thermostat

Wax pellet type with air hole

Valve opening temperature Engine coolant total capacity

74.5 ∼ 78.5°C (166.1 ∼ 173.3°F) 10.0lit (2.64 US gal)

Torque Specifications

E06RW004

ENGINE COOLING (6VE1 3.5L)

Special Tool ILLUSTRATION

TOOL NO. TOOL NAME

J–24460–01 Tester; radiator cap

J–33984–A Adapter; radiator cap

6B–13

SECTION ENGINE FUEL (6VE1 3.5L)

6C–1

AXIOM

ENGINE ENGINE FUEL CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Fuel Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . In–Tank Fuel Filter . . . . . . . . . . . . . . . . . . . . . Fuel Pump Flow Test . . . . . . . . . . . . . . . . . . . Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Pump and Associated Parts . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tube / Quick – Connector Fittings . . . . . Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . Cautions During Work . . . . . . . . . . . . . . . . . .

6C–1 6C–2 6C–3 6C–4 6C–4 6C–4 6C–5 6C–5 6C–5 6C–5 6C–6 6C–6 6C–6 6C–7 6C–8 6C–8 6C–8

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reuse of Quick–Connector . . . . . . . . . . . . . Assembling Advice . . . . . . . . . . . . . . . . . . . . Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank and Associated Parts . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . . Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6C–8 6C–9 6C–9 6C–10 6C–10 6C–10 6C–10 6C–11 6C–11 6C–12 6C–12 6C–12 6C–12 6C–12 6C–13 6C–13

6C–2

ENGINE FUEL (6VE1 3.5L)

General Description

140R200004

Legend (1) Fuel Filler Cap (2) Fuel Tank (3) Rollover Valve (4) Fuel Pump and Sender Assembly (5) Fuel Filter (6) Fuel Rail Right (7) Right Bank (8) Fuel Rail Left (9) Left Bank

(10) (11) (12) (13) (14) (15) (16) (17) (18)

Fuel Pressure Control Valve Common Chamber Duty Solenoid Valve Throttle Valve Canister Vent Hose Vent Solenoid Valve Separator Shut off Valve (With Over Pressure Relief Valve)

ENGINE FUEL (6VE1 3.5L) When working on the fuel system, there are several things to keep in mind: B Any time the fuel system is being worked on, disconnect the battery ground cable except for those tests where battery voltage is required. B Always keep a dry chemical (Class B) fire extinguisher near the work area. B Replace all pipes with the same pipe and fittings that were removed. B Clean and inspect “O” rings. Replace if required. B Always relieve the line pressure before servicing any fuel system components. B Do not attempt repairs on the fuel system until you have read the instructions and checked the pictures relating to that repair. B Adhere to all Notices and Cautions. All gasoline engines are designed to use only unleaded gasoline. Unleaded gasoline must be used for proper emission control system operation. Its use will also minimize spark plug fouling and extend engine oil life. Using leaded gasoline can damage the emission control system and could result in loss of emission warranty coverage. The vapor pressure sensor and vent solenoid valve for vapor pressure sensor are used to detect abnormalities in the evaporative emission control system. The PCM decides whether there is an abnormality in the evaporative emission control system based on vapor pressure sensor signal.

6C–3

Fuel Metering The Powertrain Control Module (PCM) is in complete control of this fuel delivery system during normal driving conditions. The intake manifold function, like that of a diesel, is used only to let air into the engine. The fuel is injected by separate injectors that are mounted over the intake manifold. The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which result from engine load and speed changes, which the MAP sensor converts to a voltage output. This sensor generates the voltage to change corresponding to the flow of the air drawn into the engine. The changing voltage is transformed into an electric signal and provided to the PCM. With receipt of the signals sent from the MAP sensor, Intake Air Temperature sensor and others, the PCM determines an appropriate fuel injection pulse width feeding such information to the fuel injector valves to affect an appropriate air/fuel ratio. The Multiport Fuel Injection system utilizes an injection system where the injectors turn on at every crankshaft revolution. The PCM controls the injector on time so that the correct amount of fuel is metered depending on driving conditions. Two interchangeable “O” rings are used on the injector that must be replaced when the injectors are removed. The fuel rail is attached to the top of the intake manifold and supplies fuel to all the injectors. Fuel is recirculated through the rail continually while the engine is running. This removes air and vapors from the fuel as well as keeping the fuel cool during hot weather operation. The fuel pressure control valve that is mounted on the fuel rail maintains a pressure differential across the injectors under all operating conditions. It is accomplished by controlling the amount of fuel that is recirculated back to the fuel tank based on engine demand. See Section “Driveability and Emission” for more information and diagnosis.

6C–4

ENGINE FUEL (6VE1 3.5L)

Fuel Filter 5. Remove fuel filter(3).

041RW003

Legend (1) Fuel Hose (2) Fuel Filter Fixing Bolt (3) Fuel Filter

140R100023

Legend (1) Fuel Filler Cap (2) Receive Rubber Drain 3. Disconnect fuel hoses(1) from fuel filter on both engine side and fuel tank side. 4. Fuel filter fixing bolt(2). B Remove the fuel filter fixing bolt(2) on fuel filter holder.

Inspection 1. Replace the fuel filter if the fuel leaks from fuel filter body or if the fuel filter body itself is damaged. 2. Replace the filter if it is clogged with dirt or sediment. 3. Check clogged drain port of the receive rubber by the foreign material, repair or clear if found clog it.

ENGINE FUEL (6VE1 3.5L)

Installation

6C–5

Fuel Pump Flow Test

1. Install the fuel filter in the proper direction. 2. Install fuel filter holder fixing bolt. 3. Connect fuel hoses on engine side(1) and fuel tank side(2).

If reduction of fuel supply is suspected, perform the following checks. 1. Make sure that there is fuel in the tank. 2. With the engine running, check the fuel feed pipe and hose from fuel tank to injector for evidence of leakage. Retighten, if pipe or hose connection is loose. Also, inspect bent or kink fuel pipes and hoses. 3. Insert the hose from fuel feed pipe into a clean container, and check for fuel pump flow rate. 4. Connect the pump relay terminals with a jumper wire(1) as shown and start the fuel pump to measure delivery.

041RW001

4. Install fuel filler cap 5. Connect the battery ground cable.

Inspection After installation, start engine and check for fuel leakage.

In–Tank Fuel Filter The filter is located on the lower end of fuel pickup tube in the fuel tank. The fuel filter prevents dirt and water the fuel system not unless the filter is submerged in water. The fuel filter is maintenance free, that requires no maintenance. Excess water and sediment in the tank restricts fuel supply to the engine, resulting in engine stall. If this happens, the fuel tank would need to be cleaned thoroughly.

140R200003

CAUTION: Never generate sparks when connecting a jumper wire. Delivery Times

Delivery

15 seconds

0.38 liters minimum

If the measure value is out of standard, conduct the pressure test.

Pressure test For the pressure test to the fuel system, see Section 6E “Fuel Control System”.

6C–6

ENGINE FUEL (6VE1 3.5L)

Fuel Pump Fuel Pump and Associated Parts

140R200008

Legend (1) Fuel Feed Port (2) Fuel Tube/Quick Connector (3) Fuel Return Port (4) Fuel Pump and Sender (FPS) Assembly

Removal CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section “Driveability and Emission”. 1. Remove fuel tank assembly(8). Refer to “Fuel Tank Removal” in this section. 2. Remove Fuel Tube/Quick Connector (2). NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this section when performing any repairs.

(5) (6) (7) (8) (9)

Connector; Fuel Feed Pump Connector; Fuel Tank Pressure Sensor Retainer (Fuel Pump Lock) Fuel Tank Assembly Seal; Fuel Pump

ENGINE FUEL (6VE1 3.5L) 3. Remove the retainer (7) with tool J–39765 and remove the fuel pump and sender (FPS) assembly (4).

140R200007

NOTE: After removing pump assembly (4), cover fuel tank to prevent any dust entering.

Installation 1. Install FPS assembly(4) with retainer (7) and new seal; fuel pump (9) by J–39765. 2. Install Fuel Tube/Quick Connector (2). NOTE: Refer to “Fuel Tube/Quick Connector Fittings” in this section when performing any repairs. 3. Install fuel tank assembly(8). Refer to “Fuel Tank Installation”.

6C–7

6C–8

ENGINE FUEL (6VE1 3.5L)

Fuel Tube / Quick – Connector Fittings Precautions

Removal

B Do not light a match or create a flame. B Keep flames away from your work area to prevent flammable materials from catching fire. B Disconnect battery ground cable to prevent electrical shorts. B Pre-treat piping system or associated parts from thermal damage or from spattering when welding or similar heat-generating work.

1. Open the fuel cap to relieve the fuel pressure in the tank. Use compressed air to remove any dirt on the fuel quick connect fittings prior to disconnecting the fittings.

Cautions During Work

141R100002

When disconnecting the fuel pipe, cover the area with a cloth to prevent fuel from splashing as the fuel pipe may still have some pressure in it. 140R100032

Legend (1) (2) (3) (4) NOTE:

2. For removal of the quick connector, pull out the connector with the other hand while pressing the square relieve button of the connector, as illustrated.

O-ring Port Connector Plastic Tube An O-ring inside the quick connector provides the seal between the quick connector and the port. Be careful not to damage the mating surfaces and O-ring when attaching the connector. Do not allow foreign material to enter the connector or the port.

Do not expose the assembly to battery electrolyte or do not wipe the assembly with a cloth used to wipe off spilt battery electrolyte. Piping that has been splattered with battery electrolyte or battery electrolyte soaked cloth that was wiped on the piping cannot be used. 140R200001

ENGINE FUEL (6VE1 3.5L) NOTE: Do not use tools of any kind. Only use bare hands when disconnecting the connector. Use a lubricant (light oil) and/or push and pull the connector until the pipe is disconnected. Cover the connectors that was removed with a plastic bag, to prevent dust or rain water from entering.

6C–9

Assembling Advice By applying engine oil or light oil to the pipe, port makes pipe assembly easier. The pipe assembly should take place immediately after applying oil (to prevent dust from sticking to the pipe surface – which may decrease sealing ability). Test/Inspection After Assembling 1. Reconnect the battery negative cable. 2. Turn the ignition key to the “ON” position and listen for pump start-up sound. Inspect for leaks, the fuel pressure will increase as the fuel pump is actuated. 3. Perform leak inspection (step 2) several times. 4. Start the engine and observe the engine idle speed. The presence of dirt in the fuel system may affect the fuel injection system.

140R100028

Reuse of Quick–Connector B Replace the port and connector if scratch, dent or crack is found. B Remove any dirt build up on the port when installing the connector. Replace the connector, if there is any forms of rust, dent, scratch. B After cleaning the port, insert it straight into the connector until it clicks. After it clicks, try pulling it out to make sure that it is not drawn and is securely locked.

140R100036

6C–10

ENGINE FUEL (6VE1 3.5L)

Fuel Pump Relay General Description In order to control the fuel pump and sender (FPS) operation, the FPS relay is provided. When the starter switch is turned to “ON” position, the FPS relay operates the FPS for 2 seconds. When the key is turned to “START” position, the Engine Control Module receives the reference pulse from the Ignition Control Module and it operates the relay, again causing the FPS to feed fuel.

Fuel Tank Fuel Tank and Associated Parts

140R200006

Legend (1) Fuel Tank Assembly (2) Fuel Tank Fixing Bolt (QTY: 5) (3) Fuel Tank Fixing Nut (QTY: 1) (4) Separator Fixing Bolt (QTY: 2) (5) Fuel Filler Hose

(6) (7) (8) (9) (10)

Fuel Vent Hose Fuel Feed Hose Fuel Return Hose Vapor Pressure Sensor Connector Fuel Feed Pump Connector

ENGINE FUEL (6VE1 3.5L)

Removal CAUTION: When repair to the fuel system has been completed, start engine and check the fuel system for loose connection or leakage. For the fuel system diagnosis, see Section “Driveability and Emission”. 1. Drain the fuel from the fuel tank, refer to the “Fuel Pump Flow Test” in this section. 2. Disconnect battery ground cable. 3. Loosen fuel filler cap to reduce the pressure in fuel tank. 4. Support underneath of the fuel tank assembly (1) with a lifter. 5. Disconnect fuel feed hose (7) and fuel return hose (8) near the fuel filter. NOTE: Plug both ends of the fuel hoses to prevent fuel leakage. 6. Disconnect fuel filler hose (5) and fuel vent hose (6) at the fuel filler neck. NOTE: Cover fuel hoses to prevent any dust entering. 7. Remove two bolts (4) and remove separator. 8. Remove the five fuel tank assembly fixing bolts (2) and one nut (3). 9. Lower the tank and disconnect the wiring connectors (9, 10).

Installation 1. Raise the fuel tank assembly (1) and connect the wiring connectors (9, 10). 2. Install fuel tank assembly along with protectors and tighten the five fixing bolts (2) and one nut (3) to the specified torque. Torque: 68 N·m (50 lb ft) 3. Install the separator and tighten two bolts (4). Torque: 10 N·m (95 lb in) 4. Connect fuel filler hose (5) and fuel vent hose and clip them firmly. 5. Connect fuel feed hose (7) and fuel return hose(8), and clip them firmly. 6. Tighten fuel filler cap until at least three clicks are heard. 7. Connect battery ground cable.

6C–11

6C–12

ENGINE FUEL (6VE1 3.5L)

Fuel Gauge Unit Removal and Installation Refer to “Fuel Pump” in this section for removal and installation of the Fuel Gauge Unit, since the fuel gauge unit is linked to the fuel pump and sender assembly.

Fuel Filler Cap General Description

Inspection

A vacuum valve and pressure valve are built into the fuel filler cap which adjusts the fuel pressure in the fuel tank to prevent fuel tank damage.

The fuel filler cap must be inspected for seal condition. The fuel filler cap must be replaced if found defective.

140R100029

Legend (1) Vacuum Valve (2) Pressure Valve (3) Seal Ring

CAUTION: A replacement fuel filler cap must be the same as the original. The fuel filler cap valve was designed primarily for this application and must be replaced with the same type or decreased engine performance may occur.

ENGINE FUEL (6VE1 3.5L)

6C–13

Main Data and Specifications Torque Specification

140R200023

Special Tool ILLUSTRATION

TOOL NO. TOOL NAME

J–39765 Remover; fuel pump retainer

SECTION ENGINE ELECTRICAL (6VE1 3.5L)

6D1–1

AXIOM

ENGINE ENGINE ELECTRICAL (6VE1 3.5L) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charging . . . . . . . . . . . . . . . . . . . . . .

6D1–1 6D1–2 6D1–2 6D1–2 6D1–3

Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . Battery Removal . . . . . . . . . . . . . . . . . . . . . . Battery Installation . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . .

6D1–3 6D1–4 6D1–4 6D1–5

6D1–2

ENGINE ELECTRICAL (6VE1 3.5L)

Battery 3. Voltage Check

General Description The battery is completely sealed except for the two small vent holes (2) on the side. These vent holes (2) permit the escape of small amounts of gas generated by the battery. This type of battery has the following advantages over conventional batteries: 1. There is no need to add water during the entire service life of the battery. 2. The battery is much less vulnerable to self discharge than a conventional type battery.

Diagnosis 1. Visual Inspection Inspect the battery for obvious physical damage, such as a cracked or broken case, which would permit electrolyte loss. Replace the battery if obvious physical damage is discovered during inspection. Check for any other physical damage and correct it as necessary.

2. Hydrometer Check There is a built–in hydrometer (Charge test indicator(1)) at the top of the battery. It is designed to be used during diagnostic procedures. Before trying to read the hydrometer, carefully clean the upper battery surface. If your work area is poorly lit, additional light may be necessary to read the hydrometer. a. BLUE RING OR DOT VISIBLE(4) – Go to Step 3. b. BLUE RING OR DOT NOT VISIBLE(3) – Replace the battery.

1. Put voltmeter test leads to battery terminals. a. VOLTAGE IS 12.4V OR ABOVE – Go to Step 4 Load Test. b. VOLTAGE IS UNDER 12.4V – Go to procedure (2) below. 2. Determine fast charge amperage from specification. (See Main Data and Specifications in this section). Fast charge battery for 30 minutes at amperage rate no higher than specified value. Take voltage and amperage readings after charge. a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF AMPERAGE RATE – Replace battery. b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF AMPERAGE RATE – Drop charging voltage to 15V and charge for 10 – 15 hours. Then go to Step 4 Load Test. c. VOLTAGE IS BETWEEN 12V AND 16V – Continue charging at the same rate for an additional 3–1/2 hours. Then go to Step 4 Load Test. d. VOLTAGE BELOW 12V – Replace the Battery.

4. Load Test 1. Connect a voltmeter and a battery load tester across the battery terminals. 2. Apply 300 ampere load for 15 seconds to remove surface charge from the battery. Remove load. 3. Wait 15 seconds to let battery recover. Then apply specified load from specifications (See Main Data and Specifications in this section). Read voltage after 15 seconds, then remove load. a. VOLTAGE DOES NOT DROP BELOW THE MINIMUM LISTED IN THE TABLE – The battery is good and should be returned to service. b. VOLTAGE IS LESS THAN MINIMUM LISTED – Replace the battery. ESTIMATED TEMPERATURE

061R200001

MINIMUM VOLTAGE

°F

°C

9.6

9.5

9.4

9.3

–1

9.1

–7

8.9

–12

8.7

–18

8.5

The battery temperature must be estimated by feel and by the temperature the battery has been exposed to for the preceding few hours.

ENGINE ELECTRICAL (6VE1 3.5L)

Battery Charging Observe the following safety precautions when charging the battery: 1. Never attempt to charge the battery when the fluid level is below the lower level line on the side of the battery. In this case, the battery must be replaced. 2. Pay close attention to the battery during charging procedure. Battery charging should be discontinued or the rate of charge reduced if the battery feels hot to the touch. Battery charging should be discontinued or the rate of charge reduced if the battery begins to gas or spew electrolyte from the vent holes. 3. In order to more easily view the hydrometer blue dot or ring, it may be necessary to jiggle or tilt the battery. 4. Battery temperature can have a great effect on battery charging capacity. 5. The sealed battery used on this vehicle may be either quick charged or slow charged in the same manner as other batteries. Whichever method you decide to use, be sure that you completely charge the battery. Never partially charge the battery.

Jump Starting Jump Starting with an Auxiliary (Booster) Battery CAUTION: Never push or tow the vehicle in an attempt to start it. Serious damage to the emission system as well as other vehicle parts will result. Treat both the discharged battery and the booster battery with great care when using jumper cables. Carefully follow the jump starting procedure, being careful at all times to avoid sparking. WARNING: FAILURE TO CAREFULLY FOLLOW THE JUMP STARTING PROCEDURE COULD RESULT IN THE FOLLOWING: 1. Serous personal injury, particularly to your eyes. 2. Property damage from a battery explosion, battery acid, or an electrical fire. 3. Damage to the electronic components of one or both vehicles particularly. Never expose the battery to an open flame or electrical spark. Gas generated by the battery may catch fire or explode. Remove any rings, watches, or other jewelry before working around the battery. Protect your eyes by wearing an approved set of goggles. Never allow battery fluid to come in contact with your eyes or skin.

6D1–3

Never allow battery fluid to come in contact with fabrics or painted surfaces. Battery fluid is a highly corrosive acid. Should battery fluid come in contact with your eyes, skin, fabric, or a painted surface, immediately and thoroughly rinse the affected area with clean tap water. Never allow metal tools or jumper cables to come in contact with the positive battery terminal, or any other metal surface of the vehicle. This will protect against a short circuit. Always keep batteries out of reach of young children.

Jump Starting Procedure 1. Set the vehicle parking brake. If the vehicle is equipped with an automatic transmission, place the selector level in the “PARK” position. If the vehicle is equipped with a manual transmission, place the shift lever in the “NEUTRAL” position. Turn “OFF” the ignition. Turn “OFF” all lights and any other accessory requiring electrical power. 2. Look at the built–in hydrometer. If the indication area of the built–in hydrometer is completely clear, do not try to jump start. 3. Attach the end of one jumper cable to the positive terminal of the booster battery. Attach the other end of the same cable to the positive terminal of the discharged battery. Do not allow the vehicles to touch each other. This will cause a ground connection, effectively neutralizing the charging procedure. Be sure that the booster battery has a 12 volt rating. 4. Attach one end of the remaining cable to the negative terminal of the booster battery. Attach the other end of the same cable to a solid engine ground (such as the air conditioning compressor bracket or the generator mounting bracket) of the vehicle with the discharged battery. The ground connection must be at least 450 mm (18 in.) from the battery of the vehicle whose battery is being charged. WARNING: NEVER ATTACH THE END OF THE JUMPER CABLE DIRECTLY TO THE NEGATIVE TERMINAL OF THE DEAD BATTERY. 5. Start the engine of the vehicle with the good battery. Make sure that all unnecessary electrical accessories have been turned “OFF”. 6. Start the engine of the vehicle with the dead battery.

6D1–4

ENGINE ELECTRICAL (6VE1 3.5L)

7. To remove the jumper cables, follow the above directions in reverse order. Be sure to first disconnect the negative cable from the vehicle with the discharged battery.

Battery Removal

061RX002

1. Remove negative cable (1). 2. Remove positive cable (2). 3. Remove retainer screw and rods (3). 4. Remove retainer (4). 5. Remove battery (5).

Battery Installation 1. Install battery (5). 2. Install retainer (4). 3. Install retainer screw and rods (3). NOTE: Make sure that the rod is hooked on the body side. 4. Install positive cable (2). 5. Install negative cable (1).

ENGINE ELECTRICAL (6VE1 3.5L)

Main Data and Specifications General Specifications Model

24R–600

Voltage (V)

Cold–Cranking Performance (Amp)

600

Reserve Capacity (Min)

118

Load Test (Amp)

300

BCI Group No.

6D1–5

SECTION IGNITION SYSTEM (6VE1 3.5L)

6D2–1

AXIOM

ENGINE IGNITION SYSTEM (6VE1 3.5L) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6D2–1 6D2–2 6D2–2 6D2–3 6D2–3 6D2–3 6D2–3 6D2–5

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft Position Sensor . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

6D2–5 6D2–5 6D2–5 6D2–6 6D2–6 6D2–6 6D2–7

6D2–2

IGNITION SYSTEM (6VE1 3.5L)

General Description Ignition is done by the electronic ignition (El) that directly fires the spark plugs from ignition coils through spark plug wires without using a distributor. The firing orders are selected No.1, No.2, No.3, No.4, No.5, and No6. Since the cylinder on exhaust stroke requires less energy to fire its ignition plug, energy from the ignition coils can be utilized to fire the mating cylinder on compression stroke. After additional 360° rotation, respective cylinder strokes are reversed. The EI consists of six ignition coils,ignition control module, crank position sensor, powertrain control module (PCM) and other components. The ignition coils are connected with the PCM by means of a 80 pin connector.

The ignition control module turns on/off the primary circuit of ignition coils, and also it controls the ignition timing at the engine speed below 538 rpm. A notch in the timing disc on the crankshaft activates the crank position sensor which then sends information such as firing order and starting timing of each ignition coil to the PCM. Further, the El employs ignition control (IC) to control similar to a distributor system. By receiving signals such as crank position,engine speed, water temperature and Manifold Absolute Pressure (MAP), the PCM controls the ignition timing.

D06RY00037

Diagnosis Refer to Section Drivability and Emissions for the diagnosis to electronic ignition system (El system).

IGNITION SYSTEM (6VE1 3.5L)

6D2–3

Ignition Coil Measure resistance of ignition coil assembly, and replace the ignition coil assembly if its value exceeds the standard.

Removal 1. Disconnect battery ground cable. 2. Ignition coil connector and ignition coil. B Disconnect three connector from ignition coil. B Remove harness bracket bolt on cylinder head cover. B Remove fixing bolts on ignition coil.

060RW006

Installation

060RY023

Legend (1) Ignition Coil Connector (2) Bolt (3) Ignition Coil Assembly

1. Install the ignition coil assembly (3). Connect ignition coil connector (1) and ignition coil (3), then tighten bolt (2) to the specified torque. Torque: 4 N·m (35 lb in)

Inspection and Repair Check the ignition coil assembly for insulation. Check terminals for corrosion or damage, and replace as necessary. Measuring resistance of ignition coil assembly. Terminal No.

Limit

1 to 2

Without 0 ohm or infinity maximum ohm.

1 to 3

Same as above

2 to 3

Same as above 060RY023

6D2–4

IGNITION SYSTEM (6VE1 3.5L)

CAUTION: Ignition coil assembly #6 is different from ignition coil assembly from #1 to #5. Ignition coil assembly #6 is short type. So, note it when installing ignition coil assembly of #6.

060RY00002

Legend (1) Long type Ignition Coil Assemblies (#1 ∼ #5) (2) Short type Ignition Coil Assembly (#6) 2. Connect battery ground cable.

IGNITION SYSTEM (6VE1 3.5L)

6D2–5

Spark Plug Sooty Spark Plugs

Removal

Much deposit of carbon or oil on the electrode and insulator of spark plug reduces the engine performance. Possible causes:

1. Remove spark plugs.

Inspection and Repair The spark plug affects entire engine performance and therefore its inspection is very important. B Check electrode and insulator for presence of cracks, and replace if any. B Check electrode for wear, and replace if necessary. B Check gasket for damage, and replace if necessary. B Measure insulation resistance with an ohmmeter, and replace if faulty. B Adjust spark plug gap to 1.0 mm – 1.1 mm (0.0394 in – 0.0433 in).

B Too rich mixture B Presence of oil in combustion chamber B Incorrectly adjusted spark plug gap

Burning Electrodes This fault is characterized by scorched or heavily oxidized electrode or blistered insulator nose. Possible causes: B Too lean mixture B Improper heat value

Measuring Insulation Resistance B Measure insulation resistance using a 500 volt megaohm meter. B Replace spark plugs if measured value is out of standard. Insulation resistance: 50 MW or more

011RS011

NOTE: – Do not adjust the spark plugs gap without new spark plugs. – Do not damage to tip of spark plugs. – Do not cleaning the spark plugs. If require the cleaning it due to heavy dirt, it is allowed only 20 seconds to be used spark plug cleaner. B Check fuel and electrical systems if spark plug is extremely dirty. B Use spark plugs having low heat value (hot type plug) if fuel and electrical systems are normal. B Use spark plugs having high heat value (cold type plug) if insulator and electrode are extremely burned.

011RS010

Installation 1. Spark plugs B Tighten spark plugs to the specified torque. Torque: 18 N·m (13 lb ft)

6D2–6

IGNITION SYSTEM (6VE1 3.5L)

Crankshaft Position Sensor Removal

Installation

1. Disconnect battery ground cable 2. Wiring connector from crankshaft position sensor. 3. Remove crankshaft position sensor from cylinder block.

1. Install crankshaft position sensor into the cylinder block. Before installation,apply small amount of engine oil to the O–ring. Torque: 10 N·m (87 lb in) 2. Reconnect wiring connector to crankshaft position sensor.

012RS008

IGNITION SYSTEM (6VE1 3.5L)

6D2–7

Main Data and Specifications General Specifications Ignition System Ignition Form

Electronic Ignition System (El system) with Crankshaft position Sensor

Spark Plug Type

Plug gap Torque

K16PR–P11 RC10PYP4 PK16PR11 1.0 mm – 1.1 mm (0.0394 in – 0.0433 in) 18 N·m (13lb ft)

Torque Specifications

E06R100003

SECTION STARTING AND CHARGING SYSTEM (6VE1 3.5L)

6D3–1

AXIOM

ENGINE STARTING AND CHARGING SYSTEM (6VE1 3.5L) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Starting System . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . Charging System . . . . . . . . . . . . . . . . . . . . . . . .

6D3–1 6D3–2 6D3–2 6D3–4 6D3–5 6D3–5 6D3–5 6D3–7 6D3–8 6D3–10 6D3–13 6D3–14 6D3–17

General Description . . . . . . . . . . . . . . . . . . . . General On–Vehicle Inspection . . . . . . . . . . . Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

6D3–17 6D3–17 6D3–18 6D3–18 6D3–18 6D3–19 6D3–19 6D3–20 6D3–21 6D3–23 6D3–24 6D3–25

6D3–2

STARTING AND CHARGING SYSTEM (6VE1 3.5L)

Starting System General Description Cranking Circuit The cranking system consists of a battery, starter, starter switch, starter relay, etc. These main components are connected.

Starter The cranking system employs a magnetic type reduction starter in which the motor shaft is also used as a pinion shaft. When the starter switch is turned on, the contacts of magnetic switch are closed, and the armature rotates. At the same time, the plunger is attracted, and the pinion is pushed forward by the shift lever to mesh with the ring gear. Then, the ring gear runs to start the engine. When the engine starts and the starter switch is turned off, the plunger returns, the pinion is disengaged from the ring gear, and the armature stops rotation. When the engine speed is higher than the pinion, the pinion idles, so that the armature is not driven.

STARTING AND CHARGING SYSTEM (6VE1 3.5L)

6D3–3

060R200062

6D3–4

STARTING AND CHARGING SYSTEM (6VE1 3.5L)

Diagnosis Condition Starter does not run

Possible cause

Correction

Charging failure

Repair charging system

Battery Failure

Replace Battery

Terminal connection failure

Repair or replace terminal connector and/or wiring harness

Starter switch failure

Repair or replace starter switch

Starter relay failure

Replace

Starter failure

Repair or replace starter

STARTING AND CHARGING SYSTEM (6VE1 3.5L)

6D3–5

Starter Removal

Installation

1. Battery ground cable. 2. Disconnect Heated O2 Sensor connector (1). 3. Remove exhaust front left pipe(2).

1. Install starter assembly(4). 2. Install mounting bolts and tighten bolts to specified torque(3). Torque: 40 N·m (30 lb ft) 3. Reconnect the connectors to terminals “50” (2) tighten terminals “30” (1) to specified torque. Torque: 9 N·m (78 lb in)

150R100011

4. Disconnect starter wiring connector from terminals “30” (1) and “50” (2). 5. Remove starter assembly mounting bolts on inside and outside(3). 6. Remove starter assembly (4) toward the bottom of engine.

065RY00050

Legend (1) Terminal “30” (2) Terminal “50” (3) Fixing Bolts (4) Starter Assembly 4. Install exhaust front left pipe (2) and tighten bolts and nuts to specified torque. Stud Nuts Torque: 67 N·m (49 lb ft) Bolts Torque: 43 N·m (32 lb ft)

065RY00050

Legend (1) Terminal “30” (2) Terminal “50” (3) Fixing Bolts (4) Starter Assembly

6D3–6

STARTING AND CHARGING SYSTEM (6VE1 3.5L)

5. Connect two Heated O2 Sensor connector (1).

150R100011

6. Reconnect the battery ground cable.

STARTING AND CHARGING SYSTEM (6VE1 3.5L)

6D3–7

Disassembled View

065R100012

Legend (1) Lead Wire (2) Through Bolt (3) Yoke Assembly (4) Yoke Cover (5) Brush and Brush Holder (6) Armature

(7) (8) (9) (10) (11) (12) (13)

Housing Over Running Clutch Return Spring Steel Ball Idle Pinion Retainer Magnetic Switch

6D3–8

STARTING AND CHARGING SYSTEM (6VE1 3.5L)

Disassembly 1. Remove the lead wire (1) from the magnetic switch. 2. Remove the through bolts (2).

065RY00055

Legend (1) Spring (2) Brush 065RY00053

6. Remove the armature. 7. Remove the housing. 8. Remove the overrunning clutch from the housing.

Legend (1) Lead Wire (2) Through Bolt 3. Remove the yoke from the magnetic. 4. Remove the yoke cover. 5. Use the long nose pliers to remove the brush and brush holder.

065RY00056

065RY00054

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 9. Remove the return spring from the magnetic switch.

11. Remove the idle pinion from the magnetic switch.

065R100014

10. Remove the steel ball from the overrunning clutch.

6D3–9

065R100015

12. Remove the retainer from the magnetic switch.

065RY00058

065R100016

13. Remove the magnetic switch.

6D3–10 STARTING AND CHARGING SYSTEM (6VE1 3.5L)

Inspection and Repair Repair or replace necessary parts if extreme wear or damage is found during inspection.

Armature

Check for continuity between commutator and shaft. Also, check for continuity between commutator and armature core, armature core and shaft. Replace commutator if there is continuity (i.e., internally grounded).

Measure the outer diameter of commutator, and replace with a new one if it is out of the limit. Standard: 30 mm (1.1811 in) Limit: 29 mm (1.1417 in)

065RS016

Measure runout of the commutator with a dial gauge. Repair or replace, if it exceeds the limit. Limit: 0.4 mm (0.0157 in) 065RS014

Check for continuity between segment and segment on the commutator. Replace commutator if there is no continuity (i.e., disconnected).

065RY00061

065RS015

STARTING AND CHARGING SYSTEM (6VE1 3.5L) Polish the commutator surface with sandpaper #500 to #600 if it is rough.

6D3–11

Brush Measure the length of brush. Replace with a new one, if it is below the limit. Standard: 15 mm (0.5906 in) Limit: 11 mm (0.43 in)

065RW012

Measure the depth of insulator in commutator. Replace, if it is below the limit. Standard: 0.45 mm to 0.75 mm (0.0177 in to 0.0295 in) Limit: 0.2 mm (0.008 in)

065RW014

Brush Holder Check for continuity between brush holder (+) (4) and base (–). Replace, if there is continuity (i.e., insulation is broken).

065RY00070

Legend (1) Insulator (2) Depth of Insulator (3) Commutator Segments

065RW015

6D3–12 STARTING AND CHARGING SYSTEM (6VE1 3.5L)

Brush Spring Use spring balancer to measure the spring setting force when remove the spring from the brush. Standard: 17.65–23.54 N (38.9–51.9 lb) Limit: 11.77 N (25.9 lb)

Magnetic Switch

3. Return test Connect the ground (–) to terminal 50 and magnetic switch body. Verify that the pinion pulls out when the battery (+) pole is connected to terminal C and the pinion pulls away when the lead wire is disconnected from terminal 50.

Temporarilly connect the magnetic switch between the overrunning clutch and housing. Perform the steps described below in 3 to 5 seconds. 1. Pull in test Connect the ground (–) to terminal C and magnetic switch body. Verify that the pinion pulls out when the battery (+) pole is connected to terminal 50.

065R100019

Field Coil 1. Check for continuity between the end of the field coil and yoke body. Replace the field coil, if there is continuity.

065R100017

2. Hold in test Observe that the pinion stays when the lead wire is disconnected from terminal C.

065RY00065

065R100018

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 2. Check continuity between the lead wire of terminal C and brush. Replace the yoke assembly, if there is no continuity.

6D3–13

Bearing 1. Inspect excessive wear or damage. Replace the bearing if an abnormal noise is heard under normal operating condition.

065RY00066

Overrunning Clutch

065RY00068

1. Visual check for excessive wear or damage. 2. Test the pinion rotation, it must rotate smoothly when rotated clockwise and it shouldn’t rotate when turned counterclockwise.

Reassembly To install, follow the removal steps in the reverse order, noting the following points: Grease application places B Bearing in rear cover B Gears in reduction gear B Sliding portion of pinion

065RY00067

6D3–14 STARTING AND CHARGING SYSTEM (6VE1 3.5L)

Main Data and Specifications General Specifications Model

Specification

Rating Voltage

12 V

Output

1.4 Kw

Time

30 sec

Number of teeth of pinion Rotating direction(as viewed from pinion) Weight(approx.)

9 Clockwise 37 N

No–load characteristics Condition: Voltage

11.5V

Current

90A or less

Speed

3000rpm or more

Load characteristics Condition: Voltage/Torque

8.5V/13.2 N·m (113 lb in)

Current

Maximum 350A

Speed

1000rpm or more

Locking characteristics Condition: Voltage

2.4V

Current

Maximum 500A

Torque

11.8N·m or more

STARTING AND CHARGING SYSTEM (6VE1 3.5L)

6D3–15

Torque Specifications

065R100013

6D3–16 STARTING AND CHARGING SYSTEM (6VE1 3.5L)

150R100012

STARTING AND CHARGING SYSTEM (6VE1 3.5L)

6D3–17

Charging System General Description The IC integral regulator charging system and its main components are connected as shown in illustration. The regulator is a solid state type and it is mounted along with the brush holder assembly inside the generator installed on the rear end cover. The generator does not require particular maintenance such as voltage adjustment.

The rectifier connected to the stator coil has diodes to transform AC voltage into DC voltage. This DC voltage is connected to the output terminal of generator.

F06RX002

General On–Vehicle Inspection A basic wiring diagram is shown in the illustration. When operating normally, the indicator bulb will come on when the switch is turned on, and will then go out when the engine starts. If the indicator operates abnormally, or if an undercharged or overcharged battery condition occurs, the following procedure may be used to diagnose the charging system. Remember that an undercharged battery is often caused by accessories being left on overnight, or by a defective switch which allows a bulb, such as a trunk or glove box light, to stay on.

Observe the following procedure: 1. Visually check belt and wiring. 2. Go to step 5. for vehicles without charge indicator light. 3. Switch on, engine stopped, light should be on. If not, detach harness at generator, ground “L” terminal lead.

a. Lamp lights, replace or repair generator. b. Lamp dose not light, locate open circuit between grounding lead and ignition switch. Bulb may be open. 4. Switch on, engine running at moderate speed. Light should be off. If not, detach wiring harness at generator. a. If light goes off, replace or repair generator. b. If light stays on, check for grounded “L” terminal wire in harness. 5. Battery undercharged or overcharged. a. Detach wiring harness connector from generator. b. With switch on, engine not running connect voltmeter from ground to “L” terminal in wiring harness, and to “IG” terminal. If used. Wiring harness may connect to either “L” or “IG” or both. c. Zero reading indicates open circuit between terminal and battery. Connect as required.

6D3–18 STARTING AND CHARGING SYSTEM (6VE1 3.5L) d. Re-connect harness connector to generator, run engine at moderate speed, with electrical accessories turned off. e. Measure voltage across battery. If above 16.0V, replace or repair generator. f. Connect ammeter at generator output terminal. Turn on accessories, load battery with carbon pile to obtain maximum amperes output. Maintain voltage at 13.0V or above.

2. If not within 15 amperes of rated output, replace or repair generator.

1. If within 15 amperes of rated output, generator is OK.

Generator Removal

Inspection

1. Disconnect battery ground cable. 2. Move drive belt tensioner to loose side using wrench then remove drive belt (1). 3. Disconnect the wire from terminal “B” and disconnect the connector (4). 4. Remove generator fixing bolt (3). 5. Remove generator assembly (2).

1. Disconnect the wiring connector from generator. 2. With the engine stopped, turn starter switch to “on” and connect a voltmeter between connector terminal L (1) and ground or between terminal S (2) and ground.

066RX002

If there is no voltage present, then perform appropriate repair. 060RW002

3. Reconnect the wiring connector to the generator, run the engine at must indicate idle speed, and turn off all electrical devices other than engine. 4. Measure battery voltage. If it exceeds 16V, repair or replace the generator. 5. Connect an ammeter to output terminal of generator, and measure output current under load by turning on the other electrical devices (eg., headlights). At this time the amperes must not be less than 15A and the voltage must not be less than 13V.

STARTING AND CHARGING SYSTEM (6VE1 3.5L)

Installation 1. Install generator assembly to the position. 2. Install generator assembly and tighten the fixing bolts to the specified torque.

6D3–19

4. Move drive belt tensioner to loose side using wrench, then install drive belt to normal position. 5. Reconnect battery ground cable.

Torque: M10 bolt: 41 N·m (30 Ib ft) M8 bolt: 21 N·m (15 Ib ft) 3. Connect wiring harness connector and direct terminal “B”.

Disassembled View

066RW022

Legend (1) Pulley Nut (2) Pulley (3) Front Cover Assembly (4) Rotor Assembly (5) Stator Assembly (6) Through Bolt

(7) (8) (9) (10) (11) (12)

Nut Terminal Insulator Rear Cover Assembly Rectifier Brush Holder Assembly Regulator Assembly

6D3–20 STARTING AND CHARGING SYSTEM (6VE1 3.5L) 4. Remove the screws with bearing retainer from front cover and remove bearing.

Disassembly 1. Remove the through bolt. Insert the tip of a pry bar into the gaps between the front cover and the stator core. Pry apart and separate the front cover, rotor, the rear cover and stator. NOTE: Take care not to scratch or otherwise damage the stator coil with pry bar.

F06RT023

5. Remove the mounting nuts holding the “B” terminal, the diode, and the brush holder. 6. Separate the rear cover from the stator.

F06RT021

2. Clamp the rotor in a vise and then remove the nut and pulley. 3. Remove the rotor assembly from the front cover.

F06RT024

F06RT022

STARTING AND CHARGING SYSTEM (6VE1 3.5L) 7. Remove bolts which secure stator terminal to rectifier terminal, and remove stator.

6D3–21

Inspection and Repair Repair or replace necessary parts if extreme wear or damage is found during inspection.

Rotor Assembly 1. Check the face of the slip rings for contamination and roughness. If found to be scored, dress with a fine sandpaper (#500 –600). If found to be contaminated, clean with a cloth saturated with alcohol. 2. Measure the outside diameter of the slip rings. Standard: 27mm (1.06in) Limit: 26mm (1.02in)

066RS030

8. Remove Bolts which secure regulator, rectifier and brush-holder, and separate these parts. NOTE: Do not apply a shock or load to regulator, rectifier and brush holder.

066RS032

3. Check resistance between slip rings, and replace if there is no continuity. Standard: 3.75W or less

066RW025

066RS033

6D3–22 STARTING AND CHARGING SYSTEM (6VE1 3.5L) 4. Check for continuity between slip ring and rotor core. In case of continuity, replace the rotor assembly.

2. Check for continuity across one of the stator coils and stator core. If a continuity exists, replace the coil. Standard: More than 1MW

066RS017 066RS035

Stator Coil 1. Check for continuity across the stator coils. If no continuity exists, replace the coils. Resistance value at 20°C. Standard: Approx. 0.07W

Brush Measure the brush length. Replace the brush if it exceeds the limit. Standard: 18.0mm (0.709in) Limit: 5.5mm (0.217in)

066RS034 066RW024

STARTING AND CHARGING SYSTEM (6VE1 3.5L)

Rectifier Assembly 1. Measure the resistance between each diode terminal and aluminum diode fin in forward and reverse directions with the connection of the tester leads switched. The diodes are normal if resistance is nearly zero ohms in one direction and is infinitely high in the other direction. 2. If a diode has no resistance or equal resistance in both directions, it is defective and should be replaced together with the holder.

6D3–23

4. Measure the voltage at “V4” (the voltage across the variable resistor center tap and terminal E with the variable resistor resistance held constant). The measured voltage should be within the specified (14.4±0.3 volts) limits. If it is not, the regulator must be replaced.

066RX003

Reassembly 066RS036

IC Regulator Assembly Connect a variable resistor, two 12V batteries, a fixed resistor, and a voltmeter to the IC regulator as shown in illustration. a. Measuring equipment specifications 1. Fixed resistor (R1) : 10 Ohms /3W 2. Variable resistor (Rv) : 0-300 Ohms/12W 3. Batteries (BAT1, BAT2) : 12V (2 Batteries) 4. DC voltmeter : 0-50V/0.5 steps (4 Check points) b. Measuring procedure 1. Measure the voltage “V1” across the first battery (BAT1). If the reading is between 10 and 13 volts, the battery is normal. 2. Measure the voltage “V3” across both the batteries (BAT1, BAT2). If the reading is between 20 and 26 bolts, the batteries are normal. 3. Gradually increase the resistance of the variable resistor from zero. Measure the voltage “V2” (the voltage across the F and E terminals). Check to see that the voltage across “V1” changes at this time. If there is no change, the voltage regulator is faulty and must be replaced.

To reassemble, follow the disassembly steps in the reverse order, noting the following points: NOTE: B Never make battery connections with polarities reversed, or battery will be shorted via the diodes. This will cause damage to the diodes. B Do not connect generator B terminal to ground; it is connected directly to the battery. This cable will burn if it is connected to ground. B Make sure to disconnect the positive (+) terminal of the battery when quick-charging battery . Diodes may be damaged due to abnormal pulse voltage generated by the quick charger. B When reassembling the front section to rear section, insert a stiff wire into hole in the rear face of the rear cover from the outboard side to support the brush in raised position, then insert the front section to which rotor is assembled. B Reassemble parts carefully to be sure they fit into their original position, paying attention to the insulated portions. B Wipe insulating tubes, washers and plates clean and install them in position carefully to avoid getting oil or grease on them.

6D3–24 STARTING AND CHARGING SYSTEM (6VE1 3.5L) 1. Using a press with a socket wrench attached, reassemble rotor and rear end cover assembly in the front cover.

Bench Test Conduct a bench test of the generator.

066RS023 066RS022

2. Install pulley on the rotor. Secure the pulley directly in the vise between two copper plates, and tighten nut to the specified torque. Torque: 111 N·m (82 lb ft)

Preparation Remove generator from the vehicle (see “Generator removal”). 1. Secure generator to the bench test equipment and connect wires. Terminal “IG” for energization Terminal “L” for neutral (warning lamp) Terminal “B” for output 2. Conduct the generator characteristic test. Characteristics of generator are shown in illustration. Repair or replace the generator if its outputs are abnormal.

066RS010

066RX001

STARTING AND CHARGING SYSTEM (6VE1 3.5L)

Main Data and Specifications General Specifications Battery voltage

Rated output

Direction of rotation (as viewed from pulley side)

Clockwise

Rated rotation speed

rpm

5000

Maximum speed

rpm

18000

6D3–25

SECTION 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–1

AXIOM

ENGINE 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS CONTENTS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . Tightening Specifications . . . . . . . . . . . . . . . Diagrams and Schematics . . . . . . . . . . . . . . . . PCM Wiring Diagram (1 of 7) . . . . . . . . . . . . PCM Wiring Diagram (2 of 7) . . . . . . . . . . . . PCM Wiring Diagram (3 of 7) . . . . . . . . . . . . PCM Wiring Diagram (4 of 7) . . . . . . . . . . . . PCM Wiring Diagram (5 of 7) . . . . . . . . . . . . PCM Wiring Diagram (6 of 7) . . . . . . . . . . . . PCM Wiring Diagram (7 of 7) . . . . . . . . . . . . PCM Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Blue Connector – Row “F1 ∼ 20” . . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Blue Connector – Row “F20 ∼ 40” . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Blue Connector – Row “F41 ∼ 60” . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Blue Connector – Row “F61 ∼ 80” . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Red Connector – Row “S1 ∼ 20” . . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Red Connector – Row “S21 ∼ 40” . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Red Connector – Row “S41 ∼ 60” . . . . . . . . . . . . . . . . . . . . . PCM Pinout Table, 80-Way Red Connector – Row “S61 ∼ 80” . . . . . . . . . . . . . . . . . . . . . Component Locators . . . . . . . . . . . . . . . . . . . Undercarriage Component Locator . . . . . . Fuse and Relay Panel (Underhood Electrical Center) . . . . . . . . . . . . . . . . . . . . . Sensors and Miscellaneous Component Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Strategy-Based Diagnostics . . . . . . . . . . . . . DTC Stored . . . . . . . . . . . . . . . . . . . . . . . . . . . No DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Matching Symptom . . . . . . . . . . . . . . . . . Intermittents . . . . . . . . . . . . . . . . . . . . . . . . . . No Trouble Found . . . . . . . . . . . . . . . . . . . . . Verifying Vehicle Repair . . . . . . . . . . . . . . . . General Service Information . . . . . . . . . . . . . . OBD II Serviceablity Issues . . . . . . . . . . . . . Emissions Control Information Label . . . . . Visual / Physical Engine Compartment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic Knowledge of Tools Required . . . . . . Serial Data Communications . . . . . . . . . . . . . .

6E–6 6E–6 6E–7 6E–7 6E–8 6E–9 6E–10 6E–11 6E–12 6E–13 6E–14 6E–14 6E–15 6E–16 6E–17 6E–19 6E–21 6E–23 6E–25 6E–27 6E–29 6E–30 6E–31 6E–33 6E–33 6E–33 6E–33 6E–33 6E–33 6E–33 6E–33 6E–33 6E–33 6E–34 6E–34 6E–35 6E–35

Class 2 Serial Data Communications . . . . . On-Board Diagnostic (OBD II) . . . . . . . . . . . . . On-Board Diagnostic Tests . . . . . . . . . . . . . Comprehensive Component Monitor Diagnostic Operation . . . . . . . . . . . . . . . . . . System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations . . . . . . . . . . . . . . . . . . Common OBD II Terms . . . . . . . . . . . . . . . . . The Diagnostic Executive . . . . . . . . . . . . . . . DTC Types . . . . . . . . . . . . . . . . . . . . . . . . . . . Decimal/Binary/Hexadecimal Conversions Verifying Vehicle Repair . . . . . . . . . . . . . . . . Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool . . . . . . . . . . . . . . . . . Tech 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tech 2 Features . . . . . . . . . . . . . . . . . . . . . . . Getting Started . . . . . . . . . . . . . . . . . . . . . . . . Operating Procedure (For Example) . . . . . DTC Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC Information Mode . . . . . . . . . . . . . . . . . Miscellaneous Test . . . . . . . . . . . . . . . . . . . . Lamps Test . . . . . . . . . . . . . . . . . . . . . . . . . . . Relays Test . . . . . . . . . . . . . . . . . . . . . . . . . . . EVAP Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System Test . . . . . . . . . . . . . . . . . . . . . . Instruments Test . . . . . . . . . . . . . . . . . . . . . . . EGR Control Test . . . . . . . . . . . . . . . . . . . . . . Variable Intake Manifold Solenoid Test . . . Injector Balance Test . . . . . . . . . . . . . . . . . . . Plotting Snapshot Graph . . . . . . . . . . . . . . . . . Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information) . . . . . . Flow Chart for Snapshot Replay (Plotting Graph) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primary System-Based Diagnostic . . . . . . . . . Primary System-Based Diagnostic . . . . . . . Fuel Control Heated Oxygen Sensor . . . . . HO2S Heater . . . . . . . . . . . . . . . . . . . . . . . . . Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation . . . . . . . . . . . . . . Misfire Monitor Diagnostic Operation . . . . . . . Misfire Monitor Diagnostic Operation . . . . . Misfire Counters . . . . . . . . . . . . . . . . . . . . . . .

6E–35 6E–35 6E–35 6E–35

6E–36 6E–36 6E–36 6E–37 6E–39 6E–39 6E–39 6E–40 6E–41 6E–41 6E–42 6E–43 6E–43 6E–44 6E–44 6E–46 6E–47 6E–48 6E–50 6E–52 6E–52 6E–54 6E–54 6E–55 6E–56 6E–57 6E–57 6E–57 6E–57 6E–57 6E–58 6E–58 6E–58

6E–2

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuel Trim System Monitor Diagnostic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Trim System Monitor Diagnostic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Trim Cell Diagnostic Weights . . . . . . . On-Board Diagnostic (OBD II) System Check Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . A/C Clutch Control Circuit Diagnosis . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . A/C Clutch Diagnosis . . . . . . . . . . . . . . . . . . Electronic Ignition System Diagnosis . . . . . . . EVAP Canister Purge Solenoid and EVAP Vent Solenoid Valve . . . . . . . . . . . . . . . . . . . . . Visual Check of The Evaporative Emission Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Metering System Check . . . . . . . . . . . . . Fuel System Pressure Test . . . . . . . . . . . . . . . Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) . . . . . . . . . . . . . . . . . . . . . . . . . . Powertrain Control Module (PCM) Diagnosis Multiple PCM Information Sensor DTCs Set Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Gas Recirculation (EGR) Diagnosis Engine Tech 2 Data Definitions and Ranges Typical Scan Data Values . . . . . . . . . . . . . . . . Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . No Malfunction Indicator Lamp (MIL) . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Malfunction Indicator Lamp (MIL) “ON” Steady . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . No Reduced Power Lamp (RPL) . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Reduced Power Lamp (RPL) “ON” Steady . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Starter Control System Check . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Engine Cranks But Will Not Run . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . .

6E–59 6E–59 6E–59 6E–60 6E–60 6E–60 6E–60 6E–63 6E–63 6E–63 6E–64 6E–68 6E–68 6E–68 6E–68 6E–68 6E–68 6E–68 6E–69 6E–73 6E–73 6E–73 6E–73 6E–76 6E–76 6E–78 6E–78 6E–84 6E–84 6E–84 6E–87 6E–87 6E–87 6E–89 6E–89 6E–89 6E–89 6E–93 6E–93 6E–93 6E–93 6E–96 6E–96 6E–96 6E–100 6E–102 6E–102

Test Description . . . . . . . . . . . . . . . . . . . . . . . Fuel System Electrical Test . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Fuel Pressure Relief Procedure . . . . . . . . . Electric Throttle Control (ETC) System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Test Description . . . . . . . . . . . . . . . . . . . . . . . Fuel Pressure Relief Procedure . . . . . . . . . Exhaust Gas Recirculation (EGR) System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Manifold Absolute Pressure (MAP) Output Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Evaporative (EVAP) Emissions Canister Purge Valve Check . . . . . . . . . . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . PCM Diagnostic Trouble Codes . . . . . . . . . . . DTC P0101 MAF System Performance . . . . DTC P0102 MAF Sensor Circuit Low Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0103 MAF Sensor Circuit High Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0106 MAP System Performance . . . . DTC P0107 MAP Sensor Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0108 MAP Sensor Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0112 IAT Sensor Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0113 IAT Sensor Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0117 ECT Sensor Circuit Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0118 ECT Sensor Circuit High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0125 ECT Excessive Time to Closed Loop Fuel Control . . . . . . . . . . . . . . . . . . . . . . . DTC P0128 Thermostat Insufficient Temperature for Stable Operation . . . . . . . . . DTC P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0132 HO2S Circuit High Voltage Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0133 HO2S Slow Response Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1 . . . . . . . . . . . . . . . . .

6E–102 6E–107 6E–108 6E–108 6E–108 6E–108 6E–111 6E–112 6E–112 6E–112 6E–115 6E–116 6E–116 6E–117 6E–120 6E–120 6E–122 6E–122 6E–124 6E–124 6E–124 6E–127 6E–131 6E–134 6E–137 6E–140 6E–143 6E–146 6E–149 6E–152 6E–155 6E–158 6E–161 6E–164 6E–166 6E–169 6E–172 6E–176

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC P0135 HO2S Heater Circuit Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0138 HO2S Circuit High Voltage Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0141 HO2S Heater Circuit Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0152 HO2S Circuit High Voltage Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0153 HO2S Slow Response Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0155 HO2S Heater Circuit Open Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0158 HO2S Circuit High Voltage Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0161 HO2S Heater Circuit Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . DTC P0171 Fuel Trim System Lean Bank 1 . DTC P0172 Fuel Trim System Rich Bank 1 . DTC P0174 Fuel Trim System Lean Bank 2 . DTC P0175 Fuel Trim System Rich Bank 2 . DTC P0201 Injector 1 Control Circuit . . . . . . DTC P0202 Injector 2 Control Circuit . . . . . . DTC P0203 Injector 3 Control Circuit . . . . . . DTC P0204 Injector 4 Control Circuit . . . . . . DTC P0205 Injector 5 Control Circuit . . . . . . DTC P0206 Injector 6 Control Circuit . . . . . . DTC P0300 Engine Misfire Detected . . . . . . . DTC P0301 Cylinder Misfire Detected . . . . . . DTC P0302 Cylinder Misfire Detected . . . . . . DTC P0303 Cylinder Misfire Detected . . . . . . DTC P0304 Cylinder Misfire Detected . . . . . . DTC P0305 Cylinder Misfire Detected . . . . . . DTC P0306 Cylinder Misfire Detected . . . . . . DTC P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault . . . . . . DTC P0336 58X Reference Signal Circuit . . DTC P0337 CKP Sensor Circuit Low Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0351 Ignition 1 Control Circuit . . . . . . . DTC P0352 Ignition 2 Control Circuit . . . . . . . DTC P0353 Ignition 3 Control Circuit . . . . . . . DTC P0354 Ignition 4 Control Circuit . . . . . . . DTC P0355 Ignition 5 Control Circuit . . . . . . .

6E–179 6E–182 6E–185 6E–188 6E–191 6E–194 6E–197 6E–200 6E–204 6E–207 6E–210 6E–213 6E–216 6E–219 6E–222 6E–226 6E–230 6E–234 6E–238 6E–241 6E–244 6E–247 6E–250 6E–253 6E–256 6E–260 6E–262 6E–264 6E–266 6E–268 6E–270 6E–272 6E–275 6E–278 6E–281 6E–284 6E–287 6E–290 6E–293

DTC P0356 Ignition 6 Control Circuit . . . . . . . DTC P0401 EGR Flow Insufficient . . . . . . . . . DTC P0402 EGR Pintle Crank Error . . . . . . . DTC P0404 EGR Open Stuck . . . . . . . . . . . . . DTC P0405 EGR Low Voltage . . . . . . . . . . . . DTC P0406 EGR High Voltage . . . . . . . . . . . DTC P0420 TWC System Low Efficiency Bank 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0430 TWC System Low Efficiency Bank 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0440 EVAP System . . . . . . . . . . . . . . . . DTC P0442 EVAP System Small Leak Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0444 EVAP Purge Control Circuit Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0445 EVAP Purge Control Circuit Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0446 EVAP Canister Vent Control Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0447 EVAP Vent Solenoid Circuit Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0448 EVAP Vent solenoid Circuit Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage . . . . . DTC P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage . . . . . DTC P0456 EVAP Very Small Leak . . . . . . . DTC P0461 Fuel Level Sensor Performance DTC P0462 Fuel Level Sensor Circuit–Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0463 Fuel Level Sensor Circuit–High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0462 Fuel Level Sensor Noisy Signal DTC P0502 VSS Circuit Low Input . . . . . . . . . DTC P0506 Idle Air Control System Low RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0507 Idle Air Control System High RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0562 System Voltage Low . . . . . . . . . . DTC P0563 System Voltage High . . . . . . . . . DTC P0565 Cruise Main Switch Circuit Error DTC P0566 Cruise Cancel Switch Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0567 Cruise Resume Switch Circuit Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0568 Cruise Set Switch Circuit Error . DTC P0571 No Brake Switch Signal . . . . . . . DTC P0601 PCM Memory . . . . . . . . . . . . . . . . DTC P0602 PCM Programming Error . . . . . . DTC P0604 PCM RAM Error . . . . . . . . . . . . . . DTC P0606 PCM Internal Performance . . . . DTC P1106 MAP Sensor Circuit Intermittent High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . .

6E–3 6E–296 6E–299 6E–302 6E–304 6E–306 6E–309 6E–312 6E–315 6E–318 6E–321 6E–324 6E–326 6E–328 6E–331 6E–333 6E–335 6E–338 6E–341 6E–344 6E–346 6E–349 6E–351 6E–353 6E–356 6E–359 6E–362 6E–364 6E–366 6E–368 6E–370 6E–372 6E–374 6E–376 6E–378 6E–380 6E–382 6E–384

6E–4

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1107 MAP Circuit Intermittent Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1111 IAT Sensor Circuit Intermittent High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1112 IAT Sensor Circuit Intermittent Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1114 ECT Sensor Circuit Intermittent Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1115 ECT Sensor Circuit Intermittent High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Trouble Code(DTC)P1120-TPS 1 Throttle Position Sensor (TPS1) Output Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1125 ETC (Electric Throttle Control) Limit Performance Mode . . . . . . . . . . . . . . . . . DTC P1133 HO2S Insufficient Switching Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P1134 HO2S Transition Time Ratio Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P1153 HO2S Insufficient Switching Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . DTC P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . DTC P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1) . . . . . . . . . . . . . . . . . . . . DTC P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2) . . . . . . . . . . . . . . . . . . . . DTC P1171 Fuel System Lean During Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1220 Throttle Position Senser2 (TPS2) Circuit Fault . . . . . . . . . . . . . . . . . . . . . DTC P1221 TPS1 – TPS2 Correlation (Circuit Performance) . . . . . . . . . . . . . . . . . . . DTC P1271 APS 1– 2 Correlation Error . . . DTC P1272 APS 2 – 3 Correlation Error . . . DTC P1273 APS 1 – 3 Correlation Error . . . . DTC P1275 APS 1 Output Fault . . . . . . . . . . . DTC P1280 APS 2 Output Fault . . . . . . . . . . . DTC P1285 APS 3 Output Fault . . . . . . . . . . . DTC P1290 ETC Forced Idle Mode . . . . . . . . DTC P1295 ETC Power Management Mode DTC P1299 ETC Forced Engine Shutdown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1310 ION Sensing Module Diagnosis DTC P1311 ION Sensing Module SEC Line 1 Circuit Fault . . . . . . . . . . . . . . . . . . . . . . DTC P1312 ION Sensing Module SEC Line 2 Circuit Fault . . . . . . . . . . . . . . . . . . . . . . DTC P1326 ION Sensing Module Combustion Quality Input Circuit Fault . . . . . . . . . . . . . . . . DTC P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail) . . . . . . DTC P1404 EGR Stuck Closed . . . . . . . . . . . DTC P1441 EVAP System Flow During Non-Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1514 TPS — MAF Correlation Error . . .

6E–386 6E–388 6E–391 6E–393 6E–395

6E–398 6E–401 6E–404 6E–408 6E–412 6E–416 6E–420 6E–422 6E–424 6E–427 6E–430 6E–433 6E–436 6E–439 6E–442 6E–444 6E–446 6E–448 6E–451 6E–455 6E–459 6E–462 6E–465 6E–468 6E–471 6E–474 6E–477 6E–480

DTC P1515 Command — Actual TPS Correlation Error . . . . . . . . . . . . . . . . . . . . . . . . DTC P1516 Command — Actual TPS Correlation Error . . . . . . . . . . . . . . . . . . . . . . . . DTC P1523 Actuator Control Return Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1571 Brake Switch No Operation . . . . DTC P1625 PCM Unexpected Reset . . . . . . . DTC P1635 Reference Voltage # 1 Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1639 Reference Voltage # 2 Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1640 Driver-1-Output Circuit Fault (ODM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1650 Quad Driver Module “A” Fault . . Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . Default Matrix Table . . . . . . . . . . . . . . . . . . . . . On Vehicle Service Crankshaft Position (CKP) Sensor . . . . . . . . . Engine Coolant Temperature (ECT) Sensor . Heated Oxygen Sensor (HO2S) . . . . . . . . . . . Intake Air Temperature (IAT) Sensor . . . . . . . ION Sensing Module . . . . . . . . . . . . . . . . . . . . . Mass Air Flow (MAF) Sensor . . . . . . . . . . . . . Manifold Absolute Pressure (MAP) Sensor . Malfunction Indicator Lamp (MIL) . . . . . . . . . . Reduced Power Lamp . . . . . . . . . . . . . . . . . . . Powertrain Control Module (PCM) . . . . . . . . . Service Precaution . . . . . . . . . . . . . . . . . . . . EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Position (TP) Sensor . . . . . . . . . . . . . Vehicle Speed Sensor (VSS) . . . . . . . . . . . . . Air Cleaner/Air Filter . . . . . . . . . . . . . . . . . . . . . Common Chamber . . . . . . . . . . . . . . . . . . . . . . Accelerator Pedal Replacement . . . . . . . . . . . Accelerator Position Sensor Replacement . . Accelerator Position Sensor Adjustment . . . . Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Metering System . . . . . . . . . . . . . . . . . . . . Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . . . . Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Body (TB) . . . . . . . . . . . . . . . . . . . . . . . Electronic Ignition System . . . . . . . . . . . . . . . . Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Thermo Relay . . . . . . . . . . . EVAP Canister Hoses . . . . . . . . . . . . . . . . . . . . EVAP Canister . . . . . . . . . . . . . . . . . . . . . . . . . . EVAP Canister Vent Solenoid . . . . . . . . . . . . .

6E–484 6E–487 6E–490 6E–493 6E–495 6E–496 6E–498 6E–500 6E–503 6E–506 6E–535 6E–538 6E–538 6E–539 6E–542 6E–542 6E–543 6E–544 6E–545 6E–545 6E–545 6E–545 6E–547 6E–547 6E–548 6E–549 6E–549 6E–550 6E–551 6E–551 6E–552 6E–552 6E–553 6E–554 6E–555 6E–555 6E–556 6E–557 6E–558 6E–558 6E–560 6E–561 6E–561 6E–561 6E–562 6E–562

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Fuel Tank Pressure (Vapor Pressure) Sensor . . . . . . . . . . . . . . . . . EVAP Canister Purge Solenoid (Purge Duty Solenoid Valve) . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank Vent Valve (Vent Solenoid Valve) . . . . . . . . . . . . . . . . . . . Linear Exhaust Gas Recirculation (EGR) Valve . . . . . . . . . . . . . . . . Positive Crankcase Ventilation (PCV) Valve . Wiring and Connectors . . . . . . . . . . . . . . . . . . . PCM Connectors and Terminals . . . . . . . . . . . Wire Harness Repair: Twisted Shielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twisted Leads . . . . . . . . . . . . . . . . . . . . . . . . . . Weather-Pack Connector . . . . . . . . . . . . . . . . . Com-Pack III . . . . . . . . . . . . . . . . . . . . . . . . . . . Metri-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description (PCM and Sensors) . . . General Description (Air Induction) . . . . . . . . General Description (Fuel Metering) . . . . . . . General Description (Electronic Ignition System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/C Clutch Diagnosis . . . . . . . . . . . . . . . . . . . . General Description (Evaporative (EVAP) Emission System) . . . . . . . . . . . . . . . . . . . . . . General Description (Exhaust Gas Recirculation (EGR) System) . . . . . . . . . . . . . General Description (Positive Crankcase Ventilation (PCV) System) . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .

6E–563 6E–564 6E–565 6E–565 6E–566 6E–566 6E–567 6E–567 6E–568 6E–569 6E–570 6E–571 6E–572 6E–577 6E–578 6E–580 6E–583 6E–583 6E–588 6E–589 6E–591

6E–5

6E–6

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Specifications Tightening Specifications Application

N·m

Lb Ft.

Lb In.

EGR Bolt

—

Engine Coolant Temperature Sensor

—

Fuel Drain Plug

—

Fuel Pressure Regulator Attaching Screw

—

Fuel Rail Bolts

—

Fuel Tank Undercover Retaining Bolts

—

Heated Oxygen Sensor

—

Lower Intake Manifold to Engine Block Bolts

—

Lower Intake Manifold to Engine Block Nuts

—

Spark Plugs

—

Throttle Body Mounting Bolts

—

Common Chamber to Lower Intake Manifold Bolts

—

VSS Retaining Bolt

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–7

Diagrams and Schematics PCM Wiring Diagram (1 of 7)

060R200082

6E–8

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Wiring Diagram (2 of 7)

060R200083

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–9

PCM Wiring Diagram (3 of 7)

060R200043

6E–10

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Wiring Diagram (4 of 7)

060R200065

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–11

PCM Wiring Diagram (5 of 7)

060R200041

6E–12

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Wiring Diagram (6 of 7)

060R200046

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–13

PCM Wiring Diagram (7 of 7)

060R200084

6E–14

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Pinouts PCM Pinout Table, 80-Way Blue Connector – Row “F1 ∼ 20”

060RY00045

PIN Function

Wire Color

IGN ON

ENG RUN

Refer To

PCM Ground

BLK

0.0V

Chassis Electrical

5Volt Reference“2” (AP Sensor 2)

GRN

5.0V

Accelerator Position (AP) Sensor

5Volt Reference“2” (TP Sensor 2)

RED/WHT

5.0V

Throttle Position (TP) Sensor

A/C Clutch

GRY/RED

B+(A/C off)

General Description and Operation, A/C Clutch Circuit Operation

Relay Shift Solenoid

GRN/RED

0.0V

Not Used

—

Tachometer

8.8V

10.0V (at idle)

Not Used

—

Not Used

—

F10

Not Used

—

F11

T.O.D

—

F12

Not Used

—

F13

Starter Feed

PNK

—

F14

Mass Air Flow(MAF)

BLK/BLU

4.9V

4.2V

F15

Not Used

—

F16

Not Used

—

F17

Bank 1 HO2S Low

0.3V

0.1–0.9V

F18

Not Used

—

F19

Ignition Feed

RED/GRN

B+

6D Section

F20

Ignition Feed

RED/WHT

B+

6D Section

— BLK/RED

RED/WHT —

RED

4L30E T/Mission — Chassis Electrical

General Description, Mass Air Flow Sensor

General Description and Operation, Catalyst Monitor HO2S 2

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–15

PCM Pinout Table, 80-Way Blue Connector – Row “F20 ∼ 40”

060RY00156

PIN Function

Wire Color WHT

IGN ON

ENG RUN

Refer To

0.0V

—

0.0V

General Description

—

F21

Bank 1 HO2S 1 Ground

F22

Not Used

F23

Bank 2 HO2S 1 Ground

F24

Not Used

F25

ION Sensing Module

RED/BLU

1.555V

General Description and Operation, ION Sensing Module

F26

ION Sensing Module

RED/BLK

1.555V

General Description and Operation, ION Sensing Module

F27

Intake Air Temperature (IAT) Sensor Signal

GRN

0.5–4.9V

General Description and Operation, IAT

F28

Not Used

—

F29

Manifold Absolute Pressure (MAP) Sensor Signal

3.5V–4.9V (depends on altitude and barometric pressure)

0.6-1.3V

General Description and Operation, Manifold Absolute Pressure

F30

Not Used

—

F31

Not Used

—

F32

Not Used

—

F33

Not Used

—

F34

Not Used

—

F35

Not Used

—

F36

Not Used

—

F37

Power Steering Pressure (PSP)

GRN/YEL

B+

Power Steering

F38

Illuminated Switch

GRN/YEL

B+

Chassis Electrical

F39

Brake Switch

RED

0.0V

4L30E T/Mission

F40

PCM Ground

BLK/BLU

0.0V

Chassis Electrical

— BLU —

— RED

6E–16

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Pinout Table, 80-Way Blue Connector – Row “F41 ∼ 60”

060RY00046

PIN Function

Wire Color

IGN ON

ENG RUN

Refer To

F41

Throttle Position(TP) 1 Sensor Ground

GRN

0.0V

General Description and Operation, TPS

F42

Fuel Pump Relay

PNK/WHT

0.0V

B+

On Vehicle Service, Fuel Pump Relay

F43

Adaptor Case

VIO/RED

0.0V

4L30E T/Mission

F44

Bank 1 HO2S 2 Heater Ground

ORN/WHT

0.0V

General Description and Operation, Catalyst Monitor HO2S 2

F45

A/C Request

GRN/BLK

0.0V

Chassis Electrical

F46

Stop Lamp Switch

BRN/RED

0.0V

Chassis Electrical

F47

Adaptor Case

VIO/WHT

B+

4L30E T/Mission

F48

Throttle Valve DC Motor(–: REV)

BLU

Duty Cycle

F49

Not Used

—

F50

Bank 2 HO2S 2 Ground

0.0V

—

F51

Not Used

—

F52

Bank 1 HO2S 2 Ground

RED

0.0V

—

F53

ECT Ground

YEL/BLK

0.0V

General Description and Operation, ECT Sensor

F54

Vapor Pressure (Fuel Tank Pressure) Sensor Ground

GRN

0.0V

General Description and Operation, VP Sensor

F55

Not Used

—

F56

Injector Cylinder #5

GRN/BLK

B+

General Description and Operation, Fuel Injector

F57

Ignition Feed

RED/WHT

B+

Chassis Electrical

F58

Class 2 Data

ORN/BLK

0.0V

F59

Not Used

—

F60

Not Used

—

— ORN —

—

General Description and Operation, ETC

—

General Description

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–17

PCM Pinout Table, 80-Way Blue Connector – Row “F61 ∼ 80”

060RY00047

PIN Function

Wire Color

IGN ON

ENG RUN

Refer To

F61

Throttle Position(TP) 2 Sensor Ground

GRN/WHT

0.0V

General Description and Operation, TPS

F62

Injector Cylinder #2

GRN/ORN

B+

General Description and Operation, Fuel Injector

F63

AP Sensor 1 Sensor Ground

RED

0.0V

F64

Injector Cylinder #4

GRN/RED

B+

General Description and Operation, Fuel Injector

F65

Throttle Position(TP) 2 Sensor Signal

BLU/WHT

0.5–0.8V

0.8–0.8V (at idle)

General Description and Operation, TPS

F66

Injector Cylinder #3

GRN

B+

General Description and Operation, Fuel Injector

F67

ION Sensing Module

YEL

1.555V

General Description and Operation, ION Sensing Module

F68

ION Sensing Module

RED

1.555V

General Description and Operation, ION Sensing Module

F69

Injector Cylinder #1

GRN/WHT

B+

General Description and Operation, Fuel Injector

F70

ANTI Theft

WHT/GRN

—

F71

Bank 2 HO2S 2 Heater Ground

GRN/WHT

0.0V

General Description and Operation, Catalyst Monitor HO2S 1

F72

Auto Cruise Switch Resume

WHT/BLU

0.0V

Chassis Electrical

F73

Crankshaft Position Sensor

WHT/BLU

0.3V

2.2V

General Description and Operation, CKP sensor

F74

ECT Sensor

BLU/RED

0.5–4.9V

General Description and Operation, ECT Sensor

F75

Ignition Feed

RED/GRN

B+

Chassis Electrical

F76

Mode Switch

PNK/BLK

B+

4L30E T/Mission

F77

Mode Switch

PNK/BLU

B+

4L30E T/Mission

On-Vehicle Service

—

6E–18 PIN

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PIN Function

Wire Color

IGN ON

ENG RUN

Refer To

F78

Mode Switch

PNK/YEL

0.0V

4L30E T/Mission

F79

Mode Switch

PNK

0.0V

4L30E T/Mission

F80

AP Sensor 2 Ground

BLU

0.0V

On-Vehicle Service

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–19

PCM Pinout Table, 80-Way Red Connector – Row “S1 ∼ 20”

060RY00069

PIN Function

Wire Color

IGN ON

ENG RUN

Refer To

PCM Ground

BLK/PNK

0.0V

Chassis Electrical

Bank 1 HO2S 1 Heater Ground

BLK/ORN

0.0V

General Description and Operation, Catalyst Monitor HO2S

Not Used

—

Not Used

—

5Volt Reference“2” (CKP Sensor)

WHT

5.0V

Appropriate Sensor (CKP Sensor, AP2 Sensor)

Auto Cruise Switch Cancel

GRY/GRN

0.0V

Chassis Electrical

Purge Duty Solenoid Valve

RED/BLU

B+

M.I.D

0.5 GRN

—

Not Used

—

S10

Shift High (Band Apply)

BRN/YEL

B+

4L30E T/Mission

S11

Malfunction Indicator (Check Engine) Lamp

WHT/GRN

0.0V

B+

Chassis Electrical

S12

Not Used

—

S13

ION Sensing Module

RED/WHT

1.555V

S14

Bank 2 HO2S 1 Ground

BLU

0.0V

—

S15

Bank 2 HO2S 2 Ground

ORN

0.0V

—

S16

Bank 2 HO2S 2 Low

BLU

0.0V

0.1V

S17

Bank 1 HO2S 1 Ground

WHT

0.0V

S18

Bank 1 HO2S 1 Low

WHT/BLU

0.0V

0.1V

—

EVAP Emission Control System

— General Description and Operation, ION Sensing Module

General Description and Operation, Catalyst Monitor HO2S — General Description and Operation, Catalyst Monitor HO2S

6E–20

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PIN Function

S19

ION Sensing Module

S20

Transmission Fluid Temperature Sensor Ground

Wire Color

IGN ON

ENG RUN

RED/YEL

1.555V

RED/WHT

0.0V

Refer To General Description and Operation, ION Sensing Module 4L30E T/Mission

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–21

PCM Pinout Table, 80-Way Red Connector – Row “S21 ∼ 40”

060RY00049

PIN Function

Wire Color

IGN ON

ENG RUN

Refer To

S21

Audio

YEL/GRN

—

Chassis Electrical

S22

Transmission Output Speed Sensor

BLU/YEL

0.0V

4L30E T/Mission

S23

PCM Ground

BLK

0.0V

Chassis Electrical

S24

Bank 1 HO2S 2 Ground

RED

0.0V

—

S25

Not Used

—

S26

EGR Control High

BLU/RED

B+

S27

VSS Input

BLK/YEL

0.0V

0.1V (at rest)

S28

Injector Cylinder #6

GRN/YEL

B+

General Description and Operation, Fuel Injector

S29

Winter Switch

VIO/GRN

B+

4L30E T/Mission

S30

Auto Cruise Main Switch

WHT/RED

0.0V

Chassis Electrical

S31

Shift Solenoid

GRN

0.0V

4L30E T/Mission

S32

Ignition Feed

RED/GRN

B+

Chassis Electrical

S33

TCC Solenoid

BRN/WHT

0.0V

S34

Not Used

—

S35

ION Sensing Module

RED/GRN

1.555V

S36

5Volt Reference (AP Sensor 1)

BLK

5.0V

AP Sensor

S37

5Volt Reference (Vapor Pressure {Fuel Tank Pressure} Sensor/MAP Sensor/EGR Position Sensor)

GRY/RED

5.0V

(Fuel Tank Pressure Sensor/MAP Sensor/EGR Position Sensor) Sensor

S38

5Volt Reference (TP Sensor 1)

RED

5.0V

TP Sensor

—

General Description and Operation, EGR Control Chassis Electrical

T/Mission — General Description and Operation, ION Sensing Module

6E–22 PIN

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PIN Function

Wire Color

IGN ON

ENG RUN

Refer To

S39

Auto Cruise Set Lamp

WHT

0.0V

Chassis Electrical

S40

PCM Ground

BLK/YEL

0.0V

Chassis Electrical

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–23

PCM Pinout Table, 80-Way Red Connector – Row “S41 ∼ 60”

060RY00050

PIN Function

S41

AP Sensor 3 Sensor Ground

S42

Wire Color

IGN ON

ENG RUN

ORN/BLU

0.0V

On-Vehicle Service

Bank 2 HO2S 1 Heater Ground

WHT/RED

0.0V

General Description and Operation, Catalyst Monitor HO2S

S43

Solenoid Power Supply

GRY/WHT

B+

S44

Rr Def. Relay

RED/WHT

—

S45

Starter Relay

BLK/BLU

—

S46

Fuel Gauge

YEL/RED

B+

Chassis Electrical

S47

Water Temp. Gauge

WHT/BLK

B+

4L30E T/Mission

S48

Fuel Gauge

YEL/RED

B+

General Description and Chassis Electrical

S49

DLC

RED/WHT

B+

General Description

S50

Fuel Sender Unit

ORN/GRN

0.0V

S51

TCC Solenoid

BRN/BLU

0.0V

S52

Vapor Pressure (Fuel Tank Pressure) Sensor Signal

GRY

0.2–4.8V

S53

Power Switch

VIO/RED

B+

S54

Bank 2 HO2S 1 Low

BLU

0.0V

0.1V

General Description and Operation, Catalyst Monitor HO2S

S55

Transmission Output Speed Sensor

BLU/GRN

0.0V

4L30E T/Mission

S56

Not Used

—

S57

Not Used

—

S58

Bank 1 HO2S 1 High

0.3V

0.1–0.9V

ORN/BLU

Refer To

4L30E T/Mission

— T/Mission General Description and Operation, VP Sensor 4L30E T/Mission

General Description and Operation, Catalyst Monitor HO2S

6E–24 PIN

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS PIN Function

Wire Color

IGN ON

ENG RUN

S59

Auto Cruise Set Switch

Light GRN

0.0V

S60

Fuel Sender Unit

BLU/YEL

0.5–4.9V

Refer To Chassis Electrical On-Vehicle Service PCM and Sensors

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–25

PCM Pinout Table, 80-Way Red Connector – Row “S61 ∼ 80”

060RY00051

PIN Function

Wire Color

IGN ON

ENG RUN

Refer To

0.0V

General Description and Operation, IAT General Description and Operation, ION Sensing Module

S61

Intake Air Temperature (IAT) Sensor Ground

YEL/GRN

S62

ION Sensing Module

RED

1.555V

S63

Bank 1 HO2S 2 High

WHT

0.3V

0.1–0.9V

General Description and Operation, Catalyst Monitor HO2S

S64

Bank 2 HO2S 1 High

PNK

0.3V

0.1–0.9V

General Description and Operation, Catalyst Monitor HO2S

S65

Bank 2 HO2S 2 High

GRN

0.3V

0.1–0.9V

General Description and Operation, Catalyst Monitor HO2S

S66

Transmission Fluid Temperature Sensor

RED/BLK

0.5–4.9V (depends on temperature)

S67

Exhaust Gas Recirculation (EGR) Position Signal

GRY/RED

0.6V

S68

Accelerator Position (AP) Sensor 1

WHT

0.41–0.45V

On-Vehicle Service

S69

Throttle Valve DC Motor(+: FWD)

GRN

Duty Cycle

General Description and Operation, ETC

S70

Not Used

—

S71

Not Used

—

S72

Ignition Feed

RED/GRN

B+

Chassis Electrical

S73

Auto Cruise Main Lamp

GRN/WHT

B+

Chassis Electrical

S74

Variable Intake Manifold

YEL/BLK

0.0V

B+ (rpm 3600 over)

General Description

S75

Canister Purge Cut Solenoid Valve

RED/WHT

6.0V Tank empty

5.7V Tank empty

General Description and Operation, EVAP

S76

Throttle Position (TP) 1 Sensor Signal

BLU

0.5–0.8V

0.5–0.8V (at idle)

General Description and Operation, TPS

4L30E T/Mission

General Description and Operation, EGR Control

6E–26

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PIN Function

S77

5Volt Reference (AP Sensor 3)

S78

Wire Color

IGN ON

ENG RUN

Refer To

ORN

5.0V

Accelerator Position (AP) Sensor 2

YEL

0.41–0.45V

On-Vehicle Service

S79

Accelerator Position (AP) Sensor 3

BLU/GRN

4.55–4.99V

0.41–0.45V

On-Vehicle Service

S80

Manifold Absolute Pressure (MAP) Sensor Ground

GRN

AP Sensor

General Description and Operation, Manifold Absolute Pressure

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–27

Component Locators Engine Component Locator

060R200040

6E–28

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Engine Component Locator Table Number

Name

Location

Linear Exhaust Gas Recirculation (EGR) Valve

Rear right side of the engine

Throttle Position (TP) Sensor

On the throttle body

Intake Air Temperature (IAT) Sensor

On the intake air duct near the throttle body

Check Engine (MIL) Light

On the instrument panel beneath the tachometer

Positive Crankcase Ventilation (PCV) Valve

On the left of the cylinder head cover

Air Cleaner

Left front of the engine bay

Mass Air Flow (MAF) Sensor

Attached to the air filter box

Fuel Rail

On the Common Chamber

Fuel Pressure Regulator

Rear side of the engine

ION Sensing module

Bolted to the top of the Common Chamber

Common Chamber

Top of the engine

EVAP Duty Solenoid Valve

Bolted to the front of the coolant pipe

Fuse/Relay Box

Along the inside of the right fender

Manifold Absolute Pressure (MAP) Sensor

Bolted to the top of the Common Chamber

Throttle Body

Between the intake air duct and the Common Chamber

Engine Coolant Temperature Sensor

On the coolant crossover pipe at the front of the engine, near the throttle body

Power Train Control Module (PCM)

Along the inside of the left fender

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

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Undercarriage Component Locator

014RW142

Undercarriage Component Locator Table Number

Name

Location

Fuel Pump Assembly and Vapor Pressure (Fuel Tank Pressure) Sensor

Installed in the top of the fuel tank

Fuel Gauge Unit

Installed in the top of the fuel tank

Evaporative (EVAP) Canister

On the top of the bracket that is located behind the cross member

Vent Solenoid (EVAP Canister)

On the top of the bracket that is located behind the cross member

Fuel Filter

Located along the inside of the right frame rail, ahead of the fuel tank

Vehicle Speed Sensor (VSS)

Protrudes from the transmission housing, just ahead of the propeller shaft

Heated Oxygen Sensor (Bank 1, HO2S 1)

Threaded into the exhaust pipe behind the right-hand catalytic converter

Heated Oxygen Sensor (Bank 1, HO2S 2)

Threaded into the exhaust pipe ahead of the right-hand catalytic converter

Heated Oxygen Sensor (Bank 2, HO2S 1)

Threaded into the exhaust pipe ahead of the left-hand catalytic converter

Heated Oxygen Sensor (Bank 2, HO2S 2)

Threaded into the exhaust pipe behind the left-hand catalytic converter

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuse and Relay Panel (Underhood Electrical Center)

060R200085

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–31

Sensors and Miscellaneous Component Locators

060RY00013

060RW111

T321067

060R200080

014RW126

055RY00002

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

041RW004

060RY00016

025RW005

060RY00023

060RY00014

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnosis Strategy-Based Diagnostics Strategy-Based Diagnostics The strategy-based diagnostic is a uniform approach to repair all Electrical/Electronic (E/E) systems. The diagnostic flow can always be used to resolve an E/E system problem and is a starting point when repairs are necessary. The following steps will instruct the technician how to proceed with a diagnosis: 1. Verify the customer complaint. B To verify the customer complaint, the technician should know the normal operation of the system. 2. Perform preliminary checks. B Conduct a thorough visual inspection. B Review the service history. B Detect unusual sounds or odors. B Gather diagnostic trouble code information to achieve an effective repair. 3. Check bulletins and other service information. B This includes videos, newsletters, etc. 4. Refer to service information (manual) system check(s). B “System checks” contain information on a system that may not be supported by one or more DTCs. System checks verify proper operation of the system. This will lead the technician in an organized approach to diagnostics. 5. Refer to service diagnostics.

DTC Stored Follow the designated DTC chart exactly to make an effective repair.

No DTC Select the symptom from the symptom tables. Follow the diagnostic paths or suggestions to complete the repair. You may refer to the applicable component/system check in the system checks.

No Matching Symptom 1. Analyze the complaint. 2. Develop a plan for diagnostics. 3. Utilize the wiring diagrams and the theory of operation. Combine technician knowledge with efficient use of the available service information.

Intermittents Conditions that are not always present are called intermittents. To resolve intermittents, perform the following steps: 1. Observe history DTCs, DTC modes, and freeze frame data. 2. Evaluate the symptoms and the conditions described by the customer.

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3. Use a check sheet or other method to identify the circuit or electrical system component. 4. Follow the suggestions for intermittent diagnosis found in the service documentation. Most Scan Tools, such as the Tech 2, have data-capturing capabilities that can assist in detecting intermittents.

No Trouble Found This condition exists when the vehicle is found to operate normally. The condition described by the customer may be normal. Verify the customer complaint against another vehicle that is operating normally. The condition may be intermittent. Verify the complaint under the conditions described by the customer before releasing the vehicle. 1. Re-examine the complaint. When the complaint cannot be successfully found or isolated, a re-evaluation is necessary. The complaint should be re-verified and could be intermittent as defined in Intermittents section, or could be normal. 2. Repair and verify. After isolating the cause, the repairs should be made. Validate for proper operation and verify that the symptom has been corrected. This may involve road testing or other methods to verify that the complaint has been resolved under the following conditions: B Conditions noted by the customer. B If a DTC was diagnosed, verify a repair by duplicating conditions present when the DTC was set as noted in the Failure Records or Freeze Frame data.

Verifying Vehicle Repair Verification of the vehicle repair will be more comprehensive for vehicles with OBD II system diagnostics. Following a repair, the technician should perform the following steps: IMPORTANT: Follow the steps below when you verify repairs on OBD II systems. Failure to follow these steps could result in unnecessary repairs. 1. Review and record the Failure Records and the Freeze Frame data for the DTC which has been diagnosed (Freeze Frame data will only be stored for an A or B type diagnostic and only if the MIL(”Check Engine” lamp) has been requested). 2. Clear the DTC(S). 3. Operate the vehicle within conditions noted in the Failure Records and Freeze Frame data. 4. Monitor the DTC status information for the DTC which has been diagnosed until the diagnostic test associated with that DTC runs.

General Service Information OBD II Serviceablity Issues With the introduction of OBD II diagnostics across the entire passenger car and light-duty truck market in 1996, illumination of the MIL (“Check Engine” lamp) due to a non-vehicle fault could lead to misdiagnosis of the vehicle, increased warranty expense and customer

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

dissatisfaction. The following list of non-vehicle faults does not include every possible fault and may not apply equally to all product lines. Fuel Quality Fuel quality is not a new issue for the automotive industry, but its potential for turning on the MIL (“Check Engine” lamp) with OBD II systems is new. Fuel additives such as “dry gas” and “octane enhancers” may affect the performance of the fuel. If this results in an incomplete combustion or a partial burn, it will show up as a Misfire DTC P0300. The Reed Vapor Pressure of the fuel can also create problems in the fuel system, especially during the spring and fall months when severe ambient temperature swings occur. A high Reed Vapor Pressure could show up as a Fuel Trim DTC due to excessive canister loading. High vapor pressures generated in the fuel tank can also affect the Evaporative Emission diagnostic as well. Using fuel with the wrong octane rating for the vehicle may cause driveability problems. Many of the major fuel companies advertise that using “premium” gasoline will improve the performance of the vehicle. Most premium fuels use alcohol to increase the octane rating of the fuel. Although alcohol-enhanced fuels may raise the octane rating, the fuel’s ability to turn into vapor in cold temperatures deteriorates. This may affect the starting ability and cold driveability of the engine. Low fuel levels can lead to fuel starvation, lean engine operation, and eventually engine misfire. Non-OEM Parts All of the OBD II diagnostics have been calibrated to run with OEM parts. Something as simple as a high-performance exhaust system that affects exhaust system back pressure could potentially interfere with the operation of the EGR valve and thereby turn on the MIL (“Check Engine” lamp). Small leaks in the exhaust system near the post catalyst oxygen sensor can also cause the MIL (“Check Engine” lamp) to turn on. Aftermarket electronics, such as transceivers, stereos, and anti-theft devices, may radiate EMI into the control system if they are improperly installed. This may cause a false sensor reading and turn on the MIL (“Check Engine” lamp). Environment Temporary environmental conditions, such as localized flooding, will have an effect on the vehicle ignition system. If the ignition system is rain-soaked, it can temporarily cause engine misfire and turn on the MIL (“Check Engine” lamp). Refueling A new OBD II diagnostic was introduced in 1996 on some vehicles. This diagnostic checks the integrity of the entire evaporative emission system. If the vehicle is restarted after refueling and the fuel cap is not secured correctly, the on-board diagnostic system will sense this as a system fault and turn on the MIL (“Check Engine” lamp) with a DTC P0440.

Vehicle Marshaling The transportation of new vehicles from the assembly plant to the dealership can involve as many as 60 key cycles within 2 to 3 miles of driving. This type of operation contributes to the fuel fouling of the spark plugs and will turn on the MIL (“Check Engine” lamp) with a P0300 Misfire DTC. Poor Vehicle Maintenance The sensitivity of OBD II diagnostics will cause the MIL (“Check Engine” lamp) to turn on if the vehicle is not maintained properly. Restricted air filters, fuel filters, and crankcase deposits due to lack of oil changes or improper oil viscosity can trigger actual vehicle faults that were not previously monitored prior to OBD II. Poor vehicle maintenance can’t be classified as a “non-vehicle fault”, but with the sensitivity of OBD II diagnostics, vehicle maintenance schedules must be more closely followed. Related System Faults Many of the OBD II system diagnostics will not run if the PCM detects a fault on a related system or component. One example would be that if the PCM detected a Misfire fault, the diagnostics on the catalytic converter would be suspended until Misfire fault was repaired. If the Misfire fault was severe enough, the catalytic converter could be damaged due to overheating and would never set a Catalyst DTC until the Misfire fault was repaired and the Catalyst diagnostic was allowed to run to completion. If this happens, the customer may have to make two trips to the dealership in order to repair the vehicle.

Emissions Control Information Label The engine compartment “Vehicle Emissions Control Information Label” contains important emission specifications and setting procedures. In the upper left corner is exhaust emission information. This identifies the emission standard (Federal, California, or Canada) of the engine, the displacement of the engine in liters, the class of the vehicle, and the type of fuel metering system. There is also an illustrated emission components and vacuum hose schematic. This label is located in the engine compartment of every vehicle. If the label has been removed it should be replaced. It can be ordered from Isuzu Dealership.

Visual / Physical Engine Compartment Inspection Perform a careful visual and physical engine compartment inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to repairing a problem without further steps. Use the following guidelines when performing a visual/physical inspection: B Inspect all vacuum hoses for pinches, cuts, disconnections, and proper routing. B Inspect hoses that are difficult to see behind other components.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B Inspect all wires in the engine compartment for proper connections, burned or chafed spots, pinched wires, contact with sharp edges or contact with hot exhaust manifolds or pipes.

Basic Knowledge of Tools Required NOTE: Lack of basic knowledge of this powertrain when performing diagnostic procedures could result in an incorrect diagnosis or damage to powertrain components. Do not attempt to diagnose a powertrain problem without this basic knowledge. A basic understanding of hand tools is necessary to effectively use this section of the Service Manual.

Serial Data Communications Class 2 Serial Data Communications Government regulations require that all vehicle manufacturers establish a common communication system. This vehicle utilizes the “Class 2” communication system. Each bit of information can have one of two lengths: long or short. This allows vehicle wiring to be reduced by transmitting and receiving multiple signals over a single wire. The messages carried on Class 2 data streams are also prioritized. If two messages attempt to establish communications on the data line at the same time, only the message with higher priority will continue. The device with the lower priority message must wait. The most significant result of this regulation is that it provides Scan tool manufacturers with the capability to access data from any make or model vehicle that is sold. The data displayed on other Scan tools will appear the same, with some exceptions. Some Scan tools will only be able to display certain vehicle parameters as values that are a coded representation of the true or actual value. On this vehicle the Scan tool displays the actual values for vehicle parameters. It will not be necessary to perform any conversions from coded values to actual values.

On-Board Diagnostic (OBD II) On-Board Diagnostic Tests A diagnostic test is a series of steps, the result of which is a pass or fail reported to the diagnostic executive. When a diagnostic test reports a pass result, the diagnostic executive records the following data: B The diagnostic test has been completed since the last ignition cycle. B The diagnostic test has passed during the current ignition cycle. B The fault identified by the diagnostic test is not currently active. When a diagnostic test reports a fail result, the diagnostic executive records the following data: B The diagnostic test has been completed since the last ignition cycle. B The fault identified by the diagnostic test is currently active. B The fault has been active during this ignition cycle. B The operating conditions at the time of the failure.

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Remember, a fuel trim DTC may be triggered by a list of vehicle faults. Make use of all information available (other DTCs stored, rich or lean condition, etc.) when diagnosing a fuel trim fault.

Comprehensive Component Monitor Diagnostic Operation Comprehensive component monitoring diagnostics are required to monitor emissions-related input and output powertrain components. The CARB OBD II Comprehensive Component Monitoring List Of Components Intended To illuminate MIL is a list of components, features or functions that could fall under this requirement. Input Components: Input components are monitored for circuit continuity and out-of-range values. This includes rationality checking. Rationality checking refers to indicating a fault when the signal from a sensor does not seem reasonable, i.e. Throttle Position (TP) sensor that indicates high throttle position at low engine loads or MAP voltage. Input components may include, but are not limited to the following sensors: B Vehicle Speed Sensor (VSS) B Crankshaft Position (CKP) sensor B Throttle Position (TP) sensor B Engine Coolant Temperature (ECT) sensor B Manifold Absolute Pressure (MAP) sensor B Mass Air Flow (MAF) sensor In addition to the circuit continuity and rationality check, the ECT sensor is monitored for its ability to achieve a steady state temperature to enable closed loop fuel control. Output Components: Output components are diagnosed for proper response to control module commands. Components where functional monitoring is not feasible will be monitored for circuit continuity and out-of-range values if applicable. Output components to be monitored include, but are not limited to, the following circuits: B Control module controlled EVAP Canister Purge Valve B Electronic Transmission controls B A/C relays B VSS output B MIL control B Cruise control inhibit Refer to PCM and Sensors in General Descriptions. Passive and Active Diagnostic Tests A passive test is a diagnostic test which simply monitors a vehicle system or component. Conversely, an active test, actually takes some sort of action when performing diagnostic functions, often in response to a failed passive test. For example, the EGR diagnostic active test will force the EGR valve open during closed throttle decel and/or force the EGR valve closed during a steady state. Either action should result in a change in manifold pressure.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Intrusive Diagnostic Tests This is any on-board test run by the Diagnostic Management System which may have an effect on vehicle performance or emission levels. Warm-Up Cycle A warm-up cycle means that engine at temperature must reach a minimum of 70°C (160°F) and rise at least 22°C (40°F) over the course of a trip. Freeze Frame Freeze Frame is an element of the Diagnostic Management System which stores various vehicle information at the moment an emissions-related fault is stored in memory and when the MIL is commanded on. These data can help to identify the cause of a fault. Refer to Storing And Erasing Freeze Frame Data in this section for more detailed information. Failure Records Failure Records data is an enhancement of the OBD II Freeze Frame feature. Failure Records store the same vehicle information as does Freeze Frame, but it will store that information for any fault which is stored in on-board memory, while Freeze Frame stores information only for emission-related faults that command the MIL on.

System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations I/M Ready Status means a signal or flag for each emission system test that had been set in the PCM. I/M Ready Status indicates that the vehicle on-board emissions diagnostics have been run. I/M Ready Status is not concerned whether the emission system passed or failed the test, only that on-board diagnosis is complete. Not all vehicles use all possible I/M flags.

Common OBD II Terms Diagnostic When used as a noun, the word diagnostic refers to any on-board test run by the vehicle’s Diagnostic Management System. A diagnostic is simply a test run on a system or component to determine if the system or component is operating according to specification. There are many diagnostics, shown in the following list: B Misfire B Oxygen sensors B Oxygen sensor heaters B EGR B Catalyst monitoring Enable Criteria The term “enable criteria” is engineering language for the conditions necessary for a given diagnostic test to run. Each diagnostic has a specific list of conditions which must be met before the diagnostic will run. “Enable criteria” is another way of saying “conditions required”.

The enable criteria for each diagnostic is listed on the first page of the DTC description in Section 6E under the heading “Conditions for Setting the DTC”. Enable criteria varies with each diagnostic, and typically includes, but is not limited to the following items: B engine speed B vehicle speed B ECT B MAF/MAP B barometric pressure B IAT B TP B high canister purge B fuel trim B TCC enabled B A/C on Trip Technically, a trip is a key on-run-key off cycle in which all the enable criteria for a given diagnostic are met, allowing the diagnostic to run. Unfortunately, this concept is not quite that simple. A trip is official when all the enable criteria for a given diagnostic are met. But because the enable criteria vary from one diagnostic to another, the definition of trip varies as well. Some diagnostics are run when the vehicle is at operating temperature, some when the vehicle first starts up; some require that the vehicle be cruising at a steady highway speed, some run only when the vehicle is idle; some diagnostics function with the TCC disabled. Some run only immediately following a cold engine start-up. A trip then, is defined as a key on-run-key off cycle in which the vehicle was operated in such a way as to satisfy the enabling criteria for a given diagnostic, and this diagnostic will consider this cycle to be one trip. However, another diagnostic with a different set of enable criteria (which were not met) during this driving event, would not consider it a trip. No trip will occur for that particular diagnostic until the vehicle is driven in such a way as to meet all the enable criteria.

The Diagnostic Executive The Diagnostic Executive is a unique segment of software which is designed to coordinate and prioritize the diagnostic procedures as well as define the protocol for recording and displaying their results. The main responsibilities of the Diagnostic Executive are listed as the following: B Commanding the MIL (“Check Engine” lamp) on and off B DTC logging and clearing B Freeze Frame data for the first emission related DTC recorded B Non-emission related Service Lamp B Operating conditions Failure Records buffer, (the number of records will vary) B Current status information on each diagnostic B System Status (I/M ready)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS The Diagnostic Executive records DTCs and turns on the MIL when emission-related faults occur. It can also turn off the MIL if the conditions cease which caused the DTC to set. Diagnostic Information The diagnostic charts and functional checks are designed to locate a faulty circuit or component through a process of logical decisions. The charts are prepared with the requirement that the vehicle functioned correctly at the time of assembly and that there are no multiple faults present. There is a continuous self-diagnosis on certain control functions. This diagnostic capability is complemented by the diagnostic procedures contained in this manual. The language of communicating the source of the malfunction is a system of diagnostic trouble codes. When a malfunction is detected by the control module, a diagnostic trouble code is set and the Malfunction Indicator Lamp (MIL) (“Check Engine” lamp) is illuminated. Malfunction Indicator Lamp (MIL) The Malfunction Indicator Lamp (MIL) looks the same as the MIL you are already familiar with (“Check Engine” lamp). However, OBD II requires that it illuminate under a strict set of guide lines. Basically, the MIL is turned on when the PCM detects a DTC that will impact vehicle emissions. The MIL is under the control of the Diagnostic Executive. The MIL will be turned on if an emissions-related diagnostic test indicates a malfunction has occurred. It will stay on until the system or component passes the same test, for three consecutive trips, with no emissions related faults. If the vehicle is experiencing a misfire malfunction which may cause damage to the Three-Way Catalytic Converter (TWC), the MIL will flash once per second. This will continue until the vehicle is outside of speed and load conditions which could cause possible catalyst damage, and the MIL will stop flashing and remain on steady. Extinguishing the MIL When the MIL is on, the Diagnostic Executive will turn off the MIL after three(3) consecutive trips that a “test passed” has been reported for the diagnostic test that originally caused the MIL to illuminate. Although the MIL has been turned off, the DTC will remain in the PCM memory (both Freeze Frame and Failure Records) until forty(40) warm-up cycles after no faults have been completed. If the MIL was set by either a fuel trim or misfire-related DTC, additional requirements must be met. In addition to the requirements stated in the previous paragraph, these requirements are as follows: B The diagnostic tests that are passed must occur within 375 RPM of the RPM data stored at the time the last test failed. B Plus or minus ten (10) percent of the engine load that was stored at the time the last failed.

6E–37

B Similar engine temperature conditions (warmed up or warming up ) as those stored at the time the last test failed. Meeting these requirements ensures that the fault which turned on the MIL has been corrected. The MIL (“Check Engine” lamp) is on the instrument panel and has the following function: B It informs the driver that a fault affects vehicle emission levels has occurred and that the vehicle should be taken for service as soon as possible. B As a bulb and system check, the MIL will come “ON” with the key “ON” and the engine not running. When the engine is started, the MIL will turn “OFF.” B When the MIL remains “ON” while the engine is running, or when a malfunction is suspected due to a driveability or emissions problem, a Powertrain On-Board Diagnostic (OBD ll) System Check must be performed. The procedures for these checks are given in On-Board Diagnostic (OBD) System Check. These checks will expose faults which may not be detected if other diagnostics are performed first.

DTC Types Each DTC is directly related to a diagnostic test. The Diagnostic Management System sets DTC based on the failure of the tests during a trip or trips. Certain tests must fail two (2) consecutive trips before the DTC is set. The following are the four (4) types of DTCs and the characteristics of those codes: B Type A B Emissions related B Requests illumination of the MIL of the first trip with a fail B Stores a History DTC on the first trip with a fail B Stores a Freeze Frame (if empty) B Stores a Fail Record B Updates the Fail Record each time the diagnostic test fails B Type B B Emissions related B “Armed” after one (1) trip with a fail B “Disarmed” after one (1) trip with a pass B Requests illumination of the MIL on the second consecutive trip with a fail B Stores a History DTC on the second consecutive trip with a fail (The DTC will be armed after the first fail) B Stores a Freeze Frame on the second consecutive trip with a fail (if empty) B Stores a Fail Record when the first test fails (not dependent on consecutive trip fails) B Updates the Fail Record each time the diagnostic test fails (Some special conditions apply to misfire and fuel trim DTCs) B Type C (if the vehicle is so equipped) B Non-Emissions related B Requests illumination of the Service B Stores a History DTC on the first trip with a fail

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B Does not store a Freeze Frame B Stores Fail Record when test fails B Updates the Fail Record each time the diagnostic test fails B Type D B Non-Emissions related B Not request illumination of any lamp B Stores a History DTC on the first trip with a fail B Does not store a Freeze Frame B Stores Fail Record when test fails B Updates the Fail Record each time the diagnostic test fails IMPORTANT: Only four Fail Records can be stored. Each Fail Record is for a different DTC. It is possible that there will not be Fail Records for every DTC if multiple DTCs are set. Special Cases of Type B Diagnostic Tests Unique to the misfire diagnostic, the Diagnostic Executive has the capability of alerting the vehicle operator to potentially damaging levels of misfire. If a misfire condition exists that could potentially damage the catalytic converter as a result of high misfire levels, the Diagnostic Executive will command the MIL to “flash” at a rate of once per second during those the time that the catalyst damaging misfire condition is present. Fuel trim and misfire are special cases of Type B diagnostics. Each time a fuel trim or misfire malfunction is detected, engine load, engine speed, and engine coolant temperature are recorded. When the ignition is turned off, the last reported set of conditions remain stored. During subsequent ignition cycles, the stored conditions are used as reference for similar conditions. If a malfunction occurs during two consecutive trips, the Diagnostic Executive treats the failure as a normal Type B diagnostic, and does not use the stored conditions. However, if a malfunction occurs on two non-consecutive trips, the stored conditions are compared with the current conditions. The MIL will then illuminate under the following conditions: B When the engine load conditions are within 10% of the previous test that failed. B Engine speed is within 375 rpm, of the previous test that failed. B Engine coolant temperature is in the same range as the previous test that failed.

Storing and Erasing Freeze Frame Data and Failure Records Government regulations require that engine operating conditions be captured whenever the MIL is illuminated. The data captured is called Freeze Frame data. The Freeze Frame data is very similar to a single record of operating conditions. Whenever the MIL is illuminated, the corresponding record of operating conditions is recorded to the Freeze Frame buffer. Freeze Frame data can only be overwritten with data associated with a misfire or fuel trim malfunction. Data from these faults take precedence over data associated with any other fault. The Freeze Frame data will not be erased unless the associated history DTC is cleared. Each time a diagnostic test reports a failure, the current engine operating conditions are recorded in the Failure Records buffer. A subsequent failure will update the recorded operating conditions. The following operating conditions for the diagnostic test which failed typically include the following parameters: B Air Fuel Ratio B Air Flow Rate B Fuel Trim B Engine Speed B Engine Load B Engine Coolant Temperature B Vehicle Speed B TP Angle B AP Angle B MAP/BARO B Injector Base Pulse Width B Loop Status Intermittent Malfunction Indicator Lamp In the case of an “intermittent” fault, the MIL (“Check Engine” lamp) may illuminate and then (after three trips) go “OFF”. However, the corresponding diagnostic trouble code will be stored in memory. When unexpected diagnostic trouble codes appear, check for an intermittent malfunction. A diagnostic trouble code may reset. Consult the “Diagnostic Aids” associated with the diagnostic trouble code. A physical inspection of the applicable sub-system most often will resolve the problem. Data Link Connector (DLC) The provision for communication with the control module is the Data Link Connector (DLC). It is located at the lower left of the instrument panel behind a small square cover. The DLC is used to connect to the Tech 2 Scan Tool. Some common uses of the Tech 2 are listed below:

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B B B B

Identifying stored Diagnostic Trouble Codes (DTCs). Clearing DTCs. Performing output control tests. Reading serial data.

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Verifying Vehicle Repair Verification of vehicle repair will be more comprehensive for vehicles with OBD II system diagnostic. Following a repair, the technician should perform the following steps: 1. Review and record the Fail Records and/or Freeze Frame data for the DTC which has been diagnosed (Freeze Frame data will only be stored for an A or B type diagnostic and only if the MIL has been requested). 2. Clear DTC(s). 3. Operate the vehicle within conditions noted in the Fail Records and/or Freeze Frame data. 4. Monitor the DTC status information for the DTC which has been diagnosed until the diagnostic test associated with that DTC runs. Following these steps are very important in verifying repairs on OBD ll systems. Failure to follow these steps could result in unnecessary repairs.

Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool TS24064

Decimal/Binary/Hexadecimal Conversions Beginning in 1996, Federal Regulations require that all auto manufacturers selling vehicles in the United States provide Scan Tool manufacturers with software information to display vehicle operating parameters. All Scan Tool manufacturers will display a variety of vehicle information which will aid in repairing the vehicle. Some Scan Tools will display encoded messages which will aid in determining the nature of the concern. The method of encoding involves the use of a two additional numbering systems: Binary and Hexadecimal. The binary number system has a base of two numbers. Each digit is either a 0 or a 1. A binary number is an eight digit number and is read from right to left. Each digit has a position number with the farthest right being the 0 position and the farthest left being the 7 position. The 0 position, when displayed by a 1, indicates 1 in decimal. Each position to the left is double the previous position and added to any other position values marked as a 1. A hexadecimal system is composed of 16 different alpha numeric characters. The alpha numeric characters used are numbers 0 through 9 and letters A through F. The hexadecimal system is the most natural and common approach for Scan Tool manufacturers to display data represented by binary numbers and digital code.

The procedure for reading diagnostic trouble code(s) is to use a diagnostic Scan Tool. When reading DTC(s), follow instructions supplied by tool manufacturer. Clearing Diagnostic Trouble Codes IMPORTANT: Do not clear DTCs unless directed to do so by the service information provided for each diagnostic procedure. When DTCs are cleared, the Freeze Frame and Failure Record data which may help diagnose an intermittent fault will also be erased from memory. If the fault that caused the DTC to be stored into memory has been corrected, the Diagnostic Executive will begin to count the “warm-up” cycles with no further faults detected, the DTC will automatically be cleared from the PCM memory. To clear Diagnostic Trouble Codes (DTCs), use the diagnostic Scan Tool “clear DTCs” or “clear information” function. When clearing DTCs follow instructions supplied by the tool manufacturer. When a Scan Tool is not available, DTCs can also be cleared by disconnecting one of the following sources for at least thirty (30) seconds. NOTE: To prevent system damage, the ignition key must be “OFF” when disconnecting or reconnecting battery power. B The power source to the control module. Examples: fuse, pigtail at battery PCM connectors, etc. B The negative battery cable. (Disconnecting the negative battery cable will result in the loss of other on-board memory data, such as preset radio tuning).

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Tech 2 From 98 MY, Isuzu dealer service departments are recommended to use the Tech 2 Scan Tool. Please refer to the Tech 2 user guide.

901RW180

Legend (1) PCMCIA Card (2) RS 232 Loop Back Connector

(3) SAE 16/19 Adaptor (4) DLC Cable (5) Tech–2

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Tech 2 Features 1. Tech 2 is a 12 volt system. Do not apply 24 volts. 2. After connecting and/or installing the Vehicle Communications Interface (VCI) module, PCMCIA card and DLC connector to the Tech 2, connect the tool to the vehicle DLC. 3. Make sure the Tech 2 is OFF when removing or installing the PCMCIA card. 4. The PCMCIA card has a capacity of 10 Megabytes which is 10 times greater than the memory of the Tech 1 Mass Storage Cartridge. 5. The Tech 2 has the capability of two snapshots. 6. The PCMCIA card is sensitive to magnetism and static electricity, so care should be taken in the handling of the card. 7. The Tech 2 can plot a graph when replaying a snapshot. 8. Always return to the Main Menu by pressing the EXIT key several times before shutting down. 9. To clear Diagnostic Trouble Codes (DTCs), open Application Menu and press “F1: Clear DTC Info”.

7. Power the Tech 2 ON and verify the Tech 2 power up display.

060RW009

NOTE: The RS232 Loop back connector is only to use for diagnosis of Tech 2. Refer to user guide of the Tech 2.

Getting Started B Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. Insert the Isuzu system PCMCIA card (1) into the Tech 2 (5). 2. Connect the SAE 16/19 adapter (3) to the DLC cable (4). 3. Connect the DLC cable to the Tech 2 (5) 4. Make sure the vehicle ignition is off. 5. Connect the Tech 2 SAE 16/19 adapter to the vehicle DLC.

826RW002

6. Turn on the vehicle ignition.

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Operating Procedure (For Example) The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card. Follow the operating procedure below.

060R200038

060R100102

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Menu B The following table shows which functions are used for the available equipment versions.

060RW223

060R100018

DTC Modes

The following is a brief description of each of the sub menus in DTC Info and DTC. The order in which they appear here is alphabetical and not necessarily the way they will appear on the Tech 2.

DTC Information Mode

060R100077

On OBD II vehicles there are options available in Tech 2 DTC mode to display the enhanced information available. After selecting DTC, the following menu appears: 1. Read DTC Info by Priority 2. Freeze Frame 3. Fail Records (not all applications) 4. DTC Info 5. Clear Info

Use the DTC info mode to search for a specific type of stored DTC information. DTC Status This selection will display any DTCs that have not run during the current ignition cycle or have reported a test failure during this ignition up to DTCs. DTC tests which run and pass will cause that DTC number to be removed from Tech 2 screen. Fail This Ignition This selection will display all DTCs that have failed during the present ignition cycle. History This selection will display only DTCs that are stored in the PCM’s history memory. It will display all type A and B DTCs that have requested the MIL and have failed within the last 40 warm-up cycles. In addition, it will display all type C and type D DTCs that have failed within the last 40 warm-up cycles. Last Test Failed This selection will display only DTCs that have failed the last time the test run. The last test may have run during a previous ignition cycle if a type A or type B DTC is displayed. For type C and type D DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MILSVC or Message Request This selection will display only DTCs that are requesting the MIL. Type C and type D DTCs cannot be displayed using this option. This selection will report type B DTCs only after the MIL has been requested.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Not Run Since Code Cleared This option will display up to DTCs that have not run since the DTCs were last cleared. Since any displayed DTCs have not run, their condition (passing or failing) is unknown. Test Failed Since Code Cleared This selection will display all active and history DTCs that have reported a test failure since the last time DTCs were cleared. DTCs that last failed more than 40 warm-up cycles before this option is selected will not be displayed.

4. Select F0:Lamps Test in the Miscellaneous Test.

Miscellaneous Test This test consists of eight menus-Lights, Relays, EVAP, Fuel System, Instruments, EGR Control, Variable Intake Manifold Solenoid, and Injector Balance Tests. In these tests, Tech 2 sends operating signals to the systems to confirm their operations thereby to judge the normality of electric circuits. To judge intermittent trouble, 1. Confirm DTC freeze frame data, and match the freeze frame data as test conditions with the data list displayed by Miscellaneous Test. 2. Confirm DTC setting conditions, and match the setting conditions as test conditions with the data list displayed by Miscellaneous Test. 3. Refer to the latest Service Bulletin. Check to see if the Latest software is released or not. Down load the LATEST PROGRAMMED SOFTWARE to the replacement PCM.

060RY00080

5. Select F0:Malfunction Indicator Lamp.

Lamps Test This test is conducted check MIL, Up Shift Lamp, Low Fuel Lamp, Reduced Power Lamp and Cruise Control Lamp for its working. Tech2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu. 060RY00091

6. Push”On” soft key. 7. Make sure Lamp illuminates. 8. If lamp illuminates, the Lamp is operating correctly.

060R100078

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–45

17. Select F3:Reduced Power Lamp

9. Select F2: Up Shift Lamp

060RY00076

060RY00077

10. Push “On” soft key. 11. Make sure Lamp illuminates. 12. If Lamp illuminates, the Lamp is operating correctly. 13. Select F2:Low Fuel Lamp

18. Push “On” soft key. 19. Make sure Lamp illuminates. 20. If Lamp illuminates, the Lamp is operating correctly. 21. Select F5:Cruise Control Lamp

060RY00092

060RY00078

14. Push “On” soft key. 15. Make sure Lamp illuminates. 16. If Lamp illuminates, the Lamp is operating correctly.

22. Push “On” soft key. 23. Make sure Lamp illuminates. 24. If Lamp illuminates, the Lamp is operating correctly.

6E–46

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 5. Select F0:Fuel Pump Relay.

Relays Test This test is conducted to check Fuel Pump Relay and A/C Clutch for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is “On”. 3. Select F3: Miscellaneous Test in the Application Menu.

060RX021

6. Push “On” soft key.

060R100078

4. Select F1:Relay Test in the Miscellaneous Test.

060RY00093

7. Control Fuel Pump Relay and check data list. 8. If the data list changes, the Fuel Pump Relay is normal. 9. Select F1:A/C Clutch Relay. 10. Run the Engine at idle.

060RY00081

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 11. Turn on Air Conditioning.

6E–47

4. Select F2: EVAP Test in the Miscellaneous Test.

060RY00094

12. Turn “On” and “Off” A/C Switch. 13. Contol A/C Clutch Relay and check data list. 14. If the data list changes, the Fuel Pump Relay is normal.

060RY00082

5. Select F0: Purge Solenoid.

EVAP Test This test is conducted to check EVAP system for its power operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu.

060RX025

060R100078

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6. Push “Decrease” or “Increase” soft key.

11. Push “On” or “Off” soft key.

060RY00095

7. Control EVAP Purge Solenoid and check a data list. 8. If the data list changes, the Purge Solenoid is normal. 9. Turn engine off, turn ignition SW “On”. 10. Select F1:EVAP Vent Solenoid.

060RY00096

12. Control EVAP Vent Solenoid and check data list. 13. If the data list changes, the EVAP Vent Solenoid is normal.

Fuel System Test This test is conducted check Fuel system for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is “On”. 3. Select F3: Miscellaneous Test in the Application Menu.

060RX025

060R100078

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 4. Select F3: Fuel System in the Miscellaneous Menu.

6. Push “Disable” or “Enable” soft key.

060RY00083

5. Select F0: Fuel Trim Enable.

6E–49

060RY00097

7. Control Fuel Trim and check data list. 8. If data list changes, the Fuel Trim is normal. 9. Select F1: Fuel Trim Reset.

060R200071

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

10. Push “Reset” soft key.

13. Push “Open Loop” or “Closed Loop” soft key.

060RY00098

11. Select F2: O2-Loop status.

060RY00099

14. Control O2-Loop and check data list. 15. If data list changes, the O2-Loop is normal.

Instruments Test This test is conducted check Instruments for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Ignition SW is “On”. 3. Select F3: Miscellaneous Test in the Application Menu.

060R200071

12. This test is check the “Closed Loop Status” performance.

060R100078

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 4. Select F4: Instruments in the Miscellaneous Menu.

060RY00106

5. Select F0: Fuel Gauge level.

6E–51

6. Push “Decrease” or “Increase” soft key.

060RY00100

7. Control Fuel Level and check data list. 8. If data list and Fuel gauge meter changes, Fuel Gauge level is normal. 9. Select F1: Tachometer Control Test.

060RY00107

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

10. Push “Inactive” or “active” soft key.

4. Select F5: EGR Control Test in the Miscellaneous Test.

060RY00101

11. Control tachometer and data list. 12. If data list and meter changes, the tachometer control is normal.

060RY00084

5. Control EGR Valve and check data list.

EGR Control Test This test is conducted check EGR valve for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu.

060RY00103

6. If data list changes, the EGR Control is normal.

Variable Intake Manifold Solenoid Test This test is conducted check VIM Solenoid for proper operation. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC.

060R100078

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 2. Ignition SW is “On”.

6E–53

4. Select F6: Variable Intake Manifold Solenoid Test.

060RY00104

3. Select F3: Miscellaneous Test in the Application Menu.

060RY00085

5. Push “On” or “Off” soft key.

060RX028 060R100078

6. Control VIM Solenoid check data list. 7. If data list changes, the VIM Solenoid is normal.

6E–54

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 5. Select injector number and push “injector off” soft key.

Injector Balance Test This test is conducted to make sure the appropriate electric signals are being sent to injectors Nos. 1–6. Tech 2 must be used for this test. Test Procedure: 1. Connect Tech 2 to the vehicle DLC. 2. Run the Engine at idle. 3. Select F3: Miscellaneous Test in the Application Menu.

060RY00105

6. Make sure of engine speed change. 7. If engine speed changes, the injector electric circuit is normal. If engine speed does not change, the injector electric circuit or the injector itself is not normal.

Plotting Snapshot Graph 060R100078

4. Select F7: Injector Balance Test in the Miscellaneous Test.

This test selects several necessary items from the data list to plot graphs and makes data comparison on a long term basis. It is an effective test particularly in emission related evaluations.

060RY00086 060RX037

For trouble diagnosis, you can collect graphic data (snap shot) directly from the vehicle. You can replay the snapshot data as needed. Therefore, accurate diagnosis is possible, even though the vehicle is not available.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–55

Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)

060R200070

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Flow Chart for Snapshot Replay (Plotting Graph)

060R200072

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Primary System-Based Diagnostic Primary System-Based Diagnostic There are primary system-based diagnostics which evaluate system operation and its effect on vehicle emissions. The primary system-based diagnostics are listed below with a brief description of the diagnostic function: Oxygen Sensor Diagnosis The fuel control heated oxygen sensors (Bank 1 HO2S 1 and Bank 2 HO2S 1) are diagnosed for the following conditions: B Heater performance (time to activity on cold start) B Slow response B Response time (time to switch R/L or L/R) B Inactive signal (output steady at bias voltage – approx. 450 mV) B Signal fixed high B Signal fixed low The catalyst monitor heated oxygen sensors (Bank 1 HO2S 2 and Bank 2 HO2S 2) are diagnosed for the following conditions: B Heater performance (time to activity on cold start). B Signal fixed low during steady state conditions or power enrichment (hard acceleration when a rich mixture should be indicated). B Signal fixed high during steady state conditions or deceleration mode (deceleration when a lean mixture should be indicated). B Inactive sensor (output steady at approx. 438 mV). If the oxygen sensor pigtail wiring, connector or terminal are damaged, the entire oxygen sensor assembly must be replaced. DO NOT attempt to repair the wiring, connector or terminals. In order for the sensor to function properly, it must have clean reference air provided to it. This clean air reference is obtained by way of the oxygen sensor wire(s). Any attempt to repair the wires, connector or terminals could result in the obstruction of the reference air and degrade oxygen sensor performance. Refer to On-Vehicle Service, Heated Oxygen Sensors in this section.

Fuel Control Heated Oxygen Sensor The main function of the fuel control heated oxygen sensors is to provide the control module with exhaust stream oxygen content information to allow proper fueling and maintain emissions within mandated levels. After it reaches operating temperature, the sensor will generate a voltage, inversely proportional to the amount of oxygen present in the exhaust gases. The control module uses the signal voltage from the fuel control heated oxygen sensors while in closed loop to adjust fuel injector pulse width. While in closed loop, the PCM can adjust fuel delivery to maintain an air/fuel ratio which allows the best combination of emission control and driveability. The fuel control heated oxygen sensors are also used to determine catalyst efficiency.

6E–57

HO2S Heater Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control to begin operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors (Bank 1 HO2S 1 and Bank2 HO2S 1) to become active. Oxygen sensor heaters are required by catalyst monitor and sensor (Bank 1 HO2S 2 and Bank 2 HO2S 2) to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further away from the engine.

Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation

TS24067

To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The PCM has the ability to monitor this process using the pre-catalyst and post-catalyst heated oxygen sensors. The pre-catalyst sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The post-catalyst sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalyst’s ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the pre-catalyst signal will be far more active than that produced by the post-catalyst sensor. In addition to catalyst monitoring, the heated oxygen sensors have a limited role in controlling fuel delivery. If the sensor signal indicates a high or low oxygen content for an extended period of time while in closed loop, the PCM will adjust the fuel delivery slightly to compensate.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B For the 3.5L w/automatic transmission, the pre-catalyst sensors are designated Bank 1 HO2S 1 and Bank 2 HO2S 1. The post-catalyst sensors are Bank 1 HO2S 2 and Bank 2 HO2S 2. Catalyst Monitor Outputs The catalyst monitor diagnostic is sensitive to the following conditions: B Exhaust leaks B HO2S contamination B Alternate fuels Exhaust system leaks may cause the following: B Preventing a degraded catalyst from failing the diagnostic. B Causing a false failure for a normally functioning catalyst. B Preventing the diagnostic from running. Some of the contaminants that may be encountered are phosphorus, lead, silica, and sulfur. The presence of these contaminants will prevent the TWC diagnostic from functioning properly. Three-Way Catalyst Oxygen Storage Capacity The Three-Way catalyst (TWC) must be monitored for efficiency. To accomplish this, the control module monitors the pre-catalyst HO2S and post-catalyst HO2S oxygen sensors. When the TWC is operating properly, the post-catalyst oxygen sensor will have significantly less activity than the pre-catalyst oxygen sensor. The TWC stores and releases oxygen as needed during its normal reduction and oxidation process. The control module will calculate the oxygen storage capacity using the difference between the pre-catalyst and post catalyst oxygen sensor’s voltage levels. If the activity of the post-catalyst oxygen sensor approaches that of the pre-catalyst oxygen sensor, the catalyst’s efficiency is degraded. Stepped or staged testing level allow the control module to statistically filter test information. This prevents falsely passing or falsely failing the oxygen storage capacity test. The calculations performed by the on-board diagnostic system are very complex. For this reason, post catalyst oxygen sensor activity should not be used to determine oxygen storage capacity unless directed by the service manual. Two stages are used to monitor catalyst efficiency. Failure of the first stage will indicate that the catalyst requires further testing to determine catalyst efficiency. The seconds stage then looks at the inputs for the pre and post catalyst HO2S sensors more closely before determining if the catalyst is indeed degraded. This further statistical processing is done to increase the accuracy of oxygen storage capacity type monitoring. Failing the first (stage 1) test DOES NOT indicate a failed catalyst. The catalyst may be marginal or the fuel sulfur content could be very high.

Aftermarket HO2S characteristics may be different from the original equipment manufacturer sensor. This may lead to a false pass or a false fail of the catalyst monitor diagnostic. Similarly, if an aftermarket catalyst does not contain the same amount of cerium as the original part, the correlation between oxygen storage and conversion efficiency may be altered enough to set a false DTC.

Misfire Monitor Diagnostic Operation Misfire Monitor Diagnostic Operation Misfire is monitored as a function of the combustion quality (CQ) signals generated from the ignition current sense system. Combustion signals represent the degree of combustion in each cylinder. Misfire is detected when the combustion signal is below a predetermined value. The misfire ratio is calculated once every 100 engine cycles. For example, on a 6-cylinder engine, 600 ignition plug sparks occur every 100 cycles and if a misfire occurs 12 times during that time, the misfire is 12/600 × 100 = 2 %.

Misfire Counters Whenever a cylinder misfires, the misfire diagnostic counts the misfire and notes the crankshaft position at the time the misfire occurred. These “misfire counters” are basically a file on each engine cylinder. A current and a history misfire counter are maintained for each cylinder. The misfire current counters (Misfire Cur #1-6) indicate the number of firing events out of the last 100 cylinder firing events which were misfires. The misfire current counter will display real time data without a misfire DTC stored. The misfire history counters (Misfire Hist #1-6) indicate the total number of cylinder firing events which were misfires. The misfire history counters will display 0 until the misfire diagnostic has failed and a DTC P0300 is set. Once the misfire DTC P0300 is set, the misfire history counters will be updated every 100 cylinder firing events. A misfire counter is maintained for each cylinder. If the misfire diagnostic reports a failure, the diagnostic executive reviews all of the misfire counters before reporting DTC. This way, the diagnostic executive reports the most current information. When crankshaft rotation is erratic, a misfire condition will be detected. Because of this erratic condition, the data that is collected by the diagnostic can sometimes incorrectly identify which cylinder is misfiring. Misfires are counted from more than one cylinder. Cylinder #1 has the majority of counted misfires. In this case, the Misfire Counters would identify cylinder #1 as the misfiring cylinder. The misfires in the other counters were just background noise caused by the erratic misfire rotation of the crankshaft. If the number of accumulated misfires is sufficient for the diagnostic to identify a true misfire, the diagnostic will set DTC P0300 – Misfire Detected. Use diagnostic equipment to monitor misfire counter data on OBD II-compliant vehicles. Knowing which specific cylinder(s) misfired can lead to the root cause, even when dealing with a multiple cylinder misfire. Using the information in the misfire counters, identify which cylinders are misfiring. If the counter indicate cylinders

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS numbers 1 and 4 misfired, look for a circuit or component common to both cylinders number 1 and 4. Misfire counter information is located in the “Eng”. menu, “Misfire Data” sub-menu of the data list. The misfire diagnostic may indicate a fault due to a temporary fault not necessarily caused by a vehicle emission system malfunction. Examples include the following items: B Contaminated fuel B Low fuel B Fuel-fouled spark plugs B Basic engine fault

Fuel Trim System Monitor Diagnostic Operation Fuel Trim System Monitor Diagnostic Operation This system monitors the averages of short-term and long-term fuel trim values. If these fuel trim values stay at their limits for a calibrated period of time, a malfunction is indicated. The fuel trim diagnostic compares the averages of short-term fuel trim values and long-term fuel trim values to rich and lean thresholds. If either value is within the thresholds, a pass is recorded. If both values are outside their thresholds, a rich or lean DTC will be recorded. The fuel trim system diagnostic also conducts an intrusive test. This test determines if a rich condition is being caused by excessive fuel vapor from the EVAP canister. In order to meet OBD II requirements, the control module uses weighted fuel trim cells to determine the need to set a fuel trim DTC. A fuel trim DTC can only be set if fuel trim counts in the weighted fuel trim cells exceed specifications. This means that the vehicle could have a fuel trim problem which is causing a problem under certain conditions (i.e., engine idle high due to a small vacuum leak or rough idle due to a large vacuum leak) while it operates fine at other times. No fuel trim DTC would set (although an engine idle speed DTC or HO2S DTC may set). Use the Tech 2 to observe fuel trim counts while the problem is occurring. A fuel trim DTC may be triggered by a number of vehicle faults. Make use of all information available (other DTCs stored, rich or lean condition, etc.) when diagnosing a fuel trim fault.

Fuel Trim Cell Diagnostic Weights No fuel trim DTC will set regardless of the fuel trim counts in cell 0 unless the fuel trim counts in the weighted cells are also outside specifications. This means that the vehicle could have a fuel trim problem which is causing a problem under certain conditions (i.e. engine idle high due to a small vacuum leak or rough due to a large vacuum leak) while it operates fine at other times. No fuel trim DTC would set (although an engine idle speed DTC or HO2S DTC may set). Use the Tech 2 to observe fuel trim counts while the problem is occurring.

6E–59

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

On-Board Diagnostic (OBD II) System Check

060R200048

Circuit Description The on-board diagnostic system check is the starting point for any driveability complaint diagnosis. Before using this procedure, perform a careful visual/physical check of the PCM and engine grounds for cleanliness and tightness. The on-board diagnostic system check is an organized approach to identifying a problem created by an electronic engine control system malfunction.

Diagnostic Aids An intermittent may be caused by a poor connection, rubbed–through wire insulation or a wire broken inside the insulation. Check for poor connections or a damaged harness. Inspect the PCM harness and connector for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart: 1.The MIL (“Check Engine lamp”) should be “ON” steady with the ignition “ON ” and the engine “OFF”. If not, the “No MIL” chart should be used to isolate the malfunction. 2.The RPL (“Reduced Power lamp”) should be “ON” steady with the ignition “ON ”and the engine “OFF”. If not, the “No RPL”chart should be used to isolate the malfunction.

3.Checks the Class 2 data circuit and ensures that the PCM is able to transmit serial data. 4.This test ensures that the PCM is capable of controlling the MIL (“Check Engine lamp”) and the MIL (“Check Engine lamp”) driver circuit is not shorted to ground. 5.This test ensures that the PCM is capable of controlling the RPL (“Reduced Power lamp”) and the RPL (“Reduced Power lamp”) driver circuit is not shorted to ground. 7.Check the DTCs (System ,Volts Supply circuit). 8.Check the DTCs (PCM{Software} detect Errors). 11.If the engine will not start, the Cranks But Will Not Run chart should be used to diagnose the condition. 14.A Tech 2 parameter which is not within the typical range may help to isolate the area which is causing the problem. 15.This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors of this section. 10. If the starter motor will not start, the starter control system chart should be used to diagnose the condition.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

On-Board Diagnostic (OBD II) System Check Step

Action

1. 2. 3. 4.

Go to Step 12

Go to Step 5

Go to MIL(“Check Engine lamp”) On Steady

—

Go to Step 6

Go to RPL(“Reduce d Power lamp”) On Steady

—

Go to Step 7

Go to Step 11

—

Go to applicable DTC table

Go to Step 8

—

Go to applicable DTC table

Go to Step 9

—

Go to “Multiple PCM Information sensor DTCs Set”

Go to Step 10

Go to Starter control system

Go to Step 6

Go to Cranks But Will Not Run

—

Stored DTCs. P1514, P1515, P1516, P1523, P1125, P1290, P1295, P1299 Are the applicable DTCs stored?

Go to Step 4

Stored DTCs. P0562, P0563, P0601, P0602, P0604, P0606, P1625, P1635, P1639, P1640, P1650 Are the applicable DTCs stored?

—

Select “Display DTCs” with the Tech 2. Are any DTCs stored?

Go to Step 3

1. Using the Tech 2 output tests function, select MIL (“Check Engine lamp”) control and command the RPL (“Reduced Power lamp”) “OFF”. 2. Observe the RPL (“Reduced Power lamp”). Did the MIL (“Reduced Power lamp”) turn “OFF”?

—

Go to No RPL(“Reduce d Power lamp”)

1. Using the Tech 2 output tests function, select MIL (“Check Engine lamp”) control and command the MIL (“Check Engine Lamp”) “OFF”. 2. Observe the MIL (“Check Engine lamp”). Did the MIL (“Check Engine lamp”) turn “OFF”?

Go to Step 2

—

Ignition “OFF”. Install Tech 2. Ignition “ON”. Attempt to display PCM engine data with the Tech 2.

Does the Tech 2 display PCM data? 4

Stored DTCs. 1.

P0425, P0106, P0107, P1107, P0401, P1404, P0405, P1120, P1221, P1515, P1516, P1275, P1635, P1271, P1273, P1285, P1272 2. P0336, P0337, P1220, P1515, P1221, P1516, P1280, P1639, P1271, P1272 Are the applicable DTCs stored? 10

Attempt to crank the starter motor Did the starter motor crank?

Go to No MIL(“Check Engine lamp”)

1. Ignition “ON”, engine “OFF”. 2. Observe the “Reduced Power lamp”. Is the RPL (“Reduced Power lamp”) “ON”?

Yes

1. Ignition “ON”, engine “OFF”. 2. Observe the malfunction indicator lamp (MIL or “Check Engine lamp”). Is the MIL (“Check Engine lamp”)“ON”?

Value(s)

—

Attempt to start the engine. Did the engine start and continue to run?

—

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

On-Board Diagnostic (OBD II) System Check (Cont’d) Step

Action

Compare PCM data values displayed on the Tech 2 to the typical engine scan data values. Are the displayed values normal or close to the typical values?

—

Go to Symptom

Refer to indicated Component System Checks

—

Go to Step 2

Go to Step 14

—

Go to Step 2

Go to Step 15

—

Go to Step 2

—

1. Attempt to reprogram the PCM. Refer to Powertrain Control Module (PCM) in On-Vehicle Service. 2. Attempt to display PCM data with the Tech 2. Does the Tech 2 display PCM engine data?

Yes

1. Ignition “OFF”, disconnect the PCM. 2. Ignition “ON”, engine “OFF”. 3. Check the Class 2 data circuit for an open, short to ground, or short to voltage. Also, check the DLC ignition feed circuit for an open or short to ground and the DLC ground circuit for an open. 4. If a problem is found, repair as necessary. Was a problem found?

Value(s)

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–63

A/C Clutch Control Circuit Diagnosis

060R100063

Circuit Description When air conditioning and blower fan are selected, and if the system has a sufficient refrigerant charge, a 12-volt signal is supplied to the A/C request input of the powertrain control module (PCM). The A/C request signal may be temporarily canceled during system operation by the electronic thermostat in the evaporator case. When the A/C request signal is received by the PCM, the PCM supplies a ground from the compressor clutch relay if the engine operating conditions are within acceptable ranges. With the A/C compressor relay energized, voltage is supplied to the compressor clutch coil. The PCM will enable the compressor clutch to engage whenever A/C has been selected with the engine running, unless any of the following conditions are present: B The throttle is greater than 90%. B The ignition voltage is below 10.5 volts. B The engine speed is greater than 4500 RPM for 5 seconds or 5400 RPM.

B The engine coolant temperature (ECT) is greater than 125 °C (257 °F). B The intake air temperature (IAT) is less than 5°C (41°F). B The power steering pressure switch signals a high pressure condition.

Diagnostic Aids To diagnose an the intermittent fault, check for following conditions: B Poor connection at the PCM–Inspect connections for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness–Inspect the wiring harness for damage. If the harness appears to OK, observe the A/C clutch while moving connectors and wiring harnesses related to the A/C. A sudden clutch malfunction will indicate the source of the intermittent fault.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

A/C Clutch Diagnosis This chart should be used for diagnosing the electrical portion of the A/C compressor clutch circuit. A Tech 2 will be used in diagnosing the system. The Tech 2 has the ability to read the A/C request input to the PCM. The Tech 2 can display when the PCM has commanded the A/C clutch “ON”. The Tech 2 should have the ability to override the A/C request signal and energize the A/C compressor relay.

Test Description IMPORTANT: Do not engage the A/C compressor clutch with the engine running if an A/C mode is not selected at the A/C control switch. The numbers below refer to the step numbers on the Diagnostic Chart:

3. This a test determine is the problem is with the refrigerant system. If the switch is open, A/C pressure gauges will be used to determine if the pressure switch is faulty or if the system is partially discharged or empty. 4. Although the normal complaint will be the A/C clutch failing to engage, it is possible for a short circuit to cause the clutch to run when A/C has not been selected. This step is a test for that condition. 7. There is an extremely low probability that both relays will fail at the same time, so the substitution process is one way to check the A/C Thermostat relay. Use a known good relay to do a substitution check.

A/C Clutch Control Circuit Diagnosis Step

Action

Value(s)

—

Go to Step 2

Go to OBD System Check

—

Go to the other DTC chart(s) first

Go to Step 3

—

Go to Air Conditioning to diagnose the cause of the open pressure switch

Go to Step 4

—

Go to Step 37

Go to Step 5

—

Refer to Diagnostic Aids

Go to Step 6

—

Go to Step 26

Go to Step 7

Was the “On-Board Diagnostic (OBD) System Check” performed? Are any other DTCs stored?

1. Disconnect the electrical connector at the pressure switch located on the receiver/drier. 2. Use an ohmmeter to check continuity across the pressure switch. Is the pressure switch open?

Yes

IMPORTANT: Before continuing with the diagnosis, the following conditions must be met: B The intake air temperature must be greater than 15°C. (60°F). B The engine coolant temperature must be less than 119°C (246°F). 1. A/C “OFF”. 2. Start the engine and idle for 1 minute. 3. Observe the A/C compressor. Is the A/C compressor clutch engaged even though A/C has not been requested?

1. 2. 3. 4.

Idle the engine. A/C “ON”. Blower “ON”. Observe the A/C compressor.

Is the A/C compressor magnetic clutch engaged? 6

1. 2. 3. 4.

Engine idling. A/C “ON”. Blower “ON”. Observe the “A/C Request” display on the Tech 2. (Refer to the Miscellaneous test)

Does the tool “A/C Request” display indicate “Yes”?

6E–65

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

A/C Clutch Control Circuit Diagnosis (Cont’d) Step

Action

Value(s)

Yes

Temporarily substitute the A/C compressor relay in place of the A/C thermostat relay, then repeat Step 5. Did the “A/C Request” display indicate “Yes”?

—

Go to Step 8

Go to Step 9

Is the action complete?

—

Verify repair

—

Does the blower operate?

—

Go to Step 10

Go to Step 11

Repair the blower. —

Verify repair

—

Go to Step 13

Go to Step 12

—

Verify repair

—

Go to Step 14

Go to Step 17

B+

Go to Step 17

Go to Step 15

—

Go to Step 16

Go to Step 17

—

Verify repair

—

Go to Step 18

Go to Step 19

—

Verify repair

—

B+

Go to Step 21

Go to Step 20

—

Verify repair

—

Replace the original A/C thermostat relay.

Is the action complete? 11

Check for a faulty 10A A/C fuse in the underdash fuse panel. Was the 10A fuse OK?

Check for short circuit and make repairs if necessary. Replace the 10A A/C fuse. Is the action complete?

1. Remove the glove box to gain access to the A/C thermostat. 2. Disconnect the thermostat connector. 3. Attach a fused jumper between ground and the thermostat wire. 4. A/C “ON”. 5. Blower “ON”. Dose A/C request indicate “YES” on the Tech 2?

1. Ignition “ON”. 2. Use a DVM to check voltage at the electronic A/C thermostat. Was voltage equal to the specified value?

Check for open wire between the thermostat and the A/C switch. Was the wire open?

Repair the open wire between the thermostat and the A/C switch. Is the action complete?

Check for an open circuit between A/C thermostat relay and PCM A/C request terminal (F45). Was there an open circuit?

Repair the open circuit between the PCM and A/C thermostat relay. Is the action complete?

1. Ignition “ON”. 2. Use a DVM to check voltage at the A/C pressure switch. Was voltage equal to the specified value?

Repair the open circuit between the 10A A/C fuse and the pressure switch. Is the action complete?

6E–66

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

A/C Clutch Control Circuit Diagnosis (Cont’d) Step

Action

Use an ohmmeter to check continuity between the pressure switch and the A/C thermostat relay. Was the circuit open?

—

Go to Step 22

Go to Step 23

—

Verify repair

—

Go to Step 24

Go to Step 25

—

Verify repair

—

Verify repair

—

B+

Go to Step 28

Go to Step 27

—

Verify repair

—

B+

Go to Step 32

Go to Step 29

—

Go to Step 30

Go to Step 31

—

Verify repair

—

Go to Step 24

Go to Step 25

Repair the damaged pin or terminal. Is the action complete?

Check for damaged pin or terminal at F45 of the PCM. Was a damaged pin or terminal found?

Yes

Repair the open circuit between the pressure switch and the A/C thermostat relay. Is the action complete?

Value(s)

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

1. Remove the A/C compressor relay. 2. Ignition “ON”. 3. Use a DVM to check voltage at both of the wires at the A/C compressor relay socket. Is the voltage equal to the specified value?

Repair the faulty wire between the A/C fuse and the A/C compressor relay . Is the action complete?

1. 2. 3. 4. 5.

A/C compressor relay removed. Engine idling. A/C “ON”. Blower “ON”. Use a DVM to measure voltage between the wire at the A/C compressor relay socket and battery±.

Did the DVM indicate the specified value? 29

Check for an open wire between PCM terminal F4 and the A/C compressor relay. Was the wire open?

Repair the open wire between the PCM and the A/C compressor relay. Is the action complete?

Check for a damaged pin or terminal at F4 of the PCM. Was a damaged pin or a terminal found?

6E–67

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

A/C Clutch Control Circuit Diagnosis (Cont’d) Step

Action

1. A/C compressor relay removed. 2. Connect a fused jumper at the A/C compressor relay socket with either wire. 3. Engine idling. 4. A/C “ON”. 5. Blower “ON”. Did the compressor magnetic clutch engage?

—

Go to Step 35

Go to Step 36

—

Verify repair

—

Verify repair

—

Go to Step 38

Go to Step 39

—

Verify repair

—

Go to Step 40

Go to Step 42

—

Go to Step 41

Go to Step 25

—

Verify repair

—

Verify repair

—

Repair the short to ground between the PCM and A/C compressor relay. Is the action complete?

—

Use a DVM to check for a short to ground between the A/C compressor relay and F4 of the PCM. Was a short detected?

Verify repair

1. Reinstall the A/C compressor relay. 2. Remove the A/C thermostat relay. 3. Engine idling. Is the compressor clutch still engaged when A/C is not selected?

—

Repair the short to voltage between the A/C clutch and A/C compressor relay. Is the action complete?

Go to Step 34

1. Remove the A/C compressor relay. 2. Idle the engine. Is the compressor clutch still engaged when A/C is not selected?

Go to Step 33

Service the compressor clutch or replace the compressor due to a faulty internal overheat switch. Is the action complete?

—

Repair the open circuit between the compressor Clutch and the A/C compressor relay. Is the action complete?

Check for an open circuit between the A/C compressor relay and the A/C clutch. Was an open circuit found?

Yes

Repair the A/C compressor relay. Is the action complete?

Value(s)

Repair the short to ground between the A/C thermostat relay and the electronic thermostat. Is the action complete?

6E–68

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Electronic Ignition System Diagnosis If the engine cranks but will not run or immediately stalls, the Engine Cranks But Will Not Start chart must be used to determine if the failure is in the ignition system or the fuel system. If DTC P0300 through P0306, P0341, or P0336 is set, the appropriate diagnostic trouble code chart must be used for diagnosis. If a misfire is being experienced with no DTC set, refer to the Symptoms section for diagnosis.

Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure

EVAP Canister Purge Solenoid and EVAP Vent Solenoid Valve A continuous purge condition with no purge commanded by the PCM will set a DTC P1441. Refer to the DTC charts for further information.

Visual Check of The Evaporative Emission Canister B If the canister is cracked or damaged, replace the canister. B If fuel is leaking from the canister, replace the canister and check hoses and hose routing.

Fuel Metering System Check Some failures of the fuel metering system will result in an “Engine Cranks But Will Not Run” symptom. If this condition exists, refer to the Cranks But Will Not Run chart. This chart will determine if the problem is caused by the ignition system, the PCM, or the fuel pump electrical circuit. Refer to Fuel System Electrical Test for the fuel system wiring schematic. If there is a fuel delivery problem, refer to Fuel System Diagnosis, which diagnoses the fuel injectors, the fuel pressure regulator, and the fuel pump. If a malfunction occurs in the fuel metering system, it usually results in either a rich HO2S signal or a lean HO2S signal. This condition is indicated by the HO2S voltage, which causes the PCM to change the fuel calculation (fuel injector pulse width) based on the HO2S reading. Changes made to the fuel calculation will be indicated by a change in the long term fuel trim values which can be monitored with a Tech 2. Ideal long term fuel trim values are around 0%; for a lean HO2S signal, the PCM will add fuel, resulting in a fuel trim value above 0%. Some variations in fuel trim values are normal because all engines are not exactly the same. If the evaporative emission canister purge is “ON”, the fuel trim may be as low as –38%. If the fuel trim values are greater than +23%, refer to DTC P0131, DTC P0151, DTC P0171, and DTC 1171 for items which can cause a lean HO2S signal.

Fuel System Pressure Test A fuel system pressure test is part of several of the diagnostic charts and symptom checks. To perform this test, refer to Fuel Systems Diagnosis.

T32003

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Relieve the fuel pressure by connecting the J 34730-1 Fuel Pressure Gauge to the fuel pressure connection on the fuel rail. CAUTION: In order to reduce the risk of fire and personal injury, wrap a shop towel around the fuel pressure connection. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. Place the fuel pressure gauge bleed hose in an approved gasoline container. With the ignition switch “OFF”, open the valve on the fuel pressure gauge. 3. Record the lowest voltage displayed by the DVM after the first second of the test. (During the first second, voltage displayed by the DVM may be inaccurate due to the initial current surge.) Injector Specifications: Resistance (Ohms)

Voltage Specification at 10°C-35°C (50°F-95°F)

11.8 – 12.6

5.7 – 6.6

B The voltage displayed by the DVM should be within the specified range. B The voltage displayed by the DVM may increase throughout the test as the fuel injector windings warm and the resistance of the fuel injector windings changes.

6E–69

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B An erratic voltage reading (large fluctuations in voltage that do not stabilize) indicates an intermittent connection within the fuel injector. 5. Injector Specifications: Highest Acceptable Voltage Reading Above/Below 35°C/10°C (95°F/50°F)

Acceptable Subtracted Value

9.5 Volts

0.6 Volts

7. The Fuel Injector Balance Test portion of this chart (Step 7 through Step 11) checks the mechanical (fuel delivery) portion of the fuel injector. An engine cool-down period of 10 minutes is necessary in order to avoid irregular fuel pressure readings due to “Hot Soak” fuel boiling.

Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)

R262001

CYLINDER

1st Reading (1)

296 kPa (43 psi)

2nd Reading (2)

131 kPa (19 psi)

117 kPa (17 psi)

124 kPa (18 psi)

145 kPa (21 psi)

131 kPa (19 psi)

130 kPa (19 psi)

Amount of Drop (1st Reading–2nd Reading)

165 kPa (24 psi)

179 kPa (26 psi)

172 kPa (25 psi)

151 kPa (22 psi)

165 kPa (24 psi)

166 kPa (24 psi)

Av.drop = 166 kPa/24 psi ± 10 kPa/1.5 psi = 156 – 176 kPa or 22.5 – 25.5 psi

Faulty, Rich (Too Much Fuel Drop)

Faulty, Lean (Too Little Fuel Drop)

NOTE: These figures are examples only.

6E–70

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) Step

Action

Value(s)

Yes

—

Go to Step 2

Go to OBD System Check

10°C (50°F) to 35°C (95°F)

Go to Step 3

Go to Step 5

5.7-6.6 V

Go to Step 4

Go to Step 7

—

Go to Step 7

—

Was the “On-Board Diagnostic (OBD) System Check” performed? 1. Turn the engine “OFF”. NOTE: In order to prevent flooding of a single cylinder and possible engine damage, relieve the fuel pressure before performing the fuel injector coil test procedure. 2. Relieve the fuel pressure. Refer to Test Description Number 2. 3. Connect the J 39021-5V Fuel Injector Tester to B+ and ground, and to the J 39021-90 Injector Switch Box. 4. Connect the injector switch box to the grey fuel injector harness connector located on the front of the EVAP canister bracket. 5. Set the amperage supply selector switch on the fuel injector tester to the “Coil Test” 0.5 amp position. 6. Connect the leads from the J 39200 Digital Voltmeter (DVM) to the injector tester. Refer to the illustrations associated with the test description. 7. Set the DVM to the tenths scale (0.0). 8. Observe the engine coolant temperature. Is the engine coolant temperature within the specified values?

1. Set injector switch box injector #1. 2. Press the “Push to Start Test” button on the fuel injector tester. 3. Observe the voltage reading on the DVM. IMPORTANT: The voltage reading may rise during the test. 4. Record the lowest voltage observed after the first second of the test. 5. Set the injector switch box to the next injector and repeat steps 2, 3, and 4. Did any fuel injector have an erratic voltage reading (large fluctuations in voltage that did not stabilize) or a voltage reading outside of the specified values?

Replace the faulty fuel injector(s). Refer to Fuel Injector. Is the action complete?

6E–71

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) (Cont’d) Step

Action

Value(s)

Yes

Go to Step 6

0.6 V

Go to Step 4

Go to Step 7

Go to Step 8

Go to Fuel System Diagnosis

Go to Step 9

Go to Fuel System Diagnosis

CAUTION: In order to reduce the risk of fire and personal injury, wrap a shop towel around the fuel pressure connection. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge. Place the towel in an approved container when the connection of the fuel pressure gauge is complete. 1. Connect the J 34730-1 Fuel Pressure Gauge to the fuel pressure test port. 2. Energize the fuel pump using the Tech 2. 3. Place the bleed hose of the fuel pressure gauge into an approved gasoline container. 4. Bleed the air out of the fuel pressure gauge. 5. With the fuel pump running, observe the reading on the fuel pressure gauge. Is the fuel pressure within the specified values?

Go to Step 4

1. Identify the highest voltage reading recorded (other than those above 9.5 V). 2. Subtract the voltage reading of each injector from the highest voltage selected in step 1. Repeat until you have a subtracted value for each injector. For any injector, is the subtracted Value in step 2 greater than the specified value?

9.5 V

296-376 kPa (43-55 psi)

Turn the fuel pump “OFF”. Does the fuel pressure remain constant?

—

6E–72

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11) (Cont’d) Step

Action

Value(s)

1. Connect the J 39021-5V Fuel Injector Tester and J 39021-90 Injector Switch Box the fuel injector harness connector. 2. Set the amperage supply selector switch on the fuel injector tester to the “Balance Test” 0.5–2.5 amp position. 3. Using the Tech 2 turn the fuel pump “ON” then “OFF” in order to pressurize the fuel system. 4. Record the fuel pressure indicated by the fuel pressure gauge after the fuel pressure stabilizes. This is the first pressure reading. 5. Energize the fuel injector by depressing the “Push to Start Test” button on the fuel injector tester. 6. Record the fuel pressure indicated by the fuel pressure gauge after the fuel pressure gauge needle has stopped moving. This is the second pressure reading. 7. Repeat steps 1 through 6 for each fuel injector. 8. Subtract the second pressure reading from the first pressure reading for one fuel injector. The result is the pressure drop value. 9. Obtain a pressure drop value for each fuel injector. 10.Add all of the individual pressure drop values. This is the total pressure drop. 11. Divide the total pressure drop by the number of fuel injectors. This is the average pressure drop. Does any fuel injector have a pressure drop value that is either higher than the average pressure drop or lower than the average pressure drop by the specified value?

Yes

10 kPa (1.5 psi)

Go to Step 10

Go to OBD System Check

10 kPa (1.5 psi)

Go to Step 11

Go to Symptoms

—

Verify repair

—

Re-test any fuel injector that does not meet the specification. Refer to the procedure in step 9. NOTE: Do not repeat any portion of this test before running the engine in order to prevent the engine from flooding. Does any fuel injector still have a pressure drop value that is either higher than the average pressure drop or lower than the average pressure drop by the specified value?

Replace the faulty fuel injector(s). Injector. Is the action complete?

Refer to Fuel

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Powertrain Control Module (PCM) Diagnosis To read and clear diagnostic trouble codes, use a Tech 2. IMPORTANT: Use of a Tech 2 is recommended to clear diagnostic trouble codes from the PCM memory. Diagnostic trouble codes can also be cleared by turning the ignition “OFF” and disconnecting the battery power from the PCM for 30 seconds. Turning off the ignition and disconnecting the battery power from the PCM will cause all diagnostic information in the PCM memory to be cleared. Therefore, all the diagnostic tests will have to be re-run. Since the PCM can have a failure which may affect only one circuit, following the diagnostic procedures in this section will determine which circuit has a problem and where it is. If a diagnostic chart indicates that the PCM connections or the PCM is the cause of a problem, and the PCM is replaced, but this does not correct the problem, one of the following may be the reason: B There is a problem with the PCM terminal connections. The terminals may have to be removed from the connector in order to check them properly. B EEPROM program is not correct for the application. Incorrect components or reprogramming the PCM with the wrong EEPROM program may cause a malfunction and may or may not set a DTC. B The problem is intermittent. This means that the problem is not present at the time the system is being checked. In this case, refer to the Symptoms portion of the manual and make a careful physical inspection of all component and wiring associated with the affected system. B There is a shorted solenoid, relay coil, or harness. Solenoids and relays are turned “ON” and “OFF” by the PCM using internal electronic switches called drivers. A shorted solenoid, relay coil, or harness will not damage the PCM but will cause the solenoid or relay to be inoperative.

Multiple PCM Information Sensor DTCs Set Circuit Description The powertrain control module (PCM) monitors various sensors to determine the engine operating conditions. The PCM controls fuel delivery, spark advance, transmission operation, and emission control device operation based on the sensor inputs. The PCM provides a sensor ground to all of the sensors. The PCM applies 5 volts through a pull–up resistor, and determines the status of the following sensors by monitoring the voltage present between the 5–volt supply and the resistor: B The engine coolant temperature (ECT) sensor B The intake air temperature (IAT) sensor B The transmission fluid temperature (TFT) sensor

6E–73

The PCM provides the following sensors with a 5–volt reference and a sensor ground signal: 1 B The exhaust gas recirculating (EGR) pintle position sensor B The manifold absolute pressure (MAP) sensor B The throttle position (TP) sensor 1 B The acceleration position (AP) sensor 1 B The acceleration position (AP) sensor 3 B The Vapor Pressure Sensor 2 B The Crank position (CKP) sensor B The throttle position (TP) sensor 2 B The acceleration position (AP) sensor 2 The PCM monitors the separate feedback signals from these sensors in order to determine their operating status.

Diagnostic Aids IMPORTANT: Be sure to inspect PCM and engine grounds for being secure and clean. A short to voltage in one of the sensor input circuits may cause one or more of the following DTCs to be set: B P0425 B P0108, P1106 B P0406 B P1120, P1515, P1221, P1516, P1635 B P1275, P1639, P1271, P1273 B P1285, P1272, P1273 B P0336, P0337 B P1220, P1515, P1221, P1515, P1516 B P1280, P1271, P1272 IMPORTANT: If a sensor input circuit has been shorted to voltage, ensure that the sensor is not damaged. A damaged sensor will continue to indicate a high or low voltage after the affected circuit has been repaired. If the sensor has been damaged, replace it. An open in the sensor ground circuit between the PCM and the splice will cause one or more of the following DTCs to be set: B P0425 B P0108, P1106 B P0406 B P1120, P1515, P1221, P1516, P1635 B P1275, P1639, P1271, P1273 B P1285, P1272, P1273 B P0336, P0337 B P1220, P1515, P1221, P1515, P1516 B P1280, P1271, P1272 A short to ground in the 5–volt reference A or B circuit will cause one or more of the following DTCs to be set: B P0453 B P0106, P0107, P1107 B P0401, P1404, P0405 B P1120, P1515, P1221, P1516, P1635

6E–74

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B P1275, P1639, P1271, P1273 B P1285, P1272, P1273 B P0336, P0337 B P1220, P1515, P1221, P1515, P1516 B P1280, P1271, P1272 Check for the following conditions: B Poor connection at PCM. Inspect the harness connectors for backed–out terminals, improper mating, broken locks, improperly formed or damage terminals, and a poor terminal–to–wire connection.

B Damaged harness. Inspect the wiring harness for damage. If the harness is not damaged, observe an affected sensor fs displayed value on the Tech 2 with the ignition “ON” and the engine “OFF” while you move the connectors and the wiring harnesses related to the following sensors: B Vapor Pressure (Fuel Tank Pressure) Sensor B MAP Sensor B EGR B TPS1/TPS2 B APS1/APS2/APS3 B CKP

Multiple PCM Information Sensor DTCs Set Step

Action

Go to Step 2

—

Go to Step 3

Go to Step 4

—

Verify repair

—

Go to Step 5

Go to Step 6

—

Verify repair

—

Go to applicable DTC table

Go to Step 7

—

Go to Step 9

Go to Step 8

Check the sensor ground circuit for the following conditions: B A poor connection at the PCM or the affected sensors. B An open between the PCM connector and the affected sensors. Repair the open or the poor connection. Is the action complete?

—

Go to OBD System Check

Repair the open or short.

Is there an open or a poor connection? 5

1. Turn the ignition “OFF”, disconnect the PCM. 2. Turn the ignition “ON”, check the 5 volt reference 1 and 2 circuit for the following conditions: B A poor connection at the PCM. B An open between the PCM connector and the splice. B A short to ground. B A short to voltage.

Is the action complete? 4

Yes

Was the “On-Board (OBD) System Check” performed?

Is there an open or short? 3

Value(s)

Following below the DTCs stored: P1635, P1639 Measure the resistance below the items: B Between EGR sensor supply circuit and Vapor Pressure Sensor supply circuit. B Between MAP sensor supply circuit and Vapor Pressure Sensor supply circuit. B Between Vapor Pressure Sensor supply circuit and PCM harness connector. (5Volt supply circuit) Is the resistance near the specified value?

6E–75

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Multiple PCM Information Sensor DTCs Set (Cont’d) Step

Action

Go to Step 11

Go to Step 10

—

Verify repair

—

Go to Step 13

Go to Step 12

—

Verify repair

—

Go to Step 15

Go to Step 14

—

Verify repair

—

Go to applicable DTC table

Go to Step 16

—

Go to OBD System Check

—

Locate and repair the short circuit in the CKP sensor signal or GND circuit. Is the action complete?

—

1. Disconnect the CKP sensor connector. 2. Ignition “ON”. 3. Measure the voltage of the blow areas: B CKP sensor GND circuit and shield circuit. Does the voltage resistance near the specified value?

—

Locate and repair the open circuit in the CKP or CMP sensor supply circuit. Is the action complete?

Verify repair

Measure the resistance of the blow areas: B Between CKP Sensor supply circuit and PCM harness connector. (5Volt supply circuit) Does the voltage resistance near the specified value?

—

Locate and repair the short circuit in the MAP or EGR or Vapor Pressure sensor signal or GND circuit. Is the action complete?

1. Disconnect the MAP, Vapor pressure sensor and EGR connector. 2. Ignition “ON”. 3. Measure the resistance of the blow areas: B MAP sensor GND circuit. B EGR GND circuit. B Vapor pressure sensor GND circuit. Does the voltage resistance near the specified value?

Yes

Locate and repair the open circuit in the MAP or EGR or Vapor Pressure sensor supply circuit. Is the action complete?

Value(s)

Are more of the following items for DTCs stored? EGR, Vapor Pressure Sensor, MAP, CKP, TPS, APS Replace the PCM. The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6E–76

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Exhaust Gas Recirculation (EGR) Diagnosis An EGR flow check diagnosis of the linear EGR system is covered by DTC P0401. Pintle position error diagnosis is covered by DTC P0402, P0404, P1404, P0405, P0406. If EGR diagnostic trouble codes P0401 and/or P0402, P0404, P1404, P0405, P0406 are encountered, refer to the DTC charts.

Engine Tech 2 Data Definitions and Ranges A/C CLUTCH – Tech 2 Displays ON or OFF – Indicates whether the PCM has commanded the A/C clutch ON. Used in A/C system diagnostic. A/C REQUEST — Tech 2 Displays YES or NO — Indicates the state of the A/C request input circuit from the HVAC controls. The PCM uses the A/C request signal to determine whether A/C compressor operation is being requested. AIR/FUEL RATIO — Tech 2 Range 0.0-25.5 — Air/fuel ratio indicates the PCM commanded value. In closed loop, the air/fuel ratio should normally be displayed around “14.2-14.7”. A lower air/fuel ratio indicates a richer commanded mixture, which may be seen during power enrichment or TWC protection modes. A higher air/fuel ratio indicates a leaner commanded mixture. This can be seen during deceleration fuel mode. AP1 —Tech 2 Range 0%-100% — AP (accelerator pedal) angle is computed by the PCM from the AP sensor voltage. AP angle should display “13%” at idle and “85-89%” at wide open throttle. AP2 —Tech 2 Range 0%-100% — AP (accelerator pedal) angle is computed by the PCM from the AP sensor voltage. AP angle should display “85-89%” at idle and “11-15%” at wide open throttle. AP3 —Tech 2 Range 0%-100% — AP (accelerator pedal) angle is computed by the PCM from the AP sensor voltage. AP angle should display “85-89%” at idle and “32-36%” at wide open throttle. BAROMETRIC PRESSURE — Tech 2 Range 10-105 kPa/0.00-5.00 Volts — The barometric pressure reading is determined from the MAP sensor signal monitored during key up and wide open throttle (WOT) conditions. The barometric pressure is used to compensate for altitude differences and is normally displayed around “61-104” depending on altitude and barometric pressure. CHECK TRANS LAMP — AUTO TRANSMISSION — Indicates the need to check for a DTC with the Tech 2 when the lamp is flashing 0.2 seconds ON and 0.2 seconds OFF. DESIRED EGR POS. — Tech 2 Range 0%-100% — Represents the EGR pintle position that the PCM is commanding. DESIRED IDLE — Tech 2 Range 0-3187 RPM — The idle speed that the PCM is commanding. The PCM will compensate for various engine loads based on engine coolant temperature, to keep the engine at the desired speed.

ECT — (Engine Coolant Temperature) Tech 2 Range –40°C to 151°C (–40°F to 304°F) — The engine coolant temperature (ECT) is mounted in the coolant stream and sends engine temperature information to the PCM. The PCM applies 5 volts to the ECT sensor circuit. The sensor is a thermistor which changes internal resistance as temperature changes. When the sensor is cold (high resistance), the PCM monitors a high signal voltage and interprets that as a cold engine. As the sensor warms (decreasing resistance), the voltage signal will decrease and the PCM will interpret the lower voltage as a warm engine. EGR DUTY CYCLE — Tech 2 Range 0%-100% — Represents the EGR valve driver PWM signal from the PCM. A duty cycle of 0% indicates that no EGR flow is being commanded; a 100% duty cycle indicates maximum EGR flow commanded. EGR FEEDBACK — Tech 2 Range 0.00-5.00 Volts — Indicates the EGR pintle position sensor signal voltage being monitored by the PCM. A low voltage indicates a fully extended pintle (closed valve); a voltage near 5 volts indicates a retracted pintle (open valve). ENGINE LOAD — Tech 2 Range 0%-100% — Engine load is calculated by the PCM from engine speed and MAF sensor readings. Engine load should increase with an increase in RPM or air flow. ENGINE RUN TIME — Tech 2 Range 00:00:00-99:99:99 Hrs:Min:Sec — Indicates the time elapsed since the engine was started. If the engine is stopped, engine run time will be reset to 00:00:00. ENGINE SPEED — Range 0-9999 RPM — Engine speed is computed by the PCM from the 58X reference input. It should remain close to desired idle under various engine loads with engine idling. EVAP PURGE PWM — Tech 2 Range 0%-100% — Represents the PCM commanded PWM duty cycle of the EVAP purge solenoid valve. “0%” displayed indicates no purge; “100%” displayed indicates full purge. FUEL PUMP — Tech 2 Displays ON or OFF — Indicates the PCM commanded state of the fuel pump relay driver circuit. HO2S BANK 1, SEN. 1 — Tech 2 Range 0-1132 mV — Represents the fuel control exhaust oxygen sensor output voltage. Should fluctuate constantly within a range between 10 mV (lean exhaust) and 1000 mV (rich exhaust) while operating in closed loop. HO2S BANK 1, SEN. 2 — Tech 2 Range 0-1000mV — Monitors the exhaust oxygen sensor output voltage. The PCM monitors the operating efficiency of catalytic converter by comparing the output voltages of sensor 1 and sensor 2 in this bank. If the catalytic converter is operating efficiently, the output voltage of sensor 1 will give a greater fluctuation than that of sensor 2. If the PCM detects an abnormal level of voltage fluctuation from sensor 2, a DTC P0420 will be set, indicating that the catalytic converter for this bank is no longer operating efficiently.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS HO2S BANK2, SEN. 1 —Tech 2 Range 0-1132 mV— Represents the fuel control exhaust oxygen sensor output voltage. Should fluctuate constantly within a range between 10mV (lean exhaust) and 1000 mV (rich exhaust) while operating in closed loop. HO2S BANK 2, SEN. 2—Tech 2 Range 0-1000 mV— Monitors the exhaust oxygen sensor output voltage. The PCM monitors the operating efficiency of catalytic converter by comparing the output voltages of sensor 1 and sensor 2 in this bank. If the catalytic converter is operating efficiently, the output voltage of sensor 1 will have a greater fluctuation than that of sensor 2. If the PCM detects an abnormal level of voltage fluctuation from sensor 2, a DTC P0430 will be set, indicating that the catalytic converter for this bank is no longer operating efficiently. HO2S BANK 1, SEN. 1—Tech 2 Displays NOT READY or READY— Indicates the status of the exhaust oxygen sensor. The Tech 2 will indicate that the exhaust oxygen sensor is ready when the PCM detects a fluctuating HO2S voltage sufficient to allow closed loop operation. This will not occur unless the exhaust oxygen sensor is warmed up. HO2S BANK 2, SEN. 1 — Tech 2 Displays NOT READY or READY — Indicates the status of the exhaust oxygen sensor. The Tech 2 will indicate that the exhaust oxygen sensor is ready when the PCM detects a fluctuating HO2S voltage sufficient to allow closed loop operation. This will not occur unless the exhaust oxygen sensor is warmed up. HO2S WARM UP TIME BANK 1, SEN. 1/BANK 1, SEN 2/BANK 2 SEN. 1/BANK 2 SEN. 2 — Tech 2 Range 00:00:00-99:99:99 HRS:MIN:SEC — Indicates warm-up time for each HO2S. The HO2S warm-up time is used for the HO2S heater test. The PCM will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started the PCM will monitor the HO2S voltage. When the HO2S voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that tool much time was required for the HO2S to become active, a DTC will set. If the engine was warm when started, HO2S warm-up will the display “00:00:00”. IAT (INTAKE AIR TEMPERATURE) — Tech 2 Range –40°C to 151°C (–40°F to 304°F) — The PCM converts the resistance of the intake air temperature sensor to degrees. Intake air temperature (IAT) is used by the PCM to adjust fuel delivery and spark timing according to incoming air density. IGNITION 1 — Tech 2 Range 0-25.5 Volts — This represents the system voltage measured by the PCM at its ignition feed.

6E–77

INJ. PULSE BANK 1/INJ. PULSE BANK 2 — Tech 2 Range 0-1000 msec. — Indicates the amount of time the PCM is commanding each injector “ON” during each engine cycle. A longer injector pulse width will cause more fuel to be delivered. Injector pulse width should increase with increased engine load. LONG TERM FUEL TRIM BANK 1/BANK 2 — The long term fuel trim is derived from the short term fuel trim values and represents a long term correction of fuel delivery for the bank in question. A value of 0% indicates that fuel delivery requires no compensation to maintain the PCM commanded air/fuel ratio. A negative value significantly below 0% indicates that the fuel system is rich and fuel delivery is being reduced (decreased injector pulse width). A positive value significantly greater than 0% indicates that a lean condition exists and the PCM is compensating by adding fuel (increased injector pulse width). Because long term fuel trim tends to follow short term fuel trim, a value in the negative range due to canister purge at idle should not be considered unusual. Fuel trim values at maximum authority may indicate an excessively rich or lean system. Fuel System STATUS — Tech 2 Displays OPEN or CLOSED — “CLOSED” indicates that the PCM is controlling fuel delivery according to oxygen sensor voltage. In “OPEN” the PCM ignores the oxygen sensor voltage and bases the amount of fuel to be delivered on TP sensor, engine coolant, and MAF sensor inputs only. MAF — Tech 2 Range 0.0-512 gm/s — MAF (mass air flow) is the MAF input frequency converted to grams of air per second. This indicates the amount of air entering the engine. MAP — Tech 2 Range 10-105 kPa (0.00-4.97 Volts) — The manifold absolute pressure (MAP) sensor measures the change in the intake manifold pressure from engine load, EGR flow, and speed changes. As intake manifold pressure increases, intake vacuum decreases, resulting in a higher MAP sensor voltage and kPa reading. The MAP sensor signal is used to monitor intake manifold pressure changes during the EGR flow test, to update the BARO reading, and as an enabling factor for several of the diagnostics. MIL — Tech 2 Displays ON or OFF — Indicates the PCM commanded state of the malfunction indicator lamp. MISFIRE CUR. CYL. #1 /#2 /#3 /#4 / #5 / #6 — Tech 2 Range 0-255 Counts — The misfire current counters increase at a rate according to the number of the possible misfires being detected on each cylinder. The counters may normally display some activity, but the activity should be nearly equal for all the cylinders.

6E–78

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

MISFIRE CUR. CYL. #1 /#2 /#3 /#4 / #5 / #6 — Tech 2 Range 0-65535 Counts — The misfire history counters display the relative level of misfire that has been detected on each cylinder. The misfire history counters will not update or show any activity until a misfire DTC (P0300) has become active. MISFIRE FAILURES SINCE FIRST FAIL — Tech 2 Range 0-65535 Counts — Indicates the number of 200 crankshaft revolution sample periods during which the level of misfire was sufficiently high to report a fail. MISFIRE PASSES SINCE FIRST FAIL — Tech 2 Range 0-65535 Counts — Indicates the number of 200 crankshaft revolution sample periods during which the level of misfire was sufficiently low to report a pass. POWER ENRICHMENT — Tech 2 Displays ACTIVE or INACTIVE — “ACTIVE” displayed indicates that the PCM has detected conditions appropriate to operate in power enrichment mode. The PCM will command power enrichment mode when a large increase in throttle position and load is detected. While in power enrichment mode, the PCM will increase the amount of fuel delivered by entering open loop and increasing the injector pulse width. This is done to prevent a possible sag or hesitation from occurring during acceleration. SPARK — Tech 2 Range –64° to 64° — Displays the amount of spark advance being commanded by the PCM on the IC circuit. START-UP ECT — Tech 2 Range –40°C to 151°C (–40°F to 304°F) — Indicates the engine coolant temperature at the time that the vehicle was started. Used by the HO2S diagnostic to determine if the last start-up was a cold start. START-UP IAT — Tech 2 Range –40°C to 151°C (–40°F to 304°F) — Indicates the intake air temperature at the time that the vehicle was started. Used by the HO2S diagnostic to determine if the last start-up was a cold start. TOTAL MISFIRE CURRENT COUNT — Tech 2 Range 0-255 — Indicates the total number of cylinder firing events that were detected as being misfires during the last 200 crankshaft revolution sample period. TP — Tech 2 Range 0%-100% — TP (throttle position) angle is computed by the PCM from the TP sensor voltage. TP angle should display “3-5%” at idle and “100%” at wide open throttle. CATALYST PROTECTION MODE — Tech 2 Displays YES or NO — “YES” displayed indicates that the PCM has detected conditions appropriate to operate in TWC protection mode. The PCM will decrease the air/fuel ratio to a value that depends on mass air flow (higher mass air flow = lower air/fuel ratio).

UPSHIFT LAMP (MANUAL TRANSMISSION) VEHICLE SPEED — Tech 2 Range 0-255 km/h (0-155 mph) — The vehicle speed sensor signal is converted into km/h and mph for display. WEAK CYLINDER — Tech 2 Displays Cylinder Number — This indicates that the PCM has detected crankshaft speed variations that indicate 2% or more cylinder firing events are misfires.

Typical Scan Data Values Use the Typical Scan Data Values Table only after the On-Board Diagnostic System Check has been completed, no DTC(s) were noted, and you have determined that the on-board diagnostics are functioning properly. Tech 2 values from a properly-running engine may be used for comparison with the engine you are diagnosing. The typical scan data values represent values that would be seen on a normally-running engine. NOTE: A Tech 2 that displays faulty data should not be used, and the problem should be reported to the Tech 2 manufacturer. Use of a faulty Tech 2 can result in misdiagnosis and unnecessary replacement of parts. Only the parameters listed below are referred to in this service manual for use in diagnosis. For further information on using the Tech 2 to diagnose the PCM and related sensors, refer to the applicable reference section listed below. If all values are within the typical range described below, refer to the Symptoms section for diagnosis.

Test Conditions Engine running, lower radiator hose hot, transmission in park or neutral, closed loop, accessories off, brake not applied and air conditioning off.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–79

3.5L V-6 Engine (Automatic and Manual Transmission) Tech 2 Parameter

Data List

Units Displayed

Typical Data Values (IDLE)

Typical Data Values (2500 RPM)

Refer To

A/C Clutch Relay

Engine

On/Off

Off

General Description and Operation, A/C Clutch Circuit Operation

A/C Request

Engine

Yes/No

General Description and Operation, A/C Request Signal

Air/Fuel Ratio

Engine

Ratio: _ to 1

14.7

General Description and Operation, Fuel System Metering Purpose

APP Sensor1

Engine

Percent

11–13

35–40

General Description and Operation

APP Sensor2

Engine

Percent

87–88

60–65

General Description and Operation

APP Sensor3

Engine

Percent

87–88

50–57

General Description and Operation

Barometric Pressure

Engine

kPa

61-104 (depends on altitude and barometric pressure)

General Description and Operation

Brake Light Switch

Engine

Open 0V/Closed 12V

Open 0V

Refer to Section 5

Check Trans Lamp (Auto Trans)

Engine

On/Off

Off

4L30-E Automatic Transmission Diagnosis

Cruise Main Switch

Engine

Active/Inactive

Inactive

Refer to Section 10

Cruise Set Switch

Engine

Active/Inactive

Inactive

Refer to Section 10

Cruise Cancel Switch

Engine

Active/Inactive

Inactive

Refer to Section 10

Cruise Resume Switch

Engine

Active/Inactive

Inactive

Refer to Section 10

Decel Fuel Cutoff

Engine

Active/Inactive

Inactive

General Description and Operation, Deceleration Mode

Desired EGR Position

Engine

Percent

General Description and Operation, EGR Pintle Position Sensor

Desired Idle Speed

Engine

RPM

750

800

General Description and Operation

ECT (Engine Coolant Temp)

Engine

Degrees C, Degrees F

80-100°C (176-212°F)

General Description and Operation, Engine Coolant Temperature (ECT) Sensor

EGR Closed Pintle Position

Engine

Steps

20-40

General Description and Operation, EGR Pintle Position Sensor

6E–80

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Tech 2 Parameter

Data List

Units Displayed

EGR Duty Cycle

Engine

Percent

EGR Feedback

Engine

Volts

0.45-0.80

EGR Normalized

Engine

Percent

Engine Load

Engine

Percent

2.0% — 5.5%

8.0% — 16.0%

Time From Start

Engine

Sec

Varies. Resets at each engine start.

Engine Speed

Engine

Within –50 to +100 of “Desired Idle”

Actual engine speed

RPM

Typical Data Values (IDLE)

Typical Data Values (2500 RPM)

Refer To

General Description and Operation, Linear EGR Operation and Results of Incorrect Operation — — General Description and Operation, Mass Air Flow (MAF) Sensor —

—

EVAP Purge Solenoid

Engine

Percent

Diagnosis, EVAP Emission Canister Purge Valve Check

EVAP Vent Valve

Engine

On/Off

Off

Diagnosis, EVAP Canister Purge Solenoid and EVAP Vacuum Switch and Visual Check; DTCs: P1441, P1442

Fuel System Status

Engine

Open Loop/Closed Loop

Closed Loop

General Description

Fuel Level

Engine

Percent

Fuel Level Sensor

Engine

Volts

Fuel Tank (Vapor) Pressure Sensor

Engine

Volts

Fuel Pump

Engine

On/Off

Engine Fuel

HO2S Bank 1 Sen.1 (millivolts)

O2 Sensor Data

Millivolts

50-950 changing quickly

50-950, always changing quickly

General Description and Operation, Fuel control HO2S

HO2S Bank 1 Sen.2 (millivolts) (Auto Trans)

O2 Sensor Data

Millivolts

200-700 changing slowly

250-650 changing slowly

General Description and Operation, Fuel Metering System

HO2S Bank 1 Sen.2 (millivolts) (Manual Trans)

O2 Sensor Data

Millivolts

50-950 changing quickly

General Description and Operation, Fuel Metering System

HO2S Bank 1 Sen.3 (millivolts) (Manual Trans)

O2 Sensor Data

Millivolts

200-700 changing slowly

250-650 changing slowly

General Description and Operation, Catalyst Monitor Heated Oxygen Sensor (Manual Trans)

—

1.02 – 1.86

in. H2O

1.02 – 2.57

—

Engine Fuel Engine Fuel General Description and Operation

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Tech 2 Parameter

Typical Data Values (IDLE)

Typical Data Values (2500 RPM)

6E–81

Data List

Units Displayed

Refer To

HO2S Bank 2 Sen.1 (millivolts)

O2 Sensor Data

Millivolts

50-950 changing quickly

General Description and Operation, Fuel Control HO2S

HO2S Bank 2 Sen.2 (millivolts) (Auto trans)

O2 Sensor Data

Millivolts

200-700 changing slowly

250-650 changing slowly

General Description and Operation, Fuel Metering System

HO2S Bank 1 Sen.1 (ready/not ready)

O2 Sensor Data

Ready Yes/No

Ready Yes

General Description and Operation, Fuel Control HO2S; DTC: P0135

HO2S Bank 2 Sen.1 (ready/not ready)

O2 Sensor Data

Ready Yes/No

Ready Yes

General Description and Operation, Fuel Control HO2S

HO2S Warm-Up Time Bank 1 Sen.1

O2 Sensor Data

Seconds

25-45

General Description and Operation, Fuel Control HO2S

HO2S Warm-Up Time Bank 1 Sen.2

O2 Sensor Data

Seconds

60-100

General Description and Operation, Fuel Control HO2S

HO2S Warm-Up Time Bank 2 Sen.1

O2 Sensor Data

Seconds

25-45

General Description and Operation, Fuel Control HO2S

HO2S Warm-Up Time Bank 2 Sen.2

O2 Sensor Data

Seconds

60-100

General Description and Operation, Catalyst Monitor Heated Oxygen Sensor (Auto Trans)

IAT (Intake Air Temp)

Engine

Degrees C, Degrees F

0-100°C, depends on underhood temperature

0-80°C, depends on underhood temperature

General Description and Operation, Intake Air Temperature (IAT) Sensor

Illumination Switch

Engine

Closed 0V/Open 12V

Closed 0V

Refer to Section 8

Ignition Voltage

Engine

Volts

12.8-14.1

General Description and Operation, Electronic Ignition System

Inj. Pulse Bank 1

Engine

Milliseconds

2.0-4.0

2.5-4.0

General Description, Fuel Metering, Fuel Injector

Inj. Pulse Bank 2

Engine

Milliseconds

2.0-4.0

2.5-4.0

General Description, Fuel Metering, Fuel Injector

Knock Present

Engine

No/Yes

General Description and ION Sensing Module

Knock Signal

Engine

Percent

1∼4

General Description and ION Sensing Module

Knock Sensor Retard

Engine

°CA

General Description and ION Sensing Module

Knock Counter

Engine

Counts

—

General Description

Long Term FT Bank 1 (Long Term Fuel Trim)

Misfire

Counts and Percentage

100 to 150 counts, –22% to +17%

Diagnosis, Fuel Trim System Monitor; DTCs: P0171, P0172

6E–82

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Tech 2 Parameter

Data List

Units Displayed

Typical Data Values (IDLE)

Typical Data Values (2500 RPM)

Refer To

Long Term FT Bank 2 (Long Term Fuel Trim)

Misfire

Counts and Percentage

100 to 150 counts, –22% to +17%

Diagnosis, Fuel Trim System Monitor; DTCs: P0171

MAF (Mass Air Flow)

Engine

Grams per second

2.85-6.65

9.5-16.5

General Description and Operation, MAF; DTCs: P101, P0102, P0103

MAP kPa (Manifold Absolute Pressure)

Engine

Kilopascals

23-40

19-32

Volts

0.65-1.32

0.46-1.10

General Description and Operation, Manifold Absolute Pressure (MAP) Sensor; DTCs: P0106, P0107, P0108

MIL

Engine

On/Off

Off

On-Board Diagnostic System Check

Misfire Cur. Cyl #1

Misfire

Counts

0-2

DTC P0300

Misfire Cur. Cyl #2

Misfire

Counts

0-2

DTC P0300

Misfire Cur. Cyl #3

Misfire

Counts

0-2

DTC P0300

Misfire Cur. Cyl #4

Misfire

Counts

0-2

DTC P0300

Misfire Cur. Cyl #5

Misfire

Counts

0-2

DTC P0300

Misfire Cur. Cyl #6

Misfire

Counts

0-2

DTC P0300

Misfire Hist. Cyl #1

Misfire

Counts

DTC P0300

Misfire Hist. Cyl #2

Misfire

Counts

DTC P0300

Misfire Hist. Cyl #3

Misfire

Counts

DTC P0300

Misfire Hist. Cyl #4

Misfire

Counts

DTC P0300

Misfire Hist. Cyl #5

Misfire

Counts

DTC P0300

Misfire Hist. Cyl #6

Misfire

Counts

DTC P0300

Misfire Failures Since First Fail

Misfire

Counts

DTC P0300

Misfire Passes Since First Fail

Misfire

Counts

DTC P0300

PNP (Park/Neutral Position)

Engine

P-N / R-D-3-2-L

P-N

4L30-E Automatic Transmission Diagnosis

Power Enrichment

Engine

NO/YES

General Description and Operation, Acceleration Mode

PSP Switch (Power Steering Pressure)

Engine

Normal/Hi

Normal Pressure

Refer to 2A Section

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Tech 2 Parameter

Typical Data Values (IDLE)

Data List

Units Displayed

Spark (Advance)

Engine

Degrees Before Top Dead Center

15-22

34-44

General Description and Operation, Electronic Ignition System

Start-Up ECT (Engine Coolant Temp)

Engine

Degrees C, Degrees F

Depends on engine coolant temperature at time of start-up

General Description and Operation, Engine Coolant Temperature (ECT) Sensor

Start-Up IAT (Intake Air Temp)

Engine

Degrees C, Degrees F

Depends on intake air temperature at time of start-up

General Description and Operation, Intake Air Temperature (IAT) Sensor

TCC Cruise Brake Switch

Engine

Active/Inactive

Active

Refer to Section 10

Total Misfire Current Count

Misfire

Counts

0-5

DTC P0300

TP Sensor 1 (Throttle Position Sensor 1)

Engine

Percentage

8–12

28–36

General Description and Operation, Throttle Position (TP) Sensor

TP Sensor 2 (Throttle Position Sensor 2)

Engine

Percentage

8–12

28–36

General Description and Operation, Throttle Position (TP) Sensor

Throttle at Idle

Engine

No/Yes

Yes

General Description and Operation, Throttle Position (TP) Sensor

Upshift Lamp (manual trans)

Engine

On/Off

Off

Manual Transmission

Vehicle Speed

Engine

MPH / km/h

4L30-E Automatic Transmission Diagnosis

Weak Cylinder

Misfire

Cylinder #

—

Typical Data Values (2500 RPM)

6E–83

—

Refer To

DTC P0300

6E–84

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

No Malfunction Indicator Lamp (MIL)

060R200049

Circuit Description

Test Description

The “Check Engine” lamp (MIL) should always be illuminated and steady with the ignition “ON” and the engine stopped. Ignition feed voltage is supplied to the MIL bulb through the meter fuse. The powertrain control module (PCM) turns the MIL “ON” by grounding the MIL driver circuit.

Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. A “No MIL” condition accompanied by a no-start condition suggests a faulty PCM ignition feed or battery feed circuit. 9. Using a test light connected to B+, probe each of the PCM ground terminals to ensure that a good ground is present. Refer to PCM Terminal End View for terminal locations of the PCM ground circuits. 12.In this step, temporarily substitute a known good relay for the PCM relay. The horn relay is nearby, and it can be verified as “good” simply by honking the horn. Replace the horn relay after completing this step. 17.This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures Powertrain Control Module (PCM) and Sensors.

Diagnostic Aids An intermittent MIL may be cased by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: B Inspect the PCM harness and connections for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. B If the engine runs OK, check for a faulty light bulb, an open in the MIL driver circuit, or an open in the instrument cluster ignition feed. B If the engine cranks but will not run, check for an open PCM ignition or battery feed, or a poor PCM to engine ground.

6E–85

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

No Malfunction Indicator Lamp (MIL) Step

Action

1. 2. 3. 4.

Go to Step 5

Go to Step 13

—

Go to Step 10

Go to Step 11

—

Go to Step 7

Go to Step 15

—

Go to Step 8

Go to Step 12

—

Go to Step 9

Go to Step 14

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 17

—

Verify repair

Go to Step 18

—

Verify repair

Go to Step 13

—

Verify repair

—

Verify repair

—

Substitute a known “good” relay for the PCM main relay. Repair the open in the ignition feed circuit. Is the action complete?

—

Check for an open MIL driver circuit between the PCM and the MIL.

Was the malfunction fixed? 13

Go to Step 16

Check for damaged terminals at the PCM.

Was a problem found? 12

Go to Step 4

Check for a faulty PCM ground connection.

Was a problem found? 11

—

Probe the battery feed circuit at the PCM harness connector with a test light to ground.

Was a problem found? 10

Go to Step 6

Ignition “OFF”. Disconnect the PCM. Ignition “ON”. Probe the ignition feed circuit at the PCM harness connector with a test light to ground.

Is the test light “ON”? 9

Go to Step 3

Check the PCM ignition feed and battery feed fuses (15 A engine fuse and 15 A PCM fuse).

Is the test light “ON”? 8

—

1. Ignition “OFF”. 2. Disconnect the PCM. 3. Jumper the MIL driver circuit at the PCM connector to ground. 4. Ignition “ON”.

Are both fuses OK? 7

Go to Step 2

Ignition “ON”, probe the ignition feed circuit at the cluster connector with a test light to ground.

Is the MIL “ON”? 6

—

Go to OBD System Check

Check the meter fuse for the instrument cluster ignition feed circuit.

Is the test light “ON”? 5

Attempt to start the engine.

Is the fuse OK? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the engine start? 3

Value(s)

Locate and repair the open PCM battery feed circuit. Is the action complete?

6E–86

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

No Malfunction Indicator Lamp (MIL) (Cont’d) Step

Action

Locate and repair the short to ground in the PCM ignition feed circuit or PCM battery feed circuit. Is the action complete?

Yes

—

Verify repair

—

Verify repair

—

Verify repair

—

Verify repair

Go to Instrument Panel in Electrical Diagnosis

Locate and repair the short to ground in the ignition feed circuit to the instrument cluster, and replace the fuse. Is the action complete?

Value(s)

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to PCM in ON-Vehicle Service for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Check the MIL driver circuit for a poor connection at the instrument panel connector. Was a problem found? —

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–87

Malfunction Indicator Lamp (MIL) “ON” Steady

060R200049

Circuit description

Test Description

The malfunction indicator lamp (MIL) should always be illuminated and steady with ignition “ON” and the engine stopped. Ignition feed voltage is supplied directly to the MIL indicator. The powertrain control module (PCM) turns the MIL “ON” by grounding the MIL driver circuit. The MIL should not remain “ON” with the engine running and no DTC(s) set. A steady MIL with the engine running and no DTC(s) suggests a short to ground in the MIL driver circuit.

Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If the MIL does not remain “ON” when the PCM is disconnected, the MIL driver wiring is not faulty. 3. If the MIL driver circuit is OK, the instrument panel cluster is faulty. 6. This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors.

Diagnostic Aids An intermittent may be caused by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: B Poor connection or damaged harness – Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness.

6E–88

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Malfunction Indicator Lamp (MIL) “ON” Steady Step

Action

Go to Step 2

—

Go to Step 3

Go to Step 5

—

Go to OBD System Check

Go to Step 4

—

Go to OBD System Check

—

Go to OBD System Check

Go to Step 6

—

Go to OBD System Check

—

Replace the instrument panel cluster.

1. Ignition “OFF”, reconnect the PCM. 2. Ignition “ON”, reprogram the EEPROM. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. 3. Using the Tech 2 output controls function, select MIL dash lamp control and command the MIL “OFF”. (Refer to the Miscellaneous test) Did the MIL turn “OFF”?

—

Go to OBD System Check

1. Ignition “OFF”, disconnect the instrument panel cluster. 2. Check the MIL driver circuit between the PCM and the instrument panel cluster for a short to ground. 3. If a problem is found, repair as necessary.

Is the action complete? 5

1. Ignition “OFF”, disconnect PCM. 2. Ignition “ON”, observe the MIL (Service Engine Soon lamp).

Was the MIL driver circuit shorted to ground? 4

Yes

Was the “On-Board diagnostic (OBD) System Check” performed?

Is the MIL “ON”? 3

Value(s)

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–89

No Reduced Power Lamp (RPL)

060R200073

Circuit Description The Reduced Power lamp (RPL) should always be illuminated and steady with the ignition “ON” and the engine stopped. Ignition feed voltage is supplied to the RPL bulb through the meter fuse. The powertrain control module (PCM) orders the RPL “ON” signal for Multiplex Control Unit. When Multiplex Control Unit is received RPL “ON” signal that turn RPL “ON” by grounding the RPL driver circuit.

Diagnostic Aids An intermittent RPL may be caused by a poor connection, rubbed-through wire insulation, or a wire broken inside the insulation. Check for the following items: B Inspect the PCM and Multiplex Control Unit harness and connections for improper mating, broken locks, improperly formed or damaged terminals, poor terminal to wire connection, and damaged harness. B If the engine runs OK, check for a faulty light bulb, an open in the MIL driver circuit, or an open in the instrument cluster ignition feed. B If the engine cranks but will not run, check for an open PCM ignition or battery feed, or a poor PCM to engine ground.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart.

2. A “No RPL” condition accompanied by a no–start condition suggests a faulty PCM ignition feed or battery feed circuit. 9. Using a test light connected to B+, probe each of the Multiplex Control Unit ground terminals to ensure that a good ground is present. Refer to Multiplex Control Unit Terminal End View for terminal locations of the Unit Terminal End View for terminal locations of the Multiplex Control Unit ground circuits. 12.Using a test light connected to B+, probe each of the PCM ground terminals to ensure that a good ground is present. Refer to PCM Terminal End View for terminal locations of the PCM ground circuits. 21.In this step, temporarily substitute a known good relay for the PCM relay. The horn relay is nearby, and it can be verified as “good” simply by honking the horn. Replace the horn relay after completing this step. 24.This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors.

6E–90

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

No Reduced Power Lamp (RPL) Step

Action

Go to Step 14

Go to Step 4

—

Go to Step 5

Go to Step 15

—

Go to Step 16

Go to Step 6

—

Go to Step 7

Go to Instrument Panel in Electrical Diagnosis

—

Go to Step 8

Go to Step 17

—

Go to Step 18

Go to Step 9

—

Go to Step 19

Go to Step 10

—

Go to Step 20

Go to Step 11

—

Go to Step 12

Go to Step 21

Check the Multiplex Control Unit ground connection and circuit. Check for damaged terminals at the Multiplex Control Unit. Was a problem found?

—

1. Ignition “OFF”. 2. Disconnect the PCM. 3. Check the circuit (Lamp driver Circuit) between PCM and Multiplex Control Unit.

Was a problem found? 10

Go to Step 11

1. Ignition “OFF”. 2. Probe the ignition feed circuit at the Multiplex Control Unit connector with a test light to ground. 3. Ignition “ON”.

Was a problem found? 9

Go to Step 3

1. Reconnect the cluster meter connector. 2. Disconnect the Multiplex Control Unit. 3. Jumper the RPL driver circuit at the Multiplex Control Unit connector to ground. 4. Ignition “ON”.

Is the test light “ON”? 8

—

1. Ignition “OFF”. 2. Disconnect the Multiplex Control Unit. 3. Check the circuit (Lamp driver Circuit) between PCM and Multiplex Control Unit.

Is the RPL “ON”? 7

Go to Step 2

1. Ignition ”OFF”. 2. Disconnect the cluster meter connector. 3. Ignition “ON”, Probe the ignition feed circuit at the cluster connector with a test light to ground.

Was a problem found? 6

—

Go to OBD System Check

Check the following fuses: MAIN(100A), B+1(60A), B+2(50A), METER(15A), ECM(15A) , ENGINE(15A)

Is the test light “ON”? 5

Attempt to start the engine.

Was a problem found? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” Performed?

Does the engine start? 3

Value(s)

1. Ignition “ON”. 2. Probe the ignition feed circuit at the PCM harness connector with a test light to ground. Is the test light “ON”?

6E–91

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

No Reduced Power Lamp (RPL) (Cont’d) Step

Action

Value(s)

1. Ignition “OFF”. 2. Check for a faulty PCM ground connection and Circuit. Was a problem found?

—

Verify repair

—

Verify repair

—

Verify repair

—

Verify repair

—

Verify repair

—

Verify repair

—

Verify repair

Go to Step 22

—

Verify repair

—

Verify repair

—

Verify repair

—

Locate and repair the ground connection for PCM circuit. Is the action complete?

—

Repair the open in the ignition feed circuit. Is the action complete?

Verify repair

Substitute a known “good” relay for the PCM main relay. Was the malfunction fixed?

—

Reconnect the Multiplex Control Unit. circuit. Is the action complete?

Go to Step 25

Locate and repair the ground connection for Multiplex Control Unit circuit. Is the action complete?

Go to Step 24

Locate and repair the between Multiplex Control Unit and PCM open circuit. Is the action complete?

—

Locate and repair the circuit Multiplex Control Unit battery feed open circuit. Is the action complete?

Go to Step 13

Locate and repair the circuit between cluster meter and Multiplex Control Unit open circuit. Is the action complete?

Go to Step 23

Locate and repair the cluster meter battery feed open circuit. Is the action complete?

—

Replace the fuse. Is the action complete?

Check for damaged terminals at the PCM. Was a problem found?

Yes

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6E–92

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

No Reduced Power Lamp (RPL) (Cont’d) Step

Action

1. 2. 3. 4. 5.

—

Verify repair

Go to Step 26

—

Go to Step 27

Go to Step 24

—

Go to Step 25

—

1. Ignition “OFF”. 2. Disconnect the PCM. 3. Check the circuit (DLC line) between PCM and DLC. Was a problem found?

Yes

Ignition “OFF”. Reconnect all connectors. Install the Tech 2. Ignition “ON”. Using the Tech 2 output controls function, select RPL dash lamp control and command the RPL “ON”. (Refer to the Miscellaneous test)

Did the RPL turn “ON”? 26

Value(s)

Locate and repair the circuit the between PCM and DLC. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–93

Reduced Power Lamp (RPL) “ON” Steady

060R200073

Diagnostic Aids An intermittent RPL may be caused by a poor connection, rubbed through wire insulation, or a wire broken inside the insulation. Check for the following items:

B Poor connection or damaged harness – Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, poor terminal to wire connection, and damaged harness.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If the RPL does not remain “ON” when the Multiplex Control Unit is disconnected, the RPL driver wiring is not faulty. 3. If the RPL driver circuit is OK, the instrument panel cluster is faulty. 10. This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors.

6E–94

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Reduced Power Lamp (RPL) “ON” Steady Step

Action

1. 2. 3. 4.

Go to Step 3

Go to Step 4

—

Verify repair

Go to Step 4

—

Verify repair

Go to Step 5

—

Go to Step 6

Go to Step 7

—

Go to Step 7

—

Go to Verify repair

Go to Step 8

—

Go to Step 9

Go to Step 10

Locate and repair the circuit between Multiplex Control Unit and PCM open circuit. 1. Install the Tech 2 2. Ignition “ON”. 3. Using the Tech 2 output controls function, select RPL dash lamp control and command the RPL “OFF”. (Refer to the Miscellaneous test) Did the MIL turn “OFF”?

—

1. Ignition “OFF”. 2. Disconnect the PCM. 3. Check the circuit (Lamp driver Circuit) between PCM and Multiplex Control Unit.

Is the action complete? 7

Go to Step 2

Replace the Multiplex Control Unit. Install the Tech 2 Ignition “ON”. Using the Tech 2 output controls function, select RPL dash lamp control and command the RPL “OFF”. (Refer to the Miscellaneous test)

Was a problem found? 6

—

Go to OBD System Check

1. Ignition “OFF”, disconnect the instrument panel cluster. 2. Check the RPL driver circuit between the Multiplex Control Unit and the instrument panel cluster for a short to ground. 3. If a problem is found, repair as necessary.

Did the MIL turn “OFF”? 5

1. Ignition “OFF”, disconnect Multiplex Control Unit. 2. Ignition “ON”, observe the RPL (Reduced Power Lamp).

Was the RPL driver circuit shorted to ground? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is the RPL “ON”? 3

Value(s)

1. Ignition ”OFF”. 2. Disconnect the PCM. 3. Check the circuit (DLC line) between PCM and DLC. Was a problem found?

6E–95

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Reduced Power Lamp (RPL) “ON” Steady (Cont’d) Step

Action

Value(s)

Locate and repair the circuit between PCM and DLC. Is the action complete?

Yes

—

Go to Step 2

—

Go to OBD System Check

—

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6E–96

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Starter Control System Check

060R200062

Circuit Description Starter control system is controlled by the Power Train Control Module (PCM). The PCM monitors starter switch signal (“START”position ) and MODE switch (park or neutral) signal. PCM is operated by the ignition switch. Ignition feed voltage is supplied to the MODE switch and starter relay through the engine fuse. PCM turns the starter relay “ON” by grounding the starter relay driver circuit. The starter motor is operated until 30 seconds based on starter relay signal.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Mis routed harness.

B Rubbed through wire insulation. B Broken wire inside the insulation.

Test Description 2.If Anti-theft system is “ON”, PCM does not operate starter control system. 19.Refer to 6D section. 21.Refer to 6D section. 24.This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is replaced,the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors.

Starter Control System Check Step

Action

Value(s)

Yes

—

Go to Step 2

Go to OBD System Check

—

Go to Step 3

Go to Step 7

Was the “On-Board (OBD) System Check” performed?

Was the “Anti-theft System” normally? Refer to Owner’s Manual.

6E–97

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Starter Control System Check (Cont’d) Step

Action

1. 2. 3. 4.

Go to Step 5

Go to Step 6

—

Go to DTCs Chart

—

Go to Step 27

Go to Step 7

—

Go to Step 8

Go to Step 9

—

Verify repair

—

Go to Step 10

Go to Step 11

—

Verify repair

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Go to Step 14

Go to Step 15

—

Verify repair

—

Go to Step 16

Go to Step 17

1. Probe the anti-theft module circuit to GND. 2. Turn the key to “START” position. Is the engine cranking?

—

Repair the circuit as necessary. Is the action complete?

Go to Step 4

Check the anti–theft module circuit. Check the circuit between PCM and anti–theft module. Is the problem found?

Go to Step 27

1. Gear position is “park or neutral”. 2. Do not depress the accelerator pedal. 3. Turn the key to “START” position. Is the engine cranking?

—

Review and record for Tech 2 Failure Records data and DTCs. Were any DTCs information stored?

Check the anti-theft system. Refer to section 8H anti-theft. Check the starter relay, starter fuse and engine fuse. Is the problem found?

Replace the starter relay, starter fuse and engine fuse. Is the action complete?

1. Install the Tech 2. 2. Select “Display DTCs” with the Tech 2. Are any DTCs stored?

Yes

Gear position is “park or neutral”. Do not depress the accelerator pedal. Turn the key to “START” position. Release the key switch to the to “ON” position.

Does the engine crank? 4

Value(s)

Check the starter circuit. 1. Ignition is ”OFF”. 2. Remove the starter relay. 3. Check the circuit between starter relay and starter motor. Is the problem found?

Repair the circuit as necessary. Is the action complete?

Check the starter circuit. 1. Remove the main fuse (100A). 2. Check the circuit between main fuse and starter motor. 3. Check the circuit between GND and starter motor. Is the problem found?

6E–98

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Starter Control System Check (Cont’d) Step

Action

Yes

Repair the circuit as necessary. Is the action complete?

Value(s)

—

Verify repair

—

Go to Step 18

Go to Step 19

—

Verify repair

—

Go to Step 20

Go to Step 21

—

Verify repair

—

Go to Step 22

Go to Step 23

—

Verify repair

—

Go to Step 24

Go to Step 25

Verify repair

—

Go to Step 26

Go to Step 28

Verify repair

—

Check the starter signal circuit. 1. Remove the starter fuse (10A). 2. Disconnect the PCM. 3. Check the circuit between Powertrain Control module (PCM) and starter fuse. Is the problem found?

Repair the circuit as necessary. Is the action complete?

Check the “park or neutral” signal circuit. 1. Remove the starter relay. 2. Disconnect the PCM. 3. Check the circuit between PCM and starter relay. Is the problem found?

Repair the circuit as necessary. Is the action complete?

Check the “park or neutral” signal circuit. 1. Remove the starter relay. 2. Disconnect the MODE switch. 3. Remove the engine (15A) fuse and back up (15A) fuse. 4. Check the circuit between MODE switch and starter relay. 5. Check the circuit between MODE switch and engine fuse. 6. Check the circuit between MODE switch and PCM. 7. Check the circuit between MODE switch and back up fuse. Is the problem found?

Repair the circuit as necessary. Is the action complete?

Check the MODE switch. Refer to 4L30E Automatic transmission. Is the problem found?

Replace the MODE switch. Is the action complete?

—

Check the starter motor. Refer to Section 6D Engine Electrical. Is the problem found?

Replace the starter motor. Is the action complete?

—

6E–99

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Starter Control System Check (Cont’d) Step

Action

Value(s)

Yes

10 sec.

System OK

Go to the Engine Cranks But Will Not Run Chart

—

Verify repair

—

Check the engine start times. Is the engine start time less than specified value?

Replace the PCM. IMPORTANT: The replacement PCM must be programmed.Refer to ON-Vehicle Service in Power ControlModule and Sensors for procedures.And also refer to latest Service Bulletin.Check to see if the latest software is released ornot. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6E–100

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Engine Cranks But Will Not Run

060R200083

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–101

060R200075

6E–102

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Circuit Description

Test Description

The electronic Ignition system uses a coil -at-plug method of spark distribution. In this type of ignition system, the powertrain control module (PCM) triggers the correct driver outside the Ignition Current Sense System (ICSS), which then triggers the correct ignition coil based on the 58X signal received from the crankshaft position sensor (CKP). The spark plug connected to the coil fires when the ICSS opens the ground circuit for the coil’s primary circuit. During crank, the PCM monitors the CKP 58X signal. The CKP signal is used to determine which cylinder will fire first. After the CKP 58X signal has been processed by the PCM, it will command all six injectors to allow a priming shot of fuel for all the cylinders. After the priming, the injectors are left “OFF” during the next six 58X reference pulses from the CKP. This allows each cylinder a chance to use the fuel from the priming shot. During this waiting been received by the PCM. The ION sensor signal allows the PCM to operate the injectors sequentially based on camshaft position. If the camshaft position signal is not present at start — up, the PCM will begin sequential fuel delivery with a 1 -in-6 chance that fuel delivery is correct. The engine will run without a ION sensor signal, but will set a DTC code.

Number(s) below refer to the step number(s) on the Diagnostic Chart. 5. An obvious cause of low fuel pressure would be an empty fuel tank. 6. The engine will easily start and run if a few injectors are disabled. It is not necessary to test all injectors at this time since this step is only a test to verify that all of the injectors have not been disabled by fuel contamination. 7. A blinking test light verifies that the PCM is monitoring the 58X crankshaft reference signal and is capable of activating the injectors. If there is an open or shorted driver circuit, DTCs 201 – 206 and a misfire DTC 300 – 306 should be set. 19. By using a spark tester, each ignition coil’s ability to produce 25,000 volts is verified. 25. If there is an open or shorted driver circuit, DTCs 201 – 206 and a misfire DTC 301 – 306 should be set. All six injector driver circuits can be checked at one time without removing the intake manifold if a J 39021 – 95 test light is available. This is the alternative procedure: B With the ignition “OFF”, disconnect the gray connector located at the rear of the air filter, attached to a bracket on the purge canister. B Connect test light J 39021 – 95 to the connector. Do any of the light constantly illuminate or fail to blink when the engine is cranked? If so, repair the short or open circuit, or replace the PCM if indicated. This procedure only tests the driver circuit as far as the test connection, so step 31 is added to test the circuit all the way to the injector.

Diagnostic Aids An intermittent problem may be caused by a poor connection, rubbed — through wire insulation or a wire broken inside the insulation. Check for the following items: B Poor connection or damaged harness-Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. B Faulty engine coolant temperature sensor-Using a Tech 2, compare engine coolant temperature with intake air temperature on a completely cool engine. Engine coolant temperature should be within 10 ° C of intake air temperature. If not, replace the ECT sensor.

Engine Cranks But Will Not Run Step

Action

Yes

—

Go to Step 2

Go to OBD System Check

—

Go to Step 3

Go to Step 4

—

Verify repair

—

Was the “On-Board Diagnostic (OBD) System Check” performed? Check the ignition coil fuse, the engine fuse, and the PCM fuse. Was a fuse blown?

Value(s)

Check for a short to ground and replace the fuse. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–103

Engine Cranks But Will Not Run (Cont’d) Step

Action

Value(s)

Go to Step 18

—

Go to Step 8

Go to Step 24

—

Go to Step 12

Go to Step 9

—

Go to Step 10

Go to Step 11

—

Verify repair

—

Verify repair

—

Go to Step 14

Go to Step 13

—

Verify repair

—

Repair the ION sensing module. 1. Reconnect the ION sensing module 11-pin connector. 2. Remove the electrical connector from each coil. 3. With a test light to B+, probe each of the coil connectors at the wire which runs to the ION sensing module. Does the light flash at each coil connector when the engine is cranked?

Go to Step 7

Repair the open ignition feed circuit or ground circuit to the ION sensing module.

Is the action complete? 12

—

1. Remove the 4-pin connector at the ION sensing module. 2. Ignition “ ON”. 3. Use a test light at the harness connector to verify that the module is being supplied with B + and ground.

Is the action complete? 11

Go to Fuel System Diagnosis

1. Ignition “ OFF”. 2. Disconnect the 11-pin connector at the ION sensing module. 3. With a test light to B + , probe each of the 6 exposed ION sensing module pins, one at a time, while the engine is cranked. (Use the gray narrow Metri — Pak  flexible female connector from the J — 35616 kit to make the pin accessible.)

Was a problem found? 10

—

Go to Fuel System Electrical Test

Install an injector test light at the #2 cylinder injector harness connector.

Does the light flash at each pin when the engine is cranked? 9

Go to Step 5

Install the switch box J 39021–2 at the injector test connector and activate an injector.

Does the light blink when the engine is cranked? 8

Go to Step 6

Is any fuel pressure indicated?

Did the fuel pressure drop when the injector was activated? 7

1. Ignition “OFF”, install a fuel pressure gauge at the test fitting on the fuel supply line in the engine compartment. (Use a shop cloth to absorb any fuel leakage while making the connection.) 2. Ignition “ON”, observe the fuel pressure. Is the fuel pressure within the specified values, and 285 — 375 kPa does it hold steady? (43 – 55 psi)

Yes

Check for an open circuit between the coil and ION sensing module. Is the action complete?

6E–104

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Engine Cranks But Will Not Run (Cont’d) Step

Action

1. Ignition “ON”. 2. While the coil connectors are disconnected, touch each coil connector’s ignition feed terminal with a grounded test light (the ignition feed wire is YEL tracer). Did the test light illuminate?

Verify repair

—

Go to Step 18

Go to Step 17

—

Verify repair

—

Verify repair

Go to Step 19

—

Go to Step 21

Go to Step 20

—

Verify repair

—

Refasten all coils with their screws

Go to Step 22

—

Correct the fouling condition

Go to Step 23

Repeat Step 19 for each coil. Remove only one coil at a time, and reinstall each coil on its spark plug after testing, but do not refasten coils with screws at this time. After all coils have passed the spark test, does the engine start?

—

Replace the ignition coil, and return to Step 19 to test the remaining coils. Is the action complete?

Go to Step 15

1. Remove any ignition coil and install a spark tester at the spark plug end of the coil. 2. Observe the tester while the engine is cranking. Was a crisp, blue spark observed? Only one or two sparks followed by no result is considered the same as “No Spark”.

Go to Step 16

1. Test the fuel for contamination. 2. If a problem is found, clean the fuel system and correct the contaminated fuel condition as necessary. Replace the fuel filter and replace any injectors that are not delivering fuel (see Injector Balance Test). Was a problem found?

—

Repair the open secondary ground circuit. Is the action complete?

While the coil connectors are disconnected, touch each connector’s secondary ground terminal with a test light to B +. (The ground wires are black.) Did the test light illuminate at each coil connector?

Yes

Repair the open ignition feed circuit. Is the action complete?

Value(s)

1. Remove the spark plugs from all cylinders. 2. Visually inspect the spark plug electrodes. 3. Replace any spark plugs with loose or missing electrodes or cracked insulators. Did your inspection reveal any spark plugs exhibiting excessive fouling?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–105

Engine Cranks But Will Not Run (Cont’d) Step

Action

Refer to Engine Mechanical Diagnosis to diagnose the following conditions: B Faulty or incorrect camshaft drive belts B Leaking or sticky valves or rings B Excessive valve deposits B Weak valve springs B Incorrect valve timing B Leaking head gasket Is the action complete?

—

Go to Step 25

Go to Step 34

—

Go to Step 26

Go to Step 32

—

Go to Step 27

Go to Step 29

—

Go to Step 28

Go to Step 33

—

Verify repair

—

Go to Step 31

Go to Step 30

—

Verify repair

Go to Step 33

1. Using the same test location as in step 26, connect a test light between the ignition terminal and one of the driver circuits. 2. Crank the engine and observe the test light. 3. Repeat for each injector driver circuit. Did the light blink during the test for each circuit?

Go to Step 25

Locate and repair the short to ground in the injector driver circuit. Is the action complete?

Verify repair

1. Ignition “OFF”, disconnect the PCM. 2. Ignition “ON”, observe the test light. Is the test light “ON”?

—

1. At the PCM (female) side of the connector, connect a test light between the ignition + terminal and one of the injector driver circuits at the same connector. 2. Ignition “ON”. 3. Observe the test light, and repeat the test for each injector driver circuit. Did the test light stay on when checking any of the 6 injector driver circuits?

1. Disconnect the 7-pin gray connector at the rear of the air filter beneath the point where the air duct attaches to the MAF sensor. 2. Ignition “ON”. 3. Using a test light connected to ground, probe the ignition terminal at the PCM (female) side of the 7-pin connector. Is the test light “ON”?

Yes

Observe the “Engine Speed” data display on the Tech 2 while cranking the engine. Is the engine RPM indicated?

Value(s)

Check for an open injector driver circuit. Was a problem found?

6E–106

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Engine Cranks But Will Not Run (Cont’d) Step

Action

Value(s)

1. At the injector (male) side of the gray connector mentioned in step 25, connect an ohmmeter between the ignition pin and one of the driver circuit pins. 2. Check for continuity in the circuit. 3. Repeat for each injector circuit. The readings should be approximately equal to the specified value for injector resistance. Was a problem found?

12.5 W

Verify repair

Go to Step 8

—

Verify repair

—

Verify repair

—

Go to Step 36

Go to Step 35

—

Verify repair

—

Go to Step 38

Go to Step 37

—

Verify repair

—

Verify repair

Go to Step 39

—

Verify repair

Go to Step 33

Repair the ignition feed circuit. Is the action complete?

Yes

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

1. Raise the vehicle and disconnect the CKP sensor harness. 2. Ignition “ON”. 3. With a test light to ground, probe the harness ignition feed terminal. Did the light illuminate?

Check the ignition feed wire between the sensor and the PCM for a short to ground or open circuit. Is the action complete?

1. Ignition “ON”. 2. At the CKP harness connector, connect a test light between the ignition and ground terminals. Did the light illuminate?

Check the sensor ground circuit for an open or short to voltage. Is the action complete?

Check the signal circuit between the sensor and the PCM for a short to ground, short to voltage, or an open. Was a problem found?

Replace the CKP position sensor. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–107

Fuel System Electrical Test

060R200044

6E–108

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Circuit Description When the ignition switch is first turned “ON”, the powertrain control module (PCM) energizes the fuel pump relay which applies power to the in-tank fuel pump. The fuel pump relay will remain “ON” as long as the engine is running or cranking and the PCM is receiving 58X crankshaft position pulses. If no 58X crankshaft position pulses are present, the PCM de-energizes the fuel pump relay within 2 seconds after the ignition is turned “ON” or the engine is stopped. The fuel pump delivers fuel to the fuel rail and injectors, then to the fuel pressure regulator. The fuel pressure regulator controls fuel pressure by allowing excess fuel to be returned to the fuel tank. With the engine stopped and ignition “ON”, the fuel pump can be turned “ON” by using a command by the Tech 2.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If the fuel pump is operating but incorrect pressure is noted, the fuel pump wiring is OK and the “Fuel System Pressure Test” chart should be used for diagnosis. CAUTION: To reduce the risk of fire and personal injury: B It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge. Refer to Fuel Pressure Relief Procedure, below. B A small amount of fuel may be released when disconnecting the fuel lines. Cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when the procedure is completed.

Fuel Pressure Relief Procedure 1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay center. 3. Start the engine and allow it to stall. 4. Crank the engine for an additional 3 seconds.

Fuel Gauge Installation 1. Remove the shoulder fitting cap. 2. Install fuel gauge J 34730-1 to the fuel feed line located in front of and above the right side valve train cover . 3. Reinstall the fuel pump relay.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–109

Fuel System Electrical Test Step

Action

—

Test completed

Go to Step 12

—

Go to Step 6

Go to Step 5

—

Verify repair

—

Go to Step 12

Go to Step 7

—

Go to Step 8

Go to Step 9

—

Verify repair

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 11

Locate and repair open in the fuel pump relay ground circuit. Check for short or open between the PCM and the fuel pump relay. Was a problem found?

Go to Step 4

1. With a test light connected to battery (–), probe the fuel pump relay connector at the wire which runs from the relay pull-in coil to the PCM. 2. Ignition “ON”.

Is the action complete? 9

Go to Step 3

1. Connect a test light between the two wires that connect to the fuel pump relay pull-in coil. 2. Ignition “ON”.

Did the test light illuminate for 2 seconds and then turn off? 8

—

Repair short or open battery feed to fuel pump relay.

Did the test light illuminate for 2 seconds and then turn off? 7

Go to Step 2

1. Ignition “OFF”. 2. Remove the fuel pump relay. 3. Using a test light connected to ground, probe the battery feed to the relay.

Is the action complete? 6

—

Go to OBD System Check

1. Verify that the pump is not running by removing the fuel filler cap and listening. 2. Command the pump “ON” with the Tech 2.

Did the light illuminate? 5

1. Read the “Caution” above. 2. Relieve the fuel system pressure and install the fuel pump pressure gauge to the test fitting. 3. Ignition ON, Engine is Off. 4. Use a Tech 2 to command the fuel pump “ON”. (Refer to the Miscellaneous Test.)

Did the pump turn “OFF” after 2 seconds? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is there an immediate pressure build-up which indicates the pump is running? 3

Value(s)

1. Check the fuel pump relay circuit for a poor terminal connection at the PCM. 2. If a problem is found, replace terminal as necessary. Was a problem found?

6E–110

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuel System Electrical Test (Cont’d) Step

Action

Value(s)

Yes

—

Go to Step 17

Go to Step 14

—

Verify repair

—

Go to Step 18

Go to Step 16

—

Verify repair

—

Verify repair

—

Verify repair

—

1. Re-connect the horn relay in its proper location. 2. Replace the fuel pump relay. Is the action complete?

Go to Step 13

Repair the open circuit in the fuel pump ground wire. Is the action complete?

Go to Step 15

1. With the fuel pump electrical connector at the fuel tank disconnected, connect a test light between the feed wire and the ground wire (harness side). 2. Command the fuel pump “ON” with a Tech 2. Did the test light illuminate for 2 seconds?

—

1. Re-connect the horn relay in its proper location. 2. Check for a short circuit, blown fuse or open circuit between the relay and the fuel tank. Is the action complete?

—

1. Honk the horn to verify that the horn relay is functioning. 2. Substitute the horn relay for the fuel pump relay. 3. Leave the test light connected as in step 12. 4. Command the fuel pump “ON” with the Tech 2. Did the test light illuminate for 2 seconds when the fuel pump was commanded “ON”?

Verify repair

1. Reconnect the fuel pump relay. 2. Disconnect the fuel pump electrical connector at the fuel tank. 3. Using a test light connected to ground, probe the fuel pump feed wire (harness side). 4. Command the fuel pump “ON” with a Tech 2. Did the light illuminate for 2 seconds?

—

Replace the fuel pump. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–111

Electric Throttle Control (ETC) System Check

060R200065

6E–112

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Circuit Description B The powertrain control module (PCM) controls engine speed by adjusting the position of the throttle control valve (DC motor). The throttle motor is a DC motor driven by one coil. The PCM applies current to the DC motor coil in PWM (%) to adjust the throttle valve into a passage in the throttle body to allow air flow. This method allows highly accurate control of engine speed and quick response to changes in engine load. B The accelerator position (AP1) sensor circuit provides a voltage signal relative to accelerator pedal angle. The accelerator pedal angle will vary about 13% at idle position to about 87% at wide open throttle(WOT). APS signal is used to determine which DC motor will adjust throttle position. After the APS signal has been processed by the PCM, it will command DC motor to allow movement of throttle position.

Diagnostic Aids B An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for poor connections or a damaged harness. Inspect the PCM harness and connector for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. B Throttle body – Check for objects blocking the DC motor or throttle bore, excessive deposits in the ETC passage and on the valve spring, and excessive deposits in the throttle bore and on the throttle valve plate. B Accelerator pedal – Check for objects blocking the AP sensor or pedal arm with spring, and excessive deposits in the accelerator pedal arm and on the accelerator pedal.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Visually/physically inspect for the following throttle valve conditions. 3. Visually/physically inspect for the following accelerator pedal conditions. 5. Check the following circuits for throttle valve and DC motor. Check the following TP sensor resistance and DC motor. 7. Check the following circuits for accelerator pedal. Check the following AP sensor resistance. 10. Following DTC: Software detect Error for ETC system. 11. Following DTC: Software detect Error for ETC system.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–113

Electric Throttle Control (ETC) System Check Step

Action

—

Go to Step 2

—

Refer to appropriate section for on-vehicle service

Go to Step 3

—

Refer to appropriate section for on-vehicle service

Go to Step 4

—

Verify repair

Go to Step 5

Vcc–GND 1–7kW SIG–GND change resistance 0.3–100W

Verify repair

Go to Step 6

Visually/physically inspect for the following conditions: B Accelerator pedal tampering. B Accelerator pedal : Check for objects blocking the spring or pedal arm. B Accelerator pedal : For check for objects to move the accelerator pedal that pedal is smooth movement, and accelerator pedal arm has not excessive play. 1. Check for a poor connection at the throttle body harness connector. 2. Check for a poor connection at the accelerator position sensor harness connector. 3. If a problem is found, replace faulty terminals as necessary. Was a problem found?

Go to OBD System Check

Visually/physically inspect for the following conditions: B Throttle body tampering. B Restricted intake throttle system. Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. B Throttle body: Check for objects blocking the throttle passage or throttle bore, excessive deposits in the throttle passage and on the throttle valve, and excessive deposits in the throttle bore and on the throttle plate. B Throttle body with lever: When check for objects to send round the throttle spring lever that lever is smooth movement by less than 9 l·bm{1.0 N·m}, and spring lever has not excessive play. B Throttle function: Check for the throttle function. When ignition switch “ON” that throttle lever is smooth operated by step on the accelerator pedal.

Did any of the above require a repair? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Did any of the above require a repair? 3

Value(s)

Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: B Throttle position sensor 1 circuit. B Throttle position sensor 2 circuit. B Throttle DC motor circuit. B Throttle position sensor resistance. B Throttle DC motor resistance. If a problem is found, repair as necessary. Was a problem found?

6E–114

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Electric Throttle Control (ETC) System Check (Cont’d) Step

Action

1. Install the Tech 2 2. Ignition “ON” but not engine run. 3. Chech the valve for APS and TPS. Was the problem found?

Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: B Accelerator position sensor 1 circuit. B Accelerator position sensor 2 circuit. B Accelerator position sensor 3 circuit. B Accelerator position sensor resistance. If a problem is found, repair as necessary. Was a problem found?

Idle AP1 = 11–13% AP2 = 87–88% AP3 = 87–88% TP1 = 1–6% TP2 = 1–6% WOT AP1 = 85–89% AP2 = 11–15% AP3 = 32–36% TP1 = 98–100% TP2 = 98–100%

Go to Step 10

Go to Step 7

—

Go to Step 8

—

Vcc–GND 4–6kW SIG–GND change resistance

Verify repair

Go to Step 9

—

Go to Step 10

–

—

Go to applicable DTC chart

Go to Step 11

—

Go to applicable DTC chart

Go to Step 12

—

Verify repair

—

Replace the accelerator position sensor. Is the action complete?

Yes

Replace the throttle valve. Is the action complete?

Value(s)

Following below the DTCs stored: P1125, P1290, P1295, P1299 Following below the DTCs stored: P1514, P1515, P1516, P1523, P1271, P1272, P1273 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–115

Fuel System Diagnosis

140R200004

Legend (1) Fuel Filler Cap (2) Fuel Tank (3) Rollover Valve (4) Fuel Pump and Sender Assembly (5) Fuel Filter (6) Fuel Rail Right (7) Right Bank (8) Fuel Rail Left (9) Left Bank

(10) (11) (12) (13) (14) (15) (16) (17) (18)

Fuel Pressure Control Valve Common Chamber Purge Duty Solenoid Valve Throttle Valve Canister Vent Hose Vent Solenoid Valve Separator Shut off Valve (With Over Pressure Relief Valve)

6E–116

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Circuit Description When the ignition switch is turned “ON”, the powertrain control module (PCM) will turn “ON” the in-tank fuel pump. The in-tank fuel pump will remain “ON” as long as the engine is cranking or running and the PCM is receiving 58X crankshaft position pulses. If there are no 58X crankshaft position pulses, the PCM will turn the in-tank fuel pump “OFF” 2 seconds after the ignition switch is turned “ON” or 2 seconds after the engine stops running. The in-tank fuel pump is an electric pump within an integral reservoir. The in-tank fuel pump supplies fuel through an in-line fuel filter to the fuel rail assembly. The fuel pump is designed to provide fuel at a pressure above the pressure needed by the fuel injectors. A fuel pressure regulator, attached to the fuel rail, keeps the fuel available to the fuel injectors at a regulated pressure. Unused fuel is returned to the fuel tank by a separate fuel return line.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Connect the fuel pressure gauge to the fuel feed line as shown in the fuel system illustration. Wrap a shop towel around the fuel pressure connection in order to absorb any fuel leakage that may occur when installing the fuel pressure gauge. With the ignition switch “ON” and the fuel pump running, the fuel pressure indicated by the fuel pressure gauge should be 333-376 kPa (48-55 psi). This pressure is controlled by the amount of pressure the spring inside the fuel pressure regulator can provide. 3. A fuel system that cannot maintain a constant fuel pressure has a leak in one or more of the following areas: B The fuel pump check valve. B The fuel pump flex line. B The valve or valve seat within the fuel pressure regulator. B The fuel injector(s). 4. Fuel pressure that drops off during acceleration, cruise, or hard cornering may case a lean condition. A lean condition can cause a loss of power, surging, or misfire. A lean condition can be diagnosed using a Tech 2. If an extremely lean condition occurs, the oxygen sensor(s) will stop toggling. The oxygen sensor output voltage(s) will drop below 500 mV. Also, the fuel injector pulse width will increase. IMPORTANT: Make sure the fuel system is not operating in the “Fuel Cut-Off Mode”. When the engine is at idle, the manifold pressure is low (high vacuum). This low pressure (high vacuum) is applied to the fuel pressure regulator diaphragm. The low pressure (high vacuum) will offset the pressure being applied to the fuel pressure regulator diaphragm by the spring inside the fuel pressure regulator. When this happens, the result is lower fuel pressure. The fuel pressure at idle will vary slightly as the barometric pressure changes, but the fuel pressure at idle should always be less than the fuel pressure noted in step 2 with the engine “OFF”.

16.Check the spark plug associated with a particular fuel injector for fouling or saturation in order to determine if that particular fuel injector is leaking. If checking the spark plug associated with a particular fuel injector for fouling or saturation does not determine that a particular fuel injector is leaking, use the following procedure: B Remove the fuel rail, but leave the fuel lines and injectors connected to the fuel rail. Refer to Fuel Rail Assembly in On-Vehicle Service. B Lift the fuel rail just enough to leave the fuel injector nozzles in the fuel injector ports. CAUTION: In order to reduce the risk of fire and personal injury that may result from fuel spraying on the engine, verify that the fuel rail is positioned over the fuel injector ports and verify that the fuel injector retaining clips are intact. B Pressurize the fuel system by connecting a 10 amp fused jumper between B+ and the fuel pump relay connector. B Visually and physically inspect the fuel injector nozzles for leaks. 17.A rich condition may result from the fuel pressure being above 376 kPa (55 psi). A rich condition may cause a DTC P0132 or a DTC P0172 to set. Driveability conditions associated with rich conditions can include hard starting (followed by black smoke) and a strong sulfur smell in the exhaust. 20.This test determines if the high fuel pressure is due to a restricted fuel return line or if the high fuel pressure is due to a faulty fuel pressure regulator. 21.A lean condition may result from fuel pressure below 333 kPa (48 psi). A lean condition may cause a DTC P0131 or a DTC P0171 to set. Driveability conditions associated with lean conditions can include hard starting (when the engine is cold ), hesitation, poor driveability, lack of power, surging , and misfiring. 22.Restricting the fuel return line causes the fuel pressure to rise above the regulated fuel pressure. Command the fuel pump “ON” with the Tech 2. The fuel pressure should rise above 376 kPa (55 psi) as the fuel return line becomes partially closed. NOTE: Do not allow the fuel pressure to exceed 414 kPa (60 psi). Fuel pressure in excess of 414 kPa (60 psi) may damage the fuel pressure regulator. CAUTION: To reduce the risk of fire and personal injury: B It is necessary to relieve fuel system pressure before connecting a fuel pressure gauge. Refer to Fuel Pressure Relief Procedure, below. B A small amount of fuel may be released when disconnecting the fuel lines. Cover fuel line fittings with a shop towel before disconnecting, to catch any fuel that may leak out. Place the towel in an approved container when the procedure is completed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuel Pressure Relief Procedure

6E–117

Fuel Gauge Installation

1. Remove the fuel cap. 2. Remove the fuel pump relay from the underhood relay center. 3. Start the engine and allow it to stall. 4. Crank the engine for an additional 3 seconds.

1. Remove the shoulder fitting cap. 2. Install fuel gauge J 34730-1 to the fuel feed line located in front of and above the right side valve train cover. 3. Reinstall the fuel pump relay.

Fuel System Diagnosis Step

Action

Value(s)

Yes

—

Go to Step 2

Go to OBD System Check

290-376 kPa (42-55 psi)

Go to Step 3

Go to Step 17

—

Go to Step 4

Go to Step 12

Did the reading drop by the amount specified after the engine was started?

21-105 kPa (3-15 psi)

Go to Step 5

Go to Step 9

Is fuel pressure dropping off during acceleration, cruise, or hard cornering?

—

Go to Step 6

Check for improper fuel

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

Was the “On-Board Diagnostic (OBD) System Check” performed? 1. Turn the ignition “OFF”. 2. Turn the air conditioning system “OFF”. 3. Relieve fuel system pressure and install the fuel pressure gauge. 4. Turn the ignition “ON”. NOTE: The fuel pump will run for approximately 2 seconds. Use the Tech 2 to command the fuel pump “ON”. (Refer to the Miscellaneous Test.) 5. Observe the fuel pressure indicated by the fuel pressure gauge with the fuel pump running. Is the fuel pressure within the specified limits?

NOTE: The fuel pressure will drop when the fuel pump stops running, then it should stabilize and remain constant. Does the fuel pressure indicated by the fuel pressure gauge remain constant?

5 6

1. When the vehicle is at normal operation temperature, turn the ignition “ON” to build fuel pressure and observe the measurement on the gauge. 2. Start the engine and observe the fuel pressure gauge.

Visually and physically inspect the following items for a restriction: B The in-pipe fuel filter. B The fuel feed line. Was a restriction found?

Remove the fuel tank and visually and physically inspect the following items: B The fuel pump strainer for a restriction. B The fuel line for a leak. B Verify that the correct fuel pump is in the vehicle. Was a problem found in any of these areas?

6E–118

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuel System Diagnosis (Cont’d) Step

Action

—

Verify repair

—

Verify repair

—

Go to Step 13

Go to Step 15

—

Verify repair

Go to Step 14

—

Verify repair

Go to Step 8

—

Go to Step 11

Go to Step 16

—

Verify repair

—

376 kPa (55 psi)

Go to Step 18

Go to Step 21

Locate and replace any leaking fuel injector(s). Is the action complete?

Go to Step 11

1. If the pliers are still clamped to the fuel supply hose, remove the locking pliers. 2. With suitable locking pliers, which will not damage the hose, clamp the fuel return line to prevent fuel from returning to the fuel tank. 3. Run the fuel pump with the Tech 2. 4. After pressure has built up, remove power to the pump. Does the fuel pressure indicated by the fuel pressure gauge remain constant?

Go to Step 10

Remove the fuel tank and inspect for leaky hose or in-tank fuel line. Was a problem found?

21-105 kPa (3-15 psi)

Visually inspect the fuel supply line and repair any leaks. Was a problem found?

—

1. Run the fuel pump with the Tech 2. 2. After pressure has built up, turn off the pump and clamp the supply hose shut with suitable locking pliers which will not damage the hose. Does the fuel pressure indicated by the fuel pressure gauge remain constant?

Verify repair

Replace the fuel pressure regulator. Is the action complete?

—

Locate and repair the loss of vacuum to the fuel pressure regulator. Is the action complete?

1. Disconnect the vacuum hose from the fuel pressure regulator. 2. With the engine idling, apply 12-14 inches of vacuum to the fuel pressure regulator. Does the fuel pressure indicated by the fuel pressure gauge drop by the amount specified?

Yes

Replace the fuel pump. Is the action complete?

Value(s)

Is the fuel pressure indicated by the fuel pressure gauge above the specified limit?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–119

Fuel System Diagnosis (Cont’d) Step

Action

1. Relieve the fuel pressure. Refer to the Fuel Pressure Relief. 2. Disconnect the fuel return line from the fuel rail. 3. Attach a length of flexible hose to the fuel rail return outlet passage. 4. Place the open end of the flexible hose into an approved gasoline container. 5. Run the fuel pump with the Tech 2. 6. Observe the fuel pressure indicated by the fuel pressure gauge with the fuel pump running. Is the fuel pressure within the specified limits?

Is the fuel pressure indicated by the fuel pressure gauge above the specified value?

290-376 kPa (42-55 psi)

Go to Step 19

Go to Step 20

—

Verify repair

—

Verify repair

Go to Step 11

0 kPa (0 psi)

Go to Step 22

Go to Step 23

376 kPa (55 psi) 414 kPa (60 psi)

Go to Step 11

Go to Step 7

Go to Fuel System Electrical Test Chart

1. Command the fuel pump “ON” with the Tech 2. 2. Using suitable pliers which will not damage the fuel hose, gradually apply pressure with the pliers to pinch the flexible fuel return hose closed. CAUTION: Do not let the fuel pressure exceed the second specified value. Does the fuel pressure indicated by the fuel pressure gauge rise above the first specified value?

Visually and physically inspect the fuel rail outlet passages for a restriction. Was a restriction found?

Yes

Locate and correct the restriction in the fuel return line. Is the action complete?

Value(s)

1. Command the fuel pump “ON” with the Tech 2. 2. Remove the fuel filler cap and listen for the sound of the fuel pump running. 3. Turn the pump off. Was the fuel pump running?

—

6E–120

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Exhaust Gas Recirculation (EGR) System Check

060R200050

Circuit Description

Diagnostic Aids

A properly operation exhaust gas recirculation (EGR) system will directly affect the air/fuel requirements of the engine. Since the exhaust gas introduced into the air/fuel mixture is an inert gas (contains very little or no oxygen), less fuel is required to maintain a correct air/fuel ratio. Introducing exhaust gas into the combustion chamber lowers combustion temperatures and reduces the formation of oxides of nitrogen (NOx) in the exhaust gas. Lower combustion temperatures also prevent detonation. If the EGR pintle were to stay closed, the inert exhaust gas would be replaced with air and the air/fuel mixture would be leaner. The powertrain control module (PCM) would compensate for the lean condition by adding fuel, resulting in higher long term fuel trim values.

The EGR valve chart is a check of the EGR system. An EGR pintle constantly in the closed position could cause detonation and high emissions of NOx. It could also result in high long term fuel trim values in the open throttle cell, but not in the closed throttle cell. An EGR pintle constantly in the open position would cause a rough idle. Also, an EGR mounted incorrectly (rotated 180°) could cause rough idle. Check for the following items: B EGR passages – Check for restricted or blocked EGR passages. B Manifold absolute pressure sensor – A manifold absolute pressure sensor may shift in calibration enough to affect fuel delivery. Refer to Manifold Absolute Pressure Output Check.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–121

Exhaust Gas Recirculation (EGR) System Check Step

Action

—

EGR system working properly. No problem found.

Go to Step 4

—

Go to Step 6

Go to Step 5

—

Verify repair

Go to Step 6

—

Go to Step 7

Go to Step 8

—

Verify repair

Go to Step 8

—

Go to Step 9

Go to DTC P1406 chart

—

Go to Step 10

EGR system working properly. No problem found.

—

Verify repair

—

1. Remove the EGR inlet and outlet pipes from the intake and exhaust manifolds. 2. Visually and physically inspect manifold EGR ports and EGR inlet and outlet pipes for blockage or restriction caused by excessive deposits or other damage. Do the manifold EGR ports or inlet and outlet pipes have excessive deposits, obstructions, or any restrictions?

—

1. Ground the EGR valve metal case to battery (–). 2. Using a Tech 2, command EGR “ON” and observe the EGR valve pintle for movement. Does the EGR valve pintle move according to command?

Verify repair

Clean or replace EGR system components as necessary. Was the problem corrected?

—

1. Remove the EGR valve. 2. Visually and physically inspect the EGR valve pintle, valve passages and adapter for excessive deposits, obstructions or any restrictions. Does the EGR valve have excessive deposits, obstructions or any restrictions?

Go to Step 3

Repair the EGR harness ignition feed. Was the problem corrected?

Go to Step 2

1. Engine “OFF”. 2. Ignition “ON”. 3. Using a test light to ground, check the EGR harness between the EGR valve and the ignition feed. Does the test light illuminate?

—

1. Place the transmission selector in Park or Neutral. 2. Start the engine and idle until warm. 3. Using a Tech 2, command EGR “50% ON”. (Refer to the Miscellaneous Test.) Does the engine idle rough and lose RPMs?

Tighten the EGR valve. Is the action complete?

Yes

Check the EGR valve for looseness. Is the EGR valve Loose?

Value(s)

Clean or replace EGR system components as necessary. Is the action complete?

6E–122

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Manifold Absolute Pressure (MAP) Output Check

060R200051

Circuit Description

Test Description

The manifold absolute pressure (MAP) sensor measures the changes in the intake MAP which result from engine load (intake manifold vacuum) and engine speed changes; and converts these into a voltage output. The powertrain control module (PCM) sends a 5-volt reference voltage to the MAP sensor. As the MAP changes, the output voltage of the sensor also changes. By monitoring the sensor output voltage, the PCM knows the MAP. A lower pressure (low voltage) output voltage will be about 1-2 volts at idle. Higher pressure (high voltage) output voltage will be about 4-4.8 volts at wide open throttle. The MAP sensor is also used, under certain conditions, to measure barometric pressure, allowing the PCM to make adjustments for different altitudes. The PCM uses the MAP sensor to diagnose proper operation of the EGR system, in addition to other functions.

IMPORTANT: Be sure to used the same diagnostic test equipment for all measurements. The number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Applying 34 kPa (10 inch Hg) vacuum to the MAP sensor should cause the voltage to be 1.5-2.1 volts less than the voltage at step 1. Upon applying vacuum to the sensor, the change in voltage should be instantaneous. A slow voltage change indicates a faulty sensor. 3. Check the vacuum hose to the sensor for leaking or restriction, Be sure that no other vacuum devices are connected to the MAP hose. IMPORTANT: Make sure the electrical connector remains securely fastened. 4. Disconnect the sensor from the bracket. Twist the sensor with your hand to check for an intermittent connection. Output changes greater than 0.10 volt indicate a bad sensor.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–123

Manifold Absolute Pressure (MAP) Output Check Step

Action

—

Go to Step 3

Go to Step 4

—

Go to Step 5

Go to Step 4

—

Verify repair

—

Go to Step 6

Go to Step 7

—

Verify repair

—

Verify repair

—

Refer to On-Vehicle Service, MAP Sensor. Is the action complete?

Go to Step 5

Check the sensor connection. Is the sensor connection good?

Go to Step 2

Repair the hose blockage. Is the action complete?

—

Check the sensor cover for leakage or restriction. Does the hose supply vacuum to the MAP sensor only?

1. Disconnect the vacuum hose at the MAP sensor and plug the hose. 2. Connect a hand vacuum pump to the MAP sensor. 3. Start the engine. 4. Apply 34 kPa (10 in.Hg) of vacuum and note the voltage change. Is the voltage change 1.5-2.1 volts less than Step 1?

Yes

1. Turn the ignition “OFF” and leave it “OFF” for 15 seconds. 2. Ignition “ON”. Don’t crank engine. 3. The Tech 2 should indicate a manifold absolute pressure (MAP) sensor voltage. 4. Compare this scan reading to scan reading of a known good vehicle obtained using the exact same procedure as in Steps 1-4. Is the voltage reading the same +/–0.40 volt?

Value(s)

Repair the poor connection. Is the action complete?

6E–124

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Evaporative (EVAP) Emissions Canister Purge Valve Check

060RY00398

Circuit Description Canister purge is controlled by a solenoid valve that allows manifold vacuum to purge the canister. The powertrain control module (PCM) supplies a ground to energize the solenoid valve (purge “ON”). The EVAP purge solenoid control is turned “ON” and “OFF” several times a second. The duty cycle (pulse width or “ON” time) is determined by engine operating conditions including load, throttle position, coolant temperature and ambient temperature. The duty cycle is calculated by the PCM and the purge solenoid is enabled when the appropriate conditions have been met: B The engine run time after start is more than 60 seconds. B The engine coolant temperature is above 30°C (86°F). B The fuel control system is operating in the closed-loop mode.

Diagnostic Aids B Make a visual check of vacuum hoses. B Check the throttle body for cracks. B Check the malfunction indicator lamp for a possible mechanical problem.

Test Description The number(s) below refer to the step number(s) on the Diagnostic Chart. 1. Check to see if the solenoid is open or closed. The solenoid is normally de-energized in this step, so it should be closed. 2. This step checks to determine if the solenoid was open due to an electrical circuit problem or a defective solenoid. 3. This should normally energize the solenoid, opening the valve and allowing the vacuum to drop (purge “ON”).

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–125

Evaporative (EVAP) Emissions Canister Purge Valve Check Step

Action

—

Go to Step 3

Go to Step 2

—

Go to Step 4

Go to Step 7

—

Go to Step 8

Go to Step 9

—

Go to Step 5

Go to Step 6

—

Verify repair

—

Verify repair

—

Verify repair

—

1. Disconnect the solenoid electrical connector. 2. As in Step 1, apply vacuum (10 in. Hg or 34 kPa) to the solenoid. Does the solenoid hold the vacuum?

Yes

1. Ignition “OFF”. 2. Ignition “ON”, engine “OFF”. 3. At the throttle body, disconnect the hose that goes to the purge solenoid. 4. Using a hand vacuum pump with an attached vacuum gauge J 23738-A, apply vacuum (10 in. Hg or 34 kPa) to the solenoid. Does the solenoid hold the vacuum?

Value(s)

1. At the throttle body, put a cap over the vacuum port where the hose was disconnected for testing. This is to prevent a vacuum leak when the engine is started. 2. Ignition “OFF”. 3. Install the Tech 2. 4. Apply vacuum to the purge solenoid with the hand vacuum pump. 5. Start the engine, run at 2500 RPM. 6. Using the Tech 2, select Powertrain, 3.5–V6 6VE1, F3: Misc. Tests, F2: EVAP Purge, F0: EVAP Purge. (Refer to the Misellaneous Test.) 7. Turn the purge solenoid “ON”. Did the vacuum drop when the purge was turned on?

Check for a short to ground in the S7 Pin wire. Is there a short?

Repair the short to ground. Is the action complete?

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Servicein Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

Replace the faulty purge solenoid. Refer to On-Vehicle Service, EVAP Canister Purge Solenoid. Is the action complete?

6E–126

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Evaporative (EVAP) Emissions Canister Purge Valve Check (Cont’d) Step

Action

Value(s)

1. Turn the ignition “OFF”. 2. At the throttle body, install a vacuum gauge where the hose from the purge solenoid was disconnected for testing. 3. Start the engine. 4. Stabilize the engine speed at about 2500 RPM. 5. Momentarily snap the throttle open and let it return to idle.

Yes

—

No problem found in the EVAP emission canister purge valve check

Refer to Diagnostic Aids

—

Go to Step 7

Go to Step 10

—

Go to Step 11

Go to Step 12

Is the action complete?

—

Verify repair

—

Does one of the terminals light the test lamp?

—

Go to Step 13

Go to Step 14

Check for an open in the S7 Pin wire between the purge solenoid and the PCM. —

Go to Step 15

Go to Step 6

—

Verify repair

—

Verify repair

—

Is there approximately 10 in. Hg (34 kPa) of vacuum available at the EVAP emission canister purge solenoid? 9

1. Disconnect the solenoid electrical connector. 2. Connect a test lamp between the harness terminals. Does the test lamp light?

Probe terminal A and terminal B with a test lamp to ground. Does the test lamp light on both terminals?

Repair the short to voltage in the S7 Pin wire.

Was there an open circuit? 14

Repair the open in the BLK/YEL wire. Is the action complete?

Repair the open in the S7 Pin wire. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–127

PCM Diagnostic Trouble Codes The following table lists the diagnostic trouble codes supported by this vehicle application. If any DTCs not listed here are displayed by a Tech 2, the Tech 2 data may be faulty; notify the Tech 2 manufacturer of any DTCs displayed that are not included in the following table. PCM Diagnostic Trouble Codes DTC

Description

Type

Illuminate MIL (Check Engine Lamp)

Illuminate RPL (Reduced Power Lamp)

P0101

MAF System Performance

Yes

P0102

MAF Sensor Circuit Low Frequency

Yes

P0103

MAF Sensor Circuit High Frequency

Yes

P0106

MAP Rationality/Performance

Yes

P0107

MAP Circuit Low Input Voltage

Yes

P0108

MAP Circuit High Input Voltage

Yes

P0112

IAT Circuit Low Input Voltage

Yes

P0113

IAT Circuit High Input Voltage

Yes

P0117

ECT Circuit Low Input Voltage

Yes

P0118

ECT Circuit High Input Voltage

Yes

P0125

ECT Insufficient for Closed Loop Fuel Control

Yes

P0128

ECT Below Thermostat Regulating Temperature

Yes

P0131

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)

Yes

P0132

O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)

Yes

P0133

O2 Sensor Circuit Slow Response (Bank 1 Sensor 1)

Yes

P0134

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)

Yes

P0135

O2 Sensor Heater Circuit (Bank 1 Sensor 1)

Yes

P0137

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 2)

Yes

P0138

O2 Sensor Circuit High Voltage (Bank 1 Sensor 2)

Yes

P0140

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2)

Yes

P0141

O2 Sensor Heater Circuit (Bank 1 Sensor 2)

Yes

P0151

O2 Sensor Circuit Low Voltage (Bank 2 Sensor 1)

Yes

P0152

O2 Sensor Circuit High Voltage (Bank 2 Sensor 1)

Yes

P0153

O2 Sensor Circuit Slow Response (Bank 2 Sensor 1)

Yes

P0154

O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 1)

Yes

P0155

O2 Sensor Heater Circuit (Bank 2 Sensor 1)

Yes

P0157

O2 Sensor Circuit Low Voltage (Bank 2 Sensor 2)

Yes

P0158

O2 Sensor Circuit High Voltage (Bank 2 Sensor 2)

Yes

P0160

O2 Sensor Circuit No Activity Detected (Bank 2 Sensor 2)

Yes

P0161

O2 Sensor Heater Circuit (Bank 2 Sensor 2)

Yes

P0171

O2 Sensor – System too Lean (Bank 1)

Yes

P0172

O2 Sensor – System too Rich (Bank 1)

Yes

P0174

O2 Sensor – System too Lean (Bank 2)

Yes

P0175

O2 Sensor – System too Rich (Bank 2)

Yes

6E–128

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC

Description

Type

Illuminate MIL (Check Engine Lamp)

Illuminate RPL (Reduced Power Lamp)

P0201

Injector 1 Control Circuit

Yes

P0202

Injector 2 Control Circuit

Yes

P0203

Injector 3 Control Circuit

Yes

P0204

Injector 4 Control Circuit

Yes

P0205

Injector 5 Control Circuit

Yes

P0206

Injector 6 Control Circuit

Yes

P0300

Engine Misfire Detected

Yes

P0301

Engine Misfire Detected Cylinder #1

Yes

P0302

Engine Misfire Detected Cylinder #2

Yes

P0303

Engine Misfire Detected Cylinder #3

Yes

P0304

Engine Misfire Detected Cylinder #4

Yes

P0305

Engine Misfire Detected Cylinder #5

Yes

P0306

Engine Misfire Detected Cylinder #6

Yes

P0325

ION Sensing Module

Yes

P0336

CKP Sensor Circuit Range/Performance (58X)

Yes

P0337

CKP Sensor Circuit No signal (58X)

Yes

P0351

Ignition 1 Control Circuit

Yes

P0352

Ignition 2 Control Circuit

Yes

P0353

Ignition 3 Control Circuit

Yes

P0354

Ignition 4 Control Circuit

Yes

P0355

Ignition 5 Control Circuit

Yes

P0356

Ignition 6 Control Circuit

Yes

P0401

EGR Flow Insufficient

Yes

P0402

EGR Flow Excessive

Yes

P0404

EGR Range/Performance (Open Valve)

Yes

P0405

EGR Sensor Circuit Low Voltage

Yes

P0406

EGR Sensor Circuit High Voltage

Yes

P0420

Catalyst System Low Efficiency (Bank 1)

Yes

P0430

Catalyst System Low Efficiency (Bank 2)

Yes

P0440

EVAP Control System

Yes

P0442

EVAP Control System Small Leak Detected

Yes

P0444

EVAP Purge Control Circuit Open

P0445

EVAP Purge Control Circuit Short

P0446

EVAP Canister Vent Control Malfunction

Yes

P0447

EVAP Vent Solenoid Circuit Open

P0448

EVAP Vent Solenoid Circuit Short

P0452

EVAP Control System Tank Pressure Sensor Low Input

Yes

P0453

EVAP Control System Tank Pressure Sensor High Input

Yes

P0456

EVAP Control System Very Small Leak Detected

Yes

P0461

Fuel Level Sensor Circuit Range/Performance

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS DTC

Description

6E–129

Type

Illuminate MIL (Check Engine Lamp)

Illuminate RPL (Reduced Power Lamp)

P0462

Fuel Level Sensor Circuit Low Input Voltage

Yes

P0463

Fuel Level Sensor Circuit High Input Voltage

Yes

P0464

Fuel Level Sensor Noisy Signal

P0502

No VSS Signal

Yes

P0506

Idle Speed Control RPM too Low

Yes

P0507

Idle Speed Control RPM too High

Yes

P0562

System Voltage is Low

P0563

System Voltage is High

Yes

P0565

Cruise Main Switch Circuit Error

P0566

Cruise Cancel Switch Circuit Error

P0567

Cruise Resume Switch Circuit Error

P0568

Cruise Set Switch Circuit Error

P0601

PCM/ECM Memory Checksum

Yes

P0602

PCM/ECM Programming error

P0604

PCM/ECM RAM error

P0606

PCM/ECM Internal Performance

P1106

MAP Circuit Intermittent High Voltage)

P1107

MAP Circuit Intermittent Low Input Voltage

P1111

IAT Circuit Intermittent High Voltage

P1112

IAT Circuit Intermittent Low Input Voltage

P1114

ECT Circuit Intermittent Low Voltage

P1115

ECT Circuit Intermittent High Voltage

P1120

TPS1 Circuit

Yes

P1125

ETC Limit Performance Mode

Yes

P1133

O2 Sensor – Too Few Rich/Lean and Lean/Rich Switches (Bank 1 Sensor 1)

Yes

P1134

O2 Sensor – Transition Switch Time ratio (Bank 1 Sensor 1)

Yes

P1153

O2 Sensor – Too Few Rich/Lean and Lean/Rich Switches (Bank 2 Sensor 1)

Yes

P1154

O2 Sensor – Transition Switch Time ratio (Bank 2 Sensor 1)

Yes

P1167

Fuel supply System RICH During Decel Fuel Cut Off (Bank 1)

P1169

Fuel supply System RICH During Decel Fuel Cut Off (Bank 2)

P1171

Fuel supply System Lean During Power Enrichment

P1220

TPS2 Circuit

Yes

P1221

TPS1–TPS2 Correlation (Circuit Performance)

P1271

APS1–APS2 Correlation (Circuit Performance)

P1272

APS2–APS3 Correlation (Circuit Performance)

P1273

APS1–APS3 Correlation (Circuit Performance)

P1275

APS1 Circuit

Yes

P1280

APS2 Circuit

Yes

P1285

APS3 Circuit

Yes

6E–130

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC

Description

Type

Illuminate MIL (Check Engine Lamp)

Illuminate RPL (Reduced Power Lamp)

P1290

ETC Forced Idle Mode

Yes

P1295

ETC Power Management Mode

Yes

P1299

ETC Forced Engine Shutdown in Mode

Yes

P1310

ION Sensing Module Diagnostic

Yes

P1311

ION Sensing Module SEC 1 Line Circuit Fault

Yes

P1312

ION Sensing Module SEC 2 Line Circuit Fault

Yes

P1326

ION Sensing Module Combustion Quality circuit

Yes

P1340

ION Sensing Module – Cylinder Synchronization

Yes

P1404

EGR Range/Performance (Closed Valve)

Yes

P1441

EVAP Control System Continuous Open Purge Flow

Yes

P1514

TPS–MAF Correlation

Yes

P1515

Command–Acrual TPS Correlation

Yes

P1516

Command–Acrual TPS Correlation Error

Yes

P1523

Throttle Actuator Control Return Performance

P1625

PCM/ECM System Reset

P1635

Reference Voltage #1 Circuit

P1639

Reference Voltage #2 Circuit

P1640

ODM Output circuit Fault

P1650

QDM Output Circuit Fault

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–131

Diagnostic Trouble Code (DTC) P0101 MAF System Performance

060R200052

Circuit Description The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain control module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantity of air entering the engine indicates an acceleration or high load situation, while a small quantity or air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 4 to 7g/s at idle to around 25 to 40g/s at maximum engine load. DTC P0101 will be set if the signal from the MAF sensor does not match a predicted value based on throttle position and engine RPM.

Conditions for setting the DTC B B B B

The engine is running. No TP sensor and MAP sensor DTCs are set. No MAF frequency DTCs are set. System voltage is between 11.5 volts and 16 volts.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected fault. B The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure.

B The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0101 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P0101 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. B The duct work at the MAF sensor for leaks. B An engine vacuum leak. B The PCV system for vacuum leaks. B An incorrect PCV valve. B The engine oil dip stick not fully seated. B The engine oil fill cap loose or missing. Check for the following conditions:

6E–132

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness- Inspect the wiring harness for damage. If the harness appears to be OK, observe the Mass Air Flow (MAF) display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. B Plugged intake air duct or filter element B A wide–open throttle acceleration from a stop should cause the mass air flow displayed on a Tech 2 to

increase from about 3–6 g/s at idle to 100 g/s or greater at the time of the 1–2 shift. If not, check for a restriction. A change in the display will indicate the location of the fault. If DTC P0101 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P001 Diagnostic Chart may isolate the cause of the fault.

DTC P0101 – MAF System Performance Step

Action

Go to Step 2

—

Go to Step 6

Go to Step 3

11.5 to 12.5 Volt

Go to Step 5

Go to Step 4

—

Verify repair

—

Verify repair

—

Verify repair

Go to Step 7

1. Ignition “OFF”. 2. Check the 12 volt signal circuit for the following conditions: B An open circuit B A short to ground Check the MAF ground circuit for the following conditions: B An open circuit B A short to voltage Was a problem found?

—

Go to OBD System Check

1. Ignition “ON”, Engine “OFF”. 2. Using a Digital Voltmeter (DVM), check the 12 volt signal circuit for the correct voltage.

Was the problem found? 5

1. Ignition “OFF”. 2. Disconnect the Mass Air Flow (MAF) Sensor harness connector from the MAF Sensor. 3. Place an unpowered test lamp between the 12 volt signal circuit and the ground circuit, both at the MAF Sensor connector. 4. Ignition “ON”, Engine“OFF”.

Did the DVM indicate a value within the following range? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Did the test lamp illuminate? 3

Value(s)

1. Ignition “OFF”. 2. Check the MAF Sensor signal circuit between the PCM and the MAF Sensor for the following conditions: B An open circuit B A short to ground B A short to battery voltage Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–133

DTC P0101 – MAF System Performance (Cont’d) Step

Action

4 to 7 g/s

Go to Step 8

Go to Step 9

25 to 40 g/s

Go to Step 10

Go to Step 9

—

Verify repair

—

Verify repair

—

Replace the MAF Sensor. Is the action complete?

Observe the Tech 2 value while increasing the engine RPM to its upper limit. Does the Tech 2 display the following value(s)?

Yes

1. Connect the MAF Sensor wiring harness connector to the MAF Sensor. 2. Connect the Tech 2 to the vehicle. 3. Place the Transmission in Park/Neutral, and fully apply the Parking Brake. 4. Start the engine. 5. Select the Mass Air Flow (MAF) parameter on the Tech 2. With the engine idling, does the Tech 2 display the following value(s)?

Value(s)

Replace the PCM. IMPORTANT: The PCM must be reprogrammed. Refer to PCM reprogramming. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6E–134

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency

060R200052

Circuit Description The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain control module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantity of air entering the engine indicates an acceleration or high load situation, while a small quantity of air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 4 to 7g/s at idle to around 25 to 40 g/s at maximum engine load. DTC P0102 will be set if the signal from the MAF sensor is below the possible range of a normally operating MAF sensor.

Conditions for Setting the DTC B The engine is running above 500 RPM for more than 10 seconds. B System voltage is above 11.5 volts. B MAF signal frequency is below 1.6g/s for a total of 50-percent of the last 1000 samples monitored. A sample is taken every cylinder event.

B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0102 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0102 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Misrouted harness – Inspect the MAF sensor harness to ensure that it is not routed too close to high voltage wires. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the Tech 2 while moving connectors and wiring harnesses related to the MAF sensor. A change in the display will indicate the location of the fault. B Plugged intake air duct or filter element – A wide-open throttle acceleration from a stop should cause the mass air flow displayed on a Tech 2 to increase from

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS about 3-6 g/second at idle to 100 g/second or greater at the time of the 1-2 shift. If not, check for a restriction. If DTC P0102 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

Test Description

6E–135

2. This step verifies that the problem is present at idle. 4. A voltage reading of less than 4 or over 5 volts at the MAF sensor signal circuit indicates a fault in the wiring or a poor connection. 5. This verifies that ignition feed voltage and a good ground are available at the MAF sensor.

Number(s) below refer to the step number(s) on the Diagnostic Chart.

DTC P0102 – MAF Sensor Circuit Low Frequency Step

Action

1. 2. 3. 4.

Go to Step 3

Go to Step 5

—

Go to Step 4

Refer to Diagnostic Aids

11.5–12 V

Go to Step 5

Go to Step 8

—

Go to Step 7

Go to Step 6

—

Go to Step 11

Go to Step 7

—

Verify repair

Go to Step 12

Go to Step 9

Go to Step 10

Connect a test light between the MAF sensor ignition feed circuit and battery ground. 1. Check for a poor connection at the MAF sensor. 2. If a poor connection is found, replace the faulty terminal(s). Was a poor connection found?

1.6 g/s

Connect a test light between the MAF sensor ignition feed and ground circuits at the MAF sensor harness connector.

Is the test light “ON”? 7

Go to Step 2

Ignition “OFF”. Disconnect the MAF sensor connector. Ignition “ON”, engine “OFF”. Using a DVM, measure voltage between the MAF sensor signal circuit and battery ground.

Is the test light “ON”? 6

—

Go to OBD System Check

1. Ignition “ON”, engine “OFF”. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor “DTC” info for DTC P0102.

Is the voltage near the specified value? 5

1. Start the engine. 2. With the engine idling, monitor “MAF Frequency” display on the Tech 2.

Does the Tech 2 indicate DTC P0102 failed this ignition? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is the “MAF Frequency” below the specified value? 3

Value(s)

1. Ignition “OFF”. 2. Disconnect the MAF sensor. 3. Disconnect the PCM connector for the MAF signal circuit. 4. Ignition “ON”, engine “OFF”. 5. With the DVM, measure the voltage between the MAF signal terminal at the PCM and battery ground. Is the voltage under the specified value?

6E–136

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0102 – MAF Sensor Circuit Low Frequency (Cont’d) Step

Action

1. 2. 3. 4.

—

Verify repair

Go to Step 13

—

Verify repair

—

Verify repair

—

Verify repair

Go to Step 14

—

Verify repair

—

Replace the MAF sensor. Is the action complete?

Verify repair

Locate and repair the open in the ignition feed circuit to the MAF sensor. Is the action complete?

—

Locate and repair the open in the ground circuit to the MAF sensor. Is the action complete?

Ignition “OFF”. Disconnect the PCM connector. Ignition “ON”. Check the MAF sensor signal circuit between the PCM and the MAF sensor for an open, short to ground, or short to the MAF ground circuit.

Is the action complete? 11

Yes

Ignition “OFF”. Disconnect the PCM connector. Ignition “ON”. Check the MAF sensor signal circuit for a short to 5 volts.

Is the action complete? 10

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–137

Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency

060R200052

Circuit Description The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain control module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantity of air entering the engine indicates an acceleration or high load situation, while a small quantity of air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 4 to 7g/s at idle to around 25 to 40 g/s at maximum engine load. DTC P0103 will be set if the signal from the MAF sensor is above the possible range of a normally operating MAF sensor.

B The PCM calculates an airflow value based on idle air control valve position, throttle position, RPM and barometric pressure. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0103 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0103 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

Diagnostic Aids

B The engine is running above 500 RPM for more than 10 seconds. B System voltage is above 11.5 volts. B MAF signal frequency is above 40g/s for a total of 50 percent of the last 200 samples monitored. A sample is taken every cylinder event.

If DTC P0103 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected the fault.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. This step verifies that the problem is present at idle.

6E–138

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

4. A frequency reading with the MAF sensor connector disconnected indicates an electromagnetic interference (EMI) related fault. 8. This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only memory (EEPROM). When the PCM is being replaced, the new PCM must be programmed. Refer to PCM Replacement and Programming Procedures in Powertrain Control Module (PCM) and Sensors.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–139

DTC P0103 – MAF Sensor Circuit High Frequency Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Refer to Diagnostic Aids

40g/s

Go to Step 4

Go to Step 7

0g/s

Go to Step 5

Go to Step 6

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 7

40g/s

Go to Step 5

Go to Step 8

—

Verify repair

—

1. Start the engine. 2. With the engine idling, monitor “MAF Frequency” display on the Tech 2. Is “MAF Frequency” above the specified value?

1. 2. 3. 4.

Ignition “OFF”. Disconnect the MAF sensor connector. Ignition “ON”, engine idling. Using a Tech 2, monitor “MAF Frequency”.

Does the Tech 2 indicate a “MAF Frequency” at the specified value? 5

Replace the MAF sensor. Is the action complete?

1. Check the MAF harness for incorrect routing near high voltage components (solenoids, relays, motors). 2. If incorrect routing is found, correct the harness routing. Was a problem found?

1. With the engine idling, monitor “MAF Frequency” display on the Tech 2. 2. Quickly snap open throttle to wide open throttle while under a road load and record value. Does the Tech 2 indicate “MAF Frequency” above the specified value?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

6E–140

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0106 MAP System Performance

060R200051

Circuit Description The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the powertrain control module (PCM) varies from below 2 volts at idle (high vacuum) to above 4 volts at wide-open throttle (low vacuum) at sea level. The MAP sensor is used to determine manifold pressure changes while the linear exhaust gas recirculation (EGR) flow test diagnostic is being run (refer to DTC P0401), engine vacuum level for some other diagnostics, and barometric pressure (BARO). The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that varies excessively above or below the calculated value, DTC P0106 will set.

Conditions for Setting the DTC B B B B B B B B

No TP sensor DTCs are present. Engine speed is steady, changing less then 100 RPM. Engine speed is between 1000 rpm and 4000 rpm. Throttle position is steady, throttle angle changes less than 1%. EGR flow rate is steady, changing less than 4%. No change in brake switch, A/C clutch, TCC or power steering pressure switch status. Above conditions are met for longer than 1 second. Actual MAP value varies more than 10 kPa.

B The MAP value must vary for a total of 10 seconds over a 20-second period of time that the samples were monitored. B The failure must occur for 2 consecutive trips.

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. B The PCM will default to a BARO value of 79.3 kPa. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0106 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0106 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0106 cannot be duplicated, the information included in the Failure Records data can be useful in

6E–141

determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1107 Diagnostic Chart may isolate the cause of the fault.

DTC P0106 – MAP System Performance Step

Action

—

Go to Step 4

Go to Step 3

—

Verify repair

Refer to Diagnostic Aids

11 kPa

Go to Step 5

Go to Step 13

105 kPa

Go to Step 6

Go to Step 9

104 kPa

Go to Step 7

Go to Step 8

—

Verify repair

Go to Step 11

1. Connect a test light between B+ and the MAP sensor signal circuit at the MAP sensor harness connector. 2. Observe the MAP value displayed on the Tech 2. 1. Jumper the 5 volt reference circuit and the MAP signal circuit together at the MAP sensor harness connector. 2. Observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value?

Go to Step 2

1. Disconnect the MAP sensor electrical connector. 2. Observe the MAP value displayed on the Tech 2.

Is the MAP value near the specified value? 6

—

Go to OBD System Check

1. Check for the following conditions: B Vacuum hoses disconnected, damaged, or incorrectly routed B Intake manifold vacuum leaks B Vacuum leaks at throttle body B Vacuum leaks at EGR valve flange and pipes B Crankcase ventilation valve faulty, missing or incorrectly installed. 2. If a problem is found, repair as necessary.

Is the MAP value near the specified value? 5

Was a problem found? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Tech 2 indicate DTC P0106 failed? 3

Value(s)

1. Ignition “OFF”. 2. Disconnect the PCM and check the sensor ground circuit for high resistance, an open between the PCM and the MAP sensor, or for a poor connection at the PCM. 3. If a problem is found, repair as necessary. Was a problem found?

6E–142

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0106 – MAP System Performance (Cont’d) Step

Action

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 14

—

Verify repair

Go to Step 12

—

Verify repair

—

Verify repair

Go to Step 14

—

Verify repair

—

1. Ignition “OFF”, disconnected the PCM. 2. Ignition “ON”, check the MAP signal circuit for a short to voltage or a short to the 5 volt reference circuit. 3. If a problem is found, repair as necessary. Was a problem found?

Go to Step 10

Replace the MAP sensor. Is the action complete?

Verify repair

1. Check for a poor connection at the MAP sensor. 2. If a problem is found, repair as necessary. Was a problem found?

—

1. Check the MAP sensor signal circuit for a poor connection at the PCM. 2. If a problem is found, repair as necessary. Did the terminal require replacement?

1. Ignition “OFF”. 2. Disconnect the PCM, and check the MAP sensor signal circuit for high resistance, an open, a short to ground, or a short to the sensor ground circuit. 3. If a problem is found, repair as necessary. Was a problem found?

Yes

1. Check the 5 volt reference circuit for high resistance, an open between the PCM and the MAP sensor, or a poor connection at the PCM. 2. If a problem is found, repair as necessary. Was a problem found?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–143

Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage

060R200051

Circuit Description

Action Taken When the DTC Sets

The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the powertrain control module (PCM) varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition “ON”, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the exhaust gas recirculation (EGR) flow test diagnostic is being run (refer to DTC P0401), to determine engine vacuum level for some other diagnostics and to determine barometric pressure (BARO). The PCM monitors the MAP signals for voltages outside the normal range of the MAP sensor. If the PCM detects a MAP signal voltage that is excessively low, DTC P0107 will be set.

B The PCM will ON the MIL after second trip with detected fault. B The PCM will default to a BARO value of 79.3 kPa. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Setting the DTC B No TP sensor DTCs present. B Engine is running. B Throttle angle is above 1% if engine speed is less than 1000 RPM. B Throttle angle is above 2% if engine speed is above 1000 RPM. B The MAP sensor indicates manifold absolute pressure at or below 11 kPa for a total of approximately 10 seconds over a 16-second period. B Ignition voltage more than 11 volts.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0107 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0107 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Check for intermittent codes. B The MAP sensor shares a 5 Volt reference with the Fuel Tank Pressure Sensor. If these codes are also set, it could indicate a problem with the 5 Volt reference circuit . B The MAP sensor shares a ground with the Fuel Tank Pressure Sensor, the ECT sensor, and the Transmission Fluid Temperature sensor. B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken

6E–144

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

If DTC P0107 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0107 Diagnostic Chart may isolate the cause of the fault.

DTC P0107 – MAP Sensor Circuit Low Voltage Step

Action

1. Ignition “ON”, engine “OFF”. 2. With the throttle closed, observe the MAP value displayed on the Tech 2.

0 V 11 kPa at sea level

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

5 V 104 kPa

Go to Step 10

Go to Step 5

5 V 104 kPa

Go to Step 6

Go to Step 8

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 11

1. Ignition “OFF”. 2. Disconnect the PCM and check the 5 volt reference circuit for an open or short to ground. 3. If the 5 volt reference circuit is open or shorted to ground, repair it as necessary. Was the 5 volt reference circuit open or shorted to ground?

Go to Step 2

1. Disconnect the jumper. 2. Connect a test light between B+ and the MAP sensor signal circuit at the MAP sensor harness connector. 3. Observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value.

—

1. Ignition “OFF”. 2. Disconnect the MAP sensor electrical connector. 3. Jumper the 5 volt reference circuit and the MAP signal together at the MAP sensor harness connector. 4. Ignition “ON”. 5. Observe the MAP value displayed on the Tech 2. Is the MAP value near the specified value? (If no, start with diagnosis chart for other sensors in the circuit and see if 5V returns.)

Go to OBD System Check

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is the MAP value near the specified value? 3

Value(s)

Check the 5 volt reference circuit for a poor connection at the PCM and replace the terminal if necessary. Did the terminal require replacement?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–145

DTC P0107 – MAP Sensor Circuit Low Voltage (Cont’d) Step

Action

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 11

—

Verify repair

—

Verify repair

—

Replace the MAP sensor. Is the action complete?

Check the MAP sensor signal circuit for a poor connection at the PCM and the MAP sensor; replace the terminal if necessary. Did the terminal require replacement?

Yes

1. Ignition “OFF”. 2. Disconnect the PCM, and check the MAP signal circuit for an open, short to ground, or short to the sensor ground circuit. 3. If the MAP sensor signal circuit is open or shorted to ground, repair it as necessary. Was the MAP signal circuit open or shorted to ground?

Value(s)

6E–146

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage

060R200051

Circuit Description

Action Taken When the DTC Sets

The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the powertrain control module (PCM) varies from below 2 volts at idle (high vacuum) to above 4 volts with the key “ON”, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the linear EGR flow test diagnostic is being run (refer to DTC P0401), to determine engine vacuum level for some other diagnostics and to determine barometric pressure (BARO). The PCM monitors the MAP signals for voltages outside the normal range of the MAP sensor. If the PCM detects a MAP signal voltage that is excessively high, DTC P0108 will be set.

Conditions for Setting the DTC B No TP sensor DTCs present. B Engine is running for more than 10 seconds. B Throttle position is below 3% if engine speed is below 1000 RPM. B Throttle position is below 10% if engine speed is above 1000 RPM. B The MAP sensor indicates an intermittent manifold absolute pressure above 80 kPa for a total of approximately 10 seconds over a 16-second period.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0108 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0108 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B The MAP sensor shares a 5 Volt reference with the Fuel Tank Pressure Sensor (Vapor Pressure Sensor). If these codes are also set, it could indicate a problem with the 5 Volt reference circuit. B The MAP sensor shares a ground with the Fuel Tank Pressure Sensor, the ECT sensor, and the Transmission Fluid Temperature sensor. B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

6E–147

If DTC P0108 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1108 Diagnostic Chart may isolate the cause of the fault.

DTC P0108 – MAP Sensor Circuit High Voltage Step

Action

1. 2. 3. 4.

Ignition “OFF”. Disconnect the MAP sensor electrical connector. Ignition “ON”. Note the MAP sensor voltage displayed on the Tech 2. (If no, start with diagnostic chart for other sensors in the circuit and see if 5V returns.)

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

11 kPa 0.0 V

Go to Step 5

Go to Step 6

—

Go to Step 7

Go to Step 9

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 12

—

Verify repair

Go to Step 10

Check for a plugged or leaking vacuum supply to the MAP sensor. Is the vacuum supply plugged or leaking?

Go to Step 4

1. Check for a poor sensor ground terminal connection at the MAP sensor electrical connector. 2. If a problem is found, replace the faulty terminal. Did the terminal require replacement?

90 kPa

1. Check the MAP signal circuit for a short to voltage or a short to the 5 volt reference circuit. 2. If the MAP sensor signal circuit is shorted, repair circuit as necessary. Was the MAP sensor signal circuit shorted?

Go to Step 2

Probe the sensor ground circuit with a test light to B+. Is the test light “ON”?

—

Go to OBD System Check

Is the MAP sensor voltage at the specified value? 5

1. If the engine idle is rough, unstable or incorrect, repair the idle problem before using this chart. Refer to Symptoms section. 2. With the engine idling, note the MAP value on the Tech 2.

Does the Tech 2 indicate DTC P0108 failed this ignition? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is the MAP reading above the specified value? 3

Value(s)

1. Check for a poor sensor ground terminal connection at the PCM. 2. If a problem is found, replace the faulty terminal. Did the terminal require replacement?

6E–148

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0108 – MAP Sensor Circuit High Voltage (Cont’d) Step

Action

1. Check the continuity of the MAP sensor ground circuit. 2. If the MAP sensor ground circuit measures over 5 ohms, repair open or poor connection. Was a condition found and corrected?

Value(s)

Yes

—

Verify repair

Go to Step 11

—

Verify Repair

—

Verify repair

—

Replace the MAP sensor. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–149

Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage

D06RY00147

Circuit Description

Conditions for Clearing the MIL/DTC

The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The powertrain control module (PCM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the PCM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance is lower, causing the PCM to monitor a lower voltage. DTC P0112 will set when the PCM detects an excessively low signal voltage on the intake air temperature sensor signal circuit.

B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0112 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0112 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC B The engine has been running for over 15 seconds. B Vehicle speed is greater than 30 mph (48 km/h) . B IAT signal voltage indicates and intake air temperature greater than 148°C (298°F) (about 5 volts) for a total of 12.5 seconds over a 25-second period of time.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected fault. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-bout terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A change in the IAT display will indicate the location of the fault. If DTC P0112 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

6E–150

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Verifies that the fault is present. 3. If DTC P0112 can be repeated only by duplicating the Failure Records condition, refer to the Temperature vs. Resistance Value table. The table may be used to test the IAT sensor at various temperatures to evaluate the possibility of a “shifted” sensor that may be stored above or below a certain temperature. If this is the case, replace the IAT sensor. If the IAT sensor appears to be OK, the fault is intermittent; refer to Diagnostic Aids.

Intake Air Temperature Sensor °C

°F

OHMS

Temperature vs. Resistance Values (approximate) 100

212

177

176

332

140

667

113

1188

1802

2796

4450

7280

–5

12300

–15

21450

–30

–22

52700

–40

100700

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–151

DTC P0112–IAT Sensor Circuit Low Voltage Step

Action

1. 2. 3. 4.

Ignition “OFF”. Disconnect the IAT sensor electrical connector. Ignition “ON”. Observe the intake air temperature on the Tech 2.

148°C (283°F)

Go to Step 4

Go to Step 3

—

Refer to Test Description

Refer to Diagnostic Aids

–38°C (–36°F)

Go to Step 6

Go to Step 5

—

Verify repair

Go to Step 7

—

Verify repair

—

Verify repair

—

Replace the IAT sensor. Is the action complete?

Go to Step 2

1. Ignition “OFF”. 2. Disconnect the PCM electrical connectors. 3. Check the IAT sensor signal circuit for a short to ground. Is the IAT sensor signal circuit shorted to ground?

—

Go to OBD System Check

1. Ignition “ON”, engine “OFF”. Review and record Tech 2 Failure Records data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor the “DTC” info for DTC P0112.

Is the intake air temperature below the specified value? 5

1. Ignition “ON”, engine “OFF”. 2. Using a Tech 2, monitor the intake air temperature (IAT).

Does the Tech 2 indicate DTC P0112 failed this ignition? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is the intake air temperature greater than the specified value? 3

Value(s)

6E–152

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage

D06RY00147

Circuit Description

Conditions for Clearing the MIL/DTC

The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The powertrain control module (PCM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the PCM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance is lower causing the PCM to monitor a lower voltage. DTC P0113 will set when the PCM detects an excessively high signal voltage on the intake air temperature sensor signal circuit.

B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0113 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0113 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC B B B B B

The engine has been running for over 30 seconds. Vehicle speed is less than 20 mph (32 km/h). ECT signal temperature is above 60°C (140°F). Mass air flow is less then 20 g/second. IAT signal voltage indicates an intake air temperature less than –39°C (–38°F) for total of 12.5 seconds over a 25-second period.

Diagnostic Aids Check for the following conditions: B The IAT sensor shares a ground with the EGR position sensor and the TP sensor. Check the ground if these DTC’s are set. B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A change in the IAT display will indicate the location of the fault. If DTC P0113 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

6E–153

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description

Intake Air Temperature Sensor

Number(s) below refer to the step number(s) on the Diagnostic Chart: 2. Verifies that the fault is present. 3. If DTC P0113 can be repeated only by duplicating the Failure Records conditions, refer to the “Temperature vs. Resistance Values” table. The table may be used to test the IAT sensor at various temperatures to evaluate the possibility of a “shifted” sensor that may be open above or below a certain temperature. If this is the case, replace the IAT sensor. If the IAT sensor appears to be OK, the fault is intermittent; refer to Diagnostic Aids.

°C

°F

OHMS

Temperature vs. Resistance Values (approximate) 100

212

177

176

332

140

667

113

1188

1802

2796

4450

7280

–5

12300

–15

21450

–30

–22

52700

–40

100700

DTC P0113 –IAT Sensor Circuit High Voltage Step

Action

Ignition “ON”, engine “OFF”. Observe the “Intake Air Temp” display on the Tech 2.

1. Ignition “OFF”. 2. Disconnect the IAT sensor electrical connector. 3. Jumper the IAT signal circuit and the sensor ground circuit together at the IAT sensor harness connector. 4. Ignition “ON”. 5. Observe the “Intake Air Temp” display on the Tech 2. Is the “Intake Air Temp” at the specified value?

1. Jumper the IAT signal circuit at the IAT sensor harness connector to chassis ground. 2. Observe the “Intake Air Temp” display on the Tech 2. Is the “Intake Air Temp” at the specified value?

—

Go to Step 2

Go to OBD System Check

–38°C (–36°F)

Go to Step 4

Go to Step 3

—

Refer to Test Description

Refer to Diagnostic Aids

140°C (284°F)

Go to Step 6

Go to Step 5

140°C (284°F)

Go to Step 7

Go to Step 8

1. Ignition “ON”, engine “OFF”. 2. Review and record Tech 2 Failure Records data parameters. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor “DTC” info for DTC P0113. Does the Tech 2 indicate DTC P0113 failed?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is the “Intake Air Temp” below the specified value? 3

Value(s)

6E–154

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0113 –IAT Sensor Circuit High Voltage (Cont’d) Step

Action

Go to Step 10

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 11

—

Verify repair

—

Verify repair

—

Replace the IAT sensor. Is the action complete?

Verify repair

Check for a poor sensor ground or IAT signal circuit terminal connection at the PCM and replace terminal(s) if necessary. Did any of the terminals need to be replaced?

—

1. Ignition “OFF”. 2. Disconnect the PCM, and check the IAT signal circuit for an open. 3. If the IAT sensor signal circuit is open, repair it as necessary. Was the IAT signal circuit open?

1. Ignition “OFF”. 2. Disconnect the PCM, and check the IAT sensor ground circuit for an open. 3. If the IAT sensor ground circuit is open, repair it as necessary. Was the IAT sensor ground circuit open?

Yes

Check for poor connections at the IAT sensor and replace terminals if necessary. Did any terminals require replacement?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–155

Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage

D06RY00148

Circuit Description

Conditions for Clearing the MIL/DTC

The engine coolant temperature (ECT) sensor is a thermistor mounted on a coolant crossover pipe at the front of the engine. The powertrain control module (PCM) applies a voltage (about 5 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the PCM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes lower, and the ECT signal voltage measured at the PCM drops. With a fully warmed-up engine, the ECT signal voltage should measure about 1.5 to 2.0 volts.

B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0117 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0117 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC B Engine running time is longer than 120 seconds. B The ECT sensor signal indicates an engine coolant temperature greater than 150°C (302°F) (about 0.10 V) for a total of 50 seconds over a 100–second period.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected fault. B The PCM will substitute the ECT reading with a default engine coolant temperature value. The default value is based on start-up intake air temperature and running time. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the ECT sensor. A change in the ECT display will indicate the location of the fault. If DTC P0117 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1114 Diagnostic Chart may isolate the cause of the fault.

6E–156

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Verifies that the fault is present. 3. If DTC P0117 can be repeated only by duplicating the Failure Records conditions, refer to the “Temperature vs. Resistance Values” table. The table may be used to test the ECT sensor at various temperatures to evaluate the possibility of a “shifted” sensor that may be shorted above or below a certain temperature. If this is the case, replace the ECT sensor. If the ECT sensor appears to be OK, the fault is intermittent; refer to Diagnostic Aids.

Engine Coolant Temperature Sensor °C

°F

OHMS

Temperature vs. Resistance Values (approximate) 100

212

177

176

332

140

667

113

1188

1802

2796

4450

7280

–5

12300

–15

21450

–30

–22

52700

–40

100700

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–157

DTC P0117 – ECT Sensor Low Voltage Step

Action

1. Ignition “ON”, engine “OFF”. 2. Observe the “Eng Cool Temp” display on the Tech 2.

1. Disconnect the ECT sensor electrical connector. 2. Observe the “Eng Cool Temp” display on the Tech 2. Is the “Eng Cool Temp” at the specified value?

Go to Step 2

139°C (282°F)

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

–39°C (–38°F)

Go to Step 6

Go to Step 5

—

Verify repair

Go to Step 7

—

Verify repair

—

Verify repair

—

Replace the ECT sensor. Is the action complete?

—

1. Ignition “OFF”. 2. Disconnect the PCM and check the ECT signal circuit for a short to ground or a short to the sensor ground circuit. 3. If the ECT signal circuit is shorted. repair it as necessary. Was the ECT signal circuit shorted to ground?

Go to OBD System Check

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is the “Eng Cool Temp” below the specified value? 3

Value(s)

6E–158

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage

060R200053

Circuit Description

Conditions for Clearing the MIL/DTC

The engine coolant temperature (ECT) sensor is a thermistor mounted in on a coolant crossover pipe at the front of the engine. The powertrain control module (PCM) applies a voltage (about 5 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the PCM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes less, and the ECT signal voltage measured at the PCM drops. With a fully warmed-up engine, the ECT signal voltage should measure about 1.5 to 2.0 volts.

B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0118 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0118 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC B Engine running time is longer than 90 seconds. B The ECT sensor signal indicates an engine coolant temperature of –39°C (–38°F) or less (about 5 volts) for a total of 50 seconds over a 100-second period.

Diagnostic Aids Check for the following conditions: The ECT shares a ground with the Transmission Fluid Temperature sensor, the Fuel Tank Pressure sensor, and the MAP sensor. Check the ground if these DTCs are also set. B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the ECT sensor. A change in the ECT display will indicate the location of the fault. If DTC P0118 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently,

6E–159

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS performing the DTC P1115 Diagnostic Chart may isolate the cause of the fault.

Engine Coolant Temperature Sensor °C

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Verifies that the fault is present. 3. If DTC P0118 can be repeated only by duplicating the Failure Records conditions, refer to the “Temperature vs. Resistance Value” table. The table may be used to test the ECT sensor at various temperatures to evaluate the possibility of a “shifted” sensor that may be shorted above or below a certain temperature. If this is the case, replace the ECT sensor. If the ECT sensor appears to be OK, the fault is intermittent; refer to Diagnostic Aids.

°F

OHMS

Temperature vs. Resistance Values (approximate) 100

212

177

176

332

140

667

113

1188

1802

2796

4450

7280

–5

12300

–15

21450

–30

–22

52700

–40

100700

DTC P0118 – ECT Sensor Circuit High Voltage Step

Action

1. Ignition “ON”, engine “OFF”. 2. Observe the “Eng Cool Temp” display on the Tech 2.

1. Disconnect the ECT sensor electrical connector. 2. Jumper the ECT signal circuit and the sensor ground circuit together at the ECT sensor harness connector. 3. Observe the “Eng Cool Temp” display on the Tech 2. Is the “Eng Cool Temp” at the specified value?

1. Jumper the ECT signal circuit at the ECT sensor harness connector to chassis ground. 2. Observe the “Eng Cool Temp” display on the Tech 2. Is the “Eng Cool Temp” at the specified value?

—

Go to Step 2

Go to OBD System Check

–39°C (–38°F)

Go to Step 4

Go to Step 3

—

Refer to Test Description

Refer to Diagnostic Aids

140°C (284°F)

Go to Step 6

Go to Step 5

140°C (284°F)

Go to Step 7

Go to Step 8

—

Verify repair

Go to Step 10

1. Ignition “ON”, engine “OFF”. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor the “DTC” info for DTC P0118. Does the Tech 2 indicate DTC P0118 failed?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is the “Eng Cool Temp” below the specified value? 3

Value(s)

Check for poor connections at the ECT sensor and replace terminals if necessary. Did any terminals require replacement?

6E–160

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0118 – ECT Sensor Circuit High Voltage (Cont’d) Step

Action

Verify repair

Go to Step 9

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 11

—

Verify repair

—

Verify repair

—

Replace the ECT sensor. Is the action complete?

—

Check for a poor sensor ground or ECT signal circuit terminal connection at the PCM and replace terminal(s) if necessary. Did any of the terminals need to be replaced?

1. Ignition “OFF”. 2. Disconnect the PCM, and check the ECT signal circuit for an open. 3. If the ECT sensor signal circuit is open, repair it as necessary. Was the ECT signal circuit open?

Yes

1. Ignition “OFF”. 2. Disconnect the PCM, and check the ECT sensor ground circuit for an open. 3. If the ECT sensor ground circuit is open, repair it as necessary. Was the ECT sensor ground circuit open?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–161

Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control

060R200053

Circuit Description To provide the best possible combination of driveability, fuel economy, and emission control, a “closed loop” air/fuel metering system is used. When the vehicle is first started, the powertrain control module (PCM) controls fuel delivery in “open loop”, ignoring the heated oxygen sensor (HO2S) signals and calculating air/fuel ratio based on inputs from the engine coolant temperature, throttle position, and mass air flow sensors. The PCM will begin using the Bank 1 HO2S 1 and Bank 2 HO2S 1 signals for controlling fuel delivery under “closed loop” conditions when the following conditions have been met: B The HO2S output signals are varying, indicating that the sensors are hot enough to operate properly. B The engine coolant temperature sensor indicates coolant temperature above 50°C (122°F). B Time since start-up is at least 16 seconds for a warm engine or 23 seconds for a cold engine.

Conditions for Setting the DTC B B B B

No active IAT, MAF or ECT DTC(s) are present. Engine is running. Vehicle speed is greater than 5 mph (8 km/h) . Intake air temperature is greater than –10°C (14°F) 0°C (32°F). B Start–up engine coolant temperature is between –10°C (–14°F) and 28°C (82°F).

B For a warm engine (intake air temperature is greater than 10°C/50°F), engine coolant temperature sufficient to allow “closed loop” operation (50°C/122°F) is not achieved within 2 minutes of start-up. For a cold engine (intake air temperature between (–7°C and 10°C), engine coolant temperature sufficient to allow “closed loop” operation (50°C/122°F) is not achieved within 10 minutes of start-up. B The above condition fails 20 consecutive times.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0125 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0125 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–162

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids

Engine Coolant Temperature

DTC P0125 set indicates a faulty ECT sensor. Comparing the engine coolant temperature displayed on a Tech 2 with actual coolant temperature measured with a thermometer may isolate this condition. If the displayed engine coolant temperature is not close to the actual coolant temperature, replace the ECT sensor. Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0125 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage wince the DTC was last set.

°C

°F

OHMS

Temperature vs. Resistance Values (approximate) 100

212

177

176

332

140

667

113

1188

1802

2796

4450

7280

–5

12300

–15

21450

Test Description

–30

–22

52700

Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Comparing the engine coolant temperature displayed on a Tech 2 with actual coolant temperature measured with a thermometer may isolate this condition. If the displayed engine coolant temperature is not close to the actual coolant temperature, replace the ECT sensor. If the temperatures are close, the fault is intermittent; refer to Diagnostic Aids.

–40

100700

DTC P0125 –ECT Excessive Time to Closed Loop Fuel Control Step

Action

—

Go to Step 2

Go to OBD System Check

—

Go to applicable ECT sensor DTC chart

Go to Step 3

—

Go to Step 4

Go to Step 9

21°C (70°F)

Refer to Diagnostic Aids

Go to Step 5

—

Go to Step 6

Go to Step 9

Are any ECT sensor DTCs set?

1. Allow the engine to cool completely. 2. Check the cooling system coolant level (refer to Cooling and Radiator). 1. Start the engine. 2. With the engine idling, monitor “ENG COOL TEMP” display on the Tech 2. Does “ENG COOL TEMP” increase to above the specified value within 2 minutes?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is the coolant level OK? 4

Value(s)

Check for proper operation of the thermostat (refer to Cooling and Radiator). Is the thermostat operating correctly?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–163

DTC P0125 –ECT Excessive Time to Closed Loop Fuel Control (Cont’d) Step

Action

—

Go to Step 12

Go to Step 8

—

Go to Step 10

Go to Step 11

—

Verify repair

—

Verify repair

—

Verify repair

—

Verify repair

—

Replace the ECT sensor. Is the action complete?

Go to Step 7

Replace the faulty terminal(s) or repair faulty wiring as necessary. Is the action complete?

Go to Step 9

Refer to Cooling and Radiator for cooling system diagnosis and repair condition as necessary. Is the action complete?

—

Check for high resistance in wiring related to the ECT sensor. Also, check for poor connections at the ECT sensor and the PCM. Was a problem found?

1. Ignition “OFF”. 2. Disconnect the PCM. 3. Using a DVM, measure the resistance of the ECT at the PCM connector. 4. Compare the DVM reading with the chart in “Test Description”. Is the chart value approximately equal to the thermometer reading?

Yes

Compare engine coolant temperature displayed on the Tech 2 to the actual coolant temperature measured with a thermometer. (Observe normal precautions when opening the cooling system.) Is the Tech 2 engine coolant temperature indication close to the measured temperature?

Value(s)

6E–164

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code(DTC) P0128 Thermostat Insufficient Temperature for Stable Operation

060R200053

Circuit Description

Conditions for Clearing the MIL/DTC

B The engine coolant temperature (ECT) sensor thermistor mounted on a coolant crossover pipe at the front of the engine. This code determines if system has insufficient coolant temperatures for stable operation.

B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0128 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P0128 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed. Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for setting the DTC B Engine running. B No IAT, ECT and MAF DTCs set. B No VSS DTC set. Warm case(Ambient temperature is between 50°F and 128°F.): B Time for coolant to reach stabilized closed loop value is less than 239 sec. Cold case(Ambient temperature is between 20°F and 50°F.): B Time for coolant to reach stabilized thermostat regulation temperature is more than 263 sec.

6E–165

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS If the harness appears to be OK, observe the ECT display on the Tech2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0128 cannot be duplicated, the information included in the Failure Records data can be useful in

determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0128 Diagnostic Chart may isolate the cause of the fault.

Diagnostic Trouble Code (DTC) P0128 Thermostat Insufficient Temperature for stable operation Step

Action

1. Ignition “ON”, engine “OFF”. 2. Oberve the “Eng Cool Temp” display on the Tech 2.

—

Verify repair

Go to Step 3

—

Verify repair

Go to Step 4

—

Go to Step 5

Refer to Diagnostic Aids

139°C (282°F)

Verify repair

Go to Step 6

—

Verify repair

Refer to Diagnostic Go to Step 7

—

Verify repair

1. Ignition “OFF”. 2. Disconnect the PCM and check the ECT signal circuit for a short to ground or a short to the sensor ground circuit. 3. If the ECT signal circuit is shorted, repair it as necessary. Was a problem found?

Go to Step 2

1. Ignition “ON”, engine “OFF”. 2. Review and record Tech 2 Failure Records. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor “DTC” info for DTC P0128.

Is the “Eng Cool Temp” below the specified value? 6

—

Go to OBD System Check

1. Remove and check the Thermostat for stable operation. Refer to 6B section. 2. Replace the thermostat if necessary.

Does the Tech 2 indicate DTC P0128 failed this ignition? 5

1. Visually/physically check air duct and water pipe for splits, kinks, and proper connections and routing. 2. If a problem is found, repair as necessary.

Was a problem found? 4

Yes

Was the “On-Board(OBD)System Check” performed?

Was a problem found? 3

Value(s)

—

6E–166

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1

060R200054

Circuit Description The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 350 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during “closed loop” operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 1 voltage remains excessively low for an extended period of time, DTC P0131 will be set.

Conditions for Setting the DTC B B B B

No related DTCs. Vehicle is operating in “closed loop”. Engine coolant temperature is above 60°C (140°F). “Closed loop” commanded air/fuel ratio is between 14.5 and 14.8. B Bank 1 HO2S 1 signal voltage remains below 22 mV during normal “closed loop” operation for a total of 77 seconds over a 90-second period of time.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected fault.

B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. B “Open loop” fuel control will be in effect.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0131 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0131 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Heated oxygen sensor wiring – The sensor pigtail may be routed incorrectly and contacting the exhaust system. B Poor PCM to engine block grounds. B Fuel pressure – The system will go lean if pressure is too low. The PCM can compensate for some decrease. However, If fuel pressure is too low, a DTC P0131 may be set. Refer to Fuel System Diagnosis. B Lean injector(s) – Perform “Injector Balance Test”. B Vacuum leaks – Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, EGR system, and PCV system.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B Exhaust leaks – An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the system to appear lean. Check for exhaust leaks that may cause a false lean condition to be indicated. B MAF sensor – The system can go lean if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if the lean condition is corrected. If so, replace the MAF sensor. B Fuel contamination – Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated. Excessive alcohol in the fuel can also cause this condition. Refer to Fuel System Diagnosis for the procedure to check for fuel contamination.

6E–167

B If none of the above conditions are present, replace the affected HO2S.

Test Description Number(s) below refer to step numbers on the diagnostic chart. 3. DTC P0131 failing during operation may indicate a condition described in the “Diagnostic Aids” above. If the DTC P0131 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0131 –HO2S Circuit Low Voltage Bank 1 Sensor 1 Step

Action

22 mV

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

—

Go to Step 5

Go to Step 6

—

Verify repair

—

Go to Step 7

Go to Step 8

—

Verify repair

—

Repair the Bank 1 HO2S 1 signal circuit. 1. Turn the ignition “OFF”, HO2S 1 and PCM disconnected. 2. Check for short circuit between the high and low signal circuits. Was there continuity between the high and low circuits?

Go to Step 2

1. Turn the ignition “OFF”. 2. Disconnect the PCM. 3. Check the Bank 1 HO2S 1 high and low circuits for a short to ground or a short to the heater ground circuit.

Is the action complete? 6

—

Go to OBD System Check

1. Ignition “ON”, engine “OFF”, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor “DTC” info for DTC P0131 until the DTC P0131 test runs. Note test result.

Are the Bank 1 HO2S 1 signal circuits shorted to ground? 5

1. Install the Tech 2. 2. Run the engine at normal operating temperature. 3. Operate the vehicle within the parameters specified under “Conditions for Setting the DTC” criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 1 HO2S 1 voltage.

Does Tech 2 indicate DTC P0131 failed this ignition? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Bank 1 HO2S 1 voltage remain below the specified value? 3

Value(s)

Repair the short between the high and low circuits. Is the action complete?

6E–168

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0131 –HO2S Circuit Low Voltage Bank 1 Sensor 1 (Cont’d) Step

Action

1. Ignition “OFF”. 2. Reconnect the disconnected. 3. Ignition “ON”.

PCM,

Value(s)

leave

the

sensor

Does the Tech 2 indicate Bank 1 HO2S 1 voltage between the specified values? 9

Yes

425-475 mV

Refer to Diagnostic Aids

Go to Step 9

—

Verify repair

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–169

Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1

060R200054

Circuit Description

Action Taken When the DTC Sets

The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal and low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during “closed loop” operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 1 voltage remains excessively high for an extended period of time, DTC P0132 will be set.

B The PCM will ON the MIL after second trip with detected fault. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. B “Open loop” fuel control will be in effect.

Conditions for Setting the DTC B No related DTCs. B Engine coolant temperature is above 60°C (140°F) B “Closed loop” commanded air/fuel ratio is between 14.5 and 14.8. B Bank 1 HO2S 1 signal voltage remains above 952 mV during normal “closed loop” operation for a total of 77 seconds over a 90-second period. OR B Bank 1 HO2S 1 signal voltage remains above 500 mV during “deceleration fuel cutoff mode” operation for 3 seconds.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0132 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0132 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check the following items: B Fuel pressure – The system will go rich if pressure is too high. The PCM can compensate for some increase. However, if fuel pressure is too high, a DTC P0132 may be set. Refer to Fuel System Diagnosis. B Perform “Injector Balance Test” – Refer to Fuel System Diagnosis.

6E–170

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B Check the EVAP canister for fuel saturation – If full of fuel, check canister control and hoses. Refer to Evaporative (EVAP) Emission Control System. B MAF sensor –The system can go rich if MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see it the rich condition is corrected. If so, replace the MAF sensor. B Check for a leak in the fuel pressure regulator diaphragm by checking the vacuum line to the regulator for the presence of fuel. There should be no fuel in the vacuum line. B An intermittent TP sensor output will cause the system to go rich due to a false indication of the engine acceleration. B Shorted Heated Oxygen Sensor (HO2S) –If the HO2S is internally shorted, the HO2S voltage displayed on the Tech 2 will be over 1 volt. Try disconnecting the affected HO2S with the key “ON”, engine “OFF”. If the displayed HO2S voltage changes from over 1000 mV to around 450 mV, replace the HO2S. Silicon contamination of the HO2S can also cause a high HO2S voltage to be indicated. This condition is indicated by a powdery deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S. B Open HO2S Signal Circuit or Faulty HO2S–A poor connection or open in the HO2S signal circuit can

cause the DTC to set during deceleration fuel mode. An HO2S which is faulty and not allowing a full voltage swing between the rich and lean thresholds can also cause this condition. Operate the vehicle by monitoring the HO2S voltage with a Tech 2. If the HO2S voltage is limited within a range between 300 mV to 600 mV, check the HO2S signal circuit wiring and associated terminal conditions. B If none of the above conditions are present, replace the affected HO2S.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0132 failing during “deceleration fuel cutoff mode” operation may indicate a condition described in the “Diagnostic Aids” above. If the DTC P0132 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0132 – HO2S Circuit High Voltage Bank 1 Sensor 1 Step

Action

1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within parameters specified under “Conditions for Setting the DTC” included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 1 HO2S 1 voltage.

1. 2. 3. 4.

—

Go to Step 2

Go to OBD System Check

952 mV (500 mV in deceleration fuel cutoff mode)

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

3-4 V

Go to Step 5

Go to Step 6

1. Ignition “ON”, review and record Tech 2 Failure Records data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor “DTC” info for DTC P0132 until the DTC P0132 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0132 failed this ignition?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Bank 1 HO2S 1 voltage remain above the specified value? 3

Value(s)

Ignition “OFF”. Disconnect Bank 1 HO2S 1. Ignition “ON”. At HO2S Bank 1 Sensor 1 connector (PCM side) use a DVM to measure voltages at the high and low signal terminals.

Are the voltages in the specified range?

6E–171

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0132 – HO2S Circuit High Voltage Bank 1 Sensor 1 (Cont’d) Step

Action

—

Verify repair

—

10 mV

Go to Step 7

Go to Step 8

425-475 mV

Refer to Diagnostic Aids

Go to Step 8

—

Verify repair

—

1. Disconnect the jumpers to ground from Bank 1 HO2S 1 PCM-side connector. 2. With the HO2S 1 connector disconnected, monitor Bank 1 HO2S 1 voltage. Is Bank 1 HO2S 1 voltage between the specified values?

1. Ignition “ON”, engine“OFF”. 2. At Bank 1 HO2S 1 connector (PCM side) jumper both the HO2S high and low signal circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 1 HO2S 1 voltage. Is Bank 1 HO2S 1 voltage below the specified value?

Yes

Repair short to voltage in signal circuit. Is the action complete?

Value(s)

6E–172

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1

060R200054

Circuit Description The powertrain control module (PCM) continuously monitors the heated oxygen sensor (HO2S) activity for 90 seconds after “closed loop” has been enabled. During the monitoring period the PCM counts the number of times that a rich-to-lean and lean-to-rich response is indicated and adds the amount of time it took to complete all rich-to-lean transitions and lean-to-rich transitions. With this information, an average time for rich-to-lean and lean-to-rich transitions can be determined. If the average response time of either transition is too slow, a DTC P0133 will be set. A lean-to-rich transition is indicated when the HO2S voltage changes from less than 300 mV to greater than 600 mV. A rich-to-lean transition is indicated when the HO2S voltage changes from more than 600 mV to less than 300 mV. An HO2S that responds too slowly is likely to be faulty and should be replaced.

Conditions for Setting the DTC B No related DTCs. B Engine coolant temperature (ETC) is above 60°C (140°F). B Engine is operating in “closed loop”. B Engine has been running for at least 90 seconds. B Engine speed is between 1500 RPM and 3000 RPM. B Canister purge duty cycle is greater than 2%.

B Mass air flow is between 18 g/second and 42 g/second. B All above conditions are met for 3 seconds. B 90 seconds after “closed loop” has been enabled, Bank1 HO2S 1 average transition time between 300 mV and 600 mV is too slow. The lean-to-rich average transition response time was longer than 94 milliseconds or rich-to-lean average transition response time was longer than 105 milliseconds.

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator Lamp (MIL) after the second consecutive trip in which the fault is detected. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. B “Open loop” fuel control will be in effect.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0133 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0133 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 1 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0133 cannot be duplicated, reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Verifies that the fault is currently present. 3. HO2S transition time, ratio mean volts and switching DTCs set for multiple sensors indicate probable contamination. Before replacing the sensors, isolate and correct the source of the contamination to avoid damaging the replacement sensors.

6E–173

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0133 – HO2S Slow Response Bank 1 Sensor 1 Step

Action

Value(s)

Go to Step 2

NOTE: If any DTCs are set (expect P0153, P1133, P1134, P1153, and/or P1154), refer to those DTCs before proceeding with this diagnostic chart. 1. Install the Tech 2. 2. Idle the engine at normal operating temperature. 3. Operate the vehicle within parameters specified under “Conditions for Setting the DTC” included in Diagnostic Support. 4. Using a Tech 2, monitor “DTC” info for DTC P0133 until the DTC P0133 test runs. 5. Note the test result.

3 4

Does the Tech 2 indicate DTC P0133 failed this ignition?

—

Go to Step 3

Refer to Diagnostic Aids

Did the Tech 2 also indicate DTC P0153, P1133, P1134, P1153, and/or P1154 failed this ignition?

—

Go to Step 17

Go to Step 4

—

Go to Step 5

Go to Step 6

—

Go to Step 2

—

Go to Step 7

Go to Step 8

—

Go to Step 2

—

Go to Step 2

Go to Step 10

—

Go to Step 2

—

Go to Step 11

Go to Step 12

—

Go to Step 2

—

Go to Step 13

Go to Step 14

—

Go to Step 2

—

Check for leaks at the pipe joints. Are the joints leaking?

Tighten the U–bolt nuts at the leaking joints. Is the action complete?

Check for gaskets that are damaged or improperly installed. Are there damaged or misaligned gaskets?

1. Replace damaged gaskets. 2. Align the connections. 3. Tighten the connections. Is the action complete?

Check for loose exhaust flange connections. Are the flange connections loose?

Tighten the stud nuts or bolts to specifications. Is the action complete?

Check for burned or corroded exhaust pipes. Are the exhaust pipes burned or corroded?

Replace the exhaust pipes, as required. Is the action complete?

Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

Tighten the bolts to specifications to replace the manifold if necessary. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–175

DTC P0133 – HO2S Slow Response Bank 1 Sensor 1 (Cont’d) Step

Action

Visually/physically inspect the following items: B Ensure that the Bank 1 HO2S 1 is securely installed. B Check for corrosion on terminals. B Check terminal tension (at Bank 1 HO2S 1 and at the PCM). B Check for damaged wiring. Was a problem found in any of the above areas?

—

Go to Step 18

Go to Step 15

3-4 V

Go to Step 16

Go to Step 19

—

Go to Step 21

Go to Step 22

—

Verify repair

—

Verify repair

—

Verify repair

Go to Step 20

—

Verify repair

—

Verify repair

—

Verify repair

—

1. With Bank 1 HO2S 1 disconnected, jumper the high and low (PCM side) signal circuits to ground. 2. Ignition “ON”. 3. Using a Tech 2, monitor the Bank 1 HO2S 1 voltage. Does the Tech 2 indicate less than 10 mV and immediately return to about 450 mV when the jumper is removed?

Yes

1. Disconnect Bank 1 HO2S 1. 2. Ignition “ON”. 3. Using a DVM at the PCM side of the HO2S 1 connector, measure the voltage between the high signal circuit and ground. Also measure the voltage between the low signal circuit and ground. Are both voltages in the specified range?

Value(s)

Replace the affected heated oxygen sensors. NOTE: Before replacing sensors, the cause of the contamination must be determined and corrected. B B B

Fuel contamination. Use of improper RTV sealant. Engine oil/coolant consumption.

Is the action complete? 18

Repair condition as necessary. Is the action complete?

Check for faulty PCM connections or terminal damage. Is the action complete?

Repair open, short or grounded signal circuit. Is the action complete?

Replace Bank 1 HO2S 1. Is the action complete?

6E–176

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1

060R200054

Circuit Description B The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) high and low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during “closed loop” operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 1 voltage remains at or near the 450 mV bias for an extended period of time, DTC P0134 will be set, indicating an open sensor signal or sensor low circuit. B Heated oxygen sensors are used to minimize the amount of time required for “closed loop” fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. B Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.

Conditions for Setting the DTC B No related DTCs. B Battery voltage is above 10 volts.

B The engine has been running for over 5 seconds. B Engine coolant temperature (ETC) is above 60°C (140°F). B Oxygen sensor heater has been determined to be functioning properly. B Bank 1 HO2S 1 signal voltage remains between 400 mV and 500 mV for a total of 77 seconds over a 90-second period of time.

Action Take When the DTC Sets B The PCM will ON the MIL after second trip with detected fault. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. B “Open loop” fuel control will be in effect.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0134 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0134 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids Check for the following conditions: B Poor connection or damaged harness – Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. B Faulty HO2S heater or heater circuit – With the ignition “ON”, engine “OFF”, after a cool down period, the HO2S 1 voltage displayed on the Tech 2 is normally 455-460 mV. A reading over 1000 mV indicates a signal line shorted to voltage. A reading under 5 mV indicates a signal line shorted to ground or signal lines shorted together. Disconnect the HO2S and connect a test light between the HO2S ignition feed and heater ground circuits. If the test light does not light for 2 seconds when the ignition is turned on, repair the open ignition feed or sensor ground circuit as necessary. If the test light lights and the HO2S signal and low circuits are OK, replace the HO2S.

B Intermittent test – With the Ignition “ON”, monitor the HO2S signal voltage while moving the wiring harness and related connectors. If the fault is induced, the HO2S signal voltage will change. This may help isolate the location of the malfunction.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. If the DTC P0134 test passes while the Failure Records conditions are being duplicated, an intermittent conditions is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0134 –HO2S Circuit Insufficient Activity Bank 1 Sensor 1 Step

Action

Go to Step 2

400-500 mV

Go to Step 3

Go to Step 4

—

Go to Step 4

Refer to Diagnostic Aids

—

Verify repair

Go to Step 5

—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

Check for a damaged harness. Check for poor Bank 1 HO2S 1 high and low circuit terminal connections at the Bank 1 HO2S 1 harness connector and replace terminal(s) if necessary. Did any terminals require replacement?

—

Go to OBD System Check

Was a problem found? 5

1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the engine above 1200 RPM for two minutes.

Does the Tech 2 indicate DTC P0134 failed this ignition? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Tech 2 indicate Bank 1 HO2S 1 voltage varying outside the specified values? 3

Value(s)

Check for poor Bank 1 HO2S 1 high and low circuit terminal connections at the PCM and replace terminals if necessary. Did any terminals require replacement?

6E–178

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0134 –HO2S Circuit Insufficient Activity Bank 1 Sensor 1 (Cont’d) Step

Action

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

0-10 mV

Go to Step 10

Go to Step 11

—

Verify repair

—

Verify repair

—

Replace Bank 1 HO2S 1. Is the action complete?

—

1. Ignition “ON”, engine “OFF”. 2. Disconnect Bank 1 HO2S 1 and jumper the HO2S high and low circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 1 HO2S 1 voltage. Is Bank 1 HO2S 1 voltage in the specified range?

1. Ignition “OFF”. 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 1 low circuit. 3. If the Bank 1 HO2S 1 low circuit measures over 5 ohms, repair open or poor connection as necessary. Was a Bank 1 HO2S 1 low circuit problem found and corrected?

Yes

1. Ignition “OFF”. 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 1 high circuit. 3. If the Bank 1 HO2S 1 high circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 1 HO2S 1 high circuit problem found and corrected?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–179

Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1

060R200054

Circuit Description

Conditions for Setting the DTC

Heated oxygen sensors are used to minimize the amount of time required for “closed loop” fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. The powertrain control module (PCM) will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started the PCM will monitor the HO2S voltage. When the HO2S voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that too much time was required for the Bank 1 HO2S 1 to become active, a DTC P0135 will set. The time it should take the HO2S to reach operating temperature is based on the accumulated amount of air that has passed through the MAF sensor and into the engine (more accumulated air flow = shorter time to HO2S activity).

B The engine has been running for over 120 seconds. B Heater signal is below 0.1A. B Bank 1 HO2S 1 voltage does not change more than 150 mV from the bias voltage (between 400 mV and 500 mV) for a longer amount of time than it should. The maximum amount of time to come up to operating range is 150 seconds. This warm-up time depends on the engine coolant temperature at start-up and accumulate air flow since start-up.

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0135 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0135 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–180

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the ECT display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description

2. The HO2S should be allowed to cool before performing this test. If the HO2S heater is functioning, the signal voltage will gradually increase or decrease as the sensor element warms. If the heater is not functioning, the HO2S signal will remain near the 450 mV bias voltage. 4. Ensures that the ignition feed circuit to the HO2S is not open or shorted. The test light should be connected to a good chassis ground, in case the HO2S low or HO2S heater ground circuit is faulty. 5. Checks the HO2S heater ground circuit. 6. Checks or an open or shorted HO2S heater element. 10.An open HO2S signal or low circuit can cause the HO2S heater to appear faulty. Check these circuits before replacing the sensor.

Number(s) below refer to the step number(s) on the Diagnostic Chart.

DTC P0135 – HO2S Heater Circuit Bank 1 Sensor 1 Step

Action

—

Go to Step 2

Go to OBD System Check

Above 650 mV or below 250 mV

Refer to Diagnostic Aids

Go to Step 3

—

Go to Step 15

Go to Step 4

—

Go to Step 5

Go to Step 7

—

Go to Step 6

Go to Step 8

Inspect the fuse for the Bank 1 HO2S 1 ignition feed. Is the fuse open? 1. 2. 3. 4.

Ignition “OFF”. Raise the vehicle. Disconnect the Bank 1 HO2S 1 electrical connector. Using a test light connected to a good ground (do not use Bank 1 HO2S 1 heater ground or Bank 1 HO2S 1 low), probe the ignition feed circuit at the Bank 1 HO2S 1 electrical connector (PCM harness side).

Does the test light illuminate? 5

NOTE: If the engine has just been operating ,allow the engine to cool for at least 15 minutes before proceeding.

Did the HO2S voltage go from bias voltage to above or below the specified values?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

1. Remove the fuel pump relay. 2. Connect a fused jumper at the fuel pump relay socket, between the battery positive at the relay and the relay wire that leads to the fuel pump and HO2S fuses. 3. Ignition “OFF”. 4. Install a Tech 2. 5. Ignition “ON”, engine “OFF”. 6. Monitor the Bank 1 HO2S 1 voltage for several minutes.

Value(s)

Connect the test light between the Bank 1 HO2S 1 ignition feed and the Bank 1 HO2S 1 heater ground. Does the test light illuminate?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–181

DTC P0135 – HO2S Heater Circuit Bank 1 Sensor 1 (Cont’d) Step

Action

—

Verify repair

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 14

—

Verify repair

—

Verify repair

—

Replace the Bank 1 HO2S 1. Is the action complete?

—

Check for a poor Bank 1 HO2S 1 high circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement?

Verify repair

Check for a poor Bank 1 HO2S 1 low circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement?

—

1. Ignition “OFF”. 2. Disconnect the PCM and check the continuity of the Bank 1 HO2S 1 signal circuit and the Bank 1 HO2S 1 low circuit. 3. If the Bank 1 HO2S 1 high circuit or HO2S low circuit measures over 5 ohms, repair open or poor connection as necessary. Was a problem found?

Go to Step 10

Check for a poor Bank 1 HO2S 1 high or low circuit terminal connection at the Bank 1 HO2S 1 harness connector and replace terminal(s) if necessary. Did any terminals require replacement?

Go to Step 9

1. Check for a poor connection at the Bank 1 HO2S 1 harness terminals. 2. If a poor connection is found, replace terminals. Was a poor connection found?

3-6 ohms

Repair the open Bank 1 HO2S 1 heater ground circuit to Bank 1 HO2S 1. Is the action complete?

Repair the open Bank 1 HO2S 1 ignition feed circuit to Bank 1 HO2S 1. Is the action complete?

Yes

1. Allow the HO2S to cool for at least 15 minutes. 2. Using a DVM, measure the resistance between the Bank 1 HO2S 1 ignition feed and the Bank 1 HO2S 1 heater ground at the Bank 1 HO2S 1 pigtail. Is the HO2S heater resistance within the specified values?

Value(s)

Locate and repair the short to ground in Bank 1 HO2S 1 ignition feed circuit and replace the fault fuse. Is the action complete?

6E–182

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2

060R200054

Circuit Description The powertrain control module (PCM) supplies bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm impedance digital voltmeter, this may display as low as 350 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when exhaust is rich, down through about 10 mV when the exhaust is lean. The PCM constantly monitors the HO2S signal during “closed loop” operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 2 signal voltage remains excessively low for an extended period of time, DTC P0137 will be set.

Conditions for Setting the DTC B B B B

No related DTCs. Engine is operating in “closed loop”. Engine coolant temperature is above 60°C (140°F). “Closed loop” commanded air/fuel ratio is between 14.5 and 14.8. B Throttle angle is between 3% and 19%. B Bank 1 HO2S 2 signal voltage remains below 22 mV during normal “closed loop” operation for a total of 106 seconds over a 125-second period of time. OR

B Bank 1 HO2S 2 signal voltage remains below 400 mV during power enrichment mode fuel control operation for up to 5 seconds.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected fault. B The PCM will store conditions which were present when the DTC set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0137 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0137 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B B B

compensate for some decrease. However, if fuel pressure is too low, a DTC P0137 may be set. Refer to Fuel System Diagnosis. Lean injector(s) – Perform “Injector Balance Test”. Vacuum leaks – Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, EGR system, and PCV system. Exhaust leaks – An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the DTC P0137 to set. Check for exhaust leaks near the Bank 1 HO2S 2 sensor. MAF sensor – The system can go lean if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if the lean condition is corrected. If so, replace the MAF sensor. Fuel contamination – Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated. Excessive

6E–183

alcohol in the fuel can also cause this condition. Refer to Fuel System Diagnosis for procedure to check for fuel contamination. B If none of the above conditions are present, replace the affected HO2S.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0137 failing during operation may indicate a condition described in the “Diagnostic Aids” above. If the DTC0137 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0137 –HO2S Circuit Low Voltage Bank 1 Sensor 2 Step

Action

Go to Step 2

22 mV

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

—

Go to Step 5

Go to Step 6

—

Verify repair

—

Go to Step 7

Go to Step 8

1. Turn ignition “OFF”. 2. Disconnect the PCM. 3. Check the Bank 1 HO2S 2 high and low signal circuits for a short to ground or a short to the heater ground circuit. Repair the Bank 1 HO2S 2 signal circuit. Is the action complete?

—

Go to OBD System Check

Were Bank 1 HO2S 2 signal circuits shorted? 5

1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within the parameters specified under “Conditions for Setting the DTC” criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 1 HO2S 2 voltage.

Does the Tech 2 indicate DTC P0137 failed this ignition? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Bank 1 HO2S voltage remain below the specified value? 3

Value(s)

1. Ignition “OFF”. 2. Leave the PCM and HO2S 2 disconnected. 3. Check for continuity between the high and low signal circuits. Was there continuity between the high and low circuits?

6E–184

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0137 –HO2S Circuit Low Voltage Bank 1 Sensor 2 (Cont’d) Step

Action

—

Verify repair

—

425-475 mV

Refer to Diagnostic Aids

Go to Step 9

—

Verify repair

—

1. Ignition “OFF”. 2. Reconnect the PCM, leave HO2S 2 disconnected. 3. Ignition “ON”. Does the Tech 2 indicate Bank 1 HO2S 2 voltage near the specified value?

Yes

Repair the short between the high and low circuits. Is the action complete?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–185

Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2

060R200054

Circuit Description The powertrain control module (PCM) supplies bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when exhaust is rich, down through about 10 mV when the exhaust is lean. The PCM constantly monitors the HO2S signal during “closed loop” operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 1 HO2S 2 voltage remains excessively high for an extended period of time, DTC P0138 will be set.

Conditions for Setting the DTC B No related DTCs. B Engine is operating in “closed loop”. B “Closed loop” commanded air/fuel ratio is between 14.5 and 14.8. B Engine coolant temperature is above 60°C (140°F). B Throttle angle is between 3% and 19%. B Bank 1 HO2S 2 signal voltage remains above 952 mV during normal “closed loop” operation for a total of 106 seconds over a 125-second period of time. OR

B Bank 1 HO2S 2 signal voltage remains above 500 mV during deceleration fuel cut–off mode operation for up to 3 seconds.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0138 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0138 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Fuel pressure – An excessively rich fuel mixture can cause a DTC P0138 to be set. Refer to Fuel System Diagnosis. B Rich injector(s) – Perform “Injector Balance Test”. B Leaking injector – Refer to Fuel System Diagnosis.

6E–186

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B Evaporative emissions (EVAP) canister purge – Check for fuel saturation. If full of fuel, check the canister control and hoses. Refer to Evaporative Emission (EVAP) Control System. B MAF sensor –The system can go rich if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if the rich condition is corrected. If so, replace the MAF sensor. B Check for a leak in fuel pressure regulator diaphragm by checking the vacuum line to the regulator for the presence of fuel. There should be no fuel in the vacuum line. B TP sensor – An intermittent TP sensor output will cause the system to go rich, due to a false indication of the engine accelerating. B Shorted Heated Oxygen Sensor (HO2S) – If the HO2S is internally shorted the HO2S voltage displayed on the Tech 2 will be over 1 volt. Try disconnecting the affected HO2S with the key “ON”, engine “OFF”. If the displayed HO2S voltage changes from over 1000 mV to around 450 mV, replace the HO2S. Silicon contamination of the HO2S can also cause a high HO2S voltage to be indicated. This condition is indicated by a powdery deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S.

B Open HO2S Signal Circuit of Faulty HO2S – A poor connection or open in the HO2S signal circuit can cause the DTC to set during deceleration fuel mode. An HO2S which is faulty and not allowing a full voltage swing between the rich and lean thresholds can also cause this condition. Operate the vehicle while monitoring the HO2S voltage with a Tech 2. If the HO2S voltage is limited within a range between 300 mV to 600 mV, check the HO2S signal and wiring and associated terminal connections. B If none of the above conditions are present, replace the affected HO2S.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0138 being set during deceleration fuel mode operation may indicate a condition described in the “Diagnostic Aids” above. If the DTC P0138 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0138 – HO2S Circuit High Voltage Bank 1 Sensor 2 Step

Action

1. 2. 3. 4.

—

Go to Step 2

Go to OBD System Check

952 mV (500 mV in deceleration fuel cutoff mode)

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

3-4 V

Go to Step 5

Go to Step 6

1. Ignition “ON”, review and record Tech 2 Failure Records data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor “DTC” info for DTC P0138 until the DTC P0138 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0138 failed this ignition?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Bank 1 HO2S voltage remain above the specified value? 3

Value(s)

Ignition “OFF”. Disconnect Bank 1 HO2S 1. Ignition “ON”. At the HO2S Bank 1 Sensor 2 connector (PCM side), use a DVM to measure voltages at the high and low signal terminals.

Are the voltages above the specified range?

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0138 – HO2S Circuit High Voltage Bank 1 Sensor 2 (Cont’d) Step

Action

—

Verify repair

—

10 mV

Go to Step 7

Go to Step 8

425-475 mV

Refer to Diagnostic Aids

Go to Step 8

—

Verify repair

—

1. Disconnect the jumpers to ground from Bank 1 HO2S 2 PCM–side connector. 2. With the HO2S 2 connector disconnected, monitor BANK 1 HO2S 2 voltage. Is the Bank 1 HO2S 2 voltage between the specified values?

1. Ignition “ON”, engine“OFF”. 2. At Bank 1 HO2S 2 connector (PCM side) jumper both the HO2S high and low signal circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 1 HO2S 2 voltage. Is Bank 1 HO2S 2 voltage below the specified value?

Yes

Repair short to voltage in the signal circuit. Is the action complete?

Value(s)

6E–188

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2

060R200054

Circuit Description To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 1 HO2S 1 and the Bank 1 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 2 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalyst’s ability to convert exhaust gases efficiently. If catalyst is operating efficiently, the Bank 1 HO2S 1 signal will be far more active than that produced by the Bank 1 HO2S 2 sensor. If the Bank 1 HO2S 2 signal voltage remains between 400 mV and 500 mV for an extended period of time, DTC P0140 will be set. Heated oxygen sensors are used to minimize the amount of time required for “closed loop” fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to

maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.

Conditions for Setting the DTC B B B B B B

No related DTCs. Engine coolant temperature is above 60°C (140°F). The engine has been running for over 5 seconds. Oxygen sensor heater is functioning properly. Engine is operating in “closed loop” Bank 1 HO2S 2 signal voltage remains between 426 mV and 474 mV for a total of 106 seconds over a 125-second period of time.

Conditions for Cleaning the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0140 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0140 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–189

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids Check for the following conditions: B Poor connection or damaged harness– Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. B Faulty HO2S heater or heater circuit–With the ignition“ON”, engine “OFF”, the HO2S voltage displayed on a Tech 2 should gradually drop to below 250 mV. If not, disconnect the HO2S and connect a test light between the HO2S ignition feed and heater ground circuits. If the test light does not light, repair the open ignition feed or sensor ground circuit as necessary. If the test light lights and the HO2S signal and low circuits are OK, replace the HO2S.

B Intermittent test–With the ignition “ON”, monitor the HO2S signal voltage while moving the wiring harness and related connectors. If the fault is induced, the HO2S signal voltage will change. This may help isolate the location of the malfunction.

Test Description Number (s) below refer to the step number (s) on the Diagnostic Chart. 3. If the DTC P0140 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0140 – HO2S Circuit Insufficient Activity BANK 1 SENSOR 2 Step

Action

425-475 mV

Go to Step 3

Go to Step 4

—

Go to Step 4

Refer to Diagnostic Aids

—

Verify repair

Go to Step 5

—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

Check for poor Bank 1 HO2S 2 high and low circuit terminal connections at the Bank 1 HO2S 2 harness connector and replace terminal(s) if necessary. Check for poor Bank 1 HO2S 2 high and low circuit terminal connections at the PCM and replace terminal(s) if necessary. Did any terminals require replacement?

Go to Step 2

Check for a damaged harness.

Did any terminals require replacement? 6

—

Go to OBD System Check

1. Ignition “ON”, engine “OFF”, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor “DTC” info for DTC P0140 until the DTC P0140 test runs. 4. Note the test result.

Was a problem found? 5

1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the engine above 1200 RPM for two minutes.

Does the Tech 2 indicate DTC P0140 failed this ignition? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Tech 2 indicate Bank 1 HO2S 2 voltage varying outside the specified values? 3

Value(s)

1. Ignition “OFF”. 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 2 high circuit. 3. If the Bank 1 HO2S 2 high circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 1 HO2S 2 high circuit problem found and corrected?

6E–190

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0140 – HO2S Circuit Insufficient Activity BANK 1 SENSOR 2 (Cont’d) Step

Action

—

Verify repair

Go to Step 9

0-10 mV

Go to Step 10

Go to Step 11

—

Verify repair

—

Verify repair

—

Replace Bank 1 HO2S 2. Is the action complete?

1. Ignition “ON”, engine“OFF”. 2. Disconnect Bank 1 HO2S 2 and jumper the HO2S high and low circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 1 HO2S 2 voltage. Is Bank 1 HO2S 2 voltage in the specified range?

Yes

1. Ignition “OFF”. 2. With the PCM disconnected, check continuity of the Bank 1 HO2S 2 high circuit. 3. If the Bank 1 HO2S 2 low circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 1 HO2S 2 low circuit problem found and corrected?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–191

Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2

060R200054

Circuit Description Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. The powertrain control module (PCM) will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started the PCM will monitor the HO2S voltage. When the Bank HO2S voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that too much time was required for the Bank 1 HO2S 2 to become active, a DTC P0141 will set. The time it should take the HO2S to reach operating temperature is based on the total amount of air that has passed through the MAF sensor and into the engine (more total airflow = shorter time to HO2S activity).

Conditions for Setting the DTC B No related DTCs. B The engine has been running for over 120 seconds.

B Ignition voltage is between 11 volts and 18 volts. B Bank 1 HO2S 2 voltage does not change more than 150 mV from the bias voltage (between 400 mV–500 mV) for a longer amount of time than it should. The maximum amount of time to come up to operating range is 120 seconds. This warm-up time depends on the engine coolant temperature at start-up and accumulated air flow since start-up.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0141 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0141 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions:

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart.

2. The HO2S should be allowed to cool before performing this test. If the HO2S heater is functioning, the signal voltage will gradually increase or decrease as the sensor element warms. If the heater is not functioning, the HO2S signal will remain near the 450 mV bias voltage. 4. This ensures that the ignition feed circuit to the HO2S is not open or shorted. The test light should be connected to a good chassis ground, in case the HO2S low or HO2S heater ground circuit is faulty. 5. This checks the HO2S heater ground circuit. 6. This checks for an open or shorted HO2S heater element. 11.An open HO2S signal or low circuit can cause the HO2S heater to appear faulty. Check these circuits before replacing the sensor.

DTC P0141 – HO2S Heater Circuit Bank 1 Sensor 2 Step

Action

—

Go to Step 2

Go to OBD System Check

Above 650 mV or below 250 mV

Refer to Diagnostic Aids

Go to Step 3

—

Go to Step 15

Go to Step 4

—

Go to Step 5

Go to Step 7

—

Go to Step 6

Go to Step 8

Inspect the fuse for Bank 1 HO2S 2 ignition feed. Is the fuse open? 1. 2. 3. 4.

Ignition “OFF”. Raise the vehicle. Disconnect the Bank 1 HO2S 2 electrical connector. Using a test light connected to a good ground (do not use Bank 1 HO2S 2 heater ground or Bank 1 HO2S 2 low), probe the ignition feed circuit at the Bank 1 HO2S 2 electrical connector (PCM harness side).

Does the test light illuminate? 5

NOTE: If the engine has just been operating, allow the engine to cool for at least 15 minutes before proceeding.

Did the HO2S voltage go from bias voltage to above or below the specified values?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

Connect the test light between the Bank 1 HO2S 2 ignition feed and the Bank 1 HO2S 2 heater ground. Does the test light illuminate?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–193

DTC P0141 – HO2S Heater Circuit Bank 1 Sensor 2 (Cont’d) Step

Action

—

Verify repair

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 14

—

Verify repair

—

Verify repair

—

Replace Bank 1 HO2S 2. Is the action complete?

—

Check for a poor Bank 1 HO2S 2 high circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement?

Verify repair

Check for a poor Bank 1 HO2S 2 low circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement?

—

1. Ignition “OFF”. 2. Disconnect the PCM and check the continuity of the Bank 1 HO2S 1 signal circuit and the Bank 1 HO2S 1 low circuit. 3. If the Bank 1 HO2S 1 high circuit or the HO2S low circuit measures over 5 ohms, repair the open or poor connection as necessary. Was a problem found?

Go to Step 10

1. Ignition “OFF”. 2. Disconnect the PCM and check the continuity of the Bank 1 HO2S 2 signal circuit and the Bank 1 HO2S 2 low circuit. 3. If the Bank 1 HO2S 2 signal circuit or the HO2S low circuit measures over 5 ohms, repair the open or poor connection as necessary. Was a problem found?

Go to Step 9

1. Check for a poor connection at the Bank 1 HO2S 2 harness terminals. 2. If a poor connection is found, replace the terminals. Was a poor connection found?

3-6 ohms

Repair the open Bank 1 HO2S 2 heater ground circuit. Is the action complete?

Repair the open Bank 1 HO2S 2 ignition feed circuit to Bank 1 HO2S 2. Is the action complete?

Yes

1. Allow the HO2S to cool for at least 15 minutes. 2. Using a DVM, measure the resistance between the Bank 1 HO2S 2 ignition feed and the Bank 1 HO2S 2 heater ground at the Bank 1 HO2S 2 pigtail. Is the HO2S resistance within the specified values?

Value(s)

Locate and repair the short to ground in Bank 1 HO2S 2 ignition feed circuit and replace the faulty fuse. Is the action complete?

6E–194

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1

060R200054

Circuit Description The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during “closed loop” operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 2 HO2S 1 voltage remains excessively low for an extended period of time, DTC P0151 will be set.

Conditions for Setting the DTC B B B B

No related DTCs. The engine is operating in “closed loop”. Engine coolant temperature is above 60°C (140°F). “Closed loop” commanded air/fuel ratio is between 14.5 and 14.8. B Bank 2 HO2S 1 signal voltage remains below 22 mV during normal “closed loop” operation for a total of 77 seconds over a 90-second period of time.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected fault.

B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. B “Open loop” fuel control will be in effect.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0151 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0151 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Heated oxygen sensor wiring – The sensor pigtail may be mispositioned and contacting the exhaust system. B Poor PCM to engine block grounds. B Fuel pressure – The system will go lean if pressure is too low. The PCM can compensate for some decrease. However, if fuel pressure is too low, a DTC P0151 may be set. Refer to Fuel System Diagnosis. B Lean injector(s) – Perform “Injector Balance Test”. B Vacuum leaks – Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, EGR system, and PCV system.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B Exhaust leaks – An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the system to appear lean. Check for exhaust leaks that may cause a false lean condition to be indicated. B MAF sensor –The system can go lean if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if the lean condition is corrected. If so, replace the MAF sensor. B Fuel contamination – Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated. Excessive alcohol in the fuel can also cause this condition. Refer to Fuel System Diagnosis for the procedure to check for fuel contamination.

6E–195

B If none of the above conditions are present, replace the affected HO2S.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0151 failing during operation may indicate a condition described in the “Diagnostic Aids” above. If the DTC P0151 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicate. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0151 – HO2S Circuit Low Voltage Bank 2 Sensor 1 Step

Action

22 mV

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

—

Go to Step 5

Go to Step 6

—

Verify repair

—

Go to Step 7

Go to Step 8

—

Verify repair

—

Repair the Bank 2 HO2S 1 signal circuit. 1. Ignition “OFF”. 2. Leave the PCM and HO2S 1 disconnected. 3. Check for continuity between the high and low signal circuits. Was there continuity between the high and low circuits?

Go to Step 2

1. Turn ignition “OFF”. 2. Disconnect the PCM. 3. Check the Bank 2 HO2S 1 high and low signal circuits for a short to ground or a short to the heater ground circuit.

Is the action complete? 6

—

Go to OBD System Check

1. Ignition “ON”, engine “OFF”, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor “DTC” info for DTC P0151 until the DTC P0151 test runs. 4. Note test result.

Were Bank 2 HO2S 1 signal circuits shorted? 5

Does the Tech 2 indicate DTC P0151 failed this ignition? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Bank 2 HO2S 1 voltage remain below the specified value? 3

Value(s)

Repair the short between the high and low circuits. Is the action complete?

6E–196

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0151 – HO2S Circuit Low Voltage Bank 2 Sensor 1 (Cont’d) Step

Action

1. Ignition “OFF”. 2. Reconnect the PCM, leave HO2S disconnected. 3. Ignition “ON”. Does the Tech 2 indicate Bank 2 HO2S 1 voltage near the specified value?

Value(s)

Yes

425-475 mV

Refer to Diagnostic Aids

Go to Step 9

—

Verify repair

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–197

Diagnostic Trouble Code (DTC) P0152 HO2S Circuit High Voltage Bank 2 Sensor 1

060R200054

Circuit Description

Action Taken When the DTC Sets

The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) signal high and signal low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during “closed loop” operation and compensates for a rich or lean condition by decreasing or increasing the injector pulse width as necessary. If the Bank 2 HO2S 1 voltage remains excessively high for an extended period of time, DTC P0152 will be set.

B The PCM will “ON” the MIL after second trip with detected fault B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data. B “Open loop” fuel control will be in effect.

Conditions for Setting the DTC B No related DTCs. B The engine is operating in “closed loop”. B The engine coolant temperature is above 60°C (140°F). B Bank 2 HO2S 1 signal voltage remains above 952 mV during normal “closed loop” operation for a total of 77 seconds over a 90-second period. OR B Bank 2 HO2S 1 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for up to 3 seconds.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0152 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0152 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Fuel pressure – The system will go rich if pressure is too high. The PCM can compensate for some increase. However, if fuel pressure is too high, a DTC P0152 may be set. Refer to Fuel System Diagnosis. B Rich injector(s) – Perform “Injector Balance Test”. B Leaking injector – Refer to Fuel System Diagnosis. B Evaporative emissions (EVAP) system – Check the canister for fuel saturation. If the canister is full of fuel,

6E–198

B B B

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

check EVAP control system components and hoses. Refer to Evaporative Emission (EVAP) Control System. MAF sensor – The system can go rich if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if rich condition is corrected. If so, replace MAF sensor. Check for leaking fuel pressure regulator diaphragm by checking vacuum line to regulator for the presence of fuel. There should be no fuel in the vacuum line. TP sensor – An intermittent TP sensor output will cause the system to go rich, due to a false indication of the engine accelerating. Shorted Heated Oxygen Sensor (HO2S)– If the HO2S is internally shorted, the HO2S voltage displayed on the Tech 2 will be over 1 volt. Try disconnecting the affected HO2S with the key “ON”, engine “OFF”. If the displayed HO2S voltage changes from over 1000 mV to around 450 mV, replace the HO2S. Silicon contamination of the HO2S can cause a high HO2S voltage to be indicated. This condition is indicated by powdery deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S. Open HO2S Signal Circuit of Faulty HO2S– A poor connection or open in the HO2S signal circuit can

cause the DTC to set during deceleration fuel mode. An HO2S which is faulty and not allowing a full voltage switch between the rich and lean thresholds can also cause the condition. Operate the vehicle while monitoring the HO2S voltage with a Tech 2. If the HO2S is limited within a range between 300 mV to 600 mV, check the HO2S signal circuit wiring and associated terminal connections. B If none of the above conditions are present, replace the affected HO2S.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0152 failing during deceleration fuel cutoff mode operation may indicate a condition described in the “Diagnostic Aids” above. If the DTC P0152 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0152 – HO2S Circuit High Voltage Bank 2 Sensor 1 Step

Action

1. Install the Tech 2. 2. Engine is at operating temperature. 3. Operate the vehicle within the parameters specified under “Conditions for Setting the DTC” criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 2 HO2S 1 voltage.

1. 2. 3. 4.

—

Go to Step 2

Go to OBD System Check

952 mV (500 mV in deceleration fuel cut-off mode)

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

3-4 V

Go to Step 5

Go to Step 6

1. Ignition “ON”. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor “DTC” info for DTC P0152 until the DTC P0152 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0152 failed this ignition?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Bank 2 HO2S 1 voltage remain above the specified value? 3

Value(s)

Ignition “OFF”. Disconnect Bank 2 HO2S 1. Ignition “ON”. At HO2S Bank 2 Sensor 1 connector (PCM side) use a DVM to measure voltages at the high and low signal terminals.

Are the voltages in the specified range?

6E–199

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0152 – HO2S Circuit High Voltage Bank 2 Sensor 1 (Cont’d) Step

Action

—

Verify repair

—

10 mV

Go to Step 7

Go to Step 8

425-475 mV

Refer to Diagnostic Aids

Go to Step 8

—

Verify repair

—

1. Disconnect the jumpers to ground from Bank 2 HO2S 1 PCM-side connector. 2. With the HO2S 1 connector disconnected, monitor Bank 2 HO2S 1 voltage. Is the Bank 2 HO2S 1 voltage between the specified values?

1. Ignition “ON”, engine“OFF”. 2. At Bank 2 HO2S 1 connector (PCM side) jumper both the HO2S high and low signal circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 2 HO2S 1 voltage. Is Bank 2 HO2S 1 voltage below the specified value?

Yes

Repair short to voltage in signal circuit. Is the action complete?

Value(s)

6E–200

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1

060R200054

Circuit Description The powertrain control module (PCM) continuously monitors the heated oxygen sensor (HO2S) activity for 90 seconds after “closed loop” has been enabled. During the monitoring period the PCM counts the number of times that a rich-to-lean and lean-to-rich response is indicated and adds the amount of time it took to complete all rich-to-lean transitions and lean-to-rich transitions. With this information, an average time for rich-to-lean and lean-to-rich transitions can be determined. If the average response time of either transition is too slow, a DTC P0153 will be set. A lean-to-rich transition is indicated when the HO2S voltage changes from less than 300 mV to greater than 600 mV. A rich-to-lean transition is indicated when the HO2S voltage changes from more than 600 mV to less than 300 mV. An HO2S that responds too slowly is likely to be faulty and should be replaced.

Conditions for Setting the DTC B No related DTCs. B Engine coolant temperature (ECT) is above 60°C (140°F). B The engine is operating in “closed loop”. B Engine has been running for over 60 seconds. B Canister purge duty cycle is above 2%. B Engine speed is between 1500 RPM and 3000 RPM.

B Mass air flow is between 18 g/second and 42 g/second. B All above conditions are met for 3 seconds. B 90 seconds after “closed loop” has been enabled, Bank 2 HO2S 1 average transition time between 300 mV and 600 mV is too slow. The lean-to-rich average transition response time was longer than 94 milliseconds or the rich-to-lean average transition response time was longer than 105 milliseconds.

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. B The PCM will store conditions which were present when the DTC set as Freeze Frame and in the Failure Records data. B “Open loop” fuel control will be in effect.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0153 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0153 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 2 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

6E–201

6E–202

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0153 – HO2S Slow Response Bank 2 Sensor 1 Step

Action

Value(s)

Go to Step 2

NOTE: If any DTCs are set, (except P0133, P1133, P1134, P1153, and/or P1154), refer to those DTCs before proceeding with this diagnostic chart. 1. Install the Tech 2. 2. Idle the engine at operating temperature. 3. Operate the vehicle within parameters specified under “Conditions for Setting the DTC” criteria included in Diagnostic Support. 4. Using a Tech 2, monitor “DTC” info for DTC P0153 until the DTC P0153 test runs. 5. Note the test result.

3 4

Does the Tech 2 indicate DTC P0153 failed this ignition?

—

Go to Step 3

Refer to Diagnostic Aids

Did the Tech 2 also indicate DTC P0153, P1133, P1134, P1153, and/or P1154 test failed this ignition?

—

Go to Step 17

Go to Step 4

—

Go to Step 5

Go to Step 6

—

Go to Step 2

—

Go to Step 7

Go to Step 8

—

Go to Step 2

—

Go to Step 9

Go to Step 10

—

Go to Step 2

—

Go to Step 11

Go to Step 12

—

Go to Step 2

—

Go to Step 13

Go to Step 14

—

Go to Step 2

—

Check for leaks at the pipe joints. Are the joints leaking?

Tighten the U-bolt nuts at the leaking joint. Is your action complete?

Check for gaskets that are damage or improperly installed. Are there damaged or misaligned gaskets?

1. Replace the damaged gaskets. 2. Align the connections. 3. Tighten the connections. Is your action complete?

Check for loose exhaust flange connections. Are the flange connections loose?

Tighten the stud nuts or bolts to specifications. Is your action complete?

Check for burned or corroded exhaust pipes. Are the exhaust pipes burned or corroded?

Replace the exhaust pipes, as required. Is your action complete?

Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

Tighten the bolts to specifications or replace the manifold if necessary. Is your action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–203

DTC P0153 – HO2S Slow Response Bank 2 Sensor 1 (Cont’d) Step

Action

1. Visually/physically inspect the following items: B Ensure that the Bank 2 HO2S 1 is securely installed. B Check for corrosion on terminals. B Check terminal tension (at Bank 2 HO2S 1 and at the PCM). B Check for damaged wiring. Was a problem found in any of the above areas?

—

Go to Step 18

Go to Step 15

3-4 V

Go to Step 16

Go to Step 19

—

Go to Step 21

Go to Step 22

—

Verify repair

—

Verify repair

—

Verify repair

Go to Step 20

—

Verify repair

—

Verify repair

—

Verify repair

—

1. With Bank 2 HO2S 1 disconnected, jumper the high and low (PCM side) signal circuits to ground. 2. Ignition “ON”. 3. Using a Tech 2, monitor the Bank 2 HO2S 1 voltage. Does the Tech 2 indicate less than 10 mV and immediately return to about 450 mV when the jumper is removed?

Yes

1. Disconnect Bank 2 HO2S 1. 2. Ignition “ON”. 3. Using a DVM at the PCM side of the HO2S 1 connector, measure the voltage between the high signal circuit and ground. Are both voltages in the specified range?

Value(s)

Replace the affected heated oxygen sensors. NOTE: Before replacing the sensors, the cause of the contamination must be determined and corrected. B B B

Fuel contamination. Use of improper RV sealant. Engine oil/coolant consumption.

Is the action complete? 18

Repair condition as necessary. Is the action complete?

Check for faulty PCM connections or terminal damage. Is the action complete?

Repair open, short or grounded signal circuit. Is the action complete?

Replace Bank 2 HO2S 1. Is the action complete?

6E–204

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1

060R200054

Circuit Description The powertrain control module (PCM) supplies a bias voltage of about 450 mV between the heated oxygen sensor (HO2S) high and low circuits. When measured with a 10 megaohm digital voltmeter, this may display as low as 320 mV. The oxygen sensor varies the voltage within a range of about 1000 mV when the exhaust is rich, down through about 10 mV when exhaust is lean. The PCM constantly monitors the HO2S signal during “closed loop” operation and compensates for a rich or lean condition by decreasing or increasing injector pulse width as necessary. If the Bank 2 HO2S 1 voltage remains at or near the 450 mV bias for an extended period of time, DTC P0154 will be set, indicating an open sensor signal or sensor low circuit. Heated oxygen sensors are used to minimize the amount of time required for “closed loop” fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.

Conditions for Setting the DTC B No related DTCs. B Engine coolant temperature is above 60°C (140°F).

B The engine has been running for over 5 seconds. B Oxygen sensor heater is functioning properly. B Bank 2 HO2S 1 signal voltage remains between 400 mV and 500 mV for a total of 77 seconds over a 90-second period of time.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0154 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0154 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Poor connection or damaged harness – Inspect the harness connectors for backed-out terminals,

6E–205

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire-connection, and damaged harness. B Faulty HO2S heater or heater circuit – With the ignition “ON”, engine “OFF”, the HO2S 1 voltage displayed on the Tech 2 is normally 455-460 mV. A reading over 1000 mV indicates a signal line shorted to voltage. A reading under 5 mV indicates a signal line shorted to ground or signal lines shorted together. If not, disconnect the HO2S and connect a test light between the HO2S ignition feed and heater ground circuits. If the test light does not light for 2 seconds when the ignition is turned on, repair the open ignition feed or sensor ground circuit as necessary. If the test light lights and the HO2S signal and low circuits are OK, replace the HO2S. B Intermittent test – With the ignition “ON”, monitor the HO2S signal voltage while moving the wiring harness

and related connectors. If the fault is induced, the HO2S signal voltage will change. This may help isolate the location of the malfunction.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. If the DTC P0154 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0154 –HO2S Circuit Insufficient Activity Bank 2 Sensor 1 Step

Action

Go to Step 2

400-500 mV

Go to Step 3

Go to Step 4

—

Go to Step 4

Refer to Diagnostic Aids

—

Verify repair

Go to Step 5

—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

Check for a damaged harness. Check for a poor Bank 2 HO2S 1 high and low circuit terminal connections at the Bank 2 HO2S 1 harness connector and replace terminal(s) if necessary. Did any terminals require replacement?

—

Go to OBD System Check

1. Ignition “ON”, engine “OFF”. 2. Review and record Tech 2 Failure Records data and note parameters. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor “DTC” info for DTC P0154 until the DTC P0154 test runs. 5. Note the test result.

Was a problem found? 5

1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the engine above 1200 RPM for two minutes.

Does the Tech 2 indicate DTC P0154 failed this ignition? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Tech 2 indicate Bank 2 HO2S 1 voltage varying outside the specified values? 3

Value(s)

Check for a poor Bank 2 HO2S 1 high and low circuit terminal connections at the PCM and replace terminal(s) if necessary. Did the terminal require replacement?

6E–206

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0154 –HO2S Circuit Insufficient Activity Bank 2 Sensor 1 (Cont’d) Step

Action

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

0-10 mV

Go to Step 10

Go to Step 11

—

Verify repair

—

Verify repair

—

Replace Bank 2 HO2S 1. Is the action complete?

—

1. Ignition “ON”, engine “OFF”. 2. Disconnect Bank 2 HO2S 1 and jumper the HO2S high and low circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 2 HO2S 1 voltage. Is the Bank 2 HO2S 1 voltage in the specified range?

1. Ignition “OFF”. 2. With the PCM disconnected, check continuity of the Bank 2 HO2S 1 low circuit. 3. If the Bank 2 HO2S 1 low circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 2 HO2S 1 low circuit problem found and corrected?

Yes

1. Ignition “OFF”. 2. With the PCM disconnected, check continuity of the Bank 2 HO2S 1 high circuit. 3. If the Bank 2 HO2S 1 high circuit measures over 5.0 ohms, repair open or poor connection as necessary. Was a Bank 2 HO2S 1 high circuit problem found and corrected?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–207

Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Open Bank 2 Sensor 1

060R200054

Circuit Description Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. The powertrain control module (PCM) will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started the PCM will monitor the HO2S voltage. When the Bank HO2S voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that too much time was required for the Bank 2 HO2S 1 to become active, a DTC P0155 will set. The time it should take the HO2S to reach operating temperature is based on the total amount of air that has passed through the mass air flow (MAF) sensor and into the engine (more total air flow = shorter time to HO2S activity).

Conditions for Setting the DTC B No related DTCs. B The engine has been running for over 120 seconds.

B Ignition voltage is between 11 volts and 18 volts. B Heater signal is below 0.1A. B Bank 1 HO2S 2 voltage does not change more than 150 mV from the bias voltage (between 400 mV-500 mV) for a longer amount of time than it should. The maximum amount of time to come up to operating range is 120 seconds. This warm-up time depends on the engine coolant temperature at start-up and accumulated air flow since start-up.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0155 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0155 can be cleared by using the Tech 2 “Clear info” function or by disconnecting the PCM battery feed.

6E–208

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description

2. The HO2S should be allowed to cool before performing this test. If the HO2S heater is functioning, the signal voltage will gradually increase or decrease as the sensor element warms. If the heater is not functioning, the HO2S signal will remain near the 450 mV bias voltage. 4. Ensures that the ignition feed circuit to the HO2S is not open or shorted. The test light should be connected to a good chassis ground, in case the HO2S low or HO2S heater ground circuit is faulty. 5. Checks the HO2S heater ground circuit. 6. Checks for an open or shorted HO2S heater element. 10.An open HO2S signal or low circuit can cause the HO2S heater to appear faulty. Check these circuits before replacing the sensor.

Number(s) below refer to the step number(s) on the Diagnostic Chart.

DTC P0155 – HO2S Heater Circuit Open Bank 2 Sensor 1 Step

Action

—

Go to Step 2

Go to OBD System Check

Above 650 mV or below 250 mV

Refer to Diagnostic Aids

Go to Step 3

—

Go to Step 15

Go to Step 4

—

Go to Step 5

Go to Step 7

—

Go to Step 6

Go to Step 8

Inspect the fuse for the Bank 2 HO2S 1 ignition feed. Is the fuse open? 1. 2. 3. 4.

Ignition “OFF”. Raise the vehicle. Disconnect the Bank 2 HO2S 1 electrical connector. Using a test light connected to a known good ground (do not use Bank 2 HO2S 1 heater ground or Bank 2 HO2S 1 low), probe the ignition feed circuit at the Bank 2 HO2S 1 electrical connector (PCM harness side).

Does the test light illuminate? 5

NOTE: If the engine has just been operating, allow the engine to cool for at least 15 minutes before proceeding.

Did the HO2S voltage go from bias voltage to above or below the specified value?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

Connect the test light between Bank 2 HO2S 1 ignition feed and Bank 2 HO2S 1 heater ground. Does the test light illuminate?

6E–209

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0155 – HO2S Heater Circuit Open Bank 2 Sensor 1 (Cont’d) Step

Action

—

Verify repair

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 14

—

Verify repair

—

Verify repair

—

Replace Bank 2 HO2S 1. Is the action complete?

—

Check for a poor Bank 2 HO2S 1 signal circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement?

Verify repair

Check for a poor Bank 2 HO2S 1 low circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement?

—

1. Ignition “OFF”. 2. Disconnect the PCM and check the continuity of the Bank 2 HO2S 1 signal circuit and the Bank 2 HO2S 1 low circuit. 3. If the Bank 2 HO2S 1 signal circuit or HO2S low circuit measures over 5 ohms, repair open or poor connection as necessary. Was a problem found?

Go to Step 10

Check for a poor Bank 2 HO2S 1 signal or low circuit terminal connection at the Bank 2 HO2S 1 harness connector and replace terminal(s) if necessary. Did any terminals require replacement?

Go to Step 9

1. Check for a poor connection at the Bank 2 HO2S 1 harness terminals. 2. If a poor connection is found, replace terminals. Was a poor connection found?

3-6 ohms

Repair the open Bank 2 HO2S 1 heater ground circuit. Is the action complete?

Repair the open Bank 2 HO2S 1 ignition feed circuit to Bank 2 HO2S 1. Is the action complete?

Yes

1. Allow the HO2S to cool for at least 15 minutes. 2. Using a DVM, measure resistance between the Bank 2 HO2S 1 ignition feed and the Bank 2 HO2S 1 heater ground at the Bank 2 HO2S 1 pigtail. Is the HO2S resistance within the specified values?

Value(s)

Locate and repair short to ground in Bank 2 HO2S 1 ignition feed circuit and replace the faulty fuse. Is the action complete?

6E–210

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2

060R200054

Circuit Description To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 2 HO2S 1 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 2 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 2 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalyst’s ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 2 HO2S 1 signal will be far more active than that produced by the Bank 2 HO2S 2 sensor. If the Bank 2 HO2S 2 signal voltage remains excessively low for an extended period of time, DTC P0157 will be set.

Conditions for Setting the DTC B No related DTCs. B The engine is operating in “closed loop”. B Engine coolant temperature is above 60°C (140°F).

B “Closed loop” commanded air/fuel ratio is between 14.5 and 14.8 B Bank 2 HO2S 2 signal voltage remains below 22 mV during normal “closed loop” operation for a total of 106 seconds over a 125-second period of time. OR B Bank 2 HO2S 2 signal voltage remains below 400 mV during “power enrichment” mode fuel control operation for up to 5 seconds.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0157 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0157 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids Check for the following conditions: B Heated oxygen sensor wiring – The sensor pigtail may be mispositioned and contacting the exhaust system. B Poor PCM to engine grounds. B Fuel pressure – A condition which causes a lean exhaust can cause DTC P0157 to set. The system will go lean if pressure is too low. The PCM can compensate for some decrease. However, if fuel pressure is too low, a DTC P0157 may be set. Refer to Fuel System Diagnosis. B Lean injector(s) – Perform “Injector Balance Test”. B Vacuum leaks – Check for disconnected or damaged vacuum hoses and for vacuum leaks at the intake manifold, throttle body, EGR system, and PCV system. B Exhaust leaks – An exhaust leak may cause outside air to be pulled into the exhaust gas stream past the HO2S, causing the DTC P0157 to set. Check for exhaust leaks near the Bank 1 HO2S 2 sensor. B MAF sensor – The system can go lean if the MAF sensor signal indicates an engine airflow

6E–211

measurement that is not correct. Disconnect the MAF sensor to see if the condition is corrected. If so, replace the MAF sensor. B Fuel contamination – Water, even in small amounts, can be delivered to the fuel injectors. The water can cause a lean exhaust to be indicated. Excessive alcohol in the fuel can also cause this condition. Refer to Fuel System Diagnosis for the procedure to check for fuel contamination. B If none of above conditions are present, replace the affected HO2S 2.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0157 failing during operation may indicate a condition described in the “Diagnostic Aids” above. If the DTC P0157 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated.

DTC P0157 – HO2S Circuit Low Voltage Bank 2 Sensor 2 Step

Action

—

Go to Step 2

Go to OBD System Check

22 mV

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

—

Go to Step 5

Go to Step 6

—

Verify repair

—

1. Ignition “ON”, engine “OFF”. 2. Review and record Tech 2 Failure Records data and note parameters. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor “DTC” info for DTC P0157 until the DTC P0157 test runs. 5. Note the test result.

1. Turn the ignition “OFF”. 2. Disconnect the PCM. 3. Check the Bank 2 HO2S 2 high and low signal circuits for a short to ground or a short to the heater ground circuit. Were Bank 2 HO2S 2 signal circuits shorted?

Does the Tech 2 indicate DTC P0157 failed this ignition? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Bank 2 HO2S 2 voltage remain below the specified value? 3

Value(s)

Repair the Bank 1 HO2S 2 signal circuit. Is the action complete?

6E–212

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0157 – HO2S Circuit Low Voltage Bank 2 Sensor 2 (Cont’d) Step

Action

—

Go to Step 7

Go to Step 8

—

Verify repair

—

425-475 mV

Refer to Diagnostic Aids

Go to Step 9

—

Verify repair

—

1. Ignition “OFF”. 2. Reconnect the PCM, leave HO2S 2 disconnected. 3. Ignition “ON”. Does the Tech 2 indicate Bank 2 HO2S 2 voltage near the specified value?

Repair the short between the high and low circuits. Is the action complete?

Yes

1. Ignition “OFF”. 2. Leave the PCM and HO2S 2 disconnected. 3. Check for continuity between the high and low signal circuits. Was there continuity between the high and low circuits?

Value(s)

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to the latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–213

Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2

060R200054

Circuit Description To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 2 HO2S 1 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 2 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 2 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalyst’s ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 2 HO2S 1 signal will be far more active than that produced by the Bank 2 HO2S 2 sensor. If the Bank 2 HO2S 2 signal voltage remains excessively high for an extended period of time, DTC P0158 will be set.

Conditions for Setting the DTC B No related DTCs. B Engine is operating in “closed loop”. B “Closed loop” commanded air/fuel ratio is between 14.5 and 14.8.

B Engine coolant temperature is above 60°C (140°F). B Bank 2 HO2S 2 signal voltage remains above 952 mV during normal “closed loop” operation for a total of 106 seconds over a 125-second period. OR B Bank 2 HO2S 2 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for up to 3 seconds.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0158 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0158 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–214

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids Check for the following conditions: B Fuel pressure – An excessively rich fuel mixture can cause a DTC P0158 to be set. Refer to Fuel System Diagnosis. B Rich injector(s) – Perform “Injector Balance Test”. B Leaking injector – Refer to Fuel System Diagnosis. B Evaporative emissions (EVAP) canister purge – Check for fuel saturation. If full of fuel, check canister control and hoses. Refer to Evaporative Emission (EVAP) Control System. B MAF sensor –The system can go rich if the MAF sensor signal indicates an engine airflow measurement that is not correct. Disconnect the MAF sensor to see if a rich condition is corrected. If so, replace the MAF sensor. B Check for a leaking fuel pressure regulator diaphragm by checking the vacuum line to the regulator for the presence of fuel. There should be no fuel in the vacuum line. B TP sensor – An intermittent TP sensor output will cause the system to go rich, due to a false indication of the engine accelerating. B Shorted Heated Oxygen Sensor (HO2S) – If the HO2S is internally shorted, the HO2S voltage displayed on the Tech 2 will be over 1 volt. Try disconnecting the affected HO2S with the key “ON”, engine “OFF”. If the displayed HO2S voltage changes from over 1000 mV to around 450 mV, replace the HO2S. Silicon contamination of the HO2S can also cause a high HO2S voltage to be indicated. This condition is

indicated by a powdery deposit on the portion of the HO2S exposed to the exhaust stream. If contamination is noticed, replace the affected HO2S. B Open HO2S signal or low circuit, or faulty HO2S – A poor connection or open in the HO2S signal or low circuit can cause the DTC to set during deceleration fuel cutoff mode operation. An HO2S which is faulty and does not allow full voltage swing between the rich and lean thresholds can also cause this condition. Operate the vehicle while monitoring the HO2S voltage with a Tech 2. If the HO2S voltage is limited within a range between 300 mV to 600 mV, check the HO2S signal and low circuit wiring and associated terminal connections. If the wiring and connections are OK, replace the HO2S. B If none of above conditions are present, replace the affected HO2S.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. DTC P0158 being set during deceleration fuel cutoff mode operation may indicate a condition described in the “Diagnostic Aids” above. If the DTC P0158 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0158 – HO2S Circuit High Voltage Bank 2 Sensor 2 Step

Action

Yes

1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the vehicle within parameters specified under “Conditions for Setting the DTC” criteria included in Diagnostic Support. 4. Using a Tech 2, monitor Bank 2 HO2S 2 voltage.

—

Go to Step 2

952 mV (500 mV in deceleration fuel cut-out mode)

Go to Step 4

Go to Step 3

Go to Step 4

Refer to Diagnostic Aids

1. Ignition “ON”. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Records conditions as noted. 4. Using a Tech 2, monitor “DTC” info for DTC P0158 until the DTC P0158 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0158 failed this ignition?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Bank 2 HO2S 2 voltage remain above the specified value? 3

Value(s)

—

6E–215

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0158 – HO2S Circuit High Voltage Bank 2 Sensor 2 (Cont’d) Step

Action

1. 2. 3. 4.

Go to Step 5

Go to Step 6

—

Verify repair

—

10 mV

Go to Step 7

Go to Step 8

425-475 mV

Refer to Diagnostic Aids

Go to Step 8

—

Verify repair

—

1. Disconnect the jumpers to ground from Bank 2 HO2S 2 PCM-side connector. 2. With the HO2S 2 connector disconnected, monitor Bank 2 HO2S 2 voltage. Is Bank 2 HO2S 2 voltage between the specified values?

3-4 V

1. Ignition “ON”, engine “OFF”. 2. At Bank 2 HO2S 2 connector (PCM side) jumper both the HO2S high and low signal circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 2 HO2S 2 voltage. Is Bank 2 HO2S 2 voltage below the specified value?

Repair short to voltage in signal circuit. Is the action complete?

Yes

Ignition “OFF”. Disconnect Bank 2 HO2S 2. Ignition “ON”. At the HO2S Bank 2 Sensor 2 connector (PCM side), use a DVM to measure voltages at the high and low signal terminals.

Are the voltages in the specified range? 5

Value(s)

6E–216

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2

060R200054

Circuit Description To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalytic converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 2 HO2S 1 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 2 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 2 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalyst’s ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 2 HO2S 1 signal will be far more active than that produced by the Bank 2 HO2S 2 sensor. If the Bank 2 HO2S 2 signal voltage remains between 400 mV and 500 mV for an extended period of time, DTC P0160 will be set. Heated Oxygen sensors are used to minimize the amount of time required for “closed loop” fuel control operation and allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank

2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.

Conditions for Setting the DTC B B B B B B

No related DTCs. Battery voltage is above 10 volts. The engine has been running for over 5 seconds. Oxygen sensor heater is functioning properly. Engine is in “closed loop” operation. Bank 2 HO2S 2 signal voltage remains between 426 mV and 474 mV for a total of 106 seconds over a 125-second period of time.

6E–217

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B DTC P0160 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Poor connection or damaged harness – Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. B Faulty HO2S heater or heater circuit – With the ignition “ON”, engine “OFF”, the HO2S voltage displayed on a Tech 2 should gradually drop to below 250 mV. If not, disconnect the HO2S and connect a test light between the HO2S ignition feed and heater ground circuits. If the test light does not light, repair the open ignition feed or sensor ground circuit as necessary. If the test light lights and the HO2S signal and low circuits are OK, replace the HO2S.

B Intermittent test – With the ignition “ON”, monitor the HO2S signal voltage while moving the wiring harness and related connectors. If the fault is induced, the HO2S signal voltage will change. This may help isolate the location of the malfunction.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. If the DTC P0160 test passes while the Failure Records conditions are being duplicated, an intermittent condition is indicated. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0160 – HO2S Circuit Insufficient Activity Bank 2 Sensor 2 Step

Action

Go to Step 2

425-475 mV

Go to Step 3

Go to Step 4

—

Go to Step 4

Refer to Diagnostic Aids

—

Verify repair

Go to Step 5

—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

Check for a damaged harness. Check for poor Bank 2 HO2S 2 high and low circuit terminal connections at the Bank 2 HO2S 2 harness connector and replace terminal(s) if necessary. Did either terminal require replacement?

—

Go to OBD System Check

1. Ignition “ON”, engine “OFF”, review and record Tech 2 Failure Records data and note parameters. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor “DTC” info for DTC P0160 until the DTC P0160 test runs. 4. Note the test result.

Was problem found? 5

1. Install the Tech 2. 2. Run the engine at operating temperature. 3. Operate the engine above 1200 RPM for two minutes.

Does the Tech 2 indicate DTC P0160 failed this ignition? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Tech 2 indicate Bank 2 HO2S 2 voltage varying outside the specified values? 3

Value(s)

Check for poor Bank 2 HO2S 2 high and low circuit terminal connections at the PCM and replace terminals if necessary. Did any terminals require replacement?

6E–218

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0160 – HO2S Circuit Insufficient Activity Bank 2 Sensor 2 (Cont’d) Step

Action

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

0-10 mV

Go to Step 10

Go to Step 11

—

Verify repair

—

Verify repair

—

Replace Bank 2 HO2S 2. Is the action complete?

—

1. Ignition “ON”, engine “OFF”. 2. Disconnect Bank 2 HO2S 2 and jumper the HO2S high and low circuits (PCM side) to ground. 3. Using a Tech 2, monitor Bank 2 HO2S 2 voltage. Is Bank 2 HO2S 2 voltage in the specified range?

1. Ignition “OFF”. 2. With the PCM disconnected, check continuity of the Bank 2 HO2S 2 low circuit. 3. If the Bank 2 HO2S 2 low circuit measures over 5 ohms, repair open or poor connections as necessary. Was a Bank 2 HO2S 2 low circuit problem found and corrected?

Yes

1. Ignition “OFF”. 2. With the PCM disconnected, check continuity of the Bank 2 HO2S 2 high circuit. 3. If the Bank 2 HO2S 2 high circuit measures over 5.0 ohms, repair open or poor connections as necessary. Was a Bank 2 HO2S 2 high circuit problem found and corrected?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–219

Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2

060R200054

Circuit Description Heated oxygen sensors are used to minimize the amount of time required for “closed loop” fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature which allows accurate exhaust oxygen content readings further from the engine. The powertrain control module (PCM) will run the heater test only after a cold start (determined by engine coolant and intake air temperature at the time of start-up) and only once during an ignition cycle. When the engine is started, the PCM will monitor the HO2S voltage. When the Bank 2 HO2S 2 voltage indicates a sufficiently active sensor, the PCM looks at how much time has elapsed since start-up. If the PCM determines that too much time was required for the Bank 2 HO2S 2 to become active, a DTC P0161 will set. The time it should take the HO2S to reach operating temperature is based on the total amount of air that has passed through the MAF sensor and into the engine (more total air flow = shorter time to HO2S activity).

Conditions for Setting the DTC B No related DTCs. B The engine has been running for over 120 seconds.

B Ignition voltage is between 11 volts and 18 volts. B Average mass air flow for the sample period is less than 23 g/second. B Bank 2 HO2S 2 voltage does not change more than 150 mV from the bias voltage (between 400 mV-500 mV) for a longer amount of time than it should. The maximum amount of time to come up to operating range is 120 seconds. This warm-up time depends on the engine coolant temperature at start-up and accumulated air flow since start-up.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0161 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0161 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–220

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description

2. The HO2S should be allowed to cool before performing this test. If the HO2S heater is functioning, the signal voltage will gradually increase or decrease as the sensor element warms. If the heater is not functioning, the HO2S signal will remain near the 450 mV bias voltage. 4. This ensures that the ignition feed circuit to the HO2S is not open or shorted. The test light should be connected to a good chassis ground, in case the HO2S low or HO2S heater ground circuit is faulty. 5. This checks the HO2S heater ground circuit. 6. This checks for an open or shorted HO2S heater element. 11.An open HO2S signal or low circuit can cause the HO2S heater to appear faulty. Check these circuits before replacing the sensor.

Number(s) below refer to the step number(s) on the Diagnostic Chart.

DTC P0161 – HO2S Heater Circuit Bank 2 Sensor 2 Step

Action

—

Go to Step 2

Go to OBD System Check

Above 650 mV or Below 250 mV

Refer to Diagnostic Aids

Go to Step 3

—

Go to Step 15

Go to Step 4

—

Go to Step 5

Go to Step 7

—

Go to Step 6

Go to Step 8

Inspect the fuse for the Bank 2 HO2S 2 ignition feed. Is the fuse open? 1. 2. 3. 4.

Ignition “OFF”. Raise the vehicle. Disconnect the Bank 2 HO2S 2 electrical connector. Using a test light connected to a known good ground (do not use Bank 2 HO2S 2 heater ground or Bank 2 HO2S 2 low), probe the ignition feed circuit at the Bank 2 HO2S 2 electrical connector (PCM harness side).

Does the test light illuminate? 5

NOTE: If the engine has just been operating, allow the engine to cool for at least 15 minutes before proceeding.

Did the HO2S voltage go from bias voltage to above or below the specified values?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

Connect the test light between the Bank 2 HO2S 2 ignition feed and the Bank 2 HO2S 2 heater ground. Does the test light illuminate?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–221

DTC P0161 – HO2S Heater Circuit Bank 2 Sensor 2 (Cont’d) Step

Action

—

Verify repair

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 14

—

Verify repair

—

Verify repair

—

Replace Bank 2 HO2S 2. Is the action complete?

—

Check for a poor Bank 2 HO2S 2 high circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement?

Verify repair

Check for a poor Bank 2 HO2S 2 low circuit terminal connection at the PCM and replace the terminal if necessary. Did the terminal require replacement?

—

1. Ignition “OFF”. 2. Disconnect the PCM and check the continuity of the Bank 2 HO2S 2 signal circuit and the Bank 2 HO2S 2 low circuit. 3. If the Bank 2 HO2S 2 signal circuit or HO2S low circuit measures over 5 ohms, repair the open or poor connection as necessary. Was a problem found?

Go to Step 10

Go to Step 9

1. Check for a poor connection at the Bank 2 HO2S 2 harness terminals. 2. If a poor connection is found, replace the terminals. Was a poor connection found?

3-6 ohms

Repair the open Bank 2 HO2S 2 heater ground circuit. Is the action complete?

Repair the open Bank 2 HO2S 2 ignition feed circuit to Bank 2 HO2S 2. Is the action complete?

Yes

1. Allow the HO2S to cool for at least 15 minutes. 2. Using a DVM, measure resistance between the Bank 2 HO2S 2 ignition feed and the Bank 2 HO2S 2 heater ground at the Bank 2 HO2S 2 pigtail. Is the HO2S resistance within the specified values?

Value(s)

Locate and repair the short to ground in the Bank 2 HO2S 2 ignition feed circuit and replace the faulty fuse. Is the action complete?

6E–222

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1

060R200054

Circuit Description To provide the best possible combination of driveability, fuel economy, and emission control, a “closed loop” air/fuel metering system is used. While in “closed loop”, the powertrain control module (PCM) monitors the Bank 1 HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel delivery based upon the HO2S signal voltages. A change made to fuel delivery will be indicated by the long and short term fuel trim values which can be monitored with a Tech 2. Ideal fuel trim values are around 0%; if the HO2S signals are indicating a lean condition the PCM will add fuel, resulting in fuel trim values above 0%. If a rich condition is detected, the fuel trim values will be below 0%, indicating that the PCM is reducing the amount of fuel delivered. If an excessively lean condition is detected on Bank 1, the PCM will set DTC P0171. The PCM’s maximum authority to control long term fuel trim allows a range between –15% (automatic transmission) or –12% (manual transmission) and +20%. The PCM monitors fuel trim under various engine speed/load fuel trim cells before determining the status of the fuel trim diagnostic.

B Engine coolant temperature is between 6°C (42.8°F) and 105°C (221°F). B Intake air temperature is between –40°C (–40°F) and 120°C (248°F). B Manifold absolute pressure is between 24 kPa and 99 kPa. B Throttle angle is steady below 95%. B Vehicle speed is below 136 km/h (85 mph). B Engine speed is between 400 and 6,000 RPM. B Barometric pressure is greater than 72.5 kPa. B Mass air flow is between 2 g/second and 200 g/second. B Ignition voltage is above 9.5 volts. B Fuel system is in “closed loop”. B Canister purge duty cycle is greater than 0% if on.

Conditions for Setting the DTC

Conditions for Clearing the MIL/DTC

B None of the following: EGR DTCs, HO2S DTCs, (response, transition, open, low volts, no activity), MAF DTCs, TP sensor DTCs, MAP DTCs, IAT DTCs, canister purge DTCs, EVAP DTCs, injector circuit DTCs, or misfire DTCs.

B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0171 will clear after 40 consecutive warm-up cycles have occurred without a fault.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B DTC P0171 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 1 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the engine harness. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. DTCs other than P0171 and P0174 may indicate a condition present which may cause a lean condition. If this is the case, repairing the condition which caused the other DTC will most likely correct the DTC P0171/P0174. 4. If the DTC P0171 test passes while the Failure Records conditions are being duplicated, the lean condition is intermittent. Refer to Diagnostic Aids or Symptoms for additional information on diagnosing intermittent problems.

6E–223

6E–224

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0171 – Fuel Trim System Lean Bank 1 Step

Action

Yes

—

Go to Step 2

—

Go to the applicable DTC charts and repair the other DTCs before proceeding with this chart

Go to Step 3

L.T. Fuel Trim: +20%

Go to Step 5

Go to Step 4

Are any DTCs set other than P0171 and P0174?

1. Start the engine and operate the vehicle in “closed loop”. 2. Observe the “BANK 1 L.T. FUEL TRIM” display on the Tech 2.

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is the displayed value greater than the specified value? 4

Value(s)

1. Review and record the Tech 2 Failure Records data. 2. Clear the DTC P0171/P0174 and operate the vehicle to duplicate the Failure Records conditions. 3. Monitor the Tech 2 “DTC” info for DTC P0171 while operating the vehicle to duplicate the Failure Records conditions. 4. Continue operating the vehicle until the DTC P0171 test runs and note the test result. Does the Tech 2 indicate DTC P0171 failed this ignition?

—

Go to Step 5

The lean condition is not present. If a driveability symptom still exists, refer to Symptoms section.

Was DTC P0174 also set?

—

Go to Step 6

Go to Step 15

Visually and physically inspect the vacuum hoses for disconnections, splits, kinks, improper routing and improper connections and repair any problem found. —

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

—

Go to Step 10

Go to Step11

—

Verify repair

Go to Step 11

Did your inspection reveal a problem requiring repair? 7

Visually and physically inspect the crankcase ventilation valve for proper installation and repair any problem found (refer to Crankcase Ventilation System). Did your inspection reveal a problem requiring repair?

1. Inspect the MAF sensor inlet screen for damage or for the presence of foreign objects which may partially block the air flow sample through the MAF sensor. 2. Correct any problem that is found as necessary. Did your inspection of the MAF sensor reveal a condition requiring repair?

Start the engine and note the idle quality. Is a high or unsteady idle being experienced?

1. Visually and physically inspect the throttle body, intake manifold, EGR valve and the EGR feed pipe for vacuum leaks. 2. Repair any vacuum leaks as necessary. Did your inspection reveal a vacuum leak?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–225

DTC P0171 – Fuel Trim System Lean Bank 1 (Cont’d) Step

Action

Check the fuel for excessive water, alcohol, or other contaminants (see Diagnosis in Engine Fuel for the procedure) and correct the contaminated fuel condition if present (see Engine Fuel). Was the fuel contaminated?

Verify repair

Go to Step 13

Go to Step 19

Go to Step 14

—

Verify repair

Go to Step 15

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

—

Verify repair

Go to Step 18

—

Verify repair

Refer to Diagnostic Aids

—

Verify repair

—

1. Visually and physically inspect the Bank 1 HO2S 1 to ensure that it is installed securely and that the Bank 1 HO2S 1 pigtail and wiring harness are not contacting the exhaust or otherwise damaged. 2. If a problem is found, correct it as necessary. Did your inspection reveal a problem?

—

Perform the “Injector Balance Test”, and correct any problem found (refer to Fuel Metering System). Did Injector Balance Test isolate a problem?

Go to Step 12

Visually and physically inspect the Bank 1 exhaust manifold for leaks and loose or missing hardware and correct any problem found. Did your inspection reveal a problem?

Verify repair

1. Visually and physically inspect the intake manifold, injector O-rings, EGR adapter, EGR valve and the EGR feed pipes for vacuum leaks. 2. Repair any problem that is found. Did your inspection reveal a problem?

—

Perform the procedure in the “Fuel System Pressure Test” and repair fuel system problem if necessary. Did Fuel System Pressure Test isolate a condition requiring repair?

1. Disconnect the MAF sensor electrical connector. 2. Operate the vehicle in “closed loop” while monitoring the “BANK 1 S.T. FUEL TRIM” displayed on the Tech 2. Does “BANK 1 S.T. FUEL TRIM” value decrease to near the specified value?

Yes

1. Visually and physically inspect the PCM injector grounds, power grounds and sensor grounds to ensure that they are clean, tight, and in their proper locations. 2. If a faulty ground condition is present, correct it as necessary. Did your inspection reveal a condition requiring repair?

Value(s)

Replace the MAF sensor. Is the action complete?

6E–226

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1

060R200054

Circuit Description To provide the best possible combination of driveability, fuel economy, and emission control, a “closed loop” air/fuel metering system is used. While in “closed loop”, the powertrain control module (PCM) monitors the Bank 1 heated oxygen sensors (HO2S) 1 and Bank 2 HO2S 1 signals and adjusts fuel delivery based upon the HO2S signal voltages. A change made to fuel delivery will be indicated by the long and short term fuel trim values which can be monitored with a Tech 2. Ideal fuel trim values are around 0%; if the HO2S signals are indicating a lean condition the PCM will add fuel, resulting in fuel trim values above 0%. If a rich condition is detected, the fuel trim values will be below 0%, indicating that the PCM is reducing the amount of fuel delivered. If an excessively rich condition is detected on Bank 1, the PCM will set DTC P0172. The PCM’s maximum authority to control long term fuel trim allows a range between –15% (automatic transmission) or –12 (manual transmission) and +20%. The PCM’s maximum authority to control short term fuel trim allows a range between –11% and +20%. The PCM monitors fuel trim under various engine speed/load fuel trim cells before determining the status of the fuel trim diagnostic.

Conditions for Setting the DTC B None of the following was set: EGR DTCs, HO2S DTCs, (response, transition, open, low volts, no activity), MAF DTCs, TPS DTCs, MAP DTCs, IAT

B B B B B B B B B B B

DTCs, canister purge DTCs, EVAP DTCs, injector circuit DTCs, or misfire DTCs. Engine coolant temperature is between 6°C (42.8°F) and 105°C (221°F). Intake air temperature is between –40°C (–40°F) and 120°C (248°F). Manifold absolute pressure is between 24 kPa and 99 kPa. Throttle angle is steady below 95%. Vehicle speed is below 136 km/h (85 mph). Engine speed is between 400 and 6,000 RPM. Barometric pressure is greater than 72.5 kPa. Mass air flow is between 2 g/second and 200 g/second. Ignition voltage is above 9.5 volts. Fuel system is in “closed loop”. Canister purge duty cycle is greater than 0%, if “ON”.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B A history DTC P0172 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0172 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–227

the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. DTCs other than P0172 and P0175 may indicate a condition present which may cause a lean condition. If this is the case, repairing the condition which caused the other DTC will most likely correct the DTC P0172/P0175. 4. If the DTC P0172 test passes while the Failure Records conditions are being duplicated, the rich condition is intermittent. Refer to Diagnostic Aids or Symptoms for additional information on diagnosing intermittent problems.

DTC P0172 – Fuel Trim System Rich Bank 1 Step

Action

Yes

—

Go to Step 2

—

Go to the applicable DTC charts and repair the other DTCs before proceeding with this chart

Go to Step 3

L.T. Fuel Trim: –15% (auto. trans.) OR –12% (man. trans.)

Go to Step 5

Go to Step 4

Are any DTCs set other than P0172 and P0175?

1. Start the engine and operate the vehicle in “closed loop”. 2. Observe “B1 Long Term Fuel Trim” display on the Tech 2.

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is the displayed value more negative than the specified value? 4

Value(s)

1. Review and record the Tech 2 Failure Records data. 2. Clear the DTC P0172/P0175 and operate the vehicle to duplicate the Failure Records conditions. 3. Monitor the Tech 2 “DTC” info for DTC P0172 while operating the vehicle to duplicate the Failure Records conditions. 4. Continue operating the vehicle until the DTC P0172 test runs and note test result. Does the Tech 2 indicate DTC P0172 failed this ignition?

—

Go to Step 5

The rich condition is not present. If a driveability symptom still exists, refer to Symptoms.

Is DTC P0175 also set?

—

Go to Step 6

Go to Step 15

Visually and physically inspect the air filter element and replace it if necessary. —

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

Did the air filter require replacement? 7

Visually and physically inspect the air intake duct for collapse or restriction and repair if necessary. Did your inspection reveal a condition requiring repair?

6E–228

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0172 – Fuel Trim System Rich Bank 1 (Cont’d) Step

Action

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

Minimum 8% Maximum 92%

Go to Step 13

Go to Step 21

Go to Step 22

Go to Step 14

—

Verify repair

Go to Step 15

—

Go to Step 16

Go to Step 19

—

Go to Step 17

Go to Step 18

—

Verify repair

—

Check for short to ground in the wire (YEL/RED) between the canister purge solenoid and PCM terminal S-48. Was there a short to ground?

Go to Step 11

1. Ignition “ON”, engine “OFF”. 2. Connect a test light between the harness connector terminals of canister purge solenoid. Is the test light on?

Go to Step 10

1. Perform “Fuel System Pressure Test”. 2. If Fuel System Pressure Test isolates a problem, repair as necessary (refer to Engine Fuel or Fuel Metering System). Did the Fuel System Pressure Test isolate a problem requiring repair?

—

1. Disconnect the MAF sensor electrical connector. 2. Operate the vehicle in “closed loop” while monitoring the “BANK 1 L.T. FUEL TRIM” and “BANK 1 S. T. FUEL TRIM” display on the Tech 2. Did both values change to near the specified value?

Go to Step 9

Ignition “ON”, engine “OFF”, monitor the TP1 Angle display on the Tech 2 while slowly depressing the accelerator pedal. Does the TP Angle display increase steadily and evenly from minimum value at closed throttle to maximum value at wide-open throttle?

Verify repair

1. Disconnect the vacuum hose from the fuel pressure regulator and inspect the hose for the presence of fuel. 2. If fuel is present in the vacuum hose, replace the fuel pressure regulator (refer to Fuel Metering System). Did the fuel pressure regulator require replacement?

—

1. Ignition “OFF”. 2. Physically inspect the throttle body bore and throttle plate for coking and foreign objects. 3. If a problem was found, repair as necessary. Did your inspection reveal a condition requiring repair?

Start the engine and note the idle quality. Is a low or unsteady idle being experienced?

Yes

Inspect the MAF sensor inlet screen for damage or for the presence of foreign objects which may partially block air flow through the screen and correct any problem found. Did your inspection of the MAF sensor reveal a condition requiring repair or replacement?

Value(s)

Repair the short to ground. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–229

DTC P0172 – Fuel Trim System Rich Bank 1 (Cont’d) Step

Action

Value(s)

Yes

—

Verify repair

Go to Step 20

—

Verify repair

Refer to Diagnostic Aids

—

Verify repair

—

Verify repair

—

1. Check the TP sensor mounting screws and tighten or replace them as necessary if they are loose or missing. 2. If the screws are OK, replace the TP sensor. Is the action complete?

—

1. Remove and visually/physically inspect the Bank 1 HO2S 1 for silicon contamination. This will be indicated by a powdery deposit on the portion of the HO2S that is exposed to the exhaust stream. 2. If contamination is evident on the Bank 1 HO2S 1, replace the contaminated sensors. Did the sensor require replacement?

Verify repair

1. Perform the “Injector Balance Test”. 2. If Injector Balance Test isolates a problem, repair as necessary (refer to Fuel Metering System). Did the Injector Balance Test isolate a problem requiring repair?

—

Replace the MAF sensor. Is the action complete?

6E–230

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2

060R200054

Circuit Description To provide the best possible combination of driveability, fuel economy, and emission control, a “closed loop” air/fuel metering system is used. While in “closed loop”, the powertrain control module (PCM) monitors the Bank 1 HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel delivery based upon the HO2S signal voltages. A change made to fuel delivery will be indicated by the long and short term fuel trim values which can be monitored with a Tech 2. Ideal fuel trim values are around 0%; if the HO2S signals are indicating a lean condition the PCM will add fuel, resulting in fuel trim values above 0%. If a rich condition is detected, the fuel trim values will be below 0%, indicating that the PCM is reducing the amount of fuel delivered. If an excessively lean condition is detected on Bank 2, the PCM will set DTC P0174. The PCM’s maximum authority to control long term fuel trim allows a range between –15%(automatic transmission) or –12%(manual transmission) and +20%. The PCM monitors fuel trim under various engine speed/load fuel trim cells before determining the status of the fuel trim diagnostic.

Conditions for Setting the DTC B None of the following DTCs are set: idle system, EGR, HO2S, (response, transition, open, low volts, no activity), MAF, TP sensor, MAP, IAT, canister purge, EVAP, injector circuit, or misfire. B Engine coolant temperature is between 6°C (42.8°F) and 105°C (221°F).

B Intake air temperature is between –40°C (–40°F) and 120°C (248°F). B Manifold absolute pressure is between 24 kPa and 99 kPa. B Throttle angle is steady between 3 and 95%. B Vehicle speed is below 136 km/h (85 mph). B Engine speed is between 400 and 6,000 RPM. B Barometric pressure is greater than 72.5 kPa. B Mass air flow is between 2 g/second and 200 g/second. B Ignition voltage is above 9.5 volts. B Fuel system is in “closed loop”. B Canister purge duty cycle is greater than 0%, if “ON”.

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the failure is detected. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0174 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0174 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the Bank 2 HO2S 1 display on the Tech 2 while moving connectors and wiring harnesses related to the engine harness. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. DTCs other than P0171 and P0174 may indicate a condition present which may cause a lean condition. If this is the case, repairing the condition which caused the other DTC will most likely correct the DTC P0171/P0174. 4. If the DTC P0174 test passes while the Failure Records conditions are being duplicated, the lean condition is intermittent. Refer to Diagnostic Aids or Symptoms for additional information on diagnosing intermittent problems.

6E–231

6E–232

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0174 – Fuel Trim System Lean Bank 2 Step

Action

Yes

—

Go to Step 2

Go to OBD System Check

—

Go to the applicable DTC charts and repair the other DTCs before proceeding with this chart.

Go to Step 3

L.T. Fuel Trim: +20%

Go to Step 5

Go to Step 4

Was the “On-Board Diagnostic (OBD) System Check” performed? Are any DTCs set other than P0174 and P0171?

1. Start the engine and operate the vehicle in “closed loop”. 2. Observe the “BANK 2 L.T. FUEL TRIM” display on the Tech 2. Is the displayed values greater than the specified values?

Value(s)

1. Review and record Tech 2 Failure Records data. 2. Clear the DTC P0171/P0174 and operate the vehicle to duplicate the Failure Records conditions. 3. Monitor the Tech 2 “DTC” info for DTC P0174 while operating the vehicle to duplicate the Failure Records conditions. 4. Continue operating the vehicle until the DTC P0174 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0174 failed this ignition?

—

Go to Step 5

The lean condition is not present. If a driveability symptom still exists, refer to Symptoms section.

Was DTC P0171 also set?

—

Go to Step 6

Go to Step 15

Visually and physically inspect the vacuum hoses for disconnections, splits, kinks, improper routing and improper connections and repair any problem found. —

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

—

Go to Step 10

Go to Step 11

Did your inspection reveal a problem requiring repair? 7

Start the engine and note the idle quality. Is a high or unsteady idle being experienced?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–233

DTC P0174 – Fuel Trim System Lean Bank 2 (Cont’d) Step

Action

Go to Step 12

—

Verify repair

Go to Step 13

Go to Step 19

Go to Step 14

—

Verify repair

Go to Step 15

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

—

Verify repair

Go to Step 18

—

Verify repair

Refer to Diagnostic Aids

—

Verify repair

—

1. Visually and physically inspect the Bank 2 HO2S 1 to ensure that it is installed securely and that the Bank 2 HO2S 1 pigtail and wiring harness are not contacting the exhaust or otherwise damaged. 2. If a problem is found, correct it as necessary. Did your inspection reveal a problem?

Verify repair

Perform the “Injector Balance Test” and correct any problem found (refer to Fuel Metering System). Did the Injector Balance Test isolate a problem?

—

Visually and physically inspect the Bank 2 exhaust manifold for leaks and loose or missing hardware and correct any problem found. Did your inspection reveal a problem?

Go to Step 11

Verify repair

Perform the procedure in the ”Fuel System Pressure Test” and repair fuel system problem if necessary. Did the Fuel System Pressure Test isolate a condition requiring repair?

—

1. Disconnect the MAF sensor electrical connector. 2. Operate the vehicle in “closed loop” while monitoring the “BANK 2 S.T. FUEL TRIM” displayed on the Tech 2. Does the “BANK 2 S.T. FUEL TRIM” value decrease to near the specified value?

Yes

Check the fuel for excessive water, alcohol, or other contaminants (see Diagnosis in Engine Fuel for procedure) and correct the contaminated fuel condition is present (see Engine Fuel). Was the fuel contaminated?

Value(s)

Replace the MAF sensor. Is the action complete?

6E–234

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2

060R200054

Circuit Description To provide the best possible combination of driveability, fuel economy, and emission control, a “closed loop” air/fuel metering system is used. While in “closed loop”, the powertrain control module (PCM) monitors the Bank 1 HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel delivery based upon the HO2S signal voltages. A change made to fuel delivery will be indicated by the long and short term fuel trim values which can be monitored with a Tech 2. Ideal fuel trim values are around 0%; if the HO2S signals are indicating a lean condition the PCM will add fuel, resulting in fuel trim values above 0%. If a rich condition is detected, the fuel trim values will be below 0%, indicating that the PCM is reducing the amount of fuel delivered. If an excessively rich condition is detected on Bank 2, the PCM will set DTC P0175. The PCM’s maximum authority to control long term fuel trim allows a range between –15%(automatic transmission) or –12%(manual transmission) and +20%. The PCM’s maximum authority to control short term fuel trim allows a range between –11% and +20%. The PCM monitors fuel trim under various engine speed/load fuel trim cells before determining the status of the fuel trim diagnostic.

Conditions for Setting the DTC B None of the following DTCs are set: idle system, EGR, HO2S, (response, transition, open, low volts, no

B B B B B B B B B B

activity), MAF, TPS, MAP, IAT, canister purge, EVAP, injector circuit, or misfire. Engine coolant temperature is between 6°C (42.8°F) and 105°C (221°F). Intake air temperature is between –40°C (–40°F) and 120°C (248°F). Manifold absolute pressure is between 24 kPa and 99 kPa. Throttle angle is steady between 3 and 95%. Vehicle speed is below 136 km/h (85 mph). Engine speed is between 400 and 6,000 RPM. Barometric pressure is greater than 72.5 kPa. Mass air flow is between 2 g/second and 200 g/second. Ignition voltage is above 9.5 volts. Fuel system is in “closed loop”.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B A history DTC P0175 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0175 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–235

the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. DTCs other than P0172 and P0175 may indicate a condition present which may cause a lean condition. If this is the case, repairing the condition which caused the other DTC will most likely correct the DTC P0172/P0175. 4. If the DTC P0175 test passes while the Failure Records conditions are being duplicated, the rich condition is intermittent. Refer to Diagnostic Aids or Symptoms for additional information on diagnosing intermittent problems.

DTC P0175 – Fuel Trim System Rich Bank 2 Step

Action

Yes

—

Go to Step 2

—

Go to the applicable DTC charts and repair the other DTCs before proceeding with this chart.

Go to Step 3

L.T. Fuel Trim: –15% (auto. trans.) OR –12% (man. trans.)

Go to Step 5

Go to Step 4

Are any DTCs set other than P0172 and P0175?

1. Start the engine and operate the vehicle in “closed loop”. 2. Observe the “BANK 2 L.T. FUEL TRIM” display on the Tech 2.

Go to OBD System Check

Was the ”On-Board Diagnostic (OBD) System Check” performed?

Is the displayed value more negative than the specified value? 4

Value(s)

1. Review and record the Tech 2 Failure Records data. 2. Clear the DTC P0172/P0175 and operate the vehicle to duplicate the Failure Records conditions. 3. Monitor the Tech 2 “DTC” info for DTC P0175 while operating the vehicle to duplicate the Failure Records conditions. 4. Continue operating the vehicle until the DTC P0175 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0175 failed this ignition?

—

Go to Step 5

The rich condition is not present. If a driveability symptom still exists, refer to Symptoms.

Was DTC P0172 also set?

—

Go to Step 6

Go to Step 15

Visually and physically inspect the air filter element and replace it if necessary. —

Verify repair

Go to Step 7

Did the air filter require replacement?

6E–236

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0175 – Fuel Trim System Rich Bank 2 (Cont’d) Step

Action

—

Go to Step 10

Go to Step 11

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

Minimum 8% Maximum 92%

Go to Step 13

Go to Step 21

Go to Step 22

Go to Step 14

—

Verify repair

Go to Step 15

—

Go to Step 16

Go to Step 19

—

Go to Step 17

Go to Step 18

1. Ignition “ON”, engine “OFF”. 2. Connect a test light between the harness connector terminals of canister purge solenoid. Is the test light on?

Go to Step 9

1. Perform the “Fuel System Pressure Test”. 2. If Fuel System Pressure Test isolates a problem, repair as necessary (refer to Engine Fuel or Fuel Metering System). Did the Fuel System Pressure Test isolate a condition requiring repair?

Verify repair

1. Disconnect the MAF sensor electrical connector. 2. Operate the vehicle in “closed loop” while monitoring the “BANK 2 L.T. FUEL TRIM” and “BANK 2 S.T. FUEL TRIM” display on the Tech 2. Did both values change to near the specified value?

—

1. Ignition “ON”, engine “OFF”. 2. Monitor the TP Angle display on the Tech 2 while slowly depressing the accelerator pedal. Does the TP Angle display increase steadily and evenly from minimum value at closed throttle to maximum value at wide-open throttle?

Go to Step 8

Verify repair

1. Turn the ignition off and physically inspect the throttle body bore, throttle plate, and IAC passages for coking and foreign objects. 2. If a problem was found, repair as necessary. Did your inspection reveal a condition requiring repair?

—

Start the engine and note the idle quality. Is a low or unsteady idle being experienced?

Yes

Visually and physically inspect the air intake duct for collapse or restriction and repair if necessary. Did your inspection reveal a problem requiring repair?

Value(s)

Check for short to ground in the wire (YEL/RED) between the canister purge solenoid and PCM terminal S-48. Was there a short to ground?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–237

DTC P0175 – Fuel Trim System Rich Bank 2 (Cont’d) Step

Action

Yes

Repair the short to ground. Is the action complete?

Value(s)

—

Verify repair

—

Verify repair

—

Verify repair

Go to Step 20

—

Verify repair

Refer to Diagnostic Aids

—

Verify repair

—

Verify repair

—

1. Perform the “Injector Balance Test”. 2. If the Injector Balance Test isolates a problem, repair as necessary (refer to Fuel Metering System). Did the Injector Balance Test isolate a problem requiring repair?

1. Remove and visually/physically inspect the Bank 2 HO2S 1 for silicon contamination. This will be indicated by a powdery deposit on the portion of the HO2S that is exposed to the exhaust stream. 2. If contamination is evident on the Bank 2 HO2S 1, replace the contaminated sensor. Did the sensor require replacement?

1. Check the TP sensor mounting screws and tighten or replace them as necessary if they are loose or missing. 2. If the screws are OK, replace the TP sensor. Is the action complete?

Replace the MAF sensor. Is the action complete?

6E–238

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit

060R200023

Circuit Description

Conditions for Clearing the MIL/DTC

The powertrain control module (PCM) has six individual injector driver circuits. Each controls an injector. When a driver circuit is grounded by the PCM, the injector is activated. The PCM monitors the current in each driver circuit. The voltage on each driver is monitored to detect a fault. If the voltage is not what the PCM expects to monitor on the circuit, a DTC is set. This DTC is also set if an injector driver is shorted to voltage or if there is an open circuit.

B The PCM will turn “OFF” the MIL on the third consecutive trip cycle in which the diagnostic has been run and the fault is no longer present. B A history DTC P0201 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P0201 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

An injector driver circuit that is open or shorted to voltage will cause a DTC P0201 to set. It will also cause a misfire due to an inoperative injector. A misfire DTC will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.

B The battery voltage is more than 9 volts. B Engine speed is more than 700 rpm. B The engine is turning, determined by 58X crankshaft position input signal. B The injector voltage does not equal the ignition voltage when the injector is commanded “OFF” or the injector voltage does not equal 0 volts when the injector is commanded “ON”. B The above conditions are met for 5 seconds.

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Diagnostic Aids

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–239

Test Description The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0201 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold. The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 1 is “ON” steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.

R321054

7. Because the test light was “ON” steady, voltage to the injector is OK, but the driver circuit is grounded at all times. This step determines if the circuit is shorted to ground or the PCM is faulty. 9. The reading should be about 12-14W. 10.Locating the open in the harness or in the injector will require removal of the manifold to provide access.

DTC P0201 – Injector 1 Control Circuit Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to Engine Cranks But Will Not Run chart

—

Go to Step 5

Go to Step 4

—

Go to Step 5

Go to Diagnostic Aids

—

Go to Fuel Injector Coil Test Procedure

Go to Step 6

Will the engine start?

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0201 reset?

1. Review the Freeze Frame data with the ignition “ON” and the engine “OFF” and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0201 reset?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

1. Engine “OFF”. 2. Disconnect the injector connector. 3. Install an injector test light J-39021-65 on the injector test connector. 4. Crank the engine and note the light. Does the injector test light blink?

6E–240

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0201 – Injector 1 Control Circuit (Cont’d) Step

Action

—

Go to OBD System Check

—

Go to Step 11

Go to Step 10

—

Verify repair

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Go to Step 14

Go to Step 15

—

Verify repair

—

Verify repair

—

Repair the open circuit. Is the action complete?

Go to Step 15

Check for an open circuit between the injector test connector and the PCM. Was there an open circuit?

Go to Step 8

Repair the short to voltage. Is the action complete?

—

At the PCM side of the injector test connector, check the green/white wire for a short to voltage. Was there a short to voltage?

Go to Step 9

Repair the open injector harness wire or open injector. Is the action complete?

Go to Step 7

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 1 (green with white tracer). Does the ohmmeter indicate continuity?

—

Repair short to ground in the injector driver circuit. Is the action complete?

1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit. Does the test light illuminate?

Yes

Note whether the injector test light for cylinder 1 was “OFF” or “ON” steady in step 5. Was the test light “ON” steady while cranking the engine?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–241

Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit

060R200023

Circuit Description

Conditions for Clearing the MIL/DTC

B The PCM will turn “OFF” the MIL on the third consecutive trip cycle in which the diagnostic has been run and the fault is no longer present. B A history DTC P0202 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P0202 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

An injector driver circuit that is open or shorted to voltage will cause a DTC P0202 to set. It will also cause a misfire due to an inoperative injector. A misfire DTC will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.

Diagnostic Aids

6E–242

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0202 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold. The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 2 is “ON” steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.

R321055

7. Because the test light was “ON” steady, voltage to the injector is OK, but the driver circuit is grounded at all times. This step determines if the circuit is shorted to ground or the PCM is faulty. 9.The reading should be about 12-14W. 10.Locating the open in the harness or in the injector will require removal of the manifold to provide access.

DTC P0202 – Injector 2 Control Circuit Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to Engine Cranks But Will Not Run chart

—

Go to Step 5

Go to Step 4

—

Go to Step 5

Go to Diagnostic Aids

—

Go to Fuel Injector Coil Test Procedure

Go to Step 6

Will the engine start?

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0202 reset?

1. Review the Freeze Frame data with the ignition “ON” and the engine “OFF” and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0202 reset?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

1. Engine “OFF”. 2. Disconnect the injector test connector. 3. Install an injector test light J-39021-65 on injector connector. 4. Crank the engine and note the light. Does the cylinder 2 test light blink?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–243

DTC P0202 – Injector 2 Control Circuit (Cont’d) Step

Action

—

Go to OBD System Check

—

Go to Step 11

Go to Step 10

—

Verify repair

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Go to Step 14

Go to Step 15

—

Verify repair

—

Verify repair

—

Repair the open circuit. Is the action complete?

Go to Step 15

Check for an open circuit between the injector test connector and the PCM. Was there an open circuit?

Go to Step 8

Repair the short to voltage. Is the action complete?

—

At the PCM side of the injector test connector, check the green/orange wire for a short to voltage. Was there a short to voltage?

Go to Step 9

Repair the open injector harness wire or open injector. Is the action complete?

Go to Step 7

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 2 (green with orange tracer). Does the ohmmeter indicate continuity?

—

Repair short to ground in the injector driver circuit. Is the action complete?

1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit. Does the test light illuminate?

Yes

Note whether the injector test light for cylinder 2 was “OFF” or “ON” steady in step 5. Was the test light “ON” steady while cranking the engine?

Value(s)

6E–244

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit

060R200023

Circuit Description

Conditions for Clearing the MIL/DTC

The powertrain control module (PCM) has six individual injector driver circuits. Each controls an injector. When the driver circuit is grounded by the PCM, the injector is activated. The PCM monitors the current in each driver circuit. The voltage on each driver is monitored to detect a fault. If the voltage is not what the PCM expects to monitor on the circuit, a DTC is set. This DTC is also set if an injector driver is shorted to voltage or if there is an open circuit.

B The PCM will turn “OFF” the MIL on the third consecutive trip cycle in which the diagnostic has been run and the fault is no longer present. B A history DTC P0203 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P0203 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

An injector driver circuit that is open or shorted to voltage will cause a DTC P0203 to set. It will also cause a misfire due to an inoperative injector. A misfire DTC will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.

B The battery voltage is more than 9 volts. B Engine speed is more than 700 rpm. B The engine is turning, determined by the 58X crankshaft position input signal. B The injector voltage does not equal the ignition voltage when the injector is commanded “OFF” or the injector voltage does not equal 0 volts when the injector is commanded “ON”. B The above conditions are met for 5 seconds.

Diagnostic Aids

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–245

Test Description The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0203 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold. The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 3 is “ON” steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.

R321056

DTC P0203 – Injector 3 Control Circuit Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to Engine Cranks But Will Not Run chart

—

Go to Step 5

Go to Step 4

—

Go to Step 5

Go to Diagnostic Aids

—

Go to Fuel Injector Coil Test Procedure

Go to Step 6

Will the engine start?

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0203 reset?

1. Review the Freeze Frame data with the ignition “ON” and the engine “OFF” and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0203 reset?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

1. Engine “OFF”. 2. Disconnect the injector test connector . 3. Install an injector test light J-39021-65 on injector connector. 4. Crank the engine and note the light. Does the cylinder 3 test light blink?

6E–246

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0203 – Injector 3 Control Circuit (Cont’d) Step

Action

—

Go to OBD System Check

—

Go to Step 11

Go to Step 10

—

Verify repair

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Go to Step 14

Go to Step 15

—

Verify repair

—

Verify repair

—

Repair the open circuit. Is the action complete?

Go to Step 15

Check for an open circuit between the injector test connector and the PCM. Was there an open circuit?

Go to Step 8

Repair the short to voltage. Is the action complete?

—

At the PCM side of the injector test connector, check the green wire for a short to voltage. Was there a short to voltage?

Go to Step 9

Repair the open injector harness wire or open injector. Is the action complete?

Go to Step 7

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 3 (green). Does the ohmmeter indicate continuity?

—

Repair short to ground in the injector driver circuit. Is the action complete?

1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit. Does the test light illuminate?

Yes

Note whether the injector test light for cylinder 3 was “OFF” or “ON” steady in step 5. Was the test light “ON” steady while cranking the engine?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–247

Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit

060R200023

Circuit Description

Conditions for Clearing the MIL/DTC

B The PCM will turn “OFF” the MIL on the third consecutive trip cycle in which the diagnostic has been run and the fault is no longer present. B A history DTC P0204 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P0204 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

An injector driver circuit that is open or shorted to voltage will cause a DTC P0204 to set. It will also cause a misfire due to an inoperative injector. A misfire DTC will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.

Diagnostic Aids

6E–248

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0204 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold. The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 4 is “ON” steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.

R321057

DTC P0204 – Injector 4 Control Circuit Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to Engine Cranks But Will Not Run chart

—

Go to Step 5

Go to Step 4

—

Go to Step 5

Go to Diagnostic Aids

—

Go to Fuel Injector Coil Test Procedure

Go to Step 6

Will the engine start?

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0204 reset?

1. Review the Freeze Frame data with the ignition “ON” and the engine “OFF” and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0204 reset?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–249

DTC P0204 – Injector 4 Control Circuit (Cont’d) Step

Action

—

Go to OBD System Check

—

Go to Step 11

Go to Step 10

—

Verify repair

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Go to Step 14

Go to Step 15

—

Verify repair

—

Verify repair

—

Repair the open circuit. Is the action complete?

Go to Step 15

Check for an open circuit between the injector test connector and the PCM. Was there an open circuit?

Go to Step 8

Repair the short to voltage. Is the action complete?

—

At the PCM side of the injector test connector, check the green/red wire for a short to voltage. Was there a short to voltage?

Go to Step 9

Repair the open injector harness wire or open injector. Is the action complete?

Go to Step 7

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 4 (green/red). Does the ohmmeter indicate continuity?

—

Repair short to ground in the injector driver circuit. Is the action complete?

1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit. Does the test light illuminate?

Yes

Note whether the injector test light for cylinder 4 was “OFF” or “ON” steady in step 5. Was the test light “ON” steady while cranking the engine?

Value(s)

6E–250

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit

060R200023

Circuit Description

Conditions for Clearing the MIL/DTC

The powertrain control module (PCM) has six individual injector driver circuits. Each controls an injector. When the driver circuit is grounded by the PCM, the injector is activated. The PCM monitors the current in each driver circuit. If the voltage is not what the PCM expects to monitor on the circuit, a DTC is set. This DTC is also set if an injector driver is shorted to voltage or if there is an open circuit.

B The PCM will turn “OFF” the MIL on the third consecutive trip cycle in which the diagnostic has been run and the fault is no longer present. B A history DTC P0205 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P0205 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

Diagnostic Aids

An injector driver circuit that is open or shorted to voltage will cause a DTC P0205 to set. It will also cause a misfire due to an inoperative injector. A misfire DTC will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–251

Test Description The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0205 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold.The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 5 is “ON” steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.

R321058

DTC P0205 – Injector 5 Control Circuit Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to Engine Cranks But Will Not Run chart

—

Go to Step 5

Go to Step 4

—

Go to Step 5

Go to Diagnostic Aids

—

Go to Fuel Injector Coil Test Procedure

Go to Step 6

Will the engine start?

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0205 reset?

1. Review the Freeze Frame data with the ignition “ON” and the engine “OFF” and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0205 reset?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

6E–252

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0205 – Injector 5 Control Circuit (Cont’d) Step

Action

—

Go to OBD System Check

—

Go to Step 11

Go to Step 10

—

Verify repair

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Go to Step 14

Go to Step 15

—

Verify repair

—

Verify repair

—

Repair the open circuit. Is the action complete?

Go to Step 15

Check for an open circuit between the injector test connector and the PCM. Was there an open circuit?

Go to Step 8

Repair the short to voltage. Is the action complete?

—

At the PCM side of the injector test connector, check the green/black wire for a short to voltage. Was there a short to voltage?

Go to Step 9

Repair the open injector harness wire or open injector. Is the action complete?

Go to Step 7

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 5 (green with black tracer). Does the ohmmeter indicate continuity?

—

Repair short to ground in the injector driver circuit. Is the action complete?

1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit. Does the test light illuminate?

Yes

Note whether the injector test light for cylinder 5 was “OFF” or “ON” steady in step 5. Was the test light “ON” steady while cranking the engine?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–253

Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit

060R200023

Circuit Description

Conditions for Clearing the MIL/DTC

B The PCM will turn “OFF” the MIL on the third consecutive trip cycle in which the diagnostic has been run and the fault is no longer present. B A history DTC P0206 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P0206 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

An injector driver circuit that is open or shorted to voltage will cause a DTC P0206 to set. It will also cause a misfire due to an inoperative injector. A misfire DTC will also be set indicating which cylinder is inoperative. Long term and short term fuel trims that are excessively high or low are a good indication that an injector is faulty. Use Fuel Injector Coil Test Procedure to check for faulty injectors.

Diagnostic Aids

6E–254

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description The number(s) below refer to the step number(s) on the Diagnostic Chart. 3. This step determines if DTC P0206 is the result of a hard failure or an intermittent condition. 5. A special injector test connector is provided so that the injectors can be electrically tested without removal of the manifold.The test connector can be identified by the blue connector lock which is tethered to the wiring harness. If the light for cylinder 6 is “ON” steady before cranking the engine as well as while cranking the engine, then the injector driver circuit is shorted to ground. If the test light blinks while cranking, the PCM and the wiring to the injectors are OK. The Fuel Injector Coil Test Procedure will check if the injectors are faulty.

R321059

DTC P0206 – Injector 6 Control Circuit Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to Engine Cranks But Will Not Run chart

—

Go to Step 5

Go to Step 4

—

Go to Step 5

Go to Diagnostic Aids

—

Go to Fuel Injector Coil Test Procedure

Go to Step 6

Will the engine start?

1. Install the Tech 2. Clear the DTC. 2. Idle the engine for one minute. Does DTC P0206 reset?

1. Review the Freeze Frame data with the ignition “ON” and the engine “OFF” and note the parameters. 2. Operate the vehicle within the Freeze Frame conditions as noted. Does P0206 reset?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–255

DTC P0206 – Injector 6 Control Circuit (Cont’d) Step

Action

—

Go to OBD System Check

—

Go to Step 11

Go to Step 10

—

Verify repair

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Go to Step 14

Go to Step 15

—

Verify repair

—

Verify repair

—

Repair the open circuit. Is the action complete?

Go to Step 15

Check for an open circuit between the injector test connector and the PCM. Was there an open circuit?

Go to Step 8

Repair the short to voltage. Is the action complete?

—

At the PCM side of the injector test connector, check the green/yellow wire for a short to voltage. Was there a short to voltage?

Go to Step 9

Repair the open injector harness wire or open injector Is the action complete?

Go to Step 7

1. Disconnect the injector test connector. 2. At the injector side of the harness, connect an ohmmeter between the positive wire (red with blue tracer) and the wire for cylinder 6 (green with yellow tracer). Does the ohmmeter indicate continuity?

—

Repair short to ground in the injector driver circuit. Is the action complete?

1. Disconnect the PCM connector for the affected injectors. 2. With a test light connected to B+, probe the affected injector driver circuit. Does the test light illuminate?

Yes

Note whether the injector test light for cylinder 6 was “OFF” or “ON” steady in step 5. Was the test light “ON” steady while cranking the engine?

Value(s)

6E–256

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected Circuit Description Misfire is monitored as a function of the combustion quality (CQ) signals generated from the ION Sensing Module. Combustion signals represent the degree of combustion in each cylinder. Misfire is detected when the combustion signal is below a predetermined value. This DTC P0300 will determine if a multiple cylinder misfire is occurring by monitoring the Combustion Quality.

Conditions for Setting the DTC B None of the following DTCs occur: TP sensor, MAF sensor, VSS, ECT sensor. B The engine speed is between 600 and 6250 RPM. B The system voltage is between 11 and 16 volts. B The engine temperature sensor (ECT) indicates an engine temperature between –7°C (20°F) and 110°C (230°F). B Throttle angle is steady and throttle changes less than 2% per 125 milliseconds.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected the fault. B If the misfire is severe enough to cause possible catalyst damage, the PCM will flash the MIL for as long as the misfire remains at catalyst damaging levels. B The PCM will disable the TCC operation. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0300 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P0300 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids The Tech 2 display “Misfire Cur. #1 through #6” can be useful to determine whether the misfire is isolated to a single cylinder.

B Damaged or faulty ignition coil – Check for cracks or other damage. B Substitute a known good coil – Swap the ignition coils and retest. If the misfire follows the coil, replace the ignition coil. If the misfire is random, check for the following conditions: B System grounds – Ensure all connections are clean and properly tightened. B MAF – A mass air flow (MAF) sensor output that causes the PCM to sense a lower than normal air flow will cause a lean condition. B Air induction system – Air leaks into the induction system which bypass the MAF sensor will cause a lean condition. Check for disconnected or damaged vacuum hoses, incorrectly installed or faulty PCV valve, or for vacuum leaks at the throttle body, EGR valve, and intake manifold mounting surfaces. B Fuel pressure – Perform a fuel system pressure test. A faulty fuel pump, plugged filter, or faulty fuel system pressure regulator will contribute to a lean condition. B Injector(s) – Perform an injector coil/balance test to locate faulty injector(s) contributing to a lean or flooding condition. In addition to the above test, check the condition of the injector O-rings. B EGR – Check for a leaking valve, adapter, or feed pipes which will contribute to a lean condition or excessive EGR flow. B Fuel quality – Using fuel with the wrong octane rating for the vehicle may cause driveability problems. Although alcohol-enhanced fuels may raise the octane rating, the fuel’s ability to turn into vapor in cold temperatures deteriorates. This may affect the cold driveability of the engine. The Reid Vapor Pressure of the fuel can also create problems in the fuel system, especially during the spring and fall when changes by the refineries may not coincide with changes in the weather. B Vehicle marshalling – The transportation of new vehicles from the assembly plant to the dealership can involve as many as 60 key cycles within 2 to 3 miles of driving. This type of operation contributes to the fuel fouling of the spark plugs and will turn on the MIL with a P0300 Misfire DTC. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–257

DTC P0300 – Engine Misfire Detected Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Refer to Diagnostic Aids

—

Verify repair

Go to Step 4

—

Verify repair

Go to Step 5

—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

1. Start the engine. Run the engine at idle. 2. Review and record the Tech 2 Freeze Frame data. 3. Operate the vehicle to duplicate the conditions present when the DTC was set (as defined by the Freeze Frame data). 4. Monitor the Tech 2 “Misfire Cur. #” display for each cylinder. Is “Misfire Cur. #” display increasing for any cylinder (indicating a misfire currently occurring)?

1. Visually and physically inspect the vacuum hoses for splits, kinks, and improper connections. 2. If a problem is found, repair or replace the vacuum hoses as necessary. Did your inspection reveal a problem?

1. Visually and physically inspect the following areas for vacuum leaks: B The intake manifold B The injector O-rings B The EGR adapter B The EGR feed pipes B ION Sensing Module 2. If a problem is found, repair the vacuum leak as necessary. Did your inspection reveal a vacuum leak?

1. Visually and physically inspect the crankcase ventilation valve for improper installation or damaged grommet. 2. If a problem is found, repair as necessary (refer to Crankcase Ventilation System). Did your inspection reveal a problem?

1. Inspect the MAF sensor inlet screen for damage or for the presence of foreign objects that may partially block the air flow sample through the MAF sensor. 2. If a problem is found, repair or replace the MAF sensor as necessary. Did your inspection of the MAF sensor reveal a condition requiring repair or replacement?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

1. Remove the EGR valve and visually/physically inspect the valve to ensure that the pintle is not sticking partially open. Also, inspect the EGR valve pintle and seat for carbon deposits or burrs that may interfere with the pintle closing completely. 2. If a problem is found, clean the EGR valve pintle and seat or replace the EGR valve as necessary. Did your inspection reveal a problem?

6E–258

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0300 – Engine Misfire Detected (Cont’d) Step

Action

Verify repair

Go to Step 10

—

Go to Engine Mechanical Diagnosis

Go to Step 11

—

Verify repair

Go to Step 12

Go to Step 13

Replace the ignition coil of the affected cylinder

—

Verify repair

—

Verify repair

Go to Step 15

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

1. Visually and physically inspect the PCM injector grounds, power grounds and sensor grounds to ensure that they are clean, tight and in their proper locations. 2. If a problem is found, correct the faulty ground condition as necessary. 1. Perform the “Fuel System Pressure Test” procedure. 2. If a problem is found, repair as necessary (refer to Engine Fuel or Fuel Metering System). Was a fuel system problem found?

—

Replace the ignition coil control module.

Did your inspection reveal a poor ground? 15

Go to Step 9

1. Disconnect the MAF sensor electrical connector. ”BANK 1 L.T. 2. Operate the vehicle in “closed loop” while FUEL TRIM” monitoring the “BANK 1 L.T. FUEL TRIM” and below +20%; “BANK 1 S.T. FUEL TRIM” display on the Tech 2. “BANK 1 S.T. Do both values decrease below the specified values? FUEL TRIM” below +50% Is the action complete?

Go to Step 14

1. Visually inspect the spark plug insulators for cracks, carbon tracking, or other damage. 2. If a problem is found, replace the faulty spark plug(s) as necessary. Did your inspection reveal a problem?

—

1. Remove the spark plugs from the cylinders that were indicated as misfiring. 2. Visually inspect the spark plug electrodes. Does your inspection reveal any spark plugs exhibiting excessive fouling?

1. Remove and visually/physically inspect the ignition coil(s) associated with the cylinders that were indicated as misfiring. Ensure that the coil(s) are free of cracks. 2. If a problem is found, replace the damaged ignition coil(s) as necessary. Did any ignition coils require replacement?

Yes

1. Install a spark tester at the spark plug end of the ignition coil for a cylinder that indicated a misfire. 2. Crank the engine while observing the spark tester. A crisp, blue spark should be observed. Is adequate spark present?

Value(s)

1. Check the fuel for excessive water, alcohol, or other contaminants (refer to Diagnosis in Engine Fuel for procedure). 2. If a problem is found, correct the contaminated fuel condition as necessary. Was the fuel contaminated?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–259

DTC P0300 – Engine Misfire Detected (Cont’d) Step

Action

1. Perform the “Injector Coil/Balance Test”. 2. If a problem is found, replace faulty injector(s) as necessary. Did any of the injectors require replacement?

—

Verify repair

Go to Step 18

—

Verify repair

Go to Step 19

—

Verify repair

Go to Step 20

—

Verify repair

—

1. Check for a transmission TCC problem. Refer to 4L30-E Automatic Transmission Diagnosis. 2. If a problem is found, repair the transmission as necessary. Refer to 4L30-E Automatic Transmission Unit Repair. Was a transmission problem found and repaired?

Yes

1. Check for an engine mechanical problem. Refer to Engine Mechanical Diagnosis to diagnose the following conditions: B A faulty or incorrect camshaft B Leaking or sticky valves or rings B Excessive valve deposits B Weak valve springs B Incorrect valve timing B A leaking head gasket B A loose or broken motor mount 2. If a problem is found, repair as necessary. Was a basic engine mechanical problem found and repaired?

Value(s)

Replace the MAF sensor. Is the action complete?

6E–260

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected Circuit Description

Conditions for Clearing the MIL/DTC

Misfire is monitored as a function of the combustion quality (CQ) signals generated from the ignition current sense system. Combustion signals represent the degree of combustion in each cylinder. Misfire is detected when the combustion signal is below a predetermined value. This DTC P0301 will determine if the No.1 cylinder misfire is occurring by monitoring the Combustion Quality.

B The PCM will turn the MIL “OFF” on the third consecutive ignition cycle in which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0301 will clear after 40 consecutive ignition cycles occur without a fault. B DTC P0301 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC B None of the following DTCs occur: TP sensor, MAF sensor, vehicle speed sensor, ECT sensor. B The engine speed is between 600 and 6250 RPM. B The system voltage is between 11 and 16 volts. B The ECT indicates an engine temperature between –7°C (28°F) and 110°C (230°F). B The throttle angle is steady and throttle change less than 2% per 125 milliseconds.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected the fault. B If the misfire is severe enough to cause possible catalyst damage, the PCM will flash the MIL for as long as the misfire remains at catalyst damaging levels. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Diagnostic Aids Check for the following conditions: B System grounds – Ensure all connections are clean and properly tightened. B Injector – Perform the injector coil/balance test to locate a faulty injector that contributes to a lean condition on the affected cylinder. In addition to the above test, check the condition of the injector O-ring. B Faulty spark plug – Check for a cracked insulator, carbon tracking, incorrect gap, and worn electrodes. B Damaged or faulty ignition coil – Check for cracks or other damage. B Substitute a known good coil – Swap the ignition coils and retest. If the misfire follows the coil, replace the ignition coil.

DTC P0301 – Cylinder Misfire Detected Step

Action

—

Go to Step 2

Go to OBD System Check

—

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

—

Verify repair

Go to Step 5

—

Go to Step 8

Go to Step 6

Monitor “Misfire Hist. #1” while operating the vehicle to duplicate the conditions present when the DTC was set (as defined by the Freeze Frame data recorded in Step 2).

1. Visually and physically inspect the vacuum hoses for splits, kinks, and improper connections. Also, inspect the intake manifold for a vacuum leak. 2. If a problem is found, repair it as necessary. Did the inspection reveal a problem?

1. Start the engine. Run the engine at idle. 2. Review and record Tech 2 Freeze Frame data. 3. Monitor “Misfire Cur. #1” on the Tech 2.

Is “Misfire Hist. #1” increasing (indicating a misfire currently occurring)? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is “Misfire Cur. #1” increasing (indicating a misfire currently occurring)? 3

Value(s)

1. Install a spark tester at the spark plug end of the cylinder #1 ignition coil. 2. Crank the engine while observing the spark tester. A crisp, blue spark should be observed. Is adequate spark present?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–261

DTC P0301 – Cylinder Misfire Detected (Cont’d) Step

Action

—

Verify repair

Go to Step 7

2.6-2.7 KW

Verify repair

Go to Step 12

—

Go to Contaminatio n Diagnosis chart in Engine Mechanical Diagnosis

Go to Step 9

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

Verify repair

Refer to Diagnostic Aids

Remove the cylinder #1 spark plug and visually inspect the spark plug electrode. Does the inspection reveal excessive fouling?

1. Visually inspect the spark plug insulator for cracks, carbon tracking, or other damage. 2. If the spark plug is damaged, replace the spark plug. Did the inspection reveal a problem?

1. Perform the “Injector Coil/Balance Test”. 2. If any faulty injectors are found, replace them as necessary. Did any of the injectors require replacement?

1. Inspect the injector O-rings for a vacuum leak. 2. If a problem is found, repair it as necessary. Did the inspection reveal a problem?

1. Measure the ignition coil primary resistance. 2. If resistance is not within the specified value, replace the faulty ignition coil. Did the ignition coil require replacement?

Yes

1. Remove and visually/physically inspect the ignition coil associated with cylinder #1. Ensure that the coil is free of cracks and carbon tracking. 2. If a problem is found, replace the damaged ignition coil as necessary. Did the visual inspection reveal a problem?

Value(s)

Check for an engine mechanical problem. Refer to Engine Mechanical Diagnosis to diagnose and repair the following conditions: B A faulty or incorrect camshaft B Leaking or sticky valves or rings B Excessive valve deposits B Weak valve springs B A leaking head gasket Was a basic engine mechanical problem found?

—

6E–262

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected Circuit Description

Conditions for Clearing the MIL/DTC

Misfire is monitored as a function of the combustion quality (CQ) signals generated from the ignition current sense system. Combustion signals represent the degree of combustion in each cylinder. Misfire is detected when the combustion signal is below a predetermined value. This DTC P0302 will determine if the No.2 cylinder misfire is occurring by monitoring the Combustion Quality.

B The PCM will turn the MIL “OFF” on the third consecutive ignition cycle in which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0302 will clear after 40 consecutive ignition cycles occur without a fault. B DTC P0302 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. B If the misfire is severe enough to cause possible catalyst damage, the PCM will flash the MIL for as long as the misfire remains at catalyst damaging levels. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Diagnostic Aids Check for the following conditions: B System grounds – Ensure all connections are clean and properly tightened. B Injector – Perform the injector coil/balance test to locate a faulty injector that contributes to a lean condition on the affected cylinder. In addition to the above test, check the condition of the injector O-ring. B Faulty spark plug – Check for a cracked insulator, carbon tracking, incorrect gap, and worn electrodes. B Damaged or faulty ignition coil – Check for cracks, carbon tracking or other damage. B Substitute a known good coil – Swap the ignition coils and retest. If the misfire follows the coil, replace the ignition coil.

DTC P0302 – Cylinder Misfire Detected Step

Action

—

Go to Step 2

Go to OBD System Check

—

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

—

Verify repair

Go to Step 5

—

Go to Step 8

Go to Step 6

Monitor “Misfire Hist. #2” while operating the vehicle to duplicate the conditions present when the DTC was set (as defined by the Freeze Frame data recorded in Step 2).

1. Start the engine. Run the engine at idle. 2. Review and record Tech 2 Freeze Frame data. 3. Monitor “Misfire Cur. #2” on the Tech 2.

Is “Misfire Hist. #2” increasing (indicating a misfire currently occurring)? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is “Misfire Cur. #2” increasing (indicating a misfire currently occurring)? 3

Value(s)

1. Install a spark tester at the spark plug end of the cylinder #2 ignition coil. 2. Crank the engine while observing the spark tester. A crisp, blue spark should be observed. Is adequate spark present?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–263

DTC P0302 – Cylinder Misfire Detected (Cont’d) Step

Action

—

Verify repair

Go to Step 7

2.6-2.7 KW

Verify repair

Go to Step 12

—

Go to Contaminatio n Diagnosis chart in Engine Mechanical Diagnosis

Go to Step 9

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

Verify repair

Refer to Diagnostic Aids

Remove the cylinder #2 spark plug and visually inspect the spark plug electrode. Does the inspection reveal excessive fouling?

1. Visually inspect the spark plug insulator for cracks, carbon tracking, or other damage. 2. If the spark plug is damaged, replace the spark plug. Did the inspection reveal a problem?

1. Perform the “Injector Coil/Balance Test”. 2. If any faulty injectors are found, replace them as necessary. Did any of the injectors require replacement?

1. Inspect the injector O-rings for a vacuum leak. 2. If a problem is found, repair it as necessary. Did the inspection reveal a problem?

1. Measure the ignition coil primary resistance. 2. If resistance is not within the specified value, replace the faulty ignition coil. Did the ignition coil require replacement?

Yes

1. Remove and visually/physically inspect the ignition coil associated with cylinder #2. Ensure that the coil is free of cracks and carbon tracking. 2. If a problem is found, replace the damaged ignition coil as necessary. Did the visual inspection reveal a problem?

Value(s)

—

6E–264

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected Circuit Description

Conditions for Clearing the MIL/DTC

Misfire is monitored as a function of the combustion quality (CQ) signals generated from the ignition current sense system. Combustion signals represent the degree of combustion in each cylinder. Misfire is detected when the combustion signal is below a predetermined value. This DTC P0303 will determine if the No.3 cylinder misfire is occurring by monitoring the Combustion Quality.

B The PCM will turn the MIL “OFF” on the third consecutive ignition cycle in which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0303 will clear after 40 consecutive ignition cycles occur without a fault. B DTC P0303 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected the fault. B If the misfire is severe enough to cause possible catalyst damage, the PCM will flash the MIL for as long as the misfire remains at catalyst damaging levels. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Diagnostic Aids Check for the following conditions: B System grounds – Ensure all connections are clean and properly tightened. B Injector — Perform the injector coil/balance test to locate a faulty injector that contributes to a lean condition on the affected cylinder. In addition to the above test, check the condition of the injector O-ring. B Faulty spark plug – Check for a cracked insulator, carbon tracking, incorrect gap, and worn electrodes. B Damaged or faulty ignition coil – Check for cracks, carbon tracking or other damage. B Substitute a known good coil – Swap the ignition coils and retest. If the misfire follows the coil, replace the ignition coil.

DTC P0303 – Cylinder Misfire Detected Step

Action

—

Go to Step 2

Go to OBD System Check

—

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

—

Verify repair

Go to Step 5

—

Go to Step 8

Go to Step 6

Monitor “Misfire Hist. #3” while operating the vehicle to duplicate the conditions present when the DTC was set (as defined by the Freeze Frame data recorded in Step 2).

1. Start the engine. Run the engine at idle. 2. Review and record Tech 2 Freeze Frame data. 3. Monitor “Misfire Cur. #3” on the Tech 2.

Is “Misfire Hist. #3” increasing (indicating a misfire currently occurring)? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is “Misfire Cur. #3” increasing (indicating a misfire currently occurring)? 3

Value(s)

1. Install a spark tester at the spark plug end of the cylinder #3 ignition coil. 2. Crank the engine while observing the spark tester. A crisp, blue spark should be observed. Is adequate spark present?

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6E–265

DTC P0303 – Cylinder Misfire Detected (Cont’d) Step

Action

—

Verify repair

Go to Step 7

2.6-2.7 KW

Verify repair

Go to Step 12

—

Go to Contaminatio n Diagnosis chart in Engine Mechanical Diagnosis

Go to Step 9

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

Verify repair

Refer to Diagnostic Aids

Remove the cylinder #3 spark plug and visually inspect the spark plug electrode. Does the inspection reveal excessive fouling?

1. Visually inspect the spark plug insulator for cracks, carbon tracking, or other damage. 2. If the spark plug is damaged, replace the spark plug. Did the inspection reveal a problem?

1. Perform the “Injector Coil/Balance Test”. 2. If any faulty injectors are found, replace them as necessary. Did any of the injectors require replacement?

1. Inspect the injector O-rings for a vacuum leak. 2. If a problem is found, repair it as necessary. Did the inspection reveal a problem?

1. Measure the ignition coil primary resistance. 2. If resistance is not within the specified value, replace the faulty ignition coil. Did the ignition coil require replacement?

Yes

1. Remove and visually/physically inspect the ignition coil associated with cylinder #3. Ensure that the coil is free of cracks and carbon tracking. 2. If a problem is found, replace the damaged ignition coil as necessary. Did the visual inspection reveal a problem?

Value(s)

—

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected Circuit Description

Conditions for Clearing the MIL/DTC

Misfire is monitored as a function of the combustion quality (CQ) signals generated from the ignition current sense system. Combustion signals represent the degree of combustion in each cylinder. Misfire is detected when the combustion signal is below a predetermined value. This DTC P0304 will determine if the No.4 cylinder misfire is occurring by monitoring the Combustion Quality.

B The PCM will turn the MIL “OFF” on the third consecutive ignition cycle in which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0304 will clear after 40 consecutive ignition cycles occur without a fault. B DTC P0304 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected the fault. B If the misfire is severe enough to cause possible catalyst damage, the PCM will flash the MIL for as long as the misfire remains at catalyst damaging levels. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Diagnostic Aids Check for the following conditions: B System grounds – Ensure all connections are clean and properly tightened. B Injector – Perform the injector coil/balance test to locate a faulty injector that contributes to a lean condition on the affected cylinder. In addition to the above test, check the condition of the injector O-ring. B Faulty spark plug – Check for a cracked insulator, carbon tracking, incorrect gap, and worn electrodes. B Damaged or faulty ignition coil – Check for cracks, carbon tracking or other damage. B Substitute a known good coil – Swap the ignition coils and retest. If the misfire follows the coil, replace the ignition coil.

DTC P0304 – Cylinder Misfire Detected Step

Action

—

Go to Step 2

Go to OBD System Check

—

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

—

Verify repair

Go to Step 5

—

Go to Step 8

Go to Step 6

Monitor “Misfire Hist. #4” while operating the vehicle to duplicate the conditions present when the DTC was set (as defined by the Freeze Frame data recorded in Step 2).

1. Start the engine. Run the engine at idle. 2. Review and record Tech 2 Freeze Frame data. 3. Monitor “Misfire Cur. #4” on the Tech 2.

Is “Misfire Hist. #4” increasing (indicating a misfire currently occurring)? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is “Misfire Cur. #4” increasing (indicating a misfire currently occurring)? 3

Value(s)

1. Install a spark tester at the spark plug end of the cylinder #4 ignition wire. 2. Crank the engine while observing the spark tester. A crisp, blue spark should be observed. Is adequate spark present?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–267

DTC P0304 – Cylinder Misfire Detected (Cont’d) Step

Action

—

Verify repair

Go to Step 7

2.6-2.7 KW

Verify repair

Go to Step 12

—

Go to Contaminatio n Diagnosis chart in Engine Mechanical Diagnosis

Go to Step 9

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

Verify repair

Refer to Diagnostic Aids

Remove the cylinder #4 spark plug and visually inspect the spark plug electrode. Does the inspection reveal excessive fouling?

1. Visually inspect the spark plug insulator for cracks, carbon tracking, or other damage. 2. If the spark plug is damaged, replace the spark plug. Did the inspection reveal a problem?

1. Perform the “Injector Coil/Balance Test”. 2. If any faulty injectors are found, replace them as necessary. Did any of the injectors require replacement?

1. Inspect the injector O-rings for a vacuum leak. 2. If a problem is found, repair it as necessary. Did the inspection reveal a problem?

1. Measure the ignition coil primary resistance. 2. If resistance is not within the specified value, replace the faulty ignition coil. Did the ignition coil require replacement?

Yes

1. Remove and visually/physically inspect the ignition coil associated with cylinder #4. Ensure that the coil is free of cracks and carbon tracking. 2. If a problem is found, replace the damaged ignition coil as necessary. Did the visual inspection reveal a problem?

Value(s)

—

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected Circuit Description

Conditions for Clearing the MIL/DTC

Misfire is monitored as a function of the combustion quality (CQ) signals generated from the ignition current sense system. Combustion signals represent the degree of combustion in each cylinder. Misfire is detected when the combustion signal is below a predetermined value. This DTC P0305 will determine if the No.5 cylinder misfire is occurring by monitoring the Combustion Quality.

B The PCM will turn the MIL “OFF” on the third consecutive ignition cycle in which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0305 will clear after 40 consecutive ignition cycles occur without a fault. B DTC P0305 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC B None of the following DTCs occur: TP sensor, MAF sensor,vehicle speed sensor, ECT sensor. B The engine speed is between 600 and 6250 RPM. B The system voltage is between 11 and 16 volts. B The ECT indicates an engine temperature between –7°C (28°F) and 110°C (230°F). B The throttle angle is steady and throttle change less than 2% per 125 milliseconds.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected the fault. B If the misfire is severe enough to cause possible catalyst damage, the PCM will flash the MIL for as long as the misfire remains at catalyst damaging levels. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Diagnostic Aids Check for the following conditions: B System grounds – Ensure all connections are clean and properly tightened. B Injector – Perform the injector coil/balance test to locate a faulty injector that contributes to a lean condition on the affected cylinder. In addition to the above test, check the condition of the injector O-ring. B Faulty spark plug – Check for a cracked insulator, carbon tracking, incorrect gap, and worn electrodes. B Damaged or faulty ignition coil – Check for cracks, carbon tracking or other damage. B Substitute a known good coil – Swap the ignition coils and retest. If the misfire follows the coil, replace the ignition coil.

DTC P0305 – Cylinder Misfire Detected Step

Action

—

Go to Step 2

Go to OBD System Check

—

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

—

Verify repair

Go to Step 5

—

Go to Step 8

Go to Step 6

Monitor “Misfire Hist. #5” while operating the vehicle to duplicate the conditions present when the DTC was set (as defined by the Freeze Frame data recorded in Step 2).

1. Start the engine. Run the engine at idle. 2. Review and record Tech 2 Freeze Frame data. 3. Monitor “Misfire Cur. #5” on the Tech 2.

Is “Misfire Hist. #5” increasing (indicating a misfire currently occurring)? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is “Misfire Cur. #5” increasing (indicating a misfire currently occurring)? 3

Value(s)

1. Install a spark tester at the spark plug end of the cylinder #5 ignition wire. 2. Crank the engine while observing the spark tester. A crisp, blue spark should be observed. Is adequate spark present?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–269

DTC P0305 – Cylinder Misfire Detected (Cont’d) Step

Action

—

Verify repair

Go to Step 7

2.6-2.7 KW

Verify repair

Go to Step 12

—

Go to Contaminatio n Diagnosis chart in Engine Mechanical Diagnosis

Go to Step 9

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

Verify repair

Refer to Diagnostic Aids

Remove the cylinder #5 spark plug and visually inspect the spark plug electrode. Does the inspection reveal excessive fouling?

1. Visually inspect the spark plug insulator for cracks, carbon tracking, or other damage. 2. If the spark plug is damaged, replace the spark plug. Did the inspection reveal a problem?

1. Perform the “Injector Coil/Balance Test”. 2. If any faulty injectors are found, replace them as necessary. Did any of the injectors require replacement?

1. Inspect the injector O-rings for a vacuum leak. 2. If a problem is found, repair it as necessary. Did the inspection reveal a problem?

1. Measure the ignition coil primary resistance. 2. If resistance is not within the specified value, replace the faulty ignition coil. Did the ignition coil require replacement?

Yes

1. Remove and visually/physically inspect the ignition coil associated with cylinder #5. Ensure that the coil is free of cracks and carbon tracking. 2. If a problem is found, replace the damaged ignition coil as necessary. Did the visual inspection reveal a problem?

Value(s)

—

6E–270

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected Circuit Description

Conditions for Clearing the MIL/DTC

Misfire is monitored as a function of the combustion quality (CQ) signals generated from the ignition current sense system. Combustion signals represent the degree of combustion in each cylinder. Misfire is detected when the combustion signal is below a predetermined value. This DTC P0306 will determine if the No.6 cylinder misfire is occurring by monitoring the Combustion Quality.

B The PCM will turn the MIL “OFF” on the third consecutive ignition cycle in which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0306 will clear after 40 consecutive ignition cycles occur without a fault. B DTC P0306 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC B None of the following occur: TP sensor, MAF sensor, vehicle speed sensor, ECT sensor. B The engine speed is between 600 and 6250 RPM. B The system voltage is between 11 and 16 volts. B The ECT indicates an engine temperature between –7°C (28°F) and 110°C (230°F). B The throttle angle is steady and throttle change less than 2% per 125 milliseconds.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected the fault. B If the misfire is severe enough to cause possible catalyst damage, the PCM will flash the MIL for as long as the misfire remains at catalyst damaging levels. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

DTC P0306 – Cylinder Misfire Detected Step

Action

—

Go to Step 2

Go to OBD System Check

—

Go to Step 4

Go to Step 3

—

Go to Step 4

Refer to Diagnostic Aids

—

Verify repair

Go to Step 5

—

Go to Step 8

Go to Step 6

Monitor “Misfire Hist. #6” while operating the vehicle to duplicate the conditions present when the DTC was set (as defined by the Freeze Frame data recorded in Step 2).

1. Start the engine. Run the engine at idle. 2. Review and record Tech 2 Freeze Frame data. 3. Monitor “Misfire Cur. #6” on the Tech 2.

Is “Misfire Hist. #6” increasing (indicating a misfire currently occurring)? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is “Misfire Cur. #6” increasing (indicating a misfire currently occurring)? 3

Value(s)

1. Install a spark tester at the spark plug end of the cylinder #6 ignition wire. 2. Crank the engine while observing the spark tester. A crisp, blue spark should be observed. Is adequate spark present?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–271

DTC P0306 – Cylinder Misfire Detected (Cont’d) Step

Action

—

Verify repair

Go to Step 7

2.6-2.7 KW

Verify repair

Go to Step 12

—

Go to Contaminatio n Diagnosis chart in Engine Mechanical Diagnosis

Go to Step 9

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

Verify repair

Refer to Diagnostic Aids

Remove the cylinder #6 spark plug and visually inspect the spark plug electrode. Does the inspection reveal excessive fouling?

1. Visually inspect the spark plug insulator for cracks, carbon tracking, or other damage. 2. If the spark plug is damaged, replace the spark plug. Did the inspection reveal a problem?

1. Perform the “Injector Coil/Balance Test”. 2. If any faulty injectors are found, replace them as necessary. Did any of the injectors require replacement?

1. Inspect the intake manifold and the injector O-rings for a vacuum leak. 2. If a problem is found, repair it as necessary. Did the inspection reveal a problem?

1. Measure the ignition coil primary resistance. 2. If resistance is not within the specified value, replace the faulty ignition coil. Did the ignition coil require replacement?

Yes

1. Remove and visually/physically inspect the ignition coil associated with cylinder #6. Ensure that the coil is free of cracks and carbon tracking. 2. If a problem is found, replace the damaged ignition coil as necessary. Did the visual inspection reveal a problem?

Value(s)

—

6E–272

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault

060R200055

Circuit Description The Power Control Module (PCM) checks the validity of the signals used in the ION Sensing module at the following engine operating conditions. B The test is performed to evacuate the Knock Intensity (KI) signal pulse width if it is within a predetermined range. If the KI signal pulse width is out of the predetermined range, the fail counter will be incremented. If the failure counter exceeds the calibration, then test is complete and a failure will be reported. If the sample counter threshold is reached before the failure threshold, then the test is complete and a pass will be reported. This test will detect an open/short in the KI line circuit, ION module faults and analog input faults in the PCM.

Conditions for setting the DTC B B B B

Ignition voltage is between 10volt and 16 volts. No Crank DTCs set. No EST DTCs set. No Misfire DTCs set.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected the fault. B The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure.

B The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0325 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P0325 can be cleared using the Tech2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–273

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS If the harness appears to be OK, observe the Knock Present, Knock Sensor Noise Channel display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

If DTC P0325 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0325 Diagnostic Chart may isolate the cause of the fault.

DTC P0325 — ION Sensing Module Knock Intensity Circuit Fault Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Refer to Diagnostic Aids

—

Go to Step 4

—

Verify repair

Go to Step 5

—

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

—

Go to Step 10

Go to Step 11

—

Verify repair

Go to Step 11

1. Ignition “OFF”. 2. Disconnect the ION sensing module. 3. Disconnect the PCM. Is the action complete?

Check the ION sensing harness between the PCM (F68) and ION sensing module circuit (RED Wire) at the KI line harness connector. Was a problem found?

1. Disconnect the ignition coil. Is the action complete?

Check the ION sensing harness for open or short circuit between the ignition coil and ION sensing module circuit at the harness connector. Was a problem found?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Check the following items; 1. Ignition coil and ignition coil circuit. 2. Ignition coil ground circuit for a poor connection. 3. If a problem is found, repair wiring harness as necessary. Was a problem found?

Replace the Ignition coil. Is the action complete?

Check the following items; 1. ION sensing module ground circuit for a poor connection. 2. If a problem is found, repair wiring harness as necessary. Was a problem found?

Repair wiring harness. Is the action complete?

6E–274

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0325 — ION Sensing Module Knock Intensity Circuit Fault (Cont’d) Step

Action

Yes

Replace the ION Sensing module. Is the action complete?

Value(s)

—

Verify repair

Go to Step 12

—

Verify repair

—

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the latest software is released or not .And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–275

Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit

060R200066

Circuit Description

Action Taken When the DTC Sets

The 58X reference signal is produced by the crankshaft position (CKP) sensor. During one crankshaft revolution, 58 crankshaft pulses will be produced. The powertrain control module (PCM) uses the 58X reference signal to calculate engine RPM and crankshaft position. The PCM constantly monitors the number of pulses on the 58X reference circuit. If the PCM receives an incorrect number of pulses on the 58X reference circuit, DTC P0336 will set.

B The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Setting the DTC B Engine is running. B Extra or missing pulse is detected between consecutive 58X reference pulses. B Above condition is detected in 10 of 100 crankshaft rotations.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0336 will clear after 40 consecutive warm–up cycles have occurred without a fault. B DTC P0336 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–276

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for: B Poor connection — Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, disconnect the PCM, turn the ignition on and observe a voltmeter connected to the 58X reference circuit at the PCM harness connector while moving connectors and wiring harnesses related to the PCM. A change in voltage will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–277

DTC P0336 – 58X Reference Signal Circuit Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to “Engine Cranks But Will Not Run” chart

—

Go to Step 4

Refer to Diagnostic Aids

—

Verify repair

Go to Step 5

2.5 V

Go to Step 8

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

—

Verify repair

Go to Step 9

—

Verify repair

—

Attempt to start the engine. Does the engine start? —

1. 2. 3. 4.

Review and record Failure Records information. Clear DTC P0336. Start the engine and idle for 1 minute. Observe DTCs.

Is DTC P0336 set? 4

1. Disconnect the PCM and CKP sensor. 2. Check for an open or a short to ground in the 58X reference circuit between the CKP sensor connector and the PCM harness connector. 3. If a problem is found, repair as necessary. Was a problem found?

1. Reconnect the PCM and CKP sensor. 2. Connect a DVM to measure voltage on the 58X reference circuit at the PCM connector. 3. Observe the voltage while cranking the engine. Is the voltage near the specified value?

Check the connections at the CKP sensor and replace the terminals if necessary. Did any terminals require replacement?

Replace the CKP sensor. Use caution to avoid any hot oil that may drip out. Is the action complete?

Check connections at the PCM and replace the terminals if necessary. Did any terminals require replacement?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

6E–278

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency

060R200066

Circuit Description

Action Taken When the DTC Sets

The 58X reference signal is produced by the crankshaft position (CKP) sensor. During one crankshaft revolution, 58 crankshaft reference pulses will be produced. The powertrain control module (PCM) uses the 58X reference signal to calculate engine RPM and crankshaft position. The PCM constantly monitors the number of pulses on the 58X reference circuit. If the PCM does not receive pulses on the 58X reference circuit, DTC P0337 will set.

Conditions for Setting the DTC B Engine cranking. B Crankshaft position (CKP) sensor signal is not present between two cam pulses. B CKP reference pulse is not detected within 8 CMP pulses.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0337 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0337 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids An intermittent may be caused by a poor connection, rubbed-through wire insulation or a wire broken inside the insulation. Check for: B Poor connection – Inspect the PCM harness and connectors for improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, disconnect

6E–279

the PCM, turn the ignition on and observe a voltmeter connected to the 58X reference circuit at the PCM harness connector while moving connectors and wiring harnesses related to the PCM. A change in voltage will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0337 – CKP Sensor Circuit Low Frequency Step

Action

1. 2. 3. 4.

Go to Chart 3

—

Go to Step 4

Refer to Diagnostic Aid

—

Go to Step 7

Go to Step 5

—

Go to Step 6

Go to Step 11

—

Verify repair

—

Verify repair

Go to Step 8

2.5 V

Go to Step 11

Go to Step 9

—

Verify repair

Go to Step 10

1. Ignition “OFF”. 2. Disconnect the PCM and CKP sensor. 3. Check for an open or a short to ground in the 58X reference circuit between the CKP sensor connector and the PCM harness connector. 4. If a problem is found, repair as necessary. 1. Reconnect the PCM and CKP sensor. 2. Connect a DVM to measure voltage on the 58X reference circuit at the PCM connector. 3. Observe the voltage while cranking the engine. Is the voltage near the specified value?

Go to Step 3

Check 5 V reference or ground between the CKP sensor and PCM and repair the open circuit, short to ground or short to voltage.

Was a problem found? 8

—

1. Ignition “ON”. 2. With a DVM, backprobe the PCM connector 5 V reference and ground connections.

Is the action complete? 7

Go to Step 2

1. Disconnect the CKP sensor. 2. Ignition “ON”. 3. Using a DVM, verify that 5 V reference and ground are being supplied at the sensor connector (PCM side).

Are 5 V reference and ground available at the PCM? 6

—

Go to OBD System Check

Review and record Failure Records information. Clear DTC P0337. Start the engine and idle for 1 minute. Observe DTCs.

Are 4-6 volts and ground available at the sensor? 5

Attempt to start the engine.

Is DTC P0337 set? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the engine start? 3

Value(s)

Check the connections at the CKP sensor and replace the terminals if necessary. Did any terminals require replacement?

6E–280

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0337 – CKP Sensor Circuit Low Frequency (Cont’d) Step

Action

Replace the CKP sensor. Use caution and avoid hot oil that may drip out. Is the action complete?

Yes

—

Verify repair

—

Verify repair

Go to Step 12

—

Verify repair

—

Check the connections at the PCM and replace the terminals if necessary. Did any terminals require replacement?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–281

Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit

060R200055

Circuit Description ION Sensing Module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. The PCM controls ignition timing and dwell time. This diagnosis detects open circuit or short-circuiting in the Ignition Electronic Spark Timing (EST) line by monitoring EST signals. A failure determination is made when the signal voltage remains higher or lower than the threshold for corresponding fault code beyond a predetermined time period. When the PCM detects a problem on EST control circuit 1, it will set a DTC P0351.

Conditions for Setting the DTC B The ignition is “ON”. B The engine is running, determined by the 58X crankshaft position input signal. B The output voltage is not equal to 5 volts when output is “ON”.

B The output voltage is not equal to 0 volts when output is “OFF”. B Ten test failures occur within 10 samples of continuous spark events.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0351 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P0351 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

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Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect the harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connections. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the

Tech 2 display related to DTC P0351 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0351 – Ignition 1 Control Circuit Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to Diagnostic Aids

—

Verify repair

Go to Step 4

—

Verify repair

Go to Step 5

25-55 mV

Go to Step 6

Go to Step 9

100-180 mV

Go to Step 7

Go to Step 13

Does the voltage measure between the specified values? 200-1200 mV

Go to Step 8

Go to Step 11

—

Verify repair

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 13

1. Ignition “ON”, engine “OFF”. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Record conditions as noted. 4. Use a Tech 2 to monitor the “DTC” information for DTC P0351 until the DTC P0351 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0351 failed this ignition cycle?

Check for faulty connection at ignition coil. Was a problem found?

Check for faulty connection at PCM connector. Was a problem found?

1. Ignition “ON”, engine “OFF”. 2. Back probe the ignition control circuit 1 at the ION Sensing Module with a DVM. Is the voltage near the specified value?

1. Ignition “ON”, engine running. 2. Back probe the ignition control circuit at the ION Sensing Module for the cylinder being tested. Is the voltage in the specified range, rapidly toggling back and forth to a reading 20-50 mV higher?

1. Ignition “OFF”. 2. Disconnect the 3-pin and connector at the ignition coil. 3. Check ignition control circuit 1 voltage at the ignition coil connector while cranking the engine.

Replace the ignition coil. Is the action complete?

1. Ignition “OFF”. 2. Disconnect the PCM and the ignition coil. 3. Check ignition control circuit 1 for short to ground. Was a problem found?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

Check ignition control circuit 1 for short to voltage. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–283

DTC P0351 – Ignition 1 Control Circuit (Cont’d) Step

Action

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Verify repair

—

Repair the open ignition control circuit. Is the action complete?

Yes

Check for an open ignition control circuit 1. Was the ignition control circuit open?

Value(s)

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit

060R200055

Conditions for Setting the DTC B The ignition is “ON”. B The engine is running, determined by the 58 X crankshaft position input signal. B The output voltage is not equal to 5 volts when output is “ON”.

B The output voltage is not equal to 0 volts when output is “OFF”. B Ten test failures occur within 10 samples of continuous spark events.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0352 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P0352 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–285

Tech 2 display related to DTC P0352 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0352 – Ignition 2 Control Circuit Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to Diagnostic Aids

—

Verify repair

Go to Step 4

—

Verify repair

Go to Step 5

25-55 mV

Go to Step 6

Go to Step 9

100-180 mV

Go to Step 7

Go to Step 13

Does the voltage measure between the specified 200-1200 mV values?

Go to Step 8

Go to Step 11

—

Verify repair

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 13

1. Ignition “ON”, engine “OFF”. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Record conditions as noted. 4. Use a Tech 2 to monitor the “DTC” information for DTC P0352 until the DTC P0352 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0352 failed this ignition cycle?

Check for faulty connection at ignition coil. Was a problem found?

Check for faulty connection at PCM connector. Was a problem found?

1. Ignition “ON”, engine “OFF”. 2. Back probe the ignition control circuit 2 at the ION Sensing Module with a DVM . Is the voltage near the specified value?

1. Ignition “OFF”. 2. Disconnect the 3-pin connector at the ignition coil. 3. Check ignition control circuit 2 voltage at the ignition coil connector while cranking the engine connector.

Replace the ignition coil. Is the action complete?

1. Ignition “OFF”. 2. Disconnect the PCM and the ignition coil. 3. Check ignition control circuit 2 for short to ground. Was a problem found?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

Check ignition control circuit 2 for short to voltage. Was a problem found?

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DTC P0352 – Ignition 2 Control Circuit (Cont’d) Step

Action

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Verify repair

—

Repair the open ignition control circuit. Is the action complete?

Yes

Check for an open ignition control circuit 2. Was the ignition control circuit open?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–287

Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit

060R200055

B The output voltage is not equal to 0 volts when output is “OFF”. B Ten test failures occur within 10 samples of continuous spark events.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0353 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P0353 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Tech 2 display related to DTC P0353 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0353 – Ignition 3 Control Circuit Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to Diagnostic Aids

—

Verify repair

Go to Step 4

—

Verify repair

Go to Step 5

25-55 mV

Go to Step 6

Go to Step 9

100-180 mV

Go to Step 7

Go to Step 13

Does the voltage measure between the specified 200-1200 mV values?

Go to Step 8

Go to Step 11

—

Verify repair

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 13

1. Ignition “ON”, engine “OFF”. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Record conditions as noted. 4. Use a Tech 2 to monitor the “DTC” information for DTC P0353 until the DTC P0353 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0353 failed this ignition cycle?

Check for faulty connection at ignition coil. Was a problem found?

Check for faulty connection at PCM connector. Was a problem found?

1. Ignition “ON”, engine “OFF”. 2. Back probe the ignition control circuit 3 at the ION Sensing Module with a DVM positive lead with the negative lead to ground. Is the voltage near the specified value?

1. Ignition “OFF”. 2. Disconnect the 3-pin connector at the ignition coil. 3. Check ignition control circuit 3 voltage at the ignition coil connector while cranking the engine.

Replace the ignition coil. Is the action complete?

1. Ignition “OFF”. 2. Disconnect the PCM and the ignition coil. 3. Check ignition control circuit 3 for short to ground. Was a problem found?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

Check ignition control circuit 3 for short to voltage. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–289

DTC P0353 – Ignition 3 Control Circuit (Cont’d) Step

Action

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Verify repair

—

Repair the open ignition control circuit. Is the action complete?

Yes

Check for an open ignition control circuit 3. Was the ignition control circuit open?

Value(s)

6E–290

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit

060R200055

B The output voltage is not equal to 0 volts when output is “OFF”. B Ten test failures occur within 10 samples of continuous spark events.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0354 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P0354 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–291

Tech 2 display related to DTC P0354 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0354 – Ignition 4 Control Circuit Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to Diagnostic Aids

—

Verify repair

Go to Step 4

—

Verify repair

Go to Step 5

25-55 mV

Go to Step 6

Go to Step 9

100-180 mV

Go to Step 7

Go to Step 13

Does the voltage measure between the specified 200-1200 mV values?

Go to Step 8

Go to Step 11

—

Verify repair

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 13

1. Ignition “ON”, engine “OFF”. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Record conditions as noted. 4. Use a Tech 2 to monitor the “DTC” information for DTC P0354 until the DTC P0354 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0354 failed this ignition cycle?

Check for faulty connection at ignition coil. Was a problem found?

Check for faulty connection at PCM connector. Was a problem found?

1. Ignition “ON”, engine “OFF”. 2. Back probe the ignition control circuit 4 at the ION Sensing with a DVM positive lead with the negative lead to ground. Is the voltage near the specified value?

1. Ignition “OFF”. 2. Disconnect the 3-pin connector at the ignition coil. 3. Check ignition control circuit 4 voltage at the ignition coil connector while cranking the engine.

Replace the ignition coil. Is the action complete?

1. Ignition “OFF”. 2. Disconnect the PCM and the ignition coil. 3. Check ignition control circuit 4 for short to ground. Was a problem found?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

Check ignition control circuit 4 for short to voltage. Was a problem found?

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0354 – Ignition 4 Control Circuit (Cont’d) Step

Action

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Verify repair

—

Repair the open in ignition control circuit. Is the action complete?

Yes

Check for an open ignition control circuit 4. Was the ignition control circuit open?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–293

Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit

060R200055

B The output voltage is not equal to 0 volts when output is “OFF”. B Ten test failures occur within 10 samples of continuous spark events.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0355 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P0355 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Tech 2 display related to DTC P0355 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0355 – Ignition 5 Control Circuit Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to Diagnostic Aids

—

Verify repair

Go to Step 4

—

Verify repair

Go to Step 5

25-55 mV

Go to Step 6

Go to Step 9

100-180 mV

Go to Step 7

Go to Step 13

Does the voltage measure between the specified 200-1200 mV values?

Go to Step 8

Go to Step 11

—

Verify repair

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 13

1. Ignition “ON”, engine “OFF”. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Record conditions as noted. 4. Use a Tech 2 to monitor the “DTC” information for DTC P0355 until the DTC P0355 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0355 failed this ignition cycle?

Check for faulty connection at ignition coil. Was a problem found?

Check for faulty connection at PCM connector. Was a problem found?

1. Ignition “ON”, engine “OFF”. 2. Back probe the ignition control circuit 5 at the ION Sensing Module with a DVM positive lead with the negative lead to ground. Is the voltage near the specified value?

1. Ignition “OFF”. 2. Disconnect the 3-pin connector at the ignition coil. 3. Check ignition control circuit 5 voltage at the ignition coil connector while cranking the engine.

Replace the ignition coil. Is the action complete?

1. Ignition “OFF”. 2. Disconnect the PCM and the ignition coil. 3. Check ignition control circuit 5 for short to ground. Was a problem found?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

Check ignition control circuit 5 for short to voltage. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–295

DTC P0355 – Ignition 5 Control Circuit (Cont’d) Step

Action

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Verify repair

—

Repair the open ignition control circuit. Is the action complete?

Yes

Check for an open ignition control circuit 5. Was the ignition control circuit open?

Value(s)

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit

060R200055

B The output voltage is not equal to 0 volts when output is “OFF”. B Ten test failures occur within 10 samples of continuous circuit monitoring.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle in which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0356 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P0356 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–297

Tech 2 display related to DTC P0356 while moving the connector and wiring related to the ignition system. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0356 – Ignition 6 Control Circuit Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to Diagnostic Aids

—

Verify repair

Go to Step 4

—

Verify repair

Go to Step 5

25-55 mV

Go to Step 6

Go to Step 9

100-180 mV

Go to Step 7

Go to Step 13

Does the voltage measure between the specified 200-1200 mV values?

Go to Step 8

Go to Step 11

—

Verify repair

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 13

1. Ignition “ON”, engine “OFF”. 2. Review and record Tech 2 Failure Records data. 3. Operate the vehicle within Failure Record conditions as noted. 4. Use a Tech 2 to monitor the “DTC” information for DTC P0356 until the DTC P0356 test runs. 5. Note the test result. Does the Tech 2 indicate DTC P0356 failed this ignition cycle?

Check for faulty connection at ignition coil. Was a problem found?

Check for faulty connection at PCM connector. Was a problem found?

1. Ignition “ON”, engine “OFF”. 2. Back probe the ignition control circuit 6 at the ION Sensing Module with a DVM positive lead with the negative lead to ground. Is the voltage near the specified value?

1. Ignition “OFF”. 2. Disconnect the 3-pin connector at the ignition coil. 3. Check ignition control circuit 6 voltage at the ignition coil connector while cranking the engine.

Replace the ignition coil. Is the action complete?

1. Ignition “OFF”. 2. Disconnect the PCM and the ignition coil. 3. Check ignition control circuit 6 for short to ground. Was a problem found?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

Check ignition control circuit 6 for short to voltage. Was a problem found?

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DTC P0356 – Ignition 6 Control Circuit (Cont’d) Step

Action

—

Go to Step 12

Go to Step 13

—

Verify repair

—

Verify repair

—

Repair the open ignition control circuit. Is the action complete?

Yes

Check for an open ignition control circuit 6. Was the ignition control circuit open?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–299

Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient

060R200050

Circuit Description The powertrain control module (PCM) tests the exhaust gas recirculation (EGR) system during deceleration by momentarily commanding the EGR valve to open while monitoring the manifold absolute pressure (MAP) sensor signal. When the EGR valve is opened, the PCM monitors the change in MAP input signal. The PCM compares the MAP change to a RPM vs. BARO table. When the PCM interprets the change in MAP to be out of limits, the PCM will set DTC P0401. The number of test samples required to accomplish this may vary according to the severity of the detected flow error. Normally, the PCM will only allow one EGR flow test sample to be taken during an ignition cycle. To aid in verifying a repair, the PCM allows twelve test samples during the first ignition cycle following a Tech 2 “Clear Info” or a battery disconnect. Between nine and twelve samples should be sufficient for the PCM to determine adequate EGR flow and pass the EGR test.

Conditions for Setting the DTC B No TP sensor, vehicle speed sensor (VSS), MAP sensor, IAT sensor, IAC, EGR Pintle Position sensor, ECT sensor, misfire, or automatic transmission DTCs set. B Engine coolant temperature is greater than 60°C (140°F). B Ignition voltage between 11.5 and 16 volts. B Vehicle speed is greater than 24 km/h (15 mph).

B A/C clutch status is unchanged. B TCC status is unchanged.

Start Test B B B B B B

B B B

TP angle is less than 0.8%. EGR duty cycle is less than 1%. MAP is steady, changing less than 2 kPa. Engine speed is between 1100 RPM and 2000 RPM (M/T). MAP between 10 kPa and 40 kPa. Engine speed is between 900 RPM and 1500 rpm (A/T). The test will be aborted if the vehicle speed changes by more than 16 km/h (10 mph), engine speed changes by more than 100 RPM or the EGR is opened less than 95% of commanded position. The PCM will only run the EGR test during a closed throttle condition. The PCM will only run the EGR test at vehicle speeds above 24 km/h (15 mph). Several deceleration cycles will be necessary to run a sufficient number of EGR flow tests.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected fault.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Diagnostic Aids Check for the following conditions: B Poor connection or damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the Actual EGR Position display on the Tech 2 while moving connectors and wiring harnesses related to the EGR valve. A change in the display will indicate the location of the fault. B Ensure EGR valve is correctly mounted. See On-Vehicle Service. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition. NOTE: If the EGR valve shows signs of excessive heat, check the exhaust system for blockage (possibly a plugged catalytic converter) using the “Restricted Exhaust System Check”.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart 3. A malfunctioning MAP sensor can set an EGR DTC. The MAP sensor could send a constant signal which is not low enough to set a low MAP DTC. The constant signal from the MAP sensor also may not be high enough to set a high MAP DTC. This step verifies that the MAP sensor is responding.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–301

DTC P0401 – EGR Flow Insufficient Step

2 3

Action

—

Go to DTC 1404

Go to Step 3

—

Go to Step 5

Go to Step 4

—

Verify repair

—

Go to Step 8

Go to Step 6

—

Go to Step 8

Go to Step 7

—

Go to Step 8

Refer to Diagnostic Aids

—

Repair complete

1. Inspect the exhaust system for modification of original installed parts or leaks. 2. If a problem was found, repair exhaust system as necessary. 1. Remove the EGR valve. 2. Visually and physically inspect the pintle, valve passages and the adapter for excessive deposits or any kind of a restriction. 3. If a problem is found, clean or replace EGR system components as necessary. 1. Remove the EGR inlet and outlet pipes from the exhaust manifold and the intake manifold. 2. Inspect the manifold EGR ports and the EGR inlet and outlet pipes for a blockage caused by excessive deposits or other damage. 3. If a problem is found, correct the condition as necessary. Was a condition present that required repair?

Go to Step 2

Replace the MAP sensor.

Was a condition present that required repair? 7

—

1. Start the engine. 2. Monitor the MAP signal with a Tech 2 while idling. 3. While idling, jab the accelerator pedal about halfway down and immediately let the engine return to idle.

Was a condition present that required repair? 6

Go to OBD System Check

Is DTC P1404 also set?

Is the action complete? 5

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Did the MAP value on the Tech 2 show an immediate large change? 4

Value(s)

1. Review and record the Tech 2 Failure Records data. 2. Clear DTC and monitor the Tech 2 System Info Screen while operating the vehicle as specified in “Diagnostic Aids”. 3. Using a Tech 2, monitor “DTC” info for DTC P0401 until the DTC P0401 test runs. 4. Note the test result. Does the Tech 2 indicate DTC P0401 failed this ignition?

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error

060R200050

Circuit Description The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM, and to detect a fault if pintle position is stuck open. If the PCM detects a pintle position signal indicates more than 21.5% and more than for 625 msec during cranking, the PCM will set DTC P0402.

Conditions for Setting the DTC B Ignition voltage is between 11 and 16 volts. B At Engine revolution less than 600 RPM, EGR pintle position indicates more than 21.0% and more than for 625 msecs.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

B A history DTC P0402 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0402 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Foreign material on EGR valve between pintle and seat may cause EGR stuck open. Inspect foreign material in EGR valve. B Excessive carbon deposit may cause unsmooth operation of EGR valve shaft. Inspect for carbon deposit and clean up inside of carbon deposit. B Poor connection or damaged harness–inspect the wiring harness for damage If the harness appears to be OK, observe the EGR actual position display on the Tech 2 while moving connectors and wiring harnesses related to EGR valve. A change in the display will indicate the location of the fault. NOTE: If the EGR valve shows signs of excessive heat, check the exhaust system for blockage (possibly a plugged catalytic converter) using the “Restricted Exhaust System Check”.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–303

DTC P0402 – EGR Pintle Crank Open Error Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Refer to Diagnostic Aids

—

Go to Step 4

Go to Step 5

—

Verify repair

—

Go to Step 6

Go to Step 7

—

Go to Step 7

—

Go to Step 8

—

Go to Step 9

Verify repair

—

Verify repair

—

1. Ignition “ON”, engine “OFF”, review and record Tech 2 Failure Records data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor “DTC” info for DTC P0402 until the DTC P0402 test runs. Note the result. Does the Tech 2 indicates DTC P0402 failed this ignition?

1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals?

Repair the damaged pin or terminal. Is the action complete?

1. Remove EGR valve from Engine. 2. Inspect EGR valve whether there is any foreign material between seat and pintle. Was any foreign material in EGR valve?

1. Remove EGR valve foreign material from EGR valve and clean up inside. 2. Visually inspect for damage of pintle and seat, which leakage may occur. Was there any severe damage which affects function?

1. 2. 3. 4. 5. 6.

Replace the EGR valve. Does DTC P0402 still fail “DTC” test on the Tech 2?

Verify repair Go to Step 8

Reconnect. Ignition “OFF”. Install the Tech 2. Run the engine at idle. On Tech-II, select special function for EGR. Use the “UP” arrow to increase the EGR from 0% to 40%.

Did EGR work properly? 8

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

Replace the PCM. Is the action complete?

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Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck

060R200050

Circuit Description The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM, and to detect a fault if pintle position is different from commanded position. If the PCM detects a pintle position signal indicates more than 15 points different between current and commanded and more than 15 seconds, the PCM will set DTC P0404.

Conditions for Setting the DTC B B B B B

The engine is running. Ignition voltage is between 11 and 16 volts. Intake Air Temp is more than 3°C (37.4°F). Desire EGR position is less than 3%. The difference between desired EGR and current EGR is less than 3%. B Difference EGR pintle position between current and commanded position becomes more than 15% and last more than 15 seconds, and this condition meets three times in a trip. Then it trigger, the PCM lights on.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected the fault.

B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0404 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0404 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Excessive carbon deposit on EGR valve shaft may cause EGR stuck open or unsmooth operation. Those carbon deposit may occur by unusual port operation. Clean up carbon may make smooth function of EGR valve. B Poor connection or damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the EGR actual position display on the Tech 2 while moving connectors and wiring harnesses related to EGR valve. A change in the display will indicate the location of the fault.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–305

DTC P0404 – EGR Open Stuck Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Refer to Diagnostic Aids

—

Go to Step 4

Go to Step 5

—

Verify repair

Is the action complete?

—

Go to Step 6

Go to Step 7

—

Go to Step 8

—

Go to Step 8

—

Go to Step 9

Verify repair

—

Verify repair

—

1. Ignition “ON”, engine “OFF”, review and record Tech 2 Failure Records Data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor “DTC” info for DTC P0404 until the DTC P0404 test runs. Note the result. Does the Tech 2 indicates DTC P0404 failed this ignition?

1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals?

4 5

Repair the damaged pin or terminal. 1. Remove EGR valve from Engine. 2. Inspect EGR valve whether there is any excessive carbon deposit on EGR shaft. Was excessive carbon deposit on EGR valve shaft?

1. Clean up EGR valve shaft and inside of EGR valve. 2. Visually inspect damage of pintle and seat if is bent, leakage may occur. Was there any severe damage which affects function?

1. 2. 3. 4. 5. 6.

Replace the EGR valve. Does DTC P0404 still fail “DTC” test on the Tech 2?

Verify repair Go to Step 7

Reconnect. Ignition “OFF”. Install the Tech 2. Run the engine at idle. On the Tech 2, select EGR Control Test. Use the “UP” arrow to increase the EGR from 0% to 40%.

Did EGR work properly? 8

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

6E–306

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage

060R200050

Circuit Description

Conditions for Clearing the MIL/DTC

The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to command from the PCM. If current pintle position voltage indicates less than 0.1 V and last more than 10 seconds, then the PCM will set DTC P0405.

B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0402 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0405 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC B Ignition voltage is between 11 and 16 volts. B Intake Air Temp is more than 3°C (37.4°F). B EGR pintle position is less than 2% and last more than 10 sec. Action taken when the DTC sets.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected the fault. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data.

Diagnostic Aids Check for the following conditions: B Poor connection or damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the EGR actual position display on the Tech 2 while moving connectors and wiring harnesses related to EGR valve. A change in the display will indicate the location of the fault.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–307

DTC P0405 – EGR Low Voltage Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Refer to Diagnostic Aids

—

Go to Step 4

Go to Step 5

—

Verify repair

—

4–6 V

Go to Step 6

Go to Step 7

5–5.5 KW

Go to Step 10

Go to Step 17

4–6 V

Go to Step 8

Go to Step 18

—

Verify repair

—

Verify repair

—

1 to 1.25 KW

Go to Step 13

Go to Step 17

Less than 0.1 V

Go to Step 17

Go to Step 12

1. Ignition “ON”, engine “OFF”, review and record Tech 2 Failure Records Data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor “DTC” info for DTC P0405 until the DTC P0405 test runs. Note the result. Does the Tech 2 indicates DTC P0405 failed this ignition?

1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals?

Repair the damaged pin or terminal. Is the action complete?

1. Disconnect the EGR harness connector. 2. Ignition “ON”. 3. At the EGR valve, use a DVM to check the voltage at the 5 volt reference wire (BLU/RED) and ground. Did the DVM indicate the specified value?

1. Disconnect the EGR harness connector. 2. Measure resistance between terminal 5 volt reference wire and ground. Was resistance in range?

1. Ignition “ON”. 2. At the PCM connector, backprobe with a DVM at the 5 volt reference for the EGR valve. Did the DVM indicate the specified value?

Repair the open 5 volt reference circuit. Is the action complete?

Repair the damaged sensor ground wire. Is the action complete?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

1. Disconnect the EGR harness 2. Use an ohmmeter to measure between the pintle position pin and the sensor ground pin on the EGR valve. NOTE: J-35616 Connector Test Adapter Kit may be useful for gaining access to the recessed pins on the valve. Was the ohmmeter reading approximately equal to the specified value?

1. Ignition “ON”. 2. Backprobe with a DVM to measure voltage at EGR valve pintle position pin and sensor ground pin. Was voltage in range?

6E–308

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0405 – EGR Low Voltage (Cont’d) Step

Action

1. Ignition “ON”. 2. Backprobe with a DVM to measure voltage at PCM sensor ground pin and pintle position pin. Was voltage in range?

1. 2. 3. 4.

Ignition “OFF”. Disconnect the PCM. Ignition “ON”. Measure the voltage between the EGR pintle position circuit and ground.

Is the measured voltage near the specified value? 16

Less than 0.1 V

Go to Step 13

Go to Step 18

—

Go to Step 14

Go to Step 18

—

Verify repair

—

Less than 0.1 V

Go to Step 17

Go to Step 16

—

Repair short circuit and then Verify repair

Go to Step 17

—

Go to Step 18

Verify repair

—

Go to Step 4

Go to Step 19

—

Verify repair

—

Check for a short circuit between other wires and the pintle position circuit Is there any short circuit?

Replace the EGR valve. Does DTC P1404 still fail “DTC test on the Tech 2?

Examine the PCM pin and terminal connection. Was there a damaged terminal?

Locate and repair the short to ground in the pintle position circuit Is the action complete?

Yes

1. Ignition “OFF”. 2. Disconnect the EGR harness. 3. Check short circuit between EGR pintle position circuit and EGR ground circuit. Was any short circuit?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–309

Diagnostic Trouble Code (DTC) P0406 EGR High Voltage

060R200050

Circuit Description

Conditions for Clearing the MIL/DTC

The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to command from the PCM. If current pintle position voltage indicates more than 4.8 V and last more than 10 seconds, then the PCM will set DTC P0406.

B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0402 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0404 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC B Ignition voltage is between 11 and 16 volts. B Intake Air temp is more than 3°C (37.4°F). B EGR pintle position is more than 99% and last more than 10 sec.

6E–310

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0406 – EGR High Voltage Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Refer to Diagnostic Aids

—

Go to Step 4

Go to Step 5

—

Verify repair

Is the action complete?

4–6 V

Go to Step 8

Go to Step 6

4–6 V

Go to Step 7

Go to Step 16

—

Verify repair

—

5 to 5 KW

Go to Step 9

Go to Step 15

—

Go to Step 15

Go to Step 10

—

Go to Step 14

Go to Step 11

1. Ignition “ON”, engine “OFF”, review and record Tech 2 Failure Records Data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor “DTC” info for DTC P0406 until the DTC P0406 test runs. Note the result. Does the Tech 2 indicates DTC P0406 failed this ignition?

1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals?

Repair the damaged pin or terminal. Is the action complete?

1. Disconnect the EGR harness connector. 2. Ignition “ON”. 3. At the EGR valve, use a DVM to check the voltage at the 5 volt reference wire (BLU/RED). Did the DVM indicate the specified value?

1. Ignition “ON”. 2. At the PCM connector, backprobe with a DVM at the 5 volt reference for the EGR valve. Did the DVM indicate the specified value?

Repair the open 5 volt reference circuit Is the action complete?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

1. Ignition “OFF” 2. Disconnect the EGR harness. 3. Use a DVM to check for an resistance between 5 V reference and Sensor Ground at EGR sensor terminals. NOTE: J-35616 Connector Test Adapter Kit may be useful for gaining access to the recessed pins on the valve. Was the measured resistance in range?

1. Ignition “OFF”. 2. Disconnect the EGR harness. 3. Use a DVM to check for an resistance between Sensor Ground and Signal Wire at EGR sensor terminal. Is there an open circuit?

1. Ignition “OFF”. 2. Disconnect the EGR harness at PCM connector. 3. Use a DVM to check for shorted wire between S37 and F53. Is there a shorted wire?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–311

DTC P0406 – EGR High Voltage (Cont’d) Step

Action

1. Ignition “ON”. 2. Use a DVM to backprobe at terminal Connector of EGR valve for voltage. Was measured voltage more than 4.8 V?

Go to Step 12

4.8 V

Go to Step 16

Go to Step 13

—

Verify repair

—

Verify repair

—

Go to Step 16

Verify repair

—

Verify repair

—

Replace the EGR valve. Does DTC P1404 still fail “DTC test on the Tech 2?

more than 4.8 V

Replace EGR harness. Is the action complete?

1. Locate short circuit at EGR harness between BLU/RED to GRY/RED or GRY/RED to YEL, BLU/RED. 2. Replace EGR harness. Is the action complete?

Yes

1. Ignition “ON”. 2. Stay the EGR harness connected. 3. Check voltage by backprobing at PCM S37 terminal. Was voltage more than 4.8 V?

Value(s)

6E–312

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1

T321075

Circuit Description

B Barometric Pressure is more than 72 kPa.

To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalyst (TWC) is used. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 1 HO2S 1 and the Bank 1 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalyst’s ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 1 HO2S 1 signal will be far more active than that produced by the Bank 1 HO2S 2 sensor. If the PCM detects a level of Bank 1 HO2S 2 activity that indicates the catalyst is no longer operating efficiently, DTC P0420 will be set.

Action Taken When the DTC Sets

Conditions for Setting the DTC B B B B B B B B B B

No related DTCs. The engine is operating in “closed loop”, Engine air load is below 99%. Engine coolant temperature is between 70°C (158°F) and 120°C (248°F). Mass air flow is between 2.5 g/second and 10 g/second. Engine speed is below 200 RPM. Catalyst temperature is above 350°C (662°F). The PCM determines that the catalyst’s oxygen storage capacity is below the acceptable threshold. Intake Air Temperature is between –10°C (14°F) and 70°C (158°F). Throttle angle is less than 1.5%.

B The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0420 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0420 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition. The “TWC Monitor Test Counter” displayed on the Tech 2 may be used to monitor the progress of the TWC diagnostic. To complete the TWC diagnostic with a good catalyst, the counter must be allowed to increment to 49 samples and roll over to 0 at least twice. A failed catalyst

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS will require three or more 50-sample tests to report a failure.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 7. Difficulty completing the DTC P0420 “Status This Ign”, test may be encountered in areas where test conditions cannot be maintained easily, especially in urban areas. To minimize the amount of driving required to complete the DTC P0420 “Status This Ign”, test, use the following procedure: B Allow the engine to warm up completely. B With the vehicle in “Park”, monitor mass air flow on the Tech 2 and hold part throttle to maintain a reading of over 12 g/second for at least 2 minutes. This will achieve the “warm catalyst” required for running the test. B Operate the vehicle in second or third gear to remain in the DTC P0420 test conditions described in “Conditions for Setting the DTC” as much as possible. If you must stop the vehicle, maintain the “warm catalyst” criteria as follows: – Place the vehicle in “Park” or “Neutral”, – Hold part throttle to maintain a mass air flow reading of over 15 g/second for the duration of the stop.

6E–313

6E–314

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0420 – TWC System Low Efficiency Bank 1 Step

Action

—

Go to Step 2

—

Diagnose other DTC(s) first

Go to Step 3

—

Go to Step 6

Go to Step 4

—

Go to Step 7 to verify repair

Go to Step 5

—

Go to Step 7 to verify repair

Go to Step 6

—

Go to Step 7 to verify repair

—

Complete repair. If a driveability symptom still exists, refer to Symptoms.

Go to the Diagnostic Aids

1. Visually and physically inspect the three-way catalytic converter for damage. Check for the following: B dents B severe discoloration caused by excessive temperatures B holes B internal rattle caused by damaged catalyst 2. Also, ensure that the three-way catalytic converter is a proper original equipment manufacturer part. 1. Visually and physically inspect the exhaust system between the three-way catalytic converter and the rear converter flange for leaks, damage, and loose or missing hardware. 2. If a problem is found, repair as necessary. 1. Visually and physically inspect the Bank 1 HO2S 2. 2. Ensure that the Bank 1 HO2S 2 is secure and that the pigtail and wiring harness is not contacting the exhaust pipe or is not otherwise damaged. 3. If a problem is found, repair as necessary. Did your inspection reveal a problem?

Replace the three-way catalytic converter. NOTE: Check for conditions which may cause catalyst damage (refer to Diagnostic Aids). Is the action complete?

Go to OBD System Check

Are any other DTCs set (such as P0140)?

Did your inspection reveal a problem? 5

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Did your inspection reveal a problem? 4

Value(s)

1. Review and record the Tech 2 Failure Records data. 2. Clear DTC P0420. 3. Start the engine and allow it to warm up until the engine coolant temperature monitored on the Tech 2 is above the specified value. 4. Run the engine to maintain the specified mass air flow range for at least 2 minutes. Engine 5. Operate the vehicle to maintain DTC P0420 test coolant temp: conditions (refer to DTC Test Description in greater than Diagnostic Support for detailed instructions). 60°C 6. Using a Tech 2, monitor “DTC” info for DTC P0420 (140°F). until the DTC P0420 test runs. Mass air flow: 7. Note the test result. between 8 Does the Tech 2 indicate DTC P0420 passed this g/second and ignition? 50 g/second

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–315

Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2

T321075

Circuit Description To control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx), a three-way catalyst (TWC) is used. The catalyst promotes a chemical reaction which oxidizes the HC and CO present in the exhaust gas, converting them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx, converting it to nitrogen. The powertrain control module (PCM) has the ability to monitor this process using the Bank 2 HO2S 1 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 2 HO2S 1 sensor produces an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 2 HO2S 2 sensor produces an output signal which indicates the oxygen storage capacity of the catalyst; this in turn indicates the catalyst’s ability to convert exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 2 HO2S 1 signal will be far more active than that produced by the Bank 2 HO2S 2 sensor. If the PCM detects a level of Bank 2 HO2S 2 activity that indicates the catalyst is no longer operating efficiently, DTC P0430 will be set.

Conditions for Setting the DTC B B B B

No related DTCs. The engine is operating in “closed loop”. Engine air load is below 99%. Engine coolant temperature is between 70°C (158°F) and 120°C (248°F).

B Mass air flow is between 2.5 g/second and 10 g/second. B Change in engine load is below 8%. B Engine speed is below 200 RPM. B Catalyst temperature is above 350°C (662°F). B The PCM determines that the catalyst’s oxygen storage capacity is below the acceptable threshold. B Intake air temperature is between –20°C (4°F) and 70°C (158°F). B Throttle angle is less than 1.5%. B Barometric Pressure is more than 72 kPa.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0430 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0430 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–316

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 7. Difficulty completing the DTC P0430 “Status This Ign”, test may be encountered in areas where test conditions cannot be maintained easily, especially in urban areas. To minimize the amount of driving required to complete the DTC P0430 “Status This Ign”, test, use the following procedure: B Allow the engine to warm up completely. B With the vehicle in “Park”, monitor mass air flow on the Tech 2 and hold part throttle to maintain a reading of over 12 g/second for at least 2 minutes. This will achieve the “warm catalyst” required for running the test. B Operate the vehicle in second or third gear to remain in the DTC P0430 test conditions described in “Conditions for Setting the DTC” as much as possible. If you must stop the vehicle, maintain the “warm catalyst” criteria as follows: – Place the vehicle in “Park” or “Neutral”, – Hold part throttle to maintain a mass air flow reading of over 15 g/second for the duration of the stop. The “TWC Monitor Test Counter” displayed on the Tech 2 may be used to monitor the progress of the TWC diagnostic. To complete the TWC diagnostic with a good catalyst, the counter must be allowed to increment to 49 samples and roll over to 0 at least twice.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–317

DTC P0430 – TWC System Low Efficiency Bank 2 Step

Action

—

Go to Step 2

—

Diagnose other DTC(s) first

Go to Step 3

—

Go to Step 6

Go to Step 4

—

Go to Step 7 to verify repair

Go to Step 5

—

Go to Step 7 to verify repair

Go to Step 6

—

Go to Step 7 to verify repair

—

Complete repair. If a driveability symptom still exists, refer to Symptoms.

Go to the Diagnostic Aids

1. Visually and physically inspect the three-way catalytic converter for damage. Check for the following: B dents B severe discoloration caused by excessive temperatures B holes B internal rattle caused by damaged catalyst 2. Also, ensure that the three-way catalytic converter is a proper original equipment manufacturer part. 1. Visually and physically inspect the exhaust system between the three-way catalytic converter and the rear converter flange for leaks, damage, and loose or missing hardware. 2. If a problem is found, repair as necessary. 1. Visually and physically inspect the Bank 2 HO2S 2. 2. Ensure that the Bank 2 HO2S 2 is secure and that the pigtail and wiring harness is not contacting the exhaust pipe or is not otherwise damaged. 3. If a problem is found, repair as necessary. Did your inspection reveal a problem?

Replace the three-way catalytic converter. NOTE: Check for conditions which may cause catalyst damage (refer to Diagnostic Aids). Is the action complete?

Go to OBD System Check

Are any other DTCs set (such as P0160)?

Did your inspection reveal a problem? 5

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Did your inspection reveal a problem? 4

Value(s)

1. Review and record the Tech 2 Failure Records data. 2. Clear DTC P0430. 3. Start the engine and allow it to warm up until the engine coolant temperature monitored on the Tech 2 is above the specified value. 4. Run the engine to maintain the specified mass air flow range for at least 6 minutes. Engine 5. Operate the vehicle to maintain DTC P0430 test coolant temp: conditions (refer to DTC Test Description in greater than Diagnostic Support for detailed instructions). 70°C 6. Using a Tech 2, monitor “DTC” info for DTC P0430 (158°F). until the DTC P0430 test runs. Mass air flow: 7. Note the test result. between 2.5 Does the Tech 2 indicate DTC P0430 passed this g/second and ignition? 10 g/second

6E–318

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0440 EVAP System

060RY00398

Circuit Description The evaporative system includes the following components: B Fuel tank B EVAP canister purge duty solenoid valve B Fuel tank (vapor) pressure sensor B Fuel pipes and hoses B Vapor lines B Fuel cap B Evaporative emissions canister B Purge lines B EVAP canister vent valve (purge solenoid) The evaporative leak detection diagnostic strategy is based on applying vacuum to the EVAP system and monitoring vacuum decay. The powertrain control module (PCM) monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid and the EVAP canister vent solenoid are turned “ON”, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system. If a sufficient vacuum level cannot be achieved, a large leak or a faulty EVAP canister purge solenoid is indicated. This can be caused by the following conditions: B Disconnected or faulty fuel tank pressure sensor B Missing or faulty fuel cap B Disconnected, damaged, pinched, or blocked EVAP purge line B Disconnected or damaged EVAP vent hose

B Disconnected, damaged, pinched, or blocked fuel tank vapor line B Disconnected or faulty EVAP canister duty solenoid B Open ignition feed circuit to the EVAP canister vent solenoid B Damaged EVAP canister B Leaking fuel sender assembly O-ring B Leaking fuel tank or fuel filler neck Any of the above conditions can set DTC P0440.

Conditions for Setting the DTC B No TP sensor, IAT sensor, ECT sensor, or MAP sensor DTCs set. B Start-up engine coolant temperature is less than 32°C (90°F). B Start-up engine coolant temperature is not more than 7°C (13°F) greater than start-up intake air temperature. B Start-up intake air temperature is greater than 4°C (39°F) . B Start-up intake air temperature is not more than 2°C (4°F) greater than start-up engine coolant temperature. B Vehicle speed is less than 5 mph (8 km/h). B Throttle position is greater than 3%. B Minimal fuel slosh. B BARO is greater than 70 kPa. B The EVAP system is unable to achieve or maintain vacuum during the diagnostic test.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B Engine speed is less than 1200 RPM. B Above conditions are present for 60 to 180 seconds.

Action Taken When the DTC Sets B The PCM will ON the MIL after second trip with detected the fault. B The PCM will store conditions which were present when the DTC set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” when the diagnostic has been run and the fault condition is no longer present. B A history DTC P0440 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0440 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Cracked or punctured EVAP canister. B Damaged or disconnected source vacuum line, EVAP purge line, vent hose or fuel tank vapor line. B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness–Inspect the wiring harness to the EVAP canister vent solenoid, EVAP canister purge solenoid and the fuel tank pressure sensor for an intermittent open or short circuit. B Kinked, pinched, or plugged vacuum source, EVAP purge, or fuel tank vapor line–Verify that the lines are not restricted.

6E–319

Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If an EVAP canister vent solenoid or an EVAP canister purge solenoid electrical fault is present, the purge system will not operate correctly. Repairing the electrical fault will very likely correct the condition that set DTC P0440. 3. Checks the fuel tank pressure sensor at ambient pressure. 4. Determines whether or not the EVAP system can be sealed sufficiently to be pressurized. If not, the large leak must be located and corrected before continuing with diagnosis. 5. Verifies that the fuel tank pressure sensor accurately reacts to EVAP system pressure changes. 8. Checks for a blocked EVAP canister purge solenoid. The PCM commands the EVAP canister purge solenoid “OFF” (open) and the vent solenoid “ON” (closed) with the Tech 2 “System Perf”, EVAP output control function activated. Any pressure in the system should be released through the EVAP canister purge solenoid within a few seconds when “System Perf”, is activated. 9. Ensures that sufficient source vacuum is present at the EVAP canister purge solenoid.

DTC P0440 – EVAP System Step

2 3

Action

Yes

—

Go to Step 2

—

Go to other DTC first

Go to Step 3

1.51 V

Go to Step 4

Go to DTC P0452 or DTC P0453

1.47–1.51 V

Go to Step 7

Go to Step 6

Is DTC P0452 or P0453 also set? 1. 2. 3. 4.

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed?

Ignition “OFF”. Remove the fuel cap. Ignition “ON”. Observe “Fuel Tank Pressure” on the Tech 2.

Does the Tech 2 indicate “Fuel Tank Pressure” at the specified value? 4

Value(s)

1. Replace the fuel cap. 2. Engine is running. 3. Observe “Fuel Tank Vacuum” on the Tech 2. Does Tech 2 indicate “Fuel Tank Vacuum” at the specified value?

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0440 – EVAP System (Cont’d) Step

Action

Value(s)

Yes

Ignition “OFF”. 1. Disconnect the fuel tank vapor line and the EVAP purge line from the EVAP canister. 2. Block the canister fitting for the fuel tank vapor line. 3. Connect a hand vacuum pump to the canister fitting for the EVAP purge line. 4. Ensure that the EVAP canister vent solenoid is still commanded “ON” (closed). 5. Attempt to apply vacuum to the EVAP canister. Observe “Fuel tank pressure” on the Tech 2. Does the Tech 2 indicate “Fuel tank pressure” at the specified value?

Verify repair

Go to Step 11

—

Verify repair

Go to Step 9

—

Verify repair

—

Verify repair

—

Verify repair

—

Locate and repair cause of no source vacuum to the EVAP canister purge solenoid. Is the action complete?

—

Replace the EVAP canister purge solenoid. Is the action complete?

Verify repair

1. Visually/physically check for the following conditions: B Missing or faulty fuel cap. B Disconnected or leaking fuel tank vapor line. B Disconnected or damaged EVAP purge line. 2. If a problem is found, repair as necessary. Was a problem found?

—

Go to DTC P0452 or DTC P0453

1. Visually/physically check for the following conditions: B Vent hose disconnected or the damaged. B EVAP canister damaged. 2. If a problem is found, repair as necessary. Was a problem found?

Go to Step 7

1. Visually/physically check for the following conditions: B Restricted fuel tank vapor line. B Restricted EVAP purge line. 2. If a problem is found, repair as necessary. Was a problem found?

Go to Step 8

1.47–1.51 V

Replace the EVAP canister vent solenoid. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–321

Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected

060RY00398

Circuit Description

Conditions for Setting the DTC

The evaporative system includes the following components: B Fuel tank B EVAP canister vent solenoid B Fuel tank (vapor) pressure sensor B Fuel pipes and hoses B Vapor lines B Fuel cap B Evaporative emissions canister B Purge lines B EVAP canister purge solenoid The evaporative leak detection diagnostic strategy is based on applying vacuum to the EVAP system and monitoring vacuum decay. The powertrain control module (PCM) monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid and the EVAP canister vent solenoid are turned “ON”, allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system. After the desired vacuum level has been achieved, the EVAP canister purge solenoid is turned “OFF”, sealing the system. A leak is detected by monitoring for a decrease in vacuum level over a given time period, all other variables remaining constant. A small leak in the system will cause DTC P0442 to be set.

B No TP sensor, ECT sensor, Tank pressure sensor, IAT sensor, or MAP sensor DTCs set. B BARO is more than 70 kPa. B Engine speed is less than 1200 RPM. B Fuel level is between 15% and 85%. B Vehicle speed is less than 5 mph (8 km/h). B The DTC P0440 diagnostic test has passed. B A vacuum decay condition, indicating a small leak, is detected during the diagnostic test.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0442 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0442 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–322

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids Check for the following conditions: B Cracked or punctured EVAP canister. B Damaged source vacuum line, EVAP purge line, EVAP vent hose or fuel tank vapor line. B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness–Inspect the wiring harness to the EVAP canister vent solenoid, EVAP canister purge solenoid and the fuel tank pressure sensor for an intermittent open or short circuit. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often

the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0442 – EVAP System Leak Detected Step

Action

Value(s)

1. 2. 3. 4.

Go to Step 2

Go to Step 3

Go to Fuel Tank Pressure System

Go to Step 4

Go to Fuel Tank Pressure System

Go to Step 5

Refer to Diagnostic Aids

Ignition “OFF”. Remove the fuel cap. Ignition “ON”. Observe “Fuel Tank Pressure” on the Tech 2.

Does the Tech 2 indicate “Fuel Tank Pressure” at the specified value?

1.51V

IMPORTANT: Before continuing with diagnosis, zero the EVAP pressure and vacuum gauges on EVAP pressure/purge cart J 41413 (refer to tool operating instructions). 1. Replace the fuel cap. 2. Capture Failure Records data for DTC P0442 and clear DTCs. 3. Connect the EVAP pressure/purge cart J 41413 to the EVAP service port. 4. Using the Tech 2, command the EVAP canister vent solenoid “ON” (closed). 5. Using the EVAP pressure/purge cart J 41413, pressurize the EVAP system to the specified value. 6. Observe “Fuel Tank Pressure” on the Tech 2. Does the Tech 2 indicate “Fuel Tank Pressure” at the specified value?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

1.47V

1. Ignition “ON”, engine idling. 2. Using the Tech 2, command the EVAP canister vent solenoid “ON” (closed). 3. Using the EVAP pressure/purge cart J 41413, pressurize the EVAP system to 15 in. H2O. 4. Switch the rotary switch on the cart to “HOLD” and observe the EVAP pressure gauge. Does the pressure decrease to less than the specified value within 2 minutes?

1.47 – 1.51V

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–323

DTC P0442 – EVAP System Leak Detected (Cont’d) Step

Action

Go to Step 6

—

Go to Step 10

Go to Step 7

—

Go to Step 10

—

Go to Step 10

Go to Step 9

—

Go to Step 10

—

2.14V

Go to Step 2

Verify repair

1. Using Tech 2, command the EVAP canister vent solenoid “ON” (closed). 2. With the cart connected to the EVAP service port, continuously attempt to pressurize the EVAP system by leaving the cart control knob in the pressurize position. 3. Using ultrasonic leak detector J 41416, locate and repair leak in EVAP system. (It may be necessary to partially lower the fuel tank to examine the connections on top of the tank.) Is the action complete?

Go to Step 8

1.46V

Replace the EVAP canister vent solenoid. Is the action complete?

1. Visually/physically check for the following conditions: B Vent hose disconnected or damaged. B EVAP canister damaged. 2. If a problem is found, repair as necessary. Was a problem found?

Yes

1. Disconnect the fuel tank vapor line and the EVAP purge line from the EVAP canister. 2. Block the canister fitting for the fuel tank vapor line. 3. Connect a hand vacuum pump to the canister fitting for the EVAP purge line. 4. Ensure that the EVAP canister vent solenoid is still commanded “ON” (closed). 5. Attempt to apply vacuum to the EVAP canister. Can the vacuum be maintained at the specific value?

Value(s)

1. Ignition “ON”, engine not running. 2. Using the Tech 2, command the EVAP canister vent solenoid “ON” (closed). 3. Using the EVAP pressure/purge cart J 41413, pressurize and monitor the EVAP system to 15 in. H2O. 4. Switch the rotary switch on the cart to “HOLD” and observe the EVAP pressure gauge. Does the pressure decrease to less than the specified value within 2 minutes?

6E–324

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0444 EVAP Purge Control Circuit Open

060RY00398

Circuit Description The canister purge solenoid valve is controlled by the Power Train Control Module (PCM).The PCM monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid is “ON,” allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system.

Conditions for setting the DTC B The Ignition is “ON”. B Engine is running. B System voltage is between 11.5 volts and 16 volts.

Action Taken When the DTC Sets B The PCM will not illuminate the malfunction indicator lamp (MIL). B The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

B DTC P0444 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Mis routed harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the EVAP purge solenoid display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0444 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0444 Diagnostic Chart may isolate the cause of the fault.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–325

DTC P0444 EVAP Purge Control Circuit Open Step

Action

Value(s)

Go to Step 2

Refer to Diagnostic Aids

Go to Step 3

Battery voltage

Go to Step 4

Go to Step 5

—

Go to Step 5

Go to Step 6

—

Verify repair

—

25–30 W (at 68°F{20°C})

Go to Step 8

Go to Step 7

—

Verify repair

—

Verify repair

—

1. Install the Tech 2. 2. Ignition is “ON”, 3. Engine is “ON” and operate the accelerator pedal for 3 or 4 times. 4. Observe the EVAP purge solenoid reading on the Tech 2. Is the EVAP purge solenoid reading near the specified More than 1% value?

Check the power supply circuit. 1. 2. 3. 4.

Ignition is “OFF”. Disconnect the canister purge solenoid valve. Ignition is “ON”. Using a DVM, measure at the EVAP purge solenoid connector between ground and voltage supply.

Was the measurement near the specified value? 4

Check the signal circuit for the EVAP purge solenoid. 1. 2. 3. 4.

Ignition is “OFF”. Disconnect the canister purge solenoid valve. Disconnect the PCM. Check the circuit between EVAP purge solenoid connector and PCM connector.

Is the problem found? 5

Repair the circuit as necessary. Is the action complete?

Check the canister purge solenoid valve. Using a DVM, measure resistance for purge solenoid valve connector terminal. Is the purge solenoid valve resistance within the specified values?

Replace the canister purge solenoid valve. Is the action complete?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Replace the IMPORTANT: The programmed.

replacement

PCM

must

6E–326

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0445 EVAP Purge Control Circuit Short

060RY00398

Circuit Description The canister purge solenoid valve is controlled by the Power Train Control Module (PCM). The PCM monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid is “ON,” allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system.

Conditions for setting the DTC B The Ignition is “ON”. B Engine is running. B System voltage is between 11.5 volts and 16 volts.

B DTC P0445 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the EVAP purge solenoid display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0445 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0445 Diagnostic Chart may isolate the cause of the fault.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–327

DTC P0445 EVAP Purge Control Circuit Short Step

Action

Value(s)

Go to Step 3

—

Go to Step 4

Go to Step 5

—

Verify repair

—

25–30 (at 68°F{20°C})

Go to Step 7

Go to Step 6

—

Verify repair

—

Verify repair

—

Repair the circuit as necessary. Is the action complete? Check the canister purge solenoid valve. Using a DVM, measure resistance for purge solenoid valve connector terminal.

Replace the canister purge solenoid valve. Is the action complete?

Refer to Diagnostic Aids

Ignition is “OFF”. Disconnect the canister purge solenoid valve. Disconnect the PCM. Check the circuit between EVAP purge solenoid connector and PCM connector.

Is the purge solenoid valve resistance within the specified values? 6

Go to Step 2

Check the signal circuit for canister purge solenoid valve.

Is the problem found?

— 1. Install the Tech 2. 2. Ignition is “ON”, 3. Observe the EVAP purge solenoid reading on the Tech 2.

1. 2. 3. 4.

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed?

Is the EVAP purge solenoid reading near the specified value? 3

Yes

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6E–328

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Control Malfunction

060RY00398

Circuit Description

If any of these conditions are present, DTC P0446 will set.

The evaporative system includes the following components: B Fuel tank B EVAP canister vent solenoid B Fuel tank (vapor) pressure sensor B Fuel pipes and hoses B Vapor lines B Fuel cap B Evaporative emissions canister B Purge lines B EVAP canister purge solenoid An incorrect fuel tank pressure sensor signal is detected by monitoring fuel tank pressure when the key is first turned “ON” during a cold start. If the fuel tank pressure signal is out of range, DTC P0446 will set. A restricted or blocked EVAP vent path is detected by monitoring fuel tank pressure during normal operation (EVAP canister vent solenoid open, EVAP canister purge solenoid normal). With the EVAP canister vent solenoid open, vacuum level in the system should be very low unless the vent path is blocked. A blockage can be caused by the following condition: B Faulty EVAP canister vent solenoid (stuck closed). B Plugged, kinked or pinched vent hose. B Shorted EVAP canister vent solenoid driver circuit. B Plugged evaporative canister.

Conditions for Setting the DTC B No TP sensor, ECT sensor, Tank pressure sensor, IAT sensor, or MAP sensor DTCs set. B Start-up engine coolant temperature and start-up intake air temperature are more than 4°C (39°F) but less than 34°C(93°F). B Start-up engine coolant temperature is not more than 7°C (13°F) greater than start-up intake air temperature. B Fuel tank level is between 15% and 85%. B BARO is greater than 70 kPa.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B DTC P0446 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–329

how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Diagnostic Aids

Test Description

Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. If a vent solenoid electrical fault is present, the purge system will not operate correctly. Repairing the electrical fault will very likely correct the condition that set DTC P0446. 3. Checks the fuel tank pressure sensor at ambient pressure. 4. Verifies that the fuel tank pressure sensor accurately reacts to EVAP system pressure changes. 6. Checks for a blocked EVAP canister.

DTC P0446– EVAP Canister Vent Control Malfunction Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to Fuel Tank Pressure System

1.52 – 1.69V

Go to Step 4

Go to Fuel Tank Pressure System

0 in. H2O

Refer to Diagnostic Aids

Go to Step 5

1. Ignition “ON.” 2. Capture Failure Records data for DTC P0446 and clear DTCs. 3. Ignition “OFF.” 4. Remove the fuel cap. 5. Ignition “ON.” 6. Observe “Fuel Tank Pressure” on the Tech 2. Does Tech 2 indicate “Fuel Tank Pressure” at the specified value?

1.51V

IMPORTANT: Before continuing with diagnosis, zero the EVAP pressure and vacuum gauges on the EVAP pressure/purge cart J 41413 (refer to tool operating instructions). 7. Replace the fuel cap. 8. Using the Tech 2, command the EVAP vent solenoid “ON” (closed). 9. Connect the EVAP pressure/purge cart J 41413 to the EVAP service port. 10.Using the EVAP pressure/purge cart J 41413, pressurize the EVAP system to the specified value. 11. Observe “Fuel Tank Pressure” on the Tech 2. Does Tech 2 indicate “Fuel Tank Pressure” at the specified value?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

1. Maintain the EVAP pressure at 5 in. at H2O. 2. Using Tech 2, command the EVAP vent solenoid “OFF” (open) while observing the EVAP pressure gauge on the cart J 41413. Does the EVAP pressure return to the specified value within 5 seconds?

6E–330

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0446– EVAP Canister Vent Control Malfunction (Cont’d) Step

Action

Go to Step 6

Go to Step 8

—

Go to Step 9

Go to Step 7

—

Go to Step 9

—

Go to Step 9

—

0 in. H2O

Verify repair

Go to Step 2

Replace the EVAP canister. Is the action complete?

30 in. H2O

Replace the EVAP canister vent solenoid. Is the action complete?

1. Inspect the vent hose between the EVAP canister and the EVAP canister vent solenoid for kinks, pinched areas, or any other form of blockage. 2. If a problem is found, repair as necessary. Was a problem found?

Yes

1. Disconnect the large vent hose (marked “AIR”) from the EVAP canister. 2. Switch the rotary switch on the cart J 41413 to “PURGE.” 3. Ignition “ON,” engine idling at normal operating temperature. 4. Observe vacuum gauge for 5 seconds while holding the engine speed at 2500 RPM. Does the vacuum remain less than the specified value?

Value(s)

1. Using Tech 2, command the EVAP canister vent solenoid “ON” (closed). 2. Using the EVAP pressure/purge cart J 41413, pressurize and monitor the EVAP system to 15 in. H2O. 3. Switch the rotary switch on cart J 41413 to “HOLD.” 4. Using the Tech 2, command the EVAP canister vent solenoid “OFF” (open) while observing the EVAP pressure gauge on cart J 41413. Does the EVAP pressure return to the specified value within 5 seconds?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–331

Diagnostic Trouble Code (DTC) P0447 EVAP Vent Solenoid Circuit Open

060RY00398

Circuit Description The canister purge solenoid valve is controlled by the Power Train Control Module (PCM).The PCM monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister vent solenoid is “ON,” allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system.

Conditions for setting the DTC B The Ignition is “ON”. B Engine is running. B System voltage is between 11.5 volts and 16 volts.

B DTC P0447 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the EVAP vent valve display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0447 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0447 Diagnostic Chart may isolate the cause of the fault.

6E–332

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0447 EVAP Vent Solenoid Circuit Open Step

Action

Value(s)

Ignition is “OFF”. Disconnect the canister vent solenoid valve. Ignition is “ON”. Using a DVM, measure at the EVAP vent solenoid connector between ground and voltage supply.

Battery voltage

Go to Step 4

Go to Step 5

—

Go to Step 5

—

Verify repair

—

21.8-28.5W (at 68°F{20°C})

—

Verify repair

—

Verify repair

—

Repair the circuit as necessary. Is the action complete? Check the canister vent solenoid valve. Using a DVM, measure resistance for vent solenoid valve connector terminal. Is the vent solenoid valve resistance within the specified values? Replace the canister vent solenoid valve. Is the action complete?

Go to Step 3

Ignition is “OFF”. Disconnect the canister vent solenoid valve. Disconnect the PCM. Check the circuit between EVAP vent solenoid connector and PCM connector.

Is the problem found?

—

Refer to Diagnostic Aids

Check the signal circuit for vent solenoid valve. 1. 2. 3. 4.

Go to Step 2

Check the power supply circuit.

Was the measurement near the specified value?

— 1. Install the Tech 2. 2. Ignition is “ON”, 3. Engine is “ON”and operate the acceleration pedal for 3 or 4 times. 4. Observe the EVAP vent solenoid reading on the Tech 2.

1. 2. 3. 4.

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed?

Is the EVAP vent solenoid reading to “ON”? 3

Yes

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–333

Diagnostic Trouble Code (DTC) P0448 EVAP Vent solenoid Circuit Short

060RY00398

Circuit Description The canister purge solenoid valve is controlled by the Power Train Control Module (PCM). The PCM monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister vent solenoid is “ON,” allowing engine vacuum to draw a small vacuum on the entire evaporative emissions system.

Conditions for setting the DTC B The Ignition is “ON”. B Engine is running. B System voltage is between 11.5 volts and 16 volts.

B DTC P0448 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the EVAP vent valve display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0448 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0448 Diagnostic Chart may isolate the cause of the fault.

6E–334

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0448 EVAP Vent Solenoid Circuit Short Step

Action

Value(s)

Go to Step 3

—

Go to Step 4

Go to Step 5

—

Verify repair

—

21.8-28.5W (at 68°F{20°C})

Go to Step 7

Go to Step 6

—

Verify repair

—

Verify repair

—

Repair the circuit as necessary. Check the canister vent solenoid valve. Using a DVM, measure resistance for purge solenoid valve connector terminal. Is the vent solenoid valve resistance within the specified values? Replace the canister vent solenoid valve. Is the action complete?

Refer to Diagnostic Aids

Ignition is “OFF”. Disconnect the canister vent solenoid valve. Disconnect the PCM. Check the circuit between EVAP vent solenoid connector and PCM connector.

Is the action complete?

Go to Step 2

Check the signal circuit for canister vent solenoid valve.

Is the problem found?

— 1. Install the Tech 2. 2. Ignition is “ON”, 3. Observe the EVAP vent solenoid reading on the Tech 2.

1. 2. 3. 4.

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed?

Is the EVAP vent solenoid reading near the specified value? 3

Yes

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–335

Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage

060R200050

Circuit Description The powertrain control module (PCM) monitors fuel tank pressure sensor (Vapor pressure sensor) of the Enhanced Evap system. When the tank pressure output indicates low voltage, PCM will set DTC P0452.

Conditions for Setting the DTC B Tank sensor output is less than 0.2 volts for 12.5 sec. B 100 test failures within a 200 tests.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

B A history DTC P0402 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0404 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Open circuit of 5 volt reference line – Inspect wiring harness from PCM to the sensor. The PCM turns P0452, and P0107 at the same time. B Open circuit or short circuit to ground line – Inspect wiring harness from PCM to the sensor. The PCM turns P0452 and P0107 at the same time. B Tank fuel pressure sensor malfunction may cause P0452. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

6E–336

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0452 – Tank Pressure Sensor Low Voltage Step

Action

1. 2. 3. 4.

1. Ignition “ON” 2. At the PCM connector, backprobe with a DVM at the sensor output for the voltage. At the sensor output terminal, backprobe with a DVM at the sensor output Was voltage within range?

—

P0452/P0107 turn on Go to Step 3 P0452 turns on Go to Step 6

Refer to Diagnostic Aids

4–6 V

Go to Step 4

Go to Step 10

4–6 V

For P0452 go to Step 5 and for P0107, go to diagnosis section.

Go to Step 5

—

Verify repair

—

Less than 0.2 V

Go to Step 7

Go to Step 10

Less than 0.2 V

Go to Step 9

Go to Step 8

—

Verify repair

—

1. Locate open wiring of 5 volt reference circuit from the PCM to fuel tank pressure sensor. 2. Repair wiring harness.

Was voltage within the range? 7

Go to Step 2

1. Ignition “OFF”. 2. Connect the PCM connector to the PCM. 3. Backprobe with a DVM at fuel tank pressure sensor between 5 V reference terminal and sensor ground terminal.

Is the action complete? 6

—

Ignition “OFF”. Disconnect connector at the PCM. Ignition “ON”. At the PCM connector, measure voltage with a DVM at F54 and S37 terminals.

Was the voltage within range? 5

Go to OBD System Check

Was the voltage in range? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Tech 2 indicates DTC P0452 or P0452/P0107 failed this ignition? 3

Value(s)

1. Locate open circuit or short circuit to ground line. 2. Repair the harness. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–337

DTC P0452 – Tank Pressure Sensor Low Voltage (Cont’d) Step

Action

Yes

1. Locate open circuit or short circuit to ground line. 2. Repair the harness. Is the action complete?

Value(s)

—

Verify repair

—

Verify repair

—

6E–338

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage

060R200050

Conditions for Setting the DTC B Tank sensor output is more than 4.9 volts for 12.5 sec. B 100 test failures within a 200 tests.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

B A history DTC P0453 will clear after 40 consecutive warm-up cycles have occurred without a fault. B Info function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Open circuit of sensor ground line – Inspect wiring harness from PCM to the sensor. The PCM turns P0453, and P0108 at the same time. B Open circuit or short circuit to 5 volt reference line – Inspect wiring harness from PCM to the sensor. The PCM turns P0453 and P0108 at the same time. B Tank fuel pressure sensor malfunction may cause P0453. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–339

DTC P0453 – Fuel Tank Pressure Sensor High Voltage Step

Action

1. 2. 3. 4.

1. Ignition “ON”. 2. At the PCM connector, backprobe with a DVM at the sensor output for the voltage. At the sensor output terminal, backprobe with a DVM at the sensor output. Was the voltage within range?

—

P0453/P0108 turn on Go to Step 3 P0452 turns on Go to Step 6

Refer to Diagnostic Aids

4–6 V

Go to Step 4

Go to Step 10

4–6 V

For P0453 go to Step 6 and for P0108, go to diagnosis section.

Go to Step 5

—

Verify repair

—

More than 4.9 V

Go to Step 7

Go to Step 10

More than 4.9 V

Go to Step 9

Go to Step 8

—

Verify repair

—

1. Locate open wiring of ground line from the PCM to fuel tank pressure sensor. 2. Repair wiring harness.

Was voltage within range? 7

Go to Step 2

1. Ignition “OFF”. 2. Connect the PCM connector to the PCM. 3. Disconnect sensor harness at fuel pressure sensor. Measure voltage with a DVM at the end of the tank pressure wiring between 5 V reference terminal and sensor ground terminal.

Is the action complete? 6

—

Ignition “OFF”. Disconnect connector at the PCM. Ignition “ON”. At the PCM connector, measure voltage with a DVM at F54 and S37 terminals.

Was the voltage within range? 5

Go to OBD System Check

Was the voltage in range of voltage? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the Tech 2 indicates DTC P0452 or P0452/P0107 failed this ignition? 3

Value(s)

1. Locate open circuit or short circuit to ground line. 2. Repair the harness. Is the action complete?

6E–340

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0453 – Fuel Tank Pressure Sensor High Voltage (Cont’d) Step

Action

Yes

Replace the tank pressure sensor. Is the action complete?

Value(s)

—

Verify repair

—

Verify repair

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–341

Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak

060R200050

Circuit Description

Conditions for setting the DTC

The evaporative system includes the following components: B Fuel tank B EVAP canister vent solenoid B Fuel tank (vapor) pressure sensor B Vapor lines B Fuel cap B Evaporative emissions canister B Purge lines B EVAP canister purge solenoid The evaporative leak detection diagnostic strategy is based on applying vacuum to the EVAP system and monitoring vacuum decay. The powertrain control module(PCM)monitors vacuum level via the fuel tank pressure sensor input. At an appropriate time, the EVAP canister purge solenoid and the EVAP canister vent solenoid are turned “ON”, allowing engine vacuum to draw a very small look on the entire evaporative emissions system. After the desired vacuum level has been achieved, the EVAP canister purge solenoid is turned “OFF”, sealing the system. A leak is detected by monitoring for a decrease in vacuum level over a given time period, all other variables remaining constant. A very small leak in the system will cause DTC P0456 to be set.

B B B B B B B B B B B

No MAP DTC’s set. No TPS DTC’s set. No IAT DTC’s set. No ECT DTC’s set. No tank pressure sensor DTC’s set. Baro is more than 70KPa. Fuel level is between 40% and 80%. Throttle angle is less than 3%. Engine speed is less than 1200 RPM. Vehicle speed is less than 5 mph (8 km/h). A vacuum decay condition, indicating a very small leak, is detected during the diagnostic test.

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. B The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data. Warm up cycles have occurred without a fault.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B A history DTC P0456 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault. B DTC P0456 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Cracked or punctured EVAP canister. B Damaged source vacuum line, EVAP purge line, EVAP vent hose or fuel tank vapor line. to wire connection. B Poor connection at PCM–Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness to the EVAP canister purge solenoid and the fuel tank pressure sensor for an intermittent open or short circuit. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–343

Diagnostic Trouble Code(DTC)P0456 EVAP Very Small Leak Step

Action

Value(s)

1. 2. 3. 4.

Go to Step 2

1.51V

Go to Step 3

Go to Fuel Tank Pressure System

—

Verify repair

Go to Step 4

—

Go to Step 5

Refer to Diagnostic Aids

—

Refer to Diagnostic Aids

Go to Step 6

—

Verify repair

Go to Step 7

Verify repair

Refer to Diagnostic Aids

Ignition “OFF”. Remove the fuel cap. Ignition “ON”. Observe “Fuel Tank Pressure” on the Tech 2.

Does the Tech 2 indicate “Fuel Tank Pressure” at the specified value? 3

1. Visually/physically check for the following conditions: B Vent hose disconnected or damaged. B EVAP canister damaged. B Fuel cap damaged 2. If a problem is found, repair as necessary. Was a problem found?

1. 2. 3. 4.

Ignition “ON”, engine “OFF”. Install the fuel cap. Review and record Tech 2 Failure Records data. Operate the vehicle within Failure Records conditions as noted. 5. Using theTech 2,monitor the “DTC” info for DTC P0456. Does the Tech 2 indicate DTC P0456?

1. Ignition “ON”, engine idling. 2. Observe “Fuel Tank Pressure” on the Tech 2. Does the Tech 2 indicate “Fuel Tank Pressure” at the specified value?

1. Ignition “ON”, engine idling. 2. Using theTech 2, command the EVAP canister vent solenoid “ON” (closed) 3. Observe “EVAP canister vent solenoid operation” second value? 4. If a problem is found, repair as necessary. Was a problem found?

Go to OBD System Check

Was the “On-Board(OBD)System Check” performed? —

Yes

1. Visually/physically check for the following conditions: B Disconnected or leaking fuel tank vapor line. B Disconnected or damaged EVAP purge line. 2. If a problem is found, repair as necessary. Was a problem found?

—

6E–344

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0461 Fuel Level Sensor Performance

060RY00163

Circuit Description The fuel level sensor is an important input to powertrain control module (PCM) for the enhanced evaporative system diagnostic. Fuel level information is needed for the PCM to know the volume of fuel in the tank. The fuel level affects the rate of change in air pressure in the evaporative system. The sending unit is a float in the fuel tank which moves a wiper arm across a variable resistor. Low fuel level causes high resistance in the sending unit, and this is recognized by the PCM because the circuit operates at a corresponding low voltage. When the circuit is continuously open or has a high resistance connection, DTC P0461 is set.

Conditions for Setting the DTC B Sensor output change is more than 2% within 200km. Or Sensor movement position change is less than 15% within 200km. B IAT is more than 0°C. B MAP changing in 3 sec is less than 10kPa. B Engine speed changing in 3 sec is less than 50rpm.

When there are 12 test failures within 80 test samples, it is stored.

Conditions for Clearing the DTC B DTC P0461 can be cleared by using the scan tool “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids B Damaged harness–Inspect the wiring harness for damage. If the harness appears to be OK, observe the fuel level display on the scan tool while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–345

DTC P0461– Fuel Level Sensor Performance Step

Action

1. 2. 3. 4.

—

Go to Step 2

Go to OBD System Check

—

Go to applicable DTC table

Go to Step 3

—

Go to DTC P464 table

Go to Step 4

—

Verify repair

—

Ignition “Off”, Engine “Off”. Install Tech 2. Ignition “On”, Engine “Off”. Check DTC P0462, P0463.

Check DTC P0464. Was the DTC stored?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Was the DTC stored? 3

Value(s)

1. Ignition “Off”, Engine “Off”. 2. Replace the fuel level sensor. Was the action complete?

6E–346

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit–Low Voltage

060RY00163

Circuit Description

Action Taken When the DTC Sets

The fuel level sensor is an important input to powertrain control module (PCM) for the enhanced evaporative system diagnostic. Fuel level information is needed for the PCM to know the volume of fuel in the tank. The fuel level affects the rate of change in air pressure in the evaporative system. Several of the enhanced evaporative system diagnostic sub-tests are dependent upon correct fuel level information. The diagnostic will not run when the tank is more than 85% or less than 15% full. Fuel level DTCs should be diagnosed before other evaporative system DTCs because they can cause other DTCs to be set. The sending unit is a float in the fuel tank which moves a wiper arm across a variable resistor. Low fuel level causes high resistance in the sending unit, and this is recognized by the PCM because the circuit operates at a corresponding low voltage. When the circuit is continuously open or has a high resistance connection, DTC P0462 is set.

B The PCM will ON the MIL after second trip with detected the fault. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Setting the DTC B B B B B

Fuel tank level “slosh test” is completed. Fuel tank level “main test” is completed. Fuel tank level data is valid. Fuel tank level signal is less than a specified value. There are 100 test failures within a 200-test sample.

Conditions for Clearing the DTC B The PCM will turn the MIL “OFF” after three consecutive trips without a fault condition present. A history DTC will be cleared if no fault conditions have been detected for 40 warm-up cycles (engine coolant temperature has risen 4°C (40°F) from the start-up ECT, and ECT exceeds 71°C (160°F) during that same ignition cycle). B DTC P0462 can be cleared by using the scan tool “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 8. The following chart can be used to check the sending unit:

6E–347

6E–348

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0462– Fuel Level Sensor Circuit –Low Voltage Step

Action

Go to Step 6

Go to Step 3

Go to Step 4

Go to Step 9

—

Go to Step 5

Go to Step 9

—

Verify repair

—

Go to Step 7

Go to Step 9

—

Verify repair

—

Verify repair

—

Verify repair

—

Remove the fuel level sensor and check the following: B Does the arm move freely? B Are the wires open or intermittently open when wiggled? B Do the resistance values match the specification chart? Replace the fuel level sensor. Is the action complete?

Check for open or high resistance connection in the ground wire between the PCM and the fuel level sensor.

Was a problem found? 7

Go to Step 2

1. Ignition “ON”, engine “OFF”. 2. Fuel level sensor disconnected from wiring harness. 3. With a DVM, probe the 5-volt supply wire at the sensor harness.

Is the action complete? 6

—

Go to OBD System Check

1. Ignition “ON”, engine “OFF”. 2. With a DVM, backprobe the PCM connector at the terminal which supplies 5 volts to the fuel level sensor.

Is the voltage approximately equal to the value measured in Step 4? 5

1. Disconnected the fuel level sensor harness from its connector at the fuel tank. 2. Ignition “ON”, engine “OFF”. 3. Using a DVM, measure the voltage between the sensor harness positive and ground wires.

Is the voltage approximately equal to the specified value? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is the voltage approximately equal to the specified value? 3

Value(s)

Short to ground between the PCM connector and the fuel level sensor. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–349

Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit–High Voltage

060RY00163

Circuit Description

Action Taken When the DTC Sets

The fuel level sensor is an important input to powertrain control module (PCM) for the enhanced evaporative system diagnostic. Fuel level information is needed for the PCM to know the volume of fuel in the tank. The fuel level affects the rate of change in air pressure in the evaporative system. Several of the enhanced evaporative system diagnostic sub-tests are dependent upon correct fuel level information. The diagnostic will not run when the tank is more than 85% or less than 15%, full. Fuel level DTCs should be diagnosed before other evaporative system DTCs because they can cause other DTCs to be set. The sending unit is a float in the fuel tank which moves a wiper arm across a variable resistor. High fuel level causes low resistance in the sending unit. This is recognized by the PCM because the circuit operates at a corresponding high voltage. When the circuit is continuously shorted to a voltage source greater than a specified value, or when the 5 volt signal is shorted to ground, DTC P0463 is set.

B The PCM will ON the MIL after second trip with detected the fault. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Setting the DTC B B B B B

Fuel tank level “slosh test” is completed. Fuel tank level “main test” is completed. Fuel tank level data is valid. Fuel tank level signal is greater than a specified value. There are 100 test failures within a 200-test sample.

Conditions for Clearing the DTC B The PCM will turn the MIL “OFF” after three consecutive trips without a fault condition present. A history DTC will be cleared if no fault conditions have been detected for 40 warm-up cycles (engine coolant temperature has risen 4°C (40°F) from the start-up ECT, and ECT exceeds 71°C (160°F) during that same ignition cycle) or the scan tool clearing function has been used. B DTC P0463 can be cleared by using the scan tool “Clear Info” function or by disconnecting the PCM battery feed.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids

Test Description

B Damaged harness–Inspect the wiring harness for damage. If the harness appears to be OK, observe the fuel level display on the scan tool while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault.

Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. The ETC and MAP sensors share a ground at PCM terminal D9. 9. Equates the resistance values at various float positions to the following fuel gauge readings:

DTC P0463– Fuel Level Sensor Circuit –High Voltage Step

Action

—

Go to Step 2

Go to Step 8

Go to Step 3

—

Go to Step 4

Go to Step 5

—

Verify repair

—

Does the DVM indicate a voltage greater than the specified value?

Go to Step 4

Go to Step 6

Open circuit between the PCM connector and the fuel level sensor?

—

Verify repair

Go to Step 7

—

Verify repair

—

Go to Step 9

Go to Step 7

—

Verify repair

—

With the negative DVM lead connected to ground, use the positive DVM lead to probe the sensor ground wire with the harness still disconnected. Repair short to voltage between the sensor and the PCM. Is the repair complete?

6 7

Go to OBD System Check

Does the DVM indicate a short to a voltage source? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Is the voltage approximately equal to the specified value? 3

Value(s)

With the negative DVM lead connected to ground, use the positive DVM lead to probe the sensor positive wire with the harness still disconnected.

Remove the fuel level sensor and check the following: B Does the arm move freely? B Are the wire leads shorted together? B Do the resistance values match the specification chart? Was a problem found?

Replace the fuel level sensor. Is the repair complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–351

Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Noisy Signal

060RY00163

Conditions for Setting the DTC B B B B B

Sensor output changing is more than 15%. Fuel volume level is more than 0.01%. IAT is more than 0°C. Vehicle speed is more than 1km/h. Throttle position is more than 2%.

When there are 12 test failures within 80 test samples, it is stored.

Conditions for Clearing the DTC B DTC P0464 can be cleared by using the scan tool “Clear Info” function or by disconnecting the PCM battery feed.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0464 – Fuel Level Sensor Noisy Signal Step

Action

—

Go to Step 2

Go to OBD System Check

—

Verify repair

Go to Step 3

—

Go to Step 4

Go to Step 5

—

Verify repair

Go to Step 5

—

Verify repair

—

1. Disassemble fuel tank on the vehicle. 2. Check the below items. B Fuel sender Replace the Fuel sender. Was the action complete?

1. Ignition “Off”, Engine “Off”. 2. Perform “Visual/Physical Check” for following points. B Lose harness connector B Clacked harness connector B Poor wire condition B Fuel tank condition B Poor sensor condition 3. If a problem is found, repair as necessary.

Was a problem found? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Was a problem found? 3

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–353

Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input

060R200056

Circuit Description

Conditions for Clearing the MIL/DTC

The vehicle speed sensor has a magnet rotated by the transmission output shaft. Attached to the sensor is a hall effect circuit the interacts with the magnetic field treated by the rotating magnet. A 12-volt operating supply for the speed sensor hall circuit is supplied from the meter fuse. The VSS pulses to ground the 9-volt signal sent from the powertrain control module (PCM) on the reference circuit. The PCM interprets vehicle speed by the number of pulses to ground per second on the reference circuit.

B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0502 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0502 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

Number(s) below refer to the step number(s) on the Diagnostic Chart. 10. To avoid backprobing the VSS and possibly damaging a seal or terminal, the VSS output can be tested at the point where the transmission harness connects to the engine harness. Power and ground are applied by jumpers to the VSS through the connectors which are located to the rear of the air cleaner assembly. The VSS signal is monitored with a DVM as the rear driveshaft turns. The wheels can be turned to rotate the driveshaft, or in 2-wheels-drive vehicles the driveshaft can be turned directly.

B B B B B

Engine is running. Engine speed is between 1800 RPM and 2500 RPM. Throttle angle is between 10% and 40%. Engine load is greater than 50 kPa. PCM detects no VSS signal for 12.5 seconds over a period of 15 seconds.

Test Description

6E–354

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0502 – VSS Circuit Low Input Step

Action

Does the speedometer work?

1. Disconnect the VSS connector. 2. Ignition “ON”. 3. Using a test light to battery +, probe the connector ground wire. Did the light illuminate?

1. Ignition “ON”, sensor disconnected. 2. Using a DVM, measure at the VSS connector between ground and voltage supply. Was the measurement near the specified value?

—

Go to Step 10

Go to Step 3

—

Go to Step 5

Go to Step 4

—

Verify repair

—

Battery voltage

Go to Step 7

Go to Step 6

—

Verify repair

—

7.5-8 V

Go to Step 9

Go to Step 8

—

Verify repair

Go to Step 9

—

Verify repair

—

Check for an open or short circuit between the speedometer and the VSS. Was an open or short circuit located?

Go to Step 2

1. Ignition “ON”, VSS disconnected. 2. Using a DVM, measure at the VSS connector between ground and the wire from the speedometer. Was the measurement near the specified value?

—

Go to OBD System Check

Repair the open or short to ground which may have blown the meter fuse. Is the action complete?

Repair the sensor ground. Is the action complete?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

Replace the speedometer. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–355

DTC P0502 – VSS Circuit Low Input (Cont’d) Step

Action

1. Ignition “OFF”. 2. Disconnect the MAF sensor. The connector attaches the VSS wires from the transmission harness to the left-side engine harness. 3. Disconnect the black 16-way connector. 4. Select a terminal adapter from kit J 35616 that can be used with a jumper to supply B+ to the blue wire with a yellow tracer (transmission side of the connector). 5. Use another terminal adapter to attach a voltmeter to the light-green wire with a white tracer (next to the wire in the previous step.) 6. Disconnect the blue connector next to the black 16-way connector, and locate the black/red tracer wire at one corner of the blue connector. The black/red wire is the VSS ground. Use a terminal adapter to attach a jumper to ground to the black/red VSS ground wire at the transmission side of the blue connector. 7. Raise the rear wheels off the ground with transmission in neutral. Does the DVM toggle back and forth between 0.6 V and 10 V as the wheels (and driveshaft) are rotated?

—

Go to Step 11

Go to Step 12

—

Verify repair

—

Verify repair

Go to Step 13

—

Verify repair

—

Check for an open or short between the PCM and the speedometer. Was a problem found?

Yes

Replace the VSS. Is the action complete?

Value(s)

Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. ANd also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6E–356

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM

060R200057

Circuit Description The powertrain control module (PCM) controls engine speed by adjusting the position of the throttle control valve (DC motor). The throttle motor is a DC motor driven by one coil. The PCM applies current to the DC motor coil in position (%) to adjustment the throttle valve into a passage in the throttle body to air flow. This method allows highly accurate control of engine speed and quick response to changes in engine load. If the PCM detects a condition where too low of an idle speed is present and the PCM is unable to adjust idle speed by increasing the throttle position, DTC P0506 will set, indicating a problem with the idle control system.

Conditions for Setting the DTC B No TPS, VSS, ECT, EGR, MAF, MAP, IAT, low voltage, fuel system, canister purge, injector control, or ignition control DTCs are set. B MAP is less than 60 kPa. B Canister purge duty cycle is above 10%. B Engine running time is more than 125 seconds. B Vehicle speed is less than 1 mph. B Engine coolant temperature (ECT) is above 50°C (122°F). B Ignition voltage is between 9.5 volts and 16.7 volts. B The throttle is closed. B EVAP purge duty cycle more than 10%. B All conditions are met for 10 seconds. B Barometric pressure is more than 74.5 kPa.

B Engine speed is more than 100-200 RPM lower than desired idle based upon coolant temperature.

Conditions for Clearing the MIL/DTC B DTC P0506 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Poor connection at PCM or throttle DC motor – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. B Restricted air intake system – Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. B Throttle body – Check for objects blocking the ETC passage or throttle bore, excessive deposits in the

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS ETC passage and on the ETC position, and excessive deposits in the throttle bore and on the throttle plate. B Large vacuum leak – Check for a condition that causes a large vacuum leak, such as an incorrectly installed or faulty PCV valve or brake booster hose disconnected.

6E–357

DTC P0506 – Idle Air Control System Low RPM Step

Action

—

Go to Step 2

—

Refer to appropriate section for on–vehicle service

Go to Step 3

—

Refer to appropriatese ction for on-vehicle service

Go to Step 4

—

Verify repair

Go to Step 7

Verify repair

Go to Step 6

Visually/physically inspect for the following conditions: B Acceleration pedal tampering. B Acceleration pedal : Check for objects blocking the spring or pedal arm. B Acceleration pedal : Check for objects move the acceleration pedal that pedal is smooth movement, and acceleration pedal arm has not excessive play. 1. Check for a poor connection at the throttle body harness connector. 2. Check for a poor connection at the acceleration position sensor harness connector. 3. If a problem is found, replace faulty terminals as necessary. Was a problem found?

Go to OBD System Check

Do any of the above require a repair? 4

Yes

Was the “On-Board (OBD) System Check” performed?

Do any of the above require a repair? 3

Value(s)

Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: B Throttle position sensor 1 circuit. B Throttle position sensor 2 circuit. B Throttle DC motor circuit. Vcc-GND 1–7kW B Throttle position sensor resistance. SIG-DND B Throttle DC motor resistance. change B If a problem is found, repair as necessary. resistance0.3 – 100W Was a problem found?

6E–358

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P0506 – Idle Air Control System Low RPM (Cont’d) Step

Action

Sensor resistance. 2. If a problem is found, repair as necessary. Was a problem found?

—

Go to Step 3

—

Vcc-GND 4–6kW SIG-DND change resistance

Verify repair

Go to Step 8

—

Go to Step 9

—

Go to applicable DTC table

Go to Step 10

—

Go to applicable DTC table

Go to Step 11

—

Verify repair

—

Replace the acceleration position sensor. Is the action complete?

1. Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: Accelerator position sensor 1 circuit. Accelerator position sensor 2 circuit.

Yes

Replace the throttle valve. Is the action complete?

Value(s)

Following below the DTCs stored: P1125, P1290, P1295, P1299 Following below the DTCs stored:P1514, P1515, P1516, P1523, P1271, P1272, P1273 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–359

Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM

060R200057

Circuit Description The powertrain control module (PCM) controls engine speed by adjusting the position of the throttle control valve (DC motor). The throttle motor is a DC motor driven by one coil. The PCM applies current to the DC motor coil in position (%) to adjustment the throttle valve into a passage in the throttle body to air flow. This method allows highly accurate control of engine speed and quick response to changes in engine load. If the PCM detects a condition where too high of an idle speed is present and the PCM is unable to adjust idle speed by increasing the throttle position, DTC P0507 will set, indicating a problem with the idle control system.

Conditions for Setting the DTC B No TPS, VSS, ECT, EGR, MAF, MAP, IAT, low voltage, fuel system, canister purge, injector control or ignition control DTCs are set. B Barometric pressure is above 75 kPa. B Canister purge duty cycle is above 10%. B Engine running time is more than 125 seconds. B Vehicle speed is less than 1 mph. B Engine coolant temperature (ECT) is above 50°C (122°F). B Ignition voltage is between 9.5 volts and 16.7 volts. B The throttle is closed. B EVAP purge duty cycle is more than 10%.

B All conditions are met for 10 seconds. B Engine speed is more than 100-200 RPM higher than desired idle based upon coolant temperature. B Barometric pressure is more than 74.5 kPa.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0507 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0507 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–360

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. B Vacuum leak – Check for a condition that causes a vacuum leak, such as disconnected or damaged hoses, leaks at EGR valve and EGR pipe to intake manifold, leak at the throttle body, a faulty or incorrectly installed PCV valve, leaks at the intake manifold, etc.

B Throttle body – Check for sticking throttle plate. Also inspect the air passage for deposits or objects which will not allow the ETC position to fully extend or properly seat. If DTC P0507 cannot be duplicated, reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

DTC P0507 – Idle Air Control System High RPM Step

Action

—

Go to Step 2

Go to OBD System Check

—

Refer to appropriate section for on-vehicle service

Go to Step 4

—

Refer to appropriate section for on-vehicle service

Go to Step 4

—

Verify repair

Go to Step 7

Visually/physically inspect for the following conditions: B Throttle body tampering. B Restricted intake throttle system. Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. B Throttle body: Check for objects blocking the throttle passage or throttle bore, excessive deposits in the throttle passage and on the throttle valve, and excessive deposits in the throttle bore and on the throttle plate. B Throttle body with lever: Check for objects send round the throttle spring lever that lever is smooth movement, and spring lever has not excessive play Visually/physically inspect for the following conditions: B Accelerator pedal tampering. B Accelerator pedal : Check for objects blocking the spring or pedal arm. B Accelerator pedal : Check for objects move the accelerator pedal that pedal is smooth movement, and accelerator pedal arm has not excessive play. Do any of the above require a repair?

Yes

Was the “On-Board (OBD) System Check” performed?

Do any of the above require a repair? 3

Value(s)

1. Check for a poor connection at the throttle body harness connector. 2. Check for a poor connection at the accelerator position sensor harness connector. 3. If a problem is found, replace faulty terminals as necessary. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–361

DTC P0507 – Idle Air Control System High RPM (Cont’d) Step

Action

Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: B Throttle position sensor 1 circuit. B Throttle position sensor 2 circuit. B Throttle DC motor circuit. Vcc-GND 1–7kW B Throttle position sensor resistance. SIG-GND B Throttle DC motor resistance. change B If a problem is found, repair as necessary. resistance 0.3 – 100W Was a problem found?

1. Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: B Accelerator position sensor 1 circuit. B Accelerator position sensor 2 circuit. B Sensor 3 circuit. B Sensor resistance. 2. If a problem is found, repair as necessary. Was a problem found?

Verify repair

Go to Step 6

—

Go to Step 3

—

Vcc-GND 4–6kW SIG-GND change resistance

Verify repair

Go to Step 8

—

Go to Step 9

—

Go to applicable DTC table

Go to Step 10

—

Go to applicable DTC table

Go to Step 11

—

Verify repair

—

Replace the accelerator position sensor. Is the action complete?

Yes

Replace the throttle valve. Is the action complete?

Value(s)

Stored DTCs: P1125, P1290, P1295, P1299

Stored DTCs: P1514, P1515, P1516, P1523, P1271, P1272, P1273 Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. ANd also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6E–362

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0562 System Voltage Low

060R200058

Circuit Description

Conditions for Clearing the MIL/DTC

The powertrain control module (PCM) monitors the system voltage on the ignition feed terminal to the PCM. A system voltage DTC will set whenever the voltage is below a calibrated value.

B A history DTC P0562 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0562 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC B Ignition “ON”. B System voltage is below 11.5 volts for 40 seconds.

Action Taken When the DTC Sets B The PCM will not illuminate the malfunction indicator lamp (MIL). B The PCM will store as Failure Records conditions which were present when the DTC was set. This information will not be stored as Freeze Frame data.

Diagnostic Aids If the DTC sets when an accessory is operated, check for a poor connection or excessive current draw.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–363

DTC P0562 – System Voltage Low Step

Action

Value(s)

Go to Step 2

Go to Step 3

Charge battery, then go to Step 3

2000 RPM 12.8-14.1 V

Go to Step 4

Go to Starting/Char ging

—

Go to Step 5

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 7

—

Verify repair

—

Using a DVM, measure the battery voltage at the battery. Is the battery voltage greater than the specified value?

1. Ignition “OFF”. 2. Disconnect the PCM connector at the PCM. 3. Using a DVM, measure the battery voltage at the PCM connector F-20 and F-57. Is it approximately equal to battery voltage?

1. Check for faulty connections at the PCM harness terminals. 2. Repair as necessary. Was a repair necessary?

Check for an open battery feed circuit to the PCM. Is the action complete?

11.5 V

1. Install a Tech 2. 2. Select “Ignition Volts” on the Tech 2. 3. Start the engine and raise the engine speed to the specified value. 4. Load the electrical system by turning on the headlights, high blower, etc. Is the ignition voltage approximately equal to the specified value?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

6E–364

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0563 System Voltage High

060R200058

Circuit Description

Conditions for Clearing the MIL/DTC

The powertrain control module (PCM) monitors the system voltage on the ignition feed terminals to the PCM. A system voltage DTC will set whenever the voltage is above a calibrated value.

B A history DTC P0563 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0563 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC B Ignition “ON”. B System voltage is above 16 volts for 40 seconds.

Diagnostic Aids If the DTC sets when an accessory is operated, check for a poor connection or excessive current draw.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–365

DTC P0563 – System Voltage High Step

Action

—

Go to Step 2

Go to OBD System Check

11.5 V

Go to Step 3

Go to Step 4

11.5 V

Replace battery

Go to Step 4

2000 RPM

Go to Starting/ Charging

Go to Step 5

—

Verify repair

—

1. Charge the battery and clean the battery terminals. 2. Clean the battery ground cable connection if corrosion is indicated. 1. 2. 3. 4.

Turn “OFF” all the accessories. Install a Tech 2. Select the ignition voltage parameter on the Tech 2. Start the engine and raise the engine RPM to the specified value.

Is the voltage more than 2.5 volts greater than the measurement taken in step 2 or 3? 5

Using a DVM, measure the battery voltage at the battery.

Is the battery voltage less than the specified value? 4

Yes

Was the “ON-Board Diagnostic (OBD) System Check” performed?

Is the battery voltage less than the specified value? 3

Value(s)

6E–366

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0565 Cruise Main Switch Circuit Error

060R100094

Circuit Description

Action Taken When the DTC Sets

The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received. When the main switch is turned on with the vehicle in the running mode, the battery voltage is applied to power train control module(PCM). When a signal from the control switch is input to PCM while the vehicle is in this state, the cruise control system is activated. Also, while the PCM is operating, the “CRUISE MAIN” indicator light in the meter assembly lights up.

B The PCM will not illuminate the malfunction indicator lamp (MIL). B The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for setting the DTC B B B B B

The Ignition is “ON’’. Engine is running. System voltage is between 11.5 volts and 16 volts. The switch contact remains on for 15 seconds or more. Noises are generated by poor switch contact 60 times within 1 second.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0565 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault. B DTC P0565 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following:

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B Poor connections. B Mis routed harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the

6E–367

cruise main switch display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0565 cannot be duplicated, the information included n the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P0565 Diagnostic Chart may isolate the cause of the fault.

DTC P0565 Cruise Main Switch Circuit Error Step

Action

Value(s)

—

Go to Step 2

—

Go to Step 3

Go to Step 4

—

Go to Diagnostic Aids

Go to Step 4

—

Go to Step 5

Go to Step 6

—

Verify repair

—

Go to Step 7

Go to Step 8

—

Verify repair

—

Verify repair

—

1. Ignition “ON,” engine “ON.” 2. Observe the cruise main lamp in the switch. 1. Push the auto cruise main switch. 2. Observe the cruise main lamp in the switch. Is the cruise main lamp “OFF?”

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed?

Is the cruise main lamp “ON?” 3

Yes

Check the signal circuit for auto cruise main switch. 1. Ignition is “OFF”. 2. Disconnect the powertrain control module(PCM). 3. Disconnect the cruise main switch. Check for an open cruise main switch signal circuit between the PCM and the cruise main switch. Is a problem found?

Repair the auto cruise main switch signal circuit. Is the action complete?

Check the auto cruise main switch and lamp circuit. Is a problem found?

Repair or replace the auto cruise main switch and lamp circuit. Is the action complete?

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6E–368

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0566 Cruise Cancel Switch Circuit Error

060R100094

Circuit Description The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received. When the main switch is turned on with the vehicle in the running mode, the battery voltage is applied to powertrain control module(PCM). When a signal from the control switch is input to PCM while the vehicle is in this state, the cruise control system is activated. Also, while the PCM is operating, the “CRUISE MAIN” indicator light in the meter assembly lights up. When the cancel switch is “ON”, cruise system is “OFF”.

Conditions for setting the DTC B B B B

The Ignition is “ON”. Engine is running. System voltage is between 11.5 volts and 16 volts. The switch contact remains on for 40 seconds or more.

B Noises are generated by poor switch contact 100 times within 1.6 seconds.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B DTC P0566 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–369

B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the cruise cancel switch display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0566 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTCP0566 Diagnostic Chart may isolate the cause of the fault.

DTC P0566 Cruise Cancel Switch Circuit Error Step

Action

Value(s)

Yes

—

Go to Step 2

Go to OBD System Check

—

Go to Step 3

Go to Step 4

—

Verify repair

—

Go to Step 5

Go to Step 6

—

Verify repair

—

Verify repair

—

Was the “On-Board (OBD) System Check” performed?

Check the signal circuit for auto cruise cancel switch. 1. Ignition is “OFF”. 2. Disconnect the powertrain control module(PCM). 3. Disconnect the cruise cancel switch. Check for cruise cancel switch signal circuit between the PCM and the cruise cancel switch. Is a problem found?

Repair the main cruise cancel switch signal circuit. Is the action complete?

Check the auto cruise main switch. Is a problem found?

Repair or replace the main cruise main switch. Is the action complete?

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6E–370

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0567 Cruise Resume Switch Circuit Error

060R200086

Circuit Description The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received. When the main switch is turned on with the vehicle in the running mode, the battery voltage is applied to powertrain control module(PCM). When a signal from the control switch is input to PCM while the vehicle is in this state, the cruise control system is activated. Also, while the PCM is operating, the “CRUISE MAIN” indicator light in the meter assembly lights up. When the resume switch is “ON”, vehicle speed is reset to the previous set speed.

Conditions for setting the DTC B B B B

The Ignition is “ON”. Engine is running. System voltage is between 11.5 volts and 16 volts. The switch contact remain on for 50 seconds or more.

B Noises are generated by poor switch contact 100 times within 1.6 seconds.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0567 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P0567 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–371

If the harness appears to be OK, observe the Cruise resume switch display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0567 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTCP0567 Diagnostic Chart may isolate the cause of the fault.

DTC P0567 Cruise Resume Switch Circuit Error Step

Action

Value(s)

Go to Step 2

Go to OBD System Check

Go to Step 3

Go to Step 4

—

Verify repair

—

Go to Step 5

Go to Step 6

—

Verify repair

—

Verify repair

—

Was the “On-Board (OBD) System Check” performed? —

Yes

Check the signal circuit for auto cruise resume switch. 1. Ignition is “OFF”. 2. Disconnect the powertrain control module (PCM). 3. Disconnect the cruise resume switch. Check for cruise resume switch signal circuit between the PCM and the cruise resume switch. Is a problem found?

Repair the main cruise resume switch signal circuit. Is the action complete?

Check the auto cruise resume switch. Is a problem found?

Repair or replace the main cruise resume switch. Is the action complete?

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6E–372

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0568 Cruise Set Switch Circuit Error

060R200086

Circuit Description The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received. When the main switch is turned on with the vehicle in the running mode, the battery voltage is applied to powertrain control module (PCM). When a signal from the control switch is input to PCM while the vehicle is in this state, the cruise control system is activated. Also, while the PCM is operating, the “CRUISE MAIN” indicator light in the meter assembly lights up. When the set switch is “ON”, vehicle speed is set.

Conditions for setting the DTC B B B B

The Ignition is “ON”. Engine is running. System voltage is between 11.5 volts and 16 volts. The switch contact remain on for 120 seconds or more.

B Noises are generated by poor switch contact 100 times within 1.6 seconds.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B DTC P0568 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–373

B Damaged harness–Inspect the wiring harness for damage. If the harness appears to be OK, observe the cruise set switch display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P0568 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTCP0568 Diagnostic Chart may isolate the cause of the fault.

DTC P0568 Cruise Set Switch Circuit Error Step

Action

Value(s)

—

Go to Step 2

—

Go to Step 3

Go to Step 4

—

Go to Diagnostic Aids

Go to Step 5

Go to Step 6

—

Verify repair

—

Go to Step 7

Go to Step 8

—

Verify repair

—

Verify repair

—

1. Ignition “ON,” engine “ON.” 2. Observe the cruise indicator lamp in the meter. 1. Push the auto cruise set switch. 2. Observe the cruise indicator lamp in the meter. Is the cruise indicator lamp “OFF ?”

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed?

Is the cruise indicator lamp “ON?” 3

Yes

Check the signal circuit for auto cruise set switch. 1. Ignition is “OFF”. 2. Disconnect the powertrain control module (PCM). 3. Disconnect the cruise set switch. Check for cruise set switch signal circuit between the PCM and the cruise set switch. Is a problem found?

Repair the main cruise set switch signal circuit. Is the action complete?

Check the auto cruise set switch. Is a problem found?

Repair or replace the main cruise set switch. Is the action complete?

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6E–374

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0571 No Brake Switch Signal

060R100093

Circuit Description

Action Taken When the DTC Sets

The brake switch has 3 functions. B Brake pedal operation check B Brake light operation (On and off) B Cruise control (Cancel) The PCM receives vehicle speed and switch position signals from the brake switch. The PCM sets brake operating conditions in response to these signals. If the brake switch is on, the brake system is in normal operation (cruise control cancelled).

B The PCM will not turn the malfunction indicator lamp (MIL) “ON”. B The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

Conditions for Setting the DTC B Two brake switch signals not acknowledged after signal changed. B VSS not defective. B Engine is running. B Vehicle speed above 20km/h.

Conditions for Clearing the DTC B DTC P0571 can be cleared by using the scan tool “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–375

DTC P01571 No Brake Switch Signal Step

Action

Value(s)

Yes

—

Go to Step 2

Go to OBD System Check

—

Verify repair

Go to Step 3

—

Verify repair

Go to Step 4

—

Verify repair

Go to Step 5

1. Disconnect the connector at brake switch. 2. Check following terminal pin at ohmmeter. (Leave the shaft position at brake switch. Don’t Between pin1 push it.) and pin2 is B Between pin 1 and pin 2 0W, Between B Between pin 3 and pin 4 pin3 and pin4 Was it specified value? is ∞W

Go to Step 6

Go to Step 9

1. Disconnect the connector at brake switch. 2. Check following terminal pin at ohmmeter. (Push the shaft position at brake switch and hold it) Between pin1 and pin2 is B Between pin 1 and pin 2 ∞W, Between B Between pin 3 and pin 4 pin3 and pin4 is 0W Was it specified value?

Go to Step 7

Go to Step 9

—

Verify repair

Go to Step 8

—

Verify repair

—

Verify repair

—

Was the “On-Board Diagnostic (OBD) System Check” performed? 1. Ignition “Off”. Engine “Off”. 2. Check following fuses. B BACK 15A B STOP LAMP 15A Was a problem found?

1. Make adjustment to the brake switch. The brake switch is installed to the brake pedal assembly. (Refer to “Brake switch” in “10A CRUISE CONTROL SYSTEM”.) Was the problem found?

1. Push the shaft at brake switch. 2. Check shaft operation for smooth movements. Was the problem found?

1. Probe related circuits for open or short to ground. 2. If a problem was found, repair as necessary. Was a problem found?

1. Replace the ECM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Was the action completed?

1. Replace the brake switch. Was the action completed?

6E–376

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0601 PCM Memory

060RY014

Circuit Description The powertrain control module (PCM) used in this vehicle utilizes an electrically erasable programmable read-only memory (EEPROM). The EEPROM contains program information and the calibrations required for engine, transmission, and powertrain diagnostics operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. When the PCM is replaced or a calibration update is required, the PCM must be programmed using a Tech 2. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for the EEPROM programming procedure.

B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0601 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0601 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

Diagnostic Aids

B The PCM detects an internal program fault (check sum error).

B DTC P0601 indicates that the contents of the EEPROM have changed since the PCM was programmed. The only possible repair is PCM replacement. Remember to program the replacement PCM with the correct software and calibration for the vehicle.

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–377

DTC P0601 – PCM Memory Step

Action

Value(s)

Yes

—

Go to Step 2

Go to OBD System Check

—

Verify repair

—

Was the “On-Board Diagnostic (OBD) System Check” performed? Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. ANd also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6E–378

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0602 PCM Programming Error

060RY014

Circuit Description The powertrain control module (PCM) uses Main CPU and Watchdog CPU software/calibration.

Conditions for Setting the DTC B This code detects inconsistencies between Main CPU and Watchdog CPU software/calibration.

Action Taken When the DTC Sets B The PCM will not illuminate the malfunction indicator lamp (MIL).

B The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0602 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0602 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–379

DTC P0602 – PCM Programming Error Step

Action

Value(s)

Yes

—

Go to Step 2

Go to OBD System Check

—

Verify repair

—

6E–380

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0604 PCM RAM Error

060RY014

Circuit Description The powertrain control module (PCM) uses Main CPU RAM and Watchdog CPU RAM.

Conditions for Setting the DTC B This code detects inconsistencies between Main CPU RAM and Watchdog CPU RAM.

Action Taken When the DTC Sets B The PCM will not illuminate the malfunction indicator lamp (MIL).

B The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0604 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0604 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–381

DTC P0604 – PCM RAM Error Step

Action

Value(s)

Yes

—

Go to Step 2

Go to OBD System Check

—

Verify repair

—

6E–382

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance

060RY014

Circuit Description

Action Taken When the DTC Sets

The input/output devices in the PCM include analog-to-digital converters, signal buffers, counters, and special drivers. The PCM controls most components with electronic switches which complete a ground circuit when turned “ON”. These switches are arranged in groups of 4 and 7, called either a surface-mounted quad driver module (QDM), which can independently control up to 4 output terminals, or QDMs which can independently control up to 7 outputs.

B The PCM will not illuminate the malfunction indicator lamp (MIL). B The PCM will store conditions which were present when the DTC was set in the Failure Records data only.

Conditions for Setting the DTC B This code detects inconsistencies between Main CPU A/D converters and Watchdog CPU A/D converters.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P0606 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P0606 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–383

DTC P0606 – PCM Internal Performance Step

Action

Value(s)

Yes

—

Go to Step 2

Go to OBD System Check

—

Verify repair

—

6E–384

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage

060R200051

Circuit Description

Action Taken When the DTC Sets

The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the PCM varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition “ON”, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the liner EGR flow test diagnostic is being run (refer to DTC P0401), to determine engine vacuum level for some other diagnostics and to determine barometric pressure (BARO). The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that is intermittently above the calculated value, DTC P1106 will set.

B The PCM will not illuminate the malfunction indicator lamp (MIL). B The PCM will store conditions which were present when the DTC was set as Failure Records data only. This information will not be stored as Freeze Frame data.

Conditions for Setting the DTC B No TP sensor DTCs are present. B Engine is running for at least 10 seconds. B Throttle angle is below 3% if engine speed is below 1000 RPM. B Throttle angle is below 10% if engine speed is above 1000 RPM. B The MAP sensor indicates an intermittent manifold absolute pressure above 80 kPa for a total of approximately 5 seconds over a 16-second period of time.

Conditions for Clearing the MIL/DTC B A history DTC P1106 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1106 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Leaking or plugged vacuum supply line to the MAP sensor. B Inspect PCM harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Inspect the wiring harness for damage. If the harness appears to be OK, observe the MAP display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition. B The MAP sensor shares a 5 Volt Reference with the Fuel Tank Pressure sensor. Check the 5 Volt reference if this DTC is also set.

6E–385

B The MAP sensor shares a ground with the Fuel Tank Pressure sensor and the ECT Sensor. Check the ground if these other DTCs are also set.

DTC P1106 – MAP Sensor Circuit Intermittent High Voltage Step

Action

Check for a poor sensor ground circuit terminal connection at the MAP sensor. Was a problem found?

Go to Step 3

—

Go to Step 6

Go to Step 4

—

Go to Step 9

Go to Step 5

—

Go to Step 10

Go to Step 8

—

Go to Step 10

Go to Step 7

—

Go to Step 9

Go to Step 8

—

Go to Step 10

Refer to Diagnostic Aids

—

Verify repair

—

Verify repair

—

Check for an intermittent open or a faulty splice in the sensor ground circuit. Was a problem found? Replace the faulty harness connector terminal for the sensor ground circuit. Is the action complete?

—

Go to DTC P0108 chart first

Check for a poor sensor ground circuit terminal connection at the PCM. Was a problem found?

Go to Step 2

Check for an intermittent short to voltage on the 5 volt reference circuit between the PCM and the following components: B MAP sensor B EGR valve B TP sensor Was a problem found?

—

Check the MAP signal circuit between the MAP sensor connector and the PCM for an intermittent short to voltage. Was a problem found?

Go to OBD System Check

Is DTC P0108 also set?

Are DTC P1111, P1115, and/or P1120 also set?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

Locate and repair the intermittent open/short circuit in the wiring harness as necessary. Is the action complete?

6E–386

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage

060R200051

Circuit Description The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the powertrain control module (PCM) varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition “ON”, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine manifold pressure changes while the linear EGR flow test diagnostic is being run (refer to DTC P0401), to determine engine vacuum level for some other diagnostics and to determine barometric pressure (BARO). The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that is intermittently below the calculated value, DTC P1107 will be set.

approximately 5 seconds over a 16-second period of time.

Action Taken When the DTC Sets B The PCM will not illuminate the malfunction indicator lamp (MIL). B The PCM will store conditions which were present when the DTC was set as Failure Records data only. This information will not be stored as Freeze Frame data.

Conditions for Clearing the MIL/DTC B A history DTC P1107 will Clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1107 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

Diagnostic Aids

B B B B

Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B The MAP Sensor shares a 5 Volt reference with the EGR Valve. If these codes are also set, it could indicate a problem with the 5 Volt reference circuit or components itself. B The MAP Sensor share a ground with the EGR Valve and the IAT Sensor.

No TP sensor DTCs are present. Engine is running. Ignition voltage is more than 11 volts. Throttle angle is above 1% if engine speed is less than 1000 RPM. B Throttle angle is above 3% if engine speed is above 1000 RPM. B The MAP sensor indicates an intermittent manifold absolute pressure below 11 kPa for a total of

6E–387

DTC P1107 – MAP Sensor Circuit Intermittent Low Voltage Step

Action

Go to Step 3

—

Go to Step 8

Go to Step 4

—

Go to Step 9

Go to Step 7

—

Go to Step 9

Go to Step 6

—

Go to Step 8

Go to Step 7

—

Go to Step 9

Refer to Diagnostic Aids

—

Verify repair

—

Verify repair

—

Check for a poor 5 volt reference terminal connection at the PCM. Check for an intermittent open or a faulty splice in the 5 volt reference circuit.

Replace the faulty harness connector terminal(s) for the 5 volt reference circuit and/or the MAP signal circuit as necessary. Is the action complete?

—

Go to DTC P0107 chart first

Check for an intermittent short to ground on the 5 volt reference circuit between the PCM and the following components: B MAP sensor B EGR valve B TP sensor

Was a problem found? (If no, start with the diagnosis chart for other sensors in the circuit and see if 5V returns.) 8

Go to Step 2

Check the MAP signal circuit between the MAP sensor connector and the PCM for an intermittent open or short to ground.

Was a problem found? 7

—

Check for a poor 5 volt reference circuit or MAP signal circuit terminal connection at the MAP sensor.

Was a problem found? 6

Go to OBD System Check

Is DTC P0107 also set?

Was a problem found? 5

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Was a problem found? 4

Value(s)

Repair intermittent open/short circuit in the wiring harness as necessary. Is the action complete?

6E–388

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage

D06RY00147

Circuit Description The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The powertrain control module (PCM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the PCM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance is lower causing the PCM to monitor a lower voltage. DTC P1111 will set when the PCM intermittently detects an excessively high signal voltage on the intake air temperature sensor signal circuit.

Conditions for Setting the DTC B B B B B

The engine has been running for over 30 seconds. Vehicle speed is less than 32 km/h (20 mph). Engine coolant temperature is above 60°C (140°F). Mass air flow is less than 20g/second. IAT signal voltage indicates and intake air temperature intermittently less than –39°C (–38°F) (about 5 volts) for approximately 2.5 seconds over a 25-second period of time.

Action Taken When the DTC Sets B The PCM will substitute a default value for intake air temperature.

B The PCM will store conditions which were present when the DTC set as Failure Records data only. This information will not be stored as Freeze Frame data. B DTC P1111 does not illuminate the MIL.

Conditions for Clearing the MIL/DTC B A history DTC P1111 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1111 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids Check for the following conditions: B Poor connection at PCM –Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A change in the IAT display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Intake Air Temperature Sensor °C

°F

OHMS

Temperature vs. Resistance Values (approximate) 100

212

177

176

332

140

667

113

1188

1802

2796

4450

7280

–5

12300

–15

21450

–30

–22

52700

–40

100700

6E–389

6E–390

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1111 –IAT Sensor Circuit Intermittent High Voltage Step

Action

1. Check for a poor sensor ground circuit terminal connection at the IAT sensor. 2. If a problem is found, repair as necessary. Was a problem found?

—

Go to DTC P0113 chart first

Go to Step 3

—

Go to Step 6

Go to Step 4

—

Verify repair

Go to Step 5

—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

Verify repair

Refer to Diagnostic Aids

1. Check the IAT signal circuit between the IAT sensor connector and the PCM for an intermittent short to voltage. 2. If a problem is found, repair as necessary. Was a problem found? 1. Check for a poor sensor ground circuit terminal connection at the PCM. 2. If a problem is found, repair as necessary. Was a problem found?

Go to Step 2

1. Check the IAT signal circuit between the IAT sensor connector and the PCM for an intermittent open. 2. If a problem is found, repair as necessary. Was a problem found?

—

1. Check for a poor IAT signal circuit terminal connection at the IAT sensor. 2. If a problem is found, repair as necessary. Was a problem found?

Go to OBD System Check

Is DTC P0113 also set?

Is DTC P1115, also set?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

1. Check for an intermittent open or a faulty splice in the sensor ground circuit. 2. If a problem is found, repair as necessary. Was a problem found?

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–391

Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage

D06RY00147

Circuit Description

Conditions for Clearing the MIL/DTC

The intake air temperature (IAT) sensor is a thermistor which measures the temperature of the air entering the engine. The powertrain control module (PCM) applies 5 volts through a pull-up resistor to the IAT sensor. When the intake air is cold, the sensor resistance is high and the PCM will monitor a high signal voltage on the IAT signal circuit. If the intake air is warm, the sensor resistance becomes lower, causing the PCM to monitor a lower voltage. DTC P1112 will set when the PCM intermittently detects an excessively low signal voltage on the intake air temperature sensor signal circuit.

B A history DTC P1112 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1112 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC B The engine has been running for over 15 seconds. B Vehicle speed is greater than 48 km/h (30 mph). B IAT signal voltage is greater than 148°C (298°F) (about 0.10 volt) for a total of 2.5 seconds over a 25-second period of time.

Diagnostic Aids Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage. If the harness appears to be OK, observe the IAT display on the Tech 2 while moving connectors and wiring harnesses related to the IAT sensor. A change in the IAT display will indicate the location of the fault. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

6E–392

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description

Intake Air Temperature Sensor

Number(s) below refer to the step number(s) on the Diagnostic Chart. 2. Verifies that the fault is present. 3. If DTC P1112 can be repeated only by duplicating the Failure Records conditions, refer to the “Temperature vs. Resistance Value Chart”. The chart may be used to test the IAT sensor at various temperatures to evaluate the possibility of a “shifted” sensor that may be shorted above or below a certain temperature. If this is the case, replace the IAT sensor.

°C

°F

OHMS

Temperature vs. Resistance Values (approximate) 100

212

177

176

332

140

667

113

1188

1802

2796

4450

7280

–5

12300

–15

21450

–30

–22

52700

–40

100700

DTC P1112 – IAT Sensor Circuit Intermittent Low Voltage Step

2 3

Action

Value(s)

Yes

—

Go to Step 2

Go to OBD System Check

—

Go to DTC P0112 first

Go to Step 3

Verify repair

Refer to Diagnostic Aids

Was the “On-Board Diagnostic (OBD) System Check” performed? Is DTC P0112 also set? 1. Check the IAT signal circuit between the IAT sensor connector and the PCM for an intermittent short to ground. 2. If a problem is found, repair as necessary. Was a problem found?

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–393

Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage

060R200053

Circuit Description The engine coolant temperature (ECT) sensor is a thermistor mounted in the engine coolant stream. The powertrain control module (PCM) applies a voltage (about 5.0 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the PCM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes less, and the ECT signal voltage measured at the PCM drops. With a fully warmed up engine, the ECT signal voltage should measure about 1.5 to 2.0 volts. If the PCM detects an ECT signal that is intermittently below the range of the ECT sensor, DTC P1114 will set.

Conditions for Setting the DTC B Engine run time longer than 120 seconds. B The ECT sensor signal is intermittently greater than 150°C (302°F) (about 0.10 volt) for a total of 10 seconds over a 100-second period.

Action Taken When the DTC Sets B The PCM will not illuminate the malfunction indicator lamp (MIL).

B The PCM will store conditions which were present when the DTC set as Failure Records data only. This information will not be stored as Freeze Frame data.

Conditions for Clearing the MIL/DTC B A history DTC P1114 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1114 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–394

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Engine Coolant Temperature Sensor °C

°F

OHMS

Temperature vs. Resistance Values (approximate) 100

212

177

176

332

140

667

113

1188

1802

2796

4450

7280

–5

12300

–15

21450

–30

–22

52700

–40

100700

DTC P1114 – ECT Circuit Intermittent Low Voltage Step

2 3

Action

Value(s)

Yes

—

Go to Step 2

Go to OBD System Check

—

Go to DTC P0117 first

Go to Step 3

Verify repair

Refer to Diagnostic Aids

Was the “On-Board Diagnostic (OBD) System Check” performed? Is DTC P0117 also set? 1. Check the ECT signal circuit between the ECT sensor connector and the PCM for an intermittent short to ground. 2. If a problem is found, repair as necessary. Was a problem found?

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–395

Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage

060R200053

Circuit Description The engine coolant temperature (ECT) sensor is a thermistor mounted in the engine coolant stream. The powertrain control module (PCM) applies a voltage (about 5.0 volts) through a pull-up resistor to the ECT signal circuit. When the engine coolant is cold, the sensor (thermistor) resistance is high, therefore the PCM will measure a high signal voltage. As the engine coolant warms, the sensor resistance becomes less, and the ECT signal voltage measured at the PCM drops. With a fully warmed up engine, the ECT signal voltage should measure about 1.5 to 2.0 volts. If the PCM detects an ECT signal that is intermittently above the range of the ECT sensor, DTC P1115 will set.

Conditions for Setting the DTC B Engine running time longer than 90 seconds. B The ECT sensor signal is intermittently greater than –39°C (–38°F) (about 5 volts) for a total of 10 seconds over a 100-second period.

Action Taken When the DTC Sets B The PCM will not illuminate the malfunction indicator lamp (MIL).

B The PCM will store conditions which were present when the DTC was set as Failure Records data only. This information will not be stored as Freeze Frame data.

Conditions for Clearing the MIL/DTC B A history DTC P1115 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1115 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–396

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Engine Coolant Temperature Sensor °C

°F

OHMS

Temperature vs. Resistance Values (approximate) 100

212

177

176

332

140

667

113

1188

1802

2796

4450

7280

–5

12300

–15

21450

–30

–22

52700

–40

100700

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–397

DTC P1115 – ECT Sensor Circuit Intermittent High Voltage Step

Action

1. Check for a poor sensor ground circuit terminal connection at the ECT sensor. 2. If a problem is found, repair as necessary. Was a problem found?

—

Go to DTC P0118 chart first

Go to Step 3

—

Go to Step 8

Go to Step 4

—

Verify repair

Go to Step 5

—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

Verify repair

Refer to Diagnostic Aids

1. Check the ECT signal circuit between the ECT sensor connector and the PCM for an intermittent short to voltage. 2. If a problem is found, repair as necessary. Was a problem found? 1. Check for a poor sensor ground circuit terminal connection at the PCM. 2. If a problem is found, repair as necessary. Was a problem found?

Go to Step 2

1. Check the ECT signal circuit between the ECT sensor connector and the PCM for an intermittent open. 2. If a problem is found, repair as necessary. Was a problem found?

—

1. Check for a poor ECT signal circuit terminal connection at the ECT sensor. 2. If a problem is found, repair as necessary. Was a problem found?

Go to OBD System Check

Is DTC P0118 also set?

Is DTC P1111 also set?

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

1. Check for an intermittent open or a faulty splice in the sensor ground circuit. 2. If a problem is found, repair as necessary. Was a problem found?

—

6E–398

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code(DTC) P1120-TPS 1 Throttle Position Sensor (TPS1) Output Abnormal

D06RY00111

Circuit Description B The throttle position (TP) sensor circuit provides a voltage signal relative to throttle blade angle. The TPS1 voltage will vary about 8% (0.4V) to about 92% (4.6V) at Wide Open Throttle (WOT) in the specified voltage (about 5V). This code detects a continuous short to ground or high in either the circuit or the sensor.

Conditions for setting the DTC B The Ignition is “ON”. B The TPS1 output is more than 93.6 milliseconds, less than 2.5% or more than 97.5% in the specified voltage (5V).

Action Taken When the DTC Sets B The PCM will turn “ON” the MIL after second trip with detected fault. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

B A history DTC P1120 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1120 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the TPS 1 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1120 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set.

6E–399

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS If it is determined that the DTC occurs intermittently, performing the DTC P1120 Diagnostic Chart may isolate the cause of the fault.

Diagnostic Trouble Code(DTC)P1120-TPS 1 Output Abnormal Step

Action

Go to Step 3

Go to Step 6

—

Go to Step 5

Go to Step 4

—

Verify repair

Go to Step 12

—

Verify repair

—

Refer to Diagnostic Aids

Go to Step 7

Go to Step 8

Go to Step 9

Go to Step 11

Go to Step 10

—

Verify repair

Go to Step 12

Observe the TP angle reading on the Tech 2 while Throttle slowly opening the throttle. Closed TPS1 Does the TP angle increase steadily and evenly from 8–10 % TPS2 the closed throttle value to the wide open throttle 8–10 % Wide Open Throttle value? TPS1 90–92 % TPS2 90–92 % 1. Disconnect the TP sensor. 2. Observe the TP sensor reading on the Tech 2. 1. Connect a test light between the 5Volt reference circuit and the TP sensor signal circuit at the TP sensor harness connector. 2. Observe the TP sensor reading on the Tech 2. Is the TP sensor reading near the specified value?

65kPa

Replace the MAP sensor.

Is the TP sensor reading near the specified value? 8

Go to Step 2

1. Check the MAP signal circuit between the PCM and MAP ground circuit. 2. If the MAP signal circuit is open or shorted, repair it as necessary.

Is the action complete? 6

—

Go to OBD System Check

1. Disconnect the MAP sensor. 2. Connect a test 5 volt reference circuit and the MAP signal at the MAP sensor harness connector. 3. Observe the MAP reading on the Tech 2.

Was the MAP signal circuit open or shorted? 5

1. Ignition “ON”, engine not running. 2. Observe the MAP reading on the Tech 2.

Is the MAP reading less than the specified value? (If no, start with diagnosis chart for other sensors in the circuit and see if 5V returns.) 4

Yes

Was the “On-Board(OBD)System Check” performed?

Is the MAP reading less than the specified value? 3

Value(s)

Check the following items; 1. TP1 signal circuit for a short to voltage. 2. TP1 sensor ground circuit for high resistance between the PCM and the TP sensor. 3. TP1 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found?

6E–400

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code(DTC)P1120-TPS 1 Output Abnormal (Cont’d) Step

Action

Value(s)

Yes

Check the following items; 1. TP signal circuit or 5 volt reference circuit for a poor connection. 2. TP signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found?

Verify repair

Go to Step 12

—

Verify repair

—

Verify repair

—

Replace the TP sensor. Is the action complete?

—

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–401

Diagnostic Trouble Code (DTC) P1125 ETC (Electric Throttle Control) Limit Performance Mode

060R200064

Circuit Description B The accelerator position (AP1) sensor circuit provides a voltage signal relative to accelerator pedal angle. The accelerator pedal angle will vary about 13 % at idle position to about 87 % at wide open throttle (WOT). This code detects if the system is in Limit Performance Mode (Fail safe Mode) and Multiple DTCs performance Mode.

Conditions for setting the DTC B The Ignition is “ ON”. B Limit Performance Mode is active. (Fail safe Mode)

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected.

B The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1125 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault. B DTC P1125 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Mis routed harness.

6E–402

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the AP sensor 1, AP sensor 2, AP sensor 3 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor.

A change in the display will indicate the location of the fault. If DTC P1125 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1125 Diagnostic Chart may isolate the cause of the fault.

DTC P1125 – ETC Limit Performance Model Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to ETC System Check

Idle position AP sensor 1 =13 % AP sensor 2, 3 =85 ∼ 89 % open throttle AP sensor 1 =85 ∼ 89 % AP sensor 2 =11 ∼ 15 %

Refer to Diagnostic Aids

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 7

Go to Step 8

—

Verify repair

Go to Step 9

Was the “Electric Throttle Control (ETC) System Check” performed? Observe the AP angle reading on the Tech 2 while slowly opening the throttle. Does the AP angle increase steadily and evenly from the closed throttle value to the wide open throttle value?

1. Disconnect the AP sensor. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

1. Connect a test light between the 5 Voltage supply circuit and the AP1, AP2 AND AP3 sensor signal circuit at the AP sensor harness connector. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Check the following items; 1. AP1, AP2 or AP3 signal circuit for a short to voltage. 2. AP1, AP2 or AP3 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP1, AP2 or AP3 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–403

DTC P1125 – ETC Limit Performance Model (Cont’d) Step

Action

Value(s)

Yes

Check the following items; 1. AP1, AP2 or AP3 signal circuit or 5 voltage supply circuit for a poor connection. 2. AP1, AP2 or AP3 signal circuit or 5 voltage supply circuit for high resistance between the PCM and the AP1, AP2 or AP3 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found?

Verify repair

Go to Step 9

—

Verify repair

—

Verify repair

—

Replace the AP sensor. Is the action complete?

—

6E–404

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1

060R200054

Circuit Description The powertrain control module (PCM) monitors the heated oxygen sensor (HO2S) activity for 90 seconds after “closed loop” and stoichiometric operation have been enabled. During this test period the PCM counts the number of times that the HO2S signal voltage crosses the rich-to-lean and lean-to-rich threshold. If the PCM determines that the HO2S did not switch enough times, DTC P1133 will be set. A lean-to-rich switch is determined when the HO2S voltage changes above and below 450 mV. Heated oxygen sensors are used to minimize the amount of time required for “closed loop” fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.

Conditions for Setting the DTC B Engine coolant temperature (ECT) is above 60°C (140°F). B Engine is operating in “closed loop”. B The engine has been running at least one minute. B Canister purge duty cycle is greater than 2%. B Engine speed is between 1500 RPM and 3000 RPM.

B Mass air flow (MAF) is between 9 g/second and 42 g/second. B Above conditions are present for 3 seconds. B 90 seconds after “closed loop” and stoichiometric operation have been achieved, the PCM monitors the oxygen sensor as it switches above and below 450 mV. If fewer than 23 rich-to-lean and lean-to-rich switches are detected, DTC P1133 will be set.

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) after the second consecutive trip in which the fault is detected. B ”Open loop” fuel control will be in effect. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1133 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1133 can be cleared by using Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids A malfunction in the HO2S heater ignition feed or ground circuit may cause a DTC P1133 to set. Check HO2S heater circuitry for intermittent faults or poor connections. If connections and wiring are OK and DTC P1133 continues to set, replace the Bank 1 HO2S 1. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help to determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

6E–405

3. A condition that affects other heated oxygen sensors indicates probable contamination. To avoid damaging the replacement sensors, correct the condition which caused the contamination before replacing the affected sensors. 5. This step checks for conditions which may cause the heated oxygen sensor to appear faulty. Correct any of the described conditions if present. 11.To avoid damaging replacement sensors, correct the condition which caused the contamination before replacing the affected sensors.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart.

DTC P1133 – HO2S Insufficient Switching Bank 1 Sensor 1 Step

Action

Value(s)

Go to Step 2

IMPORTANT: If any DTCs are set (except P1153 or P1154) refer to those DTCs before proceeding with this diagnostic chart. 1. Engine idling at operating temperature. 2. Operating the vehicle within parameters specified under “Conditions for Setting the DTC” criteria included in Diagnostic Support. 3. Using a Tech 2, monitor “DTC” info for DTC P1133 until the DTC P1133 test runs. 4. Note the test result.

3 4

Does the Tech 2 indicate DTC P1133 failed this ignition?

—

Go to Step 3

Refer to Diagnostic Aids

Did the Tech 2 also indicate that the P1153 or P1154 tests failed?

—

Go to Step 20

Go to Step 4

—

Go to Step 5

Go to Step 6

—

Go to Step 2

—

Go to Step 7

Go to Step 8

—

Go to Step 2

—

Go to Step 9

Go to Step 10

—

Go to Step 2

—

Go to Step 11

Go to Step 12

Check for leaks at the exhaust pipe joints. Are the joints leaking?

Tighten the bolt/nuts at the leaking joints. Is your action complete?

Check for gaskets that are damaged or improperly installed. Are there damaged or misaligned gaskets?

1. Replace the damaged gaskets. 2. Align the connections. 3. Tighten the connections. Is your action complete?

Check for loose exhaust flange connections. Are the flange connections loose?

Tighten the stud nuts or bolts to specifications. Is your action complete?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

Check for burned or corroded exhaust pipes. Are the exhaust pipes burned or corroded?

6E–406

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1133 – HO2S Insufficient Switching Bank 1 Sensor 1 (Cont’d) Step

Action

—

Go to Step 2

—

Verify repair

Go to Step 15

3-4 mV

Go to Step 18

Go to Step 16

—

Verify repair

Go to Step 17

—

Verify repair

Go to Step 18

—

Verify repair

Go to Step 19

425-475 mV

Go to Step 21

Go to Step 22

—

Verify repair

—

With the PCM connected and Bank 1 HO2S 1 disconnected from the harness, check Bank 1 HO2S 1 with a Tech 2. Is the voltage in the specified range?

Go to Step 14

1. Ignition “OFF”. 2. Disconnect the PCM connector. 3. With the HO2S disconnected, check for high and low signal circuits shorted together between the PCM and HO2S. Was a problem found?

Go to Step 13

Check for a short to voltage or ground or an open in the signal circuit. Was a problem found?

—

1. Ignition “OFF”. 2. Check for damage to PCM pins or terminals. Was a problem found.

—

1. Disconnect Bank 1 HO2S 1. 2. Ignition “ON”. 3. Using a DVM at the PCM side of the connector, check the voltage between the high signal circuit and ground. Also measure between the low signal circuit and ground. Are both voltages in the specified range?

Go to Step 2

Visually/physically inspect the following items: B Ensure that the Bank 1 HO2S 1 is securely installed. B Check for corrosion on the terminals. B Check the terminals at Bank 1 HO2S 1 and at the PCM. B Check for damaged wiring. Was a problem found in any of the above areas?

—

Tighten the bolts to specifications or replace the manifold if necessary. Is your action complete?

Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold?

Yes

Replace the exhaust pipes, as required. Is your action complete?

Value(s)

Replace the affected heated oxygen sensors. NOTE: Before replacing the sensors, the cause of the contamination must be determined and corrected. B B B

Fuel contamination Use of improper RTV sealant. Engine oil/coolant consumption.

Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–407

DTC P1133 – HO2S Insufficient Switching Bank 1 Sensor 1 (Cont’d) Step

Action

Yes

Replace Bank 1 HO2S 1. Is the action complete?

Value(s)

—

Verify repair

—

Verify repair

—

6E–408

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1

060R200054

Circuit Description The powertrain control module (PCM) monitors the heated oxygen sensor (HO2S) activity for 90 seconds after “closed loop” and stoichiometric operation have been established. During the monitoring period the PCM counts the number of times that the HO2S responds from rich-to-lean and from lean-to-rich and adds the amount of time it took to complete all transitions. With this information, an average time for all transitions can be determined. The PCM then divides the rich-to-lean average by the lean-to-rich average to obtain a ratio. If the HO2S transition time ratio is not within this range, DTC P1134 will be set, indicating that the oxygen sensor is not responding as expected to changes in exhaust oxygen content.

Conditions for Setting the DTC B No related DTCs. B Engine coolant temperature (ECT) is above 60°C (140°F). B Engine is operating in “closed loop”, B The engine has been running at least one minute. B Canister purge duty cycle is greater than 2%. B Engine speed is between 1500 RPM and 3000 RPM. B Mass air flow (MAF) is between 18 g/second and 42 g/second. B Above conditions are present for a 3-second monitoring period.

B 90 seconds after “closed loop” and stoichiometric operation have been enabled, Bank 1 HO2S 1 transition ratio between lean-to-rich and rich-to-lean is less than 0.44 or greater than 3.8.

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) after second consecutive trip in which the fault is detected. B ”Open loop” fuel control will be in effect. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1134 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1134 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids A malfunction in the HO2S heater ignition feed or ground circuit may cause a DTC P1134 to set. Check HO2S heater circuitry for intermittent faults or poor connections. If connections and wiring are OK and DTC P1134 continues to set, replace the Bank 1 HO2S 1.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description

6E–409

5. This step checks for conditions which may cause the heated oxygen sensor to appear faulty. Correct any of the described conditions if present. 8. To avoid damaging replacement sensors, correct the condition which caused the contamination before replacing the affected sensors.

Number(s) below refer to the step number(s) on the Diagnostic Chart. 3. A condition that affects other heated oxygen sensors indicates probable contamination. To avoid damaging replacement sensors, correct the condition which caused the contamination before replacing the affected sensors.

DTC P1134 – HO2S Transition Time Ratio Bank 1 Sensor 1 Step

Action

Value(s)

Go to Step 2

IMPORTANT: If any DTCs are set (except P1153 and/or P1154), refer to those DTCs before proceeding with this diagnostic chart. 1. Idle the engine at operating temperature. 2. Operate the vehicle within parameters specified under “Conditions for Setting the DTC” criteria included in Diagnostic Support. 3. Using a Tech 2, monitor “DTC” info for DTC P1134 until the DTC P1134 test runs. 4. Note the test result.

3 4

Does Tech 2 indicate DTC 1134 failed this ignition?

—

Go to Step 3

Refer to Diagnostic Aids

Did the Tech 2 also indicate P1153, and/or P1154 test failed?

—

Go to Step 17

Go to Step 4

—

Go to Step 5

Go to Step 6

—

Go to Step 2

—

Go to Step 7

Go to Step 8

—

Go to Step 2

—

Go to Step 9

Go to Step 10

—

Go to Step 2

—

Go to Step 11

Go to Step 12

—

Go to Step 2

—

Check for leaks at the exhaust pipe joints. Are the joints leaking?

Tighten the U-bolt nuts at the leaking joints. Is your action complete?

Check for gaskets that are damaged or improperly installed. Are there damaged or misaligned gaskets?

1. Replace the damaged gaskets. 2. Align the connections. 3. Tighten the connections. Is your action complete?

Check for loose exhaust flange connections. Are the flange connections loose?

Tighten the stud nuts or bolts to specifications. Is your action complete?

Check for burned or corroded exhaust pipes. Are the exhaust pipes burned or corroded?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

Replace the exhaust pipes, as required. Is your action complete?

6E–410

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1134 – HO2S Transition Time Ratio Bank 1 Sensor 1 (Cont’d) Step

Action

Go to Step 14

—

Go to Step 2

—

Go to Step 18

Go to Step 15

3-4V

Go to Step 16

Go to Step 19

—

Go to Step 21

Go to Step 22

—

Verify repair

—

Verify repair

—

Verify repair

Go to Step 20

—

Verify repair

Go to Step 7

Go to Step 13

1. Disconnect Bank 1 HO2S 1. 2. Ignition “ON”. 3. Using a DVM at the PCM side of the HO2S 1 connector, measure the voltage between the high signal circuit and ground. 4. Also measure the voltage between the low signal circuit and ground. Are both voltages in the specified range?

—

Visually/physically inspect the following items: B Ensure that the Bank 1 HO2S 1 is securely installed. B Check for corrosion on terminals. B Check the terminal tension (at Bank 1 HO2S 1 and at the PCM). B Check for damaged wiring. Was a problem found in any of the above areas?

Tighten the bolts to specifications or replace the manifold if necessary. Is your action complete?

Yes

Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold?

Value(s)

Replace affected heated oxygen sensors. NOTE: Before replacing sensors, the cause of the contamination must be determined and corrected. B B B

Fuel contamination. Use of improper RTV sealant. Engine oil/coolant consumption.

Is the action complete? 18

Repair condition as necessary. Is the action complete?

Check for faulty PCM connections or terminal damage. Is the action complete?

Repair open, short or grounded signal circuit. Is the action complete?

6E–411

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1134 – HO2S Transition Time Ratio Bank 1 Sensor 1 (Cont’d) Step

Action

Yes

Replace Bank 1 HO2S 1. Is the action complete?

Value(s)

—

Verify repair

—

Verify repair

—

6E–412

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1

060R200054

Circuit Description The powertrain control module (PCM) monitors the heated oxygen sensor (HO2S) activity for 90 seconds after “closed loop” and stoichiometric operation have been enabled. During this test period the PCM counts the number of times that the HO2S signal voltage crosses the rich-to-lean and lean-to-rich thresholds. If the PCM determines that the HO2S did not switch enough times, DTC P1153 will be set. A lean-to-rich switch is determined when the HO2S voltage changes above and below 450 mV. Heated oxygen sensors are used to minimize the amount of time required for “closed loop” fuel control operation and to allow accurate catalyst monitoring. The oxygen sensor heater greatly decreases the amount of time required for fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 to become active. Oxygen sensor heaters are required by post-catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine.

Conditions for Setting the DTC B The engine is operating in “closed loop”, B Engine coolant temperature (ECT) is above 60°C (140°F). B The engine has been running for over 60 seconds. B Canister purge duty cycle is greater than 2%. B Engine speed is between 1500 RPM and 3000 RPM.

B Mass air flow is between 8 g/second and 42 g/second. B Above conditions are present for a 3 seconds. B 90 seconds after “closed loop” and stoichiometric operation have been enabled, the PCM monitors the oxygen sensor switching above and below 450 mV. If fewer than 27 rich-to-lean and lean-to-rich switches for Bank 2 HO2S 1 are detected, DTC P1153 will set.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1153 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1153 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Aids A malfunction in the HO2S heater ignition feed or ground circuit may cause a DTC P1153 to set. Check HO2S heater circuitry for intermittent faults or poor connections. If connections and wiring are OK and DTC P1153 continues to set, replace the Bank 2 HO2S 1. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

6E–413

3. A condition that affects other heated oxygen sensors indicates probable contamination. To avoid damaging replacement sensors, correct the condition which caused the contamination before replacing the affected sensors. 5. This step checks for conditions which may cause the heated oxygen sensor to appear faulty. Correct any of the described conditions if present. 8. To avoid damaging replacement sensors, correct the condition which caused the contamination before replacing the affected sensors.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart.

DTC P1153 – HO2S Insufficient Switching Bank 2 Sensor 1 Step

Action

Value(s)

Go to Step 2

IMPORTANT: If any DTCs are set, (except P1133 and/or P1134), refer to those DTCs before proceeding with this diagnostic chart. 1. Idle the engine at operating temperature. 2. Operate the vehicle within parameters specified under “Conditions for Setting the DTC” criteria included in Diagnostic Support. 3. Using a Tech 2, monitor “DTC” info for DTC P1153 until the DTC P1153 test runs. Note the test result.

3 4

Does Tech 2 indicate DTC failed this ignition?

—

Go to Step 3

Refer to Diagnostic Aids

Did the Tech 2 also indicate P1133 and/or P1134 test failed?

—

Go to Step 20

Go to Step 4

—

Go to Step 5

Go to Step 6

—

Go to Step 2

—

Go to Step 7

Go to Step 8

—

Go to Step 2

—

Go to Step 9

Go to Step 10

—

Go to Step 2

—

Go to Step 11

Go to Step 12

Check for leaks at the exhaust pipe joints. Are the joints leaking?

Tighten the U-bolt nuts at the leaking joints. Is your action complete?

Check for gaskets that are damaged or improperly installed. Are there damaged or misaligned gaskets?

1. Replace the damaged gaskets. 2. Align the connections. 3. Tighten the connections. Is your action complete?

Check for loose exhaust flange connections. Are the flange connections loose?

Tighten the stud nuts or bolts to specifications. Is your action complete?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

Check for burned or corroded exhaust pipes. Are the exhaust pipes burned or corroded?

6E–414

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1153 – HO2S Insufficient Switching Bank 2 Sensor 1 (Cont’d) Step

Action

—

Go to Step 2

—

Verify repair

Go to Step 15

3-4V

Go to Step 18

Go to Step 16

—

Verify repair

Go to Step 17

—

Verify repair

Go to Step 18

—

Verify repair

Go to Step 19

425-475 mV

Go to Step 21

Go to Step 22

—

Verify repair

—

With the PCM connected and Bank 2 HO2S 1 disconnected from the harness, check Bank 2 HO2S 1 with a Tech 2. Is the voltage in the specified range?

Go to Step 14

1. Ignition “OFF”. 2. Disconnect the PCM connector. 3. With HO2S disconnected, check for high and low signal circuits shorted together between the PCM and HO2S. Was a problem found?

Go to Step 13

Check for short to voltage or ground or an open in the signal circuit. Was a problem found?

—

1. Ignition “ON”. 2. Check for damage to PCM pins or terminals. Was a problem found?

—

1. Disconnect Bank 2 HO2S 1. 2. Ignition “ON”. 3. Using a DVM at the PCM side of the connector, check the voltage between the high signal circuit and ground. Also measure between the low signal circuit and ground. Are both voltages in the specified range?

Go to Step 2

Visually/physically inspect the following items: B Ensure that the Bank 2 HO2S 1 is securely installed. B Check for corrosion on terminals. B Check the terminal tension at Bank 2 HO2S 1 and at the PCM. B Check for damaged wiring. Was a problem found in any of the above areas?

—

Tighten the bolts to specifications or replace the manifold if necessary. Is your action complete?

Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold?

Yes

Replace the exhaust pipes, as required. Is your action complete?

Value(s)

Replace affected heated oxygen sensors. NOTE: Before replacing sensors, the cause of the contamination must be determined and corrected. B B B

Fuel contamination. Use of improper RTV sealant. Engine oil/coolant consumption.

Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–415

DTC P1153 – HO2S Insufficient Switching Bank 2 Sensor 1 (Cont’d) Step

Action

Yes

Replace Bank 2 HO2S 1. Is the action complete?

Value(s)

—

Verify repair

—

Verify repair

—

6E–416

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1

060R200054

Circuit Description The powertrain control module (PCM) monitors the heated oxygen sensor (HO2S) activity for 90 seconds after “closed loop” and stoichiometric operation have been enabled. During the monitor period the PCM counts the number of times that the HO2S responds from rich-to-lean and from lean-to-rich and adds the amount of time it took to complete all transitions. With this information, an average time for all transitions can be determined. The PCM then divides the rich-to-lean average by the lean-to-rich average to obtain a ratio. If the HO2S transition time ratio is not within this range, DTC P1154 will be set, indicating that the oxygen sensor is not responding as expected to changes in exhaust oxygen content.

Conditions for Setting the DTC B No related DTCs. B Engine coolant temperature (ETC) is above 60°C (140°F). B The engine is operating in “closed loop”, B The engine has been running at least one minute. B Canister purge duty cycle is greater than 2%. B Engine speed is between 1500 RPM and 3000 RPM. B Mass air flow is between 18 g/second and 42 g/second. B Above conditions are present for a 3-second monitoring period.

B 90 seconds after “closed loop” and stoichiometric operation have been enabled, Bank 2 HO2S 1 transition ratio between lean to rich and rich to lean is less than 0.44 or greater than 3.8.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1154 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1154 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids A multifunction in the HO2S heater ignition feed or ground circuit may cause a DTC P1154 to set. Check HO2S heater circuitry for intermittent faults or poor connections.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS If connections and wiring are OK and DTC P1154 continues to set, replace the Bank 2 HO2S 1. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart.

6E–417

DTC P1154 – HO2S Transition Time Ratio Bank 2 Sensor 1 Step

Action

Value(s)

Go to Step 2

IMPORTANT: If any other DTCs are set (except P1133 and/or P1134), refer to those DTCs before proceeding with this diagnostic chart. 1. Idle the engine at operating temperature. 2. Operate the vehicle within parameters specified under “Conditions for Setting the DTC” criteria included in Diagnostic Support. 3. Using a Tech 2, monitor “DTC” info for DTC P1154 until the DTC P1154 test runs. Note the test result.

3 4

Does Tech 2 indicate DTC failed this ignition?

—

Go to Step 3

Refer to Diagnostic Aids

Did the Tech 2 also indicate P1133, and/or P1134 test failed?

—

Go to Step 17

Go to Step 4

—

Go to Step 5

Go to Step 6

—

Go to Step 2

—

Go to Step 7

Go to Step 8

—

Go to Step 2

—

Go to Step 9

Go to Step 10

—

Go to Step 2

—

Go to Step 11

Go to Step 12

—

Go to Step 2

—

Check for leaks at the exhaust pipe joints. Are the joints leaking?

Tighten the U-bolt nuts at the leaking joints. Is your action complete?

Check for gaskets that are damaged or improperly installed. Are there damaged or misaligned gaskets?

1. Replace the damaged gaskets. 2. Align the connections. 3. Tighten the connections. Is your action complete?

Check for loose exhaust flange connections. Are the flange connections loose?

Tighten the stud nuts or bolts to specifications. Is your action complete?

Check for burned or corroded exhaust pipes. Are the exhaust pipes burned or corroded?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

Replace the exhaust pipes, as required. Is your action complete?

6E–418

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1154 – HO2S Transition Time Ratio Bank 2 Sensor 1 (Cont’d) Step

Action

Go to Step 14

—

Go to Step 2

—

Go to Step 18

Go to Step 15

3-4 V

Go to Step 16

Go to Step 19

—

Go to Step 21

Go to Step 22

—

Verify repair

—

Verify repair

—

Verify repair

Go to Step 20

—

Verify repair

—

Go to Step 13

1. Disconnect Bank 2 HO2S 1. 2. Ignition “ON”. 3. Using a DVM at the PCM side of the HO2S 1 connector, measure the voltage between the high signal circuit and ground. Also measure the voltage between the low signal circuit and ground. Are both voltages in the specified range?

—

Visually/physically inspect the following items: B Ensure that the Bank 2 HO2S 1 is securely installed. B Check for corrosion on terminals. B Check terminal tension (at Bank 2 HO2S 1 and at the PCM). B Check for damaged wiring. Was a problem found in any of the above areas?

Tighten the bolts to specifications or replace the manifold if necessary. Is your action complete?

Yes

Check for leaks at the exhaust manifold. Are there leaks at the exhaust manifold?

Value(s)

Replace affected heated oxygen sensors. NOTE: Before replacing sensors, the cause of the contamination must be determined and corrected. B B B

Fuel contamination. Use of improper RTV sealant. Engine oil/coolant consumption.

Is the action complete? 18

Repair condition as necessary. Is the action complete?

Check for faulty PCM connections or terminal damage. Is the action complete?

Repair open, short or grounded signal circuit. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–419

DTC P1154 – HO2S Transition Time Ratio Bank 2 Sensor 1 (Cont’d) Step

Action

Yes

Replace Bank 2 HO2S 1. Is the action complete?

Value(s)

—

Verify repair

—

Verify repair

—

6E–420

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1)

060R200054

Circuit Description

Action Taken When the DTC Sets

The powertrain control module (PCM) continuously monitors the heated oxygen sensor (HO2S) activity for 90 seconds after “closed loop” has been enabled. During the monitoring period the powertrain control module (PCM) counts the number of times a rich to lean response is indicated and adds the amount of time it look to complete all rich to lean transitions and lean to rich transitions. This code detects if Bank1 O2 sensor indicated rich exhaust while in Decel Fuel Cut Off (DFCO) for fuel control sensors.

B The PCM will not illuminate the malfunction malfunction indicator lamp (MIL). B The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

Conditions for setting the DTC B No related DTCs. B The engine coolant temperature is more than 60 °C (140 °F). B Engine is operating in “closed loop” power enrichment mode for 3 seconds. B While in “power enrichment” mode the oxygen sensor voltage remains more than 600mV in DFCO.

Conditions for Clearing the MIL/DTC B A history DTC P1167 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1167 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids B Check for faulty fuel injectors and fuel pump.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–421

Diagnostic Trouble Code (DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank1) Step

Action

Value(s)

Go to Step 2 Go to component DTC charts

Go to Step 3

Go to OBD System Check

Go to Step 4

Go to OBD System Check

Go to Step 5

325KPa (46psi) 414KPa (60psi)

Refer to Diagnostic Aids

Go to Step 6

—

Verify repair

—

Are any component related DTCs set?

1. Place the transmission in Park. 2. Using a Tech 2, HO2S 1 voltage while running warm engine 75 °C – 95 °C (167 °F – 203 °F) at 1200 RPM. 3. HO2S 1 voltages should vary within the specified range. (100 – 900mV) 4. Quickly open the wide open the throttle for a few seconds. Did the voltage suddenly rise toward the low end of the 100 – 600 mV specified range?

1. Disconnect the fuel pump relay and crank the engine to relieve the fuel pressure. 2. Install the fuel pressure gauge. 3. Start the engine and idle at normal operating temperature. 4. Disconnect the vacuum line going to the fuel pressure regulator. With the engine running, is the fuel pressure within the 280 – 325Kpa specified range? (41 – 46psi)

1. Ignition “OFF”. 2. Remove the fuel pump relay and replace it with a fused jumper which will connect the relay’s battery terminal to the terminal leading to the fuel pump fuse. 3. While the fuel pump is operating, use pliers to slowly close the return line (do not exceed the first specified value). Using the pliers to restrict the return line, can the fuel pressure be manipulated to exceed the second value? Is the fuel pressure gauge reading near the specified value?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Check the following items; B Faulty fuel pump B Incorrect fuel pump B Incorrect fuel being used B Cold fuel If a problem is found, repair as necessary. Was a problem found?

6E–422

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2)

060R200054

Circuit Description

Action Taken When the DTC Sets

The powertrain control module(PCM) continuously monitors the heated oxygen sensor (HO2S) activity for 90 seconds after “closed loop” has been enabled. During the monitoring period the powertrain control module (PCM) counts the number of times a rich to lean response is indicated and adds the amount of time it look to complete all rich to lean transitions and lean to rich transitions. This code detects if Bank2 sensor indicated rich exhaust while in Decel Fuel Cut Off (DFCO) for fuel control sensors.

B The PCM will not illuminate the malfunction malfunction indicator lamp(MIL). B The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

Conditions for Clearing the MIL/DTC B A history DTC P1169 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1169 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids B Check for faulty fuel injectors and fuel pump. B Check the pressure regulator.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–423

Diagnostic Trouble Code (DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank2) Step

Action

Value(s)

Go to Step 2 Go to component DTC charts

Go to Step 3

Go to OBD System Check

Go to Step 4

Go to OBD System Check

Go to Step 5

325KPa (46psi) 414KPa (60psi)

Refer to Diagnostic Aids

Go to Step 6

—

Verify repair

—

Are any component related DTCs set?

1. Place the transmission in Park. 2. Using a Tech 2, HO2S 2 voltage while running warm engine75 C – 95 C (167 F – 203 F) at 1200 RPM. 3. HO2S 1 voltages should vary within the specified range. (100 – 900mV) 4. Quickly open the wide open the throttle for a few seconds. Did the voltage suddenly rise toward the low end of the specified range? 100 – 600 mV

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Check the following items; B Faulty fuel pump B Incorrect fuel pump B Incorrect fuel being used B Cold fuel. If a problem is found, repair one as necessary. Was a problem found?

6E–424

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration

060R200054

Circuit Description

Action Taken When the DTC Sets

The powertrain control module (PCM) internal circuitry can identify if the vehicle fuel system is capable of supplying adequate amounts of fuel during heavy acceleration (power enrichment). The PCM monitors the voltage of the oxygen sensor during power enrichment. When a power enrichment mode of operation is requested during “closed loop” operation (by heavy acceleration), the PCM will provide more fuel to the engine. Under these conditions the PCM should detect a “rich” condition (high oxygen sensor voltage). If this “rich” exhaust is not detected at this time, a DTC P1171 will set. A plugged fuel filter, restricted fuel line, restricted in-tank filter or defective fuel pump can prevent adequate amounts of fuel from being supplied during power enrichment mode.

Conditions for Setting the DTC

Diagnostic Aids

B No related DTCs. B Engine is operating in “closed loop power enrichment” mode for 3 seconds. B Engine coolant temperature is above 60°C (140°F). B While in “power enrichment” mode the oxygen sensor voltage remains below 400 mV for 3 seconds.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1171 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1171 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

B A restricted fuel filter or fuel line, restricted in-tank filter, or a defective fuel pump may supply adequate amounts of fuel at idle, but may not be able to supply enough fuel during heavy acceleration. B Water or alcohol in the fuel may cause low HO2S voltage during acceleration. B Check for faulty or plugged fuel injector(s). B Check for low fuel.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 4. When the engine is idling or at steady cruise, the HO2S voltage should vary from between approximately 100 mV to 900 mV. It is possible to measure a satisfactory fuel pressure at idle even though the pressure may drop at high flow requirements. It may be necessary to watch fuel pressure at high engine load. 5. Wrap a shop towel around the fuel pressure connector to absorb any small amount of fuel leakage that may occur when installing gauge. Ignition “ON”, pump pressure should be 280-320 kPa. 7. Add Caution, Use correct pliers so damage to fuel lines will not occur.

6E–425

6E–426

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1171 – Fuel System Lean During Acceleration Step

Action

—

Go to component DTC charts

Go to Step 3

—

Go to Step 4

Go to Step 5

100-900 mV

Go to Fuel System Electrical Test

Go to Step 5

280-325 kPa (41-46 psi)

Go to OBD System Check

Go to Step 6

—

Verify repair

Go to Step 7

325 kPa (46 psi) 414 kPa (60 psi)

Go to Diagnostic Aids

Go to Step 8

—

Verify repair

—

Check for restricted fuel lines or restricted in-line filter. 1. Ignition “OFF”. 2. Remove the fuel pump relay and replace it with a fused jumper which will connect the relay’s battery terminal to the terminal leading to the fuel pump fuse. 3. While the fuel pump is operating, use pliers to slowly close the return line (do not exceed the first specified value). Using the pliers to restrict the return line, can the fuel pressure be manipulated to exceed the second specified value?

Go to Step 2

1. Place the transmission in park. 2. Using a Tech 2, observe HO2S 1 voltage while running warm engine 75°C-95°C (167°F-203°F) at 1200 RPM. 3. HO2S 1 voltage should vary within the specified range. 4. Quickly open the throttle too halfway for a few seconds.

Was a problem found? 7

—

1. Check the vehicle’s fuel tank for an adequate amount of fuel. 2. Add fuel to the vehicle’s fuel tank if the tank is almost empty.

With the engine running, is the fuel pressure within the specified range? 6

Go to OBD System Check

Are any component-related DTCs set?

Did the voltage suddenly rise toward the high end of the specified range? 5

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Was fuel added to the vehicle’s fuel tank? 4

Value(s)

Check for: B Faulty fuel pump B Restricted fuel pump strainer (sock) B Incorrect fuel pump B Incorrect fuel being used B Hot fuel Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–427

Diagnostic Trouble Code (DTC) P1220 Throttle Position Senser2 (TPS2) Circuit Fault

D06RY00111

Circuit Description B The throttle position (TP2) sensor circuit provides a voltage signal relative to throttle blade angle. The TPS2 voltage will vary from about 8% (0.4V) to about 92% (4.6V) at Wide Open Throttle (WOT) in the specified voltage (about 5V). This code detects a continuous short to ground or high in either the circuit or the sensor.

Conditions for setting the DTC B The Ignition is “ON”. B The TPS2 output is more than 93.6 milliseconds, less than 2.5% or more than 97.5% in the specified voltage (5V).

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

B A history DTC P1120 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1120 can be cleared using the Tech2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B The MAP sensor shares a 5 Volt reference with the Fuel Tank Pressure. If these codes are also set, it could indicate a problem with the 5 Volt reference circuit. B The MAP sensor shares a ground with the Fuel Tank Pressure, the ECT sensor, and the Transmission Fluid B Poor connection at PCM-Inspect harness connectors for backed out terminals,improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness–Inspect the wiring harness for damage. If the harness appears to be OK, observe the TP sensor display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1120 cannot be duplicated, the

6E–428

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1120 Diagnostic Chart may isolate the cause of the fault.

DTC P1220-TPS 2 Circuit Fault Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to ETC System Check

65 kPa

Go to Step 4

Go to Step 7

—

Go to Step 6

Go to Step 5

—

Verify repair

Go to Step 13

—

Verify repair

—

Refer to Diagnostic Aids

Go to Step 8

Go to Step 9

Go to Step 10

Go to Step 12

Go to Step 11

Was the “Electric Throttle Control (ETC) System Check” performed? 1. Ignition “ON”, engine not running. 2. Observe the MAP reading on the Tech 2. Is the MAP reading less than the specified value?

1. Disconnect the MAP sensor. 2. Connect a test 5 volt reference circuit and the MAP signal at the MAP sensor harness connector. 3. Observe the MAP reading on the Tech 2. Is the MAP reading less than the specified value? (If no, start with diagnosis chart for other sensors in the circuit and see if 5V returns.)

1. Check the MAP signal circuit between the PCM and MAP ground circuit. 2. If the MAP signal circuit is open or shorted, repair as necessary. Was the MAP signal circuit open or shorted?

Replace the MAP sensor. Is the action complete?

Observe the TP angle reading on the Tech-2 while Closed TPS1 slowly opening the throttle. 8–10 % TPS2 Does the TP angle increase steadily and evenly from 8–10 % WTO the closed throttle value to the wide open throttle TPS1 90–92 % TPS2 value? 90–92 % 1. Disconnect the TP sensor. 2. Observe the TP sensor reading on the Tech2. Is the TP sensor reading near the specified value?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

1. Connect a test light between the 5Volt reference circuit and the TP2 sensor signal circuit at the TP sensor harness connector. 2. Observe the TP sensor reading on the Tech 2. Is the TP sensor reading near the specified value?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–429

DTC P1220-TPS 2 Circuit Fault (Cont’d) Step

Action

Value(s)

Yes

Check the following items; 1. TP2 signal circuit for a short to voltage. 2. TP2 sensor ground circuit for high resistance between the PCM and the TP2 sensor. 3. TP2 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found?

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 13

—

Verify repair

—

Verify repair

—

Check the following items; 1. TP2 signal circuit or 5 volt reference circuit for a poor connection. 2. TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found?

Replace the TP sensor. Is the action complete?

6E–430

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnosis Trouble Code(DTC) P1221 TPS1 – TPS2 Correlation(Circuit Performance)

060R200069

Circuit Description B The powertrain control module (PCM) controls engine speed by adjusting the position of the throttle control valve (DC motor). The throttle motor is a DC motor driven by one coil. The PCM applies current to DC motor coil in duty (%) to adjustment the valve into a passage in the throttle body to air flow. This method allows highly accurate control of engine speed and quick response to changes in engine load. B The accelerator position (AP) sensor circuit provides a voltage signal relative to accelerator pedal angle. The accelerator pedal angle (AP1) will vary from about 13% at idle position to about 87% at open throttle(WOT). APS signal is used to determine which DC will adjust throttle position. After the APS signal has been processed by the PCM, it will command the DC motor to move the throttle position. B Accelerator pedal – Check for objects blocking the AP sensor or pedal arm with spring, and excessive deposits in the accelerator pedal arm and on the accelerator pedal.

Conditions for Setting the DTC B The ignition is “ON”.

B A difference of between TPS1 and TPS2 correlation of over 6.5% within 125 milliseconds.

Action Taken When the DTC Sets B The PCM will not turn the malfunction indicator lamp (MIL) “ON”. B The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

Condition for Clearing the MIL/DTC B A history DTC 1221 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC 1221 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 7.Check the following circuits for accelerator pedal problems. Check the following AP sensor resistance. 9.Following DTC: Software detect Error for ETC system. 10.Following DTC: Software detect Error for ETC system.

Diagnostic Aids B An intermittent may be caused by a poor connection, rubbed–through wire insulation or a wire broken inside

6E–431

the insulation. Check for poor connections or a damaged harness. Inspect the PCM harness and connector for improper mating, broken locks, improperly formed or damaged terminals, poor terminal-to-wire connection, and damaged harness. B Throttle body – Check for objects blocking the DC motor or throttle bore, excessive deposits in the ETC passage and on the valve spring, and excessive deposits in the throttle bore and on the throttle valve plate.

Diagnosis Trouble Code(DTC) P1221 TPS1 – TPS2 Correlation(Circuit Performance) Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Go to ETC System Check

—

Refer to appropriate section for on–vehicle service

Go to Step 4

—

Refer to appropriate section for on–vehicle service

Go to Step 5

—

Verify repair

Go to Step 6

Was the “Electric Throttle Control (ETC) System Check” performed? Visually/physically inspect for the following conditions: B Throttle body tampering. B Restricted intake throttle system. Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. B Throttle body: Check for objects blocking the throttle passage or throttle bore, excessive deposits in the throttle passage and on the throttle valve, and excessive deposits in the throttle bore and on the throttle plate. B Throttle body with lever: Check for objects send round the throttle spring lever that lever is smooth movement, and spring lever has not excessive play Do any of the above require a repair?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

6E–432

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnosis Trouble Code(DTC) P1221 TPS1 – TPS2 Correlation(Circuit Performance) (Cont’d) Step

Action

Value(s)

Yes

1. Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: Throttle position sensor 1 circuit. Throttle position sensor 2 circuit. Throttle DC motor circuit.

Vcc-GND 1–7kW SIG-GND change resistance 0.3 – 100W

Verify repair

Go to Step 7

1. Check the following circuits for an open, short to voltage, short to ground, or poor connection at the PCM: B Accelerator position sensor 1 circuit. Vcc-GND B Accelerator position sensor 2 circuit. 1–7kW B Sensor 3 circuit. SIG-GND B Sensor resistance. change 2. If a problem is found, repair as necessary. resistance 0.3 – 100W Was a problem found?

Verify repair

Go to Step 8

—

Go to Step 9

—

Go to applicable DTC table

Go to Step 10

—

Go to applicable DTC table

Go to Step 11

—

Verify repair

—

Throttle position sensor resistance. Throttle DC motor resistance. 2. If a problem is found, repair as necessary. Was a problem found? 7

Replace the accelerator position sensor. Is the action complete?

Stored DTCs; P1125, P1290, P1295, P1299 Stored DTCs; P1514, P1515, P1516, P1523, P1271, P1272, P1273 Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–433

Diagnostic Trouble Code (DTC) P1271 APS 1– 2 Correlation Error

060R200064

Circuit Description B The accelerator position (AP) sensor circuit provides a voltage signal relative to accelerator pedal angle. The accelerator pedal sensor (AP1) will vary from about 13 % at idle position to about 87 % at wide open throttle(WOT) to specified voltage (about 5V). This code detects a correlation error between APS1 and APS2.

Conditions for setting the DTC B The Ignition is “ON”. B The accelerator pedal angle difference is more than 4.5 % between ASP1 and APS2 for more than 265 milliseconds.

B DTC P1271 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Mis routed harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the AP sensor 1, AP sensor 2 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1271 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTCP1271 Diagnostic Chart may isolate the cause of the fault.

6E–434

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1271 – APS 1– 2 Correlation Error Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to ETC System Check

Refer to Diagnostic Aids

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 8

Go to Step 7

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 8

Was the “Electric Throttle Control (ETC) System Check” performed? —

Observe the AP angle reading on the Tech 2 while slowly opening the throttle.

Idle position AP sensor 1 =13 % AP Does the AP angle increase steadily and evenly from the closed throttle value to the wide open throttle sensor 2 =85 ∼ 89 % Wide value? open throttle AP sensor 1 =85 ∼ 89 % AP sensor 2 =11 ∼ 15 % 1. Disconnect the AP sensor. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

1. Connect a test light between the 5 V supply circuit and the AP sensor signal circuit at the AP1, AP2 sensor harness connector. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Check the following items; 1. AP1and AP2 signal circuit for a short to voltage. 2. AP1and AP2 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP1and AP2 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found?

Check the following items; 1. AP1and AP2 signal circuit or 5 V supply circuit for a poor connection. 2. AP1and AP2 signal circuit or 5 V supply circuit for high resistance between the PCM and the AP1 and AP2 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–435

DTC P1271 – APS 1– 2 Correlation Error (Cont’d) Step

Action

Value(s)

Replace the AP sensor. Is the action complete?

Yes

—

Verify repair

—

Verify repair

—

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6E–436

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1272 APS 2 – 3 Correlation Error

060R200064

Circuit Description B The accelerator position (AP) sensor circuit provides a voltage signal relative to accelerator pedal angle. The accelerator pedal sensor (AP2) will vary from about 87 % at idle position to about 13 % at wide open throttle (WOT) to specified voltage (about 5V). This code detects a correlation error betweenAPS2 and APS3.

Conditions for setting the DTC B The Ignition is “ON”. B The acceleration pedal angle difference is more than 4.5 % between ASP2 and APS3 for more than 265 millisecond.

B DTC P1272 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals,improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the AP sensor 2, AP sensor 3 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1272 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1272 Diagnostic Chart may isolate the cause of the fault.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–437

DTC P1272 – APS 2 – 3 Correlation Error Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to ETC System Check

Refer to Diagnostic Aids

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 8

Go to Step 7

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 8

Was the “Electric Throttle Control (ETC) System Check” performed? —

Observe the AP angle reading on the Tech 2 while slowly opening the throttle.

Idleposition AP sensor 2 Does the AP angle increase steadily and evenly from =86 ∼ 88 % the closed throttle value to the wide open throttle AP sensor 3 =86 ∼ 88 % value? Wide open throttle AP sensor 2 =12 ∼ 14 % AP sensor 3 =32 ∼ 36 % 1. Disconnect the AP sensor. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

1. Connect a test light between the 5 Voltage supply circuit and the AP sensor signal circuit at the AP2 and AP3 sensor harness connector. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Check the following items; 1. AP2 and AP3 signal circuit for a short to voltage. 2. AP2 and AP3 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP2 and AP3 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found?

Check the following items; 1. AP2 and AP3 signal circuit or 5 voltage supply circuit for a poor connection. 2. AP2 and AP3 signal circuit or 5 voltage supply circuit for high resistance between the PCM and the AP2 and AP3 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found?

6E–438

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1272 – APS 2 – 3 Correlation Error (Cont’d) Step

Action

Yes

Replace the AP sensor. Is the action complete?

Value(s)

—

Verify repair

—

Verify repair

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–439

Diagnostic Trouble Code (DTC) P1273 APS 1 – 3 Correlation Error

060R200064

Circuit Description B The accelerator position (AP) sensor circuit provides a voltage signal relative to accelerator pedal angle. The accelerator pedal sensor (AP1) will vary from about 13 % at idle position to about 87 % at wide open throttle (WOT) to specified voltage (about 5V). This code detects a correlation error between APS1 and APS3.

Conditions for setting the DTC B The Ignition is “ON”. B The accelerator pedal angle difference is more than 4.5 % between ASP1 and APS3 for more than 265 milliseconds.

B DTC P1273 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the AP sensor 1, AP sensor 3 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1273 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently,performing the DTC P1273 Diagnostic Chart may isolate the cause of the fault.

6E–440

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1273 – APS 1 – 3 Correlation Error Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to ETC System Check

Refer to Diagnostic Aids

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 8

Go to Step 7

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 8

Was the “Electric Throttle Control (ETC) System Check” performed? —

Observe the AP angle reading on the Tech2 while slowly opening the throttle.

Idleposition AP sensor 1 =13 % AP Does the AP angle increase steadily and evenly from the closed throttle value to the wide open throttle sensor 3 =85 ∼ 89 % Wide value? open throttle AP sensor 1 =85 ∼ 89 % AP sensor 3 =32 ∼ 36 % 1. Disconnect the AP sensor. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

1. Connect a test light between the 5 Voltage supply circuit and the AP sensor signal circuit at the AP1 and AP3 sensor harness connector. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Check the following items; 1. AP1 and AP3 signal circuit for a short to voltage. 2. AP1 and AP3 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP1 and AP3 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found?

Check the following items; 1. AP1 and AP3 signal circuit or 5 voltage supply circuit for a poor connection. 2. AP1 and AP3 signal circuit or 5 voltage supply circuit for high resistance between the PCM and the AP1 and AP3 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–441

DTC P1273 – APS 1 – 3 Correlation Error (Cont’d) Step

Action

Yes

Replace the AP sensor. Is the action complete?

Value(s)

—

Verify repair

—

Verify repair

—

6E–442

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1275 APS 1 Output Fault

060R200064

Circuit Description B The accelerator position (AP) sensor circuit provides a voltage signal relative to accelerator pedal angle. The accelerator pedal sensor (AP1) will vary from about 13 % at idle position to about 87 % at wide open throttle (WOT) to specified voltage (about 5V). This code detects a continuous short to ground or high in either the circuit or the sensor.

Conditions for setting the DTC B The Ignition is “ON”. B The accelerator pedal sensor 1 is less than 2.5 % or more than 97 % in the specified voltage (5V) for more than 62.4 milliseconds.

B DTC P1275 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the APP sensor 1 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1275 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1275 Diagnostic Chart may isolate the cause of the fault.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–443

DTC P1275 – APS 1 Circuit Fault Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to ETC System Check

Refer to Diagnostic Aids

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 8

Go to Step 7

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 9

—

Verify repair

—

Verify repair

—

Was the “Electric Throttle Control (ETC) System Check” performed? —

Observe the AP angle reading on the Tech 2 while slowly opening the throttle.

Idle position =12 ∼ 14 % Wide open Does the AP angle increase steadily and evenly from the closed throttle value to the wide open throttle throttle =86 ∼ 88 % value? 1. Disconnect the AP sensor. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

1. Connect a test light between the 5 Volt supply circuit and the AP1 sensor signal circuit at the AP sensor harness connector. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Check the following items; 1. AP1 signal circuit for a short to voltage. 2. AP1 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP1 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found?

Check the following items; 1. AP1 signal circuit or 5 volt supply circuit for a poor connection. 2. AP1 signal circuit or 5 volt supply circuit for high resistance between the PCM and the AP1 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found?

Replace the AP sensor. Is the action complete?

6E–444

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1280 APS 2 Output Fault

060R200064

Circuit Description B The accelerator position (AP) sensor circuit provides a voltage signal relative to accelerator pedal angle. The accelerator pedal sensor (AP2) will vary from about 87 % at idle position to about 13 % at wide open throttle(WOT) to specified voltage (about 5V). This code detects a continuous short to ground or high in either the circuit or the sensor.

Conditions for setting the DTC B The Ignition is “ON”. B The accelerator pedal sensor 2 is less than 2.5 % or more than 97 % in the specified voltage (5V) for more than 62.4 milliseconds.

B DTC P1280 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the APP sensor 2 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1280 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1280 Diagnostic Chart may isolate the cause of the fault.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–445

DTC P1280 — APS 2 Circuit Fault Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to ETC System Check

Refer to Diagnostic Aids

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 8

Go to Step 7

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 9

—

Verify repair

—

Verify repair

—

Was the “Electric Throttle Control (ETC) System Check” performed? —

Observe the AP angle reading on the Tech 2 while slowly opening the throttle.

Idle position =86 ∼ 88 %Wide open Does the AP angle increase steadily and evenly from the closed throttle value to the wide open throttle throttle =12 ∼ 14 % value? 1. Disconnect the AP sensor. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

1. Connect a test light between the 5 voltage supply circuit and the AP2 sensor signal circuit at the AP sensor harness connector. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Check the following items; 1. AP2 signal circuit for a short to volt. 2. AP2 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP2 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found?

Check the following items; 1. AP2 signal circuit or 5 volt supply circuit for a poor connection. 2. AP2 signal circuit or 5 volt supply circuit for high resistance between the PCM and the AP2 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found?

Replace the AP sensor. Is the action complete?

6E–446

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1285 APS 3 Output Fault

060R200064

Circuit Description B The accelerator position (AP) sensor circuit provides a voltage signal relative to accelerator pedal angle. The accelerator pedal sensor (AP3) will vary from about 87 % at idle position to about 34 % at wide open throttle(WOT) to specified voltage (about 5V). This code detects a continuous short to ground or high in either the circuit or the sensor.

Conditions for setting the DTC B The Ignition is “ON”. B The accelerator pedal sensor 3 is less than 2.5 % or more than 97 % in the specified voltage (5V) for more than 62.4 milliseconds.

B DTC P1285 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the AP sensor 3 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1285 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1285 Diagnostic Chart may isolate the cause of the fault.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–447

DTC P1285 – APS 3 Circuit Fault Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to ETC System Check

Refer to Diagnostic Aids

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 8

Go to Step 7

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 9

—

Verify repair

—

Verify repair

—

Was the “Electric Throttle Control (ETC) System Check” performed? —

Observe the AP angle reading on the Tech 2 while slowly opening the throttle.

Idle position =86 ∼ 88 %Wide open Does the AP angle increase steadily and evenly from the closed throttle value to the wide open throttle throttle =32 ∼ 36 % value? 1. Disconnect the AP sensor. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

1. Connect a test light between the 5 volt supply circuit and the AP3 sensor signal circuit at the AP sensor harness connector. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Check the following items; 1. AP3 signal circuit for a short to voltage. 2. AP3 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP3 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found?

Check the following items; 1. AP3 signal circuit or 5 volt supply circuit for a poor connection. 2. AP3 signal circuit or 5 voltage supply circuit for high resistance between the PCM and the AP3 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found?

Replace the AP sensor. Is the action complete?

6E–448

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1290 ETC Forced Idle Mode

060R200069

Circuit Description B The accelerator position (AP) sensor circuit provides a voltage signal relative to accelerator pedal angle. The accelerator pedal angle (AP1) will vary from about 13 % at idle position to about 87 % at wide open throttle (WOT). This code detects that if the system is in Forced Idle Mode. (Fail safe Mode)

Conditions for setting the DTC B The Ignition is “ON”. B Forced Idle Mode is active. (Fail safe Mode)

B DTC P1290 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Mis routed harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the AP sensor 1, AP sensor 2, AP sensor 3 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1290 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1290 Diagnostic Chart may isolate the cause of the fault.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–449

DTC P1290 — ETC Forced Idle Mode Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to ETC System Check

Refer to Diagnostic Aids

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 8

Go to Step 7

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 9

Was the “Electric Throttle Control (ETC) System Check” performed? —

Observe the AP angle reading on the Tech2 while slowly opening the throttle.

Idle position AP sensor 1 Does the AP angle increase steadily and evenly from =12 ∼ 14 % the closed throttle value to the wide open throttle AP sensor 2, 3 =86 ∼ 88 % value? Wide open throttle AP sensor 1 =86 ∼ 88 % AP sensor 2 =12 ∼ 14 % AP sensor 3 =32 ∼ 36 % 1. Disconnect the AP sensor. 2. Observe the AP sensor reading on the Tech 2. Is the AP sensor reading near the specified value?

1. Connect a test light between the 5 voltage supply circuit and the AP1, AP2 and AP3 sensor signal circuit at the AP sensor harness connector. 2. Observe the AP sensor reading on the Tech2. Is the AP sensor reading near the specified value?

Go to OBD System Check

Was the “On — Board (OBD) System Check” performed? —

Yes

Check the following items; 1. AP1,AP2 and AP3 signal circuit for a short to voltage. 2. AP1, AP2 and AP3 sensor ground circuit for high resistance between the PCM and the AP sensor. 3. AP1, AP2 and AP3 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found?

Check the following items; 1. AP1, AP2 and AP3 signal circuit or 5 volt supply circuit for a poor connection. 2. AP1, AP2 and AP3 signal circuit or 5 volt supply circuit for high resistance between the PCM and the AP1, AP2 and AP3 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found?

6E–450

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1290 — ETC Forced Idle Mode (Cont’d) Step

Action

Yes

Replace the AP sensor. Is the action complete?

Value(s)

—

Verify repair

—

Verify repair

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–451

Diagnostic Trouble Code (DTC) P1295 ETC Power Management Mode

D06RY00111

Circuit Description

Action Taken When the DTC Sets

B The throttle position (TP) sensor circuit provides a voltage signal relative to throttle position (blade angle). The throttle blade angle will vary from about 8 % at closed throttle to about 92 % at wide open throttle (WOT). B The DC motor circuit provides a voltage signal relative to command throttle position (blade angle). B The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain Control Module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantity of air entering the engine indicates an accelerator or high load situation, while a small quantity or air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 4 to 7g/s at idle to around 25 to 40g/s at maximum engine load. B This DTC detects that if the system is in Power Management Mode.(Fail safe Mode)

B The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. B The PCM calculates an air flow value based on throttle blade position, RPM and barometric pressure. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for setting the DTC B The ignition is “ON”. B Power Management Mode is active. (Fail safe Mode)

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1295 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1295 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–452

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the TP sensor 1, TP sensor 2 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1295 cannot be duplicated, the

information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determining that the DTC occurs intermittently, performing the DTC P1295 Diagnostic Chart may isolate the cause of the fault.

DTC P1295 — ETC Power Management Mode Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to ETC System Check

Go to Step 4

Refer to Diagnostic Aids

Go to Step 9

Go to Step 5

0.3 ∼ 100 W

Go to Step 6

Go to Step 8

—

Verify repair

Go to Step 7

Verify repair

Go to Step 8

—

Verify repair

—

Go to Step 10

Go to Step 11

Was the “Electric Throttle Control (ETC) System Check” performed? —

Closed throttle TP Does the TP angle increase steadily and evenly from sensor 1 =8 ∼ 10 % TP the closed throttle value to the wide open throttle sensor 2 =90 value? ∼ 92 % Wide open throttle TP sensor 1 =90 ∼ 92 % TP sensor 2 =8 ∼ 10 % 1. Ignition “OFF”. 2. Disconnect the DC motor. Check the DC motor harness between the PCM and DC Motor circuit at the DC motor harness connector. Was a problem found?

—

Observe the TP angle reading on the Tech 2 while slowly opening the throttle.

Is the DC motor reading near the specified value? 6

Check the throttle valve assembly. Was a problem found?

Replace the DC motor. (Replace the Throttle valve assembly) Is the action complete?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

1. Disconnect the TP sensor. 2. Observe the TP sensor reading on the Tech 2. Is the TP sensor reading near the specified value?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–453

DTC P1295 — ETC Power Management Mode (Cont’d) Step

Action

1. Connect a test light between the 5Volt reference “A” circuit and the TP1 and TP2 sensor signal circuit at the TP sensor harness connector. 2. Observe the TP sensor reading on the Tech 2. Is the TP sensor reading near the specified value?

Value(s)

Yes

Go to Step 13

Go to Step 12

—

Verify repair

Go to Step 14

—

Verify repair

Go to Step 14

—

Verify repair

—

6 ∼ 10 g/s

Go to Step 15

Go to Step 18

0g/s

Go to Step 16

Go to Step 17

—

Verify repair

—

Verify repair

Go to Step 23

6 ∼ 10 g/s

Go to Step 16

Go to Step 19

Check the following items; 1. TP1 and TP2 signal circuit for a short to voltage. 2. TP1 and TP2 sensor ground circuit for high resistance between the PCM and the TP sensor. 3. TP1and TP2 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found?

Check the following items; 1. TP1and TP2 signal circuit or 5 volt reference circuit for a poor connection. 2. TP1 and TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP1and TP2 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found?

Replace the TP sensor. Is the action complete?

1. Start the engine. 2. With the engine idling, monitor “MAF Frequency” display on the Tech 2. Is the “MAF Frequency” below the specified value?

1. 2. 3. 4.

Ignition “OFF”. Disconnect the MAF sensor connector. Ignition “ON”, engine idling. Using a Tech 2, monitor “MAF Frequency”.

Does the Tech 2 indicate a “MAF Frequency” at the specified value? 16

Replace the MAF sensor. Is the action complete?

1. Check the MAF harness for incorrect routing near high voltage components (solenoids, relays, motors). 2. If incorrect routing is found, correct the harness routing. Was a problem found?

6E–454

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1295 — ETC Power Management Mode (Cont’d) Step

Action

Go to Step 20

Go to Step 23

Go to Step 22

Go to Step 21

—

Verify repair

Go to Step 23

—

Verify repair

—

Verify repair

—

Replace the MAP sensor. Is the action complete?

65kPa

1. Check the MAP signal circuit between the PCM and MAP ground circuit. 2. If the MAP signal circuit is open or shorted, repair it as necessary. Was the MAP signal circuit open or shorted?

Yes

1. Ignition “ON”, engine not running. 2. Observe the MAP reading on the Tech 2. Is the MAP reading less than the specified value?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–455

Diagnostic Trouble Code (DTC) P1299 ETC Forced Engine Shutdown Mode

060R200061

Circuit Description

Action Taken When the DTC Sets

B The throttle position sensor circuit provides a voltage signal relative to throttle position (blade angle). The throttle blade angle will vary from about 8% at closed throttle to about 92% at wide open throttle(WOT). B The DC motor circuit provides a voltage signal relative to command throttle position (blade angle). B The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain Control Module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantity of air entering the engine indicates an accelerator or high load situation, while a small quantity or air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 4 to 7g/s at idle to around 25 to 40g/s at maximum engine load. B This DTC detects if the system is in ETC Forced Engine Shutdown Mode.(Fail safe Mode)

B The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. B The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for setting the DTC B The ignition is “ON”. B ETC Forced Engine Shutdown Mode is active. (Fail safe Mode)

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1299 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1299 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–456

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determining that the DTC occurs intermittently, performing the DTC P1299 Diagnostic Chart may isolate the cause of the fault.

DTC P1299 — ETC Forced Engine Shutdown Mode Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to ETC System Check

Go to Step 8

Go to Step 4

0.3 ∼ 100W

Go to Step 5

Go to Step 7

—

Verify repair

Go to Step 6

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

Go to Step 9

Go to Step 10

Go to Step 12

Go to Step 11

Was the “Electric Throttle Control (ETC) System Check” performed? —

Observe the TP angle reading on the Tech 2 while slowly opening the throttle.

Check the DC motor harness between the PCM and DC Motor circuit at the DC motor harness connector. Was a problem found?

Check the throttle valve assembly. Was a problem found?

Replace the DC motor. (Replace the Throttle valve assembly) Is the action complete?

1. Disconnect the TP sensor. 2. Observe the TP sensor reading on the Tech 2. Is the TP sensor reading near the specified value?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

1. Connect a test light between the 5 Volt reference circuit and the TP1 and TP2 sensor signal circuit at the TP sensor harness connector. 2. Observe the TP sensor reading on the Tech 2. Is the TP sensor reading near the specified value?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–457

DTC P1299 — ETC Forced Engine Shutdown Mode (Cont’d) Step

Action

Value(s)

Yes

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 13

—

Verify repair

—

6 ∼ 10 g/s

Go to Step 16

Go to Step 17

0g/s

Go to Step 15

Go to Step 16

—

Verify repair

Go to Step 18

—

Verify repair

Go to Step 22

6 ∼ 10 g/s

Go to Step 15

Go to Step 18

65kPa

Go to Step 19

Go to Step 22

Replace the TP sensor. Is the action complete?

1. Start the engine. 2. With the engine idling, monitor “MAF Frequency” display on the Tech 2. Is the “MAF Frequency” below the specified value?

1. 2. 3. 4.

Ignition “OFF”. Disconnect the MAF sensor connector. Ignition “ON”, engine idling. Using a Tech 2, monitor “MAF Frequency”.

Does the Tech 2 indicate a “MAF Frequency” at the specified value? 15

Replace the MAF sensor. Is the action complete?

1. Check the MAF harness for incorrect routing near high voltage components (solenoids, relays, motors). 2. If incorrect routing is found, correct the harness routing. Was a problem found?

1. Ignition “ON”, engine not running. 2. Observe the MAP reading on the Tech 2. Is the MAP reading less than the specified value?

6E–458

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1299 — ETC Forced Engine Shutdown Mode (Cont’d) Step

Action

Value(s)

1. Disconnect the MAP sensor. 2. Connect a test 5 volt reference circuit and the MAP signal at the MAP sensor harness connector. 3. Observe the MAP reading on the Tech 2. Is the MAP reading less than the specified value?(If no, start with diagnosis chart for other sensors in the circuit and see if 5V returns.)

—

Go to Step 20

Go to Step 21

—

Verify repair

Go to Step 22

—

Verify repair

—

Verify repair

—

Replace the MAP sensor. Is the action complete?

1. Check the MAP signal circuit between the PCM and MAP ground circuit. 2. If the MAP signal circuit is open or shorted ,repair it as necessary. Was the MAP signal circuit open or shorted?

Yes

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–459

Diagnostic Trouble Code (DTC) P1310 ION Sensing Module Diagnosis

060R200068

Circuit Description

Conditions for setting the DTC

The Power Control Module (PCM) checks the validity of the signals used in the ION Sensing module at the following engine operating conditions. B The Deceleration Fuel Cut Off (DFCO) test is performed to evaluate the Combustion Quality (CQ) signal pulse width B If it is below a predetermined value, the value it is expected to be during DFCO conditions. If the CQ signal pulse width is above the predetermined threshold, the fail counter will be incremented. If the failure counter exceeds the calibration, then the test is complete and a failure will be reported. B The Power Enrichment (PE) test is performed to evaluate the Combustion Quality (CQ) signal pulse width B If it is below a predetermined value, the value is expected to be during PE conditions. If the CQ signal pulse width is above the predetermined threshold, the fail counter will be incremented. If the failure counter exceeds the calibration, then the test is complete and a failure will be reported. B The Combustion Quality (CQ) test is performed to check if inappropriate (CQ) signal status were detected. If missing CQ pulses or multiple CQ pulses or CQ pulse width calculation errors were detected, the fail counter will be incremented. If the failure counter exceeds the calibration, then the test is complete and a failure will be reported.

B B B B B B

Ignition voltage is between 10volt and 16 volts. MAP sensor signal is between 26kPa and 100 kPa. Fuel level is more than 19%. Engine speed is between 650rpm and 6500rpm. No Crank DTCs set. No System voltage DTCs set.

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. B The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1310 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault. B DTC P1310 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–460

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1310 cannot be duplicated, the information included in the Failure Records data can be useful in determined vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1310 Diagnostic Chart may isolate the cause of the fault.

DTC P1310 — ION Sensing Module Diagnostic Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Refer to Diagnostic Aids

—

Go to Step 4

Go to Step 3

—

Verify repair

Go to Step 6

—

Go to Step 6

Go to Step 5

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 10

1. Ignition “OFF”. 2. Disconnect the ION Sensing module. 3. Disconnect the PCM. Is the action complete?

Check the ION Sensing harness between the PCM and ION Sensing module circuit harness connector. Was a problem found?

1. Disconnect the ignition coil. Is the action complete?

Check the ION Sensing harness between the ignition coil and ION Sensing module circuit at the ION Sensing Module harness connector. Was a problem found?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Replace the Ignition coil. Is the action complete?

Check the following items; 1. ION Sensing module ground circuit for a poor connection. 2. If a problem is found, repair wiring harness as necessary. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–461

DTC P1310 — ION Sensing Module Diagnostic (Cont’d) Step

Action

Value(s)

Replace the ION Sensing module. Is the action complete?

Yes

—

Verify repair

Go to Step 11

—

Verify repair

—

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6E–462

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1311 ION Sensing Module SEC Line 1 Circuit Fault

060R200068

Circuit Description

Action Taken When the DTC Sets

B The Power Control Module (PCM) will compare the secondary current reading to predetermined maximum and minimum thresholds. If the secondary current signal pulse width is out of the predetermined range, the fail counter will be incremented. If the failure counter exceeds the calibration, then the PCM is complete and a failure will be reported. If the sample counter threshold is reached before the failure threshold, then the PCM is complete and pass will be reported. This PCM will detect an open/short circuit in the secondary current sense input circuit, misfire on the entire bank for the secondary current sense input circuit, coil failure, and same internal Ignition Current Sense System (ICSS) module faults.

B The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. B The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for setting the DTC B B B B B

Ignition voltage is between 10volt and 16 volts. MAP sensor signal is between 26kPa and 100 kPa. Fuel level is more than 19%. Engine speed is between 650rpm and 6500rpm. ION Sensing Module circuit is open or shorted signals on the SEC 1 line.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1311 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1311 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the moving connectors and wiring harnesses related to the sensor.

6E–463

B A change in the display will indicate the location of the fault. If DTC P1311 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. B If it is determined that the DTC occurs intermittently, performing the DTC P1311 Diagnostic Chart may isolate the cause of the fault.

DTC P1311 — ION Sensing Module SEC Line 1 Circuit Fault Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Refer to Diagnostic Aids

—

Go to Step 4

Go to Step 3

—

Verify repair

Go to Step 5

—

Go to Step 6

Go to Step 5

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 10

1. Ignition “OFF”. 2. Disconnect the ION Sensing module. 3. Disconnect the PCM. Is the action complete?

Check the ION Sensing module harness between the PCM and ION Sensing module circuit at the ION Sensing module harness connector. Was a problem found?

1. Disconnect the ignition coil. Is the action complete?

Check the ION Sensing module harness between the ignition coil and ION Sensing module circuit at the SEC line 1 harness connector. Was a problem found?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Replace the Ignition coil. Is the action complete?

Check the following items; 1. ION Sensing module ground circuit for a poor connection. 2. If a problem is found, repair wiring harness as necessary. Was a problem found?

6E–464

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1311 — ION Sensing Module SEC Line 1 Circuit Fault (Cont’d) Step

Action

Value(s)

Replace the ION Sensing module. Is the action complete?

Yes

—

Verify repair

Go to Step 11

—

Verify repair

—

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–465

Diagnostic Trouble Code (DTC) P1312 ION Sensing Module SEC Line 2 Circuit Fault

060R200068

Circuit Description

Action Taken When the DTC Sets

B The Power Control Module (PCM) will compare the secondary current reading to predetermined maximum and minimum thresholds. If the secondary current signal pulse width is out of the predetermined range, the fail counter will be incremented. If the fail counter exceeds the calibration, then the PCM is complete and a failure will be reported. If the sample counter threshold is reached before the failure threshold, then the PCM is complete and pass will be reported. This PCM will detect an open/short circuit in the secondary current sense input circuit, misfire on the entire bank for the secondary current sense input circuit, coil failure, and same internal Ignition Current Sense System (ICSS) module faults.

Conditions for setting the DTC B B B B B

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1312 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1312 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–466

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

A change in the display will indicate the location of the fault. If DTC P1312 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1312 Diagnostic Chart may isolate the cause of the fault.

DTC P1312 — ION Sensing Module SEC Line 2 Circuit Fault Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Refer to Diagnostic Aids

—

Go to Step 4

Go to Step 3

—

Verify repair

Go to Step 5

—

Go to Step 6

Go to Step 5

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 10

1. Ignition “OFF”. 2. Disconnect the ION Sensing module. 3. Disconnect the PCM. Is the action complete?

Check the ION Sensing module harness between the PCM and ICSS module circuit at the ION Sensing Module harness connector. Was a problem found?

1. Disconnect the ignition coil. Is the action complete?

Check the ION Sensing module harness between the ignition coil and ION Sensing module circuit at the SEC line 2 harness connector. Was a problem found?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Replace the Ignition coil. Is the action complete?

Check the following items; 1. ION Sensing module ground circuit for a poor connection. 2. If a problem is found, repair wiring harness as necessary. Was a problem found?

6E–467

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1312 — ION Sensing Module SEC Line 2 Circuit Fault (Cont’d) Step

Action

Value(s)

Replace the ION Sensing module. Is the action complete?

Yes

—

Verify repair

Go to Step 11

—

Verify repair

—

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

6E–468

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1326 ION Sensing Module Combustion Quality Input Circuit Fault

060R200068

Circuit Description

Conditions for Clearing the MIL/DTC

The Power Control Module (PCM) checks the validity of the signals used in the ION Sensing module at the following engine operating conditions. B The test is performed to evacuate the Combustion Quality (CQ) signal pulse width if it is within a predetermined range. If the CQ signal pulse width is out of the predetermined range, the fail counter will be incremented. If the failure counter exceeds the calibration, then test is complete and a failure will be reported. If the sample counter threshold is reached before the failure threshold, then the test is complete and a pass will be reported. This test will detect an open/short in the CQ line circuit, ION Sensing module faults and analog input faults in the PCM.

B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1326 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1326 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for setting the DTC B Ignition voltage is between 10volt and 16 volts. B No Crank DTCs set. B No cylinder ID DTCs set.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1326 cannot be duplicated, the information included in the Failure Records data can

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS be useful in determined vehicle mileage since the DTC was last set.

6E–469

If it is determined that the DTC occurs intermittently, performing the DTC P1326 Diagnostic Chart may isolate the cause of the fault.

DTC P1326 — ION Sensing Module Combustion Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Refer to Diagnostic Aids

—

Go to Step 4

Go to Step 3

—

Verify repair

Go to Step 5

—

Go to Step 6

Go to Step 5

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 10

1. Ignition “OFF”. 2. Disconnect the ION Sensing module. 3. Disconnect the PCM. Is the action complete?

Check the ION Sensing module harness between the PCM and ION Sensing module circuit at the QC line harness connector. Was a problem found?

1. Disconnect the ignition coil. Is the action complete?

Check the ION Sensing module harness between the ignition coil and ICSS module circuit at the ION Sensing Module harness connector. Was a problem found?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Replace the Ignition coil. Is the action complete?

Check the following items; 1. ION Sensing module ground circuit for a poor connection. 2. If a problem is found, repair wiring harness as necessary. Was a problem found?

6E–470

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1326 — ION Sensing Module Combustion (Cont’d) Step

Action

Value(s)

Replace the ION Sensing module. Is the action complete?

Yes

—

Verify repair

Go to Step 11

—

Verify repair

—

Replace the PCM. IMPORTANT: The programmed.

replacement

PCM

must

Refer to ON-Vehicle Service in Power Control Module and Sensors for procedures. And also refer to latest Service Bulletin .Check to see if the latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–471

Diagnostic Trouble Code (DTC) P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)

060R200068

Circuit Description The Power Control Module (PCM) checks the validity of the signals used in the ION Sensing module at the following engine operating conditions. B This test will return a fault if the cylinder synchronization routine has not been completed after a predetermined number of events after crank. This test will detect fault that will prevent the PCM from synchronization, such as Knock Signal (KI) Combustion Quality (CQ) lines being swapped, shorted spark plugs, ION Sensing module faults, an PCM hardware faults.

Conditions for setting the DTC B B B B B B B

Ignition voltage is between 11volts and 16 volts. Engine speed is between 650rpm and 6250rpm. No ECT DTCs set. No injector DTCs set. No Fuel Trim DTCs set. No Misfire DTCs set. No system voltage DTCs set.

B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1340 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1340 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–472

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

A change in the display will indicate the location of the fault. If DTC P1340 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

If it is determined that the DTC occurs intermittently, performing the DTC P1340 Diagnostic Chart may isolate the cause of the fault.

DTC P1340 — ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail) Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Refer to Diagnostic Aids

—

Go to Step 4

Go to Step 3

—

Verify repair

Go to Step 5

—

Go to Step 6

Go to Step 5

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 10

1. Ignition “OFF”. 2. Disconnect the ION Sensing module. 3. Disconnect the PCM. Is the action complete?

Check the ION Sensing module harness between the PCM and ICSS module circuit at the QC line harness connector. Was a problem found?

1. Disconnect the ignition coil. Is the action complete?

Check the ION Sensing module harness between the ignition coil and ION Sensing module circuit at the ION Sensing Module harness connector. Was a problem found?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

Replace the Ignition coil. Is the action complete?

Check the following items; 1. ION Sensing module ground circuit for a poor connection. 2. If a problem is found, repair wiring harness as necessary. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–473

DTC P1340 — ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail) (Cont’d) Step

Action

Yes

Replace the ION Sensing module. Is the action complete?

Value(s)

—

Verify repair

Go to Step 11

—

Verify repair

—

6E–474

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed

060R200050

Circuit Description

Conditions for Clearing the MIL/DTC

The powertrain control module (PCM) monitors the EGR valve pintle position input to ensure that the valve responds properly to commands from the PCM, and to detect a fault if current pintle zero position is different from the learned zero position. If the PCM detects a pintle position signal indicates more than 30 % different between current zero position and the learned zero position for more than 5 seconds, and this condition exists 3 times during trip, then the PCM will set DTC P1404.

B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1404 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1404 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC

Check for the following conditions: B Excessive carbon deposit on EGR valve shaft and/or foreign material may cause the EGR valve not to fully seat. The carbon deposit may occur by unusual port operation. Remove foreign material and/or excessive carbon deposit on EGR valve shaft and to allow the EGR valve to be fully seated. B Poor connection or damaged harness – Inspect the wiring harness for damage. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

B B B B

Ignition voltage is between 11 and 16 volts. Intake Air temp is more than 3°C. Desired EGR position is more than 3 %. Difference of EGR pintle position between current and the learned zero is more than 30 % for more than 5 seconds, and exists three times to the above condition during a trip the PCM will set DTC 1404. Then it trigger the PCM light on.

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) after consecutive 2nd trip in which the fault is detected. B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data.

Diagnostic Aids

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–475

DTC P1404 – EGR Stuck Closed Step

Action

Value(s)

Go to Step 2

—

Go to Step 3

Refer to Diagnostic Aids

—

Go to Step 4

Go to Step 5

—

Verify repair

—

Go to Step 6

Go to Step 7

—

Go to Step 9

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

1. Ignition “ON”, engine “OFF”, review and record Tech 2 Failure Records Data. 2. Operate the vehicle within Failure Records conditions as noted. 3. Using a Tech 2, monitor “DTC inf.” for DTC P1404 until the DTC P1404 test runs. Note the result. Does the Tech 2 indicates DTC P1404 failed this ignition?

1. Disconnect the EGR valve harness connector. 2. Inspect the EGR valve and connectors for damaged pin or terminals. Were there any damaged pins or terminals?

Repair the damaged pin or terminal. Is the action complete?

1. Remove EGR valve from Engine. 2. Inspect EGR valve for any excessive carbon deposit on EGR shaft. 3. Inspect for any foreign material inside of EGR valve. Was excessive carbon deposit on EGR valve shaft and/or foreign material in EGR valve ?

1. Clean up EGR valve shaft and inside of EGR valve. 2. Remove foreign material from EGR valve. 3. Visually inspect damage of pintle and seat to see if it is bent. If damaged, leakage may occur. Was there any severe damage which affects function?

1. 2. 3. 4. 5. 6.

Verify repair Go to Step 7

Install the EGR valve. Ignition “OFF”. Install the Tech 2. Run the engine at idle. On the Tech 2, select EGR Control Test. Use the “UP” arrow to increase the EGR from 0% to 40%.

Did EGR work properly? 8

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

1. Reset the learned zero EGR valve position. 2. Repeat step 7. Did EGR work properly?

6E–476

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1404 – EGR Stuck Closed (Cont’d) Step

Action

Yes

Replace the EGR valve. Does DTC P1404 still fail “DTC” test on the Tech 2?

Value(s)

—

Go to Step 10

Verify repair

—

Verify repair

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–477

Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge

060RY00398

Circuit Description Canister purge is controlled by a solenoid valve that allows manifold vacuum to purge the canister. The powertrain control module (PCM) supplies a ground to energize the solenoid valve (purge “ON”). The EVAP purge solenoid control is pulse-width modulated (PWM) or turned “ON” and “OFF” several times a second. The duty cycle (pulse width) is determined by engine operating conditions including load, throttle position, coolant temperature and ambient temperature. The duty cycle is calculated by the PCM and the output is commanded when the appropriate conditions have been met.

Conditions for Setting the DTC B No active ECT sensor, IAT sensor, MAP sensor, or TP sensor DTCs set. B BARO reading is above 85 kPa. B Engine coolant temperature is below 70°C (158°F). B Start-up intake air temperature (IAT) and start-up engine coolant temperature (ECT) are both above 5°C (41°F). B The difference between start-up ECT and start-up IAT is less than 25°C (45°F). B TP sensor indicates a throttle position above 12%. B Battery voltage is between 11.5 volts and 16 volts. B Engine speed is between 800 and 6,000 RPM. B Canister purge duty cycle is below 3%.

B Fuel level is between 15% and 85%. B All conditions are present for at least 3 seconds.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1441 will clear after 40 consecutive warm–up cycles have occurred without a fault. B DTC P1441 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6E–478

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart.

3. Determines if the PCM is able to control the EVAP purge solenoid valve. 4. Determines if the DTC will set under the conditions present when the DTC was originally stored. If not, the fault is intermittent. 5. Checks for a grounded EVAP purge solenoid driver circuit, a faulty EVAP vacuum switch, or a leaking EVAP purge solenoid valve.

DTC P1441 – EVAP System Flow During Non-Purge Step

Action

Value(s)

1. 2. 3. 4.

Go to Step 2

1.51V

Go to Step 3

Go to DTC P0452 or P0453

1.52 — 1.60V

Go to Step 4

Go to Step 6

1.47 — 1.51V

Go to Step 6

Go to Step 5

—

Verify Repair

—

Ignition “OFF”. Remove the fuel filler cap. Ignition “ON”. Observe “Fuel Tank Pressure” on the Tech 2.

Is “Fuel Tank Pressure” at the specified value? 3

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

1. Re-install the fuel filler cap. 2. Using the Tech 2, command the EVAP Vent Solenoid Valve “ON” (Closed). 3. Disconnect the canister side rubber hose end that hose is connected between the Purge Solenoid Valve and Canister. IMPORTANT: Before continuing with the diagnosis, zero the EVAP pressure/purge cart J41413 (refer to the tool operating instructions). And them monitor the fuel tank inner pressure using the Tech 2. Does the fuel tank pressure remain the specified value?

1. Disconnect the EVAP pressure/purge cart J41413, and then plug the hose end. 2. Disconnect the rubber hose end of engine vacuum source side, (the hose connected between Purge Solenoid Valve and engine). 3. Connect the vacuum hand pump to this rubber hose end. 4. Then apply the -15 in H2O vacuum by the vacuum pump. 5. Monitor the fuel tank inner pressure using the Tech 2. Does the fuel tank inner pressure hold the specified value?

Replace the Purge Solenoid Valve.

6E–479

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1441 – EVAP System Flow During Non-Purge (Cont’d) Step

Action

Yes

1. Check leaks, kinks or pinched hoses at the EVAP system rubber hose line, and also check if the rubber hoses are correctly connected or not. 2. Check for a leak from Vent Solenoid Valve and EVAP system rubber hoses, and also check for clogged Filter of air separator which is located near the vent solenoid valve. Was a problem found? Using the Vacuum Hose Routing Diagram, repair or re-connect the rubber hoses correctly.

Value(s)

—

Verify Repair

Go to Step 7

Verify Repair

Go to Diagnostic Aids

1. Start engine. 2. Remove the Fuel Filler cap. 3. Using the Tech 2, command the EVAP Vent Solenoid Valve “ON” (closed) and Purge Solenoid Valve “OFF” (0%). 4. Replace the Fuel Filler Cap. 5. Run the engine at 2500RPM constant while monitoring “Fuel Tank Vacuum” on the Tech 2. Does the fuel tank vacuum remain at the specified value while the EVAP Vent Solenoid Valve “ON” (closed) and Purge Solenoid Valve “OFF” (0%)?

30 — 40 %

6E–480

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1514 TPS — MAF Correlation Error

060R200061

Circuit Description

Action Taken When the DTC Sets

B The throttle position (TP) sensor circuit provides a voltage signal relative to throttle blade angle. The throttle blade angle will vary from about 8 % at closed throttle to about 92 % at wide open throttle (WOT). B The mass air flow (MAF) sensor measures the amount of air which passes through it into the engine during a given time. The powertrain Control Module (PCM) uses the mass air flow information to monitor engine operating conditions for fuel delivery calculations. A large quantity of air entering the engine indicates an accelerator or high load situation, while a small quantity or air indicates deceleration or idle. The MAF sensor produces a frequency signal which can be monitored using a Tech 2. The frequency will vary within a range of around 4 to 7g/s at idle to around 25 to 40g/s at maximum engine load.

B The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. B The PCM calculates an air flow value based on idle air control valve position, throttle position, RPM and barometric pressure. B The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for setting the DTC B B B B

The engine is running. No MAF sensor DTCs are set. Throttle actuation mode is not off. MAF reading-ETC estimated air flow is less than 40g/s for 250 failures within test 1000 test samples (15.6 m sec).

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault conditions is no longer present. B A history DTC P1514 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1514 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness — Inspect the wiring harness for damage. If the harness appears to be OK, observe the Mass Air Flow, TP sensor 1, TP sensor 2 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. B Plugged intake air duct or filter element B A wide — open throttle acceleration from a stop should cause the mass air flow displayed on a Tech 2 to increase from about 3 – 6 g/s at idle to 100 g/s or

6E–481

greater at the time of the 1 – 2 shift. If not, check for a restriction. A change in the display will indicate the location of the fault. If DTC P1514 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1514 Diagnostic Chart may isolate the cause of the fault.

DTC P1514 — TPS-MAF Correlation Error Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to ETC System Check

—

Go to Step 4

Refer to Diagnostic Aids

6 ∼ 10 g/s

Go to Step 5

Go to Step 8

0g/s

Go to Step 6

Go to Step 7

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 19

6 ∼ 10 g/s

Go to Step 6

Go to Step 9

65kPa

Go to Step 10

Go to Step 13

Was the “Electric Throttle Control (ETC) System Check” performed? —

1. Start the engine. 2. With the engine idling, monitor “MAF Frequency” display on the Tech 2. Is the “MAF Frequency” below the specified value?

1. 2. 3. 4.

Ignition “OFF”. Disconnect the MAF sensor connector. Ignition “ON”, engine idling. Using a Tech 2, monitor “MAF Frequency”.

Does the Tech 2 indicate a “MAF Frequency” at the specified value? 6

Replace the MAF sensor. Is the action complete?

1. Check the MAF harness for incorrect routing near high voltage components (solenoids, relays, motors). 2. If incorrect routing is found, correct the harness routing. Was a problem found?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

1. Ignition“ON”, engine not running. 2. Observe the MAP reading on the Tech 2. Is the MAP reading less than the specified value?

6E–482

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1514 — TPS-MAF Correlation Error (Cont’d) Step

Action

Go to Step 11

Go to Step 12

—

Verify repair

Go to Step 13

—

Verify repair

—

Refer to Diagnostic Aids

Go to Step 14

Go to Step 15

Go to Step 16

Go to Step 18

Go to Step 17

—

Verify repair

Go to Step 19

Closed throttle TP Does the TP angle increase steadily and evenly from sensor 1 =8 ∼ 10 % TP the closed throttle value to the wide open throttle sensor 2 =90 value? ∼ 92 % Wide open throttle TP sensor 1 =90 ∼ 92 % TP sensor 2 =8 ∼ 10 % 1. Disconnect the TP sensor. 2. Observe the TP sensor reading on the Tech2. 1. Connect a test light between the 5Volt reference circuit and the TP1 and TP2 sensor signal circuit at the TP sensor harness connector. 2. Observe the TP sensor reading on the Tech2. Is the TP sensor reading near the specified value?

—

Observe the TP angle reading on the Tech 2 while slowly opening the throttle.

Is the TP sensor reading near the specified value? 15

Replace the MAP sensor. Is the action complete?

Yes

1. Check the MAP signal circuit between the PCM and MAP ground circuit. 2. If the MAP signal circuit is open or shorted, repair it as necessary. Was the MAP signal circuit open or shorted?

Value(s)

Check the following items; 1. TP1 and TP2 signal circuit for a short to voltage. 2. TP1 and TP2 sensor ground circuit for high resistance between the PCM and the TP sensor. 3. TP1 and TP2 sensor ground circuit for a poor connection. 4. If a problem is found, repair wiring harness as necessary. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–483

DTC P1514 — TPS-MAF Correlation Error (Cont’d) Step

Action

Value(s)

Yes

Verify repair

Go to Step 18

—

Verify repair

—

Verify repair

—

Replace the TP sensor. Is the action complete?

—

6E–484

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1515 Command — Actual TPS Correlation Error

D06RY00111

Circuit Description B The throttle position (TP) sensor circuit provides a voltage signal relative to throttle position (blade angle). The throttle blade angle will vary from about 8 % at closed throttle to about 92 % at wide open throttle(WOT). B The DC motor circuit provides a voltage signal relative to command throttle position (blade angle). B This DTC detects the difference between actual throttle position and command throttle position.

Conditions for setting the DTC B The ignition is “ON”. B Throttle actuation mode is normal. B Command Throttle position — Actual Throttle position is more than + 5 % for 100 counts within 1000 test samples (15.6 m sec) else Actual Throttle position is less than + 40 % and Command Throttle position Actual Throttle position is more than — 5 % or Command Throttle position — Actual Throttle position is more than — 20 % for 150 failures within test 1000 test samples (15.6 m sec).

Action Taken When the DTC Sets B The PCM will illuminate the malfunction indicator lamp (MIL) the first time the fault is detected. B The PCM calculates an air flow value based on throttle blade position, RPM and barometric pressure.

B The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1515 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1515 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1515 cannot be duplicated, the information included in the Failure Records data can

6E–485

be useful in determing vehicle mileage since the DTC was last set. If it is determined that the DTC occurs intermittently, performing the DTC P1515 Diagnostic Chart may isolate the cause of the fault.

DTC P1515 — Command — Actual TPS Correlation Error Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to ETC System Check

Go to Step 4

Refer to Diagnostic Aids

Go to Step 5

Go to Step 8

0.3 ∼ 100 W

Go to Step 6

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 6

Go to Step 9

Go to Step 10

Go to Step 12

Go to Step 11

Was the “Electric Throttle Control (ETC) System Check” performed? —

Replace the DC motor. Is the action complete?

1. Disconnect the TP sensor. 2. Observe the TP sensor reading on the Tech 2. Is the TP sensor reading near the specified value?

—

Observe the TP angle reading on the Tech 2 while slowly opening the throttle.

Is the DC motor reading near the specified value? 6

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

1. Connect a test light between the 5Volt reference circuit and the TP1 and TP2 sensor signal circuit at the TP sensor harness connector. 2. Observe the TP sensor reading on the Tech2. Is the TP sensor reading near the specified value?

6E–486

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1515 — Command — Actual TPS Correlation Error (Cont’d) Step

Action

Value(s)

Yes

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 13

—

Verify repair

—

Verify repair

—

Replace the TP sensor. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–487

Diagnostic Trouble Code (DTC) P1516 Command — Actual TPS Correlation Error

D06RY00111

Circuit Description

Conditions for Clearing the MIL/DTC

B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1516 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1516 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for setting the DTC B The ignition is “ON”. B Throttle Actuation mode is normal. B Command Throttle position-Actual Throttle position is less than 8 % when desired TPS is steady within 0.5 % for 30 seconds within test samples (30 second)

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness — Inspect the wiring harness for damage. If the harness appears to be OK, observe the TP sensor 1, TP sensor 2 display on the Tech2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1516 cannot be duplicated, the

6E–488

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

If it is determined that the DTC occurs intermittently, performing the DTC P1516 Diagnostic Chart may isolate the cause of the fault.

DTC P1516 — Command — Actual TPS Correlation Error Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to ETC System Check

Go to Step 4

Refer to Diagnostic Aids

Go to Step 5

Go to Step 8

0.3 ∼ 100 W

Go to Step 6

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 6

Go to Step 9

Go to Step 10

Go to Step 12

Go to Step 11

Was the “Electric Throttle Control (ETC) System Check” performed? —

Replace the DC motor. Is the action complete?

1. Disconnect the TP sensor. 2. Observe the TP sensor reading on the Tech2. Is the TP sensor reading near the specified value?

—

Observe the TP angle reading on the Tech 2 while slowly opening the throttle.

Is the DC motor reading near the specified value? 6

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–489

DTC P1516 — Command — Actual TPS Correlation Error (Cont’d) Step

Action

Value(s)

Yes

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 13

—

Verify repair

—

Verify repair

—

Check the following items; 1. TP1and TP2 signal circuit or 5 volt reference circuit for a poor connection. 2. TP1 and TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP1 and TP2 sensor. 3. If a problem is found, repair wiring harness as necessary. Was a problem found?

Replace the TP sensor. Is the action complete?

6E–490

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1523 Actuator Control Return Performance

D06RY00111

Circuit Description B The throttle position (TP) sensor circuit provides a voltage signal relative to throttle position (blade angle). The throttle blade angle will vary from about 8 % at closed throttle to about 92 % at wide open throttle(WOT). B The DC motor circuit provides a voltage signal relative to command throttle position (blade angle). B This DTC detects if the throttle return to the default position at key on is steady.

Conditions for setting the DTC B The ignition is “ON”. B Normalized TPS is less than 7 % or Normalized TPS is more than 25 %.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present.

B A history DTC P1523 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1523 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Diagnostic Aids An intermittent may be caused by the following: B Poor connections. B Misrouted harness. B Rubbed through wire insulation. B Broken wire inside the insulation. Check for the following conditions: B Poor connection at PCM-Inspect harness connectors for backed out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal to wire connection. B Damaged harness-Inspect the wiring harness for damage. If the harness appears to be OK, observe the TP sensor 1, TP sensor 2 display on the Tech 2 while moving connectors and wiring harnesses related to the sensor. A change in the display will indicate the location of the fault. If DTC P1523 cannot be duplicated, the information included in the Failure Records data can be useful in determining vehicle mileage since the DTC was last set.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–491

If it is determined that the DTC occurs intermittently, performing the DTC P1523 Diagnostic Chart may isolate the cause of the fault.

DTC P1523 — Actuator Control Return Performance Step

Action

Value(s)

Go to Step 2

Go to Step 3

Go to ETC System Check

Go to Step 4

Go to Step 7

0.3 ∼ 100 W

Go to Step 5

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 5

Go to Step 8

Go to Step 9

Go to Step 11

Go to Step 10

—

Verify repair

Go to Step 12

Was the “Electric Throttle Control (ETC) System Check” performed? —

Observe the TP angle reading on the Tech 2 while slowly opening the throttle.

Check the DC motor harness between the PCM and DC Motor circuit at the DC motor harness connector. Was a problem found?

Replace the DC motor. Is the action complete?

1. Disconnect the TP sensor. 2. Observe the TP sensor reading on the Tech 2. Is the TP sensor reading near the specified value?

Go to OBD System Check

Was the “On-Board (OBD) System Check” performed? —

Yes

6E–492

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1523 — Actuator Control Return Performance (Cont’d) Step

Action

Value(s)

Yes

Go to Step 12 —

Verify repair

—

Verify repair

—

Verify repair

—

Replace the TP sensor. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–493

Diagnostic Trouble Code (DTC) P1571 Brake Switch No Operation

060R200067

Circuit Description

Action Taken When the DTC Sets

Conditions for Setting the DTC B Two break switch signals do not acknowledge after signal changed. B Switch does not change during accelerating vehicle or decelerating. B VSS is not fault. B Engine is running.

Conditions for Clearing the DTC B DTC P1571 can be cleared by using the scan tool “Clear Info” function or by disconnecting the PCM battery feed.

6E–494

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1571 Brake Switch No Operation Step

Action

Value(s)

Yes

—

Go to Step 2

Go to OBD System Check

—

Verify repair

Go to Step 3

—

Verify repair

Go to Step 4

—

Verify repair

—

Go to Step 6

Go to Step 9

Between pin1 and pin2 is ∞W, Between pin3 and pin4 is 0W

Go to Step 7

Go to Step 9

—

Verify repair

Go to Step 8

—

Verify repair

—

Verify repair

—

Was the “On-Board Diagnostic (OBD) System Check” performed? 1. Ignition “Off”. Engine “Off”. 2. Check following fuses. B BACK 15A B STOP LAMP 15A Was a problem found?

1. Make adjustment to the brake switch. (Refer to “Brake switch” in “10A CRUISE CONTROL SYSTEM”.) Was the problem found?

1. Push the shaft on brake switch. 2. Check shaft operation for smooth movement. Was the problem found?

1. Disconnect the connector at brake switch. 2. Check following terminal pin by ohmmeter. (Leave the shaft position at brake switch. Don’t Between pin1 push it.) and pin2 is B Between pin 1 and pin 2 0W, Between B Between pin 3 and pin 4 pin3 and pin4 Was it specified value? is ∞W 1. Disconnect the connector at brake switch. 2. Check following terminal pin at ohmmeter. (Don’t press the button of the brake switch.) B B

•Between pin 1 and pin 2 •Between pin 3 and pin 4

Was it specified value? 7

1. Probe related circuits for open or short to ground. 2. If a problem was found, repair as necessary. Was a problem found?

1. Replace the PCM. IMPORTANT: The replacement PCM must be programmed. Refer to On-Vehicle Service in Powertrain Control Module and Sensors for procedures. And also refer to latest Service Bulletin. Check to see if the Latest software is released or not. And then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM. Was the action completed?

1. Replace the brake switch. Was the action completed?

6E–495

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset Circuit Description

Conditions for Clearing the MIL/DTC

The powertrain control module (PCM) monitors unexpected PCM reset. This will not turn on MIL light on, only record code DTC P1625.

B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1625 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1625 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Conditions for Setting the DTC B Clock or COP (Computer Operating Properly) reset.

Action Taken When the DTC Sets B The PCM will not illuminate the malfunction indicator lamp (MIL). B The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

Diagnostic Aids Check for the following conditions: B P1625 stored alone does not need diagnosis. Clear DTC code.

DTC P1625 – PCM Unexpected Reset Step

Action

Value(s)

1. 2. 3. 4.

Go to Step 2

Go to Step 3

Go to Diagnostic Aids

—

Go to Step 4

Go to Diagnostic Aids

—

Verify repair

—

Ignition is “ON”. Install the Tech 2. Start the engine and let it Idle. On the Tech 2, select “DTC info”.

Does the Tech 2 indicate DTC P1625 failed? 3

1. 2. 3. 4.

—

Ignition is “ON”. Clear DTC P1625 by using the Tech 2 “Clear Info”. Start the engine and let it Idle. On the Tech 2, select “DTC info”.

Does the Tech 2 indicate DTC P1625 failed?

Go to OBD System Check

Was the “On-Board Diagnostic (OBD) System Check” performed? —

Yes

1. Check for aftermarket electronics, such as transceiver, stereos, and anti theft devices. They may radiate EMI into the control system if they are improperly installed. (This may cause a false sensor reading and turn on the MIL.) 2. If a problem is found, repair as necessary. Was a problem found?

6E–496

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1635 Reference Voltage # 1 Circuit Fault

D06RY00093

Circuit Description The TP sensor # 1 shares a 5 Volt reference with the PCM. If the PCM detects the 5 Volt reference for the TP sensor # 1 is failure, DTCP1635 will be set.

Conditions for setting the DTC B The ignition is “ON”. B The 5 Volt reference voltage for the TP sensor # 1 is less than 4 volts. B The 5 Volt reference voltage for the TP sensor # 1 is more than 5 volts.

Action Taken When the DTC Sets B The PCM will not illuminate the malfunction indicator lamp (MIL) .

B The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1635will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1635 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed. Tech2 “ Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–497

Diagnostic Trouble Code (DTC) P1635 Reference Voltage # 1 Circuit Fault Step

Action

Go to Step 2

4.95 – 5.0V

Go to ETC System Check

Go to Step 3

11.6 – 12.7V

Go to Step 4

Go to Step 5

11.6 – 12.7V

Go to Step 6

Go to Step 5

—

Verify repair

Go to Step 6

—

Verify repair

—

1. Ignition “ON”, engine not running. 2. Using a DVM at the PCM side of the connector, check the voltage at terminal F57 (RED/WHT) pin. Observe the battery voltage and circuit. If a problems found, repair it as necessary. Was the problem found?

—

1. Ignition “ON”, engine not running. 2. Using a DVM at the PCM side of the connector, check the voltage at terminal F20 (RED/WHT) pin.

Is the voltage in specified range? 5

Go to OBD System Check

1. Ignition “ON”, engine not running. 2. Using a DVM at the PCM side of the connector, check the voltage at terminal S38 (RED) pin.

Is the voltage in specified range? 4

Yes

Was the “On-Board(OBD)System Check” performed?

Is the voltage in specified range? 3

Value(s)

6E–498

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1639 Reference Voltage # 2 Circuit Fault

060R200064

Circuit Description The AP sensor # 1shares a 5 Volt reference with the PCM. If the PCM detects the 5 Volt reference for the AP sensor # 1 is failure, DTC P1635 will be set.

Conditions for setting the DTC B The ignition is “ON”. B The 5 Volt reference voltage for the AP sensor # 1 is less than 4 volts. B The 5 Volt reference voltage for the AP sensor # 1 is more than 5 volts.

Action Taken When the DTC Sets B The PCM will not illuminate the malfunction indicator lamp (MIL).

B The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1639 will clear after 40 consecutive trip cycles during which the warm up cycles have occurred without a fault. B DTC P1639 can be cleared using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed. Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–499

Diagnostic Trouble Code (DTC) P1639 Reference Voltage # 2 Circuit Fault Step

Action

Go to Step 2

4.95 – 5.0V

Go to ETC System Check

Go to Step 3

11.6 – 12.7V

Go to Step 4

Go to Step 5

11.6 – 12.7V

Go to Step 6

Go to Step 5

—

Verify repair

Go to Step 6

—

Verify repair

—

1. Ignition “ON”, engine not running. 2. Using a DVM at the PCM side of the connector, check the voltage at terminal F57 (RED/WHT) pin. Observe the battery voltage and circuit. If a problem is found, repair it as necessary. Was the problem found?

—

1. Ignition “ON”, engine not running. 2. Using a DVM at the PCM side of the connector, check the voltage at terminal F20(RED/WHT) pin.

Is the voltage in specified range? 5

Go to OBD System Check

1. Ignition “ON”, engine not running. 2. Using a DVM at the PCM side of the connector, check the voltage at terminal S36 (BLK) pin.

Is the voltage in specified range? 4

Yes

Was the “On-Board (OBD) System Check” performed?

Is the voltage in specified range? 3

Value(s)

6E–500

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM) Circuit Description

Diagnostic Aids

Output driver modules (ODMs) are used by the powertrain control module (PCM) to turn “ON” many of the current-driven devices that are needed to control various engine and transmission functions. Each ODM is capable of controlling up to 7 separate outputs by applying ground to the device which the PCM is commanding “ON”. Unlike the Quad Driver Modules (QDMs) used in prior model years, ODMs have the capability of diagnosing each output circuit individually. DTC P1640 set indicates an improper voltage level has been detected on an ODM output. Since A/C is an option, No A/C will cause the air conditioning clutch relay output to always fail. If a fault is seen on the air conditioning clutch relay output, it will not be logged as a fault until the A/C request input interrupts a high voltage, indicating that A/C has been installed.

Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage, If the harness appears to be OK, disconnect the PCM, turn the ignition “ON” and observe a voltmeter connected to the suspect driver circuit at the PCM harness connector while moving connectors and wiring harnesses related to the MIL. A change in voltage will indicate the location of the fault. B Poor connection at component – Examine for damaged connectors, unplugged connector, or damaged terminals at the following locations: Instrument cluster harness, canister purge solenoid, A/C clutch relay. An open ignition feed circuit at any of these components will cause DTC P1640 to be set. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Conditions for Setting the DTC B B B B

Ignition “ON”. Engine running. Ignition voltage is above 13.2 volts for 4 seconds. Output voltage does not equal ignition voltage when output is “OFF” or output voltage is not less than 1 volt when output is “ON”. B Above conditions occur for at least 1 second.

Action Taken When the DTC Sets B The PCM will not illuminate the malfunction indicator lamp (MIL). B The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

Conditions for Clearing the MIL/DTC B A history DTC P1640 will clear after 40 consecutive warm-up cycles occur without a fault. B DTC P1640 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 4. The Tech 2 Driver Module Status indicates the PCM pin that is affected. 9. The Tech 2 may indicate “short circuit” even when the problem is an open circuit. The cause of an open circuit may be in the component itself-lamp, purge, solenoid, or A/C compressor relay. 11.A short to ground on the ignition side of the component will blow the fuse. Since the fuse was checked in Step 2, a short to ground would be between the affected component and the PCM.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–501

DTC P1640 – Driver-1-Output Circuit Fault (ODM) Step

Action

—

Go to Step 2

—

Go to Step 3

Go to Step 4

—

Verify repair

—

Go to Step 5

Go to Step 6

Is the action complete?

—

Verify repair

—

Were either of the lamp circuits for “Check Engine” or “Check Trans” indicated as faulty by the Tech 2?

—

Go to Step 7

Go to Step 13

B+

Go to Step 15

Go to Step 8

—

Go to Step 10

Go to Step 9

—

Verify repair

—

Go to Step 11

Go to Step 12

—

Verify repair

—

Verify repair

—

Check the fuse for the driver circuit that was shown as faulty. 1. Check for a short to ground between the fuse and the affected component. 2. Replace the fuse after making any necessary repairs. Disconnect the PCM connector for the affected driver circuit. Is there any damage to the PCM pin or connector?

5 6 7

Repair the damaged pin or terminal.

1. Leave the PCM connector for the lamp driver circuit disconnected. 2. Ignition “ON”. 3. Using a DVM, check the voltage at the PCM connector for the affected lamp driver circuit. Was the voltage equal to the specified value?

1. Ignition “ON”. 2. Check for battery voltage at the fuse for the affected lamp circuit. Was battery voltage available at the fuse?

Repair the open circuit between the ignition switch and the fuse. Is the action complete?

1. Ignition “OFF”. 2. Disconnect the PCM connector for the affected driver terminal. 3. Connect an ohmmeter between a good ground and the PCM connector for the affected driver. Did the ohmmeter indicate continuity?

Repair the short to ground between the affected component and its PCM driver terminal. Is the action complete?

Go to OBD System Check

Is the action complete? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Was the fuse blown? 3

Value(s)

Repair the open circuit between the fuse and the PCM driver terminal for the affected circuit. Is the action complete?

6E–502

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1640 – Driver-1-Output Circuit Fault (ODM) (Cont’d) Step

Action

1. Connect the PCM. 2. Start the engine and let it idle. 3. Backprobe the affected terminal at the PCM with a DVM. Was the voltage equal to the specified value?

Yes

Go to Step 15

Go to Step 14

—

Go to Step 10

Go to Step 9

—

Verify repair

—

1. Run the engine at idle. 2. Check for battery voltage at the fuse for the affected circuit. Was battery voltage available at the fuse?

Value(s)

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–503

Diagnostic Trouble Code (DTC) P1650 Quad Driver Module “A” Fault Circuit Description

Diagnostic Aids

The Quad Driver Module (QDMs) are used by the powertrain control module (PCM) to turn “ON” current–driven devices that are needed to control two engine functions. The PCM monitors open or short circuit of either of Canister Control Purge (CCP) Vent solenoid or Variable Intake Manifold (VIM).

Check for the following conditions: B Poor connection at PCM – Inspect harness connectors for backed-out terminals, improper mating, broken locks, improperly formed or damaged terminals, and poor terminal-to-wire connection. B Damaged harness – Inspect the wiring harness for damage, If the harness appears to be OK, disconnect the PCM, turn the ignition “ON” and observe a voltmeter connected to the suspect driver circuit at the PCM harness connector while moving connectors and wiring harnesses relates to the MIL. A change in voltage will indicate the location of the fault. B Poor connection at component – Examine for damaged connectors, unplugged connector, or damaged terminals at the following locations: canister purge solenoid, fuel level sensor. An open ignition feed circuit at any of these components will cause DTC P1650 to be set. Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.

Conditions for Setting the DTC B B B B

Ignition “ON”. Engine running. Ignition voltage. Output voltage does not equal voltage and is not less than 1 volt when out put is “ON”. B Above conditions occur for at least 0.5 second.

Action Taken When the DTC Sets B The PCM will not illuminate the malfunction indicator lamp (MIL). B The PCM will store conditions which were present when the DTC was set as Failure Records only. This information will not be stored as Freeze Frame data.

Conditions for Clearing the MIL/DTC B The PCM will turn the MIL “OFF” on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present. B A history DTC P1650 will clear after 40 consecutive warm-up cycles have occurred without a fault. B DTC P1650 can be cleared by using the Tech 2 “Clear Info” function or by disconnecting the PCM battery feed.

The following PCM pins are controlled by Quad driver modules (QDMs): B S74 – VIM B S48 – Canister control purge

Test Description Number(s) below refer to the step number(s) on the Diagnostic Chart. 4. The Tech 2 Driver Module Status indicates the PCM pin that is affected. 9.The Tech 2 may indicate “short circuit” even when the problem is an open circuit. The cause of an open circuit may be in the component itself. 11.A short to ground on the ignition side of the component will blow the fuse. Since the fuse was checked in Step 2, a short to ground would be between the affected component and the PCM.

6E–504

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

DTC P1650 – Quad Driver Module (QDM) Fault Step

Action

—

Go to Step 2

—

Go to Step 3

Go to Step 4

—

Verify repair

—

Go to Step 5

Go to Step 6

Is the action complete?

—

Verify repair

—

Were either of the lamp circuits for “Check Engine” or “Check Trans”. indicated as faulty by the Tech 2?

—

Go to Step 7

Go to Step 13

B+

Go to Step 15

Go to Step 8

—

Go to Step 10

Go to Step 9

—

Verify repair

—

Go to Step 11

Go to Step 12

—

Verify repair

—

Verify repair

—

5 6 7

Repair the damaged pin or terminal.

1. Ignition “ON”. 2. Check for battery voltage at the fuse for the affected lamp circuit. Was battery voltage available at the fuse?

Repair the open circuit between the ignition switch and the fuse. Is the action complete?

Repair the short to ground between the affected component and its PCM driver terminal. Is the action complete?

Go to OBD System Check

Is the action complete? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Was the fuse blown? 3

Value(s)

Repair the open circuit between the fuse and the PCM driver terminal for the affected circuit. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–505

DTC P1650 – Quad Driver Module (QDM) Fault (Cont’d) Step

Action

1. Connect the PCM. 2. Start the engine and let it idle. 3. Backprobe the affected terminal at the PCM with a DVM. Was the voltage equal to the specified value?

Yes

Go to Step 15

Go to Step 14

—

Go to Step 10

Go to Step 9

—

Verify repair

—

1. Run the engine at idle. 2. Check for battery voltage at the fuse for the affected circuit. Was battery voltage available at the fuse?

Value(s)

6E–506

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Symptom Diagnosis Preliminary Checks Before using this section, perform the “On-Board Diagnostic (OBD) System Check” and verify all of the following items: B The powertrain control module (PCM), and malfunction indicator lamp (MIL) (Check Engine lamp) and Reduced Power Lamp (RPL) are operating correctly. B There are no DTC(s) stored. B Tech 2 data is within normal operating range. Refer to Typical Scan Data Values. B Verify the customer complaint and locate the correct symptom in the table of contents. Perform the procedure included in the symptom chart.

Visual/Physical Check Several of the symptom procedures call for a careful visual/physical check. This can lead to correcting a problem without further checks and can save valuable time. This check should include the following items: B PCM grounds for cleanliness, tightness and proper location. B Vacuum hoses for splits, kinks, and proper connections, as shown on the “Vehicle Emission Control Information” label. Check thoroughly for any type of leak or restriction. B Air intake ducts for collapsed or damaged areas. B Air leaks at throttle body mounting area, mass air flow (MAF) sensor and intake manifold sealing surfaces. B Ignition components for cracking, hardness, and carbon tracking. B Wiring for proper connections, pinches and cuts.

Intermittents IMPORTANT: An intermittent problem may or may not turn on the malfunction indicator lamp (MIL) or store a DTC. DO NOT use the Diagnostic Trouble Code (DTC) charts for intermittent problems. The fault must be present to locate the problem. Most intermittent problems are caused by faulty electrical connections or wiring. Perform a careful visual/physical check for the following conditions: B Poor mating of the connector halves or a terminal not fully seated in the connector (backed out). B Improperly formed or damaged terminal. B All connector terminals in the problem circuit should be carefully checked for proper contact tension. B Poor terminal-to-wire connection. This requires removing the terminal from the connector body to check. Road test the vehicle with a J 39200 Digital Multimeter connected to a suspected circuit. An abnormal voltage when the malfunction occurs is a good indication that there is a fault in the circuit being monitored. Use a Tech 2 to help detect intermittent conditions. The scan tool has several features that can be used to locate

an intermittent condition. Use the following feature to find intermittent faults: B Using a Tech 2’s “Freeze Frame” buffer or “Failure Records” buffer can aid in locating an intermittent condition. Review and record the information in the freeze frame or failure record associated with the intermittent DTC being diagnosed. The vehicle can be driven within the conditions that were present when the DTC originally set. To check for loss of diagnostic code memory, disconnect the MAP sensor and idle the engine until the MIL (Check Engine lamp) comes on. DTC P0107 should be stored and kept in memory when the ignition is turned “OFF”. If not, the PCM is faulty. When this test is completed, make sure that you clear the DTC P0107 from memory. An intermittent MIL (Check Engine lamp) with no stored DTC may be caused by the following: B Ignition coil shorted to ground and arcing. B MIL (Check Engine lamp) wire to PCM shorted to ground. B Poor PCM grounds. Refer to the PCM wiring diagrams. Check for improper installation of electrical options such as lights, cellular phones, etc. Check all wires from the PCM to the ignition coils for poor connections. Check for an open diode across the A/C compressor clutch and check for other open diodes (refer to wiring diagrams in Electrical Diagnosis). If problem has not been found, refer to PCM Connector Symptom tables. B Check the “Calibration ID” of the PCM, and compare it with the latest Isuzu service bulletins and/or Isuzu EEPROM reprogramming equipment to determine if an update to the PCM’s reprogrammable memory has been released. To check the “Calibration ID”, connect the Tech 2, then look for “Powertrain”, then select “Calibration ID”. This identifies the contents of the reprogrammable software and calibration contained in the PCM. If the “Calibration ID” is not the most current available, it is advisable to reprogram the PCM’s EEPROM memory, which may either help identify a hard-to-find problem or may fix the problem. B Calibration ID (example) Part number Broadcast Code Identifier

9377709 CYYD 801

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–507

Hard Start Symptom Step

Action

Go to Step 2

—

Go to Step 3

Go to ETC System Check

—

Verify repair

Go to Step 4

Go to Step 5

Go to Visual/ Physical Check

Go to Step 10

Go to Step 6

—

Go to Step 8

Go to Step 7

—

Verify repair

—

Verify repair

—

Verify repair

Go to Step 10

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

—

1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a visual/physical check performed? —

Check engine coolant temperature (ECT) sensor for shift in value. After 8 hours with the hood up and the engine not running, connect the Tech 2. With the ignition “ON” and the engine not running, compare engine coolant temperature to intake air temperature. Are ECT and IAT within the specified value of each ± 5°C (± 9°F) other?

1. Using a Tech 2, display the engine coolant temperature and note the value. 2. Check the resistance of the engine coolant temperature sensor. 3. Refer to Engine Coolant Temperature Sensor Temperature vs. Resistance chart on DTC P0118 Diagnostic Support for resistance specifications. Is the resistance value near the resistance for the temperature noted?

Replace the ECT sensor. Is the action complete?

Locate and repair high resistance or poor connection in the ECT signal circuit or the ECT sensor ground. Is the action complete?

1. Check for a faulty, plugged, or incorrectly installed PCV valve. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check for water- or alcohol-contaminated fuel. 2. If a problem is found, repair as necessary. Was a problem found?

Go to OBD System Check

Was the “Electric Throttle Control (ETC) System Check” performed?

Was a bulletin found that addresses the symptom? 4

Yes

DEFINITION: Engine cranks, but does not start for a long time. Does eventually run, or may start but immediately stall. Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

1. Perform the procedure in Fuel System Pressure Test. 2. If a problem is found, repair as necessary. Was a problem found?

6E–508

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Hard Start Symptom (Cont’d) Step

Action

1. Check for proper ignition voltage output with spark tester J 26792 (ST-125). Refer to Electric Ignition System for procedure. 2. If a problem is found, repair as necessary. Was a problem found?

Value(s)

Yes

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 14

—

Verify repair

Go to Step 15

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

Verify repair

Contact Technical Assistance

1. Remove spark plugs. Check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Electronic Ignition System. NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check for a loose ignition coil ground and ION Sensing module circuit. 2. If a problem is found, repair as necessary. Was a problem found?

1. Remove the ignition coils and check the ignition coils for cracks or carbon tracking. 2. If a problem is found, replace affected coil(s) as necessary. Was a problem found?

1. Check for the following engine mechanical problems (refer to Engine Mechanical): B Low compression B Leaking cylinder head gaskets B Worn or incorrect camshaft B Camshaft drive belt slipped or stripped 2. If a problem is found, repair as necessary. Was a problem found?

1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: B Visual/physical inspection B Tech 2 data B Freeze Frame data/Failure Records buffer B All electrical connections within a suspected circuit and/or system. 3. If a problem is found, repair as necessary. Was a problem found?

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–509

Surges and/or Chuggles Symptom Step

Action

Go to Step 2

—

Go to Step 3

Go to ETC System Check

—

Verify repair

Go to Step 4

—

Go to Step 5

Go to Visual/ Physical Check

—

System OK

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Go to Step 9

Go to Step 10

—

Go to Step 11

Verify repair

—

1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a visual/physical check performed?

Be sure that the driver understands transmission torque converter clutch and A/C compressor operation as explained in the owner’s manual. Inform the customer how the TCC and the A/C clutch operate. Is the customer experiencing a normal condition?

Go to OBD System Check

Was the “Electric Throttle Control (ETC) System Check” performed?

Was a bulletin found that addresses the symptom? 4

Yes

DEFINITION: Engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and slows down with no change in the accelerator pedal. Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

1. Check the fuel control heated oxygen sensors (HO2S, B1S1 and B2S1). The fuel control heated oxygen sensors (HO2S) should respond quickly to different throttle positions. If they don’t, check them for silicone or other contaminants from fuel or use of improper RTV sealant. The sensors may have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The PCM will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. For more information, refer to Powertrain Control Module (PCM) and Sensors. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check the fuel pressure. Refer to Fuel System Pressure Test. 2. If a problem is found, repair as necessary. Was a problem found?

Monitor the long term fuel trim on the Tech 2. Is the long term fuel trim significantly in the negative range (rich condition)?

1. Check items that can cause the engine to run rich. Refer to Diagnostic Aids in DTC P0172 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found?

6E–510

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Surges and/or Chuggles Symptom (Cont’d) Step

Action

1. Check items that can cause the engine to run lean. Refer to Diagnostic Aids in DTC P0171. 2. If a problem is found, repair as necessary. Was a problem found?

—

Go to Step 11

Verify repair

—

Verify repair

Go to Step 12

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 15

—

Verify repair

Go to Step 15

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

—

Verify repair

Go to Step 18

—

Verify repair

Go to Step 19

1. Check the ignition coils for cracks or carbon tracking. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check for a loose ignition coil ground and ION Sensing module circuit. 2. If a problem is found, repair as necessary. Was a problem found?

Yes

1. Check for proper ignition voltage output with spark tester J 26792 (ST-125). Refer to Electric Ignition System for procedure. 2. If a problem is found, repair as necessary. Was a problem found?

Value(s)

1. Remove the spark plugs and check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Electronic Ignition System. NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check the injector connections. 2. If any of the injector connectors are connected to an incorrect cylinder, correct as necessary. Was a problem found?

1. Check PCM grounds for the cleanliness, tightness and proper locations. Refer to the PCM wiring diagrams in Electrical Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check MAF sensor connections. 2. If a problem is found, replace the faulty terminals as necessary. Refer to Electrical Diagnosis for wiring repair procedures. Was a problem found?

1. Visually/physically check vacuum hoses for splits, kinks, and proper connections and routing as shown on the “Vehicle Emission Control Information” label. 2. If a problem is found, repair as necessary. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–511

Surges and/or Chuggles Symptom (Cont’d) Step

Action

1. Check the exhaust system for possible restriction: B Inspect the exhaust system for damaged or collapsed pipes. B Inspect the muffler for heat distress or possible internal failure. B Check for a possible plugged three-way catalytic converter by checking the exhaust system back pressure. Refer to Restricted Exhaust System Check. 2. If a problem is found, repair as necessary. Was a problem found?

Value(s)

—

Yes

Verify repair

Go to Step 20

Verify repair

Contact Technical Assistance

—

6E–512

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Lack of Power, Sluggish, or Spongy Symptoms Step

Action

—

Verify repair

Go to Step 4

—

Go to Step 5

Go to Visual/ Physical Check

—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 10

1. Check for low fuel pressure. Refer to Fuel System Pressure Test. 2. If a problem is found, repair as necessary. 1. Check for water- or alcohol-contaminated fuel. 2. If a problem is found, repair as necessary. 1. Install the Tech 2. 2. Run the engine at idle. 3. On the Tech 2, select F3: Miscellaneous Test, F6: Variable Intake Manifold. 4. Repeat Switch ON or OFF of VIM solenoid valve by using the Tech 2. 5. Check to see if the actuator works normally. 6. If a problem is found, repair as necessary. Was a problem found?

Go to Step 3

1. Remove and check the air filter element for dirt or restrictions. Refer to Air Intake System in ON-Vehicle Service. 2. Replace the air filter element if necessary.

Was a problem found? 8

—

Go to ETC System Check

Was a visual/physical check performed?

Was a problem found? 7

Go to Step 2

—

1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin.

Was a repair required? 6

Go to OBD System Check

Was the “Electric Throttle Control (ETC) System Check” performed?

Was a bulletin found that addresses the symptom? 4

Yes

DEFINITION: Engine delivers less than expected power. Little or no increase in speed when accelerator pedal is pushed down part-way. Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

1. Check for proper ignition voltage output with spark tester J 26792 (ST-125). Refer to Electronic Ignition System for procedure. 2. If a problem is found, repair as necessary. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–513

Lack of Power, Sluggish, or Spongy Symptoms (Cont’d) Step

Action

1. Remove the spark plugs and check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Electronic Ignition System.

Value(s)

Yes

NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. 2. If a problem is found, repair as necessary. Was a problem found? 11

Go to Step 12

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 14

—

Verify repair

Go to Step 15

—

Verify repair

Go to Step 16

Verify repair

Contact Technical Assistance

1. Check for an engine mechanical problem. Check for low compression, incorrect or worn camshaft, loose timing belt, etc. Refer to Engine Mechanical. 2. If a problem is found, repair as necessary. Was a problem found?

Verify repair

1. Check the torque converter clutch (TCC) for proper operation. Refer to 4L30-E Transmission Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found?

—

Go to Step 11

1. Check the PCM grounds for cleanliness, tightness and proper locations. Refer to the PCM wiring diagrams in Electrical Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found?

Verify repair

1. Check the ignition coils for cracks or carbon tracking. 2. If a problem is found, repair as necessary. Was a problem found?

—

6E–514

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Detonation/Sparks Knock Symptoms Step

Action

Go to Step 3

—

Go to Step 4

Go to Visual/ Physical Check

—

Go to Step 5

Verify repair

—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Go to Step 9

—

Verify repair

Go to Step 10

1. Check for obvious overheating problems: B Low engine coolant. B Restricted air flow to radiator, or restricted water flow through radiator. B Correct coolant solution should be a 50/50 mix of approved antifreeze/coolant and water. Refer to Engine Cooling. B EGR operation. Refer to DTC P0401. B ION sensing module fault. 2. If a problem is found, repair as necessary. 1. Ignition “OFF”. 2. Disconnect the ION sensing module. 3. Disconnect the PCM. Is the action complete?

Verify repair

1. Check TCC operation. Refer to 4L30-E Transmission Diagnosis. 2. If a problem is found, repair as necessary.

Was a problem found? 8

—

1. Check the transmission range switch circuit. Use a Tech 2 and be sure the Tech 2 indicates that the vehicle is in drive with the gear selector in drive or overdrive. 2. If a problem is found, diagnose and repair the transmission range switch as necessary (refer to 4L30-E Automatic Transmission Diagnosis).

Was a problem found? 7

Go to Step 2

If Tech 2 readings are normal (refer to Typical Scan Values) and there are no engine mechanical faults, fill the fuel tank with a known quality gasoline that has a minimum octane rating of 87 and re-evaluate the vehicle performance.

Was a problem found? 6

—

Go to OBD System Check

Was a visual/physical check performed?

Is detonation present? 5

1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom?

Yes

DEFINITION: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change with throttle opening. Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

Check the ION sensing harness between the PCM (F68) and ION sensing module circuit (RED Wire) at the Kl line harness connector. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–515

Detonation/Sparks Knock Symptoms (Cont’d) Step

Action

—

Go to Step 11

—

Verify repair

Go to Step 12

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 14

—

Go to Step 10

Go to Step 16

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

—

Verify repair

Go to Step 18

—

Verify repair

Go to Step 19

—

Go to Step 20

Verify repair

Check the ION sensing harness between the ignition coil and ION sensing module circuit at the DC motor harness connector. Was a problem found?

Yes

1. Disconnect the ignition coil. Is the action complete?

Value(s)

Replace the Ignition coil. Is the action complete?

Check the following items; 1. ION sensing module ground circuit for a poor connection. 2. If a problem is found, repair wiring harness as necessary. Was a problem found?

Replace the ION sensing module. Is the action complete?

1. Check fuel pressure. Refer to Chart Fuel System Pressure Test. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check items that can cause an engine to run lean (long term fuel trim significantly in the positive range). For a lean condition, refer to Diagnostic Aids in DTC P0171 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found?

1. Spark plugs for proper heat range. Refer to General Information. 2. If incorrect spark plugs are installed, replace spark plugs as necessary. Did any spark plugs require replacement?

1. Remove excessive carbon buildup with a top engine cleaner. Refer to instructions on the top engine cleaner can. 2. Re-evaluate vehicle performance. Is detonation still present?

6E–516

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Detonation/Sparks Knock Symptoms (Cont’d) Step

Action

1. Check for an engine mechanical problem. Perform a cylinder compression check. Refer to Engine Mechanical. 2. If a problem is found, repair as necessary. Was a problem found?

Value(s)

—

Yes

Verify repair

Go to Step 21

Verify repair

Contact Technical Assistance

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–517

Rough, Unstable, or Incorrect Idle, Stalling Symptom Step

Action

Go to Step 2

—

Go to Step 3

Go to ETC System Check

—

Go to Step 14

Go to Step 4

—

Go to Step 5

Go to Visual/ Physical Check

—

Verify repair

Go to Step 6

—

Go to Step 7

Go to Step 8

Was a problem found?

—

Verify repair

Go to Step 10

Is the long term fuel trim significantly in the positive range (lean condition)?

—

Go to Step 9

Go to Step 10

—

Verify repair

Go to Step 10

Desired Idle Speed

Go to Step 12

Go to Step 11

1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a visual/physical check performed?

1. Check the PCM grounds for cleanliness, tightness and proper routing. Refer to the PCM wiring diagrams in Electrical Diagnosis. 2. If a problem is found, repair as necessary. Observe the long term fuel trim on the Tech 2. Is the long term fuel trim significantly in the negative range (rich condition)?

8 9

1. Check items that can cause the engine to run rich. Refer to Diagnostic Aids in DTC P0172 Diagnostic Support. 2. If a problem is found, repair as necessary.

1. Check items that can cause the engine to run lean. Refer to Diagnostic Aids in DTC P0171 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found?

—

Was the “Electric Throttle Control (ETC) System Check” performed?

Was a problem found? 6

Go to OBD System Check

Was a bulletin found that addresses the symptom? 4

Yes

DEFINITION: Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM. Either condition may be severe enough to stall the engine. Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

1. Check for incorrect idle speed. Ensure that the following conditions are present: B The engine is fully warm. B The accessories are “OFF”. 2. Using a Tech 2, monitor the Engine Speed. Is the Engine Speed within the specified values?

6E–518

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Rough, Unstable, or Incorrect Idle, Stalling Symptom (Cont’d) Step

Action

1. Visually/physically inspect for the following conditions: B Restricted air intake system. Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. B Large vacuum leak. Check for a condition that causes a large vacuum leak, such as an incorrectly installed or faulty crankcase ventilation valve or a disconnected brake booster hose. 2. If a problem is found, repair as necessary. Was a problem found?

Verify repair

Go to Step 9

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 14

—

Verify repair

Go to Step 15

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

—

Verify repair

Go to Step 18

—

Verify repair

Go to Step 19

1. Check for proper ignition voltage output with spark tester J 26792 (ST-125). Refer to Electronic Ignition System for the procedure. 2. If a problem is found, repair as necessary. Was a problem found?

—

1. Check for fuel in the pressure regulator vacuum hose. 2. If fuel is present, replace the fuel pressure regulator assembly. Refer to Fuel Metering System. 3. If a problem is found, repair as necessary. Was a problem found?

1. Perform the “Injector Coil/Balance Test” in Fuel Metering System. 2. If a problem is found, repair as necessary. Was a problem found?

Yes

Check the injector connections. If any of the injectors are connected to an incorrect cylinder, correct as necessary. Was a problem found?

Value(s)

1. Check for a loose ignition coil ground and ION Sensing Module circuit. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check ignition coils for cracks or carbon tracking. 2. If a problem is found, repair as necessary. Was a problem found?

6E–519

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Rough, Unstable, or Incorrect Idle, Stalling Symptom (Cont’d) Step

Action

Using a Tech 2, monitor the throttle position 1 and 2 angle with the engine idling. Is the TP angle at the specified value and steady?

8 ∼ 10%

Go to Step 20

Refer to DTC for further diagnosis

—

Verify repair

Go to Step 21

—

Verify repair

Go to Step 22

—

Verify repair

Go to Step 23

—

Verify repair

Go to Step 24

Verify repair

Contact Technical Assistance

Yes

1. Check the positive crankcase ventilation (PCV) valve for proper operation. Refer to Crankcase Ventilation System. 2. If a problem is found, repair as necessary. Was a problem found?

Value(s)

1. Check for the following engine mechanical items. Refer to Engine Mechanical for diagnosis procedures: B Low compression B Sticking or leaking valves B Worn camshaft lobe(s) B Camshaft drive belt slipped or stripped B Incorrect valve timing B Worn rocker arms B Broken valve springs 2. If a problem is found, repair as necessary. Was a problem found?

1. Check for faulty motor mounts. Refer to Engine Mechanical for inspection of mounts. 2. If a problem is found, repair as necessary. Was a problem found?

—

6E–520

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Poor Fuel Economy Symptom Step

Action

Verify repair

Go to Step 3

—

Go to Step 4

Go to Visual/ Physical Check

—

Go to Step 5

Go to Step 6

—

System OK

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

—

Verify repair

Go to Step 10

1. Visually/physically check: Vacuum hoses for splits, kinks, and improper connections and routing as shown on the “Vehicle Emission Control Information” label. 2. If a problem is found, repair as necessary. 1. Remove and check the air filter element for dirt or for restrictions. Refer to Air Intake System. 2. Replace the air filter element if necessary. Was a repair required?

—

Review the items in Step 4 with the customer and advise as necessary.

Was a problem found? 7

Go to Step 2

Check owner’s driving habits. B Is the A/C “ON” full time (defroster mode “ON”)? B Are tires at the correct pressure? B Are excessively heavy loads being carried? B Is acceleration too much, too often?

Is the action complete? 6

—

Go to OBD System Check

Was a visual/physical check performed?

Was a problem found? 5

1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom?

Yes

DEFINITION: Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, economy is noticeably lower than it was on this vehicle at one time, as previously shown by an actual road test. (Non-standard tires will cause odometer readings to be incorrect, and that may cause fuel economy to appear poor when it is actually normal.) Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

1. Remove spark plugs and check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Spark Plug Replacement. NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check for low engine coolant level. Refer to Engine Cooling. 2. If a problem is found, repair as necessary. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–521

Poor Fuel Economy Symptom (Cont’d) Step

Action

1. Check for an incorrect or faulty engine thermostat. Refer to Engine Cooling. 2. If a problem is found, repair as necessary. Was a problem found?

Verify repair

Go to Step 12

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 14

—

Go to Step 16

Go to Step 15

—

Verify repair

—

Verify repair

Go to Step 17

—

Verify repair

Go to Step 18

—

Contact Technical Assistance

Verify repair

1. Review all diagnostic procedures within this table. 2. When all procedures have been completed and no malfunctions have been found, review/inspect the following: B Visual/physical inspection B Tech 2 data B Freeze Frame data/Failure Records buffer B All connections within a suspected circuit and/or system. 3. If a problem is found, repair as necessary. Was a problem found?

—

1. Check the air intake system and the crankcase for air leaks. Refer to Air Intake System and Crankcase Ventilation System. 2. If a problem is found, repair as necessary. Was a problem found?

Go to Step 11

Diagnose and repair an inaccurate speedometer condition as necessary. Refer to Vehicle Speed Sensor in Electrical Diagnosis. Was a problem found?

Verify repair

Check for proper calibration of the speedometer. Does the speed indicated on the speedometer closely match the vehicle speed displayed on the Tech 2?

—

1. Check the TCC operation. Refer to 4L30-E Transmission Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found?

Yes

1. Check for low engine compression. Refer to Engine Mechanical. 2. If a problem is found, repair as necessary. Was a problem found?

Value(s)

Perform the procedure in Fuel System Pressure Test. Was the fuel pressure normal?

6E–522

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Excessive Exhaust Emissions or Odors Symptom Step

Action

Go to Step 4

—

Go to Step 13

Go to Step 5

—

Go to Step 6

Go to Step 13

—

Go to Step 13

Go to Step 7

—

Go to Step 13

Go to Step 8

—

Go to Step 13

Go to Step 9

—

Go to Step 13

Go to Step 10

—

Go to Step 13

Go to Step 11

—

Go to Step 13

Go to Step 12

1. Perform the “Injector Coil/Balance Test” in Fuel Metering System. 2. If a problem is found, repair as necessary. 1. Refer to Engine Cooling for cooling system diagnosis. 2. If a problem is found, repair as necessary. Was a problem found?

—

Go to Visual/ Physical Check

1. Check the injector connections. 2. If any of the injectors are connected to an incorrect cylinder, correct as necessary.

Was a problem found? 10

Go to Step 3

1. Check for a faulty, plugged, or incorrectly installed crankcase ventilation valve; also check the crankcase ventilation system for plugging. 2. If a problem is found, repair as necessary.

Was a problem found? 9

Go to Step 13

1. Check the fuel pressure. Perform the procedure in Fuel System Pressure Test. 2. If a problem is found, repair as necessary.

Was a problem found? 8

—

1. Check the fuel cap for proper installation. 2. Secure the fuel cap if necessary.

Was a problem found? 7

Go to Step 2

1. Check for vacuum leaks. Check vacuum lines, intake manifold, throttle body, etc. 2. If a problem is found, repair as necessary.

Was the fuel cap installed properly? 6

—

Go to OBD System Check

Was a thorough visual/physical check performed?

Were any vacuum leaks located? 5

1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom?

Yes

DEFINITION: Vehicle fails an emission test. Vehicle has excessive “rotten egg” smell. (Excessive odors do not necessarily indicate excessive emissions.) Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

1. Check EVAP canister for fuel loading. Refer to Evaporative Emission Control System. 2. If a problem is found, repair as necessary. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–523

Excessive Exhaust Emissions or Odors Symptom (Cont’d) Step

Action

1. Remove excessive carbon buildup with a top engine cleaner. Refer to the instructions on the top engine cleaner can. 2. Perform the exhaust emission test.

Go to Step 14

Does the vehicle pass the test?

—

System OK

Go to Step 14

Does the exhaust emission test indicate excessive CO and HC levels or is long term fuel trim significantly in the negative range (rich condition)?

—

Go to Step 15

Go to Step 16

—

System OK

Go to Step 17

—

System OK

Go to Step 17

—

Go to Step 13

Go to Step 18

—

Go to Step 13

Go to Step 19

Verify repair

Contact Technical Assistance

Perform the exhaust emission test.

1. Check items that can cause the engine to run rich. Refer to Diagnostic Aids in DTC P0172 Diagnostic Support. Make any necessary repairs. 2. Perform the exhaust emission test. 1. Check items that can cause the engine to run lean. Refer to Diagnostic Aids in DTC P0171 Diagnostic Support. Make any necessary repairs. 2. Perform the exhaust emission test. Does the vehicle pass the test?

1. Check the EGR system (refer to DTC P0401). 2. If a problem is found, repair as necessary. Was a problem found?

System OK

Does the vehicle pass the test? 16

Yes

—

Does the vehicle pass the test? 13

Value(s)

1. Check for an engine mechanical problem. Perform a cylinder compression check (refer to Engine Mechanical). 2. If a problem is found, repair as necessary. Was a problem found?

1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: B Visual/physical inspection B Tech 2 data B Freeze Frame data/Failure Records butter B All electrical connections within a suspected circuit and/or system. 3. If a problem is found, repair as necessary. Was a problem found?

—

6E–524

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Dieseling, Run-On Symptom Step

Action

—

Go to Step 2

Go to OBD System Check

—

Verify repair

Go to Step 3

—

Go to Step 4

Go to Visual/ Physical Check

—

Verify repair

Go to Step 5

Verify repair

Contact Technical Assistance

Was a visual/physical check performed?

1. Check for a short between B+ and any of the ignition feed circuits. 2. If a problem is found, repair as necessary. Was a problem found?

1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom?

Yes

DEFINITION: Engine continues to run after key is turned “OFF,” but runs very rough. If engine runs smooth, check ignition switch and adjustment. Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: B Visual/physical inspection B Tech 2 data B Freeze Frame data/Failure Records butter B All electrical connections within a suspected circuit and/or system 3. If a problem is found, repair as necessary. Was a problem found?

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–525

Backfire Symptom Step

Action

—

Go to Step 2

Go to OBD System Check

—

Verify repair

Go to Step 3

—

Go to Step 4

Go to Visual/ Physical Check

—

Verify repair

Go to Step 5

—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

—

Verify repair

Go to Step 8

—

Verify repair

Go to Step 9

Was a visual/physical check performed?

1. Check for proper ignition voltage coil output with spark tester J 26792 (ST-125). Refer to Electric Ignition System for procedure. 2. If a problem is found, repair as necessary. Was a problem found?

1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom?

Yes

DEFINITION: Fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

1. Remove spark plugs and check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Electronic Ignition System. NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. Refer to DTC P0172 to determine the cause of a rich condition or Engine Mechanical for an oil fouling condition. 2. If a problem is found, repair as necessary. Was a problem found?

1. Visually/physically inspect the ignition coils for cracks. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check for an intermittent ignition system malfunction: B Intermittent CKP 58X signal. B Intermittent ignition feed circuit or sensor ground circuit to the crankshaft position sensor. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check the fuel pressure. Refer to Fuel System Pressure Test. 2. If a problem is found, repair as necessary. Was a problem found?

6E–526

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Backfire Symptom (Cont’d) Step

Action

Value(s)

Yes

1. Check for the following engine mechanical conditions. Refer to Engine Mechanical for diagnosis procedures: B Low compression B Sticking or leaking valves B Worn camshaft lobe(s) B Camshaft drive belt slipped or stripped B Incorrect valve timing 2. If a problem is found, repair as necessary. Was a problem found?

Verify repair

Go to Step 10

—

Verify repair

Go to Step 11

Verify repair

Contact Technical Assistance

1. Check the intake and exhaust manifold(s) for casting flash. Refer to Engine Mechanical. 2. If a problem is found, repair as necessary. Was a problem found?

—

1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: B Visual/physical inspection B Tech 2 data B Freeze Frame data/Failure Records butter B All electrical connections within a suspected circuit and/or system. 3. If a problem is found, repair as necessary. Was a problem found?

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–527

Cuts Out, Misses Symptom Step

Action

—

Go to Step 2

—

Go to Step 14

Go to Step 3

Go to Step 4

Go to Visual/ Physical Check

—

Go to Step 5

Go to ETC System Check

—

Verify repair

Go to Step 6

—

Go to Step 7

Go to Step 8

Was a problem found?

—

Verify repair

Go to Step 10

Is the long term fuel trim significantly in the positive range (lean condition)?

—

Go to Step 9

Go to Step 10

—

Verify repair

Go to Step 10

Desired Idle Speed

Go to Step 12

Go to Step 11

1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a visual/physical check performed? —

Was the “Electric Throttle Control (ETC) System Check” performed? 1. Check the PCM grounds for clearness, tightness and proper routing. Refer to the PCM wiring diagrams in Electrical Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found?

Observe the long term fuel trim on the Tech 2. Is the long term fuel trim significantly in the negative range (rich condition)?

8 9

1. Check items that can cause the engine to run rich. Refer to Diagnostic Aids in DTC P0172 Diagnostic Support. 2. If a problem is found, repair as necessary.

1. Check items that can cause the engine to run lean. Refer to Diagnostic Aids in DTC P0171 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found?

Go to OBD System Check

Was a bulletin found that addresses the symptom? 3

Yes

DEFINITION: Steady pulsation or jerking that follows engine speed; usually more pronounced as engine load increases. Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

1. Check for incorrect idle speed. Ensure that the following conditions are present: B The engine is fully warm. B The accessories are “off”. 2. Using a Tech 2, monitor the Engine Speed. Is the Engine Speed within the specified values?

6E–528

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Cuts Out, Misses Symptom (Cont’d) Step

Action

1. Visually/physically inspect for the following conditions: B Restricted air intake system. Check for a possible collapsed air intake duct, restricted air filter element, or foreign objects blocking the air intake system. B Large vacuum leak. Check for a condition that causes a large vacuum leak, such as an incorrectly installed or faulty PCV valve or brake booster hose disconnected . 2. If a problem is found, repair as necessary. Was a problem found?

Verify repair

Go to Step 9

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 14

—

Verify repair

Go to Step 15

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

—

Verify repair

Go to Step 18

—

Verify repair

Go to Step 19

Go to Step 20

Refer to DTC P0123 for further diagnosis

—

1. Perform the “Injector Coil/Balance Test” in Fuel Metering System. 2. If a problem is found, repair as necessary. Was a problem found?

Yes

Check the injector connections. If any of the injectors are connected to an incorrect cylinder, correct as necessary. Was a problem found?

Value(s)

1. Check for a loose ignition coil ground and ION Sensing module circuit. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check ignition coils for cracks or carbon tracking. 2. If a problem is found, repair as necessary. Was a problem found?

Using a Tech 2, monitor the TP 1, 2 angle with the engine idling. Is the TP angle at the specified value and steady?

8 ∼ 10%

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–529

Cuts Out, Misses Symptom (Cont’d) Step

Action

1. Check the PCV valve for proper operation. Refer to Crankcase Ventilation System. 2. If a problem is found, repair as necessary. Was a problem found?

Yes

—

Verify repair

Go to Step 21

—

Verify repair

Go to Step 22

—

Verify repair

Go to Step 23

—

Verify repair

Go to Step 24

Verify repair

Contact Technical Assistance

Value(s)

1. Check the following engine mechanical items. Refer to Engine Mechanical for diagnosis procedures: B Low compression B Sticking or leaking valves B Worn camshaft lobe(s) B Camshaft drive belt slipped or stripped B Incorrect valve timing B Worn rocker arms B Broken valve springs 2. If a problem is found, repair as necessary. Was a problem found?

1. Check for faulty motor mounts. Refer to Engine Mechanical for inspection of mounts. 2. If a problem is found, repair as necessary. Was a problem found?

1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: B Visual/physical inspection B Tech 2 data B Freeze Frame data/Failure Records butter B All electrical connections within a suspected circuit and/or system 3. If a problem is found, repair as necessary. Was a problem found?

—

6E–530

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Hesitation, Sag, Stumble Symptom Step

Action

Go to Step 2

Go to OBD System Check

—

Go to Step 3

Go to ETC System Check

—

Verify repair

Go to Step 4

—

Go to Step 5

Go to Visual/ Physical Check

—

Verify repair

Go to Step 6

—

Verify repair

Go to Step 7

—

Go to Step 8

Go to Step 9

—

Go to Step 9

Go to Step 10

—

Verify repair

Go to Step 11

—

Was the “Electric Throttle Control (ETC) System Check” performed? 1. Perform a bulletin search. 2. If a bulletin that addresses the symptom is found, correct the condition as instructed in the bulletin. Was a bulletin found that addresses the symptom?

Yes

DEFINITION: Momentary lack of response as the accelerator is pushed down. Can occur at any vehicle speed. Usually most pronounced when first trying to make the vehicle move, as from a stop sign. May cause the engine to stall if severe enough. Was the “On-Board Diagnostic (OBD) System Check” performed?

Value(s)

Was a visual/physical check performed?

1. Check the fuel control heated oxygen sensors (HO2S, B1S1 and B2S1). The fuel control heated oxygen sensors (HO2S) should respond quickly to different throttle positions. If they don’t, check them for silicon or other contaminants from fuel or use of improper RTV sealant. The sensors may have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The PCM will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. For more information, refer to Powertrain Control Module (PCM) and Sensors. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check the fuel pressure. Refer to Fuel System Pressure Test. 2. If a problem is found, repair as necessary. Was a problem found?

Observe the TP 1, 2 angle display on the Tech 2 while slowly increasing accelerator pedal depression. Does the TP angle display steadily increase from 8 ∼ 10% at closed throttle to 90 ∼ 92% at WOT?

Monitor the long term fuel trim on the Tech 2. Is the long term fuel trim significantly in the negative range (rich condition)?

1. Check items that can cause the engine to run rich. Refer to Diagnostic Aids in DTC P0172 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–531

Hesitation, Sag, Stumble Symptom (Cont’d) Step

Action

1. Check items that can cause the engine to run lean. Refer to Diagnostic Aids in DTC P0171 Diagnostic Support. 2. If a problem is found, repair as necessary. Was a problem found?

—

Verify repair

Go to Step 11

—

Verify repair

Go to Step 12

—

Verify repair

Go to Step 13

—

Verify repair

Go to Step 14

—

Verify repair

Go to Step 15

—

Verify repair

Go to Step 16

—

Verify repair

Go to Step 17

1. Check the ignition coils for cracks or carbon tracking. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check for a loose ignition coil ground and ION Sensing module circuit. 2. If a problem is found, repair as necessary. Was a problem found?

Yes

Value(s)

1. Remove spark plugs and check for wet plugs, cracks, wear, improper gap, burned electrodes, or heavy deposits. Refer to Electronic Ignition System. NOTE: If spark plugs are gas or oil fouled, the cause of the fouling must be determined before replacing the spark plugs. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check the PCM grounds for clearness, tightness and proper routing. Refer to the PCM wiring diagrams in Electrical Diagnosis. 2. If a problem is found, repair as necessary. Was a problem found?

1. Check the MAF sensor connections. 2. If a problem is found, replace the faulty terminals as necessary. Refer to Electrical Diagnosis for wiring repair procedures. Was a problem found?

6E–532

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Hesitation, Sag, Stumble Symptom (Cont’d) Step

Action

Value(s)

—

Yes

Verify repair

Go to Step 18

Verify repair

Contact Technical Assistance

1. Review all diagnostic procedures within this table. 2. If all procedures have been completed and no malfunctions have been found, review/inspect the following: B Visual/physical inspection B Tech 2 data B Freeze Frame data/Failure Records butter B All electrical connections within a suspected circuit and/or system 3. If a problem is found, repair as necessary. Was a problem found?

—

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–533

Bank 1 Restricted Exhaust System Check Step

Action

—

Go to Step 2

Go to OBD System Check

8.62 kPa (1.25 psi)

Go to Step 3

Go to Step 4

—

Verify repair

—

8.62 kPa (1.25 psi)

Go to Step 5

No trouble found. If a driveability symptom exists, refer to symptom charts

—

Verify repair

—

Repair the restriction in the exhaust system after the catalytic converter. Possible faults include: B Collapsed pipe B Heat distress B Internal muffler failure 1. Install the Bank 1 HO2S 2. 2. Install the Exhaust Backpressure Tester in place of Bank 1 HO2S 1. 3. Run the engine at normal operating temperature. 4. Increase the engine speed to 2000 RPM and allow 10 seconds for pressure to build. 5. Observe the exhaust system backpressure reading on the gauge. Does the reading exceed the amount in the value column?

1. Remove the Bank 1 HO2S 2. 2. Install the Exhaust Backpressure Tester (BT-8515-V or equivalent) in place of the Bank 1 HO2S 2. 3. Run the engine at normal operating temperature. 4. Increase the engine speed to 2000 RPM and allow 10 seconds for pressure to build. 5. Observe the exhaust system backpressure reading on the gauge.

Is the action complete? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the reading exceed the amount in the value column? 3

Value(s)

Repair the restriction in the catalytic converter. Is the action complete?

NOTE: DTCs will be set by running the vehicle to normal operating temperature after a cold start with the O2 sensor disconnected. After performing these tests, use the Tech 2 to erase the DTCs that were set by the lack of O2 sensor activity.

6E–534

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Bank 2 Restricted Exhaust System Check Step

Action

—

Go to Step 2

Go to OBD System Check

8.62 kPa (1.25 psi)

Go to Step 3

Go to Step 4

—

Verify repair

—

8.62 kPa (1.25 psi)

Go to Step 5

No trouble found. If a driveability symptom exists, refer to symptom charts

—

Verify repair

—

Repair the restriction in the exhaust system after the catalytic converter. Possible faults include: B Collapsed pipe B Heat distress B Internal muffler failure 1. Install the Bank 2 HO2S 2. 2. Install the Exhaust Back pressure Tester in place of Bank 1 HO2S 1. 3. Run the engine at normal operating temperature. 4. Increase the engine speed to 2000 RPM and allow 10 seconds for pressure to build. 5. Observe the exhaust system backpressure reading on the gauge. Does the reading exceed the amount in the value column?

1. Remove the Bank 2 HO2S 2. 2. Install the Exhaust Backpressure Tester (BT-8515-V or equivalent) in place of the Bank 2 HO2S 2. 3. Run the engine at normal operating temperature. 4. Increase the engine speed to 2000 RPM and allow 10 seconds for pressure to build. 5. Observe the exhaust system backpressure reading on the gauge.

Is the action complete? 4

Yes

Was the “On-Board Diagnostic (OBD) System Check” performed?

Does the reading exceed the amount in the value column? 3

Value(s)

Repair the restriction in the catalytic converter. Is the action complete?

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–535

Default Matrix Table Service Procedure Default Strategy A referral strategy has been established to assist the technician with additional information when the cause of the failure cannot be determined. If no problem is found after performing diagnostics, then refer to the default matrix table for further diagnostic information. Default Matrix Table Strategy Based Diagnostic Charts

Initial Diagnosis

Default Section(s)

On-Board Diagnostic (OBD) System Check

Vehicle does not enter diagnostics.

Chassis Electrical

On-Board Diagnostic (OBD) System Check

Vehicle enters diagnostics and communicates with the Tech 2. MIL is “ON” in diagnostics. Engine does not start and run.

Ignition System Check

On-Board Diagnostic (OBD) System Check

Engine starts and runs, no PCM codes set. Customer complains of vibration.

On-Board Diagnostic (OBD) System Check

Engine starts and runs, no PCM codes set. Customer complains of harsh or soft shift, poor performance, delayed or no engagement into drive or reverse, transmission fluid leak, transmission noise or vibration, or improper TCC operation.

Automatic Transmission

PCM Power and Ground Check

On-Board Diagnostic (OBD) System Check.

Chassis Electrical

PCM Power and Ground Check

On-Board Diagnostic (OBD) System Check. PCM power and ground circuits OK. Data link voltage incorrect.

Chassis Electrical

On-Board Diagnostic (OBD) System Check

Automatic Transmission

Symptoms

Initial Diagnosis

—

Default Section(s)

Intermittents

1. On-board Diagnostic (OBD) system check. 2. Careful visual/physical inspections.

Chassis Electrical

Hard Starts

1. OBD system check. 2. ETC system check. 3. Sensors (ECT, MAP, MAF, TP) ; MAP output chart. 4. Fuel system electrical test, fuel system diagnosis. 5. Ignition system.

Engine Mechanical, Ignition System Check, Exhaust System Diagnosis

6E–536

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Symptoms

Initial Diagnosis

Default Section(s)

Surges and/or Chuggles

1. 2. 3. 4. 5.

OBD system check. ETC system check. Heated oxygen sensors. Fuel system diagnosis. Ignition system.

Calibration ID/Service Bulletins, Ignition System Check, Generator Output, Exhaust System Diagnosis, 4L30-E System Test

Lack of Power, Sluggish or Spongy

1. 2. 3. 4. 5. 6.

OBD system check. ETC system check. Fuel system diagnosis. Ignition system. EGR operation. EGR system check.

Refer to Exhaust System in Engine Exhaust, TCC Operation, Calibration ID/Service Bulletins

Detonation/Spark Knock

1. 2. 3. 4. 5. 6. 7. 8.

OBD system check. Transmission range switch. EGR operation. EGR system check. TCC operation. Fuel system diagnosis. Ignition system. ION sensing module check.

TCC operation, Cooling System, Ignition System Check, Calibration ID/Service Bulletins

Rough, Unstable, or Incorrect Idle, Stalling

1. OBD system check. 2. ETC system check. 3. Fuel injector and fuel injector balance test. 4. EVAP emission canister purge valve check. 5. Ignition system. 6. EGR operation.

MAP Output Check, Throttle Linkage, EGR System Check, A/C Clutch Control Circuit Diagnosis, Crankcase Ventilation System, Calibration ID/Service Bulletins, Generator Output Voltage (refer to Chassis Electrical), Exhaust Diagnosis

Poor Fuel Economy

1. 2. 3. 4.

TCC Operation, Exhaust System (refer to Engine Exhaust)

Hesitation, Sag, Stumble

1. 2. 3. 4. 5. 6.

OBD system check. ETC system check. TP. MAP output check. Fuel system diagnosis. Fuel injector and fuel injector balance test. 7. EVAP emission canister purge valve. 8. Ignition system.

EGR Operation, EGR System Check, Generator Output Voltage (refer to Chassis Electrical), Calibration ID/Service Bulletins, Ignition System Check

Cuts Out, Misses

1. OBD system check. 2. Cylinder balance test. 3. ETC system check.

Ignition System Check

Engine Cranks But Will Not Run

1. OBD system check.

Fuel System Electrical Diagnosis, Fuel System Diagnosis, Fuel Injector and Fuel Injector Balance Test.

OBD system check. Careful visual/physical inspection. Ignition system. Cooling system.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS Symptoms

6E–537

Initial Diagnosis

Default Section(s)

OBD system check. Emission test. Cooling system. Fuel system diagnosis. Fuel injector and fuel injector balance test. EVAP emission canister purge valve. Crankcase ventilation system. Ignition system. MAP output check.

EGR System Check, Exhaust Diagnosis, Calibration ID/Service Bulletins

Dieseling, Run-On

1. OBD system check. 2. Careful visual/physical inspection. 3. Fuel system diagnosis.

—

Backfire

1. 2. 3. 4.

OBD system check. Ignition system. Fuel system diagnosis. Fuel injector and fuel injector balance test. 5. EGR operation, EGR system check.

Exhaust System Diagnosis, Intake Casting Flash, Ignition System Check

Misfire

1. 2. 3. 4.

Vibrations, Transmission, Driveshaft and Axle

Catalyst Monitor

1. OBD system check. 2. Careful visual/physical inspection. 3. Heated oxygen sensors.

Exhaust System

Fuel Trim

1. 2. 3. 4.

Exhaust System Intake Air System

Evaporative Emissions

1. OBD system check. 2. Careful visual/physical inspection. 3. Fuel system diagnosis.

Heated Oxygen Sensors

1. OBD system check. 2. Careful visual/physical inspection.

Excessive Exhaust Emissions or Odors

1. 2. 3. 4. 5. 6. 7. 8. 9.

OBD system check. Ignition system. Fuel system diagnosis. Fuel injector and fuel injector balance test.

OBD system check. Careful visual/physical inspection. Fuel system diagnosis. Heated oxygen sensors, MAF sensors.

—

Exhaust System

6E–538

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

On Vehicle Service Crankshaft Position (CKP) Sensor Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector to the CKP sensor. 3. Remove one bolt and the CKP sensor from the right side of the engine block, just behind the mount. NOTE: Use caution to avoid any hot oil that might drip out.

TS22909

3. Connect the electrical connector to the CKP sensor. 4. Connect the negative battery cable.

Engine Coolant Temperature (ECT) Sensor Removal Procedure NOTE: Care must be taken when handling the engine coolant temperature (ECT) sensor. Damage to the ECT sensor will affect proper operation of the fuel injection system.

TS22909

1. Disconnect the negative battery cable. 2. Drain the radiator coolant. Refer to Draining and Refilling Cooling System in Engine Cooling section. 3. Disconnect the electrical connector.

Inspection Procedure 1. Inspect the sensor O-ring for cracks or leaks. 2. Replace the O-ring if it is worn or damaged. 3. Lubricate the new O-ring with engine oil. 4. Install the lubricated O-ring.

Installation Procedure 1. Install the CKP sensor in the engine block. 2. Install the CKP sensor mounting bolt. Tighten B Tighten the mounting bolt to 9 N·m (78 lb in.).

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 4. Remove the ECT sensor from the coolant crossover.

3. Connect the electrical connector.

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Installation Procedure 1. Apply sealer or the equivalent to the threads of the ECT sensor. 2. Install the ECT sensor in the coolant crossover. Tighten B Tighten the ECT sensor to 30 N·m (22 lb ft.).

6E–539

014RY00003

4. Fill the radiator with coolant. Refer to Draining and Refilling Cooling System in Engine Cooling section. 5. Connect the negative battery cable.

Heated Oxygen Sensor (HO2S) Removal Procedure 1. Disconnect the negative battery cable. 2. Locate the four oxygen sensors.

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060RW008

6E–540

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B Bank 1 sensor 1 is mounted on the exhaust pipe ahead of the right-hand catalytic converter.

TS22912

B Bank 1 sensor 2 is mounted behind the right-hand catalytic converter.

TS22913

B Bank 2 sensor 1 is mounted on the exhaust pipe ahead of the left-hand catalytic converter.

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B Bank 2 sensor 2 is mounted behind the left-hand catalytic converter.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–541

3. Disconnect the pigtail from the wiring harness.

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IMPORTANT: The pigtail is permanently attached to the sensor. Be careful not to pull the wires out. NOTE: Do not use a torch to remove an HO2S unless the sensor is being replaced. Using a torch could damage the sensor. 4. Remove the sensor from the exhaust pipe. B Because of the expansion and contraction of the metal in the exhaust system over time, this may be difficult if the engine temperature is below 48°C (120°F).

Installation Procedure IMPORTANT: B There is a special anti-seize compound on the HO2S threads. This compound consists of glass beads suspended in a liquid graphite solution. The graphite burns away with engine heat, but the glass beads will remain, making the sensor easier to remove. B New or service sensors will already have the compound applied to the threads. If a sensor is removed and is to be reinstalled for any reason, the threads must have anti-seize compound applied. 1. Apply anti-seize compound or the equivalent to the threads of the oxygen sensor, if necessary. 2. Install the oxygen sensor on the exhaust pipe in its original position. Tighten B Tighten the oxygen sensor to 55 N·m (40 lb ft.).

060RY00128

Inspection Procedure All four sensors are identical. Inspect each in the same way. 1. Inspect the pigtail and the electrical connector for grease, dirt, corrosion, and bare wires or worn insulation. 2. Inspect the louvered end of the sensor for grease, dirt, or other contaminations.

060RY00128

3. Connect the pigtail to the wiring harness. 4. Connect the negative battery cable.

6E–542

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Intake Air Temperature (IAT) Sensor

3. Install the engine cover. 4. Connect the negative battery cable.

ION Sensing Module

Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the engine cover 3. The IAT sensor is located in the intake air duct, behind the throttle body. 4. Disconnect the electrical connector from the IAT sensor.

Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the ION sensing module connector. 3. Remove the bolts and the ION sensing module from the common chamber.

060RY00087

TS23741

5. Remove the IAT sensor from the intake air duct by using a rocking motion while pulling the sensor.

Installation Procedure 1. Install the ION sensing module on the common chamber with the bolts.

Installation Procedure 1. Install the IAT sensor into the grommet in the intake air duct. 2. Correct the IAT electrical connector.

TS23741

Tighten B Tighten the ION sensing module to 4 N·m (35 lb in.).

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 2. Connect the ION sensing module connectors as shown in the illustration.

4. Remove the intake air duct from the MAF sensor. 5. Remove the MAF sensor from the air cleaner.

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Legend (1) Green Color Connector (2) Blue Color Connector

6E–543

TS23781

Installation Procedure

3. Connect the negative battery cable.

Mass Air Flow (MAF) Sensor

1. Install the MAF sensor on the air cleaner with the clamp. 2. Install the intake air duct and the clamp on the MAF sensor.

Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAF sensor.

TS23781

3. Tighten the clamps to secure the MAF sensor to the intake air duct and the air cleaner. 4. Connect the MAF electrical connector. 5. Connect the negative battery cable.

TS23740

3. Loosen the clamps which secure the intake air duct and the air cleaner to the MAF sensor.

6E–544

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Manifold Absolute Pressure (MAP) Sensor

Installation Procedure 1. Install the MAP sensor in the mounting bracket.

Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the MAP sensor.

055RW002

2. Install the mounting bracket retaining bolt on the common chamber. Tighten B Tighten the bolt to 20 N·m (12 lb ft.). 3. Connect the MAP electrical connector. 055RY00001

3. Remove the bolt securing the MAP sensor to the mounting bracket on the common chamber. 4. Remove the MAP sensor from the mounting bracket.

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4. Connect the negative battery cable.

055RW002

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Malfunction Indicator Lamp (MIL) Removal and Installation Procedure Refer to Warning light bulb, indicator light valve, illumination light bulb, A/T indicator light bulb in Meter and Gauge.

Reduced Power Lamp The reduced power lamp (RPL) turns on when the ignition key is moved to the ON position. It should turn off in approximately 3 seconds or immediately after the engine starts. If the RPL turns on during vehicle operation, a vehicle system failure resulting in reduced engine output is indicated. If both the reduced RPL and the check engine light turn on, a serious problem affecting vehicle performance is indicated. Refer to the OBD system check NO and RPL “ON” steady in this manual.

Powertrain Control Module (PCM) Service Precaution NOTE: To prevent possible electrostatic discharge damage to the PCM, do not touch the connector pins or soldered components on the circuit board.

Electrostatic Discharge (ESD) Damage Electronic components used in the control systems are often designed to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. By comparison, it takes as much as 4,000 volts for a person to even feel the zap of a static discharge. There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of charging by friction is a person sliding across a car seat. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore, it is important to use care when handling and testing electronic components. NOTE: To prevent possible Electrostatic Discharge damage, follow these guidelines: B Do not touch the control module connector pins or soldered components on the control module circuit board.

6E–545

B Do not open the replacement part package until the part is ready to be installed. B Before removing the part from the package, ground the package to a known good ground on the vehicle. B If the part has been handled while sliding across the seat, or while sitting down from a standing position, or while walking a distance, touch a known good ground before installing the part. NOTE: To prevent internal PCM damage, the ignition must be in the “OFF” position in order to disconnect or reconnect power to the PCM (for example: battery cable, PCM pigtail, PCM fuse, jumper cables, etc.). IMPORTANT: When replacing the production PCM with a service PCM, it is important to transfer the broadcast code and production PCM number to the service PCM label. This will allow positive identification of PCM parts throughout the service life of the vehicle. Do not record this information on the metal PCM cover. IMPORTANT: The ignition should always be in the “OFF” position in order to install or remove the PCM connectors. Service of the PCM should normally consist of either replacement of the PCM or EEPROM programming. If the diagnostic procedures call for the PCM to be replaced, the PCM should be checked first to ensure it is the correct part. If it is, remove the faulty PCM and install the new service PCM. The service PCM EEPROM will not be programmed. DTC P0601 indicates the check sum error.

Removal Procedure 1. Disconnect the negative battery cable. 2. Block the wheels. 3. Remove the two screws from the PCM electrical connectors. 4. Disconnect the PCM electrical connectors.

060RY00065

6E–546

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

5. After removing the clip which fixes the PCM to the bracket, remove PCM.

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Installation Procedure 1. Install the PCM to bracket and fix with the clip.

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2. Connect the PCM electrical connectors. 3. Install the two screws to PCM electrical connectors.

060RY00065

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

EEPROM

6E–547

3. Remove the bolts and the TP sensor from the throttle body.

General Description The Electronically Erasable Programmable Read Only Memory (EEPROM) is a permanent memory that is physically soldered within the PCM. The EEPROM contains program and calibration information that the PCM needs to control powertrain operation.

EEPROM Programming 1. Set-up – Ensure that the following conditions have been met: B The battery is fully charged. B The ignition is “ON.” B The Vehicle Interface Module cable connection at the DLC is secure. 2. Program the PCM using the latest software matching the vehicle. Refer to up-to-date Techline equipment user’s instructions. 3. If the PCM fails to program, proceed as follows: B Ensure that all PCM connections are OK. B Check the Techline equipment for the latest software version. B Attempt to program the PCM. If the PCM still cannot be programmed properly, replace the PCM. The replacement PCM must be programmed.

Functional Check 1. Perform the On-Board Diagnostic System Check. 2. Start the engine and run for one minute. 3. Scan for DTCs using the Tech 2.

060RY00159

NOTE: Do not clean the TP sensor by soaking it in solvent. The sensor will be damaged as a result.

Function Check Use a Tech 2 to check the TP sensor output voltage at closed throttle. B The voltage should be TP1 about 0.4V, TP2 about 4.6V and TP3 about 4.6V. B If the reading is abnormal value, check the throttle shaft to see if it is binding.

Installation Procedure 1. Install the TP sensor on the throttle body with the bolts.

Throttle Position (TP) Sensor Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the TPS electrical connector.

060RY00159

2. Connect the TP electrical connector. 3. Install the negative battery cable.

6E–548

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Vehicle Speed Sensor (VSS) Removal Procedure CAUTION: The VSS is located on the right side of the transfer case just ahead of the rear propeller shaft and very close to the exhaust pipes for 4WD and on the extension cover for 2WD. Be sure that the exhaust pipes are cool enough to touch before trying to remove the VSS. If the pipes are hot, you could be burned.

Inspection Procedure 1. Inspect the electrical connector for signs of corrosion or warping. Replace the VSS if the electrical connector is corroded or warped. 2. Inspect the VSS driven gear for chips, breaks, or worn condition. Replace the VSS if the driven gear is chipped, broken or worn. 3. Inspect the O-ring for wear, nicks, tears, or looseness. Replace the O-ring if necessary.

Installation Procedure

1. Disconnect the negative battery cable. 2. Disconnect the VSS electrical connector.

1. Install the VSS in the transfer case with the notch for the connector facing the rear. 2. Secure the VSS in place with the clamp and the bolt. Tighten B Tighten the bolt to 16 N·m (12 lb ft.).

TS23748

3. Remove the bolt and the clamp securing the VSS in place. IMPORTANT: Have a container ready to catch any fluid that leaks out when the VSS is removed from the transfer case for 4WD and on the extension cover for 2WD.

TS23780

3. Connect the VSS electrical connector.

TS23780

4. Remove the VSS from the transfer case by wiggling it slightly and pulling it straight out.

TS23748

4. Check the transfer case oil level. necessary. 5. Connect the negative battery cable.

Add fluid if

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Air Cleaner/Air Filter

6E–549

Installation Procedure

Removal Procedure 1. Loosen the clamp between the air cleaner lid and the mass air flow sensor.

1. Install the air cleaner housing in the vehicle with the retaining bolts. 2. Install the air filter element in the air cleaner housing. 3. Install the air cleaner lid on the MAF sensor and the air cleaner housing.

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2. Release the four latches securing the lid to the air cleaner housing. 3. Remove the air cleaner lid. 4. Remove the air filter element. 5. Remove the retaining bolts and the air cleaner housing from the vehicle.

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Legend (1) Air Cleaner Housing (2) Air Filter Element (3) Air Cleaner Lid (4) Mass Air Flow Sensor 4. Tighten the clamp and secure the four latches between the lid and the air cleaner housing.

Common Chamber Removal and Installation Procedure Refer to Common Chamber in Engine Mechanical section.

025RY00002

Legend (1) Air Cleaner Housing (2) Air Filter Element (3) Air Cleaner Lid

6E–550

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Accelerator Pedal Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical harness accelerator position sensor.

from

the

Installation Procedure 1. Install the accelerator pedal assembly on the bulkhead. 2. Install the two screws to the accelerator pedal assembly. Tighten B Tighten the screws to 22 N·m (16 lb ft.).

101RY00006 101RY00007

Legend (1) Accelerator Position Sensor (2) Accelerator Pedal Assembly

3. Connect the electrical harness to the accelerator position sensor.

3. Remove the two screws from the accelerator pedal assembly.

101RY00006

Legend (1) Accelerator Position Sensor (2) Accelerator Pedal Assembly 101RY00007

4. Remove the accelerator pedal assembly from the bulkhead.

4. Install the negative battery cable.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Accelerator Position Sensor Replacement CAUTION: Remove the Accelerator (A) pedal assembly as a unit to have it serviced. Do not remove the Accelerator Position (AP) sensor on the A pedal. If the AP sensor is removed for emergency cause, refer to following items as necessary.

Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical harness from the AP sensor.

6E–551

Legend (1) AP Sensor (2) AP Screw

Installation Procedure 1. Install the accelerator position (AP) sensor to bolts with accelerator (A) pedal. 2. Connect the connector to AP sensor. 3. Install the negative battery cable.

Accelerator Position Sensor Adjustment AP sensor is controled three maltiple control system, and adjust the idle position and WOT position are between A and B for AP sensor 1, AP sensor 2, and AP sensor 3. Refer to “How to adjust for AP sensor”.

Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical harness from the AP sensor.

How To Adjust For AP Sensor 1. Connect the Tech 2 to DLC on vehicle. 2. Ignition “ON,” engine “OFF.”. 3. Display the APS date list. Check the following item for AP position (%). 101RY00006

Legend (1) AP Sensor (2) A Pedal Assembly 3. Remove the AP sensor.

AP position (%) Idle position A

WOT position B

APS1

13%

87 ± 2%

APS2

87 ± 2%

13 ± 2%

APS3

87 ± 1%

34 ± 2%

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060RY00305

6E–552

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

4. If the problem was found, adjust as necessary.

Fuel Filter Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the fuel filler cap.

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Fuel Filler Cap General Description The fuel filler cap includes a vacuum valve and a pressure valve. If high vacuum or high pressure occurs in the fuel tank, each valve works to adjust the pressure in order to prevent damage to the tank.

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3. Disconnect the fuel hose from the fuel filter on the engine side. 4. Disconnect the fuel hose from the fuel filter on the fuel tank side. 5. Remove the bolt on the fuel filter holder.

TS23767 041RW003

Inspection Procedure NOTE: Replace the fuel filler cap with the same type of filler cap that was originally installed on the vehicle. B Check the seal ring in the filler cap for any abnormality and for seal condition. B Replace the filler cap if any abnormality is found.

Legend (1) Fuel Hose (2) Fuel Filter Fixing Bolt (3) Fuel Filter 6. Remove the fuel filter.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Inspection Procedure 1. Replace the fuel filter when the following occur: B Fuel leaks from the fuel filter body. B The fuel filter body is damaged. B The fuel filter is clogged with dirt or sediment.

6E–553

Legend (1) Fuel Hose (2) Fuel Filter Fixing Bolt (3) Fuel Filter 5. Install the fuel filler cap.

2. If the drain hole is clogged, clean the drain.

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6. Connect the negative battery cable. 041RY00002

Fuel Gauge Unit

Installation Procedure 1. Install the fuel filter in the correct direction. 2. Install the bolt on the fuel filter holder.

Removal Procedure Refer to Fuel Gauge Unit Engine Fuel section.

Tighten B Tighten the screws to 20 N·m (14 lb ft.). 3. Connect the fuel hose on the engine side. 4. Connect the fuel hose on the fuel tank side.

014RW133

041RW003

6E–554

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 4. Remove the injector retainer clip.

Fuel Injectors Removal Procedure NOTE: If the fuel injectors are leaking, the engine oil may be contaminated with fuel. Check the oil for signs of contamination and change the oil and the filter if necessary. NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. The fuel injector is an electrical component and should not be immersed in any type of cleaner as this may damage the fuel injector. IMPORTANT: Fuel injectors are serviced as a complete assembly only. 1. Disconnect the negative battery cable. 2. Remove the common chamber. Refer to Common Chamber in Engine Mechanical section. 3. Remove the fuel rail. Refer to Fuel Rail section.

040RY00001

5. Remove the fuel injector assembly. 6. Remove the O-ring from the fuel injector. 7. Remove the O-ring backup from the fuel injector .

Inspection Procedure 1. Inspect the O-rings for cracks or leaks. 2. Replace worn or damaged O-rings. 3. Lubricate the new O-rings with engine oil before installation.

Installation Procedure 1. Install the O-ring backup on the fuel injector. 2. Install the new O-ring on the fuel injector. 3. Install the fuel injector on the fuel rail.

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4. Use new fuel injector retainer clips to retain the fuel injector to the fuel rail. 5. Coat the end of the fuel injector with gasoline.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6. Install the fuel rail. Refer to Fuel Rail section.

6E–555

2. Remove the fuel pump relay from the underhood relay box. Refer to Fuel Pump Relay section.

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7. Install the common chamber. Refer to Common Chamber in Engine Mechanical section. 8. Install the engine cover. 9. Connect the negative battery cable.

Fuel Metering System

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3. Start the engine and allow it to stall. 4. Crank the engine for 30 seconds. 5. Disconnect the negative battery cable.

Fuel Pump Assembly

Fuel Pressure Relief Procedure

Removal Procedure

CAUTION: To reduce the risk of fire and personal injury, there are necessary to relieve the fuel system pressure before filler and gauge unit servicing the fuel system components.

Refer to Fuel Tank In Fuel Pump Relay section.

CAUTION: After relieving the system pressure, a small amount of fuel may be released when servicing fuel lines or connections. Reduce the chance of personal injury by covering the fuel line fittings with a shop towel before you disconnect the fittings. The towels will absorb any fuel that may leak out. When the disconnect is completed, place the towel in an approved container. 1. Remove the fuel cap.

014RW133

6E–556

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuel Pump Relay

Installation Procedure

Removal Procedure 1. Remove the fuse and relay box cover from under the hood. 2. Consult the diagram on the cover to determine which is the correct relay. 3. Insert a small screwdriver into the catch slot on the forward side of the fuel pump relay. B The screwdriver blade will release the catch inside.

1. Insert the relay into the correct place in the fuse and relay box with the catch slot facing forward. 2. Press down until the catch engages. B An audible “click” will be heard.

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3. Install the fuse and relay box cover.

D08RY00291

4. Pull the relay straight up and out of the fuse and relay box.

014RY00004

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–557

2. If an injector becomes separated from the fuel rail, the infector O-ring seals and the retainer clip must be replaced.

Fuel Rail Assembly Removal Procedure

3. Drain residual fuel into an approved container.

NOTE: B Do not attempt to remove the fuel inlet fitting on the fuel rail. It is staked in place. Removing the fuel inlet fitting will result in damage to the fuel rail or the internal O-ring seal. B Use care when removing the fuel rail assembly in order to prevent damage to the injector electrical connector terminals and the injector spray tips. B Fittings should be capped and holes plugged during servicing to prevent dirt and other contaminants from entering open lines and passages. IMPORTANT: An eight-digit identification number is stamped on the side of the fuel rail. Refer to this number when you service the fuel rail or when a replacement part is required.

014RW164

8. If removal of the fuel pressure regulator is necessary, refer to Fuel Pressure Regulator section. 9. If removal of the fuel injectors is necessary, refer to Fuel Injectors section.

Installation Procedure 1. If the fuel injectors were removed, install them. Refer to Fuel Injectors section. 2. If the fuel pressure regulator was removed, install it. Refer to Fuel Pressure Regulator section. 3. Install the common chamber. Refer to common chamber in engine Mechanical section. 014RY00008

Before removal, the fuel rail assembly may be cleaned with a spray type engine cleaner. Follow the spray package instructions. Do not immerse the fuel rails in liquid cleaning solvent. 1. Depressurize the fuel system. Refer to Fuel Pressure Relief Procedure in this Section. 2. Disconnect the negative battery cable. 3. Remove the engine cover. 4. Disconnect the throttle position sensor electrical connector from throttle body. 5. Disconnect the connectors from manifold absolute pressure sensor, solenoid valve, electric vacuum sensing valve. 6. Disconnect the vacuum hose on canister VSV and positive crankcase ventilation hose. 7. Remove the common chamber. Refer to the common chamber in Engine Mechanical section. 1. Lift up carefully on the fuel injectors. Do not separate the fuel injectors from the fuel rail.

014RW164

4. Connect the vacuum hose on Canister VSV and positive crankcase ventilation hose.

6E–558

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

5. Connect the connectors to manifold absolute pressure sensor, solenoid valve, electric vacuum sensing valve. 6. Connect the throttle position sensor electrical connector to throttle body. 7. Install the engine cover. 8. Connect the negative battery cable. 9. Crank the engine until it starts. Cranking the engine may take longer than usual due to trapped air in the fuel rail and in the injectors.

Fuel Tank

Throttle Body (TB) Removal Procedure 1. Disconnect the negative battery cable. 2. Drain the cooling system. Refer to Cooling System section. 3. Disconnect the electrical connectors: B Throttle position (TP) sensor. B Intake air temperature (IAT) sensor. Refer to Intake Air Temperature Sensor section.

Removal Procedure Refer to Fuel Tank In Fuel Pump Relay

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014RW134

4. Disconnect the vacuum hose below the air horn. 5. Remove the intake air duct clamp. 6. Disconnect the intake air duct. 7. Disconnect the coolant lines from the throttle body. 8. Remove the bolts from the common chamber. 9. Remove the throttle body from the common chamber. 10. Remove the gasket from the common chamber.

025RY00004

11. Remove the TP sensor. Refer to Throttle Position (TP) Sensor section.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Inspection Procedure NOTE: Do not use solvent of any type when you clean the gasket surfaces on the intake manifold and the throttle body assembly. The gasket surfaces and the throttle body assembly may be damaged as a result.

6E–559

9. Connect all the electrical connectors: B Throttle position (TP) sensor. B Intake air temperature (IAT) sensor. Refer to Intake Air Temperature Sensor section.

B If the throttle body gasket needs to be replaced, remove any gasket material that may be stuck to the mating surfaces of the manifold. B Do not leave any scratches in the aluminum casting.

Installation Procedure 1. Install the TP sensor. Refer to Throttle Position (TP) Sensor section. 2. Install the gasket on the common chamber. 3. Install the throttle body on the common chamber. 4. Secure the gasket and the throttle body with the four bolts. B The vacuum lines must be properly routed under the throttle body before tightening the mounting bolts. Tighten B Tighten the throttle body mounting bolts to 10 N·m (87 lb in).

025RY00004

5. Install the coolant lines. 6. Connect all the vacuum lines. 7. Install the intake air duct. 8. Tighten the intake air duct clamp.

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10. Install the accelerator cable assembly. Refer to Accelerator Cable in Engine Speed Control System section. 11. Fill the cooling system. Refer to Cooling System section. 12. Install the negative battery cable.

6E–560

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Electronic Ignition System

CAUTION: Ignition coil assembly #6 is different from ignition coil assembly #1 to #5. Ignition coil assemblies #6 is short type. Be careful it when installing ignition coil assembly of #6.

Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the ignition coil connector at the ignition coil assemblies. 3. Remove the two screws that secure the ignition coil assemblies to the rocker cover.

060RY00002

Legend (1) Long Type Ignition Coil Assemblies (#1 ∼ #5) (2) Short Type Ignition Coil Assembly (#6) 060RY022

Legend (1) Ignition Coil Connectors (2) Bolts (3) Ignition Coil Assemblies

3. Install ignition coil assemblies and tighten the fixing bolts to the specified torque. Torque: 4 N·m (35.4 Ib in)

4. Remove the ignition coil assemblies and the spark plug boot from the spark plug. B Twist the ignition coil assemblies while pulling it straight up. 5. Use the appropriate spark plug socket in order to remove the spark plug from the engine.

Installation Procedure NOTE: The plug must thread smoothly into the cylinder head and be fully seated. Use a thread chaser if necessary to clean the threads in the cylinder head. Cross-threading or failure to fully seat the spark plug can cause plug overheating, exhaust blow-by gases, or thread damage. Do not overtighten the spark plugs. Over tightening can cause aluminum threads to strip. 1. Install the spark plug in the engine. appropriate spark plug socket.

Use the

Tighten B Tighten the spark plug to 18 N·m (13 lb ft.). 2. Install the ignition coil assemblies and spark plug boot over the spark plug.

060RY022

Legend (1) Ignition Coil Connectors (2) Bolts (3) Ignition Coil Assemblies 4. Connect the ignition coil connector at the ignition coil assemblies. 5. Connect the negative battery cable.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Catalytic Converter

6E–561

Installation Procedure

Removal and Installation Procedure Refer to Engine Exhaust in Engine section.

Air Conditioning Thermo Relay

1. Insert the relay into the correct place in the fuse and relay box with the catch slot facing forward. 2. Press down until the catch engages. B An audible “click” will be heard. 3. Install the fuse and relay box cover.

014RY00007

EVAP Canister Hoses Service Information To view the routing of the EVAP canister hoses, refer to Vehicle Emission Control Information in Diagnosis. Use 6148M or equivalent when you replace the EVAP canister hoses. D08RW131

4. Pull the relay straight up and out of the fuse and relay box.

014RY00007

6E–562

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 4. Connect the two hoses to the EVAP canister.

EVAP Canister Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the two hoses from the EVAP canister. 3. Disconnect the fuel vapor connector and the purge hose from the EVAP canister vent solenoid. 4. Remove the two retaining bolts the EVAP canister to the mounting bracket on the cross member. 5. Remove the retaining bolt on the mounting bracket the slide the canister out of mounting bracket.

060R200081

5. Disconnect the negative battery cable.

EVAP Canister Vent Solenoid Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the connector and hose.

060R200081

Inspection Procedure 1. Inspect the hoses for cracks and leaks. 2. Inspect the canister for a damaged case.

Installation Procedure 1. Slide the canister into mounting bracket and install the mounting bracket bolt. 2. Install the retaining bolts the EVAP canister to the mounting bracket on the cross member. 3. Connect the fuel vapor connector to the EVAP canister vent solenoid. 014RW132

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 3. Slide the out of EVAP canister vent solenoid from mounting bracket.

6E–563

2. Connect the connector and hose.

014RW132 014RW135

Inspection Procedure 1. Check for cracks or leaks. 2. Energize the solenoid and try to blow through it. The solenoid should not allow passage of air when energized. (J 35616 Connector Test Kit can be used to easily attach jumper wires from the battery to the solenoid).

Installation Procedure

3. Connect the negative battery cable.

Fuel Tank Pressure (Vapor Pressure) Sensor Removal Procedure 1. Remove the fuel pump assembly. Refer to Fuel Tank In Fuel Pump. 2. Carefully pry the fuel tank pressure sensor out of the top of the fuel pump assembly.

1. Slide the into EVAP canister vent solenoid into the mounting bracket.

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Inspection Procedure 1. Inspect the vapor pressure sensor for cracks in the housing and corrosion on the electrical terminals. 2. Inspect the rubber grommet for tears and signs of rot.

6E–564

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 3. Disconnect the vacuum hoses from the EVAP canister purge solenoid.

Installation Procedure 1. Install the rubber grommet on the fuel pump assembly.

060R200080

014RW133

2. Install the fuel tank vapor pressure sensor on the fuel pump assembly. B Insert the sensor nipple firmly into the grommet. B Keep twisting and pushing the sensor until the wide portion of the nipple shows on the other side of the grommet. 3. Install the fuel pump assembly on the fuel tank. Refer to Fuel Tank In Fuel Pump..

EVAP Canister Purge Solenoid (Purge Duty Solenoid Valve) Removal Procedure

4. Remove the EVAP canister purge solenoid retaining bolt from the common chamber. 5. Remove the EVAP canister purge solenoid.

Installation Procedure 1. Install the EVAP canister purge solenoid on the upper intake manifold. 2. Install the EVAP canister purge solenoid retaining bolt. Tighten B Tighten the bolts to 20 N·m (16 lb ft.). 3. Connect the vacuum hoses to the EVAP canister purge solenoid. 4. Connect the electrical connector to the EVAP canister purge solenoid.

1. Disconnect the negative battery cable. 2. Disconnect the electrical connector from the EVAP canister purge solenoid.

060R200080

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Fuel Tank Vent Valve (Vent Solenoid Valve)

6E–565

Installation Procedure

Removal and Installation Procedure

1. Install the gasket on the common chamber. 2. Install the EGR valve on the common chamber. 3. Secure the EGR valve and the gasket with the bolts. Torque: 25 N·m (18 Ib ft)

Refer to Fuel Pump section.

NOTE: It is possible to install the EGR valve rotated 180° from the correct position. Make sure that the base of the valve is placed so that it aligns with the mounting flange.

Linear Exhaust Gas Recirculation (EGR) Valve Removal Procedure 1. Disconnect the negative battery cable. 2. Disconnect the electrical connector at the EGR valve.

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4. Connect the electrical connector at the EGR valve.

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3. Remove the bolts from the common chamber.

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5. Connect the negative battery cable.

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4. Remove the EGR valve from the common chamber manifold. 5. Remove the gasket from the common chamber manifold.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Positive Crankcase Ventilation (PCV) Valve

2. Install the vacuum hose on the PCV valve and secure the vacuum hose with the clamp.

Removal Procedure 1. Remove the vacuum hose at the PCV valve. B Slide the clamp back to release the hose. 2. Pull the PCV valve from the rubber grommet in the right valve cover.

014RW097

Wiring and Connectors Wiring Harness Service 014RW097

Inspection Procedure Before inspecting the PCV valve, make sure that the hoses are connected properly and are in good condition. Also check that the oil pan and rocker cover gaskets are sealing properly.

PCV Valve 1. Run the engine at normal operating temperature. 2. Disconnect the valve from the rocker cover. RESULT: A hissing noise should be heard from the valve. If no noise is heard, the PCV valve or hose is plugged. 3. Remove the PCV valve from the engine. a. Blow air into the rocker cover side of the valve. RESULT: Air should pass freely. b. Blow air into the air cleaner side of the valve. RESULT: Air should not pass through the valve. 4. Re-install the PCV valve and remove the oil filler cap. RESULT: A small vacuum should be felt at the oil filler hole.

Installation Procedure 1. Push the PCV valve into the rubber grommet in the left valve cover.

The control module harness electrically connects the control module to the various solenoids, switches and sensors in the vehicle engine compartment and passenger compartment. Replace wire harnesses with the proper part number replacement. Because of the low amperage and voltage levels utilized in powertrain control systems, it is essential that all wiring in environmentally exposed areas be repaired with crimp and seal splice sleeves. The following wire harness repair information is intended as a general guideline only. Refer to Chassis Electrical section for all wire harness repair procedures.

Connectors and Terminals Use care when probing a connector and when replacing terminals. It is possible to short between opposite terminals. Damage to components could result. Always use jumper wires between connectors for circuit checking. NEVER probe through Weather-Pack seals. Use an appropriate connector test adapter kit which contains an assortment of flexible connectors used to probe terminals during diagnosis. Use an appropriate fuse remover and test tool for removing a fuse and to adapt the fuse holder to a meter for diagnosis. Open circuits are often difficult to locate by sight because oxidation or terminal misalignment are hidden by the connectors. Merely wiggling a connector on a sensor, or in the wiring harness, may temporarily correct the open circuit. Intermittent problems may also be caused by oxidized or loose connections. Be certain of the type of connector/terminal before making any connector or terminal repair. Weather-Pack and Com-Pack III terminals look similar, but are serviced differently.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

PCM Connectors and Terminals

6E–567

4. Strip the insulation as necessary.

Removal Procedure 1. Remove the connector terminal retainer. 2. Push the wire connected to the affected terminal through the connector face so that the terminal is exposed. 3. Service the terminal as necessary.

Installation Procedure 1. Bend the tab on the connector to allow the terminal to be pulled into position within the connector. 2. Pull carefully on the wire to install the connector terminal retainer.

Wire Harness Repair: Twisted Shielded Cable

048

Installation Procedure

Removal Procedure 1. Remove the outer jacket. 2. Unwrap the aluminum/mylar tape. Do not remove the mylar.

1. Splice the wires using splice clips and rosin core solder. 2. Wrap each splice to insulate. 3. Wrap the splice with mylar and with the drain (uninsulated) wire.

047

3. Untwist the conductors. 049

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

4. Tape over the whole bundle to secure.

Installation Procedure 1. Use splice clips and rosin core solder in order to splice the two wires together.

050

Twisted Leads

052

2. Cover the splice with tape in order to insulate it from the other wires.

Removal Procedure 1. Locate the damaged wire. 2. Remove the insulation as required.

053

051

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 3. Twist the wires as they were before starting this procedure.

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Weather-Pack Connector Tools Required J 28742-A Weather-Pack II Terminal Remover

Removal Procedure A Weather-Pack connector can be identified by a rubber seal at the rear of the connector. This engine room connector protects against moisture and dirt, which could form oxidation and deposits on the terminals. This protection is important, because of the low voltage and the low amperage found in the electronic systems. 1. Open the secondary lock hinge on the connector.

054

4. Tape the wires with electrical tape. Hold in place.

070

2. Use tool J 28742-A or the equivalent to remove the pin and the sleeve terminals. Push on J 28742-A to release. NOTE: Do the use an ordinary pick or the terminal may be bent or deformed. Unlike standard blade terminals, these terminals cannot be straightened after they have been improperly bent. 055

071

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

3. Cut the wire immediately behind the cable seal.

5. Push the terminal and the connector to engage the locking tangs.

072 070

6. Close the secondary locking hinge.

Installation Procedure Make certain the connectors are properly seated and all of the sealing rings are in place when you reconnect the leads. The secondary lock hinge provides a backup locking feature for the connector. The secondary lock hinge is used for added reliability. This flap should retain the terminals even if the small terminal lock tangs are not positioned properly. Do not replace the Weather-Pack connections with standard connections. Read the instructions provided with the Weather-Pack connector and terminal packages. 1. Replace the terminal. 2. Slip the new seal onto the wire. 3. Strip 5 mm (0.2”) of insulation from the wire. 4. Crimp the terminal over the wire and the seal.

073

Com-Pack III General Information The Com-Pack III terminal looks similar to some Weather-Pack terminals. This terminal is not sealed and is used where resistance to the environment is not required. Use the standard method when repairing a terminal. Do not use the Weather-Pack terminal tool J 28742-A or equivalent. These will damage the terminals.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–571

2. The terminal (1) is then crimped onto the wire.

Metri-Pack Tools Required J 35689 Terminal Remover

Removal Procedure Some connectors use terminals called Metri-Pack Series 150. These may be used at the engine coolant temperature (ECT) sensor. 1. Slide the seal (1) back on the wire. 2. Insert the J 35689 tool or equivalent (3) in order to release the terminal locking tang (2).

061

3. Then the terminal is pulled back into the connector to seat it in place.

060

3. Push the wire and the terminal out through the connector. If you reuse the terminal, reshape the locking tang.

Installation Procedure Metri-Pack terminals are also referred to as “pull-to-seat” terminals. 1. In order to install a terminal on a wire, the wire must be inserted through the seal (2) and through the connector (3).

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

General Description (PCM and Sensors) 58X Reference PCM Input The powertrain control module (PCM) uses this signal from the crankshaft position (CKP) sensor to calculate engine RPM and crankshaft position at all engine speeds. The PCM also uses the pulses on this circuit to initiate injector pulses. If the PCM receives no pulses on this circuit, DTC P0337 will set. The engine will not start and run without using the 58X reference signal.

PCM calculates the engine coolant temperature. Engine coolant temperature affects most of the systems that the PCM controls. The Tech 2 displays engine coolant temperature in degrees. After engine start-up, the temperature should rise steadily to about 85°C (185°F). It then stabilizes when the thermostat opens. If the engine has not been run for several hours (overnight), the engine coolant temperature and intake air temperature displays should be close to each other. A hard fault in the engine coolant sensor circuit will set DTC P0177 or DTC P0118. An intermittent fault will set a DTC P1114 or P1115.

A/C Request Signal This signal tells the PCM when the A/C mode is selected at the A/C control head. The PCM uses this to adjust the idle speed before turning “ON” the A/C clutch. The A/C compressor will be inoperative if this signal is not available to the PCM. Refer to A/C Clutch Circuit Diagnosis section for A/C wiring diagrams and diagnosis for the A/C electrical system.

Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor provides a signal used by the powertrain control module (PCM) to calculate the ignition sequence. The CKP sensor initiates the 58X reference pulses which the PCM uses to calculate RPM and crankshaft position. Refer to Electronic Ignition System section for additional information. 0016

Electrically Erasable Programmable Read Only Memory (EEPROM) The electrically erasable programmable read only memory (EEPROM) is a permanent memory chip that is physically soldered within the PCM. The EEPROM contains the program and the calibration information that the PCM needs to control powertrain operation. Unlike the PROM used in past applications, the EEPROM is not replaceable. If the PCM is replaced, the new PCM will need to be programmed. Equipment containing the correct program and calibration for the vehicle is required to program the PCM.

Fuel Control Heated Oxygen Sensors

0013

Engine Coolant Temperature (ECT) Sensor The engine coolant temperature (ECT) sensor is a thermistor (a resistor which changes value based on temperature) mounted in the engine coolant stream. Low coolant temperature produces a high resistance of 100,000 ohms at –40°C (–40°F). High temperature causes a low resistance of 70 ohms at 130°C (266°F). The PCM supplies a 5-volt signal to the ECT sensor through resistors in the PCM and measures the voltage. The signal voltage will be high when the engine is cold and low when the engine is hot. By measuring the voltage, the

The fuel control heated oxygen sensors (Bank 1 HO2S 1 and Bank 2 HO2S 1) are mounted in the exhaust stream where they can monitor the oxygen content of the exhaust gas. The oxygen present in the exhaust gas reacts with the sensor to produce a voltage output. This voltage should constantly fluctuate from approximately 100 mV to 900 mV. The heated oxygen sensor voltage can be monitored with a Tech 2. By monitoring the voltage output of the oxygen sensor, the PCM calculates the pulse width command for the injectors to produce the proper combustion chamber mixture. B Low HO2S voltage is a lean mixture which will result in a rich command to compensate. B High HO2S voltage is a rich mixture which will result in a lean command to compensate.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS An open Bank 1 HO2S 1 signal circuit will set a DTC P0134 and the Tech 2 will display a constant voltage between 400-500 mV. A constant voltage below 300 mV in the sensor circuit (circuit grounded) will set DTC P0131. A constant voltage above 800 mV in the circuit will set DTC P0132. Faults in the Bank 2 HO2S 1 signal circuit will cause DTC 0154 (open circuit), DTC P0151 (grounded circuit), or DTC P0152 (signal voltage high) to set. A fault in the Bank 1 HO2S 1 heater circuit will cause DTC P0135 to set. A fault in the Bank 2 HO2S 1 heater circuit will cause DTC P0155 to set. The PCM can also detect HO2S response problems. If the response time of an HO2S is determined to be too slow, the PCM will store a DTC that indicates degraded HO2S performance.

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will make a slight adjustment to fuel trim to ensure that fuel delivery is correct for catalyst monitoring. A problem with the Bank 1 HO2S 2 signal circuit will set DTC P0137, P0138, or P0140, depending on the specific condition. A problem with the Bank 2 HO2S 2 signal circuit will set DTC P0157, P0158, or P0160, depending on the specific condition. A fault in the heated oxygen sensor heater element or its ignition feed or ground will result in lower sensor response. This may cause incorrect catalyst monitor diagnostic results.

TS24067

060RY00127

Catalyst Monitor Heated Oxygen Sensors Three-way catalytic converters are used to control emissions of hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx). The catalyst within the converters promotes a chemical reaction. This reaction oxidizes the HC and CO present in the exhaust gas and converts them into harmless water vapor and carbon dioxide. The catalyst also reduces NOx by converting it to nitrogen. The PCM can monitor this process using the Bank 1 HO2S 2 and the Bank 2 HO2S 2 heated oxygen sensors. The Bank 1 HO2S 1 and the Bank 2 HO2S 1 sensors produce an output signal which indicates the amount of oxygen present in the exhaust gas entering the three-way catalytic converter. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors produce an output signal which indicates the oxygen storage capacity of the catalyst. This indicates the catalyst’s ability to efficiently convert exhaust gases. If the catalyst is operating efficiently, the Bank 1 HO2S 1 and the Bank 2 HO2S 1 signals will be more active than the signals produced by the Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors. The catalyst monitor sensors operate the same as the fuel control sensors. The Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors’ main function is catalyst monitoring, but they also have a limited role in fuel control. If a sensor output indicates a voltage either above or below the 450 mV bias voltage for an extended period of time, the PCM

TS23365A

Legend (1) Bank 1 Sensor 1 (Fuel Control) (2) Catalytic Converter (3) Bank 1 Sensor 2 (Catalyst Monitor) (4) Bank 2 Sensor 1 (Fuel Control) (5) Bank 2 Sensor 2 (Catalyst Monitor)

Intake Air Temperature (IAT) Sensor The intake air temperature (IAT) sensor is a thermistor which changes its resistance based on the temperature of air entering the engine. Low temperature produces a high

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

resistance of 100,000 ohms at –40°C (–40°F). High temperature causes low resistance of 70 ohms at 130°C (266°F) . The PCM supplies a 5-volt signal to the sensor through a resistor in the PCM and monitors the signal voltage. The voltage will be high when the incoming air is cold. The voltage will be low when the incoming air is hot. By measuring the voltage, the PCM calculates the incoming air temperature. The IAT sensor signal is used to adjust spark timing according to the incoming air density. The Tech 2 displays the temperature of the air entering the engine. The temperature should read close to the ambient air temperature when the engine is cold and rise as underhood temperature increases. If the engine has not been run for several hours (overnight), the IAT sensor temperature and engine coolant temperature should read close to each other. A fault in the IAT sensor circuit will set DTC P0112 or DTC P0113.

Linear Exhaust Gas Recirculation (EGR) Control The PCM monitors the exhaust gas recirculation (EGR) actual position and adjusts the pintle position accordingly. The PCM uses information from the following sensors to control the pintle position: B Engine coolant temperature (ECT) sensor. B Throttle position (TP) sensor. B Mass air flow (MAF) sensor.

Mass Air Flow (MAF) Sensor The mass air flow (MAF) sensor measures the difference between the volume and the quantity of air that enters the engine. “Volume” means the size of the space to be filled. “Quantity” means the number of air molecules that will fit into the space. This information is important to the PCM because heavier, denser air will hold more fuel than lighter, thinner air. The PCM adjusts the air/fuel ratio as needed depending on the MAF value. The Tech 2 reads the MAF value and displays it in terms of grams per second (gm/s). At idle, the Tech 2 should read between 4-7 gm/s on a fully warmed up engine. Values should change quickly on acceleration. Values should remain stable at any given RPM. A failure in the MAF sensor or circuit will set DTC P0101, DTC P0102, or DTC P0103.

0007

Manifold Absolute Pressure (MAP) Sensor The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure (vacuum). The MAP sensor signal voltage to the PCM varies from below 2 volts at idle (high vacuum) to above 4 volts with the ignition ON, engine not running or at wide-open throttle (low vacuum). The MAP sensor is used to determine the following: B Manifold pressure changes while the linear EGR flow test diagnostic is being run. Refer to DTC P0401. B Barometric pressure (BARO). If the PCM detects a voltage that is lower than the possible range of the MAP sensor, DTC P0107 will be set. A signal voltage higher than the possible range of the sensor will set DTC P0108. An intermittent low or high voltage will set DTC P1107, respectively. The PCM can detect a shifted MAP sensor. The PCM compares the MAP sensor signal to a calculated MAP based on throttle position and various engine load factors. If the PCM detects a MAP signal that varies excessively above or below the calculated value, DTC P0106 will set.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Powertrain Control Module (PCM) The powertrain control module (PCM) is located in the passenger compartment below the center console. The PCM controls the following: B Fuel metering system. B Transmission shifting (automatic transmission only). B Ignition timing. B On-board diagnostics for powertrain functions. The PCM constantly observes the information from various sensors. The PCM controls the systems that affect vehicle performance. The PCM performs the diagnostic function of the system. It can recognize operational problems, alert the driver through the MIL (Check Engine lamp), and store diagnostic trouble codes (DTCs). DTCs identify the problem areas to aid the technician in making repairs.

PCM Function The PCM supplies either 5 or 12 volts to power various sensors or switches. The power is supplied through resistances in the PCM which are so high in value that a test light will not light when connected to the circuit. In some cases, even an ordinary shop voltmeter will not give an accurate reading because its resistance is too low. Therefore, a digital voltmeter with at least 10 megohms input impedance is required to ensure accurate voltage readings. Tool J 39200 meets this requirement. The PCM controls output circuits such as the injectors, fan relays, etc., by controlling the ground or the power feed circuit through transistors or through either of the following two devices: B Output Driver Module (ODM) B Quad Driver Module (QDM)

sensor, heated oxygen sensor (HO2S), and vehicle speed sensor (VSS). The PCM also controls certain engine operations through the following: B Fuel injector control B Ignition control module B ION sensing module B Automatic transmission shift functions B Cruise control B Evaporative emission (EVAP) purge B A/C clutch control

PCM Voltage Description The PCM supplies a buffered voltage to various switches and sensors. It can do this because resistance in the PCM is so high in value that a test light may not illuminate when connected to the circuit. An ordinary shop voltmeter may not give an accurate reading because the voltmeter input impedance is too low. Use a 10-megohm input impedance digital voltmeter (such as J 39200) to assure accurate voltage readings. The input/output devices in the PCM include analog-to-digital converters, signal buffers, counters, and special drivers. The PCM controls most components with electronic switches which complete a ground circuit when turned “ON.” These switches are arranged in groups of 4 and 7, called either a surface-mounted quad driver module (QDM), which can independently control up to 4 output terminals, or QDMs which can independently control up to 7 outputs. Not all outputs are always used.

PCM Input/Outputs Inputs – Operating Conditions Read B B B B B B B B B B B B B B B

Air Conditioning “ON” or “OFF” Engine Coolant Temperature Crankshaft Position Exhaust Oxygen Content Electronic Ignition Manifold Absolute Pressure Battery Voltage Throttle Position Vehicle Speed Fuel Pump Voltage Power Steering Pressure Intake Air Temperature Mass Air Flow Engine Knock Acceleration Position

Outputs – Systems Controlled 060RY00068

PCM Components The PCM is designed to maintain exhaust emission levels to government mandated standards while providing excellent driveability and fuel efficiency. The PCM monitors numerous engine and vehicle functions via electronic sensors such as the throttle position (TP)

6E–575

B B B B B B B

EVAP Canister Purge Exhaust Gas Recirculation (EGR) Ignition Control Fuel Control ION Sensing Module Electric Fuel Pump Air Conditioning

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B Diagnostics – Malfunction Indicator Lamp – Data Link Connector (DLC) – Data Output B Transmission Control Module

Transmission Fluid Temperature (TFT) Sensor

PCM Service Precautions The PCM is designed to withstand normal current draws associated with vehicle operation. Avoid overloading any circuit. When testing for opens and shorts, do not ground or apply voltage to any of the PCM’s circuits unless instructed to do so. These circuits should only be tested using digital voltmeter J 39200. The PCM should remain connected to the PCM or to a recommended breakout box.

The transmission fluid temperature sensor is a thermistor which changes its resistance based on the temperature of the transmission fluid. For a complete description of the TFT sensor, refer to 4L30-E Automatic Transmission Diagnosis section. A failure in the TFT sensor or associated wiring will cause DTC P0712 or DTC P0713 to set. In this case, engine coolant temperature will be substituted for the TFT sensor value and the transmission will operate normally.

Transmission Range Switch (Mode Switch)

Reprogramming of the PCM is done without removing it from the vehicle . This provides a flexible and cost-effective method of making changes in software calibrations. Refer to the latest Techline information on reprogramming or flashing procedures.

IMPORTANT: The vehicle should not be driven with the transmission range switch disconnected; idle quality will be affected. The four inputs from the transmission range switch indicate to the PCM which position is selected by the transmission selector lever. This information is used for ignition timing, EVAP canister purge, EGR operation. For more information on the transmission on the transmission range switch, refer to 4L30-E Automatic Transmission section.

Throttle Position (TP) Sensor

Vehicle Speed Sensor (VSS)

The throttle position (TP) sensor is a potentiometer connected to the throttle shaft on the throttle body. The PCM monitors the voltage on the signal line and calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP1 sensor is low. As the throttle valve opens, the output increases so that at wide open throttle (WOT), the output voltage should be above 92% (Tech 2 Display). The PCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector and unstable idle because the PCM thinks the throttle is moving.

The PCM determines the speed of the vehicle by converting a pulsing voltage signal from the vehicle speed sensor (VSS) into miles per hour. The PCM uses this signal to operate the cruise control, speedometer, and the TCC and shift solenoids in the transmission. For more information on the TCC and shift solenoids, refer to 4L30-E Automatic Transmission section.

Reprogramming The PCM

0008

Use of Circuit Testing Tools

060RY00027

Do not use a test light to diagnose the powertrain electrical systems unless specifically instructed by the diagnostic procedures. Use Connector Test Adapter Kit J 35616 whenever diagnostic procedures call for probing connectors.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–577

Aftermarket (add-on) electrical and vacuum equipment is defined as any equipment which connects to the vehicle’s electrical or vacuum systems that is installed on a vehicle after it leaves the factory. No allowances have been made in the vehicle design for this type of equipment.

B Charge by induction occurs when a person with well insulated shoes stands near a highly charged object and momentary touches ground. Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore it is important to use care when handling and testing electronic components.

NOTE: No add-on vacuum equipment should be added to this vehicle.

NOTE: To prevent possible electrostatic discharge damage, follow these guidelines:

NOTE: Add-on electrical equipment must only be connected to the vehicle’s electrical system at the battery (power and ground). Add-on electrical equipment, even when installed to these guidelines, may still cause the powertrain system to malfunction. This may also include equipment not connected to the vehicle electrical system such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain problem is to eliminate all aftermarket electrical equipment from the vehicle. After this is done, if the problem still exists, it may be diagnosed in the normal manner.

B Do not touch the PCM connector pins or soldered components on the PCM circuit board. B Do not open the replacement part package until the part is ready to be installed. B Before removing the part from the package, ground the package to a known good ground on the vehicle. B If the part has been handled while sliding across the seat, while sitting down from a standing position, or while walking a distance, touch a known good ground before installing the part.

Aftermarket Electrical and Vacuum Equipment

Electrostatic Discharge Damage Electronic components used in the PCM are often designed to carry very low voltage. Electronic components are susceptible to damage caused by electrostatic discharge. Less than 100 volts of static electricity can cause damage to some electronic components. By comparison, it takes as much as 4000 volts for a person to feel even the zap of a static discharge.

General Description (Air Induction) Air Induction System The air induction system filters contaminants from the outside air, and directs the progress of the air as it is drawn into the engine. A remote-mounted air cleaner prevents dirt and debris in the air from entering the engine. The air duct assembly routes filtered air to the throttle body. Air enters the engine by to following steps: 1. Through the throttle body. 2. Into the common chamber. 3. Through the cylinder head intake ports. 4. Into the cylinders.

TS23793

There are several ways for a person to become statically charged. The most common methods of charging are by friction and induction. B An example of charging by friction is a person sliding across a vehicle seat.

055RV010

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

General Description (Fuel Metering) Acceleration Mode The PCM provides extra fuel when it detects a rapid increase in the throttle position and the air flow.

Battery Voltage Correction Mode When battery voltage is low, the PCM will compensate for the weak spark by increasing the following: B The amount of fuel delivered. B The idle RPM. B Ignition dwell time.

Clear Flood Mode Clear a flooded engine by pushing the accelerator pedal down all the way. The PCM then de-energizes the fuel injectors. The PCM holds the fuel injectors de-energized as long as the throttle remains above 80% and the engine speed is below 800 RPM. If the throttle position becomes less than 80%, the PCM again begins to pulse the injectors “ON” and “OFF,” allowing fuel into the cylinders.

Deceleration Mode The PCM reduces the amount of fuel injected when it detects a decrease in the throttle position and the air flow. When deceleration is very fast, the PCM may cut off fuel completely for short periods.

Engine Speed/Vehicle Speed/Fuel Disable Mode The PCM monitors engine speed. It turns off the fuel injectors when the engine speed increases above 6400 RPM. The fuel injectors are turned back on when engine speed decreases below 6150 RPM.

Fuel Cutoff Mode No fuel is delivered by the fuel injectors when the ignition is “OFF.” This prevents engine run-on. In addition, the PCM suspends fuel delivery if no reference pulses are detected (engine not running) to prevent engine flooding.

Fuel Injector The sequential multiport fuel injection (SFI) fuel injector is a solenoid-operated device controlled by the PCM. The PCM energizes the solenoid, which opens a valve to allow fuel delivery. The fuel is injected under pressure in a conical spray pattern at the opening of the intake valve. Excess fuel not used by the injectors passes through the fuel pressure regulator before being returned to the fuel tank. A fuel injector which is stuck partly open will cause a loss of fuel pressure after engine shut down, causing long crank times.

014RY00009

Fuel Metering System Components The fuel metering system is made up of the following parts: B The fuel injectors. B The throttle body. B The fuel rail. B The fuel pressure regulator. B The PCM. B The crankshaft position (CKP) sensor. B The ION sensing module. B The fuel pump. B The fuel pump relay. Basic System Operation The fuel metering system starts with the fuel in the fuel tank. An electric fuel pump, located in the fuel tank, pumps fuel to the fuel rail through an in-line fuel filter. The pump is designed to provide fuel at a pressure above the pressure needed by the injectors. A fuel pressure regulator in the fuel rail keeps fuel available to the fuel injectors at a constant pressure. A return line delivers unused fuel back to the fuel tank. Refer to Section 6C for further information on the fuel tank, line filter, and fuel pipes.

Fuel Metering System Purpose The basic function of the air/fuel metering system is to control the air/fuel delivery to the engine. Fuel is delivered to the engine by individual fuel injectors mounted in the intake manifold near each intake valve. The main control sensor is the heated oxygen sensor (HO2S) located in the exhaust system. The HO2S tells the PCM how much oxygen is in the exhaust gas. The PCM changes the air/fuel ratio to the engine by controlling the amount of time that fuel injector is “ON.” The best mixture to minimize exhaust emissions is 14.7 parts of air to 1 part of gasoline by weight, which allows the catalytic converter to operate most efficiently. Because of the constant measuring and adjusting of the air/fuel ratio, the fuel injection system is called a “closed loop” system.

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6E–579

The PCM monitors signals from several sensors in order to determine the fuel needs of the engine. Fuel is delivered under one of several conditions called “modes.” All modes are controlled by the PCM.

Fuel Pressure Regulator The fuel pressure regulator is a diaphragm-operated relief valve mounted on the fuel rail with fuel pump pressure on one side and manifold pressure on the other side. The fuel pressure regulator maintains the fuel pressure available to the injector at three times barometric pressure adjusted for engine load. It may be serviced separtely. If the pressure is too low, poor performance and a DTC P0131, DTC P0151,DTC P0171 or DTC P1171 will be the result. If the pressure is too high, excessive odor and/or a DTC P0132, DTC P0152,DTC P0172 will be the result. Refer to Fuel System Diagnosis for information on diagnosing fuel pressure conditions. 055RW009

Run Mode

014RY00010

Fuel Pump Electrical Circuit When the key is first turned “ON,” the PCM energizes the fuel pump relay for two seconds to build up the fuel pressure quickly. If the engine is not started within two seconds, the PCM shuts the fuel pump off and waits until the engine is cranked. When the engine is cranked and the 58 X crankshaft position signal has been detected by the PCM, the PCM supplies 12 volts to the fuel pump relay to energize the electric in-tank fuel pump. An inoperative fuel pump will cause a “no-start” condition. A fuel pump which does not provide enough pressure will result in poor performance.

Fuel Rail The fuel rail is mounted to the top of the engine and distributes fuel to the individual injectors. Fuel is delivered to the fuel inlet tube of the fuel rail by the fuel lines. The fuel goes through the fuel rail to the fuel pressure regulator. The fuel pressure regulator maintains a constant fuel pressure at the injectors. Remaining fuel is then returned to the fuel tank.

The run mode has the following two conditions: B Open loop B Closed loop When the engine is first started the system is in “open loop” operation. In “open loop,” the PCM ignores the signal from the heated oxygen sensor (HO2S). It calculates the air/fuel ratio based on inputs from the TP, ECT, and MAF sensors. The system remains in “open loop” until the following conditions are met: B The HO2S has a varying voltage output showing that it is hot enough to operate properly (this depends on temperature). B The ECT has reached a specified temperature. B A specific amount of time has elapsed since starting the engine. B Engine speed has been greater than a specified RPM since start-up. The specific values for the above conditions vary with different engines and are stored in the programmable read only memory (PROM). When these conditions are met, the system enters “closed loop” operation. In “closed loop,” the PCM calculates the air/fuel ratio (injector on-time) based on the signal from the HO2S. This allows the air/fuel ratio to stay very close to 14.7:1.

Starting Mode When the ignition is first turned “ON,” the PCM energizes the fuel pump relay for two seconds to allow the fuel pump to build up pressure. The PCM then checks the engine coolant temperature (ECT) sensor and the throttle position (TP) sensor to determine the proper air/fuel ratio for starting. The PCM controls the amount of fuel delivered in the starting mode by adjusting how long the fuel injectors are energized by pulsing the injectors for very short times.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Throttle Body Unit The throttle body has a throttle plate to control the amount of air delivered to the engine. The TP sensor are also mounted on the throttle body. Vacuum ports located behind the throttle plate provide the vacuum signals needed by various components. Engine coolant is directed through a coolant cavity in the throttle body to warm the throttle valve and to prevent icing.

0013

Ignition Coils A separate coil-at-plug module is located at each spark plug. The coil-at-plug module is attached to the engine with two screws. It is installed directly to the spark plug by an electrical contact inside a rubber boot. A three-way connector provides 12-volt primary supply from the 15-amp ignition fuse, a ground-switching trigger line from the PCM, and a ground. 025RY00005

General Description (Electronic Ignition System) Crankshaft Position (CKP) Sensor The crankshaft position (CKP) sensor provides a signal used by the powertrain control module (PCM) to calculate the ignition sequence. The sensor initiates the 58X reference pulses which the PCM uses to calculate RPM and crankshaft position. Refer to Electronic Ignition System section for additional information.

Electronic Ignition The electronic ignition system controls fuel combustion by providing a spark to ignite the compressed air/fuel mixture at the correct time. To provide optimum engine performance, fuel economy, and control of exhaust emissions, the PCM controls the spark advance of the ignition system. Electronic ignition has the following advantages over a mechanical distributor system: B No moving parts. B Less maintenance. B Remote mounting capability. B No mechanical load on the engine. B More coil cooldown time between firing events. B Elimination of mechanical timing adjustments. B Increased available ignition coil saturation time.

060RY00022

Ignition Control The ignition control (IC) spark timing is the PCM’s method of controlling the spark advance and the ignition dwell. The IC spark advance and the ignition dwell are calculated by the PCM using the following inputs: B Engine speed. B Crankshaft position (58X reference). B Engine coolant temperature (ECT) sensor. B Throttle position (TP) sensor. B ION sensing module. B Park/Neutral position (PRNDL input).

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B Vehicle speed (vehicle speed sensor). B PCM and ignition system supply voltage. B The crankshaft position (CKP) sensor sends the PCM a 58X signal related to the exact position of the crankshaft.

6E–581

B EST line is enabled.

060RY00029

Ignition Control PCM Output TS22909

Based on these sensor signals and engine load information, the PCM sends 5V to each ignition coil.

The PCM provides a zero volt (actually about 100 mV to 200 mV) or a 5-volt output signal to the ignition control (IC) module. Each spark plug has its own primary and secondary ignition coil assembly (”coil-at-plug”) located at the spark plug itself. When the ignition coil receives the 5-volt signal from the PCM, it provides a ground path for the B+ supply to the primary side of the coil-at -plug module. When the PCM shuts off the 5-volt signal to the ION sensing module, the ground path for the primary coil is broken. The magnetic field collapses and induces a high voltage secondary impulse which fires the spark plug and ignites the air/fuel mixture. The circuit between the PCM and the ignition coil is monitored for open circuits, shorts to voltage, and shorts to ground. If the PCM detects one of these events, it will set one of the following DTCs: B P0351: Ignition coil Fault on Cylinder #1 B P0352: Ignition coil Fault on Cylinder #2 B P0353: Ignition coil Fault on Cylinder #3 B P0354: Ignition coil Fault on Cylinder #4 B P0355: Ignition coil Fault on Cylinder #5 B P0356: Ignition coil Fault on Cylinder #6

060RY00116

This module has the function to energize and de-energize the primary ignition coil in response to signals from the PCM. The Throttle PCM controls ignition timing and dwell time. Continuity and out-or-range value check: This diagnosis detects open circuit or short-circuiting in the Electronic Spark Timing (EST) line by monitoring EST signals. A failure determination is made when the signal voltage remains higher or lower than the threshold for corresponding fault code beyond a predetermined time period. Diagnosis enabling conditions are as follows: B RPM is higher than the specified threshold.

Powertrain Control Module (PCM) The PCM is responsible for maintaining proper spark and fuel injection timing for all driving conditions. To provide optimum driveability and emissions, the PCM monitors the input signals from the following components in order to calculate spark timing: B Engine coolant temperature (ECT) sensor. B Intake air temperature (IAT) sensor. B Mass air flow (MAF) sensor. B PRNDL input from transmission range switch. B Throttle position (TP) sensor. B Vehicle speed sensor (VSS) .

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

B Crankshaft position (CKP) sensor.

Spark Plug Although worn or dirty spark plugs may give satisfactory operation at idling speed, they frequency fail at higher engine speeds. Faulty spark plugs may cause poor fuel economy, power loss, loss of speed, hard starting and generally poor engine performance. Follow the scheduled maintenance service recommendations to ensure satisfactory spark plug performance. Refer to Maintenance and Lubrication section. Normal spark plug operation will result in brown to grayish-tan deposits appearing on the insulator portion of the spark plug. A small amount of red-brown, yellow, and white powdery material may also be present on the insulator tip around the center electrode. These deposits are normal combustion by-products of fuels and lubricating oils with additives. Some electrode wear will also occur. Engines which are not running properly are often referred to as “misfiring.” This means the ignition spark is not igniting the air/fuel mixture at the proper time. While other ignition and fuel system causes must also be considered, possible causes include ignition system conditions which allow the spark voltage to reach ground in some other manner than by jumping across the air gap at the tip of the spark plug, leaving the air/fuel mixture unburned. Refer to DTC P0300. Misfiring may also occur when the tip of the spark plug becomes overheated and ignites the mixture before the spark jumps. This is referred to as “pre-ignition.” Spark plugs may also misfire due to fouling, excessive gap, or a cracked or broken insulator. If misfiring occurs before the recommended replacement interval, locate and correct the cause. Carbon fouling of the spark plug is indicated by dry, black carbon (soot) deposits on the portion of the spark plug in the cylinder. Excessive idling and slow speeds under light engine loads can keep the spark plug temperatures so low that these deposits are not burned off. Very rich fuel mixtures or poor ignition system output may also be the cause. Refer to DTC P0172. Oil fouling of the spark plug is indicated by wet oily deposits on the portion of the spark plug in the cylinder, usually with little electrode wear. This may be caused by oil during break-in of new or newly overhauled engines. Deposit fouling of the spark plug occurs when the normal red-brown, yellow or white deposits of combustion by products become sufficient to cause misfiring. In some cases, these deposits may melt and form a shiny glaze on the insulator around the center electrode. If the fouling is found in only one or two cylinders, valve stem clearances or intake valve seals may be allowing excess lubricating oil to enter the cylinder, particularly if the deposits are heavier on the side of the spark plug facing the intake valve.

TS23995

Excessive gap means that the air space between the center and the side electrodes at the bottom of the spark plug is too wide for consistent firing. This may be due to improper gap adjustment or to excessive wear of the electrode during use. A spark plug gap that is too small may cause an unstable idle condition. Excessive gap wear can be an indication of continuous operation at high speeds or with engine loads, causing the spark to run too hot. Another possible cause is an excessively lean fuel mixture.

TS23992

Low or high spark plug installation torque or improper seating can result in the spark plug running too hot and can cause excessive center electrode wear. The plug and the cylinder head seats must be in good contact for proper heat transfer and spark plug cooling. Dirty or damaged threads in the head or on the spark plug can keep it from seating even though the proper torque is applied. Once spark plugs are properly seated, tighten them to the torque shown in the Specifications Table. Low torque may result in poor contact of the seats due to a loose spark plug. Overtightening may cause the spark plug shell to be stretched and will result in poor contact

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS between the seats. In extreme cases, exhaust blow-by and damage beyond simple gap wear may occur. Cracked or broken insulators may be the result of improper installation, damage during spark plug re-gapping, or heat shock to the insulator material. Upper insulators can be broken when a poorly fitting tool is used during installation or removal, when the spark plug is hit from the outside, or is dropped on a hard surface. Cracks in the upper insulator may be inside the shell and not visible. Also, the breakage may not cause problems until oil or moisture penetrates the crack later.

6E–583

A/C Clutch Circuit Purpose The A/C compressor operation is controlled by the powertrain control module (PCM) for the following reasons: B It improvises idle quality during compressor clutch engagement. B It improvises wide open throttle (WOT) performance. B It provides A/C compressor protection from operation with incorrect refrigerant pressures. The A/C electrical system consists of the following components: B The A/C control head. B The A/C refrigerant pressure switches. B The A/C compressor clutch. B The A/C compressor clutch relay. B The PCM.

A/C Request Signal This signal tells the PCM when the A/C mode is selected at the A/C control head. The PCM uses this to adjust the idle speed before turning on the A/C clutch. The A/C compressor will be inoperative if this signal is not available to the PCM. Refer to A/C Clutch Circuit Diagnosis section for A/C wiring diagrams and diagnosis for A/C electrical system.

General Description (Evaporative (EVAP) Emission System) TS23994

A/C Clutch Diagnosis A/C Clutch Circuit Operation A 12-volt signal is supplied to the A/C request input of the PCM when the A/C is selected through the A/C control switch. The A/C compressor clutch relay is controlled through the PCM. This allows the PCM to modify the idle air control position prior to the A/C clutch engagement for better idle quality. If the engine operating conditions are within their specified calibrated acceptable ranges, the PCM will enable the A/C compressor relay. This is done by providing a ground path for the A/C relay coil within the PCM. When the A/C compressor relay is enabled, battery voltage is supplied to the compressor clutch coil. The PCM will enable the A/C compressor clutch whenever the engine is running and the A/C has been requested. The PCM will not enable the A/C compressor clutch if any of the following conditions are met: B The throttle is greater than 90%. B The engine speed is greater than 6315 RPM. B The ECT is greater than 119°C (246°F). B The IAT is less than 5°C (41°F). B The throttle is more than 80% open.

EVAP Emission Control System Purpose The basic evaporative emission (EVAP) control system used on all vehicles is the charcoal canister storage method. Gasoline vapors from the fuel tank flow into the canister through the inlet labeled “TANK.” These vapors are absorbed into the activated carbon (charcoal) storage device (canister) in order to hold the vapors when the vehicle is not operating. The canister is purged by PCM control when the engine coolant temperature is over 60°C (140°F), the IAT reading is over 10°C (50°F), and the engine has been running. Air is drawn into the canister through the air inlet grid. The air mixes with the vapor and the mixture is drawn into the intake manifold.

EVAP Emission Control System Operation The EVAP canister purge is controlled by a solenoid valve that allows the manifold vacuum to purge the canister. The powertrain control module (PCM) supplies a ground to energize the solenoid valve (purge on). The EVAP purge solenoid control is pulse-width modulated (PWM) (turned on and off several times a second). The duty cycle (pulse width) is determined by engine operating conditions including load, throttle positron, coolant temperature and ambient temperature. The duty cycle is calculated by the PCM. The output is commanded when the appropriate conditions have been met. These conditions are: B The engine is fully warmed up. B The engine has been running for a specified time. B The IAT reading is above 10°C (50°F).

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

A continuous purge condition with no purge commanded by the PCM will set a DTC P1441. Poor idle, stalling and poor driveability can be caused by: B A malfunctioning purge solenoid. B A damaged canister. B Hoses that are split, cracked, or not connected properly.

Enhanced Evaporative Emission Control System The basic purpose of the Enhanced Evaporative Emissions control system is the same as other EVAP systems. A charcoal-filled canister captures and stores gasoline fumes. When the PCM determines that the time is right, it opens a purge valve which allows engine vacuum to draw the fumes into the intake manifold. The difference between this and other systems is that the PCM monitors the vacuum and/or pressure in the system to determine if there is any leakage. If the PCM determines that the EVAP system is leaking or not functioning properly, it sets a Diagnostic Trouble Code (DTC) in the PCM memory. The enhanced EVAP system is required to detect evaporative fuel system leaks as small as 0.020 in. (1.0 mm) between the fuel filler cap and purge solenoid. The system can test the evaporative system integrity by applying a vacuum signal (ported or manifold) to the fuel tank to create a small vacuum. The PCM then monitors the ability of the system to maintain the vacuum. If the vacuum remains for a specified period of time, there are no evaporative leaks and a PASS report is sent to the diagnostic executive. If there is a leak, the system either will not achieve a vacuum, or a vacuum cannot be maintained. Usually, a failure can only be detected after a cold start with a trip of sufficient length and driving conditions to run the needed tests. The enhanced EVAP system diagnostic will conduct up to eight specific sub-tests to detect fault conditions. If the diagnostic fails a sub-test, the PCM will store a Diagnostic Trouble Code (DTC) to indicate the type of detected.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–585

140R200004

Legend (1) Fuel Filler Cap (2) Fuel Tank (3) Rollover Valve (4) Fuel Pump and Sender Assembly (5) Fuel Filter (6) Fuel Rail Right (7) Right Bank (8) Fuel Rail Left (9) Left Bank

(10) (11) (12) (13) (14) (15) (16) (17) (18)

Fuel Pressure Control Valve Common Chamber Duty Solenoid Valve (EVAP Purge Solenoid) Throttle Valve Canister (EVAP Canister) Vent Hose Vent Solenoid Valve Separator Shut off Valve (With Over Pressure Relief Valve) and Vapor Pressure Sensor

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

Electrical Components The electrical components that make up the enhanced EVAP system are: B Fuel Tank (Vapor) Pressure Sensor. The fuel tank pressure sensor is a three-wire strain gauge sensor similar to a common MAP sensor. However, the fuel tank pressure sensor has very different electrical characteristics due to its pressure differential design. The sensor measures the difference between the air pressure (or vacuum) in the fuel tank and the outside air pressure. The sensor mounts at the top of the fuel pump assembly. A three-wire electrical harness connects it to the PCM. The PCM supplies a five-volt reference voltage and a ground to the sensor. The sensor will return a voltage between 0.1 and 4.9 volts. When the air pressure in the fuel tank is equal to the outside air pressure, such as when the fuel cap is removed, the output voltage of the sensor will be 1.3 to 1.7 volts. When the air pressure in the fuel tank is 4.5 in. H2O (1.25 kPa), the sensor output voltage will be 0.5 ± 0.2 V. When there is neither vacuum nor pressure in the fuel tank, the sensor voltage will be 1.5 V. At –14 in. H2O (–3.75 kPa), the sensor voltage will be 4.5 ± 0.2 V. B EVAP Canister Purge Solenoid. Normally closed, the purge solenoid opens upon the PCM’s signal to allow engine vacuum to purge gasoline fumes from the canister. Mounted on the water pipe to front of the engine assembly.

060R200081

B Fuel Level Sensor. The fuel level sensor is an important input to the PCM for the enhanced EVAP system diagnostic. The PCM needs fuel level information to know the volume of fuel in the tank. The fuel level affects the rate of change of air pressure in the EVAP system. Several of the enhanced EVAP system diagnostic sub-tests are dependent upon correct fuel level information. The diagnostic will not run when the tank is less than 15% or more than 85% full. Be sure to diagnose any Fuel Level Sensor DTCs first, as they can cause other DTCs to set.

060R200080

B EVAP Canister Vent Solenoid. Located next to the canister, the vent solenoid opens to allow air into the EVAP system. Fresh air is necessary to completely remove gasoline fumes from the canister during purge. The EVAP vent solenoid closes to seal off the evaporative emissions system for leak testing.

014RW114

B Manifold Absolute Pressure (MAP) Sensor. The PCM compares the signals from the fuel tank pressure sensor and the MAP sensor to ensure that a relative vacuum is maintained the EVAP system.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

055RW004

Non-Electrical Components B Purge/Vacuum Hoses. Made of rubber compounds, these hoses route the gasoline fumes from their sources to the canister and from the canister to the intake air flow. B EVAP Canister. Mounted on a bracket ahead of the fuel tank, the canister stores fuel vapors until the PCM determines that engine conditions are right for them to be removed and burned. B Fuel Tank. The tank has a built-in air space designed for the collection of gasoline fumes.

060R200081

B Vacuum Source. The vacuum source is split between two ports, one on either side of the throttle body. B Fuel Cap. The fuel cap is designed to be an integral part of the EVAP system.

6E–587

System Fault Detection The EVAP leak detection strategy is based on applying vacuum to the EVAP system and monitoring vacuum decay. The PCM monitors vacuum level via the fuel tank pressure sensor. At an appropriate time, the EVAP purge solenoid and the EVAP vent solenoid are turned “ON,” allowing the engine vacuum to draw a small vacuum on the entire evaporative emission system. After the desired vacuum level has been achieved, the EVAP purge solenoid is turned “OFF,” sealing the system. A leak is detected by monitoring for a decrease in vacuum level over a given time period, all other variables remaining constant. A small leak in the system will cause DTC P0442 to be set. If the desired vacuum level cannot be achieved in the test described above, a large leak or a faulty EVAP purge solenoid is indicated. Leaks can be caused by the following conditions: B Disconnected or faulty fuel tank pressure sensor B Missing or faulty fuel cap B Disconnected, damaged, pinched, or blocked EVAP purge line B Disconnected or damaged EVAP vent hose B Disconnected, damaged, pinched, or blocked fuel tank vapor line B Disconnected or faulty EVAP purge solenoid B Disconnected or faulty EVAP vent solenoid B Open ignition feed circuit to the EVAP vent or purge solenoid B Damaged EVAP canister B Leaking fuel sender assembly O-ring B Leaking fuel tank or fuel filler neck A restricted or blocked EVAP vent path is detected by drawing vacuum into the EVAP system, turning “OFF” the EVAP vent solenoid and the EVAP purge solenoid (EVAP vent solenoid “OPEN,” EVAP purge Pulse Width Modulate (PWM) “0%”) and monitoring the fuel tank vacuum sensor input. With the EVAP vent solenoid open, any vacuum in the system should decrease quickly unless the vent path is blocked. A blockage like this will set DTC P0446 and can be caused by the following conditions: B Faulty EVAP vent solenoid (stuck closed) B Plugged, kinked or pinched vent hose B Shorted EVAP vent solenoid driver circuit B Plugged EVAP canister The PCM supplies a ground to energize the purge solenoid (purge “ON”). The EVAP purge control is PWM, or turned “ON” and “OFF,” several times a second. The duty cycle (pulse width) is determined by engine operating conditions including load, throttle position, coolant temperature and ambient temperature. The duty cycle is calculated by the PCM and the output is commanded when the appropriate conditions have been met.

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6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

The system checks for conditions that cause the EVAP system to purge continuously by commanding the EVAP vent solenoid “ON” and the EVAP purge solenoid “OFF” (EVAP vent solenoid “CLOSED,” EVAP purge PWM “0%”). If fuel tank vacuum level increases during the test, a continuous purge flow condition is indicated, which will set a DTC P1441. This can be cause by the following conditions: B EVAP purge solenoid leaking B EVAP purge and engine vacuum lines switched at the EVAP purge solenoid B EVAP purge solenoid driver circuit grounded Fuel vapor recovery system

057RW002

Linear EGR Valve The main element of the system is the linear EGR valve. The EGR valve feeds small amounts of exhaust gas back into the combustion chamber. The fuel/air mixture will be diluted and combustion temperatures reduced.

Linear EGR Control

060R100095

Separator attaches after hose evaporative fuel. It protects EVAP Canister from liquid fuel. It guarantees EVAP Canister performance. When vibration bounces fuel level, liquid fuel will accrete to EVAP Canister. It separates liquid fuel.

General Description (Exhaust Gas Recirculation (EGR) System) EGR Purpose The exhaust gas recirculation (EGR) system is use to reduce emission levels of oxides of nitrogen (NOx). NOx emission levels are caused by a high combustion temperature. The EGR system lowers the NOx emission levels by decreasing the combustion temperature.

The PCM monitors the EGR actual positron and adjusts the pintle position accordingly. The uses information from the following sensors to control the pintle position: B Engine coolant temperature (ECT) sensor. B Throttle position (TP) sensor. B Mass air flow (MAF) sensor.

Linear EGR Valve Operation and Results of Incorrect Operation The linear EGR valve is designed to accurately supply EGR to the engine independent of intake manifold vacuum. The valve controls EGR flow from the exhaust to the intake manifold through an orifice with a PCM controlled pintle. During operation, the PCM controls pintle position by monitoring the pintle position feedback signal. The feedback signal can be monitored with a Tech 2 as “Actual EGR Pos.” “Actual EGR Pos.” should always be near the commanded EGR position (”Desired EGR Pos.”). If a problem with the EGR system will not allow the PCM to control the pintle position properly, DTC P1406 will set. The PCM also tests for EGR flow. If incorrect flow is detected, DTC P0401 will set. If DTCs P0401 and/or P1406 are set, refer to the DTC charts. The linear EGR valve is usually activated under the following conditions: B Warm engine operation. B Above-idle speed. Too much EGR flow at idle, cruise or cold operation may cause any of the following conditions to occur: B Engine stalls after a cold start. B Engine stalls at idle after deceleration.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS B Vehicle surges during cruise. B Rough idle. B DTC P0300 (misfire detected). Too little or no EGR flow may allow combustion temperatures to get too high. This could cause: B Spark knock (detonation). B Engine overheating. B Emission test failure. B DTC P0401 (EGR flow test). B Poor fuel economy.

6E–589

addition, the PCV valve can seal the common chamber off in case of sudden high pressure in the crankcase.

028RV002

While the engine is running, exhaust fuses and small amounts of the fuel/air mixture escape past the piston rings and enter the crankcase. These gases are mixed with clean air entering through a tube from the air intake duct.

0017

EGR Pintle Position Sensor The PCM monitors the EGR valve pintle position input to endure that the valve responds properly to commands from the PCM and to detect a fault if the pintle position sensor and control circuits are open or shorted. If the PCM detects a pintle position signal voltage outside the normal range of the pintle position sensor, or a signal voltage that is not within a tolerance considered acceptable for proper EGR system operation, the PCM will set DTC P1406.

General Description (Positive Crankcase Ventilation (PCV) System) Crankcase Ventilation System Purpose The crankcase ventilation system is use to consume crankcase vapors in the combustion process instead of venting them to the atmosphere. Fresh air from the throttle body is supplied to the crankcase and mixed with blow-by gases. This mixture is then passed through the positive crankcase ventilation (PCV) valve into the common chamber.

Crankcase Ventilation System Operation The primary control is through the positive crankcase ventilation (PCV) valve. The PCV valve meters the flow at a rate that depends on the intake vacuum. The PCV valve restricts the flow when the inlet vacuum is highest. In

060R200063

During normal, part-throttle operation, the system is designed to allow crankcase gases to flow through the PCV valve into the throttle body to be consumed by normal combustion.

6E–590

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

A plugged valve or PCV hose may cause the following conditions: B Rough idle. B Stalling of slow idle speed. B Oil leaks. B Sludge in the engine. A leaking PCV hose would cause: B Rough idle. B Stalling. B High idle speed.

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

6E–591

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

ILLUSTRATION

TOOL NO. TOOL NAME

J 39200 High Impedance Multimeter (Digital Voltmeter – DVM)

J 37027-A IAC Motor Analyzer

(1) PCMCIA Card (2) RS232 Loop Back Connector (3) SAE 16/19 Adapter (4) DLC Cable (5) TECH–2

J 23738-A Vacuum Pump with Gauge

J 34142-B Unpowered Test Light

BT-8515/8515V Exhaust Back Pressure Tester

Connector Test Adapter Kit J 35616-A/BT-8637

J 39194-B Heated Oxygen Sensor Wrench

J 26792/BT-7220-1 Spark Tester

J 35689-A Terminal Remover

J 34730-E Port Fuel Injection Diagnostic Kit

J 28742-A Weather Pack II Terminal Remover

6E–592

6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS

ILLUSTRATION

TOOL NO. TOOL NAME

J 39021-90 Injector Switch Box

J 39021-65 Injector Test Light

J 41413! EVAP Pressure/Purge Diagnostic Station

J 41416@ Ultrasonic Leak Detector

1. J 41413 EVAP Pressure/Purge Diagnostic Station is a multipurpose tool which is used to perform several diagnostic procedures for enhanced emission testing. The station will accommodate a nitrogen gas filled cylinder which is used to pressurize the vehicle EVAP system for a leakdown test and leak location test when a vehicle is repaired for leakage in the enhanced evaporative emission control system. It also has two additional gauges (inches of mercury and inches of water) which are used to measure both source vacuum and EVAP canister purge vacuum to verify correct operation and vapor flow within the canister purge circuit. 2. J 41416 Ultrasonic Leak Detector is a microprocessor-based device used to detect leaks in the enhanced evaporative emission control system. The evaporative system is pressurized to 30 inches of water using the J 41413 EVAP Pressure/Purge Diagnostic System. Small leaks in the EVAP system will emit sound at a high frequency undetectable by a human ear but detectable with the J 41416. The technician traces along the evaporative system and can pinpoint leaks due to corroded lines, cracked hoses, or a damaged EVAP component. The detector includes a high quality set of headphones to block out surrounding shop noise and the LED sensitivity meter allows a visual reference for locating leaks in conjunction with the audio output heard through the headphones. Powered by (1) nine volt battery.

SECTION ENGINE EXHAUST (6VE1 3.5L)

6F–1

AXIOM

ENGINE ENGINE EXHAUST (6VE1 3.5L) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Three Way Catalytic Converter RH and Forked Exhaust Pipe . . . . . . . . . . . . . . . . . . . . Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three Way Catalytic Converter LH and Forked Exhaust Pipe . . . . . . . . . . . . . . . . . . . . Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6F–1 6F–2 6F–3 6F–3 6F–3 6F–3 6F–4 6F–4 6F–4 6F–4

Forked Exhaust Pipe . . . . . . . . . . . . . . . . . . . . Forked Exhaust Pipe and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Silencer . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Silencer and Associated Parts . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . Rear Exhaust pipe and Associated Parts . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

6F–5 6F–5 6F–5 6F–5 6F–6 6F–6 6F–6 6F–6 6F–7 6F–7 6F–7 6F–7 6F–8

6F–2

ENGINE EXHAUST (6VE1 3.5L)

General Description

150RW023

When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating the floor pan and possible damage to the passenger compartment insulation and trim materials. Check complete exhaust system and nearby body areas and rear compartment lid for broken, damaged, missing or mispositioned parts, open seams, holes, loose connections or other deterioration which could permit exhaust fumes to seep into the rear compartment or passenger compartment. Dust or water in the rear compartment may be an indication of a problem in one of these areas. Any faulty areas should be corrected immediately.

Hangers Various types of hangers are used to support exhaust system(s). These include conventional rubber straps, rubber rings, and rubber blocks. The installation of exhaust system supports is very important, as improperly installed supports can cause annoying vibrations which can be difficult to diagnose.

Three Way Catalytic Converter The three way catalytic converter is an emission control device added to the exhaust system to reduce pollutants from the exhaust gas stream. CAUTION: The catalytic converter requires the use of unleaded fuel only. Periodic maintenance of the exhaust system is not required. If the vehicle is raised for other service, it is advisable to check the condition of the complete exhaust system. A dual bed monolith catalytic converter is used in combination with three way catalytic converter. Catalytic Converter Types: Three way (Reduction/Oxidation) catalyst The catalyst coating on the three way (reduction) converter contains platinum and rhodium which lowers the levels of nitrous oxide (NOx) as well as hydrocarbons (HC) and carbon monoxide (Co).

Gasket The gasket must be replaced whenever a new exhaust pipe, muffler or catalytic converter is installed.

ENGINE EXHAUST (6VE1 3.5L)

6F–3

Three Way Catalytic Converter RH and Forked Exhaust Pipe Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts

150RY00003

Legend (1) Front Exhaust Pipe Assembly Fixing Nuts (2) O2 Sensor Terminal Connector (3) Three Way Catalytic Converter RH (4) Mounting Rubber (5) Forked Exhaust Pipe Fixing Bolts

Removal 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Disconnect O2 sensor harness connectors (2) (6). 4. Remove the forked exhaust pipe fixing bolts and nuts (5) (8) (10) and the exhaust silencer fixing nuts (9), then remove the forked exhaust pipe (7) and the mass damper. 5. Remove the front exhaust pipe assembly fixing nuts (1) and the mounting rubber (4), then remove the three way catalytic converter (3).

(6) (7) (8) (9) (10)

O2 Sensor Terminal Connector Forked Exhaust Pipe Forked Exhaust Pipe Fixing Nuts Exhaust Silencer Fixing Nuts Forked Exhaust Pipe Fixing Bolts

Installation 1. Install the three way catalytic converter (3) and the mounting rubber (4), and tighten the fixing nuts (1) to the specified torque. Torque Nuts : 67 N·m (49 lb ft) 2. Install the forked exhaust pipe (7), and tighten the fixing bolts (5) & nuts (8) (9) to the specified torque. Torque Bolts&Nuts : 43 N·m (32 lb ft) Nuts : 43 N·m (32 lb ft) 3. Connect the O2 sensor connectors (2) (6).

6F–4

ENGINE EXHAUST (6VE1 3.5L)

Three Way Catalytic Converter LH and Forked Exhaust Pipe Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts

150RY00004

Legend (1) Forked Exhaust Pipe Fixing Bolts (2) Forked Exhaust Pipe (3) Forked Exhaust Pipe Fixing Nuts (4) Exhaust Silencer Fixing Nuts (5) Forked Exhaust Pipe Fixing Bolts

Removal 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Disconnect O2 sensor harness connectors (7) (9). 4. Remove the forked exhaust pipe fixing bolts and nuts (1) (3) (5) and the exhaust silencer fixing nuts (4), then remove the forked exhaust pipe (2). 5. Remove the front exhaust pipe assembly fixing nuts (10) and the mounting rubber (6), then remove the three way catalytic converter (8).

(6) (7) (8) (9) (10)

Mounting Rubber O2 Sensor Terminal Connector Three Way Catalytic Converter LH O2 Sensor Terminal Connector Front Exhaust Pipe Assembly Fixing Nuts

Installation 1. Install the three way catalytic converter (8) and the mounting rubber (6), and tighten the fixing nuts (10) to the specific torque. Torque Nuts: 67 N·m (49 lb ft) 2. Install the forked exhaust pipe (2) and tighten the fixing bolts (1) (5) and nuts (3) (4) to the specified torque. Torque Bolts&Nuts: 43 N·m (32 lb ft) Nuts: 43 N·m (32 lb ft) 3. Connect the O2 sensor connectors (7) (9).

ENGINE EXHAUST (6VE1 3.5L)

6F–5

Forked Exhaust Pipe Forked Exhaust Pipe and Associated Parts

150RY00005

Legend (1) Forked Exhaust Pipe Fixing Bolts (2) Forked Exhaust Pipe

Removal 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Remove the forked exhaust pipe fixing bolts & nuts (1) (3) (5) and the exhaust silencer fixing nuts (4), then remove the forked exhaust pipe (2).

(3) Forked Exhaust Pipe Fixing Nuts (4) Exhaust Silencer Fixing Nuts (5) Forked Exhaust Pipe Fixing Bolts

Installation 1. Install the forked exhaust pipe (2), and tighten the fixing bolts (1) (5) and the nuts (3) (4) to the specified torque. Torque Bolts&nuts : 43 N·m (32 lb ft) Nuts : 43 N·m (32 lb ft)

6F–6

ENGINE EXHAUST (6VE1 3.5L)

Exhaust Silencer Exhaust Silencer and Associated Parts

150RY00006

Legend (1) Forked Exhaust Pipe (2) Support Rubber Fixing Nuts

Removal 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Remove the support rubber fixing nuts (2), the exhaust silencer fixing nuts (4) and rear exhaust pipe fixing nuts (5), then remove the exhaust silencer (3).

(3) Exhaust Silencer (4) Exhaust Silencer Fixing Nuts (5) Rear Exhaust Pipe Fixing Nuts

Installation 1. Install the exhaust silencer (3) and tighten the fixing nuts (4) (5) to the specified torque. Torque Nuts: 43 N·m (32 lb ft) 2. Tighten the support rubber fixing nuts (2) to the specified torque. Torque Bolts: 15 N·m (11 lb ft)

ENGINE EXHAUST (6VE1 3.5L)

6F–7

Rear Exhaust pipe Rear Exhaust pipe and Associated Parts

Removal 1. Disconnect battery ground cable. 2. Lift up the vehicle and support with suitable safety stands. 3. Remove the rear exhaust fixing nuts (2) and the mounting rubbers (1) (3), then remove the rear exhaust pipe (4).

Installation 1. Install the rear exhaust pipe (4) and the mounting rubbers (1) (3), then tighten the fixing nuts (2) to the specified torque. Torque Nuts: 43 N·m (32 lb ft)

150RW028

Legend (1) Mounting Rubber (2) Rear Exhaust Pipe Fixing Nuts (3) Mounting Rubber (4) Rear Exhaust Pipe

6F–8

ENGINE EXHAUST (6VE1 3.5L)

Main Data and Specifications Torque Specifications

150RY00007

SECTION ENGINE LUBRICATION (6VE1 3.5L)

6G–1

AXIOM

ENGINE ENGINE LUBRICATION (6VE1 3.5L) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump and Associated Parts . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection and Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan and Crankcase . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6G–1 6G–2 6G–3 6G–3 6G–4 6G–4 6G–5 6G–7 6G–7 6G–7

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Oil Seal . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specification . . . . . . . . . . . . . .

6G–9 6G–9 6G–9 6G–11 6G–11 6G–11 6G–12 6G–12 6G–12 6G–13

6G–2

ENGINE LUBRICATION (6VE1 3.5L)

General Description

C06RW003

Legend (1) Oil Strainer (2) Oil Pump (3) Relief Valve (4) Oil Pressure Switch (5) Oil Filter (6) Safety Valve (7) Oil Gallery (8) Crankshaft Bearing (9) Crankshaft

(10) (11) (12) (13) (14) (15) (16) (17) (18)

Connecting Rod Bearing Connecting Rod Piston Oil Gallery; Cylinder Head Camshaft Camshaft Journal Front Journal; Camshaft Drive Gear Rear Journal; Camshaft Drive Gear Oil Pan

ENGINE LUBRICATION (6VE1 3.5L)

6G–3

Oil Pump Oil Pump and Associated Parts

051RW005

Legend (1) Crankshaft Timing Pulley (2) Crankcase with Oil Pan (3) Oil Pipe (4) Oil Strainer (5) Oil Pump Assembly (6) Plug (7) Spring

(8) (9) (10) (11) (12) (13) (14)

Relief Valve Oil Pump Cover Driven Gear Drive Gear Oil Seal O-ring Oil Pump Body

6G–4

ENGINE LUBRICATION (6VE1 3.5L)

Disassembly

Body and Gears

1. Remove crankshaft timing pulley. 2. Remove crankcase with oil pan. 3. Remove oil pipe. 4. Remove oil strainer. 5. Remove oil pump assembly. 6. Remove plug. 7. Remove spring. 8. Remove relief valve. 9. Remove oil pump cover. 10. Remove driven gear. 11. Remove drive gear. 12. Remove oil seal. 13. Remove O-ring.

The pump assembly must be replaced if one or more of the conditions below is discovered during inspection. B Badly worn or damaged driven gear (10). B Badly worn drive gear (11) driving face. B Badly scratched or scored body sliding face (14) or driven gear (10). B Badly worn or damaged gear teeth. Measure the clearance between the body and the driven gear with a feeler gauge. Standard : 0.10 mm–0.18 mm (0.0039 in.–0.0070 in) Limit : 0.20mm (0.0079 in)

Inspection and Repair CAUTION: Make necessary correction or parts replacement if wear, damage or any other abnormal conditions are found during inspection.

Relief Valve B Check to see that the relief valve slides freely. B The oil pump must be replaced if the relief valve does not slide freely. B Replace the spring and/or the oil pump assembly (5) if the spring is damaged or badly worn.

051RS004

B Measure the clearance between the drive gear and driven gear with a feeler gauge. Standard : 0.11 mm–0.24 mm (0.0043 in–0.0094 in) Limit : 0.35mm (0.0138 in)

051RS002

051RS003

ENGINE LUBRICATION (6VE1 3.5L) B Measure the side clearance with a precision straight edge and a feeler gauge. Clearance Standard : 0.03 mm–0.09 mm (0.0011 in–0.0035 in)

6G–5

4. Install relief valve (8) and apply engine oil to the relief valve and spring (7). 5. Install spring (7). 6. Install the plug (6). Torque : 8 N·m (69 lb in)

Limit : 0.15mm (0.0059 in)

051RS007 051RS005

Oil Strainer Check the oil strainer for cracking and scoring. If cracking and scoring are found, the oil strainer must be replaced.

7. Install oil pump assembly (5). B Carefully remove any oil from the cylinder body and the pump. Apply sealant (TB–1207B or equivalent) to the pump fitting face as shown in illustration. Take care that sealant is not applied to oil port surfaces. The oil pump assembly must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. CAUTION: Do not apply an excessive amount of sealant to the contact surface. Applying too much sealant will overflow the contact surfaces. This could cause serious damage to the engine. B Attach oil pump assembly to cylinder body. B Tighten the oil pump fixing bolts. Torque : 25 N·m (18 lb·ft)

051RS006

Reassembly 1. Install drive gear (11). 2. Install driven gear (10). 3. Install oil pump cover (9) and first, loosely tighten all of the attaching screws. Next, tighten the attaching screws to the specified torque. Torque : 10 N·m (87 lb in) After installation, check that the gear rotates smoothly.

051RW002

6G–6

ENGINE LUBRICATION (6VE1 3.5L) 9. Install oil strainer (4) with O-ring (13). Torque: 25 N·m (18 lb ft) 10. Install oil pipe (3) with O-ring (13). Torque: 25 N·m (18 lb ft) 11. Install crankcase with oil pan (2). B Remove oil on crankcase mounting surface and dry the surface. B Apply a proper 4.5 mm (0.7 in) wide bead of sealant (TB1207C or equivalent) to the crankcase mounting surface. The bead must be continuous. B The crankcase must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. B Tighten fixing bolts to the specified torque. Torque : 10 N·m (87 lb in) 051RW001

Legend (1) Around Bolt Holes (2) Around Dowel Pin 8. Install the new oil seal (12). Apply engine oil to the oil seal lip before installation then use J–39202 oil seal Installer, install oil seal.

013RW010

12. Install crankshaft timing pulley.

015RS001

ENGINE LUBRICATION (6VE1 3.5L)

6G–7

Oil Pan and Crankcase Removal 1. Disconnect battery ground cable. 2. Lift vehicle by supporting the frame. 3. Remove under cover. 4. Drain engine oil. 5. Remove front wheels. 6. Remove oil level dipstick from level gauge tube. 7. Remove radiator under fan shroud. 8. Remove shift on the fly from axle housing. 9. Remove suspension cross member fixing bolts, 2 pcs each per side and remove suspension cross member. 10. Remove axle housing assembly four fixing bolts from housing isolator side and mounting bolts from wheel side. At this time support the axle with a garage jack and remove axle housing assembly. (for 4×4) 11. Remove the steering unit assembly. 12. Remove starter fixing bolts. 13. Remove oil pan fixing bolts. 14. Remove oil pan, using J-37228 sealer cutter, remove oil pan.

013RS003

Installation 1. Install crankcase. A. Remove residual sealant, lubricant and moisture from mounting surface, then dry thoroughly. B. Properly apply a 4.5 mm (0.7 in) wide bead of sealant (TB-1207C or equivalent) to mounting surface of crankcase. Sealant bead must be continuous. B The crankcase must be installed within 5 minutes after sealant application to prevent premature hardening of sealant.

013RS003

15. Remove crankcase fixing bolts. 16. Remove crankcase, using J-37228 sealer cutter, remove crankcase. NOTE: Do not deform or damage the flange of oil pan and crankcase. Replace the oil pan and/or crankcase if deformed or damaged. 013RW010

6G–8

ENGINE LUBRICATION (6VE1 3.5L)

C. Install crankcase, tighten crankcase fixing bolts to the specified torque. Torque : 10 N·m (87 lb in)

4. Install axle housing assembly and tighten fixing bolts to the specified torque. (for 4×4) Axle case bolts Torque : 82 N·m (61 lb ft) Mounting bolts Torque : 152 N·m (112 lb ft)

013RW004

2. Install oil pan A. Remove residual sealant, lubricant and moisture from mounting surface, then dry thoroughly. B. Properly apply a 4.5 mm (0.7 in) wide bead of sealant (TB-1207C or equivalent) to mounting surface of oil pan. Sealant beat must be continuous. B The crankcase must be installed within 5 minutes after sealant application to prevent premature hardening of sealant.

013RW003

C. Install oil pan, tighten oil pan fixing bolts to the specified torque. Torque : 10 N·m (87 lb in) 3. Install starter and tighten fixing bolts. Torque: 40 N·m (30 lb ft)

013RW005

5. Install the shift on the fly. 6. Install relay lever assembly and tighten fixing bolts. Torque: 44 N·m (33 lb ft) 7. Install suspension cross member and tighten fixing bolts to the specified torque. Torque : 78 N·m (58 lb ft)

013RW007

8. Install radiator under fan shroud. 9. Install under cover. 10. Install engine oil level dipstick. 11. Fill engine oil until full level on engine oil gauge dipstick.

ENGINE LUBRICATION (6VE1 3.5L)

6G–9

Oil Pump B Use J-39202 installer when installing new oil seal.

Removal 1. Disconnect battery ground cable. 2. Drain engine oil. 3. Remove crankcase assembly. B Refer to removal procedure for Oil Pan and Crankcase in this manual. 4. Remove crankshaft pulley. B Refer to removal procedure for Crankshaft Pulley in this manual. 5. Remove timing belt. B Refer to removal procedure for Timing Belt in this manual. 6. Remove timing pulley from crankshaft. 7. Remove four fixing bolts from oil filter assembly. 8. Remove oil strainer fixing bolts, remove oil strainer assembly with O-ring. 9. Remove three bolts from oil pipe and O-ring. 10. Remove eight oil pump fixing bolts, then oil pump assembly. 11. Remove sealant from mounting surface of oil pump assembly, cylinder block and take care not to damage mounting surfaces of oil pump and cylinder block.

B Apply engine oil to oil seal lip. B Install oil pump assembly to the cylinder block. NOTE: Do not damage oil seal during installation of oil pump assembly.

015RS001

Installation

B Tighten fixing bolts to the specified torque.

1. Install oil pump assembly B Apply sealant (TB-1207B or equivalent) to the oil pump mounting surfaces as shown in the illustration.

Torque : 25 N·m (18 lb ft)

B The oil pump assembly must be installed within 5 minutes after sealant application to prevent premature hardening of sealant. NOTE: Do not apply sealant to the oil ports.

051RW001

2. Install oil pipe with O-ring, tighten fixing bolt to the specified torque. Torque : 10 N·m (87 lb in) 3. Install oil strainer with O-ring, tighten fixing bolt to the specified torque. Torque : 25 N·m (18 lb ft) 051RW002

6G–10 ENGINE LUBRICATION (6VE1 3.5L) 4. Install oil filter assembly and tighten bolts to the specified torque. Torque : 25 N·m (18 lb ft)

050RW001

Legend (1) Oil Pump (2) Oil Filter (3) Oil Gallery (4) From Oil Filter (5) To Oil Filter 5. Install timing pulley on crankshaft. Install timing belt. B Refer to installation procedure for Timing Belt in this manual. 6. Install crankshaft pulley. B Refer to install procedure for Crankshaft Pulley in this manual. 7. Install crankcase assembly. B Refer to installation procedure for Oil Pan and Crankcase in this manual. 8. Refill engine oil until full level on engine oil dipstick.

ENGINE LUBRICATION (6VE1 3.5L)

6G–11

Oil Pump Oil Seal Removal 1. Disconnect battery ground cable. 2. Drain engine oil. 3. Remove crankshaft pulley. B Refer to removal procedure for Crankshaft Pulley in this manual. 4. Remove timing belt. B Refer to removal procedure for Timing Belt in this manual. 5. Remove timing pulley from crankshaft. 6. Remove oil pump oil seal using a sealer puller.

Installation 1. Install oil pump oil seal, apply engine oil to oil seal lip, then install oil seal using J-39202 installer.

NOTE: Take care not to damage sealing surfaces of oil pump and crankshaft when removing oil seal.

015RS001

2. Install timing pulley to crankshaft. 3. Install timing belt. B Refer to installation procedure for Timing Belt in this manual. 4. Install crankshaft pulley. B Refer to installation procedure for CRANKSHAFT PULLEY in this manual. 5. Refill engine oil until full level.

6G–12 ENGINE LUBRICATION (6VE1 3.5L)

Oil Filter Removal 1. Disconnect battery ground cable. 2. Drain engine oil. 3. Remove oil filter using J-36390 filter wrench.

Installation 1. Apply a light coat of engine oil to the oil filter gasket. 2. Hand tighten the filter until the gasket contacts the sealing face. 3. Using J–36390 filter wrench, tighten the filter an additional 7/8 turn or by torque 22 N·m (16 lb ft).

050RW001

Legend (1) Oil Pump (2) Oil Filter (3) Oil Gallery (4) From Filter (5) To Filter 4. Fill the oil to the proper lever by following the oil level check procedures. 5. Reconnect battery ground cable. 6. Run the engine and inspect for leaks.

ENGINE LUBRICATION (6VE1 3.5L)

6G–13

Main Data and Specification General Specification Item Oil capacity

Specifications 6VE1 5.3 liters

Torque Specifications Crankcase, Oil pan, Timing belt tensioner, Timing pulley, Timing belt cover, Oil pump, Oil gallery, Oil strainer

E06R100004

SECTION ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L)

6H–1

AXIOM

ENGINE ENGINE SPEED CONTROL SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . Accelerator Pedal and Associated Parts . .

6H–1 6H–2 6H–2

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6H–2 6H–2

6H–2

ENGINE SPEED CONTROL SYSTEM (6VE1 3.5L)

Accelerator Pedal Accelerator Pedal and Associated Parts

101RY00006

Legend (1) Accelerator Position Sensor (2) Accelerator Pedal Assembly

Removal 1. Disconnect battery ground cable. 2. Disconnect Accelerator position (AP) sensor (1) connector from Accelerator pedal assembly. 3. Remove Accelerator pedal assembly (2).

Installation 1. Install Accelerator pedal assembly (2). 2. Connect AP sensor (1) harness connector. 3. Connect battery ground cable.

SECTION INDUCTION (6VE1 3.5L)

6J–1

AXIOM

ENGINE INDUCTION (6VE1 3.5L) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6J–1 6J–2 6J–2

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6J–2 6J–2

6J–2

INDUCTION (6VE1 3.5L)

Air Cleaner Element Removal

Installation

1. Remove positive ventilation hose connector(1). 2. Remove intake air temperature sensor(2). 3. Remove air flow sensor(3). 4. Remove air cleaner duct assembly(4). 5. Remove air cleaner element(5).

1. Install air cleaner element(5). 2. Attach the mass air cleaner duct cover to the body completely, then clamp it with the clip(4). 3. Install air flow sensor(3). 4. Install air temprature sensor(2). 5. Install positive crankcase ventilation hose connector(1).

130R200001

Inspection

130R200001

Check the air cleaner filter for damage or dust clogging. Replace if it is damaged, or clean if it is clogged.

Cleaning Method Tap the air cleaner filter gently so as not to damage the paper filter, or clean the element by blowing with compressed air of about 490 kPa (71 psi) from the clean side if it is extremely dirty.

130RW002

SECTION AUTOMATIC TRANSMISSION (4L30–E)

7A–1

AXIOM

TRANSMISSION CONTENTS Automatic Transmission (4L30–E) . . . . . . . . . Transmission Control System (4L30–E) . . . .

7A 7A1

AUTOMATIC TRANSMISSION (4L30–E) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . Range Reference Chart . . . . . . . . . . . . . . . . . . Normal Operation Of 2002 4L30–E Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driver Information . . . . . . . . . . . . . . . . . . . . . . . General Diagnosis Procedure . . . . . . . . . . . . . Preliminary Inspection Chart . . . . . . . . . . . . . . Checking Transmission Fluid Level and Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart . . . . . . . . . . . . . . . . . . . . Mechanical / Hydraulic Diagnosis Symptoms Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Line Pressure Test . . . . . . . . . . . . . . . . . . . . . . Shift Speed Chart . . . . . . . . . . . . . . . . . . . . . . . Lockup Speed Chart . . . . . . . . . . . . . . . . . . . . . Changing Transmission Fluid . . . . . . . . . . . . . Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Select Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shift Lock Cable . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Assembly . . . . . . . . . . . . . . . . . . Transmission and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid (Main Case Valve Body) . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7A–2 7A–3 7A–4 7A–5 7A–5 7A–5 7A–8 7A–9 7A–10 7A–11 7A–12 7A–13 7A–23 7A–23 7A–24 7A–26 7A–27 7A–27 7A–27 7A–27 7A–29 7A–29 7A–29 7A–32 7A–34 7A–34 7A–34 7A–35 7A–35 7A–36 7A–37 7A–37 7A–38 7A–43 7A–47 7A–47

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solenoid (Adapter Case Valve Body) . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Body Assembly (Main Case) . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Body Assembly (Adapter Case) . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Powertrain Control Module (PCM) . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Sensor (Extension Assembly) . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission Oil Temperature Sensor (Main Case) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Oil Seal (Converter Housing) . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Oil Seal (Extension Assembly) . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission (4L30–E) . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Converter Housing And Oil Pump Assembly Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .

7A–47 7A–48 7A–48 7A–48 7A–49 7A–49 7A–49 7A–50 7A–50 7A–50 7A–50 7A–50 7A–50 7A–51 7A–51 7A–51 7A–52 7A–52 7A–52 7A–53 7A–53 7A–53 7A–53 7A–53 7A–53 7A–54 7A–54 7A–58 7A–68 7A–68 7A–68 7A–68 7A–68 7A–69 7A–69 7A–69 7A–70 7A–70

7A–2

AUTOMATIC TRANSMISSION (4L30–E)

Main Case Valve Body . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Adapter Case Valve Body . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Third Clutch And Sprag Unit . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Third Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Sprag Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . .

7A–71 7A–71 7A–71 7A–72 7A–72 7A–73 7A–73 7A–73 7A–73 7A–74 7A–75 7A–75 7A–75 7A–75 7A–76 7A–77 7A–77 7A–77 7A–77 7A–77 7A–79 7A–79 7A–79 7A–79 7A–79

Second Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4 Accumulator Piston . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse Clutch Piston And Center Support . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Overrun Clutch And Turbine Shaft . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection And Repair . . . . . . . . . . . . . . . . . . Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data And Specification . . . . . . . . . . . . . . General Specifications . . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4L30–E Parts List . . . . . . . . . . . . . . . . . . . . . . .

7A–80 7A–80 7A–80 7A–81 7A–81 7A–82 7A–82 7A–82 7A–83 7A–83 7A–84 7A–84 7A–84 7A–85 7A–85 7A–86 7A–86 7A–87 7A–87 7A–87 7A–89 7A–89 7A–90 7A–93 7A–96

AUTOMATIC TRANSMISSION (4L30–E)

7A–3

Construction

A07R100002

Legend (1) Torque Converter Clutch (TCC) (2) Overdrive Free Wheel (One Way Clutch) (OFW) (3) Fourth Clutch (C4) (4) Overrun Clutch (OC) (5) Overdrive Unit

(6) (7) (8) (9)

Reverse Clutch (RC) Second Clutch (C2) Third Clutch (C3) Principle Sprag Assembly (One Way Clutch) (PFW) (10) Ravigneaux Planetary Gear Set (11) Brake Band (B)

7A–4

AUTOMATIC TRANSMISSION (4L30–E)

Range Reference Chart

C07RY00032

AUTOMATIC TRANSMISSION (4L30–E)

7A–5

Normal Operation Of 2002 4L30–E Transmission

Diagnosis

Torque Converter Clutch (Electronically Controlled Capacity Clutch : ECCC) Application Conditions:

The systematic troubleshooting information covered by this Section offers a practical and systematic approach to diagnosing 4L30–E transmission, using information that can be obtained from road tests, electrical diagnosis, oil pressure checks or noise evaluation. The key to correcting a complaint is to make use of all of the available symptoms and logically letting them direct you to the cause. When dealing with automatic transmission complaints, it is best to gather as many symptoms as possible before making the decision to remove the transmission from the vehicle. Frequently, the correction of the complaint does not require removal of the transmission from the vehicle.

The clutch apply is controlled by moving the converter clutch control valve by commanding Torque Converter Clutch (TCC) solenoid using the PWM signal. The TCC is normally applied in 2nd, 3rd and 4th gears only when all of the following conditions exist: — The engine coolant temperature is above 70°C (158°F) and ATF temperature is above 18°C (64.5°F). — The shift pattern requests TCC apply. Moreover, TCC is always applied in 2nd, 3rd and 4th gears when the transmission oil temperature is above 135°C (275°F). This mode should be canceled at 125°C (257°F).

ATF Warning Lamp The ATF warning lamp will be constantly on (not flashing) if the transmission oil temperature is above 145°C (293°F). The ATF warning lamp goes off again when the transmission oil temperature is below 125°C (257°F).

Reverse Lock Out With the selector lever in reverse position, the PCM will not close the PWM solenoid until the vehicle is below 11 km/h (6.8 mph), thus preventing reverse engagement above this speed.

Introduction

Driver Information To analyze the problem fill out a complete description of the owner’s complaint. Please draw a circle around the right information and complete the following form. (The next page is an example of a completed form). You can draw a circle around many numbers if you are not sure.

7A–6

AUTOMATIC TRANSMISSION (4L30–E)

F07RT036

Example of form completed.

AUTOMATIC TRANSMISSION (4L30–E)

7A–7

F07RT037

7A–8

AUTOMATIC TRANSMISSION (4L30–E)

General Diagnosis Procedure

F07RT038

AUTOMATIC TRANSMISSION (4L30–E)

7A–9

Preliminary Inspection Chart

F07R200003

7A–10

AUTOMATIC TRANSMISSION (4L30–E)

Checking Transmission Fluid Level and Condition Checking fluid level and condition (color and odor) at regular intervals will provide early diagnosis information about the transmission. This information may be used to correct a condition that, if not detected early, could result in major transmission repairs. IMPORTANT: When new, automatic transmission fluid is red in color. As the vehicle is driven, the transmission fluid will begin to look darker in color. The color may eventually appear light brown. A dark brown color with burnt odor may indicate excessive fluid deterioration and signal a need for fluid change.

NOTE: Check transmission fluid temperature with scan tool. Minimum fluid level → 57°C (135°F) Maximum fluid level → 32°C (90°F)

Fluid Level When adding or changing fluid, use only DEXRON –III. Refer to Maintenance and Lubrication in General Information section for maintenance information and servicing interval. CAUTION: DO NOT OVERFILL. Overfilling will cause foaming, loss of fluid, abnormal shifting and possible damage to the transmission. 1. Park the vehicle on level ground and apply the parking brake firmly. 2. Check fluid level with engine running at idle. NOTE: Be sure that transmission fluid temperature is below 30°C (86°F). 3. Move the selector lever through all gear ranges. 4. Move the selector lever to “Park”. 5. Let engine idle for 3 minutes and open the overfill screw (1). 6. Add released transmission fluid until it flows out over the overfill screw opening. 7. Let engine idle until a fluid temperature between 32°C (90°F) and 57°C (135°F) is reached, then close the overfill screw (1). Torque: 38 N•m (28 lb ft) NOTE: To prevent fluid leaks, the overfill screw and oil drain screws gasket must be replaced each time these screws are removed.

242R200001

CAUTION: Do not open overfill screw with engine stopped. CAUTION: DO NOT CHECK FLUID LEVEL UNDER THESE CONDITIONS: B Immediately after driving at sustained highway speeds. B In heavy city traffic during hot weather. B If vehicle is towing a trailer. If the vehicle has been operated under these conditions, shut the engine off and allow the vehicle to “cool” for thirty (30) minutes. After the cool down period, restart the vehicle and continue from step 2 above.

AUTOMATIC TRANSMISSION (4L30–E)

7A–11

Fluid Condition FLUID CONDITION NORMAL*

CONTAMINATED

COLOR

RED OR LIGHT BROWN

BROWN

NON–TRANSPARENT / PINK

BROWN

DRAIN REQUIRED?

YES

NONE

Very small amount of foreign material in bottom of pan

Contamination by coolant or other source

Large pieces of metal or other foreign material in bottom of pan

– – – – –

– Repair/replace radiator cooler – Transmission overhaul required – Check for: B Damaged plates and seals B Contaminated solenoids – Flush cooler – Add new fluid – Check level

– Transmission overhaul required – Flush cooler and cooler lines – Add new fluid – Check level

CONTAMINA– TION

CORRECT LEVEL AND CONDITION

1. LOW LEVEL: A. Add fluid to obtain proper level & check for external leaks. B. Correct cause of leak. 2. HIGH LEVEL: – Remove excess fluid

Remove both pans Change filter Flush cooler Add new fluid Check level

*Fluid should be changed according to maintenance schedule.

Test Driving Some 4L30–E automatic transmission complaints will require a test drive as a part of the diagnostic procedure. Some codes will not set unless the vehicle is moving. The purpose of the test drive is to duplicate the customer’s complaint condition and set a current Powertrain Control Module (PCM) trouble code. Perform this procedure before each 4L30–E automatic transmission repair, and again after repairs are made. IMPORTANT: B Duplicate the condition under which the customer’s complaint was observed. B Depending on the complaint, the line pressure gauge and the scan tool may be required during the test drive. B During the test drive, it is important to record all necessary data from the areas being monitored, for use in diagnosis. Also listen for and note any unusual noises. The following procedure should be used to test drive 4L30–E automatic transmission complaint vehicles: 1. Turn the ignition ON without starting the engine. Check that the “CHECK TRANS” lamp comes on for approximately 2 seconds and then goes out and remains out. B If the lamp is flashing, GO TO Check Trans Indicator in Transmission Control System (4L30–E) section.

B If no serial data is present, GO TO OBD System Check. Refer to Driveability and Emissions in Engine section. B If the lamp stays ON or stays OFF, GO TO “Check Trans” Check in Transmission Control System (4L30–E) section. 2. Drive the vehicle. During the test drive, be sure that the transmission achieves normal operating temperature (approx. 20 minutes). Allow the transmission to go through all of its gear ranges, checking shift timing and firmness. Duplicate the owner ’s complaint condition as closely as possible during the test drive. 3. If, during the test drive, the “CHECK TRANS” lamp comes on, use the scan tool to check for trouble codes. 4. If, during the test drive, a problem is felt, but the “CHECK TRANS” lamp does not come on and no trouble codes are present, drive the vehicle with the PCM disconnected (manually shifting the vehicle). B In Manual L, the vehicle operates in first gear. B In Manual 2, the vehicle operates in third gear. B In Manual 3 or “D”, the vehicle operates in fourth gear. If the problem still exists with the PCM disconnected, refer to Mechanical/Hydraulic Diagnosis in this section. 5. If no problem has been found at this point, check all underhood connections that supply power to the PCM and ignition fuses. Physically and visually inspect all the PCM harness connectors for loose or corroded terminals. Inspect the PCM ground points.

7A–12

AUTOMATIC TRANSMISSION (4L30–E)

Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart Perform Preliminary Inspection First!

F07RT013

When the “CHECK TRANS” indicator is flashing, it indicates that a problem related to the transmission, the Powertrain Control Module (PCM), or the vehicle harness has occurred. The system is now operating in a “BACKUP MODE” where the risk of further damaging the transmission has been reduced. The vehicle may be shifted manually. If the initial problem is intermittent or seldom, switching the engine OFF/ON might allow normal operation again until the problem reoccurs.

AUTOMATIC TRANSMISSION (4L30–E)

7A–13

Mechanical / Hydraulic Diagnosis Symptoms Index Perform Preliminary Inspection First! CHART

SYMPTOMS

NO ENGINE START IN NEUTRAL OR PARK

NO FORWARD GEARS IN ANY RANGE/NO REVERSE

NO ENGINE BRAKE IN ANY RANGE

POOR SHIFTING IN ALL GEARS (ALL HARSH OR ALL SOFT)

DELAYS IN DRIVE AND REVERSE

DELAYS IN REVERSE ONLY

DIAGNOSTIC TROUBLE CODE (DTC) P0730

HARSH 1–2 SHIFT

HARSH 3–4 SHIFT

3–2 DOWNSHIFT COMPLAINT

HARSH SHIFT WHEN SHIFTING INTO “D” OR ACCELERATING FROM STOP

COASTDOWN HARSH SHIFT OR CLUNK AT 3–2 DOWNSHIFT

INTERMITTENT 4TH TO 2ND GEAR DOWNSHIFT AT STEADY SPEED

ENGINE FLARE AT SHIFTING DURING TURNING ONLY (USUALLY WITH WARM ENGINE)

ENGINE FLARE DURING 1–2 OR 2–3 SHIFT

SHUDDER ONLY DURING TORQUE CONVERTER CLUTCH (TCC) APPLYING

POSSIBLE CAUSES OF TRANSMISSION NOISE

15a

POSSIBLE CAUSES OF LOW LINE PRESSURE

15b

POSSIBLE CAUSES OF HIGH LINE PRESSURE

POSSIBLE CAUSES OF TRANSMISSION FLUID LEAKS

NOTE: Numbers with parenthesis on the following charts refer to Parts List at end of this section.

Chart 1: No Engine Start In Neutral Or Park Step

Action

Yes

Does engine start when shift lever moved from drive to neutral mostly in hot condition?

Go to Step 2

Go to Step 3

Re–test vehicle

Go to Step 4

Go to Step 5

Re–test vehicle

Go to Step 5

Locate and repair open(s)

Replace mode switch (63)

Does engine start in park at any condition?

Does engine also not start in neutral when shift lever moved from park to neutral?

Check mode switch (63) setting. Readjust if necessary. Problems fixed?

Check start circuit of mode switch (63) open in neutral. Was open found?

7A–14

AUTOMATIC TRANSMISSION (4L30–E)

Chart 2: No Forward Gears In Any Range/No Reverse Step

Action

Check line pressure. Refer to Line Pressure Test in this section.

Yes

Go to Step 2

Use Chart 15a: Possible Causes of Low Line Pressure in this section

Repair or replace

—

Yes

Go to Step 2

Use Chart 15a: Possible Causes of Low Line Pressure in this section

Repair or replace

—

Was line pressure normal?

1. Check internal linkage: – Manual linkage (58) not moving manual valve (326). 2. Check for internal mechanical damage: – Turbine shaft (506) broken loose. – Overrun roller clutch (516) broken loose. Was the problem found?

Chart 3: No Engine Brake In Any Range Step

Action

Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal?

1. Check for overrun clutch leaks caused by: – Damaged piston lip (513) – Check ball defective (504) 2. Check for overrun lockout valve (705) stuck by foreign material. 3. Check for leaks at turbine shaft (506) caused by: – Teflon seal rings damaged (508) – Excessive wear of turbine shaft bearing surfaces. Was the problem found?

AUTOMATIC TRANSMISSION (4L30–E)

7A–15

Chart 4: Poor Shifting In All Gears (All Harsh Or All Soft) Step

Action

Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal?

Go to Step 2

Go to Step 3

Repair or replace

—

Go to Step 4

Use Chart 15a: Possible Causes of Low Line Pressure in this section

Diagnose those DTC(s) first

Use Chart 15b: Possible Causes of High Line Pressure in this section

1. Check for these conditions which could affect clutch apply time: – Defective band apply solenoid (323). – Defective servo or/and accumulator piston. – Excessive clutch piston travel. 2. Check of possible causes of internal leaks: – Cut or damaged sealing ring(s) – Damaged sealing gasket(s) – Check ball missing or out of location in 2nd and 3rd clutch pistons. 3. Check for causes of burned clutch plates or band. Was the problem found?

Yes

Was the line pressure high?

Does DTC P0705 set?

Chart 5a: Delays In Drive And Reverse NOTE: A short delay (less than 3 seconds) when first engaging drive or reverse after allowing vehicle to sit overnight is normal. Step

Action

Yes

Check line pressure. Refer to Line Pressure Test in this section.

More than 3 second delay in drive and reverse with engine off 1 hour or less. Teflon seals (508) on turbine shaft damaged. Repair

Use Chart 15a: Possible Causes of Low Line Pressure in this section.

Yes

Go to Step 2

Use Chart 15a: Possible Causes of Low Line Pressure in this section.

Repair

—

Was line pressure normal?

Chart 5b: Delays In Reverse Only Step

Action

Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal?

Main case valve body gasket (88) damaged. – Reverse check ball (85) in valve body (84) missing or out of location. – Check for restrictions at valve body transfer plate orifice. Was the problem found?

7A–16

AUTOMATIC TRANSMISSION (4L30–E)

Chart 6: Diagnostic Trouble Code (DTC) P0730 Step

Action

Check line pressure. Refer to Line Pressure Test in this section.

Yes

Go to Step 2

Use Chart 15b: Possible Causes of High Line Pressure in this section

Repair or replace

—

Shift solenoid A stuck. Replace shift solenoid A.

Go to Step 4

Repair or replace

—

Was line pressure normal?

1. 1st and 2nd gear missing or 3rd and 4th gear missing. Check appropriate shift valve. If OK replace solenoid. 2. No engine brake in any range (All ranges in Drive and Reverse are OK). Check for suspected conditions modifying delays to clutch apply: – Overrun clutch seal damaged. – Excessive overrun clutch piston travel. – Defective 3–4 accumulator piston. – Causes of internal leaks. – Causes of burned clutch plates. 3. 1st and 4th gear missing or 2nd and 3rd gear missing. Shift solenoid A stuck. Replace shift solenoid A. 4. DTC P0730 is set in D range 1st gear above 3500 rpm. Go to Step 3. 5. DTC P0730 is set in D range 3rd gear between 55-80 mph. NOTE: Perform this test within safe and legal limits. Check for suspected conditions modifying delays to clutch apply: – – – – –

4th clutch seal damaged. Excessive 4th clutch piston travel. Defective 3–4 accumulator piston. Causes of internal leaks. Causes of burned clutch plates.

Was the problem found? 3

Check 3rd gear in “D” in winter mode. Does vehicle move?

Check for suspected conditions modifying delays to clutch apply: – 2nd clutch seal damaged. – Excessive 2nd clutch piston travel. – Defective accumulator piston. – Causes of internal leaks. – Check ball missing or out of location in 2nd clutch. – Seals cut, damaged or missing. – Gaskets defective. – Causes of burned clutch plates. Was the problem found?

AUTOMATIC TRANSMISSION (4L30–E)

7A–17

Chart 7: Harsh 1–2 Shift Step

Action

Yes

Check line pressure. Refer to Line Pressure Test in this section.

Check for 1–2 accumulator valve (320) stuck by foreign material in main case valve body.

Use Chart 15b: Possible Causes of High Line Pressure in this section.

Yes

Go to Step 2

Use Chart 15b: Possible Causes of High Line Pressure in this section

Repair or replace

—

Yes

Go to Step 2

Use Chart 15a: Possible Causes of Low Line Pressure in this section

Diagnose P1850 first

Replace band apply solenoid (PWM) (323)

Was line pressure normal?

Chart 8: Harsh 3–4 Shift Step

Action

Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal?

1. Check for 3–4 accumulator valve (407) stuck in adapter case valve body (401). 2. Check for 3–4 accumulator piston (18) stuck in adapter case (20). Was the problem found?

Chart 9a: 3–2 Downshift Complaint Step

Action

Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal?

Does DTC P1850 set?

Chart 9b: Harsh Shift When Shifting Into “D” Or Accelerating From Stop Step

Action

Check line pressure. Refer to Line Pressure Test in this section.

Yes

Go to Step 2

Use Chart 15b: Possible Causes of High Line Pressure in this section

Diagnose P1850 first

Replace band apply solenoid (PWM) (323)

Was line pressure normal?

Does DTC P1850 set?

7A–18

AUTOMATIC TRANSMISSION (4L30–E)

Chart 9c: Coastdown Harsh Shift Or Clunk At 3–2 Downshift Step

Action

Check line pressure. Refer to Line Pressure Test in this section.

Yes

Go to Step 2

Use Chart 15b: Possible Causes of High Line Pressure in this section

Diagnose P1850 first

Replace band apply solenoid (PWM) (323)

Was line pressure normal?

Does DTC P1850 set?

Chart 10: Intermittent 4TH TO 2ND Gear Downshift At Steady Speed Step 1

Action Check for consistent speed sensor reading with scan tool. Was the reading correct?

Yes

Replace mode switch for intermittent contact.

Go to Step 2

—

Replace speed sensor.

1. Check for wiring harness damage or short to ground. If OK, go to (2). 2. Check transmission speed sensor connections. If OK, go to (3). 3. Replace transmission speed sensor. Was the replacement complete?

Chart 11: Engine Flare At Shifting During Turning Only (Usually With Warm Engine) Step 1

Action Check for oil leaks at transmission. Was the problem found?

Yes

Replace transmission oil filter and gasket

—

Yes

Go to Step 2

Use Chart 15a: Possible Causes of Low Line Pressure in this section

Repair or replace

—

Chart 12: Engine Flare During 1–2 Or 2–3 Shift Step

Action

Check line pressure. Refer to Line Pressure Test in this section. Was line pressure normal?

1. Check for a stuck 1–2 accumulator valve (320). 2. Check for servo piston (106) leaks. 3. Check for a stuck band apply solenoid (323). Was line pressure normal?

AUTOMATIC TRANSMISSION (4L30–E)

7A–19

Chart 13: Shudder Only During Torque Converter Clutch (TCC) Applying Step

Action

1. TCC shudder is one of the most commonly misdiagnosed conditions in an automatic transmission. The key to diagnosing TCC shudder is to note when it happens and under what conditions. Once the TCC has been fully applied, it is nearly impossible to make it shudder. TCC shudder (short burst of noise normally less than 1 second) will only occur during clutch applying. It is not a steady state condition. 2. Drive until whole drivetrain is at normal operating temperature. – On 4WD vehicles, the test must be performed with transfer case selector lever in “2H” position. – Shudder is a short burst of noise normally less than 1 second in duration, and can be induced by the following maneuver: 3. From coast condition at 50 mph in “D” range (Normal mode), depress the throttle to 1/4-1/3 throttle. If present, shudder will occur within 5 seconds together with TCC application.(The scan tool may be used to determine the exact time of TCC applying) Was the problem found?

Yes

Replace transmission fluid and filter (remove both pans) and flush cooler lines. Replace converter assembly and O-ring on turbine shaft

Perform mechanical inspection of other drivetrain components.

Chart 14: Possible Causes Of Transmission Noise CAUTION: Before checking transmission for what is believed to be transmission noise, ensure presence and positioning of insulating plugs, pads etc. Also make sure that noise does not come from other drivetrain components. Condition

Possible cause

Whine or Buzz

Knocking noise transmission transmission.

from

front

Knocking noise while driving, mostly on acceleration.

Knocking noise when vehicle is stationary stationary.

Correction

Oil level low

Fill with ATF, check for external leaks.

Plugged or restricted oil filter

Inspect oil filter. Replace oil filter or ATF as necessary.

Damaged oil filter gasket

Replace oil filter gasket.

Loose bolts (Converter to flex plate)

Tighten to specifications.

Cracked or broken flex plate

Replace flex plate.

Converter damaged

Replace converter.

Transmission mount loose or broken

Tighten mount bolts or replace transmission mount.

Cooler line mounts loose or broken

Tighten or replace cooler line mounts.

Cooler lines touching body or frame

Repair or replace as necessary.

Loose flex plate mounting bolts

Tighten to specifications.

Cracked or broken flex plate

Replace flex plate.

Damaged converter

Replace converter.

7A–20

AUTOMATIC TRANSMISSION (4L30–E)

Chart 15a: Possible Causes of Low Line Pressure Step 1

Action

Check for defective throttle position sensor. Was the problem found?

Check for plugged, loose, or damaged oil filter (79). Was the problem found?

Check for a stuck force motor plunger (404). (Adapter case valve body) Was the problem found?

Check for a stuck feed limit valve (412). (Adapter case valve body) Was the problem found?

Check for loose converter bolts (4 & 5). Was the problem found?

Check for a stuck pressure regulator valve (217). (Oil pump) Was the problem found?

Check for a stuck boost valve (213).(Oil pump) Was the problem found?

Go to Step 2

Replace throttle position sensor

Go to Step 3

Inspect oil filter, tighten bolts or replace oil filter (79)

Go to Step 4

Replace force motor plunger (404)

Go to Step 5

Replace feed limit valve (412)

Go to Step 6

Tighten converter bolts (4 & 5)

Go to Step 7

Replace pressure regulator valve (217)

Go to Step 8

Replace boost valve (213)

Go to Step 9

Replace oil pump

Go to Step 10

Replace oil pump

Go to Step 11

Install balls, or correct ball location Replace seals Replace gaskets

—

Check for defective oil pump (9, 201, 202 & 228). Was the problem found?

Fill with ATF

Check for blocked intermediate oil passages to pressure regulator valve. (Oil pump) Was the problem found?

Check oil level. Was the problem found?

Yes

Check for internal leaks. – Check balls missing or out of location in valve bodies – Seals cut or damaged – Gaskets defective, etc. Was the problem found?

AUTOMATIC TRANSMISSION (4L30–E)

7A–21

Chart 15b: Possible Causes Of High Line Pressure NOTE: If transmission is operating in backup mode, high line pressure will be present. Action

Step 1

Check for defective throttle position sensor. Was the problem found?

Check for a stuck force motor plunger (404). (Open circuit/intermittent) (Adapter case valve body) Was the problem found?

Check for a stuck feed limit valve (412). (Adapter case valve body) Was the problem found?

Check converter bolts (4 & 5). Was the problem found?

Check for a stuck pressure regulator valve (217). (Oil pump) Was the problem found?

Check for a stuck boost valve (213). (Oil pump) Was the problem found?

Check for internal leaks. – Check balls missing or out of location in valve bodies – Seals cut or missing – Gaskets defective, etc. Was the problem found?

Yes

Replace throttle position sensor.

Go to Step 2.

Replace force motor plunger (404)

Go to Step 3

Replace force motor plunger (412)

Go to Step 4

Tighten converter bolts (4 & 5)

Go to Step 5

Replace pressure regulator valve (217)

Go to Step 6

Replace boost valve (213)

Go to Step 7

Install balls, or correct ball location Replace seals Replace gaskets

—

7A–22

AUTOMATIC TRANSMISSION (4L30–E)

Chart 16: Possible Causes Of Transmission Fluid Leaks Before attempting to correct an oil leak, the actual source of the leak must be determined. In many cases, the source of the leak may be difficult to determine due to “wind flow” around the engine and transmission. The suspected area should be wiped clean before inspecting for the source of the leak.

Oil leaks around the engine and transmission are generally carried toward the rear of the vehicle by the air stream. In determining the source of an oil leak, the following two checks should be made: 1. With the engine running, check for external line pressure leaks. 2. With the engine off, check for oil leaks due to the raised oil level caused by drainback of converter oil into the transmission.

Possible Causes Of Fluid Leaks Due To Sealing Malfunction

240RX008

Legend (1) Electrical Connector (Main Case) Seal (2) Transmission Vent (Breather) (3) Speed Sensor O–Ring (4) Extension (Adapter) Lip Seal (5) Extension (Adapter) to Main Case Gasket (6) Overfill and Oil Drain Screws Gasket (7) Oil Pan Gasket (Main Case) (8) Selector Shaft Seal

(9) Oil Cooler Connectors (2) (10) Oil Pan Gasket (Adapter Case) (11) Converter housing attaching bolts not correctly torqued (12) Converter Housing Lip Seal (13) Line Pressure Tap Plug (14) Electrical Connector (Adapter Case) Seal (15) Adapter Case Seal Rings (2)

AUTOMATIC TRANSMISSION (4L30–E)

7A–23

Stall Test The stall test allows you to check the transmission for internal abrasion and the one way clutch for slippage. Torque converter performance can also be evaluated. The stall test results together with the road test results will identify transmission components requiring servicing or adjustment.

Stall Test Procedure: 1. Check the level of the engine coolant, the engine oil, and the automatic transmission fluid. Replenish if necessary. 2. Block the wheels and set the parking brake. 3. Connect a tachometer to the engine. 4. Start the engine and allow it to idle until the engine coolant temperature reaches 70 – 80°C (158 – 176°F). 5. Hold the brake pedal down as far as it will go. 6. Place the selector in the “D” range. 7. Gradually push the accelerator pedal to the floor. The throttle valve will be fully open. Note the engine speed at which the tachometer needle stabilizes. Stall Speed : 2,100 ±150 rpm NOTE: Do not continuously run this test longer than 5 seconds. 8. Release the accelerator pedal. 9. Place the selector in the “N” range. 10. Run the engine at 1,200 rpm for one minute. This will cool the transmission fluid. 11. Repeat Steps 7 – 10 for the “3”, “2”, “L” and “R” ranges.

Line Pressure Test The line pressure test checks oil pump and control valve pressure regulator valve function. It will also detect oil leakage.

Line Pressure Test Procedure: 1. Check the level of the engine coolant, the engine oil, and the automatic transmission fluid. Replenish if required. 2. Block the wheels and set the parking brake. 3. Remove the pressure detection plug at the left side of the transmission case. Set J–29770–A pressure gauge and adapter to the pressure detection plug hole.

241RS001

4. Start the engine and allow it to idle until the engine coolant temperature reaches 70 – 80°C (158 – 176°F). 5. Hold the brake pedal down as far as it will go. 6. Place the selector in the “D” range. 7. Note the pressure gauge reading with the engine idling. 8. Gradually push the accelerator pedal to the floor. The throttle valve will be fully open. Note the pressure gauge reading with the accelerator pedal fully depressed. NOTE: Do not continuously run this test longer than 5 seconds. 9. Release the accelerator pedal. 10. Place the selector in the “N” range. 11. Run the engine at 1,200 rpm for one minute. This will cool the transmission fluid. 12. Repeat Steps 7 – 11 for the “3”, “2”, “L”, and “R” ranges. 13. Install a pressure detection plug to the transmission case, applying recommended thread locking agent (LOCTITE 242) or its equivalent to thread of plug. Make sure that thread is cleaned before applying locking agents. 14. Tighten the pressure detection plug to the specified torque. Torque: 9 – 14N·m (7 – 10lb ft)

7A–24

AUTOMATIC TRANSMISSION (4L30–E) MODE

LEVER POSITION

ENGINE SPEED

NORMAL/POWER

D,3,2,L

LINE PRESSURE kPa

PSI

FORCE MOTOR CURRENT (mA)

IDLE

590 – 730

86 – 106

680 – 720

IDLE

300 – 390

44 – 57

1,020 – 1,060

NORMAL/POWER WINTER

REVERSE

IDLE

460 – 630

67 – 91

880 – 920

NORMAL/POWER

D, 3, 2, L

STALL SPEED

1,250 – 1,380

181 – 200

70 – 110

STALL SPEED

1,250 – 1,380

181 – 200

70 – 110

REVERSE

STALL SPEED

1,400 – 1,580

203 – 229

340 – 380

WINTER

WINTER NORMAL/POWER WINTER

Shift Speed Chart Transfer gear ratio:

High: 1.000

Rear axle ratio:

4.300

“Normal mode” Upshift Range

Throttle opening

1→2 2→3 (First Gear) (Second Gear) (Second Gear) (Third Gear) km/h (mph) km/h (mph)

3→4 (Third Gear) (Fourth Gear) km/h (mph)

D (Drive)

Fully opened

53 ∼ 59 (33 ∼ 37)

110 ∼ 116 (68 ∼ 72)

166 ∼ 172 (103 ∼ 107)

Half throttle

32 ∼ 38 (20 ∼ 24)

57 ∼ 63 (35 ∼ 39)

99 ∼ 105 (61 ∼ 65)

3 (Third)

Fully opened

53 ∼ 59 (33 ∼ 37)

110 ∼ 116 (68 ∼ 72)

—

Half throttle

32 ∼ 38 (20 ∼ 24)

57 ∼ 63 (35 ∼ 39)

—

2 (Second)

Fully opened

53 ∼ 59 (33 ∼ 37)

—

Half throttle

32 ∼ 38 (20 ∼ 24)

—

Downshift Range

D (Drive)

3 (Third)

2 (Second) L (First)

Throttle opening

1←2 2←3 (First Gear) (Second Gear) (Second Gear) (Third Gear) km/h (mph) km/h (mph)

3←4 (Third Gear) (Fourth Gear) km/h (mph)

Fully opened

45 ∼ 51 (28 ∼ 32)

97 ∼ 103 (60 ∼ 64)

155 ∼ 161 (96 ∼ 100)

Half throttle

14 ∼ 20 (9 ∼ 12)

33 ∼ 39 (20 ∼ 24)

64 ∼ 70 (40 ∼ 43)

Fully closed

13 ∼ 19 (8 ∼ 12)

19 ∼ 25 (12 ∼ 16)

27 ∼ 33 (17 ∼ 21)

Fully opened

45 ∼ 51 (28 ∼ 32)

97 ∼ 103 (60 ∼ 64)

—

Half throttle

14 ∼ 20 (9 ∼ 12)

33 ∼ 39 (20 ∼ 24)

—

Fully closed

13 ∼ 19 (8 ∼ 12)

19 ∼ 25 (12 ∼ 16)

—

Fully opened

45 ∼ 51 (28 ∼ 32)

92 ∼ 98 (57 ∼ 61)

—

Half throttle

14 ∼ 20 (9 ∼ 12)

92 ∼ 98 (57 ∼ 61)

—

Fully closed

13 ∼ 19 (8 ∼ 12)

92 ∼ 98 (57 ∼ 61)

—

48 ∼ 54 (30 ∼ 34)

—

AUTOMATIC TRANSMISSION (4L30–E)

7A–25

“Power mode” Upshift Range

Throttle opening

1→2 2→3 (First Gear) (Second Gear) (Second Gear) (Third Gear) km/h (mph) km/h (mph)

3→4 (Third Gear) (Fourth Gear) km/h (mph)

D (Drive)

Fully opened

53 ∼ 59 (33 ∼ 37)

110 ∼ 116 (68 ∼ 72)

174 ∼ 180 (108 ∼ 112)

Half throttle

41 ∼ 47 (25 ∼ 29)

84 ∼ 90 (52 ∼ 56)

136 ∼ 142 (84 ∼ 88)

3 (Third)

Fully opened

53 ∼ 59 (33 ∼ 37)

110 ∼ 116 (68 ∼ 72)

—

Half throttle

41 ∼ 47 (25 ∼ 29)

84 ∼ 90 (52 ∼ 56)

—

2 (Second)

Fully opened

53 ∼ 59 (33 ∼ 37)

—

Half throttle

41 ∼ 47 (25 ∼ 29)

—

Downshift Range

D (Drive)

3 (Third)

2 (Second)

Throttle opening

1←2 2←3 (First Gear) (Second Gear) (Second Gear) (Third Gear) km/h (mph) km/h (mph)

3←4 (Third Gear) (Fourth Gear) km/h (mph)

Fully opened

45 ∼ 51 (28 ∼ 32)

104 ∼ 110 (65 ∼ 68)

163 ∼ 169 (101 ∼ 105)

Half throttle

22 ∼ 28 (14 ∼ 17)

57 ∼ 63 (35 ∼ 39)

108 ∼ 114 (67 ∼ 71)

Fully closed

13 ∼ 19 (8 ∼ 12)

23 ∼ 29 (14 ∼ 18)

46 ∼ 52 (29 ∼ 32)

Fully opened

45 ∼ 51 (28 ∼ 32)

104 ∼ 110 (65 ∼ 68)

—

Half throttle

22 ∼ 28 (14 ∼ 17)

57 ∼ 63 (35 ∼ 39)

—

Fully closed

13 ∼ 19 (8 ∼ 12)

23 ∼ 29 (14 ∼ 18)

—

Fully opened

45 ∼ 51 (28 ∼ 32)

92 ∼ 98 (57 ∼ 61)

—

Half throttle

22 ∼ 28 (14 ∼ 17)

92 ∼ 98 (57 ∼ 61)

—

Fully closed

13 ∼ 19 (8 ∼ 12)

92 ∼ 98 (57 ∼ 61)

—

48 ∼ 54 (30 ∼ 34)

—

L (First)

—

“Winter mode” D range, winter mode ON → OFF

31 ∼ 37 km/h (19 ∼ 23 mph)

7A–26

AUTOMATIC TRANSMISSION (4L30–E)

Lockup Speed Chart Transfer gear ratio

High: 1.000

Rear axle ratio

4.300 ECCC Apply 2nd Km/h (mph)

3rd Km/h (mph)

4th Km/h (mph)

2nd Km/h (mph)

3rd Km/h (mph)

4th Km/h (mph)

Normal

57 ∼ 63 (35 ∼ 39)

42 ∼ 48 (26 ∼ 30)

43 ∼ 49 (27 ∼ 31)

52 ∼ 58 (32 ∼ 36)

32 ∼ 38 (20 ∼ 24)

41 ∼ 47 (25 ∼ 29)

Power

57 ∼ 63 (35 ∼ 39)

67 ∼ 73 (42 ∼ 45)

57 ∼ 63 (35 ∼ 39)

52 ∼ 58 (32 ∼ 36)

32 ∼ 38 (20 ∼ 24)

49 ∼ 55 (30 ∼ 34)

Mode D range Throttle opening i 6%

ECCC Release

AUTOMATIC TRANSMISSION (4L30–E)

Changing Transmission Fluid There is no need to change the transmission fluid unless the transmission is used under one or more of the following heavy duty conditions. A. Repeated short trips B. Driving on rough roads C. Driving on dusty roads D. Towing a trailer If the vehicle is used under these conditions, change the fluid every 20,000 miles (32,000 km). 1. Place a large drain pan under the oil pan. 2. Remove the transmission oil drain screw (2) and drain fluid. 3. Tighten drain screw (2).

7A–27

NOTE: To prevent fluid leaks, the overfill screw and oil drain screws gasket must be replaced each time these screws are removed. NOTE: Check transmission fluid temperature with scan tool. 7. Reset “Oil Life Monitor” data by using Tech 2. Refer to Tech 2 OBD II Connection in Transmission Control System (4L30-E) section.

Torque: 38 N•m (28 lb ft) 4. Remove the transmission overfill screw (1) and fill transmission through overfill screw opening, using DEXRON–III ATF. NOTE: Add transmission fluid until it flows out over the overfill screw opening. 5. Let engine idle until a fluid temperature between 32°C (90°F) and 57°C (135°F) is reached. 6. Add transmission fluid until it flows out over the overfill screw opening, then close the overfill screw (1). Torque: 38 N•m (28 lb ft) 242R200001

Selector Lever Inspection

Removal

1. Make sure that when the selector lever is shifted from “P” to “L”, a “clicking” can be felt at each shift position. Make sure that the gear corresponds to that of the position plate indicator. 2. Check to see if the selector lever can be shifted as shown in illustration.

1. Disconnect battery ground cable. 2. Set ignition Key in “LOCK” position and selector lever in ”P” position. 3. Remove knee pads (1), cluster upper cover (2) and center cluster assembly (3).

740R200021 C07RW009

7A–28

AUTOMATIC TRANSMISSION (4L30–E)

4. Remove rear console.

6. Remove selector lever knob and cover assembly.

745R200003

5. Remove front console.

256R200001

7. Disconnect select cable. B Refer to Select Cable in this section. 8. Disconnect shift lock cable. B Refer to Shift Lock Cable in this section. 9. Disconnect harness connector.

745R200004

AUTOMATIC TRANSMISSION (4L30–E) 10. Remove selector lever subassembly.

7A–29

Installation 1. Install selector lever subassembly. 2. Connect harness connector. 3. Connect shift lock cable. B Refer to Shift Lock Cable in this section. 4. Connect select cable. B Refer to Select Cable in this section. 5. Install selector lever knob and cover assembly. 6. Install front console. 7. Install rear console. 8. Install center cluster assembly, cluster upper cover and knee pads. 9. Connect negative (–) battery cable. 10. After installation, make sure that the selector lever operates normally, and that each selector position is properly indicated. (The red mark shows through the window.) 256R200005

Select Cable Removal 1. Set selector lever in “P” position. 2. Remove knee pads, cluster upper cover, center cluster assembly, rear console, front console, selector lever knob and cover assembly. B Refer to Selector Lever in this section. 3. Disconnect inner cable by pulling projection on pin.

256R200006

7A–30

AUTOMATIC TRANSMISSION (4L30–E)

4. Press down claws and disconnect cable assembly.

A07RW017

5. Remove nuts that fasten grommet in select cable assembly. 6. Disconnect inner cable.

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AUTOMATIC TRANSMISSION (4L30–E)

7A–31

7. Slide sleeve and disconnect cable assembly.

A07RW082

8. Pull lock.

A07RW015

9. Draw select cable assembly into the interior side.

7A–32

AUTOMATIC TRANSMISSION (4L30–E)

Installation 1. Set selector lever in “P” position. 2. Let out select cable transmission side end from floor hole. 3. Fit outer cable into bracket in selector lever assembly.

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4. Set inner cable end in selector lever and push pin into selector lever hole and inner cable end.

256R200007

AUTOMATIC TRANSMISSION (4L30–E) 5. Check that lock projects.

7A–33

8. Push lock into adjust end fitting attachment.

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6. Connect adjust end fitting attachment to the bracket on transmission. 7. Set select lever “P” position and connect inner cable to select lever.

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9. Install grommet. 10. About following installation steps, refer to Selector Lever in this section.

7A–34

AUTOMATIC TRANSMISSION (4L30–E)

Shift Lock Cable Removal 1. Set ignition key in “LOCK” position and selector lever in “P” position. 2. Remove knee pads, cluster upper cover, center cluster assembly, rear console, and front console. B Refer to Selector Lever in this section. 3. Disconnect inner cable from selector lever assembly then push claw and disconnect cable assembly.

6. Remove spring pin and disconnect inner cable. B Disconnect outer cable from bracket.

256RW008

Installation

256R200002

4. Disconnect lock adjust.

1. Set ignition key in “LOCK” position and selector lever in “P” position. 2. Connect outer cable to bracket near steering lock. B Connect inner cable to steering lock and install spring pin. 3. Install steering column cover and instrument lower cover. 4. Install adjust body of cable assembly to bracket in selector lever assembly. B Install inner cable to lever, pulling inner cable with outer cable.

256R200003

5. Remove instrument panel lower cover and steering column cover.

256R200004

AUTOMATIC TRANSMISSION (4L30–E) 5. Check that cable moves smoothly, lightly pulling outer cable rearward. 6. Connect lock adjust, aligning “T” mark in the “Up” position.

7A–35

7. About following installation steps, refer to Selector Lever in this section. 8. Check the shift lock operation: a. Selector lever should not be moved out of “P” position with ignition key in “Lock” position. b. Selector lever can be moved out of “P” position with ignition key in “ON”position only when brake pedal is depressed. c. ignition key can be turned to “LOCK” position only when selector lever is in “P” position (key can be pulled out). 9. If a. and c. fail, readjust cable. If b. fails, readjust connector wiring and brake pedal switch.

256R200003

Mode Switch Removal 1. Place selector lever in neutral. 2. Disconnect battery ground cable. 3. Remove mode switch cover (1) (V6). 4. Disconnect selector lever (2) from the mode switch. 5. Remove bracket with cable (3). 6. Disconnect transmission harness from the mode switch connector (4). 7. Remove bracket with mode switch connector from the transmission case. 8. Remove mode switch connector (4) from the bracket (5). 9. Remove two mode switch bolts and nut then remove mode switch (6).

210RW014

7A–36

AUTOMATIC TRANSMISSION (4L30–E)

Installation To install, follow the removal steps in the reverse order, noting the following points; 1. Torque

i. Remove multimeter and install mode switch harness connector with bracket to the transmission case. j. Connect transmission harness connector to mode switch connector.

Mode switch bolt: 13 N•m (113 lb in) Selector lever nut: 23 N•m (17 lb ft) 2. Mode switch setting procedure Perform either of the following adjustment procedures: Procedure 1 a. b. c. d. e.

Place selector lever in neutral. Remove selector lever from the mode switch. Remove the mode switch cover. Loosen the two 10 mm screws. Rotate the mode switch until the slot in the mode switch housing aligns with the selector shaft bushing, and insert a 3/32 in. (2.4 mm) drill bit or punch (1) into the slot. f. Tighten the screws to 13 N·m (113 lb in). g. After completing adjustment, snap the mode switch cover into place. h. Reinstall the selector lever.

249RW001

Procedure 2 a. Place selector lever in neutral. b. Disconnect transmission harness connector from mode switch connector. c. Remove mode switch connector with bracket from the transmission case. d. Connect multimeter (resistance mode) to terminals 1(E) and 4(H) on mode switch connector. e. Loosen two mounting screws. f. Rotate mode switch slightly in both directions to determine the range (approx. 5 degrees) of electrical contact. g. Position mode switch in middle of contact range. h. Tighten two mounting screws.

F07RW003

AUTOMATIC TRANSMISSION (4L30–E)

7A–37

Transmission Assembly Transmission and Associated Parts

240R200005

Legend (1) Fairing Plate (2) Transfer Protector (4×4) (3) Under Cover (4) Front Propeller Shaft (4×4) (5) Transmission Oil Cooler Pipe (6) Select Cable (7) Rear Propeller Shaft (4×2) (8) Rear Propeller Shaft (4×4) (9) Rear Mount Rubber and Propeller Protector Assembly (4×2) (10) Fuel Pipe (11) Fuel Pipe Heat Protector

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Third Crossmember (4×4) Third Crossmember (4×2) Center Exhaust Pipe (4×4) Starter Harness Heat Protector Torque Converter Bolt Engine-Transmission Bolt Rear Mount Nut (4×4) Rear Mount Nut (4×2) Harness Connector Transmission Assembly with Transfer Assembly (4×4) (23) Transmission Assembly (4×2)

7A–38

AUTOMATIC TRANSMISSION (4L30–E)

Removal 1. Disconnect battery ground cable. 2. Remove transfer protector (4×4) and fairing plate.

401R200008

150R200001

4. Remove center exhaust pipe (4×4). 5. Remove fuel pipe heat protector and clip from third crossmember. 6. Disconnect fuel pipe bracket from third crossmember.

3. Remove rear propeller shaft and front propeller shaft (4×4). NOTE: Apply alignment marks on the flange at both front and rear sides.

141RW004

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AUTOMATIC TRANSMISSION (4L30–E) 7. Disconnect fuel pipe bracket from transmission side.

7A–39

Fuel hose connector removal procedure If removal of the fuel hose connector is required for transmission servicing and/or replacement, follow the steps below.

141R200003

(4×4) 141R200001

NOTE: B An O-ring is used as a seal between the fuel pipe and the connector. Take care not to damage the contact surfaces during the removal procedure. Do not allow the surface to become contaminated with dirt or other foreign material. B Perform the entire removal procedure with your hands. Do not use tools.

240R200010

(4×2)

141R200002

7A–40

AUTOMATIC TRANSMISSION (4L30–E)

1. Separating the connector and fuel pipe 1. Clean the fuel pipe and connector to remove mud and other dirt. 2. Pull the black plastic piece toward the connector. Hold the piece near the connector. Pull the connector from the fuel pipe. If the connector and fuel pipe are stuck together, jiggle the connector back and forth to loosen the connector. Do not yank the connector from the fuel pipe.

3. Tie a vinyl bag around the connector and fuel pipe to protect them from dirt.

141RY00004

2. Joining the connector and fuel hose

141RY00002

1. Remove the vinyl bag from the connector and fuel hose. Check that the contact surfaces are undamaged and free of dirt and other foreign material. Clean if necessary. 2. Align the axis of the fuel pipe and connector. Push the connector into the fuel pipe until a distinct click is heard.

141RY00003 141RY00005

AUTOMATIC TRANSMISSION (4L30–E) 3. Gently pull on the connector to check that it is securely latched.

7A–41

10. Support transmission with a jack. Remove rear mount nuts from third crossmember. (4×4)

141RY00006

8. Disconnect transmission harness connector and clip. Connector : Adapter case, mode switch, main case, magnetic sensor, transfer switch (4×4), 2–4 actuator (4×4) and car speed sensor.

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(4×2)

9. Remove harness heat protector.

F07R100005

815RW002

11. Remove third crossmember. 12. Disconnect transmission oil cooler pipes from A/T side. 13. Remove oil pipe clamp and bracket from the converter housing.

7A–42

AUTOMATIC TRANSMISSION (4L30–E)

14. Loosen oil cooler pipe clamp bolt at the engine mount side.

18. Remove flex plate torque converter fixing bolts (6 pieces) by turning crankshaft.

(4×4)

240RX010 253RY001

15. Remove select cable by disconnecting inner cable from select lever and removing outer cable with bracket.

256RW025

16. Remove starter. 17. Remove under covers from the transmission and engine.

19. Remove engine transmission fixing bolts. 20. Pull out transmission assembly from the engine. 21. Remove the rear mount rubber and propeller protector assembly if required (4×2).

AUTOMATIC TRANSMISSION (4L30–E)

7A–43

Installation 1. Slowly raise transmission jack until front of transmission assembly is aligned with rear of engine. Attach the transmission assembly to engine. 2. Tighten engine transmission bolts as shown in figure.

the the the the

F07R200004

3. Align the flex plate torque converter bolt boss with flex plate hole by turning the torque converter. Install flex plate torque converter bolts (6 pieces) by turning the crankshaft. Torque: 54 N•m (40 lb ft) NOTE: Do not reuse the flex plate torque converter bolt.

240RX010

7A–44

AUTOMATIC TRANSMISSION (4L30–E)

4. Install under covers to the transmission and engine. 5. Install starter. Torque: 40 N•m (30 lb ft)

10. Install third crossmember. Torque: 116 N•m (85 lb ft) 11. Install rear mount nuts.

6. Install select cable by connecting inner cable to select lever and installing outer cable with bracket.

Torque: 50 N•m (37 lb ft) (4×4)

256RW025 F07RW008

7. Connect transmission oil cooler pipes to A/T.

(4×2)

Torque: 44 N•m (33 lb ft) 8. Install oil cooler pipe clamp and bracket to the converter housing. (4×4)

F07R100005

253RY001

9. Tighten oil cooler pipe clamp bolt at the engine mount side.

AUTOMATIC TRANSMISSION (4L30–E) 12. Install harness heat protector.

7A–45

(4×4)

Torque: 6 N•m (52 lb in)

240R200010

815RW002

(4×2)

13. Connect transmission harness connector and clip. Connector : Adapter case, mode switch, main case, magnetic sensor, transfer connectors (4×4) and car speed sensor. 14. Connect fuel pipe bracket to transmission side. NOTE: See “NOTE” of removal steps.

141R200002

141R200003

7A–46

AUTOMATIC TRANSMISSION (4L30–E)

15. Install fuel pipe heat protector and clip. 16. Connector fuel pipe bracket to third crossmember.

141RW004

17. Install center exhaust pipe (4×4). Torque: 43 N•m (32 lb ft) 18. Install front propeller shaft (4×4) and rear propeller shaft. Torque: 63 N•m (46 lb ft) 19. Install transfer protector (4×4) and fairing plate. Torque (transfer protector bolt): 37 N•m (27 lb ft)

150R200001

AUTOMATIC TRANSMISSION (4L30–E)

7A–47

Solenoid (Main Case Valve Body) Removal 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Remove transfer protector (4×4). 4. Drain fluid. 5. Support transfer case with a jack and remove third crossmember. 6. Remove sixteen 10 mm screws, main case oil pan, magnet, and gasket. 7. Remove three 13 mm screws, oil filter. 8. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 9. Remove spring pin for shift solenoid A, shift solenoid B, and band control solenoid respectively, using suitable pliers taking care not to damage solenoids.

10. Remove shift solenoid A, shift solenoid B, band control solenoid, and gaskets from main case valve body. Do not pull on wiring harness. Remove solenoids by grasping the metal tip.

Installation 1. Install shift solenoid A, shift solenoid B, band control solenoid with new gaskets to main case valve body respectively. 2. Carefully install spring pin with hammer to avoid damage to valve body, etc.

243RW004

3. Connect wiring harness to solenoids. 4. Install oil filter with a new gasket and the three 13 mm screws. Tighten the screws to the specified torque. Torque: 20 N•m (15 lb ft) 210RW010

5. Install magnet, main case oil pan with new gasket, sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 N•m (96 lb in) 6. Install third crossmember and rear mount nuts. Tighten the nuts and bolts to the specified torque. Third crossmember bolt: 116 N•m (85 lb ft) Rear mount nut: 50 N•m (37 lb ft) 7. Install the transfer protector. Tighten the bolts to the specified torque (4×4). Torque: 37 N•m (27 lb ft) 8. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON–III. Refer to Changing Transmission Fluid in this section. 9. Connect the battery ground cable.

244RW003

7A–48

AUTOMATIC TRANSMISSION (4L30–E)

Solenoid (Adapter Case Valve Body) Removal

Installation

1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove adapter case oil pan twelve fixing 10 mm screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan and drain the fluid carefully. 5. Disconnect wiring harness from force motor solenoid and converter clutch PWM solenoid. Pull only on connectors, not on wiring harness. 6. Remove 11 mm bolt, bracket and converter clutch PWM solenoid with two O–rings.

1. Install force motor solenoid, retainer, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque: 10 N•m (87 lb in) 2. Install converter clutch PWM solenoid with two O– rings, bracket, and 11 mm bolt to adapter case valve body. Tighten the bolt to the specified torque. Torque : 10 N•m (87 lb in) 3. Connect wiring harness assembly to solenoids. 4. Install adapter case oil pan, new gasket, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque : 11 N•m (96 lb in) 5. Fill transmission through overfill screw hole oil pan, using ATF DEXRON–III. Refer to Changing Transmission Fluid in this section. 6. Connect battery ground cable.

210RY001

7. Remove 11 mm bolt, retainer, and force motor solenoid.

210R100002

AUTOMATIC TRANSMISSION (4L30–E)

7A–49

Valve Body Assembly (Main Case) 4. Install seven 13 mm screws, and tighten them to the specified torque.

Removal 1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Remove transfer protector (4×4). 4. Drain fluid. 5. Support transfer case with a jack and remove third crossmember. 6. Remove sixteen 10 mm screws, main case oil pan, magnet and gasket. 7. Remove three 13 mm oil filter fixing screws, then remove oil filter. 8. Remove two 13 mm manual detent fixing screws, then remove roller and spring assembly. 9. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness. 10. Remove four 13 mm servo cover fixing screws, then remove servo cover and gasket. 11. Remove seven 13 mm valve body fixing screws. 12. Remove main case valve body with manual valve link and transfer plate. Note the position of the link (long end into valve, short end into range selector lever). 13. Remove transfer plate gasket from main case. 14. Remove two check balls from main case.

Torque: 20 N•m (15 lb ft)

243RS008

5. Remove two guide pins from main case. 6. Install servo cover gasket, cover, and four 13 mm screws. Tighten the screws to the specified torque. Torque: 25 N•m (18 lb ft) 7. Connect wiring harness to band control and shift solenoids. 8. Install roller and spring assembly to manual detent. B Install two 13 mm screws, and tighten them to the specified torque.

Installation 1. Install two check balls to main case.

Torque: 20 N•m (15 lb ft) 9. Install oil filter and three 13 mm screws. Tighten the screws to the specified torque. Torque : 20 N•m (15 lb ft) 10. Install oil pan gasket, magnet, oil pan and sixteen 10 mm screws. Tighten the screws to the specified torque. Torque: 11 N•m (96 lb in) 11. Install third crossmember and rear mount. Tighten the bolts and nuts to the specified torque. Torque Third crossmember bolt: 116 N•m (85 lb ft) Rear mount nut: 50 N•m (37 lb ft) 244RW002

2. Inspect electrical 7 way connector and seal of main case. Replace if necessary. 3. Use two J–25025–B guide pin to install main case. B Install valve body assembly and manual valve link. NOTE: Valve must be extended as the short end of manual valve link is connected to the range selector lever. Long end of link goes into valve.

12. Install transfer protector. Tighten the bolts to the specified torque (4×4). Torque: 37 N•m (27 lb ft) 13. Fill transmission through overfill screw hole of oil pan, using ATF DEXRON–III. Refer to Changing Transmission Fluid in this section. 14. Connect battery ground cable.

7A–50

AUTOMATIC TRANSMISSION (4L30–E)

Valve Body Assembly (Adapter Case) Removal

Installation

1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove twelve 10 mm adapter case oil pan fixing screws, adapter case oil pan, and gasket. NOTE: Oil pan still contains transmission fluid. Place a large drain container under the oil pan. Drain the fluid carefully. 5. Disconnect wiring harness from force motor solenoid and converter clutch solenoid. Pull only on connectors, not on wiring harness. 6. Remove seven 13 mm screws from adapter case valve body assembly, then remove transfer plate, two gaskets, and adapter case valve body.

1. Inspect electrical 4 way connector and seal of adapter case. Replace if necessary. 2. Install gasket, transfer plate, and gasket. 3. Install adapter case valve body and seven 13 mm screws. Tighten the screws to the specified torque. Torque: 20 N•m (15 lb ft) 4. Connect wiring harness assembly to converter clutch solenoid and force motor. 5. Install oil pan gasket, oil pan, and twelve 10 mm screws. Tighten the screws to the specified torque. Torque: 11 N•m (96 lb in) 6. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON–III. Refer to Changing Transmission Fluid in this section. 7. Connect battery ground cable.

Powertrain Control Module (PCM) Removal

Installation

1. Disconnect battery ground cable. 2. Disconnect PCM wiring harness connectors from PCM. 3. Remove PCM from bracket.

825R100018

1. Install PCM to bracket. 2. Connect PCM wiring harness connectors to PCM. 3. Connect battery ground cable.

AUTOMATIC TRANSMISSION (4L30–E)

7A–51

Speed Sensor (Extension Assembly) Removal

Installation

1. Raise the vehicle and support on jack stands. 2. Disconnect battery ground cable. 3. Disconnect speed sensor harness connector from speed sensor. 4. Remove one 10 mm screw and speed sensor with O–ring. Sensor Location (4×4)

241R200002

Sensor Location (4×2)

241R200001

1. Inspect the speed sensor O–ring, and replace it if necessary. 2. Install speed sensor assembly and 10 mm screw. Torque: 9 N•m (78 lb in) 3. Connect speed sensor harness connector to speed sensor. 4. Connect battery ground cable.

7A–52

AUTOMATIC TRANSMISSION (4L30–E)

Transmission Oil Temperature Sensor (Main Case) Removal

Installation

1. Raise the vehicle and support it on jack stands. 2. Disconnect battery ground cable. 3. Drain fluid. 4. Remove sixteen 10 mm main case oil pan fixing screws, main case oil pan, and gasket. 5. Disconnect wiring harness from shift solenoids, band apply solenoid, and 7 way connector of main case. Pull only on connectors, not on wiring harness. 6. Remove wiring harness assembly with transmission oil temperature sensor.

1. Install wiring harness assembly with transmission oil temperature sensor to band apply solenoid, shift solenoids, and 7 way connector of main case. 2. Install oil pan gasket, oil pan, and sixteen 10 mm fixing screws. Tighten the screws to the specified torque. Torque: 11 N•m (96 lb in) 3. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON–III. Refer to Changing Transmission Fluid in this section. 4. Connect battery ground cable.

244RY001

AUTOMATIC TRANSMISSION (4L30–E)

7A–53

Front Oil Seal (Converter Housing) Removal

Installation

1. Remove transmission assembly from the vehicle. Refer to Transmission Assembly in this section. 2. Remove torque converter from converter housing. 3. Remove three screws and oil seal ring from converter housing.

1. Apply clean ATF to the new oil seal ring lip. B Install oil seal ring to converter housing. Tighten the screws to the specified torque. Torque: 3 N•m (26 lb in) 2. Install torque converter to converter housing. 3. Install transmission assembly to the vehicle. Refer to Transmission Assembly in this section.

241RW008

Rear Oil Seal (Extension Assembly) Removal

Installation

1. Remove transfer case assembly (4×4) or extension assembly (4×2) from the vehicle. Refer to Transfer Case in Drive Line/Axle section (4×4). 2. Remove rear oil seal from transmission extension assembly.

241RW005

1. Use J–36797 extension assembly oil seal installer, and install the rear oil seal to the transmission extension assembly. 2. Install the transfer case assembly (4×4) or extension assembly (4×2) to the vehicle. Refer to Transfer Case in Drive Line/Axle section (4×4).

7A–54

AUTOMATIC TRANSMISSION (4L30–E)

Transmission (4L30–E) Disassembly NOTE: During the disassembly and reassembly, perform the following: B Wash each part thoroughly, and blow air through each oil passage and groove to eliminate blockage. B Seal rings, roll pins, and gaskets should be replaced. B When assembling the components, apply DEXRON–III Automatic Transmission Fluid (ATF) to each seal, rotating part, and sliding part. B Do not dip part facings, such as clutch or brake drive plates, in cleaner when washing it. Also, always coat parts with new ATF two or three times after cleaning with solvent. 1. Remove torque converter (1). B Drain fluid from torque converter. B Attach J–8763–02 holding fixture to the transmission and set it on J–3289–20 holding fixture base. NOTE: Do not overtighten the tool, as case damage may result.

420RW021

2. Remove O–ring (2) from turbine shaft. 3. Remove two 10mm mode switch screws, selector lever nut, cover, and mode switch (3). 4. Remove twelve 10mm adapter case oil pan (4) fixing screws, adapter oil pan, and gasket. 5. Disconnect electrical wiring connections (5) from solenoids and 4 way connector of adapter case. Pull on connectors only, not on wiring harness. 6. Remove seven 13mm adapter case valve body (6) fixing screws, adapter case valve body assembly, transfer plate, and two gaskets. B Remove wiring harness and 4 way connector. 7. Remove sixteen 10mm main case oil pan (7) fixing screws, main oil pan, magnet, and gasket. 8. Remove three 13mm oil filter (8) fixing screws and oil filter.

9. Remove two 13mm manual detent (9) fixing screws, roller and spring, and manual detent. 10. Disconnect wiring harness assembly (10) from band apply solenoid, shift solenoids, and main case 7 way connector. Pull on connectors only, not on wiring harness. 11. Remove four 13mm servo cover (11) fixing screws, servo cover, and gasket. 12. Remove seven 13mm valve body screws from main case. B Remove wiring harness assembly (5) from the adapter case side. B Remove main valve body assembly (12) with manual valve link and transfer plate. Note the position of the link (long end into valve, short end into range selector lever). B Remove 7 way connector. B Remove gasket transfer plate from main case.

AUTOMATIC TRANSMISSION (4L30–E)

7A–55

13. Remove two check balls (13) from main case.

240RY001

14. Turn transmission to vertical position to drain fluid. Return back to horizontal position when drained. B Install J–23075 servo piston spring compressor with offset to the rear of case. B Compress servo piston assembly. B Remove servo piston retaining ring (14). B Slowly release servo piston assembly (15). B Remove tool.

7A–56

AUTOMATIC TRANSMISSION (4L30–E)

15. Remove servo piston assembly (15), return spring (16), and servo apply rod (17).

19. Remove speed wheel (21). 20. Remove wheel parking lock (with seal ring) (22).

242RS002

16. Rotate transmission to horizontal position, pan side down. B Remove one 10mm screw, and speed sensor (18) with “O” ring. 17. Remove seven 8mm extension housing hexagon socket head screws, extension housing assembly (19), and gasket. 18. Remove retaining ring (20). (4×4) NOTE: Use extra long, needle- nose pliers. B Remove flange nut (20). (4×4) B Remove flange and O–ring (20). (4×2)

241RW012

21. Rotate transmission to vertical position, converter housing up. B Loosen the converter housing and oil pump assembly fixing screws, but do not remove the five 13 mm inner screws if oil pump disassembly is required. B Remove seven outer screws. B Remove converter housing and oil pump assembly (23). 22. Remove gasket (24).

AUTOMATIC TRANSMISSION (4L30–E) 23. Remove selective thrust washer (25).

7A–57

28. Remove thrust washer (31).

241RW004

24. Remove fourth clutch retainer (26). 25. Grasp turbine shaft and lift out the overrun clutch housing assembly (27) and fourth clutch plates (28). 26. Remove thrust bearing assembly (29). 27. Remove overdrive internal gear (30).

252RS001

29. Remove adapter case and center support assembly (with fourth clutch piston) (32). 30. Remove seal ring (33). 31. Remove selective thrust washer (34) and two O–ring seals (35) from main case. 32. Use J–23327 and J–23327–90 compressor to compress the fourth clutch spring retainer and springs (37). B Release snap ring (36) from groove. B Remove clutch compressor and snap ring (36). 33. Remove retainer and spring assembly (37). 34. Insert two converter housing/main case screws to hold adapter case while pulling out fourth clutch piston (38). B Remove fourth clutch piston assembly (38) from the adapter case. B Remove converter housing/main case screws. 35. Grasp intermediate shaft, twist and pull out the second and third clutch drum assemblies with reverse clutch plates (39) while holding onto output shaft.

7A–58

AUTOMATIC TRANSMISSION (4L30–E)

36. Separate second (40) and third clutch (41) assemblies. 37. Remove thrust washer (42). 38. Remove reverse clutch plates (43 and 44) and reverse clutch pressure plate (45). 39. Remove bearing (46) and washer (47). 40. Remove planetary carrier assembly (48). 41. Remove thrust bearing (49). 42. Remove reaction sun gear (50) 43. Remove needle bearing (51). 44. Remove brake drum (52). 45. Remove brake band (53). 46. Remove thrust bearing (54).

NOTE: Insert wire in the center of the spring pin to prevent it from collapsing during removal. Be aware of pin height. Protect machined face of main case. 48. Remove parking lock and range selector lever 17 mm nut (57). 49. Remove parking lock and range selector lever (56), and actuator assembly. 50. Remove selector shaft (58). NOTE: Inspect the shaft for burrs before removing to prevent damaging seal. If necessary, remove burrs by lightly sanding with an oilstone.

249RS004

Reassembly 1. Inspect selector shaft seal, and replace it if necessary. NOTE: Use a seal installer when replacing the seal. B Install selector shaft. NOTE: Spring pin groove must be positioned inside the case.

242RS003

47. Rotate case to horizontal position, valve body side facing up. B Remove spring pin (55), using cutting pliers, then remove parking lock and selector lever assembly (56).

2. Install spring pin. Be sure the selector shaft can move freely. Do not push the pin flush with the case surface. Leave enough height for removal. 3. Install actuator assembly (1). 4. Install parking lock and range selector lever (2) and new 17 mm nut. Tighten the nut to the specified torque. Torque: 22 N•m (16 lb ft)

AUTOMATIC TRANSMISSION (4L30–E)

7A–59

11. Install the thrust bearing (9) on the output shaft. NOTE: Use petroleum jelly to hold the thrust bearing in place.

249RS005

5. Rotate main case to vertical position, extension end facing down. B Install brake band assembly (3). NOTE: Be sure to align servo pin area with the servo hole. 6. Install thrust bearing (4).

12. Align planetary pinions. Each pinion is marked with double points to indicate the master tooth space and exactly opposite with a single point to indicate the master tooth. The markings on the planetary carrier consist of double lines which are to be lined up with the double points on two opposite pinions; the single lines are to be lined up with the single points on the other two pinions. B After all four pinions are lined up, slide on the third clutch assembly. Rotate third clutch and check mark alignment. Considering that the ring gear tooth between the double points of one planetary pinion is tooth number 1, count the teeth to check that the single points on the two adjacent pinions are between teeth 23 and 24 of the ring gear, and that the ring gear tooth between the double points of the opposite pinion is tooth number 46. If the ring gear and pinions are not lined up, remove, and realign them. 13. Install planetary carrier (8) with third clutch (12). NOTE: Do not force. When properly aligned, the parts will fit together easily.

NOTE: The case bushing acts as a guide for the thrust bearing. 7. Install brake drum (5). 8. Install reaction sun gear (6). 9. Install needle bearing (7). 10. Inspect planetary carrier assembly (8) for wear and damage. If necessary replace it. B Measure pinion end play clearance with a feeler gauge. Clearance: 0.13mm–0.89mm (0.005 in–0.035 in) If clearance is outside specified value, replace the planetary carrier assembly.

248RS002

14. Remove the third clutch (12). 15. Install bearing (11) and washer (10). 248RS001

7A–60

AUTOMATIC TRANSMISSION (4L30–E)

NOTE: Use petroleum jelly to hold the washer and bearing in place.

18. Install second and third clutch assemblies into the main case. Twist output shaft and clutch assemblies to ensure proper fit.

247RS001

19. Install pressure plate (15) with lip side up, tang facing valve body face. 20. Install reverse clutch plates. Start with a steel plate (17) and alternate with a lined plate (16). 21. Install waved clutch plate (18) with center tang facing valve body side.

242RW002

16. Carefully align the second clutch plate inner tangs. B Install thrust washer, tangs pointing downward, and locating tang positioned in slot on second clutch hub. NOTE: Use petroleum jelly to hold thrust washer in place. 17. Install third clutch and intermediate shaft assembly (13) into the second clutch drum (14).

247RS002

AUTOMATIC TRANSMISSION (4L30–E)

7A–61

22. Second clutch end play measurement 1. Install the J–23085–A Selective washer gauging tool (with spacer ring) on the case flange and against the intermediate shaft. 2. Position the inner shaft of the gauging tool against the thrust surface of the second clutch hub. 3. Tighten thumb screw. Remove the tool. 4. Fit the spacer ring on the inner shaft of the tool. 5. Measure the gap, and select the appropriate washer as shown in the chart. Selective Thrust Washer Gap: mm(in)

Color

1.53 – 1.63 (0.060 – 0.064)

Yellow

1.72 – 1.82 (0.068 – 0.072)

Red

1.91 – 2.01 (0.075 – 0.079)

Black

2.10 – 2.20 (0.083 – 0.087)

Natural

2.29 – 2.39 (0.090 – 0.094)

Green

2.48 – 2.58 (0.098 – 0.102)

Blue

247RS004

FOLLOWING THE PROCEDURE SHOULD RESULT IN FINAL END–PLAY FROM 0.36 mm TO 0.79 mm (0.014 in TO 0.031 in)

23. Inspect fourth clutch piston seals and replace if necessary. B Lubricate J–38554 fourth clutch piston fitter and install it on fourth clutch piston (19). B Install fourth clutch piston (19) in adapter case (20). B Remove fitter.

252RS003

247R100001

7A–62

AUTOMATIC TRANSMISSION (4L30–E)

24. Install retainer and spring assembly (22) into fourth clutch piston (21). 25. Install snap ring (23) in adapter case. B Install J–23327 and J–23327–90 fourth clutch spring compressor. B Seat snap ring in groove.

26. Install selective washer using petroleum jelly. 27. Install two O–ring seals (24) in main case and adapter case/main case seal ring (25). 28. Install J–38588 guide pins. B Install adapter case and center support assembly to main case.

B Remove compressor.

252RW002

242RS004

29. Install thrust washer (26) into adapter case, with tangs pointing downwards. 30. Preassemble overdrive internal gear (27) and thrust bearing assembly (28) onto the turbine shaft and overrun clutch assembly. NOTE: Install bearing assembly, black side up. Use petroleum jelly to keep assembly in place.

252RS004

31. Install overdrive carrier (30) and internal gear assembly into adapter case. 32. Install fourth clutch plates (29) in the following order: Steel, Lined, Steel, Steel, Lined, Steel. Steel plates go in with short tang facing towards valve body surface.

AUTOMATIC TRANSMISSION (4L30–E)

7A–63

33. Install fourth clutch retainer (31) with the notch facing up and positioned towards valve body surface.

252RS005

252RW004

34. Overdrive clutch end play measurement 1. Install the J–23085–A selective washer gauging tool on the adapter case flange and against the input shaft. 2. Position the inner shaft of the tool against the thrust surface of the overrun clutch housing. 3. Tighten thumb screw. Remove the tool. 4. Measure gap. Select appropriate size washer as shown in the chart. 5. Set selective thrust washer aside. Selective Thrust Washer Gap: mm(in)

Color

1.53 – 1.63 (0.060 – 0.064)

Yellow

1.72 – 1.82 (0.068 – 0.072)

Red

1.91 – 2.01 (0.075 – 0.079)

Black

2.10 – 2.20 (0.083 – 0.087)

Natural

2.29 – 2.39 (0.090 – 0.094)

Green

2.48 – 2.58 (0.098 – 0.102)

Blue

FOLLOWING THE PROCEDURE SHOULD RESULT IN FINAL END–PLAY FROM 0.1 mm TO 0.8 mm (0.004 in TO 0.03 in)

252RS006

35. Install selective washer (32). NOTE: Use petroleum jelly to hold selective washer in place. 36. Install gasket (33). 37. Install converter housing and oil pump assembly (34) to adapter case. B Fit and tighten seven outer 13 mm screws. Torque: 39 N•m (29 lb ft)

7A–64

AUTOMATIC TRANSMISSION (4L30–E)

B Ensure free rotation of oil pump using J–23082–01 oil pump rotation tool.

NOTE: If end play is not correct, repeat selective washer selection.

252RW001

39. Inspect extension housing oil seal and replace if necessary, using J–36797 extension housing oil seal installer. B Rotate transmission to horizontal position, with valve body side down. B Inspect parking wheel seal ring. necessary.

Replace if

B Install wheel parking lock assembly (35). 40. Install speed wheel (36) and snap ring (37). (4×4) 241RW010

38. Overdrive clutch end play measurement 1. Fit J–25022 and J–24773–1 turbine shaft puller on turbine shaft. 2. Position axial play checking tool on converter housing mating face. 3. Pull turbine shaft upwards with puller until first resistance is met. (due to weight of overdrive assembly). 4. Maintain shaft in this position and set indicator to zero. 5. Pull turbine shaft further upwards with puller. Read end play shown on indicator. End play: 0.1mm – 0.8mm (0.004 in – 0.031in) 6. Remove axial play checking tool and puller.

NOTE: Use extra long, needle-nose pliers. 41. Install flange, O–ring and nut. (4×2) 42. Install gasket onto extension assembly with a thin coating of oil. B Install extension housing assembly (38), and align parking pawl shaft. B Install actuator assembly into extension assembly. B Install seven 8 mm hexagon socket head screws. Torque: 32 N•m (24 lb ft)

AUTOMATIC TRANSMISSION (4L30–E) 43. Inspect speed sensor O–ring. Replace if necessary. B Install speed sensor assembly (39) and 10 mm screw. Torque: 9 N•m (78 lb in)

7A–65

44. Main case end play measurement 1. Attach axial play checking tool on the extension housing and set indicator to zero on output shaft. 2. Manually push output shaft upwards. End play: 0.36mm – 0.80mm (0.014 in – 0.031in) 3. Remove axial play checking tool. 4. If end play is not correct, repeat selective washer selection.

241RS005

45. Inspect servo piston seal ring. Replace if necessary. B Ensure brake band is correctly positioned. Rotate output shaft if necessary. B Install J–38428 servo piston fitter in servo bore. 241RW013

B Install apply rod (40), round end toward band, return spring (41) and piston assembly (42). 46. Install the J–23075 servo spring compressor with offset to rear of case. B Compress servo piston seal ring, using fitter while tightening the tool screw. B Install servo piston retaining ring (43). B Remove tool. B Adjust the brake band by tightening the servo adjusting screw to 4.5 N·m (39.8 lb in) torque. Be certain the lock nut is loose, then back–off the screw five turns exactly. Hold piston sleeve with wrench and tighten lock nut to 18.5 N·m (13.6 lb ft) torque. Be certain the adjusting screw does not turn.

241RS004

7A–66

AUTOMATIC TRANSMISSION (4L30–E) NOTE: Valve must be extended as the short end of manual valve link is connected to the range selector lever. Long end of link goes into valve. B Install seven 13 mm screws. Torque: 20 N•m (15 lb ft) B Remove two guide pins. 50. Install servo cover gasket, cover (46) and four 13 mm screws. Torque: 25 N•m (18 lb ft) 51. Connect wiring harness (47) to band control, shift solenoids, and main case 7 way connector. 52. Install manual detent roller and spring assembly (48) with clip. B Install two 13 mm screws. Torque: 20 N•m (15 lb ft) 53. Install oil filter (49), and three 13 mm screws. Torque: 20 N•m (15 lb ft) 54. Install oil pan gasket, magnet, main oil pan (50), and sixteen 10 mm screws. Torque: 11 N•m (96 lb in)

242RW004

47. Install two check balls (44).

55. Inspect adapter case electrical connector and seal. Replace if necessary. B Install electrical 4 way connector and harness assembly (52) in bottom of adapter case. 56. Install gasket, transfer plate, and gasket. B Install adapter case valve body (51) and seven 13 mm screws. Torque: 20 N•m (15 lb ft) 57. Connect wiring harness harness assembly (52) to converter clutch PWM solenoid, force motor, and 4 way connector. 58. Install oil pan gasket, adapter case oil pan (53), and twelve 10 mm screws. Torque: 11 N•m (96 lb in) B Rotate transmission, with bottom pan facing down. 59. Install mode switch (54), two 10 mm screws, selector lever nut, and cover. 10 mm screw Torque: 13 N•m (113 lb in) Nut Torque: 23 N•m (17 lb ft)

244RW002

48. Inspect main case electrical connector and seal, replace if necessary. B Install electrical 7 way connector/main case and wiring harness. 49. Install two J–25025–B guide pins into main case. B Install main case valve body complete assembly (45) and manual valve link.

B Adjust using setting tool, refer to Mode Switch in this section. 60. Install O–ring (55) on turbine shaft. 61. Install torque converter (56). The converter assembly must be replaced under any of the following conditions: a. Evidence of damage to the pump assembly. b. Metal particles are found after flushing the cooler lines. c. External leaks in hub weld area. d. Converter pilot broken, damaged, or poor fit into crankshaft.

AUTOMATIC TRANSMISSION (4L30–E) e. Converter hub scored or damaged. f. Internal failure in stator. g. Contamination from engine coolant. h. Excess end play. B Rotate transmission, bell housing up. Spin converter to insure proper fit.

7A–67

62. Fill transmission through the overfill screw hole of oil pan, using ATF DEXRON–III. Refer to Changing Transmission Fluid in this section.

240RY002

7A–68

AUTOMATIC TRANSMISSION (4L30–E)

Converter Housing And Oil Pump Assembly Disassembled View

241RY001

Legend (1) Converter Housing (2) Outer Seal Ring (3) Gasket

Disassembly 1. Remove oil pump assembly from converter housing. 2. Remove outer seal ring. 3. Remove gasket. 4. Remove wear plate. 5. Remove oil seal ring.

(4) Wear Plate (5) Oil Pump Assembly (6) Oil Seal Ring

B Tighten five inner 13mm bolts in an alternating pattern. Torque: 20 N•m (15 lb ft)

Inspection And Repair Visual Check: If any damage, deformation, or local wear is found in a converter housing, outer seal ring, wear plate, or oil seal ring, replace it.

Reassembly 1. Install wear plate onto oil pump assembly. 2. Install converter housing onto complete oil pump assembly. Align with two short J–38588 guide pins on outer bolt holes. B Loosely install five 13mm bolts. B Center converter housing using J–38557 centering tool.

241RW002

3. Install oil seal ring (3 screws). Torque: 3 N•m (26 lb in) 4. Install gasket. 5. Install outer seal ring.

AUTOMATIC TRANSMISSION (4L30–E)

7A–69

Oil Pump Disassembled View

241RY002

Legend (1) Oil Pump Drive Gear (2) Oil Pump Driven Gear (3) Pin (4) Plug (5) Seal Ring (6) Torque Converter Clutch Control Valve (7) Converter Clutch Control Valve Spring (8) Pin (9) Converter Clutch Regulator Sleeve (10) Converter Clutch Regulator Spring (11) Converter Clutch Regulator Valve (12) Isolator Spring (13) Isolator Valve (14) Pin

Disassembly 1. Remove oil pump drive gear (1) and driven gear (2). 2. Remove pin (3) from oil pump assembly (29). 3. Remove plug (4) and seal ring (5), torque converter clutch control valve (6) and spring (7). 4. Remove pin (8) from oil pump assembly (29).

(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29)

Enable Valve Spring Guide Enable Valve Spring Enable Valve Snap Ring Spring Seat Throttle Signal Accumulator Spring Throttle Signal Accumulator Piston Sleeve Pin Boost Valve Sleeve Boost Valve Spring Seat Pressure Regulator Valve Spring Spring Seat Pressure Regulator Valve Oil Pump Assembly

5. Remove torque converter regulator sleeve (9), converter clutch regulator spring (10), converter clutch regulator valve (11), isolator spring (12) and isolator valve (13). 6. Remove pin (14) from oil pump assembly (29). 7. Remove enable valve spring (16), spring guide (15) and enable valve (17). 8. Remove snap ring (18) from oil pump assembly (29).

7A–70

AUTOMATIC TRANSMISSION (4L30–E)

9. Remove spring seat (19), spring (20) and throttle signal accumulator piston (21). 10. Remove sleeve pin (22) from oil pump assembly (29). 11. Remove boost valve sleeve (23), boost valve (24), spring seat (25), valve spring (26), spring seat (27), and pressure regulator valve (28).

Inspection And Repair Visual Check: If any damage, deformation or wear is found, replace the damaged part.

Reassembly 1. Lubricate and preinstall pressure regulator spring seat (27) on valve (28), with the flat side against shoulder. 2. Install pressure regulator valve (28) and spring seat (27) assembly, valve spring (26), and spring seat (25) with the flat side away from spring to oil pump assembly (29). 3. Assemble boost valve (24) into sleeve (23). 4. Install boost valve and sleeve assembly, and sleeve pin (22) to oil pump assembly (29). 5. Install throttle signal accumulator piston (21), spring (20), and spring seat (19), with the flat side away from the spring, and snap ring (18) to oil pump assembly (29). 6. Install enable valve (17), spring guide (15), enable valve spring (16) and retainer pin (14) to oil pump assembly (29). 7. Assemble torque converter regulator spring (10) and torque converter regulator valve (11) into sleeve (9). 8. Install isolator valve (13), isolator valve spring (12) and the torque converter regulator sleeve and valve assembly into the oil pump assembly (29). 9. Install torque converter clutch control valve spring (7), torque converter clutch control valve (6), plug (4) and seal ring (5), and retainer pin (3) to oil pump assembly (29). 10. Install oil pump driven gear (2) and drive gear (1).

AUTOMATIC TRANSMISSION (4L30–E)

7A–71

Main Case Valve Body Disassembled View

244RS010

Legend (1) Gaskets and Transfer Plate (2) Manual Valve (3) Band Control Solenoid (4) Pin (5) Waved Washer (6) Spring Pin (7) Solenoid A (8) Retainer (9) 1–2/3–4 Shift Valve (10) Spring (11) Spring Pin (12) Solenoid B (13) Retainer (14) 2–3 Shift Valve

Disassembly 1. Remove two 11mm bolts from valve body (28), then remove gaskets and transfer plate (1). 2. Remove manual valve (2). 3. Push in band control solenoid (3) to compress waved washer (5), and remove pin (4). 4. Remove band control solenoid (3) and waved washer (5).

(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)

Spring Spring Pin Plug Spring Low Pressure Control Valve Spring Pin Plug Band Control Screen Assembly Spring Pin Plug 1–2 Accumulator Valve 1–2 Accumulator Control Valve Check Ball Main Case Valve Body

5. Remove spring pin (6) with a 3 mm dia punch. 6. Remove solenoid A (7) by grasping the metal tip. Do not grasp the connector housing. 7. Remove retainer (8), 1–2/3–4 shift valve (9), and spring (10). 8. Remove spring pin (11) with a 3 mm dia punch. 9. Remove solenoid B (12) by grasping the metal tip. Do not grasp the connector housing.

7A–72

AUTOMATIC TRANSMISSION (4L30–E)

10. Remove retainer (13), 2–3 shift valve (14), and spring (15). 11. Remove spring pin (16), plug (17), spring (18), and low pressure control valve (19). 12. Remove spring pin (20), plug (21), and band control screen assembly (22). 13. Remove spring pin (23), plug (24), 1–2 accumulator valve (25), and 1–2 accumulator control valve (26). 14. Remove check ball (27) from valve body (28).

9. Install gasket (valve body/transfer plate) and transfer plate using two J–3387–2 guide pins. B Install two 11mm bolts. Torque: 13 N•m (113 lb in)

Inspection And Repair Inspect for the following, and replace any damaged or worn parts: 1. Damage or wear to each valve. 2. Damage in oil passeges. 3. Cracks or damage to valve body. 4. Valve operations. 5. Spring fatigue.

Reassembly 1. Install 1–2 accumulator control valve (26), 1–2 accumulator valve (25), plug (24), and spring pin (23). 2. Install band control screen assembly (22), plug (21), and spring pin (20). 3. Install low pressure control valve (19), spring (18), plug (17), and spring pin (16). 4. Install spring (15), 2–3 shift valve (14), retainer (13), solenoid B (12), and spring pin (11). 5. Install spring (10), 1–2/3–4 shift valve (9), retainer (8), solenoid A (7), and spring pin (6). 6. Install waved washer (5), band control solenoid (3), and pin (4). 7. Install manual valve (2). 8. Install check ball (27) to valve body (28).

244RS004

B Install gasket (transfer plate/main case).

AUTOMATIC TRANSMISSION (4L30–E)

7A–73

Adapter Case Valve Body Disassembled View

243RY001

Legend (1) Bracket (2) Converter Clutch PWM Solenoid (3) Retainer (4) Force Motor Solenoid (5) Retainer (6) Plug (7) 3/4 Accumulator Valve (8) 3/4 Accumulator Control Valve

Disassembly 1. Remove 11mm bolt from valve body. B Remove bracket (1) and converter clutch PWM solenoid (2). 2. Remove 11mm bolt and retainer (3) from valve body. B Remove force motor solenoid (4). 3. Remove retainer (5), plug (6), 3/4 accumulator valve (7), and 3/4 accumulator control valve (8). 4. Remove spring (9), retaining ring (10), and feed limit valve (11). 5. Remove plug retainer (12), O–ring (13), plug (14), and force motor screen assembly (15). B Use 5 mm bolt to pull plug.

(9) (10) (11) (12) (13) (14) (15) (16)

Spring Retaining Ring Feed Limit Valve Plug Retainer O–Ring Plug Force Motor Screen Assembly Adapter Case Valve Body

7A–74

AUTOMATIC TRANSMISSION (4L30–E)

Reassembly 1. Install force motor screen assembly (15), plug (14), O–ring (13), and plug retainer (12). 2. Install feed limit valve (11), retaining ring (10), and spring (9). 3. Install 3/4 accumulator control valve (8), 3/4 accumulator valve (7), plug (6), and retainer (5). 4. Install force motor solenoid (4). B Place solenoid terminals pointing towards mating face. B Install retainer (3) and bolt. Torque: 10 N•m (87 lb in) 5. Install converter clutch PWM solenoid (2) with two O–rings (2) and bracket (1) to valve body. B Install bolt. Torque: 10 N•m (87 lb in)

AUTOMATIC TRANSMISSION (4L30–E)

7A–75

Third Clutch And Sprag Unit Disassembled View

248RW001

Legend (1) Retaining Ring (2) Input Sun Gear and Sprag Unit Assembly (3) Retaining Washer (4) Bearing

(5) (6) (7) (8)

Thrust Washer Clutch Plates Third Clutch Spring Cushion Plate Third Clutch Drum Assembly

Disassembly 1. Place the third clutch drum and intermediate shaft assembly upright, using the overdrive internal gear as a support. 2. Locate the ends of the retaining ring. Depress one end of the ring using a small screwdriver instead of the depressor handle provided with the tool J-38450-A. Slide one blade down between the third clutch drum and the retaining ring. 3. Remove a screwdriver and repeat this step for the other end of retaining ring. 4. Install the remaining four blades approximately (five) notches apart using a screwdriver to depress the retaining ring. 5. Pull up on input sun gear and sprag unit assembly (1 and 2) to release the retaining ring from third clutch drum assembly (8). 6. Remove the tool blades.

248RX001

7. Remove retaining washer (3), bearing (4), thrust washer (5), and clutch plates (6 and 7) from the third clutch drum assembly (8).

Inspection And Repair Visual Check: If any damage, deformation or wear is found, replace the damaged part.

7A–76

AUTOMATIC TRANSMISSION (4L30–E)

Reassembly 1. Place third clutch drum and intermediate shaft assembly upright, using the overdrive internal gear as a support. 2. Install third clutch spring cushion plate (7), bevel face down. 3. Install third clutch plates (6) into third clutch drum assembly (8). Start with the steel clutch plate and alternate with lined plates. 4. Install thrust washer (5), bearing (4), and retaining washer (3). 5. Fully engage the hub splines of the input sun gear and sprag unit assembly (2) into the third clutch inner tangs. B Simultaneously rotate the outer sprag race to engage into the third clutch drum assembly (8). 6. Place J-38450-A blades between the retaining ring and the third clutch drum apporximately (five) notches apart, and one blade at each end of the retaining ring (1). Push down on sprag assembly until the assembly is seated into the third clutch drum assembly (8). 7. Remove the tool blades and engage retaining ring into groove of third clutch drum.

248RX002

AUTOMATIC TRANSMISSION (4L30–E)

7A–77

Third Clutch Disassembled View

248RS006

(3) Springs (4) Piston Assembly (5) Third Clutch Drum

Legend (1) Retaining Ring (2) Spring Seat

2. Release the spring seat (2).

Disassemble 1. Compress spring seat using the J–23075 spring compressor and J–23075–12 adapter tool. NOTE: Do not over–stress the springs and seat. This will cause damage to the spring seat. B Remove the tool.

NOTE: Do not let the spring seat catch in the ring groove. B Remove spring seat (2) and springs (3). 3. Remove piston assembly (4) from third clutch drum (5).

Inspection And Repair

B Remove retaining ring (1).

Visual check: If any damage, deformation or wear is found, replace the damaged part.

Operation check: Shake the piston and listen for check ball movement indicates proper check ball operation. Replace the piston if the check ball is missing or falls out.

Reassembly 1. The lip of the piston seal must point toward the front of the transmission. Lubricate the seal lip with transmission fluid. B Install piston assembly (4) into the third clutch drum (5). Use the J–23084 third clutch piston installer to protect the outer seal during installation. B Remove the seal installer. 248RS007

7A–78

AUTOMATIC TRANSMISSION (4L30–E)

248RS008

2. Install twelve springs (3) and spring seat (2). 3. Place retaining ring (1) onto spring seat. B Compress the piston springs, using the J–23075 piston spring compressor and J–23075–12 adapter. CAUTION: Do not over stress the springs and seat. Do not let the spring seat catch in the ring groove. This may cause damage to the spring seat. B Install spring seat retaining ring (1). B Remove the piston spring compressor and adapter.

AUTOMATIC TRANSMISSION (4L30–E)

7A–79

Sprag Unit Disassembled View

248RS009

Legend (1) Retaining Ring (2) Sprag Outer Race (3) Ring

Disassembly 1. Remove the sprag outer race, retaining ring, and sprag assembly from the third clutch hub and sun gear assembly. 2. Remove the rings and sprag assembly from the sprag outer race.

(4) Sprag Assembly (5) Ring (6) Third Clutch Hub and Sun Gear Assembly

NOTE: Check correct rotation by holding the sun gear in your left hand and turning the outer race. The outer sprag race should turn freely towards you and should lock turning away from you.

Inspection And Repair Visual Check: If any damage, deformation or wear is found, replace the damaged part.

Reassembly NOTE: Flared shoulder of the sprag cage faces the sun gear. This procedure must be followed exactly to be sure that the sprag assembly is installed properly. 1. Install rings and sprag assembly onto the third clutch hub and sun gear. 2. Install sprag outer race and retaining ring assembly over the sprag cage assembly. B Place third clutch hub and sun gear assembly on a flat surface, sun gear facing up. Place sprag outer race and sprag assembly over the sun gear assembly, push down and turn the input sun counterclockwise at the same time.

248RS010

7A–80

AUTOMATIC TRANSMISSION (4L30–E)

Second Clutch Disassembled View

247RW001

Legend (1) Retaining Ring (2) Ring Gear (3) Retaining Ring (4) Spacer (5) Clutch Plates

(6) (7) (8) (9) (10) (11)

Waved Washer Retaining Ring Spring Seat Springs Piston Assembly Second Clutch Drum

Disassembly 1. Remove retaining ring (1) from second clutch drum (11). 2. Remove ring gear (2), retaining ring (3), and spacer (4). 3. Remove clutch plates (5) and waved washer (6). 4. Remove retaining ring (7) using J–23327 compressor to compress the spring seat (8). 5. Remove spring seat (8), springs (9) and piston assembly (10) from second clutch drum (11).

247RS006

AUTOMATIC TRANSMISSION (4L30–E)

Inspection And Repair Visual Check: If any damage, deformation or wear is found, replace the damaged part.

7A–81

2. Install twenty–two piston springs (9) and spring seat (8) on the second clutch piston (10). Place retaining ring (7) onto spring seat. B Use the J–23327 compressor to compress the piston springs. NOTE: Do not let spring seat catch in ring groove.

Operation Check: Shake the piston and listen for check ball movement. Movement indicates proper check ball operation. Replace the piston if the check ball is missing or falls out.

Reassembly 1. Install piston assembly (10) into the second clutch drum (11). B Lubricate the lip seal with transmission fluid. Use the J–23080–A second clutch piston installer to protect the outer piston lip seal. NOTE: Lip of the seal should point toward front of transmission. B Remove the installer.

247RS007

B Remove the compressor. 3. Install waved plate (6) and clutch plates (5). Start with a steel plate and alternate with lined plates. B Align second clutch inner tangs. 4. Install spacer (4), with the fluted end toward clutch plates. 5. Install retaining ring (3), ring gear (2) and retaining ring (1).

7A–82

AUTOMATIC TRANSMISSION (4L30–E)

3–4 Accumulator Piston Disassembled View

244RS005

(3) Spring (4) Piston Assembly

Legend (1) Snap Ring (2) Cover

Disassembly 1. Install the J–38559–A cover compressor on adapter case. B Compress piston cover then remove snap ring.

2. Install the J–41096 cover remover and J–38584 adapter to center hole of cover. B Use the J–23907 slide hammer to remove cover. 3. Remove spring and piston assembly.

242RW001 242RS007

AUTOMATIC TRANSMISSION (4L30–E)

Inspection And Repair Visual Check: If any damage, deformation or wear is found, replace the damaged part.

Reassembly 1. Place the J–38553 piston fitter into adaptor case and push the piston into position, using suitable diameter tube. B Remove the piston fitter.

244RS006

2. Install spring and cover. 3. Install snap ring, using the J–38559–A compressor tool. B Install snap ring in groove. B Remove the compressor tool.

242RS007

7A–83

7A–84

AUTOMATIC TRANSMISSION (4L30–E)

Reverse Clutch Piston And Center Support Disassembled View

242RY001

Legend (1) Retaining Ring (2) Spring Seat (3) Springs (4) Piston Assembly (5) Center Support (6) Gasket (7) Transfer Plate (8) Gasket

Disassembly 1. Install the J–23327 compressor tool on spring seat, then compress the spring seat. B Remove retaining ring (1). NOTE: Do not over–stress the springs and seat, as this will cause damage to the spring seat. B Remove the compressor tool.

(9) (10) (11) (12) (13) (14) (15) (16) (17)

Restrictor Retainer Plate Plug Spring Overrun Lock Out Valve Retainer Plate Plug Spring Reverse Lock Out Control Valve

AUTOMATIC TRANSMISSION (4L30–E)

247RS008

2. Remove spring seat (2) and springs (3). 3. Remove piston assembly (4). 4. Remove 8 bolts from center support (5), then remove center support (5) from adapter case. 5. Remove gasket transfer plate/outer support (6), center support transfer plate (7), and gasket transfer plate/adapter case (8). 6. Remove restrictor (9) from adapter case housing. 7. Remove retainer plate (10), plug (11), spring (12), and overrun lock out valve (13) from center support (5). 8. Remove retainer plate (14), plug (15), spring (16) and reverse lock out valve (17) from center support (5).

Inspection And Repair Visual Check: If any damage, deformation or wear is found, replace the damaged part.

Reassembly 1. Install reverse lock out valve (17) and spring (16) to center support. NOTE: Ensure correct assembly of valve. The spring should be located over the long small diameter end. 2. Install plug (15) and retainer plate (14). 3. Install overrun lock out valve (13) and spring (12) to center support. NOTE: Ensure correct assembly of valve. The spring should be located over the long small diameter end. 4. Install plug (11) and retainer plate (10). 5. Place restrictor (9) in the lube overdrive channel in the adapter case housing.

7A–85

242RS005

6. Install gasket transfer plate/adapter case (8), center support transfer plate (7), and gasket transfer plate/center support (6). 7. Install center support (5) with 8 bolts. Torque : 25 N•m (18 lb ft) 8. Install piston assembly (4) into center support (5). 9. Install twenty four springs (3), spring seat (2), and retaining ring (1). B Install the J–23327 compressor and compress spring seat (2) and springs (3), then seat snap ring (1) in groove. B Remove the tool.

7A–86

AUTOMATIC TRANSMISSION (4L30–E)

Overrun Clutch And Turbine Shaft Disassembled View

252RW005

Legend (1) Snap Ring (2) Overdrive Carrier Assembly (3) Sun Gear (4) Turbine Shaft (5) Snap Ring (6) Backing Plate (7) Clutch Plates

(8) (9) (10) (11) (12) (13) (14) (15)

Snap Ring Overrun Roller Clutch Cam Roller Clutch Assembly Overrun Clutch Release Spring Retainer Diaphragm Spring Piston Assembly Overrun Clutch Drum Turbine Shaft Seal Rings

AUTOMATIC TRANSMISSION (4L30–E)

Disassembly

7A–87

Inspection And Repair

1. Position overrun clutch assembly upright, using the overdrive internal gear as a support. B Remove snap ring (1).

Overdrive Carrier Check B Check pinion end play with a feeler gauge. Clearance: 0.24mm–0.64mm (0.0094in–0.025in) If clearance is outside specified value, replace overdrive carrier assembly.

252RS009

2. Remove overdrive carrier assembly (2), sun gear (3) and turbine shaft (4). 3. Remove snap ring (5), backing plate (6), and clutch plates (7). 4. Compress diaphragm spring with the J–23327–91 compressor, then remove snap ring (8).

252RS011

Visual Check: If any damage, deformation or local wear is found, replace the damaged part.

Reassembly 1. Install turbine shaft seal rings (15) with grease (petroleum jelly).

252RS010

5. Remove overrun roller clutch cam (9) and roller clutch assembly (10). 6. Remove overrun clutch release spring retainer (11) and diaphragm spring (12). 7. Remove piston assembly (13) from overrun clutch drum (14). 8. Remove turbine shaft seal rings (15).

241RS008

7A–88

AUTOMATIC TRANSMISSION (4L30–E)

2. Install the J–38555 inner installer on the drum (14). B Pre–install piston assembly into J–38555 outer installer. B Install overrun clutch piston assembly (13). Use the outer installer while pushing piston into drum (14). B Remove the installer.

3. Install diaphragm spring (12). 4. Install overrun clutch release spring retainer (11) (lip faces upwards), overrun roller clutch assembly (10), and cam (9). 5. Place snap ring loosely on spring retainer. B Hold the J–23327–91 compressor in a vise and compress piston return spring with compressor. B Set snap ring (8) in ring groove. B Remove the compressor. 6. Install clutch plates (7), start with steel plate and alternate with lined plates. 7. Install backing plate (6). 8. Install snap ring (5). 9. Install overdrive sun gear with countersink pointing downwards. 10. Install the overdrive carrier assembly (2). NOTE: Turn the assembly in a counter–clockwise direction only until roller clutch enters the outer race. After installation, rotate the assembly and listen for loose rollers. 11. Install turbine shaft (4) and snap ring (1).

252RS012

252RS013

AUTOMATIC TRANSMISSION (4L30–E)

7A–89

Main Data And Specification General Specifications Remarks Model

THM 4L30–E

Engine

V6 3.5L 6VE1

Type

Control systems

Gear ratio

Automatic four speed overdrive in 4th gear lock–up clutch torque converter Shift control

Hydraulic

Shift pattern

Electronic

Shift quality

Electronic

Lock–up clutch

Electronic

1st

2.856

2nd

1.618

3rd

1.000

4th (O/D)

0.723

Reverse

2.000

Gear set Oil used

DOHC

Noiseless, high torque capability Name

ATF DEXRON–III

Q’ty liter (qt)

8.6 (9.1) 2,100 ± 150

Torque converter Reverse clutch

Second clutch

Third clutch

Brake band

Stall speed (rpm)

Number of discs

Double wrap

Fourth clutch

Overrun clutch

Overdrive

OFW

Number of rollers

Principal

PFW

Number of sprags

Ravigneaux g planetary gear set

Overdrive O d i planel tary gear set

Input sun gear

Pinion gear

Long pinion

Ring gear

Long pinion

Output sun gear

Sun gear

Pinion gear

Ring gear

Number of discs

Number of teeth

7A–90

AUTOMATIC TRANSMISSION (4L30–E)

Torque Specifications

E07R200003

AUTOMATIC TRANSMISSION (4L30–E)

7A–91

E07RY003

7A–92

AUTOMATIC TRANSMISSION (4L30–E)

E07R200002

AUTOMATIC TRANSMISSION (4L30–E)

7A–93

Special Tools ILLUSTRATION

TOOL NO. TOOL NAME

ILLUSTRATION

TOOL NO. TOOL NAME

J–23075 Spring compressor (For servo piston)

J–23085–A Selective washer gauging tool

J–38450–A Third clutch snap ring compressor

J–23327–90 Fourth clutch spring compressor (Use with J–23327)

J–23075–12 Third clutch spring compressor adapter (Use with J–23075)

J–38553 3/4 Accumulator piston fitter

J–23084 Third clutch piston installer

J–41096 Cover remover (Use with J–38584)

J–23327 Third clutch spring compressor

J–38584 Slide hammer adapter (Use with J–23907)

J–23080–A Second clutch piston installer

J–38554 Fourth clutch piston fitter

7A–94

AUTOMATIC TRANSMISSION (4L30–E)

ILLUSTRATION

TOOL NO. TOOL NAME

ILLUSTRATION

TOOL NO. TOOL NAME

J–38588 Guide pins; adapter case to main case

J–23082–01 Oil pump rotation tool

J–38555 Overrun clutch piston seal installer set

J–25025–B Guide pins; valve body to main case

J–3387–2 Guide pins; gasket and transfer plate to valve body

J–38428 Servo piston fitter

J–25022 Turbine shaft puller (Use with J–24773–1)

J–23327–91 Overrun clutch spring compressor

J–23129 Oil seal remover (Use with J–23907 and J–38584)

J–38559–A 3/4 Accumulator piston cover compressor

J–38557 Oil pump centering tool

J–8763–02 Holding fixture

AUTOMATIC TRANSMISSION (4L30–E) ILLUSTRATION

TOOL NO. TOOL NAME

J–36797 A/T extension assembly oil seal installer (Inside)

J–3289–20 Holding fixture base

J–29770–A Pressure gauge

J–24773–1 End play fixture (Use with J–25022)

J–23907 Slide hammer

7A–95

7A–96

AUTOMATIC TRANSMISSION (4L30–E)

4L30–E Parts List Case And Associated Parts

241RY00021

Legend (1) Torque Converter (2) Screw, Seal Ring Assembly (3) Seal Ring Assembly, Converter Housing (4) Screw, Converter Housing/Main Case (5) Screw, Converter Housing/Oil Pump (6) Housing, Converter (7) Plug, Converter Housing (8) Seal, O–Ring (9) Wear Plate, Oil Pump Body (10) Pump Assembly, Oil (11) Gasket (12) Washer, Thrust Selective (13) Ring, Snap (14) Cover, 3–4 Accumulator Piston (15) Seal, O–Ring, 3–4 Accumulator (16) Spring, 3–4 Accumulator Piston

(17) (18) (19) (20) (22) (23) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37)

Pin, 3–4 Accumulator Piston Piston, 3–4 Accumulator Ring, 3–4, Accumulator Piston Case, Adapter Connector, Electrical/Adapter Case Screw, Pan Restrictor, Oil Gasket, Transfer Plate/Adapter Plate, Transfer Adapter/Center Support Support Assembly, Center Screw, Center Support Ring, Oil Seal Seal, O–Ring Main Case Fitting, Cooler Fitting Assembly, Cooler Case, Main Breather, Pipe

AUTOMATIC TRANSMISSION (4L30–E) (38) (39) (42) (43) (44) (45) (46) (47) (48) (49) (50) (52) (53) (54) (55) (56) (57) (58) (59) (60) (61) (62) (63) (64) (65) (67) (68) (69) (70) (71) (72) (73)

Seal, O–Ring Reservoir Gasket, Extension Case Extension Assembly Seal, O–Ring/Speed Sensor Sensor Assembly, Speed Screw, Speed Sensor Nut, Output Shaft/Drive Flange Seal, O–Ring/Drive Flange Flange, Drive Seal, Extension Assembly Screw, Extension/Main Case Spring, Parking Pawl Lock Pawl, Parking Lock Connector, Electrical/Main Case Actuator Assembly, Parking Lock Nut, Parking Lock Lever Link, Manual Valve Pin, Spring Lever, Parking Lock and Range Selector Shaft, Selector Seal, Selector Shaft Mode Switch Assembly Screw and Conical Washer Assembly Shield, Mode Switch Pan, Bottom/Adapter Case Gasket, Bottom Pan/Adapter Case Harness Assembly, Adapter Case Screw, Valve Body Valve Body Assembly, Adapter Case Gasket, Adapter Valve Body Plate, Adapter Valve Body/Transfer

(74) (75) (76) (77) (78) (79) (80) (82) (84) (85) (86) (87) (88) (89) (90) (91) (92) (93) (94) (95) (96) (97) (98) (99) (100) (101) (102) (103) (104) (105) (106)

7A–97

Pan, Bottom/Main Case Gasket, Bottom Pan/Main Case Gasket, Oil Drain or Overfill Screw Screw, Oil Drain or Overfill Magnet, Chip Collector Filter Oil Harness Assembly, Main Case Roller and Spring Assembly, Manual Detent Valve Body Assembly, Main Case Ball, Check Gasket, Main V.B./Transfer Plate Plate, Main V.B./Transfer Gasket, Transfer/Main Case Screw, Transfer Plate on V.B. Screw, Servo Cover Cover, Servo Piston Gasket, Cover/Servo Piston Ring, Retaining Servo Piston Clip, Servo Piston Nut, Servo Screw Screw, Servo Piston Piston, Servo Seal, Ring/Servo Piston Spring, Cushion/Servo Piston Seat, Cushion Spring Sleeve, Servo Piston Adjust Rod, Apply/Servo Piston Spring, Return/Servo Piston Gasket, Adapter Case/Transfer Plate Powertrain Control Module Servo Piston Assembly

7A–98

AUTOMATIC TRANSMISSION (4L30–E)

Pump Assembly

241RY003

Legend (201) Gear, Oil Pump Drive (202) Gear, Oil Pump Driven (203) Pin, Plug Converter Clutch Control (204) Plug, Converter Clutch Control Valve (205) Spring, Converter Clutch Control Valve (206) Valve, Converter Clutch Control (207) Ring, Snap/Throttle Signal Accumulator (208) Seat, Spring/Throttle Signal Accumulator (209) Spring, Throttle Signal Accumulator (210) Piston, Throttle Signal Accumulator (211) Pin, Boost Valve Sleeve (212) Sleeve, Boost Valve (213) Valve, Boost (214) Seat, Spring/Pressure Regulator Valve

(215) (216) (217) (218) (219) (220) (221) (222) (223) (224) (225) (226) (227) (228) (229)

Spring, Pressure Regulator Valve Seat, Spring/Pressure Regulator Valve Valve, Pressure Regulator Isolator Valve Spring, Isolator Valve, Converter Clutch Regulator Spring, Converter Clutch Regulator Sleeve, Converter Clutch Regulator Pin, Retainer Sleeve Valve, Enable Spring, Enable Valve Spring Guide, Enable Valve Pin, Enable Valve Pump Assembly Seal Ring, Plug

AUTOMATIC TRANSMISSION (4L30–E)

7A–99

Valve Body Assemblies

244RS009

Legend (301) Body, Valve Main Case (302) Pin, Spring (303) Solenoid Assembly, ON/OFF N.C. (304) Valve, 1–2 and 3–4 Shift (305) Spring, 1–2 and 3–4 (2–3) Shift (306) Retainer, Valve (307) Solenoid Assembly, ON/OFF N.O. (308) Valve, 2–3 Shift (309) Pin, Spring (310) Plug, Valve Bore

(311) (312) (317) (318) (320) (321) (322) (323) (324) (325) (326)

Spring, Valve Low Pressure Control Valve, Low Pressure Control Ball, Check Valve, 1–2 Accumulator Control Valve, 1–2 Accumulator Washer, Waved PWM Solenoid Pin, Solenoid PWM Solenoid Assembly, Band Control PWM Screen Assembly, PWM Solenoid Plug, Screen Valve, Manual

7A–100

AUTOMATIC TRANSMISSION (4L30–E)

243RY002

Legend (401) Body, Valve/Adapter Case (402) Screw, Solenoid Force Motor (403) Retainer, Force Motor (404) Solenoid, Force Motor (405) Plug, 3–4 Accumulator (406) Plug and Spring Retainer (407) Valve, 3–4 Accumulator (409) Valve, 3–4 Accumulator Control

(410) (411) (412) (413) (414) (415) (416) (417) (418)

Spring, Feed Limit Valve Ring, Retainer Valve, Feed Limit Seal, O–Ring Plug Filter Plug, Screen Screen Assembly, Force Motor Solenoid, Torque Converter Clutch, PWM Retainer, Screen Plug Bracket, PWM Solenoid

AUTOMATIC TRANSMISSION (4L30–E)

7A–101

Overdrive Internal Components

252RW003

Legend (501) Retainer, 4th Clutch (502) Plate, 4th Clutch (Steel) (503) Plate Assembly, 4th Clutch (Lined) (504) Retainer And Ball Assembly, Check Valve (505) Seal, O–Ring/Turbine Shaft (506) Shaft, Turbine (508) Ring, Oil Seal/Turbine Shaft (510) Housing, Overrun Clutch (513) Piston, Overrun Clutch (514) Spring, Overrun Clutch Release (515) Retainer, Release Spring/Overrun Clutch (516) Roller Assembly, Overdrive Clutch (517) Cam, Overdrive Roller Clutch (518) Ring, Snap/Overrun Clutch Hub (519) Gear, Overdrive Sun

(520) (521) (522) (523) (524) (525) (526) (527) (528) (529) (530) (531) (532) (533) (534)

Plate, Waved/Overrun Clutch Plate, Overrun Clutch (Steel) Plate Assembly, Overrun Clutch (Lined) Plate, Backing/Overrun Clutch Ring, Snap/Overrun Clutch Housing Carrier Assembly, Overdrive Complete Ring, Snap/Turbine Shaft/Carrier Bearing Assembly, Thrust Gear, Overdrive Internal Washer, Thrust/Internal Gear/Support Ring, Snap/Adapter/4th Clutch Spring Retainer and spring assembly, 4th clutch Piston, 4th Clutch Seal, 4th Clutch Piston (Inner) Seal, 4th Clutch Piston (outer)

7A–102

AUTOMATIC TRANSMISSION (4L30–E)

Internal Components

247RW002

Legend (608) Seal, Reverse Clutch Piston (Inner) (609) Seal, Reverse Clutch Piston (Outer) (610) Piston, Reverse Clutch (611) Spring, Piston Clutch (612) Seat, Spring/Reverse Clutch (613) Ring, Retaining (614) Plate, Waved/Reverse Clutch (615) Plate, Reverse Clutch (Steel) (616) Plate Assembly, Reverse Clutch (Lined) (617) Plate, Reverse Clutch Pressure/Selective (618) Drum Assembly, 2nd Clutch (620) Seal, 2nd Clutch Piston (Inner) (621) Seal, 2nd Clutch Piston (Outer) (622) Piston, 2nd Clutch (623) Seat, Spring/2nd Clutch (625) Plate, Waved/2nd Clutch (626) Plate, 2nd Clutch (Steel)

(627) (628) (629) (630) (631) (632) (634) (635) (636) (637) (638) (639) (640) (641) (642) (643) (644) (645)

Plate Assembly, 2nd Clutch (Lined) Spacer, 2nd Clutch Ring, Retaining Gear, Ring Washer, Thrust/2nd Clutch/3rd Clutch Thrust Washer, Clutch Hub Drum Assembly, 3rd Clutch Seal, 3rd clutch piston (Inner) Washer, Retaining Seal, 3rd Clutch Piston (Outer) Piston 3rd Clutch Seat, Spring/3rd Clutch Ring, Retaining Plate, Spring Cushion/3rd Clutch Plate, 3rd Clutch (Steel) Plate Assembly, 3rd Clutch (Lined) Washer, Thrust/Input Sun Bearing, Input Shaft/Gear Assembly

AUTOMATIC TRANSMISSION (4L30–E) (646) (647) (648) (649) (650) (651) (652) (653)

Gear Assembly, Input Sun Race Assembly, Sprag Ring, Retaining/Sprag Ring, Retaining Cage Assembly, Sprag Bearing, Output Shaft/Input Sun Washer, Output Shaft/Input Sun Carrier Assembly, Planetary

(658) (659) (664) (667) (668) (672) (673) (675)

7A–103

Gear, Reaction Sun Drum, Reaction Sun Band Assembly, Brake Seal, Ring/Wheel Parking Lock Wheel, Parking Lock Wheel, Speed Ring, Retaining Bearing, Thrust Assembly

Center Support Assembly

242RY002

Legend (701) Center Support (702) Retainer Plate (703) Plug, Lockout

(704) Spring, Lockout (705) Valve, Overrun Lockout (706) Valve, Reverse Lockout Control

SECTION TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–1

AXIOM

TRANSMISSION TRANSMISSION CONTROL SYSTEM (4L30–E) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Electronic Control Diagram . . . . . . . . . . . . . Powertrain Control Module (PCM) . . . . . . . Control System Diagram . . . . . . . . . . . . . . . Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . Band Apply Control . . . . . . . . . . . . . . . . . . . . Torque Converter Clutch Control (Electronically Controlled Capacity Clutch = ECCC) . . . . . . . . . . . . . . . . . . . . . . Line Pressure Control . . . . . . . . . . . . . . . . . . On–Board Diagnostic System . . . . . . . . . . . Fail Safe Mechanism . . . . . . . . . . . . . . . . . . . Torque Management Control . . . . . . . . . . . . ATF Warning Control . . . . . . . . . . . . . . . . . . . Reverse Lock Out Control . . . . . . . . . . . . . . Downhill Control . . . . . . . . . . . . . . . . . . . . . . . Uphill Control . . . . . . . . . . . . . . . . . . . . . . . . . Shift Mode Control . . . . . . . . . . . . . . . . . . . . . Gear Shift Control . . . . . . . . . . . . . . . . . . . . . Winter Drive Mode . . . . . . . . . . . . . . . . . . . . . Backup Mode . . . . . . . . . . . . . . . . . . . . . . . . . Functions of Input / Output Components . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Diagnosis . . . . . . . . . . . . . . . . . . . Check Trans Indicator . . . . . . . . . . . . . . . . . . Diagnostic Check . . . . . . . . . . . . . . . . . . . . . . “Check Trans” Check . . . . . . . . . . . . . . . . . . Tech 2 OBD II Connection . . . . . . . . . . . . . . Transmission Data . . . . . . . . . . . . . . . . . . . . . OBD II Diagnostic Management System . . 16 – Terminal Data Link Connector (DLC) . Malfunction Indicator Lamp (MIL) . . . . . . . . DTC Types . . . . . . . . . . . . . . . . . . . . . . . . . . . Clear DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC Check . . . . . . . . . . . . . . . . . . . . . . . . . . . PCM Precaution . . . . . . . . . . . . . . . . . . . . . . . Information On PCM . . . . . . . . . . . . . . . . . . . Intermittent Conditions . . . . . . . . . . . . . . . . . Transmission And PCM Identification . . . . . Diagnostic Trouble Code (DTC) Identification . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0218 Transmission Fluid Over Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . .

7A1–2 7A1–2 7A1–3 7A1–4 7A1–5 7A1–6 7A1–6

7A1–6 7A1–6 7A1–6 7A1–6 7A1–6 7A1–6 7A1–6 7A1–6 7A1–6 7A1–7 7A1–8 7A1–9 7A1–9 7A1–10 7A1–11 7A1–11 7A1–11 7A1–11 7A1–12 7A1–13 7A1–18 7A1–19 7A1–20 7A1–21 7A1–21 7A1–22 7A1–22 7A1–22 7A1–22 7A1–23 7A1–23 7A1–24 7A1–25

DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position . . . . . . . . . . . . DTC P0706 Transmission Range Switch (Mode Switch) Performance . . . . . . . . . . . . . . DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance . . . . . . . . . . . . . . DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input . . . . . . . . . . . DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input . . . . . . . . . . . DTC P0719 Brake Switch Circuit Low (Stuck On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input . . . . . . . . . . DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent . . . . . . . . . DTC P0724 Brake Switch Circuit High (Stuck Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0730 Gear Error Without Input Speed DTC P0742 Torque Converter Clutch (TCC) System Stuck On . . . . . . . . . . . . . . . . . . . . . . . DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical . . . . . . . . . . . DTC P0751 Shift Solenoid A Performance (Stuck Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0752 Shift Solenoid A Performance (Stuck On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0753 Shift Solenoid A Electrical . . . . . DTC P0756 Shift Solenoid B Performance (Stuck Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0757 Shift Solenoid B Performance (Stuck On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P0758 Shift Solenoid B Electrical . . . . . DTC P1850 Brake Band Apply Solenoid Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . DTC P1860 TCC PWM Solenoid Electrical . DTC P1870 Transmission Component Slipping (TCC Stuck Off) . . . . . . . . . . . . . . . . . . . . . . . . Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . Harness Connector Faces . . . . . . . . . . . . . . . . Transmission Fluid Temperature (TFT) Sensor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .

7A1–27 7A1–30 7A1–33 7A1–36 7A1–39 7A1–42 7A1–45 7A1–48 7A1–51 7A1–53 7A1–56 7A1–58 7A1–60 7A1–62 7A1–64 7A1–67 7A1–69 7A1–71 7A1–75 7A1–79 7A1–82 7A1–84 7A1–86 7A1–87 7A1–89

7A1–2

TRANSMISSION CONTROL SYSTEM (4L30–E)

Service Precaution

General Description

The 4L30–E is a 4–speed fully automatic transmission. It uses a microcomputer as a control unit to judge running conditions including throttle opening rate and vehicle speed, then it sets the shifting point in the optimum timing so that best driving performance can be achieved. In addition, the built–in shift mode select function can select three shift modes according to the driver’s preference: B Normal mode –Normal shift pattern. B Winter mode –Starts in 3rd gear to reduce slippage on ice or snow. B Power mode has a delayed upshift when more powerful acceleration is required. Also, the built–in fail safe function (“backup mode”) assures driving performance even if the vehicle speed sensor, throttle signal or any solenoid fails. Further, the self–diagnostic function conducts diagnosis in a short time when the control system fails, thus improving serviceability. The major features of 4L30–E are as follows: B A compact structure consisting of 2 sets of planetary gears and flat torque converter. B Electronic control selects the optimum shift mode according to the driving conditions. B Electronic control maintains the optimum hydraulic pressure for clutch, band brake as well as transmission so that shift feeling is improved. B Two sets of planetary gears reduce friction of power train. Also, a lockup mechanism in the torque converter reduces fuel consumption.

B Wide gear ratio and high torque rate of torque converter provide excellent starting performance.

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–3

Electronic Control Diagram

C07R200003

7A1–4

TRANSMISSION CONTROL SYSTEM (4L30–E)

Powertrain Control Module (PCM)

C07R200004

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–5

Control System Diagram

C07R100005

7A1–6

TRANSMISSION CONTROL SYSTEM (4L30–E)

Shift Control

Fail Safe Mechanism

The transmission gear is shifted according to the shift pattern selected by the driver. In shifting gears, the gear ratio is controlled by the ON/ OFF signal using the shift solenoid A and the shift solenoid B.

If there is a problem in the transmission system, the PCM will go into a “backup” mode. The vehicle can still be driven, but the driver must use the select lever to shift gears.

Band Apply Control

Torque Management Control

The band apply is controlled when in the 3–2 downshift (engine overrun prevention) and the garage shift (shock control). The band apply solenoid is controlled by the signal from the Pulse Width Modulation (PWM) to regulate the flow of the oil.

The transmission control side sends the absolute spark advance signal to the engine control side while the transmission is being shifted. This controls the engine spark timing in compliance with the vehicle running condition to reduce the shocks caused by the change of speed.

Torque Converter Clutch Control (Electronically Controlled Capacity Clutch = ECCC)

ATF Warning Control

The clutch apply is controlled by moving the converter clutch valve by commanding Torque Converter Clutch (TCC) solenoid using the PWM signal.

Line Pressure Control The throttle signal allows the current signal to be sent to the force motor. After receiving the current signal, the force motor activates the pressure regulator valve to regulate the line pressure.

On–Board Diagnostic System Several malfunction displays can be stored in the Powertrain Control Module (PCM) memory, and read out of it afterward. The serial data lines, which are required for the testing of the final assembly and the coupling to other electronic modules, can be regulated by this function.

The oil temperature sensor detects the ATF oil temperature to control the oil temperature warning, TCC, and the winter mode.

Reverse Lock Out Control With the selector lever in reverse position, the PCM will not close the PWM solenoid until the vehicle is below 11 km/h (6.8 mph), thus preventing reverse engagement above this speed.

Downhill Control This mode is automatically activated from “NORMAL” mode only when downhill conditions are recognized. The shift pattern is identical to “NORMAL” mode except 3-4 and 4-3 shift lines at low throttle modified to get engine braking on a larger speed range. ECCC lines unchanged compared to “NORMAL” mode.

Uphill Control When Uphill condition are recognized the 2-3 and 3-4 shift and TCC apply take place only when the engine torque is sufficient in order to avoid shift hunting.

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–7

Shift Mode Control

F07RX001

7A1–8

TRANSMISSION CONTROL SYSTEM (4L30–E)

Gear Shift Control

F07RT034

TRANSMISSION CONTROL SYSTEM (4L30–E)

Winter Drive Mode 1. Operation The winter switch will operate when switched on after all of the following conditions are present: Conditions: a. The select lever position is “D” range only. b. Vehicle speed is 7 mph (11 km/h) or less. c. Transmission oil temperature is 130°C (266°F) or less. d. Accelerator opening is at 8% or less. 2. Cancel Release 1. Cancellation by driver a. Turning off the winter drive mode switch b. Shifting select position to “3”, “2”, or “L” (winter drive mode is not canceled by selecting “N”, “R”, or “P”). c. Ignition key is turned off. 2. Automatic cancellation a. When vehicle runs at 21mph (34 km/h) or more for 1 second or more b. When transmission oil temperature reaches 130°C (266°F) or above NOTE: The mode returns to normal drive mode or power drive mode after the winter drive mode is canceled.

Backup Mode If a major system failure occurs which could affect safety or damage the transmission under normal vehicle operation, the diagnostic system detects the fault and overrides the Powertrain Control Module (PCM). The “CHECK TRANS” light flashes to alert the driver, and the transmission must be manually shifted as follows: Select lever position

Gear Ratio Selected

4 (Fourth)

Manual 3

4 (Fourth)

Manual 2

3 (Third)

Manual L

1 (First)

Reverse

Shifts are firmer to prevent clutch slip and consequent wear. The fault should be corrected as soon as possible.

7A1–9

7A1–10 TRANSMISSION CONTROL SYSTEM (4L30–E)

Functions of Input / Output Components Components

Function

Speed sensor (fixed to transmission)

Senses rotation of output shaft and feeds the data to Powertrain Control Module (PCM).

Throttle position sensor (TPS) (fixed to engine)

Senses the extent of throttle valve opening and the speed of the throttle valve lever motion to open the valve. Feeds the data to PCM.

Brake switch I (fixed to brake pedal) N P Mode switch (fixed to U transmission) T Power drive switch (fixed to front console) S T/M oil temperature sensor I G Engine coolant N temperature sensor A Engine speed signal L Air conditioning information

Senses whether the driver has pressed the brake pedal or not and feeds the information to PCM.

Senses whether the driver has selected the power mode, and feeds the information to PCM. Senses the T/M oil temperature and feeds the data to PCM Senses the engine coolant temperature, and feeds the data to PCM. Feeds the signals monitoring engine speed to PCM from crank angle sensor. Senses whether the air conditioner has been switched on or not, and feeds the information to PCM.

Winter switch (fixed to front console)

Senses whether the driver has selected the winter mode, and feeds the information to PCM.

Cruise controller (Overdrive OFF signal)

Downshift takes place when overdrive OFF signal is received from auto cruise controller integrated in PCM.

O U T P S O U T L E N S I O I G D N A L

Senses the select lever position, and feeds the information to PCM.

Shift solenoid A, B

Selects shift point and gear position suited to the vehicle running condition on the basis of PCM output.

Band apply solenoid

Controls oil flow suited to the vehicle running condition on the basis of PCM output.

Torque Converter Clutch PWM solenoid

Controls clutch apply suited to the vehicle running condition on the basis of PCM output.

Force motor (Pressure regulator valve)

Adjusts the oil pump delivery pressure to line pressure suited to the vehicle running condition on the basis of PCM output.

TRANSMISSION CONTROL SYSTEM (4L30–E)

Diagnosis Electronic Diagnosis How To Diagnose The Problem 1. To avoid incorrect diagnostics, this book needs to be followed accurately. Unless stated, do not jump directly to a section that could contain the solution. Some important information may be missed. 2. The sections in CAPITALS and bold are the main sections that can be found in the contents. 3. The GO TO “SECTION” means to continue to check going to the “section”. 4. The GO THROUGH “SECTION” means to go through the “section” and then to go back to the place the GO THROUGH was written. 5. BASIC ELECTRIC CIRCUITS: You should understand the basic theory of electricity. This includes the meaning of voltage, amps, ohms, and what happens in a circuit with an open or shorted wire. You should also be able to read and understand wiring diagrams.

7A1–11

2. Turn on the ignition but not the engine. 3. Push “F0” on Tech 2 to see the Diagnostic Trouble Code (DTC): 4. Do you have a DTC? YES: write down all code numbers and do the DTC CHECK NO: the DTC can not help you finding the problem. 1. GO THROUGH “CHECK TRANS” CHECK 2. If it is flashing and the flash is 0.2 seconds ON and 0.2 seconds OFF, this means that you should have a DTC stored. Please recheck GO TO DIAGNOSTIC CHECK and if you find the same problem, replace the Powertrain Control Module (PCM). Normal

Check Trans Indicator Find CHECK TRANS indicator and verify if it is A. Flashing: GO TO DIAGNOSTIC CHECK. B. Staying on: GO THROUGH CHECK TRANS CHECK. C. Is never ON when the ignition key is turned on: GO THROUGH CHECK TRANS CHECK D. Is ON during 2 seconds at ignition but OFF after: Normal operation. No DTC or malfunction.

C07R200005

Abnormal

821R200014

Diagnostic Check This test determines if the transmission or its input or output connections or sensors are failing. 1. Connect the Tech 2: GO THROUGH Tech 2 OBD II CONNECTION.

C07R200006

7A1–12 TRANSMISSION CONTROL SYSTEM (4L30–E)

“Check Trans” Check

Abnormal

1. Indicator is ON during 2∼3 seconds at ignition (or when the engine is cranked) but it is OFF after the engine starts. The indicator is working normally GO TO DIAGNOSTIC CHECK.

C07R200006

3. Indicator is staying ON always when Ignition is ON. 1. This means that connection between the lamp and the indicator control unit is shorted to ground. 821R200014

Normal

2. Verify if instrument panel terminal 27 of connector I–24 is shorted to ground. 3. Verify if the indicator control unit connector B–16 terminal 20 is shorted to ground. 4. Verify that the instrument panel terminal 14 of connector I–24 is connected to battery. 5. If problem solved: GO TO CHECK TRANS INDICATOR. NO:Replace Powertrain Control Module (PCM). 4. Indicator is staying OFF with the ignition ON (engine OFF). 1. This means that connection between the lamp and the indicator control unit is shorted to battery or opened. 2. Verify if instrument panel terminal 27 of connector I–24 is shorted to battery or open. 3. Verify if the indicator control unit connector B–16 terminal 20 is shorted to battery or open.

C07R200005

2. Indicator is flashing and the flash is 0.2 seconds ON and 0.2 seconds OFF always when ignition is on (engine cranked or not). This means that there is a malfunction. GO TO DIAGNOSTIC CHECK.

4. Verify that the instrument panel terminal 14 of connector I–24 is connected to battery. If not, check the fuses and the connections (terminal 7 of connector H–17) voltage.

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–13

5. If problem solved: GO TO CHECK TRANS INDICATOR. NO: Replace Powertrain Control Module (PCM).

D07R200003

Tech 2 OBD II Connection In order to access OBD II Powertrain Control Module (PCM) data, use of the Tech 2 scan tool kit (7000086) is required. 1. The electronic diagnosis equipment is composed of: 1. Tech 2 hand held scan tool unit (7000057) and DLC cable (3000095).

2. SAE 16/19 adaptor (3000098) (1), RS 232 loop back connector (3000112) (2), and PCMCIA card (3000117) (3).

F07RW033

901RW176

7A1–14 TRANSMISSION CONTROL SYSTEM (4L30–E) 2. Connecting the TECH2

901RW180

Legend (1) PCMCIA Card (2) RS 232 Loop Back Connector B Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. The Isuzu 2002 System PCMCIA card (1) inserts into the Tech 2 (5).

(3) SAE 16/19 Adapter (4) DLC Cable (5) Tech 2

2. Connect the SAE 16/19 adapter (3) to the DLC cable (4). 3. Connect the DLC cable to the Tech 2 (5) 4. Make sure the vehicle ignition is off.

TRANSMISSION CONTROL SYSTEM (4L30–E) 5. Connect the Tech 2 SAE 16/19 adaptor to the vehicle DLC.

7A1–15

8. The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card. Follow the operating procedure below.

826R200011

6. The vehicle ignition turns on. 7. Verify the Tech 2 power up display.

060RW009

NOTE: The RS232 Loop back connector is only to use for diagnosis of Tech 2 and refer to user guide of the Tech 2.

060R200032

7A1–16 TRANSMISSION CONTROL SYSTEM (4L30–E) Once the test vehicle has been identified an “Application (Powertrain) Menu” screen appears. Please select the appropriate application. The following table shows, which functions are used for the available equipment versions. F0: Diagnostic Trouble Codes F0: Read DTC Info Ordered By Priority F1: Clear DTC Information F2: DTC Information F1: Data Display F0: Transmission Data F2: Snap Shot F3: Actuator Tests F0: Lamps F0: Check Light F1: Winter Drive Lamp F2: Power Drive Lamp F3: AT Oil Temperature Lamp F1: Solenoids F0: Solenoid 1-2/3-4 Test F1: Solenoid 2-3 Test F2: TCC Solenoid F3: Band Apply Solenoid F4: Pressure Control Solenoid (PCS) F4: Function Tests F0: Reset Oil Life Monitor

060R200033

TRANSMISSION CONTROL SYSTEM (4L30–E) Diagnostic Trouble Codes The purpose of the “Diagnostic Trouble Codes” mode is to display stored PCM trouble codes. When “Diagnostic Trouble Codes” is selected an “Application Menu” screen appears. Clear DTC Information The purpose of the “Clear DTC Information” mode is to command the clearing of stored PCM trouble codes. When “Clear DTC Information” is selected, a “Clear DTC Information”, warning screen appears. This screen informs you that by cleaning DTC’s, “all stored DTC information in controller will be erased”. Do you want to clear DTC’s (Yes/No). Press either the Yes or No key when answering. After clearing codes, confirm system operation by test driving the vehicle. Allow the vehicle to shift through all four forward gears in a manner which attempts to repeat the failure condition. NOTE: When the trouble has not been repaired and the trouble code cannot be erased, check the vehicle again. DTC Information When “DTC Information” is selected, an “Application Menu” appears with a list of DTC information function keys addressing DTC specifics and their origins. Function key selections may vary for particular vehicle and/or system. Data Display The purpose of the “Data Display” mode is to continuously monitor data parameters. The current actual values of all important sensors and signals in the system are display through F1 mode. When “Data Display” is selected an “Application Menu” appears. Please select either “Engine” or “Transmission Data Display”. See “Transmission Data” on next page. Snapshot When “Snapshot” is selected an “Application Menu” appears. When “Transmission Snapshot” application is selected from the “Application Menu”, a “Snapshot Menu” appears, displaying several options. “Snapshot” options may vary from one system to another. “Snapshot” allows a recording of all vehicle parameters. There parameters may then be replayed at a future point in time. This action allows you to focus on making the condition occur, rather than trying to view all of the data in anticipation of the fault. The snapshot will collect parameter information around a trigger point that you select. When a snapshot is taken. It is recorded onto the PCMCIA memory card. When the Tech 2 is powered down. Snapshots are not lost. Actuator Tests The purpose of “Actuator Tests” mode is to check for correct operation of electronic system actuators.

7A1–17

Lamps You can operate the lamps by pressing the ON and OFF buttons. Preconditions: none Solenoid Solenoid 1-2/3-4, Solenoid 2-3, TCC Solenoid You can operate the solenoids by pressing the ON and OFF buttons. Preconditions: P–N position, no vehicle speed, no engine speed Band Apply Solenoid You can operate the solenoid by pressing the ON and OFF buttons. Preconditions: P-N position, idle engine speed, no vehicle speed. Pressure Control Solenoid (PCS) You can set desired PCS Current using the “Increment” (+25) and “Decrement” (–25) button. The PC Solenoid Data informs about PCS Current, Pressure and Duty Cycle. Preconditions: P–N position, no engine speed, no vehicle speed Reset Oil Life Monitor Displays parameter “Oil Life Monitor” and resets to 100% if Yes-button is pressed on Reset-question. “No” leaves test. Preconditions: no vehicle speed, no engine speed NOTE: Freeze Frame (Powertrain DTC A/B Type) Freeze Frame is an element of the Diagnostic Management System which stores various vehicle information at the moment an emissions-related fault is stored in memory and when the MIL is commanded on. These data can help to identify the cause of a fault. Refer to Storing And Erasing Freeze Frame Data for more detailed information. Failure Records (Powertrain DTC C/D Type) Failure Records data is an enhancement of the OBD II Freeze Frame feature. Failure Records store the same vehicle information as does Freeze Frame, but it will store that information for any fault which is stored in on-board memory, while Freeze Frame stores information only for emission-related faults that command the MIL on.

7A1–18 TRANSMISSION CONTROL SYSTEM (4L30–E)

Transmission Data Tech 2 string

Unit

Engine running at idle 12.8 ∼ 14.1 V

Ignition Voltage

Engine Speed

RPM

Vehicle Speed

km/h, MPH

0 MPH

RPM

0 RPM

AT Output Speed (Automatic Transmission) AT Input Speed Ratio (Automatic Transmission) Throttle Position

750 ∼ 900 RPM

0.0 %

AT Oil Temperature (Automatic Transmission)

°C, °F

70 ∼ 80°C (158 ∼ 176°F)

Transmission Temperature

°C, °F

75 ∼ 110°C (167 ∼ 230°F)

AT Oil Temperature Lamp (Automatic Transmission)

On/Off

Off

AT Oil Life Monitor (Automatic Transmission) AT Oil Life Lamp (Automatic Transmission)

% On/Off

100 % (Not used)

Commanded Gear

Current Gear

Mode Switch A

Inactive/Active

Active

Mode Switch B

Inactive/Active

Inactive

Mode Switch C

Inactive/Active

Inactive

Mode Switch G

Inactive/Active

Active

Selector Position

Park

1–2 Shift Solenoid A

On/Off

Off

2–3 Shift Solenoid B

On/Off

Solenoid Brake Band

On/Off

Off

TCC Slip Speed TCC Solenoid

RPM

750 ∼ 900 RPM

On/Off

Off

TCC Duty Cycle

PCS Current (Pressure Control Solenoid)

approx. 1.0 A

PCS Duty Cycle (Pressure Control Solenoid)

approx. 45 ∼ 60 %

Desired PCS Pressure (Pressure Control Solenoid)

kPa

43 ∼ 52 kPa

Shift Pressure

kPa

43 ∼ 52 kPa

Brake Switch

On/Off

Winter Switch

On/Off

Off

Winter Drive Lamp

On/Off

Off

Power Switch

Normal

Power Drive Lamp

Off/On

Off

Emergency Mode

Inactive/Active

ABS Status

On/Off

Inactive (Not used)

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–19

OBD II Diagnostic Management System Powertrain Control Module (PCM) Location

825R100018

Class 2 Serial Data Bus OBD II technology requires a much more sophisticated PCM than does OBD I technology. The OBD II PCM diagnostic management system not only monitors systems and components that can impact emissions, but they also run active tests on these systems and components. The decision making functions of OBD II PCMs have also greatly increased. To accommodate this expansion in diagnostic complexity, Isuzu engineers have designed the Class 2 serial data bus, which meets SAE J1850 recommended practice for serial data. “Serial Data” refers to information which is transferred in a linear fashion – over a single line, one bit at a time. A “Data Bus” is an electronic pathway through which serial data travels.

826RY002

AXIOM previously used a 5 volt data bus called UART, which is an acronym for “Universal Asynchronous Receive and Transmit”. When neither the vehicle’s control module nor the diagnostic tool, such as a Tech 2, are “talking,” the voltage level of the bus at rest is 5 volts. The two computers talk to each other at a rate of 8,192 bits per second, by toggling or switching the voltage on the data bus from 5 volts to ground. Class 2 data, which is used on OBD II vehicles, is quite different. Data is transferred at a rate of 10.4 kilobits per second, and the voltage is toggled between zero and 7 volts.

7A1–20 TRANSMISSION CONTROL SYSTEM (4L30–E)

C07RT006

Class 2 data is also pulse width modulated. Each bit of information can have one of two lengths: long or short. On the other hand, UART data bits come in only one length (short). The pulse width modulation of Class 2 data allows better utilization of the data line. The message carried on Class 2 data streams are also prioritized. This means that if two devices try to communicate on the data line at the same time, only the higher priority message will continue. The device with the lower priority message must wait. NOTE: The Class 2 data wire is always terminal 2 of the new 16–terminal Data Link Connector (DLC).

16 – Terminal Data Link Connector (DLC) OBD II standardizes Data Link Connector (DLC) configurations. The DLC, formerly referred to as the ALDL, will be a 16–terminal connector found on the lower left side of the driver’s side instrument panel. All manufacturers must conform to this 16–terminal standard.

826R200011

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–21

DTC Types

810RT022

PIN 1 – PIN 2 – PIN 3 – PIN 4 – PIN 5 – PIN 6 – PIN 7 – PIN 8 – PIN 9 – PIN 10 – PIN 11 – PIN 12 – PIN 13 – PIN 14 – PIN 15 – PIN 16 –

DIAG. SW J1850 Bus + L line on 2–wire systems, or single wire (Class 2) Active suspension diagnostic enable Chassis ground pin Signal ground pin (Not used) TOD diagnostic enable TOD diagnostic enable Primary UART (Not used) (Not used) ABS diagnostic or CCM diagnostic enable SIR diagnostic enable (Not used) (Not used) Battery power from vehicle unswitched (4 AMP MAX.)

Malfunction Indicator Lamp (MIL) The Malfunction Indicator Lamp (MIL) looks the same as the MIL you are already familiar with (“CHECK ENGINE” lamp). However, OBD II requires for it illuminate under a strict set of guidelines. Basically, the MIL is turned on when the PCM detects a DTC that will impact the vehicle’s emissions. The MIL is under the control of the Diagnostic Executive. The MIL will be turned on if a component or system which has an impact on vehicle emissions indicates a malfunction or fails to pass an emissions–related diagnostic test. It will stay on until the system or component passes the same test, for three consecutive trips, with no emissions–related faults.

Each DTC is directly related to a diagnostic test. The Diagnostic Management System sets DTC based on the failure of the tests during a trip or trips. Certain tests must fail two (2) consecutive trips before the DTC is set. The following are the four (4) types of DTCs and the characteristics of those codes: B Type A B Emissions related B Requests illumination of the MIL of the first trip with a fail B Stores a History DTC on the first trip with a fail B Stores a Freeze Frame (if empty) (DTC Information for 6VE1 engine) B Stores a Fail Record B Updates the Fail Record each time the diagnostic test fails B Type B B Emissions related B “Armed” after one (1) trip with a fail B “Disarmed” after one (1) trip with a pass B Requests illumination of the MIL on the second consecutive trip with a fail B Stores a History DTC on the second consecutive trip with a fail (The DTC will be armed after the first fail) B Stores a Freeze Frame on the second consecutive trip with a fail (if empty) (DTC Information for 6VE1 engine) B Stores a Fail Record when the first test fails (not dependent on consecutive trip fails) B Updates the Fail Record each time the diagnostic test fails (Some special conditions apply to misfire and fuel trim DTCs) B Type C (if the vehicle is so equipped) B Non-Emissions related B Requests illumination of the Service Lamp or the service message on the Drive Information Center (DIC) on the first trip with a fail B Stores a History DTC on the first trip with a fail B Does not store a Freeze Frame B Stores Fail Record when test fails B Updates the Fail Record each time the diagnostic test fails B Type D B Non-Emissions related B Not request illumination of any lamp B Stores a History DTC on the first trip with a fail B Does not store a Freeze Frame B Stores Fail Record when test fails B Updates the Fail Record each time the diagnostic test fails

7A1–22 TRANSMISSION CONTROL SYSTEM (4L30–E) IMPORTANT: Only four Fail Records can be stored. Each Fail Record is for a different DTC. It is possible that there will not be Fail Records for every DTC if multiple DTCs are set.

Clear DTC NOTE: If you clear the DTC (Diagnostic Trouble Codes) you will not be able to read any codes recorded during the last occurrence. NOTE: To use the DTC again to identify a problem, you will need to reproduce the fault or the problem. This may require a new test drive or just turning the ignition on (this depends on the nature of the fault). 1. If you have a Tech 2: 1. Connect the Tech 2 if it is still not connected GO THROUGH Tech 2 OBD II CONNECTION. 2. Push “F1: Clear DTC Information” in the Application Menu and answer “Yes” to the question “Do you want to clear DTC’s?” a. When a malfunction still exists and the Tech 2 displays “4L30E CODES NOT CLEARED”. This means that the problem is still there or that the recovery was not done. Please GO TO DTC CHECK. b. When a malfunction has been repaired and the recovery is done. The Tech 2 displays “4L30E CODES CLEARED”. 2. If you have no Tech 2: Disconnect the PCM battery feed as necessary.

DTC Check 1. Diagnostic Trouble Codes (DTC) have been identified by Tech 2. 2. You have written the list of the DTCs. The order of the malfunctions has no meanings for this PCM. Usually only one or two malfunctions should be set for a given problem. 3. Check directly the DTCs you identified. The DTCs are sorted by number. Refer to Diagnostic Trouble Code (DTC) Identification in this section.

PCM Precaution The PCM can be damaged by: 1. Electrostatic discharge 2. The short circuit of some terminals to voltage or to ground. Electrostatic Discharge Damage Description: 1. Electronic components used to control systems are often designed to carry very low voltage, and are very susceptible to damage caused by electrostatic discharge. It is possible for less than 100 volts of static electricity to cause damage to some electronic components. By comparison, it takes as much as 4,000 volts for a person to even feel the zap of a static discharge.

2. There are several ways for a person to become statically charged. The most common methods of charging are by friction and induction. An example of charging by friction is a person sliding across a car seat, in which a charge of as much as 25,000 volts can build up. Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges for the same polarity are drained off, leaving the person highly charged with the opposite polarity. Static charges of either type can cause damage, therefore, it is important to use care when handling and testing electronic components. NOTICE: To prevent possible electrostatic discharge damage: 1. Do not touch the PCM connector pins or soldered components on the PCM circuit board. 2. Be sure to follow the guidelines listed below if servicing any of these electronic components: 3. Do not open the replacement part package until it is time to install the part. 4. Avoid touching electrical terminals of the part. 5. Before removing the part from its package, ground the package to a known good ground on the vehicle. 6. Always touch a known good ground before handling the part. This step should be repeated before installing the part if the part has been handled while sliding across the seat, while sitting down from a standing position or while walking some distance.

Information On PCM 1. The Powertrain Control Module (PCM) is located in the center console and is the control center of the electronic transmission control system. 2. The PCM must be maintained at a temperature below 85° (185°F) at all times. This is most essential if the vehicle is put through a paint baking process. The PCM will become inoperative if its temperature exceeds 85°C (185°F). Therefore, it is recommended that the PCM be removed or that temporary insulation be placed around the PCM during the time the vehicle is in a paint oven or other high temperature process. 3. The PCM is designed to process the various inputs and then respond by sending the appropriate electrical signals to control transmission upshift, downshift, shift feel and torque converter clutch engagement. 4. The PCM constantly interprets information from the various sensors, and controls the systems that affect transmission and vehicle performance. By analyzing operational problems, the PCM is able to perform a diagnostic function by displaying DTC(s) and aid the technician in making repairs.

TRANSMISSION CONTROL SYSTEM (4L30–E)

Intermittent Conditions If the Tech 2 displays a diagnostic trouble code as intermittent, or if after a test drive a DTC does not reappear though the detection conditions for this DTC are present, the problem is most likely a faulty electrical connection or loose wiring. Terminals and grounds should always be the prime suspect. Intermittents rarely occur inside sophisticated electronic components such as the PCM. Use the DTC information to understand which wires and sensors are involved. When an intermittent problem is encountered, check suspect circuits for: 1. Poor terminal to wire connection. 2. Terminals not fully seated in the connector body (backed out). 3. Improperly formed or damaged terminals. 4. Loose, dirty, or corroded ground connections: HINT: Any time you have an intermittent in more than one circuit, check whether the circuits share a common ground connection. VEHICLE Type

Engine

Rr axle Ratio

Isuzu / Axiom

3 5L V6 3.5L

4 300 4.300

5. Pinched or damaged wires. 6. Electro–Magnetic Interference (EMI): HINT: Check that all wires are properly routed away from coil, and generator. Also check for improperly installed electrical options, such as lights, 2–way radios, etc. Use the F2: SNAPSHOT mode of the Tech 2 to help isolate the cause of an intermittent fault. The snapshot mode will record information before and after the problem occurs. Set the snapshot to “trigger” on the suspect DTC. If you notice the reported symptom during the test drive, trigger the snapshot manually. After the snapshot has been triggered, command the Tech 2 to play back the flow of data recorded from each of the various sensors. Signs of an intermittent fault in a sensor circuit are sudden unexplainable jump in data values out of the normal range.

Transmission And PCM Identification The chart below contains a list of all important information concerning rear axle ratio, Powertrain Control Module (PCM), and transmission identification.

PCM ISUZU Parts No. 8–97287–830–0 8–09389–969–0

7A1–23

TRANSMISSION Calibration Code

Isuzu Part No.

Model Code

G26

8–96023–779–0

YB (4×4)

G26

8–96024–169–0

YE (4×2)

240R200001

7A1–24 TRANSMISSION CONTROL SYSTEM (4L30–E)

Diagnostic Trouble Code (DTC) Identification DTC NUMBER

DTC NAME

DTC TYPE

MIL “CHECK ENGINE”

“CHECK TRANS”

P0218

Transmission Fluid Over Temperature

P0705

Transmission Range Switch (Mode Switch) Illegal Position

P0706

Transmission Range Switch (Mode Switch) Performance

P0711

Transmission Fluid Temperature (TFT) Sensor Performance

P0712

Transmission Fluid Temperature (TFT) Sensor Circuit Low Input

P0713

Transmission Fluid Temperature (TFT) Sensor Circuit High Input

P0719

Brake Switch Circuit Low (Stuck On)

P0722

Automatic Transmission Output Speed Sensor (OSS) Low Input

Flash

P0723

Automatic Transmission Output Speed Sensor (OSS) Intermittent

Flash

P0724

Brake Switch Circuit High (Stuck Off)

P0730

Gear Error Without Input Speed

P0742

Torque Converter Clutch (TCC) System Stuck On

P0748

Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical

P0751

Shift Solenoid A Performance (Stuck Off)

Flash

P0752

Shift Solenoid A Performance (Stuck On)

Flash

P0753

Shift Solenoid A Electrical

Flash

P0756

Shift Solenoid B Performance (Stuck Off)

Flash

P0757

Shift Solenoid B Performance (Stuck On)

Flash

P0758

Shift Solenoid B Electrical

Flash

P1850

Brake Band Apply Solenoid Malfunction

P1860

TCC Solenoid Electrical

Flash

P1870

Transmission Component Slipping (TCC Stuck Off)

Flash

DTC TYPE

Flash ON

Flash Flash

DEFINITION

Emission related, turn on MIL (Check Engine) and flashing Check Trans after 2 consecutive trips (Removal to confirmed)

Non–emission related, flashing Check Trans on 1st failure

Non–emission related, no lamps

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–25

DTC P0218 Transmission Fluid Over Temperature

D07R200004

Circuit Description The Transmission Fluid Temperature (TFT) sensor is a thermister that controls the signal voltage to the PCM. The PCM supplies a 5–volt reference to the sensor on circuit RED/BLK. When the transmission fluid is cold, the sensor resistance is high and the PCM will sense high signal voltage. As the fluid temperature warms to a normal transmission operating temperature of 100°C (212°F), the sensor resistance becomes less and the voltage decreases to 1.5 to 2.0 volts. This DTC detects a high transmission temperature for a long period of time. This is a type “D” DTC.

Conditions For Setting The DTC B No TFT DTCs P0712 or P0713. B TFT is greater than 135°C (275°F). B All conditions met for 21 seconds.

Action Taken When The DTC Sets B Hot mode TCC Shift Pattern. B The PCM will not illuminate the Malfunction Indicator Lamp (MIL). B ATF Lamp ON. (TFT is greater than 145°C (293°F)) B Disable E–side TCC OFF request.

Conditions For Clearing The DTC B The DTC can be cleared from the PCM history by using a scan tool. B The DTC will be cleared from history when the vehicle has achieved 40 warm–up cycles without a failure reported.

B The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled “off” long enough to power down the PCM.

Diagnostic Aids B Inspect the wiring for poor electrical connections at the PCM and transmission 7-way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. B Check harness routing for a potential short to ground in circuit RED/BLK. B Scan tool TFT sensor temperature should rise steadily to about 100°C (212°F), then stabilize. B Check for a “skewed” (mis–scaled) sensor by comparing the TFT sensor temperature to the ambient temperature after a vehicle cold soak. A “skewed” sensor can cause delayed garage shifts or TCC complaints. B Check for a possible torque converter stator problem. B Verify customer driving habits, trailer towing, etc.

Test Description The numbers below refer to the step numbers on the diagnostic chart. 3. This test checks for a “skewed” sensor or shorted circuit. 4. This test simulates a TFT DTC P0713.

7A1–26 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0218 Transmission Fluid Over Temperature Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Go to Step 2

Go to OBD System Check Refer to Driveability and Emissions in Engine section

Go to Step 3

—

Go to Step 4

Go to Diagnostic Aids

Go to Internal Wiring Harness Check

Go to Step 5

Go to Step 7

Go to Step 6

Go to Step 7

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

Perform the following checks: B Check for possible engine system problems. B Transmission fluid checking procedure. Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30–E) Section. Were the checks performed?

Yes

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Failure Records” for reference, as data will be lost when “Clear Info” function is used. 3. Record the DTC “Failure Records”. Is the TFT sensor signal voltage less than 1.54 volts?

1. Turn the ignition “off”. 2. Disconnect the transmission 7–way connector (additional DTCs may set). 3. With the engine “off”, turn the ignition switch “on”.

E–42

Is the TFT sensor signal voltage greater than 4.92 volts? 5

Inspect/repair circuit RED/BLK for a short to ground. Was a problem found?

1. Inspect the PCM for poor connections. 2. Replace the PCM if no poor connections were found. Is the replacement complete?

1. After the repair is complete, use the scan tool to select “DTC”, then “Clear Info” function and ensure the following conditions are met: TFT is less than 125°C (257°F) for at least 10 seconds. 2. Review the scan tool “DTC Info”. Has the last test failed or is the current DTC displayed?

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–27

DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position

D07R200005

Circuit Description B The range switch supplies the Powertrain Control Module (PCM) with information regarding the selector lever position: P, R, N, D, 3, 2 or L. The selector lever position is indicated by the state of four ON/OFF contacts. The range switch is located on one side of the transmission. It is on the transmission manual shaft and is fixed to the main case. B The range switch is also used to provide the information P or N to the engine crank wiring. The engine can be cranked only if connector E–41 terminal 4(H) is connected to terminal 1(E) which is connected to ground. B The range switch is also used to provide the backup lamp power in reverse. This is the reason why the range switch is supplied through a 15A fuse (TURN, BACK UP). This fuse can burn due to a short circuit in the back up lamp. This DTC detects when a fuse is open or the range switch circuit does not work. This is a type “D” DTC.

Conditions For Setting The DTC B Range switch illegal positions met for 5 seconds.

Action Taken When The DTC Sets B Default to D position. B Inhibit torque management. B Maximum line pressure.

B Turn Force Motor OFF. B The PCM will not illuminate the Malfunction Indicator Lamp (MIL).

Conditions For Clearing The DTC B The DTC can be cleared from the PCM history by using a scan tool. B The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. B The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled “off” long enough to power down the PCM.

Diagnostic Aids B Refer to accompanying chart for the normal range signals and the illegal combinations. B Inspect the wiring for poor electrical connections at the PCM and at the transmission 8–way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. B Refer to the “Range Switch Logic Table” for further information.

7A1–28 TRANSMISSION CONTROL SYSTEM (4L30–E)

Test Description The numbers below refer to the step numbers on the diagnostic chart: 3. This test checks the indicated range signal to the manual valve actually selected. 6. This test checks for continuity between each selected range switch connector terminals. Range Switch Logic Table Range Switch Pin

Range g Position

P(G)

Park

OFF

Reverse

OFF

Neutral

OFF

Illegal

OFF

Illegal

OFF

7A1–29

TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Go to Step 2

Go to OBD System Check Refer to Driveability and Emissions in Engine section

Go to Step 3

—

Go to Diagnostic Aids

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 9

—

Go to Step 7

Go to Step 8

Go to Step 9

—

Go to Step 9

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

Perform the following checks: B The transmission linkage from the select lever to the manual valve is adjusted properly. B Diagnostic circuit check. Were the checks performed?

Yes

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 3. Record the DTC “Freeze Frame” and “Failure Records”. 4. Select each transmission range: DL, D2, D3, D4, N, R, and P. Does each selected transmission range match the scan tool “Range Switch” display?

Are all range switch pin displays incorrect?

Check fuse and wiring to the 8–way connector terminal 5(D) for opens. Refer to Mode Switch in Automatic Transmission (4L30–E) section. If no problem was found, replace the range switch. Is the replacement complete?

1. Disconnect the 8–way range switch connector. 2. Using ohmmeter, check continuity between terminal 5(D) and respectively terminals 3(G), 6(C), 7(B) and 8(A) of the 8–way range switch connector. 3. Move shift selector lever through all positions and compare results with “Range Switch Logic Table”. Is one range switch pin display incorrect?

Check the affected wiring and connector, and repair. Is the repair complete?

Check the Powertrain Control Module (PCM) connectors for poor connection. If no problem was found, replace the PCM. Is the replacement complete?

1. After the repair is complete, use the scan tool to select “DTC”, then “Clear Info” function and road test the vehicle. 2. Review the scan tool “DTC Info”. Has the last test failed or is the current DTC displayed?

7A1–30 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0706 Transmission Range Switch (Mode Switch) Performance

D07R200005

Circuit Description B The range switch supplies the Powertrain Control Module (PCM) with information regarding the selector lever position: P, R, N, D, 3, 2 or L. The selector lever position is indicated by the state of four ON/OFF contacts. The range switch is located on one side of the transmission. It is on the transmission manual shaft and is fixed to the main case. B The range switch is also used to provide the information P or N to the engine crank wiring. The engine can be cranked only if connector E–41 terminal 4(H) is connected to terminal 1(E) which is connected to ground. B The range switch is also used to provide the back up lamp power in reverse. This is the reason why the mode switch is supplied through a 15A fuse (TURN, BACK UP). This fuse can burn due to a short circuit in the back up lamp. B This DTC detects an invalid state of the range switch or the range switch circuit by deciphering the range switch inputs. This is a type “D” DTC.

Conditions For Setting The DTC This DTC will set if any of the following conditions occurs:

Condition 1 (“R” bad position): B Engine is running. B No output speed DTCP0722, P0723.

B Output speed greater than 3,200 RPM. B Range switch indicates “R”. B All conditions met for 4 seconds.

Condition 2 (“P” or “N” bad position): B B B B B B

Engine is running. No TPS codes. Engine speed is less than 3,000 RPM. TP angle is greater than 20%. Range switch indicates “P” or “N”. All conditions met for 4 seconds.

Action Taken When The DTC Sets B Default to “D” position. B The PCM will not illuminate the Malfunction Indicator Lamp (MIL).

TRANSMISSION CONTROL SYSTEM (4L30–E)

Diagnostic Aids B Refer to the accompanying chart for the normal range signals and the illegal combinations. B Inspect the wiring for poor electrical connections at the PCM and at the transmission 8–way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. B Refer to the “Range Switch Logic Table” for further information.

Range g Position

P(G)

Park

OFF

Reverse

OFF

Neutral

OFF

Illegal

OFF

Illegal

OFF

7A1–31

7A1–32 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0706 Transmission Range Switch (Mode Switch) Performance Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Go to Step 2

Go to OBD System Check Refer to Driveability and Emissions in Engine section

Go to Step 3

—

Go to Diagnostic Aids

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 9

—

Go to Step 7

Go to Step 8

Go to Step 9

—

Go to Step 9

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

Perform the following checks: B The transmission linkage from the select lever to the manual valve is adjusted properly. B Diagnostic circuit check. Were the checks performed?

Yes

Are all range switch pin displays incorrect?

Check the affected wiring and connector, and repair. Is the repair complete?

Check the Powertrain Control Module (PCM) connectors for poor connection. If no problem was found, replace the PCM. Is the replacement complete?

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–33

DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance

D07R200004

Circuit Description The TFT sensor is a thermister that controls the signal voltage to the PCM. The PCM supplies a 5 volt reference signal to the sensor on circuit RED/BLK. When the transmission fluid is cold, the sensor resistance is high and the PCM detects high signal voltage. As the transmission fluid temperature increases to normal operating temperature of 100°C (212°F), the sensor resistance becomes less and the voltage decreases to 1.5 to 2 volts. When the PCM detects a TFT sensor that remains at the startup value, or a sensor that has a change delta of greater than 20°C (36°F) less than 1 second, DTC P0711 sets. DTC P0711 is a type D.

Conditions For Setting The DTC B B B B B B B B B B

No VSS DTCs P0722 or P0723. No Transmission Component Slipping DTC P1870. Engine is running. TFT is between 20 A/D (Analog/Digital) counts and 248 A/D counts. TFT is between –40°C (–40°F) and +21°C (69.8°F) at engine startup. Engine coolant temperature is greater than 70°C (150°F). Engine coolant temperature has changed by greater than 50°C (90°F) since engine startup. Vehicle speed has been greater than 5 mph for greater than 410 seconds since engine startup (cumulative timer). TCC slip speed has been greater than 120 rpm for greater than 410 seconds since engine startup (cumulative timer). Battery voltage is between 10 and 16 volts.

All of the above is true and either of the following occurs: B If the sensor is stuck, the TFT has not changed for greater than 2 counts (from startup temperature) for greater than 410 seconds.

B If the sensor shows an unrealistic change, the TFT exhibits a change delta of greater than 20°C (36°F), greater than 14 times in 7 seconds.

Action Taken When The DTC Sets B Transmission default temperature will be: 80°C (176°F) if engine temperature code is set. 100°C (212°F) if engine temperature is warm. 80°C (176°F) if engine run time is greater than 5 minutes. 21°C (69.8°F) if engine run time is less than 5 minutes. B The PCM will not illuminate the Malfunction Indicator Lamp (MIL).

Diagnostic Aids B Inspect the wiring for poor electrical connection at the PCM. Inspect the wiring for poor electrical connections at the transmission 7-way connector. Look for the following conditions: a. A bent terminal b. A backed out terminal c. A damaged terminal d. Poor terminal tension e. A chafed wire f. A broken wire inside the insulation

7A1–34 TRANSMISSION CONTROL SYSTEM (4L30–E) B When diagnosing for an intermittent short or open connection, move the wiring harness while watching the test equipment for a change. B First diagnose and clear any engine DTCs or TP Sensor codes. Then inspect for any transmission DTCs that may have reset.

Test Description The number below refers to the step number on the diagnostic chart: 3. This test checks PCM and associated wiring up to the 7–way connector. If the voltage increases to match chart the problem is isolated to the transmission wiring.

DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance Step

Action

Was the Powertrain On–Board Diagnostic (OBD) System Check performed?

Yes

Go to Step 2

Go to OBD System Check Refer to Driveability and Emissions in Engine section

Go to Step 3

Go to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30–E) section

Go to Step 6

Go to Step 4

Does the DVOM MAX display a resistance greater than the value recorded in Action item 6 of this step?

Go to Step 7

Go to Step 5

Does the DVOM MIN display a resistance less than the value recorded in Action item 6 of step 4?

Go to Step 8

—

Go to Step 12

Go to Step 11

Perform the transmission fluid checking procedure. Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30–E) section. Did you perform the fluid checking procedure?

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch to the “on” position. NOTE: Before clearing DTCs, use the scan tool in order to record the Freeze Frame and Failure Records for reference. The Clear Info function will erase the data. 3. Record the DTC Freeze Frame and Failure Records. 4. Select TFT on the scan tool. 5. While observing the scan tool display, move or massage the engine wiring harness from PCM connectors E35–66 and E35–20 to the transmission 7–way connector E–42. Does the TFT change by more than ±20°C (36°F)?

5 6

1. Turn the ignition “off”. 2. Disconnect the transmission 7–way connector E–42. 3. Install Jumper Harness on the transmission side of the 7–way connector E–42. 4. Using the J39200 DVOM and J35616 Connector Test Adapter Kit, connect the DVOM leads from terminal E42–4(F) to terminal E42–1(E). 5. Set the DVOM on MIN/MAX to measure resistance. 6. Record the TFT sensor resistance. 7. Move or massage the automatic transmission wiring harness assembly from the PCM to the TFT sensor connector. (See Transmission Fluid Temperature (TFT) Sensor Specifications.)

Inspect circuit RED/BLK and RED/WHT of the engine wiring harness for an intermittent open or short condition. Repair the circuits if necessary. Did you find a problem?

7A1–35

TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance (Cont’d) Step

Action

Inspect the automatic transmission wiring harness assembly for an intermittent open in circuits RED/BLK and RED/WHT. Did you find a problem?

Go to Step 9

Go to Step 10

Go to Step 12

—

Go to Step 12

—

Go to Step 12

—

System OK

Begin the diagnosis again Go to Step 1

Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30–E) section. Is the replacement complete?

Go to Step 10

Replace TFT Sensor. Refer to Transmission Oil Temperature Sensor (Main Case) in Automatic Transmission (4L30–E) section. Is the replacement complete?

Go to Step 9

Replace the automatic transmission wiring harness assembly. Is the replacement complete?

Inspect the automatic transmission wiring harness assembly for an intermittent shorted condition in circuits RED/BLK and RED/WHT. Did you find a problem?

Yes

In order to verify your repair, perform the following procedure. 1. Select DTC. 2. Select Clear Info. 3. Drive the vehicle and ensure the following conditions are met: B The TFT changes by more than 2.25°C (4.05°F) for 11 seconds since startup. B The TFT does not change by more than 20°C (36°F) within 0.200 second for a period of at least 11 seconds. 4. Select Specific DTC. 5. Enter DTC P0711. Has the test run and passed?

7A1–36 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input

D07R200004

Circuit Description The TFT sensor is a thermister that controls the signal voltage to the PCM. The PCM supplies a 5–volt reference signal to the sensor on circuit RED/BLK. When the transmission fluid is cold, the sensor resistance is high. The PCM detects high signal voltage. As the transmission fluid temperature increases to the normal operating temperature of 100°C (212°F), the sensor resistance becomes less and the voltage decreases to 1.5 to 2 volts. With transmission fluid over temperature and DTC P0218 also set, check the transmission cooling system. This DTC detects a continuous short to ground in the TFT signal circuit or the TFT sensor. This is a type “D” DTC.

Conditions For Setting The DTC B B B B

Battery voltage is between 10 and 16 volts. Ignition is “on”. TFT sensor indicating a voltage less than 0.4 volts. All conditions met for 20 seconds.

Conditions For Clearing The DTC B The DTC can be cleared from the PCM history by using a scan tool.

B The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. B The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled “off” long enough to power down the PCM.

Diagnostic Aids B Check harness routing for a potential short to ground in circuit RED/BLK. Scan tool TFT display should rise steadily to about 100°C (212°F), then stabilize. B Inspect the wiring for poor electrical connection at the PCM and transmission 7-way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. B The temperature to resistance value scale may be used to test the TFT sensor at the various temperature levels to evaluate the possibility of a “skewed” (mis–scaled) sensor. A “skewed” sensor could result in delayed garage shifts or TCC complaints. B Verify customer driving habits, trailer towing, etc.

Test Description The numbers below refer to the step numbers on the diagnostic chart: 3. This test checks for a short to ground or a “skewed” sensor. 4. This test checks for an internal fault within the transmission by creating an open.

7A1–37

TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Yes

Go to Step 2

Go to OBD System Check Refer to Driveability and Emissions in Engine section

Go to Step 3

Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30–E) section

Go to Step 4

Go to Diagnostic Aids

Go to Step 5

Go to Step 10

Go to Diagnostic Aids

Go to Step 6

Go to Diagnostic Aids

Go to Step 7

Go to Step 9

Go to Step 8

Go to Diagnostic Aids

Go to Step 9

Go to Step 13

—

Go to Step 13

Go to Step 11

Perform the transmission fluid checking procedure. Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30–E) section Was the fluid checking procedure performed?

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 3. Record the DTC “Freeze Frame” and “Failure Records”. Does the scan tool display a TFT sensor signal voltage less than 0.4 volts?

1. Turn the ignition “off”. 2. Disconnect the transmission 7–way connector E–42. 3. Turn the ignition “on”. Does the TFT signal voltage change to match the voltage 4.92 volts?

Using the J39200 DVOM, measure the resistance between terminals E42–4(F) and E42–1(E). Is the resistance within specifications? (See Transmission Fluid Temperature (TFT) Sensor Specifications.)

1. Disconnect the transmission 7–way connector E–42. 2. Using the J39200 DVOM, measure the resistance between terminals E42–4(F) and E42–1(E). Is the resistance within specifications? (See Transmission Fluid Temperature (TFT) Sensor Specifications.)

1. Remove the transmission oil pan. Refer to Transmission Oil Temperature Sensor (Main Case) in Automatic Transmission (4L30–E) section. 2. Check the internal wiring harness for a short to ground. Was a problem found?

1. Disconnect the internal wiring harness at the TFT sensor. 2. Measure the resistance of the TFT sensor. Is the resistance within specifications? (See Transmission Fluid Temperature (TFT) Sensor Specifications.)

Replace the TFT Sensor. Is the replacement complete?

Check circuit RED/BLK for a short to ground. Was a problem found?

7A1–38 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input (Cont’d) Step 11

Action

Go to Step 13

Go to Step 12

Go to Step 13

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30–E) section. Is the replacement complete?

Check the PCM for faulty connections. Was a problem found?

Yes

1. After the repair is complete, use the scan tool to select “DTC”, then “Clear Info” function and ensure the following conditions are met: TFT sensor indicates a voltage greater than 0.33 volts for 2 seconds. 2. Review the scan tool “DTC info”. Has the last test failed or is the current DTC displayed?

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–39

DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input

D07R200004

Circuit Description The TFT sensor is a thermistor that controls the signal voltage to the PCM. The PCM supplies a 5–volt reference signal to the sensor on circuit RED/BLK. When the transmission fluid is cold, the sensor resistance is high and the PCM will sense high signal voltage. As the transmission fluid temperature warms to the normal operating temperature of 100°C (212°F), the sensor resistance becomes less and the voltage decreases to about 1.5 to 2 volts. This DTC detects a continuous open or short to power in the TFT signal circuit or the TFT sensor. This is a type “D” DTC.

Conditions For Setting The DTC B Battery voltage is between 10 and 16 volts. B Ignition is “on”. B TFT sensor indicating a voltage greater than 4.86 volts. B All conditions met for 20 seconds.

Conditions For Clearing The DTC B The DTC can be cleared from the PCM history by using a scan tool.

Diagnostic Aids B Inspect the wiring for poor electrical connection at the PCM and transmission 7-way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. B Scan tool displays transmission fluid temperature in degrees. After transmission is operating, the temperature should rise steadily to about 100°C (212°F), then stabilize. B The temperature to resistance value scale may be used to check the TFT sensor at the various temperature levels to evaluate the possibility of a “skewed” (mis–scaled) sensor. A “skewed” sensor could result in hard shifts or TCC complaints.

Test Description The numbers below refer to the step numbers on the diagnostic chart: 3. This check verifies problem in the TFT sensor circuit. 4. This test simulates a TFT sensor DTC P0712. If the PCM recognizes the low signal voltage (high temperature), and the scan tool displays 146°C (295°F) or greater, the PCM and wiring are OK. 5. This test checks the TFT sensor and internal wiring harness.

7A1–40 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Yes

Go to Step 2

Go to OBD System Check Refer to Driveability and Emission in Engine section

Go to Step 3

Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30–E) section

Go to Step 4

Go to Diagnostic Aids

Go to Step 5

Go to Step 10

Go to Diagnostic Aids

Go to Step 6

Go to Diagnostic Aids

Go to Step 7

Go to Step 14

Go to Step 8

Go to Diagnostic Aids

Go to Step 9

Go to Step 14

—

Perform the transmission fluid checking procedure. Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30–E) section. Was the fluid checking procedure performed?

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 3. Record the DTC “Freeze Frame” and “Failure Records”. Does the scan tool display a TFT sensor signal voltage greater than 4.86 volts?

1. Turn the ignition “off”. 2. Disconnect the transmission 7–way connector E–42. 3. Install a fused jumper wire from terminal E42–4(F) to E42–1(E) on the engine harness. 4. Turn the ignition “on”. Does the TFT signal voltage drop to less than 0.4 volts?

1. Turn the ignition “off”. 2. Using the J39200 DVOM, measure the resistance between terminals E42–4(F) and E42–1(E). Is the resistance within specifications? (See Transmission Fluid Temperature (TFT) Sensor Specifications.)

1. Remove the transmission oil pan. 2. Check the internal wiring harness for an open. Refer to Transmission Oil Temperature Sensor (Main Case) in Automatic Transmission (4L30–E) section. Was a problem found and corrected?

Replace TFT sensor. Refer to Transmission Oil Temperature Sensor (Main Case) in Automatic Transmission (4L30–E) section. Is the replacement complete?

7A1–41

TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input (Cont’d) Step 10

Action

Go to Step 14

Go to Step 12

Go to Step 14

Go to Step 13

Go to Step 14

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30–E) section. Is the replacement complete?

Go to Step 11

Check the PCM for faulty or intermittent connections. Was a problem found?

Go to Step 14

Check circuit RED/WHT for an open. Was a problem found?

Check circuit RED/BLK for an open or short to B+. Was a problem found?

Yes

1. After the repair is complete, use the scan tool to select “DTC”, then “Clear Info” function and ensure the following conditions are met: 2. TFT sensor indicates a voltage less than 4.92 volts for 2 seconds. 3. Review the scan tool “DTC Info”. Has the last test failed or is the current DTC displayed?

7A1–42 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0719 Brake Switch Circuit Low (Stuck On)

D07R200007

Circuit Description: The brake switch indicates brake pedal status to the Powertrain Control Module (PCM). The brake switch is a normally–closed switch that supplies battery voltage on circuit BRN/RED to the PCM. Applying the brake pedal opens the switch, interrupting voltage to the PCM. When the brake pedal is released, the PCM receives a constant voltage signal. If the PCM receives a zero voltage signal at the brake switch input, and the Torque Converter Clutch (TCC) is engaged, the PCM de–energizes the Torque Converter Clutch Solenoid Valve (TCC Sol. Valve). The PCM disregards the brake switch input for TCC scheduling if there is a brake switch circuit fault (Refer to Diagnostic Aids). When the PCM detects an open brake switch circuit (0 volts, low input) during accelerations, then DTC P0719 sets. DTC P0719 is a type D DTC.

Conditions For Setting The DTC B No OSS Assy. DTCs P0722 or P0723. B The PCM detects an open brake switch or circuit (0 volts) for 15 minutes without changing for 2 seconds, and the following events occur seven consecutive times. B The vehicle speed is less than 8 km/h (5 mph). B then the vehicle speed is 8–32 km/h (5–20 mph) for 4 seconds. B then the vehicle speed is greater than 32 km/h (20 mph) for 4 seconds.

Action Taken When The DTC Sets B The PCM does not illuminate the Malfunction Indicator Lamp (MIL). B DTC P0719 stores in PCM history.

Conditions For Clearing The DTC B A scan tool can clear the DTC from the PCM history. The PCM clears the DTC from the PCM history if the vehicle completes 40 warm–up cycles without a failure reported. B The PCM cancels the DTC default actions when the fault no longer exists and the ignition is OFF long enough in order to power down the PCM.

Diagnostic Aids B Inspect the wiring for poor electrical connections at the PCM and brake switch. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. B Check customer driving habits and/or unusual driving conditions (i.e. stop and go, highway). B Check brake switch for proper mounting and adjustment.

TRANSMISSION CONTROL SYSTEM (4L30–E)

Test Description The numbers below refer to the step numbers on the diagnostic chart: 3. This step isolates the brake switch as a source for setting the DTC.

7A1–43

7A1–44 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0719 Brake Switch Circuit Low (Stuck On) Step

Action

Was the Powertrain On–Board Diagnostic (OBD) System Check performed?

Yes

Go to Step 2

Go to Powertrain OBD System Check

Go to Step 3

Go to Step 4

Go to Step 7

Go to Step 9

Go to Step 5

Go to Step 8

Go to Step 11

Go to Step 6

Go to Step 11

Go to Step 10

Go to Step 11

—

Go to Step 11

—

Go to Step 11

Go to Step 10

Go to Step 11

—

System OK

Begin the diagnosis again. Go to Step 1

1. Install the scan tool. 2. With the engine “off,” turn the ignition switch to the “on” position. NOTE: Before clearing the DTC(s), use the scan tool in order to record the “Failure Records” for reference. Using the “Clear Info” function will erase the stored “Failure Records” from the PCM. 3. Record the “DTC Failure Records”, then clear the DTC(s). 4. Select “TCC Brake Switch” on the scan tool. 5. Disconnect the brake switch connector from the brake switch. 6. Connect a test lamp from cavity I31–3 of the brake switch connector to a known good ground. Is the test lamp ON?

Install a J 36169–A Fused Jumper Wire from terminal I31–2 to terminal I31–3 of the brake switch connector. Did the TCC Brake Switch status change from Open to Closed?

1. Remove the fuse “TURN, BACK UP”. 2. Inspect the fuse for an open. Is the fuse open?

Inspect circuit WHT/GRN for a short to ground condition. Repair the circuit if necessary. Did you find a short to ground condition?

Inspect circuit BRN/RED for a short to ground condition. Repair the circuit if necessary. Did you find a short to ground condition?

Replace the brake switch. Is the replacement complete?

Inspect circuit WHT/GRN for an open condition. Repair the circuit if necessary. Did you find and correct an open condition?

Inspect circuit BRN/RED for an open. Did you find an open condition?

Replace the PCM. Is the replacement complete?

In order to verify your repair, perform the following procedure: 1. Select DTC. 2. Select Clear Info. 3. With the engine “off,” turn the ignition switch to the “on” position. 4. Do not depress the brake pedal. 5. Verify that the Brake Switch status indicates “Closed” (12 volts) for 2 seconds. 6. Select Specific DTC. Enter DTC P0719. Has the test run and passed?

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–45

DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input

D07R200006

Circuit Description Output speed information is provided to the PCM by the OSS, which is a permanent magnet (PM) generator. The PM generator produces a pulsing AC voltage. The AC voltage level and number of pulses increases as the speed of the vehicle increases. The PCM then converts the pulsing voltage to output speed, which is used for calculations. The vehicle speed can be displayed with a scan tool. This DTC detects a low output speed when there is a high engine speed in a drive gear range. This is a type “B” DTC.

Conditions For Setting The DTC B No MAP DTCs P0107 or P0108, P0106, P1106, P1107. B No TPS DTCs P0122 or P0123. B Not in Park or Neutral. B TP angle is greater than 10%. B Engine vacuum is between 0 and 70kPa. B Engine speed is between 3000 and 7000 rpm. B Transmission output speed is less than 0 rpm. B All conditions met for 5 seconds.

Action Taken When The DTC Sets B B B B

Fixed to 4th gear. Maximum line pressure. Inhibit TCC engagement. For lamp illuminate refer to DTC type definition (type B).

Conditions For Clearing The MIL/DTC B The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. B The DTC can be cleared from the PCM history by using a scan tool. The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. B The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled “off” long enough to power down the PCM.

Diagnostic Aids B An OSS DTC P0722 will set when no output speed is at detected at start off. B Inspect the wiring for poor electrical connection at the PCM. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move or massage the wiring harness while observing test equipment for a change.

Test Description The numbers below refer to the step numbers on the diagnostic chart: 4. This test checks the OSS circuit. 5. This test checks the integrity of the OSS. 7. This test checks the 5–volt and ground circuit of the PCM.

7A1–46 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input Step

Action

Yes

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Go to Step 2

Go to OBD System Check Refer to Driveability and Emissions in Engine section

Go to Diagnostic Aids

Go to Step 3

Go to Step 16

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 7

Go to Step 8

Go to Step 17

Go to Step 8

Go to Step 16

Go to Step 10

Go to Step 17

Go to Step 9

Is the replacement complete?

Go to Step 17

—

Was the reading in step 7 less than 4.0 volts?

Go to Step 12

Go to Step 11

Was the reading in Step 7 greater than 5.1 volts?

Go to Step 15

—

Using the J 39200 DVOM to chassis ground, measure the voltage on circuit BLU/YEL. Go to Step 13

Go to Step 14

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 3. Record the DTC “Freeze Frame” and “Failure Records”. 4. Raise the drive wheels. 5. Start the engine. 6. Place the transmission in any drive range. With the drive wheels rotating, does the “Trans Output Speed” increase with the drive wheel speed?

Check for the most current and/or incorrect calibration. Is the calibration current?

1. Turn the ignition “off”. 2. Disconnect the E35 (RED) PCM connector. 3. Using the J39200 DVOM, measure the resistance between harness connector terminals E35–22 and E35–55. Is the reading 3000 ohms?

1. Select AC volts. 2. Rotate the rear wheels, ensuring the driveshaft is turning. Is the voltage greater than 0.5 volts?

Inspect circuits BLU/YEL and BLU/GRN for a poor connection or an open circuit. Was a problem found?

1. 2. 3. 4.

Reconnect the E35 (RED) PCM connector. Disconnect the OSS harness from the OSS. With the engine “off”, turn the ignition “on”. Using the J 39200 DVOM, measure the voltage at the OSS harness connector terminals E44–1 and E44–2.

Is the reading between 4.0 to 5.1 volts? 8

1. Remove the OSS. 2. Check the output shaft speed sensor rotor for damage or misalignment. Refer to Speed Sensor (Extension Assembly) in Automatic Transmission (4L30–E) section. Was a problem found?

Replace the OSS.

Is the reading between 4.0 to 5.1 volts?

7A1–47

TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input (Cont’d) Step 13

Action

Go to Step 17

Go to Step 16

Go to Step 17

—

Go to Step 17

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

Replace the PCM. Refer to Powertrain Control Module (PCM) in automatic Transmission (4L30–E) section. Is the replacement complete?

—

Repair the short to B+ in circuit BLU/YEL. Is the repair complete?

Go to Step 17

Check circuit BLU/YEL for a short to ground or open. Was a problem found and corrected?

Repair the open in circuit BLU/GRN. Is the repair complete?

Yes

1. After the repair is complete, use the scan tool to select “DTC”, then “Clear Info” function and operate the vehicle under the following conditions: Transmission output speed is greater than 101 rpm for 3 seconds. 2. Review the scan tool “DTC Info”. Has the last test failed or is the current DTC displayed?

7A1–48 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent

D07R200006

Circuit Description Output speed information is provided to the PCM by the OSS, which is a permanent magnet (PM) generator. The PM generator produces a pulsing AC voltage. The AC voltage level and number of pulses increases as the speed of the vehicle increases. The PCM then converts the pulsing voltage to output speed, which is used for calculations. The vehicle speed can be displayed with a scan tool. This DTC detects a fast decrease of output speed when engine running in a drive gear range. This is a type “B” DTC.

Conditions For Setting The DTC Drive range B Engine running time is greater than 5 seconds. B Output speed is greater than 1300 rpm for 2 second. B NORAW–NOLAST < 200 rpm for 2 seconds. B NORAW: Latest raw data of output shaft speed. B NOLAST: Fitered previous data of output speed. B Transmission negative output speed change is greater than 1300 rpm. B Conditions met for 3 seconds. Action During Detection Time B Output speed value is frozen

Action Taken When The DTC Sets B B B B

Fixed to 4th gear. Maximum line pressure. Inhibit TCC engagement. For lamp illuminate refer to DTC type definition (type B).

Conditions For Clearing The MIL/DTC B The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. B The DTC can be cleared from the PCM history by using a scan tool. B The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. B The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled “off” long enough to power down the PCM.

Diagnostic Aids B A OSS DTC P0723 will set when output speed has been detected and is lost. B Inspect the wiring for poor electrical connection at the PCM. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.

7A1–49

TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent Step

Action

Yes

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Go to Step 2

Go to OBD System Check Refer to Driveability and Emissions in Engine section

Go to Diagnostic Aids

Go to Step 3

Go to Step 16

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 7

Go to Step 8

Go to Step 17

Go to Step 8

Go to Step 16

Go to Step 10

Go to Step 17

Go to Step 9

Is the replacement complete?

Go to Step 17

—

Was the reading in step 7 less than 4.0 volts?

Go to Step 12

Go to Step 11

Was the reading in Step 7 greater than 5.1 volts?

Go to Step 15

—

Using the J 39200 DVOM to chassis ground, measure the voltage on circuit BLU/YEL. Go to Step 13

Go to Step 14

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 3. Record the DTC “Freeze Frame” and “Failure Records”. 4. Raise the drive wheels. 5. Start the engine. 6. Place the transmission in any drive range. With the drive wheels rotating, does the “Trans Output Speed” increase with the drive wheel speed?

Check for the most current and/or incorrect calibration. Is the calibration current?

1. Select AC volts. 2. Rotate the rear wheels, ensuring the driveshaft is turning. Is the voltage greater than 0.5 volts?

Inspect circuits BLU/YEL and BLU/GRN for a poor connection or an open circuit. Was a problem found?

1. 2. 3. 4.

Is the reading between 4.0 to 5.1 volts? 8

Replace the OSS.

Is the reading between 4.0 to 5.1 volts?

7A1–50 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent (Cont’d) Step 13

Action

Go to Step 17

Go to Step 16

Go to Step 17

—

Go to Step 17

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30–E) section. Is the replacement complete?

—

Repair the short to B+ in circuit BLU/YEL. Is the repair complete?

Go to Step 17

Check circuit BLU/YEL for a short to ground or open. Was a problem found and corrected?

Repair the open in circuit BLU/GRN. Is the repair complete?

Yes

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–51

DTC P0724 Brake Switch Circuit High (Stuck Off)

D07R200007

Circuit Description: The brake switch indicates brake pedal status to the Powertrain Control Module (PCM). The brake switch is a normally–closed switch that supplies battery voltage on circuit BRN/RED to the PCM. Applying the brake pedal opens the switch, interrupting voltage to the PCM. When the brake pedal is released, the PCM receives a constant voltage signal. If the PCM receives a zero voltage signal at the brake switch input, and the Torque Converter Clutch (TCC) is engaged, the PCM de–energizes the Torque Converter Clutch Solenoid Valve (TCC Sol. Valve). The PCM disregards the brake switch input for TCC scheduling if there is a brake switch circuit fault (Refer to Diagnostic Aids). When the PCM detects a closed brake switch circuit (12 volts, high input) during decelerations, then DTC P0724 sets. DTC P0724 is a type D DTC.

Conditions For Setting The DTC B No OSS Assy. DTCs P0722 or P0723. B The PCM detects a closed brake switch circuit (12 volts) without changing and the following events occur seven consecutive times. B The vehicle speed is greater than 32 km/h (20 mph) for 4 seconds. B then the vehicle speed is between 8–32 km/h (5–20 mph) for 4 seconds. B then the vehicle speed is less than 8 km/h (5 mph).

Action Taken When The DTC Sets B The PCM does not illuminate the Malfunction Indicator Lamp (MIL). B DTC P0724 stores in PCM history.

Diagnostic Aids B Inspect the wiring for poor electrical connection at the PCM. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. B Check customer driving habits and/or unusual traffic conditions (i.e. stop and go, expressway). B Check brake switch for proper mounting and adjustment.

7A1–52 TRANSMISSION CONTROL SYSTEM (4L30–E)

Test Description The numbers below refer to the step numbers on the diagnostic chart: 2. This step isolates the brake switch as a source for setting the DTC.

DTC P0724 Brake Switch Circuit High (Stuck Off) Step

Action

Was the Powertrain On–Board Diagnostic (OBD) System Check performed?

Yes

Go to Step 2

Go to Powertrain OBD System Check

Go to Step 3

Go to Step 4

Go to Step 6

—

Go to Step 6

Go to Step 5

Go to Step 6

—

System OK

Begin the diagnosis again. Go to Step 1

1. Install the scan tool. 2. With the engine “off,” turn the ignition switch to the “on” position. NOTE: Before clearing the DTC(s), use the scan tool in order to record the “Failure Records” for reference. Using the “Clear Info” function will erase the stored “Failure Records” from the PCM. 3. Record the DTC Failure Records, then clear the DTC(s). 4. Select “Brake Switch” on the scan tool. 5. Disconnect the brake switch connector from the brake switch. Did the TCC brake switch status change from “Closed” to “Open”?

Replace the brake switch. Is the replacement complete?

Inspect circuit BRN/RED for a short to B+ condition. Repair the circuit if necessary. Did you find a short to B+ condition?

Replace the PCM. Is the replacement complete?

In order to verify your repair, perform the following procedure: 1. Select DTC. 2. Select “Clear Info”. 3. With the engine “off” turn the ignition switch to the “on” position. 4. Apply the brake pedal. 5. Verify that the brake switch status indicates “Open” (0 volts) for 2 seconds. 6. Select Specific DTC. Enter DTC P0724. Has the test run and passed?

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–53

DTC P0730 Gear Error Without Input Speed

D07RY00055

Circuit Description B The Powertrain Control Module (PCM) calculates the slippage of the converter and transmission based upon the engine speed, the output speed, and the current gear ratio. B The slippage of the converter at a high enough engine speed is low. The transmission should not slip more than a given value when there is no shift. B This DTC detects a slip at each gear. This is a type “C” DTC.

Conditions For Setting The DTC B B B B

No Output Speed Sensor DTC(s) P0722, P0723. Not in Park, Neutral, or Reverse. Engine speed is greater than 3,500 rpm. 3 seconds since upshift.

B No Transmission Range Switch DTC(s) P0705, P0706. B 3 seconds since downshift. B 3 seconds since garage shift (N→D). B And one of the following conditions occur: – Slip is greater than 508 rpm in 1st gear. – Slip is greater than 468 rpm in 2nd gear. – Slip is greater than 449 rpm on 3rd gear. – Slip is greater than 440 rpm on 4th gear. B All conditions met for 5.5 seconds.

Action Taken When The DTC Sets B Maximum line pressure. B The PCM will not illuminate the Malfunction Indicator Lamp (MIL).

7A1–54 TRANSMISSION CONTROL SYSTEM (4L30–E) B The PCM will illuminate the CHECK TRANS Lamp. B Turn force motor OFF.

Conditions For Clearing The DTC/CHECK TRANS Lamp B The PCM will turn “off” the CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. B The DTC can be cleared from PCM memory by using a scan tool. B The DTC can also be cleared from memory when the vehicle has made 40 warmup cycles without a failure reported. B The PCM will cancel the DTC Actions Taken items when the fault conditions no longer exist and the ignition is cycles “off” long enough to power down the PCM.

Diagnostic Aids B Check for intermittent output speed sensor circuit problems. B Check for possible incorrect calibration. (PCM part No., tire specification, and rear axle ratio)

Test Description The numbers below refer to the step numbers on the diagnostic chart: 3. This step checks for possible low fluid level causing slipping resulting in an undefined gear ratio. 4. This step checks for correct gear ratios for commanded gears. 5. This step checks for low line pressure.

DTC P0730 Gear Error Without Input Speed Step

Action

Were you sent here from the “On–Board Diagnostic (OBD) System Check”?

Go to Step 2

Go to OBD System Check Refer to Driveability and Emission in Engine section

Go to Step 7

Go to Step 3

Go to Step 4

Go to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30–E) section

Refer to Diagnostic Aids

Go to Step 5

Visually inspect the transmission cooling system for fluid leaks. B Refer to Chart 16: Possible Causes of Transmission Fluid Leaks of Mechanical/Hydraulic Diagnosis Symptoms Index in Automatic Transmission (4L30–E) section Was condition found and corrected?

Yes

Refer to Checking Transmission Fluid Level and Condition in Automatic Transmission (4L30–E) section. Has transmission fluid checking procedure been performed?

1. Install the scan tool. 2. Turn the ignition switch to the “on” position. 3. Engine not running. NOTE: Before clearing DTC(s) use the scan tool to record the “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 4. Record the Failure Record data. 5. Use the scan tool snapshot mode to record transmission gear ratios. 6. Drive vehicle in transmission gear ranges L, 2, 3, and D with the engine speed is greater than 3,500 rpm for 5.5 seconds. 7. Record each transmission gear. 1st:2.73 – 2.99 2nd:1.54 – 1.71 3rd:0.93 – 1.05 4th:0.66 – 0.78 Does commanded gear ratio match ranges as shown?

7A1–55

TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0730 Gear Error Without Input Speed (Cont’d) Step

Action

Perform line pressure check. B Refer to Line Pressure Test in Automatic Transmission (4L30–E) section. Was condition found and corrected?

Go to Step 7

Go to Step 6

Go to Step 7

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

Check for possible clutch slippage. B Refer to Chart 6: Diagnostic Trouble Code (DTC) P0730 of Mechanical/Hydraulic Diagnosis Symptoms Index in Automatic Transmission (4L30–E) section. Was condition found and corrected?

Yes

1. After the repair is complete, use the scan tool to select “DTC”, then “Clear info” function. 2. Operate the vehicle under the following conditions: B Drive the vehicle in D4 with the engine speed greater than 3,500 rpm to obtain anyone of the following gear ratios for seven seconds. 1st 1:2.73 – 1:2.99 2nd 1:1.54 – 1:1.71 3rd 1:0.93 – 1:1.05 4th 1:0.66 – 1:0.78 Has the last test failed?

7A1–56 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0742 Torque Converter Clutch (TCC) System Stuck On

D07R200008

Circuit Description The PCM energizes the TCC solenoid by creating an ignition voltage on circuit BRN/BLU. When ignition voltage is energized by the PCM, the TCC solenoid stops converter signal oil from exhausting. This causes converter signal oil pressure to increase and move the TCC valve. The TCC solenoid will deenergize when the PCM no longer provides ignition voltage. When the TCC solenoid is deenergized, it will exhaust fluid and release the TCC. This DTC detects low torque converter slip when the TCC is commanded “off”. This is a type “B” DTC.

Conditions For Setting The DTC The following conditions occur once per TCC cycle, three consecutive times: B No TPS DTCs P0122 or P0123. B No OSS DTCs P0722 or P0723. B No TCC solenoid DTC P1860. B TP angle is greater than 20%. B Engine speed is greater than 500 rpm and less than 3,000 rpm. B Engine vacuum is between 0 and 70 kPa. B Commanded gear is not 1st. B Gear range is D4. B TCC is commanded “off”. B No TCC Stuck off DTC P1870.

B TCC slip speed is between –20 and 40 rpm for 2 seconds. B Vehicle speed is greater than 25 km/h (15 mph) and less than 120 km/h (75 mph). B Speed ratio is greater than 0.9 and less than 2.0.

Action Taken When The DTC Sets B For lamp illuminate refer to DTC type definition (type B). B Inhibit TCC engagement.

Conditions For Clearing The MIL/DTC B The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. B The DTC can be cleared from the PCM history by using a scan tool. B The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. B The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled “off” long enough to power down the PCM.

7A1–57

TRANSMISSION CONTROL SYSTEM (4L30–E)

Diagnostic Aids

Test Description

B If the TCC is mechanically stuck “on” with the parking brake applied and any gear range selected, the TCC fluid will mechanically apply the TCC, possibly causing an engine stall.

The number below refers to the step number on the diagnostic chart: 3. This test checks the mechanical state of the TCC. (When the PCM commands the TCC solenoid “off”, the slip speed should increase).

DTC P0742 Torque Converter Clutch (TCC) System Stuck On Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Yes

Go to Step 2

Go to OBD System Check Refer to Driveability and Emissions in Engine section

Go to Step 3

Go to Diagnostic Aids

Go to Step 4

Go to Diagnostic Aids

Go to Step 5

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 3. Record the DTC “Freeze Frame” and “Failure Records”. 4. Using the scan tool, verify the “TP Sensor” operation. Are the “TP Sensor” values within 0.6 – 5.0 volts?

Drive the vehicle in the D4 drive range in fourth gear under steady acceleration, with a TP angle greater than 20%. Does the scan tool display “TCC Slip Speed” between –30 and +30 rpm, while the displayed TCC solenoid state is “off”?

The TCC is mechanically stuck “on”. Check the following items: B Clogged exhaust orifice in the TCC solenoid. B Converter clutch apply valve stuck in the apply position. B Misaligned or damaged valve body gasket. B Restricted release passage. Was a problem found and corrected?

1. After the repair is complete, use the scan tool to select “DTC”, then “Clear Info” function and ensure the following conditions are met: TCC slip speed must be between 200 and 2,500 rpm for 4 seconds. 2. Review the scan tool “DTC Info”. Has the last test failed or is the current DTC displayed?

7A1–58 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical

D07R200009

Circuit Description The PCS is a PCM–controlled device used to regulate transmission line pressure. The PCM compares TPS voltage, engine rpm, and other inputs to determine the line pressure appropriate for a given load. The PCM will regulate the pressure by applying a varying amperage to the PCS. The applied amperage can vary from 70 to 1060 milliampere (mA), and is monitored by the PCM. This DTC detects a continuous open or short to ground in the PCS circuit or the PCS. This is a type “C” DTC.

Conditions For Setting The DTC B Battery voltage is between 10 and 16 volts. B The PCM detects that the different between commanded and actual current is 200 milliampere (mA) for over 1 second. B Engine speed is greater than 300 rpm.

Action Taken When the DTC Sets B The PCM will not illuminate the Malfunction Indicator Lamp (MIL). B Maximum line pressure. B The PCM will illuminate the CHECK TRANS Lamp. B Turn Force Motor OFF (Durability).

Conditions For Clearing The DTC/CHECK TRANS Lamp B The PCM will turn “off” the CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported.

B The DTC can be cleared from PCM history by using a scan tool. B The DTC will be cleared from memory when the vehicle has achieved 40 warmup cycles without a failure reported. B The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled “off” long enough to power down the PCM.

Diagnostic Aids B Inspect the wiring for poor electrical connection at the PCM and at the transmission 4–way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.

Test Description The numbers below refer to the step numbers on the diagnostic chart: 2. This test checks the ability of the PCM to command the PCS. 3. This test checks the PCS and internal wiring harness for incorrect resistance.

7A1–59

TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Is the “PC Act. Current” reading always within 160 mA?

Go to Step 5

Go to Step 10

—

Go to Step 10

—

Go to Step 10

Go to Step 8

Go to Step 10

Go to Step 9

Go to Step 10

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30–E) section. Is the replacement complete?

Go to Step 6

Inspect/repair circuits VIO/WHT and VIO/RED for a short to ground or poor connections. Was a problem found?

Go to Step 4

Inspect/repair circuits VIO/WHT and VIO/RED. Was a problem found?

Go to Step 7

Repair the internal wiring harness for an open. Is the repair complete?

Go to Step 3

Replace the PCS. Is the replacement complete?

Go to Diagnostic Aids

1. Remove the transmission oil pan. Refer to Solenoid (Adapter Case Valve Body) in Automatic Transmission (4L30–E) section. 2. Disconnect the internal wiring harness at the PCS. 3. Measure the resistance of the PCS. Is the resistance within 3–7 ohms?

Go to Step 2

Go to OBD System Check Refer to Driveability and Emission in Engine section

1. Turn the ignition “off”. 2. Disconnect the transmission 4–way connector E–40. 3. Using the J39200 DVOM, measure the resistance between terminals E40–2(B) and E40–4(C). Is the resistance within 3–7 ohms?

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 3. Record the DTC “Failure Records”. 4. While the engine is operating, put the transmission in Park. 5. Using the scan tool, apply 70 through 1060 milliampere (mA) while observing “PC Ref. Current” and “PC Act. Current”.

Yes

1. After the repair is complete, use the scan tool to select “DTC”, then “Clear Info” function and ensure the following conditions are met: The PCS duty cycle is not at its electrical high or low limit. 2. Review the scan tool “DTC Info”. Has the last test failed or is the current DTC displayed?

7A1–60 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0751 Shift Solenoid A Performance (Stuck Off)

D07RT011

Circuit Description The shift solenoid A is used to control fluid flow acting on the 1–2 and 3–4 shift valves. The solenoid is a normally close exhaust valve that is used with the shift solenoid B to allow four different shifting combinations. The DTC detects when there is only a 1–1–4–4 shift pattern depending on the state of the mechanical failure instead of a 1–2–3–4 shift pattern. This is a type “B” DTC.

Conditions For Setting The DTC B B B B B B B

No ETC DTCs. No OSS DTCs P0722 or P0723. No TCC solenoid DTCs P0742, P1860, P1870. No shift solenoid A DTC P0753. No shift solenoid B DTC P0758. Gear range is D4. Transmission temperature is between 20° and 130°C (68° and 266°F). B Output speed is greater than 375 rpm. B No range code P0705, P0706. B No torque code (to be confirmed). B Engine run for more 0 seconds and not influed cut-off (to be confirmed). All the above conditions have been met and the combination of conditions 1, 2 occur two consecutive times.

Condition 1: B B B B B B

2nd gear is commanded for ≥ 1 second. 40 ≤ Engine Torque ≤ 400 N·m Speed ratio ≥ 0.6 Throttle position ≥ 10 % 800 ≤ TCC Slip ≤ 4000 rpm 2.75 ≤ Modeled Ratio ≤ 3.2 for 1 second.

Condition 2: B B B B B B

3rd gear is commanded for ≥ 1 second. 40 ≤ Engine Torque ≤ 400 N·m Throttle position ≥ 10 % –8000 ≤ TCC Slip ≤ 8000 rpm Speed ratio ≥ 0.45 0.62 ≤ Modeled Ratio ≤ 0.92 for 3 second.

Action Taken When the DTC Sets B Maximum line pressure. B For lamp illuminate refer to DTC type definition (type B). B Turn Force Motor OFF.

Conditions For Clearing The The MIL/DTC B The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. B The DTC can be cleared from the PCM history by using a scan tool. B The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. B The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled “off” long enough to power down the PCM.

Diagnostic Aids B Verify that the transmission meets the specifications in the 4L30–E shift speed chart. B Other internal transmission failures may cause more than one shift to occur.

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–61

Test Description The numbers below refer to the step numbers on the diagnostic chart: 2. This test checks the function of the range switch (mode switch). 3. This test checks that the scan tool commanded all shifts, all shifts solenoids responded correctly, but all the shifts did not occur.

DTC P0751 Shift Solenoid A Performance (Stuck Off) Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Yes

Go to Step 2

Go to OBD System Check Refer to Driveability and Emission in Engine section

Go to Step 3

Go to “Range Switch Logic Table”

Go to Step 4

Go to Diagnostic Aids

Go to Step 5

Go to Diagnostic Aids

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 3. Record the DTC “Freeze Frame” and “Failure Records”. 4. With the engine operating, apply the brake pedal and select each transmission range DL, D2, D3, D4, N, R, and P. Does each selected transmission range match the “TR Switch” on the scan tool?

1. While the engine is operating, raise the drive wheels. 2. With the transmission in D4 range, use the scan tool to command 1st, 2nd and 3rd, and 4th gears while accelerating the vehicle. Was a 1–1–4–4 only shift pattern detected? (Road testing the vehicle may be necessary).

Check the shift solenoid/hydraulic circuit for: B One or both of the shift solenoids for an internal malfunction. B Contamination or sediment in one or both of the shift solenoids. B Damaged seals on one or both of the shift solenoids. Refer to Solenoid (Main Case Valve Body) in Automatic Transmission (4L30–E) section. Was a problem found and corrected?

7A1–62 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0752 Shift Solenoid A Performance (Stuck On)

D07RT011

Circuit Description The shift solenoid A is used to control fluid flow acting on the 1–2 and 3–4 shift valves. The solenoid is a normally close exhaust valve that is used with the shift solenoid B to allow four different shifting combinations. The DTC detects when there is only a 2–2–3–3 shift pattern depending on the state of the mechanical failure instead of a 1–2–3–4 shift pattern. This is a type “B” DTC.

Conditions For Setting The DTC B B B B B B B B

No ETC DTCs. No OSS DTCs P0722 or P0723. No TCC solenoid DTC P0742, P1860, P1870. No shift solenoid A DTC P0753. No shift solenoid B DTC P0758. Gear range is D4. Output speed is greater than 375 rpm. Transmission temperature is between 20° and 130°C (68° and 266°F). B No range code P0705, P0706. B No torque code (to be confirmed). B Engine run for more 0 seconds and not influed cut-off (to be confirmed). All the above conditions have been met and the combination of condition 1, 2 occur two consecutive times.

Condition 1: B B B B B B B

1st gear is commanded for ≥ 1 sec 40 ≤ Engine Torque ≤ 400 N·m Throttle positon ≥ 10% –8000 ≤ TCC slip ≤ 8000 rpm Transmission out speed ≥ 375 rpm Speed ratio ≥ 0.3 1.5 ≤ Modeled Ratio ≤ 2.4 for 0.687 seconds

Condition 2: B B B B B B

4th Gear is commanded for ≥ 1 sec. 40 ≤ Engine Torque ≤ 400 N·m Trottle position ≥ 10% –8000 ≤ TCC slip ≤ 8000 rpm Speed ratio ≥ 0.6 0.92 ≤ Modeled Ratio ≤ 1.5 for 7 seconds

Action Taken When the DTC Sets B Maximum line pressure. B For lamp illuminate refer to DTC type definition (type B). B Turn Force Motor OFF.

Diagnostic Aids B Verify that the transmission meets the specifications in the 4L30–E shift speed chart. B Other internal transmission failures may cause more than one shift to occur.

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–63

DTC P0752 Shift Solenoid A Performance (Stuck On) Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Yes

Go to Step 2

Go to OBD System Check Refer to Driveability and Emissions in Engine section

Go to Step 3

Go to “Range Switch Logic Table”

Go to Step 4

Go to Diagnostic Aids

Go to Step 5

Go to Diagnostic Aids

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 3. Record the DTC “Freeze Frame” and “Failure Records”. 4. With the engine operating, apply the brake pedal and select each transmission range DL, D2, D3, D4, N, R, and P. Does each selected transmission range match the “TR Switch” on the scan tool?

1. While the engine is operating, raise the drive wheels. 2. With the transmission in D4 range, use the scan tool to command 1st, 2nd and 3rd, and 4th gears while accelerating the vehicle. Was a 2–2–3–3 only shift pattern detected? (Road testing the vehicle may be necessary).

7A1–64 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0753 Shift Solenoid A Electrical

D07R200010

Circuit Description B The shift solenoid A is a simple on/off solenoid located in the main case valve body. The solenoid is the normally closed type. In second or third gear the Powertrain Control Module (PCM) energizes the solenoid to open a fluid inlet port. When the port is open, fluid pressure actuates the shift valve. B The solenoid is activated by a current. This current is produced by applying a voltage to one side (the High side) and a ground to the other side (Low side). B The High Side Driver (HSD) is a circuit of the PCM that acts as a switch between the solenoids and the supply voltage. The High side of the solenoid is permanently supplied with voltage, except in BACKUP MODE or when ignition is off the HSD is turned off. This DTC detects a continuous open or short to ground in the shift solenoid A circuit or the shift solenoid A. This is a type “B” DTC.

Conditions For Setting The DTC B Ignition is “on”, Engine “run”. B Battery voltage is between 10 and 16 volts. B The PCM commands the solenoid “on” and the voltage remains high (B+), or the PCM commands the solenoid “off” and the voltage remains low (zero volts). B All conditions met for 0.84 – 1.0 seconds.

Action Taken When The DTC Sets B B B B

Maximum line pressure. Immediate landing to 4th gear. Inhibit TCC engagement. For lamp illuminate refer to DTC type definition (type B).

Conditions For Clearing The MIL/DTC B The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. B The DTC can be cleared from the PCM history by using a scan tool. B The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. B The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled “off” long enough to power down the PCM.

Diagnostic Aids B Inspect the wiring for poor electrical connection at the PCM and at the transmission 7-way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation.

TRANSMISSION CONTROL SYSTEM (4L30–E) B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change. B An open ignition feed circuit can cause multiple DTCs to set. B A shift solenoid B DTC P0758 could also set with a shift solenoid A electrical failure.

7A1–65

5. This test measures the resistance of the component. 8. This test checks the function of the shift solenoid A and the transmission internal wiring harness. Shift Solenoid Status Chart Gear

Shift solenoid A

Shift solenoid B

1st

OFF

Test Description

2nd

The numbers below refer to the step numbers on the diagnostic chart: 3. This test checks for power to the shift solenoid A from the ignition through the PCM.

3rd

OFF

4th

OFF

DTC P0753 Shift Solenoid A Electrical Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Yes

Go to Step 2

Go to OBD System Check Refer to Driveability and Emission in Engine section

Go to Step 3

Go to Diagnostic Aids

Go to Step 4

Go to Step 5

Go to Step 10

Go to Step 5

Go to Step 6

Go to Step 8

Go to Step 11

Go to Step 7

Go to Step 12

Go to Step 9

1. Install the scan tool. 2. With the engine “on”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 3. Record the DTC “Freeze Frame” and “Failure Records”. Were DTCs P0753, P0758, P1860 set?

1. Turn the ignition “on”. 2. Using the J39200 DVOM, measure the voltage between PCM connector terminals E35–43 and E34–1 (GND). Is the voltage within 10–12 volts?

1. 2. 3. 4.

Turn the ignition “off”. Disconnect the E-34 (BLUE) and E-35 (RED) PCM connector. Turn the ignition “on”. Using the J39200 DVOM, measure the voltage between PCM connector terminals E34–5 and ground.

Is the voltage within 10 – 12 volts? 5

1. Turn the ignition “off”. 2. Disconnect the E-34 (BLUE) and E-35 (RED) PCM connector. 3. Using the J39200 DVOM, measure the resistance between PCM connector terminals E35–43 and E34–5. Is the resistance within 18 – 20 ohms?

1. Disconnect the E-34 (BLUE) and E-35 (RED) PCM connectors. 2. Using the J39200 DVOM, check a continuity between PCM terminals E34–5 and ground. Is there a continuity?

Using the J39200 DVOM, check a continuity between E-35 (RED) PCM terminal 43 and ground. Is there a continuity?

7A1–66 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0753 Shift Solenoid A Electrical (Cont’d) Step

Action

1. Disconnect the transmission main case 7–way connector E–42. 2. Using the J39200 DVOM, measure the resistance between terminals E42–2(D) and E42–3(C). Is the resistance within 18–20 ohms?

Go to Step 17

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Go to Step 17

—

Go to Step 17

—

Go to Step 17

—

Go to Step 17

—

Go to Step 17

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

Repair the PCM connector connection. Was a problem found and corrected?

—

The PCM may be faulty. Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30–E) section. Is the replacement complete?

Go to Step 17

The shift solenoid A is faulty. Replace the shift solenoid A. Refer to Solenoid (Main Case Valve Body) in Automatic Transmission (4L30–E) section. Is the replacement complete?

Go to Step 15

The wiring harness between PCM connector E-34 or E-35 and transmission 7–way connector E42 is open or poor connection. Was a problem found and corrected?

Go to Step 16

The wiring harness between PCM connector terminals E35–43 and transmission harness terminal E42–2(D) is shorted to ground. Was a problem found and corrected?

Go to Step 14

The wiring harness between PCM connector terminal E34–5 and transmission harness terminal E42–3(C) is shorted to ground. Was a problem found and corrected?

Go to Step 13

The wiring harness between PCM connector terminals E34–5 and transmission harness terminal E42–3(C) is shorted to voltage. Was a problem found and corrected?

Check every connection at the PCM connector. Was a problem found?

Yes

1. After the repair is complete, use the scan tool to select “DTC”, then “Clear Info” function and operate the vehicle under the following conditions: B The shift solenoid A is commanded “on” and the voltage drops to zero. B The shift solenoid A is commanded “off” and the voltage increases to B+. 2. Review the scan tool “DTC Info”. Has the last test failed or is the current DTC displayed?

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–67

DTC P0756 Shift Solenoid B Performance (Stuck Off)

D07RT011

Circuit Description The shift solenoid B is used to control fluid flow acting on the 2–3 shift valves. The solenoid is a normally open exhaust valve that is used with the shift solenoid A to allow four different shift combinations. This DTC detects when there is only a 4-3-3-4 shift pattern depending on the state of the mechanical failure instead of a 1-2-3-4 shift pattern. This is a type “B” DTC.

Conditions For Setting The DTC B B B B B B B

No ETC DTCs. No OSS DTCs P0722 or P0723. No TCC solenoid DTCs P0742, P1860, P1870. No shift solenoid DTCs P0753, P0758. Gear range is D4. Output speed is greater than 375 rpm. Transmission fluid temperature is between 20° and 130°C (68° and 266°F). B No range code P0705, P0706. B No torque code (to be confirmed). B Engine run for more 0 seconds and influed cut-off (to be confirmed). All the above conditions have been met and the combination of condition 1, 2 occur two consecutive times.

Condition 1: B B B B B B B

1st gear is commanded for ≥ 1 second 40 ≤ Engine Torque ≤ 400 N·m Throttle position ≥ 10 % –2300 ≤ TCC Slip ≤ 200 rpm. Transmission output speed ≥ 400 rpm Speed ratio ≥ 0.3 0.60 ≤ Modeled Ratio ≤ 1.49 for 1 second.

Condition 2: B B B B B B

2nd gear is commanded for ≥ 1 second 40 ≤ Engine Torque ≤ 400 N·m Throttle position ≥ 10 % –8000 ≤ TCC Slip ≤ 8000 rpm. Speed ratio ≥ 0.6 0.92 ≤ Modeled Ratio ≤ 1.5 for 0.687 second.

Action Taken When the DTC Sets B Maximum line pressure. B For lamp illuminate refer to DTC type definition (type B). B Turn Force Motor OFF.

Conditions For Clearing The MIL/DTC B The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. B The DTC can be cleared from the PCM history by using a scan tool. B The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. B The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled “off” long enough to power down the PCM.

Diagnostic Aids B Verify that the transmission meets the specifications in the 4L30-E shift speed chart. B Other internal transmission failures may allow more than one shift to occur.

7A1–68 TRANSMISSION CONTROL SYSTEM (4L30–E)

Test Description The numbers below refer to the step numbers on the diagnostic chart: 2. This test checks the function of the range switch (mode switch). 3. This test checks for selected gear ratio vs. a ratio not obtainable under normal driving conditions.

DTC P0756 Shift Solenoid B Performance (Stuck Off) Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Yes

Go to Step 2

Go to OBD System Check Refer to Driveability and Emission in Engine section

Go to Step 3

Go to “Range Switch Logic Table”

Go to Step 4

Go to Diagnostic Aids

Go to Step 5

Go to Diagnostic Aids

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 3. Record the DTC “Freeze Frame” and “Failure Records”. 4. With the engine operating, apply the brake pedal and select each transmission range DL, D2, D3, D4, N, R, and P. Does each selected transmission range match the “TR Switch” on the scan tool?

1. While the engine is operating, raise the drive wheels. 2. With the transmission in D4 range, use the scan tool to command 1st, 2nd, and 3rd, and 4th gears while accelerating the vehicle. Was a 4–3–3–4 shift pattern detected? (Road testing the vehicle may be necessary.)

Check the shift solenoid/hydraulic circuit for: B One or both of the shift solenoids for an internal malfunction. B Contamination or sediment in one or both of the shift solenoids. B Damaged seals on the one or both of the shift solenoids. Refer to Solenoid (Main Case Valve Body) in Automatic Transmission (4L30–E) section. Was a problem found and corrected?

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–69

DTC P0757 Shift Solenoid B Performance (Stuck On)

D07RT011

Circuit Description The shift solenoid B is used to control fluid flow acting on the 2–3 shift valves. The solenoid is a normally open exhaust valve that is used with the shift solenoid A to allow four different shift combinations. This DTC detects when there is only a 1–2–2–1 shift pattern depending on the state of the mechanical failure instead of a 1–2–3–4 shift pattern. This is a type “B” DTC.

Conditions For Setting The DTC B B B B B B B B

No ETC DTCs. No OSS DTCs P0722 or P0723. No TCC solenoid DTC P0742, P1860, P1870. No shift solenoid A DTCs P0753. No shift solenoid B DTC P0758. Gear range is D4. Output speed is greater than 375 rpm. Transmission fluid temperature is between 20° and 130°C (68° and 266°F). B No range code P0705, P0706. B No torque code (to be confirmed). B Engine run for more 0 seconds and not influed cut-off (to be confirmed). All of the above conditions have been met and the combination of condition 1,2 occur two consecutive times.

Condition 1: B B B B B B B

3rd gear is commanded for ≥ 1 second 40 ≤ Engine Torque ≤ 400 N·m Throttle positon ≥ 10% –8000 ≤ TCC slip ≤ 8000 rpm Transmission out speed ≥ 375 rpm Speed ratio ≥ 0.6 1.44 ≤ Modeled Ratio ≤ 2.4 for 4 seconds

Condition 2: B B B B B B

4th Gear is commanded for ≥ 1 second 15 ≤ Engine Torque ≤ 400 N·m Trottle position ≥ 10% –8000 ≤ TCC slip ≤ 8000 rpm Speed ratio ≥ 0.6 2.75 ≤ Modeled Ratio ≤ 3.2 for 2 seconds

Action Taken When the DTC Sets B Maximum line pressure. B For lamp illuminate refer to DTC type definition (type B). B Turn Force Motor OFF.

Conditions For Clearing The MIL/DTC B The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. B The DTC can be cleared from the PCM history by using a scan tool. B The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. B The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled “off” long enough to power down the PCM.

Diagnostic Aids B Verify that the transmission meets the specifications in the 4L30-E shift speed chart. B Other internal transmission failures may cause more than one shift to occur.

7A1–70 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0757 Shift Solenoid B Performance (Stuck On) Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Yes

Go to Step 2

Go to OBD System Check Refer to Driveability and Emissions in Engine section

Go to Step 3

Go to “Range Switch Logic Table”

Go to Step 4

Go to Diagnostic Aids

Go to Step 5

Go to Diagnostic Aids

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 3. Record the DTC “Freeze Frame” and “Failure Records”. 4. With the engine operating, apply the brake pedal and select each transmission range DL, D2, D3, D4, N, R, and P. Does each selected transmission range match the “TR Switch” on the scan tool?

Check the shift solenoid/hydraulic circuit for: B One or both of the shift solenoids for an internal malfunction. B Contamination or sediment in one or both of the shift solenoids. B Damaged seals on the one or both of the shift solenoids. Refer to Solenoid (Main Case Valve Body) in Automatic Transmission (4L30–E) section. Was a problem found and corrected?

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–71

DTC P0758 Shift Solenoid B Electrical

D07R200010

Circuit Description B The shift solenoid B is a simple on/off solenoid located in the main case valve body. It is normally open. When the port is open, fluid pressure actuates the shift valve. In first or second gear, the Powertrain Control Module (PCM) energizes the solenoid to close a fluid inlet port. B The solenoid is activated by current. This current is produced by applying a voltage to one side (the High side) and a ground to the other side (Low side). B The High Side Driver (HSD) is a circuit of the PCM that acts as a switch between the solenoids and the supply voltage. The High side of the solenoid is permanently supplied with voltage. In BACKUP MODE or when the ignition is off, the HSD is turned off. This DTC detects a continuous open or short to ground in the shift solenoid B circuit or shift solenoid B. This is a type “B” DTC.

Action Taken When The DTC Sets B B B B

Fixed to 4th gear. Maximum line pressure. Inhibit TCC engagement. For lamp illuminate refer to DTC type definition (type B).

Conditions For Clearing The MIL/DTC B The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. B The DTC can be cleared from the PCM history by using a scan tool. B The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. B The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled “off” long enough to power down the PCM.

7A1–72 TRANSMISSION CONTROL SYSTEM (4L30–E) B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.

Test Description The numbers below refer to the step numbers on the diagnostic chart: 5. This test measures the resistance of the component. 6. This test checks the function of the shift solenoid B and the transmission internal wiring harness. 9.This test checks for power to the shift solenoid B from the ignition through the PCM. Shift Solenoid Status Chart Gear

Shift solenoid A

Shift solenoid B

1st

OFF

2nd

3rd

OFF

4th

OFF

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–73

DTC P0758 Shift Solenoid B Electrical Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Yes

Go to Step 2

Go to OBD System Check Refer to Driveability and Emission in Engine section

Go to Step 4

Go to Step 3

Go to Step 7

Go to Diagnostic Aids

Go to Step 13

Go to Step 5

Go to Step 14

Go to Step 6

Go to Step 15

Go to Step 16

Go to Step 8

Go to Step 10

Go to Step 17

Go to Step 9

Go to Step 18

Go to Step 11

Go to Step 19

Go to Step 20

1. The engine “on”. 2. Apply brake pedal and select transmission range “D”. 3. Press and hold down the winter switch and select transmission mode “winter”. Does the scan tool display DTC P0758 at 3rd gear?

1. Turn the ignition “off”. 2. Disconnect the E-34 (BLUE) and E-35 (RED) PCM connectors. 3. Turn the ignition “on”. 4. Using the J39200 DVOM, measure the voltage between PCM connector terminals E35–31 and E35–1. Is the voltage within 10 – 12 volts?

1. Turn the ignition “off”. 2. Using the J39200 DVOM, measure the resistance between PCM connector terminals E35–31 and E35–43. Is the resistance within 18 – 20 ohms?

1. Disconnect the transmission main case connector E–42. 2. Using the J39200 DVOM, measure the resistance between terminals E42–6(A) and E42–2(D). Is the resistance within 18 – 20 ohms?

1. Turn the ignition “off”. 2. Disconnect the E-34 (BLUE) and E-35 (RED) PCM connectors. 3. Using the J39200 DVOM, measure the resistance between PCM connector terminals E35–31 and E35–43. Is the resistance within 18 – 20 ohms?

Using the J39200 DVOM, check a continuity between PCM connector terminal E35–31 and ground. Is there a continuity?

Using the J39200 DVOM, check a continuity between PCM connector terminal E35–43 and ground. Is there a continuity?

1. Disconnect the transmission main case connector E-42. 2. Using the J39200 DVOM, measure the resistance between terminals E42–6(A) and E42–2(D). Is the resistance within 18 – 20 ohms?

7A1–74 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P0758 Shift Solenoid B Electrical (Cont’d) Step 11

Action

—

Go to Step 22

—

Go to Step 22

—

Go to Step 22

—

Go to Step 22

—

Go to Step 22

—

Go to Step 22

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

Replace the PCM. Is the replacement complete?

Go to Step 22

The internal wiring harness from the shift solenoid B is open, or the shift solenoid B is faulty. Was a problem found and corrected?

—

The wiring harness between PCM connector terminal E35–31 and transmission main case connector terminal E42–6(A), or between PCM connector terminal E35–43 and main case connector terminal E42–2(D) is open. Was a problem found and corrected?

Go to Step 22

The wiring harness between PCM connector terminal E35–43 and transmission main case connector terminal E42–2(D) is shorted to ground. Was a problem found and corrected?

—

The wiring harness between PCM connector terminal E35–31 and transmission main case connector terminal E42–6(A) is shorted to ground. Was a problem found and corrected?

Go to Step 22

The shift solenoid B is faulty, or the internal wiring harness from the shift solenoid B is shorted. Was a problem found and corrected?

Go to Diagnostic Aids

The wiring harness between PCM connector and transmission main case 7-way connector is shorted. Was a problem found and corrected?

Go to Step 21

The PCM internal terminal E35–31 is shorted to voltage. Replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30–E) section. Is the replacement complete?

Go to Step 12

The wiring harness between PCM connector terminal E35–31 and transmission main case terminal E42–6(A) is shorted to voltage. Was a problem found and corrected?

Go to Step 22

1. Connect the E-34 (BLUE) and E-35 (RED) PCM connectors to the PCM. 2. Turn the ignition “on”, the engine “on”. 3. Repeat Step 3. Does the scan tool display DTC P0758 at 3rd gear?

Check every connection of the PCM. Was a problem found and corrected?

Yes

1. After the repair is complete, use the scan tool to select “DTC”, then “Clear Info” function and operate the vehicle under the following conditions: B The shift solenoid B is commanded “on” and voltage drops to zero. B The shift solenoid B is commanded “off” and voltage increases to B+. 2. Review the scan tool “DTC Info”. Has the last test failed or is the current DTC displayed?

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–75

DTC P1850 Brake Band Apply Solenoid Malfunction

D07R200010

Circuit Description B The brake band apply solenoid is a normally open solenoid which controls the flow of fluid for brake band application. The Powertrain Control Module (PCM) uses Pulse Width Modulation (PWM) and changes the duty cycle to control the solenoid. The PCM turns the solenoid on (energized) and off (deenergized) at a constant frequency. The length of time the solenoid is energized during each on/off cycle is called the pulse width. By varying or “modulating” the pulse width, the solenoid output pressure is changed. Since the solenoid is normally open, increasing the pulse width increases the duty cycle and decreases the output pressure. PWM control provides smooth band application without an accumulator. The band is only applied in first and second gears. B In the event of an electrical failure (open), the solenoid regulates at the maximum oil flow (0% duty cycle). B The solenoid is activated by a current. This current is produced by applying a voltage to one side (the High side) and a ground to the other side (Low side). B The High Side Driver (HSD) is a circuit of the PCM that acts as a switch between the solenoids and the supply voltage. The High side of the solenoid is permanently supplied with voltage. When the ignition is off, the HSD is turned off.

This DTC detects a continuous open or short to ground in the brake band apply solenoid circuit or the brake band apply solenoid. This is a type “D” DTC.

Conditions For Setting The DTC B Battery voltage is between 10 and 16 volts. B Ignition is “on”, Engine “run”. B The PCM commands the solenoid “on” and the voltage remains high (B+), or the PCM commands the solenoid “off” and the voltage remains low (zero volts). B All conditions met in 1.34 ∼ 1.56 seconds.

Action Taken When The DTC Sets B Inhibit brake band apply solenoid. B The PCM will not illuminate the Malfunction Indicator Lamp (MIL).

7A1–76 TRANSMISSION CONTROL SYSTEM (4L30–E)

Diagnostic Aids B Inspect the wiring for poor electrical connection at the PCM and at the transmission 7–way connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.

Test Description The numbers below refer to the step numbers on the diagnostic chart: 3. This test checks for power to the brake band apply solenoid from the ignition through the PCM. 4. This test checks the resistance of the transmission internal wiring harness and brake band apply solenoid. 5. This test checks the ability of the PCM and wiring to control the ground circuit.

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–77

DTC P1850 Brake Band Apply Solenoid Malfunction Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Yes

Go to Step 2

Go to OBD System Check Refer to Driveability and Emission in Engine section

Go to Step 3

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 10

Go to Step 11

Go to Step 19

Go to Step 4

Go to Step 7

Go to Step 8

Go to Step 13

Go to Step 14

Go to Step 19

Go to Step 9

Go to Step 15

Go to Step 16

Go to Step 12

Go to Step 19

Go to Step 18

Go to Step 16

Using the J39200 DVOM, back probe between PCM connector terminals E35–43 and E35–1. Is the voltage between 10 to 12 volts?

Using the J39200 DVOM, back probe between PCM connector terminals E35–10 and E35–1. Is the voltage between 10 to 12 volts?

1. Turn the ignition “off”. 2. Disconnect the E-34 (BLUE) and E-35 (RED) PCM connector. 3. Using the J39200 DVOM, check continuity between PCM terminal E35–43 and ground. Is there a continuity?

1. Disconnect the transmission main case connector E-42. 2. Using the J39200 DVOM, check continuity between the terminal E42–7(B) and ground. Is there continuity?

1. Disconnect the E-34 (BLUE) and E-35 (RED) PCM Connector. 2. Using the J39200 DVOM, measure the resistance between the PCM connector terminals E35–43 and E35–10. Is the resistance within 10–12 ohms?

1. Disconnect the transmission main case connector E-42. 2. Using the J39200 DVOM, measure the resistance between the terminals E42–7(B) and E42–2(D). Is the resistance within 10–12 ohms?

Using the J39200 DVOM, check continuity between PCM terminal E35–10 and ground. Is there continuity?

1. Disconnect the transmission main case connector E-42. 2. Using the J39200 DVOM, measure the resistance between the terminals E42-7(B) and E42-2(D). Is the resistance within 10–12 ohms?

7A1–78 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P1850 Brake Band Apply Solenoid Malfunction (Cont’d) Step

Action

1. Disconnect the transmission main case connector E-42. 2. Using the J39200 DVOM, check continuity between the terminals E42–7(B) and ground. Is there a continuity?

—

Go to Step 20

—

Go to Step 20

—

Go to Step 20

—

Go to Step 20

—

Go to Step 20

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

Check every connection at the PCM. If OK, replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30–E) section. Is the replacement complete?

Go to Step 20

The wiring harness between the PCM connector terminal E35–10 and the transmission main case connector terminal E42–7(B) is open. Was a problem found and corrected?

—

The wiring harness between the PCM connector terminal E35–10 and the transmission main case connector terminal E42–7(B) is shorted to ground. Was a problem found and corrected?

Go to Step 20

The brake band apply solenoid is faulty, or the internal wiring harness from the brake band apply solenoid is open. Was a problem found and corrected?

Go to Step 17

The wiring harness between the PCM connector terminal E35–43 and the transmission main case connector terminal E42–2(D) is open. Was a problem found and corrected?

Go to Step 13

The wiring harness between the PCM connector terminal E35–43 and the transmission main case connector terminal E42–2(D) is shorted to ground. Was a problem found and corrected?

The brake band apply solenoid is faulty, or the internal wiring harness from the brake band apply solenoid is shorted to ground. Was a problem found and corrected?

Yes

1. After the repair is complete, use the scan tool to select “DTC”, then “Clear Info” function and ensure the following conditions are met: B The brake band apply solenoid is commanded “on” and the volts drop to zero. B The brake band apply solenoid is commanded “off” and the volts increase to B+. 2. Review the scan tool “DTC Info”. Has the last test failed or is the current DTC displayed?

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–79

DTC P1860 TCC PWM Solenoid Electrical

D07R200011

Circuit Description The PCM allows current to flow through the solenoid coil according to the duty cycle (percentage of “on” and “off” time). This current flow through the solenoid coil creates a magnetic field that magnetizes the solid core. The magnetized core attracts the check ball to seat against spring pressure. This blocks the exhaust for the TCC signal fluid and allows 2–3 drive fluid to feed to TCC signal circuit.The TCC signal fluid pressure acts on the TCC regulator valve to regulate line pressure and to apply fluid pressure to the torque converter clutch shift control valve. When the TCC shift valve is in the apply position, regulated apply fluid pressure is directed through the TCC valve to apply the torque converter clutch. The TCC PWM solenoid is used in conjunction with the TCC PWM solenoid to regulate fluid to the torque converter. The TCC PWM solenoid is attached to the valve body within the transmission. This DTC detects a continuous open or short to ground or ignition in the TCC circuit or the TCC PWM solenoid. This is a type “B” DTC.

Conditions For Setting The DTC B B B B B

Battery voltage is between 10 and 16 volts. No shift solenoid A DTCs P0751 or P0752 or P0753. No shift solenoid B DTCs P0756 or P0757 or P0758. Ignition is “on”, Engine “run”. The PCM commands the solenoid “on” and the voltage remains low (zero volts). B The PCM commands the solenoid “off” and the voltage remains high (B+). B All conditions met for 0.875 ∼ 1.25 seconds.

Action Taken When The DTC Sets B Inhibit TCC engagement.

B For lamp illuminate refer to DTC type definition (type B).

Conditions For Clearing The MIL/DTC B The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. B The DTC can be cleared from the PCM history by using a scan tool. B The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. B The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled “off” long enough to power down the PCM.

Diagnostic Aids B Inspect the wiring for poor electrical connections at the PCM and at the transmission connector. Look for possible bent, backed out, deformed or damaged terminals. Check for weak terminal tension as well. Also check for a chafed wire that could short to bare metal or other wiring. Inspect for a broken wire inside the insulation. B When diagnosing for a possible intermittent short or open condition, move the wiring harness while observing test equipment for a change.

Test Description The numbers below refer to the step numbers on the diagnostic chart: 3. This test checks for voltage to the solenoid. 4. This test checks the ability of the PCM and wiring to control the ignition circuit. 9. This test checks the resistance of the TCC solenoid and the internal wiring harness.

7A1–80 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P1860 TCC PWM Solenoid Electrical Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Yes

Go to Step 2

Go to OBD System Check Refer to Driveability and Emission in Engine section

Go to Step 3

Go to Step 4

Go to Step 5

Go to Step 6

Go to Step 9

Go to Diagnostic Aids

Go to Step 7

Go to Step 8

Go to Step 15

Go to Step 16

Go to Step 15

Go to Step 16

Go to Step 13

Go to Step 14

Go to Step 15

Go to Step 10

Go to Step 11

Go to Step 12

Go to Step 17

—

1. Install the scan tool. 2. With the engine “on”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the“Clear Info” function is used. 3. Record the DTC “Freeze Frame” and “Failure Records”. Was DTC P1860 set?

Using the J39200 DVOM, back probe between PCM connector terminals E35–51 and E35–33. Is the voltage 0?

1. Apply brake pedal and select transmission range “D”. 2. Do a test drive, and increase the vehicle speed to TCC “on” at 4th. Does the scan tool display DTC P1860 at TCC “ON”?

1. Turn the ignition “off”. 2. Disconnect the E-35 (RED) PCM connector. 3. Using the J39200 DVOM, measure the resistance between PCM connector terminals E35–51 and E35–33. Is the resistance within 18 – 20 ohms?

The wiring harness between PCM connector terminal E35–51 and transmission adapter case connector terminal E40–1(A) is shorted to voltage. Was a problem found and corrected?

Intermittent condition. Check the wiring harness and terminals between PCM connector J2 and transmission adapter case connector E–40. Was a problem found and corrected?

1. Disconnect the transmission adapter case connector E–40. 2. Using the J39200 DVOM, measure the resistance between terminal E40–1(A) and ground. Is the resistance within 18 – 20 ohms?

1. Turn the ignition “off”. 2. Disconnect the E-35 (RED) PCM connector. 3. Using the J39200 DVOM, measure the resistance between terminals E35–51 and E35–33. Is the resistance within 18 – 20 ohms?

1. Disconnect the transmission adapter case connector E–40. 2. Using the J39200 DVOM, measure the resistance between terminal E40–1(A) and ground. Is the resistance within 18–20 ohms?

The wiring harness between PCM connector E-35 and adapter case connector E-40 is shorted to ground. Was a problem found and corrected?

7A1–81

TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P1860 TCC PWM Solenoid Electrical (Cont’d) Step

Action

The TCC solenoid is faulty, or the internal wiring harness from the TCC solenoid is shorted to ground. Was a problem found and corrected?

Go to Step 17

—

Go to Step 17

—

Go to Step 17

—

Go to Step 17

—

Begin diagnosis again Go to Step 1

Repair verified Exit DTC table

Check the PCM connector terminal E35–51, and transmission adapter case connector terminal E40–1(A). Was a problem found and corrected?

—

Check every connection at the PCM. If OK, replace the PCM. Refer to Powertrain Control Module (PCM) in Automatic Transmission (4L30–E) section. Is the replacement complete?

Go to Step 17

The TCC solenoid is faulty, or the internal wiring harness from the TCC solenoid is open. Was a problem found and corrected?

The wiring harness between PCM connector terminal E35–51 and adapter case terminal E40–1(A) is open. Was a problem found and corrected?

Yes

1. After the repair is complete, use the scan tool to select “DTC”, then “Clear Info” function and ensure the following conditions are met: B The TCC solenoid is commanded “on” and the volts increase to B+. B The TCC solenoid is commanded “off” and the volts drop to zero. 2. Review the scan tool “DTC Info”. Has the last test failed or is the current DTC displayed?

7A1–82 TRANSMISSION CONTROL SYSTEM (4L30–E)

DTC P1870 Transmission Component Slipping (TCC Stuck Off)

D07R200008

Circuit Description The PCM monitors the difference in engine speed and transmission output speed. For example in D3 drive range with the ECCC commanded, the engine speed should closely match transmission output speed. This DTC detects excessive TCC slip when the ECCC is engaged. This is a type “B” DTC.

Conditions For Setting The DTC The following conditions are met for three TCC cycles with reported excessive TCC slip conditions. B No OSS DTCs P0722 or P0723. B No shift solenoid A DTCs P0751 or P0752 or P0753. B No shift solenoid B DTCs P0756 or P0757 or P0758. B No TCC solenoid DTCs P0742 or P1860 or P1870. B Engine speed is between 1,000 and 3,500 rpm for 0.5 seconds. B Gear range is D4. B 13% < TPS < 99% B 50 < Engine Torque < 300 N·m B TFT is between 20° and 150°C (68° and 302°F). B TCC slip speed is between 250 rpm and 800 rpm for 3 times 7 seconds. B Vehicle speed is between 25 km/h (15 mph) and 225 km/h (158 mph). B Speed ratio is between 0.6 and 0.95. B ECCC is “ON”.

B Low (0.8) < TCC Capacity < hi (0.99) for 5 seconds

Action Taken When The DTC Sets B Only stored in memory. B For lamp illuminate refer to DTC type definition (type B).

Conditions For Clearing The MIL/DTC B The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported. B The DTC can be cleared from the PCM history by using a scan tool. B The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported. B The PCM will cancel the DTC default actions when the fault no longer exist and the ignition is cycled “off” long enough to power down the PCM.

Diagnostic Aids B Range switch malfunction could set a DTC P1870. B A mechanical failure of the shift solenoids, TCC solenoid, or TCC PWM solenoid could set a DTC P1870. B Internal transmission failures may set a DTC P1870. B An intermittent or incorrect engine speed signal may set a DTC P1870.

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–83

Range Switch Logic Table

Test Description The numbers below refer to the step numbers on the diagnostic chart: 2. This test checks the indicated range signal to the actual selected range. A faulty switch could set a DTC P1870. 3. This test checks the torque converter for slippage while in a commanded lockup state.

Range Switch Pin

Range g Position

P(G)

Park

OFF

Reverse

OFF

Neutral

OFF

Illegal

OFF

Illegal

OFF

DTC P1870 Transmission Component Slipping (TCC Stuck Off) Step

Action

Were you sent here from the “Powertrain On–Board Diagnostic (OBD) System Check”?

Yes

Go to Step 2

Go to OBD System Check Refer to Driveability and Emissions in Engine section

Go to Step 3

Go to “Range Switch Logic Table”

Go to System Diagnosis Charts

Go to Diagnostic Aids

1. Install the scan tool. 2. With the engine “off”, turn the ignition switch “on”. NOTE: Before clearing DTC(s), use the scan tool to record “Freeze Frame” and “Failure Records” for reference, as data will be lost when the “Clear Info” function is used. 3. Record the DTC “Freeze Frame” and “Failure Records”. 4. Apply the brake pedal. 5. Select each transmission range: DL, D2, D3, D4, N, R, and P. Does each selected transmission range match the scan tool “TR Switch” display?

Drive the vehicle in 4th gear while the TCC is engaged. At any time is the “TCC Slip Speed” greater than 130 rpm for 8 seconds while the TCC is engaged?

7A1–84 TRANSMISSION CONTROL SYSTEM (4L30–E)

Circuit Diagram

D07R200012

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–85

D07R200013

7A1–86 TRANSMISSION CONTROL SYSTEM (4L30–E)

Parts Location

D07R200014

Legend (1) Connector I–10 (2) Connector E–44 (3) Connector I–22 (4) Connector I–23 (5) Connector I–24 (6) Data Link Connector C–39 (7) Connector H–9, H–11, H–16 (8) Connector I–32 (9) Connector I–31 (10) Connector B–16

(11) Powertrain Control Module (PCM) Connector E–34, E–35 (12) Connector H–3, H–5, H–6 (13) Connector E–42 (14) Connector E–41 (15) Connector E–40 (16) Connector E–11 (17) Connector E–33 (18) Connector X–11 (19) Connector H–8, H–14, H–17, H–18 (20) Connector E–7

TRANSMISSION CONTROL SYSTEM (4L30–E)

Harness Connector Faces No.

Connector face

No.

B-16

E-42

C-39

E-44

E-7

H-3

E-11

H-5

E-33

H-6

E-34 (J1)

H-8

E-35 (J2)

H-9

E-40

H-11

E-41

H-14

Connector face

7A1–87

7A1–88 TRANSMISSION CONTROL SYSTEM (4L30–E) No. H-16

H-17

H-18

I-10

I-22

I-23

I-24

I-31

I-32

Connector face

No. X-11

Connector face

TRANSMISSION CONTROL SYSTEM (4L30–E)

7A1–89

Transmission Fluid Temperature (TFT) Sensor Specifications Temperature

Temperature

Minimum Resistance

Nominal Resistance

Maximum Resistance

Signal

°F

°C

Volts

-40

600500

664200

731100

5.00

-22

-30

319800

350400

382400

4.65

-4

-20

177400

192700

208600

4.41

-10

102200

110100

118300

4.00

60870

65110

69450

3.52

37410

39750

42120

2.98

23660

24980

26300

2.40

15270

16120

16970

1.85

104

10040

10660

11290

1.43

122

6758

7211

7673

4.29

140

4645

4980

5324

4.04

158

3255

3506

3765

3.69

176

2323

2513

2710

3.34

194

1685

1831

1982

3.04

212

100

1242

1355

1472

2.58

230

110

929

1017

1109

2.24

248

120

704

773

846

1.97

266

130

540

595

653

1.67

284

140

419

464

511

1.42

302

150

329

365

403

1.16

SECTION LIGHTING SYSTEM

8A–1

AXIOM

BODY AND ACCESSORIES CONTENTS Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . Wiper / Washer System . . . . . . . . . . . . . . . . . . Entertainment . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . Meter and Gauge . . . . . . . . . . . . . . . . . . . . . . .

8A 8B 8C 8D 8E

Body Structure . . . . . . . . . . . . . . . . . . . . . . . . . . Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Security and Locks . . . . . . . . . . . . . . . . . . . . . . Sunroof / Convertible Top . . . . . . . . . . . . . . . . Exterior / Interior Trim . . . . . . . . . . . . . . . . . . . .

8F 8G 8H 8I 8J

LIGHTING SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight Assembly . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight Adjustment . . . . . . . . . . . . . . . . . . Side Marker Light Bulb . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . License Plate Light Bulb . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stoplight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . High Mounted Stoplight Assembly . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Mounted Stoplight Bulb . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Backup Light Bulb . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Turn Signal Light Bulb . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Rear Turn Signal Light Bulb . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dome Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8A–2 8A–3 8A–3 8A–3 8A–4 8A–4 8A–4 8A–4 8A–6 8A–6 8A–6 8A–7 8A–7 8A–7 8A–8 8A–8 8A–8 8A–8 8A–8 8A–9 8A–9 8A–9 8A–9 8A–9 8A–9 8A–10 8A–10 8A–10 8A–10 8A–10 8A–11 8A–11 8A–11 8A–11 8A–11 8A–11

Map Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Courtesy Light Bulb . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Luggage Room Light Bulb . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shift Lever Illumination Light Bulb (A/T) . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vanity Mirror Illumination Light Bulb . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Switch Unit Assembly Illumination Light Bulb (Power/Winter & Intelligent Suspension Switch) . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . TOD Switch Illumination Light Bulb . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cruise Control Main Switch Illumination Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wiper and Washer Switch Illumination Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Heater Switch Illumination Light Bulb . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Lighting Switch (Combination Switch) . . . . . .

8A–12 8A–12 8A–12 8A–12 8A–12 8A–12 8A–13 8A–13 8A–13 8A–13 8A–13 8A–13 8A–14 8A–14 8A–14

8A–14 8A–14 8A–14 8A–15 8A–15 8A–15 8A–15 8A–15 8A–15 8A–16 8A–16 8A–16 8A–16 8A–16 8A–16 8A–17 8A–17 8A–17

8A–2

LIGHTING SYSTEM

Removal and Installation . . . . . . . . . . . . . . . Dimmer·Passing Switch (Combination Switch) . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Front Door Switch . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door Switch . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Lock Switch . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Remind Switch (Starter Switch) . . . . . . .

8A–17 8A–17 8A–17 8A–17 8A–17 8A–17 8A–18 8A–18 8A–18 8A–18 8A–18 8A–18 8A–19

Removal and Installation . . . . . . . . . . . . . . . Hazard Warning Light Switch . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stoplight Switch . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Turn Signal Light Switch (Combination Switch) . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Illumination Controller . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

8A–19 8A–19 8A–19 8A–19 8A–20 8A–20 8A–20 8A–20 8A–20 8A–20 8A–20 8A–21

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

LIGHTING SYSTEM

8A–3

Headlight Bulb Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the headlight bulb. B Disconnect the connector (2). B Remove the socket counterclockwise.

(1)

turning

CAUTION: Do not touch the headlight bulb with your fingers. The oil on your fingers will leave a residue which will shorten the life of the halogen bulb. In order to prevent this problem, clean the bulb lens before installing the headlight bulb.

801R200021

To install, follow the removal steps in the reverse order. noting the following point: 1. Make sure to set the retaining ring and the bulb cover. If the set is incomplete, there is a possibility that the water comes in the light.

8A–4

LIGHTING SYSTEM

Headlight Assembly 1. Set a vertical screen on a level surface. 2. Toward the screen (1) from the bulb center mark of the headlight, extend parallel lines to the floor. Mark point (A) and (B) on the screen at the intersection of parallel line and the screen. 3. Draw vertical lines through point (A) and (B) on the screen.

Removal 1. Disconnect the battery ground cable. 2. Remove the front combination light (2). B Remove the screw. B Disconnect the connector. 3. Remove the headlight assembly (1). B Disconnect the connector. B Remove four screws.

801R200019

801R200022

4. Keep the vehicle (2) 3m (9.8 ft) apart from the screen (1). 5. Draw a horizontal line through point (A) and (B) on the screen (1).

Installation To install, follow the removal steps in the reverse order. noting the following point: 1. After installing the headlight, be sure to adjust the headlight aim.

Headlight Adjustment Preparation Place the vehicle with 1 person in driver seat on a level surface and check to see if the inflation pressure of the tires is correct, the lenses are clean, the battery is sufficiently charged, and adjust to place vehicle by using the screen.

801R200009

LIGHTING SYSTEM 6. Turn the headlight low beam on. 7. Adjust the CUTLINE 30 mm (1.18 in) below the horizontal line (H).

801R200011

Vertical Adjustment Use a screwdriver for vertical adjustment.

801R200012

8A–5

8A–6

LIGHTING SYSTEM

Side Marker Light Bulb Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the front combination light (1). B Remove the screw. 3. Remove the bulb (2). B Remove the side marker light socket (3) by turning it counterclockwise. B Remove the bulb by turning it counterclockwise while pushing it at the same time.

801R200013

To install, follow the removal steps in the reverse order.

LIGHTING SYSTEM

8A–7

Taillight Bulb Removal

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the rear combination light assembly (1). B Remove two screws. B Pull out the rear combination light assembly outside.

803R200011

3. Remove the bulb (1). B Remove the taillight counterclockwise.

socket

turning

B Remove the bulb by turning it counterclockwise while pushing it at the same time.

803R200002

8A–8

LIGHTING SYSTEM

License Plate Light Bulb Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the license plate light garnish. B Remove the three screws. 3. Remove the lens cover (3). B Remove two screws. 4. Remove the license plate light socket by turning it counterclockwise. 5. Remove the bulb (2). B Pull out the bulb from the socket (1).

To install, follow the removal steps in the reverse order.

803R200003

Stoplight Bulb Removal and Installation Refer to Taillight Bulb in this section.

LIGHTING SYSTEM

8A–9

High Mounted Stoplight Assembly Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the high mounted stoplight assembly (1). B Remove the cover (2).

To install, follow the removal steps in the reverse order.

B Remove two screws. B Disconnect the connector.

803R200004

High Mounted Stoplight Bulb Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the cover. 3. Remove the high mounted stoplight assembly (1). B Remove two screw. 4. Remove the bulb (2). B Remove the socket by turning it counterclockwise.

803R200005

To install, follow the removal steps in the reverse order.

8A–10 LIGHTING SYSTEM

Backup Light Bulb Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the rear combination light assembly. B Refer to Taillight Bulb in this section. 3. Remove the bulb (1). B Remove the backup light socket by turning it counterclockwise.

To install, follow the removal steps in the reverse order.

B Pull out the bulb from the socket.

803R200007

Front Turn Signal Light Bulb Removal and Installation Refer to Side Marker Light Bulb in this section.

LIGHTING SYSTEM

8A–11

Rear Turn Signal Light Bulb Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the rear combination light assembly. B Refer to Taillight Bulb in this section. 3. Remove the bulb (1). B Remove the rear turn signal light socket by turning it counterclockwise.

To install, follow the removal steps in the reverse order.

B Remove the bulb by turning it counterclockwise while pushing it at the same time.

803R200006

Dome Light Bulb Removal

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the lens (2). 3. Remove the bulb (1). B Pull out the bulb.

825RW075

8A–12 LIGHTING SYSTEM

Map Light Bulb Removal

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the lens (2). 3. Remove the bulb (1). B Pull out the bulb.

805R200002

Courtesy Light Bulb Removal

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the lens (2). 3. Remove the bulb (1). B Pull out the bulb.

825RW076

LIGHTING SYSTEM

8A–13

Luggage Room Light Bulb Removal

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the lens (2). 3. Remove the bulb (1). B Pull out the bulb.

805R200001

Shift Lever Illumination Light Bulb (A/T) Removal

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the console assembly. B Refer to Consol in Body Structure section. 3. Remove the indicator cover (1). 4. Remove the bulb (2). B Turn the bulb socket counterclockwise. B Pull out the bulb from the socket.

825R200022

8A–14 LIGHTING SYSTEM

Vanity Mirror Illumination Light Bulb Removal

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the lens (1). 3. Remove the bulb (2).

805R200004

Switch Unit Assembly Illumination Light Bulb (Power/Winter & Intelligent Suspension Switch) Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the center cluster assembly. B Refer to Instrument Panel Assembly in Body Structure section. 3. Remove the audio. B Refer to Audio in Entertainment section. 4. Remove the illumination light bulb.

825R200036

To install, follow the removal steps in the reverse order.

LIGHTING SYSTEM

8A–15

TOD Switch Illumination Light Bulb Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the meter cluster (1). B Refer to Instrument Panel Assembly in Body Structure section. 3. Remove the bulb (3). B Disconnect the TOD switch connector and cruise control main switch connector.

To install, follow the removal steps in the reverse order.

B Remove the TOD switch (2).

825R200033

Cruise Control Main Switch Illumination Light Bulb Removal 1. Disconnect the battery ground cable. 2. Remove the meter cluster panel (4). B Refer to Instrument Panel Assembly in Body Structure section. 3. Remove the bulb (1). B Disconnect the TOD switch connector and cruise control main switch connector. B Remove the TOD switch (3). B Remove the cruise main switch (2).

825R200032

Installation To install, follow the removal steps in the reverse order.

8A–16 LIGHTING SYSTEM

Rear Wiper and Washer Switch Illumination Light Bulb Removal

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the lower cover assembly (3). B Remove the dash side trim cover. 3. Remove the bulb (1). B Disconnect the connector. B Remove the rear wiper and washer switch (2).

825R200037

Seat Heater Switch Illumination Light Bulb Removal 1. Disconnect the battery ground cable. 2. Remove the center consol assembly (3). B Refer to Consol in Body Structure section. 3. Remove the bulb (2). B Disconnect the seat heater switch connector. B Remove the seat heater switch (1).

825R200034

Installation To install, follow the removal steps in the reverse order.

LIGHTING SYSTEM

8A–17

Starter Switch Removal and Installation Refer to Lock Cylinder in Steering section.

Lighting Switch (Combination Switch) Removal and Installation Refer to Combination Switch in Steering section.

Dimmer·Passing Switch (Combination Switch) Removal and Installation Refer to Combination Switch in Steering section.

Front Door Switch Removal

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the door switch (2). B Remove the screw (3). B Disconnect the connector (1).

825R200038

8A–18 LIGHTING SYSTEM

Rear Door Switch Removal

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the door switch (2). B Remove the screw (3). B Disconnect the connector (1).

825R200039

Tailgate Lock Switch Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the tailgate outside handle. B Refer to Tail Gate Outside Handle in Security and Locks section. 3. Remove the tail gate lock switch (1). B Disconnect the switch connector (2) and lock actuator connectors (3).

825R200031

To install, follow the removal steps in the reverse order.

LIGHTING SYSTEM

8A–19

Key Remind Switch (Starter Switch) Removal and Installation Refer to Lock Cylinder in Steering section.

Hazard Warning Light Switch Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the center cluster assembly (1). B Refer to Instrument Panel Assembly in Body Structure section. 3. Remove the hazard warning switch (2). B Disconnect the switch connector. B To remove the switch, push the lock from the back side of the center cluster assembly.

825R200026

To install, follow the removal steps in the reverse order.

8A–20 LIGHTING SYSTEM

Stoplight Switch Removal and Installation Refer to Stoplight Switch in Brake section.

Turn Signal Light Switch (Combination Switch) Removal and Installation Refer to Combination Switch in Steering section.

Illumination Controller Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the meter cluster panel cover assembly (2). B Refer to Instrument Panel Assembly in Body Structure section. 3. Remove the illumination controller (1). B Disconnect the controller connector. B Remove the controller knob (4). B Remove the nut (3). B Remove the controller from the back side of the meter cluster panel assembly.

825R200027

To install, follow the removal steps in the reverse order.

LIGHTING SYSTEM

8A–21

Main Data and Specifications Light and Bulb Specifications

801R200020

Legend (1) High Mounted Stoplight (2) Luggage Room Light (3) Vanity Mirror Illumination Light (4) Map Light (5) Dome Light (6) Meter

(7) Front Turn Signal Light/Front Side Marker Light/Parking Light (8) Headlight (9) Courtesy Light (10) Taillight/Stoplight (11) Backup Light (12) Rear Turn Signal Light (13) License Plate Light

8A–22 LIGHTING SYSTEM Light Name

Bulb No.

Rated Power

Number of Bulbs

Lens Color

Remarks

9005/9006

60w/51w

White

Halogen

1157NA

27w/8w

Amber

Rear Turn Signal Light

7440

21w

Amber

Backup Light

921

18w

White

Taillight/Stoplight

7443

21w/5w

Red

High Mounted Stoplight

921

18w

Red

License Plate Light (Tailgate type)

168

White

Map Light

—

White

Dome Light

—

10w

White

Luggage Room Light

—

White

Courtesy Light

—

3.4w

White

Check Trans

—

1.4w

Red

Meter

A/T Oil Temp

—

1.4w

Red

Meter

Cruise Set

—

1.4w

Green

Meter

Power Drive

—

1.4w

Amber

Meter

Winter Drive

—

1.4w

Green

Meter

Turn Signal

—

1.4w

Green

Meter

Check TOD

—

1.4w

Red

Meter

High Beam

—

1.4w

Blue

Meter

ABS

—

1.4w

Amber

Meter

Seat Belt

—

Red

Meter

Malfunction Indicator (Check Engine)

—

1.4w

Amber

Meter

Low Fuel

—

1.4w

Amber

Meter

Reduced Power

—

1.4w

Amber

Meter

Sports Mode

—

1.4w

Green

Meter

TOD Front

—

1.1w

Green

Meter

TOD Auto

—

1.1w

Green

Meter

TOD Rear

—

1.1w

Green

Meter

Oil Pressure

—

1.4w

Red

Meter

Brake System

—

1.4w

Red

Meter

Charge

—

1.4w

Red

Meter

A/T Shift Position

—

1.1w

P,N,D,3,2,L :Green R: Amber

Meter

Air Bag

—

Red

Meter

—

3.4w

Shift lever

—

1.4w

White

Shift lever

Vanity Mirror

—

White

Sun Visor

Cigarette Lighter

—

1.4w

White

Cigarette Lighter

Ashtray

—

1.4w

White

Ashtray

Headlight Front Turn signal Light/ Front Side Marker Light/Parking Light

Indicator/Warning Light g

Illumination Light

Meter

SECTION WIPER/WASHER SYSTEM

8B–1

AXIOM

BODY AND ACCESSORIES WIPER / WASHER SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Windshield Wiper/Washer System . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Windshield Wiper And Washer Switch . . . . . Removal and Installation . . . . . . . . . . . . . . . Windshield Wiper Motor . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Washer Motor . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Washer Spray Pattern . . . . . . . . . Windshield Wiper Linkage . . . . . . . . . . . . . . . . Windshield Wiper Linkage and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Wiper Arm/Blade . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Wiper Blade Rubber . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wiper/Washer System . . . . . . . . . . . . . .

8B–1 8B–2 8B–2 8B–2 8B–2 8B–2 8B–2 8B–2 8B–3 8B–3 8B–3 8B–4 8B–5 8B–5 8B–5 8B–5 8B–6 8B–6 8B–6 8B–7 8B–7 8B–7 8B–8

General Description . . . . . . . . . . . . . . . . . . . . . . Rear Wiper and Washer Switch . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Washer Motor . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm and Relay Control Unit . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wiper Arm/Blade . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Washer Nozzle . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Washer Spray Pattern . . . . . . . . . . . . . Rear Wiper Blade Rubber . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

8B–8 8B–8 8B–8 8B–8 8B–9 8B–9 8B–9 8B–10 8B–10 8B–10 8B–11 8B–11 8B–11 8B–11 8B–11 8B–11 8B–12 8B–12 8B–12 8B–12 8B–13 8B–13 8B–13 8B–14

8B–2

WIPER/WASHER SYSTEM

Windshield Wiper/Washer System General Description The circuit consists of the starter switch, windshield wiper & washer switch, windshield wiper motor, windshield washer motor and alarm & relay control unit. When the windshield wiper & washer switch is turned on with the starter switch on, the battery voltage is applied to the wiper motor to activate the wiper. The washer motor squirts glass cleaning fluid while the washer switch is being pushed. The alarm & relay control unit relay is used to control motion of the wiper.

Windshield Wiper And Washer Switch Removal and Installation Refer to Combination Switch in Steering section.

Windshield Wiper Motor Removal

Installation

1. Disconnect the battery ground cable. 2. Disconnect the connector(2). 3. Remove 4 mounting bolts. 4. Remove the nut of the wiper motor shaft, and disconnect the linkage. 5. Remove the windshield wiper motor(1). CAUTION: To facilitate the removal of the nuts, be sure to put out the tip portion of the linkage sufficiently through the mounting hole of the motor by sliding the linkage slowly.

880RW002

To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the wiper motor shaft nut to the specified torque. Torque: 14 N·m (122 lb in) 2. Remove the wiper arms on both sides, and rotate the wiper motor until it gets to the autostop position to secure windshield wiper correct operation.

WIPER/WASHER SYSTEM

8B–3

Windshield Washer Motor Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the fender panel (right side). B Refer to Fender Panel in Body Structure section. 3. Disconnect the windshield washer motor connector and the rear washer motor connector. 4. Disconnect the windshield washer hose connector and the rear washer hose connector. 5. Remove the filler neck (3). B Remove the bolt. 6. Remove the washer tank (2). B Remove the three nuts. 7. Remove the windshield washer motor (4). B Pull out the motor from the washer tank.

880R200001

To install, follow the removal steps in the reverse order.

8B–4

WIPER/WASHER SYSTEM

Windshield Washer Spray Pattern

880R200006

Legend (1) Spray Target (2) Washer Nozzle

WIPER/WASHER SYSTEM

8B–5

Windshield Wiper Linkage Windshield Wiper Linkage and Associated Parts

880RW004

Legend (1) Windshield Wiper Arm/Blade (2) Vent Cowl Cover

Removal 1. Disconnect the battery ground cable. 2. Remove the windshield wiper arm/blade. 3. Remove the vent cowl cover. 4. Remove the windshield wiper motor. 5. Remove the pivot assembly mounting nuts. 6. Take out the windshield wiper linkage assembly from the opening of the cowl.

(3) Windshield Wiper Linkage Assembly (4) Windshield Wiper Motor

Installation To install, follow the removal steps in the reverse order.

8B–6

WIPER/WASHER SYSTEM

Windshield Wiper Arm/Blade Removal

Installation To install, follow the removal steps in the reverse order, noting the following points:

1. Pry the cap(2) off with the tip of a screwdriver. 2. Remove the nut. 3. Remove the wiper arm/blade(1).

880RW006

880RW003

1. Before installing the wiper arm/blade to the shaft, confirm that the motor stops at the autostop position. 2. Set the wiper arm/blade so that the tips of both blades are positioned about 40 mm (1.57 in) from the upper edge of the cowl cover as shown in the figure. 3. Tighten the nuts to the specified torque. Torque: 23 N·m (17 lb ft)

WIPER/WASHER SYSTEM

8B–7

Windshield Wiper Blade Rubber Removal

Installation

1. Push the wiper blade lock(1) while pulling the wiper blade in the arrow direction as shown in the figure. CAUTION: When the wiper blade has been removed, wrap the tip of the wiper arm with cloth, to avoid damaging the glass.

To install, follow the removal steps in the reverse order, noting the following points: 1. Install the click of the blade stay in the groove of the new rubber and slide it in. Complete wiper blade installation by pushing the click in the concavity (3).

880R200003 880RS011

2. Pull the end of rubber and remove the concavity (3) from the click of the blade stay (2).

2. Finally, check that the click of the stay has caught in the hole of the rubber.

880R200004 880R200002

3. Pull the rubber out in the same direction.

8B–8

WIPER/WASHER SYSTEM

Rear Wiper/Washer System General Description The circuit consists of the starter switch, rear wiper & washer switch, rear wiper motor, rear washer motor and Alarm & relay control unit. When the rear wiper & washer switch is turned on with the starter switch on, the battery voltage is applied to the wiper motor to activate the wiper. The washer motor squirts glass cleaning fluid while the washer switch is being pushed. The alarm & relay control unit is used to control motion of the wiper.

Rear Wiper and Washer Switch 4. Remove the rear wiper & washer switch (4). B Disconnect the connector.

Removal 1. Disconnect the battery ground cable. 2. Remove the dash side trim panel(1). 3. Remove the lower cover assembly(2).

B Push the lock from the back side of the lower cover assembly (3).

825R200028 821RW254–1

Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Push the switch with your fingers until it locks securely.

WIPER/WASHER SYSTEM

8B–9

Rear Wiper Motor 3. Tighten the wiper arm nut (3) to the specified torque.

Removal 1. Disconnect the battery ground cable. 2. Remove the tailgate trim pad. B Refer to Tailgate Trim Pad in Body Structure section. 3. Remove the wiper arm/blade. Refer to Rear Wiper Arm/Blade in this section.

Torque: 9 N·m (78 lb in)

4. Remove the rear wiper motor (1). B Disconnect the connector. B Remove the rear wiper motor fixing screws.

885R200001

4. Install the wiper arm/blade so that the wiper arm contact as shown in the figure.

885R200002

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Before installing the wiper arm/blade (1) to the motor shaft (6), confirm that the motor stops at the autostop position. 2. Tighten the motor shaft nut (5) to the specified torque. Torque: 10 N·m (87 lb in) 885R200005

8B–10 WIPER/WASHER SYSTEM

Rear Washer Motor Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the fender panel (right side). B Refer to Fender Panel in Body Structure section. 3. Disconnect the windshield washer motor connector and the rear washer motor connector. 4. Disconnect the windshield washer hose connector and the rear washer hose connector. 5. Remove the filler neck (3). B Remove the bolt. 6. Remove the washer tank (2). B Remove the three nuts. 7. Remove the rear washer motor (1). B Pull out the motor from the washer tank.

880R200001

To install, follow the removal steps in the reverse order.

WIPER/WASHER SYSTEM

8B–11

Alarm and Relay Control Unit Removal

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the grove box (1). 3. Remove the alarm and relay control unit (2). Disconnect the connector.

826R200020

Rear Wiper Arm/Blade Removal

Installation Refer to Rear Wiper Motor in this section.

1. Open the cap (2). 2. Remove the arm nut (3). 3. Remove the wiper arm/blade (1).

885R200011

8B–12 WIPER/WASHER SYSTEM

Rear Washer Nozzle Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the high mounted stoplight (1). B Refer to High Mounted Stoplight in Lighting System section. 3. Remove the washer nozzle(3). B Pull out the washer nozzle from the washer hose (2).

To install, follow the removal steps in the reverse order.

Rear Washer Spray Pattern

885R200006

885R200003

Legend (1) Washer Nozzle (2) Spray Target (3) High Mounted Stoplight

WIPER/WASHER SYSTEM

8B–13

Rear Wiper Blade Rubber Removal

Installation

1. Remove the wiper blade from the wiper arm. 2. Press and hold the wiper rubber under the wiper blade hook (1). 3. Pull the wiper rubber out from wiper blade.

1. Install the wiper blade rubber. B Matching the grove of the wiper rubber (3) and the guide (2) of the wiper blade (1), insert the wiper rubber to the wiper blade.

CAUTION: When the wiper blade has been removed, wrap the tip of the wiper arm with cloth, to avoid damaging the glass.

885R200009

B Check that the wiper rubber is set between the right hook and left hook of the wiper blade. 885R200004

885R200008

8B–14 WIPER/WASHER SYSTEM

Main Data and Specifications Torque Specifications Application

N·m

Lb Ft

Lb In

Windshield Wiper Motor Shaft Nut

—

122

Windshield Wiper Arm Nuts

—

Rear Wiper Motor Shaft Nut

—

Rear Wiper Arm Nut

—

SECTION ENTERTAINMENT

8C–1

AXIOM

BODY AND ACCESSORIES ENTERTAINMENT CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rod Type Antenna . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessory Socket . . . . . . . . . . . . . . . . . . . . . . . Front Accessory Socket . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Accessory Socket . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Audio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Speaker . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Tweeter Assembly . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door Speaker . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Tweeter Assembly . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8C–1 8C–2 8C–2 8C–2 8C–2 8C–3 8C–3 8C–3 8C–4 8C–4 8C–4 8C–4 8C–4 8C–4 8C–4 8C–5 8C–5 8C–5 8C–6 8C–6 8C–6 8C–6 8C–6 8C–6 8C–6 8C–6 8C–6 8C–7 8C–7 8C–7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display (MID) . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . MID Control Unit . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . GPS Control Unit . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Diagnosis Flow Chart–1 . . . . . . . . . . . . Self-Diagnosis Flow Chart–2 (Audio) . . . . . Self-Diagnosis Flow Chart–3 (Display) . . . Self-Diagnosis Flow Chart–4 (MID) . . . . . . Audio Self-Diagnosis . . . . . . . . . . . . . . . . . . . Display Self-Diagnosis . . . . . . . . . . . . . . . . . MID Self-Diagnosis . . . . . . . . . . . . . . . . . . . . Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . MID Not Appears . . . . . . . . . . . . . . . . . . . . . . No COMPASS, CLOCK, FUEL CONSUMPTION, or SERVICE Display . . No COMPASS Display . . . . . . . . . . . . . . . . . No SERVICE Display . . . . . . . . . . . . . . . . . . Other Trouble Symptom . . . . . . . . . . . . . . . . MID Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . Harness Connector Faces . . . . . . . . . . . . . .

8C–7 8C–8 8C–8 8C–8 8C–8 8C–8 8C–8 8C–9 8C–9 8C–9 8C–10 8C–10 8C–10 8C–11 8C–11 8C–12 8C–13 8C–14 8C–15 8C–16 8C–17 8C–18 8C–18 8C–19 8C–20 8C–20 8C–21 8C–22 8C–23

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

8C–2

ENTERTAINMENT

Cigarette Lighter General Description

Installation

When the cigarette lighter is pushed in with the starter switch at either “ACC” or “ON” position, a circuit is formed in the cigarette lighter case to heat the lighter coil. The cigarette lighter springs back to its original position after the lighter coil is heated.

To install, follow the removal steps in the reverse order, noting the following point: 1. When installing the bezel, align the projected portion of the socket with the notch of the bezel.

Removal 1. Disconnect the battery ground cable. 2. Remove the center cluster assembly (1). B Refer to Instrument Panel Assembly in Body Structure section. 3. Remove the cigarette lighter assembly (2). B Disconnect the connectors. B Remove the socket (3) and nut (4).

826R200012

ENTERTAINMENT

8C–3

Rod Type Antenna Removal

Installation

1. Disconnect the battery ground cable. 2. Turn the antenna rod (1) counterclockwise to remove it. 3. Remove three screws and nine clips to remove the fender inner liner (5). 4. Disconnect the feeder cable connector (4) at the inside of the vehicle. 5. Turning the lock nut (2) counterclockwise removes it together with the base mold (3). 6. Pull down and remove the housing (7) from the panel. 7. Pull and remove the cable with the grommet (6).

890R200040

To install, follow the removal steps in the reverse order.

8C–4

ENTERTAINMENT

Accessory Socket Front Accessory Socket

Rear Accessory Socket

Removal

1. Disconnect the battery ground cable. 2. Remove the front console assembly (2). B Refer to Instrument Panel Assembly in Body Structure section. 3. Remove the front accessory socket (1). B Disconnect the connectors.

1. Disconnect the battery ground cable. 2. Remove the quarter trim lower cover. 3. Remove the rear accessory socket (1). B Disconnect the connectors (3). B Pull out the rear accessory socket from the socket cover (2).

B Remove the holdernut (3).

826R200014

826R200013

Installation To install, follow the removal steps in the reverse order.

ENTERTAINMENT

8C–5

Audio Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the center cluster assembly (1). B Refer to Instrument Panel Assembly in Body Structure section.

890R200032

3. Remove the audio (2). B Remove the two fixing screws (3). B Disconnect the connector and the antenna cable.

890R200033

To install, follow the removal steps in the reverse order.

8C–6

ENTERTAINMENT

Speaker Front Speaker Removal 1. Disconnect the battery ground cable. 2. Remove the front door trim pad. B Refer to Front Door in Body Structure section. 3. Remove the front speaker (2). B Remove the three screws and the speaker spacer (1). B Disconnect the connector (3).

890R200030

Installation To install, follow the removal steps in the reverse order.

Rear Door Speaker Removal

890R200028

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the rear door trim pad. B Refer to Rear Door in Body Structure section. 3. Remove the rear speaker (2). B Remove the three screws and the speaker spacer (1). B Disconnect the connector (3).

Front Tweeter Assembly Removal 1. Disconnect the battery ground cable. 2. Remove the front door trim pad (2). B Refer to Front Door in Body Structure section. 3. Remove the tweeter (1). B Disconnect the connector.

890R200028

ENTERTAINMENT

Installation To install, follow the removal steps in the reverse order.

Rear Tweeter Assembly Removal 1. Disconnect the battery ground cable. 2. Remove the rear door trim pad (2). B Refer to Rear Door in Body Structure section. 3. Remove the tweeter (1). B Disconnect the connector.

890R200031

Installation To install, follow the removal steps in the reverse order.

8C–7

8C–8

ENTERTAINMENT

Horn Removal

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the horn. B Disconnect the connector. B Remove the horn mounting bolt. NOTE: High (1), Low (2)

828R200003

Display (MID) Removal 1. Disconnect the battery ground cable. 2. Remove the cluster upper cover. B Disconnect the sun sensor connector and the GPS control unit connector. 3. Remove the center cluster. B Refer to Instrument Panel Assembly in Body Structure. 4. Remove the Display (1). B Remove the screws (2). B Disconnect the Display connector and MID control unit connector.

890R200036

Installation To install, follow the removal steps in the reverse order.

ENTERTAINMENT

8C–9

MID Control Unit Removal

Installation To install, follow the removal steps in the reverse order.

1. Disconnect the battery ground cable. 2. Remove the MID control unit (3). B Refer to MID (1) in this section. B Remove the control unit (3) from the bracket (2). CAUTION: When the battery is disconnected, the MID control unit directional data is lost (the control unit returns to its start-up condition). When the battery is reconnected, the display will be erroneous until the control unit receives a clear GPS satellite signal and resets its directional data. After reconnecting the battery, wait until the satellite mark indicator turns on. Select an area where there are no high buildings or other obstacles to electromagnetic waves. Drive the vehicle in a straight line at a speed exceeding 32 km/h (20 mph) for at least 20 seconds.

D08R200055

CAUTION: When installing the MID control unit, turn the face with part number (4) stamped on the MID control unit toward the front of vehicle.

8C–10 ENTERTAINMENT

GPS Control Unit Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the cluster upper cover (3). B Disconnect the sun sensor connector and the GPS control unit connector. 3. Remove the GPS control unit (2). B Remove the screws (1).

890R200035

To install, follow the removal steps in the reverse order.

ENTERTAINMENT

8C–11

Self-Diagnosis Self-Diagnosis Flow Chart–1

826R200015

8C–12 ENTERTAINMENT

Self-Diagnosis Flow Chart–2 (Audio)

826R200021

ENTERTAINMENT

8C–13

Self-Diagnosis Flow Chart–3 (Display)

826R200022

8C–14 ENTERTAINMENT

Self-Diagnosis Flow Chart–4 (MID)

826R200023

ENTERTAINMENT

8C–15

Audio Self-Diagnosis Step

Action

Value(s)

Yes

1. Simultaneously press and hold the RESET key and the CLOCK key (on the display panel). 2. Turn the ignition switch to the ON position.

—

Go to Step 2

Check power supply and component connections. Start self-diagnosis again.

—

Go to Step 3

Go to Step 11

Does DIAG appear on the display screen?

Press and release the SERVICE key (1 time only). Does DIAG AUDIO appear on the display?

Press and release the SERVICE key (1 time only) to check tape connections. Does TAPE OK appear on the display?

On NG display, —

Go to Step 4

Press and release the SERVICE key (1 time only) to check CD changer connections. Does CD CHG OK appear on the display?

Go to Step 11 On NG display,

—

Go to Step 5

Press and release the SERVICE key (1 time only) to check communication with A/C unit.

Go to Step 11 On NG display,

Does A/C DATA OK appear on the display?

—

Go to Step 9

Is A/C DATA ERR1(abnormal display data line) displayed?

—

Refer to A/C self-diagnosis

Go to Step 7

Is A/C DATA ERR2 (abnormal CLOCK data line) displayed?

—

Refer to A/C self-diagnosis

Go to Step 8

Is A/C DATA ER3 (abnormal SW data line) displayed?

—

Go to Step 11

—

Press and release the SERVICE key (1 time only) to display the A/C unit error history. —

Go to Step 10

—

Go to Step 12

Go to Step 11

—

Go to Step 1

—

Go to Step 1

Go to Step 13

—

Go to Step 3

—

6 7

Is the action complete? 10

Go to Step 6

1. Press and release the SERVICE key (1 time only) to change to the key diagnosis mode. 2. Press and release each key. NOTE: As a key is pressed, its name should appear on the display. The A/C LED should blink at 1–second intervals. Did the events described in Step 2 occur?

Replace the audio unit. Is the action complete?

Press and release the ON/OFF key. Is the action complete?

Press and release the SERVICE key (1 time only). Is the action complete?

8C–16 ENTERTAINMENT

Display Self-Diagnosis Step

Action

Value(s)

Yes

1. Simultaneously press and hold the RESET key and the CLOCK key (on the display panel). 2. Turn the ignition switch to the ON position.

—

Go to Step 2

Check power supply and component connections. Start self-diagnosis again.

—

Go to Step 3

Go to Step 10

Does DIAG appear on the display screen?

Press and release the RESET key (1 time only). Does DIAG DISP appear on the display?

Press and release the RESET key (1 time only) to start audio communications diagnosis. Does AUD DAT OK appear on the display?

Go to Step 6

— On NG display, Go to Step 7

—

Go to Step 8

—

Go to Step 1

—

Go to Step 9

—

Go to Step 11

Go to Step 10

—

Go to Step 1

—

Go to Step 1

Go to Step 12

—

Go to Step 3

—

Press and release the ON/OFF key to complete display self-diagnosis. Is the action complete?

—

Replace the display unit. Is the action complete?

—

Press and release the RESET key (1 time only) to open all segments. Do all segments light?

Go to Step 1

1. Press and release the RESET key (1 time only) to display MID communications error history. 2. Confirm that the error history is displayed on the screen. Is the error history displayed?

—

Replace the MID unit. Is the action complete?

Go to Step 5

Press and release the RESET key (1 time only) to start MID communications diagnosis. Does MID DATA OK appear on the display?

Go to Step 4

—

1. Press and release the RESET key (1 time only). 2. Confirm that the trouble history is displayed on the screen. Is the trouble history displayed?

On NG display,

Replace the audio unit. Is the action complete?

Press and release the SERVICE key. Is the action complete?

ENTERTAINMENT

8C–17

MID Self-Diagnosis Step

Action

Value(s)

Yes

1. Simultaneously press and hold the RESET key and the CLOCK key (on the display panel). 2. Turn the ignition switch to the ON position.

—

Go to Step 2

Check power supply and components connections. Start self-diagnosis again.

—

Go to Step 3

—

Go to Step 5

On ERROR1, Go to Step 4

—

Go to Step 1

—

Go to Step 7

On ERROR2, Go to Step 6

—

Go to Step 1

—

Go to Step 9

On ERROR3, Go to Step 9

—

Go to Step 1

—

Go to Step 11

On ERROR4, Go to Step 10

—

Go to Step 1

—

Go to Step 13

On ERROR5, Go to Step 12

—

Go to Step 1

—

Go to Step 1

Go to Step 14

—

Go to Step 2

—

Does DIAG appear on the display screen?

Press and release the CLOCK key (1 time only). Does DIAG MID appear on the display?

Press and release the CLOCK key (1 time only) to begin GPS communications diagnosis. Does GPS OK appear on the display?

Repair open circuit between MID and GPS receiver (I-13–2 ∼ I-16–5). Is the action complete?

Press and release the CLOCK key (1 time only) to begin fuel injection pulse diagnosis. Does F-INJ OK appear on the display?

Repair open fuel injection pulse circuit (I-13–5 ∼ E35–8). Is the action complete?

Press and release the CLOCK key (1 time only) to begin fuel remainder pulse diagnosis. Does F-SENS OK appear on the display?

Repair open fuel remainder pulse circuit (I-13–6 ∼ E35–48). Is the action complete?

Press and release the CLOCK key (1 time only) to begin gyro-sensor diagnosis. Does GYRO OK appear on the display?

Replace the MID control unit. Is the action complete?

1. Press and release the CLOCK key (1 time only) to begin vehicle speed sensor diagnosis. 2. Drive vehicle. Does SPEED OK appear on the display?

Repair open vehicle speed sensor circuit (I-13–15 ∼ E43–3). Is the action complete?

Press and release ON/OFF key to return to start of diagnosis screen. Is the action complete?

Press and release the SERVICE key. Is the action complete?

8C–18 ENTERTAINMENT

Symptom Diagnosis MID Not Appears Step

Action

Is fuse (AUDIO 20A) normal?

Remove connectors at display unit. Is there battery voltage across terminal No. I-12–16 (display unit harness connector)?

Replace fuse

12V

Go to Step 4

Go to Step 3

—

Go to Step 2

—

12V

Go to Step 6

Go to Step 5

—

Go to Step 4

—

12V

Go to Step 8

Go to Step 7

—

Go to Step 6

—

Go to Step 1

—

Repair open circuit between terminal No. I-12–14 (display unit harness connector) and the battery. Is the action complete?

Go to Step 2

Move the starter switch to the IGN position. Is there battery voltage across terminal No. I-12–14 (display unit harness connector)?

—

Repair open circuit between terminal No. I-12–7 (display unit harness connector) and the battery. Is the action complete?

Move the ignition switch to the ACC position. Is there battery voltage across terminal No. I-12–7 (display unit harness connector)?

Yes

Repair open circuit between terminal No. I-12–16 (display unit harness connector) and the battery. Is the action complete?

Value(s)

Replace the display unit. Is the action complete?

ENTERTAINMENT

8C–19

No COMPASS, CLOCK, FUEL CONSUMPTION, or SERVICE Display Step

Action

12V

Go to Step 4

Go to Step 3

—

Go to Step 2

—

Go to Step 1

—

12V

Go to Step 7

Go to Step 6

—

Go to Step 5

—

Go to Step 1

—

Repair open circuit between terminal No. I-13–7, terminal No. I-13–8, and terminal No. I-13–16. Is the action complete?

Go to Step 5

Remove the MID connectors. Is there battery voltage between the No. I-13–7 terminal, the No. I-13–8 terminal, and the No. I-13–16 terminal (display unit harness connector)?

Go to Step 2

Replace the display unit. Is the action complete?

Repair open circuit between terminal No. I-12–7 and terminal No. I-12–16. Is the action complete?

Remove the connectors form the display unit. Is there battery voltage between the No. I-12–7 terminal and the No. I-12–16 terminal (display unit harness connector)?

Yes

1. Remove the connectors from the display unit. 2. Turn the ignition switch to the ON position. Is there approximately 5 volts across terminal No. I-12–1 (display unit harness connector)?

Value(s)

Replace the MID Is the action complete?

8C–20 ENTERTAINMENT

No COMPASS Display Step

Action

Value(s)

Does “—” appear on the display?

Use the self-diagnosis mode to perform MID self-diagnosis followed by GPS receiver and gyro-sensor self-diagnosis. Is the action complete?

Yes

—

Go to Step 2

Go to Step 3

—

Go to Step 1

—

Go to Step 1

—

Replace the MID and/or DISPLAY. Is the action complete?

No SERVICE Display Step

Action

Value(s)

Yes

—

Go to Step 3

Go to Step 2

Is the action complete?

—

Go to Step 1

—

Does SERVICE display change?

—

Go to Step 4

Go to Step 5

CALENDER does not display —

Refer to self-diagnosis items

—

Refer to self-diagnosis items

—

Is SERVICE displayed?

Replace the MID and/or display.

MID self-diagnosis self-diagnosis

followed

MID self-diagnosis self-diagnosis

followed

by by

GPS GPS

receiver receiver

ENTERTAINMENT

8C–21

Other Trouble Symptom Condition

Possible cause

Correction

Elapsed time does not display

An open circuit between GPS receiver and MID control unit.

Repair an open circuit.

Fuel consumption does not display

MID control unit and/or DISPLAY not functioning.

Replace the MID control unit and/or DISPLAY.

Possible turning distance does not change

An open circuit between MID control unit No.I-13–6 terminal and PCM No.E35–48 terminal.

Repair an open circuit.

Average fuel consumption does not display

An open circuit between MID control unit No.I-13–5 terminal and PCM No.E35–8 or MID control unit NO.I-13–15 terminal and vehicle speed sensor terminal No.E43–3.

Repair an open circuit.

Current fuel consumption does not display

Refer to average fuel consumption items.

Repair an open circuit.

Compass does not change

An open circuit between MID control unit and GPS receiver or insufficient signal output of gyro sensor.

Repair an open circuit and/or replace gyro sensor.

CALENDER does not display

MID control unit and/or display not functioning.

Replace the MID control unit and/or DISPLAY.

SERVICE does not change

An open circuit of the vehicle speed sensor.

Repair an open circuit.

Units cannot be changed

MID not functioning.

Replace the MID control unit.

8C–22 ENTERTAINMENT

MID Circuit

D08R200053

ENTERTAINMENT

Harness Connector Faces No. E-35

E-43

I-12

I-13

I-16

Connector face

8C–23

SECTION WIRING SYSTEM

8D–1

AXIOM

BODY AND ACCESSORIES WIRING SYSTEM CONTENTS Fuse, Relay and Diode . . . . . . . . . . . . . . . . . . . Relay / Fuse Box Location . . . . . . . . . . . . . . Relay / Fuse Box (Instrument Panel) . . . . . Relay / Fuse Box (Engine Room) . . . . . . . . Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . Fuse Block Circuit . . . . . . . . . . . . . . . . . . . . . Ground Location (Engine Room) . . . . . . . . Ground Location (Cabin) . . . . . . . . . . . . . . . Starter and Generator . . . . . . . . . . . . . . . . . . PCM–1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCM–2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight and Fog Light . . . . . . . . . . . . . . . . Turn, Hazard, Stop, Back Up, Horn and A/T Shift Lock . . . . . . . . . . . . . . . . . . . . . . . . Dome Light, Luggage Room Light, Courtesy Light, Spot Light, and Warning Buzzer . . . Power Window and Door Lock . . . . . . . . . . Alarm and Relay Control Unit . . . . . . . . . . .

8D–2 8D–2 8D–3 8D–4 8D–5 8D–5 8D–6 8D–7 8D–8 8D–9 8D–10 8D–11 8D–12 8D–13 8D–14 8D–15

Rear Wiper/Washer and Rear Defogger . . Audio, Clock, Cigarette Lighter and ACC Socket . . . . . . . . . . . . . . . . . . . . . . . . . . MID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-theft with Keyless Entry . . . . . . . . . . . . Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRS–Air Bag . . . . . . . . . . . . . . . . . . . . . . . . . . Intelligent Suspension . . . . . . . . . . . . . . . . . . T.O.D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sunroof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Illumination Light . . . . . . . . . . . . . . . . . . . . . . Windshield Wiper and Washer . . . . . . . . . . Power Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Heater . . . . . . . . . . . . . . . . . . . . . . . . . . .

8D–16 8D–17 8D–18 8D–19 8D–20 8D–21 8D–22 8D–23 8D–24 8D–25 8D–26 8D–27 8D–28 8D–29 8D–30 8D–31

8D–2

WIRING SYSTEM

Fuse, Relay and Diode Relay / Fuse Box Location

810R200003

Legend (1) Relay/Fuse Box (Engine Room) (2) Relay/Fuse Box (Instrument Panel)

WIRING SYSTEM

8D–3

Relay / Fuse Box (Instrument Panel)

D08RY00529

Legend (1) Fuse/Relay Box (2) Diode (3) Diode (4) Tail Relay (5) Not Used (6) ACC Socket Relay (7) Power Window Relay (8) Not Used (9) Rear Defogger Relay (10) Fuse ACC Socket (15A) (11) Fuse Audio (+B) (15A) (12) Fuse Starter (10A) (13) Fuse Tail (15A) (14) Fuse Room Lamp (10A) (15) Fuse Stop Lamp (15A) (16) Fuse Door Lock (20A) (17) Fuse Mirror Defogger (10A)

(18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35)

Fuse Rear Defogger (15A) Fuse Rear Defogger (15A) Fuse Meter (15A) Fuse ENG. (15A) Fuse IG. Coil (15A) Fuse Back Up (15A) Fuse ELEC. IG. (15A) Fuse RR Wiper (10A) Fuse FRT Wiper (20A) Fuse Audio (ACC) (10A) Fuse Cigar Lighter (15A) Fuse Anti-theft (10A) Fuse SRS (10A) Fuse (Not Used) Circuit Breaker Power Window (30A) Spare Fuse (20A) Spare Fuse (15A) Spare Fuse (10A)

8D–4

WIRING SYSTEM

Relay / Fuse Box (Engine Room)

D08R200046

Legend (1) Fuse/Relay Box (2) Option Box (3) Diode (Not Used) (4) Diode (5) Heater Relay (6) A/C Compressor Relay (7) Headlamp Relay RH (8) Not Used (9) Fog Lamp Relay (10) Not Used (11) Not Used (12) Thermo Relay (13) Headlamp Relay LH (14) Starter Relay (15) ECM Main (16) Fuel Pump Relay (17) Not Used (18) IG.1 (+B.1 60A) (19) Main (100A)

(20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39)

ECM (30A) ABS (50A) IG.2 (+B.2 50A) Condenser Fan (30A) Hazard (15A) Horn (10A) ACG–S (10A) Seat Heater (15A) Blower (15A) Blower (15A) A/C (10A) Headlamp–LH (20A) Headlamp–RH (20A) Fog Lamp (15A) O2 Sensor (20A) Fuel Pump (20A) ECM (15A) TOD (15A) Intelligent Suspension Relay (30A) Condenser Fan Relay

WIRING SYSTEM

8D–5

Circuit Diagram Fuse Block Circuit

D08R200017

8D–6

WIRING SYSTEM

Ground Location (Engine Room)

D08R200015

WIRING SYSTEM

8D–7

Ground Location (Cabin)

D08R200016

8D–8

WIRING SYSTEM

Starter and Generator

D08R200019

WIRING SYSTEM

8D–9

PCM–1

D08R200038

8D–10

WIRING SYSTEM

PCM–2

D08R200040

WIRING SYSTEM

8D–11

Headlight and Fog Light

D08R200020

8D–12

WIRING SYSTEM

Turn, Hazard, Stop, Back Up, Horn and A/T Shift Lock

D08R200003

WIRING SYSTEM

8D–13

Dome Light, Luggage Room Light, Courtesy Light, Spot Light, and Warning Buzzer

D08R200057

8D–14

WIRING SYSTEM

Power Window and Door Lock

D08R200047

WIRING SYSTEM

8D–15

Alarm and Relay Control Unit

D08R200024

8D–16

WIRING SYSTEM

Rear Wiper/Washer and Rear Defogger

D08R200006

WIRING SYSTEM

8D–17

Audio, Clock, Cigarette Lighter and ACC Socket

D08R200048

8D–18

WIRING SYSTEM

MID

D08R200026

WIRING SYSTEM

8D–19

Door Mirror

D08R200010

8D–20

WIRING SYSTEM

Meter

D08R200007

WIRING SYSTEM

8D–21

Anti-theft with Keyless Entry

D08R200049

8D–22

WIRING SYSTEM

Air Conditioning

D08R200025

WIRING SYSTEM

8D–23

ABS

D08R200008

8D–24

WIRING SYSTEM

SRS–Air Bag

D08R200045

WIRING SYSTEM

8D–25

Intelligent Suspension

D08R200012

8D–26

WIRING SYSTEM

T.O.D

D08R200051

WIRING SYSTEM

8D–27

Sunroof

D08R200056

8D–28

WIRING SYSTEM

Illumination Light

D08R200052

WIRING SYSTEM

8D–29

Windshield Wiper and Washer

D08R200005

8D–30

WIRING SYSTEM

Power Seat

D08R200013

WIRING SYSTEM

8D–31

Seat Heater

D08R200014

SECTION METER AND GAUGE

8E–1

AXIOM

BODY AND ACCESSORIES METER AND GAUGE CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Meter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights . . . Table for Meter/Gauge Connector Terminal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning Light Bulb and Indicator Light Bulb .

8E–1 8E–1 8E–2 8E–2 8E–2 8E–4 8E–6 8E–6 8E–6

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/T Shift Indicator Light Bulb . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

8E–6 8E–6 8E–7 8E–7 8E–8 8E–9 8E–9 8E–9 8E–9 8E–9 8E–10

General Description The circuit consists of the starter switch, meter assembly, vehicle speed sensor, transmission switch, lighting switch, turn signal switch, thermo unit, oil pressure unit, Powertrain Control Module (PCM), fuel tank unit, 4WD switch, oil pressure switch, parking brake switch, brake fluid switch, seat belt switch, illumination controller, meter and ambient sensor.

8E–2

METER AND GAUGE

Meter Assembly General Description The meter assembly has the speedometer, tachometer, engine coolant temperature gauge, fuel gauge and warning/indicator lights.

Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights Front View

821R200022

Legend (1) Tachometer (2) Warning Light Lens (3) Speedometer (4) Fuel Gauge

(5) (6) (7) (8)

Reset Button Warning Light Lens A/T Shift Indicator Engine Coolant Temperature Gauge

METER AND GAUGE

8E–3

Rear View

821R200018

Legend (1) Illumination Light Bulb (2) Illumination Light Bulb

(3) (4)

Illumination Light Bulb Illumination Light Bulb

8E–4

METER AND GAUGE

Table for Meter/Gauge Connector Terminal Connections

821RY00053

Legend (1) Connector A

(2) (3)

Connector B Connector C

METER AND GAUGE Connector A

Connector B

Terminal

Function

Terminal

Function

—

A/T shift indicator light “R”

Intelligent suspension indicator light

A/T shift indicator light

TOD indicator light “Rear”

A/T shift indicator light “N”

A/T shift indicator light “P”

Illumination light

Engine revolution pulse

4 5

— TOD indicator light “AUTO”

—

TOD indicator light “Front”

Speed sensor pulse

A/T shift indicator light “3”

Turn signal indicator light (LH)

A/T shift indicator light “D”

Brake warning light

A/T shift indicator light “2”

High beam indicator light (+)

SRS – air bag warning light

High beam indicator light (–)

Ground

Turn signal indicator light (RH)

Battery

Turn signal indicator light

Stater switch

A/T oil temperature warning light

Illumination light

Seat belt indicator light

Ground

Charge warning light

—

Terminal

—

Connector C Function Starter switch

A/T shift indicator light “L”

—

ABS warning light

Fuel gauge

—

Low fuel warning light

—

Cruise set indicator light

Reduced power warning light

—

Oil pressure warning light

—

Check trans warning light

—

MIL(check engine) warning light

—

Check TOD

Engine coolant temperature gauge

Sport mode indicator light —

Winter drive indicator light

Power drive indicator light

—

8E–5

8E–6

METER AND GAUGE

Removal 1. Disconnect the battery ground cable. 2. Remove the Dash Side Trim Panel –LH. 3. Remove the lower cover Assembly(2). B Refer to Instrument Panel Assembly in Body Structure section. 4. Remove the meter cluster Assembly(1). B Refer to Instrument Panel Assembly in Body Structure section.

5. Remove the meter assembly(3). B Remove four fixing screws. B Disconnect the meter connectors.

825RW197

CAUTION: The removed meter assembly should be placed upright or with its face side up.

Installation To install, follow the removal steps in the reverse order. 821R200020

Warning Light Bulb and Indicator Light Bulb Removal 1. Disconnect the battery ground cable. 2. Remove the meter assembly. B Refer to Meter Assembly in this section. 3. Remove the bulb. B Hold the bulb socket by hand, rotate counterclockwise and pull it out.

Installation To install, follow the removal steps in the reverse order.

METER AND GAUGE

8E–7

A/T Shift Indicator Light Bulb Removal 1. Disconnect the battery ground cable. 2. Pry up the bended portions(2) of the metal cover(1).

821RY00060

8E–8

METER AND GAUGE

3. Remove the meter lense(3) from the meter visor(4). 4. Remove the meter visor from the meter case(5).

821RY00061

5. Remove the meter assembly. B Push the metal cover(6) with the screw driver(7).

821RY00062

6. Remove the meter rear cover. 7. Remove the meter circuit board. 8. Remove the A/T shift indicator bulb.

Installation To install, follow the removal steps in the reverse order.

METER AND GAUGE

8E–9

Vehicle Speed Sensor Removal

Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the vehicle speed sensor to the specified torque.

1. Disconnect the battery ground cable. 2. Remove the vehicle speed sensor(1). B Disconnect the connector. B Rotate the sensor counterclockwise.

Torque: 25 N·m (18 lb ft)

225R200001

Fuel Tank Unit Removal Refer to Engine Fuel section.

8E–10 METER AND GAUGE

Main Data and Specifications Torque Specifications Application Vehicle Speed Sensor Fixing

N·m

Lb Ft

Lb In

—

SECTION BODY STRUCTURE

8F–1

AXIOM

BODY AND ACCESSORIES BODY STRUCTURE CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Frame Dimensions . . . . . . . . . . . . . . . . . . . . General Description (Bumper) . . . . . . . . . . . . Front Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Description (Sheet Metal) . . . . . . . . . Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Hood Lock . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Fender Panel . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Body Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . Body Dimension . . . . . . . . . . . . . . . . . . . . . . . . Front Section . . . . . . . . . . . . . . . . . . . . . . . . . Room Section (Front Side) . . . . . . . . . . . . . . Room Section (Rear Side) . . . . . . . . . . . . . . Rear Section . . . . . . . . . . . . . . . . . . . . . . . . . . Side Body Section (Front side) . . . . . . . . . . Side Body Section (Rear side) . . . . . . . . . . General Description (Body) . . . . . . . . . . . . . . . Instrument Panel Assembly . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8F–2 8F–2 8F–2 8F–3 8F–4 8F–4 8F–4 8F–5 8F–6 8F–7 8F–7 8F–8 8F–9 8F–10 8F–10 8F–10 8F–11 8F–11 8F–13 8F–13 8F–13 8F–14 8F–15 8F–15 8F–16 8F–16 8F–18 8F–18 8F–18 8F–19 8F–19 8F–22 8F–24 8F–26 8F–28 8F–30 8F–32 8F–32 8F–32 8F–33

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Door Assembly . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door Assembly . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Window Regulator, Glass and Glass Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Window Regulator, Glass and Glass Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare Tire Hanger . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Quarter Glass . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Glass . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

8F–34 8F–35 8F–35 8F–35 8F–36 8F–37 8F–37 8F–37 8F–38 8F–39 8F–39 8F–40 8F–41 8F–42 8F–42 8F–43 8F–45 8F–46 8F–46 8F–47 8F–48 8F–49 8F–49 8F–50 8F–50 8F–51 8F–51 8F–51 8F–52 8F–55 8F–55 8F–55 8F–56 8F–57 8F–57 8F–57 8F–58 8F–59

8F–2

BODY STRUCTURE

Frame General Description Proper frame alignment is important to assure normal vehicle life and performance of many other parts of the vehicle. If the vehicle has been involved in a fire, collision or has been overloaded, it is necessary to check the frame alignment.

BODY STRUCTURE

8F–3

Frame Dimensions

501R200004

8F–4

BODY STRUCTURE

General Description (Bumper) Front and rear bumpers consist of bumper fascia, support, and reinforcement. The absorbing capability for both front and rear bumper systems are achieved through reinforcements in each bumper.

Front Bumper Parts Location

601R200011

Legend (1) Front Bumper Mounting (2) Front Bumper Side Bracket (3) Front Bumper Back Bar Assembly (4) Front Bumper Center Bracket

(5) (6) (7) (8)

Front Bumper Center Retainer Front Bumper Side Retainer Front Bumper Reinforcement Assembly Front Bumper Fascia

BODY STRUCTURE

Removal 1. Disconnect the battery ground cable. 2. Remove the front bumper fascia. B Remove the nine clips (2), the three bolts (1) and two screws (3).

8F–5

8. Remove the front bumper back bar assembly. B Remove the two bolts from both sides of the front bumper.

601R200004

9. Remove the front bumper mounting (1). B Remove the screw (2) from both sides. 601R200012

3. Remove the front bumper center retainer. B Remove the two nuts and the bolt. 4. Remove the front bumper sides’s retainers. B Remove the four nuts and the bolt from both sides. 5. Remove the front bumper reinforcement assembly. B Remove the four bolts. 6. Remove the front bumper center bracket. B Remove the two bolts. 7. Remove the front bumper sides’s brackets (1). B Remove the two nuts (2) from both sides.

601R200006

601R200005

8F–6

BODY STRUCTURE

Installation To install, follow the removal steps in reverse order noting the following points: 1. Tight the front bumper back bar assembly fixing bolts to the specified torque. Torque : 147 N·m (108 lb ft) 2. Front bumper adjustment. B When the bolts fixing front bumper assembly are tightened, adjustment should be made between the back bar and front side bumper so that there is a clearance of 3 mm (0.12 in) between the top of the bumper and the fender. The angled portion of the bumper must be flush with the fender.

601R200001

BODY STRUCTURE

8F–7

Rear Bumper Parts Location

601R200002

Legend (1) Rear Bumper Mounting (2) Rear Bumper Side Bracket (3) Rear Bumper Back Bar Assembly (4) Rear Bumper Reinforcement Assembly

(5) (6) (7) (8) (9)

Rear Bumper Retainer Bracket Assembly Rear Bumper Support Assembly Rear Bumper Retainer Assembly Rear Reflector Assembly Rear Bumper Fascia

8F–8

BODY STRUCTURE

Removal 1. Disconnect the battery ground cable. 2. Remove the rear bumper fascia. B Remove the two screws (1), six bolts (3) and nine clips (2).

5. Remove the rear bumper reinforcement assembly. B Remove the six bolts.

690R200005

601R200010

3. Remove the rear bumper retainer assembly. B Remove the four nuts. 4. Remove the rear bumper retainer bracket assembly. B Remove the two nuts (1) from both sides.

6. Remove the rear bumper support assembly (5). B Remove the two nuts (4) and the screw (6) from both sides. 7. Remove the rear bumper side bracket (3). B Remove the two nuts (4) from both sides. 8. Remove the rear bumper mounting (2). B Remove the screw (1) from each sides.

690R200009 690R200004

BODY STRUCTURE 9. Remove the rear bumper back bar assembly. B Remove the two bolts from both sides.

690R200007

10. Remove the reflector assembly. B Remove the two nuts.

Installation To install, follow the removal steps in reverse order, noting the following points: 1. Tighten the rear bumper back bar assembly fixing bolts to the specified torque. Torque : 147 N·m (108 lb ft) 2. Rear bumper adjustment. B When the bolts fixing rear bumper assembly are tightened, adjustment should be made with shims so that clearances shown in the figure below are provided between the body (tailgate) (1) and the rear bumper (2).

690R200008

8F–9

8F–10

BODY STRUCTURE

General Description (Sheet Metal) This section includes items of front end sheet metal that are attached by bolts, screws or clips and related accessory components. Anticorrosion materials have been applied to the interior surfaces of some metal panels to provide rust resistance. When servicing these panels, areas on which this material has been disturbed, should be properly recoated with service–type anticorrosion material.

Engine Hood Parts Location

610R200006

Legend (1) Engine Hood Assembly

(2) Windowshield Washer Nozzle Tube (3) Hood Hinge Bolt

BODY STRUCTURE

8F–11

2. Check the engine hood and fender(1).

Removal

Clearance: 4.5 mm (0.18 in)

1. Open the hood. 2. Support the hood. 3. Remove the windshield washer nozzle tube.

Height (step): 0.5 mm (0.02 in) B Adjust clearance with the hinges on the engine hood. B Adjust height (step) with the hood rests(2).

860R200005

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

610R200003

610RX001

610R200002

5. Remove the engine hood.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the engine hood hinge fixing bolts to the specified torque. Torque : 10 N·m (87 lb in)

8F–12

BODY STRUCTURE

610R200004

BODY STRUCTURE

8F–13

Engine Hood Lock Parts Location

610R200012

Legend (1) Engine Hood Lock Assembly (2) Control Cable

(3) Hood Lock Control Lever (4) Inner Liner

Removal 1. Remove the hood lock control lever. 2. Remove the inner liner. 3. Remove the engine hood lock assembly. B Apply setting marks(1) to the hood lock assembly and the body prior to removal.

610R200013

4. Remove the control cable. B Remove the cable fixing clips from the engine hood lock.

8F–14

BODY STRUCTURE

Installation To install, follow the removal steps in the reverse order noting the following points: 1. Reroute the control cable to its original position, and check and see if the lock assembly and control lever work normally. 2. Tighten the hood lock assembly fixing bolts to the specified torque. Torque : 10 N·m (87 lb in)

BODY STRUCTURE

8F–15

Front Fender Panel Parts Location

605R200001

Legend (1) Antenna Assembly (2) Rocker Cover Assembly (3) Front Turn Signal Light Assembly

(4) Front Bumper Fascia Assembly (5) Inner Liner (6) Front Fender Panel

8F–16

BODY STRUCTURE

Removal 1. Disconnect the battery ground cable. 2. Remove the front bumper fascia assembly. B Refer to Front Bumper in this section. 3. Remove the front turn signal light assembly. B Remove the fixing screw and disconnect the connector.

6. Remove the antenna assembly. B Refer to Rod Type Antenna in Entertainment section. 7. Remove the front fender panel (1). B Remove the eight fixing bolts. 8. Remove the engine compartment upper extension (2).

614R200002 610R200008

4. Remove the rocker cover assembly. B Refer to Rocker Cover Assembly in Exterior/Interior Trim section. 5. Remove the inner liner.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the front fender panel fixing bolts to the specified torque. Torque : 7 N·m (61 lb in) 2. Check the fender and front door (1). Clearance: 5.0 mm (0.196 in) Height (step): Flush

647RY00003

610R200009

BODY STRUCTURE

610RW001

8F–17

8F–18

BODY STRUCTURE

Body Mounting Parts Location

501R200002

Legend (1) No.1 Body Mounting (2) No.2 Body Mounting (3) No.3 Body Mounting

Tightening Torque 1. Tighten the body mounting bolts to specified torque. Torque : 50 N·m (41 lb ft)

(4) (5) (6) (7)

No.4 Body Mounting No.5 Body Mounting Body Side Mounting Bracket Frame Side Mounting Bracket

BODY STRUCTURE

8F–19

Body Dimension Front Section

A10R200015

8F–20

BODY STRUCTURE

A10R200002

BODY STRUCTURE

8F–21

A10R200003

8F–22

BODY STRUCTURE

Room Section (Front Side)

A10R200016

BODY STRUCTURE

8F–23

A10R200005

8F–24

BODY STRUCTURE

Room Section (Rear Side)

A10R200017

BODY STRUCTURE

8F–25

A10R200007

8F–26

BODY STRUCTURE

Rear Section

A10R200018

BODY STRUCTURE

8F–27

A10R200009

8F–28

BODY STRUCTURE

Side Body Section (Front side)

A10R200019

BODY STRUCTURE

8F–29

A10R200011

8F–30

BODY STRUCTURE

Side Body Section (Rear side)

A10R200020

BODY STRUCTURE

8F–31

A10R200013

8F–32

BODY STRUCTURE

General Description (Body) This publication contains essential removal, installation, adjustment and maintenance procedures.

Instrument Panel Assembly Parts Location

740R200024

Legend (1) Cross Beam (2) Vent Duct Assembly (3) Instrument Panel Stay (4) Passenger Air Bag (5) Passenger Air Bag Cover (6) Dash Side Trim Panel (RH) (7) Instrument Upper Reinforcement (8) Glove Box Side Reinforcement (9) Passenger Lower Bracket (10) Glove Box (11) Display Unit (12) Audio Kit

(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24)

Front Console Assembly Knee Pad Center Cluster Assembly Cluster Upper Cover Instrument Panel Driver Lower Cover Assembly Driver Knee Bolster Assembly Dash Side Trim Panel (LH) Meter Cluster Assembly Instrument Panel Center Reinforcement Meter Assembly Instrument Panel Assembly Instrument Harness Assembly

BODY STRUCTURE

8F–33

Removal CAUTION: For precautions on installation or removal of SRS – air bag system, refer to Supplemental Restraint System (SRS) – AIR BAG in Restraint section. 1. Disconnect the battery ground cable. 2. Pry the knee pads (4). 3. Remove the cluster upper cover (1) and connectors. 4. Remove the center cluster assembly (2). B Remove six screws and pull out the cluster at the six clip positions. B Disconnect the cigarette lighter (6), ash tray (5) illumination and hazard switch (3) connectors.

470RW002

10. Remove the instrument panel driver lower cover assembly. B Remove the engine hood opener two fixing screws and another one fixing screw. After four clips are pried, disconnect switch connector and duct.

740R200008

5. Remove the display unit. B Remove the four fixing screws and connectors. 6. Remove the audio kit. B Remove the four fixing screws and connectors. 7. Remove the front and rear consoles. B Refer to Consoles in Exterior/Interior Trim section. 8. Remove the dash side trim panels. B Remove the sill plates, then remove the trim panels. 9. Remove the glove box. B Remove the two fixing screws.

610R200007

11. Remove the meter cluster assembly. B Remove the six fixing screws and switch connectors. 12. Remove the meter assembly. B Remove the four fixing screws and disconnect the connectors. 13. Remove the driver knee bolster assembly. B Remove the six fixing bolts and screw. 14. Remove the instrument panel assembly. CAUTION: For precautions on installation or removal of SRS – air bag system, refer to Supplemental Restraint System (SRS) – AIR BAG in Restraint section.

8F–34

BODY STRUCTURE

B Disconnect the instrument harness connectors (six connectors on the driver’s side, three connectors on the passenger side and two connectors on the center side). B Disconnect radio antenna cable plug and the ground cable fixing bolts from dash side panel. B Remove the two fixing bolts of passenger air bag assembly and disconnect the connector. B Remove the two fixing screws from fuse box. B After pry the three hole cover from the surface of instrument panel, remove the three nuts.

17. Remove the passenger lower bracket. B Remove the three screws. 18. Remove the glove box side reinforcement. 19. Remove the instrument upper reinforcement. B Remove the nine screws. 20. Remove the instrument panel center reinforcement. B Remove the six screws. 21. Remove the instrument panel harness assembly (1). B Remove the clips.

B Remove the six bolts and one screw.

740R200023

740R200022

15. Remove the passenger air bag (1). B Remove the four fixing nuts. CAUTION: For precautions on installation or removal of SRS – air bag system, refer to Supplemental Restraint System in Restraint section.

22. Remove the instrument panel stays. B Remove the two fixing nuts and two fixing bolts for each bracket. 23. Remove the cross beam. B Remove the five fixing nuts, two fixing bolts (upper) and six fixing bolts (lower).

840RW005

827RY00004

16. Remove the vent duct assembly. B Remove the five fixing screws.

Installation To install, follow the removal steps in the reverse order.

BODY STRUCTURE

8F–35

Front Door Assembly Parts Location

630R200010

Legend (1) Front Door Assembly (2) Upper Hinge Bolt

(3) Door Harness Connector (4) Door Check Arm (5) Lower Hinge Bolt

Removal 1. Disconnect the battery ground cable. 2. Apply a setting mark on the body side hinge. 3. Remove the door check arm bolt.

630R200011

8F–36

BODY STRUCTURE

4. Remove the upper and lower hinge bolts. B Position a wood block under the door for protection and support the door assembly with hands during removal or installation.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Align the door fitting to the body. B Check the fender and front door (1). Clearance: 5.0 mm (0.196 in) Height (step): Flush B Check the front door and rear door (2). Clearance: 5.0 mm (0.196 in) Height (step): Flush B Check the rear door and body (3). Clearance: 5.0 mm (0.196 in) Height (step): Flush Adjust clearance with door hinges. Adjust height (step) by tapping on the fender lightly with a rubber hammer.

635R200013

5. Remove the door harness connector. B Pull the door harness grommet out in order to disconnect the harness connector.

610R200005

2. Tighten the door hinge bolts to the specified torque. Torque : 34 N·m (25 lb ft) 3. Tighten the door check arm bolt and nuts to the specified torque. Torque : 9 N·m (78 lb in) 630R200012

6. Remove the front door assembly.

BODY STRUCTURE

8F–37

Rear Door Assembly Parts Location

650R200001

(3) Door Check Arm (4) Door Harness Connector (5) Upper Hinge Bolt

Legend (1) Rear Door Assembly (2) Lower Hinge Bolt

4. Remove the upper and lower hinge bolts. B Position a wood block under the door for protection and support the door assembly with hands during removal or installation.

Removal 1. Disconnect the battery ground cable. 2. Apply a setting mark on the body side hinge. 3. Remove the door check arm bolt.

650R200004 650R200002

8F–38

BODY STRUCTURE

5. Remove the door harness connectors. B Pull the door harness grommet out in order to disconnect the door harness connectors.

650R200003

6. Remove the rear door assembly.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Align the door fitting to the body by referring to Front Door Assembly in this section. 2. Tighten the door hinge bolts to the specified torque. Torque : 34 N·m (25 lb ft) 3. Tighten the door check arm bolt and nuts to the specified torque. Torque : 9 N·m (78 lb in)

BODY STRUCTURE

8F–39

Front Window Regulator, Glass and Glass Run Parts Location

635R200012

Legend (1) Glass (2) Glass Run (3) Door Mirror Assembly (4) Door Mirror Cover (5) Tweeter (6) Speaker Spacer (7) Speaker Assembly (8) Inner Waist Seal (9) Door Trim Panel (10) Power Window Switch (11) Inside Lock Bracket

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Inside Handle Pull Box Courtesy Light Pull Box Bracket Waterproof Sheet Front Door Panel Door Lock Assembly Door Lock Cylinder Outside Handle Window Regulator Outer Waist Seal

8F–40

BODY STRUCTURE 4. Remove the inside handle. B Open the screw cover (1) and remove the screw.

Removal 1. Disconnect the battery ground cable. 2. Remove the pull box. B Remove the one fixing screw.

B Disconnect the cable.

635R200003

635R200004

3. Remove the power window switch (1). B Pull the power window switch and remove the connector.

5. Remove the door mirror cover. 6. Remove the trim panel at the 8 clip positions (1). B Disconnect the tweeter and courtesy light connectors.

635R200005 635R200002

BODY STRUCTURE

8F–41

7. Remove the inner waist seal. 8. Remove the tweeter. 9. Remove the courtesy light. 10. Remove the pull box bracket. 11. Remove the inside lock bracket. B Disconnect the cable. 12. Remove the speaker (2) and speaker spacer (1). B Disconnect the speaker connector (3).

631R200002

16. Remove the window regulator. B Remove the 7 fixing bolts and disconnect the window regulator motor harness connector. 17. Remove the glass run. B Pull the glass run (6) from the door frame.

890R200028

13. Remove the waterproof sheet. 14. Remove the outer waist seal. B Remove the rear side screw and pull the outer waist seal upward. 15. Remove the window glass. B Operate the requlator (power window switch) to adjust the glass height and expose the access hole. Remove the 2 bolts fixing the bottom channel and the requlator. Remove the glass.

631RS007

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Check to see that the window regulator operates smoothly and the glass opens and closes properly. 2. Install the waterproof sheet tightly against the door panel. 3. Tighten the window regulator assembly fixing bolts to the specified torque. Torque : 6 N·m (52 lb in) 631R200001

8F–42

BODY STRUCTURE

Rear Window Regulator, Glass and Glass Run Parts Location

655R200009

Legend (1) Glass Run (2) Glass (3) Division Bar (4) Fixed Glass (5) Window Regulator (6) Outside Handle (7) Door Lock Assembly (8) Pull Box Bracket (9) Speaker Spacer (10) Speaker

(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)

Pull Box Door Trim Panel Courtesy Light Power Window Switch Inside Handle Inside Lock Bracket Inner Waist Seal Tweeter Waterproof Sheet Outer Waist Seal Rear Door Panel

BODY STRUCTURE

8F–43

4. Remove the inside handle. B Open the screw cover and remove the screw.

Removal 1. Disconnect the battery ground cable. 2. Remove the pull box. B Remove the fixing screw.

B Disconnect the cable.

655R200008

655R200003

3. Remove the power window switch (1). B Pull the power window switch and remove the connector.

5. Pull the trim panel at the 7 clip positions. B Disconnect the tweeter and courtesy connectors.

light

655R200005

655R200004

6. Remove the inner waist seal. 7. Remove the tweeter and the courtesy light. 8. Remove the pull box bracket. 9. Remove the speaker and the speaker spacer. B Disconnect the speaker harness connector. 10. Remove the inside lock bracket. B Disconnect the cable.

8F–44

BODY STRUCTURE

11. Remove the waterproof sheet (1). B Taking notice of the door harness, peel the waterproof sheet off the door panel carefully.

651RW007

B Remove the fixed window glass (2) by removing the screw from the top of the division bar (1) and the bolt from the bottom of the division bar. 651R200004

12. Remove the outer waist seal. B Remove the front side screw and pull the waist seal upward. 13. Remove the window glass. B Operate the requlator (powe window switch) to adjust the glass hight and expose the access hole. Remove the 2 bolts fixing the bottom channel and the requlator. Remove the galss.

651R200002

651R200001

BODY STRUCTURE 14. Remove the window regulator. B Remove the 6 fixing bolts and pull the regulator out from the lower hole of the door panel.

651R200003

15. Remove the glass run. B Pull the glass run from the door frame.

8F–45

8F–46

BODY STRUCTURE

Tailgate Parts Location

681R200006

Legend (1) Tailgate Assembly (2) Tailgate Stay Assembly (3) Rear Roof Trim Cover (4) Tailgate Upper Cover Assembly (5) Tailgate Hinge (6) High Mount Stoplight (7) Dove Tail (8) Tailgate Lock Assembly (9) Vent Grill

(10) (11) (12) (13) (14) (15) (16) (17) (18)

Tailgate Upper Center Trim Cover Tailgate Upper Side Trim Cover Tailgate Lower Trim Cover Tailgate Pull Box Clip Rear Wiper Motor Assembly Tailgate Panel Assembly Outside Handle Clip

BODY STRUCTURE

Removal 1. Disconnect the battery ground cable. 2. Remove the rear roof trim cover. B Pry the six clip positions free from the body panel. 3. Remove the tailgate upper center trim cover. B Pry the four clip positions (1) free from the tailgate. 4. Remove the tailgate pull box. B Pry the tailgate pull box from the tailgate assembly. 5. Remove the three clips. 6. Remove the tailgate lower trim cover. B Pry the thirteen clip positions (1) free from the tailgate. 7. Remove the tailgate upper side trim cover. B Pry the three clip positions (1) free from the tail gate (RH/LH).

8F–47

19. Remove the tailgate lock assembly and outside handle. B Refer to Tailgate Lock in Security And Locks section. 20. Remove the license plate garnish (1). B Remove the four screws (3) and the clip (2).

803R200010

21. Remove the license plate light. 22. Remove the tailgate harness.

681R200007

8. Disconnect the high mount stoplight and rear defogger and tailgate lock harness connectors. 9. Pull out the washer hose. 10. Remove the tailgate hinges (RH/LH). B Remove the two bolts. 11. Remove the tailgate stay assembly (RH/LH). B Remove the two bolts. 12. Remove the tailgate assembly. B Remove the tailgate assembly may require two people. B Carefully remove the tailgate assembly not to damage the hinge. 13. Remove the tailgate upper cover assemblies (RH/LH). 14. Remove the dove tails (RH/LH). 15. Remove the vent grills (RH/LH). 16. Remove the high mount stoplight. 17. Remove the rear wiper arm. B Refer to Rear Wiper Arm/Blade in Wiper/Washer System section. 18. Remove the rear wiper motor assembly.

8F–48

BODY STRUCTURE

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. When installing the hinge to the body, exercise special care not to damage the body paint surface. 2. Align the tailgate fitting to the body. B Check the roof and tailgate (1). Clearance: 10.7 mm (0.42 in) Height (step): –2 mm (0.08 in) B Check the tailgate fitting to the rear quarter panel (2), (4). Clearance: 5.0 mm (0.196 in) Height (step): Flush B Check the tailgate fitting to the rear bumper. Clearance: 6.5 mm (0.26 in) Adjust clearance with tailgate hinges. Adjust height (step) by tapping on the tailgate lightly with a rubber hammer.

610R200011

BODY STRUCTURE

8F–49

Spare Tire Hanger Parts Location

530R200002

Legend (1) Spare Tire Hanger Assembly Fixing Bolt (2) End Cross Member (3) Rear Suspension · Cross Member (4) Spare Tire Support (5) Spare Tire Support Fixing Bolt

(6) (7) (8) (9) (10) (11)

Spare Tire Stopper Rubber (RH) Spare Tire Stopper Rubber (Front) Stopper Rubber Fixing Clip Spare Tire Spare Tire Stopper Rubber (LH) Spare Tire Hanger Assembly

8F–50

BODY STRUCTURE

Removal 1. Open the hatch gate and tail gate. 2. Remove the spare tire (3). B Put the spare tire handle (1) to the center of upper side of rear bumper (2) and turn counterclockwise. Put spare tire down.

530R200001

3. Remove the spare tire support. B Remove the four bolts that are fixed to frame cross member. 4. Remove the spare tire hanger assembly. B Remove the two fixing bolts.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Install the spare tire firmly. 2. Tighten the spare tire support fixing bolts to the specified torque. Torque : 40 N·m (4.1 kg·m) 3. Tighten the spare tire hanger fixing bolts to the specified torque. Torque : 19 N·m (1.9 kg·m)

BODY STRUCTURE

8F–51

Windshield Parts Location

607R200003

Legend (1) Windshield Wiper Arm (2) Windshield Upper Molding (3) Windshield

Removal 1. Disconnect the battery ground cable. 2. Remove the front pillar trim cover. B Turn up the finisher and pry the trim cover clips free from the body panel. 3. Remove the sunvisors and sunvisor holders. B Refer to Headlining in Exterior/Interior Trim section.

(4) (5) (6) (7)

Windshield Side Molding Windshield Support Front Cowl Cover Hood Rear Seal

4. Remove the interior mirror. B Refer to Interior Mirror Assembly in Exterior/Interior Trim section. 5. Remove the windshield wiper arm. B Refer to Windshield Wiper Arm/Blade in Wiper/Washer System section. 6. Remove the windshield side molding. B Pull the molding out from drip rail. 7. Remove the front cowl cover.

8F–52

BODY STRUCTURE

8. Remove the windshield support. 9. Remove the upper moulding. 10. Remove the windshield. B Use a knife to cut through part of the adhesive caulking material. B Secure one end of a piece of steel piano wire (0.02 inches in diameter) to a piece of wood that can serve as a handle. B Use a pair of needle nose pliers to insert the other end of the piano wire through the adhesive caulking material at the edge of the windshield glass.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Clean the bonding surfaces of both the windshield and body panel with a soft rag and white gasoline. 2. Install the spacer. B Attach spacers in six locations as shown in the figure. B Always use new spacer.

B Secure the other end of the piano wire to another piece of wood. B With the aid of an assistant, carefully move the piano wire with a sawing motion to cut through the adhesive caulking material around the entire circumference of the windshield glass. B Attach some cloth tape (1) on the body for protecting the painting surface.

607R200001

3. Install the windshield upper molding. B Peel off the tear-away paper from the windshield upper molding, and start applying it with one end of the glass and cut away the surplus at the other end of the glass for length adjustment. B Always use new upper molding.

607RW012

B Clean the remaining adhesive caulking material from the area of the body which holds the windshield.

4. Temporary install the windshield support. 5. Apply the primer to the windshield and body panel. B Apply the primer (3) (Sun star # 435-40 or equivalent) to the windshield side bonding surface as shown in the figure. B Apply the primer (Sun star # 435-95 or equivalent) to the body side bonding surface. NOTE: Apply an adhesive 3 minutes or more but within 24 hours after the application of primer. If more than 24 hours have passed, reapply primer. Primer should be handled as following: 1. Use the primer manufactured 3 months or less ago and having been kept in an refrigerator. 2. Wipe off primer-stains on positions other than requires application.

BODY STRUCTURE

8F–53

3. Stir the primer for a minute or more before use.

607RW003

Legend (1) Adhesive (2) Sealing Dam

(3) Primer Coating Area (4) Windshield (5) Upper Molding

6. Apply the adhesive (1) to the windshield. B After drying primer completely, apply a sealing adhesive (Sun star # 555 or equivalent) along the edge of the glass so that the sealing adhesive has a 20 mm (0.79 in) junction at middle of the base of the glass.

607RW015

8F–54

BODY STRUCTURE

NOTE: Apply an adhesive 3 minutes or more but within 24 hours after the application of primer. If more than 24 hours have passed, reapply primer. Adhesive should be handled as follows: 1. Use the adhesive manufactured 3 months or less ago. 2. Wipe off adhesive-stains on positions other than requires application. 7. Install the windshield. B Set the windshield with sealing adhesive applied to entire circumference in the body panel. Specifically, adjust windshield support with the upper molding making contact with the body panel, press the glass, and tighten the windshield support. NOTE: Affix the glass within 5 minutes of application.

607RX010

10. Install windshield wiper arm.

607RS017

8. Install the front cowl cover. 9. Install side molding. B Use alcohol wipe or equivalent cleaner with soft cloth to wipe away any excess adhesive. B Cure the bonding at a temperature of 20°C – 30°C (68°F – 86°F) for 24 hours. B Check the windshield for any signs of water leak.

BODY STRUCTURE

8F–55

Rear Quarter Glass Parts Location

641R200005

Legend (1) Clip (2) Rear Quarter Glass (3) Adhesive (4) Fastener Tape

Removal 1. Disconnect the battery ground cable. 2. Remove the rear quarter trim covers. B Refer to Interior Trim Panels in Exterior/Interior Trim section. 3. Remove the air outlet garnish assembly. B Pry the two clip positions free from the body panel. 4. Remove the rear quarter moulding. B Pry the five clip positions free from the body panel.

(5) (6) (7) (8) (9)

Spacer Rear Quarter Trim Covers Air Outlet Garnish Assembly Rear Quarter Moulding Moulding

5. Remove the rear quarter glass. B Refer to Windshield in this section.

8F–56

BODY STRUCTURE

Installation To install, follow the removal steps in the reverse order, noting the following points:

641R200003

Legend (1) Primer Coating Area (Glass side) (2) Adhesive

1. Clean the bonding surfaces of both the window glass and body panel with a soft rag and white gasoline. 2. Apply the primer to the window glass and body panel. B Apply the primer (Sun star # 435-40 or equivalent) to the window glass side bonding surface as shown in the figure. B Apply the primer (Sun star # 435-95 or equivalent) to the body side bonding surface. 3. Apply sealing adhesive to the window glass. B Make sure that the primer has dried completely. B Apply sealing adhesive (SunStar 555 or the equivalent) to the circumference of the window glass. There should be a 20 mm (0.79 in) overlap at the lower front corner of the glass. 4. Attach the fastener tape and spacers to the points shown in the illustration. 5. Attach the glass clips to the panel. Press the glass into the panel until it adheres to the panel. NOTE: Immediately wipe away any excess sealing adhesive oozing from the panel and glass.

(3) Primer Coating Area (Body panel side) (4) Rear Quarter Glass (5) Moulding

6. Allow the assembly to dry for 24 hours (20∼30°C). 7. Check to make sure that there is no water leakage from the rear quarter glass.

BODY STRUCTURE

8F–57

Tailgate Glass Parts Location

641R200004

Legend (1) Adhesive (2) Sealing Dam (3) Primer Coating Area (Glass Side) (4) Tailgate Glass

Removal 1. Disconnect the battery ground cable. 2. Remove the tailgate trim covers. B Refer to Tail Gate in Body Structure section. 3. Remove the rear wiper arm. B Refer to Rear Wiper Arm/Blade in Wiper/Washer System section.

(5) (6) (7) (8)

Clip Primer Coating Area (Body Panel Side) Mark Stamping Location Fastner

4. Remove the license plate garnish. B Refer to Tailgate in this section. 5. Disconnect the high mount stoplight and rear defogger harness connector. 6. Remove the high mount stoplight.

8F–58

BODY STRUCTURE

7. Remove the tailgate glass assembly. B Use a knife to cut through part of the adhesive caulking material. Secure one end of a piece of steel piano wire (0.02 inches in diameter) to a piece of wood that can serve as a handle. B Use a pair of needle nose pliers to insert the other end of the piano wire through the adhesive caulking material at the edge of the tailgate glass. B Secure the other end of the piano wire to another piece of wood. B With the aid of an assistant, carefully move the piano wire with a sawing motion to cut through the adhesive caulking material around the entire circumference of the tailgate glass. B Attach some cloth tape (1) on the body for protecting the painting surface.

3. Stir the primer for a minute or more before use. 3. Apply the adhesive to the tailgate glass. B After drying primer completely, apply a sealing adhesive (Sun star # 555 or equivalent) along the edge of the glass so that the sealing adhesive has a 20 mm (0.79 in) junction at middle of the base of the glass. NOTE: Adhesive an adhesive 3 minutes or more but with in 24 hours after the application of primer. If more than 24 hours have passed, reapply primer. Primer should be handled as follows: 1. Use the adhesive manufactured 3 months or less ago. 2. Wipe off adhesive-stains on positions other than requires application. 4. Install the tailgate glass. B Set the window (adhesive applied) to the tailgate window frame. Carefully align the clips (bottom corners) and fasteners (top corners). NOTE: Affix the glass within 5 minutes of application.

607RW012

B Clean the remaining adhesive caulking material from the area of the body which holds the tailgateglass.

Installation To install, follow the removal steps in reverse order, noting the following points: 1. Clean the bonding surfaces of both the tailgate glass and tailgate with a soft rag and white gasoline. 2. Apply the primer to the tailgate glass and tailgate. B Apply the primer (Sun star # 435-40 or equivalent) to the tailgate side bonding surface. B Apply the primer (Sun star # 435-95 or equivalent) to the tailgate side bonding surface. NOTE: Apply an adhesive 3 minutes or more but with in 24 hours after the application of primer. If more than 24 hours have passed, reapply primer. Primer should be handled as following: 1. Use the primer manufactured 3 months or less ago having been kept in an refrigerator. 2. Wipe off primer-stains on positions other than require application.

607RS017

5. Install tailgate wiper arm.

BODY STRUCTURE

8F–59

Main Data and Specifications Torque Specification

501R200003

8F–60

BODY STRUCTURE

601R200008

635R200009

BODY STRUCTURE

8F–61

630R200014

650R200005

8F–62

BODY STRUCTURE

530R200003

SECTION SEATS

8G–1

AXIOM

BODY AND ACCESSORIES SEATS CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Front Seat Assembly . . . . . . . . . . . . . . . . . . . . Front Seat Assembly and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Seat Assembly . . . . . . . . . . . . . . . . . . . Power Seat Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8G–1 8G–2 8G–2 8G–2 8G–3 8G–4 8G–4 8G–5 8G–6

Rear Seat Assembly . . . . . . . . . . . . . . . . . . . . . Rear Seat Cushion Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Seat Back Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

8G–7 8G–7 8G–8 8G–8 8G–9 8G–9 8G–10 8G–11

8G–2

SEATS

Front Seat Assembly Front Seat Assembly and Associated Parts

750R200011

Legend (1) Front Seat Assembly (Passenger’s Seat Only) (2) Hinge Cover (3) Rear Cover (4) Front Seat Belt Buckle Assembly (5) Seat Adjuster (6) Front Cover

Removal 1. Disconnect the battery ground cable. 2. Remove the front and rear covers. 3. Remove the front seat assembly. B Remove the four fixing bolts.

(7) (8) (9) (10) (11) (12)

Reclining Knob Side Cover Reclining Device Seat Back Assembly Guide Holder Headrest

SEATS 4. Pull out the reclining knob. 5. Remove the side cover. B Remove the two screws. 6. Remove the headrest. 7. Remove the reclining device. B Pull up on the seat back trim cover in order to remove the reclining device fixing bolts.

9. Remove the trim cover (Seat back side). 10. Remove the guide holder. B Pull the guide holder out by holding the bottom end of it from the seat back assembly. 11. Remove the seat adjuster. B Disconnect the release wire (4) and remove the fixing bolts.

750RW006

750R200007

8. Remove the seat back assembly. B Remove the seat back assembly fixing nut on the opposite side of the reclining device.

8G–3

12. Remove the seat belt buckle assembly. 13. Remove the trim cover (Seat cushion side).

750R200008

8G–4

SEATS

Power Seat Assembly Power Seat Assembly and Associated Parts

750R200009

Legend (1) Headrest (2) Guide Holder (3) Seat Back Frame Assembly (4) Connecting Pipe (5) Seat Back Pad (6) Seat Heater (Required Option) (7) Reclining Device Cover (8) Reclining Device (9) Outer Side Cover (10) Reclining Switch Knob (11) Slide Switch Knob (12) Power Lumbar Switch (Driver’s Side) (13) Power Seat Switch (14) Seat Cushion Frame Assembly

(15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27)

Power Seat Harness Adjuster Bracket Rear Cover Outer Seat Adjuster Assembly Adjuster Bracket Front Cover Front Cover Sliding Motor Cable Inner Seat Adjuster Assembly Seat Cushion Pad Seat Cushion Assembly/Seat Cushion Trim Cover Seat Belt Buckle Assembly Inner Side Cover Power Lumbar Support Assembly (Driver’s Side) Seat Back Assembly/Seat Back Trim Cover

SEATS

8G–5

Removal 1. Remove the adjuster bracket rear cover and the fixing bolts on the rear side of the seat adjuster assembly. B Before removal, slide the power seat assembly forward. 2. Remove the adjuster bracket front cover and the fixing bolts on the front side of the seat adjuster assembly. B Before removal, slide the power seat assembly backward. 3. Disconnect the battery ground cable. 4. Remove the power seat assembly. B Disconnect the power seat harness connectors and the seat belt warning connector of the driver side. CAUTION: When raising power seat assembly (1), use the handle (2) not the cable (3). A bent cable causes noise to occur during power seat operation. 760R100037

B Please grip the handle (4).

12. Remove the reclining device covers. 13. Remove the trim cover and pad (Seat back side). 14. Remove the seat heater and connector (seat back side). 15. Remove the power lumbar support assembly. 16. Remove the guide holder. B Pull the guide holder out by holding the bottom end of it from the seat back assembly. 17. Remove the seat adjuster assembly. B Remove the four fixing bolts and disconnect the sliding motor connector. 18. Remove the sliding motor cable (2). B Remove the nuts of each side.

B Don’t grip the cable (5).

CAUTION: Be sure to maintain the same position for both outer and inner seat adjust assembly (1).

750R200012

5. Pull the switch knobs out. 6. Remove the outer side cover. B Remove the two fixing screws and disconnect the power seat switch connector. 7. Remove the power seat switch. B Remove the two fixing screws. 8. Remove the power lumber switch. B Remove the two fixing screws and connectors. 9. Remove the inner side cover. 10. Remove the headrest. 11. Remove the reclining device (2). B Flip up the seat back trim cover (1) in order to remove the reclining device fixing bolts. B Disconnect the reclining motor harness connector (3).

760R100038

8G–6

SEATS

19. Remove the seat belt buckle assembly. 20. Remove the trim cover and pad (Seat cushion side) 21. Remove the seat heater and connector (Seat cushion side). 22. Remove the power seat harness.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the reclining device fixing bolts to the specified torque. Torque: 46 N·m (34 lb ft) 2. Tighten the seat adjuster fixing bolts to the specified torque. Torque: 21 N·m (15 lb ft) to seat cushion Torque: 39 N·m (29 lb ft) to body 3. Tighten the seat belt buckle assembly fixing bolts to the specified torque. Torque: 29 N·m (22 lb ft)

SEATS

8G–7

Rear Seat Assembly Rear Seat Cushion Assembly and Associated Parts

755RY00009

Legend (1) Rear Seat Lock Striker (2) Rear Seat Lock Assembly (3) Rear Seat Belt Buckle Assembly

(4) (5) (6) (7)

Seat Cushion Hinge Hinge Cover Seat Cushion Fixing Bolt Rear Seat Cushion Assembly

8G–8

SEATS

Removal 1. Remove the hinge covers. 2. Remove the seat cushion fixing bolts. 3. Remove the seat cushion assembly (2). B Pull the strap (1) of the rear seat lock assembly to release the seat lock.

6. Remove the rear seat lock assembly and rear seat belt buckle assembly. 7. Remove the rear seat lock strikers. B Remove the four bolts at each striker.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the rear seat lock assembly and rear seat belt buckle assembly fixing bolts to the specified torque. Torque: 39 N·m (29 lb ft) 2. Tighten the rear seat lock striker fixing bolts to the specified torque. Torque: 39 N·m (29 lb ft) 3. Tighten the seat cushion hinge fixing bolts to the specified torque. Torque: 39 N·m (29 lb ft)

755R100006

4. Remove the seat cushion hinges. 5. Remove the rear cushion trim cover (1) and rear seat cushion pad (2). B Remove cushion trim cover from the rear cushion frame (3) by prying on the plastic retainers (4).

755RX028

SEATS

8G–9

Rear Seat Back Assembly and Associated Parts

755R200005

Legend (1) Headrest (2) Seat Back Assembly (3) Guide Holder (4) Release Knob

Removal 1. Pull the release knob and pull the seat back assembly forward. 2. Remove the seat lock covers. B Remove the three screws from each side. 3. Remove the luggage floor carpets. B Pull the nine carpet fixing clips from the backside of the seat back assembly.

(5) (6) (7) (8) (9)

Seat Lock Cover Seat Lock Striker Side Hinge Body Floor Panel Center Hinge

4. Remove the seat back assembly. B Remove the four fixing bolts at each seat back. 5. Remove the headrests. 6. Remove the release knobs. B Turn the knob counterclockwise to remove it. 7. Remove the trim covers. 8. Remove the guide holders. 9. Remove the side hinges. B Remove the one fixing nut at each side hinge.

8G–10 SEATS 10. Remove the center hinge. B Remove the two fixing bolts.

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Tighten the center hinge fixing bolts to the specified torque. Torque: 39 N·m (29 lb ft) 2. Tighten the side hinge fixing nuts to the specified torque. Torque: 29 N·m (22 lb ft) 3. Tighten the side lock striker fixing bolts to the specified torque. Torque: 19 N·m (14 lb ft)

SEATS 8G–11

Main Data and Specifications Torque Specifications

750R200010

8G–12 SEATS

755R200009

SECTION SECURITY AND LOCKS

8H–1

AXIOM

BODY AND ACCESSORIES SECURITY AND LOCKS CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Front Door Lock Assembly . . . . . . . . . . . . . . . Front Door Lock Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Outside Handle . . . . . . . . . . . . . . . . . . . . Front Outside Handle and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door Lock Assembly . . . . . . . . . . . . . . . . Rear Door Lock Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Outside Handle . . . . . . . . . . . . . . . . . . . . Rear Outside Handle and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Lock and Outside Handle . . . . . . . . . Tailgate Lock, Outside Handle and Associated Parts . . . . . . . . . . . . . . . . . . . . . .

8H–1 8H–2 8H–2 8H–2 8H–4 8H–5 8H–5 8H–5 8H–5 8H–6 8H–6 8H–6 8H–8 8H–9 8H–9 8H–9 8H–9 8H–10 8H–10

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Door Lock System . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . Door Lock Key Switch . . . . . . . . . . . . . . . . . . Front Door Lock Actuator . . . . . . . . . . . . . . . Rear Door Lock Actuator . . . . . . . . . . . . . . . Tailgate Lock Actuator . . . . . . . . . . . . . . . . . . Anti-Theft System . . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . Anti–Theft & Keyless Entry Controller . . . . Anti–Theft Indicator . . . . . . . . . . . . . . . . . . . . Anti–Theft Horn . . . . . . . . . . . . . . . . . . . . . . . Engine Hood Switch . . . . . . . . . . . . . . . . . . . Anti–theft & Keyless Entry Control Unit/Transmitter Replacement . . . . . . . . . . Keyless Entry System . . . . . . . . . . . . . . . . . . . . ID Code Registration . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

8H–10 8H–11 8H–12 8H–12 8H–12 8H–13 8H–13 8H–13 8H–13 8H–13 8H–13 8H–14 8H–14 8H–14 8H–14 8H–14 8H–15 8H–15 8H–16 8H–16 8H–19

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

8H–2

SECURITY AND LOCKS

Front Door Lock Assembly Front Door Lock Assembly and Associated Parts

635R200008

Legend (1) Door Mirror Cover (2) Power Window Switch (3) Door Trim Panel (4) Inside Lock Bracket (5) Inside Handle

(6) (7) (8) (9) (10) (11)

Pull Box Pull Box Bracket Waterproof Sheet Door Lock Assembly Door Lock Cylinder Outside Handle

Removal 1. Disconnect the battery ground cable. 2. Remove the pull box. B Remove the one fixing screw.

635R200004

SECURITY AND LOCKS 3. Remove the power window switch (1). B Pry the power window switch and remove the connector.

8H–3

5. Remove the door mirror cover. 6. Pull the door trim panel at the 8 clip positions (1). B Disconnect the courtesy light and tweeter harness connectors.

635R200002

4. Remove the inside handle. B Open the screw corer (1) and remove the screw. B Disconnect the cable.

635R200005

7. Remove the pull box bracket. 8. Remove the inside lock bracket. B Disconnect the cable. 9. Remove the waterproof sheet. B Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 10. Raise the glass up to the uppermost position. 11. Remove the door lock assembly. B Disconnect the locking links and harness connector. B Remove the 3 fixing Torx screws and bolt.

635R200003

632R200001

8H–4

SECURITY AND LOCKS

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Apply chassis grease to the lock assembly and striker moving surface. 2. Tighten the door lock assembly fixing screws to the specified torque. Torque 7 N·m (61 Ib in) 3. Check that the door lock operates smoothly.

SECURITY AND LOCKS

8H–5

Front Outside Handle Front Outside Handle and Associated Parts

635R200008

Legend (1) Door Mirror Cover (2) Power Window Switch (3) Door Trim Panel (4) Inside Lock Bracket (5) Inside Handle

Removal 1. Disconnect the battery ground cable. 2. Remove the door trim panel. B Refer to Front Door Lock Assembly in this section. 3. Remove the waterproof sheet. B Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 4. Disconnect the locking links and remove the outside handle. 5. Remove the fixing clip to remove the door lock cylinder.

(6) (7) (8) (9) (10) (11)

Pull Box Pull Box Bracket Waterproof Sheet Door Lock Assembly Door Locking Cylinder Outside Handle

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Be sure to install the door lock cylinder at a specified angle to the outside handle. 2. Check for smooth outside handle and lock cylinder operation. 3. Tighten the outside handle fixing bolts to the specified torque. Torque 7 N·m (61 Ib in)

8H–6

SECURITY AND LOCKS

Rear Door Lock Assembly Rear Door Lock Assembly and Associated Parts

655R200007

Legend (1) Outside Handle (2) Door Lock Assembly (3) Pull Box Bracket (4) Pull Box

(5) (6) (7) (8) (9)

Door Trim Panel Power Window Switch Inside Handle Inside Lock Bracket Waterproof Sheet

Removal 1. Disconnect the battery ground cable. 2. Remove the pull box. B Remove the fixing screw.

655R200003

SECURITY AND LOCKS 3. Remove the power window switch (1). B Pry the power window switch and remove the connector.

655R200004

4. Remove the inside handle. B Open the screw cover and remove the screw. B Disconnect the cable.

8H–7

5. Pull the trim panel at the 7 clip positions. B Disconnect the tweeter and courtesy connectors.

light

655R200005

6. Remove the pull box bracket. 7. Remove the inside lock bracket. B Disconnect the cable. 8. Peel the waterproof sheet. B Taking notice of the door harness, peel the waterproof sheet off the door panel carefully.

655R200008

651R200004

8H–8

SECURITY AND LOCKS

9. Remove the door lock assembly. B Disconnect the locking link and harness connector. B Remove the 3 fixing Torx screws and bolt.

652R200001

Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Apply chassis grease to the lock assembly and striker moving surface. 2. Tighten the door lock assembly fixing screws to the specified torque. Torque 7 N·m (61 Ib in) 3. Check that the door lock operates smoothly.

SECURITY AND LOCKS

8H–9

Rear Outside Handle Rear Outside Handle and Associated Parts

655R200007

Legend (1) Outside Handle (2) Door Lock Assembly (3) Pull Box Bracket (4) Pull Box

Removal 1. Disconnect the battery ground cable. 2. Remove the door trim panel. B Refer to Rear Door Lock Assembly in this section. 3. Peel the waterproof sheet. B Taking notice of the door harness, peel the waterproof sheet off the door panel carefully. 4. Disconnect the locking link and remove fixing bolts to remove the outside handle.

(5) (6) (7) (8) (9)

Door Trim Panel Power Window Switch Inside Handle Inside Lock Bracket Waterproof Sheet

Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Check that the outside handle operates smoothly. 2. Tighten the outside handle fixing bolts to the specified torque. Torque 7 N·m (61 Ib in)

8H–10 SECURITY AND LOCKS

Tailgate Lock and Outside Handle Tailgate Lock, Outside Handle and Associated Parts

681R200008

(4) (5) (6) (7)

Legend (1) Tailgate Panel Assembly (2) Tailgate Lower Trim Cover (3) Tailgate Pull Box

Clip Tailgate Lock Assembly Locking Link Tailgate Outside Handle

Removal 1. Disconnect the battery ground cable. 2. Remove the tailgate pull box. 3. Remove the three clips. 4. Remove the tailgate lower trim cover. B Pull the tailgate lower trim cover at the thirteen clip positions. 5. Remove the tailgate lock assembly. B Remove the three fixing bolts. B Disconnect connector.

the

locking

links

and

harness

6. Remove the tailgate outside handle. B Remove the two fixing nuts. 7. Remove the tailgate lock cylinder(2). B Remove the fixing clip(3) pull lock cylinder from the outside handle (1). 681R200005

SECURITY AND LOCKS

Installation To install, follow the removal steps in the reverse order, noting the following points: 1. Check for smooth outside handle and lock cylinder operation. 2. Tighten the tailgate lock assembly fixing bolts to the specified torque. Torque 7 N·m (61 Ib in) 3. Tighten the tailgate outside handle fixing nuts to the specified torque. Torque 7 N·m (61 Ib in)

8H–11

8H–12 SECURITY AND LOCKS

Key Key Coding

730RX001

Legend (1) Key (Actual size) (2) Key Code Tag

One key is used for the ignition, door, and tailgate lock cylinders. The keys are cut on both edges to make them reversible. Key identification is obtained from the five character key code stamped on the key code tag. From this key code, the key code cutting combination can be determined from a code list (available to owners of key cutting equipment from suppliers). If key codes are not available from records or tags, the key code can be obtained from the right hand door lock cylinder (if lock has not been replaced). Lock cylinders supplied by the factory as service parts are unmarked. If the original key is available, the key code cutting combination can be determined by laying the key on the diagram shown in the figure.

(3) Position (4) Level

Key Styles

730RX002

Legend (1) Blank Key Style “A” (2) Blank Key Style “B” The keys come in styles A or B depending on the key code cutting combination. When the first position in the combination is a 1, 2 or 3, Style A is used. When the first position is a 4, Style B (factory pre-cut key) is used.

SECURITY AND LOCKS

Power Door Lock System General Description The circuit consists of the door lock (& power window) switch, door lock actuator for the front and rear door, tailgate lock actuator and the door lock key switch. The front door lock switch–LH is always provided with the battery voltage. The key or the inside lock button on both driver’s and front passenger’s door can activate the lock mechanism of all the doors (including the tailgate). When the driver’s door lock switch or the front passenger’s door lock switch is turned on, current flows for about one second to the door lock actuator of each door connected in parallel with the front door lock (& power window) switch–LH to activate the actuator to lock and unlock the doors.

Door Lock Key Switch Removal and Installation B Refer to the Front Door Lock Assembly removal and installation steps in this section.

Front Door Lock Actuator Removal and Installation B Refer to the Front Door Lock Assembly removal and installation steps in this section.

Rear Door Lock Actuator Removal and Installation B Refer to the Rear Door Lock Assembly removal and installation steps in this section.

Tailgate Lock Actuator Removal and Installation B Refer to the Tailgate Lock Assembly removal and installation steps in this section.

8H–13

8H–14 SECURITY AND LOCKS

Anti-Theft System General Description

Anti–Theft Indicator

The circuit consists of the starter switch, anti–theft & keyless entry controller, anti–theft horn, front door and tailgate key switch (detect and tamper) switch, door lock actuator for each door, engine hood switch, clutch start switch (M/T), ANTI–THEFT indicator light and mode switch (A/T). The system operates as follows: After locking the starter switch and removing the starter key (this sets the alarm), if the door is unlocked in any way other than with the proper key, the headlights will start flashing, the horn sounds, and the starter circuit is disabled. (However, the engine hood and all the doors must be locked and closed.) Once the system has been placed in the warning or alarm condition, it can be released only when the starter switch is shifted from “OFF” to “ACC” by the starter key, or when the lock of the front door or the tailgate is released (to activate the detect switch) by the starter key.

Removal and Installation Refer to GPS in Entertainment section.

Anti–Theft Horn Removal 1. Disconnect the battery ground cable. 2. Remove the anti–theft horn (1). B Disconnect the connector. B Remove a fixing bolt.

Anti–Theft & Keyless Entry Controller Removal 1. Disconnect the battery ground cable. 2. Remove the glove box from the instrument panel assembly (1). B Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the anti–theft & keyless entry controller (2). B Disconnect the connector. B Remove two fixing screws. 828RW001

Installation To install, follow the removal steps in the reverse order.

826RW007

Installation To install, follow the removal steps in the reverse order.

SECURITY AND LOCKS

Engine Hood Switch

8H–15

Anti–theft & Keyless Entry Control Unit/Transmitter Replacement

Removal

Anti–theft & Keyless Entry Control Unit Replacement

1. Disconnect the battery ground cable. 2. Disconnect the connector. 3. Remove the engine hood switch (1).

1. Remove and install the control unit. B Refer to Anti–theft & Keyless Entry Control Unit Removal and Installation in this section. 2. Register ID code. B Refer to ID Code Registration in this section. 3. Check that the keyless entry system works normally.

Transmitter Replacement 1. Prepare a new transmitter. 2. Register ID code. B Refer to ID Code Registration in this section. 3. Check that the keyless entry system works normally.

Transmitter Battery Replacement

828RW002

Installation To install, follow the removal steps in the reverse order.

1. Remove a screw to remove the cover. 2. Remove the batteries. 3. Set the new batteries into the transmitter. 4. Install the cover to the transmitter. 5. Check that the keyless entry system works normally.

8H–16 SECURITY AND LOCKS

Keyless Entry System ID Code Registration The following procedures are available to register keyless entry ID codes. There are four different ID codes which can be registered for each vehicle.

ID Code New Registration This procedure erases all registered ID codes and registers a new ID code instead. Step 1

Action

Go to Step 2

—

Go to Step 3

Go to Step 1

Go to Step 4

Go to Step 1

Go to Step 5

Go to Step 1

Go to Step 6

Go to Step 1

Go to Step 7

Go to Step 1

Go to Step 8

Go to Step 1

Go to Step 9

Go to Step 1

1. Make sure that the all the doors are closed and unlocked. 2. Open the driver’s side door. 3. Insert the starter key into the starter switch. Is the action complete?

Yes

Turn the starter switch to ACC position and return it to OFF position quickly three times. NOTE: This step must be carried out within five seconds after step 1 is finished. Is the action complete?

Close and open the drive’s side door quickly two times. NOTE: This step must be carried out within ten seconds after step 2 is finished. Is the action complete?

1. Turn the starter switch to ACC position and return it to OFF position quickly five times. 2. Close and open the driver’s side door quickly one time. NOTE: This step must be carried out within ten seconds after step 3 is finished. Is the action complete?

The control unit locks and unlocks the doors one time. Does the control unit work normally?

Operate the lock or unlock button of the transmitter. NOTE: This step must be carried out within twenty seconds after step 5 is finished. Is the action complete?

The control unit locks and unlocks the doors one time. Does the control unit work normally?

Operate the lock or unlock button of the transmitter. NOTE: This step must be carried out within twenty seconds after step 7 is finished. Is the action complete?

If registration succeeds, the control unit locks and unlocks the doors one time. If registration fails, the control unit locks and unlocks the doors three times.

SECURITY AND LOCKS

8H–17

ID Code Additional Registration This procedure additionally registers a new ID code with holding registered ID codes. If total number of registered ID codes and newly registered ID code exceed four, the oldest one is erased. Action

Step 1

Go to Step 2

—

Go to Step 3

Go to Step 1

Go to Step 4

Go to Step 1

Go to Step 5

Go to Step 1

Go to Step 6

Go to Step 1

Go to Step 7

Go to Step 1

Go to Step 8

Go to Step 1

Go to Step 9

Go to Step 1

1. Make sure that the all the doors are closed and unlocked. 2. Open the driver’s side door. 3. Insert the starter key into the starter switch. Is the action complete?

Yes

Turn the starter switch to ACC position and return it to OFF position quickly three times. NOTE: This step must be carried out within five seconds after step 1 is finished. Is the action complete?

Close and open the driver’s side door quickly two times. NOTE: This step must be carried out within ten seconds after step 2 is finished. Is the action complete?

1. Turn the starter switch to ACC position and return it to OFF position quickly three times. 2. Close and open the driver’s side door quickly one time. NOTE: This step must be carried out within ten seconds after step 3 is finished. Is the action complete?

The control unit locks and unlocks the doors two times. Does the control unit work normally?

Operate the lock or unlock button of the transmitter. NOTE: This step must be carried out within twenty seconds after step 5 is finished. Is the action complete?

The control unit locks and unlocks the doors one time. Does the control unit work normally?

Operate the lock or unlock button of the transmitter. NOTE: This step must be carried out within twenty seconds after step 7 is finished. Is the action complete?

If registration succeeds, the control unit locks and unlocks the doors one time. If registration fails, the control unit locks and unlocks the doors three times.

8H–18 SECURITY AND LOCKS

ID Code Check This procedure checks how many ID codes are registered. Step 1

Action

Go to Step 2

—

Go to Step 3

Go to Step 1

Go to Step 4

Go to Step 1

Go to Step 5

Go to Step 1

1. Make sure that the all the doors are closed and unlocked. 2. Open the driver’s side door. 3. Insert the starter key into the starter switch. Is the action complete?

Yes

Turn the starter switch to ACC position and return it to OFF position quickly three times. NOTE: This step must be carried out within five seconds after step 1 is finished. Is the action complete?

Close and open the drive’s side door quickly two times. NOTE: This step must be carried out within ten seconds after step 2 is finished. Is the action complete?

1. Turn the starter switch to ACC position and return it to OFF position quickly one time. 2. Close and open the drive’s side door quickly one time. NOTE: This step must be carried out within ten seconds after step 3 is finished. Is the action complete?

The control unit locks and unlocks the doors twice as many registered ID codes.

SECURITY AND LOCKS

8H–19

Main Data and Specifications Torque Specifications

635R200011

SECTION SUN ROOF/CONVERTIBLE TOP

8I–1

AXIOM

BODY AND ACCESSORIES SUNROOF/CONVERTIBLE TOP CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Sunroof Glass . . . . . . . . . . . . . . . . . . . . . . . . . . Sunroof Glass and Associated Parts . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sunroof Deflector . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sunshade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembled View . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sunroof Frame Complete Assembly . . . . . . .

8I–1 8I–2 8I–2 8I–2 8I–3 8I–3 8I–3 8I–3 8I–4 8I–4 8I–4 8I–5 8I–6

Sunroof Frame Complete Assembly and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sunroof Switch . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sunroof Control Unit . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sunroof Motor . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

8I–6 8I–6 8I–7 8I–7 8I–7 8I–7 8I–8 8I–8 8I–8 8I–8 8I–8 8I–8 8I–9

8I–2

SUN ROOF/CONVERTIBLE TOP

Sunroof Glass Sunroof Glass and Associated Parts

665R200003

Legend (1) Sunroof Weatherstrip (2) Sunroof Glass

Removal 1. Tilt the sunroof and open the sunshade. 2. Disconnect the battery ground cable. 3. Pull out the front of sight shield (2). 4. Remove four sunroof glass fixing Torx screws (3) to remove the sunroof glass (1).

665R200004

SUN ROOF/CONVERTIBLE TOP

Installation 1. Be sure to install the sunroof weatherstrip so that the joint of the weatherstrip is on the rear side of the vehicle. 2. Temporary install the glass to the sunroof frame. 3. Open and shut the sunroof four to five times to position correctly the sunroof weatherstrip and the glass in the longitudinal and latitudinal setting positions.

8I–3

4. Adjust the setting position to flush the surface between the roof panel and weatherstrip of sunroof glass. 5. Tighten the sunroof glass fixing screws to the specified torque. Torque: 4 N·m (35 lb in) 6. Inspect the sunroof alignment after installing the sunroof glass. Use the fixing screws to adjust the sunroof if not aligned.

Sunroof Deflector Removal

Installation

1. Open the sunroof. B Let a 5 mm (0.20 in) drill go through two blind rivets (2) to disengage riveted portions. 2. Remove the sunroof deflector (1).

665R200001

To install, follow the removal steps in the reverse order.

8I–4

SUN ROOF/CONVERTIBLE TOP

Sunshade Disassembled View

665RW012

Legend (1) Sunroof Glass (2) Sight Shield

(3) Sunshade Stopper (4) Sunshade

Removal 1. Tilt the sunroof. 2. Disconnect the battery ground cable. 3. Remove the sunroof glass. B Refer to Sunroof Glass in this section. 4. Pull the sight shield upward using screwdriver.

665RW006

SUN ROOF/CONVERTIBLE TOP 5. Remove 2 sunshade stopper fixing screws and remove sunshade stopper (1).

665RW007

6. Pull out the sunshade (4) up to the guide rail edge. Lift the front of sunshade and clear the projection (3) of sunshade through the notch (2) of guide rail edge, then draw the sunshade out of the roof.

665RW009

Installation To install, follow the removal steps in the reverse order.

8I–5

8I–6

SUN ROOF/CONVERTIBLE TOP

Sunroof Frame Complete Assembly Sunroof Frame Complete Assembly and Associated Parts

665R200005

Legend (1) Sunroof Drain Hose

Removal 1. Disconnect the battery ground cable. 2. Remove the headlining. B Refer to Headlining in Exterior/Interior Trim section.

(2) Sunroof Frame Complete Assembly (3) Headlining

SUN ROOF/CONVERTIBLE TOP 3. Disconnect the sunroof drain hose at the sunroof frame side as shown in the figure.

8I–7

4. Disconnect the sunroof harness connection. 5. Remove two sunroof frame assembly fixing nuts (front side) and six fixing bolts from the frame complete assembly, and then remove the sunroof frame complete assembly. NOTE: Be sure to remove the frame assembly while supporting it.

Installation 1. Install the sunroof frame assembly. 2. After installing the frame assembly, loosen the sunroof glass fixing nuts and adjust the sunroof glass setting position. B Refer to Sunroof Glass in this section. 3. Install the sunroof drain hose. 4. Install the headlining. B Refer to Headlining in Exterior/Interior Trim section. 665RW010

Sunroof Switch Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the sunroof switch (1). B Remove the switch by pushing the spring with the tip of a screwdriver. B Disconnect the switch connector.

825R200021

To install, follow the removal steps in the reverse order.

8I–8

SUN ROOF/CONVERTIBLE TOP

Sunroof Control Unit Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the headlining. B Refer to Headlining in Exterior/Interior Trim section. 3. Remove the sunroof control unit (1). B Disconnect two connectors.

To install, follow the removal steps in the reverse order.

B Remove two screws.

665RW013

Sunroof Motor Removal 1. Disconnect the battery ground cable. 2. Remove the headlining. B Refer to Headlining in Exterior/Interior Trim section. 3. Remove the sunroof motor (1). B Disconnect the connector. B Remove three nuts and two screws.

665RW014

Installation To install, follow the removal steps in the reverse order.

8I–9

SUN ROOF/CONVERTIBLE TOP

Main Data and Specifications Torque Specification Application

N·m

lb ft

lb in

Sunroof Glass Fixing Screws

—

Sunroof Frame Fixing Bolts and Nuts

—

SECTION EXTERIOR/INTERIOR TRIM

8J–1

AXIOM

BODY AND ACCESSORIES EXTERIOR / INTERIOR TRIM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Consoles and Associated Parts . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Door Trim Panel . . . . . . . . . . . . . . . . . . . Front Door Trim Panel and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Door Trim Panel . . . . . . . . . . . . . . . . . . . . Rear Door Trim Panel and Associated Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Door Mirror Assembly . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interior Mirror Assembly . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interior Trim Panels . . . . . . . . . . . . . . . . . . . . . . Interior Trim Panels and Associated Parts Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Console . . . . . . . . . . . . . . . . . . . . . .

8J–2 8J–3 8J–3 8J–3 8J–4 8J–4 8J–4 8J–5 8J–5 8J–6 8J–6 8J–7 8J–7 8J–8 8J–8 8J–8 8J–8 8J–8 8J–8 8J–9 8J–9 8J–9 8J–11 8J–12 8J–12 8J–12 8J–13 8J–14

Parts Location (W/O Sunroof) . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location (W/ Sunroof) . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Arch Cover . . . . . . . . . . . . . . . . . . . . . . . Wheel Arch Cover and Associated Parts . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Locker Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . Locker Cover and Associated Parts . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filler Door . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Roof Moulding . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Location . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Door Mirror System . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Door Mirror Switch . . . . . . . . . . . . . . . . . . . . . Power Window System . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Power Window Switch Driver Seat Side . . Power Window Motor . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

8J–14 8J–14 8J–14 8J–15 8J–15 8J–15 8J–16 8J–16 8J–16 8J–16 8J–17 8J–17 8J–17 8J–17 8J–18 8J–18 8J–18 8J–18 8J–19 8J–19 8J–19 8J–19 8J–20 8J–20 8J–20 8J–21 8J–21 8J–21 8J–22 8J–23

8J–2

EXTERIOR/INTERIOR TRIM

8J–3

Consoles Consoles and Associated Parts

745R200005

Legend (1) Cluster Upper Cover (2) Center Cluster (3) Knee Pad (4) Seat Heater Switch (Required Option) (5) Rear Console Assembly

Removal 1. Disconnect the battery ground cable. 2. Remove the cluster upper cover and connectors. 3. Pry the knee pads. 4. Remove the center cluster. B Remove the six screws and pull out the center cluster at the six clip positions.

(6) (7) (8) (9) (10)

CD Changer Rear Console Bracket Front Console Bracket Front Console Assembly Accessory Socket

B Disconnect the connectors. 5. Remove the rear console assembly. B Open the rear console lid and remove two screws. 6. Remove the front console assembly. B Remove six fixing screws and disconnect the accessory socket connectors. B Disconnect the seat heater switch connectors (if so equipped).

8J–4

EXTERIOR/INTERIOR TRIM

7. Remove the CD changer. B Remove the four fixing bolts and the connector.

Installation To install, follow the removal steps in the reverse order.

Front Door Trim Panel Front Door Trim Panel and Associated Parts

635R200012

(12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Inside Handle Pull Box Courtesy Light Pull Box Bracket Waterproof Sheet Front Door Panel Door Lock Assembly Door Lock Cylinder Outside Handle Power Window Regulator Outer Waist Seal

EXTERIOR/INTERIOR TRIM

8J–5

4. Remove the inside handle. B Open the screw cover (1) and remove the screw.

Removal 1. Disconnect the battery ground cable. 2. Remove the pull box. B Remove the one fixing screw.

B Disconnect the cable.

635R200003

635R200004

3. Remove the power window switch (1). B Pry the power window switch out and disconnect the switch connector.

5. Remove the door mirror cover. 6. Remove the door trim panel. B Remove the trim panel with the eight clips (1) from the door panel.

635R200005 635R200002

B Disconnect the connectors.

tweeter

and

courtesy

light

7. Remove the inner waist seal. 8. Remove the courtesy light. 9. Remove the tweeter.

Installation To install, follow the removal steps in the reverse order.

8J–6

EXTERIOR/INTERIOR TRIM

Rear Door Trim Panel Rear Door Trim Panel and Associated Parts

655R200009

Legend (1) Glass Run (2) Glass (3) Division Bar (4) Fix Window Glass (5) Power Window Regulator (6) Outside Handle (7) Door Lock Assembly (8) Pull Box Bracket (9) Speaker Spacer (10) Speaker

(11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)

Pull Box Door Trim Panel Courtesy Light Power Window Switch Inside Handle Inside Lock Bracket Inner Waist Seal Tweeter Waterproof Sheet Outer Waist Seal Rear Door Panel

EXTERIOR/INTERIOR TRIM

8J–7

4. Remove the inside handle. B Open the screw cover and remove the screw.

Removal 1. Disconnect the battery ground cable. 2. Remove the pull box. B Remove the fixing screw.

B Disconnect the cable.

655R200008

655R200003

3. Remove the power window switch. B Pry the power window switch (1) and remove the connector.

5. Remove the door trim panel. B Remove the trim panel with the seven clips from the door panel.

655R200005

655R200004

B Disconnect the tweeter and the courtesy light connectors. 6. Remove the inner waist seal. 7. Remove the tweeter. 8. Remove the courtesy light.

Installation To install, follow the removal steps in the reverse order.

8J–8

EXTERIOR/INTERIOR TRIM

Door Mirror Assembly Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the door mirror cover (3). 3. Remove the door mirror assembly (1). B Remove the three nuts and disconnect the connector (2).

To install, follow the removal steps in the reverse order.

635R200006

Interior Mirror Assembly Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the covers (1). 3. Remove the interior mirror assembly (4). B Pull the interior mirror up with the stay and remove the interior mirror from the base (3). B Disconnect the connector (2).

720R200004

To install, follow the removal steps in the reverse order.

EXTERIOR/INTERIOR TRIM

8J–9

Interior Trim Panels Interior Trim Panels and Associated Parts

643R200003

Legend (1) Assist Grip (Front & Rear) (2) Door Finisher (Front & Rear) (3) Upper Quarter Pillar Trim Cover (4) Upper Rear Pillar Trim Cover (5) Rear Roof Trim Cover (6) Tailgate Weather Strip (7) Multi Hook

Removal 1. Disconnect the battery ground cable. 2. Remove the sill plates (Front & Rear). 3. Remove the dash side trim cover. 4. Remove the lower center pillar trim cover. B Remove the lower anchor bolt cover and lower anchor bolt from the front seat belt. B Pry the trim cover with the clips from the body panel. 5. Remove the door finishers (Front & Rear).

(8) (9) (10) (11) (12) (13) (14)

Rear End Floor Trim Cover Lower Quarter Trim Cover Sill Plate (Front & Rear) Lower Center Pillar Trim Cover Upper Center Pillar Trim Cover Dash Side Trim Cover Front Pillar Trim Cover

8J–10

EXTERIOR/INTERIOR TRIM

6. Remove the upper center pillar trim cover. B Remove the cover (1) and screw. B Remove the shoulder anchor cap (2) and upper anchor bolt (3) from the front seat belt.

12. Remove the multi hooks. B While raising the notch of the hook with the screwdriver, pull out the hook by turning 180°.

B Pry the trim cover with the clip from the body panel.

643R200004

760R200006

7. Remove the front pillar trim cover. B Ply the trim cover with the clips from the body panel. 8. Remove the tailgate weather strip. 9. Remove the rear end floor trim cover. B Remove the four screw cover and nine fixing screws. 10. Remove the rear roof trim cover. B Pry the trim cover with the clips from the body panel. 11. Remove the tonneau cover assembly (1).

13. Remove the lower quarter trim cover (1). B Remove the lower anchor bolt cover (4) and the lower anchor bolt (3) from the rear seat belt. B Pull the trim cover at the five clip positions (2). B Disconnect the accessory socket connectors (LH side).

643R200006

14. Remove the upper quarter pillar trim cover (1). B Remove the cover and screw, pull the trim cover at the two clip positions (2). B Remove the shoulder anchor cap (4) and upper anchor bolt (3) from the rear seat belt. 643R200001

EXTERIOR/INTERIOR TRIM 15. Remove the upper rear pillar trim cover (5). B Pull the trim cover at the six clip positions (6) from the body panel.

Installation To install, follow the removal steps in the reverse order, noting the following point: 1. Tighten the seat belt anchor bolt to the specified torque. Torque: 39 N·m (29 lb ft)

643R200007

16. Remove the assist grip (1) (Front & Rear). B Pull the assist grip downword. B Remove the caps and fixing bolts.

743R200001

8J–11

8J–12

EXTERIOR/INTERIOR TRIM

Headlining Parts Location

666R200001

Legend (1) Interior Trim Panels (2) Headlining (Without Sunroof) (3) Clip (4) Luggage Room Light (5) Assist Grip (6) Headlinng (With Sun Roof)

Removal 1. Disconnect the battery ground cable. 2. Remove the interior trim panels. B Refer to Interior Trim Panels in this section. 3. Remove the dome light. B Remove the dome light lens and the fixing screws.

(7) Sunroof Finisher (With Sunroof) (8) Overhead Console/Sunroof Switch (With Sunroof) (9) Dome Light (10) Overhead Console (Without Sunroof) (11) Sunvisors (12) Sunvisor Holder

B Disconnect the dome light connectors.

EXTERIOR/INTERIOR TRIM 4. Remove the luggage room light. B Remove the luggage room light lens (1) and the fixing screw. B Disconnect the luggage room light connector.

8J–13

Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Install the headlining so that the fixing clips will not come off. 2. To install the sunroof finisher (1), first fit it in at one place with the headlining (3) close to the sunroof frame (2), then install the entire finisher tightly by hitting it with a plastic hammer, not allowing it to move up.

825R200030

5. Remove the overhead console/sunroof switch (With sunroof). B Refer to Overhead Console in this section. 6. Remove the overhead console (without sunroof). 7. Remove the sunvisors. B Remove the fixing screws and pull out the sunvisor holder (1) to remove it. B Disconnect the vanity mirror illumination connector.

743R200003

8. Remove the sunroof finisher (With sunroof). 9. Remove the headlining. B Remove the four headlining fixing clips.

665RW003

8J–14

EXTERIOR/INTERIOR TRIM

Overhead Console Parts Location (W/O Sunroof)

743R200005

Legend (1) Overhead Console Bracket (2) Harness Connector (3) Head Lining

Removal 1. Disconnect the battery ground cable. 2. Remove the overhead console assembly. B Open the lid and remove the two screws. B Disconnect the harness connector. 3. Remove the sunvisor and sunvisor holder. (right and left) 4. Remove the front assist grip. (right and left) 5. Remove the front piller trim cover.

(4) (5) (6) (7)

Room Mirror Overhead Console Assembly Front Door Finisher Front Assist Grip

6. Remove the front door finisher. B Remove the upper side of door finisher. 7. Remove the interior mirror. B Refer to Interior Mirror in this section. 8. Remove the overhead console bracket. B Remove the two screws.

Installation To install, follow the removal steps in the reverse order.

EXTERIOR/INTERIOR TRIM

8J–15

Parts Location (W/ Sunroof)

743R200004

Legend (1) Sunroof Weatherstrip (2) Overhead Console Bracket

Removal 1. Disconnect the battery ground cable. 2. Remove the overhead console. B Open the lid and remove the two screws. B Pull the over head console at the two clip positions. B Disconnect the harness connectors. 3. Remove the head lining. B Refer to Head Lining in this section. 4. Remove the overhead console bracket. B Remove the five fixing screws.

(3) Head Lining (4) Overhead Console (5) Clip Position

Installation To install, follow the removal steps in the reverse order.

8J–16

EXTERIOR/INTERIOR TRIM

Wheel Arch Cover Wheel Arch Cover and Associated Parts

620R200002

Legend (1) Wheel Arch Seal Assembly (2) Rear Door Outer Panel (3) Rear Door Inner Panel (4) Clip

Removal 1. Remove the rear door wheel arch seal. B After disengage four six, peel off the double sided adhesive tape. 2. Remove the wheel arch cover. B Remove the three fixing screws.

(5) (6) (7) (8)

Body Side Outer Panel Wheel Arch Cover Screw Cover Adhesive Tape

Installation To install, follow the removal steps in the reverse order, noting following point. 1. Use a new double sided adhesive tape whenever installing the rear door wheel arch seal. Use rubbing alcohol to clean the area where the double sided adhesive is to be attached.

EXTERIOR/INTERIOR TRIM

8J–17

Locker Cover Locker Cover and Associated Parts

620R200001

Legend (1) Clip Position (2) Lock Cover Assembly

Removal 1. Remove the 8 clips. 2. Remove the two screws. 3. Remove the 8 clip positions. 4. Remove the locker cover assembly.

(3) Clip (4) Screw

Installation To install, follow the removal steps in the reverse order.

8J–18

EXTERIOR/INTERIOR TRIM

Fuel Filler Door Parts Location

Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Install the fuel filler door to match the basic hole. 2. Adjust the clearance between outer quarter panel (1) and fuel filler door (2).

686RX003

686R200002

Legend (1) Fuel Filler Door Fixing Screw (2) Basic Hole (3) Fuel Filler Door Buffer (4) Fuel Filler Door (5) Fuel Filler Door Hinge Buffer

Removal 1. Open the fuel filler door. 2. Remove the fuel filler door. B Remove the two fixing screws. 3. Pull out the fuel filler door buffer. 4. Pull out the fuel filler hinge buffer.

EXTERIOR/INTERIOR TRIM

8J–19

Roof Moulding Parts Location

660R200003

Legend (1) Roof Moulding Assembly (2) Clips

Removal 1. Remove the roof moulding. B Pry the roof moulding covers with the nine clip positions from the roof panel.

(3) Roof Panel (4) Body Side Outer Panel

Installation To install, follow the removal steps in the reverse order.

8J–20

EXTERIOR/INTERIOR TRIM

Power Door Mirror System General Description

Door Mirror Switch

The system consists of the starter switch, door mirror switch, rear defogger/mirror defogger switch and door mirrors on both sides. When the door mirror switch is operated with the starter switch at either “ACC” or “ON” position, the motor in the door mirror (on either side) rotates to allow the horizontal and vertical adjustment of mirror angles. When the rear defogger/mirror defogger switch is turned “ON” with the starter switch “ON”, the heater of the left and right mirrors and the tailgate glass are activated.

Removal 1. Disconnect the battery ground cable. 2. Remove the instrument panel lower cover (2). Refer to the Instrument Panel Assembly in Body Structure section. 3. Remove the door mirror switch (1).

825RW094

Rear Defogger/Mirror Defogger Switch Refer to the Rear Defogger/Mirror switch removal and installation steps in Lighting System section.

Door Mirrors Refer to Door Mirror Assembly in this section.

EXTERIOR/INTERIOR TRIM

8J–21

Power Window System General Description The power window system consists of power window switches and power window motors on driver and passenger sides and power window relay. With the starter switch in “ON” position, the battery voltage is supplied through power window relay to the power window switches on driver and passenger sides. Selection of up or down switch changes the motor rotating direction to open or close the window. When the power window “LOCK” switch on the driver side is pressed, the power source for the other switches are disconnected causing the power window operation to seize.

Power Window Switch Driver Seat Side Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). B Pull out the switch by pushing the spring with the tip of a screwdriver. B Disconnect the connector.

825R200025

Installation To install, follow the removal steps in the reverse order.

Rear-Left and Right Sides Removal 1. Disconnect the battery ground cable. 2. Remove the rear power window switch (1). B Pull out the switch by pushing the spring with the tip of a screwdriver. B Disconnect the connector.

635R200002

Installation To install, follow the removal steps in the reverse order.

Front Passenger Seat Side Removal 1. Disconnect the battery ground cable. 2. Remove the switch (1). B Pull out the switch by pushing the spring (2) with the tip of a screwdriver. B Disconnect the connector.

655R200004

Installation To install, follow the removal steps in the reverse order.

8J–22

EXTERIOR/INTERIOR TRIM

Power Window Motor

Rear-Right Side

Driver Seat Side

Removal

Removal 1. Disconnect the battery ground cable. 2. Remove the window regulator assembly (2). B Refer to the Window Regulator and Glass removal steps in Body Structure section. 3. Remove the power window motor (1). B Remove three screws.

1. Disconnect the battery ground cable. 2. Remove the rear window regulator assembly (2). B Refer to the Rear Window Regulator and Glass removal steps in Body Structure section. 3. Remove the power window motor (1). B Remove three screws.

655R200006

635R200007

Installation To install, follow the removal steps in the reverse order.

Front Passenger Seat Side Removal and Installation Refer to the Front Window Motor — Driver Seat side removal and installation steps in this section.

Installation To install, follow the removal steps in the reverse order.

Rear-Left Side Removal and Installation Refer to the Rear Power Window Motor — Right Side removal and installation steps in this section.

EXTERIOR/INTERIOR TRIM

8J–23

Main Data and Specifications Torque Specifications Application Front & Rear Seat Belt Anchor Bolts

N·m

lb ft

lb in

—

SECTION SEAT BELT SYSTEM

9A–1

AXIOM

RESTRAINTS SEAT BELT SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Front Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . Front Seat Belt and Associated Parts . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Seat Belt and Associated Parts . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Seat Buckle Assembly . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Center Seat Belt / Buckle Assembly . . .

9A–1 9A–2 9A–2 9A–2 9A–3 9A–4 9A–5 9A–5 9A–5 9A–6 9A–6 9A–7 9A–7 9A–7 9A–8

Rear Center Seat Belt / Buckle Assembly and Associated Parts . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Child Seat Tether Anchorage Bracket (Child Restraint) . . . . . . . . . . . . . . . . . . . . . . . . Child Seat Tether Anchorage Bracket and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Child Seat Lower Anchorage Striker . . . . . . . Child Seat Lower Anchorage Striker and Associated Parts . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Data and Specifications . . . . . . . . . . . . .

9A–8 9A–8 9A–8 9A–9 9A–9 9A–9 9A–9 9A–10 9A–10 9A–10 9A–11 9A–12

9A–2

SEAT BELT SYSTEM

Front Seat Belt Front Seat Belt and Associated Parts

760R200015

Legend (1) Door Seal Finisher (Front & Rear) (2) Adjustable Shoulder Anchor Assembly (3) Upper Center Pillar Trim Cover (4) Seat Belt Upper Anchor Bolt (5) Shoulder Anchor Cap (6) Front Seat Belt Assembly

Removal 1. Disconnect the battery ground cable. 2. Remove the sill plate (Front & Rear). 3. Remove the anchor cover and seat belt lower anchor bolt. 4. Remove the lower center pillar trim cover. 5. Remove the door seal finisher (Front & Rear). 6. Remove the seat belt upper anchor bolt (3). B Remove the shoulder anchor cap (2).

(7) (8) (9) (10) (11) (12) (13)

Anchor Cover Seat Belt Lower Anchor Bolt Lower Center Pillar Trim Cover Retractor Webbing Guide Rear Sill Plate Front Sill Plate

SEAT BELT SYSTEM

9A–3

7. Remove the upper center pillar trim cover. B Remove screw cover (1) and screw. B Pry the trim cover with the clip from the body panel.

760R200006

8. Remove the retractor fixing bolt and screw. 9. Remove the seat belt assembly. B Pull out the webbing guide. 10. Remove the adjustable shoulder anchor assembly. B Remove the two fixing bolts. 760R200019

Inspection If any of the following abnormalities is found, replace on an assembly basis. B Deformed and malfunctioning adjustable shoulder anchor (1). B Uneven movement of upper/lower anchors (2) in the circumferential direction. B Damaged and/or deformed through ring (3). B Damaged and/or deformed tongue (4). B Damaged and/or frayed webbing (5). B Deformed retractor bracket (6). B Seat belt does not retract (7). B Resistance or abnormal sound when seat belt is pulled out or retracted (7). B Retractor (7) abnormality.

Inspection of retractor 1. ELR (Emergency Locking Retractor) lock inclining angle check. B The seat belt should not lock when pulled gently at a 15 degree angle. Also, the seat belt should lock when pulled at a 45 degree angle or higher. 2. ELR lock check. B The seat belt should not lock when pulled slowly, however, the seat belt should lock when pulled quickly. 3. ALR (Automatic Locking Retractor)/ELR check (Except for driver’s seat). B Make sure the seat belt is locked when pulled out fully. B Make sure the seat belt can be pulled out and retracts after when rewound fully. CAUTION: Do not disassemble the retractor.

9A–4

SEAT BELT SYSTEM

Installation To install, follow the removal steps in the reverse order, noting the following points. CAUTION: When replacing the front seat belt, always replace the seat belt with the same parts/part number. 1. Tighten the adjustable shoulder anchor assembly fixing bolts to the specified torque. Torque: 39 N·m (29 lb ft) 2. Tighten the seat belt anchor bolts (Upper & Lower) and the retractor fixing bolts to the specified torque. Torque: 39 N·m (29 lb ft)

SEAT BELT SYSTEM

9A–5

Rear Seat Belt Rear Seat Belt and Associated Parts

760R200017

Legend (1) Adjustable Shoulder Anchor Assembly (2) Upper Quarter Pillar Trim Cover (3) Seat Belt Upper Anchor Bolt (4) Shoulder Anchor Cap (5) Rear Seat Belt Assembly (6) Tailgate Weather Strip

Removal 1. Disconnect the battery ground cable. 2. Remove the tailgate weather strip. 3. Remove the rear end floor trim cover. 4. Remove the rear sill plate. 5. Remove the anchor cover and the lower anchor bolt. 6. Remove the lower quarter trim cover. B Refer to Interior Trim Panel in Exterior/Interior Trim section. 7. Remove the seat belt upper anchor bolt (3). B Remove the shoulder anchor cap (4).

(7) (8) (9) (10) (11) (12) (13)

Rear End Floor Trim Cover Lower Quarter Trim Cover Anchor Cover Seat Belt Lower Anchor Bolt Rear Sill Plate Retractor Rear Door Seal Finisher

9A–6

SEAT BELT SYSTEM

8. Remove the upper quarter pillar trim cover (1). B Remove the screw cover and screw. B Pry the trim cover with the clip positions (2) from the body panel.

760R200011

9. Remove the retractor. B Remove the screw and bolt. 10. Remove the rear seat belt assembly. 11. Remove the adjustable shoulder anchor assembly. B Remove the two fixing bolts.

760R200019

Inspection of retractor

1. ELR (Emergency Locking Retractor) lock inclining angle check. B The seat belt should not lock when pulled gently at a 15 degree angle. Also, the seat belt should lock when pulled at a 45 degree angle or higher. 2. ELR lock check. B The seat belt should not lock when pulled slowly, however, the seat belt should lock when pulled quickly. 3. ALR (Automatic Locking Retractor)/ELR check (Except for driver’s seat). B Make sure the seat belt is locked when pulled out fully. B Make sure the seat belt can be pulled out and retracts after when rewound fully. CAUTION: Do not disassemble the retractor.

Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the adjustable shoulder anchor assembly fixing bolts to the specified torque. Torque: 39 N·m (29 lb ft) 2. Tighten the seat belt anchor bolts (Upper & Lower) and the retractor fixing bolts to the specified torque. Torque: 39 N·m (29 lb ft)

SEAT BELT SYSTEM

9A–7

Front Seat Buckle Assembly Removal

Installation

1. Disconnect the battery ground cable. 2. Disconnect the seat belt warning connector (driver’s side) and remove a clip. 3. Remove the front seat buckle assembly (1).

760R200009

To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the buckle anchor bolt to the specified torque. Torque: 29 N·m (22 lb ft)

9A–8

SEAT BELT SYSTEM

Rear Center Seat Belt / Buckle Assembly Rear Center Seat Belt / Buckle Assembly and Associated Parts

755R200006

Legend (1) Rear Seat Lock Assembly

Removal 1. Remove the rear cushion frame assembly. B Refer to Rear Seat Assembly in Seats section. 2. Remove the rear seat lock assembly and rear seat belt buckle assembly.

(2) Rear Seat Belt Buckle Assembly (3) Rear Cushion Frame Assembly

Installation To install, follow the removal steps in the reverse order, noting the following point. 1. Tighten the rear seat lock assembly and rear seat belt buckle assembly fixing bolts to the specified torque. Torque: 39 N·m (29 lb ft) NOTE: Removal and installation procedure of rear center seat belt assembly same as rear seat belt buckle assembly procedures.

SEAT BELT SYSTEM

9A–9

Child Seat Tether Anchorage Bracket (Child Restraint) Child Seat Tether Anchorage Bracket and Associated Parts

760R200010

Legend (1) Rear Seat (2) Luggage Floor Carpet (3) Tether Anchorage Bracket Cover

Removal 1. Open the tether anchorage bracket cover. 2. Remove the fixing bolt and child seat tether anchorage bracket.

(4) Child Seat Tether Anchorage Bracket (5) Luggage Floor Panel (6) Insulation

Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Install the bracket such that its tether belt hook hole is facing toward the front of the vehicle. 2. Tighten the fixing bolts to the specified torque. Torque: 19 N·m (14 lb ft)

9A–10

SEAT BELT SYSTEM

Child Seat Lower Anchorage Striker Child Seat Lower Anchorage Striker and Associated Parts

755R200007

Legend (1) Rear Seat Back Assembly (2) Release Knob (3) Headrest (4) Front Luggage Floor Carpet

(5) (6) (7) (8) (9)

Seat Lock Cover Lower Anchorage Striker (LH) Lower Anchorage Striker (RH) Body Floor Panel Rear Seat Cushion Assembly

Removal 1. Raise the seat cushion assembly (2). B Pull the strap (1) of the rear seat lock assembly to release the seat lock.

755R100006

SEAT BELT SYSTEM 2. Remove the headrests. 3. Pull the release knobs and fall down the seat back assembly forward. 4. Remove the seat lock covers. B Remove the three fixing screws from each seat lock cover. 5. Remove the front luggage floor carpets. B Pull the nine carpet fixing clips from the backside of the seat back assembly. 6. Remove the four lower anchorage strikers. B Remove the two fixing bolts of each lower anchorage striker.

Installation To install, follow the removal steps in the reverse order, noting the following points. 1. Install the lower anchorage strikers with matching the inside of the tab and the trim edge of the body floor panel.

755R100008

2. Tighten the lower anchorage striker fixing bolts to the specified torque. Torque: 25 N·m (18 lb ft)

9A–11

9A–12

SEAT BELT SYSTEM

Main Data and Specifications Torque Specifications

760R200018

SEAT BELT SYSTEM

9A–13

760R200012

SECTION SUPPLEMENTAL RESTRAINT SYSTEM

9J–1

AXIOM

RESTRAINTS SUPPLEMENTAL RESTRAINT SYSTEM (SRS) CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Restraint Devices . . . . . . . . . . . . . . . . . . . . . . System Description . . . . . . . . . . . . . . . . . . . . SRS Component and Wiring Location View Component Description . . . . . . . . . . . . . . . . . . SDM (Sensing and Diagnostic Module) . . . “Air Bag” Warning Lamp . . . . . . . . . . . . . . . . SRS Coil Assembly . . . . . . . . . . . . . . . . . . . . Air Bag Assemblies . . . . . . . . . . . . . . . . . . . . Steering Column . . . . . . . . . . . . . . . . . . . . . . Knee Bolster . . . . . . . . . . . . . . . . . . . . . . . . . . Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnostic Trouble Codes . . . . . . . . . . . . . . Scan Tool Diagnostics . . . . . . . . . . . . . . . . . . Use of Special Tools . . . . . . . . . . . . . . . . . . . SRS Connector Body Face Views . . . . . . . . . Repairs and Inspections Required After an Accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accident With Deployment – Component Replacement and Inspections . . . . . . . . . . Accident With or Without Deployment—Component Inspection . . . . SDM Replacement Guidelines . . . . . . . . . . Wiring Damage . . . . . . . . . . . . . . . . . . . . . . . SRS Connector (Plastic Body And Terminal Metal Pin) Damage . . . . . . . . . . . SRS Wire Pigtail Damage . . . . . . . . . . . . . . On–Vehicle Service . . . . . . . . . . . . . . . . . . . . . . Service Precautions . . . . . . . . . . . . . . . . . . . Disabling The SRS . . . . . . . . . . . . . . . . . . . . Enabling The SRS . . . . . . . . . . . . . . . . . . . . . Handling / Installation / Diagnosis . . . . . . . . Air Bag Assembly Handling / Shipping / Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . Live (Undeployed) Air Bag Assembly . . . . . Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag Assemblies . . . Deployed Air Bag Assembly . . . . . . . . . . . . Air Bag Assembly Scrapping Procedure . . Deployment Outside Vehicle (Driver Air Bag Assembly) . . . . . . . . . . . . . . Deployment Outside Vehicle (Passenger Air Bag Assembly) . . . . . . . . .

9J–2 9J–2 9J–2 9J–3 9J–4 9J–4 9J–4 9J–5 9J–5 9J–5 9J–6 9J–6 9J–6 9J–7 9J–7 9J–7 9J–8 9J–8 9J–8 9J–9 9J–9 9J–9 9J–9 9J–9 9J–9 9J–9 9J–9 9J–9 9J–9 9J–10 9J–10 9J–10 9J–11 9J–11 9J–11 9J–11 9J–13

Deployment Inside Vehicle (Vehicle Scrapping Procedure) . . . . . . . . . . Deployed Air Bag Assembly Handling . . . . Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . J–41433 SRS Driver/Passenger Load Tool J–39200 DVM . . . . . . . . . . . . . . . . . . . . . . . . . Scan Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J–35616–A Connector Test Adapter Kit . . . J–42986 SRS Deployment Tool . . . . . . . . . J–42987 SRS Adapter For Load Tool . . . . . J–41497 SRS Deployment Fixture . . . . . . . Tech 2 Scan Tool . . . . . . . . . . . . . . . . . . . . . . DTC Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . Plottong Snapshot Graph . . . . . . . . . . . . . . . . . Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information) . . . . . . Flow Chart for Snapshot Replay (Plotting Graph) . . . . . . . . . . . . . . . . . . . . . . . Service Precaution . . . . . . . . . . . . . . . . . . . . . . Disabling The SRS . . . . . . . . . . . . . . . . . . . . Enabling The SRS . . . . . . . . . . . . . . . . . . . . . Handling / Installation / Diagnosis . . . . . . . . Inspections Required After An Accident . . Sensing and Diagnostic Module (SDM) . . . . Service Precautions . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driver Air Bag Assembly . . . . . . . . . . . . . . . . . Service Precautions . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . Service Precautions . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . SRS Coil Assembly . . . . . . . . . . . . . . . . . . . . . . Service Precaution . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Column . . . . . . . . . . . . . . . . . . . . . . . . Service Precaution . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Passenger Air Bag Assembly . . . . . . . . . . . . . Service Precaution . . . . . . . . . . . . . . . . . . . .

9J–15 9J–18 9J–18 9J–18 9J–19 9J–19 9J–19 9J–19 9J–20 9J–20 9J–21 9J–24 9J–24 9J–25 9J–26 9J–27 9J–27 9J–27 9J–27 9J–27 9J–28 9J–28 9J–28 9J–29 9J–29 9J–29 9J–29 9J–30 9J–30 9J–30 9J–30 9J–31 9J–32 9J–32 9J–32 9J–32 9J–34 9J–34 9J–34 9J–35 9J–36 9J–36

9J–2

SUPPLEMENTAL RESTRAINT SYSTEM

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9J–36

Service Precaution

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9J–36

Restraint Devices

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM (SRS). REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING. WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING, REFER TO THE SRS SERVICE INFORMATION. FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY, OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. CAUTION: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. ISUZU will call out those fasteners that require a replacement after removal. ISUZU will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (Paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.

General Description CAUTION: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.

827RS035

Legend (1) Deployed Air Bag (2) Knee Bolster (3) Seat Belt The Supplemental Restraint System (SRS) helps supplement the protection offered by the driver and front passenger seat belts by deploying an air bag from the center of the steering wheel and from the top of the right side of the instrument panel. The air bag deploys when the vehicle is involved in a frontal crash of sufficient force up to 30 degrees off the centerline of the vehicle. To further absorb the crash energy there is a knee bolster located beneath the instrument panel for both the driver and passenger, and the steering column is collapsible.

827RS036

SUPPLEMENTAL RESTRAINT SYSTEM

9J–3

System Description The SRS consists of the Sensing and Diagnostic Module (SDM), the driver air bag assembly, the SRS coil assembly, the passenger air bag assembly, and the “AIR BAG“ warning lamp in the instrument cluster. The SDM, SRS coil assembly (driver side only), driver air bag assembly, passenger air bag assembly and connector wire make up the deployment loops. The function of the deployment loops is to supply current through air bag assembly, which will cause deployment of the air bags in the event of a frontal crash of sufficient force, up to 30 degrees off the centerline of the vehicle. The air bag

assemblies are only supplied enough current to deploy when the SDM detects vehicle velocity changes severe enough to warrant deployment. The SDM contains a sensing device which converts vehicle velocity change to an electrical signal. The electrical signal generated is processed by the SDM and then compared to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the air bag assembly deploying the air bags.

D09R200001

9J–4

SUPPLEMENTAL RESTRAINT SYSTEM

SRS Component and Wiring Location View

060R200036

Legend (1) Battery (2) Relay & Fuse Box (3) Passenger Air Bag Assembly (4) SDM (5) Meter Assembly (6) SRS Coil Assembly (7) Driver Air Bag Assembly (8) Starter Switch (9) Fuse Box, SRS–1

ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. The Sensing and Diagnostic Module (SDM) is designed to perform the following functions in the SRS: 1. Energy Reserve — The SDM maintains 24–Volt Loop Reserve (24VLR) energy supply to provide deployment energy when ignition voltage is lost in a frontal crash. 2. Frontal Crash Detection — The SDM monitors vehicle velocity changes to detect frontal crashes which are severe enough to warrant deployment. 3. Air Bag Deployment — When a frontal crash of sufficient force is detected, the SDM will cause enough current to flow through the air bag assembly to deploy the air bag. 4. Malfunction Detection — The SDM performs diagnostic monitoring of SRS electrical components and sets a diagnostic trouble code when a malfunction is detected. 5. Frontal Crash Recording — The SDM records information regarding SRS status during frontal crash. 6. Malfunction Diagnosis — The SDM displays SRS diagnostic trouble codes and system status information through the use of a scan tool. 7. Driver Notification — The SDM warns the vehicle driver of SRS malfunctions by controlling the “Air Bag” warning lamp. The SDM is connected to the SRS wiring harness by a 24–pin connector. This harness connector uses a shorting clip across certain terminals in the contact area. This shorting clip connects the “AIR BAG” warning lamp to ground when the SDM harness connector is disconnected or CPA (Connector Position Assurance) is not inserted even if completely connected. This will cause the “AIR BAG” warning lamp to come “ON” steady whenever the ignition switch is at the ON or START positions with the SDM disconnected.

Component Description SDM (Sensing and Diagnostic Module) WARNING: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDLING A SENSING AND DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTED TOWARD THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY

827RW023

SUPPLEMENTAL RESTRAINT SYSTEM

9J–5

“Air Bag” Warning Lamp Ignition voltage is applied to the “AIR BAG” warning lamp when the ignition switch is at the ON or START positions. The SDM controls the lamp by providing ground with a lamp driver. The “AIR BAG” warning lamp is used in the SRS to do the following: 1. Verify lamp and SDM operation by flashing SEVEN (7) times when the ignition switch is first turned “ON”. 2. Warn the vehicle driver of SRS electrical system malfunctions which could potentially affect the operation of the SRS. These malfunctions could result in nondeployment in case of a frontal crash or deployment for conditions less severe than intended. The “AIR BAG” warning lamp is the key to driver notification of SRS malfunctions. For proper lamp operation, refer to the “SRS Diagnostic System Check” in this section. 825RS071

Air Bag Assemblies

060R200035

SRS Coil Assembly

The air bag assembly consist of an inflatable air bag assembly and an inflator (a canister of gas–generating material and an initiating device). When the vehicle is in a frontal crash of sufficient force. The SDM causes current flow through the deployment loops. Current passing through the inflator ignites the material in the air bag assembly. The gas produced from this reaction rapidly inflates the air bag assembly. There is a shorting clip on the driver air bag assembly connector which connects the SRS coil assembly. The shorting clip shorts across the driver air bag assembly circuits when driver air bag assembly connector is disconnected. The circuit to the driver air bag assembly is shorted in this way to help prevent unwanted deployment of the air bag when servicing the driver air bag assembly, the steering column or other SRS components.

The SRS coil assembly consists of two current carrying coils. This is attached to the steering column and allow rotation of the steering wheel while maintaining continuous contact of the driver deployment loop to the driver air bag assembly. There is a shorting clip on the yellow 2–pin connector near the base of steering column which connects the SRS coil to the SRS wiring harness. The shorting clip shorts to the SRS coil and driver air bag assembly when the yellow 2–pin connector is disconnected. The circuit to the driver air bag assembly is shorted in this way to help prevent unwanted deployment of the air bag when servicing the steering column or other SRS components.

827RX001

9J–6

SUPPLEMENTAL RESTRAINT SYSTEM

There is a shorting clip on the passenger air bag assembly connector which connects to the SRS harness. The shorting clip shorts across the passenger air bag assembly circuit when the passenger air bag assembly connector is disconnected. The circuit to the passenger air bag assembly is shorted in this way to help prevent unwanted deployment of the air bag when servicing the passenger air bag assembly, the instrument panel or other SRS components.

Knee Bolster The knee bolsters are used to absorb energy to protec knees and control the forward movement of the vehicle’s front seat occupants during a frontal crash, by limiting leg movement.

740RS021

Definition 827RY00001

Legend (1) Passenger Air Bag Door (2) Passenger Air Bag Assembly (3) Passenger Air Bag Harness (4) Cross Beam

Air Bag An inflatable cloth cushion designed to deploy in certain frontal crashes. It supplements the protection offered by the seat belts by distributing the impact load more evenly over the vehicle occupant’s head and torso. Asynchronous Performed in a nonperiodic fashion, (i. e., no defined time or interval).

Steering Column The steering column absorbs energy and is designed to compress in a frontal crash to decrease the chance of injury to the driver.

(B+) Battery voltage, (B+) The voltage available at the battery at the time of the indicated measurement. With the key “ON” and the engine not running, the system voltage will likely be between 12 and 12.5 volts. At idle the voltage may be 14 to 16 volts. The voltage could be as low as 10 volts during engine cranking. Bulb Check The SDM will cause the “AIR BAG” warning lamp to flash seven times and then go “OFF” whenever the ignition switch transitions to the ON position from any other ignition switch position and no malfunctions are detected. “CONTINUOUS MONITORING” Tests performed by the SDM on the SRS every 100 milliseconds while “Ignition 1” voltage is in the normal operating voltage range at the SDM. Data Link Connector (DLC) Formerly “DLC” a connector which allows communication with an external computer, such as a scan tool. Datum Line A base line parallel to the plane of the underbody or frame from which all vertical measurements originate.

431R200006

SUPPLEMENTAL RESTRAINT SYSTEM Deploy To inflate the air bag. Deployment Loops The circuits which supply current to the air bag assemblies to deploy the air bag. Diagnostic Trouble Code (DTC) Formerly “Code”, a numerical designator used by the SDM to indicate specific SRS malfunctions. Driver Current Source An output of the SDM which applies current into the driver air bag assembly circuit during the “Initiator Assembly Resistance Test”. Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag, an inflator and an initiator. EEPROM Electronically Erasable Programmable Read Only Memory. Memory which retains its contents when power is removed from the SDM. Ignition Cycle The voltage at the SDM “Ignition 1” inputs, with ignition switch “ON”, is within the normal operating voltage range for at least ten seconds before turning ignition switch “OFF”. Ignition 1 A battery voltage (B+) circuit which is only powered with the ignition switch in the ON, or START positions. Initiator The electrical component inside the air bag assembly which, when sufficient current flows, sets off the chemical reaction that inflates the air bag. “Initiator Assembly Resistance Test” Tests performed once each ignition cycle when no malfunctions are detected during “Turn–ON” or “Continuous Monitoring.” This test checks for the correct SDM configuration for the vehicle, shorts to “Ignition 1” in the deployment loops, high resistance or opens in the “Driver Side High”, “Driver Side Low”, “Passenger Side High” and “Passenger Side Low” circuits and measures the resistance of the inflator assembly consisting of: 1) Initiators, 2) SRS coil assembly (driver side only), 3) Connectors and associated wiring. Normal Operating Voltage Range The voltage measured between the SDM “Ignition 1” terminals and “Ground” terminals is between 9 and 16 volts. Passenger Current Source An output of the SDM which applies current into the passenger air bag assembly circuit during the “Initiator Assembly Resistance Test”. Passenger Air Bag Assembly An assembly located in the right side of the instrument panel consisting of an inflatable bag, an inflator and an initiator. Scan Tool An external computer used to read diagnostic information from onboard computers via the data link connector.

9J–7

SDM Sensing and Diagnostic Module which provides reserve energy to the deployment loops, deploys the air bags when required and performs diagnostic monitoring of all SRS components. Serial Data Information representing the status of the SRS. SRS Supplemental Restraint System. SRS Coil Assembly An assembly of two current–carrying coils in the driver deployment loop that allows the rotation of the steering wheel while maintaining the continuous contact of the driver deployment loop to the driver air bag assembly. SRS Wiring Harness The wires and connectors that electrically connect the components in the SRS. “Turn–ON” Test which the SDM performs on the SRS once during each ignition cycle immediately after “Ignition 1” voltage is applied to the SDM and before “Continuous Monitoring”.

Diagnosis WARNING: TO AVOID DEPLOYMENT WHEN TROUBLESHOOTING THE SRS, DO NOT USE ELECTRICAL TEST EQUIPMENT SUCH AS A BATTERY–POWERED OR AC–POWERED VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN THAT SPECIFIED IN THIS MANUAL. DO NOT USE A NON–POWERED PROVE–TYPE TESTER. INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT.

Diagnostic Trouble Codes The “SRS Diagnostic System Check” must always be the starting point of any SRS diagnosis. The “SRS Diagnostic System Check” checks for proper “AIR BAG” warning lamp operation and checks for SRS diagnostic trouble codes using the scan tool. 1. Current diagnostic trouble codes – Malfunctions that are presently being detected. Current diagnostic trouble codes are stored in RAM (Random Access Memory). 2. History diagnostic trouble codes – All malfunctions detected since the last time the history memory was cleared. History diagnostic trouble codes are stored in EEPROM.

Scan Tool Diagnostics A scan tool is used to read current and history diagnostic trouble codes and to clear all diagnostic trouble codes after a repair is completed. The scan tool must be updated to communicate with the SRS through a replaceable cartridge before it can be used for SRS diagnostics. To use the scan tool, connect it to the data link connector and turn the ignition switch “ON”. The scan

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SUPPLEMENTAL RESTRAINT SYSTEM

tool reads serial data from the SDM “Serial Data” line terminal “24” to the data link connector terminal “9”.

Use of Special Tools WARNING: TO AVOID DEPLOYMENT WHEN TROUBLESHOOTING THE SRS, DO NOT USE ELECTRICAL TEST EQUIPMENT SUCH AS A BATTERY–POWERED OR AC–POWERED VOLTMETER, OHMMETER, ETC, OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN THAT SPECIFIED IN THIS MANUAL. DO NOT USE A NON POWERED PROVE–TYPE TESTER. INSTRUCTIONS

IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT. YOU SHOULD BE FAMILIAR WITH THE TOOLS LISTED IN THIS SECTION UNDER THE HANDLING SRS SPECIAL TOOLS. You should be able to measure voltage and resistance. You should be familiar with proper use of a scan tool such as the Tech 2 Diagnostic Computer, SRS Driver/Passenger Load Tool J–41433, Connector Test Adapter Kit J–35616–A, and the DVM (Digital Multimeter) J–39200.

SRS Connector Body Face Views

D09RW003

Legend (1) SDM (2) Driver Air Bag Assembly (3) Passenger Air Bag Assembly

Repairs and Inspections Required After an Accident NOTE: If any SRS components are damaged, they must be replaced. If SRS component mounting points are damaged, they must be replaced. B Never use SRS parts from another vehicle. This does not include remanufactured parts purchased from an authorized dealer; they may be used for SRS repairs.

(4) “Air Bag” Warning Lamp (5) SRS Coil Assembly (6) DLC

B Do not attempt to service the SDM, the SRS coil assembly, or the air bag assembly. Service of these items is by replacement only. B Verify the part number of replacement air bag assembly. CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly. The air bag assembly has identification colors on the bar code label as follows.

SUPPLEMENTAL RESTRAINT SYSTEM Light blue color for driver air bag assembly. Light blue color for passenger air bag assembly. Use only the air bag assembly for AXIOM (UP) models. CAUTION: Proper operation of the sensors and Supplemental Restraint System (SRS) requires that any repairs to the vehicle structure return it to the original production configuration. Deployment requires, at a minimum, replacement of the SDM, air bag assembly and dimensional inspection of the steering column. Any visible damage to the SDM mounting bracket (s) requires replacement, and the steering column must be dimensionally inspected, whether deployment occurred or not.

9J–9

SRS Connector (Plastic Body And Terminal Metal Pin) Damage If any connector or terminal in the SRS wire harness (except pigtails) is damaged, it should be replaced.

SRS Wire Pigtail Damage If the wiring pigtail (a wire or wires attached directly to the device, not by a connector) is damaged, the entire component (with pigtail) must be replaced. Examples of “pigtail” components are the driver air bag assembly, the passenger air bag assembly, and the SRS coil assembly.

On–Vehicle Service

Accident With Deployment – Component Replacement and Inspections

Service Precautions

Certain SRS components must be replaced or inspected for damage after a frontal crash involving air bag deployment. Those components are: B Air bag assembly B SDM

WARNING: WHEN PERFORMING SERVICE ON OR AROUND SRS COMPONENTS OR SRS WIRING, FOLLOW THE PROCEDURES LISTED BELOW TO TEMPORARILY DISABLE THE SRS. FAILURE TO FOLLOW PROCEDURES COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY OR OTHERWISE UNNEEDED SRS REPAIRS.

CAUTION: Refer to “SDM Replacement Guidelines” below for important information on SDM replacement in both deployment and non deployment crashes. B SRS coil assembly—Inspect wiring and connector for any signs of scorching, melting, or damage due to excessive heat. Replace if damaged. Refer to SRS coil assembly in this section.

Accident With or Without Deployment—Component Inspection Certain SRS and restraint system components must be inspected after any crash, whether the air bag deployed or not. Those components are: B Steering column—Dimensionally inspect per “Checking Steering Column for Accident Damage” in 3 of this workshop manual. B Knee bolsters and mounting points— Inspect for any distortion, bending, cracking, or other damage. B I/P steering column reinforcement plate— Inspect for any distortion, bending, cracking, or other damage. B I/P braces—Inspect for any distortion, bending, cracking, or other damage. B Seat belts and mounting points—Refer to “Seat Belts” in 10 of this workshop manual.

SDM Replacement Guidelines SDM replacement policy requires replacement of SDM, after crash involving air bag deployment when “SRS Warning Lamp” turn “ON”, “SRS Diagnosis” should be done according to “Section 9J1”.

Wiring Damage If any SRS wire harness is damaged, it should be replaced. Don’t repair SRS. It is replace only.

The SDM in Driver—Passenger SRS can maintain sufficient voltage to cause a deployment for up to 15 seconds after the ignition switch is turned “OFF”, the battery is disconnected, or the fuse powering the SDM is removed. Many of the service procedures require removal of the “SRS–1” fuse, and disconnection of the air bag assembly from the deployment loop to avoid an accidental deployment. If the air bag assembly is disconnected from the deployment loop as noted in the “Disabling the SRS” procedure that follows, service can begin immediately without waiting for the 15 second time period to expire.

Disabling The SRS Removal Turn the ignition switch to “lock” and remove key. 1. Remove SRS fuse SRS–1, from left dash side lower fuse block or disconnect battery. 2. Disconnect yellow 2–pin connector at the base of steering column. 3. Remove glove box assembly, Refer to “Passenger Air Bag Assembly Replacement” in section 9J–28. 4. Disconnect yellow 2–pin connector behind the glove box assembly. CAUTION: With the “SRS–1” fuse removed and ignition switch “ON”, “AIR BAG” warning lamp will be “ON”. This is normal operation and does not indicate an SRS malfunction.

Enabling The SRS Installation CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly.

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The air bag assembly has identification colors on the bar code label as follows. Light blue color for driver air bag assembly. Light blue color for passenger air bag assembly. Use only the air bag assembly for AXIOM (UP) models. Turn ignition switch to “LOCK” and remove key. 1. Connect yellow 2–pin connector passenger air bag assembly. 2. Install glove box assembly, refer to “Passenger Air Bag Assembly Replacement” in section 9J–28. 3. Connect yellow 2–pin connector at the base of steering column. 4. Install “AIR BAG” fuse SRS–1 to left dash side lower fuse block or connect battery. Turn ignition switch to “ON” and verify that the “AIR BAG” warning lamp flashes seven times and then turns “OFF” If it does not operate as described, perform the “SRS Diagnostic System Check” in section 9J1–3.

Handling / Installation / Diagnosis 1. Air bag assembly should not be subjected to temperatures above 93°C (200°F). 2. Air bag assembly, and SDM should not be used if they have been dropped from a height of 100 centimeters (3.28 feet). 3. When a SDM is replaced, it must be oriented with the arrow on the sensor pointing toward the front of the vehicle. It is very important for the SDM to be located flat on the mounting surface, parallel to the vehicle datum line. It is important that the SDM mounting surface is free of any dirt or other foreign material. 4. Do not apply power to the SRS unless all components are connected or a diagnostic chart requests it, as this will set a diagnostic trouble code. 5. The “SRS Diagnostic System Check” must be the starting point of any SRS diagnostics. The “SRS Diagnostic System Check” will verify proper “AIR BAG” warning lamp operation and will lead you to the correct chart to diagnose any SRS malfunctions. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacement.

827RW009

WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG OPENING IS POINTED AWAY FROM YOU. IN CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. NEVER CARRY THE AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF THE MODULE.

Air Bag Assembly Handling / Shipping / Scrapping Live (Undeployed) Air Bag Assembly Special care is necessary when handling and storing a live (undeployed) air bag assembly. The rapid gas generation produced during deployment of the air bag could cause the air bag assembly, or an object in front of the air bag assembly, to be thrown through the air in the unlikely event of an accidental deployment. 827RS044

SUPPLEMENTAL RESTRAINT SYSTEM

Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag Assemblies Service personnel should refer to the latest Service Bulletins for proper SRS air bag assembly shipping procedures.

Deployed Air Bag Assembly You should wear gloves and safety glasses. After the air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present.

Air Bag Assembly Scrapping Procedure During the course of a vehicle’s useful life, certain situations may arise which will necessitate the disposal of a live (undeployed) air bag assembly. This information covers proper procedures for disposing of a live air bag assembly. Before a live air bag assembly can be disposed of, it must be deployed. Alive air bag assembly must not be disposed of through normal refuse channels. WARNING: FAILURE TO FOLLOW PROPER SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG ASSEMBLY DISPOSAL PROCEDURES CAN RESULT IN AIR BAG DEPLOYMENT WHICH MAY CAUSE PERSONAL INJURY. AN UNDPLOYED AIR BAG ASSEMBLY MUST NOT BE DISPOSED OF THROUGH NORMAL REFUSE CHANNELS. THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS OR PERSONAL INJURY IF THE SEALED CONTAINER IS DAMAGED DURING DISPOSAL. DISPOSAL IN ANY MANNER INCONSISTENT WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE, AND / OR LOCAL LAW.

9J–11

followed exactly. Always wear safety glasses during this deployment procedure until a deployed air bag assembly is scrapped or until an undeployed air bag assembly is shipped. Before performing the procedures you should be familiar with servicing the SRS and with proper handling of the air bag assembly. Procedures should be read fully before they are performed. The following procedure requires use of J–41434 SRS deployment harness with appropriate pigtail adapter. Do not attempt procedure without J–41434 adapter. WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT HARNESS TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT HARNESS TO THE DRIVER AIR BAG ASSEMBLY. DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. WEAR SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL PROCEDURE. NOTE: This information applies only to driver air bag assembly . Refer to “Deployment Outside Vehicle (Passenger Air Bag Assembly)” in this section for information on passenger air bag assembly scrapping. 1. Turn ignition switch to “LOCK”, remove key and put on safety glasses. 2. Inspect J–41434 SRS Deployment Harness and appropriate pigtail adapter for damage. If harness or pigtail adapter is damaged, discard and obtain a replacement. 3. Short the two SRS deployment harness leads together by fully seating one banana plug into the other. SRS deployment harness shall remain shorted and not be connected to a power source until the air bag is to be deployed.

In situations which require deployment of a live air bag assembly module, deployment may be accomplished inside or outside the vehicle. The method employed depends upon the final disposition of the particular vehicle, as noted in “Deployment Outside Vehicle” and “Deployment Inside Vehicle” in this section.

Deployment Outside Vehicle (Driver Air Bag Assembly) Deployment outside the vehicle is proper when the vehicle is to be returned to service. This includes, for example, situations in which the vehicle will be returned to useful service after a functionally or cosmetically deficient air bag assembly is replaced. Deployment and disposal of a malfunctioning air bag assembly is, of course, subject to any required retention period. For deployment of a live (undeployed) air bag assembly outside the vehicle, the deployment procedure must be

827RS004

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SUPPLEMENTAL RESTRAINT SYSTEM

4. Connect the appropriate pigtail adapter to the SRS deployment harness. 5. Remove the driver air bag assembly from vehicle. Refer to Inflator Module Removal in this Section 9J–3. WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG ASSEMBLY UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE AIR BAG AND TRIM COVER UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN PERSONAL INJURY. 6. Place the driver air bag assembly on a work bench or other surface away from all loose or flammable objects with its trim cover facing up, away from the surface.

827RW015

8. Place the driver air bag assembly, with its trim cover facing up, on the ground in the space just cleared. 9. Stretch the SRS deployment harness and pigtail adapter from the driver air bag assembly to its full length. 10. Place a power source near the shorted end of the SRS deployment harness. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 11. Connect the driver air bag assembly to the pigtail adapter on the SRS deployment harness. Deployment harness shall remain shorted and not be connected to a power source until the air bag is to be deployed. The driver air bag assembly will immediately deploy the air bag when a power source is connected to it.

827RW009

7. Clear a space on the ground about 183 cm (six feet) in diameter where the driver air bag assembly is to be deployed. A paved, outdoor location where there is no activity is preferred. If an outdoor location is not available, a space on the shop floor where there is no activity and sufficient ventilation is recommended. Ensure no loose or flammable objects are within the deployment area.

NOTE: Ensure that the pigtail adapter is firmly seated into the driver air bag assembly connector. Failure to fully seat the connectors may leave the shorting bar located in the driver air bag assembly connector functioning (shorted) and may result in non deployment of the driver air bag assembly. 12. Verify that the area around the driver air bag assembly is clear of all people and loose or flammable objects. 13. Verify that the driver air bag assembly is resting with its trim cover facing up. 14. Notify all people in the immediate area that you intend to deploy the driver air bag. The deployment will be accompanied by a substantial noise which may startle the uninformed. 15. Separate the two banana plugs on the SRS deployment harness. NOTE: When the air bag deploys, the driver air bag assembly may jump about 30 cm (one foot) vertically. This is a normal reaction of the driver air bag to the force of the rapid gas expansion inside the air bag. NOTE: When the air bag deploys, the rapid gas expansion will create a substantial noise. Notify all

SUPPLEMENTAL RESTRAINT SYSTEM people in the immediate area that you intend to deploy the driver air bag. WARNING: DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT HARNESS TO THE POWER SOURCE SHOULD ALWAYS BE THE LAST STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL INJURY. 16. Connect the SRS deployment harness wires to the power source to immediately deploy the driver air bag. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 17. Disconnect the SRS deployment harness from the power source. 18. Short the two SRS deployment harness leads together by fully seating one banana plug into the other. 19. In the unlikely event that the driver air bag assembly did not deploy after following these procedures, proceed immediately with Steps 24 through 26. If the driver air bag assembly did deploy, proceed with Steps 20 through 23. 20. Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed driver air bag assembly. After the driver air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This power consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with the atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment. WARNING: SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE METAL SURFACES OF THE AIR BAG ASSEMBLY WILL BE VERY HOT. ALLOW THE INFLATOR MODULE TO COOL BEFORE HANDLING ANY METAL PORTION OF IT. DO NOT PLACE THE DEPLOYED AIR BAG ASSEMBLY NEAR ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN FIRE OR PERSONAL INJURY. AFTER A DRIVER AIR BAG ASSEMBLY HAS BEEN DEPLOYED, THE METAL CANISTER AND SURROUNDING AREAS OF THE DRIVER AIR BAG ASSEMBLY WILL BE VERY HOT. DO NOT TOUCH THE METAL AREAS OF THE DRIVER AIR BAG ASSEMBLY FOR ABOUT TEN MINUTES AFTER DEPLOYMENT. IF THE DEPLOYED DRIVER AIR BAG ASSEMBLY MUST BE MOVED BEFORE IT IS COOL,

9J–13

WEAR GLOVES AND HANDLE BY THE AIR BAG OR TRIM COVER. 21. Disconnect the pigtail adapter from the driver air bag assembly as soon after deployment as possible. This will prevent damage to the pigtail adapter or SRS deployment harness due to possible contact with the hot driver air bag assembly canister. The pigtail adapter can be reused. They should, however, be inspected for damage after each deployment and replaced if necessary. 22. Dispose of the deployed driver air bag assembly through normal refuse channels after it has cooled for at least 30 minutes. 23. Wash your hands with mild soap and water afterward. NOTE: The remaining steps are to be followed in the unlikely event that the driver air bag assembly did not deploy after following these procedures. 24. Ensure that the SRS deployment harness has been disconnected from the power source and that its two banana plugs have been shorted together by fully seating one banana plug into the other. 25. Disconnect the pigtail adapter from the driver air bag assembly. WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE INFLATOR MODULE UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG AND TRIM COVER UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN PERSONAL INJURY. 26. Temporarily store the driver air bag assembly with its trim cover facing up, away from the surface upon which it rests.

Deployment Outside Vehicle (Passenger Air Bag Assembly) WARNING: FAILURE TO FOLLOW PROPER SRS AIR BAG ASSEMBLY DISPOSAL PROCEDURES CAN RESULT IN AIR BAG DEPLOYMENT WHICH MAY CAUSE PERSONAL INJURY. UNDEPLOYED AIR BAG ASSEMBLIES MUST NOT BE DISPOSED OF THROUGH NORMAL REFUSE CHANNELS. THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS OR PERSONAL INJURY IF THE SEALED CONTAINER IS DAMAGED DURING DISPOSAL. DISPOSAL IN ANY MANNER INCONSISTENT WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE AND/OR LOCAL LAWS. Deployment out of the vehicle is proper when the vehicle is to be returned to service. This includes, for example, situations in which a functionally or cosmetically deficient air bag assembly is replaced. Deployment and disposal of an air bag assembly is, of course, subject to any required retention period. For deployment of a live air bag assembly out of the vehicle, the deployment procedure must be followed exactly. ALWAYS wear safety glasses during this

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SUPPLEMENTAL RESTRAINT SYSTEM

deployment procedure until the deployed air bag assembly is scrapped. Before performing the procedures, you should be familiar with servicing the SRS system and with proper handling of the air bag assembly. Procedures should be read fully before they are performed. The following procedure requires use of J–42986 SRS Deployment Harness with the appropriate pigtail adapter. The procedure also requires the use of J–41497 Passenger Side SRS Module Deployment Fixture. Do not attempt this procedure without J–42986 and fixture J–41497. WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT HARNESS TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT HARNESS TO THE AIR BAG ASSEMBLY. DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. WEAR SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL PROCEDURE. NOTE: This information applies only to passenger air bag assembly. Information for disposing of a live driver air bag assembly can be found in “Deployment Outside Vehicle” (Driver Air Bag Assembly) in this section. 1. Turn ignition switch to “LOCK” remove key, and put on safety glasses. 2. Inspect J–41434 SRS Deployment Harness and appropriate pigtail adapter for damage. If harness or pigtail is damaged, discard and obtain a replacement. 3. Short the two SRS Deployment Harness leads together by fully seating one banana plug into the other. The SRS Deployment Harness shall remain shorted and not be connected to a power source until the air bag is to be deployed.

827RS004

5. Remove passenger air bag assembly from vehicle. Refer to “Passenger Air Bag Assembly Removal ” in this Section. 6. Clear a space on the ground approximately 185 cm (six feet) in diameter where the fixture with attached air bag assembly is to be placed for deployment. A paved outdoor location where there is no activity is preferred. If an outdoor location is not available, a space on the shop floor where is no activity and sufficient ventilation is recommended. Ensure that no loose or flammable objects are within the deployment area. 7. Place the J–41497 on the bench vice. This is necessary to provide sufficient stabilization of the fixture during deployment. 8. Attach the passenger air bag assembly in the J–41497. Air bag assembly must be mounted such that the bag will deploy upward. SECURELY HAND–TIGHTEN ALL FASTENERS PRIOR TO DEPLOYMENT. 9. Stretch the SRS Deployment Harness and pigtail adapter from the air bag assembly to its full length. 10. Place a power source near the shorted end of the SRS deployment harness. (Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested.) 11. Connect the air bag assembly to the pigtail adapter on the SRS deployment harness. The SRS Deployment Harness shall remain shorted and not be connected to a power source until the air bag is to be deployed. The air bag assembly will immediately deploy the air bag when a power source is connected to it. NOTE: Ensure that the pigtail adapter is firmly seated into the air bag assembly connector. Failure to fully seat the connectors may leave the shorting bar located in the air bag assembly connector functioning (shorting the deployment circuit) and may result in non deployment of the air bag assembly.

827RS003

4. Connect the appropriate pigtail adapter to the SRS Deployment Harness

12. Verify that the area around the passenger air bag assembly is clear of all people and loose or flammable objects.

SUPPLEMENTAL RESTRAINT SYSTEM 13. Verify that the passenger air bag assembly is firmly and properly in J–41497. 14. Notify all people in the immediate area of your intention to deploy the passenger air bag assembly. The deployment will be accompanied by a substantial noise which may startle the uninformed. 15. Separate the two banana plugs on the SRS deployment harness. NOTE: When air bag deploys, the rapid gas expansion will create a substantial noise. Notify all people in the immediate area that you intend to deploy the air bag assembly. WARNING: DEPLOYMENT HARNESS SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT HARNESS TO THE POWER SOURCE SHOULD ALWAYS BE THE LAST STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED MAY RESULT IN PERSONAL INJURY. 16. Connect the SRS deployment harness wires to the power source to immediately deploy the air bag assembly. Recommended application : 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 17. Disconnect the SRS deployment harness from the power source. 18. Short the two SRS deployment harness leads together by fully seating one banana plug into the other. 19. In the unlikely event that the passenger air bag assembly did not deploy after following these procedures, proceed immediately with Steps 24 through 26. If the passenger air bag assembly deployed as intended, proceed with Steps 20 through 23. 20. Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. After the air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide quickly reacts with the atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present for very long after deployment. WARNING: SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE METAL SURFACES OF THE AIR BAG ASSEMBLY WILL BE HOT. ALLOW THE AIR BAG ASSEMBLY TO COOL BEFORE HANDLING ANY METAL PORTION

9J–15

OF IT. DO NOT PLACE THE DEPLOYED INFLATOR MODULE NEAR ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN FIRE OR PERSONAL INJURY. AFTER AN AIR BAG ASSEMBLY HAS BEEN DEPLOYED, THE METAL CANISTER AND SURROUNDING AREAS OF THE AIR BAG ASSEMBLY WILL BE HOT. DO NOT TOUCH THE METAL AREAS OF THE AIR BAG ASSEMBLY FOR ABOUT THIRTY MINUTES AFTER DEPLOYMENT. IF THE DEPLOYED AIR BAG ASSEMBLY MUST BE MOVED BEFORE IT IS COOL, WEAR GLOVES AND HANDLE BY THE AIR BAG ITSELF. 21. Disconnect the pigtail adapter from the air bag assembly as soon after deployment as possible to avoid damage to the pigtail adapter or SRS deployment harness from contacting the hot air bag assembly canister. The pigtail adapter and SRS deployment harness are designed to be reused. They should, however, be inspected for damage after each deployment and replaced if necessary. 22. Dispose of the deployed air bag assembly through normal refuse channels after it has cooled for at least 30 minutes. 23. Wash your hands with mild soap and water afterward. NOTE: The remaining steps are to be followed in the unlikely event that the air bag assembly did not deploy after following the above procedures. 24. Ensure that the SRS deployment harness has been disconnected from the the power source and that its two banana plugs have been shorted together by fully seating one banana plug into the other. 25. Disconnect the pigtail adapter from the air bag assembly. WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG ASSEMBLY UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG UP AND AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES MAY RESULT IN PERSONAL INJURY. 26. Temporarily store the air bag assembly with the bag facing up, away from the surface upon which it rests.

Deployment Inside Vehicle (Vehicle Scrapping Procedure) Deployment inside vehicle is proper when the vehicle is to be destroyed or salvaged for component parts. This includes, but is not limited to, the following situations: 1. The vehicle has completed its useful life. 2. The vehicle has been damaged beyond repair in a non deployment type accident. 3. The vehicle has been stripped or damaged beyond repair in a theft. 4. The vehicle will be salvaged for component parts to be used on a vehicle with a different Vehicle Identification Number (VIN) as opposed to being rebuilt as same VIN. Never use SRS components from another vehicle.

9J–16

SUPPLEMENTAL RESTRAINT SYSTEM

WARNING: FAILURE TO FOLLOW PROPER SRS AIR BAG ASSEMBLY DISPOSAL PROCEDURES CAN RESULT IN AIR BAG DEPLOYMENT WHICH MAY CAUSE PERSONAL INJURY. UNDEPLOYED AIR BAG ASSEMBLIES MUST NOT BE DISPOSED OF THROUGH NORMAL REFUSE CHANNELS. THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS OR PERSONAL INJURY IF THE SEALED CONTAINER IS DAMAGED DURING DISPOSAL. DISPOSAL IN ANY MANNER INCONSISTENT WITH PROPER PROCEDURES MAY BE A VIOLATION OF FEDERAL, STATE AND/OR LOCAL LAWS. 1. Turn ignition switch to “LOCK”, remove key and put on safety glasses. 2. Remove all loose objects from front seats. 3. Disconnect SRS coil assembly, yellow 2–pin connector located at the base of the steering column. 4. Cut the SRS coil assembly yellow 2–pin harness connector from the vehicle leaving at least 16 cm (six inches) of wire at the connector. 5. Strip 1/2 inch (13 mm) of insulation from yellow–green and yellow–black wire lead of the connector. 6. Cut two 30 feet (900 cm) deployment wires from 18 gauge (0.8 mm@) or thicker multi–strand wire. These wires will be used to fabricate the driver deployment harness. 7. Strip 1/2 inch (13 mm) of insulation from both ends of the wires cut in the previous step. 8. Short the wires by twisting together one end from each. Deployment wires shall remain shorted and not be connected to a power source until the air bag is to be deployed. WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT WIRES TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY LEADS. DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. WEAR SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL PROCEDURE. 9. Twist together one connector wire lead to one deployment wire. The connection should be mechanically secure. 10. Bend twisted connection made in the previous step flat and wrap tightly with electrical tape to insulate and secure. 11. Twist together, bend and tape the remaining connector wire lead to the remaining deployment wire. 12. Connect the deployment harness to the driver air bag assembly, yellow 2–pin connector at the base of the steering column. Route deployment harness out the driver side of the vehicle.

WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. 13. Disconnect passenger air bag assembly, yellow 2–pin connector located behind glove box assembly. 14. Cut the passenger air bag assembly harness connector from the vehicle leaving at least six inches (16 cm) of wire at the connector. 15. Strip 1/2 inch (13 mm) of insulation from yellow–green and yellow–red wire lead of the connector. 16. Cut two 30 feet (900 cm) deployment wires from 18 gauge (0.8 mm@) or thicker multi–strand wire. These wires will be used to fabricate the passenger deployment harness. 17. Strip 1/2 inch (13 mm) of insulation from both ends of the wires cut in the previous step. 18. Short the wires by twisting together one end from each. Deployment wires shall remain shorted and not be connected to a power source until the air bag is to be deployed. WARNING: FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. NEVER CONNECT DEPLOYMENT WIRES TO ANY POWER SOURCE BEFORE CONNECTING DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY LEADS. DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN SAFETY GLASSES THROUGHOUT THIS ENTIRE DEPLOYMENT AND DISPOSAL PROCEDURE. 19. Twist together one connector wire lead to one deployment wire. The connection should be mechanically secure. 20. Bend twisted connection made in the previous step flat and wrap tightly with electrical tape to insulate and secure. 21. Twist together, bend and tape the remaining connector wire lead to the remaining deployment wire. 22. Connect the deployment harness to the passenger air bag assembly, yellow 2–pin connector located behind the glove box assembly. Route deployment harness out the passenger side of the vehicle. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE

SUPPLEMENTAL RESTRAINT SYSTEM DEPLOYMENT WIRES SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. 23. Verify that the inside of the vehicle and the area surrounding the vehicle are clear of all people and loose or flammable objects. 24. Stretch the driver and passenger deployment harness to their full length. 25. Completely cover windshield area and front door window openings with a drop cloth, blanket or similar item. This reduces the possibility of injury due to possible fragmentation of the vehicle’s glass or interior. 26. Notify all people in the immediate area that you intend to deploy the air bags. The deployment will be accompanied by a substantial noise which may startle the uninformed. 27. Separate the two ends of the driver deployment harness wires. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY. NOTE: When the air bag deploys, the rapid gas expansion will create a substantial noise. Notify all people in the immediate area that you intend to deploy the air bags. 28. Connect the driver deployment harness wires to a power source to immediately deploy the driver air bag assembly. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. 29. Separate the two ends of the passenger deployment harness wires. WARNING: DEPLOYMENT WIRES SHALL REMAIN SHORTED AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR BAG IS TO A POWER SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. THE AIR BAG ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO IT. CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW PROCEDURES IN THE ORDER LISTED COULD RESULT IN PERSONAL INJURY.

9J–17

30. Connect the passenger deployment harness wires to a power source to immediately deploy the passenger air bag assembly. Recommended application: 12 volts minimum, 2 amps minimum. A vehicle battery is suggested. Put on a pair of shop gloves and safety gasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly. After an air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment. WARNING: SAFETY PRECAUTIONS MUST BE OBSERVED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE METAL SURFACES OF THE AIR BAG ASSEMBLY WILL BE VERY HOT. ALLOW THE AIR BAG ASSEMBLY TO COOL BEFORE HANDLING ANY METAL PORTION OF IT. DO NOT PLACE THE HOT DEPLOYED AIR BAG ASSEMBLY NEAR ANY FLAMMABLE OBJECTS. FAILURE TO FOLLOW PROCEDURES COULD RESULT IN FIRE OR PERSONAL INJURY. After an air bag assembly has been deployed, the metal canister and surrounding areas of the air bag assembly will be very hot. Do not touch the metal areas of the air bag assembly for about 30 minutes after deployment. If the deployed air bag assembly must be moved before it is cool, wear gloves and handle by the air bag or trim cover. 31. Short the driver deployment harness wires by twisting together one end from each. Repeat this procedure for the passenger deployment harness. 32. Carefully remove drop cloth from vehicle and clean off any fragments or discard drop cloth entirely. 33. Disconnect driver deployment harness and passenger deployment harness from vehicle and discard. 34. In the unlikely event that either or both of the air bag assemblies did not deploy after following these procedures, proceed immediately with Steps 36 through 37. If the air bag assembly deployed, proceed to step 35. 35. With both air bags deployed, the vehicle may be scrapped in the same manner as a non–SRS equipped vehicle. NOTE: The remaining steps are to be followed in the unlikely event that the air bag assembly did not deploy after following these procedures. 36. Remove the undeployed air bag assembly (s) from the vehicle. For driver air bag assembly refer to in the “Passenger Air Bag Assembly Removal” in this section 9J–28. WARNING: WHEN STORING A LIVE AIR BAG ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG

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SUPPLEMENTAL RESTRAINT SYSTEM

ASSEMBLY UNATTENDED ON A BENCH OR OTHER SURFACE, ALWAYS FACE THE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW PROCEDURES COULD RESULT IN PERSONAL INJURY. 37. Temporarily store the air bag assembly with the air bag opening facing up, away from the surface upon which it rests.

After the air bag assembly has been deployed, the surface of the air bag may contain a powdery residue. This powder consists primarily of cornstarch (used to lubricate the bag as it inflates) and by products of the chemical reaction. Sodium hydroxide dust (similar to lye soap) is produced as a by product of the deployment reaction. The sodium hydroxide then quickly reacts with atmospheric moisture and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium hydroxide will be present after deployment.

Deployed Air Bag Assembly Handling Put on a pair of shop gloves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly.

Special Tools WARNING: TO AVOID DEPLOYMENT WHEN TROUBLESHOOTING THE SRS, DO NOT USE ELECTRICAL TEST EQUIPMENT SUCH AS A BATTERY–POWERED OR AC–POWERED VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN THAT SPECIFIED IN THIS MANUAL. DO NOT USE A NON POWERED PROBE–TYPE TESTER. INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT.

J–41433 SRS Driver/Passenger Load Tool The SRS Driver/Passenger Load Tool J–41433 is used only when called for in this section. It is used as a diagnostic aid and safety device to prevent inadvertent air bag assembly deployment. The load tool has four yellow connectors attached to its case. The three small connectors are electrically functional and serve as resistive load substitutions. No more than two connectors are used at any time. One of the small connectors is used to substitute for the load of the driver air bag assembly when it is connected at the top of the column to the SRS coil assembly. Another small connector is used to substitute for the load of the driver air bag assembly and the SRS coil assembly when it is connected at the base of the column to the SRS wiring harness. The third small connector is used to substitute for the load of the passenger air bag assembly when connected to the passenger air bag assembly harness connector. By substituting the resistance of the load tool when called for, a determination can be made as to whether an inflator circuit component is causing system malfunction and which component is causing the malfunction. The load tool should be used only when specifically called for in the diagnostic procedures.

901RS146

SUPPLEMENTAL RESTRAINT SYSTEM

9J–19

J–39200 DVM

J–35616–A Connector Test Adapter Kit

The J–39200 DVM is the preferred DVM for use in SRS diagnosis and repair. However, J–34029–A may be used if J–39200 is not available. No other DVMs are approved for SRS diagnosis and repair.

The J–35616–A Connector Test Adapter Kit must be used whenever a diagnostic procedure requests checking or probing a terminal. Using the appropriate adapter will ensure that no damage to the terminal will occur from the DVM prove, such as spreading or bending. The adapter will also give an idea of whether contact tension is sufficient, helping to find an open or intermittent open due to poor terminal contact.

901RS153

Scan Tool The Tech 2 is used to read and clear SRS Diagnostic Trouble Codes (DTCs). Refer to the Tech 2 Operator’s Manual for specific information on how to use the Tech 2.

901RS151

J–42986 SRS Deployment Tool The J–42986 SRS Deployment Tool must be used for deployment of the undeployed air bag.

901RW176

901RW106

9J–20

SUPPLEMENTAL RESTRAINT SYSTEM

J–42987 SRS Adapter For Load Tool The J–42987 SRS Adapter be used for connect previous load tool to new SRS system when inspect SRS system harness.

901RW107

J–41497 SRS Deployment Fixture The J–41497 SRS Deployment Fixture must be used for deployment of the undeployed passenger side air bag.

901RW088

SUPPLEMENTAL RESTRAINT SYSTEM

9J–21

Tech 2 Scan Tool From 2002 AXIOM (UP), dealer service departments are recommended to use Tech 2. Please refer to Tech 2 scan tool user guide.

901RW180

Legend (1) PCMCIA Card (2) RS 232 Loop Back Connector

(3) SAE 16/19 Adaptor (4) DLC Cable (5) Tech–2

9J–22

SUPPLEMENTAL RESTRAINT SYSTEM

Getting Started B Before operating the Isuzu PCMCIA card with the Tech 2, the following steps must be performed: 1. The Isuzu System PCMCIA card (1) inserts into the Tech 2 (5). 2. Connect the SAE 16/19 adapter (3) to the DLC cable (4). 3. Connect the DLC cable to the Tech 2 (5) 4. Make sure the vehicle ignition is off. 5. Connect the Tech 2 SAE 16/19 adapter to the vehicle DLC.

Operating Procedure The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card. Follow the operating procedure below.

060R200039

6. The vehicle ignition turns on. 7. Verify the Tech 2 power up display.

060R100102

060RW009

NOTE: The RS232 loop back connector is only to use for diagnosis of Tech 2 and refer to user guide of the Tech 2.

SUPPLEMENTAL RESTRAINT SYSTEM

060R200037

9J–23

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SUPPLEMENTAL RESTRAINT SYSTEM

Menu B The following table shows which functions are used for the available equipment versions.

B Read DTC info by Priority B Clear Info

060RY00115 060RY00113

DTC Modes

Plottong Snapshot Graph This test selects several necessary items from the data list to plot graphs and makes data comparison on a long term basis. It is an effective test particularly in emission related evaluations. For trouble diagnosis, you can collect graphic data (snap shot) directly from the vehicle. You can replay the snapshot data as needed. Therefore, accurate diagnosis is possible, even though the vehicle is not available.

060RY00114

SUPPLEMENTAL RESTRAINT SYSTEM

9J–25

Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)

060RX041

9J–26

SUPPLEMENTAL RESTRAINT SYSTEM

Flow Chart for Snapshot Replay (Plotting Graph)

060RX040

SUPPLEMENTAL RESTRAINT SYSTEM

Service Precaution CAUTION: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. if the above conditions are not followed, parts or system damage could result. WARNING: WHEN PERFORMING SERVICE ON OR AROUND SRS COMPONENTS OR SRS WIRING, FOLLOW THE PROCEDURES LISTED BELOW TO TEMPORARILY DISABLE THE SRS. FAILURE TO FOLLOW PROCEDURES COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY OR OTHERWISE UNNEEDED SRS REPAIRS. The SDM in Driver–Passenger SRS can maintain sufficient voltage to cause a deployment for up to 15 seconds after the ignition switch is turned “OFF,” the battery is disconnected, or the fuse powering the SDM is removed. Many of the service procedures require removal of the “SRS–1” fuse, and disconnection of the air bag assembly from the deployment loop to avoid an accidental deployment. If the air bag assembly is disconnected from the deployment loop as noted in the “Disabling the SRS” procedure that follows, service can begin immediately without waiting for the 15 second time period to expire.

Disabling The SRS Removal Turn the ignition switch to “OFF” and turn the steering wheel so that the vehicle’s wheels are pointing straight ahead. 1. Remove SRS fuse SRS–1, from left dash side lower fuse block or disconnect battery. 2. Disconnect yellow 2–pin connector at the base of steering column. 3. Remove glove box assembly; Refer to “Passenger Air Bag Assembly Replacement” in this section. 4. Disconnect passenger air bag assembly yellow 2–pin connector behind the glove box assembly. CAUTION: With the “SRS–2” fuse removed and ignition switch “ON,” the “AIR BAG” warning lamp will be “ON.” This is normal operation and does not indicate an SRS malfunction.

Enabling The SRS Installation Turn ignition switch to “LOCK” and remove key. 1. Connect yellow 2–pin connector passenger air bag assembly. 2. Install glove box assembly, Refer to “Passenger Air Bag Assembly Replacement” in this section.

9J–27

3. Connect yellow 2–pin connector at the base of the steering column. 4. Install “AIR BAG” fuse SRS–1 to left dash side lower fuse block or connect battery. Turn ignition switch to “ON” and verify that the “AIR BAG” warning lamp flashes seven times and then turns “OFF” If it does not operate as described, perform the “SRS Diagnostic System Check” in section 9J–2.

Handling / Installation / Diagnosis 1. Air bag assembly should not be subjected to temperatures above 65°C (150°F). 2. Air bag assembly, and SDM should not be used if they have been dropped from a height of 100 centimeters (3.28 feet) or more. 3. When a SDM is replaced, it must be oriented with the arrow on the SDM pointing toward the front of the vehicle. It is very important for the SDM to be located flat on the mounting surface, parallel to the vehicle datum line. It is important that the SDM mounting surface is free of any dirt or other foreign material. 4. Do not apply power to the SRS unless all components are connected or a diagnostic chart requests it, as this will set a diagnostic trouble code. 5. The “SRS Diagnostic System Check” must be the starting point of any SRS diagnostics. The “SRS Diagnostic System Check” will verify proper “AIR BAG” warning lamp operation and will lead you to the correct chart to diagnose any SRS malfunctions. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis, and incorrect parts replacements.

Inspections Required After An Accident CAUTION: Certain SRS components must be replaced after a frontal crash involving air bag deployment. In all types of accidents regardless of “Air Bag” deployment, visually inspect all of the following components and replace as required: — Driver air bag assembly — Passenger air bag assembly — Steering wheel — SRS coil assembly — Steering column — Knee bolster and instrument panel mounting attachments — Driver seat and belt — Passenger seat and belt — SDM SDM always should be checked according to “SDM Replacement Guidelines”. CAUTION: Refer to “SDM replacement Guidelines” below for important information on SDM replacement in both deployment and non–deployment crashes. Inspect SRS coil assembly wiring and steering wheel for any signs of scorching, meting, or damage due to excessive heat. If coil assembly wire or steering wheel is

9J–28

SUPPLEMENTAL RESTRAINT SYSTEM

damaged, replace them. The steering column and wheel must be dimensionally checked to determine if they are damaged. Refer to in this Section 9J–3 of this manual. Never use SRS parts from another vehicle. This does not include remanufactured parts purchased from an authorized Retailer; they may be used for SRS repairs. Do not attempt to repair the SDM, the SRS harness, the SRS coil assembly, the air bag assembly, the steering

wheel, or the steering column. Service of these items is replacement only. Verify replacement part numbers. CAUTION: Proper operation of the SDM and Supplemental Restraint System (SRS) requires that any repairs to the vehicle structure return it to its original production configuration.

Sensing and Diagnostic Module (SDM) Service Precautions

10. Remove air conditioning duct for rear seat. (Transform the duct during removing it)

WARNING: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDLING SDM. NEVER STRIKE OR JAR SDM. UNDER SOME CIRCUMSTANCES, IT COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY OR IMPROPER OPERATION OF THE SUPPLEMENTAL RESTRAINT SYSTEM (SRS). SDM MOUNTING BRACKET BOLTS MUST BE CAREFULLY TORQUED TO ASSURE PROPER OPERATION. NEVER POWER UP THE SRS WHEN SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. WARNING: PROPER OPERATION OF THE SENSING AND DIAGNOSTIC MODULE (SDM) REQUIRES THE SDM TO BE RIGIDLY ATTACHED TO THE VEHICLE STRUCTURE AND THAT THE ARROW ON THE SENSOR BE POINTING TOWARD THE FRONT OF THE VEHICLE. SDM is specifically calibrated and is keyed to the SDM location SRS wiring harness. Caution should be used to ensure proper location of the SDM. The keying of the SDM to its location and wiring harness connectors should never be modified in the field.

827RW023

11. Pull CPA (1) (Connector Position Assurance–red color) out and push connector lock down to disconnect the SDM harness connector (2). 12. Remove the three SDM fixing bolts (4) and remove SDM (3).

Removal 1. Disable the SRS. (Refer to “Disable the SRS” in this manual) 2. Remove dressing panel around the radio and disconnect cigar lighter harness. 3. Remove the transfer sift lever knob. 4. Remove the center console. 5. Remove three connector from PCM. 6. Remove PCM with bracket.(Fixed four bolts) 7. Remove right side stay between instrument panel and floor. 8. Remove driver and passenger seat. 9. Turn over carpet to rear side.

827RW022

SUPPLEMENTAL RESTRAINT SYSTEM

9J–29

6. Install PCM with bracket and tighten to the specified torque.

Installation 1. Install the SDM (3) on bracket and fixing bolts (4) and tighten the fixing bolts to the specified torque. Torque: 10 N·m ± 3 N·m (87 lb in ± 26 lb in) 2. Connect the SDM harness connector (2) and after that, put CPA into connector (1).

Torque: 10 N·m ± 3 N·m (87 lb in ± 26 lb in) 7. Reconnect three connector to PCM. 8. Install the center console. 9. Install the transfer shift lever knob. 10. Install the dressing panel around the radio and reconnect cigar lighter harness. 11. Enable the SRS. (Refer to “Enabling the SRS” in this manual)

827RW022

3. Install air conditioning duct for rear seat to normal position. 4. Return carpet normal position. 5. Install right side stay between instrument panel and floor, tighten to the specified torque.

827RW023

Torque: 10 N·m ± 3 N·m (87 lb in ± 26 lb in)

Driver Air Bag Assembly Service Precautions WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWDER ON THE AIR BAG ASSEMBLY IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS. WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE AIR BAG

ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. NOTE: In the event deployment has occurred, inspect coil assembly wire for any signs of scorching, melting or any other damage due to excessive heat. If the coil has been damaged, replace it.

Removal 1. Disable the SRS. (Refer to “Disabling the SRS” in this section.) 2. Remove air bag assembly from steering wheel by removing two bolts. Lift air bag assembly out of steering wheel.

9J–30

SUPPLEMENTAL RESTRAINT SYSTEM

3. Disconnect connector and remove air bag assembly.

CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly. The air bag assembly has identification colors on the bar code label as follows. Light blue color for driver air bag assembly. Light blue color for passenger air bag assembly. Use only the air bag assembly for “UP”.

431R200005

Installation 1. Connect air bag to wiring harness connector. NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of air bag to prevent lead wire from being pinched. 2. Install air bag into steering wheel and tighten bolts to specified sequence as shown in figure.

431R200005

3. Enable the SRS. (Refer to “Enabling the SRS” in this section.)

Torque: 8.8 N·m (78 lb in)

Steering Wheel Service Precautions WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWDER ON THE AIR BAG ASSEMBLY IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS. WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL

WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. NOTE: In the event deployment has occurred, inspect coil assembly wire for any signs of scorching, melting or any other damage due to excessive heat. If the coil has been damaged, replace it.

Removal 1. Disable the SRS. (Refer to “Disabling the SRS” in this section.) 2. Remove the air bag assembly (5) from steering wheel (6) by removing two bolts (7). Lift air bag assembly out of steering wheel. 3. Disconnect connector (2) and remove air bag assembly. 4. Disconnect horn lead (1) 5. Remove steering wheel attachment nut (4).

SUPPLEMENTAL RESTRAINT SYSTEM 6. Move the tires to the straight ahead position before removing the steering wheel. Install steering wheel puller onto steering wheel and remove steering wheel with J–29752. 7. Apply a setting mark (3) across the steering wheel and shaft so parts can be reassembled in their original position. 8. Feed wiring through the wheel and remove wheel. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit.

9J–31

5. Install air bag into steering wheel and tighten bolts (7) to specified sequence as show in figure. Torque: 8.8 N·m (78 lb in) CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly. The air bag assembly has identification colors on the bar code label as follows. Light blue color for driver air bag assembly. Light blue color for passenger air bag assembly. Use only the air bag assembly for “UP”.

827RX002

Installation 1. Install the steering wheel and align the setting marks (3). 2. Tighten the steering wheel fixing nut (4) to the specified torque. Torque: 34 N·m (25 lb ft) 3. Connect horn lead (1). 4. Connect air bag to wiring harness connector (2). NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of air bag to prevent lead wire from being pinched.

6. Enable the SRS. (Refer to “Enabling The SRS” in this section.)

9J–32

SUPPLEMENTAL RESTRAINT SYSTEM

SRS Coil Assembly Service Precaution WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWDER ON THE AIR BAG ASSEMBLY IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS.

11. Remove the steering column cover (3). 12. Disconnect the wiring harness connectors (10) located at the base of steering column. CAUTION: Never apply force to the steering wheel in the direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 13. Remove the combination switch assembly with SRS coil (9). NOTE: SRS coil is a part of combination switch assembly, which cannot be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly.

WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. NOTE: In the event deployment has occurred, inspect coil assembly wire for any signs of scorching, melting or any other damage due to excessive heat. If the coil has been damaged, replace it.

Removal 1. Disable the SRS. (Refer to “Disabling the SRS” in this section.) 2. Remove the air bag assembly (6) from steering wheel (7) by removing two bolts (8). Lift air bag assembly out of steering wheel. 3. Disconnect the 2–pin yellow connector (2) and remove air bag assembly. 4. Disconnect horn lead connector (1). 5. Remove the steering wheel attachment nut (5). 6. Move the tires to the straight ahead position before removing the steering wheel and remove wheel with J–29752. 7. Apply a setting mark (4) across the steering wheel and shaft so parts can be reassembled in their original position. 8. Feed wiring though the wheel and remove wheel. 9. Remove the steering lower cover. 10. Remove the driver knee bolster assembly.

825RX008

Installation 1. Install the combination switch assembly with SRS coil (9). 2. Connect the wiring harness connectors (10) located at the base of steering column. 3. Turn the SRS coil clockwise to full, return about 3 turns and align the neutral mark. NOTE: Whenever installing the new combination switch with SRS coil, be sure to tear off the lock pin for aligning the neutral position before it is installed to the base of steering column. CAUTION: When turning the SRS coil clockwise to full, stop turning if resistance is felt. Forced further turning may damage the cable in the SRS coil. 4. Install the steering column cover (3). CAUTION: When installing the steering column cover, be sure to through each harness as illustrated so that the harnesses starter switch, combination switch and SRS coil may not catch wiring. 5. Install the driver knee bolster assembly. 6. Install the steering lower cover.

SUPPLEMENTAL RESTRAINT SYSTEM 7. Install the steering wheel and align the setting marks (4). 8. Tighten the steering wheel fixing nut (5) to the specified torque. Torque: 34 N·m (25 lb ft) 9. Connect horn lead (1). 10. Connect air bag to wiring harness connector (2). NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of air bag to prevent lead wire from being pinched. 11. Install Air Bag (6) into steering wheel and tighten bolts (8) to specified sequence as figure. Torque: 8.8 N·m (78 lb in) CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly. The air bag assembly has identification colors on the bar code label as follows. Light blue color for driver air bag assembly. Light blue color for passenger air bag assembly. Use only the air bag assembly for “UP”.

825RX008

12. Enable the SRS. (Refer to “Enabling The SRS” in this section.)

9J–33

9J–34

SUPPLEMENTAL RESTRAINT SYSTEM

Steering Column Service Precaution WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWDER ON THE AIR BAG ASSEMBLY IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS. WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT.

9. Remove the steering lower cover. 10. Remove the driver knee bolster assembly. 11. Remove the steering column cover (1). 12. Disconnect the wiring harness connectors (10) located at the base of steering column. CAUTION: Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel. The steering shaft is designed as an energy absorbing unit. 13. Remove the combination switch assembly with SRS coil (9). NOTE: SRS coil is a part of combination switch assembly, which cannot be replaced separately. Therefore, be sure not to remove the SRS coil from the combination switch assembly. 14. Remove the snap ring. 15. Remove the cushion rubber. 16. Disconnect shift lock cable (A/T only) 17. Disconnect the starter switch harness connector (12) located base of steering column. 18. Remove steering lock cylinder assembly (11). 19. Remove steering column assembly (13).

NOTE: In the event deployment has occurred, inspect coil assembly wire for any signs of scorching, melting or any other damage due to excessive heat. If the coil has been damaged, replace it.

Removal 1. Disable the SRS. (Refer to “Disabling The SRS” in this section.) 2. Remove the air bag assembly (4) from steering wheel (2) by removing two bolts (5). Lift air bag assembly out of steering wheel. 3. Disconnect the 2–pin yellow connector (7) and remove air bag assembly. 4. Disconnect horn lead connector (8). 5. Remove the steering wheel attachment nut (3). 6. Move the tires to the straight ahead position before removing the steering wheel and removing wheel with J–29752. 7. Apply a setting mark (6) across the steering wheel and shaft so parts can be reassembled in their original position. 8. Feed wiring though the wheel and remove wheel.

431R200004

SUPPLEMENTAL RESTRAINT SYSTEM

Installation 1. Install the steering column assembly (13) and align the setting marks on the universal joint and steering shaft made during removal. 2. Tighten the steering column fixing bolts (dash panel side) to the specified torque. Torque: 20 N·m (14 lb ft) 3. Tighten the steering column fixing nuts (Cross beam) to the specified torque. Torque: 20 N·m (14 lb ft)

9J–35

17. Install air bag into steering wheel and tighten bolts (5) to specified sequence as shown in figure. Torque: 8.8 N·m (78 lb in) CAUTION: Never use the air bag assembly from another vehicle and difference model year air bag assembly. The air bag assembly has identification colors on the bar code label as follows. Light blue color for driver air bag assembly. Light blue color for passenger air bag assembly. Use only the air bag assembly for “UP”.

4. Tighten the universal joint to the specified torque. Torque: 31 N·m (23 lb ft) 5. Install steering lock cylinder assembly (11). 6. Connect shift lock cable (For A/T) 7. Install cushion rubber. 8. Install snap ring. 9. Install the combination switch assembly with SRS coil (9). 10. Connect the wiring harness connector (10) located on the base of steering column. 11. Turn the SRS coil clockwise to full, return about 3 turns and align the neutral mark. CAUTION: When turning the SRS coil clockwise to full, stop turning if resistance is felt. Further forced turning may damage the cable in the SRS coil. 12. Install steering column cover (1). CAUTION: When installing the steering column cover, be sure to wire (through each harness) as illustrated so that the harnesses starter switch, combination switch and SRS coil may not catch wiring. 13. Install the steering wheel (2) and align the setting marks (6). 14. Tighten the steering wheel fixing nut (3) to the specified torque. Torque: 34 N·m (25 lb ft) 15. Connect horn lead (8). 16. Connect air Bag wiring harness connector (7). NOTE: Pass the lead wire through the tabs on the plastic cover (wire protector) of air bag to prevent lead wire from being pinched.

431R200004

18. Enable the SRS (Refer to “Enabling The SRS” in this section.)

9J–36

SUPPLEMENTAL RESTRAINT SYSTEM

Passenger Air Bag Assembly Service Precaution

5. Remove passenger air bag assembly from glove box opening of instrument panel.

WARNING: SAFETY PRECAUTIONS MUST BE FOLLOWED WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT OF THE DEPLOYMENT REACTION, THAT IS IRRITATING TO THE SKIN AND EYES. MOST OF THE POWDER ON THE AIR BAG ASSEMBLY IS HARMLESS. AS A PRECAUTION, WEAR GLOVES AND SAFETY GLASSES WHEN HANDLING A DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR HANDS WITH MILD SOAP AND WATER AFTERWARDS. WARNING: WHEN CARRYING A LIVE AIR BAG ASSEMBLY, MAKE SURE THE BAG AND TRIM COVER ARE POINTED AWAY FROM YOU. NEVER CARRY AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE. IN THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN DEPLOY WITH MINIMAL CHANCE OF INJURY. WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE, ALWAYS FACE BAG AND TRIM COVER UP, AWAY FROM THE SURFACE. NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL. THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT. OTHERWISE, PERSONAL INJURY COULD RESULT. NOTE: In the event deployment has occurred, inspect coil assembly wire for any signs of scorching, melting or any other damage due to excessive heat. If the coil has been damaged, replace it.

Removal 1. Disable the SRS. (Refer to “Disabling the SRS” in this section.) 2. Remove glove box assembly. 3. Disconnect passenger air bag assembly harness connector. 4. Remove air bag assembly fixing bolts and nuts.

827RY00001

Legend (1) Passenger Air Bag Door (2) Passenger Air Bag Assembly (3) Passenger Air Bag Harness (4) Cross Beam

Installation 1. Install passenger air bag assembly from glove box opening of instrument panel. 2. Install air bag assembly fixing nuts and bolts, and tighten to specified torque. Torque: 7.8 N·m (69 lb in) 3. Connect air bag assembly harness connector. 4. Install glove box assembly. 5. Enable the SRS (Refer to “Enabling the SRS” in this section.)

SECTION RESTRAINT CONTROL SYSTEM

9J1–1

AXIOM

RESTRAINTS SRS CONTROL SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . Diagnostic Information . . . . . . . . . . . . . . . . . . . Diagnostic Procedures . . . . . . . . . . . . . . . . . Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . How To Read Trouble Codes . . . . . . . . . . . . How To Clear Trouble Codes . . . . . . . . . . . . Scan Tool Diagnostics . . . . . . . . . . . . . . . . . . Basic Knowledge Required . . . . . . . . . . . . . Basic Electrical Circuits . . . . . . . . . . . . . . . . . “Flash Code” Diagnostics . . . . . . . . . . . . . . . System Schematic . . . . . . . . . . . . . . . . . . . . . . SRS Diagnostic System Check . . . . . . . . . . . . Circuit Description . . . . . . . . . . . . . . . . . . . . . Notes On System Check Chart: . . . . . . . . . Diagnostic Aids: . . . . . . . . . . . . . . . . . . . . . . . Chart A SDM Integrity Check . . . . . . . . . . . . . Chart B “AIR BAG” Warning Lamp Comes “ON” Steady . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart C “AIR BAG” Warning Lamp Does Not Comes “ON” Steady . . . . . . . . . . . . . . . . . DTC 15 Passenger Deployment Loop Resistance High . . . . . . . . . . . . . . . . . . . . . . . .

9J1–1 9J1–2 9J1–2 9J1–2 9J1–2 9J1–2 9J1–2 9J1–2 9J1–2 9J1–3 9J1–3 9J1–4 9J1–4 9J1–4 9J1–4 9J1–6 9J1–8 9J1–10 9J1–13

DTC 16 Passenger Deployment Loop Resistance Low . . . . . . . . . . . . . . . . . . . . . . . . DTC 17 Passenger Deployment Loop Open DTC 18 Passenger Deployment Loop Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . DTC 19 Passenger Deployment Loop Short To Voltage . . . . . . . . . . . . . . . . . . . . . . . . DTC 21 Driver Deployment Loop Resistance High . . . . . . . . . . . . . . . . . . . . . . . . DTC 22 Driver Deployment Loop Resistance Low . . . . . . . . . . . . . . . . . . . . . . . . DTC 24 Driver Deployment Loop Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . DTC 25 Driver Deployment Loop Short To Voltage . . . . . . . . . . . . . . . . . . . . . . . . DTC 26 Driver Deployment Loop Open . . . . DTC 51 Deployment Event Commanded . . . DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range . . . . . . . . . . . . . . . . . DTC 61 Warning Lamp Circuit Failure . . . . . DTC 71 Internal SDM Fault . . . . . . . . . . . . . .

9J1–16 9J1–19 9J1–21 9J1–23 9J1–25 9J1–28 9J1–31 9J1–33 9J1–36 9J1–39

9J1–41 9J1–43 9J1–45

9J1–2

RESTRAINT CONTROL SYSTEM

Diagnostic Information Diagnostic Procedures WARNING: WHEN FASTENERS ARE REMOVED, ALWAYS REINSTALL THEN AT THE SAME LOCATION FROM WHICH THEY WERE REMOVED. IF A FASTENER NEEDS TO BE REPLACED, USE THE CORRECT PART NUMBER FASTENER FOR THAT APPLICATION. IF THE CORRECT PART NUMBER FASTENER IS NOT AVAILABLE, A FASTENER OF EQUAL SIZE AND STRENGTH (OR STRONGER) MAY BE USED. FASTENERS THAT ARE NOT REUSED, AND THOSE REQUIRING THREAD LOCKING COMPOUND WILL BE CALLED OUT. THE CORRECT TORQUE VALUE MUST BE USED WHEN INSTALLING FASTENERS THAT REQUIRE IT. IF THE ABOVE CONDITIONS ARE NOT FOLLOWED, PARTS OR SYSTEM DAMAGE COULD RESULT. WARNING: TO AVOID DEPLOYMENT WHEN TROUBLESHOOTING THE SRS, DO NOT USE ELECTRICAL TEST EQUIPMENT SUCH AS A BATTERY–POWERED OR AC–POWERED VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF ELECTRICAL EQUIPMENT OTHER THAN THAT SPECIFIED IN THIS MANUAL. DO NOT USE A NONPOWERED, PROBE–TYPE TESTER. INSTRUCTIONS IN THIS MANUAL MUST BE FOLLOWED CAREFULLY, OTHERWISE PERSONAL INJURY MAY RESULT. The diagnostic procedures used in this section are designed to aid in finding and repairing SRS problems. Outlined below are the steps to find and repair SRS problems quickly and effectively. Failure to carefully follow these procedures may result in extended diagnostic time, incorrect diagnosis and incorrect parts Replacement. 1. Perform The “SRS Diagnostic System Check.” The “SRS Diagnostic System Check” should always be the starting point of any SRS diagnostics. The “SRS Diagnostic System Check” checks for proper “AIR BAG” warning lamp operation and checks for SRS trouble codes using both “Flash Code” and “Scan Tool” Methods. 2. Refer To The Proper Diagnostic Chart As Directed By The “SRS Diagnostic System Check.” The “SRS Diagnostic System Check” will lead you to the correct chart to diagnose any SRS problems. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis and incorrect parts Replacement. 3. Repeat the “SRS Diagnostic System Check” After Any Repair Or Diagnostic Procedures Have Been Performed. Performing the “SRS Diagnostic System Check” after all repair or diagnostic procedures will assure that the repair has been made correctly and that no other conditions exist.

Diagnostic Codes The Sensing and Diagnostic Module (SDM) maintains a history record of all diagnostic codes that have been detected since the SRS codes were last cleared during service. 1. Active Codes—Faults that are presently detected this ignition cycle. Active codes are stored in RAM (Random Access Memory). 2. History Codes—All faults detected since the last time the history fault memory was cleared. History codes are stored in EEPROM. (Electronically Erasable Programmable Read only Memory)

How To Read Trouble Codes All codes (Active and history) can be read (or cleared) by using a scan tool or equivalent. If a DTC is not available, have the vehicle serviced by dealer.

How To Clear Trouble Codes Trouble codes can only be cleared by using a scan tool. If a scan tool is not available then inform the owner of the stored codes and suggest that the codes are cleared upon the next visit to a dealership.

Scan Tool Diagnostics A scan tool can be used to read current and history codes and to clear all history codes after a repair is complete. The scan tool must be updated to communicate with the SRS through a replaceable cartridge for SRS diagnostics. To use the scan tool, connect it to the DLC and turn the ignition switch “ON”. Then follow the manufacturer’s directions for communication with the SRS. The scan tool reads serial data from the SDM “Serial Data” output (terminal 24) to the DLC.

Basic Knowledge Required Before using this section of the Service Manual, there is some basic knowledge which will be required. Without this knowledge, you will have trouble using the diagnostic procedures in this section. Use care to prevent harm or unwanted deployment. Read all cautions in the service manual and on warning labels attached to SRS components.

Basic Electrical Circuits You should understand the basic theory of electricity including series and parallel circuits, and understand the voltage drops across series resistors. You should know the meaning of voltage (volts), current (amps), and resistance (ohms). You should understand what happens in a circuit with an open or a shorted wire. You should be able to read and understand a wiring diagram.

RESTRAINT CONTROL SYSTEM

“Flash Code” Diagnostics Flash code diagnostics can be used to read current codes and to determine if history codes are present but cannot be used to clear codes or read history codes. Flash code diagnostics is enabled by grounding by terminal 13 shorting to terminal 4 of the DLC with the ignition switch “ON”. Grounding terminal 13 of the DLC pulls the “Diagnostics Request” input (Terminal 1) of the SDM low and signals the SDM to enter the flash code diagnostic display mode. The SDM displays the trouble codes by flashing the warning lamp. Each code that is displayed will consist of a number of flashes which represents the tens digit, a 1.2 second pause, following by a number of flashes which represents the ones digit of the code. Each code is

9J1–3

displayed one time before moving on to the next code. After all of the codes have been displayed, the entire code sequence will continually by repeated until ground is removed from terminal 13 of the DLC. Two special codes exist when reading in the flash code mode (Flash Code 12 and Flash Code 13). “Flash Code 12” will always be the first code displayed when the flash code mode is enabled Code 12 is not an indication of a SRS problem but an indication that the flash code mode has been enabled. If there are no current or history codes present, the SDM will display code 12 until ground is removed from the DLC at terminal 13. “Flash Code 13” will be displayed if there are history codes. To read the history codes, a scan tool must be used.

System Schematic

D09R200001

9J1–4

RESTRAINT CONTROL SYSTEM

SRS Diagnostic System Check

Diagnostic Aids:

The diagnostic procedures used in this section are designed to find and repair SRS malfunctions. To get the best results, it is important to use the diagnostic charts and follow the sequence listed below: A. Perform the “SRS Diagnostic System Check.” The “SRS Diagnostic System Check” must be the starting point of any SRS diagnostics. The “SRS Diagnostic System Check” checks for proper “AIR BAG” warning lamp operation, the ability of the SDM to communicate through the “Serial Data” line and whether SRS diagnostic trouble codes exist.

The order in which diagnostic trouble codes are diagnosed is very important. Failure to diagnose the diagnostic trouble codes in the order specified may result in extended diagnostic time, incorrect diagnosis and incorrect parts Replacement.

B. Refer to the proper diagnostic chart as directed by the “SRS Diagnostic System Check.” The “SRS Diagnostic System Check” will lead you to the correct chart to diagnose any SRS malfunctions. Bypassing these procedures may result in extended diagnostic time, incorrect diagnosis and incorrect parts replacement. C. Repeat the “SRS Diagnostic System Check” after any repair or diagnostic procedures have been performed. Performing the “SRS Diagnostic System Check” after all repair or diagnostic procedures will ensure that the repair has been made correctly and that no other malfunctions exist

Circuit Description When the ignition switch is first turned “ON”, “ignition 1” voltage is applied from the “SRS–1” fuse to the SDM at the “ignition 1” input terminals “12”. The SDM responds by flashing the “AIR BAG” warning lamp seven times while performing tests on the SRS.

Notes On System Check Chart: Number(s) below refer to step number(s) on the “SRS Diagnostic System Check” chart. 1. The “AIR BAG” warning lamp should flash seven times after ignition is first turned “ON.” 2. After the “AIR BAG” warning lamp flashes seven times, it should turn “OFF.” 3. Improper operation of the “AIR BAG” warning lamp is indicated. This test differentiates a warning lamp stays “ON” condition from a warning lamp does not come “ON” condition. 4. This test checks for the proper operation of the “Serial Data” line. This test will also determine whether history diagnostic trouble codes are stored and, if so, identify them. 5. This test checks for proper operation of the “Serial Data” line. This test will also identify the stored diagnostic trouble codes and whether they are current or history.

RESTRAINT CONTROL SYSTEM

9J1–5

SRS Diagnostic System Check Step

Action

Confirm the “AIR BAG” warning lamp when ignition switch is turned “ON.” Does the “AIR BAG” warning lamp flash seven (7) times?

1. 2. 3. 4. 5.

Ignition switch “OFF.” Connect a scan tool to data link connector. Follow direction given in the scan tool instruction manual. Ignition switch “ON.” Request the SRS diagnostic trouble code display recode all history diagnostic trouble code(s) specify as such, on repair order.

Is diagnostic trouble code(s) displayed?

Go to Step 2

Go to Step 3

Go to Step 4

Go to Step 5

Go to Chart B.

Go to Chart C.

Ignition switch “OFF.” When DTC 71 is set, go to DTC 71 chart. For all other history codes refer to “Diagnostics Aids” for that specific DTC. A history DTC indicates the malfunction has been repaired or is intermittent.

SRS is functional and free of malfunctions, no further diagnosis is required. If scan tool indicates “No Data Received,” refer to chassis electrical section.

Ignition switch “OFF.” When DTC 53 is set, go to DTC 53 chart. When DTC 51 is set, go to DTC 51 chart. When DTC 19 is set, go to DTC 19 chart. When DTC 25 is set, go to DTC 25 chart. Diagnose remaining current DTCs from lowest to highest.When only history DTCs exist, Refer to “Diagnostics Aids” for that specific DTC. A history DTC indicates the malfunction has been repaired or is intermittent.

If scan tool indicates “No Data Received,” refer to chassis electrical section.

Confirm the “AIR BAG” warning lamp when ignition switch is turned “ON.” Does the “AIR BAG” warning lamp come “ON” steady?

Confirm the “AIR BAG” warning lamp after it flashed 7 times. Does the “AIR BAG” warning lamp go “OFF”?

Yes

1. 2. 3. 4. 5.

Ignition switch “OFF.” Connect a scan tool to data link connector. Follow directions as given in the scan tool instruction manual. Ignition switch “ON.” Request the SRS diagnostic trouble code display, recode all diagnostic trouble code(s), specifying as current or history on repair order.

Is diagnostic trouble code(s) displayed?

9J1–6

RESTRAINT CONTROL SYSTEM

Chart A SDM Integrity Check

D09R200001

Circuit Description:

Chart Test Description:

When the SDM recognizes “ignition 1” voltage, applied to terminals “12”, is greater than 9 volts, the “AIR BAG” warning lamp is flashed 7 times to verify operation. At this time the SDM performs “Turn–ON” tests followed by “Continuous Monitoring” tests. When a malfunction is detected, the SDM sets a current diagnostic trouble code and illuminates the “AIR BAG” warning lamp. The SDM will clear current diagnostic trouble codes and move them to a history file when the malfunction is no longer detected and/or the ignition switch is cycled, except for DTCs 51, 53 and 71. DTC 71 can only be cleared using a scan tool “Clear Codes” command in case that the malfunction on DTC 71 has been solved and no DTCs 51 and 53 were remained. DTCs 51, 53 and 71 can not be cleared after a “Clear Codes” command is issued.

Number(s) below refer to step number(s) on the diagnostic chart: 1. This test Confirm s a current malfunction. If no current malfunction is occurring (history DTC set) the “Diagnostic Aids” for the appropriate diagnostic trouble code should be referenced. The SDM should not be replaced for a history diagnostic trouble code. 2. This test checks for a malfunction introduced into the SRS during the diagnostic process. It is extremely unlikely that a malfunctioning SDM would cause a new malfunction to occur during the diagnostic process. 3. When all circuitry outside the SDM has been found to operate properly, as indicated by the appropriate diagnostic chart, then and only then should the SDM be replaced.

RESTRAINT CONTROL SYSTEM

9J1–7

Chart A SDM Integrity Check WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. Step

Action

1. This chart assumes that the “SRS Diagnostic System Check” and either a symptom chart or a diagnostic trouble code chart diagnosis have been performed When all circuitry outside the SDM has been found to operate properly, as indicated by the appropriate diagnostic chart, and the symptom or DTC remains current, the following diagnostic procedures must be performed to verify the need for SDM Replacement. 2. Ignition switch “OFF.” 3. Reconnect all SRS components, ensure all components are properly mounted. 4. Ensure the ignition switch has been “OFF” for at least 15 seconds. 5. Confirm “AIR BAG” warning lamp as ignition switch is turned “ON.” Does warning lamp flash 7 times then go “OFF”?

Using a scan tool, request diagnostic trouble code display. Is the same symptom or DTC occurring as was when the “SRS Diagnostic System Check ” was first performed?

1. Clear “SRS Diagnostic Trouble Codes.” 2. Ignition switch “OFF” for at least two minutes. 3. Confirm “AIR BAG” warning lamp as ignition switch is turned “ON.” Does warning lamp flash 7 times then go “OFF”?

Reconnect all SRS components, ensure all components are properly mounted. Was this step finished?

Yes

The symptom or DTC is no longer occurring. Clear SRS diagnostic trouble codes. Repeat the “SRS Diagnostic System Check.”

Go to Step 2

Ignition switch “OFF.” Go to the appropriate chart for the indicated malfunction.

Go to Step 3

SRS is functional and free of malfunctions. No further diagnosis is required. Go to Step 4

Ignition switch “OFF.” Replace SDM. Go to Step 4

Repeat the “SRS Diagnostic System Check.”

Go to Step 4

9J1–8

RESTRAINT CONTROL SYSTEM

Chart B “AIR BAG” Warning Lamp Comes “ON” Steady

D09R200001

Circuit Description:

Chart Test Description:

When the ignition switch is first turned “ON”, “ignition 1” voltage is applied from the “MA01” meter fuse to “AIR BAG”, warning lamp which is connected to “SRS warning lamp”, terminal “7”. The “SRS–1” fuses apply system voltage to the “ignition 1” inputs, terminals “12”. The SDM responds by flashing the “AIR BAG” warning lamp 7 times. If “ignition 1” voltage is less than 9 volts, the “AIR BAG” warning lamp will come “ON” solid with no DTCs set.

Number (s) below refer to step number (s) on the diagnostic chart. 2. This test checks for an open in the “ignition 1” circuit to the SDM. 3. This test checks for the voltage of “ignition 1.” 4. This test determines whether the malfunction is a short to ground in CKT IB04 – GRN.

RESTRAINT CONTROL SYSTEM

9J1–9

Chart B “AIR BAG” Warning Lamp Comes “ON” Steady Step

Action

1. When measurements are requested in this chart use J–39200 DVM with correct terminal adapter from J–35616–A. 2. Ignition switch “OFF.” 3. Connect scan tool to data link connector, Follow directions as given in the scan tool instruction manual. 4. Ignition switch “ON.” 5. Request SRS diagnostic trouble code display. Does scan tool indicate “No Data Received”?

Go to Step 2

Go to Step 3

Ignition switch “OFF.” Replace SDM. Go to Step 5

Connect SDM securely to de–activate shorting clip in SDM harness connector. Go to Step 5

Go to Step 4

Ignition switch “OFF.” Replace SDM. Go to Step 5

Go to Chart A.

Replace SRS harness. Go to Step 5

Repeat the “SRS Diagnostic System Check.”

Go to Step 5

1. Ignition switch “OFF.” 2. Inspect SDM harness connector connection to SDM. Is it securely connected to the SDM?

Yes

Using scan tool, request SRS data list. Is “ignition” more than 9 volts?

1. Ignition switch “OFF.” 2. Disconnect SRS coil and passenger air bag assemblies. Yellow 2–pin connectors located at base of steering column and behind the glove box assembly. 3. Disconnect SDM. 4. Measure resistance from SDM harness connector terminal “6” to ground. Does J–39200 display “0L” (infinite)?

Reconnect all SRS components, ensure all components are properly mounted. Was this step finished?

9J1–10 RESTRAINT CONTROL SYSTEM

Chart C “AIR BAG” Warning Lamp Does Not Comes “ON” Steady

D09R200001

Circuit Description: When the ignition switch is first turned “ON”, “ignition 1” voltage is applied from the “MA01” meter fuse to the “AIR BAG” warning lamp which is connected to “SRS warning lamp”, terminal “7”. The “SRS–1” fuse apply system voltage to the “ignition 1” inputs, terminals “12”. The SDM responds by flashing the “AIR BAG” warning lamp seven times. If “ignition 1” voltage is more than 16 volts, the “AIR BAG” warning lamp will be still “OFF” solid with no DTCs set.

Chart Test Description: Number(s) below refer to step number(s) on the diagnostic chart:

1. This test decides whether power is available to SDM warning lamp power feed circuit. 2. This test determines whether the voltage is present in the warning lamp circuit. 3. This test determines if the malfunction is in the instrument cluster. 4. This test checks for open in the warning lamp circuitry. 5. This test isolates the IB04–GRN circuit and checks for a short in the IB04–GRN circuit to B+. 8. This test checks for a short from the SDM warning lamp power feed circuit to ground. 9. This test determines whether the short to ground is due to a short in the wiring.

RESTRAINT CONTROL SYSTEM

9J1–11

Chart C “AIR BAG” Warning Lamp Does Not Comes “ON” Steady Step

Action

1. When measurements are requested in this chart use J–39200 DVM with correct terminal adapter from J–35616–A. 2. Ignition switch “OFF.” 3. Remove and inspect “MA01” meter fuse to the “AIR BAG” warning lamp. Is fuse good?

1. 2. 3. 4.

1. Install bulb. 2. Measure resistance from instrument meter cluster harness connector IB04–GRN terminal to SDM harness connector terminal “7”. Is resistance 5.0 ohms or less?

Go to Step 7

Go to Step 4

Go to Step 3

Go to Step 5

Replace bulb. Go to Step 6

Go to Chart A.

Replace SRS harness. Go to Step 6

Service instrument meter cluster. Go to Step 6

Replace SRS harness. Go to Step 6

Repeat the “SRS Diagnostic System Check.”

Go to Step 6

Go to Step 8

Go to Step 1

Install “MA01” meter fuse. Go to Step 10

Go to Step 9

Ignition switch “OFF.” Disconnect instrument meter cluster harness connector. Ignition switch “ON.” Measure voltage on SDM harness connector from terminal “7” to terminal “6” (ground).

Is voltage 1 volt or less? 5

Go to Step 2

1. Ignition switch “OFF.” 2. Remove instrument meter cluster. 3. Check for proper connection to instrument cluster at IB04–GRN terminal. 4. If OK, then remove and inspect “AIR BAG” bulb. Is bulb good?

1. Ignition switch “OFF.” 2. Disconnect SRS coil and passenger air bag assemblies. Yellow 2–pin connectors located at base of steering column and behind the glove box assembly. 3. Disconnect SDM. 4. Ignition switch “ON.” 5. Measure voltage on SDM harness connector from terminal “7” to terminal “6” (ground). Is system voltage present on terminal “7”?

Yes

Reconnect all SRS components, ensure all components are properly mounted. Was this step finished?

Were you sent here from chart C?

1. Replace “MA01” meter fuse. 2. Ignition switch “ON” wait 10 seconds then ignition switch “OFF.” 3. Remove and inspect “MA01” meter fuse. Is fuse good?

9J1–12 RESTRAINT CONTROL SYSTEM

Chart C “AIR BAG” Warning Lamp Does Not Comes “ON” Steady (Cont’d) Step

Action

1. Disconnect SRS coil and passenger air bag assemblies. Yellow 2–pin connectors located at base of steering column and behind the glove box assembly. 2. Disconnect SDM. 3. Replace “MA01” meter fuse. 4. Ignition switch “ON” wait to 10 seconds. 5. Ignition switch “OFF”. 6. Remove and inspection “MA01” meter fuse. Is fuse good?

Reconnect all SRS components, ensure all components are properly mounted. Was this step finished?

Yes

Install “MA01” meter fuse. Go to Chart A .

Replace SRS harness. Replace“MA01” meter fuse. Go to Step 10

Repeat the “SRS Diagnostic System Check.”

Go to Step 10

RESTRAINT CONTROL SYSTEM

9J1–13

DTC 15 Passenger Deployment Loop Resistance High

D09R200001

Circuit Description:

DTC Will Set When:

When the ignition switch is turned “ON”, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests “ignition 1”, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. The SDM then proceeds with the “Resistance Measurement Test”. “Passenger Bag Low” terminal “16” is grounded through a resister and the passenger current source connected to “Passenger Bag High” terminal “15” allows a known amount of current to flow. By monitoring the voltage difference between “Passenger Bag High” and “Passenger Bag Low” the SDM calculates the combined resistance of the passenger air bag assembly, harness wiring CKTs IB07–YEL/GRN and IB08–YEL/RED connector terminal contact.

The combined resistance of the passenger air bag assembly, harness wiring CKTs IB07–YEL/GRN and IB08–YEL/RED, and connector terminal contact is above a specified value. This test is run once each ignition cycle during the “Resistance Measurement Test” when: 1. No “higher priority faults” are detected during “Turn–ON.” 2. “Ignition 1” voltage is in the specified value.

Action Taken: SDM turns “ON” the “AIR BAG” warning lamp and sets a diagnostic trouble code.

DTC Will Clear When: The ignition switch is turned “OFF.”

9J1–14 RESTRAINT CONTROL SYSTEM

Diagnostic Aids: An intermittent condition is likely to be caused by a poor connection at the passenger air bag assembly harness connector terminals “1” and “2”, SDM terminal “15” and “16”, or a poor wire to terminal connection in CKTs IB07–YEL/GRN and IB08–YEL/RED. This test for this diagnostic trouble code is only run while the “AIR BAG” warning lamp is performing the bulb check, unless DTC 17 or DTC 26 is detected. When a scan tool “Clear Codes” command is issued and the malfunction is still present, the DTC will not reappear until the next ignition cycle.

RESTRAINT CONTROL SYSTEM

9J1–15

DTC 15 Passenger Deployment Loop Resistance High Step 1

Action

Go to Step 4

Seat passenger air bag assembly yellow 2–pin connector properly. Go to Step 7

Go to Step 5

Ignition switch “OFF.” Go to Step 7

Go to Step 6

Ignition switch “OFF.” Replace the passenger air bag assembly. Go to Step 7

Replace SRS harness. Go to Step 7

Go to Chart A .

Repeat the “SRS Diagnostic System Check.”

Go to Step 7

1. Ignition switch “OFF.” 2. Disconnect SRS coil and passenger air bag 2–pin connectors located at the base of the steering column and behind the glove box assembly. 3. Connect J–41433 SRS driver / passenger load tool and appropriate adapters to SRS coil and passenger air bag assembly harness connectors. 4. Ignition switch “ON.” 1. Ignition switch “OFF.” 2. There has been an increase in the total circuit resistance of the passenger inflator deployment loop. 3. Use the high resolution ohmmeter mode of the DVM while checking CKTs IB07–YEL/GRN and IB08–YEL/RED, and SDM connector terminal “15” and “16” to locate the root cause. Was a fault found?

Go to Chart A .

1. Disconnect and inspect the passenger air bag assembly yellow 2–pin connector located behind the glove box assembly. 2. If OK, reconnect the passenger air bag assembly 2–pin connector. 3. Ignition switch “ON.”

Is DTC 15 current? 6

Go to Step 3

1. Ignition switch “OFF.” 2. Make sure the passenger air bag assembly yellow 2–pin connector located behind the glove box assembly is seated properly.

Is DTC 15 current? 5

Go to Step 2

Go to the “SRS Diagnostic System Check.”

1. When measurements are requested in this chart use J–39200 DVM with correct terminal adapter from J–35616–A. 2. Use scan tool data list function, read and record the passenger deployment loop resistance.

Is the yellow 2–pin connector connected properly? 4

Was the “SRS Diagnostic System Check” performed?

Is passenger resist more than 2.9 ohms? 3

Yes

1. Reconnect all components ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished?

9J1–16 RESTRAINT CONTROL SYSTEM

DTC 16 Passenger Deployment Loop Resistance Low

D09R200001

Circuit Description:

DTC Will Set When:

When the ignition switch is turned “ON”, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests “ignition 1”, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. The SDM then proceeds with the “Resistance Measurement Test”. “Passenger Bag Low” terminal “16” is grounded through a resistor and the passenger current source connected to “Passenger Bag High” terminal “15” allows a known amount of current to flow. By monitoring the voltage difference between “Passenger Bag High” and “Passenger Bag Low”, the SDM calculates the combined resistance of the passenger air bag assembly, harness wiring CKTs IB07–YEL/GRN and IB08–YEL/RED connector terminal contact.

The combined resistance of the passenger air bag assembly, harness wiring CKTs IB07–YEL/GRN and IB08–YEL/RED, and connector terminal contact is above a specified value. This test is run once each ignition cycle during the “Resistance Measurement Test” when: 1. No “higher priority faults” are detected during “Turn–ON”, 2. “Ignition 1” voltage is in the specified value.

Action Taken: SDM turns “ON” the “AIR BAG” warning lamp and sets a diagnostic trouble code.

DTC Will Clear When: The ignition switch is turned “OFF.”

RESTRAINT CONTROL SYSTEM

DTC Chart Test Description: Number(s) below refer to step number(s) on the diagnostic chart: 2. This test determines whether the malfunction is in the SDM. 3. This test verifies connection of the yellow 2–pin connector. 4. This test cheeks for proper operation of the shorting clip in the yellow 2–pin connector. 5. The test checks for a malfunction passenger air bag assembly. 6. This test determines whether the malfunctioning is due to shorting in the wiring.

Diagnostic Aids: An intermittent condition is likely to be caused by a short between CKTs IB07–YEL/GRN and IB08–YEL/RED, or a malfunctioning shorting clip on the passenger air bag assembly which would require replacement of the air bag assembly. The test for this diagnostic trouble code is only run while “AIR BAG” warning lamp is performing the bulb check, unless DTC 17 or DTC 26 is detected. When a scan tool “Clear Codes” command is issued and the malfunction is still present, the DTC will not reappear until the next ignition cycle.

9J1–17

9J1–18 RESTRAINT CONTROL SYSTEM

DTC 16 Passenger Deployment Loop Resistance Low Step 1

Action

Go to Step 4

Seat passenger air bag assembly yellow 2–pin connector properly. Go to Step 7

Go to Step 5

Ignition switch “OFF.”Go to Step 7

Go to Step 6 .

Ignition switch “OFF.” Replace the passenger air bag assembly. Go to Step 7

Replace SRS harness. Go to Step 7

Go to Chart A .

Repeat the “SRS Diagnostic System Check.”

Go to Step 7

1. Ignition switch “OFF.” 2. Disconnect SRS coil and passenger air bag 2–pin connectors located at the base of the steering column and behind the glove box assembly. 3. Connect J–41433 SRS driver / passenger load tool and appropriate adapters to SRS coil and passenger air bag assembly harness connectors. 4. Ignition switch “ON.” 1. Ignition switch “OFF.” 2. There has been a decrease in the total circuit resistance of the passenger inflator deployment loop. 3. Use the high resolution ohmmeter mode of the DVM while checking CKTs IB07–YEL/GRN and IB08–YEL/RED, and SDM connector terminal “15” and “16” to locate the root cause. Was a fault found?

Go to Chart A .

Is DTC 16 current? 6

Go to Step 3

1. Ignition switch “OFF.” 2. Make sure the passenger air bag assembly yellow 2–pin connector located behind the glove box assembly is seated properly.

Us DTC 16 current? 5

Go to Step 2

Go to the “SRS Diagnostic System Check.”

1. When measurements are requested in this chart use J–39200 DVM with correct terminal adapter from J–35616–A. 2. Using scan tool data list function, read and record the passenger deployment loop resistance.

Is the yellow 2–pin connector connected properly? 4

Was the “SRS Diagnostic System Check” performed?

Is passenger resist. less than 1.4 ohms? 3

Yes

1. Reconnect all components, ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished?

RESTRAINT CONTROL SYSTEM

9J1–19

DTC 17 Passenger Deployment Loop Open

D09R200001

Circuit Description:

DTC Will Set When:

When the ignition switch is turned “ON”, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests, “ignition 1”, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. During “Continuous Monitoring” diagnostics, a fixed amount of current is flowing in the deployment loop. This produces proportional voltage drops in the loop. By monitoring the voltage difference between “Passenger Bag High” and “Passenger Bag Low”, the SDM calculates the combined resistance of the passenger air bag assembly, harness wiring CKTs IB07–YEL/GRN and IB08–YEL/RED, and connector terminal contact.

The voltage difference between “Passenger Bag High” terminal “15” and “Passenger Bag Low” terminal “16” is above or equal to a specified value for 500 milliseconds during “Continuous Monitoring”.

Action Taken: SDM turns “ON” the “AIR BAG” warning lamp and sets a diagnostic trouble code.

DTC Will Clear When: The voltage difference between “Passenger Bag High” terminal “15” and “Passenger Bag Low” terminal “16” is below a specified value for 500 milliseconds during “Continuous Monitoring”.

9J1–20 RESTRAINT CONTROL SYSTEM

5. The test checks for a malfunctioning passenger air bag assembly. 6. This test determines whether there is an open in the wiring.

Diagnostic Aids: An intermittent condition is likely to be caused by a poor connection at the passenger air bag assembly harness connector terminals “1” and “2,” SDM terminals “15” and “16,” or an open in CKT IB07–YEL/GRN and IB08–YEL/RED.

DTC 17 Passenger Deployment Loop Open Step 1

Action

Go to Step 4

Seat passenger air bag assembly yellow 2–pin connector properly. Go to Step 7

Go to Step 5

Ignition switch “OFF.” Go to Step 7

Go to Step 6

Ignition switch “OFF.” Replace the passenger air bag assembly. Go to Step 7

Replace SRS harness. Go to Step 7

Go to Chart A .

Repeat the “SRS Diagnostic System Check.”

Go to Step 7

1. Ignition switch “OFF.” 2. Disconnect SRS coil and passenger air bag assembly yellow 2–pin connectors located at the base of the steering column and behind the glove box assembly. 3. Connect J–41433 SRS driver / passenger load tool and appropriate adapters to SRS coil and passenger air bag assembly harness connectors. 4. Ignition switch “ON.” 1. Ignition switch “OFF.” 2. There has been an open circuit in the passenger inflator deployment loop. 3. Use the high resolution ohmmeter mode of the DVM while checking CKTs IB07–YEL/GRN and IB08–YEL/RED, and SDM connector terminal “15” and “16” to locate the root cause. Was a fault found?

Go to Chart A .

1. Disconnect and inspect the passenger air bag assembly yellow 2–pin connector located behind the glove box assembly. 2. If OK, reconnected the passenger air bag assembly yellow 2–pin connector. 3. Ignition switch “ON.”

Is DTC 17 current? 6

Go to Step 3

1. Ignition switch “OFF.” 2. Make sure the passenger air bag assembly yellow 2–pin connector located behind the glove box assembly is seated properly.

Is DTC 17 current? 5

Go to Step 2

Go to the “SRS Diagnostic System Check.”

Is the yellow 2–pin connector connected properly? 4

Was the “SRS Diagnostic System Check” performed?

Is passenger differential voltage. more than 4.0 volts? 3

Yes

1. Reconnect all components ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished?

RESTRAINT CONTROL SYSTEM

9J1–21

DTC 18 Passenger Deployment Loop Short To Ground

D09R200001

Circuit Description:

Action Taken:

SDM turns “ON” the “AIR BAG” warning lamp and sets a diagnostic trouble code.

DTC Will Set When: Neither of the two air bag assemblies is open. “Ignition 1” is within the normal operating voltage range. Once these conditions are met and the voltage at “Passenger Bag Low” is below a specified value, DTC 18 will set. This test is run once each ignition cycle and “Continuous Monitoring”.

DTC Will Clear When: This malfunction is no longer occurring and the ignition switch is turned “OFF”.

DTC Chart Test Description: Number(s) below refer to circled number(s) on the diagnostic chart: 2. This test determines whether the SDM is malfunctioning. 3. This test isolates the malfunction to one side of the passenger air bag assembly yellow 2–pin connector behind glove box compartment. 4. This test determines whether the malfunction is in CKT IB07–YEL/GRN.

9J1–22 RESTRAINT CONTROL SYSTEM 5. This test determines whether the malfunction is in CKT IB08–YEL/RED.

Diagnostic Aids:

Inspect CKTs IB07–YEL/GRN and IB08–YEL/RED carefully for cutting or chafing. If the wiring pigtail of the passenger air bag assembly is damaged, the component must be replaced.

An intermittent condition is likely to be caused by a short to ground in the passenger air bag assembly circuit.

DTC 18 Passenger Deployment Loop Short To Ground Step 1

Action

Go to Chart A .

Go to Step 4

Ignition switch “OFF.” Replace passenger air bag assembly. Go to Step 6

Go to Step 5

Replace SRS harness. Go to Step 6

Go to Chart A .

Replace SRS harness. Go to Step 6

Repeat the “SRS Diagnostic System Check.”

Go to Step 6

1. Ignition switch “OFF.” 2. Disconnect SRS driver / passenger load tool. 3. Measure resistance on SDM harness connector from terminal “15” to terminal “6” (ground). Measure resistance on SDM harness connector from terminal “6” “16” to terminal (ground). Does J–39200 display “0L” (infinite)?

Go to Step 3

1. Ignition switch “OFF.” 2. Disconnect passenger air bag assembly yellow 2–pin connector behind the glove box assembly.. 3. Leave driver air bag assembly connected. Connect SRS driver / passenger load tool J–41433 and appropriate adapter to passenger air bag assembly harness connector. 4. Ignition switch “ON.”

Does J–39200 display “0L” (infinite)? 5

Go to Step 2

Go to the “SRS Diagnostic System Check.”

1. When measurements are requested in this chart use J–39200 DVM with correct terminal adapter from J–35616–A. 2. Ignition switch “OFF.” 3. Connect scan tool data link connector. Follow directions as given in the scan tool operator’s manual. 4. Ignition switch “ON.” 5. Read passenger sense LO.

Is DTC 18 current? 4

Was the “SRS Diagnostic System Check” performed?

Is passenger sense LO less than 1.5 volts? 3

Yes

1. Reconnect all components, ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished?

RESTRAINT CONTROL SYSTEM

9J1–23

DTC 19 Passenger Deployment Loop Short To Voltage

D09R200001

Circuit Description:

Action Taken:

SDM turns “ON” the “AIR BAG” warning lamp and sets DTC 19 and also DTC 71.

DTC Will Set When: “Ignition 1” is within the normal operating voltage range. Once these conditions are met and the voltage at “Passenger Bag Low” is above a specified value, DTC 19 will set. This test is run once each ignition cycle and “Continuous Monitoring”.

DTC Will Clear When: The SDM is replaced.

DTC Chart Test Description: Number(s) below refer to step number(s) on the diagnostic chart: 2. This test determines whether the malfunction is in the SDM. 3. This test isolates the malfunction to one side of the passenger air bag assembly yellow 2–pin connector behind glove box compartment. 4. This test determines whether the malfunction is in CKT IB07–YEL/GRN.

9J1–24 RESTRAINT CONTROL SYSTEM 5. This test determines whether the malfunction is in CKT IB08–YEL/RED.

Diagnostic Aids: An intermittent condition is likely to be caused by a short to B+ in the passenger air bag assembly circuit. Inspect CKTs IB07–YEL/GRN and IB08–YEL/RED carefully for

cutting or chafing. If the wiring pigtail of the passenger air bag assembly is damaged, the component must be replaced. A careful inspection of CKT IB07–YEL/GRN and IB08–YEL/RED, including the passenger air bag assembly pigtail is essential to ensure that the replacement SDM will not be damaged.

DTC 19 Passenger Deployment Loop Short To Voltage CAUTION: When DTC 19 has been set, it is necessary to replace the SDM. Setting DTC 19 and 25 or 51 or 53 will also cause DTC 71 to set. When a scan tool “CLEAR CODES” command is issued and the malfunction is no longer present, DTC 71 will remain current. Ensure that the short to voltage condition is repaired prior to installing a replacement SDM to avoid damaging the SDM. Step 1

Action

1. 2. 3. 4.

Go to Step 4

Ignition switch “OFF.” Replace passenger air bag assembly. Go to Step 6

Go to Step 5

Replace SRS harness. Go to Step 6

Go to Chart A .

Replace SRS harness. Go to Step 6

Ignition switch “OFF.”Replace SDM.Go to Step 7

Go to Chart A .

Repeat the “SRS Diagnostic System Check.”

Go to Step 7

Measure resistance on SDM harness connector from terminal “16” to terminal “12” (IGNITION 1). 1. Reconnect all components, ensure all component are properly mounted. 2. Ignition switch “ON.” Is passenger sense LO less than 3.5 volts?

Go to Chart A .

Ignition switch “OFF.” Disconnect SDM. Disconnect SRS driver / passenger load tool. Measure resistance on SDM harness connector from terminal “15” to terminal “12” (IGNITION 1).

Does J–39200 display “0L” (infinite)? 6

Go to Step 3

1. Ignition switch “OFF.” 2. Disconnect passenger air bag assembly yellow 2–pin connector behind the glove box assembly. 3. Leave driver air bag assembly connected. 4. Connect SRS driver / passenger load tool J–41433 and appropriate adapter to passenger air bag assembly harness connector. 5. Ignition switch “ON.”

Does J–39200 display “0L” (infinite)? 5

Go to Step 2

Go to the “SRS Diagnostic System Check.”

Is passenger sense LO more than 3.5 volts? 4

Was the “SRS Diagnostic System Check” performed?

Is passenger sense LO more than 3.5 volts? 3

Yes

1. Reconnect all components, ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished?

RESTRAINT CONTROL SYSTEM

9J1–25

DTC 21 Driver Deployment Loop Resistance High

D09R200001

Circuit Description:

DTC Will Set When:

When the ignition switch is turned “ON”, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests, “ignition 1”, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. The SDM then proceeds with the “Resistance Measurement Test” “Driver Bag Low” terminal “4” is grounded through a current sink and the driver current source connected to “Driver Bag High” terminal “3” allows a known amount of current to flow. By monitoring the voltage difference between “Driver Bag High” and “Driver Bag Low”, the SDM calculates the combined resistance of the driver air bag assembly, SRS coil assembly, harness wiring CKTs IB05–YEL and IB06–YEL/BLK, and connector terminal contact.

The combined resistance of the driver air bag assembly, SRS Coil assembly, harness wiring CKTs IB05–YEL and IB06–YEL/BLK, and connector terminal contact is above a specified value. This test run once each ignition cycle during the “Resistance Measurement Test” when: No “higher priority faults” are detected during “Turn–ON” “Ignition 1” voltage is in the specified value.

Action Taken: SDM turns “ON” the “AIR BAG” warning lamp and sets DTC 21.

DTC Will Clear When: The ignition switch is turned “OFF”.

9J1–26 RESTRAINT CONTROL SYSTEM

DTC Chart Test Description: Number(s) below refer to step number(s) on the diagnostic chart: 2. This test determines whether the malfunction is in the SDM. 3. This test verifies proper connection of the yellow 2–pin connector at the base of the steering column. 4. This test checks for proper contact and/or corrosion of the 2–pin connector terminals at the base of steering column. 5. This test isolate the malfunction to one side of the SRS coil assembly yellow 2–pin connector located at the base of the steering column. 6. This test determines whether the malfunction is due to high resistance in the wiring. 7. This test determines whether the malfunction is in the SRS coil assembly or the driver air bag assembly.

Diagnostic Aids: An intermittent condition is likely to be caused by a poor connection at terminals “1” and “2” of the SRS coil 2–pin connector at the base of the steering column, terminal “1” and “2” of the driver air bag assembly 2–pin connector at the top of the steering column, SDM terminals “3” and “4” or a poor wire to terminal connection in CKT IB05–YEL or IB06–YEL/BLK. The test for this diagnostic trouble code is only run while the “AIR BAG” warning lamp is performing the bulb check, unless DTC 17 or DTC 26 is detected. When a scan tool “Clear Codes” command is issued and the malfunction is still present, the DTC will not reappear until the next ignition cycle.

RESTRAINT CONTROL SYSTEM

9J1–27

DTC 21 Driver Deployment Loop Resistance High Step 1

Action

1. Ignition switch “OFF.” 2. There has been a increase in the total circuit resistance of the driver deployment loop. 3. Use the high resolution ohmmeter mode of the DVM while checking CKTs IB05–YEL/IB06–GRN and YEL/BLK, and SDM connector terminal “3” and “4” to locate the root cause. 1. Ignition switch “OFF.” Disconnect SRS driver / passenger load tool from SRS coil assembly harness connector. Connect SRS driver / passenger load tool J–41433 on the top of steering column. Reconnect SRS coil assembly harness connector as the base of steering column. Ignition switch “ON.” Is DTC 21 current?

Go to Step 4

Seat SRS coil assembly 2–pin connector properly.Go to Step 8

Go to Step 5

Ignition switch “OFF.” Go to Step 8

Go to Step 6

Go to Step 7

Replace SRS harness. Go to Step 8

Go to Chart A .

Ignition switch “OFF.” Replace SRS COIL ASSEMBLY. Refer to in this section 9J–24. Go to Step 8

Ignition switch “OFF.” Replace driver air bag assembly. Go to Step 8

Repeat the “SRS Diagnostic System Check.”

Go to Step 8 .

1. Ignition switch “OFF.” 2. Disconnect SRS coil and passenger air bag assembly yellow 2–pin connectors located at the base of steering column and behind the glove box assembly. 3. Connect SRS driver / passenger load tool J–41433 and appropriate adapter to SRS coil and passenger air bag assembly harness connectors. 4. Ignition switch “ON.”

Was a fault found? 7

Go to Chart A .

1. Disconnect and inspect the SRS coil assembly yellow 2–pin connector located base of steering column. 2. If OK, reconnect the SRS coil assembly yellow 2–pin connector. 3. Ignition switch “ON.”

Is DTC 21 current? 6

Go to Step 3

1. Ignition switch “OFF.” 2. Disconnect driver air bag assembly yellow 2–pin connector located at base of steering column is seated properly.

Is DTC 21 current? 5

Go to Step 2

Go to the “SRS Diagnostic System Check.”

1. When measurements are requested in this chart use J–39200 DVM with correct terminal adapter from J–35616–A. 2. Use scan tool data list function, read and record the driver deployment loop resistance.

Is the 2–pin connector connected properly? 4

Was the “SRS Diagnostic System Check” performed?

Is driver deployment loop resistance more than 4.4 ohms? 3

Yes

Reconnect all components, ensure all component are properly mounted. Clear diagnostic trouble codes. Was this step finished?

9J1–28 RESTRAINT CONTROL SYSTEM

DTC 22 Driver Deployment Loop Resistance Low

D09R200001

Circuit Description:

DTC Will Set When:

When the ignition switch is turned “ON”, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests “ignition 1”, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges.The SDM then proceeds with the “Resistance Measurement Test” “Driver Bag Low” terminal “4” is grounded through a current sink and the driver current source connected to “Driver Bag High” terminal “3” allows a known amount of current to flow. By monitoring the voltage difference between “Driver Bag High” and “Driver Bag Low” the SDM calculates the combined resistance of the driver air bag assembly, SRS coil assembly, harness wiring CKTs IB05–YEL and IB06–YEL/BLK and connector terminal contact.

The combined resistance of the driver air bag assembly, SRS coil assembly, harness wiring CKTs IB05–YEL and IB06–YEL/BLK and connector terminal contact is above a specified value. This test is run once each ignition cycle during the “Resistance Measurement Test” when: 1. No “higher priority faults” are detected during “Turn–ON” 2. “Ignition 1” voltage is in the specified value.

Action Taken: SDM turns “ON” the “AIR BAG” warning lamp and sets DTC 22.

DTC Will Clear When: The ignition switch is turned “OFF.”

RESTRAINT CONTROL SYSTEM

DTC Chart Test Description: Number(s) below refer to step number(s) on the diagnostic chart: 2. This test determines whether the malfunction is in the SDM. 3. This test verifies proper connection of the yellow 2–pin connector at the base of the steering column. 4. This test checks for proper operation of the shorting clip in the yellow 2–pin connector. 5. This test isolate the malfunction to one side of the SRS coil assembly yellow 2–pin connector located at the base of steering column. 6. This test determines whether the malfunction is due to shorting in the wiring. 7. This test determines whether the malfunction is in the SRS coil assembly or the driver air bag assembly.

Diagnostic Aids: An intermittent condition is likely to be caused by a short between CKT IB05–YEL or IB06–YEL/BLK or a malfunctioning shorting clip on the driver air bag assembly or SRS coil assembly which would require replacement of the component. The test for this diagnostic trouble code is only run while the “AIR BAG” warning lamp is performing the bulb check, unless DTC 17 or DTC 26 is detected. When a scan tool “Clear Codes” command is issued and the malfunction is still present, the DTC will not reappear until the next ignition cycle.

9J1–29

9J1–30 RESTRAINT CONTROL SYSTEM

DTC 22 Driver Deployment Loop Resistance Low Step 1

Action

1. Ignition switch “OFF.” 2. There has been a decrease in the total circuit resistance of the driver deployment loop. 3. Use the high resolution ohmmeter mode of the DVM while checking CKTs IB05–YEL and IB06–YEL/BLK, and SDM connector terminal “3” and “4” to locate the root cause. 1. Ignition switch “OFF.” 2. Disconnect SRS driver / passenger load tool from SRS coil assembly harness connector. 3. Connect SRS driver / passenger load tool J–41433 to the top of steering column. 4. Reconnect SRS coil assembly harness connector as the base of steering column. 5. Ignition switch “ON.” Is DTC 22 current?

Go to Step 4

Seat driver air bag assembly 2–pin connector properly. Go to Step 8

Go to Step 5

Ignition switch “OFF.” Go to Step 8

Go to Step 6

Go to Step 7

Replace SRS harness. Go to Step 8

Go to Chart A .

Ignition switch “OFF.” Replace SRS coil assembly. Refer to in this section 9J–24. Go to Step 8

Ignition switch “OFF.” Replace driver air bag assembly. Go to Step 8

Repeat the “SRS Diagnostic System Check.”

Go to Step 8

1. Ignition switch “OFF.” 2. Disconnect SRS coil and passenger air bag 2–pin connectors located at the base of steering column and behind the glove box assembly. 3. Connect SRS driver / passenger load tool J–41433 and appropriate adapter to SRS coil and passenger air bag assembly harness connectors. 4. Ignition switch “ON.”

Was a fault found? 7

Go to Chart A .

1. Disconnect and inspect the SRS coil assembly yellow 2–pin connector located base of steering column. 2. If OK, reconnect the driver air bag assembly yellow 2–pin connector. 3. Ignition switch “ON.”

Is DTC 22 current? 6

Go to Step 3

1. Ignition switch “OFF.” 2. Make sure the SRS coil assembly yellow 2–pin connector located at the base of steering column is seated properly.

Is DTC 22 current? 5

Go to Step 2

Go to the “SRS Diagnostic System Check.”

Is the 2–pin connector connected properly? 4

Was the “SRS Diagnostic System Check” performed?

Is driver resist. less than 1.9 ohms? 3

Yes

1. Reconnect all components, ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished?

RESTRAINT CONTROL SYSTEM

9J1–31

DTC 24 Driver Deployment Loop Short To Ground

D09R200001

Circuit Description:

Action Taken:

SDM turns “ON” the “AIR BAG” warning lamp and sets a diagnostic trouble code.

DTC Will Set When: Neither of the two air bag assemblies is open. “Ignition 1” is within the normal operating voltage range. This test is run once each ignition cycle and “Continuous Monitoring”. Once these conditions are met and the voltage at “Driver Bag Low” is below a specified value, DTC 24 will set.

DTC Will Clear When: The malfunction is no longer occurring and the ignition is turned “OFF.”

DTC Chart Test Description: Number(s) below refer to step number(s) on the diagnostic chart: 2. This test determines whether the SDM is malfunctioning 3. This test isolates the malfunction to one side of the SRS coil assembly yellow 2–pin connector at the base of the steering column. 4. This test determines whether the malfunction is in CKT IB05–YEL.

9J1–32 RESTRAINT CONTROL SYSTEM 5. This test determines whether the malfunction is in CKT IB06–YEL/BLK. 6. This test determines whether the malfunction is in the SRS coil assembly or the driver air bag assembly.

Diagnostic Aids: An intermittent condition is likely to be caused by a short to ground in the driver air bag assembly circuit. Inspect CKTs IB05–YEL and IB06–YEL/BLK carefully for cutting or chafing.

DTC 24 Driver Deployment Loop Short To Ground Step 1

Action

1. 2. 3. 4.

Go to Step 4

Go to Step 6

Go to Step 5

Replace SRS harness. Go to Step 7

Go to Chart A .

Replace SRS harness. Go to Step 7

Ignition switch “OFF.” Replace SRS coil assembly. Refer to in this section 9J–24. Go to Step 7

Ignition switch “OFF.” Replace driver air bag assembly. Go to Step 7

Repeat the “SRS Diagnostic System Check.”

Go to Step 7

Measure resistance on SDM harness connector from terminal “4” to terminal “6” (ground). 1. Ignition switch “OFF.” 2. Disconnect SRS driver / passenger load tool J–41433 from SRS coil assembly harness connector. 3. Connect SRS driver / passenger load tool J–41433 and appropriate adapter J–35616–A to driver air bag assembly harness connector. Located top of the steering column. 4. Reconnect SRS coil assembly harness connector as the base of steering column. 5. Ignition switch “ON.” Is DTC 24 current?

Go to Chart A .

Ignition switch “OFF.” Disconnect SDM. Disconnect SRS driver / passenger load tool. Measure resistance on SDM harness connector “3” to terminal “6” (ground).

Does J–39200 display “0L” (infinite)? 6

Go to Step 3

1. Ignition switch “OFF.” 2. Disconnect SRS coil assembly yellow 2–pin connector located at base of the steering column. Leave passenger air bag assembly connected. 3. Connect SRS driver / passenger load tool J–41433 and appropriate adapter to SRS coil assembly harness connector. 4. Ignition switch “ON.”

Does J–39200 display “0L” (infinite)? 5

Go to Step 2

Go to the “SRS Diagnostic System Check.”

Is DTC 24 current? 4

Was the “SRS Diagnostic System Check” performed?

Is driver sense LO less than 1.5 volts? 3

Yes

1. Reconnect all components, ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished?

RESTRAINT CONTROL SYSTEM

9J1–33

DTC 25 Driver Deployment Loop Short To Voltage

D09R200001

Circuit Description:

Action Taken:

SDM turns “ON” the “AIR BAG” warning lamp and sets DTC 25 and also DTC 71

DTC Will Set When: “Ignition 1” is in the normal operating voltage range. This test is run once each ignition cycle and “Continuous Monitoring”. Once these conditions are met and the voltage at “Driver Bag Low” is above a specified value, DTC 25 will set.

DTC Will Clear When: The SDM is replaced.

DTC Chart Test Description: Number(s) below refer to step number(s) on the diagnostic chart: 2. This test determines whether the SDM is malfunctioning. 3. This test isolates the malfunction to one side of the SRS coil assembly yellow 2–pin connector at the base of steering column. 4. This test determines whether the malfunction is in CKT IB05–YEL. 5. This test determines whether the malfunction is in CKT IB06–YEL/BLK.

9J1–34 RESTRAINT CONTROL SYSTEM 6. This test determines whether the malfunction is in the SRS coil assembly or the driver air bag assembly.

Diagnostic Aids: An intermittent condition is likely to be caused by a short to B+ in the driver air bag assembly circuit. Inspect CKTs IB05–YEL and IB06–YEL/BLK carefully for cutting or chafing. If the wiring pigtail of the driver air bag assembly and SRS coil assembly is damaged, the components must be replaced. A careful inspection of CKT IB05–YEL and IB06–YEL/BLK, including the SRS coil assembly and driver air bag assembly is essential to ensure that the replacement SDM will not be damaged.

RESTRAINT CONTROL SYSTEM

9J1–35

DTC 25 Driver Deployment Loop Short To Ignition CAUTION: When DTC 25 has been set, it is necessary to replace the SDM. Setting DTC 25 will also cause DTC 71 to set. When a scan tool “CLEAR CODES” command is issued and the malfunction is no longer present, DTC 71 will remain current. Ensure that the short to voltage condition is repaired prior to installing a replacement SDM to avoid damaging the SDM. Action

Step 1

1. 2. 3. 4.

1. Ignition switch “OFF.” 2. Connect SRS driver / passenger load tool J–41433 and appropriate adapter J–35616–A to driver air bag assembly harness connector located of top of the steering column. 3. Reconnect SRS coil assembly harness connector as the base of steering column. 4. Ignition switch “ON.” 1. Reconnect all components, ensure all components are properly mounted. 2. Ignition switch “ON.” Is passenger sense LO less than 3.5 volts?

Go to Step 4

Go to Step 6

Go to Step 5

Replace SRS harness. Go to Step 7

Go to Chart A .

Replace SRS harness. Go to Step 7

Ignition switch “OFF.” Replace SRS coil assembly. Go to Step 7

Ignition switch “OFF.” Replace driver air bag assembly. Go to Step 7

Replace SDM. Go to Step 8

Go to Chart A .

Repeat the “SRS Diagnostic System Check.”

Go to Step 8

Measure resistance on SDM harness connector from terminal “4” to terminal “12” (Ignition 1).

Is driver sense LO more than 3.5 volts? 7

Go to Chart A .

Ignition switch “OFF.” Disconnect SDM. Disconnect SRS drive / passenger load tool. Measure resistance on SDM harness connector from terminal “3” to terminal “12” (Ignition 1).

Does J–39200 display “0L” (infinite)? 6

Go to Step 3

1. Ignition switch “OFF.” 2. Disconnect SRS coil assembly yellow 2–pin connector at the base of the steering column. Leave passenger air bag assembly connected. Connect SRS driver / passenger load tool J–41433 and appropriate adapter to SRS coil assembly harness connector. 3. Ignition switch “ON.”

Does J–39200 display “0L” (infinite)? 5

Go to Step 2

Go to the “SRS Diagnostic System Check.”

Is driver sense LO more than 3.5 volts? 4

Was the “SRS Diagnostic System Check” performed?

Is driver sense LO more than 3.5 volts? 3

Yes

1. Reconnect all components, ensure all components are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished?

9J1–36 RESTRAINT CONTROL SYSTEM

DTC 26 Driver Deployment Loop Open

D09R200001

Circuit Description: When the ignition switch is turned “ON”, the SDM will perform tests to diagnose critical malfunctions within itself. Upon passing these tests, “ignition 1”, and deployment loop voltages are measured to ensure they are within their respective normal voltage ranges. During “Continuous Monitoring” diagnostics, a fixed amount of current is following in the deployment loop. This produces proportional voltage drops in the loop. By monitoring the voltage difference between “Driver Bag High” and “Driver Bag Low”, the SDM calculates the combined resistance of the driver air bag assembly, SRS coil assembly, harness wiring CKTs IB05–YEL and IB06–YEL/BLK, and connector terminal contact.

DTC Will Set When: The voltage difference between “Driver Bag High” terminal “3” and “Driver Bag Low” terminal “4” is above or

equal to a specified value for 500 milliseconds during “Continuous Monitoring.”

Action Taken: SDM turns “ON” the “AIR BAG” warning lamp and sets a diagnostic trouble code.

DTC Will Clear When: The voltage difference between “Driver Bag High” terminal “3” and “Driver Bag Low” terminal “4” is below a specified value for 500 milliseconds during “Continuous Monitoring.”

DTC Chart Test Description: Number(s) below refer to circled number(s) on the diagnostic chart: 1. This test determines whether the malfunction is in the SDM.

RESTRAINT CONTROL SYSTEM 2. This test verifies proper connection of the yellow 2–pin connector at the base of the steering column. 3. This test checks for proper contact and/or corrosion of the yellow 2–pin connector at the base of the steering column. 4. This test isolates the malfunction to one side of the SRS coil assembly yellow 2–pin connector located at the base of steering column. 5. This test determines whether the open is in the wiring. 6. This test determines whether the malfunction is in the SRS coil assembly or the driver air bag assembly.

Diagnostic Aids: An intermittent condition is likely to be caused by a poor connection at the driver air bag assembly harness 2–pin connector terminals “1” and “2” at the top of the steering column, SRS coil assembly harness 2–pin connection terminals “1” and “2”, SDM terminals “3” and “4”, or an open in CKTs IB05–YEL and IB06–YEL/BLK.

9J1–37

9J1–38 RESTRAINT CONTROL SYSTEM

DTC 26 Driver Deployment Loop Open Step 1

Action

1. Ignition switch “OFF.” 2. There has been an open circuit in the driver deployment loop. Use the high resolution ohmmeter mode of the DVM while checking CKTs IB05 YEL and IB06 YEL/BLK, and SDM connector terminal “3” AND “4” to locate the root cause.

1. Ignition switch “OFF.” 2. Disconnect SRS driver / passenger load tool from SRS coil assembly harness connector. 3. Connect SRS driver / passenger load tool J–41433 on steering column. 4. Reconnect SRS coil assembly harness connector as the base of steering column. 5. Ignition switch “ON.” Is DTC 26 current?

Go to Step 4

Seat driver air bag assembly 2–pin connector. Go to Step 8

Go to Step 5

Ignition switch “OFF.” Go to Step 8

Go to Step 6

Go to Step 7

Replace SRS harness. Go to Step 8

Go to Chart A .

Ignition switch “OFF.” Replace SRS coil assembly, refer to in this section 9J–3. Go to Step 8

Ignition switch “OFF.” Replace driver air bag assembly. Go to Step 8

Repeat the “SRS Diagnostic System Check.”

Go to Step 8

1. Ignition switch “OFF.” 2. Disconnect SRS coil and passenger air bag assembly, yellow 2–pin connectors located at the base of steering column and behind the glove box assembly. 3. Connect SRS driver / passenger load tool J–41433 and appropriate adapter to SRS coil and passenger air bag assembly harness connectors. 4. Ignition switch “ON.”

Was a fault found? 7

Go to Chart A .

Is DTC 26 current? 6

Go to Step 3

1. Ignition switch “OFF.” 2. Make sure the SRS coil assembly yellow 2–pin connector located at the base of steering column is seated properly.

Is DTC 26 current? 5

Go to Step 2

Go to the “SRS Diagnostic System Check.”

1. When measurements are requested in this chart use J–39200 DVM with correct terminal adapter from J–35616–A. 2. Use scan tool data list function, read and record the driver differential voltage.

Is the yellow 2–pin connector connected properly? 4

Was the “SRS Diagnostic System Check” performed?

Is driver differential voltage more than 4.0 volts? 3

Yes

1. Reconnect all components, ensure all component are properly mounted. 2. Clear diagnostic trouble codes. Was this step finished?

RESTRAINT CONTROL SYSTEM

9J1–39

DTC 51 Deployment Event Commanded

D09R200001

Circuit Description:

Action Taken:

The SDM contains a sensing device which converts vehicle velocity changes to an electrical signal. The electrical signal generated is processed by the SDM and then compared to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the air bag assembly deploying the air bags and causing DTC 51 to set.

SDM turns “ON” the “AIR BAG” warning lamp records “Crash Data”, and sets a diagnostic trouble code.

DTC Will Set When: The SDM detects a frontal crash, up to 30 degrees off the centerline of the vehicle, of sufficient force to warrant deployment of the air bags.

DTC Will Clear When: The SDM is replaced.

DTC Chart Test Description: Number(s) below refer to step number(s) on the diagnostic chart: 2. If air bag assembly (s) has not deployed, DTC 51 may have falsely set. 3. If DTC 51 has set with no signs of frontal impact, the diagnostic trouble code has falsely set.

9J1–40 RESTRAINT CONTROL SYSTEM

DTC 51 Deployment Event Commanded WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. Action

Step 1

Go to Step 2

Go to the “SRS Diagnostic System Check.”

Replace components and perform inspections as directed in “repairs and inspections required after an accident” in this section. Clear diagnostic trouble codes. Repeat the “SRS Diagnostic System Check.”

Go to Step 3

Ignition switch “OFF.” Replace SDM. Reconnect all SRS system components, ensure all components are properly mounted.Repeat the “SRS Diagnostic System Check.”

Was the “SRS Diagnostic System Check” performed?

Ignition switch “OFF.” Have air bag assemblies deployed?

Yes

Inspect front of vehicle and undercarriage for signs of impact. Were signs of impact found?

RESTRAINT CONTROL SYSTEM

9J1–41

DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range

D09R200001

Circuit Description:

Action Taken:

The SDM contains a sensing drive which converts vehicle velocity changes to an electrical signal. The electrical signal generated is processed by the SDM and then compared to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the air bag assembly deploying the air bags. DTC 53 is set accompanying with DTC 51 when a deployment occurs while an air bag assembly circuit fault is present that could possible result in a no deployment situation in one or both air bag assemblies.

SDM turns “ON” the “AIR BAG” warning lamp records “Crash Data”, and sets a diagnostic trouble code.

DTC Will Set When: The SDM detects a frontal crash, up to 30 degrees off the centerline of the vehicle, of sufficient force to warrant deployment of the air bags and an inflator circuit fault is present.

DTC Will Clear When: The SDM is replaced. If DTC 53 is set, one or more DTCs will be set in addition to DTC 53. Malfunction(s) setting DTC(s) (other than DTC 71) must be repaired so that DTC(s) will not be set when a new SDM is installed.

DTC Chart Test Description: Number(s) below refer to step number(s) on the diagnostic chart: 2. If air bag assembly has not deployed, DTC 53 may have falsely set. 3. If DTC 53 has set with no signs of frontal impact, the diagnostic trouble code has falsely set.

9J1–42 RESTRAINT CONTROL SYSTEM

DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. Step 1

Action

Go to Step 2

Go to the “SRS Diagnostic System Check.”

Go to Step 3

Ignition switch “OFF.” Replace SDM. Reconnect all SRS system components, ensure all components are properly mounted. Repeat the “SRS Diagnostic System Check.”

Was the “SRS Diagnostic System Check” performed?

Ignition switch “OFF.” Have air bag assemblies deployed?

Yes

Inspect front of vehicle and undercarriage for signs of impact. Were signs of impact found?

RESTRAINT CONTROL SYSTEM

9J1–43

DTC 61 Warning Lamp Circuit Failure

D09R200001

Circuit Description: When the ignition switch is turned “ON”, battery voltage is applied to the “AIR BAG” warning lamp and to the “ignition 1” input terminal “12”. The SDM responds by flashing the “AIR BAG” warning lamp seven times. The SDM monitors the lamp driver output by comparing the output state at “SRS warning lamp” terminal “7” to the microprocessor commanded state. When “ignition 1” is in the specified value, and the output state Does not match the commanded state of the lamp driver for 500 milliseconds, DTC 61 is set.

the commanded state of the lamp driver for 500 milliseconds. This test is run every 100 milliseconds during “Continuous Monitoring” tests and once per each ignition cycle at the beginning.

Action Taken: SDM attempts to turn “ON” the “AIR BAG” warning lamp and sets a diagnostic trouble code.

DTC Will Clear When: The ignition switch is turned “OFF.”

DTC Will Set When:

Diagnostic Aids:

“Ignition 1” voltage is in the specified value and the output state at the “SRS warning lamp” terminal does not match

Refer to Charts B and C to diagnose warning lamp circuit malfunctions.

9J1–44 RESTRAINT CONTROL SYSTEM

DTC 61 Warning Lamp Circuit Failure Step 1

Action

Yes

Go to Step 2

Go to the “SRS Diagnostic System Check.”

Ignition switch “OFF.” Go to Chart A .

Repeat the “SRS Diagnostic System Check.”

Was the “SRS Diagnostic System Check” performed?

1. Malfunctions within the “AIR BAG” warning lamp circuitry will set this diagnostic trouble code. 2. These malfunctions are addressed in the “SRS Diagnostic System Check” via Chart B and Chart C. 3. Failure to properly perform the “SRS Diagnostic System Check” may result in misdiagnosis. 4. Ignition switch “ON.” 5. Clear SRS diagnostic trouble codes. Is DTC 61 SET?

RESTRAINT CONTROL SYSTEM

9J1–45

DTC 71 Internal SDM Fault

D09R200001

Circuit Description:

DTC Will Set When:

DTC 71 is an indication of a potential internal SDM malfunction and will set if any of the following conditions are detected: 1) Deployment or microprocessor energy reserve failure. 2) EEPROM failure. 3) ROM failure. 4) RAM failure. 5) Calibration check sum failure. 6) Deployment switch faults. 7) Accelerometer fault. Arming sensor fault. 9) Diagnostic current faults. 10) DTC 19 11) DTC 25 12) DTC 51 13) DTC 53

Any of the above indicated malfunctions are detected by the SDM. The malfunctions described above are tested mainly during “Continuous Monitoring” and some ones run each ignition cycle.

Action Taken: SDM turns “ON” the “AIR BAG” warning lamp and sets a diagnostic trouble code.

DTC Will Clear When: A scan tool “Clear Codes” commanded is received by the SDM. Some of the indicated malfunctions will only allow the “AIR BAG” warning lamp to go out. But when DTC 19, 25, 51, 53 are also set, SDM is Replaced.

9J1–46 RESTRAINT CONTROL SYSTEM

DTC 71 Internal SDM Fault WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN PERSONAL INJURY. CAUTION: When DTC 19 or 25 or 51 or 53 has been set it is necessary to Replace the SDM. Setting DTC 19 and 25 or 51 or 53 will also cause DTC 71 to set. When a scan tool “CLEAR CODES” command is issued and the malfunction is no longer present, DTC 51 or 53 and DTC 71 will remain current. Ensure that the short to voltage condition DTC 19, 25 is repaired prior to installing a Replacement SDM to avoid damaging the SDM. Step 1

Action

Yes

Go to Step 2

Go to the “SRS Diagnostic System Check.”

Go to DTC 19 if DTC 19 is set. Go to DTC 25 if DTC 25 is set. Go to DTC 51 if DTC 51 is set. Go to DTC 53 if DTC 53 is set.

Ignition switch “OFF.” Replace SDM. Repeat the “SRS Diagnostic System Check.”

Was the “SRS Diagnostic System Check” performed?

Confirm SRS “Diagnostic System Check.” Is DTC 19 or 25 or 51 or 53 also set (current or history)? (Refer to notice above).

SECTION CRUISE CONTROL SYSTEM

10A–1

AXIOM

CONTROL SYSTEM CRUISE CONTROL SYSTEM CONTENTS Service Precaution . . . . . . . . . . . . . . . . . . . . . . General Description . . . . . . . . . . . . . . . . . . . . . Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . Powertrain Control Module (PCM) . . . . . . . . . Removal and Installation . . . . . . . . . . . . . . . Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A–1 10A–1 10A–2 10A–2 10A–2 10A–3 10A–3 10A–3

Removal and Installation . . . . . . . . . . . . . . . Cruise Control Main Switch . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cruise Control Switch (Combination Switch) Removal and Installation . . . . . . . . . . . . . . . Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10A–3 10A–3 10A–3 10A–3 10A–3 10A–3 10A–4

Service Precaution

General Description

The cruise control keeps the vehicle running at a fixed speed until a signal canceling this fixed speed is received. When the main switch “AUTO CRUISE” is turned on with the vehicle in the running mode, the battery voltage is applied to the PCM. When a signal from the control switch is input to the PCM while the vehicle is in this state, the cruise control system is activated. Also, while the system is operating, the “AUTO CRUISE” indicator light in the meter assembly lights up.

1 . SET/COAST Switch Function 1. Set Function: When the SET/COAST switch is pressed and released with the main switch on, the speed at which the vehicle is running at that moment is stored in the memory, and the vehicle automatically runs at the speed stored. 2. Coast–Down Function: When the SET/COAST switch is kept on while the vehicle is running, the vehicle decelerates during that time. The speed at which vehicle is running when the control switch is turned off is stored in the memory, and the vehicle automatically returns to the stored speed. 3. Tap–Down Function: When the SET/COAST switch is turned on and off instantaneously while the vehicle is running, the vehicle decelerates a mile for each on/off operation. The vehicle speed at which the vehicle was running when the SET/COAST was turned off last is stored in the memory, and the vehicle automatically returns to this stored speed.

10A–2 CRUISE CONTROL SYSTEM

2 . RESUME/ACCEL Switch Function

3 . CANCEL Function

1. Resume Function: When the RESUME, ACCEL switch is turned on/off after the system is temporarily deactivated by pressing the brake or clutch pedal while the vehicle is running, the vehicle resumes, the speed stored before the system was released. 2. Accelerate Function: When the RESUME/ACCEL switch is kept on after the system is released completely, the vehicle accelerates its speed during that time. The vehicle speed at which the vehicle was running when the switch was turned off is stored in the memory, and the vehicle automatically returns to this speed. 3. Tap–Up Function: When the RESUME/ACCEL switch is turned on and off instantaneously while the vehicle is running, the vehicle accelerates a mile for each on/off operation. The vehicle speed at which the vehicle was running when the switch was turned off last is stored in the memory, and the vehicle automatically returns to this stored speed.

1. Temporary Cancellation: B When the cancel switch is turned on. B When the brake pedal is pressed. B When the clutch pedal is pressed. (M/T) B When the select lever is shifted to any position other than “D”, “3”, “2” or “L”. (A/T) B When the vehicle speed has decreased about 12.5 mph (20 km/h) or more than the stored speed. B When the vehicle speed gets lower than 22.5 mph (36 km/h). 2. Complete Cancellation: B When the starter switch or the main switch is turned off. B When the failsafe function is activated.

Brake Switch Removal and Installation Refer to the Brake Pedal Replacement in Brake section.

Adjustment 1. Check that the brake pedal (3) is fully returned by pedal return spring. 2. Disconnect the switch connector. 3. Loosen the lock nut (2). 4. Rotate the brake switch (1) by hand until push rod disappears from brake switch tip (4). 5. Return the brake switch by a half turn. 6. Tighten the lock nut. 7. Connect the switch connector.

310RS028

CRUISE CONTROL SYSTEM

10A–3

Powertrain Control Module (PCM) Removal and Installation Refer to Powertrain Control Module (PCM) in Engine section.

Mode Switch Removal and Installation Refer to Mode Switch removal and installation steps in Automatic Transmission section.

Cruise Control Main Switch Removal

Installation

1. Disconnect the battery ground cable. 2. Remove the meter cluster assembly (1). B Refer to Instrument Panel Assembly in Body Structure section. 3. Remove the cruise control main switch (2). B Disconnect the switch connector.

To install, follow the removal steps in the reverse order.

B Push the lock from the back side of the instrument panel cluster assembly.

825R100019

Cruise Control Switch (Combination Switch) Removal and Installation Refer to Lighting Switch (Combination Switch) removal and installation steps in Lighting System section.

10A–4 CRUISE CONTROL SYSTEM

Diagnosis Cruise control system is controlled by the PCM as well as 6VE1 engine and automatic transmission. DTC codes are stored in the PCM if troubles occur in the circuit. DTC codes categorized “type D” are shown only by the Tech 2 scan tool. The following chart only shows some typical DTCs for cruise control system. Refer to PCM Diagnostic Trouble Codes in Driveability and Emissions for entire DTC diagnosis. DTC

TROUBLE PART

DTC TYPE

MAJOR CONDITION OF TROUBLE

DIAGNOSIS PERIOD

P0565

CRUISE MAIN CIRCUIT

B THE SWITCH CONTACT REMAINS ON FOR 15 SECONDS OR MORE. B NOISES ARE GENERATED BY THE POOR SWITCH CONTACT 60 TIMES WITHIN 1 SECOND.

DIAGNOSIS IS ENABLED IN 130 SECONDS AFTER THE SWITCH OPERATED.

P0566

CRUISE CANCEL CIRCUIT

B THE SWITCH CONTACT REMAINS ON FOR 40 SECONDS OR MORE.

DIAGNOSIS IS ENABLED IN 120 SECONDS AFTER THE SWITCH OPERATED.

P0567

CRUISE RESUME CIRCUIT

B THE SWITCH CONTACT REMAINS ON FOR 50 SECONDS OR MORE. B NOISES ARE GENERATED BY THE POOR SWITCH CONTACT 100 TIMES WITHIN 1.6 SECONDS.

DIAGNOSIS IS ENABLED IN 110 SECONDS AFTER THE SWITCH OPERATED.

P0568

CRUISE SET CIRCUIT

B THE SWITCH CONTACT REMAINS ON FOR 120 SECONDS OR MORE. B NOISES ARE GENERATED BY THE POOR SWITCH CONTACT 100 TIMES WITHIN 1.6 SECONDS.

DIAGNOSIS IS ENABLED IN 125 SECONDS AFTER THE SWITCH OPERATED.

DTC: Diagnostic Trouble Code NOTE: The DTCs are detected while the engine is running.

Источник

Manufacturer: ISUZU, Model Year: 2002,
Model line: AXIOM,
Model: ISUZU AXIOM 2002
Pages: 2100, PDF Size: 19.35 MB

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View, print and download for free: ISUZU AXIOM 2002 Service Service Manual, 2100 Pages, PDF Size: 19.35 MB. Search in ISUZU AXIOM 2002 Service Service Manual online. CarManualsOnline.info is the largest online database of car user manuals. ISUZU AXIOM 2002 Service Service Manual PDF Download. HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
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