Bseries 1997

Mazda B-Series
Workshop
Manual
@ 1997 Mazda Motor Corporation

Printed in U.S.A. 7/96
(9999-95-0228-97)
WARNING
Servicing a vehicle can be dangerous. If you have not received service-
related training, the risks of injury and property damage increase. The
recommended servicing procedures for the vehicle in this troubleshooting
manual were developed with Mazda-trained technicians in mind. This
manual may be useful to non-Mazda trained technicians, but a technician
with our service-related training and experience will be at less risk when
performing servicing operations. However, all users of this manual are
expected to know general safety procedures.
This manual contains "Warnings" and "Cautions" applicable to risks not

normally encountered in a general technician's experience. They should
be followed to reduce the risk of injury and the risk that improper service or
repair may damage the vehicle or render it unsafe. It is also important to
understand that the "Warnings" and "Cautions" are not exhaustive. It is
impossible to warn crf all the hazardous consequences that might result
from failure to follow the procedures.
The procedures recommended and described in this manual are effective

methods of performing troubleshooting and repair. Some require tools
specifically designed for a specific purpose. Nonrecommended proce-
dures and tools shoijld include consideration for safety of the technician
and continued safe operation of the vehicle.
Parts should be replaced with genuine Mazda replacements parts, not

parts of lesser quality. Use of a nonrecommended replacement part
should include consideration for safety of the technician and continued
safe operation of the vehicle.
CONTENTS
1997
4..
Mazda
B-Series
Workshop
Manual
Lubrication System
FOREWORD
This workshop manual is intended for use by
service technicians of Authorized Mazda
Dealers to help them service Mazda vehicles.
For proper repair and maintenance, a

thorough familiarization with this manual is
important, and it should always be kept in a Fuel and Emission
handy place for quick and easy reference.
All the contents of this manual, including

drawings and specifications, are the latest
-- available at the time of printing. As modifi-
cations affecting repair or maintenance
occur, relevant information supplementary to
this volume will be made available at Mazda
dealers. This manual s h o ~ ~be
l d kept up-to-
date.
Mazda Motor Corporation reserves the right

to alter the specifications and contents of this
manual without obligation or advance notice.
All rights reserved. No part of this book may

be reproduced or used in any form or by any
means, electronic or mechanical-including
photocopying and recording and the use of
any kind of information storage and retrieval
system-without permission in writing.
Mazda Motor Corporation

HIROSHIMA, JAPAN
APPLICATION:
This manual is applicable to vehicles with

the Vehicle Identification Numbers (VIN)
shown on the following page.
* Refer to the 1997 B-Series Body ~lehricalTroubleshooting
Manual (Form No. 1563-10-96H, Part No. 9999-95-094F-97)
for servicing of the body electrical components.
O 1996 Mazda Motor Corporation
PRINTED IN USA. AUGUST '96 1562-10-96H
VEHICLE IDENTIFICATION NUMBERS (VIN)
GENERAL INFORMATION
IMPORTANT INFORMATION ...................... GI- 2

BASIC ASSUMPTIONS ............................. GI- 2
SAFETY RISK ............................................ GI- 2
POSSIBLE LOSS OF WARRANTY ........... GI- 2
WARNING ON LUBRICANTS AND
GREASES ................................................ GI- 2
HOW TO1 USE THIS MANUAL ..................... GI- 3
PREPARATION ......................................... GI- 3
REPAIR PROCEDURE .............................. GI- 4
SYMBOLS .................................................. GI- 5
NOTES. CAUTIONS. AND WARNINGS .... GI- 5
FUNDAMENTAL PROCEDURES ................ GI- 5
PROTECTION OF THE VEHICLE ............. GI- 5
A WORD ABOUT SAFETY ........................ GI- 6
PREPARATION OF TOOLS AND
MEASURING EQUIPMENT ..................... GI- 6
SPECIAL TOOLS ....................................... GI- 6
REMOVAL OF PARTS ............................... GI- 6
DISASSEMBLY .......................................... GI- 6
ASSEMBLY ................................................ GI- 7
ADJUSTMENTS ......................................... GI- 8
RUBBER PARTS AND TUBING ................ GI- 8
JACK AND SAFETY STAND (RIGID RACK)
POSITIONS ................................................. GI- 9
FRONT END .............................................. GI-10
REAR END ................................................. GI-10
VEHICLE LIFT (2-SUPPORT TYPE)
POSITIONS ................................................. GI-11
FRONT END .............................................. GI-12
REAR END ............................................... GI-12
TOWING ....................................................... GI-13
GENERAL TOWING PROCEDURE
PREPARATORY STEPS ......................... GI-13
TOWllVG TWO-WHEEL DRIVE
VEHICLES ............................................... GI-13
TOWllVG FOUR-WHEEL DRIVE
VEHICLES ............................................... GI-14
TOWllVG EQUIPMENT .............................. GI-15
TOWllVG CONNECTIONS ......................... GI-16
VEHICLE IDENTIFICATION NUMBER ........ GI-17
SAFETY COMPLIANCE CERTIFICATION
LABELS ...................................................... GI-19
UNITS ........................................................... GI-23
ABBREVIATIONS ........................................ GI-23
SAE STANDARD NAME .............................. GI-24
CAUTION ...................................................... GI-26
ELECTRICAL TROUBLESHOOTING
TOOLS ..................................................... GI-26
CAUTION WITH ELECTRICAL PARTS..... GI-27
4BUGIX-001
IMPORTANT INFORMATION
IMPORTANT INFORMATION
BASIC ASSUMPTIONS
This workshop manual assumes that you have certain special tools that are necessary for the safe and
efficient performance of service operations on Mazda vehicles and that you know how to use them
properly. It also assumes that you are familiar with automobile systems and basic service and repair
procedures. You should not attempt to use this manual unless these assumptions are correct and you
understand the consequences described below.
4BUGIX-002
SAFETY RISK
This manual contains certain notes, warnings, and other precautionary information that you should
carefully read and follow to reduce the risk of personal injury to yourself or others and the risk of improper
service that may damage the vehicle or render it unsafe. If there is no such information in regard to any
specific service method, this does not mean there is no possibility that personal safety or vehicle safety
will be jeopardized by the use of incorrect methods or tools.
4BUGIX-003
POSSIBLE LOSS OF WARRANTY

The manufacturer'swarranty on Mazdavehicles and engines can be voided if improper service or repairs
are performed by persons other than those at an Authorized Mazda Dealer.
4BUGIX-004
WARNING ON LUBRICANTS AND GREASES

Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated
during service (e.g., engine oils) are more irritating and more likely to cause serious effects, including
skin cancer, in the event of gross and prolonged skin contact.
Wash skin thoroughly after work involving oil.

Protective hand cleaners may be of value provided they can be removed from the skin with water. Do not
use gasoline, paraffin, or other solvents to remove oil from the skin.
Lubricants and greases may be slightly irritating to the eyes.
Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary.
Particular care should be taken with used oils and greases containing lead. Do not allow work clothing
to be contaminated with oil. Dry clean or launder such clothing at regular intervals.
4BUGiX-005
HOW TO USE THlS MANUAL
HOW TO USE THlS MANUAL

PREPARATION
PREPARATION points out the needed Special Service Tool (SST) for the service operation that it
precedes. Gather all necessary SSTs before beginning work.
Example:
1
MANUAL STEERING
PREPARATION SST NUMBER USAGE
SST
49 01 18 850C
49 01 18 850C For
removal of tte rod
Puller, ball joint end
SST NAME SST ILLUSTRATION

HOW TO USE THIS MANUAL
REPAIR PROCEDURE
1. Most repair operations begin with an overview illustration. It identifies the components, shows how the
parts fit together, and visual parts inspections. If a damaged or worn part is found, repair or replace it as
necessary.
2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview
illustration.
3.Pages related to service procedures are shown under the illustration. Refer to this information when
servicing the related part.
Example:
73-!07 (7 4-10 9 54-79)
\ '1^1 SELECTIVE
\ / '21
SHOWS SHOWS TIGHTENING

EXPENDABLE TORQUE
PARTS SPECIFICATION '2
SHOWS
APPLICATION
POINT OF OIL,
ETC. SHOWS TIGHTENING
TORQUE UNIT
2 Cock ptate
16 Beanna ~nnerrace I
3 Bear~ngcup
4 Adjusting screw
5 Bearing outer race 17 Spacer
6 Locknut 18 Dr~veplnlon
7 Washer Removal page M-21
SERVICE
L I
*I: The numbering (ex. O ) shows service procedure.
**: Units shown in N.m {kgfm, ft.lbf} unless otherwise specified.
MG11001-C 4BUGIX-007
HOW TO USE THIS MANUAL, FUNDAMENTAL PROCEDURES GI
SYMBOLS
There are six symbols indicatingoil, grease, and sealant. These symbols show the points of applying such
materials during service.
Symbol Meaning
--
i
I
I
~ p p oil
~ y New engine oil or gear oil as appropriate
Only brake fluid
I Apply automatic transmission fluid
Appropriate grease
Apply sealant Appropriate sealant

I
Apply petroleum jelly Appropriate petroleum jelly
MGll002-A 4BUGIX-008
Note
When special oil or grease is needed, this is shown in the illustration.
4BUGIX-009
NOTES, CAUTIONS, AND WARNINGS

As you read through the procedures,you will come across NOTES, CAUTIONS, and WARNINGS. Each
one is there for a specific purpose. NOTES gives you added information that will help you to complete
a particular procedure. CAUTIONS are given to prevent you from making an error that could damage the
vehicle. WARNINGS remind you to be especially careful in those areas where carelessness can cause
personal injury.
4BUGIX-010
I 7 FUNDAMENTAL PROCEDURES
PROTECTION OF THE VEHICLE
Always be sure to cover fenders, seats, and floor areas
before starting the work.
GI FUNDAMENTAL PROCEDURES
1 A WORD ABOUT SAFETY
The following precautions must be followed when jacking
up the vehicle:
1. Block the wheels.
2. Use only the specified jacking positions.
3. Support the vehicle with safety stands.
Start the engine only after making certain the engine

compartment is clear of tools and people.
I I
MG11004-B 5BUGIX-017
PREPARATION OF TOOLS AND MEASURING
EQUIPMENT
Be sure that all necessary tools and measuringequipment
are available before starting any work.
Note
Mazda special service tools are specifically identi-
fied. If a Mazda special service tool is not
suggested, please use an equivalent tool.
SPECIAL TOOLS
Use special tools when they are required.
I J
MG11006-A 4BUGIX-014
REMOVAL OF PARTS
While correcting a problem, try also to determine its
cause. Begin workonly after first learning which parts and
subassemblies must be removed and disassembled for
replacement or repair.
I I
DISASSEMBLY
If the disassembly procedure is complex, requiring many
parts to be disassembled, all parts should be disas-
sembled in a way that will not affect their performance or
external appearance and identified so that reassembly
can be performed easily and efficiently.
FUNDAMENTAL PROCEDURES GI
I . Inspection of parts
When removed, each part should be carefully inspected
-,. ~ for malfunctioning, deformation, damage, and other
problems.
2. Arrangement of parts
All disassembled parts should be carefully arranged for
assembly.
Be sure to separate or otherwise identify the parts to be
replaced from those that will be reused.
3. Cleaning parts for reuse

All parts to be reused should be carefully and thoroughly
cleaned in the appropriate method.
I I
MGI1011-A 4BllGIX-019
ASSEMBLY
Standard values, such as torques and certain adjust-
ments, must be strictly observed in the assembly of all
parts. Refer to STANDARD BOLT AND NUT TIGHTEN-
ING TORQUE in Section TD for tightening torques not
mentioned in the main text.
If removed, these partsshould be replacedwith new ones:
(1) Oil seals
(2) Gaskets
(3) O-rings
(4) Lockwashers
~~11012-A (5) Cotter pins
(6) Nylon nuts
GI FUNDAMENTAL PROCEDURES
Depending on location:
(1) Sealant should be applied to gaskets.
(2) Oil should be applied to the moving components of
parts.
(3) Specified oil or grease should be applied at the pre-
scribed locations (such as oil seals) before assembly.
I I
ADJUSTMENTS
Use suitable gauges and/or testers when making adjust-
ments.
RUBBER PARTS AND TUBING

Prevent gasoline or oil from getting on rubber parts or
tubing.
JACK AND SAFETY STAND (RIGID RACK) POSITIONS
JACK AND SAFETY STAND (RIGID RACK)
POSITIONS I
Warning
To minimize the risk of personal injury, do not put
any portion of your body under the vehicle while
the vehicle is on the jack. The jack is provided for
emergency wheel and tire changing only. If the
vehicle is to be serviced, support the vehicle on
safety stands. Never start the engine while the
vehicle is supported on the jack.
On vehicles equipped with a limited slip axle, n ver
run the engine with one wheel off the ground, such
as when changing a tire. The wheel still on the
ground could cause the vehicle to move.
When lifting a vehicle with the vehicle jack or any floor

jack, set the parking brake and block the diagonally
opposite wheel to prevent the vehicle from moving.
Caution
Do not use the differential cover as a lifting point. If
any lifting device is allowed to contact the cover at
any point where the cover joins the housing, leaks
and/or damage to the differential cover may occur.
Position the floor jack under the axles or shock absorbers,

as close to the wheels as possible. Refer to the illustration,
also shown on the jacking decal and in the vehicle owner
guide.
JACK AND SAFETY STAND (RIGID RACK) POSITIONS
FRONT END
Jack position: Safety stand positions:
At the center of the crossrnember. On both sides of the frame rail.
VEHICLE LlFT (2-SUPPORT TYPE) POSITIONS
VEHICLE LlFT (2-SUPPORT TYPE)
POSITIONS
Damage to the suspension and/or steering linkage com-
ponents may occur when positioning the hoist adapter
pads. The front adapter pads should be positioned care-
fully to ensure maximum contact under the frame. Rear
adapter pads should be placed under the spring shackle,
but the adapters must not interfere with the shock ab-
sorber brackets or the stabilizer bar brackets.
When raising a vehicle on a 2-support type lift, care
should be taken to position the vehicle so that the adapter
pads do not damage the axle carrier casting or contact
the stabilizer bar and/or brackets.
Caution
Always place a wood block between the frame, the
lift point and the adapter pads to prevent lower
body damage.
On vehicles equipped with an under-chassis
mounted spare tire, remove the tire, wheel or tire
carrier from the vehicle before iit is placed in a high
lift position. These components must be removed,
in order to avoid sudden weight release from the
chassis.
GI-I I
TOWING
TOWING
GENERAL TOWING PROCEDURE PREPARATORY
STEPS
Release the parking brake and place .the transmission in
(N) Neutral. As ageneral rule, thevehicle should be towed
with the driving wheels off the ground and on a wheel lift
or on a "roll-back" dolly. If the driving wheels cannot be
raised off the ground, the vehicle will have to be placed on
a flat-bed truck, and not towed.
When a vehicle is towed on its front wheels, the steering
wheel must be clamped in the straight-ahead position.
Use asteering wheel clamping device designed for towing
service, such as those provided by towing system manu-
facturers. Do not use the vehicle's steering column lock to
lock the wheels in a straight-ahead position when the
vehicle is pulled from the rear. If the ignition key is not
available, place a dolly underneath the driving wheels of
the vehicle and tow with the non-driving wheels raised.
For non-emergency towing, such as behind a recreational
vehicle, or with all four wheels on the ground, please refer
to the owner guide for the proper procedure.
Note
On four-wheel drive vehicles, if a distance of 80 km
(50 miles) or a speed of 56 kmlh (35 mph) must
be exceeded, disconnect the propeller shafts.
(Maximum speed is 88kmlh (55 mph) with propeller
shafts disconnected.)
Caution
It is recommended that only an unloaded vehicle be
towed. If towing with a minimal load is unavoidable,
care must be taken to properly restrain the load
from shifting. Distribute the load evenly.
Warning
Never use a tow bar that attaches t o the bumper
when towing the vehicle. The bumper could be
loose and/or damaged and may separate from the
vehicle, which could cause an accident.
5BUGLX-001
TOWING TWO-WHEEL DRIVE VEHICLES

Towing with the rear wheels off the ground
For manual or automatic transmissions:
1. Place the transmission in N (Neutral).
2. Lock the steering wheel straight ahead.
3. Do not exceed 88 kmlh (55 mph).
4BUGIX-026
Towing a vehicle with a manual transmission with all

four wheels on the ground or with the front wheels off
the ground:
2.There is no limitation on the distance you can tow with a
vehicle with a manual transmission.
3.Do not exceed the maximum speed lirnited by the towing
equipment manufacturer's recommendations.
4BUGIX-027
TOWING
Towing a vehicle with an automatic transmission with
all four wheels on the ground or with the front wheels
off the ground:
2. Do not drive faster than 56 kmlh (35 mph).
3. Do not tow farther than 80 km (50 miles).
4BUGIX-028
TOWING FOUR-WHEEL DRIVE VEHICLES

Vehicles with a manual shift transfer case
2. Lock the steering wheel straight ahead if the vehicle will
be towed with the rear wheels off the ground.
3. Place the transfer case in N (Neutral).
Note
With the ignition in the ON position, both the 4x4
and LOW RANGE lights will be off when the transfer
case is in N (Neutral).
4. Set the manual locking hubs in the FREE position.

5.Vehicle speed should not exceed 88kmlh (55 mph)
regardless of which wheels are on or off the ground.
4BUGIX-029
Towing with an electronic shift control system

transfer case
2. Place the transfer case in 2H.
Note
With the ignition in the ON position, both the 4x4
and LOW RANGE lights will beoff when the transfer
case is in 2H.
3. Lock the steering wheel straight ahead if the vehicle is to

be towed with the rear wheels off the ground.
If you tow your vehicle with the rear wheels off the ground,
the front axle automatic locking hubs must first be disen-
gaged by shifting the transfer case to 2H and moving
forward for a minimum of 3m (10 f) in a straight line.
4. Do not tow faster than 88 kmlh (55 mph).
Note
Confirm by observation that the front propeller
shaft is not rotating prior to towing with the r ar
wheels off the ground.
5BUGIX-002
TOWING
TOWING EQUIPMENT
Towing Slings/Chains/Hooks
Caution
Use caution when attaching tow hooks and safety
chains to the vehicle. Position and remove hooks
with care to avoid damage to the brake hoses, brake
pipes, and steering linkage components.
To avoid metal-to-metal contact and possible damage to

chrome, the bumper, or lower body panels, aspecial wide-
belt sling should be used to lift and tow all vehicles. When
attaching the towbar, take care to avoid damage to the
license plate, frame, and the bumper.
CROSSBEAMSPACERBLOCKS
TOWING SLING MATERIAL - CROSSBEAMS
rC--1 ONE - 4 X 4 X 60" LONG

ONE - 4 X 4 X 48" LONG
SPACER BLOCKS CAN BE FABRICATEDAS SHOWN.
MATERIAL SPACER BLOCKS
DETAIL A FOUR - 2 x 4 x 6" LONG

TWO-4x4x3112"LONG
EIGHT - 114" x 7" CARRIAGE BOLT
EIGHT - 114" NUT
SIXTEEN - '1 14" WASHER
CROSSBEAM -WITHOUT SPACER BLOCKS
4 X 4 WOOD BLOCK =g-q

NOTE: 2 x 4 LUMBER ACTUALLY MEASURES 1-112" x 3-112"
4 x 4 LUMBER ACTUALLY MEASURES 3-112" x 3-112"
TOWING
TOWING CONNECTIONS
I T-HOOK 1 4x2 and 4x4 Vehicles
Front connections
1 . Insert the T-hooks into the slots in the frame forward of the
wheels.
2. Position a 4x4 wood block under the bumper, behind the

FRONT TOWING, T-HOOKS, 4x2 VEHICLES airdam and forward of the crossmember.
HORIZONTAL
T-HOOK SLOT
AIRDAM T-HOOK /
WOOD BLOCK SAFETY

CHAINS
MAIN VIEW
I FRONT TOWING - T-HOOKS - 4x4 VEHICLES I 3. Position the towbar under the airdam and against the 4x4
wood block.
4. Attach the safety chains to the axle, inboard of the springs
on 4x4 vehicles, and outboard of the springs on 4x2
vehicles.
Rear connections (with rear bumper)

I . Insert the T-hooks in the horizontal slots in the frame
behind the wheels.
TOWING, VEHICLE IDENTIFICATION NUMBER
2. Position the towbar under the bumper.
T-H 3. Attach safety chains around the axle, inboard of the spring
seat.
I I
MGll028-A 4BIJGIX-033
Rear connections (without bumper)
1. Remove the underbody spare tire.
2. Attach T-hooks to the horizontal slots on the frame behind
the wheels.
3. Position the 4x4 block under the frarne and against the
spring shackles.
4. Position the towbar in front of the 4x4 block, as shown in
the illustration.
5. Attach safety chains to the axle, inboard of the springs.

Caution
Use care to prevent damage to the axle mounting
brake pipes.
T-HooK CHAINS
I I
MGll030-B 5BUGIX-020
VEHICLE IDENTIFICATION NUMBER
A seventeen-digit combination of numbers and letters
form the Vehicle Identification Number (VIN). The VIN is
stamped on a metal tab that is riveted to the instrument
panel close to the windshield. The VIN number is viewable
by looking through the front windshield on the driver's
side. The VIN number is also found on the Safety Compli-
ance Certification Label.
4BUGIX-035
VEHICLE IDENTIFICATION NUMBER
Sample Vin Number
4F4CR12A5VTM00001
Position
1,2,3 Indicates the manufacturer, make and type (World manufacturer identifier).
- --- --
Vin Code Mfr. Make Type

4F4 (*I Mazda Truck (Completed vehicle)
* Manufactured by Ford for Mazda Motor Corporation
lnd~catesthe type of brake system and GVWR.
Vin Code GVWR Brake System

C Class C 4,001 - 5,000 Ibs Hydraulic
-
-
D Class D 5,001 - 6,000 Ibs Hydraulic
lndicates the model or series, chassis, and cab type.
, 1,
I Vin Code Series Chassis Body Vehicle
-
R12 B 4x2 I Pickup Regular cab Truck
- -
R13 B 4x4 Plckup Regular cab Truck
R16 6 4x2 I Plckup Cab Plus Truck
--,
1 1 ;:;
R17 B I 4x4 ( Pickup Cab Plus Truck
1
I .-
Indicates the engine type, displacement, cylinders, fuel type, and manufacturer.
-
Vin :ode Liters cu crnlcu in 4 ; Fuel
--
3.0 (EFI) 2,982/182 Gasol~ne
--
2.3 (EFI) 2,29411
-
40 Gasoline (1-
- -
-4.0
- ---
(EFI)
- -------
3,9491241 V-6
-- -- -
Gasoline
-- -- -
(* 1-
* Manufactured by Ford for Mazda Motor Corporation
1 -
Indicates the check digit for the vehicle.
Indicates the model year of the vehicle.
I--------
Vin Code
-- - -- 4
1 Year
- -
I
1994
- -
T 1996
--
A
V 1997
lndicates the vehicle assembly plant.

7 I I
Location
Edison, New Jersey
lndicates production sequence of the vehicle.
4F4CR12A5TT MOO001
MOO001 - M99,999
or
NO0001 - N99,999
SAFETY COMPLIANCE CERTIFICATION LABELS
SAFETY COMPLIANCE CERTIFICATION
LABELS
The English Safety Compliance Certification Label is
attached to the latch edge on the driver's side door. The
French Safety Compliance Certification Label is attached
to the latch edge on the passenger's side door. The label
contains the name of the manufacturer, the month and
year of manufacture, the certification statement, and the
Vehicle Identification Number. The label also contains
gross vehicle weight ratings, wheel and tire data, and
information codes for additional vehicle data.
The vehicle data appears on the Safety Compliance
Certification Label on the second and third lines following
the identification number. The code set (two numbers, or
two letters, or a number and a letter) above Color identi-
fies the exterior paint color. The letters and/or number
under Body designate the interior trim, seat and the body
type. The letters and/or numbers under Tape designate
the external body side tape stripe code.
The digits under WB designate the wheelbase in centi-
meters. The letter and three digits under Type-GVW
designate the truck model within a series and the gross
vehicle weight rating.
The transmission installed in the vehicle is identified under
Trans by an alphabetical code. A letter and a number or
two numbers under Axle identifiesthe rear axle ratio. The
spring usage codes for the vehicle are identified under
Spring.
A two-digit number is stamped above DSO to identify the
district which ordered the vehicle. If the vehicle is built for
a special order (Domestic Special Order, Foreign Special
Order, Limited Production Option, or other special order),
the complete order number will also appear above DSO.
The following charts list the various vehicle data codes:
4BUGIX-037
GI-I 9
GI SAFETY COMPLIANCE CERTIFICATION LABELS
MFD. BY FORD FOR MAZDA MOTOR CORP.

DATE: 4/94 GVWR: 4820 LBS 2186 KG
FRONT GAWR: 2465 LBS REAR GAWR: 2626 LBS
P215170R 14SL
14X5.5 JJ
AT 206.9 kPa 30 PSI COLD AT 241.3 kPa 35 PSI COLD
/ ,.q THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY
VIN:
STANDARDS IN EFFECT ON THE DATA OF MANUFACTURE SHOWN ABOVE. I -
@' TYPE TRUCK
4F4 C R x U 5 % 1 MOO001
(A) (6) (C) (D) 0 (F) (G) (H)
1C 23
EXTERIOR PAINT COLORS
WE 1 NPE-GVW / BODY 1 TRANS 1 AXLE 1 TAPE SPRING
I I
MG11032-C 5BUGIX-003
1. Name of the Manufacturer 13. Type vehicle
2. Date of manufacture 14. Exterior paint codes
3. Front gross axle weight rating in kilograms 15. Wheelbase
(kg) and pounds (Ib) 16. Model codes and GVWs
4. Front tire size 17. Seat types and interior fabric codes
5. Rim size 18. Transmission codes
6. Front tire cold kPa, (psi) 19. Rear axle codes
7. Gross vehicle weight rating in kilograms (kg) 20. Tape accent codes
and pounds (Ib) 21. Suspension identification codes
8. Rear gross axle weight rating in kilograms (A) Front spring code
(kg) and pounds (Ib) (B) Rear spring code
9. Rear tire size 22. Front axle accessory reserve capacity in
10. Rim size kilograms (kg) and pounds (Ib)
11. Rear tire cold kPa, (psi) 23. Total accessory reserve capacity in kilograms
12. Vehicle identification number (kg) and pounds (Ib)
Build Date Stamp Location

The vehicle build date is a four-digit number representing
month and day of manufacture. It is stamped on the front
surface of the radiator support on the passenger side of
the vehicle.
For a build date of January 24, for example, the vehicle

date stamp reads 0124; for a build date of October 21 , the
vehicle date stamp reads 1021.
Yellow ink is normally used for the date stamp. When the
marking surface is painted the body color, the date stamp
will be marked in red ink.
Exterior paint codes ulodel codes and GVWs
Note GVW
Series Code Code WB Payload GVW
clc indicates clear coat. -
Exterior ~ a i ncolor
t codes 4x2 -
R10 1 108 1250 4220
R10 , 2 108 1650 4680
Color R10 3 114 1250 4260
t - R10 5 114 1650 4700
U A Black c/c - R10 6 108 1050
t 4160
BA Light Pralrle Tan Met. c/c -- - - 7 - -
-- -- - R14 9 125 1200 4500
NA I Dark Tourmaline Met c/c
R14 7 125 1200 4740
E4
--
JA
Br~ghtRed Solid c/c - R14 B 125 1
1550 4880
Br~ghtSapph~reMet. c/c 4440
~ -- -- R14 U 125
-
1000
TR Medium Graphite Met. clc
R14 4 125 1000 4680
YZ Oxford White clc
R16 J 125 1200 4480
FL Toreador Red Met. clc
R16 8 125 1200 4700
Wheelbase in centimeterslinches
I (cmlin) I Model I
SWBO
- - -
LWBO
I 3181125 1 Cab Plus I
O SWB: Short wheel base
Q LWB: Long wheel base
MGll064-A
Seat types and interior fabric codes Rear axle codes
Code Fabric Seat type Conventionall
Code limited slip #Capacity Ratio
H Vinyl Bench I
E Cloth Split bench 82 Conventional 2750 1 3.08

I Vinyl I Split bench*
-
F Bodycloth HIB bucket
B Cloth Sport bucket*
J Cloth Sport bucket*
K Cloth Premium bucket*
-
M Cloth Split bench
Z Cloth Sport bucket*
Not available on regular cab models.
*Not available on base models.
Trim colors
1
Tape accent codes
Code Color
Code Color
A Opal-Red-Violet
UE5 Lapis
UE6 Med. Graphite B Lapis-Green-Grape
UFO Light Prairie Tan C Mocha-Rais~n-Red
D Silver-Red-Purple
Transmission codes -
E Titanium-Blue-Red
Description F Bright Magenta-Coral
-
Manual 5-speed overdrive (M50D) G Sea Green-Blue
4-speed automatic overdrive H Red-Purple
-
(4R44E) (5R55E) M Red-Titanium-Gold
N Rose-Charcoal-Silver
-
P Mocha-Teal-Mocha
- ---
Q Silver-Grape-Blue
-- - - -
R Opal-Teal-Opal
I S 1 Silver-Opal-Opal I
U Blueberry-Silver -
V Night Teal-Dawn Teal

MGIlO61-A 5BUGIX-014
UNITS, ABBREVIATIONS
UNITS
rpm ..................................................Revolutions per minute

A ......................................................... Arnpere(s)
V ......................................................... Volt(s)
Q ......................................................... Ohm(:;) (resistance)
kPa {kgf/crn2,psi} ................................Pressure (usually positive)
kPa {mmHg, inHg} .............................. Pressure (usually negative)
W ........................................................ Watt
rnrn {in} ................................................ Length 1
ABBREVIATIONS
ABDC .............. After bottom dead center
ABS ................. Anti-lock brake system
ACC ................ Accessories
AJC .................. Air conditioner
ATDC .............. After top dead center
AJT .................. Automatic transmission
ATF ................. Automatic transmission fluid
BAC ................ Bypass air control
BBDC .............. Before bottom dead center
BTDC .............. Before top dead center
EC-AT ............. Electronically-controlledautomatic transmission
EEC ................ Evaporative emission control system
EGR ................ Exhaust gas recirculation
ELR ................. Emergency locking retractor
ETR ................. Electrical tuning radio
EX ................... Exhaust
Fig ................... Figure
HAT ................. Hydraulically-controlledautomatic transmission
HLA ................. Hydraulic lash adjuster
IC .................... Integrated circuit
IG .................... Ignition
IN .................... Intake
INT .................. Intermittent
LH ................... Left hand
LSD .................Limited-slip differential
MAS ................Mixture adjust screw
MIL .................. Malfunction indicator light
M / l ..................Manual transmission
MTR ................ Mechanical tuning radio
OD .................. Outer diameter
OFF ................. Switch off
ON .................. Switch on
PBV .................Proportioning by-pass valve
PCV ................ Positive crankcase ventilation
PIS .................. Power steering
RFW ................ Remote free wheel hub
RH ................... Right hand
SW .................. Switch
TAS ................. Throttle adjust screw
TDC ................ Top dead center
VRS ................ Vibration reducing stiffener
U1G11051-A 4BUGIX-049
GI-23
ABBREVIATIONS
SAE STANDARD NAME
In accordance with the new warranty regulation, SAE *I standard names and abbreviations are adopted
and used in this rnanual.Thefollowinglist is acornparison of all SAE standard names and their application
to current Mazda counterparts.
*I SAE: Society of Automotive Engineers

4BUGIX-050
Engine and Emission Systems
Existing SAE Standard

Abbreviation 1 Name / Abbreviation / Name Remark
- AirJFuel (AIF) Solenoid Valve MC Mixture Control solenoid Carburetor
.
-
-
- - - --
Air Cleaner ACL Alr Cleaner
/
1
Airflow Meter
Airflow Sensor
-- 4 MAF / Mass Air Flow
--
Atmospheric Pressure Sensor BAR0 Barometric Pressure sensor

Battery Voltage B+ Battery Posltive Voltage ,
Catalytic Converter TWC I Three Way Catalytic Converter

I - I Circuit Opening Relay I FP Fuel Pump relay #I 1
Cooling Fan Control FC , Fan Control
I
Crank Angle Sensor CKP Crankshaft Position sensor
Diagnosis Connector DLC Data Llnk Connector
I
Direct lanition 1 El Electronic lanltion
I EGI
/
:
Electronic Gasoline Injection
Svstem
1 CFI / Continuous Fuel Injection system 1
~
--
El Electronic lgnltlon
ECM PCM Powertram Control Module
- -- -- - - -- -- -- - - - - - - A -
EVAP Evaporative Emlsslon

- - ~ - p - - - - p - - - - - - - - - --
A/C Air Condltionlng sensor

- - --- - -
CL Closed Loop system 7 -- -- -

- - - -- --
-
VR
-- - Voltage
-Regulator -- - -
Intake Air -
- --
Intercooler
Thermosensor
- -- -- -- -1-
,
I
IAT
CAC
- - --
Intake Air Temperature sensor
-
7--
Charge Alr Cooler

-
- - - - -
I - - -- -
- - --
MFI &~ltlport Fuel lnjectlon - - L-
-
- - -
Oxldlzrng Converter
- -
r OC - Oxldatlon Catalytic Converter

--
- -- - -~
Oxygen Sensor H 0 2 y - d G Oxygen Sensor Wlth heater
#1
-
02s Oxygen Sensor
Use 'Fuel Pump relay (Speed)"for the relay wh~chchanges operatbon voltage (speed) of the convent~onal
,
fuel pump
1 Wlthout heater
#2 Items controlled by the PCM

MG11052 B1 6BUGIX-002
ABBREVIATIONS
Engine and Emission Systems (Cont'd)
Existing 1 SAE Standard

Abbreviation
-
PTC
Name
Passenger Compartment
I ~ e m p e r h u r esensor
I Positive Temperature Coefficient I EFE /
Name
Air Conditioner sensor
Early Fuel Evaporation

I Remark
I Heater
- / Power Steerina Pressure Sensor I PSP I Power Steerina Pressure
Pressure Sensor
/ MAP I Manifold Absolute Pressure sensor I
/ MVZ / Manifold Vacuum Zone I
1 I 1 Secondary Air lniection System

Seauential Fuel lniection 1I 1 Secondary Air Injection
Sequential Multiport Fuel
I - / Service Codes DTC I Diaanostic Trouble Codes 1 I
I - 1 Solar Radiation Sensor I AfC / Air Conditioner sensor 1 #5 I
I - / Solenoid Valve (ISC) I IAC 1 Idle Air Control valve I I
I - I Test Modes / DTM I Diagnostic Test Mode I
I #6 I
I - 1 Throttle Sensor 1 TP 1 Throttle Position sensor I I
I - / Warning System / OBD On-Board Diagnostic systerri 1 I
AfC / Air
-
Conditioner
-
sensor
ECT Engine Coolant
sensor
#3: Without air pump.
#4: With air pump.
#5: Use "AJC (Solar Radiation)" when writing Sewice Manuals.
#6: Test mode to show the diagnostic trouble codes.
#7: Use "AIC (Water Temperature)" when writing Service Manuals.
MG11052-B2
Transmission
Existing 1 SAE Standard I

I Abbreviation I Name / Abbreviation 1 Name I Remark I
1 EC-AT Control Unit Powertrain Control Module
(transmission)
I - I Inhibitor Switch I PNP I ParWNeutral position switch I 1
- Speed Sensor
MG11054-B
- Speedometer Sensor
- . VSS Vehicle Speed Sensor
1 6BUGIX-003
CAUTION
CAUTION
f;;;;\ 1.4w OR 3.4w
ELECTRICAL TROUBLESHOOTING TOOLS

Test Light
The test light, as shown in the figure, uses a 12V bulb. The
two lead wires should be connected to probes.
The test light is used for simple voltage checks and for
checking for short circuits.
Caution
When checking the control unit, never use a bulb
over 3.4W.
Jumper Wire
The jumper wire is used for testing by shorting across
switch terminals and ground connections.
Caution
Do not connect a jumper wire from the power
source line to a body ground; this may cause
burning or other damageto harnessesor electronic
components.
Voltmeter
I VOLTMETER I The DC voltmeter is used to measure circuit voltage. A
voltmeter with a range of 15V or more is used by connect-
ing the positive (+) probe (red lead wire) to the point where
BLACK voltage is to be measured and the negative (-) probe
(black lead wire) to a body ground.
GROUND
a LINE
Diagnosis Connector
Insert the probe into the service hole when connecting a
jumper wire to the diagnosis connector.
Caution
Do not insert the jumper wire probe into the diagno-
sis connector terminal, which may damage the
terminal.
I I
Ohmmeter
The ohmmeter is used to measure the resistance between
two points in a circuit and also to check for continuity and
diagnosis of short circuits.
Caution
Do not attempt to connect the ohmmeter to any
circuit to which voltage is applied; this may burn or
otherwise damage the ohmmeter.
GI-26
CAUTION
CAUTION WITH ELECTRICAL PARTS
Battery Cable
Before disconnecting connectors or replacing electrical
parts, disconnect the negative battery cable.
Connectors
Removal of connector
Never pull on the wiring harness when disconnecting
connectors.
MGH040-A
I
I
Connectors can be removed by pressing or pulling the
lock lever as shown.
Locking of connector
When locking connectors, make sure to listen for a click
that will indicate they are securely locked.
Inspection
1. When a tester is used to check for covitinuity or to measure
voltage, insert the tester probe from the wire harness side.
CAUTION
2. Check the terminals of waterproof connectors from the
connector side, as they cannot be accessed from the wire
harness side.
Caution
Use fine wire to prevent damage to the terminal.
Do not damage the terminal when inserting the
tester lead.
Terminals
Inspection
Pull lightly on individual wires to check that they are
secured in the terminal.
Replacement of terminals
Use the appropriate tools to remove the terminal as
shown.
When installing the terminal, be sure to insert it until it
locks securely.
Female
Insert a thin piece of metal from the terminal side of the
connector, and then, with the terminal locking tab pressed
down, pull the terminal out from the connector.
Male
Same as the female type.
CAUTION
Sensors, Switches, and Relays
Handle sensors, switches, and relays carefully. Do not
drop them or strike them against other parts.
Fuse
Replacement
1. When replacing a fuse, be sure to replace it with one of
specified capacity.
If a fuse again fails after it has been replaced, the circuit
probably has a short circuit and the wiring should be
checked.
2. Be sure the negative battery terminal is disconnected
before replacing a main fuse (80A).
3. When replacing a pullout fuse, use the fuse puller supplied

in the fuse box cover.
CAUTION
Wiring Harness
Wiring color codes
Two-color wires are indicated by a two-color code symbol.
The first color indicates the base color of the wire and the
second the color of the stripe. (e.g., G/Y = green wire with
a yellow stripe).
GENERIC OBD II PID LlST
GENERIC OBD II PID LlST
PID# FREEZE ACRONYM DESCRIPTION MEASUREMENT UNITS
FRAME
0 0 01 DTC CNTM Cont. Code Counter Unitless
001 2 AIR Secondary Air Status ONIOFF
0005 X ECT Engine Coolant Temperature DEGREES
0003 X FUEL SYS 1 Fuel System Status - Bank 1 OLICLIOL DRlVElOL FAULTICL FAULT
0003 X FUEL SYS 2 -
Fuel System Status Bank 2 OLICLIOL DRIVEIOL FAULTICL FAULT
0 0 14 0 2 s 11 Oxygen Sensor 1 1 VOLTS
0 0 15 0 2 5 12 Oxygen Sensor 1 2 VOLTS
0 0 18 0 2 s 21 Oxygen Sensor 2 1 VOLTS
0 0 19 0 2 5 22 Oxygen Sensor 2 2 VOLTS
OOOF IAT Intake Air Temperature DEGREES
0007 X LONGFTI Long Term Fuel Trim 1 PERCENT
0009 X LONGFT2 Long Term Fuel Trim 2 PERCENT
0004 X LOAD Calculated Eng~neLoad PERCENT
001 0 X MAF Mass Air Flow Rate GMISEC-LBIMIN
OOOC X RPM Revolutions Per Minute RIMIN
0006 X SHRT FT1 Short Term Fuel Trim Bank 1 PERCENT
001 4 X SHRT FT11 Short Term Fuel Trim 0 2 s 11 PERCENT
001 5 X SHRT FT12 Short Term Fuel Trim 0 2 s 12 PERCENT
0 0 18 X SHRT FT21 Short Term Fuel Trim 0 2 s 21 PERCENT
0 0 19 X SHRT FT22 Short Term Fuel Trim 0 2 s 22 PERCENT
0008 X SHRT FT2 Short Term Fuel Trim Bank 2 PERCENT
OOOE SPARKADV Spark Advance Cylinder #1 DEGREES
001 1 TP Throttle Position PERCENT
OOOD X VSS Vehicle Speed Sensor MPH-KPH
X: Freeze Frame PID
OL: Open loop, have not satisfied conditions for closed loop.
CL: Closed loop using 02S(s) as feedback for fuel control.
OL DRIVE: Open loop due t o driving conditions (heavy accel.).
OL FAULT: Open loop due t o vehicle system fault.
CL FAULT: Closed loop fuel control, but fault with 02s sensor(s).
Generic OBD II PID Values

2.3L 3.0L
I PID I HOT IDLE I 2500 RPM-I I PID I HOT IDLE II 2500 RPM I Units I
1 I 1
I I
LONGFTI (-)20 - (+)20 (-)20 - (+)20 % LONGFTI I(-120 ., 1

. , - (+)20 (-120 .
. , - I+120
, 1 %
LOAD 16-18 1 24.3 % LONGFT2 (-)20-(+)20 (-)20-(+)20 %
LOAD M/T=22-24 M/T=22-24 %
GI GENERIC OBD II PID LIST
4.OL M/T 4.OL AIT

PID I HOT IDLE I 2500 RPM I Units I I PID I HOT IDLE I
I I
2500 RPM I
I
Units I
LONGFTI (-)20-(+)20 (-)20-(+)20 % I LONGFTI 1 (420 - (+)20 1 (420 - (+)20 1 % 1
LONGFT2 (-)20 - (+)20 (-)20 - (+)20 %
LOAD 22-24 22-24 % 1 LOAD I 22-28 1 23-29 1 % I
MAF 4.3-4.8 17.5-19 GIs MAF 4-5.1 17-19 G/S
SHRTFTI ( I- ( 1 ( 1 0- ( I %
SHRTFT2 ( - 1 - ( 1 (-)lO(+)lO %
SHRTFTII ( I- ( 1 (-)I0 - (+)I0 %
SHRTFT12 95-100 95-100 %
SHRTFT21 ( - 1 - ( 1 (-)lO(+)lO %
PRE-DELIVERY INSPECTION
AND
SCHEDULED MAINTENANCE
SERVICES
PRE-DELIVERY INSPECTION ................ A- 2 INSPECTION OF DISC BRAKE ............ A-16

SERVICE PRE-DELIVERY INSPECTION OF DRUM BRAKE .......... A-16
INSPECTION SHEET .......................... A- 2 REPLACEMENT OF BRAKE FLUID ..... A-16
SCHEDULED MAINTENANCE INSPECTION OF FRONT
SERVICES .............................................. A- 3 SUSPENSION BALL JOINTS .............. A-17
MAINTENANCE TABLES ..................... A- 3 INSPECTION OF PROPELLER SHAFT
DRIVE BELT TENSION . . . . . . . . . . . . . . A- 8 DUST BOOT(S) ................................... A-17
INSPECTION AND ADJUSTMENT TIGHTENING OF BOLTS AND NUTS
OF DRIVE BELT .................................. A- 8 ON CHASSIS AND BODY ................... A-17
REPLACEMENT OF DRIVE BELT ........ A-10 INSPECTION OF EXHAUST SYSTEM
REPLACEMENT OF ENGINE OIL ........ A-10 HEAT SHIELD ...................................... A-17
REPLACEMENT OF ENGINE INSPECTION OF A/C SYSTEM ............ A-17
TIMING BELT (2.3L ONLY) ................. A-1I INSPECTION OF PCV VALVE .............. A-17
REPLACEMENT OF ENGINE INSPECTION OF BRAKE AND
OIL FILTER ......................................... A-1 1 CLUTCH FLUID ................................... A-18
INSPECTION OF COOLING INSPECTION OF POWER STEERING
SYSTEM .............................................. A-12 FLUID LEVEL ....................................... A-18
REPLACEMENT OF ENGINE INSPECTION OF TIRES ........................ A-18
COOLANT ......................................... A-13 TIRE ROTATION ................................... A-20
INSPECTION OF IDLE SPEED ............. A-14 INSPECTION OF MANUAL
REPLACEMENT OF AIR CLEANER TRANSMISSION OIL ........................... A-20
ELEMENT ............................................ A-14 REPLACEMENT OF MANUAL
REPLACEMENT OF FUEL FILTER ...... A-14 TRANSMISSION OIL ........................... A-21
INSPECTION OF FUEL LINES ............. A-15 INSPECTION OF AUTOMATIC
INSPECTION OF EMISSION TRANSMISSION FLUID ...................... A-21
HOSES AND TUBES ........................... A-15 REPLACEMENT OF AUTOMATIC
REPLACEMENT OF SPARK PL.UGS .... A-15 TRANSMISSION FLUID ...................... A-22
INSPECTION OF BRAKE LINES. INSPECTION OF TRANSFEiR
HOSES AND CONNECTIONS ............ A-16 CASE OIL ............................................. A-23
REPLACEMENT OF TRANSFER
CASE OIL ............................................ A-23
6BUOAX-009
PRE-DELIVERY INSPECTION
Pre-Delivery lnspection
Service Pre-Delivery lnspection Sheet
VIN
Dealer NameINo. Address I I Stock No. I
Check radiolclock operation and set ENGINE ON - ON HOIST

components. If any repairs are required, stationsltime Check automatic transmission fluidllube
note your actions in the comment sec- Check seatbelts level (hoist in lowest position)
tion of this PDI form. Check seatback latches Check underside fuel, coolant, brake,
Check door latches steering, clutch and transmission fittings,
EXTERIOR-UNDER HOOD-ENGINE OFF connections and components for fluid
Check parking brake (including warning leaks
Check engine oil and add if necessary liaht)
- .
Check power steering fluid (hot) Check hood alignment
Check brake master cylinder fluid Check steering column lock
Check windshield washer reservoir fluid lnspect the vehicle for any damage or
Check starting of engine in park and imperfections. If any repairs are required,
level neutral note your actions in the comment sec-
Check engine coolant level (cold) Check instruments for .DroDer .
. o~eration I
tion of this PDI form. I
Check clutch master cylinder fluid Check all lights including warning and
Check battery cables for tightness and indicator lights EXTERIOR
proper assembly Check for exterior and interior metal, paint
Check electrical and vacuum connec- ENGINE ON-ROAD TEST and glass damage and repair as required
tions Check horn, wipers and washers Install all loose packaged items (wheel
Checkemission control system for loose, Check heater, air conditioner, defroster covers, antennas, etc.)
missing or damaged components and ventilation system Wash the vehicle and perform detailed
Check driveability during road test. If a clean up of the interior and the exterior
EXTERIOR-ON HOIST problem exists, perform appropriate ad-
Check fuel, engine coolant, brake, ex- justments to specifications shown on Ve- INTERIOR
haust and steering lines, fittings, and con- hicle Emission Control Information decal Check that the necessary warranty facts
nections for leaks, damage and routing or perform warranty repair. booklet and owner information materials
Check steering gear, steering linkage, Check throttle operation and idle return are in the vehicle.
flex coupling, suspension and exhaust Check squeaks and rattles Remove the body, seat and carpet pro-
system for looseness or damage tective covers.
Check brake operation
Check tire pressure and adjust if neces-
sary (Refer to Section Q) Check steering control
Check transmission and clutch perfor-
I Pre-Delivery Inspection Certification /
mance Passed all inspections
Checkcruise control system (if equipped) RepairsJadjustments performed
lnspect the operation and adjustment ot
vehicle systems. If any repairs are re- Check transfer case operation (if Comments:
quired, note your actions in thecomment equipped)
section of this PDI form.
PRE-DRIVE TEST
Check warning system
Check headlights, taillights, turn signals
and hazard warning flashers
THlS VEHICLE HAS BEEN THOROUGHLY INSPECTED AND CORRECTED TO FACTORY SPECIFICATIONS WITH THlS CHECKLIST
S
I
SS II II I
Signature of Technician Date Signature of Service Manager Date Repair Order No. Date
4BUOAX-002
SCHEDULED MAINTENANCE SERVICES A
SCHEDULED MAINTENANCE SERVICES
MAINTENANCE TABLES
Follow Schedule 1 (Normal Driving Conditions) if the vehicle is mainly operated where none of the
conditions below apply.
Follow Schedule 2 (Unique Driving Conditions) if any of the conditions below apply:
Repeated short-distance driving when outside temperatures remain below freezing
Driving in dusty conditions
Extended periods of idling and/or low-speed operation
Towing a trailer
Driving during hot weather in stop-and-go traffic
High-speed operation with a fully loaded vehicle
Off-road operation
A SCHEDULED MAINTENANCE SERVICES
Schedule 1 (Normal Driving Conditions)
MaintenanceInterval Number of Mlles {kilometers) (Thousands)
Miles 5 1 10 15 20 1 25 30 35 40 45 50 1 55 160 ( 65 8
0-- 1 85
Maintenance Item km 8 16 24 32 40 48 56 64 72 80 88 96 104 112 121 128 136
-
.
Engine
Air cleaner element - every 30 months or R I ! I
Ignition system
Spark plugs (2 3L)'4
Spark plugs (3 OU4 OLY4
8 Spark Plugs
I
I
I
!
I
I
~ I
1
-.
Coolina svstem
I
1
Englne coolant - Replace ln~t~ally
at 48 mont I I
Thereafter, replace every 36 months or I 1 R R
- ,
Coolant cond~t~on
12 months or
and protect~on,hoses and
clamps - annually - prior to cold weather every I I
I
I
I
i
/ I I I
I
Chassis and bodv
DISC brake system I I I I

Callper sl~dera~ls 1 L L ! 1
I
L L L I
Drum brake Ilnings, llnes and hoses I ! I / I I I

Exhaust system for leaks, damage, looseness I I 1 I
I I i I I ) I
7-
I I I
Manual transrn~ss~on
oil R
Exhaust system shielding (for trapped mater~al) I I I /I I I I I I I
Propeller shaft U-jolnts
( ~equ~pped
f wlth grease flttlngs) L L L L L L I L
L / L
I I
Parking brake system (for damage and operat~on) !
I
I
I
Rear propeller shaft double cardan joint
centering ball (short bed 4x4) L L
L
I
1 Front axle RH axle - shaft sl~pyoke (4x4) L
Splndle needle bearlng, splndle thrust bearrng (4x4) I/L IiL
I
Hub lock lubricat~on(4x4) I
IIL IR
Transfer case 011 (4x4) R
f
-
Steerlng llnkage joints
( ~equlpped with grease flttlngs)
Rear axle lubr~cant'~
L fL
L
I
i L
L
I
L L L
I
L
Accessory dr~vebelts ~ I I
Propeller shaft sl~pyoke ( ~equipped)
f L L L L I L L L i L L
-I
I
Transfer case shlft lever plvot bolt and control rod 1 I
-
connecting plns (4x4) L I I L ~ L L
I
i
Fuel fllterk6 I R R
Chart symbols:
I : Inspect, and if necessary
correct, clean
or replace
A : Adjust
R : Replace
T : Tighten
L : Lubricate
Remarks:
For * marked items in this maintenance chart, please pay
attention to the following points:
* I : The wheel lug nuts must be retightened to the proper
specifications at 800 k m (500 miles} of new vehicle
operation, at any wheel change, or at any other time
the wheel lug nuts have been loosened.
*2: Replace rear axle lube quantities every 160,000 k m
(100,000 miles} or if the axles have been submerged
in water. Otherwise, the lube should not be checked or
changed unless a leak is suspected or repair is re-
quired.
*3: At 96,000 km (60,000 miles), the dealer will replace
the PCV valve at no cost, except Canada and Cali-
fornia vehicles.
'4: Refer to vehicle emission control information label for
spark plug and gap specifications.
'5: Change spark plugs every 96,000 k m (60,000 miles),
if vehicle is subject to unique driving conditions.
*6: Recommended but not required for California vehicles.
Schedule 2 (Unique Driving Conditions)
Note
Follow Schedule 1 except for the following items:
Maintenance Interval Number of Miles {kilometers} (Thousands)
/Miles 3 6 9 12115 18 21 24 27
1
Maintenance Item km 5 10 15 2 0 / 2 5 30 35 40 45 50155 60 65 70 75 80 85
Engine I
Engine oif2 Replace every 3,000 miles {4,800 km) or 6 months
Oil filtet2 Replace every 3,000 miles (4,800 km} or 6 months
Ignition system
Spark plugs , i i I I i ] / i ]
Chassis and body
Automatic transmlss~onsh~ftllnkage
I
I I
(cable system flu~d)'~ llL IIL I/L I/L I/L / I/L IIL I/L
Front wheel bear~ngs'~ IIL
DISCbrake system'l I I , I
Callper sl~dera~ls'l L L L
Drum brake Ilnlngs, llnes and hoses I ---- I -- I
Exhaust system for leaks, damage, looseness I I 11 I I I I I
Exhaust system sh~eldlng I
(for trapped material) I I I I I I I I
Propeller shaft U-jo~nts
( ~equ~pped
f wlth grease fcttlngs)" L L 1 L L ' L L L L
Rear propeller shaft double cardan jolnt
center~ngball (short bed 4x4)" L L L L L L
I II L
Front axle RH axle - shaft sl~pyoke (4x4)'' 1 L
Steerlng llnkage joints
(if equipped with grease fitt~ngs) L L L L
Automat~ctransm~ss~on
flu~d 1 I I
1
I
R
Change
-- manual transmlss~onflu~d - -
R
L _ - L L 1
Rotate t ~ r e s ' ~ ~ ~ A I A 1 A A A A
Propeller shaft sllp yoke ( ~equ~pped)
f L L L L- L L L L
Clutch reservoir fluid level
Rear axle lube
I I I I , I / I I I 1
Change engine coolant: initially at 48,000 miles (77,000 km) or 48 months.

Thereafter, change engine coolant every 30,000 miles (48,000 km) or
36 months.
Replace air cleaner: every 30 months or every 30,000 miles (48,000 km).
Number of Miles {kilometers) (Thousands)

I
54 57 60 63 66 69 72 75 78 81
- 84 87 90 93
Chart symbols:
I : Inspect, and if necessary correct, clean or replace
A: Adjust
R: Replace
T: Tighten
L: Lubricate
R marks:
For * marked items in this maintenance chart, please pay attention to the following points:
* I : If the vehicle is operated "off-road" in water that is deeper than the hubs (112 wheel height), perform
daily.
*2: If driving habits FREQUENTLY include one or more of the following conditions:
Short trips of less than 16 km (10 miles) when outside temperatures remain below freezing
Towing a trailer or carrying maximum loads
Operating in severe dust conditions
Operating during hot weather in stop-and-go "rush hour" traffic
Extensive idling, such as police, taxi or door-to-door delivery service
High speed operation with a fully loaded vehicle (Max. GVW)
*3: Wheel lug nuts must be retightened to proper torque specifications at 800 km (500 miles) of new
vehicle operation. Also retighten to proper torque specification at 800 km (500 miles) after (1) any
wheel change or (2) any other time the wheel lug nuts have been loosened.
*4: City delivery vehicles and other unique applications that require constant turning may need more
frequent tire rotation.
7BUOAX-002
Note
Idling the engine for extended periods will accumulate more hours of use on your vehicle than
is actually indicated by the mileage odometer. Consequently, the odometer reading can often
be misleading when determining the right time to change your engine oil and filter.
4BUOAX-008
If you are using your Mazda vehicle in a manner which allows it to remain stationary while the engine is
running for long periods (door-to-doordelivery, taxi, police, powerlutility company trucks, or similar duty),
then Mazda recommends you increase the frequency of oil and filter changes as follows:
Interval equivalent to 200 ENGINE HOURS of use.
Since most vehicles are not equipped with hour meters, it may be necessary for you to approximateyour
idle time and plan oillfilter changes accordingly.
*3: If your driving habits frequently include one or more of the following conditions:
Operating during hot weather (above 32°C (90°F)) and carrying heavy loads driving in hilly terrain
Towing a trailer
Door-to-door delivery, police or taxi use
4BUOAX-009
DRIVE BELT TENSION

INSPECTION AND ADJUSTMENT OF DRIVE BELT
I
1. Check the drive belt for wear, cracks, and fraying. Replace
if necessary.
2. Verify that the drive belt is correctly mounted on the
pulleys.
4.0L
GENERATOR
@
WITH
A/C
TENSIONER
AIR CONDITIONING
em
GENERATOR
WITHOUT
AIR CONDITIONING
Adjustment
No adjustment is necessary. All engines are equipped
with automatic tensioners that indicate when the drive
belt is worn (stretched). A pointer and gauge are built into
the tensioner. When the pointer no longer registers within
the range limits of the gauge, the belt must be replaced.
Tension
2.3L: Tensioner indicator between the 4" and 25"
markings
BETWEEN
4" AND 25"
MARKINGS
4" BELT
REPLACEMENT
3.OL: Tensioner indicator between the 4" and 19"

markings
I I
MN1144-B 613UOAX-011
4.0L MIN
REPLACEMENT OF DRIVE BELT
2.3L WITH N C
1. On the 2.3L engine, loosen the drive belt tension by
/ lifting the tensioner pulley in the counterclockwise
direction.
GENERATOR
TENSIONER
I
I
I
MN1148-D
CRANKSHAFT NC-PS
I
2. On the 3.OL engine, loosen the drive belt tension by lifting

3.0L
AIR the tensioner pulley in the clockwise direction.
GENERATOR CONDITIONING 3.Remove and replace the drive belt. Lift the drive belt
IDLER
LESS AIC tensioner and slide the drive belt under the drive belt
POWER tensioner. Release the drive belt tensioner to rest on the
STEERING
drive belt.
WATER
PUMP
MN1172-D
REPLACEMENT OF ENGINE OIL
4.0L
BELT TENSION CHECK Warning
Be careful when draining; the oil is hot.
1 . Warm up the engine to normal operating temperature and

stop it.
2. Remove the oil filter cap and the oil pan drain plug.
3.Drain the oil into a suitable container.
TENSIONER CRANKSHAFT
I I
MA1011-B 6BUOAX-004
4. Install a new gasket and the oil pan drain plug.
Tightening torques:
2.3L: 21-33 N-m (2.0-4.3 kgf-m, 15-24 ft-lbf)
3.OL: 14 N-m (1.3 kgf-m, 10 ftelbf}
4.OL: 21-28 N-m (2.1-2.8 kgf-m, I S 2 1 ft-lbf)
5. Refill the engine with the specified type and amount of
engine oil.
I I Note
I KEEP THE OIL IN THIS RANGE I The oil level should be filled to the top of the
crosshatched part of the oil dipstick.
OIL LEVEL MAY BE Oil capacity
IN THIS RANGE liters {US qt, Imp qt)
AFTER AN OIL CHANGE
Engine type 2.3L
Engine oil replacement 3.8 i4.0,3.4)
Lwifh oil filter)

MA1000-E
1 / I
Engine oil replacement 4.7 {5.0,4.2)4.25I4.5,3.8) 4.7{5.0,4.2)
1
6. Refit the oil filler cap.
7. Run the engine and check for leaks.
8. Check the oil level and add oil if necessary.
REPLACEMENT OF ENGINE TIMING BELT

(2.3L ONLY)
Refer to Section B1.
REPLACEMENT OF ENGINE OIL FILTER

1. Place a drip pan under the oil filter.
2. Unscrew the oil filter.
3. Use aclean rag to wipe off the mounting surface on the oil
filter adapter.
4. Apply a small amount of clean engine oil to the O-ring of
the new filter.
5. Install the oil filter and tighten it by hand until the O-ring
contacts the oil filter adapter.
6. Tighten the oil filter 112 turn.
~~1009-A ~~BUOAX-005 Tightening torque:

2.3L:
13-15 N - m (132-153 kgfecm, 115-133 inalbf)
7. Start the engine and check for leaks.

Oil filter capacities:

2.3L and 4.OL:
0.9 liters (1.0 US qt, 0.9 Imp qt)
3.0L:
0.47 liters (0.5 US qt, 0.42 Imp qt)
A-I I
INSPECTION OF COOLING SYSTEM
Warning
Never remove the radiator cap while the engine is
hot.
Wrap a thick cloth around the cap when removing
it.
When removing the radiator cap, loosen it slowly to
the first stop until the pressure in the radiator is
released, and then remove it.
4BUOAX-018
Coolant Level (Engine cold)

1. Verify that the coolant level is near the radiator filler neck.
2. Verify that the coolant in the reservoir is at the COLD FILL
mark. Add coolant as necessary.
4BUOAX-019
Coolant Quality
1. Verify that there is no buildup of rust or scale around the
radiator cap or filler neck.
2. Verify that the coolant is free of oil. Replace the coolant if
necessary.
Coolant Leakage
1. Connect a radiator tester (commercially available) to the
radiator filler neck.
2. Apply 97-1 24 kPa (1.O-1.2 kgf/cm2,14-1 8 psi) pres-
sure to the system.
3. Verify that the pressure is held for at least 2 minutes. If not,
check the system for coolant leakage.
6BUOAX-006
A-I 2
SCHEDIJLED MAINTENANCE SERVICES A
Coolant Protection
COOLANT PROTECTION Caution
SPECIFIC
GRAVITY
Do not use alcohol- or methanol-based coolant.
Use only soft (demineralized) water in the coolant
mixture.
Measure the coolant temperature and specific gravity with

a thermometer and a hydrometer.
Determine the coolant protection by referring to the graph
as shown.
3. If the coolant protection is not proper, add water or coolant
as necessary.
Antifreeze solution mixture percentage
I Coolant protection 1 Water Coolant I

I Above -24°C I-1 1O F 1 1 60 1 40 1
-10
(14)
0
(32)
10
(50)
20
(68)
30
186)
40 50 60 70 80 90
1104) (122) (140) (158) (176) 11941
I Above -52°C {-62°F) 1 40 60 I
COOLANT TEMPERATURE "C ("F]
REPLACEMENT OF ENGINE COOLANT

Warning
Never remove the radiator cap vvhile the engine is
hot.
Wrap a thick cloth around the cap when loosening
it.
Use caution when draining hot coolant.
Caution
mixture.
Do not use recycled coolant.
1. Remove the radiator cap and loosen the drain plug.

2. Drain the coolant into a suitable container.
3. Flush the cooling system with water until all traces of color
are gone.
4. Tighten the drain plug.
Tightening torque:
I I
2.0-2.7 N.m (20-27 kgf-cm,
- 18,-25 inelbf)
ME1006-A 5BIJOAX-007
5. Fill with the proper amount and mixtilre of coolant.
Coolant capacities: Liters {U.S. qt., Imp qt.}
2.3L: (140 CID) Without A/C 6.2 I6.5, 5.4)
2.3L: (140 CID) With A/C 6.8 (7.2, 6.0)
3.OL: (182 CID) Without A/C 9.0 I9.5, 7.9)
3.OL: (182 CID) With A/C 9.6 (10.2, 8.5)
4.OL: (245 CID) Without A/C 7.4 (7.8, 6.5)
4.OL: (245 CID) With A/C 8.1 (8.6, 7.2)
A-I 3
6. Run the engine with the filler cap removed until the upper
radiator hose is hot.
7. With the engine idling, add coolant to the radiator until it
reaches the bottom of the filler neck.
8. lnstall the radiator cap.
INSPECTION OF IDLE SPEED

Note
Idle speed is preset and is not adjustable on 2.3L,
3.OL and 4.OL engines.
6BUOAX-007
Ignition Timing
1. Perform Preparation (Refer to above.)
2. Connect a timing light to the engine.
3. Verify that the ignition timing is within specification.
Specification: BTDC 8-1 2" (1 0 2 2")
4. If the ignition timing is not within specification, check

the crankshaft position sensor for damage. (Refer to
Section G.)
5BUOF3-036
REPLACEMENT OF AIR CLEANER ELEMENT

1. Check the air cleaner element for excessive dirt and for oil
and damage.
Caution
Do not clean the air cleaner element with com-
pressed air.
2. Replace the element if necessary.

4BUOAX-026
REPLACEMENT OF FUEL FILTER

Warning
Before performing the following operation, release
the fuel pressure from the fuel system to reduce the
possibility of injury or fire. (Refer to Section F1, F2
or F3.)
Always work away from sparks and open flames.
4BUOAX-027
High-pressure side
1. Disconnect the fuel hoses from the fuel filter
2. Remove the fuel filter and bracket.
3. Install in the reverse order of removal.
Note
When installing the fuel filter, push the fuel hoses
fully onto the fuel filter.
INSPECTION OF FUEL LINES
1. Check the fuel line fittings, connections and components
for leaks.
2. There should be no wetness or stained areas that might
indicate leaks.
3. Replace any defective hoses or clips.
INSPECTION OF EMISSION HOSES AND TUBES

1. Check the emission hoses' and tubes' fittings, connec-
tions and components for leaks.
2. There should be no wetness or stained areas that might
indicate leaks.
3. Replace any defective hoses, tubes or clips.
4BUOAX-030
REPLACEMENT OF SPARK PLUGS

1. When removingthe high-tensionleads, do not pull directly
on the lead. Grasp and twist the boot back and forth on the
lead insulator to free the boot.
MG1037-B
7 2. When removing the leads from the ignition coils, squeeze
I I the locking tabs of the coil wire retainer and remove using
SQUEEZE a twistingand pulling motion. Do not pull on the lead.
LOCKING TABS
TO REMOVE!
3. Remove and install the spark plug with a plug socket.

Caution
Be sure the socket is fit squarely over the spark
plug.
4. Apply lubricant to the spark plug threads.
5. Tighten the spark plug to the specified torque.
Tightening torques:
9-20 N-m(1.0-2.0 kgf-m, 7-15 ft-lbf}
INSPECTION OF BRAKE LINES, HOSES AND
CONNECTIONS
Check the points below, and replace any parts if
necessary:
1. Cracking, damage or corrosion of the brake hose.
2. Damage to the brake hose threads.
3. Scars, cracks or swelling of the flexible hose.
4. All lines for fluid leakage.
I I
MA1003-A 4BUOAX-032
INSPECTION OF DISC BRAKE
Check the following disc brake components:
1. Check the caliper operation and inspect for leaks.
2. Check the pads for wear.
3. Check the condition and thickness of the disc plate.
Limit:
Disc pad thickness: 1.5mm (0.06 in}
Disc plate thickness: 22.lmm (0.87 in}
5BUOAX-011
INSPECTION OF DRUM BRAKE

1. Check the wheel cylinder operation and inspect for leaks.
2. Check the linings for wear or damage.
3. Check the condition of the inner surface and the inner
diameter of the drum.
Standard diameter: Shown on drum

Diameter limit: Standard diameter + 0.762mm
(0.030 in}
I I
REPLACEMENT OF BRAKE FLUID
MPl024-A 4BUOAX-034
Caution
The fluid in the reservoir must be maintained at the
3/4 level or higher during replacement.
Do not spill brake fluid onto painted surfaces. If
spilled, wipe it off immediately.
1. Remove the brake fluid from the reservoir by using a

suction pump.
2. Fill the reservoir with clean brake fluid.
Fluid specification: FMVSS116 or DOT-3
3. Attach a vinyl tube to the farthest bleeder screw and place

the other end of the tube in a clear container.
4. Pump out the old brake fluid by loosening the bleeder
screw and pumping the brake pedal until only clean fluid
is expelled.
5. Perform the above for all the bleeder screws.
6. Fill the reservoir to the specified levels.
INSPECTION OF FRONT SUSPENSION BALL JOINTS
1 Inspect the front suspension ball joints.
I I
MA1004-A 4BUOAX-036
INSPECTION OF PROPELLER SHAFT DUST BOOT(S)
Check the dust boot on the propeller shaft for cracks,
damage, grease leakage, and a loose boot band.
4BUOAX-037
TIGHTENING OF BOLTS AND NUTS ON CHASSIS

AND BODY
1. Tighten all seat mounting bolts.
2. Retighten any loose nuts and bolts on the chassis and
body to the specified torque.
4BUOAX-038
INSPECTION OF EXHAUST SYSTEM HEAT SHIELD

1.Visually check the exhaust system heat shield for
damage.
2. Replace it if necessary.
4BUOAX-039
INSPECTION OF AIC SYSTEM

Refer to 1997 B-Series BETM.
7BUOAX-008
INSPECTION OF PCV VALVE

2.3L and 4.OL
Note
Perform this inspection while the engine is cold.
1. Run the engine at idle.

2. Disconnect the PCV valve along with the ventilation hose
from the cylinder head cover.
3. Block the PCV valve opening.
4. Verify that vacuum is felt.
5. Remove the PCV valve.
6. Blow through the valve from port Fi and verify that air
comes out of port 6.
7. Blow through the valve from port B and verify that no air
comes out of port A.
8. Replace the PCV valve if not as specified.
3.0L
TO CHARCOAL CANISTER 1. Remove the PCV valve from the cylinder head cover.
/ 2. Shake the PCV valve.
3
VALVE
3. Verify that the PCV valve rattles when shaken.
4. If the PCV valve does not rattle (sticking), then replace it.
5. Reinstall the PCV valve and hoses.
6. Warm the engine at idle.
7. Disconnect the hose from the PCV valve leading to the
wv throttle body.
8. Block the hose opening.
10. If no vacuum is felt, check for restrictions and replace the
hose if it is restricted or leaking.
11. Inspect the evaporative emission hose between the PCV
valve and the charcoal canister, and replace it if it is
leaking.
INSPECTION OF BRAKE AND CLUTCH FLUID

Check the fluid level in the reservoir. The level should be
at the MAX line on the reservoir.
If the fluid level is extremely low, check the brake system
for leaks.
Fluid specification: FMVSSI 16 or DOT-3
INSPECTION OF POWER STEERING FLUID LEVEL

Check the fluid level. When cold, the level should be at the
FULL COLD mark. When hot, the level should be at the
FULL HOT mark. Add fluid if necessary.
Fluid specification: ATF DexronBII or M-111

4BUOAX-044
INSPECTION OF TIRES
Inspection and Adjustments
A wheel or tire should be replaced if any cracks, damage,
deformation or other problem(s) are found.
SCHECIULED MAINTENANCE SERVICES A
Tire Wear
1. Check the remaining tread.
Remaining tread
Standard tires: 1.6mm (0.063 in) min.
Snow tires: 50% of tread
2.A tire should be replaced if the wear indicators are

exposed.
WEAR INDICATOR
MQ1001-A 4BIJOAX-046
Abnormal tire wear
Abnormal tire wear patterns shown in the illustration can
(a) (b) occur. Refer to the chart for the possible causes and
actions.
Possible cause Action
Underinflation Measure and adjust
(both sides worn) pressure
lncorrect camber Repair or replace
(one side worn) suspension parts
SHOULDER WEAR CENTER WE:AR Hard cornering Reduce speed
Lack of rotation Rotate tires
Overinflation Measure and adjust
pressure
Incorrect toe-in -
Adjust
-
toe-in
Incorrect camber or caster Repair or replace axle and
suspension parts
Malfunctioning suspension Repair or replace
Unbalanced wheel Balance or replace
Out-of-round brake drum Correct or replace
or disc
Other mechanical problem Correct or replace
FEATHERED EDGE UNEVEN WEAR Lack of rotation Rotate tires
lncorrect toe-in Adiust toe-in
Air Pressure
Check the air pressure of all tires, including the spare tire,
with an air pressure gauge. If necessary, adjust the air
pressure.
Air pressure: Refer to Section Q.
I
MQ1003-A 4BUOAX-0
Air Leakage
Verify that there is no air leakage from the air valve.
AIR VALVE
A-I 9
Loose Lug Nut
Verify that the lug nuts are tightened to the specified
torque.
Tightening torque:
135 N-m(14 kgf-m, 100 ft-lbf)
MQ1005-A 4BUOAX-050
TlRE ROTATION
4 TIRE ROTATION 5 TlRE ROTATION FOR USE To prolong tire life and assure uniform tire wear, rotate the
WITH REGULAR SPARE
tires every 8,000-12,000 km (5,000-7,500 miles).
Caution
Use the best tires on the front axle.
After rotating the tires, adjust each tire to the
specified air pressure. (Refer to Section Q.)
REGULAR SPARE
Wheel and Tire Runout

1. Jack up the vehicle and support it on safety stands.
2. Set the probe of a dial indicator against the wheel, and
measure the runout through one full revolution.
Runout limit
mrn {in)
t Radial direction
Lateral direction
.-
3. Replace the wheel if necessary
INSPECTIONOF MANUAL TRANSMISSION OIL

Note
Park the vehicle on level ground.
1. Remove the oil level plug and washer.
1 OIL LEVEL
PUG
I
DRAIN PLUG
2. Verify that the oil is near the bottom of the plug port.
3. If the oil level is low, add the specified amount and type of
oil through the oil level plug hole.
Fluid specification: ATF DexronB1l or M-111
-
4. Install a new washer and the oil level plug.
Tightening torque:
40-58 N.m (4.1-5.7 kgf.m, 30--42 ft-lbf)
REPLACEMENT OF MANUAL TRANSMISSION OIL

1. Remove the drain plug with washer.
2. Drain the oil into a suitable container.
3. Install a new washer and the drain plug.
Tightening torque:
40-58 N-m(4.1-5.7 kgf-m, 30--42 ft-lbf}
OIL LEVEL I
DRAIN PLUG
MJ1157-A
4. Remove the oil level plug with washer and add the
specified amount and type of oil through the oil level plug
hole until the level reaches the bottom of the oil level plug
hole.
Fluid specification: ATF MerconB or M-I11
Capacity: 2.65 liters (5.6 US pt, 4.5 Imp pt)

L
MJI 137-A ~BUOAX-054 Tightening torque:
40-58 N.m (4.1-5.7 kgf-m, 30-42 ft.lbf)
INSPECTION OF AUTOMATIC TRANSMISSION FLUID

Level
Note
Place the vehicle on a flat, level surface.
1. Apply the parking brake and position the wheel chocks

securely to prevent the vehicle from rolling.
2. Warm up the engine until the ATF: reaches 6 6 7 7 ° C
(150-1 70°F).
3. While depressing the brake pedal, shift the selector lever
to each range (Park through 1st), pausing momentarily in
each range.
4. Shift back to Park.
Note
Vehicles equipped with 4x4 applications must
have the 4x4 shift lever in any position other than
Neutral.
Use the COOL (10") range as a rough reference
only.
HOT RANGE 5. Ensure that the ATF level is in the HOT (65")range. Add
66 C TO 76 C ATF to the specification, if necessary.
(150 F T O 170 F)
I 10 h COOL RANGE
22 ~ ~ 0 3
I5 ~
DO NOT PO F TO 95 F)
DRIVE MARK
I I
MA1006-6 5BUOAX-013
7
- Condition
Note
Determine whether the automatic transmission
should be disassembled by carefully observing the
condition of the ATF.
If the ATF is muddy and varnished, it indicates
burnt drive plates.
1. Check the ATF for discoloration.

2. Check the ATF for any unusual smell.
4BU0AX-056 REPLACEMENT OF AUTOMATIC TRANSMISSION

FLUID
1. Loosen the pan attaching bolts to drain the fluid from the
transmission.
2. When all the fluid has drained from the transmission,
remove and thoroughly clean the pan.
3. Discard the pan gasket.
4. Place a new gasket on the pan, and install the pan on the
transmission.
Tightening torque:
11-13 N-m(1.2-1.3 kgf-m, 8-10 ft-lbf)
5. Add the specified fluid to the transmission through the

dipstick tube.
Fluid specification: ATF Mercons V
Caution:
Use only Mercon V@ATF or equivalent. Use of any
other fluids may result in a transmission function
or failure.
6. Check the fluid level following the room temperature
checking procedures.
Note
If it is necessary to perform a complete drain and
refill, it will be necessary to remove the residual
fluid from the cooler lines and flush the cooler lines
completely.
7BUOAX-003
INSPECTION OF TRANSFER CASE OIL
Remove the filler plug. Verify that the oil level is near the
filler plug hole. If it is low, add the specified oil.
Fluid specification: ATF DexronBII or M-I11
REPLACEMENT OF TRANSFER CASE OIL

1. Remove the filler plug and drain plug.
2. Wipe the plugs clean.
3. Apply sealant to the threads of the drain plug and filler
plug.
4. After the fluid has drained, install the drain plug.
Tightening torque:
19-30 N-m (1.9-3.0 kgf-m, 15--20 ftelbf}
5. Add the specified oil from the filler plug hole until the level
reaches the bottom of filler plug hole.
Fluid specification: ATF DexronBII or M-I11
Capacity:
1.2 liters {2.5 US pt, 2.1 Imp pt)
6. Install and tighten the filler plug.
Tightening torque:
19-30 N-m (1.9-4.0 kgfem, 15-20 ft-lbf)
4BUOAX-059
ENGINE
(2.3L)
INDEX .................................................... INSPECTION / REPAIR ......................... B1-36

OUTLINE ............................................... PREPARATION .................................. 81-36
SPECIFICATIONS .............................. CYLINDER HEAD ............................... B1-36
TROUBLESHOOTING GUIDE .............. VALVE MECHANISM .......................... B1-36
ENGINE TUNE-UP PROCEDURE ........ CAMSHAFT ........................................ B1-39
ENGINE OIL ........................................ CYLINDER BLOCK ............................. B1-40
ENGINE COOLANT ............................ PISTON. PISTON RING AND
DRIVE BELT ....................................... PISTON PIN ...................................... B1-41
HLA TROUBLESHOOTING GUIDE .... CONNECTING ROD ........................... B1-43
IGNITION TIMING. IDLE SPEED ....... CRANKSHAFT .................................... B1-44
COMPRESSION .................................... BEARING ............................................ B1-45
.. INSPECTION ......................................
ON-VEHICLE MAINTENANCE .............
TIMING BELT ...................................... B1-45
PULLEY .............................................. B1-46
PREPARATION .................................. TIMING BELT OUTER COVER .......... B1-46
TIMING BELT ...................................... FLYWHEEL (MT) ................................ B1-46
CYLINDER HEAD GASKET ............... ASSEMBLY .......................................... B1-47
HYDRAULIC LASH ADJUSTER ......... PREPARATION .................................. B1-47
FRONT OIL SEAL ............................... CYLINDER BLOCK
CAMSHAFT OIL SEAL ....................... (INTERNAL PARTS) ......................... B1-48
OIL PUMP OIL SEAL .......................... FRONT COVER .................................. B1-53
REAR OIL SEAL ................................. CYLINDER BLOCK
REMOVAL ............................................. (EXTERNAL PARTS) ........................ B1-54
PROCEDURE ..................................... CYLINDER HEAD ............................... 81-58
DISASSEMBLY ..................................... TIMING BELT ...................................... B1-62
PREPARATION .................................. AUXILIARY PARTS ............................ B1-63
AUXILIARY PARTS ............................ INSTALLATION ..................................... 8 1-67
TlMlNG BELT ...................................... PROCEDURE ..................................... 81-67
5BUOB1-001
CYLINDER HEAD ...............................
CYLINDER BLOCK
(EXTERNAL PARTS) ........................
FRONT COVER ..................................
CYLINDER BLOCK
(INTERNAL PARTS) .........................
INDEX
INDEX
FRONT OF ENGINE
I
MB1299-B 5BUOBi -002
1. Timing belt 5. Rear oil seal
Removal / Installation ........... page 81- 8 Replacement ........................ page B1-21
2. Cylinder head gasket 6. Engine
Replacement ........................ page 81-12 Removal ............................... page 81-23
3. Hydraulic lash adjuster Disassembly ......................... page 81-24
Removal / Installation ........... page 81-16 Inspection / Repair ............... page B1-36
4. Front oil seal Assembly ..... ..... .......... ..... ..... page 81-47
Replacement ........................ page I31-17 Installation ................... ......... page B1-67
OUTL.INE, TROUBLESHOOTING GUIDE B1
OUTLINE
SPECIFICATIONS
--
Gasoline, 4-cycle
Cylinder arrangement and number In-line 4 cylinders
Valve svstem OHC belt-driven, 8 valve
Displacement
Bore and stroke mm {in} 96.0 x 79.4 I3.78 x 13.126)
Lowest
-
reading within 75% of highest cylinder reading3
-
lanition timina (initial timing) 8-1 2" { I 0 + 2")
I Firina order 1 1-3-4-2 I
--
IN mm {in} 0 ;Maintenance free

Valve clearance
EX rnm {in}
IRefer to Sect~onTD
MB1047-F
Note
When the battery has been disconnected and reconnected, some abnormal drive symptoms
may occur while the powertrain control module relearns its adaptive strategy. The vehicle may
need to be driven 16 km (10 miles) or more to relearn the strategy.
4BUOB1-004
TROUBLESHOOTING GUIDE
Problem Possible Cause Action Page
ppp -- ppppp- - -- ppppp
Difficult starting Malfunction of engine-related components

Burnt valve Replace
Worn piston, piston rings, or cylinder Replace or repair
Damaged cylinder head gasket Replace
Malfunction of fuel system --Refer~SecGFT---
I Malfunction of ignition system / Refer to Section G 1 -
Poor idling Malfunction of engine-related components
Malfunction of HLA' Replace
Poor valve-to-valve seat contact Replace or repair
Damaged cyltnder head gasket Replace
-- pppp- - --
Malfunction of fuel system Refer to Section FT
Malfunction of ignition system / Refer to Section G - 1
Excessive oil Oil working up
consumption Worn piston ring groove or sticking piston ring Replace 81 -39
Worn piston or cylinder Replace or repair 81-40. 41
.- - -- - pp
---
-
Oil working down

Worn valve seal Replace
Worn valve stem or guide Replace
Worn piston rings Replace
Plugged PCV system Refer to Section F
Oil leakage Refer to Section D l 1 -
I
Problem Possible Cause Action

- - - -- -- -- -- - - - !-- - - --
Insufficient power Insufficient compression I

Malfunct~onof HLA* I Replace
Compress~onleakage from valve seat 1 Repair
1
1
Se~zedvalve stem
Weak or broken valve spring
1 Replace
1 Replace
Damaged cylinder head gasket 1 Replace
Cracked or distorted cyllnder head Replace
Stlcklng, damaged, or worn plston rlng Replace
Cracked or worn plston Replace
~- - - - -- -
1 Malfunction of fuel system

-
Refer to Sectlon FT
- - -
/ Malfunction of ignition system

-- - - -
Refer to Sectlon G
- -
[-others
I Slipping clutch
Dragglng brakes
Refer to Sectlon H
Refer to Sectlon P
Refer _-to Sectlon Q ---
- -- - ___ 1 Wrong size tlres
ppp _ - - - - - --
Abnormal Malfunction of engine-related components

combustion Malfunct~onof HLA* Replace
Stlcklng or burnt valve Replace
Weak or broken valve spring Replace B1-38
Carbon accumulat~on~ncombust~onchamber El~m~nate
carbon -
- - -
~alfunction
of fuel system Refer to Sectlon FT -
-- --
Malfunction of ignition system - -

-- - - ------ - - -
Engine noise Crankshaft- or bearing-related parts

Excessive maln bearlng 011clearance Replace or repalr 81 -49
M a ~ bearing
n se~zedor heat-damged B1-45
Excesslve crankshaft end play Replace or repair B1-50
Excess~veconnecting rod bearlng 011clearance B1-52
Connecting rod bearlng selzed or heat-damaged B1-45
- --
Piston-related parts
Worn cylinder 81-40
Worn plston or plston p ~ n 81-41
Selzed plston B1-41
I Damaged plston rlng 81 -42
~-
Bent--connecting
-
rod -
81 -43
'
Valves or timing-related parts
Malfunct~onof HLA* Replace B1-6
I Broken valve spring Replace B1-38
( Excessive valve gu~declearance / Replace B1-36
r, Malfunct~on
- 7 of cooling
-- - -
system
- - -
/ -
Refer to Sectlon E l
- - --
-
- - - - - - - --
t-- -- --
A
-
1/Others
Malfunction of fuel system
-- - - - - --
+Refer to Sectlon FT
-- - - -
-
Malfunct~onof water pump bearlng Refer to Sectlon E l -

Worn dr~vebelt Replace B1-5
Malfunction of generator bearlng Refer to Sectlon G -
Exhaust gas leakage Refer to Sect~onFT -
Loose tlmlng belt Replace or repair B1-45
Malfunct~onof timing belt tensloner 1 Replace B1-8
' Tappet nolse may occur ~f the englne has set at Idle for an exhausted per~odThe nolse should stop after the englne has reached normal operat~ngtemperature
(HLA troubleshoot~ngRefer to page 81 6)
MB1048 D2 6BUOB1-002
ENGINE TUNE-UP PROCEDURE B1
ENGINE TUNE-UP PROCEDURE
KEEP THE OIL IN THIS RANGE
ENGINE OIL
Inspection
ADD 1 1. ~e sure the vehicle is on level ground.
QUART 2. Warm up the engine to normal operating temperature and
stoo it.
OIL LEVEL MAY BE IN TI-IIS 3. wait for five minutes.
RANGE AFTER AN OIL CHANGE 4. Remove the oil dipstick and check the oil level and
condition.
5. Add or replace oil if necessary.
Note
The oil level should be filled to the top of the
dashed part of the oil dipstick.
ENGINE COOLANT
lnspection
Coolant level (engine cold)
Warning
Never remove the radiator cap while the engine
is hot.
Wrap a thick cloth around the cap when remov-
ing it.
1. Verify that the coolant level is near the filler neck of the
FRONT OF VEHICLE
radiator.
61251-A 4BUOB1-00t
2. If the coolant level is below the filler neck, add coolant as
necessary.
3. Verify that the coolant level in the reservoir is at the COLD
FILL mark. Add coolant as necessary.
Coolant quality
radiator cap, and filler neck.
2. Verify that the coolant is free of oil.
3. Replace the coolant if necessary.
4BUOB1-009
DRIVE BELT
2.3L WITH N C
lnspection
1. Check the drive belt for wear, cracks, fraying or severe
w k%p
GENERATOR
LESS N C
glazing.
2. Replace the belt if any of these conditions are observed.
Minor cracks in the back of the belt are considered
acceptable.
TENSIONER LESS
CRANKSHAFT NC-F'S
Adjustment
2.3~ No adjustment is necessary for the 2.3L drive belt. The
2.3L engine is equipped with an automatic tensioner that
indicates when the drive belt is worn (stretched). A pointer
AUTOMATIC
and gauge are built into the tensioner. When the pointer no
longer registers within the range limits of the gauge, the
belt must be replaced.
MARKINGS
1 REPLACEMENT
HLA TROUBLESHOOTING GUIDE

~ .-
I . Noise when engine is started immediately Run engine at 2,000-3,000 rpm.
Oil leakage in oil passage
after oil is changed. If noise stops after 2 seconds-1 0 minutes*,
2. Noise when engine is started after setting HLA is normal.
approx. one day. -
If not, replace HLA.
3. Noise when engine is started after cranking Oil leakage in HLA * Time required for engine oil to circulate
for 3 seconds or more. within engine includes tolerance for engine
4. Noise when engine is started after new oil condition and ambient temperature.
HLA is installed.
5. Noise continues more than 1 0 minutes. Insufficient oilpressure Check oil pressure.
If lower than specification, check for cause.
Oil pressure: 276-414 kPa (2.8-4.2
kgflcm2,40-40 psi) -2,000 rpm
Damaged HLA (Refer to page BI-16.)
Press down HLA by hand.
If it does not move, HLA is normal.
If it moves, replace HLA.
Measure valve clearance.

If more than 0 mm { 0 in}, replace HLA.
6. Noise during idle after high-speed running. Incorrect oil amount Check oil level.
Drain or add oil as necessary.
Deteriorated oil condition Check oil quality.
If deteriorated, replace with specified type and
amount of oil.
dB1049-C 5BUOB1-100
IGNITION TIMING, IDLE SPEED

lgnition Timing
Note
Initial timing is preset and is not adjustable. (Refer to Section G.)
lgnition timing: 8-1 2" {I 0k2")BTDC
ldle Speed
ldle speed: 475-575 RPM

COMPRESSION B1
COMPRESSION
If the engine exhibits low power, poor fuel economy, or poor idle, check the following:
1. Ignition system (Refer to Sectiori G.)
2. Compression (Refer to below.)
3. Fuel system (Refer to Section FT.)
INSPECTION
1. Verify that the battery is fully charged. Recharge it if
necessary. (Refer to Section G.)
2. Warm up the engine to the normal operating temperature.
3. Stop the engine and allow it to cool for about 10 minutes.
4. Remove the spark plugs on the exhaust side only.
5. Disconnect the harnessconnectors from the ignition coils.
6. Connect a compression gauge to Nu. 1 spark plug hole.
7. Fully depress the accelerator pedal and crank the engine.
8. Note the maximum gauge reading.
9. Check each cylinder as above.
MB1239-A
Compression:
Lowest reading cylinder within 75 percent of the
highest. (Refer to Section TD.)
10. If the compression in one or more cylinders is low, pour

a small amount of engine oil into the cylinder and recheck
the compression.
(1) If the compression increases, the piston, piston rings,
or cylinder wall may be worn.
(2) If the compression stays low, the valve may be stuck
or seating improperly.
~~1249-A ~BUOBI-003 (3) If the compression in adjacent cylinders stays low, the
cylinder head gasket may be damaged or the cylinder
head distorted.
11. Connect the harness connectors to the ignition coils.
12. Install the spark plugs.
Tightening torque:
7-14 N.m (0.7-1.4 kgf-m, 5-10 ft-lbf)
ON-VEHICLE MAINTENANCE
PREPARATION
SST
49 UNOl 067 For 49 UNOl 070 For
Camshaft belt
tensioner tool
retracting
timing belt
tensioner
2.3L crankshaft
seal installer
@ &W installation of
rear main
oil seal
49 UNO1 135
Valve spring
compressor
TIMING BELT
Removal 1 lnstallation
For
collapsing
valve
spring
1. Remove the drive belt. (Refer to Section G.)

49 UNOl 087
Seal remover
s For
removal of
camshaft
oil seal
5BUOB1-004
2. Recover the refrigerant from the A/C system. (Refer to Section G in the 1997 B-Series BETM.)
3. Remove the four A/C compressor bolts and position the AIC compressor aside.
4. Remove the A/C compressor and power steering pump bracket bolts and position aside with the hoses
attached.
5. Remove the water pump pulley.
6. Remove in the order shown in the figure, referring to Removal Note.
7. Install in the reverse order of removal, referring to lnstallation Note.
8. Check the ignition timing. (Refer to Section G.)
1. Crankshaft pulley 3. Timing belt

2. Timing belt outer cover Removal Note ...................... page 81-9
Removal Note ...................... page B1-9 Installation Note ................... page 81 -9
Installation Note ................... page BI-10
ON-VEHICLE MAINTENANCE B1
Removal Note
Timing belt outer cover
1. Remove the timing belt outer cover bolt.
2. Release the seven cover interlocking tabs and remove the
cover
Timing belt
Caution
If you attempt to remove the timing belt or to adjust
tension without looseningbothtiming belt tensioner
adjusting bolt and spring pivot bolt, you will break
SST (49 UNO1 067) when you attempt to relieve
tension on belt.
1. Loosen the timing belt spring pivot bolt. Do not remove.
2. Hold tensioner with SST.
3. While holding tensioner, loosen adjusting bolt and gradu-
ally release spring tension.
4. Using adjusting tool, rotate tensioner, against spring
pressure, as far clockwise as possible. While holding,
tighten adjusting bolt to hold tensioner away from belt.
5. Remove the timing belt.
Installation Note
Timing belt
1. Loosen tensioner adjusting bolt.
2. Using SST, pry tensioner clockwise against spring ten-
sion as far as possible.
3. Tighten adjusting bolt to hold tensioner in released posi-
tion.
4. Align the crankshaft pulley so that the number one piston
is at TDC with the crankshaft key pointing straight up and
the circle on the crankshaft sprock:et is aligned with the
mark on the front cover.
5. Align the triangle on the camshaft pulley with the triangle
on the timing belt inner cover.
6. Align the diamond on the oil pump pulley with the dia-
mond on the timing belt inner cover.
7. Install the new timing belt.
8. Tighten tensioner assembly again:st belt.
Tightening torque:
41-45 N .m ( 4 . 1 4 . 6 kgf. m, 30-33 ft .lbf)
B1 ON-VEHICLE MAINTENANCE
9. Tighten adjusting bolt.
Tightening torque:
3 5 4 5 N .m (3.6-4.6 kgf .m, 26-33 ft . lbf)
10. Tighten spring pivot bolt.
Tightening torque:
40-55 N. m f4.1-5.5 kgf . m, 3 0 4 0 ft . lbf)
11. Release the timing belt tensioner pulley. Rotate clock-
wise the engine two complete revoutions and check the
camshaft timing. (Refer to below.)
12. If necessary, adjust the camshaft timing. (Refer to
below.) 6BUOB1-006

Install the timing belt outer cover
Tightening torque:
8-1 2 N .m (0.8-1.1 kgf .m, 6-8 ft Ibf)
4BUOB1-021
Adjustment
Checking camshaft timing
Note
Two access plugs are provided in the timing belt
outer cover so that camshaft timing can be checked
without removal of the cover or any other parts.
1. Remove the access plugs from the timing belt outer cover
if necessary.
2. Rotate the crankshaft so that the No.1 piston is rising on
compression stroke.
3. Set the crankshaft to TDC by aligning the circular timing
mark on the timing belt pulley with the TDC mark on the
engine front cover with the crankshaft key pointing straight
UP.
Caution
Always turn the engine in the direction of normal
rotation (clockwise, as viewedfrom the front). Back-
ward rotation may cause the timing belt to jump
time, due to the arrangement of the belt tensioner.
4. Look through the access hole in the timing belt outer

cover, to make sure that the triangular timing mark on the
camshaft pulley is lined up with the triangle on the timing
belt inner cover and that the diamond on the oil pump
pulley aligns with the diamond on the timing belt inner
cover.
5. If the marks on the camshaft pulley and timing belt pulley
1 are not visible, rotate the crankshaft 360 degrees, align

the marks and check again.
6. If necessary, adjust the camshaft timing. (Refer to below.)
7. Install the access plugs.
Adjusting camshaft timing
1. Remove the timing belt outer cover.
2. If belt timing is incorrect, loosen the belt tensioner spring
bolt and the adjustment bolt. Position the SST on the
tension spring roll pin, and retract the belt tensioner.
Tighten the adjustment bolt to hold the tensioner in the
retracted position.
Note
SST Number:49 UNO1067 Camshaft Belt Tensioner
Tool
3. Remove the bolt, washer and the crankshaft pulley.

4. Remove the timing belt and inspect it for wear or damage.
If the timing belt 'k damaged, -replace it. (Refer to page
B1-8.)
5. ~ e m o v eone spark plug from each cylinder and mark
locations to ease installation.
6.Align crankshaft so number one piston is at TDC as
indicated by timing mark.
7. Align mark on crankshaft pulley with line on timing belt
cover.
8. Align the triangle on the camshaft pulley with the triangle
9. Align the diamond on the oil pump pulley with the diamond
10. Install the timing belt over the timing belt pulley and then
counterclockwiseover the oil pump and camshaft pulleys.
Align the belt fore and aft on the pulleys.
11. Loosen the belt tensioner adjustment bolt to allow the
tensioner to move against the belt. If the spring does not
have enough tension to move the roller against the belt
(the belt hangs loose), it may be necessary to manually
push the roller against the belt and tighten the bolt.
Note
The spring cannot be used to set belt tension. A
wrench must be used on the tension assembly.
12. Rotate the crankshaft two complete turns in direction of

normal rotation (clockwise) to remove the slack from the
belt. Check the alignment of the timing marks. Repeat
steps if timing marks are not properly aligned.
13. Tighten the belt tensioner adjustment bolt to the specified

torque.
Tightening torque:
3 5 4 5 N-m ( 3 . 5 4 . 5 kgfem, 25--33 ft-lbf}
14.Tighten the belt tensioner spring bolt to the specified

torque.
Tightening torque:
40-55 N-m(4.2-5.5 kgf.m, 3 0 - 4 0 ft.lbf}
15. Install the timing belt outer cover.
16. Install the spark plugs and tighten to the specified torque.
Tightening torque:
7-1 4 N-m(0.7-1.4 kgfem, 60--120 in-lbf}
CYLINDER HEAD GASKET
Replacement
Warning
Release the fuel pressure (Refer to Section F1).
Keep sparks and open flame away from fuel area.
1. Disconnect the negative battery cable.

2. Drain the cooling system.
3. Disconnect the intake air temperature sensor and mass airflow sensor connectors.
4. Remove the air cleaner assembly.
5. Remove the upper intake manifold/throttle body assembly. (Refer to Section FI.)
6. Remove the two heater hose retaining screws from the cylinder head cover.
7. Remove the engine and generator wiring harnesses.
8. Remove the high tension lead wires.
9. Remove the spark plugs, referring to Removal Note. (Refer to below.)
10. Disconnect the required vacuum hoses.
11. Remove the dipstick tube and bracket.
12. Remove the EGR valve to exhaust manifold tube.
13. Remove the cylinder head cover.
14. Remove the drive belt.
16. Disconnect the N C compressor.
17. Remove the four AIC compressor bolts and position the A/C compressor aside with the hoses attached.
18. Remove the A/C compressor and power steering pump mounting bracket bolts and position aside with
the hoses attached.
19. Disconnect the generator.
20. Remove the lower radiator hose and the heater water hoses from the water inlet tube and thermostat
housing.
21. Remove the bolts securing the water pump inlet tube to the generator bracket and remove the water pump
inlet tube.
22. Remove the generator bracket bolts and the generator bracket with the generator and ignition coils
attached.
23. Remove the upper radiator hose.
24. Remove the fan clutch.
26. Remove the timing belt. (Refer to page B1-8.)
27. Remove the timing belt tensioner.
28. Remove the front lifting eye.
29. Remove the lower intake manifold.
30. Remove the rear lifting eye.
31. Remove the exhaust manifold, referring to Removal Note. (Refer to below.)
32. Remove the cylinder head bolts.
33. Remove the cylinder head.
34. Remove the cylinder head gasket.
35. Install in reverse order of removal, referring to Installation Note.
Removal Note
Spark plugs
Note
1997 B-Truck uses double platinum enhanced
spark plugs for production. Both the ground (side)
and center electrode are enhanced with platinum.
You can also use spark plugs with the service part
number suffix letter "PP" as replacement spark
plugs.
Removal Note
Exhaust manifold
1. Remove the exhaust manifold.
2. Remove the exhaust manifold gasket.
I I
MB1304-A 713UOB1-012
Installation Note
Cylinder head
1. Clean all of the cylinder head gasket surfaces.
2. Clean the cylinder head gasket surface on the cylinder
block.
3. Position the cylinder head gasket onto the cylinder block.
Caution
Position the camshaft as shown in figure to avoid
valve and piston interference.
4. Measure the height of each dowel.

MB1293-B
Height:
14.0-1 4.5mm (0.55-0.57 in)
5. Position the cylinder head on the cylinder block.

6. Install the cylinder head bolts. Tighten the bolts in the
sequence shown in the figure in three steps.
Tightening torque:
Step 1: 70 N.m (7.1 kgf.m, 52 ft-lbf)
Step 2: 70 N-m(7.1 kgf-m, 52 ftelbf)
Step 3: Turn all cylinder head bolts an
additional 90-100 degrees, in sequence.
Cylinder head cover

1. Clean the gasket surfaces of the cylinder head cover and
cylinder head.
2. Install the cylinder head cover gasket.
3. Install the cylinder head cover.
Tightening torque:
9-13 N.m (0.9-1.3 kgf-m, 80-1 15 in-lbf}
Lower intake manifold
1. Clean the lower intake manifold gasket surface.
2. lnstall the lower intake manifold.
3. lnstall four upper manifold retaining bolts finger tight.
4. lnstall four remaining manifold bolts.
5. Tighten the bolts in the sequence shown in the figure.
Tightening torque:
26-38 N.m (2.6-3.8 kgf.m, 19--28 ftalbf)
l a FRONT OF ENGINE
Front lifting eye

lnstall the front lifting eye.
5BUOB1-086
Tightening torque:
20-30 N-rn(2.1-3.0 kgf.m, 15--22 ft-lbf}
5BUOB1-015
Exhaust manifold
Clean exhaust manifold bolts and/or stud bolts. Tighten
the bolts in two steps.
Tightening torque:
Step 1: 20-30 N-m (2.1-3.0 kgfem, 15-22 ft-lbf)
Step 2: 60-430 N.m (6.1-4.1 kgfsm, 45-59 ft-lbf)
Timing belt tensioner
Refer to page 81-63.
lnstall the timing belt outer cover
Tightening torque:
8-12 N-m(0.8-1.1 kgf.m, 6-43 ft-lbf)
I Water inlet tube
I I
MB1330-B 5EIUOB1-016
DPF EGR sensor
Note
Connect two hoses properly.
Steps After lnstallation
1. Fill the radiator and coolant reservoir with the specified amount and type of engine coolant. (Refer to
Section E l .)
2. Recharge the AIC system. (Refer to Section G in the 1997 B-Series BETM.)
3. Start the engine and check as follows:
(1) Engine oil and engine coolant leakage.
(2) Ignition timing. (Refer to Section G.)
4. Recheck the engine coolant and oil levels.
HYDRAULIC LASH ADJUSTER

1. Remove the cylinder head cover.
2. Remove the hydraulic lash adjuster, referring to Removal Note. (Refer to below.)
Removal Note
Hydraulic lash adjuster
1. Rotate the camshaft so that the base circle of the cam is
facing the applicable rocker arm.
2. Collapse the valve spring and slide the rocker over the
lash adjuster and out, using the SST.
3. Remove the hydraulic lash adjuster.
lnstallation Note
Hydraulic lash adjuster
1. Rotate the camshaft so that the base circle of the cam is
facing the applicable rocker arm.
2. Place the hydraulic lash adjuster in position in the bore.
3. Collapse the valve spring using the SST.

4. Position the rocker arm over the lash adjuster and the
valve stem.
5. Before rotating the camshaft to the next position, make
sure the hydraulic lash adjuster just installed is fully
compressed and released.
Cylindere head
e cover
e
cylinder head.
Tightening torque:
9-1 3 N.m (0.9-1.3 kgfsm, 80-1 15 in-lbf)
FRONT OIL SEAL

Replacement
3.Remove the four A/C compressor bolts and position the A/C compressor aside.
4. Remove the AIC compressor and power steering pump mounting bracket bolts and position aside with
the hoses attached.
6. Remove crankshaft pulley.
7. Remove the timing belt outer cover, referring to Removal Note. (Refer to below.)
8. Remove the timing belt. (Refer to page BI-8.)
9. Remove the timing belt pulley from the crankshaft.
10. Remove the front oil seal, referring to Removal Note. (Refer to page BI-18.)
11. Install in the reverse order of removal, referring to Installation Note.
Removal Note
2. Release the seven cover interlocking tabs and remove
cover.
I I
MB1301-A 5BUOB1-022
Front oil seal
Remove the front oil seal using the SSTs.
Installation Note
Front oil seal
Installthe front oil seal using Cam and Auxiliary Shaft Seal
Replacer T74P-6150-A, or equivalent.
4BUOB1-041

Install the timing belt outer cover.
MBIOOO-c 5BUOB1-023 Tightening torque:

8-1 2 N-m (0.8-1.1 kgf-m, 6--8 ft-lbf)
4BUOB1-042
CAMSHAFT OIL SEAL
Replacement
e
3. Remove the four A/C compressor bolts and position the A/C compressor aside.
the hoses attached.
6. Remove the crankshaft pulley.
7. Remove the timing belt outer cover, referring to Removal Note. (Refer to below.)
9. Remove the camshaft pulley, referring to Removal Note. (Refer to page B1-20.)
10. Remove the camshaft oil seal, referring to Removal Note. (Refer to page 81-20.)
Removal Note
cover.
Camshaft pulley
Remove the camshaft pulley using Cam and Auxiliary
Shaft Sprocket Tool T74P-6256-B, or equivalent.
Camshaft oil seal
Remove the camshaft oil seal using the SSTs.
Note
SST numbers: 49 UNO1 087 Seal Remover,
49 UN11 101 and 49 0223 6306 Impact Slide
Hammer.
5BUOB1-027
lnstallation Note
Camshaft oil seal
Install the camshaft oil seal using the Cam and Auxiliary
Shaft Seal Replacer T74P-6150-A, or equivalent.
4BUOB1-046

CAM AND AUXILIARY Tightening torque:

SHAFT SPROCKET TOOL
T74P-6256-6 8 - 2 N.m (0.8-1 .Ikgf-m,6 - 4ft.lbf}
4811081-047
OIL PUMP OIL SEAL

Replacement
3. Remove the four AIC compressor bolts and position the AIC compressor aside.
the hoses attached.
7. Remove the timing belt outer cover, referring to Removal Note. (Refer to page B1-21.)
9. Remove the oil pump pulley, referring to Removal Note. (Refer to page 8 1-21 .)
10. Remove the oil pump oil seal, referring to Removal Note. (Refer to page B1-21.)
12.Check the ignition timing. (Refer to Section G.)
Removal Note
Timing belt outer covere
cover.
Oil pump pulley

Remove the oil pump pulley using Cam and Auxiliary
Shaft Sprocket Tool T74P-6256-B, or equivalent.
Oil pump oil seal
Remove the oil pump oil seal using the SST.
Note
SST number: 49 UNO1 080 Sea! Remover
5BUOB1-031
Installation Note
Oil pump oil seal
Install the oil pump oil seal using Cam and Auxiliary Shaft
Seal Replacer T74P-6150-A, or equivalent.
5BUOB1-032

Tightening torque:
8-12 N.m (0.8-1 -1 kgf-m, 6-43 ftelbf}
4BUOB1-052
REAR OIL SEAL

Replacement
2. Remove the transmission. (MT-Refer to Section J1, AT-Refer to Section K.)
3. Remove the clutch cover and clutch disc. (Refer to Section H.)
4. Remove the flywheel (MT).
5. Remove the drive plate (AT).
6 . Remove the rear oil seal, referring to Removal Note. (Refer to page B1-22.)
7. Install in the reverse order of rernoval, referring to Installation Note.
Removal Note
Rear oil seal
1. Cut the oil seal lip with a razor knife.
2. Remove the oil seal by using a screwdriver protected with
a rag.
4BUOB1-054
Installation Note
Rear oil seal
lnstall the rear oil seal using the SST.
Caution
The rear face of the oil seal must be within 0.508mm
(0.019 in) of the rear face of the cylinder block.
Note
Applya small amount of clean engine oil on the new
oil seal and the seal mating surface.
lnstall the new oil seal with the spring side toward
L 1
MBI 038-c ~BUOBI-033 the engine.
I I
Drive plate (AT)
1. lnstall the drive plate.
2. Install the reinforcement plate and bolts.
Tightening torque:
73-47 N.m (7.4-4.8 kgfsm, 54--64 ft.lbf)
LMB1203-B 5BUOB1-034
1
Flywheel (MT)
Install the flywheel and bolts.
Tightening torque:
7 3 - 8 7 N-m(7.4-4.8 kgfem, 54--64 ft-lbf)
Steps After Installation

1. Connect the negative battery cable.
REMOVAL
REMOVAL
PROCEDURE
Warning
Release the fuel pressure. (Refer to Section F1.)
1. Disconnect the inertia fuel shutoff switch.

2. Release the fuel pressure. (Refer to Section F1.)
3. Disconnectthe negative battery cable from the engine. Disconnect the positive battery cable and position aside.
5. Raise the hood and install protective fender covers.
6. Mark the location of the hood hinges and remove the hood.
7. Disconnect the Intake Air Temperature (IAT) and the Mass Air Flow (MAF) sensors.
8. Disconnect the air cleaner outlet tube from the throttle body.
9. Disconnect the upper and lower radiator hoses.
10. Remove the fan guard, if equipped, or the fan shroud and position it on the fan blade.
11. Disconnect the radiator overflow hose.
12. Remove the radiator. (Refer to Section E.)
13. Disconnect the Engine Coolant Temperature (ECT) sensor.
14. Remove the generator and drive belt. (Refer to Section G.)
15. Disconnect the upper and lower heater hoses from the engine.
16. Disconnect the high-tension lead wires from the ignition coils.
17. Disconnect the engine wiring harness from the ignition coils, solenoid valves, water temperature sender
unit, and radio interference capacitor.
18. Disconnect the power brake unit vacuum hose.
19. Remove the water pump inlet tube.
20. Remove the generator bracket with the ignition coils attached.
21. Disconnect the accelerator cable from the throttle body. Leave the cable attached to the bracket.
22. Remove the accelerator cable bracket with the accelerator cable attached and po!;ition aside.
23. Disconnect the fuel charging wiring harness from the engine wiring harness.
24. Remove the DPFE sensor from the engine lifting bracket.
25. Disconnect the evaporative emission purge hose from the engine.
26. Recover the refrigerant in the A/C system, if equipped. (Refer to Section G in the 1997 B-Series BETM.)
27. Remove the air conditioning hoses from the suction accumulator and condenser, if equipped. (Refer
to Section G in the 1997 B-Series BETM.)
28. Remove the A/C compressor, if equipped.
29. Remove the A/C compressor and power steering pump bracket bolts and position the bracket and power
steering pump aside.
30. Raise the vehicle and support it with safety stands.
31. Drain the engine oil.
32. Remove the starter motor. (Refer to Section G.)
33. Disconnect both Heated Oxygen Sensors (H02S).
34. Disconnect the three way catalytic converter from the exhaust manifold.
35. Disconnect the fuel supply and return line fittings from the rear of the engine fuel rail.
36. Disconnect the ground cable from the left side of engine.
37. Remove the dust cover (MT) or the converter inspection plate (AT).
38. Remove the bell housing cover attaching bolts (MT).
39. Remove the converter-to-drive plate bolts. Remove the bell housing lower bolts (AT).
40. Lower the vehicle.
41. Support the transmission and th~ebell housing with a jack.
42. Remove the bell housing upper attaching bolts.
43. Remove the engine mount nuts.
44. Attach the engine lifting hooks to the existing lifting brackets. Lift the engine out of the vehicle.
Caution
Do not damage any compo~nentson the engine or in the e
engine compartm~ent.
7BUOB1-012
DISASSEMBLY
DISASSEMBLY
PREPARATION
SST
1 49 UNO1 067 I For 1 49 UNO1 080 I For 1
/ 49 UNOl 135 A% I For

collapsing
49 0223 6308 For
removal of
Valve spring valve Impact slide the oil seal
compressor spring hammer
1. Code all identical parts (such as pistons, piston rings, connecting rods, and valve springs) so that they
can be reinstalled in the cylinder from which they were removed.
2. Clean the parts with steam, blow off any remaining water with compressed air.
Note
During the disassembly of any part or system, be sure to study its order of assembly. Also, note
any deformation, wear or damage.
4BUOB1-061
AUXILIARY PARTS
1. Disconnect the required vacuum hoses.
2. Remove the dipstick tube and bracket, referring to Disassembly Note. (Refer to page B1-26.)
3. Remove in the order shown in the figure, referring to Disassembly Note.
DISASSEMBLY B1
MB1310-B 5BUOB1-038
1. Upper intake manifoldlthrottle body 5. Cylinder head cover
assembly 6. Cylinder head cover gasket
Removal ............................... Section F1 7. Lower intake manifold
2. Engine and generator wiring harnesses 8. Lower intake manifold gasket
3. High-tension lead wires 9. Exhaust manifold
4. Spark plugs
B1 DISASSEMBLY
Disassembly Note
Dipstick tube and bracket
Remove the stud and dipstick tube and bracket.
TIMING BELT
2. Disassemble in the order shown in the figure, referring to Disassembly Note.
I I
MB1311-A 5BUOB1-040
1. Crankshaft pulley 4. Timing belt pulley
2. Timing belt outer cover 5. Oil pump pulley
3. Timing belt 6. Timing belt tensioner
Disassembly Note ................ page B1-27 7. Camshaft pulley
DISASSEMBLY B1
Disassembly Note
,SPRING BOLT Timing belt
Caution
If you attempt to remove the timing belt or to adjust
ADJUSTMENT
BOLT tension without looseningbothtiming belt tensioner
adjusting bolt and spring pivot bolt, you will break
the SST (49 UNOl 067) when you attempt to relieve
tension on belt.
1. Loosen the timing belt spring pivot bolt. Do not remove.

2. Hold tensioner with SST.
3. While holding tensioner, loosen adjusting bolt and gradu-
ally release spring tension.
4. Using adjusting tool, rotate tensioner, against spring
pressure, as far clockwise as possible. While holding,
tighten adjusting bolt to hold tensioner away from belt.
5. Remove the timing belt.

B1 DISASSEMBLY
CYLINDER HEAD
1. Remove the cylinder head gasket and the cylinder head assembly. (Refer to steps 26 through 35 on
page B1-12.)
2. Remove the thermostat housing and thermostat. (Refer to Section E l .)
J
MB1312-B 5811081-042
1. Camshaft oil seal 8. Camshaft
Disassembly Note ................ page B1-29 Disassembly Note ................ page 61 -29
2. Camshaft thrust plate Inspection ............................. page I31-39
Disassembly Note ................ page 61-29 9. Camshaft bearings
3. Rocker arms (not shown) Disassembly Note ................ page B1-29
Disassembly Note ................ page 81-29 10. Intake valve seals
4. Valve keepers 11. Exhaust valve seals
Disassembly Note ................ page 61-29 12. Hydraulic lash adjuster
5. Upper spring seats 13. Engine oil pressure sensor
6. Valve spring
7. Valves
Disassembly Note ................ page BI-29
Inspection ............................. page B1-36
DISASSEMBLY
Disassembly Note
Camshaft oil seal
Remove the camshaft oil seal using the SSTs.
Note
SST number: 49 UNOl 080 Seal Remover and
49 0223 6308 Impact Slide Hammer.
5BUOB1-089
Camshaft thrust plate

Remove the camshaft thrust plate.
Camshaft
Remove the camshaft.

Caution
Remove the camshaft carefully to avoid damaging
the journals and lobes.
5BUOB1-091
5BUOB1-043
Rocker arms
Using the SST, depress the valve springs and remove the
rocker arms.
Note
Remove the rocker arms from the HLA side.
Valve keepers
Using the SST, depress the valve springs and remove the
valve keepers.
5BUOB1-090
I I
MB1231-C 4BUOB1-071
Camshaft bearings
CAM BEARING REPLACER Remove the camshaft bearings using Cam Bearing
T71 P-6250-A
Replacer T71 P-6250-A, or equivalent.
5BUOB1-044
Valves
If the cylinder head is being repaired, remove the deposits
from the combustion chambers with a scraper and wire
brush before removing the valves.
4BUOB1-075
B1 DISASSEMBLY
CYLINDER BLOCK (EXTERNAL PARTS)
1. Remove the clutch cover, clutch disc, and flywheel (MT), referring to Disassembly Note. (Refer to page
81-31 .)
2. ~ e m o v e
the drive plate (AT), referring to Disassembly Note. (Refer to page 81-31 .)
MB1314-B 5BUOB1-047
1. Rear cover plate 5. Oil pan
2. Water pump Disassembly Note ................ page B1-32
Disassembly Note ................ page B1-31 6. Oil pump and camshaft position sensor
3. Water temperature sender unit 7. Oil pump strainer and tube (not shown)
4. Oil filter and oil filter mounting insert Disassembly Note ................ page B1-32
DISASSEMBLY B1
Disassembly Note
Clutch cover, clutch disc, and flywheel (MT)
1. Remove the bolts and clutch cover.
2. Remove the clutch disc.
Drive plate (AT)

Remove the six bolts, the reinforcement plate and the
drive plate.
I I
MB1203-B 5BUOB1-049
Water pump
Remove the water pump bolts ancl remove the water
pump and gasket.
B1 DISASSEMBLY
Oil pan
1. Remove the bolts and the engine oil pan.
2. Remove the gasket. Clean the engine and the oil pan
gasket surfaces.
FRONT OF
ENGINE
Oil pump strainer and tube

1. Remove the nut and the two boltsand remove the oil pump
strainer and tube.
2. Remove the oil pump strainer and tube gasket.
DISASSEMBLY B1
FRONT COVER
1. Remove timing belt. (Refer to B'I -26.)
2. Remove oil pan. (Refer to 81-32.)
3. Remove crankshaft pulley.
4. Remove camshaft and oil pump pulleys.
5. Remove crankshaft position sensor.
6. Remove the inner timing belt cover.
7. Remove the front oil seal referring to Disassembly Note. (Refer to below.)
I
MB1315-A 6BUOB1-014
1. Front cover 2. Frorit cover gasket
Disassembly Note
Front oil seal
Remove the front oil seal from the front cover using the
SSTs.
Note
Remove the front oil seal while the front cover is
still mounted on the engine.
B1 DISASSEMBLY
CYLINDER BLOCK (INTERNAL PARTS)
Disassemble in the order shown in the figure, referring to Disassembly Note.
I
MB1213-D 5BUOB1-053
1. Connecting rod cap 6. Piston
Disassembly Note ........................... below Inspection ............................. page B1-41
2. Connecting rod bearing 7. Main bearing caps
Inspection ............................. page B1-45 Disassembly Note ................ page B1-35
3. Piston ring 8. Main bearing and thrust bearing, lower
Disassembly Note ................ page B1-35 9. Crankshaft
4. Piston pin Inspection ............................. page B1-44
Disassembly Note ................ page B1-35 10. Rear oil seal
Inspection ............................. page B1-43 11. Main bearing and thrust bearing, upper
5. Connecting rod 12. Cylinder block
Disassembly Note ................ page B1-35 Inspection ............................. page B1-40
Inspection ............................. page B1-43
Disassembly Note
Connecting rod cap
Before removing the connecting rod caps, measure the
connecting rod side clearance. (Refer to page B1-53.)
5BUOB1-102
DISASSEMBLY B1
Connecting
e rod
1. Before removing the connecting rods, measure the con-
necting rod bearing oil clearance by using Plastigage.
(Refer to page B1-52.)
2. Remove the Plastigage from the journals and bearings.
Note
Remove any ridges andlor deposits from the upper
end of the cylinder bores as necessary.
Turn the crankshaft until the piston to be removed
is at the bottom of its travel and place a cloth on the
piston head to collect the cut1:ings. Remove any
ridge andlor deposits from the upper end of the
cylinder bores. Remove the cylinder ridge with a
ridge cutter. Follow the instructions furnished by
the tool manufacturer.
Caution
Never cut into the ring travel area in excess of
0.8mm (0.03 in).
Do not scratch the crankshaft journals or the cylin-
der walls.
3. Use the handle of a hammer to push the piston and

connecting rod assembly through the top of the cylinder
I T 5BUOB1-103
Piston ring
Caution
Do not apply excessive tension, which may cause
the ring to break.
Remove the piston rings by using a piston ring expander

(commercially available).
4EiUOB1-090
Piston pin
Caution
Mark the connecting rod direction for proper reas-
sembly.
1. Mark the piston and pins to ensure assembly with the

same rod and installation in the same cylinders from which
they were removed.
2. Using an arbor press and Piston Pin Remover and Re-
placer T68P-6135-A, or equivalent press the pin from the
piston and connecting rod.
4BUOB1-091
Main bearing caps
1. Measure the crankshaft end play before removal.
End play: 0.1 0--0.20mm (0.004--0.008 in)

Maximum: 0.30mm (0.012 in)
2. Remove the two bolts from each main bearing cap and
remove the main bearing caps with the bearings.
B1 INSPECTION IREPAIR
INSPECTION / REPAIR
PREPARATION
1. Clean all parts, being sure to remove all gasket fragments, dirt, oil, etc.
2. Perform the inspections and repairs in the order specified.
Caution
Do not damage the joints or friction surfaces of aluminum alloy components.
4BUOB1-093
CYLINDER HEAD
1. Inspect the cylinder head for damage, cracks and leakage
of water and oil. Replace if necessary.
2. Using a straightedge, measure the cylinder head distor-
tion in six directions.
Note
Before grinding the cylinder head, check the
following. Repair or replace as necessary.
(1) Sinking of valve seat.
(2) Damage of manifold contact surface.
(3) Camshaft oil clearance and end play.
3. If distortion exceeds specification,grind the cylinder head.

I
MB1215-A
Distortion:
0.08mm (0.003 in) max, per 152mm (6.0 in) and
0.15mm (0.006 in) max overall
Grinding: 0.25mm (0.01 in)
4. Using a straightedge, measure intake and exhaust mani-

fold contact surfaces for distortion in six directions.
Distortion: 0.08mm (0.003 in)
5. If distortion exceeds specification, grind the surface or

replace the cylinder head.
VALVE MECHANISM
R STEM TIP
Valve and Valve Guide
1. Inspect each valve for the following. Replace or resurface
as necessary.
(1) Damaged or bent stem
(2) Rough or damaged face.
(3) Damaged or unevenly worn stem tip.
INSPECTION 1 REPAIR B1
2. Measure the valve stem diameter and' replace the valve if
necessary.
Diameter
e
Standard
IN: 6.97-7.00mm (0.2746-0.27!54 in)
EX: 6.95-6.97mm (0.2736-0.2744 in)
Oversize-0.38mm (0.015 in)

IN: 7.36-7.38mm (0.2896-0.2904 in)
EX: 7.33-7.35mm (0.2886-0.2894 in)
Oversize-O.76mm (0.030 in)

IN: 7.74-7.76mm (0.3046-0.3054 in)
EX: 7.71-7.73mm (0.3036-0.3044 in)
3. Measure each valve guide inner bore diameter and record.
Inner diameter
8.71--8.74mm (0.3433-0.3443 in)
4. Calculate the valve stem-to-guide clearance. With the

valves in place, measure the clearance using Valve Stem
Clearance Tool TOOL-6505-E, or equivalent, and a dial
indicator with a flat-end indicator point.
(1) Install the tool on the valve stem ~ ~ nitt iisl fully seated
and tighten the knurled setscrew firmly. Permit the
valve to drop away from its seat until the tool contacts
the upper surface of the valve guide.
(2) Position the dial indicator with its flat tip against the
center portion of the tool's spherical section, at ap-
proximately 90" to the valve stem axis. Move the tool
back and forth in line with the indicator stem. Take a
reading on the dial indicator without removing the tool
from the valve guide upper surface. (Divide the reading
by two, the division factor for the tool.) If the valve stem-
to-guide clearance exceeds the wear limit, ream the
valve guide for the next oversize valve stem.
Clearance
IN: 0.0254.068mm (0.0010-0.0027 in)
VALVE STEM EX: 0.038-0.081 mm (0.0015-0.0032 in)
CLEARANCE TOOL Service Limit Clearance Maximum
TOOL-6505-E
0.139mm (0.0055 in)
B1 INSPECTION I REPAIR
5. Measure the hydraulic lash adjuster bore diameter.
Diameter: 21.4-24.0mm (0.8430-0.9449 in}
6. If the hydraulic lash adjuster bore diameter exceeds the

maximum, replace the cylinder head.
Valve Seat
1. lnspect the contact surface of the valve seat and valve
face for the following:
(1) Roughness
(2) Damage
2. If necessary, resurface the valve seat.
3. Apply a thin coat of Prussian blue to the valve face.
4. Check the valve seating by pressing the valve against the
seat.
(1) If blue does not appear 360" around the valve face,
replace the valve.
(2) If blue does not appear 360" around the valve seat,
resurface the seat.
5. Check the valve seat runout with a valve seat runout

gauge, as illustrated. Follow the instructions of the
gauge manufacturer. If the runout exceeds the wear
limit, resurface the valve and valve seat.
Runout Limit: 0.05mm (0.002 in}

Valve Spring
1. lnspect the valve spring, valve spring retainers and keys,
for wear or damage. Discard any damaged parts.
I
4BUOB1-09
APPLY TORQUE UNTIL 2. Check the springs (separated from dampers) for proper
pressure at the specified spring lengths. Follow the in-
AND MULTIPLY structions of the spring tester manufacturer. Replace any
READING BY TWO spring not within specification.
Pressurellength:
57-63 Ibs. at 39.6mm (1.56 in)
VALVE SPRING
SET KNOB TO
COMPRESSED
LENGTH OF
SPRING
3. Check the valve spring free length.
Free length: 51.3mm (2.02 in) (approximate)

INSPECTION / REPAIR B1
4. Check the out-of-square of the valve spring.
e limit: 1.98mm (0.078 in)

Out-of-square
Caution
D DOWNWARD Make sure the springs are reassembled to their
original dampers by pushing the damper onto the
spring. Do not open the damper, with any kind of
tool, in order to reassemble.
B
6BIJOB1-016
CAMSHAFT
1. Check the carnshaft journals for wear or scoring. If the
journals are excessively worn or scored, replace the
camshaft.
2. The camshaft journals can be refinishedto accommodate
0.38mm (0.015 in} undersize bearings. If the journals can
not be cleaned, replace the camshaft.
3. Set camshaft on V-blocks and measure the runout.
Runout: 0.127mm (0.005 in) max.
4. Inspect the camshaft for wear and damage. Replace the

camshaft if necessary.
MB1218-A
5. Measure the camshaft lobe lift. To rrieasure the lift, pro-
ceed as follows:
(1) Measure the distance between miajor (A-A) and minor
(B-B) diameters of each cam lobe with a Vernier
caliper and record the readings. The difference in
B readings on each cam diameter is the lobe lift.
(2) If readings do not meet specification, replace the
camshaft.
Lobe lift: 5.49mm (0.21 63 in)

A
ME31024-A
I
/ 6. Measure the camshaft journal diameters in the X and Y
directions at two points. Replace the camshaft as neces-
sary.
Journal diameter:
44.9945.0mm (1.7713-1.77201 in)
B1 INSPECTION / REPAIR
7. Measure the camshaft journal-to-bearing clearance by
measuring the journal diameter and the bore diameter.
Subtract the journal diameter from the bore diameter to
determine the clearance.
Clearance: 0.025-0.076mm (0.0014.003 in)

8. Measure the camshaft end play.

Caution
Prying against the camshaft pulley with the valve
train load on the camshaft can break or damage the
pulley. Therefore, the rocker arm adjusting nuts
must be backed off, or the rocker and shaft assem-
bly must be loosened sufficiently to free the cam-
shaft. After checking the camshaft end play, adjust
the valve clearance.
(1) Push the camshaft toward the rear of engine. Install a

dial indicator so the indicator point is on the camshaft
gear.
(2) Zero the dial indicator. Pull camshaft forward and
release it. Compare reading with specifications. If end
play is excessive, replace the thrust plate.
(3) Remove dial indicator.
End play: 0.025-0.177mm (0.001--0.007 in}

End play: 0.229mm (0.009 in) Max
CYLINDER BLOCK
1. Check the cylinder block for the following. Repair as
necessary.
(1 ) Leakage damage
(2) Cracks
(3) Scoring of wall
2. Using a straightedge, measure the cylinder block deck for

distortion in six directions.
Distortion:
0.07mm (0.003 in) per 152.4mm (6.0 in}
Overall distortion:
0.152mm (0.006 in)
3. If distortion exceeds the maximum, replace the cylinder

block.
INSPECTION 1 REPAIR B1
4. Measure the cylinder bore diameter in X and Y directions,
at three levels (A,B,C), as shown.
e
Cylinder bore:
96.000-96.01 5mm (3.7795-3.7801 in)
1
MB1026-A
5. Measure the cylinder bore taper. If the difference between
measurement A and C exceeds the maximum taper,
rebore all cylinders to oversize diameter.
Taper: 0.25mm (0.01 in}
6. If the difference between measurements X and Y exceeds

\ - _ _I the maximum out-of-round, rebore all cylinders to the
oversize diameter.
/
~~1027-A
1
~ELUOBI-018
Out-of-round: 0.038mm (0.0015 in)
Limit: 0.127mm (0.005 in)
PISTON, PISTON RING AND PISTON PIN

Piston
1. Inspect the outer circumferences of all pistons for seizing
and scoring. Replace as necessary.
2. Measure outer diameter of each piston at a right angle to
the piston pin 14.58mm (0.58 in) below the bottom of the
oil ring.
Note
The pistons are color-coded red, blue, or yellow on
the dome of the piston.
Piston diameter
I Piston color code

Red 96 2228-95
-
~iarneter~'
994 {:3 7883-3.7793)
- 1 mm {in}
I Measured 14.58mm (0.57 in) from bottom of skirt, centerline 90" to the pin
MB1277-D
3. Measure the piston-to-cylinder clearance.
Clearance:
0.061-0.086mm (0.0024-0.0034 in)
4. If the clearance exceeds the maximum, select a piston to

obtain the specified clearance.
mm {in}
Cylinder bore diameter Piston color code
.
96.2228-95.994 {3.7883-3.77931
- - -- - --
96.076-96.114 I3.7825-3.7840) Yellow

MB1235-C
Note
If a piston is replaced, the piston ring must also be
replaced.
Piston and Piston Rings
1. Measure the piston to ring land clearance around the
entire circumference by using a new piston ring.
Clearance
Top: 0.0414.084mm (0.0016-0.0033 in}
Second: 0.041--0.084mm (0.001 6-4.0033 in)
Oil Ring: Snug fit
Service Limit: 0.15mm (0.006 in} max
2. If the clearance exceeds the maximum, replace the

MB1029-A piston.
3. Inspect the piston ring for damage, abnormal wear, or
breakage. Replace as necessary.
4. Insert the piston ring into the cylinder by hand and use
the piston to push it to the bottom of the ring travel.
Caution
Use care to avoid damage to the ring or the cylinder
bore.
PISTON
RING
5. Measure each piston ring end gap by using afeelergauge.

Replace the piston ring as necessary.
End gap
Top: 0.20-0.41 mm (0.008-0.01 6 in)
Second: 0.33-0.48mm (0.01 3-0.01 9 in)
Oil Ring: 0.33-0.76mm (0.013-0.030 in)
Piston pin
1. Measure each piston pin bore diameter in X and Y
directions at four points.
Diameter
23.1725-23.1 800mm (0.91 23-0.9126 in)
2. Measure each piston pin diameter in the X and Y direc-

tions at four points.
I I Diameter
I I
MB1032-A 6BUOB1-020 Standard
23.1 67-23.1 70mm C0.9121-0.9122 in)
0.001 Oversize:
23.193-23.195mm (0.91 31-0.91 32 in)
0.002 Oversize:
23.21 8-23.221 mm (0.91 41-0.91 42 in)
=arance.
3. Calculate the related piston to pin cl~,
Clearance
0.005-0.01 0mm (0.0002-0.00014 in)
4. If the clearance exceeds specification, replace the piston

and/or piston pin.
5. Measure each piston pin length.
Length:
62.3-70.1 mm (2.73-2.76 in)
6. If the length exceeds specifications, replace the piston
pin.
CONNECTING ROD
1. Measure the small end inner bore diameter of each
connecting rod.
Diameter:
23.1 24-23.1 44mm (0.91 04-0.91 12 in)
Caution
If the connecting rod is replaced, the connecting
rod cap must also be replaced, since they are a
matched set.
2. Check the bend and twist factor of each connecting rod.

Repair or replace as necessary.
Bend: 0.038mm (0.0015 in)

Twist: 0.076mm (0.003 in)
Length (Center to Center):
138.58-1 38.67mm (5.4558-5.4591 in)
INSPECTION / REPAIR
-
- - -
Note
The piston pin bore and crankshaft bearing bore
must be parallel and in the same vertical plane,
within the specified total difference when mea-
sured at the ends of an 203.2mm (8 in} bar, 101.6mm
(4 in) on each side of the connecting rod centerline.
3. Measure the connecting rod crankshaft bearing bore

diameter.
Diameter
55.170-55.1 90mm (2.1720-2.1728 in)
4. If the diameter exceeds the specification, replace the

connecting rod.
out-of-round and taper.
Out-of-round: 0.01 mm (0.0004 in)

Taper: 0.01 mm (0.0004 in)
6. If the out-of-round or taper measurements exceed the

maximum, replace the connecting rod.
CRANKSHAFT
1. Check the journals and pins for damage, scoring, and oil
hole clogging.
2. Set the crankshaft on V-blocks.
3. Measure the crankshaft runout at the center main bearing

journal. Replace the crankshaft if necessary.
Runout: 0.0508mm (0.002 in)

Max: 0.127mm (0.005 in)
4. Measure each journal diameter in the X and Y directions

at two points.
Main journal
Diameter: 56.02-56.00mm (2.2059-2.2051 in}
Crankpin journal
Diameter: 51.97-51.99mm (2.0462-2.0472 in)
INSPECTION I REPAIR B1
5. If the diameter is less than the minimum, grind the journals
to accept undersize bearings.
Undersize bearing
0.050mm (0.002 in) (main journal and crankpin)
Main journal diameter undersize
rnm {in)
Bearing size
-- --
0.050 10.0021
- --- -
Journal diameter
-- -
k5.97-55.95 12.2039-2.2031 I
Crankpin journal diameter undersi2.e
rnrn (in1
Bearing size Journal diameter
-----h-~9~2.01~2-2.04921
10.050 10.0021
BEARING
Main Bearing and Connecting Rod Bearing
Check the main bearing and connecting rod bearings for
peeling, scoring and other damage.
CRATERS OR POCKETS BRIGHT (POLISHED)
SECTIONS TIMING BELT
I FATIGUE FAILURE IMPROPER SEATING

Caution
Never forcefully, twist, turn inside out, or bend the
timing belt.
Be careful not to allow oil or grease on the belt.
SCRATCHES DIRT 1. Replace the timing belt if there is any grease on it.
IMBEDDED OLJT
INTO BEARING
MATERIAL
SCRATCHED BY DIRT LACK OF OIL OR
w3
IMPROPER CLEARANCE
OVERLAY GONE
FROMEDGES RADIUS R113E
HOURGLASSING RADIUS R113E
INSPECTION 1 REPAIR
2. Check the timing belt for damage, wear, peeling, cracks,
and hardening. Replace if necessary.
DAMAGE, PULLEY
WEAR Timing Belt Pulley and Camshaft Pulley
Caution
Do not clean the pulleys with cleaning fluids. If
necessary, use a soft rag to wipe clean and avoid
scratching them.
lnspect the teeth of each pulley for wear, deformation and

MB1238-A 4BUOB1-106
other damage. Replace as necessary.
6BUOB1-022
TIMING BELT OUTER COVER

Inspect the timing belt outer cover for damage and cracks.
Replace as necessary.
4BUOB1-108
FLYWHEEL (MT)
I . Inspect the flywheel for cracks, heat check, or other
damage that would make it unfit for further use.
2. Acceptable flywheels may be repaired by polishing with
fine grade (400 grit) sandpaper. Flywheels may be resur-
faced to remove scratches or grooves. After resurfacing,
the flywheel thickness must be less than the dimensions
listed below.
Note
The inspection procedures for the 3.OL and 4.OL
flywheels are the same as the 2.3L inspection pro-
cedure described above.
2.3L
Dimension A: 25.95mm (1.02 in)
Dimension 6: 28.45mm (1.I2 in}
3.0L
Dimension A: 28.18mm (1.I0 in)
Dimension B: 28.85mm (1.I4 in)
4.0L
Dimension A: 25.95mm (1.02 in)
Dimension B: 28.45mm (1.I2 in)
INSPECTION 1 REPAIR, ASSEMBLY B1
Note
/ DOWEL HEIGHT
PRESSURE PLATE
BOLT HEIGHT I Dimension "A" is the minimum acceptable dimen-
I 'IN \ / FLYWHEEL \ I sion from the crankshaft mounting surface to the

new resurfaced clutch facesurface. Dimension "B"
is the referenced minimum acceptable dimension
for the overall width of the outer edge.
3. Mount the flywheel rigidly on the crankshaft mounting

flange.
I
\
CRANKSHAFT GEAR
Surface runout: 0.13mm (0.005 in) TIR
Surface finish:
4.011.3 micrometer (160152 microinch)
4. The major diameter of dowel pin (press-fit diameter) must

not extend above the new surface.
5.The clutch cover retaining bolts must screw into the
flywheel under hand torque to within 1.52mm (0.06 in} of
new surface.
6. Flywheels with dimensions less than the charted dimen-
sions must not be used; install a new flywheel.
ASSEMBLY
PREPARATION
SST
-- 49 UNOl 135 For 49 UNOl 070 For
Valve spring
compressor
collapsing
valve
spring
2.3L crankshaft
seal installer
@ & @j
installation of
rear main
oil seal
I 49
068
Front cover
For
installation
of front
al~gnmenttool cover
1. Clean all parts before assembly.

2. Apply clean engine oil to all sliding and rotating parts.
3. Tighten all bolts and nuts to the specified torque.
Caution
Do not reuse gaskets or oil seals.
ASSEMBLY
Assemble in the order shown in figure, referring to Assembly Note.
STEP 1:Tighten all bolts by hand until seated.

STEP 2: 66-41 {6.9-8.1,50-59)
STEP 3:102-115 {I 0.4--11.7,75-85)
N.m {kgf.m, ft4bf)
MB1219-D 5BUOB1-057
1. Main bearings and thrust bearing, upper 7. Connecting rods
2. Crankshaft 8. Piston pins
Assembly Note ..................... page 61-49 Assembly Note ..................... page 81-50
3. Main bearings and thrust bearing, lower 9. Piston rings
4. Main bearing caps Assembly Note ..................... page 81-51
5. Rear oil seal 10. Connecting rod bearings
Assembly Note ..................... page B1-50 11. Connecting rod caps
6. Pistons Assembly Note ..................... page 81-52
Assembly Note ..................... page B1-51
ASSEMBLY
Assembly Note
Crankshaft
1. Measure the main bearing oil clearances as described
below:
Oil clearance inspection

(1) Remove any foreign material and oil from the jour-
nals and bearings.
(2) lnstall the upper main bearings and thrust bearing
(3) lnstall the lower main bearings into the main bearing
caps.
(4) lnstall the crankshaft into the cylinder block.
(5) Position Plastigage atop the journals in the axial
direction.
(6) Apply clean engine oil to the threads and seat faces
of the main bearing cap bolts.
(7) lnstall the main bearing cap.
(8) Lightly oil main bearing bolt or stud. Alternately
tighten to 68-81 N. m (6.9--8.2 kgf .m, 50-60
ft .lbf). Retighten to 102-1 15 N .m (1 0.4-1 1.7
kgf . m, 75-85 ft . lbf).
(9) Remove the main bearing cap.
(10) Measure the Plastigage at each journal at the widest
point for the smallest clearance, and the narrowest
point for the largest clearance.
Oil clearance
Number One Main Bearing:
Standard: 0.010-0.054mm (0.0004-0.0021 in)
Maximum: 0.054 (0.0021 in)
Number Two to Five Main Bearings:

Standard: 0.020--0.064mm (0.0008-0.0025 in)
Maximum: 0.064 (0.0025 in)
(1 1) If the oil clearance exceeds the maximum, grind the

crankshaft and install undersize bearings.
2. lnstall the main bearing caps as follows:
(1) Remove the Plastigage from the journals and bear-
ings.
(2) Apply a liberal amount of clean engine oil to the main
bearings.
(3) Apply a 7mm (0.27 in) dot of sealant on each side of
cylinder block as shown in the figure.
ASSEMBLY
(4) lnstall the main bearing caps as shown in the figure.
(5) Tighten the main bearing cap bolts in three steps.
Note
Caps must be seated prior to bolt installation.
Do not let the crankshaft rotate the bearings.
Tightening torque:
Step 1: Tighten all bolts by hand until seated
Step 2: 68-81 N m (6.9-8.1 kgf . m, 50-59 ft .lbf)
Step 3: 102-11 5 N - m (10.4--11.7 kgf .m, 75-85 ft.Ibf)
3. Measure the crankshaft end play
End play: 0.01--0.2mm, (0.0044.008 in)

Maximum: 0.3mm (0.01 2 in)
4. If the end play exceeds the maximum, grind the crankshaft

and install an oversize thrust bearing, or replace the
. , ,, ,, crankshaft and thrust bearing.
FRONT CF ENGINE
Rear oil seal
1. Lubricate rear oil seal and mating surface with clean
engine oil before installation.
2. Install the rear main oil seal using the SST.
Caution
FRONT OF E The rear face of the seal must be within 0.508mm
(0.019 in) of the rear face of the block.
Note
Apply asmall amount of clean engine oil on the new
oil seal and the seal mating surface.
Install the new oil seal with the spring side toward
the engine.
Piston pins
NOTCH POINTINGTOWARD 1. Start the piston pin into the piston and connecting rod; this
RONT OF ENGINE may require a light tap with a mallet.
2. Finish installing piston pin into piston using Piston Pin
SQUIRT HOLE Remover and Replacer T68P-6135-A, or equivalent until
the pin is centered in the piston.
Note
Assemble the piston to the connecting rod with the
oil squirt holes on the side of the connecting rod
and the arrow in the piston positioned as shown.
NUMBER OF LEFT Piston pins must be installed in the original piston
SIDE OF ROD from which they were removed.
MB1040-A 4BUOB1-115
ASSEMBLY
Piston rings
Install the piston rings on the pistori using a piston ring
expander (commercially available).
25.4 mrn {I IN) @ 25.4 mm {I inch)
Note
Piston rings must be staggered on the piston to
make sure the piston ring end gaps are not aligned.
If new piston rings are to be installed, and no visible
cross hatch marks remain on the cylinder wall, or
an unfinished cylinder wall, then the wall must be
refinished using a spring-type Cylinder Hone Set
T73L-6011-A, or equivalent.
Never install piston rings with hands.
4BU081-116
Pistons
Note
All pistons, connecting rods, bearings and con-
necting rod bearing caps must be installed in the
original location from which they were removed.
I FRONT
1. Oil all pistons, piston rings and cylinder walls before
installation.
Caution
The connecting rod and bearing caps are num-
bered 1 to 4. The numbers on the connecting rod
and bearing cap must be on the same side after
installation.
2. Check the piston rings for correct gap alignment.
PISTON RING 3. Install a piston ring compressor on the piston.

OF \ / COMPRESSOR 4. Push the piston into the cylinder block in with a hammer
handle until it is slightly below the top of the cylinder. Be
sure to guide the connecting rods to avoid damaging the
crankshaft journals.
Caution
lnstall the piston with the indentation notch in the
piston head toward the front olf the engine.
ASSEMBLY
Connecting rod cap
1. Measure the connecting rod bearing oil clearances as
follows:
Caution
Do not rotate the crankshaft when measuring the
oil clearances.
Oil clearances must be measured with the connect-
ing rod in the BTDC position.
(1) Remove any foreign material and oil from the journals
and bearings.
(2) Install the connecting rod bearing into the connecting
rod cap.
direction.
(4) Apply clean engine oil to the threads and seat faces of
the connecting rod cap bolts.
(5) Install the connecting rod cap.
(6) Tighten the connecting rod cap nuts in two sequences.
Tightening torque:
Step 1: 3 4 4 1 N-m( 3 . 5 4 . 1 kgf-m, 25-30 ftslbf)
Step 2: 4 1 4 9 N.m (4.1-4.9 kgf.m, 30-36 ftelbf)
(7) Remove the connecting rod cap.

point for the smaller clearance, and the narrowest
Oil clearance
Number One Main Bearing:
Standard: 0.010-0.054mm (0.0004--0.0021 in)
Maximum: 0.054 (0.0021 in)
Number Two to Five Main Bearings:

Standard: 0.020-0.064mm (0.0008-0.0025 in)
Maximum: 0.064 (0.0025 in)
(9) If the oil clearance exceeds the maximum, grind the

2. Install the connecting rod bearings and caps as follows:
ings.
(2) Apply a liberal amount of clean engine oil to the
connecting rod bearings.
(3) lnstall the bearing in the connecting rod and cap, with
the tangs fitting the slots provided.
(4) Turn the crankshaft throw to the bottom of its stroke.
Push the piston all the way down until the connecting
rod bearing seats on the crankshaft journal.
(5) Install the connecting rod cap. The connecting rod cap
nuts must be tightened in two steps.
Tightening torque:
Step 1: 3 4 4 1 N-m(3.5-4.1 kgf.m, 25-30 ft.lbf)
Step 2: 4 1 4 9 N-m( 4 . 1 4 . 9 kgf-m, 30-36 ft.lbf)
ASSEMBLY
3. After the piston and connecting rod assemblies have been
installed, check the side clearance between the connect-
ing rods on each crankshaft journal.
Side clearance
Standard: 0.08-0.26mm {0.003!j-0.0105 in)
4. If the clearance exceeds the maximu,m, replace the con-

necting rod and cap.
FRONT COVER
Assemble in the order shown in the figure, referring to Assembly Note.
L --
MB1323-A 5BUOB1-066
1. Front cover gasket 2. Front cover
Assembly Note ................................ below
Front cover
Note
Before finally adjusting the cover into position and
tightening attaching bolts, use the SST to position
thecover in relation to the crankshaft-Tightenbolts
to specification with this tool in place. This will
ensure that the timing belt does not interfere with
the front cover when operating.
1. Install the front oil seal with Cam ancl Auxiliary Shaft Seal
2. Install the front cover.
Tightening torque:
13-1 6 N.m { I .4-1.6 kgf-m, 10.-11 ft-lbf)
ASSEMBLY
1. Assemble in the order shown in the figure, referring to Assembly Note.
2. Install the clutch cover, clutch disc, and flywheel (MT), referring to Assembly Note. (Refer to 81-57.)
3. Install the drive plate (AT), referring to Assembly Note. (Refer to B1-57.)
N.m {kgf-m, ft.lbf)
MB1321-B 5BUOB1-060
1. Oil pump strainer and tube (not shown) 4. Oil filter and oil filter mounting insert
Assembly Note ..................... page 81-55 5. Water temperature sender unit
2. Oil pump and camshaft postion sensor 6. Water pump
3. Oil pan Assembly Note ..................... page 81-57
Assembly Note ..................... page I31-55 7. Rear cover plate
ASSEMBLY
Assembly
e Note
Oil pump strainer and tub
1. Oil all parts thoroughly.
2. Position a new gasket and the oil purrlp strainer and tube
on the cylinder block. Make sure the rnating surfaces are
clean and free of protrusions.
3. Install the oil pump strainer and tube bolts and nut.
Tightening torque:
Oil inlet tube bolts: 20-30 N-m{[2.0-3.0 kgfam,
15-22 ftelbf)
Oil inlet tube nut: 40-55 N-m (4.1- 5.5 kgf-m,
3 0 4 0 ft-lbf)
Oil pan
14--16 N.m {143--162 kgf-cm,124--141 in4bf)
I.Apply sealant in six places at joints between the front
\ SPAC tiRS
(SELECTIVE)
A cover and the cylinder block and rear main bearing cap
and engine block as shown in figure.
2. Install a new oil pan gasket to the engine so the trans-
mission mounting face of the oil pan is aligned with and
square to the engine block rear face.
3. Install the engine oil pan.
Tightening torque:
14-16 N.m (143-162 kgf-cm, 1:24-141 in-lbf)
Note
The transmission bolts to both the engine and the
oil pan when installed. It is necessary to measure
the gap between the surface of the rear face of the
oil pan (at spacer locations) and the rear face of the
engine block. Refer to the following procedure for
checking dimension.
ASSEMBLY
4. With the oil pan installed on the engine, position a straight-
edge flat on the rear of the engine block so that it extends
over one of the oil pan/transmission bolt mounting pads.
5.Measure the gap between the mounting pad and the

straightedge using a feeler gauge. Repeat the procedure
Shim for the other mounting pad. Select spacers of the required
thickness from the chart.
-- -
Caution
Failure to measure the required spacer thickness
-- -
can result in insufficient, or excessive clearance
between the engine oil pan and the transmission,
7 --
Blue when installed in the vehicle. This can result in oil

pan damage, and/or an oil leak.
0.78- / 0.031- 0.762 1 0.030 Pink
6. Install the selected spacers to the mounting pads on the
rear of the oil pan before bolting the engine and transmis-
sion together.
ASSEMBLY
Water pump
1. Position the gasket on the water pump (use contact
cement).
2. Install the water purnpon the cylinder blockand tighten the
bolts to the specified torque. Apply sealant to bolts prior to
installation.
Tightening torque:
20-30 N.m (2.0-3.0 kgfam, 15--22 ftdbf)
Flywheel, clutch disc, and clutch cover (MT)

1. Install the flywheel.
Tightening torque:
73-87 N - m (7.5-8.8 kgf .m, 54-64 ft .Ibf}
2. Install the clutch disc.

3. Clean the clutch cover and flywheel surfaces with suitable
commercial alcohol base solvent so ,thatthe surfaces are
free from any oil film.
Note
Do not use cleaners with a petroleum base. Do not
immerse the clutch cover in solvent.
4. Position the clutch disc on flywheel so Clutch Aligner

T74P-7137-K, or equivalent can enter clutch pilot bearing
and align disc.
5. When installing original clutch cover, align clutch cover
and flywheel with rnarks made during removal.
6. Position the clutch cover on flywheel. Align the clutch
cover and disc.
Tightening torque:
21-32 N.m (2.0-3.3 kgfam, 15--24 ft-lbf)
7. Remove the clutch disc pilot tool.
Drive plate (AT)

Install the drive plate and the reinforcement plate.
Tightening torque:
7 3 - 8 7 N.m {7.4-8.8 kgfem, 5 4 - 4 4 ft-lbf}
ASSEMBLY
CYLINDER HEAD
2. Assemble the thermostat housing and the thermostat. (Refer to Section E l .)
N-m {kgf.m, ft-lbf)

I
MB1324-B 5BUOB1-068
1. Hydraulic lash adjuster 8. Valves
2. Exhaust valve seals 9. Valve spring
Assembly Note ..................... page 81-59 Assembly Note ..................... page 61 -59
3. Intake valve seals 10. Upper spring seat
Assembly Note ..................... page B1-59 11. Valve keepers
4. Camshaft bearings Assembly Note ..................... page B1-61
Assembly Note ..................... page B1-60 12. Rocker arms (not shown)
5. Camshaft Assembly Note ..................... page B1-61
Assembly Note ..................... page I31-60 13. Cylinder head
6. Camshaft thrust plate Assembly Note ..................... page B1-61
Assembly Note ..................... page 61-61 14. Engine oil pressure sensor
7. Camshaft oil seal
Assembly Note ..................... page 61-61
ASSEMBLY
Assembly Note
VALVE SEAL PROTECTOR Valve seals
(PLASTIC INSTALLATION CAP) 1. Put valve seal protector (plastic installation cap supplied
SUPPLIED WITH VALVE SEALS
with valve seals) over end of valve.
w VALVE
2. Start valve seal carefully over valve seal protector. Push
valve seal down until jacket touches top of valve guide.
3. Remove valve seal protector.
'
4. Use SST to seat valve seal on valve guide.
4
(0 28-0 30 INCH)
70-75MM
Valve spring assembly

1. Installthe valve spring and install retainer by compressing
valve with SST.
ASSEMBLY
2.Check the installed height of the spring and damper
assembly.
INSTALLED
SPRING HEIGHT Note
38.635-40.546mm
(1.52-1.59 inch) Spring and damper assembly must be com-
pressed beyond the height of 27.5mm (1.08 in)
during assembly.
Spring and damper assembly installed height is
equivalent to valve spring installed height plus
damper material thickness of 1.Ol mm (0.04 in).
If the assembled height is greater than specified,
install the necessary 0.76mm (0.030 in) thick
spacers between the cylinder head spring pad and
the valve spring damper assembly to bring the
assembled height to the recommendeddimension.
Do not install spacers unless necessary. Use of
spacers in excess of recommendations will result
in overstressing the valve springs and overloading
the camshaft lobes. This could lead to spring break-
age and worn cam lobes.
/ CAM BEARING REPLACER

T71 P-6250-A
Camshaft bearings
Install the camshaft bearings using Cam Bearing
Replacer T71 P-6250-A, or equivalent.
5BUOB1-070
Camshaft
Note
Camshaft must be positioned as shown to protect
protruding valves.
Install the camshaft through the camshaft bearings on the

cylinder head.
I I
MB1293-B 5BUOB1-096
Note
Make sure the threaded plug is in the rear of the
camshaft. If not, remove the threaded plug from the
old camshaft and install it.
Coat the camshaft lobes with multi-purpose grease
and lubricate the journals with heavy oil before
installation.
Carefully slide the camshaft through the bearings.
ASSEMBLY B1
Valve keepers
Using the SST, depress the valve springs and install the
valve keepers.
Rocker arms
Using the SST, depress the valve springs and install the
rocker arms.
4BUOB1-137
Camshaft thrust plate

Install the carnshaft thrust plate.
Tightening torque:
8-12 N.m (0.8-1.2 kgf.m, 6-9 ft-lbf)
4BUOB1-138
(0.55-0.57 inch)
Camshaft oil seal
I' Install the camshaft oil seal using Cam and Auxiliary Shaft
4BUOB1-139
Cylinder head
1. Clean all cylirider head gasket surfa.ces.
2. Clean all lower intake manifold gasket surfaces.
3. Clean all exhaust manifold gasket surfaces.
4. Blow the oil out of the cylinder head bolt block holes.
5. Position the cylinder head gasket on the cylinder block.
6. Position the cylinder head to the cylinder block.
7. Measure the height of each dowel.
Height: 14.0-1 4.5mm (0.55-0.57 in)
8. Install the cylinder head bolts. Tighten in the sequence

shown in three steps.
Tightening torque:
Step 1: 70 N-m (7.1 kgf-m, 52 ft.lb)
Step 2: 70 N.m (7.1 kgf-m, 52 ftlbf)
Step 3: Turn all cylinder head bolts an additional
90-100 degrees, in sequence.
ASSEMBLY
TIMING BELT
N.m (kgfm, ft4bf)

5BUOB1-072
1. Camshaft pulley 5. Timing belt

Assembly Note ..................... page B1-63 Assembly Note ..................... page B1- 9
2. Timing belt tensioner 6. Timing belt outer cover
Assembly Note ..................... page B1-63 Assembly Note ..................... page B1-63
3. Oil pump pulley 7. Crankshaft pulley
4. Timing belt pulley Assembly Note ..................... page B1-63
ASSEMBLY
Assembly note
Camshaft pulley
1. Position key and the camshaft pulley on the camshaft.
2.lnstall Cam and Auxiliary Shaft Sprocket Tool
T74P-6256-B or equivalent, without the threaded puller
insert, on the pulley.
3. lnstall the washer and the camshaft pulley bolt to hold the
gear.
Tightening torque:
70-95 N-m(7.2-9.6 kgfem, 52-70 ft-lbf)
5BUOB1-073
CAM AND AUXILIARY

SHAFT SPROCKET TOOL
T74P-6256-6
Timing belt tensioner

SPRING BOLT 1. lnstall the timing belt tensioner.
2. lnstall the tirning belt tensioner adjustment bolt and
spring bolt.
ADJUSTMENT
BOLT
'
Tightening torque:
Adjustment bolt: 35-45 N.m (3.5-4.5 kgf-m,
25-33 ftelbf)
Spring bolt: 40-55 N-m(4.2-5.5 kgf.m,
3 0 4 0 ftellbf)
I 2
MB1003-A 5BUOB1-098
lnstall the timing belt outer cover.
Tightening torque:
8-12 N-m (0.8-1.1 kgf.m, 6-8 ft-lbf)
4BUOB1-144
Crankshaft pulley
lnstall the crankshaft pulley.
Tightening torque:
125-1 65 N.m (12.7-1 6.8 kgfm, 92-1 21 ftslbf)
5BUOB1-074
AUXILIARY PARTS
2. lnstall the dipstick tube and bracket, referring to Assembly Note. (Refer to page B1-66.)
3. Connect the required vacuum hoses.
4. lnstall the two heater hose retaining screws on the cylinder head.
5. Install the air cleaner assembly.
ASSEMBLY
1. Exhaust manifold 5. Cylinder head cover

Assembly Note ..................... page 81-65 Assembly Note ..................... page 81-66
2. Lower intake manifold gasket 6. Spark plugs
3. Lower intake manifold 7. High-tension lead wires
Assembly Note ..................... page 81-65 8. Engine and generator wiring harness
4. Cylinder head cover gasket 9. Upper intake manifoldlthrottle body
Installation ................................. Section F1
ASSEMBLY
Assembly Note
Exhaust manifold
Install the eight exhaust manifold retaining bolts and/or
stud bolts. Tighten the bolts in the sequence shown in two
steps.
Tightening torque:
Step 1: 20-30 N.m (2.1-3.0 kgfem, 15-22 ftslbf)
Step 2: 6 0 - 4 0 N.m (6.1-4.1 kgf-m,45-59 ft-lbf}
I I
MB1330-B 5BUOB1-076
1. Install the lower intake manifold.
2. Install four upper manifold retaining bolts finger tight.
3. Install four remaining manifold bolts.
.
- 4. Tighten the bolts in the sequence shown in the figure.
Tightening torque:
26-38 N-m (2.7-3.8 kgfm, 19--28 ftalbf)
0 FRONT OF ENGINE
MB1331-A 5EIUOB1-077
B1 ASSEMBLY
Cylinder head cover
cylinder head.
Tightening torque:
9-13 N-m (0.9-1.3 kgf.cm, 80-1 15 inslbf)

Install the dipstick tube and bracket.
Tightening torque:
20-30 N.m (2.1-3.0 kgfxm, 15-22 ft.lbf)
INSTALLATION
INSTALLATION
PROCEDURE
1. Carefully lower the engine into the engine compartment.
Caution
Do not damage any components in the engine
compartment.
2. Install the engine mount nuts.

FRONT OF VEHICLE Tightening torque:
88-118 N-m (9.0-12.0 kgf-m,6 5 - 4 7 ft-lbf)
3. On vehicles equipped with an automatic transmission,

start the converter pilot into the crankcase.
4. On a vehicle with a manual transmission, start the trans-
mission primary shaft into the clutch disc. It may be
necessary to adjust the position of .the transmission in
relation to the engine if the primary shaft will not enter the
clutch disc. If the engine hangs up after the shaft enters,
turn the crankshaft in the clockwise direction slowly (trans-
mission in gear), until the shaft splines mesh with the
clutch disc splines.
5. Install the bell housing upper attaching bolts. Remove the
engine lifting hooks from the lifting brackets.
Tightening torque:
38-51 N-m (3.8-5.2 kgfam, 28--37 ft-lbf}
6. Remove the jack from under the trar~smissionand raise

the vehicle.
~~1278-A
7 . 0 n a vehicle with an automatic transmission, attach
the converter-to-drive plate bolls and tighten to
specifications.
Tightening torque:
3 1 - 3 9 N-rn (3.1-3.9 kgfem, 23-39 ft-lbf}
8. Ona vehicle with a manual transmission, install the bell

housing lower bolts and tighten to specifications.
Tightening torque:
38-51 N-rn (3.8--5.2 kgfem, 28-37 ft.lbf}
INSTALLATION
9. Install the bell housing cover attaching bolts and tighten to
specifications.
Tightening torque:
38-51 N.m (3.8-5.2 kgfem, 28-37 ft.lbf)
10. Install the dust cover (MT) or converter inspection plate

(AT).
Tightening torque:
Dust cover: 8-1 1 N.m (0.8-1.1 kgf-m, 5.9-4.1
ft-lbf}
Converter inspection plate: 2.5-3.6 N-m
(24-36 kgf-cm, 22.1-31.8 in-lbf)
11. Connect the ground cable to the engine.

12. Connect the fuel supply and return lines to the two fuel rail
fittings.
13. Connect the three way catalytic converter to the exhaust

FRONT OF VEHICLE manifold. Tighten to specifications.
Tightening torque:
3 4 4 6 N.m ( 3 . 4 4 . 6 kgfem, 25-33.9 ft.lbf)
14. Connect both the Heated Oxygen Sensors (H02S).

15. Install the starter motor. (Refer to Section G.)
INSTALLATION B1
17. Install the AIC compressor and power steering pump
bracket.
Tightening torque:
Bolt A: 41-54 N.m (4.1-5.5 kgf-m, 30--40 ft4bf)
Bolt B: 21-28 N-m (2.1-2.8 kgf.m, 16-21 ft-lbf)
18. Install the air conditioning compressor to the mounting

bracket, if equipped.
Tightening torque:
22-28 N.rn (2.3-2.9 kgfem, 16--21 ftelbf)
A: 41-54 t4.1-5.5,
19. Connect the air conditioning hoses to the suction
accumulator and to the condenser, ilf equipped. (Refer
to Section G in the 1997 B-Series BETM.)
20. Connect the evaporative emission purge hose to the

engine.
21. Install the DPFE sensor to the engine lifting bracket.
22. Connect the fuel charging wiring harness to the engine
wiring harness.
23.Install the accelerator cable bracket to the upper intake
manifold.
Tightening torque:
21-28 N-m (2.1-2.8 kgfem, 16-21 ft-lbf)
24. Connect the accelerator cable to the throttle body.

25. Install the generator bracket.
I
MB1333-A
Tightening torque:
44-54 N . m (4.4--5.5 kgf - m, 3 2 4 0 ft - lbf)
26. Install the water pump inlet tube to the generator bracket
and water pump.
Tightening torque:
9- 2 N-m (92-1 22 kgf-cm, 80-1 06 in-lbf)
INSTALLATION
27. Connect the high-tension lead wires to the ignition coils.
28. Connect the upper and lower heater hoses to the engine.
29. Connect the power brake unit vacuum hose.
30. Connect the engine wiring harness 'to the ignition coils,
solenoid valves, water temperature sender unit, and radio
interference capacitor.
31. Install the generator and drive belt. (Refer to Section G.)
32. Connect the Engine Coolant Temperature (ECT) sensor.
33. Install the radiator. (Refer to Section E l .)
34. Connect the radiator overflow hose.
35. Install the fan guard, if equipped, or the fan shroud.
36. Connect the upper and lower radiator hoses.
37. Connect the air cleaner outlet tube to the throttle body.
38. Connect the Mass Air Flow (MAF) and Intake Air Tem-
perature (IAC) sensors.
39. Install the hood and align.
40. Connect fuel pump inertia switch connector.

1. Fill the engine with specified amount and type of engine oil. (Refer to Section D l .)
2. Fill the radiator with the specified amount and type of engine coolant. (Refer to Section E l .)
3. If the transmission was drained, fill it with the specified amount and type of transmission oil.
5. Start the engine and check the following.
(1) Engine oil, transmission oil, and engine coolant leakage.
(2) Drive belt tension.
(3) Ignition timing and idle speed. (Refer to page B1-6.)
(4) Operation of emission contrcll system.
(5) Kickdown cable (AT).
6. Perform a road test.
7. Recheck the engine oil and coolant levels.
ENGINE
3.0L
INDEX .................................................... 82- 2 INSPECTION 1 REPAIR ........................... B2-36

OUTLINE ............................................... B2- 3 PREPARATION .................................... B2-36
SPECIFICATIONS ............................... 82- 3 CYLINDER HEAD ................................ B2-36
TROUBLESHOOTING GUIDE ............... 82- 3 VALVE MECHANISM ........................... B2-37
ENGINE TUNE-UP PROCEDURE ......... B2- 5 CAMSHAFT ......................................... B2-39
ENGINE OIL ......................................... B2- 5 TAPPET ............................................... B2-41
ENGINE COOLANT ............................. B2- 5 CYLINDER BLOCK .............................. B2-41
DRIVE BELT ........................................ B2- 5 PISTONS. PISTON RINGS
IGNITION TIMING. IDLE SPEED ........ B2- 6 AND PISTON PINS ............................ B2-42
COMPRESSION ..................................... 82- 7 CONNECTING RODS .......................... B2-44
INSPECTION ....................................... 82- 7 CRANKSHAFT ..................................... B2-45
ON-VEHICLE MAINTENANCE .............. B2- 8 BEARING ............................................. B2-46
PREPARATION ................................... B2- 8 PULLEYS ............................................. 82-46
CYLINDER HEAD GASKET ................ 82- 8 TIMING CHAIN OUTER COVER ......... 82-46
TAPPET .............................................. 82-16 FLYWHEEL .......................................... B2-46
FRONT OIL SEAL ................................ B2-18 ASSEMBLY ........................................ 82-46
REAR OIL SEAL .................................. B2-19 PREPARATION ................................... B2-46
REMOVAL .............................................. B2-21 CYLINDER BLOCK
PROCEDURE ...................................... B2-21 (INTERNAL PARTS) ........................... B2-47
DISASSEMBLY ....................................... 82-23 CYLINDER BLOCK
AUXILIARY PARTS .............................. B2-23 (EXTERNAL PARTS) .......................... B2-54
TIMING CHAIN .................................... 82-26 CYLINDER HEAD ................................. B2-56
CYLINDER HEAD ................................ B2-29 TIMING CHAIN .................................... B2-60
CYLINDER BLOCK AUXILIARY PARTS ............................. B2-63
(EXTERNAL PARTS) .......................... B2-30 INSTALLATION ...................................... B2-66
CYLINDER BLOCK PROCEDURE ...................................... B2-66
5BUOB2-001
(INTERNAL PARTS) ........................... B2-32
INDEX
INDEX
COMPRESSION INSPECTION:
1. Timing chain 5 . Rear oil seal

Disassembly .......................... page B2-26 Replacement ......................... page B2-19
Assembly ............................... page B2-60 6. Engine
2. Cylinder head gasket Removal ................................ page B2-21
Replacement ......................... page B2-8 Disassembly .......................... page B2-23
3.Tappet InspectionIRepair .................. page B2-36
Removal/lnstallation .............. page B2-16 Assembly ............................... page B2-46
4 . Front oil seal Installation ............................. page B2-66
Replacement ......................... page B2-18
OUTL.INE,TROUBLESHOOTING GUIDE B2
OUTLINE
SPECIFICATIONS
- --
\
Item ---_--.
--%__
Engine 3.0L
- .-- -. --
JY pe Gasoline, 4-cycle
G i n d e r arrangement and number 60"-V configuration, 6 c:ylinders
Valve system OHV chain driven, 12 valve
-
Displacement cm3, (CUin} -

2968 { I 82) --
&e and stroke mm {in) 89.0 x 80.0 i3.50 x :3.14)
- ~
Compression pressure Lowest reading within 75% of highest

--
cylinder readingo
. .~~
mm {in) 0: Maintenance free

Valve clearance
0: Maintenance free
Ignition timing (Initial timing) 8-1 2" (10 + 2")
Firing order 1-4-2-5-3--6
@ Refer to Section TD
MB1161-D 5BUOB2-003
Note
When the battery has been disconnected and reconnected, some abnormal1 driving symptoms
4BUOB2-004
.-
Problem Possible Cause 7 Action I Page
Burnt valve Replace 62-37
Worn piston, piston rings, or cylinder Replace or repair 62-42,43
Replace 82-8
i Malfunction d fuel system Refer to Section FT -
Malfunction of ignition system ! Refer to Section G -
--

Poor valve-to-valve seat contact Replace or repair 62-38
Damaged cylinder head gasket Replace 82-8
Damaged push rod(s) Replace 62-10
Damaged tappet Replace 62-16
.
- p--p----pP--
Malfunction of fuel system

-
Refer to Section FT -
Malfunction of ignition system Refer to Section G
-
! -
consumption Worn piston ring groove or sticking piston ring Replace 82-43
Worn piston or cylinder Replace or repair 62-42,43
Oil working down
Worn valve seal Replace B2-37
/ Worn valve stem or guide
Worn piston rings
Plugged PCV system
1 Replace
Replace
Refer to Section FT
62-37
B2-42
-
Oil leakage -
ME1 162-01
Problem Possible Cause Action Page

Insufficient power lnsufficient compression
Compression leakage from valve seat Repair
Seized valve stem Replace
Weak or broken valve spring Replace
Cracked or distorted cylinder head Replace
Sticking, damaged, or worn piston ring Replace
Cracked or worn piston Replace
Damaged push rod(s) Replace
Damaged tappet Replace
Malfunction of ignition system Refer to Section G
Others
Slipping clutch Refer to Section H
Dragging brakes Refer to Section P
Wrong size tires Refer to Section Q
Abnormal Malfunction of engine-related components
combustion Sticking or burnt valve Replace
Weak or broken valve spring Replace
Carbon accumulation in combustion chamber Eliminate carbon
I Malfunction of fuel system j Refer to Section FT I -
Malfunction of ignition system 1 Refer to Section G
Engine noise Crankshaft- or bearing-related parts
Excessive main bearing oil clearance Replace or repair
Main bearing seized or heat-damaged Replace
Excessive crankshaft end play Replace or repair
Excessive connecting rod bearing oil clearance Replace or repair
Connecting rod bearing seized or heat-damaged Replace
Piston-related parts
Worn cylinder Replace or repair
Worn piston or piston pin Replace
Seized piston Replace
Damaged piston ring Replace
Bent connecting rod Replace
Valves or timing-related parts
Broken valve spring Replace
Excessive valve guide clearance Replace
1 Malfunction of cooling system 1 Refer to Section E2 - I
I Malfunction of fuel system 1 Refer to Section FT 1 - 1
Others
Malfunction of water pump bearing Refer to Section E2
Worn drive belt Replace
Malfunction of generator bearing Refer to Section G
Exhaust gas leakage Refer to Section FT
Loose timing belt Replace or repair
Worn timing chain Replace
ENGINE TUNE-UP PROCEDlJRE

ENGINE OIL
lnspection
1. Be sure the vehicle is on level ground.
2. Warm up the engine to normal operating temperature and
stop it.
3. Wait for five minutes.
4. Remove the oil dipstick and check the oil level and
condition.
KEEP THE OIL IN THlS RANGE 5. Add or replace oil if necessary.
Note
Theoil level should be filled to the top of thedashed
part of the oil dipstick.
OIL LEVEL MAY BE IN THIS
RANGE AFFER AN OIL CHANGE ENGINE COOLANT
lnspection
Coolant level (Engine cold)
Warning
hot.
it.
When removing the radiator cap, loosen it slowly
until the pressure in the radiator is released, and
then remove it.
Coolant quality
radiator cap, or filler neck.
necessary.
4BUOB2-009
DRIVE BELT
lnspection
1. Check the drive belt for wear, cracks, fraying or severe
glazing.
2. Replace the belt if any of these conclitions are observed.
Minor cracks in the back of the belt are considered
acceptable.
- - - - - - -
- -

pulleys.
Adjustment
No adjustment is necessary for the 3.OL drive belt. The
3.OL engine is equipped with an automatic tensioner that
indicates when thedrive belt is worn (stretched). A pointer
and gauge are built into the tensioner. When the pointer no
longer registers within the range limits of the gauge, the
belt must be replaced. (Refer to Section G.)

Initial Timing
Note
Initial timing is preset and is not adjustable.
Initial timing can be checked. (Refer to Section F2.)
Ignition timing: 8-12" BTDC (Refer to Section F2.)
ldle speed
Note
ldle speed is preset and is not adjustable.
ldle speed can be checked. (Refer to Section F2.)
5BUOB2-005
COMPRESSION
COMPRESSION
If the engine exhibits low power, poor fuel economy, or
poor idle, check the following:
1. Ignition system (Refer to Section G.)
2. Compression (Refer to below.)
3. Fuel system (Refer to Section F2.)
INSPECTION
1. Verify the battery is fully charged. Recharge it if neces-
sary.
3. Remove the spark plugs.
4. Disconnect the harness connector f~romthe ignition coil.

5. Connect a compression gauge to N13.1spark plug hole.
Compression:
Lowest reading cylinder is within 75 percent of
the highest. (Refer to Section T'D.)
9. If the compression in one more cylinders is low, pour a

small amount of engine oil into the cylinder and recheck
the compression.
(1) If the compression increases, the piston, piston rings,
(2) If the compression stays low, the valve may be stuck
or seating improperly.
(3) If the compression in adjacent cylinders stays low, the
head distorted.
10. Connect the harness connector to the ignition coils.
Note
If installing the original spark plugs, install them in
their original locations.
LH BANK: WHITE
RH BANK: DARK GREEN
Tightening torque:
9-20 N . rn (0.9-2.0 kgf .m, 7-1 5 ft - Ibf)
PREPARATION
SST
49 UNOI 064 For

lnstallatlon
of rear
Rear maln main 011
seal installer seal

Replacement
Warning
Release the fuel pressure. (Refer to Section F2).

3. Remove the clean air flex tube from upper intake manifold/throttle body assembly, air cleaner and PCV
closure hose.
4. Remove throttle body (Refer to Section F2).
5. Disconnect the fuel lines.
6. Mark the vacuum line locations and disconnect the lines.
7. Disconnect the upper radiator hose and heater water hoses and move them out of the way.
8. Remove the ignition coil, referring to Removal Note. (Refer to page 82-9.)
9. Remove the upper intake manifold. (Refer to Section F2.)
11. Remove the left and/or right cylinder head auxiliary parts, referring to Removal Note. (Refer to B2-9.)
12. Disconnect the high-tension leads.
14. Remove the front pipe assembly and exhaust manifold(s).
15. Remove the cylinder head covers, referring to Removal Note. (Refer to page B2-10.)
16. Loosen the rocker arms, referring to Removal Note. (Refer to page B2-10.)
17. Remove the lower intake manifold, referring to Removal Note. (Refer to page B2-10.)
18. Remove the cylinder head bolts.
19. Remove the cylinder head.
20. Remove the cylinder head gasket(s).
Removal note
Ignition coil
1. Disconnect electrical connector.
2. Remove the ignition coil nuts.
3. Remove the ignition coil.
I
MB1348-A 513UOB2-008
I FRONT OF ENGINE 7Auxiliary parts (left side)

1. Remove the power steering oil pump bracket bolts and
nut, if equipped.
2. Remove the power steering oil pump, bracket and lines as
an assembly. Set them aside to prevent fluid leakage, if
equipped.
3. Remove the engine oil dipstick tube nut from the exhaust
manifold stud.
4. Remove the tube from the manifold.
5. Remove the fuel line bracket bolt from the front of cylinder
head.
L I
MB1280-B 5 ~ ~ 0 ~ 2 - 0 0 9 6. Remove the PCV valve.
7. Remove the fuel injector harness stand-offs from the
inboard cylinder head cover studs and move them out of
the way.
Auxiliary parts (right side)
1. Disconnect the generator harness c:onnectors.
2. Remove the belt tensioner bolts and the tensioner
assembly.
3. Remove the generator bracket and the adjusting arm
bolts.
4. Remove the bracket assembly.
5. Remove the closure hose from the (cylinderhead cover.
6. Disconnect the engine harnessconn~?ctors from the cover.
inboard studs. Move them out of the way.
8. Remove the PCV closure from the hose oil fill adapter.
4BUOB2-032
FRONT OF ENGINE Cylinder head cover

1. Remove the high-tension lead separator assembly from
the cylinder head cover studs and move them out of the
way.
2. Loosen all of the cylinder head cover bolts.
3. Carefully slide a sharp, thin-bladed knife between the
cylinder head gasket surface and cylinder head cover
gasket at two RTV junctions. Cut only the RTV sealer and
avoid cutting the integral gasket.
4. Lift the cover from the cylinder head while making sure
that the RTV sealer is not pulling the gasket from the
cover.
Note
The cylinder head cover incorporates an integral
gasket which should last the life of the vehicle.
Rocker arms
1. Loosen the rocker arm fulcrum bolts enough to allow the
rocker arm to be lifted off and rotated to one side.
d
Note
Regardless of which cylinder head is being re-
moved, the No. 3 cylinder intake valve push rod
must be removed to allow removal of the lower
intake manifold.
2. Remove the push rods.

Note
Identify the position of each rod. The rods must b
installed in their original location when reass-
embled.
1. Remove the fuel line safety clips.
2. Disconnect the following harness connectors:
(1) Intake air temperature sensor
(2) Idle air control solenoid
(3) Engine coolant temperature sensor
(4) Ignition coil
(5) Water temperature indicator sender
3. Disconnect the upper radiator hose from the thermostat
housing.
4. Disconnect the heater hoses.
5. Remove the bolts.
Note
Before attempting to remove the lower intake mani-
fold, break the seal between the manifold and the
cylinder block. Wedge a large screwdriver or simi-
lar heavy duty tool between the manifold and the
cylinder block.
6. Remove the lower intake manifold.

5BUOB2-010
Installation note
Cylinder head
1. Lay a clean shop rag in the tappet valley to catch any
gasket particles. Clean the cylinder hlead, intake manifold
and the cylinder head to block gasket surfaces. After
scraping, lift the cloth so no gasket material falls into the
holes. Check the cylinder head anti the cylinder block
gasket surfaces for flatness. (Refer lo page B2-36.)
Caution
Gouges in aluminum components will cause gas-
kets to leak.
2. Position the new head gasket(s) on the cylinder block

using the dowels for alignment. Make sure the gasket is
aligned as shown in the figure.
Note
Replace the alignment dowels if they are damaged.
3. Carefully position the cylinder head(s) on the cylinder

block.
4. Install the new bolts and hand tighten.
1 *'0
FRONT OF ENGINE
5. Tighten the bolts in sequence as shown in the figure.
Tightening torque:
80 N.m (8.1 kgf-m, 59 ft-lbf)
6. Back off all of the bolts a minimum of one full turn (360").
7. Re-tighten the bolts, in the sequence illustrated, in two
steps.
Tightening torques:
Step 1: 45-55 N m (4.5-5.5 klgf m, 33-41 ft . lbf)
Step 2: 85--99 N .m (8.5-9.9 kgf m, 63-73 ft - Ibf)
Note
When the cylinder head bolts have been tightened
using the above procedure, it is not necessary to
retighten the bolts after extended engine opera-
tion.
FRONT OF ENGINE I
1. Lightly oil all bolts and stud threads before installation.
2. Clean the mating gasket surfaces of the lower intake
manifold and the cylinder head. Lay a clean shop rag in
the tappet valley to catch any gasket material. After
scraping, carefully lift the cloth from the tappet valley
preventing any particles from entering the oil drain holes
or the cylinder head. Use a suitable solvent to remove the
old rubber sealant.
Caution
Aluminum components gouge easily which can
cause gasket leaks. Always use care when scrap-
ing aluminum gasket surfaces.
3. If installing a new lower intake manifold, transfer the fuel

injectors, fuel supply manifold, engine coolant tempera-
ture sensor, thermostat, gasket and housing, heater
hose elbow and the water temperature indicator sender to
the new manifold.
4. Apply sealant to the intersection of the cylinder block and

FRONT OF ENGINE
cylinder head at the four corners, as shown in the figure.
CYLINDER 5--6mm
HEAD (0.20-41.24 in)
II CYLINDER HEAD GASKET

11
I I
ME1 128-6
5. Position the lower intake manifold gaskets onto the
cylinder heads. Align the lower intake manifold gasket
locking tabs to the provisions on the cylinder head gas-
kets, as shown in the figure.
6. lnstall the front and rear lower intake manifold seals as
shown in the figure. Secure with retaining features.
7. Place the lower intake manifold into position, aligning the

manifold bolt holes to those in the cylinder head. Use care
to prevent disturbing the rubber sealer which can cause
sealing voids. Install bolts 1,2,3, and 4 and hand tighten.
lnstall the remaining bolts and tighter1 in sequence using
a two-step process. Tighten in numerical sequence.
Tightening torques:
Step 1 : 15 N.m (1.5 kgf.m, 11 ftelbf)
Step 2: 26--32 N.m (2.6-3.2 kg(-m, 19-24 ft-lbf)
8. Connect the heater hoses.

9.Connect the upper radiator hose to the thermostat
housing.
10. lnstall the fuel line safety clips.
LOWER 11. Connect the following harness connectors:
INTAKE (1) Intake air temperature sensor
BLOCK (4) Ignition coil
END RAIL GAP
AS INSTALLED 1 (5) Water temperature indicator sender
Rocker arms
1. Apply clean engine oil to all push rods.
2. lnstall the push rods in their original location.
3. Rotate the camshaft to position "A" as shown.
#5 EXH 4. lnstall the rocker arms, fulcrums, and the bolts in locations
specified in position "A".
Tightening torque:
11 N . m (111 kgf-cm, 97 in-Ibf)
I RIGHTHEAD LEFT HEAD

I
CENTER LINE OF
KEYWAY VERTICAL
WITHIN = 5"
TIMING
MARKS
CAMSHAFT POSITION A
5. Rotate the crankshaft 120" to position "B" as shown.
-
INSTALLATION ROCKER ARM, 6. Installthe rocker arms, fulcrums, and the bolts in locations
PUSH ROD AND FULCRUMS specified in position "B".
#3 INT #6 EXH
I #3 EXH #6 INT / Tightening torque:
11 N.m (111 kgf-cm, 97 inslbf)
7. Tighten all of the fulcrum bolts to the specified torque.
Tightening torque:
26-38 N m (2.6-3.9 kgf .m, 19-28 ft .Ibf}
RIGHT HEAD LEFT HEAD Caution
The fulcrums must be fully seated in the cylinder
CENTER LINE head and the push rods must be fully seated in the
OF ENGINE
rocker arm sockets and tappets before final tight-
TIMING ening.
MARKS
Note
Camshaft positions "A" and "B" are required to
place the tappet assembly on the base circle of the
camshaft lobe to check the collapsed tappet gap.
Tappet gap: 2.15 4 . 6 9 m m (0.08-0.1 8 in)

FULCRUM AND BOLT MUST BE FULLY
SEATED AFTER FINAL TORQUE
Refer to the chart for which valve gaps to set when
the camshaft is in either position "A" or "B".
Set Gap of Valves Noted
1 Camshaft Position
No.
-
- - ---
-
Exh
--- -- - -
Int. -- --
None Int.-Exh. --
4 Exh.
- --
5- Exh.
---
Int
6 None Int.-Exh.
ME1 136-A
8. Apply clean engine oil to all of the rocker arm assemblies.
Exhaust manifolds
( FRONT OF ENGINE I 1. Install the exhaust manifold(s).
Tightening torque:
20-30 N - m (2.0-3.0 kgf .m, 15-22 ft lbf)
2. Install the front pipe assembly nuts.
Tightening torque:
41 N.m (4.1 kgf.m, 30 ft-lbf)
Dipstick tube
Install the dipstick tube.
Tightening torque:
16-20 N.m (1.6-2.0 kgf.m, 12--15 ftelbf)
5BUOB2-016
Spark plugs
lnstall the spark plugs.
Note
their original location.
LH BANK: WHITE
RH BANK: DARK GREEN
Tightening torque:
9-20 N.m (0.9--2.0 kgf.m, 7-14 ftelbf)
5BUOB2-017
Cylinder head covers

1. Apply a bead of sealer at the cylinder head-to-intake
manifold rail step (two places per rail).
2. Position the cover on the cylinder head.
Note
When positioning the cover to the cylinder head,
use a straight down approach to align the holes.
Once the cover comes in contact with the RTV
sealer, any adjustment for bolt alignment can roll
ONT OF ENGINE the gasket from the cover channel, resulting in
leaks.
Tightening torque:
10-1 4 N-m(1.&I .4 kgfem, 7-1 0 ft.lbf)
3. If installing the left cylinder head cover, perform the

following:
(1) lnstall the fuel injector harness .stand-offs to the in-
board cylinder head cover studs.
(2) lnstall the PCV valve and connect the hoses.
(3) lnstall the upper intake manifold/i:hrottlebody assem-
bly.
(4) lnstall the fuel line bracket to the front of the cylinder
head.
Tightening torque:
35 N-m(3.6 kgf.m, 26 ft-lbf)
(5) lnstall the power steering oil pump and bracket assem-
bly, if equipped.
Tightening torque:
40-42 N-rn{4.0--6.2 kgfern, 30--46 ft.lbf)
(6) lnstall the drive belt.

FRONT OF ENGtNE
4. If installing the right cylinder head cover, perform the
following:
(1) lnstall the engine harness connectors to the cylinder
head cover retainer and connect to the main vehicle
harness.
(2) lnstall the fuel injector harness stand-offs to the in-
board cover studs.
(3) lnstall the PCV closure hose to the oil fill adapter.
(4) lnstall the closure hose from the cylinder head cover oil
fill adapter to the air cleaner.
(5) lnstall the generator and the bracket assembly.
I I
MB1280-B 5BUOB2-018
Tightening torque:
48 N . m (4.8 kgf-m, 35 ft-lbf]
(6) lnstall the drive belt.

(7) Connect the generator electrical harness.
5. Connect the high-tension leads to the spark plugs.
6. lnstall the high-tension lead separator stand-offs to the
cover studs.

1. Fill the cooling system with the specified amount and type of coolant.
(1) Engine oil leakage
(2) Engine coolant leakage
TAPPET
Removal 1 Installation
Warning
Release the fuel pressure (Refer to Section F2).

3. Remove the PCV closure hose from the cylinder head cover and clean air flex tube.
4. Remove the clean air flex tube from the upper intake manifold/throttle body assembly and air cleaner
5. Remove the fuel line safety clips.
6. Disconnect the fuel lines.
7. Mark the vacuum line locations and disconnect the lines.
(4) Ignition coil
9. Disconnect the upper radiator hose from the thermostat housing.
10. Remove the ignition coil and bracket, referring to Removal Note. (Refer to page 82-9.)
11. Disconnect the fuel injector harness retaining stand-offs from the inboard cylinder head cover studs.
12. Disconnect the harness connectors from each injector and remove the harness.
13. Remove the heater hoses at the engine.
14. Disconnect the high-tension leads from the spark plugs.
15. Remove the high-tension lead stand-offs from the cylinder head cover.
16. Remove the cylinder head covers, referring to Removal Note. (Refer to page B2-10.)
17. Loosen the No. 3 intake valve rocker arm, referring to Removal Note. (Refer to b~elow.)
18. Remove the lower intake manifold, referring to Removal Note. (Refer to page B2-10.)
19. Loosen the rocker arm fulcrum bolt(s) of the tappet(s) to be removed, referring to Removal Note. (Refer
to below.)
20. Remove the tappets, referring to Removal Note. (Refer to below.)
5BUOB2-021
Removal note
No. 3 intake valve rocker arm
1. Loosen the No. 3 intake valve rocker arm fulcrum bolt
enough to allow the rocker arm to be lifted off and rotated
to one side.
Note
The No. 3 cylinder intake valve push rod must be
removed to allow removal of the intake manifold.
2. Remove the push rod.

4811082-046
Tappets
FRONT OF
ENGINE
1. Loosen the tappet guide plate bolts.
2. Remove the guide plate retainer assembly.
0 3. Remove the tappet guide plates from the tappets by lifting
straight up.
4. Remove the tappets.
Note
If the valve tappets are stuck in the bore(s) due to
excessive varnish or gum deposits, i t may be nec-
essary to use a claw-type tool to aid removal.
Rotate tappets back and forth to loosen from de-
MB1145-A 513UOB2-022
I 7 posits.
Installation note
Tappets
1. Lubricate and install the tappets.
2. Install the tappet guide plate.
Note
lnstall the tappet guide plate with the word "UP"
and/or the button visible.
3. Install the tappet guide plate retainer assembly.

I I
MB1145-A 5BU082-023 Note
Lightly oil the bolt threads before installation.
Tightening torque:
10-14 N - m (1.0-1.4 kgf-m, 7--10 ft-lbf)
Refer to page B2-17.

1. Fill the cooling system with the specified amount and type of coolant.
(2) Engine coolant leakage
FRONT OIL SEAL

Replacement
3. Remove the crankshaft pulley, referring to Removal Note. (Refer to below.)
4. Remove the damper, referring to Removal Note. (Refer to below.)
5. Remove the front oil seal, referring to Removal Note. (Refer to below.)
Removal note
Crankshaft pulley
1. Remove the pulley-to-damper bolts.
Damper
1. Remove the damper bolt and washer.
2. Remove the damper using Crankshaft Damper Remover
T58P-6316-D and Damper Remover Adapter T82L-
6316-B, or equivalents.
0 FRONT OF ENGINE
MB1118-A 4BUOB2-054
Front oil seal
Pry the seal from the timing cover with a flat-bladed
screwdriver or other similar tool.
Note
Use care to prevent damage to the timing cover or
crankshaft. 4~~0~2-055
Installation note
Front oil seal
Note
Inspect the timing cover and the shaft seal surface
of the damper for damage, nicks, burrs, or other
roughness which may cause the new seal to fail.
Service or replace components as necessary.
Lubricate the seal lip with clean engine oil and install the
seal using Damper and Front Cover Seal Installer T82L-
631 6-A and Front Cover Seal Replacer T70P-6B070-A, or
equivalents.
4BUOB2-056
Damper
1. Coat the damper sealing surface with clean engine oil.
2. Apply sealer to the keyway on the damper prior to instal-
lation.
3. Install the damper using Damper arid Front Cover Seal
Installer T82L-6316-A, or equivalent.
4. Install the washer and bolt.
Tightening torque:
125-1 65 N.m (12.7-1 6.8 kgf-rn, 92-1 22 ft.lbf)
5BUOB2-026
Crankshaft pulley
Install the crankshaft pulley.
Tightening torque:
32 N.m (3.3 kgf-m , 24 ft-lbf)

(2) Drive belt for proper routing
3. Check the engine oil level.
REAR OIL SEAL

Replacement
1. Remove the transmission. (MT, Refer to Section J1 ; AT, Refer to Section K.)
2. Remove the clutch cover and disc (MT). (Refer to Section H.)
3. Remove the flywheel (MT), referring to Removal Note. (Refer to page B2-20.)
4. Remove the drive plate (AT), referring to Removal Note. (Refer to page B2-20.)
5. Remove the rear oil seal, referring to Removal Note. (Refer to page B2-20.)
FRONT OF ENGINE
Removal note
Flywheel (MT)
Remove the bolts and the flywheel.
Drive plate (AT)

FRONT OF
ENGINE Remove the bolts, the reinforcement plate and the drive
plate.
Rear oil seal
Note
Clean exterior surface of seal and cylinder block
prior to removal of seal.
Using a sharp awl, punch one hole into the rear oil seal
metal surface between the lip and block. Screw in the
threaded end of Jet Plug Remover T77L-9533-B, or
equivalent and remove the seal. Avoid scratching or
damaging the oil seal surface.
5BUOE2-027
Installation note
Rear oil seal
1. Apply clean engine oil to the outer lips and the inner seal
edge.
2. Position the seal onto the SST.
3.Install the seal and alternate bolt tightening to seat the seal
properly.
Protrusion: 0.5mm (0.02 in)
INSTALLED
HEIGHT
SECTION A
0.5 mm
(0.02 in}
ON-VEHICLE MAINTENANCE, REMOVAL
Drive
e platee (AT)
Install drive plate, the reinforcement plate, and bolts.
Tightening torque:
7 3 - 8 7 N.rn (7.4-4.8 kgf-m, 54--64 ft-lbf}
L
MB1167-A 513UOB2-029
Flywheel (MT)
Install the flywheel on the crankshafi~using clutch aligner
CLUTCH ALlG T71 P-7137-H, or equivalent. Install the bolts using the
T71 P-7137-H
standard cross-tightening sequence.
Note
The three dowels must be bottomed out in the
flywheel.
Tightening torque:
7 3 - 8 7 Nern (7.4-8.8 kgfem, 54-64 ft-lbf)

1. Start the engine and check engine oil leakage.
2. Check the operation of the transmission.
3. Check the engine oil level.
REMOVAL
PROCEDURE
Warning
Release the fuel pressure. (Refer to Section F2).

4. Remove the hood.
5. Remove the air cleaner assembly. (Refer to Section F2.)
6. Disconnect the upper and lower hoses from the radiator.
7. Remove the radiator and fan shroud. (Refer to Section E2.)
8. Remove the generator and bracket. Position the generator out of the way. Disconriect the ground wire.
9. Recover the refrigerant and reniove the AIC compressor, if equipped.
10. Remove the power steering oil pump, if equipped. (Refer to Section N.)
11. Disconnect the heater hoses from the water pump and the lower intake manifold.
12. Remove the ground wires from the cylinder block.
13. Release the fuel system pressure. (Refer to Section F2.)
14. Disconnect the fuel lines at the chassis-to-engine connections.
15. Disconnect the accelerator cable shield and linkage at the upper intake manifoldlthrottle body assembly
and the lower intake manifold.
16. Disconnect all vacuum connectionsfrom the rear vacuum fitting in the upper intake manifoldlthrottle body
assembly.
17. Disconnect the power brake unit hose.
18. Disconnect the wiring and harness connectors, referring to Removal Note. (Refer to page 82-22.)
19. Remove the camshaft position sensor from the engine.
REMOVAL
20. Remove the ignition coil and bracket, referring to Removal Note. (Refer to page B2-9.)
21. Remove the engine front support-to-crossmember nuts.
23. Remove the retaining bracket holding the transmission oil cooler lines to the right side of the cylinder block
(AT only).
24. Disconnect the front pipe assembly from the exhaust manifolds.
25. Remove the starter. (Refer to Section G.)
26. Remove the clutch housing to cylinder block bolts (MT only).
27. Remove the hydraulic clutch pipe, referring to Removal Note. (Refer to below.) (MT only)
28. Remove the drive plate bolts from the converter, referring to Removal Note. (Refer to below.) (AT only)
29. Remove the converter housing-to-cylinder block bolts and adapter plate-to-converter housing bolt (AT
only).
31. Attach an engine lift to the engine.
32. Position a jack under the transmission.
33. Raise the engine slightly and carefully pull it from the transmission.
Caution
Do not damage the rear cover plate or any other engine components when removing the
engine.
5BUOB2-031
Wiring and harness connectors

Disconnect the following wiring and harness connectors:
( I ) Ignition coil
(2) Three body wiring connectors on top of the right
cylinder head cover
(3) Oil pressure and engine coolant temperature sensors
(4) Injector harness
(6) Throttle position sensor
(7) Heated oxygen sensor
(8) Camshaft position sensor
(9) DPFE sensor
Hydraulic clutch pipe (MT)

Caution
After removing the clutch pipe, plug it to avoid fluid
leakage.
Disconnect the pipe using Clutch Disconnect Tool T88T-

CLUTCH DISCONNECT
70522-A, or equivalent.
TOOL T88T-70522-A
Drive plate (AT)
1. Remove the converter inspection plate.
MALE COUPLING 2. Disconnect the drive plate from the converter.
4BUOB2-072
DISASSEMBLY
DISASSEMBLY
1. Code or arrange all identical parts (such as pistons, piston rings, connecting rods, and valve springs) so
that they can be reinstalled in the original cylinder from which they were removed.
2. Clean the parts by using a steam cleaner. Blow dry with compressed air.
Note
During disassembly of any part of the system, be sure to study its order of assembly. Also, note
any deformation, wear, or damage, and repair or replace as necessary.
4811082-073
AUXILIARY PARTS
2. Remove the oil filter.
DISASSEMBLY
I GASKET.
SEAL,
REPLACE
MB1169-B 5811082-033
1. Dipstick tube and bracket (not shown) 4. Cylinder head cover
2. Ignition coil Disassembly Note ................. page B2-25
3. Upper intake manifoldlthrottle body 5. Lower intake manifold
assembly Disassembly Note ................. page B2-25
Removal ................................ Section F2 6. Exhaust manifolds
Disassembly Note ................. page B2-25
DISASSEMBLY
Disassembly Note
Cylinder head cover
1. Disconnect the high-tension leads from the spark plugs.
2. Remove the high-tension lead separator assembly from
the cylinder head cover studs and move it out of the way.
inboard cylinder head cover studs arld move the harness
out of the way.
5. Disconnect the engine harness connectors on the right
cylinder head cover.
6. Remove the PCV closure hose frorr~the oil fill adapter.
7. Loosen all of the cylinder head cover bolts.
8. Carefully slide a sharp, thin-bladed knife between the
cylinder head gasket surface and the cylinder head cover
gasket at the two RTV junctions. Cut only the RTV sealer
and avoid cutting the integral gasket. Lift the cover from
the cylinder head while making sure that the RTV sealer
is not pulling the gasket from the cover.
Note
The cylinder head cover incorporates an integral
gasket which should last the life of the vehicle.
4BUOB2-075

1. Mark the location of vacuum lines and remove them.
(4) Ignition coil
3. Disconnect each injector's electrical connector and re-
move the harness from the engine.
4. Loosen the No. 3 cylinder intake valve rocker arm retain-
ing bolt and rotate the arm off the push rod and away from
the valve stem.
5. Remove the push rod from the No. 3 cylinder intake valve.
Note
Before attempting to remove the lower intake mani-
fold, break the seal between the manifold and the
cylinder block. Wedge a large screwdriver or simi-
lar heavy-duty tool between the manifold and the
cylinder block.
I
MB1140-A
1 7. Remove the lower intake manifold.
613UOB2-009
Exhaust manifolds
Note
Spray the nuts with rust penetrant prior to loosen-
ing to prevent the removal of thie stud with the nut.
DISASSEMBLY
FRONT OF ENGINE Remove the bolts, studs and the exhaust manifolds.
TIMING CHAIN
1. Remove the bolts and the crankshaft pulley from the damper.
2. Remove the damper from the crankshaft, referring to Disassembly Note. (Refer to below.)
3. Remove the screws and remove the clutch and fan assembly.
4. Remove the bolts and the water pump pulley.
5. Remove the heated air intake duct.
6. Remove the timing cover front nuts (automatic transmission vehicles with air conditioning).
7. Remove the air conditioner compressor bracket (automatic transmission vehicles with air conditioning).
8. Remove the oil pan, referring to Disassembly Note. (Refer to page B2-27.)
9. Remove the timing cover, referring to Disassembly Note. (Refer to page B2-27.)
10. Remove the front oil seal from the timing cover, referring to Disassembly Note. (Refer to page B2-27.)
11. Remove the timing chain, referring to Disassembly Note. (Refer to page B2-28.)
5BUOB2-069
Disassembly Note
Damper
Remove the bolt, washer and the damper from the crank-
shaft using Crankshaft Damper Remover T58P-6316-D
and Damper Remover Adapter T82L-6316-B, or equiva-
lents.
FRONT OF ENGINE
MBI 118-A 4811082-079

DISASSEMBLY
Oil pan
FRONT OF ENGINE 1. Remove the bolts.
2. Remove the oil pan.
3. Remove and discard the old gasket.
4. Remove and discard the front and rlear oil pan seals.
Timing cover
1. Remove the timing cover bolts.
2. Remove the timing cover.
la FRONT OF ENGINE
Note
To remove the timing cover without removing the
water pump,do not remove bolts marked 11 through
15, as shown.
3. Remove the old gasket.
Front oil seal

Pry the seal from the timing cover with a flat-bladed
screwdriver.
Note
Take care not to damage the timing cover while
removing the seal.
4811082-082
VIEW - FRONT OF ENGINE

B2 DISASSEMBLY
Timing chain
1. Rotate the crankshaft until No.1 piston is at the top dead
center (TDC) and the timing marks are aligned, as shown.
2. Check the timing chain for deflection and for excessive
wear.
TIMING MARKS MUST
3. Remove the camshaft pulley bolt.
BE IN POSITION
SHOWN WITH NO. 1
PISTON AT TDC FIRING
MB1121-A
4. Slide the pulleys and timing chain forward and remove as
an assembly.
DISASSEMBLY
CYLINDER HEAD
1. Remove the rocker arms, referring to Disassembly Note. (Refer to below.)
FRONT OF ENGINE
I I
ME1 180-A 5811082-070
1. Cylinder head 4. Valve springs
Inspection .............................. page B2-36 Inspection .............................. page 82-39
2. Valve keepers 5. Valves
Disassembly Note ........................... below lrispection .............................. page B2-37
3. Valve spring seats 6. Valve seals
Disassembly Note ................. page B2-30
Disassembly Note
Rocker arm
2. Remove the fulcrums.
3. Remove the rocker arms.
Valve keepers
1. Compress the valve springs using Valve Spring Compres-
sor T81 P-6513-A, or equivalent.
2. Remove the valve keepers and release the spring.
4BUOB2-086
DISASSEMBLY
Valve seals
Remove the valve seals.
Note
The three intake valve seals are different from the
three exhaust valve seals.
Identify all valve parts as to which cylinder they
were removed from and whether it i s intake or
exhaust.
Exhaust valve seal: Red band
Intake valve seal: Silver band

1. Remove the clutch cover and the clutch disc (MT). (Refer to Section H.)
2. Remove the flywheel (MT), referring to Disassembly Note. (Refer to below.)
3. Remove the drive plate (AT), referr~ngto Disassembly Note. (Refer to below.)
4. Remove the oil pump with the intermediate shaft, referring to Disassembly Note. (Refer to page B2-31.)
5BUOB2 071
Disassembly Note
Flywheel (MT)
Remove the bolts and the flywheel.
MB1166 A 4BUOB2 089

Drive plate (AT)
Remove the bolts, reinforcement plate and the drive plate.
DISASSEMBLY
1 Oil pump
1. demoie the oil pump assembly bolt.
2. Remove the oil pump assembly and the intermediate
shaft.
FRONT OF ENGINE
MB1147-A 4EiUOB2-091
DISASSEMBLY

1. Remove the tappets, referring to Disassembly Note. (Refer to page B2-33.)
DISASSEMBLY
1. Camshaft thrust plate 8. Piston
2. Camshaft Inspection .............................. page B2-42
Disassembly Note ........................... below 9. Connecting rods
Inspection .............................. page B2-39 Disassembly Note ................. page B2-34
3. Camshaft bearings lnspection .............................. page B2-44
Disassembly Note ................. page B2-34 10. Main bearing caps
4. Connecting rod cap Disassembly Note ................. page 82-36
Disassembly Note ................. page 82-34 11. Main bearing, lower
5. Connecting rod bearing Inspection .............................. page B2-46
Inspection .............................. page B2-46 12. Crankshaft
6. Piston rings Disassembly Note ................. page 82-36
Disassembly Note ................. page 82-35 Inspection .............................. page B2-45
Inspection .............................. page B2-43 13. Main bearing, upper
7. Piston pins Inspection .............................. page B2-46
Disassembly Note ................. page B2-35 14. Rear oil seal
Inspection .............................. page B2-44
Disassembly Note
Tappets
1. Loosen the tappet guide plate bolts.
2. Remove the guide plate retainer assembly.
3. Remove the tappet guide plates frorri the tappets by lifting
straight up.
4. Remove the tappets.
Camshaft
1. Rotate the crankshaft to 0' at top dead center (TDC) on
the compression stroke.
2.Align the marks on the camshaft and the crankshaft
pulleys, as illustrated.
3. Check the camshaft end play. (Refer to page B2-40.)
TIMING MARKS MUST

BE IN POSITION
SHOWN WITH NO. 'I
PISTON AT TDC FlFllNG
4. Remove the two camshaft thrust plate retaining bolts and

CAMSHAFT
the thrust plate.
5. Remove the camshaft by pulling it slowly toward the front
of engine, keeping the camshaft perfectly in line with
camshaft bores. Damage to the camshaft bearings and/or
FRONT OF ENGINE
the camshaft can occur if the camshaft is allowed to drop
on the bearing surface or the cylinder block.
DISASSEMBLY
Camshaft bearings
1. Using a sharp chisel or punch and hammer, cut a hole in
the center of the rear bearing bore plug.
2. Remove the plug using the SST. The plug can also be
pried from the bore using a large punch. Use care to
prevent damage to the plug bore.
Note
SST Number: 49 0223 6308 Impact Slide Hammer
3. Remove the camshaft bearing with Camshaft Bearing Set

4. Select the proper size expanding collet and backup nut,
and assemble on the expanding mandrel. With the ex-
panding collet collapsed, install the collet assembly in the
camshaft bearing, and tighten the backup nut on the
expanding mandrel until the collet fits the camshaft bear-
CAMSHAFT
ing.
BEARING SET 5. Assemble the puller screw and extension, if necessary,
T65L-6250-A and install on the expanding mandrel.Wrap acloth around
the threads of the puller screw to protect the bearing or
journal. Tighten the puller nut against the thrust bearing
and the pulling plate to remove the camshaft bearing. Be
sure to hold the end of the puller screw to prevent it from
turning.
6. Repeat steps 4 and 5 for each bearing. To remove the
front bearing, install the puller from the rear of the block.
Connecting rod cap
Before removina the connectina rod caps, measure the
connecting rod side clearance. l ~ e f eto
r page 62-44.)
5BUOB2-074
Connecting rods
2. Remove the Plastigage from the journals and bearings.
3. Inspect the top of the cylinder bore(s) before removing the
piston assembly. If a ridge has formed at the top of the
cylinder, it must be removed before piston extraction.
Remove the ridge as follows:
(1) Turn the crankshaft until the piston to be removed is at
the bottom of the cylinder bore.
(2) Place a clean shop cloth over the piston to collect
cuttings.
(3) Remove the ridge using a suitable ridge reamer,
following the manufacturer's instructions. Never cut
into the piston ring travel more than 0.794mm
(0.032 in} when removing a ridge.
4. Rotate the crankshaft to place the piston at the top of its
travel in the bore.
Caution
Use extreme care to prevent scratching or nicking
the crankshaft journal.
DISASSEMBLY
5. Install protective rubber caps onto the connecting rod
bolts to protect the crankshaft jourrlal contact from the
bolts' threads.
Note
If the crankshaft journal inhibits safe removal of the
piston assembly, rotate the crankshaft out of the
way once the protective caps are clear of th jour-
nal.
Protective caps may be made from a rubber fuel
hose.
6. Push the piston up slightly using the wooden end of a

hammer or similar tool, while guiding the connecting rod
from the crankshaft journal. Remove the upper bearing
insert from the connecting rod.
Note
If the bearing remains on the crankshaft journal,
carefully rotate the bearing arollnd the journal and
remove the upper bearing.
7. Push the piston and the connecting rod up and out of the
bore by tapping with the wooden end of a hammer or
~~1178-A 6~3~0~2-010
similar tool while guiding the connecting rod from the
crankshaft journal.
Caution
Do not push the piston assembly out of the bore too
fast, as damage to the piston andlor the machined
surfaces can result from contacit to the connecting
rod.
8. Install the cap in its original position and secure it with

retaining nuts.
Piston rings
Remove piston rings using a suitable piston ring
expander (commercially available).
1 I I I PRESS RAM
Piston pins
Remove the piston pins using an arbor press and Piston
PIN PUSHE Pin Remover and Replacer T68P-6'135-A, or equivalent.
Press the piston pin from the piston and connecting rod.
PISTON PIN
REMOVER AND plcrnrl
REPLACER t
T68P-6135-A
PRESS PLATES - \ TUBE

DISASSEMBLY, INSPECTION 1 REPAIR
Main bearing caps
1 . Loosen the main bearing cap bolts in several passes and
remove the bolts.
2. Remove the caps.
4BUOB2-100
Crankshaft
Lift the crankshaft straight up from the engine block. Make
sure the crankshaft bearing surfaces are not scratched or
damaged by contact with the cylinder block.
4BUOB2-101
INSPECTION / REPAIR
PREPARATION
1 . Clean all parts, being sure to remove all gasket fragments,
dirt, oil, etc.
2. Performthe inspectionsand repairs in the order specified.
Caution
Do not damage the joints or friction surfaces of
aluminum alloy components (such as the cylinder
head or pistons).
4BUOB2-102
CYLINDER HEAD
1. Inspect the cylinder head for damage, cracks, and leak-
age of water and oil. Replace if necessary.
2. Using a straightedge, measure the cylinder head for
distortion in the six directions shown in the figure.
Distortion: 0.18mm (0.007 in)

Note
Before grinding the cylinder head, ch ck for the
following and repair or replace as necessary:
(1) Sinking of valve seat

1 I (2) am age to manifold contacl: surface
4f3UOB2-I03
3. If distortion exceedsspecification, grind thecylinder head.
4. If it is still out of specification, replace the cylinder head.
VALVE MECHANISM
'8 STEM TIP

1. Inspect each valve for the following, and replace or
resurface as necessary:
(2) Rough or damaged face
(3) Damaged or unevenly worn stem tip
MB1017-A
1 2. Measure the valve stem diameter arid redace the valve
if necessary.
Diameter
Standard
IN: 7.96-J.948mm (0.31 34-0.31 26 in)
EX: 7.948-7.928mm (0.31 29-0.31 21 in)
Oversize-0.38mm (0.01 5 in)
IN: 8.34-8.32mm (0.3283-4.3276 in)
EX: 8.328--8.308mm (0.3279-0.3271 in)
I I
~~1018-A Oversize-0.76mm (0.030 in)
IN: 8.72-4.70mm (0.3433-4.3425 in)
EX: 8.708--8.688mm (0,3428-4.3420 in)
INSPECTION / REPAIR
3. Measure each valve guide inner bore diameter and record.
Inner diameter: 8.745--8.72mm (0.3443-4.3433 in)
I I
MBlOl9-A
4. Calculate the valve stem-to-guide clearance. With the
valves in place, measure the clearance with Valve Stem
Clearance Tool TOOL-6505-E, or equivalent and a dial
indicator. Use a flat-end indicator point.
(1) Install the tool on the valve stem until it is fully seated,
and tighten the knurled setscrew firmly. Permit the
valve to drop away from its seat until the tool contacts
the upper surface of the valve guide.
(2) Position the dial indicator with its flat tip against the
center portion of the tool's spherical section at approxi-
mately 90" to the valve stem axis.
(3) Move the tool back and forth in line with the indicator
stem. Take a reading on the dial indicator without
removing the tool from the valve guide upper surface.
(4) Divide the reading by two, the division factor for the
tool. If the valve stem-to-guide clearance exceeds the
wear limit, ream the valve guide for the next oversize
valve stem.
Clearance
VALVE STEM IN: 0.026--0.068mm (0.001 0-4.0027 in)
CLEARANCE TOOL
TOOL-6505-E EX: 0.038-0.081 mm (0.0015 4 . 0 0 3 2 in)
MB1020-C 5BUOB2-037
Valve Seat
I . Inspect the contact surface of the valve seat and valve
(1) Roughness
(2) Damage
2. Measure the valve seat angle.
Valve seat angle: 45"
If necessary, resurface the valve seat.

Apply a thin coat of Prussian blue to the valve face.
Check the valve seating by pressing the valve against the
seat.
(1) If blue does not appear 360" around the valve face,
replace the valve face.
resurface the seat.
INSPECTION / REPAIR
6. Check the valve seat runout. Follow the instructions of the
gauge manufacturer. If the runout exceeds the wear limit,
resurface the valve and valve seat.
Runout limit::0.076mm (0.003 in)
7. Measure the seat contact width.
Width: 1.5-2.0mm (0.06-0.08 in)
APPLY TORQUE UNTIL

Valve Spring
1. Inspect the valve spring, valve spring retainers and the
AND MULTIPLY
keepers for wear or damage. Discard any damaged parts.
READING BY TWO \ 2. Check the springs for proper pressure at the specified
spring lengths. Weak valve springs cause poor engine
performance. Replace any spring nol: within specification.
VALVE SPRING
Pressurellength:
SET KNOB TO Loaded: 800.6 N (180 Ibs) at 29.5mm (1.16 in)
COMPRESSED
LENGTH OF Unloaded: 288.1 N (65 Ibs) at 48.lmm (1.58 in)
SPRING
3. Check the valve spring free length.
Free length:
46.7mm (1-84 in} (approximate)
Assembled length:
44.1 741.98mrn { I .736-1.650 in)
CAMSHAFT
1. Check the camshaft journals for wear or scoring. If the
journals are excessively worn or !scored, replace the
camshaft.
2. Camshaft journals can be refinished to accommodate
0.38mm (0.01 5 in) undersize bearings. If the journals can
3. Set the camshaft on V-blocks and mleasure the camshaft
runout and out-of-round.
Runout: 0.05mm (0.002 in) maximum

Out-of-round: 0.025mm (0.001 in} maximum
B2-39
INSPECTION 1 REPAIR
4. Inspect the camshaft for wear or damage.
5. Measure the camshaft lobe lift. To measure the lift,
proceed as follows:
(1) Measure the distance between major (A-A) and minor
(B-B) diameters of each cam lobe with a Vernier
B caliper and record readings. The difference in read-
ings on each cam diameter is the lobe lift.
(2) If the readings are not within specification, replace the
camshaft.
A Lobe lift: 6.604mm (0.260 in}
~~1024-A Minimum: 6.477mm (0.255 in)
6. Measure the camshaft journal diameters in the X and Y
"
directions at two points. Replace the camshaft as neces-
sary.
Journal diameter:
50.987-51 -013mm (2.0074-2.0084 in)
7 . Measure the camshaft oil clearance by measuring the

journal diameter and the bore diameter. Subtract the
journal diameter from the bore diameter to determine the
31 282-A 4~~062-107 oil clearance.
Oil clearance:
0.025--0.076mm (0.001-0.003 in]
8. Measure the camshaft end play.

Caution
Prying against the camshaft pulley with the valve
train load on the camshaft can break or damage the
gear. Therefore, the rocker arm adjusting nuts must
be backed off, or the rocker and shaft assembly
must be loosened sufficiently to free the camshaft.
(1) Push the camshaft toward the rear of the engine.

Install a dial indicator so the indicator point is on the
camshaft pulley.
(2) Zero the dial indicator. Pull the camshaft forward and
release it. Compare the reading with specifications. If
end play is excessive, replace the thrust plate.
(3) Remove the dial indicator.
End play: 0.003mm (0.007 in)

INSPECTION / REPAIR
TAPPET
1. Clean all tappet parts in clean so1ven.t and wipe them with
a clean, lint-free cloth.
2. Inspect tappet for signs of pitting, scoring or excessive
wear. Replace the entire assembly if tlie plunger is not free
in the body. The plunger should drop to the bottom of the
body by its own weight when assembled dry.
3. The tappets can also be checked witt-Ia hydraulic tester to
test the leakdown rate. Follow the instructions of the test
unit manufacturer.
4. Measure the tappet diameter.
Diameter: 22.206mm (0.874 in)
5. If the tappet diameter is not within specifications, replace

the tappet.
6. Measure the tappet oil clearance by measuring the tappet
bore diameter and subtracting the tappet diameter from
the bore diameter.
Tappet oil clearance:

Standard: 0.018-0.069mm (0.0007-0.0027 in)
Limit: 0.127mm (0.005 in)
7. Measure the collapsed tappet gap.
Collapsed tappet gap (nominal):

2.23-4.77mm (0.088-4.1 89 in)
4BUOB2-108
CYLINDER BLOCK
1 . Check the cylinder block for the following and repair as
necessary:
(1) Leakage damage
(2) Cracks
(3) Scoring of wall
2. Using a straightedge, measure the cylinder block decks
for distortion in six directions.
Distortion: 0.08mm (0.003 in) per 152.0mm (6.0 in)

block.
4. Measure the cylinder bore diameter in X and Y directions

at three levels (A,B,C), as shown.
Cylinder bore diameter
rnm {in)
Cylinder bore diameter P'istoncolor code
1 89.009-89.035 i3.5043-3.5053) 1 Red I
INSPECTION / REPAIR
Caution
When reboring the cylinder block, base the bore
size on an oversize piston and bore all cylinders to
the same size.
5. If the cylinder bore exceeds the maximum, rebore all
cylinders to oversize diameter.
6. If the difference between measurement A and C exceeds
the maximum taper, rebore all cylinders to oversize
diameter.
Taper: 0.050mm (0.002 in) maximum
I/ 7. If the difference between measurements X and Y exceeds

the maximum out-of-round. rebore all cvlinders to the
oversize diameter.
Out-of-round:
Standard: 0.025mm (0.001 in)
1 I
MB1027-A 4BUOB2-109
PISTONS, PISTON RINGS AND PISTON PINS
Pistons
2. Measure the outer diameter of each piston at a right
angle (90") to the piston pin 14.58mm (0.57 in) below
the bottom of the oil ring.
Note
The pistons are color-coded red, blue, or yellow on
the dome of the piston.
Piston diameter:
mm (in)
I
(
Color
Blue
Yellow
Piston
1
j
Diameter
88.962-88.978
88.988-89.004
I
13.5024-3.503T
13.5035-3.50411
89.014--89.030 13.5045-3.5051}
1
1
MB1285-A
Note
Oversize pistonsareavailable in the following sizes:
0.508mm (0.020 in), 0.762mm (0.030 in)and 1.016mm
(0.040 in).
INSPECTION / REPAIR
3. Measure the piston-to-cylinder bore clearance.
Clearance: 0.030--0.056mm (0.00'12-4.0022 in}

Maximum: 0.081 mm (0.0031 in)
4. If the clearance exceeds the maximum, replace the piston

or rebore the cylinders to fit oversize pistons.
Note
If a piston is replaced, the piston rings of that
-It+
CLEARANCE piston must also be replaced.
MB1028-A 5ElUOB2-039
Piston Rings
1. Measure the piston-to-ring land clearance around the
entire circumference by using a newf piston ring.
Clearance
Top: 0.0404.095mm (0.001 6-0.0037 in)
Bottom: 0.0404.095mm (0.0016-0.0037 in)
Oil Ring: Snug fit
Service Limit: 0.15mm (0.006 in) maximum
2. If the clearance exceeds the maxi!mum, replace the

MBI 029-A piston.
3. Inspect the piston rings for damage, abnormal wear, or
4. Insert the piston ring into the cylinder by hand and use the
piston to push it to the bottom of the ring travel.
Caution
Use care to avoid damage to the ring or the cylinder
bore.
PISTON
RING
5. Measure each piston ring end gap by using a feeler

gauge. Replace if necessary.
End gap
Top: 0.25--0.50mm (0.01 0-0.0:20 in)
Bottom: 0.25-0.50mm (0.010-.0.020 in)
Oil Ring: 0.25-.1.25mm (0.010--0.049 in)
Piston Pins
1. Measure each piston pin bore diameter in X and Y
directions at four points.
Diameter: 23.1 05-23.1 45mm (0.90964.91 12 in)
2. Measure the piston pin diameter in the X and Y directions

at four points.
Diameter: 23.1 62-23.175mm (0.91 1 9 4 . 9 1 24 in)

I
MBlo32-A 5~~0~2.0401 3.Calculate the related piston-to-pin clearance.
Clearance: 0.005-0.01 2mm (0.00024.0005 in}

and/or piston pin.
5. Measure the piston pin length.
Length: 76.5-77.2mm (3.01 2-3.039 in)
6. If the length exceeds specifications, replace the piston

pin.
CONNECTING RODS
1. Measure the small end inner bore diameter of each
connecting rod.
Diameter: 23.1 05-23.1 45mm (0.9096-4.91 12 in)

Caution
rod cap must also be replaced, since they are a
matched set.
2. Check the bend and twist factor of the connecting rod.
Bend: 0.04mm (0.0016 in)/25.4mm (1.0 in)

Twist: 0.075mm (0.003 in)/25.4mm (1.0 in)
Length (Center to Center): 140.46-1 40.54mm
(5.530-5.533 in}
3. If either the bend or twist factors exceed the specifica-

tions, replace the connecting rod.
INSPECTION / REPAIR
4. Check the connecting rod-to-crankshaft side clearance.
Clearance (assembled to crank)

Standard: 0.1 5-0.35mm (0.006---0.014 in)
5. If the side clearance exceeds the maximum, check both

the connecting rod and the crankshaft, and replace as
necessary.
diameter.
Diameter: 57.15-57.1 7mm (2.250--2.251 in]
7. If the diameter exceeds the specification, replace the

connecting rod.
8. Measure the connecting rod bearing thickness.
Bearing thickness
Standard: 1.557-1.570mm (0.061 2-4.0618 in)
CRANKSHAFT
hole clogging.
3. Measure the crankshaft runout. Replace the crankshaft if
necessary.
Runout: 0.05mm (0.002 in)
4. Measure each journal diameter in the X and Y directions

at two points.
Main journal
Diameter: 63.983-64.003mm (2.51 90-2.51 98 in)
Out-of-round: 0.008mm (0.0003 in) maximum
Crankpin journal
Diameter: 53.983-54.003mm (2.1 253-2.1 261 in)
Out-of-round: 0.006mm {0.000:! in) maximum
0.015mm (0.000ti in) Total
5. If the diameter is less than the minimum, grind the journals

to accept undersize bearings.
Undersize bearings:
0.025mm (0.001 in)
0.050mm (0.002 in)
6. Measure the taper of each journal
Main journal
Taper: 0.008mm125mm (0.0003 iinll in)
Crankpin journal
Taper: 0.008mm/25mm (0.0003 iinll in)
7. If the out-of-round or taper measurements exceed the

maximum, replace the crankshaft.
82-45
INSPECTION I REPAIR, ASSEMBLY
BEARING
CRATERS OR POCKETS BRIGHT (POLISHED)
SECTIONS
( FATIGUE FAILURE IMPROPER SEATING
SCRATCHES DIRT
IMBEDDED OUT
II lNTO BEARING
MATERIAL
SCRATCHED BY DIRT M C K OF OIL OR
IMPROPER CLEARANCE 1
FROM EDGES RADIUS RIDE
I HOURGLASSING
RADIUS RlDE
I
PULLEYS
Camshaft Pulley and Crankshaft Pulley
lnspect the teeth of each pulley for wear, deformation and
other damage, replace as necessary.
4BUOB2-116
TIMING CHAIN OUTER COVER

lnspect the outer cover for damage and cracks. Replace
as necessary.
4BUOB2-117
FLYWHEEL
Refer to Section 61.
ASSEMBLY
PREPARATION
SST
49 UNOl 064 For

installation
of rear
Rear main main seal
seal installer
1. Clean all parts before reinstallation.

3. Replace plain bearings if they are peeling, burned, or otherwise damaged.
Caution
ASSEMBLY

2. Install the tappets, referring to Assembly Note. (Refer to page B2-54.)
ASSEMBLY
1. Main bearings, upper Assembly Note ...................... page 82-50
Assembly Note ................................ below 9. Connecting rod bearing
2. Crankshaft Assembly Note ...................... page 62-50
3. Main bearings, lower 10. Connecting rod cap
Assembly Note ................................ below Assembly Note ...................... page 62-51
4. Main bearing caps 11. Crankshaft rear main oil seal
Assembly Note ................................ below Assembly Note ...................... page 62-53
5. Piston 12. Camshaft bearings
Assembly Note ...................... page B2-50 Assembly Note ...................... page B2-53
6. Piston pin 13. Camshaft
Assembly Note ...................... page B2-50 Assembly Note ...................... page 62-54
7. Connecting rod 14. Camshaft thrust plate
Assembly Note ...................... page 62-50 Assembly Note ...................... page B2-54
8. Piston ring
Assembly Note
Upper main bearing, lower main bearing and main
bearing cap
below:
Oil clearance inspection

(1) Remove any foreign material and oil from the jour
nals and bearings.
(2) Install the upper main bearings.
(3) Install the lower main bearings into the main bearing
caps.
(4) Install the crankshaft into the cylinder block.
direction.
(7) Install the main bearing cap.
(8) Tighten the main bearing cap bolts.
Tightening torque:
7 5 - 4 5 N-m (7.5-4.5 kgf-m, 5 5 - 4 3 ft.lbf)

point for the smallest clearance, and at the narrowest
Oil clearance
Standard: 0.025--0.035mm (0.001--0.0014 in)
Allowable: 0.020-0.066mm (0.0008-0.0025 in)

ASSEMBLY
2. Install the main bearing caps as follows:
ings.
bearings.
(3) Apply sealant to the rear main bearing caps mounting
surface.
(4) Install the main bearing caps.
Note
Install the main bearing caps in their original
positions.
** PRY FORWARD
(5) Pry the crankshaft forward against the thrust surface of
the upper half of the bearing.
1 THRUST
BEARING
PRY CRANKSHAFT FORWARD
MI31 153-A
(6) Hold the crankshaft cap to the rear. This will align the
thrust surfaces of both halves of .the bearing.
HOLD PRY CAP

CRANKSHAFT BACKWARD
FORWARD
THRUST
BEARING
,
PRY CAP BACKWARD
MB1154-A
(7) Retain the forward pressure on the crankshaft and
tighten the main bearing cap bolts.
Note
THRU FORWARD
Do not let the crankshaft rotate the bearings.
BEAR
Tightening torque:
75-45 N m (7.5-4.5kgf-m,55--63 ft-lbf)
3. Measure the crankshaft end play.
TIGHTEN CAP
End play: 0.10-0.20mm (0.004-01.008 in)
4. If the end play exceeds the specif~cation,replace the

crankshaft.
ASSEMBLY
NOTCH ON PISTON DOME AND BUTTON ON Connecting rods
CONNECTING ROD lDENTlFlCATlON MARKS MUST 1. Check the fit of a new piston in the cylinder bore before
BE ON SAME SIDE AND TOWARDS THE FRONT OF
assembling the piston pin to the connecting rod.
2. Apply a light coat of clean engine oil to all parts.
3. Assemble the piston to the connecting rod, putting the
notch in the piston dome and the connecting rod on the
same side.
VIEWED FROM FRONT OF ENGINE

WB1156-D
4. Start the piston pin in the piston and connecting rod (this
I INSTALLATION 1 may require a light tap with a mallet). Using an arbor press
MAKE CERTAIN
PISTON FLOATS and Piston Pin Remover and Replacer T68P-6135-A, or
INSTALLATION
equivalent, press the piston pin through the piston until
OPERATION the pin is centered in the piston.
EMOVER AND
T68P-6135-A
Piston rings
Install the piston rings to the piston using a piston ring
expander.
Note
Never install the piston rings with hands.
Piston rings should be staggered on the piston to
make sure the piston ring end gaps are not aligned.
If new piston rings are to be installed, and no visible
cross-hatch marks remain on the cylinder wall, or
an unfinished cylinder wall, then the wall must be
refinished using a spring-type Cylinder Hone Set
4BUOB2-123
Pistons and connecting rods assembly

Note
All pistons, connecting rods, bearings and con-
necting rod bearing caps must be installed in the
original location from which they were removed.
1. Oil all pistons, piston rings and cylinder walls before

installation.
2. Install protective rubber caps on the connecting rod studs.
3. Rotate the crankshaft journal to the top of its travel.
4. Check the piston rings for proper end gap positioning.
5. Install a piston ring compressor to the piston.
6. Remove the protective rubber caps.
7. Install a clean, dry upper connecting rod bearing.
ASSEMBLY
Note
Be sure to install pistons in the same cylinders from
which they were removed or were fitted. The con-
necting rod and bearing caps are identified with
matching correlated letters. Letters on the con-
necting rod and the bearing cap must be on the
same side when installed. If a connecting rod from
a different cylinder block is used, new bearings
should be fitted.
NOTCH ON PISTON DOME AND BUTTON ON 8. Carefully align the piston to the cylinder bore, making sure
CONNECTING ROD IDENTIFICATIONMARKS MUST the piston dome notch and the button on the connecting
BE ON SAME SIDE AND TOWARDS THE FROIVT OF rod face the front of engine.
w
I VIEWED FROM FRONT OF ENGINE
9. Install a piston by tapping with a wooden hammer handle

RING
iSSOR or similar device while aligning the connecting rod to the
crankshaft journal.
10. Apply engine oil to bearing surfaces and the crankshaft
journal.
FRONT OF ENGINE
Connecting rod cap

follows.
Caution
oil clearances.
Oil clearances must be measuredwith the connect-
(1 ) Remove any foreign material and oil from the journals

and bearings.
rod cap.
(3) Position Plastigage atop the jourr~alsin the axial direc-
tion.
ASSEMBLY
(6) Tighten the connecting rod cap nuts.
Tightening torque:
31-39 N.m (3.2-3.8 kgfam, 23-28 ftlbf)

I Oil clearance
Standard: 0.025-0.035mm (0.001 0 4 . 0 0 1 4 in)

Allowable: 0.020--0.066mm (0.0008-0.0025 in)

2. Install the connecting rod bearings and caps as follows:
ings.
(3) Install the bearing in the connecting rod and cap, with
the tangs fitting in the slots provided.
(4) Turn the crankshaft throw to the bottom of its stroke.
Push the piston all the way down until the connecting
rod bearing seats on the crankshaft journal.
(5) Make sure the connecting rod is seated correctly on
the crankshaft journal. Install the cap and bearing
assembly and tighten the nuts.
Tightening torque:
31-39 N-m(3.2-3.8 kgf.m, 23-28 ft.lbf)
3. After the piston and connecting rod assemblies have been

installed, check the side clearance between the connect-
ing rods on each crankshaft journal.
Side clearance
Standard: 0.1 5 4 . 3 5 m m (0.0064.01 4 in)
4. If the clearance exceeds the maximum, replace the con-

necting rod and cap.
MB1082-B 5BUOB2-044
B2-52
ASSEMBLY
Crankshaft rear main oil seal
1. Apply clean engine oil to the outer lips and inner seal edge.
2. Position the seal on the SST. Position the SST and the
seal to the rear of the engine. Alternate bolt tightening to
seat the seal properly.
Protrusion: 0.5mm (0.02 in)
Camshaft bearings
Note
The camshaft bearings are available pre-finishedto
size and require no reaming for standard and
0.38mm (0.015 in) undersize journal diameters.
1. Position new bearings at the bearing bores and press

CAMSHAFT them in place with Camshaft Bearing Set T65L-6250-A, or
BEARING SET
T65L-6250-A equivalent. Be sure to center the p ~ ~ l l i nplate
g and puller
screw to avoid damage to the bearing.
Caution
Failure to use the correct exlpanding collet can
cause severe bearing damage.
Note
Align the oil holes in the bearings with the oil holes
in the cylinder block before pressing the bearings
into place.
Make sure the front bearing is installed 0.51-
0.89mm (0.020-4.035 in) below the front face of the
cylinder block.
2. Install the camshaft rear bearing bore plug using a suit-

able driver.
Note
Apply sealer to the sealing edge of the plug before
installation.
Oversize plugs are identified by the "0s"stamped
in the flat located on the cup siide of the plug.
ASSEMBLY
Camshaft and camshaft thrust plate
1. Lubricate the camshaft lobes and bearing surfaces liber-
ally w ~ t h
engine oil. Lubricatethe distributor drive gearwith
gear lube. Carefully slide the camshaft through the bear-
FRONT OF ENGINE ings into the cylinder block, remembering to keep the
camshaft perfectly In line with the front bearing.
Q 2. Lubricate the camshaft thrust plate with clean engine oil
and install the two bolts.
Tightening torque:
8-1 2 N.m (0.8-1.2 kgfem, 6--8 ft-lbf)
A81 146-8 5BUOB2-047
Tappets
GUIDE PLATE 1. lnstall the tappets.
RETAINER
ASSEM,BLY 2. Install the tappet guide plate.
Note
lnstall the tappet guide plate with the word "UP"
and/or button visible.
FRONT OF 3. lnstall the guide plate retainer assembly.
Tightening torque:
10-1 4 N-m(1.O-1.4 kgfem, 7.3-1 0.3 ft-lbf)
PLATE

I . lnstall the oil pump with intermediate shaft, referring to Assembly Note. (Refer to page B2-55.)
2. Install the drive plate (AT), referring to Assembly Note. (Refer to page 82-55.)
3. lnstall the flywheel (MT), referring to Assembly Note. (Refer to page 62-55.)
4. lnstall the clutch cover and clutch disc (MT). (Refer to Section H.)
ASSEMBLY
Assembly Note
Oil pump with intermediate shaft
1. Install the oil pump and intermediate shaft.
2. Tighten the bolts to specification.
Tightening torque:
40-55 N-m (4.1-5.5 kgf-m, 3 0 4 0 ftalbf)
FRONT OF ENGINE
Drive plate (AT)

FRONT OF Install the drive plate and reinforcement plate and install
the bolts usirig the standard cross-tightening sequence.
Tightening torque:
7 3 - 4 7 N.m (7.3-4.7 kgf-m, 541-64 ftelbf)
-
ME1 167 A '581
Flywheel (MT)
Install the flywheel on the crankshaft using Clutch Aligner
CLUTCH ALIGNER T71 P-7137-H, or equivalent. Install the bolts using the
standard cross-tightening sequence.
Note
The three dowels must be bottomed out in the
flywheel.
Tightening torque:
7 3 - 8 7 N.m (7.3-4.7 kgf-m, 54-64 ft-lbf)
ASSEMBLY
CYLINDER HEAD
2. Install the rocker arms, referring to Assembly Note. (Refer to page B2-57.)
FRONT OF ENGINE
r)
I I
MB1284-A 5BUO02-078
1. Valves 4. Valve spring seat
Assembly Note ................................ below Assembly Note ...................... page B2-57
2. Valve seals 5. Valve keepers
3. Valve springs 6. Cylinder head
Assembly Note ...................... page B2-57 Assembly Note ...................... page B2-58
Assembly Note
Valves
1. Apply clean engine oil to all valves before installation.
2. Apply grease to the valve tips before installation.
3. Install each valve in the port from which it was removed or
to which it was fitted.
4BUO02-135
ASSEMBLY
Valve seals
Install the valve seal. Use a 518 in deep-well socket and a
light mallet or hammer to seat the seal on the valve stem.
Make sure the intake seals and exh,austseals are on the
proper stem.
Note
The intake valve seals are different from the ex-
haust valve seals.
4BUOB2-136
Valve springs, valve spring seat and valve keepers

1. Install the valve spring over the valve and then install the
valve spring seat. Compress the spring and install the
valve keepers.
2. Measure the assembled height of the valve spring from
the top of the spring seat to the underside of the valve
keepers with dividers. Check the dividers against the
scale. If the assembled height is greater than specifica-
tion, install necessary 0.762mm (0.030-in) thick spacer(s)
between the cylinder head spring pad and the valve
spring. This will bring the assembled height within speci-
fication.
Valve spring height: 44.1 741.98mm

(1.736-1.650 in)
Caution
Do not install the spacers unless necessary. Use of
spacers in excess of recommendations will result
in overstressing of the valve springs and overload-
ing the camshaft lobes, which could lead to spring
breakage andlor worn camshaft lobes.
5811082-051
Rocker arms
1. Apply clean engine oil to all push rods.
2. Install the push rods into their origir~alposition.
#1 INT 3. Rotate the camshaft to position "A" as shown.
#5 EXH
4. Install rocker arms, fulcrums, and bolts in the locations
specified in position "A".
Tightening torque:
7-1 1 N-m(71-1 11 kgf.cm, 62,-97 in-lbf)
RIGHT HEAD LEFT HIEAD
CENTER LINE OF
KEYWAY VERTICAL
WITHIN = 5"
TIMING
MARKS
CAMSHAFT POSITION A
IB1133-A
ASSEMBLY
5. Rotate the crankshaft 120" to position "B" as shown.
-
INSTALLATION ROCKER ARM, 6. Install rocker arms, fulcrums, and bolts in the locations
PUSH ROD AND FULCRUMS specified in position "B".
#3 INT #6 EXH
1 #3 EXH
/#21NT #5 INT 1
Tightening torque:
7-1 1 N-m(71-1 11 kgfecm, 62-97 inslbf)
7. Tighten all rocker arm bolts to their final torque.
Tightening torque:
32 N.m (3.3 kgf.m, 24 ft-lbf)
RIGHT HEAD LEFT HEAD Caution
The fulcrum must be fully seated into the cylinder
CENTER LINE head and the push rod must be fully seated in
OF ENGINE
the rocker arm and lifter sockets prior to final
TIMING
tightening.
MARKS
Note
Camshaft positions "A" and "8" are required to
place the tappet assembly on the base circle of the
CAMSHAFT POSITION B camshaft lobe to check the collapsed tappet gap.
I I
MI31 134-A
Tappet gap: 2.234.77mm (0.088-0.189 in)
FULCRUM AND BOLT MUST BE FULLY
SEATED AFTER FINAL TORQUE
Refer to the chart for which valve gaps to set when
2.15--4.69 mm
{0.08+0.184 in) the camshaft is in either position "A" or "8".
Set Gap of Valves Noted

-- - -
Camshaft Position
CY~
No. A B
1 Int. Exh.
2 Exh. Int.
3
-
None Int.-Exh.
-
4 Int. Exh.
5
-
Exh. Int.
6 None Int.-Exh.
MI31 136-A
8. Apply clean engine oil to all of the rocker arm assemblies.
Cylinder head
1. Lay a clean shop rag in the tappet valley to catch any
gasket particles. Clean the cylinder head, intake manifold
and the cylinder head-to-block gasket surfaces. After
scraping, lift the cloth so no gasket material falls into the
holes. Check the cylinder head and the cylinder block
gasket surfaces for flatness. (Refer to page 62-36.)
Caution
Gouges in aluminum components will cause gas-
kets to leak.
ASSEMBLY B2
2. Position the new head gasket(s) on the cylinder block
using the dowels for alignment. Make sure the gasket is
aligned as shown in the figure.
Note
Replace the alignment dowels if they are damaged.
"V" CUT HERE
IS FOR TRUCK
3. Carefully position the cylinder head(s) on the cylinder
block.
4. Install the new bolts and hand tighten.
- NOTE: LEFT SlDE SHOWN

RIGHT SlDE 7YPICAL
( 0 FRONTOF ENGINE
-
MB1126-A
5. Tighten the bolts in sequence as shown in the figure.
Tightening torque:
80 N.m (8.1 kgf.m, 59 ft-lbf)
6. Back off all of the bolts a minimum 0.f one full turn (360").
7. Retighten the bolts, in the sequence illustrated, in two
steps.
Tightening torques:
Step 1: 45-55 N.m (4.5-5.5 kgfam, 3 3 4 1 ft-lbf}
Step 2: 85-99 N-m(8.5-9.9 kgf.m, 63-73 ftelbf}
Note
When the cylinder head bolts have been tightened
using the above procedure, it is not necessary to
retighten the bolts after extended engine opera-
tion.
FRONT OF ENGINE
Q
ASSEMBLY
TIMING CHAIN
1. lnstall the timing chain, referring to Assembly Note. (Refer to below.)
2. lnstall the timing cover, referring to Assembly Note. (Refer to below.)
3. lnstall the oil pan assembly, referring to Assembly Note. (Refer to page 82-61).
4. lnstall the air conditioner compressor bracket, if equipped.
5. lnstall the timing cover front nuts.
6. lnstall the heated air intake duct.
7. lnstall the water pump pulley and tighten with bolts.
8. lnstall the clutch and fan assembly, tighten with screws, referring to Assembly Note. (Refer to page
B2-61.)
9. lnstall the damper to the crankshaft, referring to Assembly Note. (Refer to page 82-62.)
10. lnstall the crankshaft pulley, referring to Assembly Note. (Refer to page 82-62,)
5BUOB2-079
Assembly Note
Timing chain
1. Clean and inspect all parts before installation.
2. Slide the pulleys and the timing chain on as an assembly,
with the timing marks aligned, as shown.
TIMING MARKS MUST
3. Lubricate the chain and pulleys with clean engine oil.
BE IN POSITION 4. lnstall the camshaft retaining bolt and washer.
SHOWN WITH NO. 1
PlSTON AT TDC FIRING
Tightening torque:
55-70 N-m (5.5-7.0 kgf+m,41-52 ft-lbf)
Note
The camshaft sprocket bolt has a drilled oil pas-
sage for timing chain lubrication. If the bolt is
damaged, do not replace it with a standard bolt.
Clean oil passage with solvent.
Timing cover
1. lnstall a new front oil seal using Front Cover Seal
Installer T82L-6316-A and Front Cover Seal Replacer
T70P-6B070-A, or equivalents.
2. Position a new gasket onto the dowels.
3. lnstall the timing cover.
I FRONT OF ENGINE
ASSEMBLY
4. Apply sealant to the bolts as shown in the figure.
1
5. Tighten bolts to specification.
Tightening torques:
A: 20-30 N.m (2.0-3.0 kgf-m, 115-22 ft-lbf)
6: 8-1 2 N.m (0.8-1.2 kgf-m, 6 - 4ft.lbf)
Oil pan
1. Lightly oil all bolt threads before instisllation.
2. Clean the gasket surfaces on the cylinder block and oil
pan.
ASSEMBLY
3.Apply a 4.0-6.0mm (0.2 in) bead of sealant to the
FRONT CYLINDER junction of the rear main bearing cap and cylinder block
COVER BLOCK and the junction of the front cover assembly and cylinder
block.
SEALANT
4. Position the oil pan gasket to the cylinder block and secure
with adhesive.
5. lnstall the oil pan.
6. lnstall the bolts and tighten to specification.
STOP SEALANT BEAD Tightening torque:
3 mm (0.12 in)
FROM TIMING CHAIN 10-14 N.m (1.O-1.4 kgf-m, 7-10 ft.lbf)
CAVITY
Ll-
*-6 & m
{0.16-0.24
4 in]
REAR MAIN
BEARING CAP
Damper
1. Coat the damper sealing surface with clean engine oil.
FRONT OF ENGINE 2.Apply sealant to the keyway of the damper prior to
installation.
0 3. lnstall the damper using Damper and Front Cover Seal
Installer T82L-6316-A, or equivalent.
4. lnstall the washer and bolt and tighten.
Tightening torque:
125-1 65 N-m (12.7-1 6.8 kgf.m, 93-1 21 ftlbf}
5BUOB2-056
Crankshaft pulley
lnstall the crankshaft pulley.
Tightening torque:
53-70 N-m(5.3-7.0 kgfam, 40-52 ft-lbf)
5BUOB2-057
\ 'DAMPER
125--165 N-m,
(12.7-1 6.8 kgf-m,
93--121 ftelbf)
1 I
MB1352-A
Clutch and fan assembly
I.lnstall the clutch and fan assembly.
2. Tighten the screws to the specified torque.
Tightening torque:
41-135 N.m (4.1-13.6 kgfem, 30-99 ftalbf)
4BUOB2-144
ASSEMBLY
AUXILIARY PARTS
2. Install the oil filter.
GASKET,
/'NEW
15 {1.5, 11)
STEP 2:
2 6 3 2 ( 2 . 6 3 . 2 , 19--24)
REPLACE
2-0 {2.0--3.0,
I I
MB1175-C 5BUOB2-058
1 . Exhaust manifolds 4. Upper intake manifold/throttle body assembly
Assembly Note ...................... page B2-64 Iristallation ............................. Section F2
2. Lower intake manifold 5. Ignition coil (Not shown)
Assembly Note ...................... page B2-64 6. Dipstick tube and bracket (Not shown)
3. Cylinder head covers Assembly Note ...................... page B2-66
Assembly Note ...................... page B2-66 7. DPFE sensor
ASSEMBLY
Assembly Note
Exhaust manifolds
1. Clean the mating surface of the manifolds and the cylinder
head of carbon deposits.
2. Position the manifolds onto the cylinder head and hand-
tighten the retaining bolts and studs.
Tightening torque:
20-30 N-m 12.0-3.0 kgf.m, 15-22 ft-lbf)

1. Lightly oil all bolts and stud threads before lower installa-
tion.
2. Clean the mating gasket surfaces of the lower intake
manifold and the cylinder head. Lay aclean shop rag in the
tappet valley to catch any gasket material. After scraping,
carefully lift the cloth from the tappet valley, preventing
any particles from entering the oil drain holes or the
cylinder head. Use a suitable solvent to remove the old
rubber sealant.
Caution
Aluminum components gouge easily which can
cause gasket leaks. Always use care when scrap-
ing aluminum gasket surfaces.
3.If installing a new lower intake manifold, transfer the fuel

injectors, fuel supply manifold, engine coolant tempera-
ture sensor, thermostat, gasket and housing, heater hose
elbow and the water temperature indicator sender to the
new manifold.
4. Apply a 5--6mm (0.20-0.24 in) drop of sealant to the

FRONT OF ENGINE
intersection of the cylinder block and cylinder head as-
sembly at four corners, as shown.
0
CYLINDER M m m
4 2 HEAD
. : ? , in)
CYLINDER BLOCK
I CYLINDER HEAD GASKET I

ASSEMBLY
5. Position the lower intake manifold gaskets onto the cylin-
FRONT OF ENGINE der heads. Align the lower intake manifold gasket locking
Q tabs to the provisions on the cylinder head gaskets, as
shown.
6. Install the front and rear lower intake manifold seals as

shown. Secure with retaining features.
FRONT OF
ENGINE
7. Place the lower intake manifold into position, aligning the

manifold bolt holes to those in the cylinder head. Use care
to prevent disturbing the rubber sealer which can cause
sealing voids. Install bolts 1,2,3, anti 4 and hand tighten.
Install the remaining bolts and tighten in sequence using
a two-step process. Tighten in numerical sequence.
Tightening torques:
Step 1: 15 N.m (1.5 kgf-m, 11 ft-lbf)
Step 2: 26---32 N.m (2.6-3.2 kgf-rn,19-24 ftelbf)

9.Connect the upper radiator hose to the thermostat
housing.
10. Connect the following harness connectors:
LOWER (1) Water temperature indicator sen'der
INTAKE (2) Engine coolant temperature sensor
11. lnstall the required vacuum lines.
END RAIL GAP
AS INSTALLED
ASSEMBLY, INSTALLATION
1.Apply a bead of sealant to the cylinder head-to-intake
manifold joints (one at the front edge of the cylinder head
and one at the rear edge of the cylinder head), as shown.
2. lnstall the cylinder head covers.
Tightening torque:
10-1 4 N.m (1-0-1.4 kgf-m,7-1 0 ft.1bf)
Note
Intersection of head and intake manifold must be
flush to within f 1 mm (0.04 in). Gasket must not
MB1165-A 5BUOB2-061
protrude above highest surface.
lnstall the dipstick tube and bracket.
Tightening torque:
18 N.m (1-8 kgfem, 13 ftdbf)
EGR valve
1. Position the EGR valve to exhaust manifold tube on the
EGR valve.
2. Start the first few threads of the flare nut.
3. lnstall the bolt at the exhaust manifold end.
Tightening torque:
20-30 N-m(2.0-3.0 kg.m, 15-22 ft-lb)
4. Tighten flare nut.
Tightening torque:
35-65 N.m ( 3 . 5 4 . 5 kg-m, 2 6 - 4 7 ft.ft)
5BUOB2-080
INSTALLATION
PROCEDURE
1. Lower the engine carefully into the engine compartment, referring to lnstallation Note. (Refer to page
B2-67.)
2. Raise the vehicle and secure it with safety stands.
3. lnstall the starter motor. (Refer to Section G.)
4. Connect the front pipe assembly to the exhaust manifolds.
6. lnstall ground cables to cylinder block.
7. lnstall camshaft position sensor. (Refer to Section F2.)
8. Connect the wiring and harness connectors and vacuum hoses (power brake unit and rear vacuum
fittings) referring to Installation Note. (Refer to page B2-68.)
9. lnstall accelerator cable. lnstall speed control actuator, if equipped. lnstall accelerator control splash
shield.
10. Connect two fuel tank lines at the chassis.
11. Connect the heater hoses to the water pump.
12. lnstall A/C compressor mounting bracket with assembled A/C compressor and power steering pump.
(Refer to page B2-67)
13. Position A/C hose and manifold assembly in engine compartment with hoses vented as originally with no
kinks.
INSTALLATION
14. lnstall air conditioner compressor, if equipped, referring to lnstallation Note. (Refer to page B2-68.)
15. lnstall the generator and bracket.
16. lnstall water pump pulley and four screws. Tighten to 21.2-28.8 N-m (2.1-2.8 kgm, 16-21 ftalb)
17. Connect the generator ground wire to the cylinder block.
18. Position the fan shroud over the fan. lnstall the radiator and connect the upper and lower hoses.
19. lnstall the power steering oil purnp, if equipped, referring to lnstallation Note. (Refer to page B2-68.)
20. lnstall the fan shroud bolts, referring to lnstallation Note. (Refer to page B2-68.)
21. lnstall the drive belt.
22. lnstall the air intake hose.
23. lnstall the air cleaner assembly.
24. lnstall the hood.
lnstallation Note
Engine
1 . Make sure the exhaust manifolds are properly aligned
with the pipes.
2. On vehicles with manual transmissions, start the primary
shaft into the clutch disc. It may be necessary to adjust the
position of the transmission in relation to the engine if the
primary shaft will not enter the clutch disc. If the engine
hangs up after the shaft enters, turn the crankshaft slowly
(with the transmission in gear) until the shaft splines mesh
with the clutch disc splines.
3. lnstall the engine front support and ruts and washers, or
through bolts, attaching it to the crossmember.
4. On vehicles with an automatic transmission, start the
converter pilot into the crankshaft.
Note
Make sure the torque converter rotates freely and is
not bound up.
5. Check dimension "A" in the figure.
Minimum distance:10.23mm (0.401in}

Maximum distance: 14.43mm (0.57 in}
6. lnstall the clutch housing or converter housing upper

bolts, making sure that the dowels in the cylinder block
engage the flywheel housing.
7. lnstall the hydraulic clutch pipe.
8. Remove the jack from under the tra~ismission.
9. Remove the engine lift from the engine.
Air conditioning bracket

lnstall the air conditioning bracket lower bolts and tighten
them to the specified torque.
Tightening torque:
40.3-54.7 N-m (4.0-5.4 kgf-m, 3 0 4 0 ft-lbf)
5BUOB2-064
INSTALLATION
Harness connectors and wires
Connect the following harness connectors and wires:
(1) Heated oxygen sensors
(4) Injector harness
(5) Oil pressure and engine coolant temperature sensors
(6) Three body wiring connectors on top of the right
cylinder head cover
(7) Wires to the ignition coil
5BUOB2-065
Air conditioner compressor

Install the air conditioner compressor.
Tightening torque:
41-61 N-m (4.1-4.0 kgf-m, 3 0 - 4 4 ftalbf)
4BUOB2-157
Power steering oil pump

Install the power steering oil pump.
Tightening torque:
4 0 - 4 2 N.m (4.0-6.2 kgf-m, 29--45 ft-lbf)
4BUOB2-158
Fan shroud
Install the fan shroud.
Tightening torque:
5.5-4 N.m (56-41 kgf-cm, 48-70 in-lbf)
4BUOB2-159

1. Fill the radiator with the specified amount and type of engine coolant. (Refer to Section E2.)
2. Fill the engine with the specified amount and type of engine oil. (Refer to Section D2.)
3. If the transmission was drained, fill it with the specified amount and type of transmission fluid. (MT: Refer
to Section J1; AT: Refer to Section K.)
5. Charge the air conditioning system, if required.
6. Start the engine and check the following:
(1) Engine oil, transmission and engine coolant leakage
(2) Drive belt for proper alignment and tension
(3) Ignition timing and idle speed
(4) Operation of emission control system
7. Perform a road test.
ENGINE
(4.0L)
INDEX ................................................. AUXILIARY PARTS ......................... 83-30

OUTLINE ............................................ CYLINDER BLOCK
SPECIFICATIONS ........................... (EXTERNAL PARTS) ..................... B3-32
TROUBLESHOOTING GUIDE ............ TIMING CHAIN ................................ B3-34
ENGINE TUNE-UP PROCEDURIE ..... CYLINDER HEAD ............................ B3-35
PREPARATION ............................... CYLINDER BLOCK
ENGINE OIL ..................................... (INTERNAL PARTS) ...................... B3-37
ENGINE COOLANT ......................... INSPECTION / REPAIR ...................... B3-40
DRIVE BELT .................................... CYLINDER HEAD ............................ B3-40
IGNITION TIMING. IDLE SPEEiD .... VALVE MECHANISM....................... 83-41
COMPRESSION ................................. CAMSHAFT ..................................... 83-43
.- INSPECTION .................................
ON-VEHICLE MAINTENANCE ..........
TAPPETS .........................................
CYLINDER BLOCK ..........................
83-44
B3-44
CYLINDER HEAD GASKET ............ PISTON. PISTON RING AND
TAPPETS ......................................... PISTON PIN ................................... 83-45
CYLINDER HEAD COVER CONNECTING ROD ........................ B3-47
GASKET ......................................... CRANKSHAFT ................................. 83-47
ROCKER ARM ASSEMBLY ............ BEARING ......................................... B3-48
TIMING CHAIN COVER ..................... TIMING CHAIN ................................ 83-48
PREPARATION ............................... PULLEY ........................................... 83-48
REMOVAL I INSTALLATION ........... FLYWHEEL ...................................... 83-48
TIMING CHAIN ................................... ASSEMBLY ........................................ B3-49
REMOVAL I INSPECTION I PREPARATION ............................... 83-49
INSTALLATION.............................. CYLINDER BLOCK
FRONT OIL SEAL .............................. (INTERNAL PARTS) ...................... 83-50
PREPARATION ............................... CYLINDER HEAD ............................ B3-55
REPLACEMENT .............................. TIMING CHAIN ................................ B3-58
REAR OIL SEAL ................................ CYLINDER BLOCK
PREPARATION ............................... (EXTERNAL PARTS) ..................... B3-59
REPLACEMENT .............................. AUXILIARY PARTS ......................... 83-61
REMOVAL .......................................... INSTALLATION .................................. B3-64
PROCEDURE .................................. PROCEDURE .................................. 83-64
DISASSEMBLY .................................. 5811083-032
PREPARATION .............................
B3 INDEX
INDEX
COMPRESSION PRESSURE
INSPECTION: PAGE 83-8
INDEX
1 . Timing chain 6. Rocker arm assembly
Removal 1 Inspection 1 Removal / Installation ............ page B3-19
Installation ............................. page B3-24 7 . Engine
2. Cylinder head gasket Removal ................................ page B3-27
Replacement ......................... page 83-10 Disassembly .......................... page 63-29
3 . Rear oil seal Inspection / Repair ................ page B3-40
Replacement ......................... page B3-26 Assembly ............................... page B3-49
4 . Front oil seal Installation ............................. page B3-64
Replacement ......................... page B3-25
5. Cylinder head cover gasket
Removal ................................ page B3-14
Installation ............................. page B3-16
OUTLINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
- Item Engine 4.0L
-- -
Type -p---ppp
Gasoline,
-
4-cycle
-
Cyl~nderarrangement and number 60"-V configurat~on,6 cylrnders
Valve system OHV. chain driven. 12 valve
t Displacement
-
Bore and stroke
Compression ratio
-
cm3, {CU in)
mm {in)
4,000 (244)
100 x 84 13.94 x 3.311
Compression pressure Lowest cylinder reading within

75 Dercent of hiahest cvlinder readina '
Valve clearance IN mm {in} 0: Maintenance free
I
EX mm {in} 0: Maintenance free
Idle speed rPm {not adjustable)
Ignition timing (Initial timing) BTDC 8-12" { I 0 k 2"] {not adjustable]
I - order
Firina I
14-2-5-3-6 - .
I
'' Refer to Section TD.
MB1102-F 5BUOB3-002
Note
4811083-004
Burnt valve Replace
Worn piston, piston rings, or cylinder Replace or repair
Damaged cylinder head gasket - -
Replace --

Malfunction of ignition system Refer to Section G I -
Poor valve-to-valve seat contact Replace or repair
Damaged tappet Re~lace
Malfunction of ignition system Refer to Section G -
consumption Worn piston ring groove or sticking piston ring Replace B3-46
Worn piston or cylinder Replace or repair 63-44, 45
Oil working down
Worn valve seal Replace 63-41
Worn valve stem or guide Replace 63-41
Oil leakage Refer to Sectlon 0 3 -
Pluged PCV system Refer to Section FT -
6BUOB3-OC
Problem P ssible Cause Action

--A -- - - - -
Insufficient power
o
Compression leakage from valve seat Repalr
Se~zedvalve stem Replace
Weak or broken valve sprlng Replace
Damaged cyllnder head gasket Replace
Cracked or d~stortedcyllnder head Replace
Stlcklng, damaged, or worn plston ring Replace
Cracked or worn plston Replace
--- ---- -- --
- -
Refer
--
to Sectlon FT
-- p---p -- -
Malfunction of ignition system Refer to Sect~onG
I
--
Others
Slipping clutcti Refer to Section H -
Dragging brakes Refer to Section P -
Wrong size tires Refer to - Q
Section - -
- -- -------p -- - -
~bnormal Malfunction of engine-related components
combustion Sticking or burnt valve Replace B3-41
Weak or broken valve spring Replace B3-43
Carbon accuniulation in combustion chamber I Eliminate carbon -
Damaged push rod(s) B3-19
Damaged tappet Replace 83-35
Malfunction of fuel system Refer to Section FT -
Malfunction of ignition system , Refer to Section G -

-- - -... --
Engine noise Crankshaft- or bearing-related parts ,

Excessive ma.in bearing oil clearance Replace or repair 83-51
Main bearing seized or heat-damaged 1 Replace 83-48
Excessive cra.nkshaft end play 1 Replace or repair 83-52
Excessive connecting rod bearing oil clearance Replace or repair B3-53
Connecting rod bearing-seized or 83-48
L __.
' Piston-related parts
Worn cylinder Replace or repair B3-44
I Worn piston or piston pin Replace 83-45,46
Seized piston Replace 83-45
83-46
-
B3-47
-
Broken valve spring Replace 83-43

Excessive valve guide clearance Replace 83-41
Damaged push rod(s) Replace 83-19
Damaged tappet Replace B3-35
- -
Refer to Section E3
Others
Malfunction o.f water pump bearing
Worn drive belt
Malfunction of generator bearing
Exhaust gas leakage
Malfunction of timing chain tensioner
Refer to Section E3
Replace
Refer to Section G
Refer to Section FT
Replace l-l 83-24
60~0~3-009
ENGINE OIL
Inspection
1. Position the vehicle on level ground.
stop it.
condition.
5. Add or replace oil as necessary.
Note
The oil level should be filled to the top of the dashed
4~~0~3-008 part of the oil dipstick.
ENGINE COOLANT
lnspection
Coolant level (engine cold)
Warning
hot.
it.
1. Verify the coolant level is at the filler neck.

2. Verify that the coolant in the coolant reservoir is at the
COLD FILL mark.
3. Add coolant if necessary.
Coolant quality
radiator cap and filler neck.
2. Verify that the coolant is free of oil.
3. Replace the coolant if necessary.
ENGINE TUNE-UP PROCEDURE B3
DRIVE BELT
Inspection
1. Check the drive belt for wear, cracks and fraying. Replace
V RIBBED BELT
if necessary.
2. Verify the drive belt is correctly mounted on the pulleys.
Adjustment
A/C COMPRESSOR PULLEY
GENERATOR
n A No adjustment is necessary. The 4.OL engine is
equipped with an automatic tensioner that indicates
when the drive belt is worn (stretched). A pointer
and gauge are built into the tensioner. When the
pointer no longer registers within the range limits of
the gauge, the belt must be replaced.
GENERATOR
n
IDLER
PIS OIL PIJMP
1
PULLEY
PULLEY
PULLEY
BELT
REPLACEMENT

Initial Timing
Note
Initial timing is preset and is not adjustable.
Initial timing can be checked. (Refer to Section G.)
Ignition timing: 8-12" (10k2")BTDC (Refer to Section G.)

ldle speed
Note
ldle speed is preset and is not adjustable.
ldle speed can be checked.
COMPRESSION B3
COMPRESSION
If the engine exhibits low power, poor fuel economy or
poor idle, check the following:
1. Ignition systern (Refer to Section G.)
2. Compression
3. Fuel system (Refer to Section FT.)
INSPECTION
1. Verify that the battery is fully charged. Recharge it if
necessary.
3.Remove the spark plugs.

4. Disconnect the connector from the ignition coil pack.
5. Insert a compression gauge into the FJo.1 spark plug hole.
Compression:
Lowest reading cylinder is within 75 percent of
the highest. (Refer to Section TD.)
9. If the compression in one or more cylinders is low, pour a

small amount of clean engine oil into the cylinder and
recheck the compression.
(1) If the compression increases, the piston, piston rings
(2) If the compression stays low, a valve may be stuck or
improperly seating.
(3) If the compression in adjacent cylinders stays low, the
head distorted.
10. Connect the ignition coil pack connector.
5EiUOB3-005
Tightening torque:
14-20 N-m (1.4-1.9 kgf.m, 10--14 ft-lbf)
Note
their original locations.
Replacement
Warning
Keep sparks and open flame away from the fuel area.

2. Drain the coolant.
3. Remove the upper intake manifold. (Refer to Section F3.)
4. Remove the lower intake manifold. (Refer to Section F3.)
5. Remove the cylinder head cover gasket. (Refer to page B3-14.)
7. If removing the left cylinder head, perform the following:
(1) Remove the AIC compressor, if equipped.
(2) Remove the power steering oil pump and bracket.
8. If removing the right cylinder head, perform the following:
(1) Remove the generator and bracket.
(2) Remove the ignition coil pack and bracket.
10. Remove the exhaust manifold(s) and front pipe assembly. (Refer to Section F3.)
11. Remove the rocker arm and shaft assembly, referring to Removal Note. (Refer to page 83-1 1.)
12. Remove in the order shown in the figure.
BOLT.
REPLACE
0--J
STEP 1: 30-45 (3.0--3.5. 22-26
GASKET,
REPLACE
MB1053-E
1. Bolt 2. Cylinder head
Installation Note .............................. below 3. Gasket
C)N-VEHICLE MAINTENANCE 83
Removal Note
Rocker arm and shaft assembly
Caution
Loosen the bolts gradually to prevent bending the
rocker arm shaft.
2. Remove the rocker arm and shaft assemblies.

Note
Mark the position of each push rod for installation.
Installation Note
Bolt
1. Tighten the new cylinder head bolts in the order shown in
the figure.
Tightening torque:
30-35 N-rn(3.0-3.5 kgfam, 22--26 ft-lbf)
2. Apply sealant to the cylinder head rnating surfaces as

shown in the figure.
Note
The lower intake manifold must be installed within
fifteen minutes of applying sealant.
3. Install the lower intake manifold.

4. Install the lower intake manifold nuts and bolts.
I I
MB1355-A
5.Tighten the lower intake manifold bolts and nuts in the
order shown in the figure.
Tightening torque:
4-43 N-m((9.41-0.82 kgf-m, 3-6 ftlbf)
6. Tighten the new cylinder head bolts in the order shown in
the figure.
Tightening torque:
70-75 N-m(7.0-7.5 kgf-m, 52-56 ft-lbf)
7.Tighten the lower intake manifold bolts and nuts in the

order shown in the figure.
Tightening torque:
8-15 N.m (0.82-1.5 kgf.m, 6-1 1 ft-lbf)
8. Tighten the new cylinder head bolts an additional 90" in

the order shown in the figure.
9. Tighten the lower intake manifold bolts and nuts.
Tightening torque:
15-22 N . m (1.5-2.2 kgfsm, 11-16 ftalbf)
6BUOB3-001
Rocker arm and shaft assembly
I . Install the push rods.
2. Install the rocker arm and shaft assemblies.
3. Tighten the rocker arm shaft bolts.
Tightening torque:
32 N.m (3.3kgf.m, 24 ft.lbf) + 90 degrees
Caution
The bolts should be tightened gradually, two turns
at a time.
Note
Lubricate the rocker arm and shaft assemblies with
clean engine oil.
Spark plugs
Tightening torque:
14--20 N.m (1.4-1.9 kgf.m, 10--14 ft.lbf}
Note
If installing the original spark plugs, install them
into their original locations.
Note
This engine has either spark plugs with platinum
grounds or platinum electrodes.
5BUOB3-008
TAPPETS
Removal I Inspection I Installation
Warning
Keep sparks and open flame away from the fuel area.

2. Remove the cylinder head gaskets. (Refer to page B3-10.)
3. Remove the tappets, referring to Removal Note. (Refer to below.)
Removal Note
Tappets
Note
Note the position which they were removed, for
installation.
Inspection
Inspect the tappet friction surfaces for wear and damage.
Replace the tappet if necessary.
4BUOB3-022
Installation Note
Tappets
1. Coat the friction surfaces of the tappet with clean engine
oil prior to installing into the bore.
2. Install the tappets with the alignment tab in the groove
of the bore.
Note
The tappets should be install d in th bor they
were removed from.
CYLINDER HEAD COVER GASKET
Removal
2. Remove the accelerator cable shield, referring to Removal Note. (Refer to page 63-15.)
3. Remove the air intake hose, referring to Removal Note. (Refer to page 83-15.)
4. Remove the air conditioning pipe bolt from the upper intake manifold, if equipped.
5. Remove the high tension leads from the cylinder head covers.
6. If removing the right cylinder head cover, perform the following:
(1) Remove the generator. (Refer to Section G.)
(2) Remove the ignition coil pack. (Refer to Section G.)
(3) Remove two wiring harnesses from right cylinder head cover.
(4) Disconnect the filler neck vacuum hose, referring to Removal Note. (Refer to page 63-15.)
(5) Unfasten the right wiring harness from clip, referring to Removal Note. (Refer to page 63-15.)
(6) Remove the right cylinder head cover bolts, reinforcement plates.
7. If removing the left cylinder head cover, perform the following:
(1) Remove the upper intake manifold. (Refer to Section F3.)
(2) Disconnect the A/C compressor clutch connector, if equipped.
(3) Remove the A/C compressor bolts, if equipped. Position the A/C compressor aside.
(4) Remove the power brake vacuum hose.
(5) Disconnect and tag the hoses connected to the vacuum tee, referring to Removal Note. (Refer ct
page B3-16.)
(6) Disconnect and remove the PCV valve.
(7) Unfasten the left wiring harness from clip, referring to Removal Note. (Refer to page 63-16.)
(8) Remove the fuel hose clip bolt and position the fuel hoses to gain access to left cylinder heac
upper bolts.
(9) Remove the left cylinder head cover bolts, reinforcement plates.
I
ME1243-A 5BUOB3-0
1. Cylinder head cover
2. Gasket
Removal Note
Accelerator cable shield
Remove the accelerator cable shield bolts and shield.
I
MB1356-A 513UOB3-009
Air intake hose
1. Loosen the clamps.
2. Remove the breather hose.
3. Remove the air intake hose.
Filler neck vacuum hose

Pull the coupling to remove the filler neck vacuum hose.
I
MB1059-B 4BUOB3-027
Right wire harness
Pull up on the clips and remove the wire harness.
Vacuum hoses
Disconnect the vacuum hoses from vacuum tee "A."
MBlO61-A 4BUOB3-029
Left wire harness
Pull up on the clip and remove the wire harness.
lnstallation
1. If installing the left cylinder head cover, perform the following:
(1) lnstall a new cylinder head cover gasket, referring to lnstallation Note. (Refer to page B3-17.)
(2) lnstall the cylinder head cover, reinforcement plates and left cylinder head cover bolts, referring to
lnstallation Note. (Refer to page B3-17.)
(3) Position the fuel hoses correctly and install the fuel hose clip bolt.
(4) Fasten the left wiring harness to the clip, referring to lnstallation Note. (Refer to page B3-17.)
( 5 ) lnstall and connect the PCV valve.
(6) Connect the hoses to the vacuum tee, referring to lnstallation Note. (Refer to page B3-18.)
(7) lnstall the power brake vacuum hose.
(8) lnstall the A/C compressor, if equipped, referring to lnstallation Note. (Refer to page B3-18.)
(9) Connect the A/C compressor clutch connector, if equipped.
(10) lnstall the upper intake manifold. (Refer to Section F3.)
2. If installing the right cylinder head cover, perform the following:
(1) lnstall a new cylinder head cover gasket, referring to lnstallation Note. (Refer to below.)
(2) lnstall the cylinder head co~ver,reinforcement plates and cylinder head covler bolts, referring to
lnstallation Note. (Refer to below.)
(3) Fasten the right wiring harness to the clip, referring to lnstallation Note. (Refer to page B3-18.)
(4) Connect the filler neck vacuum hose, referring to lnstallation Note. (Refer to page B3-18.)
(5) lnstall two wiring harnesses onto the right cylinder head cover.
(6) lnstall the ignition coil pack. (Refer to Section G.)
(7) lnstall the generator. (Refer to Section G.)
3. Install the high tension leads onto the cylinder head covers.
4. lnstall the air conditioning pipe bolt onto the upper intake manifold, if equipped.
5. lnstall the air intake hose, referring to lnstallation Note. (Refer to page B3-19.)
6. lnstall the accelerator cable shield, referring to lnstallation Note. (Refer to page B3-19.)
lnstallation Note
LOWER Cylinder head cover, reinforcement plates and
CYLINDER INTAKE CYLINDER
MANIFOLD cylinder head cover gasket
Apply sealant to the seam between the lower intake
manifold and cylinder head and an 8mm (0.125 in) ball
to each bolt hole on the exhaust ~nanifoldside of the
cylinder head cover as shown.
Cylinder head cover bolts
CYLINDER
BLOCK
Tightening torque:
6--8 N.m (0.62-0.81 kgf-m, 4.5;-5.9 ftslbf)
4BUOB3-033
Left wire harness

lnstall the wire harness and push down on the clip.
Vacuum hoses
Connect the vacuum hoses to vacuum tee "A".
4BUOB3-035
A/C compressor
Install the AIC compressor to the bracket.
Tightening torque:
24-30 N.m (2.5--3.1 kgfam, 18-23 ftelbf)
4BUOB3-036
Right wire harness

Install the wire harness and push down on the clip.
Filler neck vacuum hose

Press the coupling to the filler neck to install the filler neck
vacuum hose.
Air intake hose
I . lnstall the air intake hose.
2. lnstall the breather hose.
3. Tighten the clamps.
I
MB1058-A 4BUOB3-039
Install the accelerator cable shield and bolts.
ROCKER ARM ASSEMBLY

Removal l lnstallation
1. Remove the cylinder head cover gaskets. (Refer to page U3-14.)
3. lnstall in the reverse order of removal, referring to lnstallation Note.
N.m {kgfm, ft.lbf)
MB1065-C 5BUOB3-015
1. Rocker arm shaft bolts 3. Push rods
Removal Note ...................... page B3-20 Removal Note ....................... page B3-20
Installation Note .................... page B3-20 Installation Note .................... page B3-20
2. Rocker arm shaft assembly
ON-VEHICLE MAINTENANCE, TIMING CHAIN COVER
Removal Note
Rocker arm shaft bolts
Caution
rocker arm shaft.
4EUOB3-042
Push rods
Note
40~0~3-043
Installation Note
Push rods
Note
Install the push rods in the position which they
were removed from.
4811083-044
Rocker arm shaft bolts

Caution
The bolts should be tightened gradually; two turns
at a time.
Tightening torque:
32 N.m (3.3 kgf.m, 24 ft.lbf) + 90 degrees
Note
Apply clean engine oil to the rocker arm and shaft
assemblies.
5BUOB3-016
TIMING CHAIN COVER

PREPARATION
SST

removing removal /
Crankshaft crankshaft Fan clutch installation
damper pulley holding tool of fan
remover

installing removal /
Crankshaft crankshaft Fan clutch installation
damper pulley nut wrench of fan
replacer
TIMING CHAIN COVER
REMOVAL / INSTALLATION
1. Remove the engine assembly. (Refer to page B3-27.)
2. Remove the oil pan. (Refer to Section D3.)
3. Remove the fan assembly, referring to Removal Note. (Refer to below.)
4. Remove the water pump. (Refer to Section E3.)
5. Remove the crankshaft pulley, referring to Removal Note. (Refer to below.)
6. Remove the crankshaft position sensor, referring to Removal Note. (Refer to below.)
7. Remove the timing chain cover, referring to Removal Note. (Refer to page 83-22.}
Removal Note
Fan assembly
1. Hold the water pump pulley with the SST. Loosen the
clutch assembly with the SST.
Note
The clutch assembly has left-hand threads and
must be rotated clockwise for loosening.
2. Remove the fan and clutch assembly.
Crankshaft pulley
Remove the crankshaft pulley using the SST.
Note
SST number: 49 UNOI 001 Crankshaft Damper
Remover
4BUOB3-049
I ICrankshaft position sensor

1. ~isconnedtthe crankshaft position sensor connector.
2. Remove the screws and the crankshaft position sensor.
TIMING CHAIN COVER
Timing chain cover
1. Remove the timing chain cover bolts and studs.
2.Tap lightly with a plastic hammer to remove the timing
chain cover.
Installation Note
Timing chain cover
1. Apply a bead of sealant to the timing chain cover.
2. Install the timing chain cover.
3. Tighten the timing chain cover bolts and studs as shown.
Tightening torque:
17-21 N-m (1 -8-2.0 kgfem, 13-1 5 ftdbf)
Bolt length:
Bolt A: M8 x 47
I I
Bolt B: M8 x 25
MBIO~~-A 48~083-052 Stud C: M8 x 25
I 1
Crankshaft position sensor
1. Install the crankshaft position sensor
2.Tighten the bolts.
Tightening torque:
9-12 N-m (0.9-1.2 kgf-m, 6.6-4.8 ft.lbf)
3. Connect the crankshaft position sensor connector
I 1
MB1068-A 4BUOB3-053
Crankshaft pulley
Install the crankshaft pulley using the SST
Note
SST number: 49 UNO1 002 Crankshaft Damper
Replacer
4BUOB3-054
TIMING CHAIN COVER
Fan assembly
1. Install the fan and clutch assembly.
2. Hold the water pump pulley with the SST. Tighten the
Tightening torque:
40-1 35 N.m (4.1-1 3.8 kgf-m, 30-1 00 ft.lbf)
Note
must be rotated counterclockwise for tightening.
TIMING CHAIN
TIMING CHAIN
REMOVAL I INSPECTION I INSTALLATION
2. Remove the timing chain cover. (Refer to page B3-20.)
3. Retract the timing chain auto tensioner and secure it with a retaining clip, referring to Removal Note.
(Refer to page 83-25.)
4. Remove the timing chain pulley key.
5. Remove in the order shown, referring to Removal Note.
1. Camshaft pulley 3. Timing chain pulley

Removal Note ....................... page 63-25 Removal Note ....................... page B3-25
Inspection .............................. page 83-48 Inspection .............................. page B3-48
Installation Note .................... page B3-25 Installation Note .................... page 83-25
2. Timing chain
Removal Note ....................... page B3-25
Inspection .............................. page 83-48
Installation Note .................... page 63-25
TIMING CHAIN, FRONT OIL SEAL
Retaining clip
Push the timing chain auto tensioner away from the chain
and insert a retaining clip.
Camshaft pulley, timing chain and timing chain pulley
Remove the camshaft pulley, timing chain and timing
chain pulley as an assembly.
4811083-059
Inspection
Inspect the following and repair or replace as necessary:
(1) Timing chain (Refer to page B3-48.)
(2) Timing chain pulley (Refer to page B3-48.)
(3) Camshaft pulley (Refer to page E33-48.)
5BUOB3-041
lnstallation Note
Camshaft pulley, timing chain and timing chain pulley
1. Turn the camshaft pulley and timing chain pulley to align
the timing marks.
2. Install the camshaft pulley, timing chain and timing chain
pulley as an assembly.
Note
The tensianer side of the timing chain is held
inward, and the guide side shoi~ldbe tight.
3. Install the camshaft pulley bolt.
Tightening torque:
60-68 N-m (6.1-6.9 kgfem, 44--50 ftelbf]
4. Remove the clip.

5. Check the camshaft end play. (Refer to page B3-44.)
FRONT OIL SEAL

PREPARATION
SST
49 UN01
UNOl 004 I For
installing
49 UNO1 002 For
installing
Front seals Crankshaft crankshaft
cover damper pulley
aligner replacer :3
3
I I
REPLACEMENT
2. Remove the timing chain cover. (Refer to page B3-20.)
3. Remove the front oil seal by using a screwdriver protected with a rag.
FRONT OIL SEAL, REAR OIL SEAL
Installation Note
Front oil seal
1. Coat the new front oil seal with clean engine oil.
2. Install the new front oil seal using the SST.
3. Install the crankshaft pulley using the SST.
Note
Replacer
1 4.Tighten the bolt.

I J
MB1242-A 4811083-064 Tightening torque:
40-50 N-m(4.1-5.1 kgfsm, 30-37 ft-lbf) + 80-90"
5. Start the vehicle and check for oil leaks.
REAR OIL SEAL

PREPARATION
SST
49 UNOI 136 For

installation of
crankshaft
Rear main seal rear oil seal
oil seal pilot &
-
seal replacer
k4
5811083-017
REPLACEMENT
2. Remove the engine assembly. (Refer to page 83-27.)
3. Cut the rear oil seal lip with a razor knife.
4. Remove the rear oil seal by using a screwdriver protected with a rag.
5. lnstall in the reverse order of removal, referring to Installation Note.
5811083-043
lnstallation Note
1. Apply a small amount of clean engine oil to the lip of the
new oil seal.
2. Push the oil seal slightly in by hand.
3. Install the oil seal using two flywheel bolts and the SST.
4. Measure from the rear face of cylinder block to the oil seal.
Specification:
10.7-1 0.9mm (0.421-4.425 in}
REMOVAL
REMOVAL
PROCEDURE
Warning
Release fuel pressure. (Refer to Section F3.)

3. Remove the air intake hose, referring to Removal Note. (Refer to page 83-28.)
4. Disconnect the radiator hoses.
5. Remove the radiator and shroud cover. (Refer to Section E3.)
6. Remove the generator. (Refer to Section G.)
7. Remove the A/C compressor if equipped, referring to Removal Note. (Refer to page 83-28.)
8. Remove the power steering oil pump, referring to Removal Note. (Refer to page 83-28.)
10. Disconnect the ground wires.
11. Disconnect the fuel hoses, referring to Removal Note. (Refer to page B3-28.)
12. Remove the accelerator cable shield, referring to Removal Note. (Refer to page B3-28.)
13. Disconnect the accelerator cable and kickdown control shaft rod.
14. Remove the throttle cable bracltet.
15. Disconnect and tag the vacuurrl hoses connected to the vacuum tee, referring to Removal Note.
(1) Ignition coil pack
(2) Oil pressure sensor
(4) Injectors
(7) Water temperature indicator' sender
17. Remove the power brake unit hose.
18. Raise the vehicle on a vehicle hoist.
19. Remove the front pipe assembly from the exhaust manifold. (Refer to Section F3.)
21. Remove the engine mount nuts, referring to Removal Note. (Refer to page 83-29.)
22. Remove the torque converter nuts, referring to Removal Note. (AT only) (Refer to page 83-29.)
23. Remove the bell housing to cylinder block bolts.
25. Remove the battery cable bracltet bolt and wire harness-to-engine clip.
26. Remove the transmission line bracket-to-engine bolts. (AT only)
27. Install engine lifting brackets on the exhaust manifold.
28. Attach Engine Lifting Sling 014-00036, or equivalent to the engirie lifting brackets.
29. Support the transmission with a jack.
30. Lift the engine out of the vehicle.
31. Mount theengine to a stand.
6BUOB3-004
REMOVAL
Removal Note
Air intake hose
1. Loosen the clamps.
2. Remove the breather hose.
3. Remove the air intake hose.
A/C compressor
1. Remove the AIC compressor bolts.
2. Remove the A/C compressor with the hoses still attached.
3. Position the A/C compressor away from the engine and
secure it with wire.
4BUOB3-069

1. Remove the power steering oil pump bolts.
2. Remove the power steering oil pump with the hoses still
attached.
3. Position the power steering oil pump away from the
engine and secure it with wire.
4BUOB3-070
Fuel hoses
Disconnect the fuel hoses.
Warning
Keep sparks and open flame away from the fuel
area.
Caution
Cover the hose with a rag because fuel will spray
out when disconnecting.
Plug the disconnected hoses to avoid fuel leakage.
4BUOB3-071

Remove the accelerator cable shield and bolts.
REMOVAL, DISASSEMBLY
Vacuum hoses
Disconnect the vacuum hoses from vacuum tee "A".
I I
MBlO61-A 41311083-073
Engine mount nuts
Remove the engine mount nuts.
413UOB3-074
Torque converter nuts (AT only)
Access the torque converter nuts through the starter
mounting opening.
4BUOB3-075
DISASSEMBLY
PREPARATION
SST
For 49 UNOI 001

removal 1 removal
Fan clutch installation Crankshaft of crankshaft
holding tool of fan damper pulley
remover
b
49 UNOI 008 For

removal1
Fan clutch installation
nut wrench of fan
DISASSEMBLY
1. Code or arrange all identical parts (such as pistons, piston rings, connecting rods, push rods and valve
springs) so that they can be reinstalled in the position from which they were removed.
2. Clean the parts by using a steam cleaner. Blow dry with compressed air.
Note
During disassembly of any part of the system, be sure to study its order of assembly. Also, note
any deformation, wear or damage and repair or replace as necessary.
AUXILIARY PARTS
2. Remove the exhaust manifolds.
3. Remove the ignition coil pack, referring to Disassembly Note. (Refer to below.)
4. Remove the upper intake manifold, referring to Disassembly Note. (Refer to below.)
5. Remove the fuel supply manifold, referring to Disassembly Note. (Refer to page B3-31.)
6. Remove the lower intake manifold, referring to Disassembly Note. (Refer to page B3-31.)
7. Remove the fan assembly, referring to Disassembly Note. (Refer to page B3-31.)
8. Remove the oil filter and oil filter adapter, referring to Disassembly Note. (Refer to page B3-32.)
9. Remove the oil dipstick and tube.
10. Remove the oil pump drive assembly, referring to Disassembly Note. (Refer to page B3-32.)
5BUOB3-044
Disassembly Note
Ignition coil pack
Remove the bracket bolts and the ignition coil pack.
Upper intake manifold

1. Remove the upper intake manifold nuts.
2. Remove the upper intake manifold and gasket.
DISASSEMBLY

1. Remove the lower intake manifold nuts and bolts.
2. Remove the lower intake manifold and gasket.
Fan assembly
1. Hold the water pump pulley with tlie SST. Loosen the
Note
must be rotated clockwise for Yoosening.
DISASSEMBLY
Oil filter and oil filter adapter
1 . Unscrew the 011 filter.
2. Remove the through bolt and O-ring.
3. Remove the oil filter adapter and O-ring.
ME1075 A 4BUOB3 085

Oil pump drive assembly
1. Remove the bolt and clamp.
2. Remove the oil pump drive assembly and O-ring.

1. Remove the oil pan, referring to Disassembly Note. (Refer to below.)
2. Remove the oil pump, referring to Disassembly Note. (Refer to below.)
3. Remove the baffle, referring to Disassembly Note. (Refer to page B3-33.)
4. Remove the water pump, referring to Disassembly Note. (Refer to page B3-33.)
5. Remove the crankshaft position sensor, referring to Disassembly Note. (Refer to page B3-33.)
6. Remove the crankshaft pulley, referring to Removal Note. (Refer to page B3-33.)
7. Remove the timing chain cover, referring to Disassembly Note. (Refer to page 63-33.)
58UOB3-045
Disassembly Note
Oil pan
1. Remove the nuts and bolts.
2. Remove the oil pan and gasket.
Oil pump
1 . Remove the screws.
2. Remove the oil pump and gasket.
DISASSEMBLY
9 1 Baffle
1. Remove the nuts.
. ,
MD1013-A 413UOB3-090
Water pump
1. ~ e m o v ethe water pump pulley
2. Remove the water pump bolts.

1. Remove the screws.
2. Remove the crankshaft position sensor.
Crankshaft pulley
Remove the crankshaft pulley using the SST.
Note
SST Number: 49 UNO1 001 Crankshaft Damper
Remover
4BUOB3-093
Timing chain cover

irlB1078-A 413UOB3-092
1. Remove the timing chain cover bolt:; and studs.
2.Tap lightly with a plastic hammer to remove the timing
chain cover.
4BUOB3-094
DISASSEMBLY
TIMING CHAIN
1. Retract the timing chain auto tensioner and secure it with a retaining clip, referring to Disassembly Note.
(Refer to below.)
2. Remove the timing chain pulley key.
3. Disassemble in the order shown, referring to Disassembly Note.
I
MB1079-A
I
4811083-095
1. Camshaft pulley 3. Timing chain pulley
Disassembly Note ........................... below Disassembly Note ........................... below
2. Timing chain 4. Timing chain auto tensioner
Disassembly Note ........................... below 5. Guide
Disassembly Note
Timing chain, camshaft pulley, timing chain pulley
1. Push the timing chain auto tensioner away from the chain
and insert a retaining clip.
2. Remove the camshaft pulley, timing chain and timing
chain pulley as an assembly.
DISASSEMBLY
CYLINDER HEAD
1. Remove the cylinder head covers, referring to Disassembly Note. (Refer to page B3-36.)
2. Remove the rocker arm assemblies and push rods, referring to Disass mbly Not . (Refer to page
B3-36.)
VALVE SEAL, REPLACE
I 1
ME1080-A 5811083-046
1. Cylinder head 6. Valve
2. Gasket 7. Valve seal
3. Valve keeper [)isassembly Note ................. page 63-36
Disassembly Note ................. page 83-36 Inspect for wear or damage
4. Valve spring seat 8. Tappet
Disassembly Note ................. page B3-36 Inspection .............................. page 63-44
5. Valve spring
Disassembly Note ................. page 63-36
DISASSEMBLY
Disassembly Note
Remove the cylinder head cover bolts, reinforcement
plates, cylinder head covers, and gaskets.
Rocker arm assemblies and push rods

Caution
rocker arm shaft.
2. Remove the rocker arm and shaft assemblies.

Note
Valve keeper, valve spring seat and valve spring
VALVE SPRING COMPRESSOR 1. Assemble Valve Spring Compressor T86L-6565-A, or
T86L-6565-A
equivalent and Valve Spring Compressor Bar T74P-
6565-B, or equivalent.
2. Compress the valve spring using the Valve Spring Com-
pressor T86L-6565-A, or equivalent and Valve Spring
Compressor Bar T74P-6565-B, or equivalent.
3. Remove the valve keeper, valve spring seat and valve
spring.
4. Remove Valve Spring Compressor T86L-6565-A, or
equivalent and Valve Spring Compressor Bar T74P-
Valve seal
Caution
Do not reuse the valve seal.
DISASSEMBLY B3
DISASSEMBLY
1. Connecting rod cap 6. Piston
Disassembly Note ........................... below Inspection .............................. page B3-45
2. Connecting rod bearing 7. Main bearing cap
Disassembly Note ........................... below 8. Main bearing, lower
Inspection .............................. page B3-48 Disassembly Note ........................... below
3. Piston ring 9. Crankshaft
Disassembly Note ................. page 83-39 Inspection .............................. page B3-47
Inspection .............................. page B3-46 10.Main bearing, upper
4. Piston pin Disassembly Note ........................... below
Disassembly Note ................. page B3-39 11. Cylinder block
Inspection .............................. page B3-46 Inspection .............................. page B3-44
5. Connecting rod 12. Camshaft
Disassembly Note ........................... below Disassembly Note ................. page B3-39
Inspection .............................. page 83-47 Inspection .............................. page B3-43
13. Thrust plate
Disassembly Note
Connecting rod cap
Before removing the connecting rod caps, measure the
connecting rod side clearance. (Refer to page B3-54.)
ME1082-6 6BUOB3-010
Connecting rod bearing, lower main bearing and
upper main bearing
Mark the location of the bearings so they can be rein-
stalled in the position they were removed.
4BUOB3-104
Connecting rod
(Refer to page 83-53.)
2. Remove the Plastigage from the crankshaft journals.
Caution
Do not scratch the crankshaft journals or the
cylinder walls.
3. Use the handle of a hammer to push the piston and

connecting rod assembly through the top of the cylinder
block.
5BUOB3-049
DISASSEMBLY
Piston ring
Caution
Do not apply excessive tension, which may cause
the rings to break.
Remove the piston rings using a piston ring expander

(commercially available).
MB1083-A 4BUOB3-106
Piston pin
1. Before disassembling the piston and connecting rod,
check the oscillation torque. If the large end does not drop
by its own weight, replace the pistori or the piston pin.
2.Assemble Piston Pin Tool D81L-6'135-A, or equivalent
into the piston pin as shown.
Caution
Verify that Piston Pin Tool 0811.-6135-A, or equiva-
lent is fit squarely into the piston before pressing.
3. Press out the piston pin.

MB1084-A 4BUOB3-107
Caution
Mark the connecting rod direction for proper reas-
sembly.
Camshaft
1. Remove the thrust plate screws.
2. Remove the thrust plate.
3. Remove the camshaft.
INSPECTION I REPAIR
1. Clean all parts, being sure to remove all gasket fragments, dirt, oil, etc.
2. Perform the inspections and repair in the order specified.
Caution
Do not damage the joints or friction surfaces of aluminum alloy components (such as the
cylinder head or pistons).
4BUOB3-109
CYLINDER HEAD
1. Inspect the cylinder head for damage, cracks and leakage
of water and oil. Replace if necessary.
2. Using astraightedge measurethe cylinder headdistortion
in the six directions shown in figure.
Distortion
Maximum: 0.07mm (0.003 in), per 152mm (6.0 in)
Note
Before grinding the cylinder head, check the fol-
lowing. Repair or replace as necessary.
dB1015-A
(1) Sinking of valve seat.
(2) Damage to manifold contact surface.
(3) Camshaft oil clearance and end play.
3.If distortion exceeds specification,grind thecylinder head.

4. Using a straightedge measure intake and exhaust mani-

fold contact surfaces for distortion in the six directions
shown in figure.
INTAKE
- I Distortion:
0.07mm (0.003 in) max. per 152mm (6.0 in)
5. If distortion exceeds specification, grind the surface or

replace the cylinder head.
EXHAUST
MBIO16-A 4BUOB3-I 10
INSPECTION IREPAIR B3
VALVE MECHANISM
'8 STEM TIP

1. Inspect each valve for the following. Replace or resurface
as necessary:
(2) Rough or damaged face
(3) Damaged or unevenly worn stem tip
MB1017-A
2. Measure the valve stem diameter and replace the valve if
/ / / necessary.
Diameter
Standard
IN: 8.02-8.04mm (0.315 9 4 . 3 167 in)
EX: 8 . 0 0 4 . 0 1 mm (0.3149-0.3'1 56 in)
Oversize4.20mm (0.008 in)
IN: 8.23-8.24mm (0.32394.3245 in}
EX: 8 . 2 0 4 . 2 1 mm (0.3228-0.3:235 in)
Oversize4.40mm (0.016 in)
IN: 8.43-8.44mm (0.3318-0.3324 in)
EX: 8.40-8.41 mm (0.3307-0.3:314 in)
3. Measure each valve guide inner diameter and record.
Inner diameter:
8.71--8.74mm (0.3174-0.3184 iin)
INSPECTION 1 REPAIR
4. Calculate the valve stem-to-guide oil clearance. With the
valves in place, measure the oil clearance with Valve
Stem Clearance Tool TOOL-6505-E, or equivalent and a
dial indicator.
Clearance
IN: 0.02004.0635mm (0.0008--0.0025 in}
EX: 0.0457--0.0889mm (0.0018--0.0035 in}
Service Limit Clearance Maximum:

0.1397mm (0.0055 in}
5. If the clearance exceeds the maximum, install an oversize

stem valve and ream the guide.
VALVE STEM
CLEARANCE TOOL
TOOL-6505-E
4BUOB3-Ill
Valve Seat
1. Inspect the contact surface of the valve seat and valve
(I ) Roughness
(2) Damage
2. If necessary, resurfacethe valve seat by using a 45" valve
cutter and/or resurface the valve face.
3. Apply a thin coat of Prussian blue to the valve face.
4. Check the valve seating by pressing the valve against the
seat.
( I ) If blue does not appear 360" around the valve face,
replace the valve face.
resurface the seat.
5. Measure the seat contact width.
Width: 1.524--2.000mm (0,0604.079 in}

INSPECTION / REPAIR
6. Check the valve seat runout.
Runout Limit:
0.0381 mm (0.0015 in}
APPLY TORQUE UNTIL

Valve Spring
1. Inspect the valve spring, valve spring retainers and keys
TORQUE WRENCH for wear or damage. Discard any damaged parts.
AND MULTIPLY
READING BY TWO \ 2. Check the springs for proper pressure at the specified
spring lengths. Replace any !spring not within
specification.
VALVE SPRING
Pressurellength:
SET KNOB TO 132-1 49 kgf (60-68 Ibs.} at 40.3mm (1.585 in}
COMPREiSSED
LENGTH OF 304-327 kgf (138-149 Ibs.) at 31.0mm (1.222 in)
SPRING
I I
MBI 022-6 3. Check the valve spring free length.
Free length:
48.5mm (1.91 in} (approximate)
4. Check the out-of-square of the valve spring.
Out-of-square:
1.98mm (0.078 in)
Caution
Make sure the springs are reassembled to their
original dampers.
MB1023-B 4BUOB3-113
CAMSHAFT
1. Check the camshaft journals for wear or scoring. If the
journals are excessively worn or scored, replace the
camshaft.
2. Camshaft journals can be refinished to accommodate
0.38 mm (0.015 in} undersize bearings. If the journals can
3. Set the camshaft on V-blocks and rneasure the runout.
Replace the camshaft if necessary.
Runout: 0.127mm (0.005 in} max.
4. Measure the camshaft lobe height in Ihe two points (A and

B) as shown.
Subtract B from A == lobe height
Replace the camshaft if necessary.
Height
IN: 10.221mm (0.4024 in}
EX: 10.221mm (0.4024 in}
Minimum
IN: 10.094mm (0.3974 in}
EX: 10.094mm (0.3974 in)
5. Measure the camshaft oil clearance.

(1) Measure the camshaft bore (A).
(2) Measure the camshaft journal diameter (B).
(3) Subtract B from A = oil clearance
Oil clearance
Standard: 0.0254-0.0660mm (0.0010-0.0026 in)
Maximum: 0.1524mm (0.006 in)
1
1 6. Measure the camshaft end play.
End play
0.065-0.1 65 mm (0.025-0.064 in)
TAPPETS
Inspect the tappet friction surfaces for wear and damage.
Replace the tappet if necessary.
6BUOB3-008
I I
MB1089-B 4811083-I 14
CYLINDER BLOCK
1 . Check the cylinder block for the following and repair as
necessary.
(1 ) Leakage damage
(2) Cracks
(3) Scoring of wall
2. Using a straightedge, measure the cylinder block decks

for distortion in six directions.
Distortion: 0.07mm (0.003 in) per 152.4mm (6.0 in}

block.
4. Measure the cylinder bore diameter in X and Y directions

at three levels (A, 6 and C) as shown.
mm {in)
Size Diameter
--
Standard I 100 40-1 00 43 {3 9527-3 9543)

0.50 {O 020) overslze ~ 09727--~ 974% ~
INSPECTION 1 REPAIR
Caution
When reboring the cylinder block, base the bore
size on an oversize piston and bore all cylinders t o
the same size.
5. If the cylinder bore exceeds the maximum, rebore all

cylinders to oversize diameter.
6. If the difference between measurement A and C exceeds
the maximum taper, rebore all cylinders to oversize
diameter.
Taper: 0.254mm (0.010 in)
7. If the difference between measurements X and Y exceeds

the maximum out-of-round, rebore all cylinders to the
oversize diameter.
Out-of-round
Standard: 0.0381 mm (0.001 5 in]
MB1027-A
I
4ELUOB3-115
PISTON, PISTON RING AND PISTON PIN
Piston
2. Measure outer diameter of each piston at a right angle
(90") to the piston pin 25.4 mm (1.OO in) below the oil ring
groove.
Piston diameter
mm {in)
I Standard 1 100.40-1 00.408 13.9524-3.9531 1 1

I 0.50 10.0201 oversize 1 100.90-1 00.908 13.9724-3.9731 1 1
3. Measure the piston-to-cylinder clearance.
Clearance:
0.020-0.048mrn (0.0008-0.00119 in)
4. If the oil clearance exceeds the maximum, replace the

piston or rebore the cylinders to fit oversize pistons.
Note
If a piston is replaced, the piston ring must also be
replaced.
INSPECTION 1 REPAIR
Piston and Piston Rings
1. Measure the piston to ring land clearance around the
entire circumference by using a new piston ring.
Clearance
Top: 0.0514.084mm (0.00204.0033 in)
Bottom: 0.0514.084mm (0.00264.0033 in)
Oil Ring: Snug fit
Maximum: 0.1524mm (0.006 in)
2. If the clearance exceeds the maximum, replace the pis-

ton.
3. Inspect the piston ring for damage, abnormal wear, or
4. Insert piston ring into cylinder by hand and use the piston
to push it to the bottom of the ring travel.
PISTON
RING
5. Measure each piston ring end gap by using afeelergauge.

Replace if necessary.
End gap
Top: 0.381-0.584mm (0.015-4.023 in)
Bottom: 0.381--0.584mm (0.015-0.023 in)
Oil Ring: 0.381-1.397mm (0.015--0.055 in)
Piston and Piston Pin

1. Measurethe piston pin bore diameter in X and Y directions
at four points.
Diameter: 24.003-24.008mm (0.94504.9452 in]

INSPECTION I REPAIR
2. Measure the piston pin diameter in >(:and Y directions at
four points.
Diameter
Red: 23.992-23.997mm (0.9446i0.9448 in}
Blue: 23.992-24.000mm (0.9446-4.9449 in}
3. Calculate the piston pin-to-piston clearance.
Clearance: 0.007-0.01 5mm (0.00034.0006 in)

and/or piston pin.
CONNECTING ROD
1. Measure the connecting rod small end bore.
Diameter: 23.957-23.975mm (0.94324.9439 in)

Caution
rod cap and bolts must also be replaced, since they
are a matched set.
2. Check the bend arid twist factor of the connecting rod.

Bend: 0.050mm (0.002 in)

Twist: 0.1524mm (0.006 in}
Length (Center to Center):

130.52-1 30.58mm (5.1 386-5.11 413 in)
CRANKSHAFT
hole clogging.
3. Measure the crankshaft main journal runout at the No.2
and No.3 journals.
4. If runout exceeds the maximum, replace the crankshaft.
Runout: 0.0508mm (0.002 in}

Max: 0.127mm {0.005 in)
INSPECTION I REPAIR
1 5. Measure each journal diameter in X and Y directions at

two points
Main journal
Diameter: 56.9798-57.0026mm
(2.2433-2.2442 in)
Out-of-round: 0.0152mm f0.0006 in1
UJ Crankpin journal
Diameter: 53.9800-54.0004mm
9 (2.1 252-2.1 260 in)
MBlO91-A 4BUOB3-120
6. If thediameter is less than the minimum, grind the journals

to match undersize bearings.
Undersize bearing: 0.0254mm (0.001 in)
BEARING
CRATERS oh POCKETS BRIGHTFOLISHED)
SECTIONS
FATIGUE FAILURE IMPROPER SEATING
SCRATCHES DIRT
IMBEDDED OUT
INTO BEARING
MATERIAL
SCRATCHED BY DIRT LACK OF OIL OR
IMPROPER CLEARANCE
TIMING CHAIN
Check the timing chain for damage, wear or excessive
FROM EDGES RADIUS RIDE
looseness. Replace it if necessary.
RADIUS RlDE 4BUOB3-122
HOURGLASSING
PULLEY
Timing Chain Pulley and Camshaft Pulley
Inspect the teeth of each pulley for wear, deformation and
other damage. Replace as necessary.
4BUOB3-123
Timing chain cover

Inspect the timing chain cover for damage and cracks.
Replace it if necessary.
4BUOB3-124
FLYWHEEL
Refer to Section B1.
ASSEMBLY
ASSEMBLY
--
PREPARATION
SST
49 UNOl 002 For

installing
49 UNOl 136 I For
installation of
Crankshaft crankshaft Rear main seal crankshaft
damper pulley oil seal pilot & rear oil seal
replacer seal replacer 8
8
49 UNOl 007 For 49 LO12 001 I For
removal 1 installing
Fan clutch installation seals
holding tool of fan Valve stem
seal replacer
49 UNOl 008
removal /
Fan clutch installation
nut wrench of fan
1. Clean all parts before installation.

3. Tighten all bolts and nuts to the specified torque.
Caution
ASSEMBLY
ASSEMBLY
1. Main bearing, upper 8. Piston ring
2. Crankshaft 9. Piston, piston pin, and connecting
Assembly Note ................................ below rod assembly
3. Main bearing, lower Assembly Note ....................... page B3-53
Assembly Note ................................ below 10. Connecting rod bearing
4. Main bearing cap Assembly Note ...................... page B3-53
Assembly Note ................................ below 11.Connecting rod cap
5. Pistcn Assembly Note ...................... page B3-53
Assembly Note ...................... page 83-52 12. Camshaft
6. Piston pin Assembly Note ...................... page B3-55
Assembly Note ...................... page 83-52 13. Thrust plate
7. Connecting rod
Assembly Note ...................... page B3-52
Assembly Note
Upper main bearing, crankshaft, lower main bearing
and main bearing cap
below:
(1) Remove any foreign material and oil from the jour-
nals and bearings.
(2) lnstall the upper main bearing:; with the tang in the
slot.
(3) lnstall the lower main bearings into the main bearing
caps.
(4) Install the crankshaft into the c:ylinder block.
direction.
(7) lnstall the main bearing cap.
(8) Tighten the main bearing cap bolts.
Tightening torque:
90-104 N-m (9.1-10.6 kgf-m, 66-77 ftelbf}

point for the smallest clearancle, and the narrowest
Oil clearance
Standard: 0.020--0.038mm (0.0008-0.0015 in)
Allowable: 0.0127--0.0482mm (0.0005-0.0019 in}

crankshaft and install undersize bearings. (Refer to
page 82-48.)
2. Install the main bearing caps as follows:
ings.
ASSEMBLY
bearings.
(3) Apply sealant to the rear main bearing cap's mounting
surface as shown in figure.
(4) Install the main bearings and caps.
(5) Apply engine oil to the threads and seat faces of the
cap bolts and tighten them.
Tightening torque:
90-1 04 N.m (9.1-1 0.6 kgf-m, 66-77 ft-lbf)
Note
Make sure the main bearing caps are installed in
their original position.
3. Measure the crankshaft endplay.
End play: 0.05--0.32mm (0.002--0.012 in}
4. If the end play exceeds the maximum, install an oversize

thrust bearing.
5BUOB3-052
Piston, piston pin, and connecting rod
1. Assemble a suitable piston pin tool, into the piston pin
as shown.
Caution
Verify that the piston pin tool is fit squarely into
the piston before pressing.
2. Apply clean engine oil to the piston pin.

3. Press the piston pin into the piston and connecting rod.
Piston ring
4BUOB3-129
Note
The upper and lower oil rails are the same.
* Each rail can be installed with either face upward.
I.Install the three-piece oil rings on the pistons.
(1) Apply clean engine oil to the oil ring spacer and rails.
(2) lnstall the oil ring spacer so that the opening faces
upward.
(3) lnstall the upper rail and lower rail.
2. Verify that both rails are expanded by the spacer tangs, as

shown in the figure, by verifying that they turn smoothly in
both directions.
3. Installthe second ring to the piston, and then install the top
ring. Use a piston ring expander (commerciallyavailable).
4. Apply a liberal amount of clean engine oil to the piston
rings.
ASSEMBLY
5. Position the end (
I gap of each ring as shown in the figure.
OIL RING Piston, piston pin and connecting rod assembly
UPPER RAIL TC)P RING 1. Remove any foreign material and oil from the connecting
rod journals and bearings.
OIL RING 2. Install the upper connecting rod bearings in the connect-
ing rods.
3. Apply a liberal amount of clean engine oil to the cylinder
walls, pistons, piston rings and conrlecting rod cap bolts.
OIL RING SECOND
LOWER RAIL Caution
Be careful not to damage the! crankpin journals
~ B094-A
I 4~~0~3-130 when installing the piston assemblies.
4. Check the piston ring for proper end gap positioning.

5. Insert the piston assemblies into the cylinder block with
the indent on the top of the piston facing the front of the
engine. Use a piston installer tool (commercially avail-
able) to install.
4BUOB3-131
Connecting rod cap and connecting rod bearing

follows:
Caution
oil clearances.
Oil clearance must be measured with the connect-
(1) Remove any foreign material and oil from the journals
and bearings.
rod cap.
(3) Position Plastigage atop the journals in the axial direc-
tion.
(6) Tighten the connecting rod cap bolts.
Tightening torque:
25-32 N.m (2.5-3.3 kgfsm, 18-24 ft.lbf)
ASSEMBLY
Oil clearance
Standard: 0.008--0.060mm (0.0003--0.0024 in)
Allowable: 0.0127--0.0558mm (0.00054.0022 in)

crankshaft and install undersize bearings. (Refer to
page B3-48.
2. Install the connecting rod caps as follows:
ings.
(3) Install the connecting rod bearings and caps.
(4) Apply engine oil to the threads and seat faces of the
cap bolts and tighten them.
Tightening torque:
25-32 N-m(2.5-3.3 kgf-m, 18-24 ftelbf)
Note
Make sure the connecting rod caps are installed in
their original position.
3.Measure the connecting rod side clearances.

Side clearance:
0.00514.0635mm (0.00024.0025 in)
Maximum: 0.3556mm (0.014 in)

ASSEMBLY
Camshaft
1. lnstall the camshaft into the cylinde~rblock.
Caution
Do not scratch the camshaft bearings while install-
ing the camshaft.
2. lnstall the thrust plate and screws.

3. Tighten the thrust plate screws.
Tightening torque:
9-13 N.m (0.97-1.24 kgf-m, 7.-9 ft.lbf)
4. Check camshaft end play as follows:

II (1) Measure camshaft end play.
End play
0.065-0.165 mm (0.025-0.064 in)
CYLINDER HEAD
2. Install the rocker arm shaft assemblies and push rods, referring to Assembly Note. (Refer to page
B3-57.)
3. Install the lower intake manifold, referring to Assembly Note. (Refer to page B3.-11,Step 3.)
4. lnstall the cylinder head cover. gaskets and bolts, referring to Assembly Note. (Refer to page B3-17.)
ASSEMBLY
REPLACE
STEP 1:30--35 (3.0--3.5, 22-26)
STEP 2: 70-75 (7.0-7.5, 52-56)
STEP 3: Tighten an additional 90"
N.m (kgfem, ft-lbf)
MBI 097-D 5811003-024

1 . Tappets 5. Valve spring seat
Assembly Note ................................ below 6. Valve keeper
2. Valve Assembly Note ...................... page B3-57
3. Valve seal 7. Gasket
Assembly Note ...................... page 63-57 8. Cylinder head
4. Valve spring 9. Bolt
Assembly Note ...................... page 63-57 Assembly Note ...................... page B3-11
Assembly Note
Tappets
1. Coat the friction surfaces of the tappets with oil prior to
installing into the bore.
2. Install the tappets with the alignment tab in the groove of
the bore.
Note
The tappets should be installed in the bore they
were removed from.
ASSEMBLY
Valve seal
1. Apply clean engine oil to the valve gl~ide.
2. Coat the valve seal with clean engine oil.
3. lnstall the new valve seal with the SST.
Caution
Do not reuse the valve seal.
Note
SST numbers: 49 LO12 001 and 49 LO12 002 Valve
Stem Seal IReplacer
I I
~~1098-A 4B"0B3.136 4. Measure the clearance between the valve seal and valve
guide boss.
Clearance
0.5mm (0.019 in)
Valve spring and valve keepers

VALVE SPRING COMPRESSOR 1. Assemble Valve Spring Compressor T86L-6565-A, or
equivalent and Valve Spring Compressor Bar
T74P-6565-B, or equivalent.
2. lnstall the spring and spring seat.
Note
lnstall the spring with the close coils toward the
cylinder head.
3. Compress the spring using Valve Spring Compressor

T86L-6565-A, or equivalent and Valve Spring Compres-
sor Bar T74P-6565-B, or equivalent.
4. lnstall the valve keepers.
5. Tap the end of.thevalvestem lightly tufoor three times with
a plastic hammer to verify that the keepers are fully
seated.
\ 7 R
A
R
VALVE SPRING
B, ; , ,?,g
Rocker arm shaft assemblies and push rods

1. lnstall the push rods.
Note
lnstall the push rods in the position which they
were removed from.
Coat the push rods with clean engine oil.
2. lnstall the rocker arm shaft assemblies.

3. Tighten the rocker arm shaft bolts.
ASSEMBLY
Tightening torque:
3 2 N.m (3.3 kgf.m, 2 4 ft.lbf) + 90 degrees
Caution
The bolts should be tightened gradually; two turns
at a time.
Note
Apply clean engine oil to the rocker arm
assemblies.
Cylinder head cover gaskets and bolts
TIMING CHAIN
1. Assemble in the order shown, referring to Assembly Note.
2. Install the timing chain pulley key.
1. Guide 4. Camshaft pulley

2. Timing chain pulley 5. Timing chain auto tensioner
3. Timing chain
Assembly Note ...................... page 63-59
Assembly Note
Guide
Tightening torque:
10-1 2 N-m (1.O-1.2 kgf-m, 7.4-4.8 ft-lbf)
4611083-141
ASSEMBLY
Timing chain pulley, timing chain and camshaft pulley

1.Turn the camshaft pulley and timing chain pulley to align
the timing marks.
2. lnstall the camshaft pulley, timing chain and timing chain
pulley as an assembly.
Note
The tensioner side of the tim~ingchain is held
inward and the guide side should be tight.
L I
ME1051- 6 4EiUOB3-142
3. lnstall the camshaft pulley bolt.
Tightening torque:
6 0 - 4 8 N.m (6.1-6.9 kgf-m, 44-50 ft-lbf)
Timing chain auto tensioner
1. Tighten the timing chain auto tensioner bolt.
Tightening torque:
9-1 1 N.m (0.97-1.1 kgf.m, 7-8 ftelbf}
2. Removethe clip and release the timing belt auto tensioner.

4BUOB3-143

- 1. Install the timing chain cover, referring to Assembly Note. (Refer to below.)
2. lnstall the crankshaft pulley, referring to Assembly Note. (Refer to below.)
3. lnstall the crankshaft position sensor, referring to Assembly Note. (Refer to page 63-60.)
4. lnstall the water pump, referring to Assembly Note. (Refer to page B3-60.)
5. lnstall the baffle, referring to Assembly Note. (Refer to page 63-60.)
6. lnstall the oil pump, referring to Assembly Note. (Refer to page 83-60.)
7. lnstall the oil pan. (Refer to Section D3.)
8. lnstall the rear oil seal, referring to Assembly Note. (Refer to page B3-61.)
5BUOB3-055
Assembly Note
Timing chain cover
1. Apply a bead of sealant to the timing chain cover.
2. lnstall the timing chain cover.
3. Tighten the timing chain cover bolts and studs as shown.
Tightening torque:
17-21 N-m(1.8-2.0 kgf.m, 13--15 ft.lbf}
Bolt A: M8 x 47
Bolt B: M8 x 25
Stud C: M8 x 25
Crankshaft pulley
1. lnstall the crankshaft pulley using the SST.
Note
Replacer
2. Tighten the bolt.
Tightening torque:
40-50 N-m(4.1-5.1 kgf.m, 30--37 ft-lbf) +
80-90"
ASSEMBLY
1. Install the crankshaft position sensor
2. Tighten the screws.
Tightening torque:
9-12 N.m (0.9-1.2 kgf-m, 7.0--8.8 ft.lbf)
Water pump
1. Apply sealant to the mating surface of the water pump.
2. Install the water pump and water pump bolts.
3. Tighten the water pump bolts.
Tightening torque:
8.5-12 N.m (0.83-1 -24 kgf-m,6-9 ft.lbf)
4. lnstall the water pump pulley.

4BUOB3-148
Baffle
1. lnstall the baffle.
2. Tighten the nuts.
Tightening torque:
17-21 N-m(1.&-2.0 kgfsm, 13-15 ft-lbf)
Oil pump
Note
Fill the oil pump with oil and rotate the oil pump
shaft to prime the oil pump.
1. lnstall the oil pump.

Tightening torque:
17-21 N.m (1.8-2.0 kgf-m, 13-1 5 ft.lbf}
ASSEMBLY
Rear oil seal
1. Apply oil to the rear oil seal.
2. lnstall the rea:r oil seal, using the SST.
Note
It is recommended that no engine oil be added for
24 hours.
AUXILIARY PARTS
1. Install the camshaft position sensor. (Refer to Section FT.)
rccc
2. lnstall the exhaust manifolds, referring to Assembly Note. (Refer to page B3-62.)
3. lnstall the oil dipstick and tube.
4. lnstall the oil filter and oil filter adapter, referring to Assembly Note. (Refer to page B3-62.)
5. lnstall the fan assembly, referring to Assembly Note. (Refer to below.)
6. lnstall the fuel supply manifold, referring to Assembly Note. (Refer to page B3-62.)
7. lnstall the upper intake manifolcf, referring to Assembly Note. (Refer to page B3-63.)
8. lnstall the ignition coil pack, referring to Assembly Note. (Refer to page B3-63.)
Exhaust manifolds
1. lnstall new exhaust manifold gaskets.
2. lnstall the exhaust manifolds.
3. Tighten the exhaust manifold bolts.
Tightening torque:
25 N.m (2.6 kgf-m, 19 ft-lbf}
ASSEMBLY
Oil filter and oil filter adapter
1. lnstall a new O-ring.
2. lnstall the oil filter adapter.
3. lnstall a new O-ring on the through bolt.
4. Tighten the through bolt.
Tightening torque:
3 5 4 0 N.m ( 3 . 6 4 . 1 kgf.m, 26-30 ft.lbf)
Fan assembly
1. lnstall the fan and clutch assembly
2. Hold the water pump pulley with the SST. Tighten the
Tightening torque:
40-1 35 N.m (4.1-1 3.8 kgf-m, 30-1 00 ftelbf)
Note
must be rotated counterclockwise for tightening.
Fuel supply manifold

1. lnstall a new fuel supply manifold gasket.
2. lnstall the fuel supply manifold.
ASSEMBLY
1. Install a new upper intake manifold gasket.
2. Install the upper intake manifold.
3. Tighten the upper intake manifold nuts.
Tightening torque:
20-25 N.m (2.1-2.4 kgf-m, 15--18 ftdbf)
Ignition coil pack

1. Install the ignition coil pack.
5 - 7 N.m (44-62 in-lb)
2. Tighten the bracket bolts.
7
%
' Tightening torque:
26-32 N-m (2.6-4.3 kgf.m, 19--24 ft-lbf)
INSTALLATION
INSTALLATION
PROCEDURE
1. Remove the engine from the stand.
2. Lower the engine into the vehicle, referring to lnstallation Note. (Refer to below.)
3. lnstall the bell housing upper bolts, referring to lnstallation Note. (Refer to page B3-65.)
4. Remove the jack from under the transmission.
5. Remove Engine Lifting Sling 014-00036, or equivalent from the engine lifting brackets.
6. lnstall the battery cable bracket bolt and wire harness-to-engine clip.
7. lnstall the transmission line bracket-to-engine bolts. (AT only)
9. Position the transmission linkage bracket and install the bell housing lower bolts, referring to Installa-
tion Note. (Refer to page 63-65.)
10. lnstall the torque converter nuts, referring to lnstallation Note. (AT only) (Refer to page B3-65.)
11. lnstall the starter. (Refer to Section G.)
12. lnstall the engine mount nuts, referring to lnstallation Note. (Refer to page B3-65.)
13. lnstall the front pipe assembly on the exhaust manifolds. (Refer to Section F3.)
15. Connect the ground wires.
16. Connect the following harness connectors:
(1) Ignition coil pack
(2) Oil pressure sensor
(4) Injectors
17. lnstall the power brake unit hose.
18. lnstall the throttle cable bracket.
19. Connect the accelerator cable and kickdown control shaft rod.
20. lnstall the accelerator cable shield, referring to lnstallation Note. (Refer to page 83-65,)
21. Connect the fuel hoses, referring to lnstallation Note. (Refer to page B3-65.)
22. Connect the vacuum hoses to the vacuum tee, referring to lnstallation Note. (Refer to page B3-66.)
24. lnstall the generator. (Refer to Section G.)
25. lnstall the A/C compressor, if equipped, referring to lnstallation Note. (Refer to page 83-66.)
26. lnstall the power steering oil pump, referring to lnstallation Note. (Refer to page 83-66.)
27. Remove the radiator and shroud cover. (Refer to Section E3.)
28. Connect the radiator hoses.
29. lnstall the air intake hose, referring to lnstallation Note. (Refer to page B3-66.)
30. Fill the cooling system.
lnstallation Note
Engine installation
Caution
Do not damage any components in the engine
compartment.
Note
Align the torqueconverter pilot into the crankshaft.
(AT only.)
Align the exhaust manifolds with the front pipe
assembly.
4BUOB3-161
INSTALLATION
Bell
e housing upper bolts
Tightening torque:
38-51 N-m (3.9-7.0 kgfam, 28-37 ft-lbf)
4811083-162
Bell housing lower bolts
Tightening torque:
3&51 N-m(3.9-7.0 kgfam, 28-37 ft-lbf)
4BUOB3- 164
Torque converter nuts (AT only)

Access the torque converter nuts through the starter
mounting opening.
-
Tiahtenina toraue:
45-61 fi - m i4.5-6.2 kgf - m, 3,3-45 ft - lbf)
6BUOB3-007
Engine mount nuts
Tightening torque:
88-1 15 N-m(9.0-1 1.7 kgf-m, 65-45 ftelbf)

Install the accelerator cable shield and bolts.
5BUOB3-030
Fuel hoses
Warning
Keep sparks and open flame away from the fuel
area.
Caution
Cover the hose with a rag because fuel will leak out
when connecting.
1. Remove the plugs from the hoses.

2. Connect the fuel hoses.
4BUOB3-168
63-65
INSTALLATION
Vacuum hoses
Connect the vacuum hoses to vacuum tee "A".
I I
MBlO61-A 4BUOB3-169
AIC compressor
1. Position the A/C compressor on the bracket.
2. Tighten the AIC compressor bolts.
Tightening
- torque:
3 4 - 4 7 ~ . ('3.54.6
m kgf-m,25-34 ftdbf)
4BUOB3-170

1. Position the power steering oil pump on the bracket.
2. Tighten the power steering oil pump bolts.
Tightening
- torque:
40-55 ~ . (4.1-5.5
m kgf-m,3 0 4 0 ftalbf)
4BUOB3-171
Air intake hose

1. lnstall the air intake hose.
2. lnstall the breather hose.
3. Tighten the clamps.

1. Fill the engine with the specified amount and type of engine oil. (Refer to Section 03.)
2. Fill the radiator with the specified amount and type of engine coolant. (Refer to Section E3.)
3. If the transmission was drained, fill it with the specified amount and type of transmission oil. (MT: Refer
to Section J1, AT: Refer to Section K.)
4. Install the front wheels.
6 . Start the engine and check the following:
(1) Engine oil, transmission oil, and engine coolant leakage.
(2) Drive belt tension (Refer to page 83-7.)
(3) Ignition timing, idle speed (Refer to page B3-8.)
(4) Operation of emission control system
7. Perform a road test
LUBRICATION
SYSTEM
(2.3L)
INDEX .......................................................... Dl- 2

OUTLlNlE ...................................................... Dl- 3
SPECIFICATIONS ..................................... Dl- 3
TROUBL.ESHOOTING GUIDE ..................... Dl- 3
OIL PRESSURE ........................................... Dl- 4
PREPARATION ......................................... Dl- 4
INSPECTION ............................................. D l. 4
ENGINE OIL ................................................. Dl- 4
INSPEiCTlON ............................................. Dl- 4
REPLACEMENT ........................................ Dl- 5
OIL FILTER ................................................... Dl- 5
REPLACEMENT ........................................ Dl- 5
OIL PAN1 ........................................................ Dl- 6
REMOVAL I INSTALLATION ..................... Dl- 6
INSPECTION ............................................. Dl- 7
OILPUMP ..................................................... Dl- 8
REMOVAL/ INSTALLATION ..................... Dl- 8
OIL PUMP STRAINER AND TUBE .............. Dl- 9
REMOVAL / INSTALLATION ..................... Dl- 9
5BUOD1-001
INDEX
INDEX
k I
MD1054-B 5BUOD1-002
1. Oil pressure 4. Oil pan
Inspection .............................. page D l -4 Removal / Installation ............ page Dl - 6
2. Engine oil Inspection .............................. page Dl - 7
Inspection .............................. page Dl -4 5. Oil pump
Replacement ......................... page Dl -5 Removal / Installation ............ page Dl - 8
3.Oil filter 6. Oil pump strainer and tube
Replacement ......................... page 01-5 Removal / Installation ............ page D 1- 9
OUTL-INE,TROUBLESHOOTING GUIDE Dl
OUTLINE
SPECIFICATIONS
----
Item -----__.
--\__
Engine 2.3L
Oil filter type
~ --
Full-flow paper element
Engine
-- --
oil
-- - .-
- - - - --- -
API service SG Energy Cons'erving
--
I1 (ECII) -
Below 0°C {32"F) SAE 5W-30
Viscosity
Above -1 8°C {O°F] SAE 1OW-30
Engine oil replacement {with oil filter)
4.7 I5.0, 4.2)
Oil capacity
liters {US qt, Imp qt)
Engine oil replacement {without oil filter} ! 3.8 {4.0, 3.4)
WD1025-D 6BUOD1-001
Note
4BUOD1-004
Possible Cause
lnsufficient engine oil -

Refer to Section B1
consum~tion Oil leakaae Reoair
Oil pressure drop lnsufficient engine oil Add oil
Oil leakage Repair
Worn and/or damaged oil pump Replace
Worn plunger (inside oil pump) or weak spring Replace
Clogged oil pump strainer and tube Clean
Excessive main bearing or connecting rod
Refer to Section B1
Oil pressure As described above
gauge (meter) does Malfunction of oil pressure gauge Refer to 1997 B-series BETM
not operate -- Malfunction of electrical system
Malfunction of electrical system
- --Refer to 1997 B-series BETM
Refer to 1997 B-series BETM
Warning lamp
illuminates while lnsufficient engine oil Add oil
engine is running
OIL PRESSURE, ENGINE OIL
OIL PRESSURE
PREPARATION
SST
/ 490187280 1 For
inspection of
I
oil pressure
Gauge,
oil pressure
4BUOD1-006
INSPECTION
I I
MD1060-A
2. Screw the SST into the oil pressure sensor installation
hole.
3. Warm up the engine to normal operating temperature.
4. Run the engine at 2000 rpm, and note the gauge
readings.
Oil pressure: 2 7 6 4 1 3 kPa (2.8--4.2 kgflcm2,

40-60 psi)-2,000 rpm
5. If the pressure is not as specified, check for the cause and

repair as necessary. (Refer to Troubleshooting Guide.)
MDIO61-A
6. Apply sealant to the oil pressure sensor threads as shown.
7. Remove the SST and install the oil pressure sensor.
Tightening torque:
11-24 N-m (1.1-2.4 kgfem, 8-18 ft-lbf)
0 1 ENGINE OIL
KEEP THE OIL IN THlS RANGE
INSPECTION
stop it.
OIL LEVEL MAY BE IN THlS 3. Wait for five minutes.
RANGE AFTER AN OIL CHANGE 4. Remove the oil dipstick and check the oil level and
condition.
5. Add or replace as necessary.
ENGINE OIL, OIL FILTER
REPLACEMENT
Warning
? Be careful when draining; the oil is hot.
1. Warm the engine to normal operating temperature and

stop it.
2. Remove the oil filler cap and the oil pan drain plug.
4. Install a new gasket and the drain plug.
DRAIN PLUG
Tightening torque:
21-33 N-rn(2.0-3.3 kgf.m, 15-24 ftelbf)

engine oil.
Oil capacity liters {US qt, Imp qt}

(with oil filter)
--

OIL FILTER
REPLACEMENT
1. Remove the oil filter.
2. Remove insert if necessary. The insert is not normally
removed for replacing filter.
3. Use a clean rag to wipe off the mouriting surface of the oil
filter.
4.Apply a small arnount of clean engine oil to the oil
gasket of the new filter.
5. Install insert.
Tightening torque:
28-35 N.m (2.8-3.5 kgf-m, 21-26 ft-lbf}
Note
Do not tighten with oil filter wrench as that will make
it difficult to remove.
6. Install the oil filter and tighten it by hand until the oil
gasket contacts the mounting base.
8. Check the oil level and add if necessary.
Oil filter capacity: 0.9 liter (1.0 U!S qt., 0.8 Imp qt)
5BUOD1-005
Dl OIL PAN
OIL PAN
I FRONT OF
ENGINE REMOVAL I INSTALLATION
2. Remove the engine assembly. (Refer to Section B1.)
3. Mount the engine on an engine stand with the oil pan
facing up.
4. Remove the oil pan, referring to Removal Note.
5. Remove the oil pan gasket.
6. Install in the reverse order of removal, referring to
Installation Note.
Removal Note
Oil pan
Caution
Do not force a prying tool between the cylinder
block and the oil pan which may damage the con-
tact surfaces.
Do not damage or scratch the contact surfaces
when removing the old sealant.

5BUOD1-014
OIL PAN
INSPECTION
Oil Pan
Visually check for cracks, deformation and damage.
4BUOD1-013
Installation Note
14-16 N.m (143-162 kgf.cm, 124-141 in-lbf)
Oil pan
SPACIERS
1. Remove all foreign material from the contact surfaces.
2. Apply sealant in six places at joints between the front
cover and the cylinder block and between the rear main
bearing cap and the cylinder block as shown in figure.
3. Install a new oil pan gasket to the oil pan and position the
pan to the engine so the transmission mounting face of the
oil pan is aligned with and square to the engine block.
4. Install the engine oil pan.
Tightening torque::
14-16 N-m(143-1 62 kgfzm, 1:24-141 in-lbf)
Note
The transmission bolts to the engine and oil pan
when installed. It is necessary to measure the gap
betweenthe surface of the rear face of th oil pan (at
spacer locations) and the rear face of the engine
block so that it extends over one of the oil pan/
transmission bolt mounting padls.
I I
5BIJODl-008
1
5. With the oil pan installed on the engine, position a straight-
edge flat on the rear of the engine blolck so that it extends
over one of the oil panltransmission bolt mounting pads.
OIL PAN, OIL PUMP
6.Measure the gap between the mounting pad and the
straightedge using a feeler gauge. Repeat the procedure
for the other mounting pad. Select spacers of the required
thickness from the chart.
I
0.0- 0.0- None None Caution
0.254 0.010 Failure to measure the required spacer thickness
0.27- 0.011- 0.254 0.010 Yellow can result i n insufficient, or excessive clearance
0.51 0.020 between the engine oil pan and the transmission,
when installed in the vehicle. This can result in oil
0.76 0.030 pan damage, andlor an oil leak.
0.78- 0.031- 0.762 0.030 Pink
1.01 0.040 7. Install the selected spacers to the mounting pads on the
~~1027-B rear of the oil pan before bolting the engine and transmis-
sion together.

1. Fill with specified amount and type of engine oil. (Refer to page D l -5.)
OIL PUMP
Note
The oil pump is only serviceable as a unit. Do not overhaul the pump.
REMOVAL IINSTALLATION
1. Remove the timing belt. (Refer to Section B1.)
2. Remove the oil pump pulley. (Refer to Section B1.)
3. Remove the camshaft position sensor.
4. Remove the oil pump, referring to Removal Note.
Removal Note
Oil pump
1. Remove the four oil Dump bolts.
2. Pry between the cylinder block and an ear on the oil pump
to loosen.
3. Remove the oil pump and the oil pump gasket.
5BUOD1-010
OIL PUMP, OIL PUMP STRAINER AND TUBE
lnstallation Note
Oil pump
1. If the original oil pump is to be reused, install new oil pump
O-ring seals on the oil pump.
Note
Inspect and clean oil pump hole in the cylinder
block before installing the oil pump.
1 2. Prime the oil pump with 236 ml(8 ounces) of fresh engine
oil.
I
3. Install a new oil pump gasket and the oil pump.
Tightening torque:
10-1 4 N-m(102-1 43 kgf.cm, 89-1 24 ft-lbf)
lnstallation Note
Camshaft position sensor
Tightening torque:
-d
OIL PUMP STRAINER AND TUBE
1. Remove the engine. (Refer to Section €31 .)
3. Remove strainer and tube, referring to Removal Note.
4. Install in the reverse order of rernoval, referring to lnstallation Note.
Removal Note
1. Remove nut and two screws.
2. Remove strainer and tube.
lnstallation Note
1. Thoroughly clean strainer and tube.
2. Clean all mounting surfaces.
3. Install two screws and nut.
Tightening torque:
Screws: 20-30 N-m(2.0-3.0 kgf.m, 14-22 ft-lbf)
Nut: 40-55 N.m (4.1-5.5 kgf.m, 3 0 - 4 1 ftelbf}
LUBRICATION SYSTEM
3.0L
INDEX ........................................................... D2- 2

OUTLINE ...................................................... D2- 3
SPECIFICATIONS ..................................... D2- 3
TROUBLESHOOTING GUIDE ..................... D2- 3
OIL PRESSURE ........................................... D2- 4
PREPAFlATlON ......................................... 02- 4
INSPEC'TION ............................................. 02- 4
ENGINE OIL ................................................. 02- 5
INSPECTION ............................................. D2- 5
REPLACEMENT ........................................ D2- 5
OIL FILTER ................................................... D2- 6
REPLACEMENT ........................................ D2- 6
OIL PAN ........................................................ D2- 7
REMOVAL / INSTALLATION ..................... D2- 7
INSPEC'TION ............................................. D2- 7
OIL PUMP ..................................................... D2- 9
DISASSEMBLY / ASSEMBLY
(REFER TO SECTION D3)
INSPEC'TION ............................................D2-10
5BUOD2-001
INDEX
INDEX
I I
MD1052-A 5BUOD2-002
Inspection ............................... page D2-4 Removal / Installation ............. page D2-7
2. Engine oil Inspection ............................... page D2-7
Inspection ............................... page D2-5 5. Oil pump
Replacement .......................... page D2-5 Removal / Installation ............. page D2-9
3. Oil filter Disassembly / Assembly ........ Section D3
Replacement .......................... page D2-6 Inspection ............................... page D2-10
OUTLIINE, TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
I ltem Engine 1 3.0L I
/
Oil filter type
I
Relief valve spring tension 28.2 mrn { I . l l in)/
40.5-44.9 N {21-22 kgf, 9.1-10.1
Full-flow, paper element
Ibf} I
Oil capacity 3.8i4.0, 3.4)
4.25 I4.5, 3.81
t Engine oil
1 Viscosity Number
1
I
(with oil filter)
L (US qt, Imp qt)
Above -18°C {O°F}

Below 0°C 132°F) I
--
SH Energy API service I1

.. Conserving (EC 11) ILSAC
SG,
SAE 1 0 ~ - 3 0
SAE 5W-30
7
I
Note
need to be driven 16 km (10 miles} or more to relearn the strategy.
4BUOD2-004
I Problem ( Possible Cause 1 Remedy I Page I
/ Engine hard starting
1 Improper engine oil
Insufficient enaine oil
i Replace
i Add oil
J-
-
Excessive oil Oil working up or down Refer to Section 62

consumption Oil leakage Re~air
Oil pressure drop Insufficient engine oil Add oil
Oil leakage Repair
Worn and/or damaged oil pump Replace
Worn or damaged oil pump shaft Replace
Clogged oil strainer Clean
Excessive main bearing or connecting rod bearing Refer to Section B2
clearance
Oil pressure drop As described above
gauge (meter) does Malfunction of oil pressure gauge Refer to 1997 B-series BETM
Malfunction of electrical system -
Refer to 1997 B-series BETM
Warning light Malfunction of oil level switch Refer to 1997
illuminates while Malfunction of electrical system Refer to 1997 B-series BETM
Insufficient enaine oil Add oil
MD2042-D
OIL PRESSURE
OIL PRESSURE
PREPARATION
SST
49 0187 280 I For

inspection of
Gauge, oil pressure
oil pressure
I I I
4BUOD2-022
INSPECTION
0 1 1. Remove the oil pressure sensor.
MD1003-B
1 2. Screw the SST into the oil pressure sensor installation

hole.
4. Run the engine at 2,500 rpm, and note the gauge read-
ings.
Oil pressure: 2 7 6 4 1 3 kPa (2.8-4.2 kgf/cm2,

40-40 psi)--2,500 rpm

OIL PRESSURE, ENGINE OIL
6. Apply sealant to the oil pressure sensor threads as shown
in the figure.
7. Remove the oil pressure gauge and install the oil pressure
sensor.
Tightening torque:
16-22 N.m (1 -6-2.2 kgf-m, 12-1 6 ft.lbf)
ENGINE OIL
KEEP THE OIL IN THlS RANGE INSPECTION

1. Position the vehicle on level grouncl.
ADD 1 stop it.
QUART
4. Remove the dipstick and check the oil level and condition.
OIL LEVEL MAY BE IN THlS
RANGE AFTER AN OIL CHANGE 5. Add or replace oil as necessary.
I
~~1250-A
1 part of the dipstick.
5~~0~2-006 -
;O:ehe oil level should be filled to the top of thedashed
REPLACEMENT
Warning

stop it.
2. Remove the oil filler cap and the oil pan drain plug.
"DRAIN 3. Drain the oil into a suitable container.
I PLUG ( 4. Install a new gasket and the oil pan drain plug.
MDI 063-A !5BUOD2-007
Tightening torque:
20-34 N-m (2.0-3.4 kgf-m, 15-25 ft.lbf)

engine oil.
Oil capacity
L {US qt, Imp qt)
I Engine oil replacement 3.8 (4.0, 3.4)
Engine oil replacement (with oil filter) I 4.25 (4.5, 3.8)
MDI 035-C

OIL FILTER
OIL FILTER
REPLACEMENT
2. Unscrew the oil filter from the cylinder block.
3. Clean the cylinder block mating surface.

the new filter.
contacts the cylinder block.
6. Tighten the oil filter 112 turn after the filter contacts the
mating surface.
Oil filter capacity: 0.47 liters (0.5 US qt, 0.42 Imp qt)
OIL PAN
OIL PAN
REMOVALIINSTALLATION
1. Remove engine from vehicle. (Refer to Section B2.)
I -
. I
MD1036-C 5BUOD2-008
1. Oil pan 2. Gasket
Removal Note ........................ page D2-7
Inspection ............................... page D2-7
Installation Note ..................... page D2-8
Removal Note
Oil pan
Note
The oil pan fits tightly between the transmission
spacer plate and oil pump tube. Use care when
removing to avoid damaging either part.
INSPECTION
Oil pan
Visually check for cracks, deformation and damage. Re-
pair or replace if necessary.
4BUOD2-013
OIL PAN
i0.16-0.23
4-6mm Lx
in)
CYLINDER
BLOCK
/
REAR MAIN
BEARING CAP
Installation Note
Oil pan
1. Clean the gasket surfaces on the cylinder block and oil
pan.
2. Apply a 4-6 mm (0.164.23 in) bead of sealant to the
joint between the main bearing cap and the cylinder block
and to the joint between the timing chain cover and the
cylinder block as shown in the figure.
3. Apply a 4-6 mm (0.16-4.23 in) bead of sealant to the

cylinder block between the guide pin hole and the timing
I
I
GUIDE PIN
\
CYLINDER
BLOCK I chain cavity as shown in the figure.
4. Position a new oil pan gasket to the cylinder block and
secure with adhesive.
5. Position the oil pan to the cylinder block.
I (3mm (0.1 1 in)
FROM TIMING
CHAIN CAVITY) Note
4-6mm
-6mm Lightly oil the bolt threads before installation.
0 . 1 6 0 . 2 3 in)
(,,.160.23
I I
Tightening torque:
10-14 N-m(1 .O-1.4 kgf-m,7.4-10.3 ft-lbf)

1. Fill with the specified amount and type of engine oil. (Refer to page 02-5.)
OIL PUMP
OIL PUMP
1. Remove the oil pan. (Refer to page D2-7.)
N-rn (kgfm, ft.lbf)
MD1039-A 5BUOD2-010
1. Oil pump 2. Oil pump intermediate shaft
Disassembly 1
Assembly ....................Refer to Section D3
Inspection ................................. page D2-10
Installation Note
Oil pump bolt
1. Apply clean engine oil to the bolts.
2. Install the bolts.
Tiahtening torque:
w
40-55 k r n ('4.1-5.5 kgfm, 29.5--40.5 ft-lbf)

4BUOD2-019
DISASSEMBLY I ASSEMBLY
Refer to Section D3.
OIL PUMP
INSPECTION
Oil Pump
1. Check the inside of the pump housing and the inner and
outer gears for damage or excessive wear.
2. Check the mating surface of the pump cover for wear.
Minor scuff marks are normal, but if the cover, gears, or
housingsurfaces are excessivelyworn, scored,orgrooved,
replace the pump. Inspect the rotor for nicks, burrs or
score marks. Remove minor imperfections with an oil
stone.
Note
With the rotor assembly removed from the pump
and resting on a flat surface, the inner and outer
rotor tip clearance must not exceed the limit with a
feeler gauge inserted a distance of 13 mm (0.5 in).
Clearance: 0.30 mm (0.012 in)
c
MDlO31-A
3. With the rotor assembly installed in the housing, place a
straightedge over the rotor assembly and the housing.
4. Measure the vertical clearance (rotor end play between
the straightedge and both the inner rotor and the outer
race). Maximum clearance must not exceed the limit.
Limit: 0.13 mm (0.005 in)

IGHTEDGE
5. Inspect the relief valve spring to see if it is collapsed or
worn. Check the relief spring tension. If the tension is not
within specification and/or the spring is worn ordamaged,
MDI 032-8 ~BUODI-012 replace the pump. Check the relief valve piston for free
operation in the bore.
Relief spring tension:

28.2 mm (1.1 1 in) / 21-22 kgf (9.1-10.1 Ibf)
Note
Internal components are not serviced. If any com-
ponent is out of specification, the pump assembly
must be replaced.
5BUOD2-011
LUBRICATION
SYSTEM
(4.0L)
INDEX ........................................................... D3- 2

OUTLINE ...................................................... D3- 3
SPECIFICATIONS ..................................... 03- 3
TROUBLESHOOTING GUIDE ..................... D3- 3
OIL PRESSURE ........................................... D3- 4
PREPARATION ......................................... D3- 4
INSPECTION ............................................. D3- 4
ENGINE OIL ................................................. D3- 5
INSPECTION ............................................. D3- 5
REPL.ACEMENT ........................................ 03- 5
OIL FILTER ................................................... D3- 6
REPLACEMENT ........................................ D3- 6
OIL FILTER ADAPTER ................................ D3- 6
REMOVAL 1 INSTALLATION ..................... D3- 6
OILPAW ........................................................ D3- 7
PREPARATION ........................................ D3- 7
INSPECTION ............................................. D3- 8
OIL PUMP ..................................................... D3-11
REMOVAL I INSTALLATION ..................... D3-11
DISASSEMBLY / ASSEMBLY ................... D3-11
INSPECTION (REFER TO SECTION D l )
4BUO03-001
INDEX
INDEX
ENGINE OIL SPECIFICATION

API SERVICE SG ENERGY CONSERVING I1 (ECIl)
TOTAL CAPACITY 4.7 liters {5.0 US qt, 4.2 Imp qt)
I I
MD1007-C 4BUOD3-002
Inspection ............................. page D3-4 Removal / Installation ........... page D3- 7
2. Engine oil Inspection ............................. page D3- 8
Inspection ............................. page D3-5 6. Oil pump
Replacement ........................ page D3-5 Removal / Installation ........... page D3-11
3. Oil filter Disassembly / Assembly ...... page D3-11
Replacement ........................ page D3-6 Inspection ................... Refer to Section D l
4. Oil filter adapter
Removal / Installation ........... page 03-6
OUTLINE
SPECIFICATIONS
-. __2_
Item --\
--
- --
Oil filter type
~ n z n oil
e replacement liters {US qt, Imp qt}
Oil capacity
-
p
-p
p
.
Oil pump Relief valve spring tension

--
{I 3.6-1 4.7 lbf)
Energy Conserving 11 (ECII)

SAE 1OW-30
SAE 5W-30
MD1008-C 4BUOD3-019
Note
need to be driven 16 km (1C) miles) or more to relearn the strategy.
4BUOD3-003
Problem Possible Cause Remedy Page
--
Engine hard starting Improper engine oil Replace
Insufficient engine oil Add oil - - f 5
D3- 5
Excessive oil 1 011 working up or down Refer to Sectlon B3 -
consumption I Oil leakage Repa~r -
Oil pressure drop 1 lnsuffic~entoil Add oil D3- 5
011 leakage Repair -
1 Worn andlor damaged o ~pumpl Replace D3-11
Worn plunger (inside oil pump) or weak spring Replace D3-11
-
Clogged
Excess~ve
oilmaln
strainer
bearing or connecting rod - p ~ Clean
~ ~ c t l B3
o n
bear~ngclearance -
-
pp
Oil pressure 011pressure drop As described above

gauge (meter) does Malfunction of 011pressure gauge Refer to 1997 B-series BETM -
not operate Malfunction of electrical system Refer to 1997 B-series BETM -
1
--
Warning lamp Malfunction of oil level switch Refer to 1997 B-series BETM -
illuminates while Malfunction of electrical system Refer to 1997 B-series BETM -
engine is running Insufficient engine oil Add oil D3 5
MD2022 D 6BUOD3 001
OIL PRESSURE
OIL PRESSURE
PREPARATION
SST
1 49 0187 280 1 For I
2. Screw the SST into the oil pressure sensor installation

hole.
4.Run the engine at 2000 rpm, and note the gauge
readings.
Oil pressure: 2 7 6 4 13 kPa (2.8-4.2 kgf/cm2,

40-60 psi) -2,000 rpm

6.Apply sealant to the oil pressure sensor threads as

7. Remove the SST and install the oil pressure sensor.
Tightening torque:
11-16 N-m(1.1-1.7 kgf-m,8-12 ft.lbf)
ENGINE OIL
KEEP THE OIL IN THlS RANGE

m
I INSPECTION
2. Warm up the engine to normaloperating temperature and
stop it.
'+
OIL LEVEL MAY BE IN THlS
RANGE AFTER AN OIL CHANGE condition.
I I
1 5. Add or replace oil as necessary.
Note
MB1250-C 5HUOD3-004
The oil level should be filled to the top of the dashed
part of the oil dipstick.
REPLACEMENT
Warning
--
stop it.
2. Remove the oil filter cap and the oil pan drain plug.
4. Install a new gasket and the oil pan drain plug.
FRONT OF ENGINE
Tightening torque:
MD1048-A 4EIUOD3-006
21-28 N.m (2.1-2.8 kgf-m, 15--21 ft-lbf}

engine oil.
Oil capacity liters {US qt, Imp qt}
I Engine oil replacement I 3.8 14.0,3.4) I
I Engine oil replacement (with oil filter) I 4.7 (5.0,4.21 I

OIL FILTER, OIL FILTER ADAPTER
OIL FILTER
REPLACEMENT
2. Unscrew the oil filter from the oil filter adapter.
3. Use a clean rag to wipe off the mounting surface on the oil
filter adapter.
the new filter.
contacts the oil filter adapter.
6. Tighten the oil filter 112 turn.
Oil filter capacity: 0.9 liters (1.0 US qt, 0.9 Imp qt)
OIL FILTER ADAPTER

L I
MD1010-B 4BUOD3-008
1. Oil filter
Replacement ................................... above
2. Through bolt
3. Oil filter adapter
OIL PAN
OIL PAN
PREPARATION I
SST
49 UNOl 136 0 For

a
d
rear oil
seal
Rear main seal m installation
oil seal pilot and -1
seal replacer 1 t
@
2. Remove the engine assembly. (Refer to Section 63.)
3. Mount the engine on an engine stand with the oil pan facing up.
MD1012-C 5BUOD3-002
1. Spacer 4. Baffle
Installation Note ................... page D3- 9 Removal Note ...................... page D3- 8
2. Oil pan Installation Note ................... page D3- 9
Installation Note ................... page D3-10 5. Main bearing cap
3. Oil pump Removal Note ...................... page D3- 8
Removal Note ...................... page D3- 8 Installation Note ................... page D3- 8
Installation Note ................... page D3- 9 6. Rear oil seal
Disassembly / Assembly ...... page 03-1 1 Installation Note ................... page D3-10
OIL PAN -- -
Removal Note
Oil pump
1. Remove the screws.
2. Remove the oil pump and gasket.
Baffle
1. Remove the nuts.
2. Remove the baffle.
Main bearing cap
2. Remove the main bearing cap.
3. Remove and discard the rear oil seal.
INSPECTION
Oil pan
~ ' l s u a l check
l~ for cracks, deformation and damage.
Repair or replace if necessary.
4BUOD3-013
Installation Note
Note
Remove all foreign material from all contact sur-
faces.
4BUOD3-014
Main bearing cap

1. Apply sealant to the main bearing cap.
2. Coat the main bearing insert and the main journal with oil.
3. Install the main bearing cap.
Caution
Main bearing cap must be aligned and installed
properly to seal. Misalignment will cause an oil
leak.
4. Tighten the new main bearing cap bolts.
Tightening torque:
90-104 N.m (9.1-10.6 kgf-m, 6 6 7 7 ft.lbf)
OIL PAN
Baffle
I . Install the baffle.
Tightening torque:
17-21 N-m(1.8-2.0 kgfem, 13-1 5 ft-lbf)
I I
MD1013-A 4BUOD3-017
1
Oil pump
Note
Fill the oil pump with oil and rotate the oil pump
shaft to prime the oil pump.
I . Install the oil pump.

Tightening torque:
17-21 N.m (1 3-2.0 kgf.m, 13--15 ft-lbf)
MDO
I -IA 40~0~3-018 Spacer
Note
The spacers are usedto delete any gap betweenthe
oil pan and transmission.
1. Use the following steps to determine spacer thickness.

STRAIGHTEDGE (1) Attach the oil pan to the cylinder block.
(2) Place straightedge across the cylinder block so it
hangs over the mounting pad.
(3) Measure the clearance at point A.
(4) Repeat steps 1 through 3 for other mounting pad.
2. Install the correct spacers.
Caution
Incorrect spacers can cause oil pan damage and/or
PADS an oil leak.
Measured Gap Spacer Required
mm
--- None None
----
0.01 0 Yellow
--
0.020 Blue
0.030 Pink
OIL PAN
Oil pan
1. Apply a bead of sealant in the oil pan gasket groove at the
radius areas at the front and rear of the oil pan.
2. lnstall the gasket in the groove of the oil pan.
3. Apply a bead of sealant on top of the gasket at the radius
areas at the front and rear of the oil pan.
4. Install the oil pan.
5. lnstall and finger tighten the oil pan nuts.
6. Align the rear of the oil pan with the rear of the cylinder
block.
Note
Appropriate spacers should be installed if the rear
of the oil pan cannot be aligned within .010 inch of
the engine block.
7. Install and finger tighten the oil pan bolts and nuts.
4BUOD3-021
Rear oil seal

1. Apply oil to the rear oil seal.
2. lnstall the rear oil seal, using the SST.
Note
It is recommended that no engine oil be added for
24 hours.
OIL PAN, OIL PUMP
Install the engine assembly. (Refer to Section B3.)
Note
Be sure to install and tighten the transmission oil pan bolts.
Tightening torque:
38-51 N-m(3.8-5.2 kgf-m, 28--38 ft-lbf)
Be sure to tighten the oil pan bolts and nuts.
Tightening torque:
7-10 N.m (0.69-4.96 kgfem, 5-7 ft.lbf}
OIL PUMP
REMOVAL I INSTALLATION
Refer to page D3-8.
DISASSEMBLY IASSEMBLY
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly, referring to Assembly Note.
MD1049-A
1. Cover 4. Plug
2. Rotor and shaft 5. Spring
Inspection ................................. Section D l 6. Plunger
Assembly Note ..................... page D3-12
3. Outer race
Assembly Note ..................... page D3-12
pl
OIL PUMP
Assembly Note
Outer race, rotor and shaft assembly
RAND
SHAFT ASSY Install t h e outer race and t h e rotor and s h a f t a s s e m b l y .
Caution
Make sure the dimple (identification mark) on th
OUTER outer race is facing outward, on the same side as
IDENTIFICATION RAGE the identification mark on the rotor. The rotor and
MARKS
shaft assembly and the outer race are serviced as
an assembly. One part should not be replaced
HOUSING without replacing the other.
,-,
-,
COOLING SYSTEM
(2.3L)
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E l .1
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E l .3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .E l .3
TROUBLESHOOTING GUIDE . . . . . . . . . . . .E l .3
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . E l .4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . E l .4
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . E l .5
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . E l .5
RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . El .6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . El .6
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E l .7
REMOVAL / INSTALLATION . . . . . . . . . . . . El .7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . E l .8
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . El .9
REMOVAL / INSTALLATION . . . . . . . . . . . . El .9
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . El .10
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . El .12
REMOVAL / INSTALLATION . . . . . . . . . . . . E l .12
COOLING FAN AND CLUTCH . . . . . . . . . . . . E l .13
REMOVAL / INSTALLATION . . . . . . . . . . . . E l 13 .
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . E l .14
REMOVAL 1 INSTALLATION . . . . . . . . . . . . E l .14
6BUOE1-200
INDEX
INDEX
ENGINE COOLANT TOTAL CAPACITY:

WITH A/C 6.8 LITERS (7.2 US qt, 6.0 Imp qt}
WITHOUT A/C 6.2 LITERS (6.5US qt, 5.4
Imp qt)
ME1027-C
1 . Engine Coolant 4. Thermostat
Inspection .............................. page E 1-4 Removal / Installation ............ page E l - 9
Replacement ......................... page E 1-5 Inspection .............................. page E l -10
Air Bleeding ........................... page E 1-5 5. Water Pump
2. Radiator Cap Removal / Installation ............ page E l -12
Inspection .............................. page E 1-6 6. Cooling Fan and Clutch
3. Radiator Removal / Installation ............ page E l -13
Removal / Installation ............ page E l -7
Inspection .............................. page E l -8
OUTL,INE,TROUBLESHOOTING GUIDE
OUTLINE
SPECIFICATIONS
Cooling system
Coolant capacity liters {US qt, Imp qt}
2.3' -1
Water-cooled, forced circulation
Without A/C 6.2 {6.5, 5.4)
With A/C 6.8 (7.2, 15.0}
Centrifugal, V-ribbed belt driven
Water pump
Water seal Unif~edmechanical
-- - -
Wax, bottom-bypass
----
Openlng temperature "C {OF} ---
89" { I 92")
Thermostat -
Full-open temperature -. "C {OF} ' I00° {212"}

Full-open lift
TYpe
-
mm {in}
.-
3.2 {0.126} minimum
Corrugated fin
Belt driven
EI =
Cooling fan -- --
No. of Blades 8
ME1002-E 5BUOE1-010
Note
4BUOE1-004
r
I Problem 1 Possible Cause I Action I Page I
Overheating Coolant level insufficient Add El- 4
Coolant leakage Repair or replace -
Radiator fins clogged Clean El- 8
Radiator cap malfunction Replace El- 6
Thermostat malfunction Replace El- 9
Water passage clogged Clean El- 5
Water pump nialfunction Replace E l -12
Worn or broken drive belt Replace Section G
Cooling fan inoperative ReDlace E l -13
I Corrosion lm~uritiesin coolant Re~lacecoolant , EI-5 1
ME1020-D
ENGINE COOLANT
ENGINE COOLANT
INSPECTION
Warning
hot.
it.
then remove it.
4BUOE1-006
I I

Coolant Quality
necessary.
5BUOE1-004
Coolant Leakage
2. Apply 83-1 10 kPa (0.9-1.1 kgf/cm2, 12-16 psi) of
pressure to the system.
3. Verify that the pressure is held for at least 2 minutes. If
not, check the system for coolant leakage.
COOLANT PROTECTION 4BUOE1-009
SPECIFIC
GRAVITY Coolant Protection
Caution
Do not use alcohol-based coolant. Use only soft
(demineralized) water in the coolant mixture.
1 . Measure the coolant temperature and specificgravity with

a thermometer and a hydrometer.
2. Determine the coolant protection by referring to the graph
as shown.
as necessary.
Antifreeze solu ixture percentage
-10 0 10 20 30 40 50 60 70 80 90
(141 (321 (50) (68) (86) (104) (122) (140) (158) (176) (194) Coolant protection
COOLANT TEMPERATURE "C ("F] Above -24°C {-I 1OF}
Above -52°C (-62°F)
60
40 60
40 -I
ENGINE COOLANT
REPLACEMENT
Warning
hot.
it.
Caution
Do not use alcohol or methanol-based coolant.
mixture.

are gone; then, let the system drain completely.
m
Tightening torque:
2.0-2.7 N.m (20-27 kgf.cm, 18-25 in-lbf)
5. Fill with the proper amount and mixt~~re

of coolant. (Refer
to page E l -4.)
'
Coolant capacity:
With AIC: 6.8 liters (7.2 US qt, 6.0 Imp qt)
Without AIC: 6.2 liters (6.5 US qt, 5.4 Imp qt)
8. Install the radiator cap.
9.Verify that the coolant in the reservoir is at the COLD
FlLL mark. Add coolant as necessary.
AIR BLEEDING
@-
When refilling the coolant system after draining the
coolant, perform the following:
1. Slowly pour the coolant into the radiator up to the filler
neck.
2. Fill the coolant reservoir to the C0L.D FlLL mark.
3. Install the radiator cap securely and start the engine.
4. Run the engine at idle speed until it reaches normal
-7- !n operating temperature.
Caution
~~1003-B ~BUOEI-012 If the temperature increases beyond normal, there
is excessive air in the system.
Stop the engine and allow it to cool; then repeat
steps 1-3.
5. Run the engine at 2,000 rpm for 3-4 minutes.

6. Stop the engine and wait until it cools down.
7. Repeat steps 1-6; then go to step 8.
ENGINE COOLANT, RADIATOR CAP
Warning
Do not remove the radiator cap until the engine is
cool.
Remove the radiator capcarefullyand slowly, using
a thick rag.
8. Remove the radiator cap, and verify that the engine

coolant level is near the filler neck. If not, repeat
steps 1-8.
9. Ensure that the coolant in the reservoir is at the COLD
RADIATOR CAP
INSPECTION
Radiator Cap Valve
1. Remove all foreign matter (such as water residue) from
between the radiator cap valve and the valve seat.
2. Attach the radiator cap to a radiator cap tester (commer-
cially available) and apply pressure gradually to 83 kPa
(0.9 kgf/cm2, 12 psi).
3. Verify that the pressure is held for at least 10 seconds.
Negative Pressure Valve

1. Pull the negative pressure valve to open it. Verify that it
closes completely when released.
2. Check for damage of the contact surfaces and for cracked
and deformed seal packing.
3.Replace the radiator cap if necessary.
RADIATOR
RADIATOR
Caution
Positionthe hose clamp in the original position on the hose, and squeeze the clamp lightly with
large pliers to ensure a good fit.

2. Drain the engine coolant.
I I
ME1039-8 5BUOE1-005
I . Overflow hose 4. Transmission cooler lines
2. Fan shroud Installation Note ..................... page E l -8
3. Radiator hose, upper and lower 5. Radiator
Installation Note ..................... page E l -8 Inspection ............................... page E l -8
RADIATOR
INSPECTION
Radiator
Check for the following and repair or replace as neces-
sary.
1. Cracks, damage and water leakage.
2. Bent fins. (Repair with a screwdriver.)
3. Distorted and bent radiator inlet and outlet.
4BUOE1-016
lnstallation Note
Transmission cooler lines (ATX)
Note
When installing a new radiator on automatic
transmission equipped vehicles, transfer the
transmission cooler line fittings from the old
radiator and install them on the new radiator.
5BUOE1-006
Radiator hose, upper

Position the hose on the radiator neckso that the stripe on
the hose is at the 12 o'clock position.
4BUOE1-017
Radiator hose, lower

Position the hose on the radiator with the stripe on the
hose at the 6 o'clock position.
4BUOE1-018

1. Fill the radiator with the specified amount and type of engine coolant. (Refer to page E l -4.)
4. Bleed the cooling system. (Refer to page E l -5.)
THERMOSTAT
THERMOSTAT
Caution

3. Disconnect the heater return hose from the thermostat housing.
FRONT OF ENGINE \
GASKET, REPLACE
1. Thermostat cover 3. Gasket

Installation Note ...................... page E l -1 1 Installation Note ..................... page E l -1 1
2. Thermostat
Inspection ............................... page E l -1 0
Installation Note ...................... page E l -1 1
THERMOSTAT
INSPECTION
Thermostat
Mechanical
1. Visually check that the thermostat valve is airtight.
2. Place the thermostat and a thermometer in water.
3. Heat the water and check the following.
Initial-opening temperature:
89°C (192°F)
Full-open temperature:
ME1028-A 5BUOE1-014 100°C (212°F)
Full-open lift:
3.2 mm (0.126 in) minimum
4. If the gasket surface of the thermostat is damaged,

replace the thermostat.
Electrical
Note
This test should be performed at temperatures less
than 37.S°C (100°F) ambient air.
1. Hook up the New Generation Star (NGS) tester. (Refer to

Section FT.)
Note
For an accurate test reading the engine cooling fan
must be running.
2. Make sure AIC switch is in OFF position.

3. Place the vehicle in Park (P) or Neutral (N).
4. Start the vehicle and allow the engine to run for 2 minutes.
5. Record the Engine Coolant Temperature (ECT) sensor
voltage reading.
6. Record the ECT sensor voltage reading every 60
seconds.
7. When ECT voltage reverses direction trend or changes
slightly (0.03 volt or less), thermostat has opened.
8. Refer to the chart for the voltage and corresponding
temperature to verify thermostat operation.
Temperature OC { O F ] PID Volts
(1) If the opening voltage is between 0.75 volts (82.2"C

(180°F)) and 0.5 volts (90.6"C (195"F)), the
thermostat is operating.
(2) If the opening voltage is not within this range, replace
the thermostat.
Installation Note
Gasket
Position the gasket on the cylinder head before the
thermostat is installed.
6BUOE1-002
Thermostat
Note
It is critical that the correct thermostat installation
alignment is made, to provide coolant flow to the
heater.
Install the thermostat into the thermostat cover and

rotate the thermostat into the water outlet connector in
a clockwise direction to secure the thermostat to the
connector.
4BUOE1-023
Thermostat cover
Install the thermostat cover.
Tightening torque:
20-30 N-m (1.9-2.9 kgf.m, 14--21 ftelbf}
4BUOE1-024

WATER PUMP
WATER PUMP
Caution
Do not disassemble the water pump. If a problem is found, replace the water pump assembly.

3. Remove the two fan shroud attaching screws and lift the fan shroud out of the two lower attaching clips.
4. Remove the four cooling fan retaining bolts, the cooling fan and fan shroud.
5. Lift the drive belt tensioner pulley in a counterclockwise direction and remove the drive belt.
7. Disconnect the heater hose from the water pump.
8. Remove the timing belt outer cover.
9. Disconnect the lower radiator hose from the water pump.
ENGINE
1
MElO21-C 5BUOE1-008
1. Water pump
2. Gasket
COOLING FAN AND CLUTCH

I
ME1011-B 5BUOE1-00
1. Fan shroud
2. Cooling fan clutch
3. Cooling fan
ENGINE BLOCK HEATER - - -
ENGINE BLOCK HEATER

1. Block heater cable

Removal Note . . . . . . . . . . . .page E l -15
2. Block heater
Removal Note . . . . . . . . . . . . page E l -15
Installation Note . . . . . . . . . . . page E l -15
ENGINE BLOCK HEATER
Removal Note
Block heater cable
Use door trim panel removing tool or equivalent to remove
wiring from battery tray, inner fender, engine mount brackets
and cylinder block.
6BUOE1-101
Block heater
1. Note position that element is pointed (e.g., 6 o'clock, 12
o'clock) when removing heater.
2. Clean inside diameter of core plug hole machined surface
and hole entrance. Remove any burrs at hole entrance to
avoid damage to O-ring.
3. Cover rubber O-ring with a liberal coating of premium
long-life grease or equivalent.
6BUOE1-102
Installation Note
Block heater
Insert heater in core plug hole in same position as it was
removed and tighten.
Tightening torque:
1.6-1.8 N .m {I6-1 8 kgf - cm, 1 4--16 in - Ibf)
COOLING SYSTEM
(3.0L)
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E2 .2
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2 .3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . E2 .3
TROUBLESHOOTING GUIDE . . . . . . . . . . . . E2 .3
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . .E2 .4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . E2 4 .
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . E2 .5
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . .E2 6 .
RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . E2 7 .
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . .E2 .7
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E2 .8
REMOVAL / INSTALLATION . . . . . . . . . . . . E2 .8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . E2 .9
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . E2 .10
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . E2 .11
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . E2 .13
REMOVAL IINSTALLATION . . . . . . . . . . . . E2 .13
COOLING FAN AND CLUTCH . . . . . . . . . . . . E2 .15
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . E2 .15
REMOVAL I INSTALLATION . . . . . . . . . . . . E2 .15
ENGINE BLOCK HEATER . . . . . . . . . . . . . . .E2 .17
REMOVAL / INSTALLATION . . . . . . . . . . . .E2 .17
6BUOE2-100
INDEX
INDEX
I
ME9601 -C 5BUOE2-001
1. Engine coolant 4. Thermostat
lnspection .............................. page E2-4 Removal / lnstallation ............ page E2-10
Replacement ......................... page E2-5 lnspection .............................. page E2-11
Air bleeding ........................... page E2-6 5. Water pump
2. Radiator cap Removal 1 lnstallation ............ page E2-13
lnspection .............................. page E2-7 6. Cooling fan and clutch
3. Radiator Removal I lnstallation ............ page E2-15
Removal 1 lnstallation ............ page E2-8
lnspection .............................. page E2-9
OUTLINE
SPECIFICATIONS
~ t e i m - _ _ _ _
Cooling system Water-cooled, forced circulation
Coolant capacity liters {US qt, Imp qt} Without A/C 9.0 I9.5, 7.9)
With A/C 9.6 (10.2, 8.5)
Water seal Unified mechanical seal
Thermostat
1ooO(212")
3.2" {O.126) minimum
--
Corrugated fin
Belt driven
Cooling fan
Number of blades
Note
4BUOE2-004
TROUBLESHOOTING GLJIDE
I Problem Possible Cause I Action I page I
Overheating Coolant level insufficient Add E2- 4
Coolant leakage Repair or replace -
Radiator fins clogged Clean E2- 9
Radiator cap malfunction Replace E2- 7
Thermostat malfunction Replace E2-10
Water passage clogged Clean E2- 4
Water pump malfunction Replace E2-13
Cooling fan inoperative Replace E2-15
Corrosion lmourities in coolant Re~lacecoolant E2- 5
ENGINE COOLANT
ENGINE COOLANT
INSPECTION
Warning
is hot.
it.
then remove it.
4BUOE2-006

5BUOE2-002
Coolant Quality
necessary.
5BUOE2-003
Coolant Leakage
2. Apply 83-1 10 kPa (0.9-1.1 kgf/cm2, 12-1 6 psi) of
4BUOE2-009
ENGINE COOLANT
Coolant Protection
COOLANT PROTECTION
SPECIFIC Caution
GRAVITY Do not use alcohol-based coolant. Use only soft
(demineralized) water in the coolant mixture.
1. Measure the coolant temperature and specific gravity

with a thermometer and a hydrometer.
2. Determinethe coolant protection by referring to the graph
as shown.
as necessary.
Antifreeze solution mixture percentage
- G I
I
Coolant protection
Above -24°C (-1 1OF) I
Volume percentage
60 1 40 I
I Above -52°C {-62°F) 40 60
ME1007-D
COOLANT TEMPERATURE "C ("F)
I I
ME1005-B 413UOE2-010
REPLACEMENT
Warning
hot.
it.
Caution
mixture.
ENGINE COOLANT
Tightening torque:
2.0-2.7 N-m (20-27 kgf-cm, 18-25 inelbf)
5. Fill with the proper amount and mixture of coolant. (Refer

to page E2-5.)
I I
ME1006-A 5BUOE2-010
Coolant capacity:
With AIC: 9.6 Liters (10.2 US qt, 8.5 Imp qt)
Without AIC: 9.0 Liters (9.5 US qt, 7.9 Imp qt)
9. Verify that the coolant in the reservoir is at the COLD FlLL
AIR BLEEDING
When refilling the cooling system after draining the
coolant, perform the following:
neck.
2. Fill the coolant reservoir to the COLD FlLL mark.
operating temperature.
Caution
If the temperature increases beyond normal, there
dE1003-B 4BUOE2-012
steps 1-3.
5. Run the engine at 2,000 rpm for 3-4 minutes.

Warning
Do not remove the radiator cap until the engine is
cool.
Remove the radiator cap carefully and slowly,
using a thick rag.

coolant level is near the filler neck. If not, repeat
steps 1-8.
FlLL mark. Add coolant as necessary.
RADIATOR CAP
RADIATOR CAP
INSPECTION
Radiator Cap Valve
1. Remove all foreign matter (such as \ ~ a t e residue)
r from
(0.9 kgfIcm2, 12 psi).

2. Check for damage to the contact surfaces and for cracked
or deformed seal packing.
3. Replace the radiator cap if necessary.
E2 RADIATOR
RADIATOR
Caution
Positionthe hose clamp in the original positionon the hose, and squeeze the clamp lightly with

3. Loosen the drive belt tension by lifting the tensioner pulley in the clockwise direction.
5. Disengage the constant tension hose clamps from the bypass fitting connection.
8. Install the drive belt.
I I
ME9602-B 7BUOE2-001
1. Overflow hose 5. Transmission cooler lines
2. Fan shroud Installation Note .................... page E2-9
3. Radiator hose, upper 6. Radiator
Installation Note .................... page E2-9 Inspection ............................ page E2-9
4. Radiator hose, lower
Installation Note .................... page E2-9
RADIATOR
INSPECTION
Radiator
sary:
2. Bent fins (repair with a screwdriver).
6BUOE2-001
Installation Note
Transmission Cooler Lines
Note
When installing a new radial:or, transfer the
transmission cooler line fittings from the old
radiator and install them on the new radiator.
5BUOE2-005

Position the hose on the radiator neckso that the stripe on
4BUOE2-017

1. Position the hose on the radiator with the stripe on the
2. Ensure that the bypass hose on lower radiator hose is
routed so that it adequately clears the water pump pulley.
3. Reinstall the hose clamps.

1. Fill the radiator with the specified amount and type of engine coolant. (Refer to page E2-5.)
4. Bleed the cooling system. (Refer to page E2-6.)
THERMOSTAT
THERMOSTAT
Caution
Position the hose clamp in the original position on the hose, and squeeze the clamp lightly
with large pliers to ensure a good fit.

GASKET,
REPLACE
N-m (kgf.m, ft.lbf)

ME1014-B 4BUOE2-020
1. Radiator hose, upper 4. Gasket
2. Thermostat cover Installation Note .................... page E2-12
3. Thermostat
Inspection .............................. page E2-1 1
THERMOSTAT
INSPECTION
Thermostat
Mechanical
1. Visually check that the thermostat valve is airtight.
3. Heat the water and check the following:
Initial-opening temperature: 89°C {192"F)

Full-open temperature: 100°C (212°F)
Full-open lift: 3.2 mm (0.126 in) minimum
MEIO~~-A
4. If the gasket surface of the therrr~ostat is damaged,
5 ~ ~ 0 ~ 2 . 0 4 ~
Electrical
Note
This test should be performed at temperatures less
than 37.8"C (100°F) ambient air,.
1. Hook up the New Generation Star (N'GS)tester. (Refer to

Section FT.)
Note
must be running.
2. Make sure A/C switch is in OFF position.

3.Place the vehicle in Park (P) or Neutral (N).
voltage reading.
6. Record the ECT sensor voltage reading every 60
seconds.
7. When ECT voltage reverses direction trend or changks
Coolant
Temperature O C { O F ) PID Volts
21.7{71)
42.8 {l09)
70.6 {l59)

(180°F)) and 0.5 volts (90.6OC (195"F)), the
(2) If the opening voltage is not within this range, replace
the thermostat.
Installation Note
Gasket
4BUOE2-022
Thermostat
Note
alignment is made, to provide coolant to the heater.
Install the thermostat into the thermostat cover and rotate

the thermostat into the water outlet connector in a clock-
wise direction to secure the thermostat to the connector.
THERMOSTAT ASSEMBLY SHOWN IN
PLACE IN WATER OUTLET CONNECTOR Thermostat cover
Install the thermostat cover,
Tightening torque:
20-30 N-m(2.1-4.1 kgf.m, 1 5 2 2 ftelbf)
4BUOE2-024

WATER PUMP
WATER PUMP
Caution

3. Remove the fan shroud attaching screws and lift the fan shroud out of the two lower attaching clips.
4. Remove the cooling fan retaining bolts, the cooling fan and fan shroud.
5. Loosen the water pump pulley bolts.
6. Lift the drive belt tensioner pulley in a clockwise direction and remove the drive belt.
8. Remove the generator adjusting arm and brace from the throttle body.
9. Disconnect the heater hose from the water pump.
10. Rotate the belt adjuster out of the way.
12. Inspect all parts and repair or replace as necessary.
I I
ME1016-A 4BUOE2-026
1. Water pump 2. Gasket
Installation Note ..................... page E2-14 Installation Note ..................... page E2-14
WATER PUMP
Installation Note
Gasket
1. Clean the gasket surface on the timing cover and the
water pump.
Note
Use carewhen scraping aluminum surfaces because
gouging could form leak paths.
2. Apply sealant to both sides of a new gasket and place it on

the water pump.
4BUOE2-027
Water Pump
Install the water pump bolts.
Bolt length:
(A) Length: M8 x 1.25
( 0 ) Length: M6 x 1.OO
Tightening torque:
(A) 25 N-m(2.7 kgf-m, 19 ft.lbf)
( 6 )10 N-m(1.0 kgf-m, 7 ft-lbf)
Note
Apply clean engine oil to all bolt and stud threads
before installation.

4BUOE2-029
1. Cooling fan 2. Clutch

Removal Note ................................. below
Removal Note
Cooling fan
1. Remove the two fan shroud attaching screws and lift the
fan shroud out of the two lower attaching clips.
2. Remove the nut attaching the clutch to the water pump.
Caution
The nut which attaches the clutch to the water
pump shaft has a left-hand thread and must be
rotated clockwise for removal.
Installation Note
Cooling fan
1. Install the cooling fan on the water pump.
Tightening torque:
6--8 N.m (61.2-41.6 kgf-cm, 53-70 in-lbf)
2. Install the clutch on the water pump.
Tightening torque:
41-1 35 N m 14.1-1 3.8 kgf .m, 30-1 00 ft .lbf)
Caution
rotated counterclockwise for installation.
ENGINE BLOCK HEATER
ENGINE BLOCK HEATER
Removal
e 1 lnstallation

- Removal Note . . . . . . . . . . . . . page E2-2
2. Block heater
Removal Note . . . . . . . . . . . . . page E2-2
Installation Note . . . . . . . . . . . . page E2-2
Removal Note
Block heater cable
and cylinder block. 6~~0~2-103
Block heater
6BUOE2-104
lnstallation Note
Block heater
Tightening torque:
1.6-1.8 N - m (16-18 kgfecm, 14-16 in-Ibf)
6BUOE2-105
COOLING SYSTEM
(4.0L)
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E 3 - 2
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E 3 - 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . E3 .3
TROUBLESHOOTING GUIDE . . . . . . . . . . . . E3 .3
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . E3 .4
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . E3 .4
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . E3 .5
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . E3 .6
RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . .E3 .7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . .E3 .7
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E3 .8
RENIOVAL IINSTALLATION . . . . . . . . . . . . E3 .8
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . E3 .10
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . E3 .11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . E3 .12
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . E3 .14
REMOVAL I INSTALLATION . . . . . . . . . . . . E3 .14
COOLING FAN AND CLUTCH . . . . . . . . . . . . E3 .15
PREPARATION . . . . . . . . . . . . . . . . . . . . . . . E3 .15
ENGINE BLOCK HEATER . . . . . . . . . . . . . . . E3 17 .
REMOVAL / INSTALLATION . . . . . . . . . . . . E3 17 .
6BUOE3-001
INDEX
INDEX
ENGINE COOLANT TOTAL CAPACITIES:

WITH AIC: 8.1 LITERS {8.6US qt, 7.2 Imp
WITHOUT A/C: 7.4 LITERS 17.8 US qt, 6.5
1 I
ME1030-D 5BUOE3-001
1. Engine coolant 4. Thermostat
Inspection ............................. page E3- 4 Removal / Installation ........... page E3-11
Replacement ........................ page E3- 5 Inspection ............................. page E3-12
Air bleeding .......................... page E3- 6 5. Water pump
2. Radiator cap Removal / Installation ........... page E3-14
Inspection ............................. page E3- 7 6. Cooling fan and clutch
3. Radiator Removal / Installation ........... page E3-15
Removal 1 Installation ........... page E3- 8
Inspection ............................. page E3-10
OUTLINE, TROUBLESHOOTING GUIDE E3
OUTLINE
SPECIFICATIONS
Engine
C- With AIC
4.0 liter
Without AIC
I Coolina svstem I Water-cooled, forced circulation I
I Coolant capacity liters {US qt, Imp qt} 1
Water pump TYpe Centrifugal, V-ribbed belt-driven
Water seal Unified mechanical seal
Type Wax, bottom-bypass
Opening temperature "C { O F } 89 (1921
Thermostat
Full-open temperature "C { O F } 100 {212}
Full-o~enlift mm {in) 3.2 (0.1261 minimum
I Radiator I Tvpe I Corruaated fin I
I _ .. . I Type
-. 1 Belt driven
I Tan I No. of Blades 7
Note
4BUOE3-004
I Problem I Possible Cause I Action
Ov rheating Coolant level insufficient Add E3- 4
Coolant leakage Repair or replace
Radiator fins clogged Clean E3-10
Radiator cap malfunction Replace E3- 7
Thermostat malfunction Replace E3-11
Water passage clogged Clean E3- 5
Water pump malfunction Replace E3-14
Cooling fan inoperative Replace E3-15
Corrosion ( Impurities in coolant T G c o o ~ a n t
ME1026-E
E3 ENGINE COOLANT
ENGINE COOLANT
INSPECTION
Warning
hot.
it.
then remove it.
4BUOE3-006

Coolant Quality
necessary.
4BUOE3-008
Coolant Leakage
2. Apply 83-1 10 kPa (0.9-1.1 kgf/cm2, 12-1 6 psi) of
4BUOE3-009
ENGINE COOLANT E3
0 7 Coolant Protection
COOLANT PROTECTION Caution
SPECIFIC Do not use an alcohol-based coolant. Use only soft
GRAVITY
1.100 (demineralized) water in the coolant mixture.
1.090
1. Measure the coolant temperature and the specific gravity
1.080 with a thermometer and a hydrometer.
1.070
2. Determine the coolant protection by referringto the graph,
as shown.
1.060 3. If the coolant protection is not proper, add water or
1.050 coolant, as necessary.
1.040 Antifreeze solution mixture percentage
1.030
1.020
1.010
I
Coolant protection
Above -24°C (-1 1OF) I
Water
60
1
Volume percentage
1
Coolant
40 I
1.ooo I Above -52°C (-62°F) 40
0 L l I l I l l I I l l ME1007-D ~;LJOE3-01!
-10 0 10 20 30 40 50 60 70 80 90
(14) (32) (50) (68) (86) (104) (122) (140) (158) 1176) (194)
REPLACEMENT
Warning
is hot.
Wrap a thick cloth around1 the cap when
loosening it.
Caution
Do not use an alcohol or methanol-based coolant.
mixture.
E3 ENGINE COOLANT
Tightening torque:
2.0-2.7 N.m (20-27 kgf-cm, 18-25 in.lbf)
5. Fill with the proper amount and mixture of coolant. (Refer

to page E3-5.)
Coolant capacities:
With AIC: 8.1 liters (8.6 US qt, 7.2 Imp qt)
Without AIC: 7.4 liters (7.8 US qt, 6.5 Imp qt)
9. Verify that the coolant in the reservoir is at the COLD FlLL
AIR BLEEDING
When refilling the coolant system after draining the cool-
ant, perform the following:
neck.
2. Fill the coolant reservoir to the COLD FlLL mark.
Caution
If the temperature increases beyond normal, there
ME1003-6 4BUOE3-013
steps 1-3.
ENGINE COOLANT, RADIATOR CAP E3
5. Run the engine at 2,000 rpm for 3-4 minut s.
Warning
Do not remove the radiator cap [until the engine is
cool.
Remove the radiator cap carefully and slowly, us-
ing a thick rag.

coolant level is near the filler neck. If not, repeat steps
1-8.
RADIATOR CAP
INSPECTION
Radiator Cap Valve
1. Remove all foreign matter (such as vvater residue) from
(0.9 kgfIcm2, 12 psi).

2. Check for damage of the contact surfaces and for cracked
and deformed seal packing.
3. Replace the radiator cap, if necessary.
RADIATOR
RADIATOR
Caution
Position the hose clamp in the original position on the hose, and squeeze the clamp lightly with

RADIATOR E3
I I
ME1037-C 6BUOE3-004
I.Overflow hose 5. Transmission cooler lines
2. Fan shroud Installation Note .............................. page E3-10
3. Radiator hose, upper 6. Radiator
Installation Note .............................. page E3-10 Inspection ........................................ page E3-10
4. Radiator hose, lower
Installation Note .............................. page E3-10
E3 RADIATOR
INSPECTION
Radiator
sary:
2. Bent fins (repair with a screwdriver).
6BUOE3-005
lnstallation Note
Note
When installing a new radiator, transfer the oil
cooler line fittings from the old radiator and install
them on the new radiator.
5BUOE3-003

Positionthe hose on the radiator neck so that the stripe on
4BUOE3-018

Position the hose on the radiator with the stripe on the
4BUOE3-019

6BUOE3-006
THERMOSTAT
THERMOSTAT
Caution

GASKET
nc~laci q4 I(fPi
' "y' VIEW A \

I I
ME1024-C 6BUOE3-007
1. Radiator hose, upper 4. Gasket
2. Thermostat cover Installation Note ................... page E3-13
Installation Note ................... page E3-13 5. Sealing ring
3. Thermostat Installation Note ................... page E3-13
Inspection ............................. page E3-12
Installation Note ................... page E3-13
E3 THERMOSTAT
INSPECTION
Thermostat
--
Mechanical
I.Visually check that the thermostat valve is airtight.
3. Heat the water and check the following:
Initial-opening temperature: 89°C (192°F)
Full-open temperature: 100°C (212°F)
Full-open lift: 3.2mm (0.126 in) minimum.
4. If the gasket surface of the thermostat is damaged,

WE1 028-A 4BUOE3-022
Electrical
Note
This test should be performedat temperatures less
than 37.8"C (100°F) ambient air.
1. Hook up the New Generation Star (NGS) tester. (Refer to

Section FT.)
Note
must be running.
2. Make sure AIC switch is in OFF position.

3. Place the vehicle in Park (P) or Neutral (N).
voltage reading.
6. Record the ECT sensor voltage reading every
60 seconds.
7. When ECT voltage reverses direction trend or changes
Coolant I ECT
Temperature "C { O F ) PID Volts
21.7 {71) 3.00
42.8 (109) 2.01 -
70.6 {I59) 1.01

.-
82.2 {I 80) -
0.75 .
- -
90.6 {I95) 0.59 - -
96.7 {206) 0.50

105.1 (221) 0.40
ME1040-A

(180°F)) and 0.5 volts (90.6"C (195"F)), the
(2) If the operation voltage is not within this range, replace
the thermostat.
THERMOSTAT
7 Installation note
I VIEW A 1 Sealing ring
Note
Make sure the sealing ring is properly installed on
the thermostat before the thermostat cover is in-
stalled.
Gasket
4BUOE3-024
ME1025-8 6BUOE3-008
Thermostat
Note
alignment is made, to provide coolant to the heater.
Install the thermostat into the thermostat housing,
making sure that the air release valve is in the up
position.
Install the thermostat into the thermostat cover and rotate

the thermostat into the water outlet connector in a clock-
wise direction to secure the thermostat to the connector.
4BUOE3-025
Thermostat cover
Install the thermostat cover bolts.
Tightening torque:
20-30 N .m (2.1-3.1 kgf .m, 14-21 ft lbf)
6BUOE3-009

6BUOE3-010
WATER PUMP
WATER PUMP
-
REMOVAL 1 INSTALLATION
Caution

3. Remove the radiator lower hose and the heater return hose from the water pump.
4. Remove the cooling fan and clutch assembly. (Refer to page E3-15.)
5. Loosen the generator mounting bolts.
6. Lift the drive belt tensioner pulley in a counterclockwise direction and remove the drive belt.
7. For vehicles with air conditioning, remove the generator and bracket.
9. Remove the water pump attaching bolts and water pump.
10. Remove the water pump gasket.
6BUOE3-011
Installation Note
Gasket
1. Clean the surface of the gasket on the front cover and on
the water pump.
Note
Use care when scraping aluminum surfaces be-
cause gouging could form leak paths.
2. Apply sealer to both sides of a new gasket and place it on

the water pump.
4BUOE3-029
Water pump
Install the water pump bolts and tighten.
Tightening torque:
8.5-1 2.0 N.m (0.8-1.1 kgf-m, 6--8 ft-lbf}
4BUOE3-030
Water pump pulley

Install the water pump pulley bolts.
Tightening torque:
25 N-m (3.45 kgf-m, 19 ftelbf)
Generator mounting bracket.

Install the mounting bracket bolts.
Tightening torque:
40.3-54.7 N.m {4.2-5.5 kgf-m,3 0 4 0 ftelbf)
4BUOE3-032

COOLING FAN AND CLUTCH E3
PREPARATION
SST
49 UNOl 007 For 49 UNOI 008 For

removal and removal and
Fan clutch installation installation
holding of the cooling Fan clutch of the cooling
tool fan clutch nut wrench fan clutch
I I
ME1038-A 6BUOE3-013
1. Cooling fan
Removal Note ...................... page E3-6
2. Clutch
Removal Note
Cooling fan
1. Remove the two fan shroud attaching screws and lift the
fan shroud out of the two lower attaching clips.
2. Remove the nut attaching the clutch to the water pump

using the SST.
Caution
rotated clockwise for removal.
Installation Note
Cooling fan
1. Install the cooling fan to the water pump.
Tightening torque:
6 - 8 N-m (61.2-81.6 kgfxm, 53-70 in-lbf)
2. Install the clutch on the water pump using the SST.
Tightening torque:
41-1 35 N .m (4.1 -1 3.8 kgf - m, 30-1 00 ft .Ibf)
ENGINE BLOCK HEATER E3
ENGINE BLOCK HEATER
- 1. Disconnect the negative battery cable.
ME3001-A 6BUOE3-015
Removal Note . . . . . . . . . . . . .page E3-18
2. Block heater
Removal Note . . . . . . . . . . . . page E3-18
Installation Note . . . . . . . . . . . page E3-18
E3 ENGINE BLOCK HEATER
Removal Note
Block heater cable
and cylinder block.
6BUOE3-016
Block heater
6BUOE3-017
Installation Note
Block heater
Tightening torque:
1.6-1.8 N - m (16-18 kgf-em, 14-16 in.Ibf)
6BUOE3-018
ENGINE CONTROL TROUBLESHOOTING
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FT- 2 FUEL EVAPORATIVE EMISSION SYSTEM

OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . FT- 10 (FOR 2.3L. 3.OL. 4.OL) . . . . . . . . . . . . . . . FT-160
SPECIFICATIONS . . . . . . . . . . . . . . . . . FT- 10 . DESCRIPTION .................... FT-160
WIRING DIAGRAM (4.OL) . . . . . . . . . . FT- 11 OPERATION . . . . . . . . . . . . . . . . . . . . . FT-161
WIRING DIAGRAM (3.OL) . . . . . . . . . . FT- 16 SYSTEM OPERATION . . . . . . . . . . . . . FT-161
WIRING DIAGRAM (2.3L) . . . . . . . . . . FT- 21 EVAPORATIVE EMISSION (EVAP)
EEC-V COMPONENT CANISTER PURGE SOLENOID . . .
DESCRIPTIONS . . . . . . . . . . . . . . . . FT- 26 PURGE FLOW SENSOR (PFS) . . . . .
TROUBLESHOOTING GUIDE . . . . . . . . FT- 31 EVAPORATIVE EMISSION
USING THIS SECTION . . . . . . . . . . . . FT- 31 CANISTER . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC INDEX . . . . . . . . . . . . . . FT- 33 FUEL VAPOR VALVE . . . . . . . . . . . . . .
SYMPTOM TROUBLESHOOTING . . FT- 35 DECHOKE CONTROL SYSTEM
ON-BOARD DIAGNOSIS SYSTEM . . . . FT- 70 (2.3L ONLY) . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION . . . . . . . . . . . . . . . . . . . FT- 70 DESCRIPTION . . . . . . . . . . . . . . . . . . .
QUICK TEST DESCRIPTION . . . . . . . FT- 70 SYSTEM OPERATION . . . . . . . . . . . . .
DIAGNOSTIC TROUBLE CODE A/C CUTOFF SYSTEM
(DTC) NUMBER . . . . . . . . . . . . . . . . FT- 71 (FOR 2.3L. 3.OL. 4.OL) . . . . . . . . . . . . . . .
INTAKE AIR SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . .
(FOR 2.3L. 3.OL. 4.OL) . . . . . . . . . . . . . . . FT-146 CONTROL SYSTEM
THROTTLE BODY . . . . . . . . . . . . . . . . FT-146 (FOR 2.3L. 3.OL. 4.OL) . . . . . . . . . . . . . . .
THROTTLE RETURN SCREW . . . . . . FT-146 PREPARATION . . . . . . . . . . . . . . . . . . .
-. IDLE SPEED CONTROL SYSTEM POWERTRAIN CONTROL
(FOR 2.3L. 3.OL. 4.OL) . . . . . . . . . . . . . . . FT-147 MODULE (PCM) . . . . . . . . . . . . . . . .
DESCRIPTION . . . . . . . . . . . . . . . . . . . FT-147 PCM POWER RELAY
IDLE AIR CONTROL SOLENOID . . . . FT-147 (BATTERY POWER) . . . . . . . . . . . . .
FUEL SYSTEM EEC PWR FUSE
(FOR 2.3L. 3.OL. 4.OL) . . . . . . . . . . . . . . . FT-148 (PCM MEMORY POWER:) . . . . . . . .
DESCRIPTION . . . . . . . . . . . . . . . . . . . FT-148 GROUND . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION . . . . . . . . . . . . . . . . . . . FT-149 MASS AIR FLOW SENSOR . . . . . . . .
PRECAUTION . . . . . . . . . . . . . . . . . . . . FT-149 VEHICLE SPEED SENSOR (VSS) . .
SYSTEM OPERATION . . . . . . . . . . . . . FT-150 THROTTLE POSITION SENSOR . . . :
FUEL PUMP ............. ENGINE COOLANT
INERTIA FUEL SHUTOFF TEMPERATURE SENSOR . . . . . . .
SWITCH . . . . . . . . . . . . . . . . . . . . . . . FT-152 INTAKE AIR TEMPERATURE
FUEL PUMP RELAY . . . . . . . . . . . . . . . FT-153 SENSOR . . . . . . . . . . . . . . . . . . . . . . .
PRESSURE REGULATOR . . . . . . . . . FT-154 OCTANE ADJUST SHORTIN
INJECTOR . . . . . . . . . . . . . . . . . . . . . . . FT-155 BAR . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST SYSTEM HEATED OXYGEN SENSORS . . . . . .
(FOR 2.3L. 3.OL. 4.OL) . . . . . . . . . . . . . . . FT-156 DIFFERENTIAL PRESSURE:
COMPONENTS . . . . . . . . . . . . . . . . . . . FT-156 FEEDBACK EGR SENSOR . . . . . .
POSITIVE CRANKCASE VENTILATION CLUTCH PEDAL POSITIOhI (CPP)
(PCV) SYSTEM SWITCH (M/T ONLY) . . . . . . . . . . . .
(FOR 2.3L. 3.OL. 4.OL) . . . . . . . . . . . . . . . FT-157 TRANSMISSION RANGE (TR)
DESCRIPTION . . . . . . . . . . . . . . . . . . . FT-157 SENSOR (AIT ONLY) . . . . . . . . . . . .
PCV VALVE (FOR 2.3L 1 4.OL) . . . . . . FT-157 TRANSMISSION FLUID
PCV VALVE (FOR 3.OL) . . . . . . . . . . . . FT-157 TEMPERATURE (TFT) SEINSOR
(Am ONLY) . . . . . . . . . . . . . . . . . . . . .
EXHAUST GAS RECIRCULATION (EGR) TURBINE SHAFT SPEED (XSS)
FUNCTION CONTROL SYSTEM SENSOR (A/T ONLY) . . . . . . . . . . . .
(FOR 2.3L. 3.OL. 4.OL) . . . . . . . . . . . . . . . FT-158 POWER STEERING PRESSURE
DESCRIPTION . . . . . . . . FT-158 SWITCH (2.3 ONLY)
EGR VACUUM REGULATOR
SOLENOID . . . . . . . . . . . . . . . . . . . . . FT-158
CRANKSHAFT POSITION'SENSOR.'
CAMSHAFT POSITION SENSOR . . . .
:
EGR VALVE . . . . . . . . . . . . . . . . . . . . . . FT-159
FT INDEX
FOR 4.OL
1. Air intake hose 6. Accelerator pedal (not shown)

Removal / Inspection / 'Removal / Inspection /
Installation . . . . . . . . . . . . . . . page F3-3 Installation . . . . . . . . . . . . . . . page F3-7
2. Air cleaner housing / Air cleaner element 7. Accelerator cable (not shown)
Removal / Inspection / Inspection/Adjustment . . . . . . page F3-7
Installation . . . . . . . . . . . . . . . page F3-3 8. Pressure regulator
3. Throttle body Inspection . . . . . . . . . . . . . page FT-154
Removal / Installation . . . . . . . page F3-3 Removal 1 Installation . . . . . . page F3-13
Inspection . . . . . . . . . . . . . . page FT-146 9. Injector
4. Upper intake manifold lnspection (On-vehicle) . . page FT-155
Removal / Installation . . . . . . . page F3-3 Removal / Installation . . . . . . . page F3-3
Inspection . . . . . . . . . . . . . . . . . page F3-6 Inspection . . . . . . . . . . . . . . page FT-155
5. Intake manifold 10. Fuel distributor
Removal 1 Installation . . . . . . . page F3-4 Removal 1 Installation . . . . . . page F3-13
Inspection . . . . . . . . . . . . . . . . . page F3-6 11. Fuel lines
Removal / Installation . . . . . . page F3-13
INDEX FT
FOR 3.OL
1. Air cleaner element 6. Intake manifold

2. Upper intake manifold / throttle 7. Pressure regulator
body assembly Inspection . . . . . . . . . . . . . page FT-154
Inspection . . . . . . . . . . . . . . . . . page F2-6 8. Injector
3. Air intake hose lnspection (On-vehicle) . . page FT-155
4. Accelerator pedal (not shown) Inspection . . . . . . . . . . . . . . page FT-155
Removal / Inspection 1 9. Fuel lines (not shown)
Installation . . . . . . . . . . . . . . . page F2-7 Removal / Installation . . . . . . . page F2-9
5. Accelerator cable (not shown) 10. Fuel distributor
Removal / Inspection / Removal / Installation . . . . . . . page F2-9
Installation . . . . . . . . . . . . . . . page F2-7
INDEX
FOR 2.3L
1. Air cleaner element / Air cleaner housing 7. Accelerator cable (not shown)
Removal / Installation . . . . . . . page F1-3 Inspection / Adjustment . . . . . page F1-5
2. Air intake hose 8. Pressure regulator
Removal / Inspection / Inspection . . . . . . . . . . . . . page FT-154
Installation . . . . . . . . . . . . . . . page F1-3 Removal / Installation . . . . . . . page F1-7
3. Throttle body 9. Injector
Removal / Installation . . . . . . . page F1-3 lnspection (On-vehicle) . . page FT-155
Inspection . . . . . . . . . . . . . . page FT-146 Removal / Installation . . . . . . . page F1-7
4. Upper intake manifold Inspection . . . . . . . . . . . . . . page FT-155
Removal / Installation . . . . . . . page F1-3 10. Fuel lines (not shown)
Inspection . . . . . . . . . . . . . . . . . page F1-4 Removal / Installation . . . . . . . page F1-7
5. Intake manifold 11. Fuel distributor
Removal / Installation . . . . . . . page F1-3 Removal / Installation . . . . . . . page FA-7
Inspection . . . . . . . . . . . . . . . . . page F1-4
6. Accelerator pedal (not shown)
Removal / Inspection /
Installation . . . . . . . . . . . . . . . page F1-5
--
INDEX FT
FOR 4.OL / 3.OL
1. Silencer 3. Front pipe assembly

Removal / Inspection / Removal 1 Inspection /
Installation . . . . . . . . . . . . . pages F2-11, Installation . . . . . . . . . . . . . . pages F2-11,
F3-15 F3-15
2. Three way catalytic converter 4. Exhaust manifold
Removal / Installation . . . . . pages F2-11, Removal / Inspection /
F3-15 Installation . . . . . . . . . . . . . pages F2-11,
Inspection.. . . . . . . . . . . . . . page FT-156 F3-15
INDEX
FOR 2.3L
FRONT OF VEHICLE
REGULAR CAB
FRONT OF VEHICLE
CAB PLUS
VIEW A FRONT OF VEHICLE VIEW B
ONT OF VEHICL
3
VlEW C FRONT OF VEHICLE
1. Silencer 3. Exhaust manifold

Removal / Inspection / Removal 1 Inspection /
Installation . . . . . . . . . . . . . . . . page F1-9 Installation . . . . . . . . . . . . . . . . page F1-9
2. Three way catalytic converter
Removal 1 Installation . . . . . . . . page F1-9
Inspection . . . . . . . . . . . . . . . page FT-156
INDEX FT
FOR 4.OL / 3.OL / 2.3L
I
I REGULAR CAB
1. Fuel tank 3. Fuel pump

Removal / Inspection / Inspection . . . . . . . . . . . . . . . page FT-151
Installation . . . . . . . . . . . . . . . . page F3-9 Removal / Installation . . . . . . . page F3-12
2. Fuel filter (low-pressure side) 2. Fuel vapor valve
Replacement . . . . . . . . . . . . . . page F3-11 Inspection . . . . . . . . . . . . . . . page FT-163
FT INDEX
FOR 4.OL / 3.OL 12.3L
INDEX FT
1. Fuel pump relay 14. EGR valve
Inspection . . . . . . . . . . . . . . page FT-153 Inspection . . . . . . . . . . . . . . page FT-159
2. Engine coolant temperature Replacement . . . . . . . . . . . page FT-159
(ECT) sensor (on intake manifold) 15. Octane adjust shorting bar
Removal / Installation . . . . page FT-186 Inspection . . . . . . . . . . . . . . page FT-187
Inspection . . . . . . . . . . . . . . page FT-186 16. Fuel filter (high-pressure side)
3. Powertrain control module (PCM) (not shown)
Removal / Installation . . . . page FT-164 Replacement . . . . . . . . . . . . . section F1,
Inspection . . . . . . . . . . . . . . page FT-164 F2 & F3
4. Mass air flow (MAF) sensor 17. PCV valve (not shown)
5. Throttle position (TP) sensor 18. Crankshaft position sensor
Inspection . . . . . . . . . . . . . . page FT-185 (not shown, near crankshaft pulley)
6. Camshaft position sensor Removal / Installation . . . . page FT-191
(not shown, for 2.3L: on oil pump, 19. Evaporative emission canister
for 3.OL 14.OL: on rear of intake manifold) (not shown, right side of battery)
Removal / Installation Inspection . . . . . . . . . . . . . . page FT-163
(2.3L, 3.OL) . . . . . . . . . . . page FT-192 20. Heated oxygen sensors (not shown)
Inspection Inspection . . . . . . . . . . . . . . page FT-188
(2.3L, 3.OL) . . . . . . . . . . . page FT-192 Removal 1 Installation . . . . page FT-188
(4.OL) . . . . . . . . . . . . . . . . page FT-192 21. Transmission range (TR) sensor
7. PCM power relay (AT only) (not shown, on transmission)
8. Idle air control (IAC) solenoid 22. Vehicle speed sensor (not shown)
9. Differential pressure feedback 23. Brake onloff (BOO) switch (not shown)
EGR (DPFE) sensor (not shown) Refer to 1996 6-series BETM
Inspection . . . . . . . . . . . . . . page FT-188 24. Power steering pressure switch
10. EGR vacuum regulator (EVR) (2.3L only) (not shown)
solenoid (not shown) Inspection . . . . . . . . . . . . . . page FT-191
Inspection . . . . . . . . . . . . . . page FT-158 25. EVAP canister purge solenoid
11. Intake air temperature (IAT) sensor (not shown)
Inspection . . . . . . . . . . . . . . page FT-187 26. Purge flow sensor (not shown)
12. A/C pressure switch Inspection . . . . . . . . . . . . . . page FT-162
Refer to 1996 B-series BETM 27. Clutch pedal position switch (CPP)
13. Wide open throttle A/C shutoff relay (MT only) (not shown)
Refer to 1996 B-series BETM Inspection . . . . . . . . . . . . . . page FT-189
FT OUTLINE
OUTLINE
SPECIFICATIONS (FOR 4.OL / 3.OL 12.3L)
SPECIFICATION
ITEM
I I I
lgnltlon tlm~ng( ~ n ~ tt~m~ng)

~al BTDC 10 & 2" (not adjustable)
- - -- - - -- -- - -- - -- - -- - ppp - -- - --
Throttle body
- -- - - -- - - - - ------ -- - -- -- -
Type
- - - - -- - - - - - -- -- --
Hor~zontaldraft
-- - - -- -- -- - -- -
Fuel pump
I Type ,
I Impeller (in-tank) I
( Maximum output pressure kPa {kgf/cm2,psi} 1 862 (8.8, 125) I
I Fuel filter I
--
TYPe
Pressure regulator
Z- Low-pressure side
High-pressure side
Nylon element (on fuel pump)
Paper element
Regulating pressure kPa {kgf/cm2,PSI} [ 270 (2.7, 39)

Injector
I
Type of drive I Voltage
Resistance 11-18 (at 20°C {68"F))
Idle air solenoid
Solenoid resistance 6-13 (at 20°C (68°F))
I Evaporative emission canister purge solenoid
Solenoid resistance
- ----- ----
- I -- -- --
30-90
-
(at 20" C {68" F))
- ---- - -
--- -- --- - ---- ----

7~ ~ a b ~ r e ~ c t a ~ e
- --
Type - -pKdev~ce
ICrankshaft position sensor 1
I Type Variable reluctance 1
I Mass air flow sensor I
1 Type 1 Heat resistor 1
I Engine coolant temperature sensor 1
20°C {68"F) 37.3 (3.06 V)
Resistance 40°C{1040F) 16.15 (2.16 V)
(PID value) 80°C {176"F} 3.84 (0.80 V)
Intake air temperature sensor
Resistance kS2 / 30°C{86"F) 1 24.27 (2.62 V) I

( Air cleaner 1
1 Element type 1 Paper
6BUOFT-008
Note
4BUOF3-008
FT-10
X.210 BRAKE ONIOFF (BOO)
-.8.212 SHIFT LOCK ACTUATOR 8-249 INERTIA FUEL SHUTOFF 8.1009 FUEL PUMPIFUELGAUGE 8-1002 VEHICLE SPEED SENSOR X01 ENGINE COMPARTMENT FUSURELAY BOX (OPHJ)
SWITCH (MA) (MA) (IFS) SWITCH (MA) SENDER (RL) wSS) (ECE) X-02 IP FUSE PANEL (MA)
X-114 COMMON CON (ECS).(ECE)
X-124 COMMON CON (ECSMDPHJ)
X-129 COMMON CON (ECS)-(ECE)
X I 3 6 COMMONCON (MAHDPKI)
% m i COMMONCON (MA)-(CLSE)/(ILF)
X213 IGNITIONSWrrCH
.,
X-1007 COMMON CON (CLSOlOLF)-;'R_L_',-. ,
.
SEE COMMON CONNECTGS JST bsb Iw1.r A
B-7a 4.oL IGNITION SYSTEM ENGINE CONTROL SYSTEM I In
1
R
(DPW
I
BRRB T/B LGIO T W BWY

(ECS) (ECS) (ECS) (ECS) (ECS) (ECS)
BILG GYM
(ESC) (ECS)
TW TW
SEE COMMON CONNECTOR UST - SECTION X

B-8 4.0L ENGINE CONTROL SYSTEM
4WABS SYSTEM METER METER HEATER AND AK:
(SECTION0-1) (SECTION Gla) DATA LINK CONNECTOR (DLC) (SECTION Gla) (SECTION G )
8 0 6 1@ @1
T T T
(B-8al 4.OL ENGINE CONTROL SYSTEM 1
BATTERY ENGINE COMPARTMEKI
FUSEBELAY BOX
lo x.01
Y( D W
TIB OPW)
Y OPW)
,+~
I
[Y (MA)
T/B (MA)
Y (DPW)
r124 x42 M2
Y (ECS)
0 (MA) : CONNECTOR
IP FUSE PANEL
METER
ENGINE
CONTROL
SYSTEM
(SECTION 6-9)
Q
T
R (ECE) R (ECE) GYiR (ECE) TIW (ECS) WILG (ECS) I I
PDmmUlN m O L MDWLE (PCH)
DATA UNK
I I I I I CONNECTOR OLC)
O N (ECE) PUIO (ECE) P/B (ECE) PUN (ECE) WN (ECQ 0/8 (ECE)
I I +=====+=====+=====+=====+====
E M (ECS) BWO (ECS) O N (ECS) PUlO (ECS) P/B (ECS) PUN (ECS) WN (ECS) 0/8 fECS1 BIW (MA)
SO1 ENGINE COMPARTMENT FUSEIRELAY BOX (DPMI)
. GYN . PN ' . R T I M T W W Y W
X-02 IP FUSE PANEL (MA)
X-114 COMMON CON (EcO-(ECS)
DWIDGD- -. .- . .. BWP T N LBW W I B)W Vm X.124 COMMON CON (ECS).(DPHJ)
X.134 COMMON CON (MA)-IDPWJ
LBIBPh8Tm DL GY .Iw e vm x
'U
X.135 COMMON CON. (MA)-(DPW)
X.136 COMMON CON. (MA)-(DPHJ)
8-207 TRANSMISSION CONTROL 0.209 DATA UNK CONNECTOR (DLC) (MA) 8-1006 5R55E TRANSMSlSSlON (ECE) X.213 IGNITIONSWITCH (MA)
W c H FCs) (MA)
-
SEE COMMON CONNECTOR UST SECTION X
ENGINE CON'IROL SYSTEM

(SECTION6-78)
ENGINE
COMPARTMENT
ENGINE CONTROL SYSTEM
ENGINE
OYm (ECE) -*@ CONTROL

SYSTEM
(SECTION 6-8)
ENGINE
ENGINE
GYIR (ECE) -+@
(SECTION B h )
(SECTION &8a)
BMl WW GYRB
(DPW) (ECS) (ECS)
YLB (ECS) RIB (ECS) W D (ECS) WLG (ECS)
X124 COMMON CON. (ECS)-(DPW)

XI29 COMMON CON. (ECE)-(ECS)
-
X-128 COMMON CON. (ECQ (ECS)
XI36 COMMON CON. (MA)-(DPW)
X-213 IGNITIONSWITCH (MA)
-
SEE COMMON CONNECTOR UST SECTIONX
I I I I I
B-4 3.OL IGNITION SYSTEM ENGINE CONTROL SYSTEM
X.210 BRAKE ONIOFF (800) 8-212 SHIFT LOCK ACTUATOR 8-1009 FUEL PUMPIFUELGAUGE 8-1002 VEHICLE SPEED SENSOR X.01 ENGINE COMPARTMENT FUSEIRELAY BOX (DPKI)
SWITCH (MA) SENDER (RL) (vSS) W E ) X.02 llP FUSE PANEL lMAl
X 114 COMMON CON ~ECS)-(ECE)
X.124 COMMON CON (ECS)-(DPKI)
X 129 COMMON CON (ECS) -(ECE)
X-136 COMMON CON (MA)-(DPKI)
X.201 COMMON CON (MA)-(CLSE)/(ILF)
X-213 IGNITIONSWITCH
X.1007 COMMON C O (CLSE)/(ILF)
~ -(RL)
-
SEE COMMON CONNECTOR LIST SECTION X
8-111 POMRTRAIN CONTFlOL

MODULE (PCM) (ECS) 79
t
B-4a 3.OL IGNITION SYSTEM ENGINE CONTROL SYSTEM
4WABS SYSTEM METER METER HEATER AND N C
(SECTION 0-1) (SECTION C-la) DATA UNK CONNECTOR (DLC)
----------
----------
GY/R
X.128 COMMON CONNECTOR (ECE)-(ECS)

X.134 COMMON CONNECTOR (MA).(DPHJ)
X-136 COMMON CONNECTOR (MA)-(DPHJ)
OUTLINE FT
--
X-01 ENGINE COMPARTMENTFUSEIRELAY BOX (DPHJ)

X-02 IF' FUSE PANEL (MA)
X.114 COMMON CON (ECE)-(ECS)
X-124 COMMON COh (ECSI-(DPMJ)
X 128 COMMON CON lECE).(ECS.
X.129 COMMON CON. (ECE).(ECS)
X.136 COMMON CON. (MA)-(DPHJ)
X-213 IGNITION SWITCH (MA)
I 8-2I I
2.3L ENGINE CONTROL SYSTEM
4WABS SYSTEM METER M€ER HEATER AND AIC
(SECTION 0.1) (SECTION C-la) DATA UNK CONNECTOR (DLC) (SECTIONC-la) (SECTION 0 )
@ @ --------- 0
--------- aB-209 8 1e ' 1
3
T T T T T
I LiB PU PRB TI0 PAG
TI0 PILG
(DPHJ) (DpW) (DPHJ)
_----_____
-----__-__
LBB PU PILB TI0
tPlLG PN DGIO
(ECS) (ECS) (ECS) (ECS) (ECS) (ECS) (ECS)
-----------
-----------
e9 0 @ @ 63 8
@ @ @ @ 8
@ 8 ----------- 69 POWERTR*INCONIROLMOWi.EiPCM~
----------- ----------- a-rrt
INTAKE
AIR TEMPERATURE
TEMPERATURE 6.1 12
(ECT) SENSOR
DIGITAL
TRANSMISSION
RANGE (DTR)
SENSOR
t - Gym p P W )
~ ~ ! ~ w m O LC
(SECTION 8-31
GYP (ECS)
@ Gym (ECS)
I
~ y (ECS)
m / XI28
GYR (ECR
GY~R
(ECR
GYiR ECEl -+@
ENGINE
CONTROL
FE"E!NB.Z.I
-
SEE COMMON CONNECTOR UST SECTION X
l ~ - 2 a / 2.3L ENGINE CONTROL SYSTEM
- - - -
I
BAlTERY ENGINE COMPARTMENT
FUSEIRELAY BOX
Y (DPHJ) Y (ECS)
X-124 so2 X-02 8-209 DATA UNK
T B (DPHJ) ((TIB (MA) -%;; -. 0 (MA) : CONNECTOR
@ 10A @LC)
Y (DPHJ) Y (MA) IIP FUSE
X-213
IGNITION PANEL METER
(SECTION C-la)
DRL SYSTEM
B I/P
FUSE (SECTION E-3) 8
(Bc) PANEL p u / o (MA) ---+STOP AND BACKUP
LAMPS
e :
(MA) 1~ X.02 (SECTION F-1) WILG (MA)
ENGINE
-
ENGINE CONTROL '02 @ 8-207
CONTROL
SYSTEM
SYSTEM
(SECTION 8 - l a ) ENGINE
TRANSMISSION
CONTROL
f X-136
(SECTION 8-3)
8 CONTROL -, SWITCH (TCS) WILG (DPHJ)
0 SYSTEM
T (SECTION 8-2) 8.207 X.136
T
GY/R
R (ECE) 8
T
TAN (MA) +t TAN (DPHJ)
X-124
(WE) R (ECE) R (ECE) R (ECE) GYIR (ECE) TAN (ECS) WILG (ECS)
DATA LINK
CONNECTOR (DLC)
DGMECE) BRIO (ECE) O N (ECE) PUIO (ECE) P B (ECE) P U N (ECE) W N (ECE) OIB (ECE)
+======+=====+=====*====+=====+=====+=====+ X-114 ------

D G f f l (ECS) BRIO (ECS) O N (ECS) PUIO (ECS) P/B (ECS) PUN (ECS) W N (ECS) 018 (ECS) BAN (MA)
X.135 B
1:3[4
@ 8 0 a 0 8 @ 0
BAN (DPHJ) B (DPHJ)
P M R W N W M R O L MODULE IPCMI
0
1 6-1 11 POWERTRAIN CONTROL 1 X-01 ENGINE COMPARTMENT FUSORELAY BOX (DPKI)
MODULE (PCM) (ECS) 7s
X.02 IIP FUSE PANEL (MA)
X-114 COMMON CON (ECE)-(ECS)
X-124 COMMON CON (ECS)-(DPHJ)
X.134 COMMON CON (MA)-(DPHJ)
X-135 COMMON CON (MA)-(DPHJ)
X.136 COMMON CON (MA)-(DPHJ)
X-213 IGNITION SWlTCH (MA)
SEE COMMON CONNECTOR LIST - SECTION X
8-3 2.3L ENGINE CONTROL SYSTEM
X.136
ENGINE CONTROL
ENGINE
COMPARTMENT
FUSEIRELAY ENGINE
BOX
0 (SECTION B-2a)
,
(SECTION 8-1)
GYIR (ECS)
LBlO (DPHJ)
I
8-110
GYlR (ECS)
I
LBlO (ECS)
\.
0 (ECS)
La10 (ECS) --
GY/R (ECS)
, L======~~B~loo~
WIB (ECE)
------
+======+
HEATED
OXYGEN
SENSOR
B.lw3 ( H O W X2
WLG (ECE)
X-114
~ = = = = = = ~ ~ B - ~ O O
WIB (ECE)
------
------
WLG (ECE)
,
I
.
~
HmTED
OXYGEN
SENSOR
(H02S) #2
WIB (ECS) RlLG (ECS) WIB (ECS) WLG (ECS)

HEATED
OXYGEN
I A I [ J, J, 1
DG SENSOR I
Y
(ECS) AIT 7- 't' MK
I ---------------- ---
WIB
(ECS)
WLG
(ECS)
-----a,-,,------ --- B-111
POWERTWIN CONTROL MODULE IPCM) POWERTRAINCONTROL MODULE IPCM)
X-01 ENGINE COMPARTMENT FUSEIRELAY BOX (DPW)

X.02 IIP FUSE PANEL (MA)
X-114 COMMON CON. (ECE)-)ECS)
X.115 COMMON CON. (ECS)-(ECE)
X.124 COMMON CON. (ECS)-(DPHJ)
X.136 COMMON CON. (MA)-(DPW)
X.213 IGNITION SWITCH (MA)
(CMP) SENSOR (ECS)
B-1 a 2.3L IGNITION SYSTEM 8 ENGINE CONTROL SYSTEM
XI24
-+
ENGINE
R
I 1
(DPW) (DPHJ) R (ECS) R (ECS) R (ECS) R (ECS) R (ECS)
8-105
MASS AIR
FLOW (MAF)
t t SENSOR
SOLENOID
0W
(DPHJ)
BILG
(DPHJ) 1 ($&)
WllB
(ECS)
0Rm
(ECS) ENGINE
CONTROL
T
(ECS)
BWLB
(ECS)
W
(ECS)
BWY
(ECS)
SYSTEM
1 (SECTION 0.21)
LBm
(ECS)
B
(ECS)
BILG GYN
(ESC) (ECS)
-----------
0 @ 6
------------------------
........................
POWERTWIN WNTROL MOWLE IPCH)
8 0 8 8 8
0
IECS) ,vI CPANKSHAFI
WSRlCU ICKPI SENSOR B/W B/W B/W B f f l B f f l
(ECS) (ECS) (ECS) (ECS) (ECS)
TN TN
I
T N (MA)
"
,-,
X.210 BRAKE ONIOFF (BOO) 5212SHlFT LOCK ACTUATOR 8-249lNERTlA FUEL SHUTOFF B.1009 FUEL PUMPIFUEL GAUGE 8-1W2 VEHICLE SPEED SENSOR X.01 ENGINE COMPARTMENT FUSURELAY BOX (DPHJ)
SWITCH (MA) (MA) (IFS) SWITCH (MA) SENDER (RL) (VSS) W E ) X-02 IIP FUSE PANEL (MA)
X I 1 4 COMMON CON. (ECS)-(ECE)
X-124 COMMON CON. (ECS)-(DPHJ)
X-130 COMMON CON (ECSI-(ECE)
X-136 COMMON CON (MA)-(DPHJ)
X.201 COMMON CON. (MA)-(CLSE)/(ILF)
X-213 IGNITION SWITCH
X-lW7 COMMON CON. (CLSE)/(ILF) -(RL)
0-111 POWERTRAIN CONFIOL

MODULE (PCM) (ECS) 79 101
26
FT OUTLINE
EEC-V COMPONENT DESCRIPTIONS
COMPONENT FUNCTION REMARK
- --- - +- - - - - - -- -- -. - -- - -- -- -- -- - --
Air cleaner Filters air entering throttle body.
- -- - - -- - -- -- -- -- - .- - -- -- - --
#C cycling switch Sends a voltage s~gnalinput to PCM when

N C IS requested.
A/C pressure switch Prevents N C pressure from rising to a level Uses normally closed switch.
that would open the AIC high pressure relief Open switch contacts when AIC head pressure is
valve. extremely high.
Brake OnIOff (BOO)
switch
--- - --
Camshaft position
p-pp
Sends a battery voltage signal to PCM when
depressing brake pedal.
PCM adjusts or controls the following:
1. Maintains idle speed with brake applied
2. N C compressor ON/OFF
3. Disengages torque converter clutch
--~ ---p
Detects position of camshaft and sends

~
1 If all stoplamp bulbs are open, a high voltage is
present at PCM due to a pull-up resistor in PCM.
This provides fail safe function in event circuit to
BOO switch has failed.
Uses a Hall Device Type for 3.OU4.OL or a

sensor (CMP) signal to PCM. Variable Reluctance type for 2.3L.
PCM uses for synchronizing firing of CMP identifies when #1 piston is at top dead
sequential fuel injectors. center of its compression stroke.
CMP for 3.OL is adjustable.
-
Carbon canister Provides storage of fuel vapors. Contains activated carbon, which has the ability to
store fuel vapors and to purge stored fuel vapors.
Clutch pedal position Detects a load on engine. Uses normally open switch.
(CPP) switch PCM uses load information in mass air flow One volt or less signal input at PCM indicates a
(MK only) and fuel calculations. reduced engine load. 5 volts signal input at PCM
indicates engine load. On PJT model, jumper is
connected to connector.
Coast clutch solenoid Applies and releases coast clutch. Uses normally closed and ONJOFF style solenoid.
(ccs) PCM outputs driver signals to solenoids. Solenoid is an electro-hydraulic actuator
combining a solenoid and regulator valve.
Crankshaft position Monitors trigger wheel to indicate crankshaft CKP is a magnetic transducer.
(CKP) sensor position and speed information to PCM. CKPs for all three engines are not adjustable.
PCM uses this signal for ignition control.
Data link connector Connector for scan tool or NGS tester. Uses SAE defined J1962 data link connector.
@LC) Located left side of hood release lever.
Differential pressure Monitors differential pressure through two
feedback EGR sensor
(DPFE)
, hoses referred to as down and upstream
pressure hoses and outputs voltage to PCM.
Uses a ceramic capacitive type pressure
transducer.
Marks HI and REF signals on sensor housing for
PCM uses signal to adjust EVR solenoid identification (HI signal uses a larger diameter
duty cycle and achieve desired EGR flow. hose).
Electronic vacuum Regulates vacuum supply to EGR valve. ! As duty cycle increases, vacuum output also
regulator (EVR) PCM outputs a duty cycle to drive the EVR increases. With 0 percent duty cycle or no
solenoid solenoid. electrical signal applied, EVR solenoid allows
some vacuum to pass, but not enough to open
; EGR valve.
EGR valve Increases or decreases flow of exhaust gas Uses conventional vacuum-actuated valve.
recirculation. At vacuum signal of 1.6 in-Hg (41 mm-Hg) or less,
spring force in EGR valve closes valve. Valve is
fully opened at about 4.5 in-Hg (114 mm-Hg).
Electronic pressure Controls transmission line pressure used to Uses normally closed and variable force style
control (EPC) apply and release clutches and bands in solenoid. Solenoid is an electro-hydraulic actuator
solenoid transmission. combining a solenoid and regulator valve.
PCM outputs driver signals to solenoid. Produces resisting forces to main regulator and
line modulator circuits. If EPC solenoid is shorted
to ground, PCM outputs DTC for VSS.
OUTLINE

e coolant
Engine Detects engine coolant temperature. Uses thermistor devices.
e (ECT)
temperature
e Sensor resistance affects voltage drop Resistance changes with temperature:
sensor across sensor terminals and provides Resistance decreases as temperature
electrical signals to PCM corresponding to increases.
temperature. Resistance increases as temperature
PCM controls the following: decreases.
1 Ignition timing Sensor is connected to voltage divider so that
2. EGR varying resistance of sensor causes a variation in
3. Required fuel injector pulse width total current flow. Dropped voltage across a fixed
4. ShiWtorque converter clutch scheduling resistor in a series with sensor determines voltage
signal at PCM.
EVAP canister purge Controls flow of vapors from carbon canister Solenoid is a normally closed valve. Solenoid
solenoid to intake manifold during various engine ground is controlled by PCM. Ground signals are
operating modes. cycled ontoff at 10 Hz frequency with a variable
duty cycle.
I e filler cap
Fuel Prevents fuel spill and closes evaporative1
fuel system to atmosphere.
e filter
Fuel Contains four filtering or screen devices as Fuel filter between fuel pump and injector is
follows: serviceable. Other three fuel filters are replaced as
1. A fine mesh nylon sock mounted on assemblies.
intake side of fuel pump
2. Filtertscreen at fuel rail port of injector
3. Filtertscreen at fuel inlet side of pressure
regulator
4. Fuel filter between fuel pump and injector
Fuel pressure Regulates fuel pressure supplied to injectors. Regulator is a diaphragm-operated relief valve.
regulator Excess fuel is bypassed through regulator One side of diaphragm senses fuel pressure and
and returned through fuel return line to fuel other side is connected to intake manifold vacuum.
tank. Balancing one side of diaphragm with manifold
vacuum maintains a constant fuel pressure drop
across injectors.
--
Fuel pump Provides fuel to injectors. Fuel pump has a discharge check valve that
maintains system pressure after ignition has been
turned off to minimize starting concerns.
Fuel pump relay is controlled by PCM. Fuel pump monitor:
PCM turns relay on in following conditions: Fuel pump monitor is spliced into power-to-pump
1. For one second after IG:ON circuit.
2. During receive Profile Ignition Pickup (PIP) PCM uses this circuit for diagnostic purposes.
signal
( Fuel vapor valve I Prevents fuel from flowing into canister 1 I
Heated oxygen Detects oxygen in exhaust mixture and H02S produces a variable voltage at a H02S top
sensor (HOPS) outputs a variable voltage to PCM. temperature of 350°C (662" F) as follows:
PCM uses inputs from upstream H02S to - High concentration of oxygen: less than 0.4 volt
fine tune airlfuel ratio by controlling required - Low concentration of oxygen: greater than 0.6
fuel injector pulse width. volt
Downstream sensors are monitors for No interchangeability between upstream H02S
normal switches. (green connector) and downstream H02S (blue
connector). H02S identification is as follows:
- Upstream H02S on #l cylinder bank: H02S11
- Upstream H02S on opposite bank: H02S21
- Downstream H02S: H02S12
HLOS - Hardware HLOS is a PCM function. HLOS allowable output functions:
Limited Operation HLOS provides minimal engine operation Spark output controlled directly by PIP signal.
Strategy should the PCM stop functioning correctly. Fixed fuel pulse width s!~nchronizedwith PIP
All modes of self-test are not functional and signal.
electronic hardware is in control of system. Fuel pump energized.
Idle speed control output signal functional.
HLOS disabled outputs to default state:
EGR solenoids
No converter lock-up.
OUTLINE
I COMPONENT 1 FUNCTION 1 REMARK I

ldle air control (IAC) Controls idle speed and provides a dashpot IAC solenoid is duty-controlled solenoid.
solenoid function. IAC is not adjustable and cannot be cleaned.
PCM uses IAC to control the following:
1. No touch start
2. Cold engine fast idle
3. ldle (corrects for engine load)
4. Provides a dashpot function
Ignition coil A coil in a coil pack is turned on by PCM, Spark plugs are paired so that as one spark plug
then turned off, firing two spark plugs at once. fires on the compression stroke, the other spark
plug fires on the exhaust stroke.
-- -- -- -
Ignition diagnostic IDM signal communicates informat~onby IDM circuit is enclosed in PCM.
1 monitor signal (IDM) 1 pulse width modulation.
Inertia fuel shutoff IFS is used in conjunction with fuel pump IFS consists of a steel ball held in place by a
(IFS) switch and is used to shut off fuel pump if a collision magnet. When sharp impact occurs, ball breaks
occurs. loose from magnet, rolls up a conical ramp and
Once switch is open, it must be manually strikes a target plate which opens electrical
reset before restarting vehicle. contacts and shuts off fuel pump.
Injector Amount of fuel is controlled by length of time Fuel injector is a normally closed and solenoid-
injector is held open. lnjector is operated by operated valve that meters fuel flow to engine.
12 volts from PCM power relay and ground If injector has been replaced, it is necessary to
signal is controlled by PCM. clear learned values contained in Keep Alive
Memory in PCM by disconnecting battery or PCM
for five minutes.
Intake air temperature Detects intake air temperature. Uses thermistor devices.
(IAT) sensor Sensor has the same function as ECT. Resistance changes with temperature:
PCM uses IAT signals as correction factors Resistance decreases as temperature
in calculation of fuel, spark and MAF. increases.
Resistance increases as temperature
decreases.
Sensor is connected to voltage divider so that
varying resistance of sensor causes a variation in
total current flow. Dropped voltage across a fixed
resistor in a series with sensor determines voltage
signal at PCM.
1 Intake manifold i Supplies intake air to all cylinders. 1 I
Keep alive memory PCM stores data in KAM about vehicle KAM remains powered when ignition is off so
(KAM) operating conditions, and then uses data to that information is not lost until PCM connector
compensate for component variability. disconnected or battery cable disconnected.
Malfunction indicator Alerts driver to an OBD II emission-related If OBD II related component or system is
lamp (MIL) component or system malfunction. malfunctioning, OBD II DTC will be set.
MIL comes on in runlcrank mode as a bulb To extinguish MIL after repair, a reset command
check until PIP signal detected. from scan tool or NGS must be sent, or three
MIL should turn off after PIP signal detected. consecutive drive cycles must be completed
MIL remains on in the following conditions: without a malfunction.
A short to ground of MIL circuit
Operation in HLOS
When vehicle was last shut down
After DTC is stored in memory
MIL blinks in the following procedures:
A severe misfire is detected
Intermittent in MIL circuit
Mass air flow (MAF) Detects intake air mass. Uses a hot wire sending element to measure
sensor I Outputs analog voltage signal to PCM. intake air mass. Hot wire is maintained at 200°C
PCM controls operation as follows: (392°F)above ambient temperature as measured
1. Required fuel injector pulse width by a constant cold wire. Air passing hot wire
2. EPC causes it to cool. The current required to maintain
3. ShiWtorque converter clutch scheduling hot wire temperature is proportional to air mass
flow. MAF then outputs signal to PCM.
Octane adjust OCT ADJ shorting bar is used to retard OCT ADJ self test is to check state of OCT ADJ
(OCT ADJ) shorting spark three degrees when bar is removed shorting bar. DTC will be present if bar is removed
1 bar from in-line connector. or if there is an oDen circuit.
OUTLINE
I COMPONENT / FUNCTION I REMARK I

Orifice tube assembly Provides flow path for EGR to intake Contains metering orifice arid two pressure
(for EGR) manifold. pick-up tubes. Internally located orifice creates a
measurable pressure drop across it as EGR valve
1 O g ~test
t mode OTM aids in servicing output actuators
associated with PCM. It energizes and
de-energizes most of system output
opens and closes.
actuators on command.
Output shaft speed Monitors output shaft speed and sends a Magnetic pick-up type.
(OSS) sensor signal to PCM for EPC and shifVtorque
converter scheduling.
Overdrive drum
speed (ODs) sensor
/ Monitors overdrive drum speed and sends a
signal to PCM.
Magnetic pick-up type.
Parameter PID is certain data values, analog and digital PlDs listed on Generic OBC) II PID list must be
identification (PID) inputs and outputs, calculated value, and accessed from all scan tools.
system status information. PID can be
accessed from scan tool or NGS tester.
Positive crankcase Cycles crankcase gases back through PCV regulates amount of ventilating air and
ventilation (PCV) engine, where they are burned. blow-by gas to intake manifold and prevents
from traveling into crankcase.
Positive seal retainer PSR is used as a redundant seal to PSR is a spring operated closing plate at bottom of
(PSR) evaporative system in case fuel filler cap housing located in fuel filler neck.
missing.
Powertrain control PCM receives input from sensors and other PCM has a 104-pin electrical connector.
module (PCM) electronic components. Based on data
received and programmed into memory,
PCM generates output signals to control
various relays, solenoids and actuators.
-
PCM power relay Supplies current to output devices and PCM.
Power steering Monitors hydraulic pressure and sends PSP switch is a normally closed switch that opens
pressure (PSP) switch signal to PCM. as the hydraulic pressure increases.
(2.3L only) PCM controls the following:
1. Adjusts idle rpm
2. Adjusts transmission line pressure during
increased engine load.
Profile ignition PCM generates an internal PIP signal from / PIP signal circuit is enclosed In PCM.
pickup (PIP) signal crankshaft position sensor signal. PIP signal 1
is used to calculate SPOUT signal and to
supply a clean, inverted signal for
tachometer operation.
1
I
I
I
Purge flow sensor Monitors vapor flow through EVAP solenoid
and sends signal to PCM. PCM sends output i
signal to solerioid based on flow cond~tions. 1

Shift solenoids Provides gear selection by controlling Use normally closed and OWIOFF style solenoids.
(SS1, SS2, SS3, SS4) transmission fluid pressure of shift valve. When solenoids are ON, holds pressure. When
PCM outputs driver signals to solenoids. solenoids are OFF, exhausts pressure.
Spark output signal SPOUT is a pulse width modulated digital SPOUT signal circuit is enclosed in PCM
(SPOUT) signal which is used internally by PCM as a
calculated spark target.
Three-way catalytic Catalyzes oxidation reactions of unburned Contains either platinum and rhodium or palladium
(TWC) converter hydrocarbons and carbon monoxide, and and rhodium. Catalyst is a rnaterial that remains
reduction reaction of oxides of nitrogen. unchanged when it initiates and increases speed
Three-way conversion only occurs with of a chemical reaction. Catalyst will enable a
airlfuel near stoichiometry. chemical reaction to occur at lower temperature.
Throttle body Meters air to engine during idle, part throttle,
and wide open throttle conditions. IAC
solenoid and throttle position sensor are
SealanVcoating on bore (must not be cleaned).
I
mounted on throttle body.
OUTLINE

Throttle position (TP) Detects throttle plate opening angle and Uses a rotary potentiometer that is rotated by
sensor outputs analog voltage signal to PCM. throttle shaft. As throttle plate is opened or closed,
PCM determines four operating conditions: output signal changes linearly.
1. Closed throttle (idleldeceleration)
2. Part throttle (cruise/acceleration)
3. Wide open throttle (maximum
acceleration)
4. Throttle angle rate
- - -
Torque converter Controls application, modulation and release TCC solenoid is normally open and pulse width
clutch (TCC) solenoid of torque converter clutch. modulated solenoid.
PCM outputs driver signal to solenoid.
~- -- -- ~
Transmission control PCM controls lamp ONIOFF function

indicator lamp (TCIL) depending on TCS ONIOFF conditions.
If transmission-related device is
malfunctioning, lamp starts to flash.
-~ .-
Transmission control Outputs keypower whenever TCS is cycled Uses a momentary contact switch.
switch (TCS) to PCM.
Transmission fluid errnistor devices.

temperature (TFT) nce changes with temperature:
sensor
Resistance increases as temperature

PCM controls the following:
1. Shift scheduling for cold fluid
2. Inhibits TCC operation
ries with sensor determines voltage

~ - -- pp --
Digital transmissio cts transmission range. Uses a ratiometric sensor with six resistors in
range sensor
PCM controls the following: neutral sense for 4x4 control.

TR sensor is adjustable.
2. Shift scheduling
Turbine shafi speed Detects speed coming in. Uses a magnetic pick-up sensor.
(TSS) sensor Outputs voltage signal to PCM. Sensor is mounted on center support of
PCM controls the following: transmission.
1. Shiftltorque converter clutch scheduling
- -- -- - - --- - -- -
Vehicle speed sensor Detects speed going out. 1 Uses a variable reluctance sensor. Sensor
(VSS) Outputs frequency signal to PCM. ( generates a sine wave type waveform with a
) PCM controls operation as follows: I frequency.
; 1. Fuel injection High frequency as vehicle velocity increases.
: 2. Ignition timing : Low frequency as vehicle velocity decreases.
i 3. Shiftltorque converter clutch scheduling Installed in transmission (4x2) or transfer case
I 4. EPC (4x4).
If EPC solenoid is shorted to ground, PCM outputs
DTC for VSS. Diagnose EPC solenoid first, then
check VSS.
Wide open throttle Disengages A/C clutch during the following WAC relay is normally closed relay.
A/C cut-off (WAC) conditions: When A/C switch is turned on, and A/C cycling
relay Engine cranking switch and N C pressure switch are closed,
Engine overheated voltage is supplied to relay and PCM. PCM will
Wide open throttle then verify that A/C clutch operation is desirable.
PCM controls as follows:
If desirable: Adjust idle speed and unground
relay
If not desirable: Ground relay.
7BUOFT-009
-
USING THIS SECTION
Introduction
Most of the fuel and emission control systems are electronically controlled, often making it difficult to
diagnose problems, especially intermittent problems. Before undertaking actual checks, take a few
minutes to talk with the customer who approaches with a driveability complaint. The customer is often a
good source of information on such problems, especially the intermittent ones. Through a talk with the
customer, you will usually find out what the symptoms are and under what conditions they occur.
4BUOF3-010
o flow
Work
CHECK IN
REFERTOTROUBLESH0C)TING PAGETHAT-------------------------- DIAGNOSTIC INDEX

CORRESPONDS TO ACTUAL SYMPTOM (Refer to page FT-33)
-CHECKFOR
I
WHAT IS BAD IN SYSTEM--------------------------- INSPECTION
CHECK FOR WHAT PART IS BAP--------------- ACTION

I------------
-
NO
DETERMINE IF TROUBLE HAS BEEN ELIMINATED
1
CHECK OLlT
Diagnostic index
-- TROUBLESHOOTING GUIDE F3
OIAWOSTIC WDEX
Page:
No.: / Shows the referenc page
Each troubleshooting item is or section.
assigned a number.
Description:
Describes each troubleshooting
item.
Troubleshooting Item:
There are 33 troubleshooting
items. Choose the item that
most closely corresponds to
the actual symptom.
Troubleshooting chart
HARD STARTILONG CRANKIERRATIC STARTIERRATIC CRANK

--
I
Starter cranks engine at normal speed but engine requires excessive cranking time
DESCRIPTION before start
Battery in normal condition
INSPECTION ACTION
Are any diagnostic trouble codes displayed Yes Diagnostic trouble code displayed
during Key On Engine Off, Key On Check for cause (Refer to Diagnostic Trouble Code
Engine Running or Continuous Memory inspection? chart) page FT-77
page FT-77
No diagnostic trouble codes displayed
Go to next step
-
Is a strong blue spark visible at each disconnected Yes Go to next step
high-tension lead while cranking engine?
-NO Check camshaft position sensor s~gnaiat PCM
page FT-165
If OK, check as follows:
Crankshaft pos~tionsensor @ page FT-162
High-tension leads Section G
Spark plugs
If not OK, check wiring harness
s Go to next step
DESCRIPTION:
Further describes the system.
Confirm that the chart addresses the actual symptom before beginning troubleshooting.
4BUOF3-014
STEP:
This shows the order of troubleshooting. Proceed with troubleshooting as indicated.
4BUOF3-015
INSPECTION:
This describes an inspection to quickly determine the malfunction of parts. If a detailed procedure is
necessary to perform the INSPECTION, refer to the page specified by the "m"mark.
4BUOF3-016
ACTION:
This recommends the appropriate action to take as a result (YesINo) of the INSPECTION. How to perform
the action is described on the reference page specified by the "w"mark.
4BUOF3-017
TROUBLESHOOTlNG GUIDE FT
DIAGNOSTIC INDEX
TROUBLESHOOTING ITEM
DESCRIPTION
TROUBLE
rpp
1 ;1
-
-
I I , Melts fuse
1 / I I
1 r:; 1
2 Will not crank Starter does not work FT-36
1 , Hard start/long cranklerratic start/ Starter cranks engine at normal speed but engine
1 1
1 erratic crank
Engine stalls w---i
Cranks normally but will not start
requires excessive cranking time before starting
Engine stops unexpectedly at idle and/or after start
Starter cranks engine at normal speed but engine

FT-37
will not run

Slow return to idle Engine takes more time than normal to return to FT-43
idle speed
7 1 Engine runs At idle Engine speed fluctuates between specified idle :;peed
1 rough/rolling
idle
and lower speed and excessive engine shake
Idle speed too slow and excessive engine shake
1 8 1 Fast idle 1 Engine speed continues at fast idle after warm-up 1 FT-45 I
1 9 ~
Low idlelstalls during deceleration
Engine stalls/ Accelerationicruise

Engine stops unexpectedly at beginning of
deceleration or recovery from deceleration
Engine stops unexpectedly at beginning of acceleration
quits or during acceleration
Engine stops unexpectedly while cruising
Engine runs
rough
Accelerationicruise Engine speed fluctuates during acceleration or
cruising 1 FT-47
Misses
BucWjerk
Accelerationlcruise /gine misses during acceleration or cruising
Vehicle bucksljerks during acceleration, cruising,
1
Hesitation1
stumble
1
deceleration
Acceleration
or deceleration
Momentary pause at beginning of acceleration, or
durina acceleration i
+1
I 11 I Suraes 1 Acceleration/cruise Momentarv minor irreaularitv in enaine o u t ~ u t 1 FT-49 I
Backfires Idle/acceleration/
deceleration
Sound produced from exhaust system 1 FT-51
I
LacWloss of Accelerationicruise Performance poor under load
power (i.e., power down when climbing hills)
-- ~ ~
Knocking/ Sound produced when airlfuel mixture is ignited by

pinging something other than spark plug
(i.e., hot spot in combustion chamber)
15 Poor fuel economy ,
--Fuel economy unsatisfactory
- -p-ppp-p-
16 I Emissions com~liance I Fails emissions test
I I' I1 MllJTClL never on/

M I U C I L alwavs on
Malfunction indicator lamp never/always on
Transmission control indicator lam^ neverlalwavs on
1 FT-591
18 Automatic Upshift/downshift/ Automatic transmission concerns not related to Section K

engine performance
-
. ---
Oil consumption excessive
20 concerns
Overheating
overheats
1 22 /
Cooling system Runs cold
concerns
Exhaust smoke 1
Engine does not reach normal operating temperature
Blue, black, or white smoke from exhaust svstern

I FT-61
FT-61
II
1 23 / Fuel odor (in engine compartment) 1 Gasoline fuel smell or visible leaks 1 FT-63 1
1 24 / Engine noise I Engine noise from under hood 1 FT-64 I
1 25 / Vibration concerns (engine) I Vibration from under hood or driveline 1 FT-65 I
FT TROUBLESHOOTING GUIDE
--
DESCRIPTION PAGE
No. TROUBLE
26 AIC does not work AIC compressor magnetic clutch does not engage FT-65
I when A/C IS turned on
27 -- NCalways on1 AJC compressor magnetlc clutch does not disengage FT-66
- A/C compressor runs continuously
28 N C does not cut off under wlde open
,
throttle condrtlons
A/C compressor magnetlc clutch does not disengage
under wlde open throttle
, FT-67
29 Exhaust sulphur smell Rotten egg smell (sulphur) from exhaust FT-68
30
-
lntermlttent concerns Symptom occurs randomly and IS difficult to dlagnose FT-69
31 Output test mode not functlonlng Output test mode cannot be entered FT-69
- FT-131
DTCs or to actrvate KOEO or KOER self-
-
-
33 Retrleve DTC not llsted - FT-131
TROUBLESHOOTING GUIDE FT
SYMPTOM TROUBLESHOOTING
MELTS FUSE
---
Shorted harness or unit Deterioration
Repair as necessary Replac~sfuse

FUSE
'7
- ---- -- -
Damaged Fuse - -
Related Wiring Harness --
-
IIP FUSE PNL (50A) FUSE PNL fuse Number 1 fuse (TlE3)
Number 5 fuse (TIE3)
Number 9 fuse (Tlf3)
Number 13 fuse (LIB)
Number 17 fuse (TIB)
-
- --- ,
IGN (50A) I(;N fuse lgnitlon switch (Y)
1
- - -
lgnit~on
----
switch (Y) --
-- - -- -
HORN (20A) -
HORN fuse Horn relay
-
(YILB)
- --
- -
PCM PWR (30A) PCM PWR fuse PCM (Y)

- -- - -- --
PCM (Y)
- -- ---
ELEC SHIFT fuse Electr~cshift control unit (DGILG)
--I
ELEC SHIFT
- -
(20A) -
PWR LOCKSNVINDOWSISEATS PWR LOCWWINDOWISEAT fuse Rlght power lumbar swltch (BIW)
(204 Left power bolster sw~tch(BIW)
Left power lumbar switch (BNV)
Left seat control switch (BNV)
All lock relay (BNV)
All unlock relay (BIW)
Driver's unlock relay (BNV)
Power window relay (B/W)
-- -- --
FUEL SYSTEMIANTI-THEFT (20A) FUEL SYSTEMIANTI-THEFT fuse Fuel pump relay (LBIO)
RAP module (WlL13)
BLOWER MOTOR (40A)

LAMPS (1 5A) 1 GENERATOR fuse
DAYTIME RUNNING LAMPS fuse
BLOWER MOTOR fuse
Generator (YIW)
Daytime running lamps
Blower motor relay (BILG)
-- - --
PARK LAMPS (20A) F'ARK LAMPS fuse I/P number 3 fuse (BNV)
FT TROUBLESHOOTlNG GUIDE
Damaged Fuse Related Wiring Harness

-
4WABS MAIN RELAY (30A) 4WABS MAIN RELAY fuse 4WABS main relav (TIY)
4WABS PUMP MOTOR (30A) 1 4WABS PUMP MOTOR fuse 4WABS pump motor relay (YILG)
HEADLAMPS (20A) 1 HEADLAMPS fuse Multifunction switch (DLIO)
Main light switch (DILO)
PCM MEMORY POWER (15A) PCM MEMORY POWER fuse PCM (Y)
I AIR BAG (10A) 1 AIR BAG fuse -
Air bag diagnostic monitor (RIW)
H02S fuse Oxygen sensor 11 (LBIO)
Oxygen sensor 12 (LBIO)
Oxygen sensor 21 (LBIO)
t POWER POINT (30A)

AUDIO (20A)
POWER POINT fuse
AUDIO fuse
--
Auxiliary power socket (BRJP)
Audio svstem (LGIP)
1 2 / WILL NOT CRANK 1

I DESCRIPTION / Starter does not work I
1 STEP / INSPECTION I ACTION I
Is a clicking sound heard from the starter relay Yes / Go to next step
when the ignition switch is turned to START?
i Go to step 3
-
No
2 Check the starting system.
Is the starting system OK?

Section G
Yes
I Check for seized/hydrolocked engine, flywheel

For 2.3L: Section B1
For 3.OL: Section B2, For 4.OL: Section B3
Service as required
= Section G
3 1 Do any other electrical accessories work? Yes Go to next step
No Check the charging system
Section G
4 Are any diagnostic trouble codes displayed during Yes Diagnostic trouble code displayed
Key On Engine Off or Continuous Memory
inspection?
-page FT-71
Check for cause (Refer to Diagnostic Trouble Code
chart)

w page FT-77
Go to next step
I Check as follows: Yes Go to next step
Transmission Range (TR) sensor adjustment
Transmission linkage adjustment
= Section K
Clutch pedal position (CPP) switch
Ignition switch Service as required
Starter relay
= 1997 B-series BETM
Are components/systems OK?
6 Verify test results. If OK, return to diagnostic index to service any additional symptoms
MF4059-F 6BUOFT-012
3 HARD STARTILONG CRANKIERRATIC STARTIERRATIC CRANK
--
Starter cranks engine at normal speed but engine requires excessive cranking time
DESCRIPTION before start
Battery in normal condition
STEP INSPECTION ACTION

1 Are any diagnostic trouble codes displayed Yes Diagnostic trouble code displayed
during Key On Engine Off, Key On Check for cause (Refer to Diagnostic Trouble Code
Engine Running or Continuous Memory inspection? chart) a s page FT-77
as page FT-71 No No diagnostic trouble codes displayed
Go to next step
Is a strong blue spark visible at each disconnected Yes 1 GOto next step
e Check camshaft position sensor :signal at PCM
= page FT-168,174,180
If OK, check as follows:
Crankshaft position sensor Section G
High-tension leads Section G
Spark plugs Section G
If not OK, check wirina harness
3 Perform Fuel Line Pressure Inspection.
ua= page FT-147
70 to next step
--
Is fuel line pressure correct?
Fuel line pressure:

No
1
/ Zero or low:
Check fuel pump circuit
page FT-151
240-280 kPa I2.5--2.8 kgflcm2,35--40 psi) Check pressure regulator diaphragm
D ~ Ppage FT-154
High:
Check pressure regulator for high
pressure cause
e page FT-154
Check for clogged fuel return li~ie
--
4 1 Perform Fuel Line Pressure Hold Inspection. Yes Go to next step
i/ page FT-147
1 Does fuel line pressure hold?

Check pressure regulator diaphragm condition
I
w page FT-154
If condition is OK, check injector
page FT-155
If condition is not OK, replace pressure regulator
Disconnect the vacuum hose from the pressure Yes Go to next step
regulator and plug hose. Start the engine.
Does the fuel line pressure remain within
f20 kPa i0.21 kgf/cm2,3 psi) while driving vehicle Check for clogged fuel filter
l 6 I Connect the vacuum hose to the pressure

regulator. Install a vacuum gauge
- to the intake
1 Yes Go to next step
11
-
manifold. Start the engine.
Does fuel pressure gauge reading increase as the pump pressure regulator
vacuum gauge reading decreases and/or does Start the engine
fuel pressure gauge reading decrease as the Check that fuel pressure reading changes as
i
vacuum gauge reading increases? vacuum changes
i If chancles, check vacuum line
I / I no change, replace pressure regulator
STEP
-__A_-
I INSPECTION ACTION
7 Is idle speed correct7 Yes Go to next step
;
Check idle air control solenoid and wiring harness

@ page FT-147
Check throttle body for damage = page FT-146

Check PCM us page FT-164
Is there a restriction in exhaust system? , Yes Check exhaust system

page FT-156 page FT-156
Go to next step
Remove PCV valve and shake it.

Does PCV valve rattle?
Replace PCV valve
Start the engine and bring to normal operating I Yes Go to next step
temperature. Disconnect crankcase ventilation
hose from remote air cleaner. Place a stiff piece No Check evaporative emission system as follows:
of paper over the hose end. Disconnect evaporative hose and place a stiff
Does vacuum hold the paper? piece of paper over hose
Does vacuum hold paper?
If yes, check evaporative
emission system
G=page FT-160
If no, check for vacuum leak in PCV system,
oil cap, PCV valve, rocker cover for bolt
torquelgasket leak
Check for contaminated mass air flow sensor. Yes Replace the mass air flow sensor
Is there any contamination?
-- --- --
No Go to next step
- -- - - -- -- - -- - -- -- -- - - - -
Disconnect vacuum hose from EGR valve Yes Check as follows:

and plug it. EGR vacuum regulator solenold for st~cklng
Does condition improve? Cond~t~on of EGR vacuum regulator solenold
connector female term~nal(s)
- --- - --- --
Check ~fEGR valve moves smoothly

If yes, go to next step
If no, replace EGR valve
Check starting system. Yes Go to next step

Section G -
. --
Is starting system normal? Repair or replace components as required
Verify test results

If OK, return to diagnostic index to service any additional symptoms
MF1460-F2 6BUOFT-013
1
,
AFTER START
i-iTip
ENGINE STALLS ATIDLE
DESCRIPTION
G
ta;=;- idle and/or after start
I
ppp
pp-pp
INSPECTlON ACTION
Does the engine stall at idle in P (Park) or N
(Neutral) with all accessories off?
Does the engine idle roughly in P (Park) or

N (Neutral)? PIGO to neit step -I
Are any diagnostic trouble codes displayed during Yes Diagnostic trouble code displayed
Key On Engine Off, Key On Engine Running, or Check for cause (Refer to Diagnostic Trouble Code
Continuous Memory inspection? chart) r e page FT-77
I@? page FT-71
Go to step 9
Are any diagnostic trouble codes displayed Yes Diagnostic trouble code displa~yed
during Key On Engine Off or Continuous Check for cause (Refer to Diagnostic Trouble Code
Memory inspection? chart)-
- -
I@? page FT-71
No diagnostic trouble codes
Go to next step
Attempt to start engine at part throttle. Yes Check idle air control solenoid and wiring harness
Will engine run smoothly at part throttle? uz page FT-147
Check throttle body for damage
e FT-146
page
Check PCM
m- page FT-164
-
No Go to step 9
-
Are any diagnostic trouble codes displayed Yes Diagnostic trouble code
during Key On Engine Off or Continuous Check for cause (Refer to Diagnostic Trouble Code
Memory inspection? chart) * ~ a a FT-77
e
@ page
s FT-71 No diagnostic trouble codes displayed
Go to next step
Start engine and let idle to bring engine to normal Go to step 9

operating temperature. Does engine stall or RPM Go to next step
drop with idle air control solenoid disconnected?
Are any diagnostic trouble codes displayed Diagnostic trouble code displayed
during Key On Engine Running or Continuous Check for cause (Refer to Diagnostic Trouble Code
Memory inspection? chart) m- page FT-77
Check PID values of the following:

I@? page FT-71
No No diagnostic trouble codes displayed
-
Check idle air control solenoid and wiring harness
page FT-147
DPFEGR sensor No Repair ar replace poor connection in circuit

ECT sensor or component as necessary
IAC solenoid
LONGFT1lLONGFT2
VPWR
VREF
page FT-74
Are PID values within specification?
-- --
Disconnect vacuum hose from EGR on vacuum hose to EGR valve for
valve and plug it. obstruction or leak
Is drive symptom eliminated? If OK, replace EGR vacuum regulator solenoid
-
If not OK, repair or replace vac:uum line
-A-

11 Does EGR valve seat properly? Yes Go to next step
No Check the EGR valve and EGR vacuum regulator
solenoid
= page FT-158,159
12 Remove PCV valve and shake it. Yes Install PCV valve
- -
I Go to next step
, - --- -- - -- -
- - -.
No . Replace PCV valve
+ -p-p-pp. - --- -- -
13 Start engine. Disconnect crankcase ventilation hose Yes Go to next step

the 'lace a stiff piece of paper
over the hose end. No Check system as follows:
Does vacuum hold the paper? Disconnect evaporative hose and place a stiff piece of
paper over hose
-
If yes, check evaporative emission system
page FT-160
If no, check for vacuum leak in PCV system, oil
cap, PCV valve, rocker cover for bolt torquetgasket
--
leak
14 Perform Fuel Line Pressure Inspection. Yes Go to next step
page --150
Is fuel line pressure correct? 7Zero or low:
Check pressure regulator diaphragm
Fuel line pressure: = page FT-154
240-280 kPa (2.5-2.8 kgf/cm2,35-40 psi) Check fuel pump circuit
= page FT-151
High:
i Check pressure regulator for high pressure cause
w page FT-154
Check for clogged fuel return line
15 Visually look for fuel leakage at injector O-ring, Yes Go to next step
pressure regulator, and fuel line. Service as
necessary, Per-formFuel Pressure Hold Inspection Check pressure regulator diaphragm
GF page FT-150
= page FT-154
Does fuel line pressure hold? If condition is OK, check injector
= page FT-155
16 Disconnect inertia fuel shutoff switch connector. Yes ! Go to next step
Crank engine for 5 seconds. Does pressure drop
more than 34 kPa {0.35 kgflcm2, psi) by the end NO Check resistance of injectors at PCM connector
of 5 second crank cycle? i If resistance is OK, check as follows:
Injector drive signal
Injector flow rate
PCM
If resistance is not OK, check for open in injector
circuit
17 Is strong blue spark visible at each disconnected Yes Check spark plugs
high-tension lead while cranking engine? Section G
For 2.3L: If OK, go to next step if symptom occurs
during parking maneuvers
If OK, go to step 19 if symptom occurs
during AIC on
For 3.OU4.OL: If OK, go to step 19
No Check as follows:
High tension leads
= Section G
= Section G
--- -.~
page FT-168,174,180
-- .- -- -
18 Do RPM increase with power steering pressure Yes Replace power steering pressure switch
switch disconnected? - -~ - -- - -
No Check for short circuit in wiring harness from power

steering pressure switch to PCM
- -
MF1746-C2
FT-40
STEP / INSPECTION
Is voltage at ACCS test pin 41 greater than 10.5V
with AIC ON?
Yes
No
1 Check PCM
ACTION?
OK, go to next step

= page FT-164
Check for open circuit in wiring harness from AIC

Dressure switch to PCM 1
Is there a restriction or leak in exhaust system? Yes Check exhaust system
= page FT-156 = page FT-156
Go to next step I
Is air leakage felt or heard at intake air system
component while racing engine to higher speed?
Is engine compression correct?

tE Repair or replace
Go to next step
Check for cause

~r For 2.3L: Section 61
For 3.OL: Section 6 2
Verify test results. If OK, return to diagnostic index to service any additional symptoms
1 5 1 CRANKS NORMALLY BUT WILL NOT START I

DESCRIPTION Starter cranks engine at normal speed but engine will not run
Refer to "ENGINE STALLS" if this symptom appears after engine stall
Fuel in tank
Battery in normal condit~on
Inertia fuel shutoff (IFS) switch is set
I STEP 1 INSPECTION I ACTION 1
inspection?
- page FT-71
Check for cause (refer to Diagnostic Trouble Code
chart)

" pagee FT-77
Perform VREF pinpoint test

If test results are OK, go to next step
Perform Fuel Line Pressure Inspection. Yes Go to next step
Zero or low:
Fuel line pressure: Check pressure regulator diaphragm
240-280 kPa (2.5-2.8 kgf/cm2,35-40 psi) G- page FT-154
= page FT-150 Check fuel pump circuit
a9 page FT-151
High:
Check pressure regulator for high pressure cause
= page FT-154
Visually look for fuel leakage at injector O-ring, Yes Go to next step
necessary. Check pressure regulator diaphragm condition
Perform Fuel Pressure Hold Inspection. = page FT-154
Does fuel line pressure hold?
If condition is not OK, redace oressure reaulator
I STEP INSPECTION
I
ACTION
1 4 : D~sconnectthe Inertla fuel shutoff switch connector. Yes Go to next step
I Crank engine for 5 seconds.
1 Does pressure drop more than 34 kPa No ) Check resistance of injector(s) at PCM connector 1
(0.35 kgf/cm2, 5 psi) by the end of 5 second If res~stance1s OK, check as follows
crank cycle? Injector drive s~gnal
Injector flow rate
PGM
If resistance 1s not OK, check for open in Injector
c~rcult
- - - - -- - - -- -- -- ---- - --
;-iDoes engine stan and run smoothly at part Idle? Check Idle alr control solenold and wlrlng harness
m page FT-147
I
Check throttle body for damage
a* page FT-146
CheckPCM
a* page FT-164
Is voltage at throttle position sensor connector
--
7
termins VREF between 4.0 volts and 6.0 volts with
the ignition switch ON?
-
Key on engine off.
No
Yes
Repair open in VREF circuit
Repair Pin 13 circuit short to power

a* . -
oaae FT-144
Measure voltage between Pin 13 (module

programming signal) at data link connector and
battery negative post. No Go to next step
Is voltage greater than 9.0 volts?
rF -
8 Is a strong blue spark visible at each disconnected Y=(~oxt step
1 high-tension lead'while cranking engine? No Check camshaft pos~t~on sensor slgnal at PCM
-
page FT-168,174,180
If OK, check as follows.
Crankshaft posltlon sensor
= Section G
H~gh-tenslonleads
Section G
Spark plugs
a* Section G
, Check EGR vent on vacuum hose to EGR valve for

If not OK, check wlrlng harness
I-
- --
Disconnect vacuum hose from EGR valve and Yes
plug it. obstruct~onor leak
Is drive symptom eliminated? If OK, replace EGR vacuum regulator solenold
If not OK, repalr or replace vacuum l~ne
- -- -- - - - - -
i
No Go to next step -- -
-
. - -- -- --
- 10 Does EGR valve seat properly (fully closed)? Yes Go to next step - - -
- pp - -- - -
No Check as follows: = page FT-158,159

EGR valve malfunction
EGR flange gasket leak~ng
EGR valve attach~ngnuts or bolts loose or mlsslng
EGR valve contamlnatlon
EGR vacuum regulator solenord malfunct~on
11 Is there a restr~ct~on
~nexhaust system? Yes Check exhaust system
a9- page FT-156 = page FT-156
No Go to next step
12 Is englne compression correct? Yes Go to next step
No Check for cause
For 2.3L: Section 61
For 3.OL: Section 62
For 4.OL: Section B3
13 Verlfy test results If OK, return to d~agnost~c
index to servlce any add~t~onal
symptoms
6 SLOW RETURN TO tDLE
-
-
DESCRIPTION Englne takes more tlme than normal to return to Idle speed
ACTION
-- -
Are any dlagnostlc trouble codes displayed dur~ng Yes Diagnostic trouble code displayed
Key On Englne Off, Key On Eng~neRunning or Check for cause (refer to Diagnostic Trouble Code
Cont~nuousMemory inspection? chart)
= page FT-71 --
w page FT-77
No No diagnostic trouble codes tlisplayed
Go to next step
r-2 ' Remove PCV valve and shake it. Yes Install PCV valve
1 Does PCV valve rattle? GO to next step
1 No Replace PCV valve
I Start engine. Disconnect crankcase ventilation hose
1 from the throttle body. Place a stiff piece of paper
over the hose end.
Does vacuum hold the paper?

= page FT-160
cap, PCV valve, rocker cover for bolt torquetgasket
--
Is the throttle body free of contamination?
= page FT-146
components while racing engine to higher speed?
~o/Goton-;xtii&-----
-Verfiyti results. If OK, return to diagnostic index to service any additional symptoms
ENGINE RUNS ROUGHIROLLING IDLE ATIDLE

DESCRIPTION Engine speed fluctuates between specified idle
shake
Idle speed too slow and excessive engine shake
INSPECTION 1 ACTION 1
Key On Engine Off or Continuous Memory Check for cause (refer to Diagnostic Trouble Code
inspection? chart)
w page FT-71 = page FT-77
Go to next step
- - -- -- --
Start engine and let it idle to bring to normal Yes Go to next step
Does engine stall or RPM drop with idle air control No Check idle air control solenoid and wiring harness
solenoid disconnected? = page FT-147
-
Disconnect vacuum hose from EGR valve and Yes Check EGR vent on vacuum hose to EGR valve for
plug it. obstruction or leak
If not OK, repair or replace vacuum line
-
No Go to next step
I
4 Does EGR valve seat properly? Yes Go to next step

No Check EGR valve and EGR vacuum regulator
solenoid
= page FT-158,159
INSPECTION ACTION
Fuel Line Pressure Inspection.

Fuel line pressure: .g page FT-154
240-280 kPa (2.5-2.8 kgf/cm2, 35-40 psi) Check fuel pump circuit
@ page FT-151
I 1 yig&eck pressure regulator for hlgh pressure cause

.g page FT-154
Check for clogged fuel return llne
- -
Vlsually look for fuel leakage at Injector 0-r~ng, Yes Go to next step
pressure regulator, and fuel llne Service as
No Check pressure regulator diaphragm condltlon
necessary.
Perform Fuel Pressure Hold Inspection.
= page FT-154
If cond~tlonIS OK, check ~njector
@ page FT-150
Does fuel l~nepressure hold? = page FT-155

If condltlon IS not OK, replace pressure requlator
-
Yes Install PCV valve
Does PCV valve rattle7 Go to next step
L A +
No Replace PCV valve

- _ -
Start engine. Disconnect crankcase ventilation hose Go to next step

---- -
from the throttle body. Place a stiff piece of paper
~~~~~
Check evaporative emission system as follows:

over the hose end.
Disconnect evaporative hose and place a stiff piece
of paper over hose
~3page FT-160
cap, PCV valve, rocker cover for bolt torquelgasket
leak
Disconnect inertia fuel shutoff switch connector. Yes Go to next steD
more than 34 kPa (0.35 kgflcm2, 5 psi) by the end
of 5 second crank cycle? If resistance is OK, check as follows:
Injector flow rate
PCM
I If resistance is not OK, check for open in injector
circuit
- - -
Is strong blue spark visible at each disconnected Yes Check spark plugs
high-tension lead while cranking engine? @ Section G
For 2.3L: If OK, go to next step if symptom occurs

during parking maneuvers
If OK, go to step 12 if symptom occurs
during AIC on
-- For 3.OU4.OL: If OK, go to step 12
I No I Check as follows:
= page FT-168,174,180
High-tension leads
Section G
Does EGR valve seat properly? I Yes !Go to next step
solenoid
= page FT-158,159
INSPECTION ACTlOlU
--
US page FT-164
If OK, go to next step
circuit in wiring harness from A/C
r
I pressure switch to PCM
Is there a restriction in exhaust system?
@ page FT-156 GZ= page FT-156

1 s For 2.3L: Section B1

--
If vehicle has MT, go to next step.
Inspect automatic transmission (AT --
Is automatic transmission OK? = Section K

pppppp
FAST IDLE
DESCRIPTION Engine speed continues at fast idle after engine warm-up
1 / Check engine
- coolant temperature sensor PID
Start engine and warm to operating temperature.

Does ECT sensor PID voltage remain greater than = For 2.3L: e o El
Section
0.3 volts (temperature less than 116°C {240°F})? For 3.OL: Section E2
For 4.OL: Section E3
Key On Engine Off, Key On Engine Running or Check for cause (refer to Diagnostic Trouble Code
Continuous Memory inspection? chart)
GZ= page FT-71 page FT-77
@

Go to next steD
Is engine compression correct'? Go to next step
Check for cause
I= For 2.3L: Section B1

1 1
Yes
No
Repair or replace -
Go to next step
r ~ e r i f test
y results. If OK, return to diagnostic index to service any additional symptoms
1
9 LOW IDLEISTALLS DURING DECELERATION
DESCRIPTION Engrne stops unexpectedly at beglnnlng of deceleration or recovery from deceleration
--
STEP-
--
--
- INSPECTION ACTION
---
1 Start englne and let Idle to brlng to normal operating Yes Go to step 3
,
temperature. Does englne stall or RPM drop wlth
idle air control solenold d~sconnected? No Go to next step
+- - - ---- ---- --- - --- - -pp -- pp -- - - - - -
2 Are any dlagnostlc trouble codes displayed durlng Yes Diagnostic trouble code displayed
Key On Englne Off, Key On Englne Runnlng or Check for cause (refer to Dlagnostlc Trouble Code
Contrnuous Memory rnspectlon? chart)
m page FT-71 = page FT-77
I No Check Idle air control solenold and wiring harness
= page FT-147
I
has MT, go to next step Yes Go to next step
71
Inspect automatlc transmlsslon (AT vehlcles only).
KT Section K NO Check for cause
Is automatlc transmasion OK7 Section K
- - - - -- --- - - - -- - - -- - -- - -- -.
Fuel Llne Pressure Inspection. I Yes Go to next step

- -- -- - -- - - -- -
page FT-l ;N low:

Is fuel lrne pressure correct?
I Fuel line pressure:
240-280 kPa (2.5-2.6 kgf/cm2, 35-40 psi) Check fuel pump circult
1 1 1 High:
a* page FT-151
Check pressure regulator for hlgh pressure cause

I
w page FT-154
Check for cloaaed fuel return line
5 Vlsually look for fuel leakage at Injector 0-r~ng,
pressure regulator, and fuel Ilne. Service as
necessary.
Perform Fuel Pressure Hold Inspectlon. page FT-154
page FT-150 If condrtlon IS OK, check Injector
.g page FT-155
Does fuel llne pressure hold?
If condltlon IS not OK, replace pressure regulator
6 , Disconnect inertia fuel shutoff switch connector. Yes Go to next step
more than 34 kPa (0.35 kgf/cm2, 5 psi} by the end No Check resistance of lnjector(s) at PCM connector
, of 5 second crank cycle? If reslstance IS OK, check as follows
Injector drlve slgnal
I Injector flow rate
PCM
If reslstance IS not OK, check for open In Injector
clrcult
f -- - - -- -- -- - - -- - - -. - -- -- - -- - - - ---
7 Check the throttle body for the following: Go to next step

1 Damage
Sticking, bindlng or grabbing condition
Vacuum leaks No Repair or replace as necessary
Proper attachment to accelerator cable
Is the throttle body OK?
Is engine compresslon correct? Yes Go to next step
No Check for cause
E* For 2.3L: Section B1
I
I
I For 4.OL: Section 83
Verlfy test results. If OK, return to diagnostic index to service any add~tlonalsymptoms
1 ENGINE STALLSIQUITS / ACCELERATIONICRUISE
ENGINE RUNS ROUGH ACCELERATIONICRUISE
, ACCELERATIONlCRUISE/DECELERATlON
.p-pp-p- , - - - -
I ACCELERATION
---
1 Engine stops unexpectedly at beginning of acceleration or during acceleration
I Engine stops unexpectedly while cruising
DESCRIPTlON
I Engine speed fluctuates during acceleration or cruising
Engine misses during acceleration or cruising
i
': Vehicle bucksljerks during acceleration, cruising, or deceleration
Momentary pause at beginning of acceleration or during acceleration
INSPECTION
--PA - ..
-
ACTION
-
= page FT-71 --
US page FT-77
~ ~
Go to next steD
Disconnect vacuum hose from EGR valve and plug Yes Check EGR vent on vacuum hose to EGR valve for
It. obstruction or leak
Is drlve symptom el1minated7 If OK, replace EGR vacuunn regulator solenold
1 If not OK, repair or replace vacuum hose
a- - -pp -
No Go to next step -
- -- --- --- - pp ,
-
-P
- - - - -- -- p- ---- -
Does EGR valve seat properly' Yes Go to next step

-- P- - - -- -- --
valve and EGR v,acuum regulator
= page FT-158,159
4 Remove PCV valve and shake it. Yes Install PCV valve
Does PCV valve rattle? Go to next step
Start engine. Disconnect crankcase ventilation hose Yes Go to next step
-
-
No Check evaporative emission system as follows:
over the hose end.
Disconnect evaporative hose .and place a stiff piece
of paper over hose
page FT-160
--P
leak
p-pp-p

= page FT-150 --Pp
Zero or low:
~ -------pppp

Fuel line pressure:
= page FT-154
240-280 kPa (2.5-2.8 kgflcm2, 35-40 psi)
US page FT-151
High:
@ page FT-154

--
necessary.
E* page FT-154
Perform Fuel Pressure Hold Inspection. If condition is OK, check injector
= page FT-150 ah. page FT-155

I
8 Disconnect inertia fuel shutoff switch connector. 1 Yes 1 Go to next step

more than 34 kPa C0.35 kgflcm2, 5 psi) by the end No 1 Check resistance of injector($ at PCM connector
Injector flow rate
PCM
circuit
.
-
9 I Is strong blue spark visible at each disconnected Yes Check spark plugs
high-tensionlead while cranking engine? If OK, go to next step
If not OK, clean or replace spark plugs
High-tension leads
c* Section G
.g Section G
rn page FT-168,174,180
a restriction in exhaust system?

= page FT-156
Yes
No
! Check exhaust system
Go to next step
@ page FT-156
Is air leakage felt or heard at intake air system '

Yes Repa~ror replace
components wh~leraclng engine to h~gherspeed?
) No 1 Go to next step
Is engine compression correct? I Go to next step 1
1 Check for cause - For 2.3L:Section B1
--
Is automatic transmission OK?

-
Inspect automatic transmission (AT vehicles only).
Section K
Yes
No
/ Go to next step
Check for cause
n Section K
1
1
/ 14
MFI 750-C2 60UOFT-019
I 11 / SURGES / ACCELERATIONICRUISE I
I DESCRIPTION Momentary minor irregularity in engine output I
I STEP I INSPECTION 1 ACTION I
Continuous Memory inspection?

-
Key On Engine Off, Key On Engine Running or
page FT-71
No
chart)
- -
= page FT-77
Go to next step
Disconnect vacuum hose from EGR valve and plug Yes Check EGR vent on vacuum hose to EGR valve for
it. obstruction or leak
If not OK, repair or replace
Go to next step
3 Does EGR valve seat properly? I Yes 1 Go to next step I
Check EGR valve and EGR vacuum regulator
solenoid
= page FT-158,159
Start engine. Disconnect crankcase ventilation

from thethrottle body. Place a stiff piece of paper
over the hose end. P
No Check
G G a
evaporitive
emission
t i v e hose and phce a stiff piece of
. .
If yes, check evaporative ernission system
= page FT-160
leak
= page FT-150 Zero or low:
--

Fuel line pressure:
240-280 kPa (2.5-2.8 kgflcrn*, 35-40 psi) Check fuel pump circuit
-
= page FT-154
page FT-151
High:
-

page FT-154
necessary. Check pressure regulator diaphragm condition
= page FT-150 page FT-155
1 8 1 Disconnect inertia fuel shutoff switch connector. I Yes 1 Go to next s t e ~ I
more than 34 kPa (0.35 kgf/cma, 5 psi) by the end Check resistance of injector(s) at PCM connector
Injector drive s i ~ n a l
lnjector flow rate
PCM
clrcuit
I STEP / INSPECTION 1 ACTION I

Is strong blue spark visible at each disconnected
Yes ' Check spark plugs
--
I Check as follows:
High-tension leads
Section G
= Section G
= page FT-168,174,180
i
Is there a restriction in exhaust system7 Yes Check exhaust system
page FT-156
L
=
-
page FT-156
-- - -
No Go to next step
Is engine compression correct? Yes Go to next step

Check for cause
= For 2.3L: Section B1
13 If vehicle has MT, go to next step.
Section K
Is automatic transm~ssionOK? G$. Section K
12 BACKFIRES IDLEIACCELERATIONIDECELERATlON
DESCRIPTION Sound produced from exhaust system
1 Are any diagnostic trouble codes
Key On Engine Off, Key On Engine Running or , Check for cause (refer to Diagnostic Trouble Code
Continuous Memory inspection? 1 chart)
No No diagnostic trouble codes displayed
Go to next step
2 Perform Fuel Line Pressure Inspection. Yes Go to next step
page FT-l 50 NO z e r o or low:
Fuel line pressure:
= page FT-154
240-280 kPa (2.5-2.8 kgflcm2, 35-40 psi)
= pagee FT-151
High:
= pagee FT-154
Check for clogged fuel returr~line
1 3 1 Visually look for fuel leakage at injector O-ring, Yes / Go to next step I
necessary.
= page FT-154
i , If condition is not OK, replace pressure regulator
Disconnect inertia fuel shutoff switch connector. Yes Go to next step
No Check resistance of injector(s) at PCM connector
more than 34 kPa (0.35 kgf/cm2, 5 psi) by the end
lnjector drive signal
Injector flow rate
1 PCM
i circuit
Is strong blue spark visible at each disconnected Yes Check spark plugs
high-tensionlead while cranking engine? If OK, go to next step
1 H~gh-tens~on
leads
Crankshaft posrtlon sensor

-
= Section G
Section G
r
Camshaft posit~onsensor
= page FT-168,174,180
6 i Is engine compression correct? Yes Go to next step
No Check for cause
@ For 2.3L: Section 61
Yes F c k exhaust system
8
= page FT-156
--
ii-h0 f-----
next step
= page FT-156
13 LACKILOSS OF POWER / ACCELERATIONICRUISE

1 DESCRIPTION I Performance poor under load (i.e.. power down when climbina hills) 1
( STEP / INSPECTION 1 ACTION I
Are any diagnostic trouble codes displayed during
Key On Engine Off, Key On Engine Running or Check for cause (refer to Diagnostic Trouble Code
= page FT-71
Go to next step
Check PID values of the following: Yes Go to next step
DPFEGR sensor
ECT sensor
IAC solenoid
LONGFTltLONGFT2
-
No Repair or replace poor connection in circuit or
VPWR component as necessary
VREF
page FT-74
[ 3 1 Perform Fuel Line Pressure Inspection. Yes ( Go to next step 1
I I Is fuel line pressure correct?
Fuel line pressure:

= page FT-l N o r low:
- page FT-154
240-280 kPa (2.5-2.8 kgflcm2,35-40 psi) Check fuel pump circuit
= page FT-151
High:
= page FT-154
4 Visually look for fuel leakage at injector O-ring,
1 1
L r e s s u r e regulator. and fuel line. Service as
-
1
necessary.
( Perform Fuel Pressure Hold Inspection. If condition is OK, check injector
I page FT-150
i Does fuel line pressure hold? If condition is not OK, replace pressure regulator
1 5 Disconnect inertia fuel shutoff switch connector. Yes / Go to next steo I
of injector(s) at PCM connector
more than 34 kPa (0.35 kgf/cm2,5 psi) by the end
Injector dr~vesignal
Injector flow rate
PCM
circuit
Is strong blue spark visible at each disconnected Yes Check spark plugs for improper gap, cracks or worn
high-tension lead while cranking engine? electrodes
Clean or replace as necessary
= Section G
High-tension leads

- Section G
= Section G
= page FT-168,174,180
7 Is there a restriction or leak in exhaust system? Yes Check exhaust system
m= page FT-156 w page FT-156
No Go to next step
MF1753-C1
components while racing engine to higher speed? necessary

No Check for cause
= For 2.3L: Section 8 1
-
o B3
For 4.OL: Section
If vehicle has MT, go to next step. Yes Go to next step
= section K Check for cause
1 Go to next step
-
Is the brake system functioning properly? Yes
= Section P Check for cause
Section P
- -
Disconnect vacuum hose from EGR valve and Yes Check EGR vent on vacuum hose to EGR valve for
plug it. obstruction or leak
If not OK, repair or replace vacuum line
No 1 Go to next step
+
Does EGR valve seat properly? Yes 1 Go to next step
-
Check EGR valve and EGR vac:uum regulator
solenoid
-
page FT-158,159
I
Is voltage at ACCS test pin 41 greater than 10.5V Yes Check PCM
with AIC ON? page FT-164
No Check for open circuit in wiring harness from A/C
pressure switch to PCM
Does the A/C cut out (turn off) under wide open Yes Go to next step I
throttle (WOT) conditions?
Go to the "NC DOES NOT CUT OFF UNDER
WIDE OPEN THROTTLE CON131TIONSn Diagnostic
Troubleshooting Chart No. 28
1 16 / Verify test results. If OK, return to diagnostic index to service any additional symptoms I
1 14 KNOCKINGIPINGING I ACCELERATIONICRUISE I
DESCRIPTION 1 Sound produced when airlfuel mixture is ignited by something other than spark plug I
STEP 1 -
INSPECTION I ACTION
1 Check engine coolant temperature sensor PID Yes Go to next step
--
value.
page FT-186 NO Check coollng system for cause of overheating
Start engine and warm to operating temperature. w For 2.3L: Section E l
Does ECT sensor PID voltage remain greater than For 3.OL: Section E2
0.3 volts (temperature less than 116°C {240°F))7 For 4.OL: Section E3
- -- -- -
- -- -
2 Are any diagnostic trouble codes displayed durlng Yes Diagnostic trouble code displayed
Key On Englne Off, Key On Englne Runnlng or
Continuous Memory 1nspectlon7
-
page FT-71
Check for cause (refer to Dlagnostlc Trouble Code
chart)
w page FT-77
--
3
- - - -- -- --
Is englne compression correct?
- - Yes
I No
' No diagnostic trouble codes displayed
Go to next step
Go to next step
- -- -- -
-- - - - - -
No Check for cause

- --- ---- --- - / -- -- -
4 Perform Fuel Llne Pressure lnsoectlon Yes Go to next steo

--
: No
-- - ---
ex page FT-l 50
I Check oressure reaulator
" . .
dlaohraam
a9 page FT-154
Fuel line pressure:
240-280 kPa I2.5-2.8 kgflcm2,3 5 4 0 psi)
page FT-151
High:
= page FT-154
5 Visually look for fuel leakage at injector O-ring, 1 Yes Go to next step
No Check pressure regulator diaphragm condition
necessary.
= page FT-154
1 Does fuel line pressure hold?
= page FT-150 1 If condition is OK, check injector
= page FT-155
6
I
/ Disconnect inertia fuel shutoff switch connector.

I
I
I
1 Yes
II If condition is not OK, replace pressure requlator
1 Go to next step
- 1
- I
more than 34 kPa (0.35 kgf/cm2, 5 psi) by the end
No / Check resistance of injector(s) at PCM connector
Injector flow rate
PCM
If resistance IS not OK, check for open in injector
clrcult
- ---- - - --- - -- -
Is strong blue spark visible at each disconnected Yes Check spark plugs for Improper gap, cracks or worn
high-tension lead while cranking engine? electrodes
i Clean or replace as necessary
High-tension leads
u* Section G
/ Crankshaft position sensor
1 Camshaft position sensor

= Section G
=*page FT-168,174,180
-- pp - - -- -. - - - ---- - - --
8 Remove PCV valve and shake rt. Yes Install PCV valve
MF1754-C1
STEP INSPECTION ACT
O
IN-
lgl
Is OCT ADJ shorting bar removed and is a
modification decal attached to the vehicle indicating
ppp--
OCT ADJ shorting bar

that the OCT ADJ shorting bar was removed? If OK, go to next step
10 Is air leakage felt or heard at intake air system
11 Is engine oil quality OK?
12 Verify test results. If OK, return lo diagnostic index to service any additional symptoms
MF1754-C2 6BUOFT-023
1 15 / POOR FUEL ECONOMY 7

DESCRIPTION Fuel economy unsatisfactory
STEP / INSPECTION
Continuous Memory inspection'?

-
page FT-71
chart)

-
Check for cause (refer to Diagriostic Trouble Code
page FT-77
Go to next step
Check PID values of the following:
DPFEGR sensor
ECT sensor
IAC solenoid
LONGFTllLONGFT2 Repair or replace poor connec1:ion in circuit or
VPWR component as necessary
VREF
II-~page FT-74
p.ppp-p-
Perform Fuel Line Pressure Inspection. I Yes / G o to next step I

a page FT-150
Zero or low:
Fuel line pressure:
= page FT-154
240-280 kPa (2.5-2.8 kgflcm2,35-40 psi)
page FT-151
II-~
High:
= page FT-154
Visually look for fuel leakage at injector O-ring, I Yes / G o to next step I
necessary.
= page FT-154
I I - ~page FT-150
I I - ~page FT-155
Does fuel line pressure hold? If condition is not OK, replace pressure regulator
Disconnect inertia fuel shutoff switch connector. Yes / G o to next step I
Crank engine for 5 seconds. Does pressure drop / Check resistance of injector(s) at PCM connector
more than 34 kPa (0.35 kgflcm2,5 psi) by the end
of 5 second crank cycle? If resistance is OK, check a:s follows:
* lnjector drive signal
* Injector flow rate
* PCM
, circuit
I STEP / INSPECTION ACTION

6
1 Is strong blue spark visible at each disconnected
high-tensionlead while cranking engine?
Yes Check spark plugs for improper gap, cracks or worn
electrodes
Clean or replace as necessary
Section G
~r--
No
1 Check as follows:
High-tension leads
= Section G
Crankshaft posltlon sensor
a* Section G
Camshaft posit~onsensor
= page FT-168,174,180
Is there a restriction or leak in exhaust system?

page FT-156

Yes
Yes
Check exhaust system
GO to next step
Go to next step
.;;z page FT-156
I
.a Section K Check for cause
Remove PCV valve and shake it. Yes Install PCV valve
Does PCV valve rattle? I Go to next step -
-
; Is the brake system functioning properly? Yes Go to next step
I
* Section P No Repair or replace
ux For 2.3L: Section B1

Is air leakage felt or heard at intake air system Repair or replace
No Go to next step
Is the cooling system functioning properly? Yes Go to next step
pp ---.
- - - -- --
Inspect coollng system for cause of overheating

= For 2.3L: Section E l
( 14 / Verify test results. If OK, return to diagnostic index to service any additional symptoms 1
1 16 / EMISSIONS COMPLIANCE I
I DESCRIPTION Fails emissions test I
-- --

-
page FT-71
chart)
-
page
e FT-77
Go to next step
Check PID values of the following: Yes Go to next step
DPFEGR sensor
ECT sensor
IAC solenoid
LONGFT1lLONGFT2
VPWR
VREF
No
! Repair or replace poor connection in circuit or
component as necessary
= page FT-74
1 Perform Fuel Line Pressure Inspection. I Yes 1 Go to next step I
= page FT-150 No Zero or low:
Fuel line pressure: = page FT-154
240-280 kPa (2.5-2.8 kgflcm2, 35-40 psi) Check fuel pump circuit
.;g page FT-151
High:
= page FT-154
Check for cloaaed fuel return line
Visually look for fuel leakage at injector O-ring, Yes / Go to next step I
necessary. No Check pressure regulator diaphragm condition
= page FT-150
Does fuel line pressure hold? = page FT-155
,- If- -
condition is not OK, replace pressure reaulator
Disconnect inertia fuel shutoff switch connector. Yes Go lo next step
more than 34 kPa {0.35 kgf/cm2, 5 psi) by the end No Check resistance of injector(s) at PCM connector
Injector flow rate
PCM
circuit
Is strong blue spark visible at each disconnected Yes Check spark plugs for improper gap, cracks or worn
high-tensionlead while cranking engine? electrodes
Check or replace as necessary
= Section G
Check as follows:
High-tension leads
= Section G
Section G
= page FT-168,174,180
1 Yes Install PCV valve
Go to next step
Replace PCV valve
FT TROU6LESHOOTlNG GUIDE
1 STEP 1 INSPECTION ACTION I

Start engine. Disconnect crankcase ventilation hose Yes I Go to next step
No Check evaporative emission system as follows:
over the hose end.
Disconnect evaporative hose and place a stiff piece
of paper over hose
= page FT-160
leak
Is there a restriction or leak in exhaust system?
Does EGR valve seat properly?

= page FT-156
Yes
No
Go to next step
= page FT-156
Check EGR valve and EGR vacuum regulator

I
solenoid
= page FT-158,159
No Check for cause
= For 2.3L: Section B1
Is air leakage felt or heard at intake air system I Yes Repair or replace
I No 1 Go to next step
13 1 Is the engine operating at the proper temperature? Yes --
for cause of overheating

MF1756-C2 6BUOFT-025
17 / MlVTClL NEVER ON
1 MlVTClL ALWAYS ON
Malfunction indicator lamp (MIL) never on
Transmission control indicator lamp (TCIL) never on
Malfunction indicator lamp always on
Transmission control indicator lamp always on
Is the symptom MIL never on or TCIL never on
(including the prove-out bulb check when the engine
is first started)?
Yes
I Go to step 7 for MIL
GOto step 10 for TCIL
No 1 Go to next step 1
Does the engine start?
No Check for cause
Go to the "CRANKS NORMAL.LY BUT WILL NOT
START" Diagnostic Troubleshooting chart No. 5
3 Does the engine idle roughly in P (Park) or N 1 Go to next step 1
(Neutral)?
/ GO to step 5 I
Diagnostic trouble code displayed
inspection?
= page FT-71 L chart)

-
page FT-77
Check for cause

Go the the "ENGINE RUNS ROUGHIROLLING IDLE"
Diaanostic Troubleshootina chart No. 7
Are any diagnostic trouble codes displayed during Yes 1 Diagnostic trouble code displayed
Key On Engine Off, Key On Engine Running, or Check for cause (refer to Diagnostic Trouble Code
Continuous Memory in spec ti or^? chart)
= page FT-71
Is the MIL or TCIL always on with the engine

running?
Yes
No
1 Go to next step
Go to step 12 for MIL
Go to step 13 for TCIL
Check MIL or TCIL circuit for !short to ground
Is the MIL fuse burnt? Yes I Repair wiring harness and replace fuse I
No / Go to next step 1
1 8 Is voltage greater than 10.5 volts between MIL B+

at the instrument cluster connector and ground with
keyON?
?
Yes Go to next step
ignition
Repair open
switchin wiring harness between fuse block and
Disconnect PCM. Yes Refer to 1997 B-series BETM to check instrument

Does continuity exist between MIL socket and MIL cluster bulb
test pin 2 (P/LG)? If OK, replace PCM
Repair open in wiring harness between PCM and MIL
socket
Reconnect PCM
10 1 Are any diagnostic trouble codes displayed during Yes Diagnostic trouble code displayed
I Key On Engine Running inspection? Check for cause (refer to Diagnostic Trouble Code
= page FT-71 chart)
= page FT-77
I e
I Go to next step

- -.
11 Key OFF. 'I Yes Replace PCM

Install breakout box. Leave PCM disconnected.
Key ON. No ' Refer to 1997 B-series BETM to check instrument
Is the voltage between TClL test pin 79 and PWR
GND test pin 24 and between TClL test pin 79 and
~ cluster bulb
If OK, repair open in wiring harness between
PWR GND test pin 76 at breakout box greater than ignition switch and test pin 79 at harness connector
2.0 volts?
-- -- pp-p.p ~- ~-
1j Key
~
12 OFF. Yes Repair short circuit between test pin 2 and MIL
Install breakout box. Leave PCM disconnected. Reconnect PCM
Key ON.
Is the resistance between MIL test pin 2 and PWR
GND test pin 51 or PWR GND test pin 103 at No Replace PCM
breakout box less than 5.0 ohms?
--
13 Disconnect PCM and inspect both ends for damage, Yes Repair short circuit between TClL bulb and test pin 79
moisture, pushed out pins, loose wires. Service as
necessary. -
Key ON, engine off. No Replace PCM
Does the TClL remain on? I
I
19 1 HIGH OIL CONSUMPTIONILEAKS
DESCRIPTION 011
consumption excesslve
1 Remove PCV valve and shake PCV valve. Yes Go to next step
2 Is blue smoke comlng from exhaust? Yes Check for cause
Go to the "EXHAUST SMOKE"
D~agnost~c Troubleshoot~ngchart No 22
'.g page FT-61
No Go to next step
3 Verlfy test results If OK, return to dtagnostlc ~ndexto servlce any addlt~onalsymptoms
1 20 1 COOLING SYSTEM CONCERNS OVERHEATINGI I

( DESCRIPTION ( Engine runs at higher than normal temperatureloverheats 1
I STEP I INSPECTION 1 ACTION 1
I 1 Is drive belt OK? / Yes 1 Go to next steo I
Section
No Replace drive belt
7 a;.. Section G
1 NO Check for cause

-
3 Inspect engine block for leaks or blockage. Yes Repair or replace
Is fault present?
No Go to next step
-
-
1 21 / COOLING SYSTEM CONCERNS 1 RUNS COLD I
DESCRIPTION Engine does not reach normal operating temperature
-
.

1 Is cooling system operating properly? Yes Go to next step
No Check for cause
n= For 2.3L: Section E l
e o E2
For 3.OL: Section
e o E3
For 4.OL: Section
2 Is complaint "Lack of passenger compartment heat" Yes Refer to 1996 B-series BETM to check heating
and the engine is operating at normal temperature? system
--
i No Go to next step
Is temperature gauge working properly? I Yes / G o to next step I
/
No
I Refer to 1996 B-series BETM lo check temperature
wuge
1 4 Verify test results. If OK, return to diagnostic index to service any additional symptoms I
1 22 / EXHAUST SMOKE I
I DESCRIPTION I Blue, black, or white smoke from exhaust system 1
I STEP I INSPECTION I ACTION 1
What is the color of smoke coming from exhaust I
Blue Go to next step
system?
White I Go to step 4
I 1 / Black / Go to step 5 I
Remove PCV valve and shake it. 1 Yes / G o to next step
/ No 1 Replace PCV valve

Does cooling system hold pressure? Yes I Go step 10
No Check for cause
For 2.3L: Section E l
e
= page FT-71 - -
= page FT-77
Go to next step
Perform Fuel Line Pressure Inspection. Yes 1 Go to next step 1
li-8 page FT-150
No Zero or low:
Fuel line pressure: page FT-154
240-280 kPa C2.5-2.8 kgf/cm2, 35-40 psi) Check fuel pump circuit
= page FT-151
High:
= page FT-154

1
-- -1
7 Perform Fuel Pressure Hold Inspection. Yes Go to next step
u* page FT-150 Check pressure regulator diaphragm
. No
Does fuel l~nepressure hold?
page FT-154
!
If OK, check injector
page FT-155
If not OK, replace pressure regulator
Disconnect inertia fuel shutoff switch connector. Yes Go to next steo
more than 34 kPa C0.35 kgflcm2, 5 psi) by the end No Check resistance of injector(s) at PCM connector
If resistance is OK, check as follows:
of 5 second crank cycle?
Injection flow rate
PCM
circuit
high-tensionlead while cranking engine?

If not OK, clean or replace spark plugs --
High-tensionleads
23 FUEL ODOR (IN ENGINE COMPARTMENT)
-- --
DESCRIPTION I Gasoline fuel smell or visible leaks
I STEP 1 INSPECTION 1 ACTlOlU I
1 Visually look for fuel leakage at injector O-ring,
necessary.
Perform Fuel Pressure Hold Inspection. e
= page FT-150 If condition is OK, check injector
If condition is not OK, re~lacewressure reaulator
Start the engine and bring to normal operating Yes Go to next step
temperature. Disconnect crankcase ventilation hose
from the throttle body. Place a stiff piece of paper Check evaporative emission system as follows:
over the hose end. Disconnect evaporative hose and place a stiff piece
Does vacuum hold the paper? of paper over hose
page FT-160
leak
Remove a plug line to evaporative emission Yes Repair or replace
canister. Remove gas cap and install a vacuum
pumplgauge gas cap. Apply air pressure.
Air pressure: Go to next step
20-27 kPa (0.21-4.28 kgf/cm2, 3--4 psi)
Is either a vacuum or fuel leak detected?
Check for blockagelrestrictions or open (hoses) Yes Replace vacuum hose
between engine vacuum port and evaporative
emission canister. Check for blockage in fuel tank
vent system. No Go to next step
Is a fault detected?
Check evaporative emission canister purge Yes Go to next step
solenoid. --
Is the solenoid operating properly? No Replace the evaporative emission canister purge
= page FT-161 solenoid
6 Are any diagnostic trouble codes
page FT-71 = page FT-77
Go to next step
MF1478-F 6BUOFT-030
1 24 / ENGINE NOISE I
I DESCRIPTION Enaine noise from under hood 1
STEP / INSPECTION ACTION
1 Is a squeal, click or chirp sound present? Yes Check as follows:
id. For 2.3L: Section B1
Engine oil level
Drive belts
Tappets and push rods
No Go to next step
2 Is a rumble or grind sound present? Yes Check drive belt
No Go to next step
- - --
3 - - $ g i rattle sound present? Yes Check location of rattle for loose parts
-
.-- - - -
No Go to next step
-- - - -. --
Is a hiss sound present? Yes Check as follows:
Engine cooling system for leaks
Vacuum leaks
Spark plug loose
Intake air system leaks
Evaporative emission system leaks
No Go to next step
5 Is a snap sound present? Yes Check secondary ignition system for shorts
= Section G
No Go to next step
1 Is a rap or roar sound present?
!-I
6 Yes Check exhaust system for loose parts
= page FT-156
-
No Go to next step
Yes Go to the "KNOCKING/PINGING" Diagnostic
Troubleshooting chart No. 14
= page FT-54
No Go to next steo I
MF1479-C 6BUOFT-031
-i
VIBRATION CONCERNS (ENGINE)
--
under hood or driveline
INSPECTION I- ACTION
1 Check the following components for loose attaching Yes Repair or replace
bolts or worn parts:
Cooling fan
Drive belt and pulleys
Engine mounts Go to next step
Vibration damper
; Is a fault present?
2 Check the following systems for malfunctioning Yes / Repair or replace
components:
Tires
Wheels
Transmission No Go to next step
Driveline
Suspension
Is a fault present?
1 3 1 Verify test results. If OK, return lo diagnostic index to service any additional symptoms I
1 26 1 AIC DOES NOT WORK I

( DESCRIPTION / N C compressor magnetic clutch does not engage when N C is turned on I
1 Key OFF. Disconnect N C cycling switch (ACCS). Yes Key OFF
Install a jumper wire in the ACCS vehicle harness Connect A/C clutch and ACCS
connector to complete the circuit. Disconnect A/C Remove jumper wire
clutch connector. Connect a DVOM between the Refer to 1997 B-series BETM to check the heater and
power pin and ground pin at the A/Cclutch vehicle air conditioning systems
harness connector. Start engine. Turn A/C on and
2
I wait 15 seconds.
Was DVOM voltage greater than 10.5 volts?
Key OFF. Disconnect ACCS. Install a jumper wire in Yes
1 Go to next step
Go to next step
the ACCS vehicle harness connector to complete
the circuit. Connect New Generation Star (NGS)
tester to data link connector. Start engine. Turn A/C No Refer to 1997 B-series BETM to check the heater and
on. Access and view ACCS PID. air conditioning systems
Was ACCS PID on?
Go to next step
A/C ALWAYS ON
AIC COMPRESSOR RUNS CONTINUOUSLY
DESCRIPTION / N C compressor magnetic clutch does not disengage
_1
I STEP / INSPECTION I ACTION I
N C and defroster OFF. Disconnect AIC clutch
connector. Connect a DVOM between the power pin Connect N C clutch
1 and ground pin at the AIC clutch vehicle harness
! connector. Start engine. Monitor voltage.
Refer to the 1997 8-series BETM to check the heater
1 Is voltage less than 2.0 volts?

2 ' Key OFF. Connect New Generation Star (NGS) Yes Refer to the 1997 B-series BETM to check the heater
tester to data link connector. Start engine. N C and and air conditioning systems
defroster off. Access and view N C cycling switch
(ACCS) PID. No Go to next step
Is ACCS PID off?
3 Key OFF. Disconnect N C cycling switch. Yes KeyOFF
Key ON, engine off. Access the ACCS PID. Refer to the 1997 B-series BETM to verify the
Is the ACCS PID off? operation of the N C switch
If OK, repair short to power in N C switch to N C
cycling switch circuit
No Key OFF
Go to next step
-- - -- -
-
4 Key OFF. Disconnect wide open throttle N C cutout Yes Key OFF
relay. Key ON. Go to next step
Is voltage between power-to-clutch of WAC relay
vehicle harness connector and chassis ground less No Key OFF
than 1.0 volt? Repair short circuit to power
5 Key OFF. Disconnect N C cycling switch and wide Yes Go to next step
open throttle N C cutout relay. Disconnect PCM and
inspect for damage, moisture, pushed out pins,
loose wires. Service as necessaw. Install breakout
box, leave PCM disconnected.~e~ ON. No Repair short to power in ACCS circuit
Is voltage between ACCS test pin 41 and PWR
GND test in 51 and PWR GND test oin 103 at
I breakout box less than 1.0 volt?
I
I I
6 Key OFF. Connect wide open throttle N C cutout Yes Replace PCM
relay. N C cycling switch disconnected. Breakout
box installed. PCM disconnected. Kev ON.
Is voltage between ACCS test pin 41sand PWR No Replace wide open throttle N C cutout relay
GND test pin 51 and PWR GND test pin 103 at
breakout box less than 1.0 volt? I
I I
I I
MF4082-B 6BUOFT-034
1 28 1 AIC DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS I
1 DESCRIPTION / N C compressor magnetic clutch does not disengage under wide open throttle I
I STEP / INSPECTION 1 ACTlOhl 1
Remove the wide open throttle NC cutout relay.
Is voltage at terminal (R) of the wide open throttle
Yes GOto next step
I
N C cutout relay connector greater than 10.5 volts No Repair wide open throttle N C c:utout power circuit
with the ignition switch ON? Go to step 4
1 2 1 Refer to the 1997 B-series BETlW to check the wide I Yes Go to next steo I
open throttle N C cutout relay.
Is the wide open throttle A/C cutout relay OK? F - F p ~ c widee bpen throttle NC
Go to step 4
Is voltage at WAC test pin 69 ( P N ) correct? Yes Check wiring harness between wide open throttle N C
= page FT-167,173,179 cutout relay and PCM for open or short circuit
Go to next step
No Replace PCM
= page FT-164
Go lo next step
1 4
1 Verify test results. If OK, return to diagnostic index to service any additional symptoms I
MF4083-E 6BUOFT-035
29 EXHAUST SULPHUR SMELL

DESCRIPTION i Rotten egg smell (sulphur) from exhaust
NOTE:
Some slight sulphur smell may be normal. Catalysts with less than 8-16 thousand kilometers
(5-10 thousand miles) are more likely to have a sulphur smell concern due to the highly active
state of new catalysts. Replacing the catalyst if no problem is found may actually make the
symptom worse.
STEP I INSPECTION I ACTION
1 / Perform Fuel Line Pressure Inspection. / Yes 1 Go to next step
io
= page FT-150
t
--
Is fuel line pressure correct? Zero or low:

a-s page FT-154
Fuel line pressure:
240-280 kPa (2.5-2.8 kgflcm2,3 5 4 0 psi) Check fuel pump circuit
a-s page FT-151
High:
a-s page FT-154
-
Vlsually look for fuel leakage at injector 0-ring, Yes ' Go to next step
pressure regulator, and fuel Ilne. Service as
necessary. No Check pressure regulator diaphragm condition
a-s page FT-154
I If condition is not OK, replace pressure re<ulator
-
= page FT-71 w page FT-77
--
Go to next step
4 Start engine. Disconnect crankcase ventilation hose Yes Go to next step
over the hose end. No Check evaporative emission system as follows:
Does vacuum hold the paper? Disconnect evaporative hose and place a stiff piece
of paper over hose
page FT-160
leak
1 5 Verify test results. If OK, return to diagnostic index to service any additional symptoms I
1 30 INTERMITTENT CONCERNS I
DESCRIPTION Symptom occurs randomly and is difficult to d~agnose.
INSPECTION I-ACTION P
1 Talk to customer. Review the vehicle service history. Yes Go to next step
1/ and
Does the vehicle have a number of previous repairs
components replaced for a certain symptom?
--
Go to diagnostic chart for symptom

i
; Key OFF. Connect scan tool or NGS to data link Yes lnspect each wire for corrosion, bent or loose terminal
I connector. If input is switch-type component, turn crimps
1 on manually. Key ON, engine off. Access PlDs
/ for suspect component. Lightly tap on suspect
,
i
component, wiggle and pull each wirelconnector at
suspect component or PCM. Go to next step
i Are any PID values out of range, or suddenly
/ change and go back into range?
Key ON, engine running. Lightly tap on suspect lnspect each wire for corrosion, bent or loose terminal
component, wiggle and pull each wirelconnector at crimps
suspect component or PCM.
Are any PID values out of range, or suddenly Go to next step
change and go back into range?
!I
Key OFF. Connect scan tool or NGS to data link Yes Fault area is identified
connector. Key ON, engine running. Access PlDs If fault occurred while spraying on component:
for suspect component. Accurately spray water on Replace part and verify repair
suspect component wire, component or vacuum line If fault occurred while spraying vviring:
related to possible fault area. Inspect each wire for corrosion, bent or loose
Are any PID values out of range, or suddenly change terminals and poor wire terminal crimps
and go back into range, or was there a noticeable If fault occurred while spraying vacuum line:
engine misfirelstumble? Repair vacuum hose(s)
No Go to-
next step
- --
- --- -
. -
Key OFF. Connect scan tool or NGS to data link connector.

Key ON, engine running. Access PlDs for suspect component.
Record PID value at HOT IDLE, 30 MPH and 55 MPH.
Compare actual values to PCM reference value. lnspect wire and connector at suspect component for corrosion,
bent or loose terminals, poor wire terminal crimps and high tension of wire.
Repair as necessary.
1 31 / OUTPUT TEST MODE NOT FUNCTIONING I

I DESCRIPTION Output test mode cannot be entered I
Key OFF. lnspect connection between scan tool or Yes Go to next step
NGS and data link connector for damaged or
oushed out ins. lnsoect scan tool or NGS cable
8 ~ ~
~ -
~
for obvious damage.' No Repair or replace as necessary

Are DLC and scan tool or NGS properly connected
and is cable OK?
Key OFF. Inspect connector and cable between
scan tool or NGS and vehicle battery supply or at
cigarette lighter for obvious damage.
Are power supply connector and cable OK?
Yes
No Repair or replace as necessary d

Verify that proper key sequence was used for
output(s) in Output Test Mode.
6BUOFT-038
FT ON-BOARD DIAGNOSIS SYSTEM
ON-BOARD DIAGNOSIS SYSTEM

PREPARATION
SST
QUICK TEST DESCRIPTION

Quick Test is divided into three special tests: Key On Engine Off On-Demand Self-Test, Key On Engine
Running On-Demand Self-Test and RetrieveIClear Continuous DTC Self-Test. Quick Test also provides
a quick check of the powertrain control system and is usually performed at the start of each diagnostic
procedure and at the end of most pinpoint testsfor verification of repair and to ensure no other faults exist.
6BUOFT-039
Key On Engine Off On-Demand Self-Test

Key On Engine Off is a functional test of the powertrain control system performed on demand. A fault
has to be present at the time of testing for the Key On Engine Off Self-Test to detect the fault. When a
fault is detected, a Diagnostic Trouble Code (DTC) will be output on the data link when requested by
a scan tool.
6BUOFT-040
Key On Engine Running On-Demand Self-Test

Key On Engine Running is afunctional test of the powertrain control system performed on demand with
the engine running and vehicle stopped. A check of the inputs and outputs is made during operating
conditions and at normal temperature. A fault has to be present at the time of testing. When a fault is
detected, a Diagnostic Trouble Code (DTC) will be output on the data link when requested by a scan
tool.
6BUOFT-041
RetrieveIClear Continuous DTC Self-Test

Continuous DTC access is also a functional test of the powertrain control system. The continuous self-
test is always active. The test consists of all the OBD II monitors and the comprehensive component
monitor, and is designed to detect failures contributing to driveability and emission concerns. As part of
Quick Test, the technician may perform a specific drive cycle before running Quick Test. This is neces-
sary to detect certain faults not tested during other self-test operations. All self-tests are menu driven in
the New Generation Star (NGS) scan tool.
6BUOFT-042
Parameter Identification (PID) Access

The PID mode allows access to certain data values, analog and digital inputs and outputs, calculated
values, and system status information.
5BUOF3-041
Brake OnIOff Test

On vehicles equipped with Brake OntOff (BOO) input, the brake pedal MUST be depressed and released
after Key On Engine Running Self-Test is initiated.
5BUOF3-042
Transmission Control Switch Test

On vehicles equipped with a transmission control switch (TCS), the switch MUST be cycled after the Key
On Engine Running Self-Test is initiated.
5BUOF3-043
Wigglerrap Test
The wigglettap test is performed by the technician in an attempt to re-create an intermittent fault.
5BUOF3-044
ON-BOARD DIAGNOSIS SYSTEM FT
,PROGRAM 4DIAGNOSTIC TROUBLE CODE (DTC) NUMBER
Next Generation Start (NGS) Hook-up Procedure
Note
Make sure Key is OFF.
CONNECTOR
1. Insert the vehicle ~nterfacemodule and program card ~ n t o

TRIGGER KEYS
the SST (NGS) control unit.
VEHICLE INTERFACE 2. Plug the NGS OBD II adapter into the interface module
MODULE (VIM)
and the large 5-pin connector ~ntothe vehicle data link
MF2012 A connector (DLC) located under the dash to left of hood
release.
3. Plug the (NGS) tester power cable into the NGS OBD II
adapter power cable connector, cigarette lighter or use
battery hook-up adapter.
Note
Use battery hook-up adapter only when using NGS
as voltmeter or ohmmeter. Do not use the adapter
to pull DTCs.
MF1667-A
4, Listen for a double beep. SST (NGS) is now initialized. It
I 1 will briefly display the system check screen.
DIAGNOSTIC LlNK MODULE 85-96 VlNl V2.01
0
MF2013-A
7
6BUOFT-042
Retrieving DTC(s)
Note
Start engine and bring up to operating temperature
syau
- before running Quick Test.
DIAGNOSTIC DATA LlNK
VIEW RECORDER AREAS
DIGITAL MEASUREMENT SYSTEM 1. Perform the necessary vehicle preparation and visual
GENERIC OED # FUNCTIONS
inspection. Hook up SST (NGS) to vehicle.
I" SELECT ITEM AND PRESS TRIGGER TO START
d
1 2. Move the cursor to VEHICLE AND ENGINE SELEC-
TION. Press the trigger key to enter this selection.
3. Move the cursor to SELECT NEW VEHICLE YEAR &

MODEL. Press the trigger key to enter this selection.
I I 11 NO VEHICLE SELECTED
I
DESELECT CURRENT MODEL
SF1 F C T I T F M A N n P R F 9 9 T R I G G F R TO .START
4. Move the cursor to 1997-VIN #1 O:V. Press the trigger key
to enter this selection.
II I1
1993 - VIN # l o = P
1992-VIN#iO=N
1991 - VIN # i 0 = M
I' I)
SELECT ITEM AND PRESS TRIGGER TO START
I I
MF4016-A
5. Move the cursor to appropriate model. Press the trigger
P1 I( key to enter this selection.
6. he vehicle selection screen showing the selected
vehicle will be displayed. ~ o v the
e cursor to the vehicle
selected. Press the trigger key.
96 4.0L MAN 84000
7. Move the cursor to DIAGNOSTIC DATA LINK in the main

menu screen. Press trigger key to enter into menu system
- ~ diagnostics.
VIEW RECORDER AREAS

DIGITAL MEASUREMENT SYSTEM
GENERIC OED # FUNCTIONS
I '
C)N-BOARD DIAGNOSIS SYSTEM FT
8. Move the cursor to PCM. Press trigger.
ABS - ANTILOCK BRAKE SYSTEM

GEM - GENERIC ELECTRONIC MODULE
IABM - INTEGRATEDAIR BAG MODULE
RAP - REMOTE ANTI-THEFT MODULE
II
4
I
9. Move the cursor to DIAGNOSTIC TEST MODE. Press

the trigger key to enter this selection.
ACTIVE COMMAND MODES

DIAGNOSTIC TROUBLE CODE LIBRARY
I I
MF2022-A
1 RETRIEVWCLEAR CONTINUOUS DTCS 1

10. Move the cursor to appropriate mode. Press the trigger
key to enter this selection.
11. Retrieve DTCs as follows:

1 ) Continuous DTCS
I 1I 2) KOEO DTCs
KOEO ON-DEMAND SELF TEST
KOER ON-DEMAND SELF TEST
ON BOARD SYSTEM READINESS TESTS 3) KOER DTCs
I' SELECT ITEM AND PRESS TRIGGER TO START I' I
Note
The first test to run is RetrieveIClear Continuous DTCs. Record the DTCs on a piece of paper
and proceed to the KOEO test.
Note
The purpose of recording continuous DTCs at this time is to make sure they are not uninten-
tionally cleared during any KOEO or KOER service. KOEO and KOER codes are always
addressed before continuous codes.
5BUOF-112
RetrievelClear Continuous DTCs
1. Move the cursor to RETRIEVEICLEAR CONTINUOUS DTCs.
Press the trigger key to enter this selection.
2. Turn key on. Press START.
3. Follow operating instruction frorn the menu.
4. If there are DTC(s), refer to Diagnostic Trouble Code Chart on page FT-77 for further diagnosis informa-
tion. After repairs, clear DTCs. Press "C-ALL" (Key #7) button and press trigger.
5. If there are no codes, press CANCEL. Perform KOEO On-Demand Self-Test.
KOEO On-Demand Self-Test ~BUOFT-046
1. Move the cursor to KOEO ON-DEMAND SELF-TEST.
2. Turn key on. Press START.
3. Follow operating instruction frorn the menu.
4. Note any KOEO DTCs. Press CANCEL. Perform KOER On-Demand Self-Test.
KOER On-Demand Self-Test e

1. Move the cursor to KOER ON-DEMAND SELF-TEST.
2. Start engine. Press START.
3. Follow operating instruction from the menu and perform BOO, TCS and PSP cycling test, if equipped.
Caution
On vehicles
e equipped with Brake OnIOff input, the brake pedal must be depressed and
released
ee after KOER ON-DEMAND SELF-TEST is initiated.
On vehicles
e equipped with Transmission Control Switch (TCS), the switch must be cycled after
e
KOER ON-DEMAND SELF-TEST is initiated.
On vehicles
e equipped with Power Steering Switch (PSP) the steering wheel must be turned to
the
e right and left after KOER ON-DEMAND SELF-TEST is initiated.
4. Note any KOER DTCs.

5. Press CANCEL several times to return to the main menu.
After Repair Procedure

1. After repairs have been made, connect SST (NGS) to
Data Link Connector.
2. Select Clear Codes function in GENERIC OBD IIFUNC-
TIONS and clear DTCs.
3. Perform Quick Test to ensure customer's concern has
been resolved. If DTC PI000 is present, go to that DTC
chart.
I I
MF1693-A 5BUOF3-050
I PIDIDATA Monitor and Record
-- 1 Procedure
1. Hook up SST (NGS) to Data Link Connector. (Refer to
page FT-71.)
DIAGNOSTIC TEST MODE 2. Perform step 1 through step 9 from "Retrieving DTC(s)".
(Refer to pages FT-71, 72 and 73.)
II 111 DIAGNOSTIC TROUBLE CODE LIBRARY
I1 II
I!
I I
MF2024-A
pi
3. Turn key on or start engine.
4. Move the cursor to PIDIDATA MONITOR AND RECORD.
5. Move cursor to PID values to view. Press trigger.
6. Select START to begin.
7. When ready to capture and store the selected PIDs, press
02~21 the trigger button.
GATT ST 1 -02522 MAF
8. Press trigger again when ready to save information.
9. The information is now located in the main recording
area. Store to a viewing area before starting another
recording or the data will be overwritten.
MF2025-A 6BUOFT-049
C)N-BOARD DIAGNOSIS SYSTEM FT
Playback of Stored PlDs
Note
Look for abnormal behavior or values that are
clearly
e incorrect. Inspect the signals for abrupt or
unexpected changes.
Look for agreement in related signals.
Make sure the signals act in proper sequence.
e
/ Procedure
SUDDEN SPIKE - POSSIBLE FAULT 1. Select VIEW RECORDER AREAS.
2. Select a viewing area.
3. Select up to four PlDs to review in the table format or two
PlDs to review in the graph mode.
4. Table Format: Scroll through the PID data while ana-
lyzing the information. Look for sudden drops or spikes in
the values.
For example:
Notice the major jump in the TP voltage while scrolling
through the information. This example would require a
smooth and progressivethrottle pedal travel during a key
INONLINEAR- ON and engine OFF mode.
POSSIBLE FAULT IN SENSORICIRCUIT
5. Graph Format: Scroll through the PID data while ana-
lyzing the information. Look for sudden drops or spikes in
the linear lines showing the transformation of values to
the line graph.
Output Test Mode
Procedure
I I/ DIAGNOSTIC TEST MODE

PIDIDATA MONITOR AND RECORD 7 1. Hook up SST (NGS) to data link c:onnector. (Refer to
page FT-71.)
II I
"
I1 1 2. Perform step 1 through step 9 from "Retrieving DTC(s)"
3. urn key on:

.
Procedure. (Refer to Daaes" FT-71 throuah
" 73.)
4. Move the cursor to ACTIVE COMMAND MODES. Press

the trigger key to enter this selection.
5. Move the cursor to OUTPUT TEST MODE. Press the
~~2028-A ~BUOF-122 trigger key to enter this selection.
6. Press MODE (Key #3) repeatedly to change the mode
from ALL ON to LOW FAN, HlGH FAN, and ALL OFF.
Return the mode to ALL ON.
Note
LOW FAN and HlGH FAN do not apply to 1996
B-Series.
7. Press START (Key #4) to run the fuel pump. Press
STOP (Key #4) to turn off the fuel pump.
8. To open and close certain actuators in the emission
system, press PIDS (Key #7).
9. Press CLEAR (Key #5) to clear previously selected
PIDS.
Note
To select desired PIDs, place the shaded bar ov r
o appears
the item(s) and press trigger. A star symbol e
next to the item when it's selected. Press START
(Key #7). The selected PID(s) and value@) appear.
You can only select 30 PlDs at a time.
10. Press START (Key #4) to turn on the fuel pump.
Observe the values change from OFF to ON or from 0%
to 100%. Press STOP (Key #4) to turn off the fuel pump.
11. Press CANCEL.
Oxygen Sensor Monitoring Test Results Access
Note
The Oxygen Sensor MonitoringTest Results allows
access to the on-board oxygen sensor fault limits
and actual values during OBD II drive cycle.
Procedure
1. Hook up SST (NGS) to data linkconnector. (Refer to page
FT-71.)
2. Select VEHICLE AND ENGINE SELECTION.
3. Select NEW VEHICLE YEAR & MODEL. Select year,
engine, model with appropriate qualifier, if needed. (Refer
to pages FT-71, 72.)
4. Turn key on.
5. Move cursor to GENERIC OBD II FUNCTIONS. Press
trigger key to enter this selection.
DIAGNOSTIC DATA LINK
VIEW RECORDER AREAS 6. Select OXYGEN SENSOR TESTS. Press trigger.
DIGITAL MEASUREMENT SYSTEM 7. Select MANUFACTURING SPECIFIC TEST ID. Press
trigger.
8. Scroll up to the test number (41H) and press trigger.
OBD I1 Drive Cycle

6BUOFT-052
Note
Only perform this procedure when instructed to do
SO.
1. Start the engine.

2. Drive vehicle in any mode for 4 minutes.
3. Monitor ECT PID drive vehicle until ECT PID reaches
0.6 volts (180°F (82°C)) or greater.
4. Idle for 80 seconds.
5. Accelerate to 45 rnph at 114-112 throttle for approxi-
mately 8 seconds.
6. Drive at a speed between 30 and 45 rnph for 4 minutes.
7. Drive for 1 minute in the range of 30 to 40 rnph at steady
throttle.
8. Decelerate and idle for 80 seconds.
9. Accelerate to 55 rnph at 114-112 throttle for approxi-
mately 8 seconds.
10. Decelerate at closed throttle for 10 seconds.
11. Accelerate to 55 rnph at 1/4-112 throttle for approxi-
mately 8 seconds.
12. Decelerate at closed throttle for 10 seconds.
13. Accelerate back to steady throttle mode at 114-112
throttle for approximately 8 seconds.
14. Cruise at a speed between 40 and 60 rnph (posted
speed) for 5 minutes at steady throttle.
15. Drive at 2 5 4 0 rnph with at least 6 stops for 10 minutes.
16. Decelerate and idle.
17. With the ignition key ON (vehicle at idle or engine off),
check for RetrieveIClear Continuous DTCs.
DIAGNOSTIC TROUBLE CODE NUMBERS
NO. DIAGNOSED CIRCUIT CONDITION PAGE
Mass Airflow Sensor (MAF) MAF signal went below 0.39 volts sometime during normal engine FT-82
operation or KOER self-test
MAF signal went above 3.90 volts during KOEO or KOER self-test.(')
Intake Air Temperature IAT signal is less than 0.2 volt (250°F (121 "C}).
(IAT) Sensor IAT signal was not received during KOEOIKOER self-test, but was
output during RetrieveIClear Continuous DTC Self-Test.
IAT signal is greater than 4.6 volts (-46°F (-50°C)).
IAT signal was not received during KOEOIKOER self-test, but was
Engine Coolant ECT signal is less than 0.2 volt (250°F (121"C)).
Temperature (ECT) Sensor ECT signal was not received during KOEO/KOER self-test, but was
ECT signal is greater than 4.6 volts (-46°F {-50°C)).
ECT signal was not received during KOEOIKOER self-test, but was
PO121 Throttle Posit~on(TP)
Sensor
FT-87
Engine Coolant ECT signal has not achieved required temperature level to enter closed
Temperature (ECT) Sensor loop operating conditions within a specified amount of time after
starting engine.
Heated Oxygen Sensor generates a negative voltage.
(H02S)-11
POI 33 Response rate of H02S-11 is below calibrated window. FT-90
1 PO135 1 H02S HTR 11 / H02S-11 heater circuit has a short to ground, open, or short to VPWR. I FT-92 I
Heated Oxygen Sensor H02S-12 output voltage is less than calibrated functional window.
1 (H02S)-12 Any exhaust leaks between engine and end of catalyst may cause this
DTC.
I PO141 i H02S HTR 12 1 H02S-12 heater circuit has a short to ground, open, or short to VPWR. I FT-92 I
H02S-21 generates a negative voltage. I FT-90 I
Response rate of H02S-21 is below calibrated window.
I PO155 1 H02S HTR 21 H02S-21 heater circuit has a short to ground, open, or short to VPWR.
-- --
Adaptive Fuel Control Fuel adaptive system is at rich correction limit due to fuellair ratio too
lean (#1 cylinder bank).
Fuel adaptive system is at lean correction limit due to fuellair ratio too
rich (#I cylinder bank).
Fuel adaptive system is at rich correction limit due to fuellair ratio too
lean (opposite bank).
Fuel adaptive system is at lean correction limit due to fuellair ratio too
rich (opposite bank).
PO230 Fuel Pump Relay / Fuel pump primary circuit failure. / FT-102
PO231 Fuel pump secondary circuit failure between B+ supply and fuel pump FT-102
monitor (test pin 40) connection to power-to-pumpcircuit.
Fuel pump monitor circuit voltage was high when fuel pump was
commanded off. FT-102
PO300 Misfire Detection Monitor Multiple cylinders misfiring, or cannot identify cylinder due to camshaft
position sensor failure.
--
Cylinder #1 misfiring.
Cylinder $2 misfiring.
Cylinder #3 misfiring. FT-106
NO. I DIAGNOSED CIRCUIT CONDITION

--
PO304 ,
t
Misfire Detection Monitor Cylinder #4 misfiring.

-
--
PO305
- 1
~ -
Cylinder #5 misfiring.
--- --
- ---
PO306 Cylinder #6 misfiring.
1
PO320
1 (PCM)
1
Powertrain Control Module
Camshaft Position (CMP)

Sensor
Erratic Profile Ignition Pickup (PIP) signal
1 Self-test has detected a Camshaft Position (CMP) sensor circuit failure.

i
I- Section G
-
< - -
PO350 lgnition Coil 1 lgnition coil primary circuit malfunction. --
Section G
- --
PO351 1 lgnition coil A primary circuit malfunction. Section G
PO352 , I lgnition coil B primary circuit malfunction. Section G
lgnition coil C primary circuit malfunction. Section G
PO400 Exhaust Gas Recirculation Self-test has detected an EGR system malfunction. FT-109
(EGR) System Continuous DTC PO400 indicates that self-test has detected an
EGR system malfunction sometime during vehicle operation.
I
I Continuous self-test has detected insufficient EGR flow.
i Self-test has detected EGR flow at idle.
I PO420 Catalyst Efficiency Monitor 1 Bank 1 catalyst system efficiency is below acceptable threshold. I FT-122 I
1 PO443 EVAP Purge Solenoid I Failure in solenoid circuit. I FT-122 /
PO500 Vehicle Speed Sensor PCM detected loss of VSS signal during operation. FT-124
--A, I
(VSS) VSS circuit intermittent.
-- --
FT-125
PO505 Idle Air Control (IAC) Self-test has detected IAC system malfunction. FT-125
System
. -.
PO605
I Powertrain Control Module
(PCM)
! PCM has experienced a power interrupt in Keep Alive Power (KAPWR) I
circuit.
Read Only Memory (ROM) test error.
7--
FT-126
FT-126
PO703 Brake OnIOff (BOO) Switch BOO signal did not cycle high and low when brake pedal was pressed FT-127
and released during KOER.
PO704 Clutch Pedal Position Switch is malfunctioning. FT-128
(CPP) Switch
PO705 Transmission Range (TR) TR sensor circuit failure. Section K
------ ---
Sensor
PO708 TR signal is high or open. I Section K
PO712 Transmission Fluid TFT signal exceeds scale set for temperature of 157°C (315°F). i Section K
PO713 ' Temperature (TFT)
TFT signal exceeds scale set for temoerature of -40% (-40°FI. 1 Section K
PO715
1 Turbine Shaft Speed (TSS)
Sensor
/ PCM detected a loss of TSS signal during operation.
-4 PO720
PO721
Output Shaft Speed (OSS)
sensor
detected a loss of OSS signal during operation.
detected an erratic OSS signal.
/ Section K
/ Section K
1 Gear #I incorrect ratio (no first gear). I Section K
1 Gear #2 incorrect ratio (no second gear). I Section K 1
Section K
PO736 Section K
---- -
'
_I (TCC) Solenoid PCM picked up an excessive amount of TCC slippage during normal
1 vehicle operation.
Section K
PO743 TCC circuit fails to provide voltage drop across solenoid during
on-board diagnostic.
Section K /
(1 DIAGNOSED CIRCUIT I CONDITION / PAGE I
/ PO746
1
Electrical Pressure Control
(EPC) Solenoid
EPC solenoid malfunction.
PO750 Shift Solenoid 1 (SSI ) SSl circuit open or shorted or PCM driver failure during on-board Section K
diagnostic.
i PO751
PO755 Shift solenoid 2 (SS2)
/
diagnostic.
(mechanical or hydraulic failure).
SS2 circuit open or shorted or PCM driver failure during
SS2 functional failure (mechanical or hydraulic failure). I Section K

I PO760 / Shift Solenoid 3 (SS3) Section K
Section K
;;;;; 1
PO765 / Shift Solenoid 4 (SS4)
AT Solenoid Gear # I incorrect ratio.
Gear #2 incorrect ratio.
Section K
Section K
b i n c O r r e C t ratio.
I
PI000
P I 001
/ OBD II Drive Cvcle
Data Link Connector (DLC)
t Gear #4 incorrect ratio.
OBD II monitor testing not complete.
1 KOER self-test not able to complete or aborted. 1
Section K
FT-131 I
I PHOO
Mass Airflow Sensor (MAF)
1 MAF signal went below 0.39 volt or above 3.90 volts sometime during
last 40 warm-uo cvcles
MAF signal was greater than 0.20 volt during KOEO self-test
PI 101(*) Mass Airflow Sensor (MAF)
(outputs KOEO DTC PI101 ).
MAF signal was not between 0.34-1.96 volts during KOER self-test
(outputs KOER DTC PI101).
I PI112
!I Intake Air Temperature
(IAT) Sensor
IAT signal was not received during KOEO and KOER self-test, but was
output during RetrieveIClear Continuous DTC self-test.
1 FT-85 1
PI 116 Engine Coolant ECT signal went below 0.3 volt or above 3.7 volts during KOEO or
- - -
PI117
Temperature (ECT) KOER self-test.
1 ECT signal was not received during KOEO and KOER self-test, but
was output during RetrieveIClear Continuous DTC self-test.
P I 120 Throttle Position (TP) TP signal is within self-test range but below closed throttle position
Sensor range of 0.1 7 to 0.49 volts (3.43 to 9.80°/0).
-
PI121
PI124
I
:
/ TP signal is inconsistent with MAF sensor signal.
TP rotational setting and signal are not in self-test range of 0.66 to 1.20
I
volts (13.23 to 24.02%).
P I 125 TP signal went below 0.49 volts (9.80%) or above 4.60 volts (92.27%)
sometime during last 80 warm-up cycles.
II I Heated Oxygen Sensor

(H02S)-12
H02S-12 heater was not on during KOER self-test.
P I 127 I Heated Oxygen Sensor

(H02S)
Upstream H02S signal(s) are swapped from bank to bank during
KOER. 1 FT-loo I
PI 130 1 Heated Oxygen Sensor Fuel control has reached its maximum compensation for lean or rich
i (H02S)-11 and H02S is not switching.
PI131 Fuellair ratio is correcting rich for overly lean condition (H02S voltage
is less than 0.45 volts).
Fuellair ratio is correcting lean for overly rich condition (H02S voltage
is greater than 0.45 volts).
P I 150 Heated Oxygen Sensor Fuel control has reached its maximum compensation for lean or rich
(H02S)-21 and H02S is not switching.
- -
Fuellair ratio is correcting rich for overly lean condition (H02S voltage
is less than 0.45 volts).
PI152 ( Heated Oxygen Sensor FueVair ratio is correcting lean for overly rich condition
, (H02S)-11 is greater than 0.45 volts).
FT-79
NO. DIAGNOSED CIRCUIT I CONDITION I PAGE

Pi260 : Antl-Theft System I Ant)-theft system has detected a break rn the onboard security test due
or system hardware fallure-
to an attempted theft- I
FT-132
PI G a Over-Revv~ng
-
+ -
--
- - - --- - ppp
Eng~neRPM or vehicle speed lrmrt reached-----

----
f
*- El32
- -
P1351 Powertraln Control Module Loss of lgnltlon D~agnostlcMon~tor(IDM) Sect~onG

---
(PCM) I
-
+---
P I 358 - - 1 -
I
- - - - - - --
P I 352 lgnitlon Coll lgnltlon cod A prlmary circurt malfunct~on. Sect~onG

- A-
P I 353 coil B prlmary crrcult malfunct~on

lgn~t~on Sect~onG
--- --
- - -
PI 354
--- - ----
lgnltlon coil C primary clrcuit malfunction
-- --- -- p- - -- - - --
i Sect~onG -- -
P1359 Powertram Control Module Loss of Spark Output (SPOUT) s~gnal. Sect~onG
(PCM) I
P I 360 I lgnition Coil I Ignition coil A secondary circuit malfunction. 1 Section G
I
lgnition coil B secondary circuit malfunction.
- - --
Ignition coil C secondary circuit malfunction.
-- -
-
Ignition coil primary circuit malfunction.

-p--.-pp.pp-p --
1 Ignition coil secondary circuit malfunction. / Section G

~
I P I 390 1 OCT ADJ Shorting Bar I OCT ADJ shorting bar is not in or OCT ADJ circuit is open
PI 400 ' Differentla1Pressure detected DPFE SIG c~rcu~t
--
input below minimum
----
I Feedback EGR (DPFE) detected DPFE SIG c~rcultinput above maximum
-
- Sensor
Pi405 Cont~nuousself-test has detected that exhaust man~folds~de
---
I hose IS off or plugged
----
P I 406 Cont~nuousself-test has detected that ~ntakeman~folds~de
(downstream) DPFE pressure hose IS off or plugged
PI408 EGR System KOER self-test has detected EGR flow out of range. FT-113
P I 409 , EGR Vacuum Regulator Self-test has detected an electrical malfunction in EVR circuit. FT-121
(EVR) Solenoid Continuous DTC P I 409 indicates that continuous self-test has
detected an electrical malfunction in EVR circuit sometime during
vehicle operation. -
i
P I 443 Evaporator System Purge flow malfunction. FT-134
PI444 Purge Flow (PF) Sensor PF SIG clrcult Input below mlnlmum
PI445
I PF SIG clrcult ~nputabove maxlmum
--- - -- - -- -
Pi460 Wlde-Open Throttle AIC AIC was on durlng self-test or WAC clrcurt fault T~T.138-
Cut-Off (WAC) Relay Continuous DTC P I 460 ~nd~cates that WAC crrcuit failure has \
---- -+
occurred during vehicle operation ---- -L--
P I 464 i AIC
--
to PCM was h ~ g hduring self-test
FT-138
PI 500 , Veh~cleSpeed Sensor PCM detected an erratlc VSS s~gnaldurlng operat~on
-----
FT-124
- -I (VSS)(3) t-
PI 501 VSS s~gnalhas been detected out of self-test range FT-124
- - 4 -- -7 - -
P I 504 Idle Air Control (IAC) Self-test has detected IAC c~rcu~t
malfunction FT-125
-
Solenold
P I 505 IAC system has reached adaptlve cllp
P I 506
. --- ---- ---
P I 507 FT-125
- - + - -- - - --- - --- - - - -
P I 605 I Powertraln Control a power Interrupt in Keep Allve Power (KAPWR) /-FT-126-
I (PCM)
FT-143
PI651 PSP s~gnalnot changlng state durlng KOER (2.3L only) FT-143
- -- -- -- --- -- -
P I 701 'A? Solenold EPC pressure IS low, no drop ~nTSS rpm, TR rndicates reverse Sect~onK
NO. DIAGNOSED CIRCUIT CONDITION
P1703 Brake OnIOff (BOO) Switch Brake not cycled during KOER or BOO circuit failure during KOEO. FT-127
P1704 Transmission Range (TR) TR sensor misaligned or failed electrically. Section K
-----------i sensor
--
P1705 / TR signal is not in PARK during KOEO self-test. Section K
P1709 1 Clutch Pedal Position Voltage is high or CPP is
(CPP) Switch should be closed grounding.
P I 711 Transmission Fluid TFT signal went either low or high end of acceptable range during Section K
Temperature (TFT) Sensor self-test.
P1714 Shift Solenoid 1 (SS1) SS1 malfunction (mechanical failure). Section K
P1715 Shift Solenoid 2 (SS2) SS2 malfunction (mechanical failure). Section K
P1716 Shift Solenoid 3 (SS3) SS3 malfunction (mechanical failure).
P1717 Shift Solenoid 4 fSS41 SS4 malfunction (mechanical failure). Section K
1 P1719 Overdrive Drum Speed
! (ODs)
PCM detected loss of ODs signal during operation.
[ P1
729 j 4x4 Low SW --
Switch error.
-
t --
P I 740
P1741 ,
P1742
/
Torque Control Clutch
I
(TCC) Control
Torque Control Clutch

, TCC control error.
TCC solenoid has failed ON (turn on MIL).

Section K
(TCC) Solenoid
TCC solenoid has failed ON by electric, mechanical or hydraulic Section K
concern (turn on TCIL).
P1744 Torque Control Clutch TCC system mechanically stuck in OFF position. Section K
(TCC) System
P1746 Electronic Pressure Control EPC circuit open. Section K
(EPC) Solenoid
P1747 EPC circuit shorted.
P1749 EPC solenoid failed low.
I P1751 1 Shift Solenoid 1 (SS1)
--
SSl functional failure (mechanical or hydraulic failure). / Section K I
rP1754 I coast clutch Solenoid
fCCS)
CCS circuit open or shorted or PCM driver failure during on-board
diaanostic.
SS2 funct~onalfa~lure(mechanical or hydraul~cfa~lure)
1 Section 1
1 1 1
--- - --
P1761 : Shift Solenoid 3 (SS3) SS3 functional fa~lure(mechan~calor hydraulic failure).
--
Sect~onK
P1762 Transmiss~on I S S Y S S 4 1 K b a n d failure
;;;:I control TCS was not cycled during KOER self-test. TCS circuit open or
shor-, Section K
Switch (TCS)
Out of self-test range.
P1783 Transmission Transmission fluid temperature exceeds 127°C (270°F).
(1) DTC PO103 could be generated by foreign material blocking the MAF sensor screen causing an air flow
restriction. If contaminants are found on the screen, check air filter installation in air cleaner tray and
proper sealing of air cleaner and air tubes before proceeding.
(2)DTC PI101 could be generated by a low charged vehicle battery or the garage exhaust ventilation
system. Service the battery as necessary. Then remove ventilation system and properly vent to outside
atmosphere.
(3) An EPC solenoid that is shorted to ground may result in a false vehicle speed sensor code (DTC PI 500
or P I 501 ). Diagnose the EPC solenoid first, then recheck the VSS.
(4) 3.OL and 4.OL models have been built without a PSP switch. Disregard servicing DT'Cs P I 650 or P I 651.
6BUOFT-055
Caution
e perform the After Repair Procedure to verify the fault has been
After repairing a failure,
corrected.
6BUOFT-056
Troubleshooting
Diagnostic trouble code MASS AIR FLOW (MAF) SENSOR
No. P0102, P0103,
P1100, PI101
Symptom Input voltage from MAF sensor is below 0.39volts or above 3.90volts or intermittent
when ignition sw~tchis turned on
STEP INSPECTION 1 ACTION -
1 Key OFF. For KOER DTC PI101 :
Inspect for damaged or pushed out pins, corrosion, loose Go to next step.
wrres at MAF or PCM connector. For KOEO DTC PI101:
Repair or replace ~fnecessary. Go to step 3.
Follow drrect~onin Action.
For RetrievelClear Continuous DTC P1100:
Go to step 4.
For DTC PO102:
Go to step 6.
I For DTC PO103:
i Go to step 18.
Drive vehicle for 6 to 10 minutes.
Rerun KOEO and RetrieveIClear Continuous DTC self-test. 1 Yes For RetrievelClear Continuous DTC P0102:
1 GOto step 6.
I 1 Is a RetrieveIClear Continuous DTC present with KOER
DTC PllOl?
I
For RetrievelClear Continuous DTC P0103:
Go to step 18.
I I1 For all other RetrieveIClear Continuous

DTCs:
Return to DTC chart.
; No 1 Go to next step.
Key OFF. ; Yes Go to step 12.
Install breakout box, reconnect PCM. I
Key ON, engine off. I -
Step 8.
Is voltage between MAF SIG test pin 88 and PWR GND
test pin 24 or 103 at breakout box greater than 0.20V? I NO
'0
Start engine and bring to Idle. Yes Inspect MAF sensor connector.
Note: If a stabilized idle is not at least 700 rpm, go to If OK, replace the MAF sensor.
Diagnostic Index. t Go to step 21.
Run at 1,500rprn for 5 seconds, bring ~tback to idle.
Access MAF PID for a fault indication wh~leperforming the
following: I
- Lightly tap on MAF sensor and w~ggleharness No Go to next step.
connector to s~mulateroad shock.
Is the MAF PID changlng below the mlnlmum 0.39volts or )
above a maximum 3.90volts?
Key OFF. Yes Repair short or open ~nMAF SIG or MAF RTN
Install breakout box, reconnect PCM. circuit.
Key ON, engine off.
Measure voltage between MAF SIG test pin 88 and MAF
RTN test pin 36 at breakout box while performing the
followinq:
,i I
Go to step 21.
-
- ~ra@ the vehicle harness closest to MAF sensor 1
connector. No Unable to duplicate and/or identify fault at this
- Shake and bend a small section of harness all the way ' I time. Go to "Intermittent Concerns."
to dash oanel. 1 1
I
page FT-69
1 ;
- Wlggle, shake and bend harness from dash panel to PCM
Is voltage changlng below the mlnlmum 0.39 volts or
above the maxlmum 3.90 volts7
-- -- - --
lnspect broken/loose air outlet tube clamps at throttle body Yes j Go to next step.
and a ~cleaner
r assembly ends, cracksfholes ~na ~outlet
r I
tube, worn gaskets between MAF sensor and alr cleaner
assembly. -
Start englne and brlng to idle. No For KOER reading between 0.60 and
Note: If KOER DTC PO505 is present, return to DTC 1 1.OO volt:
chart. If a stabilized idle is not at least 700 rpm, go to Go to step 15.
Diagnostic Index.
For 2.3L
go to step 9.
If vehicle stalls and cannot maintain idle,
Run at 1500 rpm for 5 seconds, then brlng ~tback to ~dle

Access MAF PID. Is MAF PID less than 0 39 volts7
I
1
All others:
Go to step 3.
I STEP ! INSPECTION ACTION
Key OFF. Yes Go to next step.
Disconnect MAF sensor.
Key ON, engine off.
Is voltage between VPWR (R) circuit at MAF sensor No Repair open in VPWR circuit.
connector and battery negative terminal greater than 10.5 Go to step 21.
volts? - ----

Leave PCM and MAF disconnected. -
-
Is resistance between VPWR (R) circuit at MAF sensor No Repair open in VPWR circuit.
connector and VPWR test pin 71 or 97 at breakout box Go to step 21.
less than 5.0 ohms?
Key OFF. Go to next step.
Leave PCM and MAF disconnected.
Disconnect scan tool or NGS from data link connector.
Measure the resistance between MAF SIG test pin 88 and Repair short circuit between MAF SIG and
MAF RTN test pin 36 and PWR GND test pins 24 or 103 GROUND or MAF RTN.
at the breakout box. Go to step 21.
Is each resistance areater than 10,000ohms?
Key OFF.
Leave PCM and MAF disconnected.
Is resistance between MAF SIG (LBIR) at MAF sensor
connector and MAF SIG test pin 88 at breakout box less Go to step 21.
than 5.0 ohms?
Key OFF.
Leave MAF sensor disconnected.
1 Yes / GO to step I 3.
I
Reconnect PCM to breakout box.
Key ON, engine off. Go to next step.
Is the voltage between VPWR (R) and PWR GND (B)
circuit at MAF sensor connector areater than 10.5volts?
Key OFF.
Leave MAF and scan tool or NGS disconnected.
Disconnect PCM.
No 1 Repair open in PWR GND circuit.
Is the resistance between PWR GND (B) circuit at MAF
sensor connector and battery negative terminal less than 1 GO
1
to step 21.
10.0ohms? i
Key OFF. Yes j Go to next step.
Leave MAF sensor disconnected.
Disconnect PCM.
Is the resistance between MAF RTN (TtLB) circuit at MAF No Repair open in MAF RTN circuit.
sensor connector and MAF RTN test pin 36 at breakout Go to step 21.
box less than 5.0 ohms?
I l4 1 Key OFF.
Leave MAF and scan tool or NGS disconnected.
1 Yes Go to next step.

No / MAF SIG shorted to PWR GND or MAF RTN
Measure resistance between MAF SIG test pin 88 and
MAF RTN test pin 36 and PWR GND test pin 24 or 103 at , in PCM. Replace PCM.
the breakout box. , Go to step 21.
Is each resistance areater than 10,000ohms?
Connect MAF sensor connector.
Install breakout box and reconnect PCM.
Key ON, engine running.
Note: If a stabilized idle is not at least 700 rpm, go to No MAF SIG or PWR GND is open in MAF
Diagnostic Index. sensor, or MAF SIG is shorted to MAF RTN in
For 2.3L AIR If vehicle stalls and cannot maintain idle, MAF sensor. Replace NlAF sensor.
replace PCM. Go to step 21.
Is the voltage between MAF SIG test pin 88 at breakout
box and battery negative terminal at idle between 0.34and
1.96volts?
Key ON, engine running. e Go to next step.
Measure voltage between MAF SIG test pin 88 and MAF MAF RTN open in MAF sensor.
RTN test pin 36 at breakout box. Replace MAF sensor.
Is voltage between 0.34 and 1.96 volts? Go to ster, 21.
I
( STEP INSPECTION ACTION
Key ON, engine running. Yes Unable to identify fault at this time.
Access MAF V PID. Go to "Intermittent Concerns."
Is MAF V PID between 0.34 and 1.96 volts? -
MAF SIG or MAF RTN is open or shorted
together in PCM. Replace PCM.
Go to step 21.
Start engine and bring to idle. Yes MAF SIG shorted to VPWR in MAF sensor.
Note: If a KOER DTC PO505 is present, go to DTC Replace MAF sensor. Remove jumper.
charts. If stabilized idle is not at least 700 rpm, go to Go to step 19.
Diagnostic Index.
For 2.3L Am If vehicle stalls and cannot maintain idle,
replace PCM.
Run at 1500 rpm for 5 seconds, and bring it back to idle.
Access MAF PID (MAF PID should be greater than
3.90V).
Key OFF. No ' Remove jumper. Go to next step.
Disconnect MAF sensor and jumper PWR GND (B) and
MAF RTN (TILB) pins at MAF sensor connector.
Again access MAF PID.
Did MAF PID drop from the previous reading to below
0.39 volts?
Key OFF. Yes Repair short between MAF SIG and power in
MAF sensor disconnected. circuit.
Install breakout box, leave PCM disconnected. Go to step 21.
Key ON, engine off.
Is the voltage between MAF SIG test pin 88 and PWR I
GND test pin 24 or 103 at breakout box greater than NO GOto next step.
10.5 volts?
Key OFF. Yes MAF SIG shorted to power in PCM.
Leave MAF and PCM disconnected. Replace PCM and go to next step.
Disconnect scan tool or NGS.
Is the resistance between MAF SIG test pin 88 and Repair short between MAF SIG and VPWR
VPWR test pin 71 or 97 at breakout box greater than in circuit.
10,000 ohms? Go to next step.
( 21 ( Perform After Repair Procedure to ensure customer's concern has been resolved.
6BUOFT-057
TEST PIN 24/51/76/77/103 BIW B PWRfGND VEHICLE

FROM POWER RELAY L HARNESS
-1
r
CONNECTOR
TEST PIN 71/97 Q R EXTENSION
TEST PIN 88 0 LBlR MAF SIG TO MASS AIR
FLOW (MAF)
SENSOR
TEST PIN 36 0 Tf LB MAF RTN CONNECTOR
(VIEW FROM PIN SIDE)
TEST PINS LOCATED ON BREAKOUT BOX

ON-BOARD DIAGNOSIS SYSTEM pI
Diagnostic trouble code PO112 IPO113 1P1112: INTAKE AIR TEMPERATURE (IAT) SENSOR
No. P0112, P0113, PO117 1PO118 1PO125 IPI116 1P1117: ENGINE COOLANT TEMPERATURE (ECT)
PO117, PO118, PO125, SENSOR
P1112, P1116, PI117 -
Symptom Input from IAT or ECT sensor is below 0.2 volt or above 4.6 volts or intermittent when
ignition is turned on.
Insufficient coolant temperature for stable operation or to enter closed loop fuel control
I (DTC PO125).
STEP / INSPECTION ACTION
Key OFF. For DTC P1116:
wires at IAT, ECT or PCM connector. For DTC PO113 or P0118:
Repair or replace if necessaly. Go to step 6.
Follow direction in Action.
For DTC PO112 or POllX:
Go to step 9.
For RetrieveIClear Continuous DTC P0112,
P0113, P0117, P0118, PI112 or P1117:
Go to step 12.
For DTC P0125:
-
Go to step 14.
Warm up engine at normal operating temperature. Yes For symptom of cooling system concern:
I No Starts: Go to step 4. Do not service DTC P1116. Service next DTC. If
' Vehicle Stalls: Go to Diagnostic Index. no other DTCs exist, return to Diagnostic Index.
Check that upper radiator hose IS hot and pressurized. All others:
Rerun KOER self test. Go to next step.
Is DTC PI116 present?
Engine was not at closed loop operating
conditions. Repair any other DTCs as
necessaw.
3 1 Key OFF.
.
Disconnect throttle ~ositionITP), sensor connector.
Go to next step.
Key ON, engine off.'

Measure voltage between VREF and SIG RTN circuit at TP No Go to pinpoint test ''VREIZ."
sensor connector.
Is voltage between 4.0 and 6.0 volts?
Key OFF. For ECT sensor with a No Start:
Yes
Disconnect ECT sensor connector. Do not service DTC PI116 at this time. Return to
Is resistance of sensor within specification? Diagnostic Index.
page FT-186 All others:
Go to next step.
--
No Replace ECT sensor.
Go to step 15.
Note: Verify that engine is at operating temperature Yes Replace PCM.
before taking ECT readings. Go to step 15.
Key OFF.
Leave ECT sensor connector disconnected.
Run engine for two minutes at 2,000 rpm.
Is resistance of sensor within specification?
page FT-186
Key OFF. Yes Replace suspect sensor.
Disconnect suspect sensor connector. Remove jumper wire.
Connect a jumper wire between the sensor signal circuit and Go to step 15.
SIG RTN circuit at the sensor connector.
Key ON.
Note: If a scan tool or NGS communication problem Remove jumper wire.
exists, remove jumper wire immediately and go to step 8. Go to next step.
Access ECT or IAT PID.
Is ECT or IAT PID less than 0.2 volt?
Key OFF. Yes Replace PCM.
Leave suspect sensor connector disconnected. Go to step 15.
Install breakout box, leave PCM disconnected.
Measure resistance between sensor signal circuit at sensor
connector and ECT test pin 38 or IAT test pin 39 at breakout
box. Repair open in sensor signal or SIG RTN circuit.
Measure resistance between SIG HTN at sensor connector Go to step 15.
and SIG RTN test pin 91 at breakout box.
Is each resistance less than 5.0 ohms?
p1 ON-BOARD DIAGNOSIS SYSTEM
STEP 1 INSPECTION ACTION

8 Key OFF. Yes Replace PCM
Disconnect suspect sensor connector. Go to step 15.
Is each resistance between ECT test pin 38 or IAT test pin 39 Repair short to VREF.
and VREF at breakout box greater than 10,000 ohms? Go to step 15.
9 Key OFF. Yes Replace sensor.
Disconnect suspect sensor connector. Go to step 15.
Kev ON.
~ c c e s sECT or IAT PID.
IS ECT or IAT PID more than 4.2 volts?
NO / GOto next step.
Key OFF. T / ~ e c o n n e c sensor
t ~ connector.
Disconnect TP sensor connector. Go to next step.
Key ON, engine off.
Measure voltage between VREF and SIG RTN circuit at TP
sensor connector.
No
I Reconnect TP sensor connector.
GOto pinpoint test "VREF?'
Key OFF. 1 Yes / Replace PCM.

Leave suspect sensor connector disconnected. ~
!
i
I
Go to step 15.
Measure resistance between ECT test pin 38 or IAT test pin I
39 and PWR GND test pin 24 or 51 and SIG RTN test pin 91 No / Repair short in ECT or IAT circuit to ground.
at breakout box. j Go to step 15.
Is each resistance greater than 10,000 ohms?
Key ON. Yes Replace sensor.
Access ECT or IAT PID. Go to step 15.
Monitor PID while performing the following:
- Tap on sensor to simulate road check.
- Wiggle sensor connector. No Go to next step.
Is there any large change in reading?
Key ON. Isolate fault and repair as necessaw.
Monitor ECT or IAT PID while performing the following: Go to step 15.
- Hold vehicle harness close to sensor connector. !- .-
Wiggle, shake and bend small sections of wiring No Fault is not present at this time.
harness while working toward PCM. Go to next step.
Is there anv chanae in readina?
14 Is coolant level fill correct? Yes / Check thermostat.
-
15 Perform After R e ~ a iProcedure
r to ensure customer's concern has been resolved.
Note:
Ambient temperature should be above 10°C (50°F) to receive acceptable input from the intake
air temperature sensor.
Engine coolant temperature must be greater than 10°C (50°F) to pass the KOEO self-test and
greater than 82°C (180°F) to pass the KOER self-test. To accomplish this, the engine should
be at normal operating temperature.
6BUOFT-059
TEST PIN 91 SIG RTN -GYIR 1 ! I ]

GY LG/R
0
39 IAT SIG
6
38 ECT SIG
I 'TEST PINS LOCATED ON BREAKOUT BOX

Diagnostic trouble code THROTTLE POSITION (TP) SENSOR CIRCUIT MALFUNCTION
No. P0121, P0122,
P0123, P1120, P1121,
~
P1124, Pi125
Symptom Input voltage from TP sensor is below 0.1 7 volts or above 4.60 volts, out of range when
ignition is turned on or inconsistent with MAF sensor signal.
1 Key OFF. For DTC P1124:
wires at TP or PCM connector. For DTC PI120:
Repair or replace if necessary. Go to step 4.
For DTC P0123:
Go to step 8.
i For DTC P0122:
I Go to step 11.
I
For DTC P I121:
Go to step 15.
For DTC P1125:
Go to step 20.
I!
For DTC PO121:
Go to step 22.
2 Check for DTC PI400 in KOEO or KOER self-test. Yes Go to pinpoint test for DTC P1400.
Is KOEO or KOER DTC PI400 present with P1124? No Go to next step.
3 Visually inspect the throttle linkage and throttle plate for Yes Go to step 8.
binding or sticking. Verify throttle plate and linkage is at No Repair or replace as necessary.
closed throttle position. Are plate and linkage OK? Go to step 23.
-
.
4 Key ON, engine off. Yes Go to next step.

Access TP PID.
While slowly moving throttle frorn closed throttle position
to wide open throttle position, is TP PID reading below No Go to step 20.
0.49 volts (9.80%)?
5 Key OFF. Yes Go to next step.
Disconnect TP sensor connector.
Key ON, engine off. --
GOto pinpoint test "VREF."
Is voltage between VREF circuit and SIG RTN circuit at
TP sensor connector between 4.0 and 6.0 volts?
C
Leave TP sensor connector disconnected.
Install breakout box, leave PCM disconnected. Repair corrosion or open in TP SIG circuit.
Is resistance between TP SIG at TP sensor connector and Go to step 23.
TP SIG test pin 89 at breakout box less than 5.0 ohms?
7 Key OFF. 1I ~ eGo to sstep 23.
i - 1
Connect TP sensor connector and PCM connector.
Start engine and run at idle for 2 minutes.
Is voltage between TP SIG test pin 89 and SIG RTN test Return KOEO and KOtiR. If DTC PI120 is
pin 91 at breakout box between 0.17 to 0.49 volts at any still present.
time while slowly moving to open throttle from closed Go to step 20.
position?
Note: An intermittent fault can cause a RetrieveIClear Yes Go to next step.
Continuous DTC P0123. If this code is still present
after step 8 through step 10, go to step 20.
Key OFF.
Disconnect TP sensor connector. Go to step 10.
Key ON, engine off.
Access TP PID.
Is TP PID less than 0.17 volt (3.43%)?
Key OFF. TP SIG shorted to VREF or SIG RTN open in
Leave TP sensor connector disconnected. TP sensor.
Kev ON. enaine off. Replace TP sensor.
Is ;ohage bGtween VREF and SIG RTN circuit at TP Go to step 23.
sensor connector between 4.0 and 6.0 volts? to pinpoint test "VREF."
STEP
--- - -- -
INSPECTION
-- -- - --- - --
ACTION
-- - - -
10 Key OFF. y e s 1 Replace PCM
Leave TP sensor d~sconnected. I Go to step 23.
Install breakout box, leave PCM d~sconnected. I
ISeach resistance between TP SIG test plr7 89 and VREF
'
No Repair short between ~p SIG and VREF
test pln 90 and VPWR test pin 71 or 97 at breakout box
greater than 10,000 ohms?
Note: An intermittent fault can cause a Continuous Yes Remove jumper and replace TP sensor.
Memory DTC P0122. If this code is still present after Go to step 23.
step 11 through step 14, go to step 20.
Key OFF.
-
Jumper VREF and TP SIG circuit at TP sensor connector.
Key ON, engine off. I
No Remove jumper.
Access TP PID.
Note: If any scan tool or NGS communication problem
exists, remove jumper and go to step 14.
Is TP PID greater than 4.6 volts (92.27%)?
Leave TP sensor disconnected.
! I
1 Yes
I
GOto next step.
; Reconnect TP sensor connector.

Key ON, engine off. / Go to next step. .
-
Is voltage between VREF and SIG RTN circuits at TP
sensor connector between 4.0 and 6.0 volts?
No 1 Reconnect TP sensor connector.
I Go to pinpoint test "VREF."
Key OFF. 1 Yes I Go to next step.
Is resistance between TP circuit at TP SIG sensor No ; Repair open In TP SIG clrcult.
connector and TP SIG test pin 89 at breakout box less I Go to step 23.
than 5.0 ohms?
Key OFF. I Yes Replace PCM.
Leave TP and PCM connector disconnected. 1 Go to step 23.
---
Measure resistance between TP SIG test pin 89 and SIG
RTN test pin 91 and PWR GND test pin 24 or 103 at N O -Repair TP SIG shorted to SIG RTN or PWR
breakout box. GND in harness.
1 Is each resistance greater than 10,000 ohms? Go to step 23.
15 Attempt to start engine. Yes ) Go to next step.
Does engine run? I No I Check for major leaks, cracks, and openings
I 1 between MAF sensor and throttle body.
If OK, go to No. 5, "Cranks Normally But Will
Not Start."
Key ON, engine off. Yes 1/ Go
Replace TP sensor.
to step 23.
Access TP PID.
Slowly move throttle from closed position to wide open I
throttle position and observe TP PID for smooth reading i
change. .- ~
While opening and closing throttle, is there a sudden drop

in TP PID below 0.66 volt (13.23%) or a sudden jump in 1 1
TP PID above 1.20 volts (24.02%)?

Key ON, engine running. Yes Check for air leaks between MAF sensor a n b
Do normal drive, exercising throttle and TP sensor while
~
; throttle body, including air noise sounds while
accessing PIDs. ) engine is running. If OK, replace TP sensor.
Access TP PID and LOAD PID and record readings. 1 Go to step 23.
Is TP PI0 greater than 2.44 volts (49.02O/0) and LOAD PID
reading less than 25%? / No Go to next step.
-
- -. - --
1 -
+ --
Yes , Check for TP sensor loosely connected to
-
-
- -- -- -- -
Note: If vehicle is a No Start, go to No. 5, "Cranks

Normally But Will Not Start."
~ j throttle body. If RetrieveIClear Continuous
1 DTC P I 121 is now present, replace MAF
Access TP PID and LOAD PID and record readings. ( sensor.
Is TP PID less than 0.24 volts (4.90%) and LOAD PID i Go to step 23.
greater than 60%?
; No I Go to next stem
- -
19 ' Key ON, engine running. Yes . Check for TP sensor loosely connected to
Do normal drive, exercise throttle and TP sensor near throttle body. If RetrieveIClear Continuous
higher gears while accessing PIDs. DTC PI121 is now present, replace MAF
Access TP PID and LOAD PID and record readings. sensor.
Is TP PID less than 0.24 volts (4.90%) and LOAD PID Go to step 23.
greater than 60%? I No Unable to identify fault at this time. If vehicle
20 Run engine to 1500 rpm for 5 seconds.

Access TP PID for a fault indication while performing the
following:
- Lightly tap on TP sensor and wiggle harness connector
j to simulate road shock. Go to next step.
,
i Is TP PID changing below minimum 0.49 volts (9.80%) or
/ above maximum 4.60 volts (92.27%). - . -
1 Yes ' Isolate fault and repair or replace as
Install breakout box, reconnect PCM. necessary.
Kev ON, enaine off. Go to step 23.
-
~easur6 votage between TP SIG test pin 89 and SIG
RTN test pin 91 at breakout box while doing the following: Unable to duplicate andlor identify fault at this
- Grasp, shake, bend and wiggle harness. time. Go to "lntermitter~tConcerns."
Is voltage changing below 0.49V or above 4.60V? page FT-69
Key OFF. Yes Check for opens in TP SIG and SIG RTN
Start engine. circuit between TP and PCM. If no open
Activate KOER self-test at idle. circuit exists, replace T'P sensor.
Is DTC PO121 present or does KOER self-test fail to Go to next stet).
- -
terminate? Go to Diagnostic Index for possible fast idle

I LA
concerns.
-
I Perform After Repair Procedure to ensure customer's concern has been resolved.
6BUOFT-060
SIG F1TN TP SIG

TEST PIN 91 TEST PIN 89 VREF
GY/R GYAN TEST PIN 90
\
AN
THROTTLE POSITION SENSOR

CONNECTOR (TP)
Diagnostic trouble code P0131lP0133: # I CYLINDER SIDE UPSTREAM HEATED OXYGEN SENSOR
No. PO133, PO153,P0131, PO151 PO151lP0153: OTHER SlDE UPSTREAM HEATED OXYGEN SENSOR
Symptom H 0 2 S generates a negative voltage.
Response rate of H 0 2 S is below calibrated window.
1 For P0131/0151: Yes I Complete
Complete PCM reset to clear DTCs.
Key OFF.
Connect scan tool or NGS to data link connector.
Key ON, engine off.
Access Generic OBD II functions and trigger.
Scroll Oxygen Sensor Test and trigger. I
1~ a H02S monitor drive cycle.
Repeat test step 1. If test result is greater than 0.6
volt, testing is complete.
Scroll to Manufacturer Specific Test ID and trigger. No Go to next step.

Scroll to Test ID:(41H) and trigger.
Is measurement for H02S fault greater than 0.6 volt?
2 Investigate the following items as a potential source of H02S Yes Repair source of contamination.
contamination: Replace H02S and oillfilter.
- Use of unapproved silicon sealers. Complete PCM reset to clear DTCs and H02S
- Fuel contaminated by silicon additives. monitor drive cycle.
I
- Excessive oil burning.
- Glycol leaking internally in engine. !
1
- Lead contaminated fuel. / No Go to next step.
- Use of unapproved cleaning agents.
Are any of the above conditions present?
I
~
1
3 Fuel calculations can be affected by unmetered air leaks: Yes Repair source of air leak.
- Hoses connecting mass airflow meter. Complete PCM reset to clear DTCs and H02S
- Hoses connecting to throttle body. 1 monitor drive cycle.
- Intake manifold gasket leaks. 1
! - PCV disconnected.
' - Vacuum lines disconnected.
: - Improperly seated dipstick and tube.
- Exhaust leaks at flange and gaskets.
1
I
NO
!
GOto next step.
Are there any air leaks? I

-
4 Key OFF. Yes / Replace H02S and oillfilter.
Disconnect suspect H02S connector. ' Complete PCM reset to clear DTCs and H02S
Jumper H02S SIG to VPWR at H02S connector. 1 monitor drive cycle.
Connect scan tool or NGS to data link connector. I
I
Key ON, engine off.
Access correct H02S PID or 0 2 s on scan tool. No Go to next step.
Measure resistance between H02S SIG test pin at breakout ,
box and H02S connector.
- H02S SIG test pin: 60 for H02S-11/87 for H02S-21
i
No i Repair open circuit. Complete H02S monitor drive
Measure resistance between SIG RTN test pin at breakout I cycle.
box and H02S connector.
1 - H02S SIG RTN test pin: 91 for H02S-11 and H02S-21 I II
Is resistance less than 5.0 ohms? 1 I
I
6 ' Key OFF. Yes 1 Replace PCM. Complete H02S monitor drive cycle.
Leave PCM disconnected.
Measure resistance between H02S SIG and VPWR test pins 1
at breakout box and H02S SIG and SIG RTN test pins at _j
/1 Complete
--
breakout box. No Repair short circuit.
- H02S SIG test pin: 60 for H02S-11/87 for H02S-21 H02S monitor cycle.
- VPWR test pin: 71/97 for H02S-11 and H02S-21
- H02S SIG RTN test pin: 91 for H02S-11 and H02S-21
7 For PO133/0153: Yes Repair source of water entry. Dry out connector.
Is there water in H02S connector? Replace H02S. Go to step 9.
1 No Go to next step.
8 Key OFF. Yes ( Replace H02S.
Disconnect suspect H02S sensor connector. Go to step 9.
1 Install breakout box, leave PCM disconnected.
Measure resistance between appropriate test pins at breakout

( box and H02S SIG and SIG RTN at H02S connector.
- H02S SIG test pin: 60 for H02S-11/87 for H02S-21
- H02S SIG RTN test pin: 91 for H02S-11 and H02S-21 I Repair wiring as necessary.
Go to step 9.
Is resistance less than 5.0 ohms?
9 Perform After Repair Procedure to ensure customer's concern has been resolved.
6BUOFT-061
FT-90
HEATED OXYGEN SENSOR H02S LOCATION
CONNECTOR (H02S)
FRONT CYL
ENGINE
HEATER VPWR (6 CY L)
GROUND
(HTR GND)
H02S SIG SIG RTN
'TEST PINS LOCATED ON

BREAKOUT BOX
Signal
--
Wire Color Test Pin
:-
VPWR
SIG RTN GYIR - -- ---
91
-- - - - .--
--- -
H02S SIG-11
- -- --
GYILB - - - - - t-- - --
60
H02S HTR-11 (GND) RIW 1 93
- - -
t -
- - - -- -- - -- --
--
H02S SIG-12 RiLG 35
- -
- - 1
H02S HTR-12 (GND) WIBR I 95
+ - I - - - - - - -
H02S SIG-21 -
RIB I
87
- - - -- - -
-
I
H02S HTR-21 (GND) YILB 94
I INJECTORS
CYLINDERS
1 PIN# 1I WIRE COLOR I

INJECTOR
GND TO PCM
71/91 VPWR HARNESS

Diagnostic trouble code P0135: #1 CYLINDER SIDE UPSTREAM HEATED OXYGEN SENSOR HEATER
No. PO135, PO141, P0141lP1127: DOWNSTREAM HEATED OXYGEN SENSOR HEATER
P0155. PI127 P0155: OTHER SIDE UPSTREAM HEATED OXYGEN SENSOR HEATER - -
I Heater circuit has a short to ground, open or short to vehicle power.

I Heater was not on during KOER self-test.
INSPECTION I
I ACTION
Visually inspect H02S circuit for exposed wiring, Repair any concerns.
1 2
contamination, corrosion and proper assembly.
Were any concerns found during visual inspection?
1KevOFF.
cdnnect scan tool or NGS to data link connector.
Key ON, engine runnlng.
Run engine at 2000 rpm for 10 minutes and return to idle.
Activate KOER self-test.
Are DTCs P0135, P0141, PO155 or PO161 present7
/
1 Yes
No
- b e r m i t t e n t .
I
Concerns."
1
GOto s t e ~
) Go to next step.
11.
Go to next steo.
- A
Go to "Intermittent
page FT-69
I
1
1
I I
3 Key ON. Yes GO to step 6.
Access HTR 11, HTR 12 and HTR 21 PIDs.
Are all PID values between 0.3 and 3.0 amps? / No Go to next step
Key OFF. I Yes Go to step 6.
Disconnect suspect H02S connector.
Inspect ends of connector for damaged or pushed out pins,
moisture, corrosion, and contamination.
Key ON, engine off. No Go to next step.
Measure voltage between VPWR and SIG RTN circuit at
H02S connector.
------ --- -
Leave suspect H02S connector disconnected.
Measure resistance between VPWR test pin 71 and 97 at Check fuse. If fuse is OK, repair open circuit.
breakout box and VPWR at sensor connector. Go to step 11.
Key OFF. Disconnect suspect H02S connector I Yes For faults with heater current PID out
Measure resistance between HTR GND and VPWR at sensor 1 of range:
connector I Go to step 9.
Is res~stancebetween 3 0 and 30 ohms7 For all others:
Go to next step.
Replace H02S.
GOto s t e ~
11.
Leave suspect H02S connector disconnected. ' Yes Go to next step.
Measure resistance between H02S HTR GND at H02S
connector and H02S case.
Measure resistance between H02S VPWR at H02S sensor i
,
i,Replace H02S.
connector and H02S sensor case. Go to step 11.
Is resistance greater than 10,000 ohms?
Leave suspect sensor and PCM connector disconnected. Yes Go to next step.
Measure resistance between following appropriate test pins at
I
breakout box:
- DTC P0135: Test pin 93 & test pins 24, 76, 91, 97, 103 No Repair short circuit.
- DTC P0141: Test pin 95 8 test pins 24, 76, 91, 97, 103 Go to step 11.
- DTC P0155: Test pin 94 & test pins 24, 76, 91, 97, 103
Is resistance greater than 10,000 ohms? 1 A-
- -- - _ - --
Leave suspect sensor and PCM connector disconnected. / Gotostep 11.
Measure resistance between appropriate test pins at breakout I
box and H02S HTR GND at H02S connector. +
- For H02S HTR-11. Test pin 93 No ' Repair open or cause of excessive resistance in
- For H02S HTR-12: Test pln 95 1 harness.
- For H02S HTR-21: Test pin 94 Gotostep 11.
Key ON, engine running. Access HTR 11A, 12A and 21A / Yes Repair other DTC(s) ~favailable.
PIDs. I I Go to s t e ~
11.
~ o a lPlDs
l indicate on?
Run engine until all PlDs indicate on.
Repair other DTC(s) if available.
Go to step 11.
1 11 I Perform After Repair Procedure to ensure customer's concern has been resolved. 1
I I
CONNECTOR (H02S)
ENGINE ENGINE
HEATER VPWR (6 CY L)
GROUND
(HTR GND)
H02S SIG SIG RTN

BREAKOUT BOX
(VIEW FROM PIN SIDE!)
I I
Signal Wire Color Test Pin
VPWR
SIG RTN
.-
-
--
-
If ---
-
R
GYIR
- I -
- - --
- -
71I97
91
- -
- . --
H02S SIG-11 GYILB I 60
-- - - + - -
i
H02S HTR-11 (GND)
-- - -
RIW 93
--
- - -- -
H02S-
SIG-12
- - -
RILG 35
- -- -
-
H02S HTR-12 (GND)
-- -- -
H02S SIG-21
--
-- - - WIBR
RIB I 95-
87
- -
-
H02S HTR-21 (GND) YILB 94
INJECTORS
CYLINDERS
PIN# 1 WIRECOLOR I
2 101 W
3 94 BRN
4 100 BRILB
---
5 73 TIB
- ---
6 99 LG/O

INJECTOR
GND TO PCM
VEHICLE
71/91 VPWR HARNESS
- CONNECTOR
PI ON-BOARD DIAGNOSIS SYSTEM
Diagnostic trouble code ADAPTIVE FUEL CONTROL

No. P0171, P0172, P0174,
P0175, P1130, P1131, P1132,
P1150. P1151. PI152
Symptom Fuel adaptive system is at rlch correction limit due to fuellair ratlo too lean.
Fuel adaptive system is at lean correction limit due to fuellair ratio too rich.
Fuellair ratio is correcting for an overly-lean condition.
Fuellair ratio is correcting for an overly-rich condition.
Fuel control has reached ~ t smaxlmum compensation for lean or rich and H02S is not
---
switching.
INSPECTION ACTION
Check air intake for leaks, blockage or vacuum leak. Yes Repair as necessary.
Check integrity of PCV system. Go to step 25.
Check for improperly seated dipstick.
Are there any of the above concerns? j NO GO to next step.
L . .
2 Key OFF. I Yes Go to next step.
Disconnect fuel vapor hose from intake manifold and plug I
1
No For DTC P1130, P1150, P0171, P0174,
PO172 and PO175:
fitting at intake manifold. i Go to next step.
Run engine at 2000 rpm for 1 minute and return to idle.
Perform KOER self-test. If PI132 andlor PI152 are no longer
Are DTCs P1131, P1132, PI151 or PI152 present? present:
Reconnect fuel vapor line and go to step 1
of pinpoint test for DTC P1443.
For all others: Go to "Intermittent Concerns."
= pane FT-69
I
Install fuel pressure gauge.
Verify vacuum source to fuel pressure regulator.
If engine will start:
Record fuel pressure at ~dle. -
Increase engine speed to 2500 rpm and maintain for One ' N, Perform "Fuel Line Pressure Inspection,"
minute. Record fuel pressure. G=page FT-150
If no start:
Cycle key on and off several times. Record fuel pressure.
Is fuel pressure between 240-280 kPa (2.5-2.8 Kgf/cm2,
1 35-40 psi)? ,
4 Leave fuel pressure gauge connected Yes For DTCs P1130, Pl150, PO171, P0172,
Cycle key on and off several t~mes. PO174 and PO175:
Verlfy that there are no external leaks. Go to next step
Does fuel pressure remain w~thln5 PSI of h~ghestreadlng
after one rnlnute?
, For No Starts:
Go to step 6
For fuel control DTCs displayed with
I misfire DTCs:
I Go to step 7
All other DTCs:
Go to step 11.
' No Perform "Fuel Pressure Hold Inspection."
j = page FT-150
Yes For DTCs P1130, PI150, PO171 and PO174:
5 Leave fuel pressure gauge connected
Cycle key on and off several t~mes.
Turn key on, englne off
, Go to step 7
Does the fuel pressure remaln wrthrn 5 PSI of the h~ghest NO For DTCs Po172 and P0175:
readlng after 10 seconds? Go to step 9.
6 Leave fuel pressure gauge connected.

Cycle key on and off several tlmes
D~sconnectInertla fuel shut-off sw~tchconnector.
Yes
/ EEC-V system IS not the cause of the no
start. Return to "D~agnostlcIndex" chart
Mon~torpressure gauge whlle crank~ngenglne for at least NO 1 R c ? ~ ~ ~ nInenla

e c t fuel shut-off switch
flve seconds.
Was there a pressure drop greater than 5 PSI? I 22:",',"' step.
Inspect PCM for damaged or pushed out pins, corrosion, Ye&- 10.
or loose wires.
Note: If misfire DTC(s) are displayed with fuel control
1
DTC(s), use misfire DTC(s) to determine the injector
circuit requiring testing.
Measure resistance between suspect injector test pin(s) -,-
and test pin 71 or 97 at breakout box. No Go to next step.

QlA Test in Cvl. Test pin
1 75 4 100 I
2 101 5 73
3 74 6 99
Is resistance between 11.O-18.0 ohms?
Key OFF.
Leave PCM disconnected.
Disconnect injector harness connector at suspect injector.
Measure resistance between test pin 71 or 97 at breakout
box and VPWR pin at injector connector.
Measure resistance between injector test pin(s) at
breakout box and SIG pin at injector connector.
Cvl. Test pin Cvl. Test pin Go to step 25.
1 75 4 100
2 101 5 73
3 74 6
99
~I
Leave PCM and suspect injector connector disconnected.
Measure resistance between injector test pin(s) and test
pin 71 or 97,24,76 and 103 at breakout box.
Measure resistance between injector test pin at breakout
box and chassis ground.
No Repair short circuit.
Cvl. Test pin Cvl. Test in Go to step 25.
1 75 4 100
2 101 5 73
3 74 6 99
Connect PCM to breakout box.
Connect standard 12 volt test lamp between test pin 71 or
97 and each injector test pin.
Cvl. Test ?in Cvl. Test pin
1 75 4 100 Replace PCM.
Go to step 25.
Crank or start engine.

Does test lamp have a dim glovv while cranking or running
engine?
Note: Use misfire DTC(s) displayed on prior DTC Yes For DTCs P1131, PI130, PI151 and P1150:
retrieval to determine at which cylinder(s) to check Go to next step.
compression. For DTCs PI132 and P1152:
Check compression. (Refer to Section B1, 82 or B3.) Go to step 17.
Are cylinder compression readings within specifications?
For DTCs P0171, P0172, PO174 and P0175:
Go to "Intermittent Concerns."
= page FT-69
Misfire DTCs displayed with fuel control
DTCs:
Go to step 8 in "Misfire Detection Monitor."
-- = page FT-106
Repair as necessary.

12 , Key OFF. Yes Go to next step.
, lnspect H02S harness for chafing, burned out wires or
I other damage, and service.
( lnspect H02S and connector for indications of submission

in water, oil or coolant, and service as necessary. No H02S system is OK. Fuel system is OK.
Run engine at 2000 rpm for two minutes. Testing is complete at this time.
Are DTCs P I 131 and/or PI151 present? I
13 Key OFF.
7
1 Yes Go to next step.
Run engine at 2000 rpm for two minutes.

Activate KOER self-test. Replace H02S.
Does voltmeter indicate greater than 0.5 volt during or at Go to step 25.
the end of self-test?
Key OFF
Install breakout box, leave PCM disconnected
D~sconnectsuspect H02S sensor connector.
lnspect both ends of connector for damaged or pushed
; Yes
I
Go to next step.
I
out plns, moisture, corrosion or loose pins, and service
I Measure resistance between H02S SIG test pin at
breakout box and H02S SIG at H02S sensor connector Repair open in H02S SIG or SIG RTN circuit.
- H02S-11 SIG. Test pln 60
- H02S-21 SIG. Test pin 87 Go to step 25.
Measure SIG RTN test pln at breakout box and H02S SIG
RTN at sensor connector
- H02S SIG RTN Test pln 91
-- Is each resistance less than 5.0 ohms?

Key OFF.
------ -
Yes , Go to next step.

Leave PCM and suspect H02S connector disconnected
Measure resistance between H02S SIG test pin and test
pins 24,51,76, 77 and 103 at breakout box
I
~ Repair short circuit.
- H02S-11 SIG Test pin 60 Go to step 25.
- H02S-21 SIG Test pin 87
Key OFF. Yes For DTCs PI130 and P I 150:
Leave PCM disconnected. Go to next step.
Reconnect H02S connector. For Continuous Memory DTCs PI131
Measure resistance between PWR GNDISIG RTN test pin and P1151:
and H02S SIG test pin at breakout box. Go to step 23.
- H02S-11 SIG: Test pin 60
- H02S-21 SIG: Test pin 87 For KOER DTCs PI131 and PI151 :
- H02S PWR GND: Test pin 24,76 and 103 Re~lacePCM.
- H02S SIG RTN: Test pin 91 Replace H02S.
Key OFF. Connect scan tool or NGS to data link
connector.
1: Go to step 25.
Go to next step.
-
Go to "intermittent Concerns."
Activate KOER. ULT page FT-69
Are DTCs PI132 or PI152 present?
Key ON, engine off. t Yes ( Go to next step.
Access H02S PID or 0 2 s on scan tool corresponding to
DTCs received. No Go to step 21.
Is voltage greater than 1.0 volt and less than 4.0 volts?
lnspect PCM for damaged or pushed out pins, corrosion
or loose wires, and service as necessary.
Measure resistance between the following appropriate test
pins at breakout box: Repair short to power.
- For DTC P1130lP1132: Go to step 25.
Test pin 60 and test pins 71,93 and 97
- For DTC PI150lP1152:
Test pin 87 and test pins 71,93 and 97
INSPECTION--
P R e p l a c e H02S.
Leave suspect H02S disconnected. Go to step 25.
Key ON, engine off.
Access H02S PID or 0 2 s on scan to01 corresponding to ---+
N~ , Re~lacePCM.
DTCs received. ~ oto' step 25.
Is voltage less than 0.2 volt?
Key OFF. Remove jumper and go to next step.
Disconnect suspect H02S connector and jumper H02S
SIG at H02S connector to battery negative terminal. Inspect both ends of connector for damaged
Key ON, engine running. or pushed out pins, moisture, corrosion or
I loose pins, and service as necessary. If OK,
Are DTCs PI131 or PI151 present? replace PCM.
Key OFF. Yes Reconnect vacuum hose and H02S

Leave suspect H02S disconnected. connector.
Disconnect any vacuum hose from vacuum tree. Go to next step.
Start engine and run at 2000 rpm.
Is voltage between H02S SIG and SIG RTN at H02S No Replace H02S and reconnect vacuum hose.
connector less than 0.4 volts within 30 seconds? Go to step 25.
Key ON, engine running. Yes i Isolate cause of lack of H02S switching.
Engine at operating temperature. I Go to step 25.
I
Access suspect H02S PID or 0 2 s on scan tool while
wiggling, bending and shaking small sections of vehicle
harness from PCM to H02S.
--
No Go to next step.
Did H02S PID stay greater than 0.45 volt or less than
0.45 volt?
Access H02S PID or 0 2 s on scan tool. Unable to duplicate fault. Testing complete at
Does H02S PID appear to switch properly while driving this time.
vehicle under different road corrditions in an attempt to Replace H02S.
simulate original fault? Go to step 25.
Perform After Repair Procedure to ensure customer's concern has been resolved. 1 6BUOFT-063

CONNECTOR (H02S)
HEATER ENGINE ENGINE

VPWR (6 CYL)
GROUND
(HTR GND)
H02S SIG SIG RTN H02S

11

BREAKOUT BOX H02S
12
Signal Wire Color Test Pin

- - -- - - - - - - --- - --- -
VPWR - R 71/97
-- - -- - -- - - -- - -- - - .
SIG RTN -- -- - - -
GYIR
- - - -- - - - --
91
- -- - .
H02S SIG-11 GYILB 60

-
--
A - - - - -- - - -- - --
H02S HTR-11 (GND) R/W 93

-
-
- - + -- -- - - - -.
H02S SIG-12 --i - - -
R/LG
- -
35 - - - -
---
H02S HTR-12 (GND)
-- + WIBR -
95
-- - - + - - - --
H02S SIG-21 - - , ---

RIB
t -
87
- -
H02S HTR-21 (GND) Y/LB 94

MF 1777-B
1 INJECTORS
CYLINDERS
PIN # WIRE COLOR /
GND TO PCM INJECTOR
71/91 VPWR HARNESS
MF2031-A
ON-BOARD DIAGNOSIS SYSTEM p1
OXYGEN SENSOR
Symptom H02S output voltage is less than calibrated functional window.

between engine and end of catalyst may cause this DTC.
ACTION
lnspect downstream H02S harness for pinched, shorted
and corroded pins.
lnspect for exhaust leaks and contaminated or defective
Yes
, Repair or replace as necessary.
Go to step 8.
sensor.
Are any of the above concerns present?
Key OFF. Yes I Go to next step.
Disconnect downstream H02S connector.
Measure resistance between H02S SIG test pin 35 and
SIG RTN test pin 91 at breakout box.
Measure resistance between H02S SIG test pin 35 and 1 No Repair short circuit.
VPWR 71 or 97 and VREF test pin 90 at breakout box. Go to step 8.
Measure resistance between H02S SIG test pin 35 and
PWR GND test pin 24, 76 and 103 at breakout box.
Key OFF. Yes 1 Go to next step.
Leave PCM and H02S disconnected.
Measure resistance between H02S SIG test pin 35 at + --
breakout box and H02S SIG at H02S connector. Measure NO R~~~~~open clrcult
res~stancebetween H02S SIG RTN test pin 91 at Go to step 8
breakout box and H02S SIG RTN at H02S connector
Is resistance less than 5 0 ohms?
-
- --
Key OFF. Yes Go to step 7.

Reconnect PCM and H02S connector.
Key ON, engine off. No Go to next step.
Access H02S PID or 0 2 s on scan tool.
Is the voltage greater than 1.5 volts?
Key OFF. Yes Remove breakout box and reconnect PCM.
Connect PCM to breakout box and disconnect veh~cle I Go to next step.
I
harness from breakout box. --
Measure resistance between SIG RTN test pin 91 and ~~~l~~~ PCM
PWR GND test pin 24, 76 and 103 at breakout box. Go to step 8
Is resistance less than 5.0 ohms? 1
Key OFF. Yes Replace H02S.
Disconnect downstream H02S connector. Go to step 8.
Jumper VPWR to H02S SIG circuit at H02S connector.
Key ON. Replace PCM.
Access H02S PID or 0 2 s on scan tool. Go to step 8.
Is H02S PID greater than 1.5 volts?
Connect PCM to vehicle harness connector. Go to step 8.
Disconnect downstream H02S connector.
Key ON.
Measure voltage between SIG RTN at H02S connector
and battery negative terminal. Replace H02S.
Measure voltage between H02S SIG at H02S connector Go to step 8.
and battery negative terminal.
Perform After Repair Procedure to ensure customer's concern has been resolved.
I
I Diagnostic trouble code

No. PI128
1 DTC P1128: UPSTREAM HEATED OXYGEN SENSOR
Symptom 1 Upstream H02S signal(s) are swapped from bank to bank during KOER self-test.
I
STEP --
INSPECTION ACTION --- - -.
--
Key OFF. Repair as necessary.

Visually inspect HO2S vehicle connector for stretched
wires or improper mounting. ---
1 GO to step 3.
-- -
Are there any indications of crossed connections or wires? No Gotopstep.

Key OFF. I Yes Go to next step.
Install breakout box, leave PCM d~sconnected.
- For DTC P1128: H02S 11/21 for upstream H02S.
Measure resistance between H02S SIG test p ~ at
n
-
No Repair open circuit in H02S SIG.
breakout box and H02S vehicle connector. Go to next step.
- H02S-11: Test pin 60
- H02S-21: Test pln 87

CONNECTOR (H02S)
HEATER ENGINE ENGINE

VPWR (6 CYL)
GROUND
(HTR GND)
H02S SIG SIG RTN

BREAKOUT BOX
1 Signal Wire Color Test Pin
VPWR
SIG RTN
H02S SIG-12 RILG

H02S HTR-12 (GND)
H02S SIG-21 RIB
I H02S HTR-21 (GND) I YlLB 1 94 I
1 INJECTORS
CYLINDERS
PIN X
!
WIRE COLOR I
I 3
I
! 74 i BRN I
GND TO PCM INJECTOR

VEHICLE
71/91 VPWR HARNESS
CONNECTOR
Diagnostic trouble code FUEL PUMP (FP) PRIMARY OR SECONDARY CIRCUIT

No. P0230, P0231, PO232 pppp.
Symptom FP primary circuit failure and/or secondary circuit malfunction.

--
STEP ~
INSPECTION -
ACTION ~ ~
1 Inspect PCM, fuel pump or fuel pump relay connectors or Continuous Memory DTC P0232:
damaged or pushed out pins, corrosion or loose wires.
Repair or replace if necessary. For Continuous Memory DTC PO231:
Memory DTC P0230:
r all other DTCs:
2 Disconnect fuel pump relay.

Key ON, engine off.
Is voltage between VPWR at fuel pump relay connector on I No Repair open in VPWR circuit between PCM
power relay and fuel pump relay.
power distribution box and chassis ground greater than
10.5 volts?
1 Go to step 23.
I --
Measure resistance between VPWR pin and FUEL PUMP
pin of fuel pump relay.
Resistance should be between 40 and 120 ohms. - ~ ~~-
Measure resistance between FP pin and both

power-to-pump and B+ pins of fuel pump relay.
Resistance should be greater than 10,000 ohms.
Are all resistances OK?
4 Key OFF.
Leave fuel pump relay disconnected.
Key ON, engine off.
Is voltage between FP test pin 80 at breakout box and
chassis ground less than 1.0 volt?
5 Key OFF.
Measure resistance between FP test pin 80 and PWR
GND test pin 51, 103 and 91 at breakout box.
-- - --- - -
6 Key OFF.
Is resistance between FP at fuel pump relay connector on
power distribution box and FP test pin 80 at breakout box
less than 5.0 ohms?
-
7Key OFF.
Remove breakout box and reconnect PCM and relay.
Connect scan tool or NGS to data link connector. .
Key ON, engine off.

Access FPF PID.
Key ON, engine off.

crank engine.
No Replace PCM.
Is FPF PID off during crank? Go to ster, 23.
Does engine start? Yes If DTC PO231 was present:
Replace PCM.
For all others:
Go to next step. --
No If DTC PO231 was present:
Go to step 18.
For all others:
Go to step 13.
STEP INSPECTION
10 Key ON. Wait five seconds.
Listen for motor noise from fuel pump.
11
Is fuel pump off?
Kev OFF. Disconnect fuel .pump
. relay.
--
/ Go to next step.
1
~ e ON.
y No Go to step 23.
Is fuel pump off? Repair short to power in power-to-pump or
FPM circuit.
Go to step 23.
Disconnect fuel pump relay.
Measure resistance between FPM test pin 40 at breakout
box and power-to-pump pin at fuel pump relay connector Repair open circuit.
on power distribution box. Go to step 23.
Key OFF.
Disconnect inertia fuel shut-off switch. -
No
-
Yes
-
Go to next step.
Replace or reset inertia fuel shut-off switch.
Measure resistance between C and NC pins of switch. 1
Is resistance less than 5.0 ohms? I Go to step 23.

Key OFF. Yes Reconnect fuel pump relay.
Leave inertia fuel shut-off switch disconnected. Go to next step.
Measure resistance of power-to-pump between fuel pump Repair open in power-1.0-pumpcircuit
relay connector on power distribution box and inertia fuel between inertia fuel shut-off switch and FPM
shut-off switch connector. connection to circuit.
Is resistance less than 7.0 ohms? Go to step 23.
Leave inertia fuel shut-off switch disconnected.
Disconnect fuel pump.
Is resistance between fuel pump motor ground circuit at Repair open in fuel purnp ground circuit,
fuel pump connector and chassis ground less than Go to step 23.
5.0 ohms?
Key OFF.
Leave fuel pump and inertia fuel pump shut-off switch
disconnected.
Is resistance of power-to-pumpcircuit between inertia fuel
Yes Go to next step.
Repair open circuit.

I
pump shut-off switch connector and fuel pump connector Go to step 23.
less than 5.0 ohms?
Key OFF.
Leave fuel pump and inertia fuel pump shut-off switch
1 Yes Fuel pump circuit is OK.
I
disconnected. Replace fuel pump
Is internal resistance of fuel punip motor less than Go to step 23.
10.0 ohms?
Key OFF. Yes Go to next step. I
Is voltage between B+ circuit at fuel pump relay connector Check fuse for B+ supply to fuel pump relay.
on power distribution box and chassis ground greater than If OK, repair open in B.+circuit.
10.5 volts? Go to step 23.
1 19 1 Key OFF. Leave fuel pump relay disconnected. / Yes Replace fuel pump relay. I
Is resistance between power-to-pumpcircuit at fuel pump Go to step 23.
relay connector on power distribution box and battery Repair open in
negative terminal less than 10.0 ohms? between FPM splice and fuel pump relay.
I 1 1 1 Go to step 23. I
20 Key ON, engine off. Access FPM PID. Yes Isolate fault and repair as necessary.
Perform FPM PID while performing the following: Go to step 23.
Note: FPM PID will turn on when open or short to
power is detected.
- Shake, wiggle, bend power-to-pumpcircuit between
pump relay and fuel pump, pump ground circuit, or time. Go to "Intermittent Concerns."
FPM circuit to PCM. = page FT-69
- Lightly tap pump, relay and inertia fuel shut-off switch. I
1 Is fault indicatedtfound? 1 1
STEP INSPECTION
Install scan tool or NGS to data link connector.
Key ON, engine off.
~ I
Go to step 23.
ACTION
Access Output Test Mode in "Active Command Mode."

While in Output Test Mode, access FPM PID. I
Command the outputs on. FPM PID will be on. No ) Unable to duplicate and/or identify fault at this
Observe FPM PID while performing the following: 1 time. Go to "lntermittent Concerns."
- Shake, wiggle, bend B+ circuit to fuel pump relay or = page FT-69
power-to-pump circuit between pump relay and FPM.
Is a fault indicated?
Install scan tool or NGS to data link connector. Yes Isolate fault and repair as necessary.
Key ON, engine off. Wait five seconds. 1 Go to step 23.
Access FPF PID and observe PID while ~erformina - the
following:
- Shake, wiggle, bend FP circuit between PCM and fuel No Unable to duplicate andlor identify fault at this
pump relay or VPWR circuit between PCM power relay time. Go to "Intermittent Concerns."
and fuel pump relay. .g page FT-69
- Lightly tap fuel pump relay.
B(+)
TEST PIN 80 @ LB/O FP

'I
'
FUEL PUMP
RELAY CONNECTOR
000
*
TEST PIN 71 0 !4 FROM POWER
RELAY
TEST PIN 97 0
TEST PIN 40 a DGlY FPM
(FUEL PUMP MONITOR)
POWER
-TO-
PUMP
'TEST PINS LOCATED ON BREAKOUT BOX
INERTIA FUEL
SHUT OFF SWITCH
FUEL PUMP
RELAY C:ONNECTOR
\
LJ u
POWER DISTRIBUTION BOX
Diagnostic trouble MISFIRE DETECTION MONITOR

code NO. P0300, P0301, P0302,
P0303, P0304, P0305, PO306 -- - - ------- --- -- - -
Symptom Random mlsflre detected or cyllnder 1, 2, 3, 4, 5, or 6 mlsf~redetected

STEP p
Has the vehicle recently run out of fuel? Yes OBD II system OK.
I GO to step 11.
No Go to next step.
Are any Key On Engine Off DTCs or any other Continuous Yes Go to Dlagnostlc Trouble Code chart and
Memory reported (disregard Key On Engine Running DTCs)? address other DTCs first.
-- -
No Check spark plugs and hlgh tension leads.

If OK, go to next step.
If not OK, repair or replace components as
necessary
Go to step 11
Are any KOER DTCs reported? ! Yes If DTC P1131 or PI151 are present: Go to next
step.
All others: Go to Diagnostic Trouble Code chart
and address other DTCs first.
/ Key OFF.
Dtsconnect PCM connector.
Does the suspect ~njectorconnector(s) or the PCM connector
have a poor connection?
Note: This erases Continuous Memory DTCs.
1
Yes
No
' Go to next step.
Reparr or replace connector
Go to step 11
i Go to next step.
)
1 I K Install
ey breakout box. leave PCM drsconnected.
OFF.
Is resistance between 11.0 and 18.0 ohms between the
Yes 1 Go to next step.
I
suspect Injector test pin and VPWR test pins 71/97 at Go to step 7 In plnpolnt test for P0171/P0172/
breakout box? PO174/P0175/P113O/P1131/P1132/P1150/
GyU Test Prn Test Prn P1151/P1152.
1 75 4 100 page FT-94
2 101 5 73

Connect a standard 12V test lamp between test pin 71 or 97
and suspect injector test pin.
Cvl. Test Pin Cvl.# Test Pin
1 75 4 100 No Replace PCM.
2 101 5 73 Gotostep 11.
3 74 6 99
Start engine.
Does test lamp have a dim glow while running engine?
1
-
Is the fuel system OK? Yes Go to next step.
- Fuel llne pressure
- Pressure hold inspection I No Servlce fuel system as necessary.
= page FT-150 page FT-148
.
-
/ G o to step 11.
Are there any leaks, restrictions or damage to the vacuum
lines? yes I Service vacuum system as necessary.
Go to step 11.
I I No Go to next step.
9 Is the evaporative emission system OK? Yes Go to next step.
= page FT-160 -
- Check for excess amount or liquid fuel in canister. No Service evaporative emission system as
- Check for leak or blockage in evap line. necessary.
- Check for EVAP canister purge solenoid. Gotostep 11.
10 Is the posrtrve crankcase venttlat~onsystem OK7 / Yes 1 Englne mechanrcal malfunction
Section B l , 82, & 83
Go to next step. -
necessa,
N ,~1 GO
= nto
~nnext
l , astep
s
11 Perform After Repair Procedure to ensure customer's concern has been resolved
MF1835-C
PO300 Multiple injectors or camshaft
position sensor error
I Diagnostic trouble
code No. PO340
1 CAMSHAFT POSITION (CMP) SENSOR MALFUNCTION
I Svm~tom 1 Camshaft position sensor circuit failure I

INSPECTION ACTION 1
Does vehicle have a No Start symptom? I Yes Return to "CRANKS NORMALLY BUT WILL
NOT START" Diagnostic Troubleshooting
Guide chart No. 5.
1 No Go to next step. 1
Clear DTCs, start engine, and run engine up to 1500 RPM For 2.3L: Go to step 5.
for 10 seconds. Repeat two times. Retrieve Continuous For 3.OU4.OL: Go to next step.
Memory DTCs. Intermittent poor connector or component
Is DTC PO340 present? malfunction in CMP sensor circuit.
Key OFF and disconnect CMP sensor connector. Go to next step. 1
Key ON. -
Is the voltage greater than 10.5 volts between the CMP Repair open in VPWR
sensor connector terminal VPWR (R) and chassis ground? Go to step 10.
Key OFF. Leave CMP disconnected. Go to next step.
Is resistance between CMP sensor connector terminal
Repair open in PWR GND circuit.
PWR GND (BNV) and ground less than 5.0 ohms?
Go to step 10.
Leave CMP disconnected.
Is resistance between CMP sensor connector terminal CID
(DUO) and CID test pin 85 at breakout box less than 5.0
ohms? Repair open in CID circuit.
For 2.3 L, also measure the following: Go to step 10.
Is resistance between SIG RTN circuit at CMP connector
and SIG RTN test pin 91 at breakout box less than 5.0
ohms?
Leave PCM and CMP disconnected.
Key ON, engine off. Repair short in CID circuit.
Is the voltage less than 1.0 volt between CID test pin 85 Go to step 10.
and PWR GND test pins 511103 at breakout box?
Key OFF.
Leave PCM and CMP disconnected.
Go to next step
I
Is the resistance greater than 10,000 ohms between CID Repair short in CID circuit to GND or SIG
test pin 85 and PWR GND test pins 511103 and SIG RTN RTN.
test pin 91 at breakout box? Go to step 10.
Key OFF.
Leave CMP disconnected. Reconnect PCM to breakout
1 yes Go to next step.
Is the resistance greater than 500 ohms between CID test Replace PCM.
pin 85 and PWR GND test pins 511103. VPWR test pins Go to step 10.
71/97, SIG RTN test pin 9l'and IGN GND test pin 23 at
breakout box?
STEP INSPECTION I ACTION 1

9 Key OFF. Yes Replace PCM.
Reconnect PCM and CMP. Go to next step.
Does the AC voltage vary greater than 0.1 volt between
CID test pin 85 and PWR GND test pins 511103 at
breakout box while running the engine at varying speeds? 1 Go to next step.
10 / Perform After Repair Procedure to ensure customer's concern has been resolved.
MFI 836-C2
4.0L
TEST PIN 71
TEST PIN 97
3 T FROM POWER RELAY
VPWR
CAMSHAFT POSITION SENSOR ICMP)
-
I
I
P
- \
(VIEW FROM
PIN SIDE)
,
SHIELD
TEST PIN 85 bDUO -CID .,--..*, . 2.3L
TEST PIN 51 -
TEST PIN 103 . zJ- f PWR GND
TEST PlNS LOCATED ON BREAKOUT BOX

-..,,
1
3.0L HALL DEVICE TYPE CMP 'TEST PINS LOCATED I

ON BREAKOUT
TEST PIN 51 o d - B / w ~ P W R GND BOX. ALL HARNESS
TEST PIN 103 - SHIELD CONNECTORS
TEST PIN 85 -CID ,
-
,,-
, - -- - ?., VIEWED INTO
DUO ,u- --- - 1 MATING SURFACE
TEST PIN 71 VPWR A
T E S T P I N 9 7 % - R I (VIEW FROM PIN SIDE)
FROM
POWER
RELAY
VARIABLE RELUCTANCE (VR)

TYPE CMP
.TEST PIN 85 DBiO-CID

TEST PIN91 &GY/R- SIG RTN
i
,
SHIELD
,
7
vs
I 1
Diagnostic trouble EGFl SYSTEM
code N . PO400 ~~~~~
has detected
-
insufficient EGH system function.
INSPECTION 7- ACTION
If only Continuous DTC PO400 is present, go to step 31. Yes Go to step 5.
Key ON, engine off. Access DPI-EGR PID.
Is DPFEGR PID voltage less than 0.2 volt? Go to next step.
Key ON, engine off. Yes Go to step 8.

Is DPFEGR PID voltage greater than 4.0 volts? Go to next stem
Start engine and run it at idle. Yes Go to next step.
Note: If engine will not start, or it stalls, go directly to
next step.
With engine at idle, look at DPFEGR PID voltage and
compare it to engine off reading.
Note: An increase i n voltage at idle indicates that Go to step 21.
DPFE sensor is sensing EGR flow.
Is DPFEGR PID voltage greater at idle by a minimum of
0.1 5 volt than with engine off?
4 Key OFF. Inspect EGR valve for !signs of contamination,
Disconnect vacuum hose at EGR valve and plug hose. unusual wear, carbon deposits, binding and
Compare DPFEGR PID voltage with engine off and engine other damage.
at idle as described in step 3, but with EGR vacuum hose Go to step 32.
disconnected this time.
Is DPFEGR PID voltage greater at idle by a minimum of L-
0.15 volt than with engine off, or is engine a no start or No Go to step 15.
stall?
5 Key OFF.
Disconnect DPFE sensor connector.
Yes
I Replace DPFE sensor.
GOto step 32.
Connect jumper wire between VREF circuit and DPFE SIG
circuit at DPFE sensor connector.
Key ON, engine off. No Remove jumper wire.
Access DPFEGR PID. Go to next step.
Is DPFEGR PID voltage between 4.0 and-6.0
-
volts?
6 Leave DPFE sensor connector disconnected. Yes Go to next step.
Key ON, engine off.
Measure voltage between VREF circuit and SIG RTN
circuit at DPFE sensor connector. No Go to pinpoint test "VREF."
Leave DPFE sensor connector disconnected. Go to step 32.
Measure resistance between DI'FE SIG test pin 65 and Repair short circuit between DPFE SIG and
SIG RTN test pin 91 and PWR GND test pins 511103 at ground or SIG RTN.
breakout box. Go to step 32.
Key ON, engine off. ---
Measure voltage between DPFE SIG at DPFE sensor No Go to step 10.
connector and chassis ground.
Is voltage greater than 10.5 volts? I
Key OFF. Yes Repair short between DPFE SIG and PWR
Disconnect DPFE sensor connector. circuit.
Key ON, engine off.
Measure voltage between DPFE SIG test pin 65 and PWR No Replace PCM.
GND test pins 511103 at breakout box. Go to step 32.
FT-I 09
STEP
- INSPECTION ACTION -
10 Key OFF. Yes Remove jumper wire.
Leave DPFE sensor connector disconnected. I Go to next step.
Connect jumper wire between DPFE SIG circuit and SIG
RTN circuit at sensor connector.
- -
Key ON, engine off. No Go to step 13.

Access DPFEGR PID.
--
Is DPFEGR PID voltage less than 0.05 volt?
-
Key ON, engine off.
I
Measure voltage between VREF clrcuit and SIG RTN
circuit at DPFE sensor connector. No Go to pinpoint test "VREF."
Is voltage between 4.0 and 6 0 volts?
--
12 Key OFF.
Leave DPFE r osensor
s n e .connector
' . - ' disconnected.
. . . . . . : Go to step 32.
Install breakout box, leave PCM disconnected
Measure resistance between DPFE SIG test pin 65 and Repair short between DPFE SIG and VREF
VREF test pin 90 at breakout box. I c~rcult.
Is resistance greater than 10,000 ohms7 I Go to step 32.
- -- I
13 Key OFF. Yes Go to next step
Leave DPFE sensor connector disconnected.
Install breakout box. leave PCM disconnected.
Measure resistance between DPFE SIG test pin 65 at No Repair open in DPFE SIG circuit.
breakout box and DPFE SIG c~rcuitat DPFE sensor Go to step 32.
connector.
--
Yes Replace PCM.

Leave DPFE and PCM disconnected. Go to step 32.
Measure resistance between SIG RTN test pin 91 at
breakout box and SIG RTN circuit at DPFE sensor No Repair open in SIG RTN c~rcuit.
connector. Go to step 32.
Yes Reconnect vacuum hoses.
lnipect vacuum hoses for routing, pinching or plugging. Go to next step.
Are vacuum hoses OK? No Repair or replace vacuum hoses as
necessary.
- -- - - - ~ -- --
' Go to step
-
32. - - - --

Access and note DPFEGR PID.
Disconnect EVR solenoid connector.
Start engine and run it at idle.
Compare DPFEGR PID at idle to engine off voltage. No Go to step 18.
Is DPFEGR PID voltage greater at idle by a minimum of
0.15 volt than with engine off, or is engine a no start or
stall?
-
17 Key OFF.
Disconnect EVR solenoid vacuum hoses.
1 Yes Repair or replace EVR solenoid.
I Go to step 32.
Remove EVR solenoid vent cap.
Remove filter and inspect for blockage or icing in case.
With EVR vacuum supply port plugged, apply 10 to 15
in-Hg of vacuum directly to EVR vacuum source port with ' No Replace EVR solenoid.
a hand vacuum pump. Go to step 32.
- If vacuum holds or is slow to release to atmosphere,
EVR vent could be plugged or restricted.
Is EVR vent or filter plugged or restricted?
1
1
18 Key OFF. (
I
Leave EVR solenoid connector disconnected.
I Measure resistance across EVR solenoid. I No Replace EVR solenoid.
Is resistance between 26 and 40 ohms? Go to step 32.
C)N-BOARDDIAGNOSIS SYSTEM FT
&
STEP INSPECTION --
ACTION
19 Key OFF Yes Replace DPFE sensor
Disconnect pressure hoses at DPFE sensor to step 32
Connect a hand vacuum pump to downstream plckup
marked "REF on DPFE sensor
Key ON, englne off and access DPFEGR PID
1 Apply 8-9 ~n-Hg vacuum to DPFE sensor.
should
vacuumbefrom
above
sensor.
4.0 volts. T s to P F E sensor
Quickly
- PID voltage
release
- PID voltage should drop to less than 1 volt in less
than 3 seconds
Does DPFEGR PID ~ndlcatea fault In DPFE sensor?
--
20 Key OFF Yes Replace PCM
Leave EVR solenold connector d~sconnected
Install breakout box, leave PCM d~sconnected L --
Is resistance between EVR test pin 47 and PWR GND test No Repair short between E VR and ground
plns 511103 at breakout box greater than 10,000 ohms? 1
Go to step 32
Are DPFE sensor pressure hoses connected properly?
Go to step 32.
lnspect both DPFE sensor and orifice tube assembly for

plugging or damage.
Is fault found?
23 Key OFF.
Disconnect pressure hoses at DPFE sensor.
Connect a hand vacuum pump to downstream pickup
marked "REF on DPFE sensor.
Key ON, engine off and access DPFEGR PID.
Apply 8-9 in-Hg vacuum to DPFE sensor.
- PID voltage should be above 4.0 volts.
Quickly release vacuum from sensor. Go to next step.
than 3 seconds. I i
Does DPFEGR PID indicate a fault in DPFE sensor?
24 Key OFF.
Disconnect vacuum hoses at EGR valve and plug hose.
Connect vacuum pump to EGR valve.
Access DPFEGR PID and RPM PID.
1 Slowly apply 5-10 in-Hg of vacuum to EGR valve and hold
/ it for 10 seconds. If engine wants to stall, increase rpm
I with throttle to maintain a minimum of 800 rpm.
Look for the following:
- EGR valve starts opening at about 1.6 in-Hg
vacuum, indicated by increasing DPFEGR PID.
- DPFEGR PID increasing until EGR valve is fully
open. DPFEGR PID should read 2.5 volts minimum
with full vacuum applied.
- DPFEGR PID steady when vacuum is held. If
voltage drops within a few seconds, EGR valve or
vacuum source could be leaking.
Does DPFEGR PID indicate that EGR valve is functioning
as described in this test?
Key OFF. Yes I Reconnect all components.
Disconnect vacuum hoses at EVR solenoid. i Go to next step.
Connect vacuum gauge to EVR vacuum supply hose.
Warm up engine and run it at idle.
lnspect vacuum line for leaks, kinks, disconnects, No Isolate fault and repair or replace as
blockage, routing or any damage. necessary.
Is vacuum gauge reading a minimum of 15 in-Hg at idle Go to step 32.
and are vacuum lines OK?
INSPECTION ACTION
I
Key ON, engine off. No Repair open in VPWR circuit.
Is voltage between VPWR circuit at EVR solenoid Go to step 32.
connector and chassis ground greater than 10.5 volts?
--
1
I I Leave EVR solenoid connector drsconnected.
IS resistance across solenold between 26 and 40 ohms7
Replace EVR solenold
Go to steo 32.
EVR solenoid connector disconnected. I Yes Repair short in EVR circuit to PWR.
Install breakout box, leave PCM disconnected. , Go to step 32.
I/ /
Key ON, engine off. - -
Is voltage between EVR test pin 47 at breakout box and NO GO to next step.
chassis ground greater than 1.0 volt7
--
I
----
5 Key OFF I Yes Go to next step.
, Leave EVR and PCM disconnected.
I Is resistance between EVR test pin 47 at breakout box and N, R~~~~~open EVR
EVR arcuit at EVR solenold connector less than 5.0 Go to step 32.
ohms?
-
- -
Yes Replace PCM.
Reconnect PCM and EVR connectors. Go to step 32.
I I Disconnect vacuum hose at EGR valve and connect a

vacuum gauge to hose.
1
I
Key 0N,>n$ne running. No Replace EVR solenoid.
Jumper EVR test pin 47 at breakout box to chass~s Go to step 32.
ground.
/ Is vacuum gauge reading 4.0 in-Hg or greater?
31 Record all DTCs received for reference and clear DTCs
Complete EGR monitor drive cycle.
Perform KOEO and KOER self-test
I Is DTC PO400 output? DTC PO400 is only output from
ontinuous Memory:
nspect EGR valve and intake man~foldfor
ontamlnatron and restr~ct~on.
If OK, go to
Intermcttent Concerns "
@ page FT-69
TEST PIN 65 DPFE SIG DIFFERENTIAL

TEST PIN 91 PFE (DPFE)
~ S I RTN
G SENSOR
TEST PIN 90 VREF CONNECTOR

I 'TEST PINS LOGATED ON BREAKOUT BOX
TEST PIN 71197 R EVR SOLENOID

TEST PIN 47 BRIP CONNECTOR

'TEST PlNS LOCATED ON BREAKOUT BOX
Diagnostic trouble EGR SYSTEM
code No. P0401, P I408 --
Symptom , Self-test has detected insufficient EGR flow or EGR flow out of range.
INSPECTION 1-
Run KOER self-test. --
Go to next step.
Is KOER DTC PI408 output? Inspect EGR valve and intake manifold EGR
port for restriction.
--
If OK, go to step 13.
Is DTC PI406 output? Go to step 1 of "DTC P'I405lP14 0 6 pinpoint
test.
--
page FT-120
Go to next steD.
Disconnect vacuum hose at EGR valve and connect hose
to a vacuum gauge.
Run KOER self-test while monitoring gauge.
- Approximately 30 seconds into the test, EGR flow will
be requested for a few seconds. The vacuum at this
time should increase above 1.6 in-Hg to open valve.
Note: Since EGR vacuum hose i s disconnected,
ignore DTCs during this test.
Does vacuum increase to 3.0 in-Hg or greater at any time 1
during KOER self-test?
Visually inspect both hoses for reversed connection at
DPFE sensor or at orifice tube assembly. Go to step 15.
lnspect both hoses for improper routing. Hoses should not
be pinched or have dips in them where water could settle
or freeze.
Inspect both hoses for leaks and blockage.
Inspect DPFE sensor and orifice tube assembly for Go to next step.
blockage or damage at pickup tubes.
Is there a fault detected?
Disconnect DPFE sensor connector. Yes Reconnect DPFE sensor.
Key ON, engine off. I Go to next step.
Measure resistance between VREF circuit and SIG RTN
circuit at DPFE sensor connector.
Is VREF voltage between 4.0 a r ~ d6.0 volts?
I
Key OFF. I Yes Replace DPFE sensor.

Disconnect pressure hoses at DPFE sensor. Go to step 15.
Apply 8-9 in-Hg vacuum to DPFE sensor. ---
- PID voltage should be above 4.0 volts. I No Go to step 13.
Quickly release vacuum from sensor.
than 3 seconds.
Does DFREGR PID indicate a fault in DPFE sensor?
Key OFF. Reconnect all components.
Disconnect vacuum hoses at EVR solenoid. Go to next step.
Connect EVR vacuum supply hose to a vacuum gauge.
- -
Warm up engine and run it.2 idle.
lnspect vacuum lines between vacuum source and EVR Isolate fault and repair or replace as
and between EVR and EGR valve for leaks, kinks, necessary.
disconnects, blockage, routing or damage. Go to step 15.
Is vacuum gauge reading a minimum of 15 in-Hg at idle
and are vacuum lines OK?

Key ON, engine off.
Measure voltage between VPWR terminal at EVR solenoid Repair open in EVR VF'WR circuit.
connector and chassis ground. Go to step 15.
STEP --
INSPECTION ACTION
Leave EVR solenold disconnected. ---- - -- -- --
Measure resistance across EVR solenold. No Replace EVR solenold.

Is res~stancebetween 26 and 40 ohms? ) Go to step 15.
Key OFF.
Yes
1 Repair short to PWR circuit.
Go to step 15.
Key ON, engine off. i -

Measure voltage between EVR test pin 47 at breakout box NO G, to next step,
and chassis around. I
I / Is voltage gr&ter than 1.0 volts?
1 l1 I Key OFF.
Leave EVR solenoid and PCM disconnected.
Measure resistance between EVR test pin 47 at breakout
Yes
N,
I
Go to next step
i R~~~~~open in EVR circuit,

box and EVR circuit at solenoid connector. Go to step 15.
Is resistance less than 5.0 ohms? I
I

Reconnect PCM and EVR solenoid connectors. 1 Go to step 15.
I
Disconnect vacuum hose at EGR valve and connect to
vacuum gauge. i
Key 0 ~ , > n $ n e running. No 1 Replace EVR solenoid.
Jumper EVR test pin 47 at breakout box to chass~sground
while enaine is at idle.
I GO to step 15.
i
Is vacuuh gauge reading 4.0 in-Hg or greater? i
13 Key OFF.
Disconnect vacuum hoses at EGR valve and plug hoses.
Connect vacuum pump to EGR valve.
Access DPFEGR PID and RPM PID.
Slowly apply 5-10 in-Hg of vacuum to EGR valve and hold
it for 10 seconds. If engine wants to stall, increase rpm
with throttle to maintain a minimum of 800 rpm.
Look for the following:
- EGR valve starts opening at about 1.6 in-Hg
vacuum, indicated by increasing DPFEGR PID.
- DPFEGR PID increasing until EGR valve i s fully
open. DPFEGR PID should read 2.5 volts minimum
with full vacuum applied.
- DPFEGR PID steady when vacuum is held. If I
voltage drops within a few seconds, EGR valve or
vacuum source could be leaking. i
Does DPFEGR PID indicate that EGR valve is functioning
as described in this test?
--
14 Key OFF. Yes Isolate fault and repair or replace as

Install breakout box to PCM and vehicle harness necessary.
connector. Go to next step.
Disconnect vacuum hose at EGR valve and connect to
vacuum gauge.
Jumper EVR test pin 47 at breakout box to chassis ground - -. ----- -
while engine is at idle.

Observe vacuum gauge whil me. Go to "Intermittent Concerns."
- Lightly tap on EVR solenoi page FT-69
connector, vacuum lines and vehicle harness.
- Fault is indicated by a sudden drop in vacuum reading. I
Is fault indicated?
pa-
TEST PIN 65 DPFE SIG - DIFFERENTIAL

TEST PIN 91 -
SIG RTN PFE (DPFE)
SENSOR
TEST PIN 90 WVREF- CONNECTOR

*TEST PINS LOCATED ON BREAKOUT BOX
APPLY (VIEW FROM PIN SIDE)

VACUUM TO TEST PINS LOCATED ON BREAKOUT BOX
MF1708-C
Diagnostic trouble
code No. PO402
1 EGR SYSTEM
Symptom 1 Self-test has detected EGR flow at idle.

Key OFF.
Disconnect vacuum hose from EGR valve and plug hose.
Run KOER self-test.
Is KOER DTC PO402 output, or unable to run KOER
~ Yes
-
lnspect pressure hoses first for pinching and
icing. If OK, inspect EGR valve and hose for
signs of contamination, unusual wear, carbon
deposits, binding and other damage.
1
self-test due to engine stall or no start?
L-
1
Go to step 13.
I Reconnect vacuum hose.
/ Go to next steo.
EGR vacuum hose connected.
Run KOER self-test.
1 Yes 1 Go to next step.
Is KOER DTC PO402 output or unable to run KOER No I lnspect pressure hose!; for pinching and icing.
self-test due to engine stall or no start? ) If OK. go to step 9.
3 Are vacuum hoses OK? 1 Yes 1 Go to next step.
Key OFF.
I 1 Repair or replace hoses.
Go to step 13.
Disconnect pressure hoses at CIPFE sensor. Go to step 13.

Apply 8-9 in-Hg vacuum to DPFE sensor. +
- PID voltage should be above 4.0 volts. to DPFE sensor.
Quickly release vacuum from sensor. Go to next step.
than 3 seconds.
---
FT-I 15
I STEP I INSPECTION ACTION

Disconnect vacuum hose at EGR valve and connect hose
to vacuum gauge.
While monitoring vacuum gauge, disconnect EVR solenoid
connector.
NO j GO to step 7
Does vacuum reading remain greater than 1.6 in-Hg at idle I
even after EVR is electronically disconnected?
Key OFF. Yes ( Repair or replace EVR solenoid.
Disconnect vacuum hoses from EVR solenoid. Go to step 13.
Remove EVR solenoid vent cap if equipped.
Remove filter and inspect for blockage or icing in case.
Plug vacuum supply port on EVR solenoid.
Apply 10 to 15 in-Hg of vacuum directly to EVR vacuum
source port with a hand vacuum pump.
- If vacuum holds or is slow to release to
atmosphere, the EVR vent could be plugged or
I
i
Replace EVR solenoid.
Go to step 13.
restricted.
Is EVR vent or vent filter plugged or restricted?
7 /Key OFF. Yes / Go to next step.
I Disconnect EVR solenoid connector. I
Measure resistance across EVR solenoid. No Replace EVR solenoid.

Is resistance between 26 and 40 ohms? Go to step 13.
--- .. --
Replace PCM.
Leave EVR solenoid connector disconnected. Go to step 13.
Is resistance between EVR test pin 47 and PWR GND test
pins 511103 at breakout box greater than 10,000 ohms?
~ - - - - -
Key OFF.
Disconnect pressure hoses at DPFE sensor.
Apply 8-9 in-Hg vacuum to DPFE sensor.
- PID voltage should be above 4.0 volts.
/ Quickly release vacuum from sensor,
than 3 seconds.
10 Key ON, engine off. I Yes Inspect EGR valve for signs of contamination,
Access DPFEGR PID and note voltage. unusual wear, carbon deposit, binding and
Note: DPFEGR PID is 0.45 + 0.25 volts. other damage.
Disconnect vacuum hose at EGR valve and plug hose.
Connect a hand vacuum pump to EGR valve.
Observe DPFEGR PID at idle and compare to KOEO
voltage.
Apply just enough vacuum to EGR valve to open it without
stalling engine and release vacuum.
Repeat several times while observing DPFEGR PID. No Reconnect EGR vacuum hose.
- DPFEGR PID voltage should increase as valve Go to next step.
begins to open and return to initial voltage as
vacuum is released. 1
- A slow-to-return voltage could be an indication of a
binding or a slow-closing EGR valve.
Does DPFEGR PID voltage indicate an open, binding or
slow-closing EGR valve?
--
11 Key OFF. Yes Isolate fault and repair or replace as
Disconnect vacuum hose at EG13 valve and connect hose necessary.
to a vacuum gauge. Go to step 13.
Key ON, engine off.
Observe vacuum gauge while performing the following:
- Lightly tap on EVR solenoid and wiggle EVR solenoid Reconnect vacuum hose and go to next step.
connector and harness.
' Is fault ind~cated?
Key OFF. Yes Repair or replace EVR :solenoid or EGR
Remove EVR solenoid vent cap if equipped. vacuum hose as necessary.
Remove filter and inspect for contamination and excessive Go to next step.
1 water absorption.
Inspect EGR vacuum hose for possible blockage or Unable to duplicate and/or identify fault at this
pinching. time. Go to "Intermittent Concerns."
Is EVR solenoid vent or filter contaminated or vacuum line = page FT-69
/ plugged?
13 / Perform After Repair Procedure to ensure customer's concern has been resolved. A6BUOFT-070
TEST PIN 65 DPFE SIG - DIFFERENTIAL

TEST PIN 91 SIG RTN - PFE (DPFE)
SENSOR
TEST PIN 90 VREF - CONNECTOR
(VIEW FROMPIN
SIDIE)
MF1707-B
TEST PIN 71/97 R

TEST PIN 47 BRIP EVR
TEST PlNS LOCATED ON BREAKOUT BOX
MF1708-C
Diagnostic trouble DPFE SENSOR

code No. P I 400, P I 401
Symptom DPFE SIG circuit i n ~ ubelow
t minimum or above maximum.
1 Key ON, engine off If less than 0.2 volt: Go to next step.
Access DPFEGR PID If greater than 4.0 volts:
IS DPFEGR PID voltage less than 0.2 volt or greater than
4.0 volts?
Inspect pressure signal hoses for leaks and
repair or replace as necessary.
I If OK. ao to steD 12.
1
2 Key OFF. Yes Replace damaged DPFE sensor.
Disconnect DPFE sensor connector. Go to step 13.
Connect jumper wire between sensor VREF circu~tand
DPFE SIG circuit at DPFE sensor connector.
Key ON, engine off. I No Remove jumper wire.
Access DPFEGR PID. Go to next step.
Is DPFEGR PID value between 4.0 and 6.0 volts?
j---
3 Leave DPFE sensor connector. 1 Yes Go to next step.
Key ON, engine off.
Measure voltage between sensor VREF circuit and SIG
RTN circuit at DPFE sensor connector. j No Go to Pinpoint Test "VREF."
4
Is VREF voltage between 4.0 and 6.0 volts?
Key OFF.
Leave DPFE sensor disconnected.
1
I
Yes Replace PCM.

Go to step 13.
Install breakout box, leave PCM disconnected. I
Measure resistance between DPFE SIG test pin 65 and

SIG RTN test pin 91, PWR GND test pins 511103 at
breakout box.
I
I
NO
Repa~rshort clrcult between DPFE SIG
ground or SIG RTN
Go to step 13.
-- --- -- --i--_,
Key ON, engine off.
Is voltage between DPFE SIG circuit at DPFE sensor No Go to step 7.
I connector and battery ground terminal greater than 10.5
volts? i
I
Key OFF Yes 1 Repair short between DPFE SIG and PWR
Leave DPFE sensor connector disconnected. circuit.
Install breakout box, leave PCM disconnected. ----- -
Is voltage between DPFE SIG test pin 65 and PWR GND

test pins 51/103 at breakout box greater than 10.5 volts?
Go to ster, 13.
Key OFF. Yes Remove jumper wire
Disconnect DPFE sensor connector. Go to next step.
Connect a jumper wire between DPFE SIG circuit and SIG
RTN circuit at DPFE sensor connector.
Key ON, engine off. No Go to step 10.
Access DPFEGR PID.
, Is DPFEGR PID voltage less than 0.05 volt?
Key ON, engine off.
Measure voltage between VREF and SIG RTN circuits at 1 --
DPFE sensor connector. No Go to Pinpoint Test "VREF."

Is VREF voltage between 4.0 and 6.0 volts?
Key off. Yes ; Replace DPFE sensor.
Leave DPFE sensor connector disconnected. i, Go to steD 13.
lnstall breakout box, leave PCM disconnected. No Repair short between DPFE SIG and VREF
Is resistance between DPFE SIG test pin 65 and VREF
test pin 90 at breakout box greater than 10,000 ohms? ~ 1
circuit.
Go to step 13.
STEP INSPECTION
Key OFF.
Leave DPFE sensor connector disconnected.
Install breakout box, leave PCM disconnected. --
Measure resistance between DPIZESIG test pin 65 at Repair open circuit in DF'FE SIG circuit.
breakout box and DPFE SIG circuit at DPFE sensor Go to step 13.
connector. I
Is resistance less than 5.0 ohms'?
Leave DPFE sensor and PCM disconnected. Go to step 13.
Measure resistance between SIG RTN test pin 91 at
breakout box and SIG RTN circuit at DPFE sensor " ~ ~ F K N circuit.
connector.
Is resistance less than 5.0 ohms'?
Key ON, engine off. Yes Isolate fault and repair or replace as
Access DPFEGR PID. necessary.
Observe DPFEGR PID while performing the following: Go to next step
- Lightly tap on DPFE sensor.
- Wiggle DPFE sensor connector and vehicle harness. No Unable to duplicate and/or identify fault at this
Is a fault indicated by a sudden change in DPFEGR PID time. Go to "Intermittent Concerns."
voltaae?
" A
= page FT-69
I 1
I Perform After R e ~ a iProcedure

r to ensure customer's concern has been resolved.
TEST PIN 65
TEST PIN 91
TEST PIN 90 *VREF
DPFE SIG
-
SIG RTN
-
- BR/LG
GYIR
BRIW
=cijj I
DIFFERENTIAL
PFE (DPFE)
SENSOR
CONNECTOR

T E S T PINS LOCATED ON BREAKOUT BOX
tI ON-BOARD DIAGNOSIS SYSTEM
Diagnostic trouble
code No. P1405, PI406
DPFE SENSOR
1
STEP
- -. .-
Symptom
I--.Exhaust manifold side (upstream) DPFE pressure hose is off or plugged (DTC P1405).
Intake manifold side (downstream) DPFE pressure
INSPECTION
.- hose is off or plugged (DTC P1406).
ACTION
~ - -
Key OFF. Reconnect hose(s) or repair or replace as

Inspect upstream or downstream hose at DPFE sensor necessary.
and orifice tube assembly for disconnect or poor
connection.
Is hose off or poorly connected?
-
Visually inspect upstream or downstream hose routing. / Yes / Repair or replace hose(s) as necessary.
Hose should not be pinched or have dips in it where water 1 / Go to step 5.
could settle or freeze. I
Carefully remove upstream or downstream hose and
inspect for plugging, water or leaks. No 1 Go to next step.
Is there a fault detected in the hose?
3 Inspect connection marked "HI" for DTC PI405 or "REF Yes I Repa~ror replace DPFE sensor or orlflce tube
for DTC PI406 on DPFE sensor for plugglng or damage at assembly as necessary
sensor Go to step 5.
Inspect exhaust man~folds~depressure plckup hose at
orlflce tube assembly for plugglng or damage. -
Is DPFE sensor or or~f~ce tube assembly plugged or No Go to next step

damaged?
Key OFF. j Yes Replace DPFE sensor.
Disconnect pressure hoses at DPFE sensor. I Go to step 5.
Connect a hand vacuum pump to downstream plckup
Key ON, englne off and access DPFEGR PID. 1
- PID voltage should be above 4.0 volts. I
Quickly release vacuum from sensor. ' No Go to next step.

than 3 seconds.
Does DPFEGR PID lndlcate a fault In DPFE sensor?
1 5 1 Perform After Repair Procedure to ensure customer's concern has been resolved. I
6BUOFT-072
code N PI409.
I EvR CIRCU'T
Symptom 1 Self-test has detected an electrical malfunction in EVR circuit.

I -r-
STEP lNsPEcTloN
Note: If continuous DTC P140!3 is indicated,
go to step 5.
Yes / GOto next step.
ACTION
Key OFF.
Disconnect EVR solenoid. No Replace EVR solenoid.
Go to step 6.
Measure EVR solenoid resistance.
Is resistance between 26 and 40 ohms?
; 0"
1
Key ON, engine off. GO to next step.
Is voltage between VPWR circuit at EVR solenoid
Repair open in VPWR circuit to EVR solenoid.
connector and chassis ground greater than 10.5 volts? , Go to step 6.
Key OFF. 1 yes 1 Go to next step.
Leave EVR solenoid connector disconnected. I
Install breakout box, leave PCM disconnected. L---
Measure resistance between EVR test pin 47 at breakout No Repair open in EVR circuit.
box and EVR circuit at EVR solenoid connector. Go to step 6.
Leave PCM and EVR solenoid connectors disconnected. Go to step 6.
Measure resistance between EVR test win 47 and VPWR
test pins 71/97 at breakout box.
Measure resistance between EVR test pin 47 and PWR GND circuits.
GND test pins 241103 at breakout box. Go to step 6.
Install breakout box, leave PCM disconnected. Yes Isolate fault and repair or replace as
Key ON, engine off. necessary.
Measure voltage between EVR lest pin 47 and PWR GND Go to next step.
test pin 24 at breakout box.
Voltage should read greater than 10.5 volts. For an
indication of fault, look for this voltage to drop while No Unable to duplicate and/or identify fault at this
performing the following: time. Go to "Intermittent Concerns."
- Lightly tap, wiggle and grasp EVR solenoid harness. = page FT-69
Is fault indicated?
1 I
-
6 / Perform After Repair Procedure to ensure customer's concern has been resolved.
I EVR VENT, 1
TEST PIN 71/97 R .VPWR EVR SOLENOID
VACUUM
SUPPLY TEST PIN 47 BR/P EVR CONNECTOR
PORT
PLUGGED
/
I APPLY
VACUUMTO
SOURCE PORT
TEST PINS LOCATED ON BREAKOUT BOX
Diagnostic trouble I CATALYST MONITORING SYSTEM

code No. PO420
I Catalvst efficiencv below threshold.
INSPECTION 1 ACTION
Are any DTCs recorded other than P0420? Yes 1 Go to Diagnostic Trouble Code chart and
1 address other DTCs first.
No 1 Go to next step.
Key OFF.
Does the rear H02S sensor connector or PCM connector
have a poor connection or is it improperly routed?
I yes I1
I
Repair or replace connector,
Go to s t e ~
4.
-
No Go to next step.
1
Is fuel pressure OK?
page FT-154 ~1 Yes
Check the exhaust system for leaks or
restrictions.
0-8 page FT-156
Go to next stem
No
1
Repair the fuel delivery system.
GO to next step.
Not :
Complete spark timing check before proceeding with this pinpoint test. Spark timing
r tard d below specification may increase exhaust gas temperature and decrease
catalyst efficiency over time.
Be sur customer has not:
1) Refueled vehicle with lead gasoline.
2) Experienced high engine oil consumption.
Internal deterioration of a catalytic converter is usually caused by abnormal engine
op ration upstream of catalyst.
1 Diagnostic trouble
code No. PO443
1 EVAPORATIVE EMISSION (EVAP) CANISTER PURGE SOLENOID
Symptom EVAP canister purge solenoid circuit voltage high or low, or solenoid or valve
malfunction.
I STEP 1 INSPECTION 1 ACTION I
Is DTC PO443 present only in Continuous Memory? Yes Go to step 8.
No Go to next step.
Does EVAP canister purge solenoid connector or PCM , Yes I Repair or replace connector.
connector have a poor connection? Go to step 9.
No Go to next steD.
3 Key OFF.
Disconnect EVAP canister purge solenoid connector.
1 Yes , Go to next step.
Key ON, engine off. No Repair open in VPWR circuit.
Is voltage between VPWR at solenoid connector and Go to step 9.
battery ground terminal greater than 10.5 volts?
4 Key OFF. Yes / Go to next step.
Disconnect EVAP canister purge solenoid connector. - -- ~~
, Is resistance between 30 and 90 ohms between EVAP No Replace solenoid.

I SIG and VPWR pins at solenoid? Go to step 9.
5 / Measure resistance between EVAP SIG pin at solenoid Yes , Go to next step.
and solenoid casing.
Measure resistance between VPWR PIN at solenoid and No Replace solenoid.
solenoid casing. Go to step 9.
Are both resistance readings greater than 90 ohms? I
I STEP I INSPECTION ACTION I

Install breakout box, leave PCM disconnected. 1 I
Disconnect EVAP canister purge solenoid connector.
1
Is there continuity between the EVAP canister purge Repair open in EVAP SIG circuit.
solenoid connector terminal EVAP SIG (GYiY) and EVAP Go to step 9.
SIG test pin 67 at breakout box?
7 Key OFF. e Replace PCM.
Leave PCM and solenoid discorinected. Go to next step.
Is resistance greater than 10,000 ohms between EVAP
SIG test pin 67 and PWR GND test pins 241103 at Repair short in EVAP SIG circuit.
breakout box? Go to next step.
8 Key OFF.
Measure resistance between EVAP SIG test pin 67 and
VPWR test pin 71/97, while performing the following:
~ necessary.
Go to next step.
- Lightly tap on EVAP canister purge solenoid.

- Wiggle solenoid connector and harness between
solenoid and PCM. Go to "Intermittent Concerns."
Does resistance reading change to below 30 ohms or 1 page FT-69
above 90 ohms?
1
9
MF1841-C
I
EVAPORTATIVE EMISSION
TEST PIN 67 GYN- EVAP SIG CANISTER PURGE
SOLENOID
I CONNECTOR
FROM POWER
RELAY +--i +R-
TEST PIN 71
TEST PIN 97 R-- VPWR 3
MFI 709-C
FROM
POWER
RELAY
< TEST PIN 71 0
TEST PIN97 a R -VPWR
TEST PIN 11 c b B/LG -PF SIG PURGE FLOW

SENSOR (PF)
CONNECTOR
TEST PIN -c
24/51 /76f?7/103

Diagnostic trouble VEHICLE SPEED SENSOR (VSS)

code No. P0500, P0503, P1500,
-- -
P1501 --- - --
Symptom 1 Vehicle speed sensor circuit malfunction, circuit voltage high or low, or intermittent.
INSPECTION
---
7- ACTION
-
S F : 1 For DTC P1500 or P1501:

I Check for damaged or pushed out pins, corrosion, loose / Unable to duplicate or identify fault at this
I wires at VSS or PCM connector. I time.
Repair or replace if necessary. 1 Go to "Intermittent Concerns."
I e page FT-69
For DTC PO500 or P0503: Go to next step.
Key OFF. Yes I Go to next step.
Disconnect VSS connector. 1

Measure resistance between VSS (+) test pin 58 at pp --
breakout box and VSS (+) at VSS connector. I No Repair open ~nVSS (+) or VSS (-) circuit.
I Measure resistance between VSS (-) test pin 33 at I Go to step 5 to verify repair.
breakout box and VSS(-) at VSS connector.
1 Is each resistance less than 5.0 ohms?
Leave VSS and PCM disconnected.
Measure resistance between VSS(+) test pin 58 and PWR
GND test pin 51, 103, VSS(-) test pin 33, SIG RTN test
i pin 91 and VPWR test pin 77 at breakout box. No Repair short c~rcu~t.
Measure resistance between VSS (-) and VPWR test pin , Go to step 5 to verify repair.
I
71 at breakout box.
Is each resistance greater than 500 ohms?
Key OFF. Yes j Replace PCM.
Measure resistance of VSS. I Go to steD 5 to verifv re~air.
Is resistance between 190 and 250 ohms? Replace VSS. Go to step 5 to verify repair.
No
Warm engine at normal operating temperature. Perform the following test at least three times. After complete test,
retrieve any Continuous Memory DTCs.
If no DTCs are generated, testing is complete.
Test Procedure:
1. Place gear selector in DRIVE range (M)or shift to second gear from first gear (MTT).
2. Obey all local traffic laws.
3. Accelerate heavily to 35 mph (56 kmlh) on A i l or 40 mph (64 kmlh) on M/T.
4. Coast down to an idle and stop vehicle.
5. Shut engine off.

I
AIR CONTROL (IAC) SYSTEM
Symptom IAC system malfunction.

I
Minimum rom cannot be reached or IAC undersweed error or intermittent fault detected.
i
Is DTC P0505, PI504 or PI507 present in Continuous I Go to next step.
Memory or KOER?
Note: If unable t o perform KOER to completion, IAC system is OK.
go t o next step.
--

lnspect IAC solenoid connector or PCM connector for a
poor connection.
Disconnect IAC solenoid connec:tor.
Key ON.
i
I
No Repair open in VPWR to IAC.
Is voltage between VPWR at solenoid connector and
battery negative terminal greater than 10.5 volts?
--
Is internal resistance of IAC solenoid between 6.0 and

13.0 ohms?
Note: Due t o diode i n solenoid, place voltmeter (+) No Replace IAC solenoid.
lead on VPWR pin and (-) lead on IAC SIG pin. Go to step 12.
I
Key OFF. Yes For DTC P1504: Go to step 7.
Is the resistance greater than 10,000 ohms between either All others: Go to next step.
IAC solenoid pins and IAC case? No Replace IAC solenoid.
Go to step 12.
Inspect entire inlet air system for debris, blockage and Yes Go to next step.
other damage.
Inspect air cleaner element for t?xcessivedirt. No Repair or replace if necessary.
Is air intake system OK? Go to step 12.
Key ON, engine running at idle. Yes Repair or replace if necessary.
Are any air leaks detected? Go to step 12.
(Cracked or punctured intake air tube, loose air intake
system, IAC gasket, EGR gasket, PCV connectors and No Go to next step.
hose, vacuum tubes.)
Key OFF.
Install breakout box, leave PCNl disconnected.
Yes Go to next step. I
Is there continuity between IAC solenoid connector No I Repair open In IAC SIC; circuit.
terminal IAC SIG (WILB) and IAC SIG test pin 83 (WILB)? ' Go to step 12.
Key OFF.
Disconnect IAC solenoid.
Key ON, engine off. No Repair short circuit.
Is voltage between IAC SIG test pin 83 at breakout box Go to step 12.
and chassis ground less than 1.0 volt?
Measure resistance between IAC SIG test pin 83 and --- -
PWR GND test pins 51 and 103 at breakout box. No Repair short circuit.
Is resistance greater than 10,000 ohms? I Go to step 12.
Key OFF. Yes For Continuous Memoly DTCs P1504 and

Reconnect PCM and IAC solenoid. , P1507: Go to step 11.
Start engine and slowly increase rpm to 3000 rpm. All others: lnspect throttle body for damage. If
Is voltage between IAC SIG test pin 83 and PWR GND
test pin 51 at breakout box 3.0-'11.5volts?
---
No I
OK, replace IAC.
Replace PCM and go to step 12.
--
7-
Key ON, engine running. Yes Isolate fault and repair as necessary.
Access IAC and RPM PIDs. Go to step 12.
Note: IAC duty cycle should be between 20% and 45%
with engine at normal operating temperature, No ' For idle quality, starting, or stalling symptoms
accessories off and at idle. currently present: Replace IAC.
Do IAC or RPM PlDs suddenly change in value, indicating All others: Go to "Intermittent Concerns."
a fault, while lightly tapping IAC, wiggling or grasping I e FT-69
page
vehicle harness?
1 12 / Perform After Reoair Procedure to ensure customer's concern has been resolved. I
IDLE AIR
CONTROL
SOLENOID
CONNECTOR
TEST PIN83
TEST PIN 71
0 WILB
R
IAC SIG
VPWR--.--7 1
L!YI
TEST PIN 97 ad FROM POWER
RELAY
Diagnostic trouble POWERTRAIN CONTROL MODULE (PCM)

code No. P0603, P0605, PI605
I Symptom PCM has experienced a power interrupt in Keep Alive Power (KAPWR) circuit or Read
Onlv Memow (ROM) test error.
I STEP I INSPECTION ACTION 1
Note: If KAPWR is interrupted to PCM (i.e. when Yes Go to next step.
battery is disconnected or breakout box is installed),
DTC P0603/P0605/P1605 may be generated on the first
power-up. No Repair battery terminal.
lnspect battery cables for loose connections or corrosion. Go to step 5.
Are the battery terminal connections in good condition?
1 2 1 lnspect EEC-V wiring for proximity to ignition components Yes Reroute as necessary.
1 3
/ or wires.
Is wiring too close to ignition components or wires?
Key OFF.
1 NO
Yes
Go to step 5.
GO to next step.
Isolate and repair or replace open c~rcu~t
In
Disconnect PCM. KAPWR circuit.
lnspect for damaged or pushed out pins, corrosion or Go to step 5
loose wires.
Measure voltage between KAPWR test pin 55 and PWR I
GND test pins 51 or 103 at breakout box while performing No ( Go to next step.
the following:
-Wiggle, grasp, shake or bend harness to PCM.
1 Is voltage reading less than 10.5 volts?
4 Disconnect breakout box and reconnect all components.
Cycle ignition switch on and off 40 times.
Yes 1 Replace PCM.
Go to next step.
Key ON, engine off.
Activate KOEO self-test. No , Repair other DTCs as necessary.
1 Is DTC P0603/P0605/P1605 present? I If none, testing is complete.
1 5 Perform After Repair Procedure to ensure customer's concern has been resolved I
r---- 7
I I
TESTPIN55 - Y - K A P W ~ - ~ ~
L---J 0 0 --
FUSE BLOCK BATTERY
TEST PIN LOCATED ON BREAKOUT BOX.
ALL CONNECTORS VIEWED INTO MATING SURFACE.
Diagnostic tr uble BRAKE ONlOFF (BOO) SWITCH
code No. P0703, PI703 --
Symptom BOO switch input voltage high or low, or out of self-test range.
1 Note: This test is for DTC PO703 only. For other DTC, Yes Go to step 3.
go to step 2.
Was brake pedal pressed and released during KOER? No Rerun KOER self-test.
2 Was brake pedal pressed during KOEO self-test? Yes Rerun KOEO self-test.
No Go to next step.
3 Key ON and check stoplamp operation. Yes Go to next step.
No Stoplamps never on::Go to step 5.
Stoplamps always on: Go to step 7.
Check for damaged or pushed out pins, corrosion or loose Go to step 10.
wire. Repair or replace as necessary.
i-
Install breakout box, leave PCM disconnected. No Repair open in BOO c:ircuit between PCM and
Does voltage between BOO test pin 92 and PWR GND BOO connection to st~splampcircuit.
test pin 76 or 77 at breakout box cycle while pressing and Go to step 10.
releasing brake?
5 Key OFF. Disconnect BOO switch. Yes Go to next step.
Is voltage between switch and chassis ground greater than No Repair open B+ circuit to switch.
10 volts? Go to step 10.
6 Is resistance of BOO switch less than 5.0 ohms while Yes Repair open circuit between BOO and
pressing brake pedal? ---
No
ground.
Replace BOO switch.
- Go to step 10.
7 Key OFF. Yes , Go to next step.
Disconnect BOO switch connector. ,I
Key ON, engine off. No If BOO switch is properly installed, replace

Are stoplamps still on? BOO.
--
Leave BOO switch connector tlisconnected.
Disconnect PCM. Key ON.
Are stoplamps still on?
PO Replace PCM and go to step 10.
9 Key OFF. Yes Repair short to power in BOOIstoplamp

Leave BOO and PCM connector disconnected. circuit.
Disconnect shiftlock actuator, cruise control module, ABS Go to next step.
module and GEM. Key ON. No Repair short in accessories.
Are lamps still on? Go to next step.
MF1845-C
BRAKE
ON/OFF
SWITCH
0 BOO SIG - LG 4
TEST PIN 92
TO ACCESSORIES 4 STOPLIGHT
TEST PINS LOCATED ON BREAKOUT BOX.

1 Diagnostic trouble
code No. P0704. PI704
CLUTCH PEDAL POSITION (CPP) SWITCH
Symptom -
CPP switch malfunction, or CPP circuit voltage out of self-test range.
1
k-r-- INSPECTION ACTION

-.
Note: During KOEO self-test, clutch pedal must be Yes Inspect PCM connector for damaged or
down. pushed out pins, corrosion, loose wire.
Key OFF.
Access CPP PID and observe PID cycling ONIOFF with
clutch pedal up, then down. No Go to next step.
Does reading go from ON to OFF?
Key OFF. Yes Repa~ror replace connector.
Does CPP connector have a poor connect~on? I Go to step 6.
--
, No Go to next step.
-
Key OFF. I Yes Go to next step.

Measure res~stanceof CPP swltch with clutch pedal down. 1 No Replace the CPP switch
a9 Section H ~ Go to step 6.

Yes Go to next step. I
Is there continuity between CPP SIG test pin 64 at -. -
breakout box and the CPP switch connector terminal CPP No Repair open circuit.
SIG (LBJY)? Go to step 6.
Is there continuity between SIG RTN test pin 91 at
breakout box and SIG RTN pin at CPP switch connector?
Yes Replace PCM.
Install breakout box, leave PCM disconnected. Go to next step.
Disconnect CPP connector.
Is the resistance greater than 10,000 ohms between test No Repair short clrcult.
pin 64 and ground? Go to next step.
1 6 / Perform After Repair Procedure to ensure customer's concern has been resolved. 1
MF1846-C
CLUTCH PEDAL
POSITION SWITCH
I
CPP SIG -L B N I
c----
CLUTCH PEDAL
POSITION SWITCH
SIG RTN -GY/R 0
CONNECTOR
0
TO STARTER
SWITCH START
*TEST PIN LOCATED ON BREAKOUT BOX

Diagnostic tr uble 0BD I1 DRIVE CYCLE

code No. PI000 I
1
Symptom
INSPECTION
This pinpoint test should be used only if DTC PI000
7
1 ;: 1
OBD II monitor testing not complete.
Repair other DTCs.
1; 1
was received in Continuous Memory. Ignore any DTC
P1000s in KOEO or KOER. No EEC-V system faults have been detected.
2
Were any other DTCs received with PlOOO?
Has a customer requested DTC P I 000 be removed?
Go to next step.
Perform OBD I1 drive cycle. - we
If DTC PI000 is still present, go to next step.

Test is completed.
3 Perform a short road test and check VSS PID Yes Go to next step.
Was VSS PID greater than zero mphlkmh?
4 Drive vehicle long enough to obtarn highest engine Additronal driving is required Perform OBD II
Was ECT PID reading greater than 82°C (180°F)? page FT-76
MF1851-C
I drive cycle.
-
Replace cooling system thermostat Perform
OBD 1
page FT-76
6BUOFT-081
Note:
Diagnostic Trouble Code (DTC) PI000 indicates that not all of the On-Board Diagnostic 1 I
(OBD II) monitors have completed. In some states, this DTC must be cleared to pass an
inspectionlmaintenance test. The customer should be informed that the law specifies that
additional city and highway driving must be done to complete the check of the On-Board
Diagnostic system. This additional driving must occur before the vehicle is tested at the
inspectionlmaintenance station. The amount of driving required varies with individual
driving patterns. To complete this requirement in the shortest amount of time, refer to Driv
Cycles. (Refer to FT-76.)
DTC P i 000 is set by the PCM with any of the following conditions:
The vehicle is new from the factory and has not yet been through a complete OBD II Drive Cycle.
The battery or PCM has been disconnected.
An OBD II monitor failure occurred before completion of an OBD II Drive Cycle.
The PCM DTCs have been erased with a scan tool as part of the normal repair process.
DTC P I 000 may not be removed from the PCM because:
There is a thermostat stuck open and a DTC is not output.
There is an open VSS circuit and a DTC is not output.
The only way a DTC P I000 can be removed from memory is when all the OBD IImonitors have
successfully completed during normal vehicle operation.
DRIVE INSTRUCTIONS OVER TIME I

C)N-BOARDDIAGNOSIS SYSTEM FT
I
Diagnostic trouble code -
NO. PlOOl o r DTC n o t listed 1
STEP /
Symptom
L Unetble to access Continuous Memory DTCs or to activate KOEO or KOER self-test.
Scan tool communlcation
-- -
INSPECTION
- - -
problem or DTC displayed
p- -
by scan tool not I~sted.
--
ACTION
----

Disconnect scan tool or NGS frorr~data link connector.
Inspect data link connector (DLC) for damage. No Complete self-test using correct procedure
Verify that the correct procedure was used to activate self-test (i.e. selected model/model year, use of correct
for scan tool or NGS. program card, scan tool or NGS cable
Was correct self-test activation method used? connection to data link connector, etc.).
Key OFF. Yes 1 Reconnect sensor connector.

Throttle position sensor disconnected. ' Go to next step.
Key ON,' engine off. - -- - - - - --
Is voltage between VREF and SIC; RTN circults at throttle No , Go to plnpo~nttest "VREF."
posltlon sensor connector between 4.0 and 6 0 volts?
Could Contrnuous Memory DTCs be accessed before thls
plnpoint test was entered?
Could KOEO self-test be activateti/completed before this Go to next step.

pinpoint test was entered?
Go to step 7.
Could KOER self-test be activated/completed before this pin- Yes Check that correct PCM is installed on vehicle.
point test was entered? Also check a service bulletin or MTO for any
further information.
+-
-.
' No Go to next step.
-r---
Connect scan tool or NGS to DLC:. , Yes Go to Diagnostic Trouble Code chart and repair
Key ON, engine off. as necessary.
Retrieve Continuous Memory DTCs.
Were any Continuous Memory DTCs present? Go to next step.
Key ON, engine off.

Was voltage between B+ circuit at DLC and engine block
--
Yes ----
Go to next step
ground greater than 10.5 volts? No Repa~ropen In data llnk connector B+ clrcuit.
- - - Go to step 15
- --
Key OFF. Yes Go to next step

--- - -
Is reslstance between chass~sgrclund clrcult at DLC and
englne block ground less than 5.0 ohms? No Repalr open In data llnk connector ground
clrcuit
1 Go to steD 15.
D~sconnectPCM and inspect for damaged or pushed out
pins, loose wires or corrosion. Repair open ~ndata l ~ n k
Install breakout box, leave PCM d~sconnected. c~rcuit.
Is res~stancebetween PWR GND test plns 51/103 at breakout Go to step 15.
box and PWR GND clrcult at DLC less than 5.0 ohms?
Is reslstance between BUS(-) test pln 15 at breakout box and Yes Go to next step.
BUS(-) clrcult at DLC less than 5.0 ohms?
-
No Repalr open In BUS(-) c~rcult.
-- -
Go to step 15.
-- --- - -- --
Is res~stancebetween BUS(-) test pin 15 at breakout box and -
-+
-- -- - --
englne block ground greater than 10,000 ohms?
No Repalr short to around Irr BUS(-) clrcult
I 1 ~o'tostep 15. -
1
!
Key ON, engine off. Yes Repair short to power in BUS(-) circuit.
Leave scan tool or NGS disconnected. GOto step 15.
Is voltage between BUS(-) test pin 15 and PWR GND test --
pins 511103 at breakout box greater than 1.Ovolt? No Go to next step.
I
Is resistance between BUS(+) test pin 16 at breakout'box and
BUS(+) circuit at DLC less than 5.0 ohms? Repair open in data link connector BUS(+)
circuit.
to step I 5.
Key ON, engine off.
_ j
Yes I
Go
Repair short to power in
Is voltage between BUS(+) test pin 16 and PWR GND test Go to next step.
pins 511103 at breakout box greater than 1.O volt?
I Go to next step.
Perform After Repair Procedure to ensure customer's concern has been
--
resolved.
6BUOFT-083
'TEST PIN 16 a- TtO BUS(+)
CHASSIS GROUND
TEST PIN 51 PWR GND
J-b
1
DATA LINK
1
CONNECTOR
9 0013000 16 (nl c\
TEST PIN 77
76
) : I:o : >
TEST PIN ('IEw 'IN 'IDE)
TEST PIN 15 a- P/LB -

TEST PIN 13 0
B+
'TEST PIN LOCATIONS ON BREAKOUT BOX

ALL HARNESS CONNECTORS VIEWED INTO
MATING SURFACES
Diagnostic trouble code ANTI-THEFT SYSTEM

No. P1260
I Symptom Theft detected causing fuel delivery to be d~sabled,or system hardware failure
occurred.
- - -
INSPECTION ACTION
1 Are any DTCs recorded other than P I 260? 1 Yes GOto D~agnosticTrouble Code chart and
address other DTCs first.
I
No ' Go to next step.
Disarm anti-theft.
rn 1997 B-series BETM
Will engine start after Continuous Memory is cleared?
I Yes
Vehicle OK.
Go to s t e 4.
~
No / Go to next step.
Is DTC P I 260 still present? Yes ' Diaanose anti-theft system.
! - w 1997 B-series BETM
j Go to next step.
, Return to Troubleshooting Guide number 5 to
service No Start condition.
m page FT-41
i Go to next step.
Perform After Repair Procedure to ensure customer's concern has been resolved. I
1
Diagnostic trouble code
No. P1270 ~ ENGINE RPMIVEHICLE SPEED LIMITER
Symptom 1 Engine rpm or vehicle speed limiter has been reached.

STEPP INSPECTION
Has vehicle been operated to cause any of the following Yes Vehicle OK, clear DTCs.
conditions? Go to next step.
Wheel slippage
Engine over-revved in N (Neutral) No
Driven at high rate of speed 1 Clear DTCs and refer to Troubleshooting
Guides to address any driveability concerns.
1 2 1 Perform After R e ~ a i Procedure
r to ensure customer's concern has been resolved. I
ON-BOARD DIAGNOSIS SYSTEM t1
No. PI390
/ OCTANE ADJUST (OCT ADJ) CIRCUIT
1 Symptom I OCT ADJ shorting bar is not in or OCT ADJ circuit is open. I
STEP I INSPECTION
7 1 ACTION
/
Is OCT ADJ shorting bar removed?
Go to step 4.
I / 2 Is there a modification decal indicating that OCT ADJ

shorting bar was removed?
Key OFF. 1 Yes 1

Return to DTC chart.
GOto next step.
Go to next step.
-4
Replace OCT ADJ shorting bar.
Key ON.
Activate KOEO self-test.
Is DTC P I 390 present? ! I OBD I1 system OK.
Go to step 6.
1 z tzff
- --
Key OFF. connector.
Does OCT ADJ connector or PCM connector have a poor
connection?
5 Key OFF.
Is there continuity between SIG RTN test pin 91 (GYIR)
and OCT ADJ test pin 30 (DG) at breakout box?
Repair open in OCT ADJ circuit.
Go to next step.
SHORTING
BAR
TEST PIN 91 +SIG R'TN
TEST PIN 30 -0CT ADJ -DG
OCTANE ADJUST
SHORTING BAR
CONNECTOR

Diagnostic trouble code PURGE FLOW SYSTEM CIRCUIT

No. PI443
1 Symptom Vacuum supply malfunct~on,or evaporatlve emlsslon system malfunct~on,or purge flow
sensor clrcurt malfunctlon
pp - - - -- -
- -
7
- - -
INSPECTION -
ACTION
Key ON, engine running. Yes For PF PID voltage from 2.30 to 2.60:
Access PF PID. Go to step 7.
Does PF PID fluctuate around 2.50 volts or 1.OO volt in For PF PID voltage from 0.90 to 1.10:
one minute? Go to step 6.
Go to next step.
1 Check for cracks or other damage to canister.

Is canister cracked or damaged?
Remove fuel vapor hose between fuel tank and canister.

Yes
No
Yes
Replace can~sterand go to step 15.
Go to next step.
--
Check for poss~bleblockage in fuel vapor

--
Install a hand-held pressure pump w~thgauge to open end hose between tank and canister.
of fuel vapor hose. Go to step 15.
Apply 1.0 ~n-Hg(0.5 psi) maxlmum pressure to hose wlth
pressure pump. + -- - ---
Is fuel tank-to-carbon canlster system holding a constant No Go to next step.

- - ----
pressure?
- - -- - -- -- - - - -- -- - - - - -
4 Check for fuel tank damage. Yes Repa~ror replace as necessary.

Is fault lndlcated? Go to step 15.
No Go to next steD
Key OFF. , Yes Go to next step.
Disconnect fuel vapor hose between canister and EVAP
canister purge solenoid at both ends.
Plug one end of hose and ~nstalla vacuum pump at
remaining end. No Replace hose and go to step 15.
Apply 16 in-Hg of vacuum to hose.
Does hose hold vacuum applied for at least 15 seconds?
Key OFF Yes Go to next step.
Dlsconnect vacuum hose at both ends of EVAP canlster
purge solenold
Install hand-held vacuum pump to Intake man~foldvacuum ,
s ~ d eof soleno~d. No Replace solenoid.
D~sconnectsolenold connector Go to step 15.
Apply 16 ~n-Hg(53 kPa) of vacuum to solenold
Does solenold hold vacuum for 20 seconds7
7 1 Reconnect solenoid connector. Yes Dlsconnect vacuum pump.
Apply 16 in-Hg (53 kPa) of vacuum to solenold Inspect fuel vapor hose between can~sterand
Key ON, engine off. solenold for blockage or k~nks
Access on scan tool or NGS. If OK, qo
- to next step.
i Does solenold open and vacuum readlng on pump drop No Check solenold,
1 when command~ngoutput on7 Go to steD 15.
Reconnect EVAP canister purge solenoid connector and
vacuum hose. No Check vacuum hoses for proper routrng,
Disconnect vacuum hose of intake manifold vacuum side leaks, cracks, blockage and klnks.
of solenoid. Repa~ror replace the evaporatlve emlsslon
Start engine and place thumb on open end of vacuum canlster purge solenold valve and/or vacuum
hose at solenoid. hoses.
Is vacuum present at vacuum hose opening? Go to step 15.
--
Key OFF. Yes Replace purge flow sensor
Disconnect vacuum hose between intake manifold and Go to step 15.
purge flow sensor from sensor and connect hand-held
vacuum port to purge flow sensor opening port.
Disconnect vacuum hose between EVAP canister purge - -- - -- -- -
solenoid and purge flow sensor from solenoid and plug No Connect all vacuum hoses
hose. Go to step 10.
Apply 4.1 in-Hg (13.6 kPa) of vacuum to sensor.
Does sensor bleed off all vacuum in less than 2.5
seconds?
FT-I 34
ACTION
Go to next step.
Start engine.
Place thumb on open end of hose
Is vacuum present7 Go to step 15.
-
-
11 Key OFF. D~sconnectpurge flow sensor connector.

Measure reslstance between PF SIG (p~n2) and VPWR
(p~n1) on sensor.
Measure reslstance between PWR GND (pln 3) and
VPWR (pln 1) on purge flow sensor.
Is reslstance greater than 250 ohms between pins 1 and 2
and greater than 280 ohms between pins 1 and 37
Key OFF.
Purge flow sensor disconnected.
I Yes ' Go to next step.
Is resistance between test pins 71 and 97 at breakout box open in VPWR circuit.
and VPWR circuit at sensor connector less than 5.0 Go to step 15.
ohms?
Key OFF. , Yes Go to next step.
Disconnect purge flow sensor and EVAP canister purge
solenoid connectors.
Measure resistance between EVAP SIG and VPWR on Replace solenoid.
solenoid. Go to step 15.
--
Key OFF.
--
Leave EVAP canister purge solenoid disconnected.

1 Yes Replace PCM.
Go to next step.
Install breakout box. Leave PCM disconnected.
Measure resistance between EVAP SIG test pin 67 and Repair short between EiVAP SIG and VPWR
VPWR test pins 71/97 at breakout box. circuit.
Is resistance greater than 10,000 ohms? Go to next step.
1 15 1 Perform After Reoair Procedure to ensure customer's concern has been resolved. I
FROM POWER (VIEW FROM PIN SIDE)

RELAY
TEST PIN 71 R --
TEST PIN 97 R --
Diagnostic trouble code PURGE FLOW SENSOR (PF) CIRCUIT MALFUNCTION

No. P1444, P1445
Symptom PF circuit voltage high or low.
I
1 Key OFF. / For DTC P1444:
1 Go to next step.
1
Inspect for damaged or pushed out pins, corrosion, loose
wlres at PCM or purge flow sensor connector. Repair or
replace if necessary.
1 For DTC P1445:
Go to step 6.

Is PF PID voltage less than 0.14 volts or greater than 4.89 .-..- ~-
volts? No ! Go to step 5.
-
3 Key OFF. Yes Replace sensor.
Disconnect purge flow sensor connector. Go to step 13.
Is resistance between PF SIG (pin 2) and PWR GND - ~ - ~ - --
(pin 3) on sensor less than 25.50 ohms? No , Go to next step.

I
4 K e y
Disconnect purge flow sensor connector. I
Install breakout box, leave PCM disconnected. No 1 Repair short between PF SIG and PWR GND.
Is resistance between PF SIG test pin 11 and PWR GND
test pin 241103 at breakout box greater than 10,000 ohms?
i ( Go to step 13.
-- ~ - - - - --_ I ~.. -
5 1 Key ON, engine off. Yes ; Isolate fault and repair as necessary.
Access PF PID. ; Go to step 13.
Is fault indicated while performing the following?
- Lightly tap on sensor or wiggle PF sensor connector No I Unable to duplicate andlor identify fault at this
and vehicle harness. A fault is indicated by a sudden time.
j Go to "Intermittent Concerns."
change in PF PID voltage (less than 0.14 volts). I
page FT-69
@

Access PF PID.
Is PF PID voltage greater than 4.89 volts? I No Go to step 12.
. - - ~
7 Key OFF. Yes , Go to next step.

Disconnect PF sensor connector.
Measure resistance between PF SIG (pin 2) and VPWR I
(pin 1) on purge flow sensor at room temperature No I Go

Replace sensor.
to step 13.
(55 to 80°F [I31 to 176"CI). I
Is resistance between 60 and 200 ohms? 1
8 Leave PF sensor disconnected. 1 Yes : Go to next step.

Key ON, engine off.
Is voltage between PF SIG circuit at sensor and battery
ground terminal greater than 10.5 volts?
No I G~ to step
1
9 Key OFF. Yes / Repair short between PF SIG and VPWR
Leave PF sensor disconnected. ! j circuit.
Install breakout box, leave PCM disconnected. I / Go to step 13.
Key ON, engine off.
/ Is voltage between PF SIG test pin 11 and PWR GND test No I Replace PCM.
pins 241103 at breakout box greater than 10.5 volts? Go to step 13.
I
10 Key OFF. j Yes Go to next step.

Disconnect PF sensor connector. I

Measure resistance between PF SIG test pin 11 at / No Repair open in PF SIG circuit.
breakout box and PF SIG circuit at sensor. Go to step 13.
I
.---- - -. .- ~ ~-
11 Key OFF.
Leave PF sensor and PCM disconnected.
Is the resistance between PWR GND test pins 241103 at
~
b-
No
Replace PCM.
Go to step 13.
~ -
Repair open in PWR GND circuit.

breakout box and PWR GND circuit at sensor connector
less than 5.0 ohms? I Go to step 13.
12 Key ON, engine off. Yes Isolate fault and repair as necessary.
Access PF PID. ( Go to next step.
Is a fault indicated while performing the following?
- Lightly tap on PF sensor or wiggle sensor connector No
Go to "Intermittent Concerns."
and vehicle harness. e page FT-69
I
MF1859-C 6BUOFT-088
FT-136
PURGE FLOW
FROM
POWER
RELAY
-< TEST PIN 71 0
SENSOR (PF)
CONNECTOR
TEST PIN 97 R -VPWR
TEST PIN 11 6BILG-- PF SIG
TEST PIN a
24/51 /76/77/103
(PIN 3)
'TEST PINS LOCATED ON BRlfAKOUT BOX
MF2034-A
Diagnostic trouble code DTC P1460: WIDE OPEN THROTTLE N C CUT-OFF (WAC) RELAY
No. P1460, PI464
--
DTC P1464: N C CONTROL SIGNAL (ACCS) -
- -- -
Symptom - - AIC
-
was -
on, a WAC circu~t
-- --
fault or ACCS Input to PCM was hlgh durlng self-test. --- -
-
--
INSPECTION ACTION- ----
- -
Note: Verify that N C and defrost were off during Yes Go to next step.
KOEOIKOER self-tests. If vehicle is not equipped with
AIC, WAC circuit is not used and DTC PI460 can be
ignored.
If Continuous Memory DTC PI460 is present, go
directly to step 11.
No Go to step 7.
Start englne.
Make sure A/C and defroster are turned off
Access ACCS PID
Is ACCS PID off7
- --- - -- --
Key ON, englne off Yes Go to next step

D~sconnectWAC relay -. pp -----
Is voltage between VPWR clrcu~tat WAC relay co
on power dlstr~but~on
box and chass~sground gre
10 5 volts"
.--
Key OFF
Leave WAC relay dlsconnected.
Inspect WAC relay coll resfstance between plns 85 and 86 ---
at WAC relay (should be between 40 and 120 ohms). No Replace WAC relay
Inspect resistance between pin 85 and pin 30, 87 and 87A Go to step 13
at WAC relay (should be greater than 10,000 ohms).
Are all reslstance checks OK7
Leave WAC relay dlsconnected
Install breakout box, leave PCM d~sconnected
Key ON, englne off. No Repair short to power.
Is voltage between WAC test pln 69 at breakout box and Go to step 13.
chass~sground less than 1.0 volt7
- - -- -- --- - - - ,- -- - - - -

D~sconnectscan tool or NGS
Leave PCM and WAC relay d~sconnected
Measure reslstance between WAC test pln 69 and PWR No Repair short clrcult.
GND test pins 51/103 and SIG RTN test pin 91 at Go to step 13.
breakout box
Is each resistance greater than 10,000 ohms7
Leave PCM and WAC relay d~sconnected. Go to step 13.
Is reslstance between WAC test pln 69 at breakout box
and WAC clrcult at relay connector on power d~str~but~on No Repa~ropen c~rcult
box less than 5.0 ohms7 Go to step 13.
,
-- -- -- -- -- -- -- - - -- - - -- -- -
Key OFF. Yes lnspect operat~onof A/C sw~tch.

Disconnect A/C pressure switch. If OK, repair short to power In A/C sw~tchto
Key ON, englne off. A/C pressure swltch c~rcuit.
Access ACCS PID Go to--
-
step 13.--
+
- -- -- -
Is ACCS PID off? No Go to next step.

- - - - - - - -- - - - - - -- - -
D~sconnectWAC relay
Key ON, englne off -- - -- - -
Is voltage between power-to-clutch c~rcultof WAC relay No Repa~rshort to power.

connector on power dlstribut~onbox and chass~sground Go to step 13.
less than 1 0 volt7
Key OFF Yes Go to next step
Leave WAC relay and A/C pressure sw~tchd~sconnected.
Install breakout box, leave PCM disconnected. -
Key ON, engine off No Repa~rACCS clrcult short to power.

Is voltage between ACCS test pin 41 and PWR GND test Go to step 13.
pins 511103 at breakout box less than 1 0 volt7
STEP ~ INSPECTION 1 ACTION I
Key OFF, reconnect WAC relay. Replace PCM.
Leave PCM and A/C pressure switch disconnected. Go to step 13.
Key ON, engine off.
Is voltage between ACCS test pin 41 and PWR GND test Replace WAC relay.
pins 511103 at breakout box less than 1.O volt? Go to step 13.
Key OFF. Yes Isolate fault and repair or replace as
Disconnect N C cycling switch. necessary.
Connect a jumper wire to both terminals at N C cycling Go to step 13.
switch connector.
Key ON, engine off.
Turn AJC switch on.
lnspect WAC circuit for open or short to power while
performing the following: Go to next step.
- Shake, wiggle, bend harness.
- Lightly tap on WAC relay.
Note: N C clutch will click on when a fault is detected.
Key ON, engine off. Yes lsolate fault and repair or replace as
Connect a jumper wlre to both terminals at N C cycllng necessary.
swltch connector
Turn N C sw~tchon.
Connect scan tool or NGS to data llnk connector
Access Output Test Mode.
Turn all outputs off Unable to duplicate and/or identify fault at this
lnspect WAC clrcult for short to ground and open In VPWR time. Go to "lntermitter~tConcerns."
or IGN RUN clrcu~twhlle perforrnlng the following: = page FT-69
- Shake, w~ggle,bend harness.
- Llghtly tap on WAC relay.
Note: N C clutch will click off when a fault is detected.
Is a fault indrcated?
1 13 1 Perform After R e ~ a i Procedure
r to ensure customer's concern has been resolved. I
'TEST PIN 71
-.TR- VPWR
I TEST PIN 97 0
I- I I
TEST PIN 41 0 DGIO ACCS
WAC RELAY
FROM AIC
SWITCH e s
AIC CYCLING ACPSW U
HARNESS
CONNECTOR
SWITCH
POWEFl
-TO-
TEST PIN 69 O Ply WAC
-
-L
Qi
.
= J
J ,, I I I I I I I I WAC RELAY
8.+T+8;
I I I I I I I
- -
-
I-.
n u 1 1-"11
0
0
0
,IOIIOCl!J
L1
COIL - 85 AND 86
m" -
COMMON - 30
NO - 87 1

NO.P I 505
IDLE AIR CONTROL (IAC) SYSTEM CIRCUIT
1 System at adaptive clip.

!
INSPECTION
Inspect the inlet air system for any vacuum leaks, plugged 1 I
I
i Go to next step.
ACTION ----I
air filter, loose throttle body connection, or contaminated or
damaged IAC valve assembly. Repair or replace components as necessary.
Is the inlet air system OK? Go tostep 11.
I I
1 Do the throttle body linkage, accelerator cable, and speed / Yes : Go to next step.
control cable travel freely-when exercised individually w~th
the accelerator cable and speed control cable
disconnected^ I
I NO
;
If cables stick or bind. repair or replace
cables.
' Gotoste~ll.
1
I
I , If cables are OK, ao to steo 6.
Leave cables disconnected from throttle body linkage.
Verify that throttle return screw is in contact with throttle
linkage lever arm when throttle is in closed-plate position.
Does throttle return screw contact lever arm?
-=- Yes Go to next step.
--
Adjust screw position.
--
= page FT-146
I Go to next step.
Key ON, engine off. Yes Go to next step.
Access TP PID.
Slowly move throttle from closed to wide open throttle
position and observe TP PID for smooth reading change. --
Release throttle and allow to return to fully closed position. No Check TP sensor.
Is TP PID reading between 13% (0.66 volts) and 240h
(1.20 volts) at closed throttle position?
, Yes
i ;I
Remove cables from throttle body. Go to "Dlagnostic Flow Chart."
Does throttle rotate freely without sticking, binding or
grabbing condition? GO to step 9.
-- --
Key ON. Go to next step.

Monitor the RPM and IAC PlDs with transmission in P I
(Park) [N (Neutral)], the engine running at normal

operating temperature with cooling fan off, and all
accessories off.
Are the IAC PID and RPM PID as follows?
2.3L MT
AT
RPM PID
695-745 rprn
743-793 ipm
IAC PID
20-45%
20-44%
r~ ---
I
, Go to step 8.
3.OL MT 825-875 rprn 20-44%

AT 875-925 rprn 20-44OlO
4.OL MT 725-775 rprn 20-45%
AT 799-849 rprn 20-44%
With transmission in P (Park) [N (Neutral)], the engine Yes Go to next step.
running at normal operating temperature with cooling fan
off, and all accessories off:
Does the engine stall or does the rprn fluctuate
~
j No Air intake system OK - return to Diagnostic
excessively before returning to normal idle when the
Index to check other driveability symptoms.
throttle is snapped? I
[ 1: indicates MT models i
With transmission in P (Park) [N (Neutral)], the engine Yes / If fast idle symptom:
running at normal operating temperature with cooling fan 1 Go to step 10.
off, and all accessories off: I If not fast idle symptom:
Does the rpm drop or does the engine stall when the IAC GO to next step.
solenoid is disconnected?
No Replace IAC solenold.
[ 1: indicates MT models Note: Do not attempt to clean IAC.
Go tostep 11.
Key OFF. Yes Return to Diagnostic Index to check other
Remove throttle body and check the following: driveability symptoms.
Hold throttle body up to a light source.
No light should be visible belween plate and bore with
plate closed.
Rotate throttle lever and allow it to return. Replace throttle body.
It should not stick or bind and should return to closed Go to step 11.
plate position freely when released.
Does throttle body pass these checks?
Disconnect IAC solenoid. Go to step 11.
Is the resistance greater than 10,000 ohms between IAC Repair short in IAC St(; circuit.
SIG test pin 83 and PWR GND test pins 511103 at Go to step 11.
breakout box?
I 11 / Perform After Repair Procedure to ensure customer's concern has been resolved. I
IDLE AIR
CCINTROL
SOLENOID
CC)NNECTOR
TEST PIN 83
TEST PIN 71
TEST PIN 97 FROM POWER
RELAY
/ Diagnostic trouble code

No. P1506
1 IDLE AIR CONTROL (IAC) SYSTEM CIRCUIT
I Symptom 1 Overspeed error detected. 1

I STEP / INSPECTION ACTION 1
Inspect the inlet air system with the engine running, Yes Repa~ror replace components as necessary.
listening for vacuum leaks, and looking for any cracks or Go to step 7.
leaks in the system. - - - - --
Are any leaks detected? No Go to next step.

--
Disconnect hoses at EVAP canister purge solenoid.
Connect hand vacuum pump to either port and apply No Replace EVAP purge solenoid.
16 in-Hg (53 kPa) of vacuum. Go to step 6.
Does solenoid hold vacuum for 20 seconds?
I
With the transmission in P (Park) [N (Neutral)] and the I Yes Go to next step.
engine running at normal operating temperature, does the
lnspect throttle body for damage or defects.
rpm drop or the engine stall when the IAC solenoid is If OK, replace IAC valve.
disconnected?
If not OK, repair or replace throttle body.
[ 1: indicates MT models Go to step 6.
Key OFF. Disconnect ISC solenoid. I Yes For fast idle symptom currently present:
Install breakout box, leave PCM disconnected. Replace PCM.
Is the resistance greater than 10,000 ohms between IAC All others:
SIG test pin 83 and PWR GND test pins 511103 at Go to step 5.
breakout box?
Repair short in IAC SIG circuit.
Go to steD 6.
/ Key ON, engine running.

i Monitor the IAC and RPM PlDs with all accessories off.
Is the IAC PID between 20% and 45% at ~dle,or do the
Yes Repair malfunctioning IAC components as
intermittent faults are identified.
I Go to step 6.
1
--
IAC'ID and RPM suddenly change during a wigglelta~
For idle quality, starting, or stalling
' No '
test, or when snapped?
symptoms currently present:
Replace IAC solenoid.
Go to next step.
6
All others:
Go to "lntermrttent Concerns."
page FT-69 -
MF1863-C
IDLE AIR
CONTROL
SOLENOID
CONNECTOR
vpw
TEST PIN 83 WILE IAC SIG
TEST PIN 71 " '

RELAY
I-
Diagnostic trouble code POWER STEERING PRESSURE (PSP) SWITCH CIRCUIT (2.:3L ONLY)
No. P I 650, P I 651
Symptom PSP switch circuit voltage out of self-test range or circuit malfunction.
I STEP / INSPECTION I ACTION 1
Key ON, engine running. Yes Intermittent poor connection or component
Does PSP PID indicate ONIOFF switching as the steering malfunction (repair or replace as necessary).
wheel is turned right and left? No Go to next step.
With the vehicle in P (Park) [N (Neutral)], does the idle Yes Replace PSP.
speed increase when the PSP switch is disconnected? Go to step 7.
[ 1: indicates MT models No Go to next step.
Key OFF. Yes Repair or replace connector.
Does PSP switch connector or PCM connector have a GOto step 7.
poor connection? No Go to next step.
Key OFF.
Is there continuity between PSP switch connector terminal
PSP SIG (YILG) and PSP SIG test pin 31 (YILG), and
between PSP switch connector terminal SIG RTN (GYIR)
and SIG RTN test pin 91 (GYIR)?
Key OFF.
Is the resistance greater than '10,000 ohms between PSP
1-
Yes
-
GOto next step.
SIG test pin 31 (YILG) and SIG RTN test pin 91 (GYIR) or Repair short in PSP SIG circuit.
chassis ground? I Go to step 6.
Is resistance of PSP switch less than 5.0 ohms?
-
.
MF1658-B
TEST PIN 31 0-
TEST PIN 91 0- GY/R POWER Sl-EERING

PRESSURE SWITCH
CONNECTOR
TEST PINS LOCATED ON BREAKOUT BOX.
ALL CONNECTORS VIEWED IN MATING SURFACE. (VIEW FROM PIN SIDE)
Pinpoint Test VREF (Reference Voltage)

I
INSPECTION ACTION
greater than 6.0 volts when measured in the Yes Go to step 15.
previous step? , No Go to next stew.
I
Key ON, engine off. Yes Go to next step.
Is voltage across battery terminals greater than 10 5
volts? No Inspect charging system (refer to sectlon G)
Key ON, engine off. , Yes Go to next step.
- --
Disconnect sensor where VREF check fa~led.

Measure voltage between battery positive terminal and
SIG RTN circult at appropriate sensor connector
1
No Go to step 10.
Is voltage greater than 10.5 volts and w~thin1.O volt of
battery voltage?
Note: The purpose of this step is to determine if scan Yes /I Go to step 9
tool or NGS is able to communicate with PCM. I
Key ON, englne off.
Attempt to access ECT PID. No 1 Go to next step.
I
Can ECT PID be accessed?
5 Key OFF. Yes Reconnect IAC solenoid connector.
Disconnect TP sensor connector. I Go to next step.
Disconnect IAC solenoid connector.
Key ON, engine off. I
Measure voltage between VPWR circuit at IAC solenoid NO Repair open VPWR circuit,
connector and battery negative terminal. I
I Is voltage greater than 1 6 5 volts?

6 Key OFF. Yes Replace DPFE sensor.
Leave TP sensor disconnected.
Key ON, engine off.
Measure voltage between VREF and SIG RTN circuits at No Go to step 7.
TP sensor connector.
Key ON, engine off. No Repair open VPWR circuit between PCM and
Measure voltage between VPWR test pin 71 and PWR PCM relay.
GND test pin 77 at breakout box.
1 / Is voltage greater than 10.5 volts?
Key OFF.
1
!
Yes Replace PCM.
I
Measure resistance between VREF test pin 90 and PWR

GND test pins 51/103 at breakout box.
I
Key OFF. ' Yes / Replace PCM.

Disconnect sensor connector where VREF check failed.
i
Measure resistance between VREF test pin 90 and VREF No Repair open VREF circuit.
circuit at appropriate sensor connector.
--
Note: The purpose of this step is to determine if scan / Yes I Go to next step.
tool or NGS is able to communicate with PCM. I1
1
Key ON, engine off.
Attempt to access ECT PID. Go to step 13.
Can ECT PID be accessed? ,
I
No
Are KOEO DTCs present for two or more sensors 1 Yes GOto next step.
connected to SIG RTN circuit? I
Sensors conn cted to SIG RTN: 1
DPFE sensor, TP sensor, IAT sensor, ECT sensor, OCT No ( Repair open SIG RTN circuit to sensor where
I
ADJ connector, TR sensor, H02S-11, H02S-12,
H02S-21. CPP switch. PSS switch I VREF check failed.
STEP INSIPECTION ACTION

12 Key OFF.
Disconnect sensor connector where VREF check failed.
Measure resistance between SIG RTN circuit at
appropriate sensor connector and SIG RTN test pin 91 at
breakout box.
Is resistance less than 5.0 ohms? .
13 Key OFF.
Measure resistance between battery negative terminal
and PWR GND test pins 51/76/77/103 at breakout box.
-~ .
14 Key OFF.
Connect PCM to breakout box.
--
Measure resistance between SIG RTN test pin 91 and
PWR GND test pins 51/76177/'103 at breakout box.
Is each resistance less than 5.0 ohms? -.
15 i Key OFF.
/ Disconnect sensor connector vvhere VREF check failed.
Disconnect TP and DPFE sensor connectors.
Disconnect PCM connector.
Key ON, engine off. Repair VREF short to power in harness.
Measure voltage between VREF circuit at TP sensor
connector and battery negative terminal.
6BUOFT-093
IDLE AIR

TEST PIN 83
TP SIG TEST PIN 71

TEST PIN 89
SIG RTN
GYMl
TEST PIN 97
A
RELAY
DIFFERENTIAL
THROmLE POSITION SENSOR TEST PIN 65 SDPFE
SG
I- BRILG PFE (DPFE)
CONNECTOR (TP) SENSOR
TEST PIN 91 SSIG
RTN GYlR CONNECTOR
TEST PIN 90 &VREF BRMl
-TEST PINS LOCATED ON BREAKOUT BOX
FT-I45
FT INTAKE AIR SYSTEM (FOR 2 . 3 1
~3 . 0 1
~4 . 0 ~ )
INTAKE AIR SYSTEM (FOR 2.3L 13.OLI 4.OL)

)
THROTTLE BODY
lnspection
1. Check the throttle body for wear and deposits.
2. Verify that the throttle valve moves smoothly when the
throttle lever is moved from fully closed to fully open.
3. Replace the throttle body, if necessary.
Caution
The throttle body must not be cleaned. A sealant I
~BUOFT-094 coating covering the throttle bore and throttle
valve makes the throttle body tolerant to engine
intake sludge accumulation.
THROTTLE RETURN SCREW
lnspection
Caution
Do not perform this inspection unless instructedto
do so.
Remove all cables from throttle body linkage.

Remove clean air tube from throttle body and verify there
is no foreign material obstructing throttle plate.
Verify that the throttle return screw is in contact with
throttle linkage lever arm when throttle plate is in closed
position.
4. If throttle return screw is not contacting throttle linkage
lever arm, perform Adjustment procedure.
Adjustment
I . Place a 0.002 inch feeler gauge between throttle return
screw and throttle linkage lever arm.
2. Adjust the throttle return screw until it just contacts the
feeler gauge.
3. Remove the feeler gauge and turn the throttle return
screw clockwise 112 turn.
Removal I Installation
Refer to section F1 for 2.3L, Section F2 for 3.OL or Section
F3 for 4.OL.
IDLE-SPEED CONTROL SYSTEM (FOR 2.3L / 3.OL 14.OL) FT
IDLE-SPEED CONTROL SYSTEM (FOR 2.3L / 3.OL 14.OL)
DESCRIPTION
The idle-speed control system controls the bypass air amount that passes through the throttle body to
improve idle stability warm-up and driveability. This systerr~consists of the idle air control solenoid,
powertrain control module (PCM) and input devices.
If the idle air control solenoid or circuit has an open or short, Diagnostic Trouble Code No. P0505,
P1504, P1505, PI506 or PI507 is output.
If the circuit is open, the idle air control solenoid will be fully closed causing rough idle, engine stalling
and acceleration hesitation when cold.
If the circuit is shorted, the idle air control solenoid will be fully open causing high idle.
6BUOFT-096
IDLE AIR CONTROL SOLENOID

Inspection
1. Connect scan tool or SST (NGS) to data link connector.
Access IAC PlD and check the IAC PID values.
For 4.OL
ldle Air Control (IAC) - PID Voltage Values (DCV / V%)
Key ON engineTHofd-p~ 1 55-65MPH
1 1
25-30MPH i
VBAT / 0% 11-11.7128-32% 7.6-10 / 9.1-10.41
30-55Y0 38-47Y0 [AT]
42-55% lMTl
MFI 590-B
CHECK
For 3.OL
ldle Air Control (IAC) - PID Voltage Values (DCV / %)
T- i 30-55MPH 55-65MPH
For 2.3L
FOR 3 OL
ldle Air Control (IAC) - PID Voltage Values (DCV I %)
IDLE AIR
CONTROI.. 1 Key ON engine off
1 Hot idle I 1 30-55MPH 55-65MPH
/ VBAT 1 O0/0
25-30MPH
A T1 1 lOlO:l~9 1.7 I
MF1590-A
2. Measure the resistance of the idle air control solenoid.
For 4.OL / 3.OL / 2.3L

Resistance: 6.0--13.0Q (at 20°C ,[68"F))
3. If not as specified, replace the idle air control solenoid.
Tightening torque:
8-11 N - m (82-112 kgf.cm, 71--97 inelbf)
6BUOFT-097
FT FUEL SYSTEM (FOR 2 . 3 /~3 . 0 /~4 . 0 ~ 1
FUEL SYSTEM (FOR 2.3L I3.OL 14.OL)

DESCRIPTION
This system supplies fuel to the fuel injectors at a constant pressure. Fuel is metered and injected into
the intake manifold according to injection control signals from the PCM. This system consists of the fuel
tank, fuel pump, fuel filters, pressure regulator, fuel injectors and fuel pump relay.
(ILLUSTRATION SHOWS
4 DL MODEL)
FUEL FILTER (HIGH-PRESSURE SIDE)
MF1268-D
13 . 0 I
FUEL SYSTEM (FOR 2 . 3 ~ ~4 . 0 ~ 1 FT
PREPARATION
SST
49 UNOl 010 For 49 UNO1 006 For

inspection fuel
Fuel of fuel Fuel line return line
pressure pressure coupling removal
gauge tool
(for 4.OL only)
49 TO88 OAO For

inspection of 49 051
NGS set PCM terminal fuel return
voltage and Spring lock line removal
inpuffoutput coupling
devices tool (318 in.)
(for 2.3L / 3.OL)
49 UNO1 052 For

fuel supply
Spring lock line removal
coupling
tool (112 in.)
(for 2.3L / 3.OL)
PRECAUTION
Fuel Pressure and Servicing Fuel System Releasing
Fuel in the fuel system remains under high pressure when
the engine is not running.
1. Before disconnecting any fuel line, release the fuel
pressure from the fuel system to reduce the possibility of
injury or fire.
(1) Connect the SST to the fuel pressure relief valve
(SchradeP valve), located on the fuel distribution
pipe.
(2) Place the SST drain hose in a suitable container.
(3) Depress the pressure relief button until the pressure
is released.
Alternate method
(1) Disconnect the inertia fuel shutoff switch.
(2) Crank the engine for 15 to 20 sec. to relieve the
pressure.
2. Use a rag for protection from fuel spray when disconnect-
ing the hoses.
3. When inspecting the fuel system, use the SST.
\ \ VALVE I
WF1038-A 4BUOF3-122
FT / 4.0~)
FUEL SYSTEM (FOR 2 . 3 /~3 . o ~
SYSTEM OPERATION (For 2.3L 13.OL / 4.OL)
Fuel Line
e Pressure1
e Fuel Pressure Hold Inspection
Warning
the fuel pressure from the fuel system to reduce
the possibility of injury or fire. (Refer to above.)
1. Install the SST.

2. Key ON, engine off.
3. Connect the SST (NGS) to the data link connector and
select Active Command Mode.
4. Select Output Test Mode. Press MODE to change to the
"ALL ON" mode, and press start to run fuel pump.
5. Turn relay OFF.
6. Observe the fuel pressure.
Fuel pressure:
240-280 kPa (2.5-2.8 kgf / cm2y 35-40 psi)
Zero or
pressure low -
Check the fuel pump. (Refer to page
FT-151.) If as specified, the fuel line
or fuel filter might be clogged or
MF1038-A 6BUOFT-200 restricted.
Pressure high - Perform pressure regulator high
pressure inspection. (Refer to page
FT-154.)
7. Observe the fuel pressure after 1 min.
Fuel pressure:
Within 34 kPa (0.35 kgf / cm2,-5 psi) of reading in
test step 5.
8. If not as specified, perform the following inspections:

Pressure regulator diaphragm inspection. (Refer to
page FT-154.)
Injector fuel leakage. (Refer to page FT-155.)
If results of fuel line pressure and pressure hold inspec-
tion are OK, perform "Fuel Line Pressure Under Load
Inspection" on next page.
6BUOFT-201
FUEL SYSTEM (FOR 2 . 3 1 I4 . 0 ~ )
~3.0~ FT
Fuel Line Pressure Under Load Inspection
-
Warning
Before performing the following operation release
the possibility of injury or fire. (Refer to page
FT-149.)
1. Install the SST.

2. Disconnect the vacuum hose from the pressure regulator
and plug it.
3. Start the engine and drive the vehicle under heavy
acceleration.
4. Verify that the fuel line pressure does not increase or
decrease more than 20 kPa (0.2 kgf P cm2, 3 psi) during
heavy acceleration.
5. If not as specified, perform the following inspection:
Fuel vapor valve (Refer to page FT-163.)
6. If the fuel vapor valve is ok, replace tlhe fuel filter.
FUEL PUMP
If the fuel pump monitor signal circuit has an open or
short, Diagnostic Trouble Code No. P0230, PO231 or
MF1038-A 6BUOFT-202 PO232 is output.
If the circuit is shorted, the fuel pump will not operate and
the engine will stall and not restart. 5~~0~3-143
lnspection
1. Verify that the battery is fully charged. (Refer to Sec-
tion G.)
2. Verify that fuel tank unit connector is securely connected.
4. Connect SST (NGS) to the data link connector and select
Active Command Mode.
5 . Select OUTPUTTEST MODE. Press MODE to change to
the "ALL ON" mode, and press START to run fuel pump.
6. Listen to the fuel pump to verify operation.
7. Turn the relay off.
8. If the fuel pump does not operate, perform the following
inspections:
Continuity inspection
1. Disconnect the fuel tank unit connector.
2. Check for continuity between the fuel tank unit power and
ground terminals.
3. If continuity does not exist, replace tlie fuel pump.
FT FUEL SYSTEM (FOR 2 . 3 1
~3 . 0 1
~4 . 0 ~ )
Voltage inspection
1. Connect SST (NGS) to data link connector.
3. Select ACTIVE COMMAND MODE.
4. Select OUTPUT TEST MODE. Press MODE to change to
the "ALL ON" mode, and press START to run fuel pump.
5. Measure the voltage at the power terminal of the fuel tank
unit connector.
' VlEW FROM TERMINAL SlDE
Specification: Greater than 10.5 volts
06. If not as specified, perform the following inspections:
MF 1042-A ~BUOFT-~O~
Fuel pump relay (Refer to page FT-153.)
Inertia fuel shutoff switch (Refer to page FT-152.)
If voltage is OK, but fuel pump still inoperative, inspect fuel

pump ground circuit as follows:
Ground inspection
GROUND 2. Measure the resistance between the fuel tank unit
TERMINAL connector ground terminal and a chassis ground.
Specification: Less than 1 ohm
3. If not as specified, service the connector to chassis

ground.
VlEW FROM ERMINAL SlDE
I INERTIAFUEL
SHUTOFF SWITCH CASE
1-
HEATFRINERTIA FUEL SHUTOFF SWITCH
Inspection
LOCATEDUNDERTHE 1. Disconnect the inertia fuel shutoff switch connector.
INSTRUMENT PANEL
TO THE RIGHT OF THE BUTTON 2. Check continuity between terminals of the inertia fuel
TRANSMISSION HUMP / I I / shutoff switch.
Specification:
Condition Continuity
I
Tripped No
HUTOFF SWITCH Not Tripped Yes
3. If not as specified, replace the inertia fuel shutoff switch.

FUEL SYSTEM (FOR 2 . 3 I
~3 . 0 1~4 . 0 ~ ) FT
FUEL PUMP RELAY
If the fuel pump relay or circuit has an open or short, Diagnostic Trouble Code No. P0230, PO231 or
PO232 is output.
If the circuit is open, the engine will not start.
If the circuit is shorted, the fuel pump will operate whenever the ignition switch is ON.
5BUOF3-152
Inspection
Operational check
Install the fuel pump relay and listen for clicking of the fuel
pump relay while cranking the engine.
4BUOF3-139
Continuity inspection
COIL - 85 AND 86 1. Measure resistance between pins 85 and 86 at the relay.
COMMON - 30
NO - 87
NC - 87A Specification: 40-120 ohms
0
MF1044-B
12. Measure resistance between pin 85 and both pins 30 and
6BUOFT-207
87 of relay.
Specification: Greater than 10,000 ohms.
3. Apply battery positive voltage (B+) a.nd check continuity

between terminals of the relay.
Specification:
B+ : Battery positive v ltag
I Terminal 85-86 1 Terminal 30-87 I
r B + applied I Yes I
4. If not as specified, replace the fuel pump relay.
FT FUEL SYSTEM (FOR 2 . 3 1
~3 . 0 ~
14.0~)
PRESSURE REGULATOR
Inspection
Fuel line pressure
Warning
Before performingthe following operation, release
the possibility of injury or fire. (Refer to page
rr-149)
1. Connect the SST.

2. Start the engine and run it at idle.
3. Disconnect the vacuum hose from the pressure regulator
and plug it.
DRA 4. Drive vehicle with heavy acceleration while observing fuel
HOS pressure gauge reading.
Fuel pressure reading:

Hold steady within 20.6 kPa (0.21 kgf /cm2, 3 psi)
5. If the fuel line pressure does not hold, check for clogged
~ONNECT TO FUEL
fuel filter
PRESSURE RELIEF 6. Connect a vacuum pump to the pressure regulator.
VALVE 7. Apply vacuum to the pressure regulator.
8. Verify that the fuel line pressure decreases as vacuum
increases.
9. If the fuel line pressure does not decrease when vacuum
increases, replace the pressure regulator. If the fuel line
pressure decreases when vacuum increases, check
vacuum hose and vacuum source.
High pressure inspection

1. Connect the SST.
2. Disconnect the fuel return line from the fuel rail.
3. Connect a short hose from the fuel rail to a one liter (one
quart) measuring container.
5. Connect SST (NGS) to the data link connector and
select Active Command Mode.
6. Select OUTPUT TEST MODE. Press MODE to change
to the "ALL ON" mode, and press START to run fuel
pump.
7. Measure the fuel line pressure and verify fuel is flowing
into container.
D
8. If the fuel line pressure is still high, then replace the
H pressure regulator.
9. If the fuel line pressure is OK, then inspect the fuel return
line for clog.
10. Remove SST (NGS.)
Diaphragm inspection
1. Start the engine and run it at idle for 10 seconds.
2. Turn the ignition switch OFF for 10 seconds.
\\ PRESSURE RELIEF
VALVE 3. Start the engine and run it at idle for 10 seconds.
4. Turn the ignition switch OFF.
5. Disconnect the vacuum hose from the pressure regulator.
6. Check the vacuum port on the pressure regulator.
7. If the diaphragm is leaking fuel, replace the pressure
regulator.
4BUOF3-145
FUEL SYSTEM (FOR 2 . 3 ~1 3 . 0 ~
14.0~) FT
INJECTOR
If an injector has an open or short, Diagnostic Trouble Code No. P0300, P0301, P0302, P0303, P0304,
-. PO305 or PO306 is output.
If the circuit is open, the injector will not operate, causing rough idle and misfiring.
If the circuit is shorted, the injector will inject fuel constantly causing a hard start or no start condition.
5BUOF3-150
lnspection (On-vehicle)
1. Warm up the engine and run it at idle (or cranking if it does
not start.)
2. Listen for the operational sound of each injector with a
I
sound scope.
Note
Compare the operational sound of each injector
because of the difficulty of verifying the sound of
individual injectors.
lnspection (Off-Vehicle)
Caution
Do not remove the injector from the fuel distributor
unless it is necessary.
6BUOFT-210
I I
MF1047-A 4BUOF3-146 Note
Refer to Section F1 for 2.3L, Section F2 for 3.OL, or
Section F3 for 4.OL for Injector Removal 1 Installa-
tion procedure.
Injector resistance
1. Disconnect the injector connectors.
2. Measure the resistance of the injectors.
Resistance: 11-1 8 ohms (20°C (68°F))
3. If not as specified, replace the injectlor(s).

6BUOFT-211
Fuel leakage test

Warning
the fuel pressure in the fuel system to r duc the
possibility of injury or fire. (Refer to pag FT-149.)
1. Remove the fuel rail assembly from the intake manifold.

2. Connect the fuel lines.
3. Connect the data link connector terminal FP to ground by
using a jumper wire.
4. Turn the ignition switch ON and check for fuel leaks from
injectors.
Fuel leakage: Less than 1 drop I 2 min.
5. If not as specified, remove the leaking injector and check

the O-rings and fuel rail damage. Replace as necessary.
FT FUEL SYSTEM (FOR 2 . 3 ~
13.0~
14.0~)
Note
Perform the following installation carefully to pre-
vent fuel leakage from the O-ring.
6. Install the injector.

7. Turn the ignition switch ON and check for leaks from
injector.
8. If not as specified, replace the injector.
4BUOF3-151
EXHAUST SYSTEM (FOR 2.3L / 3.OL / 4.OL)

COMPONENTS
Inspection (On-vehicle)
1. Start the engine and verify that there is no exhaust gas
leakage from the exhaust system components.
2. If an exhaust leak is found, replace parts as necessary.
3. Connect a vacuum gauge to the intake manifold vacuum
source.
4. Connect a tachometer to the engine.
5.Start the engine and place the transmission into neutral.
6. Gradually increase the engine speed to 2000 rpm while
observing the vacuum gauge.
7. Decrease the engine speed to idle while observing the
vacuum gauge.
Note
The vacuum gauge reading may be normal when
the engine is first started and idled. However,
excessive restriction in the exhaust system will
cause the vacuum gauge to drop to a low point
even while the engine is idled.
8. The manifold vacuum should exceed 53 kPa

(406 mmHg, 16 inHg).
9. If the manifold vacuum exceeds specified vacuum, then
the exhaust system is OK.
10. If the manifold vacuum does not exceed specified
vacuum or the vacuum is slow to return to normal, then
inspect the following components for restrictions:
Silencer
Three-way catalytic converter
Exhaust manifold(s)
FT-156
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM (FOR 2.3L 13.OL I4.OL) 1
POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM
(FOR 2.3L 1 3.OL 14.OL)
DESCRIPTION
The PCV valve is operated by the intake manifold vacuum. When the engine is running at idle, the PCV
valve is slightly open and a small amount of blowby gas is drawn into the upper intake manifold to be
reburned. As the engine speed rises,the PCV valve is opened further, allowing a larger amount of blowby
gas to be drawn into the upper intake manifold.
PCV VALVE (FOR 2.3L / 4.OL)

Inspection
Note
Perform this inspection while the engin is cold.

2. Disconnect the PCV valve along with the ventilation hose
from the cylinder head cover.
3. Block the PCV valve opening.
6. Blow through the valve from port h and verify that air
comes out of port B.
7. Blow through the valve from port B and verify that no air
comes out of port A.
8. Shake PCV. PCV should rattle.
9. Replace the PCV valve if not as specified.
PCV VALVE (FOR 3.OL)

I TO EVAPORATIVE EMISSION CANISTER lnspection
1. Remove the PCV valve from the valve cover.
EE%
2. Shake the PCV valve.
3. Verify that the PCV valve rattles when shaken.
4. If the PCV valve does not rattle (sticking), then replace
it.
5. Reinstall the PCV valve and hoses.
TO THR0TIl-E BODY
6. Warm the engine at idle.
7. Disconnect the hose from the PCV valve leading to the
throttle body.
8. Block the hose opening.
10. If no vacuum is felt, check for restrictionsand replace the
hose if restricted or leaking.
11. Inspect the evaporative emission hose between the
PCV valve and the evaporative erriission canister, and
replace it if it is leaking.
6BUOFT-214
EXHAUST GAS RECIRCULATION (EGR) FUNCTION CONTROL SYSTEM
FT (FOR 2.3L 13.OL 14.OL)
EXHAUST GAS RECIRCULATION (EGR) FUNCTION CONTROL SYSTEM
(FOR 2.3L 13.OL 14.OL)
DESCRIPTION
This system recirculatesa small amount of exhaust gas into the intake manifoldto reduce the combustion
temperature and reduce the NOx emissions. This system consists of the EGR valve, EGR vacuum regu-
lator solenoid, differential pressure feedback EGR sensor, powertrain control module (PCM) and input
devices.
4BUOF3-167
Differential Pressure Feedback EGR Sensor

If the differential pressure feedback EGR sensor or circuit has an open or short, DiagnosticTrouble Code
No. P0400, P0401, P0402, P1400, P1401 or P I 408 is output.
If exhaust manifold side or intake manifold side hose is off or plugged, DTC No. Pi405 or PI406 is output.
6BUOFT-215
EGR Vacuum Regulator Solenoid

If the EGR vacuum regulator solenoid or circuit has an open or short, Diagnostic Trouble Code No. P1409
is output.
If the circuit is open, no driveability symptom will be noticed.
If the circuit is shorted, the EGR valve will remain open, causing engine stalling and hard starting.
6BUOFT-216
PCM
-
DUTY CYCLE OUTPUT
I
EGR VACUUM
REGULATOR (EVR)
SOLENOID
E E AIR
S H
ANALOG
INPUT
DIFFERENT'IAL I I \
PRESSURE
FEEDBACK EGR (DPFE)
SENSOR
'7 METERING
ORIFICE
4
INTAKE VACUUM
1 I
EXHAUST PRESSURE
Operation
Cold engine (Coolant temperature IS less than 55 C (131-F))
EGR operailon 1s stopped to Improve drlveabll~tywhen the englne temperature IS cold
Warm Engtne
The powertra~ncontrolmodule IPCMI controls the EGR vacuum regulator solenod to supply EGR gases
EGR VACUUM REGULATOR SOLENOID

Inspection
1. Disconnect the vacuum hoses from the solenoid.
2. Connect the vacuum pump to the port A.
3. Plug the port B.
4. Apply the vacuum and make sure that the needle of the
vacuum pump stays at zero.
EXHAUST GAS RECIRCULATION (EGR) FUNCTION CONTROL. SYSTEM
(FOR 2 . 3 1
~3 . o ~1 4 . 0 ~ ) FT
5. Apply the battery voltage to the terminal A and ground the
terminal B as shown.
Caution
Never apply the battery voltage to the terminal B.
The diode in solenoid may be damaged.
MF2037-A 5BUOF1-189
6. Apply the vacuum and make sure that the needle of the
vacuum pump jumps up and returns to zero.
7. If not as specified, replace the solenoid.
EGR VALVE
Inspection
~~1535-A ~HUOFI-190 1. Install a tachometer.
2. Disconnect the idle air control solenoid connector.
3. Remove and plug the vacuum supply hose from the EGR
valve.
4. Start the engine and run it at idle with the transmission in
neutral.
5. Observe the idle speed.
6. Connect a vacuum pump to the EGR valve and slowly
apply vacuum.
Specification:
17-34 kPa {I 27-254 mmHg, 5-1 0 inHg}
7. Verify that the idle speed drops more than 100 rpm with
vacuum applied and returns to normal { * 25 rpm) after
the vacuum is removed.
8. If not as specified, replace the EGR valve.
4BUOF3-170
Replacement
1. Remove the EGR valve in the sequence shown below:
(1) Remove DPFE sensor retaining bolt (4.OL only)
(2) Reposition DPFE sensor (4.OL o111y)
(3) EGR tubes
(4) Vacuum hose
(5) EGR valve and gasket
Note
Before installingthe EGR valve, install new gasket.
2. Install the EGR valve in the reverse order of removal.
Tightening torques:
EGR valv to tube nuts: 3 4 4 8 N.m
( 3 . 5 4 . 8 kgf .m, 25-35 ft - Ibf)
EGR valve to manifold: 20-30 N 0 m
(2.1-3.1 kgfem, 15-22 ft-lbf)
6BUOFT-217
FT FUEL EVAPORATIVE EMISSION SYSTEM (FOR 2.3L 13.OL 14.OL)
FUEL EVAPORATIVE EMISSION SYSTEM (FOR 2.3L 13.OL 14.OL)

DESCRIPTION
The fuel evaporative emission system consists of the fuel vapor valve, evaporative emission canister,
evaporative emission canister purge solenoid, purge flow sensor, powertrain control module (PCM) and
input devices. The amount of evaporative fumes introduced into the engine and burned is controlled by
the solenoid corresponding to the engine's operating conditions. To provide the best engine perfor-
mance, the solenoid is controlled by the PCM using an input signal from the purge flow sensor.
5BUOF3-114
Evaporative Emission Canister Purge Solenoid Valve

If the evaporative emission canister purge solenoid valve or circuit has an open or short, Diagnostic
Trouble Code No. PO443 is output.
If the circuit is open, no driveability symptom will be noticed.
If the circuit is shorted, the engine may stall at low speed.
A short circuit may cause an improper aidfuel ratio, causing rough idle and hard starting.
~BUOFT-218
Purge Flow Sensor

If the purge flow sensor circuit has an open or short, Diagnostic Trouble Code No. PI444 or PI445 is
output.
If the purge flow sensor circuit is open or shorted, no driveability symptom will be noticed.
If purge flow is malfunctioning, DTC No. P1443 is output.
6BUOFT-219
FUEL EVAPORATIVE EMISSION SYSTEM (FOR 2.3L / 3.OL / 4.OL) FT
OPERATION
The evaporative emission canister purge solenoid is con-
trolled by signals from the PCM to perform purging of the
evaporative emission canister. The purge flow sensor
monitors vapor flow through the evaporative emission
canister purge solenoid and signals the PCM of flow or no
flow conditions. The PCM monitors this signal and other
input signals regarding engine condition. Purging is done
when the following conditions are met:
(1) After warm up
(2) Accelerator pedal depressed (off idle)
~BUOFT-220
SYSTEM OPERATION
3. Disconnect the vacuum hose from the evaporative emis-
sion canister purge solenoid leading to the evaporative
emission canister.
4. Check that no vacuum is felt.
5. Place the transmission in N (Neutral) and depress the
accelerator pedal.
6. Verify that vacuum is felt with the accelerator pedal
depressed.
7. Disconnect the vacuum hose at the purge flow sensor
from the intake manifold.
8. Verify that vacuum is felt with the accelerator pedal
depressed.
9. If vacuum is not as specified, check the vacuum hose and
supply.
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE

SOLENOID
Inspection
1. Remove the evaporative emission canister purge sole-
noid.
2. Connect a vacuum pump to the vacuum source port and
EVAPORATIVE VACUUM
apply vacuum.
EMISSION SOURCE
CANISTER PORT Specification: 54 kPa (406 mmHg, 16 inHg)
PORT
3. Verify that the vacuum holds.

FT FUEL EVAPORATIVE EMISSION SYSTEM (FOR 2.3L 13.OL 1 4.OL)
- - -
4. Apply battery voltage to the evaporative emission canis-

ter purge solenoid.
5 . Verify that vacuum releases when battery voltage is
applied.
6. Measure the resistance between the terminals of the
evaporative emission canister purge solenoid.
Resistance: 30-90 ohms

PORT
7. If vacuum, operation or resistance are not as specified,

replace the evaporative emission canister purge sole-
noid.
PURGE FLOW SENSOR (PFS)

Inspection
1. Disconnect the vacuum hoses from the PFS.
2. Plug the port leading to the evaporative emission canister
purge solenoid valve.
3. Apply 13.6 kPa (104 mmHg, 4.1 inHg} to the PFS.
4. Verify that vacuum holds.
5. Measure the resistance between PFS SIG (Pin 2 ) and
~~1052-E 56~0~3-115 PWR GND (Pin 3) on the PFS.
Resistance: 25.65-28.35 ohms
6. Measure the resistance between PFS SIG (Pin 2) and

VPWR (Pin 1) on the PFS.
Resistance: 75-1 00 ohms
7. Measure the resistance between VPWR (Pin 1) and PWR

GND (Pin 3) on the PFS.
~~1726-A Resistance: 95-1 30 ohms
8. Confirm all wires of PFS vehicle harness have a good

connection (i.e., at solder of Red wire). Repair as neces-
sary.
9. If vacuum and/or resistance are not as specified, replace
the PFS. 6BUOFT-221
EVAPORATIVE EMISSION CANISTER
lnspection
1. Remove the evaporative emission canister.
2. Visually check the evaporativeemission canister for dam-
age, fuel saturation and leakage.
3. Blow through each port and verify tha.t air flows.
4. If not as specified, replace the evaporative emission can-
ister.
FUEL VAPOR VALVE

Inspection
1. Verify that air flows through the valve frlom port A when the
valve is held as shown in the figure.
I I
-c-
MFI054-A
2. Verify that no air flows through the valve from port A when
the valve is held as shown in the figure.
3. If not as specified, replace the fuel vapor valve.
A 0
1
MF1055-A 4BUOF2-160
DECHOKE CONTROL SYSTEM (2.3L ONLY)

DESCRIPTION
To facilitate starting the engine when the spark plugs
become fouled, such as when the engine is flooded, fuel
injection is cut if the throttle valve is held wide open during
cranking. This allows the spark plugs to dry and purges
excess fuel from the cylinders.
4BUOF1-169
I
MFIO~~-A 6EiU0FT-222 SYSTEM OPERATION
1. Turn the ignition switch to START and verify that an injec-
tor operating sound is heard while the engine is cranking.
2. Depress the accelerator pedal fully and turn the ignition
switch to START. Verify that no operating sound is heard
while cranking engine.
3. If an operating sound is heard, check the PCM terminal
89. (Refer to page FT-181.)
A/C CUTOFF SYSTEM (FOR 2.3L 13.OL / 4.OL)
DESCRIPTION
An N C cutoff system is used to improve idle smoothness immediately after starting the engine and to
improve acceleration and performance.
A/C Signal
If the A/C is on during the diagnostic trouble code check, Dlagnostic Trouble Code No. P I 464 is output.
If the circuit is open, wide open throttle N C cutoff will not occur.
If the circuit is shorted, the N C will not operate. ~BUOFT-223
Wide Open Throttle A/C Cutoff Relay (WAC)

If the wide open throttle A/C cutoff relay circuit has an open or short, or A/C was on during self-test,
Diagnostic Trouble Code No. PI460 is output.
If the circuit is open, A/C cutoff will not occur.
If the circuit is shorted, A/C will not operate. ~BUOFT-224
Operation
Engine condition Purpose
Immediately after engine starts Improved idle
Throttle valve fully open Improved driveability
--
Overheating Prevent engine from overheating
CONTROL SYSTEM (FOR 2.3L 13.OL 14.OL)

PREPARATION
SST
POWERTRAIN CONTROL MODULE (PCM)

2. Disconnect the powertrain control module connector.
3. Remove the two nuts and remove the powertrain control
module.
4. Reverse the removal procedure to install. 4131.~0~3-182
Inspection
1. Disconnect the PCM connector.
5-7 N-m {51-71 KgCcm, 44-62 in-lbf) 2. Connect the SST (104 pin breakout box) between vehicle
harness and PCM.
3. Measure the voltage at each terminal with a voltmeter.
For 2.3L: Refer to pages FT-177 through FT-181
For 3.OL: Refer to pages FT-171 through FT-175
For 4.OL: Refer to pages FT-165 through FT-169
4. If any PCM terminal voltage is incorrect, check the related
input or output devices and wiring. If no problem is found,
replace the PCM. (Refer to above.)
Note
You can also inspect any PID values through scan
tool or SST (NGS). To obtain PID(s) through NGS,
refer to page FT-74.
CONTROL SYSTEM (FOR 4.OL) t-1
Specification
e (For 4.OL)
Note
e
All values shown may vary ~t20% depending e
on operating e factors. RPM
conditions and other
values are axle and tire dependent.
Terminal 1 Connected To Test Condition
-
.
I Specification
--
I Remark I Possible Cause 1
I 1 Transmission in second gear / Below 1.OV 1 c ~ r ~ eornsriorl
_L__. lrortl .SS2
'__-
I
.-_.
- I
h
(Output)
1 Shift solenoid 2 (SS2) Trans~nissionout of second 1 R, IG ON: B+
PCM.
I aear
MIL always ON:
Below 1.OV PID ON Short from MIL to PCM.
2 P(;M malfunct~on.
(Output) lamp (MIL)
' Lamp not Illuminated
MIL never ON:
T--
1 0 ~ ) e nfrom MIL to PCM.
Key ON
TR sensor out of
Transm~sslonrange Hot Idle -- - adjustment.
[An] sensor(TR1) 1 Drlvlng 48 km/h (30 mph) Open or short from TR
(input) _ - - - -- -
sensor to PCM.
Drlvrncj 88 km/h (55 mph) 11.5V
Output shafi speed / Hot idle

sensor (OSS)
1 Drivin~
88 kmlh (55 mph) 2610-2640 RPM 1 1 I
Key ON
-
Hot Idle Open or short from purge
I Purge flow sensor -- I flow sensor to PCM.
Dr~vlng48 kmlh (30 mph) 1.5-3.2V
Drlvlng 88 km/h (55 mph)
p--- -
13 Flash EPROM power Open or short to GND or

Key ON
(Input) supply -- st-lort to voltage.
I 4x4 low engaged OV Open or short from GEM
7--
4x4 low disengaged B+ to PCM

I -
-
, -
-
ov
- - -
17 - T -
- - -
-
I--
18 - - -
- -- -- ----
19 - - -
- --
20 - -
-
- -- --
Key ON DC 1 5V Open or short from
21 & 22 Crankshaft pos~t~on Idle
(Input) sensor (CKP) Drlvlng 48 kmlh (30 mph)
1 Drlvlng 88 kmlh (55 mph) AC 4 6V
- I -
23
1 24 1 Power around / Constant 1 OV I 1 Open circuit. I
25
- --
I
Case ground
-- - --
1 Constant Open circuit.
- -
Open or short from coll

26 Ignition coil 1 i Constant #'I to PCM.
(Output) +
: Tra~smlsslonIn
- -- - -
27 Sh~ftsolenold (SSI ) - first gear

- Below 1 OV Open of short from SSI
(Output) Transm~ss~on
out of f~rstaear Below 1 OV
7BUOFT-226
FT CONTROL SYSTEM (FOR 4 . 0 ~ )
I Terminal
- -4
Connected To
A-
1 Test Condition
--
1 S~ecification Remark
- - - --
Possible Cause I
28 C--OID OFF l~ghtON
I
Open or short from CCS
(Output) , Sh~ftsolenold 4 (SS4) I OiD OFF I i-~ hOFF
T---------
t
--
1 IG ON B+
- - --
to PCM
Transmission control / Switch on

Swltch off PID OFF PCM
I 30 ) Octane acijust Constant

1 OV 1 PID CLOSED Disconnect shorting bar
- : - 31-
- --3-I
-
--
(Input)
32
- - -
-
--
--
-
c-- --
---
-
-
-
-
P-
---
f
I
I
-
-
-r
+
-
-
O ~ e circult.
-
--
n
-
--
-
-
-
-
33
-
(Input)
J
' Vehlcle speed sensor
i (VSS) (-)
- --
Constant
-- -- -
1 --
ov 1 -
Poor ground or open from
VSS to PCM
- - -- --
Key ON Open or short from

35 Heated oxygen
(Input) sensor-12 (rear) Englne runnlng at operatlng I *1 sensor to PCM
Below 02V Contamination
I temperature
- -
1 36
(Input)
I Mass air flow (MAF)
sensor return
Constant - Poor connection at PCM
Open from MAF to PCM
1
-- - ---
Transmlss~onflu~dat Open or short from TFT

37 Transmlss~onfluld amb~enttemperature approx 3 OV
temperature (TFT) - -- -- -- - - - - to PCM.
(Input) sensor Transm~ss~on fluid at normal approx Transmission overheat
operating temperature condition.
I Engine coolant
Englne at operatlng
38 temperature (ECT) temperature approx. 0.6V PID 120-200°F Open Or short ECT
to PCM.
(Input) sensor
+ - - - -
Key ON
-- -- -
39 Intake alr temperature Hot2e 2 ov

- , PID 50-1200F Open or short from IAT to
(Input) (IAT) sensor Drlvlng 48 km/h (30 mph) 2 1V PCM
-- -- -
Drlvlng 88 kmlh (55 mph)

- -
40 Englne off Open or short from fuel
Fuel pump mon~tor --
Englne runnlng pump relay to PCM I
AIC on B+
41 A/C cycling switch -- -- I
I - PID ON Open or short from swltch
- -- --- - - -- -
AIC off
-- --- --
ov <
PID O F F
--,
to PCM
- -
- -
- -
-
--
-
-- --- -
-
+
-
-
-
- - -
--
-
---
-
-
-- -- - - P A P - -- - - -
- - - - -
- - - - -- -- 7- -
-
a -- ---
,
- - - - -
-- - -- - - -- - - -
1 - -
46 - - - - -
- -- - - -- -
-
- --
Key ON
---- --
+ TL-
7 - -
PID 0%
- - --
I
- P-- ---
47 EGR vacuum regulator - Idle
(Output) (EVR) solenold
Hot-
Drlvlng 48 km/h (30 rnph)
P-
- -
--
- --
--
1 -B+---
--
11 5-B+
--
-- + ---
PID 0.400/~
--
- Open clrcult from EVR
solenold to PCM
-
- Drlvlng 88 kmlh (55 mph) -I 10 8-11 1 PID 35-45%

48
(Output)
- -
Clean tachometer
output to I P.
- - --- --
Key ON -
- --
---
- -
--
-
I-
t -
i+ -
-P-
-
-
- Poor connectlon at PCM

Englne running 6.2~ - or GND, or open circuit
- - -- - --- pp -- -
- --+ --
I
Key ON
- -- -
I ov -
I -- TR sensor out of
49 Transm~ssionrange - Hot Idle - ----
ov
lml sensor (TR3)
-- - - - ---
--
Drlvlng 48 kmlh (30 rnph)
--
Drlvlng 88 kmlh (55 rnph)

-- --
-- -- -
11 5V
-
11 5v
-
--
-P
-
-
- -
adjustment
Open or short from TR
sensor to PCM
I - - - --
j
Kev ON OV
I
I
50
[A]li
(Input)
Transm~ss~on
sensor (TR4)
range -Hot Idle
-
-- - --
Drlvlng 48 km/h (30 rnph)

Drivlna
--
.,88 kmlh (55 mahl

--
--
1 ,
--
OV
-
11 5v
11 5V
-
-
TR sensor out of
adjustment.
sensor to PCM. 1
I
I I
'1 : When catalyst rnonitor is on, voltage switches at 0.45V 7BUOFT-22:
1
Terminal
-~ ..
51
1
Connected To
Power ground
I
i Constant
1
CONTROL SYSTEM (FOR 4 . 0 ~ )
Test Condition specification

7 * r a m e R -
-
Poor connection or open

at PCM or GND.
FT
I Open or short from coil
I
52 Ignition coil 2 Constant # 2to PCM.
(Output,
I (Output)
j3
Shift solenold 3 (SS3)
-
Torque converter
8
Trarismission in 4th gear
%%srnlssion out of 4th
-qear
1 Key ON
/ Hot I Bit
I IG ON: B+
PID 0%
m e n circu~tfrom S S to
PCM,
1 ;?E, circuit in TCC to

~
54
(Output) clutch (TCC) solenoid Er$x/h(40mph)- 7.5-8.4V PID 35-70% 1
Driving 88 kmih (55 mph) 2.5-3.3V PID 79-100% 1 --
Keep alive power 1 Constant - T 3 p e n or short to ground.
0 RPM
1
--
Overdrive drum speed Hot idle - 810-830 RPM

Res~stance Open or short from ODs
sensor (ODs)
.
Driving 88 kmlh (55 mph)
-
- -- --
-.
1 -
0 RPM
- +-
Key ON
Heated oxygen -
-
sensor-11 (front) Englne runnlng at

operating temperature
- - -.
--
- I -
-----
- -. - -
- - 1_ - - ---
- - - - -
--
I Park 4 23-4.68V PID 0000
Reverse 3.52-3.89V PID 1100
-- TR sensor out of
Transm~ss~onrange Neutral 2.80-3.1 OV 'ID adjustment.
(TR) sensor
----
I Drive
Second
2.09-2.31 V
1 39-1.53V
PID 1111
PID 1001
sensor to PCM.
---
F~rst 0.68-0 76V PID 0011
64 1
Clutch pedal pos~t~on 'IUtCh pedal depressed 0 1v Open or short from CPP
iMT]
(In~ut) 1
(CPP) swltch
I Clutch pedal released T 5V PID DRIVE switch to PCM.
Key ON
D~fferent~al
pressure H O ~idle
Open or short from DPFE
feedback EGR (DPFE) sensor to PCM.
sensor Drlvlng
--- -- 48 kmlh (30 mph) -
I Driv~na88 kmlh (55 m ~ h ) I 1-1.7V 1
I ,
, / Evaoorative emission I - 'iort from
I .,, b..-.
l
,, I canister Durae
/ snlennln m.- .PCM
I
I I During purge conditions / Below 1. ov-~ I

68 - -
-- --
Key ON (AiC ON) Below 1 OV
Open clrcult from WAC to
69 W ~ d eopen throttle A/C Idle (A/C ON) B+
I
--
-
(Output) cut-off WAC relay Accelerate (AiC ON) 0 2V
, Cri~~s
steady
e B+
--
PID ON
7BUOFT 228
FT-I 67
I Terminal / Connected To ! Test Condition I Specification ( Remark ' Possible Cause (
/ 1 Vehicle power
Key OFF
Key ON
I
-
- - - -
PCM relay malfunction.
Open or short clrcult
-
- - -
LKey ON
I Hot idle
Lpp B+
--
I/
73 3.4-3 6 msec Open or short clrcult from
Injector #5 --- -
(Output) 1 Driving 48 kmlh (30 mph) 2 9-5 7 msec 1 Injector #5 to PCM.
-- -
Driving 88 km/h (55 mph) 1 5-8.8 msec 1
Key ON
---
74
(Output)
1 Injector ~3
Hot ~ d l e
---
Driving 48 km/h (30 mph)
-
3.4-3.6 rnsec
2.9-5.7 msec
Open or short circult from
injector #3 to PCM.
Key ON
---
75 Hot idle 3.4-3.6 msec Open or short clrcult from

Injector # I -- -
(Output) Driving 48 kmlh (30 injector # I to PCM.
. . ~
Drivina 88 kmlh (55
Power ground Constant - Poor connection at PCM

or open circuit.
Poor connection at PCM
Power ground Constant
or open circuit
. -- -
78 Open or short from coll
Ignition coil 3 Constant
(Output)
- - ---- -A- - - +- -- -- #3 to PCM
-- -
TClL always ON
Lamp lllumlnated Below 1 OV PID ON Short circu~tfrom TClL to
79 Transmission control PCM.
[AT1
(Output)
indicator lamp (TCIL) - PCM malfunction.
Lamp not illuminated B+ PID OFF TClL never ON.
open circult
- 1
- -
II
1 Fuel pump ON PID OFF
80 Open clrcult from fuel
(Output) 1 Fuel pump relay -
Fuel pump OFF PID ON pump relay to PCM
- &
. p
p
-
pii -- - - - -- - -
I I Key ON
-
6-9V
81
(Output) I Electronic pressure
control (EPC) solenoid
Drlvlng 88 kmth (55 mph)
-
- -
Open or short clrcult from
EPC to PCM.
- - -- - -- --
-
--- --- -
Key ON
--.
Hot Idle
83 Idle air control (IAC)
(Output) solenoid
Drivlng 88 krn/h (55 mph)
Hot ldle 118Hz I PIDORPM

-----
Turb~neshaft speed Open or short clrcult from
(TSS) sensor D r ~ v n g48 krnlh (30 mph) RPM TSS to PCM
Driving 88 krnih (55 rnph) / 220-290 Hz

PID 2200-2230
RPM
Key ON
Cyl~nderidentification
(camshaft position
6.3-6.5 Hz 1 -
Open or short circuit from
camshaft pos~tionsensor
sensor) -- to PCM.
I Drivlno 88 krn/h (55 mob) 15 Hz
CONTROL SYSTEM (FOR 4 . 0 ~ ) FT
I Terminal 1 Connected To Test Condition / Specification I Remark 1 Possible Cause I
I Key ON
Mass air flow (MAF) - Open or short circuit from
sensor / Driving 48 kmlh (30 mph) 0.8-1.6V MAF to PCM.
I Driving 88 kmlh (55 mph) 1.5-2.5V /

Key (3N
Throttle position (TP) Hot idle Open or short circuit from

-
- -
sensor Driving 48 kmlh (30 TP to PCM.
Driving 88 kmlh (55 mph) I 1.l-1.4V
90
(Output)
Vehicle reference
voltage (VREF)
!
/ Key ON 5V
OV
1 Open or short VREF from
PCM.
PCM malfunction.
/ )ut::l(
Brake OnIOff (BOO)
iswitch
/ constant I
+ 1
- /
- -1
Brake pedal depressed
Brake pedal released
OV -
PID OFF
Open circuit.
Boo to PCM.
-
. --
93
(Input)
1 Heated oxygen sensor
-11 (FRT.RT.) Engine runnlng at normal
'ID OFF ' Open or short circu~tfrom
1sensor to PCM.
PID ON Contaminated sensor.
I operating temperature
Heated oxygen sensor

-21 (FRT.LFT)
K ~ ON
Y
+ ' dI P , I ~ l
Engine running at normal
Key ON B+ PI0 OFF 1
sensor to PCM.
Contaminated sensor.
Heated oxygen sensor --------- Open or short c~rcultfrom

-12 (rear) Engl~ierunnlng at normal 0.2V sensor to PCM.
operatlng temperature PID ON Contammated sensor.
Key ON Open or short circuit from

Vehicle power PCM power relay to
Key OFF PCM.
3.4-3.6 msec Open or short circuit from

-- -. -
- - -- -
injector #6 to PCM.
Driving 88 kmlh (55 mph) 5-8.8 msec

Key ON
Hot ~dle Open or short circuit from
injector #4 to PCM.
-- -
-
Drlv~ng88 kmlh (55 mph) 5-8.8 msec
Key ON B+
Hot idle 3.4--3.6 msec Clpen or short circuit from
injector #2 to PCM.
Driving 88 kmlh (55 mph) 5-8.8 msec
1 103
I! Power ground Constant
Poor connection at PCM.
FT-I 69
FT CONTROL SYSTEM (FOR 4 . 0 ~ 1
PID Data Monitor (4.OL)
Sensors I Inputs1 --- Measured I PID Valves - -
Actuators IOutputs I units

Hot Idle 30 rnph 55 rnph Measured 1 PID
LOAD 42-55 24-30 30-38
0FF OFF OFF
--
0 760-850 0- 1560-21 00
I FUELPWI
L_.-.
LONGFTl
-
I I
SHRTFT2 0 (-)6-(+)6 (-)6-(+)6 -
(-)6--(+)6 YO
0 22 20-3 1 28-30 DEG
I VPWR 1 VBAT VBAT VBAT VBAT 1 DCV
CONTROL SYSTEM (FOR 3.OL) FT
Specification (For 3.OL)
Note
*
All values shown may vary 20% depending on operating conditions and other factors. RPM
values are axle and tire dependent.
Terminal I Connected To Test Condition 1 Specification Remark Possible Cause I
Transmission in second gear 1 Below 1.OV 1 Open or short from SS2
1 to PCM.
(Output)
Shift solenoid 2 (SS2) T,an~~S~o~tofsecond
gear ~ IGON: B+
MIL always ON:

Lamr, illuminated Below 1.OV PID ON Short from MIL to PCM.
Malfunction indicator --- -
- -- -- L.-- PCM malfunction.
Lamp not ~lluminated B+ PID OFF MIL never ON:
Open from MIL to PCM.
I Key ON
L- -
1-R sensor out of
1
Transmission range
sensor (TRI )
p d l e
/
-t 11.5V 1
- adjustment.
sensor to PCM.
; Key ON 1 1.1V I -
Hot Idle Open or short from purge
Purge flow sensor
(Input) Driving 48 km/h (30 mph) flow sensor to PCM.
13
(Input) I Flash EPROM power
supply
Key ON
I-----
4x4 low engaged
Open or short to GND or
--
4x4 low sw~tch Open or short from GEM

(Input) ' 4x4 low disengaged to PCM.
16 - Bus (+) I ov I -
Open or short from

Crankshaft position / Hot idle c:rankshaft position
sensor (CKP) Driving 48 kmlh (30 mph) sensor to PCM.
24 -
Power around / Constant 1 OV 1 - Open circuit.
Case ground --*i~- Open circuit.
26 i Open or short from coil
(Output)
Ignition coil 1 1 Constant # I to PCM.
&----
27 shift solenoid (SSI ) I,

Transmission
- in first gear Below 1.OV -
- -
Open of short from SSI
to PCM.
(Output) I / Transmission out of first gear Below 1.OV
Terminal Remark Possible Cause

- -- - - --
- --
I
Coast clutch solenold O/D OFF l~ghtON Below 1.OV Open or short from CCS
28 1
-
(Output) (CCS) I to PCM
O/D OFF llght OFF B+
- -- -- -
I
-- -- -- -
1
Transm~ss~on
sw~tch(TCS)
control On
Sw~tchoff 1 --
PID ON
-
-
PID OFF
--
Open or short from TCS
to PCM.
30
(Input)
Octane adjust Constant
i OV
I PID CLOSED
D~sconnectshortlng bar
Open clrcult.
33
(Input)
1 Vehicle speed sensor
(VSS) (-)
! Constant
I o V - Poor ground or open from
VSS to PCM.
c
3
35
(Input)
(Input)
-- -
6 EG(MAF~
1
Heated oxygen
sensor-12 (rear)
sensor return I
c
p
;
y ON
Englne running at operating
temperature
Constant
--
-
1
-
-
I
- +
--
OV
-
OV
Below 0.2V
- -I -
-
_
*l
-
--
---
-,--
--
Open or short from
sensor to PCM
Contamrnat~on
--
-
--

Open from MAF to PCM
--
I
37 1
I
Transmlss~onfluld
temperature (TFT)
I Transmiss~onfluid at
amb~enttemperature
approx. 3 OV
-
Open or short from TFT
to PCM
(Input) Transm~ss~on overheat
/ operating temperature cond~t~on
I I
Englne at operating Open or short from ECT
temperature (ECT) temperature approx 0 6V PID 120-200°F to PCM
4 Key ON
I - - - - a - -- - -- -
'
( I t ) I Intake alr temperature
(IAT) sensor I
Hot idle
30 m ~ h
- -- -
i -
25V
-
2.5V - 1 PID 50-,200F
Open or short from IAT to
PCM
55 mph
-- - - -- - --
Englne off
- -- - . PID OFF Open or short from fuel
Fuel pump mon~tor
-
-
Enaine
" runnlna
" B+ PID ON pump relay to PCM
-- - -,- - - -- -- - -- -- -- -- -
AIC on
A/C cycling switch ---- -- ---- ----
N C off OV PID OFF
'
I Open or short from swltch
PCM.
vacuum regulator en circuit from EVR
TR sensor out of

sensor to PCM.
*1: When catalyst monitor is on, voltage switches at 0.45V. 7BUOFT-233

I Terminal I Connected To Test Condition 1 Specification 1 Remark Possible Cause
I Poor connection or open
Power ground /
I
Constant
at PCM or GND.
Ignition coil 2 1 Constant

I
I
I Bi
Open or short from coil
#2 to PCM.
53 Open circuit from SS3 to
1
(Output)
(Output)
54
Torque converter
clutch (TCC) solenoid
Key ON
ldle
----
1
B+
B+ PID 0%
PID 0%
PID 35-70%
Open circuit in TCC to
PCM. I
1 55 mph 1 2.5-3.3V / PID 79-100% I
Open or short from VSS
i
OV Open or short from
Heated oxygen Switch rich to
spnsor to PCM,
sensor-11 (front) Engirie running at normal leanevery
operating temperature / Switch at 0.45V seconds Contaminated sensor.
1 Park 1 4.23-4.68V 1 PID PARK ~

Transmission range adjustment.
(TR) sensor 2.09-2.31 V
sensor to PCM.
Second 1.39-1.53V
0.68-0.76V
Clutch pedal position
(CPP) switch
Differential pressure
feedback EGR (DPFE)
I Hot idle I
0.7V I Open or short from DPFE
sensor Driving 48 km/h (30 mph)
-
-
1 0.5-0.9V sensor to PCM.
Drivirig 88 kmlh (55 mph) I I-1.7V
Evaporative emission
canister purge
----------A B+
-
- open or short from
-- 1 solenoid to PCM.
solenoid / Below 1V i
1 I
' - - p r i
I Kev ON (A/C ON) / Below 1V I PID OFF I Open circuit in WAC to 1
I Wide Open throttle A/C PCM.
cut-off WAC relay ldle or cruise (AIC ON) Open circuit from A/C
(Output)
69 Accelerate (AIC ON) Below 1V PID OFF signal line to PCM.
PlSM relay malfunction.

Vehicle power Open or short circuit
Key ON
Terminal Connected To I Test Condition Specification Remark Possible Cause

- - -- 7 -
-
7- ----
--- -- - -
72 - I - -
- - -- 4. -- - - - -- +- - -- -- A
Key ON
I L- --- - -- - - -- -
' Hot idle
-
Open or short arcutt from

I Drlvlng 48 kmlh (30 mph) 5.9-6 7 ms injector #5 to PCM
C---
Drlvlng 88 kmlh (55 mph) 8 1-12.2 ms
-- .---
I Key ON

74 Injector #3
(Output) I Drlvlng 48 kmlh (30 mph) 5.9-6.7 ms ~njector#3 to PCM
-- -- - -- ---- - -- -
Key ON
I
Hot idle 4.1-4.3 ms Open or short ctrcuit from
75
(Output) ,
:
Injector # I
I Drlvlng 48 kmih (30 mph)
----
5.9-6 7 ms ~njector# I to PCM
76 Power ground j Constant

I
"
+
I
oV - ~ 0 0 1 c
or open circuit.
o n ~ a l ~ ~ M -
Power ground 1 Constant or open circult
78
(Output)
----
( Ignition coil 3
--
Constant
-
I
'
Open or short from
cod #3 to PCM.
--
1 TClL always ON
79
[AT]
(Output)
I
Transmission control
~nd~cator
lamp (TCIL)
Lamp illuminated
Lamp not lllumlnated

C Below 1 OV
---
B+
--
PID ON
PID OFF
Short circu~tfrom TClL to
PCM.
PCM malfunct~on
TClL never ON
Open clrcult
C---- ;---
Fuel pump ON PID ON
--- --- -
Open c~rcuitfrom fuel

80
(Output)
. ---1-
, Fuel pump relay
)
--
--- -
Fuel pump OFF PID OFF pump relay to PCM.
I Key ON
l---L 6-9V
----
PID 24 PSI
I
-- I t--
L-
81 Electronlc pressure Idle

--
10.6V
-
PID 25 PSI
- Open or short from EPC
PCM
(Output) control (EPC) solenold Drlvlng 48 km/h (30 mph) 9.8-1 Ov PID 30 PSI
t ~ ~ ~ 8 8 k m -
/ h-
l ~-
~ r --
- - - - -
82 - - -
-- - - ,-- - -- --- -- -- - --
Key ON PID 0%
--
83 Idle air control (IAC) -Hot Idle PID 2832% , Open or short clrcult from
(Output) solenoid Drlvlng 48 kmlh (30 mph) PID 30-550,~ IAC to PCM.

-- --
Key ON PID 0 RPM

Hot ~dle 118 Hz PID 0 RPM
Turbine shaft speed 11 Driving 48 kmlh (30 mph) 190-220 Hz
p , ~00-
200 RPM
) Open or short circuit from
1 TSS to PCM.
(TSS) sensor
--
7-
'
II
Drlvlng 88 kmlh (55 rnph) 220-290 Hz
PID 220&
2230 RPM
-----
85
(Input)
1 Cylinder ~dentif~cat~onHot idle
(camshaft posltlon
sensor)
Key ON
-
--- -
--
Open or short circu~tfrom
A camshaft posltlon sensor
to PCM
Drlvlng 88 kmlh (55 mph) 20 Hz
- -
86 - - - - -
I I
/ Terminal Connected To Test Condition 1 Specification Remark Possible Cause
Key ON
Mass air flow (MAF)
sensor 48 kmlh (30 mph)
1 Driving 88 kmlh (55 mph) 1
j
j
1.1~
0.8-1.8V
I.!%-2.5V
-1
-
-
MAF to PCM.
Throttle position (TP) Hot idle 0.9V Open or short circuit from
--
(Input) sensor Driving 48 kmlh (30 mph) 0 9-1.3V TP to PCM.

Drivinq 88 kmlh (55 mph) 1 1-26V
Vehicle reference Key ON 5V Open or short VREF

voltage (VREF) from PCM.
(Output) 1 Key OFF OV PC;M malfunction.
/ Sianal return I Constant I ov I - I Open circuit.
/ Brake OnIOff (BOO) i Brake-Pedaldepressed 1 Open or short circuit
;1 ,P''
(Input) 1 switch ! Brake pedal released I from BOO to PCM.
1 Heated oxygen
' sensor-11 (FRT.RT.)
Key ON
Engine running at normal
B+
0.3V
open or shortcircuit
from sensor to PCM.
I I Key ON Open or short circuit from
Heated oxygen
sensor-21 (FRT.LT) I Engine running at normal sensor to PCM.
I operating temperature Contaminated sensor
Heated oxygen
i Key ON 'ID OFF Open or short circuit from
sensor-12 (rear) sensor to PCM
0 2V PID ON Contaminated sensor.
I operating temperature
F -4
Key ON Open or short circuit from
Vehicle power --
(Input) Key OFF 1-sensor to PCM.
Key ON - I
Hot idle 4.1 4 . 3 msec Open or short circuit
lnjector #6
(Output) from injector #6 to PCM
a-
100
(Output)
Injector #4
/ Key C)N
Hot idle
+
Drivinq 48 kmlh (30 mph)
I
Driving 88 kmlh (55 mph)-81--nsec

/ Key ON I
4.1-4.3
--
B+
5.9--6.7 msec
nisec
-
-
-
-
,
--I
1
Open or short circuit
from injector #4 to PCM
(Output)
Injector #2
1 Hot idle
1 4.1-4.3
5.9-6.7
B+
msec
msec
1
I -
I 1 Open or short circuit
from injector #2 to PCM
/ Driving 88 kmlh (55 mph) 1 8.1-12.2 msec / - 1
Power ground Constant

I OV
Power connection at PCM.
Open circuit.
FT CONTROL SYSTEM (FOR 3 . 0 ~ 1
PID Data Monitor (For 3.OL)

Measured !PID Valves
Sensors 1 Inputs/ I
Actuators I Outputs Units
KOEO , Hot Idle 30 mph 55 mph Measured I PID
( LOAD 1 42-77 12-20 22-30 30-38 I YO 1
I MlSF 1 OFF OFF OFF OFF ( OFF-ON 1
0 760-790 1360-1490 1 1560-2100 1 RPM
0 4.14.3 4.0-6.7 1 8.1-12.2 1 rnS
I
FUELPW2 0 I 4.14.3 4.0-6.7 j 8.1-12.2 rnS
HTR 11 OFF ON ON I ON OFF-ON
I
HTR12
--
OFF
I
j ON ON 1 ON OFF-ON
LONGFTl (-)6-(+)6 (-)6--(+)6 (-18-(+)8 (-)8-(+)8 YO
LONGFT2
- -
(-)6-(+)6 (-)6-(+)6 (-18-(+)8 (-)8--(+I8 Yo
- 7--- -- - --
SHRTFTl 0 i (-)6-(+)6 (-)6--(+)6 (-)6--(+)6 YO

SHRTFT2 I
0 1 (-)6-(+)6 (-)6--(+)6 (-)6-(+)6 Yo
I
SPARKADV (T~rnlng) i 0 13 20-32 28-38 DEG
I VPWR 1 VBAT I VBAT
I
VBAT VBAT DCV I
FT-I 76
Specification (For 2.3L)
Note
All values shown may vary k20% depending on operating conditions and other factors. RPM
values are axle and tire dependent. -
I Terminal Connected To
I T e s t Condition Specification Remark Possible Cause
Open or short from SS2
Lamp illuminated
I
Malfunction indicator --
(Output) lamp (MIL)
Lamp not illuminated B+ PID OFF MIL never ON:
1 Open from MIL to PCM.
TR sensor out of
Transmission range I Hot idle I OV I adjustment.
sensor (TRI )
k Driving 48 kmlh (30 mph)
Driving 88 krnlh(55 rnph)
sensor to PCM.
I Key ON
Open or short from purge
Purge flow sensor flow sensor to PCM.
/ Drivirig 48 kmlh (30 mph) 1.7V
I I n ; 88 krn/h (55 mph) / 1.8V -
I Flash EPROM power

SUDD~V
1 Key ON 1 Open or short to GND or
I short to voltage.
Bus (+) I OV I - 1 - I
430-520 Hz Open or short from
T r r l
Crankshaft position
(CKP) sensor crankshaft position
Driving 48 krnlh (30 mph) 800-1 OoO Hz sensor to PCM.
i e88 kmlh (55 mph)
TDriving AC 4.OV 1140-1250 Hz
24 1 Power wound I Constant 1 OV 1 - / Open circuit. I

25 1 Case ground / Constant Open circuit.
26 1 Ignition coil 1 Constant -

I coil #I
(Output)
27
(Output)
Shift solenoid 1 (SSl )
1
1
Transmission in first gear
Transmission out of first gear
1 B+ 1
Below 1.OV
IG ON: 0.1 V
,t PCM,
to PCM.
1 Open or short from SS1
FT
Terminal
28
(Output)
29
(Output)
Connected To
Coast clutch solenoid
(CCS)
switch (TCS)
--
-pppp
Test Condition
O/D OFF llght ON
O/D OFF light OFF
Switch on
Switch off
--
--
-4
CONTROL SYSTEM (FOR 2 . 3 ~ )
1
Specification
Beol:
Below I OV
ov
OV
-----
I
1
I
Remark
-
-
PIC) ON
PID OFF
PID CLOSED
--
--
I
.-
PCM
Possible Cause
Open or short from CCS
to PCM
--
Open or short from TCS

-
Disconnect shortlng bar.

30 Octane adjust Constant
(Input) Open circult.
- --
31
(Output)
Power steering
pressure swltch
I
/ Engine running and steering
wheel turned
Englne runnlng and steerlng
wheel not turned
swltch to PCM
-- - - - - -- -
32 - - -
- - -- - 1 - - -- -- -
~-
--
-
33
(Input)
34
-4-
--
Vehlcle speed sensor
(VSS)
-
(-)--
-
- --- Constant
-
I
ov Poor ground or open from
VSS to PCM
-
-
-
- -- -- - -
-
Key ON
35 Heated oxygen Open or short from
*1 sensor to PCM
(Input) sensor-12 (rear)
36
+ -- -
1 Mass air flow sensor
--
temperature
- - - - - Contamination
-- -
Constant Poor connectton at PCM

(Input) (MAF) return Open from MAF to PCM
-i--
---
- - __ - -
I Transmission fluid at
37 1 Transmlsslon fluid amb~enttemperature ( approx 3 ov - Open or short from TFT
temperature (TFT) - -- +-- - - A
to PCM
Transmlss~onoverheat
sensor Transmiss~onfluld at nor- approx 1 1V -
rnal operating temperature I condit~on
Engine coolant I
I Engine at operating I Open or short from ECT
38 1 temperature (ECT) temperature approx. 0.6V I PID 120-200°F to PCM
(Input) 1 sensor
39 Intake air temperature Hot idle- 1 7v I Open or short from IAT to

(Input) (IAT) sensor
--
-
Driving 48 kmih (30 mph)

-
-- - -- --
1 7V -1 PID 50-1200F
PCM
\ I
- - - - --
- - -- -- -
Drivinq 88 kmih (55 rnph)
- - -- - -
i8V -
-4
1 - - -- - -
, Engine off Ov PID OFF Open or short from fuel

Fuel pump mon~tor + -- - - -
I Engine running PID ON pump relay to PCM

AIC on B+ PID ON Open or short from switch
41 NC cycling switch
I
r-
-- - - - I
--- -
1 AIC off PID OFF PCM.
- t - + --
- - - -- -- - - - -
-
+---____
- -- -
42 - -
-- -4- -- - ---- - - - -
- --
43
-+
-
--
-
1
- -
- -
-
--
44
-
-
--
- - -
- - -- -- ---- - - - - -- --
45 - - -
,- -- - - - - - - - - - -
46 - - - -
-
- -- - -- --- -
.
47 EGR vacuum regulator --
B+ I PID 0% Open clrcurt from EVR
(Output) (EVR) solenoid 1O - B + V ~ o ~ to PCM
solenold
kmih (55 mph) 1 9-113V PID 35.50%
48 Clean tachometer Key ON Poor connection at PCM
(Output) output to I P. Engine running or GND, or open circuit.
----____ --
I
Key ON
TR sensor out of
49 Transm~ssionrange Hot Idle adjustment.
I sensor (TR3)
Driving 48 kmih (30 mph) I Open or short from TR
(Input) 7- +--- sensor to PCM.
-
4
I I
I
I
. ,
Dr~vina88 km/h (55 mohl 11.5V
I
'1: When catalyst monitor is on, voltage switches at 0.45V. 70UOFT-239
(;ONTROL SYSTEM (FOR 2.3~) FT
Terminal Connected To Test Condition I specificat- Remark Possible Cause
Key ON OV
-
. --.
.- -- --- - -- TR sensor out of
50
I Transmission range
' idle OV adjustment.
sensor (TR4) Driving 48 km/h (30 mph) 11.5V
(Input) ! sensor to PCM.
i Driving 88 km/h (55 mph) 11.5V
Poor connection or open
51 Power ground Constant at PCM or GND.
-
52 Open or short from
Ignition coil 2 Constant B+
(Output) coil #2 to PCM.
Transrnission in 4th gear
53 Open or short from SS3
Shift soIenoid 3 (SS3) TransrnissionhofP
(Output) B+
gear
54
(Output)
Torque converter
clutch (TCC) solenold
~ --.
k
- p
+--- +- ~
open circuit Tee to -
L- PID 30.70% PC
I Drlvlng 88 km/h (55 mph) 3 3V ~ ~ 1 ~ 7 5 - 0 %
I
55
--
56
57
-
PC
+
1
Keep allve power
-
-
-
-
-
, -- ---
---
Constant
---
-
-
1 I
I
-
- 4
Open or short to ground.
I
i - ~ ~
Hot idle DCOV PID 0 mph
Vehicle Driving 48 km/h (30 mph) AC 3.0-5.2V PID 30 mph OFtenOr short from VSS
( v s s ) (+) Drivina 88 km/h (55 m ~ h ) AC 5.0-8.OV PID 55 mah to PCM.
Heated oxygen
sensor-11 (front)
ELunning
operating temperature,Xm+&d 1 Switch rich to
lean
3 seconds
every
Open or short from
S~IISO~ to PCM.
Park
Reverse
TFl sensor out of
TranSmlsslon range adlustment.
(TR) sensor Dr~ve 2.09-2.31 V Open or short from TR
sensor to PCM.
Second 1.39-1.53V
i First / 0.68-0.76V 1 - I
Clutch pedal position
Constant
(CPP) switch
/ Key ON
--
0 6V
65 D~fferent~al
pressure h i e
Open or short from DPFE
(Input) I
I sensor EGR (DPFE)
feedback 0 5-0 9V sensor to PCM.
I Drlv~ng88 kmlh (55 mph) 0 8-1 5V
I
I Key ON
67 Evaporative emlsslon F-
Open or short from
canlster purge Idle
a---
(Output) solenoid
/ During purge condltlons
1 1 1 Fl'x; 1 % " " ~ 1

I-
K ~ ON
Y (AIC ON)
Wide Open throttleA/C B e l g lv WAC
(Output) cut-off (WAC) relay ldle or cruise (AIC ON) Open circuit from A/C
I Accelerate Below 1V PID OFF signal line to PCM.
7BUOFT-240
- Terminal1 Connected To Test Condition Specification Remark 1 Possible Cause

- -
p p
- - - -1 -- -
-
--
1
70 I
71
(Input) )
Vehicle power ' PCM relay malfunction.
Open or short circuit.
Lp-- -
-
- A=
/ Key ON
--
--- -- -- -A
1 (Output)
74
Injector #3 -
Hot idle
/ Driving 88 kmlh (55 mph) 1
3.4-3.5
5.7-6.9
5.8-8.4
ms
ms
ms 1 -
1I Open or short circuit from
injector #3 to PCM.
I Key ON
Hot idle
2. "+ --
-
4
-I
I
3.4-3.5 ms I - I Open or short circuit from

Driving 48 kmlh (30 mph) 5.7-6.9 ms - 1 injector # I to PCM.
--
5.8-8.4 ms -
4
1 76 1 Power ground
i
1 Constant O V I -
1 Poor connection at PCM
/ or open circuit.
/
Power ground
) Ignition coil 3
Constant
j Poor connection at PCM
/ or open circuit.
'/ Open
-
- -1
-
(O,$ut)
- -- & .
t----
/i Constant i B + I -j . p -
or short from
coil #3 to PCM. I
I
79
I
/
1 Lamp illuminated
TCIL always ON:
circuit from TClL to
[AT] ! indicator lamp (TCIL) PCM malfunction.

(output) j
! 1 Lamp not illuminated B+ PID OFF 1 TClL never ON:
/ Open circuit.
i - a - - --
I (Output)
80
Fuel pump relay
key^
Fuel pump ON
I Fuel pump OFF +Fe1
1
I
PID ON / Open c~rcultfrom fuel
pump relay to PCM.
1
1 (Output)
Electronic pressure
control (EPC) solenoid
1 Hot idle
9.7i",",v
6-9V PID 24 psi
PID 25 PSI
PID 30 PSI
i
'' Open or short from EPC

to PCM.
1
*
Drivlng 88 kmlh (55 mph) 8-1 0.4V PID 30 PSI ,
t-- - - - - -
--
82 I
-----
Key ON B+ PID OO/o
I
1
C
I
83 Idle air control (IAC) Hot idle Open or short circuit from
(Output) solenoid I D r i v i n ~48 kmlh (30 mph) PID 30-55% / IAC to PCM.
--- +--
1 Drlvlng 88 kmlh (55 mph)
---
+7-IO.1V PID 60-65"
j Key ON 0 HZ PID 0,M
PR
Turbine shaft speed

L-
-
1 Hot ~dle
--
--I-~F PID 0 RPM /

(TSS) sensor Driving 48 kmlh (30 mph) i 190-220 HZ
1 Driving 88 kmlh (55 mph)

250-290 Hz 1 22302200-
PID RPM I
Cyl~nderident~ficat~on Open or short c~rcultfrom
(camshaft poslt~on camshaft posltlon sensor
Drlvlng 48 kmlh (30 mph) to PCM
Drivlng 88 kmlh (55 mph)
--
19 Hz - i
87
-
-
-
-
-
-
-
-
t I
-
-
6BUOFT-241
CONTROL SYSTEM (FOR 2.3L)
Terminal
-
Connected To
, Key ON
s t Condition Specififiion R e y k
-
1 possible cause 1
r--
Mass air flow (MAF) Open or short circuit from
sensor I Drlv~ng48 kmlh (30 mph) MAF to PCM.
-
.
I
Throttle position (TP) 1 idle 0.8V -
sensor / Driving 48 km/h (30 mph) 0.9-1.2V - TP to PCM.
/ Driving 88 kmlh (55 mph) 1 1.I-1.3V I - 1

90
(Output)
91
92
(Input)
1 Vehicle reference
voltage (VREF)
S~gnalreturn
Brake OnIOff ( 8 0 0 )
switch
ON
Key OFF
-
-
Constant
/ Brake pedal depressed
' Brake pedal released
;; 4 3,,
B+
OV
-
.
-
.
-
-
PCM malfunction.
Open Or
circuit.

from BOO to PCM.
1
93 Heated oxygen Open or short circuit
(Input) sensor-11 (front) Engine running at normal 0.1 V from sensor to sensor.
Contaminated PCM.
I 1 operating temperature
Heated oxygen Open or short circuit from

sensor-12 (rear) i Engine running at normal sensor to PCM.
5 operating temperature Contaminated sensor.
97 Key ON
Vehicle power Open or short circuit from
Key OFF P(;M relay to PCM.
-
-
Key ON
Hot idle
I
I B+
3 4-3.5
5.7-6.9
msec]
- -
msec
I 1 Open or short circuit
from injector #4 to PCM.
Driving 88 kmlh (55 mph)-8.4mA-l 1

Injector #2
(Output) from injector #2 to PCM.
I Driving 88 kmlh (55 mph) I 5.8-8.4 msec / - 1
103 Power ground Constant Poor connection at PCM.

Open circuit.
-
---
IO4 lgnltlon colt #4

(Output)
PID Data Monitor (For 2.3L)

Measured IPID Valves
Sensors 1 Inputs1 , - Units
Actuators 1 Outputs I
KOEO Hot Idle 30 mph 55 mph Measured I PID

- -
LOAD 4S70
I
12-1 8 (AT) ; 26-30 (AT) 30-39 (AT)
To
w-
12-1 6 (MT) ' 20-33 (MT) 3 0 - 4 1 (MT) I
1
OFF OFF I OFF 1 OFF OFF-ON
+-
-- +-
--
r -+ -
0 760-790 1 1230-1380 1820-1930 I RPM

I FUELPWl 1 0 3.44
I
4-6.9 5 7-8.4 mS
FUELPW2 0 0 mS
-
- t
HTR11 ON ON I OFF-ON
-
HTR12 ON ON I OFF-ON
---- - --,
+ - --- .
LONGFT1 (-)6-(+)6 1 Yo
I 20-31 (AT)
SPARKADV (T~rning) 0 25 20-31 DEG
18-35 (MT)
~,
IVPWR-~ d
VBAT VBAT VBAT VBAT DCV
~3 . 0 1
CONTROL SYSTEM (FOR 2 . 3 I ~4 . 0 ~ ) FT
PCM POWER RELAY (BATTERY POWER)
If the circuit is shorted, the EEC PWR fuse (30A) will burn out.
Circuit
t O ~ e circuit
n
Engine will not start
Condition
Short circuit
EEC PWR fuse (30A)
Poor ground
burns out with ignition

PCM (97)-PCM power relay switch ON
Inspection
1. Measure resistance between pins 85 and 86 of the relay.
Specification: 40-1 20 ohms.
-
J
86 2. Measure resistance between pin 85 and both pins 30 and
87 of relay.
Specification: greater than 10,000 ohms.
COIL - 85 AND 86 3. Apply battery voltage (B+) and check for continuity
COMMON - 30
NO - 87 between terminals of the relay.
NC - 8 7 ~ Specification:
B+ : Battery positive voltage
-& Terminal 30-87
'1 044-6 6BUOFT-244
Terminal 85-86
B+ applied
4. If not as specified, replace the PCM power relay.
EEC PWR FUSE (PCM MEMORY POWER)

If the EEC PWR fuse circuit has an open or short, Diagnostic Trouble Code No. F'0603, PI605
is output.
If the circuit is open, the PCM rnemory function will not operate and Diagnostic Trouble Codes
for intermittent malfunctions will not be indicated. Also,the learning control will be canceled.
- Condition
Circuit -
-
open circuit T-- -PocGndmd----I
I
-- --
-
PCM (55)-Maln fuse block , Code No. PO603 or burns out. Code No. NIA
- P I 605 ouout
GROUND
If there is a poor ground, the engine may not start.
rp
fl 1 1 1
Condition
Circuit i Open circuit Short circuit
PCM (24)-Ground
PCM (25)-Ground
Engine may not start
PCM (76)-Ground Engine will not start NA Hard starting
PCM (77)-Ground
PCM (103)-Ground
6BUOFT-246
FT CONTROL SYSTEM (FOR 2 . 3 1
~3.01
~4.0~)
MASS AIR FLOW SENSOR
If the mass air flow sensor or circuit has an open or short, Diagnostic Trouble Code No. PO102,
P0103, PI100 or P1101 is output.
A malfunction in the mass air flow sensor circuit may cause lack of power, poor acceleration,
hesitate at driveaway or vehicle shake on deceleration.
If battery power circuit shorts to ground, engine may stall and may not restart. This will melt EEC
PWR fuse.
6BUOFT-247
Inspection
MASS AIR FLOW SENSOR
Caution
\ Do not drop or subject the sensor to sharp shock.
Do not put or allow anything in the sensor.
1. Disconnect the mass air flow sensor connector.
2. Remove the mass air flow sensor.
3. Check for damage of the sensor.
4. Reconnect the mass air flow sensor.
5. Connect the SST (NGS) to the data link connector.
6. Turn the ignition switch ON or run the engine. Select the
PID/DATA monitor and Record function on the NGS.
Specification:
VOLTAGE Engine Condition PID Voltages
------- -
ov
I
Hot Idle 0.8V
Driving 48 krnlh (30 mph) 0.8-2.OV
Driving 88 krnlh (55 mph) 1.5-2.5V
MF1107-D
7. If not as specified, replace the mass air flow sensor.

For 2.3L: Section F1.
For 3.OL: Section F2.
For 4.OL: Section F3.
Tightening torque:
f IDLE 32 krnlh
(20 mph)
64 kmlh
(40 mph)
96 krn/h
(60 mph)
10 N - m{I02 kgfecm, 89 inelbf)
MF1395-B
Voltage to mass air flow conversion table

Voltage Signal
Application - .
0.34V 0.39V 0.60V 1.OOV 1.96V 3.90V
---
2.3L, 3.0L 1.07 grnlsec 1.71 grnlsec 4.58 grnlsec 16.23 gmlsec , -- -
135.17 grnlsec
-- --- --
4.0L 1.46 grnlsec 1.68 grnlsec 2.52 grnlsec 7.64 grnlsec 27.09 gmlsec ' 151.79 grnlsec
6BUOFT-249
CONTROL SYSTEM (FOR 2 . 3 1
~3.01
~4 . 0 ~ ) FT
VEHICLE SPEED SENSOR (VSS)
If the vehicle speed sensor or circuit has an open or short, Diagnostic Trouble Code No. P0500,
P0503, P I 500 or P1501 is output.
If the vehicle speed sensor circuit fails, no 3-4 or 4-3 shifts or torque converter lockup (AT) will
occur.
lnspection
1. Disconnect the vehicle speed sensor connector.
2. Measure the resistance between the terminals of the vehicle speed sensor.
e
3. If not specified, replace the vehicle speed sensor. (Refer to Section K.)
~BUOFT-250
If the throttle position sensor or circuit has an open or
short, Diagnostic Trouble Code No. PO121, PO122,
P0123, P1120, P1121, PI124 or PI125 is output.
If the throttle position sensor circuit fails, rough idle, poor
acceleration or shift shock (AT) may occur.
Inspection
2. Turn the ignition switch ON.
3. Select PIDIDATA monitor and Record function on NGS.
I
~~1667-A Select TPS to monitor.
SIGNAL
4. Rotate the throttle linkage by hand and verify that the
voltage is within specification. Verify that the voltage
smoothly changes.
Specification:
I Throttle Valve Position

(Degrees)
PID Voltages
IDLE THROTTLE SHAFT ROTATION

(OTO ISe) (DEGREES - TP ROTATIONALANGLE)
WIDEOPEN T
(WOT) (76 1 0 9 4 ' 1
H 1 ~
MF1668-B
5. If not as specified, replace the throttle position sensor.

Note
The throttle position sensor is not adjustable.
Removal l Installation
1. Disconnect the throttle position sensor connector
2. Remove the throttle position sensor screws.
3. Remove the throttle position sensor.
Caution
Slide rotary tangs into position over throttle shaft
blade, then rotate throttle position sensor clock-
wis only to install position.
Failure to install throttle position sensor in this
manner may result in excessive idle speeds.
FT-185
FT CONTROL SYSTEM (FOR 2 . 3 I
~3 . 0 I
~4 . 0 ~ )
Tightening torque:
3-4 N . m (31-40 kgf - cm, 27-35 in - Ibf)
6BUOFT-251
ENGINE COOLANT TEMPERATURE SENSOR

If the engine coolant temperature sensor or circuit has an open or short, Diagnostic Trouble Code
No. P0117, P0118, P0125, P I 116, or PI117 is output.
If the engine coolant temperature sensor circuit fails, no torque converter lockup will occur (AT).
Removal / Installation
Warning
Never remove the engine coolant temperature
sensor while the engine is hot.
1. Disconnect the engine coolant temperature sensor con-

nector.
2. Remove the engine coolant temperature sensor.
Tightening torque:
16-24 N-m (1.7-2.3 kgf.m, 12-1 7 ftdbf)
6BUOFT-252
Inspection
1. Disconnect the engine coolant temperature connector.
2. Check for damaged or pushed out pin(s), corrosion and
loose wires.
3. Reconnect the sensor connector.
4. Connect the SST (NGS) to the data link connector. Turn
the ignition switch ON.
5. Access ECT PID and record function on the NGS.
Specification:
Voltage values were calculated for VREF = 5.0 volts.
These values may vary 15 percent due to sensor and
;h
VREF variations.
Temperature PID Voltages (V) Resistance (K)
.- ----- L-- -
F DEG
. -
1OoC{5O0F}
- -
20°C (68" F}
- 4- '
-
3.52
3.06
- - - -
58.75
37.30
-- - - - - - - - - -- -- -- - -- - -- - -
30°C {86" F) 2.62 24.27

~ - - - -- -- - -
.- -
40°C {104" F}
- - -
16.15
!
too
50
- --
50°C (122" F}
- - -- -
60°C (140" F} 1.35
-- -
10 9 7
7.60
0
-- - - -- - - -- - - - -- - - - -
-50
70°C (158" F} t 1 0 4 5.37
ov IV 2v 3V 4V 5v -- -
VOLTS
! 80°C (176" F) 0.80 3 84
-
MF1397-B 90°C{194"F} 1 0.61 2.80

-
100°C {212" F) 2.07

-
llO°C (230" F} 1.55
/
120°C {248" F} 0.28 1.18

MF1665-A
6. If ECT PID is out of specification, place the sensor in

water with a thermometer and heat the water gradually.
7. Measure the resistance.
CONTROL SYSTEM (FOR 2 . 3 /~3 . o I
~4 . 0 ~ ) FT
INTAKE AIR TEMPERATURE SENSOR
If the intake air temperature sensor or circuit has an open or short, Diagnostic Trouble Code No.
PO112, PO113 or P I 112 is output.
If the intake air temperature sensor circuit fails, no particular driveability symptom will be noticed.
1. Disconnect the intake air temperature sensor connector.
2. Remove the intake air temperature sensor.
6BUOFT-254
lnspection
1. Disconnect the intake air temperature sensor connector.
2. Check for damaged or pushed out pin(s), corrosion, and
loose wires.
3. Reconnect the sensor connector.
Turn the ignition switch ON.
5. Access IAT PID and record value.
Specification:
Voltage values were calculated for VREF = 5.0 volts.
~ h e s evalues may vary 15 percent due to sensor and
VREF variations.
I Temperature I PID Voltages (V) Resistance (K) I
INTAKE AIR
TEMPERATURE
SENSOR
6. If IAT PID is out of specification, place the sensor in water

with a thermometer and heat the water gradually.
7. Measure the resistance of the sensor.
OCTANE ADJUST SHORTING BAR
(FOR 2.3L 13.OL 14.OL)
If the octane adjust shorting bar or circuit has an open,
Diagnostic Trouble Code No. PI390 is output.
lnspection
Refer to Pinpoint test for PI390 (page FT-133).
6BUOFT-257
FT CONTROL SYSTEM (FOR 2 . 3 I
~3 . o I
~4 . 0 ~ )
HEATED OXYGEN SENSORS
If a heated oxygen sensor or circuit has an open or short, Diagnostic Trouble Code No. PO131,
P0133, P0135, P0136, P0141, P0151, PO153 or PO155 is output.
If a heated oxygen sensor circuit fails, poor fuel economy may occur.
lnspection of voltage
stop it.
2. Disconnect the heated oxygen sensor connector.
3. Connect a voltmeter to the heated oxygen sensor.
4. Start the engine and increase engine speed to 2000 rpm.
5.Check that the voltage changes between 0.2-1.OV
when accelerating and decelerating.
6BUOFT-258
lnspection of heater
2. Measure the resistance between the heater terminals.
Resistance: 2-5 ohms (at 20°C (68°F))

Hot to warm resistance: 5-30 ohms
3. If not as specified, replace the heated oxygen sensor(s).

6BUOFT-259
2. Remove the heated oxygen sensor.
4BUOF3-196
Note
Upstream H02S: Green Connector
Rear H02S: Blue Connector
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR

lnspection
1. Connect SST (NGS) to data link connector.
2. Warm-up engine and run it at idle.
3. Access DPFEGR PID and record value.
Specification:
1 Engine condition
Ignition switch ON
DPFEGR PID
1
Hot ~ d l e
1 Driving 48 krnlh (30 rnph)
I PRESSURE
DIFFERENTIAL
IkPaI
Driv~ng88 krnlh (55 rnph)
MF1202-B
4. If not as specified, perform the following:

(1) Turn ignition switch ON. Access DPFEGR PID on
NGS.
(2) Disconnect tubes from sensor.
(3) Connect hand vacuum pump to intake manifold side
(downstream side = smaller diameter) of DPFE
sensor.
(4) Apply vacuum and check PID. If not at specificat~on.
replace the differential pressure feedback EGR
sensor.
~3.01
~4 . 0 ~ ) FT
CLUTCH PEDAL POSITION (CPP) SWITCH (MT ONLY)
If the clutch pedal position switch circuit has an open or
short, Diagnostic Trouble Code No. PO704 is output.
If the clutch pedal position switch is open or shorted,
vehicle will not start or speed control will not disengage
properly or idle speed will be too high with clutch pedal
depressed.
lnspection
1. Disconnect the clutch pedal position switch connector.
2. Connect an ohmmeter to the switch, as shown.
3. Check the continuity of the switch between the terminals,
as shown.
Specification:
I Pedal 1 (2ontinuity I
I Depressed I Yes 1
Released No
MF1666-A
4. If not as specified, replace the clutch pedal position

switch. (Refer to Section H.)
TRANSMISSION RANGE SENSOR (A/T ONLY)

lnspection
Refer to Section K.
Replacement l Adjustment
Refer to Section K.
OVERDRIVE DRUM SPEED (ODs) SENSOR (AIT ONLY)

lnspection
Refer to Section K.
OUTPUT SHAFT SPEED (OSS) SENSOR ( A n ONLY)

lnspection
Refer to Section K.
FT-I 89
FT CONTROL SYSTEM (FOR 2 . 3 I~ 3 . 0 I~4 . 0 ~ )
I TEMPERATURE
I TRANSMISSION FLUID TEMPERATURE (TFT)
SENSOR (AIT ONLY)
If the transmission fluid temperature sensor circuit has
an open or short, Diagnostic Trouble Code No. P0712,
PO713, or P I711 is output.
If the transmission fluid temperature sensor is open or
shorted, erratic shifting may be felt.
lnspection
VOLTAGE READING luoltsl
1. Access TFT PID on SST (NGS tester).
2. Monitor the TFT PID voltage as the engine warms to
MF1891-A normal operating temperature.
Specification:
Temperature PID Voltage (V) Resistance (K)
10°C (50°F) 3.525 59.175
- -
20°C (68°F) 3.095 37.387

30°C {86"F) 2.623 24.215
40°C {104"F} 2.149 16.043
-- --- -- -- --
50°C {122"F} 1.71 10.85

- - ---
60°C {14OoF} 1.333 7.487

-- ---- - P .- -- --- -
70°C {158"F} 1.025 5.268
3. If TFT PID does not increase as engine reaches normal

operating temperature, inspect TFT sensor resistance
with SST (AT Tester: 49-UN01-071). Refer to Section K.
6BUOFT-263
TURBINE SHAFT SPEED (TSS) SENSOR (MONLY)

If the turbine shaft speed sensor has an open or short, Diagnostic Trouble Code No. PO715 is output.
If the turbine shaft speed sensor circuit is open or shorted, no symptom will be noticed.
lnspection
1. Access TSS PID on SST (NGS tester).
2. Monitor TSS PID at vehicle driving condition.
Driving Condition TSS PID
Key ON, engine off 0 rpm
Hot idle 0 rpm
30 mph 1100-1 200 rpm
55 mph 2200-2300 rpm
3. If not within specification, disconnect the TSS sensor

connector.
4. Measure the resistance between the terminals of the TSS
sensor.
5. If not as specified, replace the TSS sensor. (Refer to
Section K.)
6BUOFT-264
CONTROL SYSTEM (FOR 2.3L 13.OL 14.OL) FT
POWER STEERING PRESSURE SWITCH (2.3L ONLY)
If the power steering pressure switch or circuit has an open or short, DiagnosticTrouble Code NO.PI650
or P I 651 is output.
lnspection
1. Start engine and run it at idle. Access PSP PID on SST (NGS tester).
2. While observing PSP PID, turn steering wheel from right to left.
Specification:
Steering Wheel
Straiaht ahead
3. If not as specified, disconnect the power steering pressure switch.

4. Start the engine and let it idle.
5. Connect an ohmmeter to the switch.
6. Check the continuity between the terminals of the switch.
Specification:
--
Steering Wheel
-
-
I
I
Continuity I
I Turned
[ Straight ahead Yes I
7. If not as specified, replace the power steering pressure switch.
CRANKSHAFT POSITION SENSOR (FOR 2.3L 13.OL 14.OL)

If the crankshaft position sensor circuit has an open or short, the vehicle may stall; and not restart.
lnspection
For 2.3L, 3.OL or 4.OL, refer to Section G.
For 2.3L, 3.OL or 4.OL, refer to Section G.
Note
The crankshaft position sensor for all three engines is not adjustable.
t1 CONTROL SYSTEM (FOR 2.3L 13.OL 14.OL)
CAMSHAFT POSITION SENSOR (FOR 2.3L)
If the camshaft position sensor or circuit has an open or short, Diagnostic Trouble Code No. PO340 is
output.
If the camshaft position sensor circuit fails, the engine will stall and will not restart.
Note
The camshaft position sensor is not adjustable.
lnspection
Refer to PCM specification chart. (Refer to page FT-177.)
1. Disconnect the camshaft position sensor connector.
2. Remove the camshaft position sensor.
Tightening torque:
5-7 N - m (51-71.4 kgf -cm, 44-42 in. Ibf)
6BUOFT-267
CAMSHAFT POSITION SENSOR (for 3.OL & 4 . 0 ~ )

output.
If the camshaft position sensor circuit fails, the engine may stall and not restart.
lnspection
Refer to PCM specification chart. (Refer to page FT-171. FT-165.)
Caution
I \ CMP SENSOR
Prior to the removal of the camshaft position
sensor, set No. 1 cylinder to 0 degrees top dead
center (TDC) of compression stroke. Then note the
position of the camshaft position sensor electrical
connector. The installation procedure requires
that the connector be located in the same position.
HOLD-DOWN
CLAMP
\ Removal
1. Disconnect battery ground cable.
2. Disconnect fuel charging wiring connector from stator
assembly.
3. Remove the CMP sensor retaining screws and camshaft
position sensor from synchronizer assembly.
4. If synchronizer assembly is to be removed from the cylin-
der block, proceed with step 5. If the synchronizer
assembly is not being removed, proceed to installation
step 6.
5. Remove hold-down clamp.
6. Remove synchronizer assembly from cylinder block.
~3 . 0 1
~4.0~) FT
Installation
-.._ Caution
If the replacement synchronizer assembly housing
does not contain a plastic locator cov r tool, SST
must be obtained prior to installation of the
replacement synchronizer assembly. Failure to
follow this procedure will result in the fuel system
being out of time with theengine, possibly causing
engine damage.
Do not move crankshaft until entire assembly pro-
cedure is complete. Doing so will result in th fuel
MFI 887-A 5BUOF2-153
system being out of time with the engine, r sulting
in possible engine damage.
1. Attach SST.
2. Align the synchronizer vane with the radial slot of the
SST.
3. Rotate the SST on the synchronizer base until the SST's
boss engages the base notch.
4. Dip gear end into engine oil to coat gear, thrust washer
and lower bearing.
5. Insert the synchronizer assembly (with SST) into
lo FRONT OF ENGINE the block. The SST should be aimed approximately

75 degrees (3.OL), 60 degrees (4.OL) counterclockwise
off the centerline of the engine.
6. Install hold-down clamp.
Tightening torque:
18-29 N - m(1 3-2.9 kgf em, 13--21 ft-lbf)
Caution
If camshaft position sensor electrical connector is
not positioned properly, DO NOT reposition th
connector by rotating the synchronizer assembly.
This will result in the fuel system being out of tim
with the engine, possibly causing engine damag .
Remove the synchronizer assembly and repeat
installation procedure, beginning with Step 1.
CENTERLINE OF
ENGINE
4 7. Remove SST.
8. Install CMP sensor and retaining sc;rews.
Tightening torque:
* 75"for 3.OL
1.5-4.0 N .m (16-40 kgf .cm, 14-35 in. Ibf)
60" for 4.OL
PI CONTROL SYSTEM (FOR 2.3L / 3.OL / 4.OL)
9 . Connect connector to camshaft position sensor stator
assembly.
10. Connect battery ground cable.
Note
When the battery has been disconnected and
reconnected, some abnormal drive symptoms
may occur while the powertrain control module
relearns its adaptive strategy. The vehicle may
need to be driven 16 km (10 miles) or more to
relearn the strategy. 5 ~ ~ 0 ~ 2 - 1 5 4
FUEL AND EMISSION
CONTROL SYSTEMS
Refer
e
e
to section FT for fuel and emission diagnosis procedures.
Section F1 contains removal and installation procedures only. 1
INTAKE AIR SYSTEM F1 - 2
PREPARATION F1 - 2
COMPONENTS F1 - 2
ACCELERATOR CABLE AND PEDAL F1 - 5
FUEL SYSTEM F1 - 6
PREPARATION F1 - 6
PRECAUTION F1 - 6
FUEL TANK Refer to F3 - 8
FUEL FILTEZR Refer to F3 - 11
FUEL PUMP Refer to F3 - 12
INJECTORIPRESSURE REGULATOR F1 - 7
EXHAUST SYSTEM F1 - 8
COMPONENTS F1 - 8
INTAKE AIR SYSTEM
INTAKE AIR SYSTEM

PREPARATION
SST
49 UNOI 052 For 49 UNOl 051 For

fuel supply fuel return
Spring lock line removal Spring lock line removal
coupling coupling
tool (% in) tool (% in)
COMPONENTS
Removal / Inspection / Installation
1. Disconnect the electrical connector from the following parts:
- Mass air flow sensor
- Intake air temperature sensor
-Throttle position sensor
- Idle air control solenoid
2. Disconnect accelerator cable. (Refer to page F1-5.)
INTAKE AIR SYSTEM
GASKET, REPLACE
GASKET, REPLACE
STEP 2: 26-46 f2.7-3.8, 1-28}
GASKET, REPLACE
2-0 (2.13.1, 15--22)

N-m
L I
MFI 572-E
1. Air cleaner 5. Fuel rail
2. Air intake hose Removal Note . . . . . . . . . . . . .page F1-4
Inspect for damage 6. Fuel injector
3. Throttle body 7. Intake manifold
4. Upper intake manifold Installation Note . . . . . . . . . . page F1-4
Inspection . . . . . . . . . . . . . . . . page F1-4 Inspection . . . . . . . . . . . . . . . . page F1-4
Installation Note . . . . . . . . . . . page F1-4
6BUOF1-002
INTAKE AIR SYSTEM
Removal Note
Fuel rail
Warning
the fuel pressure from the system to reduce the
possibility of injury or fire. (Refer to page F1-6.)
1 . Release fuel pressure from the fuel system. (Refer to

page F1-6.)
2. Disconnect the fuel supply line using the SST.
3. Disconnect the fuel return line using the SST.
6BUOF1-011
Installation Note
Intake manifold
1. Clean and apply a small amount of clean engine oil to all
bolts and stud threads before installing them.
2. Install the intake manifold and hand-tighten all the bolts
and stud.
3. Tighten the intake manifold bolts and stud in the order
shown to the specified torque.
l a FRONT OF ENGINE Tightening torque:

26-38 N-m(2.7-3.8 kgfm, 19-28 ft.lbf)
5BUOF1-094
I.Install the upper intake manifold and hand-tighten all the
bolts and studs.
2. Tighten the upper intake manifold bolts and studs in the
order shown in two steps.
Tightening torque:
Step 1: 7-10 N-m(7.1-10 kgf-cm, 61-48 in.lbf)
Step 2: 26-38 N-m(2.7-3.8 kgf-m, 19-28 ft-lbf)
5BUOF1-095
I
MF1573-A
FRONT OF ENGINE
5BUOF1-007
UPPER INTAKE MANIFOLD 1 INTAKE MANIFOLD

Inspection
1 . Check for damage and cracks.
2. Verify flatness of the manifold contact surface.
3. Replace it if necessary. 6BUOF1-003
INTAKE AIR SYSTEM
ACCELERATOR CABLE AND PElDAL
- 1. Remove in the order shown in the figure.
2. lnspect all parts and repair or replace as necessary
Accelerator Cable
Inspection / Adjustment
1. Verify that the throttle valve is fully closed.
2. lnspect the cable for restrictions.
3. Depress the accelerator pedal fully'and verify that the
throttle valve is at wide open throttle.
4. If not as specified, replace the accelerator cable.
Note
The accelerator cable is not adjustable.
5BUOF1-098
FUEL SYSTEM
FUEL SYSTEM
PREPARATION
SST
PRECAUTION
Fuel Pressure and Servicing Fuel System Releasing
1. Before disconnecting any fuel line, release the fuel pres-
sure from the fuel system to reduce the possibility of injury
or fire.
(Schrader@valve),located on the fuel distribution pipe.
(3) Depressthe pressure relief button until the pressure is
released.
Alternate method
pressure.
ing the hoses.
FUEL TANK
Removal 1 Inspection I Installation
Refer to page F3-8 in section F3.
FUEL FILTER
Replacement
FUEL PUMP
FUEL SYSTEM
INJECTOR 1 PRESSURE REGULATOR
Warning
Before performing the following operation, release th fu I pr ssur from the fuel system to
reduce the possibility of injury or fire. (Refer to page F1-6.)
When removing the fuel system components, keep sparks, cigarettes and open flames away
from the fuel area.
Use new O-rings.

I 2 0 - 3 0 {2.1-3.1,15-22) GASKET. REPLACE
2 0 - 3 0 (2.1-3.1, 15-22)
GASKET, REF'LACE
STEP 1: 7-10 N.m {7.1-10 kgf.cm,

61--88 in4bf)
GASKET, REPLACE
2 6 - 3 8 t2.7-3.8, 19-28) - 26--38 (2.7-3.8, 19--28)
1. Air intake hose (not shown) 5. Fuel rail

n 2. Upper intake manifold 6. Fuel injector
3. Fuel injector connector 7. Pressure regulator
4. Fuel lines
Removal Note . . . . . . . . . . . . . page F1-8
F1 FUEL SYSTEM. EXHAUST SYSTEM
1 Removal Note
Fuel lines
1. Disconnect t
I J
MFI 148-A
EXHAUST SYSTEM
COMPONENTS
Removal 1 Inspection 1 Installation
2. Check all parts and repair or replace, if necessary.
EXHAUST SYSTEM
FRONT OF VEHICLE
REGULAR CAB
FRONT OF VEHICLE
N.m {kgf.m, ft-lbf)
MF1874-A 6BUOF1-O(
1. Silencer 4. Rear bracket and insulator assembly
Inspect for deterioration and restriction Removal Note . . . . . . . . . . . . page F1-10
2. Three way catalytic converter Installation Note . . . . . . . . . . . page F1-10
Inspect for deterioration and restriction 5. Center bracket and insulator assembly
3. Exhaust manifold 6. Front bracket and insulator assembly
Inspect for deterioration and cracks 7. Silencer heat shield
Removal Note . . . . . . . . . . . . page F1-10
Installation Note . . . . . . . . . . . page F1-10
EXHAUST SYSTEM
Removal Note
Rear bracket and insulator assembly
1. Remove the silencer.
2. Remove the rivet which attaches the bracket and insulator
assembly to the frame.
4BUOF1-152
Exhaust manifold
1. Remove the intake air system components. (Refer to
page F1-2.)
2. Remove the EGR pipe at the exhaust manifold and
loosen at the EGR valve.
4. Remove the two nuts and remove the rear engine lifting
eye from the exhaust manifold studs.
5. Remove the exhaust manifold retaining bolts and studs.
6. Remove the exhaust manifold from the vehicle.
6BUOF1-009
Installation Note
1. Position the bracket and insulator assembly on the frame.
2. Attach the bracket and insulator assembly with a nut and
bolt.
Tightening torque:
68-94 N-m (6.9-9.6 kgfem, 50-70 ft-lbf)
4BUOF1-154
1
Exhaust manifold
1. lnstall two guide pins into cylinder head holes 1 and 8.
2. lnstall the gasket over the guide pins.
3. lnstall the exhaust manifold over the gasket and guide
pins.
4. lnstall the two bolts and remove the guide pins.
5. lnstall the remaining bolts and studs and tighten in the
sequence shown in two steps.
Tightening torque:
Step 1: 20-30 N.m (2.1-3.4 kgf-m, 15-22 ft.lbf)
Step 2: 6 0 - 4 0 N-m (6.1-4.1 kgfvm, 45-59 ft.lbf)
6. lnstall the rear engine lifting eye on the studs with the nuts
and tighten.
Tightening torque:
20-44 N-m I2.1-3.0 kgfem, 15-22 ft.lbf)
7. Connect the heated oxygen sensor connector.

8. Connect the EGR pipe at the exhaust manifold and
tighten.
I / ~ighteningtorque:
34--47 N - m (3.4--4.8 kgf .m, 25-35 ft - lbf)
MB1330-B 6BUOF1-010
9. lnstall the intake air system-components. (Refer to page
F1-2.)
FUEL AND EMISSION
CONTROL SYSTEMS
I Refer to section FT for fuel and emission diagnosis

I Section F2 contains removal and installation procedures only. I
INTAKE AIR SYSTEM F2 - 2

PREPARATION F2 - 2
COMPONENTS F2 - 2
ACCELERATOR CABLE AND PEDAL F2 - 2
FUEL SYSTEM -
F2 8
PREPARATION F2 - 8
PRECAUTION F2 - 8
FUEL TANK Refer to F3 - 8
FUEL FILTEER Refer to F3 - 11
FUEL PUMP Refer to F3 - 12
INJECTOR/PRESSURE REGULATOR F2 - 9
EXHAUST SYSTEM F2 - 11
COMPONENTS F2 - 11
F2 INTAKE AIR SYSTEM
INTAKE AIR SYSTEM

PREPARATION
SST
49 UNO1 052 For 49 UNO1 051 For

fuel supply fuel return
Spring lock line removal Spring lock line removal
coupling coupling
tool (% in) tool (% in)
I
COMPONENTS
Removal / Inspection / lnstallation
1. Disconnect intake air temperature sensor, mass air flow sensor, throttle position sensor and idle
speed control solenoid connectors.
I I
MF9610-B 7BUOF2-001
1. Air intake hose 5. Intake manifold (not shown)

Inspect for damage Removal Note . . . . . . . . . . . . page F2-3
2. Air cleaner housing Installation Note . . . . . . . . . . page F2-4
3. Ignition coil and bracket assembly 6. Idle air control solenoid
4. Upper intake rnanifoldlthrottle body assembly 7. Tube
Inspection . . . . . . . . . . . . . . . . page F2-6
Installation Note . . . . . . . . . . page F2-5
INTAKE AIR SYSTEM
Removal
e Note
Upper intake manifold I throttle body assembly
1. Remove the accelerator cable shield.
2. Disconnect the vacuum hoses frorn the upper intake
manifold 1 throttle body assembly.
3. Disconnect the accelerator and cruise control cables.
4. Remove the ignition coil and bracket assembly and the
ignition coil support bracket.
5. Disconnect the throttle position selisor and air intake
temperature sensor connectors.
6. Remove the upper intake manifold 1 throttle body assem-

bly and discard the gasket.
Intake manifold
1. Drain the coolant. (Refer to Section E2.)
2. Release fuel pressure from the fuel system to reduce the
possibility of injury or fire. (Refer to page F2-8.)
INTAKE AIR SYSTEM
6. Disconnect the fuel injector wiring harness.
7.Disconnect the vacuum hoses from the pressure
regulator.
8. Remove the fuel rail and injectors.

9. Disconnect the upper radiator hose from the thermostat
housing.
11. Remove the cylinder head covers. (Refer to Section B2.)
13. Remove the intake manifold and discard the gasket.
Installation Note
Intake manifold
1 . Apply a small amount of clean engine oil to all retaining
2. Apply appropriate sealant to the intersection of the cylin-
der block and cylinder head at the 4 corners.
3. Install new intake manifold gaskets and seals.
4. Installfuel injectors and the fuel rail to the intake manifold.
5. Install the intake manifold carefully, without damaging the
sealant.
INTAKE AIR SYSTEM F2
6. lnstall all bolts hand-tight. Then, tigh1:en bolts in two steps
in the order shown.
Tightening torques:
Step 1: 15 N,m (1.5 kgf.m, 11 ft-lbf)
Step 2: 26 N.m (2.6 kgf.m, 19 ft-lbf)
7. lnstall the cylinder head covers.
Tightening torque:
12 N.m (1.2 kgfem, 9 ft-lbf)
8. Connect the heater hoses and upper radiator hose.

9. Connect the vacuum hoses to the pressure regulator.
10. Connect the fuel injector wiring harness.

11. Connect the engine coolant temperature sensor
connector.
12. Connect the fuel supply and return lines.
13.Fill the radiator with specified coolant. (Refer to
Section E2.)
Upper intake manifold 1 throttle body assembly

1. Clean and apply a small amount of clean engine oil to all
2. lnstall a new gasket.
3. lnstall the upper intake manifold 1throttle body assembly.
4. Tighten the upper intake manifold1throttle body assembly
bolts in the order shown.
Tightening torque:
25 N.m (2.6 kgf-m, 19 ft-lbf)
5. Connect the throttle position sensor and intake air tem-

perature sensor connectors.
6. lnstall the ignition coil and bracket assembly and the
ignition coil support bracket.
7. Connect the accelerator and cruise control cables.
8. Connect the vacuum hoses to the upper intake manifold1
throttle body assembly.
9. lnstall the accelerator cable shield.
INTAKE AIR SYSTEM
UPPER INTAKE MANIFOLD 1THROTTLE BODY
ASSEMBLY
Inspection
1. Check the upper intake rnanifoldlthrottle body assembly
for damage, cracks or deposits.
2. Verify that the throttle valve moves smoothly when the
throttle lever is moved from fully closed to fully open.
3. Verify the flatness of the upper intake manifoldlthrottle
body assembly contact surf ace.
4. Replace the upper intake manifold1throttle body assem-
bly, if necessary.
Caution
The throttle body must not be cleaned. A sealant1
coating covering the throttle bore and throttle valv
makes the throttle body airflow tolerant to engine
intake sludge accumulation.
ACCELERATOR CABLE AND PEDAL
1. Shield 4. Shield bracket

2. Accelerator cable 5. Accelerator pedal
Inspection ........................................ below Inspect for damage
3. Accelerator cable bracket
Accelerator Cable
lnspection
2. Inspect the cable for restrictions.
3. Depress the accelerator pedal fully and verify that the
Note
The accelerator cable is not adjustable.
4BUOF2-109
FUEL SYSTEM
PREPARATION
SST
tool (% in)
FUEL SYSTEM
tool (% in)
PRECAUTION
-
Fuel Pressure and Servicing Fuel System
Releasing
I
or fire.
(Schrader@valve),located on the fuel distribution pipe.
(3) Depress the pressure relief button until the pressure is
released.
Alternate method
pressure.
ing the hoses.
FUEL TANK
6BUOF2-005
FUEL FILTER
Replacement
68UOF2-006
FUEL PUMP
6BUOF2-007
FUEL SYSTEM
INJECTOR I PRESSURE REGULATOR
Removal IInstallation
Warning
Before performing the following operation, release the fuel pressure from the fuel
system to reduce the possibility of injury or fire. (Refer to page F2-8.)
When removing the fuel system components, keep sparks, cigarettes and open flames
away from the fuel area.
Use new O-rings.
1. Remove upper intake manifold / throttle body assembly. (Refer to page F2-2.)
3. Install in the reverse order of rernoval, referring to Installation Note.
-
O-RING,
REPLACE
II
MF1898-A 6BUOF2-008
1. Fuel injector connector 5. Pressure regulator
2. Vacuum hose Removal Note . . . . . . . . . . . . page F2-10
3. Fuel rail Installation Note . . . . . . . . . . page F2-10
4. Injector
F2 FUEL SYSTEM
r 1 Removal Note
Fuel lines
L 1
MF1148-B
MF1253-A 4BUOF2-137
Pressure regulator
1. Remove three Allen head screws from the pressure
regulator and discard.
2. Remove the pressure regulator and discard the gasket
and O-ring.
MF1254-A 4BUOF2-138
Installation Note
Pressure regulator
1. Apply a small amount of clean engine oil to the O-ring
before installing it.
2. Install a new O-ring and gasket.
3. Installthe pressure regulator using new Allen head screws.
Tightening torque:
3 - 4 N-m(32--40 kgf.m, 27-35 inelbf)
4BUOF2-139
EXHAUST SYSTEM F2
EXHAUST SYSTEM
COMPONENTS
Removal 1 Inspection 1 lnstallation
2. Check all parts and repair or replace, if necessary.
3. Install in the reverse order for removal, referring to lnstallation Note.
/ NOTE: DISCONNECT I
I
V
34-46 13.5-4.6,~~-33) H02 SENSOR CONNECTORS
TO REMOVE FRONT PIPE
I
dF1878-A 6BUOF2-009
Inspect for deterioration and restriction Removal Note ................................ below
2. Three way catalytic converter Installation Note ................... page F2-12
Inspect for deterioration and restriction 6. Center bracket and insulator assembly
3. Front pipe assembly 7. Front bracket and insulator assembly
Inspect for deterioration and cracks 8. Silencer heat shield
4. Exhaust manifold Removal Note ...................... page F2-12
Inspect for deterioration and cracks Installation Note ................... page F2-12
Removal Note ..................... page F2-12
Installation Note .................. page F2-12
Removal Note
1. Remove silencer.
4BUOF2-145
F2 EXHAUST SYSTEM
Silencer heat shield
1. Remove the band strap.
2. Remove the two screws and washer assembly which
attach the heat shield to the rear of the silencer.
4BUOF2-146
Exhaust manifold
2. If removing the left exhaust manifold, remove the oil level
dipstick tube retaining nut and rotate the tube out of the
way. Remove the EGR pipe from the exhaust manifold.
4BUOF2-147
Installation Note
1. Position the bracket and insulator assembly on frame.
bolt.
Tightening torque:
68-94 N-m(6.9-9.6 kgfem, 50-70 ft.lbf}
4BUOF2-148

1. Position the heat shield under the silencer body.
2. Install two screws to the rear of the silencer.
Tightening torque:
16-23 N.m (1.6-2.3 kgf,m, 12-17 ft-lbf)
3. Start the band strap and tighten.
Tightening torque:
2 N-m(20kgfecm, 18 in-lbf)
Exhaust manifold
1. Clean the mating surfaces of the exhaust manifold and
cylinder head.
2. Position the manifold in place and tighten the bolts and
studs.
Tightening torque:
20-30 N.m (2.0-3.0 kgfem, 15-22 ft-lbf)
3. If installing the left exhaust manifold, rotate the oil level
dipstick tube to the exhaust manifold stud and install the
retaining nut.
Tightening torque:
18 N-m{I.8 kgfam, 13 ft.lbf}
4. If installing the left exhaust manifold, install the EGR pipe
to the manifold.
Tightening torque:
1 1 N.m (1.1 kgf-m, 8 ft-lbf}
FUEL AND EMISSION
CONTROL SYSTEMS
I Refer
e to section FT for fuel and emission diagnosis p o c e r l
I Section
e F3 contains removal and installation procedures only.
m
INTAKE AIR SYSTEM

PREPARATION
COMPONENTS
FUEL SYSTEM
PREPARATION
PRECAUTION
FUEL TANK
FUEL FILTER
FUEL PUMP
INJECTORIPRESSURE REGULATOR
EXHAUST SYSTEM
COMPONENTS
INTAKE AIR SYSTEM
INTAKE AIR SYSTEM

PREPARATION
SST
49 UNOl 006 For

fuel
Fuel line return line
coupling removal
tool
COMPONENTS
1. Disconnect the electrical connector from the following
parts:
- Intake air temperature sensor
- Mass air flow sensor
- Throttle position sensor
- Idle air control (IAC) solenoid
3. Remove in the order shown in the figure, referring to
Removal Note.
5. Install in the reverse order of removal, referring to
Installation Note.
I -- I
MF9620-E 7BUOF3-001
1. Air intake hose 7. Fuel injector
2. Air cleaner housing 8. Intake manifold
3. Throttle body Removal Note . . . . . . . . . . . . page F3-4
4. Upper intake manifold Installation Note . . . . . . . . . . page F3-4
lnspection . . . . . . . . . . . . . . . . page F3-6 lnspection.. . . . . . . . . . . . . . . page F3-6
5. Fuel lines 9. Idle air control (IAC) solenoid
6. Fuel distributor 10. Tube
Removal Note
Fuel distributor
Refer to page F3-13 for removal procedures.
6BUOF3-003
Intake manifold
1. Remove the ignition coil and the mounting bracket.
2. Remove the cylinder head covers. (Refer to Section 83.)
3. Remove the intake manifold and discard the gasket.
Installation Note
Intake manifold
1. Apply the appropriate sealant to the intersection of the
cylinder block and the cylinder head at the four corners as
shown.
I EXAMINE CLOSELY FOR EROSION,

CORROSION, OR PITTING 1 2. Install the new intake manifold gasket.
3. Apply the appropriate sealant to the intersection of the
cylinder block and cylinder head at the four corners as in
step 1.
APPLY SILICON
SEALER
INTAKE AIR SYSTEM
4. Position the intake manifoldwith the aid of two guide studs
located in position 3 and 4 below, and install the bolts
hand-tight. Then remove the two guide studs and replace
with bolts.
I I
MBI 355-A
5 1 5. Tighten the bolts in three steps in the order shown.
Tightening torques:
Step 1 : 4-43 N-m(0.5-4.8 kgfam, 3-6 ftelb)
Step 2: 8-15 N-m (0.8-1 -5 kgf.m, 6-1 1 ft-lbf)
Step 3: 15-18 N.m (1.5-1.8 kgf-m, 11-13 ft-lbf)
I 1I 6. Install the cylinder head covers. (Refer to Section 83.)
Tightening torque:
MF1265-A 6-43 N.m (0-7-4.8 kgfem,4.5-5.9 ftlbf)
7. Install the upper intake manifold and tighten the nuts.
Tightening torque:
20-25 N-m(2.0-2.5 kgf-m, 15--18 ftdb)
'
8. Install the ignition coil and mounting bracket.
Tightening torque:
26-32 N.m (2.7-3.3 kgf-m, 19-24 ft-lbf)
MF1787-A 5BUOF3-094
UPPER INTAKE MANIFOLD
lnspection
1. Check for damage and cracks.
2. Verify flatness of the upper intake manifold contact sur-
face.
3. Replace the upper intake manifold, if necessary.
INTAKE MANIFOLD
lnspection
1. Check for damage and cracks.
2. Verify flatness of the intake manifold contact surface.
3. Replace the intake manifold, if necessary.
MANIFOLD
e
2. lnspect all parts and repair or replace as necessary.
I
MF1906-A 4BUOF3-117
1. Shield 3. Accelerator cable bracket
2. Accelerator cable 4. Accelerator pedal
Inspection/Adjustment..................... below Inspect for damage
Accelerator Cable
Inspection 1 Adjustment
2. lnspect the cable for restrictions.
3. Depress the accelerator pedal fully and verify that the
Note
e accelerator
The e e
cable is not adjustab8.
4BUOF3-118
FUEL SYSTEM
FUEL SYSTEM
PREPARATION
SST
49 UNO1 010 For 49 UNO1 006 For

inspection fuel
Fuel of fuel Fuel line return line
pressure pressure coupling removal
gauge tool
PRECAUTION
Fuel Pressure and Servicing Fuel System
Releasing
or fire.
( ~ c h r a d e pvalve), located on the fuel distribution
pipe.
(3) Depress the pressure relief button until the pressure is
released.
Alternate method
pressure.
ing the hoses.
PRESSURE REUEF
FUEL TANK
Removal / Inspection IInstallation
Warning
system to reduce the possibility of injury or fire. (Refer to above.)
When removing the fuel tank, keep sparks, cigarettes and open flames away from it.
Before repairing the fuel tank, clean it thoroughly with a steam cleaner to remove all
explosive gas.

Note
Drain the fuel from the fuel tank before removing the tank.
FUEL SYSTEM
--
F3
Regular Cab
I I
I
MF1908-A 6BUOF3-OC
1. Filler hose (not shown) 3. Fuel tank strap
2. Heat shield 4. Fuel tank
Removal Note ...................... page F3-11
F3 FUEL SYSTEM
Cab Plus
1. Filler hose (not shown) 3. Fuel tank strap

2. Heat shield 4. Fuel tank
FUEL SYSTEM
Removal Note
Fuel tank
1. Lower the fuel tank.
2. Disconnect the fuel return and fuel supply hoses from the
fuel pump.
3. Disconnectthe fuel vapor hoses from the fuel vapor valve.
5. Remove the fuel tank and inspect it for cracks.
FUEL FILTER
Replacement
Warning
Before performing the following operation, release the fuel pressure from the fuel system to
reduce the possibility of injury or fire. (Refer to page F3-8.)
Always work away from sparks and open flames.
6BUOF3-007
High-pressure side
The fuel filter must be replaced a.t the intervals outlined in the maintenance schedule.
2, Install in the reverse order of removal.
Note
o
H-- When installing the fuel filter, push the fuel hoses fully onto the fuel filter.
MF2003-A
1. Fuel hoses
2. Fuel filter (High-pressure side)
FUEL SYSTEM
FUEL PUMP
1. Remove the fuel tank. (Refer to page F3-8.)
I
I
----- - - -- - -- - - - - II
I CAB PLUS I I
L I
MF1149-C 6BUOF3-008
1. Shield (Regular cab only) 3. Fuel pump
2. Fuel pump ring 4. Fuel pump gasket
lnstallation Note .............................. below
lnstallation Note
Fuel pump ring (Cab Plus only)
Rotate the fuel pump ring clockwise until the flange
touches the stopper.
4BUOF3-138
FUEL SYSTEM
INJECTOR 1 PRESSURE REGULATOR
e
Warning
system to reduce the possibility of injury or fire. (Refer to page F3-8.)
When removing the fuel system components, keep sparks, cigarettes and open flames
away from the fuel area.
Use new O-rings.
I
MF1269-C
N.m {kgfecm, inelbf)
6BUOF3-009
1. Air intake hose 4. Fuel distributor
2. Upper intake manifold 5. Fuel injector
3. Fuel lines 6. Pressure regulator
F3 FUEL SYSTEM
@)TO DISCONNECT
Removal Note
PUSH FllTlNG TOWARDS FUEL LINE Fuel lines
1
Disconnect the fuel return line using SST, as s h o w n .
- PRESSURE
1 T . , REGULATOR
@ INSERT SST
I v// I
@SLIDE FITTING AND SST

OFF OF FUEL LINE
--
n
EXHAUST SYSTEM F3
EXHAUST SYSTEM
COMPONENTS
2. Check all parts and repair or replace if necessary.
34-46 f3.5-4.6, 25-33)
NOTE: DISCONNECT
H 0 2 SENSOR CONNECTORS
TO REMOVE FRONT PIPE
I
MF1878-A 6BUOF3-010
lnspect for deterioration and restriction Removal Note ..................... page F3-16
2. Three way catalytic converter Installation Note .................. page F3-16
lnspect for deterioration and restriction 6. Center bracket and insulator assembly
3. Front pipe assembly 7. Front bracket and insulator assembly
lnspect for deterioration and cracks 8. Silencer heat shield
4. Exhaust manifold Removal Note ..................... page F3-16
lnspect for deterioration and cracks Installation Note .................. page F3-16
Installation Note .................. page F3-17
F3 EXHAUST SYSTEM
Removal Note
1. Remove the silencer.
4BUOF3-155

1. Remove the band straps.
2. Remove the two screws and washer assembly which
attach the heat shield to the rear of the silencer.
4BUOF3-156
Exhaust manifold
Left
1. Remove the oil level dipstick tube support bracket.
2. Remove the power steering oil pump pressure and return
hoses, if necessary.
4BUOF3-157
Right
1. Remove the heater hose support bracket.
4BUOF3-158
Installation Note
1 . Position the bracket and insulator assembly on the frame.
bolt.
Tightening torque:
20-27 N.m (2.0-2.7 kgf.m, 15-20 ft-lbf)
4BUOF3-159

1. Position the heat shield under the silencer body.
2. Install two screws to the rear of the silencer.
Tightening torque:
16-23 N-m (1.6-2.3 kgf-m, 12-1 7 ft-lbf)
3. Start the band straps and tighten.
Tightening torque:
7 N.m (70 kgf-cm, 60 in-lbf)
EXHAUST SYSTEM
Exhaust manifold
Note
Lightly oil all bolts and stud threads before instal-
lation.
4BUOF3-161
Left
cylinder head.
2. Position the manifold in place and tighten bolts and studs.
Tightening torque:
27 N-m (2.7 kgf-m, 20 ft-lbf)
3.Connect the power steering oil pump pressure and return

hoses, if removed.
4. Install the oil level dipstick tube support bracket. Apply the
appropriate sealant to the end of the tube to prevent an oil
leak at the block.
4BUOF3-162
Right
cylinder head.
2. Position the manifold in place and tighten the bolts and
studs.
Tightening torque:
27 N-m (2.7 kgf-m, 20 ft.lbf)
3. Install the heater hose support bracket.

5. Fill and bleed the cooling system. (Refer to Section E3.)
4BUOF3-163
ENGINE
ELECTRICAL SYSTEM
INDEX ........................................................... G- 2
OUTLINE ...................................................... G- 5
SPECIFICATIONS ..................................... G- 5
TROUBLESHOOTING GUIDE ..................... G- 5
DIAGNOSTIC INDEX ................................. G- 5
SYMPTOM TROUBLESHOOTING ............ G- 6
CHARGING SYSTEM ................................... G- 8
PREPARATION ........................................ G- 8
CIRCUIT DIAGRAM ................................... G- 9
TROUBLESHOOTING ............................. G-12
BATTERY ................................................... G-13
GENERATOR .......................................... G-15
VOLTAGE REGULATOR1
BRUSH HOLDER ASSEMBLY ................ G-17
GENERATOR PULLEY AND
REGULATORTERMINAL........................ G-19
DRIVE! BELT ............................................. G-20
ELECTRONIC IGNITION SYSTEM .............. G-22
PREPARATION ......................................... G-22
CIRCUIT DIAGRAM ................................... G-23
TROUBLESHOOTING ............................... G-30
SECONDARY IGNITION SYSTEM
DISPLAY DIAGNOSIS ............................. G-41
IGNITION TIMING ...................................... G-42
SPARK PLUGS .......................................... G-43
IGNITION COIL ASSEMBLIES .................. G-46
CRANKSHAFT POSITION SENSOR ........ G-50
STARTING SYSTEM .................................... G-54
CIRCUIT DIAGRAM ................................... G-54
STARTER RELAY ...................................... G-56
STARTER .................................................. G-56
CLUTCH PEDAL POSITION SWITCH
(MT) .......................................................... G-63
5BUOGX-001
G INDEX
INDEX
I I I
2.3L ENGINE IGNITION SYSTEM
INDEX G
1 3.OL ENGINE IGNITION SYSTEM
FRONT OF VEHICLE
4.OL ENGINE IGNITION SYSTEM

INDEX
1. Battery 6. Ignition coil assemblies
Inspection ............................... page G-13 Removal 1 Installation ............. page G-46
Recharging ............................. page G-14 7 . Crankshaft position sensor
2 . Generator Inspection ............................... page G-50
Removal / Installation ............. page G-15 Removal ................................. page G-51
3 . Voltage regulator / brush holder Installation .............................. page G-53
assembly 8 . Starter
Removal 1 Installation ............. page G-17 Inspection (On-Vehicle) .......... page G-56
4 . Spark plugs Removal / Installation ............. page G-56
Removal 1 Installation ............. page G-43 Disassembly / Assembly ........ page G-58
5 . High-tension leads 5BUOGX-003
Inspection ............................... page G-46

OUTLINE
SPECIFICATIONS
Item --- Engine 1 2.3~
I Batterv I Positive voltacle 1
I Generator I Reaulator t v ~ e I Voltage regulator, on housing I
Automatic Automatic Automatic
Tensionera ~ensioner~ Tensioner
Drive belt tension
I
--
Permanent magnetic
amp 800-70 + 10
Starter
amp 130-220
140-220 rpm
Ignition system El
Spark advance Electronic spark advance (ESA)
I lanition timina BTDCI 10°+2" 1 10°+2" 1 10" +2" I
t Spark plug/ Plug gap

~ i i n order
a
mm {in) /
3 Automatic tensioner indicator must fall between 4" and 25" mark~ngson belt tensioner
Refer to VECl decal in engine compartment
3 Automatic tensioner indicator must fall between 4" and 19" markings on belt tensioner
El = Electrical Distributorless Ignition System
MG1063-G
Note
need to be driven 16 km (10 mi) or more to relearn the strategy.
4BUOGX-005
DIAGNOSTIC INDEX
Troubleshooting items
- - -- -
-
~ i lnot
l crank-starter motor does not operate
1 2 1
Will not crank-starter motor spins I G-6 I
1 3 /
Cranks slowlv I G-7 I
t k t ~ e n e r a t owarning
r light illuminates while engine running G-7
5 Discharged battery
6 No start (NO SPARK)
MG1000-D 5BUOGX-005
Will not crank-starter motor does not operate
-
-
INSPECTION 1 ACTION
Does engine crank with fully charged battery? Yes ( Check charging system page G-12
) y r l . r p e d a l position switch OK? (MT)
.
-
clutch pedal position switch page G-63
-- .- - --
Is battery positive voltage present at terminal B? Yes Go to next step
(AT: in Park or Neutral; MT: clutch pedal depressed)
TERMINAL-B
- -
Check wiring harness
I
Is battery positive voltage present at terminal S Yes Check magnetic switch
with ignition switch in START position? Check yoke
TERMINAL-S
Check armature
Check parklneutral position switch

(AT) Section K
Check ignition switch 1997 B-Series BETM
Check starter relay E@= page G-56
Check wiring harness
2 Will not crank-starter motor spins

-- -- -- - --- --- -- - - - - - - -- --
STEP
-~
- - -
INSPECTION
-- -- I ACTION
--
'
1 Is drive pinton pushed out wh~lecranklng
(Is cl~ckheard)?
I Yes
1 Remove starter and check rlng gear teeth
and starter drive pinton teeth page G-62
TROUBLESHOOTING GUI I E , CHARGING SYSTEM
1 3 1 Cranks slowly I
Does engine crank normally with fully charged Yes Check charging system * page G-12
battery?
No Go to next step
Are starter cable connections loose or corroded?

I I
Yes Repair connection
Check starter for binding (brush,

armature, etc.) a s page G-61
Inspect ring gear and service
as required * page G-62
Generator warning light illuminates while engine running I

STEP INSPECTION
Is battery positive voltage correct at idle?
terminal and generator warning light
Specification 14.1-1 4.7V

as page G-12
1 5 1 Discharged battery I
STEP
---
INSPECTION ACTION I
1 Is charging system OK? Yes Turn ignition switch ON and mt,lasure
u s page G-12 dark current as shown
Dark current: Below 0.05A

If the dark current exceeds 0.05A, check for constant
current drain such as a vehicle lamp. If not visibly
noticeable, pull the fuses one at a time until the
cause of the drain is located.
Repair or replace regulator or generator
I
G CHARGING SYSTEM
CHARGING SYSTEM
Note:
5 0
0
I
B
z
-
I;)
z
I;)
V,
<
V,
-I
rn
z
XI34 COMMON CON. (MA)-(DPHJ)

XI36 COMMON CON. (MA)-(DPW)
X I 3 9 COMMON CON. (DPHJ)-(ARS)
X.213 IGNmON SWITCH (MA)
-
CHARGING SYSTEM - - -
The generator has a self-diagnosis function to warn of the following problems in the charging system. If
a problem arises, the generator warning light illuminates.
1. Terminal S circuit open.
2. No voltage output.
3. Field coil circuit open.
4. Terminal B circuit open.
5. Voltage output too high.
4BUOGX-010
G CHARGING SYSTEM
TROUBLESHOOTING
B+: Battery positive voltage
INSPECTION 1 ACTION
I
Check battery positive voltage; is it correct? Go to next step
Specification: Above 12.4V Check battery page G-13
2 Does charge warnlng light lllumlnate w ~ t h Yes Go to Step 3

tgnltton sw~tchON7
No Check warning light bulb and wiring harness

(Charge lamp-Terminal I)
Does charge warning light go out after engine

started?
Yes / Go to Step 5
Go to next step
Is voltage at generator termmais correct? Yes Check wiring harness and fuse link
Specifications: (Battery-Terminal B)
--
14.1-14 7
--- 6.6-6 9 -
Check wiring harness and fuse link

TERMINAL-S TERMINAL-B
Replace regulator or generator page G-15, 17
TERMINAL-I
5 1. Connect an ammeter (90A min.) between Yes Charging system normal

terminal B and harness
2. Start engine
3. Turn all electrical loads ON and depress brake
pedal
4. Is output current 95A or more at 2000 rpm?
Caution:
Do not ground terminal B
I
I + No Go to next step
3
0
+
2I-
3
O ENGINE
I
Is drive belt tension OK? Replace generator page G-15
/ Adjust drive belt tension

Replace drive belt
CHARGING SYSTEM G
BATTERY
Inspection
Battery discharge test
I Measure voltage of battery (with digital voltmeter capable of reading 0.01 V)

I
I
I I
Below 11.5V Above 11.5V
I
35A and recheck voltage
Replace battery
to battery using a battery load tester
1
Record battery positive voltage at end of 15
seconds; is voltage more than specification?
Battery voltage with load

Approximate Minimum
of battery after
2 minutes 21"C {70°F}
16°C (60°F)
10°C {50°F}
I I 4°C {40°F} 9.3
Below 11.5V Above 11.5V -1 "C {30°F}
I I -7°C {20°F} 8.9
-1 2°C { I O°F} 8.7
-1 8°C {O°F} 8.5
Terminal and cable

Caution
Because the battery is a maintenance-free battery,
the fluid level need not be checked.
Do not remove the vent caps.
Be sure the top of the battery is clean. Clean it with
baking soda and water if necessary.
CHARGING SYSTEM
1. Check the tightness of the terminals to ensure good

electrical connections.
Tightening torque:
6.8-10.0 N-m (0.69-1 .O1 kgf.m, 5-7 ftslbf)
2. Check for corroded and frayed battery cables. Clean or

replace as necessary.
3. Check the rubber protector on the positive terminal for
proper coverage.
4. Clean the terminals if necessary, and coat them with

grease.
Recharging
Caution
Do not perform quick charging for over 20 minutes
to prevent damaging the battery.
Place the battery i n water to prevent it from over-
heating.
Warm up the battery to 5°C (41O F ) before charging.
Warning
Before performing maintenance or recharging the
battery, turn off all accessories and stop the en-
gine.
When disconnecting the battery, the negative cable
must be removed first and installed last.
Slow charging
If the battery has passed the load test, it can be recharged
in 2 hours at 20A. If a full state of charge is desired, the
charge can be completed by a low constant current of 3 to
5 amps for several hours.
4BUOGX-015
Quick charging
1 . Remove the battery from the vehicle to perform a quick
charge.
2. Charge the battery for 20 minutes at 35A.
4BUOGX-016
CHARGING SYSTEM G
GENERATOR
Removal
e IInstallation
Caution
Be sure the battery connections are not reversed, this will damage the generator.
Do not use a high-voltage tester such as a megger, it will damage the voltage regulator1
brush holder assembly.
Remember that battery positive voltage is always present at generator Terminal B.

2. Remove the snowlice shield and the fresh air inlet tube.
3. Remove the generator, referring to Removal Note. (Refer to below.)
4. Inspect all parts and repair or replace if necessary.
5. Install in reverse order of removal, referring to Installation Note.
Removal Note
Generator
1. Disconnect the voltage regulator Ibrush holder assembly
harness connecter.
2. Remove the harness connector bracket.
3. Disconnect the Terminal B wire.
4. Loosen the drive belt tensioner and remove the drive belt.
5. Remove the generator bolts.
CHARGING SYSTEM
Installation Note
Generator
1. Install the generator
Tightening torque:
40-54 N.m (4.1-5.5 kgfem, 3 0 4 0 ft-lbf)
2. Connect Terminal B wire.
Tightening torque:
9.0-1 2.0 N.m (0.91-1.22 kgf-m, 6.6-9.0 ftdbf}
3. Connect the harness connector to the voltage regulator 1

brush holder assembly.
CHARGING SYSTEM
VOLTAGE REGULATOR I BRUSH HOLDER ASSEMBLY
Note
The voltage regulator 1 brush holder assembly, generator pulley and regulator terminal are
serviceable. If the generator requires further service, it must be replaced as an assembly.

2. Install in reverse order of remo\/al, referring to Installation Note.
I
MGlO31-A 4BUOGX-020
1. Voltage regulator/brush holder assembly
Installation Note ..................... page G-18
Removal Note
Voltage regulator 1 brush holder assembly
1. Remove the fourTorx@(T20)screws attaching the voltage
regulator / brush holder assembly to the generator rear
housing.
2. Remove the voltage regulator, with brush holder assem-
bly attached, from the generator.
3. Remove the cap covering the Terminal A screw lead.
4. Removethe two TorxB(T20) screws attaching the voltage
regulator to the brush holder assembly.
5. Separate the voltage regulator from the brush holder
assembly.
G CHARGING SYSTEM
Installation Note
Voltage regulator I brush holder assembly
1. Install the brush holder assembly on the voltage regulator.
Tightening torque:
2 . 8 4 . 0 N.m ( 2 9 4 0 kgf-cm, 24--35 in-lbf)
2. Replace the cap of the Terminal A screw.

3. Depress the brushes into the brush holder assembly and
hold the brushes in position by inserting a standard size
paperclip. Insert the paperclip through both the location
hole in the voltage regulator and through the hole in the
brushes.
4. Install the voltage regulator / brush holder assembly on
the generator.
Tightening torque:
2.3-3.4 N-m (23-34 kgf.cm, 20-30 in.1bf)
4BUOGX-022
CHARGING SYSTEM
GENERATOR PULLEY AND REGULATOR TERMINAL
Note
The voltage regulatorlbrush holder assembly, generator pulley and regulator terminal are
serviceable. If the generator requires further service, it must be replaced as an assembly.
2. Inspect all parts and repair or replace if necessary.
I I
MG1073-B 4BUOGX-023
1. Pulley 2. Rear bracket
Installation Note .............................. below 3. Regulator terminal
lnstallation Note
Pulley
1. Join the front and rear covers, and install the bolts.
Tightening torque:
4.1-6.7 N-m (41.9-68.3 kgf-cm,,3 5 - 6 0 inelbf)
2. Install the pulley and tighten the nut.
Tightening torque:
82-1 35 N-m (8.4-1 3.7 kgf-m, 610-1 00 ft-lbf)
4BUOGX-024
CHARGING SYSTEM
DRIVE BELT
Inspection
1. Check the d r i v e b e l t and p u l l e y s f o r wear, cracks and
d a m a g e . Replace if necessary.
GBUOGX-011
Note
4.0L No adjustment is necessary. All engines are
GENERATOR A,C equipped with automatic tensioners that indicate
GENERATOR when the drive belt is worn (stretched). A pointer
and gauge are built into the tensioner. When the
pointer no longer registers within the range limits
of the gauge, replace the belt.
TENSIONER
C'S
WITH WITHOUT
AIR CONDITIONING AIR CONDITIONING
MIN
\
BELT
REPLACEMENT
CHARGING SYSTEM
1
Adjustment
All three engines are equipped with automatic tensioners
and adjustment is not required.
'1 4" BELT

REPLACEMENT 1
MN1144-A 4BUOGX-027
Replacement
2.3~
1. On 2.3L and 4.OL engines, lift tensioner by rotating it
counterclockwise and remove the old belt.
LESS
CRANKSHAFT NC-PS
kEfi
GENERATOR
GENERATOR
IDLER
TENS
I WITH
AIR CONDITIONING
WITHOUT
AIR CONDITIONING

AIR
the tensioner pulley in the clockwise direction and remove
GENERATOR CONDlTlONllVG the old belt.
IDLER
LESS N C
POWER
WATER
PUMP
3. Install the new belt over the pulleys. Make sure that all
V-grooves make proper contact with the pulley as shown.
Note
Make sure that the belt is properly seated on the
pulleys. One revolution of the engine with an incor-
I rectly seated belt may snap the belt cords.
4. Lift the tensiorier and slide the belt under the tensioner
pulley. Release the tensioner and allow the tensioner
pulley to rest on the belt.
G ELECTRONIC IGNITION SYSTEM
--
ELECTRONIC IGNITION SYSTEM
PREPARATION
SST
~- --
____,..
For 49 UNO1 130 For 2.3L
removal ignition
of the 104 Pin system
Bearing distributor breakout diagnosis
remover gear box
I
49 UNO1 057 For 4.OL 49 UNOl 058 For
lgnitron ~gnltlon
system Breakout system
EDlS diagnostic d~agnos~s box I d~agnos~s
harness
I
Note
The diagnostic cables may be connected with the breakout box in series with the ignition
system components. The ignition system can be diagnosed by placing the correct overlay on
the breakout box and monitoring the ignition system signals.
4BUOGX-119
B-1 1 2.3L IGNITION SYSTEM . ENGINE CONTROL SYSTEM
X210 BRAKE ONIOFF (BOO) B-212SHIFT LOCK ACTUATOR B-2491NERTIA FUEL SHUTOFF 8-1009 FUELPUMP/FUELGAUGE 51002 VEHICLE SPEED SENSOR X-01 ENGINE COMPARTMENT FUSE/RELAY BOX (DPHJ)
SWITCH (MA) (MA) (IFS) SWITCH (MA) SENDER (RL) VSS) (ECE) X-02 Iff FUSE PANEL (MA)
X.114 COMMON CON. (ECS)-(ECO
X-124 COMMON CON. (ECS)-(DPHJ)
X-130 COMMON CON. (ECS).(ECE)
rHl (
-
2 @
%I36 COMMON CON. (MA)-(DPHJ)
X-X)1 COMMON CON. (MA)-(CLSE)/(ILFl
XI007 COMMON
CON. (CLSQlflLF! -IRL!
8-111 POWERTRAIN CONTROL

MODULE (PCM) (ECS)
- -- -
B-1a
ENGINE
2.3L
XI24
IGNITION SYSTEM
R ECS)
I
-
I
SYSTEM
R
(DpW)
R
(DPHJ) R (ECS) R (ECS)
1
R (ECS) R (ECS) R (ECS) R (ECS)
(IAC) VALVE
SOLENOID
Bffl
(DPMI)
BILG
(DPKI) 1 (I?&)
WILE
(ECS)
BW P
(ECS) CONTROL
ENGINE
SYSTEM
1 (SECTION B-2a)
BILG GYM
(ESC) (ECS)
0 8
1 B41 3.OL IGNITION SYSTEM ENGINE CONTROL SYSTEM I
X-210 BRAKE ONIOFF (BOO) B-212SHIFT LOCK ACTUATOR B-249lNERTlAFUEL SHUTOFF 0-1009 FUEL PUMPIFUELGAUGE E l 0 0 2 VEHICLE SPEED SENSOR X-01 ENGINE COMPARTMENTFUSEIREW BOX (DPHJ)
SWITCH (MA) (MA) (IFS) SWITCH (MA) SENDER (RL) (VSS) (ECE) X-02 I/P FUSE PANEL (MA)
X-114 COMMON CON. (ECS).(ECE)
<=)
x124 COMMON CON. (ECS)-(DPHJ)
X-129 COMMON CON. (ECS) -(ECE)
I , , ]
@
X-136 COMMON CON. (MA).(DPHJ)
%2Ol COMMON CON. (MA)-(CLSE)/(ILF)
X-Zl3lGNITlONSWTCH
X-1007 COMMON c0k (CLSE)/(ILF) -(RL)
u"- SEE COMMON CONNECTOR US1 - SECTION X
B-4a 3.OL IGNITION SYSTEM ENGINE CONTROL SYSTEM 1
X-124
(SECTION B 4 @
R 8
ENGINE CONTROL
(DPW R (ECSI SYSTEM
B-105 (SECTION B-6)
MASS AIR
FLOW CONTROL FLoW (MAF)
SENSOR (IAC) VALVE SENSOR
8-105
SOLENOID
BR/LB T/B LG/O T W BWY
(ECS) (ECS) (ECS) (ECS) (ECS) (ECS)
BAG GYN
1 (ECS) (ECS) X-114
(ESC) (ECS)
Q
X-210 BRAKE ONIOFF (BOO) 8-212 SHlFl LOCK ACTUATOR 8.249 INERTIA FUEL SHUTOFF 8.1009 FUEL PUMPIFUELGAUGE 8-1002 VEHICLE SPEED SENSOR X-01 ENGINE COMPARTMENT FUSVRELAY BOX (DPW)
SWITCH (MA) (MA) (IFS) SWITCH (MA) SENDER (RL) vSS) (ECE) X-02 IIP FUSE PANEL (MA)
X.114 COMMON CON. IECS)-(ECE)
X-124 COMMON CON (ECS)-(DPHJ)
X-129 COMMON CON. (ECS)-(ECE)
X-136 COMMON CON (MA)-(DPMI)
I X-201 COMMON CON (MA)-(CLSE)/(ILF)
XI007 COMMON CON (CLSE)/(ILF) -(RL)
SEE COMMON CONNECTOR USI - SECTION x
8-111 POWERTWIN CONTROL

MODULE (PCMJ (ECS) m
B W
(ECS)
T/8
(ECS)
LGIO
(ECS)
T
(ECS)
W
(ECS)
BWY
(ECS) 1%:

BNV B/w BAN BNV B/W
X.134 COMMON CON. (MA)-(OPW)

ELECTRONIC IGNITION SYSTEM G
El (High Data Rate) Diagnostic Cabl (49 UNO1 057)
For 2.3L, 3.OL and 4.OL
I EI-HIGH DATA RATE

IGNITION DlAGNOSTlC
CABLE
IDM PUSH BUITON
(OPENS IDM CIRCUIT
WHEN PUSHED)
' \
SPOUT PUSH B m O N DRIVER TEST
~ ~ ~ S p ~ ~ ~ ~ ~ (NOT
I RUSED)
C U I T
TROUBLESHOOTING
2.3L, 3.OL & 4.OL El (High Data Rate) Ignition System
NO START (NO SPARK)

STEP
-
INSPECTION ^ I- ACTION
--
looseness, shorting or other damage

1
Check high-tension leads for insulation damage, Yes Reinstall plugs and leads
Go to step 2
Remove and check spark plugs for damage, wear,
carbon deposits and proper plug gap
Examine all wiring harnesses and connectors
for damaged, burned or overheated insulation, Replace damaged component
damaged pins and loose or broken conditions
Check crank shaft position sensor shield
connector
Are spark plugs and leads OK? 1-
Key ON, engine OFF 1 Yes Go to step 8.
Disconnect Scan Tool or NGS from DLC
Inspect PCM for damaged or pushed out pins,
corrosion or loose wires.
Install 104-pin breakout box and connect PCM.
Caution: Do not use an incandescent lamp to Go to step 3.
check crankshaft position (CKP) sensor circuit.
The lamp will prevent the circuit from operating.
Measure voltage between Pin 21 at 104 pin
breakout box and ground
Is voltage between 1.O and 2.0 volts?
C-
. --
Key OFF 1 Yes
I
Go to step 4.
Disconnect CKP sensor from the vehicle harness
connector
Key ON, engine OFF
Measure voltage between Pin 21 at 104 pin Bias fault
breakout box and ground Go to step 16.
Is voltage greater than 1.0 volt but less than 2.0
volts?
INSPECTION I ACTION I
Key ON, engine OFF --
CKP sensor (Short to ground)
Measure voltage between Pin 22 at 104 pin Bias fault
breakout box and ground Go to step 5
Is voltage between I.O and 2.0 volts?
Was bias voltage reading in step 4 less
than 1.0 volt? Go to step 6
Key OFF
Disconnect PCM from 104 pin breakout box
Measure resistance between Pin 22 at 104 pin repair short in CKP(-)
breakout box and ground circuit to ground
Is resistance areater than 1Ok ohms?
Key OFF
1 1 Yes Replace PCM
Key ON, engine OFF No Check connectors, repair short in CKP(-)

Measure voltage between Pin 22 at 104 pin circuit to power
breakout box and ground
Is voltaae less than 0.5 volts?
I 8 l Crank the engine and measure voltage between

Pin 21 and Pin 22 at 104 in breakout box
Is settled AC voltage reading greater than 0.4 volt?
1 1 Yes Go to diagnostic procedure
DTC P0351,0352.0353 or 0350

1 1 Yes Replace PCM
--
Crank the engine and measure voltage between
Pin 21 and Pin 22 at 104 pin breakout box
1 10 1
Is settled AC voltaae readina areater than 0.4 volt?
K~~OFF
Measure resistance between Pin 22 and Pin 21 at
1 y e s GO tostep 14
I 1 104 pin breakout box

I Yes / Go to ster, 15 (Low resistance fault)
Was the resistance from step 10 less than
300 ohms? 1 / NO GOto step 12 (High resistance fault)
Key OFF
Install El diagnostic harness to 60 pin breakout
box and CKP sensor and vehicle harness
Connect El diagnostic harness negative lead
to battery, leave positive lead disconnected
For 6 Cylinder Applications:
Use El (High data rate) 6 overlay
Set El diagnostic harness box type switch to
"416 cylinder" position
For 2.3L Dual Plug Applications:
Use El (High data rate) 2.3L Dual Plug overlay
Set El diagnostic harness box type switch to
"8 cylinder" position
Measure resistance between J31 at 60 pin
breakout box and Pin 21 at 104 pin breakout box
Is resistance less than 1050 ohms?
1
1
STEP
-- -
13
14
[
-
1
Key OFF
-
Key OFF
--
Key OFF
-
-
--
INSPECTION
Measure resistance between J32 at 60 pin

breakout box and Pin 22 at 104 pin breakout
box
IS resistance less than 1050 ohms?
l5 Disconnect CKP sensor from vehicle harness

connector
-
Measure resistance between Pin 21 and Pin 22 at

104 pin breakout box
Is resistance
-- -- - -
MG1096-63
.
-
!
greater than 1000 ohms?
1.0 volt?
--
Key OFF
- -
-.
- -
Check trigger wheel and CKP sensor for damage

Is CKP sensor and trigger wheel OK?
Was bias voltage reading in step 3 less than
Measure resrstance between Pin 21 at 104

prn breakout box and ground
Is resrstance greater than 1Ok ohms?
%&,"Zct PCM from 104 in breakout box

Key ON, engtne OFF
Measure voltage between Prn 21 at 104 pin
breakout box and around
Is voltage less thai 0.5 volt?
--
Disconnect PCM from PCM tee, leave El diagnostic

harness connected to vehicle harness connector
-
-
Yes
No
--
-
1
P
1
I
Yes
No
Yes
NO
Yes
No
Yes
No
Yes
I
CKP(-)
ACTION
Low bias voltage fault

Go to step 17
High bias voltage fault
Go to step 18
Replace PCM
- --
Replace CKP sensor (High resistance)
Check connectors, repair open in CKP(-) circuit
Replace CKP sensor (No output from sensor)
1 Repair or replace damaged parts

I
pp~
Replace CKP sensor (Shortened sensor windings)

-
Check connectors, repair short in CKP(+) circuitto
Check connectors, reparr short In CKP(+) crrcurt

to ground
1I Replace PCM
o 1 Check connectors, reparr short in CKP(+) clrcurt
1
!
to ground
---
~-
6BUOGX-002
-
-
DTC: P0351, P0352, P0353, OR P0350lP1352, P1353,
P1354, P1360, P1361, P1362, P1364, OR PI365
STEP 1NSPECTlON ACTION
--
1 Note: Yes Ignition system OK

3.OL and 4.OL - Follow step 1 through step 24 Check other system
2.3L - Follow step 25 through step 58
Check for spark at all high-tension leads while
cranking -
When using the timing light, place the grooved No Go to step 2
end as close as possible to the plug boot
Very weak or no flashing may be caused by
a fouled plug
Is spark consistent on all high-tension leads
(one spark per crankshaft revolution)?
2 Check high-tension leads for insulation damage, Yes Reinstall plugs and leads
looseness, shorting or other damage Go to step 3
Remove and check spark plugs for damage, wear,
carbon deposits and proper plug gap
Examine all wiring harnesses and connectors for
damaged, burned or overheated insulation,
damaged pins, and loose or broken conditions
Check crankshaft position (CKP) sensor shield No Repair or replace damaged co~nponent
connector
Are spark plugs and high-tension
-
leads
-
OK?
3 Warning: Yes Go to step 4
Never connect PCM t o 104 pin breakout box
when performing El diagnostics
i
Key OFF
Install El diagnostic harness to 60-pin breakout I
box and set switch to "416 cylinder" position
Install the coil tee (the tee is blue with 4 pins) No Check connectors, repair open in coil PWR circuit
Use El (High data rate) 6 overlay
Key ON, engine OFF
Measure voltage between J5 and J7 at 60 pin
breakout box
4 Key ON, engine OFF Yes Go to step 5
Measure voltage between J3 and J7 at 60 pin . -- -
breakout box No , Go to step 16
Is voltage greater than 10.0 volts? .
5 Key ON, engine OFF Yes I Go to step 6

i
Measure voltage between J6 and J7 at 60 pin ..l---_____
breakout box No Go to step 18
Is voltage greater
---
than 10.0 volts? - - ---A

Measure voltage between J10 and J7 at 60 pin - - -
Is voltage greater than 10.0 volts? - -
breakout box and J7 at 60 pin breakout box No Check connectors, repair open in coil circuit
L
I STEP I INSPECTION
Key ON, engine OFF Yes Go to step 9

~- I

Measure voltage between Pin 78 at 104 pin -
breakout box and J7 at 60 pin breakout box NO Check connectors, repair open in coil circuit
Is voltage greater than 10.0 volts? I
Key OFF Yes Go to step 11

Disconnect the coil from the coil tee
Leave El diagnostic harness coil tee connected Go to step 22
to vehicle harness coil connector
Key ON, engine OFF
breakout box
1 Is voltage less than 0.5 volt?
Is voltaae less than 0.5 volt?
Measure voltage between J10 and J7 at 60
pin breakout box
Caution: Yes Go to step 14
(2.3L and 3.OL) When performing this test
procedure, remove El diagnostic connector
from CKP sensor and vehicle harness
Reconnect vehicle harness to CKP sensor
Connect El diagnostic harness positive lead No Replace PCM
to battery
connect-incandescent test lamp between J1 and
A-
J3 at 60 pin breakout box
Crank the engine
Does lamp blink consistently and brightly (one blink
per engine revolution)?
--
Caution: Yes Go to step 15
Connect incandescent test lamp between J1 and Replace PCM
Crank the engine
Caution: Yes Replace coil pack (No high voltage output)
procedure, remove El diagnostic connector from
CKP sensor and vehicle harness
Connect test lamp between J1 and J10 at 60 pin No Replace PCM
breakout box
Crank the engine
per revolution)?
STEP INSPECTION ACTION 7

Key OFF Yes Replace coil pack
Disconnect coil from coil tee, leave El diagnostic
harness connected to vehicle harness coil
connector Go to step 17
Measure resistance between J7 and J3 at 60
pin breakout box
Is resistance greater than 2k ohms?
Key OFF Yes Replace PCM
Disconnect PCM from vehicle harness connector
Measure resistance between J7 and J3 at 60 No Check connectors, repair short in coil circuit to ground
pin breakout box
-r
Is resistance greater than 1Ok ohms?
Key OFF Yes Replace coil pack
T-
connector No Go to step 19
pin breakout box
Is resistance greater than 2k ohms?
Measure resistance between J6 and J7 at 60 No Check connectors, repair short in coil circuit to ground
pin breakout box
Key OFF Yes 1 Replace coil pack
connector No Go to step 21
pin breakout box
..
Is resistance areater than 2k ohms?
21 Key OFF Yes Replace PCM
Measure resistance between J7 and J10 at 60 short in coil circuit to ground
pin breakout box
Key ON, engine OFF
Measure voltage between J3 and J7 at 60 No Check connectors, repair short in coil circuit to power
pin breakout box
Is voltage less than 0.5 volt? --
Key ON, engine OFF
Measure voltage between J6 and J7 at 60 No Check connectors, repair short in coil circuit to power
pin breakout box
Is voltaae less than 0.5 volt?
Key OFF
1 1
Yes Replace PCM
Key ON, engine OFF

Measure voltage between J10 and J7 at 60 Check connectors, repair short in coil circuit to power
pin breakout box
25 Check for spark at all high-tensionleads while Yes Ignition system is OK
cranking Check other system
When using the timing light, place the grooved end ---
as close as possible to the plug boot Go to step 26
Very weak or no flashing may be caused by
a fouled plug
Is spark consistent on all high-tension leads (one
spark per crankshaft revolution)?
MGI 097-83
- - - -
STEP
-- -
INSPECTION
--
ACTION I
26 Was spark consistent on all right
(one spark per crankshaft revolution)?
Note:
Go to step 27
I
Check spark at spark plugs
--
Go to step 43
I
Check left side coil pack high-tension leads for Reinstall plugs and leads
insulation damage, looseness, shorting or other Go to step 28
damage
Remove and check left side spark plugs for
damage, wear, carbon deposits and proper plug
I 1 Left coil plugs and leads are attached to the

gapcoil ~ a c k
left 8

No Repair or replace damaged component

damaged pins and loose or broken condition
Are spark plugs and leads OK?
Warning: Yes Go to step 29
Never connect PCM to 104 pin breakout
box when performing El diagnostics
Key OFF
Install El diagnostic harness to 60 pin breakout
box
,
Install the left coil tee (the tee is yellow)
Connect El diagnostic harness negative lead Check connectors, repair open in coil PWR circuit
, to batterv
Use 2 3 i El (H~ghdata rate -8) overlay
Set El harness type sw~tchto "8 cyl~nder"
posrtlon
Key ON, englne OFF
Measure voltage between J 11 and J 7 at 60
pin breakout box
Is voltage greater than 10.0 volts? -
29h $ O ~ . e n ~ I n eOFF Yes Go to step 30
1
Measure voltage between J10 and J7 at --
60 prn breakout box No Go to step 37
-- I Is voltage greater than 10 0 volts?
- -- --- .-
-7
30 Key ON, englne OFF Yes Go to step 31

asure voltage between J18 and J7 at -- - -- -
pin breakout box

voltage greater than 10 0 volts? - ~- -
I - - - - - -
Yes 1 Go to step 32
en Pln 78 at 104 pin --
----
,-- - -- - --
-- -
60 p ~ breakout
n box No 1 Check connectors, repalr open ~ncoll c~rcult
10 0 volts?
- -- - -
Yes Go to step 33
(
I(Yes-
Measure voltage between Pln 104 at 104 ptn -- -- - -- -- ---
breakout box and J7 at 60 pln breakout box No Check connectors, repalr open ~ncod c~rcult
-- ., -
I Is voltaae -
areater than 10.0 volts?
- -- -- -- -- -- -- -- --
Key OFF - GO to step 34

I
Disconnect the left cot1 pack from the coil tee I
Leave El diagnostic harness coll tee connected to
vehlcle harness left coil connector 1 No Go to step 41
Key ON, engrne OFF
I
Measure voltage between J10 and J7at 60
pln breakout box
34 Key ON, engine OFF
pin breakout box
j Is voltage less than 0.5 volt?
MG1097-84
STEP INSPECTION ACTION 7

Caution:
Connect El diagnostic harness positive lead to
battery
Connect incandescent test lamp between J1 and
Crank the engine
Caution:
Crank the engine
Der enaine revolution)?
Key OFF Yes / Go to step 38
connector
Measure resistance between J7 and J10 at
60 pin breakout box
I / Is resistance less than 2k ohms? I I
Disconnect PCM from vehicle harness
connector
Measure resistance between J7 and J10 at No Check connectors, repair short in c o ~circuit
l to ground
60 pin breakout box
harness connected to vehicle harness coil - - .~
connector No Replace left coil pack
60 pin breakout box
Is resistance less than 2k ohms?-
---- -

connector
Measure resistance between J7 and J18 at No Check connectors, repair short in coil circuit to ground
60 pin breakout box
Key OFF Replace PCM
connector - - - -
Key ON, engine OFF Check connectors, repair short in coil circuit to power
Measure voltage between J10 and J7 at
60 pin breakout box
Is voltage less than 0.5 volt? -. -pp-pp--p
Key OFF Replace PCM

connector
Key ON, engine OFF Check connectors, repair short in coil circuit to power
60 pin breakout box
, Is voltaoe less than 0.5 volt?
STEP ~
I
INSPECTION
I I
ACTION
Check right side coil pack high-tension leads for Yes Reinstall plugs and leads
insulation damage, looseness, shorting or other Go to step 44
damage
Remove and check right side spark plugs for
damage, wear, carbon deposits and proper plug gap I
/I %$; coil plugs and leads are attached

to the right coil pack
Repair or replace damaged component
damaged pins and loose or broken condition
Are spark plugs and leads OK?
Warning: Yes Go to step 45
Never connect PCM to 104 pin breakout
I
1
box when performing El diagnostics
Key OFF
Install El d~agnosticharness to 60 pin breakout
box
Install the right coil tee
Connect El diagnostic harness neqat~ve
to battery
- lead 1 - -
repair open in coil PWR circuit

Use 2.3L El (High data rate) overlay
Set El harness type switch to "8 cylinder"
position
Key ON, engine OFF
pin breakout box
Is voltage greater than 10.0 volts? - --- -- -- -

60 pin breakout box P o ' GO to step 53
volts?
Is voltage greater than 10.0- .
-
Key ON, engine OFF

1 60 pin breakoui box pi GO to step 55
47
Is voltaae areater than 10.0 volts?
Key ON, engine OFF
1 1
Yes Go to step 48
- -
Is voltage greater than 10.0 volts?- -
P
48 Key ON, engine OFF

Measure voltaae between Pin 52 at 104 Din
breakout box and J7 at 60 pin breakout box r ~ w c o n n e c t o r s repair
. open in coil c ~ r c z
-
Is voltaae areater
" than 10.0 volts?
49 Key OFF Yes Go to step 50
) Disconnect the right coil pack from the coil tee
Leave El diagnostic harness coil tee connected to
vehicle harness riaht coil connector I
Key ON, engine ~ F F No Go to step 57
Measure voltaae between J3 and J7 at
60 pln breakout box
50 Key ON, engine OFF Go to step 51
Measure voltage between J6 and J7 at I
60 pin breakout box No Go to step 58
Is voltaqe less than 0.5 volt?
STEP INSPECTION 1 ACTION I

Caution:
Connect El diagnostic harness positive lead
to battery
Crank the engine
per enaine revolution)?
Caution: Yes / Replace right coil pack
I / Reconnect vehicle harness to CKP sensor

N,G~P~- -
Crank the engine

Does lamp blink consistently and brightly (one blink ;
Go to step 54
harness connected to vehicle harness coil connector
60 pin breakout box
Is resistance less than 2k ohms?
Key OFF
No
I I Yes
Replace right coil pack
Replace PCM
connector
Measure resistance between J7 and J3 at No Check connectors, repair short in coil circuit to ground
60 in breakout box
I I harness connected to vehicle harness coii connector1 1 --
Measure resistance between J7 and J6 at ~ i ~ e p ~ right
u ccoile pack
60 pin breakout box
I / Is resistance less than 2k ohms? 1 1 I
+- I
connector
Measure resistance between J7 No Check connectors,repair short in coil circuit to ground
and J6 at 60 pin breakout box
Is resistance-greaterthan 1Ok ohms?
Key OFF
connector
Key ON, engine OFF No Check connectors, repair short in coil circuit to power
pin breakout box
Is voltage less than 0.5 volt? -.
Key OFF
connector
Key ON, engine OFF
Measure voltaae between J 6 and J7 at 60
T---
Yes
No
Replace PCM
Check connectors. repair short in coil circuit to ground

pin breakout b<x
MG1097-B7 6BUOGX-003
DTC: PI359
INSPECTION ACTION 1
Note: Yes / GO to step 2
Continuous memory DTC P I 359 indicates a loss of
spark output (SPOUT) inside PCM
Key OFF
Disconnect throttle position sensor connector I
Key ON, engine OFF I
No Check for "Reference Voltage" circuit
Measure voltaae between VREF circuit as SIG RTN
I circu~tat the throttle position sensor vehicle
I harness connector
i
Is voltage
- -
between 4.0 and 6.0 volts?- -
Is the crankshaft position sensor or trigger wheel Yes I Repair or replace as necessary
damaged, loose or misaligned? NO / Reolace PCM
I DTC: PO320
I STEP 1 INSPECTION 1 ACTION I
Note: Yes Repa~ror replace as necessary
Continuous memory DTC PO320 indicates two
successive erratic Profile lgnition Pickup (PIP)
pulses occurred inside PCM, resulting in a possible
engine miss or stall
Check for the following:
Loose wires/connectors
Arcing secondary ignition components No I For No starts: Go to "NO START" diagnostic
On-board transmitter procedure in section F
Note: For intermittent faults: Go to "INTERMITTENT"
Verify all 2-way radio installations diagnostic procedure in section F
Carefully follow manufacturer's installation All others: Replace PCM
instructions regarding the routing of antenna
and power leads
Intermittent fault
Are any of the above present?
DTC: P1351lP1358
INSPECTION 1 ACTION I
Note: YES Go to page ~ ' 3 3
Continuous memory DTC P1351/PI 358 indicates a
loss of lgnition Diagnostic Monitor (IDM) signal
occurred inside PCM.
Is vehicle a no start or is continuous memory DTC
P0350, P0351, PO352 or PO353 present
I Loss of IDM.
Replace PCM.
SECONDARY IGNITION SYSTEM DISPLAY
DIAGNOSIS
Procedure
1. Connect an engine analyzer to view parade display of
secondary ignition system.
2. Start the engine and slowly increase engine speed from
idle to 1,300 rpm.
3. Compare the engine analyzer display to the following
display illustrations in the Evaluation of Secondary
Display.
Note
The illustrations shown are for the 2.3L four cylin-
der model, but are typical for the 3.OL and 4.OL
engines.
4BUOGX-035
Evaluation of Secondary Display

FIRING
EVENNESS VOLTAGE
(HIGH TO LOW) I
AVERAGE
VOLTAGE I I Note
The 2.3L, 3.OL, and 4.OL B-Truck have th capability
of operating in a multi-strike mode (the spark plugs
are fired four (4) strikes per firing). The operating
modes are limited to about 1500 rpm. Although the
PCM provides these operating modes, the PCM
must also request them in order for the operating
modes to be activated. Result #1 through Result #5
display multi-strike operating modes.
Result 1
The average value of spark plug firing voltage is 20 kV or
less with evenness of spark plug firing voltage 8 kV or
less.
If the result is as indicated, the ignition system is OK.
Result 2
The average value of spark plug firing voltage is greater
than 20 kV with evenness of spark plug firing voltage
8 kV or less.
If the result is as indicated, check the following:
High tension leads for proper installation in coil
Resistance of high-tension lead
Spark plug gap (Refer to page G-43.)
Result 3
Evenness of spark plug firing voltage is greater than 8 kV.
Result 4
Consistently high spark plug firing voltage in one or
more cylinders.
High-tension lead connections (not firmly connected)
Resistance of high-tension leads (Refer to page G-46.)
Result 5
Consistently low spark plug firing voltage or stopping
spark line in one or more cylinders.
Fouled spark plugs
Grounded high-tension leads
IGNITION TIMING
Adjustment
Ignition timing is preset at 8-12' (10 +2") BTDC, and is
not adjustable.
5BUOGX-023
SPARK PLUGS
Removal IInstallation
1. Remove and install the high-tension leads, referring to
Removal Note. (Refer to page G-44.)
Caution
When the spark lead is to be pulled off, be sure to
pull on the boot itself, not the lead.
2. Remove and install the spark plug with a plug socket.

Caution
Be sure the socket fits squarely over the spark plug.
Note
If the original spark plugs are to be reinstalled, they
must be installed in the locations from which they
were removed.
3. Apply anti-seize compound or molybdenum-based lubri-

cant to the spark plug threads.
4. Tighten the spark plug to the specified torque.
Tightening torque:
2.3L13.OL: 9-20 N.m {I .O-1.9 kgf-m, 7-1 4 ft-lbf}
4.OL: 14-20 N.m (1.4-1.9 kgfem, 10-14 ft.lbf}
Note
Coat the entire interior surface of the high-tension
lead boot with a silicone dielectric compound or
equivalent.
5BUOGX-010
Note
1996 6-Truck uses double platinum enhanced
spark plugs for production. Both the ground (side)
and center electrode are enhanced with platinum.
You can also use spark plugs with the s rvice part
number suffix letter "PP" as replacement spark
plugs.
Note
Factory installed spark plugs are painted for left
and right bank. These plugsare not interchangeabl .
Spark plugs for Left bank: White marked
Spark plugs for Right bank: Dark Green marked
Service part can install at any place.
5BUOGX-026
Removal Note
High-tension lead
SQUEEZE
LOCKING TABS When removing leads from the coil packs, squeeze the
TO REMOVE locking tabs of the coil wire retainer and remove using a
twisting and pulling motion. Do not pull on the lead.
MG1038-A 5BUOGX-024
Spark test
1. Remove the spark plug.
2. Connect the spark plug to a high-tension lead.
3. Hold the high-tension lead and spark plug with insulated
pliers 5-10mm (0.20-4.39 in) from a ground.
4. Crank the engine and verify that there is a strong blue
spark.
5. If there is no spark, refer to page G-30.
I WEAR AND CARBON I Inspection

Spark plugs
Check the following points. If a problem is found, replace
the spark plug.
Damaged insulation
DAMAGE AND Worn electrodes
DETERlORATlON
Carbon deposits
If cleaning is necessary, use a plug cleaner or a wire
brush. Clean the upper insulator, also.
Damaged gasket
Burnt
Plug gap
Refer to the Vehicle Emission Control Information
(VECI) decal, located in the engine compartment for
spark plug gap.
4BUOGX-050
1 GAPBWDOED I OI FOULED '7

IDENTIFIED BY WET BLACK
IDENnFlED BY DEPOSIT BUILD- DEPOSITS ON THE INSULATOR
UP CLOSING GAP BETWEEN SHELL BORE ELECTRODES.
ELECTROMS.
CAUSED BY OIL OR CARBON CAUSED BY EXCESSIVE OIL
FOULING, REPLACE PLUG, OR. ENTERING COMBUSTON CHAMBER
IF DEPOSITS ARE NOT EXCESSIVE THROUGH WORN RINGS AND
THE PLUG CAN BE CLEANED. PISIDhlS, EXCESSIVE CLEARANCE
BETWEEN VALVE GUIDES AND
STEMS.& WORNOR WSE
BEARINGS. CORRECT OIL
PROBLEM. REPLACE THE PLUG
CARBON FOULED
1 N O W
IDENTIFIED BY BLACK. DRY FLUFFY IDENTIFIED BY MELTED ELECTRODES

CARBON DEPOSITS ON INSULATOR AND POSSIBLY BLISTERED INSULATOR.
TIPS, EXPOSED SHELL SURFACES AND IDENTIFIED BY LIGHT TAN OR GRAY METALLIC DEPOSITS ON INSULATOR
ELECTRODES. ceosrrs ON THE FIRING TIP INDICATE ENGINE DAMAGE.
CAUSED BY TOO COLD A PLUG. WEAK CAUSED BY WRONG TYPE OF FUEL.
IGNITION. DIRTY AIR CLEANER. INCORRECT IGNITION TIMING OR
DEFECTIVE FUEL PUMP. TOO RICH A ADVANCE. TOO HOT A PLUG, BURNT
FUEL MIXTURE, IMPROPERLY OPERATING VALVES OR ENGINE OVERHEATING.
HEAT RISER OR EXCESSIVE IDLING. REPLACE THE PLUG.
CAN BE CLEANED.
I
L r 1
OVORHf3llNG FUSED SPOT DEPOST
IDENTIFIED BY A W M E OR LIGHT
GRAY INSULATOR WITH SMALL
BLACK OR GRAY BROWN SPOTS IDENTIFIED BY MELED OR S P O W
AND WITH BLUISKBURNT DEPOSITS RESEMBLING BUBBLES OR
OF ELECTRODES. BUSTERS.
CAUSED BY ENGINE OVER- CAUSED BY SUDDEN ACCELERATKX.

HEATING. WRONG TYPE OF CAN BE CLEANED IF NOT EXCESSIVE.
FUEL, LOOSE SPARK PLUGS. TOO OTHERWlE REPLACE PLUG.
HOT A PLUG. LOW FUEL W W
PRESSURE OR INCORRECT
IGNmON TIMING. REPLACE
THE PLUG.
High-tension lead
,
:11p
.)I111 I . Measure resistance of the high-tension leads.
Specifications: less than 22.9 kR p. r 1m (3.28 ft)
2. If not as specified, replace the high-tension lead set.
IGNITION COIL ASSEMBLIES

I _1
MG1092-A 5BUOGX-027
1. Ignition coil
Removal Note ........................ page G-48
I I
MG1093-A 5BUOGX-028
1. Ignition coil
I I
MG1047-C 5BUOGX-029
1. Ignition coil
Removal note
lgnition coil (2.3L)
SQUEEZE
LOCKING TABS 1. Disconnect the high-tension leads from the ignition coils
TO REMOVE by squeezing the locking tabs on the lead by hand. Use a
twisting and pulling motion to tree the boot from terminal.
Do not pull on the wire.
2. Disconnect the harness connector from the ignition coil.
~ 3.Remove the screws and remove coil.
i
MG1038-A 5BUOGX-030
lgnition coil (3.OL)
1. Disconnectthe high-tension leads from the ignition coil by
squeezing the locking tabs on the lead by hand. Use a
twisting and pulling motion to free the boot from terminal.
Do not pull on the wire.
2. Disconnect the harness connector from the ignition coil.
3. Remove the bolt and the EGR vacuum regulator from the
ignition coil.
4. Remove the bolts and the ignition coil.
5BUOGX 031
lgnition coil (4.OL)

1. Disconnect the harness connector from the coil.
2. Disconnect the high-tension leads by squeezing the lock-
ing tabs to release the coil boot.
Note
On vehicles equipped with AIC, remove the air
conditioning tube-to-plenum bolt and move the
tube enough to gain access to the upper coil pack
bolts.
3. Remove the coil bolts and remove the coil.

4BUOGX-063
Installation note
lgnition coil assembly (2.3L)
1. Mount the ignition coil to its bracket and install screws.
Tightening torque:
5-7 N.m (51-71 kgf.cm, 44-66 in.lbf)
2. Reconnect engine harness electrical connector to the

ignition coil.
3. Insert each lead on the proper terminal of the ignition coil.
Make sure that the coil boots are fully seated and both
locking tabs are engaged.
Note
PARALLEL TO
CENTER LINE The terminals are identified on the ignition coils.
OF CRANKSHAFT Install wires as shown in the illustration. The 2.3L
firing order is 1-3-4-2for both ignition coil assem-
blies.
( FRONT OF ENGINE 0
Ignition coil (3.OL)
1. Position the ignition coil on the upper intake manifold/
throttle body assembly.
2. Install the bolts.
Tightening torque:
16-20 N.m (1.7-1.9 kgf-m, 12-14 ftdbf}
3. Position the EGRvacuum regulator on the ignitioncoil and

install the bolt.
Caution
Connect the vacuum hoses to the original position
on the EGR vacuum regulator.
Tightening torque:
8-1 2 N-m(0.8-1 .I kgf-m, 6-44 ft-lbf}
4. Connect the harness connector and the high-tension

leads.
:
MGllo4-A
Whenever a high tension lead is removed for any
reason from a spark plug or ignition coil, or a new
lead is installed, apply a silicone dielectric com-
pound to the lead boot prior to installation.
5BUOGX-033
Ignition coil (4.OL)
1. Position the coil on the mounting bracket.
Tightening torque:
5-7 N-m (51-71 kgf-cm, 44--62 in-lbfj
2. On vehicles equipped with AIC, reposition the air condi-

tioning tube.
Tightening torque:
2 6 - 4 2 N-m (2.6-3.1 kgf-m, 19-24 ft-lbf)
3. Connect the high-tension leads and the harness connec-

tor to the ignition coil.
5BUOGX-034
CRANKSHAFT POSITION SENSOR

Inspection
1. Connect SST (104 pin breakout box) to the PCM and
vehicle harnesses.
2. Crank the engine and measure voltage between Pin 21
and Pin 22 at breakout box.
3. Verify that the AC voltage is greater than 0.4 volt.
4. If voltage is not as specified, go to procedure 5. If voltage
is OK, crankshaft position sensor is OK.
5. Key OFF and disconnect the PCM from the breakout box.
6. Crank the engine and verify that the AC voltage is greater
than 0.4 volt between Pin 21 and Pin 22.
7. If voltage is not as specified, go to procedure 6. If voltage
is OK, replace PCM.
8. Key off and measure resistance between Pin 21 and
Pin 22 at breakout box.
Specification: 300--800Cl
9. If resistance is not as specified, check the wiring harness.

If the wiring harness is OK, replace the CKP sensor. If the
resistance is OK, go to procedure 10.
10. Check trigger wheel and CKP sensor for damage.
11. If CKP sensor and trigger wheel is OK, replace CKP
sensor. If any damage are found, repair or replace
damaged posts.
5BUOGX-035
Removal
2.3L
2. Remove the generator.
4. Remove water outlet tube.
5. Disconnect the crankshaft position sensor harness connector.
6. Remove the crankshaft position sensor bolt.
7. Pry the crankshaft position sensor from the engine front cover
FRONT OF ENGINE
MG1094-A Q
- 5BUOGX-036
3.0L 14.0L
2. Raise vehicle on a hoist. (3.OL only).
3. Disconnect the crankshaft position sensor harness
connector from the wiring harness.
4. Remove the crankshaft position sensor screws and
remove the sensor.
Installation
2.3L
Note
Engine front cover design precisely locates crank-
shaft position sensor so no adjustment is required.
1. Position the crankshaft position sensor and install the

retaining bolt.
Tightening torque:
8-12 N-m (0.8-1.1 kgf-m, 6--8 ft.lbf)
2. Connect the harness connector.

3. Install the water outlet tube with a new O-ring and install
the bolts.
Tightening torque:
10.5 N.m (1-1 kgfem, 8 ft-lbf}
4. Install the generator.

5. Fill the cooling system.
4.0L 3.0L 1 4.0L

1. Position the crankshaft position sensor on engine.
2. Install the two sensor screws.
Caution
Do not overtighten crankshaft position sensor
screws.
CRANKSHAFT
POSITION Tightening torques:
SENSOR
(CKP) 3.OL: 5-7 N-m (46-70 kgfecm, 4 0 - 4 1 in.lbf)
CONNECTOR 4.OL: 9-1 2 N-m (92-1 21 kgfecm, 75-1 06 inelbf)
3. Lower vehicle. (3.01- only).

4. Route the sensor harness and connect the harness
connector.
A-2 FOR M/T STARTING AND CHARGING SYSTEM
rr 3.OL
LLI 2.3L
mm ANTI-THEFT
ppppp
STARTER RELAY (DPHJ) A-206 CLUTCH PEDAL A-168 GENERATOW A-169 GENERATOW GENERATOR / W1 ENGINE COMPARTMENT FUSEIRELAY BOX (DPHJ)
POSITION (CPP) REGULATOR (ARS) REGULATOR (ARS) REGULATOR (ARS)
SWITCH (MA) X02 IIP FUSE PANEL (MA)
X03 RELAY BOX #1 (MA)
X.124 COMMON CON (ECE)-(ECS)
X-129 COMMON CON (ECE) (ECS)
XI30 COMMON CON (DPHJ)-(ECS)
'
X134 COMMON CON (MA)-(DPHJ)
X I 3 6 COMMON CON (MA)-(DPKI)
XI39 COMMON CON (DPHJ)-(ARS)
X 213 IGNITION SWITCH (MA)
SEE COMMON CONNECTOR LIST - SECTION X
A+7 STARTER MOTOR A 4 8 STARTER MOTOR
...WIO
W/
ANTI-THEFT
STARTING SYSTEM
STARTER RELAY
lnspection (on-vehicle)
1. Check the starter relay housing ground.
2. Place the transmission in P or N (AT) or depress the clutch
pedal (MT).
3.Turn the ignition switch to START and measure the
voltage between the starter relay start terminal and the
relay housing ground. Measure the voltage between the
output terminal and relay housing ground.
Specification: 12.00-1 2.45V
4. If not as specified, check the wiring harness, ignition

switch, anti-theft relay, clutch pedal position switch (MT),
and parktneutral position switch (AT). If OK, replace the
starter relay.
STARTER
Inspection (on-vehicle)
1. Measure the battery voltage.
Specification: Above 12.4V
2. Crank the engine, and verify that the starter turns smoothly.
3. If the starter does not turn, check the voltage at Terminal
B and Terminal S, with the ignition switch in START
and the clutch pedal depressed (MT) or transmission in
park or neutral (AT).
4. If the voltage is more than 8V, remove and inspect the
starter. If the voltage is less than BV, check the wiring
harness, ignition switch, anti-theft relay, starter relay,
clutch pedal position switch (MT), and parklneutral
position switch (AT).
5BUOGX-041
Warning
When servicing the starter or performing any maintenance in the area of the starter, note that
the heavy gauge input lead connected to the starter solenoid is hot at all times. Make sure the
protective cap is installed over the terminal and is replaced after service.

2. Raise the vehicle on a hoist, and support it with safety stands.
3. Remove the starter, referring to Removal Note. (Refer to page G-57.)
STARTING SYSTEM
R moval Note
Starter
1. Remove the Terminal B nut and disconnect the push-on
connector frorri the magnetic switch.
Caution
When disconnecting the hardshell connector at
Terminal S, grasp the plastic shell and pull off.
Do not pull on the wire. Be careful to pull straight
off to prevent damage to the connector and
Terminal S. If any part of the connection is
damaged, replace the damaged components.
2. Remove the upper and lower bolts.

3. Remove the starter.
4BUOGX-095
Installation Note
Starter
1. Position the starter motor and install the upper and lower
bolts.
Tightening torque:
21-28 N.m (2.1-2.7 kgfem, 16-21 ft-lbf}
2. Connect the magnetic switch connector. Be careful to

push straight on and make sure the connector locks in
position with a notable click or detent.
3. Install the Terrninal B nut.
Tightening torque:
11-13 N.m (1 .l-1.3 kgf-m, 91--122 in-lbf)
4. Replace the red magnetic switch safety cap.

5BUOGX-042
Performance Inspection
No-load test
Caution
Make sure that the starter is securely mounted in a
bench vise while testing, or the starter will move or
jump.
1. Connect a circuit as shown. (Starter will run at no-load.)

2.Turn the rheostat to the maximum counterclockwise
position (no current flowing through ammeter).
3. Record the voltage reading on the voltmeter.
MG 1020.~1 5BU0GX-043 4. Disconnect the starter from the battery.
5. Reduce the resistance of the rheostat until the voltmeter
indicates the same reading as that obtained while the
starter was running.
6. Record the current draw reading on the ammeter.
Specification: 70 +I 0A
7. If current exceeds specification, check armature, brush

and brush holder, and bearings.
G STARTING SYSTEM
-
Disassembly / Assembly
1. Remove the positive brush connector from magnetic switch Terminal M.
2. Remove in the order shown in the figure, referring to Disassembly Note.
3. Inspect all parts and replace if necessary.
4. Install in the reverse order of removal, referring to Assembly Note.
1
MG1056-C 5BUOGX-047
1. Magnetic switch 7. Lever and housing seal
Inspection ............................... page G-60 8. Front cover
2. Rear cover 9. Stop ring and retainer
3. Brush holder assembly 10. Pinion and reduction gear
Disassembly Note .................. page G-59 Inspection ............................... page G-62
Assembly Note ....................... page G-59 Assembly Note ....................... page G-53
Inspection ............................... page G-61 11. E-ring
4. Armature 12. Internal gear
Inspection ............................... page G-61 Inspection ............................... page G-62
5. Planetary gears 13. Shaft
Inspection ............................... page G-62 14. Spring
6. Starter frame
STARTING SYSTEM
Disassembly Note
Brush holder assembly
1. Remove the brush spring and pull the brushes loose from
REMCWE RIVET the brush holder.
HEAD AND PUNC 2. Remove the brush holder assembly.
-\\\\ RIVET OUT
3. Remove the front cover housing and the plunger lever
return spring.
4. Remove the starter drive plunger lever pivot pin, lever and
remove the armature.
5. Remove the ground brush rivet head with a file or chisel
and remove the rivet with a 118-in punch.
6. Cut the brush leads from the field coils as close to the filed
connection point as possible.
Assembly Note
Pinion and reductiori gear
Partially fill the rear cover housing bearing bore with
grease (approximately 114 full). Install the pinion and
reduction gear assembly in the housing, making sure to
line up the bolt holes in the gear assembly and the
housing.
4BUOGX-100
Brush holder assembly

BRIGHTEN THIS AREA
1. Position the new field brush lead on the field coil connec-
tion. Position and crimp the clip provided with the brushes
to hold the brush lead to the connection. Solder the lead
clip and connection together using rosin core solder. Use
a 300 watt iron.
2. Rivet the ground brush lead to the frame with rivets
provided in the brush kit.
3. Clean the commutator with sandpaper.
4. Install the armature in the starter frame.
5. Install the starter plunger lever to the frame and starter
drive assembly. Install the pivot pin.
G STARTING SYSTEM
6. lnstall the brush holder.
7. Insert the brushes in holder.
8. lnstall the brush springs.
9. lnstall the rear cover.
10. lnstall the two through-bolts.
Tightening torque:
5-10 N.m (51-102 kgfecm, 4 4 - 4 8 in-lbf)
11. Install the starter drive plunger lever cover and tighten
the screw.
Inspection
Magnetic switch
1. Remove the magnetic switch from the starter.
2. Check for continuity between Terminals S and M.
3. Check for continuity between Terminal S and the body.
4. Check for no continuity between Terminals B and M

5. Replace the magnetic switch if not as specified.
STARTING SYSTEM
Brush and brush holder
1. Checkfor no continuity between each insulated brush and
the plate. Replace the brush holder if there is continuity.
2. Measure the force of the brush spring by using a spring
balance.
Spring force: 18N (1.83 kgf, 4.04 Ibf}
3. Replace the spring if not as specified.
Brush
If a brush is worn almost to, or beyond, the wear limit,
replace all of the brushes.
Brush length: 16.8mm (0.66 in)
Armature
1. Check for no contirluity between the commutator and the
core. Replace the armature if there is continuity.
I
MG1024-A
2. Check for no continuity between the commutator and the
shaft. Replace the armature if there is continuity.
3. Inspect the armature windings for broken or burned insu-
lation and unwelded or open connections.
STARTING SYSTEM
4. Place the armature on V-blocks, and measure the runout
by using a dial indicator.
If the runout is not within the specification, replace the
armature.
Maximum Runout: 0.12mm (0.005 in)
5. If the commutator surface is dirty, wipe it with a cloth; if it

is rough or out of round, replace the armature.
I
1 Note
MGlO26-A
1
4BUOGX-105
Do not wash the armature with solvent.
Internal gear and planetary gears
Check for wear and damage. Replace as necessary.
4BUOGX-106
Yoke
Check for damage. Replace as necessary.
4BUOGX-107
Pinion and reduction gear

Check for wear and damage. Replace as necessary.
NORMAL WEAR SMALL WEAR

PAlTERN PATTERN
MG1027-A
MILLED CONDITION EXCESSlV

WEAR ON 2 OR 3 TEETH
MILLED TOOTH-METAL BUILD

WILL NOT PERMIT ENGAGEMENT
MILLED GEARS
028-A 4BUOGX-
STARTING SYSTEM
CLUTCH PEDAL POSITION SWITCH (MT)
This system is similar to that of the parWneutral position
switch on an AT vehicle. (Refer to Section K.)
If the clutch pedal is not depressed during starting, battery
power will not be supplied to the starter and it will not
operate.
4BUOGX-109
Inspection
1. Disconnect the clutch pedal position switch connector.
2. Connect a circuit tester to the switch.
3. Check for continuity.
4. Replace the switch, if necessary.
Released 1 No
MGI 075-A
CLUTCH
INDEX ........................................................... H- 2
OUTLINE ...................................................... H- 3
SPECIFICATIONS ..................................... H- 3
TROUBLESHOOTING GUIDE ..................... H- 3
CLUTCH FLUID ............................................ H- 4
INSPECTION ............................................. H- 4
REPLACEMENT ........................................ H- 4
AIR BLEEDING .......................................... H- 4
CLUTCH PEDAL ........................................ H- 6
ADJUSTMENT ........................................... H- 6
REMOVAL / INSTALLATION ..................... H- 6
CLUTCH PEDAL POSITION SWITCH ......... H- 7
CLUTCH MASTER CYLINDER .................... H- 8
AIR BLEEDING (REFER TO PAGE H-4)
CLUTCH RELEASE CYLINDER .................. H- 9
AIR BLEEDING (REFER TO PAGE H-4)
OVERHAUL ............................................... H-10
INSPECTION ............................................. H-I1
CLUTCH UNIT .............................................. H-12
REMOVAL / INSTALLATION ..................... H-12
CLUTCH COVER ........................................ H-15
INSPECTION ............................................. H-15
CLUTCH DISC .............................................. H-15
INSPECTION ............................................. H-15
CLUTCH RELEASE COLLAR ..................... H-15
INSPECTION ............................................ H-15
PILOT BEARING .......................................... H-16
INSPECTION ............................................. H-16
FLYWHEEL .................................................. H-16
INSPECTION ............................................. H-16
5BUOHX-001
H INDEX
INDEX
FLUID SPECIFICATION
FMVSSIIG DOT-3
FLUID LEVEL
EVEN WITH STEP
TRANSMISSION SERVICE,
SECTION J1
I
FRONT OF VEHICLE
I
MH1000-C
1. Clutch pedal 6. Clutch cover
Adjustment ............................. page H- 6 Removal / Installation ............. page H-12
Removal / Installation ............. page H- 6 Inspection ............................... page H-15
2. Clutch pedal position switch 7. Clutch disc
Removal / Installation ............. page H- 7 Removal / Installation ............. page H-12
3. Clutch master cylinder Inspection ............................... page H-15
Removal / Installation ............. page H- 8 8. Pilot bearing
Air bleeding ............................ page H- 4 Removal / Installation ............. page H-12
4. Clutch release cylinder Inspection ............................... page H-16
Removal / Installation ............. page H- 9 9. Flywheel
Overhaul ................................. page H-10 Removal / Installation ............. page H-12
Inspection ............................... page H-11 Inspection ............................... page H-16
5. Clutch release collar
Inspection ............................... page H-15
OUTLINE, TROUBLESHOOTING GUIDE H
OUTLINE
SPECIFICATIONS
-
Item
Enginemransaxle 2.3L 71
M50D
4.0L
--
Clutch control Hydraulic
--
Clutch cover Diaphragm spring
Type --
Suspended
Clutch pedal Free play Automatically self-adjusting
Pedal position Not adjustable
Clutch fluid FMVSS116 DOT 3
MH1020-B 4BUOHX-003
Note
4BUOHX-037
Problem Possible cause Action Page
Slipping Clutch disc facing worn Replace H-12
Clutch disc facing surface hardened or oiled Repair or replace H-12,15
Clutch cover damaged Replace H-12
Diaphragm spring damaged or weakened Replace H-12
Clutch pedal sticking Repair or replace H- 6
Flywheel damaged Repair or replace H-12,16
Poor Excessive runout or damaged clutch disc Replace H-12
disengagement Clutch disc splines rusted or worn Remove rust or replace H-12
Oil on clutch disc facing Repair or replace H-12,15
Diaphragm spring weakened or damaged Replace H-12
Clutch cover warped Replace H-12
Insufficient clutch fluid Add fluid H- 4
Leakage of clutch fluid Locate and repair or replace -
Pilot bearing worn or damaged Replace H-12
Air in system --
Bleed air H- 4
- -
Vibration of clutch Oil on clutch disc facing Repair or replace H-l2,15
when accelerating Torsion springs weakened Replace H-12
Clutch disc facing hardened or damaged Repair or replace H-l2,15
Clutch disc facing rivets loose Replace H-12
Clutch cover damaged or has excessive runout Replace H-12
Flywheel surface hardened or damaged Repair or replace H-12,16
Loose or worn engine mount Tighten or replace -
Clutch pedal Pedal shaft not properly lubricated Lubricate or replace H- 6
sticking Damaged clutch master cylinder Replace H- 8
Clutch release collar seized at clutch release cylinder
-- Replace - H- 9
Abnormal noise Clutch release collar damaged Replace H- 9
Poor lubrication of release collar sleeve Lubricate or replace H- 9
Torsion springs weakened Replace H-12
Excessive crankshaft end play Repair Refer to
Sections
B1, B2, B3
Pilot bearing worn or damaged Replace 1 H-12
Poor lubrication of clutch system Lubricate 1 H- 6
MH1021-C 5BUOHX-003
CLUTCH FLUID
CLUTCH FLUID
INSPECTION
1. Verify that the fluid level in the reservoir is at or above the
CYLINDER RESERVOIR step in the translucent reservoir body.
2. If the fluid level is extremely low check the clutch system
for leakage.
REPLACEMENT
I ( Note
The fluid in the reservoir must be maintained at the
MH1001-A 4BUOHX-005
314 level or higher during replacement.
Caution
Becareful not to spill the fluid on a painted surface.
If spilled, wipe it off immediately.
Use only the specified type of fluid.
Do not mix different brands of fluid.
Do not reuse the drained clutch fluid.
4BUOHX-006
AIR BLEEDING
In-Vehicle Bleeding Procedure
1. Disconnect the clutch pipe from the transmission using
Clutch Disconnect Tool T88T-70522-A or equivalent, by
MALE COUPLING 1\\ ' sliding the clutch white plastic sleeve toward the clutch
release cylinder while applying a slight tug on the clutch
pipe.
2. Clean dirt and grease from around the reservoir cap.
3. Remove the cap and diaphragm and fill the reservoir to
the step with the specified fluid. Brake fluid must be
certified to DOT 3 specification.
I
MHIOOS-C 4.Using a small screwdriver, depress the internal
mechanism of the male coupling to open the valve.
While continuing to hold the valve open, slowly depress
the clutch pedal to the floor and hold.
5. Remove the screwdriver from the coupling, closing the
valve.
6. Release the clutch pedal.
7. Refill the reservoir to the step.
Note
The reservoir must be kept full at all times to ensure
that there will be no additional introduction of air to
the system.
8. Repeat steps 4 through 7.

9. Install the reservoir cap. Reconnect the clutch pipe to the
clutch release cylinder. Check that the connection is
secure by applying a slight tug to the clutch tube.
10. Stroke the clutch pedal as rapidly as possible for 5 to 10
strokes.
11. Wait 1 to 3 minutes.
12. Repeat steps 10 and 11 three more times.
CLUTCH FLUID
BLEED 13. Loosen the bleed screw (located in the clutch release
cylinder body next to the inlet connection).
14. Depress and hold the clutch pedal while tightening the
bleed screw.
Tightening torque:
3-5 N-m(0.3-0.5 kgf-m, 2.2-3.7 ft-lbf}
15. Refill reservoir to the step.

16. Check the operation of the clutch system.
COMPACT TRUCK BENCH BLEED

Bench Bleeding Procedure
Note
I
PROCEDURE
When installing dry clutch master cylinder or tube
service parts, do the Bench Bleed Procedure first.
REMOVE CAP AND DIAPHRAM
TO FILL If air is entrapped in the clutch hydraulic system, a
"soft" unresponsive clutch pedal may be felt or the
clutch may be unable to release.
The truck is more difficult to bleed because the
downward angle of the master cylinder makes it
difficult for air to escape up into the reservoir. Ifthe
master cylinder is removed from the vehicle and
bled while held in vertical orientation (a bench
bleed) air can escape much more efficiently.
IN AN UPRIGHT POSITION,
1. Hold the master cylinder vertically with the reservoir feed
hose in the highest position on the body.
2. Fill the reservoir and extend above the master cylinder
and assure the quick connect on the clutch line is below
the master cylinder (lightly clamp reservoir in a vise).
3. Using a small screwdriver, depress the internal mecha-
nism of the male quick connect pipe to open the valve.
OPEN COUPLING
4. Stroke and hold the master cylinder pushrod.

STROKE BY HAND 5. Close quick connect valve.
6. Release master cylinder pushrod.
7. Fill reservoir.
8. Repeat Steps 3 and 7 four more times.
9. With the master cylinder still being held with theoutlet tube
and reservoir feed tube ends high, quick connect closed
and the reservoir full, proceed as follows:
(a) Quickly push the pushrod into the body several times
to remove any remaining air.
(b) If it is a remote reservoir, pinch the supply hose with
your fingers two or three times to help move air into
reservoir.
10. When the movement of the pushrod is 4mm (0.160 in) or
less when stroked in Step 9, reinstall the master cylinder
into the vehicle and couple it to the slave cylinder.
H CLUTCH PEDAL
CLUTCHPEDAL
ADJUSTMENT
Height, Free Play
The hydraulic clutch system locates the clutch pedal and
provides automatic clutch adjustment. The clutch actua-
tion system does not have free play; it is automatically
self-adjusting and will not require any routine service
throughout the life of the clutch. No adjustment of clutch
linkage or pedal position is required.
4BUOHX 008
1. Remove left side plastic kick panel.
2. Disconnect the clutch master cylinder push rod by prying the retainer bushing and push rod off of the
pedal.
3. Remove the bolts securing parking brake mechanism. Swing the mechanism out of the way.
6. Install in the reverse order of the removal.
L 2
MH1002-C 5BUOHX 005
1. Retaining ring 2.Clutch pedal and shaft assembly
CLUTCH PEDAL POSITION SWITCH H
CLUTCH PEDAL POSITION SWITCH
?-
I -- I
MH1003-B 4BUOHX-010
1. Harness connector 3. Clutch pedal position switch
2. Plastic retainer Removal Note ................................. below
Removal Note
Plastic retainer
Remove the retainer as shown in the figure.
-=@I
Clutch pedal position switch

1. Pull the orientation clip away from the switch to separate
from the pin on the switch.
2. Rotate the switch to expose the location of the plastic
retainer.
3. Remove the switch from the push rod.
H CLUTCH MASTER CYLINDER
CLUTCH MASTER CYLINDER
Caution
Be careful not to spill clutch fluid on a painted surface. If spilled, wipe it off immediately.

4. After installation, bleed the clutch system. (Refer to page H-4).
2.1-2.7
(21.4-27.5 kgf-cm,
19-23 in. lbf}
11.4-15.5 {1.161.59,
8.4-11.5)
FRONT OF
VEHICLE
N - m {kgf.m,ft.Ibf)
MH1004-C 5BUOHX-006
1. Master cylinder push rod 5. Bolts
2. Clutch pedal position switch 6. Clutch master cylinder
Removal / Installation ............. page H-7 Inspect for fluid leakage from cylinder bore
Inspection ............................... Section FT Installation Note ..................... page H-9
Air bleeding ............................ page H-4
3.Screw
4. Clutch pipe
Removal Note ........................ page H-8
Removal Note
Clutch pipe
Caution
MALE COUPLING leakage.
1. Disconnect the clutch pipe from the transmission using

Clutch Disconnect Tool T88T-70522-A, or equivalent.
2. Slide the white plastic sleeve toward the clutch release
cylinder while applying a slight tug on the pipe.
CLUTCH MASTER CYLINDER, CLUTCH RELEASE CYLINDER H
lnstallation Note
Clutch master e cylinder
e
Install the clutch master cylinder and bolts.
Tightening torque:
11.4-15.6 N-m (1.16-1.59 kgfsm, 8.4-1 1.5 ft-lbf}
AIR BLEEDING
Note
Refer to page H-4 for air bleeding procedure.
CLUTCH RELEASE CYLINDER

Caution
Be careful not to spill clutch fluid on a painted surface. If spilled, wipe it off immediately.
1. Disconnect the clutch pipe from the transmission using Clutch Disconnect Tool T88T-70522-A, or
equivalent, referring to Removal Note.
2. Remove the transmission (Refer to Section J1).
FRONT OF
VEHICLE
N-m {kgf-m, ft-lbf)

I I
MH1006-D 5BUOHX-008
Overhaul ................................. page H-10 Installation Note ..................... page H-10
H CLUTCH RELEASE CYLINDER
Removal Note
CLUTCH DISCONNECT Clutch pipe
TOOL T88T-70522-A
Caution
1. Disconnect the clutch pipe by using Clutch Disconnect

Tool T88T-70522-A, or equivalent.
I I
~~1005-c ~ B L J ~ H X - O O ~ Installation
Note
Clutch release cylinder
Install the clutch release cylinder.
Tightening torque:
19.1-25.9 N-m (1.9-2.6 kgf-m, 14.1-19.1 ft.lbf)
4BUOHX-019
OVERHAUL
3. Assemble in the reverse order of disassembly.
DISASSEMBLY ASSEMBLY
I
I I
MHlO16-C 5BUOHX-010
1. Retaining ring 3. Spring
2. Clutch release collar 4. Clutch release cylinder
CLUTCH RELEASE CYlLlNBER H
BLEED SCREW
INSPECTION
Releasee collar travel
' 1. Remove the rubber plug from the inspection port in the
side of the transmission housing.
PORT (RUBBER PLUG
2. Using the black plastic bearing retainer rear edge as an

indicator, take a reading with the clutch pedal fully up
using Bearing'Travel Gauge D87T-4201-A, or equivalent.
3. Have an assistant fully depress the clutch pedal and take
another measurement.
4.The difference between the two readings is the total
bearing travel.
5. If the release collar travel is less than 10.8mm (0.425 in),
inspect the hydraulic system for leaks. If a leak is located
in the system, replace the worn or damaged component
and bleed the system.
6. If no leak is found, bleed the system. Recheck the release
collar travel after repairs.
Note
The illustrationshows how a tool may be fabricated
locally.
CLUTCH UNlT
CLUTCH UNlT
1. Disconnect battery negative cable.
2. Disconnect clutch master cylinder push rod by prying the retainer bushing and push rod off of the pedal.
3. Raise vehicle on hoist and position suitable safety stands under vehicle.
4. Remove the starter. (Refer to Section G).
5. Disconnect the clutch pipe from the transmission using Clutch Disconnect Tool T88T-70522-A, or
equivalent, referring to Removal Note.
Note
Do not remove the pilot bearing unless necessary.

L _I
MH1007-B SBUOHX-011
1. Transmission 5. Pilot bearing
Service ................................... Section J1 Removal Note ........................ page H-13
Installation Note ..................... page H-14 Installation Note ..................... page H-14
3. Clutch cover 6. Flywheel
Removal Note ........................ page H-13 Removal Note ........................ page H-13
Inspection ............................... page H-15 Inspection ............................... page H-16
Installation Note ..................... page H-14 Installation Note ..................... page H-13
4. Clutch disc
Removal Note ........................ page H-13
Installation Note ..................... page H-14
CLUTCH UNIT H
Removal Note
CLUTCH e
Clutch pipe
TOOL T8
Caution
1. Disconnect the clutch pipe by using Clutch Disconnect

Tool T88T-705224, or equivalent.
Clutch cover and clutch disc

Note
Check clutch cover finger heiglht variations before
removing.
1. Mark assembly position of clutch cover to flywheel if

installing original components.
2. Loosen each bolt one turn at a time in a crisscross pattern
until the spring tension is released.
3. Remove the clutch cover and disc.
Pilot bearing
If removing the pilot bearing, use Puller Attachment
T58L-101-B, or equivalent.
4BUOHX-025
Flywheel
Note
After removing the flywheel, inspect for oil leakage
past the crankshaft rear oil seal. If necessary,
replace the oil seal. (Refer to Sections B1, B2, B3).
1. Remove the bolts in a crisscross pattern.

2. Remove the flywheel.
4BUOHX-026
Installation Note
Flywheel
Caution
Clean the screw holes of the crankshaft.
1. Install the flywheel to the crankshaft.

2. Loosely tighten the bolts.
( 7
3. Tighten the bolts in a crisscross pattern.
Tightening torque:
80 N-m (8.2 kgfam, 60 ft-lbf)
H CLUTCH UNIT
T71 P-7137-C Pilot bearing
PILOT BEARIN lnstall a new pilot bearing by using Pilot Bearing Re-
REPLACER
placer T71 P-7137-C and Clutch Aligner T71 P-7137-H,
or equivalents.
CLUTCH ALIGNE
T71 P-7137-H
Clutch disc
1. Clean the clutch disc splines and main drive gear splines.
2.Apply organic molybdenum sulfide grease to the splines.
3. Hold the clutch disc in position by using Clutch Aligner
T74P-7137-K, or equivalent.
Clutch cover
1. Align the dowel holes with the flywheel dowels and install
the clutch cover.
2. Install Clutch Aligner T74P-7137-K, or equivalent.
3. Tighten the bolts evenly and gradually in the pattern
shown.
Tightening torque:
21-32 N-m (2.0-3.3 kgf.m, 15-24 ft.lbf)
Clutch release cylinder

Install the clutch release cylinder and bolts.
Tightening torque:
17.1-25.9 N-m (1.9-2.6 kgf-m, 14.1-19.1 ft.lbf)
4BUOHX-031
CLUTCH COVER, CLUTCH DISC, CLUTCH RELEASE COLLAR H
CLUTCH COVER
INSPECTION
1. Inspect the clutch cover surface for burn marks, scores, or
ridges.
2. Clean the clutch cover surface with a suitable commercial
alcohol-based solvent.
Note
Measure the wear diagonally.
3. Inspect the flatness of the pressure plate contact surface

with a straightedge.
EXCESSIVE WARPAGE
I I
MH1012-A 4BIJOHX-032
CLUTCH DISC
INSPECTION
Note
Minor scoring or burning should be removed with
emery paper.
1. lnspect the lining surface for burning and oil contamina-

WEAR PATERN FROM
tion. Replace the clutch disc if it is badly burned or oil
WARPED CLUTCH COVER soaked.
MH1013-B 4BUOHX-033
2. Inspect for loose facing rivets and torsion springs.
Replace the clutch disc if either is loose.
3.Check the disc for warpage and loose rivets.
1 SWE
CYLINDER
\
PRELOAD
SPRING
\
CLUTCH RELEASE COLLAR
INSPECTION
Note
The clutch release collar is a sealed bearing
and must not be washed.
1. Rotate the outer race while pushing in on the collar

2. If the rotation is rough, replace it.
H PILOT BEARING, FLYWHEEL
PILOT BEARING
RECESS FOR INSPECTION
REMOVAL
TOOL
Note
lnspect the pilot bearing while it is in the flywheel.
1.Turn the bearing while applying force in the axial

direction.
2. Check the condition of the bearing's seal.
3. If the bearing sticks, has excessive resistance, or visible
grease leakage, replace it.
IRON COLLAR
NOTE: IRON COLLAR AND NEEDLE

ROLLER BEARING ARE ONE
ASSEMBLY AND CANNOT BE
REPLACED INDIVIDUALLY
1 I
MH1015-B 4BUOHX-035
FLYWHEEL
INSPECTION
Note
Minor scoring or burning should be removed with
emery paper.
1. lnspect the contact surface of the clutch disc for scoring,

cracks, and burning. Repair or replace as necessary.
2. lnspect the ring gear teeth for wear and damage. If
necessary, replace the ring gear.
3. If it is necessary to remove morethan 1.143mm(0.045 in)
of stock from the original thickness, replace the flywheel.
4. Measurethe flywheel runout with a dial indicator. Replace
the flywheel if runout is excessive.
Runout: 0.13mm (0.005 in) max.
STYLUS CONTAC
FORWARD OR
MANUAL
TRANSMISSION
(M50D)
INDEX ........................................................... J1- 2

OUTLINE ...................................................... J1- 3
SPEClFlCATlONS ..................................... J1- 3
TROUBLESHOOTING GUIDE ..................... J1- 3
TRANSMISSION OIL .................................... J1- 4
lNSPE.CTlON ............................................. J1- 4
REPLACEMENT ........................................ J1- 4
TRANSMISSION ........................................... J1- 5
PREPARATION ......................................... J1- 5
REMOVAL .................................................. J1- 5
DISASSEMBLY .......................................... J1- 7
INSPECTION ............................................. J1-13
ASSEMBLY ................................................ J1-15
INSTALLATION .......................................... J1-29
TRANSFER CASE ......... (REFER TO SECTION J2)
4BUOJ1-001
J1 INDEX
INDEX
K-UP LIGHT SWITCH SERVICE

6-SERIES BODY ELECTRICAL
TROUBLESHOOTING MANUAL
SECTION F
SERVICE, SECT1
GRADE: ATF DEXRONW-IIOR M-Ill

CAPACITY: 2.65 LITERS (5.6 US pt, 4.5 Imp pt}
I I
M J I 133-D 5BUOJ1-009
1. Transmission 2. Transmission oil
Removal ............................... page J1- 5 Inspection ............................. page J 1-4
Disassembly ......................... page J 1- 7 Replacement ........................ page J1-4
Inspection ............................. page J1-13
Assembly .............................. page J1-15
Installation ............................ page J1-29
OUTLINE, TROUBLESHOOTING GUIDE J1
OUTLINE
SPECIFICATIONS
Transmission
-_ -\7
Transmission control Floor shift
I 1st 3.72
Gear ratio
1.oo I
Reverse
Grade
79
3.40
MERCON@ or lM-Ill
1
3
Oil
Capacity liters {US pt, Imp pt} 2.65 I 5 . 6 4 . 5 )
MJ1134-D 5BUOJ1-010
Note
4BUOJ1-004
,
- -- -- --- --- - -
Shift lever won't Worn or seized shift forks ~eplace

shift smoothly or is
hard to shift
- - -
Too much play in Worn sh~ftforks

shift lever -
Loose sh~ftlever mounting bolts
- - - - -
Difficult to shift lnsufflc~ent011 Add oil

Deterloration of 011qual~ty Replace with oil of
specified quality
I Wear or play of shift fork or shift rod Replace
Worn synchronizer ring Replace
Excessive longitudinal play of gears Replace
Worn bearing Replace
Worn gear sliding surface of shaft gears Replace
disengagement Refer to Section H
Won't stay in gear Worn shift fork(s) Replace JI- 7
Worn clutch hub Replace J1-11
Worn clutch hub sleeve I Replace J1-11
Worn gear sliding surface of shaft gears Replace J1- 7
Worn gear sliding surface of gear Replace J1-7, 11
Excessive thrust clearance Replace J1-26
Worn bearing Replace J1-7, 11
Loose transmission mounting bolts Tighten J1-29
Worn pilot bearing Replace Section H
Abnormal noise Insufficient oil Add oil
Deterioration of oil quality Replace with oil of
specified quality
Worn bearing Replace
Worn gear sliding surface of shaft gears Replace
Damaged gear teeth Replace
Foreign material in gears Replace
! Excessive gear backlash

Damaaed differential aear
Replace
Refer to Section M
TRANSMlSSlON OIL
TRANSMISSION OIL
INSPECTION
Note
1. Remove the oil level plug and washer.

2. Verify that the oil is near the bottom of the plug port.
3. If the oil level IS low, add the specifled amount and type of
011through the oil level plug hole.
4BUOJ1-006
Specified oil
Grade: M E R C O N ~ or M-Ill
Tightening torque:
40-58 N.m (4.1-5.7 kgfam, 3 0 4 2 ft-lbf}
REPLACEMENT
1. Remove the drain plug and washer.
3. Install a new washer and the drain plug.
Tightening torque:
40-58 N.m (4.1-5.7 kgf.m, 3 0 4 2 ft.lbf)
OIL LEVEL
PLUG
DRAIN PLUG
MJ1157-A
4. Remove the oil level plug with washer and add the
specified amount and type of oil through the oil level plug
hole until the level reaches the bottom of the oil level plug
hole.
Specified oil
Grade: M E R C O N ~ or M-Ill
Capacity: 2.65 liters (5.6 US pt, 4.5 Imp pt}

4BUOJ1-007
Tightening torque:
40-58 N.m (4.1-5.7 kgf-m, 3 0 4 2 ft.lbf}
TRANSMISSION
TRANSMISSION
PREPARATION
SST
49 UNOl 01 1 For For

removal of installation of
secondary Remover / secondary 1st
Mainshaft locknut shaft replacer tube and 2nd gear/
wrench locknut countershaft
bearing
49 UNOl 073 For

removal of 49 H027 002 For
secondary 1st installation of
Bearing and 2nd gear/ secondary 1st
cone replacer Installation of Axle Bearing 1 and 2nd gear
primary shaft Seal plate
bearing I
For 49 UN17 101 For
installation of installation of
secondary 1st secondary 1st
and 2nd gear/ Bearing driver and 2nd gear
countershaft attachment
bearing
49 UNOl 012 For For

installation installation of
of front secondary 1st
Bell housing cover oil seal Wrench, main and 2nd gear
seal replacer shaft locknut
/ 49 0839 425C I For

removal of
1
secondary
Remover1 shaft locknut
replacer tube and bearing
REMOVAL
2. Place the transmission in neutral.
3. Remove the gear shift lever, referring to Removal Note. (Refer to page JI-6.)
5. Drain the transmission oil into a suitable container.
6. On 4x2 models, remove the propeller shaft. (Refer to Section L.)
7. Disconnect the clutch pipe from the transmission case, referring to Removal Note. (Refer to
page J1-6.)
8. Remove the speedometer cable from the extension housing or transfer case.
9. Disconnect the parwneutral position and back-up light switches.
11.On 3.OL and 4.OL engines, remove the necessary exhaust system componenls to gain adequate
clearance. (Refer to Sections F2, F3.)
- 12. On 4x4 models, remove the transfer case. (Refer to Sectiori J2.)
13. Position a transmission jack under the transmission.
14. Remove the transmission, referring to Removal Note. (Refer to page J1-6.)
TRANSMISSION
Removal Note
Gear shift lever
1. Remove the shift lever boot screws.
2. Slide the shift lever boot up the gear shift lever shaft.
3. Remove the lock nut from the attaching stud.
4. Install the lock nut on the other end of the stud.
5. Tighten the nut against the shift lever and tap on the
opposite end of the stud until it comes loose.
6. Remove the stud and the shift lever.
Clutch pipe
CLUTCH DISCONNECT 1. Disconnect the clutch pipe at the transmission case using
TOOL T88T-70522-A Clutch Disconnect Tool T88T-70522-A, or equivalent.
MALE COUPLING
3.Plug both ends of the line to prevent fluid leakage and the
entry of contaminants.
I I
MH1005-C 5BUOJ1-001
Transmission
1 . Remove the bolts, lockwashers and flatwashers attaching
the transmission to the engine rear plate.
2. Remove the nuts and bolts attaching the transmission
mount to the crossmember.
3. Remove the nuts attaching the crossmember to the frame
side rails and remove the crossmember.
4. Work the transmission off of the locating dowels.
TRANSMISSION J1
DISASSEMBLY
Precaution
1. Clean the transmission exterior thoroughly with a steam cleaner or cleaning solvent before disassembly.
2. Clean the removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry
with compressed air.
3. Clean out all holes and passages with compressed air, and check that there are no obstructions.
4. Wear eye protection when using compressed air to clean components.
Transmission
1. Remove the shift lever boot and gear shift lever, if necessary.
2. Remove the control case.
3. Remove the rear seal if necessary, referring to Disassembly Note. (Refer to page J1-8.)
4. Remove the extension housing, referring to Disassembly Note. (Refer to page J I -8.)
5. On 4x2 models, remove the anti-spill oil seal from the secondary shaft.
6. On 4x2 models, remove the speedometer drive gear and steel ball.
TRANSMISSION
1. Locknut (countershaft) 16. Clutch hub and sleeve assembly
Disassembly Note ................ page J1- 9 (5th/reverse)
2. Countershaft rear bearing 17.5thkeverse shift rod and fork
3. Thrust washer 18. Synchronizer ring (5th)
4. Locknut (secondary shaft) Inspection ............................. page J1-14
Disassembly Note ................ page J l - 9 19. Countershaft lever assembly
5. Bolt 20.5th gear needle bearing
6. Reverse idler gear 21.5th gear-secondary shaft
Disassembly Note ................ page J1- 9 22.5th gear sleeve
Inspection ............................. page J1-14 23.5th gear ball
7. Secondary shaft rear bearing 24. Center bearing cover
Disassembly Note ................ page J1- 9 25. Front bearing cover
8. Reverse gear Disassembly Note ................ page J1-10
Inspection ............................. page J1-13 26. Bolt
9. Sleeve 27. Oil trough
10. Countershaft reverse gear 28. Primary shaft bearing outer race
Inspection ............................. page J1-13 29. Countershaft front bearing
1 1. Needle bearings 30. Secondary shaft
12. Synchronizer ring (reverse) Disassembly Note ................ page J1-12
Inspection ............................. page J1-14 31. Primary shaft
13. Thrust washer Disassembly Note ................ page J1-10
14. Split washer 32. Countershaft gear
15.5thlreverse shift rod bolt Inspection ............................. page J1-15
Disassembly Note
Rear seal
Remove the extension housing rear oil seal using seal
remover T74P-77248-A, or equivalent.
4BUOJ1-014
Extension housing
1. Remove the extension housing bolts.
2. Pry gently at locations provided on the extension hous-
REMOVER ing and transmission case.
T74P-77248-A
TRANSMISSION J1
Locknuts
1. Shift the transrnission into 1st and 3rd gears.
2. Remove the countershaft locknut.
MJ1089-A
3. Remove the secondary shaft locknut using the SSTs.
Caution
Do not reuse the removed locknuts.
Reverse idler gear

REVERSE RETAINING RING
IDLER GEAR DIAMETER
1. Remove the reverse idler gear.
2. Remove the retaining ring, spacer, idler gear, needle
bearings and thrust washer.
IDLER SHAFT ~~~~~G RETAINING
Secondary shaft rear bearing

Remove the secondary shaft rear bearing using the SST.
Caution
Be sure the tools are properly positionedso that the
parts being removed are not damaged.
J1 TRANSMISSION
Front bearing cover
1. Remove the clutch release cylinder (Refer to Section H.)
2. Remove the front bearing cover bolts.
3.Remove the front bearing cover by threading two M8 x
1.25 (40mm or longer) bolts into the front bearing cover
clutch release cylinder bolt locations.
Note
Bolts threaded into the clutch release cylinder bolt
locations will bottom out and lift the front bearing
cover away from the transmission case.
Do not remove the plastic scoop ring from the
primary shaft at this time.
MJ1093-A 4BUOJ1-019
Primary shaft
1. Remove and discard the plastic scoop ring.
2. Remove the primary shaft bearing using Pinion Bearing

Cone Remover T71 P-4621-B, or equivalent.
Caution
Remove the bearing only if it needs to be replaced.
TRANSMISSION J1
Secondary Shaft Parts
1. Roller bearing 1 1.1 st gear sleeve

2. Snap ring 12.1 st gear
3. Spacer 13.1st gear needle bearing
4. Needle bearing 14. Synchronizer ring (1st)
5. Clutch hub and sleeve assembly (3rdf4th) Inspection ............................. page JI-14
Inspection ............................. page J1-14 15. Clutch hub and sleeve assembly (1sU2nd)
6. Synchronizer ring (3rd) Inspection ............................. page J 1-14
Inspection ............................. page JI-14 16. Synchronizer ring (2nd)
7.3rd gear Inspection ............................. page J1-14
8. Needle bearing 17.2nd gear
9. Center bearing-outer race 18.2nd gear needle bearing
10. Center bearing-inner
TRANSMISSION
Disassembly Note e
Secondary shaft
1. Place the secondary shaft into a press.
2. Press out the 1st and 2nd gear components using the
SST and Bearing Cone Replacer T53T-4621-B, or
equivalent.
Note
SST Number: 49 UNO1 073 Bearing Cone Replacer
Control Case
1 . Remove the dust cover, referring to Disassembly Note. (Refer to below.)
2. Remove the back-up light switch and pin.
3. Remove the parklneutral position switch and pin.
4. Remove the shift rods, referring to Disassembly Note. (Refer to page J1-13.)
Disassembly Note
Dust cover
Remove the dust cover screws (Torx) and the dust cover.
I DUST
COVER
TRANSMISSION
Shift rod
Warning
Wear safety glasses while performing shift rod
removal procedure.
1. Remove the shift fork interlock pins using a 5/32 in

drift punch.
Note
Make sure all shift rods and gates are positioned in
neutral.
Remove the shift gate interlock pins.

Remove the shift gates.
Remove the three shift rod service bore rubber plugs.
Cover the lock ball and friction device bores and seats
with a clean cloth.
Caution
Failure to cover the cover lock ball and friction
device borles could result in component loss.
6. Remove the Sthlreverse shift rod.

7. Remove the Istl2nd shift rod.
8. Remove the 3rdl4tIi shift rod.
9. Remove the Sthlreverse cam lockout plate.
INSPECTION
lnspect all parts and repair or replace as necessary.
Gears
1. lnspect the synchronizer cones for wear.
2. lnspect the gear teeth for damage, vrrear, and cracks.
3. lnspect the synchronizer ring matching teeth for damage
and wear.
TRANSMISSION
Synchronizer Ring
1 . lnspect the synchronizer ring teeth for damage, wear, and
cracks.
2. lnspect the tapered surface for wear and cracks.
Note
Set the synchronizer ring squarely in the gear; then
measure around the circumference.
3. Measure the clearance between the synchronizer ring

and the flank surface of the gear.
Standard clearance: 1.50mm (0.059 in)

Minimum: 0.8mm (0.031 in)
Clutch Hub Assembly

1. lnspect the clutch hub sleeve and hub operation.
2. lnspect the gear teeth for damage, wear, and cracks.
3. lnspect the synchronizer keys for damage, wear, and
cracks.
4. Measure the clearance between the hub sleeve and shift

fork.
p-
1
Clearance
--
--
SthIRev
-
-- --
0.05-0
-
0.1-0.37
-
0.1-0
37 { 0 . 0 0 1 9 4 014)
{0.003-0
- --
--
37 (0.003-0.014)
-
-
014)
-- -
--
rnm {~n)
0 8 {0 031)
-
0.8 {0.031}
0.8 {O 031)
MJI 136-B 4BUOJ1 029
Reverse Idler Gear

2. Measure the clearance between the reverse idler gear
bushing and the retaining ring.
Standard clearance:
0.10-0.20mm (0.0039-0.0078 in)
TRANSMISSION J1
Bearing
Note
When replacing the bearing, replace the bearing
and race as a set.
lnspect for darnage and rough rotation.
MJ1142-A 4BUOJ1-031
Countershaft Gear
1. lnspect the gear contact surface for damage and wear.
2. lnspect the splines for damage and wear.
4. lnspect the oil passage for clogging.
5. Measure the countershaft gear runout.
Countershaft gear runout:

0.050mm (0.0020 in) max.
Speedometer Gears
MJ1102-A 4BUOJ1-032
1. Inspect the teeth for damage and wear.
2. lnspect the O-ring for damage and wear.
ASSEMBLY
Precaution
1. All O-rings and gaskets must be replaced with new ones includetl in the overhaul Itit.
2. Verify that all parts are completely cleaned before assembly.
3. Assemble parts within 10 minutes after applying sealant. Allovvall sealant to cure at least 30 minutes after
assembly before filling the transmission with transmission oil.
4. After assembly, shift the transmission to each position, and check for smooth and correct operation.
Control Case
1. lnstall the 5thlreverse cam lockout plate, referring to Assembly Note. (Refer to page J1-16.)
2. lnstall the IsU2nd and 3rdl4th interlock pins, referring to Assembly Note. (Refer to page J1-16.)
3. lnstall the shift rods, referring to Assembly Note. (Refer to page Jl-16.)
4. lnstall the rubber plugs into the service bores.
5. lnstall the parklneutral position switch, referring to Assembly Note. (Refer to page J1-17.)
6. lnstall the back-up light switch, referring to Assembly Note. (Refer to page J1-17.)
7. lnstall the dust cover, referring to Assembly Note. (Refer to page J1-17.)
J1 TRANSMISSION
Assembly Note
Sthlreverse cam lockout plate
Install the 5thlreverse cam lockout plate and bolts.
Tightening torque:
8-10 N-m (0.8-0.9 kgf-m, 6-7 ft-lbf)
Interlock pins
Install the large and small pins in their original positions.
PARWNEUTRAL
BACK-UP POSITION
LIGHT SWITCH ,
SWITCH
LARGE
INTERLOCK
PIN / I \ PIN
5THl'
REVERSE
3RDl4TH
SPRING
1STl2ND
SPRING
SPRING AND AND
AND DETENT DETENT
DETENT BALL BALL
BALL
3rd14th shift rods

1. Position the shift rod into the control case.
2. Position the detent ball and spring into the control case
spring seats.
3. Compress the detent ball and spring assembly and push
the shift rod into position over the detent ball.
4. Engage the 3rd14th shift fork with the shift rod.
5. Position the friction device and spring into the control case
spring seats.
6. Compress the friction device and spring assembly and
push the shift rod into position over the friction device.
7. lnstall the 3rdl4th shift gate.
8. lnstall the 3rdl4th shift fork spring interlock pins.
4BUOJ1-038
TRANSMISSION J1
1stl2nd shift rods
1. Position the shift rod into the control case.
2. Position the tletent ball and spring into the control case
spring seats.
4. Engage the 1sU2nd shift fork with the shift rod.
5. Position the friction device and spring into the control case
spring seats.
6. Compress the friction device and spring assembly and
push the shift rod into position over the friction device.
7. lnstall the 1stMnd shift gate.
8. Install the 1stl2nd shift fork spring interlock pins.
Sthlreverse shiift rods

r\ 5THIREVERS5 SHIFT FORK
1. Position the shift rod into control case.
2. Position the detent ball and spring into the control case
spring seats.
4. Engage the 5thlreverse shift fork with the shift rod.
5. lnstall the Eithlreverse shift gate.
6. lnstall the 5thlreverse shift fork spring interlock pins.
4BUOJ1-039
I
MJI 144-A 4BUOJ1-037
1 DUST
COVER
Dust cover
Install the dust cover
Tightening torque:
8-1 1 N-m(0.8--1.1 kgf-m, 6 - 4ft-lbf}
4BUOJ1-040
Back-up light switch

Apply sealant to the threads and install.
Tightening torque:
2 5 - 4 5 N-rn(2.5-3.4 kgfem, 18-25 ftdbf)
4BUOJ1-041
Parklneutral position switch

Apply sealant to the threads and install.
Tightening torque:
25-35 N-M (2.5-3.4 kgf-m, 18-25 ft-lbf)
J1 TRANSMISSION
Secondary Shaft Parts
FLANGE-OUTPUT
MJ1104-A 4BUOJ1-043
1.2nd gear needle bearing 10. Center bearing-outer race
2.2nd gear 11.3rd gear needle bearing
3. Synchronizer ring (2nd) 12.3rd gear
4. Clutch hub and sleeve assembly ( I stf2nd) 13. Synchronizer ring (3rd)
5. Synchronizer ring (1st) 14. Clutch hub and sleeve assembly (3rdl4th)
6. 1st gear needle bearing 15. Spacer
7.1st gear 16. Needle bearing
8. 1st gear sleeve 17. Retaining ring
9. Center bearing-inner 18. Roller bearing
Assembly Note
Secondary shaft
Press the 1st and 2nd gear components into position
SLEEVE using the SSTs and Bearing Cone Replacer T53T-
BEARING C
REPLACER
T53T-4621-
I
MJ1105-B
Note
When installing the clutch hub and sleeve (Istl
2nd), make sure that the smaller width of the sleeve
faces the 2nd gear side. The reference marks face
the rear of the transmission.
Center bearing
Press the center bearing onto the secondary shaft using
the SSTs and sleeve.
2ND - 1ST
Note
Fabricate a sleeve where the inside diameter is
large enough to fit over the secondary shaft but
small enough to engage the inner bearing race.
Note
SST Numbers: 49 1243 465A and 49 UN17 101
Shaft Collar and 49 H027 002 Bearing Plate.
4BUOJ1-045
Clutch hub and sleeve assembly (3rdl4th)

1. Mate the clutch hub synchronizer key groove with the
slants on the inner surface of the clutch hub sleeve.
Note
The turnecl edge of the clutch hub sleeve should
face toward 4th gear.
2. Install the longer flange on the clutcli hub sleeve toward

the 3rd gear side.
Note
The 3rd gear synchronizer ring has three teeth cut
out 120°apart from each other. Directly adjacent to
one side of the missing teeth, two teeth have b en
bridged together.
I
I
MJ1107-A
3RD 1ST, 2ND, 4TH
I
I
The front and rear sides of th~eclutch hub may
appear to be similar. lnstall the clutch hub with the
chamfer facing 4th gear.
MJ1108-A 4RUOJ1-046
3. Measure the 3rdi4th clutch hub end play with the original
retaining ring installed.
Standard end play: 0.00-0.05mm1 (0.00--0.0020 in)
4. If the end play is not as specified, select the proper

retaining ring.
TRANSMISSION
- -
- - - - -
Retaining Ring Select Chart
Thickness mm {in}
- - - - - --
- - -- -- --
-
1.50 {0.059)
-- - - -
- - -- -
1.55 (0.061)
-- -- - -
- -- -
1.60 {0.0629)- - - -
-- - - -- -1.65
- {0.0649)
-- -
-
1 70 (0.0669)
- - -
I 75 {0.0688} --
. - -- --- --
1.80 (0.0708)
-- - -
~p -
1.85 (0.0728)
-- - - -
- -
1.90 (0.0748)
--- -- -
1.95 (0.0767)
MJl110-A 4BUOJl
Assembly
2. Install the speedometer drive gear, referring to Assembly Note. (Refer to page J1-28.)
3. Install the extension housing, referring to Assembly Note. (Refer to page J1-28.)
4. Install the control case, referring to Assembly Note. (Refer to page J1-28.)
5. Add the specified amount and type of transmission oil. (Refer to page J1-4.)
TRANSMISSION
MJ1111-B
1. Oil trough 20. Synchronizer ring (5th)
2. Oil trough bolt 21. Shift fork assembly
3. Countershaft assembly Assembly Note ..................... page J1-25
4. Secondary shaft center bearing outer race 22. Shift rod bolt
Assembly Note ..................... page J1-22 23. Split washer
5. Primary shaft Assembly Note ..................... page J1-25
Assembly Note ..................... page J1-22 24. Thrust washer
6. Secondary shaft assembly Assembly Note ..................... page J1-26
7. Secondary shaft center bearing outer race 25. Synchronizer ring (reverse)
8. Center bearing cover 26. Needle bearings
Assembly Note ..................... page J1-24 27. Countershaft reverse gear
9. Countershaft front bearing 28. Thrust washer
10. Front bearing cover 29. Reverse idler gear
Assembly Note ..................... page JI-23 Assembly Note ..................... page J 1-26
11.5th gear ball 30. Reverse idler gear bolt
12.5th gear sleeve 31. Secondary shaft sleeve
13. Countershaft 5th gear 32. Secondary shaft reverse gear
14.5th gear needle bearing 33. Secondary shaft rear bearing
15. Secondary shaft 5th gear P~ssemblyNote ..................... page J1-27
16. Countershaft lever assembly 34. Countershaft rear bearing
Assembly Note ..................... page J1-25 35. Locknut (secondary shaft11
17. Spring Assembly Note ..................... page J 1-27
18. Detent Ball 36. Locknut (countershaft)
19. Clutch hub and sleeve (5thlreverse) P~ssemblyNote ..................... page Jl -27
J1 TRANSMISSION
Assembly Note
Secondary shaft center bearing outer race
Use a brass drift to install the outer race.
- .
1 Note
Make sure that the outer race is squarely posi-
TRANSMISSION
CASE WALL tioned in the bore.
OUTER
RACE
II I OUTPUT
SHAFT
APPROXIMATELY Smm
I0.196 in}
TRANSMISSION
CASE WALL
OUTER
RACE
APPROXIMATELY 3mm
{0.118 in)
Primary shaft
1. Press the primary shaft bearing onto the primary shaft
PRESS using Bearing Cone Remover T71 P-4621-6, or e q u i v a -
BEARING CONE INPUT lent and the SST.
REMOVER SHAFT 2. Install the plastic scoop ring.
T71 P-4621-6 BEARING
Note
Manually rotate the scoop ring clockwise to make
sure that the main drive gear oil holes properly
engage the scoop ring. A click should be heard as
the scoop ring notches align with the primary shaft
oil holes.
TRANSMISSION J1
e
Front bearing cover
1. If removed, install ,the front cover oil seal using the SST.
MJ1115-A
2. Measure height A of the primary shaft bearing outer race.
3. Measure depth B of the front cover outer race bore.
4. Measure depth C of the countershaft front bearing race.
5. Measure depth D of the front cover outer race bore.
6. Select an adjustment shim(s) to maintain end play within
the specified limits.
B-A + adjustmenl: shim = 0.05-0.15mm

(0.002-0.006 in)
C+D - adjustment shim = 0.15-0.25mm

MJI 116-A (0.006-0.01 0 in)
Secondary Shaft Shim Select Chart
--
ADJUSTMENT Thickness mm {in)

SHIM - - -- - --- - -- - --
-- - -- - - - - - -
2 7 {0.106)
- - - - -
- -- --
2.8 (0.1 10) ------
-- --
2.9 (0.1 14) - - - --
-- -- - - --- --- -
3.0 (0.1 18) -
- -- ---
3.1 (0.122) - ---- --
-- -- -
3.2 (0.1 25) - -- -
3.3 {0.129)
I 4.1 (0.161)- 1
MJI 1PO-A 4BUOJ1-053
0.15--0.25MM
{0.006-0.010 in)
TRANSMISSION
Countershaft Spacer Select Chart
- --
Thickness mm {in)
- -- -- - -- -
- -- - - --
2.3 (0.090)
- -- -- -- --
. - - - - -- -
2.4 {0.094] - -- -
-- - - -- - -
2.5 {0.098}
-- - -- -
~ - - - - -
2.6 {0.102}
--- - - ---
-- - - - -
2.7 {0.106]
--
-- - -
~ -- - -- - -
2.8 {0 1101
- - -- --
- - - - - -
2.9 (0.1141
-- - - -- -
- - - - -- --
3.0
-
{0.118}
-- - -- - -
3.1 {0.122]
MJ1121 A 4BUOJ1
7. Position the bearing shim and baffle plate into the front
OIL BAFFLE cover (install the shim with the groove showing).
8. lnstall the spacer in the transmission countershaft front
bearing bore.
9. Tape the primary shaft splines along their entire length.
10. Apply a 118 in bead of appropriate sealant to the front
cover and bolt threads.
1 1. Install front cover.
Tightening torque:
16-22 N.m {I.7-2.2 kgf.m, 12-1 6 ft.lbf)
MJ1122-B 4BUOJ1-055
Note
Makesure that the bolt headsare marked with a "6".
Center bearing cover

Install the center bearing cover with the reference arrow
pointing up.
Tightening torque:
18-26 N.m (1.8-2.6 kgf.m, 13-19 ft.lbf)
Not
Make sure that all bolt heads are marked with
an "8".
TRANSMISSION J1
Countershaft
e lever
e e assembly
e
Install the countershaft lever assembly.
Tightening torque:
8-10 N-m .(0.8--0.9 kgf.m, 6-7 ft-lbf)
5BUOJ1-005
Shift fork assennbly

A STH/REVERS! SHIFT FORK
I . Install the spring and detent ball into the shift fork.
2. Depress the detent ball and insert the shift rail.
3. Locate the neutral position.
4. Install the 5th / reverse clutch hub and sleeve, and the
5th gear synchronizer ring on the shift fork assembly.
Note
The reference mark on the synchronizer sleeve
SPRING AND must be installed toward the rewerse gear side.
DETENT BALL
5. Install the shift fork assembly on the countershaft.
6. Apply sealant ,to the threads of shift fork assembly bolt.
IDENTIFICATION
HOLE
/, 200-
Tightening torque:
20-30 N m (2.2-3.0 kgf-my16--22 ftelbf}
5th e b REV
Split washer
1. Measure the countershaft reverse gear end play if the
original split washers are not being installed.
Standard end play: 0.25-0.35mm (0.010-0.01 4 in)
2. If the end play is not as specified, select the proper split

washer.
Split Washer Se!lect Chart
I Thickness rnrn {in} I

TRANSMISSION
Thrust washer
1. While pushing the thrust washer against the shoulder on
the countershaft, measure the clearance between the
thrust washer and the countershaft reverse gear.
Clearance: 0.25--0.35mm (0.010-4.01 4 in)
2. If the clearance is not as specified, select the proper thrust

washer.
Thrust Washer Select Chart
I I
MJ1127-A 5BUOJ1-007
Thickness mm {in) 1
Reverse idler gear

REVERSE RETAINING RING 1. Install the thrust washer onto the reverse idler gear.
IDLER GEAR DIAMETER
AFTER ASSEMBLY
Note
Make sure the tabs on the thrust washer mates with
the groove on the reverse idler shaft.
2. Install the needle bearings, idler gear, and spacer.

3. Install the original retaining ring.
4. Measure the end play between the retaining ring and the
reverse idler gear.
I I
MJlO91-B 5BUOJ1-008
End play: 0.1--0.2mm (0.0039-0.0078 in)
5. If the end play is not as specified, select the proper

retaining ring.
Reverse Idler Gear Retaining Ring Select Chart
Thickness mm {in)
- - -- - -- - -- - --
- --- --
I 5 {0.059}
- -
1 6 (0.0629)
- -- -- -- --
- -- -
I 7-{0.0669}
- - -- -
--
1.8
---
{0.0708}- - - -
1.9 {0.0748}
MJ1129 A 4BUOJ1 064
TRANSMISSION
Countershaft rear bearing
Temporarily ir~stalla suitable spacer (inner bore larger
than 21mm (0.82 in), outer bore smaller than 36mm
(1.41 in), 15-20mm (0.59-0.78 in) overall length) in
place of the countershaft bearing.
4BUOJ1-065
Secondary shaft rear bearing

lnstall the bearing using the SST, Shaft Adapter T75L-
7025-M (4x4 only), Gear Installing Spacer T88T-7025-E,
or equivalents.
4BUOJ1-066
SHAFT ADAPTER Locknuts

T75L-7025-M 14x4 ON1
Caution
Do not reuse the removed locknuts.
1. Remove the temporary spacer from the countershaft.

2. lnstall the countershaft rear bearing.
3. Lock the transmission into 1st and 3rd gears.
4. lnstall the secondary shaft locknut.
Tightening torque:
216-274 N.m (22-27 kgf-m, 159-202 ft-lbf)
5. lnstall the countershaft locknut.
Tightening torque:
128-1 96 N.m {3.0-1
I 9.8 kgf-m, 94--144 ftelbf)
6. Stake the locknuts.

Oil passage
Install the oil passage.
Tightening torque::
8-10 N-m (0.8--1.0 kgf-m, 6-7 ftalbf]
J1 TRANSMISSION
Speedometer drive gear
The speedometer drive gear contains detents into which
the steel drive ball can be installed. The steel drive ball can
be installed into any of the three detents.
4BUOJ1-069
Extension housina
EXTENSION HOUSING 1. Install the extension housing.
SEAL REPLACER
T61L-7657-A
Tightening torque:
3 2 4 6 N-m ( 3 . 3 4 . 5 kgf.m, 24--33 ft.lbf)
2. Install the extension housing rear oil seal using the Exten-
sion Housing Seal Replacer T61L-7657-A, or equivalent.
Note
Make sure that the oil seal drain hole faces
downward.
MJ1132-A 4BUOJ1-070
The extension housing bushing cannot be ser-
viced. If the bushing requires service, the exten-
sion housing must be replaced. (4x2 only)
Control case
REAR Install the control case.
Tightening torque:
16-22 N.m (1.7-2.2 kgfem, 12-1 6 ft-lbf)
Note
Do not apply sealant to the control case or trans-
mission mating surfaces.
DRAIN
HOLE
TO FACE
--
FORWARD Drain plug
Install the drain plug.
Tightening torque:
40-58 N.m (4.1-5.7 kgf.m, 3 0 4 2 ft-lbf)
4BUOJ1-072
TRANSMISSION
INSTALLATION
1. lnstall the transmission in the vehicle, referring to Installation Note. (Refer to below.)
2. lnstall the starter motor. (Refer to Section G.)
3. On 4x4 models, install the transfer case. (Refer to Section J2.)
4. lnstall the propeller shaft. (Refer to Section L.)
5. Connect the parWneutral position and back-up light switches.
6. On 3.OL and 4.OL engines, install the exhaust system. (Refer to Sections F2, F3.)
7. Connect the hydraulic clutch line and bleed the clutch system. (Refer to Section H.)
8. lnstall the speedometer cable.
9. Add the specified amount and type of transmission oil. (Refer to page J1-4.)
10. Remove the safety stands and lower the vehicle.
1 1. Connect the negative battery cable.
12. lnstall the gear shift lever, referring to lnstallation Note. (Refer to below.)
13. Test drive the vehicle and check the transmission operation.
Installation Note
Transmission
1. Make sure that the machined m a t ~ r ~surfaces
g and the
locating dowels are free of burrs, dirt, and paint.
2. lnstall the transmission on Transmission Jack 007-0008,
or equivalent.
3. Position the transmission in the vehicle and align the
primary shaft splines with the clutch disc.
4. lnstall the transmission bolts and flatwashers.
Tightening torque:
38-51 N-rn(3.9-5.1 kgf.m, 28--37 ftelbf}
5. lnstall the crossmember, insulator and damper
Tightening torque:
3.OL: 6 5 - 4 5 N-m (6.6-4.5 k g f . ~4~6, 6 2 ft.lbf)
2.3L, 4.OL: 88-1 15 N-m (9.0-1 '1.5 kgf-m, 6 5 - 8 4
ft-lbf)
Gear shift lever
- - - -
1. lnstall the gear shift lever bolt.

Note:
lnstall the stud so the flat side of the mn-threaded portion
is faang towardl the left (driver side).
Tightening torque:
2 7 4 0 N.ni (2.6-4.1 kgf-m, 20--30 ft-lbf}
2. lnstall the shift lever boot and install the screws.

4BUOJ1-075
TRANSFERCASE
INDEX ......................................................... J 2 - 2
MANUAL SHIFT TRANSFER CASE .......... 5 2 - 2
ELECTRONIC SHIFT TRANSFER
CASE! ....................................................... J 2 - 3
OUTLINE ...................................................... J 2 - 4
SPECIFICATIONS ..................................... J 2 - 4
POWERFLOW (TRANSFER) .................... 5 2 - 4
TRANSFER CASE OIL ................................. 5 2 - 6
INSPECTION ........................................... J 2 - 6
REPLACEMENT ........................................ J 2 - 6
OIL SEAL ...................................................... J 2 - 7
PREPARATION ........................................ J 2 - 7
FRONT OUTPUT SHAFT .......................... J 2 - 7
REAR OUTPUT SHAFT ............................. J 2 - 9
SHlFT LEVER (MANUAL SHlFT
TRANSFER CASE) .................................... J2-10
REMOVALIINSTALLATION ....................... J2-10
SHlFT LINKAGE (MANUAL SHlFT
TRANSFER CASE) .................................... J2-12
INSPECTION ............................................. J2-12
ADJUSTMENT ........................................... J2-12
MANUAL SHIFT TRANSFER CASE ........... J2-13
PREPARATION ......................................... J2-13
TROUBLESHOOTING GUIDE ................... J2-14
REMOVAUINSTALLATION ....................... J2-14
DISASSEMBLY .......................................... J2-17
INSPECTION ............................................. J2-23
ASSEMBLY ................................................ 52-23
ELECTRONIC SHIFT TRANSFER CASE .... 52-32
PREPARATION ......................................... J2-32
TROUBLESHOOTING GUIDE ................... J2-33
4x4 SWITCH OPERATION . . . . . . . . . . . . . J2-33
4x4 SHIFT CONTROL SWITCH . . . . . . . . J2-34
4x4 TRANSMISSION SELECT REILAY . . J2-34
ELEC1-RONIC SHlFT MOTOR
ASSEMBLY ............................................. J2-35
REMOVAL/INSTALLATION ....................... J2-36
DISASSEMBLY .......................................... J2-39
ASSEMBLY ................................................ 52-43
TROUBLESHOOTING ............................... J2-49
DIAGNOSTIC TROUBLESHOOTING
GUIDE ..................................................... J2-53
DIAGNOSTIC TROUBLESHOOTING
CODE LIST .............................................. J2-55
SYSTEM INSPECTION ................................ J2-65
4x4 SHIFT CONTROL SWITCH ................ 52-65
ELECTRONIC SHlFT MOTOR
ASSEMBLY .............................................. J2-65
6BUOJ2-020
INDEX
INDEX
MANUAL SHIFT TRANSFER CASE
-
FLUID SPECIFICATION
ATF DEXRON-II OR M-Ill
CAPACITY 1.2 LITERS
{2.5 US PT., 2.1 IMP. PT.)
MJ1146-B 5BUOJ2-001
1. Transfer case 2. Shift lever and linkage

Troubleshooting Guide .......... page J2-14 Removal / Installation ............ page J2-10
Removal / Installation ............ page J2-14 Inspection .............................. page J2-12
Disassembly .......................... page J2- 17 Adjustment ............................ page J2-12
Inspection .............................. page J2-23
Assembly ............................... page J2-23
INDEX
ELECTRONIC SHIFT TRANSFER CASE

--
FLUID SPECIFICATION
ATF DEXRON II OR M-Ill
CAPACITY 1.2 LITERS
(2.5 US PT., 2.1 IMP. PT.)
MJ7047-C 7BUOJ2-021
1 . 4 ~ shift
4 control switch 4. 4x4 Trarlsmission select relay
Removal / Installation ............ page J2-34 F?emoval/ Installation . . . . . . . . page J 2 - 3 4
Inspection .............................. page J2-65 5. Transfer case
2. Electronic shift motor assembly F3emoval / Installation ............ page J2-36
Removal / Installation ............ page J2-35 [>isassembly ......................... page J2-39
Inspection .............................. page J2-65 l~nspection............................. page J2-23
3. Shift motor sensors Assembly .............................. page J 2 - 4 3
Inspection ............................... page J2-65
OUTLINE
OUTLINE
SPECIFICATIONS
Itern
- - - -- - --- -- - -- --
Oil Capaclty Liters (US p~nt, 1.2 (2.5, 2.1)
Imp pint)
Tvpe ATF Mercon ' M-Ill
Note
When the battery is disconnectedand reconnected,some abnormal drive symptoms may occur
while the powertrain control module relearns its adaptive strategy. The vehicle may need to be
driven 16 km (10 miles) or more to relearn the strategy.
POWERFLOW (TRANSFER)
OUTLINE
J2 OUTLINE, TRANSFER CASE OIL
MJ1062-B
0 1 TRANSFER CASE OIL

INSPECTION
Note
1. Remove the filler plug.
DRAIN PLUG ILLER PLUG
2. Verify that the oil level is near the filler plug port. If it is low,
add the specified oil.
Specified oil:
ATF Mercons M-Ill
3. Apply sealant to the threads of the filler plug. Install the

filler plug.
Tightening torque:
19-30 N-m (1.9-3.0 kgf-m, 14--22 ft.lbf]
REPLACEMENT
1. Remove the filler plug and drain plug.
2. Wipe the plugs clean.
3. Apply sealant to the threads of the drain plug and filler
plug.
4. After the fluid has drained, install the drain plug.
Tightening torque:
19-30 N.m (1.9-3.0 kgfm, 14--22 ft-lbf)
TRANSFER CASE OIL, OIL SEAL
5. Add the specified amount and type of oil to the filler plug
port until the level reaches the bottom of filler plug port.
Specified oil
ATF Mercons M-Ill
Capacity
1.2 liters (2.5 US pt., 2.1 Imp pt.)
6. Install the filler plug.
Tightening torque:
19-30 N.m (1.9-4.0 kgf-m, 14-22 ftelbf}
5BUOJ2-004
OIL SEAL
PREPARATION
SST
49 U027 003 For 49 F027 003 / For

Oil seal
output shaft
oil seal Driver handle Cw m output shaft
oil seal
installer
4BUOJ2-142
FRONT OUTPUT SHAFT
Replacement
2. Place the transfer case in 4WD.
3. Set the vehicle in (P) Park for automatic transmissions
and in gear for manual transmissions.
4. Remove the damper from the transfer case, if equipped.
5. Remove the skid plate from the frame, if equipped.
6. Remove the transfer case drain plug and drain the
transfer case fluid into a suitable container. (Refer to
Replacement, page J2-6.)
7. Remove the front propeller shaft from the transfer case.
(Refer to Section L.)
I FRONT OUTPUT SHAFT 78. Remove the locknut, steel washer, rubber seal and front
yoke.
9. Remove the oil seal.
10.Tap the new oil seal into the transfer case by using the
SSTs.
Note
SST numbers: 49 U027 003 Oil Seal Installer,
49 F027 003 Driver Handle.
Caution
Tap in until the installer contacts the case.
Coat th oil seal lip with transmission fluid.
J2-7
OIL SEAL
11. lnstall the front yoke, rubber seal, steel washer and
locknut.
Tightening torque:
250-275 N.m (25-28 kgf-m, 184--204 ft-lbf)
12. Install the front propeller shaft to the transfer case.

(Refer to Section L.)
Tightening torque:
16-22 N.m (1.6-2.2 kgf-m,12-1 6 ft.lbf)
) 1 13. lnstall the transfer case drain plug.
Tightening torque:
19-30 N-m (1.9-3.0 kgf.m, 14--22 ftdbf)
14. Add the specified amount and type of fluid. (Refer to

page J2-6.)
15. lnstall the filler plug.
Tightening torque:
MJI 148-A 5BUOJ2-005 19-30 N.m (13-3.0 kgfem,14-22 ft-lbf)
16.lnstall the damper, if equipped.
Tightening torque:
3 4 4 8 N-m ( 3 . 4 4 . 8 kgf.m, 25-35 ft-lbf)
Note
Apply threadlock to the bolts.
17. lnstall the skid plate, if equipped.
Tightening torque:
20-27 N-m(2.1-2.7 kgfem, 15-20 ft.lbf)
SHIFT LEVER
Note
Lubricate
e the
e bushing and pivot bolt prior to install-
ing the shift lever.
3. Install the shift lever onto the shift shaft lever

4. Tighten the nut.
Tightening torque:
26-45 N-m(2.6-3.6 kgf-m, 19-26 ft4bf)
5. Adjust the shift linkage. (Refer to page J2-12.)

4BUOJ2-015
Vent hose
Install the vent assembly with the white mark in the shifter
notch.
Note
The upper end of the vent hose should be 19mm
(314 in) above the top of the shift lever assembly and
just below the floor pan.
Rubber boot and floor pan cover
Install the rubber boot and floor pan cover.
Tightening torque:
Shift ball
1.Heat the shift ball with a heat gun to 60-87OC
(140-1 90°F).
2. Tap the shift ball onto the shift lever.
Note
The shift ball should be installed to the knurl on the
upper portion of the shift lever.
4BUOJ2-017
52 SHIFT LINKAGE (MANUAL SHIFT TRANSFER CASE)
SHIFT LINKAGE (MANUAL SHIFT

C TRANSFER CASE)
I
INSPECTION
Verify that the clearance between the shift lever and cam
plate in the 2H front 4H rear and the 4L position is as
specified.
Specification:
Maximum: 3.30mm (0.1 3 in}
4BUOJ2-018
ADJUSTMENT
1. Raise the rubber boot to access the top of the cam plate.
2. Loosen bolts " A and "B"one turn.
3. Move the shift shaft lever to the 4L position "C".
4. Rotate the cam plate clockwise around bolt "A" until the
shift shaft contacts point "D".
5. While holding the cam plate, tighten bolt " A first then "6".
Tightening torque:
Bolt A: 94--122 N-m(9.6-12.4 kgf.m,
70-90 ft-lbf)
MJ1039-B 5BUOJ2-008 Bolt 6: 43-56 N+m(4.4-5.7 kgf-m,
32-41 ft-lbf}
6. Verify engagement in all positions.

MANUAL SHIFT TRANSFER CASE 52
PREPARATION
SST
For 49 UNOl 024 For

removal installation
of bearing of front output
Step plate Needle bearing shaft bearing
adapter set replacer (chain cover
side)
1 49 UNOl 022 For

removal of
49 F027 005 For
Installation
front output I of front output
shaft bearing Output shaft shaft bearing
bearing replace,
I
49 UNOl 036 49 U027 003 For
removal /
6 installation
,
installation of of oil seal
Pinion bearing needle bearing Oil seal
cone replacer installer
For
removal of
49 UNOl 025 1 For
installation
front output of needle
Impact slide shaft bearing Bearing bearing 1
hammer installer bushing
49 F027 003
Driver handle
49 H027 002
(@k-T-@
For
installation of
front output
shaft bearing
For
49 F401 331
Bearing
installer set e,". For
installation
of needle
bearing
removal of
needle bearing
Axle bearing1 and bearing
seal plate sleeve
52 MANUAL SHIFT TRANSFER CASE
Problem Possible Cause Action I pagelsectid

Abnormal noise Incorrect tire pressure Adjust
Excessive tire wear Replace
1 Worn or damaged input shaft Replace
Worn or damaged rear output shaft gear Replace
Worn or damaged front output shaft gear Replace
Worn or damaged H-L shift collar ; Replace
--
Won't stay in Adjust
4-wheel drive Loose transfer case mounting bolts Tighten
Insufficient lubrication of slip yokes Lubricate
Loose or damaged slip yokes Tighten or replace
Worn or damaged 2W-4W lockup assembly Replace
Worn or damaaed 2W-4W shift fork Re~lace
Locking hubs will not Extremely cold temperatures Drive vehicle to warm axle
release after driving Worn or damaged locking key Replace
in reverse 10 feet Damaged cam assembly Replace
.--
meters)
(3 - -
Damaged hub assembly
pp-ppp
Replace
Won't shift to Loose shift linkage Adjust
2 wheel drive Worn or damaged 2W-4W lockup assembly Replace
Worn or damaged 2W-4W shift fork Replace
Loose shift linkage Adjust
Worn or damaged 2W-4W lockup assembly Replace
Worn or damaged 2W-4W shift fork Reolace
3. Drain the transfer case fluid into a suitable container.
Note
Drain the transfer case fluid before removal.
4. Remove the skid plate, if equipped.

5. Remove the damper, if equipped.
6. Disconnect the 4x4 indicator.
7. Remove the front propeller shaft. (Refer to Section L.)
8. Remove the rear propeller shaft. (Refer to Section L.)
9. Disconnect the Vehicle Speed Sensor (VSS).
GASKET, Q
REPLACE
I I
MJ1040-C 5BUOJ2-010
1. Vent hose Installation Note .............................. below
Installation Note .................... page J2-16 Disassembly .......................... page J2-17
2. Shift lever Inspection .............................. page J2-23
Removal / Installation ............ page J2-10 Assembly ............................... page J2-23
3. Transfer case 4. Shift shaft lever
Removal Note
Transfer case
1. Support the transfer case with a transmission jack.
3. Remove the transfer case and gasket from the extension
housing.
4BUOJ2-023
lnstallation Note
Transfer case
1. Install a new extension housing gasket.
2. Raise and align the transfer case to the transmission
output shaft.
c 3.Tighten the bolts in the sequence shown.
Tightening torque:
3 4 4 8 N-m(3.44.8 kgf-m, 25-35 ftalbf}
Vent hose
Install the vent hose with the white mark in the notch in the
shift lever assembly.
Note
(314 in) above the top of the shift lever assembly
and just below the floor pan.
4BUOJ2-025
Transfer case drain plug

1. Apply sealant to the threads of the transfer case drain
plug.
1 ( 2.Tighten the transfer case drain plug.
Tightening torque:
19-30 N-m (1-9-3.0 kgf-m, 14-22 ft-lbf)
Damper
lnstall the damper, if equipped.
Tightening torque:
3 4 4 8 N.m ( 3 . 4 4 . 8 kgfsm, 25-35 ft.lbf}
Note
Skid plate
Install the skid plate, if equipped.
Tightening torque:
20-27 N-m(2.1-2.7 kgf.m, 15-20 ft.lbf)
4BUOJ2-029
DISASSEMBLY
Precaution
General notes:
1. Disassemble the transfer case in a clean area to prevent entry of dirt into the mechanisms.
2. Use only plastic hammers when applying force to separate the light alloy case joints.
3. Several parts look alike; organize them so they do not get mixed up.
Cleaning notes:
1. Clean the transfer case exterior thoroughly with a steam cleaner of cleaning solvents before disassembly.
2. Clean the removed parts with cleaning solvent, and dry with compressed air. Clean out all holes and
passages with compressed air, and verify that there are no obstructions.
Warning
Wear eye protection when using compressed air to clean components.
Transfer case:
1. Drain the transfer case oil into a suitable container.
1.4X4 indicator switch 29. Front adapter, planet carrier
2. Rear yoke and input shaft assembly
3. Front yoke Disassembly Note ................. page J2-21
4. Oil seal 30. Tanged snap ring
5. Transfer case 31. Front adapter
Disassembly Note ........................... below Disassembly Note ................. page J2-21
6. Speedometer drive gear 32. Oil seal
7. Snap ring 33. Snap ring
8. Bearing 34. Planet carrier
Disassembly Note ................. page J2-20 Disassembly Note ................. page J2-21
9. Spring 35. Snap ring
10. Shift collar hub 36. Ball bearing
11.2W-4W lockup assembly Disassembly Note ................. page J2-21
Disassembly Note ................. page J2-20 37. Thrust washer
12.2W-4W shift fork 38. Thrust plate
Disassembly Note ................. page J2-20 39. Sun gear
13. Snap ring 40. Input shaft
14. Thrust washer 41. Needle bearing
15. Chain and bearing sleeve
16. Front drive sprocket 42. Shift shaft lever
Disassembly Note ................. page J2-20 Disassembly IVote ................. page J2-22
17. Drive sprocket 43. Set screws
Disassembly Note ................. page J2-20 44. Shift shaft
18. Magnet Disassembly lVote ................. page J2-22
19. Rear output shaft 45. Shift cam
Disassembly Note ................. page J2-20 46. Detent plunger
20. Pump assembly 47. Spring
/ -
Disassembly Note .................. page J2-20 48. Ring gear
21 . Oil pump filter Disassembly Note .................. page J2-22
Disassembly Note ................. page J2-20 49. Oil seal
22. Oil pump drive pin 50. Front output shaft bearing
Disassembly Note ................. page J2-20 (Transfer case side)
23. Front output shaft Disassembly Note .................. page J2-22
24. Shift rail 51. Chain cover
25. H-L shift fork 52. Front output shaft bearing
Disassembly Note ................. page J2-21 (Chain cover side)
26. H-L hub Disassembly Note ................. page J2-22
Disassembly Note ................. page J2-21 53. Lockup collar
27.4L assist spring 54. Sleeve return spring
28.4L assist roller 55. Lockup hub
Disassembly Note
Transfer case
Using a plastic hammer, remove the chain cover from the
transfer case.
4BUOJ2-031
Bearing
Remove the bearing using the SST
Note
SST number: 49 H033 101 Step Plate Adapter Set
2W-4W shift fork and lockup assembly

Remove the 2W-4W lockup assembly and 2W-4W shift
fork as an assembly.
Chain, drive sprocket and front drive sprocket

Remove the chain, drive sprocket and front drive sprocket
as an assembly.
I I
MJ1020-A 4BUOJ2-034
Rear output shaft, pump assembly and oil pump filter
1. Remove the rear output shaft, pump assembly and oil filter
as an assembly.
2. Remove the oil pump assembly from the rear output shaft.
Oil pump drive pin

1. Measure and record the height of the oil pump drive pin
prior to removal.
2. Remove the oil pump drive pin.
4BUOJ2-036
I 1H-L shift fork and H-L hub
Remove the H-L shift fork and H-L hub as an assembly.
Front adapter, planet carrier and input shaft
2. Removethe front adapter, planet carrier and input shaft as
an assembly.
4BUOJ2-038
Front adapter
1. Expand the tanged snap ring in the front adapter.
2. With the input shaft against a work bench, push down on
the front adapter.
3. Lift the input shaft and planet carrier from the front
adapter.
4BUOJ2-039
Planet carrier
Separate the planet carrier from the input shaft.
4BUOJ2-040
Ball bearing
Remove the ball bearing using a press and Pinion Bear-
ing Cone Remover D79L-4621-A, or equivalent.
PINION BEARING
CONE REMOVER
D79L-4621-A
Needle bearing and bearing sleeve

1. Position the input shaft on the SSTs. (49 UNO1 036 and
INPUT SHAFT 49 H027 002.)
BEARING 2. Insert Input Shaft Bearing Remover T91T-7127-A, or
REMOVER
T91T-7127-A equivalent on top of the bearing cage.
3.Tighten the actuator pin until it stops, then press the
bearing and sleeve out.
Shift shaft lever
1. Move the shift shaft lever to the 4L position, then up two
detents to the 4H position. Mark the transfer case in
relation to the position of the shift shaft lever.
2. Remove the nut and shift shaft lever.
Shift shaft
1. Remove the clip from the shift shaft.
2. Pry the shift shaft out of the transfer case.
3.Remove the O-ring from the second groove in the shift
shaft. Discard the O-ring.
4BUOJ2-044
MJ1025-B 4BUOJ2-043
Ring gear
Use a press to remove the ring gear.
Note
Note the relation of the serration to the chamfered
pilot diameter during removal.
4BUOJ2-045
Front output shaft bearing (Transfer case side)

1. Remove the snap ring.
2. Remove the front output shaft bearing using a drift and
the SST.
Note
SST number: 49 H033 101 Step Plate Adapter Set
Front output shaft bearing (Chain cover side)

Remove the front output shaft bearing using the SSTs.
1. Lockup hub 30. H-L shift fork
2. Sleeve return spring Assembly Note ...................... page J2-29
3. Lockup collar 31. H-L hub
4. Front output shaft bearing Assembly Note ...................... page J2-29
(Chain cover side) 32. Shift rail
Assembly Note ...................... page J2-26 Assembly Note ...................... page J2-29
5. Chain cover 33. Front output shaft
6. Front output shaft bearing 34. Oil pump drive pin
(Transfer case side) Assembly Note ...................... page J2-29
Assembly Note ...................... page J2-26 35. Rear output shaft
7. Oil seal Assembly Note ...................... page J2-29
Assembly Note ...................... page J2-26 36. Pump assembly
8. Ring gear Assembly Note ...................... page J2-29
Assembly Note ...................... page J2-26 37. Oil pump filter
9. Spring Assembly Note ...................... page J2-29
10. Detent plunger 38. Magnet
11. Shift cam 39. Drive sprocket
12. Shift shaft Assembly Note ...................... page J2-30
Assembly Note ...................... page J2-27 40. Front drive sprocket
13. Shift shaft lever Assembly Note ...................... page J2-30
Assembly Note ...................... page J2-27 41. Chain
14.4L assist roller Assembly Note ...................... page J2-30
Assembly Note ...................... page J2-27 42. Thrust washer
15.4L assist spring 43. Snap ring
Assembly Note ...................... page J2-27 44.2W-4W lockup assembly
16. Set screws Assembly Note ...................... page J2-30
- Assembly Note ...................... page J2-27

17. Input shaft
18. Sun gear
19. Thrust plate
45.2W-4W shift fork
Assembly Note ...................... page J2-30
46. Shift collar hub
47. Spring
20. Thrust washer 48. Bearing
21 . Ball bearing Assembly Note ...................... page J2-30
Assembly Note ...................... page J2-28 49. Snap ring
22. Snap ring 50. Speedometer drive gear
23. Needle bearing 51. Transfer case
and bearing sleeve Assembly Note ...................... page J2-30
Assembly Note ...................... page J2-28 52. Oil seal
24. Bearing sleeve Assembly Note ...................... page J2-31
Assembly Note ...................... page J2-28 53. Front yoke
25. Planet carrier Assembly Note ...................... page J2-31
26. Snap ring 54. Rear yoke
Assembly Note ...................... page J2-28 55.4X4 indicator switch
28. Front adapter Assembly Note ...................... page J2-31
29. Front adapter, planet carrier
and input shaft assembly
Assembly Note
Coat all of the parts with ATF.
4BUOJ2-050
Front output shaft bearing (Chain cover side)

Install the front output shaft bearing (chain cover side)
using the SSTs.
Note
Make sure the bearing is straight in the bore.
MJ1035-B 4BUOJ2-051
Front output shaft bearing (Transfer case side)
I.Install the front output shaft bearing using the SSTs.
Note
The bearing must be driven straight into the bore.
SST numbers: 49 F027 005 Output Shaft Bearing
Replacer, 49 F027 003 Driver Handle.
2. Install the snap ring.

Oil seal
lnstall the oil seal using the SSTs.
MJ1026-A 4BUOJ2-052
Note
SST numbers: 49 F027 005 Output Shaft Bearing
Replacer, 49 F027 003 Driver Handle.
5BUOJ2-015
Ring gear
1. Align the serrations on the outside diameter of the ring
gear with the serrations previously cut into the transfer
case.
2. Using a press, start the chamfered end of the ring gear into
the transfer case. Press until fully seated in the case.
Note
The ring gear must be pressed straight into the
bore.
Shift shaft
Fill the second groove on the shift shaft with long-life
grease. lnstall a new O-ring.
Note
Use a rubberband to fill the first groove while
installing the O-ring. Remove the rubberband after
the O-ring is installed.
Shift shaft lever
Install the shift shaft lever and nut.
Tightening torque:
26-35 N-m(2.6-3.5 kgf-m, 19-26 ftdbf)
4BUOJ2-056
4L assist roller I assist spring

1. Place the 4L assist roller on the 90" bent tang of the 4H
assist spring.
Note
Position the shift shaft lever in the 4L detent
position.
2. Insert the roller into the assist springlroller slot of the shift
cam.
3. Position the middle section of the assist spring into the
groove of the pivot boss.
4. Press to lock the upper end of the assist spring behind the
anchor tab.
Set screws
Tighten the set screws to the specified torque.
Tightening torque:
7-10 N-m(0.72-1.0 kgf-m,5.2-7.4 ft-lbf)
Note
The set screw in the transfer case must be inserted
in the first groove of the shift shaft.
Do not bottomthe screw against the shift shaft. The
shift shaft must move freely at all detent e
positions.
4BUOJ2-035
52 MANUALSHIFT TRANSFER CASE
Ball bearing
1. Slide the sun gear, thrust plate and thrust washer onto the
input shaft.
Note
The sun gear recessed face and the snap ring
groove in the ball bearing outer race should be
toward the rear of the transfer case. The stepped
face on the thrust washer should face toward the
ball bearing.
2. Press the ball bearing over the input shaft.

Needle bearing
1. Position the input shaft on the SSTs. (49 UNOl 036 and
49 H027 002.)
2. Use a press and the SST to install the needle bearing until
it seats in the shaft.
Bearing sleeve
Use a press and the SST to install the bearing sleeve.
Oil seal
Install the oil seal in the front adapter using the SSTs.
Front adapter, planet carrier and input shaft
assembly
1. Place the tanged snap ring in the front adapter groove.
2. Using the SST place the input shawplanet carrier assem-
bly in the front adapter.
Note
SST number: 49 F401 331 Bearing Installer Set
3. Expand the tanged snap ring while pressing the input

shamplanet carrier assembly inward until the input shaft/
planet carrier assembly seats in the front adapter.
Note
Once the input shaWplanet carrier assembly is
installed, grasp the front adapter and tap the input
shaft on a bench to ensure the snap ring is seated.
4. Apply sealant to the mating surface of front adapter.
5. Position the front adapter on the transfer case and install
the bolts.
Tightening torque:
3 1 4 1 N-m (3.24.1 kgfem, 23-30 ftelbf)
4BUOJ2-063
[ I
H-L shift fork and H-L hub
Install the H-L shift fork and H-L hub as an assembly
Note
The nylon pads must be on the H-L. shift fork and
snapped into place.
I I
MJ1022-A 4BUOJ2-064
-1 2. Insert the H-L fork roller into the H-Ltrack of the shift cam.
Shift rail
1. Install the shift rail.
2. Use the shift shaft lever to position the H-L shift fork in
the 4H position.
4BUOJ2-066
Oil pump drive pin

Press a new oil pump drive pin into the rear output shaft.
I
MJ 1029-A
/
4~~0~2-06s
Oil pump drive pin height:
Height measured during disassembly or
Minimum: 1mm (0.040 in}
4BUOJ2-067
Rear output shaft, pump assembly and oil pump filter

1. Install the pump assembly onto the rear output shaft.
Note
If the oil pump assembly does not turn freely when
installed on the rear output shaft, re-align the cover
keyway to the oil pump drive pin until the pump fully
seats and rotates freelv.
I
~~1021-A
I
46~0~2-068
If a new oil pump assembly is used, remove the
plastic insert from the bore when it slides out while
installing it on the rear output shaft.
While turning the rear output shaft, prime the oil
pump assembly with ATF.
2. Installthe rear output shaft, oil pumpasseinbly and oil filter

as an assembly.
3. Make sure the retaining arm and the oil pump filter are in
the groove and notch of the transfer case.
52 -
Chain, drive sprocket and front drive sprocket
lnstall the drive chain, drive sprocket and front drive
I
I & sprocket as an assembly.

Note
The front drive sprocket (on the front output shaft)
must be installed with the "REAR" stamping facing
the chain cover, if so stamped.
2W-4W lockup assembly and 2W-4W shift fork

Install the 2W-4W lockup assembly and the 2W-4W shift
I I
MJlO19-A 4BUOJ2-070
Bearing
Install the bearing into the transfer case cover using the
SSTs.
Transfer case
1. Apply sealant to the mating surface of the transfer case.
Note
Move the chain cover up and down to ensure it
seats properly.
2. Install the transfer case to the chain cover.

MJ1036-B 4BUOJ2-071
Tightening torque:
3 1 4 1 N-m( 3 . 2 4 . 1 kgf.m, 23-30 ft-lbf)
4BUO.K-072
Problem 1 Possible Cause 1 Action

Abnormal noise Incorrect tire pressure Adjust Section Q
Excessive tire wear Replace Section Q
Worn or damaged input shaft Replace J2-39
Worn or damaged rear output shaft gear Replace J2-39
Worn or damaged front output shaft gear Replace J2-39
Worn or damaged H-L shift collar Replace 32-39
Worn or damaged 2W-4W lockup assembly Replace --
J2-39
Won't stay in Loose transfer case mounting bolts Tighten
4-wheel drive Insufficient lubrication of slip yokes Lubricate
Loose or damaged slip yokes Tighten or replace
Worn or damaged 2W-4W lockup assembly Replace ---
Locking hubs will not Extremely cold temperatures Drive vehicle to warm axle -
release after driving Worn or damaged locking key Replace Section M
in reverse 10 feet Damaged cam assembly Replace Section M
(3 meters) Damaged hub assembly Re~lace Section M
Won't shift to Malfunction of electronic shift system lnspect
Worn or damaaed 2W-4W shift fork Re~lace
Won't
o shift to Malfunction of electronic shift system Inspect
or damaged 2W-4W shift fork Replace
-
UJ1085-F
4x4 SWITCH OPERATlONl

To shift from 2WD to 4WD high, turn the knob to 4x4 high. You will hear a click from the rear of the vehicle
and the 4x4 indicator light will illuminate. To shift from 4x4 high to 4x4 low, stop the vehicle and place it in
Neutral with the brake pedal depressed (automatic transmission), or with the clutch pedal and brake pedal
depressed (manual transmission).
To shift out of 4x4 low, stop the vehicle, put the transmission in Neutral, and apply the brake (automatic
transmission) or apply the brake and the clutch (manual transmission). Drive the vehicle in reverse for a
minimum of 10 feet in order to disengage the front axle automatic locking hubs.
The vehicle can be shifted between 4x4 high and 2WD while moving.
J2 ELECTRONIC SHIFT TRANSFER CASE
4x4 SHIFT CONTROL SWITCH
I I
MN1183-A 5BUOJ2-036
1 . 4 ~ shift
4 control switch
2. Harness connector
4x4 TRANSMISSION SELECT RELAY

1. Remove audio system. (Refer to Section J of the 1997 B-Series BETM.)
I 7
I I
MJ7000-A 7BUOJ2-001
1. Harness connector. 2. 4x4 transmission select relay.
ELECTRONIC SHIFT MOTOR ASSEMBLY
3. Remove in the order shown, referring to Removal Note.
I
MJ1155-B
N.m {kgfm, ft.lbf)
6BUOJ2-003
1. Motor connector 2. Shift motor sensor
Removal Note ....................... page J2-37 3. Electronic shift motor assembly
Removal Note
Motor connector
Note
Use a bent paperclip to disconnect the motor con-
nector.
Remove the brown wire from the motor connector.

Installation Note
Mounting bracket screws
Tightening torque:
8.1-10.8 N.m (0.82-1.1 kgf.m, 6--8 ft-lbf)
5BUOJ2-023
Electronic shift motor assembly screw
Tightening torque:
8.1-10.8 N.m (0.82-1.1 kgf.m, 6-8 ftdbf)
5BUOJ2-024
Motor bracket bolt
Tightening torque:
8.1-10.8 N.m (0.82-1.1 kgf-m, 6-8 ft.lbf)
5BUOJ2-025
3. Drain the transfer case fluid into a suitable container
Note
Drain the transfer case fluid before removal.
4. Remove the skid plate, if equipped.

5. Remove the damper, if equipped, referring to Removal Note. (Refer to page J2-37.)
6. Disconnect the motor connector and remove it from the mounting bracket.
8. Remove the rear propeller shaft. (Refer to Section L.)
9. Disconnect the Vehicle Speed Sensor (VSS).
ELECTRONIC SHIFT TRANSFER CASE J2
N.m {kgf-m, ft.lbf) I

MJ1143-A 5BUOJ2-026
1. Vent hose 2. Transfer case
Installation Note .................... page J2-38 Removal Note ................................. below
Installation Note .................... page J2-38
Removal Note
Damper
Remove the damper, if equipped.
Transfer case
1. Support the transfer case with a transmission jack.
3. Remove the transfer case and gasket from the extension
housing.
4BUOJ2-092
52 ELECTRONIC SHIFT TRANSFER CASE
Installation Note
Transfer case
I . lnstall a new extension housing gasket.
2. Raise and align the transfer case to the transmission
output shaft.
I
3.Tighten the bolts in the sequence shown
Tightening torque:
3 4 4 8 N-m(3.4-4.8 kgf-m, 25-35 ft-lbf)
Vent hose
lnstall the vent hose with the white mark in the notch in the
bracket.
Note
(314 in) above the top of the shift lever assembly
MJIO~I-A 46~0~2-093 and just below the floor pan.
5BUOJ2-028
Transfer case drain plug

1. Apply sealant to the threads of the transfer case drain
plug.
2. lnstall the transfer case drain plug.
Tightening torque:
19-30 N.m (1.9--3.0 kgf-m, 14--22 ft.lbf)
Damper
lnstall the damper, if equipped.
J
~~1148-A 46~0~2-096 Tightening torque:
34-48 N-m C3.5--4.8 kgf.m, 25-35 ft-lbf)
Note
4BUGJ2-097
Skid plate
Install the skid plate, if equipped.
-
Tiahteninn torque:
20-27 ~ . (i.1-2.7
m kgfem, 15-20 ft-lbf}
4BUOJ2-098
ELECTRONIC SHIFT TRANSFER CASE J2
DISASSEMBLY
-- Precaution
General notes:
1. Disassemble the transfer case in a clean area to prevent entry of dirt into the mechariisms.
Cleaning notes:
1. Clean the transfer case exterior thoroughly with asteam cleaner of cleaning solvents beforedisassembly.
Warning
Transfer Case
1. Drain the transfer case oil into a suitable container.
2. Remove the brown wire from the motor connector, referring to Removal Note. (Refer to page J2-42.)
OIL SEAL,
REPLACE
1. Rear yoke 29. Pump assembly
2. Front yoke Disassembly Note ................. page J2-20
3. Wire harness bracket 30. Oil pump filter
4. Oil seal Disassembly Note ................. page J2-20
5. Motor connector spacer 31. Oil pump drive pin
6. Motor assembly Disassembly Note ................. page J2-20
7. Transfer case 32. Front output shaft
8. Speedometer drive gear 33. H-L shift fork
9. Bearing Disassembly Note ................. page J2-21
Disassembly Note ................. page J2-20 34. H-L hub
10. Front output shaft bearing Disassembly Note ................. page J2-21
(Chain cover side) 35. Front adapter, planet carrier
Disassembly Note ................. page J2-22 and input shaft assembly
11. Clutch coil Disassembly Note ................. page J2-21
12. Spring 36. Tanged snap ring
13. Clutch housing assembly 37. Front adapter
14.2W-4W lockup assembly 38. Oil seal
Disassembly Note ................. page J2-20 39. Snap ring
15.2W-4W shift fork 40. Planet carrier
Disassembly Note ................. page J2-20 41. Snap ring
16. Shift rail 42. Ball bearing
17. Shift cam assembly Disassembly Note ................. page J2-21
Disassembly Note ................. page J2-42 43. Thrust washer
18. Spacer 44. Thrust plate
19. Shift cam 45. Sun gear
20. Torsion spring 46. Input shaft
21. Shift shaft 47. Needle bearing
22. Snap ring and bearing sleeve
23. Thrust washer Disassembly Note ................. page J2-21
24. Chain 48. Oil seal
Disassembly Note ................. page J2-43 49. Front output shaft bearing
25. Front drive sprocket (Transfer case side)
26. Drive sprocket 50. Ring gear
27. Magnet 51. Chain cover
28. Rear output shaft 52. Lockup collar
Disassembly Note ................. page J2-20 53. Sleeve return spring
54. Lockup hub
Disassembly Note
Motor connector
Remove the brown wire from the motor connector
Clutch housing assembly

Remove the clutch housing.
Shift cam assembly

Remove the spacer, shift cam, torsion spring and shift
shaft as an assembly.
1. Lockup collar 28. Magnet
2. Sleeve return spring 29. Chain
3. Lockup hub Assembly Note ...................... page J2-30
4. Chain cover 30. Front drive sprocket
5. Front output shaft bearing Assembly Note ...................... page J2-30
(Transfer case side) 31. Drive sprocket
6. Ring gear 32. Thrust washer
Assembly Note ...................... page J2-26 33. Snap ring
7. Oil seal 34. Shift cam assembly
8. Input shaft 35. Spacer
9. Needle bearing 36. Shift cam
Assembly Note ...................... page J2-28 37. Torsion spring
10. Bearing sleeve 38. Shift shaft
Assembly Note ...................... page J2-28 39. Shift rail
11. Sun gear 40.2W-4W lockup assembly
12. Thrust plate Assembly Note ...................... page J2-46
13. Thrust washer 41.2W-4W shift fork
14. Ball bearing Assembly Note ...................... page J2-46
Assembly Note ...................... page J2-28 42. Clutch housing
15. Snap ring Assembly Note ...................... page J2-47
16. Planet carrier 43. Spring
17. Snap ring 44. Clutch coil
Assembly Note ...................... page J2-28 45. Front output shaft bearing
19. Front adapter (Chain cover side)
20. Front adapter, planet carrier Assembly Note ...................... page J2-26
f-7
and input shaft assembly 46. Bearing
21. H-L shift fork 47. Speedometer drive gear
Assembly Note ...................... page J2-29 48. Transfer case
22. H-L hub Assembly Note ...................... page J2-30
Assembly Note ...................... page J2-29 49. Motor connector spacer
23. Front output shaft 50. Motor assembly
24. Oil pump drive pin Assembly Note ...................... page J2-48
Assembly Note ...................... page J2-29 51. Oil seal
25. Rear output shaft Assembly Note ...................... page J2-31
Assembly Note ...................... page J2-29 52. Rear yoke
26. Pump assembly Assembly Note ...................... page J2-31
Assembly Note ...................... page J2-29 53. Front yoke
27. Oil pump filter Assembly Note ...................... page J2-31
Shift cam assembly
1. Slide the spacer onto the shift shaft.
2. Place the torsion spring on the shift shaft.
FIRST SPRING TANG

3. Position the first spring tang on the left of the drive tang.
SPACER S H I ~
SHAFT
dJ1053-A
4. Position the second spring tang on the right of the drive
SECOND SPRING TANG tang.
5. Push the torsion spring and spacer onto shift shaft.
6. Install the pin on the shift shaft into the hole in the transfer
case.
Note
The spring tang and drive tang should point toward
the transfer case touching the H-L shift fork.
7. Position the spring tangs and drive tang.

SPRING
DRIVE
TANG
SHIFT FORK
I I
MJ1055-A 4BUOJ2-108
2W-4W lockup assembly and 2W-4W shift fork
Install the 2W-4W lockup assembly and the 2W-4W shift
MJ1048-A 4BUOJ2-I09
J2-46
ELECTRONIC SHIFT TRANSFER CASE 52
Clutch housing
Install the clutch housing.
NOTCH
Note
The shift shaft should be in the 2H position at final
assembly.
The cavity or notches should be facing the chain
cover.
Raise the 2W-4W shift fork while holding the shift
rail in place. Engage the 2W-4W shift fork bushing
into the shift cam.
Clutch coil
1. Apply sealant to the clutch coil studs and grommet as
2. Feed the brown wire through the chain cover.
3. Install the clutch coil assembly into the chain cover.
Tightening torque:
8-11 N-m(0.82-1 .I kgfem, 5.9-4.1ft.lbf)
Motor assembly
1. Rotate the shift shaft to align it with the slot in the motor.
Note
If shift shaft will not stay in position, rotate the
motor counterclockwise during installation.
2. Apply sealant to the motor housing base.

3. Loosen the motor bracket nuts.
4. Install the wire harness bracket and motor assembly.
Tightening torque:
8.1-10.8 N.m (0.82-1.1 kgfsm, 6-43 ft.lbf)
5. Install the motor bracket.
Tightening torque:
Bolt: 8-1 1 N-m (0.82-1.1 kgf.m, 5.9-4.1 ftelbf)
Nuts: 2 4 N.m (0.2-0.4 kgf.m, 1.5-3.0 ftelbf)
6. Install the brown wire into the motor connector.

58UOJ2 032
TROUBLESHOOTING
Circuit Diagram
Retrieving DTCs
1 . Perform the necessary vehicle preparation and visual
c 2. Select VEHICLE AND ENGINE SELECTION.

VIEW RECORDER AREAS
3. Select SELECT NEW VEHICLE YEAR & MODEL.
1I
NO VEHICLE SELECTED
I" "I I
\' SELECT ITEM AND PRESS TRIGGER TO START )/
MJ 1 173-A
4. Select DIAGNOSTIC DATA LINK.
I' 1 1 1I 1
VEHICLE & ENGINE SELECTION
1 1 I 11 DIGITAL MEASUREMENT SYSTEM

GENERIC OED II FUNCTIONS
I

-- -
-
1 5. Select GEM - GENERIC ELECTRONIC MODULE.

6 . Retrieve DTCs.
1 1I
PCM - POWERTRAINCONTROI. MODULE
ABS -ANTI LOCK BRAKE MODULE
-
I 1 II RAP REMOTE ANTI THEFT MODULE
DATA LINK DIAGNOSTICS
I11
\: SELECT ITEM AND PRESS TRIGGER TO START
I
MJ1175-A
2
Erasing DTCs
1. perform the necessary vehicle preparation and visual
2
SELECT ITEM AND PRESS TRlGGlER TO START
3.Select SELECT NEW VEHICLE YEAR & MODEL.
1/71 1
NO VEHICLE SELECTED

c 4. Select DIAGNOSTIC DATA LINK.
II Ill I
VEHICLE 6 ENGINE SELECTION
VIEW RECORDER AREAS

--DIGITAL MEASUREMENT SYSTEM I
GENERIC OED II NNCTlONS
MJl174-A
5. Select GEM - GENERIC ELECTRONIC MODULE.
6. Clear DTCs.
5BUOJ2-040
PCM -POWERTRAIN CONTROL MODULE

ABS -ANTI LOCK BRAKE MODULE
RAP -
REMOTE ANTI THEFT MODULE
DATA UNK DIAGNOSTICS

lELECTRONlC SHIFT TRANSFER CASE
DIAGNOSTIC TROUBLESHOOTING GUIDE
Probl m Action
4x4L range circuit DTC P I 729 self test and 4x4L switch voltage low or high
malfunction continuous code 4x4L switch out of KOEO self test range
4x4L range circuit DTC P I 781 self test and 4x4L switch voltage low or high
malfunction continuous code 4x4L switch out of KOEO self test range
Cannot change 4x4 mode 1 DTC P1800 self test code Check circuit (RIB) between the clutch interlock
switch and GEM for short to battery 1 - 1
DTC P1812, P I 815 self test Go to Pinpoint Test A
and continuous code
DTC P I 816 self test and Check circuit ( R N )between neutral switch arrd
continuous code to battery or open
-- -.
Cannot change 4x4 gears D'TC P I 820 self test and in Pinpoint Test B
continuous code p - ~ ~ - - ~ ~ -
D'TC P I 822 self test and 5 in Pinpoint Test B

cc~ntinuouscode
-.
DTC P I 824 self test and / Go to step 8 in Pinpoint Test B
cc~ntinuouscode
D'TC P I 826 self test and
continuous code
yp I
9 in Pinpoint Test B
D'TC ~ 1 8 2 self
8 test and
continuous code
Go to step 14 in Pinpoint Test B
I J2-59 I
D'TC P1830 self test and
continuous code
I DTC P1838 continuous code /

I
1
J2-59
J2-60
1
1
11 D'TC P I 846, P I 867 self test
code
DTC P I 850 self test code
Go to step 38 in Pinpoint Test B 1 J2-61 I

DTC P I 850, P I 867 continuous Go to step 38 in Pinpoint Test B
code i
DTC P I 854, P I 867 self test Go to step 40 in Pinpoint Test B
code
DTC P1862 self test and Go to step 44 in Pinpoint Test B
continuous code
I DTC P I 864 self test code I Go to step 46 in Pinpoint Test B
48 in Pinpoint Test B J2-62
P I 866 continuous code
49 in Pinpoint Test B
P1866 continuous code
DTC P1856 self test code and Go to step 50 in Pinpoint Test B
P I 866 continuous code
Go to step 5 in Pinpoint Test C

c~sntinuouscode
PI804 self test and / Repair circuit (GY) for short to ground between
continuous code GEM C3-14 and indicator lamp
P I 808 self test and Go to step 1 in Pinpoint Test D
never illuminates continuous code
DTC P I 810 self test and
continuous code
1 Go to step 5 in Pinpoint Test D
P I 808 self test and Repair circuit (LBIB) for short to ground between
continuous code GEM module C3-10 and indicator lamp
Pi474 self test and Repair circuit (LGIO) between H2L or L2H
continuous code for short to batterv
4x4 mode switch does not - / Check circuits between 4x4 switch and GEM
illuminate with headlamp module for open or short to ground
switch ON
I Problem Action '

~aae?
Transfer case makes noise
1
lncorrect tire inflation
pressures or incorrect size
tires and wheels
Excessive tire tread wear
Make sure that all tires and wheels are the
same size, and that inflation pressures are correct.
Check tire tread wear to see if there is more than

Section
1
.06 inch difference in tread wear between front Sectlon
and rear. lnterchanae
" one front and one rear Q
wheel. Reinflate tires to specifications
Internal components OPERATE vehicle in all transmisslon aears
gears wlth transfer case In 2H, or ~1~h;an~e --
If there IS nolse In transmlsslon In neutral gear, or Section
In some gears and not In others, remove and J1 or K
repalr transmlsslon.
If there 1s nolse In all gears, operate vehlcle In
all transfer case ranges. If nolsy In all ranges or
Hlgh range only, disassembly transfer case.
Check Input gear, lntermedlate and front output J2-39
shaft gear for damage. Replace as requlred
If nolsy In Low range only, Inspect lntermedlate
gear and slldlng gears for damage.
Replace as required. -- -- - --
4-Wheel drive transfer case Incomplete shift linkage Adjust llnkage to provlde complete gear -
jumps out of gear !
L
travel 1 engagement. Adjust shift lever rubber boot
Loose mounting bolts Tighten mountlng bolts .- - pp
-
---
Lubricate and repalr slip yokes as requ~red.
dry or loose Tighten flange yoke attaching nut to -
.
- --
Internal components Disassemble transfer case. Inspect slldlng clutch

hub and gear clutch teeth for damage. Replace J2-39
' as requlred
Locking hubs will not
release
I
/
1
Drivelinelvehicle torsional
lockur,
Extremely cold ambient
Stop vehicle. Drive vehicle in reverse for 10 feet
Drive vehicle 10 miles to warm axle, then try to

- I
/ temperatures disenaaae hub locks
Driveline/torsional windup Incorrect tire inflation Make sure that all tires and wheels are the same Section
vehicle hop, wheelitire pressures or incorrect size size, and that inflation pressures are correct Q
bounce, vehicle skip -
tires
.
and
---
wheels -
-- - -- --- --- -- - -- - --
Excessive tire tread wear Refer to vehicle owner's guide for correct usage
Drlvlng vehlcle on hard of vehlcle. Advise owner
surfaceidry surface roads or
areas Drlvlng vehlcle In tlght
turns
-- -
Delayed sh~ftsto 2WD

--
1 Dr~velineitors~onalwlndup
-- -- - -
- -- -- - -- - - -
Shlft transmisslon Into neutral Jack the vehlcle

or lift on holst wlth wheel free to rotate Wlndup
-
will be released and transfer case wlll complete ~ t s

-- - -- -
sh~ft
-- -- - -- - - - -
Extremely cold ambient Drlve vehicle 10 m~lesto warm axle, then try to
ternDeratures dlsenaaae hub locks
IELECTRONIC SHIFT TRANSFER CASE
- -
DIAGNOSTIC TROUBLE CODE LIST

Diagnosed Condition
Circuit
range circuit malfunction 4x4L switch voltage low or high
4x4L switch out of KOEO self test range
I1 PI804
1I 4x4 LOW (4x4L) range circuit malfunction
~ W HIGH
D indicator
4x4L switch voltage low or high
4x4L switch out of KOEO self test range
/ Circuit failure 1 J2-63 (
P I 806 1 4WD HIGH indicator 1 Short to B+ 1 J2-63 1
Circuit failure
J2-64
Circuit failure
Short to around
P I 820 Transfer case relay rnodule CW relay ! Circuit failure J2-58
PI822 Transfer case relay rnodule CW relay 1 Short to B+ J2-58
1 P I 824 / Electric shift relay I Circuit failure / J2-58 1
1 PI826 1 Electric shift relay 1 Short to B+ 1 J2-58 1
1 PI828 1 Transfer case relav rnodule CCW relav 1 Circuit failure 1 J2-58 1
( PI830 / Transfer case relay rnodule CCW relay 1 Short to B+ 1 J2-58 1
1 P I 846 1 Transfer case touch drive plate A / Circuit failure 1 J2-58 1
( P I 848 ( Transfer case touch drive plate A (Short B+ 1 J2-58 1
Circuit failure
Circuit failure
1 P I 856 / Transfer case touch drive plate C 1 Short B+ ( J2-58 1
( P I 858 / Transfer case touch drive plate D 1 Circuit failure 1 J2-58 1
Short B+
Circuit failure
1 P I 864 / Transfer case touch drive date ( Y W ) / Short B+ 1 J2-58 1
PI866
PI867
Transfer case system concern
Transmission transfer case contact plate
-
Circuit failure -+--id J2-58
Diagnostic trouble 4x4 low (4x4L) range circuit malfunction

code No. PI 729,PI 781
- - - -- ---- -
- ---- -
Symptom DTC 1729 ind~cates4x4L sw~tchfa~lureopen or shorted
DTC 1781 indicates 4x4L sw~tchposition closed dur~ngKOEO
- 7 - -
STEP
, -- ----------------
INSPECTION ACTION --
Do GEM or PCM connectors or mating pins , - - -Yes
_ _ _ _ . Repatr
__--_ as_needed
___----
have a poor connection?
d--
No , Go to next step - -- - - -
NGS Installed
Perform KOEO qu~cktest -- --
ction 4x2 or 4x4H ava~labledur~ngqu~ck
4x2 or 4x4H and rerun quick test
ccess 4x4L and TR PID

NOTE Foot must be on brake and TR
sensor must indicate neutral posttlon before
Cycle 4x4L sw~tchto 4x2

W~gglesmall sections of vehicle harness startlng
1 at the transfer case and work towards the GEM
1 Tap vehlcle harness connector at the transfer
' case
Wiggle sections of the harness between the
/ GEM and the PCM
I Does the NGS read~ng fluctuate between 4x4L
/ and 4x2 w~ththe 4x4 sh~ftcontrol sw~tchIn the
( 4 x 4 ~pos~tton?
+ - -- - - --- ---
Key OFF
Disconnect PCM
BOB ~nstalled,leave PCM d~sconnected
Does voltage fluctuate while measurlng read~ngs

between test pins 14 and 24 at the BOB wh~le o Go to next step
I cycl~ngthe 4x4L switch?
/ NOTE Transmiss~onIn neutral, brake
\ applied
( Key OFF
Disconnect PCM
BOB ~nstalled,leave PCM disconnected
D~sconnectGEM connector T-223 -- -- --
Is res~stanceless than 5 ohms when measurlng
between test pln 14 at the BOB and the 4x4L pln
(LBIB w~re)at the GEM vehicle harness
i
1
connector?
Yes to next step
~ ~ ~PCMc ~ ~ ~ c t
BOB installed, leave PCM disconnected
I GEM d~sconnected
I Measure resistance between test plns 14 and 24 r -
at the BOB No Service short c~rcult
Measure resrstance between test plns 14 and 71
at the BOB
Is each resistance greater than 10,000 ohms? 1
Key OFF 1 Yes Refer to troubleshoot~nggulde UTpage J2-33
PCM reconnected Refer to 4x4 system d~agnost~csa;i' Section K
GEM reconnected
Instrument cluster connector C-214 disconnected. -, -
Check resistance between instrument cluster
instrument cluster printed circuit
I printed circuits 12 (018) and 15 (LBIB)
-
Is there continu~ty? l--l_ ----- - --
8 Perform After Repa~rProcedure to ensure customer's concern has been resolved

*TEST PINS LOCATED ON BREAKOUT BOX
code No. P1812, Pi815

INSPECTION 1 ACTION I
Remove and disconnect 4x4 shift control Go to steo 2.
switch. Replace 4x4 shift control switch.
Inspect wiring and connector for damage. Clear all DTCs and retest system.
Test Circuits (WILB) and (GYIR) for
resistance values in listed positions
below:
2WD - 2K-8.7KS2
4WD High - 750R-1.9KQ
4WD LOW- 160-600R
Are the values correct?
Gain access to the GEM module T-223 Yes
-
Go to step 3.
Connector. Measure resistance of Pin 08, No Repair circuit (WILB) foropen.
Circuit (WILB) between GEM module Reconnect and clear all DTCs and retest system.
and 4x4 shift control switch.
I Reconnect GEM T-223 Connector

Kev, ON- ~
1 Yes Service battery short reconnect switch.
Clear all DTCs and retest svstem.
Measure for voltage on Circuits (WILB)
and GY/R)
/ Is B+ present? 1
Disconnect GEM T-223 Connector
Check T-223 Pin 08 for continuity to a
1
C
-
yes Service circuit (WILB) for short to ground.
Clear all DTCs and retest system.
known ground Go to step 5.
Is continuitv present'? I
No
Remove GEM T-221 Connector Circuit OK. Reconnect GEM connector.

Check Circuit (GYIR between 4x4 shift Clear all DTCs and retest system.
control switch and GEM T-221 Connector Service cirucit (GYIR) for open.
Pin 21 for continuity Clear all DTCs and retest svstem.
IMJ1179-A 1 Is continuity present'? I 5BUOJ2-043
. -
Pinpoint Tests B I Cannot Change 4x4 Gears - - -
Diagnostic trouble I Refer to DTC chart for def~nltlon
code No. P1820, P1822,
P1824, P1826, P I 828, P1830,
P I 838, P I 846, P I 848, P1850,
P1852, P1854, P1856, P I 858,
P1860, PI 862, P1864, P I 866,
P1867
- - -- - - -- - -
STEP INSPECTION
- - - ---- - -- -
1 Key OFF
Check fuse #27 1OA for open - - - -- - -
Is fuse open7 Go to step 3

- - - ---- - -- -- -- - - - -
2 Key OFF Yes S e ~ l c eGY wlre clrcult for short to ground

D~sconnectGEM module T-223 connector Replace fuse 27
Check T-223 pln 16 clrcu~tfor short to ground (GY w~re) Clear DTCs and retest system
+------------- - -
f Is contlnulty present?
- - -L---- - -
3 ( ~OFFe ~ Replace electrlc shlft control module
Clear all DTCs and retest
i~~
I D~sconnecttransm~ss~on select relay connector
Check for contlnu~tybetween plns B and E of the module 1 - - - - - -- -
(see pg J2-62)
IS cont~nultypresent?
to step 4 ~6
-- - -+- - -- - -,
-- -- -- - p-
-- - - -
4 Key OFF
Measure contlnulty between GEM T-223 connector p ~ n
16 and the electrtc sh~ftcontrol module vehlcle harness
connector p ~ 08n (GY wlre) connectors Clear all DTCs and retest system
Is contlnulty present?
- - .-- --- ---
- - -
- - -- - -- -- -
5 Kev OFF
~lsconnecttransm~sslonselect relay
Measure reslstance between plns B and G of the module
(see pg J2-62)
-,
N~
-
~~~l~~~ 1 - --
shift control module
Clear all DTCs and retest system
-- -- -
Is reststance between 85-140 ohms? 1

- - ----- -- - -- -- - - - - - - - -- - - -- -
6 Key OFF Yes I S e r v o e GY wlre clrcut for short to battery Clear all
Remove transm~ssonselect relay / DTCs and retest system
Measure voltage at p ~ 08
n (GY wlre) of the vehlcle - -
harness connector
Is battery voltage present?
- -NT to step 7 .
- -- - -- - -- -
- -- - - - -- -- -- - -
7 Key OFF Yes l ~ e =re r clrcu~t

~ for short to ground
D~sconnectGEM T-223 connector / Clear all DTCs and retest system
Remove electrlc sh~ftrelay (see pg J2-62)
Check p ~ 15n GEM module (Y wlre) vehlcle harness
connector for cont~nultyto ground
- - ,
Is cont~nu~typresent?
- -- - - pp - - --
8 I W~ththe electrlc sh~ftrelay removed, check for contlnu~ty Replace electrlc sh~ftrelay Clear all DTCs and retest
-- -
between terminals C and E (see pg J2-62) of the relay pp - - --
I Is contlnu~typresent?
. - -- - - - -- - - - -- - -- - - -- -
9 W~thshlft relay removed, kev ON (see pq J2-62), check

for battery voliage at DGILG w~reat the electric sh~ft - - - / -- -
control module and also the electr~cshlft relay veh~cle Serv~ceDGILG wlre clrcult for an open
harness connectors Clear all DTCs and retest system
Is battery voltage present7
- - - -- - - --- - - -- - - - -- -- - - -
10 Key OFF < e F Service DGILG wlre clrcu~tfor a short to ground

D~sconnecttransrnlsslon select relay Clear all DTCs and retest
Check p ~ 03
n at the electrlc shlft control module (DGILG) -4---
vehlcle harness connector for contlnu~tyto ground No Go to step 12.
Is contlnu~typresent?
- - - -- - -- -- -- - -- -
11 D~sconnectGEM T-223 connector Yes 1 Go to step 13
I Measure reslstance between GEM T-223 veh~cle
harness pin 15 (Y wrre) and the electrlc shlft relay No Service Y wire circuit for an open.
vehlcle harness connector (Y wlre)
Is reslstance less than 5 ohms7
I STEP INSPECTION 1 ACTION I
Remove electric shift relay (see pg. J2-62). Service Y wire circuit for short to battery.
Disconnect GEM connector T-223. Clear all DTCs and retest.
Key ON.
Check GEM T-223 pin 15 vehicle harness connector Y
wire circuit for a short to battery. No Go to step 13.
Key OFF. Yes System OK. Reconnect relay.
Remove electric shift relay (see pg. J2-62). Clear all DTCs arid retest.
Check relay for resistance between terminals C and E. --
Is resistance between 85-140 ohms? No ' Replace relay.

Check IP fuse #27 (15A)
Is fuse OK?
Key ON. Yes Repair short to ground in BNV wire circuit.

Inspect engine compartnient fuse #7.
Is fuse open? ~ o *
Key OFF. Repair open circuit in BNV wire circuit.
Remove battery saver relay (see pg. J2-62).
Remove engine compartment fuse #7 (20A).
Check for continuity between B/W wire circuit at fuse #7 Go to step 17.
and B/W wire at battery saver connector.
I I IS continuity present? - 1 I I
Electric shift control module disconnected.
Disconnect GEM T-223 connector.
Check for continuity between electric shift control Service BRIP wire circuit for an open.
module vehicle harness pin 9 (BRIP) and GEM T-223 Clear all DTCs and retest.
vehicle harness pin 17 fur continuity.
Is continuity present?
Key OFF. Yes Replace electric shift control module.
Electric shift control module disconnected. Clear all DTCs and retest.
Check continuitv between shift control module ins D
and F (see pg. j2-62).
NO 1 GO to step 20.
19 Key OFF. Yes Service LGIO wire circuit for a short to ground.
Remove fuse #27 Clear all DTCs and retest.
D~sconnectelectrlc shlft control module
Dlsconnect electrlc shift relay (see pg J2-62).
D~sconnectbattery saver relay (see pg. J2-62)
Disconnect GEM T-224 connector NO GO to step PO.
/ Check LGIO wlre clrcult lor a short to qround at the
instrument panel fuse #27.
Is continuitv present?
Key OFF. Replace 10A IP fuse #27. Clear all DTCs and retest. If
Electric shift control disconnected. Fuse #27 removed fuse fails again go to step 21.
Check continuity between electric shift control module
vehicle harness connector pin 05 (LGIO wire), and IP No Service LGIO wire circuit for an open. Clear all DTCs
fuse terminal 27 (LGIO wire). and retest.
Key OFF. Yes Service P wire circuit for short to ground.
Remove fuse #27. Checl< IP fuse #27, P wire circuit for Replace 15A fuse #27. Clear all DTCs and retest.
continuity to ground.
Is continuity present? Go to step 22.
Key OFF. Yes Reconnect, clear all DTCs and retest system.
Remove fuse #27.
Disconnect battery saver relay (see pg. J2-62).
Check for continuity between P wire at fuse terminal #27, ---
and P wire terminal at battery saver relay No , Service P wire circuit for an open
connector. I
Key OFF.
Disconnect electric shift control module.
Disconnect GEM module connector T-223.
yes I Repair BRlP wire circuit for short to battery. Clear all
DTCs and retest. I
Kev ON. --
/ ~ h k c GEM
k module vehicle harness connector pin 17 Go to step 24.
I (BRIP wire) for battery voltage.
I Is battery voltage present? - I
STEP
-
24
, --
Key OFF
-- - -- - INSPECTION
-- -- - - -
Yes
- -- I\ -
ACTION
--
Repa~rBRiP wlre circult for short to ground Clear all
-
Dlsconnect transmission select relay

Dlsconnect GEM module connector T-223
Check GEM vehicle harness connector pln 17 BRIP wire
for cont~nultyto ground No
~ DTCs and retest
Replace all connectors and retest.

- -
25
-Check power dlstr~but~onbox 20A max~fuseR and IP
--
Is cont~nu~ty
-- -
present7
pp -- -
( Yes ( G Oto step 18
fuse #27 15A for open fuse
Are fuses open7
- - - -- --- - - ---- --
I 26 Dlsconnect electrical shift relay 1 Yes 1 Go to step 24. - -- -

Check that reslstance of relay-is 85-140 ohms.
damaged relay.
Are relays withln range?
Clear all DTCs and retest system
-
. - -- -- -- --
~sconnecttransmission select relay ( 0 ) for short to ground
heck clrcult ( 0 ) for contlnulty to a known ground Clear all DTCs and retest system
-- - -- - -- -
cont~nu~ty present?
- -- -- --- - - -- - .- -- --
ansmisslon select relay d~sconnected ( 0 ) for battery short
Check for battery voltage on clrcu~t(0)

Is battery voltage present7
- -- --
W~thtransmlssion select relay d~sconnected.
-- -
N~(.
Yes
I Clear all DTCs and retest system.
to step 26
- ---
Go to step 27
- - --
- -- -- --
dlsconnect electrlc transfer case connector

Check clrcult ( 0 ) for contrnu~tybetween transfer case - -- -
- - - - -- - -
relay module and electrlc transfer case connector

clrcult ( 0 ) Clear all DTCs and retest system
Is continu~typresent?
-- - -- -- -- - -- - ---- - - - - - -
D~sconnectelectric shift relay

Key ON I Reconnect, clear all DTCs and retest system
Check clrcurt (BR) for battery voltage
-- -- - - -- - -
Yes
No
- Go to step 28
-- --
Go to step 29.
~ t helectrlc sh~ftrelay disconnected, dlsconnect
lectrlc transfer case connector 1- ---- -- -- -- -
heck for contlnurty between electrlc sh~ftrelay 1 No Service clrcult (BR) for open
onnector clrcu~t(BR) and electrlc transfer case
onnector c~rcult(BR) for open
less than 5 ohms of reslstance present?
Ii Reconnect, clear all DTCs and retest system
-
Service circuit (BR) for short to ground.
h~ftrelay and electric transfer case Reconnect, clear all DTCs and retest system
check circuit (BR) for cont~nu~tyto a
round
resent?
1 No I Go to step 30.
- ---
33 Disconnect transm~ss~on select relay Serv~ceclrcu~t(Y) for short to ground
Key OFF Reconnect, clear all DTCs and retest system
Check clrcu~t(Y) for contlnulty to ground b - -
Is contlnu~typresent? No Go to step 31
Yes 1 Serv~ceclrcult (Y) for battery short.

clear all DTCs and retest system
heck clrcult (Y) for battery voltage - - - -- -- -- -- -
s battery voltage present? No Go to step 32

--- -- -- - - -- - - - -- ---- -- -- -
Yes System OK, clear all DTCs and retest system

+
- A_-
I
I
relay clrcult (Y) and electrlc No
yes
i
Repair open in circuit (Y).
~ e m o v eGEM T-223 connector. -.. -

-
Disconnect transfer case motor. Service circuit (PUIY) for short to ground.
Check circuit (PUIY), T-223 connector pin 21 for Reconnect all connectors.
continuity to ground. and retest system.
Is resistance greater than 1 OOk ohms? I

37 1 Key OFF. Yes Replace transfer case shift motor.
I GEM T-223 connector and transfer case motor Reconnect all connectors.
I connector disconnected. Clear all DTCs and retest system.
Check between connector on circuit (PUN) for
resistance. Service circuit (Y) for open.
, Clear all DTCs and retest system.
-
Yes
1
I GO to step 39. I
~ e m o v eGEM T-223 connector.
Disconnect transfer case motor. No Service circuit (W) for short to ground.
Check circuit (W), T-223 connector pin 20, for continuity Reconnect all connectors.
to ground. Clear all DTCs and retest system.
Is resistance greater than 1OOk ohms?
With
continuity.
Is continuity
both connectors
less than stiil
5 ohms?
Fremoved,
r check
" circuit
_ .(W) for
. c a s e
Clear all DTCs and retest
shiftmotor.
system.
Service circuit (W) for open.
Key OFF. Yes Service circuit (BRM) for short to ground.
Gain access to GEM module. Clear all DTCs and retest system.
Disconnect GEM T-223 connector.
Disconnect transfer case motor.
Check T-223 connector pin 19 for continuity to ground. Go to step 41.
With both connectors still removed, check circuit (BRM) Yes Replace transfer case shift motor.
for continuity between connectors. Reconnect all connectors.
Is continuity present? Clear all DTCs and retest system.
Service circuit (BRM) for open.
Reconnect all connectors.
Go to step 42.
Key OFF. Yes Service circuit ( O M ) for short to ground.
Gain access to GEM module. Reconnect all connectors.
Disconnect GEM T-223 connector. I Clear all DTCs and retest system.
Disconnect transfer case motor.
Check T-223 connector pin 18 for continuity to ground.
Go to step 43.
I
With both connectors still disconnected, check for Yes Replace transfer case shift motor.
continuity between connectors on circuit (OM). Reconnect all connectors.
Is continuity present? --
No Service circuit ( O M ) for open.
Reconnect all connectors.
Key OFF. Yes Service circuit (YIW) for short to ground.
Gain access to GEM module. Reconnect all connectors.
Remove GEM T-223 connector and disconnect transfer Clear all DTCs and retest system.
case shift motor connector.
Check circuit ( Y M ) for c:ontinuity to ground. Go to step 45.
45 With both connectors still disconnected, check for
continuity between connectors on circuit (YtW). yes 1 Replace transfer case shift motor. Reconnect all
connectors. Clear all DTCs and retest system.
1Ch31;;
Is continuity present? Service circuit ( Y M ) for open. Reconnect all
I connectors. Clear all DTCs and retest system.
--- --
46 1 Key OFF. Yes Service circuit ( Y M ) for battery short.
/ Remove GEM T-223 connector Reconnect, clear all DTCs and retest system.
Disconnect transfer case shift motor.
Key ON.
47 voltage on circuit ( Y M ) T-223 connector

Yes Replace transfer case shift motor.
Reconnect transfer case shift motor. Clear all DTCs and retest system.
: Reconnect GEM T-223 connector.
Key ON.
Check voltage at T-223 connector pin 12 for battery Clear all DTCs and rerun self test.
voltage to ground.
STEP 1 INSPECTION -- -
-
ACTION . ~
48
11 Remove GEM T-223 connector.
Key ON.
Check circuit (PUIY) for battery voltage.
Yes Disconnect transfer case shift motor connector.
Recheck for voltage. If voltage still exists, service
circuit (PUN) for battery short. If voltage does not
/ Is battery voltage present?
--
exist, replace transfer case shift motor.~p
!
I No Check GEM (refer to '97 B-Series BETM). -. -
-
49
1 Remove GEM T-223 connector.
Key ON.
I Check circu~t(W) for battery voltage. I
Yes Disconnect transfer case shift motor connector.
circuit (W) for battery short. If voltage does not exist,
Is battery voltage present? replace transfer case shift motor.
Reconnect, clear all DTCs and retest system. --
- p~
No Check GEM (refer to '97 B-Series BETM).

50 Remove GEM T-223 connector. Yes Disconnect transfer case shift motor connector.
1
I Key ON.
Check clrcu~t(BRIW) for battery voltage.
circuit ( B R N ) for battery short. If voltage does not
exist, replace transfer case shift motor.
1 Reconnect, clear all DTCs and retest system.
i - ~
i,
. ~-
Remove GEM T-223 connector. Disconnect transfer case shift motor connector.
51 Key ON. Recheck for voltage. If voltage still exists, service
Check circuit ( O N ) for battery voltage circuit ( O N ) for battery short. If voltage does not
Is battery voltage present? exist, replace transfer case shift motor.
j Reconnect, clear all DTCs and retest system.
p.p-p-pp---- -~
Check GEM (refer to '97 B-Series BETM).
v
4x4 TRANSMISSION
SELECT RELAY
UNLOCK RELAY
BATT. SAVER ANTI-THEFT
RELAY TERMINALS RELAY
LOCK RELAY INTERIOR LAMP
RELAY
ONE-TOUCH DOWN
WINDOW RELAY BATTERY SAVER
RELAY
ELECTRIC SHlFT
PARWLAMP / \ 4x4 ELECTRIC
RELAY SHIFT RELAY
RELAY TERMINALS
TRANSMISSION SELECT
RELAY PINS LEFT SIDE OF HEATER AIR PLENUM CHAMBER
STEP , INSPECTION ACTION

- - -
1 Remove and inspect IP fuse 11.
I Is fuse open?
--
2 Remove instrument cluster. Yes Bulb OK, Go to step 3. If sent from step 5, Go to step 4.
1 lnspect 4WD high indicator lamp. Replace faulty bulb. Reinstall connectors and retest system
I Check resistance of bulb. Clear all DTCs.
/ Is resistance between 3-8 ohms? Reinstall instrument cluster.
Inspect instrument cluster ribbon for damage.
Reconnect connectors.
Remove instrument cluster. Yes

Gain access to GEM module. Service circuit (GY) for open.
Disconnect GEM module T-223 Reconnect connectors.
connector and instrument cluster Clear all DTCs and retest system.
C-214 connector.
Check for continuity between GEM
connector T-223 connector pin 14 and
instrument cluster connector C-214
connector pin 14 circuit (GY).
I Instrument cluster C-124 connector

disconnected.
Key ON.
Check circuit (O/B) C-124 connector
Yes System OK.
Clear all DTCs and retest svstem.
Service circuit (OIB) for open.
Reinstall connectors.
pin 12 for battery voltage. Clear all DTCs and retest system.
I Is battery voltage present?
5 Remove GEM module T-223 connector. Service circuit (GY) for battery short.
Key ON. Reconnect connectors.
Check circuit (GY), C-214 connector Clear all DTCs and retest svstem.
pin 14 for battery voltage.
I NO I GOto step 2. I
MJ1181-A
Pinpoint Tests D 4WD High Indicator Lamp Never illuminates 1

Low lndlcator - Clrcult fallure - (PI 808)
Low lndlcator - Short to B+ - (P1810)
----
INSPECTION ACTION
----- --
1 Remove and inspect IP fuse 1I. I Yes Check clrcult of fuse 11 for short to ground. --
I Is fuse Open? I
No ( Go to step 2
--
Remove instrument cluster. Yes Bulb OK, Go to step 3. If sent from step 5, Go to step 4.
lnspect 4WD low indicator lamp. No Replace faulty bulb. Reinstall connector and retest system.
Check resistance of bulb. Clear all DTCs.
Is resistance between 3-8 ohms? Reinstall instrument cluster.
lnspect instrument cluster ribbon for damage.
Reconnect connectors.
3 j Remove instrument cluster. I Yes GO to step 4 ------

Gain access to GEM module. No Servrce circult (LBIB) for open.
Disconnect GEM module T-223 Reconnect connectors.
connector and instrument cluster Clear all DTCs and retest system.
C-214 connector.
Check for continuity between GEM
T-223 connector pin 10 and
1 instrument cluster C-214 connector
pin 15 circuit (LBIB).
4 Instrument cluster C-214 connector Yes System OK.
d~sconnected. Clear all DTCs and retest system.
Key ON.
- -- --
No Servlce clrcuit (OIB) for open.
I
Check circuit (OIB) C-214 connector Reinstall connectors.
pin 12 for battery voltage. Clear all DTCs and retest system.
Remove GEM module T-223 connector. Service circuit (LBIB) for battery short.
Key ON. Reconnect connectors.
Check clrcuit (LBIB), T-223 connector Clear all DTCs and retest system. -
pln 10 for battery voltage.
Is batterv voltaae ~resent?
SYSTEM INSPECTION
7 7SYSTEM INSPECTION
4x4 SHIFT CONTROL SWITCH
Inspection
1. Remove the 4x4 shift control switch and disconnect the
connector from the switch. (Refer to page J2-34.)
2. Check the resistance between the terminals of the switch.
Resistance:
- always approx. 18Q

MJ1165-A
@-@ 2WD-approx. 3.9kR
4x4 HIGH-approx. 1.l kQ
4x4 LOW-approx. 3600
3. If not as specified, replace the 4x4 shift control switch.
MJ1166-A 5BUOJ2-047
Check shift motor
1. Disconnect the electronic shift motor assembly. (Refer to
page J2-35.)
2. Check the resistance between the terminal (Y) wire and
termical (0)wire of the electronic shift motor assembly.
Resistance: Approximately 1- 0 0
3. If correct, go to magnetic clutch check.

4. If not as specified, replace the electronic shift motor
assembly. (Refer to page J2-35.)
SYSTEM INSPECTION
Check magnetic clutch
1 . Disconnect the electronic shift motor assembly. (Refer to
page J2-35.)
2. Check the resistance between the terminal (BR) wire of
the electronic shift motor assembly and a ground.
Resistance: Less than 1OR
3. If correct, go to Electronic Shift Motor Assembly Inspec-

tion.
4. If not as specified, replace the electronic shift motor
assembly. (Refer to page J2-35).
ELECTRONIC SHIFT MOTOR ASSEMBLY

Inspection
Check shift motor sensors
1 . Remove the electronic shift motor assembly. (Refer to
page J2-35.)
2. Check for continuity between the shift motor connector
pin 6 (YNV wire) and the other terminals of the electronic
shift motor connector (see chart) in the following motor
positions:
2H
4H
4L
Note:
Reconnect electronic shift motor assembly to
vehicle harness connector and shift the transfer
case to the desired position.
Verify that the shift position sensor has moved to
the correct chosen transfer case position.
SYSTEM INSPECTION 52
I Terminal
E= Edge transitional state

(Non-drivable)
If continuity is correct in all positions, go to transfer case

troubleshooting guide. (Refer to page J2-33.)
If continuity readings are inaccurate, loosen switch
screws and adjust switch position sensor until correct
continuity readings are obtained in all corresponding
transfer case positions.
If continuity readings are not attainable, replace the shift
motor assembly. (Refer to page J2-35.)
Note
View shift motor positions by holding shift motor as
shown.
AUTOMATIC TRANSMISSION
(Electronically Controlled)
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . MECHANICAL SYSTEM TEST . . . . . . K-90
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE CONVERTER CLUTCH
SPECIFICATIONS . . . . . . . . . . . . . . . . TEST . . . . . . . . . . . . . . . . . . . . . . . . . K-90
CROSS SECTIONAL VIEW . . . . . . . LINE PRESSURE TEST . . . . . . . . . . K-91
OPERATION OF COMPONENTS . . STALL TEST . . . . . . . . . . . . . . . . . . . . K-93
TROUBLESHOOTING GUIDE . . . . . . . AIR PRESSURE TEST . . . . . . . . . . . . K-96
PREPARATION . . . . . . . . . . . . . . . . . . TRANSMISSION ................... K-98
GENERAL NOTES . . . . . . . . . . . . . . . TRANSMISSION UNlT (REMOVAL). K-98
ROADTEST . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION UNlT
D RANGE TEST . . . . . . . . . . . . . . . . . (DISASSEMBLY) . . . . . . . . . . . . . . . K-102
D RANGE TEST . . . . . . . . . . . . . . . . TORQUE CONVERTER . . . . . . . . . . K-121
2 RANGE TEST . . . . . . . . . . . . . . . . . . CONVERTER HOUSING AND OIL
1 RANGE TEST . . . . . . . . . . . . . . . . . PUMP ASSEMBLY . . . . . . . . . . . . . K-123
IN-SHOP TEST . . . . . . . . . . . . . . . . . . COASTING CLUTCH DRUM
AUTOMATIC TRANSMISSION FLUID ASSEMBLY . . . . . . . . . . . . . . . . . . . K-128
(ATF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERDRIVE SHAFT AND CARRIER
QUICK DIAGNOSIS CHART ......... HUB ASSEMBLY . . . . . . . . . . . . . . . K-132
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . FORWARD CLUTCH ASSEMBLY . . K-135
QUICK DIAGNOSIS CHART (I) . . . . REVERSE AND HIGH CLUTCH . . . . K-140
QUICK DIAGNOSIS CHART (11) . . . . EXTENSION HOUSING . . . . . . . . . . . K-144
SYMPTOM TROUBLESHOOTING . . . CONTROL VALVE BODY
DIAGNOSTIC INDEX . . . . . . . . . . . . . (DISASSEMBLYIINSPECTION) . . K-146
SYMPTOM TROUBLESHOOTING MAIN CONTROL VALVE BODY . . . . K-146
#@- . CHART . . . . . . . . . . . . . . . . . . . . . . . CONTROL VALVE BODY
ON-BOARD DIAGNOSIS SYSTEM . . . (ASSEMBLY) . . . . . . . . . . . . . . . . . . K-151
DESCRIPTION . . . . . . . . . . . . . . . . . . CONTROL VALVE BODY
PREPARATION . . . . . . . . . . . . . . . . . . (ON VEHICLE REMOVAV
DIAGNOSTIC TROUBLE CODE INSTALLATION) . . . . . . . . . . . . . . . K-152
NUMBER . . . . . . . . . . . . . . . . . . . . . TRANSMISSION UNlT
ELECTRICAL SYSTEM (ASSEMBLY) . . . . . . . . . . . . . . . . . . K-157
COMPONENTS . . . . . . . . . . . . . . . . . . . . . TRANSMISSION UNlT
PREPARATION . . . . . . . . . . . . . . . . . . (INSTALLATION) . . . . . . . . . . . . . . . K-191
ENGINE COOLANT TEMPERATURE AUTOMATIC TRANSMISSION
SENSOR . . . . . . . . . . . . . . . . . . . . . . POWER FLUSHING . . . . . . . . . . . . K-192
VEHICLE SPEED SENSOR . . . . . . . OIL COOLER .AUXILIARY . . . . . . . . . K-195
TRANSMISSION RANGE (TR) REMOVAUINSPECTION/
SENSOR . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . K-195
BRAKE ON/OFF (BOO) . . . . . . . . . . . OIL COOLER PIPES . . . . . . . . . . . . . . . K-197
THROTTLE POSITION SENSOR . . . REMOVAUINSPECTIONI
TRANSMISSION FLUID INSTALLATION . . . . . . . . . . . . . . . . K-197
TEMPERATURE (TFT) SENSOR. DRIVE PLATE . . . . . . . . . . . . . . . . . . . . . K-198
TURBINE SHAFT SPEED (TSS) REMOVAUlNSPECTION/
SENSOR . . . . . . . . . . . . . . . . . . . . . . INSTALLATION . . . . . . . . . . . . . . . . K-198
OVERDRIVE DRUM SPEED (ODs) SHIFT MECHANISM . . . . . . . . . . . . . . . . K-199
SENSOR . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . K-199
OUTPUT SHAFT SPEED (OSS) SELECTOR CABLE . . . . . . . . . . . . . . K-199
SENSOR . . . . . . . . . . . . . . . . . . . . . . SELECTOR LEVER . . . . . . . . . . . . . . K-204
NGS TESTER . . . . . . . . . . . . . . . . . . . SERVICE POINTS . . . . . . . . . . . . . . . . . K-205
POWERTRAIN CONTROL OUTLINE . . . . . . . . . . . . . . . . . . . . . . . K-205
MODULE . . . . . . . . . . . . . . . . . . . . . ELECTRICAL DIAGNOSIS
TRANSMISSION CONTROL SUPPORT . . . . . . . . . . . . . . . . . . . . K-207
SWITCH (TCS) . . . . . . . . . . . . . . . .
K INDEX
INDEX
ATFTYPE:
MERCONmV
CAPACITY:
4x2: 9.0 LITERS {9.5 US qt, 7.8 Imp qt}
4x4: 9.3 LITERS (9.8 US qt, 8.1 Imp qt)
4x4 MODELS 4x2 MODELS
EXTENSION
INDEX
1. Data link connector (not shown) 8. Solenoid valves
-- Self-diagnostic function ......... page K-6 Tester hook-up procedure ..... page K-75
2.ATF Inspection (In-shop) .............. page K-76
Inspection .............................. page K-12 Inspection (On-road) ............. page K-78
3. Transmission range (TR) sensor Replacement ......................... page K-146
Replacement/Adjustment ...... page K-70 9. Powertrain Control Module (PCM)
4. Vehicle speed sensor Inspection .............................. page K-89
Inspection .............................. page K-68 Replacement ......................... page K-89
Replacement ......................... page K-68 10. Drive plate (not shown)
5. Transmission unit Removal / Inspection /
Removal ................................ page K-98 Installation ........................... page K-198
Disassembly .......................... page K-102 11. Control valve body
Assembly ............................... page K-157 Disassembly / Inspection ...... page K-146
Installation ............................. page K-191 Assembly ............................... page K-151
6. Brake On/Off (BOO) switch On-Vehicle Removal 1
(not shown) Installation ........................... page K-152
Inspection .............................. page K-71 12. Oil cooler-auxiliary
7. Selector lever Removal / Inspection /
Removal / Inspection / Installation ........................... page K-195
Installation ........................... page K-205
K OUTLINE
OUTLINE
SPECIFICATIONS
-.-
Item
Transmission I- 4R44E (2.3L. 3.OL), 5RrrE (4oL)
Column shift ---
Lockuo mechanism Eauiooed
,, -
Automatic Transmission I
Fluid (ATF) Capacity - .

4x2 4x4 -- -
liters {US qt, Imp qt) , 9.0 I9.5, 7.8) 9.3 19.8, 8.1)
.---
Thrust
-.
bearing (No. 4) rear end play
-
Identification number
Thrust bearing Reading "C" rnm {in} stamped on washer Bearing thickness mm (in)
(NO.4) 1.79-1.90 {0.070--0.074) 2.65-2.80 IO.104--0.1 l o }
selection 1.91-2.1 0 {0.075--0.0823 2.80-2.95 {0.110--0.116}
2.1 1-2.30 10.083-0.090\ 3.00-3.15 10.118-0.124\
-- --.
2.31-2.43 {0.091-0.0963
~
Coastina clutch
I Retainina rina-to-oressure olate clearance rnrn {in\ 1 1.3-2.0 10.051-0.079) 1
1.37 (0.0539}, 1.73 {0.0681), 2.08 (0.0819), 2.44 {0.0961}
Retain~ngring -
- ---- --- - 130.1

ppppp
I5.122) --.
Reverse and hiqh clutch

I
I
I
Retaining ring-to-pressure plate clearance
Retaining ring
Forward clutch
Thickness
Diameter
Retaining ring-to-pressure plate clearance

+__t_-
mrn {in)
mm {in)
mm (in)
mrn {in) 1
1.3-2.0 (0.051-0.079)
1.37 {0.0539), 1.73 (0.0681), 2.08 {0.0819), 2.44 (0.0961j
1.4-2.1
130.1 15.1221
(0.0554.083)
1
1
I
Reta~nrngring
- -- -
- Th~ckness
- - - --
-
-
I D~ameter
--
- -- -
-- -
t
mm {~n)
mm { ~ n }
1.37 {0.0539), 1 73 {0.0681), 2.08 {0.0819}, 2.44 {0 09611
- -- -- -
2.3L, 3.0L -
125.1 (4 925)
--
- r --
- - - - --
-
4.0L
- --
Coast~ngclutch 212 -- - -
212
Coastlng clutch clearance 1.3-2 0 1.3-2 0
{0.051-0.079)
--- - - --
Reverse and
high clutch
1.3-2.0
- - - -- - -
rnm-
-
{in} ---{0.051-0.079)
- -- - --
2.3L, 3.0L
Forward clutch Number
- -
of
-
driveldriven
--- -
plates -
Forward clutch clearance
rnrn {in)
Torque converter New or rebuilt converter mm {in) / 0.58 I0.023) rnax.
end play Used converter --- mrn {in} / 1.27 {0.050} max.
I Stall s ~ e e d s I
Minimum ---
2.3L
2177
2525
3.0L
2870
3338
4.0L
2
2800 3
OUTLINE K
Note
When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the powertrain control module relearns its adaptive strategy. The vehicle may need
to be driven 16 km (1 0 miles} or more to relearn the strategy.
CROSS-SECTIONAL VIEW
I I
MK1374 A 5BUOKX-004
1. Overdrive band (4R44Ei) 4. Intermediate band 7. Rear one-way clutch
Front band (5R55E) 5. Reverse and high band (4R44E) 8. Forward clutch
2. Coasting clutch Direct clutch (5R55E) 9. Sleeve
3. Overdrive one-way clutch 6. Low and reverse band 10. Torque converter clutch
OPERATION OF COMPONENTS
4R44E
- - -
-- --p
--- --
A = Applied OR = Overrunn~ng NE = No effect

H = Hold = Overdr~vecancelled
MK7100 B1
K TROUBLESHOOTING GUIDE
A = Applied OR = Overrunning NE = No effect H = Hold * = Overdrive cancelled MK 7100-62
PREPARATION
SST
...
49 TO88 OAO For 49 UNOl 130 For

inspection of inspection
NGS set PCM terminal 104 pin of PCM
voltage and breakout
input/output box
device
GENERAL NOTES
A problem with the transmission may be caused by the emission control system, the electronic control
system, the hydraulic control system, or by transmission powertrain component(s); therefore, when
troubleshooting, begin with those points which can be inspected quickly and easily. The recommended
troubleshooting sequence is described below.
5BUOKX-259
Step 1 : Self-Diagnostic System lnspection
Check for diagnostic trouble code(s) in the powertrain
control module (PCM) with the SST (NGS). (Refer to
Section FT.)
Step 2: Electrical Signal Inspection
Check the signals totfrom the powertrain control module
(PCM) with the SST (Breakout Box).(Refer to Section FT.)
6BUOKX-261
CABLE
NGS POWER Step 3: Mechanical System Test
I I
Check the Control Pressure Test. Stall Test. Air Pressure
MF1688-A 5BuoKx-260 Test and Torque Converter clutch Test. (Refer to page
K-90.)
6BUOKX-291
Step 4: Road Test

Note
For correct testing, the engine speed should be
checked with a tachometer.
Check the shift points.
5BUOKX-262
TROUBLESHOOTING GUIDE K
Service Manager
Listen To Customer
Contacts the
Complaint
Drive Olher Vehicle

To Confirm Normal Write R.O.
Technician PRE-CHECK P R O C E D U R E S
Review R.O. Review Repair History
Check Engine Electrical System Performam
Check For Non- Factory Equipment
Check Shih Linkage Adjustment
-
Vehicles Wih Ford Components KOEO and KOER Tests
Contact Service
Complaint?
Or Advisor
If Necessary)
Sheet, Request
ROAD TEST
ROAD TEST
This test is performed to determine if the electronics and shift control valves are functioning.
Note
The following procedures must be performed with the engine and transmission warmed up to
normal operating temperatures.
5BUOKX-018
@RANGE TEST
1. Shift the selector lever into @ range.
2. Accelerate the vehicle with minimum throttle, part throttle and wide open throttle.
3. For 4R44E, verify that 1-2, 243, and 3+O/D upshifts and downshifts are obtained. For 5R55E, verify
that 1+2,2~3,3-+4,4-OIDupshifts and downshifts are obtained.The shift points must be as shown in
the vehicle speed at shift point table. (Refer to page K-5.)
4. For 4R44E, drive the vehicle in OID, 3rd and 2nd gears and verify that kickdown occurs for O/D+3,3-+2,
3+1, 241. For 5R55E, drive the vehicle in OID, 4th, 3rd and 2nd gears and verify that kickdown occurs
for O/D+4, 443, 3+2, 3-11, 2+1, and that the shift points are as shown in the vehicle speed at shift
point table. (Refer to page K-9.)
Note
There is rto lockup when the Brake ONIOFF (BOO) switch is ON.
5. Drive the vehicle and verify that lockup is obtained. ~BUOKX-339
@RANGE TEST
1. Shift the selector lever into o r a n g e and switch overdrive off.
2. Accelerate the vehicle with minimum throttle, part throttle and wide open throttle.
3. For 4R44E, verify that 1+2 and 2+3 upshifts and downshifts are obtained. For 5R55E, verify that 1+2,
243,344 upshifts and downshifts are obtained. The shift points must be as shown in the vehicle speed
at shift point table. (Refer to page K-9.)
4. Drive the vehicle in 3rd and 2nd gears and verify that kickdown occurs for 3+2,3-*1, 2+1 and that the
shift points are as shown in the vehicle speed at shift point table. (Refer to page K-9.)
7BUOKX-019
2 RANGE TEST
1. Shift the selector lever into 2 range.
2. Drive the vehicle.
3. Verify that the vehicle stays in 2nd gear.
0
4. Shift the selector lever into range.
5. Drive the vehicle at 30 km/h (19 mph).
6. Release the accelerator pedal and shift the selector lever into 2 range.
7. The vehicle should shift to 2nd gear. If the vehicle shifts into 2nd gear, the shift control valves are OK.
5BUOKX.020
1 RANGE TEST
1. Shift the selector lever into 1 range.
2. Drive the vehicle.
3. Verify that the vehicle stays in 1st gear.
0
4. Shift the selector lever into range.
5. Drive the vehicle at 30 kmlh (19 mph).
6. Release the accelerator pedal and shift the selector lever into 1 range.
7. Verify that the vehicle shifts immediately into 2nd gear and shifts into 1 st gear below 17 kmlh {I 1 mph).
5BUOKX-340
ROAD TEST K
IN-SHOP TEST
This test is performed to check shift valve operation, shift delay pressures, and downshift valve operation.
1. Raise the vehicle to lift the rear wheels off the ground.
Caution
Never exceed 96 kmlh (60 mph) while performing this test.
3. Shift the selector lever into0 range.

4. Accelerate the vehicle with minimum throttle.
5. Verify the 1-+2,2+3,3+0/D shifts and that the shift points are as shown in the vehicle speed at shift point
table. (Refer to page K-9.)
6. If the shift points are within specification, the 1-2,2-3,3-4 and torque converter clutch shift valves are OK.
7. Shift the selector lever into N range and run the engine at 1000 rpm for 15 sec. to cool the transmission.
6BUOKX-386
Vehicle Speed at Shift Point Tables

2.3L
Axle ratio: 3.73
Throttle position Range Shift kmlh {mph)
Closed throttle 0 3-2 21 -32{I3-20)

0 2-1 10-17 (6-11)
Minimum throttle
--
Part throttle
Wide open throttle @ 1-2 60-69{37-43)

0 2-3 107-119 (66-741
0
0
3-2
3-1,2-1
98-11 1 {61-69)
50-62{31-39) I
I Manual pull-down 1 1 1 2-1 1 49-56{30-35) 1
ROAD TEST
Throttle position I Range I Shift

Axle ratio: 3.45 Axle ratio: 3.73
kmlh {mph}
--
Closed throttle
Wide open throttle
Manual pull-down
- -- -- -
I Throttle position j Range Shift I kmlh {mph)
Closed throttle 23-30 {I 4-19) I 21 -30 (13-19)

2- 1 15-22 19-14) 13-22 {8-I43
1-
Min~rnurnthrottle
8 1-2
2-3
20-27 {I2-1 7)
33-41 {20-263
17-25 {I0-1 6)
29-40 {I8-25}
Part throttle
---l
3a 3-4
1-2
2-3
3-4
--
73-85 (45.531
-
-
36-46 (22-29)
58-69 (36.43)
103-115 {64-72)
66-78 (41 -49)
--
33-41 (20-26)
54-64 (33-40)
93-107 {58-67)
@)
,e
4-3 87-99 (54-62) 79-91 {49-57)
-- --
0 -- 3-2
-- -
49-59 (30-37)
-
- .
46-54 {28-34)
-
W ~ d eopen throttle 1-2 62-72 {38-45) 55-65 {34-41)

a)
a 2-3
3-2
115-127 (71-79)
107-119 {66-74)
103-117 {64-73)
97-1 11 {60-69)
3-1,2-1 . 55-65-{34-413 - 50-61 {31-38)
- - -- -
I Manual pull-down 41 -48 {25-30) 41 -48 {25-30)

L - _ - - -
MK1491 B 5BUOKX 389

ROAD TEST
Axle ratio: 3.08

Throttle Postion Range Shift kmh (mph)
Closed throttle a 3-2 20-35(12-22)
0 2-1 17-25(10-16) 15-24(9-15)
Minimum throttle 1-2 23-32(14-20)
I 2-3 38-48(23-30)
3-4 75-85(46-53)
4-5 93-117 (58-73)
Part throttle
.-
Wide open throttle
-
I
t-
0
o
0
o
1-2
2-3
3-2
3-1,2-1
'
,
63-74(39-46)
1 1 3-127 (70-79)
105-117 (65-73)
55-64(34-40)
1 55-62(34-39)
98-lll(61-69)
Manual pull-down 1 1 1 1-2 I

1 49-56(30-35) 49-56(30-35)
Axle ratio: 3.08 I Axle ratio: 3.55

Throttle Postion Range kmlh (mph) kmlh (mph)
Closed throttle 20-35(12-22)
17-25(10-16)
-t-
Minimum throttle 1-2
1 23-32(14-20) 20-28(12-18)
Part throttle
.
0
0-,
a
2-3
3-4
4-5
-
38-48(23-30)
75-85(46-53)
93-117 (58-73)- 1 33-43(20-27)
63-74(39-46)
93-117 (58-73)
Wide open throttle

1 8 i 1-2
2-3
3-2
63-74(39-46)
1 13-127 (70-79)
105-117 (65-73)
1 55-62(34-39)
98-lll(61-69)
91-101(56-64)
3-1,2-1 55-64(34-40) 47-57(29-36)
Manual pull-down I 1 1-2 49-56(30-35) 49-56(30-35)
MK1493-B 7BUOKX-390
K AUTOMATIC TRANSMISSION FLUID (ATF)
AUTOMATIC TRANSMISSION FLUID (ATF)

ATF
Inspection
Level
Caution
1. Apply the parking brake and position wheel chocks se-

curely to prevent the vehicle from rolling.
2. Warm up the engine until the ATF reaches 6 6 7 6 ° C
(150-1 70°F).
3. While depressing the brake pedal, shift the selector lever
to each range (P-I), pausing momentarily in each range.
4. Shift back to P.
Note
Vehicles equipped with 4~4applicationsmust have
the 4x4 shift lever in any position other than neutral.
Use the COOL 22-35°C {70-95°F) range as a

rough reference only.
HOT RANGE 5. Ensure that the ATF level is in the HOT 66-76°C
66°C TO 76°C
{I ~ O O FTO 1 7 0 " ~ ) {150-170°F) range. Add ATF to the specification, if
necessary.
COOL RANGE
22°C TO 35°C ATF type: MerconeV
170°F TO 95°F)
Caution
Use only MerconaV or equivalent transmission fluid.
MAI 006-6 ~BUOKX-022 Use of any other fluids may result in a transmission
malfunction or failure.
Condition
Note
Determine whether the automatic transmission
should be disassembled by carefully observing the
condition of the ATF.
If the ATF is muddy and varnished, it indicates burnt drive

plates.
MA1007-A 5BUOKX-023
1. Check the ATF discoloration.
2. Check the ATF for any unusual smell.
AUTOMATIC TRANSMISSION FLUID (ATF) K
Fluid leaks
Check for ATF leaks of the transmission at the points shown and repair or replace as necessary.
1. Gaskets, O-rings, and plugs
2. Oil pipes and connections
3. Oil cooler
@ = O-RING
@ = PLUG (LINE & EPC PRESSURE) (5R55E ONLY)

MK7061-B
FRONT OIL Check for fluid leaks around the converter housing at the
PUMP SEAL. following points:
1. Oil pump seal lip
2. Oil pump bolts
3. Oil pump gasket
4. Torque converter to drive plate stud weld
5. Torque converter seam weld
6. Crankshaft rear main seal
I TORQUE CONVERTER TO
l3RNE PIATE STUD WELD
FRONT OIL
PUMP GASKET I
QUlCK DIAGNOSIS CHART
QUlCK DIAGNOSIS CHART

OUTLINE
The Quick Diagnosis Chart shows various problems and the various components that might be the cause
of the problem.
1. Components indicated in the "Self-diagnosis" line of the QUlCK DIAGNOSIS CHART (I) are diagnosed
by the powertrain control module (PCM) self-diagnosis function. The SST (NGS) can be used for easy
retrieval of the diagnostic trouble code numbers.
2. Components indicated in the "Adjustment" line of the QUICK DIAGNOSIS CHART (I) indicate that there
is a possibility that the problem may be the result of an incorrect adjustment.
3. Solenoids of the transmission indicated in the "Transmission Tester" line of the QUlCK DIAGNOSIS
CHART (I) can be easily checked by using the Transmission Tester.
4. Input and output signals of the powertrain control module (PCM) for the components indicated in the
"Breakout Box" line of the QUlCK DIAGNOSIS CHART (I) can be easily checked by using the
Breakout Box.
5. Components indicated in the "Mechanical System Test" line of the QUlCK DIAGNOSIS CHART (I) can
be checked for malfunction by observing the results of the Mechanical System Test.
6. Components indicated in the "Road Test" line of the QUlCK DIAGNOSIS CHART (I) can be checked for
malfunction by observing the results of the Road Test.
7. QUlCK DIAGNOSIS CHART (11) shows the relationship between the troubleshooting item and the
inspection point.
5BUOKX-263
QUICK DIAGNOSIS CHART K
QUICK DIAGNOSIS CHART (I)
Possible
o parts and referen
Item
Self-diagnosis (NGS)
Adjustment
Breakout box
Mechanical system test
Road test
MK1144-F
K QUICK DIAGNOSIS CHART
QUICK DIAGNOSIS CHART (11)
1
I\
Possible parts and reference page Prelim-
inary 1 Emission control system
Elec-
tronic
, system
--
On acceleration
MK1146-E
* Check EPC (see page K-78)

QUICK DIAGNOSIS CHART K
K SYMPTOM TROUBLESHOOTING
DIAGNOSTIC INDEX
I
1 No. I
TROUBLE
1
I
DESCRIPTION 1 PAGE 1
1 / Will start in other than P and N ranges Engine starts in P, N and other ranges
I Engine stalls Idle when shifted from Engine stops unexpectedly when shifted from N or P to !
1 K-20
i N or P to other ranaes other ranaes at idle
I
Engine stalls On deceleration Engine stops unexpectedly at beginning of decelera-
tion or recovery from deceleration
Exhaust afterburn
Engine runs On deceleration Engine shakes at beginning of deceleration, during
deceleration, or recovery from deceleration
Exhaust afterburn
1 K-21
J
I poor I Driveaway / Engine speed increases normally but vehicle speed 1
acceleration slowly increases during driveaway K-22
On acceleration Engine speed increases normally but vehicle speed
6
slowly increases during acceleration
Surges while cruising Momentary minor irregularity in engine output at
7 , steady vehicle speed
Lack of power Performance poor under load (i.e., power down when
8 climbing hills)
9 Poor iuel economy Fuel economy unsatisfactory , K-23
10
Vehicle does not move @, D, 2,1,
andlor R ranges
No creep at all
Vehicle does not move when accelerator pedal
depressed after shifted to @, D, 2, 1 andlor R range 1
1 K-24
1 Vehicle moves in N range Vehicle creeps in N range

Vehicle moves when accelerator pedal nbt depressed 1 K-24
/ 12 1 Veh~clemoves in P ranqe 1 Vehicle rolls in P ranqe, and drivetrain not locked up , K-24 1
1 Excessive creep ' Vehicle moves quickly in
I
a,
D, 2, 1 and R range
(accelerator pedal not depressed) 1I
1'" 1
/
Note
Excessive N to
shock felt
R range and N to @ range shift
Single range shift (Ist-r2nd, 2nd43rd or 3rd+O/D)

(4R44E)
1
I!
K-24
1
(lst+2"d, 2nd-t3rd, 3rd+4th or 4th+O/D) (5R55E) i K-25
Sometimes shifts correctly
Abnormal shift Shifts incorrectly (incorrect shift pattern)
(ex) Vehicle shifts Ist+O/D
directly when accelerating with accelerator pedal K-25
depressed slightly
1 / Frequent shifting 1 Downshift occurs when accelerator depressed slightly
in 0and D ranaes
I
1
K-25
I
I / Shift point high or low Shift points do not match shift chart
Shifts delayed when accelerating
K-25
Shifts occur too fast when accelerating and engine
I soeed does not increase
1 1 I ranae 1 1
18
1 No l o c k u ~
NOkickdown
No lockuo when vehicle soeed reaches l o c k u ~
I Does not downshift when accelerator pedal depressed 1
within kickdown range
K-26
K-26
P
20 Engine speed When accelerating Engine speed flares up on acceleration K-26

flares up When upshifting Engine flares up when upshifting I
21 andlor downshifting Engine flares up suddenly when accelerator pedal 1 K-26

depresed for downshifting
MK1151-El
SYMPTOM TROUBLESHOOTING K
TROUBLESHOOTIN(> ITEM
DESCRIPTION PAGE
NO. TROUBLE I
s h i f i p i R and/0r
I Strong shift shock felt at idle when shifting from N to [I
or R range
-- -
I K-27
When upshifting shift shock felt when accelerating at
andlor downshifting upshifting
23 j During cruising, excessive shift shock felt when
accelerator pedal depressed at downshifting
1 when
I1 ;1, No engine braking Engine speed drops to idle but vehicle does not slow K-27
accelerator pedal released during cruising at
1 medium to high speed
1
24
Transmission z n g e s Transmission noisy in all ranges when vehicle is
-
noise
1 @, D, 2, 1, R ranges Abnormal noise from transmission in D, R, @, 2, 1
27 Transmission overheats ATF smells burnt and/or is discolored
28 / Delayed shift I Vehicle shifts at high RPM I K-28
MK1151-E2 6BUOKX-266
SYMPTOM TROUBLESHOOTING CHART
A
1 WILL START IN OTHER THAN P AND N RANGES
DESCRIP- ENGINE STARTS IN P, N AND OTHER RANGES
TlON
I -- -
[TROUBLESHOOTING HINTS]
Inspect parts and wiring; adjust or replace malfunctioning parts as necessary
O Transmission range sensor rn~sadjustedor worn page K-70
urlK1154-E 6BUOKX-267
1
2 ENGINE STALLS IDLE WHEN SHIFTED FROM N OR P TO OTHER RANGES

- - ---
Engine stops unexpectedly when shifted from N or P to other ranges at idle
DESCRIP-
TION
I
--
O Eng~neidle speed low O Control valve body malfunct~on
O Torque converter clutch solenoid stuck
r l T G e speed OK? Yes Go to next step
I Section FT
Adjust idle speed

Section FT
- --
I
Is problem corrected when solenoid valve
connector is disconnected?
* Overhaul control valve body and repair or relace
parts as necessary
If large amounts of material are found, overhaul
transmission and repair or replace parts as necessary
-
3 Are solenoid valves OK? Yes Go to next step
page K-76 - I
No ' Check solenoid valve wiring harness for open
!
and/or short circuits
o If OK, replace solenoid valve(s)
o If not OK, repair or replace solenoid valve
wiring harness
--
4 Is transmission terminal voltage OK with Yes Go to next step
solenoid valve connector disconnected?
1 Condition 1 TerEnal Voltage

Check for open or short circuit in wiring harness
Ign switch ON Battery positive
voltage (Solenoid valve terminal [lo] - power relay)
--- -- - --- -- -- - - - - - -
I
- - - -- -- - - - --- - --- -
Are terminal voltages at PCM correct with PCM Yes Replace PCM
connector disconnected? Section FT
/
I
B+: Battery positive voltage
1
Solenoid ; Terminal Condition
SS3 1 53 1
lgn switch
ON
I
1
Voltage
B+
1
- -
No I
I
-- - - - - - --- - -- - - -
Check for open or short circuit In wlrlng harness
[ clutch I ( - O N 1
3 ENGINE STALLS ON DECELERATION
-
DESCRIP-
TlON 1 Engrne stalls when brake pedal depressed wh~ledr~v~ng
at low speed or stopplng
O ATF level low
O Control valve body stuck
1 Is ATF level OK7 Yes Go to next step
a page K-12
Level: Between notches on dipstick
No Adjust ATF level

a page K-12
HOT RANGE
66°C TO 76°C
{l 50°F TO 170°F)
COOL RANGE
22°C TO 35°C
DO NOT VOoFTO 95°F)
DRIVE MARK
-- --
-1- i
Is control pressure OK"
page K-91
Yes
NO
Go to No 2 "ENGINE STALLS-IDLE WHEN
SHIFTED FROM N OR P TO OTHER RANGES"
-
page K-20
-
@
Replace parts as necessary (Refer to Pressure

Test Dlagnost~cChart on page K-92 )
MK1156-F 6BUOKX-269
4 ENGINE RUNS ROUGH ON DECELERATION

Englne shakes at beg~nnlngof deceleratlon, dur~ngdeceleratlon, or recovery from decelerat~on
DESCRIP- Exhaust afterburn
TlON
---- p
p-p
-pp
-p-
--
~
KPT-
O ATF level low
pp
1 Is ATF level OK?

----
INSPECTION ACTION
I SHIFTED FROM N OR P TO OTHER RANGES"

page K-20
@
Level: Between notches on dipstick
s page K-12
u
66°C TO 76°C
{l 50°F TO 170°F)
COOL RANGE
22°C TO 35°C
I DO NOT
DRIVE MARK
MK1157 F 6BUOKX-270
K-21
POOR ACCELERATION ' DRIVEAWAY

ON ACCELERATION
- --
Engine speed increases normally but vehicle speed slowly increases during acceleration
O Control valve body malfunction
Q Torque converter clutch solenoid stuck
O Torque converter stuck
--
Are any diagnostic trouble codes displayed Yes Go to next step

during Key On Engine Off, Key On Engine
Running or continuous memory inspection?
------ -
page K-31
code(~)displayed
Check for cause of code(s)
page K-36
Is control pressure OK? Yes I Go to next step
page K-91
--
Repair or replace parts as necessary (Refer to
Pressure Test Diagnostic Chart on page K-92)
Is torque converter clutch solenoid OK?

page K-76
1 Yes 1 Go to next step
N -----
Replace torque converter clutch solenoid
-
1
-- --
Is transmission terminal voltage OK with
solenoid valve connector disconnected?
condition4 Terminal voltage 2 -- - -- - - - - - - - - -

- --
- - - - --
10 7 Batteryo~tltlve 1 NO Check for open or short circuit In wring harness

voltage (Solenold valve term~nal[I 01 - power relay)
- - - - - - - - -- - - - - -- - - -
Is term~nalvoltage at PCM correct w~thPCM Yes ( Replace PCM

connector disconnected? page K-89
B+: Battery positive voltage I
----- -- - - - - - - - -
Check for open or short circuit in wring harness
clutch
1 7 SURGES WHILE CRUISING 1
I DESCRIP- 1
Momentary minor irregularity in engine output at steady vehicle speed
O Vehicle speed sensor malfunction
O Control valve bodv malfunction
!
- --
1 Is resistance of vehicle speed sensor at Yes Go to next step
33-58
1 1
powertrain control moclule (PCM) OK?
rerm. Spec.
190-250
Condition]
Constant
(Ign: OFF)
No Check vehicle speed sensor and wiring
page K-68
Note:
58 terminal: Vehicle speed sensor
33 terminal: Ground
Is control pressure OK? Yes Replace PCM

page K-91 page K-89
Repair or replace parts as necessary

(Refer to Control Pressure Test Diagnostic Charts on
page K-92.)
6BUOKX-272
LACK OF POWER
---
Performance poor under load (i.e., power down when climbing hills)
Inspect parts; repair, adjust, or replace malfunctioning parts as necessary
O Torque converter worn GY page K-121
O Powertrain burnt (forward clutch) ET page K-135
POOR FUEL ECONOMY

----
a Fuel economy unsat~sfactory
DESCRIP-
TION
lnspect parts and wiring; repair, or replace malfunctioning parts as necessary
O Torque converter clutch solenoid worn
MKl161-D 6BUOKX-438
1 lo 1 VEHICLE DOES NOT MOVE IN @, D, 2,1, AND/OR R RANGES I

1 DESCRIP-
TION
No creep at all
Vehicle does not move when accelerator pedal depressed after shifted to @, D, 2, 1, and/or R range
lnspect parts and wiring; repair, adjust, or replace malfunctioning parts as necessary
O ATF level low page K-12
O Selector lever installation or adjustment incorrect *
page K-205
O Control pressure low page K-91
@ Powertrain slippage (coasting clutch drum, reverse and high clutch, forward clutch, overdrive band,
intermediate band, low and reverse band or one-way clutch) u s page K-102,128,135,140
O Control valve body malfunction *
page K-146
@ Parking mechanism worn page K-102
O Powertrain control module (PCM) malfunction Section FT
0 Oil pump worn *
paqe K-123
Vehicle creeps in N range

DESCRIP- Vehicle moves when accelerator pedal not depressed
TION
lnspect parts; repair, adjust, or replace malfunctioning parts as necessary
O Selector lever installation or adjustment incorrect
O Powertrain burnt (forward clutch)
@ Control valve body stuck (manual valve)
MK1163-D
( 12 / VEHICLE MOVES IN P RANGE

* page K-205
* page K-135
r@ page K-146
-
1
6BUOKX-439
1
1 DESCRIP-
TION
- - I -
Vehicle rolls in P range, and drivetrain not lockup
-- - - - - - - -
lnspect parts; repalr, adjust, or replace malfunct~on~ng
parts as necessary
O Selector lever lnstallat~onor adjustment Incorrect page K-205
O Park~ngmechanism worn @? page K-102
O Powertrain burnt (one-way clutch) page K-102
EXCESSIVE CREEP
- -- - -- -- -- -- - -- - - - - - - - -
Vehicle moves quickly in@, D, 2, 1 and R ranges (accelerator pedal not depressed)
DESCRIP-
TION Note
-- --
Excessive N to R range and N to@ range shift shock felt
PROUBLESHOOTING HINTS]
O Engine idle speed incorrect
MK1165-C !
Section FT
6BUOKX-441
14 NO SHIFT --
4R44E Single range shift (I

st+2nd, 2nd+3rd or 3rd+OlD) only
DESCRIP- 5R55E Single range shift (Ist+2nd, 2nd+3rd, 3rd+4th or 4thbOID)
TION Sometimes shifts correctly
O ATF level low e page K-12
O Selector lever adjustment incorrect pag K-205
O Control valve body stuck us? page K-146
@ Vehicle speed sensor malfunction u
s page K-68
Q Powertrain control module (PCM) malfunction @s
Section FT
8 Oil pump worn page K-123
O Powertrain worn (reverse and high clutch, overdrive band, intermediate band andtor
one-way clutch) page K-102,140
MKI 167-E 6BUOKX-273
15 ABNORMAL SHll-7
-- ---
Shifts incorrectly (incorrect shift pattern)
DESCRIP-
TION
(EX) Vehicle shifts 1st + OID directly when accelerating with accelerator pedal depressed slightly
O ATF level low @s page K-12
O Torque converter clutch solenoid worn us page K-76
O Control valve body stuck us page K-146
@ Oil pump worn e K-123
us page
MK1168-E 6BUOKX-27
16 FREQUENT SHIFTING
Downshift occurs when accelerator depressed slightly in @ , D, 2, and 1 ranges
DESCRIP-
TION
O Vehicle speed sensor malfuriction e K-68
us page
MK1169-E 6BUOKX-275
17 SHIFT POINT HIGH OR LOW

--
Shift points do not match shift charts
DESCRIP- Shifts delayed when accelerating
TION Shifts occur too fast when accelerating and engine speed does not increase
lnspect parts and wiring; repair?adjust, or replace malfunctioning parts as necessary
O ATF level low e K-12
page
O Vehicle speed sensor malfunction page K-68
@s
O Control valve body malfunction u

s page K-146
@ Oil pump worn page K-123
MK1170-E 6BUOKX-276
1 18 / NO LOCKUP 1
1 No lockup when vehicle speed reaches lockup range
DESCRIP-
-
TION
I
- - --- -
lnspect parts and wlring; repair, adjust, or replace malfunct~on~ng

parts as necessary
O Torque converter clutch solenoid and/or SS3 worn page K-76
O Brake On/Off (BOO) sw~tchmalfunction page K-71
@ Control valve body malfunction page K-146
O Throttle posltlon sensor malfunction Section FT
@ Engine coolant temperature sensor malfunction Section FT
O Powertrain control module (PCM) malfunction @
I= Section FT
@ Torque converter worn page
.- K-121
MK1171 E 6BUOKX-277
19 NO KICKDOWN
-- - -- -- - - -- - - - --
Does not downshift when accelerator pedal depressed more than 718 ~ ~ t hkickdown
in range
DESCRIP-
TION
-- -1- - _ -- - - - -- - - - - - -- -
1
lnspect parts and wiring; repalr, adjust, or replace malfunctlonlng parts as necessary
O Control valve body malfunct~on @? page K-146
O 011 pump worn page K-123
MK1172 E 6BUOKX-278
2 0
-
ENGINE - -
- -
SPEED FLARES UP
- -- --- -
1 WHEN ACCELERATING
Englne speed flares up on accelerat~on
Q Selector lever installation or adjustment incorrect G=T pageK-205
O Throttle position sensor malfunction Section FT
@? page K-146
@ Control valve body malfunction
O Powertrain slippage (intermediate band)
MK1173-E 6BUOKX-279
21 I ENGINE SPEED FLARES UP WHEN UPSHIFTING AND/OR DOWNSHlFTlNG

- - -- --- - - -- -- - - - -
Engine speed flares up when accelerator pedal depressed for upshifting
DESCRIP- Englne speed flares up suddenly when accelerator pedal depressed for downsh~fting
TlON
- - -I _ - --
lnspect parts and wlrlng, repalr, adjust, or replace malfunctioning parts as necessary
Q Selector lever installat~onor adjustment incorrect page K-205
@ Torque converter clutch solenoid worn page K-76
O Control valve body malfunction page K-146
@ Powertrain slippage (reverse and high clutch, overdrive band, intermediate band, low and reverse band
andlor one-way clutch) @? page K-102,140
011pump worn page K-123
MK1251 E 6BUOKX-28
22 I EXCESSIVE SHIFT SHOCK ~.P,NTORANDIORNTOD /
! Strong shift shock felt at idle when shining from N to I@ GRrange
--
1
O ldle speed high Section FT
O Selector lever adjustment incorrect C@ page K-205
@ Throttle position sensor malfunction Section FT
page
e K-121
- 8 Torque converter worn - -- 6BUOKX-281
MK1252-E
I 23 EXCESSIVE SHIFT SHOCK WHEN UPSHIFTING AND/OR DOWNSHIFTING

I Excessive shift shock felt when accelerating at upshifting
DESCRIP- During cruising, excessive shift shock felt when accelerator pedal depressed at downshifting
TlON ~
O ldle speed high Section
o FT
@ Control valve body malfunction page K-146
O Powertrain worn (reverse and high clutch and/or intermediate band) " page K-102,140
, 63 Oil pump worn page K-123
I 24 / NO ENGINE BRAKING
I Eng~nespeed drops to Idle but veh~cledoes not slow when accelerator pedal released durrng crulsrng at
DESCRIP- medlum to h~ghspeed
Engrne speed drops to rdle but vehlcle does not slow when accelerator pedal released when In 1 range at low
vehlcle speed - - - - - -- -- -- -- -
-
lnspect parts and wrrrng, repalr adjust, or replace malfunctlonlng parts as necessary
O Control valve body malfunct~on e K-146
page
O Torque converter worn page K-121
@ Powertra~nsl~ppage(coastrng clutch drum, overdr~veband, ~ntermediateband, low and reverse band
and/or one-way clutch)
MK1254 E 6BUOKX-339
25 TRANSMISSION NOISE
- l-- ALL RANGES
----- -----
1
--
Transmission noisy in all ranges when vehicle is idling

DESCRIP-
TION
O Shift mechanism adjustment incorrect page K-199
@ Powertrain worn (one-way c:lutch) e page K-102
O Oil pump worn
VlK1255-D 6BUOKX-442
TRANSMlSSlON NOISE @D,I, R, RANGES

2,l,
-- - -
a Abnormal nolse from transm~ss~on
In D,
D,2, 1, R
-- -
O Powertrain worn (overdrive band, intermediate band, and/or one-way clutch) a?page K-102
MK1256-D 6BUOKX-44
27 TRANSMISSION OVERHEATS
---
ATF smells burnt and/or IS discolored
DESCRIP-
TION
--
lnspect parts; repalr, adjust, or replace malfunct~on~ng
parts as necessary
O ATF level low ajs. page K-12
Q Idle speed low Section FT
@ 011 pump worn s page K-123
u
O Powertram worn (one-way clutch) a? page K-102
WK1257 D 6BUOKX 444
28 I DELAYED SHIFT --
Vehicle shifts at a high rpm
t = ~ o o T I HINTS] w
lnspect parts and wiring; repair or replace malfunctioning parts as necessary
1
Turbine shaft speed sensor malfunction page K-72
60UOKX-445
ON-BOARD DIAGNOSIS SYSTEM K
Quick Test Description
Quick Test is divided into three special tests, Key On Engine Off Self-Test, Key On Engine Running Self-
Test and Continuous Memory DTC access. Quick Test also provides a quick check of the powertrain
control system and is usi~allyperformed at the start of each diagnostic procedure and at the end of most
pinpoint tests for verification of repair and to ensure no other faults exist.
5BUOKX-283
Key
e On Engine Off Self-Test
Key On Engine Off is a functional test of the powertrain control system performed on demand. A fault has
to be present at the time of testing for the Key On Engine Off Self-Test to detect the fault. When a fault
is detected, a Diagnostic Trouble Code (DTC) will be output on the data link when requested by a scan
tool.
5BUOKX-284
Key On Engine Running Self-Test

Key On Engine Running is a functional test of the powertrain control system performed on demand with
the engine running and vehicle stopped. A check of the inputs and outputs is made during operating
conditions and at normal temperature. A fault has to be present at the time of testing. When a fault is
detected, a ~iagnostic~rouble Code (DTC) will be output on the data link when requeskd by a scan tool.
5BUOKX-285
Continuous Memory DTC Access Self-Test

Continuous Memory D I C access is also a functional test of the powertrain control system. The
Continuous Memory self-test is always active. The test consists of all the OBD II rnonitors and the
comprehensive component monitor, and is designed to detect failures contributing to driveability and
emissionconcerns. As part of QuickTest, the technician may perform a specific drive cycle before running
Quick Test. This is necessary to detect certain faults not tested during other self-test operations. All self-
+
-
,-
tests are menu driven in the New Generation Star (NGS) scan tool.
5BUOKX-286
Parameter Identification (PID) Access

The PID mode allows access to certain data values, analog and digital inputs and outputs, calculated
values, and system s t a t ~ ~information.
s
Output Test Mode

The output test mode aid:; in servicing output actuators associated with the PCM. It allows the
technician to energize and de-energize most of the system output actuators on command.
7BUOKX-905
Brake OnIOff Test

On vehicles equipped with Brake OnIOff (BOO) input, the brake pedal MUST be depressed and released
after the Key On Engine Running self-test is initiated.
5BUOKX-288
Transmission Control Switch Test

On vehicles equipped with a Transmission Control Switch (TCS), the switch MUST be cycled after the
Key On ~ n ~ i dunning
ne self-test is initiated.
Wigglenap Test
The wigglettap test is performed by the technician in an attempt to re-create an intermittent fault.
5BUOKX-290
Power Steering Pressure Switch

On vehicles equipped with a power steering pressure switch (PSP),the wheels must be turned after
the Key On Engine Running self-test is initiated.
6BUOKX-002
OBD II Drive Cycle
Please refer to Section FT for drive cycle information.
PREPARATION
SST
49 TO88 OAO For
inspection of
NGS set PCM terminal
voltage and
inpuvoutput
devices
DIAGNOSTIC TROUBLE CODE NUMBER

New Generation Star (NGS) Hook-up Procedure
Note
Make sure key is off.
-
1. Insert the vehicle interface module and program card into
the SST (NGS) control unit.
2. Plug in the NGS OBD II adapter into the interface module
and the large 5 pin connector into the vehicle data link
connector (DLC) located under the dash to left of console.
PlNS 1-8
R
PlNS 9-16
I
I
MF1685-B
DATA LINK CONNECTOR
I
I
3. Plug the (NGS) tester power cable into the cigarette lighter
or use battery hook-up adapter.
4. Listen for a double beep. SST (NGS) is now initialized.
Begin functional test of powertrain control system.
CABLE NGS POWER

SUPPLY CABLE
Key On Engine Off Quick Test
Note
Start engineand bring up to operating temperature
before running Quick Test.
1. Perform the necessary vehicle preparation and visual

inspection. (Refer to Section FT). Hook up SST (NGS) to
vehicle.
2. Select vehicle and engine selection.
3. Select vehicle year and model.
4. Select diagnostic data link.

5. Select PCM.
II II
'
VIEW RECORDER AREAS
'J
DEITAL
I
MEASUREMENT
GENERIC OBD IIFUNCTIONS
o n o n n o
-2
6. Select diagnostic test mode.
7. Select Key On Engine Off on-demand self-test.
8. Turn Key ON. Press start and trigger. Follow operating
~roceduresfrom the menu.
I I (1
PI0 DATA MON TOR AND RECORD
II
11 I I
I
MF1692-A
2
7BUOKX-294
Key On Engine Running Quick Test
Note
Start engine and bring up to normal operating
temperature before running Quick Test.
K ON-BOARD DIAGNOSIS SYSTEM

vehicle.
2. Select vehicle and engine selections.

VIEW RECORDER AREAS
DIGITAL MEASUREMENT
GENERIC OBD \IFUNCTIONS

6. Select Key On Engine Running on-demand self-test.
7. Start vehicle, press start and trigger.
8. Follow operating instructions from the menu and perform
BOO, PSP, and TCS cycling, if equipped.
PID DATA MONITOR AND RECORD
I DIAGNOSTIC TROUBLE CODE LIBRARY
1
MF1692-B 6BUOKX-004
Accessing All Continuous Memory DTCs Procedure

Note

vehicle.
2. Select vehicle and engine selection menu.
(7 4. Select diagnostic data link.

VlEW RECORDER AREAS
DIGITAL MEASUREMENT
GENERIC OBD II FUNCTIONS
L I
MF1686-A
6. Select RetrieveIClear continuous DTCs.
7. Turn key ON. Press start and trigger.
8. Follow operating instructions from the menu.
PID DATA MONITOR AND RECORD
I
MF1692-B 7BUOKX-296
Output Control Test
Note
For 5R55E diagnosis and testing, refer to Electrical
System Components in this section.
Procedure
Note
before running Output Control Test.

vehicle.
2. Select vehicle and engine selections.

VlEW RECORDER AREAS
DIGITAL MEASUREMENT
GENERIC OBD II FUNCTIONS
5. Select active command modes.

6. Select output control.
7. Turn key ON. Press start and trigger. Follow operating
instructions from the menu.
PIC DATA MONITOR AND RECORD
I 1
MF1692-B 7BUOKX-005
After Repair Procedure
1. After repairs have been made connect SST (NGS) to data
link connector.
CLEAR DIAGNOSIS CODES 2. Select Clear Codes function and clear DTCs.
3. Perform Continuous Memory DTC procedure to ensure
customer's concern has been resolved. If DTC P I 000 is
present, OBD-ll monitoring has not been completed.
Refer to Section FT.
Accessing OBD II PID Mode Procedure

Note
1. Hook up SST (NGS).

2. Select vehicle and engine selection menu.

5. Select PCM.
VEHICLE & ENGINE SELECTION

VIEW RECORDER AREAS
DIGITAL MEASUREMENT
GENERIC OBD I1FUNCTIONS
6. Select PIDJDATA Monitor and Record.
/ 7. Turn key ON or start engine.
8. Select the PID values to view and press trigger.

9. Select start to begin.
Note
DPFEGR EPCR Refer to the manufacturer provided instruction
02S2 2 HFC manual for further information and additional NGS
02521 * IAC diagnostic testing procedures.
CATT ST 1 ' 02S22 * MAF
nunrcInl
10. Press trigger to capture data.
1 1 . Press trigger to save data.
12. Select view reading.
13. Press MAX.
14. Press Graph. Monitor graph for non-linear pattern.
15. Press Table. Monitor readings for spike patterns.
Note
Although you can choose four PlDs for playback,
you can view only two at a time on the graph. By
selecting buttons 2 and 9, you can rotate through
- 1 NON LINEAR -
POSSIBLE FAULT IN SENSOWCIRCUIT all selected PIDs. By moving the cursor across the
graph or table, you can review a PID value at pre-
cise points in time relative to the trigger point.
4.2
SEC
O D 0
Diagnostic Trouble Cod Numbers
Diagnosed
No. Circuit Condition Page
PO102 Mass Air Flow (MAF) sensor Circuit low input Section FT
PO103 Mass Air Flow (MAF) sensor Circuit high input Section FT
POI 12 Intake Air Temperature (IAT) sensor Circuit low input Section FT
POI 13 Intake Air Temperature (IAT) sensor Circuit high input Section FT
POI 17 Engine Coolant Temperature (ETC) sensor Circuit low input Section FT
PO118 Engine Coolant Temperature (ECT) sensor Circuit high input Section FT
PO121 Throttle Position (TP) sensor In-range operating circuit failure Section FT
PO122 Throttle Position (TP) sensor Circuit low input Section FT
PO123 Throttle Position (TP) sensor Circuit high input Section FT
PO300 Ignition Random misfire detected Section FT
PO301 Ignition Cylinder #1 misfire detected Section FT
PO340 Camshaft Position (CMP) sensor Circuit malfunction (CID) Section FT
PO351 Ignition coil A Primary circuit malfunction Section FT
PO352 Ignition coil B Primary circuit malfunction Section FT
PO353 Ignition coil C Primary circuit malfunction Section FT
P0500/P0503 Vehicle Speed Sensor (VSS) Sensor malfunction Section FT
PO703 Brake OnlOff (BOO) switch Input malfunction Section FT
P07051P0707 Transmission Range (TR) sensor Circuit failure K-61
PO708 Transmission Range (TR) sensor Circuit high input K-61
Transmission Fluid Temperature (TFT
PO712 Circuit low input K-56
sensor
PO713 Transmission Fluid Temperature (TFT
Circuit high input K-56
sensor
PO715 Turbine Shaft Speed (TSS) sensor Circuit malfunction K-66
PO720 Output Shaft Speed (OSS) sensor Insufficient input from sensor K-66
PO721 Output Shaft Speed (OSS) sensor Erratic signal from sensor * K-66
PO731 Transmission Solenoid malfunction Incorrect first gear ratio K-38
PO732 Transmission Solenoid malfunction Incorrect second gear ratio K-38
PO733 Transmission Solenoid malfunction Incorrect third gear ratio K-38
PO734 Transmission Solenoid malfunction Incorrect fourth gear ratio K-38
PO735 Transmission Solenoid malfunction Incorrect fifth gear ratio K-38
PO736 Transmission Solenoid malfunction Incorrect ratio for reverse K-38
PO741 Torque Converter Clutch (TCC) Mechanical system performance K-38
I No.
Diagnosed
Circuit Condition
I Electrical system malfunction
Page
(
I PO743
PO746
Torque Converter Clutch (TCC)
Electrical Pressure Control (EPC) Solenoid Solenoid Malfunction
K-41
K-41
p0750/p1714 Shift Solenoid 1 (SSl) Circuit malfunction K-41
PO751 Shift Solenoid 1 (SS1) Performance K-41
P07551P1715 Shift Solenoid 2 (SS2) I Circuit malfunction I K-41
PO756
. .. - - I .
Shift Solenoid 2 (SS2), I Performance I K-41
P0760/0761/P1716 Shift Solenoid 3 (SS3) Circuit malfunction/Performance K-41
P0765lP1717 Shift Solenoid 4 (SS4) Circuit malfunction K-41
PO781 Transmission Solenoid Gear # l incorrect ratio K-41
PO782 Gear #2 incorrect ratio K-41
~1600 OBD II Drive C:ycle OBD II monitor testing not complete Section FT
P I 100 Mass Air Flow (MAF) sensor Sensor intermittent Section FT
P l 101 Mass Air Flow (MAF) sensor Out of Self-Test range Section FT
I P1120 I Throttle Position (TP) sensor I Out of range low I Section FT I
PI121 Throttle Position (TP) sensor Sensor inconsistent with MAF sensor Section FT
P1124 Throttle Position (TP) sensor Sensor out of Self-Test range Section FT
PI125 Throttle Position (TP)
. . sensor Circuit intermittent Section FT
I I
Wide Open Throttle Air Conditioning Circuit malfunctioning Section FT

P1460
.
Cutoff (WAC),
P I 500lP1501 Vehicle Speed Sensor (VSS) Circuit intermittent Section FT
P1650 Power Steering Pressure (PSP) switch Out of Self-Test range Section FT
PI651 Power Steering Pressure (PSP) switch Input malfunction Section FT
P I 701 Transmission Solenoid malfunction Reverse engagement error K-38
P1703 Brake OnlOff (BOO) switch Out of Self-Test range Section FT
1
P1705 Transmission Range (TR) sensor Out of Self-Test range K-61
Transmission Fluid Temperature (TFT)
Out of Self-Test range K-56
sensor
Switch error Section J2
P1740/1741117421 Control errorlfailed on (turns on TClL or
Torque Converter Clutch (TCC) Solenoid K-46
174311744 MIL)/mechanicallystuck in OFF position
I
1
I I
PI746 I Electronic Pressure Control (EPC) Solenoid I Ooen circuit [low inoutl I K-45
P I 747 Electronic Pressure Control (EPC) Solenoid Short circuit (high input) K-45
P I 749 Electronic Pressure Control (EPC) Solenoid Failed low K-45
PI751 Shift Solenoid 1 (SSl) Performance K-41
I I
I P1754
P 1756 I
Coast Clutch Solenoid (CSS)
Shift Solenoid 2 (SS2) I
Circuit malfunction
Performance
I PI761
PI762 I
Shift Solenoid 3 (SS3)
Transmisson
Control Switch (TCS)
I
Performance
SS3/ SS4/ OD band failure
Circuit out of Self-Test range K-54
P1781 4x4 Low switch Out of Self-Test range Section J2
Over-temperaturecondition K-56
MK7069-82 7BUOKX-007
Caution
After repairing a failure, perform Key On Engine Off Inspection to verify the fault has been
corrected. ~BUOKX-352
Diagnostic trouble codes Shift Solenoids (SS1, SS2, SS3) - 4R44E Only
P0731, P0732, P0733, P0734,
P0736, P0750, P0751, P0755, Note:
p0756, P0760, P0761, P0781, 2nd and 4th gear in OID position can only be obtained with sufficient EPC
P0782. P0783. P0784. P1714. pressure (i.e., no short in EPC circuit can be present).
PI 715; PI 716; ~ 1 7 5 1~; 1 7 5 6 ; Note:
P1761, P1762, PI701 Refer to connector information and solenoid application chart following this
test.
Check to make sure transmission harness is fully Yes Remain in OUTPUT TEST MODE
seated, terminals are fully engaged in connector and in Go to step 2.
good condition before proceeding.
Using NGS Tester, perform KOEO self-test.
Select ACTIVE COMMANDS and enter OUTPUT
TEST MODE
Select ALL ON mode.
Repeat procedure.
Push START to turn outputs ON and STOP to turn
If vehicle still does not enter OUTPUT TEST
outputs OFF
MODE, go to page FT-131.
Does vehicle enter OUTPUT TEST MODE?
Caution Yes Go to step 5.

Do not pry up on connector. Depress release
button then pull up on connector.
Disconnect 16-pin transmission vehicle harness
connector.
Using a mirror, inspect both ends of connector for
damaged or pushed out pins, corrosion, loose wires
and missing or damaged seals.
Using voltmeter, connect positive lead to VPWR Go to step 3.
terminal and negative lead to solenoid circuit of
transmission vehicle harness connector.
Using NGS tester, press START and STOP to cycle
solenoid output ON and OFF.
Does suspect solenoid output voltage change at least
0.5 volts?
Ensure transmission vehicle harness connector is
disconnected.
Disconnect PCM and install 104-pin breakout box
(BOB).
Measure resistance between test pins 1, 27 and 53 at Service open circuit. Go to step 14.
BOB and appropriate signal pin at transmission
connector.
Measure resistance between test pins 71/97 at BOB
and appropriate signal pins at transmission connector.
Is each resistance less than 5 ohms?
Ensure BOB is installed. Yes Go to step 5 .
Ensure transmission vehicle harness connector and
PCM are disconnected.
Measure resistance between test pins 1, 27, 53 and
test pin 91 and test pins 77 and 103 at BOB and
chassis ground.
Is each resistance greater than 10,000 ohms? No Service short circuit. Go to step 14.
5 Install transmission tester. K-74 Yes Go to step 6.
Perform solenoid function test. K-78
Listen for the solenoid to activate (click).
Does voltage and solenoid state change? No Check for open or short in harness, solenoid
or PCM concern.
6 Reconnect PCM. Yes Replace PCM. Go to step 14.
Perform transmission drive test. = K-78
Does the vehicle upshift when commanded by the No Go to step 7.
tester?
Using transmission tester: Yes Go to step 8.
Set MODE switch to BENCH
Rotate GEAR SELECTOR switch to OHMS CHECK
Connect negative lead of ohmmeter to SS1 jack and
positive lead to VPWR jack for SS1 test.
positive lead to VPWR jack for SS2 test.
I No 1 :%ernal harness or solenoid concerns
may cause reading out of specification.
I
positive lead to VPWR jack for SS3 test. Go to step 9.
Resistance for all three solenoids should be between
22 to 48 ohms.
Are shift solenoid resistance within specification?
Check for continuity between BAT- (engine ground)
and appropriatejack with an ohmmeter.
For SS1 test, use SS1 or VPWR jack
Connection should show infinite resistance (no
continuity) - Is there continuity? to diagnose shift concerns.
Drain fluid and remove fluid pan. Yes Go to step 10.
Caution
Use only MerconmVATF or equivalent. Use of
any other fluids may result in a transmission
Check internal harness connector is fully engaged on Service as required.
shift solenoids.
Check internal harness connector terminals are fully
seated in connector.
Inspect connectors for tiamage and wires for insulation
damage.
Is everything OK?
- STEP INSPECTION ACTION

10 Caution Yes Go to step 1 1 .
Do not probe into connector terminals.
Disconnect internal harness.
For SS1, connect positive lead from ohmmeter to
SS1 tester jack and negative lead to appropriate
signal wire at SS1 connector. At SSI, signal wire is
gray and PWR wire is white.
SS2 tester jack and negative lead to appropriate No Replace internal harness. Go to step 12.
signal wire at SS2 wire connector. At SS2, signal
wire is brown and PWR wire is white.
SS3 tester jack and negative lead to appropriate
signal wire at SS3 wire connector. At SS3, signal
wire is yellow and PWR wire is white.
All resistance readings should be less than 0.5 ohms.
11 Check for continuity between BAT- (engine ground) Yes Replace internal harness.Go to step 12.
and appropriate wire with an ohmmeter.
For SSl test, signal wire is gray and PWR
wire is white.
For SS2 test, signal wire is brown and PWR
wire is white.
For SS3 test, signal wire is yellow and PWR
wire is white.
Connection should show infinite resistance (no No Go to step 12.
continuity) - Is there continuity?
12 Check solenoid resistance by connecting ohmmeter at Yes Go to step 13.
solenoid terminals. Measure and record resistance for
all three solenoids.
Resistance for all three solenoids should be between No Replace shift solenoid.
22 to 48 ohms.
Are shift solenoid resistance within specification?
13 Check for continuity between engine ground and Yes Replace shift solenoid.
appropriate shift solenoid terminal (+I-)with ohmmeter.
Connection should show infinite resistance (no Refer to Quick Diagnosis Chart in
No
continuity) - Is there continuity? this section for further diagnosis.
6
-
Diagnostic troubl codes
P0731, P0732, P0733, P0734,
P0735, P0736, P0750, P0751,
T Shift Solen ids (SS1, SS2, SS3, SS4) and Torque Converter Clutch (TCC)
Solenoid - 5R55E Only
Not :
P0755, P0756, P0760, P0761, Read and record all DTCs. All TR sensor and VSS DTCs must be repaired
P0765, P0781, P0782, P0783, before entering Output State Control.
P0784, P1714, PI715, P I 716,
P1717, P1751, P1756, P1761, Note:
P1762, PI701 Refer to connector information and solenoid application chart following this
test.
Check to make sure transmission harness is fully Repair open or short in the vehicle harness or
seated, terminals are fully engaged in connector and in connector.
Using NGS Tester, entre OUTPUT STATE
CONTROL mode.
Wiggle all wiring and connectors to the transmission
and monitor sloenoid state for changes.
Does the suspect solenoid state change?
Monitor solenoid state by turning each solenoid ON and
OFF.
Does the solenoid turn ON and OFF when commanded
1 1 Ye;
Go to step 2.
Go to step 3.
Go to step 4.
and can solenoid activation be heard?
Perform OUTPUT STATE CONTROL Yes Clear all DTCs. Road test to verify if concern
drive cycle. K-83 is still present. Refer to Quick Diagnosis
Does the transmission upshift and downshift Chart in this section for further diagnosis.
when commanded? No Go to step 4.
Remove transmission fluid pan. Yes Go to step 5.
Caution
Use only MerconmV'ATF or equivalent. Use of
any other fluids may result in a transmission
-
Visuallv insoect all wires and connectors for damage.
Using coltmeter, connect positive lead to VPWR
~ p e n , s h o r int harness or solenoid.
terminal of suspect solenoid and negative lead to a
known good ground.
Leave voltmeter positive lead connected to VPWR Yes Go to step 6.

terminal and connect negative lead to signal terminal of
suspect solenoid.
Using NGS tester, enter OUTPUT TEST MODE. Turn
solenoid ON and OFF while monitoring voltage reading
on voltmeter. Listen for solenoid activation. No Check for open/short in harness, solenoid or
Does voltage and solenoid state change? PCM concern.
Disconnect appropriate solenoid connector. Yes Go to step 7.
Check solenoid resistance by connecting ohmmeter to
solenoid terminals.
. .
Measure and record resistance for each solenoid (SSl,
SS2, SS3, SS4 and TCC). No Replace solenoid.
Is resistance within specification?
Shift solenoids - 22 to 48 ohms
TCC solenoid - 8.9 to 16 ohms
Check continuity between BAT - engine ground and Yes Replace solenoid.
appropriate solenoid terminal (+ and -) with ohmmeter.
Connection should show infinite resistance
(no continuity)
Is there continuity? NO Refer to Quick Diagnosis Chart in this section
to diagnose shift or torque converter concerns.
7BUOK8-00s
Diagnostic trouble codes Solenoid mechanical failure - 5R55E Only

P1714, P1715, P1716, P1717,
PI740
STEP INSPECTION ACTION -
1 If any of the following DTCs are present, continue with Yes Repair TFT and other shift solenoid DTCs
test - P1714, P1715, P1716, P1717, P1740. first. Go to step 4.
Are any other DTCS present for TFT or shift solenoids? NO Replace suspect solenoid and/or body. G ~ G
step 2.
1 2 1 Perform transmission drive cvcle test. I
I yes GO to steo 3. I
3
Perform self-tests.
Does vehicle upshift and downshift OK?
Check for DTCs retreived during self-tests.

NO
Yes
to diagnose shift concerns.
Replace PCM.
1
Refer to Quick Diagnosis Chart in this section
J
Are P1714, P1715, P1716, P1717, Pi740 still present? No Testing complete, If concern still exists, refer'
to Quick Diagnosis Chart in this section for

further diagnosis.
MK7340-83 7BUOK8-010
---.
~.
STEP
NO. P0746, P1745, P1747. PI749
1
~ -~
INSPECTION
~
Electronic Pressure Control Solenoid (EPC)-4R44E Only
ACTION
1 heck to make sure transrnission harness is fully seated, terml- Yes Remain in OUTPUT TEST MODE.
als are fully engaged in connector and in good condition before Go to step 2.
sing NGS Tester, perform KOEO self-test.

elect Active Commands and enter Output Test Mode. No Repeat procedure. If vehicle still does not enter
elect ALL ON mode. OUTPUT TEST MODE, go to page FT-131 in this
ush START to turn outputs ON and STOP to turn outputs OFF. manual.
oes vehicle enter Output Test Mode?
2 Yes Go to step 5.
Do not pry u p on connector. Depress release button then
pull u p o n connector.
isconnect 16-pin transmission vehicle harness connector. i
sing a mirror, inspect both ends of connector for damaged or
ushed out pins, corrosion, loose wires and missing or damaged
seals.
Note
Refer t o connector information and solenoid application No Go to step 3.
chart following this test.
Using voltmeter, connect positive lead to VPWR terminal and
negative lead to solenoid circuit of transmission vehicle harness
connector. Set voltmeter to 20-volt scale.
Using NGS tester, press START and STOP to cycle solenoid
I output ON and OFF.
I Does suspect solenoid ou~putvoltage change at least 0.5 volts?

3
II Key OFF. Yes Go to step 4.
Ensure transmission vehic:le harness connector is disconnected.
Disconnect PCM and install 104-pin breakout box (BOB).
Measure resistance between test pin 81 at BOB and appropriate ,
1 signal pln at transm~ss~onconnector
1 Measure resistance between test pins 71197 at BOB and appropri-
1 ate s~gnalplns at transmlss~onconnector
No
1
Service open clrcults Go to step 13
1 Is each resistance less than 5 ohms7

4 1! Ensure BOB 1s Installed Yes
I Go to step 5
1 /
Ensure transmlsslon vehlcle harness connector and PCM are
1 disconnected.
! Measure resistance between test pin 81 and test pins 77, 103, 76 NO Serv~ceshort CIrcult GOto step 13
and 91 at BOB and chassis ground.
!
- -
5 Ensure transmission vehicle harness connector is disconnected. Yes Replace PCM. Go to step 13
Reconnect PCM.
Install line pressure gauge at line tap on-case.
Install transmission tester 49 UNOI 071 and 4R44E cable overlay
49 UNOI 132.
Set MODE switch to DRIVE.
Rotate GEAR SELECTOFl switch to Ist GEAR position.
Perform EPC functional test. Refer to Transmission Tester in this No Go to step 6
, section.
1 Does EPC (LED green) activate when EPC switch is depressed.
Observe line pressure on gauge while depressing EPC switch
(vehicle must be running).
Does line pressure drop?
6 1 Using trans tester, set MODE switch to BENCH.
I Rotate GEAR SELECTOR switch to OHMS CHECK position
Yes p:; step 7
1 Using ohmmeter, connect negative test lead to EPC jack and Internal harness or solenoid may be damaged.
positive lead to VPWR jack on tester. This is to test EPC solenoid
and harness. Record resistance.
Is resistance between 3.1 to 5.7 ohms?
1 No / Go to step 8.
7 Check for continuity between BAT - (engine ground) and

appropriate jack with an ohmmeter.
1 Yes 1 GOto step 8.
I
For EPC test, use EPC or EPC VPWR jack. Refer to Quick Diagnosis Chart in this section to
Connection should show infinite resistance (no continuity). diagnose hydraulic/mechanical concerns.
Is there continuity?
--
STEP INSPECTION
Drain flu~dand remove fluid pan. Yes Go to step 9
Check Internal harness connector IS fully engaged on EPC
solenoid.
Check Internal harness connector terminals are fully seated In
connector. 1 No Servlce as requrred
Inspect connectors for damage.
Is everything OK?
I
I
Disconnect internal harness from EPC solenoid. Yes Go to step 10
Connect posrtive lead from ohmmeter to EPC tester jack and
negative lead to blue wrre at EPC connector. Record resistance.
Next, connect positive lead from ohmmeter to VPWR tester
jack and negative lead at green wire at EPC connector. Record
resistance.
I No ,, Replace Internal harness
10 Check for continuity between BAT - (engine ground) and I Yes Replace internal harness. Go to step 11
appropriate wire (Green+lBlue - ) with ohmmeter.
Connection should show inffnite resistance (no continuity) No Go to step 11
1 Is there continuity?
f1 Check solenold res~stanceby connecting ohmmeter at EPC Yes Go to step 12 Replace shift solenold
term~nalsRecord resistance ,
Is res~stancebetween 3 1 to 5 7 ohms? No Replace EPC soleno~d
12 Check for cont~nu~ty between a good ground and each EPC Yes Replace EPC solenold
term~nal
Connection should show lnf~n~te res~stance(no cont~nu~ty) No Refer to Qu~ckD~agnos~s
Chart In thls sectlon for
Is there contlnulty7 further dragnosls
1 13
7BUOKX-008
MK7E39-61
1 Electronic Pressure Control Solenoid (EPCk5R55E Only

Note: Read and record all DTCs. All TR sensor and VSS DTCs must be repaired before
entering Output State Control (OSC). --
STEP 1 INSPECTION ACTION
1 Check to make sure transrnission harness is fully seated, termi- I Yes
nals are fully engaged in connector and in good condition before ; Go to step 2.
I=
oroceedina.
/ using N G Tester,
~ select ACTIVE COMMANDS. Repeat procedure. If vehicle still does not enter
OUTPUT STATE CONTROL, go to page FT-131 in
Enter OUTPUT STATE CONTROL.
Does vehicle enter OUTPlJT STATE CONTROL screen? this manual for NGS communication concerns.
2 Remain in OUTPUT STATE CONTROL.
Wiggle all wiring and connectors to the transmission
. T.- Repa~ropen or short in vehicle harness.
Repair connector.
Monitor solenoid state for changes. --
Does suspect solenoid state change? I No I Go to step 3.

3 Install 300 psi pressure gauge into EPC tap. / yes / CI
Monitor pressure gauge.
Select EPC command.
Command 15, 30, 45, 60, 70, 90 psi. Go to step 4.
Does pressure reading match the commanded pressure?
--
Remove transmission fluid pan.

Visually inspect all wires and connectors for damage.
Connect positive lead to VPWR solenoid terminal and negative
lead to a good ground. or short circuit in harness.
Is battery voltage present')
--
I Leave ~ositivelead connected to VPWR solenoid terminal and Go to step 6.
connect negatlve lead to s~gnalterm~nalof EPC solenold
Turn soleno~dsON and OFF whlle mon~torlngvoltage read~ng,
solenold state on the NGS (ON and OFF) Check for open or short clrcu~tIn harness or PCM
L~stenfor activat~onof solenold (cllck)
Does voltage and solenoid state change?
- -- -- -- ---
1 -
Disconnect veh~cleharness from transm~sslon yes I GO to step 7
Check solenold reslstance by connecting ohmmeter to solenold
terminals
Measure and record EPC solenold res~stance No Replace EPC solenoid
Res~stanceshould be between 3 1 to 5 7 ohms
Is resistance w ~ t h ~spec~f~cat~ons?
n I I
Check for continuity between engine ground and EPC solenoid Replace EPC solenoid
terminals. -
Connection should have rio continuity (infinite). Refer to Quick Diagnosis Chart for further diagnosis
Is there continuity? of pressure concerns

No. P0741, P0743, P1740, P1741,
P I 742. P I 743, PI 744
Torque Converter Clutch (TCC) Solenoid-4R44E Only
-
7
II- --
INSPECTION ACTION
- - - - - - - --- -- - - - - - -- - -- -- -- -
1 Check to make sure transm~ss~on harness IS fully seated, terml- Yes Rema~n~nOUTPUT TEST MODE
nals are fully engaged ~nconnector and In good cond~t~on before 1 Go to step 2.
proceeding.
Usina NGS Tester. aerforrn KOEO self-test
~ e l e EACTIVE
t COMMANDS and enter OUTPUT TEST MODE
Select ALL ON mode
1
-
NO
-
Repeat procedure If vehlcle st111does not enter
OUTPUT TEST MODE, go to page FT-131.
-
Push START to turn outputs ON and STOP to turn outputs OFF

Does vehlcle enter OUTPUT TEST MODE?
Do not pry up on connector. Depress release button then
pull up on connector.
Dlsconnect 16-pln transmlss~onvehlcle harness connector
Uslng a rnlrror, Inspect both ends of connector for damaged or
pushed out plns, corrosion, loose wlres and mlsslng or damaged
seals
Uslng voltmeter, connect posltlve lead to VPWR clrcu~tand No Go to step 3
I
1 negatlve lead to solenold clrcult of transmlss~on vehlcle harness
connector Set voltmeter to 20-volt scale
Uslng NGS tester, enter OUTPUT TEST MODE Press START
and STOP to cycle solenold output ON and OFF whlle observing
voltmeter
Does suspect solenold output voltage change at least 0 5 volts?
--- - - -- - --- - -- -
Key OFF Yes Go to step 4.
Ensure transmrss~onvehlcle harness connector IS disconnected
Dlsconnect PCM and Install 104-pln breakout box (BOB)
Measure reslstance between test pln 54 at BOB and appropr~ate
, s~gnalpin at transmlss~onconnector
Measure reslstance between test plns 71197 at BOB and the
VPWR p ~ n at the transm~ss~on vehlcle harness connector
No Servlce open clrcults. Go to step 14
I
1
Is each reslstance less than 5 ohms?
- - - - - - --
Ensure BOB IS installed
- - - -
Ensure transmlss~onvehlcle harness connector and PCM are

----Yes
-
Go to step 5
1 disconnected.
Measure resistance between test pin 54 and test plns 71197 at - - - - - - - -
I
-
Measure reslstance between test pln 54 and test plns 51, 76, 77,
91, and 103 at BOB and chass~sground
Is each reslstance greater than 10,000 ohms?
- - - -
No
- -
Service short clrcult Go to step 14
* - - --
Install transmrsslon tester m.= K-74 Yes Go to step 6.
I1
1
Perform TCC solenold funct~ontest K-78
Does the TCC (green LED) activate? No Go to step 7
- - - - ---- - -- -- - - - - --- -- - - - - - - ---- - -
I Reconnect PCM Yes Replace PCM Go to step 14 If codes st111appear,
Perform transmlsslon drlve test K-78 refer to Qulck D~agnos~sChart ~nthls sect~onfor
Whlle in 3rd gear, depress the TCC sw~tch torque converter concerns
Does the TCC (green LED) activate?
4 Does englne RPM drop?

------
Uslng transmlss~ontester
Set MODE sw~tchto BENCH
-- - - - - -
Rotate GEAR SELECTOR sw~tchto OHMS CHECK

No
---
Yes
Go to step 7
-- - - --- ---
Go to step 8
-- -
No Note
Connect negatlve lead of ohmmeter to TCC jack and posltlve Internal harness or solenoid concerns may
lead to VPWR jack cause reading out of specification.
Resistance should be between 8 9 to 16 ohms Go to step 9
Is res~stancew~thrnspec~f~cat~on?
- - -- - - -
Check for contlnulty between BAT- (eng~neground) and Yes Go to step 9
appropr~atelack w~than ohmmeter -- ---- - - -
For TCC test, use TCC or VPWR jack No Refer to Qulck D~agnos~s
Chart ~nthls sect~onto
Connection should show lnflnlte res~stance(no contlnu~ty) d~agnosetorque converter concerns
Is there contlnu~ty? I
I i I
I
1I
STEP INSPECTION I ACTION
Drain fluid and remove fluid an. / yes / GOto steo 10.
Caution
Use only Mercon* V ATF or equivalent. Use of any other
fluids may result in a transmission malfunction or failure.
Check Internal harness connector IS fully engaged on TCC A
solenold No Servlce as requ~red
Check internal harness connector terminals are fully seated In
connector
Inspect connector for darnage
Is everything OK? 1
Disconnect internal harness. 1 yes Go to step 11
1-
Connect positive lead frorn ohmmeter to TCC tester jack and
negative lead at purple wire of TCC connector. Resistance
reading should be less than 0.5 ohms.
Next, connect positive lead from ohmmeter to tester VPWR jack No Replace internal harness. Go to step 12.
and negative lead at black wire of TCC connector.
Is resistance less than 0.5 ohms? 1
Check for continuity between BAT- (engine ground) and I Yes ! Replace internal harness. Go to step 12.
appropriate TCC wire.
Connection should show infinite resistance (no continuity)
Check solenoid resistance by connecting ohmmeter at solenoid Go to step 13.
terminals. Measure and record resistance for TCC solenoid.
I Resistance reading for TCC solenoid is 8.9 to 16 ohms.
Replace TCC solenoid.
1 Is resistance withln specification?
Check for continuity between BAT- (engine ground) and terminal I Replace TCC solenoid
( + I - ) with ohmmeter.
Connection should show gnfinite resistance (no continuity) Refer to Quick Diagnosis Chart in this section for
Is there continuity? further diagnosis.
1 14 / Perform After Repair Procedure to ensure customer's concern has been resolved. I
-
Diagnostic trouble code Coast Clutch Solenoid (CCS)-4R44E Only -
No. PI754 Note: Refer t o connector information and solenoid application chart following this test.
-- --
-
- -
INSPECTION ACTION
pp -- - -
sure transmission harness is fully seated, terml- -i~es Remain ~nOUTPUT TEST MODE
In connector and in good cond~tlonbefore
1
I
Go to step 2
Using NGS Tester, perform KOEO self-test

Select ACTIVE COMMANDS and enter OUTPUT TEST MODE
Select ALL ON mode
~ ~ c ~ d u r e d u r e I e lzsnotenter
fvehle
OUTPUT TEST MODE, go to page FT-131
Push START to turn outputs ON and STOP to turn outputs OFF I
Does vehlcle enter OUTPUT TEST MODE? I
-
- - --
Disconnect 16-pin transmission vehicle harness connector.
Using a mirror, inspect both ends of connector for damaged or
pushed out pins, corrosion, loose wires and missing or damaged
seals. -- -
Using voltmeter, connect positive lead to VPWR terminal and No Go to step 3.

negative lead to solenoid circuit of transmission vehicle harness
connector.
Using NGS tester, enter OUTPUT TEST MODE. Press START
and STOP to cycle solenoid output ON and OFF while observing
voltmeter.
Does suspect solenoid output voltage change at least 0.5 volts?
Ensure transmission vehicle harness connector is disconnected.
Measure resistance between test pin 28 at BOB and appropriate -
signal pin at transmission connector. No Serv~ceopen clrcults Go to step 14
Measure resistance between test pins 71197 at BOB and appropri-
ate signal pins at transmission connector.
---
Key OFF, BOB is installed. Yes Go to step 5

Ensure transmission vehicle harness connector and PCM are
disconnected.
Measure resistance between test pln 28 and test pins 71/97 at No Serv~ceshort clrcuit. Go to step 14
BOB and chassis ground.
-- ---
Reconnect PCM. Yes Go to step 6.

Install transmission tester. K-74
Perform solenoid function test. K-78 No Go to step 7
Does solenoid activate (LED green)?
-- - -- -- -- - -. - -- - -
Perform transmission drlve test K-78 Yes Replace PCM Go to step 14

Does CCS actlvate when commanded by tester? -- --- -- -
Does englne braklng occur? No Go to step 7

Does coast clutch engage?
7 Using transrnlsslon tester Yes Go to step 8
Set MODE swltch to BENCH --- - -
Rotate GEAR SELECTOR sw~tchto OHMS CHECK
I No Note
Connect negatlve lead of ohmmeter to CCS jack and posltlve Internal harness or solenoid concerns may
lead to VPWR jack cause reading out of specification.
Resistance should be between 22 to 48 ohms Go to step 9
Is resistance withln speclflcatlon?
-- -
-- - -
-
r - --
Check for continuity between BAT- (englne ground) and Yes Go to step 9
appropriate jack with an ohmmeter.
For CCS test, use CCS or VPWR jack
Drain fluid and remove fluid pan.
I
I
I
No
Yes
Refer to Qulck D~agnoslsChart In thls sectlon to
diagnose torque converter concerns
Go to step 10
I
Caution
Use only MerconmVATF or equivalent. Use of any other
fluids may result i n a transmission malfunction or failure.
Check internal harness connector is fully engaged on CSS.
Check internal harness connector terminals are fully seated in No Service as required.
connector.
Inspect connector for damage.
Is everything OK?
STEP.- INSPECTION 1 ACTION I
-
-
10
-
Disconnect internal harness.

For CCS, connect positive lead from ohmmeter to CCS tester
Yes ' Go to step 11.
jack and negative lead at orange wire of CCS connector.

For CCS VPWR, connect positive lead from ohmmeter to CCS
VPWR tester jack and negative lead at white wire of CCS Replace internal harness. Go to step 12.
connector.
Check for continuity between BAT - (engine ground) and internal harness.
appropriate wire with an ohmmeter.
For CCS test, signal wire is orange and VPWR wire is white.
Resistance should be between 22 to 48 ohms. Replace CCS solenoid.

Check for continuity between engine ground and appropriate CCS Replace CCS solenoid
terminal (+I-)with ohmmeter.
Connection should show infinite resistance (no continuity). Refer to Quick Diagnosis Chart
Is there continuity? further diagnosis.
( 14 / Perform After Repair Procedure to ensure customer's concern has been resolved. I
:
DTC- Incorrect Gear Ratio
-- -- -- -- -- - -
-- ---
- - - - - -- --
P0731, PO781
- - -- --Gear #l
- - - - - P0732, PO782 - - Gear #2 --
- -- -- - -
P0733,
-
PO783- -- - -
Gear #3 -- ---
- - --
P0734, PO784
- -- -- - --- - - - -- - -
Gear #4
-- - -- -- ---
- - - ---
PO735
- -- -- - - -- - - - -
Gear
-
#5-- - -
P0736, PI701 Reverse

MF70644-B 7BUOFl 074
TSS SENSOR
MK7000-B
FROM POWER RELAY

TEST PIN 71/97 0 VPWR
TEST PIN 53 0 SS3
TRANSMISSION
TEST PIN 81 0 EPC HARNESS
CONNECTOR
TEST PIN 27 SS1
TEST PIN 1 0 SS2

TEST PIN 28 0 CCS / SS4
TEST PIN 54 0 TCC

MK7001-B
Circuit function
Toraue Converter Clutch (TCC) Power
Red e;iii; Shaft ~~ee-1
White Sensor Signal

- Return (TSS-)
4 Red Transmission Fluid Temperature (TFT)
Sensor
5 Purple Torque ~onvertetClutch(TCC)
Solenoid
6 - Not Used
7 Yellow Shift Solenoid 3 (SS3)
8 L
Red Sensor Signal Return (TFT-)
9 Orange Coast Clutch Solenoid (CCS): 4R44E
Shift Solenoid 4 (SS4): 5R55E
10 White Shift Solenoid Power
11 Green Electronic pressure Control (EPC)
Power
12 Blue Electronic Pressure Control (EPC)
--
Solenoid - -
13 - Not Used
14 Brown Shift Solenoid 2 (SS2)
- - -
15 1
- Not Used
16
I
Gray I
Shift Solenoid 1 ( s s ~ ) I
4R44E
Solenoids
Powertrain V 7
control
module
(PCM) gear Engine
Gear selector position commanded braking SS3 SS4
PIN PIN No
@ (Overdrive ON) R Yes
1 No
2 No OFF OFF
3 No ON OFF OFF
4 No OFF OFF OFF OFF
5 No ON OFF
@ I
(Overdrive OFF) 1 Yes OFF ON
2 No ON OFF ON ON
3 Yes OFF ON OFF ON
I I 4 I yes 1 OFF 1 OFF I OFF I ON I
Manual 2 7 2 Yes ON ON OFFON\
Manual 1 1 / Yes 1 ON I OFF I OFF ON
/ Gear selector position I Gear selector position
-
SSI a l w a y s ~ ~ ~ : ED 2 1 1 SSI always ON: i OD F--T- -- -
ECA gear commanded
1
- 3
Actual gear obtained
- 2
ECA gear commanded
1 1
Actual gear obtained
-
---
1
2 2 2 2' 2 2 2 2'
3 3 - - 3 1 - -
4 4 - - 4 Ratro 1.86 - -
-
Gear selector position Gear selector positioL- -- -
SS2 always OFF: OD 2 1 S S always

~ ON: OD 2 1 1
-
- -
ECA gear commanded Actual gear obtained I ECA gear commanded Actual gear obtained
1 1 - 1 2 1 - 2
2
3 3
1 2
3 2 1 -2 ' 2
-
4 4
I
1
-
-
Gear selector position
-
- 1 4 2 1
-
I
-
-
1
--
553 always OFF: L ~ 2 2 1r SS3 always ON: OD 2 1

- --
ECA gear commanded Actual gear obtained ECA gear commanded Actual gear obtained
- -- -
1 1 - 1 1 Ratto 1.86 ; - Ratlo 1.86
2 2 2 2' 2 R a t l o 1.I 1 / Ratlo 1.I 1 R a t l o 1.I1
3 3 - - I
3 - -
4 3 - - 4 I " , - -
When manual pull In occurs above a cal~bratedspeed, the trans w ~ ldownsh~ft
l from the h~ghergear unt~lthe veh~clespeed drops below this cal~bratedspeed
Gear selector position Gear selector position
-6iY-r~ 1 SSI always ON: Tiq-T-rT
Actual gear obtained PCM gear commanded Actual gear obtained
4 3 3 1
5 Ratio 1 .I Ratio 1.1 2
3 3 3 3
4 3 3 4
5 Flatio 1 .I Ratio 1 .I 5 2 Ratio 1.1 2
Gear selector position 1 I Gear selector position
SS2 always OFF: --
OD I 2 1 S S alwavs
~ ON: OD I 2 1
PCM gear commanded Actual gear obtained PCM gear commanded Actual gear obtain d
1 1 3 1 1
2 Ratio 1.1 2 2
1(a) 2(b) 3 1 3
4 3 3 4 3 3 3
5 Flatio 1.1 Ratio 1.1 5
Gear selector position I I Gear selector position
I SS3 always OFF: OD I 2 1 S S always
~ ON: I OD I 2 1
PCM gear commanded Actual gear obtained PCM gear commanded Actual gear obtained
1 1 3 1 1 2 3 1
2 1 3 1 2 1 2 Ratio 1.1 2
3 3 3 3 3 Ratio 1.1 3 3
4 4 3 3 4 5 3 3
5 4 3 3 5 5 Ratio 1.1 Ratio 1.I
Gear selector position 1
- 7 F - - r 2 1 SS4 always ON: OD 1
PCM gear commanded Actual gear obtained PCM gear commanded Actual gear obtained
1 1 1
2 2 1
Diagnostic trouble
code No. P I 780
Transmission control switch (TCS) or Transmission Control Indicator Lamp (TCIL) circuit
malfunction 1
-
Symptom
- -
/ TCS was not cycled durrng Key On Engrne Runnrng self-test
-- - ---
STEP INSPECTION 1
ACTION
1 Perform KOER self-test properly (Refer to page K-31) Yes Go to next step
Note: If TCS is not activated during KOER, DTC PI780 --
I
appears. No Go to step 16
Does DTC P I 780 st111exrst?
Key OFF Yes Repa~ras needed
Do PCM or TCS connector and matlng surfaces have a poor
connectron? No Go to next step
Check for blown fuses #I1 and #26
1 Key OFF
BOB installed, PCM disconnected
I Kev O N
I Yes
1
Replace PCM
I the TCS several times

I
r--
No
-
' Go to next step
- --
4
i Does voltage cycle between TCS SIG test pin 29 and PWR GRD
test pins 24/77?
Key OFF
--A
Yes (
Go to next step
-
Is there continuity between TCS SIG keypower at fuse #26 and -- - - -
power side of TCS connector (PU/O wire)? No Sewlce open circult

t---- -- - - -- -- -
5 i Key OFF Yes Go to next step

Is there continurty between test prn 29 at the break out box and
TCS connector T/W wire? No Sewlce open c~rcu~t
Disconnect TCS --
Is resistance reater than 10,000 ohms between test pin 29 and No 1 Service short circuit
test pin 24/77? I
Key OFF ( Yes Replace TCS/verify complaint IS resolved If not, go

BOB installed, PCM disconnected to next step
Is resistance greater than 10,000 ohms between test pin 29 and -- - - -- - --- - - - -
test pins 71/97 at the BOB?
Key OFF
--- ---- - - --
1
1
No
-
Yes
----- Sewrce short crrcurt
-- --- ---
Concern may be rntermrttent Go to step 10
-- -
BOB disconnected, PCM reconnected I

KOEO No , Go to next step
Does TClL turn on and off while cycling the TCS?
--
Key OFF Yes Reparr short to ground between bulb and test pin 79
Disconnect PCM I
Does TClL remain on with KOEO? No Go to next step
10 1 Key OFF 1 Yes Go to next step
I Reconnect PCM
NGS connected - access TClL PID
( KOEO, does TClL PID lndlcate onloff wh~lecyclrng TCS?
1 Kev OFF Yes I Isolate fault and service 1
NGS connected
KOEO, access TClL PID. Does PID value on the NGS fluctuate
while wiggling a small section of the harness all the way to the 1 No Go to step 13
PCM, or tapping the TCS button at the shift lever?
Key OFF I Yes GO to step 1
KOEO
Does TClL light after jumping test pin 79 at BOB to ground?
Remove fuse #11. Measure resistance between fuse terminal and
O/B wire at the instrument cluster connector C-214
Measure resistance between test pin 79 at the BOB, and W/LG , No Servrce open crrcu~t
wire at the instrument cluster connector C-214
I
Are both resistances less than 5 ohms? I
14 Key OFF Yes , Go to next step

BOB ~nstalled,PCM d~sconnected
Drsconnect ~nstrumentcluster connector '2-214 -
Is resistance greater than 10,000 ohms when measurrng between ! NO Sewlce short clrcurt
test pin 79 and VPWR test pins 71/97 at the BOB?
I
15 KevOFF / Yes 1 Reolace PCM
~ebonnectrnstrument cluster connector I --
BOB Installed, PCM drsconnected
Measure voltage between test plns 79 and 24/77 at the break out box
No ' Inspect for damaged TClL bulb, key power fuse, or
servlce open clrcurt
Is voltage readrng at least 2 0 V3
/ 16 1 Perform After Repair Procedure to ensure customer's concern has been resolved (pg. K-34) i
6BUOKX-009
LED
TEST PIN 0 TO KEYPOWER

79
TClL LOCATED IN
INSTRUMENT CLUSTER
TEST PIN 0
29 TCS LOCATED
O N TRANSMISSION
SHIFT LEVER
- - - - - - --
1-
Diagnostic trouble code Transmission Fluid Temperature (TFT) sensor malfunction-4R44E Only
NO. PO712, PO713, P I711, P I783
--- - -. -- - - --- -- - - - - - - -- -
Symptom Excessive shift shock, TFT out of range

PO713 is set if temperature exceeds set scale - 40°F
PO712 is set if temperature exceeds set scale 315°F
PI711 is set if signal went high or low during self-test
PI783 is set-
- --
if temperature
- -
exceeds 270°F
- - --
--1
- - - - - - -P - - -
STEP
-- - -- - -- - -
INSPECTION
-- - - - - -- - - -
ACTION
- - - - --- -
1 I Make sure transm~ss~on

harness connector IS fully seated and Yes Go to step 2
1 terrnlnals are fully engaged In connector and In good condrtion

before proceeding.
1 Have Items been checked?
No
7- -
Perform checks Erase codes and repeat self-tests
- -
> I Caution
- -- -- PP - - - -

P - -
Yes Go to step 5
Key OFF
Drsconnect 16-prn transmlss~onvehlcle harness connector
) Us~nga mlrror, Inspect both ends of connector for damaged or
pushed out plns, corrosion, loose wlres and mlsslng or damaged
I seals
I Refer to connector information and solenoid application

chart following this test
Uslng voltmeter, connect posltlve lead to TFT crrcu~tand negat~ve
Go to step 3
1 lead to SIG RTN clrcult of transm~ss~on

Set voltmeter to 20-volt scale
Key ON, englne OFF
vehrcle harness connector
Is voltage between 4 75 and 5 25 volts?

- - - - - - - -
3 Key OFF Yes
1 Ensure transmlss~onvehlcle harness connector IS disconnected
' D~sconnectPCM and Install 104 pln breakout box (BOB)
Measure res~stancebetween test pin 37 at BOB and appropr~ate
slgnal p ~ n
at transmrsslon connector Servlce open clrcu~tsGo to step 8
Measure res~stancebetween test plns 91 at BOB and approprrate
s~gnalprns at transmlss~onconnector
Are both resrstances less than 5 ohms?
- -- -
4 (Key OFF Yes Go to step 5.

Ensure transrnlss~onveh~cleharness connector IS drsconnected
Drsconnect PCM and Install 104-p~nbreakout box (BOB)
Measure res~stancebetween test pln 37 and test plns 71197 at - - - -
BOB Service short clrcu~tGo to step 8

Measure res~stancebetween test pins 37 and chass~sground, test
( plns 51.76,77, 103, and 91
Are res~stancesgreater than 10,000 ohms?
- -- - --- - - - - -
5 l Note Yes Go to step 6

Be sure trans tester solenoid select switch is in the OHMS
CHECK position or damage to ohmmeter may result.
transmlss~ontester 49 UNOl 071 and 4R44E cable overlay
1 49 UN01 132.
/ Set MODE switch to BENCH
' Rotate solenold select swltch to OHMS CHECK
1 Connect posltrve lead of ohmmeter to +TFT jack and negatrve
) lead to - TFT jack
Note
While performing the following tests, observe resistances.
DTC PO713 (open circuit) is set if resistance is above 869K
--
1 ohms. DTC PO712 (short circuit) is set if resistance is
below 597K ohms.
Perform the following tests
-
Go to step 8
- - -A -
Replace Internal transm~sslonwlrrng harness

--
Test 1 Record reslstance Refer to the TFT sensor res~stance

chart followtng t h ~ test
s
Test 2 Check for rnterrn~ttentshort or open If resrstance was
between 0 8K and 1OOK ohms, perform the follow~ngtest
If transmlsslon IS cold, run transm~ssronto warm ~t If transmls-
sron IS warm, allow transmlsslon to cool
Check TFT sensor reslstance again
Compare resrstance w ~ t hl n ~ t ~resrstance
al Resistance should
decrease ~f transmlss~onwas allowed to cool
If correct change In res~stanceoccurs, repeat self-tests
1 s; res~stancew~thlnrange?
I STEP / INSPECTION 7ACTION 7

6 Using trans tester, check continuity between BAT- (engine 1 Yes Go to step 7.
ground) and appropriate jack (-TFT or +TFT). Connection should
/
show infinite resistance (no continuity)
1 No T ~ e p l a c P
e C M GOto step 8.
7 Drain fluid and remove fluid pan. Yes Repeat self-tests. If codes are present and over-
Check internal harness connector is fully seated on TFT sensor. temp condition exists, check fluid.
Check internal harness connector terminals are fully engaged in Refer to Quick Diagnosis Chart in this section for
connector. overheat conditions. Service as required.
Inspect connectors for damage.
Is evewthina OK? No 1 Service as required. Replace internal harness.
1 8 1 Perform After Repair Procedureto ensure customer's concern has been resolved. I
.

NO. PO712, PO713, PI 711, PI
- - -- -- -
Symptom Excessive shift shock, TFT out of range

PO713 is set if temperature exceeds set scale -40°F
PO712 is set if temperature exceeds set scale 315°F
PI711 is set if signal went high or low during self-test
-
1
'
4
- -
1 Check to make sure transm~ss~on

-
I
--
P1783 is set if temperature
--
INSPECTION
-
harness connector IS fully

exceeds 270°F
-- -
-pi.-.----.
I
- --
Rernaln ~nPIDIDATA MONITOR AND RECORD

Yes
ACTION
--
--
-- --
i seated, terrnlnals are fully enqaqed

- - In connector and In qood Go to step 2
7 -- -
- -
condltlon before proceeding
Uslng NGS Tester, access TFT and TFTV PlDs No Repeat procedure If veh~clest111does not enter
Does vehlcle enter PID screen? PIDIDATA MONITOR AND RECORD, go to page
FT-131 In thls manual
- - - - - -- - 1 - - - - -
Whlle In PID mode, wlggle all connectors to the transmlsslon Yes Repalr open or short ~nvehlcle harness or
Monltor the TFT sensor PlDs for changes
Does the TFT sensor state change? -
1 No Go to-
connector
step 3 --
-- --
- - - --- -- - - - - - -- - --
Whlle monltorlng the TFT PIDs, perform the following test Yes If TFT PlDs Increase as transmlsslon IS warmed
If the transrnlsslon IS cold, warm transmlsslon up If transmlss~on up or decrease as transrnlsslon IS cooled, clear
IS warm, allow transmlsslon to cool down all DTCs and rerun self-tests If concern IS st111
Do TFT PlDs Increase as transmlsslon IS warmed up or decrease present, refer to Qulck Dlagnosls Chart for further
as transmlsslon IS cooled or do PlDs drop In and out of range7 lnformatlon
If TFT PlDs drop In and out of range, Inspect
lnternallexternal harness, sensor or connector for
- --lntermlttent
--
concerns - -
- -
No Go to step 4
1 connectors
~e6Ztransmlsslon
-
fluid pan. Vlsuallv. Inspect

for damage
. all wires and
-
Yes
,
-
Go to steD 5
-- -
--- - - -- -- -
Connect posltlve lead of voltmeter to TFT+ at sensor terminal and N, check for open or short clrcult In vehicle harness,
negatlve lead to a good ground Internal harness or PCM concern
Is voltage present?
- -- - -- - - -- --
' 5 ~ ~ s c o n i evcet h z e harness from TransrnlsGn Yes Refer to Qulck Dlagnosls Chart to further d~agnose
Connect ohmmeter across TFT + and TFT - terrnlnals at connector overheating concerns
Record reslstance See TFT speclflcatlons chart at the end of thls , -
- -- - --
test -
No Replace Internal harness (sensor IS part of harness)
Is the reslstance In range?
8 12
4
CCS (4R44E) / SS4 (5R55E)

1
TSS SENSOR
1
TEST PIN 37 @- O/Ei TFT SIG
TEST PIN 91 GYIR SIG RTN TRANSMISSION
HARNESS
CONNECTOR
( 'TEST PINS LOCATED ON BREAKOUT BOX

I
Pin Wire I pin

number
1
2
color Circuit function I number color
Orange
' Circuit function
Sh~ftSolenold 4 (SS4)-5R55E
Coast Clutch Solenold (CCS)-4R44E
7BUOKX-I1
Transmission Fluid
Temperature (TFT) Sensor
No. P0705,
STEP
Pl7059
P0707,
p17141P0708,
Symptom
s- ON-BOARD DIAGNOSIS SYSTEM
Digital Transmission Range (TR) sensor circuit malfunction-4R44E and 5R55E
TR signal shorted t o ground

TR signal is high or open
TR signal i s not i n Park during KOEO self-test
INSPECTION
I
1 ACTION
Note Yes I Go to step 2.
DTC PI705 will b e set if the vehicle is i n any other range ,
than Park during KOEO. Rerun KOEO self-test properly if
code P I 705 i s set.
~
Key OFF.
Place transmission in Park.
Check to make sure TR sensor harness connector fully seated
and terminals are fully engaged in connector and in good condi-
tion before proceeding.
- ~ o ' ~ j ~ ~ c , n s o r ~ ~ ~
Place transmission in Park and rerun self-tests.
Apply parking brake.
Place transmission in overdrive.
Verify shift linkage is adjusted in overdrive position.
Place transmission in neutral.
Verify TR sensor is in alignment using 49 UNOl 086.
Is TR sensor properly adjusted?
Place transmission in Park.
Press button and ~ u lout
l on TR harness connector.
Inspect both ends'of the connector for damage or pushed out
Yes
1 Service as required. Clear codes and rerun self-
tests. 1
pins, corrosion, loose wires and missing or damaged seals. If diagnosing a DTC, go to step 3.
Is there damage to the connector, pins or harness? If diagnosing a starting concern, back-up lamp
concern or 4x4 low engagement concern, go to
Key OFF. Yes The problem is not in the TR sensor system.

Reconnect TR sensor. Refer to Quick Diagnosis Chart in this section.
Key ON.
Using NGS tester, access PlDS TR and TR-D. I
Move transmission range lever into each gear and stop.
Observe TR and TR-D PlDS while wiggling harness and tapping
NO / GOto step 4.
on sensor.
1 If diagnosing a starting concern, back-up lamp
concern or 4x4 low engagement concern, go to
Compare PlDs to chart immediately following this test. step 8.
Do TR and TR-D PlDs follow the chart and does TR-D PID
remain steady when harness is wiggled or sensor is tapped.
Disconnect TR sensor. Concern is r~otin the TR sensor system.
install trans tester, TR cable and cable overlay. Go to step 5
Following instructions on overlay, perform sensor test.
Does status lamp on tester cable match the selected gear
positions? I Replace TR sensor. Make sure new sensor is
adjusted correctly. Go to step 9.

Disconnect TR sensor.
Measure resistance between test pin 91 at BOB and pin 2 of
TR sensor harness connector.
TR sensor harness connector
Measure resistance between test pin 49 at BOB and pin 5 of No Repair open circuit(s). Go to step 9
Are all resistances less than 5 ohms?
Measure resistance between test pin 91 and test pins 71197 at Yes Go to step 7
BOB.
Measure resistance between test pin 3 and power ground test
pins at BOB. I
pins at BOB.
Measure resistance between test pin 50 and power ground test Repair short circuit(s). Go to step 9.
pins at BOB.
pins at BOB. !
Are all resistances greater than 10,000 ohms?
STEP -
INSPECTION
-
ACTION
- - - -- -- - - - - - - - -- -- - -
7 Measure resistance between test p ~ n
3 and test plns 49, 50 an s Replace PCM Go to step 9
/ Ee:;ii:eslstance between test pln 19 and test pins 3, 50, and
-- - -- - -- - -- - -
Measure res~stancebetween test p ~ n50 and test plns 3, 49 and No Repair shorts on clrcults havlng less than 10,000
64 at BOB ohms between other TRIPCM ~nputs~gnalcircu~ts
Measure resistance between test p ~ n
64 and test plns 3, 49 and Go to step 9
50 at BOB
Are all greater than 10,000 ohms?
- - - - - - ---- -- - - ---- - - -
8 Drsconnect TR sensor Yes Concern IS not ~nthe TR sensor

Install trans tester, TR cable and cable overlay If dlagnos~nga startlng concern, go to Sectlon G
Followrng lnstruct~onson overlay, perform swltch test If dragnos~nga back-up lamp concern, refer to
Does status lamp on tester indlcate RED for the correct gear the 1997 BETM
pos~tron? If dlagnoslng a 4x4 low engagement concern,
9
1
I No
-
I Perform After Repair Procedure to ensure customer's concern has been resolved.
- go to Sectlon J2
-- -- -
Replace TR sensor and adjust as outllned Go to
step 9 -
. .- .
I W/B LBIB Y/B LBN GYIR USED
kt, L
TRANSMISSION RANGE (TR) SENSOR CONNECTOR
(VEHICLE HARNESS)
\
W/PK R/W PWO YIB LBIB WIB
TR1 TR2 TR3A TR4
t
RILB B B/PK GYIR
MK9671-B
TR SENSOR PID CHART Ppp--pp
- p-p
Gear Position - -
TR
PIN 0000
Reverse - -- REV
- -- --- --
- - -- -
Neutral NTRL --
-- -- - -- - - -- 7-- -- -
Dr~ve O/D*
Manual 2 MAN2 1001
--
pppp
Manual 1
7
MAN1 I 0011
'Will read DRIVE if O/D cancel switch is ON A
Diagnostic trouble Turbine shaft speed (TSS) sensor malfunction

code No. PO715 I -
STEP I
Symptom I
INSPECTION
Check that transmission harness connector is fully
seated, terminals are fully engaged in connector and in
good condition.
:'e
PO715 is set if PCM detects loss of signal
GO to step 2.
ACTION
Is everything OK? Repair as necessary. Clear codes and rerun-

self-tests.
Do not pry up on connector. Depress release
button then pull up on connector.
Key OFF.
Disconnect transmission vehicle harness connector.
Disconnect PCM and install 104-pin breakout box
(BOB).
Note
Refer to connector information and solenoid
application chart following this test.
Measure resistance between test pin 84 at BOB and
appropriate signal pin at transmission connector. NO Service open circuits. Go to step 7.
Measure resistance between test pins 91 at BOB and
appropriate signal pin at transmission connector.
-
Ensure transmission connector is disconnected.
Measure resistance between test pins 84, 91 and test
pins 71/97 at BOB. -
Measure resistance between test pins 84 and test pins No Service short circuit. Go to step 7.
91,71197, 77 76 and 103 at BOB.
-
Ensure transmission connector is disconnected. Yes Replace PCM.
Reconnect PCM.
Install Transmission Tester.
Connect positive lead of voltmeter to + TSS tester jack
and negitive lead of voltmeter to -TSS tester jack. Set
voltmeter to AC.
II I(
I
Perform drive test as described in transmission tester
manual.
No / Go to step 5.
Does voltage increase with an increase in vehicle 1 I I
I -
Rotate GEAR SELECTOR to OFF position. Yes Go to step 6.
Connect negative lead of ohmmeter to - TSS tester jack
and positive lead to + TSS tester jack. Note
Out of specification may be caused by
internal harness or solenoid concerns.
Resistance should be between 64 to 120 ohms. No Go to step 6.
Is TSS resistance within specification?
6 Check for continuity between BAT- (engine ground)
and appropriate jack with an ohmmeter.
For TSS test, use + TSS or - TSS jack
Connection should show infinite resistance (no
continuity).
Yes
NO
Refer to Disassembly in this section for TSS
service and hardware diagnosis.
Refer to Disassembly in this section for TSS

1
Is there continuity? service and hardware diaanosis.
-
I I
7 1 Perform After Repair Procedure to ensure customer's concern has been resolved.
1
5 9
I TSS SENSOR I
TEST PIN 84 --
TEST PIN 91 &- GY/R
TSS SIG
SIG RTN
1
TRANSMISSION
HARNESS
CONNECTOR
"TEST PINS LOCATED ON BREAKOUT BOX

'
Circuit function Circuit function

---
Coast Clutch Solenold (CCS)-4R44E

-- --
10 Shlft Solenold Power
; e na Return T - Electron~cPressure Control (EPC) Power
I
Purple
-
Yellow
Fluid Temperature (TFT)
Transm~ss~on
Sensor
Torque Converter Clutch (TCC) Solenoid
Not Used
Sh~ftSolenoid 3 (SS3)
. .
li :!
14
15
Brown
-
Electron~cPressure Control (EPC) Solenold
Not Used
Sh~ftSolenold 2 (SS2)
Not Used
---
8 I Red I Sensor Signal Return (TFT-) / 16 1 Gray 1 Shift Solenoid 1 (SS1) 1

Diagnostic trouble codes Turbine Shaft Speed (TSS) Sensor, Output Shaft Speed (OSS)
P0715, P0720, P0721, Pi721 Sensor and Overdrive Drum Speed Sensor (ODSk5R55E Only

1 Check to make sure transmission harness is fully Yes Remain in PIDIDATA MONITOR AND
seated, terminals are fully engaged in connector and in RECORD. Go to step 2.
Using NGS Tester, access TSS, ODs and OSS PIDs.

Does vehicle enter PIDIDATA MONITOR AND
RECORD screen?
No
I
Repeat procedure. If vehicle still does not
enter PlDlDATA MONITOR AND RECORD. II
I
go to Page FT-131 in this manual. 4
Remain in PIDIDATA MONITOR AND RECORD. I Yes I Repair open or short in harness. I
Wiggle all wiring and connectors in the transmission.
Monitor the PlDs for any changes.
Does TSS, ODs or OSS PID change?
No Go to step 3.
While monitoring andlor lor OSS PID, drive vehicle so
I
Yes If TSS, ODs or OSS PID increases or
transmission upshifts and downshifts through all gears. decreases with engine and vehicle speed,
clear all DTCs and road test. If concern is
Does TSS, ODs or OSS PID increase or decrease with still present, refer to Quick Diagnosis Chart
engine and vehicle speed or is the sensor signal erratic in this section for further diagnosis.
(drop to zero or near zero and return to normal
operation)? If sensor signal is erratic, inspect for
intermittent concerns in internallexternal
harness, sensor or connector.
No If TSS, ODs or OSS PID does not increase

or decrease with engine and vehicle speed,
inspect for open or short in vehicle harness,
sensor, PCM or internal hardware.
If sensor signal is steady, go to step 4.

4 Disconnect connector from OSS sensor. For TSS Yes Refer to Quick Diagnosis Chart in this section
sensor, disconnect vehicle harness connector. for further diagnosis.
ODS and/or OSS:

Connect negative lead of ohmmeter to one pin of the
sensor and positive lead to other sensor pin.
Resistance should be approximately 305-735 ohms.
TSS:
Connect negative lead of ohmmeter to signal return pin
of the sensor and positive lead to TSS signal at
transmission connector. Resistance should be 64 -
126 ohms.
No For OSS andlor ODs, replace sensor.
For TSS, refer to disassembly procedure in

this section for repair
1
I 1 Is resistance within specification?
I I I
ELECTRICAL SYSTEM COMPONENTS K
ELECTRICAL SYSTEM COMPONENTS
7.
PREPARATION
SST
For
TR sensor
Digital TR sensor inspection
and cable overlay
For
transmission
Transmission solenoid
cable and overlay tester (4R44E only) inspection
5BUOKX-025
ENGINE COOLANT TEMPERATURE SENSOR

Inspection
1. Measure resistance of ECT sensor (cold).
2. Start engine and let warm for 5 minutes.
3. Stop engine.
4. Measure the resistance of the ECT sensor (warm).
Specification:
Temperature C n c e (K)
- -- - -
10°C (50°F) 59 175
TEMPERATURE
'C :F
1 l 54 14 37 118
. -
--
20°C {68"F)
30°C (86°F)
--
--
40°C { l 04°F)
50°C { l 22°F)
60°C (14O0F}
70°C { I 58"FJ
80°C
- {-I 76"F}
-
1
--
-I
--
-
37.387
-
24 215
16.043
-1 0.85
7.487
5.268
3.775
-- .
RESISTANCE(W1)
5. If not asspecified, replace the engine coolant temperature

sensor.
6. Refer to Replacement for installation of the engine coolant
temperature sensor.
K ELECTRICAL SYSTEM COMPONENTS
Replacement
Warning
Never remove the engine coolant temperature sen-
sor while the engine is hot.
1. Disconnect the engine coolant temperature sensor

connector.
2. Remove the engine coolant temperature sensor.
3. Install a new engine coolant temperature sensor.
Tightening torque:
16-23 N-m(1.7-2.3 kgf-m, 12-17 ft.lbf)
4.Connect the engine coolant temperature sensor

connector.
4BUOKX-045
VEHICLE SPEED SENSOR

Inspection
1. Disconnect the vehicle speed sensor connector.
2. Measure the resistance between the terminals of the
vehicle speed sensor.
Resistance: 190-250R
3. If not as specified, replace the vehicle speed sensor.

Note
An EPC solenoid that is shorted to ground may
result in a false vehicle speed sensor code. Diag-
nose the EPC solenoid first, then recheck the VSS.
6BUOKX-018
Replacement
1. Raise the vehicle on a hoist.
2. Disconnectthe electrical connector from the vehicle speed
sensor on the transmission (4x2 models) or transfer case
(4x4 models).
3. Remove the retaining bolt.
4. Remove the vehicle speed sensor.
5. Remove the speedometer gear retainer.
6. Remove the driven gear.
/ 4x4M0DELS VEHICLE
SPEEDSENSO
7. Install a new driven gear on a new vehicle speed sensor.
ASSEMBLE RETAINER TO GEAR WITH 8. Secure the speedometer driven gear with the retainer.
TABS ON BACK SIDE OF CLIP TOWARD 9. Install the new vehicle speed sensor in the transmission
TEETH ON SPEEDOMETER GEAR
(4x2 models) or transfer case (4x4 models).
\ 10. Tighten the retaining bolt.
SPEEDOMETER GEAR \ , Tightening torque:
VEHICLE SPEED
2.5 N-m (25 kgf-cm, 22 in.lbf)
SENSOR ASSEMBLY
\ 11. Connect the vehicle speed sensor electrical connector.
EN
R
BEFORE ASSEMBLY
TO SENSOR ASSEMBLY
i I
NOTE: ELECTRICAL
CONNECTION MUST
BE NEAR TOP
SCREW AND WASHER

2.5 N.m (25 kgf.cm, 22 in4bfl
TRANSMISSION RANGE (TR) SENSOR

ReplacementlAdjustment
1. Remove the outer manual control lever end nut.
2. Disconnect the TR sensor from the wiring harness.
3. Remove the two TR bolts and the TR sensor.
4. Install the TR sensor on the manual lever. Finger-tighten
the bolts.
5. Position the selector lever to N.
TRANsMlsSioN RANGE 6. Rotate the manual lever to the neutral position.
(TR)SENSOR
7. Install SST 49-UN01-086 or equivalent to align the three

slots in line on the TR sensor.
Note
The tool will have to be inserted into two slots, then
rotated to the third.
The manual lever must be in the neutral position.
8. Tighten the bolts
Tightening torque:
8-1 1N.m (82-1 12 kgf cm, 71-97 in4bf) - 5R55E
9. Install the outer manual control lever and nut.

Tightening torque:
30-35 N.m (3.1 -3.5 kgf.m, 22-26 ftlbf) - 5R55E
BRAKE ONIOFF (BOO)
lnspection
Note
Check the Brake OnIOff (BOO) switch t rminal of
the powertrain control modulefor correct v Itage.
(Refer to Section FT). If it is not corr ct, check
the brake onloff switch. (Refer to the 1997 B-s ri s
BETM.)
6BUOKX-300

Inspection
2. Connect the SST (NGS) to the DLC.
4. Select the PIDiDATA monitor and record function of the

NGS.
5. Select "TPS" on the NGS display. Compare the TPS
voltages to the following chart.
Specification:
DlAGNOSrlC TROUBLE CODE LlBRAFlY
Throttle Valve Position PID Voltages
(Degrees)
6. If not as specified, replace the throttle position sensor.

Note
The throttle position sensor is not adjustable.
Replacement
1. Disconnect the throttle position sensor connector
2. Remove the throttle position sensor screws.
3. Remove the throttle position sensor.
4. Install a new throttle position sensor.
Tightening torque:
3 N-m(31 kgfacm, 27 inelbf)
5. Connect the throttle position sensor connector.

5BUOKX-032
K-71
TRANSMISSION FLUID TEMPERATURE (TFT)
SENSOR
lnspection
1. Access TFT PID.
2. Monitor the TFT PID voltage as the engine warms to
normal operating temperature.
Specification:
Temperature PID Voltages (V) Resistance (K)

--
10°C {50°F} 3.525 59.175 ~
20°C {68"F} 3.095 37.387

30°C (86°F) 2.623 24.215 -
40°C
-
{ I 04°F) 2.149 16.043
- -
i
--
50°C { I 22°F) 1.71 10.85 --
606~ {I 40°F} 1.333 7.487

70°C (158°F) 1.025 5.268 -
80°C {I 76°F) --
0.784 3.775
90°C { I 94"F} -
0.599 --
2.75 .
100°C {212"F} 0.458 2.034

11O°C {230°F) 0.352 1.523
120°C {248"F) ~ 0.272 1.155
MFI 665-A 5BOUKX-033
3. If TFT PID does not increase as engine reaches normal

operating temperature, replace TFT sensor.
Replacement
The TFT sensor is a part of the main control valve body
wiring harness. (Refer to K-152.)
6BUOKX.201
TURBINE SHAFT SPEED (TSS) SENSOR

lnspection
1. Disconnect the TSS sensor connector.
2. Measure the resistance between the terminals of the TSS
sensor.
Resistance: 64--120 ohms
3. If not as specified, replace the TSS sensor.

7BUOKX 035
Replacement
The TSS may be replaced only during a complete disassem-
bly of the transmission. (Refer to K-102.)
7BUOKX-202
OVERDRIVE DRUM SPEED (ODs) SENSOR
5R55E ONLY
lnspection
1. Disconnect the ODs sensor connector.
2. Measure resistance between the two ODS sensor termi-
nals.
Resistance: 305--735 ohms
3. If not specified, replace the ODs sensor.
Replacement
1. Disconnect vehicle harness connector.
2. Remove attaching bolt with T30 Torx socket.
3. Remove ODs sensor from case.
4. lnspect O-ring for damage.
5. Lubricate sensor O-ring with petroleum jelly.
6. Install ODs sensor into case and tighten attaching bolt.
Tightening torques:
8-11 N.m (82-112 kgf.cm, 6 1 - 8 7 inlbf)
7. Reconnect vehicle harness.
OUTPUT SHAFT SPEED (OSS) SENSOR

5R55E ONLY
lnspection
1. Disconnect the OSS sensor connector.
2. Measure resistance between the two OSS sensor termi-
nals.
3. If not as specified, replace the OSS sensor.
Replacement
1. Disconnect vehicle harness connector.
2. Remove attaching bolt with T30 Torx socket.
3. Remove OSS sensor from case.
4. lnspect O-ring for damage.
5. Lubricate sensor O-ring with petroleum jelly.
6. Install OSS sensor into case and tighten attaching bolt.
Tightening torques:
8-11 N.m (82-112 kgf.cm, 6 1 - 8 7 in-lbf)
7. Reconnect vehicle harness.
TRANSMISSION TESTER
The following instructions outline the setup and use of the
tester for the 4R44E transmission.
For 5R55E diagnostics, use the NGS Tester. The trans-
mission tester cannot be used on 5R55E transmissions.
Tester Jacks
1.VPWR pin jacks (red): vehicle power test points for
solenoid circuits.
2. TCC, EPC, CCS, SS1, SS2, and SS3 pin jacks (black):
solenoid signal test points for solenoid circuits.
3. BAT + (red) and BAT - (black) pin jacks: battery
reference points when measuring for short circuits.
4.TFT pin jacks: test points for transmission fluid
temperature sensor.
5.TSS pin jacks: test points for turbine shaft speed
sensor.
7BUOKX-038
Tester LED's and Controls

1. Overlay and cable correctly installed LED's: only LED's
with symbol and cable correctly match.
2. Status LED's: LED OFF when not activated by tester
(solenoid not activated, open circuit, or signal line short to
ground). LED GREEN when activated by tester and
current draw is correct. LED RED when activated by tester
and current draw is excessive (short to battery positive).
Note
All LED's light orange during On-Board Diagnostic.
3. Solenoid Activate Buttons: energize respective solenoids

and selected circuits.
4. BenchIDrive Switch: selects operating mode.
5. SolenoidfGear Select Switch: has three functions:
Bench Mode: acts as shift solenoid selector for click
testing.
Drive Mode: acts as gear selector in place of PCM
control.
Note
Hydraulic safety mechanisms are built into the
transmission.
Ohms Check: allows circuit resistance tests.

5BUOKX-039
Tester Use (4R44E Only)
TRANSMISSION TESTER The tester allows a technician to operate the electrical
9 0 8 portion of the transmission independently of the vehicle
I 0 0 0 4RC(E/4RSSE 1 electronics to allow the technician to determine transmis-
sion concerns. Tester use is divided into five parts:
Preparation
Hook-up Procedure
M- WCT.oLuopI
Inspection (In-shop)
Inspection (On-road)
Tester Removal
Preparation
1. Check transmission fluid.
2. Check for add-on items (phones, computers, CB radio,
etc.).
3. Inspect wiring harness and connectors.
4. Check for vehicle modifications.
5. Check shift linkage adjustment.
6. Verify customer concern.
7. Warm vehicle to normal operating temperature.
8. Perform On-board Diagnostics.
9. Record all DTCs.
10. Service all non-transmission codes.
7BUOKX-041
Hook-up Procedure
Note
During tester use additional DTCs may be set.
Therefore, it is important that all codes are erased
after service has been performed. To eliminate all
codes perform the After Repair Procedure. (Refer
to K-34.)
1. Disconnect vehicle wiring harness at transmission
connector.
Caution
Do not pry off connectors with a screwdriver. This
could damage the connector resulting in transmis-
sion concerns.
If vehicle is equipped with heat shields, remove
them. Always replace heat shields after service.
Route all cables away from heat sources.
2. Set tester solenoid switch to OHMS CHECK position.

3. Install appropriate overlay onto tester.
SST No. 49 UNOl 132
4.Connect appropriate interface cable to tester and

transmission.
SST No. 49 UNO1 132

TAP 5. Install a line pressure gauge into line pressure tap on

transmission.
Caution
Route gauge line away from heat sources.
6. Plug tester power supply into cigar lighter

Note
At this time, all LEDs should illuminate for a short
period. This is a tester internal circuit check and
I I
bulb check.
MK1457-B 6BUOKX-742
7 . Set BENCHIDRIVE switch to BENCH mode.
Inspection (In-shop)
These procedures allow for shop testing of the transmission
in the vehicle or on the bench. Completion of these tests
prove out transmission electronics.
Caution
During resistance tests, be certain the tester sole-
noid select switch is set to the OHMS CHECK
position or damage to the ohmmeter may result.
Transmission solenoids and sensors

resistance inspection
1. Check EPC solenoid
(1 ) Set ohmmeter to 100-200 ohm range.
(2) Put switch in BENCH mode.
(3) Position Solenoid Check Dial in the OHMS CHECK
position.
(4) Connect negative lead of ohmmeter to the EPC jack.
(5) Connect positive lead of ohmmeter to the VPWR
jack.
I I
(6) Record resistance.
~~1468-A ~Bu~Kx-021 ( 7 ) Refer to the following chart for values.
(8) If out of specification, perform EPC solenoid test.
(Refer to K-43.)
2. Check shift solenoid 1 (SSI), shift solenoid 2 (SS2), shift
solenoid 3 (SS3), torque converter clutch solenoid
(TCC), and coasting clutch solenoid (CCS).
(1) Set ohmmeter to 100-200 ohm range.
(2) Connect positive lead of the ohmmeter to the
appropriate VPWR jack for the solenoid being tested.
(3) Connect negative lead of ohmmeter to the appropriate
solenoid (SSI , SS2, SS3, TCC, CCS) jack.
(5) Refer to the above chart for values.
(6) If out of specification, perform shift solenoid test
(Refer to K-38), TCC test (Refer to K-46), or CCS
test (Refer to K-48).
Solenoid Resistance ( hms)

SS1 22-48
SS2 22-48
--
SS3 22-48
CCS 22-48
TCC 8.9-16.0
EPC 3.1 -5.7

MKI 463-A
3. Check transmission fluid temperature (TFT) sensor.
(1) Turn the ignition key OFF.
(2) Set ohmmeter to 1000 ohm (1 k) scale.
(3) Connect positive lead of the ohmmeter to the TFT
(+) jack.
If Transmission is Warm:
(1 ) Set ohmmeter to 1 K scale.
(2) Measure and record TFT sensor resistance
between TFT (+) jack and TFT (-) jack.
(3) Let the transmission cool, and repeat the mea-
surement. The last measurement should be
greater than the first.
If Transmission is Cold:
(1) Set ohmmeter to 1K scale.
(2) Measure and record TFT sensor resistance
between TFT (+) jack and TFT (-) jack.
(3) Drive vehicle to elevate transmission
temperature.
(4) Repeat the measurements. The last measure-
ment should be less than the first.
(5) Refer to the following chart for values.

(6) If out of specification, perform TF'T sensor test.
(Refer to K-56.)
Temperature
yT O F (Ohms)
4. Check turbine shaft speed (TSS) sensor.
(1) Set ohmmeter to 200 ohm scale.
(2) Connect positive lead of the ohmmeter to the TSS (+)
jack.
(3) Connect negative lead of ohmmeter to the TSS (-)
jack.
Specification: 64-1 20 ohms

(5) If out of specification, perform TSS sensor test.
(Refer to K-64.)
Solenoid Voltage Test

Note
LED will turn GREEN when solenoid(s) activate and
turn OFF when solenoid deactivates.
LED will turn RED if an activated solenoidlharness
is shorted to battery positive.
LED will remain OFF if an activated solenoid is
shorted to ground or if an open circuit exists.
1. Set tester BENCHIDRIVE switch to BENCH mode.

2. Set voltmeter to 20 volt DC range.
3. Connect voltmeter negative lead to the appropriate sole-
noid jack.
4. Connect voltmeter positive lead to the appropriate sole-
noid VPWR jack.
5. Check for voltage across each solenoid by activating the
solenoid switches. Select the appropriate solenoid with
the rotary switch, and depress the corresponding sole-
noid switch. The LED should illuminate, the voltage
should change, and an audible click should be heard.
6. Observe and record values.
6BUOKX-022
Inspection (On-road)
Road testing is the final step of transmission tester use. This
allows the transmission to be proven out electronically and
hydraulically.
1. Preliminary set-up.
(1) Set tester BENCHIDRIVE switch to DRIVE mode.
(2) Set gear select switch to 1 position.
(3) Place vehicle in P (PARK).
(4) Start engine.
2. Check EPC solenoid.
Caution
Do not attempt to hold the EPC switch depressed
(minimum line pressure) and stall the transmis-
sion, as damage may result.
(1) Observe line pressure. Record value.

Did line pressure rise to MAX pressure?
If no, perform EPC solenoid test (Refer to K-43.)
or perform Symptom Troubleshooting (Refer to
K -18.)
3. Check engagements.
(1) Shift from P to R (REVERSE).
Did vehicle shift into R?
Was engagement firm?
(2) Shift from R to P.
(3) Depress EPC switch.
Did line pressure drop to idle pressure?
(4) While holding down the EPC switch, shift from P to R.
Did vehicle shift into R?
Was engagement smooth?
(5) Still holding down the EPC switch, shift from R to P.
Release EPC switch.
Did line pressure rise to MAX pressure?
(6) Shift from P to D (DRIVE).
Did vehicle shift into D?
Was engagement firm?
(7) Shift from D to P.
(8) Depress EPC switch.
Did line pressure drop to idle pressure?
(9) While holding down the EPC switch, shift from P to D.
Did vehicle shift into D?
Was engagement smooth?
(10) Release EPC switch.
4. Check upshifts and downshifts.

Note
Upshifts and downshifts will be firm during this
procedure.
Pressure gauges may be removed.
These tests should be performed on the road.
If performed on the hoist, it may not be possible to
feel all shifts as they occur.
LEDs will turn GREEN when solenoids are
activated.
LEDswill turn OFF when solenoids are deactivated.
Refer to the appropriate overlay for the proper
status shift sequence during upshifts and down-
shifts.
(1) Move gearshift selector lever to D (DRIVE). Acceler-
ate to 24 km/h (15 mph). Move gearshift selector lever
on transmission tester to 2 (SECOND).
Did vehicle upshift to 2nd gear?
Did appropriate shift solenoids activateldeactivate?
(2) Accelerate to 40 kmlh (25 mph). Move gearshift selec-
tor lever on transmission tester to 3.
Did vehicle upshift to 3rd gear?
(3) Accelerate to 56-72 kmlh (35-45 mph). Move gear-
shift selector lever on transmission tester to 4.
Did vehicle upshift to 4th gear?
(4) Reverse the order to check downshifts.
Did vehicle downshift from 4th gear to 3rd?
Did vehicle downshift from 3rd gear to 2nd?
Did vehicle downshift from 2nd gear to 1st?
(5) Did the transmission pass all of these tests? If
not, perform Symptom Troubleshooting. (Refer
to K-18.)
5. Check torque converter engagement.

Caution
Do not depress torque converter clutch solenoid
switch with transmission in gear and the vehicle at
a stop. Damage to torque converter clutch may
result.
Note
This test should be performed on the road. If
performed on a hoist, feeling the torque converter
clutch engage may not be possible.
(1) Accelerate and shift vehicle up into third gear. Hold
speed steady and depress the torque converter clutch
solenoid switch.
Does torque converter engage?
Does engine RPM drop?
Did torque converter clutch solenoid activate?
(2) Holding speed steady, release switch.
Does torque converter clutch disengage?
Does engine RPM rise?
Did torque converter clutch solenoid deactivate?
(3) Does the transmission pass these tests? If not,
perform Symptom Troubleshooting. (Refer to page
K-18.)
6. Check turbine shaft speed sensor (TSS)

Note
This test may be performed on a hoist or on the
road.
(1) Set voltmeter to 20 volts AC.

(2) Connect voltmeter positive lead to +TSS.
(3) Connect voltmeter negative lead to -TSS.
(4) Slowly accelerate vehicle and monitor voltmeter.
Did voltage increase with vehicle speed?
7. Check coast clutch engagement.
Note
This test should be performed on the road. If
performed on a hoist, feeling the coast clutch en-
gage may not be possible.
(1) Accelerate and shift vehicle up into third gear.

Depress the coast clutch solenoid switch and imme-
diately back off the throttle.
Did the coast clutch engage?
Did engine braking occur?
Did the coast clutch solenoid activate?
(2) Release the coast clutch solenoid switch.
Does the coast clutch solenoid deactivate?
Does the coast clutch disengage?
(3) Does the transmission pass these tests? If not,
perform Symptom Troubleshooting. (Refer to page
K-18.)
GBUOKX 023
Transmission Tester Removal
Caution
Do not attempt to pry off connectors with a screw-
driver. This will damage the connector and could
result in a transmission concern.
1. Disconnect transmission tester from transmission

connector.
2. Reinstall vehicle wiring harness. Verify connection by
pulling up on the harness.
3. Reinstall all transmission heat shields that were previ-
ously removed.
4. Disconnect transmission tester power lead from the
vehicle.
5. Perform the After Repair Procedure. (Refer to page
K-34.)
6. Verify customer concern has been eliminated.
Transmission Range (TR) Sensor Testing Using

Tranmission Tester (4R44E and 5R55E)
T R A H S U l S S 1 0 Y T E S T E R
The transmissiontester allows a technician to operate the
electrical portion of the TR sensor.
1. Perform Preparation and Hook-up procedures. (Refer to
page K-75.)
Caution
For resistance checks, be sure that the tester
selector switch is set to the DIGITAL TR SENSOR
TEST position or damage to the ohmmeter may
result.
2. Sensor tests.
(1) Using the transmission tester and Transmission
Range (TR) Sensor Cable and Overlay 49 UNOl 154,
perform TR Sensor test (refer to page K-61) based
on the DTCs that were displayed.
Note
Select and connect the appropriate cable to the
tester and then black connector of cable to TR
sensor.
Be sure switch on tester is in the down position.
(2) Perform services as indicated by the pinpoint tests.
Always retest and road test vehicle after any service.
3. Test procedures-gear position.
(1) Place transmission range selector lever into Park.
(2) Ensure that the ANALOGIDIGITAL switch on TR
sensor cable is set to DIGITAL.
(3) Move the transmission range selector lever through
all ranges.
(4) Monitor the LEDs, located on the cable, in each gear
position. The LED should illuminat RED for the
appropriate range selected.
(5) If the LED for the applicable gear range position fails
to illuminate RED or if it lights for a position other than
the gear selected:
Verify test cable connections
Verify transmission shift linkage for proper adjust-
ment
Verify TR sensor for proper adjustment.
4. Voltage tests-parklneutral, backup lamp and optional

circuit.
(1) Set test selector switch to the DIGITAL TR SENSOR
TEST position.
(2) Press and HOLD each button while moving the
gearshift lever through EACH gear position.
(3) Monitor each LED.
(4) The status LED should indicate RED only in the
indicated position. Refer to overlay.
Note
LED will turn RED when the circuit closes and
turn OFF when the circuit is open.
(5) If the LED does NOT indicate RED in the desired
position or indicates RED in another position, first
verify Transmission Range (TR) sensor alignment
and then retest.
5. Perform tester removal. (Refer to page K-81.)
NGS TESTER (5R55E Only)

The following instructions outline the use of the NGS
Tester to operate the electrical portion of the transmission
independently of vehicle electronics to allow the techni-
cian to determine transmission concerns.
For instructions on hooking-up the NGS tester, refer to
On-Board Diagnosis System this section.
Note
The following information and tests is for the 5R55E
transmission (4.OL) only. For 4R44E transmission
(2.3L 813.OL), refer to page K-81 for use of the trans-
mission tester.The transmission tester can not b
used on a 5R55E transmission.
7BUOKX-950
Output Test Mode

This diagnostic test mode aids in servicing output actua-
tors associated with the PCM system. It allows the tech-
nician to energize and de-energize most of the system
output actuators on command.
Performing Output Test Mode

Enter Output Test Mode with key ON, engine OFF.
Using the NGS Tester:
2. Select proper model year, engine, model, if necessary.
4. Select DIAGNOSTIC TEST MODE.
5. Enter ACTIVE COMMANDS.
6. Enter OUTPUT TEST MODE
7BUOKX-951
Output State Control

Output State Control (OSC) is a new feature on the NGS.
OSC control allows you to function the main components
of the 5R55E quickly and easily, and to provide accurate
information to properly diagnose the transmission.
Performing Output State Control
Enter Output State Control with key ON, engine OFF.
Using the NGS Tester:
2. Select proper model year, engine, model, if necessary.
4. Select DIAGNOSTIC TEST MODE.
5. Enter ACTIVE COMMANDS.
6. Enter OUTPUT STATE CONTROL.
7BUOKX-952
OSC allows the technician control of certain parameters

to function the transmission and trarismission shifting
only when commanded by the technician.
If first gear is commanded, the transmission will remain
in first gear until the next gear is commanded.
TRANS - BENCH MODE OSC control is the technician commanding a shift sole-
noid to turn ON or OFF when performing an electrical
( 1 circuit check.
SELECTITEMANDPRESSENTERTOSTART OSC has two modes of operation for transmission:
BENCH MODE
DRIVE MODE
Note
To operate OSC, the Transmission Range (TR)
Sensor and the Vehicle Speed Sensor (VSS) must
be operational.
e No DTCs relatede to the
e TR sensor
e
or the VSS can be present.
7BUOKX-953
OSC-Transmission Bench Mode
Highlight TRANS-BENCH MODE and press trigger.
BENCH MODE is functional ONLY when the vehicle gear
selector is in Park or Neutral.
Depending on the test, BENCH MODE may be used in
either Key ON Engine Off (KOEO) or Key On Engine
Running (KOER).
BENCH MODE allows the technician to function the
following components.
SIGNAL OUT OFF MEAS: 0.12 V Shift Solenoid 1 (SS1)-commands the PCM to turn
PID MONITOR NOT SSI ON or OFF.
ACTIVE SELECT
PlDS TO ACTIVATE Shift Solenoid 2 (SS2)-commands the PCM to turn
SS3 XXX SS2 ON or OFF.
SS4 XXX
Shift Solenoid 3 (SS3)-commands the PCM to turn
TCC XXX
/ SS3 ON or OFF.
L 1 SIG I SEND PlDS
Shift Solenoid 4 (SS4)-commands the PCM to turn
the Pulse Width Modulated (PWM) SS4 ON or OFF.
Torque Converter Clutch (KC)-commands the
PCM to turn the TCC solenoid ON or OFF.
Electronic Pressure Control (EPC)-commands the
PCM to control the EPC solenoid to obtain commanded
pressure.
7BUOKX-954
SSI, SS2, SS3, SS4, and TCC i n BENCH MODE:

These OSC functions are used to turn solenoids OFF and
ON when performing an electrical circuit check. The
options available for these solenoids are:
OFF-Commands PCM to turn solenoid OFF
ON-Commands PCM to turn solenoid ON
XXX-Cancels OSC for that particular parameter
SEND-Sends the values to the PCM
Vehicle requirements for sending an OSC value for SSI ,
SS2, SS3, SS4 and TCC in BENCH MODE are:
Key On Engine Off (KOEO) (engine not running).
Transmission Range Selector Lever in PARK.
Note
If an OSC command i s sent and the requirements
are not met, the PCM will abort the function, and
"kick out" of the OSC mode.
If vehicle requirements are not met when sending the

OSC value, an ERROR message will appear. When the
ERROR message is received. OSC is aborted and must
be restarted.
If, after sending an OSC value, the vehicle requirements
are no longer met, the PCM will cancel the OSC value and
no error message will appear.
The OSC value-(XXX) may be sent at anytime to cancel
OSC.
7BUOKX-9t)5
SIGNAL OUT: OFF MEAS: 0.12 v EPC in BENCH MODE:
SS2 XXX PI0 MONITOR NOT BENCH MODE is used to test the functionality of the
ACTIVE SELECT
SS3 XXX
PIDS TO ACTIVATE transmission's Electronic Pressure Control (EPC).
ss4 xxx In BENCH MODE, the EPC solenoid can be commanded
TCC xxx to increase or decrease pressure from 0 to 90 psi in incre-
ERC XXX
ments of 15 psi. To command the EPC solenoid, select
] SIG 1 EPC, then select the appropriate value and press SEND
MK7952-A
to send command.
To operate EPC in BENCH MODE, attach a hydraulic
pressure gauge to the line pressure tap. The pressure
gauge is required to verify the EPC solenoid and its
associated mechanical and hydraulic components are
working correctly.
0-commands PCM to control EPC pressure to 0 psi.

XXX-cancels OSC for EPC.
I
MK8957A
Note
If an OSC command is sent and the requirements
OCS value, an ERROR message will appear.
When the ERROR message is received, OSC is aborted
and must be restarted.
If, after sending an OSC value, and the vehicle require-
ments are no longer met, the PCM will cancel the OSC
value and no error message will appear.
The OSC value (XXX) may be sent at any time to cancel
OSC.
7BUOKX-956
OSC-TRANSMISSION DRlVE MODE

Highlight DRlVE MODE and press trigger.
DRlVE MODE allows control of three transmission
parameters. Each parameter has a unique set of vehicle
operating requirements that the technician is required to
meet before operating OSC. The recommended proce-
dure, when using the DRlVE MODE, is to control one
paramenter at a time.
SIGNAL OUT OFF MEAS: 0.12 v DRIVE MODE allows the technician to perform the follow-
PID MONITOR NOT ing functions on the transmission.
ACTIVE SELECT GR-CM-commands the PCM to upshift or downshift.
PlDS TO ACTIVATE
TCC-commands the PCM to engage or disengage the
torque converter clutch.
~ ~ 7 9 5 8 - A EPC-commands the PCM to increase or decrease
EPC pressure.
7BUOKX-957
GR-CM in DRIVE MODE:
The advantage of using the OSC for changing gears is
to allow the technician to exactly duplicate the vehicle
condition.
For example, it the customer concern is a 3-4 shift up a
steep grade, the technician can drive the vehicle up a
steep grade and command a 3-4, 4-3 shift over and over
again. Also, during the shift change, the EPC pressure is
the exact pressure that the vehicle normally produces.
The OSC functions for the GR-CM parameter allows the
technician the following options:
(1)-PCM commands 1st gear
(2)-PCM commands 2nd gear
(3)-PCM commands 3rd gear
(4)-PCM commands 4th gear
(5)-PCM commands 5th gear
(XXX)-cancels OSC for GR-CM
(SEND)-sends the values to the PCM
Note
OCS value, an ERROR message will appear. When the
ERROR message is received, OSC is aborted and must
be restarted.
no error message will appear. The OSC value (XXX) may
be sent at any time to cancel the OSC.
It is recommended to use the TCC parameter in OSC to
first turn OFF the torque converter clutch before testing
transmission shift functions. This will allow the technician
to evaluate only the gear changes. If theTCC is not turned
off, the PCM may command converter clutch engage-
ment during a shift. This will make it difficult to tell whether
a shift concern is the result of the converter clutch opera-
tion or of the gear change itself.
The vehicle requirements for sending a GR-CM value
are:
engine running.
transmission range selector in Overdrive position.
vehicle speed greater than 2 mph.
TCC is OFF.
7BUOKX 958
TCC in DRIVE MODE:
This OSC function is used to test whether the torque
converter clutch (TCC) is engaging and disengaging
correctly.
The OSC functions for the TCC paramenter allow the
technician to choose the following:
(ON)-turns TCC solenoid ON to engage the converter
clutch.
(OFF)-turns TCC solenoid OFF to disengage the
converter clutch.
(XXX)-cancels the OSC for TCC.
(SEND)-sends the values to the PCM.
Note

When the ERROR message is received, the OSC is
aborted and must be restarted.
The OSC value (XXX) may be sent at ariy time to cancel
the OSC.
The vehicle requirements for sending the TCC value
(OFF) are:
engine running.
The vehicle requirements for sending the TCC value (ON)
are:
engine running.
transmission range selector in the Overdrive position.
vehicle speed is greater than 2 mph transmission in
2nd gear or higher transmission fluid temperature
(TFT) is between 60 and 275°F brake is not applied
"off" when the vehicle is below 20 mph.
no excessive load on engine (engine lugging).
7BUOKX-959
EPC in DRIVE MODE:

This OSC function is used to increase the EPC pressure
while testing the transmission gear changes.
The EPC in DRIVE MODE function can only increase the
EPC pressure greater than what the PCM normally com-
mands.
If an OSC value such as 75 or 90 psi is sent, the upshifts
and downshifts should be harsher than normal. The
harsher shifts would indicate that EPC pressure control is
working at higher pressures.
The best test for the EPC is to use BENCH MODE and a
hydraulic pressure gauge. Using the EPC in BENCH
MODE will confirm that the EPC works at both higher and
lower pressures.
The OSC functions for EPC allows changes from 0 to 90
psi in 15 psi increments.
XXX-cancels OSC for EPC.
SEND-sends the values to the PCM.
The vehicle requirements for sending an OSC value for

EPC in DRIVE MODE are:
engine running.
OSC value for EPC must be greater than what the PCM
commands (see EPC PID)
Note
When the ERROR message is received, the OSC is
aborted and must be restarted.
The OSC value (XXX) may be sent at anytime to cancel
OSC.
7BUOX-961
Linking OSC and PlDs

To confirm the OSC value was sent by the OSC and the PCM has accepted the OSC substitution, the PlDs
function must be linked to the OSC function so that the parameters can be monitored.
To link the OSC and PID functions, press the PID (button 7) at the bottom of the screen.
The PIDs selection screen will appear. Highlight the PIDs you wish to select and press the trigger. An aster-
isk will appear next to the PlDs you select.
After selecting the desired PlDs press START (button 7) and return to the OSC screen.
The following is a list of OSC parameters and their corresponding PID:
OSC Parameter
---
Corresponding PID-- Additional PlDS
SS1 SS1
--
SS1 F
- --
SS2
- - -- --- --
SS2 --- --- -- - -
SS2F
pp-p--pp - p-
SS3 SS3 SS3F
r ~
TCC
I TCC TCCF, TCCMACT (do not use PID TCCMCMD during OSC
o~eration) I
I EPC [ EPC
- -- --
GEAR TRANRAT
To confirm that the OSC substitution occurred, send the OSC value and monitor the corresponding PID
value. If no ERROR MESSAGE was received and the value of the corresponding PID remains the same
as the value sent from the OSC, then the OSC substitution was successful.
7BUOKX-962
POWERTRAIN CONTROL MODULE (PCM)
lnspection
Note
Inspect the powertrain control module (PCM) ter-
minal voltage. (Refer to Section FT.)

3. Measure the voltage at each terminal with a voltmeter.
(Refer to Section FT.)
4. If any PCM terminal voltage is incorrect, check the related
input or output devices and wiring. If no problem is found,
replace the PCM.
MF1667-A5B 6BUOKX-204
7 7Replacement
Note
The powertrain control module is located in the left
rear side of the engine compartment.

2. Remove the speed control actuator (if equipped).
3. Disconnect the powertrain control module connector.
4. Remove the two nuts and remove the powertrain control
module.
5. Install a new powertrain control module and install the two
nuts.
6. Connect the powertrain control module connector.
7. Install the speed control actuator (if equipped).
5--7 I51- 7 1 , 4 4 6 2 )
FRONT OF VEHICLE
- - . . - I
N.m (kgf.crn, in.lbf)
M K I ~ ~ ~ - A TRANSMISSION CONTROL SWITCH (TCS)

Inspection
1. Key OFF.
2. Disconnect TCS switch (under dash).
3.Check continuity between both terminals of the switch
connector while cycling TCS ONIOFF.
Switch button depressed - Continuity
Switch button released - No continuity ~BUOKX-492
K MECHANICAL SYSTEM TEST
MECHANICAL SYSTEM TEST

TORQUE CONVERTER CLUTCH TEST
Note
Engine coolant temperature must be above 53°C (128°F) and below 116°C (240°F). This
temperature can be obtained after approximately 15 minutes of highway driving. Since most
torque converter clutch shifts are difficult to feel (much less noticeable than a 1-2 or 2-3
upshift) a tachometer and vacuum pressure gauge must be connected to the engine.
To check the torque converter clutch for engagementtdisengagement, drive the vehicle at approxi-
mately 80 kmlh (50 mph) and, while maintaining this speed, release throttle for about two seconds
then reapply throttle to previous setting. The engine rpm and vacuum should increase when throttle is
released, and decrease in about five seconds after the throttle is reapplied and the clutch engages. If
the torque converter clutch does not engage, refer to Symptom Troubleshooting. (Refer to page K-18.)
6BUOKX-385
LlNE PRESSURE TEST
The line pressure test verifies that the transmission fluid pressure is within specifications.
Preparation
1. Perform the following checks, as indicated in the chart:
LlNE PRESSURE TEST
PERFORM LINKAGE CHECK

I
NOT 01<
4
II REPAIR AND/OR ' A D , m t
WHEN,
(REFER TO PAGE K-12.1
LEVEL NOT OK CONTAMINATED

C
L ADD ATF:
WHEN 01<
CLEAN AND REPAIR TRANSMISSION.
FLUSH CONVERTER AND OIL COOLER.
t
I ADJUST BAND(S) (AS A MATTER OF NORMAL MAINTENANCE, BAND ADJUSTMENT IS NOT
C
NECESSARY)]
rp- LINE PRESSURE TEST I
2. Check and correct, as necessary, the engine coolant,

engine oil, and ATF levels before testing.
3. Warm the engine and raise the engine coolant and ATF to
operating temperatures.
4. Engage the parking brake and use wheel chocks at the
front and rear of the wheels.
5. Connect a 0-3000 kPa (0-30 kgf/cm2, 0 4 0 0 psi)
pressure gauge to the line pressure tap.
Procedure
2. Check the line pressures. Refer to the following chart.
Caution
The Transmission Tester 49 UNO1 071 MUST BE REMOVED and the vehicle wiring harness
installed when performing this procedure.
Perform the line pressure test prior to performing the stall test.
DO NOT MAINTAIN WIDE OPEN THROTTLE (WOT) in any gear range FOR MORE THAN 5
SECONDS.
Line Pressure: Kpa {kfg/cm2, psi}
,
I Mod I 1 Application 1 Range EPC I
I
Idle
Line
I
EPC
WOT Stall
Line I --
MECHANICAL SYSTEM TEST K
Evaluation of Line Presslure
---
Test results Possible source

--
High at idle - All ranges Wiring harness

Electric Pressure Control (EPC) boost valve
EPC solenoid
Main regulator valve - -
Low at idle - All ranges Low fluid level
Fluid inlet filterlseal
Control valve body
Cross leaks
Gaskets
Pump
Separator plate
/ Low - All forward ranges Forward clutch
I Control valve body
Overdrive servo
I LOW in ark onlv 1 Control valve body I
Low in reverse only Separator plate
Reverse servo piston
Reverse servo cover seal
Reverse clutch
Overdrive servo
Control valve body
Forward clutch
Low in neutral only Control valve body
Overdrive servo
Low in overdrive only Forward clutch
Overdrive servo
Control valve bodv
Low in drive only (OID OFF) Forward clutch
Overdrive servo
Control valve bodv
-I
I Low in manual 1st only Forward clutch
Control valve body
I1 Low in manual 2nd only
--
Intermediate servo
Overdrive servo
I -
Forward clutch
MK1459-B
3. If line pressure is not within specifications, perform On-Board Diagnostics for DTCs P0746, P1749,
P1747 and P1746. Perform the air pressure test and service the control valve body andlor oil pump as
required.
4. If line pressure is still out of specifications after mechanical checks and there is no DTC, then the
Electronic Pressure Control (EPC) solenoid may be mechanically malfunctioning. Refer to the SYMP-
TOM TROUBLESHOOTING Diagnostic index. (page K-18.)
STALL TEST
The stall test checks converter one-way clutch operation and installation, the holding ability of the
forward clutch, the reverse clutch, the low and reverse bands, the planetary one-way clutch and engine
performance.
6BUOKX-700
Preparation
1. Perform the following checks, as indicated in the chart:
STALL TEST
1 PERFORM LINKAGE CHECK I

I
NOT OK
I
I
WHEN- PERFORM ATF CHECK.

OK (REFER TO PAGE K-12.)
LEVEL LOTOK CONTAMINATED

I
4
C
I ADD ATF
I
1 STOP! REMOVE, DISASSEMBLE,
CLEAN AND REPAIR TRANSMISSION. OK
1
WHEN OK FLUSH CONVERTER AND OIL COOLER. I
1 ADJUST BAND(S) (AS A MATTER OF NORMAL MAINTENANCE, ADJUSTING THE BANDS IS NOT NECESSARY) 1
I
1 PERFORM LINE PRESSURE TEST 1

1 STALL TEST I
2. Check and correct as necessary, the engine coolant, engine oil, and ATF levels before testing.
3. Warm the engine to raise the ATF and engine coolant to operating temperature.
4. Engage the parking brake and use wheel chocks at the front and rear of the wheels.
5. Connect a tachometer to the engine.
Procedure
2. Shift the selector lever to R range.
Caution
Holding at stall speed for longer than 5 secondscould result in damage to internal transmission
components.
If the engine speed recorded by the tachometer exceeds the maximum stall speed limit, release
the accelerator pedal immediately because clutch or band slippage is indicated.
Always perform the Line Pressure Test before performing the Stall Test. If line pressure is LOW
at stall, DO NOT perform the Stall Test.
Note
Prolonged use of this test procedure may set DTCs PO712 and P1783. After performing the stall
test, perform the Quick Test and clear diagnostic codes.
3. Firmly depress the brake pedal with the left foot, and gently depress the accelerator pedal with the right
foot.
Caution
If the engine rprn exceeds the maximum rprn specified, RELEASE the accelerator pedal
IMMEDIATELY.
4. When the engine speed no longer increases, quickly read the engine speed on the tachometer and
release the accelerator pedal.
5. Move the selector lever to the N range and run the engine at 1000 rprn for 15 seconds.
Caution
Be sure to run the engine at 1000 rprn for 15 seconds between each stall test.
6. Perform stall tests for the ranges below in the same manner.
(1) 0
range
(2) 2 range
(3) 1 range
Caution
e
If the engine rprn exceeds the maximum rprn specified, RELEASE the accelerator pedal
IMMEDIATELY. Clutch or band slippage is indicated.
Engine stall speed

2.3L: 2,177-2,525 rpm
3.OL: 2,870-3,338 rprn
4.OL: 2,405-2,800 rprn
Evaluation of Stall Test

I
Selector lever ~ o s i t i o n Stall speeds high Stall speeds low
/ @I. D and 1 Overdrive one-way clutch, rear one-way
clutch
Overdrive one-wav clutch, forward clutch 1
16) 1 Forward clutch, overdrive one-way clutch 1 -- I
General pressure concerns, forward clutch,
overdrive one-wav clutch
Reverse and high clutch and the low and
I Converter one-way clutch or engine
performance I
reverse bandlservo
1 2 only 1 Intermediate bandlservo

I --
I
[ 1 only / Low and reverse bandlservo -A
MKI 288-8 7BUOKX-009
AIR PRESSURE TEST
A no drive condition can exist, even with the correct ATF pressure, because of inoperative clutches or
bands. An erratic shift can be located through a series of checks by substituting air pressure for fluid
pressure to determine the locations of the malfunction.
A no drive condition may be caused by the following:
1. D range: inoperative forward clutch or one-way clutch
2.2 range: inoperative forward clutch
3.1 range: improper functioning of the forward clutch or simultaneous malfunction of the low and reverse
band and the one-way clutch
4. R range: malfunction of the reverse and high clutch or low and reverse band
5BUOKX-010
Preparation
1. Loosen the oil pan bolts and lower one edge to drain the ATF.
2. Remove the oil pan and oil filter.
3. Remove the main control valve body assembly. (Refer to page K-152.)
4. Attach the SST to the transmission with a gasket and Test Plate Mounting Screws T82P-7006-C, or
equivalent.
5. Connect an air nozzle with a rubber tip, to a shop air hose.
6. Apply air pressure to the various transmission case passages as indicated in the following illustration or
on the SST. Refer to the following procedure.
Note:
Use only dry regulated air pressure 276 kPa (40 psi) max.
@ REVERSE AND @)FORWARD CLUTCH

HIGH CLUTCH
APPLY
APPLY
1
I 1
Not
Cover
e vent
e in test e shop towel
e plate?with a clean, lint free e to prevent
e e spray when e
e air is applied.
s
Plugging vent hole during testing e
will result s
in inaccurate results.
Caution
Use only dry regulated air pressure 276 kPa (40 psi) max.
Procedure
Forward clutch
Apply air pressure to the transmission case forward clutch passages. A dull thud can be heard when the
clutch piston is applied. If no noise is heard, hold the input shell and again apply air pressure to the forward
or front clutch passage. Movement of the piston can be felt as the clutch is applied.
7BUOKX-012
Overdrive servo
Apply the air pressure to the overdrive servo apply passage. Operation of the servo is indicated by a
tightening of the overdrive band around the overdrive drum. Continue to apply air pressure to the servo
apply passage and introduce air pressure into the overdrive servo release passage. The overdrive servo
should stroke off, releasing the overdrive band.
SBUOKX-013
Coasting
s clutch
Apply air pressure to the coasting clutch feed passage.A dull thud indicatesthat the coasting clutch piston
has moved to the applied position.
4BUOKX-027
Reverse and high clutch

Apply air pressure to the reverse and high clutch. A dull thud indicates that the reverse and high clutch
piston has moved to the applied position. If no noise is heard, hold the clutch drum and again apply air
pressure to detect movement of the piston.
SBUOKX-015
Intermediate servo
Apply the air pressure to the intermediate servo apply passage. Operation of the servo is indicated by a
tightening of the intermediate band around the drum. Continue to apply air pressure to the servo apply
passage,and introduceair pressure into the intermediateservo release passage. The intermediateservo
should release the band against the apply pressure.
SBUOKX-016
Low and reverse servo

Apply air pressureto the low and reverse servo. The low and reverse band should tighten around thedrum
if the servo is operating properly.
5BUOKX-017
Evaluation of Air Pressure Test

If the servosdo not operate, disassemble, clean, and inspect them to locate the source of the malfunction.
If air pressure applied to either of the clutch passages fails to operate a clutch or operates both clutches
at once, remove, and with air pressure, check the fluid passages in the case and front pump to detect
obstructions.
4BUOKX-031
TRANSMISSION
TRANSMISSION
TRANSMISSION UNIT (REMOVAL)
Removal
3. Drain the ATF into a suitable container
Note
Drain the ATF before transmission removal.
4. On 3.OL models, remove the torque converter undercover, referring to Removal Note. (Refer to below.)
6. Remove the front pipe assembly. (Refer to Section F1, F2 or F3.)
7. Remove the torque converter nuts, referring to Removal Note. (Refer to below.)
8. Remove the propeller shaft(s). (Refer to Section L.) (4x2) Scribe a mark indexing the propeller shaft to
the rear differential housing. (4x4) Scribe a mark on both the transfer case flange and the rear differential
housing. Remove the rear propeller shaft (Refer to Section L).
9. Remove VSS.
Caution
The VSS may be broken if not removed prior to transfer case removal on 4x4.
10. Remove the selector cable, referring to Removal Note (Refer to page K-99.)
11. Disconnect the Transmission Range (TR) sensor and connection, referring to Removal Note. (Refer to
page K-99.)
12. Disconnect the output shaft speed (OSS) sensor and overdrive drum speed (ODs) sensor (5R55E only).
13. Disconnect the solenoid valve connector, referring to Removal Note. (Refer to page K-100.)
14. Support the transmission on a jack.
15. On 4x4 models, disconnect the transfer case linkage. (Refer to Section J2.)
16. Remove the rear engine mount and engine mounting member, referring to Removal Note. (Refer to page
K-100.)
17. Lower the jack and allow the transmission to hang.
18. Position a jack at the front of the engine.
19. Remove the upper transmission mounting bolts, referring to Removal Note. (Refer to page K-100.)
20. Disconnect the oil cooler pipes, referring to Removal Note. (Refer to page K-101.)
21. Remove the lower transmission mounting bolts.
22. Remove the oil dipstick tube from the oil filler tube.
23. Secure the transmission and transfer case, if equipped, on the jack with a chain.
Warning
Do not allow the transmission to fall from the jack.
24. Remove the transmission mounting bolts, referring to Removal Note. (Refer to page K-101.) ~BUOKX-206
Removal Note
Torque converter undercover (3.OL only)
Remove two screws from the torque converter under-
cover.
7BUOKX-393
Torque converter nuts

Remove and discard the four attaching nuts by placing a
22 mm socket and bracket bar on the crankshaft pulley
attaching bolt. Rotate the pulley clockwise (as viewed
from the front) to gain access to each of the nuts.
TRANSMISSION K
Caution
Do not damagee the
e oii cooler pipes.
On 2.3L vehicles, do not rotate e the crankshaft
pulley counterclockwise.
Note
On 2.3L and 4.OL vehicles, the torque converter
nutsare accessed through thestarter motor mount-
ing opening.
Selector cable
1. Remove the selector cable from the manual shaft lever.
2. Remove the nuts and bracket.
3. Wire the selector cable out of the way.
FRONT OF
I I
MK1454-A 5BUOKX-050
(7 Transmission Range (TR) sensor

Disconnect the TR sensor connector
K TRANSMISSION
c Solenoid valve connector

Disconnect the solenoid valve connector.
Note
The solenoid valve connector is located on the left
side of the transmission, behind the converter
housing.
-- --/- Rear engine mount and engine mounting member

REAR ENGINE
MOUNT On 2.3Lequipped vehicles, remove the rear engine mount
/ and engine mounting member as follows:
(1) Remove the rear engine mount bolts.
(2) Remove the engine mounting member through bolts.
(3) Lower the rear engine mount and engine mounting
member from the vehicle.
On 3.OL and 4.OL equipped vehicles, remove the rear

engine mount and engine mounting member as follows:
HANGER
(2) On 4.OL equipped vehicles, remove the hanger from
the rear engine mount.
(3) Remove the two engine mounting member nuts and
bolts from the right side of the engine mounting mem-
ber.
4.0L (4) Remove the engine mounting member nut and bolt
from the left side of the engine mounting member.
(5) Lower the rear engine mount and engine mounting
member from the vehicle.
ENGINE
MOUNTING
MEMBER
I
MK1064-8 5BUOKX-053
Upper transmission mounting bolts
1. Raise the engine to access the upper transmission mount-
ing bolts.
2. Remove the upper transmission mounting bolts.
TRANSMISSION K
Oil cooler pipes
Caution
Do not damage the oil cooler pipes.
I I
MK1066-A 4BUOKX-071
Transmission mounting bolts
1. Remove the transmission mounting bolts.
2. Slide the transmission toward the rear of the vehicle to
disengage the pins and the torque converter.
3. Lower the transmission from the vehicle.

Warning
Do not allow the transmission to fall from the jack.
Note
If the transmission is to be removedfor an extended
period of time support the engine with a safety
stand.
K TRANSMISSION
TRANSMISSION UNIT (DISASSEMBLY)
Preparation
SST
49 MOO5 561 For

disassembly
Differential of transmission
carrier
hanger
4BUOKX-073
Precaution
General notes:
1. Disassemble the transmission in a clean area to prevent entry of dirt into the mechanisms.
2. Inspect the individual transmission components in accordance with the QUICK DIAGNOSIS CHART
during disassembly. (Refer to page K-14.)
4. Never use rags during disassembly; they may leave particles that can clog fluid passages.
6. Disassemble the control valve body assembly and thoroughly clean it when aclutch or brake band is burnt
or when the ATF has degenerated.
6BUOKX-395
Cleaning notes:
1. Clean the transmission exterior thoroughly with asteam cleaner or cleaning solvents before disassembly.
3. Wear eye protection when using compressed air to clean components.
Warning
Do not remove the torque converter or transfer case, if equipped, from the transmission while
still on the jack. Doing so could cause the transmission to fall off of the jack.
4BUOKX-075
TRANSMISSION K
Components
TRANSMISSION
1. Torque converter 23. Overdrive band apply strut
Inspection .............................. page K-121 24. Carrier hub assembly
2. lnput shaft 25. Needle bearing (No. 2)
3. Extension housing 26. Overdrive band apply shaft
Disassembly / Assembly ....... page K-144 27. Overdrive band apply lever
4. Parking pawl 28. Bracket
5. Spring 29. Overdrive shaft assembly
6. Shaft Disassembly / Inspection I
7. Heat shield (4.OL only) Assembly . . . . . . . . . . . . . . page K-132
8. Outer manual valve lever 30. Thrust bearing (No. 3)
9. Transmission Range (TR) sensor 31. Turbine Shaft Speed (TSS) sensor
10. Output Shaft Speed (OSS) sensor 32. Solenoid valve connector
(4.OL only) 33. Center support
11. Overdrive Drum Speed ( 0 0 s ) sensor 34. lntermediate band anchor strut and
(4.OL only) adjusting screw
12. Oil pan 35. lntermediate band
13. Oil strainer 36. lntermediate apply strut
14. Detent spring 37. lntermediate apply lever and shaft
15. Reverse servo 38. Reverse and high clutch assembly
16. Control valve body Disassembly / Assembly . . . page K-140
Disassembly / Inspection . . . page K-146 39. Forward clutch assembly
Assembly . . . . . . . . . . . . . . . . page K-151 40. Forward carrier hub assembly
On-Vehicle Removal I 41. lnput shell and forward sun gear
Installation . . . . . . . . . . . . . page K-155 42. Snap ring
17. lntermediate servo 43. Thrust washer (No. 8)
18. Overdrive servo 44. Reverse carrier assembly
19. Converter housing and oil pump 45. Thrust washer (No. 9)
Disassembly / Inspection / 46. Output shaft ring gear
Assembly . . . . . . . . . . . . . . page K-123 47. Thrust washer (No. 10)
20. Overdrive band anchor strut 48. Low and reverse drum
and adjusting screw 49. Low and reverse band
21. Overdrive band 50. Output shaft
22. Coasting clutch drum assembly 51. Parking gear
Disassembly / Inspection / 52. Thrust washer (No. 11)
Assembly . . . . . . . . . . . . . . page K-128 53. Inner manual valve lever
54. Park rod
55. Manual shaft lever
TORQUE CONVERTER 56. Transmission case
Disassembly Procedure
1. Remove the torque converter using Torque Converter
Handles T81 P-7902-C or equivalent.
Warning
The torque converter is heavy, especially when it is
full of oil.
Note
Do not allow the ATF to spill when removing the
torque converter.
2. Remove the input shaft.

Note
The splines on the input shaft are not the same on
both ends. The end with the shorter splines goes
into the assembly.
TRANSMISSION K
3. If equipped, remove the transfer case.
(1) Remove the bolts.
(2) Separate the transfer case from the transmission.
(3) Remove the gasket.
4. Remove the extension housing.

Caution
The parking pawl, spring and shaft could fall out
during extension housing removal.
I SF'RING I 5. Remove the parking pawl, spring and shaft.
n.
PARK1
PAWL
6. Mount the transmission to a workbench.

A4FD HOLDING
FIXTURE ADAPTER (1) Use the extension housing bolts to attach the A4LD
T9:3T-77002-AH Holding Fixture Adapter T93T-77002-AH or equiva-
/ lent, to the transmission.
Caution
The park rod must slip freely into the adapter plate
hole.
I FIXTURE ARM I (2) Attach fixture arm (part of Bench Mounted Holding
(PART OF BENCH Fixture T57L-500-B or equivalent).
MOUNTED HOLD1
FIXTURE-T57TL-5
K TRANSMISSION
BENCH MOUNTED (3) Install the assembly to the holding fixture as shown.
HOLDING FIXTURE
~57~-900-8 Caution
Make sure the holding fixture lock pin is secure.
I I I-
(4) If these tools are unavailable, use the SST.
Caution
Do not turn the transmission over before removing
the oil pan, so that any foreign material will remain
in the oil pan.
-
JOKX
7. On 4.OL equipped vehicles, remove the heat shield, over-
drive drum speed (ODs) sensor and output shaft speed
(OSS) sensor.
HEAT
SHIELD
Remove the nut and the outer manual valve lever
9. Remove the two bolts and the transmission range (TR)

sensor.
TRANSMISSION K
10. Remove the oil pan and gasket.
Examine any material found in the oil pan or on the magnet
to determine the condition of the transmission.
Clutch facing material ........... Drive plate and brake band
wear
Steel (magnetic) ................... Bearing, gear and driven
plate wear
Aluminum (nonmagnetic)...... Cast aluminum bushing
wear
If large amounts of material are found, replace the torque
converter and carefully check the transmission for the
L I
MK1315-A 5BUOKX-069 cause.
Caution
Do not turn the transmission over before removing
the oil pan, so that any foreign material will remain
in the oil pan.
Do not reuse the gasket.
11. Remove the oil strainer and O-rings.
12.Carefully lift up on the wire loom guide and protector.

Disengage the retaining pins from the solenoid brackets.
WI
GUIDE AND
PROTECTOR
13. Disconnect the six solenoid connectors from the

solenoids by carefully pulling upward arid moving side to
side.
Note
Label the wire locations to use during assembly.
I SOLENOID
CONNECTOR
I
K TRANSMISSION
I I 1 14. Remove the detent spring.
( MANUAL VALVE DETENT SPRING

I
15. Remove the reverse servo.
(1) Remove the reverse servo cover and gasket.
Warning
The piston assembly can pop out due to spring
pressure when removing the cover.
(2) Remove the reverse servo piston and spring.
DO NOT REMOVE
16. Remove the control valve body bolts.
Note
Use a 10 mm socket to remove the sixteen M6 x 40 mm,
four M6 x 45 mm and three M6 x 35 mm main control
valve body screws.
Caution
To prevent the solenoid valves from falling out, do not
remove the two screws shown.
MK1321-A 7BUOKX-074
17. Remove the control valve body as an assembly. Discard
gasket.
CONTROL
ASSEMBLY
MK1322-B 5BUOKX-075
K-108
TRANSMISSION K
18. Remove the overdrive band and intermediate band lock-
nuts.
LOCKNUT
Caution
Discard the locknuts. The locknuts are not
reusable.
INTERMEDIATE
19. Install SST over the intermediate servo cover at the

fluid pan rail with tool stamping facing up.
Tighten the bolts.
20. Using a 1R-inch wrench, tighten the nut on the J-hook until
there is a gap between the servo cover and the snap ring.
21. Carefully remove the servo cover snap ring.

22.Carefully back off the nut on the J-hook until the servo
spring is unloaded.
Caution
The servo cover is under spring tension.
23. Remove servo cover, piston and spring by gently push-
ing on hook-type tool. Use a small piece of cardboard
or similar material to prevent tool from damaging
passage.
INTERMEDIATE
SERVO PISTON Warning
SPRING Air pressure should not be greater than 138 kPa (20
/
INTERMEDIATE psi). Wear safety glasses when using compressed
SERVO AND SEAL
ASSEMBLY air. The piston assembly can pop out unexpect dly
/ due to spring pressure behind the piston. Do not
stand directly in front of the piston.
Note
Light tapping on the cover and case, or air pressure
applied on the release side may be needed. UseTrans-
mission Test Plate and gasket.
Note
Tag the spring, piston and cover assembly. Label
accordingly for assembly. The covers have letters .
cast on the outer surface for identification.
INTERMEDIATE
SERVO PISTON 24. Remove SST.
AND ROD ASSEMBLY 25. Repeat steps 19 through 24 for overdrive servo
(4R44E) or front servo (5R55E) parts removal.
7BUOKX-077
K TRANSMISSION
26. Remove the converter housing and oil pump assembly.

(1) Remove the bolts.
Caution
Discard the bolts. The bolts are not reusable.
Note
Rotate and lift the converter housing so that the
clutch assemblies will stay in place.
(2) Remove the converter housing and oil pump
assembly.
(3) Remove the gasket and thrust washer (No. 1).
Compress the overdrivelfront band around the front

brake and coast clutch drum assembly. Remove the
overdrivelfront band and or strut and adjusting screw.
TRANSMISSION K
28. Remove the overdrivelfront band.
Caution
Identify
e which end of the band is the anchor side or
the apply side.
MK1328-A 7BUOKX-081
29. Remove the front brake and coast clutch drum assembly.
I I
MK1329-A 7BUOKX-082
30.Remove the overdrivelfront band apply strut.
BAND APPLY
31. Remove the overdrivelfront band actuating lever shaft.

Note
Tag and identify the overdrivelfront lever for
o assembly.
e
The overdrivelfront lever has a letter stamped into its
side.
Note
The overdrivelfront band actuating lever shaft is longer
than the intermediate shaft.
I I
MK7105-B 7BUOKX-399
32. Remove the planetary gear overdrivelfront carrier.
Caution
Do not bend the exciter wheel.
Note
4R44E: No. 12 thrust bearing is in this assembly.
5R55E: No. 2 thrust bearing is in this assembly.
K TRANSMISSION
i
33. Remove the overdrivelfront band lever and bracket.
OVERDRIVEIFRONT
BAND LEVER TO
CASE BRACKET
OVERDRIVEIFRONT
BAND LEVER
I
MK7106-B 7BUOKX-085
34. Remove No. 2 needle bearing.
35. Remove the overdrivelfront ring gear, overdrivelfront

one-way clutch and the overdrivelfront center shaft
assembly.
MK7107-B 7BUOKX-086
36. Remove the center shaft thrust bearing (No. 3).
MK1333-A 5BUOKX-087
K-112
TRANSMISSION K
(a) Use a 5mm Allen wrench to remove the M6 x
20mm center support capscrew.
(b) Remove the locking nut and cage from the center
support.
Caution
The center support locking nut could fall into the
transmission if not removed. This nut is not ser-
viced separately.
Carefully disconnect the turbine shaft speed sensor (TSS)

connector from the 16-pin case connector.
Caution
Do not pry on other wires or damage the connector
or case.
Carefully remove TSS sensor connector wires from
retaining slot on 16-pin case connector.
40. Remove the TSS screw. Remove the TSS.
41. Carefully route the TSS connector and wiring into the
transmission through the opening in the case.
I I
M K I 507-A 5BUOKX-400
K TRANSMISSION
Remove the case connector retaining spring.
Caution
Do not overstretch the case connector retaining
spring.
r Carefully push down on the top of the connector until it

PUSH DOWN
stops. Depress the tab and push down on the connector.
DEPRESS Remove the connector and harness through the bottom of
the case.
Caution
Do not damage the connector or harness.
Remove the center support.

(1) Remove the snap ring.
(2) Remove the center support by pulling evenly

around the center support web.
TRANSMISSION K
45. Remove the thrust bearing (No.4).
1
Caution
ldentify the bearing. Note the center support side
and the drum side to refer to during assembly.
46. Remove the intermediate band anchor strut through the

bottom of the case.
47. Remove intermediate band adjusting screw.
48. Remove the intermediate band.

Caution
ldentify the band. Note the position of the anchor
side and apply side to refer to during assembly.
49. Remove the intermediate band apply strut.
50. Remove the intermediate band actuating lever shaft.

Caution
ldentify the intermediate band actuating lever shaft
for assembly. The intermediate band apply shaft is
e
shorter than the overdrivelfront band actuating lever
shaft.
K TRANSMISSION
51. Remove the intermediate band servo lever.
Caution
Identify the intermediate band servo lever for as-
sembly. The intermediate band servo lever has a
letter stamped on its side for identification.
52. Remove the rev,erse and high clutch assembly.

53. Remove the thrust washer (4R44E) or thrust bearing
(5R55E) (No.5) from the reverse and high clutch as-
sembly or the forward clutch assembly.
54. Remove the forward clutch assembly.
55. Remove No. 6A forward ring gear hub thrust bearing

assembly.
L
NO. 6A FORWARO
RING GEAR HUB
THRUST BEARING
ASSEMBLY
MK7915-A 7BUOKX-900
56. Remove the forward ring gear and hub.
57. Remove No. 6B forward clutch thrust washer from for-
ward ring gear hub.
58. Remove the thrust bearing (No. 7).
Note
Check black oxidized side during removal to
nsure correct placement during reassembly.
Black oxidized side
e must be toward planetary
assembly. The uncoated side must face up.
TRANSMISSION K
59. Remove the forward carrier hub assembly.
M K I 348-A 5BUOKX-1
1 FORWARD 60. Remove the input shell and forward sun gear
I SUN GEAR I
61. Remove No. 8 thrust bearing.
Note
Tag and identify No. 8 thrust bearing for assembly.
THRUST
BEARING
MK1418-C 7BUOKX-
7- -
62. Remove reverse planetary ring (4R44E) or lowlreverse
planetary ring (5R55E).
63. Remove reverse planetary assembly (4R44E) or low1

reverse planetary assembly (5R55E).
K TRANSMISSION
(5R55E) (No. 9) from the output shaft ring gear,
MK1351 -A 7BUOKX-107
- - -
65. Remove output shaft sleeve.
I I
MK1352-A
1
Caution
Do not reuse the snap ring. Discard the snap ring
and replace it during assembly.
Removing the snap ring releases the
output shaft. Hold the output shaft when
removing the snap ring.

(5R55E) No. 10.
Caution
Identify the thrust washer for assembly.
TH RU
BEAR
(NO.
1
TRANSMISSION K
69. Remove the low and reverse drum.
I I
MK1414-B 7BUOKX-111
I1 70. Remove/
the low and reverse band.
Caution
Identify the band. Note the position of the anchor
side and the apply side to refer to during assembly.
71. Remove the output shaft.

Caution
The output shaft is model dependent.
The 4.OL output shaft does not use lube holes.
72. Remove the parking gear.

K TRANSMISSION
73. Remove the thrust washer (No. 11).
Note
Identify the thrust washer for assembly.
INNER MANUAL
74. Remove nut from the inner manual valve lever.
VALVE LEVER
Caution
\ Do not damage the manual shaft lever retaining pin.
75. Remove the inner manual valve lever and park rod.
Note
Removing the snap ring releases the
output shaft. Hold the output shaft when
removing the snap ring.
VALVE LEVER
76. Use a small hammer and drift to lightly tap each side of the
RETAINING PIN retaining pin. Repeat 2 to 3 times to loosen the pin prior to
removal.
Caution
Do not damage the oil pan mating surface.
MANUAL SHAFT
I LEVER I
RETAINING PIN 77. Remove the retaining pin by prying up with a narrow,
sharp edged screwdriver as shown in the figure.
Caution
Do not damage the oil pan mating surface.
TRANSMISSION K
78. Remove the manual shaft lever

Caution
Do not damage the bore.
80. Remove the band adjusting screws.

Note
The thrust washer attached to the low
sprag inner race is not removable.
TORQUE CONVERTER
Preparation
SST
I I I
49 0378 400A
checking
4BUOKX-119
The torque converter is welded together and cannot be

disassembled.
4BUOKX-120
Inspection
1. Check the outer part of the converter for damage or
cracks, and replace if necessary.
2. Check whether there is rust on the pilot hub of converter
or on the boss. If there is any, remove it completely.
4BUOKX-121
K TRANSMISSION
End play check
1. Install the SST as shown in the figure.
2. Expand the sleeve in the turbine spline by tightening the
inner post.
3. Install a dial indicator onto the SST with the pointer

touching the torque converter. Set the dial indicator to
zero.
4. Lift the tool upward as far as it will go and note the reading.
5. Replace the torque converter if reading exceeds the
specification.
Specification:
New or rebuilt: 0.58mm (0.023 in)
Used: 1.27mm (0.050 in)
Stator to impeller interference check

1. Position the oil pump on the torque converter and engage
the front oil pump splines to the torque converter one-way
clutch inner race.
I I
MK1367 A 5BUOKX 122
2. Hold the torque converter and try to rotate the
011pump
both clockwise and counterclockwise.
3. Check for signs of interference or scraping. Replace if
necessary.
Wash Inside of the Converter
1. Drain any ATF remaining in the converter.
2. Pour in ATF [approx. 0.5 liters (0.5 US qt, 0.4 Imp qt)].
3. Shake the converter to clean the inside. Pour out the ATF.
4. Pour in ATF again.
5. Shake the converter to clean the inside. Pour out the ATF.
MK1368 A 5BUOKX 123
TRANSMISSION
CONVERTER HOUSING AND OIL PUMP ASSEMBLY (4R44Et5R55E)
Preparation
SST
49 UNOl 015 For

aligning 49 UNOl 153 For installation
Pump converter Converter of front oil
alignment housing and Seal pump seal
tool set oil pump Replacer
7BUOKX-126
Disassembly / Inspectiorl / Assembly
1 . Oil pump 4. Front pump thrust washer (No. 1 )

2. Oil pump seal 5. Torque converter seals
3. Overdrive clutch drum seals (4R44E) 6. Oil pump gasket
Front clutch drum seals (5R55E) 7. Fluid pump adapter plate
K TRANSMISSION
I Disassembly Note
Oil pump
1. Remove and discard oil pump gasket.
OIL PUMP
GASKET
MK7114-A 7BUOKX-910
1 1 2. Remove and discard oil pump square cut seal ring.
I
L
SEAL
RING 1
I
MK7114-B 7BUOKX-911
3. Remove pump support seal ring.
I PUMP SUPPORT
,SEAL RING
1 I
MK7114-C 7BUOKX-912
4. Remove the screws from the oil pump with T o r e 40
wrench.
Caution
Discard the screws. They are not reusable for as-
sembly.
5. Remove the oil pump and separator plate.

Pump gears
Note
The pump gears are part of the oil pump and are not
serviced separately.
Rough casting on the pump surface crescent is not
a flaw.
4BUOKX-129
TRANSMISSION K
Front oil pump seal
1. Carefully unstake the front oil pump seal using a small
chisel.
MK1001-A
2. Remove the oil pump seal using a puller. Discardthe seal.
Assembly Note
Front oil pump seal
1. Install new front oil pump seal onto SST 49-UN01-153.
Note
Check and make sure that the garter spring has not
popped off of the converter hub-to-converterhous-
ing seal.
Caution
Place the converter housing on a block of wood or
equivalent t o protect the converter hydraulic
passages on the back side.
2. lnstall a new seal until it bottoms in housing using SST.
Pump gears
1. Install a new drive gear O-ring
K TRANSMISSION
2. Lubricate SST seat O-ring.
3. InstallSST into pump drive gear to seat O-ring into groove.
4. Remove SST.
5. Position the two pump gears into the pump housing.
MP
Caution
ARS The chamfer on the inside edge of the small gear
must be up when in the pump housing gear pocket.
The dimple on the larger gear must be down when
in the pump housing gear pocket.
CHA
Oil pump
FLUID PUMP TO
CONVERTER HOUSING Note
BUSHINGS
Do not install the oil pump onto the torque con-
verter housing until the front end play check is
performed for transmission assembly.
1. Inspect the fluid pump to converter housing bushing and
front oil pump seal. Replace converter housing assem-
bly if necessary.
Note
Fluid pump-to-converter housing bushing is not ser-
viced separately. If service is required, the converter
housing assembly must be replaced.
2. Clean and inspect the front and rear input shaft support
bushings. If worn, scored, or damaged, replace the fluid
pump support and gear assembly. Inspect the pump gear
pockets for scoring and wear. Replace if necessary.
3. Place the separator plate on top of the oil pump.

Caution
Do not allow the pump gears to come out of the
pump housing pocket.
Make sure the holes in the plate line up with the
holes in the pump.
TRANSMISSION K
4. lnstall the oil pump and separator plate on the converter
housing.
Note
The notch on the outside edge of the separator
plate will be at the 9 o'clock position, relative to the
SEPAR
PLATE converter housing.
5. Install the six screws and finger tighten.
6 . Select the correct arbor from the SST that will be the
tightest fit when placed over the pump support.
Caution
The SST must be used to properly align the pump
to the converter housing, in order to prevent seal
leakage, gear noise and breakage and bushing
failure.
7. Thread the arbor into a common handle and slide the SST
over the pump support until it bottoms in the pump gear
pocket.
I u
MK1009-A
8. Tighten the six screws.
Tightening torque:
22-28 N.m (2.2-2.9 kgf.m, 16-21 ft-lbf)
9. Remove the SST.

K TRANSMISSION
COASTING CLUTCH DRUM ASSEMBLY
PREPARATION
SST
49 GO19 025,026,027,029 For

disassembly/
$ -
Clutch - assembly of
"/
I$%
sprlng coasting
compressor clutch
b
I I I
5BUOKX-126
Preinspection
1. Push down on the clutch pack and measure the clearance
between the retaining plate and the snap ring.
Clearance: 1.3-2.0mm (0.0514.079 in)

Note
Make several measurements and calculate the
average value.
2. If not as specified, replace parts as necessary.

3. Select and install the correct snap ring when assembling.
MK1011-A 4BUOKX-135
Disassembly / Inspection IAssembly

I _I
MK1377-B 7BUOKX-127
1. Snap ring 7 . Springs
2. Pressure plate 8. Reverse and high piston
3. Clutch plates (friction) Disassembly Note ...................... page K-129
lnspect for wear or burning 9. Outer seal ring
4. Clutch plates (steel) 10. Inner seal ring
5. Snap ring 11. Overdrive brake and coasting clutch drum
Disassembly Note ...................... page K-129 (4R44E)
6. Retainer Front brake and coasting clutch drum (5R55E)
TRANSMISSION K
Disassembly Note
Snap ring
1. Install the SSTs in the coasting clutch clrum as shown.
2. Compress the springs.
4. Remove the SSTs, and remove the springs and retainer.
Reverse and high piston

Remove the piston by applying compres:sedair to the hole
on the inside diameter of the drum while blocking the other
hole with a finger.
Warning
e glasses
Do not exceed 137 kPa (20 psi). Wear safety
when using compressed air and make sure e drum
is facing down as shown.
Assembly procedure
OUTER SEAL
1. Install the coasting clutch piston.
(1) Apply ATF to the new inner and outer seals and install
them on the piston.
Caution
The seals must be positioned correctly. Care must
be taken to prevent roll over of the seal lip.
INNER SEAL
II OUTER II
SEAL
PISTON
INNER
SEAL
K TRANSMISSION
(2) Carefully press the coast clutch piston into SST.
Caution
Lubricate the inner and outer coast clutch piston
seals.
(3) lnspect the drum band surface, bushing, and thrust
surfaces for scores. Minor scores may be removed
with a crocus cloth. Badly scored parts must be
replaced.
(4) lnspect the clutch piston bore and the piston and
piston inner and outer bearing surfaces for scores.
(5) Check fluid passages for obstructions. All fluid pas-
COASTING sages must be clean and free of obstructions.
CLUTCH DRUM
(6) Make sure check ball is free and clear of debris.
(7) lnspect the clutch plates for wear, scoring and fit on
the clutch hub serrations. Replace all plates that are
CHECK BALL badly scored, worn, or do not fit freely in the hub
serrations.
(8) lnspect clutch pressure plate for scores on the clutch
plate surface. Check the clutch release springs for
distortion.
(9) Install the coasting clutch piston by pushing evenly
around the circumference, being careful not to dam-
age the seal rings.
Caution
e
Care must be take to prevent damage to the seals
during installation.
2. Install the springs and spring retainer into the coasting

clutch drum.
3. Install the SSTs in the coasting clutch drum.

Caution
Do not deform the snap ring when installing it.
6. Remove the SSTs.

TRANSMISSION K
7. Install the friction and steel clutch plates in alternating
STEEL order starting with a steel plate.
Caution
If new plates are being used, they should be
soaked in clean ATF for at least 30 minutes before
assembly.
When installing new directional friction plates, the
word "TOP" should face up. If reusing plates,
grooves must be installed clockwise (I.D. to O.D.)
L I
MK7119-B
SNAP 8. Install the retaining plate.

RING 9. Install the snap ring by using a screwdriver.
10. Measure the coasting clutch clearance.
RETAINING
PLATE
COASTING
CLUTCH
DRiJM
(1) Push down on the drive plates and measure the

clearance between the retaining plate and snap ring.
(2) If the clearance is not within specification, adjust it by
selecting a proper snap ring from below.
Coasting clutch clearance:

1.3-2.0mm (0.051 -4.079 in}
I I
MK1011-A
Snap ring sizes
Coasting clutch
- . - -
1 73 --
0.0681 130 1 5.1 22
2.08 0.081 9 130.1 5.1 22
7-
0.0961 130.1 5.122
MK1020-C
11. Air check the clutch assembly by applying air to one hole
hole with a finger.
Warning
Do not exceed 137 kPa (20 psi). Wear safety glasses
when using compressed air.
Note
The piston must apply with air pressure and release
when air i s removed.
K TRANSMISSION
OVERDRIVE SHAFT AND CARRIER HUB ASSEMBLY
Disassembly / Inspection 1 Assembly
1 . Disassemble in the order shown in the figure, referring to Disassembly Note.
1. Retaining ring 5. Overdrive (4R44E) or Front (5R55E)

2. Overdrive (4R44E) or Front (5R55E) planet thrust bearing (No. 2)
center shaft 6. Planetary gear overdrive carrier
3. Overdrive (4R44E) or Front (5R55E) 7. Sun gear thrust bearing race (No.12)
one-way clutch 8. Overdrive (4R44E) or Front (5R55E)
4. Overdrive (4R44E) or Front (5R55E) sun gear
ring gear 9. Coast clutch adapter
Disassembly Note
1. Remove the overdrive center shaft retaining ring from the
RETAINING overdrive ring gear.
OVERDRIVE
2. Remove the overdrive center shaft from the overdrive ring
CENTER SHAFT gear.
/
OVERDRIVE
RING GEAR
TRANSMISSION K
3. lnspect the rollers and springs for excessive wear or
damage.
lnspect the spring and roller cage for bent or damaged
spring retainers.
Caution
Do not remove the overdrive one-way clutch. Dam-
age to the clutch may occur if it is removed.
Note
The one-way clutch is serviced with the center
shaft.
Clean and inspect the one-way cllutch and center
shaft assembly. Check for cracks i~n the roller cage
and wear on the roller clutch. Inspect the press fit
of the one-way roller clutch t o the center shaft.
4. Temporarily insert the planetary gear overdrive carrier

assembly into the one-way clutch rollers for verification of
the one-way clutch. The planet must rotate counterclock-
wise as shown. Remove the planetary gear overdrive
carrier assembly.
Assembly Note
R CENTER SHAFT 1. Install the center shaft and one-way clutch into the
ring gear.
RING
2. Install the center shaft retaining ring.

K TRANSMISSION
3.Check the pins and shafts in the planet assemblies for
DLE
ONE-WAY CLUT
RING loose fit and/or complete disengagement. Use a new
planet assembly if either condition exists. Before installing
a planet assembly, the shaft retaining pins should be
checked for adequate staking.
lnspect the pinion gears for damaged or excessively worn
teeth.
Check for free rotation of the pinion gears. lnspect the
one-way clutch inner race for scoring.
GEAR OVERDRI Check pinion bearing and gears.
lnspect the inner and outer races for scored or damaged
surface areas where the rollers contact the races.
lnspect the needle bearing on the nose of the planetary
gear overdrive carrier.
4. Remove and inspect the No. 2 planetary thrust bearing.
5. Remove coast clutch to front carrier adapter and front

sun gear.
6. lnspect the No. 12 needle bearing inside the planetary

gear carrier.
Caution
Planets must be replaced. Do not restake.
Note
Individual parts of the planet carriers are not
serviceable.
7. Install the No. 2 planetary thrust bearing between the

center shaft face and the planetary gear carrier assem-
bly.
Note
Use petroleum jelly to hold the No. 2 overdrive
(4R44E) / front (5R55E) planet thrust bearing in
place.
1 8. Install the planet gear overdrive carrier into the center

shaft and ring gear.
TRANSMISSION K
9. lnstall the sun gear into the planetary gear carrier.
Caution
Use care not to bend or damage the exciter wheel.
Before installing the sun gear into th plan tary
gear carrier, make sure the No. 12 sun g ar thrust
bearing race is aligned with the needl b aring
inside the planetary gear carrier. The sun g ar will
not seat properly if the No. 12 sun gear thrust bear-
ing race is not aligned in the center of the sun gear.
10. Install the coasting clutch adapter on the sun gear.
FORWARD CLUTCH ASSEMBLY

PREPARATION
SST
For 49 UNOl 018 For

disassembly1 assembly
Clutch
spring k.Cf c9 assembly
of forward
Lip seal
protector
of forward
clutch
compressor clutch (outer seal) assembly
assembly
49 UNOI 072 For

assembly
Lip seal of forward
protector clutch
assembly
K TRANSMISSION
2. Assemble in the reverse order of disassembly, referring to Assembly Procedure.
MK7123-8 7BUOKX-131
1. Snap ring 7. Springs
2. Retaining plate 8. Rubber cushion spring
3. Friction plates 9. Forward piston
Inspect for wear or burning 10. Outer seal ring
4. Steel plates 11. Inner seal ring
5. Snap ring 12. Forward clutch drum
Disassembly Note ...... ...... page K-136 13. Seal rings
6. Retainer 14. No. 5 forward clutch cylinder thrust bearing
Disassembly note
Snap ring
1. Install the SSTs in the forward clutch drum as shown in the
figure.
Caution
Do not fully compress the clutch spring compres-
sor or damage to the spring retainer may occur.
MK1031-A
4. Remove the SSTs, then remove the springs, retainer and
rubber cushion spring.
Warning
Carefully release the tool pressure on the spring
and remove the SST.
TRANSMISSION K
5. Remove the forward piston.
( I ) Install the center support on the forward clutch drum.
(2) Apply air pressure to the left port in the center support
as shown.
Warning
Do not exceed 137 kPa (20 psi}.Wear safety glasses
I I
MK1038-A 7BUOKX-132
Assembly procedure
Forward clutch
1. Install the forward piston.
them on the piston.
(2) Install the rubber cushion spring.
Caution
If there is evidence of drive plate burning, replace
RUBBER the rubber cushion spring.
CUSHION
SPRING
I I
MKI 033-8
(3) Make sure the check ball is free and clear of debris.
Note
OUTER
'
SEAL RING Inspect bearing and seal rings for damage.

Seal rings and bearing are not serviceable.
\
FORWARD CHECK
PISTON BALL
(4) Use the SSTs to protect the inner and outer seals
when installingthe piston into the forward clutch drum.
2. Install the springs and spring retainer into the forward

1 - 7 RETAINER 1 clutch drum.
I I
MKI 032-A
K-I 37
K TRANSMISSION
Install the SSTs in the forward clutch drum.
Compress the springs.
Install the snap ring.
Caution
Remove the SSTs.

STEEL order starting with a steel plate.
PLATES
FRICTION Caution
PLATES
When installing new friction plates, the word "TOP"
should face up. If reusing plates, grooves must be
installed counterclockwise.
Note
If new plates are being used, they should be soaked
in clean transmission fluid (MerconBV)for at least
30 minutes before assembly.
--
Engine
-- -- Friction Plates
Steel Plates
2.3L 5 5
8. Install the retaining plate.

9. Install the snap ring by using a screwdriver.
TRANSMISSION K
10. Measure the forward clutch clearance.
selecting a proper size snap ring.
Forward clutch clearance:

1.4-2.1 mm {0.05!5-0.083 in)
Snap ring sizes
Forward clutch
-- - --
-
0 0681 ---
125.1 - -
4.925
0 0819
- -- p
125 1
-p
4.925
2.44 0 0961 125.1 4.925
11. Install the center support or Thrust Washer Select Tool

D86L-700014-A, or equivalent, onto the forward clutch
cylinder. Apply air pressure to the far left port in the center
support as shown in the figure.
Warning
Do not exceed 137 kPa (20 psi). Weair safety glasses
Note
The piston must apply with air and releasewhen the
air is removed.
K TRANSMISSION
REVERSE AND HIGH CLUTCH
PREPARATION
SST
49 GO19 025,026,027,029 For

disassembly1
Clutch sprlng F,.r" +:2-G assembly of

reverse and
I
compressor
'6
LF I
high clutch
I
5BUOKX-408
Disassembly 1 Assembly
2. Assemble in the reverse order of disassembly, referring to Assembly Procedure.
L 3
MK1385-A 7BUOKX-134
1. Snap ring 5. Retainer
2. Retaining plate 6. Springs
3. Friction and steel plates 7. Reverse and high piston
Inspect for wear or burning 8. Outer seal ring
4. Snap ring 9. Inner seal ring
Disassembly Note ....................... age K-140 10. Reverse and high clutch drum
Disassembly note
Snap ring
1. Install the SSTs in the reverse and high clutch drum as
shown.
Warning
After removing the snap ring use care when releas-
ing the pressure on the springs.
Caution
I Do not fully compress the
e clutch spring compres-
~~1040-A
sor or damage t o the spring retainer
e may occur.
K-I 40
TRANSMISSION K
4. Remove the SSTs, and remove the springs and retainer.
5. Remove the piston by applying cornpresr;ed air to the hole

hole with a finger.
Warning
Do not exceed 137 kPa (20 psi). Weair safety glasses
Assembly procedure
1. Install the reverse and high clutch piston.
1 OUTER SEAL 1 them on the piston.
Caution
The seals must be positioned corrcactly. Care must
be taken to prevent rollover of the seal lip.
(2) Carefully press the direct clutch piston into SST
Caution
Lubricate the inner and outer direct clutch piston
seals with MerconOV transmission fluid.
(3) lnspect drum band surface, bushing and thrust sur-
faces for scores. Minor scores may be removed
with a crocus cloth. Badly scored parts must be
replaced.
(4) lnspect the clutch piston bore and the piston inner
and outer bearing surfaces for scores.
(5) Check the fluid passages for obstructions. All fluid
passages must be clean and free of obstructions.
(6) lnspect the clutch plates for wear, scoring and fit
on the clutch hub serrations. Replace all plates that
are badly scored, worn, or do not fit freely in the hub
serrations.
(7) lnspect the direct clutch pressure plate for scores
on the bearing surface. Check release springs for
distortion.
K TRANSMISSION
(8) Make sure the check ball is free and clear of debris.
REVERSE AND HIGH
CLUTCH DRUM
(9) Carefully remove the direct clutch piston from SST.
MK1535-A
(10) Install the reverse and high piston by pushing evenly
around the circumference, being careful not to darn-
age the seal rings.
Caution
Care must be taken to prevent rollover of the seal
lip.
I I
MK1044-A
2. Install the springs and spring retainer into the reverse and
high clutch drum.
3. Install the SSTs in the reverse and high clutch drum.
Note
SST numbers: 49 GO19 025,026,027 and 029 Clutch
Spring Compressor

Caution
6. Remove the SSTs.

TRANSMISSION K
order starting with a steel plate.
D
P Caution
When installing new friction plates, the word "TOP"
should face up. If reusing plates, grooves must be
installed clockwise.
I
\
DRIVEN PLATES
Note
If new plates are being used, they should be soaked
I
in clean transmission fluid (Mercont")V) for at least
30 minutes before assembly.
I Engine / Steel Plates I Friction Plates
8. Install the retaining plate.

9. Install the snap ring by using a screwdriver.
10. Measure the reverse and high clutch clc,larance.

selecting a proper size snap ring.
Reverse and high clutch clearance:

1.3-2.0mm (0.051-0.070 in)
Snap ring sizes
n Thickness
1
~-pp-p
Inches
-p-p
1
Reverselhigh clutch
mm 0ia;eter
Inches
1 1. Air check the clutch assembly by applying air to one hole

on the inside diameter of the drum while blockingthe other
hole with a finger.
Warning
Do not exceed 137 kPa (20 psi}. Wear safety glasses
Note
The piston must apply with air pressure and release
when air is removed.
K TRANSMISSION
EXTENSION HOUSING
PREPARATION
SST
49 UNOl 080 For 49 0223 630B For

removal removal
Seal of oil Rear axle of oil
remover seal shafi puller seal
Disassembly IAssembly
MK1049-A 6BUOKX-154
1. Oil seal 2. Bushing
Disassembly Note ................. page K-145 Disassembly Note ................. page K-145
Assembly Note ...................... page K-145 Assembly Note ...................... page K-145
TRANSMISSION K
1 Disassembly note
EXTENSION Oil seal
HOUSING
R e m o v e t h e oil seal using t h e SST.
I I
MK1050-D SBUOKX-410
Bushing
EXTENSION
HOUSING R e m o v e the bushing using E x t e n s i o n Housing Bushing
BUSHING REMOVER R e m o v e r T77L-7697-E, o r equivalent.
l77L-7697-E
I EXTENSION
HOUSING
MKlOSl-A 48UOKX-156
A s s e m b l y note
Bushing
EXTENSION HOUSING
BUSHING REPLACER
Install t h e bushing using E x t e n s i o n H o u s i n g B u s h i n g
R e p l a c e r T77L-7697-F, or equivalent.
Note
Inspect counterbore of extension housing for
burrs. If necessary, remove burrs with an oil stone.
Caution
3 O'CLOCK The lube hole in the bushing musl: be aligned with
LUBRICATION
HOLE LOCATION the lube groove in the extension housing 3 o'clock
position from top when viewed from rear.
Oil seal
l n s t a l l t h e oil s e a l u s i n g E x t e n s i o n H o u s i r i g Seal R e p l a c e r
DRAIN HOLE T74P-77052-A, or equivalent.
EXTENSION Caution
HOUglNG
Position new output shaft and ex1:ension housing
6 O'CLOCK oil seal with drain hole positioned facing down.
EXTENSION
HOUSING
SEAL REPLACER
T74P-77052-A
TRANSMISSION
CONTROL VALVE BODY (DISASSEMBLY / INSPECTION)
Caution
Be especially careful when handling the control valve body because it consists of the precise
and delicate parts of the transmission.

L I
MK1389-A 6BUOKX-138
1. Separator plate 3. Main control valve body
2. Gasket Disassembly 1 Inspection /
Assembly ................................. page K-146
MAIN CONTROL VALVE BODY

Disassembly / Inspection / Assembly
Caution
Neatly arrange the removed parts to avoid confusing the similar parts of the transmission.
Clean the removed parts with cleaning solvent, and dry them with compressed air. Clean out
all holes and passages with compressed air.
Each valve should slide outtin under its own weight.
When a valve will not slide out under its own weight, depending on the valve, push it out with
a wire or place the valve body open side down and lightly tap it with a soft hammer. Never
scratch or otherwise damage a valve surface or bore.
Do not drop or lose the valves or internal parts.
Before assembiy, make sure all parts are thoroughly clean.
Apply ATF to all parts and bores.
Note the proper direction of the valves and internal parts.
Do not reuse any part that has been dropped.
Wrap a screwdriver or rod with tape befor- using it to insert a valve.

TRANSMISSION K
TRANSMISSION
1. Manual valve 44. TCC spring (2.3L - 1 spring/3.0L & 4.OL -

2. Extension housing lube orifice 2 springs)
3. EPC limit relief valve and spring 45. Retainer
4. Converter relief valve and spring 46. Plug
5. EPC limit circuit screen 47. Coasting clutch valve
6. Check ball 48. Coasting clutch spring
7. Identification plate 49. Retainer
8. SS1 & SS3 solenoid retainer 50. Plug
9. SS1 51. 3-2 downshift valve (4R44E)/4-3 downshift
10. SS3 valve (5R55E)
11. 3-4 shift valve (4R44E)Ii-2 and 4-5 52. 3-2 downshift spring (4R44E)/4-3 downshift
shift valve (5R55E) spring (5R55E)
12.3-4 shift spring (4R44E)Il-2 and 4-5 53. Retainer
shift spring (5R55E) 54. Plug
13. Retainer 55.1-2 shift valve (4R44E)/2-3 shift valve (5R55E)
14. Plug 56. 1-2 shift valve (4R44E)/2-3 shift valve (5R55E)
15. 3-2 shift spring (4R44E)/4-3 shift 57. 1-2 shift spring (4R44E)/2-3shift spring (5R55E)
spring (5R55E) 58. Retainer
16.3-2 shift valve (4R44E)/4-3 shift valve (5R55E) 59. Plug
17. Retainer 60.2-3 shift spring (4R44E)/3-4 shift
18. Plug spring (5R55E)
19. Manual low spring 61 .2-3 shift valve (4R44€)/3-4 shift
20. Manual low valve valve (5R55E)
21. Retainer 62. Retainer
22. Plug 63. Plug
23.3-2 coast valve (4R44E)/4-3 coast 64. Reverse modulation valve
valve (5R55E) 65. Reverse modulation spring
24. 3-2 coast spring (4R44E)/4-3 coast 66. Retainer
spring (5R55E) 67. Plug
25. Retainer 68. Reverse modulation spring
26. Thermostat bypass spring 69. Reverse modulation valve
27. Thermostat bypass valve 70. Retainer
28. Thermostat bypass valve 71. Plug
29. Thermostat bypass spring 72. Forward modulator valve
30. Retainer 73. Forward modulator spring
31. Plug 74. Retainer
32. Cooler limit spring 75. Plug
33. Cooler limit valve 76. EPC boost valve
34. EPC, SS2, CCS (4R44E)/SS4 (5R55E), 77. EPC boost spring
& TCC solenoid retainer 78. Retainer
35. EPC solenoid 79. Pressure boost valve sleeve
36. SS2 solenoid 80. Pressure boost valve
37. CCS solenoid (4R44E)l SS4 solenoid 81. Pressure boost spring
(5R55E) 82. Pressure regulator spring
38. TCC solenoid 83. Retainer
39. TCC valve 84. Pressure regulator valve
40. TCC spring 85. Retainer
41. Retainer
42. Plug
43. TCC valve (solenoid regulator valve)
Assembly Note
Main control valve body
1. Install all valves, springs, plugs, and retainers.

TRANSMISSION K
2. lnstall the EPC, SS2, CCS (4R44E)/SS4 (5R55E), and
TCC solenoids.
Caution
The solenoid terminals must face upward.
The solenoids are not interchangeable.
Note
If the TCC valve backs out, install using the TCC
I EPC
SOLENOID
/ ss2 / ;cc
CCS (4R44E)l SOLENOID
SS4 (5R55E)
solenoid.
3. lnstall the solenoid retainer.
4. lnstall SS1 and SS3.

Caution
The solenoid terminals must face upward.
The solenoids are not interchangeable.
5. lnstall the solenoid retainer
I I
MK1400-A
6. lnstall the EPC limit circuit screen.
Caution
Make sure the screen is properly located.
MK1392 A
K TRANSMISSION
0 1 7. Install the check balls.
I I
MK1393-A
8. lnstall the converter relief valve and spring.
Caution
The converter relief valve and spring are not inter-
changeable with the EPC limit relief valve and
spring.
L I
MK1394-A
9. Install the EPC limit relief valve and spring.
Caution
The converter relief valve and spring are not inter-
changeable with the EPC limit relief valve and
spring.
EXTENSION HOUSING
10. Install the extension housing lube orifice.
MK1536-A 5BUOKX-140
K-I50
TRANSMISSION K
CONTROL VALVE BODY (ASSEMBLY)
Caution
Before assembly, make sure all parts are perfectly clean.
Apply ATF t o all the parts.

I
MK1391-A 6BUOKX-141
1. Main control valve body 3. Separator plate
2. Gasket Assembly Note ............ ............. page K-151
Assembly note
Separator plate
1. Install and align the control valve body-to-separatorplate

gasket.
I I
MK1401-A
2. Install the separator plate.
(1) Position the separator plate.
(2) Install the screws finger-tight.
K TRANSMISSION
- ~~~~~
(3) Install the alignment pins as shown.
SST Numbers: 49 UNO1 139,49 UNO1 140
(4) Tighten the Torx@head screws.
Tightening torque:
6-8 N.m (61-82 kgfcm, 45-71 indbf)
3. Install the control valve body-to-gasket.

Note
Apply petroleum jelly to hold the gasket in place.
CONTROL VALVE BODY (ON-VEHICLE REMOVAL /

INSTALLATION)
On-Vehicle Removal
Caution
Clean the transmission exterior thoroughly with a
steam cleaner or cleaning solvents before removal.

2. Remove transmission heat shield (5R55E only).
3. Drain the ATF into a suitable container.
4. Remove the oil pan and gasket. Discard the gasket.
TRANSMISSION K
4. Remove the oil strainer and O-rings. Discard the O-rings.
- ~
WIRE LOOM 5. Carefully lift up on the wire loom guide and protector.
GUIDE AND Disengage the retaining pins from the solenoid brackets.
I I
MK1537-A 5BUOKX-145
6. Disconnect the six solenoid connectors from the sole-
SOLENOID CONNECTOR
r noids by carefully pulling upward and moving side to side.
7. Remove the detent spring.
8. Remove the reverse servo.

(1) Remove the reverse servo piston cover and gasket.
Warning
The piston assembly can pop out due to spring
pressure when removing the cover.
K TRANSMISSION
(2) Remove the reverse servo piston and spring.
I
MKI 320-A 5BUOKX-I 48
I DO NOT REMOVE 9. Remove the control valve body screws.

Caution
Support main control valve body.
Note
Use a 10mm socket to remove the sixteen M6 x
40mm, four M6 x45mm, two M6 x 35mm and one M6
x 30mm main control valve body screws.
10. Remove the control valve body as an assembly.
., . ..
VALVE
BODY
M K I 322-C 5BUOKX-I 50
On-vehicle installation
1. Install the alignment pins into the case in the positions
shown.
2. Install a new gasket and separator.
Note
Use petroleum jelly to hold the gasket in place.
Make sure the holes in the gasket line up with the
holes in the control valve body.
MK1322-C 5BUOKX-412
3. Install the control valve body assembly.
(1) Position the assembly.
VALVE
BODY
TRANSMISSION K
(2) Align the manual valve with the inner manual valve
lever pin as shown.
(3) Install the valve body bolts finger-tight.
(4) Remove the alignment pins.
INNER MANUAL "

VALVE LEVER PIN
\
MANUAL VALVE
MK1407-B 5BUOKX-152
(5) Installthevalve body bolts in the positionsshown in the
figure.
I M6 X 45MM @ (4 REQUIRED)
I M6 X 35MM @ (2 REQUIRED) I
I M6 X 30MM @ (2 REQUIRED)
I 20 MM @ (4REQUIRED)
(SERVO COVER)
(6) Tighten the valve body bolts in the sequence show1

the figure.
Tightening torque
8-1 1 N-m(82-1 12 kgf.cm, 71-97' in-lbf)
4. Install the detent spring and the detent spring screw.

I DETENT SPRING
I Tightening torque
8-1 1 N-m (82-1 12 kgfecm, 71-97? in.lbf]
K TRANSMISSION
5. lnstall the reverse servo spring and piston.
6. Check the reverse piston travel. (Refer to page K-185.)
lnstall a new gasket and the reverse piston cover and

tighten in order shown.
Tightening torque:
12-1 4 N.m (1 22-1 42 kgfcm, 106-1 24 in4bf)
8. Connect the solenoid connectors to the solenoids

SOLENOID CONNECTOR
I I I Note
The wiring guide snaps into place on the solenoid
retainers.
9. lnstall the wiring loom protector and guide. Align the pins
in the holes of the solenoid brackets and gently push
down.
Caution
Excessive pressure may break the locating pins.
10. Test the solenoid valves. (Refer to Inspection (In-Shop),

page K-76.)
11. lnstall new O-rings on the oil strainer.
12. Apply petroleum jelly to the O-rings.
13. lnstall the oil strainer.
Tightening torque:
8-11 1 N-m(82-1 12 kgf-cm,71-97 in-lbf)
14. lnstall the oil pan gasket.

TRANSMISSION K
15. Install the oil pan
II
Tightening torque:
e
13-1 5 N.m {I38-1 52 kgfem, 1 15--132 in.1bf)
Install transmission heat shield (5R55E) only.

Tightening torque:
8-1 I N - m (82-112 kgf-cm, 71-97 in Ibf)
Connect the negative battery cable.

Fill with ATF. (Refer to page K-12.)
Drive thevehicle and check the shift points, shift schedule
and shift shock. (Refer to Road Test, page K-8.)
TRANSMISSION UNIT (ASSEMBLY)

PREPARATION
SST
49 UNOI 016 For

selection of
Servo rod reverse
selecting servo rod
tool
Precaution
1. If the drive plates, overdrive band, intermediateband or low and reverse band are replacedwith new ones,
soak the new parts in ATF for at least thirty minutes before installation.
2. Before assembly, apply ATF to all seal rings, rotating parts, O-rings and sliding parts.
3. All O-rings, seals and gaskets must be replaced with the new ones included in the overhaul kit.
4. Use petroleum jelly, not grease, during assembly.
5BUOKX-160
Note
When replacing O-rings on the center
support, use the overdrive brake drum
and coast clutch to size the O-rings.
K TRANSMISSION
Bearing, washer and bushing locations (4R44E and 5R55E)
@ - BEARING, SLEEVE & SEAL

- BEARING RACE
- SELECTIVE WASHER
I -
NEEDLE BEARING
I -
SELECTIVE NEEDLE BEARING
- THRUST WASHER
m- BUSHING
I
m- WASHER
MK1409-C
SBUOKX
TRANSMISSION K
Components
K TRANSMISSION
1. Inner manual valve lever 32. Overdrive band apply strut
2. Park rod 33. Overdrive band
3. Manual shaft lever 34. Overdrive band anchor strut and
4. Thrust washer (No. 11) adjusting screw
5. Parking gear 35. Thrust washer (No. 1)
6. Low and reverse drum 36. Converter housing and oil pump assembly
7. Thrust washer (No. 10) 37. Intermediate servo
8. Output shaft 38. Overdrive servo
9. Output shaft ring gear 39. Solenoid valve connector
10. Thrust washer (No. 8) 40. Control valve body
11. Thrust washer (No. 9) 41. Reverse servo
12. Reverse carrier assembly 42. Detent spring
13. Snap ring 43. Oil strainer
14. Low and reverse band 44. Oil pan
15. Forward clutch assembly 45. Shaft
16. Reverse and high clutch assembly 46. Spring
17. Forward carrier hub assembly 47. Parking pawl
18. Input shell and forward sun gear 48. Extension housing
19. Intermediate apply lever and shaft 49. Transmission case
20. Intermediate band apply strut 50. Input shaft
21. lntermediate anchor strut and adjusting screw 51. Torque converter
22. Center support 52. Transmission Range (TR) sensor
23. Thrust bearing (No. 3) 53. Output Shaft Speed (OSS) sensor
24. Intermediate band (4.OL only)
25. Carrier hub assembly 54. Overdrive Drum Speed (ODs) sensor
26. Overdrive shaft assembly (4.OL only)
27. Needle bearing (No. 2) 55. Outer manual valve lever
28. Coasting clutch drum assembly 56. Heat shield (4.OL only)
29. Bracket 57. Extension housing bushing
30. Overdrive band apply lever 58. Extension housing seal
31. Overdrive band apply shaft
Assembly Procedure
I.Install the oil seal using the Shift Lever Seal Replacer
T74P-77498-A, or equivalent.
SEAL REPLACER
T74P-77498-A
2. Install the inner manual valve lever assembly.

(1) Assemble the inner manual valve lever and park rod.
INNER MANUAL
VALVE LEVER
TRANSMISSION K
(2) lnstall the manual lever shaft into the case.
Caution
Do not damage the oil pan mating surface when
installing the pin.
(3) Align the manual lever shaft with the manual control
lever shaft retaining pin. Install the retaining pin.
INNER MANUAL INNER

(4) lnstall the inner manual valve lever and parking pawl
MANUAL actuating rod into the case. Align the flats of the inner
VALVE manual valve lever with the flats on the manual lever
shaft.
(5) Tighten the hex nut.
Tightening torque:
41-54 N.m (4.2-5.5 kgf.m, 30-410ftvlbf)
VALVE LEVER NUT
3. Install the thrust washer (No. 11).

Caution
The tabs on the thrust washer s h o ~ ~face
l d the case.
Note
Petroleum jelly can be used to hold the thrust
washer into the case.
4. Install the parking gear

K TRANSMISSION
0 1 5. Install the low and reverse drum.

Note
Rotate the low and reverse drum clockwise to
install.
MK1414-C 5BUOKX-169
NO. 10 6. Install the thrust bearing (No. 10) onto output shaft ring
THRUST BEARING gear and hub assembly.
Caution
The tabs on thrust washer should face the one-way
clutch.
Note
Use petroleum jelly to hold the thrust bearing in
place.
TRANSMISSION K
1
7. Install the output shaft.
OUTPUT
SHAFT
8. Install the output shaft ring gear

K TRANSMISSION
9. lnstall a new snap ring.
Caution
Always use a new snap ring.
MK1353-C 5BUOKX-173
10. Install the output shaft sleeve with the cone facing up.
I
MK1548-A
I
7BUOKX-174
REVERSE CARRIER NO. 9 11. Install the low reverse carrier assembly.
NEEDLE
(1) Install the needle bearing (No. 8).
(2) lnstall the needle bearing (No. 9).
NEEDLE BEARING
MK7130-B
0 7BUOKX-175
TRANSMISSION K
NO. 8 REVERSE CARRIER (3) Place the assembly into the transaxle.
Caution
Make sure the thrust washers stay in place.
Note
Use petroleum jelly to hold the thrust washers in
place.
I
I
MK7132-B 7BUOKX-176
(4) Install the snap ring.
K TRANSMISSION
--. 1 12. Install the low and reverse band.
Caution
Make suree band is resting
e on the two anchor pins
in the case.
I 1
MK1419-A 7BUOKX-178
Note
Temporarily install the reverse servo to hold the
low and reverse band in place.
I
.- I
MK1181-A 5BUOKX-179
13. Install the forward gear assembly.
REVERSE AND HIGH CLUTCH
/
INPUT SHELL
(1) Install the needle bearing (No. 5) on the forward clutch.

N0.5
NEEDLE
BEARING
Note
Use petroleum jelly to hold the washer in place.
FORWARD
(2) Install the forward clutch assembly in the reverse and
CLUTCH high clutch as shown.
ASSEMBLY
REVERSE
AND HlGH
CLUTCH
TRANSMISSION K
(3) Install the thrust bearing (No. 6) in the forward clutch
assembly with the tabs facing up.
(4) Installthe thrust washer (No. 6 ) in the forward ring gear

and hub.
I
Note
Use petroleum jelly to hold the washer in place.
(5) Install the forward ring gear and hub in the forward
FORWARD
RING GEAR
THRUST
WASHER
I clutch assembly as shown.
AND HUB\ / (NO.6)
Caution
Make sure the thrust washer (No. 6) and thrust
bearing (No. 6) remain in place.
FORWARD
CLUTCH
ASSEMBLY
5BUOKX-185
( 6 ) Installthe thrust bearing (No. 7 )in the forward ring gear
as shown.
Note
Black oxidized color of thrust bearing must face
up toward planetary assembly.
7BUOKX-186
(7) Install the forward carrier hub assembly in the forward
FORWARD FORWARD
ring gear as shown.
Note
Be sure to install the carrier hub assembly
before the forward ring gear. Next, install
the forward ring gear with the reverse and
high clutch ass mbly.
K TRANSMISSION
(8) Inspect the drum gear, bushing and washer for

scoring, wear or damage. Replace as required.
Note
If sun gear, snap rings or input shell require
service, perform steps a through e.
(a) Remove rear snap ring and sun gear from input
shell.
(b) Remove front snap ring from sun gear.
(c) Install new front snap ring onto sun gear.
(d) Install forward sun gear into input shell.
(e) Install new rear snap ring onto sun gear.

K TRANSMISSION
(9) Install the input shell and sun gear on the reverse
and high clutch assembly.
10) Position the forward gear assembly in the trans-
mission.
REVERSE
AND HIGH
CLUTCH
ASSEMBLY
I I
MK1428-A 5BUOKX-I 88
THRUST CASE
14. Select the thrust bearing (No. 4).
(1) Place Gauge Bar T93T-77003-AH, or equivalent on
the transmission case shoulder as shown. Set a depth
micrometer an the gauge bar.
Note
Make sure the tool is bottomed against the case
shoulder.
T93T-T7003-AH
MK1429-A 5BUOKX-189
(2) Extend the shaft of the micrometer until it touches
the thrust bearing (No. 4) surface on the reverse
and high clutch drum. This is reading A.
(3) Remove the micrometer and record reading A.
(4) Place the micrometer on the opposite end of the
gauge bar. Extend the shaft of the micrometer until it
touches the thrust bearing (No. 4) surface of the
reverse and high clutch drum. This i:; reading 6.
(5) Remove the micrometer and record reading B.
(6) Add reading A and reading B together. Divide by two.
Subtract the thickness of Gauge Bar 1-93T-77003-AH,
or equivalent (17.78 mm (0.700 in)). This is reading C.
(7) Refer to reading C and select the thrust bearing
(No. 4) from the chart.
Reading "C" Bearing thickness

I
mm Inches stamped on washer
-- -
1 66 - 1 85
I
-
0 065 0 073 0 0104-0110
1 86 - 2 04 ----
0 074 - 0 080 1 2 80 --
-- 2.95 0-
1 1 0 - 0-
116
2 05 - 2 23 0 081 - 0 088 2 300-315 0118-0124
2 25 - 2 43 0 089 - 0 096 3 3 20 - 3 35 0 1 2 6 - 0 132
---
MK, 1 ) 1 li /t>IJOKX 1') 1
15. Install the thrust bearing (No. 4).

K TRANSMISSION
16. Install the intermediate servo lever
17. Install the intermediate band apply shaft through the

INTERMEDIATE BAND intermediate servo lever.
APPLY SHAFT
Note
The intermediate band apply shaft is shorter than
the overdrive (4R44E) or front (5R55E) band
apply shaft.
I I
MK1551-A 7BUOKX-193
I
18. Install the intermediate band apply strut on the intermedi-
ate servo lever.
1 INTERMEDIATE BAND
A"""P"'
K TRANSMISSION
9 1 19. Install the intermediate band.

Caution
Make sure the apply strut is aligned with the band
APPLY
SlDE I
notch.
ANCHOR
SIDE
INTERMEDIATE
BAND 1
20. Install the intermediate band anchor strut and intermedi-

ate band adjusting screw.
Note
Use the intermediate band adjusting screw as a
temporary guide.
Note
The intermediate band and overdrive (4R44E)l
front (5R55E) anchor struts are identical.
1 INTERMEDI~EBAND
ANCHOR STRUT
INTERMEDIATE BAND
ADJUSTING SCREW
I
THR
21. Install the thrust bearing (No. 4) selected in step 14 on the
BEA center support as shown.
(NO. 22. Install the center support.
Caution
Do not apply pressure to the center support while
installing. Damage to the sealing rings may result.
Note
Use the input shaft to help seat the center support.
Positionthe input shaft as shown and gently wiggle
the shaft until the center support is seated against
the case shoulder. Remove the input shaft.
K TRANSMISSION
THIS AREA MUST NOT RETAINING RING

23. Install the center support retaining ring in the transmission
BE OBSTRUCTED BY .- as shown.
case aroove
Caution
The retaining ring tapered side must face up.
The retaining ring opening must be positioned
as shown or damage to the Turbine Shaft Speed
(TSS) sensor wiring may result.
24. Ensure that the nut and cage assembly is in place..

Note
Make sure the cage and nut is properly
tightened. If not tightened properly, a late
shift condition may develop.
MK7135-B 5BUOKX-417
1 1 25. Install the center support capscrew into the cage and nut.
Note
0 Make sure the cage and nut are in place.
Tightening Torque:
9-1 3 N.m (92-1 32 kgf+cm,80-1 15 in-lbf)
I CENTER SUPPORT I
CAP SCREW
TRANSMISSION K
26. Route the TSS sensor connector and wiring harness
through the opening in the case.
Caution
Carefully route the Turbine Shaft Speed (TSS) Sen-
sor connectorand wiring harnessthroughthe open-
ing in the case. Do not damage the wiring.
I I
MK1558-A 5BUOKX-418
27. lnstall the Turbine Shaft Speed (TSS) sensor on the
center support.
Tightening Torque:
8-1 1 N.m (82-1 11 kgf.cm, 71-97' in-lbf}
MK1436-A 7BUOKX-201
28. lnstall the thrust bearing (No. 3).
29. lnstall the carrier hub assembly onto the center shaft
assembly.
Caution
Do not bend the exciter wheel.
~ ~ 1 3 3 3 . ~ 7BUOKX-202
30. lnstall the carrier hub and center shaft assemblies.
31. lnstall the needle bearing (No. 2).
TRANSMISSION
32. Place the thin blade of turbine shaft speed sensor gauge
over the turbine shaft speed (TSS) sensor as shown.
Rotate the exciter wheel. The exciter wheel triggering
window SHOULD pass over the thin blade of the SST.
If it doesn't, the planetary gear carrier and exciter
wheel MUST be replaced.
Note
Perform TSS air gap clearance check
------A
MK1560-A 7BUOKX-419
33. Place the thick blade of SST over the turbine shaft speed
(TSS) sensor as shown. Rotate the exciter wheel. The
exciter wheel triggering window SHOULD NOT pass
over the thick blade of the SST. If it does, the planetary
gear carrier and exciter wheel MUST be replaced.
34. Repeat the previous two steps for the remaining exciter
wheel triggering windows.
TRANSMISSION K
/ 35. Install the coasting clutch drum assembly.
COASTING
CLUTCH DRUM
36. Install the bracket and the band apply lever.
37. Install the band apply shaft.

Caution
The overdrive (4R44E)lfront (5R5!iE) band apply
shaft is longer than the intermediate band apply
shaft.
K TRANSMISSION
38. Install the band apply strut.
1 BAND APPLY
STRUT
I I
MK1562-B 7BUOKX-207
39. Install the band over the coasting clutch drum.
Note
If the band is reused, it must be installed in the
same position as when removed.
MK1328-A 7BUOKX-208
1 40. Note
Install the band anchor strut.
Use the band adjusting screw as a temporary

alignment guide.
TRANSMISSION K
Check the front end play.

(1) Place ariy thickness thrust washer (No. 1) onto the oil
THRUST pump.
WASHER
(NO 1 1
Caution
\ The tabs on the thrust washer should face the oil
pump face.
Note
Use petroleum jelly to hold the thrust washer in
place.
(2) Install the oil pump in the case.
Caution
Make sure the oil pump is seated against the
e
thrust washer and the clutch drum assembly.
The oil pump body must be below the level of the
case gasket surface.
(3) Place Gauge BarT93T-77003-AH,or equivalent across
OIL PUMP THRUST the case.
WASHER MATING
SURFACE Note
The gauge bar must rest on the case gasket sur-
face.
(4) Install a depth micrometer above the oil pump surface.
1
I
GAUGE BAR
T93T-77003-AH
MK1440-A
\
PUMP SURFACE
5BUOKX-212
I
I
READING B
(5) Extend .the micrometer shaft until it contacts the oil
PUMP SURFACE pump surface. This is reading A.
(6) Record reading A.
(7) Move the gauge bar and micrometer to the other side
of the transmission and repeat the measurement. This
is reading B.
(8) Add the two readings and divide by two to find the
average. This is reading C.
K TRANSMISSION
(9) Subtract the gauge bar thickness (17.78 mm
(0.700 in)) to find the front end play.
Front end play specification:

0.1 8-4.70 mm (0.007-0.028 in)
Caution
If the front end play is below the specification
choose a washer of less thickness. If the front end
play is above the specification choose a thicker
washer.
Thrust washer thickness

-- -
Thrust washer
mm Inches identification
1 55 - 1 60 0 061 - 0 063 Wh~te
1 75 - 1 80 I 0 069 - 0 071 Green
1 85 - 1 90 0 073 - 0 075 Red
1 95 - 2 00 i 0 077 - 0 079 Be~ge
- --
--2 0-
5-210 0 081 0 083 Black
215-220 0 085 0 087 Yellow
43. Remove the oil pump.

44. Install the appropriate thrust washer (No. 1) that will
bring the end play to within specifications.
45. Verify the end play is within specifications by repeating the
front end play check.
7BUOKX-215
46. Remove the oil pump and thrust washer (No. 1).
Caution
The rough casting portion of the oil pump i s not a
flaw and the oil pump should not be replaced.
Note
The thrust washer (No. 1) will be installed after the
oil pump and converter housing are assembled.
47. Install a new drive gear O-ring.

TRANSMISSION K
48. Lubricate SST seat O-ring.
49. Install into pump drive gear' to seat O-ring into groove.
50. Remove SST.
PUMP .Position the two pump gears into the pump housing.
EARS Apply a lubricant to the pump gears to prevent scoring
at initial start-up.
Caution
The chamfer on the inside edge of the small gear
must be up when in the pump housing gear pocket.
The dimple on the larger gear must be down when
in the pump housing gear pocket.
CHA
I I
MK1004-A 7BUOKX-423
52. Place the separator plate on top of the oil pump.
Caution
Do not allow the pump gears to come out of the
pump housing pocket.
Make sure the holes in the plate line up with the
holes in the pump.
Install the oil pump and separator plate on the converter

housing.
Note
The notch on the outside edge ad the separator
plate will be at the 9 o'clock position, relative to the
converter housing.
I
MKl006-A 5BUOKX-425
54. Install the Allen head screws and finger tighten
/-
K TRANSMISSION
55. Select the correct arbor from the SST that will be the
t~ghtestfit when placed over the pump support.
Caution
The SST must be used to properly align the pump to
the converter housing, in order to prevent seal
leakage, gear noise and breakage and bushing
failure.
MK1008 A 5BUOKX 427

56. Thread the arbor Into a common handle and slide the SST
over the pump support unt~lit bottoms in the pump gear
pocket.
MK1009-A 5BUOKX-428
2 1 57. Tighten the Allen head screws.
Tightening torque:
22-28 N.m (2.2-2.9 kgf.m, 16-21 ft.lbf)
58. Remove the SST.
I I
MKI 570-A 5BUOKX-429
59. Install a new fluid pump seal ring.
1 ' SEAL RING I

60. Install a new gasket on the converter housing.
Caution
Do not position the gasket on the case first.
Note
61. Install the correct thrust washer (No. 1) on the oil pump.
Note
Use petroleum jelly to hold the thrust washer in
place.
TRANSMISSION K
62. Turn the converter housing over and install the front pump
1 support seal ring.
Note
Verify correct seal installation.Be sure seal grooves
RIGHT WRONG
are clean and free of burrs.
FRONTPUMP
SUPPORT
SEAL RING
I I
MK1568-A 5BUOKX-431
63. Install the input shaft as a guide for the converter housing
and front pump support and gear assembly. Install the
SST or equivalent.
Note
The splines on the input shaft are not the Sam
length.The shorter splines go intab the assembly.
MKI 569-A 7BUOKX-432

64. Install the converter housing and oil pump assembly.
Remove §ST. Install eight new screws and tighten in
star pattern. Remove input shaft.
Note
Lubricate O-rings in converter housing screws.
Tightening torque:
37-51 N.m (3.8-5.2 kgf.m, 27-38 ft.lbf)
MK1325-A 7BUOKX~218
K TRANSMISSION
65. lnstall the intermediate servo assembly and front
servo assembly.
(1) Install the spring.
Note
The spring is model dependent.
(2) lnstall the piston and rod assembly.

(3) lnstall the cover with a new O-ring.
I
MK1573-A
1
7EUOKX 433
1 Caution
Do not damagethe O-ringwhen installing the cover.
(4) lnstall SST over the intermediate servo cover at the

\\ fluid pan rail. Tighten the bolts.
Note
The J-hook must be in the appropriate hole for the
servo being removed, and tool number should be
facing up.
(5) Tighten the nut on the SST until there is a gap between
the servo cover and the snap ring.
(6) Carefully install the servo cover snap ring.

(7) Carefully back off the nut on the SST until the servo
spring is unloaded.
Caution
The servo cover is under spring tension.
(8) Remove SST.

(9) Repeat step (1) through (8) for installation of the
overdrive (4R44E)l front (5R55E) servo.
66. Adjust the intermediate band.

(1) Tighten the adjusting screw.
Tightening torque:
1 4 N.m (1.38 kgf.m, 10 ftlbf)
Caution
Install, but do not tighten a new locknut on the
adjusting screw. Apply petroleum jelly to the lock-
nut seal.
(2) Back off the adjusting screw exactly two turns and
MK1441-A 7BUOKX-221
hold it in that position.
(3) Tighten the locknut.
Tightening torque:
48-41 N.m (4.9-6.2 kgf-m,3 5 4 5 ft.lbf)
TRANSMISSION K
67. Adjust the overdrive (4R44E) 1 front (5R55E) band.
Caution
The overdrive (4R44E)ifront (5R55E) servo must
be installed prior to band adjustment.
(1) Tighten the adjusting screw.
Tightening torque:
14 N,m { I .38 kgf.m, 10 ftlbf)
Caution
~~1442-B ~BUOKX-222 Install, but do not tighten a new locknut on the
adjusting screw.
(2) Back off the adjusting screw exactly two turns and hold
in that position.
(3) Tighten the locknut.
Tightening torque:
48-61 N.m (4.9-6.2 kgfsm, 354!5 ft.lbf)
1 68. Lubricate and install the solenoid valve connector into

the case until a click is heard.
Note
Make sure tab is in lock position.
I
MK1443-A 7BUOKX-225
1 69. Install the case connector retaining ring.
Caution
Do not overstretch the retaining ring spring.
K TRANSMISSION
70. Install the Turbine Shaft Speed (TSS) sensor connector
in the case connector and insert wires into retaining
slot.
71 . lnstall a new valve body gasket.

Note
Make sure the holes in the gasket line up with the
holes in the control valve body.
72. lnstall the SST or equivalent as shown.
73. Install the control valve body. Align the manual valve with
the inner manual valve lever pin as shown.
\
MANUAL VALVE 1
TRANSMISSION K
74. Install the valve body bolts.
1 M6 X 55MM @ (1 REQUIRED)
(FLUID FILTER) (1) Position the valve body bolts as s h o \ ~ nin the figure.
1 M6 X 45MM @ (4 REQUIRED)
I (2) Tighten the valve body bolts in the sequence shown in
the figure.
Tightening torque:
M6 X 35MM @ (2 REQUIRED) 8-1 1 N-m (82-1 12 kgf-cm,71-97' in-lbf}
M6 X 30MM @ (2 REQUIRED)
1 20 MM @ (4 REQUIRED)
(SERVO COVER)
75. Remove the pin near the manual valve and install the
detent spring.
Tightening torque:
8-1 1 N m (82-1 12 kgfcm, 71-97 in.lbf}
I MANUAL VALVE DETENT SPRING

I
Check the reverse piston travel.
(1) Remove the reverse servo.
(2) Install the reverse servo piston assembly.
(3) Install a new gasket and the SST.
Note
SST number: 49 UNO1 016 Servo1 Rod Selecting
Tool
(4) Tighten the servo tool adjusting screw.
Tightening torque:
4 N-m(41 kgf-cm, 35 in-lbf}
K TRANSMISSION
(5) Install adial indicator on the transmission case with the
indicator on the piston pad.
DIAL INDICATOR (6) Set the dial indicator to zero.
ADJUSTING SCREW
(7) Loosen the adjusting screw until the p~stonpad bot-

toms out on the tool. Record the distance traveled (X).
Specification: 3.0-5.6 mm (0.120-4.220 in)
54153 - --
2 11212.085
- - - -- --
1 Groove
- -
51150 2.01411.986 No Groove

PISTON TRAVEL (X) MUST BE
3.0-5.6mm (0.120-0.220 IN) I
MK1221 A
MK1220 B 4BUOKX-244
( 8 ) If the distance traveled is greater than 5.6 mm (0.220
in} replace the piston and rod with the next longer
piston and rod.
(9) If the distance traveled is less than 3.0 mm (0.1 20 in}
replace the piston and rod with the next shorter piston
and rod.
(10) Install the new piston and rod and repeat the reverse
piston servo travel check.
4BUOKX 245
77. Install the reverse servo spring onto the piston assembly.
78. Install the reverse servo piston assembly.
Caution
Replace the oil seals if they are damaged.
TRANSMISSION K
79. Install a new gasket and the reverse piston cover.Tighten
screws in sequence as shown.
Tightening torque:
12-1 4 N - m (1 24-1 38 kgf-cm 106--124 in. Ibf)
80. Connect the wires to the solenoids and irkstall wire loom
protector and guide.
81 . Perform Inspection (In-shop). (Refer to page K-62.)
I
MK1408-A
1 82. Install new O-rings on the oil strainer.

83. Apply Mercona V ATF or equivalent to the O-rings.
MK1575-A 7BUOKX 233
1 84. Install the oil strainer.
Tightening torque:
8-1 1 N.m (82-1 12 kgf.cm, 71-97 in.lbf)
85. Install the oil pan gasket.
,
ulK1316-I? 5BUOKX-234
K TRANSMISSION
- - - -- pp
II 1 86. Install the oil pan.

Tightening torque:
13-15 N . m (132-152 kgf cm 115-133 in. Ibf)
87. Remove the transmission from the holding fixture.
I SPRING
88. lnstall the shaft, spring and parking pawl.
Caution
Make sure the park rod assembly is correctly seated
into the guide cup.
89. lnstall a new gasket onto the extension housing.

Note
Use petroleum jelly t o hold the gasket i n place.
90. lnstall the extension housing. Refer to page K-144.
91. lnstall the two studs and the four bolts.
Tightening torque:
37-51 N-m(3.8-5.2 kgf-m, 27-38 ft.lbf)
92. lnstall theTransmission Range (TR) sensor on the manual

lever. Finger-tighten the bolts.
93. Rotate the manual lever to the neutral position.
Note
(TR) SENSOR Use 49-UN01-086 instead of T93P-70010-Aa
94. lnstall TR Sensor Alignment Tool T93P-70010-A , or

equivalent into the three slots on the TR sensor.
Note
The manual lever must be in the neutral position.
ALIGN THREE SLOTS

TRANSMISSION K
1 95. Tighten the bolts.
Tightening torque:
8-1 I N-m (82-1 12 kgf-cm, 71-97 in-lbf)
96. lnstall the outer manual control lever and nut.
Tightening torque:
41-54 N.m (4.2-5.5 kgf-m, 30-410ft-lbf)
97. Align transmission heat shield retaining clips over fluid

pan rail and install heat shield on the fluid pan rail
(5R55E only).
1 TRANSMISSION
HEAT SHIELD
98. Install trarlsmission heat shield nut.Tighten heat shield

nut.
Tightening torque:
8-11 1 N.m (82-1 12 kgfcm, 71-97 in.1bf)
99. Install overdrive drum speed (ODs) :sensor into case

and tighten attaching bolt (5R55E only).
Tightening torque:
8-1 I N . m (82-1 12 kgf -cm 71-07 in . Ibf)
K TRANSMISSION
100. Install output shaft speed (OSS) sensor into case and
tighten attaching bolt (5R55E only).
Tightening torque:
8-11 N . m (82-11 2 kgf-cm 71-97 in. Ibf)
install the input shaft.

Caution
The splines on the input shaft are not the same on
both ends. The shaft end with the shorter spline
goes into the oil pump support.
(1) Insert SST or equivalent into pump drive gear, to

make sure the drive gear O-ring is properly seated
prior to installing the the torque converter. Remove
tool.
102. Install the torque converter, using Torque Converter

Handles T81 P-7902-C, or equivalent.
Note
TORQUE CONVERTER
Lightly lubricate the converter hub with MerconBV
ATF or equivalent.
Warning
The torque converter can fall out if the transmis-
sion is tipped.
Caution
Make sure the torque converter hub is fully en-
gaged in the pump gear and rotates freely.
Do not damage the hub seal.
. Measure the distance between the converter housing

mating surface and the torque converter to achieve
measurement A as shown in the figure.
Specification: 10.23-1 4.43 mm (0.44-4.56 in)

Caution
The hub seal may be damaged if the torque con-
verter slides back and out.
Make sure the cooler pipe system is open and clean
b fore the transmission is installed in the vehicle.
TRANSMISSION
TRANSMISSION UNIT (INSTALLATION)
1. lnstall the transmission into the vehicle, referring to lnstallation Note. (Refer to page K-191.)
2. lnstall the transmission mounting bolts, referring to lnstallation Note. (Refer to page K-191.)
3. lnstall the upper transmission mounting bolts, referring to lnstallation Note. (Refer to page K-192.)
4. lnstall the lower transmission mounting bolts, referring to lnstallation Note. (Refer to page K - I92 )
5. lnstall the lower transmission mounting bolts, referring to lnstallation Note. (Refer to page K-192.)
6. Connect the oil cooler pipes, referring to lnstallation Note. (Refer to page K-192.)
If the transmission oil cooler is not cleaned with the proper power flushing equipment
prior to repair completion, and comeback problems occur due to clogged ail cooler
circuits, the repair cost will not be warrantable. (Refer to page K-192.)
7. On 4x4 models, connect the transfer case linkage. (Refer to Section J.)
8. lnstall the rear engine mount and engine mounting member, referring to lnstallation Note.
9. Remove the jack.
10. Connect the Transmission Range (TR) sensor connector, referring to lnstallation Note. (Refer to
page K-193.)
11. Connect the solenoid valve connector, referring to lnstallation Note. (Refer to page I.(-193.)
12. lnstall the torque converter nuts, referring to lnstallation Note. (Refer to page K-193.)
13. On 3.OL models, install torque converter undercover, referring to lnstallation Note. (Refer to page
K-194.)
14. lnstall the starter. (Refer to Section G.)
15. lnstall the front pipe assembly. (Refer to Section F1, F2 and F3)
16. lnstall the selector cable, referring to lnstallation Note. (Refer to page K-194.)
17. lnstall the propeller shaft(s). (Refer to Section L.)
18. Adjust the selector cable. (Refer to page K-204.)
19. Fill the ATF. (Refer to page K-12.)
20. Drive the vehicle and check the shift points, shift schedule and shift shock. (Refer to Road Test,
page K-8.)
lnstallation Note
Transmission
Set the transmission on a jack and lift it into place.
Transmission mounting bolts
Tightening torque:
40-55 N . m (3.9-5.4 kgf-m 30-41 ft . Ibf)
K TRANSMISSION
Upper transmission mounting bolts
Tightening torque:
40-55 N.m (3.9-5.4 kgf-m, 3 0 - 4 1 ftlbf)
Lower transmission mounting bolts
Tightening torque:
40-55 N.m (3.9-5.4 kgf,m, 30-41 ftn4bf)
Oil dipstick tube

Install the oil dipstick tube into the oil filler tube.
Tightening torque:
38-51 N.m (3.9-5.2 kgf.m, 28-38 ft.lbf)
Note
Replace the oil filler tube if it is loose in the trans-
mission case.
4BUOKX 261
Oil cooler pipes

Caution
AUTOMATIC TRANSMISSION POWER FLUSHING

Note
After servicing oil pump, torque converter, control
valve body, servo piston end band, brake band, or
transmission removal and replacement, the trans-
mission cooler must be flushed using power flush-
ing equipment.
Follow manufacturer's provided instructions on
system flushing procedures.
I I
MKl066-A 6BUOKX-025
Rear engine mount and engine mounting member
On 2.3L models, install the rear engine mount and engine
mounting member as follows:
(1) Install the rear engine mount and engine mounting
member into the vehicle.
(2) Tighten the engine mounting member through bolts.
Tightening torque:
89-1 15 N-m(9.0-1 1.7 kgf.m, 65-45 ft-lbf)
MK1063-B 4BUOKX-263
K-192
TRANSMISSION K
(3) Tighten the rear engine mount bolts.
Tightening torque:
88-1 18 N-m (97.7-1 31.5 kgfam, 72-97 ft-lbf)
On 3.OL arid 4.OL models, install the rear engine mount

and engine mounting member as follows:
(I) Install the rear engine mount and engine mounting
member into the vehicle.
(2) Tighten the engine mounting member nuts and bolts.
Tightening torque:
89-1 15 N-m (9.0-1 1.7 kgf-m, 65--85 ft-lbf)
(3) On 4.OL equipped models, install the hanger onto the

rear engine mount.
Tightening torque:
82-108 N-m (8.3-1 1.0 kgf.m, 60--80 ftalbf}
1 I
MK1064-8 5BUOKX-249
Transmission Range (TR) sensor
Connect the TR sensor connector.
Connect the overdrive drum speed (ODs) sensor
(5R55E only).
Connect the output shaft speed (OSS) sensor
(5R55E only).
I
MK1451-B 7BUOKX 250
Solenoid valve connector
I I Connect the solenoid valve connector.
Note
The solenoid valve connector is located on the left
side of the transmission behind the converter
housing.
Torque converter nuts
Tightening torque:
2 8 - 4 6 N-m (2.84.6kgf.m, 20-34 ft-lbf)
UK1452-A 5BUOKX-251
K-193
K TRANSMISSION
Caution
On 2.3L models, do not rotate the crankshaft pulley
counterclockwise.
Note
On 2.3L and 4.OL models, the torque converter nuts
are accessed through the starter motor opening.
4BUOKX-268
Torque converter undercover

Install the torque converter undercover.
Tightening torque:
17-21 N.m (1.7-2.2 kgf-m, 12-1 6 ft-lbf)
4BUOKX-269
Selector cable
1. Install the bracket.
2. Install the selector cable onto the manual shaft lever.
FRONT OF
OIL COOLER K
OIL COOLER - AUXILIARY
REMOVAL I INSPECTION / INSTALLATION
1.Remove in the order shown, referring to Removal Note.
I --- I
MK1309-A 6BUOKX-253
1. Oil cooler
Removal Note . ..... ..... .. page K-1 95
Removal note
Oil cooler
1. Raise and support the hood.
2. Remove the oil cooler bolt (upper).
4. Place a suitable container under the oil cooler.
5. Disconnect the oil cooler hoses.
6. Remove the oil cooler bolts.
Note
Make sure not to spill the remaining transmission
fluid out of the oil cooler when removing the oil
cooler from the vehicle.
~RUOKX-274
OIL COOLER
Inspection
Not
Selector cable, linkage, fluid level and control pres-
sure must be accurate before performing this in-
spection.
1. Remove the oil dipstick.

2. Place a funnel in the oil dipstick tube.
4. Disconnect the outlet oil cooler pipe from the trans-
mission case.
5. Attach a hose to the outlet oil cooler pipe and install the
free end of the hose into the funnel.
6. With the transmission in N (Neutral) run the vehicle at
1000 rpm.
7. Watch the fluid flow for a solid stream.
8. If the fluid does not flow in a solid stream, a low oil pump
capacity, main circuit system leakage, stuck converter
charge relief valve or a cooler restriction is indicated.
9. To diagnose if the problem is in the transmission or in the
oil cooler perform the same test using the inlet pipe.
5BUOKX-254
OIL COOLER PIPES K
OIL COOLER PIPES
REMOVAL 1 INSPECTION 1 INSTALLATION
1. Remove bracket bolt.
2. Remove all clips.
3.Loosen the oil cooler pipe fittings.
4. Remove the oil cooler pipe.
5. Inspect all parts and replace as necessary.
K DRIVE PLATE
DRIVE PLATE
REMOVAL I INSPECTION IINSTALLATION
1. Remove the transmission. (Refer to page K-98.)
I 1
I 3.OL SHOWN 2.3L AND 4.0L SIMIIAR N.m (kgf.m, ft.lbf)

I
1. Drive plate mounting bolts
Installation Note ...................... page K-198
2. Drive plate
Installation Note
Drive plate mounting bolts
1. Remove any old locking compound from the bolt threads
and bolt holes, and apply new locking compound to the
bolt threads.
2. Tighten the drive plate mounting bolts in two or three steps

in the order shown.
Tightening torque:
81 N.m (8.2 kgf.m, 60 ft-lbf)
SHIFT MECHANISM
SHIFT MECHANISM
TROUBLESHOOTING
--
Problem Possible Cause
-+- --- -- - - -- -- -
Excessive selector K~nkedor broken selector cable

lever shift effort
- - - --- -- ---- -- - --- - --- - - --- - - -- - - ---
Transmission will Selector cable detached from bracket Re~nstall below

not shift from Lock tab loose T~ghten below
gear to gear Broken selector cable Replace below
MK1258 B 4BlJOKX 278
lnspection and Verification

Visually inspect the components in the chart below of the shift interlock system. Determine if any
of the following electrical and/or mechanical concerns apply:
Visual lnspection Chart
- - ----
Blown fuse(~)
Poor connections
Damaged wiring harness
Mechanical -- - - -
Electrical
----
K~nkedor bound sh~ft-lockcable

Kinked or bound shift cable
Damaged selector lever
-7
Shift control selector lever out of
adjustment
MK7145-B 7BUOKX-258A
Symptom Chart
---
--
Condition --
Shrft ~nterlocksystem does not

Possible S o u r c e
Circuitry openlshorted
I Action
Go to Pinpo~ntTest A
-- Page
K-203
release or lock properly Blown fuse
Damaged brake onloff I
(BOO) switch
Damaaed shift lock actuator
Shift Control Linkage Binding / Damaged shift cable and / Go to Pinpoint Test B 1 K-203
~
~----
out of proper gear relationship bracket
Loose shlft cable and bracket
Loose retainer bracket I
- - -- - - - . .
Shlft llnkage mlsadjusted --
-- - - -- --
Transmission Range Indicator Transmission shift cable Tighten bolts holding

does not correspond to the gear bracket is loose transmission shift cable
bracket
Transmission control Adjust PRNDL at steering
indicator linkage misadjusted column housing
Transmission shift cable Tighten transmission shift
loose from the transmission cable bolts
retainer bracket
Shift linkage misadjusted Verify shift cable
adjustment. Adjust shift
cable if necessary
Clip securing the transmission Install clip properly

shift cable to the transmission
range selector lever is loose 1
Transmission Range Indicator

Lamp does not illuminate
Bulb burned out
Wiring harness damaged
Replace bulb
Install new wiring harness
1997
BETM I
Rattle, Noise, Buzz, etc. Selector lever knob loose Replace selector lever knob
Transmission range selector Tighten housing bolts
lever loose I
Shift interlock spring not Attach shift interlock spring
hooked properly
SHIFT MECHANISM
;
- -
1- - Condition
-
Possible Source Action - Paw
Water enters inside the vehicle Cable assembly grommet not Secure grommet to dash -
ecure to dash panel
able assembly grommet Install new transmission
- --- -. .- --
Excessive shift effort n transmission -
ket loose 1 bent

- - -- - -- - ..
- -- -- ~p -
. - ---
Transmission Range Selector Transmission shift cable Reinstall transmission shift -

Lever will not shift from range detached from transmission
bracket
Lock tab loose
Broken transmission shift Replace transmission shift
cable cable
Shift Lock Actuator and Shift Lock Actuator Connector

r
SHIFT MECHANISM
Pinpoint Test A Shift interlock system does not release or lock properly
-- - -- - - - - -
-
STEP INSPECTION --- ACTION

- -- -- -- --- - - -- - - -
Check fuses 1 (50A) and 2 (50A) In the englne Yes Go to Step 2 - -

- -- -
1 compartment power d~str~butlonbox

Are fuses OK7 -- ---- --- --
-- -- -
No -- Go to Step
- 3
-- - -- --
I
Check fuses 10 (7 5A) and 13 (15A) at the I/P fuse Yes Go to Step 4
2 panel.
- -- --- -
Are fuses OK7 No Go to Step 3.

-- - - - -- -- -- -- - - - - - --
---
Re~laceblown fuse(~) .. a-
Yes Go to Step 8. -~ - ~ ----- -
T U ; ~key ON.
~ ~
3
No Go to Step 4.
-- Do fuse(s) fail again?
--
.- -
-~ - -
Locate and disconnect brake on/off (BOO) switch. Yes Go to Step 5. I

Measure voltage on the LGIR wire between the BOO
sw~tchconnector and ground.
-
No 1 Serv~ceLG/R wlre for open. Retest system.-- - - -
1
Is voltage greater than 10 volts? _ _ _ - - -I
-
With BOO switch disconnected, press the brake pedal. Yes GOto Step 6.
- - -.
Measure the voltage at the LG wire termlnal between
No Replace €300switch. Retest system
the BOO switch connector and ground.
Is voltage greater than 10 volts7
-- - -- -- -- -- --- *--
Locate and d~sconnectshlft lock actuator Yes Go to Step 7.

. -- -
- -- - - -- -- - -- --
Turn key ON
6 Measure voltage on the G Y N wlre at the sh~ftlock NO Servlce G Y N wire for open. Retest system.
actuator connector
Is voltage greater than 10 volts7-- -- -
- - - - -
D~sconnectsh~ftlock actuator connector

Measure reslstance of the B wire between the sh~ft
lock actuator connector and ground. No Service B wire for open. Retest system.
Is reslstance less than 5 ohms7
-
- --
--
D~sconnectsh~ftlock actuator connector Yes Service circuit for short to ground. Replace fuse.
Remove blown fuse. Retest system. -
8 Check for contlnu~tybetween blown fuse output
No Check all other clrcults that are spl~cedInto
clrcult and known good ground.
clrcult hav~ngblown fuse. Servlce as requ~red.
Is cont~nu~typresent7 I
If all other clrcults are OK, re~lacesh~ftlock
actuator. Retest system.
--- --
MK7148-8 7BUOKX-258D
Pinpoint Test B Shift control linkage binding, out of proper gear relationship - -- -- ----
- - - - -
- - - -- - - -
STEP -- -
INSPECTION --
ACTION - ---- -
Galn access to shlft control llnkage Yes Replace shlft control llnkage Retest system.
- -- -- --
Actuate sh~ftllnkage In all ranges
I Observe all llnkages durlng operation No Go to Step 2
Is ilnkage damaged7
-- - -
- - -- -
Check transrn~ss~on shlft cable and bracket Verlfy shlft cable adjustment Fi
2 lnstallat~onand t~ghtness Yes ment" ~nthls section. Adjust shlft cable ~f
Is sh~ftcable properly ~nstalledand adjusted7 necessary Go to Step 3
--
No Serv~ceas necessary. Retest system.
.- --
Actuate transmission range selector lever in all ranges. Yes -- Service is complete. Retest system.
- .-
Does Indicator match gear selection?
p-
No Replace damaged l~nkageicableRetest systerri

SHIFT MECHANISM K
SELECTOR CABLE
3. Inspect all of the parts and repair or replace as necessary.
5. After installation, check the selector cable adjustment.
L 2
MK1455-A 6BUOKX-256
1. Selector cable
Removal Note ....................... page K-204
Adjustment ............................ page K-204
SHIFT MECHANISM K
Removal note
Selector cable
1. Pry the selector cable from the selector lever arm using a
screwdriver.
2. Bend the tab on the column bracket to disengage the
cable from the bracket.
3. Remove the selector cable from the retaining clip.
4. Raise vehicle on hoist and position suitable safety stands
under vehicle.
5. Below the engine compartment, remove cable and grom-
met from dash panel.
6. Pry the selector cable from the manual shaft lever.
7. Squeeze the cable tabs together to disengage the cable
from the bracket.
8. Remove the selector cable from the retaining bracket.
Adjustment
1. Place the selector lever in the overdrive position.
2. Hang a three pound weight on the selector lever.
4. Pry the selector cable from the manual shaft lever.
5. Release the locktab on the top side of the selector cable
by pushing down on the two tangs and unlock the adjuster
body.
6. Make sure the selector cable moves freely by moving the
selector cable back and forth the full adjustment length
four or five times to remove any dirt.
7. Shift the transmission into overdrive. Move the manual
shaft lever all the way counterclockwise and then forward
three detent positions.
8. Hold the selector cable fitting and push tlie cable rearward
until the end lines up with the manual shaft lever.
9. Connect the selector cable to the manual lever shaft.
10. Push up on the locktab to lock the adjuster body in the
correct position. Make sure the locator tab is properly
seated in the bracket.
1 1. Make sure the cable is properly routed and secured.
13. Adjust the selector lever indicator. (Refer to Section N.)
14. Remove the three pound weight from the selector lever.
15. After adjustment, check the transmission engagement in
all detent positions and readjust if necessary.
K SHIFT MECHANISM
SELECTOR LEVER
1. Remove the upper and lower steering column covers. (Refer to Section N.)
2. Remove the selector lever, referring to Removal Note.
Removal note
Selector lever
1. Depress the two locking tabs on the selector lever pivot pin
retaining clip.
2. Remove the selector lever pivot pin. Discard the pin and
clip.
Installation note
Selector lever
Install the selector lever in the shift socket with a new
selector lever pivot pin.
Note
The head of the selector lever pivot pin should be
on the top side of the shift socket.
ON-BOARD DIAGNOSIS SYSTEM, SERVICE POINTS K
SERVICE POINTS
OUTLINE
PCM Power Relay (Battery Power)
EEC PWR Fuse (PCM Memory Power)

If the EEC PWR fuse circuit has an open or short, Diagnostic Trouble Code No. PI 605 is output.
If the circuit is open, the PCM memory function will not operate and Diagnostic Trouble Codes for
intermittent malfunctions will not be indicated. Also, the learning control will be canceled, but will not
produce any particular symptom.
5BUOKX-308
Ground
If there is a poor ground, the engine may not start.
Malfunction lndicator Lamp (MIL) 1 Transmission Control Indicator Lamp (TCIL)

If the circuit is open, the MILtTCIL will not illuminate with the ignition switch ON.
If the circuit is shorted, the MILITCIL will not go off after the engine is started.
5BUOKX-309
Throttle Position (TP) Sensor

If the throttle position sensor or circuit has an open or short, Diagnostic Trouble Code No. PO121, PO122,
PO123, P I 120, P I 121, P I 124 or P I 125 is output.
If the throttle position sensor circuit fails, rough idle, poor acceleration or shift shock (AT) may occur.
---. 5BUOKX-310
SERVICE POINTS
Camshsft Position (CMP) Sensor
output.
If the camshaft position sensor circuit fails, the engine will stall and will not restart.
5BUOKX-311
Engine Coolant Temperature (ECT) Sensor

If the engine coolant temperature sensor or circuit has an open or short, Diagnostic Trouble Code No.
PO1 17, PO1 18, PO125, PO126, P I 116, or P I 117 is output.
If the engine coolant temperature sensor circuit fails, no torque converter lockup will occur.
5BUOKX-312
Brake On / Off (BOO) Switch

If the brake onloff switch or circuit has an open or short, Diagnostic Trouble Code No. PO703 or P I 703
is output.
If the circuit is open, torque converter lockup will not disengage.
If the circuit is shorted, the stoplights will not operate and torque converter lockup will not occur.
5BUOKX-313
Vehicle Speed Sensor (VSS)

If the vehicle speed sensor or circuit has an open or short, Diagnostic Trouble Code No. PO500 or P I 500
is output.
If the vehicle speed sensor circuit fails, no 3-4, 4-5, 4-3 or 5-4 shifts or torque converter lockup will
OCCUT. 7RUOKX 314
Transmission Range (TR) Sensor

If the vehicle is not in P or N range during diagnostic trouble code check, Diagnostic Trouble Code No.
P I 705 is output.
If the TR sensor is misaligned or failed electrically, PI704 is output.
If the TR sensor, circuit or PCM is shorted or grounded, PO705 is output.
If the TR sensor circuit is above maximum voltage, PO708 is output.
7BUOKX-315
Evaporative Emission (EVAP) Canister Purge Solenoid

If the evaporative emission canister purge solenoid has an open or short circuit, Diagnostic Trouble Code
No. PO443 is output.
If the circuit is open, no symptom will be noticed.
If the circuit is shorted, the engine may stall at low speeds.
A short circuit may cause an improper airtfuel ratio, causing rough idle and hard starting.
5BUOKX-316
Ignition Coil (#1 - #4)

If an ignition coil has an open or short circuit, Diagnostic Trouble Code No. P0301, P0302, P0303, P0304,
P0305, P0306, P0350, PO351 or PO352 is output.
If the circuit is open or shorted, a misfire condition may occur, causing hard starting and rough idle.
5BUOKX-317
Purge Flow Sensor

If the purge flow sensor circuit has an open or short, Diagnostic Trouble Code No. PI444 or PI445 is
output.
If the purge flow sensor circuit is open or shorted, no symptom will be noticed.
Transmission Fluid Temperature (TFT) Sensor
If the transmission fluid temperature sensor circuit has an open or short, Diagnostic Trouble Code No.
PO712, PO713, or P I 71 1 is output.
If the transmission fluid temperature sensor is open or shorted, erratic shifting may be felt.
If the transmission fluid exceeds 127°C (270°F), PI783 is output.
Turbine Shaft Speed (TSS) Sensor

If the turbine shaft speed sensor has an open or short, Diagnostic Trouble Code No. PO715 is output.
If the turbine shaft speed sensor circuit is open or shorted, no symptom will be noticed.
SERVICE POINTS
Shift Solenoids (SSI, SS2, SS3, SS4)
If a shift solenoid or circuit has an open or short. Diagnostic Trouble Code No. PO731 P0732. P0733.
P0734, P0750, P0751, P0755, P0756, P0760, P0761, P0765, P1751, P'1756, or PI761 is output.
If one of these circuits fail, the transmission will shift into incorrect gears.
If a mechanical failure of the solenoid is detected, Pl714. P I 715, P I 71 6 or Pl717 will be output (5H55E).
7BUOKX-318
Electrical Pressure Control (EPC) Solenoid

If the electrical pressure control solenoid or circuit has an open or short, Diagnostic Trouble Code No.
P I 746 or P I 747 is output.
If the electrical pressure control solenoid circuit fails, line pressure will default to maximum.
5BUOKX-319
Coasting Clutch Solenoid (CCS) (4R44E only)

If the coasting clutch solenoid or circuit has an open or short, DiagnosticTrouble Code No. P I 754 is output.
If the coasting clutch solenoid circuit fails, no engine braking will occur.
7BUOKX-320

If the torque converter clutch solenoid circuit fails, no torque converter lockup will occur
If TCC slippage is detected, PO741 or PO744 is output.
If TCC solenoid circuit fails during on-board diagnosis, PO743 is output.
If TCC malfunction is detected, P I 740 is output.
Output Shaft Speed (OSS) Sensor (5R55E only)

If OSS sensor provides insufficient input to PCM, DTC PO720 is output.
If OSS sensor signal is erratic, DTC PO721 is output.
Overdrive Drum Speed (ODs) Sensor (5R55E only)

If ODs sensor provides insufficient input to PCM, DTC PI719 is output.
1
ELECTRICAL DIAGNOSIS SUPPORT
EEC PWR Fuse (PCM Memory Power)
I-Condition
circuit
PCM (55)-Ma~n fuse block

- 6pGiiriK:r
Eng~newlll not start
Code No. PO603 or
P I 650 output
I -
-
- - --
Short circuit
EEC PWR fuse (30A)
burns out
----
Code No. PO603 or P I 650

-
1 --
2l00u
;rnd
--
-1
output
- - -
MF1113-B 5BUOKX-322
PCM Power Relay
L Condition
Circuit
Open circuit
I
----
Short circuit 7 Poor ground

-.
I
---- --
PCM (71)-PCM power relay
PCM (97)-PCM power relay

--
Eng~newill not start

- -
EECPWR~~S~(~GS----~--
switch ON
out w~thlgn~t~on ~~ NA
-
I
I - 1 - 2
MF1114 C 5BUOKX 323
Ground
Condition
Circuit -
- -
Open circuit Short circuit Poor ground

-- ~~ - - -- --
PCM (24)-Ground - --
Engine will not start Engine may not start
PCM (25)-Ground Hard startlng
NA
PCM (76)-Ground
PCM (77)-Ground -
I
-
PCM (103)-Ground
MF1115-C
--- L---
I 5RUOKX-324
SERVICE POINTS
Throttle Position (TP) Sensor
Condition
Circuit
Open circuit Poor ground
- - -- - -- ---
PCM (89)-Throttle posltlon

--- --- --
P I 120 output P I 120 output
i
-
PCM (90)-~hrottle position ldle speed drops when ldle speeddrops when AIC
- - -
(Vref) -- --
- -
I A/C ON
- -----
ON
-- -
I
-- - - -
PCM (91)-Throttle pos~t~on
s e n s o r y o d e No. P0121, P 0 1 2 2 , T
or P I t 20 output NA -
ldle speed drops when
A/C ON 1
dF1119-B 5BUOKX 325
Camshaft Position (CMP) Signal

Condition
Circuit
t
I
-- - - -- - - -- -- -- -
PCM (85)-lgnlt~on control module Code No. PO340 output Code No PO340 output
Engine may stall and may 1 Englne may stall and may NA
not restart not restart
lrlF1234 B 5BUOKX 326
Engine Coolant Temperature (ECT) Sensor

I
Condition
- - --
Circuit
--_-
PCM (38)-Eng~ne coolant
I ~ p e circuit
n Short circuit 7 C-
-
-
- --
Poor ground
-- - --
-
--
--
temperature sensor NA
- -- - --- - ---
, P I 117 output - PI 117 output -- -- - - - -- - -
PCM (91)-Engine coolant NA -

temperature sensor
MF1123-C 5BUOKX 327
Brake On 1 Off (BOO) Switch

Condition
Circuit - - - - -- - - - - - - - - -
PCM (92):~rake
- - -
on/off swltch
- - - - - - -- --
output
Open circuit
- -
I - - --
Short circuit
Code No. PO703 or P I 703 , Code No. PO703 or PI703
output Melts No. 10 fuse
- -- -- .
1I
-
Poor ground
-
/
MF1124-8
(15A) Stoplights will not
operate , 5BUOKX-328
Vehicle Speed Sensor (VSS)
I Circuit I---
Condition 1
- - - -- ------
Open circuit 1 Short circuit
---I
I
Poor ground
PCM (58)-Vehicle speed sensor Code No. PO500 or P I Code No. PO500 or P I 500
- - - -- - -- - output output I
PCM (33)-Veh~cle speed sensor NA I Code No. PO500 or P I 500

I / output
MF1125-8 5BUOJKX-329
SERVICE POINTS K
Purge Flow Sensor
--
Condition
Circuit -- - -- -- -- - - -
Open circuit Poor ground

---
PCM ( I I)-Purge flow sensor Code No. PI444 or
P I 445 output P I 445 output
PCM ~ o w e relav-Purae
r " flow Code No. PI444 or I Melts EEC PWR fuse (30A)
- 8
sensor 1 PI 445 output

MF1740-A 5BUOKX-330
Transmission Fluid Temperature (TFT) Sensor

Condition
1
--- - - - --
Circuit --A --

-- - -
PCM (37)-Transm~ss~onfluid Code No PO712, ~ 0 7 1 3 C o d Noe PO712, PO713
temperature sensor or P I 71 1 output or P I 71 1 output NA
Poor shlftlng Poor shlftlng
- -- -
PCM power relay-Transmlsslon

fluld temperature sensor ---
MF1741 B 5BUOKX 331
Turbine Shaft Speed (TSS) Sensor
Circuit
1- -P-P -
Condition --

-- - --- -
-, -
PCM (84)-Turblne shaft speed No PO715 output

sensor
I
~
- - - - -
PCM power relay-Turbine shaft

soeedsensor
MF1743-C

Condition
Circuit
1
- --
Open circuit ~h<rtcircuit j ~ o o ground

r
-
/
PCM (27)-Shift solenoid 1
I Code No. P0731, P0732,
P0733. P0734. P0750. /
Code No. P0731, P0732,
P0733. P0734. P0750.
1 !
- -
P~~ power relay-~hlft solenold ~ 0 7 5 1 PI714

: or PI751 P0751. PI714 or PI751
Improper gear selection Improper gear selection
'
---
I
Condition
Circuit -- - - --
~0133~~1;PO/^^^^^^^,
- - - --
PCM 6)-shift solenold 2 Code No. P0731, P0732, Code No. P0731, P0732,
PO734 P0755,
1 /
. L A
- - -- -- -
P0756, PI756 or PI715 P0756, PI756 or P1715
PCM power Improper gear selection Improper gear selection
SERVICE POINTS
-
Condition
Circuit
PCM (53)-Sh~ft solenotd 3

-
Open circuit
Code No. P0731, P0732,
-
I -
-
-
Short circuit
- -
Code No P0731, P0732,
- --
-
i
-
Poor ground
-- -- P0733, P0734, P0761, P0733, P0734, P0761,

PI761 or PA716 PI761 or PI716 NA
PCM power relay-Sh~ft solenold 3
lmproper gear selection / lmproper gear selectron ~ J
MK1486-A 7BUOKX-335
Shift Solenoid 4 (SS4) (5R55E only)
Condition
Circuit
PCM (28) Code No. P1717, P0735, Code No. P1717, P0735,
PO765 PO765
NA
PCM power relay Improper gear selection Improper gear selection
shift solenoid 4 Mechanical failure Mechanical failure
7BUOKX-375
Overdrive Drum Speed (ODs) Sensor (5R55E only)

Condition
Circuit
PCM (59) Code No. P1719 Code No. PI719
NA
PCM power relay - Harsh or flaring Harsh or flaring
ODs sensor 2-1, 2-3 or 5-4 shift 2-1, 2-3 or 5-4 shift
7BUOKX-376
Output Shaft Speed (OSS) Sensor (5R55E only)
Condition
Circuit
PCM (6) Code No. P0720, PO721 Code No. P0720, PO721
Harsh shifts Harsh shifts
NA
PCM power relay - No TCC engagement No TCC engagement
OSS sensor Abnormal shifts Abnormal shifts
Electrical Pressure Control (EPC) Solenoid

Condition
Circuit 1 - - - -- - - --- -- -- - -
PCM (81)--~lectr~calpressure
-1
Open circuit
I Code; N PI 746, or
-
I
1
I
- -
Short circuit
Code No P1746, or
-- -- - - --- Poor ground
-
' PI747 I
control solenold
PCM power relay-Electr~ca/-
I
1
PI 747 output
Max~rnurnl~nepressure I Max~mumline pressure 1
pressure control I 11
solenoid I
I J
MK1487 A 5BUOKX-336
SERVICE POINTS K
Coasting Clutch Solenoid (CCS) (4R44E only)
Condition
Circuit - -- --
- --- - -- ---

- - pp -v- -* --- -
PCM (28)-Coast~ng clutch solenold Code No. P I 754 output Code No. P I 754 output
No englne break~ng No engine break~ng
. NA
PCM power relay-Coastlng clutch
solenold I - .
MK1488 A 7BUOKX 137

Condition
Circuit
PCM (54)-Torque converter Code No. PO743 or P I 743 Code No. PO743 or P I 743
clutch solenoid output output NA
PCM power relay-Torque converter No torque converter lockup No torque converter lockup 1
clutch solenoid
PROPELLER SHAFT
TROUBLESHOOTING GUIDE ...................... L- 2

PROPELLER SHAFT .................................... L- 2
REMOVAL / INSTALLATION ..................... L- 2
INSPECTION ............................................. L- 3
OVERHAUL ............................................... L- 4
ADJUSTMENT ........................................... L-13
5BUOl.X-005
TROUBLESHOOTING GUIDE, PROPELLER SHAFT
Problem Possible Cause Remedy Page
- - - - - - - - - -
Deflection Faulty assembly of universal joint Repa~r L-4
Bent propeller shaft Replace L-2
Worn center support and bear~ng Replace L-4
Loose center support and bearing mountlng bolts Tlghten L-4
Loose yoke mountlng bolt T~ghten L-3, 4
Worn spllnes of slldlng joint Replace -
Faulty assembly of yoke of center bearlng

- - - -
Repa~r L-9
Abnormal noise Worn or damaged un~iersal]ocnt bear~ng ~e~lace- L-4
Worn or damaged center support and bear~ng Replace L-4
Loose yoke mountlng bolt T~ghten L-3, 4
Worn spllnes of slldlng joint Replace -
PROPELLER SHAFT
Note
Mark the propeller shaft before removing it. Vibration may be present if the propeller shaft is
not installed in the original position.
1. On Cab Plus models, remove the rear propeller shaft center bearing support from the frame crossmember.
2. Remove the bolts attaching the rear propeller shaft to the rear axle.
3. On 4x4 models, remove the bolts attaching the rear propeller shaft to the transfer case.
4. Remove the rear propeller shaft, referring to Removal Note. (Refer to below.)
5. Remove the bolts and straps that attach the front propeller shaft to the transfer case.
6. Remove the bolts and straps that attach the front propeller shaft to the front axle.
7 . Remove the front propeller shaft, referring to Removal Note. (Refer to page L-3.)
4BUOLX-003
Removal Note
Caution
Do not allow the propeller shaft to hang free. Sup-
port the propeller shaft during removal procedures.
4BUOLX-004
Rear propeller shaft (4x2)

1. Pull the propeller shaft toward the rear of the vehicle until
the slip yoke clears the transmission extension housing
and seal.
2. When the propeller shaft is removed from the extension
housing, immediately install the appropriate plug to pre-
vent lubricant leakage.
4BUOLX-005
Rear propeller shaft (Cab Plus)

Note
Remove any spacers under the center bearing
support, if equipped.
4BUOLX-006
PROPELLER SHAFT L
Front propeller e shaft
1. Remove the U-joint assembly from the front differential
axle companion flange.
2. Slide the slip yoke assembly out of the transfer case and
remove the propeller shaft assembly.
4BUOLX-007
INSPECTION
Dust boot
lnspect the dust boot for rips or tear.s and replace if
necessary. (Refer to page L-8.)
4BUOLX-008
U-joint assembly
Inspect the U-joint assembly for wear and damage and
replace if necessary. (Refer to page L-4.)
4BUOLX-010
Installation Note
Rear propeller shaft (4x2)
1. Apply lubricant to the center yoke splines.
2. Remove the plug from the extension housing and inspect
the housing seal for damage. Replace 1:heseal if neces-
sary.
3. Slide the center yoke into the transmission extension
housing, making sure the marks align.
Note
Do not allow the center yoke assembly to bottom
out on the output shaft with excessive force.
4. Align the marks and install the rear propeller shaft to the
rear axle.
Tightening torque:
m
88-1 19 N .m (9-1 2 kgf .rn, 65-87' ft - Ibf)
Rear propeller shaft (4x4 )
1. Align the niarks and install the rear propeller shaft to the
transfer case.
Tightening torque:
88-119 N.m (9-12 kgf-m, 65-87' ft.lbf)
1 2. Align the rriarks and install the rear propeller shaft to the
rear axle.
ML1011-A 6BUOLX-001
Tightening torque:
88-119 N.m (9-12 kgfem, 65-47 ft-lbf)
6BUOLX-002
L PROPELLER SHAFT
Rear
e propeller shaft (Cab Plus)
Install the center bearing support to the frame
crossmem ber.
Tightening torque:
37-50 N.m (4-5 kgfsm, 28-36 ft.lbf)
Note
Make sure that the center bearing support assem-
bly is installed properly ("square" to the vehicle).
Make sure spacers are installed, if equipped.
4BUOLX-013
Front propeller shaft

1. Align the marks and install the front propeller shaft to the
front axle.
Tightening torque:
14-20 N-m (1.4-2.0 kgf.m, 10-1 5 ft.lbf)
COMPANION
L
ML1013-A
-
2. Align the marks and install the front propeller shaft to the
transfer case
Tightening torque:
17-22 N.m (1.7-2.2 kgf-m, 13-16 ft4bf)
OVERHAUL
Caution
Universal
e joint components from different manufacturers and new and used universal joints
are never to be mixed. Universal joint kits are to be installed as complete assemblies only.
Before assembly, make sure all parts are completely clean.
Note
Mark all propeller shaft components before disassembly. Vibration may be present if any
component is not assembled in the original position.

2. Inspect all parts and replace as necessary.
PROPELLER SHAFT L
4x4 REAR (LWB I!;WB)
REAR CAB PLUS)

L PROPELLER SHAFT
1. Snap ring 9. Dust boot
Disassembly Note ........................ below lnspect for rips and tears
2. Bearing cup Disassembly Note ................. page L- 8
lnspect for damage or rough rotation Assembly Note ...................... page L-10
Disassembly Note ........................ below 10. Rear propeller shaft
Assembly Note ...................... page L-11 Inspection .............................. page L- 9
3. Spider 11. Front propeller shaft
Disassembly Note ................. page L- 7 Inspection .............................. page L- 9
Assembly Note ...................... page L-11 12. Half-round yoke
4. Front yoke Assembly Note ...................... page L- 9
5. Rear yoke 13. Center bearing support
6. Center yoke Disassembly Note ................. page L- 9
Disassembly Note ................. page L- 7 Assembly Note ...................... page L- 9
7. Centering socket yoke 14. Bushing
Disassembly Note ................. page L- 8 lnspect for hardening, cracking
Assembly Note ...................... page L - l 1 or deterioration
8. Slip yoke 15. Coupling shaft
Disassembly Note ................. page L- 8 Assembly Note ...................... page L- 9
Assembly Note ...................... page L-10 16. Rear yoke
Assembly Note ...................... page L- 9
4BUOLX-016
Disassembly Note
Snap ring
Warning
Do not clamp the propeller shaft in a vise. The
propeller shaft could fail during vehicle operation
due to a dent or fracture caused by the vise.
Remove the snap rings with pliers. Discard the snap rings.
Note
The snap rings cannot be reused.
ML1017-A 5BUOLX-001
Bearing cup
1. Clamp U-Joint Tool T74P-4635-C, or equivalent in a vise.
2. Position the yoke in the tool and press out the bearing cup.
PROPELLER SHAFT L
3. If the bearing cup cannot be pressed out all the way,
remove it with a vise grip or channel lock pliers.
4. Reposition the yoke in the tool 180" to press on the spider,

and remove the remaining bearing cup from the opposite
side.
T74P-46354
5. For front propeller shafts with double cardan U-joints,

thread the tool clockwise until the bearing cup protrudes
approximately 9.5mm (0.374 in) out of the center yoke.
ML1025-A
6. For the front propeller shaft, position the bearing cup in a
vise and tap on the center yoke to free it from the bearing
cup.
7. For the front propeller shaft, lift the two bearing cups from
the spider.
8. Remove the remaining bearing cups in the same manner.
Spider
Remove the spider after the bearing cups have been
removed.
4BUOLX-019
PROPELLER SHAFT
Centering socket yoke
CENTER Pull the centering socket yoke off the center stud, and
remove the rubber seal from the centering ball stud.
ENTERING
OCKET YOKE
1 I
ML1028-A 6BUOLX-003
-
U-JOINT TOOL
Center yoke
~74~-4635-c 1. Remove the snap rings from the center yoke and from the
propeller shaft yoke.
2. Position U-Joint Tool T74P-4635-C, or equivalent on the
propeller shaft yoke and press the bearing outward until
the inside of the center yoke almost contacts the boot ring
at the front of the propeller shaft yoke.
Caution
Pressing beyond this point can distort the boot
ring.
3. Clamp the exposed end fo the bearing in a vise and drive

the center yoke with a soft-faced hammer to free it from
the bearing.
4. Reposition the tool and press on the spider to remove the
opposite bearing.
5. Remove the center yoke from the spider.
6. Remove the spider from the propeller shaft in the same
manner.
INTERFERENCE
POINT
ML1030-A 6BUOLX-004
Slip yoke, dust boot
1 . Remove the slip yoke from the splined stub shaft after the
boot clamps have been removed with end cutter pliers.
Warning
Use gloves or a shop cloth to protect your hands
when removing the dust boot assembly.
2. Discard the clamps and inspect the dust boot for rips and
tears and replace if necessary.
PROPELLER SHAFT L
3. If the dust boot is cracked or split, check the lubricant for
contamination by rubbing it between two fingers. Any
gritty feeling indicates a contaminated center yoke and
stub shaft.
4. If contaminated, inspect the stubshaft arid the slip yoke for
wear and replace them if necessary.
5. Inspect the spline area and clean all foreign matter from
the propeller shaft spline.
Center bearing support
1. Separate the rear propeller shaft from tlne coupling shaft.
2. Remove the nut attaching the half-round yoke to the
coupling shaft and remove the yoke.
3. Check the center bearing support for wear and roughness
by rotating the outer area while holding the coupling shaft.
Replace the center bearing support if necessary.
4. Inspect the rubber bushing for evidence of hardening,
cracking or deterioration and replace if necessary.
413UOLX-023
Inspection
Front propeller shaft, rear propeller shaft
1. Measure the front and rear propeller shaft runout with a
dial indicator.
2. Replace the front and/or rear propeller shaft assembly if
runout is excessive.
Maximum runout: 0.89mm (0.035 in].

~BUOLX-024
Assembly Note
Caution
Before assembly, make sure all parts are com-
pletely clean.
4BUOLX-025
Center bearing support and half-round yoke

1. Install the center bearinq support.
2. Install the attaching nutio the coupling shaft yoke.
Tightening torque:
135-1 62 N.m (13.8--16.4 kgf-m, -1 00-1 20 ft-lbf)
Note
Make sure the yoke is reinstalled in the same
orientation as it was originally installed.
3. Install the spider assembly and straps to the half-round

yoke and tighten the bolts.
Tightening torque:
18-25 N-m {I .9-2.5 kgf-m, 13-11 8 ft-lbf)
4BUOLX-026
Coupling shaft and rear yoke (Cab Plus)

Install the coupling shaft to the rear yoke.
Tightening torque:
55-74 N.m (5.6-7.5 kgf.m, 41-!55 ft.lbf)
4BUOLX-027
L PROPELLER SHAFT
Dust boot, slip yoke
BOOT 1. Install the dust boot making sure the boot is seated in the
boot groove.
I I
ML1031 A
2. On 4x4 models, install the small diameter side first,
&a
LARGE pushing the boot as far as it will travel on the stub shaft.
SPLINED STUB DIAMETER
, r
- -
--
- LL
SMALL
DIAMETER
I 1
ML1038-A
3. On 4x4 models, install the small clamp by crimping with
CRIMP SMALL
CLAMP Clamp Pliers T63P-9171-A, or equivalent.
4 . 0 n 4x4 models, fill the dust boot with approximately
10 grams (0.35 ounces} of grease.
5. Lubricate the slip splines with grease.
6. Push the slip yoke onto the stub shaft, making sure the
blind splines are aligned.
I BLIND SPLINES I
7. Install the new clamps using Clamp Pliers T63P-9171-A,
TABS
or equivalent making sure the clamp tabs are located in
the dust boot slots.
Note
Use the new original type of clamps when installing
the boots. Use of other types of clamps may cause
propeller shaft imbalance or grease leakage due to
poor sealing.
Do not crimp the clamp to the point where the clamp
bridge is cut or the boot is damaged.
PROPELLER SHAFT
8. On 4x4 models, move the slip yoke in or out in order to
position the slip yoke about 25-38mm (1 -1.5 in) from the
collapsed position, then install the large clamp.
Centering yoke and centering socket yoke

1. Pack the socket relief and the ball with grease, then
position the center yoke over the spider ends and press in
the bearing.
2. lnstall the snap rings.
3. Install a new rubber seal on the centering ball stud.
4. Position the centering socket yoke on tlie stud.
5. Place the front spider in the center yoke.
6. With the spider loosely positioned on the center stop, seat
the first pair of bearings into the centering socket yoke,
then press the second pair into the centering yoke.
8. Apply pressure on the centering sockel: yoke and install
the remaining bearing cup.
6BUOLX-005
Bearing cup, spider

Note
The spider bosses (or lubrication^ plugs on kits)
must be assembled in their origirial positions to
provide proper clearance.
1. Start the bearing cup into the yoke of the propeller shaft.
2. Position the spider in the propeller shaft yoke and press

the bearing cup below the yoke surface using U-Joint Tool
T74P-4635-C, or equivalent.
3. For the 4x4 LWB, press the bearing cup 6.3mm (0.25 in)
U-JOINT TOO
~74~-4635-c below the yoke surface using U-Joint Tool T74P-4635-C,
or equivalent.
4. Remove the tool and install a new snap ring.
5. Start a new bearing cup into the opposite side of the yoke.
6. Check the needle rollers for proper posi~tion.

7. Position the propeller shaft in the tool and press on the
NEEDLE bearing cup until the opposite bearing cup contacts the
ROLLER
snap ring.
L PROPELLER SHAFT
8. Remove the propeller shaft from the tool and install a new
snap ring, making sure the snap ring is properly seated.
I I
ML1035-A
9. Make sure the U-joints are free to rotate easily without
binding before installing the propeller shaft. Replace the
U-joints if necessary.
I
ML1036-A
10. If binding has resulted from misalignment during the
assembly, a sharp rap on the yokes with a brass or plastic
hammer will seat the bearing needles.
Caution
Do not strike the bearings during this procedure.
PROPELLER SHAFT
ADJUSTMENT
BOlTOM OF PROPELLER
FRAME SHAFT AXLE Driveline angularity
ENGINE ANGLE PINION 1. Measure the ride height (X) between the top of the axle
tube and the bottom of the frame rail. The vehicle must be
in the curb weight (unloaded) condition. Find the recorded
ride heigh.tin the Driveline Angle chart in Section TD. The
specified driveline angles correspond to the measured
ride height.
2. Check the driveline angles (using a Pinion Angle Level
CRANKSHAFT SHAFT AXLE PINION Gauge T68P-4602-A.)
CENTERLINE CENTERLINE CENTERLINE
Note
ML1042-A
Drivelineangles up to 12 degrees (canbe inspected
using Pinion Angle Level Gauge T68P-4602-A or
equivalent. An adjustable bubble protractor is net-
essary for driveline angles over 12 degrees. All
angles should be read within 0.5 (degreeswith the
tool or with the protractor contac:tinga clean, flat
surface.
( I ) If using Pinion Angle Level Gauge T68P-4602-A or

equivalent, place the tool directly behind the rear axle
area (A) on regular cab vehicles. Place the Pinion
Angle Level Gauge T68P-4602-A or equivalent
behind the cab area (B) on Cab-Plus vehicles.
(2) Calibrate the Pinion Angle Level Gauge T68P-4602-A
or equivalent by taking the average reading from both
sides of the vehicle.
(3)The angle of the component is measured by

mounting Pinion Angle Level Gauge T68P-4602-A or
equivalent to the bearing cap of the spider.
PINION ANGLE
LEVEL GAUGE
T68P-4602-A
L PROPELLER SHAFT
3. Check the driveline angles (using an adjustable bubble
protractor.)
Note
All angles should be read with the protractor con-
tacting a clean, flat surface.
The engine angle can be measured off the bottom
of the starter motor if the transmission obstructs
the protractor.
(1) If using a protractor, place the protractor directly be-

hind the rear axle area (A) on regular cab vehicles or
behind the cab area (B) on Cab-Plus vehicles to
determine the frame angle.
L
ML1044 A
Note
FRAME
The protractor cannot be zeroed relative to the
-/I5@ frame. The measured frame angle reading will have

to be addedlsubtracted from the measured com-
1 1
COMPONENT
ANGLE
ponent angle reading before comparing to the
specification.
ML1048 A
(2) Check the engine angle by rotat~ngthe propeller shaft
YOKE EAR
*
$?I T
until one yoke ear is parallel to the floor. Place the
protractor flush against the yoke ear.
>T
Note
2
-
Make sure the protractor is not resting against any
portion of the propeller shaft assembly.
a': 2% .-
(3) Record the angle reading.
(4) To determ~nethe engine angle reading subtract the
i- . angle reading from the frame angle reading.
.;/ k7 /
Note
ML1049 A
The engine angle reading should not differ from
specification by 1 degree or more.
Check the propeller shaft and pinion angles with
the engine angle within specification.
PROPELLER SHAFT
(5) Checkthe propeller shaft angle by placing the protrac-
tor on the propeller shaft.
Note
The plane surface of the protracto~rshould be flush
against the bottom surface of the propeller shaft
and parallel to the floor.
(7) To determine the propeller shaft angle, subtract the
PROTRACTOR angle reading from the frame angle.
ML1050 A
(8) Check the axle pinion angle by placing the protractor
4'I flush against two rear axle cover retaining bolts.
(10) Subtract the angle reading from 90 degrees.
(11) Recorcl the adjusted angle reading.
(12) To determine the pinion angle, subtract the adjusted
angle reading from the frame angle.
MLlO51-A 5BUOLX 002

Engine Angle Adjustment
1. Adjust the engine angle.
(1) Looser1 the engine mount-to-frame nuts.
(2) Raise the engine off the frame.
(3) Lower and settle the engine.
(4) Tighten all fasteners to specification.
(5) Recheck the engine angle.
(6) If the engine angle is still out of specification, place
shims under the rear engine mount until the specified
angle is obtained.
5BUOLX-003
Propeller Shaft Balancing

Note
Vibration or shudder during fast acceleration,
coasting, or during engine braking, may be caused
by the rear axle casing being loa~se,tire balance,
improper driveline installation or balance.
If vibration occurs after propeller shaft service:

1. Disconnect the propeller shaft and remove the front yoke.
2. Rotate the front yoke 180 degrees.
3.Connect the propeller shaft to the front yoke and reinstall
in vehicle.
4. If the vibration persists, disconnect the propeller shaft at
the rear yoke.
5. Rotate the rear yoke 180 degrees and reconnect the
propeller shaft to the rear yoke.
Note
If rotating the propeller shaft 180 degrees does not
eliminate vibration, balance the propeller shaft.
PROPELLER SHAFT
6. Balance the propeller shaft.
Warning
Use caution when checking the propeller shaft.
(1) Raise and support the vehicle.
Note
Both front and rear axles should be supported to
allow all of the wheels to rotate at normal ride
height.
(2) With the transmission in gear, increase the vehicle
speed to the maximum vibration level.
(3) Note and record the speed of this vibration period as a
baseline speed.
(4) Run the vehicle until the propeller shaft rotating speed
is 64-80 km/h (40-50 mph).
Note
Do not run the vehicle for an extended period of
time.
(5) Carefully mark the propeller shaft with chalk as the
chalk initially contacts the rear, center and front of the
propeller shaft.
Note
The chalk marks will indicate the heavy side of the
propeller shaft.
(6) Install two hose clamps on the propeller shaft so that

their heads are located 180 degrees from the chalk
mark, starting at the rear yoke end of the propeller
shaft.
PROPELLER SHAFT L
(7) Accelerate the vehicle to the baseline speed noted in
CHALK MARK step (3).
(8) If vibration is still present, rotate the clamps approxi-
mately 45 degrees away from each other and test for
correction of vibration.
(9) If necessary, continue to rotate the clamps apart in
smaller increments until the vibration becomes re-
duced or eliminated.
(10) If the vibration continues, repeat the above procedure
and balance the front end of the propeller shaft.
(1 1) Lower and road test the vehicle.
ML1054-A 5BUOLX-004
FRONT AND
REAR AXLES
INDEX ........................................................... M- 2
OUTLINE ...................................................... M- 3
SPECIFICATIONS ..................................... M- 3
TROUBLESHOOTING GUIDE ...................... M- 4
FRONT AXLE (4x2) ...................................... M- 6
WHEEL BEARING PLAY ........................... M- 6
KNUCKLE .................................................. M- 7
FRONT AXLE (4x4) ...................................... M- 9
PREPARATION ........................................ M- 9
WHEEL BEARING PLAY ........................... M- 9
KNUCKLE AND SPINDLE ......................... M-11
FRONT AXLE DRIVE SHAFT
(DANA 28 AND DANA 35) ......................... M-14
PREPARATION ......................................... M-14
REMOVAL I INSPECTION /
INSTALLATION ........................................ M-14
DISASSEMBLY / ASSEMBLY ................... M-19
FRONT AXLE CASING (4x4) ....................... M-20
REMOVAL / INSTALLATION ..................... M-20
REAR AXLE ................................................. M-23
PREPARATION ......................................... M-23
ON-VEHICLE MAINTENANCE .................. M-23
REMOVAL / INSTALLATION ..................... M-26
REAR AXLE CASING .................................. M-29
REMOVAL 1 INSTALLATION ..................... M-29
FRONT DIFFERENTIAL ............................... M-33
PREPARATION ......................................... M-33
ON-VEHICLE MAINTENANCE .................. M-34
REMOVAL .................................................. M-36
DISASSEMBLY .......................................... M-39
INSPECTION ............................................. M-43
ASSEMBLY ................................................ M-44
INSTALLATION .......................................... M-57
REAR DIFFERENTIAL ................................. M-60
PREPARATION ......................................... M-60
STANDARD ............................................. M-61
LIMITED SLIP ............................................ M-78
WHEEL HUBS .............................................. M-86
PREPARATION ......................................... M-86
AUTOMATIC LOCKING WHEEL HUB ...... M-86
MANUAL LOCKING WHEEL HUB ............. M-89
4BUOMX-001
INDEX
INDEX
REAR AXLE
FRONT AXLE (4x2)

FRONT AXLE (4x4)
.
.
I
MM1178-A
1. Front axle (4x2) 6. Rear axle casing
Wheel bearing play ................ page M- 6 Removal/lnstallation . .... ...... .... page M-29
Knuckle .. ..... ..... ..... ..... ...... ..... .. page M- 7 7. Front differential
2. Front axle (4x4) Removal ... ..... ............... .......... page M-36
Wheel bearing play .......... ..... . page M- 9 Disassembly ........ ..... ..... ..... .... page M-39
Knuckle and spindle ............... page M-11 Inspection ...................... ......... page M-43
3. Front axle drive shaft Assembly ... ..... ..... .......... ......... page M-44
(Dana 28 and Dana 35) Installation . ..... ..... ..... ..... ..... .... page M-57
Removal / Inspection 1 8. Rear differential
Installation ....... ..... ................ page M-14 Standard ..... ..... ..... ..... ..... ..... ... page M-61
Disassembly/Assembly . ..... .... page M-19 Limited slip ............................. page M-78
4. Front axle casing (4x4) 9. Wheel hubs
Removal/lnstallation . .... .......... page M-20 Automatic locking wheel hub .. page M-86
5. Rear axle Manual locking wheel hub ...... page M-89
Removal/lnstallation ....... ........ page M-26
OUTLINE
OUTLINE
SPECIFICATIONS
(FRONT AXLE)
4x2
Bearlng play axlal d~rect~on mm { ~ n ) 0 006-0 127 {O 0002-O.C105}
MM1165 B
Bearlng preload (wlthout 011seal load)
-- -
t-
N.m {kgfmn, ~n.lbf) 1
-
-- --- --
2 8 {28 5, 25)
-
--
1
4BUOMX 191
4x4 --
---
I Dana 35 1
---+
Kern Model Dana 28
1 Bearina ~ l a axial
v direction mm {in} / 0.00-0.08 {O.OOO-0.003} I
Bearing preload (without oil seal load) N.m {kgf+cm,in.lbf) 2.8 (28.5, 25) . .. .
.
. .. ~- ~
Grade .- --
. .. ----
API Service GL-5 ...
--- .. - - -
I
~ ~~~ ~
--
Vlscoslty
-
Capac~ty
-I
CAbove -18°C {O°F}
Below -18°C {O°F1
,
-
.
--
hters {US pt, Imp pt)

- --
I
-
--
--
- -
1.42 { 3 , 2 5j
- --
SAE 90
SAE 80W
7---7 65j3.5.303) 1
MM1166 C 4BUOMX-190
(REAR AXLE)
Rear axle 1
Integral type
Axle casing --
1- ---
Axle shaft support- --- 1 Opposed tapered roller bearlngs -- -- -
Bearlng play M~n~murn mm { ~ n } ---

0.127 {O
- -
005)
- - - - -- -- - -- -
ax~aldtrection Maximum 0.762 {0.030}

- - - -- - -- - - - - - - -- - --
Rear differential - .-- - --- - -- - - - --
Gear des~gn - -- -
Hypo~dgear -
- -
t-
Grade - -- --
API Servlce GL-5
-- --
Above -18°C {O°F} SAE 90

011 Vlscoslty - -
- ---- -- --
Below -18°C {O°F} - -- --- -

SAE 80W - - - - -
-
TYpe -- -- -- -
Standard
-- --
L~m~ted--sl~p
Capac~ty llters {US pt, Imp pt) 2 4 {5 0, 4.2) 2.4-2.5 (5-5.3, 4 2-4 4)'
' Add 4 oz of an appropr~atefrict~onmod~f~er
MM1167-C
FRONT AXLE
Problem
Steering wheel
-
I
- - -
Possible Cause
Improperly adjusted wheel bearlng play
- -- -
Adjust
- --- -
Remedy
-- -
Page
M-6,9
-
vibration - -
Steering wheel pulls

- Worn or-
--
damaged wheel bear~ng
- - ----
Improperly adjusted wheel bearlng play
Replace
--- - -
Adjust
-- -- -- -
M-6,9
-
M-14- -
or one-sided braking
-
Worn or damaged wheel bearlng-
Replace - -M-14
-
Excessive steering Improperly adjusted wheel bearlng play Adjust M-6,9
wheel play - -- - - - -- -- -- - - - - - - - - - - -- -
Abnormal noise Bent axle casing Replace M-20
Bent front axle dr~veshaft I Replace M-14
Worn or damaged wheel bearing I Replace M-14
Worn front axle dr~veshaft spl~ne Replace M-14
1
1
lnsufflc~entgrease In joint or spllne of drlve shaft Replen~shor replace M-15

Excess~vebacklash on spl~neof drive shaft Replace M-14
-.
Worn
-
jolnt of drive shaft
-- - --
-- - - - --
i, Replace
- - - -
M-14
-
~rease
leakagefrom Damaged or broken boot I Replace M-14
boot Faulty boot clamp I Replace M-14
Excessive grease M-15
Oil leakage Worn or damaged 011 seal Replace M-14
Cracked axle caslng I Replace M-20
MM1000 B 4BUOMX 1
FRONT DIFFERENTIAL
Problem Possible Cause

-
Remedy Page 1
Abnormal noise lnsufflc~entfront d~fferent~al 011 ~ d d ol r
Incorrect front d~fferent~al or1 Replace
lmproperly adjusted backlash of rlng gear Adjust
Poor contact of teeth of rrng gear Adjust
Worn or damaged s ~ d ebearing Replace
Worn or damaged rlng gear Replace
Worn or damaged rear bearlng Replace
Worn or damaged pinlon and s ~ d egear Replace
Selzure of s ~ d egear and case Replace
Worn spllne of s ~ d egear Replace
Worn plnron shaft Replace
Loose companion flange locknut T~ghten
Worn s ~ d egear thrust washer Replace
lmproperly adjusted s ~ d ebearlng preload Adjust
lmproperly adjusted rear bearlng preload Adjust
Worn front axle drlve shaft splrne - -
Replace --
Heat buildup lnsuff~c~entf~ont differentla1 011 ~ d d o ~ l

lnsufflc~entbacklash of rrng gear Adjust
Excesslve bearlng preload - - --
Adjust
-
Oil leakage Excessive front drfferentral 011 Drarn oil
Clogged alr breather Repa~r
Worn or damaged 011seal Replace
MMlOOl-B
REAR AXLE
Problem Possible Cause Remedy

- --- - --
Abnormal noise Bent axle casing Replace

Bent axle shaft Replace
Worn or damaged wheel bearing Replace
Worn axle shaft spline
- - --- -- -- --
Replace
Oil leakage worn or damaged oil seal Replace
Cracked axle casing Replace
REAR DIFFERENTIAL
Possible Cause
nsufficient rear differential oil
ncorrect rear differential oil
1 Add oil
Replace
Remedy
M-23
M-23
Improperly adjusted backlash of ring gear Adjust M-75
Poor contact of teeth of ring gear Adjust M-62
Worn or damaged side bearing 1 M-64
Worn or damaged ring gear
Worn or damaged rear bearing
Worn or damaged pinion and side gear
,
1
Replace
Replace
M-64
M-64
M-64, 78
Seizure of side gear and case Replace M-64, 78
Worn spline of side gear Replace M-64, 78
Worn pinion shaft Replace M-64, 78
Loose companion flange locknut Tighten M-68
Worn side gear thrust washer Replace M-64, 78
Improperly adjusted side bearing preload Adjust M-73
Improperly adjusted rear bearing preload Adjust M-70
Worn rear axle shaft spline
- --- -- - -- -- - - -
Replace M-26
Heat buildup Insufficient rear differential oil Add c 7 - - M-23
Insufficient backlash of ring gear Adjust M-75
Excessive bearing preload Adjust M-70,73
Oil leakage
ulM1003 B
Worn or damaged oil seal
-
--
Repair
-
Oraln
Replace ---
M-23
4BIJOMX
M FRONT AXLE (4x2)
FRONT AXLE (4x2)

WHEEL BEARING PLAY
Inspection
1. Jack up the front of the vehicle and support it with safety
stands. Inspect for noticeable bearing play with the hands
held at the top and bottom of the tire.
Wheel bearing play:

0.006-0.1 27mm (0.0002-0.005 in]
I
~~1004-A ~BUOMX-005 2. Inspect the wheel for smooth rotation. Note any rough
feeling or abnormal noise from the bearing.
3. Replace the wheel bearing or adjust the wheel bearing
preload if necessary.
Adjustment
1.Jack up the front of the vehicle and support it with safety
stands.
2. Remove the wheel cover.
3. Remove the hub cap and any excess grease from the hub.
4. Remove and discard the cotter pin.
5. Remove the retainer.

6. Loosen the adjusting nut three turns.
7. Grasp and rock the wheel and tire assembly.
Note
Tap on the caliper with a plastic hammer if rocking
ADJUSTING the wheel and tire does not increase clearance
' NUT between the disc plate and brake pad.
Do not pry on caliper piston.
Clearance must be maintained during adjustment.
8. Rotate the wheel and tire assembly counterclockwise

while tightening the adjusting nut to specification.
Tightening torque:
23-34 N.m (2.3-3.4 kgf-m, 17-25 ftalbf)
9. Spin the wheel and tire and loosen the adjusting nut one-
half turn (180").
10. Tighten the adjusting nut.
Tightening torque:
2.0-2.3 N.m (20.4-23.4 kgf-cm, 18-20 in.lbf}
11. Install the retainer until the slot matches with the hole in
knuckle.
Note
Do not turn the adjusting nut to align the slot.
FRONT AXLE (4x2)
12. Install a new cotter pin.

13. Check the wheel bearing play.
Wheel bearing play:

0.006-4.1 27mm (0.0802-0.005 in)
14. Attach a pull scale to a wheel lug bolt and measure the
frictional force.
Frictional force:
2.8 N-m (28.5 kgf-cm, 25 in.lbf)
15. Install the hub cap.

16. Check the wheel rotation for roughness or noise. Remove
and lubricate the bearing if necessary. (Refer to page
M-6.)
17. Pump the brake pedal.
KNUCKLE
Removal Ilnstallation
1. Jack up the vehicle and support it with safety stands.
2. Remove the wheel and tire assembly.
3. Remove the caliper, disc plate and dust shield. (Refer to Section P.)
1. Tie-rod end 2. Knuckle

Removal Note ........................ page M-8 Removal Note ........................ page M-8
Installation Note ..................... page M-9 Installation Note ..................... page M-8
M FRONT AXLE (4x2)
Removal note
Tie-rod end
2. Remove the nut.
3. Separate the tie-rod end from the knuckle using Tie Rod
End Remover TOOL-3290-D, or equivalent.
4BUOMX-008
Knuckle
2. Remove the nut.
3. Mark the position of the camberlcaster adjuster.
4. Remove the bolt.
5. Remove the camberlcaster adjuster using Ball Joint
Remover D81T-3010-B, or equivalent.
6. Strike the lower arm as shown in the figure to remove the
knuckle.
Caution
Do not use a ball joint separator fork to separate the
knuckle from the lower arm.
Installation note
Knuckle
1 . Install the knuckle into the lower arm.
Note
Make sure the ball joint seals are in place.
2. Install the camberlcaster adjuster into the same position

it was removed from.
3. Tighten the nut.
Tightening torque:
120-1 80 N m (1 2.3-1 8.3 kgf m, 89-1 33 ft . Ibf}
4. Tighten the nut to align the next slot with the hole in the ball
joint.
6. Tighten the bolt.
Tightening torque:
68-92 N . m (6.9-9.3 kgf . m, 50-68 ft . Ibf}
6BUOMX-002
FRONT AXLE (4X2), FRONT AXLE (4x4) M
Tie-rod end
I . Install the tie-rod end into the knuckle.
2. Tighten the nut.
Tightening torque:
70-100 N-m (7.2-10.0 kgf-m, 52--73 ft.lbf)
4. Tighten the nut to align the next slot with the hole in the tie-
rod end.
4BUOMX-011
FRONT AXLE (4x4)

PREPARATION
SST
Q
49 UNOl 042 For
Hub locknut
wrench f'~ adjustment
of manual
locking hubs
I I I
4BUOMX-012
WHEEL BEARING PLAY
Inspection
1. Jack up the front of the vehicle, and support it with safety
--.
stands. Inspect for noticeable bearing play with the hands
held at the top and bottom of the tire.
Wheel bearing play:

0.00--0.08mm (0.000--0.003 in}
2. Inspect the wheel for smooth rotation. Note any rough

feeling or abnormal noise from the bearing.
~~1004-A ~BUOMX-013 3 . Replace the wheel bearing or adjust the wheel bearing
preload if necessary.
Adjustment (Manual locking hubs)
1. Jack up the front of the vehicle, and support it with safety
stands.
3. Remove the retainers and manual locking hub assembly.
r - 1 5. Remove the axle shaft spacers.

M FRONT AXLE (4x4)
6. Remove the outer locknut using the SST
7. Remove the washer.
MMlOlO B
1 8. Loosen the inner locknut usina the SST.
9. Rotate the disc plate counter~lockwisewhde tightening
the inner locknut to specification.
Tightening torque:
47 N.m (4.8 kgf-m, 35 ft.lbf)
10.Spin the disc plate and loosen the inner locknut one-
quarter turn (90").
11. Tighten the inner locknut using the SST.
Note
MM1011-B SST number: 49 UNOl 042 Hub Locknut Wrench
I I
Tightening torque:
1.8 N-m(18.3 kgfzm, 16 in-lbf)
'\\, '\I\ 1 12. Install the washer.

k \ I Note
Tighten the inner locknut slightly to align the lock-
nut pin with the washer hole.
13.Tighten the outer locknut using the SST.
Tightening torque:
203 N.m (20.7 kgf.m, 150 ftdbf)
Wheel bearing play:

0.00--0.08mm (0.00-0.003 in)
15. Attach a pull scale to a wheel lug bolt and measure the
frictional force.
Frictional force:
2.8 N.m (28.5 kgfecm, 25 inelbf)
16. Install the axle shaft spacers.

18. Install the manual locking hub assembly.
19. Install the retainers.
Adjustment (Automatic locking hubs)
(Refer to page M-87.)
5BUOMX-002
FRONT AXLE (4x4) M
KNUCKLE AND SPINDLE
f Removal I Installation
1. Jack up the front of the vehicle, and support it with safety stands.
3. Remove the caliper. (Refer to Section P.)
4. Remove the hub assembly. (Refer to page M-89 for manual locking wheel hubs and page M-86 for auto-
matic locking wheel hubs.) Remove the front wheel bearing.
5. Remove the front axle drive shaft. (Refer to page M-14.)
6. Remove the tie rod nut, referring to Removal Note. (Refer to page M-12.)
I
MM1013-B 6BUOMX-003
1. Snap ring 4. Lower ball joint
2. Nut Removal Note ........................ page M-12
Removal Note ........................ page M-12 Installation Note ..................... page M-12
Installation Note ..................... page M-13 5. Upper ball joint
3. Camberlcaster adjuster Removal Note ........................ page M-12
Installation Note ..................... page M-13 6. Knuckle
M FRONT AXLE (4x4)
Removal note
Tie rod nut
2. Remove the nut.
3. Tap on the tie-rod end to remove it from the steering
linkage.
4BUOMX-017
Nut
2. Loosen the nut.
3. Strike the knuckle with a hammer to break it loose.
Note
Remove the nut after the camber adjuster is re-
moved.
4BUOMX-018
Camberlcaster adjuster
1. Mark the position of the camberlcaster adjuster.
2. Remove the camberlcaster adjuster using Pitman Arm
Puller T64P-3590-F, or equivalent.
4BUOMX-019
Lower ball joint

2. Assemble U-Joint Tool T74P-4635-C and suitable ball
joint remover.
3. Remove the lower ball joint.
Upper ball joint

1. Assemble U-Joint Tool T74P-4635-C and suitable ball
joint remover.
2. Remove the upper ball joint.
Installation note
Lower ball joint
I RECEIVING CUP
TBOT-3010-A3 1. Assemble U-Joint Tool T74P-4635-C and Receiver Cup.
2. Install the lower ball joint.
U-JOINT TOOL
T74P-4635-C
Note
Realign the installation tool if the proper depth
cannot be achieved.

FRONT AXLE (4x4)
Upper ball joint

1. Assemble U-Joint Tool T74P-4635-C and Replacer T80T-
3010-A3, or equivalents.
2. lnstall the upper ball joint.
I
MM1017-D 6BUOMX-007
Camber I caster adjuster
lnstall the camberlcaster adjuster in the same position it
was removed from. ~BUOMX-024
Nut
1. lnstall a new nut.
Tightening torque:
122 N.m (12.4 kgfm, 90 ft-lbf)
2. Tighten the nut to align the next slot with the hole in the
lower ball joint.
3. lnstall a new cotter pin.
4. lnstall the snap ring on the upper ball joint stud.
5. lnstall and tighten the upper ball joint pinch bolt.
Tightening torque:
88-1 15 N-m (9.0-1 1.7 kgf-m, 65--85 ft-lbf)
Note
The camberlcaster adjuster will seat itself during
tightening of the bolt. Do not adjust the position.
6BUOMX-008
Tie rod nut

1. lnstall the steering linkage.
2. Tighten the tie rod nut.
Tightening torque:
70-1 00 N-m (7.2-1 0.2 kgfem, 52--73 ft-lbf)
steering linkage.
4. lnstall a new cotter pin.
4BUOMX-026
M FRONT AXLE DRIVE SHAFT (DANA 28 AND DANA 35)
FRONT AXLE DRIVE SHAFT (DANA 28 AND DANA 35)
PREPARATION
SST
49 0223 630B For 49 UNOl 076 For

removal of
Impact slide oil seal Spindle and
hammer axle seal
installer
49 F027 003 For 49 UNOI 038 For

Driver handle Spindle bearing and
( bearing 011 seal
replacer
49 UNOI 040 For

installation of
Hub seal the seal
replacer
REMOVAL / INSPECTION / INSTALLATION

1. Remove ABS speed sensor, if necessary. (Refer to Section P.)
5. Remove the hub assembly. (Refer to page M-89 for manual locking wheel hubs and page M-86 for
automatic locking wheel hubs.)
Note
The construction of the Dana 28 and Dana 35 axles are the same; their removal, disassembly,
assembly and installations will be explained together.
FRONT AXLE DRIVE SHAFT (DANA 28 AND DANA 35) M
SLINGER,
P REPLACE rn
/I @ SL-INGER, REPLACE
I
MM1018-D
1. Disc plate 11. Front axle drive shaft
2. Outer bearing Disassembly l Assembly ........ page M-19
Installation Note ..................... page M-18 12. Rubber boot
3. Seal Removal Note ........................ page M-16
Installation Note ..................... page M-18 13. Oil seal
4. lnner bearing Removal Note ........................ page M-16
5. lnner bearing cup 14. Bearing
6. Outer bearing cup 15. Slinger
7. Spindle 16. Left front axle casing
Removal Note ........................ page M-16 Removal 1 Installation ............. page M-20
Installation Note ..................... page M-18 17. Right front axle casing
8. Spindle seat Removal / Installation ............. page M-20
9. Splash shield 18. Seal
10. Clamps
Removal Note ........................ page M-16
Installation Note ..................... page M-17
FRONT AXLE DRIVE SHAFT (DANA 28 AND DANA 35)
Removal Note
Seal
Remove the seal using Seal Remover TOOL-1 175-AC, or
equivalent and the SST. Discard the seal.
Note
SST number: 49 0223 630B lmpact Slide Hammer
4BUOMX-195
Inner bearing cup

1. On Dana 35 axles, remove the inner bearing cup using
Bearing Cup Puller D78P-1225-B, or equivalent.
2. On Dana 28 axles, remove the inner bearing cup using
Bearing Cup Puller T77F-1102-A and Slide Hammer
D78P-100-A, or equivalents.
4BUOMX 029
Outer bearing cup

1. On Dana 35 axles, remove the outer bearing cup using
Bearing Cup Puller D78P-1225-B, or equivalent.
2. On Dana 28 axles, remove the outer bearing cup using
Bearing Cup Puller T77F-1102-A and Slide Hammer
D78P-100-A, or equivalents.
4BUOMX-030
Spindle
Tap the spindle with a plastic hammer to remove it from
the knuckle.
4BUOMX-031
Clamps
If removing the right front drive axle shaft, mark the yoke
and front drive axle shaft prior to separation.
~BUOMX-032
Rubber boot
If removing the right front drive axle shaft, remove the
rubber boot from the front drive axle shaft.
4BUOMX-033
Oil seal
1. On Dana 35 axles, remove the oil seal using the SST and
Seal Remover TOOL-1 175-AC, or equivalent.
Note
SST number: 49 0223 6308 lmpact Slide Hammer
2. On Dana 28 axles, remove the oil seal using the SST and
Bearing Cup Puller T77F-1102-A, or equivalent.
Note
4BUOMX-034
Bearing
1. On Dana 35 axles, remove the bearing using the SST and
Seal Remover TOOL- 1175-AC, or equivalent.
Note
2. On Dana 28 axles, remove the bearing using the SST and

Bearing Cup Puller T77F-1102-A, or equivalent.
Note
SST number: 49 0223 6308 lmpact Slide Hammer
4BUOMX-035
Slinger
Remove the slinger by driving it off with a hammer.
Installation Note
Slinger
lnstall a new slinger using a press and the SST
Bearing
lnstall the bearing using the SSTs.
Note
lnstall the bearing with the manufacturer's identifi-
cation facing outward.
Clean all dirt and grease from the bearing bore. The
bearing bore must be free from nicks and burrs.
Oil seal
lnstall the oil seal using the SSTs.
Note
Apply high temperature grease to the oil seal.
Rubber boot
If installingthe right front drive axle shaft, install the rubber
boot onto the front drive axle shaft.
4BUOMX-040
Clamps
if installing the right front drive axle shaft, refer to the
following:
(1) Align the marks made during removal.
(2) lnstall the clamps using Clamp Pliers T63P-9171-A, or
equivalent.
4BUOMX-041
M FRONT AXLE DRIVE SHAFT (DANA 28 AND DANA 35)
Spindle
Install the spindle and nuts.
Tightening torque:
54-68 N.m (5.6-6.9 kgf.m, 40-50 ft.lbf)
4BUOMX-042
inner bearing cup

lnstall the inner bearing cup using the SST and Bearing
Cup Replacer T73T-42224, or equivalent.
Note
SST number: 49 F027 003 Driver Handle
4BUOMX-043
Outer bearing cup

Install the outer bearing cup using the SST and Bearing
Cup Replacer T73T-4222-B, or equivalent.
Note
SST number: 49 F027 003 Driver Handle
4BUOMX-044
Inner and outer bearing

Pack the bearings with high temperature grease.
4BUOMX-045
Seal
Install the seal using the SSTs.
Note
Apply high temperature grease to the seal.
DISASSEMBLY IASSEMBLY
Note
To remove the stub shaft, the front differential must be removed. (Refer to page M-36.)
1. Place the axle shaft assembly in a vise, being careful not to damage it.
REPLACE
I I
MM1024-B 6BUOMX-009
1. Snap rings 3. Spider
2. Bearing cups 4. Front drive axle shaft
Disassembly Note .......................... below 5. Stub shaft
Assembly Note ............................... below
Disassembly Note
Bearing cups
Press out the bearing cups using U-Joint Tool T74P-
4635-C, or equivalent. If the bearing cannot be pressed
all the way out of the flange, remove it with a vise grip or
channel lock pliers.
Assembly Note
MM 1025-A 6BUOMX-010 Bearing cups
1. Press in the bearing cups using U-Joint Tool T74P-
4635-C, or equivalent to specification.
Specification:
6.35mm (0.25 in) with the surface of the yokes
/--
2. Repeat step 1 to install the four bearing cups.
Note
Check th shaft for fre dom of mov ment. If bind-
ing is present, tap the ears of the shaft.
Do not install the shaft if any binding is observed.
MM1026-A 4BUOMX-049
M-I 9
M FRONT AXLE CASING (4x4)
FRONT AXLE CASING (4x4)
2. Disconnect the front propeller shaft. (Refer to Section L.)
FRONT AXLE CASING (4x4)
1. Tie rod end 6. Radius arm bracket
Removal Note . . . . . . . . . . . . . . . below Installation Note . . . . . . . . . . page M-22
Installation Note . . . . . . . . . . page M-22 7. Radius arm
2. Front stabilizer bar Installation Note . . . . . . . . . . page M-22
3. Front stabilizer bar links 8. Left front axle casing
4. Spring Removal Note . . . . . . . . . . . . . . . below
Removal Note . . . . . . . . . . . . . . . below Installation Note . . . . . . . . . . . . . . below
Installation Note . . . . . . . . . . page M-22 9. Right front axle casing
5. Shock absorber Removal Note . . . . . . . . . . . . . . . below
Removal Note . . . . . . . . . . . . . . . below Installation Note . . . . . . . . . . . . . . below
Installation Note . . . . . . . . . . page M-22
Removal Note
Tie-rod end
2. Remove the nut.
3. Tap on the tie-rod end to remove it from the steering
linkage.
6BUOMX-011
Spring
1. Compress the spring using a jack and lifting the front axle
casing.
2. Remove the nut.
3. Slowly lower the jackand front axle casing and remove the
spring, spacer, seat and stud.
Note
Support the front axle casing at all times during
removal and installation. Do not allow the lower
arm to hang from the brake hose.
4BUOMX-052
Shock absorber
1. Remove the nut and washer.
2. Separate the shock absorber from the radius arm.
4BUOMX-053
Front axle casing, right and left

1. Ensure both the left and right front axle casings are
securely supported by a transmission jack.
2. Slowly lower the front axle casing.
4BUOMX-054
lnstallation Note
Front axle casing, right and left
Tightening torque:
163-203 N-m{I6.6-20.7 kgf-m, 120-1 50 ft.lbf)
Note
Do not remove the transmission lack from under
the front axle casing assembly at this time.
5BUOMX-005
M FRONT AXLE CASING (4x4)
Radius arm and bracket
Stud and nut tightening torque:

258-31 1 N - m (26.2-31.7 kgf .m, 190-229 ft . Ibf)
Front bolts tightening torque:
37-50 N .m (3.8-5.1 kgf - m, 27-37 ft .lbf}
Lower bolt tightening torque:
255-345 N . m (26.2-35.2 kgf . m, 190-255 ft . Ibf)
6BUOMX-012
Spring
1. Install the spring, spacer, seat and stud. Raise the jack to
compress the front coil spring.
2. Install the nut.
Note
Support the front axle casing at all times during
installation. Do not allow the lower arm to hang
from the brake hose.
Tightening torque:
95-1 35 N-m(9.7-1 3.8 kgf-m, 70-1 00 ftelbf)
6BUOMX-013
Shock absorber
1. Install the shock absorber onto the radius arm.
2. Install the washer and nut.
Tightening torque:
57-97 N . m (5.8-9.9 kgf . m, 42-72 ft . Ibf)
6BUOMX-014
Tie-rod end
1. Insert the tie-rod end into the knuckle.
2.lnstall the nut.
Tightening torque:
68-101 N-m (6.9-1 0.3 kgf.m, 50-75 ftelbf)
tie-rod end.
5BUOMX-008
REAR AXLE
--
M
REAR AXLE
PREPARATION
SST
49 0223 6308 For

removal of
1 49 F027 003 I For 1
Impact slide bearing
hammer
49 UNOl 033 For

removal of
1 49 UNl1 101 I removal
For
Rear axle bearing Adapter of bearing

bearing and seal
remover
49 H025 001 For

installation of
Axle tube bearing
bearing
replacer
OIL SUPPLY PORT

1 ON-VEHICLE MAINTENANCE
Rear Differential Oil
Inspection
1. Remove the oil supply port plug.
MM1028-A
2. The oil level should be the specified distance below the oil
supply port.
OIL SUPPLY PORT
Specification: 6.35--14.28rnm (0.25-4.56 in)
3. If the level is below the necessary amount, add oil of the

specified type.
4. Tighten the oil supply port plug.
I
MM1029-A
(
4BUOMX-061
Tightening torque:
2 1 - 4 0 N-rn(2.1-4.1 kgfm, 15-30 ft.lbf)
M-23
M REAR AXLE
Bearing and Seal
Replacement
1. Remove the rear axle. (Refer to page M-26.)
2. Insert the SSTs.
3. Remove the bearing and seal using the SSTs.
4. Apply clean oil to the new bearing.
5. Install the new bearing using the SST.

6. Apply high temperature grease to the seal.
7. Install a new seal using the SST.
Note
SST numbers: 49 F027 003 Driver Handle
49 H025 001 Axle Tube Bearing Replacer
8. Install the rear axle. (Refer to page M-26.)
Wheel Bearing Play

Inspection
1. Jack up the rear of the vehicle and support it with safety
stands.
2. Make sure there is no abnormal noise and that the wheel
rotates smoothly by hand.
I I
MM1033-A 4BUOMX-063
Adjustment
1. Use a dial indicator to verify that the end play is within
specification.
End play
Minimum: 0.127mm (0.005 in)
MM1034-A
M-24
REAR AXLE
2. If the end play is not within specification, replace the
C-washer as follows:
(1) Drain the differential oil into a suitable container.
(2) Remove the differential cover.
(3) Remove the lockbolt.

(4) On differentials equipped with a 3.08:1, 3.27:l or
3.45:1 ratio axle, remove the pinion shaft and pinion
gears.
(5) On differentials equipped with a 3.73:1 or a 4.10:1
ratio axle, push the pinion shaft until it contacts the
ring gear.
(6) Remove the C-washer.
(7) Insert a new C-washer to bring the end play within
specification.
(8) On differentials equipped with a 3.08:1, 3.27:1 or
3.45:1 ratio axle, install the pinion gears and pinion
shaft.
(9) On differentials equipped with a 3.73:l or a 4.10:1
ratio axle, push the pinion shaft until it aligns with the
lockbolt hole.
(10) Install the lockbolt.
Tightening torque:
2 1 - 4 0 N-m (2.1-4.1 kgf-m, 1 5 - 3 0 ft-lbf)
3. lnstall the metal differential covers as follows:

(1) Clean the old sealant from the differential cover and
axle casing.
(2) Apply a bead of sealant 3.18--4..76mm (0.125-
0.1875 in) wide to the differential cover as shown in
the figure.
(3) lnstall the differential cover within 15 minutes of
applying the sealant.
Tightening torque:
38-52 N-m (3.9-5.2 kgf-m, 28-38 ft-lbf)
4. lnstall the plastic differential covers as follows:

(1) Clean the old sealant from the axle casing
(2) Install a new differential cover and bolts.
Tightening torque:
21-27 N-m (2.1-2.7 kgf.m, 15,-20 ft-lbf)
5. Fill the differential with the specified amount and type

of oil.
REAR AXLE
1. Jack up the rear of the vehicle and support it with safety stands.
2. Remove the wheel and tire assemblies.
3. Drain the differential oil into a suitable container.
METAL COVER BOLTS

3-7 (3.5-4.8, 25-42]
PLASTIC COVER BOLTS
21-27 (2.1-2.7, 15--20)
7.5 INCH AXLE ASSEMBLY SHOWN

(8.8 INCH AXLE ASSEMBLY SIMILAR)
MM1037-C
N m {kgf-m, ft4bf)
5BUOMX-024
J
1. Brake drum 5. Pinion gears
2. Differential cover Removal Note ........................ page M-27
Removal Note ................................ below 6. C-washer
3. Lockbolt 7. Rear axle
4. Pinion shaft
Removal Note
Differential cover
Note
Plastic differential covers must be replaced once
removed from the axle casing.
6BUOMX-015
REAR AXLE M
Pinion shaft
1. On differentials equipped with a 3.08:1, 3.27:1 or 3.45:1
ratio axle, remove the pinion shaft.
2. On differentials equipped with a 3.73:1 or a 4.1 0:1 ratio

axle, push the pinion shaft until it contacts the ring gear.
Pinion gears
Note
The pinion gears may be left in place.
6BUOMX-016
Installation Note
Rear axle
1. Carefully install the rear axle.
2. Slide the splines into the side gear.
Caution
Do not damage the rear axle splines, oil seal or
bearing during installation.
Note
On differentials equipped with a 3.73:l or a 4.10:l
ratio axle, ensure the pinion shaft is contacting the
ring gear prior to installing the rear axle.
4BUOMX-069
1
C-washer
1. Install the C-washer.
2. Pull the rear axle until the axle splines engage and the
C-washer seats in the counterbore of the side gear.
REAR AXLE
Pinion shaft
Push the pinion shaft until it aligns with the lockbolt hole.
4BUOMX 072
Lockbolt
Tightening torque:
2 1 4 0 N.m I 2 . 1 4 . 1 kgf-m, 15-30 ft-lbf}
4BUOMX 073
Differential cover
1. Install the metal differential covers as follows:
(1) Clean the old sealant from the differential cover and
axle casing.
(2) Apply a beadof sealant3.18--4.76mm (0.1 2 M . 1 8 7 5
in} wide to the differential cover as shown in the figure.
(3) Install the differential cover within 15 minutes of
applying sealant.
Tightening torque:
34-47 N - m (3.5-4.8 kgf . m, 25-35 ft - Ibf)
2. Install the plastic differential covers as follows:

(1) Clean the old sealant from the axle casing.
(2) Install a new differential cover and bolts.
MM1036-A 6BUOMX-033
Tightening torque:
21-27 N.m (2.1-2.7 kgf-m, 15-20 ft.lbf)
REAR AXLE CASING M
REAR AXLE CASING
3. Drain the differential oil into a suitable container.
I I
MM1039-B 5BUOMX-010
1. Brake lines and parking brake cable 5. Shock absorber
Removal ................................... Section P Installation Note ..................... page M-31
2. Vent hose 6. U-bolt
Removal Note ........................ page M-30 7. Rear axle casing
Installation Note ..................... page M-32 Removal Note ........................ page M-30
3. Vent Installation Note ..................... page M-31
4. Rear propeller shaft
Removal / Installation ............... Section L
M REAR AXLE CASING
Removal Note
Vent hose
Unscrew the vent hose from the vent.
Rear axle casing

1. Support the rear axle casing using a transmission jack.
2. Remove the brake line from the clip.
I I
MM1042-A
3. Remove the brake line iunction block.
4. Remove the nuts and U-bolts.

5. Carefully lower the rear axle casing.
REAR AXLE CASING M
Installation Note
Rear axle casing
1. Raise the rear axle casing into the vehicle.
2. Install the U-bolts and nuts.
Tightening torque:
88-108 N-m(9.0-1 1.0 kgf-m, 65--80 ftelbf}
4. Install the brake line into the clip.
5. Screw the vent hose into the vent.
4BUOMX-078
Shock absorber
Tightening torque:
54-82 N .m (5.6-8.2 kgf . m, 40-60 ft .Ibf}
6BUOMX-017
M REAR AXLE CASING
Vent hose
Install the brake line junction block.
Tightening torque:
14-20 N-m(1.4-2.7 kgf-m, 10-1 5 ftdbf}

1. Install the wheel and tire assemblies.
Tightening torque:
115-1 55 N.m (15.3-1 5.8 kgf-m, 85-1 15 ft.lbf}
2. Fill the differential with the specified amount and type of oil. (Refer to page M-23.)
3. Bleed the brake lines. (Refer to Section P.)
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL
PREPARATION
SST
For 49 F027 003 For

removal of removal
Companion locknut Driver of inner
flange holder 4 handle and outer
bearing race
49 MOO5 561 For 49 0727 570 For

removal of inspection
Differential differential Pinion height of oil
carrier gear assembly gauge body baffle
hanger
For 49 H033 101 For
Differential
spreader
adapters
removal of
differential
gear assembly
Step plate
adapter set (@ installation
of side
bearings
49 0223 630B For 49 UN11 101 I For

removal removal of
Impact slide of oil seal Adapter oil seals
hammer and needle and needle
bearings bearing
49 UNOI 030 For 49 F401 337A

inspection installation
Dummy of differential Pinion of rear
bear~ngs gear assembly bearing bearing
-
replacer
49 UNOI 032 For 49 UNOI 031 For

removal of installation
Axle bearing needle Differential of side
remover bearing bearing bearings
replacer
49 UNOl 026 For 49 8531 565,567,568

removal of selection of
Differential differential Pinion model, oil slingerl
housing gear assembly Collar A and
spreader Collar B
M FRONT DIFFERENTIAL
49 UN27 001 For 49 UNO1 028 i For

selection of I installation
Gauge oil slingeri Axle bearing , of needle
block and seal I bear~ng
shim installer
49 F401 331 ( For

installatron
Axle bearing1 of rear
seal plate bearing
Front Differential Oil
Inspection
1. Remove the oil supply port plug.
Note
I I
MM1177-A
1 OIL SUPPLY PORT

2. The oil level should be the specified distance below the
oil supply port.
Specification: 6.35-14.28mm (0.25-4.56 in)
3. If the level is below the necessary amount, add oil of the

specified type.
4. Install the oil supply port plug.
Tightening torque:
2 1 - 4 0 N.m ( 2 . 1 4 . 1 kgf-m, 15-30 ft-ibf)
MM1029-A 4BUOMX-083
FRONT DIFFERENTIAL M
Oil Seal
Replacement
e e e
stands.
2. Drain the differential oil.
3. Remove the propeller shaft. (Refer to Section L.)
4. Hold the companion flange using the SST'and remove the
locknut and washer.
Note
SST number: 49 S120710 Companio~i
FlangeHolder
5. Remove the companion flange using Companion Flange

Remover T65L-4851-B, or equivalent.
6. Remove the dust shield.
8. Apply gear lubricant to the oil seal.
9. Install the oil seal as follows:
(1) On Dana 35 axles, install the oil seal using Pinion Oil
(2) On Dana 28 axles, install the oil seal using Pinion Oil
Seal Replacer T71T-3010-R, or equivalent.
Note
Make sure the spring does not pop out of the seal.
Replace the seal if the spring pops out.
10. Install the dust shield onto the companion flange as

follows:
(1) On Dana 35 axles, install the companion flange
using Companion Flange Replacer T85T-4851-AH, or
equivalent.
(2) On Dana 28 axles, install the co~npanionflange
using Companion Flange Replacer 183T-4851-A, or
equivalent.
Tightening torque:
271 N.m (27.6 kgf-m, 200 ft.lbf}
11. Check the rotational torque of the drive pinion.
Rotational torque:
1.7-2.8 N.m (17.4-28.5 kgf-cm, 15-25 in-lbf)
Note
If rotational torque exceeds 2.8 N.rn (28.5 kgf.cm,
25 in.lbf} the collapsible spacer must be replaced.
12. If rotational torque is not within specification tighten the

locknut until it is within specification.
Caution
Never tighten the locknut more than 474 N.m
(48.3 kgf-m, 350 ft-lbf}, or the collapsible spacer
will need to be replaced.
13. Fill the differential with the specified amount and type of
oil.
4BUOMX-084
REMOVAL
1. Jack up the front of the vehicle and support it with safety stands.
4. Remove the knuckles. (Refer to page M-11.)
5. Remove the front axle drive shafts. (Refer to page M-14.)
DANA 35
I 1
MM1045-8 4BUOMX-085
1. Differential gear assembly 4. Stub shaft
Removal Note ........................ page M-37 5. Right oil seal
Disassembly ........................... page M-39 Removal Note ........................ page M-38
Inspection ............................... page M-43 6. Left oil seal
Assembly ................................ page M-44 Removal Note ........................ page M-38
2. Left front axle casing 7. Needle bearing
3. Snap ring Removal Note ........................ page M-38
Removal
e Note
e
Differential
ee gear
e assembly
e
1. Mount the differential gear assembly on the SSTs.
Note
SST numbers:
49 UNO1 027 Differential Spreader Adapters
49 MOO5 561 Differential Carrier Hanger
2. Clean and inspect the internal working parts for wear and
damage.
3. Rotate the gears, checking for any roughness or grinding.
DAMAGED
4. Check the ring gear teeth for scoring, abnormal wear,
nicks or chips.
SCORED
MM1047-A
7 75. Measure the backlash using a dial indicator.
Backlash: 0.1 3--0.20mm (0.005--0.008 in)
MM1048-B 4BUOMX-086
Snap ring
1. Rotate the stub shaft until the open end of the snap ring is
visible.
Right oil seal
e
1. On Dana 28 axles, remove the oil seal and the needle
bearing together using the SST and a suitable seal
remover.
Note
SST number: 49 0223 6308 Impact Slide Hammer
2. On Dana35 axles, remove the oil seal using the SSTs and
Seal Puller TOOL-1 175-AC, or equivalent.
Left oil seal

Remove the oil seal using the SSTs and Axle Bearing
Puller T90T-1225-A, or equivalent.
Needle bearing
1. On Dana 28 axles, the needle bearing should be removed
while removing the oil seal.
2. On Dana 35 axles, remove the needle bearing using the
SSTs.
DISASSEMBLY
COLLAPSIBLE
REPLACE
I I
MM1054-C 4BUOMX-091
1. Differential casing 12. Oil baffle

Disassembly Note .................. page M-40 Disassembly Note .................. page M-42
2. Bearing caps 13. Bearing outer race
Disassembly Note .................. page M-40 Disassembly Note .................. page M-42
3. Differential gear assembly 14. Side bearing
Disassembly Note ................. page M-40 Disassembly Note .................. page M-42
4. Bearing cup 15. Gear case
Disassembly Note .................. page M-40 16. Shims
5. Companion flange Disassembly Note .................. page M-42
Disassembly Note .................. page M-41 17. Ring gear
6. Drive pinion, oil slingerl 18. Pinion shaft
selective shim and inner bearing Disassembly Note .................. page M-42
Disassembly Note .................. page M-41 19. Pinion gear and thrust washer
7. Oil seal Disassembly Note .................. page M-43
Disassembly Note .................. page M-41 20. Side gear and thrust washer
8. Oil slinger 21. Drive pinion
9. Front bearing 22. Rear bearing
10. Collapsible spacer Disassembly Note .................. page M-43
11. Bearing inner race 23. Oil slinger/selective shim
Disassembly Note .................. page M-41
Disassembly Note
Differential casing
1. Mount the differential casing on the SST.
2. Install the SST.

/ 3. Attach a dial indicator to the SST.
4. Spread the differential casing.
Note
Do not spread the differential casing over 0.25mm
(0.010 in}.
MM1056-B 5BUOMX-026
Bearing caps
Make a note of the matching letters on the bearing caps
and on the differential casing.
I I
MM1057-A 4BUOMX-093
Differential gear assembly
1. Remove the differential gear assembly.
Caution
Do not damage the machined surfaces.
Note
It may be necessary to pry the differential gear
assembly out of the casing.
2. Remove the SST

Note
SST number: 49 UNO1 026 Differential Housing
Spreader
4BUOMX-094
Bearing cup
Note
Tag the bearing cup locations for installation.
4BUOMX-095
Companion flange
1. Hold the companion flange with the SST and remove the
locknut and washer.
Note
SST number: 49 S120 710 Conipanion Flange
Holder
2. Remove the companion flange using Companion Flange

Remover T77F-4220-B1, or equivalent.
3. Remove the dust shield.
5BUOMX-026
Drive pinion, oil slingerlselective shim and inner

bearing
Remove the drive pinion, oil slinger/selective shim and
inner bearing using a plastic hammer.
Warning
Use care when handling the drive pinion, as the
gear teeth may be sharp.
Caution
Catch the drive pinion to prevent damage to the
teeth.
4BUOMX-097
Oil seal
Remove the oil seal using the SSTs and Seal Remover
TOOL-1175-AC, or equivalent.
MM1058-B 4BUOMX-098
7 7Bearing inner race
~ e m o v ethe bearing inner race using the SST and Pin-
ion Bearing Cup Remover T86T-4628-AH, or equivalent.
Insert the tools from the front of the differential casing, as
T86T-4628-AH
Oil baffle
Remove and replace the oil baffle with an oil baffleof equal
thickness. If an equal thickness baffle is not available, use
selective shims to compensate for the difference.
4BUOMX-100
Bearing outer race

Remove the bearing outer race using the SST and Pin-
DRIVER HANDLE ion Bearing Cup Remover T86T-4628-BH, or equivalent.
Insert the tools from the rear of the differential casing,
as shown in the figure.
PINION BEARING
CUP REMOVER
T86T-4628-BH
~BUOMX-021
Side bearing
1. Remove the side bearings using a press and Bearing
Pulling Attachment D84L-1123-A, or equivalent.
2. Match the side bearing with the bearing cup removed from
the same side.
Note
It is recommended that the side bearings be re-
placed.
4BUOMX- 102
Shims
Remove and tag the shims for location during installation.
Note
Inspect for bent shims or deep grooves.
The shims will be reused during assembly unless
they are damaged. Replace any damaged shims.
4BUOMX-103
Pinion shaft
1. Drive the lockpin out of the gear case.
2. Drive the pinion shaft out of the gear case.
Pinion gear and thrust washer

Rotate the pinion gears and thrust washers to the gear
case opening and remove them.
I I
MM1064-A 4BUOMX-105
Rear bearing
Remove the rear bearing using a press and Bearing
Pulling Attachment D84L-,1123-A,or equivalent.
Note
Be careful not to damage the oil slingerlselective
shim while removing the rear bearing.
4BUOMX-106
1 INSPECTION
Inspect for the following problems, and replace any faulty
~arts:
(1) Poor meshing, wear, and damage of the ring gear or
drive pinion
(2) Seizure, wear, rough rotation and abnormal noise of
the bearings
(3) Wear and damage of the side gears, pinion gears, or
pinion shaft
(4) cracked or worn differential casing; wear at the con-
tact point of the bearing
MM 1066-A ~BUOMX-107 (5) Cracked gear case; worn sliding parts
(6) Damage or worn contact surface of the oil seals
ASSEMBLY
1. Measure the differential end play, referring to Total Differential Gear Assembly End Play. (Refer to
page M-45.)
2. Measure the selective shim thickness, referring to Oil SlingeriSelectiveShim Thickness Check. (Refer
to page M-46.)
"
LOCKPIN,
NEW
1. Oil baffle 12. Side gears and thrust washers
Assembly Note ....................... page M-49 13. Pinion gears and thrust washers
2. Bearing inner race Assembly Note ....................... page M-51
Assembly Note ....................... page M-49 14. Pinion shaft
3. Bearing outer race Assembly Note ........................ page M-51
Assembly Note ....................... page M-49 15. Gear case
4. Oil slinger/selective shim 16. Ring gear
Assembly Note ....................... page M-50 Assembly Note ....................... page M-52
5. Rear bearing 17. Differential gear assembly
6. Drive pinion 18. Shims
7. Collapsible spacer 19. Side bearings
8. Front bearing 20. Bearing cup
9. Oil slinger 21. Differential casing
10. Oil seal Assembly Note ....................... page M-54
Assembly Note ....................... page M-50 22. Bearing cap
11. Companion flange Assembly Note ....................... page M-55
Assembly Note ....................... page M-51
DUMMY BEARINGS ~ 8 6 ~ - 4 2 2(DANA

2 - ~ ~28) Total Differential Gear Assembly End Play
OR ORIGINAL BEARING 1. Clean the gear case.
2. Install the SSTs (Dana 35) or Dummy Bearings T86T-
4222-AH, or the original bearing (Dana 28) on the gear
case.
3. Install the gear case into the differential casing.
4. Mount the dial indicator on the differential casing.

5. Press the gear case as far as it will go toward the dial
indicator and zero the dial indicator.
6. Press the gear case as far as it will go away from the dial
indicator.
7. Repeat this procedure until the same reading is obtained.
Record the measurement (A) to be used to calculate ring
gear backlash and differential bearing preload shims.
8. Remove the gear case.
Oil Slinger/Selective Shim Thickness Check
Note
On the end of the drive pinion is a plus (+) figure, a
minus (-) figure or a zero (0). This figure indicates
the position of each gear set. The position is deter-
mined by the thickness of the oil baffle between the
bearing inner cup and the casing bearing bore and
the thickness of the oil slingerlselective shim be-
tween the pinion gear and inner bearing. Pinion
depth change is made by changing the thickness of
the oil slinger/selective shim. Refer to the charts
below.
New Pinion Marking (Metric)
Old Pinion
+10
~
-8 -5 -3 0
J +3
+.08
+5
----
+.05
I +8
+.03
+10
0 --
~
.-
+8
- -
+.lo +.08 t.05 -~
+.03 1
-..L
0 -.
-.03
.
+5 +.08 + .05
-~ -
+.03
- -
.
0 -.03 -.05
--
+.I0 +.08 +.05 +.03 0 -.03 -.05
0 +.08 +.05 1 +.03 0 -.03 -.05 -.08 -
-.lo
-- -+- --
-.05 --
- .08
-
-.I 0 -.I3 --- -
----t
-5 -- +.05 0 1 -.03 -.05 -.08 -.lo -.I3 -.I5
--
-' - -- - -- .
- ---
-10 t
+.03
o 1
0
-.03 1
-.03
-.05 1 -.05
-08
1 -.08
-.lo
' -.lo
-.I3 1
-.I3
-.I5 1
-.I5
-.I8 1
-.I8
-.20
New Pinion Marking (English)

~- -- -.- - 7---.
Old Pinion
Marking -1 0 +1 +4
--- ----
+4 -- --
+3 +0.007 + +0.006 +0.005
~
+2 +0.006 +0.005 +0.004 +0.003 +0.002
~p
+0.001
-
0
+1 +.0.005
--
+0.004 1 +0.003 , +0.002 +0.001 0 -0.001
1
-~ -Up- -
-
7
0 +0.004 +0.003 +0.002 +0.001 ' 0 -0.001 -0.002

--- -. +--
-1 ' +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003
7- --
- I - -
-
-2 +0.002 +0.001 0 -0.001 , -0.002 j -0.003 -
1 -0.004 -0.005 -0.006
7---
-3
---
' +0.001 0 -0.001 -0.002 -0.003 j -0.004 - O F - ] -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
MM1071-8 SBUOMX-011
Dana 35
I . Install the oil baffle in the bearing inner race bore of the
differential casing.
INNER BEARING OUTER BEARING
2. Install the bearing inner race and the bearing outer race
CUP REPLACER CUP REPLACER using Draw Bar T75T-1176-A, Inner Bearing Cup Re-
T60K-4616-A T71P-4616-A placer T60K-4616-A and Outer Bearing Cup Replacer
T71 P-4616-A, or equivalents.
RACE OIL RACE DRAW BAR

BAFFLE T75T-1176-A
4. lnstall the SST (49 8531 568) and O-ring to the SST
(49 8531 565) and install them into the differential casing.
5. Install the SST (49 8531 567), yoke and washer.
6. Tighten the nut on the SST (49 8531 565) making sure the
yoke can still be turned by hand.
7. Install the SST (49 UN27 001) onto the SST (49 8531
565).
8. Place the SST on a surface plate and set the dial indicator
to zero.
9. Place the SST (49 0727 570) on top of the SST.
Note
SST number: 49 UN27 001 Gauge Block
10. Place the pointer of the dial indicator so that it contacts
where the side bearing is installed in the casing. Measure
the lowest position on the left and right sides of the casing.
11. Add the right and left side measurements and divide by
two to get the thickness dimension.
Specification: Omm (0 in)
12. If not within specification, adjust the pinion height by

selecting an oil slinger/selective shim which will bring the
reading within specification.
Note
If the drive pinion is marked with a plus (+) reading,
this amount must be subtracted from the thickness
dimension.
If the drive pinion is marked with a minus (-) read-
ing, this amount must be added to the thickness
dimension.
The rear bearing must be the exact same as the one
used in the previous steps.
13. Measure the oil slingerlselective shim with a micrometer

to verify the oil slingerlselective shim thickness.
INNER BEARING OUTER BEARING Dana 28

CUP REPLACER CUP REPLACER I . Install the oil baffle in the bearing inner race bore of the
T60K-4616-A T71 P-4616-A differential casing.
2. Install the bearing inner race and the bearing outer race
using Draw Bar T75T-1176-A, Inner Bearing Cup Re-
placer T60K-4616-A and Outer Bearing Cup Replacer
T71 P-4616-A, or equivalents.
BEARING
INNER
RACE
'/
OIL
BEARING
OUTER
RACE
I
"IA-
DRAW BAR
BAFFLE T75T-1176-A
FRONT DIFFERENTIAL
3. Install the rear bearing onto Aligning Adapter T76P-4020-
A1 , or equivalent.
GAUGE TUBE 4. Install the front bearing into the case bore and insert
l76P-4020-A7
Screw T76P-4020-A9,or equivalent. Attach Handle T76P-
4020-A1 1, or equivalent onto the screw.
GAUGE BLOCK
Note
T76P-4020-A10 The square drive in the handle is for obtaining the
proper bearing preload.
m
'V GAUGE DISC
T83T-4020-F57 5. InstallGauge DiscT83T-4020- F57, or equivalent onto the
u
handleJscrew assembly.
i--
6. Install Gauge Block T76P-4020-A10, or equivalent after
ALIGNING ADAPTER the gauge disc.
T76P-4020-A1
7. lnstall Gauge Tube T76P-4020-A7, or equivalent.
8. lnstall the bearing caps.
SCREW
T76P-4020-A9
\4aooooP Tightening torque:
@E
J
41-61 N . m (4.2-6.2 kgf . m, 3 0 - 4 5 ft .lbf)
9. Preload the bearing by tightening the handle.
T76P-4020-All
Tightening torque:
1.7-3.9 N m {I7.4-40.4 kgf .cm, 15-35 in Ibf)
rrrl cn -11 I ~ C GAUGE TUBE 10. Insert the thickest feeler gauge possible between the
gauge block and gauge tube.
Note
There should be drag on the feeler gauge when it is
inserted between the gauge block and gauge tube.
GAUGE BLOCK
T76P-4020-A10
1 1. This measurement is the thickness needed for the selec-

tive shim if there was no marking on the drive pinion. If the
drive pinion is marked with a plus (+) reading, the amount
marked should be subtracted from the feeler gauge mea-
surement. If the drive pinion is marked with a minus (-)
reading,the amount marked should be added to the feeler
gauge measurement.
Note
The same size rear bearing must be used during
assembly.
Assembly Note
Oil baffle, bearing outer race and bearing inner race
Note
The oil baffle, bearing outer race and bearing inner
race were installed during the oil slinger/selective
shim thickness check.
4BUOMX-I 13
Oil slinger/selective shim, drive pinion and rear
bearing
I . Install the oil slingerJselective shim on the drive pinion.
2. On Dana 35 axles, install the rear bearing using a press
and the SSTs.
3. On Dana 28 axles, install the rear bearing using a press,
the SST and Pinion Bearing Replacer T57L-4621-9, or
equivalent.
PINION BEARING
REPLACER
T57L-4621-B
Collapsible spacer
Caution
Never reuse a collapsible spacer. It must be
replaced when it is removed.
4BUOMX-115
I PINION OIL I Oil seal

1 . Apply gear lubricant to the oil seal.
2. On Dana 35 axles, install the oil seal using Pinion Oil Seal
3. On Dana 28 axles, install the oil seal using Pinion Oil Seal
Replacer T90T-4676-A, or equivalent.
Note
Make sure the spring does not pop out of the seal.
Replace the seal if the spring pops out.
Companion flange
1. Install the dust shield onto the companion flange.
2. On Dana 35 axles, install the companion flange using
Companion Flange Replacer T85T-4854 -AH, or equiva-
lent.
3. On Dana 28 axles, install the companion flange using
Companion Flange Replacer T83T-4851-A, or equiva-
lent.
Tightening torque:
271 N . m (27.6 kgf .m, 200 ft Ibf}
MM1077-A 6BUOMX-024
4. Check the rotational torque of the drive pinion.
Rotational torque:
1.7-2.8 N.m (17.4-28.5 kgf.cm, 15-25 in.lbf)
Note
If rotational torque exceeds 2.8 N-rn(28.5 kgf-cm,
25 in-lbf) the collapsible spacer must be replaced.
5. If rotational torque is not within specification, tighten the

locknut until it is within specification.
Caution
Never tighten the locknut more than 474 N.m
(48.3 kgf-m,350 ft-lbf),or the collapsible spacer will
need to be replaced.
Pinion gears and thrust washers

1. Hold the side gears with one hand and install the pinion
gears and thrust washers.
2. Rotate the side gears and pinion gears until the holes in
the pinion gears align with the hole for the pinion shaft.
Pinion shaft
1. Drive the pinion shaft into the gear case until the lockpin
hole in the pinion shaft aligns with the hole in the gear
case.
2. Drive the new lockpin into the gear case. After installing
the new lockpin, make a crimp so that it cannot come out
of the gear case.
4BUOMX-I 19
Ring gear
Tightening
e torque:
95-1 22 N - m (9.7-1 2.4 kgf .m, 70-90 ft . Ibf)
Differential gear assembly and shims

1. Install the differential gear assembly into the differential
casing with the SSTs (Dana 35) or Dummy Bearings
T83T-4222-A, or equivalent or the original bearing (Dana
28) still attached.
MM1068-B
2. Mount a dial indicator on the differential casing.
3. Press the gear case as far as it will go toward the dial
indicator and zero the dial indicator.
4. Force the ring gear against the pinion gear, rocking the
ring gear to make sure the teeth are in contact.
5. Press the gear case as far as it will go away from the dial
indicator.
6. Repeat this procedure until the same reading is obtained.
Record the measurement (B).
7. Subtract measurement B (above) from measurement A
(Total differential gear assembly end play, refer to page
~~1069-A ~BUOMX-025 M-45.) to calculate the clearance opposite the ring gear.
This is measurement C.
8. Remove the differential gear assembly from the differen-
tial casing.
9. Assemble the ring gear side shim pack by subtracting
0.13 mm (0.005 in} from measurement B.
10. Assemble the shim pack for the opposite side of the ring
gear by adding 0.25mm {.OlO in) to measurement C.
Note
On Dana 28 axles, the shims will be installed on
the gear case prior to installing the side bearings.
On Dana 35 axles, the shims will be installed into
the differential casing prior to installing the gear
case into the differential casing.
Dana 35 axles use outboard selective spacers.
Side bearings
1. On Dana 28 axies, install the side bearings as follows:
(1) Install the required amount of shims and the side
bearings onto the opposite side of the ring gear.
(2) Install the side bearings using a press, the SSTs and
DIFFERENTIAL
BEARING Differential Side Bearing Replacer T85M-4221-A, or
REPLACER equivalent.
T85M-4221-
(3) Install the required amount of shims and the side
bearings onto the ring gear side.
I I
MM1078-C
PRESS' (4) Install the side bearings on the ring gear side using a
press and Differential Side Bearing Replacer T85M-
4221-A, or equivalent and the SST. Place the SST on
DIFFERENTIAL the ring gear side to prevent damage.
T85M-4221-A
NOT SHOWN
2. On Dana 35 axles, install the side bearings as follows:
(1) Install the side bearings using the SSTs.
(2) Install the side bearings on the ring gear side using
the SSTs.
Differential casing
1. Install the SST.
2. Attach dial indicator to the SST.
3. Spread the differential casing.
Note
Do not spread the differential casing over 0.25mm
(0.010 in}.
FRONT DIFFERENTIAL
4. Install the differential gear assembly into the differential
casing.
Note
If necessary, use a plastic hammer to install the
differential gear assembly into the differential cas-
ing.
Do not nick the teeth on the ring gear or the pinion
gear.
Bearing cap
1. Install the bearing caps, referring to the location note
made during disassembly.
Tightening torques:
Dana 28: 41- 6 1 N - m (4.2-6.2 kgf m, 3 0 - 4 5 ft .Ibf}
Dana 35: 64--91 N .m (6.5-9.2 kgf .m, 47-67 ft . Ibf}
- ~..-
2. Check the ring gear and pinion backlash at three spots on

the ring gear.
Standard backlash:
0.13-0.20mm (0.005-0.008 in)
Note
The backlash readings should not vary by mor
than 0.08mm (0.003 in).
If the backlash is high, move shims to th ring gear
side from the opposite of the ring gear side to move
the ring gear toward the drive pinion.
If backlash is low, move shims to the opposite side
of the ring gear from the ring gear side to move the
ring gear away from the drive pinion.
3. The inspection and adjustment procedure is as follows:
GOOD CONTACT (1) Coat both surfaces of 6-8 teeth of the ring gear uni-
formly with a thin coat of red lead.
(2) While moving the ring gear back and forth by hand,
rotate the drive pinion several times and check the
tooth contact.
(3) If the tooth contact is correct, wipe off the coating of red
lead.
(4) If it is not correct, adjust the pinion height and then the
backlash.
I I
MM1080-A
, Toe-and-flank contact
(5)
*
I TOECONTACT FUNK CONTACT I Replace tht? oil slinger/selective shim with a thinner
one, and move the drive pinion outward.
c MMlO81-A
(6) Heel-and-face contact
Replace the oil slinger/selective shim with a thicker
HEEL CONTACT FACE CONTACT
one, and bring the drive pinion in closer.
INSTALLATION
Install in the order shown in the figure, referring to lnstallation Note.
DANA 35
54-67 (5.5--6.9,40--50)
1U.m {kgf-m, f t s l b f )
MM1083-B 4BUOMX-125
1. Needle bearing 5. Snap ring
Installation Note ............................. below Installation Note ..................... page M-58
2. Left oil seal 6. Left front axle casing
Installation Note ..................... page M-58 7. Differential gear assembly
3. Right oil seal Installation Note ..................... page M-58
4. Stub shaft
lnstallation Note
Needle bearing
1. On Dana 28 axles, install the needle bearing using the
NEEDLE BEARING SST and Needle Bearing Replacer T83T-1244-A, or
REPLACER equivalent.
T83T-1244-A
BEARING
MM1084-A
FRONT DIFFERENTIAL
1 2. On Dana 35 axles, install the needle bearing using the

SSTS.
Left and right oil seal

1. Apply high temperature grease to the oil seal.
2. On Dana 28 axles, install the left oil seal using the SST and
Needle Bearing Replacer T83T-1244-A, or equivalent.
3. On Dana 35 axles, install the oil seal using the SST and
Axle Seal Replacer T87P-3254-A, or equivalent.
Snap ring
Install the snap ring using a screwdriver.
Caution
Do not tap on the center of the snap ring, it may
damage the snap ring.
Differential gear assembly

1.Clean all of the sealant from the differential gear
assembly.
2. Apply a continuous bead of sealant to the differential gear
assembly 6.35-9.53mm (0.25-4.374 in) wide.
Note
The sealant should not pass through or outside the
bolt holes.
Install the differential gear assembly within five
minutes of applying the sealant.
4. Raise the differential into position and hand tighten the
bolts.
5.Tighten the bolts in a clockwise or counterclockwise
pattern.
Tightening torque:
5 4 - 4 7 N.m (5.5-6.9 kgf-m,40-50 ft-lbf)
6. Tighten the through bolt.
Tightening torque:
102-1 28 N-m110.4-13.1 kgfam, 75-95 ftslbf)
4BUOMX-129

1. Install the front axle drive shafts. (Refer to page M-14.)
2. Install the knuckles. (Refer to page M-11.)
3.Install the front propeller shaft. (Refer to Section L.)
4. Install the wheel and tire assemblies.
Tightening torque:
135 N-m (13.8 kgf,m, 100 ft-lbf)
6. Fill the differential with the specified amount and type of oil. (Refer to page M-34.)
M REAR DIFFERENTIAL
REAR DIFFERENTIAL
PREPARATION
SST
For 49 UN27 004 For

removal selection of
Companion of locknut Collar B oil slingsr I
flange holder selective shim
49 8531 565 For For

selection of installation
oil slingerl Pln~onseal of oil seal
Plnlon selective replacer
model shim
49 UN27 001 For 49 0727 570 For

selection of selection of
Gauge oil slingerl Pinion height oil slingerl
block selective gauge body selective
shim shim
49 UNOl 036 For For

installation installation
Pinion bearing of rear Driver of oil seal
cone replacer bearing handle
For 49 UNOl 034 For

installation installation
of races Shim of shims
driver
49 UN27 003 For For

selection of selection of
Collar A oil slinger 1 Gauge oil slingerl
selective shim block selective
shim
-
REAR DIFFERENTIAL
- - -- -- pp
M
STANDARD
Removal
Note
Removal of the differential assembly can be performed with the axle casing still in the vehicle.
2. Drain the differential axle oil into a suitable container.
4. Check and record ring gear runout, referring to Ring Gear Runout Test. (Refer to page M-62).
5. Check and record ring gear backlash, referring to Ring Gear Backlash Check. (Refer to page M-62).

I
MM1125-8 4BUOMX-I 32
1. Cover 5. Differential gear assembly
2. Brake drum Removal Note . . . . . . . . . . . page M-63
3. Rear axle Disassembly . . . . . . . . . . . . . . page M-64
Removal Note . . . . . . . . . . . page M-26 6. Bearing cup
4. Bearing cap 7. Shim
Removal Note . . . . . . . . . . . page M-62
M REAR DIFFERENTIAL
Ring Gear Runout Test
1. Mount a dial indicator on the rear axle casing so the tip of
the dial indicator contacts the back face of the ring gear.
Note
There is a space provided between the speed sen-
sor ring and the ring gear for measuring ring gear
runout.
2. Zero the dial indicator.

3. Rotate the ring gear and record the reading.
MM1164-B 6BUOMX-029
Runout
Standard: 0.076mm (0.003 in)
Maximum: 0.1 02mm (0.004 in)
4. If the runout exceeds the maximum, check for improper

torque of the ring gear bolts or dirt between the ring gear
and the case.
5. If, after checking for improper torque or dirt, the runout still
exceeds the maximum, the cause may be a warped ring
gear, worn differential bearings, or a warped differential
casing.
Ring Gear Backlash Check

Mount adial indicator on the axle casing and measure the
ring gear backlash.
Backlash
Preferred: 0.30--0.38mm (0.01 2-4.01 5 in}
Standard: 0.20-0.38mm (0.008--0.015 in)
Removal Note
Bearing cap
1. Make reference marks on the bearing caps and axle
housingto make sure the caps are installed in their original
positions.
2. Loosen the bearing cap bolts.
REAR DIFFERENTIAL M
Note
The bearing
e caps must be
e installed1in their original
positions.
U
I
WM1127-A
Differential Gear Assembly
1 . Pry the differential gear assembly, bearing cups, and
shims out until they are loose in the bearing caps.
2. Remove the bearing caps.
M REAR DIFFERENTIAL
Disassembly IInspection

~M 1 1 3 0 4 5BUOMX-014
1. Ring gear 9. Oil seal
Disassembly Note .......................... below Disassembly Note .................. page M-67
2. Speed sensor ring 10. Oil stinger
Disassembly Note .................. page M-65 11 . Front bearing
3. Side bearings 12. Collapsible spacer
Disassembly Note .................. page M-65 13. Drive pinion
4. Pinion shaft Disassembly Note .................. page M-67
Disassembly Note .................. page M-65 14. Rear bearing
5. Pinion gears and thrust washers Disassembly Note .................. page M-67
Disassembly Note .................. page M-65 15. Oil slinger/selective shim
6. Side gears and thrust washers Disassembly Note .................. page M-67
Disassembly Note .................. page M-65 16. Bearing inner race
7. Locknut Disassembly Note .................. page M-67
Disassembly Note .................. page M-66 17. Bearing outer race
8. Companion flange Disassembly Note .................. page M-67
Disassembly Note .................. page M-66 18. Gear case
Disassembly Note
Ring gear
1. Remove the ring gear bolts.
2. Remove the ring gear by striking at alternate holes around
the gear.
REAR DIFFERENTIAL M
Speed
ee sensor ring
Note
Only remove the speed sensor ring if replacement
is required. It does not have to be removed for ring
gear replacement.
Remove the speed sensor ring by tapping it with a soft-

faced hammer.
Note
The speed sensor ring must be discarded upon
removal. If removed, a new speed sensor ring must
be installed.
I I
MM 1132-A 4BUOMX-138
Side bearing
BEARING REMOVER Remove the side bearing using Differential Side Bearing
T70P-4221-A OR Remover T70P-4221-A or T57L-42204, or equivalents.
T57L-4220-A
--
I I
MM1133-A 4BUOMX-139
Pinion shaft, pinion gears and thrust washers, side
gears and thrust washers
Note
On differentials equipped with a 3.08:1,3.27:l or
3.45:1 ratio axle, the pinion shaft will be removed
during rear axle drive shaft removal.
On differentials equipped with a 3.73:1 or a 4.10:1
ratio axle, push the pinion shaft until it contacts the
ring gear.
1. Remove the pinion shaft with a brass drift.

2. Rotate the pinion gears until they turn to the case win-
dows.
3. Remove the pinion gears and thrust washers.
4. Remove the side gears and thrust washers.
~BUOMX-140
M REAR DIFFERENTIAL
Locknut
1. Check the rotational torque of the drive pinion. Record the
rotational torque to be used during assembly.
2. Mark the companion flange in relation to the drive pinion.
3. Hold the companion flange with the SST and remove the
locknut.
Companion flange
Remove the companion flange using a suitable puller.
REAR DIFFERENTIAL M
e
Oil seal
1. Pry up on the metal flange of the oil seal.
2. Install locking pliersand strike with a hammer until the seal
is removed.
Drive pinion
With a soft-faced hammer, drive the drive pinion out of the
front bearing and remove it through the rear of the axle
casing.
4BUOMX-144
Rear bearing
Remove the rear bearing using Pinior~Bearing Cone
Remover T71 P-4621-B, or equivalent.
CONE REMOVER
T71 P-4621 -B
I
MM1138-B 4BUOMX-145
Oil slinger/selective shim
~ e a s u r eand record the oil slingerlselective shim thick-
ness with a micrometer.
4BUOMX-146
Bearing races, inner and outer

Remove the bearing races using a brass drift.
4BUOMX-147
M REAR DIFFERENTIAL
Assembly
9 5 1 15 (9.7-1 1.7, 7 0 4 5 )
NEW

rn
N.m (kgf.m, ft.lbf)
I
5BUOMX-015
1. Bearing inner race 11. Locknut
Assembly Note ............................... below Assembly Note ....................... page M-72
2. Bearing outer race 12. Side gears and thrust washers
Assembly Note. .............................. below Assembly Note ....................... page M-72
3. Oil slinger/selective shim 13. Pinion gears and thrust washers
Assembly Note. ...................... page M-69 Assembly Note ....................... page M-72
4. Rear bearing 14. Pinion shaft
5. Collapsible spacer 15. Side bearings
6. Front bearing Assembly Note ....................... page M-73
7. Oil slinger 16. Speed sensor ring
8. Oil seal Assembly Note ....................... page M-73
Assembly Note ....................... page M-70 17. Ring gear
9. Drive pinion Assembly Note ....................... page M-73
Assembly Note ....................... page M-71 18. Gear case
10. Companion flange
Assembly Note
Bearing races, inner and outer
Install new bearing races using the SST.
Note
If a 0.038mm (0.0015 in) feeler gauge can be in-
serted between a bearing race and the bottom of its
bore at any point around the bearing race, the race
is not properly seated.
REAR DIFFERENTIAL M
Oil slinger/selective shim
Select a new oil slinger/selectiveshim using Pinion Depth
Gauge Set T79P- 4020-A, or equivalent as follows:
(1) Installthe original oil slinger and rear bearing onto the
SST.
(2) Install the SST (49 UN27 004), and O-ring to the SST
(49 8531 565) and install them into the rear axle
casing.
(3) Install the SST (49 UN27 003), yoke and washer.
(4) Tighten the nut on the SST (49 8531 565) making
sure the yoke can still be turned by hand.
(5) Install the SSTs (49 UN27 001 and 002) onto the
SST (49 8531 565).
(6) Place the SST on a surface plate and set the dial
indicator to zero.
(7) Place the SST (49 0727 570) on top of the SST
(49 UN27 001).
(8) Place the pointer of the dial indicator so that it

contacts where the side bearing is installed in the
housing. Measure the lowest position on the left and
right sides of the casing.
(9) Add the right and left side measurements and divide
by two to get the thickness dimension.
Specification: Omm (0 in)

M REAR DIFFERENTIAL
(10) If not within specification, adjust the pinion height by
selecting a shim which will bring the reading within
specification.
Note
If the drive pinion is marked with a plus (+) reading,
this amount must be subtracted from the thickness
dimension.
If the drive pinion is marked with a minus (-) read-
ing, this amount must be added to the thickness
dimension.
The rear bearing must be the exact same as the one
used in the previous steps.
(11) Measure the oil slingerlselective shim with a mi-

crometer to verify the oil slinger/selective shim thick-
ness.
Rear bearing
1. Place the selected oil slingerlselective shim on the drive
pinion.
2. Press on the rear bearing using the SST.
Note
The same rear bearing used in this procedure must
be used in final assembly of the axle.
Be sure that the press load is not applied to the
bearing cage.
Oil seal
1. Install the oil seal onto Drive Pinion Oil Seal Replacer
T79P-4676-A, or equivalent (7.5 in ring gear) or SSTs
(8.8 in ring gear).
2. Clean the oil seal surface.
(8.8 INCH)
3. Install the seal in the casing bore using Drive Pinion Oil
Seal Replacer T79P-4676-A, or equivalent (7.5 in ring
gear) or SSTs (8.8 in ring gear).
4. Coat the lip of the seal with grease.
Caution
Installation without the proper tool may result in
early seal failure. If the seal becomes cocked dur-
ing installation, remove it and install a new one.
OIL SEAL
REPLACER (8.8 INCH)
T79P-4676-A (7.5 INCH)
REAR DIFFERENTIAL
Drive pinion
1. Place a new collapsible spacer onto the drive pinion.
MM1147-A
2. From the rear of the axle casing, install the drive pinion into
the axle casing.
I I
MM1148-A 4BUOMX-153
Companion flange
1.Apply a small amount of lubricant to the drive pinion
splines.
2. Align the mark on the companion flange with the mark on
the drive pinion.
Note
If a new companion flange is beirig installed, dis-
regard the scribe mark on the drive pinion.
3. With the drive pinion in place in the axle casing, install the
companion flange using Companion Flange Replacer
TOOL-4858-E, or equivalent.
Note
The companion flange must never be hammered on
or installed with power tools.
4BUOMX-154
M REAR DIFFERENTIAL
Locknut
1. Start a new locknut.
2. Hold the companion flange using the SST and tighten the
locknut.
Tightening torque:
230 N-m(23.4 kgf-m, 170 ft-lbf)
3. Rotate the pinion gear occasionally to make sure the

bearing is properly seated.
MM1135-A
4. Take frequent rotational torque readings until the reading
obtained during removal is matched.
5. If the original recorded rotational torque is lower than the
specification, tighten to the specification. If the rotational
torque is higher than the specification, tighten to the
original reading.
Specification
Used bearings: 0.9-1.5 N-m(9.2-15.3 kgf-cm,
8-14 inelbf)
New bearings: 1.8-3.3 N.m (18.4-33.6 kgf-cm,
MM1149-A 4BUOMX-155 16-29 in.lbf)
Caution
Under no circumstances should the locknut be
backed off to reduce rotational torque. If rotational
torque reduction is required, a new collapsible
spacer and locknut must be installed.
Pinion gears, thrust washers, side gears and thrust

washers
Note
Always replace gears as a complete set. Do not mix
new gears with old gears, as this may cause uneven
wear and short gear life.
1. Apply differential oil to the thrust washers, hub and thrust

face of the side gears.
2. Apply differential oil to the pinion gears and thrust wash-
ers.
3. Hold the side gears in the case with one hand and install
the pinion gears and thrust washers with the other hand.
4. Rotate the side gears and pinion gears until the holes in
the thrust washers and pinion gears line up exactly with
the holes in the case.
4BUOMX-156
Pinion shaft
Note
The pinion shaft and the lockbolt will be installed
during the rear axle drive shaft installation.
4BUOMX-157
REAR DIFFERENTIAL M
Side bearings
DIFFERENTIAL
BEARING REPI Install the side bearings onto the gear case hubs using
T57L-4221 -A2 Differential Side Bearing Replacer T57L-4221-A2, or
equivalent.
Note
Press against the side bearing only.
I I
MM1150-A 4BUOMX-158
Speed sensor ring and ring gear
1. Position the ring gear and speed sensor ring on the gear
case. The tab on the speed sensor ring must be aligned
with the slot in the gear case, as shown.
2. Start the two ring gear bolts through the gear case into the
ring gear to make sure case-to-ring gear bolt hole align-
ment is achieved.
Caution
The tab on the speed sensor ring must be aligned
with the slot in the gear case.
3. Press the ring gear and speed sensor ring on the gear
case using the ring gear as a pilot.
4. Coat the threads of the ring gear bolts with sealant.
5. Install the bolts and tighten in a crisscross pattern.
Tightening torque:
95-1 15 N-m(9.7-1 1.7 kgf-m, 70-85 ft.lbf]
M REAR DIFFERENTIAL
lnstallation
Install in the order shown in the figure, referring to lnstallation Note.
7.5 INCH AXLE ASSEMBLY

(8.8INCH AXLE ASSEMBLY SIMILAR)
I
MMl161-C ~BUOMX-160
1. Bearing cup 6. Brake drum
2. Differential gear assembly 7. Differential cover
Installation Note ............................. below Installation Note ..................... page M-28
3. Shim 8. Lockbolt
4. Bearing cap
5. Rear axle
Installation .............................. page M-26
lnstallation Note
6.73mm Differential gear assembly
1. Install a 6.73mm (0.265 in} shim on the left side.
MM1153-A
M-74
REAR DIFFERENTIAL M
2. Install the left bearing cap and finger tighten the bolts.
3. Install progressively larger shims on the right side until the

largest shim selected can be assembled with a slight drag.
Note
Apply pressure toward the left side to ensure the
bearing cup is seated.
4. Install the right side bearing cap.
Tightening torque:
95-1 15 N-m (9.7-1 1.7 kgfam, 70-435 ftelbf)
5. Rotate the differential gear assembly to ensure free rota-

tion.
MM1156-A
16. Check the ring gear and pinion backlash.
Backlash
Preferred: 0.30--0.38mm (0.01 2 4 . 0 1 5 in)
Standard: 0.204.38mm (0.008--0.015 in)
7. If the backlash is within specification, proceed to step 16.

8. If the backlash is not within specification, proceed to step
12.
9. If the backlash is zero, proceed with step 10.
10. If the backlash is zero, add 0.5mm (0.020 in} to the right
/ -0.5rnm (-0.020 IN) +0.5rnrn {+0.020 IN) side and subtract 0.5mm (0.020 in) from the left side to
allow a backlash condition.
1 1. Recheck the backlash.
M REAR DIFFERENTIAL
12. If the backlash is not to specification, correct the backlash
DECREASE - INCREASE + by increasing the thickness of one shim and decreasing
FOR MORE FOR MORE
BACKLASH BACKLASH the thickness on the other shim the same amount. Refer
LEFT SIDE RIGHT SIDE to the chart for approximate shim change.
7LESS BACKLASH--I
BACKLASH SPECIFICATIONS
I
I
Backlash Thickness I Backlash Thickness
change change 1 change I change
required required 1 required required
FOR LESS
mm {in)
--
mm {in)
--- - -
+
1 -
mm {in}
- -
-
mm {in]
BACKLASH BACKLASH -
0.025 {0.001)
-- - --
0.050 {0.002} -I 0.228 {0.009] --0 304 {0 012)
0 050 {0.002) 1 0.050 (0.002) 0.254 {0.010) 0 355 {O 6-41
---
0.076 (0--
003)
0.001 {0.004)
- -
0.127 {0.005)
--
-
-
0 152 {0.006)
--
I
0.101 {0.004)
- -
-
0.152
--
-1 1 0.152
- --
--
{0.006)
{0.006)
-
1 0.203 (0.008)
I----
-
--
-
-
-
0 219 {0.011)
0.304 {0 01 2)
-- -
-1
r-
1
,-
0.330 (0.013) I 0457{0018)
-1 0
0 355 {0.014} L 45710
- -- -
0355{0014)
018)-
-
-
-
0 406 {0 016)
SHIM CODE CHART

DIFFERENTIAL SlDE BEARING
Number of stripes and Dim. A
color code mm {in)
-- - - -- -
-- -
2--~-coal
- - -- - - 7-
7978-7 8105 { 3070- 3075)
-- - - -
-
- --
I-c-coal
- - -
7-747-7 7597 { 3050- 3055)
- - -- -- --
-- -
5-blu- -
7 6962-7.7089 { 3030- 3035)
- - ---
4-blu 4 7 6454-7 6581 {.3010-,3015)
- --
3-blu
-- - --
' --
7 5946-7
- --
6073 i.2990- 2995) - -
- -
2-blu
- - -- --
7 5438-7 5565 I.2970- 2975)
--- -
- - -
- 5-plnk - 7 4422-7 4549 ( 2930- 2935)

- - -
4-pin
- - -
k 7 3914-7 4041 { 2910- 2915)
-
3-plnk
- ----
7 3406-7 3533 { 2890-,2895)
2-plnk
------ + 7 2898-7 3025 { 2870- 2875)
---
I-plnk- - -- --
7 239-7 2517 { 2850- -
- - -
2855)
-- --
--
5 3-
-
r n -- - - -
7 1882-7
-- -
2009 I.2830- 2835) - -- -
33rn
rn
4-g --- --77 0866-7
1374-7 --
1501 { 2810- 2815)
0993 { 2790-,2795)
-- -
.- - -- - ---- -
-- -
2--9 r-
-
n - -
7 0358-7 0485 { 2770-,2775)
- - --- -- -
--
I-grn
-- -- - -
6.985-6 9977 1.2750-
- -- --
- -
2755) - -
5-wh 6 9342-6 9469 1.2730- 2735)

REAR DIFFERENTIAL M
color code mm {in}
13. Install the shims by driving them into position with SST.
lnstall the bearing caps.
Tightening torque:
95-1 15 N-m (9.7-1 1.7 kgfem, 70--45 ft-lb}
14. Rotate the differential gear assembly several times.

15. Recheck the backlash. If the backlash is within specifica-
tion, go to step 16. If backlash is not within specification,
repeat step 12.
Backlash
Preferred: 0.30--0.38mm (0.012--0.015 in}
Standard: 0.20--0.38mm (0.008--0.015 in)
+o.r52mm (+0.006 16. Remove the bearing caps and bolts. To establish side
bearing preload, increase both left and right shim sizes by
0.152mm (0.006 in). Make sure shims are fully seated
and the differential gear assembly turns freely.
17. Install the bearing caps.
Tightening torque:
95-1 15 N.m (9.7-1 1.7 kgfem, 7 0 - 4 5 ftelbf)
18. Utilize white marking compound to obtain a tooth mesh

+0.152mm {+o.006 IN) contact pattern in the assembly.
19.The oil level should be below the oil supply port in the
running position.
OIL SUPPLY PORT
Specification: 6.35-14.28mm (0.25-4.56 in}
20. lnstall the oil supply port plug.
Tightening torque:
21-41 N-m (2.1-4.1 kgfam, 15-30 ft-lbf)
M REAR DIFFERENTIAL
LIMITED SLIP
Removal
Refer to page M-61.
Disassembly IInspection
1. Remove the ring gear and speed sensor ring from the gear case, referring to Disassembly Note. (Refer
to page M-79.)
2. Remove the side bearings, referring to Disassembly Note. (Refer to page M-79.)
4. Clean and inspect all parts and replace as necessary.
1. Lockbolt 5. Thrust washer

Disassembly Note .................. page M-79 6. Side gears
2. Pinion shaft Disassembly Note .................. page M-79
Disassembly Note .................. page M-79 . 7. Clutch pack
3. Preload spring 8. Shim
4. Pinion gears 9. Gear case
Disassembly Note .................. page M-79
REAR DIFFERENTIAL
- e
Disassembly Note
e and speed
Ring gear e
ee sensor ring
1. Remove the ring gear bolts.
2. Remove the ring gear from the gear case using a drift.
3. Remove the speed sensor ring by tapping with a soft-
faced hammer. Discard the speed sensor ring.
Caution
Do not damage the speed sensor ring when re-
moving the ring gear. If the speed sensor ring is
removed, it must be replaced with a new one.
MM1096-A 5BUOMX-017
Side bearings
Remove the side bearings from the gear case using
Differential Side Bearing Remover T70P-4221-A, or
equivalent.
I
MMI 097-A 4BUOMX-164
Lockbolt and pinion shaft
The lockbolt and pinion shaft will have been removed
during the rear axle procedure.
4BUOMX-165
Pinion and side gears

1. Drive the preload spring halfway out of the gear case using
a drift.
2. Rotate the gear case 180".
3. Hold the preload spring with a pair of pliers and tap the
spring to remove it from the gear case.
Warning
Care must be used when removiing the preload
spring due to the spring tension.
4. On 7.5 in axles, rotate the pinion gears until the pinion

GEAR ROTATOR gears and the thrust washers can be removed using Gear
Rotator T84P-4205-A, or equivalent.
M1099-A
M REAR DIFFERENTIAL
PINION GEAR ROTATOR

5. On 8.8 in axles, rotate the pinion gears until the pinion
TOOL T ~ O P - ~ Z O ~ - A gears can be removed using Pinion Gear Rotator Tool
MM1100-A
6. Remove the side gears and clutch packs with the shims.
Note
The side gears and clutch packs from the individual
sides should be kept together to be installed into
their original sides during assembly.
6BUOMX-032
Inspection
Clean and inspect the clutch pack, side gears and shims
for wear or damage. Replace any faulty parts.
Note
Do not use acids or solvents when cleaning the
clutch components. Wipe the components with a
clean lint-free cloth only.
REAR DIFFERENTIAL M
Assembly
s
Assemble in the order shown in the figure, referring to Assembly e
Note.
MM1168-B 4BUOMX-168
1. Shim 6. Preload spring
2. Clutch pack 7. Pinion shaft
Assembly Note ............................... below 8. Lockbolt
3. Side gears 9. Gear case
4. Thrust washer
5. Pinion gear
Assembly Note
Clutch pack
1.Assemble the clutch packs without the shims onto the
respective side gears.
Caution
Pre-lubricate all friction plates with an appropriate
friction modifier.
Note
Do not
o mix the clutch plates or the shims from on
e with the other.
side
M REAR DIFFERENTIAL
2. On 8.8 in axles, place the base of Traction-Lok Clutch
Gauge T87T-4946-A, or equivalent in a vise. Install the
clutch pack and side gear without the shim over the base
of the gauge.
3. On 7.5 in axles, place the base portion of Traction-Lok
Clutch GaugeT84P-4946-A, or equivalent in avise. Install
the clutch pack and side gear (without the differential
clutch pack shim) over the base of the gauge.
4. Install the disc of Traction-Lok Clutch Gauge T80P-

4946-A, or equivalent over the base and on top of the
clutch pack.
5. Install the top portion of Traction-Lok Clutch Gauge T80P-

TOP-TRACTION-LOK
CLUTCH GAUGE 4946-A, Or equivalent.
T80P-4946-A
REAR DIFFERENTIAL M
6. Install the nut from Traction-Lok Clutch Gauge T80P-
4946-A, or equivalent.
Tightening torque:
6.7 N-m C68.3 kgfecm, 60 in-lbf}
MM1 106-A
7. Using a feeler gauge, select the thickest blade that will
TRACTION-LOK
CLUTCH GAUGE enter between the tool and the clutch pack.
Note
This reading will be the thickness of the new shim.
Be sure to lubricate the friction plates with an
appropriate friction modifier prior to assembly.
8. Assemble thesidegear, the clutch packand the new shim.

9. Repeat steps 1 through 8 for both clutch packs.
I I
MM1107-A 4BUOMX-169
Pinion and side gears
1. Lubricate all parts thoroughly with specified lubricant prior
to assembly.
Specified lubricant: API GL-5 SAE 90
2. Mount the gear case in asoft-jaw vise and install the clutch
packs and side gears in the gear case.
3. Place the pinion gears and thrust wast-lers on the side
gears.
4. On 7.5 in axles, rotate the pinion gears until the bores in

GEAR ROTATOR the gears are aligned with the pinion shaft bores in the
T84P-4205-A
gear case using Gear Rotator T84P-4205-A, or equiva-
lent. Remove the tool from the gear case.
5. On 8.8 in axles, rotate the pinion gears until the bores in

PINION GEAR ROTATOR
TOOL T80P-4205-A the gears are aligned with the pinion shaft bores in the gear
case using Pinion Gear Rotator Tool T80P-4205-A, or
equivalent. Remove the tool from the gear case.
6. With a soft-faced hammer, install the preload spring in the
gear case.
Note
Inspect the spring for damage and replace it if
necessary.
REAR DIFFERENTIAL
7. Install the pinion shaft and lockbolt.
Note
Do not tighten the lockbolt at this point.
Bench check the differential gear assembly using Trac-

tion-Lok Torque Tool T59L-4204-A, or equivalent. Check
the torque required to rotate one side gear while the other
is held stationary.
Initial breakaway torque:

Minimum: 27 N-m (2.7 kgf.m, 20 ft.lbf)
Note
Breakaway torque may fluctuate with new clutch
plates.
9. Remove the lockbolt and the pinion shaft.

TRACTION-LOK
TORQUE TOOL Note
T59L-4204-A
The pinion shaft and the lockbolt will be installed
during the rear axle drive shaft installation.
Gear case
1. Install the gear case into the rear axle casing without the
ring gear.
Note
Press against the bearing only.
2. Check the gear case runout with the new bearings in-
stalled using dial indicator. If the runout is within specifica-
tions, use the new bearings for assembly. If the runout is
excessive, replace the gear case.
Runout specification:
MMllll B 4BUOMX 171

M-84
REAR DIFFERENTIAL M
Steps After Assembly
DIFFERENTIAL SIDE 1. Install the side bearings as follows:
BEARING REPLACER
2 1 (7.5 IN)
~ 5 7 ~ - 4 2-AI (1) On 7.5 in axles, install the side bearings on the gear
2 IN)
~ 5 7 ~ - 4 2-2 1~ (8.8 case hubs using Differential Side Bearing Replacer
T57L-4221-A1 or equivalent.
(2) On 8.8 in axles, install the side bearings on the gear
case hubs using Differential Side Bearing Replacer
T57L-4221-A2, or equivalent.
MM1110-A
2. Install the ring gear and speed sensor ring as follows:
(1) Clean the ring gear holes. If the new bolts to be used
show a green coating over approximately 12.7mm
(0.5 in} of the threaded area, use as is. If they are not
coated, apply sealant to the threads.
(2) Position the ring gear and the speed sensor ring, if the
speed sensor ring was removed, on the gear case.
Align the tab on the speed sensor ring with the slot in
the gear case as shown in the figure. Start two ring
gear bolts through the case and into the ring gear to
make sure case-to-ring gear bolt alignment is
achieved.
Caution
The tab on the speed sensor ring must be aligned
with the slot in the gear case.
(3) Press the ring gear and the speed sensor ring, if the
speed sensor ring was removed, onto the differential
gear assembly using the ring gear as a pilot.
(4) Tighten the bolts in a criss-cross pattern in three steps.
Tightening torque:
95-1 15 N-m(9.7-1 1.7 kgf-m, 70-85 ft.lbf}
Installation
Refer to page M-74.
M WHEEL HUBS
WHEEL HUBS
PREPARATION
SST
49 UNOl 037 For 49 UNOl 042

removal1 removal/
Hex locknut installation Hub locknut ~nstallat~on
wrench of automatic wrench of manual
locking locking
wheel hubs wheel hubs
AUTOMATIC LOCKING WHEEL HUB

Removal I lnstallation
1. Jack up the front of the vehicle and support it with vehicle stands.
MM1088-D 6BUOMX-040
1 . Retainer
2. Automatic locking hub assembly 5. Locking key
Installation Note ..................... page M-88 Removal Note ........................ page M-87
3. Axle shaft spacers Installation Note ..................... page M-88
Removal Note ........................ page M-87 6. Adjusting nut
4. Cam assembly Installation Note ..................... page M-87
Installation Note ..................... page M-88 7. Disc plate
WHEEL HUBS M
Removal note
Spacer
2. Remove the axle shaft spacers.
Locking key
Remove the locking key, using a magnet.
Note
Rotate the adjusting nut to relieve pressure from
the locking key.
I I
MM1090-A 4BUOMX-177
Installation note
Adjusting nut
1. Loosen the adjusting nut using the SST.
2. Rotate the disc plate counterclockwise while tightening
/?
the adjusting nut to specification using the SST.
Note
SST number: 49 UNOI 037 Hex Locknut Wrench
Tightening torque:
47 N.m (4.8 kgf-m, 35 ft.lbf)
MMlO91-A 4BU0MX-178
3. Spin the disc plate and loosen the adjusting nut one-
quarter turn (90") using the SST.
Note
SST number: 49 UNO1 037 Hex Locknut Wrench
4. Tighten the adjusting nut using the SS'T

Note
SST number: 49 UNOI 037 Hex Locknut Wrench
Tightening torque:
1.8 N-m(18.3 kgfzm, 16 in-lbf)
Wheel bearing play:

0.00--0.08mm (0.00-0.003 in)
6. Attach a pull scale to a wheel lug bolt, and measure the

frictional force.
Frictional force:
2.8 N.m (28.5 kgfecm, 25 in-lbf}
M WHEEL HUBS
Locking key
Install the locking key.
Warning
The wheel and tire assembly may come off if the
locking key is damaged.
Note
Align the closest lug in the adjusting nut with the
center of the knuckle key slot.
4BUOMX-I 79
Cam assennbly
\ Inrtqll thc cam assembly.
I ", \ I
Caution
Use extreme care when installing the cam key in the
CAM knuckle key slot.
KEY
Note
Align the cam key on the cam assembly with the
knuckle key slot.
I I
MM1092-A 4EiUOMX-180
LEGS 1 Automatic locking hub assembly

Install the automatic locking hub assembly.
Note
Align the three legs with the three notches in the
cam assembly.
WHEEL HUBS M
MANUAL LOCKING WHEEL HUB
1. Jack up the front of the vehicle and support it with vehicle stands.
I I
MM1094-C 5BUOMX-021
1. Retainer 5. Washer
2. Manual locking hub assembly Installation Note ..................... page M-91
3. Axle shaft spacers 6. Inner locknut
Removal Note ................................. below Removal Note ........................ page M-90
4. Outer locknut 7. Disc plate
lnstallation Note ..................... page M-91
Removal note
Spacer
2. Remove the axle shaft spacers.
M WHEEL HUBS
Outer locknut
I
MM1010-B 4BUOMX-184
lnner locknut
Loosen the inner locknut with the SST.
I I
MMlO11-B 4BUOMX-185
Installation note
lnner locknut
1. Install the inner locknut using the SST.
Note
SST number: 49 UNO1 042 Hub Locknut Wrench
2. Rotate the disc plate counterclockwise while tightening

the inner locknut to specification using the SST.
Note
Tightening torque:
47 N.m (4.8 kgf.m, 35 ft-lbf)
3. Spin the disc plate and loosen the inner locknut one-
quarter turn (90") using the SST.
Note
4. Tighten the inner locknut using the SST.

Note
Tightening
- torque:
1.8 ~.m-(18.3kgf.cm, 16 in-lbf)
WHEEL HUBS M
Washer
Install the washer.
Note
Tighten the inner locknut slightly to align the lock-
nut pin with the washer hole.
MM1012-6 4BUOMX-187
Outer locknut
1. Tighten the outer locknut with the SST.
Tightening torque:
203 N.m (20.7 kgfem, 150 ft-lbf}
Wheel bearing play:

0.004.08mm (0.00-0.003 in}
I 3. Attach a pull scale to a wheel lug bolt, and measure the
MMIOIO-B ~BUOMX-18;
frictional force.
Frictional force:
2.8 N-m(28.5 kgf-cm, 25 in.lbf)
Spacer
1. Install the axle shaft spacers.
STEERING SYSTEM
INDEX ........................................................... N- 2
OUTLINE ...................................................... N- 4
SPECIFICATIONS ..................................... N- 4
MANUAL STEERING ................................... N- 5
TROUBLESHOOTING GUIDE ................... N- 5
STEERING WHEEL AND COLUMN .......... N- 6
STEERING GEAR ...................................... N-23
STEERING LINKAGE ................................ N-31
POWER STEERING ..................................... N-35
PREPARATION ......................................... N-35
TROUBLESHOOTING GUIDE ................... N-35
AIR BLEEDING .......................................... N-36
POWER STEERING FLUID ....................... N-37
STEERING WHEEL AND COLUMN .......... N-39
STEERING GEAR ...................................... N-40
OIL PUMP .................................................. N-49
DRIVE BELT .............................................. N-61
5BUONX-079
INDEX
INDEX
INDEX
2.3L ENGINE 3.OL ENGINE
DRIVE BELT
P 6 DRIVE BELT TENSION
AUTOMATIC TENSION
-\
4.OL ENGINE
DRIVE BELT TENSION

(AUTOMATIC TENSION)
POWER STEERING FLUID

SPECIFICATION
ATF TYPE-F (M2C33-F) OR DEXRON II
L
MN1158-C
1. Steering wheel and column 4. Steering linkage
(power / manual) Removal / Installation ............. page N-31
On-vehicle inspection 5. Power steering fluid
(manual) ............................... page N- 6 Air bleeding ............................ page N-36
On-vehicle inspection Inspection ............................... page N-37
(power) ................................. page N-39 6. Drive belt
Removal / lnstallation ............. page N- 8 Inspection ............................... page N-61
Disassembly / Assembly ........ page N-12 Adjustment ............................. page N-62
2. Manual steering gear Replacement .......................... page N-62
Removal / lnstallation ............. page N-23 7. Oil pump
Disassembly / Inspection / Removal 1 lnstallation ............. page N-49
Assembly .............................. page N-24 Disassembly 1 Assembly ........ page N-54
3. Power steering gear Air bleeding ............................ page N-36
Removal / lnstallation ............. page N-40
Disassembly / Assembly ........ page N-41
OUTLINE
OUTLINE
SPECIFICATIONS
----- .-
Model Power
--
Steerlng wheel
Item
- .
Loc;;~-;oc~
Manual 2.3L I --AP
3.OL
--
4.0L
- -
-- -
- -
6.1 -- - -- 4 - - --- .
-
Steerlng gear Rec~rc.ball Rearc. ball

worm Tors~onbar
*----------- --- - - --
- --- -
Gear ratlo 23.75:l 17 I -
O~lllubr~cant TYpe Steerlng ATF Type-F (M2C33-F) or DEXRON5II
--- gear grease --- -- - -
Capaclty 290 grams 1 0 75L (1 6 pt)
-- - ---
( I 0.2 ounces) --- -- -
Worm bearlng preload - 0.45-1.0 N.rn (4-9 ~n-lb}not adjustable

- - - ---- -- -----
specification given for lnspect~on
- -
purposes
-
only
-
Worm-to-p~stonpreload
-.
--- - --- --
Worm bearlng preload for checking 22-68 Ncrn -

- - -- -- -- --
Total center rneshload for checklng - -
- - - - .-
(6-1 1 ~n-lbs} ---
Mln~rnurnrneshload over preload for checklng 45 N.cm -
- .
{4 ~n-lbs} ---- - -~
Worm bearlng preload when readjust~ng 56-68 N a n , -

--- pp pp
{5-6 ~n-lbs} -- -- - --- -
Total center meshload when readjusting 102-1 24 N a n ' -

-- --
- -
{9-11 ~n-lbs) - --- -- -
Mlnlrnurn rneshload over preload when readjustrng 45 N.cm -

{4 tn-lbs)
Maximum clearance between adjusting screw 0.1 rnrn - - -
head and sector shaft {O 004 ~nch)
011 pump rnlnlrnurn flow 34
-- F - - -- - - -
51 00 kpa (740 PSI} 0.95

- - -- - - - -- -
011 pump m~nirnurn
relief pressure
--
7240-
- --
8964-- - - -
7240
1050
-- - - - -- - - - - - -- + - - -- - -
8480
rel~efpressure 1230
--
1480
- 1 - -
1230
L~terslmlnute
- -- - - - - - - -
9.8 - -- -- - -
flow at 1500 rprn Gallons/rn~nute 2.6

- -- -- - -- - -
Note Flow depends on pump model, engine rprn and pulley drrve ratlo. Englne idle rprn must be set to spec~fication
when checkina DurnD rninlrnurn flow caDacltv.
Note
may occur while the powertraincontrol module relearns its adaptive strategy. The vehicle may
4BUONX-002
I
MANUAL STEERING
1 Problem
Steering feels heavy
to one side
General instability
while driving
I
Weak front sprlng

MANUAL STEERING
Possible Cause
I lmproperly adjusted wheel alignment
lncorrect tire pressure
Damaged flexible coupling
Malfunctioning steering gear assembly
lmproperly
-- -
adjusted steering gear preload
Unevenly worn tires
Worn or damaged ball joint

Dragging brake
lmproperly adjusted
. wheel alignment
Loose steering gear mounting bolts
Malfunctioning steering gear assembly
Damaged or unbalanced wheel
lmproperly adjusted steering gear preload
-
1
Adjust
Adjust
Replace
Replace
Replace
Replace
Repair
Adjust
Tighten
Repair
-
Adjust
Action
Repair or replace
Adjust
Adjust
or replace
Adjust or replace
Replace
Adjust
--
Pagelsection
--
Section R
Section Q
N- 8
N-23
N- 6
Section Q
Section Q
Section R
Section R
Section P
Section R
N-23
N-23
Section Q
Section Q
Section R
N- 6
I
Weak front spring Replace Section R

Damaged shock absorber I Replace Section R
lmproperly adjusted wheel alignment Adjust Section R
Worn or damaged flexible coupling Replace N- 8
Loose steering gear mounting bolts Tighten N-23
Loose or damaged pitman arm -- T~ghtenor replace --
N-23
Shake Excessive tire and/or wheel runout Replace Section Q
(steering wheel Loose lug nut(s) I T~ghten Section Q
vibrates upldown) Unbalanced wheel(s) Adjust or replace Section Q
Cracked or worn engine mount rubber Replace Sections B1,
B2, B3
Cracked or worn transmission mount rubber Replace Sections J1, K
-
Shimmy Cracked or worn steering gear mount rubber Replace N-23
(steering wheel Loose steering gear mounting bolts Tighten N-23
vibrates Stuck or damaged tie rod ball joint Replace N-31
circumferentially) Excessive tire and/or wheel runout Replace Section Q
Loose lug nuts Tighten Section Q
Unbalanced wheel(s) Adjust or replace Section Q
lncorrect tire pressure Adjust Section Q
Unevenly worn tires Replace Section Q
Damaged shock absorber Replace Section R
Loose shock absorber mounting bolts Tighten Section R
Stuck or damaged ball joint Replace Section R
Damaged or worn front wheel bearing Replace Section M
lmproperly
-- - - -
adjusted
- -front
-
wheel alignment Adiust Section R
-
~xcessive Geering Worn steering gear Adjust or replace N-23
wheel play Worn or damaged ball joint Replace Section R
Worn or damaged tie rod ball joint Replace N-31
Worn or damaged flexible coupling Replace
- - -- N- 8
Poor steering lncorrect tire pressure Adjust Section Q
wheel return Stuck or damagqd tie rod ball joint Replace N-31
Improperly adjusted front wheel alignment Adjust Section R
Sticking steering column bearing Replace N- 8
Malfunctioning steering gear Adjust or replace N-23
Abnormal noise from Loose steering gear mounting bolts 1 Tighten
steering system Malfunctioning steering gear I Repair or replace
MN1136-0
N MANUAL STEERING
STEERING WHEEL AND COLUMN
On-Vehicle Inspection
Preload and meshload check
Note
Be sure the front wheels are properly aligned and
the tire pressures are correct before checking the
turning effort.
Prior to checking preload and meshload in vehicle,
make sure that the steering column is properly
aligned and that the intermediate shaft flex cou-
pling is not distorted.
1. Disconnect the pitman arm from the ball stud.

2. Lubricate the wormshaft seal with a drop of ATF Type-F
(M2C33-F) or DexronBll.
3.Remove the air bag module from the steering wheel.
4. Turn the steering wheel slowly to one stop.
5. Place an in4b torque wrench on the steering wheel nut.

6. Measure the preload required to rotate the steering wheel
at a constant speed for approximately 1-112 turns.
7. If the preload is not within specifications, readjust preload.
Specifications: 0.224.68 N-m(2-6 in.lbf}
8. Rotate the steering wheel from stop to stop, counting the

total number of turns then back halfway, placing the gear
on center.
9. Place an in4b torque wrench on the steering wheel nut.
10. Observe the meshload by rotating the steering shaft back
and forth approximately 90" either way across center.
Specifications:
Meshload 0.68-1.24 N.m (6-1 1 in.lbf}
at least 0.23 N-m(2 inelbf} over the preload
11. If the meshload is out of specifications, adjust it. (Refer to

below .)
Adjustment
Preload and meshload
Note
The following adjustment requires removal of the
steering gear. (Refer t o page N-43.)
1. Tighten the sector cover bolts.
Tightening torque:
43-54 N-m( 3 2 4 0 ft-lbf)
MANUAL STEERING N
r WORMSHAFT GEAR HOUSING I 2. Loosen the preload adjuster locknut and tighten the worm
bearing adjuster nut until all end play ha:; been removed.
3. Lubricate the wormshaft seal with a drop of ATF Type-
Disconnect Brake OnIOff (M2C33-F) or Dexronmll.
4. Carefully turn the wormshaft all the way to the right with
a torque wrench.
5. Measurethe left turn torque requiredto rotate the wormshaft
at a constant speed for approximately 1-112 turns.
\
WORM BEARING Preload:
ADJUSTER 0.56-4.68 N-m (5.3-6.9 kgf-cm,5--6 in-lbf)
6. Tighten or loosen the adjuster nut until the correct preload

is obtained.
7. Tighten the adjuster locknut.
Tightening torque:
225-253 N.m (22.9-25.8 kgf.m, 166-1 87 ft-lbf}
8. Rotate the wormshaft from stop to stop, counting the total

number of turns, then turn back halfway, placing the gear
on center.
9. Measure the highest reading while the wormshaft is
turned approximately 90" either way across the center
with a torque wrench.
10. If the highest reading (meshload) is not within 102-

124 N-m (9-11 in-lbf) and at least 0.45 N.m (4 in-lbf}
over the preload, turn the sector shaft adjusting screw as
required.
11. Hold the sector shaft adjusting screw and tighten the
locknut.
Tightening torque:
19-34 N-m (2.0-3.4 kgfem, 14-25; ft.lbf}
N MANUAL STEERING
Fixed and Tilt Steering Column
Removal and lnstallation
1 . Park vehicle with the wheels straight ahead.
2. Disconnect battery negative and positive cables. Wait one minute before proceeding with removal.
MANUAL STEERING N
1. Steering wheel 5. Transmission control shift indicator
2. Steering column opening cover (not shown) (not shown)
Removal Note . . . . . . . . . . . N-9 Removal Note . . . . . . . . . . . N-9
Installation Note . . . . . . . . . . N-11 Installation Note . . . . . . . . . . N-11
3. Steering column cover reinforcement 6. Steering column
(not shown) Removal Note . . . . . . . . . . . N-9
Removal Note . . . . . . . . . . . N-9 Installation Note . . . . . . . . . . N-11
Installation Note . . . . . . . . . . N-11 7. Transmission shift cable (not shown)
4. Steering column center reinforcement Removal Note . . . . . . . . . . . N-10
(not shown) Installation Note . . . . . . . . . . N-10
Removal Note . . . . . . . . . . . N-9
Removal Note
Steering column opening cover, steering column
cover reinforcement and steering column center
reinforcement
1. Remove two screws and pull cover straight out to release
clips.
2. Remove six screws and steering column cover reinforce-
ment.
3. Remove two screws and steering column center rein-
forcement.
Transmission control shift indicator

1. Disconnect shift lock actuator (BTSI).
2. Disconnect transmission control selector indicator loop
from shift selector tube.
L
3.Remove screw and transmission control selector indi-
cator from steering column.
5BUONX-039
Steering column
1. Remove lower steering shaft pinch bolt.
2. Remove 4 steering column to instrument panel reinforce-
ment nuts.
3. Lower steering column.
N MANUAL STEERING
Transmission Shift Cable
Note
Remove shift cable after lowering steering column.
1. Snap shift cable off of selector arm using screwdriver.
2. Lift tab on shift cable retainer and remove shift cable from
bend bracket.
3. Remove steering column from vehicle.
Installation Note
Transmission Shift Cable
1. Push shift cable retainer into slot on bend bracket and
snap shift cable end onto shaft of selector lever arm.
2. Insert steering column shaft into universal joint, making
sure cutout in steering column shaft aligns with universal
joint pinch bolt hole.
MANUAL STEERING N
Steering Column
1. Raise steering column into position onto dashboard rein-
forcement studs.
Tightening Torque:
13-1 7 N.m (1-3-1.8 kgf.m, 1 1 2-'153 inelbf)
2. Install lower steering shaft pinch bolt.
Tightening Torque:
40-54 P1.m (4.2-5.4 kgf-m, 30-40ftelbf)
5BUONX-043
7 Transmission control shift indicator

1 . Connect cable loop to transmission column shift selector
P R N @ 2 1 tube.
2. Connect shift lock actuator (BTSI).
MN1177-A 6BUONX-004
Steering Column Opening Cover Reinforcement
Tightening Torque:
11-13 N.m (1 .I-1.38 kgf.m, 8-10 ft.lbf)
5BUONX-045
Steering Column Opening Cover
Tightening Torque:
2.1-2.8 N.m (21-38 kgfacm, 18-:26 in-lbf)
5BUONX-046
N MANUAL STEERING
1. Clamp the steering column in a soft-jawed vise.
3. Remove the foam weather seal from the column tube, referring to Disassembly Note.
MANUAL STEERING N
1. Tilt handle, if equipped 16. Plastic bearing retainer
2. Steering column shroud (lower) 17. Steering column lock housing bearing
3. Ignition switch lock cylinder Assembly Note ....................... page N-22
Disassembly Note .................. page N-14 18. Steering column lock gear
4. Steering column shroud (upper) Assembly Note ....................... page N-22
5. Air bag sliding contact 19. Steering column lower bearing spring
Disassembly Note .................. page N-14 (Tilt column only)
Assembly Note ....................... page N-22 Disassembly Note .................. page N-17
6. Turn indicator cancel cam 20. Suspension height sensor control ring
Disassembly Note .................. page N-15 21. Steering column lower bearing tolerance ring
7. Ignition switch 22. Steering column bearing retainer and
Assembly Note ....................... page N-21 .tolerance ring (Fixed column only)
8. Upper bearing snap ring and spring (not shown)
Assembly Note ....................... page N-21 23. Steering column lower bearing retainer and
9. Steering column tube bearing sleeve bend bracket
and upper bearing tolerance ring Assembly Note ....................... page N-20
10. Gearshift lever 24. Lock cylinder housing
11. Shift interlock solenoid and shift selector Disassembly Note .................. page N-17
position insert Assembly Note ....................... page N-20
Disassembly Note .................. page N-15 25. Steering shaft
12. Transmission control selector arm 26. Lock actuators (Upper and lower)
13. Transmission column shift selector tube Assembly Note ....................... page N-18
Assembly Note ....................... page N-22 27. Lock levers
14. Steering column lock actuator lever pin Disassembly Note .................. page N-18
Disassembly Note .................. page N-17 Assembly Note ....................... page N-19
15. Column lock shifter pawl
Assembly Note ....................... page N-20
N MANUAL STEERING
Disassembly Note e
Ignition switch lock cylinder
1. Turn lock cylinder to RUN.
2. Using flat-tipped punch, push on button below lock

cylinder.
1
MN1 182-A
1 3. Pull out lock cylinder
Air bag sliding contact

Caution
Be sure air bag sliding contact internal lock is
engaged. Hub should not turn more than 45 de-
grees in either direction.
MANUAL STEERING N
1. Remove electrical connectors from bend bracket and wire
harness clips from column using suitable tool
2. Remove key warning buzzer and anti-theft contacts from
lock cylinder pocket of column tube flange.
3. Remove contact by pushing snap back at 6:00 position,
then 3:00 position, then 12:OO position and remove from
steering shaft.
I I
MNI 184-A 5BUONX-049
Turn indicator cancel cam
Remove cancel cam by pushing up with flat-bladed screw-
driver. Note direction of flush surface.
I I
Shift interlock solenoid and shift selec:tor position
insert
Note
The shift interlock solenoid is retained to the shift
selector position insert with a push nut.
N MANUAL STEERING
1. Remove three screws attaching shift interlock solenoid
and shift selector position insert.
MN1187-A
2. Remove shift interlock solenoid and shift selector
position insert together. If necessary, remove push nut
and separate.
MANUAL STEERING N
Steering column lock actuator lever piri
Pry on end of lever pin that is sticking out and remove with
Vise-grips.
M N I 190-A
Lock cylinder housing

Caution
Steering column position spring will release when
bolts are removed.
Remove two pivot bolts arid lock cylinder housing.

N MANUAL STEERING
Lock levers
Secure locking levers with a 6-inch C-clamp. Remove
pivot pin with suitable punch. Remove levers and springs
by slowly loosening spring clamp.
I I
Inspection
Check all bearings for damage or excessive wear. If
bearings are damaged, replace according to procedures
outlined in this section.
5BUONX-056
Assembly Note
Lock actuators
1. With actuator housing upside down, slide steering shaft
into steering actuator housing.
2. Lubricate lower and upper lock actuator with appropriate

grease, connect the two actuators and slide onto actuator
housing.
MANUAL STEERING N
- -
AN1 197-A 5BUONX-057

Lock levers
1 . Position steering column lockspring ancl right column lock
lever. Using 6-inch (150mm) C-clamp, compress spring
while aligning pin hole in column lock lever with pin holes
in steering actuator housing. Tap in lock lever pivot pin up
to center pin support of actuator housing.
2. Insert asmall nut between lock lever ancl actuator housing
to hold up lock lever. Slowly loosen and remove C-clamp.
3. Position steering column lock spring and left column lock

lever. Using 6-inch (150mm) C-clamp, compress spring
while aligning pin hole in column lock lever with pin holes
in steering actuator housing with a punch. Leave punch in
place.
4. Tap in lock lever pivot pin, driving out punch at the same
time, until left end of pin is flush with pin support of actuator
housing.
5. Position nut between right lock lever and actuator hous-
ing. Slowly unscrew C-clamp and remove.
N MANUAL STEERING
Lock cylinder housing
Tilt Steering
1 . Insert column position spring between lock cylinder hous-
ing and actuator housing.
2. Position 6-inch C-clamp on outside of column position
spring pads.
3. Tighten C-clamp drawing lock cylinder housing and ac-
tuator housing together, compressing spring. At the same
time, use punch to align bushings in lockcylinder housing
with threaded pivot bolt holes in actuator housing.
c 4. Lubricate bolts with grease and install
Tightening torque:
18-26 N-m(13-2.7 kgf-m, 14-1 9 ft4bf)
5. Remove nuts from underneath right and left lock levers.

6. Slowly loosen and remove C-clamp.
I J
MN1200-A 5BUONX-078
Fixed Steering
1 . Position lockcylinder housing on upper lock lever actuator
and steering shaft.
2. Align bushings in lockcylinder housing with threaded pivot
bolt holes in actuator housing.
3. Lubricate bolts with grease and install.
Tightening torque:
18-26 N.m (1.8-2.7 kgf-m, 14-19 ft-lbf)
4. Remove nut from underneath left lock lever.

MN1201-A 6BUONX-005
Steering column lower bearing retainer and bend
bracket
Tightening torque:
7-1 1 N-m (0.7-1.2 kgf-m, 5-43 ft.lbf)
Column lock shifter pawl
1. Position lock pawl in actuator housing and install with
small hammer.
MANUAL STEERING
2. Tap pawl pin in until flush with actuator housing.
Upper bearing snap ring and spring

Install spring and new snap ring using a W4-inch ID by
2 1R inch long PVC pipe.
5BUONX-062
lgnition switch
Note
Ignition switch should be in RUN position.
Align pin from ignition switch with slot in lock/column

assembly. Position slot in locWcolumr~assembly with
index mark on casting.
Tightening torque:
5-7 N m (0.6-0.7 kgf .m, 4-5 ft . Ibf}
6BUONX-006
N MANUAL STEERING
Steering column lock gear
Install lock gear and coat with grease.
I I
MN1205-A 5BUONX-064
Steering column lock housing bearing
1. Lubricate with grease.
2. With actuator rack in 12:OO position, position bearing with
tang inboard and in 5:00 position in lock cylinder. Insert tip
of screwdriver into Double-D slot of bearing, then turn
counterclockwise 90 degrees.
1 I
MN1206-A 5BUONX-065
Transmission column shift selector tube
Install tube and coat bushing with grease.
Tightening torque:
7-1 1 N-m (0.7-1.2 kgf.m, 5 - 4 ftelbf)
MNI 207-A 5BU0NX-066 Air bag sliding contact

1. Align contact to column shaft and mounting tabs and slide
onto shaft. Push on contact to snap three tabs onto lock
cylinder housing.
2. Install contact retainers into steering column bend bracket
and connector retainers into steering column holes.
MANUAL STEERING N
Note
Make sure contacts do not slip out of lock cylinder
pocket.
3. Install key warning buzzer and anti-theft contacts to lock

cylinder pocket of column tube flange.
5BUONX-067
STEERING GEAR
1. Disengagethe flex coupling shield from the steering gear input shaft shield and slide it up the intermediate
shaft.
2. Remove the bolt and steering gear input shaft shield.
I I
I
MNl208-A 5BUONX-068
1. Pitman arm
Removal Note ........................ page N-24
Installation Note ..................... page N-24
2. Steering gear
Disassembly / Inspection /
Assembly .............................. page N-24
MANUAL STEERING
Removal Note
Pitman arm
Remove the pitman arm using Pitman Arm Puller T64P-
3590-F, or equivalent.
Caution
Do not hammer on the end of the puller as this can
damage the steering gear.
Installation Note
Steering gear
1. Rotate the input shaft from stop to stop, counting the total
number of turns. Then turn the input shaft backexactly half
way.
2. Slide the steering gear input shaft shield on the input shaft.
3. Install the steering gear to side rail.
Tightening torque:
68-84 N . m (6.9-8.5 kgf . m, 50-62 ft - lbf)
4. Install the flex coupling to steering gear input shaft bolt.
Tightening torque:
40.3-54.7 N . m (4.1-5.5 kgf .m, 29.4-39.9 ft . lbf)
6BUONX-007
Pitman arm
1. Align the two blocked teeth on the pitman arm with the four
missing teeth on the sector shaft.
2. Place the pitman arm on the sector shaft.
Tightening torque:
230-31 0 N.m 123.4-31.6 kgf.m, 170-229 ftlbf)
Disassembly IInspection IAssembly

1. Rotate the wormshaft from stop to stop, counting the total number of turns. Then turn back exactly
halfway.
2. Disassemble in the order shown, referring to Disassembly Note.
Caution
In order to prevent the entrance of dirt, all disassembly should be done in a clean area.
MANUAL STEERING N
L N m {kgfm, ft4bf) 1
MN1002-A 5BUONX-071
1. Lash adjuster locknut 11. Wormshaft upper thrust bearing

2. Sector cover and bushing assembly 12. Wormshaft lower bearing cup
Disassembly Note .................. page N-26 Disassembly Note .................. page N-26
Assembly Note ....................... page N-29 Assembly Note ........................ page N-29
3. Sector shaft 13. Wormshaft upper bearing cup
lnspection ............................... page N-27 Disassembly Note .................. page N-26
4. Lash adjuster Assembly Note ....................... page N-28
5. Lash adjuster shim 14. Sector shaft seal
6. Worm bearing adjuster locknut Assembly Note ....................... page N-28
7. Worm bearing adjuster 15. Wormshaft seal
8. Wormshaft lower thrust bearing Assembly Note ....................... page N-28
9. Ball nut 16. Housing
lnspection ............................... page N-27 lnspection ......................... ...... page N-27
10. Wormshaft Assembly Note ....................... page N-29
lnspection ............................... page N-27 17. Sector shaft needle bearing (not shown)
N MANUAL STEERING
Disassembly Note
Sector cover and bushing assembly
Remove the cover from the shaft by turning the screw
clockwise.
Note
Keep the shim with the screw.
The bushing is not serviceable. The entire sector
cover including the bushing is serviced as a unit.
9
MN1003-A 4BUONX-094
Wormshaft lower bearing cup

PULLER
T58L-101-B Remove the wormshaft lower bearing cup using Puller
T58L-101-B, or equivalent.
AN1 004-6 4BUONX-095

Wormshaft upper bearing cup
Remove the bearing cup from the housing using asuitable
hammer and a suitable size socket.
Sector shaft needle bearing
Note
The sector shaft needle bearing is serviced only as
a unit with the housing. Do not attempt to remove
the sector shaft needle bearing.
4BUONX-098
MANUAL STEERING N
Inspection
Wormshaft,
s ball nut
Not
Replace the wormshaft and ball nut assembly as a
unit.
Inspect the wormshaft and ball nut assernbly for tightness

or binding by turning the wormshaft in the ball nut. If
binding or tightness are indicated, replace the assembly
as a unit.
4BUONX-099
Housing
Note
If one or more of the needles fall abut, they may be
cleaned and put back using more steering gear lube
to hold them in place.
4BUONX-I 00
Sector shaft
1. Inspect the sector gear teeth for chipping, excessive wear
and surface breakdown. Replace the sector shaft if dam-
age is found.
2. Measure the clearance between the sector adjusting
7 . 0.lOmm MAX screw head and the bottom of the sector T-slot.
0.004 in MAX)
:HECK WITH
-EELER GAUGE Clearance
Maximum: 0.lOmm (0.004 in}
3.Add shims as required to reduce the clearance to the

specification.
4. While holding the sector adjuster screw, turn the sector
shaft back and forth. The sector shaft rnust turn freely. If
the sector shaft does not turn freely, increase the T-slot
clearance using an appropriate shim from the lash ad-
juster kit. However, make sure that the resulting clearance
is not more than 0.lOmm (0.004 in).
N MANUAL STEERING
Assembly Note e
BEARING CUP Wormshaft seal
REPLACER Install the wormshaft seal using Bearing Cup Replacer
T82T-3504-AH
T82T-3504-AH, or equivalent.
BEARING CUP REPLACER

Sector shaft seal
T82T-3504-AH Install the sector shaft seal using Bearing Cup Replacer
Wormshaft upper bearing cup

lnstall a new bearing cup using Bearing Cup Replacer
I BEARING CUP REPLACER
T82T-3504-AH
MANUAL STEERING N
Wormshaft lower
e bearing
e cup
Install a new bearing cup using Bearing Cup Replacer
Wormshaft
1. Rotate the wormshaft in the ball nut. If tightness or binding
is felt, replace the assembly.
2. Apply steering gear grease to the wormshaft bearings.
3. Install the wormshaft thrust bearings over the wormshaft
splined end.
I SECTIONAL VIEW I 4. Insert the wormshaft assembly into the housing.
5. Feed the splined end of the wormshaft through the bear-
ing cup and seal.
6. Place the remaining wormshaft thrust bearing in the
adjuster plug bearing cup.
7. Install the adjuster plug and locknut into the housing
opening.
Sector cover and bushing assembly, housing
1. Position the sector adjusting screw and shim into the
sector shaft slot.
2. Check the clearance between the screw head and the
bottom of the sector shaft T-slot.
Clearance
Maximum: 0.1Omm (0.004 in)
3. If the clearance is greater than the specification, install a

new shim as required to reduce the clearance.
4. Lubricate the steering gear with 290 grams (10.2 02.) of
steering gear grease.
(1) Rotate the wormshaft until the ball nut is near the end
of its travel.
(2) Pack grease into the housing.
(3) Rotate the wormshaft to the opposite end.
(4) Pack the remaining grease into the housing.
5. Rotate the wormshaft until the ball nut is in the center of
travel.
6. Insert the sector shaft assembly into the housing so that
the center tooth enters the center rack tooth space in the
ball nut.
7. Pack the remaining grease into the housing.
8.Apply a 3.20mm (0.13 in) wide x 3.20mm (0.13 in}
high bead of silicone sealant to the mating surfaces of the
sector cover and housing.
Note
The two mating surfaces must be! dry and free of
grease and all foreign materials.
N MANUAL STEERING
9. Approximately five minutes after applying the sealant,
engage the sector adjuster screw with the tapped hole in
the center of the sector cover by turning the screw coun-
terclockwise.
10. Install the sector cover washer and bolts.
Note
Do not torque the bolts unlessthere is lash between
the sector shaft and wormshaft. Lash can be ob-
tained by turning the screw counterclockwise.
Tightening torque:
43-54 N-m (4.4-5.5 kgf.m, 3 2 4 0 ft.lbf)
11. Adjust the steering gear preload and meshload. (Refer to

below.)
Adjustment
To adjust the preload and meshload, refer to page N-6.
4BUONX-108
MANUAL STEERING N
STEERING LINKAGE
Removal / lnstallation
3, Install in the reverse order of removal, referring to lnstallation Note.
4. Check the vehicle toe-in and adjust if necessary. (Refer to Section R.)
SPINDLE SERVICE,
TN
M
CO'TTER PIN,
0 REPLACE
VlEW W
I VlEW W
MNI 054-0
1. Center link 3. Outer tie rod
Removal Note ........................ page N-32 Removal Note ........................ page N-33
Installation Note ..................... page N-34 Installation Note ..................... page N-34
2. Inner tie rod 4. Pitman arm
N MANUAL STEERING
COTTER PIN, 7&
-.
- 7b%aim--\
. A
SPINDLE SERVICE,
0 70-100
COlTER PIN,
REPLACE
(7.2-1 0.0.
52-73} '
SECTION M
N-m (kgf.m, ft.lbfl
I d
MN1055-D SBUONX 022
1. Center link 3. Outer tie rod

Removal Note ................................. below Removal Note ........................ page N-33
2. Inner tie rod 4. Pitman arm
PITMAN ARM PUL Removal Note

Center link
1 . Remove the cotter pin and nut from the center link ball stud
at the pitman arm.
2. Place the jaws of Pitman Arm Puller T64P-3590-F, or
equivalent between the pitman arm and the center link ball
stud boot.
3. Tighten the adjusting screw until the center link separates
from the pitman arm.
4. Remove the cotter pins and nuts from the ball studs at the
inner tie rod and center link.
MN1052-B 4BUONX-111 5. Place the jaws of Pitman Arm Puller T64P-3590-F, or
equivalent between the center link and the inner tie rod
boot.
from the inner tie rod.
7. Loosen the bolts on the center link adjusting sleeve. Count
the number of turns it takes to remove the center link.
MANUAL STEERING N
Inner tie rod
1. Remove the cotter pin and nut from the inner tie rod ball
stud at the center link.
2. Place the jaws of Pitman Arm Puller T64P-3590-F, or
equivalent between the center link and the inner tie rod
boot.
from the inner tie rod.
4. Loosen the bolts on the adjusting sleeve. Count the
number of turns it takes to remove the inner tie rod.
4BUONX-112
Outer tie rod

1. Remove the cotter pin and nut from the outer tie rod ball
stud at the knuckle.
2. Place the jaws of Pitman Arm Puller 'T64P-3590-F, or
equivalent between the spindle and the outer tie rod boot.
3. Tighten the adjusting screw until the outer tie rod sepa-
rates from the spindle.
4. Loosen the bolts on the adjusting sleeve. Count the
number of turns it takes to remove the outer tie rod.
4BUONX-I13
PlTMAlJ ARM PUI

Pitman arm
T64P-3590-F 1. Remove the pitman arm nut and washer.
2. Place the jaws of Pitman Arm Puller 'T64P-3590-F, or
.equivalent between the pitman arm and the steering
gear.
3. Tighten the adjusting screw until the pitman arm sepa-
rates from the steering gear.
I
MN1053-B 4BUONX-114
Installation Note
Pitman arm
Install pitman arm on the steering gear sector shaft with
the front wheels and steering wheel in the straight-ahead
position.
Tightening torque:
230-310 N-m (23.5-31.5 kgf.m, 1'70-228 ft.lbf)
4BUONX-115
MANUAL STEERING
Outer tie rod
1. lnstall the outer tie rod in the adjusting sleeve using the
same number of turns it took to remove it.
2. Position the adjusting sleeve clamps facing down.
Tightening torque:
40-57 N-m(4.1-5.8 kgfam, 3 0 4 2 ftelbf}
3. Position the outer tie rod in the knuckle.
Tightening torque:
70-1 00 N.m (7.2-1 0.0 kgf.m, 52-73 ft.lbf}
5BUONX-023
Inner tie rod

I . Install the inner tie rod in the adjusting sleeve using the
Tightening torque:
40-57 N-m(4.1-5.8 kgf-m, 3 0 4 2 ft-lbf)
3.Position the inner tie rod in the center link.

Tightening torque:
70-1 00 N.m (7.2-1 0.0 kgf-m, 52-73 ftelbf}
5BUONX-024
Center link
1. Install the center link in the adjusting sleeve using the
Tightening torque:
40-57 N-m (4.1-5.8 kgf-m, 3 0 4 2 ft-lbf)
3. Position the center link in the pitman arm.
Tightening torque:
70-1 00 N-m (7.2-1 0.0 kgfam, 52-73 f t lbf)
4. Position the inner tie rod in the center link.
Tightening torque:
70-1 00 N.m (7.2-1 0.0 kgf-m, 52-73 ft-lbfl
5BUONX-025
POWER STEERING N
POWER STEERING
PREPARATION
SST
49 GO19 OAO For

holding
Transaxle steering gear
hanger
4BUONX-119
I Problem I Possible Cause 1 Action I Pagelsection I

Steering feels heavy lmproperly adjusted wheel alignment Adjust Section R
, lncorrect tire pressure Adjust Section Q
Damaged flexible coupling Replace N- 8
' Leakage of fluid Repair or replace -
I Loose or damaged oil pump drive belt
Adjust or replace N-61
Low fluid level or air in fluid Add flu~dor bleed air N-37, 36
Insufficient PIS oil pump pressure Replace N-49
Loose or damaged pulley Tighten or replace N-49
Malfunctioning steering gear assembly Repair or replace N-40
~ - - ~~
Improperly adjusted steering gear meshload Adjust
-- - -- -
N-39
Steering wheel pulls Adjust Section Q
to one side Unevenly worn tires Replace Section Q
Worn or damaged ball joint Replace Section R
Dragging brake Repair Section P
lmproperly adjusted wheel alignment Adjust Section R
Malfunctioning steering gear assembly -
.
Repair or replace N-40
General instability Adjust Section Q
while driving I Damaged or unbalanced wheel Adjust or replace Section Q
Worn or damaged ball joint Replace Section R
lmproperly adjusted steering gear meshload Adjust N-39
I Damaged shock absorber Replace Section R
i lmproperly adjusted wheel alignment Adjust Section R
Worn or damaged flexible coupling Replace N- 8
I Loose steering gear mounting bolts Tighten N-40
i Loose or damaged pitman arm Tighten or replace N-40
~ .- ~ ~- - - --
Shake Excessive tire andlor wheel runout Replace Section Q

(steering wheel Loose lug nut(s) Tighten Section Q
vibrates upldown) Unbalanced wheel(s) Adjust or replace Section Q
Cracked or worn engine mount rubber Replace Sections B1,
B2, B3
Cracked or worn transmission mount rubber 1 Replace Sections J1, K
Cracked or worn steering gear mount rubber Replace
steering wheel Loose steering gear mounting bolts Tighten N-40
vibrates Stuck or damaged tie rod ball joint Replace N-31
circumferentially) Excessive tire andlor wheel runout ~e'~lace Section Q
Loose lug nuts Tighten Section Q
Unbalanced wheel(s) Adjust or replace Section Q
lncorrect tire pressure Adjust Section Q
Unevenly worn tires Replace Section Q
Damaged shock absorber Replace Section R
Loose shock absorber mounting bolts Tighten Section R
lmproperly adiusted front wheel alianment Adiust Section R
N POWER STEERING
I
Problem Possible Cause Action Pagelsection

- - --- -- -- - -- --- - - -- - - - - - - - -
Excessive steering
wheel play I Worn steering gear
Loose steering gear mounting bolts
Replace
Tighten
N-39
Section R
N-40
Replace N-31
- - - - - - -- -- -- --
Replace-
- - +-- - - --- N--8 -
Poor steering Incorrect tire pressure Adjust Sect~onQ
wheel return Stuck or damaged tie rod ball joint Replace N-31
Improperly adjusted front wheel al~gnment Adjust Section R
Stlcking steering column bearing N- 8
.- - - -- -- --
N-39
Abnormal noise from N-49
steering system Loose steering gear mounting bolts T~ghten N-40
1 Loose or damaged oil pump drive belt Adjust or replace N-61
Air in system , Bleed air N-36
Malfunctioning steerlng gear 1 Repair or replace N-40
Malfunctioning PIS oil pump 1 Replace N-49
MN1138 D2 SBUONX 080
AIR BLEEDING
Procedure A
Vacuum fill process
1 . Disconnect the ignition coil harness connector to prevent
the engine from starting.
2. Fill the reservoir.
3. Crank the engine with the starter and continue adding fluid
until the level remains constant.
Caution
Be careful to avoid prolonged cranking as the
battery may be drained and the starter damaged.
4. Rotate the steering wheel approximately 30" each side of

center while continuing to crank the engine.
5. Re-check the fluid level and fill as required.
6. Reconnect the ignition coil harness connector.
7. To clear fault codes, disconnect the battery for one minute
and then reconnect the battery.
8. Start the engine, allow it to run for several minutes. Rotate
the steering wheel from stop to stop.
9. Shut off the engine and re-check the fluid level. Add as
required.
SBUONX-070
POWER STEERING
Procedure B
Devac system
Note
(1/4-5/66 INCH) TUBING Fabricate a devac purging tool as shown in the
PLEXIGLASS, STEEL
-1
OR COPPER illustration.
1
- -- .- .-
(
HOSE
6.35-7.93MM
(1/4-5/16 INCH)
HOLE
HOLD BACK AT LEAST 1/8"
MN1147-B
I I 1. Tightly insert the rubber stopper of the air evacuator
assembly into power steering oil reservoir.
2. Reconnect ignition connection and start engine.
3. Apply vacuum for minimum of three minutes at idle; main-
tain maximum vacuum with vacuum source.
Vacuum: 68-85 kPa (20-25 in-Hg)
4. Release vacuum and remove vacuum source.
5. Add fluid to FULL WARM or power steering oil reservoir
center mark.
6. Reinstall vacuum source and apply vacuum.
Vacuum: 68-85 kPa (20-25 in-Hg)
7. Cycle steering wheel from lock to lock every 30 seconds
for approximately 5 minutes.
Caution
Do not hold steering wheel on stops.
8. Shut engine off, release vacuum and remove vacuum
source.
9. Add fluid if necessary and install dipstick or reservoir cap.
POWER STEERING FLUID

RESERVOIR - On-Vehicle lnspection
lnspection of power steering fluid level
Check the power steering fluid level, and add fluid to the
specified level if necessary.
Caution
Use only the specified power steering fluid.
% Fluid specification:
ATF Type F (M2C33-F) or DexronBII
Fluid leakage
Caution
To prevent damage to the steering system, do not
keep the steering wheel in the fully turned position
for more than 15 seconds.
Start the engine and let it idle. Turn the steering wheel fully
left and right to apply fluid pressure. Check for fluid
leakage.
4BUONX-124
N POWER STEERING
Fluid pressure
I OIL PUMP
/
STEERING
GEAR
\
1. Disconnect the pressure hose from the oil pump. Attach
Power Steering Analyzer D79L-33610-A adapters, or
equivalent to the oil pump and high pressure hose.
2. Connect Power Steering Analyzer D79L-33610-A, or
equivalent to the adapters.
Tightening torque:
POWER STEERING \ I 20 N.m (2.1 kgfsm, 15 ftelbf)
ANALYZER EXISTING HOSE
D79L-33610-A HIGH PRESSURE
3. Bleed the air from the system. (Refer to page N-56.)
4. Open the gauge valve fully. Start the engine and turn the
steering wheel fully left and right to raise the fluid tempera-
ture to 74--79°C { I65-1 75°F).
Caution
If the valve is left closed for more than 5 seconds,
the fluid temperature will increase excessively and
adversely affect the oil pump.
5. Close the gauge valve completely. Measure the fluid

pressure generated by the oil pump. If the pressure is not
within specification, replace the oil pump assembly.
(Refer to page N-69.)
Oil pump fluid pressure

2.3L, 4.0L:
7240-8480 kPa (73.8436.5 kgf/cm2,
1050-1 230 psi)
3.0L:
8964-1 0205 kPa (91.4-1 04.0 kgf/cm2,
1300-1 480 psi)
6. Open the gauge valve fully.

Caution
If the steering wheel is kept in the fully turned
position for more than 15 seconds, the fluid tem-
perature will rise excessively and adversely affect
the oil pump.
7. Turn the steering wheel fully left and right and measure the
fluid pressure generated within the gear housing. If the
pressure is not within specification, repair or replace the
steering gear assembly.
Gear housing fluid pressure

2.3L, 4.0L:
7240-8480 kPa (73.8--86.5 kgf/cm2,
1050-1 230 psi)
3.0L:
8964--10205 kPa (91-4-1 04.0 kgf/cm2,
1300-1 480 psi)
8. Remove the gauge set. Install and tighten the pressure

hose to the specified torque.
Tightening torque:
41-54 N.m (4.1-5.5 kgf-m, 3 0 4 0 ft-lbf)
9. Bleed the air from the system. (Refer to page N-36.)

POWER STEERING
STEERING WHEEL AND COLUMN
On-Vehicle
e e Inspection
e
Adjustment e
e
Meshload
1. Disconnect the pitman arm from the sector shaft.
2. Disconnect the fluid return line at the reservoir and cap the
reservoir return line.
3. Place the end of the return line in a clean container and
turn the steering wheel from stop to stop several times to
drain the fluid from the gear. Discard the fluid.
4. Turn the steering wheel 45" from the right stop.
5. Attach an inelbf torque wrench to the steering wheel nut
and determine the torque required to rotate the shaft
approximately one-eighth turn from the 45" position to-
ward center.
6. Turn the steering gear back to center and determine the
torque required to rotate the shaft back and forth across
the center position (+ 90").
7. If reset is required, loosen theadjuster locknut and turn the
sector shaft adjuster screw until the reading is the speci-
fied value greater than the torque at 45" from the stop.
Meshload checking and setting
I Vehicles With 0-43046 km (0-5000 Miles)

CHECKING:
--
Vehicles With More Than 8046 km I5000 Miles) or
Where Sector Shaft Has Been Replaced
CHECKING:
---
Reset if total meshload over rr~echanicalcenter is less than Reset if meshload measured while rocking input shaft over
1.13 N.m {l0 in.lbf) greater than the torque 45" from the center is less than 1.I3 N.m (10 in.lbf) greater than the
right stop. torque 45" from the right stop.
----
RESET: RESET:
Set torque measured rocking across center to a value Set torque measured rocking across center to a value
of 1.&I .4 N-m {9--12 indbf) greater than that measured 1.O-1.4 N.m {9-12 indbf) greater than that measured 45"
45" from the right stop. from the right stop.
dN1140-B 5BUONX-02
8. Hold the sector shaft screw in place and tighten the

locknut.
9. Re-checkthe torque readings and replace the pitman arm
and steering wheel pad.
10. Connect the fluid line to the reservoir and fill the reservoir
to the specified level.
Refer to page N-8.
Refer to page N-12.
N POWER STEERING
STEERING GEAR
1. Disconnect the supply and return lines from the steering gear. Plug the lines and the ports in the gear.
4. Bleed the air from the power steering gear. (Refer to page N-36.)
N.m (kgf.m, ft.lbf)

MN1209-A 5BUONX-028
1. Steering gear shaft U-joint upper shield 4. Steering gear
2. Flex coupling Installation Note ..................... page N-41
3. Pitman arm Disassembly / Assembly
Removal Note ................................. below (for steering gear) ................. page N-41
Installation Note ..................... page N-41 Disassembly / Assembly
(for valve housing) ................ page N-47
5. Steering gear shaft U-joint lower shield
Removal Note
Pitman arm
Remove the pitman arm using Pitman Arm Puller T64P-
3590-F or equivalent.
POWER STEERING
Installation Note
Steering
e gear
1. Center the steering gear input shaft with the indexing flat
facing down.
2. Position the steering gear input shaft into the flex coupling.
Tightening torque:
40.3-54.7 N . m (4.1-5.5 kgf .m, 29.4-39.9 ft - lbf)
3. Install the steering gear bolts.
Tightening torque:
68-84 N .m (6.9-8.5 kgf m, 50-62 ft - Ibf)
4. Connect and tighten the supply and return lines.
Tightening torque:
2 7 4 1 N-m (2.8-4.1 kgf-m, 20-30 ft.lbf)
5. Add ATF Type-F (M2C33-F) or ~ e x r o n @

II.
6BUONX-009
Pitman arm
Straighten the front wheels before insfalling the pitman
arm.
Tightening torque:
230-31 0 N .m (23.5-31.4 kgf .m, 170-228 ft .lbf)
6BUONX-010
Steering gear
Note
Use a clean workbench and tools.
Thoroughly clean the exterior of the gear with solvent and drain off excess hydraulic fluid, if
necessary.
Handle all parts carefully to avoid nicks, burrs, scratches and dirt.
Do not use solvent on seals.
1. Rotate the input shaft from stop to stop, counting the total number of turns. Then turn the input shaft back
exactly half way.
Note
The indexing flat on the input shaft spline should be facing downward.
2. Remove the sector shaft cover attaching bolts.

3. Remove the sector shalt jam nut.
4. Tap the lower end of the sector shaft with a soft hammer to loosen it, and lift the cover and shaft from the
housing as an assembly. Discard the O-ring.
5. Remove the nut from the sector shaft adjusting screw. Turn the sector shaft cover couriterclockwise and
remove it from the sector shaft adjusting screw. It may be necessary to hold the screw with ascrewdriver.
Note
Refer to page N-65 for servicing of steering gear housing.

8. Adjust the meshload. (Refer to page N-39.)
N POWER STEERING
I IDENTIFICATION TAG
SECTOR SHAFT
{7.+12.4,55--90)
HOUSING
SHAFT
MN1014-C 5BUONX-031
1. Valve housing 6. Worm bearing race locknut
Disassembly Note ........................... below Disassembly Note .................. page N-43
Assembly Note ....................... page N-44 7. Worm and valve assembly
2. Ball guide clamp Disassembly Note .................. page N-43
3. Ball guide Assembly Note ....................... page N-43
4. Balls (27-29) 8. Piston
Disassembly Note ........................... below Assembly Note ....................... page N-45
5. Race locknut set screw
Disassembly Note ........................... below
Disassembly Note
Valve housing
Refer to page N-67 for disassembly and assembly.
Balls
Rotate the input shaft from stop to stop until all the ballsfall
from the piston into a container.
4BUONX-135
Race locknut set screw

Install the valve body assembly in the SST and loosen the
race locknut set screw.
4BUONX-136
POWER STEERING N
Worm bearing race locknut
TO PISTON Remove the worm bearing race locknut using Adjuster
T66P-3553-C and Locknut Wrench T66P-3553-8 and Spacer Valve
Housing To Piston T66P-3553-C, or equivalents.
Worm and valve sleeve assembly (valve sleeve seals)
Remove the valve sleeve seals from the sleeve by insert-
ing the blade of a small pocket knife under them and
cutting thern off.
Caution
Do not scratch the valve sleeve.
6BUONX-011
Assembly Note
Worm and valve sleeve assembly
1. Mount the worm end of the worm and valve sleeve
assembly into a soft-jawed vise.
I I
MNI 023-A
2. Install Mandrel Tool T75L-3517-A1,or equivalent over the
sleeve. Slide one valve sleeve ring over the mandrel tool.
3. Slide Pusher Tool T75L-3517-A2, or equivalent over the

mandrel tool. Push down on the pusher tool, forcing the
seal down the ramp into the fourth groove of the valve
sleeve.
TOOL
7-A2
N POWER STEERING
4. Repeat this step three times and add Spacer Tool T75L-
3517-A3, or equivalent each time under the pusher tool.
MANDREL TOOL
5. Apply ATF Type-F (M2C33-F) or Dexrone II to the valve
T75L-3517-A1 sleeve and rings.
SPACER TOOL
T75L-3517-A3
6. Install one spacer tool over the input shaft. Slowly install
Sizing Tool T75L-3517-A4, or equivalent over the valve
sleeve end onto the valve sleeve seals. Allow the sizing
tool to sit over the seals for five minutes.
Caution
Do not bend the seals over while using the sizing
tool.
7. Verify that the seals turn freely in the grooves.
6BUONX-012
Valve housing
1. Align the oil passage in the valve housing with the pas-
sage in the gear housing.
2. Place a new O-ring onto the passage hole of the gear
housing.
3. Install the identification tag onto the housing.
4. Install, but do not tighten, the attaching bolts.
Note
The identification tag is to be installed under the
upper right valve housing bolt.
4BUONX-140
POWER STEERING
Piston
1 . Place the piston on the bench with the ball guide holes
facing up. Insert the wormshaft into the piston so the first
groove is in line with the hole nearest the center of the
piston.
2. Apply ATF Type-F (M2C33-F) or Dexrone II to the new
O-ring.
4BUONX-141
Sector shaft
1. Rotate the piston so the teeth are in the same plane as the
sector shaft.
2. Position the sector shaft cover oil seal in the steering gear
housing. Turn the input shaft to center the piston.
3. Apply petroleum jelly or equivalent to the sector shaft
journal, and position the sector shaft and cover assembly
in the gear housing.
6BUONX-013
Steering gear housing

3. Apply a generous amount of NLGl No. 2 to the area between the two seals.
MNIO16-C
1. Snap ring 3. Pressure seal
1 5BUONX-074
2. Dust seal Disassembly Note .................. page N-46

Disassembly Note .................. page N-46 Assembly Note ....................... page N-46
N POWER STEERING
SLIDE HAMMER
Disassembly Note
Dust seal
Remove the dust seal using Puller Attachment T58C-
101-B and Slide Hammer T59L-100-B, or equivalents.
Pressure seal
Remove the pressure seal using Puller Attachment T58L-
4BUONX-145
T58L-101-B
MN1018-B 4BUONX-144
Assembly Note
Dust seal, pressure seal
1. Lubricate the new pressure seal and dust seal with NLGI
No. 2.
2. Apply NLGI No. 2 to the sector shaft seal bore.
3. Place the dust seal on Sector Seal Replacer T77L-
3576-A, or equivalent with the raised lip of the seal toward
the tool.
4. Place the pressure seal on with the lip away from the tool.
SECTOR SEAL REPLACE
T77L-3576-A Note
The flat back side of the pressure seal should be
against the flat side of the dust seal.
5. Insert Sector Seal Replacer T77L-3576-A, or equivalent

into the sector shaft bore and drive the tool until the seals
clear the snap ring groove.
Caution
Do not bottomtheseal against the bearing.The seal
will not function properly when bottomed against
the bearing.
POWER STEERING N
Valve housing
3. Apply a generous amount of NLGl No. 2 between the two seals.
SEAL,
REPLACE
1. Dust seal 4. Bearing

Disassembly Note .................. page N-48 Disassembly Note .................. page N-48
Assembly Note ....................... page N-49 Assembly Note ....................... page N-48
2. Snap ring 5. Inlet tube
3. Oil seal Assembly Note ....................... page N-48
Disassembly Note .................. page N-48 6. Outlet tube
N POWER STEERING
Disassembly Note
SHAFT BEARINGISEAL TOOL
T65P-3524-A3 Dust seal
Remove the dust seal using Puller Attachment T58L-
SHAFT BEARING/ Bearing, oil seal
1. Mount the valve housing in the SST.
2. Remove the oil seal and bearing using Shaft Bearing1
Seal Tools T65P-3524-A2 and T65P-3524-A3, or
equivalents.
Caution
Do not damage the housing when inserting and
removing the tools.
4BUONX-149
MN1020-B 4BUONX-148
Inlet, outlet tubes
Remove the inlet and outlet tubes using Tube Seat
Remover T74P-3504-L, or equivalent.
4BUONX-150
Assembly Note
Inlet, outlet tubes
1. Coat the fluid inlet and outlet tube seats with petroleum
jelly.
2. Install the seats in the housing using Tube Seat Installer
T74P-3504-M, or equivalent.
6BUONX-014
Bearing
Seat the bearing in the valve housing using TOOL
T65P-3524-A1, or equivalent.
Note
Install the bearing with the metal side covering the
rollers facing outward.
Oil seal
1 . Dip the new oil seal in ATFType-F (M2C33-F)or Dexron@ll,
and place it in the housing with the metal side facing
outward.
POWER STEERING N
2.Drive the seal into the housing using TOOL
T65P-3524-A1, or equivalent.
Snap ring
Install the snap ring using TOOL T65P-3524-A1, or
equivalent.
4BUONX-154
Dust seal
1. Place the dust seal in the housing with the dished side
facing out.
2. Drive the dust seal into place using TOOL T65P-
3524-A1, or equivalent.
4BUONX-155
OIL PUMP
1. Disconnect the pressure pipe and return hose from the oil pump.
2. Loosen the belt tension and remove the drive belt from the pulley, referring to Removal Note.
3. If necessary, remove the oil dipstick tube.
Note
Use a container or rags to collect the power steering fluid when disconnecting the pressure
pipe and return hose.

7. After installation:
(1) Check the drive belt tension. (Refer to page N-61.)
(2) Check all connections for fluid leakage.
(3) Check the fluid level. Add fluid if necessary.
N POWER STEERING
I I
MN1029-D 5BUONX-076
1. Oil pump pulley 2. Oil pump
Removal Note ......... ............... N-52 Installation Note ..................... page N-52
Installation Note ..................... N-53 Disassembly / Assembly ........ page N-54
POWER STEERING N
I
MN1030-C 5BUONX-033
1. Support brace 3. Oil pump
2. Oil pump pulley Installation Note ..................... page N-52
Removal Note ........................ page N-52 Disassembly / Assembly ........ page N-54
Removal Note
GENERATOR
Drive belt
IDLER 1. On the 2.3L and 4.OLengines, loosen drive belt tension by
lifting tensioner pulley in a counterclockwise direction.
Remove the drive belt.
TENSIONER
IDLER W/P
CRANKSHAFT
1 2.3L AND 4.OL DRIVE BELT

INSTALLATION 1
N POWER STEERING
GENERATOR IDLER
the tensioner pulley in a clockwise direction. Remove the
drive belt.
WlTHOUT
NC
IDLER CRANKSHAFT
3.OL DRIVE BELT
INSTALLATION WITH AIC
MN1172-B 4BUONX-159
Oil pump pulley
I . Install Pulley Removal Tool T69L-10300-B or equivalent
on the pulley.
2. While holding the Pulley Removal Tool nut stationary with
a wrench, rotate the inner spindle of the Pulley Removal
Tool clockwise until the pulley is pulled off the power
steering shaft.
4BUONX-160
2.3L Installation Note

Oil pump
Install the oil pump.
Tightening torque:
2.3L:
41-61 N.m (4.2-6.2 kgf-m, 30-45 ft-Ibf)
N m {kgf rn, R Ibf)

POWER STEERING N
4.0L:
47-64 N .m (4.9-6.4 kgf .m, 35-4'7 ft .Ibf)
Oil pump pulley

Install the pulley using Pulley Replacer Tool T65P-
3A733-C or equivalent.
Note
Make sure the pull-off groove on the pulley is
facing the front and is flush with the end of th
+
shaft 0.254mm (0.010 in).
6BUONX-016
N POWER STEERING
O-RING
nEPlnd~m
-
@I,
POWER STEERING
1 . Outlet fitting 12. Rotor
2. Flow control valve Assembly Note ....................... page N-59
3. Spring 13. Rotor shaft
4. Reservoir Assembly Note ....................... page N-59
5. Retaining ring 14. Dowel pins
Disassembly Note ........................... below 15. Lower plate
6. Valve cover Assembly Note ....................... page N-57
Assembly Note ....................... page N-60 16. Disc spring
7. O-ring Disassembly Note .................. page N-56
Assembly Note ....................... page N-60 Assembly Note ....................... page N-57
8. Upper plate 17. Shaft seal
9. Slippers Assembly Note ....................... page N-57
Assembly Note ....................... page N-59 18. Retainer
10. Cam insert Disassembly Note .................. page N-56
11. Rotor shaft retaining ring Assembly Note ....................... page N-57
Assembly Note ....................... page N-57 19. O-ring
Disassembly Note
Retaining ring
1. Place C-Clamp T74P-3044-Al , or equivalent in a bench
vise.
2. Place Lower Support Plate T78P-3733-A2, or equivalent

LOWER SUPPORT PLATE over the pump rotor shaft.
T78P-3733-A2 3. Install Upper Compressor Plate T78P-3733-A1, or equiva-
lent into the upper portion of the C-clamp.
4. While holding the upper compressor plate, place the
pump assembly into the C-clamp with the rotor shaft
facing down.
N POWER STEERING
5. Tighten the C-clamp until a slight bottoming of the valve
UPPER COMPRESSOR PLATE
T78P-3733-A1 cover is felt.
LOWER SUPPORT PLATE

l78P-3733-A2
I I
MN1035-B
6. Insert a small drift or suitable tool through the hole in the
side of the pump housing. Push inward on the valve cover
retaining ring. While applying pressure to the retaining
ring, place a screwdriver under the edge of the ring and
remove the ring.
MN1036-A 4BUONX-164
Lower plate, disc spring
1 . Place the pump housing on a flat surface.
2. Raise slightly and slam the housing plate down flatly until
the lower plate and disc spring fall out.
Shaft seal, retainer

Remove the rotor shaft seal and the seal retainer simulta-
neously by prying out with a screwdriver.
Note
Only use this method when the pump is disas-
sembled.
POWER STEERING N
Assembly Note
Rotor shaft retaining
e ring
Installthe retaining ring in the groove at the end of the rotor
shaft using Retaining Ring Pliers D79L-7000-A,orequiva-
lent.
4BUONX-167
Shaft seal, retainer

1. Install a new rotor shaft seal using Seal Driver T78P-3733-
A3, or equivalent and plastic mallet.
2. Install the retainer using Seal Driver T78P-3733-A3, or
equivalent and a plastic mallet.
Disc spring
The disc spring must be inserted with the dished surface
upward.
Lower plate
1. Lubricate the inner and outer O-ring seals with ATF
Type F (M2C33-F) of Dexron@ll.
2. Install the O-ring seals on the lower plate.
5. Place Seal Driver T78P-3733-A3, or equivalent into the
rotor shaft hole.
\
SEAL DRIVER
T78P-3733-A3
6. Press on the lower plate lightly to seat the O-rings.

POWER STEERING N
Rotor, slippers
1. Place the insert cam over the rotor. Be sure the recessed
fiat on the insert cam is toward the reservoir.
2. With the rotor extended upward approximately half-way
out of the cam, insert the spring into the rotor spring
pocket.
3. Use one of the slippers to compress the spring and install
the slipperwith the narrow groove spacing facing the cam.
Note
The slippers must be orientated with the narrow rail
spacing towards the cam, otherwise the pump will
not function.
4. Hold the cam stationary, and turn the rotor either right or
left one space at a time, and install another spring and
slipper until all ten rotor cavities have been filled.
Note
Be careful when turning the rotor that the springs
and slippers already installed do mot fall out.
Upper plate
When installing the upper plate into the pump housing,
observe the notch on the outside diameter of the plate.
One side has a square positioned approximately 180"
opposite the pump square mounting boss.
Note
The square recess must be facing toward the reser-
voir and positioned approximately 180" opposite
the pump square mounting boss.
Rotor shaft
PLACE DOWEL PINS
THROUGH THESE HOLES The stepped holes must be used for the dowel pins, and
the recessed notch in the cam insert must face toward the
reservoir and be approximately 180" opposite the square
pump mounting boss.
Note
The recessed notch i n the cam insert is approxi-
mately 180°0pposite of thesquare mounting lug on
the aluminum housing.
INLET PORTS
N POWER STEERING
Valve cover
1. Be sure the plastic baffle is securely in place in the valve
cover.
MNI 047-A
2. Be sure the outlet fitting is directly in line with the square
mounting boss of the pump housing plate.
Note
Pressure channel in the valve cover fits directly
over the recess in the upper plate.
MN1048-A 4BUONX-174
Retaining ring
1. Place the pump assembly in C-clamp T74P-3044-A1, or
equivalent and compress the valve cover in the pump
housing plate, until the retaining ring groove is exposed in
the pump housing plate.
2. Installthe retaining ring with the ends near the access hole
in the pump housing plate.
O-ring
Apply petroleum jelly to the reservoir O-ring seal and the
inside edge of the reservoir.
POWER STEERING N
DRIVE BELT
Inspection
1. Check the drive belt forwear, cracks, and fraying. Replace
if necessary.
pulleys.
I I
MN1142-A 4BUONX-177
Drive belt tension check
that indicate when the drive belt is worn. A pointer and
BELT gauge are built into the tensioner. When the pointer no
REPLACEMENT longer registers within the range limits of the gauge, the
belt must be replaced.
2.3L ENGINE
21" NOM /
REPLACEMENT
3.OL ENGINE
N POWER STEERING
Adjustment
and belt tension adjustment is not required.
4BUONX-180
4:
Replacement
2.3L WITH AIC
I I 1. On the 2.3L and 4.OL engines, loosen the drive belt
tension by lifting the tensioner pulley in the counterclock-
wise direction.
GENERATOR 2. On the 3.OL engine, loosen the drive belt tension by lifting
IDLER , PIS the tensioner pulley in the clockwise direction.
3. Remove and replace the drive belt.
TENSIONER
CRANKSHAFT A/C-PS
1 GENERATOR
\ D
"I':
AIR
CONDITIONING
LESSNC
I WATER
PUMP
BRAKING SYSTEM
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . P- 2 REAR ANTI-LOCK BRAKE SYSTEM

BRAKE SYSTEM . . . . . . . . . . . . . . . . P- 2 (RABS) . . . . . . . . . . . . . . . . . . . . . . . . . P- 38
PARKING BRAKE . . . . . . . . . . . . . . . . P- 4 DESCRIPTION . . . . . . . . . . . . . . . . . . P- 38
REAR ANTI-LOCK BRAKE TROUBLESHOOTING GUIDE . . . . . P- 38
SYSTEM . . . . . . . . . . . . . . . . . . . . . . P- 5 WIRING DIAGRAM . . . . . . . . . . . . . . . P- 39
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . P- 8 RELATIONSHIP CHART . . . . . . . . . . P- 40
SPECIFICATIONS . . . . . . . . . . . . . . . . P- 8 DIAGNOSTIC CHART . . . . . . . . . . . . P- 40
CONVENTIONAL BRAKE SYSTEM . . P- 9 DIAGNOSTIC INDEX . . . . . . . . . . . . . P- 41
TROUBLESHOOTING GUIDE . . . . . P- 9 SYMPTOMTROUBLESHOOTING . P- 42
AIR BLEEDING (VEHICLE SELF DIAGNOSIS FUNCTION . . . . . P- 49
EQUIPPED WITH RABS) . . . . . . . P-10 INSPECTION BY DIAGNOSTIC
AIR BLEEDING (VEHICLE TEST MODE . . . . . . . . . . . . . . . . . . P- 49
EQUIPPED WITH 4WABS) . . . . . . P-11 OUTLINE . . . . . . . . . . . . . . . . . . . . . . . P- 49
BRAKE HYDRAULIC LINE . . . . . . . . P-12 RABS HYDRAULIC UNIT . . . . . . . . . P- 64
BRAKE FLUID . . . . . . . . . . . . . . . . . . . P-13 RABS CONTROL UNIT . . . . . . . . . . . P- 65
VACUUM LINEICHECK VALVE . . . . P-13 REAR SPEED SENSOR
BRAKE PEDAL . . . . . . . . . . . . . . . . . . P-14 (RABS AND ABS) . . . . . . . . . . . . . . P- 65
MASTERCYLINDER . . . . . . . . . . . . . P-17 REAR SPEED SENSOR ROTOR
POWER BRAKE UNIT . . . . . . . . . . . . P-20 (RABS AND ABS) . . . . . . . . . . . . . . P- 66
FRONT BRAKE (DISC) . . . . . . . . . . . P-22 4-WHEEL ANTI-LOCK BRAKE
DISCPLATE . . . . . . . . . . . . . . . . . . . . P-26 SYSTEM (4WABS) . . . . . . . . . . . . . . . P- 68
CALIPER . . . . . . . . . . . . . . . . . . . . . . . P-29 DESCRIPTION . . . . . . . . . . . . . . . . . . P- 68
REAR BRAKE (DRUM) . . . . . . . . . . . P-30 TROUBLESHOOTING GUIDE . . . . . P- 68
WHEEL CYLINDER . . . . . . . . . . . . . . P-34 WIRING DIAGRAM . . . . . . . . . . . . . . . P- 69
PARKING BRAKE SYSTEM . . . . . . . . . P-35 RETRIEVING DTCS . . . . . . . . . . . . . . P- 71
TROUBLESHOOTING GUIDE . . . . . P-35 CLEARING DTCS . . . . . . . . . . . . . . . . P- 72
RELEASING CABLE TENSION . . . . P-35 ABS HYDRAULIC UNIT . . . . . . . . . . . P-122
RESETTING CABLE TENSION . . . . P-36 ACCELERATION SENSOR . . . . . . . . P-122
PARKING BRAKE SHOE . . . . . . . . . . P-37 ABS CONTROL UNIT . . . . . . . . . . . . P-123
PARKING BRAKE (PEDAL TYPE) . . P-37 FRONT SPEED SENSOR . . . . . . . . . P-124
FRONT PARKING BRAI<E CABLE .
REAR PARKING BRAKE CABLE . . .
P-37
P-37
FRONT SPEED SENSOR ROTOR .
REARSPEEDSENSOR
P-124
I
PARKING BRAKE PEDAL . . . . . . . . . P-38 (RABS AND ABS) . . . . . . . . . . . . . . P- 65
REARSPEEDSENSORROTOR
(RABS AND ABS) . . . . . . . . . . . . . . P- 66
6BUOPX-100
P INDEX
INDEX
BRAKE SYSTEM
INDEX
I . Brake hydraulic line 6. Front brake (disc)
Inspection / Removal 1 lnspection (On-vehicle) .....,..... page P-22
lnstallation ............................ page P-12 Removal / Inspection 1
2. Brake fluid lnstallation ............................ page P-23
lnspection ............... ........... ..... page P-13 7. Disc plate
Replacement .... ..... ................ page P-13 lnspection ....... ............ ....... .. page P-26
3. Brake pedal 8. Caliper
lnspection (On-vehicle) .......... page P-14 Disassembly / Inspection /
Removal / Inspection / Assembly ................. ....... ...... page P-29
lnstallation 9. Hear brake (drum)
Automatic ........................... page P-15 lnspection (On-vehicle) .......... page P-30
Manual ..... ......... ..... ............. page P-16 Removal / Inspection /
4. Master cylinder lnstallation ............................ page P-30
Removal / lnstallation ............. page P-17 10. Wheel cylinder
Disassembly / Inspection / Disassembly / Inspection /
Assembly .............................. page P-19 Assembly .............................. page P-34
5. Power brake unit 11. Parking brake shoe
Quick lnspection Removal / Inspection 1
(On-vehicle) ...... ........... ..... .... page P-20 lnstallation ...... ...... ................ page P-37
Removal / lnstallation ............. page P-21
Disassembly / Assembly ........ page P-22
INDEX
PARKING BRAKE
I __I
MP1109-C 5BUOPX-003
1. Parking brake 3. Rear parking brake cable
Adjustment ............................. page P-37 Removal / Inspection /
Releasing cable tension ......... page P-35 Installation ............................ page P-37
Resetting cable tension .......... page P-36 4. Parking brake pedal
Resetting pedal control Removal / Inspection 1
spring tension ....................... page P-36 Installation ............................ page P-38
2. Front parking brake cable
Installation ............................ page P-37
INDEX
REAR ANTI-LOCK BRAKE SYSTEM
C3
FRONT OF VEHICLE
FRONT OF VEHICLE
VIEW A VIEW B
INDEX
1. Fuses ......................................... page P-65 4. Rear speed sensor rotor (RABS and ABS)
2. RABS control unit Removal I Inspection /
Removal 1 Installation ............. page P-65 Installation ............................ page P-66
3. Rear speed sensor (RABS and ABS) 5. RABS hydraulic unit
Removal / Installation ............. page P-65 Removal / Installation ............. page P-64
INDEX
4-WHEEL ANTI-LOCK BRAKE SYSTEM
INDEX, OUTLINE
1. Rear speed sensor rotor (RABS and 4WABS) 4. Front speed sensor
Removal / Inspection / Removal / lnstallation ............. page P-124
lnstallation . . . . . . . . . . . . . . . . . . . . page P-66 5. ABS control unit
2. Rear speed sensor (RABS and 4WABS) Removal / lnstallation ............. page P-123
Removal / lnstallation . . . . . . . . . . . page P-65 6. Acceleration sensor (G-switch) (not shown)
3. ABS hydraulic unit Removal / lnstallation . . . . . . . . . page P-122
Removal / lnstallation ............. page P-122 7. Front speed sensor rotor (not shown)
Removal / lnstallation . . . . . . . . page P-124
OUTLINE
SPECIFICATIONS
1 item i Specification I
I Brake pedal / Type 1 Sus~ended I
I Master cylinder / Type 1 Tandem (with level sensor) I
/ Type I Ventilated disc
Front d ~ s c Pad mln. th~ckness mm {~n) 3.0 {0.12)
- --
brake mm {~n) 20 6 (0 811
-
Disc plate runout { I n ! . -
0.008 {0.003}
&----
I Type
.-- i Leading-trailing .
+-
--
L~nlngmln. th~ckness Worn to wlthln 0 794 {0.03} of any rivet head -
Rear drum Drum lnner dlameter
-- Std d~ametera+0 762 (0.03)
brake Shoe clearance adjustment mm {ln) Automat~cadjuster
--
Brake dlameter
-- -lp-
7
mm
- {in}
--
--
--
-
228 6 19)
254
-
O} -
{I
---
- -
Power brake T~~~ Vacuum multlpller, tandem diaphragm

unlt
- - -- - -- - -- -- - - ----
Brake flu~d --
- -- --
FMVSSI 16, DOT-3 --
- -- -- -- -
. -
-
Type Mechanical two-rear wheel control

Parklng brake -- - - -- ~ -- --
Operation system -- - - --
- Pedal
-
Rear wheel
hydraul~c Type Rear wheel antl-lock brake system
control system
.? STANDARD DIAMETER IS SHOWN ON EACH BRAKE DRUM
Note
4BUOPX-006
CONVENTIONAL BRAKE SYSTEM

PREPARATION
SST
49 UNOl 062 For For
connection of connection of
breakout breakout
Anti lock box Anti lock box
brake brake
adapter adapter
I Problem 1 Possible Cause I Action I Page I

Poor braking Leakage of brake fluid Repair
Air in system Bleed air
Worn disc pad or brake shoe Replace
Brake fluid, grease, oil or water on disc pad or Clean or replace
brake shoe
Hardening of disc pad or brake shoe surface or Grind or replace
poor contact
Malfunction of caliper piston or wheel cylinder pistor Replace
Malfunction of master cylinder Repair or replace
Malfunction of power brake unit Replace
Malfunction of check valve Replace
Damaged vacuum hose Replace
Deterioration of flexible hose Replace
-
.
lmproper adjustment of rear brakes Adjust
Brakes pull to Worn disc pad or brake shoe Replace
one side Brake fluid, grease, oil or water on disc pad or Clean or replace
brake shoe
Hardening of disc pad or brake shoe surface Grind or replace
or poor contract
Abnormal wear, distortion or eccentricity of Repair or replace
disc plate or brake drum
Malfunction of adjusting assembly Repair or replace P-30
Loose or damaged dust coverlbacking plate Tighten or replace Section M
mounting bolt
Malfunction of caliper piston or wheel cylinder pistor Replace P-29,34
Worn or improperly adjusted wheel bearing preload Adjust or replace Section M
lmproper adjustment of wheel alignment Adjust Section R
Unequal tire air pressure Adjust Section Q
Brakes do not No brake pedal play Inspect P-14
release lmproper adjustment of push rod clearance Adjust P-18
Clogged master cylinder return port Clean
Disc pad or brake shoe not returning properly Repair
Improper return or malfunction of caliper piston or Repair or replace
wheel cylinder piston
Excessive runout of disc plate or brake drum Repair or replace P-26, 30
-
.
Improper adjustment of wheel bearing preload Adiust or re~lace Section M
Pedal goes too far Air in system, insufficient brake fluid Add fluid and bleed air
(Excessive pedal lmproper adjustment of rear brakes Adjust
stroke) Worn disc Dad or brake shoe ReDlace
Abnormal noise or Worn disc pad or brake shoe Replace
vibration during Damaged disc pad or brake shoe Grind or replace
braking Brakes do not release Repair
Foreign material or scratches on disc plate or Clean
brake drum contact surface
Loose backing plateldust cover or caliper pin Replace
Damaged disc plate or brake drum contact surface Replace
Poor contact of disc pad or brake shoe Repair or replace
Insufficient grease on sliding parts Apply grease -
Loose lua nuts Tiahten Section Q
AIR BLEEDING (VEHICLE EQUIPPED
WITH RABS)
Note
Bleed the primary and secondary hydraulic brake
systems separately.
Caution
Do not let the master cylinder reservoir run dry. Add
brake fluid to the reservoir during the entire bleed-
ing procedure.
Be sure the pedal remains depressed until the
bleed screw is tightened.
Note
Two people should stay in voice contact with each
other.
1. On the master cylinder, loosen the master cylinder-to-

hydraulic pipe fittings.
Note
Wrap a shop cloth around the tubing below the
fittings to absorb leaking fluid.
2. One person should apply the brake pedal slowly. This will
force the air trapped in the system through the fittings.
3. Holding the brake pedal down, tighten the fittings. Re-
lease the brake pedal. Make sure the fittings are tight
before releasing the pedal or air will re-enter the master
cylinder.
4. Repeat this procedure until air ceases to escape at the
fittings.
MP1100-A
1 FRONT OF h 5. Place a box wrench on the bleeder fitting on the Rear Anti-
Lock Brake System hydraulic unit (if equipped). Attach a
rubber drain tube to the bleeder fitting. Insert the free end
of the tube in a partially filled container of brake fluid.
Loosen the bleeder fitting, then press the brake pedal to
the floor.
Tighten the bleeder fitting after all air bubbles cease

appearing. Release the brake pedal. Repeat this proce-
dure until air bubbles cease to appear.
I I
MP1094-A
6. Attach a vinyl hose to the right rear bleeder plug.
7. Place the other end of the vinyl tube in a clear container.
8. One person should depress the brake pedal a few times,
and then hold it in the depressed position.
9. A second person should loosen the bleeder screw, drain
out the fluid and retighten the screw.
10. Repeats steps 8 and 9 until no air bubbles are seen. Move
on the left rear, right front, and to the left front.
MP1001-A 6BUOPX-101
P-I 0
CONVENTIONAL BRAKE SYSTEM P
11. Check for correct brake operation.
12. Verify that there is no fluid leakage. Clean any spilled fluid
with rags.
13. After bleeding the air, add brake fluid to !:he reservoir up to
the specified level.
Note
Air bleeding must be done from the bleeder screw
farthest from the disassembled parts to the
nearest.
AIR BLEEDING (VEHICLE EQUIPPED WITH 4WABS)

Note
The 4WABS system must be bled in two steps.
The brake master cylinder and Hydraulic Control
Unit (HCU) must be bled using SSTs. If this proce-
dure is not followed, air will be trapped in the HCU
HARNESS
which eventually leads to a spongy brak pedal.
To bleed the brake master cylinder and HCU, dis-
connect the 40-pin plug from the Control Unit and
install the SSTs to the wire harness 40-pin plug.
~~1173-A 1. Disconnect the (40-pin plug) from ABS Control Unit.
2. Connect the SST (49 UNO1 063) to the 40-pin plug on the
vehicle harness.
3. Connect the previously released SST (49 UNOl 063) to
the 55-pin plug on the Adapter.
4. Slide the SST switch to the BLEED position.
5. Turn the vehicle ignition switch to the ON position The
OFF indicator light should be illuminated.
6. Press the MOTOR Start button. The ON indicator light
should be illuminated.
7. Run the pump motor for 20 seconds. Then push and hold
the VALVE button for 20 seconds. This bleeds any trapped
MP1123-A GBUOPX-003 air from the master cylinder and HCU. Release the VALVE
button.
Note
The pump motor will continue to run for 20 seconds
after the VALVE button is released.
The OFF indicator lamp will be illuminated when the
operation is complete.
8. Turn the vehicle ignition switch OFF. Disconnect the SST

and reconnect the vehicle harness to the Control Unit.
9. Attach a vinyl hose to the right rear bleeder plug.
Note
Press the ABORT button to turn the pump motor
OFF during the bleed function.
10. Place the other end of the vinyl tube in a clear container.
11. One person should depress the brake pedal a few times,
and then hold it in the depressed posil:ion.
12. A second person should loosen the bleeder screw, drain
out the fluid and retighten the screw.
13. Repeat steps 8 and 9 until no air bubbles are seen. Move
on the left rear, right front, and to the left front.
14. Check for correct brake operation.
15. Verify that there is no fluid leakage. Clean any spilled fluid
with rags.
16. After bleeding the air, add brake fluid to the reservoir up to
the specified level.
Note
Air bleeding must be done from the bleeder
screw farthest from the disassembled parts to the
nearest.
BRAKE HYDRAULIC LINE

Brake pipe
Check for cracks, damage, and corrosion of the brake
pipes. Replace the pipe or flare nut(s) if necessary.
4BUOPX-009
Flexible hose
Check for scars, cracks, and swelling of the flexible hose.
Replace the hose if necessary.
Note
A wet appearance on the outer cover of the flexible
hose is called "sweating." This is normal for neo-
prene rayon braid hose. "Sweating" will not result
in leaks or loss of pressure.
4BUOPX-030
Removal
1. Disconnect the flexible hose from the brake pipe.
2. Disconnect the clip and remove the flexible hose from the
bracket.
4BUOPX-Oil
Installation
1. Secure the flexible hose in the bracket and connect the
clip to it.
2. Connect the flexible hose to the brake pipe and tighten the
flare nut.
Caution
Verify that the hose is not twisted.
Verify that the hose does not contact other parts
when the vehicle bounces or when the steering
wheel is turned fully right or left.
Tightening torque:
15-20 N.m (1.5-1.9 kgf-m, 11-14 ftdbf)
5BW3PX-010
BRAKE FLUllD
lnspection
1. Depress the brake pedal several times, and inspect for
leakage of the brake system.
2. Verify that the fluid level in the reservoir is at or near the
MAX line.
3. If the fluid level is low, check the brake system for leakage.
Fluid specification: FMVSS116, DOT-,3
Replacement
Caution
Do not allow the reservoir to run dry during air
bleeding.
Do not spill brake fluid onto painted surfaces. If
spilled, wipe it off immediately.
1. Remove the brake fluid from the reservoir by using a

suction pump.
2. Fill the reservoir with clear1 brake fluid.

3. Attach a vinyl tube to the farthest bleeder fitting and place
the other end of the tube in a clear container.
4. Pump out the old brake fluid by loosening the bleeder
fitting and pumping the brake pedal until only clean fluid is
expelled.
5. Perform the above for all bleeder fittings.
6. Fill the reservoir to the specified levels.
VACUUM LINE / CHECK VALVE

Inspection
1. Remove the clamps from the intake manifold or throttle
body.
2. Apply suction and pressure to the hose from the engine
side. Verify that air flows only toward the engine. If the air
VACUUM HOSE
passes in both directions or not at all, replace the check
valve.
MP1126-A 5BUOPX-011
BRAKE PEDAL
The brake system is designed to permit a full stroke of the
master cylinder when the brake pedal is fully depressed.
Brake pedal clearance adjustment is not required.
If pedal travel is restricted, check the following:

1. Brake fluid return port in the master cylinder.
2. Brake pedal and push rod obstructions.
4BUOPX -016
Removal 1 Inspection / lnstallation
Vehicles equipped with automatic transmission
4. Check the unit for correct operation.
ESS
1
WP1002-B 4BUOPX-017
1. Stoplight switch harness connector 6. Retaining ring
(not shown) 7. Shaft
2. Spring retainer 8. Brake pedal
3. Spacer 9. Washer
4. Stoplight switch 10. Inner bushing
5. Brake pedal push rod 1I . Outer bushing
lnstallation Note .............................. below 12. Brake pedal pad
lnstallation note
Brake pedal push rod
Position the brake pedal push rod as in the figure.
P CONVENTIONAL BRAKE SYSTEM
Vehicles equipped with manual transmission
3. install in the reverse order of removal, referring to lnstallation Note.
4. Check the unit for correct operation.
CLUTCH MASTER CYLINDER

@ PUSH ROD (NOT SHOWN)
0STOPLIGHT SWITCH HARNESS

CONNECTOR (NOT SHOWN)
I _J
MP1003-C SBUOPX-128
1. Stoplight switch harness connector 7. Clutch position switch (not shown)

(not shown) Removal / Installation ............. Section H
2. Spring retainer 8. Retaining ring
3. Spacer 9. Clutch pedal
4. Stoplight switch 10. Brake pedal
5. Brake pedal push rod 11. Washer
Installation Note ..................... page P-15 12. Inner bushing
6. Clutch master cylinder push rod (not shown) 13. Outer bushing
Removal / Installation ................ Section H 14. Brake pedal pad
MASTER CYLINDER
1. Disconnect the brake fluid level sensor harness connector from the reservoir.
2. With the engine off, push the brake pedal down to expel vacuum from the power brake unit.
3. Disconnect the brake pipes from the master cylinder.
4. Remove the wrap-around clip and nut from the power brake unit master cylinder mounting stud.
7. After installation, add brake fluid, bleed air, and check for leaks.
I I
MP1076-B 5BUOPXO12
1. Master cylinder
Installation Note ..................... page P-18
Disassembly / Inspection /
Assembly .............................. page P-19
Installation Note
Master cylinder
Power brake unit push rod adjustment
1. Fabricate a gauge using the dimensions shown.
2. Place the gauge on the mounting surface of the power
brake unit as shown.
3. The engine must be running, with the vacuum line con-
nected to the power brake unit.
4. Adjust the push rod screw until the screw just touches the
inner edge of the gauge.
I I
MP1004-B 5BUOPX-013
Brake pipes
Install and tighten the brake pipes to the specified torque.
Tightening torque:
Disassembly I Inspection 1 Assembly
1. Clean the outside of the rnaster cylinder and remove the filler cap and diaphragm. Drain and discard any
brake fluid that remains in the cylinder.
3. lnspect all parts and repair or replace if necessary.
5. After assembly, perform the following:
(1) Add fluid. (Refer to page P-13.)
(2) Bleed the air. (Refer to page P-10.)
(3) Check for leakage. (Refer to page P-13.)
Caution
Secure the master cylinder in a vise when necessary.
Do not let foreign material enter the cylinder and do not scratch the inside of the cylinder or the
outer surface of the piston.
7 1
SNAP
RING,
-
REPLACE
I
I
MP1005-B 5BUOPX-015
1. Snap ring 9. Secondary piston assembly
2. Piston cup Inspect for abnormal wear, rust, and
3. Primary piston assembly damage
Inspect for abnormal wear, rust and Disassembly Note .................. page P-20
damage 10. Piston cup
4. Piston cup 11. Spring seat
5. Spring seat 12. Spring
6. Spring 13. Master cylinder body
7. Spring retainer Inspect inside of body for corrosion
8. Piston cup 14. Reservoir
15. Grommet
CONVENTIONAL BRAKE SYSTEM - - - - - pp
Disassembly Note
Secondary piston
Remove secondary piston assembly by directing com-
SECONDARY pressed air into outlet port at blind end of bore while
ASSEMBLY plugging other port.
Inspection
Brake fluid level sensor
1. Disconnect the sensor harness connector.
2. Connect an ohmmeter to the connector.
3. Checkcontinuity between terminals of the brake fluid level
sensor connector.
I L-- Terminal
- - -
I Around MAX mark I ct-------0 I

Below the MAX mark 0
MP1081-C
4. Replace the sensor if necessary.

Master cylinder body
Caution
Do not attempt to hone the master cylinder if
damage is found.
4BUOPX-026
POWER BRAKE UNIT

Quick inspection (On-vehicle)
Step 1
1. Push the brake pedal down.
3. The brake pedal should move downward when engine is
started.
Step 2
1. Run the engine for 1-2 minutes, and shut off.
2. Depress the pedal three times, refer to Note.
Note
Each time the pedal is depressed the stroke be-
comes shorter.
3. If a problem is found, inspect the check valve, vacuum

hose, and examine installation. Repair if necessary.
4BUOPX-028
Step 3
1. Start the engine and depress the brake pedal.
2. Shut engine off.
3. The brake pedal height should stay the same.
4. If problem is found, inspect the checkvalve, vacuum hose,
and connections. ~BUOPX-029
1. Disconnect the stoplight switch harness connector.
2. Disconnect the vacuum hose from power brake unit.
4. Inspect all parts, replace or repair if necessary.
5. Install in reverse order of removal, referring to lnstallation Note.
6. After installation, perform the following:
(1) Add fluid and bleed the air. (Refer to page P-10.)
(2) Check for fluid leakage. (Refer to page P-13.)
(3) Start the engine and check brake operation.
I I
MP1008-C 5BUOPX-016
1. Master cylinder 2. Spring retainer
Removal / Installation ............. page P-17 Installation Note .............................. below
Disassembly / Inspection / 3. Power brake unit
Assembly .............................. page P-19
lnstallation note
Spring retainer
Use only factory supplied spring retainers.
4BUOPX-031
The power brake unit is a self-contained unit. Disassem-
bly and assembly is not required. The only serviceable
components are the power brake unit check valve, adjust-
able push rod, and the rubber reaction disk.
Caution
The rubber reaction disc can be repositioned if
master cylinder push rod is removed or acciden-
tally pulled out. If the disc cannot be properly
installed and aligned, or cannot be located within
the power brake unit itself, the power brake unit
MP1012-A 4BUOPX-032
must be replaced as an assembly.
FRONT BRAKE (DISC)

Disc pad
stands.
2. Remove the wheel and visually inspect thickness of brake
pads.
Thickness: 1.5mm (0.05 in) min
3. Replace the pads as a set (right and left wheels) if either

is at or less than the minimum thickness.
Removal 1 Inspection
e / lnstallation
s
3. Install in reverse order of removal, referring to lnstallation e
Note.
4. After installation, perform the following:
(1) Add fluid, and bleed the brakes.
(2) Check for leakage.
(3) Depress the pedal a few times, then verify that the brakes do not drag while rotating the wheels by
hand.
FRONT OF VEHICLE
I
MP1128-A 5BUOPX-018
1. Caliper 4. Outer bearing assembly (not shown)
Removal Note ........................ page P-24 5. Disc plate
Installation Note ..................... page P-26 Removal Note ........................ page P-25
Disassembly l Inspection 1 Inspection ............................... page P-26
Assembly .............................. page P-29 Installation Note ..................... page P-26
2. Disc pad (not shown) 6. Grease seal (not shown)
Removal Note ........................ page P-24 7. Inner bearing assembly (not shown)
3. Locknut (not shown)
I
I
MP1127-A
N-m (Kgf-m, it-lbf)
2
5BUOPX-019
1. Caliper 4. Outer bearing assembly
Removal Note ................................. below 5. Disc plate
Installation Note ..................... page P-26 Removal Note ........................ page P-25
Disassembly / Inspection / Inspection ............................... page P-26
Assembly .............................. page P-29 Installation Note ..................... page P-26
2. Disc pad (not shown) 6. Grease seal
Removal Note ................................. below 7. Inner bearing assembly
3. Locknut
Removal Note
Caliper, disc pad
1. Use a C-clamp to compress the caliper piston into the
bore.
Note
Place the head of the C-clamp against the caliper,
and the screw end of the C-clamp against the outer
disc pad.
Caution
Do not use screwdriver or similar tool to pry the
piston away from the disc plate.
Do not compress the piston farther than required to
remove caliper.
2. Remove the two caliper pin bolts.

3. Remove the caliper from the disc plate. If the caliper is to
be removed for service, disconnect the brake hose from
the caliper. If not, secure the caliper.
Caution
Do not let the caliper hang with its weight on the
brake hose.
4. Slide the disc pads off the caliper anchor plate. If the disc
plate is to be removed for service, remove the two anchor
plate bolts and the anchor plate.
5BUONX-020
Disc plate
1. Remove the grease cap from the hub.
2. Remove the cotter pin, retainer, adjusting nut, and flat
washer from the spindle, and discard the cotter pin.
3. Remove the outer bearing cone, and the roller assembly.
4. Pull the disc plate off of the spindle. (Referto Section M for
hub removal.)
Note
Perform the following step if the original disc plate
is to be reinstalled.
5. Clean the inner and outer bearing cups with solvent.

Inspect the cups for scratches, pits, excessive wear, and
other damage. If the cups are damaged, remove the cups
with Front Hub RemoverIReplacer T81 P-1104-C and
Bearing Cup Puller T77F-1102-A, or equivalents. Re-
place as necessary.
FRONT HUB
REMOVEWREPLACER
T81 P-11044 \
BEARING CUP
PULLER
l77F-1102-A
Installation Note
Disc plate
1. Inspect the disc plate for cracks or other damage. Replace
as necessary.
2. If the inner or outer bearing cups were removed, install
replacement cups.
3. Place the inner bearing cone and roller assembly in the
inner cup. A light film of grease should be included
between the lips of the new grease seal.
4. lnstall the grease seal. Be sure the grease seal is properly
seated.
5. lnstall the disc plate assembly on the spindle.
Note
Keep the disc plate centered on the spindle to
prevent damage to the grease seal and the spindle
threads.
6. lnstall the outer bearing cone and roller assembly and flat
washer on the spindle.
7. lnstall the adjusting nut. (Refer to Section M for wheel
bearing adjustment.)
8. lnstall the retainer, a new cotter pin, and the grease cap.
5BUOPX-022
Caliper, disc pad

1. The caliper must be bottomed out to install the new disc
pad.
Caution
Never attempt to bottom out the piston with the
outer disc pad installed.
2. lnstall the anchor plate if removed.
Tightening torque:
100-1 30 N-m(10.3-1 3.2 kgf-m, 74--96 ft.lbf)
3. lnstall the disc pads and the caliper
Tightening torque (Caliper bolts):

24--36 N.m (2.4-3.7 kgf.m, 18-26 ft-lbf)
4. If removed, install the brake hose.

5. If necessary, add fluid and bleed the air. (Refer to page
P-10.)
DISC PLATE
Inspection
Disc plate thickness
Warning
Disc plate minimum thickness must not be less
than the specification, or less than the number cast
on the e of the disc plate
e inside e
e after refinishing.
5BUOPX-023
1. Measure the thickness of the disc plate
P Standard: 20.6mm (0.81 in)
MINIMUM OVERALL
THICKNESS
20.6mm (0.81 IN) 2. If the thickness is not within the specification, replace the
disc plate.
I
AP1103-A 4BUOPX-040
Disc plate runout
Caution
There must be no wheel bearing looseness.
1. Clamp a dial indicator to the spindle so the stylus contacts

the disc plate approximately 25.4mm (1.0 in) from the
outer edge.
2. Rotate the disc plate one turn and take an indicator
reading.
Runout: 0.08mm (0.003 in)

AP1106-B 4BUOPX-041
3. If runout is not within specification, repair or replace the

disc plate.
Rotor turning
Note
A 70mm (2.756 in) gauge ball used in conjunction
with the micrometer gauge bar is required to make
this measurement on 4x4 disc plates.
Gauge ball size Base line setting
54 rnrn (2.125 in)
70 rnm (2.756 in) (0.256 in)
Maximum allowable stock removal of the inner

e disc
pad braking surface is determined by the use of
Disc Rotor Surface Gauge and Ball T71P-1102-A, or
equivalent as follows:
1. Remove the inner grease retainer and bearing assembly

from the hub and disc plate assembly. Wipe the inner and
outer bearing cups clean.
2. Carefully place the gauge ball in the inner bearing cup
(do not drop).
3. Set the micrometer to baseline setting dimension.
SURFACE GA
Baseline setting dimension: 6.50mm (0.256 in)
4. Position the micrometer gauge bar on disc plate inner

braking surface with the micrometer centered over the
ball. To measure the distance between the micrometer
baseline setting and the ball, calculate the difference
between the reading and the baseline setting. This dis-
MPIOIS-B ~BUOPX-042 tance is equal to the maximum allowable stock removal
from the inside braking surface only.
Note
If the micrometer end of the baseline setting touches
the ball, no additional stock removal is allowed. The
disc plate must be replaced.
5. Check the disc plate for the maximum amount of stock that
can be removed from the disc plate. Measure the actual
disc plate thickness with a micrometer and subtract the
minimum allowable thickness (cast in the disc plate). The
total material removal (combination of both sides) must
not exceed this amount.
Note
If thedisc plate thickness is less than the minimum,
the disc plate must be replaced, regardless of the
gauge bar and ball measurement.
6. Set the cutting tool to just contact the high spots of disc
plate, then adjust the cutting tool to minimum depth
required to clean the disc plate face.
Do not exceed the allowable stock removal for the

inner braking surface or total disc plate thickness.
Before installingthe disc plate on spindle,do the following:
(1) Remove metal chips.
(2) Repack bearing assemblies and coat new inner grease
seal with NLGI No. 2 (lithium base).
(3) Install the disc plate on the same side it was removed.
CALIPER
Disassembly IInspection /Assembly
Note
Clean all metal parts with isopropyl alcohol. Then clean out and dry the grooves and
passageways with compressed air.
Check the cylinder bore and pistons for damage or excessive wear. Replace the pistons if they
show signs of pitting, scoring, cracks or rust.

2. lnspect all parts, repair or replace if necessary.
3. Assemble in reverse order of disassembly.
--
MP1180-A 5BUOPX-123
1. Dust boot 3. Piston seal
2. Piston 4. Bleeder screw
Disassembly Note ........................... below 5. Caliper body
Inspect for wear and rust Inspect for damage, wear, rust
Disassembly Note
Piston
Caution
Use only enough air pressure to remove the pis-
tons from the caliper.
1. Place a piece of wood 38mm x 38mm x 150mm (1.5 in

x 1.5 in x 6 in) the caliper.
2. Blow compressed air through the pipe hole to force the
pistons out of the caliper.
REAR BRAKE (DRUM)
lnspection (On-vehicle)
Brake shoe (lining)
1. Jack up the rear of the vehicle and support it with safety
stands.
2. Remove the wheels
3. Remove the brake drums. (Refer to below.)
4. Verify the thickness of the brake linings.
Minimum: Worn to within 0.794mm {0.03 in)

of any rivet head
MP1107-A 4BUOPX-045
Removal I Inspection / lnstallation

1. Remove nut and the brake drum, referring to Removal Note.
5. After installation, check the following:
(1) Add fluid and bleed the air. (Refer to page P-10.)
(2) Check for fluid leakage. (Refer to page P-13.)
(3) Depress the pedal a few times, then verify that the brakes do not drag while rotatingthe wheel by hand.
_I
4BUOPX-046
1. Adjusting level spring 9. Adjusting assembly
2. Adjusting level 10. Parking brake strut
3. Return spring - secondary shoe 11. Brake shoe (trailing side)
4. Return spring - primary shoe Removal Note ........................ page P-31
5. Anchor pin Inspection ........................................ above
6. Cable guide Installation Note ..................... page P-32
7. Hold spring, sleeve and pin 12. Link
8. Brake shoe (leading side) 13. Wheel cylinder
Removal Note ........................ page P-31 Disassembly / Inspection /
Inspection ........................................ above Assembly .............................. page P-34
Removal Note
Brake drum
Caution
Use of a drum puller or torch is not recommended.
Drum distortion may result.
If the brake drum will not come off, proceed as follows:

I . Insert a narrow screwdriver through the brake adjusting
hole in the backing plate.
2. Disengage the adjusting lever from the adjusting screw.
3. While holding the adjusting lever away from the adjusting

screw, loosen the adjusting screw.
Caution
Loosen the adjusting screw only if the drum can-
not be removed. Do not burr, chip or damage the
MOVE DOWN notches in the adjusting screw on the self adjusting
mechanism, it will not function properly.
MOVE UPWARD
TO RETRACT
BRAKE SHOES
MP1083-A 4BUOPX-047
Brake shoe
1. Inspect the wheel cylinder for signs of leaks or presence
of rust.
2. Remove the hold down springs.
#--
I I
MPI 085-8
3. Remove the brake shoe (trailing side).
On 22.8cm (9 in} rear brakes, remove the parking
brake lever from the shoe.
On 25.4cm (1 0 in} rear brakes, remove the retainer clip
and spring washer and the parking brake lever.
Inspection
Brake drum
1. Drum inner diarneter.
Standard diameter: Shown on drum
Diameter limit: Standard diameter +

0.762mm (0.030 in}
Caution
When repairing or replacing the drum check the
e
contact with the shoe.
P-31
2. Scratches, uneven or abnormal wear inside the drum.
Note
Repair if the problem is minor.
Grease points
1. Shoe and cylinder contact points.
2. Shoe anchor points.
3.Projection of backing plate
4BUOPX-050
Installation Note
Brake shoe
Before installing the rear brake shoes, the parking brake
lever must be connected to the brake shoe (trailing shoe).
Note
On 25.4 cm {I 0 in) brakes, secure the parking brake
lever with the spring washer and retaining clip.
Caution
Interchanging brake shoe adjusting screw assem-
blies from one side of the vehicle to the other will
cause the brake shoe to retract rather than expand
each time the automatic adjusting mechanism is
operated.
Note
1 ADJUSTING LEVER 1 To prevent incorrect installation, the socket end of
@
ADJUSTMENT NOTCHES
each adjusting screw is stamped with R or L. Ad-
// THRUST WASHER
/ justing nuts can be identified by the number of
rings machined around body of nut. Two lines
indicate right-hand nut; one line indicates left-hand
nut.
ADJUSTING SCREW
Brake drum
1. If a new drum is being installed, remove the protective
coating from the drum with carburetor cleaner.
2. Adjust the brakes. (Refer to page P-33.)
3. Install the brake drum.
Tightening torque (lug nuts):

135 N-m (13.8 kgf-m, 100 ft-lbf)
5BUOPX-026
Adjustment
The rear brakes are self-adjusting and require a manual
adjustment only after brake shoes have been replaced or
when the adjuster has malfunctioned and has been re-
paired or replaced.
4BUOPX-053
1 Drums removed
1. Measure the inside diameter of the drum braking surface.
I I
MP1087-B
I 2. Reverse the tool as shown and adiust the brake shoes
until they touch the gauge. The gauge must be parallel to
the vehicle with the center line through the center of the
axle.
3. Hold the automatic adjusting lever out, while rotating the
adjusting screw.
Note
After adjustment, apply the brakes several times
while driving the vehicle alternately forward and
reverse.
When the rear brake shoes have been properly
adjusted, road test to check brake operation.
Warning
Only road test the vehicle when the brakes will
apply and the vehicle can be safely stopped.
Drums installed
1. Place the transmission in neutral. Raise the vehicle and
support it with safety stands.
2. Remove the cover from the adjusting hole at bottom of

backing plate, and turn the adjusting screw inside the hole
to expand the brake shoes until they lock the drum.
3. When shoes are against the drum, loosen the adjusting
screw an additional 10 to 12 notches so the drum rotates
freely. If the drum does not rotate freely, remove the wheel
MOVE DOWN and drum and check brake shoe installation.
4. Install the adjusting hole cover on the backing plate.
MOVE UPWARD
BRAKE SHOES
5. Check and adjust other rear brake assembly.
Note
After adjustment, apply the brakes several times
while driving the vehicle alternately forward and
reverse.
When the rear brake shoes have been properly
adjusted, road test to check brake operation.
Warning
Perform the road test only when the brakes will
apply and the vehicle can be safely stopped.
WHEEL CYLINDER
Disassembly I Inspection 1 Assembly
Caution
If a problem is found in the wheel cylinder housing or piston, replace the wheel cylinder as an
assembly.
1. Disassemble in order shown in the figure.

2. Inspect all parts, repair or replace if necessary.
3. Assemble in reverse order of disassembly, referring to Assembly Note.
I 2
MP1026-A 4BUOPX-056
1. Dust boot 4. Spring
2. Piston 5. Bleeder screw
Inspect for corrosion and damage
3. Piston cup
Assembly Note
Wheel cylinder
Clamp the brake cylinder pistons against the ends of
cylinder. When using a brake cylinder repair kit, follow
the instruction in the kit and use all the parts provided.
4BUOPX 057
PARKING BRAKE SYSTEM

Problem Possible Cause Remedy
Brakes do not Improper return of parking brake cable
release
ee Worn or damaged rear brake components Replace
Parking brake does Excessive parking brake pedal stroke
not
o hold well Brake cable stuck or damaged Repair or replace
Brake fluid or oil on brake shoe Clean or replace
Hardening of brake shoe surface or poor contact Grind or replace
Improper adjustment of rear brakes Adjust
MPI 040-8
RELEASING CABLE TENSION

Note
If any component in the parking brake system
requires servicing, the cable tension must be re-
leased. After servicing is completed, the cables are
connected to the equalizer and tension is reset.
Refer to the following procedures for releasing and
resetting cable tension.
LOCK OUT PIN / 1. Place the pedal in the "released" position.
2. While an assistant relieves tension on the system by
pulling on the parking brake front cable, insert a 532-inch
steel pin or equivalent drill bit into the hole provided in the
parking brake assembly.
3. Raise the vehicle on a hoist and have one person inside
the vehicle to perform Step 4.
4. Release tension on the rear cables by pulling rearward
on the rear cable about 25.4--50.8mm (1.0-2.0 in) and
place a clamp on the rear cable behind the rear frame
crossmember.
Note
Be careful not to damage the plastic coating on the
cable strand.
5. Remove the cables.
6. To reapply tension, connect all cables and remove the
clamping device..
RESEmlNG CABLE TENSION
Resetting Pedal Control Spring Tension
Note
Parking brake control spring tension is lost when
the coil spring unwinds and disengages from the
tab on the wheel. This can occur when the cables
break, when servicing the system without inserting
the lock-out pin orwhen the lock-out pin is removed
before the cables are connected. DO NOT SERVICE
THE PARKING BRAKE SYSTEM WITHOUT
INSERTINGTHE LOCK-OUT PIN IN THE CONTROL
ASSEMBLY. DO NOT REMOVE THE LOCK-OUT
PIN FROM THE CONTROL WITH THE CABLES DIS-
CONNECTED.
1. Remove the parking brake pedal. (Refer to page P-38.)

CABLE INSERTED CABLE INSERTEDAND
lNTOPIVOTHOLE ROTATEDTOTHISPOSITION 2. Engage the coil spring on the tab on the wheel in the
IN THIS POSITION parking brake control.
3. Place the control handle in the released position to unlock
the self-adjusting pawl.
4. Slip a spare front cable around the pulley and insert the
cable anchor pin into the pivot hole in the ratchet plate
assembly.
5. With the cable on the floor, step on the cable or clamp the
end of the cable in a vise.
6. Pull on the assembly, holding the mounting bracket tightly
~~1132-A ~BUOPX-028 against the body of the parking brake control, until cable
tension rotates the cable track assembly so the lock-out
pin can be fully seated through the plate.
7. Insert the lock-out pin so the assembly is in the "cable
released" position.
8. Install the parking brake pedal. (Refer to page P-38.)
PARKING BRAKE SHOE
Drum brake e
Removal 1 Installation. (Refer to page P-30.)
Inspection. (Refer to page P-30.)
PARKING BRAKE (PEDAL TYPE)

Adjustment
The vehicles are equipped with self-adjusting parking brake systems. No manual adjustment is required.
4BUOPX-062
FRONT PARKING BRAKE CABLE

1. While an assistant relieves tension on the system by pulling on the front parking brake cable, insert a 532
inch steel pin or equivalent size drill bit into the hole provided in the parking brake assembly.
2. Disconnect the front cable from the equalizer.
3. Remove the anchor pin from the pivot hole in the control assembly.
4. Guide the front cable from the control assembly and disconnect it from the frame mounting bracket.
Remove the cable-to-frame attaching bolt, if the bolt is present, and remove the cable from the vehicle.
7. Apply and release the parking brake several times to verify operation.
5BUOPX-029
REAR PARKING BRAKE CABLE

Removal 1 Inspection / Installation
1. While an assistant relieves tension on the system by pulling on the front parking brake cable, insert a532
inch steel pin or equivalent size drill bit into the hole provided in the parking brake assembly.
Note
Be careful not to damage plastic coating on cable.
2. Raise the vehicle and remove the rear wheel assembly and brake drum. (Refer to page P-30.)
3. Disconnect the rear parking brake cable from the equalizer.
4. Disconnect right rear cable from the equalizer and from the rear guide bracket.
5. On the wheel side of the backing plate, compress the retainer fingers with a 9116-in flare nut wrench and
remove the rear cable through the hole in backing plate.
6. Lift the cable out of the slot in the parking brake lever (attached to the trailing side brake shoe). Remove
the cable through the backing plate hole.
7. inspect all parts and repair or replace as necessary.
9. Adjust the rear brakes. (Refer to page P-33.)
10. Apply and release the parking brake several times to verify operation.
P PARKING BRAKE SYSTEM, REAR ANTI-LOCK BRAKE SYSTEM (RABS)
PARKING BRAKE PEDAL
1. Remove the left side cowl trim panel.
2. Disconnect the parking brake switch harness connector.
3. While an assistant relieves tension on the system by pulling on the front cable, insert a 5132-in steel pin
or equivalent drill bit into the hole provided in the control assembly.
4. Remove the cable anchor pin from the pivot hole in the control assembly ratchet plate. Guide the cable
from the control assembly.
5. Remove the screw attaching the parking brake control assembly to the instrument panel.
9. If necessary, reset the cable tension. (Refer to page P-36.)
10. Apply and release the parking brake several times to verify correct operation. Also, verify the parking
brake switch operation.
MP1133-A
1. Parking brake pedal
REAR ANTI-LOCK BRAKE SYSTEM (RABS)

DESCRIPTION
The Rear Anti-lock Brake System (RABS) is standard on all 82300 and B3000 vehicles with 4x2 option.
The RABS control unit senses the drop in rear wheel speed and modulates hydraulic pressure to the rear
brakes, inhibiting lock-up.
6BUOPX-005
Outline
The RABS is composed of electrical components, mechanical components (hydraulic unit), and the
components of the standard brake system.
Fundamentally, malfunction of the RABS electrical or mechanical components is judged by the self-
diagnosis function within the RABS control unit. Malfunctions are indicated by the warning light in the
instrument panel. The location of a malfunction is indicated by the technician obtaining a flashing pattern
of the rear ABS warning light. The self-diagnosis and indication functions must be used when diagnosing
malfunctions of the RABS.
4BUOPX-067
P-38
WIRING DIAGRAM
P REAR ANTI-LOCK BRAKE SYSTEM (RABS)
RELATIONSHIP CHART
Output ~ Hydraulic unit

Rear ABS Brake system
Input solenoid solenoid warning light warning light
- - ppp
- --- -
. 0 0
Brake On/Off (BOO) swltch
p.ppp
0 -- -
-L-
I
0 o O --
-
RABS
--
test
- connector
-.- 0 -
lgnltlon swltch
--
I
0
Flu~dlevel sensor 0 0 0 0
Park~ngbrake swltch 0
MP1041 C 5BUOPX-034
DIAGNOSTIC CHART
- - -- -- - -- -
system warnlng l~ghtillum~nateswhen
MP1042-C 5BUOPX 035

DIAGNOSTIC INDEX
I No. i Troubleshooting Items I Remarks I Page I

1-2 seconds when ignition switch is turned ON --
when ignition switch is turned to START

3 Red brake system warning light illuminates when Brake system failure
I ignition switch is turned ON
Power failure
I Yellow rear ABS warning light remains illuminated

with the ignition switch ON after one blinking
illumination
Rear anti-lock brake system failure I p-45
I Yellow rear ABS warning light automatically begins to

flash with the i~nitionswitch ON
1
Self-diagnosis function
1 7 1I Yellow rear ABS warning light does not flash the

code when self-diagnosis function is started
Self-diagnosis function
8
MP1043-C
Other concerns - P-48 I
6BUOPX-700
Before performing the diagnostic procedure, always check the following four fuses:
- Number 9 10A Fuse

- Number 11 7.5A Fuse
- Number 13 15A Fuse
1 I Yellow rear ABS warning light does not illuminate for 1-2 seconds when ignition switch is turned ON
DETAILED DESCRIPTION Prove-out failure

-- --
Possible cause:
Number 11 7.5A fuse burnt
Failed rear ABS warning light
Open in wiring harness (rear ABS warning light circuit: instrument cluster to RABS control unit)
Poor connection of RABS control unit (terminal 7)
Faultv RABS control unit
-
STEP
----
1
-- -
INSPECTION
Is Number 11 7.5A fuse OK?
page P-60
I---
Yes
-I
No
Go to next step
--
Replace Number 11 7.5A fuse
ACTION
-- -
-
2 1 Are connectlons at RABS control unlt normal?

p - - p p p - - - - - -
lnspect terminal 7 connectlon at RABS control unit

lnspect terminal 4 connectlon at RABS control unit
II 3 l Check the resistance between terminal 4

(LGIY) of the RABS control unit connector and
ground.
Yes
1
Go to next step
I
1 Resistance: Less than i
4
Q
Are there opens In the wiring harness between

i lnspect related wiring harness and ground connection
wlrlng harness and connect~ons

term~nal7 (DG) of the RABS control unlt connector
and the Instrument cluster?
-- - ---
- -
- - - - - - - - -- - -- --
5 Are there opens in the wir~ngharness (RIY) related wlrlng harness and connections
between the instrument cluster and fuse block?
-- -- - - - - -
No Go to next step
- - - -- -- -- - -- - - - -
Is the rear ABS warn\ng light OK? Yes Replace RABS control unit
page P-58
MP1044-E
Note
I
-I-
No
I
Replace rear ABS warning light
2
6BUOPX-701
If Number 11 7.5A fuse is burnt or the wiring harness between Number 11 7.5A fuse to the
instrument cluster is open circuit, the other warning and indication lights may not be illumi-
nated either.
6BUOPX-702
1 2 Red brake system warning light does not illuminate when ignition switch is turned to START I
DETAILED DESCRIPTION Prove-out failure
Possible cause:
Number 11 7.5A fuse burnt Open brake system warning diodelresistor
Failed brake system warning light Unseated fluid level sensor connector
Open in wiring harness (brake system warning light Failed ignition switch bulb prove-out circuit
circuit: instrument cluster to ignition switch)

Turn ignition switch ON and apply parking Yes Release parking brake and turn ignition switch OFF
brake. Is the brake system warning light Go to next step
illuminated?
No Inspect Number 11 7.5A fuse t@F page P-60
lnspect brake system warning light * page P-58
lnspect parking brake switch
1997 B-series BETM
lnspect harness between fuse block (Number 11 7.5A
fuse), instrument cluster (brake system warning light)
1 2 1 Check if fluid level sensor is corroded or 1 Yes Repair or replace the connector as needed
Go to next step
Firmly reconnect the fluid level sensor connector. Yes Condition is resolved
Turn ignition switch to START position.
Is the brake system warning light illuminated?
Go to next step
Disconnect the fluid level sensor connector. Yes Go to next step

Connect a jumper wire between (DGIY) and -- - -
ground. Turn ignition switch ON. Is the brake No lnspect harness between instrument cluster (brake
system warning light illuminated? system warning light), brake system warning diode/
resistor and fluid level sensor (DGIY) for open
circuit
If harness is OK, replace brake system warning
- - - - - - J
diodelresistor
- - - - - --
Connect a jumper wire between (DGIY) and Yes Replace fluid level sensor
(TILG) at fluid level sensor connector Turn
ignition switch to START. Is the brake system No lnspect ignition switch ground circuit
warning light illuminated7 (START position) t@F 1997 B-series BETM
lnspect harness (TJLG) between ignition
switch and fluid level sensor
Note
If Number 11 7.5A fuse is burnt or the wiring harness between Number 11 7.5A fuse to the
instrument cluster is open circuit, the other warning and indication lights may not be illumi-
nated either.
6BUOPX-006
3 Red brake system warning light illuminates when ignition switch i s turned ON and parking brake
released
DETAILED DESCRIPTION Brake system failure

---
Possible cause:
Brake fluid level low in master cylinder reservoir
Faulty fluid level sensor and related wiring harness
Short in wiring harness (brake system warning light circuit: instrument cluster to ignition switch)
Faulty RABS control unit
INSPECTION
--
Check for service code 4. page P - 5 2

page P-49
1 No Go to next step
-------I----- -
.
2 , Is the brake flu~dlevel In the master cylinder
' reservoir within specification and does the
i float move freely?
lnspect the brake system for leaks
Fill the reservoir to specification
Replace the reservoir if needed
With the ignition switch OFF, disconnect the RABS Yes Reconnect the RABS control unit
control unit connector. Is the brake system Go to next step
warning light ON with the ignition switch ON?
RABS control unit
Disconnect the fluid level sensor connector. Yes Go to step 5

Is the brake system warning light ON with the
ignition switch ON?
1 No 1 Go to step 6
~ ~ - ~ p - ~ ~ ~
Disconnect the parking brake switch connector. lnspect the wiring harness for shorts
Is the brake system warning light ON with the (LGIR) *(R/Y)
ignition switch ON? (PIW)
---
(DGIY)--- - - -- - -
Replace the parking brake sw~tch
Disconnect the fluid level sensor connector. Yes lnspect the wiring harness for shorts
Connect a jumper wire between (TILG) and (TILG)
(DGtY). Turn ignition switch ON. Is the brake
system warning light illuminated?
No Replace the reservoir
Note
If the valve reset switch is open or the related circuit is malfunctioning, the brake system
warning light may be illuminated.
4BUOPX-077
REAR ANTI-LOCK BRAKE SYSTEM (RABS) P
1 4 / Yellow rear ABS warning light remains illuminated when ignition switch is turned ON I
DETAILED DESCRIPTION Power failure
Possible cause:
Number 14 20A fuse burnt
Open in wiring harness (fuse block to RABS control unit)
Short in the rear ABS warning light harness
INSPECTION ACTION
I
Go to next step
w page P-60
Ies
Replace Number 14 20A fuse
Is the voltage of terminals 1 and 9 of the RABS Yes Go to next step

control unit harness connector OK?
page P-61
lnspect harness (LBIP) between fuse block
(Number 14 20A fuse) and RABS control unit
3 Is the rear ABS warning light harness OK? Replace the RABS control unit
lnspect harness (DG) between instrument cluster

and RABS control unit I
-
5 Yellow rear ABS warning light remains illuminated with the ignition switch ON after one blinking
illumination
DETAILED DESCRIPTION Rear anti-lock brake system failure
- - - -- - - ---
Possible cause:
Fault in the rear anti-lock brake system
- - - - - - - - -- -- ---- -

-- ,-
-- -- -- . - -- --- - - -
1 Check for service codes. Inspect code as indicated

page P-49
I
6 ( Yellow rear ABS warning light automatically begins to flash with the ignition switch ON 7
DETAILED DESCRIPTION Self-diagnosis function
-- - -
Possible cause:
RABS test connector shorted to ground

Faulty wiring harness
-- --- -
INSPECTION ACTION
-- ----
Is the flashing pattern a service code? for connection to ground
1 ( Inspect code as indicated page P-52
Disconnect RABS test connector. Is there Yes Inspect harness (B/O) for short
continuity between (BIO)connector and ground?
w- I rear ABS warning light does not flash the code when self-diagnosis function is started 1
DETAILED DESCRIPTION 1 Self-diagnosis function
Possible cause:
Number 14 20A fuse burnt
Stoplights or related wiring harness
RABS test connector or related wiring harness
I STEP 1 INSPECTION I ACTION I

Is Number 14 20A fuse OK?
@s
page P-60
Check stoplight operation. Do the stoplights Yes I GO to next stkp

operate properly?
@ 1997 B-series BETM
No Service stoplight system as needed
. . ~ ~ ~ ~
Is the Brake On/Off (BOO) switch

the RABS control unit OK?
--
(LGIR) between RABS control unit
and Brake OnIOff (BOO) switch
Is the voltage of terminals 1 and 9 of the RABS Yes ( Go to next step

control unit harness connector OK?
page P-61
NO Inspect harness (LBIP) between fuse block
, (Number 14 20A fuse) and RABS control unit
Is the wiring harness (BIO) between the Yes ; Replace the RABS control unit
RABS test connector and RABS control unit
terminal 12 OK?
No / Inspect harness (BIO) between RABS test connector
, and RABS control unit
I
Note
If the stoplights are all burned out, or the wiring harness (LGIR) has an open circuit, the rear
ABS warning light will not flash any codes when self-diagnosis function is started.
5BUOPX-046
Other Concerns
I
Problem Possible Cause Action I Page

Unwarranted Premature loss of rear axle speed sensor signal
RABS activity during deceleration
Metal chips on sensor pole piece lnspect
Gap between sensor and rotor too large lnspect
Missing or damaged rotor teeth lnspect
Gap between sensor and rotor too small lnspect
Intermittent rear axle speed sensor signal to RABS
control unit during deceleration
lntermittent open or shorted sensor circuit Perform intermittent
diagnosis
Pinched wire or chafed insulation lnspect
Rear axle speed sensor test connector shorted lnspect
Improper adjustment of rear brakes
Rear brakes adjustment too tight Adjust
Brake shoes grab
One or both Hydraulic unit failure
rear wheels Damaged valve reset switch lnspect
lock up Leaky dump valve lnspect
Inoperative hydraulic unit lnspect
Rear axle speed sensor signal low or missing at
low vehicle speeds
Poor sensor signal lnspect
Conventional brake system concern
Damp or contaminated rear brake shoes Clean or replace P-30
StucWleaky wheel cylinder Replace P-34
Parking brake stuck lnspect P-35
Rear brake adjustment too tight Adjust P-33
Leaky rear axle seal lnspect Section M
Vehicle electrical concern
Hard or soft
brake pedal
Stoplight input signal missing
Stoplights inoperative
Hydraulic unit failure
Isolation valve stuck closed (hard pedal)
lnspect
lnspect
lnspect
1 A 1997 B-series BETM
Dump valve leaky (soft pedal) lnspect

Isolation valve leaky during RABS stop
(soft pedal)
Vehicle electrical concern
Stoplight switch always on while driving
Leakage of brake fluid Repair
Air in system Bleed air
Pinched brake pipe or flexible hose Repair
Poor power brake unit vacuum lnspect
-
Stuck or inoperative wheel cylinder or caliper
-
Replace
Lack of deceleration Hydraulic unit failure
during medium1 Dump valve leaky Inspect
hard braking Isolation valve stuck closed lnspect
Poor or mission rear axle speed sensor signal
to RABS control unit
lntermittent open or shorted sensor circuit Perform intermittent
diagnosis
Metal chips on sensor pole piece lnspect
Missing or damaged rotor teeth lnspect
Leakage of brake fluid Repair -
~
I
Air in system Bleed air P-10
Pinched brake pipe or flexible hose Repair -
Stuck or inoperative wheel cylinder or caliper Replace I P-29, 34
--Worn disc pad or brake shoe Replace 1
1 P-26, 30
ABS warning light Filled water in connector between courtesy lamp Remove water and
comes ON when feed and rear lamp apply grease into
braking or shifting connector
into Reverse gear
SELF-DIAGNOSIS FUNCTION
INSPECTION BY DIAGNOSTIC TEST MODE
OUTLINE
The RABS control unit contains self-diagnostic and memory functions to watch for and indicate present
and past failures.
Read and note the flashing pattern of the rear ABS warning light then take action accordingto the Service
Code Table. (Refer to page P-50.)
Note
The rear ABS warning light should illuminate for 1-2 seconds when the ignition switch is
turned ON.
A code 16 indicates that the RABS is operating normally.
A previously stored code will be automatically erased if no system faults occur for a preset
number of ignition switch cycles.
5BUOPX-048
Inspection procedure
1. Locate the RABS test connector.
Note
The RABS diagnostic test connector is located behind the right hand kick panel. The RABS
rear speed sensor test connector is located on the forward end of the power distributi n box
in the engine compartment. To retrieve RABS service codes, use the diagnostic test connector
behind the right hand kick panel.
3. Disconnect the RABS test connector.
Note
Always turn ON the ignition switch before disconnecting the RABS test connector.
4. Attach a jumper wire to the (BJO)wire terminal side of the RABS test connector and ground it to the
chassis for one second and release it. When the ground is made and broken the rear ABS warning light
will begin to flash.
BASE INSTRUMENT
CLUSTER
I REAR ABS WARNING LIGHT I

5. Count the flashing pattern of the rear ABS warning light.
Note
A flashing pattern consists of a number of short
flashes and ends with a long flash. Count the short
flashes and include the long flash in the count.
The flashing pattern will repeat until the ignition
switch is turned OFF.
Verify the flashing pattern by reading it several
times.
Memory Cancel
Service codes memorized in the RABS control unit are
canceled by performing the following steps:
1. Turn the ignition switch OFF with the RABS test connector
disconnected.
2. Reconnect the RABS test connector.
4BUOPX-088
Service Code Table
1 =ite1 Possible Cause

Pattern of Output Signal
(Rear ABS Warning Light)
/
i
Diagnosis
Chart No.
RABS-2
j RABG
j RABS-4
I
I
- - -- - --
-
- -- --
Excesswe dump valve

-- - --
actlv~ty -- -- -- - - -
Rear axle speed sensor s~gnalrap~dly

cuts
- --
In and out whlle drlvlng --- -
-- - --
No sola
-- -
at
-
ion valve
- -
self-test -- --
No dump valve self-test
9 1 H~ghrear axle speed sensor resistance -
-
- <
10
-
Low
- rear axle
-- -
speed sensor
- --
resistance
-- --
11 Brake OnlOff (BOO) sw~tchclrcult

- , -- --closed
always -- - --- -- ---
12 Loss of hydraulic brake flu~dfor one or
more seconds during an anti-lock stop
Damaged brake fluid level sensor or
I related clrcuit
I
13 RABS control unit failure I n n n n n n n n n n n n ~I , RABS-13
1 6 E Z OK 1 RABS-16
MP1051-C 5BUOPX-050
Note
While using the following diagnosis charts, follow the test steps in order. Proceed to the next
test step e previous
e only if the e es step
test e has been e e and no fault has been
e completed ee found. If a fault
is found, service as needed, perform memory cancel and recheck codes to verify repair.
4BUOPX-090
I RABS-2 / Service code: 2 1

I
Poss~blefa~lure:Open isolation -
valve circuit -
Remark
-
ppp
ppp
---
.-
Check RABS control unit connector Check for poor connection (terminal 13)
1 2 1 Check hvdraulic unit connector 1 Check for poor connection (PILG) 1 - I
Check wiring harness between RABS control
unit and hydraulic unit (terminal 13-PILG)
Check isolation valve solenoid
Check for open
Check for ooen

I
,
-
P-59
II
If all above are OK, perform memory If service code 2 is still present, replace
cancel and recheck codes RABS control unit
If service code 16 is present, concern has
been corrected. Drive vehicle and verify
r 7
proper operation
-
-
-
-p
-
.
-
Perform memory cancel and recheck codes If service code 2 is still present, perform
intermittent diagnosis
RABSS / Service code: 3 I

I Possible failure: Open dump valve circuit
Check item Remark I Refer to I
Check RABS control unit connector Check for poor connection (terminal 8/14)
--
%$heck hydrazc- Check
ppppp-
for
p pp
poor
.--
connection (YILG)
Check wirina harness between RABS control Check for ooen
unit and (teyminal 4-YILG) -- -
Check dumo~alvesolenoid Check for ooen
If all above are OK, perform memory If service code 3 is still present, replace
cancel and recheck codes RABS control unit
proper operation
Perform memory cancel and recheck codes If service code 3 is still present, perform
intermittent diagnosis
RABS-4 Service code: 4
---
Possible failure: Open or short in hydraulic unit valve reset switch circuit, hydraulic leak into dump section
of hydraulic unit
step 1 Check item Remark Refer to
1Check hydraul~cunlt
I connector Check for poor connectlon (LBJR, BIW) -
1 - - - - -- - -
2 -
--- - ---
Check RABS control unlt connector Check for poor connect~on(term~nal6) -
3 Check wlrlng harness between?^^^ Check for open or short to ground -

- ---
unlt and hydraullc unit (term~nal6-LBIR) --
4 Check ground at hydraul~cunrt wirlng Check connection to chassls ground P-60
harness connector (B/W\
5 Check hydraulic unit valve reset switch
(LBIR--chassis ground)
1 Check for closed switch
-
6
-
Check for hydraulic leak into dump

section of hydraulic unit
/ Check with hydraulic pressure applied
7 I Check hydraulic unit internal circuit / Check for open or short to ground P-60
8 1 Check isolation valve orifice I Check for blocked orifice
If all above are OK, perform memory If servlce code 4 IS st111present,
cancel and recheck codes replace RABS control unlt
If servlce code 16 IS present, concern has
been corrected. Drive vehlcle and vertfy
I proper operation
Perform memory cancel and recheck code 4 IS st111present, replace
hydraullc unlt and perform lntermlttent
d~agnos~s
RABS-5 Service code: 5 7

Possible failure: Excessive dump valve activity
Step Check item Remark I Refer to
Check rear axle speed sensor input to Check for erratic signal
RABS control unit (terminal 3-terminal 10) - -- -- - - - -
f
Check normal brak~ng system-operation Check for brakes that lock-up eas~ly
- -- -- -- -- - - -- t - - P-63
-
If all above are OK, perform memory cancel If servlce code 5 IS st111present, I P-65
and recheckcodes replace RABS control unlt
If service code 16 IS present, concern has
been corrected. Dr~veveh~cleand verify I
DroDer oDeratlon
Perform memory cancel and recheck codes If service code 5 is still present, replace
hydraulic unit and perform intermittent
diagnosis
I RABS-6 Service code:
o 6 I
/ Possible failure: Rear axle speed sensor signal rapidly cuts in and out while driving 1
1 1 1 I I
--+
step Check item Remark Refer to
Check RABS control unit connector Check for poor connection
- -
for poor connection I
1 3 / Check rear axle speed sensor harness
I routlna
Check for proper routing, secured, and
no sian of wear or beinn pinched 1 - I
I 4 l Check rear axle speed sensor input to
RABS control unit
Check wiring harness between RABS /
Check for erratic signal
Check for open or short to ground

control unit and rear axle speed sensor
(terminal 3-RIP, terminal 10-LGIB)
1 6 Check rear axle speed sensor (LGIB-RIP) I Check for roper resistance I P-62 I
1 Check rear axle speed sensor for metal
chips, damaqe and proper clearance
Replace or clean as needed P-62, 65
I
1 8 1 If all above are OK, perform memory
cancel and recheck codes
If service code 6 is still present,
replace RABS control unit
P-65
proper operation
1 9 1 Perform memory cancel and recheck codes If service code 6 is still present,
perform intermittent diagnosis
/ RABS-7 / Service code: 7 I

I Possible cause: No isolation valve self-test (isolation valve circuit short to ground) I
I Step 1 Check item
I Remark I Refer to I
I 1
I
Check wiring harness between RABS
control unit (terminal 13) and around
Check for short to ground
I I
I
Check hydraulic unit connector Check for short to ground -
IPILG-BNV. PILG--around) I
Check isolation valve solenoid Check for shorted terminals
(pin 1-pin 3) at RABS hydraulic unit (should be no continuitv)
If all above are OK, perform memory If service code 7 is still present,
cancel and recheck codes replace RABS control unit
proper operation
5 / - --
~ s r f o r mmemory cancel and recheck codes If service code 7 is still present,
I RABS-8 / Service code: 8 1
( Possible failure: No dump valve self-test (dump valve circuit short to ground) 1
Check item Remark Refer to 1
1 Check wiring harness between RABS
unit (terminal 8/14) and ground
) Check for short to ground
hydraulic unit connector
(YILG-B/W. YILG--around)
/ Check for short to ground
I 3 l Check dump valve solenoid

(win 3-win 4) at RABS hvdraulic unit
Check for shorted terminals
(should be no continuitv)
4 If all above are OK, perform memory If service code 8 is still present,
1 cancel and recheck codes replace RABS control unit
I
proper operation
I --T-- t- Perform memory cancel and recheck codes If service code 8 is still present,
I RABS-9 I Service code: 9 1

I Possible cause: High rear axle speed sensor resistance I
I Step I Check item 1 Remark Refer to 1
Check RABS control unit connector Check for poor connection -
*
- -
speed sensor connector Check for poor connection -- --
-
Check wiring harness between RABS Check for open -
1 control unit and rear axle speed sensor
-- (terminal 3-RIP, terminal 10-LGIB)
-- --- - - -- -
Check rear axle speed sensor Check for proper resistance pp- --
P-62
-
If all above OK. oerform memorv cancel If service code 9 is still oresent. P-65
, and recheck codes ' replace RABS control u'nit
been corrected. Drlve vehlcle and verlfy
- - --- - - - --- -- --- - - - - -
proper
-- operation
- - - - - -- - - - --
6 Perform memory cancel and recheck codes If service code 9 is still present, P-56
MP1059-E
I - R A B ~
Service code: 10
I - -
Possible cause: Low rear axle speed sensor resistance

-
- - - - -- -
Check item - r - -
Remark
- - - -- -
Refer to I
/ 1 ) Check RABS control unit connector
(terminal 3-terminal 10)
) Check for shorted wires
1 * I
Check rear axle speed sensor connector
(LGIB-RIP)
1 Check for shorted wires
Check wiring harness between RABS Check for short to ground or

control unit and ground short between wires
-- -
P-62
1-
If all above OK, perform memory cancel If service code 10 IS still present, P-65
and recheck codes replace RABS control unit
proper operatton
6 / Perform memory cancel and recheck codes If service code 10 is still present, P-65
MP1060-D 4BUOPX-099
P-54
I RABS-11 / Service code: 11 I

I Possible cause: Brake OnlOff (BOO) switch circuit always cl sed I
Check item Remark
Check stoplight operation Service stoplight system as needed 1997 B-series
BETM
Check Brake OnIOff (BOO) switch input Check for proper voltage
to RABS control unit (terminal 11)
Check wiring harness between RABS control Check for open
unit and Brake OnIOff (BOO) switch (terminal
11 - Brake OnIOff (BOO) switch [LGIR]) - -- -- -- ----
If all above ~ ~ , p e r f o rmemory
m cancel If service code 11 is still present,
and recheck codes replace RABS control unit
--- -
proper operation
Perform memory cancel and recheck codes If service code 11 is still present,
replace Brake OniOff (BOO) switch and
RABS-12 Service code: 12

. . -.... - --.
-..~-~ -- - . ~ -.. . .. .~. -~- - - -- -...--------p
Possible cause: Loss of hydraulic brake fluid for one or more seconds during an anti-lock stop
Damaged brake fluid level sensor or related circuit
Check item Remark Refer to I

Check brake fluid level in reservoir
-
Fill reservoir to specified level
-- --- - - -
Check brake system for fluid leaks Repair brake- -

system as needed -- -
Check fluid l e v ~ s e n s o r Check float operation, terminals and sensor
should be secure connection -- -
I - - -
Check continuity of related wiring harness for Check for open circuit
open
terminal 2 (RABS control unit)-
T N (fluid level sensor)
TN-DGN (fluld level sensor)
R N wire between RABS low flu~dresistor
and fuse --
Check that there IS no contlnulty between

related harness to ground
Check for shorts to ground
I
7-- -
terminal 2 (RABS control unit)-ground

T/Y (flu~dlevel sensor)-ground
DGIY (fluid level sensor)-ground
TIY (ignition
- -
switch)-ground
- --- --- - - -
If all above are OK, perform memory If service code 12 IS still present,
cancel and recheck codes replace RABS control unit
orooer ooeration
Perform memory cancel and recheck codes If service code 12 is still present,
replace brake fluid level sensor and
: perform intermittent diagnosis
/ --
RABS-13 Service code: 1 3
-
-
--
Possible cause: RABS control unit failure

-7---
-- T-
- -
Step Check item Refer to

Replace RABS control unit P-65
2 1 Drive vehicle and verify proper operation - _I
MP1063-C 4BUOPX-102
--
RABS-16
Step
1
.
--
--
v-
AI Service code: 16
Possible cause: RABS OK
Check item
Dr~veveh~cleand ver~fyproper operation
I
-
Remark
-
---
Refer to
--
-
- I
MP1064 D 5BUOPX-058
lntermittent Diagnosis
Intermittent faults are the most difficult to diagnose. An
understanding of code storage and automatic code era-
sure is important. Some codes may not result in finding a
fault using the diagnosis charts. Most likely, these are an
indication of an intermittent fault.
Note
Codes can only be stored if the RABS control unit
has power. The RABS control unit gets primary
power from the Number 14 20A fuse into terminals
1 and 9. If the voltage is missing or less than 11V,
the RABS control unit will not initialize and there-
fore, a code cannot be stored.
Any code already in memory will be retained as
long as the battery power (Number 9 1OA fuse) into
terminal 12 is available.
A code 16 (RABS OK) is present whenever the
RABS control unit sees the required voltage (as-
suming no other service codes are present).
A previously stored code will be automatically
erased if no system faults occur for a preset num-
ber of ignition switch cycles.
To minimize misdiagnosis, refer to the intermittent diag-

nosis procedure (refer to page P-58) if no resolution has
been reached by the end of a particular diagnosis chart.
6BUOPX-705
INSPECTION ACTION
'
I Reconnect all G p o n e n t s and perform memory
i cancel. Turn the ignition switch ON. Does the
yellow rear ABS warning light illuminate for 1-2
-- -. ... -
seconds and go out?
light stays illuminated,
Go to step 2
I
Check all of the component connections for: Service the connectors and terminals as needed
bent terminals Go to step 7
damaged connector terminal locks
i damaged connector wedge
I
I
I I
I
Are any of these conditions apparent?
3 Turn the ignition switch ON. Wiggle the circuit Yes Service the connectors and terminals as needed
in questlon connector by connector until whole Go to step 5
circuit IS tested. Does the rear ABS warning
light illuminate dur~ngthe test?
No Go to step 4
4 1 Have all the circuits in question for the code 1 Yes Turn the ignition switch OFF
being serviced been tested? Go to step 6
Go to step 3 and check next circuit
- -
Check for service codes. Is code received Inspect code as indicated
different from the code being serviced? UZ= page P-52
page P-49
Service the wiring harness, connectors, and
terminals as needed
Go to step 7
IOI
- .-A ~
Has a code been received and have all test steps Go to step 7
for the code being serviced been performed?
diagnosis chart and
7
C Perform memory cancel and recheck codes Yes RABS concern has been corrected and
Is a code 16 received? , system is OK
--- -- -- ---- - ---
No If code belng servlced IS recelved agaln,

Go to step 4
If a different code is received,
Go to appropriate diagnosis chart
MP1114 D 4BUOPX-106
Inspection of RABS system
Check rear ABS warning light harness
1. Turn the ignition switch OFF, and disconnect the RABS
RABS CONTROL control unit connector.
UNIT CONNECTOR 2. Turn the ignition switch ON.
3. If the warning light remains illuminated, check the warning
light harness for short to ground.
BASE INSTRUMENT
CLUSTER
REAR ABS WARNING LIGHT
I i
MP1134-A 5BUOPX-062
Check rear ABS warning light bulb
1. Remove the instrument cluster.
2. Remove the warning light bulb from the rear of the cluster.
3. Check the condition of the bulb.
4. Replace the bulb if necessary.
4BUOPX-109
Check brake system warning light bulb

1. Remove the instrument cluster.
2. Remove the warning light bulb from the rear of the cluster.
3. Check the condition of the bulb.
4. Replace the bulb if necessary.
4BUOPX-110
Check brake onlaff (BOO) switch
1. Depress the brake pedal.
2. Verify that the stoplights illuminate.
3. If not illuminated, check the following:
Stoplight bulb
Number 13 15A fuse
Boo switch
Stoplight harness
4. Repair or replace parts as necessary.
5BUOPX-063
Check stoplight switch harness at RABS control unit

1. Turn the ignition switch OFF.
RABS CONTROL 2. Disconnect the RABS control unit connector.
UNlT CONNECTOR
/
3. Depress the brake pedal.
4. Check for voltage between terminal 1 1 at the vehicle side
harness and ground. (Refer to page P-61.)
5. If not as specified, check wiring harness between the
stoplight switch and the RABS control unit.
Check parking brake switch
Refer to the 1996 B-series BETM.
6BUOPX-011
Check fluid level sensor

Refer to page P-20.
Check ignition switch (bulb prove-out circuit)

Refer to the 1996 B-series BETM.
6BUOPX-012
Check hydraulic unit

Check isolation valve solenoid
1. Disconnect the hydraulic unit connector.
2. Measure the resistance between terminals 1 and 3 at the
hydraulic unit.
Resistance: approx. 3-6R
3. If not as specified, replace the hydraulic unit.

I
I
UNlT
MP1067-A
1
HYDRAULIC
HYDRAULIC
UNIT
CONNECTOR
I
4BUOPX-116
Check isolation valve orifice
1. Disconnect the RABS control unit.
2. Raise the vehicle on a hoist far enough to allow the wheels
to spin freely.
3. Start the vehicle, place in gear and allow wheels to spin at
idle for at least 30 seconds.
4. Apply the brake pedal with normal force.
5. If the rear wheels react uncharacteristically slow or con-
tinue to spin, then replace the hydraulic unit.
5BUOPX-067
Check dump valve solenoid
2. Measure the resistance between terminals 4 and 3 at the
fl:
-
4
HARNESS HYD
SIDE UNIT SIDE DUMP
SOLENOID
hydraulic unit.
Resistance: approx. 1-3i2
I
~~1068-A ~BUOPX-068' Check hvdraulic unit internal circuit
VALVE
1. ~isconlnectthe hydraulic unit connector.
RESET 2. Measure the resistance between terminals 2 and 3 at the
SWITCH hydraulic unit.
Resistance: 18-26 ki2

Check hydraulic unit valve reset switch
UNIT SIDE DUMP Test 1
SOLENOID 1. Disconnect the hydraulic unit connector.
MPI 068-A 4BUOPX.119 2. Measure the resistance between terminal 2 and the hy-
draulic unit body.
3. Depress the brake pedal and apply hydraulic pressure for
at least 30 seconds.
Resistance: greater than 10 kR

4BUOPX- 120
Test 2
1. Drive the vehicle at approximately 16 kmlh (10 mph) on
dry pavement.
2. Depress the brake pedal hard enough to lock all wheels.
3. After the vehicle has stopped, place the vehicle in Park
(AT) or Neutral (MT) and take foot off of the brake pedal
and wait 30 seconds.
4. If the rear ABS warning light illuminates, perform the self-
diagnosis function. (Refer to page P-49.)
5BUOPX-069
Check hydraulic unit for leakage

1. Press hard on the brake pedal with the engine running and
keep pressure for 30 seconds.
2. Monitor the height of the brake pedal while keeping
pressure on it.
3. If the brake pedal drops slowly to the floor, then replace
the hydraulic unit. ~BUOPX-122
Check ground at hydraulic unit harness connector

2. Check for continuity between terminal 3 of harness con-
nector and chassis ground.
3. If no continuity, service the harness connection to ground.
4BUOPX- 123
Check fuse
Check the fuse. If a fuse is burnt, replace it.
5BUOPX-129
Check RABS control unit
Caution
REAR ANTI-LOCK BRAKE SYSTEM (RABS) When checking for voltage at the control unit termi-
CONTROL UNIT CONNECTOR
nals, insert the probe from the rear of the connector
(harness side) to prevent damaging the terminals.
LBIP
RIP
TPI
LG--
LGlB
1-
;:To
Lw
NOT USED
BIO
PILG
YILG
YILG
~~1071-c ~BUOPX-070 VB: Battery voltage
I Terminal / Wire Color / Connected to 1 Condition I Voltage I Remark I

Number 14 20A fuse lanition switch OFF 1 0 1
Ignition switch (ONISTART)

Fluid level sensor
lgnition switch
-
ON-. ---
Ignition switch ON, brake fluid
level normal (not grounded)
+e-
lgnition switch in START or brake
fluid level low (arounded) 0
3 LGlB Rear axle speed sensor Rear wheels stopped Measure AC
voltage between
-- - terminals 3 and 10
Rear wheels rotatlng at 3 kmlh with vehicle raised
(5 mph)
-
Ground -
Constant 1 0 1
-
Valve reset switch
-- - -
Rear ABS warning light

lgnition switch ON
- -- - . .
- - -- - -
Dump valve solenoid -...
Solenoid is ON
Solenoid OFF only when RABS
is functioning
Brake OnIOff (BOO) switch ' Brake pedal depressed
-
Brake pedal released
Number 9 10A fuse (battery) RABS test connector connected
RABS test connector I RABS test connector disconnected
--,
- -- . - - -
13 lsolat~onvalve solenold Solenold ON
I I Solenold OFF only when RABS
IS functlonlng
MP1072-D 6BUOPX-706
(Revised 1112000) (1997 B Series) P-61

Check rear axle speed sensor
REAR AXLE
SENSORROTOR 1. Jack up the vehicle and support it on safety stands.
SPEED 2. Remove the rear axle differential cover.
SENSOR
I 1
MP1073-A
3. Check the clearance between the rear axle speed sensor
POLE PIECE pole piece and the sensor rotor teeth.
Clearance: 0.1 27-1.1 43mm {0.005--0.045 in}
4. Rotate the axle 60"-90".

5. Repeat steps 3 and 4 for a total of 5 measurements.
6. If not as specified, replace the rear axle speed sensor or
sensor rotor as necessary.
Check resistance of rear axle speed sensor

1. Disconnect the rear axle speed sensor connector.
2. Check resistance at the rear axle speed sensor.
Resistance: 0.9-2.5 kQ
Check voltage of rear axle speed sensor

2. Disconnect the rear axle speed sensor connector.
3. Measure voltage while rotating a rear wheel 3 kmlh
(5 mph).
Voltage: 650 mV or greater (AC)
4. If not as specified, replace the rear axle speed sensor or

sensor rotor as necessary.
Note
The rear axle speed sensor voltage and resistance
inspections can also be performed at the rear axle
speed sensor test connector located next to the
main fuse block in the engine compartment. If no
voltage or resistance can be measured, check the
wiring harness between the rear axle speed sensor
and test connector before replacing the sensor.
Check sensor rotor
SENSORROTOR 1. Jack up the vehicle and support it on safety stands.
REAR AXLE
SPEED 2. Remove the rear axle speed sensor.
SENSOR 3. View the sensor rotor teeth through the sensor hole.
\
4. Rotate the rear axle and inspect for missing and damaged
teeth.
5. Replace the sensor rotor as necessary.
I I
MP1073-A 4BUOPX-131
Check normal braking system operation
Stopping test
1. Disconnect the RABS control unit connector.
2. Drive the vehicle at approximately 32 kmlh (20 mph).
3. Perform a light to medium stop.
4. If the rear wheels lock up, inspect the conventional brak-
ing system.
4BUOPX-132
Dry road lock up test

1. Drive the vehicle at approximately 16 kmlh (10 mph) on
dry pavement.
2. Depress the brake pedal hard enough to lock all wheels.
3. If the rear wheels lock up, replace the hydraulic unit.
4BUOPX-133
RABS operation on hoist

1. Place the vehicle on a hoist and raise high enough to clear
all wheels off the ground.
2. Place the transmission in low (AT) or first gear (MT).
3. Accelerate the vehicle wheels to 16 kmlh (10 mph).
4. Press hard on the brake pedal until the wheels stop.
5. If the wheels lock up and remain locked up, replace the
hydraulic unit.
5BUOPX~O74
RABS HYDRAULIC UNIT
1. Disconnect and plug the two brake lines connected to the hydraulic unit.
3. Remove the screw retaining the unit to frame rail and remove the hydraulic unit.
5. Bleed the brake system. (Refer to page P-10.)
Note
It is not necessary to energize the hydraulic unit
electronically to bleed the rear brakes.
Before connecting the RABS hydraulic unit con-
nector, fill the unit side connector with Dialectic
grease.
5BUOPX-075
Installation Note
Brake pipes
Connect the brake pipes to the unit and tighten as follows:
Tightening torque:
15-20 N-m(1.5-2.0 kgf-m, 11-14 ftelbf)
Caution
Do not over tighten the fittings.
5BUOPX-076
Hydraulic unit
Position the hydraulic unit on the frame and install the
bolts.
Tightening torque:
20-25 N-m(2.0-2.5 kgf-m, 14-19 ft-lbf)
5BUOPX-077
RABS CONTROL UNIT
1. Remove the instrument panel cover. (Refer to Section S).
2. Remove the screw and slide the RABS control unit to release the upper tab from the instrument panel
brace.
3. Disconnect the connector from the RABS control unit by depressing the plastic tab on connector and
pulling the connector off.
4. Remove the RABS control unit.
5. Install in reverse order of removal.
6. Check the system for proper operation.
5BUOPX-078
Fuses
Three replaceable fuses are involved with the RABS. The fuses are located in the fuse box.
- Number 9 10A Fuse
- Number 11 7.5A Fuse
REAR SPEED SENSOR (RABS AND ABS)

1. Disconnect the connector from the speed sensor.
2. Remove the bolt and remove the speed sensor from the axle housing.
lnstallation Note
Rear speed sensor
1. Clean the axle mounting surface. Use care to prevent dirt
from entering the axle housing.
2. lnspect and clean magnetized sensor pole piece to make
sure that it is free from loose metal particles which could
cause erratic system operation. lnspect the O-ring for
damage, replace if necessary.
3. Do not apply force to the plastic sensor connector. The
sensor flange should slide to the mounting surface. This
will make sure the air gap setting is between 0.127-
1.143mm (0.005--0.045 in).
4. Install the bolt and tighten to the specified torque.
Tightening torque:
34--40 N-m ( 3 . 5 4 . 0 kgf-m, 25-30 ft.lbf}
5. Connect the speed sensor connector.

REAR SPEED SENSOR ROTOR (RABS AND ABS)
1. Remove the differential from the rear axle. (Refer to Section M.)
2. Remove the bolts retaining the ring gear to the differential case.
3. Remove the ring gear, referring to Removal Note.
Note
Only remove speed sensor rotor if replacement is required. It does not have to be removed for
ring bearing replacement.
4. Remove the speed sensor rotor by tapping with a soft-face hammer. Discard the speed sensor rotor,
referring to Removal Note.
Note
The exciter ring must be discarded upon removal. If removed, a new speed sensor rotor must
be installed.
5. Install in reverse order for removal, referring to Installation Note.

5BUOPX-082
Removal Note
Ring gear
Remove the ring gear by striking at alternate holes around
the gear.
I I
MP1036-A 4BUOPX-144
Speed sensor rotor
Remove the speed sensor rotor by tapping with a soft-face
hammer. Discard the speed sensor rotor.
MP1037-A 4BUOPX-145
Installation Note
Ring gear and sensor rotor
1. Position ring gear and speed sensor rotor on differential
case. The tab on the speed sensor rotor must be aligned
with the slot in the differential case as shown. Start two
ring gear retaining bolts through the case into the ring gear
to make sure case-to-ring gear bolt hole alignment is
achieved.
Caution
The tab on the speed
e sensor
e rotor must be
e aligned
with the slot i n the differential
ee case.
2. Press the ring gear and speed sensor rotor on the differ-
ential case using the ring gear as a pilot.
3. Coat the threads of ring gear retaining bolts with sealant.
Install bolts and alternately tighten evenly.
Tightening torque:
95-1 15 N.m (9.7-1 1.7 kgf.m, 7 0 - 4 5 ft-lbf)
Inspection
1. Remove the speed sensor. (Refer to page P-65.)
2. View the speed sensor rotor teeth through the rear axle
speed sensor hole.
3. Rotate the rear axle and check the ring teeth for damage
or breakage.
Note
Dented or broken teeth could cause the anti-lock
system to function when not required.
5BUOPX-083
P 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS)
4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS)

PREPARATION
SST
'
- - -

connection of connection of
breakout breakout
Ant1 lock box Anti lock box
brake brake
adapter adapter
I
49 UNOl 058 For 49 TO88 OAO For inspection

anti-lock , of ABS control
break system unit terminal
Breakout diagnosis NGS set voltage and
box inpuffoutput
device
DESCRIPTION
The 4 Wheel Anti-lock Brake System (4WABS) is standard on all 82300 and B3000 vehicles equipped
with 4-wheel drive and on all B4000 vehicles. The 4WABS control unit senses the drop in wheel speed
and modulates hydraulic pressure to all four brakes inhibiting lock-up.
6BUOPX-014
Outline
The ABS is composed of electrical components, mechanical components (hydraulic unit), and the com-
ponents of the standard brake system.
Fundamentally, malfunction of the ABS electrical or mechanical components is judged by the self-
diagnosis function within the ABS control unit. Malfunctions are indicated by the warning light in the
instrument cluster. When a malfunction occurs, the control unit will store a five-digit diagnostic trouble
code (DTC) in its memory. To access DTCs, use the New Generation Star (NGS) tester (49-T088-OAO).
WIRING DIAGRAM
RETRIEVING DTCs
1 2. Select VEHICLE AND ENGINE SELECTION.
VlEW RECORDER AREAS

DIGITALMEASUREMENTSYSTEM
GENERIC OED IIFUNCTIONS
1 3. Select SELECT NEW VEHICLE YEAR & MODEL.
111 1
NO VEHICLE SELECTED
DESELECTCURRENTMODEL
I
MJ 1173-A
VlEW RECORDER AREAS

GENERIC OED IIFUNCTIONS 1
j
MJ1174-A
- I
i 5. Select ABS-ANTI LOCK BRAKE MODULE.
PCM - POWERTRAINCONTROL MODULE

GEM -GENERIC ELECTRONIC MODULE
-
RAP REMOTE ANTI-THEFT MODULE
CLEARING DTCs
1. Perform the necessary vehicle preparation and vlsual
~nspectlon.Hook up SST (NGS) to vehicle.
CONNECTOR-2
- - - -- --
~ ~ 7 6 A6 7
- -
- - - 1
,
I
MJ1172 A
I
-- - _ _
1
1
3. Select SELECT NEW VEHICLE YEAR & MODEL.
NO VEHICLE SELECTED

111 1
I SELECT ITEM AND PRESS TRIGGER TO START
,
) i
J
I
!
I
~ ~ 1 1 A7- 3
i i
I
J
L - -- 1
MJ1174 A
- - - - --
1 5. Select ABS-ANTI LOCK BRAKE MODULE.

6. Select RETRlEVEiCLEAR CONTINUOUS CODES.
h-I 6 I 7. Press CLEAR. Also, one DTC can be cleared by pressing

C-ONE.
1
8. Press START
1IK GEM -GENERIC ELECTRONIC MODULE

RAP -REMOTE ANTkTHEFT MODULE

4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS) P
DIAGNOSTIC TROUBLE CODE
-
DTC - Concern Sets Atp--p-pp-- Pinpoint Test Page
81432 Anti-Lock Electron~cControl Key ON Replace Anti-Lock
Module Fa~lure Electron~cControl P-123
.--- -
- Module
C1101 lnterm~ttentValve Fatlure Key ON - A P-77
+
C1185 , M a ~ nRelay Output C~rcu~t
Fa~lure Key ON - B P-78
B1317 Battery Voltage High Key ON
-- C -
P-80
8131 8t ~
---
C1198
a t t e Voltage
r ~ Low
LF I S 0 Valve Cod C~rcu~t Fa~lure
Key ON
Key ON - +
7
P-81
P-82
C1194 LF Dump Valve Coll C~rcu~t Farlure Key ON
- - -
F P-84
C1214 ' RF I S 0 Valve Coll C~rcu~tFa~lure Key ON G P-86 -
----
~1210 RF Dump Valve Corl C~rcu~t Fa~lure Key ON - H P-88
-
C1206 R I S 0 Valve Coil Clrcu~tFa~lure Key ON
--- - J --
P-90 -
~1202 R Dump Valve Coll Circu~tFa~lure Key ON -- K -

P-92
C1155 LF Wheel Speed Sensor Input Key ON L P-94
Circuit Failure
C1158 LF Wheel Speed Sensor Coherency 40 kmlh LL P-96
Fault (25 mph) ---- -
C1258 LF Wheel Speed Sensor Wheel 19 krnlh LL P-96
Speed Compar~sonFault (12 mph) ---
C1233 LF Wheel Speed Sensor Input Mlsslng >2 M I ~ . LL P-96

(Long Term)
-
-- -
,
-
-
C1145 RF Wheel Speed Sensor Input Key ON M P-100

Clrcu~t
, --
Fallure -- - - -- ---
C1148 RF Wheel Speed Sensor Coherency 40 kmlh MM P-102
Fault -- (25 mph) -- -- -
C1259 RF Wheel speed Sensor Wheel 19 kmlh MM P-102
- Speed Compar~sonFault - (12 mph)
C1234 RF Wheel Speed Sensor Input Mlsslng >2 Mln. MM P-102
, (Long Term) -
C1230 RA Wheel Speed Sensor Input Key ON N P-106
Circu~tFatlure ---- --
C1229 RA Wheel Speed Sensor Coherency 40 kmlh NN P-108
I- --7
I Fault - --
I
(25 m p h ) -_ -- - --
C1260 I RA Wheel Speed Sensor Wheel 19 kmlh
Speed Compar~sonFault pp - -- -- (12 mph)
~ 1 2 3 7' R Wheel speed Sensor Input M~ss~nq - >2 Mln.
I (Long Term)
t
16;
No code Left Valve Pa~rFunct~onTest
NO~ i d e Front R i K a Y- -e Palr ~ u n c t l G e s t i--p
-
-
-
--
--
- -- - -
P-112 ---
P-113
See Note Below P-116

P-118
P-119
NOTE: DTC C1102 indicates a G-Switch circuit failure. Ifthe yellow ABS warning lamp comes on at key ON, check for a ground short on Pins
30, 31, or 32. If the yellow ABS lamp comes on at approximately 32 kmlh (20 mph), there is either: 1) a battery short on Pins 30, 31, or 32; 2)
an open on Pins 30 and 31 ; or 3) an open on Pin 32. If the yellow ABS lamp comes on after driving the vehicle for 2 minutes at approximately
72 kmlh (45 mph), check for an open on Pin 30 or 31 (one pin only).
MP1136-B 5BUOPX-086
Breakout Box Function

1. Disconnect the 40-pin plug from the 4-WABS module.
2. Connect the SSTs (49 UNOl 062) to the 40-pin plug on the
vehicle harness and breakout box cable (49 UNOl 063).
3. Connect cable to breakout box.
4. Install overlay on box.
5. Refer to pinpoint test procedures for specific servicing
directions.
\
/
OVERLAY
BREAKOUT BOX
I Item to be Tested Pin Number@)

ABS Control Unit 1 + Chassrs Gnd Continurty
Ground Check OFF
OFF
1 14 + Chassis Gnd
17 + Chassrs Gnd
Contrnurty
Continurtv
I
ON Volts 9.5V ~rnrmbm
I
Jumper Prns 1 + 19 ON 17+ 1 9.5V Mrnrmum

(Energrzrng Marn Relay)
Power from Marn Relay
--- - - - --- -- -+- - - - - -- ---
Marn Relay Corl OFF 19+20

I
Pump Motor Relay Corl OFF 17+29
ABS Warnrng Lrght Ground Through I OFF 17+ 1
System Relay
--
--
-- -- -- - - -
t- - --
1
-
IFR lsolat~on(Inlet) Valve Resrstance OFF 17+34

IFL lsolatron (Inlet) Valve Resrstance I OFF 17 + 4 0
IRA lsolatron (Inlet) Valve Resistance OFF 17+33
OFR Dump (Outlet) Valve Resistance OFF 17 + 15
OFL Dump (Outlet) Valve Resistance OFF 17 + 2 6
-
ORA Dump (Outlet)-
-
Valve Resrstance
-
FR Wheel Speed Sensor Resrstance
OFF
-
OFF
-- ---
17+27
23 + 36
FL Wheel Speed Sensor Resrstance OFF 24 + 25
RA Wheel
- -Speed Sensor Resrstance OFF 21 + 2 2
Sensor Output
Rotate Front Wheels and Rear Axle @
60 rDm
FR (4x4) Ranger IOFF 23 + 36 Hz and mV 15.8 mV/Hz or Greater
FL (4x4) Ranger
- - 52 - Hz and mV 15.8 mV/Hz or Greatei
-
I 21 + 22 1 Hz and mV 16.0 mV/Hz or Greatel
18 (Meter Polarrty +) or I Diode Check I 0.5 volt
17 (Meter Polarity -) I
Remove Main Relay OFF 18 (Meter Polarity +) or Drode Check I lnfrnity m Ohms
I 17 (Meter Polarity -) I
MPI 138-8 6BUOPX-01
SYSTEM PRECHECK
Note
It is imperative that this procedure be performed first. Failure to do so may result in incorrect
diagnosis of problem, wasted time, and improper replacement of good components.
The system pre-check is used to screen a vehicle for relatively simple diagnostic repairs such
as loose connectors, blown fuses, etc. However, the system pre-check is also used to prepare
the vehicle for further diagnostics. In addition, warning light faults are dealt with in this test.
Procedure
I STEP 1 INSPECTION ACTION I
1 Verlfy that all of the following connectors are connected Yes Go to step 2
and the terminals are secure and free of contaminants or
corrosion:
4WABS module connector (0-1 54)
4WABS hydraulic unit connector (0-1 46)
4WABS pump motor connector (0-145)
Front wheel sensor connectors (0-1 51 and 0-1 58) No Repair or replace as necessary
Verlfy that both the 4WABS main relay and 4WABS pump Go to step 2
motor relay and diode are fully seated and secure
Verlfy that related fuses are present and Intact
Verlfy that the ground IS flrmly attached to the weld stud
and IS free of corroslon and excessive dlrt
Are all connectlons secure and fuses OK?
2 Verlfy that the 3-pln acceleration sensor connector
(4x4 only) (0-1 008) and the 2-pln rear axle sensor
Yes Go to step 3
I
1
--
connector (0-1 010 ) are connected and terminals are No Repair or replace as necessary
secure and free of contamlnants or corrosion 1 Go to step 3
I Are all connectors, terminals and grounds secure? I
Key ON / Yes Light flashes:
Does ABS warning light come on? Diagnostic circuit grounded
Stays on for 3 sec. and goes out:
Go to step 6
Comes on and stays on:
Go to step 4
4 Key OFF Yes GO to step 5 I

Connect NGS tester to Data L~nkConnector (DLC)
Is equipment hooked up properly?
- --
I Re-attempt step 4
1
5 Key ON Yes Go to the appropriate pinpoint test for each
Perform RETRIEVEICLEAR CONTINUOUS DTCs code(s) that amears
Are any DTCs present? If the vehicle has been previously serviced,
system is OK. Perform RETRIEVEICLEAR
CONTINUOUS DTCs again to recheck system
T
If the vehicle has not been previously serviced:
Check power feed circuit for open/short
from ignition switch to Fuse 14 (10A)
and from Fuse 14 (10A) to 4WABS
control module (LBIP)
@ Check 4WABS module grounds for
SELECT ITEM AND PRESS TRIGGER TO START looseness, corrosion or excessive dirt
Check for loose power lug at engine
compartment fuse box
If there is no NGS communication, go to
Pin~ointTest V
P $-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS)
STEPJ INSPECTION ACTION

--
6
i Drive vehicle
--
I Note: Step 6 is optional for additional information only yes 1
,
At or near 10 kmlh (6 rnph):
Go to steD 4
Does ABS warning light come on during any of the
following:
While vehicle moves initially?
1 While driving under 40 km/h (25 mph):
GOto step 4
While driving over 40 kmlh (25 mph):
While driving under 40 kmlh (25 mph)?
While drivina at or over 40 kmlh (25 m ~ h ) ? Go to step 4
While in an anti-lock stop? 1 Abnormal ABS or brake operation:
Inspect front wheel sensors and speed
sensor ring for damage. If damaged, go to
I Pinpoint Test LL (Left Front), Pinpoint Test
( MM (Right Front) or Pinpo~nt Test NN (Rear).

For non-ABS related symptoms, refer to the
Conventional Brake System Troubleshooting
Chart in this section. --
No Go to step 4
Is the warnlng light bulb blown? I Yes Replace bulb
1 Go to step 4
No Leave bulb out
1 GOto s t e 8
~
8 Key OFF Yes I Go to step 9
--
Insert 12V test hght between 4WABS warnlng l~ghtbulb
socket (+) and a known good chassis ground No Repair open circuit or short to ground on
Key ON warning light circuit
Does hght ~llurnlnate? Go to step 3
--- p- -- - -- -- - -
9 Remove 4WABS diode Yes Go to step 10
Verify d~odeterm\na\s are clean and firmly In place
1 Check for continuity between 4WABS bulb socket ground No Repair or replace open circuit in warning light
and drode terminal in engine compartment fuse box for ground or loose terminal
clrcult (DG) Go to step 3
Is there continuity7
-7
Remove 4WABS main relay ' Yes I Go to step 11
Verify relay terminals are clean and firmly in place I
Check for continuity between 4WABS main relay (OIY)
and a known good chassis ground.
COWL
B - No
----
Repair or replace open c~rcuitin (OIY) circuit
C
between diode and 4WABS main relay or
loose terminals
- *
C Go to step 3
AWABS
Up+ MAIN
RELAY
+U
FRONT OF
VEHICLE
.- - --- --
11 I Inspect chassis ground for looseness, corrosion or Reinsert relay and replace warning light
excessive dirt Repeat steps 8-11 of Intermittent diagnost~c
Clean and tighten as required procedure ln this section
Check for continuity between 4WABS main relay (6) and --- -- -
Repa~ror replace open c~rcu~t

between
chass~sground
Is there cont1nuity7 4WABS main relay and chassis ground 1
_1
MP1139-B2 GBUOPX 021
$-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS)
PINPOINT TEST A -
Diagnostic
o trouble code INTERMITTENT VALVE FAILURE
No. C1101 --
Description DTC C1101 is generated when the 4WABS detects an intermittent circuit failure in the
hydraulic unit valves or valve wiring harness
Possible Cause lntermittent valve failures
lntermittent wiring conditions in circuit (ON) to both pins 1 and 4 of the 8-pin HCU
valve block connector
I
1 Disconnect 8-pin connector from hydraulic unit High or low valve resistance detected
Measure resistance between the following on the Replace hydraulic unit
COMPONENT side of the connector: Perform 4WABS brake bleed wrocedure
Refer to page P-11
Pin 1, pin 4
and pin 2 (RA Inlet) 5-8 Ohms
1 Go to step 5
Pin 1, pin 4
and pin 3 (RA Outlet) 3-6 Ohms
Pin 1, pin 4
and pin 5 (FR Inlet) 5-8 Ohms
Pin 1, pin 4
and pin 6 (FR Outlet) 3-6 Ohms
Pin 1, pin 4
and pin 7 (FL Inlet) 5-8 Ohms
I
NO I GO to step 2
I
Pin 1, pin 4
and pin 8 (FL Outlet) 3-6 Ohms
Does resistance on any value move out of specifications

at any time?
CONNECTOR SIDE
Measure resistance between the following on the Yes Replace hydraulic unit
COMPONENT side of the hydraulic unit &pin connector: Perform 4WABS brake bleed procedure
Pin 1 and valve block Refer to page P-11
Pin 4 and valve block Go to step 5
Note: The valve resistance will change rapidly
Is measured resistance less than 10,000 ohms at any Go to step 3
time?
Note: Voltage reading will change rapidly Yes Service source of high resistance or open
Install 60 pin bredkout box and overlay circuit in one of the following:
Jumper pin 19 to ?in 1 or pin 14 on breakout box Circuit (ON) between hydraulic unit and main
Measure voltage bebueen pin 17 and pin 1 or pin 14 relay
Does voltage fall below 9V at any time? Circuit (TN) between battery and main relay
-
Go to step 5
No Go to steo 4
Perform intermittent diagnosis procedure (page P-120) for Service wiring fault as required
the affected circuits Go to step 5
Is wiring fault located? Replace control unit
Go to step 5
Key OFF Yes Repair is completed
Reconnect and reassemble all components
Key ON Same code is present:
Using NGS Tester, clear all codes Repeat step 1 to check for second related
Drive over rough road and through a car wash concern
Perform RETRIEVEICLEAR CONTINUOUS DTCs A new code is present:
Is System Passed obtained? Go to the appropriate pinpoint test
PINPOINT TEST B
NO.C1185
Description
MAIN RELAY CIRCUIT OUTPUT FAILURE
C1185 is generated when the 4WABS detects an open or ground short on circuits ( T N ) ,
1
(PILG) or (OIY)
Possible Cause Open or short to ground on circuits (TIY), (PILG), or (ON)
Open in circuit (LBIP) to relay coil only
30 amp fuse open
Main relav coil or contacts oDen
STEP INSPECTION -
ACTION --
7
I
Measure and record battery voltage I Yes Go to step 2
Install 60 pin breakout box and overlay
Jumper breakout box pin 19 to pin 1 or pin 14
Key ON --
Measure voltage at breakout box pin 17 No 1 Go to step 4
Is voltage between 9.5 and 18 volts and w~thln.5 volt of
battery voltage? --
1
Key OFF Yes Go to step 3 I
Fieconnect control unit No Intermittent fault
Key ON
Is ABS light on?
I Refer to intermittent diagnosis procedure for
-- -
- -- --
-1-
-
all affected circuits --
Perform RETRIEVEICLEAR CONTINUOUS DTCs I Yes Replace control unit

Is DTC C1185 (power relay output - CKT fa~lure)present7 ~ Go to step 4
No Go to aDDro~rlateDlnDolnt test
Inspect 30A fuse (Fuse 9 - engine compartment box) Yes Go to step 7
for open
Is fuse OK?
COWL
4
No /I Go to step 5
I
FRONT OF
VEHICLE
5 Remove main relay Yes Go to step 14

Check for ground short on circuit (TN)
I
I between 30A fuse (#9) and relay connector I No GOto step 6

1 Is a around short detected?
I STEP I lNsPEcTloN
1 Yes
r Go to step 14
ACTION
6 Remove main relay
Disconnect 8-way hydraulic unit valve connector
Check for ground short on circuit (ON) between relay
connector or breakout box pin 17 and hydraulic unit &way Replace relay
connector pins 1 and 4 Go to step 14
Is a ground short detected?
7 Remove 30A fuse (#9) Yes Go to step 8
Key ON --
Measure voltage at power side of fuse Repair power feed to 30A fuse
--
Key OFF Go to step 14
. ~. -
~-
1 -
Remove main relay
Measure resistance between relay and 30A fuse along No I Repair or replace openlhigh resistance in
circuit (TIY) circuit (TIY)
Is resistance less than 1 ohm? Go to step 14
~ -- - - . ~. ~ -..-----pp---

Check for ground short at circuit (PILG) (breakout box
p - - p - p - - - - p - - - - - - - -
No Repair or replace circuit (PILG) for ground

, pin 19) short
- ..--
----
10
i
Is circuit OK?
1 Measure
Key OFF
- ~ . -- -- - - . ..... -- -- --- Go to step 14
--
resistance between main relay and breakout box open,high resistance in

pin 19 along circuit (PILG)
Is resistance less than 1 ohm?
-. ..-
I GOc~rcuit(P/LG)
to step 14 -
~ Y ~ S - T G 1X2 S ~ ~ ~
-~
Measure resistance between main relay and breakout box

pin 17 along circuit (OIY)
Is resistance less than 1 ohm?
..- --
No I Repair or replace openlhigh resistance in
circuit (OiY)
Go to step 14 --- -. -
t-p -
12 Remove main relay i Yes Go to step 13

Measure resistance across relay coil
I
I
r------- 1
I Replace relay
I Go to step 14
I
!
I I
I
I
I
I
I
MAIN RELAY TERMINALS
~
I
1 -
MP1143-82 6BUOPX-024

Key ON Yes Replace relay
Measure voltage at circuit (LB/P) on main relay connector Retest
Key OFF
No Repair or replace open in circuit (LBIP)

between splice and relay
Go to step 14
MAIN RELAY CONNECTOR
--
Kev OFF Yes Repair is com~leted
Reconnect and reassemble all components
No Same code is present:
Using NGS Tester, clear all DTCs
Repeat step 1 to check for second related
Perform step 1 of vehicle drive test. Refer to page P-I20
concern
Using NGS Tester, perform RETRIEVEKLEAR
CONTINUOUS DTCs A new code is present:
Go to appropriate pinpoint test
MP1143-B3 6BUOPX-025
PINPOINT TEST C
No. B1317 -
1 BATTERY VOLTAGE HIGH
Description 81 317 IS generated when the control unit detects system voltage was greater than
18 0 volts for more than 5 seconds - -
Possible Cause 24 volt jump
ST----
Charg~ngsystem overvoltage condltron
- -- -
INSPECTION I ACTION
The most hkely cause for 81317 IS jump start~ngthe vehlcle 1 Yes Repalr IS completed
with a 24-volt system used by many towing services i I
Has the vehicle been jump-started by a towing service
within the past two weeks? I
,
Go-oto step 2
I
Key ON, engine running 1 Yes Check charging system for overvoltage
Measure voltage at 60 pin breakout box pin 20 ! condition
Is voltage 18 volts or greater?
Key OFF Yes : Check charging system for intermittent
Reconnect and reassemble all components overvoltage condition
Key ON
No 61317 is present:
Key OFF
Replace control unit
Kev ON
using NGS Tester, perform RETRIEVEICLEAR A new code is present:
CONTINUOUS DTCs Go to the appropriate pinpoint test
Did system pass?
MP1144-B 6BUOPX-026
PINPOINT TEST D
Diagnostic trouble code BAlTERY VOLTAGE LOW
No. B1318 ---
Description B1318 is generated when the control unit detects system voltage was less than 9.5 volts
for more than 5 seconds -
Possible Cause Charging system undervoltage condition
STEP ;
1 Excessive resistance in control ground circuits (pins Iand 14)
Excessive resistance in circuit (LBIP) to pin 20
INSPECTION ACTION
-- -
Measure and record battery voltage

Is battery voltage greater than 9.5 volts? system for undervoltage
I I condition
I e r , clear a11"CS 1 Yes GO to step 3
~ e ON
y
Usina NGS Tester, perform RETRIEVEICLEAR
CONITINUOUSDTCS
Is B1318 (battery voltage-low) present?
A new code is present:
System Pass is obtained:
Concern is intermittent. Perform intermittent
diagnosis procedure on all affected circuits
BATTERY VOLTAGE - LOW
- --
Ye' k e p i a c e control unlt
Go to step 4
In control
Is reslstance less than 0.5 ohm?

-- - --
Yes I Repalr IS complete
Uslng NGS Tester, clear all DTCs

Key OFF
Key ON
Uslng NGS Tester, perform RETRIEVEICLEAR ---
CONTINUOUS DTCs
I Dld system pass7 Repeat step 1 to check for second related
concern
A new code IS present:
Go to the appropriate plnpoint test
MP1145-B 6BUOPX-027
PINPOINT TEST E
Diagnostic trouble code LEFT FRONT IS0 VALVE COIL CIRCUIT FAILURE
No. C1198
Description C1198 - Open circuit to valve block or control unit, open or shorted valve coil or
internal control unit defect
Possible Cause Intermittent open in circuit (T)
Terminal backout in control unit connector pins 17 and 40
Terminal backout in hydraulic unit connector pins 1, 4 and 6
Open or shorted inlet front left (IFL) valve coil
Open or shorted driver in control unit
=PI- INSPECTION ACTION
Verify terminals at pins 17 and 40 are clean and secure in
the control unit harness connector No Go to step 2
Measure resistance between breakout box pins 17 and 40
Is reading between 5 and 8 ohms?
,
2 Disconnect 8-pin hydraulic unit connector Yes Remove main relay
Verify terminals on both halves of the 8-way connector are Repair or replace open or short to ground in
I clean and secure circuits (T) and (OIY) between hydraulic unit
Measure resistance between pins 1 and 6 and pins 4 and connector and control unit connector
6 on the valve block Install relay
Are both readings between 5 and 8 ohms? Go to step 4
I
I
~ --
I
No -~eplace hydraulic unlt
I 1
GO to step 4
~
I
This step requires that a valid diagnostic trouble code I Yes Replace control unit
r
has been obtained, ALL prior diagnostic steps have been Go to step 4
completed, and the affected wiring integrity has been
verified
CAUTION: If the above is not complete, chances --
are that replacement of this or any other system No Go to last diagnostic step completed and
c mponent without specific direction will not, in continue
most circumstances, resolve the concern and will
consequently result in customer dissatisfaction
Have all prior diagnostic steps been completed as
described above?
STEP
-
/ -
INSPECTION
7
I
I
-
ACTION --
4 / Kev ON I Yes Repair is completed
using NGS Tester, clear all DTCs Code C1198 is present:
Key OFF Go to step 3
1 L$G
n!:S Tester. ~erformRETRlEVEiCLEAR
CON~INUOUSDTCS
A new code is present:
Did system pass? Code C1198 is present and control unit has
been reulaced:
Note: ~ W A B Sis disabled with the
breakout box installed
Install breakout box with overlay
Repeat step 1 while driving vehicle
Look for any changes in indicated continuity
Inspect circuits (OIY) and (T) along their
entire length from the sensor connector to the
, control unit harness connector for chafing or

any other damage that could lead to any open
or shorted condition
Service as required
5 Note: If the above steps have been completed, the
most likely cause of the concern is wiring related
Refer to the Intermittent Diagnosis Procedure in this Replace hydraulic unit
section and perform for ALL affected circuits Perform 4WABS brake bleed procedure
Is resolution achieved? Refer to oaae P-11
PINPOINT TEST F
Diagnostic trouble code LEFT FRONT DUMP VALVE COIL CIRCUIT FAILURE
No. C1194
Description C1194 - Open clrcult to hydraulrc unit or control unit, open or shorted valve cod or
Internal control unit damage
Possible Cause lntermlttent open ~nclrcult (0)
Termtnal backout In control unit connector pins 17 and 26
Termtnal backout In valve block connector prns 1, 4 and 7
Open or shorted outlet front left (OFL) valve cod
Open or shorted drlver In control unlt
1 Key OFF
I
1 yes GO to step 5
Verify terminals at plns 17 and 26 are clean and secure ~n ---- .
the control unlt harness connector No Go to step 2
Is readlng between 3 and 6 ohms7 I
2 Disconnect 8-p~nhydraullc unlt connector Remove main relay

Verlfy terminals on both halves of the hydrauhc unrt &way 1
connector are clean and secure
Measure res~stancebetween pins 1 and 7 and pins 4 and
1 yes I Repalr or replace open or short to ground In
clrcults ( 0 ) and (ON) between hydraulrc unit
1 connector and control unit connector
7 on the hydraulic unlt I Install relay
Are both readlngs between 3 and 6 ohms7 Go to step 4
rn
.@,
I- No
------
Replace hydraullc unit
---
-
Go to step 4
3 Thls step requlres that a valld dlagnostrc trouble code

has been obtarned, ALL prlor dlagnostlc steps have
1 Yes Replace control unlt
Go to step 4
1 I
been completed, and the affected wiring lntegrlty has
been verlfled I I
CAUTION: If the above is not complete, chances I !
, are that replacement of this or any other system
c mponent without specific direction will not, in
No Go to last d~agnost~c
step completed and
contlnue
c nsequently result in customer dissatisfaction
Have all prior dlagnostlc steps been completed as I
descr~bedabove?
MP1147-81 6BUOPX-030
STEP
4
--
1
I
---- --
Key ON
1 Using
- -- .
INSPECTION
NGS Tester, clear all DTCs

Key OFF
I
4
tzsE;oSp
le
l ted
ACTION
I Code C1194 is present:

Key ON 1 Go to step 3
Using NGS Tester, perform RETRIEVEICLEAR
Did system pass? Go to appropriate pinpoint test
Code C1194 is present and control unit has
been replaced:
Note: 4WABS is disabled with the
Look for any changes in ~ndicatedcontinu~ty
Inspect circuits (0)and (O/Y) along their
control unit harness connector for chafing or
1
Service as required
-+-
Note: If the above steps have~beencompleted, the Yes Go to step 4 to confirmsystem operation
-7-
most likely cause of the concern is wiring related Most likely concern is hydraulic unit '
Is resolution achieved? Refer to page P-11
Go to step 4
PINPOINT TEST G
Diagnostic trouble code RIGHT FRONT IS0 VALVE COIL CIRCUIT FAILURE
No. C1214 -
Description C1214 -Open circuit to hydraulic unit or control unit, open or shorted valve coil or
I internal control unit damage
-
Possible Cause I Intermittent open in circuit (W)
Terminal backout in hydraulic unit connector pins 1,4 and 8
Open or shorted inlet front right (IFR) valve coil
-
STEP I INSPECTION ACTION
Key OFF / Yes GO to step 5
Install 60 pin breakout box and overlay I
the control unit harness connector
No 1 Go to step 2
- -
Disconnect &pin hydraulic unit connector Yes Remove main relay
Verify terminals on both halves of the hydraulic unit &way Repair or replace open or short to ground in
connector are clean and secure circuits (W) and (ON) between hydraulic unit
8 on the hydraulic unit Install relay
I No Replace hydraulic unit

Go to step 4
!I
This step requires that a valid diagnostic trouble code Yes i Replace control un~t
has been obtained, ALL prior diagnostic steps have Go to step 4
been completed, and the affected wiring integrity has
been verified
CAUTION: If the above is not complete, chances I
component without specific direction will not, in 1 continue
Have all prior-diagnosticsteps been completed as
described above?
-
-- - , - --- ppppppp
4 Kev ON 1 Yes Repair is completed

using NGS Tester, clear all DTCs ~o'to step 5
' -
Key OFF Code C1214 is
Key ON Go to step 3
been replaced:
Inspect circuits (OIY) and (W) along their
I
:;;
Service as required
5 , Note: If the above steps have been completed, the mr i f ; ; ; ; ;a; ; system operation
most likely cause of the concern is wiring related Most llkely concern IS In hydraul~cunit
Refer to the lntermlttent Dlagnosls Procedure In thls Replace hydraul~cunit
sectlon and perform for ALL affected clrcults Perform 4WABS brake bleed procedure
Is resolution achieved?
Go to step 4
-
MP1148 82 6BUOPX-033
PINPOINT TEST H

No. C1210
Description
Possible Cause
RIGHT FRONT DUMP VALVE COIL CIRCUIT FAILURE
C1210 - Open circuit to valve block or control unit, open or shorted valve coil or
internal control unit damaae
Intermittent open in circuit (P)
I
Open or shorted outlet front right (OFR) valve coil
STEP ' INSPECTION I ACTION
1 Install 60 pin breakout box and overlay
I Verlfy terminals at pins 17 and 15 are clean and secure In
the control unit harness connector +
No Go to step 2
-- ----
Measure reststance between breakout box plns 17 and 15

Disconnect 8-pin hydraulic unit connector Yes Remove main relay
Verify terminals on both halves of the hydraulic unit 8-way Repair or replace open or short to ground in
connector are clean and secure circuits (P) and (ON) between hydraulic unit
5 on the valve block lnstall relay
-- -- -- - -
No Replace hydraulic un~t
Go to step 4
Th~sstep requlres that a val~dd~agnostlctrouble code Yes Replace control unit

has been obtained, ALL prior diagnostic steps have Go to step 4
been completed, and the affected wlnng ~ntegr~ty has
, been ver~fred
CAUTION: If the above is not complete, chances
component without specific direction will not, in continue
descr~bedabove? I
I STEP INSPECTION ..- --

ACTION
-. -
4 , Key ON Yes Repair is completed

II Using NGS Tester, clear all DTCs Go to step 5
Key OFF No Code C1210 is present:
Key ON Go to step 3
been replaced:
Note: 4WABS i s disabled with the
Inspect circuits (P) and (ON) along their
Service as required
Note: If the above steps have been completed, the Yes --Go to step 4 to confirm system operation
most likely cause of the concern i s wiring related Most likely concern was in hydraulic unit
Go to step 4
PINPOINT TEST J
- ---
Diagnostic trouble code REAR ISO VALVE COIL CIRCUIT FCURE-

No. C1206
Description C1206 - Open circuit to hydraulic unit or control unit, open or shorted valve coil or
internal control unit damage -
Possible Cause Intermittent open in circuit (GYIB)
Open or shorted inlet rear axle (IRA) valve coil
sTEPrp INSPECTION
I
I ACTION
the control unit harness connector Go to step 2
Disconnect 8-pin hydraulic unit connector Yes Remove main relay
Verify terminals on both halves of the hydraulic unit &way Repair or replace open or short to ground in
connector are clean and secure circu~ts(GYIB) and (ON) between hydraulic
Measure resistance between pins 1 and 2 and pins 4 and unit connector and control unit connector
2 on the valve block Install relay
No Replace hydraulic unit

Go to step 4
Thls step requlres that a val~dd~agnostlctrouble code Yes Replace control unlt
has been obtained, ALL prior d~agnostlcsteps have Go to step 4
been completed, and the affected wiring lntegr~tyhas
been ver~f~ed
[
are that replacement of this or any other system Go to last d~agnostlcstep completed and
most circumstances, resolve the concern and will Go to step 4
Have all prior d~agnostlcsteps been completed as
descr~bedabove? I
--
73
STEP
- -
INSPECTION ACTION
1--
4 Key ON Repair is completed
Using NGS Tester, clear all DTCs Go to step 5
Key OFF Code C1206 is present:
Key ON Go to step 3
Uslng NGS Tester, perform RETRIEVEICLEAR
1 CONTINUOUS DTCS
I A new code IS present:
Dld system pass? Go to appropriate pinpoint test
been replaced:
, Inspect circuits (GYIB) and (ON) along their
I entire length from the sensor connector to the
I
Servlce as reaulred
1
5 Note: If the above steps have been completed, the Yes-
-- Go to step 4 to conflrm system
-- -
operation
most likely cause of the concern is wiring related No Most lrkely concern IS hydraulic unit
Refer to the lntermlttent Dlagnosls Procedure In thls Replace hydraulic unlt
sectlon and perform for ALL affected clrcults Perform 4WABS brake bleed procedure
Is resolution achieved? Refer to ~ a a e
P-11
I Go to ster, I
PINPOINT TEST K
Diagnostic trouble
code No. C1202
1 REAR DUMP VALVE COIL CIRCUIT FAILURE
I
t I
--- -- ----- - ----
Symptom C1202 - Open clrcult to hydraul~cunlt or control unit, open or shorted valve coil or
Internal control unlt damaae
Possible Cause Intermittent open circuit (T/R)
Terminal backout in valve block connector pins 1, 4, and 3
Open or shorted outlet rear axle (ORA) valve coil
O ~ e or
n shorted driver in control unit
STEP -- INSPECTION ACTION
Key OFF yes / GO to step 5
Install 60 pin breakout box and overlay I
Verify termrnals at pins 17 and 27 are clean and secure In ,
the control unit harness connector
NO I GO to step 2
Disconnect 8-pin hydraulic connector Yes Remove main relay
Verify terminals on both halves of the hydraulic 8-way Repair or replace open or short ground in
connector are clean and secure circuits (P) and (ON) between hydraulic unit
3 on the hydraulic unit Install relay

Go to step 4
- --
3
----
/
- - -- - -
This step requires that a valid diagnostic trouble code has

-,-
Yes
- - - -- --
-
Replace control unit

been obtained, ALL prior diagnostic steps have been Go to step 4
verified
are that replacement of this or any other system Go to last diagnostic step completed and
I described above?

Key ON Yes Repair is completed
Using NGS Tester, clear all DTCs Go to step 5
Key OFF No Code C1210 is present:
Key ON Go to step 3
Using NGS Tester, perform RETRIEVE/CLEAR
Did system pass? Go to the appropriate pinpoint test
been replaced:
Note: 4WABS is disabled with the breakout
box installed
RETRIEVE / CLEAR CONTINUOUS CODES
Inspect circuits (P) and (OIY)along their
Service as reauired
1 5 1 Note: If the above stem have been comoleted. the Yes / Go to s t e 4~ to confirm svstem o~eration I
I most likely cause of the concern is wirilig related concern is hydraulic unit
I I I GOto step 4 I
PINPOINT TEST L
code No. C1155
I LEFT FRONT WHEEL SPEED SENSOR INPUT CIRCUIT FAILURE
-
-
Symptom C1155 - Electrically shorted or open front left speed sensor circuit or coil
--
Possible Cause Poor connection at front left wheel sensor
Terminal damage or backout in control unit connector pins 24 or 25
Terminal damage or backout in two-pin sensor connector
Open or shorted front left speed sensor coil
Open or shorted circuit (TIO) or (TIB)
Improper front left wheel speed sensor cable routing leading to above
Defective front left wheel weed senor electrical test circuit in control unit
STEP --
INSPECTION - ---
ACTION
Measure resistance between pins 24 and 25 No Go to step 2
Is reading between 1.O-1.4 kQ?
Disconnect left front speed sensor connector Yes Speed sensor checks good
Measure resistance between the two pins on the speed Go to step 3
sensor component connector
Is reading between 1.O-1.4 kP?
- - -- -- -- -- -
No Replace speed sensor

Go to step 11
-- - - - -- - -- -- - - -- ---- -
Measure reststance between Din 24 on the breakout box Yes C~rcurt(TiO) checks OK
and wheel speed sensor harness connector pin for circuit Go to step -4- -
(TO No Repalr open or high resistance on circuit

Is there continuity (zero or near zero ohms)?
(Tic))
--- -- - - - -- -Go -to step
-
11 ,- -
---
A -
Measure resistance between pin 25 on the breakout box Yes

Circuit (TIB) checks OK
and wheel speed sensor harness connector prn for clrcult Go to step 5 -
(T/B) No Repair open or high resistance on clrcuit (TIB)
Is there contlnulty (zero or near zero ohms)? Go to steD 11
Measure resistance between pins 1 and 24 on the Yes :
Repair short to ground on circuit (TIO)
breakout box Go to step 11 -
d
Is there less than 10 ohms measured? No I Circuit (TIO) checks OK
I Go to step 6
1
6 Measure resistance between pins 1 and 25 on the Yes Repair short to ground on circu~t(TIB)
breakout box Go to step 7
Is there less than 10 ohms measured? No Circuit (TIB) checks OK
- -
Go to step 8
7 Measure resistance between sp~ndlenear sensor can and Yes Internal short ~nspeed sensor detected
erther coil c~rcuitat sensor connector Replace speed sensor
Is resistance less than 1OQ? Go to step 11 --
No Go to step 8
the wheel speed sensor cable at the affected Yes Replace speed sensor
wheel end for chafrng or other wring damage Correct any obvious routing issues
Is damage found? Go to step 11
No Go to step 9
4
~~~~p~~~
9 Note: If the above steps have been completed, the Yes Go to step 11 for system verification
most likely cause of the concern is wiring related --
Refer to the Intermittent Diagnosis Procedure in this No Wiring system has been verified as intact
section and perform for ALL affected circuits Go to step 10
10 This step requires that a valid diagnostic trouble code has Yes Replace speed sensor
been obtained, ALL prior diagnostic steps have been Go to step 11 for system verification
completed, and the affected wiring integrity has been If no resolution, replace control unit
verified Go to step 11 for system verification
1 are that replacement of this or any other system
i component without specific direction will not, in --
most circumstances, resolve the concern and will diagnostic step completed and
I consequently result in consumer dissatisfaction
described above?
Key ON -
Yes Repair is completed
p-
No Code C1155 is present:

Key OFF Return to last diagnostic step completed
Key ON
Using NGS Tester, perform RETRIEVEICLEAR A new code is present:
CONTINUOUS DTCs Go to appropriate pinpoint test
Did system pass? Code C1155 is present and step 9 is
completed:
7
box installed
SYSTEM PASSED. (NO DTCS AVAILABLE) Install breakout box with overlay
' Repeat step 3-6 while driving vehicle
RETRIEVE 1 CLEAR CONTINUOUS CODES
Inspect circuits (TIO) and (TIB) along their
a n y other damage that could lead to any open
Service as reauired
PINPOINT TEST LL
Diagnostic trouble
code No. C1158
C1258, C1233
1
Symptom Coherency Fault (C1158), Compar~sonFault (C1258), Input M~sslng- Long Term
(C1233)
---- - - - - - - - -
Possible Cause Damage/mlsslng rrng gear teeth or mlsslng ring gear

Alr gap too small or too large
Excessive rear axle v~brat~on
Weak speed sensor
Loose speed sensor
lnterm~ttentshort or open clrcult (T/O) or (TIB)
Defective trlgger clrcult in control un~t
Disturbances caused by eiectrlcal Interference Induced Into sensor clrcurt from
nearby ungrounded source
Note: If above codes are stored with C1155 (LF speed sensor-input circuit failure)
check for intermittent short to ground or open. If above codes only are stored the
concern is output related and it is not necessary to check for intermittent
I -- 1openlshori conditions -- - --- - J
STEP 1 INSPECTION -- -
ACTION
-- -
-- -
7 -
Install 60 pin breakout box and overlay I Yes Rlng gear IS damaged or mtsslng:
Raise vehicle on hoist Replace rlng gear
1 lnspect the left front ring gear for any damaged or missing
teeth
Rotate wheel to ensure all teeth are checked
Go to step 5 to check for proper sensor output
Sensor is loose:
Tighten speed sensor bolt to specifications
lnspect the speed sensor mounting in the wheel end for Go to step 5 to check for proper sensor output
looseness
CAUTION: Examine the ring carefully with good light.
Failure to catch issues with the ring gear will lead to
' unnecessary component replacement and wasted No Go to step 2
i diagnosis time
Is ring gear damage or sensor looseness found?
-- -- - - -
2 Lower vehicle so that wheels are just far enough off the Yes Output at control unlt lndlcates that the air gap
ground to permit all wheels to turn and speed sensor strength are OK
Remove left front wheel Go to step 7
Knock back the front dlsc brake callper so that the
I
wheel can move as freely as poss~ble
Remount the wheel
I Place In 4x4 low mode
Start engine and allow wheels to spin and stabll~zeat
engine Idle speed
Measure and record the frequency between plns 24
- -
and 25 on breakout box
Note: Measurements of BOTH the frequency and the Speed sensor output at control unit is
voltage output must be taken. The actual speed the insufficient
wheels are turning is not important -the result of Go to step 3
voltage output divided by the frequency will not
change with wheel speed. However, it is crucial that
both the frequency measurement and the voltage
measurement be taken at the SAME wheel speed
1 Determine the speed sensor output In mV/Hz Output -
AC VoltageIFrequency I
Is sensor output greater than 5.8 mV/Hz?
MP1157-81
STEP I INSPECTION ACTION
3 1
-.
.---~jsconnectthe speed sensor connector at the left

radiator support
,
., ___ -
Yes
- - _-
Output indicates that air gap and speed
sensor strength are OK at the speed sensor
--
I Place in 4x4 low mode Go to step 7

Start engine and allow wheels to spin and stabilize at
engine idle speed
Measure and record the frequency between the two
pins of the speed sensor component connector
Measure and record the output voltage between the two
Note: Measurements of BOTH the frequency and the
voltage output must be taken. The actual speed the
wheels are turning is not important - the result of No Go to step 4
1 voltage output divided by the frequency will not
I change with wheel speed. However, it is crucial that ~
II measurement be taken at the SAME wheel speed
Determine the speed sensor output in mV1Hz:
Output - AC VoltageIFrequency
-- .-
Is sensor output greater than 5.8 mVIHz?
4 Remove the speed sensor from the fr
spindle
Inspect mounting boss and speed sensor moun
plate for any metal flash or debris
Clean as necessary
Remount speed sensor securely
Measure the air gap between the spe Replace ring gear
one ring tooth
Repeat in at least two more wheel positions to ensure Gap is not consistent:
that gap does not vary as the wheel is turned Ring gear is not pressed on straight or axle
Note: Feeler gauges can be mounted to a welding rod
and inserted between the vanes of the front disc brake
hub and rotor to measure the gap precisely
Is the gap consistent and less than 1.78
.-
5 Place in 4x4 low mode

Start engine and allow wheels to spin and stabilize at
engine idle speed A drive test is recommend to verify sensor
Measure and record the output voltage between the tw
--
I voltage output must be taken. The actual speed the
wheels are turning is not important - the result of
voltage output divided by the frequency will not onto the rotor hub
change with wheel speed. However, it is crucial that Correct as needed
both the frequency measurement and the voltage Repeat step 5
measurement be taken at the SAME wheel speed If no resolution, replace speed sensor
Determine the speed sensor output in mVIHz: Note:
Output - AC VoltageIFrequency Do not leave this test until output is OK
Is sensor output greater than 5.8 mV/Hz?
MP1157-B2 6BUOPX-043
- -
- - - --
INSPECTION ACTION -- -
Remove the front drsc brake hub and rotor and Inspect ; Yes Go to step 5
the rlng gear hub mountlng surface
hub Correct before proceeding

Reinstall the front dlsc brake hub and rotor
Verlfy wheel end play IS wlthln allowable llmlts
L
Verlfy the ring gear IS pressed stralght and fully onto the
I No
---
Gap IS greater than 1 78 mm (0.070 rnch)
Alr gap IS too large
- -
Measure the alr gap between the speed sensor and I Go to step 4 to resolve large air gap concern
one ring tooth Repeat In at least two more wheel
and inserted between

hub and rotor to meas
Is the gap consrstent an
completed, and the affected wlrlng lntegrlty has been no resolutron, replace control unit
ver~fred o to step 9 for drlve test
are that replacement of this or any other system
component without specific direction will not, in
consequently result in consumer dissatisfaction
Have all prlor dlagnostlc steps been completed as
described above7
- - -- - - - -- --
- - -, - -
Reinstall all components and remove breakout box Yes Repalr IS completed
Key ON-Us~ng NGS Tester, clear all DTCs
Key OFF - -- - -- - - -- --
Key ON No Code belng servlced st111exlsts

Drrve vehlcle and perform the following Go to step 8
Complete at least one hard left and one hard rlght turn Drfferent code IS present
Travel over a stretch of rough road at normal vehlcle Go to appropr~ateplnpolnt test
speed
Code being servlced still exists and control
Perform one hard acceleration from a stop
Uslng NGS Tester, perform RETRIEVE/CLEAR
CONTINUOUS CODES
I
1
unlt has been replaced:
Go to step 10
Dld system pass7 I
-
-- - - - -- - I
--
At thls polnt the followlng have been verlfled or are true ~f Yes , Repalr is completed
the above steps are complete
Sensor strength 1s OK I
I
Rlng gear IS Intact wlth no damaged teeth and IS I
correctly seated agalnst the rotor hub
Alr gap IS wtthln allowable ltrntts and IS consistent as
the wheel rotates
Wirrng between speed sensor and control unit 1s intact
The control unit has been replaced
The followlng are tlme consuming and should be
performed only after all previous optrons have been
- - - --
exhausted No Go to step 8
Verify circuits (TIO) and (T/B) are twisted throughout
the wire loom
If the wires are not twisted, the control unit may be
sensitive to any outside interference. Excessive axle
vibration, especially over rough road can cause this issue
Verify front axle is not excessively noisy or otherwise
performing abnormally
Note: Blips or fallout indicate intermittent issue
.. -.
Does signal rise consistently and evenly?
83
PINPOINT TEST M
Diagnostic trouble RIGHT FRONT WHEEL SPEED SENSOR INPUT CIRCUIT FAILURE
--
code No. C1155 -- -- -
Symptom -- -
speed sensor
-
circuit or coil
- - - - - -
Possible Cause
Open or shorted front right speed sensor coil
Open or shorted circuit (Y/R) or (Y/B)
Improper front right wheel speed sensor cable routing leading to above
Defective front right wheel speed
-
sensor electr~caltest c~rcurtIn
--
control unlt
sTEK,ako
-
INSPECTION ACTION
'' -7 1
I Key OFF
box and overlay
Measure resistance between pins 36 and 23
pp
yes
- -- - --
GO to step 7
--
p i r
Is reading between 1.O-1.4 kQ7
-
Disconnect right front speed sensor connector checks good

Measure resistance between the two pins on the speed
Is reading between 1.O-1.4 kQ?
Replace speed sensor

Go to step 10
Measure resistance between pin 36 on the breakout box Yes 1 Circuit (YIR) checks OK
1 and wheel speed sensor harness connector pin for circuit '
--
i Go to step 4
(Y/R) or high resistance on circuit
Go to step 10
AI
er::\
Measure resistance between pin 23 on the breakout box
,.,
and wheel speed sensor harness connector pin for circuit
,-,
continuity (zero or near zero ohms)?

7--
Yes
L
Circuit (YIB) checks OK
Go to step 5
--
Repair open or high resistance on circuit (YIB)
Go to step 10
Measure resistance between pins 1 and 36 on the Yes / Repair short to ground on circuit (YIR)
breakout box I Go to step 10
Is there less than 10 ohms measured? Circuit (YIR) checks OK
Go to stec, 6
Measure resistance between plns 1 and 23 on the
breakout box
Is there less than 10 ohms measured?
1
I
Yes 1 Repair short to ground on circuit (YIB)
-
No
GO to step-
- ---
7 -- - ---
Circuit (YIB) checks OK
-
-- ---
Go to step 8 -- -
Measure resistance between spindle near sensor can and Yes Internal short in speed sensor detected
either coil circuit at sensor connector Replace speed sensor
Is resistance less than 1OQ? 1 Go to step 10
( Note: If the above steps have been completed, the I Yes / Go to step 10 for system verification
8
most likely cause of the concern i s wiring related
Refer to the Intermittent Diagnosis Procedure in this
section and perform for ALL affected circuits
+-+
I
No
-
, Wiring system has been verified as intact
Go to step 9

+ --
9 ( Thls step requlres that a vahd dlagnostrc trouble code has Yes Replace speed sensor
been obtained, ALL prlor dlagnostrc steps have been Go to step 10 for system verlflcatlon
I completed, and the affected wiring Integrity has been If no resolutron, replace control unlt
ver~f~ed ( Go to step 10 for system verlfrcatlon
CAUTION: If the above is not complete, chances I
most circumstances, resolve the concern and will Go to last dlagnostlc step completed and
consequently result in consumer dissatisfaction contlnue
Have all prior dlagnostlc steps been completed as 1
I
I 1 sE$;
lo Tester, clear a\\DTCS No
.-pe
I
Repair is completed
Code C1145 is present:
Return to last diagnostic step completed
Using NGS Tester, perform RETRIEVEICLEAR I A new code IS present:
I Did system pass Code C1145 is present and step 8 IS
completed.
box installed
I
I
I Install breakout box wlth overlay
, Repeat step 3-6 while driving vehicle
Look for any changes In indicated contlnulty
Inspect clrcuits (YIR) and (YIB) along thew
RETRIEVE I CLEAR CONTINUOUS CODES)
i !/entire length from the sensor connector to the
control unlt harness connector for chaflng or
I Service as required
MP1159-82 6BUOPX-046
PINPOINT TEST MM
Diagnostic trouble 1 RIGHT FRONT WHEEL SPEED SENSOR INPUT CIRCUIT FAILURE
code No. C1148
C1259, C1234
I Symptom / Coherency Fault (C1148), Comparison Fault (C1259), Input Missing (C1234)
Possible Cause Damagelmissing rotor teeth or missing rotor
Air gap too small or too large
, Excessive rear axle vibration

Weakspeedsensor
Loose speed sensor ,
Intermittent short or open circuit (YIR) or (Y/B)
Defective trigger circuit in control unit
Disturbances caused by electrical interference induced into sensor circuit from
nearby ungrounded source
Note: If above codes are stored with C1155, check for intermittent short to ground
or open. If above codes only are stored the concern is output related and it is not
necessary to check for intermittent openlshort conditions
INSPECTION ACTION
1
I
Rase vehlcle on hoist
Inspect the rlght front sensor rotor for any damaged or
1
I
yes ! Sensor rotor is damaged or missing:
Replace rotor
j Go to step 5 to check for proper sensor output
missing teeth
Rotate wheel to ensure all teeth are checked
1 Sensor is loose:
I
I Tighten speed sensor bolt to specifications
I Inspect the speed sensor mounting In the wheel end for
) Go to step 5 to check for proper sensor output
1 looseness
I CAUTION: Examine the ring carefully with good light.
Failure to catch issues with the rotor will lead to
unnecessary component replacement and wasted
diagnosis time
Is sensor rotor damage or sensor looseness found?
2 Lower vehlcle so that wheels are just far enough off the Output at control unit indicates that the air
Remove rlght front wheel Go to step 7
I Knock back the front disc brake callper so that the
I wheel can move as freely as possible

Remount the wheel
Place in 4x4 low mode
1 Start engine and allow wheels to spin and stablllze at
engine Idle speed
I Measure and record the frequency between pins 24
1 voltage output divided by the frequency will not
I change with wheel speed. However, it is crucial that

I both the frequency measurement and the voltage

Determine the speed sensor output In mV1Hz
Is sensor output greater than 5.8 mVIHz7
MP1163 51
- - -- -
-
STEP
- -- -
-
- INSPECTION ACTION --
3 Dtsconnect the speedsensor connector at the rlght indicates that air gap and speed
radlator support
Place ~n4x4 low mode
Yes
,/ Output
sensor strength are OK at the speed sensor
Go to step 7
Start engine and allow wheels to spin and stablllze at
engine Idle speed
plns of the speed sensor component connector
!
Note: Measurements of BOTH the frequency and the I
voltage output must be taken. The actual speed the , - _ _
wheels are turning i s not important - the result of No Go to step 4

change with wheel speed. However, it is crucial that
i measurement be taken at the SAME wheel speed
Determine the speed sensor output In mV/Hz:
sensor output greater than 5.8 mV/Hz?
'
Remove the speed sensor from the front wheel hub and F Replace speed sensor -- -- -
sp~ndle Go to step 5
Inspect mountlng boss and speed sensor mountlng ,
date for anv metal flash or debrls I
'Clean as necessary
Remount speed sensor securely No Gap is greater than 1.78 mm (0.070 inch):
Measure the air gap between the speed sensor and l Replace sensor rotor
1 Go to step 5
one sensor rotor tooth
Repeat in at least two more wheel posltlons to ensure Gap is not consistent:
that gap does not vary as the wheel IS turned Sensor rotor is not pressed on straight or axle
Note: Feeler gauges can be mounted to a welding rod end play is too great
1 and inserted between the vanes of the front disc brake Go to step 6
consistent and less than 1.78 mrn (0.070 Inch)?
-- -- - -- -- - - - - _- - -
Place in 4x4 low mode Yes Output IS now OK

Start englne and allow wheels to spin and stablllze at Concern IS most llkely resolved
engine idle speed A drlve test IS recommend to verlfy sensor
Measure and record the frequency between the two output IS OK for customer drlvlng condltlons
pins of the speed sensor component connector Refer to DRIVE TEST procedure In thls
Measure and record the output voltage between the two sectlon
plns of the speed sensor component connector
1 Note: Measurements of BOTH the frequency and the
1 voltage output must be taken. The actual speed the
No Verify sensor rotor is pressed straight and
I wheels are turning is not important - the result of
voltage output divided by the frequency will not fully onto the rotor hub
change with wheel speed. However, it is crucial that Correct as needed
both the frequency measurement and the voltage Repeat step 5
measurement be taken at the SAME wheel speed If no resolution, replace speed sensor
Determine the speed sensor output In mV/Hz: Note:
Output - AC VoltageIFrequency Do not leave this test until output is OK
Is sensor output greater than 5.8 mVIHz?
MP1163-62
1
I INSPECTION ACTION
Remove the front disc brake hub and rotor and inspect Yes Go to step 5
the sensor rotor hub mounting surface
Verify the sensor rotor is pressed straight and fully onto
' the hub. Correct before proceeding
Reinstall the front disc brake hub and rotor Gap is greater than 1.78 mm (0.070 inch):
Verify wheel end play is within allowable limits Air gap is too large
Measure the air gap between the speed sensor and Go to step 4 to resolve large air gap concern
one sensor rotortooth
Repeat in at least two more wheel positions to ensure Gap is not consistent:
Repeat step 6
that gap does not vary as the wheel is turned Do not leave this step until a consistent air
Note: Feeler gauges can be mounted to a welding rod gap is obta~ned
and inserted between the vanes of the front disc brake
Is the gap consistent and less than 1.78 mm (0.070 inch)?
Note: If the above steps have been completed, the Yes Concern is most likely resolved
most likely cause of the concern is wiring related A drive test is recommended to verify sensor
Refer to the Intermittent Diagnosis Procedure in this output is OK for customer driving conditions
section and perform for circuits (YIR) and (YIB)
Is resolution achieved? No 1 Go to step 8
This step requires that a valid diagnostic trouble code has ' Yes Replace speed sensor
been obtained, ALL prior diagnostic steps have been Go to step 9 for drive test
completed, and the affected wiring integrity has been , If no resolution, replace control unit
verified Go to step 9 for drive test
CAUTION: If the above is not complete, chances are
that replacement of this or any other system
component without specific direction will not, in most - 1
1 ~-
circumstances, resolve the concern and will

consequently result in consumer dissatisfaction I Go to last diagnostic step completed and
continue
Have all prior diagnostic steps been completed as 1
described above? i
1 Reinstall all components and remove breakout box 1 Yes Repair is completed
Key OFF
Key ON I Code being serviced still exists:
Drive vehicle and perform the following: Go to step 8
Complete at least one hard left and one hard right turn Different code is present:
Travel over a stretch of rough road at normal vehicle Go to appropriate pinpoint test
1
speed
Perform one hard acceleration from a stop Code being serviced still exists and control
/ Using NGS Tester, perform RETRIEVE/CLEAR unit has been replaced:
Go to step 10
CONTINUOUS CODES
Did system pass?
-- -- - --
At this point the following have been verified or are true if Yes Repair is completed
the above steps are complete:
Sensor strength is OK
Sensor rotor is intact with no damaged teeth and is
correctly seated against the rotor hub
Air gap is within allowable limits and is consistent as
i the wheel rotates
Wiring between speed sensor and control unit is intact
The control unit has been replaced
The following are time consuming and should be
-
performed only after all previous options have been
exhausted: Go to step 8
Verify circuits (YIR) and (YIB) are twisted throughout
the wire loom
If the wires are not twisted, the control unit may be
sensitive to any outside interference. Excessive axle
vibration, especially over rough road can cause this issue
Verify front axle is not excessively noisy or otherwise
! performing abnormally
; Note: Blips or fallout indicate intermittent issue
Does signal rise consistently and evenly?
PINPOINT TEST N
code No. C1230
REAR AXLE SPEED SENSOR INPUT CIRCUIT FAILURE
1
I-- Symptom
Possible Cause
C1230 - Electrically shorted or open front left speed sensor circuit or coil
Poor connection at rear axle speed sensor
--
Open or shorted front left speed sensor coil

Open or shorted circuit (RIP) or (LGIB)
Improper rear axle speed sensor cable routing leading to above
Defective rear axle speed sensor electrical test circuit in control unit
1 STEP INSPECTION --
I ACTION
--
Measure resistance between pins 21 and 22 No Go to step 2
Is reading between 800-1 400 Q?
Disconnect rear axle sensor connector Yes Speed sensor checks good
Measure resistance between the two pins on the speed Go to step 3
Is reading between 800-1 400 Q?
No i Replace speed sensor

I Go to step 11
I 3 l Measure resistance between pin 21 on the breakout box

and wheel s ~ e e sensor
d harness connector pin for circuit -
Yes j Circuit (RIP) checks OK
1 Go to step 4
I I
(RIP)
No Repair open or high resistance on circuit
(RIP)
GO to step 11 I
I
Measure resistance between pin 22 on the breakout box I Yes Circuit (LGIB) checks OK
and wheel s ~ e e dsensor harness connector pin for circuit 1 Go to s t e 5
~
(LGIB) Repair open or high resistance on circuit
No
Is there continuity (zero or near zero ohms)? (LGIB)
( G Oto step 11
Measure resistance between pins 1 and 21 on the Yes Repair short to ground on circuit (RIP)
breakout box 1 GOto s t e ~11 --
Is there less than lo& measured? No j circuit (RIP) checks OK
j Go to step 6 --
Measure resistance betwen pins 1 and 22 on the breakout j Yes / Repair short to ground on circuit (LGIB)
box I No 1 Go to step7 - -
Is there less than 10Q measured? ] Circuit (LGIB) checks OK
i GOto step 8
7 Measure resistance between spindle near sensor can and
either coil circuit at sensor connector
Yes '1 Internal short in speed sensor detected
Replace speed sensor
Is resistance less than 1OQ? 1 Go to step 11
No Go to step 8
8 Inspect the wheel speed sensor cable at the affected I Yes Replace speed sensor
wheel end for chafing or other wiring damage , Correct any obvious routing issues
Is damage found? I Go to step 11
NO I GOto step 9

1 9 1 Note: If the above st ps have be n completed, the / Yes / Go to step 11 for system verification I
Refer to the Intermittent Diagnosis Procedure in this No Wiring system has been verified as intact
section and perform ALL affected circuits Go to step 10
This step requires that a valid diagnostic trouble code has Yes Replace speed sensor
been obtained, ALL prior diagnostic steps have been Go to step 11 for system verification
verified Go to step 11 for system verification
most circumstances, resove the concern and will No / Go to last diagnostic step completed and
consequently result in consumer dissatisfaction continue
Have all prior diagnostic steps been completed as I
described above?
-+
Key ON
-
Yes Repair is com~leted 1

No Code C1230 is present:
Key ON
Using NGS Tester, perform RETRIEVEICLEAR A new code is present:
Did system pass? , Code C1230 is present and step 9 is
completed:
, Note: 4WABS is disabled with the breakout
box installed
Repeat step 3 - 4 while dirving vehicle
Inspect circuits (RIP) and (LGIB) along their
Service as reauired
PINPOINT TEST NN
-
Diagnostic trouble REAR AXLE SPEED SENSOR
code No. C1158
C1260, C1237 -- ---- -
Symptom Coherency Fault (C1229), Comparison Fault (C1260), Input Missing - Long Term
(C1237)
Possible Cause * Damagelmissing sensor rotor teeth or missing sensor rotor
Air gap too small or too large
Excessive axle vibration
Weakspeedsensor
Loose speed sensor
Intermittent short or open circuit (RIP) or (LGIB)
Defective trigger circuit in control unit
Disturbances caused by ignition or Radio Frequency Interference (RFI)
INSPECTION i ACTION
Install 60 pin breakout box and overlay Yes ) Remove debris
Raise vehicle on hoist I Go to step 6
Inspect the rear axle sensor rotor for any damaged or I Sensor rotor is not intact:
missing teeth I Replace sensor rotor
Rotate wheel to ensure all teeth are checked Go to step 6 to drive test vehicle
lnspect the speed sensor for debris on the rear axle
housing mounting flange
Clean as necessary
Is sensor rotor intact or debris found at speed sensor No Go to step 2
mounting?
Lower vehicle so that wheels are just far enough off the
I
Yes
- -
Output at control unit ~ndicatesthat the air gap
Start engine and allow rear wheels to spin and stabilize Go to step 4
at engine idle speed
Measure and record the frequency between pins 21
Measure and record the voltage output between pins 21
No I Speed sensor output at control unit is
change with wheel speed. However, it is crucial that I insufficient
Determine the speed sensor output in mV/Hz:
I
i
I GO to step 3
Output - AC VoltageIFrequency I
Is sensor output greater than 6.0 mVIHz? I
3 Disconnect the speed sensor connector at the rear axle

housing 1 sensor strength are OK at the speed sensor
Start engine and allow wheels to spin and stabilize at I Go to step 4
engine idle speed
wheels are turning i s not important -the result of
change with wheel speed. However, i t is crucial that
Determine the speed sensor output in rnV1Hz:
Is sensor output greater than 6.0 mVIHz? I
MP1167-B1

4 Note: If the above steps have been completed, the Yes , Concern is most likely resolved
most likely cause of the concern is wiring related A drive test is recommended to verify sensor
Refer to the Intermittent Diagnosis Procedure in this output is OK for customer driving conditions
section and perform for circuits (RIP) and (LGIB)
Is resolution achieved? 1x7 -p
GO
pp-------
to step 5
5 This step requires that a valid diagnostic trouble code has Yes Replace speed sensor
been obtained, ALL prior diagnostic steps have been Go to step 6 for drive test
verified Go to step 6 for drive test
most circumstances, resolve the concern and will No Go to last diagnostic step completed and
I
described above? Continue
Reinstall all components and remove breakout box Yes / Repair is completed
-,-
Key ON No i Code being serviced still exists:
Using NGS Tester, clear all DTCs 1 GO to step 5
Key OFF
Key ON
Drive vehicle and perform the following:
Complete at least one hard left and one hard right turn
1
Different code is present:
Code being serviced still exists and control
Travel over a stretch of rough road at normal vehicle unit has been replaced:
speed The following are time consuming and should
Perform one hard acceleration from a stop be performed only after all previous options
Using NGS Tester, perform RETRIEVEICLEAR have been exhausted
CONTINUOUS CODES Air gap between sensor and rear axle
Did system pass? sensor rotor may be too large
,
Ver~fyclrcurts (RIP) and (LGIB) are twisted
1 throughout the wire loom
If the wires are not twisted, the control unit
may be sensitive to any outside
interference
Excessive axle vibrat~on,especially over
' rough road can cause this issue
Verify rear axle is not excessively nolsy or
otherwise performing abnormally
I
Service as required
6BUOPX-053
- - -
PINPOINT TEST P
FUNCTION TEST
front outlet valve or speed sensor disturbance detected

diagnosis
I Possible Cause Pinched or closed brake line or hose

Worn or clogged front left outlet valve
I STEP ! INSPECTION ACTION
1 Visually inspect brake lines from hydraulic unit to front left Replace or repair brake lines
wheel
Are they damaged? 1 i!
--
No / G Oto s t e ~ 2
2 Key OFF Yes Replace hydraul~cunlt
Install 60 pin breakout box and overlay Perform 4WABS brake bleed procedure
Jumper pins 19,26, 40 and 1 together on the breakout box Refer to page P-11
Ra~sevehlcle so front left wheel IS just off the ground
Press hard on the brake pedal and have an ass~stanttry to
turn the LH front wheel
Note: This condition is similar to the master cylinder
bypass condition. It is important that the brake pedal I-----
-- ------ --
be quickly and forcefully applied to rule out master No Go to step 3

cylinder bypass as the cause if a hydraulic leak is
detected. Typically, master cylinder bypass only
1
I
I
i
-
3
occurs at low line pressures
Does the wheel turn or the brake pedal drop slowly?
CAUTION: Do not leave ignition on for more that 30-
seconds with the jumper installed
Apply brake pedal force, turn ign~tlonon and have
bS
I
,
-1
Valve~sOK
-
assistant try to turn the LH front wheel 1 No

I
Replace hydraul~cun~t
Does the wheel turn now? I
PINPOINT TEST Q
Diagnostic trouble code FRONT RIGHT VALVE PAIR FUNCTIONEST
No Code
Description Hydraulically inoperative right front outlet valve or speed sensor disturbance detected
diagnosis --
Possible Cause Pinched or closed brake line or hose
Worn or clogged front left outlet valve
STEP INSPECTION -
ACTION
1 Visually inspect brake lines from hydraulic unit to front right 1 Yes Replace or repair brake lines
wheel
Are they damaged?
Go to step 2
2 Key OFF Replace hydraulic unit
Install 60 pin breakout box and overlay Perform 4WABS brake bleed procedure
Jumper plns 15, 19, 34 and 1 together on the breakout box 1 Refer to page P-11
Raise vehicle so front right wheel is just off the ground
Press hard on the brake pedal and have an assistant try to
turn the RH front wheel
Note: This condition is similar to the master cylinder
bypass condition. It is important that the brake pedal -------------------------
MP1169-B
Does the wheel turn or the brake pedal drop slowly?
CAUTION: Do not leave ignition on for more that 30
seconds with the jumper installed
Apply brake pedal force, turn ignition on and have
assistant try to turn the RH front wheel
Does the wheel turn now?
No
I--
Yes
I
Valve is OK
Replace hydraulic unit
6BUOPX-055
PINPOINT TEST R
No Code
REAR AXLE VALVE PAIR FUNCTION TEST
Description Hydraulically inoperative rear axle outlet valve or speed sensor disturbance detected
diagnosis
Possible Cause 11 Pinched or closed brake line or hose
Worn or clogged front right outlet valve
I-
7

Visually inspect brake lines from hydraulic unit to rear Yes Replace or repair brake lines
wheels
Are lines damaged?
1
2 Key OFF Yes I Replace hydraulic unit
Install 60 pin breakout box and overlay 1 Perform 4WABS brake bleed procedure
Jumper pins 19, 27, 33 and 1 together on the breakout box Refer to page P-11
Raise vehicle so rear wheels are just off the ground
Press hard on the brake pedal and have an assistant try to
turn a rear wheel
Note: This condition is similar to the master cylinder 1
bypass condition. It is important that the brake pedal
Does the wheel turn or the brake pedal drop slowly? ~ --
3 , CAUTION: Do not leave ignition on for more that 30 Yes 1 Valve IS OK
seconds with the jumper installed 1
Apply brake pedal force, turn ignit~onon and have -
assistant try to turn a rear wheel No Replace hydraulic unit
, Does the wheel turn now7
PINPOINT TEST S
o
Diagnostic trouble
code No. C1096
PUMP MOTOR TRIGGERED BUY DID NOT RUN
--T
Description
Possible Cause
contacts, damaged pump motor -
Damaged pump motor
- - I
C1096 - Open or intermittent connection to pump motor relay, damaged relay coil or
Terminal backout in control unit harness connector pins 29 and 37

Open or shorted pump motor relay coil
Open contacts in pump motor relay
--
Terminal backout in pump motor 2-way, pins 1 or 2
S ~ T INSPECTION 1 ACTION
Make sure the battery is OK Yes / G O to step 7
Inspect control unit pins, 30 amp pump motor feed fuse
(#I0 - engine compartment fuse box) battery and ground I
connections, relay connections and pump motor
connections
Remove control unit, install 60 pin breakout box and overlay
Verify ground
Jumper pins 1 and 19 together
Key ON No / GOto step 2
(energize main relay) I
Jumper pins 1 and 29 together I

(energize pump motor relay)
Is pump motor running?
Disconnect 2-way pump motor connector II Yes GO to step 3
Using battery positive lead connect B+ to pin 2 and ground
to pin 1 on hydraulic unit side of 2-way connector I
Does pump motor run?

Go to step 9
COMPONENT SlDE
OF CONNECTOR
I
Check for continuity between pin 1 on the harness side Yes Go to step 4
connector and a known good chassis ground I
@
HARNESS SIDE
I
Repa~ropen circuit (B)
Go to step 9
I STEP I INSPECTION
I
ACTION
I Key OFF Yes GO to step 5
1 Remove pump motor relay
I Check continuity on circuit (TIR) between pump motor and
relay
El
- 0
PUMP
MOTOR
RELAY
No Repair open in circuit (TIR)
[: Go to step 9
L-
- O
/4WABS
0 MAIN
RELAY
0
*tl
FRONT OF
VEHICLE
5 Remove main relay I Yes Go to step 6

Check continuity between pump motor relay circuit (ON) i
and main relay circuit (ON) I
4WABS
PUMP
MOTOR
RELAY
Repair circuit (ON)
Go to step 9
4WABS
MAlN
RELAY
FRONT OF
VEHICLE
6 Disconnect battery negative cable

Check continuity from pump motor relay circuit (YILG) to
/ yes GO to step 7
battery positive point II I
Reconnect battery negative cable when finished I

I
Note: When the battery has been disconnected and
reconnected, some abnormal drive symptoms may No Repair open in circuit (YILG) or replace 30A
occur while the Powertrain Control Module (PCM) fuse (#I0 - engine compartment fuse box)
I Go to step 9
relearns its adaptive strategy. The vehicle may need
to be driven 16 km (10 miles) or more to relearn the
strategy
MP9654B2 7BUOPX-004
I STEP ' INSPECTION 1 ACTION I
7 1 Check continuity from pump motor relay circuit (P/LB) to Yes Replace pump motor relay
pin 29 on the breakout box Go to step 8
Repair open in circuit (PILEI)
Go to step 9
8 This step requires that a valid diagnostic trouble code has Yes Replace control unit
verified
I most circumstances, resolve the concern and will
described above?
Key ON
Key ON
Using NGS Tester, perform RETRIEVEICLEAR 1 A new code is present:
CONTINUOUS DTCs I Go to appropriate pinpoint test
Did system pass? Code C1096 is present and step 8 is
completed:
Go to steD 10
--
Note: If the above steps have been completed, the Yes Go to step 9 for system confirmation
Refer to the Intermittent Diagnostic Procedure in this
section and perform for ALL affected circuits Go to step 8
Is resolution achieved'?
PINPOINT TEST T
Diagnostic trouble G-SWITCH (ACCELERATION SENSOR) FAILURE
-- -- -
code No. C1102
p
Description C1102 - Intermittent or open connection between control unit and G-switch, damaged
-- G-switch or circuit in control unit
Possible Cause Worn or damaged G-switch
Worn or damaged control unit
G-switch terminal backout, pins 1, 2, and 3
Short to ground in circuits ( O N ) , (OIBK), and (Y)
1 STEP / INSPECTION I ACTION I
1 Disconnect G-switch harness connector I Yes Go to step 2 1
Remove the G-switch from the vehicle No All switches should be closed
Inspect the harness connector and G-switch connector Replace G-switch
cavity for water or terminal corrosion
Go to step 11
Place the G-switch on a level surface
Measure resistance between G-switch pin 1 and pin 3
Measure resistance between G-switch pin 2 and pin 3
Are both resistances measured less than 5 ohms
Raise the front of the G-switch 38.0 mm (1.5 in) Yes Go to step 3
The arrow on the connector points toward the front No Replace G-switch
-
Measure the resistance between G-switch pin 1 and pin 3 Go to step 11
Is resistance greater than 5 ohms?
RAISE FRONT OF SWITCH 25.4 MM (1 INCH)
3 Raise the rear of the G-switch 25.4 mm (1.O in) Yes G-switch is OK
Measure resistance between G-switch pin 2 and pin 3 Go to step 4
Replace sensor
Go to step 11
I 4 i Install 60 pin breakout box and overlay

Measure resistance between in 32 on the breakout box 1
Yes Repair circuit ( O N ) between control unit and
G-switch
Go to step 11
and G-switch harness connector pin 3 ( O N )
Is resistance greater than 5 ohms? C
; No Go to step 5
-
STEP INSPECTION ---

ACTION---
5 i Measure resistance between pin 32 and pin 1 or 14 on the I Yes , Go to step 6
breakout box Repair short to ground in circuit ( O N )
Is resistance greater than 5 ohms? between control unit and G-switch
Go to stet, 11
--
Measure resistance between pin 30 on the breakout box Yes Repair circuit (OIB) between control unit and
and G-switch harness connector pin 1 (OIB) G-switch
Is resistance greater than 5 ohms? Go to step 11
--
Go to stet, 7
-
Measure resistance between pin 30 and pin 1 or 14 on the Yes Go to step 8 ---
breakout box Repair short to ground in circuit (OIB)
Is resistance greater than 5 ohms? between control unit and G-switch
Go to step 11
Measure resistance between pin 31 on the breakout box Yes Repair in circuit (Y) betwec.>ncontrol unit and
and G-switch harness connector pin 2 G-switch
Is resistance greater than 5 ohms? Go to step 11
NO I GO to step 9 I
Measure resistance between pin 31 and pin 1 or 14 on the ---
breakout box circuit (Y) between
---
This step requires that a valid diagnostic trouble code has

been obtained, ALL prior diagnostic steps have been
verified Go to step 11
most circumstances, resolve the concern and will Go to last diagnostic step ~sompletedand
consequently result in consumer dissatisfaction continue
described above?
I 11 I Remove breakout box and reinstall all com~onents I yes R e ~ a iis
r completed 1
~e~ ON No Code C1102 is present:
Using NGS Tester, clear all DTCs Concern has not been corrected
Key OFF Return to last diagnostic step completed and
Key ON proceed
Code C1102 is present anti step 9 is
completed:
Go to steD 12
Note: If the above steps have been completed, the Yes Go to step 11 for confirmation of system
most likely cause of the concern is wiring related operation
Refer to the Intermittent Diagnostic Procedure in this --
ALL affected circuits No Go to step 10
MP1174-82 6BUOPX-061
PINPOINT TEST U
/ Diagnostic trouble
code No. C1095
PUMP MOTOR RUNNING BUT NOT TRIGGERED
Description 1 C1095 - Pump motor running but not triggered by control unit
Possible Cause : Damaged trigger circuit in control unit
Welded relay contacts
Ground short in circuit (PILB)
I STEP I INSPECTION ACTION I
Make sure the battery is OK , Yes Replace pump motor relay
Key OFF I Go to step 4
Is pump motor running? I No Go to step 2
Verify pin 1 is grounded
Key ON
1 Yes i Repair short to ground in circuit (PILE)
Go to step 4
Jumper breakout box pins 1 and 19 to energize main relay

Verify that contacts are not sticking or welded NO 1 GO to step 4
Is pump motor running? i
- ..-
This step requires that a valid diagnostic trouble code has Yes Replace control unit
verified
are that replacement of this or any other system --
component without specific direction will not, in No Go to last diagnostic step completed and
1~
described above?
Remove breakout box and reconnect all components Yes Repair is completed
Key ON No Code 1095 is present:
Using NGS Tester, clear all DTCs Concern has not been corrected
Key OFF Return to last diagnostic step completed and
Key ON I proceed
CONTINUOUS DTCs ( A new code is present:
Code C1095 is present and step 2 is
completed:
I Go to step 5
-
Note: If the above steps have been completed, the Yes i Go to step 4 for confirmation of system
most likely cause of the concern is wiring related I operation
Refer to the intermittent Diagnostic Procedure in this II
section and perform for ALL affected circuits
NO ; GO to step 3
PINPOINT TEST V
No Code
/ NO COMMUNICATION
I
I Description 1
Possible Cause Worn or damaged ignition switch
Open ignition feed circuit to control unit
Low battery voltage (less than 8V)
Blown ignition fuse
Open system ground
Poor ground connection circuit (BNV)
B+ short on circuit (LBNV)
Ground short in circuit (LBIP) (Fuse 14-20A blown)
- -- -.-
I
STEP INSPECTION I ACTIOPI
1 Install 60 pin breakout box and overlay
' Check 1/P fuse 14(20A) for continuity
Verify both fuse terminals in the power distribution box
Replace fuse or service terminal as
are clean and secure
appropriate
Is there continuity and are terminals clean and secure?
Go to step 3 in System Precheck
1 2 1~ e OFF
y I yes / G Oto step 3
---
I Measure voltage between breakout box pins 1 and 16 at
B+ shall on circuit
breakout box
unit and Data
Is B+ present?
Link Connector
i 1 Go to step 3 in System Precheck
3 Key OFF yes 1 GO to step 4
Inspect ground eyelet at left radlator support for excessive
drrt, corrosion, or looseness. Clean and tlght,on as I
7------
necessary No Service open circuit In ground between
Check for contrnulty between breakout box pin 1 and the 1 control unit harness connector and ground
ground eyelet at left radiator support eyelet
Check for continuity between breakout box pln 14 and the Go to step 3 in System Precheck
I ground stud at left radiator support
1 Is there continuity at both pins? 1
Measure resistance between Data Link Connector pin 7
, for circuit (LBMI) and pin 16 on breakout box
Is resistance measured less than 10 ohms?
PIN 7 ( L E N )
No Repair or replace open or high resistance
issue in circuit (LBNV)
Go to step 3 in System Prebcheck
DATA LINK CONNECTOR

I STEP I INSPECTION ACTION

5 Key OFF Yes I Go to step 6
Measure resistance between Data L~nkConnector pin 4 !
for circuit (B) and known good chassis ground
Is resistance measured less than 10 ohms?
PIN 4 (6)
/ - - --- - --
or replace as necessary
1 I
Go to step 3 in System Precheck
I
DATA LINK CONNECTOR
--- - -- - - -
6 KeyON Yes Replace control un~t

Measure voltage between pins 20 and 1 Go to steD 3 In Svstem Precheck
Is there at least 9.5 volts? 0-9.5V:
Control unit cannot initialize due to insufficient
voltage
Problem is not in ABS system
I
ov:
Serv~ceopen circuit between fuse 14 (20A) of
I/P fuse panel and control un~tharness
connector In circuit (LBIP)
I Go to step 3 in System Precheck
Drive Test
This drive test w~llbe used when either of two conditions exists.
1. Recommended repair verification
The drive test procedure can be used after all vehicle repairs. Due to the inability of the control unit to
detect some system concerns until the vehicle is being driven in a certain way, this drive test can be
helpful in ensuring confidence in 4WABS operation before delivery to the customer.
2. Symptom evaluation drive
When a vehicle is brought to the dealer, the customer may only have a general concern about the way
the vehicle is braking. In these situations there may not be a clear system concern to troubleshoot. This
drive test is designed to produce common system concern symptoms. Use this drive test to determine
a symptom. Once a symptom is found, a symptom troubleshooting procedure can be followed to repair
the vehicle. 6BUOPX-200
Procedure
STEP INSPECTION ACTION--
1 Low Speed ABS Stop

Note: Wetting down the area where stop is to be
performed will aid this test
Drive vehicle approximately 16 kmlh (10 mph)
Hit brake pedal hard enough to lock all four wheels
Note: Momentary lockup is permissible
I Yes ABS llght IS not on:
Mechan~calconcern. Posslble causes are
damp or contammated real brake shoe Ilnlngs,
stuck/leaking wheel cylinder, overadjusted
rear brakes and hung-up parklng brake
1 Refer to Conventlonal Bralte System In thls
Does ABS cycle? section for further ~nformat~on For posslble

leaklng rear axle seal, refer to Sectlon M
i
, ABS llght comes on and stay on
--
Go to step 7
I
No I Other systems are detected
Go to step 6
ABS llght IS not on:
Go to step 2 - -
fi 2 Check for Unwarranted ABS Activity Yes ABS light is not on:
Drive
Perform
vehlcle
a light
atto
approx~mately
medlum (normal
32 kmlh
trafflc)
(20stop
mph) go to the
Check front
appropriate
and rear speed
plnpolnt
sensor
test. rotors and
Turn off the wlndsh~eldwipers ~f they are on Check adjustment of rear brakes and lnspect
Feel for pulsation ~nthe brake pedal rear brake shoe llnings for contamlnatlon.
Note: In this instance, the vehicle may pull as soon Refer to Conventional Bralte System ~nthls
as the pump motor begins to run. If this happens, section for further lnformatlon
the front sensor opposite the pull should be checked. ' ABS llght comes on and stays on
Inspect the front speed sensor rotors and go to the
appropriate pinpoint test. If the pump motor turns on ,
I
and no pull is felt, inspect the rear speed sensor and
go the appropriate pinpoint test. In this instance, the
rear brakes may be adjusted too tight andlor the
linings could be contaminated. Refer to Conventional
Brake System in this section for further information.
If the vehicle pulls immediately upon braking and the
pump motor does not run, check for improperly i er symptoms are detected
I
BS llght IS not on:
adjusted rear brake, frozen or binding caliper, uneven
brake pad or shoe wear or a pinched or crimped brake
linelhose. Refer to Conventional Brake System in this
section for further information.
Does pump motor turn on and are brake pedal pulsatlons
felt any time durlng the stop7 --
3 Check for High Sensor Gap Yes Go to step 8

Key OFF
Start vehlcle and select Drlve LOW ( A l l ) or Ist gear ( M n ) - - -- - -- ppppp-
Allow vehlcle to creep fotward at idle for at least 45 No Go to step 4

1 seconds
1 Does ABS warning lrght come on?
MP1177-81 6BUOPX-201
I STEP / INSPECTION ACTION 1

4 Check for Marginally High Sensor Gap Yes ' Go to step 8
Key OFF ,
I Start vehlcle and accelerate slowly to 40 kmlh (25 mph)
Let at least 45 seconds elapse before reachlng 40 kmlh No Go to step 5
(25 mph)
, Does ABS warnlng hght come on?
Drive Test Completed Yes Stop
Has customer concern been addressed and corrected by
previous action?
----- Vehlcle ABS function has been verifled
intermittent
No Go to
---
d~agnosisprocedure
---- -
Step Based on Brake Yes Refer to Conventional Brake System in this

Symptom section for further information
Hard or soft brake pedal
Lack of sufflclent vehicle decelerat~onupon brake
application No Refer to Conventional Brake System in thls
Vehlcle pulls durlng braklng and pump motor does not section for further information
come on I
Are any of the above symptoms present?

--- --- - - -- - -
-
Yes , Go to rnterm~ttentdiagnostic procedure
Uslng NGS Tester, perform RETRIEVE/CLEAR
CONTINUOUS CODES Pinpoint test is not complete:
Is DTC the same as before and has entlre prnpo~nttest Return to last step completed in pinpoint test
for the DTC been completed? Code obtained is not same:
No DTC or system pass obtained:
Go to System Precheck
8 Obtain DTC Yes Go to appropr~ateplnpotnt test for each DTC
Uslng NGS Tester, perform
RETRIEVEICLEAR CONTINUOUS CODES No System pass is not obtalned:
Is DTC obtalned C1155, C1145, C1230, C1158, C1148, Go to the plnpolnt test for DTC obtalned
C1229, C1258, C1259, C1260, C1233, C1234 or C12377 No DTC or system pass obtained:
I
Go to System Precheck
INTERMITTENT DIAGNOSTIC PROCEDURE

Note
An understanding of DTC storage and automatic DTC erasure is important.
DTCs can only be stored if the control unit has power. The control unit gets power from
the ignition feed into Pin 20. If this voltage is missing or less than 9.5V, 4WABS will not
initialize and therefore, a DTC cannot be stored. A system pass code will be present
whenever the control unit sees the required voltage assuming no other failures are
present.
A previously stored DTC will be automatically erased if no system concerns occur for
80 ignition cycles. Therefore, some DTCs obtained in the system precheck may not
result
e in any trouble found in the pinpoint test performed. In most cases, this is an
indication of an intermittent electrical concern.
Ifyou are at this pinpoint because the warning light is on and you have been unable to
obtain any code, go to Pinpoint Test V.
6BUOPX-203
STEP 1 INSPECTION ACTION--

1 I Remove breakout box and reconnect all components as Yes Go to step 3
I required
Key ON No Go to step 2
Does ABS warning light prove out?
2 Most Ilkely, concern IS at one of affected component Repair connector and terminal as necessary
connectors such that terminals unseat or back out upon Go to step 5
installation. At each affected connection, including
intermediate connections, look for:
Bent terminals
Damaged connector terminal locks
Damaged connector wedge
Note: If one of the above conditions is found,
check the tightness of the affected circuit once the No Go to step 6
connection is remade. If the wire is too tight (short),
damage is likely to recur once the vehicle is returned
to the customer. Service the wire as necessary to
~
correct tight wire conditions.
3
Are any of the above conditions noted?
Key ON
4Key OFF
Yes
---__-__ _____
Wiggle an affected c~rcuitIn one locatlon only 1 Go to step 5

Note: Start at one component and wiggle connector
by connector until the whole circuit has been tested --b
Is ABS warning light on7
I
--
4 Have all affected clrculls for the code being servlced been
tested? Go to step 6 --
-- Go to step 3 and check next-

circuit
-
5 Using NGS Tester, perform RETRIEVEICLEAR Go to appropriate pinpoint test
- -
CONTINUOUS DTCs
terminal or connector as
Is this DTC different than the one being serviced?
-
----- necessary
Return t i t h e pinpoint test and continue
6 Has System Precheck been run and a DTC been Yes Return to plnpoint test
retrieved7
Note: If only some tests were performed, go to the --
pinpoint step last completed and continue No Return to procedure not yet performed and
Have all steps of the plnpolnt test symptoms tests for the proceed
codes belng servlced been performed?
MP1178-B 6BUOPX-204
ABS HYDRAULIC UNIT

1. Jack up the front of the vehicle and support it on safety stands.
2. Remove the left front wheel.
3. Remove the left front fender apron and the nut retaining the hydraulic unit.
4. Lower the vehicle and remove the remaining components in the order shown.
6. Bleed the brake system. (Refer to page P-11.)
-
FRONT OF VEHICLE
. , 11-14)
15--20 (1.%I
___ _ __ - - -
6BUOPX-206
MP1118-A
1. Hydraulic Unit
ACCELERATION SENSOR (G-SWITCH)

The acceleration sensor is mounted on the left hand frame
side rail forward of the number three crossmember
2. Install in reverse order of removal.
1. Connector (not shown)

2. Nuts
3. Acceleration sensor
ABS CONTROL UNIT

Note
The ABS control unit is located on the radiator support to the right of the battery tray.
1. Remove the battery.

2. Disconnect the harness connector and remove the screw from the control unit.
3. Remove the control unit.
Installation Note
Control unit
Position the control unit and install the screw.
Tightening torque:
6-8 N.m (7.4-9.7 kgf.cm, 53-71 irr-lbf)
5BUOPX-121
I 1
FRONT SPEED SENSOR ROTOR
I 1. Remove the disc plate.
2. Remove the speed sensor rotor from the disc plate using
a 3-jaw puller.
3. Install in reverseorder of removal, referring to lnstallation
Note.
5BUOPX 030
I
I
____-.--
MP1119-A
\.
L.
/,
.A
r - ------------
-1,
lnstallation Note
Front speed sensor rotor
1. Press the new speed sensor rotor on the disc plate using
a cylinder with a 79mm (3.1 in} ID and a 96mm (3.8 in}
OD.
5BUOPX 032
i
1
MP1 120-A 5BUOPX 031
FRONT SPEED SENSOR

1. From inside the engine compartment, disconnect the connector from the wiring harness.
2. Remove the bolt and remove the speed sensor from the knuckle.
lnstallation Note
Front speed sensor
Tightening torque:
8-1 0 N-m(81-1 00 kgf-cm,68-92 in.lbf}
5BUOPX-124
WHEELS AND TIRES
OUTLINE ...................................................... Q-2

SPECIFICATIONS ..................................... Q-2
TROUBLESHOOTING GUIDE ..................... Q-3
WHEELS AND TIRES .................................. Q-4
SPECIAL NOTES ABOUT WHEELS
AND TIRES .............................................. Q-4
NOTES REGARDING TlRE
REPLACEMENT ...................................... Q-4
IIVSPECTION / ADJUSTMENT .................. Q-4
REMOVAL / INSTALLATION ..................... Q-6
TIRE ROTATION ....................................... Q-6
WHEEL BALANCE ADJUSTMENT ........... Q-6
4BUOQX-001
OUTLINE
OUTLINE
SPECIFICATIONS
Standard Tire
-- -- -
7 -- -
(4x2) Regular Cab
2892 {I 143 2077 {4580)
(4x4) Regular Cab
e and Pitch Circle Diameter

Size, Offset
Refer to page TD-26.
Possible cause Action 1
-
.
Irregular tire wear -

.
Refer to page
--
Q-5 for details.
Excessive tire wear Incorrect tire pressure Adjust (2-5
Malfunction of suspension - Section R
lncorrect front end alignment Adjust Section R
lncorrect front wheel bearing adjustment Adjust Section M
Unbalanced wheel(s) Adjust Q-6
Excessive tire and wheel runout Replace
I Premature tire wear

Tire squeal
Road noise or body

-
.
Incorrect tire ~ressure
Tire deterioration
Insufficient tire pressure
/ Adiust
Adjust
Reolace
Adjust Q-5
vibration Unbalanced wheel(s) Adjust Q-6
Deformed wheel(s) or tire(s) Repair or replace Q-4
Irregular tire wear -
--Q-5 -
"Shake" occurs Excessive tire and wheel runout Replace -
(steering wheel Loose lug nuts Tighten Q-5
vibrates upldown) Unbalanced wheel(s) Adjust Q-6
Cracked or worn engine mount rubber Replace Sections B l , 82,B3
Cracked or worn transmission mount rubber Replace Sections J1, K
"Shimmy" occurs Excessive tire and wheel runout Replace -
(steering wheel Loose lug nuts Tighten Q-5
vibrates Unbalanced wheel(s) Adjust Q-6
circurnferentially) Irregular tire wear Q-5
Insufficient tire pressure Adjust Q-5
Malfunction of steering system - Section N
Malfunction of sus~ension Section R
Steering wheel pulls lncorrect tire pressure Q-5
to one side Excessive or irregular tire wear Q-5
Malfunction of steering system Section N
Malfunction of braking system Section P
Malfunction of sus~ension Section R
General driving Unequal tire air pressures Adjust Q-5
instability Deformed wheel(s) or tire(s) Repair or replace Q-4
Loose lug nuts Tighten Q-5
Malfunction of suspension - Section R
Uneven (one-sided) Unequal tire air pressures Adjust Q-5
brakina Malfunction of braking system - Section P
Heavy handling / Insufficient tire pressure Adjust Q-5
1 Malfunction of steering system -
-
Section N
.
- - - pp ----. -.-
Section R
Section N
I Malfunction of suspension -
MQ1011 -C 4BUOQX-003
WHEELS AND TIRES
WHEELS AND TIRES

SPECIAL NOTES ABOUT WHEELS AND TIRES
1. Do not use wheels or tires other than the specified types.
2. Aluminum wheels are easily scratched. When washing them, use a soft cloth, never a wire brush. If the
vehicle is steam cleaned, do not allow boiling water to contact the wheels.
3. If alkaline compounds (such as salt-water or road salts) get on aluminum wheels, wash them as soon as
possible to prevent damage. Use only a neutral detergent.
16EOQX-004
NOTES REGARDING TIRE REPLACEMENT

Note the following points when tires are to be removed from or mounted onto wheels.
1. Be careful not to damage the tire bead, the rim bead, or the edge of the rim.
2. Use a wire brush, sandpaper, or cloth to clean and remove all rust and dirt from the rim edge and the rim
bead.
3. When cleaning aluminum wheels, use a soft cloth, never a wire brush or sandpaper.
4. Remove pebbles, glass, nails, and other foreign items embedded in the tire tread.
5. Be sure the air valve is installed correctly.
6. Apply a soapy solution to the tire bead and the edge of the rim before mounting.
7. After mounting a tire onto a wheel, inflate the tire to 207-241 kPa (2.10-2.46 kgf/cm2,30-35 psi).
Verify that the bead is seated correctly onto the rim and that there are no air leaks. Then reduce the
pressure to the specified level.
Caution
Do not exceed 275 kPa (2.8 kgf/cm2,40 psi) during tire inflation.
8. If a tire iron is used to change a tire on an aluminum wheel, be sure to use a piece of rubber between the
iron lever and the wheel to avoid damage to the wheel. Work should be done on a rubber mat, not on a
hard or rough surface.
4BUOQX-004
INSPECTION I ADJUSTMENT
Visual lnspection
lnspection (Tire and Wheel)
A wheel or tire should be replaced if any cracks, damage,
deformation or other problem(s) are found.
I
MQ1000-A 4BUOQX-005
Tire Wear
1. Check the remaining tread.
Remaining tread
Standard tires: 1.6mm (0.063 in) min.
Snow tires: 5O0I0of tread
2. A tire should be replaced if the wear indicators are

exposed.
WEAR INDICATOR
WHEELS AND TIRES
-- pppp
Abnormal tire wear

Abnormal tire wear patterns shown in the illustration can
occur. Refer to the chart for the possible causes and
actions.
I Possible cause 1 Action I
(a) Underinflation Measure and adjust
(both sides worn) pressure
lncorrect camber Repair or replace
(one side worn) suspension parts
SHOULDER WEAR CENTER WEAR Hard cornering Reduce speed
- - -... .
-- ..--
(b) Overinflation Measure and adjust

pressure
Lack-of rotation - -
-- -.- --
Rotate tires
-- -
-p-
-pp
-
(c) Incorrect toe-in Adiust toe-in

(d) lncorrect camber or caster Repair or replace axle and
suspension parts
, Malfunctioning suspension Repair or replace
' Unbalanced wheel Balance or replace
I Out-of-round brake drum Correct or replace
or disc
Other mechanical problem Correct or replace
I FEATHERED EDGE
UNEVEN WEAR
Incorrect toe-ln Adiust toe-in
Air Pressure
Check the air pressure of all tires, including the spare tire,
with an air pressure gauge. If necessa.ry, adjust the air
pressure.
Air pressure: Refer to Page Q-2
I I
M Q I 003-A 16EOQX-009
Air Leakage
Verify that there is no air leakage from ,the air valve.
Loose Lug Nut

Verify that the lug nuts are tightened to the specified
torque.
Tightening torque:
135 N.rn (14 kgf-m, 100 ft-lbf)
(2 WHEELS AND TIRES
Wheel and Tire Runout
2. Set the probe of a dial indicator against the wheel, and
measure the runout through one full revolution.
Runout limit
mm {in)
.
Radial direction
- -
1 .I 4 (0.045)
- - - -- -
Lateral direction 1 .I 4 I0.045)

MQlOl3-A
3. Replace the wheel if necessary.

Installation
1. The wheel-to-hub contact surfaces must be clean.
2. Tighten the lug nuts to the specified torque.
Tightening torque:
135 N.m (14 kgf-m, 100 ftelbf)
Caution
Retighten the lug nuts to the specified torque after
about 800 km (500 miles) of driving.
/ I
4TIRE ROTATION 5 TIRE ROTATION FOR USE
WITH REGULAR SPARE
1 TIRE ROTATION
To prolong tire life and assure uniform tire wear, rotate the
tires every 8,000-12,000 km (5,000-7,500 miles).
Caution
Use the best tires on the front axle.
After rotating the tires, adjust each tire to the
specified air pressure. (Refer to page (2-2.)
I I REGULAR SPARE I
WHEEL BALANCE ADJUSTMENT
If a wheel becomes unbalanced or if a tire is replaced or
repaired, the wheel must be rebalanced to within specifi-
cation.
Maximum unbalance (at rim edge)

14-inch wheel: 10 g (0.35 oz)
15-inch wheel: 9 g i0.32 02)
Caution
a Do not use more than two balance weights on the
inner or outer side of the wheel.
One balance weight; max. 60 g (2.1 oz}.
If the total weight exceeds 85 g (3.0 oz) on one side,
rebalance after moving the tire around on the rim.
o Attach the balance weights tightly to the wheel.
Select suitable balance weights for steel or alumi-
num alloy wheels.
Do not use an on-car balancer on automatic
transmission models; it may cause transmission
damage.
SUSPENSION
INDEX ...........................................................
FRONT SUSPENSION (4x2) .....................
FRONT SUSPENSION (4x4) .....................
REAR SUSPENSION (4x2 AND 4x4) ........
OUTLINE ......................................................
SPECIFICATIONS .....................................
TROUBLESHOOTING GUIDE .....................
NVH TROUBLESHOOTING GUIDE ..........
WHEEL ALIGNMENT ...................................
PREINSPECTION ......................................
VEHICLE LEAN .........................................
ADJUSTMENT ...........................................
INSPECTION .............................................
DIAGNOSIS ...............................................
FRONT WHEEL ALIGNMENT ...................
FRONT SUSPENSION .................................
FRONT SHOCK ABSORBER
(4x2 AND 4x4) ..........................................
FRONT COlL SPRING (4x2) .....................
FRONT COIL SPRING (4x4) .....................
LOWER ARM AND PIVOT
BRACKET (4x2) .......................................
PIVOT BRACKET (4x4) .............................
CAMBERICASTER ADJUSTER
(4x2 AND 4x4) ..........................................
RADIUS ARM (4x2 AND 4x4) ....................
FRONT STABILIZER BAR
(4x2 AND 4x4) ..........................................
JOUNCE BUMPER (4x2) ...........................
JOUNCE BUMPER (4x4) ...........................
REAR SUSPENSION ...................................
REAR SHOCK ABSORBER ......................
LEAF SPRING ...........................................
REAR STABILIZER BAR ...........................
5BI
INDEX
INDEX
FRONT SUSPENSION (4x2)
I I
MR1000-E 5BUORX-002
1. Front shock absorber 5. Radius arm
Removal 1 Inspection / Removal / Inspection /
Installation ............................ page R-16 Installation ............................ page R-27
2. Front coil spring 6. Front stabilizer bar
Removal I Inspection I Removal / Inspection 1
3. Lower arm and pivot bracket 7. Jounce bumper
Removal / Inspection 1 Removal 1 Inspection /
4. Cambertcaster adjuster
Removal I Inspection /
Installation ............................ page R-26
INDEX
FRONT SUSPENSION (4x4)
I
MR1003-C 5BUORX-003
1. Front shock absorber 5. Radius arm
Removal / Inspection / Removal / Inspection /
2. Front coil spring 6. Front stabilizer bar
3. Pivot bracket 7. Jounce bumper
4. Camberlcaster adjuster
- - -
INDEX
REAR SUSPENSION (4x2 AND 4x4)
MR1001-A 4BUORX-004
1 . Rear shock absorber 3. Rear stabilizer bar
2. Leaf spring
Removal / Inspection 1
OUTLINE
OUTLINE
SPECIFICATIONS
---
Item
%_
----- Model 4x2 T r - - l
Total toe-in
Camber sDlit I .oO+ .4" 1

I Caster angle min. 1 2
20-
I Caster angle rnax. C 60 I 6 " I
I Caster split I
-1.0" f .4" 1
MR1002-C 6BUORX-001
Note
When the battery has been disconnected and reconnected, some abnormal olrive symptoms
may occur while the powertraincontrol module relearns its adaptive strategy. The vehicle may
4BUORX-006
Problem
Steering wheel
Possible Cause
Damaged or worn coil spring Replace
Action
----
Pagelsection
R-18, 20
-
pulls to one side Damaged or worn stabilizer bushings Replace R-30

Damaged ball joint Replace Section M
lmproperly adjusted wheel alignment Adjust R- 9
Malfunction of steering system Section N
Malfunction of braking system Section P
Damaged or unbalanced wheel(s)
"Shimmy" occurs Damaged or worn ball joint(s) Replace Section M
(steering wheel Loose or damaged shock absorber Tighten or replace R-16
vibrates leftlright) Damaged or worn stabilizer bushings Replace R-30
lmproperly adjusted wheel alignment Adjust R- 9
Damaged or worn wheel bearing Replace or adjust Section M
Damaged or unbalanced wheel(s) - Section Q
Loose lug nut(s) Tighten Section Q
Damaged or worn radius arm bushings Replace R-27
Damaged or worn coil spring Replace R-18, 20
-
.
Damaged or worn leaf spring Replace R-35
Riding low lncorrect tlre pressure Adjust Section d-
1 Damaged or worn coil sprlng Replace R-18, 20
Damaged or worn leaf spring Replace R-35
I Loose or damaqed shock absorber / Tighten or replace R-16
Body "rolls" I Weak stab~l~zer
Damaged or worn stabrl~zerbushlng
Incorrect trre pressure
I ;:;;:::
I Adjust
R-30
R-30
Sect~onQ
Loose or damaged shock absorber Tighten or replace R-16
1
Loose lug nut(s)
I Damaged or worn cod sprlng
Malfunct~onof steerlng system
,- T~ghten
Replace I
~ect~o Qn
R-18, 20
Sectton N
Broken leaf sprlng mountlng bolts Replace R-35
Body leans Incorrect t ~ r epressure Adjust ~ect~o Q-n
Damaged or worn coll sprlng Replace R-18, 20
- - Damaged or worn leaf spring Replace 1
+---- R-35
Abnormal noise from Loose or damaged shock absorber T~ghtenorereplace I
i
R-16
suspension system
-- Damaged or worn stab~llzer-
bushlngs
- --
Replace R-30
7 -
General driving Damaged or worn coll sprlng ~e~lace- R-18, 20
instability Damaged or worn leaf spring Replace R-35
Loose or damaged shock absorber Tighten or replace R-16
Damaged or worn stabll~zerbushlng Replace R-30
Improperly adjusted wheel al~gnment Adjust R- 9
1 Damaged ball jolnt Replace Sect~onM
Malfunct~onof steerlng system - Section N
Damaqed or unbalanced wheel(s) Section Q
Heavy steering Worn ball jo~nt Replace Sect~onM
Improperly adjusted wheel al~gnment Adjust I R- 9
I Malfunction of steering system 1 Sectlon N
Damaged or unbalanced wheel(s)
I
- i
Sect~onQ
MR1045 D 5BUORX 052
NVH TROUBLESHOOTING GUIDE
A "rattle," "clunk," "pop," "squeak," "creak or "crunch" noise may be heard from the front underbody. Use
the following diagnostic procedure along with the list of common sources of noise and recommended
repair procedures to determine where the concern is and how to correct it.
5BUORX-005
Diagnostic Procedure
STEP 1: INTERVIEW CUSTOMER

Understand the customer's description of the noise.
1
Road test the vehicle with the customer to fully understand where, how and when the noise occurs.
Is the noise speed dependent? Road surface dependent? or Temperaturelweather dependent?
STEP 2: DUPLICATE NOISE CONCERN

Is the noise heard while bouncing the bumper of the vehicle?
Or, is the noise heard while driving over rough road surface?
Or, is the noise only heard while driving while braking?
Or, is the noise heard while turning (while driving, or while parked)?
Note
Typically, front underbody noise is heard while bouncing the bumper of the vehicle. If the noise can
not be duplicated during the static bounce, or during low speed turning maneuvers, it most likely is
not suspension related.
- -
STEP 3: ISOLATE NOISE CONCERN

If the noise can be duplicated by pushing up and down on the vehicle while stationary. Use a stethoscope
or chassis ears to determine the area of the chassis that the noise appears to be coming from.
Another method of isolating a noise is to place your hand on the coils spring, radius arm, or stabilizer bar
while someone pushes up and down on the vehicle. This will allow you to feel the vibrations.
Note
This method is sometimes misleading as the vibrations may carry from one suspen5iion component
to another.
Spray a liberal amount of penetrating oil on the suspension components which appear to be creating the
noise. If the noise stops after lubrication, refer to each related page listed in the "Troubleshooting Guide" for
permanent repair action.
STEP 4: INSPECT VEHICLE

Loose fasteners
Wornlbroken parts
Excessive dirVrust accumulation
STEP 5: SERVICE VEHICLE

Service the vehicle in accordance with the repair procedures outlined in this manual.
I I
v
1 STEP 6: TEST DRIVE VEHICLE 7
Drive the vehicle over the same road surface on which the customer demonstrated the noise, to verify that
and repaired.
v
STEP 7: FOLLOW-UP WITH CUSTOMER
Follow-up with the customer about two weeks after service is performed to ensure the noise was correctly
identified and repaired.
Description of Underbody Noises
The following noises may be heard from the front underbody during normal driving conditions. A brief
description of each noise is included to provide consistency during the diagnostic and repair procedures.
Term Description
Rattle A continuous light metallic noise induced by driving over rough road surfaces (i.e., tar strips, bumps, patched
- --
surface). A sound suggesting looseness, such as
~-
marbles rolling around
.- - -- in vehicle. --
Clunk
--- -- A heavy metallic noise heard upon impact of bumps. Typically, a "clunk is heard once upon each impact.
Pop It is similar to a "clunk, but a lighter sound. It is heard upon impact of rough road surfaces, or during braking.
- - Typically,
- a pop is heard once upon -- each impact or brake application. -
Squeak A high pitch sound, like rubbing a clean window, heard during suspension movement (jounce or rebound). A
-- suspension squeak may be induced by driving over undulating surfaces, or while bouncing a stationary vehicle.
Creak A creak is similar to a squeak, but usually louder, produced by a metal-to metal, or rubber to metal rubbing
motion which may occur during suspension movement (jounce or rebound).
MR1067-A SBUORX-007
I I
--
Problem
Rattle
Condition
Drlvlng over rough road surfaces
Possible Cause
Front stablllzer bar attaching
i Action
Tlghten fasteners to speclfled torque
hardware loose -
Worn radlus arm bushlngs Replace bushlngs
Front shock absorber attachlng Tlghten fasteners to speclfled torque
hardware loose
-- -
Broken shock absorber Replace shock absorber
-
- - -
clunk-nltlal drlv~ngafter vehlcle IS Worn radlus arm bushlngs Replace bush~ngs
1 backed out of parklng space,
I Impact of large bumps and/or
.
railroad crosslnas.
--
During braking; typically one pop Loose bolt which attaches Check that bolt is set to specified
during each braking application. stabilizer bar bracket and radius torque.
arm to front axle. If loose: disassemble/inspect for
damage.
lnspect 4x4 to ensure there is a
19.05mm (314 in) flat washer under
head of bolt on both LH and RH side.
If not: install washer under head of
bolt.
During braking; typically one pop Brake caliper Check and adjust the brake pads and
during each brake application caliper knuckle clearance 0.38mm
l.015" MINI.
t
Driving over rough or undulating Crossmember to frame Check crossmember and spring tower
road surfaces attachments loose attachment frame siderails; tighten
(Not the "huck" rivet) bolts or replace loose rivet with
-- - -- - appropriate bolts
Driving over road surfaces which "Huck" rivet which attaches #1 "HUCK" rivet with a nut, bolt
induce bodylframe twist crossmember to left frame rail is
I loose
1
Squeak
Creak
When jouncing bumper or
slowly driving over rough or
undulating road surfaces
I
lncorrect radius arm bushing and
s~acers 1 Confirm vehicle has correct parts.
Radius arm bushina: Brown color
Radius arm space<white color
1
?
i Radius arm nut over-torque Tighten radius arm nut to specified
i durina installation of new radius toraue
arm h s h i n g
Upper end of coil spring is not Check upper end of coil spring for
properly seated in spring tower proper align in spring tower; reposition
sprlng
Coil spring insulator rubs against Disassemble and lubricate bottom s i d e
lower spring seat of insulator and top side of lower
spring seat with brake caliper side
-
-. - --
grease .. -
Coil spring retaining tab on Remove coil spring and re-bend tab to
upper spring tower is bent, coil position
causing contact between end
of tab and inner side of coil
spring
Front body mount rusty/loose lnspect front body mounts. Clean
mating surfaces
arm bush~ngs Conflrm vehlcle has correct parts
- Radlus arm bushlncl. Brown color
surfaces- / Radius arm spacer:~hite color
WHEEL ALIGNMENT
WHEEL ALIGNMENT
Caution
Do not attempt to adjust the front wheel alignment
without first making a preliminary inspection of the
front end parts and correcting where necessary.
1. Position the vehicle on level ground and remove all

passengers and payload.
2. Remove excessive accumulation of mud, dirt or road
deposits from the chassis and underbody.
3. Check the tire inflations and set to recommended
pressure if necessary. Check that the tire sizes are com-
parable to original equipment and that the front tires have
the same ply rating and load range.
4.Check that the spare tire, jack and tools are in the
designated positions.
5. Check that the fuel and fluid levels are filled.
6. lnspect the front wheel bearing play. Replace the bearing
if necessary.
7. lnspect the wheel and tire runout.
8. Check that the steering linkage and radius arm are not
bent or damaged. Replace parts if necessary.
9. lnspect the bushings at the radius arm-to-frame attach-
ment for wear or looseness. Replace the bushings if
necessary.
10. lnspect the ball joints for excessive wear and looseness.
1 1. Check the steering gear mounting bolts and tighten to the
specified torque.
12. Check all other suspension components for damage or
looseness.
13. Shake the vehicle to check the operation of the shock
absorber.
14. The difference in height between the left and right sides,
from the center of the wheel to the fender brim, must not
exceed 16rnm (0.63 in) for the front wheel house, 20mm
(0.79 in)forthe rear wheel house, and 2C)mm(0.79 in) for
the rear end of the pickup box.
4BUORX-008
WHEEL ALIGNMENT
VEHICLE LEAN
Specification
"A" " B" Rear End of Box
Front Wheel House Rear Wheel House (Refer to Section S)
Opening Opening
16mm (0.63 in) 20mm I0.79 in} 20mm (0.79 in}
Maximum Maximum Maximum
ADJUSTMENT
Front Lean
Note
Changing front ride height by adding the service
shim also affects caster angles and camber angles.
Adding the 4.5mm (0.18 in) thick shim may reduce
caster by up to 0.40 degrees on the side the shim is
added and also increase camber by 0.15 degrees.
1. Measure the left and right front ride heights.

Note
On 4x2 models, add 8mm (0.3125 in) to the right
side ride height measurement.
On 4x4 models, add 12mm (0.5 in) to the left side
ride height measurement.
RIDE HEIGHT
MR1053-A
2. If the difference between left and right ride heights
exceeds 16mm (518 in) and is less than 20mm (314 in),
measured at the wheel house opening to ground, add one
shim to the side of the vehicle that is low.
Note
The shim is to be placed under the lower spring
seat.
MRl054-A 6BUORX-005
R-I 0
WHEEL ALIGNMENT
3. If there is a computed side-to-side difference of 20mm
(314 in) or more in the leftfright wheel house openings,
swap springs from side-to-side.
Note
If the lean condition follows the spring (lean now
on other side of the vehicle), one or both springs
are out of specification. Replace both springs with
new ones. If lean condition remains unchanged,
something other than a bad spring is the cause and
must be diagnosed.
Rear Lean
Note
A side-to-side lean at the rear of the vehicle can be
adjusted by approximately 6mm (1114 in) by install-
ing a shim between the rear spring1 and axle on the
low side of the vehicle.
A "low at the rear" vehicle can be raised approxi-
mately 6mm (114 in) by installatiorb of n shim on
each side.
1. Raise the vehicle until the weight is off the rear springs but
with the tires still touching the floor.
2. Loosen the spring U-bolts to allow the axle to separate
from the spring approximately 13mm ('112 in).
3. Position the shim between the spring and the spring seat
I ;
with the tie bolt head through the hole in the shim.
Note
HIM On 4x4 vehicles, position the shim between the rear
HIM
spring and axle spacer. Tape may be used to hold
the shim in position.
FRONT OF VEHICLE
c3
WHEEL ALIGNMENT
4. Make sure the spring leaves are properly aligned and the
spring U-boltscontact the edges of the spring assembly or
axle seat.
5. Tighten the spring U-bolt sufficiently and make sure the
spring bolt head extends through shim into axle seat hole.
6. Tighten the U-bolt nuts to specified torque.
Tightening torque:
88-1 02 N - m (9.0-1 0.4 kgf .m,65-75 ft .lbf)
I I
MR1056-C 6BUORX-006
0 1 Side-to-Side Lean
SIDE-TO-SIDE LEAN
Note
Side-to-side vehicle lean should be verified by
measuring the fender lip-to-ground dimension
before beginning diagnosis and service actions.
The following are the normal acceptance limits:
- Maximum of 16mm (518 in) variance between left
and right front wheel lips to ground.
- Maximum of 20mm (314 in) variance between left
and right rear wheel lips to ground.
I I
MR1057-A 6BUORX-007
1. Pre~arethe "Preins~ection"stem 1-13 on Daae R-9.
2. ~ e a s u r ethe heightmofthe rightbandleft feid& lip open-
ings, dimensions A and B, noting dimensions of each and
side-to-side differences.
3. If the differences are greater than 16mm (0.63 in)
between left or right front and/or 20mm (0.79 in) between
left and right rear, factors other than suspension are the
cause.
INSPECTION
Dogtracking
1. The vehicle, by design, has a front tread that is wider than
the rear tread.
2. The front tread is the distance between the two front tires,
and likewise the rear. The illustration shows these differ-
ModeUAxle Specificati n
ences.
4xq(Dana 35) 37mm { I .45 in)
I
4x2IAll I 12mm l0.47 in)
WHEEL ALIGNMENT
3. When a vehicle with these tread differences is driven on
a crowned road, the front may tend to ride higher than the
rear, making thevehicle appear to dogtrack, as illustrated.
Refer to Diagnosis, Dogtracking. (Refer to below.)
DIAGNOSIS
Dogtracking
ModellAxle Specification 1. Find an empty stretch of road or parking lot.
2. Drive the vehicle while sighting down the hood or the body
style line to see if the vehicle is going in a straight line or
24mrn (0.94 in} dogtracking.
MR1006-C 6BUORX 3. Stop the vehicle when you notice it dogtracking. Have an
assistant mark the position of the center tread of both front
tires with chalk on the ground.
4. Slowly pull the vehicle forward until the rear tires are at the
same position as the marks made for the front tires.
5. Have an assistant mark the ground as was done for the
front tires, identifying which marks are for the front tires
and which marks are for the rear tires.
6. Move the vehicle out of the way so all of the marks can be
seen.
7. Proceed to measure the total amount of dogtracking as
follows:
(1) Measure the distance (A) between the front tire marks.
(2) Mark the ground exactly halfway between these marks.
(3) Measure the distance (B) between the rear tire marks.
(4) Mark the ground exactly halfway between these marks.
(5) The difference between the two center marks is the
amount of dogtracking present in the vehicle (C).
FRONT WHEEL ALIGNMENT

Total Toe-in
Adjustment
1. Loosen the clamp bolts at each end of the spindle con-
necting rod tube.
2. Rotate the sleeve until the correct toe adjustment is
obtained.
3. With the clamps centered between the protrusions on the
adjustment sleeve lock ring, position the bolts horizontally
with the clamp nuts facing in the direction shown. Tighten
the clamp nuts.
Tightening torque:
40-57 N-m (4.2-5.7 kgf.m, 3 0 - 4 2 ft-lbf]
4. Recheck the toe adjustment after tightening the clamps.
5. Check that the steering wheel is centered.
WHEEL ALIGNMENT
Camber and Caster
Production Adjustment
Note
The hex headed adjusting slug service part is the
same for the 4x4 and 4x2 models. The round
adjuster is for production only.
Camber and caster adjustment is possible with
adjusters available in 0°30', 1' and 1'30' incre-
ments. One adjuster is used to adjust both the
caster and camber, depending on its orientation.
dR1062-A
CASTER = 3/8 DEGREE

1. Measure the vehicle camber and caster. Note the differ-
CAMBER = -1/4 DEGREE ence between the actual measurement and the required
specifications.
2. If adjustment is necessary, determine the amount of
camber and caster in the adjuster that is installed in the
vehicle.
IF THIS ADJUSTER IS INSTALLED IN THE LH

Note
AXLE, THE AMOUNT OF CASTERICAMBER IN The degrees of camber and caster are stamped on
THE ADJUSTER AS INSTALLED IS: the top of the production adjuster. For the right
CASTER = -3/8 DEGREE
CAMBER = 1/4 DEGREE
side of the vehicle, the first number is the amount
of caster, and the second number is the amount of
camber. For the left side of the vehicle, the caster
and camber numbers are the opposite sign of the
number shown.
3. Select a new service adjuster from the table to obtain

optimum camber and caster.
Note
The camber or caster change required to obtain the
optimum settings must be added to the amounts of
camber and caster in the old or production ad-
juster.
Example: If caster and camber must be reduced 1.0
degree and camber increased +0.75 degree at the
left wheel, and the existing adjuster has +0.25
degree caster as installed, select the 1.0 degree
service adjuster and orient the slot 225 degrees
from the straight-ahead position.
WHEEL ALIGNMENT
4. Remove the front wheels.
CASTER AND
CAMBER ADJUSTER 68-92 5. Loosen the pinch bolt at the upper ball joint and pry
6&92 out the adjuster. If necessary, use Pitman Arm Puller
T64P-3590-F, or equivalent to remove the adjuster.
6. Install the new adjuster and orient the slot as specified in
the table.
7. Tighten the pinch bolt.
Tightening torque:
68-92 N m (6.9-9.3 kgf m, 50-68 ft Ibf}
N-m (kgf.m, ft-lbf)
~~1014-c G~~O~~-O1l 8. Install a new camberlcaster adjuster snap ring on 4x4s

with a Dana 35 axle.
9. Install the front wheels.
10. Check the alignment.
Note
If necessary, rotate the adjuster until th optimal
alignment setting is achieved.
11. Adjust the total toe-in. (Refer to page R-13.)
CamberICaster Adjuster Selection Table
4
--
I Position Slot --
LH Side
- - - - - -- ---- - -- --
Service Adjuster in Axle Camber Change Caster Change Camber Change Caster Change
Type (Degrees) (Degrees) (Degrees) (Degrees) (Degrees) (Degrees)
-- --
-
1I2
- - -- -
0--
-0.5 - -
0 - -- +0.5 - RH[ -- 0
-----
1 0 -1.o 0 +1.o 0
NOTE: The assembly plant sometimes builds vehicles with adjusters that are not zero-degree type to control alignment. This table shows the alignment changes
that will occur if the vehicle was originally built with zero-degree adjusters. Always check to see which adjuster has been installed (and its orientation)
before making changes.
MR1015-8 4BUORX-013
FRONT SUSPENSION
FRONT SUSPENSION
FRONT SHOCK ABSORBER (4x2 AND 4x4)
Removal 1 Inspection I lnstallation
Warning
The low pressure gas shock absorbers are charged with nitrogen gas to 930 kPa (9.45 kgf.cm2,
135 psi). Do not attempt to open, puncture or apply heat to the shock absorber.

I I
MRIOIG-B 5BUORX-014
1. Shock absorber
Inspection ............................... page R-17
Installation Note ..................... page R-17
2. Insulator
R-I 6
FRONT SUSPENSION
Inspection
Shock absorber
FLUID LEAKAGE Note
The shock absorber is non-adjustable and non-
refillable and cannot be repaired.
1. Check that the shock absorber is properly installed and

not damaged or worn. Replace if necessary.
Note
Make sure the part number of the replacement is
the same as that of the original shock absorber.
2. Replace the shock absorber if there are excessive fluid

leaks. A light film of fluid on the upper position of the shock
absorber body is permissible.
3. Check the action of the shock absorber by compressing it.
If the shock fails to extend itself when compressed, it is an
indication of a seal malfunction and the shock should be
replaced.
4. If a shock absorber is suspected of being weak, compare
the compression results with the opposite side. If the
action is similar, it is unlikely that either shock absorber is
worn or damaged.
5. Replace the shock absorber if there is a lag or skip
occurring near the midstroke of the shaft's reverse travel
direction.
6. Replace the shock absorber if there is any seizing during
the shaft's full travel, except at either end of travel.
7. Replace the shock if during the shaft's fast, reverse stroke
there is any noise other than a faint swish, such as a
clicking sound.
6BUORX-012
Installation note
Shock absorber
1. Tighten the lower shock absorber nut.
Tightening torque:
53-72 N.m (5.4-7.3 kgf.m, 39-53 ft-lbf}
2. Tighten the upper shock absorber nut.
Tightening torque:
3 4 4 6 N.m ( 3 . 5 4 . 7 kgf-m, 25-34 ft.lbf}
5BUORX-016
FRONT SUSPENSION
FRONT COIL SPRING (4x2)
Removal 1 Inspection l Installation
3. Disconnect the shock absorber from the lower shock stud.
N.m (kgfm, ft.lbf)
dR1017-D 5BUORX-01
1. Coil spring 2. Retainer
Removal Note ........................ page R-19 3. Lower seat
Installation Note ..................... page R-19 4. lnsulator
FRONT SUSPENSION
Removal note
Coil spring
Caution
The lower arm must be supported on a jack
throughout the spring removal and installation
procedure.
The lower arm must not be permi1:ted to hang by

the brake hose. If the length of the brake hose is
not sufficient to provide adequate clearance for
the removal and installation of the spring, the cali-
per must be removed from the spindle. (Refer to
Section P.) Strut Spring Compressor T81P-5310-A,
or equivalent may be used to compress the spring
sufficiently, so the caliper does not have to be
removed. After removal, the caliper must be placed
on the frame or otherwise supported to prevent
suspending the caliper from the brake hose. These
~~1047-A ~BUORX-018 precautions are absolutely necessary to prevent
serious damage to the tube portion of the caliper
hose assembly.
1. Lower the lower arm a r ~ dsupport it without stretching

the brake hose and tube assembly before removing the
coil spring.
2. Rotate the spring so that the built-in retainer on the upper
spring seat is cleared.
Note
When removing the coil spring either remove
the caliper or use Strut Spring Compressor
If sufficient slack exists in the brake hose, a pry bar
may be used to lift the spring over the bolt that
passes through the lower spring seat.
Installation note
Coil spring
1. Install the lower bolt.
Tightening torque:
255-345 N - m (26.2-35.2 kgf - m, '1 88-254 ft .lbf}
2. Install the shock absorber on the lower shock stud.
Tightening torque:
53-72 N-m(5.4--7.3 kgfam, 39-53 ft-lbf)
6BUORX-013
FRONT SUSPENSION
FRONT COIL SPRING (4x4)
3. Position a jack under the spring. Raise the jack and compress the spring.
4. Remove the lower shock absorber nut.
I I
MR1018-E 5BUORX-019
1. Radius arm (not shown) 3. Retainer
Removal / Inspection / 4. Insulator
Installation ............................ page R-27 5. Lower seat
2. Coil spring
Removal note
Coil spring
Caution
The lower arm or axle casing must be supported on
a jack throughout the spring removal and installa-
tion procedure.
The lower arm or axle casing must not be per-
mitted to hang by the brake hose. If the length of
the brake hose i s not sufficient to provide
adequate clearance for the removal and installa-
tion of the spring, the caliper must be removed
from the spindle. (Refer to Section P.) Strut Spring
Compressor T81P-5310-A, or equivalent may be
'CAI used to compress the spring sufficiently, so the
caliper does not have to be removed. After removal,
the caliper must be placed on the frame or other-
wise supported to prevent suspending the caliper
from the brake hose. These precautions are abso-
lutely necessary to prevent serious damage to the
tube portion of the caliper hose assembly.
FRONT SUSPENSION
1. Slowly lower the lower arm or axle casing until all spring
tension is released.
2. Remove the spring by rotating the upper coil out of the
upper spring seat tabs.
Note
When removing the coil spring either remove
the caliper or use Strut Spring Compressor
T81 P-5310-A, or equivalent.
3. If required, remove the stud from the lower arm or axle

casing.
Installation note
Coil spring
1. If removed, install the axle stud.
Tightening torque:
255-345 N m (26.2-35.2 kgf .m, 188-254 ft Ibf}
2. Install the spring retainer nut.
Tightening torque:
95-1 35 N.m (9.7-1 3.8 kgf-m,70-1 00 ftelbf}
3. Install the lower shock absorber nut.
Tightening torque:
53-72 N-m (5.4-7.3 kgf-m, 39-53 ft-lbf}
6BUORX-014
FRONT SUSPENSION
LOWER ARM AND PIVOT BRACKET (4x2)
Removal IInspection / lnstallation
3. Remove the front coil spring. (Refer to page R-18)
4. Remove the front stabilizer bar. (Refer to page R-30)
150--200
. (15.3--20.4,
FRONT OF VEHICLE
RH LOWER ARM INSTALLATION
REPLACE
LH LOWER A R M INSTALLATION
RH LOWER ARM SAME EXCEPT AS SHOWN
I I
MRlO19-E 5BUORX-022
1. Knuckle 4. Pivot bracket
Removal / Installation ............. Section M Removal Note ........................ page R-23
2. Radius arm Installation Note ..................... page R-23
Removal / Inspection / 5. Pivot bushing
Installation ............................ page R-27 Removal Note ........................ page R-23
3. Lower arm Installation Note ..................... page R-23
FRONT SUSPENSION
Removal note
Pivot bracket
1. Remove the four attaching nuts and the two bolts.
2. Remove the retainer assemblies.
3. Remove the axle pivot bracket.
5BUORX-023
Pivot bushing
1. Remove the left axle pivot nut and bolt.
2. Pull the pivot end of the left lower arm down until the
bushing is exposed.
Note
To remove the right pivot bushing, the entire right
lower arm must be removed in order to gain access
to the pivot bushing.
3. Place Pivot Bushing Spacer T82T-3006-AH, or equivalent

between the walls of the axle.
4. Using Forcing Screw T78P-5638-A1, Pivot Bushing

Remover 1801-5638-A2 and Receiver Cup T78P-
5638-A3, or equivalents remove the pivot bushing.
Installation note
Pivot bushing
I.Install the pivot bushing in the axle using Bushing
Replacer T82T-3006-A, or equivalent.
2. Lower the vehicle and tighten the pivot bushing and nut.
PIVOT BUSHING
Tightening torque:
T78P-5638-A1 T80T-5638-A2
150-200 N-m (15.3-20.4 kgf-m, 111-148 ftelbf}
5BUORX-025
Pivot bracket
Note
The correct nuts for this application have an under-
cut to provide clearance for the bolt knurl. Use
correct nuts or install one 5mm (0.20 in} thick
hardened washer under each nut if a standard nut
MR1022-B 5BUORX-024
is used.
Tightening torque:
98-1 32 N-m(9.9-1 3.5 kgf-m, 72-98 ft-lbf)
5BUORX-026
FRONT SUSPENSION
PIVOT BRACKET (4x4)
Removal I Inspection 1 lnstallation
3. Remove the front coil spring. (Refer to page R-20)
4. Remove the front stabilizer bar. (Refer to page R-30)
L J
MR1048-C 5BUORX-027
1. Upper retainer 5. Pivot bushing
2. Side retainer Removal Note ........................ page R-25
3. Lower retainer Installation Note ..................... page R-25
4. Pivot bracket
Removal note
Pivot bracket
1. Lower the hoist untilthe axle casing is in contact with ajack
stand.
2. Remove the bolt and nut attaching the axle casing to the
pivot bracket.
3. Raise the hoist. If necessary pry the axle casing free from
the bracket.
4. On the right pivot bracket, remove the attaching nuts.
5. Remove the upper bolt and retainer and the side bolt and
retainer.
6. Remove and discard the lower bolt and retainer.
7. Remove the pivot bracket from the crossmember.
8. On the left pivot bracket, drill out the rivets so that the
mounting holes in the bracket and the crossmember are
14.28mm (0.56 in) in diameter.
FRONT SUSPENSION
9. Remove the left pivot bracket.
4BUORX-029
Pivot bushing
1. Remove the lower arm or axle casing, referring to
Section M.
2. Using Forcing Screw T78P-5638-A1, Pivot Bushing

Remover T80T-5638-A2 and Receiver Cup T78P-
5638-A4, or equivalents remove the pivot bushing.
Installation note
FORCING SCREW Pivot bushing
T78P-5638-A1
1.Using Receiver Cup T78P-5638-A4, Forcing Screw
T78P-5638-A1, or equivalents and either Bushing
Replacer T82T-3006-A (Dana 28) or Front Suspension
Bushing Tool T80T-5638-A (Dana 35), or equivalents
PIVOT BUSHING
install the bushing.
REPLACER
T82T-3006-A (DANA 28) Note
RECEIVER CUP
OR FRONT SUSPENSION
BUSHING TOOL
After installing, the "lead in" end of the bushing
T78P-5638-A4 T80T-5638-A (DANA 35) must be flared to prevent movement.
2. Flare the bushing using Forcing Screw T78P-5638-A1,

RECEIVING CUP
T82T-3005-A1 Flaring Tool T83T-3006-A and Receiving Cup T82T-
3005-A1, or equivalents.
FLARING TOOL
T83T-3006-A
Pivot bracket
1 . 0 n the left pivot bracket, position the bracket on the
crossmember. Make sure the 14.28mm (0.56 in) drilled
holes are in alignment.
2. Install the 9/16-12 x 1-112 in Grade 8 replacement bolts,
washers (2) and nuts.
Tightening torque:
210 N-m (21.3 kgf-m, 155 ft.lbf)
FRONT SUSPENSION
3. On the right axle pivot bracket, position the bracket on the
crossmember.
4. lnstall the upper bolt and retainer. Install the side bolt and
retainer with the bolt heads facing toward the engine oil
pan to maximize clearance. Install the nuts.
113--153
{ I 1.5--15.5. Tightening torque:
83--113)
113-153 N-m{I 1.5-15.5 kgf-m, 83-1 13 ft.lbf)
150--200
{15.3-20.4,
lil-148)
------ .
'%:<.:
;
N.m (kgfm, ft.lbfj
L I
MR1020-B 6BUORX-015
5. Drill out the mountina hole for the lower bolt and the
retainer in the bracket and crossmember to a 14.28mm
(0.56 in) diameter. lnstall 9/16-12 x 1-112 in Grade 8
bolts, washers (2) and nuts.
Tightening torque:
210 N.m C21.3 kgf-m, 155 ft.lbf)
6. Lower the hoist until the axle casing engages the bracket.
Install the attaching bolt and nut.
Tightening torque:
150-200 N.m (15.3-20.4 kgf-m, 111-1 48 ft.lbf)
CAMBER ICASTER ADJUSTER (4x2 AND 4x4)

Removal IInspection 1 Installation
3. Remove the camberlcaster adjuster, referring to Removal Note. (Refer to below.)
6. Inspect the front wheel alignment and adjust as necessary.
5BUORX-031
Removal note
I CASTER AND
CAMBER ADJUSTER 68-92 Camber I caster adjuster
1. Remove the upper ball joint camberlcaster adjuster clamp
bolt from the axle.
2. Remove the camberlcaster adjuster from the axle using
Pitman Arm Puller T64-3590-F, or equivalent to remove
the adjuster out of the axle.
Installation note
Camber I caster adjuster clamp bolt
Tightening torque:
68-92 N-m(6.9-9.3 kgf.m, 50-48 ft-lbf)
5BUORX-033
FRONT SUSPENSION
RADIUS ARM (4x2 AND 4x4)
3. Remove the front coil spring. (Refer to page R-18 [4x2], R-20 [4x4].)
Caution
The lower arm or axle casing must be supported on a jack throughout the spring removal and
installation procedure, and must not be permitted to hang by the brake hose. If the length of the
brake hose is not sufficient to provide adequate clearance for the removal and installation of
the spring, the caliper must be removed from the spindle. (Refer to Section P.) Aft r removal,
the caliper must be placed on the frame or otherwise supported to prevent suspending the
caliper from the brake hose. These precautions are absolutely necessary to prevent serious
damage to the tube portion of the brake hose assembly.

I I
MR1029-E 5BUORX-034
1. Shock absorber 5. Spacer
Removal Note ........................ page R-28 6. Radius arm
Installation Note ..................... page R-29 Removal Note ........................ page R-28
2. Washer Installation Note ..................... page R-29
3. Shield 7. Inner bushing
4. Outer bushing Removal Note ........................ page R-28
Removal Note ........................ page R-28 8. Retainer
FRONT SUSPENSION
1
MRlO30-E 5BUORX-035
1. Shock absorber 5. Spacer
Removal Note ................................. below 6. Radius arm
Installation Note ..................... page R-29 Removal Note ................................. below
2. Washer Installation Note ..................... page R-29
3. Shield 7. lnner bushing
4. Outer bushing Removal Note ................................. below
Removal Note ................................. below 8. Retainer
Removal note
Shock absorber
Disconnect the lower end of the shock absorber from the
shock lower stud.
4BUORX-038
Radius arm (4x2)

Note
The rear washer shield is only on the right side on
models with 3.OL and 4.OL engines.
4BUORX-039
Radius arm (4x4)

Loosen the lower arm or axle casing pivot bolt.
Note
The rear washer shield is only on the right side.
4BUORX-040
lnner and outer bushing

1. Removethe outer bushing, spacer and shield (if equipped)
on the right radius arm.
2. Move the radius arm and the axle assembly forward and
out of the radius arm bracket.
3. Remove the inner bushing and retainer.
4BUORX-041
FRONT SUSPENSION
Installation note
Radius arm (4x2)
1. lnstall the radius arm nut.
Tightening torque:
113-1 53 N.m (11.5-1 5.5 kgf-m, 83-1 13 ft-lbf}
2. lnstall the bolt attaching the radius arm ,to the lower arm.
Tightening torque:
255-345 N m (26.2-35.2 kgf - m, 188-254 ft .Ibf}
6BUORX-016
Radius arm 94x4)

1. lnstall the radius arm nut.
Tightening torque:
113-1 53 N-m(11.5-1 5.5 kgf-m, 83-1 13 ft.lbf}
2. lnstall the stud.
Tightening torque:
255-345 N .m (26.2-35.2 kgf .m, 1' 88-254 ft - lbf)
3. lnstall the front bracket bolt.
Tightening torque:
21-29 N-m (2.1-2.9 kgfam, 15-2'1 ft-lbf}
4. lnstall the lower bracket bolt.
Tightening torque:
255-345 N - m (26.2-35.2 kgf . m, '188-254 ft .lbf)
5. Install the lower arm or axle casing pivot bolt.
Tightening torque:
150-200 N-m (15.3-20.4 kgf-m, 111-1 48 ftalbf)
6BUORX-017
Shock absorber
lnstall the shock absorber nut.
Tightening torque:
53-72 N.m (5.4-7.3 kgfam, 39-5:3 ft-lbf)
5BUORX-038
FRONT SUSPENSION
--- .- -
FRONT STABILIZER BAR (4x2 AND 4x4)

3. Remove the nuts and bolts attaching the stabilizer bar to the end links.
1. Washer 4. Stabilizer bar

2. Stabilizer bracket lnstallation Note .............................. below
3. Bushing
lnspect for damage and cracks
lnstallation note
Stabilizer bar
1. Install the stabilizer bracket.
Tightening torque:
30-40 N.m (3.04.1kgf-my22-40 ft-lbf)
2. Install the end link nuts.
Tightening torque:
40-55 N .m (4.2-5.6 kgf .my3 0 4 0 ft .Ibf)
6BUORX-018
FRONT SUSPENSION
JOUNCE BUMPER (4x2)
e
Removal / Inspection l lnstallation
I LH JOUNCE BUMPER RH JOUNCE BUMPER N.m {kgf.m, ft.lbfl
1. Hex bolts
Installation Note .............................. below
2. Jounce bumper
Removal note
Hex bolts
Remove the hex bolts with a 10mm hex socket.
4BUORX-047
lnstallation note
Hex bolts
Install the hex bolts with a 10mm hex socket.
Tightening torque:
RH: 18-26 N - m (1.8-2.6 kgf em, 13-19 ft-Ibf)
LH: 24-36 N .m (2.5-3.5 kgf .m, 118-26 ft .Ibf)
JOUNCE BUMPER (4x4)
5, Install in the reverse order of removal, referring to lnstallation Note.
LH JOUNCE BUMPER RH JOUNCE BUMPER
N-m (kgfm, ft-lbf)
MR1081-A 5BUORX-048
1. Hex bolffnut
2. Jounce bumper
Removal note
Hex boltlnut
Remove the hex bolts with a 10mm hex socket.
5BUORX-049
lnstallation note
Hex boltlnut
Install the hex bolts with a 10mm hex socket.
Tightening torque:
25-35 N-m (2.5-3.5 kgf-m,18-25 ft~lbf)
5BUORX-050
REAR SUSPENSION
REAR SUSPENSION
REAR SHOCK ABSORBER
Removal I Inspection 1 lnstallation
Caution
The low pressure gas shock absorbers are charged with nitrogen gas to 930 kF'a (9.45 kgf/cm2,
135 psi). Do not attempt to open, puncture or apply heat to the shock absorber.
1. Jack up the rear of the vehicle and support it on safety stands.

2. Remove the rear wheels.
3. Remove the shock absorber lower attaching nut and bolt, and swing the lower end free of the mounting
bracket on the axle housing.
4. Remove the attaching nut from the upper mounting bolt. Remove the shock absorber.
I v
MR1034-C
1
N.m {kgf.m, ft.lbf)
6BUORX-020
1. Washer
2. Shock absorber
Inspection ........................................ below
lnspection
Shock absorber
Note
The shock absorber is non-adjustable and non-
refillable and cannot be repaired.
REAR SUSPENSION
1. Check that the shock absorber is properly installed and
not damaged or worn. Replace if necessary.
Note
Make sure the part number of the replacement is the
same as that of the original shock absorber.
2. Replace the shock absorber if there are excessive fluid

leaks. A light film of fluid on the upper position of the shock
absorber body is permissible.
3. Check the action of the shock absorber by compressing it.
If the shock fails to extend itself when compressed, it is an
indication of a seal malfunction and the shock should be
replaced.
4. If a shock absorber is suspected of being weak, compare
the compression results with the opposite side. If the
action is similar, it is unlikely that either shock absorber is
worn or damaged.
5. Replace the shock absorber if there is a lag or skip
occurring near the midstroke of the shaft's reverse travel
direction.
6. Replace the shock absorber if there is any seizing during
the shaft's full travel, except at either end of travel.
7. Replace the shock if during the shaft's fast, reverse stroke
there is any noise other than a faint swish, such as a
clicking sound.
5BUORX-041
Installation note
Shock absorber
Install the shock absorber nuts.
Tightening torque:
53-72 N-m(5.4-7.3 kgf.m, 39-53 ftelbf)
4BUORX-051
REAR SUSPENSION
LEAF SPRING
Removal I Inspection 1 Installation
PLATE
is f6 BE
INSTALLED WITH
THE
FLANGES
UPTURNED
FORWARD Gfi
AND AFT AS SHOWN)
%$
.-
1
(4x21
88-1 18
(9.0-1 2.0,
65--87)
PLATE
(U-BOLT PLATE IS
TO BE INSTALLED
WlTH THE UPTURNED
FLANGES FORWARD
AND AFT AS SHOWN)
REAR SUSPENSION
1. U-bolts 3. Tip liner (not shown)
Removal Note ................................. below Installation Note .............................. below
2. Leaf spring 4. Service clip (not shown)
Installation Note ..................... page R-37 Installation Note .............................. below
Inspection ........................................ below
Removal note
U-bolts
Remove the U-bolts by driving them from the U-bolt plate.
4BUORX-053
Inspection
Leaf spring
1. Check for a squeaking condition at the rear leaf springs.
Determinewhether the squeak is caused by the spring or
the shackle bushings. Replace as necessary.
2. Install the spring tip liners if the spring is the cause of the
squeak.
3. If the original spring clip is damaged during removal,
install a new leaf spring service clip.
4BUORX-054
lnstallation note
Tip liner
1. Bend the spring clip to provide clearance between the
spring leaves, allowing insertion of the liners. A pry-bar
may be used between the leaves to provide additional
clearance for insertion of the liners.
2. Slide the liner between the leaves until the liner extends
approximately 6.35mm (0.25 in) beyond the tip of the
lower leaf.
Note
Do not attempt to install the liner between the
lowest primary leaf and the short 12.70mm (0.50 in)
thick secondary leaf, found at the bottom of the leaf
stack on some assemblies.
3. Set the rear axle casing on a stand to load the rear leaf
springs. Contact the leaves at the clip locations.
4. Reinstall the production clips or install a replacement
service clip.
Note
On some tip liners, sections of the edge used to
center the liner on the spring leaves may need to be
trimmed off to accommodate the spring clip.
43BUORX-055
I I Service clip
Note
I The spring leaves should contact at the clip
location.
1. Remove the damaged clip by prying back the ends of the

clip which are folded across the leaf spring until the clip
can be freed from the spring. On some clips it is necessary
to pry the locating pin out of the locating hole.
2. Make sure the locating hole is clean and free of debris.
4
REAR SUSPENSION
3. Position the lower part of the service clip across the width
of the underside of the spring, so that the clip holes align
with the locating holes in the spring. The legs of the lower
half of the clip should extend down frorn the bottom of
the spring.
4. Insert the drive rivet that comes with the clamp through the
hole in the lower service clip and the hole in the spring leaf.
The flat face of the rivet flange should rest against the clip
lower half.
5. Fully seat the rivet with a hammer.
Note
If there is not enough room to hit the rivet directly
with a hammer, a punch may be used.
6.The slotted legs of the clip lower half should extend

downward, so that the outer surface of the legs is flush with
the leaf spring sides.
7. Place the rubber service clip liner across the top of the leaf
spring. Align the lower clip with the flat surface against the
leaf and the clip locating edges extending upward.
8. Place the clip upper half between the locating edges of the
rubber liner.
9. Align the threaded holes in the clip upper half with the
lower clip slots.
10. Hand start the two screws, through the clip lower half slot,
into the clip upper half threaded hole.
Note
The screw heads will be located under the spring,
ultimately pressing against the clip lower half.
11.Squeeze the clip to the spring with one hand while

tightening the screws.
Tightening torque:
21-27 N-m (2.1-2.7 kgf-m, 15-20 ft-lbf}
Leaf spring
Install the U-bolts through the plate and .tightenthe nuts.
Tightening torque:
88-1 18 N.m (9.0-1 2.0 kgf-m, 65-07 ft-lbf)
5BUOP.X-043
REAR SUSPENSION
REAR STABILIZER BAR
N.m (kgfm, ft.lbf)
MR1041-C 5BUORX-044
1. Mounting bracket 3. End link
2. Retainer 4. Stabilizer bar
Inspect bushing for damage and cracks Installation Note ..............................below
lnstallation note
Rear stabilizer bar
1. Install the mounting bracket U-bolt nuts.
Tightening torque:
3 4 4 6 N.m (3.5-4.7 kgfam, 25-34 ft-lbf)
2. Install the end link nuts.
Tightening torque:
6 0 - 4 0 N.m (6.1-43.1 kgf-m, 44-59 ft-lbf)
5BUORX-045
BODY
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPLASH SHIELDS . . . . . . . . . . . . . . . . . S-32
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT . . . . . . . . . . . . . . . . . . . . . . . . . S-32
COMPONENTS . . . . . . . . . . . . . . . . . . REAR . . . . . . . . . . . . . . . . . . . . . . . . . . S-33
FENDER PANEL . . . . . . . . . . . . . . . . . . . WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . S-34
COMPONENTS . . . . . . . . . . . . . . . . . . COMPONENTS . . . . . . . . . . . . . . . . . . S-34
FRONT DOOR . . . . . . . . . . . . . . . . . . . . . REAR WINDOW GLASS . . . . . . . . . . . . S-37
WEATHERSTRIPS . . . . . . . . . . . . . . . . . TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-40
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . FLOORMATICARPET . . . . . . . . . . . . . . S-45
COMPONENTS . . . . . . . . . . . . . . . . . . HEADLINER . . . . . . . . . . . . . . . . . . . . . . S-47
FUEL-FILLER LID . . . . . . . . . . . . . . . . . . SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . S-49
COMPONENTS . . . . . . . . . . . . . . . . . . FRONT SEAT . . . . . . . . . . . . . . . . . . . S-49
FRONT BUMPER . . . . . . . . . . . . . . . . . . REAR SEAT . . . . . . . . . . . . . . . . . . . . . S-52
COMPONENTS . . . . . . . . . . . . . . . . . . BOX . CAB AND BOX ALIGNMENT . S-54
REAR BUMPER . . . . . . . . . . . . . . . . . . . ADJUSTMENT . . . . . . . . . . . . . . . . . . . 5-54
COMPONENTS . . . . . . . . . . . . . . . . . . SPARE TIRE STOWAGE . . . . . . . . . . . . S-56
RADIATOR GRILLE . . . . . . . . . . . . . . . . COMPONENTS . . . . . . . . . . . . . . . . . . S-56
COMPONENTS . . . . . . . . . . . . . . . . . . SPARETIRE . . . . . . . . . . . . . . . . . . . . . . S-58
EXTRACTOR CHAMBER . . . . . . . . . . . COMPONENTS . . . . . . . . . . . . . . . . . . S-58
COMPONENTS . . . . . . . . . . . . . . . . . . BODY DIMENSIONS . . . . . . . . . . . . . . . . . S-59
DASHBOARD . . . . . . . . . . . . . . . . . . . . . SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-62
COMPONENTS . . . . . . . . . . . . . . . . . . BENCH SEAT . . . . . . . . . . . . . . . . . . . S-62
CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . MANUAL BUCKET SEAT . . . . . . . . . S-64
COMPONENTS . . . . . . . . . . . . . . . . . . SIX-WAY POWER BUCKET
MOLDING . . . . . . . . . . . . . . . . . . . . . . . . . SEAT . . . . . . . . . . . . . . . . . . . . . . . . . S-66
COMPONENTS . . . . . . . . . . . . . . . . . . LUMBAR SUPPORT PAD . . . . . . . . . S-68
JUMPSEAT . . . . . . . . . . . . . . . . . . . . . S-69
SEAT BRACKET . . . . . . . . . . . . . . . . . S-70
SPLIT BENCH SEAT . . . . . . . . . . . . . S-71
BOX LEAN . . . . . . . . . . . . . . . . . . . . . . . . S-72
BOX SHIMMING . . . . . . . . . . . . . . . . . . . S-73
TROUBLESHOOTING GUIDE . . . . . . . S-74
7BUOSX-017
s INDEX
INDEX
I I
MS1000-C 5BUOSX-062
1. Hood 6. Dashboard
Removal I Installation ............. page S- 4 Removal / Installation ............. page S-26
Adjustment ............................. page S- 7 7. Windshield
2. Fender panel Removal I Installation ............. page S-34
Removal I Installation ............. page S- 9 8. Trim
3. Front door Removal I Installation ............. page S-40
Removal / Installation ............. page S-11 9. Weatherstrips
4. Radiator grille Removal / Installation ............. page 5-14
Removal I Installation ............. page S-23
5. Front bumper
Removal I Installation ............. page S-18
INDEX
MS1001-C 5BUOSX-063
1. Tailgate 6. Headliner (not shown)
Removal / Installation ............. page S-15 Removal / Installation ............. page S-47
2. Rear bumper 7. Floormat/carpet (not shown)
3. Fuel-filler lid 8. Splash shields (not shown)
4. Molding
Removal / Installation ............. page S-30
5. Rear window glass
Removal / Installation ............. page S-37
Note
When the battery has been disconnected and reconnected, some abnormal driving symptoms
may occur while the powertrain control module relearns its adaptive strategy. 'The vehicle may
4BUOSX-004
HOOD
HOOD
COMPONENTS
2. Open the hood and prop the hood in the open position.
3. Cover the cowl area to prevent paint damage.
HOOD s
1. Hood 3.1-ock assembly
Removal Note ................................. below Removal Note ................................. below
Adjustment ............................. page S- 7 Adjustment ............................. page S- 8
Installation Note ..................... page S- 7 Installation Note ..................... page S- 6
2. Hood hinges 4. Release cable
Removal Note ................................. below Removal Note ........................ page S- 6
Installation Note ..................... page S- 7 Installation Note ..................... page S- 6
Removal Note
Hood
1. Mark the hinge-to-hood location.
2. Disconnect the hood light harness connector and remove
the wiring from the hood.
3. Remove the hood light.
4. Remove the hood insulator.
5. With the aid of an assistant, hold the hoold and remove the
hinge-to-hood bolts.
6. Remove the hood.
- Hood hinges
X-OC
Each hood hinge has four spot welds securing it to the
vehicle. Drill out the four spot welds from each hinge and
remove the hinges.
4BUOSX-007
Lock assembly
1. Scribe marks on the radiator support to facilitate installa-
tion of the lock assembly.
2. Remove the bolts from the lock assembly.
I'
MS1004-A
3. Remove the bolt and the release cable from the lock
assembly.
,-
HOOD
Release cable
1. Remove the bolts and the release cable handle from the
dashboard.
2. Remove the bundling strap which holds the cable to the
steering column support bracket.
3. Remove the cable bushing from the dashboard; access it
from the inside of the vehicle.
4. From the inside of the vehicle, pull the release cable
through the dashboard.
I
5BUOSX-030
Installation Note
Release cable
1. Install the release cable into position; install it from the
inside of the vehicle.
2. Install the release cable bushing to the dashboard; install
it from the inside of the vehicle.
3. Secure the release cable to the steering column support
bracket with the bundling strap.
4. Install the release cable to the dashboard.
Tightening torque:
2.0-4.5 N . m (21-44 kgf ecm, 18-39 in Ibf)
Lock assembly
1. Position the lock assembly and install the bolts, but do not
tighten them fully.
2. Connect the release cable to the lock assembly.
Tightening torque:
1.8-2.6 N-m (18-26 kgf-cm, 15-23 in-lbf)
3. Adjust the lock assembly for positive engagement with the

hood lock striker. (Refer to page S-8.)
4. Tighten the lock assembly bolts to the specified torque.
Tightening torque:
9-11 4 N . m (93-1 42 kgf .cm, 80-1 24 in. Ibf)
HOOD
5. Lubricate the lock handle pivot, the catch pawls and the
spring with NLGl No. 2 grease.
6. Check the functional operation of the lock assembly and
the safety latch. Open and close the hood several times to
make sure the alignment is correct and that the grease has
effectively worked into the pivot points and bearing sur-
faces.
Hood hinge
1. Drill two 8.6mm (13132 in) holes in the top front surface of
the cowl on each side of the hinge (drill dimple provided).
lnstall two J-nuts to the hinge area on the cowl.
2. lnstall the hinge.
3. lnstall the bolts.
Tightening torque:
7-10 N.m (0.7-1.1 kgf-m, 5-43 ft-lbf)
4BUOSX-012
Hood
I . lnstall the hood light.
2. lnstall the hood insulator.
3. With the aid of an assistant, positionthe hoodto the hinges
and install the bolts.
Tightening torque:
7-10 N-m (0.7-1.1 kgf-m, 5-43 ft-lbf)
4. lnstall the hood light wiring and connect the harness

connector.
5. Close the hood and check both the hood and lock assem-
bly alignment. If necessary, adjust the hood alignment
and/or the lock assembly. (Refer below and/or S-8.)
5BUOSX-072
Adjustment
Hood
1. Verify that the hood can be closed easily and that there is
no looseness.
Clearance
(1): 3.0-7.0mm (0.12-0.27 in)
(2): 3.0-7.0mm (0.12-4.27 in)
(3): 13.0mm (0.512 in)
Flushness
I I
MS1071-A 4BUOSX-014 (2): k 2.0mm (0.078 in)
2. If not as specified adjust the hood by loosening the hood-

to-hinge bolts and repositioning the hood.
Tightening torque:
7-1 0 N-m(0.7-1.1 kgf-m, 5-8 ft.lbf)
HOOD
Lock assembly
e
1. Loosen the lock assembly bolts just enough to allow the
lock assembly to be moved.
2. Move the lock assembly until it is aligned with the hood
lock striker and tighten the bolts to the specified torque.
Tightening torque:
10.5-1 3.5 N .m (1.1 -1.3 kgf .m, 8-1 0 ft Ibf}
3. Check the lock assembly to make sure it makes full

engagement with the hood lockstriker. Repeat the adjust-
ment procedure until the hood lock striker and the lock
assembly are properly aligned.
6BUOSX-005
FENDER PANEL
FENDER PANEL
COMPONENTS
1. Clean all the dirt from the fender panel bolts.
2. Remove the radiator grille. (Refer to page S-23.)
N-m (kgf.m, ft-lbf)

MS1008-B 4BUOSX-016
1. Splash shield 3. Brace
Installation Note ..................... page S-10 Installation Note ..................... page S-10
2. Fender panel
Installation Note ..................... page S-10
Inspection ............................... page S-10
s FENDER PANEL
Installation Note
Brace
Install the brace.
Tightening torque:
10.8-1 3.5 N-m(1 .l-1.3 kgfem, 8-1 0 ft-lbf)
4BUOSX--017
Fender panel
1. Install the fender panel.
2. Install the fender panel bolts, but do not tighten them fully.
3. Align the fender panel before tightening the bolts.
Tightening torque:
10.8-13.5 N.m (1.I-1.3 kgf.m, 8-10 ft-lbf)
4BUOSX-018
Splash shield
Install the splash shield.
Tightening torque:
10.8-13.5 N.m (1.l-1.3 kgf-m, 8-10 ft.lbf)
FENDER Inspection
Fender panel
1. lnspect the clearance between the fender panel and the
A
GRILLE hood.
FRONT PARKING
AND SIDE Clearance (1): 3.0-7.0mm ( 0 . 1 2 4 . 2 7 in)
MARKER LIGHT
2. lnspect the clearance and the flushness between the

fender panel and the front door.
Clearance (2): 3.5-6.5mm (0.138-4.255 in)

Flushness (2): k 2.0mm (0.078 in)
3. lnspect the distance between the fender panel and the

radiator grille.
Clearance (3): 0.5-2.5mm ( 0 . 0 2 4 . 0 9 in)

FRONT DOOR
FRONT DOOR
COMPONENTS
2. Disconnect the harness connector.
4. Remove the door lock striker.
N.m (kgf-m, ftalbf)

I I
MS1011-A 4BUOSX-021
1. Front door 2. Door hinge
Removal Note ................................. below Removal Note ........................ page S-12
Adjustment ............................. page S-13
11 LOWER DOOR Removal Note

Front door
1. Remove the upper and lower hinge access hole cover
plates, if equipped, and mark the location of each hinge on
the door.
2. Support the door.
3. Remove the front door-to-lower hinge bolts.
s FRONT DOOR
4. Remove the front door-to-upper hinge bolts.
5. Remove the front door.
MS1013-A 4BUOSX-022
Door hinge
1. Mark the location of each hinge on the body.
2. Remove the hinge.
4BUOSX-023
Installation Note
Door hinge
Install the door hinge.
Tightening torque:
25-34 N.m (2.5-3.5 kgf.m, 18.4--25.8 ftelbf)
4BUOSX-024
Front door
Install the front door
Tightening torque:
25-34 N-m (2.5-3.5 kgf-m, 18.4--25.8 ft-lbf)
4BUOSX-025
FRONT DOOR s
Adjustment
Front door
1. Verify that the front door can be closed easily and that
there is no looseness.
2. Inspect the clearance and the flushness betweenthe front
door and the fender panel.
Clearance (1): 3.5--6.5mm (0.1 38-4.255 in)

+
Flushness (1): 2.0mm (0.078 in}
\3/- ' 3. lnspect the clearance betweenthe front door and the roof.
LOWER BODY
MS1073-A
Clearance (2): 2.5-7.5mm (0.09-4.29 in)
4. lnspect the clearance and the flushness between the

front door and the lower body.
Clearance (3): 3.0-9.0mm (0.12-4.35 in)

Flushness (4): 5.0mm (0.19 in}
5. lnspect the clearance between the front door and the

B-pillar.
Clearance (5): 2.5--6.5mm (0.094.25 in}

6. lnspect the underflush of the front door to the A-pillar from
point X to point Y (refer to the figure).
Underflush (6): 1.0-5.0mm (0.04-4.1 9 in)
7. If the door is not adjusted properly, loosen the front door-

to-hinge bolts and nuts just enough to permit movement of
the door. Adjust the door with a padded pry bar.
8. Tighten the door hinge bolts and nuts to the specified
torque.
4.0mm (0.157 IN.) Tightening torque:
25-34 N.m (2.5-3.5 kgf-m, 18.4--25.8 ft-lbf}
Door lock striker
1. Clean the latch jaws and the striker area.
2. Apply a thin layer of dark grease to the lock striker.
3. As the door is closed and opened, a measurable, visual
pattern will result.
4. Move the striker assembly laterally to provide a flush fit
PILLAR
- - - - - -;--L--- with the door and body.
CAUTION
Do not use more than one shim per door.
5. Tighten the striker.
Tightening torque:
33-45 N -m (3.4-4.5 kgf. m, 24-33 ft- lbf)
6BUOSX-006
s WEATHERSTRIPS
WEATHERSTRIPS
COMPONENTS
2. Remove the quarter window (movable) weatherstrip, referring to Removal Note. (Refer to below.)
I
MSlO14-B 4BUOSX-027
1. Front door lower weatherstrip
2. Front door opening weatherstrip
3. Roof side rail weatherstrip
QUARTER WINDOW Removal Note

Quarter window (movable) weatherstrip
(Cab Plus only)
1 . Open the latch.
2. Remove the latch.
3.Remove the hinges.
4. Remove the quarter window assembly.
5. Pull the weatherstrip loose and remove.
TAILGATE
TAILGATE
COMPONENTS
I - I
MSlOl5-A 6BUOSX-007
1. Tailgate 2. Tailgate striker
Removal Note ................................. below 3. Tailgate hinge
Installation Note ..................... page S-16 4. Support cable
Inspection ............................... page S-16
Removal Note
Tailgate
1. Open the tailgate.
2. Partially close the tailgate to relieve tension on the support
cables.
3. Pull up on the cable retainer spring and slide the cable
retainer to the large opening in the hook and lift it off.
Repeat this procedure for the other cable.
4. Pull the right side of the tailgate rearward to remove it from
the right hinge.
5. Move the tailgate to the right to remove it from the left
hinge.
4BUOSX-030
TAILGATE
Installation Note
Tailgate
1. If a new tailgate is being installed, transfer all moldings,
latches, hinges, brackets, cables, links, clips, washers
and all remaining hardware to the new tailgate.
2. Lubricate each hinge cup with NLGl No. 2 grease.
3. Insert the left side of the tailgate into the left hinge and
raise it to a 4S0 angle; next insert the right side into the
right hinge.
4. Support the tailgate to allow slack in the support cables
and reattach the cables one at a time.
4BUOSX-031
Inspection
Tailgate clearances
I . lnspect the clearance between the tailgate and the rear
bumper cover.
Clearance (1): 13.0-25.0mm (0.51-4.98 in)
2. lnspect the clearance between the tailgate and the tail

light molding.
I SEC. A-A SEC.&B I Clearance ( 2 ) :3.0-9.0mm (0.12-4.35 in)
3. lnspect the clearance between the quarter panel and the

top, bottom and the forward portion of tail light molding.
Clearance (1): 0.0--0.3mm (0.0-4.12 in)

FUEL-FILLER LID
FUEL-FILLER LID
COMPONENTS
1 I
MS1016-A 4BUOSX-033
1. Fuel-filler lid
lnspection ........................................ below
2. Fuel-filler lid spring
Inspection
Fuel-filler lid
Inspect the clearance and the flushness of the fuel-filler
lid.
Clearance (1): 2.0-4.0mm (0.078-0.15 in)

Flushness (1): 0.5mm outboard-1.5mm inboard
(0.02 in outboard--0.05 in inboard)
s FRONT BUMPER
FRONT BUMPER
COMPONENTS
Removal Iinstallation
2. Install in the reverse order of removal, referring to installation Note.
8
N.m (kgf-m, ftalbf)
MSlOl7-A 4BUOSX-035
1. Front bumper Inspection ............................... page S-19
Removal Note ................................. below Disassembly / Assembly ........ page S-19
Removal Note
Front bumper
1. Support the front bumper.
2. Remove the four front stud plate-to-frame nuts.
3. Disconnect each turn signal light harness connector.
4. Remove the front bumper.
4BUOSX-036
Installation Note
Front bumper
Align the bumper in the desired position before tightening
the stud plate-to-frame nuts to the specified torque.
Tightening torque:
87.5-1 18.5 N-m (9.0-1 2.0 kgf.m, 64.5-437.4
ft-lbf)
4BUOSX-037
FRONT BUMPER
RADIATOR
Inspection
GRILLE Front bumper
1. Inspect the clearance between the front bumper cover
and the fender panel.
F Clearance (1): 20.8-32.8mm (0.82-1.29 in)
B
2. lnspect the clearance between the front bumper and the

radiator grille.
SEC. 6-B SEC. A-A Clearance (2): 19.8-31.8 (0.78-1.25 in)

MS1075-A 4BUOSX-038
I
MS1018-C 5BUOSX-005
1. Stud plates 3. Turn signal light housing
Disassembly Note .................. page S-20 Disassembly Note .................. page S-20
Assembly Note ....................... page S-20
2. Valance panel
Disassembly Note .................. page S-20
Assembly Note ....................... page S-20
s FRONT BUMPER
Disassembly Note
Stud plates
Remove the stud plates from the front bumper.
40UOSX-040
Valance panel
Remove the valance panel from the front bumper.
4BUOSX-041
Turn signal light housing

Remove the turn signal light housing from the valance
panel.
4BUOSX 042
Assembly Note
Valance panel
Install the valance panel.
Tightening torque:
3.04.0 N-m(30.6--40.6 kgfzm, 26.6-35.4 in4bf)
5BUOSX-006
Stud plates
Install the stud plates
Tightening torque:
87.5-1 18.5 N-m(9.0-1 2.0 kgf-m,
64.5-47.4 ft.lbf)
5BUOSX-007
FRONT CHROME BUMPER STRIPE

1. Remove the front grille.
2. Remove any residual pieces of the bumper stripe.
Note
Use heat gun to soften the stripe during removal.
Caution
Avoid scratching the chrome surface of the bum-
per when removing the stripe.
3. Remove the adhesive residue.
ALIGN NOTCH IN PAPER Caution
WITH PLASTIC MOLDING Use 3M Citrus Cleaner to remove any residual
ON BUMPER adhesive. Avoid spraying Citrus Cleaner on the
bumper corner cover.
4. Combine rubbing alcohol and tap water in a 50150 mix-
ture. Then, apply mixture to surface of bumper.
5. Peel the stripe liner and position the stripe on the bumper
using the locator tabs.
6. Starting at the center, squeegee the stripe back to front
using light strokes. From the center, squeegee the stripe
left and right with film overlapping strokes.
7. Peel the top liner off and lightly squeegee excess water
off.
REAR BUMPER s
REAR BUMPER
COMPONENTS
I -- I
MSlO19-C 5BUOSX-008
1. Rear bumper Inspection ...................................... below
Removal Note
Rear bumper
1. Support the rear bumper.
2. Remove the rear bumper inner arm-to-frame bolts.
3. Remove the rear bumper.
lnstallation Note
Rear bumper
Install the rear bumper.
Tightening torque:
1 1 3.0-1 53.0 N-m{I1.6-1 5.6 kgf-m,
83.4--112.8 ft-lbf}
I
5BUOSX-010
lnspection
Rear bumper
1. lnspect the clearance between the rear bumper cover and
the tailgate.
Clearance (1): 13.0-25.0mm (0.51-0.98 in)
2, Inspect the distance between the rear bumper and the

quarter panel.
Clearance (2):13.0-25.0 mm (0.51-0.98 in)

S-21
s REAR BUMPER
MSi020-B
_I
5BUOSX-Oil
1. Rear bumper outer arm 2. Rear bumper inner arm

Assembly Note ................................ below Assembly Note ................................below
Assembly Note
Rear bumper inner arm
Install the rear bumper inner arm.
Tightening torque:
11 3.0-153.0 N-m(1 1 .&I 5.6 kgf-rn,
83.4-1 12.8 ft-lbf)
Rear bumper outer arm

Install the rear bumper outer arm.
Tightening torques:
11 3.0-1 53.0 N-m (11.6-1 5.6 kgfem,
83.4--112.8 ft-lbf)
3 4 4 6 N.m (3.4--4.6kgf-m,25-33.9 ft-lbf)
5BUOSX-013
RADIATOR GRILLE
RADIATOR GRILLE
COMPONENTS
I .Remove in the order shown in the figure, referring to Removal Note.
I
MS1021-B 4BUOSX-052
1. Radiator grille Inspection ............................... page S-24
Installation Note ............................... below 2. Radiator opening cover (if equipped)
Removal Note
Radiator grille
2. Raise the radiator grille slightly, tilt the top forward and
remove the grille.
4BUOSX-053
lnstallation Note
Radiator grille
Install the radiator grille.
Tightening torque:
1.6-2.2 N-m(1 6.2-22.3 kgf-cm, 14.1-1 9.4 in-lbf)
4BUOSX-054
RADIATOR GRILLE
Inspection
1 RADIATOR GRILLE RADIATOR Radiator grille
1. lnspect the clearance between the radiator grille and the
FRONT PARK1
top and bottom of the headlamp.
AND SlDE
MARKER Clearance (1): 0.5-8.5mm (0.024.33 in)
LIGHT
RADIATOR
GRILLE
SEC. C-C 7 top and the bottom of the front parking and side marker
light assembly.
FRONT PARKING AND
SlDE MARKER LIGHT Clearance (2): 3.0-7.0mm ( 0 . 1 2 4 . 2 7 in)
RADIATOR
GRILLE SEC. A-A
inboard side of the headlamp.
Clearance (3): 0.0-13.5mm (0.0-4.53 in)

outboard side of the front parking and side marker light
assembly.
I SEC. B-B
Clearance (4): 3.0-7.0mm (0.12-4.27 in}

hood.
Clearance (5): 13.0mm (0.512 in)

RADIATOR front bumper.
GRILLE
FENDER
Clearance (6): 19.8-31.8mm (0.78-1.25 in)
PANEL
FRONT
0 RADIATOR 0
fender panel.
wMPER GRILLE
FRONT PARKING A \ Clearance (7): 0.5-2.5mm (0.024.98 in)
J AND SlDE MARKER
SEC. B-B LIGHT SEC. A-A
RADIATOR GRILLE, EXTRACTOR CHAMBER
I I
MSl022-A 4BUOSX-056
1. Deflector
EXTRACTOR CHAMBER
COMPONENTS
I - I
MS1023-B 5BUOSX-032
1. Front door trim 2. Extractor chamber
Removal 1 Installation ............. page S-42
s DASHBOARD
DASHBOARD
COMPONENTS
2.1-2.8 N -m {21-28 kgf cm, {21-28 kgf cm,

18-26 in Ibf) 18-26 in. Ibf)
I 2
MS1092-B 7BUOSX-033
1. Center finish panel 4. Cluster finish panel
Installation Note ..................... page S-28 Installation Note . . . . . . . . . . page S-28
2. Steering column opening cover 5. Instrument cluster (Refer to 1997 BETM)
Removal Note ........................ below 6. Ash receptacle
Installation Note ..................... page S-28 Installation Note . . . . . . . . . . . . page S-28
3. Steering column opening reinforcement 7. Passenger air bag deactivation (PAD) switch
Installation Note ..................... page S-28 (if equipped) (Refer to 1997 BETM)
8. Glove compartment
Installation Note . . . . . . . . . . . . page S-28
9. Passenger side air bag module
(if equipped) (Refer to 1997 BETM)
10. Dashboard
Removal Note . . . . . . . . . . . page S-26
Installation Note . . . . . . . . . . page S-27
Removal Note
Steering Column Opening Cover
Remove two screws and pull cover straight out to release
clips.
Dashboard
1. Remove power distribution box from bracket and move
aside. GBUOSX 01 5
DASHBOARD
2. Disconnect three gang bulkhead connectors in engine
compartment next to vacuum booster.
3. Remove the hood release cable handle from the dash-
board.
4. Remove the bolts retainingthe parking brake assembly to
the lower left corner of the dashboard.
5. Move manual shift transfer case to 4Lor manual transmis-
sion shift lever to 2, 4 or R position, if necessary.
6. Remove bolt at right of accelerator pedal from bracket.
7. Open fuse panel cover and remove two bolts retaining
dashboard to A-Pillar beam.
MSIO~~-A ~BUOSX-035 8. Remove right-hand front side trim.
9. Remove one bolt from lower right-hand dashboard.
10. Remove defroster grille by lifting edge of grille with flat
wooden dowel to disengage clips and tabs.
11. Open glove box and disconnect radio antenna connector.
12. Disconnect three electrical connectors and ground strap
at lower right-hand dashboard area.
13. Remove lower steering column pinch bolt.
14. Disconnect Brake On/Off (BOO) switch connector.
15. Remove three bolts and two screws from top of dash-
board. Pull dashboard towards you.
16. Disconnect gang electrical connector from rear of I/P.
17. Remove the dashboard.
18. If installing a new dashboard, transfer all remaining com-
ponents to the new dashboard.
Installation Note
Dashboard
1 . Position dashboardand tighten three bolts and two screws
to top of dashboard.
Tightening torque:
Bolts to:
27-33 N.m (2.8-3.4 kgfem, 20-25 ft-lbf}
Screws to:
10-14 N.m {I .I-1.38 kgf-m, 7-10 ft.lbf)
5BUOSX-036
2. Tighten lower steering column pinch bolt.
Tightening torque:
40-54 (4.2-5.4 kgf-m, 30-40 ft-lbf)
3. Tighten lower right-hand dashboard bolt.
Tightening torque:
26-34 (2.7-3.4 kgfam, 20-25 ft-lbf)
4. Tighten bolt to bracket at right of accelerator pedal.
Tightening torque:
40-54 (4.2-5.4 kgf-m, 3 0 4 0 ft.lbf}
5BUOSX-037
s DASHBOARD
Glove compartment
lnstall the glove compartment.
Tightening torque:
2.1-2.8 N.m (21-38 kgfecm, 18-26 in-lbf)
5BUOSX-038
Ash receptacle
lnstall the ash receptacle.
Tightening torque:
2.1-2.8 N-m (21-38 kgf-cm, 18-26 indbf)
5BUOSX-039
Cluster finish panel

lnstall the cluster finish panel.
Tightening torque:
2.1-2.8 N.m (21-38 kgfecm, 18-26 in.lbf)
5BUOSX.040
Steering column opening reinforcement

lnstall the steering column opening reinforcement.
Tightening torque:
10.8-13.56 N.m (1 .l-1.38 kgfem, 8-10 ft.lbf}
5BUOSX 041
Steering column opening cover

lnstall the steering column opening cover
Tightening torque:
2.1-2.8 N.m (21-38 kgf.cm, 18-26 in-lbf)
5BUOSX..O42
Center finish panel

lnstall the center finish panel.
Tightening torque:
2.1-2.8 N-m (21-38 kgf.cm, 18-26 invlbf)
5BUOSX-043
CONSOLE
CONSOLE
COMPONENTS
TO FRONT OF VEHICLE
N.m (kgf.m, ft-lbf)

I
MS1026-B 5BUOSX-064
1. Armrest 3. Console
lnstallation Note .............................. below Installation Note .............................. below
2. Cupholder 4. Console mounting bracket
lnstallation Note .............................. below Installation Note .............................. below
lnstallation Note
Console mounting bracket
lnstall the console mounting bracket.
Tightening torque:
7-1 1 N.m (0.7-1.1 kgf-my5.1-4.0 ft-lbf}
4BUOSX-065
Console
Install the console.
Tightening torque:
2.0-3.9 N-m (27-39 kgfacm, 18-35 inelbf)
4BUOSX-066
Cupholder
lnstall the cupholder.
Tightening torque:
2.0-3.9 N-m(27-39 kgfecm, 18-35 in4bf)
4BUOSX-067
Armrest
Install the armrest.
Tightening torque:
9-1 4 N-m (91-1 42 kgf.cm, 80-1 24 indbf)
4BUQSX-068
s MOLDING
MOLDING
COMPONENTS
REGULAR CAB
CAB PLUS
L 1
MS1027-C 5BUOSX-065
1. Wheel opening moldings 3. Quarter window (stationary) molding
Removal Note ........................ page S-31 Removal Note ........................ page S-31
2. Front door belt line moldings 4. Roof side molding
Removal Note ........................ page S-31 Inspection ............................... page S-31
MOLDING
Removal Note
Wheel opening moldings
Remove the wheel opening moldings.
Front door belt line moldings
1. Lower the glass to the full down position.
2. Unsnap and remove the belt line moldings from the door.
4BUOSX-071
Quarter window (stationary) molding

b
TO FRONT OF VEHICLE
1. Remove the necessary interior trim from around the
window to gain access to the quarter window nuts.
MS1029-C 5BUOSX-044 2. Remove the quarter window nuts.
3. Remove the molding.
4BUOSX-072
Installation Note
Quarter window (stationary) molding
I . Install the molding.
2. Tighten the quarter window nuts.
Tightening torque:
1-1.9 N.m (10.2-20.3 kgf-cm, 8.8-1 7.7 inelbf)
4BUOSX-073
Wheel opening moldings

Install the wheel opening moldings.
I TO FRONT OF VEHICLE
I
Inspection
Roof side molding
Inspect the clearance between the roof side molding and
the roof panel.
Clearance (1): 4.5mm (0.17 in)
SEC. A-A
MS1079-B 4BUOSX-075
SPLASH SHIELDS
SPLASH SHIELDS
FRONT
1. Front wheel opening splash shield

lnstallation Note ..................... below
lnstallation Note
Front wheel opening splash shield
Install the front wheel opening splash shield bolts
Tightening torque:
10-1 3.5 N.m (1.0-1.3 kgf.m, 7.3-9.9 ft.lbf)
4BUOSX-080
SPLASH SHIELDS
REAR
MSI 035-A
- I 4BUOSX-081
1. Rear wheel opening splash shield
lnstallation Note .............................. below
lnstallation Note
Rear wheel opening splash shield
Install the rear wheel opening splash shield.
Tightening torque:
17-26 N-m(1.8-2.7 kgf-m, 1 2 . S 1 9 . 9 ft.lbf}
4BUOSX-082
s WINDSHIELD
WINDSHIELD
COMPONENTS
1. Remove the windshield wiper arms and blades.
2. Remove the interior trim around the windshield to prevent damage.
3. Remove the sunvisors and disconnect the harness connectors, if equipped.
4. Remove the rearview mirror, referring to the Removal Note. (Refer to below.)
5. Loosen the headliner near the windshield, and insert styrofoam blocks under the headliner to move it
away from the windshield and to prevent damage.
I 2
MSl036-A 4BUOSX-083
1. Windshield molding
2. Windshield
Removal Note ........................ page 5-35
Removal Note
Rearview mirror
1. Grasp mirror firmly.
2. Insert a small single-blade screwdriver into the slot until
the spring is contacted.
3. While pushing on the spring with the screwdriver, pull up
on the mirror to remove it from the windshield.
WINDSHIELD
Windshield
1. Insert the blade of a cold knife into the adhesive.
2. Pull the cold knife through the adhesive around the edge
of the glass.
3. Remove the windshield.
4. Trim the remaining adhesive in the windshield opening so

that it is smooth and even.
5. Clean the pinchweld.
Note
Do not damage the dress molding.
Installation Note
Windshield
Note
The front door windows should be left open to
prevent damage to the windshield from th pres-
sure created when closing the doors.
1. Remove any remaining urethane from the windshield.
2.Apply body primer to the outer surface of the flange

along the entire windshield opening perimeter.
Note
Allow the primer to dry for 30 minutes before install-
ing the windshield and adhesive.
PRIMER
3.Apply glass primer to the inner windshield perimeter,
then wipe it off immediately.
4. Apply glass primer to the inner windshield perimeter.
Allow the primer to dry for 5 minutes before applying
urethane adhesive.
5. Apply urethane adhesive to the windshield.
WINDSHIELD
6. Apply the dam to the entire windshield perimeter. Start at
the bottom of the windshield 15.5mm (0.6 in) inboard
from the glass edge. Peel the protective cover on the dam
back to expose the dam tape.
7. Install the new windshield molding to the windshield.
Note
To ensure correct molding fit, maintain a maximum
of Imm {.04 in) difference between side margins.
8. Install the windshield and press it in slightly to compress

the adhesive.
MS1040-A 5BUOSX-046
9. Use a spatula to smooth away any adhesive that oozes
out. Add more adhesive to any low areas.
Note
Position the windshield so that it is centered in the
opening.
Refer to the urethane adhesive manufacturer's in-
structions for the exact cure time of the adhesive.
10. Perform a water leak test. Repair as necessary.

REAR WINDOW GLASS
REAR WINDOW GLASS
COMPONENTS
I I
MS1095-A 5BUOSX-047
1. Rear window glass (sliding glass) 2. Rear window glass (stationary glass )
Removal Note ........................ page S-38 Removal Note ........................ page S-38
REAR WINDOW GLASS
Removal Note
Rear window glass (stationary glass)
1. Remove necessary interior trim to access rear window
glass mounting area.
2. Pull rear window glass weatherstrip away from opening
(Regular Cab).
3. Remove eight rear window glass nuts (Cab-Plus).
4. Push out rear window glass from opening with an assis-
tant to prevent damage.
5. Clean all sealant from rear window glass weatherstrip and
opening.
5BUOSX-048
Rear window glass (sliding glass)

1. From the inside of thevehicle, pull down on the weatherstrip
lip along the window opening and with an assistant, push
the movable glass and weatherstrip assembly out of the
window opening from inside of the cab.
2. Remove the weatherstrip from the glass and place the
movable window in the open position.
3. For the top of the window frame, remove the screw
retaining each division bar.
4. Remove the two screws retaining the anchor plate in the
window track and remove the plate.
5. Spread the window frame and work the movable glass out
of its track and remove it from the frame.
6. If the stationary glass is to be replaced, remove the
division bar lower screw and remove the division bar.
7. Spread the window frame just enough to permit the
stationary glass to be worked out of the frame.
5BUOSX-049
Installation Note
Rear window glass (stationary glass)
1. Install a draw cord all around the weatherstrip in the flange
crevice, allowing the cord to overlap at the bottom center
of the glass.
2. Coat the weatherstrip mounting surface with lubricant.
Note
A mixture of soap and water may be used to coat the
weatherstrip and molding to facilitate installation.
3. Install glass (Cab Plus).
Tightening torque:
1-2 N-m(1 1-19 kgfzm, 9-1 7 in-lbf)
4. Position the glass and weatherstrip to the window open-

ing. With the aid of an assistant, apply hand pressure from
the outside of the cab, and pull (from the inside) the
weatherstrip lip over the window opening flange with the
draw cord (Regular Cab).
REAR WINDOW GLASS
5. Pull the weatherstrip over the lower flange, pulling one
end of the cord at a time. Then, pull the weatherstrip over
DRAW CORD the side flanges and upper flange.
6. Clean the glass and the area around the window to
remove all excess adhesive.
7. Test for water leaks.
Rear window glass (sliding glass)
1. If the stationary glass is to be replaced, apply silicone
lubricant to the weatherstrip and track.
2. Spread the frame slightly and slide the glass into the
frame.
Note
Do not allow the weatherstrip to bunch.
3. Position the division bar in the frame and install the lower
screw.
4. Spread the frame slightly and install the movable glass
into the track.
5. Position the anchor plate in the window track and install
the screws.
6. Install the division bar upper screw.
7. Position the weatherstrip to the window frame.
8. Install adraw cord all around the weatherstrip in the flange
crevice, allowing the cord to overlap at the bottom center
of the glass.
9. Position the glass and the weatherstrip in the window
opening. With an assistant applying hand pressure from
the outside of the cab, pull the weatherstrip lip over the
window opening flange with a draw cord.
Note
Soap and water may be used to facilitate installa-
tion of the weatherstrips and moldings.
10. Pull the weatherstrip over the lower flange, pulling one
end of the cord at a time. Then pull the seal over the side
I DRAW CORD
flanges and the upper flange.
TRIM
COMPONENTS
1. Remove the A-pillar trim, referring to Removal Note. (Refer to below.)
2. Remove the scuff plate, referring to Removal Note. (Refer to below.)
3. Remove the front side trim, referring to Removal Note. (Refer to below.)
4. Remove the 6-pillar trim (Regular Cab), referring to Removal Note. (Refer to page S-41.)
5. Remove the 6-pillar trim (Cab Plus), referring to Removal Note. (Refer to page S-42.)
6. Remove the front door trim, referring to Removal Note. (Refer to page S-42.)
7. Remove the lower back trim (Cab Plus), referring to Removal Note. (Refer to page S-43.)
8. Remove the assist handles, referring to Removal Note. (Refer to page S-43.)
Removal Note
A-pillar trim
Remove the A-pillar trim.
MS1044-B 5BUOSX-016
Scuff plate
I Remove the scuff plate.
Front side trim

Remove the front side trim.
VEHICLE
TRIM
B-pillar trim (Regular Cab)
1. Remove the A-pillar trim.
MS1047-A
3. Remove the scuff plate.
4. Remove the seat belt attachment from the floor.
MS1094-A
95.Remove the B-pillar trim.

TRIM
B-pillar trim (Cab Plus)
1 . Remove A-pillar trim.
2. Remove the coat hook.
3. Remove the rear window garnish lower molding.
4. Remove the scuff plate.

5. Disconnect the seat belt attachment from the floor
6. Remove the jack cover.
7. Remove the utility tray.
8. Remove the B-pillar trim.
Front door trim

2. Remove the screws retaining the armrest area of the door
trim to the door inner panel.
3. Remove the screw retaining the door inside handle cup.
4. Remove the regulator handle.
5. Remove the front door trim finish panel, if equipped.
TRIM
6. Remove the power door lock control andlor the power
window control, if equipped.
7. Carefully pry the door trim away from the door using Trim
Pad Removing Tool 107-00401, or equivalent.
8. Remove the front door trim.
Lower back trim (Cab Plus)

1. Remove the B-pillar trim.
2. Remove the lower back trim.
Assist handles
Remove the assist handles.
TRlM
1 Installation Note
B-pillar trim (Cab Plus)
1. Install the B-pillar trim.
2. Tighten the seat belt bolt to the specified torque.
Tightening torque:
2 9 . 7 4 0 . 2 N-m (3.1-4.1 kgf-m,21.9-29.7
ft.lbf}
B-pillar trim (Regular Cab)
Tighten the seat belt bolt to the specified torque.
Tightening torque:
29.7-40.2 N.m (3.1-4.1 kgf-m,21.9--29.7
ft-lbf}
4BUOSX-102
TRIM PANEL SHOWN

FOR SIDE FACING 1 r.
SEATS ---I
"-
1. Remove the seats. (Refer to page S-62.)
2. Remove the scuff plates. (Refer to page S-40.)
3. Remove the front side trim. (Refer to page S-40.)
4. Remove the front seat belt buckles. (Refer to page S-49.)
5.If equipped, remove floor-mounted compact disc player. (Refer to 1997 BETM.)
6. On regular cab vehicles with manual transmission, remove four gearshift lever opening shield screws.
On Cab Plus, remove retaining screws in top surface of rear step section.
7. Remove the B-pillar trim (Cab Plus only). (Refer to page S-42.)
8. Remove the lower back trim (Cab Plus only). (Refer to page S-43.)
9. Graspthe carpet or mat surrounding the edge beneath the floorshifter boot and pull it outward and upward
away from the boot (Cab Plus only).
REGULAR CAB
CUT OUT
FOR MANUAL
SHIn
CUT OUT FOR

CONSOLE
CAB PLUS
CARPET
(MAT SIMILAR)
HEADLINER
HEADLINER
2. Remove both sunvisors, referring to Removal Note. (Refer to page S-48.)
3. Remove the assist handles, if equipped. (Refer to page S-43.)
4. Remove the A-pillar trim, referring to Removal Note. (Refer to page 5-48.)
5. Remove the coat hook.
6. Remove the rear window garnish lower molding, referring to Removal Note. (Refer to page 5-48.)
7. Remove the B-pillar trim. (Refer to page S-41 for Regular Cab or page S-42 for Cab Plus.)
8. Remove the dome lamp lens.
9. Remove the dome lamp assembly. (Refer to the 1997 B-series BETM.)
REGULAR CAB CAB PLUS
a TO FRONT OF VEHICLE a TO FRONT OF VEHICLE
MS1059-C 7BUOSX-017
1. Headliner
lnstallation Note ..................... page S-48
HEADLINER
Removal Note
Sunvisors
1. Remove the sunvisors.
2. Remove the sunvisor arm clips.
I I
MS1060-A 4BUOSX-106
A-pillar trim
Remove the left and right side A-pillar trim.
Rear window garnish lower molding

Remove the rear window garnish lower molding.
Installation Note
Headliner
Preshape the new headliner along the score marks to
approximately the same shape as the old headliner.
4BUOSX-109
SEAT BELTS s
SEAT BELTS
FRONT SEAT
Caution
Do not disassemble the buckle or retractor assembly.
BENCH SEAT 2 9 . 7 4 0 . 2 ( 3 . 1 4 . 1 , 21.9-29.7)
---.-
I.Front seat belt 3. Shoulder height adjuster

Inspection ............................... page S-51 Removal Note ........................ page S-5
2. Front seat belt buckle
Installation Note ..................... page 5-52
s SEAT BELTS
I 2
MS1097-A 5BUOSX-057
1. Front seat belt 3. Shoulder height adjuster
Inspection ... ..................... ..... .. page S-51 Removal Note ........................ page S-51
SEAT BELTS
I - I
MS1098-A SBUOSX-058
1. Front seat belt 3.Shoulder height adjuster
Inspection ............................... page S-51 Removal Note ........................ page S-51
Removal Note
Shoulder height adjuster
1. Pull B-pillar trim away from sheet metal to access height
adjuster.
2. Remove plastictrim from adjuster by grasping trim on both
sides of adjuster at center and pull inboard.
3. Remove two bolts.
Inspection
Front seat belt
Webbing and fittings
1. lnspect the webbing for scars, tears, and wear.
2. lnspect the fittings for deformation and damage.
3. If any problem is found, replace the seat belt assembly.
SBUOSX-059
S-51
SEAT BELTS
Retractor
1. Verify that the belt can be pulled out smoothly and that it
moves smoothly when worn.
2. Verify that the retractor locks when quickly pulling the belt.
3. Remove the retractor.
4. Hold the retractor as it is installed.
5. Slowly incline the retractor.
6. Verify that the retractor locks at approx. 30°0f inclination.
4BUOSX-114
Installation Note
Shoulder height adjuster
1. Position adjuster to vehicle. On regular cab, position
adjuster with the four hole pattern located in the back of
the adjuster at the top. On Cab Plus, align tab at top of
module with sheet metal hole.
2. Loosely install (1) lower attaching bolt and (2) upper
attaching bolt.
3. Tighten bolts.
Tightening torque:
2 9 . 7 4 0 . 2 N.m ( 3 . 1 4 . 1 kgf-m, 21.9-29.7 ft.lbf}
4. Position plastic trim over adjuster. On regular cab, the

flange around the opening of the trim must face inboard to
the center of the vehicle. On Cab Plus, the retaining
flanges on either side of the trim must face outward. Make
sure trim is secure to adjuster.
5BUOSX-060
Front seat belt

Install the front seat belt.
Tightening torque:
2 9 . 7 4 0 . 2 N.m ( 3 . 1 4 . 1 kgf-m,21.9-29.7 ft.lbf)
4BUOSX-115
Front seat belt buckle

Install the front seat belt buckle.
Tightening torque:
29.740.2 N-m( 3 . 1 4 . 1 kgf.m, 21.9-29.7 ft-lbf)
4BUOSX-116
REAR SEAT
SEAT BELTS
- I
MS1065-A 5BUOSX-027
1. Rear seat belt buckle 2. Rear seat belt
Installation Note .............................. below Inspection ........................................ below
Inspection
Rear seat belt
Webbing and fittings
1. Inspect the webbing for scars, tears, and wear.
2. lnspect the fittings for deformation and damage.
3. If any problem is found, replace the seat belt assembly.
4BUOSX-118
Retractor
1. Verify that the belt can be pulled out smoothly and that it
moves smoothly when worn.
2. Verify that the retractor locks when quickly pulling the belt.
3. Remove the retractor.
4. Hold the retractor as it is installed.
5. Slowly incline the retractor.
6. Verify that the retractor locks at approx. 30"of inclination.
4BUOSX-119
Installation Note
Rear seat belt
Install the rear seat belt assembly.
Tightening torque:
29.7-40.2 N.m ( 3 . 1 4 . 1 kgf-m, 21.9-29.7 ftslbf)
5BUOSX-069
Rear seat belt buckle

Install the rear seat belt buckle.
Tightening torque:
2 9 . 7 4 0 . 2 N.m (3.14.1 kgf.m, 21.9-29.7 ft-lbf)
5BUOSX-070
s BOX - CAB AND BOX ALIGNMENT
BOX - CAB AND BOX ALIGNMENT

ADJUSTMENT
Cab and Box Alignment
1. Loosen the six box attaching bolts.
Note
Make sure cab-to-box margin at outboard edge of box is no less than 21.0mm (0.826 in). Less
than minimum clearance may result in cab-to-box contact during severe usage.
2. Move box so front of box is centered on rear of cab.

3. If satisfactory alignment is achieved, tighten the six bolts to 54-72 N-m(5.6-7.3 kgf-m,40-53 ftslbf).
I FRONT OF VEHlCLE 0
BOX - CAB AND BOX ALIGNMENT
4. If satisfactory alignment cannot be achieved by following Steps 1-3, it may be necessary to adjust
position of cab.
5. Loosen six cab front end sheet metal mounting bolts.
Caution
Make sure cab-to-box margin is no less than 21.0mm (0.826 in}.
6. Move cab and box to achieve proper alignment.
0
REGULAR CAB
MS1088-A 6BUOSX-010
7. Tighten six box bolts to 54-72 N m (5.6-7.3 kgf -m, 40-53 ftelbf).
8. Tighten four cab bolts to 68-92 N .m (6.9-9.3 kgf. m, 50-68 ft .Ibf). Tighten front end sheet met-
al bolts to 68-92 N - m(6.9--9.3 kgf - m, 50-68ft- Ibf}. Tighten the nut on top of the front end sheet
metal bolt to 46-64 N m (4.7-6.4 kgf . m, 3 4 4 7 ft .Ibf).
9. Adjust transmission shift select cable. (Refer to Section K.) s-55
SPARE TlRE STOWAGE
SPARE TlRE STOWAGE

COMPONENTS
I 4x2 WlTH 14-INCH WHEEL

I
w
1 6-10N.m
o'(81.6102.0
kgf-cm, 7 0 - 8 0
in.lbf)
WITH 15-INCH WHEEL 4-0 (4.1-6.0,3M)
{81.&102.0
kgf-cm, 70--80
in4bt)
4-0 (4.1-6.0, 30--44)
N-m {kgf.m, ft4bf)

-
MS1086-A
1. Hinge Bolt 4. Channel bolts
lnstallation Note lnstallation Note
2. Eyebolt 5. Bracket bolts
3. Nuts lnstallation Note
lnstallation Note
S-56
SPARE TIRE STOWAGE s
Installation Note
Bracket bolt
e
Tightening torque:
40-54 N .m (4.1 -5.5 kgf . m, 3 0 4 0 ft Ibf)
6BUOSX-012
Channel bolts
Tightening torque:
20-30 N-m(2.1-3.0 kgfam, 15-22 ft.lbf)
5BUOSX-024
Nuts
Tightening torque:
40-54 N m (4.1-5.5 kgf .m, 30-40 ft Ibf)
6BUOSX-013
Eyebolt
Tightening torque:
8-1 0 N.m (81.6-1 02.0 kgf-cm,70-430 inelbf}
5BUOSX-026
Hinge bolt
Tightening torque:
28--42 N,m ( 2 . 9 4 . 1 kgfem, 21-30 ft.lbf}
5BUOSX-027
SPARE TIRE
SPARE TlRE
COMPONENTS
Note
The spare tire is designed for emergency use only.
Warning
Continuoususe of the spare tire on limitedslip rear axle equipped vehicles could cause damage
to the differential.
BODY DIMENSIONS s
BODY DIMENSIONS
(Short Bed)
DS
I' I I II I I I I I II I I I I
I I I I I I
TOP OF FRONT FENDER BOLT
1 I I I II I I I I
I fgI I 11 I I I I I II I I I I
I I I I1 I I I I
, .
mm
(INCHIIS)
,."-,
s BODY DIMENSIONS
(Long Bed)
DRIVER SlDE
1 I I I I
Top of ront Fender Bon
i I I I I II I I I I
T
~,E~,II 1 1 1 I I 1 1 11 1 1 1 I
SlDE VIEW
I I I I I
BODY DIMENSIONS
(Cab-Plus)
I I l
TOP OF FRONT FENDER BOLT
l 1 I 1
I I I II I I I I
I I I I I I I I
367 207 307 485 382

(14.451 (11.70) I12W (10.101 (15.W)
707
(27 831
-- -
A B C D E F G H I J K L M N 0 P Q
I I
MSlO91-B
Measuring Points
1.23~40 (0.9" x 1.57")
2. Front fender bolt
3. Bolt
4. Bolt
5. Bolt
6. Nut
7.16 (0.63")
8. Driver side 44 (1.73")
Passenger side 25 (0.98")
9.9 (0.35")
10.16 (0.63")
11.17~35(0.67" x 1.38")
12. Pin
13. Bolt
1 4 . 1 6 ~ 2 5(0.63" x 0.98")
15.16 x 25 (0.63" x 0.98")
16. Bolt
17. Bolt
SEATS
SEATS
BENCH SEAT
Note
Seat and seat track are removed as an assembly.
1. Remove seat and track as shown in the figure.
2. Repair and replace as necessary.
4. Torque front seat-to-floor support retaining screws and front seat track-to-front seat screws to
19-26 N .m (1 -9-2.6 kgf .m, 14-1 9 ft - Ibf)
FRONT OF
*
BODY
SEATS
1. Disassemble seat and track in the order shown in the
figure.
2. Repair or replace as necessary.
1. Head restraint 7. Adjuster wire

2. Pole guide 8. Seat tracks
3. Seat back pad support 9. Seat cushion framelspring
4. Seat latch 10. Back panel
5. Seat back 11. Seat back frame
6. Seat cushion
--
SEATS
MANUAL BUCKET SEAT
Note
1. Remove seat and track as shown in the figure.
4. Torque track-to-floor bolts to 17-23 N - m(1.7-2.3 kgf-m,13-17 ft. Ibf) and track-to-seat bolts
to 19-26 N - m (1.9-2.6 kgf.m, 14-19 ft-Ibf).
1 N . m (kgf-m, ft.lbf)
SEATS s
1. Knuckle cover 5. Seat cushion

2. Reclining knuckle 6. Seat cushion frame
3. Seat back cover 7. Seat back frame
4. Seat back
s SEATS
SIX-WAY POWER BUCKET SEAT

Note
1. Disconnect the electrical connectors.
2. Remove four bolts.
3. Remove the seat.
SEATS
e
Disassembly /Assembly
(DRIVER SIDE SHOWN,

PASSENGER SIDE SIMILAR)
MS2002-A
1. Seat garnish 9. Lumbar support pad

2. Power seat switch 10. Lumbar support valve
3. Reclining knuckle 11. Seat back tube
4. Knuckle knob 12. Seat extender pad
5. Seat cushion 13. Mounting bracket
6. Seat back 14. Seat cushion frame
7. Seat back cover 15. Power lumbar seat pump
8. Seat back frame
LUMBAR SUPPORT PAD
1. Seat cover (and tie strap on seat back frame) 3. Lumbar support pad (unclip 2 pad wires from 4
2. Lumbar support hose hooks on seat back frame)
SEATS s
JUMP SEAT
1. Remove jump seat cover trim and jump seat as shown in figure.
4. Torque bolts to 19-26 N .m (1.9-2.6 kgf . m, 14-1 9 ft Ibf).
1. Jump seat
SEATS
SEAT BRACKET
Disassembly/ Assembly
I (DRIVER SlDE SHOWN,

PASSENGER SlDE SIMILAR)
1. Rear adjuster covers 5. Return spring

2. Outer adjuster cover 6. Release wire
3. Inner adjuster cover 7. Front seat adjuster rod
4. Return springs (driver side only) 8. Seat bracket
SPLIT BENCH SEAT
Disassembly l Assembly
I (DRIVER SIDE SHOWN,

PASSENGER SIDE SIMILAR)
1. Center armrest 4. Seat back

2. Stopper 5. Seat cushion
3. Seat back cover
BOX LEAN
Box Lean
1. Place vehicle on a flat, smooth surface.
2. Inspect vehicle for any heavy add-ons that may cause excessive weight on any corner of vehicle.
3. Vehicle should be empty, fuel tanks should be full, no cargo in the box; such as tools, equipment or debris.
4. Vehicle must be sitting on the wheels and tires and not on a hoist, jack stands.
5. Check all wheels and tires.
- Wheels must be same size and design, right and left side on each axle.
- Tires must be same brand, size, tread design, and equal tread wear side-to-side on each axle.
- Wheel size and design, tire size, and tire design should be indicated on the Vehicle Certification Label.
Use of large size, off-road, wide tread wheels and/or tires are not approved.
- Check tire pressure of all tires; inflate to specifications indicated on the Vehicle Certification Label.
6. Lay a straightedge at least 6 112 feet long across the rear edge of the box and have an assistant hold
the straightedge.
7. Standing 6-8 feet behind the truck, with eye level at the top of the box, have assistant lift whichever side
of the straightedge is necessary to make parallel to the back window of the cab.
8. Measure the distance between the bottom of the straightedge and the top of the box outer panel and shim
the low side of vehicle as follows:
Criteria Action
--
mm (0-0.25 in) - ---
If dlstance IS- between 0-6.5 - - -.-
Unnecessary
- - - --
If dlstance IS between 6.6-1-7.7 mm (0.26-0.70 in)

- -- - -
- - -
Shim
-
the axle -- --
If d~stanceIS greater--than 17.7 mm (0.70 in) but less than

- -
- - --
30.4 mm (1.20 in) Shlm- the box - - - -
If dlstance IS greater than 30.4 mm (1.20 in) Shim both the axle and box
DISTANCE BETWEEN TOP

OF BOX AND STRAIGHTEDGE
STRAIGHTEDGE PARALLEL TO
BACK WINDOW OF GAB
--------------
~ - ~ F E E T ~
9. If, after shimming, the rear bumper is not aligned with the rear of box, realign the bumper as follows:
(1) Remove the four bumper-to-chassis frame attaching bolts.
(2) Ream the four holes to 17 mm (0.67 in) (two each side) on the bumper arms through which the chassis
frame attaching bolts are installed.
(3) Reinstall the bumper to chassis frame attaching bolts and align the bumper to the box.
(4) Torque the bumper attaching bolts to 95-140 N-m (9.7-14.2 kgf.m, 70-103 ft-lbf).
BOX - BOX SHIMMING
Box Shimming
1. Loosen all box attaching bolts. Remove the three bolts on the low side of the box.
2. Raise the low side of the box and insert the shims between the top of the frame and bottom of the box
cross sills as shown.
3. Install the bolts listed below on the side of the box that was shimmed and tighten all box nuts to
54-95 N-m (5.6-9.6 kgf.m, 40-70 ft.lbf).
Note:
Bolts should be held down from top of box to prevent the shoulder from popping out of the floor
while starting the nut. Tighten all bolts to 54-95 N.m (5.6-9.6 kgf.m, 40-70 ft.1b.f).
BOX SHIMMING SPECIFICATIONS
Location Type of Bolt Shirn
No. 4 box bolt (rearmost) Same as current No. 1 bolt - 8 shims (2.5 O.D. x .'75 I.D. x ,060)
. 4.25 inches,-.oval
~ -. ... shoulder - - --pp-pp-p
No. l5l; (next sill forward, it does not No change 1 "L" shim (see illustration) screwed to
have a bolt) - .- - .- No.5 sill
No. 3 box bolt (next body bolt Use current No. 2 bolt - 3.50 inches 5 shims (same as No. 4 shims)
forward of the No. 4 bolt) long, square shoulder
No. 1 box bolt (bolt at front of No change; use existing bolt - No shims
pickup box) 4.25 inches long, oval shoulder
FRONT OF VEHICLE c>
CHASSIS FRAME
NO. 5 SILL SHIM DRILL 3/16 IN. PILOT HOSE

IN STEADY REST
MATERIAL- .I36 IN. CRLC OR HRLC
STEEL 3 PIECES
FINISH- PHOSPHATE AND OIL
OR BLACK PAINT
-1 2-114IN.* k 2 - 1 1 2IN.+
.406IN.
@ CIL OF VEHICLE
TACK WELD ON EDGES TO HOLD
THE THREE PARTS TOGETHER
S-73
s TROUBLESHOOTING GUIDE
DIAGNOSTIC INDEX
SYMPTOMS PAGE
WINDNOISE - S-74
WATERLEAK WATERLEAK AT FRONT OF CAB S-78
WATERLEAKS ABOVE UPPER A-PILLAR TRIM ON HEADLINER S-82
WATERLEAKS AT REAR OF CAB-PLUS S-83
WATERLEAKS AT REAR OF REGULAR CAB S-86
WINDNOISE TROUBLESHOOTING
I
*
CHECK FOR FLUSHNESS Procedures
OF SAIL PLATE
1. SEILE Mirror Out of Position
If vehicle is equipped with SE or LE level mirrors,
verify that the mirrors are in the proper position.
Examine the top of the sail plate on the mirror.
to
If
remove
the
step
sail2.interior
plate is door
against
forward
trim
the
ofand
the
window
window
mirror
channel,
assembly
channel,
go
I
1 and reposition mirror so that is it flush with the
~BUOSX-102 door.
FOAM 2. Fender Stuffer Not Seated
Verify that the fender stuffer is seated completely.
If the fender stuffer is in the correct position, go
to step 3.
If the fender stuffer is not in the correct position,
loosen and pull back the inner fender liner.
Repositionthe fender stuffer so that it fits snugly
from top to bottom at the rear of the fender.
I
3. Secondary Cabside Weatherstrip Not Flush
~BUOSX-103 With Body
CHECK FOR
Examine the secondary cabside weatherstrip at
the top of the A-pillar for flushness against the
SECONDARY CABSIDE body.
If the secondary weatherstrip is flush with the
body, go to step 4.
If the secondary weatherstrip is not flush with
the body, remove the weatherstrip and bend the
roof and cabside seam upward slightly. Install
the secondary weatherstrip on the vehicle and
verify that the fit is improved.
TROUBLESHOOTING GUIDE 3
e Pinched
4. Primary Door Seal e A-Pillar
e by Lower
LOWER
Trim
A-PILLAR Examine the primary door seal. Verify whether the
TRIVI
door seal is pinchedltrapped by the lower A-pillar
trim.
If the seal is not pinchedltrapped, go to step 5.
If the seal is pinchedltrapped, remove that lower
A-pillar trim to release the weatherstrip and rein-
stall trim.
5. Air Leaks from Heater or A/C System
Inspect for air leaks. If OK, go to step 6.
R&R LOWER A-PILLAR

TRIM TO RELEASE
PITCHED SEAL
6. DL0 Molding Not Flush with Vehicle (LE/SE

TO FRONT OF VEHICLE
Cab-Plus Only)
Examine the D L 0 molding. Verify that the D L 0
molding is flush with the body.
If the D L 0 molding is flush with the body, go to
step 7.
If the D L 0 molding is not flush, reseat the D L 0
molding. Use clear RTV to seal the D L 0 molding
seams.
Note
Do not overtighten the DL0 molding retain-
ing nuts.
PLACE RTV IN DLO

MOLDING SEAMS
7. Poor Body Sealant at A-Pillar Body Seam and
Poor Seal of Front Windshield
REMOVE SECONDARY REMOVE SUNSHADE
WEATHERSTRIP\ , (3) SCREWS 1. Remove sunshade by removing the three (3)
.p': A
FOR FLUSHNESS
ERE
PLACE SOAPY
WATER HERE USE AIR HOSE
mounting screws. Remove secondary cabside
weatherstrip.
2. Verify seal of upper A-pillar body seam, wind-
shield and roof to cabside bodyseam. Place
soapy water on the exterior of the A-pillar and on
the cabside bodyseam. Use an airhose through
AND CHECK
CHECK ROOF FOR BUBBLES the sunshade mounting hole to increase air
A-PILLAR pressure in the concern area. Check for
bubbles.
Note
Special attention should be paid to the
RESEAL AREA BELOW roof A-pillar seam near the top of the A-pil-
4 WINDSHIELD MOLDING lar.
IF NECESSARY
If no bubbles are present, go to step 8.
If bubbles are present on the A-pillar, use RTV
to reseal area below windshield molding at
\I+-
I_--
i \'
,)I;'
the roof to A-pillar seam.
If bubbles are present at the roof to cabside
bodyseam, use RTV to reseal the concern
RESEAL CABSIDE :J
SEAM IF NECESSARY area.
CHECK FOR
WATERLEAKS 8. Cab Quarter Seam Not Sealed (Regular Cab)
Verify seal of cab quarter seam by performing a
waterleak test. Apply water to the concern area.
Inspect the bottom of rear trim panel and inspect
the bottom of the cab quarter for moisture.
If moisture is not present, go to step 9.
If moisture is present, inspect the cab quarter
seam for skips or pin holes in the sealer. Reseal
by injecting clear RTV in skips. Wipe any excess
sealant off vehicle.
TROUBLESHOOTING GUIDE s
9. Poor Seal of Rear Window
1. Verify seal of rear window by performing a
waterleak test. Apply water to the concern area.
APPLY WATER HERE
Pull cargo cover out (if equipped) and inspect
f-4
m, 1
2 . q
the top side for water, inspect bottom of rear trim
panel, inspect the rear floor for moisture.
If moisture is present, try to seat rear window by
using a padded glove to carefully strike the outer
perimeter of the glass.
WARNING
Excessive force may damage the rear
window or cause injury.
2. Perform step 9-1. If window is still leaking and
FRONT OF VEHICLE vehicle IS equipped with a solid rear window,
remove and reseal rear window. If moisture is
present and vehicle is equipped with a slide rear
window, go on to step 9-3.
3. Verify that the sliding glass is sealed properly.
Turn on heater blower fan while cycling the rear
slide window open and closed. Note any air
noise in or near the closed posrtion. Reposition1
add sealing shim if necessary.
ADDIREPOSITION SHIM TO 4. Verify that the rear window fasteners are secure
INCREASE SEALING PRESSURE
OF SLIDE GLASS and the retaining sheet metal is not bent. Repair
as necessary.
5. Verify seal at the roof/B-pillar bodyseam. If a
leak is found, inject a highlyflexible body sealant
VERIFY REAR FASTENERS ARE
SECURE AND SHEET METAL under the rear window weatherstrip.
IS NOT BENT 6. Perform step 9-1 if rear window still leaks,
remove the window and reseal.
VERIFY SEAL AT ROOFIB-PILLAR

BODY SEAM, INJECT SEALANT
UNDER MOLDING AT THIS POINT
WATERLEAK TROUBLESHOOTING
LOWER WATERLEAKS AT FRONT OF CAB
1. Pinched Primary Door Seal
Determine if the primary door seal is being pinched
by the lower A-pillar trim - see figure. If primary
IN door seal is not pinched, perform step 2.
IP If seal is pinched, remove the pinched portion of
the door seal from the trim (removal of the trim
may be necessary).
PITCHED SEAL
TO FRONT OF VEHICLE
2. Poor Body Sealant at A-Pillar Body Seam and
Poor Seal at Front Windshield
1. Remove the upper A-pillar trim.
2. Verify seal of A-pillar body seam and windshield.
Use a 318" tube connected to a garden hose to
spray water underneath the front windshield
molding as shown in illustration. A second per-
son should inspect the A-pillar area for leakage
inside the vehicle while this is being done.
3. Inspector should examine A-pillar metal seam
area closely. If no waterleak can be found, go to
step 3.
PLACE TUBE HERE
318 TUBE CONNECTED

TO GARDEN HOSE
If a waterleak occurs betweeri the winshield
urethane and the sheet metal, there is a concern
with the A-pillar seam body seal. Reseal con-
cern area by placing RTV under windshield
molding and on the inside of the A-pillar.
Note
Special attention should be paid to the roof
A-pillar seam near the top of the A-pillar.
Note
If the waterleak occurs between the wind-
\
BETWEEN WINDSHIELD IF LEAK OCCURS shield urethane and the sheet metal, THIS
AND URETHANE. SHOULD NOT BE CONSIDERED A POOR
REMOVE AND RESEAL ~ ~ ~ S & ~ E ~ ~ ~ ~ ~ N E
WINDSHIELD. WINDSHIELD SEAL.
RESEAL UNDER
WINDSHIELD If the waterleak occurs betweeri the windshield
MOLDING. and the urethane, remove and reseal the wind-
shield.
NOTE PAY CLOSE

ATTENTION TO
ROOFIA-PILLAR SEAM 3. Waterleak at Heater Case
=7
Verify seal of heater core assembly to the firewall.
Use a garden hose to spray water underneath the
hood at the heater case assembly. A second per-
son should inspect the cab floor area (both left and
right hand side) for leakage.
CONCERN AREAS
Note
Care should be taken to ensure that electri-
cal components do not become xposed to
excessive water pressure.
If no waterleak can be found, go to step 4.
If a waterleak occurs, reseal the heater core
assembly with RTV in the concern area.
4. Waterleak from Inner Fender Apron to Firewall
Body Seam
1. Verify seal of the inner fender apron to firewall
k'-a\ k-.,
7-
WATER HERE
body seam. Use a garden hose to spray water
between the door and fender.
Note
Special attention should be paid to the trian-
I _ .t 4
--\ gular seam at the top of the inner fender
I apron.
2. If no waterleak can be found, go to step 5.
3. If a waterleak occurs, remove the bolts from the
fender. Carefully move fender back 3-4" from
the inner fender.
Note
Do not use excessive force or damage to the
fender will occur.
4. Reseal area at top of apron by injecting R W into
l
;i
the seam.
5. Wait 12 hours and perform step 4-1 again. If the
REMOVE BOLTS (5) waterleak still occurs, remove the scuff plate
and the lower A-pillar trim and peel back the car-
pet. Check for skips in sealer along the floor-
board and the kickplate. Reseal as necessary.
CAREFULLY
PULL I ---
FENDER
BACK
5. Leaks From PCM Box
1. Verify seal of PCM box to firewall. Use a 3/8"
hose connected to a garden hose to direct water
into concern area as shown. Water should be
sprayed through the right hand wiper pivot hole
and sprayed in a direction towards the right side
of the vehicle (the location of the PCM box).
Note
A leak in this area may also cause driveabil-
ity concerns during wet conditions.
2. Check for leakage around the floor at the heater
core.
If a leak occurs, verify that the PCM retainer box
is centered in the firewall opening.
If PCM retainer is centered, attempt to reseal
concern area with RTV. If PCbI retainer is not
centered, remove the retainer, seal with RTV,
and re-install retainer in a centered position.
\ VERIFY PCM RETAINER
BOX IS CENTERED.
WATERLEAKS ABOVE UPPER A-PILLAR TRIM
ON HEADLINER
REMOVE SECONDARY Poor Body Sealant at A-Pillar Body Seam and
r/-WEZ-HERSTRIP Poor Seal of Front Windshield
1. Remove sunshade by removing the three (3)
mounting screws. Remove secondary cabside
weatherstrip.
Note
Before removing secondary cabside weath-
strip, note whether the weatherstrip is flush
'PLACE SOAPY WATER HERE to the body at the top of the A-pillar.
CHECK ROOF 2. Verify seal of upper A-pillar body seam, wind-
shield and roof to cabside bodyseam. Place
soapy water on the exterior of the A-pillar and on
the cabside bodyseam. Use an airhose through
the sunshade mounting hole to increase air
pressure in the concern area. Check for
/ USE AIR HOSE
AND CHECK FOR
BUBBLES
bubbles.
Note
Special attention should be paid to the roof
A-pillar seam near the top of the A-pillar.
If bubbles are present on the A-pillar, use RTV
to reseal area below windshield molding at the
roof to A-pillar seam.
If bubbles are present at the roof to cabside
bodyseam, use RTV to reseal the concern area.
Note
If the cabside weatherstrip was not flush to
the body, bend the bodyseam upward
slightly in that area to help keep the weather-
strip flush to the body.
After 12 hours, perform step 2. If bubbles are still
present, perform step 2 under section titled
"Waterleaks at Front of Cab".
WATERLEAKS AT REAR OF CAB-PLUS
1. DL0 Molding / Ditch Molding Not Sealed
1. Verify seal of DL0 molding and ditch molding.
Apply water to the concern area. Pull cargo
cover out (if equipped) and inspect the bottom
side for water, inspect bottom of rear trim panel,
inspect the bottom of the upper B-pillar trim for
moisture, and inspect the bottom of the cab
quarter for moisture.
Note
a Some moisture at the bottom of the cab
quarter is normal if vehicle is driv n thr ugh
standing water or in heavy rain.
a If moisture is not present, go to step 2.
a If moisture is present, inspect the front of ditch
INSPECT DITCH MOLDING HERE molding for skips or pin holes in the sealer.
ADD SEALANT IF NECESSARY.
-ka Reseal by injecting clear RTV under the front
side of the ditch molding.
2. Remove B-pillar trim and inspect DL0 molding
studs/nuts for sealant. If sealant is not evident
under nut, remove the nut, place clear RTV seal-
ant on stud and reinstall nut.
Note
Do not over-tighten DL0 molding nuts.
3. Perform step 1-1. If leakage still occurs, remove
and reseal ditch molding.
Note
Care should be taken when removing the
ditch molding to prevent damage to the
P painted surface of the molding.
INSPECT D L 0 NUTS
FOR SEALANT.
REMOVE NUTS AND
ADD SEALANT
IF NECESSARY.
- - p p p p p
2. Poor Seal of Cab Quarter Window

1. Verify seal of cab quarter window. Apply water
to the concern area. Pull cargo cover out (if
equipped) and inspect the bottom side for water,
inspect bottom for rear trim panel, inspect the
bottom of the upper 6-pillar trim for moisture,
and inspect the bottom of the cab quarter for
moisture.
Note
Some moisture at the bottom of the cab
quarter is normal if vehicle is driven through
standing water or in heavy rain.
If moisture is not present, go to step 3.
If moisure is present and vehicle is equipped
with a fixed cab quarter window, remove and
reseal quarter window. If moisture is present
and vehicle is equipped with a flip cab quarter
2. Verify that the quarter window is centered in the
sheet metal opening. Adjust if necessary.
3. Verify that the quarter window fasteners are
secure and that the weatherstrip is not misposi-
tioned. Repair as necessary.
4. Verify that the quarter window flip handle is not
damaged and is properly adjusted. Replace1
adjust as necessary.
If moisture is found on the top of the lower
portion of the weatherstrip, flip quarter window
open and inspect bottom edge of weatherstrip
for drainage ribs. If weatherstrip does not have
drainage ribs, remove the cab window and glue
eight (8) 1 x 2 ~ 3mm rubber pieces to the bot-
tom of the weatherstrip using rubber cement.
Re-install cab quarter window.
1. Verify seal of rear window. Apply water to the
APPLY WATER HERE
concern area. Pull cargo cover out (if equipped)
and inspect the top side for water, inspect bot-
tom of rear trim panel, inspect the rear floor for
moisture.
If moisture is present, try to seat rear window by
FRONT OF VEHICLE using a padded glove to carefully strike the outer
SLIDING GLASS
C- perimeter of the glass.
WARNING
Excessive force may damage the rear window
or injure the technician.
2. Perform step 3-1. If window is still leaking and
vehicle is equipped with a solid rear window,
remove and reseal rear window. If moisture is
TO INCREASE SEALING present and vehicle is equipped with a slide rear
PRESSURE OF SLIDE GLASS
VERIFY REAR FASTENERS 3. Verify that the sliding glass is sealed properly.
ARE SECURE AND SHEET Repositionladd sealing shim if necessary.
METAL IS NOT BENT.
4. Verify that the rear window fasteners are secure
and the retaining sheet metal is not bent. Repair
as necessary.
5. Verify seal at the roof/B-pillar bodyseam. If a
leak is found, inject a highly flexible body sealant
under the rear window weatherstrip.
6. Perform step 3-1. If rear window sill leaks,
remove the window.
Note
For areas with heavy rainfall, a fourth drain
A 4TH DRAIN HOLE MAY BE
hole can be made on the far left side of the
sliding rear window for better water drainage.
However, a small increase i n windnois I vels
may occur.
WATERLEAKS AT REAR OF REGULAR CAB
1. Cab Quarter Seam Not Sealed
Verify seal of cab quarter seam. Apply water to the
concern area. Inspect the bottom of rear trim panel
and inspect the bottom of the cab quarter for mois-
ture.
If moisture is not present go to step 2.
CHECK FOR If moisture is present, inspect the cab quarter
WATERLEAKS seam for skips or pin holes in the sealer. Reseal
by injecting clear RTV in skips. Wipe any excess
sealant off vehicle.
Refer to page S-85.
CHECK CAB
QUARTER SEAM FOR
SKIPS OR PIN HOLES
SPECIAL TOOLS
ENGINE ........................................................ ST-2

MANUAL TRANSMISSION .......................... ST-3
AUTOMATIC TRANSMISSION .................... ST-4
CHASSIS ..................................................... ST-6
CHECKER AND OTHER EQUIPMENT ....... ST-9
4BUSTX-001
ST SPECIAL TOOLS
ENGINE
TOOL NUMBER
81DESCRIPTION ILLUSTRATION
TOOL NUMBER
& DESCRIPTION 1
ILLUSTRATION
1 49 UNOl 064 I 1
Crankshaft Rear
damper main seal
remover installer
49 UNOI 002 49 UNOl 067
Crankshaft Camshaft belt

damper tensioner
replacer tool
1 49 UNOl 004 49 UNOl 068
Front Front cover

cover al~gnment
aligner tool
49 UNOI 007
Fan clutch 2.3L crankshaft

holding seal
tool installer
-
49 UNOI 008
Fan Valve
clutch nut stem seal
wrench replacer
49 UNOI 010
Impact
slide
hammer
49 UNOI 051
Spring lock Oil pressure

coupling tool
(318 inch) gauge
49 UNOl 052 49 UNOl 087
Spring lock
coupling tool
(112 inch)
SPECIAL TOOLS ST
ENGINE (Cont'd)
TOOL NUMBER
& DESCRIPTION ILLUSTRATION
49 UNOl 133 49 UNOI 135
Valve
guide
replacer
D Valve
spring
compressor
49 UNOI 134 1 49 UNO1 136 I f I

Valve Rear main oil
seal seal pilot and
replacer seal replacer
49 UNOl 006
Fuel line
coupling tool
MANUAL TRANSMISSION
TOOL NUMBER
& DESCRlPTlON ILLUSTRATION
49 UN11 101
Adapter
Bearing
driver
attachment
49 UNOl 073
Wrench,
main shaft
locknut
Remover1
replacer tube
ST SPECIAL TOOLS
MANUAL TRANSMISSION (Cont'd)
TOOL NUMBER TOOL NUMBER
& DESCRIPTION ILLUSTRATION & DESCRIPTION ILLUSTRATION
49 0839 425C
Remover1 Axle bearing1

replacer tube seal plate
AUTOMATIC TRANSMISSION
TOOL NUMBER
TOOL NUMBER
& DESCRIPTION I ILLUSTRATION /
49 UNOl 021
Front A4LD
Pump transmission
alignment kit test plate
49 UNOl 016
1 Servo rod
selecting
tool
49 UNOl 017 49 UNOl 072
Lip seal Lip seal

protector protector
49 UNOl 018
49 GO19 025,026,027,029 4 d c 4 =
kyt -
Clutch
Lip seal spring
protector compressor
(outer seal)
1 49 UNOl 020
I I 49 0378 400A
Front pump
seal staking
tool Gauge set,
oil pressure
SPECIAL TOOLS ST
AUTOMATIC TRANSMISSION (Cont'd)
TOOL NUMBER
TOOL NUMBER
& DESCRIPTION I ILLUSTRATION /
49 GO19 OAO 49 UNOl 142
Oil pump
Transaxle gear O-ring
hanger installer
49 UNOl 137 49 UNOl 143

Converter Converter
housing1case housing oil
alignment pins seal spring
keeper
@
49 UNOl 138 49 UNOl 144
Coast clutch Servo cover
outer seal compressor
sizer
QQ
49 UNOl 139 49 UNOl 145
Valve body Turbine speed

alignment pin sensor gap
(0.235 diameter) inspection tool
49 UNOl 140 49 UNOl 146
Valve body
alignment pin
(0.248 diameter) / Converter1
flywheel
alignment guide
49 UNOl 141
Direct clutch
outer seal
sizer
ST SPECIAL TOOLS
CHASSIS
TOOL NUMBER TOOL NUMBER
& DESCRIPTION ILLUSTRATION & DESCRIPTION ILLUSTRATION
1 49 UNOl 022
Collet I Oil seal

installer
49 UNOI 024
Needle Axle tube

bearing bearing
replacer replacer
49 UNOl 025
Bearing Differential
installer carrier
hanger
49 UNOl 036
Pinion Pinion bearing

bearing cone replacer
replacer
Driver handle Pinion

1" dia. seal
7" long replacer
49 UNOl 026
Output shaft Differential

bearing housing
replacer spreader
Bearing Companion
installer flange
set holder
1 49 UNOl 027 I 1
Step plate Differential
adapter spreader
adapters
SPECIAL TOOLS ST
CHASSIS (Cont'd)
/
TOOL NUMBER
& DESCRIPTION
49 UNOl 028
ILLUSTRATION
TOOL NUMBER
& DESCRIPTION
49 UNOl 036
4
ILLUSTRATION
Axle bearing Pinion

and seal bearing cone
installer replacer
49 UNOl 029 49 UNOl 037
Universal Hex
bearing locknut
puller wrench
1 49 UNOl 030 49 UNOI 038
Spindle
Dummy bearing
bearings replacer
49 UNOl 031 49 UNOl 040
Differential Hub
bearing seal
replacer replacer
49 UNOl 032 49 UNOl 042
Hub
( bearing
revo: : :
locknut
wrench
49 UNOl 033 49 UNOl 062
Rear axle Anti-lock brake

bearing adapter
remover
49 UNOl 063
Anti-lock brake
Shim adapter
driver
1 49 UNOl 035 49 UNOl 076
Pinion Spindle and

bearing cup axle seal
replacer installer
ST SPECIAL TOOLS
CHASSIS (Cont'd)
TOOL NUMBER
& DESCRIPTION I ILLUSTRATION 1 TOOL NUMBER
Gauge Bearing
block remover
Gauge Impact
block slide
hammer
49 UN11 101
Adapter
I Collar A
49 UN27 004
Axle bearing1
seal plate
Collar B
1 Pinion
t ; :p gauge
49 8531 565,567,568
Pinion model,
collar A and
collar B
SPECIAL TOOLS ST
CHECKER AND OTHER EQUIPMENT
TOOL NUMBER
ILLUSTRATION
49 UNOl 131
Air Bag
Simulator
49 UNOl 132
4R44E
Cable & Overlay
49 UNOl 071 49 UNOl 154
Digital TR Sensor Adapter

Cable and Overlay
Transrn~ss~on
49 TO88 OAO
NGS set
TECHNICAL DATA
COMPRESSION PRESSURE
LIMIT CHART ............................................ TD- 2
B1. ENGINE (2.3L) ...................................... TD- 3
B2. ENGINE (3.OL) ...................................... TD- 6
B3. ENGINE (4.OL) ...................................... TD- 9
D l / D2 / D3. LUBRICATION SYSTEM
(2.3L / 3.OL / 4.OL) ..................................... TD-12
E l / E2 / E3. COOLING SYSTEM
(2.3L / 3.OL / 4.OL) ..................................... TD-12
F1 IF2 IF3. FUEL AND EMISSION
CONTROL SYSTEMS
(2.3L /3.OL/4.OL) ..................................... TD-'I3
G. ENGINE ELECTRICAL SYSTEM ........ TD-14
H. CLUTCH ............................................... TD-14
J1. MANUAL TRANSMISSION .................. TD-15
J2. TRANSFER CASE ............................... TD-16
K. AUTOMATIC TRANSMISSION ............ TD-17
L. PROPELLER SHAFT ........................... TD-22
M. FRONT AND REAR AXLES ................ TD-24
N. STEERING SYSTEM ............................ TD-25
P. BRAKING SYSTEM ............................. TD-26
Q. WHEELS AND TIRES .......................... TD-26
R. SUSPENSION ...................................... TD-28
STANDARD BOLT AND
NUT TIGHTENING TORQUE .................... TD-29
5BUTDX-001
TECHNICAL DATA
COMPRESSION PRESSURE LIMIT CHART
The compression pressures are considered withln spec~ficat~on
if the lowest reading cyllnder is w~thin
75% of the highest.
Maximum Minimum Maximum Minimum Maximum Minimum Maximum Minimum

kPa [Kgf/crn2,psi) kPa {Kgf/cm2,PSI) kPa {Kgf/cm2,psi) kPa {Kgficm2, psi) kPa {Kgflcm2, psi) kPa {Kgf/cm2,psi) kPa {Kgf/cm2,psi) kPa {Kgf/cm2,psi)
- ~ ---- - --
923{93134) 697(71101) 1130(114,164) 848{87,123) 1337(135,194)~1000(102145) 15441156224) 1159{118168)

- .
937{95,136) 704(72102) 1144{116166) 854187,124) 1351{137196) 1014{103147) 15581158226) 1166{119169)

-
951{96,138) 717173104] 1158{117168) 869189126] 1365(138198) 1021(104148) 1572{159228} 1179(120171)
- - ~- -
965198,140) 724{74105) 1172(119,170) 876{89,127) 1379{140200) 1035{105150) 1585{161230} 1186{121172)
. -- - ~p
p--.p-pp- - - - -
979(99.142) 738{75,107) 1185{120172) 890(91129) 1392{141202} ~ 1 0 4 2 ( 1 0 6 1 5 1 ) 1599{162232) 1200{122174)

- - - -- ---- - - -+--- -
992(100144) 745176108] 1199(121 174) 904(92131) 1406{142204) 1055[108153) 1613(163234) 1207(123175)
1006(102146) 759{77110) 1213(123176) 911(93132) 1420{144206) i 1 0 6 2 { 1 0 8 1 5 4 ) 16271165236) 1221{124177)
1 0 2 0 { 1 0 3 . 1 4L
8]~- 7 8 1 1 1 ) ~ 2 7 ( 1 2 1 1 7 8 / 917(94133)
7 6 6 {- l --
4 3 4 { 1 4 5 2 0 8 ) ~ ~ 0 7 6 { l l O , 1 5 6 / 1641{165238)
- -- 1 2 2 8-
{ 1,
25178)
-
--
1034(105,150) 780(80,113) 1241{126180} 931{95135) 1447{147,210) 1083(110,157] 1654{168240} 1 2 4 2 { 1 2 6 1 8 0 )
. - -- -- _ -- --
1048{106,152) 786{80,114) 125411271827 938{96136) 1461{148,212) 1090{111,158) 1668{169242) 1248{127181)

- - & -- -- -- - --
1061{107154} 793(81 115) 1268(128184} 952(97138} 1475{149214) 1104{112,160) 1682(170244) 1262(129183)

-
1075{109,156) 807182,117) 1282{130186) 966198140] 14891151216) 1117(114,162) 16961172246) 1269{129184)
--- --
1089(11 0 158)
- --
814183, 118)
--- - -
1296{13 1 188)
--
973199 141)
- --
15031152 218) , 1124(11 5, 163) 1709{173 248) 1283(13 1 186)
-- --
1103{112160) 828{85,120)~-1310{133190) 9 7 9 { 1 0 0 1 4 2 ) ~ 1 5 1 6 { 1 5 4 2 2 0 ) ~ 3 8 ( 1 1 6 1 6 5 1) 7 2 3 ( 1 7 5 2 5 0 ) ~ 2 9 0 ( 1 3 1187)

- I- - - - --- - -
1106(113162} 834{85.121) 1323{134192) 993(101 144) 1530{155222) ~ 1 1 4 5 { 1 1 7 1 6 6 ) - -
MTD 1023 B 4BUTDX 002

TECHNICAL DATA
B1. ENGINE (2.3L)
Engine- 2.3L
Gasoline. 4-cvcle
I Cylinder arrangement and number 1 In-line 4-cvlinder I
I Valve system I OHC, belt-driven I
Bore x stroke mrn {in} -
.
96.0 x 79.4 (3.780 x 3.126)
Total piston displacement cm3(CUin} 2299 (140.35)
Compression pressure Lowest reading within 75% of highest readinga
Ignition timing BTDC lOf2" (not adiustable)
Valve clearance rnrn {in) E! 0 :Maintenance free

0 :Maintenance free
t ~ i l i n d e head
r
I
7
Distortion rnrn {in}
Inding
I
rnm {in) I 0.25 (0.01 1

' I
1
I Valve and valve guide
IN 43.7644.37 { I .723-1.7471
Valve head diameter mm {in} -
EX 37.84-38.35 11.49-1.511
IN 44"
Valve face angle limit
EX 44"
Standard 6.97-7.00 I.274S.2754)
IN 0.38 {0.015} oversize 7.36-7.38 {.2896-.2904}
Valve stem diameter 0.76 (0.030) oversize 7.74-7.76 l.3046-.30541
mm {in} Standard 6.95-6.97 {.2736-,27443
EX 0.38 {0.015} oversize 7.33-7.35 i.2886-,2894) ---
0.76 (0.030) oversize --
7.71-7.73 I.3036-,3044)
Guide inner diameter rnrn {in) 8.71-8.74 10.3433-0.34431
Valve stem-to-guide
clearance
1 I
0.025-0.068 (0.0010-0.0027)
0.038-0.081 (0.0015-0.0032} --A

L--
Maximum 0.139 {0.0055}
Valve seat
I . _ _ _ _ _ - _ _ _ _ _ _
Seat angle
IN 1.73-2.24 (0.068-0.088)
Seat contact width mm {in}
I I
EX I
1.77-2.28 10.070-0.0901 > ~
I
@ Refer to the compression pressure limit chart (Refer to page TD-2)
MTD1000-D 6BUTDX-001
TECHNICAL DATA
Item
\
____2__- Engine 1 2.3L

I Valve spring I
I Pressurellength Ibslmm {in} 57-63139.6 (1.56) I
I Free length 51.3 I2.02)
mm {in) I 1.98 I0.078) max.
- -.
I Camshaft runout
1
Camshaft end play
Cylinder block
--
Camshaft bearing oil clearance mm {in}
mm {in)
Out-of-round
NO. 1-4
Maximum
mm (in)
Standard
Maximum
/
.
-
--
--
5.49 (0.2163)
44.99145.009 11.7713-1.7720)
0.13 (0.005) rnax.
0.03-0.0~0.001-0.003)
0.15 {0.006)
0.13 {0.005) max.
--
I I
I
Distortion
-
- - --- -- -- --
mm {in} ( ~ +-~ --
0.07 {0.003)
Standard -- 96.000-96.01 5 (3.7795---3.7801)
Cylinder bore diameter 0.0380 {0.0015) oversize 96.01 5-96.076 I3.7801 -3.78253
--- -
-
mm {in} i. 0.0762 {0.0030} oversize ., -- - --
96.076-96.1 14 (3,7825-3.7840)
- - -- -
Cylinder bore taper mm {in} 0.25 (0.01)

Cylinder bore out-of-round .- _-
mrn {in)
-- - _ L --
0.13 (0.005j
Piston
1 Piston diameter
mm {in)
Red 1
Piston-to-cylinder clearance rnm (in} 0.254-0.508 (0.01 O--0.020)
Piston rina
Thickness mm {in} / Second

I
1.46-1.490 {0.058-0.059)
1.41-1.490 10.058-0.0591
J
End gap Lop-- - ---0.20-0.41

- 7 {0.008-0.016)
(Measured in cylinder) -
Second 0 33-0.48 {0.013-0.019)
mrn { ~ n } 011(rarl) 0.33-0.76 (0.010-0.030)
TOP 0.041-0.084 {0.0016-0.0033)
Second
Plston r~ng-to-r~ng
groove clearance
Max~mum
mm {in} Oil ring snug fit
Piston pin
1 Standard size 23.167-23.170 (0.9121-0.91 22) 1
Diameter mm {in} 0.025 (0.001j oversize 23.1
-
93-23.1 95 (0.9131-0.91 32)
0.050 {0.002) oversize 23.218-23.221 (0.9141-0.9142)
--
Lenath mm tin\ 62.29-70.1 0 (2.728-2.760)

Measured at 90' to pin bore axis and 14.58mm (0.574 in) below oil ring groove
MTDlOO1-D
TECHNICAL DATA TD
-
Item Engine 2.3L
Connectina rod and connectina rod bearinq
I Lenath (center to center) rnrn {in} I 138.58-1 38.66 (5.4558-5.4591 ) I
I Bendina rnrn {in) 1 0.038 {0.0015) I
Small end bore 23.124-23.1 44 (0.910 4 4 . 9 1 1 21
Crankshaft bearing bore 55.170-55.190 I2.1720-2.1728)
p~
0.076 (0.003)
Standard 0.0889-0.2667 (0.0035-0.01-
15) -
Connecting rod side clearance rnrn {in}
Maximum 0.356 {0.014)
Bearing wall Standard size 1.57-1.58 {0.0619--0.0624)
thickness mm {in} 0.050 {0.002} undersize 1.59-1.61 {0.0629--0.0634)
-
.
1 Crankshaft I
I Crankshaft runout/rnaxirnurn mm {in) 1 0.05 {0.002}/0.13 {0.005} rnax. I
Main journal Standard size -
. 56.02-56.00 {2.2059--2.2051)
diameter rnrn {in} 0.050 {0.002} undersize 55.97-55.95 I2.2039-2.2031)
Main journal out-of-round rnrn {in} 0.01 52 {0.0006)
Standard size 51.97-51.99 (2.0462-2.0472)
Crankpin diameter
rnrn {in) 0.050 I0.002) undersize 51.92-51.94 (2.0442-2.0492)
--
Crankpin taperlout-of-round mrn {in} 0.0152 {0.0006) ---
Main bearing
Main iournal bearing oil clearance / Standard 7
rnrn {in) / Allowable
I Available undersized bearing rnm {in) / 0.050 {0.002) I
Crankpin bearincj- -.
I
Standard 0.020-0.038 {0.0008-0.0015)
Crankpin bearing oil clearance mm {in} -
.
Allowable 0.020-0.066 {0.0008-0.0026)

Available undersized bearing mm {in} 0.050 {0.002}
Thrust bearing
rnrn {Standard ' ~I0.004-0.008)
0.10-0.20 ~ =
Crankshaft end play
Maximum 0.30 10.0121
Auxiliarv shaft I
1
- - -
Auxiliary shaft bearing oil clearance mrn {in) 0.01 5-0.066 {0.0006-0.0026)
MTD1002-C GBUTDX-003
TD TECHNICAL DATA
B2. ENGINE (3.0L)
Type Gasoline, 4-cycle

-
Cylinder arrangement and number 60°V configuration, 6 cylinder
---
Valve system OHV chain driven
Bore x stroke 89.0 x 80.0 13.50 x 3.14)
I Total piston displacement cm3 {CU in) I 2983 (182) I
--
Lowest reading within 75% of highest reading
10~2"
0: Maintenance free
Valve clearance mm {in]
0: Maintenance Free
I Cylinder head 1
1 Distortion mm {in) / 0.18 {0.0071 I
I Grinding mm {in} I 0.254 {0.01\ 1
k Valve and valve guide

Valve face runout
Valve face angle

-
.
0.05 (0.0021
Standard 1 7.96-7.94 l0.3134-0.3126) I
Valve stem diameter

mm {in} Standard 1 7.94-7.92 {0.3129-0.31211 I
EX 0.38 {0.015} oversize I 8.32-8.30 (0.3279-0.3271 ) I
/ 0.76 {0.030} oversize 8.70-8.68 (0.3428-0.3420)
Guide inner diameter
Valve stem-to-guide
clearance
mm (in) Ex--- mm {in)
t
8.74-8.72
0.026-0.068
0.038-0.081
{0.34434.3433)
(0.001 0-0.0027}
{0.0015-0.0032)
I Valve seat I
IN 45"
Seat angle
EX 45"
Seat contact width mm {in} kX-----I-

I Valve seat runout
I
mm {in)
I
/ 0.076 {0.0031 1
a Refer to the compression pressure l~mitchart (Refer to page TD-2)
MTDI 003-D
TECHNICAL DATA
Engine I 3.0L I
I Valve s ~ r i n a I
Free length mm {in} 46.7 { I ,841 approximatt?
Assembled length mm (in} 40.08 { I .58}
Loaded N (Ibs} @ mm {in} 800.6 { I 80) @ 29.5 { I .I(;}
Pressure/length -
-pp.
-p-
p -
N {lbs} @ mm {in} 288.1 (65) @ 40.1 (1.58]

Camshaft
Lobe lift
1 Standard mm {in) / 6.604 {0.260) ---
-~inimum mm {in} / 6.477 10.2551
II Journal
--
diameter -
Camshaft bearlnq 011clearance
Camshaft runout limit
--
mm {in) 1 0.05 {0.002} max. I

I Camshaft out-of-round limit mm {in) / 0.025 (0.001) max. I
Camshaft end play mm {in) / -
.
0.003 {0.007}
Cylinder block --
~
Distortion mm {in} per mm {in} -
-
0.08 {0.003} per 152.0 (6.0)
Cylinder bore diamete-standardsize
Cylinder bore out-of-round mm

1 Standard
Maximum
mm {in} 89.00 {3.504}
I Cylinder bore taper mm {in} , 0.050 10.0021 I

I piston I
I Red 88.962-88.978 13.5024-3.5031) I
I Blue 88.988-89.004 (3.5035-3.5041) I
mm {in) I Yellow 89.014-89.030 (3.5045-3.5051 1 I
Standard 0.030-0.050 {0.0012-0.0023)
Piston-to-cylinder clearance mm (in)
.
-
0.081 {0.0031) - -
Piston ring
TOP 0.25-0.50 (0.01 0--0.020}
Eng gap Second 0.25-0.50 (0.01 0--0.020)
(Measured in cylinder)
mm (in} Oil (rail) 0.25-1.25 (0.010-0.049)
1 Top 1.530-1.555 (0.0602-0.061 2)
Ring groove width in piston mm (in} / Second
7---- ,
1.530-1.555 (0.0602-0.0612j
- -
4.0304.055 (0.1587-0.1 5961
0.040--0.095 {0.0016-0.0037)
Piston ring-to-ring groove clearance
0.040-0.095 {0.0016-0.0037)
--
Maximum 0.15 {0.006) - -
Piston pin
Diameter mm {in) I ~ppp----
23.1 62-23.175 (0.9119-0.91 24)

Length mm {in] I -
.
76.S77.2 (3.01 2-3.039)--
I
Pin-to-piston clearance I 0.005-0.01 2 (0.0002-0.0005)
Installing pressure N {kgf, Ibf} / 4000 {409,900)
Measured at 90" to pin bore axis and 14.58mm (0.57 in) below oil ring groove GBUTDX-004
MTD1004-B
TECHNICAL DATA
Item -Engine 3.0L

Connecting rod and connecting rod bearing -- ---a -
Length (center to center) mm {in} 140.46-140.54 {5.530-5.533)

Bending rnm {in} per mm {in} 0.04 {0.0016} per 25 (0.98)
Small end bore mm (in) 23.1 05-23.1 45 {0.9096-0.9112}
Big end bore mm {in} 57.1 5-57.1 7 {2.250-2.251)
Twist mm {in) per mm {in) 0.75 {0.0029} per 25mm (0.98) -- --
Connecting rod side clearance mm {in}

! Standard 0.15-0.35 {0.006-0.014)
Maximum 0.36 {0.014}
I Crankshaft
Crankshaft runout
Standard size
---+
I
mm {in} 0.05 (0.002)
63.983--64.003 12.5190-2.5198)
I
Main journal diameter

0.025 (0.001) undersize I 63.959-63.9-78 (2.51 80-2.51 88)
mm {in}
0.050 (0.002) undersize ! 63.934-63.953 (2.517-2.51 78)
Main journal out-of-round mm {in) i 0.008 (0.0003)
Standard size 53.983-54.003 (2.1253-2.1 261) .. --
Crankpin diameter
0.025 {0.001} undersize 53.958-53.978 (2.1243-2.1 251)
mm (in} .- --.
0.050 (0.002\ undersize 53.933-53.953 (2.1233-2.1 247)

I Crankpin out-of-round mm {in} / 0.006 {0.0003)
1 Main bearina I
Main journal bearing oil clearance
I ~vailablleundersized bearing
- -
mm Iin} I Standard
Maximum
- mm (in}
t1 0.025 {0.001} & 0.050 {0.002} -- -- 1
-
1st &2nd
Main bearing wall thickness mm (in}
3rd & 4th
1 Crankpin bearing __]
1 Standard
Crankpin bearing oil clearance mm {in}
I Maximum
Available undersized bearing mm {in} / 0.0025 {0.001} & 0.050 {0.002}
Crankpin bearing wall thickness mm {in} / 1.557-1.570 {0.0612-0.0618)
Thrust bearing
Crankshaft end play mm {in} I Standard 0.1 0-0.20 {0.004-0.008)
Tappet .- -- A
-
-
-
- --
Tappet diameter mm {in) 22.206 {0.874)
Standard 0.01 8-0.069 {0.007-0.0027)
Tappet oil clearance mm (in) ---------i
Maximum 0.127 {0.005}
Collapsed tappet gap mm {in} 1 2.23-4.77 {0.0884.189)
MTDl005-A GBUTDX-005
TECHNICAL DATA
B3. ENGINE (4.0L)
I
Item
Tvpe
Cvlinder arranaement and number
Engine
1
Gasoline, 4-cycle
60°V configuration, 6 cylinder
1 I
I Valve svstem 1 OHV, chain driven, 12 valve I
100 x 84 I3.94 x 3.311
--
(not adiustable)
Ignition timing (initial timing) BTDC I -
.
10k2" (not adjustable)
Firina order 14-2-5-3-6
IN 0: Maintenance free
Valve clearance mm {in}
EX 0: Maintenance free
Cvlinder head
I Distortion mm {in} per mm {in} I 0.07 (0.003) per 152 (6.0) 1
I Grindina mm {in} / 0.254 {0.01} I
I Valve and valve auide I
Valve head diameter mm {in}
I IN --
1 EX
Valve face angle
1 Standard I 8.02-8.04 (0.3159-0.31 671 I

1 0.20 (0.0081 oversize I 8.23-8.24 (0.3239-0.3245) I
1 / I
k
Valve stem diameter 0.40 {0.016) oversize p~
8.43-8.44 (0.3318-0.3324)
8.00--8.01 {0.3149-0.3156)
0.20 {0.008} oversize -
.
8.20-8.21 IO.3228-0.3235)
mm I
8.40-8.41
Guide inner diameter mm {in} p~
8.71-8.74 (0.31 74-0.31 84)
0.0200-0.0635 {0.0008-0.0025j
Valve stem-to-guide
0.0457-0.0889 {0.0018-0.0035j
clearance pp~
mm {in} Maximum 0.1397 {0.0055}

I Valve seat I
Seat angle -----
I -
1.524-2.000 {0.060-0.079)
Seat contact width
1.524-2.000 10.060-0.079)
;;.&,5) 1
~ - -
-
.
Valve seat runout mm {in) I 0.0381

O Refer to the compression pressure limit chart (Refer to page TD-2)
TD TECHNICAL DATA
Valve spring I
Free length mm {in) 1 48.5 11.91) 1
I
Pressurellength Ibs @ mm {in)
I Out-of-square
___
-- - --
mm {in)
- - A
1.98 {0 0781 -
_I
1 Camshaft I
Standard 10.221 {0.4024)
Wear limit 10.094 {0.3974}
Cam height mrn (in)
Standard 10.221 {0.4024)
Wear limit 10.094 {0.3974)
I Camshaft bearing oil clearance mm {in) Iz-6i

Maximum
--
\Camshaftout mm {in} / 0.127 I0.005) -7

Standard 0 . 0 6 5 4 165 (0 025-0.064)
Camshaft end play mm {ln} ---
- -- - -- - --
Maxlmum 0.2286
--
{0.0090}- ----
Cylinder
-
block
- -- - - -- - - -- ----- -- -
1
- --
D~stort~on mm (~n)per mm {in] 0.07 {0 003) per 152.4 (6 0)

Cyllnder bore d~ameter 1
Standard slze mm {ln} 100 40-1 00 43 I3.9527-3 9543)
Standard 0.0381 {0 0015)
Cyl~nderbore out-of-round mm {ln]
Maxrmum 0 127 {0.005)
( Cylinder bore taper mm {in} ) 0.254 (0.010) I
I Piston I
I Piston diameter '
. . 1
mm {in)
i Standard
Piston-to-cylinder clearance mm {in) 0.020-0.048 {0.0008-0.0019)
Piston pin bore diameter mm (in] 24.003-24.008 {0.9450-0.9452)
Piston rina
End gap
(Measured In cylinder)
Ring width mm {in]

+---
vl- Second
1- -----
0.381-0.584 {0.015-0.023)
0.381-0.584 (0 01 5-0.023)
0.381-1.397 10 015-0.0551
----A-
I
0.051-0 084 {0 0020-0 00331 ---
Plston ring-to-r~nggroove clearance
{0 0020-0 0033)
- - -- --
. .
I 1 Maximum 1 0.1 524 10.006\ 1
I Piston in I
1
Piston pin diameter
Piston pin-to-piston clearance

rnrn {in]
1 Red
----
Blue
mm {in) 1 0.007-0.01 5 (0.0003-0.0006) I
.' Measured at 90" to pln bore axls and 56mm (2 205 tn) below the p~stondome
MTDl007-C
TECHNICAL DATA
Item Engine I; 4.0L

---
Connecting rod and connecting rod bearing --- --

Length (center to center) mm {in} 130.52-1 30.58 (5.1386-5:1413}
- --
Bending mm {in} 0.050 (0.002)
Small end bore mm {in) 1 23.957-23.975 IO.9432-0.9439)
I Bia end bore mm {in) 1 56.82-56.84 {2.2370-2.2378) I
I Twist mm {in) 1 0.1524 {0.006) I
I Connecting rod side clearance mrn {in) / 0.0051-0.635 {0.0002-0.0025) I
Crankshaft -
-
Crankshaft runout/maximum mm {in) 0.0508 {0.002)/0.127 {0.005}

Crankshaft end play mm {in} 0.05-0.32 {0.002-0.012)---
Main iournal diameter mm {in1 56.9798-57.0026 12.2433-2.2441 I
I Main iournal out-of-round mm (in1 I 0.01 52 {0.00061 I
1 Crank~indiameter mm (in} I 53.9800-54.0004 (2.1252-2.1 260) I
I
--
Crank~inout-of-round
~
mm {in} I 0.01 52 {0.00061 1
Main bearing
Main journal bearing oil clearance Standard 0.020-0.038
mm {in} Maximum 0.01 27-0.0482 {0.0005-0.0019)
Available undersized-bearing
. -
mm {in} 0.0254 {0.001}
1.7958-1.8034 {0.0707-0.0710)
Main bearing wall thickness mm {in) --
1.8059-1.81 35 10.0711-0.071 41
I Crank~inbearina I
I Crankpin bearing oil clearance mm {in) pt
Maximum
I Available undersized bearina mm (in) I 0.0254 (0.001) I
I Crankpin bearing wall thickness mm {in}
I Thrust bearing 1
1 Crankshaft end ~ l a v mm (in) 1 0.05-0.32 10.002-0.0121 I
TECHNICAL DATA
D l 1 D2 I D3. LUBRICATION SYSTEM (2.3L 13.OL 14.OL)
-
Item Engine 2.3L 3.0L 4.0L

--
Lubricating method Force-fed -
Oil pump -
TYpe Trochoid gear
1 33.5 {1.32}/ 28.2 {l . l 111 35.3 (1 ,3911
Relief valve spring tension mm {in} 18.5-23.3 kgf 21-22 kgf 30.0-32.3 kgf
i8.4-10.6 Ibf) i (9.1-10.1 lbfJ 113.614.7 IbR
276413 2 7 6 4 13 2 7 6 4 13
Oil pressure kPa {kgf/cm2,psi} ( 2 . 8 4 . 2 , 40--60)/ (2.8-4.2, 40-6011 ( 2 . 8 4 . 2 , 40--60}/
2000 rpm 2500 rpm 2000 rpm --
Inner rotor tooth tip to
outer rotor clearance
rnm {in} I Maximum
I
I
rnm {in} / Maximum 0.1 3 (0.005)

Oil filter
1 Full-flow, paper element I
I Engine oil I
Capacity Engine oil replacement 3.8 (4.0, 3.4)
liters {US qt, Imp qt) Engine oil replacement
/ (with oil filter) 4.7 /5.0 4.21
L ~ g e -- II
-
API Service, SG Energy Conserving 11 (EC 11) A
SAE 1OW-30
Viscosity number
SAE 5W-30
MTDl009-C
E l / E2 / E3. COOLING SYSTEM (2.3L I 3.OL I 4.OL)
1 item--
-- Engine / 2.3L 3.0L 1 4.0L 1
I Cooling method 1 Water-cooled. forced circulation 1
I Water pump I
1 Centrifuaal, V-ribbed belt-driven 1
I Water seal type 1 Unified mechanical seal I
1 Thermostat 1
I Tv~e I Wax. bottom-bv~ass I
Opening temperature 0
89 1192)
Full-open temperature "C {OF) I 100 12121
I Full-open lift mm {in) 3.2 (0.1261 I
1 Radiator 1
Corrugated fin
I Number of blades 1 8 I
I Coolant I
Capacity
liters {US qt, Imp qt)
Antifreeze solution
(Coolant protection)
with A/C
without A/C
Above -24°C (-11OF)
6.8 {7.2, 6.0)
6.2 (6.5, 5.4)
9.6 { I 0.2, 8.5)
9.0 (9.5, 7.9)
Water 6O%/Coolant 40%
t
8.1 I8.6, 7.2)
7.417.8, 6.5)
Above -52°C {-62"Fj Water 40%/Coolant 60%

TECHNICAL DATA TD
F1 1 F2 1 F3. FUEL AND EMISSION CONTROL SYSTEMS (2.3L / 3.OL I 4.OL)
Item Engine 2.3L

I Idle speed
rpm 1 (not
-
.
adiustable)
475-575
Auto acljust
h"ii;"timing (Initial timing)

- - - I (not adjustable)
Hor~zontaldraft
Fuel pump -- -- -
Impeller (in-tank)
Maximum output pressure kPa {kgflcm2,psi) -
.
862 I8.8, 125)
Fu I filter
Type Low-pressure side Nylon elerrlent (on fuel pump)
High-pressure side Paper element
Pressure regulator
I
p~
Regulating pressure kPa--{kgf/cm2,psi} -.-.

270 (2.7, 39) ----
-
Injector ~ .
- ~
Typeof drive
p~~~ . -- --- ~ .~ ~ -~ Voltage
Resistance 12-1 9
~ -p--
~- - - ~ --- - ----(at 20°C (68"Fj)
Connector color . . ~
Black
~
Flow rate #/hr --

14
Idle air control solenoid -. -~
Resistance R / 6-1 3 {at 20°C 168°F))

rcamshaft ~ositionsensor 1
Type
I V
a r i a breluctance l e Hall element pick-up
--
--
Type
Mass air flow sensor ~ .

fi-- -- - p
r.-- ~
Variable reluctance
type ---
Type - ....-. 1 Heat resistor

,
~ ~~ ~ ~ ~
Engine coolant temperature sensor

.. - - - - -
4=
I 20 C {68"F} .- --- --
37.3
-
Lp---~ ~
~
Resistance kQ 40°C {I 04"Fj

80°C {I 7 6 " ~ ) 3.84
16.15 --
Intake air temperature sensor
~ $ i l E ~ ~ ,
Resistance ~--. -- -
58.75
24.27
7.60
-
Air cleaner
-
( Element type Paper
MTD1035-D 5BUTDX-006
TD TECHNICAL DATA
G. ENGINE ELECTRICAL SYSTEM
2.3L 1 3.OL 1 -- ---

4.OL
12 -- -- - - -
- - -- .-
Voltage regulator, on housing
IT-- Automatic Automat~c 480-586
Drive belt tension
N {kgf, lbf} 1 Used
--
I Limit
1 Type ~ Permanent magnetic I
Maxrmum load - no load 800-70 2 10 --
Starter
130-220
Normal englne cranking speed-- 140-220 rpm
- -- ---
lgnrtron system 1 --Electrical
-- D~str~butorless
- lgn~tionSystem
-- - -- -
I Spark advance 1 Electronic spark advance (ESA) 1

10" + 2"&
(Not adjustable) -
compartment -
F~r~n
order
a 1-34-2 1-4-2-5-3-6
, Automatic tensioner indicator must fall between 4" and 25" markings on belt tensioner
'
2
'2,
Automatic tensioner indicator must fall between 4 O and 19" markings on belt tensioner
MG1063-G
H. CLUTCH
Fb -------------__Transmission ; M50D
I Clutch control 1 Hydraulic I
I Clutch cover 1 Diaphragm spring I
-
Suspended ___-___ - -
Automatrcally self-adjusting - - -
Not adjustable --
Clutch fluid I FMVSSI 16, DOT3
t
Flywheel
-- .-
Runout limit mm {in)

.~
1 0.2 {0.008}
-- -- ---
i
TECHNICAL DATA
J1. MANUAL TRANSMISSION
Item Transmission M50D
-
~ -~ -
-
Floor shift
Transmission shift control Shift rod
Gear ratio
+
/ Reverse 1 3.40 I
Oil
I Grade I
I Capacity liters {US ~ tImp
, pt) 1
1 Runout I
---
Secondary shaft gear runout -~
0.050 {0.0020} max.
1-2 shift fork and clutch hubsleeve 0.050-0.37 {0.0019-0.0'14)--
0.8 10.0311
3-4 shift fork and clutch hub sleeve Standard 0.1-0.37 (0.003-0.01 41
0.8 (0.0311
&reverse shift fork and clutch
hub sleeve
Synchronizer ring and gear mm {in} - I-P

Wear limit
Reverse idle gear bushing
and retaining ring
mm {in)
I
Standard
I Thrust clearance
Standard
Thrust washer and counter reverse gear
Thrust washers 7.45 {0.293}, 7.65 {0.301}, 7.85 {0.309}
mm {in} 7.35 {0.289}, 7.55 {0.297), 7.75 f0.305)
End play
Standard 1 0.00-0.05 (0.00-0.0020)
3rdl4th clutch hub end play 1.50 {0.059}, 1.55 {0.061}, 1.60 {0.0629}, 1.65 {0.0649}
Retaining rings 1.70 {0.0669}, 1.75 (0.06881, 1.80 {0.0708}, 1.85 {0.0728}
mm {in) 1.90 {0.0748), 1.95 {0.07671
Standard ~~
0.25-0.35 (0.010-0.01 4)
Counter reverse gear end play 3.0 {0.118), 3.1 (0.1221, 3.2 {0.125}, 3.3 {0.129}
Split washers 3.4 (0.1331, 3.05 {0.120), 3.15 {0.124), 3.25 {001277)
mm {in} 3.35 {0.131}, 3.45 {0.135}, 3.50 {0.137)
Standard 0 . 1 4 . 2 (0.0039-0.0078) - -
Reverse idler gear 1.5 {0.059), 1.6 {0.0629], 1.7 {0.0669}
Retaining rings
mm {in) 1.8 {0.0708}, 1.9 (0.0748)
Secondary shaft shims
Countershaft spacers
TD TECHNICAL DATA
J2. TRANSFER CASE
TECHNICAL DATA
K. AUTOMATIC TRANSMISSION
Transmission ~ 4R44E (2.3L, 3.OL), 4R55E (4.OL) I

ITransmission control 1 Column shift I
I~ockupechanism 7 -
Equipped --
TYpe MERCON~v
Automatic Transmission
Capacity 4x2
Fluid (ATF)
liters {US qt, Imp qt} 9.0 I9.5, 7.8) 9.3 {10.8, 8.1)
Thrust bearing (No. 4) rear end play mm {in) I O . O H . 5 5 lO.004-0.022)
I Identification number
I
Thrust bearing i Reading "C" mm {in} stamped on washer -
(NO.4) I 1.79-1.90 {0.070-0.074)
selection b.91-2.10 10.075-0.0821 1
I --
'-2.1 1-2.30 {0.083-0.090) I 2

-r + ~ ~
---
2.31-2.43 {0.091-0.096)
--
I
I 3 ~~ 3.20-3.35 {0.126--0.132)
Coastina clutch
Retaininq rinq-to-pressure plate clearance rnm {in) ! 1.3-2.0 (0.051-0.079)
Thickness mm {in} 1.37 {0.0539}, 1.73 {0.0681], 2.08 {0.0819), 2.44 {0.0961}
Retaining ring
Diameter mm {in) ~ 130.1 (5.1221
e
Retaining ring-to-pressure plate clearance mm {in) 1 1.3-2.0 {0.051-0.0791
Thickness mm {in} 1.37 (0.05393, 1.73 {0.0681}, 2.08 {0.0819), 2.44 {0.0961}
Retaining ring - - -
Diameter mm {in) I 130.1 l5.122)
Forward clutch
Retaming ring-to-pressure plate
-- -
clearance ,
mm {in} 1 - --
---d- --
1.4--2.1 (0.055-0.0831
Retaining ring
Enaine
1
Thickness mm { ~ n } 1.37 {0.0539}, 1.73 {0.0681}, 2.08 {0.081!3}, 2.44 {0.0961}
Diameter
---+
mm lrnl
2.3L. 3.OL
125.1 14.9251
1 4.0L
Coasting clutch -- Number of driveldriven plates
-
- -
212 212
Coasting clutch clearance 1 4-2 1 1.4-2.1
rnm {rn) {0 055-0 083) -
{0 055-0.083)-
~everseand I Enqine 2 3L, 3.OL 4.0L

high clutch 1 Number of driveldriven plates 1
1 Reverse and high clutch clearance
mm {in)
. .
/ Engine - 2.3L, 3.0L y 4 .

- 0 ~
1
Forward clutch
--
Torque converter
end play
I Number of driveldriven plates
Forward clutch clearance
New or rebu~lt
-
converter
Used converter
----
--
- -
515
1.4-2.1
- -- dr
0 58 {0.023} max.
1 27 10 050) max
-
{0
616
--
1.4-2.1
- 055-0 0831
Stall
-
speeds
-
/ Engine 4.0L
Stall speed RPM I Minimum 2177 2405
/ Maximum 1 2525 3338 I 2800 1
MTD1025-E 7BUOKX-003
TD-I 7
TD TECHNICAL DATA
Line Pressure Specifications
1
Idle WOT Stall
Application Range EPC Line EPC Line
D, 2, 1 141-211 1 540-753 789-944 1986-2465
(1.4-2.1, 20-30) (5.4-7.5, 77-107) (7.9-9.4, I 12-134) (19.9-24.7,282-350)
2.3L R 261 -331 815-1021 789-944 1986-2465
(2.6-3.3, 37-47) (8.2-10.2, 115-145) (7.9-9.4, 112-134) (19.9-24.7,282-350)
N 148-218 540-753
(15 2 . 2 , 21 -31) I5.4-7.5, 77-107)
D, 2, 1 141-211 500-711 789-944 1606-1852
(1.4-2.1, 20-30) (5-7.1, 71-101) (7.9-9.4, 112-134) I16.1-18.5, 228-263)
R 324-394 1007-121 8 789-944 1986-2465
3.OL I3.2-3.9, 46-56} (10.1-12.2, 143-173) (7.9-9.4, 112-134) (19.9-24.7, 282-350)
N 21 8-288 662-873
(2.2-2.9, 31-41) (6.6-8.7, 94-124) i
Coasting Clutch Snap Ring Selection

\ Coasting clutch
\ I-- -- -- --
\
Thickness Diameter
\
---
\'\ '- mm Inches
7-
mm -7
%chisp
Forward Clutch Snap Ring Selection
Forward clutch
\,
,, Thickness 1
i
'\,, - p--.r I
Diameter
- L
,\, mm j Inches
--
A .
-.
1.37 0.0539 125.1 4.925
B 1.73 4.925
C - 2.08
--
AK1037-B 5BUTDX-015
TECHNICAL DATA
Reverse
e and High Clutch Snap Ring Selection
ee
\ Revers /high clutch
\ Thickness Diameter
mm Inches mm Inches
A 1 1.37 0.0539 130.1 5.122
B 1.73 0.0681 130.1 5.1 22
C 2.08 0.0819 I 130.1 5.122
---
D 2.44 0.0961 130.1 5.122
Total End Play (Thrust Bearing No. 4) Selection
Reading "C" Bearing thickness

mm Inches stamped on washer mm 1 Inches
Oil Pump Thrust Washer Selection
Thrust washer thickness

. -- - Thrust washer
mm Inch identification
---
1.35-1.40 0.053-0.055 1
1.55-1.60 -
/ 0.061-0.063 -- -
2
-- --
1.65-1.70 0.065-0.067 -
3
1.75-1.80 0.069-0.071
- -
4
1.85-1.90 0.073-0.075 5
1.95-2.00 0.077-0.079 6
2.05-2.1 0 0.081-0.083 7
TD TECHNICAL DATA
Vehicle Speed Shiftpoint Table
2.3L
Axle ratio: 3.73

-
( Throttle position Range Shift kmlh {mph)
- - - - P A --+- - --
Closed throttle
1 @
0 21 -32 {I3-20]
10-17 (6-11)
- - --- -- - - - -- -,
M~n~mum
throttle 18-27 (1 1-17)
@ 33-43 {20-27)
03 3-4 71 -82 {44-51)
/ Part throttle
Wide open throttle
1 ~analalpull-down
___I.
I
I 2- 1 49-56 (30-35)
A
I
I
MK1478-B 5BUtdX-016
Closed throttle
-- --- --- ----
---
---
24-32 (15-20)
15-22 (9-14)
--- - -4 -
--
Axle ratio: 3.73
kmlh {mph)
21 -32 {I3-20)
15-22 {9-14)
-
1
I-
-
I
Mtn~murnthrottle 1-2 18-27 (I 1-171 17-25 {I0-16)
I
2-3 33-40 (20-25) I 29-40 {I8-25) I
3-4 73-83 (45-52) I 68-78 (42-49) I
/ Pan throttle
,
r--, -
W~deopen throttle
-
-- --
Manual pull-down
TECHNICAL DATA TD
1 Throttle position Range 1 Shift ~ ~

Axle ratio: 3.73
h ~ h ~ ~
Axle ratio: 4.1 0
p *(rnph)
r n l h
Closed throttle 23-30 (14-19) 21 -30 {I3-1 9)

I 15-22 {9-14) 13-22 {8-14)
Minimum throttle
Part throttle
Wide open throttle ~

I
Manual pull-down
1 I
L
! Axle ratio: 3.08 Axle ratio: 3.55
Throttle Postion
Range
Closed throttle
Minimum throttle 0
I Manual pull-down 1
TD TECHNICAL DATA
I 1
Axle ratio: 3.08
Throttle Postion Range Shift kmlh (mph) I kwh (rnwh)
Closed throttle 20-35 (12-22) 23-32 (14-20)
17-25 (10-16) I 15-24 (9-15)
( Manual pull-down I 1
L. PROPELLER SHAFT
Item Front propeller shaft Rear propeller shaft

- - ----
Runout llrnlt
-- - - -- -- -
rnrn {~n}
--
0.8G.035)
MTD1017 A 4BUTDX 01 6
TECHNICAL DATA TD
Rear propeller shaft angles
TD TECHNICAL DATA
M. FRONT AND REAR AXLES
Model Dana 28 Dana 35

.
- -
Bearing play axial direction mm {in} ~ 0.006-0.13 {0.0002-0.005)

Bearing preload
(without oil seal load)
N.m {kgfzm, in.lbf} ~
I
2.8 {29, 25)
Front axle {4x4)

Bearing
-- -
play axial direction
Bearing preload
mm {in} I 0.00-0.08 {O.OOO-0.003) -
. ---
(without oil seal load)

Grade ---
API Service GL-5
Viscosity Above -
--
-18°C-
{O°F} SAE 90
Oil
Below -18°C (0°F) SAE 80W
Capacity liters {US pt, Imp pt} 1.42 (3,2.51 1 1.65 I3.5, 3.03)
Rear axle
L-L--- I.
+p
Axle casing Integral type - --- _I
I Axle shaft support J _ --
Opposed tapered roller bearings - _1
1-
- -
Bearing play Minimum mm {in} I 0.127 {0.005}

axial direction Maximum mm {in} I 0.762 {0.030}
I Rear differential I
Gear design
-- --- -- -- -
.
Hypoid gear -. ~
Grade -
. -
-
API Service
.
.
GL-5 .-
7-
Viscosity i Above -18°C {O°F} SAE 90
Oil 1 Below -18°C {O°F} SAE 80W
Type - - Standard Limited-slip
Capacity liters {US pt, Imp pt} 2.4 {5.0, 4.2) 2.4-2.5 {5-5.3, 4.24.4)''
@ Plus 4 ounces of an appropriate friction modifier (Refer to Section M)
TECHNICAL DATA
N. STEERING SYSTEM
Model
1I Manual I 2.3L
I Steering wheel I Lock-to-lock 1 6.1 I 4.2 I
I Steering gear Recirc. ball
worm
Recirc. ball
Torsion bar
- -
Gear ratio 23.75:l 17:l
-.-.----- --
-Oil/lubricant Type Steering ATF Type-F (M2C33-F) or DEXRONaII
gear grease
Capacity 290 grams 0.75L (1.6 pt)
(10.2 ounces)
I Worm bearing preload - 0.45-1.0 N-m (4-9 in-lb} not adjustable
I Worm-to-piston preload -
specification given for inspection purposes only
0.1 1-0.34 N.m 11-3 in-lb} not adjustable
I Worm bearing preload for checking 22-48 N a n

specification given for inspection purposes only
-
I Total center meshload for checking

(2-6 in-lbs)
68-1 24 N.cm
{&I 1 in-lbs)
I
1
I Minimum meshload over preload for checking
1 14 in-lbs}
-
Worm bearing preload when readjusting 56-68 N.cm

15-6 in-lbsl I -
Total center meshload when readjusting 102-1 24 N.cm
19-1 1 in-lbsl 1 -
Minimum meshload over preload when readjusting
1 14
45in-lbsl
N-cm I -
I
Maximum clearance between adjusting screw
head and sector shaft
Oil pump minimum flow / Literslminute 76°C (170°F) I -
1I -
3.4 1
5100 kpa I740 psi} Gallons/minute 76°C { I 70°F) -
Oil pump minimum kpa - 7240
relief pressure
psi - 1050
Oil pump maximum kpa
psi
I Oil pump maximum free I Literslminute I - 1
I flow at i500 rpm ~
I
i ~ i/nute r n
I
I
- I
I------- 2.6
- - -
7
Note: Flow depends on pump model, engine rpm and pulley drive ratio. Engine idle rpm must be set to specification
when checkinq pump minimum flow capacitv.
TECHNICAL DATA
P. BRAKING SYSTEM
-
Brake pedal Type Suspended -
Master cylinder Type Tandem (with level sensor)
Type I Ventilated disc
Front disc mm {in) I 3.0 i0.121
brake mm {in) 20.6 10.811
I Disc plate runout mm {in) / 0.008 10.0031
Lining min. thickness mm {in} 1 Worn to within 0.794 {0.03} of any rivet head -
/
I Rear drum
brake
Drum inner diameter
.
-
Shoe clearance adjustment
mm {in)
. .
mm {in} /
Std. diameters+ 0.762 10.031
Automatic adjuster
. ,
--I
( Brake diameter 1 mm {in}
mm {in}
- -
228.6 {9}
-. --
Power brake
unit
-
1 T~~~
254 {1O}
Vacuum multiplier, tandem diaphragm

I
-
TYpe Mechanical two-rear wheel control

Parking brake
-- Operation system Pedal
Rear wheel
hydraulic TYpe Rear wheel anti-lock brake system
control system
6 STANDARD DIAMETER IS SHOWN ON EACH BRAKE DRUM
Q. WHEELS AND TIRES
SIZE, OFFSET AND PITCH CIRCLE DIAMETER

SIZE 1 4 x 5.5 14x6 1 5 x 4.5 15x6 15 x 7
(DIA. x JJ)
OFFSET 0.47 (121 0.47 (12) 1.12 (28) 0.47 (12) 0.47 (12)
lnch (mm)
PITCH CIRCLE DIAMETER
- BOLT CIRCLE - 4.5 (114) 4.5 (114) 4.5 (114) 4.5 (1 14) 4.5 (114)
lnch (mm)
WHEEL MATERIAL STEEL1 STEEL1
STEEL ALUMINUM STEEL STEEL ALUMINUM
ALLOY ALLOY
TIRE SIZE P I 95170R14 P195170R14 P215175R15
P215170R14 P215/70R14 P215175R15 P215175R15 P235175R15
P225170R14 P265175R15
TECHNICAL DATA
Air pressure
kPa {kgf/cm2, psi)
Vehicle
Wheel material 1 Tire 1 FrontprRear
(4x2) Regular Cab Steel
2740 (108)
Opt~on:Aluminum alloy "

-
.
-
2740 (108) Standard: Steel
O~tion:Aluminum allov "
(4x2) Regular Cab Steel 14 x 5.5 J P I 95170R14SL
2892 (1 14) 14 x 5.5 J P215170R14SL
Standard: Steel 14 x 6.0 J ~ 1 9 5 f f 0 ~ 1 4 ~ ~
Option: Aluminum alloy a 14 x 6.0 J P215/70R14SL
14 x 6.0 J P225170R14SL
(4x2) Regular Cab Steel 14 x 5.5 J P215170R14SL
- -
2740 (108) Standard: Steel 14 x 6.0 J P215170R14SL
Option: Aluminum alloy a / 14 x 6.0 J
(4x2) Cab Plus Steel /I 14x5.5J
14x5.5J
3175 (125)
Standard: Steel 14x 6.0 J -
Option: Aluminum alloy 14 x 6.0 J
7 -
/ 14 x 5.5 ~-/~215/70~1 ~ S =241I2.4,35)1241I2.4,35)1

(4x2) Cab Plus
3175 (1251
: Steel
1
Standard: Steel
Option Aluminum alloy
1 14 x 6.0 J P225170R14SL
L
14 x 6 0 J P n 0 ~ 1 4 ~ ~ 1 ~ 2 m )
241 {2 4, 351 1
241 (2.4, 35)
2740 { I 08)
Option: Aluminum alloy
Steel 15 x 6.0 J P215/75R15SL
Standard: Steel 15 x 7.0 J P215/75R15SL
O~tion:Aluminum alloy 15 x 7.0 J P235/75R15SL
(4x4) Regular Cab Steel 15 x 6.0 J P215/75RI 5SL 241 (2.4, 35) 241 (2.4, 35)
2892 (114) Standard: Steel 15 x 7.0 J ~ 2 1 5 / 7 5 ~~ 1S L 241 (2.4, 35) 241 (2.4, 351
(4x4) Regular Cab Steel 15 x 6.0 J P215/75R15SL 241 (2.4, 35)
- 241 (2.4, 35)
2892 (1 14) Standard: Steel 15 x 7.0 J P215/75R15SL 241 (2.4, 35) 241 (2.4, 351
Option: Aluminum alloy 15 x 7.0 J P235175R15SL 207 (2.1, 30) 241 (2.4, 35)
i 15 x 7.0 J P265175R15SL 267 (5.2, 39) 241 (2.4, 35)
(4x4) Cab Plus Steel 15 x 6.0 J P215175R15SL 241 (2.4, 35) 241 (2.4, 35)
3175 (1251 Standard: Steel 15 x 7.0 J ~ 2 1 5 1 7 5~~ 1S L 241 (2.4, 35) 241 (2.4, 35)
Option: Aluminum alloy 15 x 7.0 J P235175R15SL 207 (2.1, 301 241 (2.4, 35)
15 x 7.0 J P265175R15SL
- -
267 (5.2, 39) 241 (2.4, 35)
(4x4) Cab Plus j steel 15 x 6.0 J P215/75R15SL 241 (2.4, 241 (2.4, 35)
3175 { I 25) Standard: Steel 15 x 7.0 J P215175R15SL 241 (2.4, 3 5 1 7 - . 4 . 35)
Option: Aluminum alloy 15 x 7.0 J P235175R15SL 207 (2.1, 30)
-
241 (2.4, 35)
Wheel and tire runout limit mm {in} 1.14 (0.045)
Wheel unbalance at rim edge 14-inch wheel -
.
10 (0.35) --
g {oz) 15-inch wheel 9 (0.32)

'@Aluminumalloy wheel not available on Base Model 4x2 vehicles.
MTDI 021- 6 6BUTDX-013

TD TECHNICAL DATA
Temporary spare tire
lv S~ze 4x2
Front
P I 95170R14SL
Rear Temporary
spare
P I 95170R14SL
P215170R14SL P215170R14SL
P225170R14SL P225170R14SL
4x4 P215175R15SL P215175R15SL
P235175R15SL P225175R15SL
P265/75R15SL P225175R15SL --
4x2
4x4 P215175R159L
35 i2.4, 241)
35{2.4,241}
1 35 i2.4, 2413
35 {2.4, 241)
Inflation pressure 35 i2.4, 241)
psi (kglcm? kPa) P235175R155L
30 I2.1, 207)
P265175R155L
30 i2.1, 207)
MTD1036-B 4BUTDX-024
R. SUSPENSION
--
-
Item \
-
-- --
-
Model
-
-
--- ---.
4x2,4x4
-
Front suspension
Sus~ens~on I lndeoendent
Coil
Nitroaen aas
Total toe-in L-
mm {In)
- -- -
0.82 3.2 {0 030 + 0.1251
- -
Front wheel
, degree .06" + .25"
al~gnment Camber angle 25" + .5"
(Unladen Camber spllt 0" + 4"
cond~t~on)~ MIN 2"
Caster angle --- -
ITAX-
-- -
- -- -- --
6"
_-1___.-:
-_
Rear suspension
Caster spllt
I Suspension 1 Rigid axle I

Springs Type Semielliptic leaf spring
Shock absorbers Type Nitrogen gas
a? Fuel tank full; radiator coolant and engine oil at specified level, and spare tire, jack, and tools in des~gnatedposition.
TECHNICAL DATA
STANDARD BOLT AND NUT TIGHTENING TORQUE
Diameter
mm {in)
1 Pitch
mm {in}
1- ~.rn 1
4T
kgf.rn / ft.~bf ~ . r nk g f i 6T
7-ftlbf ~ ~
8T
h l b

Bseries 1997

Uploaded by

Copyright:

Available Formats

Bseries 1997

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Bseries 1997

Uploaded by

Copyright:

Available Formats

Mazda B-Series

@ 1997 Mazda Motor Corporation

This manual contains "Warnings" and "Cautions" applicable to risks not

The procedures recommended and described in this manual are effective

Parts should be replaced with genuine Mazda replacements parts, not

For proper repair and maintenance, a

All the contents of this manual, including

Mazda Motor Corporation reserves the right

All rights reserved. No part of this book may

Mazda Motor Corporation

This manual is applicable to vehicles with

IMPORTANT INFORMATION ...................... GI- 2

POSSIBLE LOSS OF WARRANTY

WARNING ON LUBRICANTS AND GREASES

Wash skin thoroughly after work involving oil.

Lubricants and greases may be slightly irritating to the eyes.

HOW TO USE THlS MANUAL

SST NAME SST ILLUSTRATION

73-!07 (7 4-10 9 54-79)

SHOWS SHOWS TIGHTENING

Only brake fluid

I Apply automatic transmission fluid

Apply sealant Appropriate sealant

NOTES, CAUTIONS, AND WARNINGS

Start the engine only after making certain the engine

3. Cleaning parts for reuse

RUBBER PARTS AND TUBING

When lifting a vehicle with the vehicle jack or any floor

Position the floor jack under the axles or shock absorbers,

TOWING TWO-WHEEL DRIVE VEHICLES

Towing a vehicle with a manual transmission with all

TOWING FOUR-WHEEL DRIVE VEHICLES

4. Set the manual locking hubs in the FREE position.

Towing with an electronic shift control system

3. Lock the steering wheel straight ahead if the vehicle is to

To avoid metal-to-metal contact and possible damage to

rC--1 ONE - 4 X 4 X 60" LONG

MATERIAL SPACER BLOCKS

DETAIL A FOUR - 2 x 4 x 6" LONG

4 X 4 WOOD BLOCK =g-q

2. Position a 4x4 wood block under the bumper, behind the

WOOD BLOCK SAFETY

Rear connections (with rear bumper)

5. Attach safety chains to the axle, inboard of the springs.

Vin Code Mfr. Make Type

lnd~catesthe type of brake system and GVWR.

Vin Code GVWR Brake System

lndicates the model or series, chassis, and cab type.

lndicates the vehicle assembly plant.

lndicates production sequence of the vehicle.

MFD. BY FORD FOR MAZDA MOTOR CORP.

Build Date Stamp Location

For a build date of January 24, for example, the vehicle

E Cloth Split bench 82 Conventional 2750 1 3.08

V Night Teal-Dawn Teal

rpm ..................................................Revolutions per minute

*I SAE: Society of Automotive Engineers

Engine and Emission Systems

Existing SAE Standard

1009-A BUOAX-005 Tightening torque: